ML19269C372
| ML19269C372 | |
| Person / Time | |
|---|---|
| Issue date: | 12/20/1978 |
| From: | Agee J, Hunnicutt D NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML19269C368 | List: |
| References | |
| REF-QA-99900219 51400, 99900219-78-2, NUDOCS 7902020031 | |
| Download: ML19269C372 (10) | |
Text
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U. S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT REGION IV Report No. 99900219/78-02 Program No. 51400 Company:
General Electric Company Switchgear Business Department 6901 Elmwood Avenue Philadephia, Pennsylvania 19142 Inspection Conducted: November 27 - December 1, 1978 Inspector:
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/2/2 Cf78 J. R. Agee, Contract Inspector, Vendor
/Date /
v Inspection Branch Approved by:
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m v>Jea W 4WL6l78 D. M. Hunnidutt, Chief, ComponentsSection II,
/Date/
Vendor Inspection Branch Summary Inspection on November 27, December 1, 1978 (99900219/78-02)
Areas Inspected:
Implementation of 10 CFR 50, Appendix B, and QA Manual, including action on previous inspection 'indings, management meeting, Design Tests, Production Tests and Field Service Problems, Audits. The inspection involved eighteen (18) inspector hours on site.
Resul ts :
In the four (4) areas inspected, no apparent deviations or unresolved items yere identified in three (3) areas; the following was identified in the remaining area:
Deviation: None.
Unresolved Item: Design Tests - qualification tests programs for switchgear products to applicable IEEE standards for Class 1E application is pending further development and completion (See Item D.3).
790202063/
. DETAILS SECTION A.
Persons Contacted W. C. Adams, Manager Service Engineering SBD/PSM-BD C. E. Bedford, General Manager D. C. Brooks, Requisition Engineer T. P. Creeden, Manager, Quality Engineering R. Crowell, Senior Design Engineer J. A. Higgins, Manager, Quality Appraisal R. H. Miller, Manager, Switchgear Development Engineering
- F. J. Pastore, Manager, Quality Assurance P. Reece, Manager, Switchgear and Breaker Engineering
- C. A. Scott, Manager, Quality Systems SSD/PSM-BD
- Denotes those present at the exit meeting.
B.
Action on Previous Inspection Findings 1.
(Closed) Deviation (Inspection Report No. 78-01): QA Manual does not accurately describe engineering practices in use.
The inspector verified by review of the revised QA Manual, dated May 25, 1978, and related revised engineering procedures concerning " Engineering Change Notice Procedure" and "Qualifica-tion Test Reports Procedure" that the revised documentation adequately describes the implemented practices for.hese functions.
2.
(Closed) Devia. ion (Inspection Report No. 78-01):
QA Manual does not accurately describe engineering change procedures actually in use.
The inspector verified by review of the revised QA Manual, dated May 25, 1978, and related revised engineering procedure concerning " Drawing Control Procedure" that the revised documentation adequately describes the implemented practices for this function.
3.
(Closed) Deviation (Inspection Report No. 78-01):
QA Manual does not describe engineering responsibilities associated with qualification testing activities, also the centract requisition engineer's responsibilities are only partially identified.
The inspector verified by review of the revised QA Manual, dated May 25, 1978, and related revised engineering procedures that the revised documentation describes the current status for qualification testing activities and the contract requisition engineer's responsibilities.
_4_
number of cases. The inspector verified that corrective actior, had been implemented to prevent recurrences of this type and that the General Electric Company had issued the company document
" Installation and Service Engineering S. ore-Advice, pSM (721)
No.161.1,
Subject:
IAC Relays, Loose h:e;rj Corrections,"
to all nuclear facilities in which the;e type relays had been installed.
9.
