ML20055F731
| ML20055F731 | |
| Person / Time | |
|---|---|
| Issue date: | 07/11/1990 |
| From: | Office of Nuclear Reactor Regulation |
| To: | |
| Shared Package | |
| ML20055F726 | List: |
| References | |
| REF-QA-99900031 NUDOCS 9007190103 | |
| Download: ML20055F731 (7) | |
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1 APPENDIX B NOTICE OF NONCONFORMANCE
. Sulzer Bingham Pumps, Inc.
Docket No.: 99900031/90-01 DuringaninspectionconductedatSulzerBinghamPumps,Inc.(SBPI) Portland Pump Division, Portland, Oregon facility on February 5-8, 1990, it was deter-mined that certain activities were not conducted in accordance with the Nuclear Regulatory Commission (NRC) requirements which are contractually ilnposed on SBPI by purchase orders with NRC licensees.
These items are set forth below and have been classified as nonconformances to the requirements of 10 CFR Part 50, Appendix B, imposed on SBPI by: (1) contract, (2)theSBPIQuality Assurance Manual (QAM). ASME Section III Division 1 Third Issue, Revision No. 2, dated December 9,1988, and (3) SBPI Procedure No. H40.45, "Q. A.
Program Supplement for Critical Safety-Related Non-ASME Code Parts / Components for Nuclear Facilities (QAPS)," Revision No. 4, dated September 20, 1989..
A..
Criterion I, " Organization," of Appendix B to 10 CFR Part 50, require.
in part, that the authority and. duties of persons and organizations per-forming activities affecting the safety-related functions of structures, systems, and components shall be clearly established and delineated in 3
writing.
1 Section 1.0, " Organization," of the SBPI-QAM, which, in part, implements Criterion. I of Appendix B to 10 CFR Part 50, requires that each Operations 1
. Manager shall have authority and responsibility for defined functions, o
to coordinate, interface, and assure that corporate functions and responsibilities are established and communicated.
Section 1.0, " Organization," of the SBPI Procedure H40.45 refers to-Section 1.0 of the SBPI QAM.
Contrary to the aboy'e, SBPI failed to clearly establish and delineate in writing the authority and responsibility of persons and organizations affecting the safety-related functions of the Field Engineering Organization. (90-01-04)-
B.
Criterion II, " Quality Assurance Program," of Appendix B to 10 CFR Part 50~,
requires, in part, that indoctrination and training shall be provided to personnel performing activities affecting quality as necessary to assure that suita>1e proficiency is achieved and maintained.
Section 1.4, " Indoctrination and Training," of the SBPI QAM which, in part implements Criterion II of Appendix B to 10 CFR Part 50, requires that each Corporate Manager and Operations Department Manager shall be responsible for the training and indoctrination of personnel to assure that an acceptable level of proficiency is developed and maintained.
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Section 3.1, " Organization," of the SBPI Procedure H40.45 refers to Section 1.0 of ths SBPI QAM.
Contrary to the abov6, SBPI failed to adequately indoctrinate and train 8 of-15 persons who were performing activities affecting quality in the QAM and QAPS requirements. This is a repeat of Nonconformances B.6 and B.10, identified by NRC during(90-01-21)the last inspection and documented Inspection Report 99900031/84-01.
C.
Criterion III, " Design Control," of Appendix B to 10 CFR Part 50, requires, in part, that measures be established to assure that appropriate quality standards are specified and included in design documents and that devia-tions from such standards are controlled; for the selection and review for suitability of application of materials, parts, equipment, and processes that are essential to the safety-related functions of the structures, systems and components; for the identification and control of design inter-faces and for coordination.among participating design organizations; and establishment of procedures among participating design organizations for
- the review, approval, release, distribution, and revision of documents involving design interfaces.
1.
Section 3.3, " Interface Control," of the SBPI QAM which, in part, implements Criterion III of Appendix B to 10 CFR Part 50, requires that Corporate Engineering documents be released to Operations Manu-facturing Engineering, Purchasing and Quality Assurance via an Engineering'ChangeandReleaseNotice(ECN).
Section 3.3, " Design Control," of the SBPI Procedure H40.45 requires that general design control of parts and pumps comply with the SBPI QAM.
Contrary to the above, SBPI failed to adequately address the required design engineering interfaces for the review and concurrence of materials, spec'ial process, or hydraulic engineering specialists when 1
specifying materials, welding, nondestructive examinations, or other-parameters that affect fluid flow. The Design Er.gineering Department interfaces with pump manufacturing activities were not adequately described in Procedure H40.45.
