ML20150F312
| ML20150F312 | |
| Person / Time | |
|---|---|
| Issue date: | 03/31/1988 |
| From: | Moist R, Potapovs U Office of Nuclear Reactor Regulation |
| To: | |
| Shared Package | |
| ML20150F297 | List: |
| References | |
| REF-QA-99900399 NUDOCS 8804050142 | |
| Download: ML20150F312 (5) | |
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ORGANIZATION: AMERICAN INSULATED WIRE CORPORATION PAWTUCKET, RHODE ISLAND REPORT INSPECTION INSPECTION NO.: 99900399/88-01 DATES: 02/24-25/88 ON-SITE HOURR-PC CORRESPONDENCE ADDRESS: American Insulated Wire Corporation ATTN: Mr. I. S. Galkin President 36 Freeman Street Pawtucket, Rhode Island 02862 ORGANIZATIONAL CONTACT: Mr. A. Madoian, Assistant Quality Assurance Manager TELEPHONE NUMBER:
(401) 726-0700 NUCLEAR INDUSTRY ACTIVITY:
None since 1984.
ASSIGNED INSPECTOR:
d/:tdd)[M M/M M 3-3/-67 R. N. Mdist, Special Projects Inspection Section Date (SPIS)
OTHEP. INSPECTOR (5):
G. T. Hubbard, Office of Special Projects. TVA Projects APPROVED BY:
"kdV D31-N U. Potapovs Chief, SPIS Vendor Inspection Branch Date INSPECTION BASES AND SCOPE:
A.
BASES:
10 CFR Part 50 Appendix 0 and 10 CFR Part 21.
B.
SCOPE: The purpose of this inspection was to review and evaluate American Insulated Wire Corporation (A!W) manufacturing, test and quality assurance (QA) records to verify that proper controls were implemented during all phases of the manufacture of silicone rubber (SR) insulated cables which are installed at Sequoyah and Watts Bar nuclear oower olents.
PLANT SITE APPLICABILITY: Sequoyah 1/2(50-327/50-328), Watts Bar 1/2 (50-390/
50-391).
8004050142 880401 PI1R OA999 EMVAMERI 9y900399 DCD
=
ORGANIZATION: AMERICAN INSULATED WIRE CORPORATION PAWTUCKET, RHODE ISLAND REPORT INSPECTION NO.: 99900399/88-01 RESULTS:
PAGF 2 nf E A.
VIOLATIONS:
None.
B.
_NONCONFORMANCES:
None.
C.
UNRESOLVED ITEMS:
None.
D.
STATUS OF PREVIOUS INSPECTION FINDINGS:
1.
(0 pen) Nonconfonnance (84-01, item B.1):
AIW QA Manual only covered manufacturing activities and did not esta-blish procedures for any of the 17 applicable criteria necessary to provide control over the equipment qualification program. No nuclear activities have been performed since 1984, therefore, imple-mentation could not be verified during this inspection.
2.
(0 pen) Nonconformance (84-01, item B.2 a, b, c, d) a.
No aging data was available for EPDM wire tested by Franklin Institute Research Laboratories (FIRL) which was reported by FIRL to be aged by AIW 200 hour0.00231 days <br />0.0556 hours <br />3.306878e-4 weeks <br />7.61e-5 months <br />; at 150*C and 600 hours0.00694 days <br />0.167 hours <br />9.920635e-4 weeks <br />2.283e-4 months <br /> at 150*C.
b.
The data source on A!W 5585-EPR 60 percent retention of original elongation used for Arrhenius plots to determine 40-year life at 80*C and at 90*C was not available. The data was reported to have been supplied by DuPont.
c.
Long term aging data per Arrhenius techniques, which was required by TVA Purchase Order 79K5-825342, was not available or maintained.
d.
AIV personnel were unable to provide test plans to the NRC inspector describing AlW tests (thennal and irradiation aging followed by flanes tests) in response to Ebasco Specification 211-73 requirenents. Moreover, the NRC inspector verified that test plans were not available for any of the qualifications
- reviewed, i
ORGANIZATION: AMERICAN INSULATED WIRE CORPORATION PAWTUCKET, RHODE ISLAND REPORT INSPECTION NO.: 99900399/88-01 RESULTS; pant i nr t AIW's responses to these nonconformances had been previously reviewed by the Vendor Inspection Branch and accepted. However, no nuclear activities have been performed since 1984, therefore, implementation of corrective action could not be verified during this inspection.
3.
(0 pen) Nonconformance (84-01, Item B.3)
Contrary to AIW response letter to NRC report No. 99900399/80-01, there was no evidence that inprocess QC inspectors had been reinstructed as comitted. A!W's response to this nonconformance was reviewed by the Vendor Inspection Branch and accepted.
