ML20041B402
| ML20041B402 | |
| Person / Time | |
|---|---|
| Site: | Duane Arnold  |
| Issue date: | 01/19/1982 |
| From: | Barnes I, Foster W NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML20041B388 | List: |
| References | |
| REF-QA-99900367 NUDOCS 8202230608 | |
| Download: ML20041B402 (13) | |
Text
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ORGANIZATION: SQUARE D COMPANY POWER EQUIPMENT DIVISION PERU, INDIANA
~
FiEPORT NO.: 99900367/81-01 INSPECTION DATEIS): 11/30-12/4/81 INSPECTION ON-SITE HOURS: 28 CORRESPONDENCE ADDRESS:
Square D Company Power Equipment Division ATTN: Mr. R. H. Brunner Plant Manager 252 North Tippecanoe Peru, IN 46970 ORGANIZATION CONTACT:
Mr. L. D. West, Manager, Quality Assurance TELEPHONE:
(317) 472-3381 PRINCIPAL PRODUCT: Motor Control Centers NUCLEAR INDUSTPY ACTIVITY: Less than one percent of total effort with current con-tracts scheduled for completion in January 1983.
4 ASSIGNED INSPECTOR:
[
Y/9/f2 t
W. E. Foster, Reactive Inspection Section (RIS)
Date r-OTHER INSPECTOR (S):
I // 9 /P 2-APPROVED BY:
c=W P l
I. Barnes, Chief, RIS Date l
i I
INSPECTION BASES AND SCOPE:
A.
BASES: Appendix B of 10 CFR Part 50 and 10 CFR Part 21.
B.
SCOPE: This inspection was made as a result of written notification of the following problems: (1) improperly crimped terminal lugs, improperly tightened screws on devices and terminal blocks, and excessively bent terminal lugs on 480 Volt motor control centers that have been furnished to the Shoreham Nuclear Power Station, Unit No.1; (2) lubricant on rubber bumpers of NEMA Size 3 starters in 480 valt motor control centers that have been furnished to the Shoreham Nuclear Pcwer Station, Unit No.1; and (3) pinched wires in 480 volt motor control centers that have been furnished to the V. C. Sumer Nuclear Power Station, Unit No.1.
Additionally, the following areas were inspected:
(1) implementation of 10 CFR Part 21; (2) follow up on previously identified E
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99900367 PDR g
ORGANIZATION: SQUARE D COMPANY, POWER FQUIPMENT DIVISION PERU, INDIANA REPORT NO.:99900367/81-01 INSPECTION RESULTS:
PAGE 2 of 5
_A.
VIOLATIONS:
None B.
NONCONFORMANCES:
1.
Contrary to Criterion V of Appendix 8 to 10 CFR Part 50 and Quality Control Procedure (QCP) No. 187, dated February 18, 1980, the report-v' ability to the NRC portion of a QCP-187 form had not been completed in regard to a problem concerning coatings on rubber bumpers of Size 3 starters.
2.
Contrary to Criterion V of Appendix B to.10 CFR Part 50 and paragraph 3.5 of the Corporate QA Manual, dated May 16, 1978, design control measures commensurate with those of the original design had not been /
performed for the field change which relocated units within the cabinets in order to eliminate the problem of pinched wires.
This was evidenced by the lack of documentation which would address the effect that unit relocation would have upon the seismic qualification of the motor control centers.
3.
Contrary to Criterion V of Appendix B to 10 CFR Part 50, and para-graphs III.C and IV of Standard Practice Bulletin No. 512.406, dated December 6, 1976, corrective action for each finding had not been 7
reviewed within 60 calendar days of the audit date of a QA Program Audit conducted July 13-14, 1978.
The QA Audit Findings Reports (9) for the audit, reflect dates of August 20, 21, 28, 1979, for satis-factory implemenfation of corrective action (Corrective Action Imple-mentation Audit).
4.
Contrary to Criterion V of Appendix B to 10 CFR Part 50 and Standard Practice Bulleti~n No. 512.307, dated November 10, 1977, Routing Change Form No. PE-1014 is not being used to effect changes to Master Record Routings.
