ML20136B050
| ML20136B050 | |
| Person / Time | |
|---|---|
| Issue date: | 09/27/1990 |
| From: | Brach E Office of Nuclear Reactor Regulation |
| To: | Vorse J NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION II) |
| Shared Package | |
| ML20136A614 | List: |
| References | |
| FOIA-96-475 NUDOCS 9703100138 | |
| Download: ML20136B050 (10) | |
Text
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/parto o UNITED STATES u NUCLEAR REGULATORY COMMISSION I' n
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, ,3 W ASHINGTON, D. C. 20555 j,e...A September 27, 1990 g CIf, c n!! 13 LIMITED DISTRIBUTION - NOT FOR PUBLIC DISCLOSURE FIP.. . ,_.. . -
MEMORANDUM FOR: James Y. Vorse, Director Office of Investigations, Field Office Region II FROM: E. William Brach, Chief Vendor Inspection Branch l Division of Reactor Inspection and Safeguards Office of Nuclear Reactor Regulation l
SUBJECT:
REPORTS OF VIB VISITS TO SPECTRONICS, ST0KLEY, POTTER &
BRUMFIELD (P&B), AND NUTHERM TO REVIEW P&B-RELAYS l
l l I am enclosing the following trip reports, prepared by Mr. K. R. Naidu of my l
staff, which document the results of the review of P&B rotary-type relays at l
the following locations:
Potter & Brumfield, Princeton, Indiana 99901213 Stokley Enterprises, Inc., Norfolk, Virginia 99901202 j Spectronics, Inc., Mobile, Alabama 99901201 1 Nutherm International, Inc., Mt. Vernon, Illinois 99900779 These reports are forwarded for your review and use in ongoing OI investigations. These reports will not be released to the public pending your approval that such release is appropriate.
l If you have any questions concerning this information, please contact me or Kamalakar R. Naidu at FTS 492-0980.
'/ }U%
E. William ach, Chief Vendor Inspection Branch Division of Reactor Inspection 4 and Safeguards Office of Nuclear Reactor Regulation
Enclosures:
As stated
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LIMITED DISTRIBUTION - NOT FOR PUBLIC DISCLOSURE .
L. s 9703100138 970301 '
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LAMBERT 96-475 PDR '/ g ,q
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Enclosure 1 VIB VISIT TO POTTER & BRUMFIELD, INCORPORATED, j IN PRINCETON,-INDIANA Prepared by: K. R. Naidu, Vendur Inspection Branch I Visit Conducted: June 20-21, 1990 l
i Docket Number: 99901213
?
l 1. Purpose The purpose of this visit was to observe visual inspections and electrical tests on 22 MDR-type rotary relays. These relays.were originally manufactured by Potter & Brumfield, Incorporated (P&B), of Princeton, 4
Indiana. The NRC obtained the relays from the Shearon Harris nuclear l power plant (Shearon Harris).
! 2. Backgroung Information 4
[ Carolina Power & Light Company (CP&L), the licensee for Shearon Harris, issued a purchase order to Spectronics, Inc., of Mobile, Alabama, for 22 MDR-type P&B commercial-grade relays. The CP&L purchase order stated that a
the relays were commercial-grade and therefore did not involve either
- 10 CFR 50, Appendix B, or 10 CFR Part 21. In response to_this purchase
'1 order, Shearon Harris received 22 relays from Stokley Enterprises, Inc.,
(Stokley) a subvendor to Spectronics. Upon receipt inspection, the Shearon Harris plant personnel inspected the relays and identified several deviations which indicated that the relays may have been refurbished.
! Shearon Harris immediately informed the NRC that they may have received refurbished P&B relays.
The NRC inspected the 22 MDR-type rotary P&B relays supplied.by Stokley on June 14, 1990, at the Shearon Harris plant. The NRC inspector verified the deficient conditions that had been identified by Shearon Harris during the receipt inspection of the relays. The NRC arranged for the transportation of the relays to P&B's manufacturing facility for visual inspections and electrical tests. The 22 relays consisted of the following:
12 MDR-138-8, 8-Pole Double-Throw (PDT),125 V de relays 6 MDR-178-1,16 PDT,125 V de relays 4 MDR-142-1, 24 PDT,125 V de relays
- 3. Observation of Inspection and Tests The inspector observed the visual inspections and electrical tests performed on the above relays by P&B personnel utilizing standard factory procedures. P&B documented the results in inspection and test reports.
P&B personnel disassembled three relays and inspected the internals. P&B determined that subcomponents of various vintage relays had been used to assemble each relay.
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- 4. Persons Contacted Potter & Brumfield M. J. Scully . Director, Quality Assurance & Approvals l Chief Engineer l R. Lamb H. Andrews Application Engineer R. Market Application Engineer l
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Enclosure 2 VIB VISIT TO ST0KLEY ENTERPRISES, INCORPORATED, IN NORFOLK, VIRGINA Prepared by: K. R. Naidu, Vendor Inspection Branch Visit Conducted: June 27-28, 1990 Docket Number: 99901201 I
- 1. Purpose i The purpose of this visit was to establish if Stokley Enterprises, l
Incorporated (Stokley), provided refurbished MDR-type rotary relays, originally manufactured by Potter & Brumfield, Incorporated (P&B), of .
