ML19274D831
| ML19274D831 | |
| Person / Time | |
|---|---|
| Issue date: | 12/08/1978 |
| From: | Donna Anderson, Jerrica Johnson NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML19274D827 | List: |
| References | |
| REF-QA-99900404 NUDOCS 7902260223 | |
| Download: ML19274D831 (15) | |
Text
VENDOR INSPECTIGN REPORT U. S. flUCLEAR REGULATORY COMMISSION OFFICE OF IrlSPECTION AND ENFORCEMENT REGION IV Report tio. 99900404/78-04 Program No. 51100 Company:
Westinghouse Electric Corporation Pressurized Water Reactor Systems Division Post Office Box 355 Pittsburgh, Pennsylvania 15230 Inspection Conducted: November 27-30, 1978
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Inspectors:
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G'. Anderson, Principal Inspector, Vendor Dat'e Inspection Branch Q m.1,4,m~.
f 1 -/ F/ rc J yM. Johnson, Contractor Auditor, Vendor Date
' Inspection Branch 5L Yb Approved by:
C. J. Hayiiei, Program Evaluation Section, Date Vendor Inspection Branch Summary Inspection on November 27-30, 1978 (99900404/78-04)
Areas Inspected:
Implementation of Topical Report No. WCAP 8370 including design process management, procurement source selection, and action on previous inspection findings. The inspection involved fifty-six (56) inspector-hours on site by two (2) USNRC inspectors.
Resul ts:
In the three (3) areas inspected, no unresolved items were i denti fied.
The following two (2) deviations were identified in two (2) of the areas inspected.
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-2 Devia tions :
Design Process Management - The most recent revision to a procedure had not been included in a controlled manual as required.
(See Notice of Deviation, Enclosure A).
Procurement Source Selection - Evaluation of the quality performance of a supplier had not been performed annually as required.
(See Motice of Deviation, Enclosure B).
DETAILS SECTION I (Prepared by D. G. Anderson)
A.
Persons Contacted K. E. Ashman, Manager, Data Management E. H. Brown, Lead Engineer J. W. Brown, Engineering Aide J. N. Chirigos, Manager, Structural Materials Engineering R. A. Clark, Technical Assistant to Manager, Systems Design Engineering J. A. Davidson, Engineer D. A. Ferg, Project Engineer TBX/TCX
- E. J. Hampton, Manager, Product Assurance Programs G. L. Hohmann, Project Manager R. A. Psiser, Engineering Aide K. A. Kloes, Engineer J. B. Lipchak, Principe.i Engineer W. E. McKnight, Manar;er, Design Production Control
- P. T. McManus, Senior Quality Engineer J. A. Puharic, Senior Engineer Dr. S. Ramchandran, Consulting Engineer R. W. Skoff, Engineer, Data Management J. L. Tain, Project Engineer TGX/THX
- Denotes those present at the exit meeting.
B.
Action on Previous Inspection Findings _
1.
(0 pen) 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. Corrective action on this item is still in progress.
Wes tinghouse/PWRSD has committed to the completion of filming, jacketing, and transfer of all equipment descriptions, system descriptions, and QA specifications to the Boyers Records Center by the end of December,1978. This item will be inspected when corrective action is completed.
2.
(Closed) Deviation (Report No. 78-03):
Procedures did not exist for the evaluation and reporting of significant changes in the evaluation moc'el as referenced in Criterion II.b of 10 CFR 50, Appendix K.
'ihe inspector reviewed the corrective actions described in the Westinghouse letters of response dated November 3,1978, and December 1,1978, and confirmed that references to 10 CFR 50, Appendix K reporting requirements are now contained in Nuclear Safety Procedure 5.2.
C.
Design Process Management 1.
Objectives The objective of this area of inspection was to examine the establishment and implementation of quality related procedures for the design process to verify that:
a.
The design process systom is dei'ined, implemented, and enforced in accordance with approved procedures, instructions, or other documentation for all groups performing safety related design activities.
b.
Design inputs are properly prescribed and used for transla-tion into specifications, drawings, instructions, or proce-dures.
Appropriate quality standards for items important to safety c.
are identified, documented, and their selection reviewed and approved.
d.
Final design can be related to the design input with this traceability documented, including the steps performed from design input to final design.
e.
Design activities are documented in sufficient detail to permit design verification and auditing.
f.
The methods are prescribed for preparing design analyses, drawings, specifications, and other design documents so that they are planned, controlled, and correctly performed.
2.
Method of Accomolishment The preceding objectives were accomplished by:
A review of the Westinghouse Topical Report,
'.-l CAP 8370, a.
