ML20140E671
| ML20140E671 | |
| Person / Time | |
|---|---|
| Issue date: | 12/06/1984 |
| From: | Parker L, Potapovs U NRC OFFICE OF INSPECTION & ENFORCEMENT (IE) |
| To: | |
| Shared Package | |
| ML20140E663 | List: |
| References | |
| REF-QA-99900323 NUDOCS 8501110232 | |
| Download: ML20140E671 (20) | |
Text
_,
0RGANIZATION: CONAX BUFFALO CORPORATION BUFFALO, NEW YORK REPORT INSPECTION INSPECTION NO.: 99900323/84-01 OATE(S): 9/24-28/84 ON-SITE HOURS:
52 CORRESPONDENCE ADDRESS: Conax Buffalo Corporation ATTN: Mr. W. S. Rautio President 2300 Walden Avenue Buffalo, New York 14225-0237 ORGANIZATIONAL CONTACT: Mr. R. E. Farchmin, Quality Assurance Manager TELEPHONE NUMBER:
(716) 684-4500 PRINCIPAL PRODUCT: Containment electrical penetrations and environmental qualification testing services.
NUCLEAR INDUSTRY ACTIVITY: Manufacture of electrical penetrations, electric conductor seal assemblies, adapter modules for other manufacturer's penetrations, heat sensing probes, and specialized cabling for nuclear power plants. Also provides environmental test facilities capable of loss-of-coolant accident (LOCA) testing Class 1E equipment. Approximately 45% of the corporate activity is devoted to nuclear product manufacture and testing.
l2/6/8 ASSIGNED INSPECTOR:
tAAAv, Equipment Qualification Section*([QSY D#te $
r B. Parl OTHERINSPECTOR(S):
J. Benson, Sandia National Laboratories bid _
APPROVED BY:
a m.42.eV>
l1 Y(
U. PotapovsT CHlef EOS, VPB Date INSPECTION BASES AND SCOPE:
A.
BASES:
10 CFR Part 21 and 10 CFR Part 50, Appendix B.
B.
SCOPE: This inspection consisted of:
(1) a review of Conax Buffalo Erji6 ration (Conax) evaluations,correctiveactions,andactionstoprevent recurrence for the following items, (a) a 10 CFR Part 50.55(e) report by theSt.LucieNuclearGeneratingStationUnit2(SLNGS1concerningConax electrical cable ring-tongue termination deficiencies, (b) a River Bend (continued on next page)
PLANT SITE APPLICABILITY:
50-271, 50-389, 50-440, 50-441, 50-445, 50-446, and 50-458, 1
Nkk b@X E
99900323 PDR
ORGANIZATION: CONAX BUFFALO CORPORATION BUFFALO, NEW YORK REPORT INSPECTION NO.-
99900323/84-01 RESULTS:
PAGE 2 of 12
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Station Unit 1 (RBS) 10 CFR Part 50.55(e) report concerning deficiencies in coaxial connector terminations (Amphenol), cuts or breaks in electrical cable insulation, an open in a electrical power cable, and electrical shorts between shield and grour.d, (c) a 10 CFR Part 21 report by Conax concerning electrical cable opens in power lead gland assemblies, (d) a 10 CFR Part 50.55(e) report by Comanche Peak Steam Electric Station (CPS) concerning electrical cable termination deficiencies; 2. a technical review of test plans and procedures used in the Conax equipment qualification program; and 3. the review of Conax's implementation of their corrective actions and actions to prevent the recurrence of deficiencies identified in previous inspections.
A.
VIOLATIONS:
None.
B.
NONCONFORMANCES:
1.
Contrary to the requirements of Criterion V of Appendix B to 10 CFR Part 50 and the M90 Calibration Pecord Logs, serial numbers of equipment calibrated had not been recorded on the MS90 Celibration Record Logs.
2.
Contrary to the requirements of Criterion V of Appendix B to 10 CFR Part 50 and paragraph 1 of the Conax " Procedural Memorandum #3,"
a notice of anomaly (NOA) was not instituted when three out of four test specimens failed during qualification testing.