(Closed) Unresolved Item (Inspection Report No. 78-01): Equipment Service Problem - loose pigtail connections may cause degredation of breaker contacts and consequently decrease the life expectancy of the contacts. The inspector verified that corrective action had been implemented to prevent recurrences of this type by review of several General Electric Instructions and Recommended Parts for Maintenance brochures which had been revised. These brochures provide handling, storage, installation, maintenance.
operation and adjustments data for Magna-Blast Circuit Breakers.
including types GEK-41902B, GEK-73478, GEI-88763E, GEK-31111C, GEK-73458 and GEK-7320E.
C.
Management Meeting 1.
Objectives The objectives of the area of the inspection were to:
Meet the new senior management of the Switchgear Business a.
Department (SBD).
b.
Acquaint them with the NRC Vendor Inspection Program (VIP).
c.
Inform them of their responsibilities under Section 206 of Public Law 93-438.
d.
Obtain information concerning organizational changes.
2.
Method of Accomplishment The preceding objectives were accomplished by:
a.
Meeting with the general manager and the quality assuranco manager and discussing details of the:
(1) NRC organizational structure.
(2)
Inspection activities of the VIP,
4.
(Closed Deviation (Inspection Report No. 78-01):
QA Manual reference to Design Adequacy Review Certification concerning (a) customer specification 10466-E-009 and (b) customer specifications 21A9300, Revision 0, and Revision 1 did not (1) identify special requirements associated with qualification testing and establishing life data ir accordance with IEEE-323 and (2) did not list special requirements associated with equipment qualification testing to IEEE-323, respectively. This deviation was withdrawn by NRC, Region IV letter, Docket No.
99900219/78-01, dated September 25, 1978.
5.
(Closed) Deviation (Inspection Report tio. 78-01):
The M/C Test and Inspection Record (Form SE 462(I), Revision 1) for a high pressure core spray system was signed-off and dated by a quality appraisal, QCE, approving the equipment for packing and shipment. The inspector verified corrective action had been implemented to prevent future cccurrencies of this type by review of the General Electric Company letter dated February 22, 1978, subject: NRC Finding - Corrected to QAI 216010, paragraph 4.4.
This QAI revision imposes a more rigid final inspection /
test activity for release of production equipment for packaging and shipment.
6.
(Closed) Deviation (Inspection Report No. 78-01):
A required weld was missing and additional welds were not spaced in accordance with Fabrication Drawing 0168C3099 and Design Instruction 191.001 for 7.2 KV switchgear.
The inspector verified that corrective action had been implemented to preclude future occurrences of this type by review of the General Electric Company letter dated February 21, 1978, entitled, Weld Fabrication Inspection - NRC Finding.
7.
(0 pen) Unresolved Item (Inspectnn Report No. 78-01):
Customer specifications reviewed require equipment qualification to IEEE Standard 323-1974.
The inspector verified that the required qualification test programs are still in progress and that projected scheduled completion of current contract conmitments for these qualification tests, i.e., qualificati 1 of switchgear products to applicable IEEE Standards has been t. oroved by affected customers.
This item will remain open e inspection pending completion of the qualification tests and publication of the qualfication test data for Class 1E switchgear products.
8.
(Closed) Unresolved Item (Inspection Report No. 78-0.):
A nu lear power plant inspection revealed that wiring connections to relay screw-type terminals to time over-current relays were loose.
Attempts to tighten the screws proved unsuccessful in a significant
- (3)
Documentation requirements of the VIP including:
(a) How results of inspections are documented, distributed, and filed in the Public Document Room.
(b) Explanation of " deviations" and " unresolved items."
(c)
Explanation of the publication of the " White Book."
b.
Discussion of the separation of the Philadelphia Facility into two (2) separate Cost Centers, namely, SBD and Power Systems Management Business Department (PSM-BD).
c.
Discussing the functional interface areas between SBD and PSM-BD, such as auditing, receiving inspection, storage, and shipping.
3.
Results a.
Management acknowledged the above discussions of NRC and VIP and their obligations in the supply of safety-related equip-ment to the nuclear industry.
b.
