ML20203A881
| ML20203A881 | |
| Person / Time | |
|---|---|
| Issue date: | 03/26/1986 |
| From: | Jeffrey Jacobson, Merschoff E NRC OFFICE OF INSPECTION & ENFORCEMENT (IE) |
| To: | |
| Shared Package | |
| ML20203A845 | List: |
| References | |
| REF-QA-99901011 99901011-85-01, 99901011-85-1, NUDOCS 8604170616 | |
| Download: ML20203A881 (5) | |
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t ORGANIZATION: TELEMECANIQUE, INC.
WESTMINISTER, MARYLAND REPORT INSPECTION INSPECTION N0.: 99901011/85-01 DATE: 12/17,31/85 ON-SITE HOURS: 20 CORRESPONDENCE ADDRESS:
Te lemecanique, Inc.
ATTN: Mr. J. V. Erhardt, Vice President Operations Engintered Controls 2002 Bethel Road Westminister, MD 21157 ORGANIZATIONAL CONTACT:
M. Fenneteau TELEPHONE NUMBER:
(301) 876-2214 NUCLEAR INDUSTRY ACTIVITY:
Telemecanique manufactures Motor Control Centers used for various applications in nuclear power plants.
ASSIGNED INSPECTOR:
[/
/A w Jhg/p6 J.B[acppon,'ReactiveInspectionSection(RIST Date OTHER INSPECTOR (S):
K. R. Naidu, RIS (12/17/85 only)
- 4!r4 APPROVED BY:
E. W. Merschoff, ief, RIS, Vendor Program Branch Date INSPECTION BASES AND SCOPE:
A.
BASES:
10 CFR 50 Appendix B, 10 CFR Part 21 B.
SCOPE: This inspection was conducted to evaluate Telemecanique's corrective action for defects previously identified with Gould (now Telemecanique) Motor Control Centers.
The items inspected included closing failures in 100 amp frame size circuit breakers in addition to trip specification changes, broken barrier plates, and undersized contact carriers in size 1 and 2 Motor Control Starters.
PLANT SITE APPLICABILITY: Beaver Valley 1 and 2 (50-334, 412),
Pilgrim 1(50-293), Millstone 1, 2, and 3 (50-245, 336, 423),
River Bend 1 and 2 (50-458, 459), and Seabrook 1 and 2 (50-443, 444).
8604170616 960415 PDR GA999 EMVTEMEC 99901011 PDR
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ORGANIZATION: TELEMECANIQUE, INC.
WESTMINISTER, MARYLAND REPORT INSPECTION 99901011/85-01 RESULTS:
PAGE 2 of 5 No.-
A.
Violations:
1.
Contrary to Section 21.21 of 10 CFR Part 21 and Gould Quality Assurance Procedure (QAP) No.15.3, Telemecanique (formerly Gould) did not properly evaluate or report a potential Part 21 defect concerning cracked plastic barrier plates in size 1 and 2 Combination Reversing Motor Starters.
(85-01-01)
B.
Nonconformances:
1.
Contrary to Criteria V and VIII of Appendix B to 10 CFR Part 50, terminal screws used in the wiring of size 1 and 2 Combination Reversing Motor Starters were omitted from material lists used in the fabrication of those units.
Consequently, incorrect (too long) screws were used which punctured the plastic barrier plate and subsequently jammed the starter.
(85-01-02) 2.
Contrary to Criteria VII of Appendix B to 10 CFR 50 Telemecanique (formerly Gould) did not assure that circuit breakers purchased from ITE Electrical Products conformed to the procurement documents.
Specifically Telemecanique (formerly Gould) did not assure that ITE had a valid 10 CFR 50 Appendix B and 10 CFR Part 21 program in effect.
(85-01-03)
C.
Unresolved Items:
None.
D.
Status of Previous Inspection Findings:
1.
(0 pen) Nonconformance (84-01, Item B.1) Could did not ensure that Siemens-Allis, a subvendor, developed and implemented a quality assurance program to meet the requirements of 10 CFR Appendix B as stated in Gould's Purchase Orders (P0s). This item is considered open pending further evaluation.
2.
(0 pen) Nonconformance (84-01, Item B.2) A test program was not established for the process of dedicating components received as commercial grade items from subvendors for use in safety related Class 1E components intended for installation in nuclear power plants. This item is considered open pending further evaluation.
a h
ORGANIZATION:
TELEMECANIQUE, INC.
WESTMINISTER, MARYLAND II REPORT INSPECTION NO.*
99901011/85-01 RESULTS:
PAGE 3 of 5 3.
(Closed) Nonconformance (84-01, Item B.3) There was a lack of documentation to sh0w that Gould. Finksburg, pursued the resolution of adverse audit findings identified in letter QAL-820223 dated February 23, 1982, to Siemens Allis, Belle-Fontaine, Ohio.
Telemecanique letter serial E095 dated July 23, 1985 to the NRC stated the corrective action response to the above audit findings was received from Siemens-Allis.
E.
Other Findings or Comments:
1.
On March 5, 1984, Public Service Company of New Hampshire reported to the NRC a problem with Gould supplied size 1 and 2 Combination Reversing Motor Starters. The problem. consisted of the use of improper terminal screws for terminations of internal wiring. The screws were too long and when fully tightened cracked a plastic barrier in the contactor assembly.
