ML20212N760
| ML20212N760 | |
| Person / Time | |
|---|---|
| Site: | Diablo Canyon  |
| Issue date: | 12/24/1969 |
| From: | Crews J, Andrea Johnson, Spencer G, Stello V US ATOMIC ENERGY COMMISSION (AEC) |
| To: | |
| Shared Package | |
| ML20212N718 | List:
|
| References | |
| FOIA-86-585 50-323-69-02, 50-323-69-2, NUDOCS 8608290143 | |
| Download: ML20212N760 (15) | |
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C U. S. ATOMIC ENERGY CO)D!ISSION DIVISION OF CO:OLL\\NCE REGION V Report of Inspection CO Report No. 323/69-2 Licensee:
Pacific Cas and Electric Cor.pany Diablo Canyon Unit No. 2 Docket No. 50-323 Cacogory A Dates of Inspection:
Deccabar 8 and 9, 1969 Inspected By:
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/2 /y A. D. Johnson (In Chargo)
-Reactor Inspector
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J. L. Creis 4
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Roactor Inspector, CO:V
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Project Engincer, DRL
< s%4 Reviewod By:
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/NF G.' S. Spencer
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Senior Reactor Inspector, CO:V Proprietary Information:
None I.
SIDotART PG&E has not as yet committed its QA program to a formal, implamenting a
document. Such a document was foand to bo in the early stacco of prepara-tion. In general, success of the program is currently dependent upcn established customs, practicco and ad hoc resolutions concerning quality assurance related matters.
In several instances the current practices deviated from those described in the PSAR. The Applicant indicated thr.t all areas of the currenc program which differ from chat described in the 8609290143 B60826'#
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?$A2 vill be remedied by the prop Ecticnof:ic:1 QA casual. The p;cp:: tion of the Q.'. :::us12 da cu';'cet ol eccc : contecc: ural ::::: c :::
botucan the Applices:. d the I.*cstic;'.ica;; C'.cctric Ccepc ::len.
The Cc=pli nce finding: of tha 12:pec:icn will to discus:cd uith :he licensco in a =cetin; echedcled fc: Jte ::y 6, 1959.
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The Quality accurence 2 og : inspectics u:: ccaduccad to cact the objectiv = cuulincd in G. S. Sp ::::'
===c ::duc dated *.'ove:Sc 21, 1959. One in:pection v: 3 :dc ::d in the lic:::co's c0dicos in Een 72::ciL:o.
The purpc:a of tha in pectica c:s to detcr=ine the dcarec ::d c:n=ce in chich che licenaco is impiccanning the propoccd cuality
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assur:nce pecgeca cu:11 cd in che applicctica fc a con truction pc mit for Ot.it No. 2 et the lican:co' Dichio Canyon sitc.
I The Pacific C:s end Electric Cc=p:ny (PCS2) is cur:cntly construct-ing Unit No.1 at the Dichio Canyon site (Docket No. 50-275) :nd 7 :ns to begin construction of Unic 2o. 2 (Docket No. 50-323) 1 subsequent to iscuence of : construction pc:mit by the A2C. Actuoi j
construction of structurce for Unic ro. I bogen in September,1959.
The construction permit for th:t Unit was issued by the A2C in l
June, 1968.
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. Ws44 j In the P3AR for Unit No. 1, cc mit=cnts concerning a dacciled QA 4
pr'og :m ucro cbsent. 2ccover, in the PSAR for Unit No. 2 POS2 has described : det:11cd o.rc"ren to to for=alsted end inn.le=cated o
for the constructica of Unit Ho. 2.
The deceribed pec3 rem h:s 1
been ovelunted by L1L : d fcund to be conciatent uith the 7:cpo:cd AEC criteri for e QA prog :a (Ocpc t of DRL to the AC2S dated Septc=bar 23, 1959). 2062 := cance, ::chitest-casinec 24 2
constructc; Oc ves princip:11y : a p c'oct m:nesc= cat c geni:::ica c= cept for the decign : tivitics pc forced by 2012' Engineerin; Dcpartment.