3.
Contrary to the requirements of Criterion V of Appendix B to 10 CFR Part 50 and Material Disposition Report (MDR) No. 27546, only three of nine pieces designated for scrap were indicated as having been scrapped.
C.
UNRESOLVED ITEMS:
None.
D.
STATUS OF PREVIOUS INSPECTION FINDINGS:
1.
(Closed) Violation (82-01):
Conax failed to specify that the provi-sions of 10 CFR Part 21 applied in a procurement document issued for irradiation services to the Georgia Institute of Technology.
, ORGANIZATION:
CONAX BUFFALO CORPORATION BUFFALO, NEW YORK REPORT INSPECTION NO.: 99900323/84-01 RESilLTS:
PAGE 3 of 12
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The NRC inspector:
- a. reviewed five Conax purchase requisitions (PR) and five purchase orders (PO) placed with subcontractors for safety-related services; b. interviewed Conax personnel responsible for these PR's and P0's; c. verified documentation of the training Conax person-nel received on imposing 10 CFR Part 21 prc'tisions on P0's.
The records, corrective actions, and preventive measures were found to be acceptable.
2.
(Closed)Nonconformance(82-01,8.1):
Exhibit A of Nuclear Quality Assurance (NQA) Procedure 14.1 was entitled " Operation' and Inspection Record (traveler)" Form Nos. N-30 and N-30A when in ' reality Exhibit A of NQA Procedure 14.1 was a table of "Conax inspection stamps."
The NRC inspector reviewed Revision E of NO\\ Procedure 8.4, Aated July 8,1983 and paragraph 8.4.2(a) now r&rences Exhibit B of NQA procedure 14.1 which is the " Operation and Inspection Record (traveler)." The records, corrective actiors and preventive measures were found to be acceptable.
3.
(Closed)Nonconformance[82-01,B.2.(a)]:
Procedures had not been written or approved by the quality control, manager for 141e calibra-tion of the Veeco helium leak detectors.
'i TheNRCinspectorreviewedQualityCc1trolInstructionh.CI)29-4-11 issued on November 2,1982 to "All Quality Control and Inspection Personnel" and the subject was " Calibration Pro:edures for Model SC-4 Veeco Leak Detectors Models MS-90(3), MS-170(1). The records,
/
corrective actions and preventive r.icasures were found to be acceptable.
(
4.
(Closed)Nonconformance[82-01,B.2.(b)]: '3erial ndibers of the Veeco ['
f helium leak detectors which had been calibrated werb pt recorded in
{1 i
the MS90 calibration record logs.
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The NRC inspector:
- a. reviewed the trainipg record of 12 inspectors a
where they had been instructed to complete, red #Ls properly; arid b, inspected the "MS90 Calibration Record Logv' fo1/ two Veeco helium' \\
leak detectors. Nonconformance B.1 was identVied in this area.
/
5.
Closed)Nonconformance(82-01,B.3): A pd.;er.l' disposition ir: port MDR) was not prepared and affixed to Par t No.
769-20002-01,t/ nit 10-8 i
as required by paragraph 15.1.3 of tha'NQ% manual after failure in che dielectric test.
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ORGANIZATION: CONAX BUFFALO CORPORATION BUFFALO, NEW YORK REPORT INSPECTION NO.: 99900323/84-01 RESULTS:
PAGE 4 of 12 Conax personnel stated that the Unit 10-8 in question had been scrap-ped. The NRC inspector reviewed an internal memorandum reinstructing personnel of the importance of documenting all nonconformances on an MDR. The Conax response on this item was accepted.
6.
(Closed) Violation (83-01): The 10 CFR Part 21 implementing procedure did not provide for the evaluation of oeviations or a method to cause evaluation by the licensee or purchaser.
The NRC inspector reviewed:
- a. paragraph 1.5.5 of NQA Procedure No.
1.5, Revision C, dated January 18, 1984 and b. IPS-1071 " Procedure for the Evaluation of Deviations in Accordance with 10 CFR 21 (sic)."
