ML19261D087
| ML19261D087 | |
| Person / Time | |
|---|---|
| Issue date: | 03/16/1979 |
| From: | Donna Anderson, Hale C, Jerrica Johnson NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML19261D080 | List: |
| References | |
| REF-QA-99900404 99900404-79-1, NUDOCS 7904270140 | |
| Download: ML19261D087 (12) | |
Text
VENDOR INSPECTION REPORT U. S. NUCl. EAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT REGION IV Report No. 99900404/79-01 Program No. 51100 Company:
Westinghouse Electric Corporation Water Reactor Divisions Post Office Box 355 Pittsburgh, Pennsylvania 15230 Inspection Conducted: March 6-9, 1979 Inspectors:
S//5 /79
,_a__
4.
m D. G. Anderson, Principal Inspector, Vendor Date Inspection Branch O.Th.
3/irl74 p4.Johnjon,ContractorAuditor, Vendor
'Date Inspection Branch f
Approved by:
5 f
S -/b~7 9 C. J. (alje Chief, PrugramTvaluation Section, Date Vendorinspection Branch Summary
?
Inspection on March 6-9, 1979 (99900404/79-01)
Areas Insoected:
Implementation of Topical Report No. WCAP 8370 including Design Change Control, Evaluation of Supplier Performance, and action on previous inspection find &gs.
The inspection involved fifty-six (56) inspector-hours on s' v by two (2) USNRC inspectors.
Resul ts :
In tt P r>
(3) areas inspected, no unresolved items were identified.
..ing deviation was identified in one (1) of the areas inspects:..
Deviation:
Evaluation of supplier performance - A procedure for the preparation, review, and approval of quality plans did not exist.
730427014o
._ DETAILS SECTION I (Prepared by D. G. Anderson)
A.
Persons Contacted E. C. Arnold, Engineer R. P. Ca.rter, Manager, Central File N. T. Dressel, Quality Assurance Manager, Primary Equipment C. W. Lin, Fellow Engineer W. E. McKnight, Manager, Data Management and Control
- P. T. McManus, Senior Quality Engineer R. J. Morrison, Engineer D. C. Richardson, Manager, Reactor Protection Analysis
- M. H. Shannon, Quality Assurance Engineer
- Indicates attendance at the exit meeting.
B.
Action on Previous Inspection Findings 1.
(Closed) Deviation (Report No. 77-02): Records which were not yet in the permanent storage facility were not being maintained in duplicate sets in separate geographical locations. Westinghouse /
PWRSD had commited tJ the completion of filming, jacketing, and transfer of all equipment specifications, system descriptions, and Quality Porcurement Specifications to the Boyers Records Center by January 1, 1979. The inspector examined the index documents for each of the records indicated above to verify that approximately 92% (8000 documents) have been prepared and trans-ferred to Boyers.
Since these documents arrive at Central ~ File for processing at a rate of approximately 100 per month, there will always be a backlog and 100% cannot be achieved at any specific point in time, therefore this item is considered closeu.
2.
(Closed) Items Identified for Further Action (Report No. 78-03):
In Section D.1.b of the referenced report, twelve (12) items were identified to Westinghouse management for their consideration.
The items related to deficiencies in orocedures and Safety Analysis Standards.
The inspector vertfied that the action out-lined in the Westinghouse letter of response dated November 3, 1979, had been taken.
3.
(Closed) Deviation (Report No. 78-04): The most recent revision to a procedure had not been included in a controlled manual as rr. + ed.
The inspector verified that the controlled copy of
__ the Projects Policies and Procedures Manual used on the TBX/TCX and TGX/THX projects is now up to date.
The inspector also verified that the action to prevent recurrence as indicated in the Westinghouse letter of response dated Juanuary 8,1979, had also been accomplished.
4.
(Closed) Deviation (Report No. 78-04):
Evaluation of the quality performance of a supplier had not been performed annually as required.
The inspector verified that a Supplier Evaluation Form 55434 had been completed for Westinghouse Nuclear Europe (WNE).
The inspector also verified that the Supplier Evaluation Schedule for the first quarter of 1979, lists WNE and Weir Pumps Ltd. for audits during March,1979.
C.
Design Change Control 1.
Objectives The objectives of this area of the inspection were to verify that:
a.
Procedures have been established and implemented for con-trolling changes to approved design documents.
b.
Design changes are reviewed for the impact of the change, documented as to the action taken, and transmitted to all affected persons and organizations.
c.
The design changes are justified and subjected to review and approval by the same groups or organizations as for the original design.
d.
