Code Of Federal Regulations
December 1, 2017Mr. David GobbiQuality Assurance ManagerFlowserve Pump Division2300 E. Vernon Ave.Vernon, CA 90058SUBJECT:FLOWSERVE PUMP DIVISION’S NUCLEAR REGULATORY COMMISSIONINSPECTION REPORT NO. 99901369/2017-201Dear Mr. Gobbi:On October 23-26, 2017, the U.S. Nuclear Regulatory Commission (NRC) staff conducted aninspection at the Flowserve Pump Division’s facility (hereafter referred to as FLS) in Vernon,CA. The purpose of this limited-scope routine inspection was to assess FLS’s compliance withprovisions of Title 10 of the Code of Federal Regulations (10 CFR) Part 21, “Reporting ofDefects and Noncompliance,” and selected portions of Appendix B, “Quality Assurance ProgramCriteria for Nuclear Power Plants and Fuel Reprocessing Plants,” to 10 CFR Part 50, “DomesticLicensing of Production and Utilization Facilities.”This technically-focused inspection specifically evaluated FLS’s implementation of the qualityactivities associated with the design, fabrication, and testing of the pumps being supplied todomestic operating reactors and for the Westinghouse Electric Company AP1000 reactordesign for Vogtle Electric Generating Plant (hereafter referred to as Vogtle), Units 3 and 4.Specifically, the NRC inspection team reviewed activities and documents related to therefurbishment of the High Pressure Safety Injection pump AB shaft for Waterford Steam ElectricStation, Unit 3, and the fabrication of two of the AP1000 pumps for Vogtle Units 3 and 4. TheAP1000 pumps were the Vogtle Unit 4 Chemical and Volume Control System Makeup pumpAPP-CVS-MP-01A (Serial Number 10RLCU0008908001) and the Vogtle Unit 3 NormalResidual Heat Removal System Centrifugal pump RNS-MP-01A (Serial Number10RLCU0008701001). The enclosed report presents the results of the inspection. This NRCinspection report does not constitute NRC endorsement of FLS’s overall quality assurance (QA)or Part 21 programs.Based on the results of this inspection, the NRC inspection team found the implementation ofyour QA program met the requirements imposed on you by your customers or NRC licensees.No findings of significance were identified.In accordance with 10 CFR 2.390, “Public Inspections, Exemptions, Requests for Withholding,”of the NRC’s “Rules of Practice,” the NRC will make available electronically for public inspection
D. Gobbi-2-a copy of this letter and its enclosure through the NRC Public Document Room or from theNRC’s Agencywide Documents Access and Management System, which is accessible ly,/RA/John P. Burke, ChiefQuality Assurance Vendor Inspection Branch-2Division of Construction Inspectionand Operational ProgramsOffice of New ReactorsDocket No.: 99901369EPID: 99901369/I-2017-201-0035Enclosure:Inspection Report No. 99901369/2017-201and Attachment
D. GobbiSUBJECT:-3FLOWSERVE PUMP DIVISION’S NUCLEAR REGULATORY COMMISSIONINSPECTION REPORT NO. 99901369/2017-201Dated: December 1, nE ResourceNRO DCIP DistributionADAMS Accession No.: ML17333A259 *via e-mailNRO-002NRO/DCIPNRO/DCIPOFFICE 1/29/1711/29/1711/30/17DATENRO/DCIPOFFICE CIAL RECORD COPY
U.S. NUCLEAR REGULATORY COMMISSIONOFFICE OF NEW REACTORSDIVISION OF CONSTRUCTION INSPECTION AND OPERATIONAL PROGRAMSVENDOR INSPECTION REPORTDocket No.:99901369Report No.:99901369/2017-201Vendor:Flowserve Pump Division2300 E. Vernon Ave.Vernon, CA 90058Vendor Contact:Mr. David GobbiQuality Assurance ManagerE-mail: dgobbi@flowserve.comPhone: (980) 722-6770Nuclear Industry Activity:Flowserve Pump Division, located at 2300 E. Vernon Ave. Vernon,CA, is an American Society of Mechanical Engineers (ASME)Boiler & Pressure Vessel (B&PV) Code Certificate Holder holdingan N and NPT stamp. Flowserve Pump Division’s scope of supplyincludes manufacturing, repair, and replacement of safety-relatedASME B&PV Code Class 1, 2, and 3 and non-ASME B&PV Codesafety-related pumps, including spare/replacement parts,components, appurtenances, and the associated engineering andfield services.Inspection Dates:October 23-26, 2017Inspectors:Jonathan Ortega-LucianoTerry JacksonIlka BerriosYamir Diaz-CastilloRobert WolfgangCheol SHEENHan-ok KOApproved O/DCIP/QVIB-2NRR/DE/EMIBKINSKINSTeam LeaderBranch ChiefObserverObserverJohn P. Burke, ChiefQuality Assurance Vendor Inspection Branch-2Division of Construction Inspectionand Operational ProgramsOffice of New ReactorsEnclosure