The records, corrective actions, and preventive measures were found to be acceptable.
7.
(Closed) Nonconformance (83-01, 8.1): The records for a lead auditor indic6te that in three out of the last five years the record update was not accomplished within the required time.
The NRC inspector reviewed:
- a. a tickler log which had been estab-lished to track lead auditor record reviews and b. currect lead auditor records. The records, corrective actions, and preventive measures were found to be acceptable.
8.
(Closed) Nonconformance (83-01, 8.2): Written reports outlining corrective action to resolve noncompliances identified in the Conax internal audit report of June 10, 1982, and the reaudit report of August 10, 1982, were not submitted to the quality assurance manager within the required time period.
The NRC inspector reviewed:
- a. the corrective action report by the delinquent manager in which he stated that future audit reports will be reviewed and responded to in ten working days; and b. 14 internal audit reports for the period January 27, 1984 through August 21, 1984.
The records, corrective actions, and preventive measures were found to be acceptable.
9.
(Closed) Nonconformance (83-01, B.5):
10 CFR Part 21 had not been posted in accordance with the Conax NQAM.
i The NRC inspector:
- a. reviewed the revised NQAM section 1.5 which no longer required the posting of current copies of 10 CFR Part 21 and
- b. observed the alternate posting of a notice in compliance with Section 21.6 of 10 CFR Part 21. The records, corrective actions, and preventive measures were found to be acceptable.
i
. ORGANIZATION: CONAX BUFFALO CORPORATION BUFFALO, NEW YORK REPORT INSPECTION NO.: 99900323/84-01 RESULTS:
PAGE 5 of 12 10.
(Closed)Nonconformance(82-01,B.4): Testing of Brard-Rex control cables was not performed using a test procedure that had been revised and approved in accordance with Conax procedures.
A member of the NRC inspection team reviewed:
- a. Revision D of IPS-800 " Design Qualification Test Plan for Control and Instrumenta-tion Cables for the Brand-Rex Company,"-dated May 4, 1983, which deleted IR readings during the loss of coolant accident (LOCA) portion of the test; b. a letter from Brand-Rex approving Revision D of IPS-800; and c. a QA Corrective Action Report in which Nuclear Products Test Facility Personnel were instructed that a customer request for test rcvisions must be made in writing and approved in accordance with the NQA manual. The records, corrective actions and preventive measures were found to be acceptable.
E.
OTHER FINDINGS OR COMMENTS:
1.
Deficiency Reports:
Florida Power and Light Company (FPL) made a 10 CFR Part 50.55(e) a.
report concerning installation of heat shrink insulttion tubing on Conax supplied ring tongue connector assemblies. These i
assemblies were terminations on SLNGS electrical penetrations.
l The tubing was found to extend over the ring tongue face, reducing the contact area.
Conax tested six terminal block test assemblies configured to simulate the terminations as installed on the SLNGS electrical l
penetrations. This testing produced an approved Test Report l
IPS-910, revision A, which through the approved Test Plan 1
IPS-881, revision C, met the aims and objectives of IEEE Standard 317-1976, "IEEE Standard for Electrical Penetration l
Assemblies in Containment Structures for Nuclear Power Generating Stations."
It was the conclusion of this testing that the ring tongue con-nectors when installed as they were at SLNGS were capable of performing the required Class 1E and other functions.
In order to make a positive correlation between the Conax test report and the field conditions, FPL retorqued all Class IE and certain non-IE terminal block retaining nuts.
. ORGANIZATION: CONAX BUFFALO CORPORATION BUFFALO, NEW YORK REPORT INSPECTION NO.-
99900323/84-01 RESULTS:
PAGE 6 of 12
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The NRC inspector reviewed a corrective action report cautioning assembly personnel and inspectors to insure that heat shrink tubing did not cover the bent portion of ring tongue connectors.
The records, corrective actions and actions to prevent recurrence were acceptable.
b.
