ML20052C154

QA Program Insp Rept 99900334/82-01 on 820125-29. Noncompliance Noted:Failure to Protect QA Records Against Fire,Damage or Loss & Failure to Perform Audit of ASME Weld Shop

ML20052C154
Person / Time
Issue date:	03/26/1982
From:	Barnes I, Sutton J NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION V)
To:
Shared Package
ML20052C146	List: ML20052C145 ML20052C148 ML20052C154
References
REF-QA-99900334 NUDOCS 8205040431
Download: ML20052C154 (21)

Text

{{#Wiki_filter:' 1 ORGANIZATION: TRANSAMERICA DELAVAL, INC. ENGINE AND COMPRESSOR DIVISION 0AKLAND, CALIFORNIA REPJRT INSPECTION INSPECTION NO.: 99900334/82-01 DATE(S) 1/25-29/82 ON-SITE HOURS: 56 CORRESPONDENCE ADDRESS: Transamerica Delaval, Inc. Engine and Compressor Division ATTN: Mr. C. Mathews, General Manager 550 85th Avenue Oakland, CA 94621 ORGANIZATIONAL CONTACT: Mr. R. E. Boyer, Manager, Quality Assurance TELEPHONE NUMBER: (415) 577-7422 PRINCIPAL PRODUCT: Standby Diesel Generators NUCLEAR INDUSTRY ACTIVITY: Commercial Nuclear Production of Transamerica Delaval, Inc., Oakland, California, of Standby Diesel Generators. 3000-13,000 HP totals 12% of total company production. Two contracts are presently in-house for current and future production. ASSIGNED INSPECTOR: 8% U - 2. 6 - P 2 [ J. W. Sutton, Reactive & Components Program Section Date (R& CPS) OTHER INSPECTOR (S): W. E. Foster, R& CPS APPROVED BY: N 3-2c.PL I. Barnes, Chief, R& CPS Date INSPECTION BASES AND SCOPE: A. BASES: 10 CFR Part 50, Appendix B, and 10 CFR Part 21. B. SCOPE: This inspection was made to review the status of previous inspection findings and also as a result of the issuance of 10 CFR 50.55(e) reports to the NRC pertaining to: (1) potentially defective valve springs in diesel generators that have been furnished to the following nuclear generating stations, (a) Bellefonte, Unit Nos. 1 and 2, (b) Hartsville A and B, Unit No. 2, and (c) Phipps Bend, Unit Nos. 1 and 2; and (2) a cracked (Cont. on next page) PLANT SITE APPLICABILITY: Potentially Defective Valve Springs: 50-519, 50-521; 50-553, 50-554; 50-458; 50-400, 50-401, 50-402, 50-403.* Cracked Stud and Spherical Washers: 50-322; 50-416, 50-417; 50-206, 50-361, 50-362.* Inadequate Starting Air Check Valve: (Cont. on next page) g 8205040431 820415 PDR GA999 ENVTRANA certified B7L gb()L 99900334 PDR

~ ORGANIZATION: TRANSAMERICA DELAVAL, INC. ENGINE AND COMPRESSOR DIVISION OAKLAND, CALIFORNIA REPORT IN5FtL11UN NO.: 99900334/82-01 RESULTS: PAGE 2 of 10 SCOPE: (Cont.) stud and three washers in the number two cylinder of the diesel generator that had been furnished to the Grand Gulf Nuclear Generating Station, Unit No. 1. The Engine and Compressor Division of Transamerica Delaval, Inc., had also issued 10 CFR Part 21 reports on the aforementioned items, as well as on a potential problem with a diesel generator starting air check valve. PLANT SITE APPLICABILITY: (Cont.) 50-329, 50-330; 50-445, 50-446; 50-440, 50-441;^ 50-438, 50-439;* 50-518, 50-519, 50-520, 50-521;* 50-553, 50-554. *

• Applicable plant unit not defined.

