ML20211K689
| ML20211K689 | |
| Person / Time | |
|---|---|
| Site: | Vogtle, 05000000 |
| Issue date: | 11/09/1982 |
| From: | Robert Lewis NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| To: | NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| Shared Package | |
| ML20011C460 | List:
|
| References | |
| FOIA-86-656, REF-PT21-82 NUDOCS 8612120289 | |
| Download: ML20211K689 (2) | |
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ATLANTA, GEOhGIA 30303 November 9, 1982 fdEMORANDUM FOR:
Chief, Vendor Inspection Branch, Region IV FROM:
R. C. Lewis, Director, Division of Project and p
Resident Programs
SUBJECT:
C0flSTRUCTION DEFICIENCY REPORT - C0!iFIRMATION OF TELECON (AITS NO. F027002S8 )
Enclosed is a 10/CFR 50.55(e)/10 CFR 21 report received from GeorQa,__,,
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_, Power Company This appears to be a generic problem. Would you pleau-followup on the generic aspects of the problem with the AE/ Vendor? Should you have additional questions, we will be glad to discuss them with you.
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,; REGIONAL ACil0il Vogtle 1 & 2 Licensee 11/8 Potential (50.55(e- Unqualified flaterial Followup per DNS:50-424 Used in Governor Drive Coupling of Delaval MC 2512 50-425 Diesel Generator (DG) - Transamerica Delaval Region IV Notified. notified the NRC by letter dated 6/23/82 that the Category II Governor Drive Couplings for Delaval Diesel Generators were fabricated using isopreme. Isopreme is not qualified for the high temperature oil atmosphere encountered in this application and could fail causing the DG to trip. GPC was notified of this defect in November thru Bechtel that this problem was applicable.pytheKoppersCompany. The licensee is evaluating ind will report by 11/30. i 8 ll 1 p W $d I, i W \\ 1 j I t o
i 0 087982 Docket No. y9900334/82-02 Transamerica Delaval, Incorporated Engine and Cogressor Division ATTH: Mr. C. Mathews General Manager 550 85th Avenue Oakland, California 94261 Gentlemen: This refers to the QA program inspection conducted by Mr. J. W. Sutton of this office on August 23-26, 1982, of your facility at Oakland, California, associated with the manufacture of standby diesel generators and to the discussions of our findings with you and members of your staff at the conclusion of the inspection. This inspection was made to review implementation of the quality assurance program and also as a result of the issuance of 10 CFR Parts 21/50.55(e) reports pertaining to the following deficiencies identified in standby diesel generators that have been furnished to msnerous nuclear generating) stations and units: (1) possible air entrapment in the governor oil system; (2 nonseis-mically qualified sensing line in the starting air system; and (3) a leaky check valve in the starting air system. Areas examined ar.d our findings are discussed in the enclosed report. Within these areas, the inspection consisted of an examination of procedures and representative records, interviews with personnel, and observations by the inspector. During the inspection it was found tnat the iglementation of your QA program failed to meet certain NRC requirements. The specific findings and references to the pertinent requirements are identified in the enclosures to this letter. Please provide us within 30 des from the date of this letter a written statement containing: (1) a description of steps that have been or will be taken to correct these items; (2) a description of steps that have been or will be taken to prevent recurrence; and (3) the date your corrective actions and preventive measures were or will be completed. Consideration my be given to extending your response time for good cause shown. ,~ 43o!05oL24 ggg RIV UPotapovsg RLBar@h.,,, ,D,:ES,,M,,,,, ,M ,,,,AD;D,V[ RAi W -,,,,,, ,S.C RAC,P,S,,,,, BC :,y,P,B,, '"'c' > CI ;,R&,CP,S,,, I ert EHJohnson Tins uw...) JW u