EXECUTIVE SUMMARYFlowserve Pump Division99901369/2017-201The U.S. Nuclear Regulatory Commission (NRC) staff conducted a vendor inspection at theFlowserve Pump Division’s (hereafter referred to as FLS) facility in Vernon, CA, to verify that ithad implemented an adequate quality assurance (QA) program that complies with therequirements of Appendix B, “Quality Assurance Criteria for Nuclear Power Plants and FuelReprocessing Plants,” to Title 10 of the Code of Federal Regulations (10 CFR) Part 50,“Domestic Licensing of Production and Utilization Facilities.” In addition, the NRC inspectionalso verified that FLS implemented a program under 10 CFR Part 21, “Reporting of Defects andNoncompliance.” Furthermore, the NRC inspection verified that FLS had implemented aprogram in accordance with the applicable requirements of Section III, “Rules for Constructionof Nuclear Facility Components,” of the American Society of Mechanical Engineers (ASME)Boiler and Pressure Vessel (B&PV) Code. The NRC inspection team conducted the inspectionon October 23-26, 2017. This was the fourth NRC inspection at the FLS facility.The Korea Institute of Nuclear Safety (KINS) participated in the inspection as observers. Theseobservations foster the sharing of international experiences with the construction of newreactors, oversight of vendors, and modular construction techniques consistent with theobjectives of the Multinational Design Evaluation Program.This technically-focused inspection specifically evaluated FLS’s implementation of qualityactivities associated with the design, fabrication, and testing of safety-related pumps for theWestinghouse Electric Company AP1000 reactor design and for the domestic operatingreactors. Specific activities observed by the NRC inspection team included: Commercial-grade dedication for safety-related items such as O-Rings and smallmachined partsCalibration of a 1000 PSI pressure gaugeIn addition to observing these activities, the NRC inspection team verified that measuring andtest equipment (M&TE) was properly identified, marked, calibrated, and used within itscalibrated range.These regulations served as the bases for the NRC inspection: Appendix B to 10 CFR Part 5010 CFR Part 21During the course of this inspection, the NRC inspection team implemented InspectionProcedure (IP) 43002, “Routine Inspections of Nuclear Vendors,” dated January 27, 2017,IP 43004, “Inspection of Commercial-Grade Dedication Programs,” dated January 27, 2017, andIP36100, “Inspection of 10 CFR Part 21 and Programs for Reporting Defects andNoncompliance,” dated February 13, 2012.-2-
The NRC inspection team determined that FLS is implementing its programs for training andqualification, 10 CFR Part 21, design control, commercial-grade dedication, oversight ofcontracted activities, control of special processes, test control, nonconforming material, parts, orcomponents, and corrective action in accordance with the applicable regulatory requirements ofAppendix B to 10 CFR Part 50. Based on the limited sample of documents reviewed andactivities observed, the NRC inspection team also determined that FLS is adequatelyimplementing its policies and procedures associated with these programs. No findings ofsignificance were identified.-3-
REPORT DETAILS1. 10 CFR Part 21 Programa. Inspection ScopeThe NRC inspection team reviewed Flowserve Pump Division’s (hereafter referred to asFLS) policies and implementing procedures that govern FLS’s Title 10 of the Code ofFederal Regulations (10 CFR) Part 21, “Reporting of Defects and Noncompliance,”program to verify compliance with the regulatory requirements. In addition, the NRCinspection team evaluated the 10 CFR Part 21 postings and a sample of FLS’s purchaseorders (POs) for compliance with the requirements of 10 CFR 21.21, “Notification ofFailure to Comply or Existence of a Defect and its Evaluation,” and 10 CFR 21.31,“Procurement Documents.” The NRC inspection team also verified that FLS’snonconformance and corrective action procedures provide a link to the 10 CFR Part 21program.Furthermore, for a sample of 10 CFR Part 21 evaluations performed by FLS, the NRCinspection team verified that FLS had effectively implemented the requirements forevaluating deviations and failures to comply. The NRC inspection team verified that thenotifications were performed in accordance with the requirements of 10 CFR 21.21, asapplicable.The NRC inspection team also discussed the 10 CFR Part 21 program with FLS’smanagement and technical staff. The attachment to this inspection report lists thedocuments reviewed by the NRC inspection team.b. Observations and FindingsNo findings of significance were identified.c. ConclusionThe NRC inspection team concluded that FLS is implementing its 10 CFR Part 21program in accordance with the regulatory requirements of 10 CFR Part 21. Based onthe limited sample of documents reviewed, the NRC inspection team also determinedthat FLS is implementing its policies and procedures associated with the 10 CFR Part 21program. No findings of significance were identified.2. Design Controla. Inspection ScopeThe NRC inspection team reviewed FLS’s policies and implementing procedures thatgovern the design control program to verify compliance with the regulatory requirementsof Criterion III, “Design Control,” of Appendix B, “Quality Assurance program Criteria forNuclear Power Plants and Fuel Reprocessing Plants,” to 10 CFR Part 50, “DomesticLicensing of Production and Utilization Facilities,” and with the applicable requirementsof Subsection ND, “Class 3 Components, of Section III “Rules for Construction ofNuclear Facility Components,” of the American Society of Mechanical Engineers (ASME)Boiler and Pressure Vessel (B&PV) Code, 1998 Edition up to and including-4-
