ML20211K634

Confirms 810701 Telcon Between WE Foster & Re Boyer Re Insp 99900334/81-02 on 810713-17 Re Turbocharger Thrust Bearing Lubrication Sys,Pump motors,6-inch Check Valve & Crankshaft Oil Plug.Related Documentation Encl

ML20211K634
Person / Time
Issue date:	07/02/1981
From:	Potapovs U NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV)
To:	Mathews C TRANSAMERICA DELAVAL, INC.
Shared Package
ML20011C460	List: ML20011C459 ML20211K553 ML20211K559 ML20211K567 ML20211K574 ML20211K579 ML20211K585 ML20211K592 ML20211K611 ML20211K617 ML20211K621 ML20211K628 ML20211K634 ML20211K640 ML20211K646 ML20211K652 ML20211K658 ML20211K663 ML20211K670 ML20211K676 ML20211K682 ML20211K689 ML20211K881 ML20211K901 ML20211K913 ML20211K919 ML20211K939 ML20211K972 ML20211K997 ML20211L003 ML20211L056 ML20211L071 ML20211L102 ML20211L160
References
FOIA-86-656, REF-QA-99900334 NUDOCS 8612120181
Download: ML20211K634 (2)

Text

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JUL 0 215El Docket No. 99900334/81-02 Transamerica Delaval. Inc.

Engine and Compressor Division ATTN: Mr. C. Mathews General IInnager 550 85th Avenue Oakland, CA 94261 Gentlemen:

This is to confirm the telephone conversation on July 1,1981, by Mr. W. E. Foster of this office with Mr. R. E. Boyer, of your staff, concerning the inspection at the Oakland, California plant on July 13-17, 1981.

The NRC inspector will be Mr. W. E. Foster.

The inspection will relate to theffo11owing problems: (1) turbocharger thrustbearingItbricationsystem;(2)pumpmotors;(3)sixinchcheck valve; and (4) crankshaft oil plug.

Your cooperation concerning this matter will be appreciated.

I Sincerely,,

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Uldis Potapovs. Chief Vendor Inspection Branch Sc: Mr. R. E. Boyer 8612120181 861203 PDR FOIA PDR ELLIS96-656 WA7

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VIB '"sPECTION. REPORT ROUTE SHEET B-6 I

Rev. 2/81

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VENDOR / CONTRACTOR: L m ny n ;m he /m /, n, < _. E., 6,,, e f Cm,, o ufn L DOCXET NO. 9990033 9 REPORT NO. 7 I -0 2 DATE OF INSPECTION:

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REPORT DUE DATE:

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PRIORITY STATUS:* DRAFT URGENT FINAL URGENT ASAP ASAP

~ ROUTINE ROUTINE (Uroent-i.e. stop other w3o in progress; ASAP-SuperTe' des other scheduled work e

. Routine-normal order of work). *0ther than Routine.must be initialed by Branch Chief.

CONTENTS: #Recort, 765,9665. -?fri. -i+d, rinsoection Plan, % nite ecox inout DRAFT:

Review / Concurrence / Signature Date Suomitted t.5/o Date,cocoieteo REPORT SUBMITTED TO CRESS (S)

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INSPECTOR /SECTION CHIEF (S)

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COMMENT:

SPECIAL NOTE: Return Iraft dpy to Branch Chief after Enforcement cooroinator p) completeo by Secretary W) completea oyInspector7Section Cniet (2) Completed by Cress

. (4) Completed by Branch Chief (5) Completed by Enforcement Coordinator

• If Enforcement Coordinator is not available, submit to Director for review / concurrence (6) Branch Chief makes determination about status of report,ie., to be redrafted, etc.,

. FINAL:

Review / Concurrence / Signature Date-Submitted Date Cccoleted

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REPORT SUBMITTED TO CRESS TO:

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• If Enforcement Coordinator is not available, submit to Director for review / concurrence TE REPLY IS DUE

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611 RYAN PLAZA DRIVE. SUITE 1000 ARLINGTON, TEXAS 76011 OCT 011982 Docket No. 99900334/81-02 Transamerica Delaval, Incorporated Engine and Compressor Division ATTN:

Mr. C. Mathews General Manager Oakland, CA 94621 Gentlemen:

Thank you for your letters of October 6,1981 and January 28, 1982 in response to our letters dated September 18,1581, andJanuary14,1$82.

Our most recent letter dated May 6, 1982, requested deferral of any further response in regard to Items C and D of the Notice of Noncon-formance until after a meeting with you concerning NRC inspection history and performance of a further planned inspection.

These activities were accomplished at your facility during August 23-27, 1982.

As a result of NRC Regional management review of the two noncon-formances in question du"ing this last inspection, a determination has been made to closecut t!e stated nonconformances without requiring any further actions by you.

This determination has been made based on our awareness that Bechtel is replacing the motors in question, and our evaluation indicating a contributory lack of specificity in the procurement requirements imposed on you by your customer.

In the event of your future receipt of domestic nuclear contracts, our inspection planning will include a detailed assessment of relevant procurement control activities.

We have no additional questions in regard to this inspection and no further correspondence is required.

