ML20040B717
| ML20040B717 | |
| Person / Time | |
|---|---|
| Issue date: | 12/31/1981 |
| From: | Barnes I, Foster W NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML20040B698 | List: |
| References | |
| REF-QA-99900279 NUDOCS 8201260349 | |
| Download: ML20040B717 (14) | |
Text
l GOULD, INC., INDUSTRIAL CONTROLS DIVISION ORGANIZATION:
FINKSBURG, MARYLAND REPORT NO.: 99900279/81-01 INSPECTION DATE(S): 11/17-19/81 INSPECTION ON-SITE HOURS: 22 CORRESPONDENCE ADDRESS: Gould, Inc.
Industrial Controls Division ATTN:
Mr. G. Kennedy Operations Manager 2002 Bethel Road FinKsburg, MD 21048 ORGANIZATION CONTACT:
Mr. R. P. Wathen, Manager, Quality Assurance TELEPHONE:
(301) 876-2214 PRINCIPAL PRODUCT: Panel boards, switch boards, special controls, and 480 volt motor control centers.
NUCLEAR INDUSTRY ACTIVITY: Forty percent of the total activity.
ASSIGNED INSPECTOR:,
/ 2 - 3 ' '- 3 i f W. E. Foster, Reactive Inspection Section (RIS)
Date OTHER INSPECTOR (S):
APPROVED BY:
ae ec-3s-yl I. Barnes, Chief, RIS Date INSPECTION BASES AND SCOPE:
A.
BASES:
10 CFR Part 21 and 10 CFR Part 50, Appendix B.
B.
SCOPE:
This inspection was made as a result of: (1) identification of potential binding problems with National Electrical Manufacturers Association Size 3 motor control starters and contactors at the Watts Bar Nuclear Power Station, Units 1 and 2; (2) failure of Type J, 15 and 30 amperes control transformer fuses in the 480 volt motor control centers supplied to the Bellefonte Nuclear Power Station, Units 1 and 2; (3) initiation of the DESI 'inED ORIGIllAL Certined By b
8201260349 820106 PDR GA999 ENVGOUL 99900279 PDR
ORGANIZATION: GOULD,'INC, INDUSTRIAL CONTROLS DIVISION FINKSBURG, MARYLAND REPORT NO.: 99900279/81-01 INSPECTION RESULTS:
PAGE 2 of 5 SCOPE CONTINUED supply feeder trip sequence due to an erroneous undervoltage condition detected by the alternating current relays used in the 6.9 kilovolt switchgear supplied to the Bellefonte Nuclear Power Station, Unit Nos. 1 and 2; and (4) assembly problems with Type JG, JL and KM circuit breakers.
Additionally, the following areas were inspected:
(1) follow up on noncon-formances; (2) implementation of 10 CFR Part 21; (3) organization (limited);
(4) manufacturing process control (limited); and (5) change control (limited).
INSPECTION RESULTS:
A.
VIOLATIONS:
Contrary to paragraph 21.6 of 10 CFR Part 21, posting of 10 CFR Part 21, Section 206 of the Energy Reorganization Act of 1974, adopted procedures or an appropriate notice, had not been accomplished at the Westminster Operation of the Industrial Control Division.
The Westminster Operation assembles starters and contactors that are used in motor control centers which are assembled and shipped from the Finksburg Operation.
B.
NONCONFORMANCES:
1.
Contrary to Criterion V of Appendix B to 10 CFR Part 50 and paragraphs 4.4 and 4.5 of Field Quality Instructions No. 15.31, Revision 0, dated September 28, 1979, the Certification of Installation section of the file copy of the Form QA-37R, had not been completed for replacement, on January 17-18, 1980, of Size 3 carriers at the Midland Nuclear Power Station.
Thirteen QA file copies of Form QA-379 were reviewed.
2.
Contrary to Criterion V of Appendix B to 10 CFR Part 50, paragraph 5.5.2, of Quality Assurance Procedure 12.1, Revision 6, and its Change Notice No. 1, figure 12.1-2, the week in which equipment is to be calibrated had not been entered on the Scheduled Work Assignment / Routine Record (Form No. 00358) for the following equipment; (1) A. C. Current Source Tester, No. C-140, (2) Welding Machines, Nos. P572, P573, P574 and P575, and (3) Test Panel No.
C-167.
Ten Forms No. 00358 were reviewed.
C.
UNRESOLVED ITEM:
The description of the organization in Quality Assurance Procedure 1.0, dated September 28, 1979, is different from that identified in Section 1.0 of the Quality Assurance Manual, Revision 5, dated January 15, 1981, and its Change Notice No. 1, issued November 5, 1981.
As an example, the 1
ORGANIZATION: GOULD; ENC. INDUSTRIAL CONTROLS DIVISION FINKSBURG, MARYLAND REPORT NO.: 99900279/81-01 INSPECTION hktSULTS:
PAGE 3 of 5 latter document indicates that the Quality Control Department reoorts directly to the Quality and Technical Services Manager while the former indicates that the Quality Control Department reports directly to the Manufacturing Manager.
As a result of this apparent conflict, the inspector could not determine which document accurately reflected the organization.
The inspector was informed that revision of the Quality Assurance Procedure is underway.
D.
STATUS OF PREVIOUS INSPECTION FINDINGS:
1.
(Closed) Deviation (79-01):
Several calibration cards had been marked, " Calibration 0.K." as opposed to specific data.
