ML20151H704
| ML20151H704 | |
| Person / Time | |
|---|---|
| Issue date: | 04/14/1983 |
| From: | Barnes I, Parker L NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML20151H696 | List: |
| References | |
| REF-QA-99900224 NUDOCS 8305050241 | |
| Download: ML20151H704 (24) | |
Text
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ORGANIZATION:
BAILEY CONTROLS COMPANY A MCDERM0TT COMPANY Wirk't T FFF. ON T ')
REPORT INSPECTION INSPECTION N0.:
99900224/83-01 DATE(S) 2/14-18/83 ON-SITE HOURS:
87 CORRESPONDENCE ADDRESS:
Bailey Controls Company a McDermott company ATTN: Mr. M. A. Keyes, President 29801 Euclid Avenue Wickliffe, Ohio (40??
ORGANIZATIONAL CONTACT: Mr. G. M. Kohl, Director of Quality Assurance TELEPHONE NUMBER:
(216) 585-5800 PRINCIPAL PRODUCT: Recording and indicating devices, sensor and control systems.
NUCLEAR INDUSTRY ACTIVITY: Control systems and control instrumentation supplied to the nuclear industry constitute 5 percent of the total production.
ASSIGNED INSPECTOR: 8 7.,Y M
4'//'///3 L. B. Parker, Reactive and Component Program
'Date Section (R& CPS)
OTHER INSPECTOR (S): G. T. Hubbard, Equipment Qualification Section J. J. Benson, Consultant, Sandia National Laboratory i
APPROVED BY:
(( Nm.:t-4- /#-R3 I. Barnes, Chief, R& CPS Date INSPECTION BASES AND SCOPE:
A.
BASES:
10 CFR Part 21 and 10 CFR Part 50, Appendix B.
B.
SCOPE:
This inspection was made as a result of:
(1) a 10 CFR Part 50.55(e) report by Consumers Power Company (CPC) concerning wiring errors in the Emergency Core Cooling Actuation System (ECCAS) at Midland Nuclear Plant, Units 1 and 2; (2) a 10 CFR Part 50.55(e) report by the Tennessee Valley (Cont. on next page)
PLANT SITE APPLICABILITY:
50-329 and 50-330 (ECCAS wiring and documentation problems); 50-438 and 50-439 (stress cracked and glued PC card connectors); 50-328, 50-390 and 50-391 (blown fuses in auxiliary control circuitry).
_ -,e DESIGIN * " ^~~
8305050241 830415 b.-
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ORGANIZATION:
BAILEY CONTROLS COMPANY A MCDERM0TT COMPANY WICKLIFFE, OHIO REPORT INSPECTION N0.-
99900224/83-01 RESULTS:
PAGE 2 of 9 SCOPE:
(Cont.) Authority (TVA) concerning stress cracked and glued connectors and support brackets used for printed subcircuit boards in the plug in modules of the Reactor Protection System (RPS) and the Engineered Safety Features Actuation System (ESFAS) at Bellefont Nuclear Plant, Units 1 and 2; and (3) a 10 CFR Part 50.55(e) report by TVA concerning blown fuse alarms in auxiliary control circuits at Sequoyah Nuclear Plant, Unit 2 and Watts Bar Nuclear Plant, Units 1 and 2.
In conjuncticn with the foregoing, an inspection of the equipment qualification program was conducted which consisted of:
(1) a review of the quality assurance procedure manual (QAPM) and supplementary manuals and procedures; and (2) the verification of the implementation of the QA requirements and procedures.
In this part of the inspection all 18 criteria of 10 CFR Part 50, Appendix B were covered.
A.
VIOLATIONS:
None B.
NONCONFORMANCES:
None C.
UNRESCLVED ITEMS:
None D.
STATUS OF PREVIOUS INSPECTION FINDINGS:
1.
(Closed) Violation (81-01):
Posting of 10 CFR Part 21 Section 206 of the Energy Reorganization Act of 1974 or an appropriate notice had not been accomplished in the fabrication area.
The NRC inspector observed a copy of the 10 CFR Part 21 notice posted on the locked bulletin board in the Bailey Controls Company (BCC) factory lobby at Wickliffe, Ohio.
It was noted, however, that instead of naming an individual to whom the report should be submitted, BCC named a managerial position.
2.
(Closed) Nonconformance A (81-01): The Divison Purchasing Manager had not established and implemented a procedure to assure that appropriate division personnel are:
(1) promptly advised of a supplier's notification of a deviation that requires evaluation by the company, and (2) advised of any defect reported by the supplier to NRC when such knowledge is received.
