ML20199L643
| ML20199L643 | |
| Person / Time | |
|---|---|
| Issue date: | 01/22/1999 |
| From: | NRC (Affiliation Not Assigned) |
| To: | |
| Shared Package | |
| ML20199L618 | List: |
| References | |
| REF-QA-99901043 99901043-98-01, 99901043-98-1, NUDOCS 9901280084 | |
| Download: ML20199L643 (2) | |
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NOTICE OF NONCONFORMANCE Westinghouse Repair and Replacement Services (RRS)
Docket No. 99901043 Cheswick, Pennsylvania Report No. 98-01 Based on the results of the Nuclear Regulatory Commission inspection conducted during October 14-15 and 28-29,1998, of activities supporting the manufacture, rework and testing of DHP type medium-voltage Westinghouse circuit breakers, it appears that certain of your activities were not conducted in accordance with NRC requirements.
l A.
Criterion Vil," Control of Purchased Material, Equipment and Services," of 10 CFR Part 50, Appendix B, states, in part, " Measures shall be established to assure that purchased material, equipment and services, whether purchased directly or through contractors or subcontractors, conform to the procurement documents. These measures shall include provisions, as appropriate, for source evaluation and selection, objective evidence of quality furnished by the contractor or subcontractor, inspection at the contractor or subcontractor source, and examination of products upon delivery."
Criterion X, " Inspection," of 10 CFR Part 50, Appendix B, states, in part, "A program for inspection of activities affecting quality shall be established and executed by or for the organization performing the activities to verify conformance with the documented instructions, procedures, and drawings for accomplishing the activity.... Examinations, measurements, or tests of material or products processed shall be performed for each work operation where necessary to ensure quality."
Contrary to the above, RRS failed to perform adequate inspections at the subcontractor source to ensure conformance with procurement documents (e.g., improperly welded breaker chassis front panel subassemblies) and failed to perform adequate inspections of breakers and their subassemblies to ensure conformance with documented instructions, procedures and drawings during and after the manufacture of new Westinghouse Type DHP circuit breakers at Eaton/ Cutler-Hammer that RRS supplied to Illinois Power Company's Clinton Power Station. As a result, RRS failed to detect numerous deficiencies that were later identified at Clinton during receipt inspections.
(98-01 01)
B.
Criterion XVI," Corrective Action," of 10 CFR Part 50, Appendix B, states, in part, that measures shall be established to assure that conditions adverse to quality such as failures, malfunctions, deficiencies, deviations, defective material and equipment, and nonconformances are promptly identified and corrected.
Contrary to the above, RRS failed to ensure that material deficiencies (i.e., improperly welded breaker chassis front panel subassemblies) were properly corrected when first identified and RRS's final corrective action, as documented in Corrective Action Report G98JD008, did not address two significant contributing causes of the problem (i.e., lack of adequate welding fixtures and not using shop travelers or other in; process control documentation) (98-01-02).
9901280084 990122 PDR GA999 ENWEST 99901043 PDR
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C.
Criterion V, " Instructions, Procedures and Drawings," of 10 CFR Part 50, Appendix B, states, in part, " Activities affecting quality shall be prescribed by documented instructions, procedures or drawings of a type appropriate to the circumstances, and shall be accomplished in accordance with these instructions, procedures or drawings.
Instructions, procedures or drawings shall include appropriate quantitative or qualitative acceptance criteria for determining that important activities have been satisfactorily accomplished."
Contrary to the above, RRS Commercial Dedication Instruction (CDI) CEB 0503, Revision 2, for dedicating Westinghouse Type DHP circuit breakers manufactured by Eaton/ Cutler-Hammer, was not appropriate to the circumstances in that (1) the CD1 lacked sufficient provisions and detailed instructions for inspecting breakers and their subassemblies; (2) instructions in the CDI for serializing the breakers (by reference to Test Specification (TS) 710030) did not provide for inscribing the breakers with unique identifiers; (3) the sequence of events in the instructions for testing the breaker anti-pump relay was incorrect; and (4) the CDI referenced TS 710030 for contact resistance tests, but the TS contained inappropriate millivolt drop test acceptance criteria. (98 03)
Please provide a written statement or explanation to the U.S. Nuclear Regulatory Commission, ATTN: Document Control Desk, Washington, D.C. 20555, with a copy to the Chief, Quality Assurance, Vendor Inspection and Maintenance Branch, Division of Reactor Controls and Human Factors, Office of Nuclear Reactor Regulation, within 30 days of the date of the letter transmitting this Notice of Nonconformance. This reply should be clearly marked as a " Reply to a Notice of Nonconformance" and should include for each nonconformance: (1) a description of steps that have been or will be taken to correct these items; (2) a description of steps that have been or will be taken to prevent recurrence; and (3) the dates your corrective actions and preventive measures were or will be completed.
O Issued this, theIday of January,1999 at Rockville, Maryland 2
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