ML20011A376

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QA Program Insp Rept 99900524/81-03 on 810804-07. Noncompliance Noted:Vendor Drawings Approved by Gibbs & Hill Did Not Satisfy in-house Design Requirement Needs for 600 psig-rated Sys
ML20011A376
Person / Time
Issue date: 09/17/1981
From: Fox D, Hale C
NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV)
To:
Shared Package
ML20011A359 List:
References
REF-QA-99900524 NUDOCS 8110090368
Download: ML20011A376 (18)


Text

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ORGANIZATION: GIBBS AND HILL, INC.

NEW YORK, NEW YORK REPORT NO.: 99900524/81-03 INSPECTION DATE(S):

8/4-7/81 INSPECTION ON-SITE HOURS: 60 CORRESPONDENCE ADDRESS: Gibbs and Hill, Inc.

ATTN: Mr. R. P. DeRienzo, Vice President 1

Quality Assurance 393 Seventh Avenue New York, NY 10001 52 7b' TELE E

PRINCIPAL PRODUCT:

Architect Engineering and Consulting Services.

NUCLEAR INDUSTRY ACTIVITY: The total effort committed to domestic nuclear design activities is approximately 25% of the 1,900 employees of Gibbs and Hill, Inc.

at their New York facilities. Major design projects include Comanche Peak, Units 1 and 2, Three Mile Island, Unit 1 FSAR update, Beaver Valley, Unit 1 equipment update, and Bellefonte, Unit I design studies.

ASSIGNED INSPECTOR: b f_k'L[f[0/-

I-/ 7 -h /

D. F'.40x, React 6r' Systems Section (RSS)

Date OTHER INSPECTOR (S):

D. D. Chamberlain, RSS C -/ 7 f /

/

O APPROVED BY:

C. J.'4Mle, Chief, RSS Date INSPECTION B/. ! AND SCOPE:

A.

BASES:

10 CF! Part 50, Appendix B; Topical Report GIBSAR-17-A; and the PSAR and FSAR for tne Comanche Peak Steam Electric Station (CPSES), Units 1 and 2.

B.

SCOPE:

Design interfaces, design change control, and status of previous inspection findings.

L DESICliATED ORIGINAL Certifica By UAR/[f 8110090368 810923 PDR GA999 EECGIBB 99900524 PDR

1 ORGAMZATION:GIBBS AND HILL, INC.

I NEW YORK, NEW YORK N NO.:99900524/81-03 INSPECTION RESULTS:

PAGE 2 of 5 4.

VIOLATIONS:

None 3.

NONCONFORMANCES:

Contrary to Criterion'V of Appendix 8 to 10 CFR Part 50 and to the requirements of Gibbs and Hill (G&H) Procedure PC-5, vendor drawings depicting valves with 300 PSI rated flanges, to be supplied by Westinghouse in accordance with their Equipment Specification for use in certain 600 PSIG rated safety-related por-tions of the safety injection and residual heat removal systems of the CPSES, were approved by G&H even though the valve' did not satisfy the G&H in-house design requirement for 600 PSIG rated flanges to be used in these systems.

C.

UNRESOLVED ITEMS:

None 4

D.

STATUS OF PREVIOUS INSPECTION FINDINGS:

1.

(Closed) Unresolved Item (80-02):

The following two safety concerns did not appear to be timely evaluated and reported in accordance with the intent of 10 CFR Part 21.

a.

HEPA filters and demisters did not appear to be seismically qualified prior to their installation at the Fort Calhoun and at the CPSES nuclear power stations.

The NRC inspector determined that the G&H procurement specifications for these items for both Fort Calhoun and CPSES required that the

... supplier wa'.1nt their design to be such that seismically induced stresses would not impair their ability to operate at maximum capacity when required...."

Review of supplier correspondence indicated that it was not industry practice, at the time these items were delivered to either site, to seismically test the units with their internal components installed. Thus, seismic qualification of the delivered units could not be established by G&H.

Subsequent seismic qualification testing of representative completed units to the CPSES seismic spectra was conducted under G&H's direction in late 1980 and early 1981.

No degradation of the physical appearance nor in the performance characteristics was reportedly observed. A G&H analysis of similar units installed at Fort Calhoun concludes that they "... are inherently capable of successfully withstanding any seismic loading to which they could possibly be subjected...."

ORGANIZAM GIBBS AND HILL, INC.

NEW YORK, NEW YORK REPORT NO.: 99900524/81-03 INSPECTION RESUI.TS:

TeAGE 3 of 5 The Texas Utilities Generating Company and the Omah a Public Power District were advised by G&H of the CPSES and Fort Calhoun results, b.

The post-LOCA airborne radiation protection afforded control room operators at the Fort _Calhoun and the CPSES nuclear power stations did not appear to be adequate.