Section 17.1.3, Design Control, which summarizes the methods used by Westinghouse /PWRSD to describe their activities related to the design process.
The design process system is defined, implemented, and enforced according to the following policy procedures and departmental procedures:
(1) OPR-110, Design Control: OPR-115, Drawing Control-OPR-300-3, Formal Design Reviews; OPR-300-4, Drawing Preparation, Review and Approval; OPR-105-1, Safety Analysis Report Control; OPR-300-1, Verification of Computer Programs Used in Engineering Analysis, Design, and Safety Analysis (PWRSD); OPR-300-5 Configuration Control of Computer Programs; and OPR-400-1, Initiation of ' New Project.
(2) Within the Engineering Department at Westinghouse /
PWRSD, seven (7) groups are performing safety related design activites.
The groups are Systems Analysis and Operations, Electrical Systems Engineering, Mechanics and Materials Technology, Mechanical Equipment Engineerii.;,
Projects, Systems Design, and Nuclear Safety. There is dupli.:ation of procedures in each of these seven (7) groups. Arrangement of these procedures into a matrix according to functional activity results in the following classification:
Design Change Control:
EFP-ES-015, MA-P/I-14, EFP-ME-30, EFP-EP-6.9, EFP-SD-2.5.
Design Control: MA-P/I-2, EFP-ME-27.
Design Verification:
Nuclear Safety Procedure 6.3, POE-S0-2, EFP-ES-014, MA-P/I-3, EFP-ME-29.
Design Interface:
Nuclear Safety Procedures 2.0.3 and 2.3.7, EFP-FSE-401-407, EFP-ES-018, MA-P/I-19, 26, 27, and 28, EFP-ME-35, Projects Procedure 4.1, EFP-SD-1.5 and 3.12.
Design Records: Nuclear Safety Procedures 1.8, 2.07, and 7.3, EFP-SAO-703, EFP-ME-6, and EFP-SD-8.4.
Design Reviews: Nuclear Safety Procedure 1.11 and 4.2, EFP-SD-4.7.
Design Document Control:
Nuclear Safety Procedure 1.6, Projects Procedure 2.5, and EFP-SD-3.11.
Design Calculations: Nuclear Safety Procedures 2.06, 2.1.2, 2.3.9, 4.6, and 5.3, EFP-STE-003, EFP-ME-31, EFP-SD-2.18 and 8.2.
Computer Codes:
Nuclear Safety Procedure 1.1 and 2.3.10, EFP-FSE-006, POE-50-3, and EFP-SD-1.8 and 8.6.
Design Specifications:
EFP-ES-010, MA-P/I-15, EFP-ME-9, EFP-SD-1.10.
Drawing Control:
EFP-ES-NCS-602, MA-P/I-25, and EFP-ME-10.
Initiation of a New Project:
Project Procedure 2.9.
Standard Information Package:
EFP-SD-4.4.
Project Master Document:
SAO-FA-1, EFP-EP-6.4 and 6.5, and EFP-SD-1.6.
Project Information Package:
EFP-SD-2.9.
Safety Analysis Report Preparation: Nuclear Safety Procedure 2.2.11, POE-S0-11, and SAO-NO-18.
b.
Design inputs were reviewed in the following documents:
(1)
Project Master Document (PMD) for the following Projects: Comanche Peak Steam Electric Station (TBX/
TCX) and South Texas Project (TGX/THX).
(2) Project Infonnation Package (PIP) for the following Projects:
Comanche Peak Steam Electric Station (TBX/
TCX) and South Texas Project (TGX/THX).
These design inputs were translated into the following:
(.1) Equipment Specifications:
Shop Order #90, TBX/TCX, 952264 Bottom Mounted (In Core) Instrumentation Flux Thimble.
953518, Bottom Mounted Instrumentation Thimble Guide Tube Manufacturing Shop Order #287, TGX/THX, 944392, Boron Injection Makeup Pump.
(2) Drawings:
Shop Order #287,1207E19, Baron Injection Makeup Pump, and 1099E77., Chemical and Volume Control System Piping and Instrument Diagram.
Shep Order #90, 1207E02, Comanche Peak Units 1 and 2 Bottom Mounted Instrumentation, and 118SE20, Thimble Assembly-Flux Bottom Mounted Instrumentation.
Shop Order #106, TBX/TCX, 1453E10, 2, 3, and 4 Loop Plants Reactor Irradiation Capsule Assembly and 1145E67, 4 Loop (UHI)
Internals-Critical Interface Features.
