ML19291B634
| ML19291B634 | |
| Person / Time | |
|---|---|
| Site: | Crane  |
| Issue date: | 06/02/1970 |
| From: | Heishman R, Howard E US ATOMIC ENERGY COMMISSION (AEC) |
| To: | |
| Shared Package | |
| ML19291B631 | List: |
| References | |
| 50-289-70-03, 50-289-70-3, 50-320-70-03, 50-320-70-3, NUDOCS 7911110039 | |
| Download: ML19291B634 (9) | |
Text
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U. S. ATOMIC ENERGY COMMISSION REGION I DIVISION OF COMPLIANCE Report of Inspection C0 Report Nos. 289/70-3 320/70-3 Licensee:
Metropolitan Edison Company Three Mile Island Units Nos. I and 2 License Nos. CPPR-40 and CPPR-66 Date of Inspection:
May 11 and 12, 1970 Date of Previous Inspection:
March 30 and 31, 1970 Inspected by:
R. M. Custafson, Metallurgical Engineer, DRS F. L. Liederbach, Staff QA Engineer, CO:HQ R. F. Heishman, Reactor Inspector, CO:I Sh O
Compiled by:
R. F. Heishman, Reactor Inspector, CO:I Date Reviewed by:
d4/pg) b ~2-70 WE.'ti. Howard, Senior Rea' lor Inspector, CO:I Date c
Proprietary Information:
None I.
Summarv The inspectors found that B&W had develop 9d and is impleuenting a quality assurance program which generally meets the commitments in the ap-plication and Appendix 3 to 10 CFR 50.
A major reorganization, which is further discussed under Criterion I, has been effected in the B&W Power Generation Division. The following areas were found by the inspectors which require further development by the licensee:
A.
Procedures for training and qualification of QA/QC personnel have not been developed or implemented; however, qualified personnel are performing QA/QC duties.
(Criterion II) 3.
Development and implementation of instructions regarding the scope and depth of design review to be performed on systems and components have not been completed.
(Criterion III)
O ON O
yggt 1582 223
2 C.
Procedures for disposition of cbsclete docu=ents were not fcund.
(Criterien VI)
D.
Policy on long term record retention was not in evidence.
(Criterion XVII)
II.
Gene ral A.
Background and Farpose The initial quality assurance inspection was conducted d iring the week of December 1,1969.* Numerous deficiencies were found in the QA efforts of the Babcock and Wilcox Ccmpany (B&W).
Based on the above findings, a reinspection of the B&W QA efforts was conducted on May 11 and 12,1970. Only those areas fcund to be deficient were reinspected. This inspection was limited to Criteria I, II, III, IV, VI, VII, IX, X, XVI, XVII, and XVIII.
The reinspection was conducted to meet en objectives outlined in cecorandum, Chief, Reactor Inspection and Enforus_ent Branc1, CO, to Senior Reactor Inspectors, Organization of Special QA Inspections, dated June 24, 1569, and PI LOCO /1, Quality Assurance.
B.
Team Membership and Assignments 1.
R. F. Heishman, Reactor Inspector, CO I - Responsible for the coordination of the inspection and inspec dion of organization and program conformance with application ecmmit=ents and Criteria I, II and XVIII.
2.
R. M. Gustafsen, Materials and Metallurgy Branch, DRS -
Responsible for procurement and ccnformance with the application and with Criteria IV,. VII, X and XVIIIof Appendix 3,10 CFR 50.
1 F. J. Liederbach, Staff Ouality Assurance Engjnear, C0;HQ -
Re-ronsible for inspection of design conformance with the applica-tien and Criteria III, VI, IX, XVI and XVII of Appendix B,10 CFR 50.
C.
Sequence of Events 5/8/70 Pre-inspection conference, all team members at C0:HQ, Bethesda, Maryland.
5/11-12/70 Incpecticn of B&W QA program for Three Mile Island 1 and 2 at the B&W design office in Lynchburg, Virginia.
- C0 Report No. 286/69-6 and 320/69-2 15S2 224
n.
. r
. D.
Personnel Contacted During Inspection Activities Metropolitan Edison Company G. F. Bierman, Project Manager, Met Ed B. G. Avers, Manager, Quality Assurance, GPU T. G. Hreczuch, Construction Engineer, Met Ed MPR. Associates N. M. Cole J. Gorman Babcock and Wilcox Company W. H. Rowand, Vice President and General Manager, NPGD J. H. MaMillan, Manager, Contract Department E. G. Ward, Project Manager, TMI-l&2 H. F. Dobel, Manager, Quality Assurance, NPGD D. W. Montgomery, Manager, NSS Engineering A. H. Lazar, Manager, NSS Components Engineering C. E. Thomas, Manager, Construction Section W. A. Cobb, Assistant Project Manager, TMI-2 F. R. Thomasson, Assistant Project Manager, TMI-l C. R. Powers, QAR, Mechanical C. M. Fletcher', QAR, Electrical R. E. Manoll, QAR, PGD Manufactured Equipment R. E. Braumiller, QAR, Fuel III.
