ML20206T109
| ML20206T109 | |
| Person / Time | |
|---|---|
| Issue date: | 09/16/1986 |
| From: | Moist R, Potapovs U NRC OFFICE OF INSPECTION & ENFORCEMENT (IE) |
| To: | |
| Shared Package | |
| ML20206T107 | List: |
| References | |
| REF-QA-99900378 NUDOCS 8609230109 | |
| Download: ML20206T109 (10) | |
Text
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ORGANIZATION:
NAMC0 CONTROLS, INC.
MENTOR, OHIO REPORT INSPECTION INSPECTION N0.: 99900378/86-01 DATES: 7/21-24/86 ON-SITE HOURS: 48 CORRESPONDENCE ADDRESS: Namco Controls, Inc.
ATTH: Mr. N. E. Swanson President 7567 Tyler Boulevard Mentor, Ohio 44060 ORGANIZATIONAL CONTACT: Mr. Douglas A. Coe, Sales Application Engineer TELEPHONE NUMBER:
(216) 946-9900 NUCLEAR INDUSTRY ACTIVITY: Supplies safety-related limit switches and conducts environmental qualification (EQ) testing of its designated limit switches for the commercial nuclear power industry and the military. All of the EQ testing is for commercial nuclear power. Approximately 10 percent of its manufactured products are for commercial nuclear.
ASSIGNED INSPECTOR:
n d, M h.1 7/ a 4 f
/6F/Tff, j R. N. Roist,' Eqtfipment Qualification Section (EQIS) Date OTHER INSPECTOR (S):
M. Jacobus, Sandia National Laboratories
(
APPROVED BY:
$_t bl.A 1%\\/2
@NE V. Potapovs, Chief, EQISi Vendor Program Branch Date INSPECTION BASES AND SCOPE:
A.
BASES:
10 CFR Part 50, Appendix B and 10 CFR Part 21.
B.
SCOPE: This inspection consisted of:
(1) Technical evaluation of equip-ment qualification (EQ) test activities for safety-related equipment (2) verification of implementation of corrective action (CA) on the noncon-formance identified in the NRC Inspection Report No. 99900378/83-01,(3) verification of implementation of the quality assurance (QA) program and (continued on next page)
PLANT SITE APPLICXblLITY: Various.
8609230109 860918 PDR GA999 EMVNAMCO 99900378 PDR
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ORGANIZATION: NAMC0 CONTROLS, INC.
MENTOR, OHIO REPORT INSPECTION NO.: 99900378/86-01 RESULTS:
PAGE 2 of 7 SCOPE:
(continued) (4) followup on a 10 CFR Part 21 report issued by Vermont to a possible defect of contact block kits supplied by Namco Yankee relating (NCI).
Controls, Inc.
A.
VIOLATIONS:
None.
B.
NONCONFORMANCES:
None.
C.
UNRESOLVED ITEMS:
None.
D.
STATUS OF PREVIOUS INSPECTION FINDINGS:
(Closed) Nonconformance (83-01, Item B.1): The QA program was not supported by written policies, procedures, or instructions. Namco has not issued implementing procedures NSP20-0005, -0006, -0007, -0008, and NSP 60-0007.
The NRC lead inspector verified that the material and intent of NSP 20-0005 had been incorporated into other procedures and that procedure NSP20-0008 had been compiled and implemented during a previous inspection documented in Inspection Report No. 99900378/84-01.
The NRC leao inspector during this inspection verified that procedures l
NSP20-0006 and NSP20-0007 titled " Reproduction and Distribution of Design Documentation" and " Preparation of Test Plans (QTP) and Test Reports (QTR)," respectively, had been compiled and implemented. Procedure NSP60-0007 titled " Inspection Procedure" referenced in procedure NSP40-0C03 dated January 1983 titled " Processing Factory Orders and Purchase Orders" has been obsoleted.
Information relating to inspection and identification of material are now compiled in procedures NSP40-0003, Revision A, dated May 1984 titled same as above, NSP60-0010, Revision B, dated March 1084 titled " Identification and Control of Products Dedicated for Use in huclear Power Plant Applications" and Sections 8 and 10 of the QA manual titled l
" Identification and Control of Paterials, Parts and Components" and l
" Inspection," respectively. The NRC inspector verified implementation of these procedures.
t i
ORGANIZATION: NAMC0 CONTROLS, INC.