Gulf States Utilities Company (GSU) made a 10 CFR Part 50.55(e) report concerning separation of coaxial cables from coaxial connectors on Conax Electrical Penetration Assemblies (EPA).
An NRC Vendor Program Branch (VPB) inspection of this deficiency was made on September 4-7, 1984 at the RBS. G5U had also established that other deficiencies existed with the Conax EPA's.
These deficiencies and their dispositions follows:
(1) Deficiencies were found in the installation of Amphenol coax and twinax connectors terminating cable pigtails on EPA's.
Subsequently, Stone & Webster Engineering Corporation (S&W) conducted a Quality Verification Inspection (QVI) at RBS of these connectors. The QVI was observed by a Conax field engineer. A total of 132 connections were examined, and it was determined that 126 were acceptable, in that any of 15 listed deficien-cies would not affect functionality. The 15 deficiencies ranged from, "not enough braid over braid clamp," to " pin damage (scrape & file marks)." Of the six unacceptable connections one pin was bent, three pins came off with the connector (with the conductor broken at the dielectric),
one pin had insufficient solder, and no evidence of solder was observed on one conductor. This problem of coax and l
twinax installation by Conax is plant specific and unique to RBS.
l The disposition of the above termination deficiencies was to:
(a) have Conax revise their coax /twinax connector to flexible cable assembly instructions and schedule training for assembly and quality control personnel according to the l
revised assembly instruction procedures, and (b) reassemble l
penetrations and reinstall all connectors using revised Conax procedures. The records, corrective actions and actions to prevent recurrence were acceptable.
l 1
IL
ORGANIZATION: CONAX BUFFALO CORPORATION BUFFALO, NEW YORK REPORT INSPECTION N0.: 99900323/84-01 RESULTS:
PAGE 7 of 12 (2) Two #12 AWG polyimide (Kapton) insulated conductors each had a nick in their insulation, these conductors in the presence of moisture shorted to each other. To establish the extent of this broken insulation problem S&W conducted a sample inspection at RBS of 201 conductors out of a lot size of 5471 conductors. The method used to conduct this inspection was a wet dielectric test. The NRC inspector observed (in situ) breaks in the Kapton insulation on t
- 12 AWG cable of two installed modules.
Fifteen out of the 201 conductors sampled were found defective. Evalua-tion of this data was continuing at the tiine of this inspection at RBS.
During the NRC inspection at Conax Buffalo, engineering was evaluating the data available from RBS. A firm concept of the cause or a base for the problem's generic effect had not been established at the time of the inspection. The NRC inspector reviewed:
(a) two audit reports of the manufacturer from whom Conax purchases the Kapton insulated wire, and it was noted that a bubbling in the Kapton had been observed on the December 1982 trip report; and (b)
IPS-30, Revision L., " Specification for Polyimide Insulated Electrical Penetration Conductors" which called for impulse dielectric testing only.
This item will be further addressed on a future inspection.
(3) A #2 AWG power conductor pigtail was not adequately inserted into a butt splice barrel on a Conax EPA. This resulted in the pigtail cable separating from the butt splice causing an open electrical circuit. To establish the extent of this problem S&W conducted a sample inspection at RBS of 50 conductors out of a lot size of 498. The method used to conduct this inspection was radiography. The NRC inspector reviewed the radiographs of these 50 butt splices. No i
deficiencies were identified by the radiography. The defective splice was examined by the NRC inspector in the RBS nonconforming storage area.
At the time of the RBS inspection the EPA module was to be returned to Conax for rework. Since no other deficiencies were identified by radiography this deficiency is considered an isolated incident. The proposed corrective action and records are considered acceptable, o
ORGANIZATION: CONAX BUFFALO CORPORATION BUFFALO, NEW YORK REPORT INSPECTION Nn - 99400171/R4-01 RESULTS:
PAGE 8 of 12
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(4) On a feedthrough module, conductor #9 (a shield) was shorted to ground. RBS returned the module to Conax. Conax tested the feedthrough module, installed and torqued it into a header plate.
Erratic and low insulation resistance between shield #9 and ground were then obtained.
