ML20198J672
| ML20198J672 | |
| Person / Time | |
|---|---|
| Issue date: | 05/22/1986 |
| From: | Merschoff E, Naidu K NRC OFFICE OF INSPECTION & ENFORCEMENT (IE) |
| To: | |
| Shared Package | |
| ML20198J630 | List: |
| References | |
| REF-QA-99900772 NUDOCS 8606030179 | |
| Download: ML20198J672 (9) | |
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{{#Wiki_filter:o. ORGANIZATION: PARSON PEEBLES ELECTRIC PRODUCTS, INC. CLEVELAND, OHIO REPORT INSPECTION [NSPECTION NO.: 99900772/86-01 DATE: 2/10-13/86 )N-SITE' HOURS: 50 CORRESPONDENCE ADDRESS: Parson Peebles Electric Products, Inc. ATTN: Mr. Ron Pollitti Vice President & General Manager 17045 Euclid Avenue Cleveland, Ohio 44112 ORGANIZATIONAL CONTACT: Mr. J. Pospisil, Chief Engineer TELEPHONE NUMBER: (216) 481-1500 NUCLEAR INDUSTRY ACTIVITY: Current activities are limited to spare parts and services for electric generators for diesel engines, including voltage and current transformers for excitation control and motors for pumps. ASSIGNED INSPECTOR:
- v f/a 1/46 K. R. Naidu, Reactive Inspection Section (RIS)
Date OTHER INSPECTOR (S): J. Jacobs n, RIS f
- 6 APPROVED BY:
E. W' Merschoff, Chief g S, Vendor Program Branch Date INSPECTION BASES AND SCOPE: i A. BASES: 10 CFR Part 21, Appendix B to CFR Part 50. l B. SCCPE: Review action taken on previous inspection findings, review i documentation related to the generators which experienced failures at l Washington Public Power Supply System (WPPSS) - 2, Watts Bar and Grand l Gulf nuclear power plants, and review documentation on modifications to static exciter voltage regulators for the Vogtle nuclear power plant. PLANT SITE APPLICABILITY: Grand Gulf, (50-416); Watts Bar Units 1 and 2, (50-390,391); WPPS Unit 2,(50-397); Vogtle, (50-424, 425). I B606030179 860527 PDR GA999 ENVPPEP 99900772 PDR
e ORGANIZATION: PARSON PEEBLES ELECTRIC PRODUCTS INC. CLEVELAND, OHIO REPORT INSPECTION ~ ' ' AGE 2 of 8 NO.: 99900772/86-01 RESULTS: A. VIOLATIONS: No violations were identified during this inspection. B. NONCONFORMANCES: 1. Contrary to Criterion IV of Appendix B to 10 CFR Part 50, and the Parson Peebles Electric Products Inc. (EPI) procedure EQ 2.5.1 of their Quality Assurance Manual, EPI did not indicate applicable drawings revisions, specifications or 10 CFR 50 Appendix B appli-cability on a purchase order to Concorde Controls for a safety-related manual voltage re ulator to be used at Grand Gulf Nuclear Power Station. (86-01-01 C. UNRESOLVED ITEMS: No unresolved items were identified during this inspection. D. STATUS OF PREVIOUS INSPECTION FINDINGS: The inspectors verified that the actions taken by Electric Products Incorporated (EPI) to correct one violation and several nonconformances identified in Inspection Report 99900772/82-01, were implemented as outlined in EPI letter dated July 15, 1982 and determined the following: 1. (Closed) Violation Item A.1. The violation identified that EPI did not post copies of 10 CFR Part 21 or Section 206 of the Energy Reorganization Act of 1974. The inspector observed that copies of these documents are now posted on the bulletin board near the building entrance. 2. (Closed) Violation Item A.2. The violation identified that records of evaluation had not been prepared for a current transformer which was out of specification. During this inspection, the inspector determined that as stated in EPI letter dated July 15, 1982, an evaluation had been performed. The evaluation was not presented during the previous inspection due to the absence of a person who was knowledgeable in these activities. 3. (Closed) Nonconformance Item B.1. The nonconformance identified that documented evidence was not available to indicate that a prototype current transformer (CT) was verified to conform to procurement documents. The inspector determined that a product traveller was developed and implemented to verify that the CT met the procurement documents.
