ML20012E117
| ML20012E117 | |
| Person / Time | |
|---|---|
| Issue date: | 03/22/1990 |
| From: | Cwalina G, Naidu K Office of Nuclear Reactor Regulation |
| To: | |
| Shared Package | |
| ML20012E116 | List: |
| References | |
| REF-QA-99901147 99901147-90-01, 99901147-90-1, NUDOCS 9003300087 | |
| Download: ML20012E117 (11) | |
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~ ORGANIZATION: GENERAL-ELECTRIC APPARATUS SERVICE SHOP' PHILADELPHIA, PENNSYLVANIA REPORT INSPECTION INSPECTION NO.: 99901147/90-01 DATE: 01/8-10 & 22-23, 1990 ON-SITE HOURS: 52 CORRESPONDENCE ADDRESS:
V. P. Kenney, Manager -
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Quality Assurance General Electric Apparatus Service Shop 1040 East Eric Avenue Philadelphia, Pennsylvania 19124-5499 ORGANIZATIONAL CONTACT:
G. W. Sanders, Program Manager, Nuclear Elec. Main.
TELEPHONE NUMBER:
(215) 962-6049 NUCLEAR. INDUSTRY ACTIVITY: Maintenance and overhauling services for electrical switchgear and generators._
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ASSIGNED INSPECTOR:
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3M i
Kr R. Naidu, Reactive Inspection Section No. 1, Date L
(RIS-1)
OTHER INSPECTORS:
C. Woodward, Division of Reactor Safety, Region I S. Mazumdar, Reactor Operations Analysis Branch G. Cw lina, Acting Chief, RIS-1 APPROVED BY:
M
//' n did6 G. Cwalina, Acting Chief, RIS-1, Vendor Inspect. ion Branch Date INSPECTION BASES AND SCOPE:
A.
BASES: 10 CFR Part 21,10 CFR 50, Appendix B.
B.
SCOPE:
Inspected five AK-type circuit breakers (CBs) returned from Beaver Valley nuclear power station (NPS) and 4.16kV CBs returned from Salem NPS, reviewed procedures to overhaul 480 volt and 4.16kV CBs, observed the disassembly of one 4.16kV CB returned from Calvert Cliffs NPS and reviewed records on the service performed on two Beaver Valley CBs.
PLANT SITE APPLICABILITY:
Beaver Valley 1 and 2 (50-336/412), Salem 1 and 2 (50-272/311), Calvert Cliffs 1 and 2 (50-317/318), Nine Mile Point I and 2 (50-220/410), Yankee Atomic Electric company and Pennsylvania Power and Light Company 9003300087 900323 Nb 01 4
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K, ORGANIZATION: GENERAL-ELECTRIC APPARATUS SERVICE SHOP-
. PHILADELPHIA, PENNSYLVANIA m
REPORT-.
INSPECTION-M
'f NO.: 99901147/90-01 RESULTS:
PAGE 2 of 11, e
A.
VIOLATIONS:
No v.iolations were identified during this inspection.
B.
NONCONFORMANCE:
4 No nonconformances were identified during-this ' inspection.
~C.
UNRESOLVED ITEMS:
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Additional information is required relative to the control, applicability, and'use of Engineering Operating Procedures not L
currently-referenced in the Quality Assurance Manual (QAM),- QAM-002 L
Revision 01, dated-November 12, 1988, but utilized by the vendor to implement the provisions of the QAM for auditing vendors and suppliers.
(90-01-01) 2.
Additional information is required relative to the selection and
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qualification of-vendors prior to placement of a purchase. order as described in Paragraph 7.4.1 in QAM-002, Revision 01.- GE staff committed to review and revise this paragraph to clearly state actions to be taken before a purchase order is placed with-a vendor.
(90-01-02)
D.
-STATUS OF PREVIOUS INSPECTION FINDINGS:
Not applicable,.this is. the first NRC inspection of this-facility.
E.
' INSPECTION FINDINGS AND OTHER COMMENTS t
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Introduction TheNuclearEnergyDivision(GENE)oftheGeneralElectricCompany.
(GE), San Jose, California, has established four~ field cffices in
-the United: States to provide repair and overhaul service for equipment supplied by GE for use in_ nuclear' power plants. GENE, Eastern Territory, which provides services to the nuclear power-plants located in the' northeast of the United States, is located in King of Prussia, Pennsylvania. GENE field engineers assigned L
to this office, work in the GE Apparatus Service Shop (GEASS) to repair and overhaul equipment when they are not providing onsite services to nuclear power plants. The four territorial GEASSs implement a QA program developed by GENE, San Jose, California.
