ML20076J552

Interim Deficiency Rept Re Delivered safety-related Electrical Equipment Not Meeting Project Requirements.Task Force Established to Investigate & Resolve Mcar 66.Next Rept by 830812

ML20076J552
Person / Time
Site:	Midland
Issue date:	06/29/1983
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, 22241, 82-16-#4, NUDOCS 8307060011
Download: ML20076J552 (10)

Text

_ _ _ _ _ _ _

h 1

CODSumBIS Power l

u-w c a Vice President - Projects, Engineen.ng and Constructwn General offices: 1945 West Parnall Road, Jackson, MI 49201. (517) 788-0453 June 29, 1983 82-16 #4 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: 22241

Reference:

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 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 August 12, 1983.

% d. M JWC/WRB/cd Attachment A: MCAR-66, Interim eport 4, dated June 14, 1983 CC: Document Control Desk, NRC Washington, DC RJCook, NRC Resident Inspector Midland Nuclear Plant Ik k

hkI$$h g \\g OC0683-0023A-MP01 S

PDR

2 Serial 22241 82-16 #4 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 INPO Records Center OC0683-0023A-MP01

/

1i8693 Attachment A I i 8 6lgehhtel 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 i

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, ase of improper wire lugs, and improper crimping have been identified on electrical 3

control panels and cabinets supplied by various vendors.

Probable Cause i

The cause for the deficiencies is being investigated and the results will be included in a future report. Preliminary results have been 2

reviewed and no significant problems have been identified.

Summary of Investiaation and Historical Backaround To date, 37 discrepancy reports (nonconformsnce reports (NCRs) and quality action requests (QARs)) have been written on electrical equipment as a result of NPQAD 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 NCAR.

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

Analysis of Safety Implications To date, 31 NCRs/QARs have been evaluated for possible impact on safety. For the cases analyzed, it is concluded that if the i

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 e

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 p

0346u

~...,

.,._._,,-,,,,...m.,.7,.,,

-,,--e-r-e-,

,---,,,.-,...,--.-e

,-w,,,

.,m..,..w.ww.

-- -,.. - -.., + -.

r

,y,m--ww,,e-

--e-.a--

li8673 iib 693 l

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 Compaay.

Corrective Action A task force has been established to investigate and resolve MCAR 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 sumanarize 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 Implications 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 work:aanship 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 i

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.

0346u

..-.n~

.a---

--.o q-.,a v,. n ag e s

~- - --.

-~..w.y s..

_v.-,

,p.3

iib 693

,1i8673 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 commodities.

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 fian pull on the termination. MPQAD will continue to investigate termination inspection criteria.

Reportab111tv This condition was reported to the NRC by Consumers Power Company as potentially reportable on December 3, 1982.

Submitted by:

rno I.G. Kovach Cognizant Group Supervisor Approved by:

E.M. Hughes Q Project Engineer Concurrence w

R.L. Castleberry Cognizant Di'scipline Chief Concurrence by:

W E.H. Smith Engineering Manager Concurrence by:

fpfM.A.Dietrich Project Quality Assurance Engineer Attachments:

1. MCAR 66 Task Force Charter

2. Summary of Deficiencies for MCAR 66

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

1i8693 Ii8673 ittecha.nt 1 to MCAR 66, Interin R3 port 4 l

TASK FORCE CHARTER l

1.

Review the findings from MPQAD'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, B.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. Based 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 NCAR 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.

(

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, an!. 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-78.

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).

0346u f

l A Y22. T .1,' M

• 1.' **.T a * * ?"*

_ _ t '2.';,^*

.K',*^*?.',3*. W % ' : \\ ' ',:,R* [ * * {

"**K,

• T *'# ' ? [ } }[

t.

i i 8693 m act en+ 2 to MCAR 66,

=

Interia Report 4 iib 673 SUlmARY OF DEFICIENCIES FOR MCAR 66(l)

Deficiency NCR/QAR Affected Type of Deficiencv(2) l a.

