ML20008E338
| ML20008E338 | |
| Person / Time | |
|---|---|
| Issue date: | 08/25/1980 |
| From: | Brown R, Whitesell D NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML20008E328 | List: |
| References | |
| REF-QA-99900394 NUDOCS 8010240584 | |
| Download: ML20008E338 (10) | |
Text
~
U.S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT REGION IV Report No.
99900394/80-02 Program No. 51300 Company:
Metal Bellows Corporation 20977 Knapp Street Chattsworth, CA Inspection Conducted: August 11-14, 1980 Inspectors: '
?~
~, V, s...,,
- -r Ross L. Brown, Contractor Inspector Date ComponentsSection I Vendor Inspection Branch
'J D. E. Whitesell, Chief Date ComponentsSection I Vendor Inspection Branch
?* dd.N.
Approved by: _. x U fe b r..,,:
D. E. Whitesell, Chief Date ComponentsSection I Vendor Inspection Branch Summary Inspection on August 11-14, 1980 (99900394/80-02)
Areas Inspected:
Implementation of 10 CFR 50, Appendix B including audits, training, document control, action on previous inspection findings, and the reported construction deficiency in the pump discharge accumulators.
The inspection involved forty four (4a) inspector hours on-site by two (2) NRC inspectors.
Results:
No deviations from commitment or unresolved items were identified during this inspection.
8010240 STt
T 2
DETAILS SECTION A.
Persons Contacted
- R. A. Ely, Quality Assurance Manager
- L. E. Furman, Assistant QA Manager-
- C. M. Parker, QA Engineer
- E. A. Jachacz, Staff Engineer J. Huffman, Senior Project Engineer.
- Attended Exit Interview.
B.
Action on Previous Inspection Findings (Closed) Deviation (Report No. 80-01).
The inspector verified that the rejection report form has been revised to include the reason for error and corrective action to prevent' recurrence. QA has also issued Standard Operating Procedure - Directive No. QAD-0-003. that describes the use of the revised 'fonn and assigns the responsibilities for the implementation.
The item is considered to be closed.
C.
General Metal Bellows Corporation (MBC) has active commercial nuclear contracts extending through the third quarter.of 1983 for the manufacture of ASME Class 2 and 3, and nuclear safety related flexible metal bellows and hoses.
D.
Audits 1..
Objectives The objectives of this area of the inspection were to verify that the following items were controlled in accordance with the QA Manual i
and applicable NRC and ASME Code requirements:
a.
A written system has been established to assure tnat audits J I are performed: and controlled in accordance with applicable codes to verify compliance with all auditable aspects of the QA program.
b.
- Planned and periodic audits are performed in accordance with written procedures or checklists by qualified personnel not having
- direct responsibilities in the areas being audited.
c.
Audit results are documented and -reviewed by management having responsibilityLin the area audited.
3 d.
Followup action, including reaudit of deficient areas, is taken where-indicated.
2.
Methods of Accomplishment The preceding objectives were accomplished by:
Review of Metal Bellows Corporation (MBC) Quality Assurance a.
Nuclear Manual Revision B. date September 7, 1979 (QAM) Section it, " Audit."
b.
Review of HBC - Quality Audit Procedure, Revision E. date August 7, 1980, c.
Review of the 1980 Quality Audits Log.
d.
Review of audit checklists.
l Review of three (3) internal audit reports.
e.
f.
Review of audit report distribution list.
g.
Review of February 1980, Management Audit of QA.
h.
Review of five (5) auditors certification files.
3.
Findings The inspector obtained the following information:
The QAM - Section 12 establishes the requirements for:
a.
(1) A periodic audit of th; averall QA system, arranged by the Vice President, Chatsworth Division.
(2) All departments to be audited at least once every six months, by qualified 1HH: auditors, using written procedures.
(3) All audit reports to be submitted to the Vice President, Chatsworth Division for his review and approval.
(4) Corrective action and re-audits if necessary.
b.
The Quality Audit Procedure, establishes an audit system to assure that all functions of each department complies with the specified requirements.
It also assigns the responsibility for the adminis-tration and operation of the system with the QA Manager.
4 The procedure also includes prepared checklists for all departments.
The audit log identifies the checklist no., department audited, c.
date audited, and date next audit due, d.
The checklist identifies the area of the program to be verified, audit results, auditor signature, audit date, corrective action (if required), and Vice Presidents signature for approval.
The auditor certifications includes the record of training and e.
experience, and are signed by the Certified Auditor.
The Certified Auditors' certification is signed by the General Manager.
No deviations from commitment or unresolved items were identified in this area of the inspection.
E.
Document Control 1.
Objectives The objectives of this area of the inspection were to verify that:
Procedures have been prepared by designated authority, ap;-oved a.
by responsible management, and reviewed by the QA function.
b.
