ML19241B912

Interim Deficiency Rept 2:during Field Insp of Engineered Safety Features Actuation Sys,Status Display Light Modules Revealed Discrepancies in Soldered Wire Connections.Caused by Lack of Insp Plan in QA Program

ML19241B912
Person / Time
Site:	Midland
Issue date:	07/19/1979
From:	BECHTEL GROUP, INC.
To:
Shared Package
ML19241B909	List: ML19241B908 ML19241B912
References
NUDOCS 7907250329
Download: ML19241B912 (3)

Text

a - - Attachment tc

- Hove-205-79 Bechtel Associates Professional Corporation

SUBJECT:

MCAR 28 (issued June 7, 1979)

INTERIM REPORT 2 DATE: July 19, 1979 PROJECT: Consumers Power Company

. Midland Plant Units 1 & 2 Bechtel Job 7220 Introduction ,

This report is an interim report on the course of action required pursuant to MCAR 28 and Bechtel NCR 2176.

Description of Discrepancy Bechtel field inspection of the installed ESFAS status display light modules on panel 1C14 revealed discrepancies regarding the soldered wire connections as follows:

Switch Te rminal Problem Description 1SV-0127 G Not soldered ISV-0127 G Loose solder joint 1SV-0127A C Cold solder joint 1M0-1257 G Not soldered IMO-5336A A Not soldered IMO-0912 G Wire touct.ag movable = ember Probable Cause lhe supplier provided his assessment of the probable cause and indicated that a specific, detailed inspection plan for soldered connection was not part of the quality assurance program. This resulted in an inade-quate inspection of soldered connections. The supplier used a general type procedure which lacked the required a=ount of detail to assure the level of quality required. The supplier =aintains that the number of soldered connections involved indicates the discrepancies are of a random nature.

Corrective Actions

1) As requested, Magnetics submitted an inspection and soldering procedure for all soldered items. Bechtel completed the review of these documents and returned them with comments for revision and resubmission. Magnetics is allowed to proceed with the work, provided the changes indicated are incorporated in the subject procedures.

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t Bechtel Associates ProfessionalCorporation MCAR 28 .

Interim Report -2 -- ~

July 19, 1979 Page 2

2) Magnetics informed Bechtel that 100% reinspection of all soldered wire terminations and connections in the main control boards will be done starting July 9, 1979. Bechtel field quality control (QC) has been informed of this schedule. 7.L2 "- .c of discrepancies for all Q-panel work with Magnetics are limited to the main control, boards as there are no new Q-panels on order or in the =anufactur-ing cycle.

3) The Bechtel Project Supplier Quality Representative (SQR) is scheduled to conduct an inspection and further investigation at the supplier's facilities during the third week of July. All of the removable status display panel codules have been received at Magnetics as reported in interim Repor: 1. They will be subj ected to 100%

reinspection and repair as necessary. In addition, the SQR will determine if any other f abrication/ inspection processes are not co"ered by Magnetics Quality Program.

4) Bechtel procurement supplier quality department has issued a Supplier Quality Information Bulletin, SQUB 79-1 dated June 11, 1979, which alerted all supplier quality personnel to be aware of ,

similar type soldering deficiencies from other suppliers. The SQP. has been instructed to determine that the supplier has a quality control plan in operation and that adequately trained personnel perform the soldering operation. Results of these in-process inspections will be covered in regular quality surveillance reports.

5) Bechtel Procurement Supplier Quality Department (PSQD) and Quality Engineering (QE) has initiated a program to define special processes in selected vendors for additional surveillance. This will include:

a. Identification of special processes and vendors

b. Performance of quality program verification to verify that the supplier has procedures in place and is i=plementing them

c. Review of the procurement documents and revision to add witness and/or hold points for the identified, selected special pr ocesses U/ 0.10

Bechtel Associates ProfessionalCorporation MCAR 28 Interim Report 2 July 19, 1979 Page 3

d. Incorporating these actions for future procure =ents. MEDs 4.55 and 4.49 and appropriate supplier quality procedures will be revised to require these actions.

The schedule for cocpletion: -

The afore=entioned tasks will be fully scoped and completion dates sc,heduled by August 31, 1979.

Safety Implication Because of the indeterminate nature of the possible failure modes and, therefore, the possibility that safety related circuits ca'f have b(en rendered inoperable, it is suggested that this problem should be considered reportable under 10 CFR 50.55E.

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Concurrence by:

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