(3) Purchase Orders:
Shop Order #106, P0 #546-SG-235975-SM, Reactor Vessel Irradiation Program.
(4)
Internal Transmittals:
MA-SME-243, TBX Surveillance Inspection, E-RCS-1332, Rod Position Indication for Shutdown Rods.
c.
The following documents were reviewed for identification and review of quality standards:
(1; Master Index-Standard Information Package, Standard Plant 412 and fiaster Index-Project Information Package, TBX/TCX, Volumes 1 and 2.
(2) Design Reviews:
SD-SPE-2258, PWRSD-196, October 26, 1978; SD-SPE-2054, PWRSD-149, July 28, 1978; SD-SPE-1840, PWRSD-85, April 28,1978; SD-SPE-1663, PWRSD-14, January 31, 1978; EP-SP-1568, PWR/EP-477,flovember 16, 1977; EP-SP-1428, PWR/EP-459, August 30, 1977; EP-SP-1253, PWR/EP-431, May 24, 1977; EP-SP-1086, February 25,1977; Dr-77-1, Flux Mapping System; DR-77-4, B C Drop Criteria; DR-76-5, System Changas to Prevent g
Bdron Dilution; DR-76-158, Nuclear Noise Monitoring.
(3)
Internal Transmittals:
E-NCS-5850, Dr-77-1 Action Items, October 30, 1978, and EP-SP-1047, Final Report Preliminary Design Review DR-76-5 System Changes to Prevent Baron Dilution (CCN 1592) 3/17/77.
d.
The inspector traced the design process from design input to final design through the Project Master Document (PMD) to the Project Information Package (PIP) with incorporation of the project unique requirements and information from the Standard Information Package (SIP).
These documents form the bases for the preparation of the P3AR and the FSAR on both the Comanche Peak Steam Electric Station (TBX/TCX) and the South Texas Project (TGX/THX). Design inputs are reviewed and approved by the Power Capability Working Group of which the following meeting minutes were reviewed:
(1) Meeting Notification:
80PSD-M-1365, October 12, 1978, 80PSD-M-1328, September 5, 1978, 80PSD-M-1293, September 8, 1978.
(2) Meeting Minutes:
B0PSD-M-1357, October 3,1978; BOPSD-M-1343, October 2,1973; B0PSD-M-1331, September 20, 1978; BOPSD-M-1325, September 14, 1978; BOPSD-M-1304, September 1,1978; B0PSD-M-1292, September 8,1978.
e.
The following activities related to casign change control were reviewed by the inspector to assure that documentation was provided in enough detail to permit design verification and auditing:
(.1) CCM Status / Project Report, TBX/TCX, December 3,1976.
(.2 ) Change Control Notices on the TBX/TCX and TGX/THX Projects: TBX 02015, Redesign DRP Rod Position Shutdown Detector, December 5,1975; TBX 01361, Steam Generator Automatic level Control; TBX 07176, RCP Locked Rotor Protection, September 9,1976; TBX 1592, System Changes to P
'ent Boron Dilution, April 1,1976; TGX 00712, Remove Isolation Valves From Frame Assembly of Flux Mapping System, September 18, 1977; TGX 01712, Revisions to Emergency Boration System, October 4,1976; TGX 01281, Addition of Boron Injection Makeup Pump, December 4,1976.
(3) Change Control Cover Sheets (Westinghouse. Form 55396A):
June 5, 1975, March 30, 1976, January 16, 1976, February 24, 1975, April 23, 1976, and October 3,1975.
f.
The inspector reviewed the following design analyses to assure that they are planned, controlled and correctly performed: NS-RPA-II-2585, B,,C Rod Drop Time Verification, March 11, 1977; NS-RPA-II-2593, B,C Rod Drop Acceptance Test Criteria, March 22, 1977; NS-RPA-I-836,NRCQuestion212.74, Comanche Peak FSAR Baron Gilution Accident, November 17, 1978.
3.
Findings In this area of the inspection, no unresolved items were identified.
One (.1) deviation from commitment was identified (See Notice of Deviation Enclosure, Item A).
D.
Exit Meeting An exit meeting was conducted with management representatives of Westinghouse /PWRSD at the conclusion of the inspection on November 30, 1978.
In addition to those individuals indicated by an asterisk in
_g_
Section A. of the Details Sections of this report, the following were in attendance:
H. Abromovitz, Manager, Project Administration H. H. Brunko, Manager, Product Assurance North J. A. Surgess, Manager, Quality Assurance C. C. noop, Manager, Engineering Administration R. A. Margolis, Senior Engineer The inspector summarized the outstanding items and the corrective actions which were reviewed during this inspection.
