ML20132G114
| ML20132G114 | |
| Person / Time | |
|---|---|
| Issue date: | 05/29/1985 |
| From: | Jocelyn Craig, Milano P NRC OFFICE OF INSPECTION & ENFORCEMENT (IE) |
| To: | |
| Shared Package | |
| ML20132G071 | List: |
| References | |
| REF-QA-99900519 NUDOCS 8507190160 | |
| Download: ML20132G114 (13) | |
Text
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ORGANIZATION: BECHTEL POWER CORPORATION EASTERN POWER DIVISION GAITHERSBURG, MARYLAND REPORT INSPECTION INSPECTION NO.: 99900519/85-01 DATE(S):
1/7-11/85 ON-SITE HOURS: 117 CORRESPONDENCE ADDRESS: Bechtel Power Corporation Eastern Power Division ATTN: Mr. H. W. Wahl Vice President & General Manager 15740 Shady Grove Road Gaithersburg, Maryland 20877-1454 ORGANIZATIONAL CONTACT: Mr. D. C. Kansal, Deputy Division QA Manager TELEPHONE NUMBER:
(301) 258-3776 PRINCIPAL PRODUCT: Architect-Engineering Services NUCLEAR INDUSTRY ACTIVITY: The Bechtel Eastern Power Division, Gaithersburg, Maryland has approximately 2000 people employed on domestic nuclear projects, n\\t \\n i
n ASSIGNED INSPECTOR:
bN NM M
6[dC(/ M 7{Section(SPIS)D. Milano, Special Proj$ ts" Inspection Date OTHERINSPECTOR(S):
R. L. Pettis, SPIS 0 P Gormley, Program Coordination Section APPROVED BY:
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/J. W. Craig, Chief, SPIS,\\fendor Program Branch Datd INSPECTION BASES AND SCOPE:
A.
BASES:
10 CFR Part 21 and 10 CFR Part 50, Appendix B.
B.
SCOPE:
Evaluate the procurement control program for safety-related equipment for the Standardized Nuclear Unit Power Plant Systems (SNUPPS) projects.
PLANT SITE APPLICABILITY:
Callaway (Union Electric) (50-481) and Wolf Creek (Kansas Gas & Electric) (50-483).
h$
bbECH 99900519 PDR
-l ORGANIZATION: BECHTEL POWER CORPORATION EASTERN POWER DIVISION GAITHERSBURG, MARYLAND REPORT INSPECTION NO.: 99900519/85-01 RESULTS:
PAGE 2 of 5 A.
VIOLATIONS:
None.
B.
NONCONFORMANCES:
1.
Contrary to Criterion V of 10 CFR 50, Appendix B, and Bechtel Engineering Department Projtet Instruction EDPI-4.58-01, design test results were approved for the Battery Chargers which did not meet specification requirements.
2.
Contrary to Criterion V of 10 CFR 50, Appendix B, and Bechtel Engineering Department Procedure EDP-4.54, objective evidence could not be provided to substantiate the certification of the Professional Engineers authorized to certify design specifications.
3.
Contrary to Bechtel EDPI-4.58-01, the Seismic Analysis Report prepared by Wachter Associates, in accordance with Technical Specification 10466-C-175 for the Spent Fuel Storage Racks, utilized a damping value of 5%, which was provided by Bechtel but contrary to the specification requirement of 4%.
C.
UNRESOLVED ITEMS:
1.-
Appendix A, Part 4.0, of Bechtel Technical Specification, 10466-C-175, Spent Fuel Storage Racks, requires the Seismic Analysis Report to contain a Certification of Compliance (C of C) attesting that all work was performed under the direction of a Registered Professional Engineer, whose seal should be displayed on the form. This document was also listed on Bechtel Form 321 D, " Engineering and Quality Verification Documentation," it. the Specification as an item requiring Bechtel Engineering review and approval.
During the inspection, the above document could not be produced although the Seismic Report had already received Bechtel approval.
The resolution of this item will be pending the location and identi-fication of the Certificate of Compliance by Bechtel.
D.
STATUS OF PREVIOUS INSPECTION FINDINGS:
1.
