ML20076B612

Interim Deficiency Rept Re delivered,safety-related Electrical Equipment Not Meeting Project Requirements.Cause Under Investigation.No Significant Problems Identified.Next Rept Expected by 830930

ML20076B612
Person / Time
Site:	Midland
Issue date:	08/12/1983
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, 3769, 82-16-5, NUDOCS 8308190421
Download: ML20076B612 (10)

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~ ~u- - ~in<oeds and Construction oeneral offices: 1945 West Parnell Road, Jockeon, MI 49201 e (517) 7880453 August 12, 1983 82-16 #5 Mr J G Keppler, Regional Administrator US Nuclear Regulatory Commission Region III 799 Roosevelt Road Glen Ellyn, IL 60137 MIDLAND NUCLEAR C0 GENERATION PLANT -

DOCKET NOS 50-329 AND 50-330 POTENTIAL 50.55(e) REPORT CONCERNING PROCURED ELECTRICAL EQUIPMENT FILE:

0.4.9.72 SERIAL:

23769

References:

J W Cook letters to J G Keppler, Same Subject (1) Serial 19130, dated December 30, 1982 (2) Serial 20716, dated February 25, 1983 (3) Serial 22197, dated May 13, 1983 (4) Serial 22241, dated June 29, 1983 This letter, as were the referenced letters, is an interim report on a potential 50.55(e) condition concerning delivered, safety-related electrical equipment not meeting project requirements. Attachment A provides a description of the problem and the overall corrective actions to resolve this issue. Another letter, either interim or final, will be sent on or before September 30, 1983.

k JWC/WRB/cd Attachment A: MCAR-66, Interim Report 5, dated June 14, 1983 CC: Document Control Desk, NRC Washington, DC RJCook, NRC Resident Inspector Midland Nuclear Plant l};

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8308190421 830812 PDR ADOCK 05000329 OC0883-0011A-MP01 S

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2 Serial 23769 82-16 #5 CC: CBechhoefer, ASLB Panel LBernabei, CAP FPCowan, ASLB Panel Jllarbour, ASLB Panel AS&L Appeal Panel MMCherry, Esq MSinclair BStamiris CRStephens, USNRC WDPaton, Esq, USNRC FJKelley, Esq. Attorney General SilFreeman, Esq. Asst Attorney General WHMarshall GJMerritt, Esq. TNK&J INPO Records Center OC0883-0011A-MP01 3

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Attachment A I i 8 6g8chtel Associates Professional Corporation

SUBJECT:

MCAR 66 (issued December 30, 1982)

Deficiencies Associated with Workmanship Conditions on Electrical control Panels and Cabinets Supplied by Various Vendors INTERIM REPORT 4 DATE:

June 14, 1983 PROJECT: Consumers Power Company Midland Plant Units 1 and 2 Bechtel Job 7220 Introduction 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 vendors.

Probable cause The cause for the deficiencies is being investigated and the results will be included in a future report.

Preliminary results have been reviewed and no significant problems have been identified.

Summary of Investiaation and Historical Backaround To date, 37 discrepancy reports (nonconformance reports (NCRs) and quality action requests (QARs)] have been written on electrical egulpment as a result of MPQAD overinspections using Consumers Power Company Project Inspection Plan 01-E-7B.

See Attachment 3 for a list and description of the NCRs/QARs associated with this MCAR.

Several discrepancy reports do not concern workmanship and are not addressed in the scope of this NCAR.

Analysis of Safety Implications l

To date, 31 NCRs/QARs have been evaluated for possible impact on safety. For the cases analyzed, it is concluded that if the workmanship deficiencies had remained uncorrected, there would be no impact on the safety of operations at Midland. Two NCRs (Attachment 3. Items 34 to 35) are under evaluation by Bechtel. The responsible equipment vendors for Items 34 and 35 have been notified and were requested to perform an evaluation of whether the equipment can be expected to perform the intended functions under the specified conditions. These vendors will be requested to visit the jobsite to investigate and evaluate the deficiencies. Based on i

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li8673 Ii8693 Bechtel Associates Professional Corporation NCAR 66 INTERIM REPORT 4 June 14, 1983 Page 2 vendor responses, Bechtel will perform a safety evaluation.

Items 3, 28, and 32 will be evaluated by Consumers Power Company.

Corrective Action A task force has been established to investigate and resolve NCAR 66.