Approved procedures provide for:
(1)
Identification of personnel positions or organizations responsible for preparing, reviewing, approving, and issuing design documents and revisions thereto.
(2) Coordination and control of design interface documents.
(3) Ascertaining that proper-documents, and revisions thereto, are accessible and are being used.
(4)
Establishing distribution lists which are updated and maintained current.
(5)
Review and approval of significant changes by the same organizations that performed the original document review and approval.
2.
Method of Accomplishment The preceding objectives were accomplished by a detailed review of:
h 5
QAM Section 2, " Design and Drawing Control."
a.
b.
Nuclear Documentation Log.
Three (3) Engineering Change Orders (ECO) and appropriate drawings.
c.
d.
Documentation of Compliance.
e.
One Design Report for Hose Ass.mbly, Flexible Metal per ASME Boiler and Pressure Vessel Co,e,Section III, Subsection NC Class 2.
f.
Customer documents (purchase order and specification) for customer PO 79KA2-826321 (MBC Job No. 14385).
3.
Findings The inspector verified the following:
a.
The QAM requires all customer and/or owner documents be entered in the receiving log.
It also establishes the distribution list for all engineering and manufacturing documents.
It further establishes the documents to be controlled and assigns the responsibilities for the action.
b.
The documentation log (one for each job no.) is divided in three (3) sections:
receiving, distribution and transmittal.
The documents identified to be controlled are entered in the appropriate section.
The ECOs and revised drawing were approved as required and c.
entered in the documentation log.
d.
The design report and documentation of compliance were complete and included in the document control program as required.
In this area of the inspection no deviations or unresolved items were identified.
F.
Training 1.
Objectives The objectives of this area of the inspection were to verify that procedures have been established-and implemented that provide for:
a.
Formal indoctrination and training or retraining programs for new employees and reassigned employees (excluding NDE personnel).
1 l
1 1
6 b.
Training of audit personnel, including technical specialists, that provide for:
(1) Orientation with applicable standards and procedures.
(2) General training in audit performance including fundamentals, objectives, characteristics, organization, performance and results.
(3) Specialized training in methods of examining, questioning, evaluating, documenting specific audit items, and methods of closing nut audit findings.
(4) On the job training, guidance, and counseling under direct supervision of an experienced, qualified auditor to include planning and performing audits; reporting and followup action; and review and study of codes, standards, procedures, instruc-tions, and other documents related to QA and QA program auditing.
c.
Training programs for other personnel performing quality related activities that include:
(1) A description of quality assurance material to be presented and method of presentation.
(2)
Identification of individuals by job description or titles or groups required to attend sessions.
d.
Documentation of attendance and retention of other applicable records for all forma,lized training accomplished.
2.
Method of Accomplishment The preceding objectives were accomplished by a detailed review of:
a.
QAM - Section 13 " Training".
b.
Record of Training on Nuclear Monual and Related Subjects.
c.
On The Job Training (0JT) Log by Departments.
3.
Findings No. deviations from commitment or unresolved items were identified.
The inspector verified the following:
4 7
The QAM requires all personnel to receive quality training as a.
appropriate to their activities.
It also assigns the QA manager the responsibility for the training of inspectors, auditors and department managers, and each department manager is responsible for the training of his departments personnel.
b.
The record of training identifies the subject of instruction, date, hours of presentation, attendees, instructor and date and the distribution list.
These records indicate that the responsible people did receive training related to the latest QAM revision.
The departmental OJT Log, for January through July 1980 identifies c.
the employee, date, length of training session, subject and instructor.
G.
Reported Construction Deficiency 1.
Background Information On June 14, 1979, TVA reported a potential construction deficiency to NRC Region II, scerning the failure of the bellows in the pulsation damper in the o..tharge piping of the reciprocating charging pump.
The failure occured during preoperational tests at Sequoyah, Unit 1, and similar units have been purchased for Watts Bar facilities.
The failure has been attributed to excessive wear between the metal bellows and its guide tube.
The purpose of the bellows is to act as a diaphram, or bladder, to maintain separation between the fluids in the charging system on one side of the bellows, and the charging gas on the other side. The pulsation damper assembly, which includes the metal bellows, absorbs reflected energy (water-hammer) that might be experienced in the charging system.
It also minimizes the intensities of the pressure waves which are inherent to positive displacement pumps.
2.
Objectives The objectives of this area of the inspection were to ascertain whether an evaluation had been performed to determine the safety significance and reportability of the problem, and whether the problem might have generic impact.
3.
Method of Accomplishment The above objectives were accomplished as follows:
8 Review of Purchase Order (PO) number 78-KAI-824720 dated 11-14-78, a.
to verify date of contract, b.