(Closed)Nonconformance(84-01):
Nine approved Engineering DepartmentProjectInstructions(EDPIs)didnothaveanissue date listed on the instruction.
The EDPIs were reviewed to verify incorporation of the issue date and found satisfactory.
ORGANIZATION: BECHTEL POWER CORPORATION EASTERN POWER DIVISION GATTHERSBURG, MARYLAND l
REPORT INSPECTION NO.: 99900519/85-01 RESULTS:
PAGE 3 of 5 2.
(Closed) Nonconformance (84-01): The design review process allowed power cable supplying Valcor solenoid valves to be specified that was not suitable for the required application.
A design change has been issued by the SNUPPS project to replace the field wiring with qualified high temperature wiring. Based on the response provided in the Bechtel letter of June 29, 1984, the corrective and preventive actions are acceptable.
E.
OTHER FINDINGS AND COMMENTS:
1.
Procurement Process Control Selected documentation was reviewed for twelve (12) safety-related equipment purchase orders. This review evaluated the effect on the original design and regulatory commitments for changes to the purchase orders, Supplier Design Deviation Requests (SDDRs) Quality Supplier Deviation Reports (QSDRs), and nonconformances.
In addition Engineer-ing and Quality Verification documentation, such as design reports, test reports, seismic and environmental qualification reports, and calculations, were reviewed for compliance with the specification requirements. Finally, correspondence and other documentation contained in the Supplier Quality and Purchasing Department files were reviewed for problems and evidence of proper evaluation and correction, such as Rework Plans.
a.
During the review of the purchase order documentation for the battery chargers, E-051, it was noted that these units experi-enced difficulty during initial operation which required the vendor to rework the units in the field. Because of this, the design change packages, called Rework Plans, and the subsequent field testing requirements were reviewed to determine that the units continued to comply with the design specification require-ments.
Earlier documentation of the design and production testing performed by the vendor was also reviewed.
In this area, it was noted that the strip charts associated with the alternat-ing and direct current transient voltage withstandability tests indicated that these tests were not fully conducted in accordance with National Electrical Manufacturers Association (NEMA)
Standard PV-5-1976 which was delineated in the specification.
Also, the battery size utilized for the ripple voltage measure-ment was smaller than stated by the NEMA Standard. The tests were reviewed by the Bechtel Supplier Quality Representative and approved by the Design Engineer, but without any statements as to
ORGANIZATION:
BECHTEL POWER CORPORATION EASTERN POWER DIVISION GAITHERSBURG, MARYLAND REPORT INSPECTION NO.: 99900519/85-01 RESULTS:
PAGE 4 of 5 the acceptability pf these deviations. The short-circuit test method described in Power Conversion Products Process Specifi-cation PS-77-8, " Production Test Procedure of SNUPPS Battery Chargers in accordance with NEMA PV-5-1976 and Technical Specifi-cation 10466," dated March 16, 1977, did not correspond with the method of the NEMA Standard PV-5.
However, a supplemental test record sheet provided with the final test data described the actual test conducted and results which were in compliance with the short-circuit test requirements of the NEMA standard.
b.
The review of the purchase order for Spent Fuel Storage Racks, C-175, centered on the seismic analysis and mechanical reports, Bechtel document numbers C-175-0014 and 0020 respectively.
From the seismic analysis report, several areas were considered to lack conformity to the technical specification, Appendix A, which outlines the criteria for the report preparation.
For example, the value used for significant seismic event (SSE) damping departured from specification requirements.
In the generation of the dynamic response spectrum input, Bechtel provided to Wachter Associates an SSE damping value of 5% vice the 4% stated in the specification.
Additionally, Part 4.0 of Appendix A to the specification for the spent fuel storage racks, required that a Certification of Compliance, signed and approved by a Registered Professional Engineer, be provided with the seismic analysis report. This documentation could not be provided during the inspection although the report was found to be approved by Bechtel.
c.
The other purchase orders reviewed included: M-218A (Sub B),
mechanical shock suppresors; M-067, spent fuel pool bridge crane; M-627B, Ruskin fire dampers; E-018, motor control center; J-301 Rosemount pressure and differential pressure cells; and J-359 containment hydrogen analyzers. The inspection in these areas did not result in any significant findings. Of note, however, was that the purchase order for the pressure and differential pressure cells was conducted without the assignment of a Supplier Quality Representative.