1 m
ORGANIZATION:
BAILEY CONTROLS COMPANY A MCDERM0TT COMPANY WICKLIFFE, OHIO REPORT INSPECTION NO.-
99900224/83-01 RESULTS:
PAGE 3 of 9
.s The NRC inspector verified that BCC Instruction No. 1271-50-05, Revision New, " Handling of Vendor Reported Safety Concerns," for Manufacturing Purchasing Section had been approved ano issued on August 14, 1981, and implemented.
3.
(Closed) Nonconformance B (81-01): A procedure had not been written to prescribe the methods, equipment, personnel capabilities, and qualification requirements for control of the special process of soldering which was bein' performed in the systems assembly and g
wiring area.
The NRC inspector verified that the Manufacturing Standard Practice had been issued on October 15, 1981, Revision Original, for
" Soldering, Hand," and a written training program established under the " Quality Control Program of Training / Certification for Manual Soldering" was approved on~0ctober 28, 1981.
Six personnel
" Certification Records" were examined and found to be complete.
4.
(Closed) Nonconformance C (81-01): [fliegibleandincomplete stamping in the "Insp. OK" column of' Audit.No. I repair lists in System Data Package for BCC Job No.'5198P201,0.
The Systems Final Workmanship Inspection Checklist for BCC Job No. 5198P2010 was reviewed and found to have rectified and accepted the deficiencies.
The NRC inspector also reviewed an internal memo written by the Manager of BCC Quality' Engineering Department on May 13,1981, which was issued to all. person..el dir.ctly involved in the generation and review of systems inspection documentation to assure that all such documentation reflect proper handling and final clearance validations.
5.
(Closed) Nonconformance D (81-01): Audit summaries had not been issued on a monthly basis in accordance with BCC Administrative Procedure No. 1768-01.
Paragraph 2.5 of BCC Administrative Procedure No. 1768-01, Revision D, was reviewed and found to have eliminated the requirement for issuing audit summaries on a monthly basis.
6.
(Closed) Unresolved Item (81-01):
It was not apparent.that quality assurance assured. audit results had been reviewed.by management responsible for audited activities.
- k
ORGANIZATION: BAILEY CONTROLS COMPANY A MCDERMOTT COMPANY WICKLIFFE, OHIO REPORT INSPECTION NO.-
99900224/83-01 RESULTS:
PAGE 4 of 9 Review by the NRC inspector of eight significant event reports (management weekly / monthly reports) showed that all levels of management were reviewing audit results.
E.
OTHER FINDINGS OR COMMENTS:
1.
10 CFR Part 50.55(e) Report:
On Dece:nber 17, 1980, CPC made a 10 CFR Part 50.55(e) report to Region II of the Nuclear Regulatory Commission (NRC) concerning ECCAS wiring and documenting nonconform-ing conditions.
Documentation was reviewed by the NRC inspector which identified the following:
(1) CCC personnel were sent to Midland Nuclear Plant and did identify wiring errors in the ECCAS; i
(2) BCC had prepared a Field Change Package to correct the wiring errors identified in (1) above; (3) CPC had verified that the field change authorizations for ECCAS wiring errors had been completed; (4) BCC had revised their " Systems Functional Testing" instruction (to preclude recurrence of the deficiency) which explicitly directed the Ccntract Engineering Technician to check all system wiring x
changes from point to point by visual inspection or ring-out; (5) no functional problems had been reported for the other systems built i
using the test instruction that had not detected the wiring errors; (6) the systems referenced in (5) include a channel test function by which control logic is " exercised" and checked; and (7) 724 sche-matics and all site problem reports for TVA-Bellefonte systems were reviewed with no wiring errors attributable to BCC manufacturing or checkout activities being found.
2.
10 CFR Part 50.55(e) Reaort: TVA-Bellefonte has identified connectors and support arackets for printed subcircuit boards in the plug in modules of the RPS and the ESFAS which contain stress fractures and show evidence of having been glued.
It was established
)
by the inspector that BCC was aware of the condition and had per-formed testing in this regard. Test samples had successfully passed lqualification testing including seismic, with the results forwarded to TYA through the Babcock and Wilcox Company.
As of this inspec-tion, TVA had not formally concluded that the crazing condition was i
acceptable.
i Subsequent to the initial crazing problem, TVA-Bellefonte identified additional problems witn approximately 150 modules in the RPS and ESFAS that have built-in indicators.
In these type 4
ORGANIZATION: BAILEY CONTROLS COMPANY A MCDERM0TT COMPANY WICKLIFFE, OHIO REFORT INSPECTION N0.:
99900224/83-01 RESULTS:
PAGE 5 of 9 modules, there is a general distribution of built-in indicators which have cracked hcusings,. loose terminals, damaged terminal studs, improper size terminals used on 24 AWG wire, and generally poor quality crimps.