3.
_T_c.e.w iferhorchie and Ansic-aten O. S. Snoacer - Senior Recctor Inspector, CO:V Rosponsibic fc the cyce 11 inapcc ica offort, including the plannin : d conduct of the inspes:ica, end the ecvico of the resulta.
A. D..Tohrson - Rc:ctor Inspector, CO:V In chsr;c and responsibic fcv the ccordinstics of the inspoetion
- e' det:11: : d fc the in:pae:ica cf 2C12's 7:c ::= reisted to
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2ccponcibio fc the incpcc:icn of PO!2's 7:cs :: portcining to.
Criteric III, V, VI,1.'VI, :NZI, :2 22 cc cic:cd to deci n :.nd g
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J. F. 2cnner, 2::ccutive Vico 2:ccaden:
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J. D. Worthington, Vice Pecsident - In31nocring D. V. ICelly, Chief L*cchenicci Enginoc J. O.' Schuylcz, Supc:vicin; ISchenicci 2nsinec:
J. P. Finney, Supervicing ISchanicci Engincor G. A. Abb'ott, Supervisin; l'echenical Engineer W. J. Lindbled, S.:nio: ISchenicci Ingince:
A. F. Ariey, Supervising ISchenical Engince R. S. Sain, Ccnctruction, Superintendent G. V. Richards, Director, Quclity Ongineering i
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.,4 R. V. Bettingce, Supervicing civil Engince J. U. Colwell, Supervising Elcetricci 2ngincor W. R. Forbec,Supervicin; 2nspec:cien Unsinoc T n..e, r:.-. ~.A,,. :....~.,,.,.,..T R. C. Nichoic, Project Mens;c 1
J. :~cCcu; hey, Q.'s Enginacr III. S TOMTF TC "3' "S '?C~.*!
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The cignificant finding: during the.ncpectica cec sunn:rised belou, tchulc:cd by criteric cc chcun in the PS.\\2 cad grouped by =cjo:
.a incpcetion cctivity. The suppcetin; de:cil: cro retcined in the C0;V files cnd cue evcilchic if ec:uired, i.
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6-concerning a particular component are returned to the cognizant engineer for review and disposition..
2.
Findinns Based on a review of the purchase order and supporting correspondence for seccm generator safety valves to be used on the Diablo units, the licensec's documented actions shoucd consistency with the requirc=cnts outlined in the PSAR.
Criterion VII. Identifiention and Control of Materints. Parts cnd Components t
l 1.
Discussion By standard contract and purchase order conditions, the l
licensee shifts the burden of this criterion to contracters and vendors by requiring that ecch maintain a system of i
material control adequcto to assure identity of all materici j
used and that it =cces the applicable specifications, prior j
to proceeding with the particulcr work.
2.
Findings The purchase order for the steam generator safety valves and i
the contract for the construction of the civil structures of Unit No. I were found to contain apprcpriate conditions to
-l assure implomontation of the requirements outlined in the
+
l PSAR. The licensee assures itself that the contractors ara implementing their specific programs through vendor and onsite inspection efforts.
Criterion VIII. Control of Purchased Material. Eauipment and Servicec w.:s4 1.
Discussion I
The licensee currently follows an informal program of evaluation and inspection of vendors and contractors.
Prior to issuance of an invitation to bid on a particular job, the Engineering Department evaluates proposed bidders to assure itself that the bidders are competent to accomplish the required work. This evaluation is based on the licensee's past experience with particular firms. In the case of now firms with whom the com'pany is not accuainted, en inspection of the firm's facil-itics is conducted by the Engineering Services group. Tho,
i inspector was shown a proposed formal evaluccion progrca (13 pages in length) that had bcon formulated for inclusion in j
the QA manual.