Project Status No project status
- information was obtained during this inspection, which was limited to the nuclear steam supplier. Only those areas found to contain deficiencies during the initial QA inspection were inspected.
IV.
Significant Inspection Findings The significant findings during the inspection are summarized below, tabu-lated by Criterion. Only those criteria found deficient during the initial QA inspection ** conducted during the week of December 1,1970, are included.
The supporting details are retained in C0:I files and are available if re-quired.
- Memo, J. P. O'Reilly to SRI Quality Assurance Inspections, dated 1/23/70
- C0 Report Nos. 289-69-6 and 320/69-2 15B2 225
e
-4 Criterion I - Organization A.
Discussion Babcock and Wilcox Company (B&W) Power Generation Division has been reorganized as shown on Figure I.
The transition from the organizational structure previously reviewed to the present structure appears to have been well planned and smoothly accomplished.
The relationship between the Nuclear Power Caneration Department (NPGD),
QA organization (Lynchburg) and the Engineering Technology Department (ETD) QA organization (Barberton) was not clearly established during the inspection.
The responsibilities of NPGD QA manager are clearly defined in the NPGD QA manual; however, a similar document was not reviewed for ETD QA.
Both ETD and NPGD QA departments provide policy on QA/QC matters and potential con-flicts are possible.
The inspectors were informed that a task force appointed by the vice president of the Power Generation Division is studying this matter and will make recommendation regarding the need for additional organizational changes.
B.
Findings "The B&W organization meets the commitments in the application and the intent of this criterion.
Criterion II - Quality Assurance Program A.
Discussion B&W has established and is implementing a QA program which generally complies with the application and Appendix.B to 10 CFR 50.
Detailed. procedures for training and qualification of QA/QC personnel have not been completed.
B&W is continuing to refine the QA program with detailed procedures and in-structions.
The NPGD QA manual and TMI Unit No. 2 QA plan have been approved and implemented in the recent past.
B.
Findings The B&W QA program meets the commitments of the application and the intent of this criterion except for the procedures and instructions regarding training end qualification of personnel.
Criterion III - Desian Control A.
Discussion Objective evidence was found that the engineering groups of B&W interact very closely and that major emphasis is placed on developing and standardizing lcJ 2
nn-<<o
n.
.. rigorous, comprehensive company standards. Not only is there an extensive review process between NPGD Systems Engineering and NPGD Components Engineer-ing, but in some cases other divisions or consultants are utilized to pro-vide additional reviews. Missing, however, was clear policy defining the scope and depth of design review to be applied against each component or design interface in a long list of items, each of which is assigned a quality level category.
B&W has assigned four levels of quality to the equipment they furnish and is now developing the list of items which will require formal design re-view. Definitions of the type and extent of design review to be conducted are in the process of being developed.
B.
Findings The B&W system of design review meets the commitments of the applica-tion and the intent of Criterion III of Appendix B to 10 CFR 50 except for the development and implementation of instructions pertaining to the scope and depth of design review to be applied to systems and equipment assigned the various quality levels.
Criterion IV - Procurement Document Control A.
Discussion B&W has developed and implemented a system for procurement. document control which is documented in sections 6A and 6B of NPGD " Quality Assurance Manual for Steam System Components and Fuel", B&W 19A-2E-4, April 21, 1970.
Objective evidence was found that confirmed procurement document control is implemented for items procured by both intern'al and external procurement groups.
B.
Findings The B&W procurement document control program meets the commitments of the application and the intent of Critericn IV of Appendix B to 10 CFR 50.
Criterion VI - Document Control A.
Discussion B&W has developed and implemented a system of document control whida is documented in the following specifications:
19A-2E4-7A, Document Control; 19A-2C4-5A, Design Control; and 19A-2E4-4A, QA Program. A computer printout is made and distributed to provide the latest information on revisions and new documents for the use of all concerned individuals. Procedures for dis-position of obsolete documtnts were not found during this inspection.
1582 227
. B.
Findings The B&W document control program when fully implemented meets the commitments in the application and the intent of Criterion VI of Appendix B to 10 CFR 50 except for procedures governing disposition of obsolete documents.
_ Criterion VII - Control of Purchased Material, Equipment and Services A.
Discussion The quality assurance group at Lynchburg has established procedures which provide tight control over their procurement of material, equipment and services.
They have a workable system of vendor evaluation, and through the development and training of their field surveillance group, have the means of implementing tight control over their vendors.
The resident QA represent-atives at the Mt. Vernon and Barberton plants provide a continual surveillance of their procurement effort, and evaluate their suppliers on. a regular basis.
B.
Findings B&W's program of control under this criterion was found to meet the commitm,ents in the application and the intent of Criterion VII.
Criterion IX - Control of Special Processes A.
