ML20024E671
| ML20024E671 | |
| Person / Time | |
|---|---|
| Issue date: | 07/26/1983 |
| From: | Hale C, Sears P NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML20024E667 | List: |
| References | |
| REF-QA-99900503 NUDOCS 8308160355 | |
| Download: ML20024E671 (10) | |
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ORGANIZATION:
BURNS AND R0E, INCORPORATED i
ORADELL, NEW JERSEY REPORT INSPECTION INSPECTION NO.:
99900503/83-02 DATE(S) 6/6-10/83 ON-SITE HOURS:
34 CORRESPONDENCE ADDRESS:
Burns and Roe, Incorporated ATTN:
Mr. K. Keith Roe Executive Vice President 550 Kinderkamack Road Oradell, NJ 07649 ORGANIZATIONAL CONTACT:
Mr. John DeLooper, Manager of Quality Audit TELEPHONE NUMBER:
(201) 265-2000 PRINCIPAL PRODUCT:
Architect Engineering and Consulting Services NUCLEAR INDUSTRY ACTIVITY:
The total effort committed to domestic nuclear activities is approximately 36% of the 2500 employee staff.
Major projects include the design of Washington Public Power Supply System, Unit 2 (WNP-2);
Clinch River Breeder Reactor; post-accident conditions update for Three Mile Island, Unit 2; and design verification for Oyster Creek.
ASSIGNED IN5PECTOR:
P. M. Sears, Reactor System Section (RSS)
Date OTHER INSPECTOR (S):
APPROVED BY:
t O_ _/
b 73 C. J.',dkle, ChieT, RSS Date INSPECTION BASES AND SCOPE:
A.
BASES:
Topical Report 8&R0E-COM4-1-NP-2A.
B.
SCOPE:
Status of previous inspection findings, Burns and Roe (B&R) 10 CFR Part 21 report of errors in ADLPIPE computer code, and B&R 10 CFR Part 21 report of remote shutdown panel design deficiencies for WNP-2.
PLANT SITE APPLICABILITY:
DESI-MATED ORIGIFAD t!NP-2, Docket No. 50-397.
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ORGANIZATION:
BURNS AND ROE, INCORPORATED ORADELL, NEW JERSEY REPORT INSPECTION NO.:
99900503/83-02 RE3ULTS:
PAGE 2 of 5 A.
VIOLATIONS:
None B.
NONCONFORMANCES:
1.
Contrary to B&R Topical Report (B& ROE-COM4-1-NP-2A) Section 2.2 and Section 6.2, no approved plan exists for source surveillance, quality assurance auditing, or performance verification of computer programs supplied by vendors of computer codes.
2.
Contrary to B&R Topical Report (8&R0E-COM4-1-NP-2A), Section 5.2, a design error involving the remote shutdown panel went undetected through the design process, including design verification.
C.
UNRESOLVED ITEMS:
None D.
STATUS OF PREVIOUS INSPECTION FINDINGS:
1.
(0 pen) Nonconformance (82-01):
The B&R, Richland, Washington, office controlled set of WNP-2 Project Instructions contained super-seded revision 4 of WMP-3-ED-010.
Action on this item was deferred pending an inspection of the B&R, Richland, Washington, office.
2.
(0 pen) Nonconformance (82-01):
Certain subanalyses of design calculation 5.51.053 were not identified as to status, not checked, nor verified as required by procedure WNP-2-ED-020.
Action on this item was deferred pending an inspection of the B&R, Richland, Washington, office.
3.
(0 pen) Nonconformance (82-02):
Procedures were not available or were not employed to require independent verification / validation of computer programs.
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ORGANIZATION:
BURNS AND ROE, INCORPORATED ORADELL, NEW JERSEY REPORT IN5FLUlluN NO.:
99900503/83-02 RESULTS:
PAGE 3 of 5 1
i Procedures are now in place to independently verify / validate computer programs; however, the procedures in place have not been completely implemented because not enough time has been available.
This item will be reviewed during the next inspection at B&R, Oradell, New Jersey, office.
4.
(Closed) Nonconformance (82-02):
Superseded revision 0 of procedure, "(Computer) Program Approval and Certification," was not removed by the designated coordinator from the controlled copy of the Corporate Operations Manual assigned to the B&R Woodbury facility library.
A special audit was performed to verify that the Corporate Operatic;.3 Manuals in the New York, New Jersey, and Richland, Washington, offices are up to date.