Conax then cut the feedthrough apart and found the cause of the problem. The cause was a metal burr on the inside of the monitoring gas entry hole in the wall of the stainless steel tube.
The burr had cut through the kynar insulation, covering the outer shield, to the copper tube shield. Conax is to supply a new module to RBS to replace the ' deficient module.
At Conax Buffalo the NRC inspector reviewed:
(a) six operation and inspection records; and (b) four material disposition records to determine that deburring was an operation and that it was an inspection point. The review revealed that Conax had inspected monitoring gas entry holes, and that stainless steel tubes had been rejected and repaired for burrs on monitoring gas entry holes.
From the records available it was concluded that the cause of the reported deficiency was an inadvertant isolated occurrence. However, during review of the material disposition records, the Nonconformance of paragraph B.3 was identified.
(5) GSU reported another deficiency, shield drain wires were shorted together on three feedthrough modules installed at RBS. To reproduce this condition in Buffalo, Conax-conducted a test on a feedthrough module containing three cables of twisted triples. The cables were soaked overnight in water and then removed from the water. This resulted in lowering the insulation resistance (IR) values from 1011 ohms range to 106 ohms range. These IR values did not change until the outer overall double layer of heat shrink tubing was removed from the areas where the copper braid of the cables terminated to the stranded pigtails and the copper tubes of the feedthrough. Over a two day l
period the IR readings returned to the original values.
Conax's recommendation was to remove the heat shrink tubing and allow the wet area to dry. While in Buffalo, the NRC inspector reviewed documentation of this testing.
Conax IPS-594 " Packaging and Shipping Procedure for Electric Penetration Assemblies for River Bend Station -
Unit 1" was also reviewed by the NRC inspector. This
. ORGANIZATION: CONAX BUFFALO CORPORATION BUFFALO, NEW YORK REPORT INSPECTION ND_*
99900173/84-01 RESlfLTS:
PAGE 9 of 12 review revealed that " Storage of electric penetrations at the plant site per ANSI N45.2.2 Level B is the responsi-bility of the customer. The deficient cables at RBS had been subjected to moisture due to installation in an area which did not meet this recommended storage level. There-fore, it was concluded that this deficiency was not a generic defect associated with the cabling manufacture or design.
c.
In a 10 CFR Part 21 report by Conax a Power Lead Gland Assembly problem was found at both Vermont Yankee and Perry 1 and 2 Nuclear Power Plants. The problem manifests itself by causing the conductor to " neck down" until a discontinuity occurs (i.e.,
an open circuit condition). A member of the NRC inspection team reviewed IPS-1093, Revision C.
Test Plan for the Power Lead Gland Assemblies; IPS-1139 Revision B, Test Report for the Power Lead Gland Assemblies; and IPS-1131 (Orig) Seismic Qualification Test Report for the Power Lead Gland Assemblies.
No areas of concern were noted.
The problem was discussed with Conax engineering pe*rsonnel to determine the present status of their investigation. Conax offered the following information:
(1) Conax has made this assembly in various sizes for over 20 years, many thousands of units, without experiencing this problem.
(2) The assemblies have been qualified (Ref. IPS-1139 and IPS-1131 above).
(3) Failure occurs only in two conductor assemblies, attempts to fail eight conductor assemblies (a larger physical unit l
of the same design) have been unsuccessful.
(4) Knopp (hardness) tests on the conductors in failed units are the same 'as on samples from Conax stock.
l (5) X-rays of four samples, two with fluorolube and two with vydex lubricant shcwed no " necking" in the area of concern.
(6) New York State University at Buffalo is currently investi-gating the problem.
(7) This design is unique to the Power Lead Gland Assembly and does not resemble the design of Conax Electric Conductor l
l
i ORGANIZATION: CONAX BUFFALO CORPORATION BUFFALO, NEW YORK REPORT INSPECTION NO.*
99900323/84-01 RESULTS:
PAGE 10 of 12 Seal Assemblies (ECSA) nor the design of feedthroughs in EPA's.