The PSM-BD organizational structure incle es the Puerto d
Rico Operations where the largest volume of the Class IE relays are manufactured.
Management explained the Puerto Rico Operations has an established quality asst ince p"ogram operating under the policy of the Quality Assurance Manual, Protective Relays and Components, Power Systems Management Business Department, dated October 30, 1978.
The Puerto Rico Operations has also implemented a separate QA Manual, with supplemental procedures, based on the criteria of 10 CFR 50, Appendix B.
D.
Design Tests 1.
Objectives The objectives of this area of the inspection were to verify that:
a.
Design and test qualifications of Class 1E switchgear have been completed.
b.
Production tests of Class 1E qualified switchgear have been conducted in compliance established codes and standards.
2.
Methods of Accomplishment The preceding objectives were accomplished by:
a.
Discussions with engineering management concerning status of the design and test qualification of Class 1E switchgear products.
b.
Review of selected documentation concerning the status of the qualification testing of switchgear products to meet Class IE requirements including the following:
(1) Seismic Simulation Test Program on a 4.16KV-250MVA Vertical Lift Metaclad Switchgear Cabinet, Report No.
43968-1.
(2) GE substitution list of qualified relays for customer specified relays that were not qualified for Class 1E applications (GE letters dated June 8 and June 14, 1978).
(3) Reviewing the document Qualification Program based on IEEE 323-1974 with specific reference to General Electric Metal-Clad Switchgear applied as Class IE Equipment for GE Requsistion No. 366-15415, Customer Order No. 77K3-82021.
Equipment: AM7.2-500 MVA 1200A.
Breaker Units and Auxilary Compartments, which includes technical and documentation evidence of the qualification of the equipment described.
(4) Review of GE letter dated June 14, 1978, to customer Requisition No. 366-15415 (77K3-820201) which requests customer approval of substitution of relay components that are ide,tified as qualified to IEEE-323 for relays that are not qualified.
This letter also requested the customer to review the list of devices for the various proposed applications to determine whether IEEE-323 qualification are required GE requested to be advised accordingly.
3.
Commments The company is proceding toward qualification of its switchgear products to meet current applicable IEEE standards for Class 1E products. Although all vendor supplied products used integrally with the switchgear have not yet been fully qualified to current applicable IEEE standards, the company is proceding to manufacture
switchgear using products from some of these suppliers. This position is based on the continued and scheduled qualification program of vendor products in which qualification test.ing will be completed before the switchgear using the products will be checke6 out for operation in a nuclear power plant.
This position is accepted by at least two (2) customers for Class 1E switchgear currently being manufactured and/or delivered.
(Note: Although the inspector is unable to report the qualification test program for Class 1E switchgear is complete the status of the test program is not reported in this section as an unresolved item since item B.7 of this report, which applies to the same qualification test program, is being carried forward as an "Open" " Unresolved Item." This Section of this report is included to provide additional information verifying the company is continuing its qualification test programs to provide Class 1E switchgear products for the commercial nuclear industry.
E.
Production Tests and Field Service Problems 1.
Objectives The objectives of this area of the inspection were to verify that:
a.
Procedures had been implemented for conducting production tests in compliance with established national codes and standards.
b.
Circuit breakers returned to the plant for service and repair are inspected and tested after repair to the same procedures as initially manufactured, inspected and tested circuit breakers.
c.
Plant engineering management was responsive to the circuit breakers field service problems at the site of Docket No.
50-322.
2.
Method of Accomplishment _
The preceding objectives were accomplished by:
a.
Review of the following Quality Assurance Instructions which describe the steps and provide the guidance for the final inspection and test for switchgear products; (1)
No. 206010, QA Test Instructions for tietal-Clad Switchgear, (2) 213022, Final Assembly Inspection Metal-Clad Equipment,
- (3) 213037, Inspection of Breaker Compartments Vertical Lift Metal-Clad Equipment, (4) 526007, Magna-Blast Breaker Inspection and Test, and
'(5) 216001, ANSI Production Test Standards, b.