Note:
The inspector was provided a document entitled,
" Operational Routing Manual" dated September 28, 1981, and informed that this manual is used to change Master Record Routings.
The inspec-tor noted that the manual had not been approved and was informed that it is in the formative stage.
5.
Contrary to Criterion V of Appendix 8 to 10 CFR Part 50, paragraph II.C of Standard Practice Bulletin No. 500.020, dated September 20, 1976, and paragraph 3 of Quality Control Procedure No. 200-9, Revi-sion C, dated October 15, 1981:
(a) personnel had not satisfactorily performed the electrocoat paint process to comply with Special Process Procedure No. B-1, dated October 12, 1977; and (B) records maintained on the electrocoat paint process did not verify control of equipment settings, chemical tests and gauge readings.
This was evidenced by the following examples:
~,
ORGANIZATION: SQUARE D COMPANY, POWER EQUIPMENT DIVISION PERU,. INDIANA REPORT NO.:99900367/81-01 INSPECTION RESULTS:
PAGE 3 of 5 Requirements Observed-12/2/81 (late morning)
Sta. No. 2, 140-180 F 128 F
~~
4, 155-165 F 146 F 7, 13-15 PSI 20 PSI 13, 325-350 F 380 F 9, pH 8.2 - 9.0 (see note below) 2, Free Alkali 8.5-16.5 pts.
(see note below)
Special Process Control Records, dated November 2-December 2, 1981, in-dicated that: (a) Station No. 2 varied from 132 to 158 F; (b) Station No. 4 varied from 138 to 156 F; (c) Station No. 7 varied from 20-30 PSI; it was also noted that the record reflects a requirement of 15-20 PSI as opposed to the procedure; (d) Station No. 13 indicated 380 F; (e) Station No. 9 varied from 8.7 to 9.5 with 25 of 39 readings out-side the requirements; and (f) Station No. 2 varied from 10.7 to 22.6, with 30 of 32 readings outside the requirements.
6.
Contrary to Criterion V of Appendix B to 10 CFR Part 50 and paragraphs II.E.1 and.4 of Standard Practice Bulletin No. 500.012, dated June 22, 1973:
(a) an entry of the date, holder and revision design notice number had not been made on the drawing location card ( or a Reproduction Services Request Form) for Drawing No. D-80103-005, which had been removed from the master files; and (b) previous revision marks had not been removed from point, part, or line of:
(1) Bills of Material, Nos. 30318-286-57, Revision A1, dated July 30, 1979; 30322-407-58, Revision R, dated August 21, 1980; and (2) Specification No. A-40004-013-01, Revision B, dated October 4, 1976.
7.
Contrary to Criterion V of Appendix B to 10 CFR Part 50 and para-graph II.B.1 of Standard Practice Bulletin No. 512.407, dated May 11, 1976, the Peru Plant QC Supervisor had not reviewed each written Quality Control Procedure annually, as evidenced by the lack of Records of Quality Control. Procedure Review.
C.
UNRESOLVED ITEMS:
Paragraph 2.1.5 of Quality Control Procedure No. 200-3, Revision B, dated to August 31, 1981, requires that Utility Sales route all nuclear safety-related purchase and change orders through Design Engineering and Quality Assurance for review and approval.
The NRC inspector verified that Design Engineering and Quality Assurance receives copies of purchase and change orders from Utility Sales; however, it could not be deteroined that these documents are reviewed and approved by Design Engineering and Quality Assurance.
The inability to make this determination results from the apparent lack of requirements to document such review and approval.
ORGANJZATION: SQUARE D COMPANY, POWER EQUIPMENT DIVISION PERU, INDIANA REPORT NO.: 99900367/81-01 INSPECTION RESULTS:
PAGE 4 of 5 D.
STATUS OF PREVIOUS INSPECTION FINDINGS:
y 1.
(Closed) Deviation (79-01):
The receiving inspector had not signed and dated the Delivery-Final Receipt copies of purchase orders for accepted material.
The NRC inspector reviewed the Delivery-Final Receipt file of purchase orders dated October 1-15, 1981, and verified that they had been signed and dated.