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~ Transamerica Delaval, Incorporated The response requested by this letter is not subject to the clearance procedures of the Office of Management and Budget as required by the Paperwork Reduction Act of 1980, PL 96-511. In accordance with 10 CFR 2.790 of the Comission's regulations, a copy of this letter and the enclosed inspection report will be placed in the NRC's Public Document Room. If this report contains any infomation that you believe to be exempt from disclosure under 10 CFR 9.5(a)(4), it is necessary that you (a) notify this office by telephone within 10 days from the date of this letter of your intention to file request for withholding; and (b) submit within 25 days from the date of this letter a written application to this office to withhold such infomation. If your receipt of this letter has been delayed such that less than 7 days are available for your review, please notify this office promptly so that a new due date may be established. Consistent with Section 2.790(b)(1), any such application must be accompanied by an affidavit executed by the owner of the information which identifies the document or part sought to be withheld, and which contains a full statement of the reasons on the basis which it is claimed that the information should be withheld from public disclosure. This section further requires the statement to address with specificity the considerations listed in 10 CFR 2.790(b)(4). The information sougnt to be withheld shall be incorporated as far as possible into a separate part of the affidavit. If we do not hear from you in this regard within the specified periods noted above, the report will be placed in the Public Document Room. Should you have any questions concerning this inspection, we will be pleased to discuss them with you. Sincerely. Uldis Potapovs. Chief Vendor Program Branch
Enclosures:
1. Appendix A - Notice of Nonconformance 2. Appendix B - Inspection Report No. 95900334/82-02 3. Appendix C - Inspection Data Sheets (6 pages) bec: IEFiles AE0D QAB NRC:PDR Reg. Administrator, I, II, III, IV, V EHJohnson, RIV R. L. Bangart, RIV ASME NES'.PVI c " '" >
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) e APPENDIX A Transamerica Delaval, Incorporated Engine and Compressor Division Docket No. 99900334/82-02 NOTICE OF NONCONFORMANCE Based on the results of an NRC inspection conducted on August 23-26, 1982, it appears that certain of your activities were not conducted in accordance with NRC requirements as indicated below: Criterion V of Appendix B to 10 CFR Part 50 states: " Activities affecting quality shall be prescribed by documented instructions, procedures, or drawings, of a type appropriate to the circumstances and shall be accomplished in accord-ance with these instructions, procedures, or drawings. Instructions, procedures, or drawings shall include appropriate quantitative or qualitative acceptance criteria for detennining that important activities have been satisfactorily accomplished." Nonconformances with these requirements are as follows: A. Paragraph 2.7.1 of Section P. of the Quality Assurance Manu'al, dated February 27, 1981, states in part, "The manual and procedures listed below are the quality assurance / control program of this division. Preparation, maintenance, revision and issuance of these manuals and procedures is the responsibility of Quality Control." Contrary to the above, the Quality Assurance / Quality Control Organizational Chart, page 1-10 of Section 1 of the Quality Assurance Manual, has not been updated to reflect changes in the Quality Assurance / Quality Control organization since January 1,1982. B. Paragraph 4.4.3 of Section 4 of the Quality Assurance Manual, dated February 27, 1981, states, " Quality Control representatives shall survey major / critical equipment suppliers at a minimum of once every three years to assure the vendor's ability to comply with the specification requirements and to review the implementation of the suppliers quality program." Contrary to the above, Kobe Steel Ltd., a supplier of diesel engine crankshafts (major / critical), had not been surveyed at a minimum of once every three years to assure their ability to comply with the specification requirements and to review the implementation of their quality program. A survey form completed by the Kobe Steel Ltd.'s american representative, dated March 8,1982, was the only record in the Transamerica Delaval supplier's file pertaining to surveys. RO\\ o3 0133 19 9
) . C. Paragraph 5.1.2 of Section 5 of the Quality Assurance Manual, dated February 27, 1982, states, "The parts list and component drawings released by Engineering constitute the final instructions to Manufacturing and Assembly defining the acceptance criteria to which the components and assemblies must conform." Paragraph 5.3.3 states in part, "All instruc-tions from Manufacturing Engineering to Manufacturing and Assembly will be in writing...." Contrary to the above: 1. The component drawing released by engineering did not constitute the final instructions to assembly for definition of assembly criteria to which the governor lube oil cooler must conform. 2. Instructions for assembly of the governor lube oil cooler to the engine had not been provided in writing from manufacturing engineering to assembly. The foregoing was evidenced by the complete lack of Transamerica Delaval documentation for detailed information regarding installation of the governor lube oil cooler onto the engine. 1
