ML20031G681

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QA Program Insp Rept 99900334/81-02 on 810713-17. Noncompliance Noted:Crankshaft Oil Plug Acceptance Criteria Not Defined,Swaging Operation Not Detailed & Tool Accuracy Not Controlled.Records Incomplete
ML20031G681
Person / Time
Issue date: 09/15/1981
From: Barnes I, Foster W
NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV)
To:
Shared Package
ML20031G674 List:
References
REF-QA-99900334 NUDOCS 8110230461
Download: ML20031G681 (14)
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Text

TRANSAMERICA DEL',VALo INC ORPORATED ORGANIZATION:

ENGINE AND COMPRESSOR DIV.

OAKLAND, CALIFORNIA REPORT NO.: 99900334/81-02 INSPECTION DATE(S): 7/13 - 17/81 INSPECTION ON-SITE HOURS: 30 CORRESPONDENCE ADDRESS: Transamerica Delaval, Incorporated Engine and Compressor Division ATTN:

Mr. C. Mathews, General Fbnager 550 85th Avenue Oakland, California 94261 ORGANIZATION CONTACT:

Mr. R. E. Boyer, Manager - Quality Assurance TELEPHONE:

(415) 577-7422 PRINCIPAL PRODUCT: Stand-by diesel generators.

NUCLEAR INDUSTRY ACTIVITY: Did not obtain during this inspection.

ASSIGNED INLPECTOR:,h[ [ N 9/f r/ p f W. E. Foster, Reactive Inspection Section Date l, OTHER INSPECTOR (S): None l

? Is'[F t APPROVED BY:

4-I. Barnes, Chief, Reactive Inspection Section Date l

l l

INSPECTION BASES AND SCOPE:

~.

BASES:

10 CFR Part 50, Appendix B.

A l

l B.

SCOPE: The Engine and Compressor Division of Transamerica Delaval, Incorpor-ated, filed 10 CFR Part 21 reports on the diesel generator's:

(1) turbocharger thrust bearing lubrication system; and (2) crankshaft oil plug installation.

l The former affected numerous nuclear power plants and resulted in followup l

requests from the Office of Inspection and Enforcement, Region II (RII).

l The latter was limited to the Phipps Bend Nuclear Power Plant, Unit 2.

OIE, RII also requested followup on:

(1) unqualified motors used for auxiliary lube oil and jacket water pumps; and (2) malfunctioning of a 6-inch check valve.

Both of thesa were located at the Grand Gulf Nuclear Power Station, l

Unit 1 for the motors; Units 1 and 2 for the valve.

Also, limited inspection was conducted on previous inspection findings.

E h AhA I

99900334 PDR CcdiNd D

TRANSAMERICA DELAVAL, INCORPORATED ORGANIZATION: ENGINE AND COMPRESSOR DIV.

0AKLAND, CALIFORNIA REFORY NO.: 99900334/81-02 INSPECTION RESULTS:

PAGE 2 of 5 INSPECTION RESULTS A.

VIOLATIONS:

None.

B.

NONCONFORMANCES:

1.

Contrary to Criterion < of Appendix B to 10 CFR Part 50 and paragraph 5.1.2 of the Quality Assurance Manual, Revision 0, dated February 27, 1981, the parts list and component drawing released by engineering ncd not defined the acceptance criteria of the installed crankshaft oil plugs.

Further, the route sheet that provided instruction for installation of the oil plugs contained no acceptance criteria.

2.

Contrary to Criterion V of Appendix B te 10 CFR Part 50 and paragraph 5.3.2 of the Quality Assurance Manual, Revision 0, dated February 27, 1981, the instructions at Element C of Operation No. 55 of the Assembly /

Test Route Sheet, Revision 1, dated June 20, 1961, for Job No. 02933 did not provide details of the swaging operation of the crankshaft oil plugs.

3.

Contrary to Criterion XII of Appendix B to 10 CFR Part 50, measures had not been established to assure that tools used in the crankshaft oil plug installation are properly controlled and adjusted at specified periods to maintain accuracy within necessary limits.

4 Contrary to Criterion XVII of Appendix B to 10 CFR Part 50 and paragraph 4.17.1 of Specification No. 9645-G-QA-1, Revision 5, dated March 1980, (and previous editions), records had not been maintained to furnish evidence that the motors for the auxiliary lube oil and jacket water pumps had been environmentally qualified.

5.

Contrary to Criterion VII of Appendix B to 10 CFR Part 50 and paragraph 4.7 of Specification No. 9645-G CA-1, Revision 5, dated March 7, 1980 (and previous editions), documer tary evidence was not available to assure that the seller of the m, tors for the auxiliary lube oil and jacket water pumps had compliec with the requirements of the purchase order.

C.

UNRESOLVED ITEM:

1.

Element K of Operation No. 55 of the Assembly / Test Route Sheet, dated June 20, 1981, for Job No. 02933, Sub-Assembly 40. 1A-5636 states,

" Final Inspection (Inspector to retain this document)." Subsequent to query, the NRC inspec;;r was informed that all uninspected elements were inspected. Also, a dye penetrant test was conducted on the oil plugs installed in the creak:naf t during Element K.

Inasmuch as no details are evident at Element K, the NRC inspector was undble to determine the final inspection requirements.

TRANSAMERICA DELAVAL, INCORPORATED ORGANIZATION: ENGINE AND COMPRESSOR DIV.

0AKLAND, CALIFORNIA REPORT NO.: 99900334/81-02 INSPECTION RESULTS:

PAGE 3 of 5 D.

STATUS OF PREVIOU3 INSPECTION FINDINGS:

1.