Sincerely, W e ghiefw 1

Uldis Potapovs, i

Vendor Program Branch

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ARLINGioN. TEXAS 76011 MAY 0 6 1982 Docket' No. 99900334/81-02 Transamerica Delaval, Incorporated Engine and Compressor Division ATTN: Mr. C. Mathews General Manager Oakland, CA 94621 Gentlemen:

Thank you for your letters of October 6,1981, and January 28, 1982, in response to our letters dated September 18, 1981, and January 14, 1982.

In this correspondence you question the validity of Nonconformance Items C and D. We find this position unacceptable, in that you have no records which attest either to environmental qualifi-cation of the motors in question, or manufacture of the motors in accordance with your purchase order.

We have no specific concerns about the use of these motors, in that we have been informed that they will be replaced with qualified motors from another vendor.

We are concerned, however, in regard to the ade-quacy of your QA program with respect to identification and implemen-tation of procurement requirements.

Accordingly, we plan to conduct an inspection in the near future to assess, in particular, your:

(1) imposition of requirements on suppliers; (2) actions in regard to supplier conformance; and (3) records that reflect the aforementioned activities. The inspectors will be accompanied by a member of NRC Regional management for the purpose of reviewing NRC inspection history l

of your facility with you.

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lt <is requested that further response to items C and 0 be deferred until

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n i Uldis Potapovs. Chief Vendor Programs Branch

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ARLINGTON. TEX AS 76011 1982 gg 14 Docket No.

99900334/81-02 Transamerica Delaval, Incorporated Engine and Compressor Division ATTN: Mr. C. Mathews General Manager 550 85th Avenue Oakland, CA 94621 Gentlemen:

Thank you for your letter of October 6,1981, in response to our letter dated September 18, 1981. We apologize for not responding sooner.

As 4

a result of our review, we find that additional information is needed, in order that we may consider your request for re-evaluation.

1.

Regarding Item B - During a future inspection, we will review control of the swaging tool by the foreman of the department that installs the crankshaft oil plugs.

Of primary concern during the review, is the determination that the tool repeatedly produces an acceptable swage that aligns with the groove in the crankshaft.

Accordingly,

-no additional written response is required on this item at this time.

'2.

Regarding Item C - Your response did not address the stated noncon-formance, in that it failed to recognize that required records had not been maintained. We, therefore, consider re-evaluation is un-wa rranted.

3.

Regarding Item D - Your response indicates that Allis-Chalmers letters dated July 23 and August 20, 1976, " document compliance of the motor manufacture to our purchase order." That statement evokes the following questions, at minimum:

(1) If your statement is true, why have you requested documentation from the motor manufacturer attest-ing to qualification of the motors? and (2) if the motor manufacturer supplied qualified motors, why does he refuse to provide you documenta-tion attesting to that fact? Further, your response did not indicate that documentary evidence is now available to assure that the seller of the motors complied with the requirements of the purchase order.

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Transamerica Delaval, Inc.

Engine and Compressor Division,

As a result of the foregoing, please provide us with 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 dates your corrective actions and preventive measures were or will be completed for Items C and D.

If you have information that existed, but was not provided to the inspector during the course of the inspection, we will gladly re-evaluate.

Otherwise, please provide the requested information within 25 days from the date of this letter in order that we may complete our review.

Sincerely, hf$S,

1 dis Potapovs, Chie l

Vendor Inspection Branch e

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,e ARLINGTON, TEXA5 76011 September 18, 1981 Docket No. 99900334/81-02 Transamerica Delaval, Incorporated Engine and Compressor Division ATTN: Mr. C. Mathews General Manager 550 85th Avenue Oakland, California 94261 Gentlemen:

This refers to the inspection conducted by Mr. W. E. Foster, of this office on July 13-17, 1981, 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 as a result of the issuance of 10 CFR Part 21 reports by the Transamerica Delaval, Incorporated, Engine and Compressor Division.

The reports pertained to the diesel generator's:

(1) turbocharger thrust bearing lubrication system; and (2) crankshaft oil plug installation. The former affected numerous nuclear power plants while the latter was limited to the Phipps Bend Nuclear Power Plant, Unit 2.

Also, there were other reports regarding:

(1) unqualified motors used for auxiliary lube oil and jacket water pumps; and (2) malfunctioning of a six inch check valve. These condi-tions affected the Grand Gulf Nuclear Power Plant, Unit i for the motors and Units 1 and 2 for the valve.

Areas examined and our findings are discussed in the enclosed report. Within these areas, the inspection consisted of an examination of procedures and repre-sentative records, interviews with personnel, and observeLions by the inspector.

During the inspection it was found that the implementation 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' days from the date of this letter a written state-ment 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 er will be taken to prevent recurrence, and (3) the date your corrective actions and preventive measures were or will be completed.

Consideration may be given to extending your response time for a good cause shown.

The responses directed by this letter are not subject to the clearance pro-cedures 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 inforTnation that you

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Transamerica Delaval, Incorporated 2

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 information.

If your receipt of this letter has been delayed such that less than 7 days are available for your tryiew, please notify I

this office promptly so that a new due date may be establisted.

Consistent with section 2.790(b)(1), any such application must be accompanied by an affidavit executed by the owner of the infonnation 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 infonnation sought 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 i

to discuss them with you.

Sincere t

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&f U Fdis Potapovs. Ch1re%"

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Enclosures:

1.

