ML20032E698
| ML20032E698 | |
| Person / Time | |
|---|---|
| Issue date: | 10/26/1981 |
| From: | Fox D, Hale C NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML20032E692 | List: |
| References | |
| REF-QA-99900400 NUDOCS 8111200821 | |
| Download: ML20032E698 (11) | |
Text
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ORGANIZATION: BABC0CK AND WILCOX COMPANY NUCLEAR POWER GENERATION DIVISION LYNCHBURG, VIRGINIA REPORT NO.: 99900400/81-02 INSPECTION DAMS): 9/15-18/81 INSPECVON ON SITE HOURS: 32 CORRESPONDENCE ADDRESS: The Babcock and Wilcox Company Nuclear Power Generation Division ATTN:
Mr. D. E. Guilbert Vice President and General Manager P. O. Box 1260 Lynchburg, VA 24505 ORGANIZATION CONTACT:
Mr. E. L. Davis, QA Manager TELEPHONE:
(804) 385-2895 PRINCIPAL PRODUCT:
Nuclear Steam Supply Systems, engineering services and operating plant support.
NUCLEAR INDUSTRY ACTIVITY:
The total effort committed to domestic nuclear activities is approximately 88% of the 1,300 employees of the Nuclear Power Generation Division.
Principal activities include the design and procurement of nine projects; Bellefonte, Midland, Washington Public Power Supply System, North Anna, and Pebble Springs Nuclear Power Plant, and providing engineering services under 129 service contracts and 38 fuel reload contracts.
ASSIGNED INSPECTOR:
hD%
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D. F. Fox, Reactor Systems Section (RSS)
Date OTHER INSPECTOR (S):
/O-d6s7/
APPROVED BY:
C. J. H a le.,/ Chi ef, RS S Date INSPECTION BASES AND SCOPE:
A.
BASES:
10 CFR Part 21,10 CFR Part 50, Appendix B and Topical Report BAW-10096A.
B.
SCOPE:
10 CFR Part 21 inspection, design inspection, status of previous inspec-tion findings, and response to a regional item (analysis of reactor coolant system piping did not consider consequences of failure of miscellaneous instru-ment piping).
EnGrMT.D C210I@ p o,
81 a>"^"<' D
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BABC0CK AND WILC0X COMPANY ORGANIZATION: NUCLEAR POWER GENERATION DIVIS!0N LYNCHBURG, VIRGINIA REPORT NO.: 99900400/81 F2 INSPECTION RESULTS:
PAGE 2 nf 4 A.
VIOLATIONS:
None B.
NONCONFORMANCES:
None C.
UNRESOLVED ITEMS:
The recently appointed QA Manager does not appear to possess the minimum quali-fications that are delineated in the NRC approved revision of the B&W Topical Report for the position. The Topical Report was subsequently revised to reflect his qualifications and submitted to NRC Headquarters for approval.
This item is considered unresolved pending NRC action on the proposed revision.
D.
STATUS OF PREVIOUS INSPECTION FINDINGS:
1.
(Closed) Nonconformance (81-01): A Certificate of Conformance and the associated Quality Assurance Data Package approval sheet were marked up without exhibiting the initials of the person marking the document nor the date of the mark-up.
The affected documents were reviewed, revised, and reissued in accordarce with procedures.
The individuals involved in the processing of QA Data Packages were re-instructed that changes to them can only be made by a formal revision of the package. A random check of twenty other packages by B&W Quality Assurance did not reveal any other instances where changes were improperly made.
2.
(Closed) Nonconformance (81-01):
Personnel qualification records were not collected nor maintained as required.
Procedure NPG-1406-10G was revised to include specific requirements for verification and documentation of the education and experience of pro-fessional employees hired after May 1, 1981.
The 1El Manual was revised to define the media, location, and storage duration of personnel qualifi-cation records.
A formal internal QA audit for compliance with the requirements is schedulec for the week of November 1, 1981; however, a random check of records of recently hired employees indicated that the applicable requirements are currently being implemented.
B&W management stated that the capability of personnel hired prior to May 1,1981, to satisfactorily perform activities affecting quality, will be objectively evaluated during the 1981 Performance Appraisal Program scheduled for execution October 1 through December 15, 1981.
3.
(Closed) Nonconformance (81-01):
Personnel training records were not collected nor maintained as required.
NPGD new employee orientation records were updated and on-the-job training (0JT) records for employees hired after May 1,1981, are now being collected
BABCCCK AND WILC0X COMPANY NUCLEAR POWER GENERATION DIVISION ORGANIZATION:
LYNCHBdRG, VIRG1NIA REPORT NO.: 99900400/81-02 INSPECTION RESULTS:
PAGE 3 of 4 and maintained as required. A formal QA audit for compliance with the requirements is scheduled for the week of November 1,1981.