BCC had no knowledge of this problem.
This condition and the initially reported problem will be further reviewed during a subsequent inspection.
3.
10 CFR Part 50.55(e) Report:
TVA Watts Bar and Sequoyah reported by a 10 CFR Part 50.55(e) report that blown fuses in equipment supplied by BCC were inadvertently actuating equipment.
BCC had no knowledge of this problem.
This item will be further reviewed during a subsequent inspection.
F.
EQUIPMENT QUALIFICATION PROGRAM INSPECTION RESULTS:
1.
QA Program Review:
The QA program is described in the QAPM, QA Instruction Manual (QAIM), and supplemental internal operating proce-l dures (IOPs).
These documents and procedures establish a QA program in accordance with the 18 criteria of 10 CFR Part 50, Appendix B.
The NRC inspector's review of the QA program consisted of an examina-tion of the two manuals and supplemental IOPs.
No nonconformances were identified.
l l
2.
QA Program Implementation Review:
The tiRC inspectors verified the I
Tiiiplementation of the QA program procedures by examining representative records and files, conducting interviews with personnel, and by visual inspections and observations.
l Findings concerning the implementation of the 18 criteria of 10 CFR Part 50, Appendix B as described in the QAPM and implementing procedures are as follows:
a.
Organization:
The NRC inspector verified organizational l
structures including functional responsibilities and
)
authorities by discussions with contract quality engineering personnel, review of organization charts, the OAPM and other supporting documents. The QA director reports directly to the company president and has the authority to stop work pending proper disposition of quality matters.
No nonconformances were identified.
1
r ORGANIZATION:
BAILEY CONTROLS COMPANY A MCDERMOTT COMPANY i
WICKLIFFE, OHIO REPORT INSPECTION
. NO.:
99900224/83-01 RESULTS:
PAGE 6 of 9 l
b.
Quality Assurance Program: The NRC inspector evaluated this l
criterion by verifying that a QA program was established by the QAPM and by verifying the implementation of the 18 criteria of 10 CFR Part 50, Appendix B.
Evaluation of four training files l
and three certificates of training verified that established training requirements of the QA program were being accomplished.
No nonconformances were identified.
c.
Design Control:
The NRC inspector's review established that BCC controls this criterion through the issuance of a' qualification test request (TR) to the qualification test lab (QTL).
The QTL generates a test plan and acceptance criteria (TPAC) document and a test procedure (TP).
Both the TPAC and TP are approved by the originator of the TR. The inspector verified implementation of this criterion by review of three TPs, two engineering l
notices (ens), one qualification test report, and discussion l
with two QTL personnel.
No nonconformances were identified.
1 l
.During tne design control review, the NRC inspector established that BCC addresses the margin requirements of paragraph 6.3.1.5 of IEEE-323-1974 for accelerated aging tests by applying margins on activation energies instead of cn temperature and/or time.
This approach was discussed with the QA director and other QA l
personnel. The inspector recommended that BCC clearly define their methodology for applying margin in future qualification reports so that customers will fully understand BCC's application of margin during testing.
BCC management realized their approach to applying margings was different from the general industry practice of applying margins to either temperature and/or time; therefore, they agreed to define their margin approach in future reports.
Reports will be reviewed during future inspections to verify that this has been accomplished.
d.
Procurement Document Control: The NRC inspector verified that BCC was complying with their procedures by reviewing two out-going purchase orders (P0s), one change order, and interviews with two contract engineering and one QA personnel.
The review of P0s verified QA involvement in P0 review and that appro-priate QA and technical requirements are being specified in P0s.
No nonconformances were identified.
l
ORGANIZATION:
BAILEY CONTROLS COMPANY A MCDERMOTT COMPANY WICKLIFFE, OHIO REPORT INSPECTION l
.NO.:
99900224/83-01 RESULTS:
DAGE 7 of 9 e.
Instructions, Procedures, and Drawings:
The NRC inspector verified implementation of this criterion by reviewing six TPs, two lab book files, one lab notebook, two ens, and the TPAC master file.
The documents reviewed were developed in accord-ance with the procedures of the QAFM and QAIM. Additional verification was achieved by evaluating the implementation of the other criteria described in procedures of the QAPM and QAIM.
No nonconformances were identified.
f.
Document Con' ol: The NRC inspector verified the implementation of this criti.-ion by examining two lab book files, one lab note-book, and the TPAC master file. Documents reviewea showed that they were approved and released by appropriate authorities and the appropriate documents and revisions were being used at the proper locations.
No nonconformances were identified.
g.