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

28, 29, 34, 37 b.

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

)

c.

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

Unidentified wiring

(,,

31 E

e.

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

Conductor not terminated 2

W g.

Conductor pulled out of termination 2, 4, 7, 15, 19, 34, M 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 tw 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, li, 13, W/E lugs or terminations 14, 21, 23,.!8, 29, 31, 35 s.

Excessive / Inadequate sole r 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 /worlunenship 5, 7, 9, 16, 17, 25, 33 W

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

(2) W = woriumanship E = engineering 0346u i

om.,~..

... #.m.m. m m..,. ~

._m

....m_.......,

,m7-.

(

ATTACNNENT 3 NCAR 66. INTERI2 REPORT 4 s

SUlgtARY OF NCR'S/QAR'S g

l CF)

Workmanship N

Responsible purchase purchase Discrepancy C,A) 4 l

Discipline /

Grder Order Inden Number Safety 10 CPR SO.55(e)

< i WCR/QAR Nveber Cossanu (7220-)

Vendor (see Attachment 2)

Impact Reportability Remarks 1) 901-9-1-097 Control Systems J-201(Q) Magnetics None NA NA Not a workmanship deficiency - separation f

removed from NCAR 66 scope

~~~

i l

2)

N01-9-1-114 Electrical E-51B(Q) solid State F. C No No - See CPCo The worknaaehty discrepancy was required and Controls, lac.

NCR Block 17 satisfactorily relaspected.

O 3)

N01-9-1-095 56W A

To be evaluated by CPCo LO 4)

N01-9-0-075 Control Systems J-201(Q) Magnetics C

No No - See CPCo Vendor followed proper procedures; equipment LA)

.l NCR Block 17 was 100E setlefactorily laspected before shipment; disposition is to retighten and use as is.

5)

N01-9-1-075 Nechaalcal N-18(Q)

Delaval N. W No No - See CPCo Not all of the NCR portalas to NCAR 66.

Some NCR Block 17 ltens were given a dispoeltlos of "use as is."

FMP issued to correct discrepancies.

6)

N01-9-0-064 Nechaalcal M-118A(Q) EBV None NA NA Not a workmanship deficiency - removed from l

MCAR 66 scope (selsene analysis report j

required); reference com 078995 i

7)

N01-9-0-066 Nechaalcal N-118A(Q) E8V C

H, W No No - See CPCo Not all of the NCR portalas to NCAR 66; some i

MCR Block 17 discrepancies were design related; reference l

Com 108181 8)

N01-9-0-068 Nechsalcal N-169(Q) Westinghouse C, R No No - See CPCo Reference com 022547 l

NCR Block 17 9)

N01-9-1-008 Electrical E-51B(Q) solid State A. E, 9. W No No - See CPCo Reference com 022114 controls Inc.

NCR Block 17 it) N01-9-0-063 Electrleal E-11(Q)

Solid State A, R No No - See CPCo Disposillon is to "use se Is"; reference E-19(Q)

Controls, Inc NCR Block 17 Com 040595 E-51B(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 r

12) QAR F-010 Electr! cal E-205(Q) ITE A, B. L No No Sr.no as NCR N01-9-0-071

13) N01-9-1-024 Nechanical N-150(Q) Nine safety L,Q.R No No - See CPCo Reference com 048488 NCR Block 17 0284u.

1

.o SUISRARY OF NCR'3/0AR's (Coattaued)

'i.

Workmanship Responsible Purchase purchase Discrepancy i

Discipline /

Order Order Indes Number Safety 10 CFR 50.55(e)

HCS/QAR Number Cossaat (72?0-) _ Vendor itee Attechaset ?)

Impact Reportability Remarks i,

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

No No Nat a workmanship discrepancy (control J-275(Q) systems). but sa laspection problem -