) ORGANIZATION: TRANSAMERICA Dt. AVAL, INCORPORATED ENGINE AND COMPRESSOR DIVISION 0AKLAND, CALIFORNIA g (' REPORT INSPECTION INSPECTION j NO.: 99900334/82-02 DATE(S) 8/23-26/82 ON-SITE HOURS-7h v CORRESPONDENCE ADDRESS: Transamerica Delaval, Incorporated Engine and Compressor Division ATTN: Mr. C. Mathews, General Manager 550 85th Avenue Oakland, California 94261 ORGANIZATIONAL CONTACT: Mr. R. E. Boyer, Manager, Quality Assurance TELEPHONE NUMBER: (415) 577-742E PRINCIPAL PRODUCT: Standby Diesel Generators NUCLEAR INDUSTRY ACTIVITY: Commercial Nuclear Production of Standby Diesel Generators (3000-13,000 HP) totals 1% of company production. One contract is inhouse for future production. ASSIGNED INSPECTOR: M //- N.# 5
- g. W. SIutton, Reactive and Component Program Date Section (R& CPS)
OTHERINSPECTORS(S): I. Barnes, R& CPS W. E. Foster, R& CPS APPROVED BY: 8- / / -a-SL I. Barnes, Chief, R& CPS Date INSPECTION BASES AND SCOPE: A. BASES: 10 CFR Part 50, Appendix B and 10 CFR Part 21. B. SCOPE: This inspection was made to review the status of previous inspection findings, QA program, procurement control and supplier evaluation, audits, and also as a result of the issuance of 10 CFR Parts 21/50.55(e) reports pertaining to the following deficiencies identified in standby diesel generators that have been furnished to numerous nuclear generating) stations and units: (1) possible air entrapment in the governor oil system; (2 nonseismically qualified sensing line in the starting air system; and (3) a leaky check valve in the starting air system. PLANT SITE APPLICABILITY: Air Entrapment: 50-416/417; 50-458; 50-413/414; 50-206; 50-440/441; 50-438/439; 50-460, 50-513; 50-329/330; 50-445/446: l (Cont. on next page) 1 930toso2&i ~ 17PP
ORGANIZATION: TRANSAMERICA lacLAVAL, INCORPORATED ENGINE AND COMPRESSOR DIVISION OAKLAND, CALIFORNIA l REPORT INSPECTION i NO.: 99900334/82-02 RESULTS: PAGE 2 of 6 PLANT SITE APPLICABILITY: (Cont.)
- Harris; *Hartsville; and *Vogtle. Sensing Line:
50-322; 50-416/417; 50-458; 50-440/441; 50-438/439; 50-460, 50-513; 50-445/446; 50-329/330;
- Harris,
eHartsville, and *Vogtle. Check Valve: 50-329/330; 50-445/446; 50-440/441; 50-438/439; 50-518/521; 50-553/ 554.
- Units not identified.
A. VIOLATIONS: None B. NONCONFORMANCES: 1. Contrary to Criterion V of Appendix B to 10 CFR Part 50 and paragraph 2.7.1 of Section 2 of the Quality Assurance Manual, dated February 27, 1981, the Quality Assurance / Quality Control Organizational Chart (page 1-10 of Section 1) has not been updated to reflact changes in the Quality Assurance / Quality Control Organization since January 1,1982. 2. Contrary to Criterion V of Appendix B to 10 CFR Part 50 and paragraph 4.4.3 of Section 4 of the Quality Assurance Manual, dated February 27, 1981, Kobe Steel Ltd., a supplier of diesel engine crankshafts (major / critical) had not been surveyed at a minimum of once every three years to assure their ability to comply with the specifica-tion requirements and to review the implementation of their quality program. A survey form completed by the Kobe Steel Ltd.'s american representative, dated March 8,1982, was the only indication of a vendor survey record in the Transamerica Delaval supplier's file. 3. Contrary to Criterion V of Appendix B to 10 CFR Part 50 and paragraphs 5.1.2 and 5.3.3 of Section 5 of the Quality Assurance Manual dated February 17, 1981: a. The component drawing released by engineering did not constitute the final instructions to assembly for definition of acceptance criteria to which the governor lube oil cooler must conform. b. Instructions for assembly of the governor lube oil cooler to the engine had not been provided in writing from manufacturing engineering to assembly. The foregoing was evidenced by the complete lack of Transamerica Delaval, Incorporated (TDI) documentation for detailed information regarding installation of the governor lube oil cooler onto the engine during the manufacturing / fabrication / assembly activities.
