ML19347E186

Responds to NRC 810105 Ltr Requiring Addl Info Re Violations Noted in IE Insp Repts 50-508/80-09 & 50-509/80-09. Corrective Actions:Will Revise Drawings to Show Acceptable Reduced Welds & Lengths & Welds Will Be Inspected

ML19347E186
Person / Time
Site:	Satsop
Issue date:	03/13/1981
From:	Dobson D WASHINGTON PUBLIC POWER SUPPLY SYSTEM
To:	Faulkenberry B NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION V)
Shared Package
ML19347E185	List: ML19347E186 ML19347E188 ML19347E327
References
GO3-81-747, NUDOCS 8104240207
Download: ML19347E186 (5)

Text

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7r PHONE {2%) 249-5001 March 13,1981 G03-81-747 Nuclear Regulatory Commission, Region V Suite 202, Walnut Creek Plaza 1990 N. California Boulevard Walnut Creek, California 94596 Attention: Mr. B. H. Faul kentarry Chief, Reactor Construction Projects Branch Gentl emen:

Subject:

WPPSS NUCLEAR PROJdCTS 3 AND 5 NRC INSPECTION OF WNP-3 AND WNP-5 DOCKET NUMBERS 50-508 AND 50-509

Reference:

1). G03-81-264, letter, D. E. Dobson to R. H. Engelken, dated January 29, 1981.

2). Letter, G. S. Spencer to F. D. McElwee, dated January 5,1981.

3). G03-8t-2966, letter, F. D. McElwee to G. S. Spencer, dated November 21, 1980.

4). Letter, F. H. Engel ken to R. L. Ferguson, dated October 23, 1980.

Reference 2 required additional information to allow NRC assessment of corrective actions stated Reference 3. The Washington Public Power Supply System responses to your specific questions are include herein.

1. What specific actions will be taken to correct the nonconforming welds on the gas decay tanks? When will this action be completed:

Richmond Engineering Company has performed a design review and determined the welding requirements specified on the drawings are excessive. Based on this review the drawirgs will be revised to show acceptable reduced weld sizes and l en gth s .

The undersize and incomplete welds will be inspected by CE/RECO to ensure they meet the reduced weld size require-ments. If they do meet the reduced requirements, CE will recommend a final disposition of "use-as-is" and will provide calculations justifying the reduced weld size. We expect the existing welds to meet the reduced weld size requirements.

• 104240'dO~f SI .50

Mr. B.H. Faulkenberry . tiarch 1301981 4

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G03-81-747 The completion date of the above actions is indeterminate at this time.

2. Your letter references a new program for vendor quality assurance.

What is the content of this program? Is this program a change from the program identified in the PSAR?

The new program referenced is a training program. On the outset, it is important to clarify that the referenced Vendor Quality Assurance Training program is 'new' in relation to the WNP-3/5 Site. This program is provided as supplementary training to the existing VQAR program described in the PSAR and does not change the scope of that program.

The on-site VQAR training is expressly designed to be a Site-specific orien-tation and training session and consists of the following topics:

a) Description of the WNP-3/5 Site Quality Assurance Program b) Receiving Inspection c) Quality Assurance Records d) Deliberate Malpractice Law The program is designed to encompass a concentrated training effort completed over a period of two-days. Lecturers consist of Quality Assurance Management and Staff personnel cognizant of the topics presented.

Due to the number of Ebasco VQARs assigned to the WNP-3/5 project and in order to assure completion of this program by all, it has been necessary to schedule several sessions. The first three (3) have been completed and the balance are scheduled to be conducted by fiay 29, 1981.

For Finding A, date of full compliance stated in Reference 3 is hereby changed to 11ay 29,1981.

3. Your letter states that strong corrective actions have been initiated to control and correct adverse trends. What are these actions? What results were achieved?

a). The Supply System responded to the NRC on 11-21-80 via G03-80-2966, regarding measures for strengthening the VQA Program, as follows:

' The WNP-3/5 Vendor Quality Assurance Program is being strengthened to function more effectively. The new program will include provisions for review of recurring problems of deficiencies. All Ebasco vendor Quality Assurance Representatives assigned to Wi!P-3/5 contracts will receive

, on-site indoctrination and training. Included in this training will be site requirements, contract requirements and a synopsis of vendor fabrication history and quality probl ems .

Mr. B.H. Faulkenb:rry March 13,1981 G03-81-747

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b. Current status and additional information concerning these efforts is as follows:

An on-site central information gathering program has been established. This activity accumulates information regarding equipment and vendor problems;' summarizes the problems and presents them to project supervision for review and action.