See Attachment 1 for the task force charter. As of the date of this interim report, several corrective actions have been initiated or completed.

a.

Safety Evaluation of Identified Conditions An investigation to summarize the deficiencies as noted on each of the NCRs/QARs has been completed and is included in this report as Attachment 2.

Safety evaluation of identified conditions is included in Attachment 3 and the Analysis of Safety Impilcations section above.

b.

Evaluation of Requirements and Vendor Programs 1.

The task force is reviewing each Bechtel purchase order for definition of workmanship requirements or criteria affected by this MCAR, and the results will be included in a future report.

2.

The task force is reviewing supplier submittals to determine if workmanship was addressed in their programs. The results of this review will be included in a future report.

3.

The task force is reviewing the project records for evidence of suppliers' implementation of their workmanship programs.

The results of this review and corrective actions will be included in a future report.

c.

Evaluation of Bechtel Programs 1.

MPQAD has reviewed the receipt inspection program and believes that for the equipment in question, the control of vendor workmanship is best controlled by source inspection.

The receiving program, as recently revised for Midland, is adequate and no further action is required.

2.

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 (Plan 01-E-78) to detect and correct workmanship problems before shipment, is being implemented.

Results of this plan are being evaluated.

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.Ii8673 Bechtel Associates Professional Corporation NCAR 66 INTERIM REPORT 4 June 14, 1983 Page 3 The supplier quality department has developed several inspection criteria guidelines and training sessions, e.g.,

a guide for compression type connectors, electrical testing, electrical codes and standards, and electrical comanodities.

In addition, the supplier quality representatives are placed in vendor shops according to their training, background experience, and complexity of the procured equipment, d.

Final Inspection Bechtel has observed a recent increase in the quantity of loose terminations on vendor equipment and believes that this was partly due to the overinspection criteria, which required a firm pull on the termination. MPQAD will continue to investigate termination inspection criteria.

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

Submitted by:

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l f.G. Kovach V-Cognizant Group Supervisor Approved by:

E.M. Hughes Q Project Engineer Concurrence w

R.L. Castleberry Cognizant Discipline Chief i

concurrence by:

~W E.H. Smith Engineering Manager Concurrence by:

fpfM.A.Dietrich l

Project Quality Assurance Engineer Attachments:

1. MCAR 66 Task Force Charter l

2. Susunary of Deficiencies for MCAR 66

3. Susunary of NCRs/QARs for MCAR 66 0346u

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Attechnent 1 to MCiR 66 Interic R3 port 4 i

l TASK FORCE CHARTER 1.

Review the findings from NPQAD's (Plan 01-E-78) overinspections of electrical control panels and cabinets, and develop recommended plans of action for the Midland project and other divisional departments to avoid recurrence on future Midland p1' ant purchase orders (

Reference:

MCAR Recommended Action Items B.2, 8.3, C.1, and C.2).

2.

Review and provide concurrence with project' engineering dispositions so that there is a consistent approach used to correct problems on existing hardware and to prevent problems on future work. Rased on that review, the task force will produce a checklist to summarize the deficiencies for each purchase order. Project engineering, in support of the task force, will review each NCR and QAR and summarize the deficiencies noted on individual checklists for each purchase order.

(

Reference:

MCAR Recommended Action Items A.1 and A.2).

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 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.

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Reference:

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

5.

Prepare a summary of corrective actions for individual purchase orders under Plan 01-E-7B where there will be future releases or where there is time in the fabrication process on existing items to implement changes. The Midland project will review, concur with/ 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 from 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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i 8693 Attacament 2 +o MCAR 66, 17.teria Report 4 iib 673 St#9mRY OF DEFICIENCIES FOR MCAR 66(l)

Deficiency NCR/QAR Affected Twoe of Deficiencvi2) a.

Cut, nicked, broken strands 3, 9, 10, 11, 12, 15, W

28, 29, 34, 37 b.

Strands outside lug barrel 11, 12, 15, 36 W

c.

Undersize / Incorrect type wiring 5, 8, 31 W/E d.

Unidentified wiring 8, 31 E

e.

Minimum bond radius violation 9, 25 W/E f.

Conductor not terminated 2

W g.

Conductor pulled out of termination 2, 4, 7, 15, 19, 34, 36 W

h.

Conductor outside wireway / support 5, 7, 23, 31 W/E problem 1.

