ML20041C401
| ML20041C401 | |
| Person / Time | |
|---|---|
| Issue date: | 02/01/1981 |
| From: | Chamberlain D, Hale C NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML20041C399 | List: |
| References | |
| REF-QA-99900507 NUDOCS 8203010281 | |
| Download: ML20041C401 (13) | |
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SARGENT & LUNDY ENGINEERS CHICAGO, ILLIN0IS REPORT NO.: 99900507/81-04 INSPECTION DATE(S): 12/14-17/81 INSPECTION ON-SITE HOURS: 28 CORRESPONDENCE ADDRESS:
Sargent & Lundy Engineers ATTN:
Mr. R. W. Patterson, Senior Partner 55 East Monroe Street Chicago, Illinois 60603 ORGANIZATION CONTACT:
Mr. J. E. McFarland, Head, Quality Assurance Division TELEPHONE:
(312) 269-6370 PRINCIPAL PRODUCT: Architect Engineering Services N,UCLEAR INDUSTRY ACTIVITY: Sargent & Lundy (S&L) has major design responsibility on the following projects:
Zimmer 1, Byron 1 & 2, Braidwood 1 & 2, La Salle 1 & 2, Clinton 1, and Marble Hill 1 and 2.
S&L also has minor design responsibility on Fermi 2 and 12 modification, repair or service contracts for various utility clients.
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A 11 OM~V L /th/
. 3 -l-R2 ASSIGNED INSPECTOR:
D. D. Ogtierlain, Rfa'ct'or Systems Section (RSS) Date 4
OTHER INSPECTORIS):
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APPROVED BY:
C.J.tg,ChielTRSS Date l
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l lNSPECTION BASES AND SCOPE:
A.
BASES:
Sargent and Lundy Topical Report No. SL-TR-1A and 10 CFR Part 50, Appendix B.
B.
SCOPE:
Status of previous inspection findings.
Special inspection resulting from an NRC Region III request concerning potential generic design problems regarding the La Salle and Zimmer projects.
l DESIGUATED ORIGIU M Cortified By l
8203010281 820212 PDR GA999 EECSALE 99900507 PDR
ORGANIZATION:.SARGENT & LUNDY ENGINEERS CHICAG0, ILLINDIS REPORT NO.:
99900507/81-04 INSPECTION RESULTS:
PAGE 2 of 5 A.
VIOLATIONS:
None B.
NONCONFORMANCES:
None C.
UNRESOLVED ITEMS:
None D.
STATUS OF PREVIOUS INSPECTION FINDINGS:
1.
(Closed) Nonconformance (81-02):
The Design Criteria Status Report did not show the latest revision or issue date of a design criteria document.
See Note 1 below for close out information.
2.
(Closed) Nonconformance (81-01):
Some design criteria documents do ot include the applicable issue of codes, standards or regulatory guides.
See Note 1 below for close out information.
3.
(Closed) Nonconformance (81-01):
An electrical Class 1E component was misclassified in the Clinton Power Station Classification Criteria Document.
See Note 1 below for close out information.
Note 1:
The corrective action and preventive measures for the three nonconformances listed above were accomplished as part of an expanded effort which included correcting the specific items identified, conducting surveys of all projects and all controlled status reports and conducting internal audits to determine the adequacy of the surveys.
The S&L internal audits resulted in 16 nonconformances issued to various projects.
The number of findings in this area resulted in changes to some of the S&L review processes and standards.
The changes will be accomplished and verified as a part of the close out of the S&L internal audit findings.
4.
(Closed) Nonconformance (81-02):
The S&L internal audit system is deficient in a number of areas resulting in a reduction of comprehensiveness and effectiveness.
Sargent & Lundy (S&L) actions to this nonconformance have resulted in a general strengthening of the S&L internal audit program and of the generic review of problems identif:ed.
The specific programmatic changes that have been made are:
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SARGENT & LUNDY ENGINEERS ORGANIZATION:
CHICAGO, ILLIN0IS REPORT NO.:
INSPECTION RESULTS:
PAGE 99900507/81-04 3 nf 5 a.
Quality Assurance Procedure GQ-18.01 was revised to provide control and guidance in determining the need for supplemental project or generic audits.
b.
New procedures were issued to require the review of nonconformances for their effect on other projects or possible trends, to provide guidance to auditors relative to sample sizing and to require project QA coordinators to review audit findings for possible effects or trends relative to their projects.
The implementation of the new and revised procedures is now in process and will be evaluated as a part of the routine programmatic NRC inspections.
E.
OTHER FINDINGS OR COMMETNS:
Potential Generic Design Problems at La Salle and Zimmer - The NRC Region III request that initiated this area of inspection was a three part request and the results of the inspection for each part are as follows:
1.
Document Control Problems Observed at General Electric (GE) - During a Region III inspection at GE on September 21-23, 1981; an observation was made that GE Design Report 22A7431 (Main Steam Piping and Equipment Loads) Revision 0, dated March 5, 1981, for the La Salle project made reference to GE document revisions which were different from the revisions that were listed in the GE Engineering Information System (EIS).