~ ORGANIZATION: PARSON PEEBLES ELECTRIC PRODUCTS INC. CLEVELAUD, OHIO REPORT INSPECTION ND_- 99900772/86-01 RESULTS: P AGE 3 of 8 4. (Closed) Nonconformance Item B.2.a. The nonconformance identified that neither the shop traveller nor job tickets for manufacturing order traveller No. (17) 200-810 7512-513 referenced inspection operations / instructions. The inspector reviewed several documents and determined that inspection instructions and results are being documented. 5. (Closed) Nonconformance Item B.2.b. The nonconformance identified that on certain travellers, manufacturing had been processed past the inspection points. The inspector reviewed several travellers and determined that inspection instructions are being properly
- implemented.
6. (Closed) Nonconformance Item B.3.a. The nonconformance identified that the " approvals to run" space on the Press Punch Quality Assurance Log had not been signed and dated as required. The inspector was informed that manufacturing operations ceased in 1984. As such, the punch presses are not being operated. 7. (Closed) Nonconformance Item B.3.b. The nonconformance identified that operations being stopped due to equipment problems had not been documented on the PPQAL. As noted in the above paragraph, EPI ceased manufacturing operations in 1984. 8. (Closed) Nonconformance Item B.4.a & 4.b. The nonconformance identified that revised Manufacturing Order Travellers 200 1810 7512-513, dated January 15,1982, and (17) 2001810 7512-513 dated January 14, 1982, and several QA documents were not reviewed and approved by the Manufacturing Manager prior to distribution. The inspector reviewed several product travellers and determined that they were being signed off as required and that the specified quality assurance documents had been reviewed. E. OTHER FINDINGS AND COMMENTS:
===1. Background=== Electric Products Incorporated (EPI) located in Cleveland, Ohio l has manufactured motors, electric generators, regulators, static excitation voltage regulators, current transformers, voltage transformers, precise power supplies and miscellaneous components. Portec bought EPI in 1969 and sold it in 1979 to Northern Engineering Industries Parson Peebles (NEI Parson Peebles) of Great Britain. The
~ ORGANIZATION: PARSON PEEBLES ELECTRIC PRODUCTS INC. CLEVELAND, OHIO REPORT INSPECTION NO.- 99900772/86-01 RESULTS: ) AGE 4 of 8 manufacturing operations of EPI ceased in the fall of 1984. At present the current activities are limited to supplying spare parts to the installed equipment and performing qualification studies for equipment installed in nuclear power stations. EPI supplied the electrical generator portion of the diesel generator units packaged by prime contractors such as Power Systems Division (PSD) of Morrison Knudsen located in Rocky Mount, North Carolina and Stewart and Stevenson located in Houston, Texas. The electrical generators have been used as both standby emergency power generators or as a power source for the high pressure core spray pump mottr in boiling water reactors. The prime contractor coordinated the design of the unit power supply between the manufacturers of the diesel engine and the electrical generator; in addition to procuring all the components necessary to assemble, test, and qualify a unit at their plant prior to shipment to a nuclear power station. The diesel generators were supplied in two designs: a single diesel engine driving an electrical generator, and two diesel engines coupled in tandem driving a single electrical generator. Both designs have been installed and are currently in operation in nuclear power plants. During the period 1983 to 1985, three failures were identified in electrical generators operating in the tandem two diesel design. In this design, insulation is provided between the bearing at the slip ring end (SRE) and the generator shaft. The purpose of this insulation is to interrupt the path of stray electrical circulating currents. The three reported failures were attributed to abnormal wear of the insulation between the inner bearing race and the shaft at the SRE. Abnormal wear permitted the generator shaft to drop and rub against the oil seals. To correct the failure and increase reliability and maintainability, EPI modified the design. In the modified design, the insulation between the bearing and the shaft j at the SRE was removed and placed between the bearing housing feet and its support structure. As a result of this inspection, the NRC issued Information Notice l 86-26 dated April 17, 1986, " Potential Problems in Generators Manufactured by EPI" which alerted users of this type of generator of the insulation failures described in this report. 2. Review of Failure at Grand Gulf Unit 1 l On July 13, 1985, during surveillance testing at the Grand Gulf Unit i nuclear power station, the generator of the high pressure core spray (HPCS) diesel engine failed. The HPCS diesel engine l . _ = _