A QA Manager, assigned to each GENE territory, ensures that the QA-program is implemented when repair and overhaul activities are performed on safety-related switchgear and other equipment, such o
as motors, transformers and pumps.
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ORGANIZATION: GENERAL ELECTRIC APPARATUS SERVICE SHOP PHILADELPHIA, PENNSYLVANIA 4
REPORT INSPECTION L
NO : 99901147/90-01 RESULTS:
PAGE1of,11 L
L This inspection was conducted to observe the activities in progress related to the repair and refurbishment of various types of CBs which were returned from the Beaver Valley, Calvert-Cliffs and Salem nuclear power plants.
2.
Observation of CBs Returned From Beaver Valley Nuclear Power Plant' (BVNPP)
The inspectors observed five 480 volt CBs which were returned t
from BVNPP. All five CBs had been received in the disassembled condition. The inspectors were informed that GEASS received them in that condition from GEASS, Hamond (Indiana) where they were previously sent for overhaul.
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3.
Review of Records The inspectors reviewed the following records relevant to the service provided to BVNPP by GEASS, Philadelphia. BVNPP issued Purchase Order (PO) No. 07935, dated August 21, 1989, to GE to refurbish 131 low voltage (480 volt) CBs as described in GENE Specification 8700-DES-0302, Revision 0, dated July 18, 1989, including Revision 2, dated November 21, 1989. The P0 stated that the reporting requirements of 10 CFR Part 21 were applicable to the work performed. Testing and inspection included long time.
short time and instantaneous trip functions with local overload and short circuit trip indicators, insulation resistance test, ductor test, trip device timing, auxiliary switch contact con-L tinuity and inspection, secondary wire insulation test and inspection, and electrical operation.
The inspectors reviewed the records documenting the overhaul performed on two AK-3A-25 type CBs with Serial Numbers 225 A l
1728-412 FG and 75 A 710 65-27-1. On the former CB, the service performed included the replacement of the secondary control wiring, trip shaft bearing, trip latch roller, CB handle, and auxiliary switch secondary disconnects including the tubes. On the latter CB, the trip shaft bearing, the trip latch roller and the closing coil were replaced.
Both the CBs were fitted with conversion kits to accommodate Micro-Versa trip (RMS-9) devices.
The records indicated that GE QAM-002, Revision 1, dated November 12, 1988, and Procedures EMP-103, Revision 2 dated August 30, 1989, entitled "AK-2A-25 CB Micro-Versa Trip (RMS-9) conversion and overhaul" were implemented during the overhaul.
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,y ORGANIZATION:~ GENERAL ELECTRIC APPARATUS SERVICE SHOP
'Y PHILADELPHIA, PENNSYLVANIA.
REPORT INSPECTION NO.: 99901147/90-01 RESULTS:
PAGE 4 of 11 4.
Review of-Activities Related 4KV CBs a.
Observation of Activities The inspectors observed five AM 416-350-2H-type 4kV CBs identified with serial numbers 224 A 6269 -13, 224 A 6259-002,
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-003, -006, and -013, which had been returned after being in service at the Salem nuclear power plant (SNPP). All five CBs were under various stages of disassembly.- The inspectors were informed that GE was awaiting information from SNPP relative to the approval of GE Procedures which were to be utilized to overhaul the 4kV CBs, the type of grease existing on the female connectors in the stationary cubicles of the 4.16kV switchgear and the format for the Certificate of Conformance which'is to L
accompany the switchgear following the overhaul.
L b.
Review of Records Public Service Electric & Gas, the licensee for SNPP issued PO No P1-336 926, dated November 26, 1989, to GE to overhaul five AM-416-350-2H type 4KV'CBs as per GE proposal No.
291-BAD 02-RPO, Revision 1.
10 CFR Part 21 and provisions of QAF-19 MM.7346 (SNPP documents) were referenced. The scope of the work included:
.(1 Pick up from and return the CBs from SNPP.
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(2 Documentation of the as-received condition of each CB.
(3 Disassembly and inspection of-the operatin0 mechanism and contact assemblies.
Inspection of the interrupters.
Replacement of worn or defective parts as required.
L Clean and lubricate the CB.