It appears Conax is continuing a satisfactory evaluation of this defect as they indicated in paragraph VII, corrective action, of the letter Rautio, Conax, to I&E, USNRC, dated 8/31/84,
Subject:
Notification of e Potential Defect.
This item will be addressed further during a future inspection.
d.
At the time of this inspection CPS reported on'a 10 CFR Part 50.55(e) that an EPA connector came off during unpacking in preparation for testing.
Conax was awaiting delivery of the returned defective module.
This item will be addressed in a future inspection.
2.
Technical Evaluation of Equipment Qualification Program a.
Review of Test Plans / Procedures A member of the NRC inspection team conducted a technical evaluation of two qualification packages, one for Brand Rex NIS triax cables and one for Conax Power Lead Gland Assemblies (see paragraph E.1.c).
Qualification testing of the Brand Rex NIS triax cable assemblies in accordance with IPS 1086 Rev. C Test Plan was recently completed by Conax. Test specimens failed to meet the accept-ance criteria of the test plan; however, Conax had not written the Design Qualification Test Report at the time of the inspec-tion.
During testing, the following was noted:
(1) Four units were subjected to thermal aging. Two of the units developed open circuit center conductors.
The Conax project test engineer stated these cables i
. ORGANIZATION:
CONAX BUFFALO CORPORATION BUFFALO, NEW YORK REPORT INSPECTION NO.: 99900323/84-01 RESULTS:
PAGE 11 of 12 were returned to Brand Rex for post-mortem; two substitute cables were subjected to thermal aging.
(2) Four assemblies were subjected to MSLB/LOCA environment. After the first temperature spike, the following was noted.
Unit #8 (not thermally aged) developed an open circuit while hot.
It recovered continuity at ambient temperature.
Unit #3 (not thermally aged) developed an open circuit while hot and at ambient.
Unit #4 (thermally aged) had a short circuit (five ohms) between center conductor and the first shield.
Unit #5 (thermally aged) was satisfactory.
All units had splits in the Raychem tubing and specimens 3 and 4 had splits in the Brand Rex jacket material.
Procedural Memorandum #3, dated 4/14/82, Dulski to Distribution, states in part:
1.a " Notice of Anomaly" should be instituted on Form NPTL 82-2 when any type test program plan or procedure acceptance criteria is exceeded. Contrary to this memo, no
" Notice of Anomaly" was available for review for the failures (open and short circuit and the cable insulation and Raychem splice splits which occurred during/after the first MSLB/LOCA ramp.
Since no N0A had been issued, this failure to follow established procedures (Procedural Memo #3) is listed as a Nonconformance paragraph B.2.
Note: Notice of Anomaly #2 for P0 67305 (Brand Rex NIS triax cable) on Test Procedure IPS-1086 Revision C Section 6.6 was written after the inspector requested the N0A for the LOCA/
MSLB failures.
b.
Observation of Testing Activities No testing was being performed at the Conax Test Laboratory.
A member of the NRC inspection team surveyed the laboratory equipment and capabilities. A complete description of the Conax Nuclear Products Test Laboratory Facility is contained in
ORGANIZATION: CONAX BUFFALO CORPORATION BUFFALO, NEW YORK REPORT INSPECTION N0.: 99900323/84-01 RESULTS:
PAGE 12 of 12 IPS-557 Revision D dated 1/4/84. The major assets of the laboratory are six Blue M ovens and one Thermotron test chamber with a Conax built insulated temperature box approximately 4'x4'x20' which are used for temperature cycling and accelerated aging of qualification specimens.
There are three Conax auto-claves which are used for MSLB/LOCA type testing. A steam heater with two superheaters provides steam to 600*F at 690 lbs.
pressure. There is a redundant chemical spray system.
Conax cannot always meet the 10-second LOCA rise time specified in IEEE-74, depending on the chamber used and on the test specimen.
No qualification work is currently being conducted. Seismic qualification has been performed by Southwest Research Institute, while radiation testing has been conducted by Georgia Tech.
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