Review of Design Specification (DS) number WBNP-DS-1935-4015-1C to ascertain the governing edition and addenda of the code, com.
class, design temperature and pressure specified, the service environment identified, and wnether the DS was certified by a registered professional engineer.
c.
Review of Metal Bellows (MB) Purchase Order Notification to verify that it had been processed in compliance with the MB QA Manual requirements.
d.
Review of Engineering Change Notices number 17774 dated 7/2/80.
e.
Review of Drawing numbers 76738 Revision A dated 11/30/78 and 76739 - Revision B dated 6/29/79 to verify that the requirements of the customer's DS had been correctly incorporated in the design drawings.
f.
Review of Design Calculations numbers CR 522 with revisions A and B to verify that design changes and as-built drawings had been reconciled with the calculations.
g.
Review of the Wear and Friction Test summary, Reference no. 13300, dated 6-25-78, conducted by M-B to establish the most appropriate materials (s) or combination of materials, which would provide the least amount of wear on the bellows.
h.
. Review of the QA Manual, Revision B, dated 09-07-79.
Section 1.5.1 " Processing Contracts;" Section 2.1.5 " Design Control;"
2.1.5.5.1; " Design Verification by Test."
To verify that the drawings and tests had been processed and controlled in a manner consistent with the Program requirements.
i.
Discussions with the cognizant Engineering and QA personnel, concerning the identified potential deficiency.
i 4.
Findings a.
The design specification requires the Pulsation Damper to be designed and manufactured in accordance with the requirements i
of the 1977 edition, through the 1977 winter addenda, of Section III of the ASME codes.
The design temperature was specified to l
be 150 F, pressure 2735 psig.
The operating temperature and pressure was recorded as being 130 F and 2235 to 2455 psig re-spectively. The charging gas was specified at 750 psig and 70 F l
L
'I
r 9
temperature.
The fluid service was identified as radioactive borated water. The environmenta' conditions stipulated, ambient temperature of 140 F (max) anu em6 'ent pressures to be - 0.3 psig, humidity 80%, radiation at 2 rad /hr. The extetaal loads and moments were given for the nozzels.
The DS stipulated that the seismic analysis would be performed by customer (TVA), the.DS was certified by a registered P.E.
that it complied with the requirements of NCA 3250,Section III of the ASME codes.
b.
It was determined that the Purchase Order had been properly processed in accordance with MB QA Program requirements.
It was verified that the customer's sad code requirements were c.
correctly incorporated in the design calculations and drawings, and that the documents were controlled in compliance with the QA Manual requirements.
5.
Corrective Action As part of the failure analysis, MB conducted a series of wear a.
and Friction tests using test specimens of various materials compatible with the specified service requirements and environ-ment; to determine the most suitable material, or combination of materials, which produced the least coefficient of static friction and amount of wear.
b.
It was determined from these tests that stainless steel and nylon, with water present is the best combination of materials, after 100,000 cycles there was no measurable wear.
No deteriation of materials occured under conditions that caused the failure experi-enced at Sequoyah.
c.
Replacement parts were then designed and manufactured from the materials proven by test to be the most acceptable.
The replace-ment parts have been shipped to both Sequoyah and Watts Bar for installation by TVA.
d.
The cavity on the gas,ide o' the bellows is charged with a specified quantity of demineralized water which provides lubri-cation between the contact surfaces of the stainless steel guide, and the nylon bearing on the moveable ;erminal of the bellows.
6.
Generic Impact MB has determined from a review of its nuclear contracts, that this problem is only generic to TVA's Sequoyah and Watts bar, and Dukes i
l
r se 10 McGuire.
Duke was notified of the problem and the appropriate replace-ment parts have been shipped to McGuire for installation.
7.
Action to Prevent Recurrence To prevent recurrence of the problem, the pertinent parts and a.
assembly drawings were revised requiring the guide to be manu-factured from 17-4PH or 17-7PH and heat treated, and the bearing on the moving terminal of the bellows to be of nylon.
8.
Safety Evaluation The Final Report transmitted by letter from TVA to NRC Region II a.
dated July 9, 1979, states that the reciprocating charging pump is not safety related.
However, the loss of the function of the Pulsation Damper, would result in the system having to absorb the pressure fluctions generated by the pump and/or any back reflected energy (water hammer) in the system which could increase the stress and/or vibrations to unacceptable levels in the safety related piping down stream from the pump.
On this basis the Licensee determined that the problem was reportable under 10 CFR 50.55(e).
H.
Exit Interview The inspector conducted an exit meeting with the Metal Bellows Corporation management representatives at the conclusion of the inspection. Those persons indicated by an asterisk in Paragraph A were in attendance.
In addition, the following persons were present:
J. K. Solheim, Vice President Operations K. Hart, Chief Engineer The inspector discussed the scope of the inspection and the details of the finding during the inspection.
The MBC management's comments were for clarification only.