L Reassemble mechanism, making all required adjustments.
Perform mechanical and electrical checks and test.
All parts to be commercial grade, dedicated by GE for safety-related service.
5.
Review of Activities Related to 4KV CBs a.
Review of Purchase Order (PO)
. Baltimore Gas & Electric company (BG&E), the licensee for Calvert Cliffs nuclear power plant Unit I and 2, issued PD 24765 EX, dated February 6,1989, to GEASS to furnish labor, material, tools, and equipment to overhaul and modify / upgrade 14 GE Magne-Blast AMH-4.76-250 type CBs.
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.c, ORGANIZATION:. GENERAL ELECTRIC APPARATUS' SERVICE SHOP-PHILADELPHIA, PENNSYLVANIA' l
. REPORT-.
INSPECTION NO.n 99901147/90-01 RESULTS:
PAGE 5 of 11:
The' work included the fol_ lowing:
(1) Replacement of 21 sleeve bearings per GE Service Advice Letter (SAL) 318.2, 318.1, 318.1A, and IE Information Notice 84-29 o
(2 Replacement of the " Driving Pawl Crank Assembly"-
(3 Replacement of " Manual Close Paddle Spring" (4
Verify / upgrade ratchet wheel assembly (must have-twoblindteeth)
(5) Reweld striker plate per SAL 325.1 The PO required the GEASS to implement a quality y
assurance program meeting the 10 CFR 50, Appendix B requirements and stated the reporting requirements of 10 CFR 21_were applicable.
GE in a letter (reference number EFS-89-052), dated April 17, 1989,-to BG&E requested BG&E to revise the P0 to read, "The provisions of 10 CFR Part 21 apply only to the' service provided against this order. All materials provided shall be certified equal to or better than original, and 1
purchased as " Commercial Grade." All services and materials shall be certified as not degrading any' existing qualification."-
In response to this letter, BG&E issued Revision 1 to'PO No-24765, dated April 12, 1989, to clarify the following:
BG&E or-its agent will witness all. testing performed on the circuit breakers. The provisions of 10 CFR Part 21 apply; only to services provided against the P0. All materials provided shall be certified equal to or better than original, and purchased commercial grade. All services and material
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shall be certified'as not degrading any existing qualification.
Since the requirements of 10 CFR Part 21 do not apply to the e
CB, dedication is required. This material can be dedicated based on:
BG&E conducting surveillance on this order during testing.
BG&E issued Revision 2 to PO No.24-765, dated December 14, 1989, increasing the quantity of CBs to be serviced -from 14 to 15.
The service was to include the following:
the ML type operating mechanism was cocked causing one side of the prop pin to rub against the side of the CB frame; verification of the operability of the closc-latch monitor switch, replace the Nylon screw on the insulation barriers, and overhaul of the CB.
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[a ORGANIZATION:
GENERAL ELECTRIC APPARATUS SERVICE SHOP i
PHILADELPHIA, PENNSYLVANIA 4
,1 x
REPORT INSPECTION NO.:. 99901147/90 RESULTS:
PAGE 6 of 11 b.-
Observation of Activities l
The inspectors witnessed the disassembly of the AMH-4.75, i
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-250-ID-type CB with serial No. 0224A 7989-003 which was L
returned from Calvert Cliffs to establish the as-found I
L condition of the CB and determined the following:
L (1) Established procedures were being'followed during the L
disassembly.
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(2) The craftsmen who disassembed the CB appeared to be knowledgeable and proficient.
(3) The inspectors witnessed ductor tests on the six air insulators _to determine the power factor. The measured power factors were less than 5.
The power factor indicates the integrity of the insulation i
resistance.
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'(4) One auxiliary switch was observed to be chipped.
L (5) One nylon screw which holds the insulation barriers on l
(6) one of the phases was observed to be missing.
The ML 13-type operating mechanism was cocked causing one side of the prop pin to rub against the side of the frame, t
(7) The craftsmen documented the results of the as-found conditions and dimensions at various stages of disassembly, c.
_ Review of BG&E Surveillance Report (SR) QAG 19-GEP89-03 The inspectors reviewed the above mentioned SR, dated January 12, 1990,. documenting the BG&E inspector's visit to witness the tests performed on an AMH-4.75-250-ID CB identified with serial no. 0224 A 7986-009. The SR identified no adverse findings and confirmed the following:
(1) The overhaul met the requirement of the P0. The bearing, Driving Pawl Crank Assembly and Manual Close Paddle were replaced. The Ratchet Wheel Assembly was determined to have two blind teeth.