Notice of Nonconfonnance 2.

Inspection Peport No. 99900334/81-02 3.

Inspection Data Sheets (9 pages) e

i l'

Transamerica Delaval, Incorporated Engine and Compressor Division Docket No. 99900334/81-02' NOTICE OF NONCONFORMANCE i

Based on the results of an NRC inspection conducted on July 13-17, 1981, it appears that certain of your activities were not conducted in accordance with

- NRC requirements, as indicated below:

A.

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 accom-plished in accordance with these instructions, procedures, or drawings.

Instructions, procedures, or drawings shall include appropriate quantitative or qualitative acceptance criteria for determining that important activities have been satisfactorily accomplished."

Nonconfonnances with these requirements are as follows:

1.

Paragraph 5.1.2 of the Quality Assurance Manual, Revision 0, dated February 27, 1981, 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."

Contrary to the above, the parts list and component drawings released by engineering had not defined the acceptance criteria of the installed crankshaft oil plugs.

Further, the route sheet that provided instruction for installation of the oil plugs contained no acceptance criteria.

2.

Paragraph 5.3.2 of the Quality Assurance Manual, Revision 0, dated February 27, 1981, states, " Instructions defining the applicable processes are issued to Manufacturing by use of route sheets, tooling sheets, numerical control readcuts and special written instructions and sketches."

\\

Contrary to the above, the instructions at Element C of Operation No. 55 of the Assembly / Test Route Sheet, Revision 1, dated June 20, 1981, for i

Job No. 02933, did not provide details for the swaging operation of the crankshaft oil plugs.

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Criterion XII of Appendix B to 10 CFR Part 50 states, " Measures shall be established to assure that tools, gages, instruments, and other measuring and testin3 devices used in activities affecting cuality are properly controlled, calibrated, and adjusted at specified periods to maintain accuracy within necessary limits."

Contrary to the above, measures had not been established to assure that tools used in the crankshaft oil plug installaticn are properly controlled and adjusted at specified periods to maintain accuracy within necessary limits.

C.

Criterion XVII of Appendix B to 10 CFR Part 50, states in part, "Suffi-cient records shall be maintained to furnish evidence of activities affecting quality."

Paragraph 4.17.1 of Specification No. 9645-G-QA-1, Revision 5, dated March 3, 1980, states in part, " Records shall be maintained to furnish documentary evidence of activities affecting quality." Note:

The 1

identical requirement was reflected in Revision 4, dated November 9, i

1 1973; which predated the purchase order to Delaval.

Specification (No. 9645-M-018.0) requires that motors be supplied in l

accordance with Appendix 0.

Paragraph 6.3 of Appendix 0 (Specification No. 9645-E-013.0) addresses service conditions relative to pressure, temperature, relative humidity, and radiation as does paragraph 5.1 of i

the governing specification (No. 9645-M-018.0).

Further, the governing specification lists IEEE standards, including 323, and states that the list is not limited to those identified; it also states that the "most stringent requirements shall apply."

l Contrary to the above, records had not been maintained to furnish evidence that the motors for the auxiliary lube oil and jacket water pumps had been environmentally qualified.

D.

Criterion VII of Appendix B to 10 CFR Part 50, states in part, " Documentary evidence that material and equipment conforn to the procurement require-ments shall be available...."

Paragraph 4.7 of Specification No. 9645-G-QA-1, Revision 5, dated March 7, 1980, states in part, "The seller shall assure that lower-tier sellers comply with the applicable requirements of the purchase order."

Note: The identical requirement was reflected in Revision 4, dated November 9, 1973; which predated the purchase order to Delaval.

t 3

Delaval Purchase Order No. 62572, dated April 13, 1976, ordered the motors for the auxiliary lube oil pumps.

Note 1, of the P.O. states in part, "Allis-Chalmers to certify that manufacture is in accord-ance with Allis-Chalmers Technical Specifications as outlined for IEEE 323, 334 and 344 motor requirements...."

P.O. Addendum No. 1, dated June 8, 1976, added the motors for the jacket water pumps and did not address the notes of the original purchase order.

Contrary to the above, documentary evidence was not available to assure that the seller of the motors, for the auxiliary lube oil and jacket water pumps, had compiled with the requirements of the purchase order.

TRANSAMERIC JELAVAL, INCORPORATED ORGANIZATION:

ENGINE AND COMPRESSOR DIV.

OAKLAND, CALZFORNZA REPORT NO.: 99900334/81-02 INSPECTION DATE(S): 7/13 - 17/81 INSPECTION ON-SITE HOURS: 30 I

CORRESPONDENCE ADDRESS: Transamerica Delaval, Incorporated Engine and Compressor Division ATTN: Mr. C. Mathews, General Manager

" ' 85th Avenue i

0 land, California 94261 ORGANIZATION CONTACT:

Mr. R. E. Boyer, Manager - Quality Assurance TELEPHONE:

(415) 577-7422 PRINCIPAL PRODUCT: Stand-by diesel generators.

NUCLEAR INDUSTRY ACTIVITY: Did not obtain during this inspection.