This activity has to date resulted in the following:

1. Identification of significant equipment problems with components supplied under Contract 3240-02, Combustion Engineering. On September 15, 1980 a stop shipment order was issued against Combustion Engineering. This action was taken because of the number and severity of probl ems.

An on-site meeting with CE Quality and Project Management personnel was arranged to discuss CE's intended corrective measures. As a result of this meeting, the Supply System developed a program which requires CE to obtain written approval from the Supply System prior to the shipment of any Quality Class I components to WNP-3/5. This program was fully implemented on 10-4-80. This program will remain in force until the contract is completed. The Supply System has also expanded vendor surveillance activities of the 3240-02 contract.

Additional actions hve been to initiate a plan to replace Ebasco Vendor Quality Assurance Representatives with Supply System Vendor quality Assurance Engineers on the 3240-02 contract.

2. A stop shipment order affecting all ASME hangers was issued against Contract 3240-04, AP&E's sub-contractor ITT Grinnel .

This order was issued on 9-15-80 because of software problems with this vendor.

On September 22, 1980 an on-site meeting was held with Mr. D.M. Sewell, Hanger Division, Quality Assurance Manager.

As a result of this meeting, the stop shipment was lifted on September 26, 1980.

3. A problem with components supplied by Ingersoll-Rand under contracts 3240-11B and 1161 was identified. A Supply System VQA Engineer visited the Ingersoll-Rand shop to investigate.

His visit resulted in identification of quality problems.

A stop shipment was issued which affected all equipment supplied by this vendor. The quality and shop problems were resolved in December,1980. Shipment of equipment resumed on 12-9-80 on a piece by piece basis.

..' ,. Mr. B.H. Faulkenberry March 13,1981

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G03-81-747

4. PX Engineering's quality performance on Contract 3240-26 was evaluated to be marginal. Since PX has been awarded a change order to provide eight (8) steam generator blowdown heat exchangers, a Supply System Vendor Quality sur/ey was performed. This survey was completed on January 15, 1981. It resulted in the issuance of fourteen (14) Quality Finding Reports. The vendor was informed that no equipment will be shipped to the site until the identified problems are resolved. The Ebasco VQAR's were also instructed not to release this equipment until all problems have been resolved to the satisfaction of the Supply System.

c. Additional measures include:

1. Transfer of. the Ebasco VQA Supervisor to the WNP-3/5 Site, effective March 2,1981.

2. Development of an on-site indoctrination and training session for Ebasco VQAR's. This training was initially given on 1-5-81. Ebasco WNP-3/5 VQAR's will have completed this session by flay 29, 1981. The program will be on-going for VQAR's assigned to WNP-3/5 contracts.

3. Review of vendor quality assurance surveillance plans for adequacy.

4. Review of the Ebasco VQA Program with the New York VQA supervision at the WNP-3/5 Site.

5. The establishment of resident vendor quality assurance representatives at:

a. AP&E, Compton, California and Clearfield, Utah

b. ITT Grinnell, Warren, Ohio

c. Borg-Warner, Van Nuys, California

d. Fought Company, Tigard, Oregon

e. Isaacson, Seattle, Washington

f. Chicago Bridge & Iron, Salt Lake City, Utah

4. Do you intend to take any action for other vendor supplied equipment which has been received at the site? If so, please identify these actions.

The answer to question 3 lists those contracts where adverse quality trends have been identified and corrective action begun. The Supply System will continue to monitor and evaluate vendor performance.

Corrective action will be initiated if adverse trends develop.

Should you have any questions or desire further information, please feel free to contact me directly.

Very truly yours, h

D.E. DOBSOY Acting Program Director, WNP-3/5 cc: D. Smithpeter - BPA Ebasco - New York WNP-3/5 Files - Richland

D.E. DOBSON, Being first duly sworn, deposes and says: That his is the Acting Program Director, WNP-3/5, for the WASHINGTON PUBLIC POWER SUPPLY SYSTEM, the applicant herein; that he is authorized to submit the foregoing on behalf of said applicant; that he has read the fore-going and knows the contents thereof; and believes the same to be true to the best of his knowledge.

DATED 3.\3 , 1981.

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D.E. DOBSON STATE OF llASHINGTON )

) ss COUNTY OF GRAYS HARBOR)

On this day personally appeared before me D.E. D0BSON to me known to be the individual who executed the foregoing instrument and acknowledged that he signed the same as his free act and deed for the uses and purposes therein mentioned.

GIVEN under my hand and seal this / day of 'OlMC L , 1981.

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. Notary Public in and for the State of Washington Residing at i t>'O