The striker plate welds were acceptable.
(2) The CB successfully passed the " Electric Close and Trip Test," ductor test and the dielectric test.
(3) The BG&E inspector authorized the CB to be shipped.
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ORGANIZATION:- GENERAL ELECTRIC APPARATUS SERVICE SHOP PHILADELPHIA,= PENNSYLVANIA REPORT INSPECTION
.NO.:
99901147/90-01 RESULTS:-
PAGE 7 of h 6.
Review of Audits Performed The inspectors reviewed GEASS compliance to the GENE QAM-002, Revision 001, dated November 12, 1988, relative to audits and determined the following:
a.
Internal Audit Schedule for 1990 The audit schedule for 1990 has been established and requires two internal audits to be performed in April and October.
b.
Review.of Internal Audits Performed in 1989 Audit No-E-89-03-PSS documents the results of an audit performed on May 9,1989, to verify the implementation of the quality assurance program at GEASS. The audit identified two audit findings and several concerns.
One audit finding related to the unavailability of a current shop organizational chart and the other related to inconsistencies in the. purchase orders issued by the shop to purchase material for safety-related applications.
The organization chart was revised to satisfy. the first audit finding. To
. satisfy the second audit. finding. the QC supervisor was provided additional training on the " Requirements for L
- quality related purchases."
Audit No-E-89-I-16 documents the results of an audit performed on October 25, 1989, to verify the completion of the action taken to correct the two adverse
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findings identified during the previous audit and to audit generic and in-process files. No adverse findings were identified.
7.
Review of Audits Performed by Licensees l
The inspectors reviewed the audits performed by various licensee organizations and their representatives and determined l
L' the following:
l BG&E Surveillance Report QAG 59-GEP-Surve111ance 02, dated a.
May 14, 1987, documenting the results of a surveillance performed on April 16, 1987, to witness the final tests on seven AMH-474-250-ID CBs following modification and overhaul, and to verify that the QA documentation was in compliance to the relevant BG&E P0.
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ORGANIZATION: GENERAL' ELECTRIC-APPARATUS' SERVICE SHOP E
. PHILADELPHIA, PENNSYLVANIA' 1
REPORT INSPECTION
.NO.: 99901147/90-01 RESULTS:
PAGE 8 of 11
'b.
Quality Systems Incorporated, Shillington, Pennsylvania performed an audit during September 15-17, 1987, on behalf of. Niagara Mohawk Power Corporation on GEASS to verify the adequacy and implementation of the established QA program.
to supply field service work and motor repair service for Nine Mile Point nuclear power station. The audit-identified three programatic audit findings which were corrected by revising existing procedures.
c.
Yankee Atomic Electric Company performed a surveillance during September 3-5, 1987, to verify that activities performed by'GEASS during the overhaul of their Core Spray Pump Motor B were in compliance'with the established QA program. - The surveillance identified that the required certifications were not provided4 at the time of shipment.
GEASS stated that the certification was withheld because-the evaluation of " Material Substitution" by GENE, l
San Jose was incomplete at the time of shipment.
d.
Pennsylvania Power & Light Company (PPL) performed an audit (87-090) on December 2-3, 1987, to assess the ability of GEASS to perform " Class 1E Motor / Generator Repairs." The audit identified no adverse findings.
8.
Review of P0s issued by GENE' The inspectors reviewed the following P0s issued by GENE,. Kin _g of Prussia,. to procure various parts required to overhaul and repair CBs.
w a.
GENE issued P0 320-0013AD8Z, dated January 18, 1990, to GE BreakerPlantOperations(GEBP0), Philadelphia,tosupply various parts for 4.16kV CBs with Cots certifying that the parts were commercial grade quality but were suitabla for use in Class IE equipment. Receipt inspections were performed to verify that the part number of the item agreed with the corresponding drawing number and that a CoC was received for that item.
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4 ORGANIZATION: GENERAL ELECTRIC APPARATUS SERVICE SHOP, c,
. PHILADELPHIA, PENNSYLVANIA r
i.
LREPORT..
INSPECTION '
I NO.: 99901147/90-01 RESULTS:
PAGE 9 of 11 L
b.
.GE 8PO issues the following three types of Cots as L
appropriate:
.(1) " Material IE."
