ML20212P633
| ML20212P633 | |
| Person / Time | |
|---|---|
| Issue date: | 08/27/1986 |
| From: | Merschoff E, Naidu K NRC OFFICE OF INSPECTION & ENFORCEMENT (IE) |
| To: | |
| Shared Package | |
| ML20212P625 | List: |
| References | |
| REF-QA-99900276 NUDOCS 8609030213 | |
| Download: ML20212P633 (7) | |
Text
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ORGANIZATION: SOLID STATE CONTROLS, INCORPORATED COLUMBUS, OHIO INSPECTION REPORT INSPECTION ON-SITE HOURS:
22 NO.-
99900276/86-01 DATES: 7/28-30/86 CORRESPONDENCE, ADDRESS: Solid State Controls, Inc.
875 Dearborn Drive ATTN: Mr. R. F. Cassidy President Columbus, Ohio 43216 ORGANIZATIONAL CONTACT:
W. G. Hampton TELEPH0NE NUMBER:
(614) 846-7500 NUCLEAR INDUSTRY ACTIVITY: Manufactures battery chargers, isolation trans-formers and uninterruptable power supplies. Less than 1% of the apparatus is intended for installation in nuclear power plants.
2I/
ASSIGNED INSPECTOR:
(
K. R. NaTdu, Reactive Inspection Section (RIS)
Date OTHER INSPECTOR (S):
7 7 c APPROVED BY:
E. W. Merschof f, Chipf RIS, Vendor Program Branch Date INSPECTION BASES AND SCOPE:
A.
BASES:
10 CFR Part 21 and Appendix B to 10 CFR Part 50.
B.
SCOPE: Review implementation of the quality assurance program in selected Observe irverters manufactured for the Surry Nuclear Power Plant areas.
and review related records.
(
PLANT SITE APPLICABILITY: Surry 1 & 2 (50-280; 50-281).
8609030213 860829 9 NOOj p EcSg c
J ORGANIZATION: SOLID STATE CONTROLS, INC.
COLUMBUS, OHIO REPORT INSPECTION NO.: 99900276/86-01 RESULTS:
PAGE 2 of 7 A.
VIOLATIONS:
None.
B.
NONCONFORMANCE:
None.
C.
UNRESOLVED ITEMS:
None.
D.
ACTION TAKEN ON PREVIOUS INSPECTION FINDINGS:
1.
(Closed) Nonconformance - 99900276/82-01 Item A.
The nonconformance identified that contrary to Criterion V of 10 CFR 50, Appendix B, Solid State Controls Incorporated (SCI) did not maintain records to assure compliance with their 10 CFR Part 21 procedure concerning failures of inverters at St. Lucie and Watts Bar nuclear power plants.
SCI developed Procedure SCI-QA-20, Revision 0, dated January 11, 1983 to investigate equipment failures in nuclear facilities. A failure report form is required to be filled out for each reported failure.
The inspector reviewed fif ty-five " Failure Reports" written in 1983.
Five of these reports pertained to normal wear and tear problems in inverters installed in nuclear power plants. The SCI Quality Assurance (QA) manager stated that to increase the efficiency of the reporting system, work done on service calls are documented in Field Service Reports (FSR) which are subsequently reviewed by QA personnel to determine whether the problems are generic in nature. The inspector reviewed twenty-three FSRs written in 1986.
Four of these reports pertained to inverters installed in nuclear power plants and the problems identified were not generic in nature.
The NRC inspector informed the SCI QA manager that documenting the service calls in FSRs instead of Failure Reports was not in accordance with their QA manual requirements.
Prior to the conclusion of the inspection, the QA manager revised procedure SCI-QA-20 to specify the use of FSRs instead of Failure Reports to document failures in inverters installed in nuclear power plants.
2.
(Closed) Nonconformance 99900276/82-01 Item B.
The nonconformance identified that contrary to Criterion V of 10 CFR 50, Appendix 8 and SCI Quality Control Instruction V Revision 2 dated December 2,1980, the project engineer used a new form SF-105A (instead of 105) to docu-
ORGANIZATION: SOLIO STATE CONTROLS, INC.
COLUMBUS, OHIO REPORT INSPECTION N0.-
99900276/86-01 RESULTS:
PAGE 3 of 7 ment the evaluation of all customer and internal specifications. The SF-105A form eliminated the Drafting Supervisor from the Design Review commi ttee. The project engineer failed to submit the review packages to the QA manager for his review.