A. VIOLATIONS: None B. NONCONFORMANCES: 1. Contrary to Criterion V of Appendix B to 10 CFR Part 50 and paragraph 16.7.1 of the QA Manual, QA Records were not being protected against fire, damage, or loss. 2. Contrary to Criterion V of Appendix B to 10 CFR Part 50 and paragraph 7.3.1 of Section 7 of the QA Manual, a welder was observed welding without the applicable welding procedure being either in his possession, or having been issued in the job package as required by instructions. 3. Contrary to Criterion V of Appendix B to 10 CFR Part 50, Specifi-cation 100-A-3 and corrective action commitments, weld material was not returned to stores within the prescribed time period. 4. Contrary to Criterion V of Appendix B to 10 CFR Part 50 and Transamerica Delaval, Inc., commitment as stated in their letter of June 5, 1981, to NRC, the audit of the ASME Weld Shop had not been performed as committed. 5. Contrary to Criterion V of Appendix B to 10 CFR Part 50 and paragraph i 4.4.3 of Section 4, dated February 27, 1981, of the Quality Assurance Manual, Betts Spring Company, a supplier of valve springs (major / critical), had not been surveyed a minimum of once every three years to assure their ability to comply with the specification requirements and to review the implementation of their quality program. This was evidenced by a Vendor Quality Program Survey (VQPS) form which had been completed February 25, 1976. An updated VQPS was received by TDI-ECD on January 27, 1982. This form is completed by the vendor and does not assure their ability to comply with specifications or review implementation of their quality program. 1

ORGANIZATION: TRANSAMERICA DELAVAL, INC. ENGINE AND COMPRESSOR DIVISION 0AKLAND, CALIFORNIA REPORT INSPECTION NO.: 99900334/82-01 RESULTS: PAGE 3 of 10 6. Contrary to Criterion V of Appendix B to 10 CFR Part 50 and paragraph 6.1.3 of the Approved Supplier List (ASL) procedure, dated March 20, 1980, Associated Spring Company (Barnes Group) had been placed on the ASL, dated August 1981, prior to completion of a survey or audit as evidenced by an incomplete Audit Form, dated August 12, 1981. Additionally, a purchase order, dated October 21, 1981, ordered valve springs. C. UNRESOLVED ITEMS: 1. The ASL, dated August, 1981, lists Associated Spring Company (Barnes Group), a new supplier, with the highest possible rating (10.0); however, no hardware had been received from them. The ASL procedure indicates that a supplier is rated according to the disposition of received hardware but it does not address how a numerical rating will be awarded to a new supplier. As a result of the foregoing, the inspector was unable to determine the validity of awarding a perfect rating to an unknown quantity; i.e., a vendor who has supplied no hardware, therefore, no history of received hardware. 2. The manufacturer (Melrose Spring and Tool Works) of defective valve springs had been excluded from the ASL, dated August 1981, as a source of supply for the valve springs. That action precludes receipt of defective springs from that source; however, the manu-facturer was not performing a unique operation. There was no indi-cation that Delaval had identified the cause of the problem. Based on the foregoing, it was not apparent that adequate measures had been taken to preclude recurrence. D. STATUS OF PREVIOUS INSPECTION FINDINGS: 1. (Closed) Deviation A (79-01) - Procedures and procedure manuals had not been established for the manufacturing and material control departments. The inspector verified by reviewing revised procedure manuals that the manuals now identify all departments that will main-tain procedures and procedure manuals. The corrective action was taken prior to the stated completion date. 2. (Closed) Deviation B (79-01) - The vendor was not recording actual readings of measuring and test equipment undergoing periodic recali-bration. The inspector verified by review of written instructions issued to supervision, and review of the revised IP 100 of the QA i

ORGANIZATION: TRANSAMERICA DELAVAL, INC. ENGINE AND COMPRESSOR DIVISION OAKLAND, CALIFORNIA REPORT 1NbFtL11UN NO.: 99900334/82-01 RESULTS: PAGE 4 of 10 Manual, that corrective action and preventive measures have been ( taken to prevent recurrence. The action was takan prior to the committed completion date. i 3. (Closed) Deviation C (79-01) - The Qualified Suppliers List had not been updated monthly nor had a monthly summary of the quality rating of vendors been forwarded to QC and Purchasing. The inspector reviewed the ravised issue of IP 700 relating to the updating and issuance of the approved vendor summary to purchasing and other designated departments. Current lists and summaries indi-cate full compliance with the revised IP 700 section of the QA Manual. 4. (Closed) Deviation D (79-01) - The activities, use and/or status of Corrective Action Requests (CAR) had not been reported by the Manager of Quality Control to the Division General Manager on a quarterly basis. The inspector verified that the Quality Control Manual had been revised to control the issuance of CAR activities to the Division General Manager. The new reporting requirements are contained in the QA and ASME Manuals. Section 14-1 and 15-1. The procedures are currently being implemented as required. 5. (0 pen) Deviation E (79-01) - The Document Control Center has not been protected against fire. The inspector verified that the vendor had purchased new cabinets and had transferred records to a microfilm system. During the inspector's review of the corrective action taken as a result of this deviation, it was noted that the current QA Manual Section 16.7.1, dated February 27, 1981, still requires the records to be protected from fire at Delaval. In addition, the Storage Cabinets for the microfilm are not rated as fireproof. (See Nonconformance B-1). 6. (Closed) Deviatian F (79-01) - Audits of the Division Quality Assurance programs processes and procedures were not performed semiannually by Quality Engineering. The inspector verified that the Quality Assurance Manual, Section 17, dated February 27, 1981, had been revised to prevent recurrence of this item. Audits are now per-formed annually. Completed audits for 1980-1981 were reviewed for compliance. 7. (Closed) Deviation G (79-01) - Industrial Engineering had not reviewed, approved or disapproved Engineering Change Notices, Engineering Log not maintained and Drawing Change Requests had not been classified as major or minor. The inspector reviewed the corrective action taken by TDI to prevent recurrence. The Engineering Division Standard Prac-

