ML20071E356

Interim Deficiency Rept Re delivered,safety-related Electrical Equipment Not Meeting Project Requirements.Task Force Established by Bechtel to Investigate & Resolve Problems.Next Rept Will Be Submitted by 830513

ML20071E356
Person / Time
Site:	Midland
Issue date:	02/25/1983
From:	Jackie Cook CONSUMERS ENERGY CO. (FORMERLY CONSUMERS POWER CO.)
To:	James Keppler NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III)
References
10CFR-050.55E, 10CFR-50.55E, 20716, 82-16, NUDOCS 8303100188
Download: ML20071E356 (7)

Text

,

O Consumers Power James W Cook O

Vice President - Prcjects, Engineering and Construction General offices: 1945 West Parnall Road, Jackson, MI 49201. (517) 78& O453 February 25, 1983 82-16 #2 Mr J G Keppler, Regional Administrator US Nuclear Regulatory Commission Region III 799 Roosevelt Road Glen Ellyn, IL 60137 l

MIDLAND NUCLEAR C0 GENERATION PLANT -

DOCKET NOS 50-329 AND 50-330 POTENTIAL 50.55(e) REPORT CONCERNING l

PROCURED ELECTRICAL EQUIPMENT l

FILE:

0.4.9.72 SERIAL: 20716 l

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Reference:

J W Cook letter to J G Keppler, Serial 19130, dated December 30, 1982 l

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This letter, as was the referenced letter, is an interim report on a potential l

50.55(e) condition concerning delivered, safety-related electrical equipment not meeting project requirements. Attachment A provides a description of the l

problem and the overall corrective actions to resolve this issue.

Another letter, either interim or final, will be sent on or before May 13, 1983.

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WRB/MJS/lr Attachment A: MCAR-66, Interim Report 2, dated February 17, 1983 l

CC: Document Control Desk, NRC l

Washington, DC RJCook, NRC Resident Inspector l

Midland Nuclear Plant 8303100188 830225 Th PDR ADOCK 05000329 MAR 71983 S

PDR OC0283-0020A-MP01

2.

Serial 20716 82-16 #2 CC: CBechhoefer, ASLB Panel FPCowan, ASLB Panel JHarbour,~ASLB Panel AS&L Appeal Panel MMCherry, Esq MSinclair BStamiris

'CRStephens USNRC WDPaton, Esq,.USNRC FJKelley, Esq. Attorney General-SHFreeman, Esq, Asst Attorney General WHMarshall GJMerritt, Esq. TNK&J k

d a

- OC0283-0020A-MP01

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Attachment A 82-16 #2 Sqrial 20716 Bechtel Associates Professional Corporation i

105_t46 105482 i

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SUBJECT:

MCAR 66 (Issued December 30, 1982)

Deficiencies Associated with Workmanship Conditions on Electrical Control Panels and Cabinets Supplied by i

Various Vendors i

INTERIM REPORT 2 l

1 DATE:

February 17, 1983 i

)

PROJECT:

Consumers Power Company Midland Plant Units 1 and 2 Bechtel Job 7220 t

Introduction j

This report provides interim status and the course of corrective action required pursuant to MCAR 66.

Description of Deficiency Unacceptable workmanship conditions, such as insufficient solder, broken wire strands, damaged wire insulation, leads pulling from lugs, loose identification tags and markers, use of improper wire lugs, and improper crimping have been identified on electrical control panels and cabinets supplied by various suppliers, i

i Summary of Investimation and Historical Backaround j

Approximately 30 discrepancy reports (nonconformance reports (NCRs) and quality action requests (QARs)) have been written in the last 2 years on electrical equipment as a result of MPQAD overinspections using Consumers Power Company Project Inspection Plan 01-E-78.

See for a list and description of the NCRs/QARs associated j

with this MCAR.

Analysis of Safety Implications A case-by-case analysis of safety implications is under evaluation and will be provided in the next interim report. As of this report, there is no basis to conclude an impact on safety of operations of the Midland' plant.