Princeton, Indiana, either directly or through distributors to nuclear power plants.
- 2. Background Information Carolina Power & Light Company (CP&L), the licensee for Shearon Harris nuclear power plant (Shearon Harris), issued a purchase order to Spectronics, Inc. (Spectronics), of Mobile, Alabama, for 22 MDR-type P&B commercial-grade relays. Shearon Harris received 22 relays from Stokley (a subvendor to Spectronics). Upon receipt inspection Shearon Harris plant personnel identified several deviations which indicated that the relays may have been refurbished. Shearon Harris imediately informed the NRC that they may have received refurbished P&B relays. l Tha NRC inspected the 22 MDR-type rotary P&B relays supplied by Stokley on )
June 14, 1990, at the Shearon Harris plant. The NRC inspector verified 1 the deficient conditions that had been identified by the Shearon Harris I plant personnel during the receipt inspection of the relays. The 22 relays consisted of the following:
12 MDR-138-8, 8-Pole Double-Throw (PDT),125 V dc relays 6 MDR-178-1,16 PDT,125 V de relays 4 MDR-142-1, 24 PDT,125 V de relays
- 3. Observation of Work Activities The inspector observed that Stokley's inventory consisted of new and used i electric and electronic components including P&B relays. Mr. Stokley stated that he purchased the components at auctions. The inspector observed personnel using various equipment to clean and paint used components. 1 i
- 4. Review of Records l
l The inspector reviewed records that included invoices, sales i
! receipts, Stokley's purchase orders (P0s) to subvendors for !
i duplicate name plates, and P0s received by Stokley for various !
components. The inspector also reviewed several P0s from EXHIBIT T l PAGE 4 0F /0 PAGE(S)
Spectronics for MDR-type P&B relays. These P0s included instructions to convert P&B relays from one model to another. The inspector's review confirmed that Stokley supplied 22 refurbished HDR-type relays to Shearon Harris to fulfill a P0 from Spectronics.
- 5. Persons Contacted W. Stokley President, Stokley Enterprises, Incorporated l l
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Enclosure 3 VIB VISIT TO SPECTRONICS, INCORPORATED, IN MOBILE, ALABAMA Prepared by: K.R. Naidu, Vendor Inspection Branch Visit Conducted: July 2-3,1990 l Docket Number: 99901201
- 1. Purpose The purpose of this visit was to establish if Spectronics, Incorporated (Spectronics), of Mobile, Alabama, provided refurbished MDR-type rotary relays, originally manufactured by Potter & Brumfield, Incorporated, (P&B), of Princeton, Indiana, to nuclear power plants either directly or through distributors to nuclear power plants.
- 2. Background Information Carolina Power & Light Company (CP&L), the licensee for Shearon Harris, issued a purchase order to Spectronics, Inc., of Mobile, Alabama, for 22 MDR-type P&B commercial-grade relays. The CP&L purchase order stated that the relays were commercial-grade and therefore did not involve either 10 CFR 50, Appendix B or 10 CFR Part 21. In response to this purchase order, Shearon Harris received 22 relays from Stokley Enterprises, Inc.,
(Stokley) a subvendor to Spectronics. Upon receipt inspection, the Shearon Harris plant personnel inspected the relays and identified several deviations which indicated that the relays may have been refurbished.
Shearon Harris immediately informed the NRC that they may have received refurbished P&B relays.
The NRC inspected the 22 MDR-type rotary P&B relays supplied by Stokley on .
June 14, 1990, at the Shearon Harris plant. The NRC inspector verified I the deficient conditions that had been identified by Shearon Harris during the receipt inspection of the relays. The NRC arranged for the 4 transportation of the relays to P&B's manufacturing facility for visual inspections and electrical tests. The 22 relays consisted of the following:
12 MDR-138-8, 8-Pole Double-Throw (PDT), 125 V dc relays 6 MDR-178-1,16 PDT,125 Y de relays 4 MDR-142-1, 24 PDT,125 Y de relays
- 3. Observation of Work Activities The inspector observed that Spectronics was an authorized dealer for several product lines including P&B relays. The inspector observed several P&B relays in their original boxes along with three MDR-170-2 relays that were supplied by Stokley.
EXHIBIT I PAGE ' 0F /0 PAGE(S)
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- 4. Review of Records The inspector reviewed records that included invoices, sales receipts and a list of the purchasers of all P&D MDR-type rotary relays furnished to Spectronics by Stokley and P&B. This list indicated that Spectronics also supplied P&B relays to the Sequoyah nuclear power plant and Nutherm International, Incorporated, which supplies safety-related parts to nuclear power plants.
- 5. Persons Contacted P. Tolbert Vice President, Spectronics, Incorporated EXHlBIT I PAGE 7 0F /o PAGE(S)
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- Enclosure 4 VIB VISIT TO NUTHERM INTERNATIONAL, INCORPORATED, i a IN MOUNT VERNON, ILLIN0IS 4 !