ORGANIZATION: TRANSAMERICA DELAVAL, INC. ENGINE AND COMPRESSOR DIVISION OAKLAND, CALIFORNIA REPORT INSPECIl0N NO.: 99900334/82-01 RESULTS: PAGE 5 of 10 tice Bulletin has been revised and reissued. The Engineering Change Notice Log had been revised and was being filled out as required. Current Change Notices were reviewed for compliance and were found to be acceptable. Compliance to the required changes were completed prior to the stated completion date. 8. (Closed) Unresolved Item (79-01) - Authority and dates of manufacturing and material control personnel performing activities affecting safety related functions had not been clearly established and delineated. The inspector verified that the current QA Manual clearly delineates the authority and duties of all personnel performing safety related activities. 9. (Closed) Deviation B (80-01) - Quality Engineering did not process a Corrective Action Request Form (CAR) for identified TDI failures to meet weld quality contract requirements in Diesel Engine Generator piping. The inspector verified by review of past and current issued corrective action requests that quality engineering is now generating CAR's as required by QA and contract requirements. In addition, the inspector reviewed documentation pertaining to the meeting held with all welding personnel on April 6, 1979. The corrective action was taken prior to the stated completion date. 10. (Closed) Deviation C (80-01) - TDI written practice IP 600 did not describe procedure for examination of Level III personnel.

Also, personnel performing visual examinations had not been qualified to methods covered by SNT-TC-1A documents.

The inspector verified by review of documentation that corrective action had been taken to prevent recurrence of this item. IP 600 has been revised and persons performing visual inspection have been requalified. Training sessions were held and documented for all personnel. Internal audits had been conducted to prevent recurrenca. The corrective action had been taken prior to the stated completion date. 11. (Closed) Deviation D (80-01) - Welding was being performed by a welder in the 3G position who had been qualified for the 1G position only. The inspector verified by review of welder qualification records that all welders had been recertified to the 6G position. The current qualified welders were reviewed for compliance. Current welder certifications have been reviewed by the committee appointed for the task. Corrective action had been taken prior to the stated completion date. 12. (0 pen) Deviation E (80-01) - Unused weld rod was not being returned to the storage area within four hours of issuance. The inspector verified by review of documentation that all welders were notified of the required control of weld materials. Corrective Action Requests