(Reference MCAR Recommended Action Item A.2.)

probable Cause

.The cause for the deficiencies is to be investigated and included in a future report.

(Reference MCAR Recommended Action Items B and C.)

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105482 Bechtel Associates Professional Corporation l05746 NCAR 66 (Issued Decenter 30, 1982)

Interim Report 2 Page 2 Corrective Action

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A task force has been established to investigate and resolve MCAR 66.

The task force charter is as follows:

1) Review the findings from MPQAD's (plan 01-E-7B) overinspections of electrical control panels and cabinets, and develop recommended i

plans of action for the Midland project and other divisional departments to avoid recurrence on' future Midland plant purchase orders.

(Reference MCAR Recommended Action Items B.2, B.3, C.1, l

and C.2.)

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2) Review and provide concurrence with project engineering dispositions so that there.is a consistent approach used to

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correct problems on existing hardware and to prevent problems on future work. Based on that review, the task force will produce a j

checklist that can be used to summarize the deficiencies for each purchase order. Project engineering, in support of the task force, will review each of the NCRs and QARs and summarize the

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i deficiencies noted on individual checklists for each purchase order.

(Reference NCAk Recommended Action Items A.1 and A.2.)

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3) Develop a list of considerations to be used in evaluating the individual purchase orders. The task force will then review each purchase order affected by this MCAR against the evaluation 2

checklist (Step 2) and summarize the strengths and weaknesses of each purchase order.

(Reference MCAR Recommended Action Items B.1 and B.2.)

4) Identify the root causes of the workmanship deficiencies and develop plans for corrective action.

(Reference MCAR Recommended Action Items B.2, B.3, C.1, and C.2.)

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5) Prepare a summary of corrective actions for individual purchase orders under Plan 01-E-7B where there will be future releases or l

where there is time in the fabrication process on existing items to implement changes. The Midland project will review, concur with or resolve, and implement the corrective actions.

(Reference MCAR Recommended Action Items B.2, B.3, and C.2.)

6) Develop a list of generic actions for purchase orders based on attributes other than those covered by Plan 01-E-7B.

This list will be developed principally feca the purchase order checklist and problem summary. The Midland project will implement the generic actions.

(Reference MCAR Recommended Action Item C.2.)

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I05482 Beqtge%2ociates Pgfgignal Corporation MCAR 66 (Issued December 30, 1982)

Interim Report 2 page 3 As of the date of this interim report, several corrective actions have been initiated or completed.

a) on near-term equipment deliveries where fabrication is complete or nearly complete, a comprehensive plan of shop inspection coupled with a parallel MPQAD in-shop overinspection to detect and correct workmanship problems before shipment is being implemented.

b) An investigation to suuznarize the deficiencies noted on each of the NCRs/QARs has been completed and is included in this report as Attachment 2.

Further. investigation is being conducted to identify the deficiencies that are workmanship related. The results of this investigation will be provided

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in the next interim report.

Reportability This condition was reported to the NRC by Consumers Power Company as potentially reportable on December 3, 1982.

1 Submitted by:

1)

J.G. Kovach

()

'g Cognizant Group Supervisor Approved by:

F M

E.M. Hughes

/ Ann Arbor Project Engineer Concurrence b R.L. Castleberry Cognizant Dir:1pline Chief Concurrence by:

E.H. Smith Engineering Manager A

concurrence by:

M.A. Dietrich Project Quality Assurance Engineer Attachments:

1.

List of NCRs/QARs Under the Scope of MCAR 66 2.

Sunsnary of Deficiencies for MCAR 66

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Att0chmest 1 t3 NCAR 66 Intcrio R: port 2 105482 105746 LIST OF NCRs/QARs UNDER THE SCOPE OF MCAR 66 NCR/0AR Purchase Order Number and Vendor 1)

M01-9-1-097 J-201(Q), Magnetics 2)

N01-9-1-114 E-51(Q), Solidstate Controls Inc.