MENTOR, OHIO REPORT INSPECTION NO.: 99900378/86-01 RESULTS:
PAGE 3 of 7 E.
OTHER FINDINGS OR COMMENTS:
1.
Technical Evaluation - The NRC inspector and Sandia Consultant (NRC inspection team) conducted a technical evaluation of four completed programs and one ongoing program for qualification testing of safety-related electrical equipment. The following table summarizes the programs examined, equipment type, plant and types of documents exam-ined.
Proaram Equipment Type Plant Documents Examined 1.
EA740 Limit Switch with Various Qualification Test Report one inch receptacle and (QTR), Cualification Test connector / cable assembly.
Plan (OTP),TestProce-dure (TP), Test Data (TD) and Purchase Orders (P0).
2.
EA180 Limit Switch with Various QTR, QTP, TP, TD and P0 one inch receptacle and connector / cable assembly.
3.
EA180 Limit Switch Various QTR 4.
Half inch receptacle and Various Similarity Analysis Cual-connector / cable assembly ification Package 5.
Material analysis of Various Test Data inpregnation materials used for qualified limit switches.
I The NRC inspection team reviewed the EQ process prescribed in each test report / test plan / procedure and reviewed test results, including the bases for accelerated thermal aging and radiation and verified calculations when applicable.
Four test programs and one ongcing program and related engineering documentation were examined for the following as applicable:
a.
Adequate test instrumentation and their accuracies were described l
and used to meet the requirements of IEEE-STD-323/1974.
I b.
Equipment interfaces were addressed.
ORGANIZATION: NAMC0 CONTROLS, INC.
MENTOR, OHI0 REPORT INSPECTION NO.: 99900378/86-01 RESULTS:
PAGE 4 of 7 Test acceptance criteria were established as described in the c.
test specification or in the design engineering documents, such as calculations and engineering letters to meet the requirements of IEEE-STD-323/1974.
d.
Same equipment was used during all phases of testing and repre-sented a standard production item.
Environmental conditions were established and described (e.g.,
e.
pressure and temperature profiles, and thermal aging factors were consistent with those outlined in the test specification or test plan).
f.
Test results were adequately reduced and evaluated against esta-blished acceptance criteria described in customer test specifica-tions or purchase orders.
g.
All prerequisites for ?.he given tests as outlined in the test specification had been met, b.
Test equipment included a description of all materials, parts and subcomponents.
i.
Notice of Anomaly reports were properly documented.
j.
Appropriate margins were applied.
k.
Functional performance requirements met.
Programs 1 and 2 - EA-180/EA-740 Limit Switches incluoing a receptacle and cne inch connector / cable assembly were qualified for inside containment applications in accordance with QTR-130 and QTR-140, respectively.
Program 3 - EA-180 Limit Switch was qualified for inside containment applications in accordance with QTR 105 as long as a qualified conduit sealing method was employed.
Program 4 - Half-inch receptacle and connector / cable assembly was qualified based on similarity to the series one-inch connectors. The lead wires on the half-inch and one-inch connectors are identical.
The cable for the half-inch connector cable assembly was qualified by similarity to the same test report as referenced for the one-inch connector cable qualification.
l l
5 ORGANIZATION: NAMCO CONTROLS, INC.
MENTOR, OHIO REPORT INSPECTION NO.: 99900378/86-01 RESULTS:
PAGE 5 of 7 Program 5 - This program was started as a result of an audit conducted by Namco on their material vendor.
It was discovered that the vendor was using a different impregnation material than that specified in Namco's process drawing. As a result, Namco tested housings with the new impregnated material to verify that it is functionally equivalent to the required material.
In addition, Namco discovered that in some cases the vendor mixed the new and the specified material together prior to impregnating the housing.
Currently N.amco is performing tests for mixtures of the two materials. The testing includes thermal shock, leak testing, thermal aging, radiation exposure and design basis event testing although not all on the same specimen. The NRC inspection team will review test results during a future inspection.
No nonconfurmances were identified during the above review.
2.