ORGANIZATION: TRANSAMERICA DELAVAL, INC. ENGINE AND COMPRESSOR DIVISION OAKLAND, CALIFORNIA HEPORI INbetL110N NO.: 99900334/82-01 RESULTS: PAGE 6 of 10 were issued and control of weld materials were verified during an audit performed on March 27, 1981. A further instance was identified during this inspection of failure to return rods within four hours of issuance. 13. (Closed) Deviation F (80-01) - Welder identification and verification of welders not identified on Route Sheets. The inspector verified by review of Production Routing Sheets that welders are being properly identified and documented on Route Sheets. A CAR was issued and training sessions have been held. Internal audits have been performed of welding operations. 14. (Closed) Deviation G (80-01) - Defective weld removed and replaced without rejection and documentation on Inspection Report. The inspector reviewed documentation and corrective action taken to resolve this item. A CAR was issued to cover the repair - an ASME rework Record has been developed and is in use. Audits have been conducted. 15. (Closed) Deviation H (80-01) - Weld was observed to contain an area with less than a required inch fillet resulting from a fit-up condition. The inspector reviewed current inspection reports for compliance. A CAR was issued covering the above deviation. Training for NDE personnel was conducted and eye examinations were given to all NDE personnel. 16. (Closed) Deviation I (80-01) - Inspection acceptance stamps had not .been entered for operations on the production sheet, nor had inspection reports been prepared to denote a rejected condition after inspection. The inspector verified that a CAR was issued to cover this item. Current jobs in progress were reviewed for compliance to IP 500 require-ments. Audits have been conducted for compliance. 17. (Closed) Unresolved Item B.4.d (80-01) - Discrepancies in dates that seismic tests to battery rack were conducted prevented a definite acceptance of the Seismic Report and Certification. The inspector verified that a corrective revision to the Seismic Analysis Report had been issued. The Seismic Test was run from January 1, 1979 to July 19, 1979. The original package was dated March 1979. A corrected certificate now indicates the correct date. 18. (Closed) Unresolved Item D.4.c (80-01) - Rework Tag No. R-0959 did not indicate by inspection if the work had been performed. The inspector reviewed documentation that indicated that the requirements of IP 300 QA Section 14 are currently being followed. Rework tags are now being properly filled out. l l

ORGANIZATION: TRANSAMERICA DELAVAL, INC. ENGINE AND COMPRESSOR DIVISION OAKLAND, CALIFORNIA REPORT INSPECl10N NO.: 99900334/82-01 RESULTS: PAGE 7 of 10 19. (Closed) Nonconformance A (80-01) - Welders using weld rod not approved for weld procedure. The inspector reviewed the corrective action taken by TDI to prevent recurrence. Training sessions were held with all welders. Each welder was issued his personal copy of weld pro-cedures. The inspector verified that current weld procedures have been rewritten on a short form. These forms would be issued with the job package and used on all future jobs. The procedure would be in the possession of the welder. (See nonconformance B.2). 20. (0 pen) Nonconformance B (81-01) - Specification 100-A-3 requires all weld rod be returned to stores after four hours. The inspector reviewed the corrective action taken by TDI to prevent recurrence. Training sessions were held with welding personnel regarding return of weld material before the time limit had been exceeded. In addition, the weld issue room attendant was instructed to monitor the time out of weld rod. He would contact welders on a three hour schedule to prevent running over the four hour schedule. (See nonconformance B.3). 21. (Closed) Nonconformance C (81-01) - Welder observed welding out of procedure electrical parameters. The inspector verified that a CAR had been issued covering the item. A training session for all welders was held and documented. Welders were instructed in the use of welding procedures. 22. (Closed) Nonconformance 0 (81-01) - An identified nonconforming compo-nent had not been documented on the inspection report form or placed in bond. The inspector verified that corrective action reports had been prepared by TDI inspection personnel. A meeting with QC staff was held and document'ad. Current nonconformances have been documented and when required, placed in segregated areas. The audit of the weld department scheduled for the fall of 1981 had not been performed. (See noncon-formance B.4). 23. (Closed) Nonconformance A (81-02) - The parts list and component drawings released by Engineering had not defined the acceptance criteria for the oil plugs. In addition, the installation instruction for the oil plugs contained no acceptance criteria. The inspector verified thru the review of revised drawings, corrective action reque.sts, docu-i mentation of training of industrial engineering and engineering person-nel, and a revised Route Sheet for the oil plug that corrective action, as stated in the TDI letter of October 6, 1981, was acceptable. The steps taken to prevent recurrence were considered acceptable. l