Conductor insulation inside lug barrel 15 W

j. Conductor insulation damaged 17, 24, 33 W

k.

Conductor not visible past lug barrel 19 W

l.

Loose terminations 11, 12, 13, 15, 17 W

18, 19, 25, 27, 34, 35, 36, 37 m.

More than two lugs on a terminal 5, 10, 22 E

n.

Class IE and non-Class IE apparently 5

E on same terminal o.

Color code violations 5, 7, 8, 16, 31, 33 E

p.

6-inch separation violations I, 5, 15, 35 E

q.

Lugs applied without proper tools 9, 13 W

r.

Incorrect size lugs / incorrect type 5, 8 10 ll 13, W/E lugs or terminations 14,II,13,18,29, 31, 35 s.

Excessive / inadequate solder in lugs 15, 35 W

t.

Terminal block ID missing / incorrect 5, 7, 8, 31, 34 W/E u.

Terminal block barrier missing / broken 28, 29, 32, 34 W

v.

Missing / inadequate inspection criteria 6, 7 E

w.

Appearance /worlunanship 5, 7, 9, 16, 17, 25, 33 W

(1) Only worlunanship deficiencies are included in the scope of MCAR 66.

(2) W = wortunanship E = engineering i

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I ATTACISBNT 3 NCAR 64. INTERIN REPORT 4 SUIstARY OF NCE*3/QAR'S g

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Workmanship N

Responsible purchase purchase Discrepancy W

Discipliae/

Order Order Indet Number Safety 10 CFR 50.55(e) t i

WCB/QAR Number Caesaar (7220-)

Vendor (see Attachment 2)

Impact Reportability Remarks

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13 N01-9-1-097 Control systems J-201(Q) Magnetics None NA NA Not a workmanship defielency - separatles removed from IICAR 66 scope i

2)

N01-9-1-114 Electrical E-51B(Q) solid State FG Mo No - See CPCo The workmanship discrepancy was required sad l

Controls, Inc.

Nck Block 17 satisfactorily relaspected.

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N01-9-1-095 s&W A

to be evaluated by CPCo W

4)

N01-9-0-075 Control systems J-201(Q) Magnetics G

No No - See CPCo Yeador followed proper procedures; equipment W

NCE Stock 17 was 100% satisfactorily laspected before shipment; disposittoa le to retighten and use as is, i

5) 3801-9-1-075 Nechselcal N-18(Q)

Delaval N. W No No - See CPCo Not all of the NCR portalas to NCAR 64.

Some NCE Block 17 ltens were given a disposition of "use as j

is."

FMP !ssued to correct discrepancles.

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N01-9-0-064 Nechaalcal N-118A(Q) ESV None NA NA Not a workmanship deficiency - removed from 30 CAR 66 scope (selsmic aselysts report i

required); reference com 078995 7)

N01-9-0-066 Nechaalcal M-118A(Q) ESV G. M. W No No - Swe CPCo Not all of the NCE pertales to NCAR 64; some NCR Block 17 discrepaneles u re destga related; reference 4

Com 108181

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8)

N01-9-0-068 Nechaalcal M-169(Q) Westinghouse C. R No No - See CPCo Reference com 022547 IsCR Block 17 9) 1801-9-1-008 Electrical E-Sle(Q) solid State A, E, Q. W No No - See CPCo Reference com 022114 Controls, Inc.

NCR Block 17

10) M01-9-0-063 Electrical E-11(Q)

Solid State A. R No No - see CPCo Disposittoa is to "use as is"; reference l

E-19(Q)

Controls, tac NCR Block 17 Com 040595 E-51E(Q)

11) N01-9-0-071 Electrical E-205(Q) ITE A

B, L. R No No - See CPCo Reference com 044815 NCR Block 17

12) QAR F-010 Electrical E-205(Q) ITE A, 3. L No No Same as NCE 1801-9-0-071

13) N01-9-1-024 Nechanical N-150(Q) Nine Safety L. Q. E h

ho - See CPCo Reference com 040488 NCR Block 17

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u SUISIARY OF NCR'5/QAR's (Contleued)

Workmanship Responsible Purchase Purchase Discrepancy Discipline /

Ceder Order Indes Number safety 10 CFR 50.55(e)

NCR/QAR Number Comeaan (7220-)

Vendor (see Attscheent 2)