The inspector discussed the scope and findings identified during this inspection.
Management representatives acknowledged the statements of the inspector with respect to the two (2) deviations which were identified during this inspection.
DETAILS SECTION II (Prepared by J. M. Johnson)
A.
Persons Contacted J. I. Bramer, Quality Engineer E. H. Brown, Shop Order Holder (205)
N. Dressel, Quality Assurance Manager, Primary Equipment (by phone)
B. R. Johnson, NDE, Level III J. Puharic, Senior Engineer E. Rusnica, Manager, Reactor Vessels and Piping
- M. H. Shannon, Quality Assurance Engineer
- E. D. Webster, Senior Buyer
- T. A. Whalen, Quality Engineer, Primary Equipment M. Zegar, Shop Order Holder (140)
- Denotes those present at exit meeting.
B.
Procurement Source Selection 1.
Objectives The objectives of this area of the inspection were to verify that procedures have been established and implemented for the selection of qualified suppliers of services, materials, and components that provide for:
a.
Requirements and methods for evaluation of the potential supplier's capability to provide items or services in accordance with the technical and quality assurance specifications of the procurement documents; Methods are consistent with applicable regulatory, code and contract requirements and include source evaluation audits, review of historical performance, and/or review and evaluation of the supplier's QA Program, manual and procedures.
b.
Qualification requirements for personnel performing source evaluation audits.
c.
Periodic re-evaluation of suppliers, maintenance and distribution to purchasing of an up-to-date listing of the evaluation status, and contract awards made only to companies designated in these documents.
d.
Measures to assure that the supplier' bid conforms to the procurement document requirements and/or has been evaluated for acceptability of exceptions taken of technical or Quality Assurance nature, and resolution of unacceptable conditions identified during bid evaluation prior to contract award or commencement of work.
2.
Method of Accomolishment The preceding objectives were accomplished by an examination of:
a.
Westinghouse Topical Report No. WCAP 8370, Revisions 7A and 8A, Sections 17.1.4.1 and 17.1.7 and Table 17-1, to determine program commitments for supplier evaluation, bid evaluation and contract award.
b.
Operating Policy and Procedure (OPR) 100-2 (Supplier Surveys):
OPR 100-5 (Auditing Quality Assurance Programs); OPR 120-2 (Procurement Control): and Product Assu ance Procedure (PAP) 4.12 (Qualification Requirements for Audit Team Personnel; PAP 5.2 (Procurement Document Review); PAP 5.9 (Supplier Evaluation and Approval); PAP 5.15 (Training, Qualification and Certification of Personnel in NDE (Non Destructive Examination); Engineering Functional Procedure (EFP) -
Mechanical Engineering (ME)-7 (Technical Evaluation of Vendor Proposals) and Purchasing Mar.ual: Section B, Memo 6.3, Section C, Memo 5.1 and Memo 5.9.
These were examined to determine specific procedural requirements for supplier evaluation, bid evaluation and contract award.
c.
Documents showing approval of supplier foc Baron Injection Pumps on Purchase Order (P.O.) 225637 dated September 8, 1976, from Weir Pumps Limited (Cathcart Works, Glasgow, Scotland) for projects THX/TGX:
Letter ME-AE-5360 dated April 8,1976, regarding:
suitability of p1'ps and supplier.
Purchase Requisition Change Notice (PRCN) 225637 dated May 3, 1976. Note: This document as approved per procedures authorizes changing the purchase requisiton to a purchase order, and indicates any changes or additions to be made.
Nestinghouse EsparIa audit dated March 1, 1976,(supplier status is approved); Westinghouse Nuclear Europe (WNE) audit dated April 14,1976, (status is conCitionally approved) and June 18, 1976, (conditionally coproved.
Restrictions include (1) Weir must obtain ASME. III, Class 2, ti stamp prior to any fabrication work and (2) corrective action to audits must be completed prior to application of QA system to pumps).
flote :
Conditionally approved status may indicate audit items requiring corrective action, and may also impose restrictions, as above.
However, purchase orders may be placed with a supplier listed as conditionally approved.
Surveillance Trip Report dated June 14, 1977, (shows first listing of TGX, indicating fabrication started near this date).
Wile audit date February 21, 1978, closing conditions (1) and (2) above and indicating that ASME stamp was received about March 1977.
d.