ORGANIZATION: PARSON PEEBLES ELECTRIC PRODUCTS INC. ~ CLEVELAND, OHIO REPORT INSPECTION NO.- 99900772/86-01 RESULTS: ' AGE 5 of 8 generator was packaged by the Power Systems Division (PSD) of Morrison Knudsen and consisted of two Electro Motive Division (EMD) diesel engines tandem coupled with an electrical generator manufactured by EPI. General Electric Company (GE) furnished the HPCS pump which is included in Nuclear Steam Supply System (NSSS) for Grand Gulf. PSD is a vendor to GE and EPI is a subvendor to PSD. A service report from EPI stated that the electrical generator with serial number 17312216 experienced problems when the unit was started and brought to speed. After several seconds, arcing was observed between the outside bearing cover and the generator shaft at the slip ring end (SRE). A representative from EPI inserted a jack undbr the SRE of this shaft, checked the up and down movement of the shaft, and observed 0.12 inch movement. He encountered difficulty when attempting to remove the outside bearing cover as there was a metal buildup on the shaft where it had made contact with the When the cover was removed, he observed that the oil slinger cover. lock nut was finger tight and the lock washer tab was bent over so it was flush with the top of the slinger nut slot. The oil was clean and clear. Inspection of the oil slinger nut, lock washer, and insulated washer indicated "no damage." The bearing housing was removed and the bearing insulation was measured at different places on the periphery of the shaft. The data suggested that the thickness of the insulation immediately under the inner race of the bearing 0 was thinner at selected locations. The EPI representative determined that abnormal wear of the insulation allowed the generator shaft to drop down and rub against the inner and outer seals (bearing cover). The insulation wear was caused by the turning or slipping of the inner bearing race. Pending further evaluation, PSD reported the failure to the NRC within 24 hours, as a potential 10 CFR Part 21 condition. PSD field personnel jacked the generator shaft, measured the values of play at different angles, and informed EPI of the results. EPI concurred with PSD that the play exceeded the nominal value of 0.012 inches. The proposed corrective action was a design change modifying the location of the insulation similar to the one accomplished at WPPSS Unit 2 which is described below (paragraph 3). EPI and PSD have developed a procedure to accomplish this design modification and forwarded it to GE who is currently using this procedure to implement the change at Grand Gulf. It should be noted that the HPCS is included in the NSSS, and that PSD is a vendor to GE, EPI is a subvendor to PSD.
1 ORGANIZATION: PARSON PEEBLES ELECTRIC PRODUCTS INC. CLEVELAND, OHIO REPORT INSPECTION NO - 99900772/86-01 RESULTS: ' AGE 6 of 8 Review of Failure at WPPSS Unit 2 3. On July 21, 1983, the A electrical generator experienced a failure. The cause of the failure was determined to be the ommission of a shim during assembly. The generator was returned to the manufacturer for repair. On September 28, 1983, the B generator experienced insu-lation failure at the slip ring end. The generator was returned to the manufacturer for repair. EPI repaired the insulation on the two generators and returned them to WPPSS after they were repaired. On July 9,1984, during monthly surveillance testing, a high vibration alarm was observed on emergency diesel generator B. Followup investi-gation revealed that the slip ring end bearing had turned on the shaft insulation reducing the insulation. This reduction in insulation thickness allowed the shaft to drop down and rub the inner and outer seals of the bearing. To increase reliability and maintainability, EPI modified the insu-lation design by relocating the insulation. The insulation between the generator shaft and the inner race of the roller bearing was re-moved and a shrink-fit machined steel sleeve was substituted. Insu-lation was placed between the bearing housing feet and its support structure. This modification was accomplished at a shop in Washington with EPI's concurrence. No abnormal operation has been reported to date. 4. Review of Failure at Watts Bar Unit 2 On June 10, 1983, The Tennessee Valley Authority (TVA) reported that during the performance of a test, at their Watts Bar Unit 2 plant, the generator shaft of a emergency diesel engine was observed to be rubbing against the inner and outer oil seals at the slip ring end. Further examination after disassembly revealed that the thickness of I the oil thrower was less than that specified in the design drawings. This caused a mismatch between the inner and outer races of the Torrington cylindrical roller bearing. The mismatch permitted the roller cage assembly to contact the bearing lock washer. EPI theorized that the bearing lock washer, which rotates at the generator shaft speed, may have propelled the bearing roller cage (which normally rotates at a lower speed) to rotate at shaft speed. This situation ) l introduced a reversed torque on the inner race of the bearing. The j torque caused the inner race of the cylindrical bearing to break loose from the layer of insulation underneath it and rotate, causing abnormal wear on the insulation to the extent that the shaft dropped and rubbed I l against the SRE inner and outer oil seals. I