- However, no nuclear activities have been performed since 1984, therefore, implementation could not be verified during this inspection.
E.
OTHER FINDINGS AND COMMENTS:
1.
Background:
On Saptember 4,1987, the Tennessee Valley Authority (TVA) notified the Nuclear Regulatory Comission (NRC), pursuant to the requirements of 10 CFR Part 21, of several failures of SR insulated cables during insitu high potential testing. The insulation failures occurred on three different SR insulated single conductor No.14 cables manufac-tured by AlW Corporation and installed at TVA's Sequoyah Nuclear Power Plant.
Subsequent testing by TVA resulted in three additional insulation failures in SR insulated cables manufactured by AlW.
AlW manufactured the SR insulated cables during October 1979 through January 1980 under contract with TVA. AIW has not manufactured SR insulated cables for other licensee's.
Two different formulations for insulation compound were used during manufacture of SR insulated cable.
Insulation compound, General Electric (GE) SE-9104, recomended by GE was used first for manufac-ture of 250,000 feet of SR insulated cable.
However, qualification test reports for this cable were found to be unacceptable to demon-strate qualification when reviewed by TVA. AIW personnel were not i
sure why the SR cable qualification reports were unacceptable but thought that the concerns related to IEEE 383 Flame Testing require-
{
AlW indicated that this cable was never shipped or used.
ments.
i Insulation compound GE SE 725 was next used for manufacture of SR insulated cable. AlW produced a sample (no record at AIW to J
o.
ORGANIZATION: AMERICAN INSULATED WIRE CORPORATION PAWTUCKET, RHODE ISLAND REPORT INSPECTION NO.: 99900399/88-01 REstn Ts!
par.r a n<
t indicate length) and submitted the sample to FIRL for qualification testing.
FIRL report F-C5119 dated May 1979 titled, "Qua'lification Tests of Electric Wires in a Simulated Loss-of-Coolant-Accident (LOCA) Environment" was deemed acceptable by TVA. Subsequently AlW produced 250,000 feet of SR insulated cable using the same manufac-turing methods that were used for qualification samples and shipped the cable to Sequoyah and Watts Bar Power Plants.
Subsequent to the insitu high potential test failures at TVA, A!W conducted spark testing of SR insulated cable at 3,200 VAC on three returned reels from TVA on September 2, 1987.
There were no failures during this testing.
2.
Review of Certified Inspection Test Reports (CITRs):
Since AIW does not consider inprocess manufacturing records to be Quality Records and they are not retained, the inspectors were unable to evaluate the process used by AIW to manufacture the SR insulated cable using the GE SE725 insulation compound.
- However, the inspectors were able to determine that AIW purchased the SR insulation compound from GE already mixed. A!W then put the compound in the extruder and extruded it on the conductor. A1W production and quality personnel :nvolved in the manufacture of SR cables were no longer at AIW; therefore the inspectors were unable to discuss the production of the cable with personnel.
Even though manufacturing records were not available, the inspectors were able to review the AIW CITRs for the subject SR cables.
The CITRs are considered Quality Records by A!W and are retained to demonstrate compliance with contract and/or specification require-The NRC inspectors reviewed seven CITRs relating to ship-ments.
ments of SR insulation cable using the GE SE725 insulation compound.
It was determined by the NRC inspection team that two lots were produced. One lot was manufactured during the last three months of 1979 and another manufactured during the first two months of 1980.
The CITR review included a review of:
l a.
Dimensional and physical test data sheets b.
Final ciectrical test reports J
~
ORGANIZATION: AMERICAN INSULATED WIRE CORPORATION i
PAWTUCKET, RHODE ISLAND REPORT INSPECTION NO.-
99900399/88-01 RF%til Ts.
panr o nr o c.
Electrical tests on wire d.
Flame test report Test report shoving tests witnessed by TVA e.
f.
Tests performed in accordance with TVA specification 3419 which included the following:
(1 Heat resistance tests (2
Initial dielectric strength test (3
Dielectric strength test while immersed (4
Horizontal flame test Leakage resistance test Dielectric strength test after bounding Moisture resisting test on covering It was determined by the NRC inspectors that the test data conformed with the acceptance criteria in TVA specification 3419.
There was no apparent difference in the test data for the two lots.
Additionally the inspectors determined that TVA Quality Personnel had performed source inspection on the cables at A!W prior to ship-ment to TVA.
The inspectors reviewed these records and identified no deficiencies.
F.
_ PERSONNEL CONTACTED:
Aram Madoian - QA Manager Normand Cagnen - QC Manager Bob Fortin - Lab Manager R&D I
l
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