ML20005G133

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Forwards Insp Rept 99900030/89-01 on 890911-14 & Notices of Violation & Nonconformance.Implementation of QA Program Failed to Meet Certain NRC Requirements
ML20005G133
Person / Time
Issue date: 01/12/1990
From: Grimes B
Office of Nuclear Reactor Regulation
To: Valli P
BW/IP INTERNATIONAL, INC. (FORMERLY BYRON JACKSON
Shared Package
ML20005G134 List:
References
REF-QA-99900030 EA-89-244, NUDOCS 9001180174
Download: ML20005G133 (4)


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January 12, 1990 I

Cocket No.: 99900030/89-01 Mr. P. C. Valli, Chief Executive Of ficer

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BW/IP International, Incorporatec j

200 Oceangate-Boulevard Suite 900 90802 j

Long Beach, California I

Dear Mr.. Valli:

This refers to the inspection conducted by Mr. R. Pettis, Mr. M. Snodderly, Mr. C. 'Hamer, and Mr. S. Matthews of this office on September 11-14, 1989 of your facility at Vernon, California and the discussions of the findings with Mr. F. Burgers, Vice President of Operations, of your staff. at the conclusion of the inspection.

'TheinspectionwasconductedasaresultofTUElectric's10CFR50.55(e)

. report to the NRCwhich identified several swing check valves, manufactured by BW/IPInternational, Incorporated (BW/IP),whichfailedtobackseatduringhot functional testing performed at the Comanche Peak Steam Electric Station (CPSES)inMay.1989. Subsequent to this event. TU. Electric informed the NRC of a broken cast swing arm, a critical component internal to the swing check l

valve, and several other swing arms which failed certain metallurgical tests.

These valves were installed in several key safety-related systems at the CPSES -

and raise concerns over the improper use of commercial grade nonpressure boundary items in safety-related applications.

During this inspection it was found that the implementation of your quality assurance (QA) program failed to meet certain NRC requirements.

The most significant problem was the failure of BW/IP to adequately qualify suppliers of internal parts, per BW/IP established procedures, which were subsequently

. installed in safety-related check valves and pumps furnished to the nuclear industry.

In one exauple BW/IP had no documentation to support the use and

, qualification, since 1985 of ACME Castings, Incorporated, as a supplier of castvalveinternals,includingswingarms,whichhavebeeninstalledinswing check valves used in nuclear safety-related applications. ACME's quality program had been found unacceptable in 1985 by BW/IP; however, they were retained and utilized as an approved vendor without a documented basis.

BW/IP also relied on certificates of conformance from ACME without a valid basis for l

. accepting such certifications. A recent order for replacement swing arms for l

the CPSES was supplied by ACME.

It was also identifieo during the inspection that contrary to BW/IP procedures, L

-BW/IP failed to perform implementation audits for suppliers holding a current

. Certificate of Authorization issued by the American Society of Mechanical Engineers (ASME)..It should be noted that licensees and their subcontractors 9001100174 900112 PDR GA999 ENVSYRON 99900030 PNV a

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are responsible for ensuring that the supplier is effectively implementing the approved QA program as discussed in NRC Information Notice 86-21, issued March 31, 1986.

The inspectors also identified that BW/IP performed an inadequate review for suitability of 8 commercial grade replacement swing arms for safety-related.

use at the CPSES.

BW/IP's dedication was inadequate with respect to verifying the mechanical and chemical properties of the swing arm material.

In addition, the results of BW/IP's visual an) dimensional inspection were not documented.

At present, the NRC is preparing an Information Notice to all licensees on this subject. A copy of such notice will be sent to BW/IP upon its issuance.

The specific findings and references to the pertinent requirements are identi-fied in the enclosures to this letter. Areas examined during the inspection and our findings are discussed in the enclosed report.

This inspection con-sisted of an examination of procedures and representative records, interviews with personnel, and observations by the inspector.

The enclosed Notice of Violation is sent to you pursuant to the provisions of Section 206 of the Energy Reorganization Act of 1974.

You are required to submit to this office within 30 days from the date of this letter a written statement containing:

(1) a description of steps that have been or will be taken to correct these items; (2) a description of steps that have been or will be taken to prevent recurrence; and (3) the dates your corrective actions and preventive measures were or will be completed.