ORGANIZATION: PARSON PEEBLES ELECTRIC PRODUCTS INC. CLEVELAND, OHIO REPORT INSPECTION NO.- 99900772/86-01 RESULTS: ' AGE 7 of 8 The generator was repaired by TVA to EPI's specifications. The repairs consisted of rebuilding oil seals, polishing the shaft under the oil seals, replacing the insulation material under the bearing, machining the bearing housing cap to correct the alignment, adding a shim to restrain the outer race and installing new bearings. TVA inspected four other generators and repaired them similarily. 5. Review of Current Activities EPI performed modifications on the Static Exciter Voltage Regulators (SEVR) supplied to Vogtle Units 1 and 2. The modification consisted of redesigning the rectifier bridge and regulator chassis, procuring the material for accomplishing the modification, installing, and testing the new SEVR. Two modified panels were being prepared for shipment. The inspectors reviewed the documentation associated with the modification of the panels and determined the following: Approved procedures were followed to procure material for the a. modification. b. An approved procedure was used to mooify the panels. An approved test procedure was used to perform the final test c. and also record the results of the tests. 6. Review of Procurement Documents The inspector examined a purchase order (#56813) from Morrison-Knudsen to EPI for a manual voltage regulator required to operate the emergency diesel electrical generator installed at the Grand Gulf Nuclear Power Station. The purchase order stated "IEEE-323-1974 and IEEE-344-1975 are applicable." EPI accepted this purchase order and supplied the regulator to Morrison-Knudsen without clarifying l what information concerning EQ/ Seismic qualification was to be furnished with the regulator. No information pertaining to EQ/ Seismic l qualification was supplied. EPI obtained the manual voltage regulator from Concorde Controls who specially manufactured the regulators to EPI specifications. The inspector found that information concerning applicable drawings, revisions, or specifications for the regulator was not included on the EPI purchase order to Concorde Controls. Also not included was the statement requiring Concorde Controls to have a quality assurance l f
W ORGANIZATION: PARSON PEEBLES ELECTRIC PRODUCTS INC. CLEVELAND, OHIO REPORT INSPECTION NO.: 99900772/86-01 RESULTS: NAGE 8 of 8 program in accordance with 10 CFR 50 Appendix B. As a result of this, a nonconformance has been identified in Section B of this report. The inspector noted that drawing number 72 05100 100 Revision B, the controlling drawing supplied to Concorde Controls by EPI for the manufacture of the manual voltage regulators listed but did not indicate the applicable revisions for other associated drawings required for the manufacture of the device. The EPI material routing slip failed to indicate who was responsible for setting receipt inspection testing requirements or whether or not testing requirements were met. Also, the purpose of "ENGRG APPR'L" and " Quality Assurance" signoffs was unclear. 7. Review of Audits Performed on EPI The inspector reviewed an audit of,. EPI by Southern Company Services for GPC Nuclear. One deficiency was noted in the area of procurement document and purchased material control. Specifically, several pur-chase orders were made to vendors not currently on the EPI approved vendor listing. The inspector verified EPI's corrective action of updating the approved vendor listing to include those vendors not previously on the list. Records of the EPI Quality Assurance Manager's internal audits were reviewed and found to be in order although some-what behind schedule. F. PERSONS CONTACTED
- N. D. Monnolly, Sales Engineer
- R. B. Politi, General Manager
- R. W. Culp, Eng. Technician
- R. C. Clasen, QA Manager
- R. A. Rossman, Manager of Materials
- F. Lamcha, Serv. Engineer
- W. T. Waller, Parts Sales Manager
- C. Moosbrugger, Engineering Specialist J. Pospisil, Chief Engineer
- Indicates those individuals who attended the exit meeting.
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