SCI in letter dated February 4, 1983 to the NRC stated that the engineering department was reorganized. The reorganization eliminated the project engineer and drafting supervisor jobs and created the production engineering supervisor.
Consequently, SCI rev.ised the procedure to insure that organizational changes are reviewed by the SCI QA manager for possible impact on the quality program. A routing sheet which accompanies the documents requires the reviewers to sign and date the routing sheet to indicate their concurrence. The latest revision of the SF-105 form is E.
During the current inspection the inspector reviewed the SF-105-E form which was completed for the Virginia Electric Power Company's purchase order for eight inverters and determined that SCI was in compliance with their QA manual require-ments.
E.
INSPECTION FINDINGS AND OTHER COMMENTS:
1.
Action taken on Capacitor Problems Cn August 28, 1984, Louisiana Power & Light Company, owner of Waterford-3 nuclear power plant reported significant construction Deficiency No. 116 in accordance with the requirements of 10 CFR 50.55(e). The report identified that capacitors with identification Code CDEKBXK1056PI, Style 020138 with date code 8139 installed in static uninterruptable power supply (SUPS) units manufactured by SCI failed. SCI informed the NRC in a letter, dated February 6, 1985, that the failure rates are higher than normal for some types of
(
j capacitors installed in their equipment during the period May 1981 i
through June 1983.
SCI determined that capacitors manufactured by Electric Utilities Company (EUC) or Cornell-Dubilier (CDE) with date codes 8117 through 8326 installed in their SUPSs may have higher than normal failure rates.
In letters dated February 4, 1985, SCI informed all their nuclear power plant custoners of the problem and suggested that they inspect the capaciters in their SUPSs to verify the date codes. SCI SCI furnished the telephone number to call if they had problems.
informed the inspector that they did not receive any replies to their I
ORGANIZATION: SOLID STATE CONTROLS, INC.
COLUMBUS, OHIO l
INSPECTION REPORT PAGE 4 of 7 NO.: 99900276/86-01 RESULTS:
letter from their customers. Review of the Field Service Reports indicated that there were no high failure rates in 1985 and 1986. The normal service life of capacitors is about 5-6 years and SCI recommends replacement of capacitors periodically to maintain the integrity of the SUPSs.
2.
Review of Purchase Orders During the inspection, SCI was manufacturing SUPSs for Virginia Electric Power Corporation (VEPCO), for installation at the Surry nuclear power station. VEPC0 purchase order (P0) ET-16288 dated December 9, 1985 to supply eight SUPSs consisting of inverters, rectifier / chargers, regulating line conditioners, static switches and manual bypass switches. The requirements of 10 CFR Part 21 and 10 CFR Part 50 Appendix B were applicable. Certificates of Conformance were required. Specification NUS-2061 Revision 1 dated November 27, 1985 specified the technical requirements.
SCI internal job order (J0) for this P0 is 27,135 JC dated June 5, 1986. The J0 identified that this equipment is class 1E intended for installation in a nuclear power plant. Additionally, the JO was properly stamped " CONTROL JOB CLASS 1E."
A Design Review Committee Report, Form SF-105E, was prepared as required after the JO was reviewed by the Design. Engineer, Test Supervisor, Product Design Supervisor, and 0A Manager.
3.
Review of SCI Procurement Activities The inspector reviewed the SCI procurement activities by examining the evaluation of suppliers, and SCI P0s issued to vendors.
SCI evaluates their suppliers and qualified suppliers are a.
listed on an Approved Vendor List consistent with their QA manual requirements. The inspector reviewe.d SCI Supplier Quality Assurance System Evaluation Surveys performed on three Vendors and determined then to be acceptable.
b.
The inspector reviewed SCI P0s to five vendors for the supply of various components. SCI stamped all the P0s to indicate that 10 CFR Part 21 was applicable.
j
\\
ORGANIZATION: SOLID STATE CONTROLS, INC.
COLUMBUS, OHIO REPORT INSPECTION NO.: 99900276/86-01 RESULTS:
PAGE 5 of 7 The inspector informed the SCI QA manager that SCI issued P0s c.
to industrial distributors for safety-related equipment who may not inform their principals of the 10 CFR Part 21 requirements.