It was Bechtel's determination that this instrumentation was of a standard design and that source inspec-tion was not necessary, although several models were specifically nuclear grade and required seismic and environmental qualification In general, deviations from the specification were at times documented by various forms of correspondence, e.g., telexs, 9
ORGANIZATION:
BECHTEL POWER CORPORATION EASTERN POWER DIVISION GAITHERSBURG, MARYLAND REPORT INSPECTION NO.: 99900519/85-01 RESULTS:
PAGE 5 of 5 memos, letters, telegrams. Most of these changes from the specifications were of a nature that supporting analysis was not necessary (i.e., the substitution of a load limit switch for the motor overtorque protection required by the spent fuel pool bridge crane specification). More complex designs were processed by the formally established design change systems.
From this area of the inspection, two (2) nonconformances and one (1) unresolved item were identified.
2.
Qualification of Personnel Performing ASME III Code Certification Activities During the review of the documentation for the purchase orders, Bechtel could not provide objective evidence to support compliance with the qualification requirements of Engineering Department Procedure EDP-4.54 for two Registered Professional Engineers engaged in certification activities for both (a) the owners design specifi-cation and (b) the N certification holders design report.
- However, both employees were certified to perform such activities in March 1984 by their Chief Engineer.
In the case of the torsional restraint design specification, employee #390844 certified a report in November 1984 over 15 months after the issuance of EDP-4.54.
The basis for the issuance of this EDP stems from the summer 1980 addenda to ASME III which became effective in December 1980. This addenda revised NCA-3255 to include ANSI /ASME N 626.3-1979 as the basis for establishing qualifications and duties of Professional Engineers engaged in Divisions 1 and 2 certification activities.
Bechtel's EDP-4.E4 was issued over three years after the June 30, 1980 release of the summer addenda.
From this area of the inspection, one (1) nonconformance was identified.
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REV. DATE DOCUMENT TITLE / SUBJECT M-212 y
Supplier Ouality Assignment Package Torsional Restraints Gulf 6 Western 2
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12/30/83 Bechtel Procurement Supplier Quality Manual 3
Qam SNUPPS-Project Procurement Manual 4
M-218 A SOSAP Pacific Scientific Mechanical Shock Arrestors (Sub B) 5 Pro 4.49-01 14 7/19/84 Fncineerine Denartment Project Tnnerncefon" Project Snorfftentinne" 6
C-175 Spent Fuel Storage Racks SQSAP 7
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DOClMENT DOCLMENT NO.
REV. DATE DOCUMENT TITLE / SUBJECT 13 QCD 1/1/85 Bechtel Supplier Print Control Register 14 Code ASME III Subsection NCA Summer 1980 Addenda 15 Computer < >utput C-175-0063 0,
7/30/80 Spent Fuel Storage Racks-East West OBE Seismic 16
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-do-SSE 17 Iteport C-175-0014 0
10/5/79 Seismic Analysis Report for Spent Fuel Storage Racks 18 Code N 626.3 0
1984 Qualifications and Duties of Persinnel Engaged in ASME Boiler and Pressure Vessel Code,Section III, Divisions 1 and 2, Certifying Activities.
19
- eport C-175-0020 0
11/30/79 Mechanical Report for Spent Fuel Storage Racks 20 Drawing M-120-40 3
W chter Associates Inc " Wall Seismic Details and Assembly" for the Spent Fuel Storage Racks.
21 Qam
- 029 10/1/82 US Tool and Die Quality Assurance Manual 22 Qam MSQ 050175 11/30/83 1974 Edition-Bechtel QA Manual ASME III Division 1-SWPPS 23 Code ASME III Subsection NF 1980 Edition 24 Pro 4.58-01 4
9/18/81 Bechtel EDPI 4.58-01 oTYPE OF DOCtMENT DWG
- DRAWING INH INTERNAL MEM0 SPEC - SPECIFICATION LTR LETTER PROC - PROCEDURE QAM
- QA MANUAL P.O.
- PtlRCilASE ORDER
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