ML20140C235

Insp Rept 99901031/85-01 on 851007-09.Noncompliance Noted: Failure to Establish Measures to Control Design Interfaces & Coordination Among Participating Organizations

ML20140C235
Person / Time
Issue date:	01/23/1986
From:	Correia R, Jocelyn Craig NRC OFFICE OF INSPECTION & ENFORCEMENT (IE)
To:
Shared Package
ML20140C216	List: ML20140C210 ML20140C228 ML20140C235
References
REF-QA-99901031 99901031-85-01, 99901031-85-1, NUDOCS 8601270278
Download: ML20140C235 (8)

Text

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ORGANIZATION: WESTINGHOUSE ELECTRIC CORP.

MURRYSVILLE, PA REPORT INSPECTION INSPECTION NO.: 99901031/85-01 DATE(S): 10/7-9/85 ON-SITE H0VPS: 48 CORRESPONDENCE ADDRESS: Westinghouse Electric Corp.

Nuclear Services Integration Division Post Office Box 78 Pittsburgh, PA 15230 ORGANIZATIONAL CONTACT: Gordon E. Michel, Quality Programs, NSID TELEPHONE NUMBER: (412) 256-6474 PRINCIPAL PRODUCT: Equipment / parts / services for operating nuclear plants.

NUCLEAR INDUSTRY ACTIVITY: Nearly all of Westinghouse Nuclear Services Integration Division (NSID) activities are related to supplying nuclear plants with replacement components and services.

ASSIGNED INSPECTOR: , /-23 -$c R. P. Correia, Special Programs Inspection Section Date (SPIS)

OTHER INSPECTOR (S): P. J. Prescott, SPIS APPROVED BY: If)3[N Jqhn W. Craig, Chief, SPQS, Vendor Program Branch Dats INSPECTION BASES AND SCOPE:

A. BASES: 10 CFR Part 21 and Part 50 Appendix B B. SCOPE: The inspection consisted of an evaluation of quality assurance and engineering activities related to the design, procurement, manu-facturing, inspection and testing of 4160/480 volt transformers procured by Omaha Public Power District for the Fort Calhoun station.

PLANT SITE APPLICABILITY: Ft. Calhoun (50-285) hI G 99901031 pR

ORGANIZATION: WESTINGHOUSE ELECTRIC CORP.

MURRYSVILLE, PA REPORT INSPECTION N0.: 99901031/85-01 RESULTS: PAGE 2 of 5 A. Violations None.

B. Nonconformances

1) Contrary to 10 CFR Part 50, Appendix B, Criterion III and Westinghouse Document No. DTT-1, " Dry Type Transformers Comercial Dedication Process" used in the dedication process for the Ft. Calhoun 4160/480 volt transformers, Westinghouse failed to document the selection and the review for suitability of application of materials and parts that were determined to be essential to the safety-related functions of the transformers. (85-01-01)

2) Contrary to 10 CFR 50, Appendix B, Criterion III, Westinghouse failed to establish measures to control design interfaces and coordination among participating organizations who determined which components of the Ft. Calhoun transformers were critical to the safety-related operation of the transformers. (85-01-02)

3) Contrary to 10 CFR Part 50, Appendix B, Criterion VII, and Westinghouse Document No. DTT-1, " Dry Type Transformers Comercial Dedication Process", Westinghouse failed to document evidence of quality furnished by the manufacturer on the 4160/480 volt transformers which were being procured by Omaha Public Power District for the Ft. Calhoun Station. This evidence includes source evaluation or information from the manufacturer or other custcmers of the manufacturer on field experience. (85-01-03)

C. Unresolved Items None.

D. Status of Previous Inspection Findings This is the first Vendor Program Branch inspection of the Nuclear Services Integration Division of Westinghouse.

E. Other Findings or Coments

1. Dedication of items Procured as Comercial Grade Westinghouse NSID personnel present at the entrance meeting with the NRC inspectors outlined the process by which the 4160/480 volt transformers procured by Omaha Public Power District for the Ft. Calhoun Station were being manufactured at a

ORGANIZATION: WESTINGHOUSE ELECTRIC CORP.

MURRYSVILLE, PA REPORT INSPECT 7ON NO.: 99901031/85-01 RESULT 5*. PAGE 3 of 5 Westinghouse facility in South Boston, Virginia as commercial grade items and in turn would be dedicated by NSID for use as nuclear safety-related components. Commercial grade items are defined in 10 CFR Part 21 as being (1) not subject to design or specification requirements that are unique to facilities or activities licensed pursuant to Parts 30, 40, 50, 60, 61, 70, 71, or 72 of chapter 1 of 10 CFR and (2) used in applications other than facilities or activities licensed pursuant to the aforementioned parts and (3) to be ordered from the manufacturer /

supplier on the basis of specifications set forth in the manufacturer's published product description.