B&W management stated that retrofit of OJT records for employees hired prior to May 1,1981, is not considered necessary since the impending 1981 Performance Appraisal Program will assess the effectiveness of this training.
4.
(Closed) Unresolved Item (81-01):
It could not be determined that the quality assurance program requirements imposed by B&W on suppliers of spare or replacement safety related parts meet current NRC requirements.
The specific QA program requirements that are imposed by B&W on each supplier of spare and replacement parts, as a minimum, envelop all of the specific requirements to which the licensee is committed.
The currently in-place B&W program appears to be consistent with guidance obtained from I&E Headquarters.
E.
OTHER FINDINGS OR COMMENTS:
1.
10 CFR Part 21 Inspection - Five safety concerns processed by B&W prior to NRC inspection 80-03, were transmitted to NRC, RIV for review by B&W 1etter to NRC, RIV dated March 18, 1981.
NRC letter dated April 27, 1981, acknowledged their receipt and indicated that they would be reviewed during future inspections.
The concerns related t7: (a) the unacceptable fuel / clad temperatures that may occur in the event that the reactor coolant pumps were tripped during a small break LOCA (16-79); (b) the failure of the pressurizer heaters that may occur in the event they become uncovered (43-79); (c) the failure of non B&W supplied reactor vessel skirt anc. hor bolting (16-80); (d) the lack of conservation in the calculated beginning of life pressure in fuel pins (19-80); and (e) the apparent inability of power operated relief valves to reliably close after passing liquid or two phase flow (41-80).
B&W concluded that each of these concerns were not reportable to NRC by B&W on the basis that the NRC was adequately informed of each of them.
The NRC inspector determined that in all cases some organizational unit in the NRC was informed of the concern by either B&W or by an affected licensee.
B&W acted in accordance with their 10 CFR Part 21 implementing procedure that was in place when the concerns were processed.
Subsequent to NRC inspection 80-03, B&W revised their procedure for pro-cessing safety concerns and issued a new procedure for implementing the requirements of 10 CFR Part 21. B&W management reaffirmed their policy that safety concerns will be timely processed, evaluated, and documented, and that those safety concerns determined by B&W to constitute substantial safety hazards in systems or components within the B&W scope of supply will be reported to NRC and to all affected customers in a timely manner.
2.
Design Inspection - The B&W Topical Report, the related sectius of the
BABC0CK AND WELCOX COMPANY D
ON ORGANIZATION:
LYNCHBURG, VfRGINZA REPORT NO.: 99900400/81-02 INSPECTION RESULTS:
PAGE 4 of 4 Bellefonte FSAR and applicable impleme ning procedures were examined to determine the commitments concerning safety related design activities.
Four system descriptions and functional requirements documents, five specifica-tions,12 calculations, six drawings, eight preliminary safety concerns, ten internal and external memoranda, and other documentation relating to the reactor coolant system were extmined to verify effective implemen-tation. Within the scope of the inspection, the committed program was being implemented.
3.
Regional Item (Deficiency in Reactor Coolant System Piping) - Review of available documentation and interviews with engineering and management per-sonnel indicate that the consequential effects of reactor coolant piping displacements, jet impingments, and primary and secondary missiles on the assumed integrity of certain vital piping and instrumentation lines connected to the reactor coolant system, were apparently omitted from the LOCA analyses of B&W plants.
The deficiency could result in an unanaly 4 accident in the event of a LOCA.
B&W notified all owners of B&W NSSSs that certain inconsistencies exist in the assumptions used in the thermal hydraulic analysis and in the structural integrity analysis of the effects of various LOCAs.
B&W has completed approximately three-fourths of the analyses that are within their scope of supply for plants under construction and are waiting for directions from licensees with operating units to proceed with analyses that are specific to their units.
This deficiency appears to have resulted from a considered engineering judg-ment, made early in the evaluation of the design, to omit what was con-sidered at that time to be "second order" effects from the ECCS analysis.
It did not appear to result from a breakdown of the B&W QA program.
To reduce the likelihood of other " potential design deficiencies" from occurring in the future, B&W has instituted a formal design review program.
This program provides for a multi-disciplined overview of selected designs that is independent of the programmatic component and rystems oriented reviews normally performed by B&W on all safety related designs.
PERSONS CONTACTED 2 l-O L Ccmpany b r o r H k d 1L c o X Cates
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