ML20151T681
| ML20151T681 | |
| Person / Time | |
|---|---|
| Issue date: | 01/31/1986 |
| From: | Correia R, Jocelyn Craig NRC OFFICE OF INSPECTION & ENFORCEMENT (IE) |
| To: | |
| Shared Package | |
| ML20151T634 | List: |
| References | |
| REF-QA-99901034 99901034-85-01, 99901034-85-1, NUDOCS 8602100336 | |
| Download: ML20151T681 (8) | |
Text
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CRGANIZATION: DIETRICH STANDARD CORPORATION BOULDER, COLORADO REFURI Anartc6Ava IN1'CCT!CN NO.: 99901034/85-01 DATE(S):
10/21-24/85 ON-SITE HOURS:
38 CORRESPONDENCE ADDRESS: Dietrich Standard Corporation ATTN: Mr. James L. Benke, President Post Office Box 9000 Boulder, Colorado 80301 ORGANIZATIONAL CONTACT: M. G. Anderson, QA Manager TELELHONE NUMBER:
(303) 530-9600 PRINCIPAL PRODUCT: Flow Measurement Systems NUCLEAR INDUSTRY ACTIVITY: A small portion of Dietrich Standard's flow elements / measurement systems are manufactured for use in nuclear facilities (approx. 3%).
ASSIGNED INSPECTOR:
M b ud
//a//s4 R. P. Correia, Special Projects inspection Date Section,(SPIS)
OTHER INSPECTOR (S):
P. J. Prescott, SPIS
/
t/3/[81 $
APPROVED BY:
Jpin W. Craig, Chief, Spedial Projects Inspection Date' 3ection 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.in general and specifically those related to the design, procurement, manufacturing, inspection and testing of a safety-related flow element for the Ft. Calhoun Station component cooling water system.
PLANT SITE APPLICABILITY:
Ft. Calhoun (50-285), Millstone 3 (50-423),
Vogtle (50-424, 425) 8602100336 e60204 PDR GA999 ENVDIETR 99701034 PDR
ORGANIZATION: DIETPICH STANDARD CORPORATION B0ULDER, COLORADO REPORT INSPECTION NO.-
99901034/85-01 RESULTS:
PAGE 2 of 6 A.
Violations None.
B.
Nonconformances 1.
Contrary to 10 CFR Part 50, Appendix B, Criterion XV, and procedures in Dietrich Standard Corporation's QA Manual, Sections 10, 12, and 13, Dietrich Standard QA inspecticn personnel released from the segregated QA inspection area the nonconforming Ft. Calhoun safety-related flow element for a nondestructive examination prior to the completion of a nonconforming material report by engineering, project administration / procurement and quality assurance personnel.
(85-01-01) 2.
Contrary to 10 CFR Part 50, Appendix B, Criterion III, the Dietrich Standard flow element calculation for the Ft. Calhoun component cooling water system did not include seismic qualification as required by Omaha Public Power District specifications.
(85-01-02) 3.
Contrary to 10 CFR Part 50, Appendix B, Criterion XVII and Dietrich Standard QA Manual procedure section 20.2.1, the required documentation for nonconformances, repair or rework and inspections resulting from the disposition of a nonconformance report were not included in the Quality Assurance master file (No.12302) for a Northeast Nuclear Energy Company procurement of safety-related flow elements.
(85-01-03)
C.
Unresolved Items None.
D.
Status of Previous Inspection Findings This is the first Vendor Progran Branch inspection of Dietrich Standard Corporation.
E.
Inspection Findings and Other Comments 1.
Inspection of the Manufacturing Facility The Dietrich Standard Corporation's manufacturing facility was inspected to observe processes by which a safety-related annubar-type
ORGANIZAT, ION: DIETRICH STANDARD CORPORATION BOULDER, COLORADO REPORT INSPECTION NO.-
99901034/85-01 RESULTS:
PAGE 3 of 6 flow element, similar to the one which Dietrich Standard is supplying to Ft. Calhoun, is manufactured. Areas included in the inspection were material receipt and inspection, standard storage (for commercial grade materials) and bonded storage (for nuclear grade materials),
machining facilities, welding, assembly and testing, and quality assurance inspection.
During the inspection of quality assurance activities, the NRC inspector examined the flow element for the Ft. Calhoun component cooling water system. Production and inspection records, the Nuclear Annubar Traveller and inspection checklists were examined. The Nuclear Annubar Traveller identifies the customer, invoice / control number, model number, drawing number, serial number, Authorized Nuclear Inspector (ANI) reviewer, preparer, quality assurance inspector and all manufacturing operations, required production activities, and inspection and ANI sign-offs. The Nuclear Annubar Traveller, when completed, becomes the permanent record of the flow element's production operations and inspections performed. During examination of the Ft. Calhoun flow element and associated records, the NRC inspectors observed a nonconformance tag on the flow element.
The flow element had been rejected as a result of a critical dimension of the length of the flow element extrusion tube / transition piece being out of tolerance. This nonconformance was recorded by the QA Inspector on a nonconformance report as required by Dietrich Standard's Quality Assurance Manual (Revision 12, dated June 1, 1985)
Section 13, Paragraph 13.2.1.1, " Nonconforming Material Report" (NMR).
Sections 10 and 13 of the Dietrich QA Manual " Examination and Inspection," and " Control of Nonconforming Material," respectively, require, in part, that NMR's be dispositioned and authorized by engineering, project administration / procurement and quality assurance personnel. Also, the nonconforming item must be retained in the quality assurance controlled area until such time that the dispositioned NMR is duly authorized.