Followup on Two 10 CFR Part 21 Reports One of the 10 CFR Part 21 reports addressed contact block kits that were supplied to Vermont Yankee Nuclear Power Corporation. The NRC inspection team visually inspected contact block kits that were returned to Namco by Vermont Yankee. The contact blocks had large chunks of material broken off at various locations en the sides of the block. The NRC inspector reviewed Namco's Inspection Report (IR) dated May 23, 1983 for that lot of contact blocks which were shipped to Vermont Yankee. The IR showed that no defective contact biccks were shipped from Namco as denoted by acceptance stamp by Namco's quality inspection personnel.
Further discussions with Namco personnel revealed that an inspector from Vermont Yankee performed an audit of the shipping activities relating to replacement contact blocks at the Namco's manufacturing plant at Newton, North Carolina recently. While there, the Vermont Yankee inspector visually verified that the replacement contact blocks were shipped from the Newton Plant in acceptable condition. However, the Vermont Yankee inspector discovered at Vermont Yankee's receiving inspection af ter opening the packages that some centact blocks had chips / chunks broken off at various locations on the side of the contact block.
It was determined by Namco that thermal shock due to temperature change during the airline flight caused some of the contact blocks to chip. Namco placed contact blocks into cry ice for twenty-four hours at their manufacturing plant and discovered that sone of the contact blocks exhibited the same condition mentior.ed above.
f.
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ORGANIZATION: NAMC0 CONTROLS, INC.
MENTOR, OHI0 REPORT INSPECTION NO.: 99900378/86-01 RESULTS:
PAGE 6 of 7 Namco shipping practices and potential customer notifications will be reviewed during a future inspection at the Newton manufacturing plant.
The second 10 CFR Part 21 report addressed cracked contact lever arms discovered at Niagara Mohawk's Nine Mile Point in qualified EA-180 limit switches. The NRC inspection team visually inspected contact lever arms (old vintage material) sent to Namco from Nine Mile Point and observed the cracks. The riveting process which secures the contacts to the lever arm is suspected to cause the cracks. Namco is initiating a program to test the returned contact lever arms in order to assess the significance of these defects. The details of the test programs were not formalized prior to completion of the inspection.
Discussions with Namco engineering personnel revealed that the cracking was not limited to the old vintage material, used prior to 1980, but was also observed in new vintage material in use af ter 1980.
Currently, Namco is conducting a life test on a production contact lever arm (new vintage material) found defective during inspection at Namco's manufacturing plant to determine if the cracks can cause failure of the contact lever arms, and if so, af ter how many normal operations.
A followup inspection will be conducted at the Namco Manufacturing Plant at Newton, North Carolina to review implementation of their QA program, in areas of process control, in-process and final inspection, and shipping practices.
3.
QA Program Implementation Review - The NRC inspection team reviewed five program files containing documentation which supported testing efforts. Documentation included P0's, EQ test plans and procedures, test reports and test data. The inspection teams review of the abcVe documentation was to verify continued implementation cf the Namco QA program. No nonconformances were noted during this review.
4.
0A Manual Review - The NRC team leader reviewed the changes that were incorporated into the different sections of both the QA Manual and Namco Standard Practice Manual (implementing procedures) since the last inspection. The NRC team leader determined that the changes were minor and did not change Namco's QA program with respect to the requirements of Appendix B to 10 CFR Part 50.
~
ORGANIZATION: NAMC0 CONTROLS, INC.
MENTOR, OHIO REPORT INSPECTION NO.: 99900378/86-01 RESULTS:
PAGE 7 cf 7 5.
Followup on a Licensee Event Re3 ort - The NRC team leader followed up on Licensee Event Report (LER) 094 issued by LaSalle County Station Unit 1 on February 7, 1985.
It stated that the operating lever arms of Namco EA 180 switches could not be sufficiently tightened on the splined switch lever shafts, when the threaded expansion plug was screwed into the end of the shaft. Review of documentation and discussions with Namco revealed that Namco notified each customer to whom they had shipped EA 180 series switches since May 1, 1983 of the potential problem. Also, Namco supplied their customers with a replacement, non-galling expansion plug for each switch, however, LaSalle County Station Unit One was not on the notification list. The NRC team leader determined the limit switch was not procured directly from Namco by LaSalle County Station and was therefore not included in the Namco notification.
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- Ccmpany NAMco &nr>tois sac.
cates yujy 91-2 5,,7pg Docket / Report No. 99900379/94-0/
Inspector R. M NJOi.sY
-f-Pre-Inspection Conference
/ Post-Inspection Conference
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