Documents showing approval of supplier and acceptable evaluation of bid for Reactor Coolant (RC) Crossover Legs on P. O. 174718 dated September 16, 1976, from Southwest Fabricating and Welding for project CBE:
Westinghouse Form 54647 (Technical Evaluation of Vendor Proposals) for base order P. O. 174710, a generic purchase order for which the project P. O. 174718 is a sub-document.
PRCil 174710, which also covers P. O. 174718.
Audits October 3,1975 (Aoproved), March 3,1976 (Approved) and June 1, 1978 (Approved).
Supplier Performance Evaluations (For : 55434):
May 13, 1976, June 8, 1977, end February 21, 1978.
Documentation showing approval of supplier for Reactor e.
Coolant (RC) fittings on P. O. 262916 and P. O. 262912 dated July 7,1977, from ESCO for projects CSL and THX:
Westinghouse Form 54647 for P. O. 262910, the base order P. O. for approximately 12 domestic plants including CSL and THX.
PRCil for base order P. O. 262910, covering the above project purchase orders.
E Audit dated August 8,1975 (Acproved), December 15, 1977 (Conditional approval) and April 27,197S (Approved).
Supplier Performance Evaluations dated September 2, 1975, September 1, 1976, September 1, 1977, and August 14, 1978.
f.
Documentation showing approval of supplier for Main Control Board on P. O. 250502 dated July 23, 1976, from Reliance for project CDE:
Audits dated July 9,1975 (Conditional approval) and October 28, 1975 and Jcnuary 13,1976 (Approved).
Supplier Performance Evaluations dated January 30, 1976, February 21, 1977, and February 20, 1978.
g.
Documents showing approval of supplier and acceptable evaluation of bid for Reactor Coolant (RC) Fittings on P. O. 197143 dated September 4, 1975, from Breda Fucine (Italy) for project NAH:
Westinghouse Form 54647 (Technical Evaluation of Proposal).
PRCN for base order P. O. 197140 (generic order covering P. O. 197143).
Audit dated March 26, 1975 (Conditional approval inoicating restrictions and P.O. conditions; audits dated August 1975, and November 1975 (Conditional approval) and June 3, 1976 (Approved) and June 21,1978 (Conditional approval).
Supplier Performance Evaluations date February 1977, and February 1978.
Manufacturing Release dated June 9,1976 (after P.O.
conditions met).
h.
Documents showing approval of supplier for new design deep well pumps (High Head Safety Injection Pumps, Low Head Safety Injection Pumps, and Containment Spray pumps) on P. O. 236991, P. O. 236992 and P. O. 236993 dated June 27, 1975, from Pacific Pumps for projects TGX and THX:
Base order P. O. 236990 dated June 27, 1975, which will result in procurement from this vendor of
. approximately 73 pumps for delivery in 1976/77, and 153 pumps for 1978/83 (not considering date slippage).
These are Vertical Auxiliary Pumps and include the three (3) purchase orders above, which appear to be the only newly designed pumps for 3XL or 4XL plants included in these orders.
Purchase Quotation Evaluation for P. O. 236990 (applicable to project p.o.s above).
PRCN for P. O. 236990.
Audits dated April 30, 1975, June 2, 1975, and June 13,1975 (Conditional approval); audits dated June 23, 1975, and July 17, 1975 (Conditional approval) and August 14, 1975 (Approved) and October 4, 1976 (Approved); Audit dated June 1, 1978 (Restricted) resulted in issuance of Supplier Corrective Action Notice (SCAN) 001277Q.
Supplier performc..ce Evaluation dated November 18, 1978, requires an audit the first quarter of 1979.
i.
Current Approved Supplier List (ASL) dated September 27, 1978, issued jointly by Purchasing and QA; above suppliers were checked for status.
j.
Documents showing approval of supplier for QA Surveillance services on P. O. 244251 from Westinghouse Nuclear Europe (WNE in Brussels, Belgium) for the Weir Pump order (P. O.
225637):
Audits of WNE dated March 8,1976 (Conditionally approved), September 10, 1976 (Conditionally approved) and follow-up on September 7, 1976, and November 22, 1976 (Approved).
k.
Training and qualifications for two (2) auditors:
Auditor 1 - Auditor Qualification Form dated January 20, 1976, and annual evaluations for 1977, and 1978.
Auditor 2 - Auditor Qualification Form dated January 20, 1976, and annual evaluations for 1977 and 1978.
. 1.
Training, qualification, and yearly eye exam forms for seven (7) ilDE personnel in the appropriate !!DE methods.
3.
F_indinas In this area of the inspection, one (1) deviation was identified (See 110tice of Deviation Enclosure, Item B).
No unresolved items were identified.