Control of Purchased Material, Equipment, and Services: The NRC inspectors verified the implementation of QAPM and QAIM proce-dures for the control of purchases.
This verification was accomplished by a review of the nuclear approved suppliers list, three vendor audits, receiving reports for three test items, and interviews with QTL receiving personnel.
No nonconformances were identified.
h.
Identification and Control of Materials, Parts and Components:
The NRC inspector evaluated BCC's method of test item identification for material control by observing test item i
markings for items in storage and in the test areas. This evaluation included review of one log book to verify test status and test item traceability.
No nonconformances were identified.
I 1.
Control of Special Processes: The NRC inspector verified that BCC coes have procedures to control special processes and the qualification of personnel; however, this criterion is not applicable to the equipment qualification work performed at the QTL.
j.
Inspection:
The NRC inspector verified implementation of BCC's QAPM and QAIM inspection procedures which require review of test data from each test sequence prior to starting the next test
ORGANIZATION:
BAILEY CONTROLS COMPANY A MCDERM0TT COMPANY WICKLIFFE, OHIO REFORT INSPECTION NO.:
99900224/83-01 RESULTS:
PAGE 8 of 9 sequence. The inspector verified that the required data review was being accomplished by review of two QTL job files, two lab book files, and discussions with QTL personnal. Test item receipt inspection was verified by review of receiving documents for three test items. No nonconformances were identifed.
k.
Test Control: The NRC inspector evaluated BCC's implementation of their QAPM and QAIM test control procedures which include obtaining test requestor / customer approval of TPACs and TPs and the use of test lab books. The inspector's evaluation included review of three TPACs, three TPs, and one qualification test report; observation of one tes+. area; and discussions with two QTL personnel.
No nonconformances were identified.
1.
Control of Measuring and Test Equipment: The NRC inspector evaluated BCC's calibration system by reviewin) five calibration records, observing test status stickers on three items of test equiprent, and reviewing the " Calibration Control System Data Bank" (CCSDB). The calibration status of one dead weight tester had not been entered in the CCSDB; however, review of records indicated that it had been calibrated and was in use. The cal-ibration status was entered in the CCSDB during the inspection; therefore, no response is required for this item. Additionally, review of an inspection report for one pressure gage revealed that its disposition had not been recorded on the report.
Review of the pressure gage records documented that the gage had not been used while out of calibration and that it had been repaired and was now in servico.
Bailey Control Company's CCSDB has been implemented since this disposition was not documented and it is designed to prevent such occurrences in the future.
No response is required for this item.
Future inspections will verify the effectiveness of the CCSDB.
No nonconformances were identified.
m.
Handling, Storage and Shipping:
The NRC inspector verified that BCC was implementing their QAPM and QAIM procedures by reviewing receiving inspection paperwork in one lab book file and the test specimen log-in book and observing the three items received. The NRC inspector also observed identified and stored test items in the QTL storeroom.
No nonconformances were identified.
n.
Inspection, Test, and Operating Status: The NRC inspector verified the use of lab books as the method described in the QAPM and QAIM to indicate test item status.
The NRC review of
ORGANIZATICN:
BAILEY CONTROLS COMPANY A MCDERM0TT COMPANY WICKLIFFE, OHIO REPORT INSPECTION NO.:
99900224/83-01 RESULTS:
) AGE 9 of 9 two completed lab book files and one lab book for an item undergoing testing verified the implementation of QAPM and QAIM procedures.
No nonconformances were identified, o.
Nonconforming Materials, Parts, or Components:
The NRC inspector verified implementation of the QAPR and QAIM proce-dures which required the use of test anomaly reports (TAR) to document deviations from the TPAC or TP.
The inspector observed one test item which had a TAR written against it and evaluated three other TARS. The three TARS had been properly disposi-tioned and reviewed by appropriate personnel.
No nonconformances were identified.
p.
Corrective Action:
The NRC inspector verified the corrective action procedures of the QAPM and QAIM by reviewing three TARS and six audit deficiency reports.
The examination also included discussions with two QTL personnel and two contract quality personnel.
No nonconformances were identified.
q.
Quality Assurance Records:
The NRC inspector's examination of one qualification test report, two lab book files, one lab note-book, and two QTL job files verified that BCC was implementing the QAPM and QAIM procedures.
No nonconformances were identified.
~
r.
Audits:
The NRC inspector verified that comprehensive internal audits were being performed by BBC and that management was involved in the audit process.
The inspector determined by evaluation of three external cudits, two internal audits, the 83-84 audit schedule, the record of auditor qualifications, six audit deficiency reports, and seven significant event reports that BCC was implementing their QAPM and QAIM procedures.
No nonconformances were identified.
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