Discussions with switchgear management regarding field problems and methods of providing corrective action, specifically to site problems of Docket No. 50-322.
c.
Inspection of circuit breakers with serial numbers 256A4665-042/
045/046/048 and 256A4663-002/005/006 that had been returned to the plant for refurbishment.
Verified that these circuit breakers were being repaired and refurbished according to Requisition No. 300-915059 and Shop Orde. No. 943006. The circuit breakers were delivered to the plant by the utility company and repaired according to the requirements of field service tags attached to each respective circuit breaker. The repaired and refurbished circuit breaker were recycled through the final inspection and final testing stages in compliance with applicable plant Quality Assurance Instructions (listed in item a. above).
Upon inspection and approval by the utility company of work performed and final inspection and testing completed the refurbished circuit breakers were returned to the site.
3.
Comments On the date of this inspection, no Class 1E products were being tested. As an alternate to inspecting floor production testing activities a random selection of a completed shop order was reviewed to verify production testing had been completed in compliance with implemented test procedures. The inspector verified the production testing of the circuit breaker shop order reviewed had been completed in compliance with QAI 526007, Magna-Blast Breaker Inspection and Test.
Test requirements of this QAI were almost identical to the test requirements of ANSI standard C37.20.
The refurbished circuit breakers from the site of Docket No.
50-322 were also to be tested to QAI 526007.
F.
Audits 1.
Objectives The objectives of this area of the inspection were to verify that:
. a.
Procedures or policy documents clearly identify organizations responsible for audits and define their responsibilities and authorities.
b.
' Measures have been established to asure that auditors are independent of any direct responsibility for performance of activities which they are auditing and that persons having direct responsibility for performance of the activities being audited are not involved in the selection of the audit team, c.
All auditing personnel including technical specialists are required to receive appropriate training or orientation to develop their competence for performing required audits.
d.
Guidelines and requirements are established for audit scheduling and that they take into consideration the status and importance of the activities to be audited, e.
SJfficient instructions or guidance are available to the auditors in the form of checklists or procedures to perform the audits effectively and in accordance with the audit plan, f.
Deficiencies identified by the audits are closed out by appropriate corrective action and timely follow-up including reaudit of deficient areas.
g.
Audit records are collected, stored and maintained in accordance with applicable code and contract requirements.
2.
Method of Accomt'ishment The precedin.
bjectives were accomplished by:
a.
Discussior.3 with QA Department personnel responsible for audit programs.
b.
Review of s.xperience and history files of personnel partic-ipating in audit programs and personnel who are qualified for auditing activites and QA management positions.
c.
Review of QA training records and records of personnel who have attended Corporate QA training courses.
d.
Review of QA audits files of audits conducted and verified that follow-up activities had been conducted as required.
. c.
Review of QA Manual, Section A-4, Quality Audits, vited May 24, 1978.
f.
Review of the QA organizational structure and responsibilities, specifically to the QA interface with the Power Systems Management Business Department f, Relays-Philadelphia, Pa.),
the Puerto Rico Operation (Relays-Puerto Rico) and Switchgear Business Department (Switchgear-Burlington, Iowa).
e.
Review of process audit files verified that process audits are conducted quarterly to established checklists and procedures.
3.
Findings Within this area of the inspection, no deviations or unresolved items were identified.
G.
Exit Interview The inspector met with management representatives (indicated by an asterisk in paragraph A) at the conclusion of the inspection on December 1, 1978.
The inspector summarized the scope of the inspection concerning the following areas and/or functions:
1.
Action on previous inspection findings.
2.
Discussions of the initial management meeting.
3.
Discussions regarding design tests.
4.
Production Tests and Field Service Problems.
5.
Audits.
An unresolved item was identified relative to the design tests area.
The management representatives acknowledged the inspection items discussed by the inspector.