The inspector verified that G&H processed this safety concern in a responsible manner and timely advised the Texas Utilities Generating Company and the Omaha Public Power District that a G&H engineer expressed concern that control room operators may be exposed to excessive radiation levels under certain postulated post-LOCA con-di tions. Responses from both indicated that they did not consider the G&H engineer's concern to constitute a substantial safety hazard to either the control room operators or to the publiE.

Further action, if any, on this item will be taken directly with the licensees by NRC Headquarters.

2.

(Closed) Nonconformance (81-01):

Management evaluation of the Engineer-ing Department and the QA program was not performed as scheduled.

Gibbs and Hill reviewed their in-place program for implementing the 10 CFR Part 50, Appendix B requirement for periodic management review of the status and adequacv of the n.-place quality assurance program and concluded that certain peccedural and methodology changes were desirable.

Procedure QAI-G (Procedare For Performance of Audits) was revised to change the requirement for Vice Presidents, or Assistant Vice Presidents to institute an annual review (audit) of the areas under their cognizance to require them to conduct an in-depth evaluation of all internal audit findings against their organizations that were reported by G&H QA since the last annual management review.

3.

(Closed) Nonconformance (81-02):

Failure to submit to NRC changes in the QA program and organization described in the G&H Topical Report GIBSAR-17-A.

Amendment 5 to GIBSAR-17-A was evaluated by NRC and deemed acceptable on July 8, 1981. G&H management stated that status reports will be issued periodically to NRC to identify changes in the QA program and organization described in the Topical Report.

4.

(Closed) Follow Up Item (81-02): The effectiveness of the intradis-ciplinary and interdisciplinary review of both G&H and vendor design documents will be evaluated.

1 ORGANIZATM GIBBS AND HILL, INC.

NEW YORK, NEW YORK REPORT NO.: 99900524/81-03 INSPECTION RESULTS:

PAGE 4,of 5 This item was elevated to a nonconformance.

See B. above.

5.

(. Closed) Follow Up Item (81-02): The basis for, and tracking of, design changes from PSAR commitments will be evaluated.

G&H Procedure DC-12 (Safety Analysis Reports - Preparation and Review Procedure) cescribes the basis for, and methodology of, initiating, reviewing, approving, and documenting SAR changes.

Implementation of this procedure will be verified during future design inspections.

E.

OTHER FINDINGS OR COMMENTS:

1.

Design Interfaces - The related sections of the CPSES Project Procedure Manual, PSAR, and FSAR were examined to determine the commitments and requirements relative to control of internal and external design inter-faces.

Five system descriptions, four specifications, fifteen drawings, three letters, twelve records of interdisciplinary reviews, nine component modification cards relating to the residual heat removal system, the safety injection system, and the chemical and volume control system were examined to verify effective implementation of commitments.

With respect to the Nonconformance identified in Section B of this report, Crosby drawing DS-C-56885-B, Fisher Drawing F-42310-E, and other valve drawings supplied by Westinghouse, depict valves rated at 300 PSIG with 300 PSIG rated flanges that were designated by Westinghouse for use in certain safety-related sy tems whose pressure and temperature design 0

conditions were stated as 600 PSIG and 400 F in Westinghouse System Description SD-TBX/TCX-284 and in the CPSES FSAR.

Six hundred PSIG rated piping flanges cannot physically mate with 300 PSIG rated valve flanges, thus the 600 PSIG rated piping flanges are reportedly being removed from piping installed at CPSES and are being replaced with Type F316 300 PSIG rated flanges and the pipe fabrication isometric drawings revised accordingly. Westinghouse Equipment Specification G-678854 (Revision 1) states in part, that "... A 300 # RF Flange of Grade F316 may be substituted for the 600 # RF Flange of Grade 5304.

whenthesystemrequirementsfallwithingheANSI300#F316 temperature and pressure conditions (600 PSIG and 400 F design conditions)...."

G&H piping Specification 2323-MS-43A does not permit this substitution.

Except as described herein, the committed program for control of design interfaces was being implemented.

ORGANIZATION: GIBBS AND HILL, INC.

NEW YORK, NEW YORK REPORT NO.: 99900524/81-03 INSPECTION RESULTS:

PAGE 5 of 5 2.

Design Change Control - The related sections of the CPSES FSAR and applicable project procedures were examined to determine commitments and requirements. The following documents were examined to verify that commitments were implemented: Component Modification Card Affected Document Report, Design Engineering Change Deviation Request List, Design Change Authorization Master Index., 20 Design Change Authorizations Requests, 5 Component Modificatio6 cards (CMC)g/ Change Deviation (D (DCA), 10 design drawings, 6 Design Ec91neerin

, and 2 OA audit reports.