2000 Addenda, and Section VIII, “Rules for Construction of Pressure VesselsDivision 1,” 2001 Edition with 2003 Addenda. The NRC inspection team also reviewed asample of part drawings, bills of materials, data sheets, design reports, engineeringchange orders, and the Westinghouse Electric Company (WEC) design specifications.With respect to FLS’s process for upgrading material in accordance with therequirements of NCA-3855.5, “Utilization of Unqualified Source Material,” the NRCinspection team reviewed a sample of material Certificate of Conformances, receivingdocuments, and the supporting laboratory test reports that included the test results of thechemical analysis and mechanical properties testing that was performed on each pieceof material. The NRC inspection team also verified that the test results were consistentand from the same heat No. as part of the NCA-3855.5 material upgrade process. TheNRC inspection team also confirmed that FLS received extra material for testing tosupport the material upgrade process.The NRC inspection team also discussed the design control program and the processfor upgrading material with FLS’s management and technical staff. The attachment tothis inspection report lists the documents reviewed by the NRC inspection team.b. Observations and FindingsFLS has a contract from WEC to design and fabricate centrifugal normal residual heatremoval (RHR) pumps for the Normal Residual Heat Removal System (RNS) andmake-up pumps for the Chemical and Volume Control System (CVS) for Vogtle ElectricGenerating Plant, Units 3 and 4 (hereafter referred to as Vogtle). The NRC inspectionteam reviewed FLS’s order number RLCU00087 for RNS centrifugal normal RHR pumpfor Vogtle Unit 3 (Serial Number 10RLCU0008701001) and FLS Order NumberRLCU0008908001 for a CVS Makeup pump for Vogtle Unit 4 (Serial Number10RLCU0008908001, and evaluated the associated design control process.The NRC inspection team verified that the WEC design specificationNo. APP-MP08-Z0-001, Revision 7, dated April 12, 2012, for the RNS centrifugal normalRHR pump for Vogtle Unit 3 and the WEC design specification No. APP-MP06-Z0-001,Revision 3, dated November 27, 2010, were properly translated into FLS’s specificationsheets, drawings, procedures, data sheets, analyses, and calculations, and thatengineering data supported this information. The specifications verified includedmaterial specifications, applicable ASME B&PV Code construction requirements,qualification reports, test requirements, and test reports. The associated documentationreviewed included design reports, pump drawings, and lists of materials of construction.All documents reviewed contained the appropriate technical details and met the WECdesign specifications.No findings of significance were identified.c. ConclusionThe NRC inspection team concluded that FLS is implementing its design controlprogram in accordance with the regulatory requirements of Criterion III of Appendix B to10 CFR Part 50. Based on the limited sample of documents reviewed, the NRCinspection team also determined that FLS is implementing its policies and proceduresassociated with the design control program. No findings of significance were identified.-5-
3. Commercial-Grade Dedicationa. Inspection ScopeThe NRC inspection team reviewed FLS’s program for the dedication ofcommercial-grade items for use in safety-related applications to verify its compliancewith the applicable regulatory requirements of Criterion III and Criterion VII, “Control ofPurchase Equipment, Materials, and Services” of Appendix B to 10 CFR Part 50.The NRC inspection team reviewed the policies and procedures governing theimplementation of commercial-grade dedication (CGD) activities, observation of CGDactivities, and review of related documentation. Specifically, the NRC inspection teamreviewed CGD packages to assess the different elements of the CGD program, includingthe technical evaluation process, design drawings, work package instructions, andinspection reports. The NRC inspection team evaluated the criteria for the identificationof item functions, credible failure mechanisms/modes, selection of critical characteristicsand acceptance criteria, and the identification of verification methods to verify effectiveimplementation of FLS’s dedication process.The NRC inspection team also discussed the CGD program with FLS’s managementand technical staff. The attachment to this inspection report lists the documentsreviewed by the NRC inspection team.b. Observations and FindingsNo findings of significance were identified.c. ConclusionThe NRC inspection team concluded that FLS is implementing its CGD program inaccordance with the regulatory requirements of Criterion III and Criterion VII ofAppendix B to 10 CFR Part 50. Based on the limited sample of documents reviewed,the NRC inspection team also determined that FLS is implementing its policies andprocedures associated