This item was evaluated at S&L to determine the effect on S&L design if an incorrect revision for a reference document was listed in the La Salle GE Design Report.
S&L uses load values from the design report and uses specific hanger drawings to develop support steel and/or support attachment design.
S&L maintains a Vendor Document Status Report which lists the latest revision and status of GE supplied documents.
Therefore, the incorrect listing of revisions for reference documents in the GE design report would not affect S&L developed design.
This item will be evaluated further at GE to determine the existence or extent of document control problems at GE.
SARGENT & LUNCY ENGINEERS ORGANIZAllON: CHICAGO, ILLIN0IS REPORT NO.: 39900507/81-04 INSPECTION RESULTS:
PAGE 4 of 5 2.
S&L Design Problem Observed at Quadrex - Region III conducted an inspection at Quadrex on September 22, 1981, relative to a La Salle allegation, concerning hanger drawing RI24-1504V, originally designed by S&L and subsequently changed by Quadrex, which called for tack welding at contacts between the pipe stanchion and variable spring support.
This application of tack welding is not permitted in S&L Specification PI-LS-16, Appendix J, Revision 3, dated March 13, 1981.
The following findings / conclusions were made from the results of this area of inspection at S&L:
Quadrex is a company that has a contract with S&L to perform pipe a.
stress analysis and hanger design for the La Salle project on specified subsystems.
b.
The original M09-RI24-1504V hanger drawing which specified tack welding was issued by S&L as revision A on September 20, 1978.
S&L issued an engineering change notice (FM-658LS) on February 13, c.
1980, which removed the tack weld and called for a fillet weld.
d.
Quadrex subsequently obtained responsibility for the hanger subsystem and incorporated the engineering change notice (FM-658LS) in revision B of drawing M09-RI24-1504V on March 30, 1981.
e.
The design error was made by S&L in 1978 and the S&L hanger design program has gone through many changes since 1978.
f.
S&L present practice for hanger design is to verify the adequacy of all welds either by reference to the specific standard used or by performing a calculation for the weld size selected.
The documentation verifying the adequacy of the welds is maintained.
g.
The present S&L practice of verifying the adequacy of all welds should preclude the improper use of tack welds.
3.
Questionable S&L Design Practice Observed at the Zimmer Sita - During a Region III site inspection in August 1978, certain hanger, snubber, pipe whip restraint, and attached structures were observed and certain design practices were questioned.
The review of the items questioned and the present design process at S&L resulted in the following findings:
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ORGANIZATION:. SARGENT & LUNDY ENGINEERS CHICAGO, ILLINDIS REPORT NO.: 99900507/81-04 INSPECTION RESULTS:
PAGE 5 of 5 a.
The S&L hanger design program has been revised numerous times since the RII inspection in 1978.
b.
All of the design areas questioned, except for one have either been j
changed or the design has been verified as adequate by S&L.
c.
The one design area that may require additional follow-up relates to beam stiffeners.
The Region III inspector noted that beam stiffeners were being installed that were welded on three sides without openings at the corners.
He stated that this is not considered an acceptable industry practice because the triaxial stresses, imposed due to welding, could result in cracking at the weldment.
S&L drawing 5-529, Reactor Building Floor Framing Sections &
Details, shows typical stiffener installations welded on three sides with openings in the two corners.
However, the S&L position on this subject is that although it is normal practice to cut the corners of beam stiffeners for proper fit and then to weld three sides with corner openings; there is nothing that prevents the constructor from welding the corner gaps.
As far as S&L is concerned, based on experience and research of the subject, this would create no problem.
S&L is not aware of any history of problems in this area.
The S&L position on this subject will be reported to Region III and further follow-up action will be taken if requested.
W ctor D. CH A rt18E RLA ld Report flo. _g g _
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- cope /Hodule STATUS OF PR6Vlot/S DOCUMEll15 EXAHillED INSPGCTsod FIHOINGS 99900509 4
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TITLE / SUBJECT 3
L BEPORT 08 mTERnRL AUDIT do, G-125 GENERIC AUDIT of 8-20-81 PROTECT STATUS REPORT 2
8 CORRtcTsv6 Action REPORT (CAR) No. 43I BYRoa PRoJLcr 8 81 08 A vilH(,
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3 AUDITIN(, INTERNA L PROCEDUR6 A UIP-7 monu ToRIHt, 9-24-81 REV. 0 HoncoHFORmANCES b
3 TA6ULATt0H of HoHC0HF08MANC65 YEAR EHOING CCTo8tR 31, ll-12-81 1%I
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8 REP 6RT oH NONccHFORmANcE TRENDS FOR 1' EAR ENDING 9-25-81 AVGUST 31, 1961 9
3 pro 3EcT cooRoINhTion INTERNAL PRocEDORE PCIP-Il 1-24 4 I REV.O INVESTIG ATING N0HconroRMANCES l0
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Scope /Hodule 86610N TE R60065T DOCUMEll15 EXAMIHED 99900507 4
1 2
TITLE / SUBJECT 3
1 1
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