ML20010A098
| ML20010A098 | |
| Person / Time | |
|---|---|
| Issue date: | 06/22/1981 |
| From: | Brown R, Whitesell D NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML20010A097 | List: |
| References | |
| REF-QA-99900317 NUDOCS 8108110062 | |
| Download: ML20010A098 (5) | |
Text
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a VENDOR INSPECTION REPORT U.S. NUCLEAR REGULATORY COPNISSION OFFICE OF INSPECTION AND ENFORCEMENT REGION IV Report No.
99900317/81-01 Program No. 51300 Company:
Cooper Industries, Inc.
Cooper Energy Services Division, C-B Reciprocating Products Grove City, PA Inspection Conducted:
June'l-5, 1981 a
Inspectors:
e M
2 Ross L. Brown, Contractor Inspector Date Components Section, Vendor Inspection Branch Approved b 7 4/s.)/p/
D.'E. Whitesell, Chief Date Components Section, Vendor Inspection Branch Summary Inspection on June 1-5, 1981 (99900317/81-01)
Areas Inspected: Management meeting, implementation of 10 CFR 50, Appendix B, including internal audits, action on previous inspection findings and 10 CFR Part 21 follow up. The inspection involveo 30 inspector hours on site by one NRC inspector.
Results:
No nonconformances or unresolved items were identified during this inspection.
9108110062 010707 PDR GA999 EMVCOIN 99900317 PDR
DETAILS SECTION A.
Persons Contacted C. C. Bemiller, Manager, Quality Control
- C. H. Patterson, Senior Quality Control Engineer
- Attended Exit Meeting B.
Vendor Activities Cooper Energy Services (CES), Grove City, Pennsylvania, management stated that they presently have one contract for two diesel-generator sets that ce scheduled for completion during the fourth quarter of 1981.
C.
Action on Previous Inspection Findings 1.
(Closed) Deviation A and B (79-01). An inter-office memo listing the required actions, commitment dates and persons responsible for the activity to correct the NRC findings (79-01). The satisfactory com-pletion of the four deviations (79-01) as scheduled verified confor-mance with the CES letter of May 1, 1979.
2.
(Closed) Deviation C (79-01). The Internal Corrective Action Master List, 14 Corrective Action Requests, and two Internal Audit Reports of Correc-tive Action Controls indicate that reminder forms have been issued for all Corrective Action Request that have been delayed for thirty days in conformance with QCP-P0-4, Revision 1.
3.
(Closed) Deviation D (79-01). The Revision 4 to QCP-10-5 that gives the Quality Control Department in each CES plant the authority to implement their internal audit program was approved and issued.
The Audit Status Reports for the first quarter of 1981, and the third and fourth quarters of 1980, indicates that the internal audits were perfonned in conformance with the established Grove City audit schedules.
4.
(Closed) Deviation E (79-01). The inter-office memo issued May 9,1979, which clarifies the meaning of the Record Code described in QCP-10-1, Documented Inspection Audit Report and three completed Inspection Plans indicate, conformance with commitment in the CES letter dated May 1, 1979.
5.
(Closed) Deviation F (79-01). The new Standard Operating Procedure QCP-1-065 describing the method by which QC procedures and QC Inspection Plans are revised, approved and issued was issued for use on June 25, 1979.
Two audit reports, Audit Status Report for first quarter of 1981, and two QC Inspection Plans verified conformance with QCP-1-065.
. D.
10 CFR Part 21 Follow dp 1.
Background Information i
Cooper Energy Services reported to the NRC on November 3, 1978, of a deficiency found within a KSV Power Engine. This engine is part j
i of the emergency standby diesel-generator set supplied by CES for installation at the following facilities:
a.
Nebraska Public Power, Cooper Station, two engines, SN's 7102 and 7103.
b.
Commonwealth Edison, Zion 1 & 2, five engines, SN's 7090, 7091, 7092, j
7093, and 7094.
l c.
Pennsylvania Power & Light, Susquehanna 1 & 2, four engines, SN's 7157, 7158, 7159, and 7160.
[
d.
Louisiana Power & Light, Waterford 3, two engines, SN's 7170 and 7171.
Carbon copies of the' letter of notification to the NRC were transmitted to the CES customer for the above facilities.