I ORGANIZATION: TRANSAMERICA.LAVAL, INCORPORATED ENGINEER AND COMPRESSOR DIVISION 0AKLAND, CALIFORNIA REPORT INSPECTION NO.: 99900334/82-02 RESULTS: PAGE 3 of 6 C. UNRESOLVED ITEMS: None D. STATUS OF PREVIOUS INSPECTION FINDINGS: 1. (Closed) Nonconformance (82-01): QA records were not being protected against fire, damage, or loss. The inspector verified that QA records and documents are being microfilmed and transferred to a second location as indicated in TDI's written reply to the NRC, dated May 6, 1982. Ninety percent of the documents have been microfilmed and stored at a second location. Procedures for control of these documents have been generated and are being implemented. 2. (Closed) Nonconfomance (82-01): Welder was observed welding without having the specified weld procedures in his possession. The inspector reviewed documentation that meetings were conducted and attended by TDI welders. Procedure 3.8, " Quality Control Technician," was reviewed for content. Audits of the ASME weld shop were conducted as required and documented. Inprocess welding was not inspected during this inspection as a result of the absence of any production welding activities. The vendor has fulfilled his comitments as outlined in their May, 6, 1982, reply to the NRC. 3. (Closed) Nonconfomance (82-01): Weld material was not returned to stores within the prescribed time period. The inspector reviewed documentation consisting of letters, instructions, and memos issued by QA to weld shop management and foremen concerning this matter. Welding operations were not in progress during this inspection, so effectiveness of corrective actions could not be verified. This item has been closed pending further review during a subsequent inspection. 4. (Closed) Nonconformance (82-01): The weld shop was not audited during the fall of 1981. The inspector verified by review of documentation that the weld shop has been audited and an internal audit schedule has been generated and is being implemented. TDI has met the comitments contained in their reply to the NRC, dated May 6, 1982. 5. (Closed) Nonconfomance (82-01): Betts Spring Company was not surveyed at a minimum of once every three years.
) ORGANIZATION: TRANSAMERICA DELAVAL, INCORPORATED ENGINEER AND COMPRESSOR DIVISION 0AKLAND, CALIFORNIA REPORT INSPECTION NO.: 99900334/82-02 RESULTS: PAGE 4 of 6 The inspector reviewed the audit 2-19, 1982. The approved suppliers list (ASL)perfonned by TDI on June , dated June 30, 1982, was also reviewed for content. The comitments of the TDI reply, dated May 6, 1982, to the NRC has been implemented. During this inspection, however, a further instance of the failure to perform a committed vendor survey was identified (see paragraph B.2 of the inspection report). 6. (Closed) Nonconformance (82-01): Associated Spring Company put on ASL without a survev being completed. The inspector verified that the Associated Spring Company had been surveyed and the results documented. Instructions were issued to all personnel who perform surveys / audits. As identified in 5. above, how-ever, a further instance was identified during this inspection of failure to perform a connitted survey. 7. (Resolved) Unresolved Item (82-01): The ASL listed Associated Spring Company, a new supplier, with a high rating. The ASL procedure does not address how a new supplier is awarded a numerical rating without a history of received hardware. The inspector verified that the ASL, dated March 31, 1982, now permits the inclusion of newly added vendors without a rating assignment. 8. (Resolved) Unresolved Item (.82-01): Absence of apparent measures to preclude recurrence of receipt of defective springs. The inspector ascertained that: (1) Melrose Spring and Tool Works was not fully aware of the time constraints placed upon the spring for stress relief; and (2) current suppliers are totally familiar with the time constraints, and this infonnation appears in the manufacturing documents of the suppliers. 9. (Closed) Nonconformance C and D (81-02): Records had not been main-a tained to substantiate accomplishment of environmental qualification of motors for auxiliary lube oil and jacket water pumps. Based upon an onsite evaluation by NRC regional management of: (.1) Bechtel's technical specification and appendices; (.2) TDI's inter-pretation of the specifications; (3) Bechtel's replacement of the motors; and (4) TDI's current lack of domestic nuclear power station activity, we consider this item closed. In the event that TDI receives additional contracts, a thorough appraisal of implementation of procurement prac-tices and translation of customer requirements will be made.