I i

i ASSIGNED INSe'ECTOR:,h[ [ N 9/f 3-/ r p I

W. E. Foster, Reactive inspection Section Date 3 OTHER INSPECTOR (S): None J' Dcm

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I APPROVED BY:

f

1. Barnes, Chief, heactive inspection Section Date i

! INSPECTION BASES AND SCOPE:

' A.

BASES:

10 CFR Part 50, Appendix B.

,B.

SCOPE: The Engine and Compressor Division of Transamerica Delaval, Incorpor-I ateo, filed 10 CFR Part 21 reports on the diesel generator's:

(1) turbocharger l

thrust bearing lubrication system; and (2) crankshaft oil plug installation.

The former affected numerous nuclear power plants and resulted in followup l'

requests from the Office of Inspection and Enforcement, Region II (RII).

The latter was limited to the Phipps Bend Nuclear Power Plant, Unit 2.

OIE, RII also requested followup on:

(1) unqualified motors used for auxiliary lube oil and jacket water pumps; and (2) malfunctioning of a 6-incn eneck valve. Both of these were located at the Grand Gulf Nuclear Pcwer Station, i

i Unit 1 for the motors; Units 1 and 2 for the valve.

i Also, limited inspection was conducted on previous inspection finoings.

<Q ONE N@h

TRANSAMERICA DELAVAL, INCORPORATED ORGANIZATION: ENGINE AND COMPRESSOR 01V.

0AKLAND, CALIFORNIA REPORT NO.: 99900334/81-02 INSPECTION RESULTS:

PAGE 2 of 5 INSPECTION RESULTS A.

VIOLATIONS:

None.

B.

NONCONFORMANCES:

1.

Contrary to Criterion V of Appendix B to 10 CFR Part 50 and paragraph 5.1.2 of the Quality Assurance Manual, Revision 0, dated February 27, 1981, the parts list and component drawing released by engineering had not defined the acceptance criteria of the installed crankshaft oil plugs.

Further, the route sheet that provided instruction for

~ installation of the oil plugs contained no acceptance criteria.

2.

Contrary tc Criterion V of Appendix B to 10 CFR Part 50 and paragraph 5.3.2 of the Quality Assurance Manual, Revision 0, dated February 27, 1981, the instructions at Element C of Operation No. 55 of the Assembly /

Test Route Sheet, Revision 1, dated June 20, 1981, for Job No. 02933 did not provide details of the swaging operation of the crankshaft oil plugs.

3.

Contrary to Criterion XII of Appendix B to 10 CFR Part 50, measures had not been established to assure that tools used in the crankshaft oil plug installation are properly controlled and adjusted at specified periods to maintain accuracy within necessary limits.

4.

Contrary to Criterion XVII of Appendix B to 10 CFR Part 50 and paragraph 4.17.1 of Specification No. 9645-G-QA-1, Revision 5, dated March 1980, (and previous editions), records had not been maintained to furnish evidence that the motors for the auxiliary lube oil and jacket water pumps had been environmentally qualified.

5.

Contrary to Criterion VII of Appendix B to 10 CFR Part 50 and paragraph 4.7 of Specification No. 9645-G-CA-1, Revision 5, dated March 7, 1980 (and previous editions), documentary evidence was not available to assure that the selier of the motors for the auxiliary lube oil and jacket water pumps had complied with the requirements of the purchase order.

C.

UNRESOLVED ITEM:

1.

Element K of Operation No. 55 of the Assembly / Test Rcute Sheet, dated June 20, 1981, for Job No. 02933, Sub-Assembly No.1A-5636 states,

" Final Inspection (Inspector to retain this document)." Subsecuent to query, the NRC inspector was informed that all uninspected elements were inspected.

Also, a dye penetrant test was concucted on the oil plugs installed in the crankshaft during Element K.

Inasmuch as no details are evident at Element K, the NRC inspector was unable to determine the final inscaction recuirements.

TRANSAMERICA.LAVAL, TNCORPORATED i

ORGANIZATION: ENGlNE AND COMPRESSOR DIV.

0AKLAND, CALIFORNIA REPORT NO.: 99900334/81-02 INSPECTION RESULTS:

PAGE 3 of 5 D.

STATUS OF PREVIOUS INSPECTION FINDINGS:

1.

(Closed) Violation (80-01):

Records had not been maintained to indicate that:

(1) The fractured thennostatic control valve had been evaluated; and (2) Actions had been taken to detennine if the improper valves (raised face flange) had been supplied to other customers.

The inspector verified that:

(1) The thermostatic control valve had been evaluated and appropriate records initiated; (2) Actions had been taken to determine if an improper valve had been furnished to other customers.

Also, the inspector reviewed records which indicated that user identified problems are evaluated for possible impact upon diesel generators suppiied for domestic nuclear power plants.

2.

(Closed) Deviation (80-01):

The gage used to measure, accept / reject the diameter and depth of the link rod dowel counterbore had not been identi-fied with :

(1) A tool and/or Gage Tryout Tag; (2) A calibration decal; or (3) Company name, gage or equipment name, part and/or serial number, as applicable.

The inspector verified that:

(1) The gage exhibited a calibration decal; and (2) The gage exhibited a number which had been etched onto it.

3.

(0 pen) Deviation (80-01): Notice of Deviation Items B through I and unresolved items in DetailsSection I, paragraphs B.4.d and 0.4.c.

remain open.

