ML19345H380

Interim Deficiency Rept 1 Re Use of Unqualified Cable in ITE-Gould Class IE Equipment,Initially Reported on 810416. Audit Scheduled for First Wk in June to Discuss Specific Quality Program Elements.Next Rept by 810731

ML19345H380
Person / Time
Site:	Midland
Issue date:	05/15/1981
From:	Jackie Cook CONSUMERS ENERGY CO. (FORMERLY CONSUMERS POWER CO.)
To:	James Keppler NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II)
References
10CFR-050.55E, 10CFR-50.55E, 11991, 81-04-#1, 81-4, 81-4-#1, NUDOCS 8105200224
Download: ML19345H380 (6)

Text

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E Consumers Power g James w cook (Q1 C0mpany vi- ~ ,u t- ~in. a .c..s ,

an i Co.struction General officos: 1945 West Parnell Road. Jackson, MI 49201 * (517) 788 0453 81-Oh#1{,F s >' 'v A Fay 15, 1961 'a v f f 1h  % l*S

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a Ls Mr J G Keppler, Regional Director y q,N s 3 Office of Inspection and Enforcement -

US Nuclear Hegulatory Co==ission  % ** -

6 Region III g//, ,

799 Roosevelt Road @

Glen Ellyn, IL 60137 MIDLAND PROJECT -

DOCKLTS NO 50-329 AND 50-330 ITE-GOULD CLASS 1E EQUIPMENT FILE: 0.h.9 52 L7I: 73*10*01, 31hh2(E) SERIAL: 11991 This letter transmits an interim 50 55(e) report concerning the use of unqualified cable in ITE-Gould Class 1E equipment. This was reported by telephone call to R J Cook and D C Boyd of USNRC Region III, Glen Ellyn, IL, on April 16, 1961. Ad.ditional information was provided concerning this subject on April 22, 1981 in a telephone call to C Jones of your staff.

Inclosures 1 and 2 provide a description of the conditien and the planned corrective action. In adfition, a meeting was held on May 11, 1981, between Consumers Power Company, Bechtel and ITE-Gould personnel to discuss specific ccrrective action details. An audit has been scheduled for the first week in June, r.t ITE-GoulC, which vill specifically address quality program elements r ascciated with the reportable condition.

Another report, e:ither interim or final, vill be sent on or before July 31, 1981.

AHB/lr

Enclosures:

(1) Bechtel Ma.nagement Ccrrective Action Report #50, dated April 22, 1981 (2) Bechtel Management Corrective Action Report #50, Interim Report 1, dated May 1,1981 8105200 #

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Ssrici 11991 2 81-OL #1 CC: Director, Office of Inspection & Enforcement Att: Mr Victor Stello, USNRC (15)

Director, Office of Management Information & Program Control, USNRC (1)

RJCook, USNRC. Resident Inspector Midland Nuclear Plant (1)

CBechhoefer, ASLB Panel JSDecker, ASLB Panel FPCowan, ASLB Panel AS&L Appeal Panel ,

MMCherry, Esq MSinclair CBStephens, USNRC WDFaton,.Esq, USNRC FJKelly, Esq, Attorney General SHFreeman, Esq, Asst Attorney Gr:neral GTTaylor, Esq, Asst Attorney General WEMarshall GJMerritt, Esq, MTK&J -

Great Lakes QA Managers

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QUALITY ASSURANCE PROGRAM Enclosure 1  !

MANA2EMENT CURRECTIVE ACTION REPORT Scrial 11991 htCAR 1 81-Oh #1 028371 REPORT NO.: 50 JOB NO.: 7220 O NO.: DATE: April 22, 1981 i DESCRIPTION * (including References):

During a check of 200 AMP thermal-magnetic circuit breakers, it was discovered that the vendor (ITE-Could) had installed unqualified non-1E cables in class IE Motor Control Centers (MCCs). This condition was reported to the client as a "potentially reportable" 10 LTR 50.55(e) item on April 16, 1981. On that same date, the client notified the NRC (D. Boyd) of the "potentially reportable" condition, Subsequent investigation has revealed that at least 30 class 1E ITE-Gould MCCs and RECOMMENDED ACTION * (Optional):

1. Investigate all in-house class IE equipment supplied by ITE-Could, for use of unqualified cables in class 1E applications. Identify and track by NCR all equipment found to contain unqualified class 1E cables. (Engrg/ Construction)

2. Replace all unqualified class 1E cables with cables qualified to the requirements of Spec 7220-E-7 or '7220-E-205 (as applicable), or demonstrate their adequacy. (Engrg and Const.)

REFERRED TO: W Engineenno 2 Construction O QA Management O T Procurement ISSUED BY: ' -

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M,A. Dietrich 1 -

11 REPORTABLE DEFICIENCY: NOTIFIED CUENT:_ t./16 /R1 l

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CORRECTIVE ACTION TAKEN I

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'Descree ri space provu$ed and attacti reference document. Pra.a Qa Egn.er o.e aanoooo. Section Number Page of

?00L[R 80L

e MCAR 50 April 22, 1981 02837i DESCRIPTION CONT.

several class IE ITE-Gould 4kv switchgear units contain unqualified class 1E cables. The client was notified of the reportability aspects of the 4ky switchgear on April 22, 1981, who notified the NRC on the same day.