Discussion B&W has developed and is implementing a system for control of special processes. Limited objective evidence was found to show the degree of imple-mentation. Recently approved documents such as the NPGD QA Manual provide the necessary guidance and implementation is being accomplished in a timely manner.
B.
Findings B&W's program of control, when completely implemented, will meet the commitments in the application and the intent of Criterion IX.
Criterion X - Inspection A.
Discussion NPGD QA, through its field surveillance group, is maintaining a check on the quality control plan of each of its suppliers. Through the use o'f QA data sheets, hold points and specific inspection functions are indicated.
Until a release is signed by NPGD QA representatives, indicating that all re-quired inspections have been completed, the manufactured item cannot be shipped.
Each supplier's quality control manual is checked to insure that it is ade-quate with respect to direct inspection, i.e.,
(NDT procedures, dimensions, i582 22B
. checks and process monitoring involving processes such as heat treatment and cleaning.)
B.
Findings The B&W program of inspection meets the commitments in the application and the intent of Criterion X.
Criterion XVI - Corrective Action A.
Discussion NPGD QA Manual devotes a section to corrective action and provides guidance to document same. In addition, the Compontents Engineering Procedures Manual, sections 5.11.2 and 7.14.0 address the subject for the engineering groups. Objective evidence was found to show the implementation of this por-tion of the program.
B.
Findings The B&W program of corrective action meets the commitments of the ap-plication and the intent of Criterion XVI of Appendix B to 10 CFR 50.
Criterion XVII - Records A.
Discussion B&W has developed a system of compiling, storing and retrieving QA records which is documented in the NPGD QA Manual, Three Mile Island QA Plans and a draf t procedure which is still being nmiewed regarding long range st,orage of records. The system includes check lists for ensuring all re-quir~ed records of quality are included in the files. Objective evidence of implementation was found during the inspection. A plan for long term record retention was not in evidence.
B.
Findings B&W's program for quality assurance records meets the commitment of the application and the intent of Criterion XVII of Appendix B to 10 CFR 50 except for long term record retention procedures.
Criterion XVIII - Audits A.
Discussion 1.
Internal Audits The NPGD QA Manual establishes a system of periodic audits of all parts of the department and vendors (both B&W departments and i582 229
t 8
outside vendors). The Manual prescribes form, detail and fre-quency of audit (four per year). Checklist and scope statements are included and also the preparation of the audit report. The audit teams will be composed of four members as follows:
1 member of QA section 1 member of standards and coordination section 2 members selected from the other sections of the depart-ment but not the department being audited.
The audit reports are distributed to management and the department head is required to submit a corrective action report to manage-ment.
Reaudit will be accomplished if appropriate, as determined by management.
No internal audits have been performed to date but a schedule has been prepared and the first one due to be performed in June 1970.
2.
Vendor Audits It was established that the NPGD QA group is systematically and regularly auditing their vendcrs at various intervals with the frequency of audit depending on the essentiality of the item.
It was pointed out that each vendor will be audited at least once a year on items of least criticality, whereas items such as cumps obtained from Bingham Pump are audited on a monthly basis.
It was indicated that for items of average importance, audits are scheduled at a frequency of 3 - 4 times a year. The procedures for auditing are detailed and-are indicated in_their QA Manual.
A number of audit reports were reviewed, which revealed that a tight audit program is in effect.
The contractor has established a satisfactory audit program for their vendors' plants and for their own manufacturing facilities.
Discussions with various members of the quality assurance staff revealed they were well qualified and knowledgeable in quality assurance matters. They had a good awareness of the intent of the AEC QA criteria, and they reflected the determination expressed by their management to administer such a program.
B.
Findings B&W has developed a system of audits which when totally implemented will meet the intent of Appendix B to 10 CFR 50 and the application.
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UNITED STATES ATOMIC ENERGY COMMISSION oivision or cours. ANCE 201 645 3942 i
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April 16, 1970 J. P. O'Reilly, Chief, Reactor Inspection and Enforcement Branch, Division of Compliance, HQ INQUIRY MEMORANDUM METROPOLITAN EDISON COMPANY (TMI-1) 289/70-A LECAY HEAT COOLERS Region I was provided the following information on April 16, 1970.
During a vendor inspection, the licensee determined that the decay heat cooler tubes (S/S) were cleaned in a chlorinated solvent (Trade-name - Valcolene). The coolers have been installed at the site.
B&W has authorized the removal and return of the coolers to the manu-facturer: Whitlock Manufacturing Company, 101 South Street, West Hartford, Connecticut.
A chemical analysis of the solvent (Valcolene) showed that it con-tained 37. methyl chloride.
N N. C. Moceley V
Senior Reactor Inspector-cc:
E. G. Case, DRS R. S. Boyd, DRL (2)
S. Levine, DRL D. J. Skovholt, DRL (2)
L. Kornblith, Jr., C0 REG files Regional Directors, CO
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