The SCI QA manager informed the inspector that he will contact the distributors'of components to stress the importance of the 10 CFR Part 21 statement on the P0s issued to them, so that the manufacturers are aware that the equipment manufactured by them is being installed in nuclear power plants.
4.
Review of Receipt Inspection Activities SCI QC inspectors perform 100% inspections on all material received if the quantity is fif ty or less.
For larger quantities, inspections are performed based on a sampling plan to meet MIL-Q-1050 reouire-ments. A QC inspector affixes an " Accepted" stamp on the device af ter he inspects it and determines it acceptable and validates the stamp with his signature and date.
If the QC inspector determines that a component is unacceptable, he affixes a " Rejected" tag to the component, stores the component on a shelf which is exclusively reserved for rejected material, and sends copies of the P0 to the QA manager identifying the unacceptable attributes. The NRC inspector discussed with a QC inspector the inspections he performed to accept circuit breakers and capacitors and determined the following:
The QC inspector stated that he uses Circuit Breaker Inspection a.
Procedure SCI-QA-15-3 Revision 1 dated March 11, 1983 to inspect circuit breakers for the following attributes.
a.
Physical damage b.
Name plate data to match purchase order requirements Verify the operation of the breaker with an ohmmeter c.
across the terminals d.
Verify the operation of the auxiliary switch, shunt trip attachment or any other device specified The QC irspector stated that if he determines that the circuit breaker is acceptable, he affixes an " Accepted" stamp to the device and validates it with his stamp and date.
If he deter-mines the breaker unacceptable, he affixes a " Rejected" tag and sends copies of the purchase order to the QA manager to obtain dispositicn.
ORGANIZATION: SOLID STATE CONTROLS, INC.
COLUMBUS, OHIO REPORT INSPECTION NO.-
99900276/86-01 RESULTS:
PAGE 6 of 7 b.
The QC inspector stated that he inspects cylindrical capacitors according to SCI drawings 010099 to 010119. These drawings list the part numbers of various sizes of capacitors and indicate their respective characteristics such as manufacturer, minimum capacitance, minimum voltage, diameter and length. The OC inspector stated that for capacitors received in quantities less than 50, he performs 100% inspections. He stated that he utilizes a sampling plan with Acceptance Quality Levels meeting MIL-Q-1050 to inspect more than 50 capacitors.
The NRC inspector observed that all unacceptable material was c.
stored on a shelf. The NRC inspector reviewed several " Rejected" tags and determined that sufficient information was provided on the tag to identify the discrepancy.
d.
SCI employs two Quality Assurance Auditors. The NRC inspector reviewed the qualifications of both the auditors and determined them acceptable.
5.
Review of Tests Performed on SUPSs SCI performs tests on standard SUPSs. completed utilizing procedure SCI-QA-5 Revision 6, dated May 23, 1985. The test procedure is adequate and lists all the standard tests. The procedure was modified to meet additional requirements specified in the VEPC0 speci fica tion. The inspector reviewed the final test report for SUPS identified as 271350401 shipped to VEPC0 and determined that the test results ret.the VEPC0 specification requirements.
6.
Review of Calibration Activities The NRC inspector randomly selected the serial numbers from crimping tools and measuring equipment on the assembly floor and reviewed their calibration records. The inspector determined that the calibra-tion of all the equipment was current. The calibraticn records indicated that standards traceable to the National Bureau of Standards were used to calibrate the SCI equipment.
7.
Results of Inspection The results of the inspection are as follows:
The failure of capacitors installed in SCI SUPS were limited a.
to units ranufactured between 1981-1983.
Subsequent failures have not been reported.
ORGANIZATION: SOLID STATE CONTROLS, INC.
COLUMBUS, OHIO REPORT INSPECTION NO.: 99900276/86-01 RESULTS:
PAGE 7 of 7 b.
The SCI QA manager revised procedure SCI-QA-20 to specify the use
~
of Field Service Reports to trend the failure of various components prior to the cor.clusion of the inspection.
E.
EXIT INTERVIEW:
The inspector met with the QA manager and the Quality Assurance Auditors, and discussed the scope of the inspection and the findings.
F.
PERSONS CONTACTED:
W. G. Hampton, Manager Quality Assurance R. J. McClung, Quality Assurance Auditor D. Dellinger, Project Engineer
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