Except as noted herein, the comitted program for design change control was implemented. Certain anomalies were noted in the Design Change Authorization Master Index (computer index) and the cerraroonding DCAs and DE/CDs. The computer index for DCAs was initiated in iate 1980 in order to accurate ~iy track design changes.

The back fit of the index for DCAs that were controlled originally by the G&H Dallas Office was done from an index received from the Dallas Office.

It appears that the information transferred from the Dallas Office index was inaccurate in certain areas. G&H must now go directly to the DCA documents and input the correct data into the computer index. G&H management stated that the back fit of the correct data is a major effort and that they would have a documented plan available for NRC review by September 15, 1981.

This plan will address projected dates for the back fit of the correct data into the computer indexes and assure that all design change documents are readily available in the project file.

Examination of recently issued documents indicated that they were properly listed in the computer indexes and were readily available in the project files.

Progress made in the competer index updates and in the ready retrievability of design change dr ;ments will be followed during future inspections.

I

PERSONS CONTACTED Company bisss 4 Wilt cates 8/3-Occket/ Report No. %90o 5 2 y/81-03 Ins;:ector D, F, Fox Page l of 7.

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Dock;t flo. '19700.92y Inspector D. F-Fox geport,,o, 7,_ g3 Sccpe/ Module O F s;c a l e p ra t-/.c r s DOCUMENTS EXAMillED 4 I 2 TITLE /5UBJECT 3 I 3 D C -S "A s> w fiv><w h e cww6 - Dir ru uix u r-I - n 4 r 2. 3 D C-9 1) n s w ki, c,. o Vx cc i s &n - S !n s ro c a ricos " C 1 ~1 '1 4 r 3 3 s c so " D e m. J k, t.

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l Dock'.t rio.17400624-i Inspector D (A4M6ER L AIN Report rio. sr-c3 Sccpe/ Module 979968 DOCUMEffTS EXAMINED l l 4 1 2 TITLE / SUBJECT 3 / 1 3 f'sorec7 6cNT6ct FRcCEDCE6 No, PC-4 DESI6N CHAN66 JUQ 31 86Y. b 2.- VRC Ttc 7 GUIDE <(( TIld 5,15 PGtlfSSIMG f rn L '*\\ A OCR 'S Y27/S.] S 3 oesw aarecL ranc Eocan No. Dc-3 06Au)Ia? racoucma RF t' A k ff 0 EbC T (-GiOL s(C TICN '9 I rdtDiflC A Tot N A F TER 06Rf tNG jf27/61 ISs0E0 Fc R FAFRtc A7 es Ano/cR ccHsTRoc trna [ 3 PRC if CT A DrnlN tSTR AT1\\lE ff c Lent:RE PR-4 ('RO C E Ot!Rt TO W51 REY. ( (CNTinL 159URNLE AND rnRINTE HRN(6 0F THF FRc7(CT 6t'oDL h 3 DFND (CEGIGN CH (.IntERf N& rHANGL DEt'IRTitN) No, 5-M44-1/22/80 1 1 rA l - C ?4 I ftGL PRt TEC TIC H PlflHG - ELECT. CmTRtL AND REY D RCx 1LinRY RI'lL DIN G S S .L M1-Il03 sert'Ic E wRT6R INTRYL PIPIMG SE V 12 9 L M 1-11c3-ci GERt' ice u:ATER INTAKE REV,10 lO 3 DLA 2588 DESl&N ( t~f 0 N(.f 0\\'THORI ?ATrl+1 FOR mi-lin'8 REV. + ll DGA %30 Il RC.1 I2 OLA 4cS2 il REll.1 l3 7 DCA 6444 u REV.o I Document Types: Columns: 1. Drawing 5. Purchas Order 1. Sequential Item Number 2. Specifica tion 6. Internal Memo 2. Type of Document 3. Procedure 7. Letter 3. Date of Document 4. QA Manual 8. Other (Specify-if necessary) 4. Revision (If applicable)

4 Inspectcr D. CHAMBERLAIN gicyt rio Scope / Module 9799bO DOCUMEffTS EXAMIflED I 2 TITLE / SUBJECT 3 4 14 cmc (ccccucar rivo,ricamu carn) 4+s56 FcR wns Vu/81 REV i 8 15 3 GMC 80134-FoR. rn !- llo 8 REV 2 16 3 c,M c 3ss20 u REV. 5~ ret / 2 17 8 cmc 33238 er 13 3 cmc 33983 FOR Ml-llo3 REl/. 2 l@ l Ml- 06!0 CCH TRla rnFH T %PRRY PflaG RRRAN(;EMEHT R6 !. ( zo S DE4 o 9 /90 FcR M 1- 0510 Rft',I 2L TGH-I9 GA AlinI T FILb 6/30k0 22 I 76fl - / 9 dd 6t/De7 bLb /5/2h/@ _2 R i Ml-n20h ' Fluo DIRGRArn AUXIURR1 f660eJRitR 54STtrA R6t!6 7.4 DCA 434% FOR MI-020h RE l. O l 2 5-ocA S44[ u REi/. 0 REV,0 26 ti Oc/i 99/7 29 ncA 94n 4 n' Nt\\! I A/21/77 23 DE/cn 5-19e u 29 5 06/co s-2395 Fcs EL-LS l'2/3)he Document Types: Columns: 1. Drawing 5. Purcha; Order 1. Sequential Item Number 2. Specification 6. Internal Memo 2. Type of Document 3. Procedure 7. Letter 3. Date of Document 4. QA Manual 8. Other (Specify-if necessary) 4. Revision (If applicable)