When responsibility has been changed, the designated organization shall have access to the pertinent information, competence in the specific area of design, and an under-standing of the requirements and intent of the original design.
2.
Method of Accomolishment The preceding objectives were accomplished by:
a.
A review of the Westinghouse Topical Report, WCAP 8370, Section 17.1.3, Design Control, which sumarizes the method used by Westinghouse /WRD to describe their activities related to Design Change Control.
The design process is defined, implemented, and established according to the following:
(1) Policies and Procedures : OPR-110, Design Control; OPR-115, Drawing Control; OPR-300-3, Fonnal Design Reviews; OPR-300-5, Cor. figuration Control of Computer Programs; and OPR-105-1, Safety Analysis Report Control.
(2) Engineering Procedures:
EFP-EP-6.9, Design Change Control; EPP-6-8, Maintenance, Processing and Retention of Design Change Documents; EFP-EP-2.5, Engineering Change Notice Instructions and Sign Off Procedures; EFP-EP-2.18, Calculation Checking Procedure; and EFP-FSE-006, Verification and Documentation of Computer Codes.
b.
A review of the following documents to assure that design changes are reviewed, documented, and cansmitted:
(1)
Computer Change Master (CCM) Status / Project Report dated October 28, 1978, which lists the Change Control Notices for TGX/THS projects.
Computer Change Master (CCM) Status / Project Report dated October 28, 1978, which lists the Change Control Notices for TBX/TCX projects.
(2)
Change Control Notices (TGX/THX): CCN #01799, change the minimum head flow characteristics of the high head safety injection pump; CCN #07915, spent fuel pit cooling and cleanup modification; CCN #07534, steam generator compartment beam; CCN #01712, revision to emergency boration system; CNN #01737, combine manual initiation of safety injection and emergency boration into one function; CCN #01280, replace (4) 4-C-58 valves in the chemical and volume control system with (4) 4-C-52 valves; CCN #01628, change shroud support struc-ture to withstand 2500 lb. tangential load and 90,000 lb.
vertical load transmitted from the shroud; CCN #01695, change 7 inch ID 4XL excore detector instrument well to 8 inch Schedule 40 pipe; CCN #05:12S, change in thimble plug dimensions for 17X17 SARS; and CCN #01123, hot leg pipe whip restraint.
Change Control Notices (TBX/TCX):
CCN #08577, Reactivity Analog Computer Static and Dynamic Reactivity Measure-ments; CCN #07176, RCP Locked Rotor Protection; CCN #08480, Elimination of Low Feedwater Flow Reactor
. Trip; CCN #08551, Failed Fuel Canisters; CCN #02104, Cavity Seal Ring Description of Changes; CCN #01361, Steam Generator Automatic Level Control; CCN #02130, Delete Loop Branch Nozzle Thermal Sleeves; CCN #00506H, Upper Head Injection Type Upper Internals; CCN #00133H, change in the number of incore thermocouples; and CCN #01661H, Miniflow Orifice for Safety Injection Pumps.
(3) Transmittal Memoranda: N4SD-TGX-028, RE: Change Control #01799; N4SA-TGX-333, TGX ECCS Injection Data; SE-SA/I-1937, 4XL (South Texas) Reduced High Head Safety Injection Flow; SE-SA/II-497, Request for TGX Fluid Systems Safeguards Data Package; ME-AE-5405, Change Control #1679-Boron Injection Pump; FSD-I-M-884, Manual Emergency Boration Signal; ME-RE-0444, 4XLR Cooling Shroud Support Ring Loads; E-RIS-2794, TGX/THX Bottom Inserted Detector Design; FLC-77-208, Change in Thimble Plug Dimensions for 17X17 SARs; ME-AE-4900, TGX/THX Boron Injection Pump; ME-PV-6344, Permanent Cavity Seal Ring for Standard Plants; and ME-PV-4458, Proposed Refueling Seal Ledge Modification.
A review of the following documents to assure that design c.
changes are justified and subjected to review and approval as required by procedures:
(1) Design Specification #944392, South Texas Project Flow Diagrams, June 10, 1975.
(2) Drawings: 1207E14 through 1207E21, South Texas Project, Unit 1, Flow Diagrams for the Chemical and Volume Control System, Residual Heat Removal System, Safety Injection System, Boron Recycle System, Emergency Boration System, Spent Fuel Pit Cooling System, and Containment Spray System.
m, (3) Engineering Change Notices: #22333, October 7, 1976;
- 22939, November 17, 1977; and #36076, October 30, 1978; revisions to South Texas Project (STP) engineering flow diagrams.