The inspector did not verify the vendors actions during this inspection due to the priority of other inspection requirements These findings, as well as those identified during inspections 81-01 and 79-01, will be verified during the next inspection.

E.

OTHER FINDINGS OR COMMENTS:

1.

Element C of Operation No. 55, of the Assembly / Test Route Sheet, Revision 1, dated June 20, 1981, for Job No. 02933, identifies the driver and swaging tool used to install the crankshaft oil plugs.

Subsequent to query, the NRC inspector was informed that the swaging tool is energized hydraulically with a pressure of 140 - 200 PSIG using a gage and tubing arrangement that attaches to the swaging tool; however, this information is not reflected in the route sheet.

(See B.2. above).

2.

The NRC inspector noted that the nylon washer is installed on the driver with a screw; also, the swaging tool is adjustable in order that the swage is positioned correctly.

However, there was no indication that these devices are subjected to periodic service.

(See B.3. above).

TRANSAMERICA w LAVAL INCORPORATED ORGANIZATION: ENGINE AND COMPRESSOR DIV.

0AKLAND, CALIFORNIA REPORT NO.:. 99900334/81-02 INSPECTION RESULTS:

PAGE 4 of 5 3.

Bechtel Power Corporation Purchase Order No. 9645-M-018.0, dated August 6,1974, and Revision 22, dated April 22, 1980, identify the motors for the auxiliary lube oil and jacket water pumps with a "Q" prefix.

Faragraph 13.1 of Specification No. 9645-M-018.0 states that equipment designated with a "Q" number, performs a safety-related function.

The specification requires that motors be supplied in accordance with Appendix 0.

Paragraph 6.3 of Appendix 0 (Specification No. 9645-E-013.0) addresses service conditions relative to pressure, temperature, relative humidity, and radiation as does paragraph 5.1 of the governing specification (No. 9645-M-018.0).

Further, the governing specification lists IEEE standards, including 323, and ',tates that the list is not limited to those identified; it also states that the "most stringent requirements shall apply."

The motors supplied for this purchase order have not been environmentally qualified.

The Engine and Compressor Division of Transamerica Delaval, Incorporated maintain that environmental qualification of the motors was not a contractual requirement. (See Section B.4. above).

4.

Delaval Purchase Order No. 62572, dated April 13, 1976, ordered the motors for the auxiliary lube oil pumps.

Note 1, of the P.O. states in part, "Allis-Chalmers to certify that manufacture is in accord-ance with Allis-Chalmers Technical Specifications as outlined for IEEE 323, 334 and 344 motor requirements...."

P.O. Change Order No. 1, dated June 2, 1976, included a change to the motor design and stated, "All else remains the same."

P.O. Addendum No. 1, dated June 8, 1976, added the motors for the jacket water pumps and did not address the notes of the original purchase order.

There were no records to certify that the motors had been manufactured in accordance with Allis-Chalmers Technical Specifications as out-lined for IEEE 323, 334 and 344.

(See 8.5. above).

5.

The corrective action regarding the turbocharger thrust bearing lubrication problem is adequate.

Prior to implementation of the modification, Research and Development had conducted tests and identified the appropriate configuration of a system that would provide the necessary lubrication to the turbocharger thrust bearings while the diesel generator was in the standby mode.

The NRC inspector was informed that the modified turbocharger thrust bearing lubrication system had been incorporated on the diesel generators at San Onofre.

However, no records were presented to reflect accomplishment of the modification or its effectiveness.

TRANSAMERfCA eELAVAL, INCORPORATED I

~

ORGANIZATION: ENG8NE AND COMPRESSOR D&V.

0AKLAND, CALIFORNIA REPORT NO.: 99900334/81-02 INSPECTION RESULTS:

PAGE 5 of 5 6.

The corrective action regarding the crankshaft oil plug problem is adequate.

The driver used to install the oil plugs had been modified to eliminate damage to the crankshaft oil plugs during installation.

7.

Transamerica Delaval Incorporated's Engine and Compressor Division was not aware of a problem with a 6-inch check valve manufactured by the Williams Gange Company.

The information they had pertained to a 5-inch check valve manufactured by the Durabia Manufacturing Company. The latter valve was reportedly stuck in an approximately 80 percent open position and documented on Condition Report No. 4186.

The Condition Report was " closed out" because the reported condition could not be duplicated.

O

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• OCTOBER 1677 (MC 0838)

UNITED 8TATSS 88UCLEAR REGULATORY COMMtASION INSPECTION & ENFORCEMENT-STATISTICAL DATA SUPPLEMENT GENE R AL INSTR ('CTIONS: 8 LOCK A MUST BE CHECKED TO SHOW TYPE OF INFORMATION CONTAINED ON THE FORM. ONE FORM IS TO 8E COMPLETED FOR EACH.

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(IF FIRST OCCURRENCE ENTER "1")

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(A) ITEM OF NONCOMPLIANCE CITED.