ORGANIZATION: TRANSAMERICA DELAVAL, INC. ENGINE AND COMPRESSOR DIVISION HEPORI 1NbPtL110N NO.: 99900334/82-01 RESULTS: PAGE 8 of 10 24. (Closed) Nanconformance B (81-02) - Measures were not established to assure that tools used in the crankshaft oil plug installation are properly controlled and adjusted at specified periods to maintain accuracy within the necessary limits. The inspector reviewed the procedure and equipment used to install the oil plug. The tool used is a rolling type tool whicn is opened by use of hydraulic pressure. The final proof of the rolling operation is the leak test that is applied to the installed plug. The inspector reevaluated the nonconformance and determined that the tool is being controlled in a manner consistent with the requirements of 10 CFR Part 50 and the TDI QA Manual requirements. 25. (0 pen) Nonconformance C (81-02) - Records had not been maintained to furnish evidence that the motors for the auxiliary lube oil and jacket water pumps had been environmentally qualified. This item remains open for further NRC evaluation. 26. (0 pen) Nonconformance D (81-02) - Documentary evidence was not available to assure that the seller of the motors, for the auxiliary lube oil and jacket water pump had complied with the requirements of the purchase order. This item remains open for further NRC evaluation. 27. (Closed) Unresolved Item C.1 - Assembly / test Route Sheet inspection elements not signed off. The irspector reviewed the Route Sheets currently in use and found that they are being signed off as required by instructions. The current Route Sheets have been revised to prevent the recurrence of the above item. Acceptable corrective action and preventive measures have been taken. E. OTHER FINDINGS OR COMMENTS 1. Follow up on 10 CFR Part 21 Reports a. Potentially Defective Valve Springs (Associated, Betts and Connor) - Curruatly, there are three sources for valve springs, Part No. 03-360-02-0M. Purchase orders had been placed with Associated and Betts. A review of three vendor inspection reports (Form P-313), dated from February 24, 1978, through January 5,1982, revealed that valve springs of the specific part number had not been received from Betts in 1979 and 1980. An unidentified, undated document indicated that TDI-ECD visited

ORGANIZATION: TRANSAMERICA DELAVAL, INC. ENGINE AND COMPRESSOR DIVISION OAKLAND, CALIFORNIA REPORT INSPEC110N NO.: 99900334/82-01 RESULTS: PAGE 9 of 10 Betts on July 24, 1981, for a plant tour. Prior to the close of this inspection, a completed Vendor Quality Program Survey form from Betts was received by TDI-ECD. This form was completed by Betts and does not assure their ability to comply with specifi-cations or review implementation of their quality program. Associated was identified as a new supplier who had supplied no hardware. While the supplier of the defective springs (Melrose) had been excluded from the ASLNCSRE, dated August 1981, there was no apparent indication that TDI-ECD had taken adequate measures to assure that valve springs from current suppliers would not be defective, b. Inadequate Starting Air Check Valve - The starting air check valve leaked during a seismic test at Structural Dynamic Research Corporation. The goal was a leakage rate of zero, however, the manufacturer (Wm. Powell Valve Co.) deemed that an unrealistic goal. Four valves had been returned to The Wm. Powell Valve Co., for rework and testing to the TCI-ECD newly established leak rate. Investigation is still underway; TDI-ECD submitted a revised 10 CFR Part 21 report on January 27, 1982. c. Cracked Stud and Spherical Washers - The use of spherical washers in the piston assembly was discontinued in late 1976 to mid-1977. At that time, a new design using belleville washers was implemented. On December 31, 1980, TDI-ECD Service Information Memo No. 324 (among others) was distributed to all users of Model R and RV diesel engines below Serial Number 75080. That document provided instructions for modifying the piston assembly and replacing the spherical with belleville washers. Several standby diesel generators have successfully undergone qualification tests subsequent to implementation of the design change. d. Paragraph 21.21(b)(3), and its subparagraphs (vii) and (viii) of Title 10, Part 21, of the Code of Federal Regulations requires that the written report contain to the extent known: (1) correc-tive action which had been, is being. or will be taken; and (2) any advice related to the defect that had been, is being, or will be given to purchasers or licensees. i I

ORGANIZATION: TRANSAMERICA DELAVAL, INC. ENGINE AND COMPRESSOR DIVISION 0AKLAND, CALIFORNIA REPORT INSPECTION NO.: 99900334/82-01 RESULTS: PAGE 10 of 10 The Transamerica Delaval, Inc. - Engine and Compressor Division's (TDI-ECD) 10 CFR Part 21 report, dated July 30, 1981, related to potentially defective valve springs, did not include that total (1) corrective action, and (2) advice given to purchasers or licensees. Specifically, (1) the supplier of the potentially defective valve springs was removed from the Approved Suppliers List, and (2) a letter to purchasers or licensees provided advice on recognition of the suspect valve springs. 2. Follow Up On A Regional Request Mississippi Power and Light Company's 10 CFR Part 50.55(e) report, dated December 10, 1981, addressed the item discussed above (paragraph D. l. c). Additionally, the report identified the following deficiencies: (1) missing wrist pin keeper; (2) grooves in cylinder liners; and (3) excessive bearing wear and deterioration. TDI-ECD informed the inspector that these had been discussed during a Delivered Product Trouble meeting and determined to be workmanship problems. No docu-ments were presented to substantiate that conclusion.

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