You are also requested to. submit a similar written statement for each item which appears in the enclosed Notice of Nonconformance. We will consider extending the response L

time if you can show good cause for us to do so.

In accordance with the " General Statement of Policy and Procedure for NRC Enforcement Actions," 10 CFR Part 2 Appendix C (1989), the violation describec l

in the enclosed Notice has been classified as a Severity Level Ill problem because a Part 21 report by BW/IP or notification of a'significant deviation to NRC licensees would have been required if BW/IP had adequately performed the required evaluation. This violation is of significant regulatory concern.

However, a civil penalty is not being proposed because pursuant to 10 CFR 21.61, the 1ailure to perform the evaluation did not appear to be the result of a knowing and conscious failure to provide the required notice.

The responses requested by the accompanying notices are not subject to the clearance procedures of the Office of Management and Budget as required by the Paperwork Reduction Act of 1980, PL 95-511.

In accordance with 10 CFR 2.790 of the Comission's regulations, a copy of this letter and its appandices will be placed in the NRC's Public Document Room.

In addition, a copy of this report will be forwarded to TV Electric and ASME for their review and information.

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Mr. P. C. Valli 3.'

Jcnu:ry 12, 1990 f.* U Should you have any questions concerning this inspection, we will be pleased to -

discuss them with you, Sincerely, t-Origin:t tiEntd by Brian K. Grirnes Brien K. Grimes, Director Division of Reactor Inspection and Safeguards Office of Nuclear Reactor Regulation 1.

Appendix A. Notice of Violation 2.

Appendix B. Notice of Nonconformance 3.

Appendix C. Inspection Report No. 99900030/89-01 cc: Mr. W. J. Cahill, Jr., Executive Vice President TU Electric 400 North Olive Street Lock Box 81 Dallas, Texas 75201 Melvin R. Green, Executive Director Codes and Standards.

American Socttty of Mechanical Engineers 345 East 47th Street New York, New York 10017 DISTRIBUTION:

VIB R/F RLPettis JLieberman DRIS R/F MSnodderly JRichardson BKGrines CGHammer EWBrach WShier, BNL ETBaker eDocket:Filei/RIOS Code IE:09

  • Previously concurred L

Document Name: BORG WARNER LETTER 1

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'NAME

RLPettis
MSnodderly
SHMatthews
CGHamer
WShier
ETBaker DATE
11/22/8S
11/22/89
11/21/89
11/22/89
11/21/89
11/24/89 DFC
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-DATE

01/j/90
12/21/89
12/22/89
01/4 /90 OFFICIAL RECORD COPY

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.3-Jcnuary 12, 1990

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Should you have any questions concerning this inspection, we will be pleased to discuss them with you.

i Sincerely, Original signed by o

Brian K. Grimes i

Brian K. Grimes, Director Division of Reactor Inspection and Safeguards Office of Nuclear Reactor Regulation r

Enclosures:

1.

Appendix A. Notice of Violation 2.

Appendix B. Notice of Nonconformance 3.

Appendix C-Inspection Report No. 99900030/89 01 t ~

. Mr. W. J. Cahill, Jr., Executive cc:

Vice President TU Electric

'400 North Olive Street Lock Box 81

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Dallas, Texas 75201 i

Melvin R. Green. Executive Director Codes and Standards American Society of Mechanical Engineers 345 East 47th Street New York, New York 10017 DISTRIBUTION: eVIS R/Fft RLPettis JLieberman DRIS R/F MSnodderly JRichardson BKGrimes CGHammer EWBrach WShier, BNL ETBaker Booke644hs/RIOS Code IE:09

  • Previously concurred Document Name: BORG WARNER LETTER OFC
VIB:DRI5:NRR*
VID:DRI5:NRR* :VIB:DRI5:NRR* :EMEB:DET*
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MSnodderly
SMMatthews
CGHammer
WShier
ETBaker LDATE 111/22/89
11/22/89
11/21/89
11/22/89
11/21/89
11/24/89

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DD:ED NAME
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.DATE.:01/j/90

12/21/89
12/22/89
01/g/90 0FFICIAL RECORD COPY

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