The inspector reviewed ten Scheduled Work Assignment / Routine Record, Forms No. 00358, and verified that the committed corrective action had been taken.
One of these was on a standard and included specific data; also, a certificate on a standard with specific data from an independent calibration laboratory was reviewed.
2.
(Closed) Deviation (79-01):
Nonconforming components were being discarded into metal baskets or bins without identifying the receptacles as collectors for scrap materials.
The inspector verified that:
(1) nonconforming items are delivered to the Receiving Inspection Hold Area; and (2) receptacles for collection of scrap materials had been identified as such.
E.
OTHER FINDINGS OR COMMENTS:
1.
Follow up on Regional Requests a.
The Tennessee Valley Authority (TVA) filed a potential construction deficiency report with the Nuclear Regulatory Commission, Region II pertaining to possible seizure ur binding of the carrier assembly within the support plate of the stationary contact assembly of National Electrical Manufacturers Association (NEMA) size 3 motor starters and contactors.
The defective hardware had been supplied to the Watts Bar Nuclear Power Station, Unit Nos. 1 and 2.
Prior to this notification, the manufacturer had issued a 10 CFR Part 21 report and the Office of Inspection and Jnforcement had issued a Circular.
The deficient conditiot resulted because the dimension of the carriage cavity was not taken into account at the time a new mold was fabricated.
Consequently, a wedge rather than a i
I
ORGANIZATION; GOULD, INCORPORATED, INDUSTRIAL CONTR0!.S DIVISION FZNKSBURG, MARYLAND REPORT NO.: 99900279/81-01 INSPECTION RESULTS:
PAGE 4 of 5 straight configuration resulted causing restricted operation of the carriage, in some cases.
The improper dimension was not detected during tool proofing or first piece inspection.
The inspector was informed that the dimension (1.392-1.400) had been identified as a critical dimension and was being checked on a sample basis at receiving inspection.
Initially, the inspector could not determine that adequate preventive measures had been taken because inspection of the identified critical dimension had not been annotated in inspection records.
Prior to the close of this inspection, the aforementioned and other critical dimensions had been made obvious on drawings used by inspection persannel.
The Certification of Installation section of the Statement of Conformance (Form QA-37R) had not been completed for replacement of the Size 3 carriers at the Midland Nuclear Power Station.
With this exception, adequate corrective actions and preventive measures had been taken.
b.
TVA filed a potential construction deficiency report with the Nuclear Regulatory Commission, Region II pertaining to failure of Type J,15 and 30 amperes control transformer fuses in 480 volt motor control centers during inital energizing and upon re-energizing following an outage.
The deficiency was observed in hardware supplied to the Bellefonte Nuclear Power Station, Units 1 and 2.
The inspector was informed that TVA was the only purchaser that used fuses in the control transformer circuits; therefore, it can be concluded that generic aspects had been assessed.
It appears that adequate corrective action had been taken.
The cause of the problem could not be determined because:
(1) The available documentation (correspondence) on fuse selection was contradictory, and (2) TVA drawings supplied with the purchase order were not available for review.
This area of the inspection will remain open.
c.
TVA filed a construction deficiency report with the Nuclear Regulatory Commission, Region II pertaining to initiation of the supply feeder trip sequence due to an erroneous undervoltage condition detected by the alternating current relays used in the 6.9 kilovolt switchgear supplied to the Bellefonte Nuclear Power Station, Units 1 and 2.
The report indicated that the hardware "was designed and supplied by Gould-Brown Boveri, Westminster, Maryland."
Currently the company's name is Gould, Inc. and personnel interviewed stated that they have no knowledge of this hardware.
The inspector will follow up on this item at the appropriate location, when that determination has been made.
ORGANIZATION GOULD, INC., INDUSTRIAL CONTROLS DIVISION FINKSBURG, MARYLAND REPORT NO.: 99900279/81-01 INSPECTION RESULTS:
PAGE 5 of 5 d.
A copy of a Telephone Report was provided to the Nuclear Regulatory Commission (NRC) Region IV by the NRC, Region I.
The report.iddressed deficient conditions of Type KM, JG and JL circuit breakers manufactured by Gould, Incorporated.
The inspector was informed that this equipment is manufactured in Philadelphia, Pennsylvania by the Circuit Protection Division (CPD) and the QA Manager of the Finksburg Operations is desirous of accompanying the NRC when an inspection of the CPD is conducted.
The inspector informed the QA Manager that he would be kept apprised of developments regarding said inspection.
2.
Programmatic Areas a.
Implementation of 10 CFR Part 21 - The inspector noted that the purchase order forms contained a provision for invoking 10 CFR Part 21.
Three outgoing purchase orders were reviewed to verify that the requirement had actually been invoked; it had.
- Also, posting was observed at the Finksburg Operations.
Personnel interviewed at the Westminster Operations indicated that posting had not been accomplished for that facility.
The inspector was also apprised of the reporting by the Westminster Operations to the Finksburg Operations, regarding 10 CFR Part 21.
The Westminster facility assembles starters and contactors which are used in motor control centers that are assembled and shipped from the Finksburg facility.
In view of this relationship, the inspector considers the Westminster facility as another assembly operation of the Finksburg facility.
b.
Change control, organization, and manufacturing process control -
These activities were limited to review of program establishment; which was verified by a review of:
(1) 11 sections of the QA Manual; (2) 32 QA Procedures; and (3) 7 QC Instructions.
Implementation was limited to one task in progress and its attendant documentation.
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