ML20133C400
| ML20133C400 | |
| Person / Time | |
|---|---|
| Issue date: | 09/11/1985 |
| From: | Merschoff E, Petrosino J NRC OFFICE OF INSPECTION & ENFORCEMENT (IE) |
| To: | |
| Shared Package | |
| ML20133C389 | List: |
| References | |
| REF-QA-99900827 NUDOCS 8510070342 | |
| Download: ML20133C400 (4) | |
Text
ORGANIZATION: ELMA ENGINEERING INCORPORATED PALO ALTO, CALIFORNIA REPORT INSPECTION INSPECTION NO : 99900827/85-01 DATE(S): May 1, 1985 ON-SITE HOURS: 6 CORRESPONDENCE ADDRESS: Elma ingineering Incorporatea ATTN: Mr. Thomas A. Beno Vice President and QA Manager 1066 East Meadow Circle Palo Alto, California 94303 ORGANIZATIONAL CONTACT: Mr. Thomas A. Beno, QA Manager TELEPHONE NUMBER: (415) 494-7303 PRINCIPAL PRODUCT: Cast Coil Transformers and D.C. Power Supplies.
NUCLEAR INDUSTRY ACTIVITY: Approximately 1%.
i ASSIGNED INSPECTOR: 9[ # 85 J J/Pe osino, Reactive Inspection Section (RIS) / Date OTHER INSPECTOR (S):
APPROVED BY: 4 E. W. MerschoF( j Chief, RIS, Vendor Program Branch Date INSPECTION BASES AND SCOPE:
A. BASES: 10 CFR Part 21.
B. SCOPE: Review vendor-licensee actions regarding Elma EigT6eering Inc. (EEI) ferroresonant power supplies (FPS).
PLANT SITE APPLICABILITY: Diablo Canyon 1 & 2 (50-275/346), Vermont Yankee (50-271), Limerick 1 & 2 (50-352/353), Peach Bottom 2 & 3 (50-277/278), Enrico Fermi (50-341), Browns Ferry 1, 2, & 3 (50-259/260/296), and Susquehanna 1 & 2 (50-387/388). Additionally, other plants are pending identification, see section C.
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.0RGANIZATION: ELMA ENGINEERING INCORPORATED PALO ALTO, CALIFORNIA REPORT INSPECTION NO.- 99900827/85-01 RESULTS: PAGE 2 of 4 j
A. INSPECTION ISSUES:
e
- 1. Defective wiring, inadequately soldered wire connections and overall poor workmanship problems identified in a Tennessee Valley Authority (TVA) Browns Ferry 10 CFR Part 21 report dated January 11, 1984.
- 2. Apparent deficiencies in the implementation of EEI's quality assurance program.
- 3. EEI's failure to evaluate and report deficiencies in accordance with the requirements of 10 CFR Part 21.
B. BACKGROUND:
- 1. Poor workmanship problems with EEI ferroresonant power supply units were identified by TVA in a January 1984, 10 CFR Part 21 report.
Following this report, Nutherm International (NI) notified the NRC of EEI FPS units with inadequately soldered wire connections and a leaky oil filled capacitor. The soldering problems included inadequate fusion, cold solder joints, excessive solder application, inadequate solder, and lack of mechanical bond prior to soldering.
The deficiencies were visible by removing the lower component mounting plate of EEI's FPS units.
- 2. During a Vendor Program Branch inspection of EEI in November 1984 the following deficiencies in eel's manufacturing process control and quality assurance programs were identified. These problems are identified as violations and nonconformances en Vendor Program Branch inspection report #99900827/84-01.
r a) EEI failed to provide complete documentation on the production q
test data sheets or maintain an adequate schedule for equipment
/ calibration.
b) Inspection and test personnel were not free of assembly responsibility and could inspect work activities which they performed.
c) An electrical test technician qualification record was not maintained.
d) Procedures to control and identify wire stripping and crimping tools, provide unique test equipment identification numbers, and verify inprocess production activities in accordance with the requirements were inadequate.
r
.0RGANIZATION: ELMA ENGINEERING INCORPORATED PALO ALTO, CALIFORNIA REPORT INSPECTION NO - 99900827/85-01 RESULTS: PAGE 3 of 4 I
e) EEI failed to have a QA Manual that conformed to ANSI N45.2 Standards, f) EEI did not meet the requirements of 10 CFR Part 21 with regard to evaluation and reporting of defects, adoption of procedures, and posting of documents. There were three separate occurrences where EEI failed to evaluate deviations for reportability, or provide the information to their customers for evaluation.
Subsequent to the inspection, EEI has taken steps to correct the above items. These corrective actions have been reviewed and found to be responsive to the findings in Vendor Program Branch inspection report #99900827/84-01. Implementation of the corrective actions will be reviewed during a future inspection.
l C. POTENTIAL NUCLEAR APPLICATIONS:
Records were reviewed to determine nuclear application of EEI's ferroresonant power supplies. The following list of customers and the number of FPS units that each received was identified. However, it has not been determined which nuclear plants were supplied EEI FPS units by General Electric Company and Reliance Electric Company. Future inspection at these two locations will be scheduled.
CUSTOMER LIST CUSTOMER ELMA REFERENCE NUMBER UNITS PURCHASED YEAR GE-Lompoc. CA 4805, 4859 34 1978 GE-San Jose, CA 4808, 4827, 4829, 4841, 33 1978 4866, 4894, 4928, 4943 GE-Lompoc, CA 5035 8 1979 GE-Daytona Beach, FL 4778 8 1978 GE-Daytona B'each, FL 5075, 5099, 5028 14 1979 GE-San Jose, CA 4037, 4043, 4224, 4358, 91 1977/1978 4407, 4494, 4511, 4513, 4519, 4584, 4666, 4675, 4677, 4689, 4704, 4712
ORGANIZATION: ELMA ENGINEERING INCORPORATED PALO ALT 0, CALIFORNIA f REPORT INSPECTION l NO.- 99900827/85-01 RESULTS: PAGE 4 of 4 l
l CUSTOMER ELMA REFERENCE NUMBER UNITS PURCHASED YEAR GE-San Jose, CA 4961, 4996, 5055, 4954 113 1979 4968, 4984, 4987, 4994, !
4997, 5013, 5030, 5033 5071, 5069, 5065, 5082, 5097, 5101, 5132, 5137, 5145, 5183 Pacific Gas & Electric 4520 1 1979 Vermont Yankee Nuclear 5124, 5361 7 1979 Vermont Yankee Nuclear 5361, 5437, 5450 6 1980/1981 Philadelphia Elec. Co. 5231, 5495 5 1980/1981 Philadelphia Elec. Co. 5616, 5794 8 1982/1983 GE-Philadelphia 5794 4 1983 Nutherm International 5470 41 1981 Nutherm International 5720 10 1983 Detroit Edison 5494 1 1981 TVA 5738 2 1983 Reliance Electric-GA 5799 8 1984 GE-San Jose, CA 5828, 5902 3 1984 Vermont Yankee Nuclear 5865 2 1984 Penn. Power & Li9nt 5867 1 1984 D.
SUMMARY
Based on the deficiencies in the implementation of EEI's QA Program, and the hardware deficiencies which resulted, all of the above listed FPS units may contain deficiencies of the type described in this report.
E. PERSONS CONTACTED:
Mr. Thomas A. Beno, Vice President and QA Manager, EEI F. DOCUMENTS EXAMINED A selective review of Elma Engineering's customer purchase orders and customer log books was performed.
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