3)

M01-9-1-095 Babcock & Wilcox 4)

M01-9-0-075 J-201(Q), Magnetics 5)

M01-9-1-075 M-18(Q), Delaval 6)

M01-9-0-064 M-118A(Q), EBV Systems, Inc.

7)

M01-9-0-066 M-118A(Q). EBV Systems Inc.

8)~

M01-9-0-068 M-169(Q), Westinghouse 9)

M01-9-1-008._

E-51(Q), Solidstate controls, Inc.

10)

M01-9-0-063-E-11(Q), Solidstate Controls, Inc.

E-19(Q), Solidstate Controls, Inc.

E-51B(Q), Solidstate Controls, Inc.

11A)

M01-9-0-071 E-205(Q), ITE 11B) QAR F-010 E-6(Q), General Electric 12)

M01-9-1-024 M-150(Q), Mine Safety 13)

QAR SD-332 J-207(Q), Vitro J-275(Q), Vitro J-281(Q), Bendix J-284(Q), Consip E-6(Q), General Electric E-7(Q), ITE M-18(Q), Delaval M-150(Q), Mine Safety M-169(Q), Westinghouse 14)

M01-9-1-128 J-201(Q), Magnetics 15)

M01-9-1-136 M-18(Q), Delaval 16)

M01-9-1-129 J-201(Q), Magnetics 17)

M01-9-1-140 E-7(Q), ITE 18)

M01-9-1-142 E-7(Q), ITE 19)

QAR SD-382 Voided 20)

QAR F-007 E-7(Q), ITE 21)

M01-9-0-067 M-150(Q), Mine Safety 22)

QAR F-070 E-51(Q), Solidstate Controls, Inc.

23)

M01-6-1-043 E-7(Q), ITE 24)

QAR F-114 E-19(Q), Solidstate Controls. Inc.

25)

M01-9-1-120 Voided 26)

M01-9-1-139 E-7(Q), ITE 27)

M01-9-1-150 Babcock & Wilcox 28)

QAR F-133 Babcock & Wilcox 29)

M01-9-1-137 Voided 30)

M01-9-1-151 M-169(Q), Westinghouse 31)

M01-9-2-082 Babcock & Wilcox 32)

M01-9-2-150 J-275(Q), Vitro 33)

M01-9-2-139 M-18(Q), Delaval

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Attcchme2t 2 to MCAR 66 Interin R port 2

SUMMARY

OF DEFICIENCIES FOR MCAR 66 I05482

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a.

Cut, nicked, broken strands 3, 9, 10, 11A, 11B, i

14, 27, 28 b.

Strands cutside lug barrel 11A, 11B, 14 c.

Undersize / incorrect type wiring 5, 8, 30 g

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d.

Unidentified wiring 8, 30

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e.

Minimum bend radius violation 9, 24 i

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Conductor not terminated 2

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Conductor pulled out of termination 2, 4, 7, 14, 18 i

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Conductor outside wireway / support 5, 7, 22, 30

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problem j

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1.

Conductor insulation inside lug barrel 14

j. Conductor insulation damaged 16, 238, 32*

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Conductor not visible past lug barrel 18 l

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Loose terminations 11A, 11B, 12, 14, 16, 17, 18, 24, 26 1

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More than two lugs on a terminal 5, 10, 21 a

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Class 1E and non-Class 1E apparently 5

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on same terminal l

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Color code violations 5, 7, 8, 15, 30, 32 p.

6-inch separation violations 1, 5, 14 q.

Lugs applied without proper tools 9, 12 r.

Incorrect size lugs / incorrect type 5, 8, 10, 11A, 12, 13, lugs or terminations 20, 22, 27, 28, 30 s.

Excessive / inadequate solder in lugs 14 t.

Terminal block ID misslag/ incorrect 5, 7, 8, 30 u.

Terminal block barrier missing / broken 27, 28, 31*

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Missing / inadequate inspection critoria 6, 7 w.

Appearance / workmanship 5, 7, 9, 15, 16, 24, 32

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