In addition, SBPI programs and procedures did not adequately consider suitability of processes, establishment of quality standards, acceptance criteria for special processes and test, inspection and test requirements, and dispositioning'of nonconformances. (90-01-12) 2.
Section 3.5, " Design Requirements," of the SBPI QAM which, in part, implements Criterion III of Appendix B to 10 CFR Part 50, requires that the Project Engineer review the applicable design documents to verify their adequacy, to ascertain the project requirements, to assure that the customer and ASME Code requirements are met, and that the design and material requirements are specified in the design specification.
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Section 3.3, " Design Control,"'of SBPI Procedure H40.45 requires 1
that general design control of parts and pumps comply with the I
SBPI QAM.
Contrary to the above:
n.
SBPI failed to perform an adequate review for suitability of
.the right< angle gear box on a model VLTM pump supplied to the Surry Power Station for use as a basic component in a safety-
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relatedapplication.(90-01-11) b.
SBPI failed to specify the criteria for insactions s'nd test fori the Colmonoy No. 6 hardfacing process for s1 aft sleeves per.
Drawing B-20541 Revision B, used on model CVIC type pumps in RHR systems. (90-01-13) 3.
Section 3.9,'" Design Change Control," of the SBPI QAM which, in part, implemants Criterion III of Appendix B to 10 CFR Part'50,' requires
= that changes to design criteria, major physical configuration, m6te-j rial, or submitted drawings shall be initiated by use of a Design ChangeRequest(DCR) app (DR). roved by the Project Engineer and' recon with the Design Report Additionally, documents which have been
.i revised shall be reissued via an Engineering Change and Release Notice t
(ECN),
Section 3.3, " Design Control," of the SBPI Procedure H40.45 requires that general design control of parts and pumps shall be in l
conjunction'with the-SBPI QAM.
Contrary to the above:
i a.
SBPI failed to document design changes to 7 of 11 safety-related impe11ers.for South Texas Project Electric Generating Station (STPEGS)PurchaseOrder(P0)No.14926-BF-36227,onaDCRorECN.
SBPI also could not produce an engineering evaluation to support the design basis change which increased the flow capacity and l
changed the material from AISI-440A to AISI-420. (90-01-05) b.
SBPI failed to document design changes to eight safety-related feedwater pump rotors for STPEGS on DCRs or the Contract Specific l.
MaterialList(CSML). SBPI also could not produce an engineering 1
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evaluation to; support the design basis change in material for shaft 1
sleeves-or provide the stress-calculations for the revised keyway design.(90-01-06) c.
SBPI failed to control revisions to the keyway designs for shaft sleeve Drawing B-33912E-X and throttle shaft sleeve Drawing B-33906E-X for safety-related Repair Order (RO) NP-1229, as 3
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, 1 verified by the inspectors using the controlled Drawing B-33912, Revision F, dated December 28, 1988. Additionally, R0 NP-1229, incorporated the recomended design changes-in Technical Bulletin (TB) No. 79, but the design changes were not reflected on the Design Control Sheet (DCS) by a DCR or ECN as required. An engi-neering evaluation to su) port these design bases changes was not L
provided for review by tie inspectors. (90-01-07) d.
SBPI failed to control the design program tapes for numerically controlled (NC)manufacturingmachines. A machinist edited NC design program tapes for one item in order to make a'different
' safety-related item without the authorization of the NC
. Programing Department. (90-01-08) 4 e.
SBPI failed to document design changes for impeller wear rings l
on model CVIC pumps used in residual heat removal (RHR) systems.
(90-01-09) f.
~ SBPI failed to document design changes for model CVIC type safety-related pump im;)ellers su Atomic Power Station. ;90-01-10)pplied to the Peach Bottom D.
Criterion IV, " Procurement Document Control," of Appendix B to 10 CFR Part 50, requires, in part, that measures be established to assure that requirements necessary to assure adequate quality are included in the documents-for procurement of materials and services.
s Section-4.1, " Purchasing," of the SBPI QAM which, in part, implements 1
Criterion IV of Appendix B to 10 CFR Part 50, requires that purchase orders include the applicable procedure requirements.
Contrary to the above:
1.
SBPI ordered heat treating services from Beaver Heat Treating Corporation (BHT)withoutincluding.ontheP0stheheattreatmentrequirementsor i
procedures that otherwise control the quality of services requested.
(90-01-14)
.I 2.
SBPI failed to determine that BHT did not have quality procedures for'evaluatingdeviationsandinformingSBPI.(90-01-17)
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5-i E..
Criterion V, " Instructions Procedures, and Drawings," of Appendix b to 10 CFR Part 50, requires that activities affecting quality shall be pre-scribed by documented instructions, procedures, or drawings that include appropriate quantitative or qualitative acceptance criteria for deter-mining that important activities have been satisfactorily accomplished.
