ML20080N222

Final Deficiency Rept Re Namco Controls Limit Switches Mfg to Inadequately Implemented QA Program.Initially Reported on 810210.Bill of Matl Spec (SP793-05-4549-00) Developed, Reviewed & Approved for Procurement of Namco Switches

ML20080N222
Person / Time
Site:	Perry
Issue date:	09/27/1983
From:	Edelman M CLEVELAND ELECTRIC ILLUMINATING CO.
To:	James Keppler NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III)
References
10CFR-050.55E, 10CFR-50.55E, RDC-26(81), NUDOCS 8310040404
Download: ML20080N222 (3)

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P.O. box 5000 - CLEVELAND. oHto 44101 - TELEPHONE (216) 622-9800 - lLLUMINATING BLDG. - 55 PUBLICSQUARE Serving The Best Location in the Nation MURRAY R. EDELMAN VICE PRESIDENT September 27, 1983 NUCMAR Mr. James G. Keppler Regional Adainistrator, Region III Office of Inspection and Enforcement U.S. Nuclear Regulatory Commission 799 Roosevelt Road Glen Ellyn, Illinois 60137 RE: Perry Nuclear Power Plant Docket Nos. 50-440; 50-441 NAMCO Limit Switches

[RDC 26(81)]

Dear Mr. Keppler:

This letter serves as our Final Report pursuant to 10CFR50.55(e) concerning NAMCO Controls limit switches which were manufactured to an inadequately implemented Quality Assurance Program. This problem was originally identified to Mr. R. Landsman at your Region III of fice on February 10, 1981, by Mr. W. J.

Kacer of The Cleveland Electric Illuminating Company. Previously submitted interim reports were transmitted on February 11, 1981; August 28, 1981; and October 29, 1982.

This report contains a Description of the Deficiency, an Analysis of Safety Implications and the Cortective Action Taken.

Description of Deficiency The Cleveland Electric illuminating Company (CEI) awarded procurement specifi-cations to various valve vendors for the fabrication of equipment to be installed in the Perry Nuclear Power Plant. These specifications required our vendors to procure NAMCO limit switches, Model EA 180 and EA 740 to be installed on some of these valves. As a result of an audit conducted by CEI Quality Assurance, it was determined that the overall NAMC0 Controls Quality Assurance Program was inadequate in implementing requirements defined by their Quality Assurance Manual, 10CFR50, Appendix B, and CEI's Quality Assurance requirements.

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Mr. Jc:aa G. Keppler Srptembsr 27, 1983 Analysis of Safety Implications Without an adequate NAMCO Quality Assurance Program, there is no assurance that the product CEI has received was fabricated the same as the prototype which NAMCO qualified to IEEE .323. Without an effective quality program implemented on the fabrication of the NAMCO limit switches, CEI could not place any credibility in NAMCO's Certificate of Compliance supplied with the limit switches.

Corrective Action Taken The following serves as a summation of the corrective actions which have seen completed, including, the steps taken to prevent inadvertent use of questionable limit switches. Also reflected are the steps taken to verify that an effective and implemented Quality Assurance Program, consistent with the requirements of 10CFR50, App. B, was in place at NAMCO Controls during the manufacture of limit switches procured directly by CEI.

Initially, the questionable limit switches procured from NAMCO by CEI's vendors, to be used'in a safety-related application, were and remain tagged " nonconforming" and placed on hold to prevent inadvertent use. This was done in accordance with Project Administration procedures for the control of nonconforming items.

-/'ABillofMaterialspecification(SP793-05-4549-00) was developed, reviewed, approved and issued for the procurement of NAMCO limit switches. This speci-fication identified specific quality assurance requirements to be implemented by NAMCO Controls prior to and during the manuf acturing cycle of the limit switches. The Quality Assurance Program requirements included specific proce-dures and documentation to be submitted for review and approval prior to and I

at the completion of manufacture.

A pre-award survey was conducted July 28 and 29,1981, at the NAMCO Controls f acility in Jef ferson, Ohio. The purpose of this survey was to assess the adequacy, effectiveness and implementation of NAMCO's revised Quality Assurance Program. In general, conditions were found to be acceptable, however, several deficiencies were noted. These deficiencies were documented and subsequently i

resolved.

After review of NAMCO's pre-manufacturing cycle documents, a fabrication release was issued to NAMCO on April 15, 1982. The entire fabrication and assembly process was witnessed by a Perry Project Inspector. The results of this inspection trip were documented in inspection trip report 090-1 dated

.May 3, 1982. In addition, an on-site receiving inspection was conducted and documented in accordance with Project Administration procedures.

At present, installation of the limit switches is being directed by the Nuclear Construction Engineering Section of the Project Organization. The NAMCO Controls' qualification test plans are currently being reviewed by GAI Engineering. Testing is expected to begin at the end of September 1983 and scheduled to be completed in July 1984.

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Mr. James G. Kappler Szptember 27, 1983 In reviewing the correspondence on this subject, it has been determined that all corrective actions necessary for resolution of the reported deficiency have been completed. The issuance of a final report concerning this matter, therefore, is not being delayed pending completion of the qualification program'or. replacement of the questionable limit switches.

Please call'if there are any additional questions.

Sincerely, Murray R. Edelman Vice President Nuclear Group MRE:pab cc: Mr. M. L. Gildner NRC Site Office Director Office of Inspection and Enforcement U.S. Nuclear Regulatory Commission Washington, D.C. 20555 U.S. Nuclear Regulatory Commission c/o Document Management Branch -

Washington, D.C. 20555 Records Center, SEE-IN Institute of Nuclear Power Operations 1100 Circle 75 Parkway, Suite 1500 Atlanta, Georgia 30339 4 P y . . , - . . ,. , , , - - . _ _ . . , , . . -

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