The Engineering Services group performs vendor inspections using the specific contract as a guidc. Subsequent to an inspection, a report of the effort is forwarded to the cognizant engineer directing his attention to any deficica-t' cios or possibic probicm arcas. These deficiencies or
( _-
and the vendor with the resciution and basis documented in a probica areas are then resolved betwocn the cognizant engineer memorandum which then becomes a part of the purchase order data package for future reference.
. ~. - -.
2.
Findinan Based on a revicw of the dets pecheco concerning the sto =
generator s fety velves cnd vendor inspectors report con-corning a deficiency observed in the manufacture of the steam generators, the incpector confiracd that the cyct==
described above had been followed. The licenaco indicated "O22%!.
yet beca inplemented; houcver, this PSAR rcquirement vill that documentation of the vendor inspection plans has not be satisfied when the propoucd formal QA Z:nusi is cp.
for use by PG&2 I
Criterion XIT.
Caliba'eto ni '".*nsnre ent and 70s Fouf er.*nt j
1.
Discussina i
i PG&E includes in its-concr: cts and purchase orders conditienc
- " d, - i which require the contreetor or vendor to catablich appropriate
,.I written proceduros end provida sufficient documentation to show that requicc=cnto of this criterica have been s tisfied.
Specifically, the conditions require the contractor or vendor l
to prepare, maintain and u o procedurcs for the mainten:nce and periodic calibration of measuring and testing equipment.
l 2
Findines g
I.
a.
Contracts ex mined by the inspectors concerning current on-sito work and p.rocurement of the secca generator safety valves included the necessary provisions to 4*>C6 satisfy the requircacnts outlined in the PSAR.
criterion XITT. Rendlinc Storaca. Shinninc red Preservation 1.
Discussion The licensec. includes in it: contr ct: nd purchsso order conditions which require the contr:ctor or vendor to catablish appropriate written procedurca and provi4c cufficient 4ocu=:n-l tation to show that requirements of this critorion have boca satisfied. Also, all docuncatstion concerning a particulcr job is required to bc retained by the vendor for a period of five years. At the end of the holding period, the licenece is required to provide inctructions to the holder as to final 1
disposition of the roccrda. Specified to:t reports are required to be furniched to the licenece subsec,uent to approval and accept:nec by the licensce's inspector, prior
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to delivery of the product.
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and 2, ucre revic:cd.
'.'ha specificationc ucro cheorved co impoco upon the vender of such co=ponents rce.uir =cn:: for special procace control. The following 10 ypical of ::he
, ~. 2.' l purchece cpecificceion icnc,u 3c in rogerd to thic critericn:
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"The = nufcci.rce ch:11 sper::o under a controlled =:nufsccur-ing system auch :: proccc: chects, shop procedure:, travelcre, etc. Specie. contro,.acs proccese cuc.
a := t:c.cing, heat i
fik' treating, nonde::ructive ecucing, and inspeccion technic,ue shall be part of and included in the cystc=."
2.
Findf- ".:
Individual cuc.mplo of heu chic critorien is bein; in:crpreted and impicacated in the ec:a of specific purch::cd ccuponener ucre observed. i.'rie:ca cc:unen: tion of hcu this critcrion it to be incorp;c cd end.;? lam:n:cd concic:ently cn an overall projec:: L::6 h:
- been prepared by pCC.
J 3.
DeM *~n b ee'nir
- m The deci n activitice ucro revicued to dator=ine if the stateman'::
cado in the P0.3 sec bch;.; i..p'.c.a.:::cd.
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rl Criterion TTI. D.?nf an nme. vt 1.
Discunninn A co=picco list of coupon:nte (daveloped feca the list pro-vided in the PO42) which uil; be subjected to the e,uclity assurance progr m vill bc included in the ::nual. P ::iculer "Yfhi$
analyses (physica, thor = 1, hydraulic, cereas, and cccident) associated with each of theco co=ponents which will be revicu-ed, will be decor =ined on en cd hoc basis.
It vac stated that the group icodert are rc:poncibic fcr performing dcaign : vicuc, including : revicu to accure th.c
. co=mit=cata = dc in the pdLR h:ve boca incorpore:cd in che design. 7er the cpecific c=c= pica concidored, it ucs r.c apparon: hcw che Orcup ic dar perfor=c this func:fon.