Section 5.4, " Written Description of Documents," of the SBPI QAM, which, in part, implements Criterion V of Appendix B to 10 CFR Part 50, requires i
that procedures and drawings used for the control of quality and examina-tions be maintained and where processes requiring special procedures i.
are performed by vendors that the procedures shall be subject to the same review and approval criteria as required for SBPI performed processes.
Section 3.5, " Instruction, Procedures and Drawings," of the SBPI l
Procedure H40.45 refers to Section 5.0 of the SBPI QAM.
Contrary to the above:
1.-
SBPI did not provide instructions or procedures to assure satisfactory accomplishment of activities affecting quality of safety-related items in the following areas:
no guidance existed to define the initiation andutilizationofTechnicalBulletins(tbs),theEngineeringDesign Manual did not list the E-29, " Supplemental Statements List," used to apply engineering requirements, and TB E31.39, obviated the require--
mentsofMSS-SP-55forvisualinspectionofcastings.(90-01-21) 2.
.SBPI had not required the use of documented procedures by BHT to L
perform heat treating of safety-related items. This is a repeat of Nonconformances B.2,.B.3, B.4, and B.5,-identified by NRC during the last inspection and documented in Inspection Report 99900031/84-01.
(90-01-16)
F.
Criterion IX, "Contrb1 of Special Processes," of Appendix B to 10 CFR Part 50, requires, in part, that measures shall~be established to assure that special processes, including welding, and heat treating are con-1 trolled and accomplished by qualified personnel using qualified pro-cedures in-accordance with applicable codes, standards, specifications,
-l criteria, and other-special requirements.
Section 9.2, " Welding," of the SBPI QAM, which, in part, implements Criterion IX of Appendix B to 10 CFR Part 50, requires that all welding procedures shall be prepared and qualified-in accordance with the requirements of ASME Code,Section III and Section IX by Corporate Engineering.
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a, Section 9.3, " Heat Treatments " of the SBPI QAM which, in part, implements Criterion IX of Appendix B to 10 CFR Part 50, requires that all heat treat-ing shall be performed in accordance with written procedures prepared by the Operations Manufacturing Engineering Department and approved by Corpor-l ate Engineering.
Section 3.9, " Control of Special Processes," of the SBPI Procedure H40.45 refers to Section 9.0 of the SBPI QAM.
Contrary to the above:
1.
SBPI failed.to ensure that BHT had measures established to assure that the quench rate for solution-annealed austenitic stainless steel safety-related items was accomplished in accordance with the materialspecificationorotherspecialrequirements.(90-01-15) 2.
The Design Engineering Department failed to specify on DR No.- 96934, the specific welding procedure to be used for repair welding on t
safety-related impe11ers for Diablo Canyon Nuclear Power Plant.
(90-01-1B) g 3.
SBPI failed to document the quench rate used to qualify the heat treatment portion of a welding procedure qualification used to repair safety-related impe11ers for Diablo Canyon Nuclear Power Plant.
(90-01-19) i E
G.
Criterion XIII, " Handling, Storage and Shipping," of Appendix B to.
10 CFR Part 50, requires, in part, that measures shall be established' L
to control the handling, storage, shipping, cleaning and preservation of material and equipment in accordance with work and inspection L
instructions to prevent damage or deterioration.
i Section 13.0, " Handling, Storage, Shipping and Preservation,"' of the SBPI.QAM, which, in part, implements Criterion XIII. of A)pendix B to 10 CFR Part 50, requires that the handling of materials >e controlled in accordance with material handling procedures and monitored by Operations Quality Assurance.
Section 3.13 " Handling, Storage and Shipping," of the SBPI Procedure H40.45 refers to Section 13.0 of the SBPI QAM.
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Contrary to the above, stainless steel safety-related pump shafts were stored on angle iron.ra=cks without protective pads, without thread protection,- and without blocking between shafts. (90-01-22) l l
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Criterion XV, " Nonconforming Materials, Parts, or Components " of Appendix 8 to 10 CFR Part 50, requires, in part, that measures shall be established to control materials, parts, or components which do not conform to requirements and nonconforming items shall be reviewed L..
and accepted, rejected, repaired, or reworked in accordance with documented procedures.
Contrary to the above, SBPI failed to describe the function and responsibility of the' Material Review Board in the SBPI QAM or QAPS.
1 The Material Review Board approved the disposition of safety-related shaf t sleeves. (90-01-23) 5 I
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1 Dated at Rockville, Maryland
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this lith day of July, 1990 h
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