The extent of the deficiency was as follows: Each power cylinder has one inlet and cae exhaust push rod assembly and two valve crosshead assemblies Psrt No. Z 25-1-2-10.
This assembly contains: a crosshead, a roller pir, and a pin collar.
It was found during performance testing that some sub-assemblies showed abnormal wear on the surface of the roller pin. No engine shutdown nor malfunction had been experienced, but CES management felt that over a longer period of engine operation this abnormal wear could progress far enough-to cause the engine to malfunction.
i, 2.
Corrective Action The corrective action taken by CES was as follows:
a.
Redesign Part No. Z 25-1-2-10 and change Part No. to Z 25-1-2-16.
Inter-office memo dated November 8,1979, states KSV Diesel Engine i
Generator was fully tested with the new designed crosshead.
Each intake and exhaust crosshead assembly was visually inspected and no evidence was found which would cause any premature failure of these assemblies.
4 l
The results of this performance test are included in Report of Witne:s Test of KSV-20-T Engine Generator Set CES-S0-0420, SN 7196.
b.
The engines which have had field running at the licensees site were inspected by CES to determine if cam rollers have become sluggish and incipient cam scuffing is occuring.
l l (1) CES Service Representative Report dated November 14, 1978, states the cam rollers in engines SN's 7102 and 7103 at Cooper Station, were inspected and no rollers looked damagech No replacement was required.
(2) CES Service Representative Report dated December 2,1979, states that the crossheads in engines SN's 7090, 7091, 7092, 7093, and 7094 at the Zion 1 & 2 sites were inspected and measured and found acceptable.
No replacements were required.
(3) CES letter to Pennsylvania Power & Light stated that the changeout of crosshead assemblies had been supervised by CES Service Repre-sentatives in the following engines SN's 7157, 7158, 7159, and 7160.
(4) CES Service Representative Report dated June 18, 1980, states that the changeout of crosshead assemblies in engines SN's 7170 and 7171 at the Waterford 3 site had been completed.
This reported deficiency appears to have been handled in accordance with the CES procedure QCP-10-14, Revision 1, dated December 10, 1980,
" Reporting of Deficiencies as Requirea by 10 CFR Part 21."
E.
Internal Audits 1.
Objectives The objectives of this area of the inspection were to verify that the following items were controlled in accordance with QA Manual and appli-cable NRC and ASME Code requirements:
a.
A written system has been established to assure that audits are per-formed 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 respon-sibility in the area audited.
d.
Follow up action, including re-audit of deficient areas, is taken where indicated.
2.
Method of Accomplishment The preceding objectives were accomplished by:
a.
Review of QAM - Section 2, Subsection 2.7 " Audit of the Quality Assurance Program.
\\
. b.
Review of five internal audit reports, c.
Review of procedure QCP-10-5, Revision 4, " Internal Audits."
d.
Review of three follow up audit reports, e.
Review of six auditor qualification records, f.
Review of audit schedule for the years 1980 and 1981.
3.
Findings a.
The i.,spector verified the following information:
(1) QAM Section requires an audit of each departnent to be con-ducted annually, as a minimum, by trained personnel using a prepared check list.
The QAM Section also requires that copies of the completed audit reports to be sent to the upper management and they shall also be made available to the ANI for review.
(2) The qualification records identifies the applicable training of each auditor.
(3) The audit schedule indicates that all plant departments shall be audited at least once, annually.
(4) The audit repcrts includes the audit check list signed by the lead auditor and QA Manager. The check list identifies the pertinent paragraph of the QAM Section to be audited, objec-tive evidence, compliance and any appropriate comments.
If deficiencies are identified, the appropriate correct action and completion date is assigned:
b.
No deviation or unresolved items were identified in this area of the inspection.
F.
Exit Interview The inspectors conducted an exit meeting with the CES management representa-tives at the conclusion of the inspection. Those persons indicated by an sterisk in Paragraph A above were in attendance.
In addition, the follow-ing were present:
S. P. Bigley, QC Technician G. Darcangelo, QC Technician B. W. Phillips, QC Technician
. The inspector discussed the scope of.the inspection and the details of the finding identified during the inspection.
The inspector also discussed the NRC method of reporting and informed those present that they will receive a copy of the inspection report for their review for any proprietary information.
The CES management comments were generally for clarification.
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