with CGD program. No findings of significance were identified.4. Oversight of Contracted Activitiesa. Inspection ScopeThe NRC inspection team reviewed FLS’s policies and implementing procedures thatgovern the implementation of its oversight of contracted activities to verify compliancewith the requirements of Criterion IV, “Procurement Document Control,” and Criterion VIIof Appendix B to 10 CFR Part 50.The NRC inspection team reviewed a sample of POs of several safety-related nuclearand commercial suppliers on FLS’s Approved Suppliers’ List. The NRC inspection teamverified that the POs included, as appropriate: the scope of work, right of access tofacilities, and extension of contractual requirements to subcontractors. In addition, theNRC inspection team confirmed that the safety-related POs invoked the requirements ofAppendix B to 10 CFR Part 50 and 10 CFR Part 21.-6-
The NRC inspection team reviewed FLS’s measures established for the use ofaccreditation in lieu of commercial-grade surveys for procurement of calibration andtesting services. FLS’s QA manual allows for the utilization of the InternationalLaboratory Accreditation Cooperation (ILAC) accreditation process in lieu ofcommercial-grade surveys for calibration services as approved by the NRC in theArizona Public Service Company QA program safety evaluation (AgencywideDocuments Access Management System Accession Number ML052710224).The NRC inspection team reviewed a sample of external audit reports for auditsperformed since the last NRC inspection in 2013. The NRC inspection team verifiedthat: (1) the audits were performed at the required frequency; (2) the audits wereperformed using approved checklists and procedures; (3) and that the audit reportscontained objective evidence of the review of the relevant QA criteria of Appendix B to10 CFR Part 50. Additionally, the NRC inspection team reviewed a sample of supplier’sannual assessments to verify FLS’s measures for ensuring that its suppliers arecontinuing to meet the quality requirements imposed.The NRC inspection team also reviewed a sample of training and qualification records ofquality control inspection personnel, lead auditors and auditors. The team alsoconfirmed that inspection personnel, lead auditors and auditors had completed therequired training and maintained qualification and certification in accordance with FLS’spolicies and procedures.The NRC inspection team also discussed the supplier oversight program with FLS’smanagement and technical staff. The attachment to this inspection report lists thedocuments reviewed by the NRC inspection team.b. Observations and FindingsNo findings of significance were identified.c. ConclusionThe NRC inspection team concluded that FLS is implementing its oversight of contractedactivities in accordance with the regulatory requirements of Criterion IV and Criterion VIIof Appendix B to 10 CFR Part 50. Based on the limited sample of documents reviewed,the NRC inspection team also determined that FLS is implementing its policies andprocedures associated with the oversight of contracted activities. No findings ofsignificance were identified.5. Control of Special Processesa. Inspection ScopeThe NRC inspection team reviewed FLS’s policies and implementing procedures thatgovern the control of special processes to verify compliance with the regulatoryrequirements of Criterion IX, “Control of Special Processes,” of Appendix B to 10 CFRPart 50 and with the requirements of Subsection NCA, “General Requirements forDivision 1 and Division 2,” Subsection NB, “Class 1 Components,” Subsection NC,“Class 2 Components,” and Subsection ND, “Class 3 Components,” of Section III, “Rulesfor Construction of Nuclear Facility Components,” Section V, “Nondestructive-7-
Examination,” and Section IX, “Welding and Brazing Qualification,” of ASME B&PV 1998Edition, 2000 Addenda, and the American Society for Nondestructive Testing (ASNT)SNT-TC-1A, “Personnel Qualification and Certification in Nondestructive Testing.”The NRC inspection team reviewed a sample of weld procedure specifications (WPS),and supporting procedure qualification records (PQRs). The NRC inspection teamverified that the applicable welding data was adequately recorded in the WPSs andPQRs. The NRC inspection team also reviewed FLS’s process for controlling weld fillermetal and observed FLS’s weld filler material control storage area. The NRC inspectionteam witnessed FLS’s process for issuing weld filler metal rod issue to ensure that the weldfiller metal was adequately controlled at all times until its consumption, and reviewedrecords associated with the storage, i
Vendor: Flowserve Pump Division 2300 E. Vernon Ave. Vernon, CA 90058 Vendor Contact: Mr. David Gobbi Quality Assurance Manager E-mail: dgobbi@flowserve.com Phone: (980) 722-6770 Nuclear Industry Activity: Flowserve Pump Division, located at 2300 E. Vernon Ave. Vernon, CA, is an American Society of Mechanical Engineers (ASME)
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