Section 12. " Nondestructive Examination" requires that NDE's be performed when the assembly reaches the NDE hold point.
The NDE hold point is identified as the next item on a Nuclear Annubar Traveller af ter the assembly is fit-up, welded, critical dimensions verified and welds visually inspected. Dietrich Standard QA personnel did not comply to the above OA requirements.
Prior to the final authorization of the NMR, the Ft. Calhoun flow element was released from the QA control area for a NDE test to be performed by a contracted examiner.
4 ORGANIZATION: DIETRICH STANDARD CORPORATION BOULDER, COLORADO REPORT INSPECTION NO.-
99901034/85-01 RESULTS:
PAGE 4 of 6 Nonconformance Item 85-01-01 was identified as a result of this finding.
2.
Flow Element Calculations The NRC inspector examined the Dietrich Standard calculations and associated engineering, production, project administration /
procurement and quality assurance documentation which substantiated the selection of materials, parts and applicable code compliance for the Ft. Calhoun flow element. The inspector also reviewed the Ft.
Calhoun " Specification for Replacement Flow Element for the Component Cooling System" which is part of the Omaha Public Power District's purchase order to Dietrich Standard, No. 08005, dated September 20, 1985. The NRC inspector noted that this specification listed seismic accelerations as a design parameter and that the governing code was ASME III ND Class 3, current edition and addenda.
Neither a Dietrich Standard calculation nor any other documentation existed which could verify that the Ft. Calhoun flow element would operate safely as intended during a seismic event. After questioning several engineers involved with the Ft. Calhoun flow element design, the Dietrich Standard Engineering Manager explained to the NRC inspector that a seismic analysis had not been performed at that time. An unverified calculation summary sheet was presented to the NRC inspector prior to the exit meeting. The unverified summary indicated that the flow element stresses were all within the allowables prescribed by the ASME III Boiler and Pressure Vessel code.
Nonconformance Item 85-01-02 was identified in the area.
3.
Quality Assurance Records During the inspection, a review of Dietrich Standard's documentation for procurement, production and inspection procedures was conducted.
For this review, the NRC inspector requested QA records of safety-related flow elements which had previously been supplied for use in a nuclear facility.
The OA manager referred the NPC inspector to the Dietrich Standard Quality Assurance Master Files, which as described in the Diotrich Standard QA Manual Section 20.2.1, " Record Retention," is required to contain all documents pertaining to the design, materials, manufacturing, testing and examinations for each order processed to ASME code requirements.
i ORGANIZATION: DIETRICH STANDARD CORPORATION B0ULDER, COLORADO REPORT INSPECTION NO.-
99901034/85-01 RESULTS:
PAGE 5 of.6 The first master file reviewed was No. N10115 SP-2 for Georgia Power Company. During the examination of this file, the NRC inspector noted on an inspection checklist, that due to a linear indication on the surface metal, a dye penetrant test was rejected for three (3) of the six (6) safety-related flow elements to be procured by Georgia Power Company.
Further review determined that the Authorized Nuclear Inspector (ANI) had signed off an inspection hold point for this test on the Nuclear Annubar Traveller referencing the dye penetrant test rejection.
A nonconforming material report (NMR) No. 1663, was written to document that linear indications were found, and the NMR was dispositioned to repair the defects. The parts traveller form, used as an attachment to the NMR, documented the repair and reinspection. However, this method of documenting disposition of NMRs is not included in Dietrich Standard's QA manual.
Section 9 of the Dietrich Standard QA Manual, " Manufacturing Control" specifies usage of the parts traveller when large quantities of itens are to be fabricated and control is to be maintained for various machine shop and inspection operations.
The second master file reviewed was No. 12302 for Northeast Nuclear Energy Company.
The NPC inspector examined NMR No. 1703, which documented nonconformances with two (2) safety-related flow elements.
The first nonconformance was dispositioned "use-as-is" and the second nonconformance required further rework. The documentation.for the rework specified on the second nonconformance could not be found in the OA master file area. The OA Manager retrieved the original NMR No. 1703 from another file. The missing parts traveller containing a ~ description of the rework and inspection documentation was photocopied on the back of the original NMR.
The 0A Manager deduced that when copies were made of the original documents for the master file, the parts traveller was misplaced.
The NRC inspector also noted during further review of master file No. 12302, that several NMRs referenced on'various inspection checklists and nuclear travellers were not included in the file.
Nonconformance Item 85-01-03 was identified as a result of this review.
f
i ORGANIZATION: DIETRICH STANDARD CORPORATION BOULDER, COLORADO REPORT INSPECTION NO.-
99901034/85-01 RESULTS:
PAGE 6 of 6 4.
Other Documents Examined The NRC inspectors examined several procurement and quality assurance records to determine whether Dietrich Standard procedures and their implementation met the requirements of 10 CFR Parts 21 and 50, Appendix B as specified on Omaha Public Power District's purchase order for the Ft. Calhoun flow element.
Purchase orders and certificates of compliance for several components of the flow element procured from sub-vendors by Dietrich Standard were examined. All sub-vendors used for these purchases appeared on Dietrich Standard's Approved Vendor's List, dated August 26, 1985.
Required documentation was in place and Dietrich Standard QA Manual procedures for use of such documents had been implemented as required.
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