The audit is complete and no examples were found where Corporate Operations Manuals were not complete.
5.
(Closed) Nonconformance (82-02):
The latest issue of the computer program index did not list:
(1) all engineering and design programs available to B&R users; nor (2) the advisor's names for all programs that were listed in the index.
The computer program index now lists all engineering and design programs available to B&R users and it also lists advisor's names for each of the programs available to B&R users.
6.
(Closed) Nonconformance (82-02):
No currently available vendor supplied programs listed in the computer program index were designated as " Certified-V" even though they were available for use by B&R computer users.
Each vendor supplied computer program, which is listed in the computer program index, has been designated as a " Certified-V" program.
7.
(Closed) Nonconformance (82-02): Procedures were not available or,ere not employed to:
a.
Control the distribution of computer program manuals to appropriate users activities.
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ORGANIZATION:
BURNS AND R0E, INCORPORATED ORADELL, NEW JERSEY REPORT INSPECTION NO.:
99900503/83-02 RESULTS:
PAGE 4 of 5 The Technical Services Librarian now requires prospective users of computer programs to request a controlled copy of the users program manual.
b.
Maintain and retain documents needed to provide traceability
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and to support " certified" computer programs with the status of a QA record.
B&R has upgraded its storage facility (vaults) to 3-hour fire-rated status and an audit of the records indicated that those records were maintained and retained with the status of a QA record.
c.
Determine the cause of significant deficiencies in computer programs and implement corrective actions in the QA program to prevent their recurrence.
B&R has implemented Project Procedure ED-003, " Reporting of Defects and Noncompliance," which delineates methods to be used to report computer code defects.
d.
Disseminate computer program experience report to cognizant design personnel.
The computer center at B&R has started to distribute experience bulletins to computer program users.
e.
Assure that the impact of changes to computer programs are considered and that the changes be subjected to design control measures that were, or should have been, applied to the original computer program.
An Engineering Standard covering the procedure for the validation of technical computer programs has been prepared and implemented and a procedure for modifying computer programs is contained in Section C, Part IV-B of the Computer Users Manual.
E.
OTHER FINDINGS OR COMMENTS:
l 1.
Errors in ADLPIPE Computer Code - ADLPIPE computer code is a tool l
used in the nuclear industry to design piping.
It is a large computer
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ORGANIZATION:
BURNS AND R0E, INCORPORATED ORADELL, NEW JERSEY REPORT IN5PtCl10N NO.:
99900503/83-02 RESULTS:
PAGE 5 of 5 code and has been in use since the early 1960's and has gone through many revisions.
ADLPIPE is owned by DIS /ADLPIPE, Inc., and is licensed for use (with disclaimers) throughout the nuclear industry.
- Recently, B&R discovered two errors in ADLPIPE computer code.
ADLPIPE output indicated nonconservative stresses at reduced branches and also, under certain circumstances, zero forces were erroneously indicated at skewed bellows. B&R reported these errors via 10 CFR Part 21, reviewed their design efforts with respect to ADLPIPE, and took internal corrective action.
(One of the ADLPIPE errors, nonconservative stresses at reduced branches, has led NRC to issue an IE Information Notice 83-31 wherein potential users were notified of the error.)
During this inspection, it was determined that B&R does extensive verification runs of ADLPIPE as new versions are released by DIS /ADLPIPE, Inc.
New versions are not released internally for use at B&R until numerous benchmark problems are run.
B&R imposes the requirements of 10 CFR Part 21 through its purchase ordcrs to vendors of computer codes which are used in the designs of various systems in nuclear power plants.
In this area of the inspection, one nonconformance was identified (see B.1 above).
2.
Remote Shutdown Panel - B&R reported under the guidelines set forth in 10 CFR Part 21, two problems associated with the remote shutdown panel at WNP-2.
Controls for a valve required to be operable from the panel did not exist on the panel.
Also, power to a supervisory panel in the remote shutdown panel originated in the control room (power to the remote shutdown Danel must be independent of the control room).
The design of the remote shutdown panel had been reviewed by B&R and no other deficiencies were identified.
Control switches for the valve (SW-PCV-388) have been relocated on the remote shutdown panel and power to the supervisory panel is now supplied from outside l
the control room.
No other facilities are affected and it was found that the cause of the problem was design error (see B.2 above).
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