2.
(Closed) Deviation (79-01):
Straight vertical lines had not been used to indicate changes to Standard Practice Bulletin (SP8) Nos. 100.013 and 512.404.
The NRC inspector verified that the SPB controlling such documents had been revised and was being implemented.
3.
(Closed) Deviation (79-01):
Rework dispositions had not been completed within the required 10 working days.
The NRC inspector verified that the SPB had been revised to require a 10 day follow-up.
It was being implemented.
4.
(Closed) Deviation (79-01):
Customer inspection hold points had not baen documented in Sauare D records.
The NRC inspector verified records are initiated to reflect customer inspection hold points.
5.
(Resolved) Unresolved Item (79-01):
Master Record Routings were being changed with forms other than what the Standard Practice Bulletin specified.
l The inspector determined that the Standard Practice Bulletin was not being implemented, despite its validity.
Consequently, a nonconfor-mance was identified.
6.
(Resolved) Unresolved Item (79-01):
The NRC inspector was unable to determine that instrumentation used in the cleaning and painting process was accurately indicating the medium being measured.
Observations and record review indicated that several controlling factors were outside the requirements of the special process proce-dure.
Consequently, a nonconformance was identified.
E.
OTHER FINDINGS OR COMMENTS:
1.
Follow up on Regional Request - Correction of defective cable termina-tions is being accomplished by site personnel.
The NRC inspector was informed that the crimping problem was restricted to Thomas and Betts (T&B) terminals and tools, and isolated to the Shoreham Nuclear l
1
ORGANIZATION: SQUARE D COMPANY, POWER EQUIPMENT DIVISION PERU, INDIANA REPORT NO.: 99900367/81-01 INSPECTION RESULTS:
PAGE 5 of 5 Power Station, Unit No. 1.
Also, the NRC inspector was informed that mr T&B terminals and tools are no longer used on nuclear orders; however, no nuclear orders were in process, so this statement could not be verified.
While Long Island Lighting Company's report to the Nuclear Regulatory Commission also addressed problems with (a) improperly tightened terminal block screws, (b) terminal lugs bent more than per-mitted by the manufacturer of the lugs, and (c) conductors improperly inserted into the lugs; these were not addressed in documcated com-plaints to Square D. Square D had been provided with numerous inspec-tion reports of activity at the site and some of the probleins were reflected.
2.
Follow up on 10 CFR Part 21 Report - The purchasers of 480 volt motor control centers (MCCs) that used Size 3 starters /contactors had been informed of the possibility of lubricant on the rubber bumpers of the starters /contactors.
Two of the three had responded.
The MCCs at the Shortham Nuclear Power Station, Unit No.1, and the San Onofre Nuclear Power Station, Unit Nos. 2 and 3, had been inspected for lubricant on the bumpers and none had been found; however, the bumoers were replaced on safety related MCCs.
The starters /contactors are fabricated at the Raleigh, NC plant, therefore, evaluation of preventive measures could not be accomplished at the Peru, IN plant.
The NRC reportabi-iity portion of Form QCP-187 had not been completed as required.
The attendant Quality Control Procedure is nothing more than a copy of the form.
3.
Pinched Wires in 480V MCC - The problem cf pinched wires in 480 volt motor control cefiters (MCCs) was corrected at the V. C. Summer Nuclear Power Plant, Unit No. 1, by relocating units within the cabinets.
The field change of relocating units within the cabinets had not been sub-jected to the design control measures employed in the original design.
This was particularly evident by the lack of documentation that would ac' dress the effect that unit relocation would have upon the seismic qualification of the MCCs.
The manufacturer, prior to this inspection, had initiated a record search which was completed during this inspection, to identify other purchasers of MCCs with the suspect configuration.
They will be noti-fied and necessary actions taken.
To preclude recurrence, drawings have been revised, the interferring tie channel has been redesigned, and is being used.
MCCs using the redesigned tie channel have not been supplied to nuclear power plants nor has this configuration been subjected to qualification tests.
PERSONS CONTACTED Company 2 m a rre D - Poun fio:gme nf D..
Dates ll/2 o - 12/</ /f /
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