(Closed) Violation (80-01):

Records had not been maintained to indicate tnat:

(1) The fractured thermostatic control valve had taen evaluated; and (2) Actions bad been taken to determine if the improper valves (raised face flange) had been supplied to other customers.

The inspector verified that:

(1) The thermostatic control valve had been evaluated and appropriate records initiated; (2) Actions had been taken to determine if an improper valve had been furnished to other customers.

Also, the irspector reviewed records which indicated that user identified problems are evaluated for possible im;,ct upon ciesel generators supplied for domestic nuclear power plants.

2.

(Closed) Deviation (80-01):

The gage used to measure, accept / reject the diameter and depth of the link rod dowel counterbore had not been identi-fied with :

(1) A tool and/or Gage Tryout Tag; (2) A calibration decal; or (3) Company name, gage or equipment name, part and/or serial number, as applicable.

The inspector verified that:

(1) The gage exhibited a calibration decal; and (2) The gage exhibited a number which had been etched onto it.

3.

(0 pen) beviation (80-01):

Notice of Deviation Items B through I and unresolved items in Details lection I, paragraphs B.4.d and 0.4.c.

remain open.

The inspector did not verify the vendors actions during this inspection due to the priority of other ir roection requirements These findings, as well as those identified during inspections 81-01 and 79-01, will be verified during the next inspection.

E.

OTHER FINDINGS OR COMMENTS:

1.

Element C of Operation No. 55, of the Assembly / Test Route Sheet, Revision 1, dated June 20, 1981, for Job No. 02933, identifies the driver and swaging tool used to install the crankshaft oil plugs.

Subsequent to query, the NRC inspector was informed that the swaging tool is energized hydraulically with a pressure of 140 - 200 PSIG using a gage and tubing arrangement that attaches to the swaging tool; however, this information is not reflected in the route sheet.

(See B.2. above).

2.

The NRC inspector noted that the nylon washer is installed on the driver with a screw; also, the swaging tool is adjustable in order that the swage is positioned correctly.

Howe"er, there was no indication that these devices are subjected to periodic service.

(See B.3. above),

i

TRANSAMERICA DELAVALo INCORPORATED ORGANIZATION: ENGINE AND COMPRESSOR DIV.

0AKLANDo CALIFORNIA REPORT NO.: 99900334/81-02 lINSPECTION RESULTS:

PAGE 4 of 5 3.

Bechtel Power Corporation Purchase Order No. 9645-M-018.0, dated August 6, 1974, and Revision 22, dated April 22, 1980, identify the motors for the auxiliary lube oil and jacket water pumps with a "Q" prefix.

Paragraph 13.1 of Specification No. 9645-M-018.0 states that equipment designated witn a "Q" number, performs a safety-related function.

The specification requires that motors be supplied in accordance with Appendix 0.

Paragraph 6.3 of Appendix 0 (Specification No. 9645-E-013.0) addresses service conditions relative to pressure, temperature, relative humidity, and radiation as does paragraph 5.1 of the governing spec'fication (No. 9645-M-018.0).

Further, the governing specification lists IEEE standards, including 323, and states that the list is not limited to those identified; it also states that the "most stringent requirements shall apply."

The motors supplied for this purchase order have not been environmentally qualified.

The Eligine and Comper.ssor Division of Transamerica Delaval, Incorporated maintain that environmental qualification of the motors was not a contractual requirement. (See Section B.4. above).

4.

Delaval Purchase Order No. 62572, dated April 13, 1976, ordered the motors for the auxiliary lube oil pumps.

Note 1, of the P.O. states in part, "Allis-Chalmers to certify that manufacture is in accord-ance witn Allis-Chalmers Technical Specifications as outlined for IEEE 323, 334 and 344 motor requirements...."

P.O. Change Order No. 1, dated June 2, 1976, included a change to the motor design and stated, "All else remains the same."

P.O. Addendum No. 1, dated June 8, 1976, added the motors for the jt.cket water pumps and did not address the notes of the original purchase order.

There were no records to certify that the motors Sad been manufastured in accordance with Allis-Chalmers Techni;al Specifications as out-lined for IEEE 323, 334 and 344.

(See B.S. above).

5.

The corrective action regarding the turbocharger thrust bearing lubrication problem is adequate.

Prior to implementation of the modification, Research and Development had conducted tests and identified the appropriate configuration of a system that would provide the necessary lubrication to the turbocharger thrust i

bearings while the diesel generator was in the standby mode.

The NNC inspector was informed that the modified turbocharger thrust bearing lubrication system had been incorporated on the diesel generators at San Onofre.

However, no records were presented to reflect accomplishment of the modification or its effectiveness.

l l

TRANSAMERICA DELAVAL0 INCORPORATED ORGANIZATION:

ENGINE AND COMPRESSOR DIV.

0AKLAND, CALIFORNIA REPORT NO.: 99900334/81-02 INSPECTK)N RESULTS:

PAGE 5 of 5 6.

The corrective action regarding the crankshaft oil plug problem is adequate.

The driver used to install the oil plugs had been modified to eliminate damage to the crankshaft oil plugs during installation.

7.

Transamerica Delaval Incorporated's Engine and Compres3or Division was not aware of a problem with a 6-inch check valve manufactured by the Williams Gange Company.

The information they had pertained to a 5-inch check valve manufactured by the Durabia Manufacturing Company.

The latter valve was reportedly stuck in an approximately 80 percent open position and documented on Condition Report No. 4186.

The Condition Report was " closed out" because the reported condition could not be duplicated.

PERSONS CCNTACTED Ccmcany Tu nw ee;<, Dal,..,1, r.,, - %,,: c..,p e,,,,, c :,;,;,,

Dates 7/,v,,/g, Docket / Report No. 97000334/El-oJ Inspector Ll. E. /~ otic R Dage /

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