ML19241B264
| ML19241B264 | |
| Person / Time | |
|---|---|
| Issue date: | 03/15/1979 |
| From: | Agee J, Hunnicutt D NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML19241B220 | List: |
| References | |
| REF-QA-99900116 99900116-79-1, NUDOCS 7907130372 | |
| Download: ML19241B264 (10) | |
Text
U. S. fiUCLEAR REGULATORY COMMISSIO:1 0FFICE OF IflSPECTIO:1 AtlD EtlFORCEMErlf REGIO 1 IV Report flo. 99900116/79-01 Program flo. 51300 Company:
Bunker Ramo Corporation Amphenol florth America Division Sams Operation 9201 Independence Avenue Chatsworth, California 91311 Inspection Conducted:
February 20-23, 1979 Inspector:
[
de
/2.ee2 />,^///f J. Rf Agee, Cohtractor Inspector, Vendor Date Inspection Branch Approved by:
NX M'b, m4#
3/J/79 D. fl. Hunnicutt, Chief,' ComponentsSection II,
' Date Vendor Inspection Branch Summary Inspection on February 2J-23, 1979 (99900116/79-01)
Areas Inscected:
Implementatior of QA Manual to ASME Code and customer requirements including:
authorized nuclear inspector; inspection to a previously reported item under 10 CFR 50.55(e); design control; customer contracts; Quality Assurance Manual / Program.
The inspection involved twenty-six (26) inspector-hours on site.
Results:
In the five (5) areas inspected one (1) deviation was identified in one (1) area.
Deviations: Quality Assurance Manual / Program - Quality Assurance Depart-ment personnel had not received specific auditor training.
b-2 ! h gU]
OIO 7907130 " 7
, Details Section A.
Persons Contacted
- E. R. Beaupre, Director of Program Management
- J. K. Cameron, Engineering Director J. Rouser, Quality Assurance Engineer L. K. Stupay, Vice President, Engineering
- G. W. Vocicerath, Director of Marketing
- B. J. Wagner, Director of Manufacturing
- H. D. Wright, Quality Assurance Manager
- Attended the exit interview.
B.
Authorized fluclear Inspector 1.
Objectives The objectives of this area of the inspection were to meet the Authorized tiuclear Inspector (ANI) and determine the extent of his activities related to the design, manufacture, inspection, and testing of electrical penetration assemblies (EPAs) for use in Class 1E applications in commercial nuclear power facili-ties.
2.
Method of Accomolishment The preceding objectives were accomplished by discussions with the ANI and review of his log which revealed his activities start with the shop order (5.0.) in which he:
a.
Reviews the design drawings with traveler.
b.
Verifies drawing revision number.
c.
Verifies design drawings are the same as those referenced in the related stress report.
d.
Witnesses Bunker Ramo affix serial numbers to equipment parts.
e.
Verifies identity of hold points on the Manufacturing and Inspection Traveler (MIT).
f.
Signs-off on S.0. when individual parts are completed per the S.0.
g.
Allows no drawing changes without re-review of the S.O.
459 019 m r.
,1 i
\\ l h.
Ilitnesses all final pneumatic tests.
i.
Applies "NPT" stamp.
The present log contains the identity of all electrical penetra-tion assemblies (EPAs) and material traceability to ASME Boiler and Pressure Vessel Code,Section III, Class MC, fabricated and pneumatically tested since January 6,1976.
3.
Results The ANI activities appear to meet criteria stated in ANSI N626.0-1974.
However, a detailed survey of the AMI's activities was not conducted with the ANI during this inspection.
C.
Inscection to a 10 CFR 50.55(e) 1.
Objectives The objectives of this area of the inspection were to:
a.
Review *ecords, b.
Examine manufacturing, inspection, and test practices, Discuss Bunker Ramo (Amphenol Sams) planned actions to c.
correct the reported defective EPAs and d.
Identify Bunker Ramo planned activities to prevent recur-rence of anomalies identified with certain EPAs at the Midland site.
2.
Method of Accomplishment
/
The preceding objectives were accomplished by:
a.
Discussions with Engineering and QA personnel familiar with details of the Midland facility defective EPAs.
These persons stated that the crimped lugs from which certain cables were pulled free by manual pull tests, were insulated lugs required by the customer.
The use of insulated lugs for this use is an uncomon practice.
b.
Examination of the production pneumatic and rnanual crimping tools used.
Reviewed the calibration history and records cards for these crimping tools and determined there was no 45')
050
_ -369 2 i C=
4_
evidence that the tools had been out of calibration or tolerance and thero : tad been no cause to replace any of the tools.
c.
Review of a tabulation prepared by Bunker Ramo of the affected EPA's with identity of the terminal boxes, module pin numbers and the number of conductors by wire size.