(4)
Calculation #N45A-TGX-50, ECCS Analysis-Generate ECCS Injection Curves for TGX Using Actual Piping Drawings (1207E17-1207E21) April 20,1977, ZEBRA Computer Runs dated April 11,1977, April 19,1977, April 20,1977,
-.. - - and May 24, 1977, and verification of ZEBRA by comparison with hand calculations April 28, 1976.
(5)
Final Safety Analysis Report, South Texas Project, Units 1 and 2, Volume 9, Figure 6.3-6, High Head Safety Injection Pump Performance Curve, and Figure 6.3-7, Low Head Safety Analysis Pump Perfor-mance Curve.
d.
A review of the following documents to assure that when responsibility for design has been changed that the original design information and requirements remain the same:
(1)
Equipment Specification #676413, Reactor Vessel /
S. O. #105, Reactor Coolant System, June 14, 1974.
(2)
Drawing #1098E22, Four Loop-173.00 ID Reactor Vessel with Rapid Refueling, July 27, 1977.
3.
Findings In this area of the inspection, there were no deviations or unresolved items identified.
D.
Followuo on Regional Request - Seismic Response Soectra This is a followup on an item identified during an inspection at Brown and Root (Inspection Report No. 99900502/79-01) which relates to an unresolved item.
It was found during the Brown and Root inspec-tion that seismic response spectra reported in the South Texas Project FSAR was inconsistent to that generated for Report #3N160SR043-B.
The inspector followed up on this item at Westinghouse and found that the Containment Floor Response Spectrum used in the purchase of the NSSS was reported in Engineering Report No. 3N160SR044-C, which contains the correct response spectra.
This report was transmitted to Westinghouse by letter, #ST-BR-WN-0566, dated November 12, 1975.
There were no deviations or unresolved items identified in this area of the inspection.
E.
Exit Meeting An exit meeting was conducted with Westinghouse /WRD management personnel at the conclusion of the inspection on March 9,1979.
Those individuals indicated by an asterisk in Section A of the details sections were in attendance.
In addition, the following were present:
. __ J. H. Chivers, Systems Analyst E. S. Hampton, Manager, Product Assurance Systems G. Harkness, Systems Analyst E. J. Kreh, NTD Staff J. A. Puharic, NED, Senior Engineer R. B. Stermon, fianager, NED Quality Assurance The inspector discussed the scope of this inspection and the details of the findings identified during this inspection.
Management representatives of Westinghouse acknowledged the statements by the inspector with respect to the one (1) deviation presented.
f
~. - - -..
- DETAILS SECTION II (Prepared by J. M. Johnson)
A.
Persons Contacted
- B. F. Barnett, Senior QA Engineer, Electrical H. Beel, Manager, QA Electrical R. B. Bremmer, Manager, QA Auxiliary Equipment N. Dressel, Manager, QA Primary Equipment
- J. J. Lescisin, Product Assurance Engineer A. N. Maccrum, Senior Engineer, Primary Equipment
- P. T. McManus, Senior Quality Engineer
- E. D. Webster, Senior Buyer C. L. Werner, Electrical Engineer
- Denotes those present at exit meeting.
B.
Evaluation of Supplier Performance 1.
Objectives The objectives of this area of the inspection were to verify that procedures have been established and implemented that assure:
a.
Initiation of pre-and post-award activities, as necessary, to assure that purchaser and supplier understand requirements of the procurement documents.
~
b.
Identification of planning techniques and processes, and hold and inspection points.
c.
Identification and review / approval of supplier generated documents.
d.
Control of changes and their processing.
e.
Establishment of exchange method of document information between purchaser and supplier.
2.
Method of Accomolishment The preceding objectives were accomplished by an examination of:
~
_ a.
Westinghouse Topical Report WCAP 8370: Sections 17.1.3 (Design Control); 17.1.4 (Procurement Document Control);
17.1.7 (Control of Purchased Material, Equipment and Services); 17.1.15 (Nonconfoming Material, Parts and Components); Table 17-1 (Positions on Reg. Guides and ANSI Standards); and Table 17-3 (Listing of Procedures),
to determine Westinghouse comitments.
b.
Operating Policies and Procedures: OPR-120-2 (Procurement Control - Policy); OPR-110-4 (Design Change Control);
OPR-il5-3 (Processing Supplier Drawings): and OPR-125-1 (Manufacturing Control), to detemine policy and require-ments for evaluation of supplier performance.
c.