(3) ITEM OF NONCOMPLIANCE NOT CITED, AND, (C) DEVIATION CITED IN ENFORCEMENT CORRESPONDENCE DOCKET NUMBER OO3N OR LICENSE NUMBER REPORT NUMBER EI-O =7 A-TYPE OF FINDINGS S-FECIFIC N/C CODE FUNCTionat 1

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• OCTO8ER 1877 (MC 0636)

UNITEo STATSS NUCLE AR REGULATORV CoasaseOSiON INSPECTION & ENFORCEMENT-STATISTICAL DATA SUPPLEMENT G E N E R AL INSTRUCTIONS: BLOCK A MUST BE CHECKED TO SHOW TYPE OF INFORMATION CONTAINED ON THE FORM. ONE FORM IS TO BE COMPLETED FOR EACH.

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• FG23 NRC 7004 I

OCTOGEQ 1977 (WC Cl38)

• =s USNTSD STATSO NUCLEAR 200ULATORY SeammESION

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INSPECTION 8 ENFORCEMENT-4TATl8TICAL DATA SUPPLEMENT

. GENER AL INSTRUCTIONS: BLOCK A MUST SE CHECKED TO SHOW TYPE OF INFORMt, TION CONTAINED ON THE FORM. ONE FORM IS TO BE COMPLETED FOR EACH.

~ (A) ITEM OF NONCOMPLIANCE CITED.

(81 ITEM OF NONCOMPLI ANCE NOT CITED. AND, f

(C) DEVIATION CITED IN ENFORCEMENT CORRESPONDENCE 9 0oD*

II' C d DOCKET NUMSER OR LICENSE NUMSER REPORT NUMBER A-TYPE OF FINDINGS S-RPECIFIC N/C CODE FUNCTIONAL (CHECK ONE SOX ONLY)

Nt DEVIATION CAuss PROC 800RE SEVERITY, AREA 7

10 11 12 A

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I S

1 2 O LICENSEE IDENTIFIED ITEMS C-MODULE NUMSER 12 13 C

DEVIATION 4 9 4 7 0 r E D-HOW ITEM IDENTIFIED E-CONSEQUENCES (CHECK ONE 80X ONLY)

(CHECK ONE BOX ONLY)

L LICENSEE A

CAUSE OR CONSTITUTED ACTUAL OCCURRENCE j

O HAD eOTENTiAL TO RESULT i~ ACTUAL OCCuaaENCE 20 1 INSPECTOR 21 P O

OTHER N E DID NOT HAVE POTENTIAL TO RESULT IN ACTUAL OCCURRENCE F -EXEMPT INFORMATION G-ADDITIONAL UNITS (ENTER M" IN FIRST BOX FOLLOWED BY OTHER 23 26 22 S CHECK BOX IF EXEMPT INFORMATION IS t#CLUDEO IN TEXT BELOW, PE R 10 CPR 2.790 H-NONCOMPLtANCE REPETITIVE OCCURRENCE 27 (IF FIRST OCCURRENCE ENTER "1")

I-TEXT (ENTER UP TO SM30 CHARACTERS FOR EACH ITEM. IF THE TEXT OF THE NONCOMPLIANCE OR DEVIATION EXCEEDS THI5 NUMBER, IT WILL BE NECESSARY TO PARAPHRASE) 1 50 Cos}manu de C w: / e n ;e w Trr e t A.,- en d;1 8 L Ic t ra Pam4 rn and aamaan L 4. 7 al' L e e l'e a l:an N 9 4. e..r G - Q A - l, R e v r Mhe i(Am) i a

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D NOTE. DATA ENTRY CLERK-THE LAST LINE ENTERED MUST CONTAIN THIS INFORMATION l

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d PORM NRC 786-5 OCTOBER 1977 WWI

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UNITES BTATES 98UCLEAR REOULATORY CoesasesSION INSPECTION & ENFORCEMENT-STATISTICAL DATA SUPPLEMENT s.

GENER AL INSTRUCTIONS: BLOCK A MUST BE CHECKED TO SHOW TYPE OF INFORMATION CONTAINED ON THE FORM. ONE FORM IS TO 8E COMPLETED FOR EACH.

(A) ITEM OF NONCOMPLIANCE CITED.

" c-(8) ITEM OF NONCOMPLIANCE NOT CITED, AND, 4

(C) DEVIATir)N CITED IN ENFORCEMENT CORRESPONDENCE DOCKET NUMBER OR LICENSE NUMSER REPORT NUM8ER A-TYPE OF FINDINGS 8-SPECIFIC N/C CODE puNcisoNAL (CHECK ONE SOX ONLY)

OR DEVIATION CAUSE PROCEDURE SEVERITY AREA 3

7 9.

10 11 12 A

NONNLIANCE l l l l l l

.l l l S

1 2 5 LICENSEE IDENTIFIED ITEMS C-MODULE NUMBER 13 19 C

DEVIATION l

l D-HOW ITEM IDENTIFIED E-CONSEQUENCES (CHECK ONE BOX ONLY1 (CHECK ONE BOX ONLY)

L LICENSEE A

CAUSE OR CONSTITUTED ACTUAL OCCURRENCE 20 8 INSPECTOR 21 P HAD POTENTIAL TO RESULT IN ACTUAL OCCURRENCE O

OTHER,

N DID NOT HAVE POTENTIAL TO RESULT IN ACTUAL OCCURRENCE F -EXEMPT INFORMATION G-ADDITION AL UNITS (ENTER M" IN FIRST BOX FOLLOWED BY OTHER 23 26 22 S O CHECK.Ox iF EXEMPT iNFOaMATiON lIIII IS INCLUDED IN TEXT BELOW. PER 10 CFR 2.790 '