RECOMMENDED ACTION CONT.

3. Place a " hold shipment" on all ITE-Gould class IE equipment presently in ITE-Gould plants, until Bechtel Supplier Quality has inspected such equipment

, and verified that no unqualified materials have been used in it: fabrication.

(Engineering and Programent)

4. Conduct special evaluation audits of all ITE-Gould facilities which supply class IE equipment to Midland, for adequacy of thei nuclear QA program plus existence and full implementation of all in-process controls necessary to assure delivery of fully acceptable class IE equipment. (Supplier Quality)

5. In all procurements of clast., IE equipment from ITE-Gould, the purchase orders shall prohibit ITE-Gould from procurement of materials and fabrication / assembly of product until their QA program has been verified and validated as described in.4 above. (Engineering and Procurement)

6. -Require ITE-Gould to. determine and document the root cause of this problem, to devise, implement, and document all necessary procedural corrective .

actions, and to provide Bechtel with a fully detailed certified report of the entire situation. (Engineering and Procurement)

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7. Provide by May 5, 1981, a schedule for completion of all required actions.

(Engineering)

NOTE: On April 21, 1981, the cognizant engineer notified procurement to place an immediate hold on all ITE-Gould class 1E equipment not already shipped until it is inspected by Bechtel Supplier Quality, for use of any unqualified cables.

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.02959? Enclosure 2 Bechtel Associates Professional Corporation **"$*,*1 "*

SUBJECT:

MCAR 50 (issued 4/23/81) 460 V Motor Control Center Unqualified Wiring INTERIM REPORT 1 DATE: hay 1, 1981 PROJECT: Consumers Power Company Midland Plant Units 1 and 2 Bechtel Job 7220

REFERENCES:

A) Qualification and Test Summary Report for Class lE Equipment (Vendor Submittal 7220-E7-129-5)

, B) Class lE Electrical Equipment 5HK-250, Indoor j Metal-Clad Switchgear Environmental Qualification Report (Vendor Submittal 7220-E205-482-1)

Introduction

, This report provides interim status and the course of corrective action required pursuant to MCAR 50-l Description of Potential Discrepancy l Subsequent to field testing of 200 amp thermal magnetic circuit breakers, t

engineering discovered that the installed power cable brands were not listed on the bfil of material in the vendor's qualificatfon report (Reference A). .

Random inspections by site personnel identified eight differest brands of power wiring and two brands of control wiring installed in Q-listed i

motor control centers (MCCs).

None of the wiring brands identified during these inspections are included in the vendor's qualification report (Reference A).

Other Q-listed equipment supplied by the vendor was inspected. Control wiring was discovered in 4.16 kV switchgear, which is not included in the vendor's respective qualification report (Reference B).

Bechtel wuspects that perhaps all Q-listed MCCs and 4.16 kV switchgear delivered under purchase orders 722.0-E7 and 7220-E205 respectively contain cable with indeterminate qualification status.

Probable Cause The discrepancy in cable materials listed in the vendor's qualification reports (References A and B) and the materials acpolied could be attri-buted to the following:

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Bechtel Associates Professional Corporation MCAR 50 Interim Report 1 May 1, 1981 Page 2

1. Incomplete Qualification Reports The supplied cable may have been qualified and mistakenly omitted from the qualification report.

2. Vendor Quality Assurance Program The discrepancy may be the result of a breakdown in the vendor's quality assurance program.

Corrective Action

1. The vendor has been informed of the deficiency and a " hold shipment" has been placed on all undelivered Class 1E equipment.

2. Bechtel will conduct meetings with the vendor to identify the magnitude of the deficiency. This will mean evaluating the possibility of qualify-ing the supplied cable. However, if qualification cannot reasonably be ensured, the vendor and Bechtel must establish an action plan for replacing the unqualified cable.

3. Bechtel will schedule meetings at the vendor's facility to evaluate the adequancy of- its quality assurance program and the required corrde-tive action to prevent a recurrence. This evaluation will be conducted by Consumers Power Company MPQAD with assistance by Bechtel supplier quality.

Safety Implications .

The unqualified wiring is installed in the power and control circuitry of Class lE 460 V MCCs and in the control circuitry of Class 1E 4.16 kV switch-gear. Insulation material failure during the qualified life of the equipment

! because of the effects of aging and irradiation, could prevent the proper i

operation of safety load groups.

Based on the possible safety implication, this discrepancy is considered to be reportable in accordance with the Code of Federal Regulations, Part 50.55(e).

Forecast Date on Corrective Action s A schedule for the corrective action will be provided in Interim Report 2.

Submitted by: .

vinic B.P. Kononetz Electrical Group Supervisor Approved by: CE M, _

L.H. Curtis N4 Proje Engineer Wl/

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, Concurrence by: '

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l K.D.piley EngineeringManage[r/

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