ML20054E685
| ML20054E685 | |
| Person / Time | |
|---|---|
| Issue date: | 05/25/1982 |
| From: | Costello J, Hale C NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML20054E680 | List: |
| References | |
| REF-QA-99900521 NUDOCS 8206140066 | |
| Download: ML20054E685 (16) | |
Text
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ORGANIZATION:
BECHTEL POWER CORPORATION LOS ANGELES POWER DIVISION NORWALK, CALIFORNIA REPORI INSPECTION INSPECTION NO.:
99900521/82-01 DATE(S) 3/8-12/82 & 3/22-26/80 ON-SITE HOURS: 64 CORRESPONDENCE ADDRESS:
Bechtel Power Corporation Los Angeles Power Division ATTN:
Mr. J. V. Morowski Vice President and General Manager P. O. Box 60600, Terminal Annex Los Angeles, CA 90060 ORGANIZATIONAL CONTACT:
Mr. R. L. Patterson, QA Manager TELEPHONE NUM8ER:
(213) 864-6011, Ext. 2061 PRINCIPAL PRODUCT: Architect Engineering Services NUCLEAR INDUSTRY ACTIVITY: The Los Angeles Power Division of the Bechtel Power Corporation is the architect engineer for nine domestic reactor units.
Fifty percent of the total personnel (approximately 7,700) are assigned to activities in connection with these units.
At the present tlme, the Houston Area office has a staff of 457.
ASSIGNED INSPECTOR:
RN k. OM d~
f/2+/92 J Et. Costello, Reactor Systems Section (RSS)
Date OTHER INSPECTOR (S):
O
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..15'[4 APPROVED BY:
l C. J. l(a_1), ' C h i~e~f,W Date' '
INSPECTION BASES AND SCOPE:
A.
BASES:
10 CFR Part 50, Appendix B, and Topical Report No. BQ-TOP-1 B.
SCOPE:
The inspection conducted at Bechtel's Norwalk and Houston facilities was to assess the effectiveness of Bechtel's program for conducting audits and training, to check on the status of previous inspection findings, and to evaluate the quality program implications of two items reported per 10 CFR Part 50.55(e) and 10 CFR Part 21.
(Cont. on next page) l PLANT SITE APPLICABILITY:
The contents of this report relate to the following dockets: 50-361, 50-362, 50-424, 50-425, 50-498, 50-499, 50-528, 50-530.
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8206140066 820527 PDR OA999 EECDECH 99900521 PDR
ORGANIZATION:
BECHTEL POWER CORPORATION LOS ANGELES POWER DIVISION NORWALK, CALIFORNIA REPORT INSPECTION NO.:
99900521/82-01 RESULTS:
PAGE 2 of 6 SCOPE:
(Cont.)
One item concerned the design of the primary loop crossover leg pipe restraint (Alvin W. Vogtle 1 & 2) and the other the omission of locking devices on fasteners of certain mechanical shock arrestors (San Onofre 2 & 3).
A.
VIOLATIONS:
None.
B.
NONCONFORMANCES:
1.
Contrary to Criterion V of 10 CFR Part 50, Appendix B and Quality Assurance Department Procedure (QADP) 5.3, no department / project /
construction managers or their designees attended the pre and post-audit conferences for the management audit of SONGS 2 and 3 engineering office.
Also, no department / project / construction manager or their designees attended the pre-audit conference for the management audit of the Vogtle design office.
2.
Contrary to Criterion V of 10 CFR Part 50, Appendix B and QADP 5.3, the response to CAR-002 of the management audit of the Vogtle Design Office was 11 days beyond the 30-day requirement and no scheduled date for response had been established.
Further the manage-I ment audit of division engineering had scheduled corrective action for CAR-001 by March 20, 1981, however, this item is still open almost
(
a year later.
CAR-001 required the establishment and documenting of a system that would provide for implementing quality requirements consistent with ANSI N45.2 in engineering initiated technical service agreements and consultant agreements.
3.
Contrary to Criterion V of 10 CFR Part 50, Appendix B and QADP 5.1, the Vogtle Audit Activity Report for January and February 1982 did not identify the personnel contacted during the pre-audit, audit, and post-audit activities.
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ORGANIZATION:
BECHTEL POWER CORPORATION LOS ANGELES POWER DIVISION NORWALK, CALIFORNIA l
REPORT IN5FtGl10N NO.
99900521/82-01 RESULTS PAGE 3 of 6 4.
Contrary to Criterion V of 10 CFR Part 50, Appendix B and Palo Verde Quality Program Procedure No. 18.0, Palo Verde Project Audit Reports PVH 5/18-29, PVH 7/81-16 and PVH5/81-9 did not include persons contacted during pre-audit, audit and post-audit activities.
No written response is required to this nonconformance as cor-rective action was taken prior to the close of the inspection.
Palo Verde Quality Program Procedure No. 18.0 was revised to require only the names and titles of persons contacted during the audit activities.
C.
UNRESOLVED ITEMS:
1.
It is not apparent that there is an effective means of revision control for the Quality Assurance Training Manual l
(which is a controlled document).
The inspector could not be certain the procedures in the manual were the latest pro-cedures since the Table,of Contents did not reference revisions.
l 2.
It is not apparent that the present method of verifying indoc-trination and training of Quality Assurance Engineers and project personnel is adequate.
The practice of using signatures, initials, and dates in the training records to show completion of indoctrination and training does not provide a measure of comprehension of the subject matter.