The resulting plastic chips then Caused the Contactor to jam. An inspection of 105 starters at Seabrook Units 1 and 2 revealed 12 with plastic scored and 11 with plastic broken by the screw.
Information supplied by Telemecanique revealed that the above starters were manufactured between April 1980 and July 1981.
Similar starters were supplied to River Bend within the same time period. When asked to review Telemecanique's (formerly Gould) Part 21 evaluation on this subject the inspector was presented with two pages of undated, unsigned notes which inadequately addressed the problem.
Specifically, the evaluation failed to address the question of whether the same screws were used on contactors manufactured during the same time period and subsequently installed at River Bend.
It appears that due to a lack of evidence indicating otherwise, notification to River Bend should have been made as to the possible existence of the problem at their facility.
Violation 85-01-01 and Nonconformance 85-01-02 are identified in Section A and B of this report as a result of Gould's failure to follow Section 8.3 of QAP 15.3,'of their Quality Assurance procedures which states that a detailed investigation and written report should have been made.
The use of the improper screws was found to be the result of not including screw size information on material lists used during manufacture of the starters.
Nonconformance 85-01-01 is identified in Section B of this report as a result of Gould's failure to follow QAM 8 of their Quality Assurance Manual which states that controls should have been established to ensure only corre:t and accepted
)
items were used in the manufacture of the starters.
. u-b ORGANIZATION: TELEMECANIQUE, INC.
WESTMINISTER, MARYLAND REPORT INSPECTION No - 90901011/85-01 RESULTS:
PAGE 4 of 5 2.
On November 8, 1983, Public Service of New Hampshire reported to the NRC a defect in molded case 100 amp Frame E2, E4, E6, HE4, and HE6 multi-pole circuit breakers installed in 480 volt motor control centers supplied by Gould.
The defect concerned the failure of one of the three poles to close when the circuit breaker was switched from the "off" to "on" position.
Gould had reported this problem to the NRC on September 26, 1983 under 10 CFR Part 21.
The circuit breakers in question were manufactured by ITE Electrical Products and sold to Gould as commercial grade equipment.
In a letter dated September 20, 1983 from ITE to Gould, ITE stated the above problem had been discovered in January 1982 and corrected in February 1982, 22 months prior to Goulds 10 CFR Part 21 report.
ITE also stated that the subject breakers had not been qualified for nuclear use.
ITE/Gould's corrective action to the closing problem appears to have been adequate but a time lapse of 22 months before reporting the problem was unsatisfactory. Although Gould purchase orders to ITE specified 10 CFR 50 Appendix B and 10 CFR Part 21 requirements it appears ITE had no such program in effect.
In a letter dated August 20, 1984 from ITE's Engineering Mana9er to Gould, ITE stated its ability to comply with 10 CFR 50 Appendix B and 10 CFR Part 21 as " unknown." Nonconformance 86-01-03 is identified in Section B of this report as a result.
3.
On March 15, 1982, Gould reported to the NRC under 10 CFR Part 21 a problem with undersized contact carriers in size 1 and 2 motor control starters. The undersized carriers were causing the contactors to jam and subsequently burning out the contactor coils. The Part 21 report stated that only starters with date codes between May 11, 1981 and March 11, 1982 were suspected and recommended that utilities inspect Motor Control Centers in which suspected faulty starters were known i
to have been installed. Since only Motor Control Centers where l
suspect starters were known to have been installed were identified, all Motor Control Centers were not inspected at this time.
On November 18, 1985, Public Service of New Hampshire reported to the NRC that the same carrier problem originally reported in March 198? was reoccuring.
Similar problems were recently discovered at Millstone Unit 3.
I u
E n
i ORGANIZATION:
TELEMECANIQUE, INC.
WESTMINISTER, MARYLAND REPORT INSPECTION NO.*
99901011/85-01 RESULTS:
PAGE 5 of 5 Upon intoection, the carrier problem seems to have resulted from the shrinking and bending of the plastic carrier material immediately after the carriers were molded.
This problem still exists but Telemecanique is now inspecting 100% of the carriers for proper dimensions before and after assembly into the starter units.
The reason for the problem reoccurrence seems to result from the fact that utilities only inspected those motor control centers where suspected faulty starters were known to have been installed as reported by Gould.
Starters with suspect date codes may have then been subsequently installed in Motor Control Centers not thought to have originally contained the faulty units.
The affected plants are Beaver Valley 1 and 2, Seabrook 1 and 2, Millstone 3, River Bend 1 and 2, and Pilgrim 1.
4 In April 1981, Gould made a change to the published specifications covering the adjustable trip range values at which size 0-4 motor starters could be set. The Gould changes were relatively small and with the exception of one coil which was slightly modified, consisted of simply ralabeling the coils and publishing new specification sheets. The change was a result of a change in the Underwriters Laboratory factory calibration specification for testing af ter manufacture from -304/+10% to 20%.
Public Service Co. of New Hampshire expressed a problem with this change due to the fact that some Motor Control Centers manufactured for Seabrook Stations Units 1 and 2 had been fitted with starters manufactured before the specification change. Additional motor control centers were to be supplied with the newly labeled starters.
Gould has relabeled all starters manufactured for Seabrook before the specification change and has exchanged trip coils as required to bring the starters within the utility's calibration requirements.
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