~ Inspector D c4Am6ERLAIN R li. Sc pe N ule NNO DOCUMEllTS EXAMIllED 1 2 TITLE / SUBJECT 3 4 30 S DCA A-234 FoR E I-IS 2 /24/81 '81 l E l-D N 9; ll ?> t' Ac INST 80rn6N 7 605 Dl5TRl6U710W R6t 6 / ONE LlHL Dlh6RRm '42 D(: A 9G3% FoR El- 003% su 76 (t'o r o ) Gt t'. L 83 L E[-005S SH, 75 50LEncto OPERATED VALL'E I-H L'- 218b R60. 3 34 5 DcA 4533 JM Ff - 003 8 SH. 76 66 t/. 2 35 L F L-Ol%7 E An. CcNTROL PANEL l-DG-02A R6t. 6 l 36 DI-/c0 5- _ccR E i- 018 7 64 o 39 L E L - 0500 - O L_r ciD gR Bell 0 LNG TRAY 4 CcHout7 PLAN REL 15 13 OC0 ICl45 fck fi- 0600 - O L &l23h'l 39 D6 SIC N 66 altd FcRrn fes El-CI57 .fE d. 4 f/2cht l_LL n S ~DcA %&C3 FOR E1 - 0500 -01 1/zi/tt 41 15 DCA %BbA Il V/5hl C6 t' L 42 3 Dr A 026I le 66v 0 43 8 DC n b 817 it EE t! l 44 3 DtkD 5-12640 i< Wi/en Document Types: Columns: 1. Drawing 5. Purchas Order 1. Sequential Item Number 2. Specification 6. Internal Memo 2. Type of Document 3. Procedure 7. Letter 3. Date of Document 4. QA Manual 8. Other(Specify-ifnecessary) 4. Revision (If applicable)

Insp ctor O. GNOM66k[blQ Dockst flo.99100624 R: port If;. g/.og Scope / Modulo 3779[o b Pag] 10 cf 10 DOCUME0T3,EkAMIllED 1 2 TITLE / SUBJECT 3 4 45 i EL-oo19 T%svk IzS/2su oc os uu oramam REV.10 46 8 DCA S 733 Fo R El M REV. o 47 5 OcA Fo% GEV. 2 u k% 8 DESIGrJ C H A Nf-6 Ar!THeRrTATlw MA 576G lN06% 5lG/TI k4 8 CC nip Nf u T Mt D t FIC A 7 ten (ARD AFf6(160 Oc( vrr1(n7 dt('tR *T f/2 7/?t-t 'S0 Of GI( N!fN(.ml{ERI N?/C DAM 6E/ M'1ATICd RfMt&T LIS T f///k/ 5I OcA s449 Fo k El-19 REII. D b? W CCA 4%2A GEY. 0 50 S (cm4NCVW (ERY iW NcT F6AR 5 F( Tit N 12 5/86/79 Document Types: Columns: i. Drawing 5. Purchas Order 1. Sequential Item Ntaber 2. Specifica tion 6. Internal Memo 2.. Type of Doctnent 3. Procedure 7. Letter 3. Date of Doctment 4. QA Mantv' 8. Other (Specify-if necessary) 4. Revision (If applicable)

V c ATTENDANCE LIST f,, COMPANY: Glb8S & HlLL tl ~ 6 3 DOCKET NO. 90000$2h Ddte: 8' b'l l l Pre-Inspection Conference lp( l Post Inspection Conference .[ (Please NAME (Please Print) TITLE (Please Print) ORGANIZATION Print) IO, P Po.x ?twc>in Eos wren v s Nxc Rse, Tr D. D, C HArABERLAll\\l CONTRACTOR INSPECTOR US H% REG 11 -E 3. z Avuna Atsr on msa G gy 11/LfbF IE4 20 N. f. Q.)- G Et if. Cza raopovslG Pro ie < F GA b' NG. G # 1/ v /V /V El'DD /S /lanwir- (d V SK// i 2.G. R 4 w d Ede who,m G+H u &c h, A4 ' & hm,11 aA n1 wM nv 6(H m 1}}