Comprehension for NDE personnel, for example, is provided by written examination and is documented.
D.
STATUS OF PREVIOUS INSPECTION FINDINGS:
(Closed) Nonconformance (81-02):
Contrary to Criterion III of 10 CFR Part 50, Appendix B, and Appendix 17A of the Alvin W. Vogtle Nuclear Power Plant (VNP) PSAR, Bechtel had revised Section 17
1 ORGANIZATION:
BECHTEL POWER CORPORATION, LOS ANGELES POWER DIVISION NORWALK, CALIFORNIA REPORT INSPECTION NO.:
99900521/82-01 RESULTS:
PAGE 4 of 6 of the VNP Project Reference Manual to allow Georgia Power Company field operations to maxe changes to approved engineering drawings, specifications, or other design documents without prior Bechtel Project Engineering approval.
Georgia Power Company requested and obtained approval from NRR to change their Quality Program commitments which will allow them to make field changes to approved drawings, specifications, or other design documents without prior design approval from Bechtel.
This action legitimizes the actions taken by Bechtel in the above non-conformance. The inspector has been informed by the Georgia Power Company (GPC) Project QA Manager that documents have been placed in the SAR file confirming this change.
The inspector has also been informed that special procedures have been instituted by GPC to control this type of field change which requires an after the fact review of the change by Bechtel.
E.
OTHER FINDINGS OR COMMENTS:
1.
Audits - Applicable quality assurance and project procedures were examined to determine quality assurance program commitments.
To verify implementation of these commitments, the following documents were examined:
one management audit report, four manage-ment quality assurance master audit plans, three quality assurance project audit reports, five quality assurance audit reports, and two audit activity reports.
Relative to the documents examined, the nonconformunces in B above were identified.
2.
Training - Section 2 of the South Texas Project Quality Program Manual, Section 1.3 of the Bechtel Procurement Supplier Quality Manual, and applicable quality assurance and engineering procedures were examined to establish quality assurance program commitments.
To verify implementation of these commitments, the following docu-l ments were examined:
quality training manual, seven training records of quality assurance engineers, five project quality program indoc-trination and training courses, and three certifications of Supplier Quality Representatives.
Relative to the documents examined two unresolved items were identified (see C.1 and C.2. above).
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ORGANIZATION:
BECHTEL POWER CORPORAT10N LOS ANGELES POWER DIVISION NORWALK, CALIFORNIA REPORT INSPECTION NO.:
99900521/82-01 RESULTS:
PAGE 5 of 6 A matter of concern was identified which pertains to the requirement of EDP 5.34, which states, "The Project Engineer shall be responsible for the formulation of the indoctrination and training program." At the present time, the South Texas Project has a Project Engineering Manager and three Project Engineers.
The Systems, NSSS, Licensing, and QA Project Engineer have been responsible for the Phase A indoctrination and training program, but the present project procedures do not clearly specify this responsibility.
The training program for Phase B has not yet been fully conceptualized and the inspector is concerned that this responsibility be identified, particularly if more than one project engineer should be involved.
3.
10 CFR Part 21 (Vogtle) - This design deficiency was reported by Bechtel to Region IV.
The deficiency was discovered as a result of a request from GPC Construction to relax alignment and contact bearing requirements, resulting in a review of the crossover leg restraint design calculation.
During the course of this review, a deficiency was identified in the assumptions used in modeling the transfer of loads from the crossover leg restraint to the slab and containment basemat.
A recheck of the original engineer's work in seven other calculations resulted in two more designs being corrected.
The original l
designs had been design verified and the fault would have to be traced to the assumptions of the original engineer, and the fact that the design reviewer accepted these assumptions as reasonable.
i l
Corrective action wa.s taken by adding stiffener plates, splice l
plates, modifying bolt material, and changing bolt dimensions to exclude bolt tnreads from shear planes.
A review of the remaining NSSS restraint ano support designs l
did not show any additional deficiencies.
This design is considered unique to the Vogtle project, but other Bechtel divisions were notifiad of this problem.
1 No nonconformances or unresolved items concerning quality l
program commitments were identified.
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ORGANIZATION:
BECHTEL POWER CORPORATION, LOS ANGELES POWER DIVISION NORWALK, CALIFORNIA REPORT INSPECTION NO.
99900521/82-01 RESULTS PAGE 6 of 6 4.
Deficiency Report 10 CFR Part 50.55(e) and 10 CFR Part 21 (San Onofre) - This deficiency was originally reported as a 10 CFR Part 50.55(e) by Southern California Edison and was later reported as a 10 CFR Part 21 by Bechtel.
The problem was first identified by a Bechtel Supplier Quality Representative on a surveillance inspection of ITT-Grinnel.
The supplier had failed to install hardened washers under the bolt heads in violation of the ASME code.
During a field survey to determine the extent of the use of soft washers in ITT-Grinnel mechanical shock arrestors, it was determined that fasteners on some Pacific Scientific supplied mechanical shock arrestors had been installed without washers or any locking device in violation of code requirements.
During the review of this problem it was found that a field change request to Construction Specification CS-P207 was issued, and incorrectly approved, to allow field installation of both ITT-Grinnell and Pacific Scientific snubbers without washers.
The problem has been corrected at San Onofre and a bulletin has been issued to other Bechtel divisions advising them of this problem.
No nonconformances or unresolved items were identified concerning quality program commitments.
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