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- Prepared by: X. R. Naidu, Vendor Inspection Branch
! Visted Conducted: July 24, 1990 i l
- Docket Number: 9990779 l
- 1. Purpose 4
The visit was to visually inspect Potter & Brumfield, Inc. (P&B),
MDR-134-1, rotary relays supplied to Nutherm International, Inc.
j (Nutherm), by Spectronics, Inc. (Spectronics), of Mobile, Alabama.
The NRC determined during a visit on July 2 and 3,1990, at Spectronics that several rotary-type P&B relays that Spectronics supplied to Nutherm may have been refurbished and provided as new equipment. During discussions with Nutherm, the inspector confirmed that Nutherm had purchased and received 32 commercial-grade MDR-134-1 relays from Spectronics.
Nutherm dedicated and upgraded these relays for a safety-related status
, and provided them to the Watts Bar nuclear power station (Watts Bar).
l Watts Bar had installed 4 of these 3? relays.
1 l As a result of inquiries from the NRC regarding the purchase of MDR-type i relays from Spectronics, Nutherm requested on approximately July 9,1990, that Watts Bar return the remaining 28 relays to Nutherm for reinspection. ,
Nutherm reinspected the relays (using information provided to them by P&B !
on refurbished relays examined at the Shearon Harris nuclear power plant),
and determined that 4 of the 28 relays did not meet the acceptance criteria. Nutherm retained the 4 unacceptable relays and returned the remaining 24 acceptable relays to Watts Bar. i
! During this visit, the NRC inspectors reviewed the relevant Nutherm ,
purchase orders issued to Spectronics and Nutherm's receipt inspection '
i records. In addition the NRC inspector reviewed the (1) four unacceptable i MDR-134-1 relays, (2),four similar relays received from Spectronics as
- replacements for the unacceptable relays, (3) one MDR-134-1 relay which
- was being used as a standard relay to dedicate other relays, and (4) one relay from storage.
- 3. Review of Nutherm Purchase Order (PO) 2996-01
- Nutherm issued P0 2996-01, dated February 15, 1990, to Spectronics for 32
- P&B MDR-134-1, 8-pole double-throw,115 V ac relays. The P0 stated that the relays were commercial-grade quality items and required documents traceable to the manufacturer. Nutherm received the relays in partial shipments. On receipt, Nutherm utilized Quality Assurance Procedure h
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QAP-7-1-00, Revision 5, to inspect the relays and document the results of inspection on receipt inspection reports (RIR). The following attributes were listed on one side of the RIR:
" Examples of items to look for: torn, crushed, splintered, damp, wet, or stained containers. Check part number of item to see if it matches P0. Check to see if item matches the l P0 description."
The other side of the RIR required model number, type, style, lot date, rating and other marks (such as date code stamp) on the item inspected.
The NRC inspector noted that (1) an RIR dated February iden-tified no adverse findings on 24 MDR-134-1 P&B relays received;20, 1990,(2) an R dated March 3, 1990, identified no adverse findings on four MDR-134-1 P&B relays received; and (3) an RIR dated April 9,1990, identified no adverse findings on two MDR-134-1 P&B relays inspected. The inspector also observed that the RIRs were incompletely filled out. In addition, the inspector noted that a nonconformance report was not written to document the adverse findings when two MDR-type relays were rejected and returned to Spectronics. There was no documentation to indicate why the relays were returned to Spectronics. This matter will be reviewed during a future inspection.
- 4. Visual Inspection of MDR-134-1 Relays The inspector visually inspected the four MDR-134-1 relays which were rejected and retained by Nutherm af ter the relays did not meet the Nutherm re-inspection criteria. The inspector observed the following deficient conditions:
- a. The name plates affixed to the four relays appeared to be i silk-screened and were clearly different from the original l P&B-engraved name plates.
- b. The lengths of rotor shafts and the rotor assembly bolts appeared to have been shortened as evidenced by rough cut ends.
- c. Red paint (instead of Glyptal) had been used to stake the nuts on the rotor assembly bolts,
- d. The top of the rotor shaft did not have a slot.
The above observations were indicative of an unauthorized conversion of the P&B relays from one type to another. This process involved the removal of contact blocks to match the type of relay required. When the contact blocks were eliminated, the rotor and rotor assembly bolts were shortened to resemble a genuine P&B relay. P&B subsequently informed the NRC that P&B does not perform such conversion activities and has never authorized anyone to perform these conversions, l
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- 5. Visual Inspection of P.eplacement Relays The inspector observed a recent shipment of four MDR-134-1 relays from
! Spectronics which were being held in the receipt inspection area. Nutherm l stated-that this shipment was accompanied by a letter from Spectronics dated July 23, 1990, which explained that these 4 relays had traceability papers and were intended to replace the relays previously shipped to Nutherm on March 28, 1990. Spectronics requested that Nutherm return the four relays shipped on March 28, 1990. The inspector visually inspected the four relays in the receipt inspection area and identified no deficient conditions.
- 6. Persons Contacted L. Patterson Manager of Quality Assurance ,
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