H-NONCOMPLt ANCE REPETITIVE OCCURRENCE 27 (IF FIRST OCCURRENCE ENTER

• 1"1 I-TEXT (ENTER UP TO 2400 CHAR ACTERS FOR EACH ITEM. IF THE TEXT OF THE NONCOMPLlANCE OR DEVIATION EXCEEDS THIS NUMPER, IT WILL 8E NECESSARY TO PARAPHRASE) 1 50 (1)

(2) l (35 (4)

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&fElN D & NOTE. DATA ENTRY CLERK-THE LAST LINE ENTERED MUST CONTAIN THIS ANFORMATION.

l (O V E R,

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• Delaval 5'5"5= =

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(415) 577-7400 October 6, 1981 1

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1 U.S. Nuclear Regulatory Commission Region IV OCTI3I981 in' b.

611 Ryan Plaza Drive, Suite 1000 it>l Arlington, Texas 76011 Docket No.: 99900334/81-02 Attention:

Mr. Uldis Potapous, Chief Gentlemen:

Please refer to your letter of September 18, 1981. This letter covered the inspection made by Mr. W. F. Foster on July 13-17, 1981 at our facility in Oakland, California.

Attached are our responses to your notice of nonconformance A, B. C, and D.

On nonconformance A, we have given our corrective action, preventative action and completion date as you requested.

We ask that you reconsider items B, C, and D in light of our attached comments and rule that items B, C, and D are, in fact, in conformance with 10CFR50B.

I f you requi re any additional information, please contact me.

Sincerely, M i kw

~

R. E. Boyer, Manager Quality Assurance REB:cjb 82.n005-c2.95 Y

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Transamenca W., i,ic%:,o.b..., o, Delaval 55"5'~"a 4

P O Boz 2161 Oakland Catdornia 94621 g"

(415) 577 7400 e

U.S. Nuclear Regulatory Commission October 6,1981 Page 2 A.1, Nonconformance The parts lists and component drawings released by Engineering had not defined the acceptance criteria of the installed crank-shaft oil plugs.

Further, the route sheet that provided instruc-tions for installation of the oli plugs contained no acceptance criteria.

Corrective Action The drawings which show the installation of the oil plug were revised Septembe r 2,1981.

The drawing now gives acceptance criteria.

The route sheet for the crankshaf t assembly has been revised to give acceptance criteria for the installation of the oil plugs. This revision was completed July 30, 1981.

Preventative Action Corrective Action Request #085 was written on July 21, 1981 to the Engineering Department. This request described the noncon-formance, the cause, and a recommended corrective action.

It was closed August 29, 1981.

Corrective Action Request #086 was written on July 22, 1981 to the Industrial Engineering Department.

This request described the nonconformance, the cause, and a recom-mended corrective action.

It was closed September 21, 1981. A training class was held October 1,1981 with Industrial Engineering and Engineering on 10CFR50B, Criterion V, our Quality Assurance Manual, paragraphs 5.1.2 and 5 3.2.

This class covered the non-conformance, the corrective action, and the related procedures to prevent reoccurrence.

A.2.

Nonconformance The Route Sheet instructions at Element C did not provide details for the swaging operation of the crankshaft oli plugs.

f Corrective Action The Route Sheet for the crankshaft assembly has been revised to give details for the oil plug swaging operation. The revision was com-pleted on July 30, 1981.

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Transamenca P!l=C;%.i..,.o, Delaval

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P O. Bon 2161 ll3 Oakland. Cahfornia 94621 (415) 577-7400 U.S. Nuclear Regulatory Commission October 6, 1981 Page 3 A.2.

Nonconformance - Cont'd Preventative Action Corrective Action Request #086 and the training class mentioned in A.I. above also covers this nonconformance.

Completion Date: October 1, 1981.

B.

Nonconformance,(Cri teria X11,10CFR508)

Heasures were not established to assure that tools used in the crankshaf t oil plug installation are properly controlled and adjusted at specified periods to maintain accuracy within the necessary limits.

Comments Criteria Xll is entitled " Control of Measuring and Test Equipment,"

the criteria states: "Heasures shall be established to assure that tools, gauges, instruments, and other measuring and testing devices used in activities affecting quality are properly controlled, cali-brated, and adjusted at specified periods to maintain accuracy within necessary limits." We feel this criteria applies only to measuring and test equipment. The tool in question is an installing tool and does not come under this criteria.

For general information, I will elaborate on our installation of the crankshaft oil plug. The tool used to install the oil plug is con-trolled by the foreman of the department that installs the plugs.

The tool is adjustable and is set each time it is used by the operator.

l Any wear of the tool would be compensated for by this adjustment.

The l

nature of the tool is such that wear would be very minimal.

The original design of the tool had a nylon washer on the bottom to prevent marking of the plug. Actual use of this tool has shown that this washer cannot contact the plug so it has been removed. The only other items used in installing this plug is a hydraulic pressure source and a pressure gauge. The pressure gauge is a controlled gauge and was reviewed by the NRC auditor with no comments.