This CoC is issued for parts and equipment to replace equipment initially purchased as " Class 1E."
(2) " Material commercial grade qualified for use in Class 1E equipment."
' (3) "Comercial grade equipment for use in safety-related equipment."
c.
GENE issued PO 320-NTE-20-2, dated February 16, 1989, to Mobil, Valley Forge, Pennsylvania, for Mobil 28 commercial grease as specified in GE Service Information Letter 448, dated December 23, 1986, along with a Test Report. Mobil l.
Oil, Woodheaven, Michigan, issued a test report certifying that the Mobil 28 supplied meets the specification of MIL-G-81322 D.
GENE stated that Mobil 28 grease when purchased in one pound cans has unlimited shelf-life because the weight of the grease does not cause the ingredients tn sepa ra te. Grease.when purchased in larger quantities has a specified shelf-life because the weight of the grease tends to separate the ingredients, according to discussions with GE personnel.
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Review of The GENE QAM The inspectors reviewed QAM-002, Revision 01, dated November 12, 1988, and determined to'following:
a.
Paragraph 7.4.2 states in part. " Vendor for nonsafety-related material and commercial grade material to be dedicated to a-safety-related function may be evaluated by the Quality Prograr's Manager or Territory Manager, QA, in a manner appropriate to the product form, size and intended application. The evaluation, or other activities performed by GE prior to material acceptance, shall be sufficient to assure that the material meets the requirements of the material specification and any other additional requirements of the applicable code or design specification. Such vendors need not be listed on the AVL at the discretion of the Quality Programs Managers."
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' 0RGANIZATION:. GENERAL ELECTRIC APPARATUS SERVICE ~ SHOP X
PHILADELPHIA, PENNSYLVANIA REPORT INSPECTION NO.: 99901147/90-01 RESULTS:
PAGE 10 of 11 There is no indication as to how GE BP0 which supplies 4.16kV Magna-Blast CBs including spare parts,. and GE, Burlington, Iowa, which supplies 480 volt metal clad CBs, including spare parts, were qualified as. approved vendors
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to. supply nonsafety-related components and placed on the
" Approved Vendors List."
.- j GENE -produced two audit reports, dated May 24, 1988,.and November 10, 1989, documenting the results of audits per-
.i formed by GENE, San Jose on GE BP0 (Philadelphia) and GE, 1
Burlington respectively. The audits were performed according to an Engineering Operating Procedure (EOP).
However,~the QAM-002 does not state that the program is implemented through the use of E0Ps. The QAM, Eastern Territory stated a
that E0Ps and other procedures, not referenced in the QAM,.
l are used to implement the QA program.- The NRC inspectors stated that pending the receipt of confirmation from GENE l
that E0Ps and other procedures.are used.tn. implement the QA
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program, this matter will be considered 'an unresolved item (UnresolvedItem 90-01-01).
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Paragraph 7.4.1 of the QAM states "Any Vendor having a valid ASME Quality Cystem Certificate (material) or a i
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' Certificate of Authorization is considered prequalified for the. material or item stated on his certificate."
o As a minimum, GENE is expected to audit the f acility, to conduct source surveillance, or otherwise to establish p
a basis for verifying the quality of procurred products l
if a purchase order is placed on a certificate holder.
L The QA Manager stated that the current QAM is being revised to modify this statement.- The NRC inspectors L
w informed GENE that pending receipt of confirmation that 1:
the QAM was revised, this matter is considered an i
unresolved item (Unresolved Item 89-01-02).
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ORGANIZATION:
GENERAL ELECTRIC APPARATilS SERVICE SHOP PHILADELPHIA, PENNSYLVANIA REPORT:
INSPECTION NO.: 99901147/90-01 RESULTS:
PAGE 11 of 11 F.
EXIT INTERVIEW The inspectors met with the individuals listed in section G and discussed.the' scope and results of the inspection.
G.
PERSONS CONTACTED V. P. Kenny, Manager, Quality
- G. W. Sander, Program Manager Nuclear Electrical Maintenance B. F. Kennedy, Quality Control Supervisor C. J. ' Rodger, Field Service Engineer
- C. Woodward, NRC, Region !
S. Mazumdau, NRC, NRR/ROAB G. Cwalina, NRC, NRR/VIB K. Naidu, NRR, NRR/VIB
- Denotes that the individual did not attend the exit interview on i
January 23, 1990.
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