Cciculations ucro perfor=cd to cc:ablich pu=7 ccpaci:y, heat exch nger si c and piping ticxibility. These c iculc-tions were f.ct cheched by any other cm=her af the engir.ccring staff. It is expected th:t this condition would bc cor cceed 7,'j '
when the writ ca procedurec cre developed,
...m.s PG&2 uses the PSAR as conceptual design document. It uas stated that a cystem will be developed to update the PSA2 as the design evolves. A =cch:nica has not yet bocn scice:cd for performing this function, although several approaches are under concideration. A particulcr approach is cxpec cd to bc chosen in the ne r future and fully impicmented in about two months.
' 6.s,s.
Design information roccived from Westinghouse is revicued by the responsibic engineer. This review was characteri:cd as somouhat superficial and docc not include a check of the details (e.g., the hcet loads following a loss-of-coolen:
accident, cooling requirc= cats for pu=ps, structural londa, etc.).
2
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Written procedurcs to guide the design roview have not yce beca developed. It is cnpacted that cuch proceduroc will be developed within cover:1 conths and will bo included in the quality Assur:nco M:nual.
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Di *n w n Writtoa procedures and inc: uccion for all cacential accivi-tics as cc:::itend in the applicerica, arc to bc 1:ccepcested into the Quality.*.ccur:nce.":nual.
- is c:Oceted th:: the
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co=plete pech:ce of pesecdurce and ine::uccisn= tcould bc ev 11 chic for ecvic'.7 ce t/ n=
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2 Fir.di - w In vic.7 of the lack of e,v ::.~ 1 procedurce end inacructions, an effort tna :dc to cccc =ine tih:2==:hed; tec:c being c cd.
- in specific ceces. E'.;ile chace =cthod eppoceed o bc rosconably cc=pic c, tr.:.
en =:necc= n: :::c=ents requiring impic==t: tics of thc a ::hed; for all i=portant sys:c=
h:ve not yet becn esecb".iched.
Criterion V". P..e
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'jj A dr: wing index cystc= and specific: tion list are being used
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to control disposition of theco docu= cats. Updcted lict: of
" i drawing and specific:tions cro published and issued to i
supervicory per onnel on
=c.n:hly basis.
t An engineer m:teri:10 =c=o 1 prcpered after a bid h been Wld accepted for picca of equip =ca but beforo the actuel con-tract 1: cisned, b'hc :.c=o incorporato: i= port:nt date, refcecnces to all pplicabic specifications and doccribes the design bo:10 for equip =cnt.
Should it bocc:a noccccery to codify n design afec i :uence of a =c=o, the =c=o in revised d desert *ac the bacia on tihich the ch nge tics found accept bic.
2 Findinan An overall procede c co hendic the con:rol of docu=:nt i= port:nc fc
- urs:ca of quality h: not yc: been cace.~oli:.h-ed. It ia c.gcc:cd th:2 such peccedures and in:truction ui*.1 be included in the Qu licy.'. urance 1* au 1.
The d :c td.:n this infor==:ica tisuld 5: cvcilabic h: no: yo: been ca.cr.blished l
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Criterinn ?~77. Cor entfv$ 'mt'nn 1.
Dicenscion Company policy, app;rently verbal undcratandin; ::ang responsibic individuals, ree.uires th: all etnor= 1 con-ditions be referred to the 20&2 cncincering staff. Di=poci-
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cion of an ebnor= 1 si:nction ic docu=:nted in cicher a 1etter to vendor.or en en31neer =sterial =c=o.
Vendor
.practicca arc monitored by cn incpec:fon depart =cnt, directed by Mr. 7or*acc. Hic orc:ni= tion keeps the engineerin; ct:ff informed of vendor cctivitics. Chan3cs cri31nceing in cho ficid are docu=ented on : pccial for= v(.ich is directed to the engincering 00 ff, 2
Pfedinae The qu lity : urance procr = cc describcd in the ?2AR included a rcquire=:n: th:t deviations in de:ign, =:nufacture, or con truction cetivizica uculd be handled by written procedures. Thecc uri Ocn procedurcs have not yce been developed.