Transamenca i;gr:J;g;;d;a.,,,o, Delaval 55"5* ^= a P.O Bon 2161 1jg OaMand. Cahfornia 94621 (415) 577 7400 U.S. Nuclear Regulatory Commission October 6,1981 Page 4 B.

Nonconforriance - Cont'd The inspection of the completed oil plug installation is also an inspection of the proper operation of the tool. We request that you re-evaluate this nonconformance after reviewing the above information. We feel we are in conformance with 10CFR50B and our Quality Assurance Manual in this matter.

C.

Nonconformance Records had not been maintained to furnish evidence that the motors for the auxiliary tube oil and Jacket water pumps had been environ-mentally qualified.

Comments Specification 9645-M-018.0, requires that motors be supplied in accordance with Appendix 0.

Paragraph 6.3 of Appendix 0 addresses service conditions relative to pressure, temperature, relative humidity, and radiation, but does not give specific values.

Appendix 0 was included as part of our Purchase Specifications.

Paragraph 5.1 of the specification gives the following environ-mental conditions:

Temperature, F 65 to 120 Pressure, PSIG Atmosphe ri c Relative Humidity, %

10 to 90 Radiation Dosage, RADS None We furnished continuous duty, totally enclosed, fan cooled, 60 C (140 F) rise motors.

These motors comply to the environmental conditions of the specifications. This information is contained i

on the nameplates of the motors and was also on the test reports we submitted to Bechtel.

Appendix 0, paragraph 4.1 is very specific on codes and standards t

that the equipment must be designed, built, rated and tested to.

There were no references to IEEE 323, 334, or 344. The only ref-erence to IEEE 323, 344 was in Specification 9645-H-018.0, para-graph 4.1.

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Transamenca fll ra: Z ; ;. 6,.

Delaval

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P.O. Bom 2161 g

Oak and. Cahtornia 94621 (418) 577 7400 U.S. Nuclear Regulatory Commission October 6,1981 Page 5 C.

Nonconformance - Cont'd The paragraph reads, "Desigt materials, manufacture, examination, testing, inspection, stamping, certification, and documentation shall conform to applicable portions of the latest issue of the following adopted or tentative specifications, standards, codes, and addenda, as applicable."

lEEE 334 is the IEEE standard for type testing continuous duty, Class 1E motors for nuclear power generating stations, but neither paragraph 4.1, nor Appendix 0, made any reference to IEEE 334.

The IEEE standards were not established for environmental qualifi-cation, but were intended to provide guidance for demonstrating the qualification of Class 1E equipment including components or equipment of any interface whose failure could adversely affect the performance of Class IE systems and electric equipment. The specifications were very specific for the electrical panels and the generator; therefore, those components were qualified to IEEE 323 and 344 standards.

The specifications did not give IEEE stan-dards for motors and therefore they were not supplied to IEEE.

The statement, "Mos t stringent requirements shall apply" has been taken out of context. The statement actually reads, " Conversely, when the requirements of the specifications are interpreted by the Seller to be less stringent than code requirements, the most strin gent requi rements shall apply." This statenent is paragraph 4.3 of the Specification 9645-M-018.0. There were no requirements of Appendix 0 for IEEE 323 or 344.

With the above actions we have provided motors in direct conformance to specification 9645-M-018.0 and Appendix 0 requi rements.

Our docu-mentation has been provided through nameplate rating information and test reports for the service conditions. The motors have been seis-mically tested by an independent lab wi th seismic reports submi tted to Bechtel.

We request that you re-evaluate this nonconformance af ter reviewing the above information.

We feel we are in compliance with 10CFR50B, our Quality Assurance Manual and the jobs specifcations.

" ~ - " ~

Transamenca E"Dme anc Comprose D nsion 550 85th Avenue

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Oaklanc. Cabfornia 94621 M15) 577 7400

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U.S. Nuclear Regulatory Commission

' October 6, 1981 Page 6 D.

Nonconformance Documentary evidence was not available to assure that the Seller of the motors, for the auxiliary lube oil and Jacket water pump had complied with the requirements of the purchase order.

Comments "Allis Chalmers to Our purchase order to Allis-Chalmers states:

certify that manufacture is in accordance with Allis-Chalmers Technical Specifications as outilned for IEEE 323, 334, and 344 motor requi rements."

We have two letters from Allis-Chalmers dated August 20, 1976 and July 23,1976. These letters were reviewed by the NRC auditor during the inspection of July 13-17, 1981.

The July 23, 1976 letter states, "The motors we have supplied on these three orders (62572) are of equal quality and built to the same high manufacturing specifications as the Q. A. motors you have on order will be built."

(The Q. A. motors referred to were IEEE motors for another contract.)

j The August 20, 1976 letter states, "On the Delaval order mentioned

+

above, (62572), the motors supplied are physically, dimensionally and performance wise no different than the motors that will be built to meet the Class 1E requi rements of IEEE 323, 333, and 344. The only difference will be the documentation and quality program sOpplied with the Class 1E motor."

These two letters document compliance of the motor manufacture to our purchase order.

We request that you re-evaluate this nonconformance after reviewing the above Information. We feel that we are in compilance with our Quality Assurance Manual, 10CFR508, and the job specifications.

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