Issect Reportability Remarks a

14) QAR SD-332 Control Systems J-207(Q) several R

No No Not a workaasship discrepancy (control J-275(Q) systems), but sa laspection problem -

J-231(Q)

(mechselcal) (esference com 102704); -.

i J-284(Q) vendors used lasulated luge m

i Electrical E-6(Q)

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E-7(Q)

Nechaalcal N-18(Q)

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W M-150(Q) w r

j N-169(Q) g f f t

15) N01-9-1-128 Control systems J-201(Q) Magnetics A. R. C I, L. 5 No No - See CPCo Reference com 089839; seen probles as i

NCE ticek 17 N01-9-0-075 l

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16) 301-9-1-136 Nechaalcal N-18(Q)

Delaval W

No No - See CPCo Origlaal perchase order did act require the f

i NCE 81ock 17 listed as discrepaneles (reference Cea 4 -

095715); Dc7 lesued to repelr discrepeacles 4

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17) 301-9-1-129 Control syste'es J-201(Q) Magnetics J.L.W No No - See CPCo Fleid to rework fleid damage and rettshton

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NCR Block 17 loose vendor terstaations i

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18) N01-9-1-140 Electrical E-7(Q)

ITE L

No No - See CPCo Reference com 049432 1

NCR Block 17 f

19) N01-9-1-142 Electrical E-7(Q)

ITE C, E. L No No - see CPCo Reference com 049431 NCR Stock 17 g

20) QAR 50-382 NA NA NA NA NA NA Volded j

21) QAR F-007 Electrical E-7(Q)

ITE None NA NA Dlopcsttlon is to "use as is"; removed from f

).

NCAR 66 scope lI l

22) 301-9-0-067 Nechanical N-150(Q) Nine safety None NA NA Reference Com 088397; removed from NCAR 66 i

scope

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23) QAR F-070 Electrical E-51a(Q) solid state None NA NA Dispositlos !s to "use se 1s"; removed from l;

Controls. Inc.

NCAR 66 scope; Reference com 042026 ij

24) N01-6-1-043 Electrical E-7(Q)

ITE None NA NA Destga consideretton mot lacluded la the scope of NCAR 66 a

25) QAR F-114 Electrical E-19(Q) solid State E. L. W No No Reference com 044010; discrepeacles were Controls Inc.

repaired

26) N01-9-1-120 NA NA NA NA NA NA Volded 2

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34NERART OF NC8'3/QAR's (Coat tooed) i Le Workasashly Seepoesible Purchase Purchase Discrepeacy Discipline /

Order order Indes Number Safety 10 CFR 50.55(e) l NCS/QAR Number ceaseau (7220-)

Vendor (see Attachment 2)

Impact Reportability Remarks df

27) N01-9-1-139 Electrical E-7(Q)

ITE L

No No - See CPCo Reference com 048442 NCa stock 17 j -,

28) 301-9-1-150 B&W A, a, U to be evaluated by CPCo CX3

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29) QAR F-133 NA NA NA NA NA NA Volded CD

30) N01-9-1-137 MA NA NA NA NA NA Volded LO CD

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31) N01-9-1-151 Nechaalcal N-169(Q) Westlaghouse C, D, N, O. R. T No No - See CPCo Reference com 094341 N

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NCE Block 17 w

32) N01-9-2-082 B&W U

To be evaluated by CPCo

33) N01-9-2-150 control Systems J-275(Q) Vitro J, 0, W No No Reference scaE 66; reference com 102311 3

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34) N01-9-2-139 Nechaalcal M-18 Delaval A. L C, U Open (reference SCRE 64); vendor mottfled via com 111741; vendor evaluatlos is regelred.

35) N01-9-2-173 Nechaalcal N-14 Terry Turblaet L. E, 3 No - See CPCo Open (reference SCRE 68 and Com 100170);

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NCE Block 24 vender motified via com 111926; vendor evaluatloa is required.

y Willamette

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36) N01-9-3-089 Control Systems J-284(Q) Constp L, 8, C No No - See CPCo Open; added to MCAR 66 la accordance with

'i WCR Block 24 CPCo serial 20749 (3/30/83); vendor will 4

repale discrepancies.

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37) N01-9-3-098 Control Systems J-202(Q) Marlo A. L No No - See CPCo Open; added to NCAR 66 la accordance with i:j.

NCR Block 24 CPCo Serial 20749 (3/30/83); vendor will repele discrepancies.

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