An in-plant analysis had isolated and identified the wire sizes that most frequently pulled free.
d.
Verified that Bunker Rama plans to replace suspect lugs already identified at the Midland site and any additional lugs that mcy be identified as a result of future scheduled manual pull tests te be conducted at the Midland site.
e.
Verified that Bunker Ramo olans to include in its manu-facturing practices a requirement for a manual pull test on all cables to which lugs have been crimped.
The pull test is currently not required by Code in the manufacture of EPAs 3.
Results Bunker Ramo has been responsive to correction of the identified field anomaly and has initiated manufacturing practices to preclude future occurrences.
D.
Design Control 1.
Objectives The objectives of this area of the inspection were to:
a.
Verify that design qualification testing per " Generic I
,e Qualification Test Procedure for Nuclear Power Generating Station Electric Penetration Assemblies" reported in flRC Inspection Report flo. 77-02 had been initiated and/or completed.
b.
Review test data and results of the test referenced in paragraph a, above.
c.
Determir.e the design qualification status of Eunker Ramo EPA's to the criteria of currently applicable codes and standards.
7 /, 0
?11 Jvi 459 051 -
2.
flethod of Accomolishment The preceding objectives were accomplished by:
Discussions with engineering management personnel concernirg a.
the current status of the Bunker Ramo Generic EPA's.
b.
Review of Qualification Specification 123-2159, Revision 4, daced August 16, 1978, entitled, " Generic I Qualification Test Procedure for fiuclear Power Generating Station Electrical Penetration Assemblies." This specification was submitted to the various environnental, physical, and electrical test facilities for their use in their respective portions of the quali fication tests.
c.
Review of fifteen (15) drawings which were issued with the above (referenced in paragraph b) specification.
These drawings represent the prototype EPA from which production units will be manufactured, contingent upon satisfactory qualification test results.
These drawings include the following:
(1) flPD 1243, Top Assembly, Generic I, 18 IPS.
(2) fiPD 1237, Header Plate Assembly.
(3) flPD 1254, Junction Box Assembly.
(4) flPD 1233-02, Handling and Tesc Fixture.
(5) flPD 1238-02, Pressure Vessel.
(6) flPD 1241, Header Plate,12 IPS.
3.
Findings a.
Deviations flone.
a b.
Unresolved Item All of the required qualification tests for the Generic I EPAs have been conducted and completed. Raw data from these tests is currently being analyzed for presentation in the final qualification test report which is scheduled for publication by or during the second quarter,1979.
Since the Generic EPA qualification test report was 43) 052 incomplete and not available for review, it will be reviewed during subsequent inspection.
E.
Customer Contracts 1.
Objectives The objectives of this area of the inspection were to:
a.
Review current contracts (customer purchase orders) to verify that applicable Codes and standards had been imposed on Bunker Ramo.
b.
Verify that products (EPAs) released for shipment are typical of production units for which prototype units have been fully qualification tested.
Verify the status of qualification test reports for Generic c.
I EPA's.
2.
Method of Accomolishment The preceding objectives were accomplished by:
Determining that final qualification reports, indicating a.
that Generic I EPA's are certified as fully qualified as Class IE products for nuclear applications, were not complete and would not be complete before EPAs for cer-tain nuclear contracts were scheduled for shipment.
b.
Review of the Customer Purchase Order tio. CP-0460 dated October 10, 1977, which required shipment of fully qualified Class IE EPA's by February 1979.
/
c.
Verifying that approval for partial shipment of the EPAs for the P.O. (paragraph b above) was made per customer approval, TWX 10 124 dated September 15, 1978, which states in part, "We will accept delivery of... prior to recei approved test data if the BIL test results are statused (ptsic) satisfactory...."
d.
Verifying that partial shipment of the EPAs for the above P.O., was made per customer Quality Assurance Release rio. 2516 dated February 6, 1979.
Specific Bunker Psamo part and material numbers include EPA flo.1 E59, P/tl 50020445-01 and AS 176-53, respectively.
MG 9 ') 1 sv fss) e.
Review of Customer P.O.10466-E-035-1, Revision 2, dated flovember 7,1978.
This P.O. includes technical specifica-tions requiring compliance to such applicable Codes and standards as IEEE, AflSI, fiEMA, ASTM, ASME, and IPCEA.
Some of specific standards include IEEE-317(1976), -323(1974),
-344(1975), and -383(1974).
Initial shipment of the EPA's for this e.0. is scheduled for March 1979.
3.
Findings a.
Deviations None.
b.
Comrents Same as Item D.3.b. of this report.
F.
Quality Assurance Manual / Program 1.
Objectives The objectives of this area of the inspection were to verify that the:
a.
QA Manual has been maintained current per commitment.
b.