J-281(Q)

(mechaalcal) (reference com 102704); -.

(t J-284(Q) vendors used lasulated luge CE)

~~"

Electrical E-6(Q)

E-7tQ)

CO i,'

Nechaalcal N-18(Q)

C71 N

M-150(Q)

W w

j N-169(Q) g t

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

1 NCR Block 17 N01-9-0-075 1

[*

16) N01-9-1-136 Nechaalcal N-18(Q)

Delaval W

No No - See CPCo Origleal purchase order did not require the NCR Block 17 listed as discrepancies (reference com 095715); DCP leeued to repair discrepancles

,j ;

5

17) N01-9-1-129 Control Systems J-201(Q) Magnetics J. L. W No No - See CPCo Field to rework fleid damage and retighton NCR Block 17 loose vendor teralaations

)

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

ITE L

No No - See CPCo Reference com 049432

)

NCE Block 17

'I i

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

ITE C. E. L No No - See CPCo Reference com 049431 j

NCE Block 17 gf

21) QAR SD-382 NA NA NA NA NA NA Volded j'

I f

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

ITE None NA NA Disposition le to "use as is"; removed from i

jJ.

MCAR 66 scope 1i l

22) N01-9-0-067 Nechaalcal N-150(Q) Mlae safety None NA NA Reference Com 088397; removed free NCAR 66 a

i scope l -i l

23) QAR F-070 Electrical E-51B(Q) Solid State None NA NA Dispositlos is to "use as is"; removed from

(}

Controls. Inc.

MCAR 66 scope; Reference com 042026

.i

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

III None NA NA Design consideration act lacluded la the

(&

scope of MCAR 66 l 6

25) QAR F-114 Electrical E-19(Q)

Solid State E. L. W No No Reference com 044010; discrepeacles were Contecle. Inc, repaired

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

C284u, 2

a

BENEl&RY OF WCR*3/0&R's (ContIamed) i e ii e

i!

Workmansbly j -

Discipline /

Order Order Indes Number Safety 10 CFR 50.55(e)

Responsible purchase purchase Discrepancy li NCR/QAR Number comoaan (7220-)

Vendor (see Attachment 2)

Insect Reportability Remarks E

lj f

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

ITE L

No No - See CPCo Reference com 048642 NCE Block 17

(

'!!.i l

20) 301-9-1-150 B&W A. R, U To be evaluated by CPCo

i 03

{

29) QAR F-133 NA NA NA NA NA NA Volded oy w

en l'

30) N01-9-1-137 NA NA NA NA hA NA Volded

I Cd CT3

• )

31) N01-9-1-151 Nechaalcal N-169(Q) Westinghouse C, D, N, 0, R, 7 No No - See CPCo Reference com 096341 N

Mi NCR Block 17 W

s.1 i

.J

32) N01-9-2-002 B&W U

To be evaluated by CPCo J1

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

'a

• )

30 N01-9-2-139 Nechaalcal N-18 Delaval A. L. C, U Open (referents SCRE 64); vendor actified via com 111741; vendce evaluatlos is re9ulted.

35) N01-9-2-173 Nechaalcal N-14 Terry Turbloe/ L. R, 3 No - See CPC9 Open (reference SCRE 64 and Com 100170);

!?

((

Blagham -

NCR Block 24 voador actifled via com 111926; vendor

y,

evaluation is retuired.

Willamette q,

? 't

+

lj

36) N01-9-3-049 Control Systeme J-284(Q) Consip L. B. G No No - See CPCo Open; added to NCAR 66 la accordance with t

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

h repele discrepancies.

l ':

O{,

37) N01-9-3-098 Control systems J-202(Q) Narlo A. L No No - See CPCo Open; added to NCAR 66 la accordance with NCR Block 24 CPCo Serial 20749 (3/30/83); vendor will

!a repele discrepancies.

.1 d

d ay 3n l'

I

!i Q

i

{

0284u,

3 1

a