Westinghouse Procedure No. WCAP-10859 (Rev. O, dated 6/85),

" Renewal Parts Dedication Process" is the base document used to dedicate comercial grade items. This is a general procedure which requires that each type of component have a set of procedures specific to its dedication for use as a nuclear safety-related component. Document No. DTT-1, " Dry Type Transformers Comercial Dedication Process", defines the scope and activities by which a series of disc wound, polyester-encapsulated dry-type transformers are to be dedicated. These activities are then implemented by an

" Engineering Control Instruction" (ECI). The ECI outlines specific instructions by which a single series of transformers of a specific electrical rating are to be physically inspected, dimensionally, materially and energized operability checked. These three documents (WCAP-10859, DTT-1 and an ECI) are the ones by which the 4160/480 volt transformers procured by Omaha Public Power District for Ft.

Calhoun are to be dedicated.

During discussions between the NRC inspectors and Westinghouse engineers involved with the Ft. Calhoun transformer procurement, the portions of the dedication process which had been completed were reviewed:

a. Vendor / Manufacturer Selection Westinghouse selects a vendor / manufacturer of comercial grade transformers which follows a quality control program based on comercial industry practice and manufactures a transformer which meets the electrical requirements specified by the customer. If possible, the vendor would provide as much availa-ble literature on the transformer and any information from other customers on field experience with similar type transformers.

. ORGANIZATION: WESTfNGHOUSE ELECTRIC CORP.

MURRYSVILLE, PA REPORT INSPECTION N0.: 99901031/85-01 RESULTS: PAGE 4 of 5 Westinghouse NSID had selected a Westinghouse transformer manufacturer in South Boston, Virginia to supply the commercial grade transformers to fill Omaha Public Power District purchase orders via the dedication process. The basis of this selection was Westinghouse NSID's knowledge of the history of the South Boston facility's production of transformers and that this facility used materials for their transformers that have Westinghouse established material specifications. Westinghouse NSID had not documented this information. See Nonconformance Items 85-01-01 and 85-01-03.

b. Determination and Qualification of Critical Parts Westinghouse engineers determine which parts of the transformer are critical to its safe operation during all plant conditions as identified and required by the customer. Once this has been established, the critical parts are analyzed, tested and inspected to assure that the requirements of 10 CFR Part 21 and Part 50, Appendix B as specified by the customer are met and that they would perform as intended.

Determination and evaluation of critical parts of the trans-former and their subsequent analyses, tests and inspections were decided during meetings held by members of a review committee. Verification of the operability of the critical parts are considered adequate by Westinghouse upon completion of the inspection and testing of the transformers. The only documentation that existed for this evaluation process was the minutes of these meetings. Nonconformance item 85-01-02 was identified as a result of this finding.

2. Testing and Inspection During discussions between NRC inspectors and Westinghouse engineer-ing personnel, NRC inspectors learned how the transformers were to be tested and inspected as part of the verification method used to check the adequacy of the evaluations which determined the components classified as critical to the safe operation of the transformers. A computer-aided seismic structural analysis of the transformer frame would be performed, and upon delivery of one of the eight transformers being manufactured by the South Boston facility to Westinghouse's test facility in large, Pennsylvania, a shake-table test would be performed in accordance with IEEE 344-1975.

ORGANIZATION: WESTINGHOUSE ELECTRIC CORP.

MURRYSVILLE, PA REPORT INSPECTION N0.: 99901031/85-01 RESULTS: PAGE 5 of 5 The shake-table test would demonstrate both functionality of the transformer and the integrity of the supporting and enclosing structures. Also, the transformer's environmental qualification will be based on a comparison analysis to components similar in construction, and materials prequalified by Westinghouse's aging / qualification testing programs.

Upon completion of the manufacturing of the seven transformers for installation at Ft. Calhoun, Westinghouse engineering, quality assurance and inspection personnel were to inspect and test each transformer to the recuirements specified for this type of transformer in accordance with " Engineering Control Instruction No. TRC-100485.01." This instruction specifies physical, dimensional, material and energized operability checks are to be performed after the manufacturer has tested, (witnessed by NSID personnel) accepted and certified completion of industry standard production tests. Upon completion and acceptance of inspection and testing the transformers will be readied for shipment to Ft. Calhoun.

3. Inspection of Westinghouse Seco Road Facility The NRC inspectors visited Westinghouse's NSID inspection and test facility at Seco Road. This facility is normally used to inspect and test components purchased commercially to be dedicated for nuclear safety-related use. Areas of the facility inspected were the receipt, storage, assembly, testing and calibration. The NRC inspectors examined the facility's QA manual and records of components previously tested and inspected for dedication.

During discussions between NRC inspectors and Seco Road personnel, the method Westinghouse procures, receives, inspects, assembles, and tests commercial grade components was reviewed. Previously, the components tested at the Seco Road facility for use as basic components have been small in size and the entire component has been inspected and tested for dedication. The Ft. Calhoun transformers are the first commercial grade items procured by Westinghouse NSID to be dedicated for safety-related use in which only specific parts of the unit were deemed critical to safety and subsequently, these parts were tested and inspected.

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