Pragram has been implemented in such areas as auditing, training, receiving inspection and measuring, and test equipment per commitment.
2.
Method of Accomplishment The preceding objectives were accomplished by:
a.
Review of the QA Manual, specifically the following sections:
(1) 1.4.2 Quality Assurance Organizational Responsibilities.
(2) 5.6 Receiving Inspection.
(3) 6.0 Identification and Control of Material.
(4) 7.0 Control and Items f ;ufacturing Processes.
(5) 10.0 Control of Measuring and Test E uipment.
\\S9 054
'n m,
JU/
-u
,g s
4
& L cL a '., C & A L.Me?.: u J, :<l". :.M & M-X ' '. _
I. ' '.i
- r_ _.....
.L-)
) -
f~ Y; ?.
1:
7.-
7..
n; (6) 13.0 fionconforming Materials or Items.
e,
(7) 16.0 Audits.
&f-
- a b.
Verifying the QA Manual generally addresses the appropriate i..
criteria of 10 CFR 50, Appendix B, and the ASME Code, the QA l5 E
~~~
Manual wa' revised January 5,1979, in preparation for the
'y ASME surve' conducted in February 1979, for renewal of
'.. : '~'
Certificate of Authorization Number fi-1314.
The survey L
results were satisfactory and the reviewed Certificate of D..*g* '.
Authorization is forthcoming.
4 c.
Verifying by review of on-going practices in the receiving 4
i inspection area that materials are compared and dimensionally
%.. ~ n/
checked with purchase requirements and related drawings.
1 Mill Certified Material Test Reports have been provided and y"5 meet material specifications, fluclear Quality Assurance i
Engineer records the AS (Amphenol Sams) serial / traceability
~. '
number in the Certified Material Test Report, acceptable i
i materials are tagged as accepted and fonvarded to nuclear assigned stock, and the nonconforming items are identified
.i and tagged as " rejected" and segregation in a locked segregated uea for disposition.
?.
d.
Verifying the record system for maintaining calibration,
~
storage, location of test measuring instruments is being
,j properly administered.
Approximately thirty (30) instruments
.I ~,.
in the receiving inspection, final assembly and test area i
were examined and compared with related calibration labels
- j and records.
fio anomalies were identified.
Categories of instruments' examined included power.nd manual crimping E c tools, cablemaster cable testers, cv ona test set, mass
.3 spectrometer, gas leak tester, varaum test pump and roughing f.~'
station, surface plates, dial gauges, micrometers, plug gauges, t
Rockwell Hardness tester, and height gauges.
- f..
j e.
Review of audit files containing internal and management
-z' 1
audit reports.
Verified that audits have been completed i,
on a timely scheduled basis using prepared checklists.
v
~s f.
l.eview of quality assurance department training records
- f.'
which indicated that periodic group training sessions are conducted on the QA Manual chapters.
f.
- l
.{. 3 9
Review of six (6) manufacturing department personnel 4
.I training records which indicated that each operator had
~
Or5
'1 tS9 a
i
-T 7 /O
-' ~,.
.A
,) () 7
- c. a,
1.
.: 1
".N
\\ m -m..,.
r s.. ml.7...
r.,f,:,q,.. c. r
/.,. _.. _.. -).
~ - v n u. m, =,.. n... ~.~;q,.b_.
,..y e.
v.=
x.
- y
\\
,q
,., y, -
.~..m :.,..
[
E _
been provided on-the-jub training for their res9ective
,a currentlj occuppied positisiis.
Each record carC was dated
~"
with a description of tha training received inc the classi-fication of the task the operator is permittad tc perform.
h.
Review of manufacturing instructions.
{
3.
F_indings i
s a.
Deviations (See Enclosure.)
b.
Cor. men ts Recent EPA design changes have resulted in equipment modifications which require revision and updating of manu-facturing instructions.
On a temporary basis the manu-factur.'ng instructions have been improvised on an as-needed basis.
The formal revision of all affected manufacturing E
instructions are in progrcss and will be further reviewed in a subseq ant inspection.
G.
Exit Interview The inspector mat with management represnntatives. denoted in para-F-
graph A at the conclusion of the inspectie i on February 23, 1979, at tiie Chatsworth Plant.
The ir.:pector summarized the scope and findings of the inspection related to the following areas:
E-1.
Inspection ta a 10 CFR 50.55(e).
2.
Design Con?rol.
c 2.
Customer Coltracts.
4.
Quality As',urance Manual / Program related to
{_
~~
a.
Recr:iving Inspection.
"[
b.
Ide itification and Control of Materials.
c.
Control Manufacturing Proc 2sses.
~
d.
Control of Measuring and Test Equipmant.
459 056
a e.
fionconforming f4aterials.
f.
Audits.
The Management representatives had no comments in response to the items discussed.
.f 459 05f