ORGANIZATION: TRANSAMERICA u6LAVAL, INCORPORATED ENGINEER AND COMPRESSOR DIVISION OAKLAND, CALIFORNIA REPORT INSPECTION NO.: 99900334/82-02 RESULTS: PAGE 5 of 6 E. OTHER FINDINGS OR COMMENTS: 1. Followup on Headquarters and Regional Requests: l a. TDI Engine and Compressor Division, filed a 10 CFR Part 21 Report on December 9,1981, regarding a potential problem of air entrapment in the Woodward Governor oil System. The potential problem occurs if the governor lube oil cooler is installed above the oil level of the governor and the oil level in governor is low. The report to the Comission and letters to the customers indicated that detailed instructions for relocating / retubing the lube oil coolers would be sent to each site by January 15, 1982. The detailed instructions were not provided to each site by January 15, 1982; however, the inspector noted that instructions (a procedure and drawing) had been provided to three sites between March 16 and July 6, 1982. Also, the inspector noted that Woodward Governor Company's Engine and Control Division Drawing No. 9988-214, dated July 1979 depicts a remotely installed governor lube oil cooler, while Publications Nos. 36641B and 36641D state in part, regarding remotely mounted I heat exchangers, "The heat exchanger should be mounted as near as conveniently possible to the governor and below the governor's oil level so no air will be trapped in the system." TDI elected to disregard the infomation provided by Woodward. Further, the inspector noted that TDI had no documented instructions, procedures, or drawings regarding installation of the governor lube oil cooler onto the engine during the manufacturing / fabrication / assembly activities (see nonconfomance, paragraph B.3). b. The Tennessee Valley Authority filed a 10 CFR Part 50.55(e) report on March 3, 1982, regarding a leaky check valve in the air start system of the standby diesel generators. This deficiency was addressed in Vendor Inspection Report No. 99900334/82-01. Subsequent to the aforementioned report, a modified check valve has successfully completed the seismic qualification test. Documenta-tion regarding identification of the tested article and certification of test requirement was not thorough. Efforts are still undemay to correct the deficient valves, and documentation of the tested article will be reviewed during a subsequent inspection. c. Bechtel Power Corporation, Grand Gulf Project filed a 10 CFR Part 21 report on March 3, 1982. The report addressed the nonseismically qualified starting air pressure sensing line which is attached
) I \\ ORGANIZATION: TRANSAMERICA DELAVAL INCORPORATED ENGINEER AND COMPRESSOR DIVISION 0AKLAND, CALIFORNIA i REPORT INSPECTION N0.: 99900334/82-02 RESULTS: PAGF 6 nf 6 between the air compressor and storage tank. TDI also filed a 10 CFR Part 21 report, dated March 19, 1982. TDI has performed some tests which resulted in a solution of the problem; however, there was no evidence that the sensing line had been supplied by them. 2. 0A Program: The inspector reviewed TDI's QA Manual, Sections 1 and 2, cated February 27, 1982. The organizational charts and duties of personnel were also reviewed. As a result of this review, one noncon-formance was identified. The organizational chart, page 1-10 of Section 1, had not been updated to reflect the current quality assurance / quality control organization and duties (see nonconformance, paragraph B.1). 3. Procurement Control and Supplier Evaluation: The inspector reviewed TDI's QA Manual, Section 4, " Procurement Document Control." The inspector also reviewed documentation letters, purchase orders, and specifications to determine if the requirements of this section of the QA Manual were being implemented. Surveys, long and short form, of suppliers audit / survey schedules were reviewed for compliance to the QA/QC requirements. As a result of this review of documentation, one nonconfonnance was identified. TDI had ordered components (crankshafts) from a vendor who had not been surveyed as required by the QA manual commitments (see nonconformance, paragraph B.2.). 4. Audits: The inspector reviewed TDI's QA Manual, Section 17. " Internal Audits," seven internal and two management audits. The current audit schedule, qualification of auditors, and audit training files were also reviewed. The corrective action taken as a result of audit findings was reviewed for implementation. As a result of this review, the inspector determined that the requirements for internal and management audits were being followed in accordance with QA program conunitments.
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