Critorion XVTT. Roeneds 1.
Discussion Ceneral requirc=cnts on record retention arc included in the purchase specifications. A docu=cnt containing "typicci" requiremonto for record retention ws: reviewed. Included in
'*d**M the requirc=cnts crc:
(1) the ti=c records =ust be retained, (2) option for P002 to pick up the records, and (3) identifi-cation of particular records that must be sub=itted :o PCa2 2.
Findinac
.I Statements ucre meda in the PSAR that "procedurcs will establich that record: vill be caintained to document the Quality /.ccurance 2roget.u." These procedurcs have not ycc boon cat blished.
It la anticipcted that such procedurca will bc availabic in caversi =onths.
Critorfon XV TT, Audien 1.
nineussion Mr. Cordon Richcrds hac been appointed to the recently created position of Dirce:ce of Quality Engineering. Ze has been given the rc:poncibility for perfor=in; the audit functica as described in the PSA2. Ouc to a lack of procedurcs, it was 4
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not possibic to obtain information on the detailed mechanism of the audits.
Information required on the audit function, as outlined in the inspection plan, was explained.
Mr.
i Richards indicated that this type of-information would be available when the procedures are developed and would in i
fact be included in the procedurcs.
2.
Findings Written procedurcs for performing the audit function are currently being developed but a schedule for compiccion of the procedures has not been established. No specific audit l
of the QA program has been conducted to dato; however, PC&E and Westin; house have, as part of the process of developing a manual, performed a review of the QA process being followed by PG&E. Results of this audit wer2 not available, i
C.
On-site Activitics i
i On-site activitics were reviewed to determine if the state =ents
. l made in the PSAR are being impicconted. The contract between
' l PG&E and Guy F. Atkinson Company concerning construction of the major l
civil structures for Unit No. I was principally used as a source for l
obtaining objective evidence of the details on program impicmentation Critorion X. Inspection 1.
Discussion The inspectors found individual examples of detailed and
,g.;4gg comprehensive procedurcs covering inspection activitics at the site.
Procedures reviewed included those which had been prepared by the Guy F. Atkinson Company (Atkinson) for implementation during construction of the reactor l
l building and other civil structures of Diablo Canyon, Unic No. 1.
- i The requirements relating to the content, preparation, I
approval and impicmentation of inspection procedures werc found to be clearly defined in conditions of the contract between Atkinson and POLE in the case of the civil structurcs.
These specifications require the contractor (Atkinson) to prepare, maintain and use procedures for the maintenanco and l
periodic calibration of measuring and testing equipment.
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Additionally, the contract specificautons require that the contractor submit to PG&2 in writing biographical data relating to the qualifications of inspection and test per-sonnel.
2 Findincs The absence of a written program describing those requirc-ments to be imposed by PG&E in the case of all structures and components important to safety prevented a finding of program consistency in regard to those criteria.
Criterion XT Toct Control.
1.
Discussion The inspectors sc1ceted for revicw and discussion of this criterion the PG53 program relating to preoperational testing.
Discussions were held with PG&2 representatives of the Engineering, General Construction and Operating Departments, each of which have varying degrecs of responsibility relating e d.
to preoperational testing.
An internal PG&E instruction, designated Standard Practico No. 420-1, describes the functional responsibilities relating to the preoperational or acceptance testing of power plant equipment and systems. This instruction assigns principal-responsibility for test control and impicmentation to the General Constru.: tion Department.,T.ur Operations Department
,g,g of PG&E is to participate in a subordinate roic, during the conduct of tests, by manipulating system controls under the direction of the General Construction Department.