Product Assurance Procedures: PAP 5.2 (Procurement Document Review); PAP 5.3 (Quality Plans - deleted June,1978); PAP 5.7 (Supplier Surveillance); PAP 5.5 (Control of Nonconforming Materials, Parts and Comporents);
PAP 5.18 (Notification er.d Scheduling of Hold / Notification Points); 7.nd Engineering Functional Procedure (Mechanical Engineeri1g) EFP-ME-23 (Processing Document Submittal Forms), to determine specific procedural requirements for evaluation of supplier performance.
d.
Purchasing Manual, Section C: Memos 2.6 (Procurement Advisory Release); 2.2 (Writing P.0s and CNs (Change Notices)), and 2.8 (Submittal and Distribution of Vendor Documents).
e.
Documents related to Purchase Order No. P.O. 236990 (Base order) and 236992 (Project Order) for Safeguard Pumps from Pacific Pumps :
(1)
Engineering Specification 678815, Revision 2, Section 6.4, identifying required hold and witness points.
(2) Administrative Specification 54823 identifying methods of submittal, comunication, forms, etc.
(3)
P.O. test requirements, including those ir.voked by Change Notices 004 and 009.
(4)
P.J.Section VII regarding submittal requirements, and Change Notice 008 invoking Interim Change No.
4 regarding sof tware submittals.
_ (5) Supplier submittals including:
Document Submittal Form (DSF) 55640 and associated Procurement Advisory Release (PAR) 13 for Pump and Motor Outline Drawing, Revision 1; DSF55636 and associated PAR 1 for Valid Document List (VDL);
DSF 99705 and PAR 25 for Pump and Motor Outline Drawing, Revision 5; DSF B9190 and PAR 33 regarding Performance Test Curve; DSF B9132 and PAR 32 regarding Deviation Notice 003247; DSF B4355 and PAR 31 regarding Instruction and Maintenance Manual; DSF B103082 and PAR 29 regarding Design Report; and Inspection Reports documenting witness of hold points.
(6) Post-award meeting reports dated June and October, 1975.
f.
Documents related to P.O. 271480 for Post-Accident Monitoring Recorders (Main Control Board) from Westing-house Computer and Instrument Division (WCID) for approximately 10 plants:
Equipment Specification Sheet 05410; Engineering Specification 953419,Section III (Sub-
~,
mittals Required) and Section IV (Additional Require-ments, which includes identification of hold and notification points and QA Data Package required contents);
DSF 98666 and associated PAR regarding Baseline Design Document; DSF 104174 and associated PAR regarding Baseline Design Material Control ;
DSF 98359 and associated PAR regarding Certified Drawings; Post-Award trip report re QA requirements; and Post-Award trip report regarding Baseline Control for Material and Documentation.
4 9 Documents related to P.O. 265752, 265753 and 265754 for 1-E Transmitters (Pressure transmitters including Class A transmitters in containment) from ITT Barton (Base order for 12 plants):
Administrative Specification invoked by base order; Submittal Requirements including Hydrotest procedure, which was submitted on DSF 990034 and approved by PAR 7; Hold and Notification points invoked by base order; DSF B5829 regarding Data Package and associated PAR 2; and Surveillance Reports regarding acceptance tags for parts dated May 2-5, 1977 and May 30-31, 1977.
h.
Documents related to base order P.O. 263770 and project P.O.s 263771 and 263772 for RCS (Reactor Coolant System)
Fabricated Supports (which includes supports for Reactor Vessel, RC pump, Pressurizer, Crossover Legs, Hot Leg and Steam Generator) from Teledyne Brown:
Administrative Specification 54823, Revision 5, including method of submittal, forms, etc. ;
Westinghouse Equipment Specificatior. G 952628, Revision 1, including submittal requirements for shop drawings, weld procedures, NDT procedures, etc.;
Change Notice 1 adding identification of notification and hold points; and DSF 103363 and associated PAR 87 regarding Data Package.
i.
Memo QAE-76-279 from C. N. Beel to F. B. Hyland regarding Discontinued Review of QA Plans j.
QA Notice 75-7 regarding Interim Change to PAP 5.3 k.
QA Standards including QA-STD-100 (II), and memo QAV-75-034 dated March 2, 1979 1.
Revision 17 to Product Assurance Manual dated June 19, 1978, deleting PAP 5.3 and PAP 5.14 and their replacement by PAP 5.7.
. 3.
Findings In this area of the inspection, one (1) deviation was identi-fied (See flotice of Deviation Enclosure).
No unresolved items were identified.
9