The responsibilitics of the Engineering Department in regard to preoperational testing were not defined in Standard Practice No. 420-1. For exampic, the participation of the design engineers in the establish =cnt of proceduro detail, such as test conditions and acceptance criteria, was not mentioned. Nor did this instruction mention participation by the design enginects in the evaluation and approval of test resul s.
According to Messrs. Esin and Carroll, the design engineers will participate, informally, in the review of preoperational test procedurcs and testing resul,ts. X:. Bain discussed two ceans by which the designer's review is to be accomplished.
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In this regard, he spoke of " informal discussions" between test engineers and design engineers. Another indirect means of accomplishing design engineering review is by the assignment of General Conscruction Dopsetment and Operating Department personnel to the Engineering Department where they will work with design engineers, and thus gain familiar-ity with design requirements.
Mr. Carroll stated that the iM.d,.
On-Site Review Committee would be functioning during the 1
preoperational testing period. He said that this committee would review preoperational testing results, t
2.
Findings A written procedure had not been preparc'd to describe the means by which design engineering review of testing procedures and testing results is to be accccplished in a consistent manner.
Criterion XIV. Innnection ned Tect Sen5ts
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Discussion The means by which PC&E is to insure, adherence to its intent of this criterion on an overall project basis had not been documented in approved written procedures.
The inspectors reviewed procedures relating to this ' criterion
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which had been prepared by the Guy F. Atkinson Company t
(Atkinson), and which are to be inplemented during construc-j.
.. J i tion of the civil structures of Diablo Canyon, Unit No.1.
These procedures, which were included as part of the Atkinson QA Manual, included " typical" exampics of the means by which inspection and test status is to be determined and documented.
Specific procedures, for which typical examples were contained in the Atkinson QA Manual, included: Fabrication Procedurc
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- Sequence Forms. NLT Report Forms, QA Examination Check Lists.
and Weld Maps.
2 Findinns t
Individual exampics of how this criterion is being inter-proted and impicmented by PG&E in the case of specific structures of the Diablo Canyon, Unit No. 1 were obscrved.
The absence of a definitive written procedure of overall project scope in regard to this critorion, however, make it impossible to determine with reasonable assurance that N.
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this criterion will be int 4rpreted and implemented in s' consistent manner in the case'of Diablo Canyon, Unit No. 2 s
Criterion XV Nonconformine Materini, ? arcs, nr Com,nnents 1.'
Discussion gfyhQf A draft written procedure reisting to thic critarion vos reviewed, and discussions were hold with representatives of the PG&E General Construction and Engineering Departments.
The, draft procedure, entitled " Instructions for Diceropency Concrol", discussed the for=ation and functioning of a Fbterial Review Daard (M2B) at the construction site. Mom-bership of the N33 is to include representativos of the contractor (s), the PG&E General Construction Department i
Resident Engineering staff, and the PGSE Quality Assurance Engineering staff. The procedure stated that the Mr.3 may c'
either make decisions relating to the disposition of.
l nonconforming material itself or refer cuch matters to tho-J.g PG&E Engineering Department for dioposition review and
' 4-approval. The procedure did not attempt to clarify,the limits of authority of the M1B, or specify chose cases involving nonconformance which require mandatory, review cud
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approval by the Engineering Department. The procedure did
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not discuss the measures which would be^taken to prevent,the inadvertent use of nonconforming material, i.e.,
identifica-tion, segregation, quarantine, etc.
.fygg.yp Discussions with PG&E Engineering personnel Otossrs.
Bettinger and Schuyler) revealed that it is their understand-ing that the Engineering Department will review and approve the use of materials or work practices which involvo devia-I tions from the designer's specifications. They further stated that the basis for such approval by the Engineering Department would be documented in writing, which is consistent with statements in the ?SAR.
2.
Findinns The absence of written procedures covering thio ncasures to'
'c be taken to prevent the inadvertent use of ncnconforming
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material and the participation of the Engincoring Department concerning the disposition of nonconforming asterial or work practices prevented a finding by the inspectors that an '
adequate program wou,1d be impicmented in a consistent manner with regard tg this criterion.
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