ML20238C599
| ML20238C599 | |
| Person / Time | |
|---|---|
| Issue date: | 09/01/1987 |
| From: | Jeffrey Jacobson, Potapovs U Office of Nuclear Reactor Regulation |
| To: | |
| Shared Package | |
| ML20238C567 | List: |
| References | |
| REF-QA-99901094 99901094-87-01, 99901094-87-1, NUDOCS 8709100238 | |
| Download: ML20238C599 (8) | |
Text
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ORGANIZAT20N: SATIN AMERICAN CORPORATION
. SHELTON, CONNECTICUT REPORT INSPECTION INSPECTION i NO.: 99901094/87-01 DATES: 07/06-08/87 ON-SITE HOURS: 16 i
- CORRE5FONDEliLL AUUMLbb: dat1n American LorporaT,lon ATTN: Mr. Joseph Satin President j Fost Office Box 619 '
40 Oliver Terrace Shelton, Connecticut 06484 l ORGANIZATIONAL CONTACT: Aram Nahabedian TELEPHONE NUMBER: 203-729-6363
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NUCLEAR INDbSTRY ACTIVITY: Satin American provides new anc returD1snea l circuit breakers and switchgear to the nuclear industry.
i n b ASSIGNED INSPECTOR: h,va / h r , P//3/p ,
JefFey . cobson, 5; fecial Projects Inspection Date JFec on PIS)
OTHER INSPECTOR (S): Richard P. McIntyre, SPIS
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APPROVED BY: ) b t<A#
Uldis Potapovs Chief, SPIS, Vendor Inspection Branch 9 l'7 Date INSPECTION BASES AND SCOPE:
A. BASES: 10 CFR Part 21 and Appendix B to 10 CFR Part 50.
B. SCOPE: This inspection was conducted to review records pertaining to the supply of 200 Class lE circuit breakers to the Farley Nuclear Plant.
Additionally, a review of Satin American's quality assurance program was performed.
PLANT SITE APPLICABILITY: Farley 50-348/364, Maine Yankee 50-309, Indian Point 2, 50-247.
8709100238 870908 PDR GA999 EPfvJSAT 99901094 PDR
ORGANIZATION: SATIN AMERICAN CORPORATION
'- SHELTON, CONNECTICUT REPORT INSPECTION NO.- 99901094/87-01 RESULTS: PAGE 2 of 7 A. VIOLATIONS:
None.
B. NONCONFORMANCES: (
- l. Contrary to criterion VII of Appendix B to 10 CFR Part 50, the Satin American Corporation quality assurance program does not require that vendors who supply components to be used in safety-related applica-tions, be on the Satin American Corporation Approved Vendors List (APL). (87-01-01)
- 2. Contrary to Criterion IX of Appendix B to 10 CFR Part 50, welders, whose qualification had not been established, were listed as quali-fied in the Satin American quality assurance manual. (87-01-02)
C. UNRESOLVED ITEMS:
None.
D. STATUS OF PREVIOUS INSPECTION FINDINGS:
None.
E. OTHER FINDINGS OR COMMENTS:
- 1. Supply of safety-related molded case breakers to the Farley Nuclear Plant A recent inspection conducted at the Farley Nuclear Plant by the NRC revealed that a large number (200) of safety-related molded case circuit breakers had been procured from Satin American Corporation for use in Farley's 600 volt motor control centers. Further inspec-tion revealed the fact that a number of these breakers had a 480 volt rather than a 600 volt U.L. rating and that Satin American had tagged and certified these breakers as being acceptable for use in 600 vac circuits. During the inspection at Farley, Alabama Power was asked to provide documentation which would support the use of these 480 volt rated breakers in their 600 volt motor control centers. Also in question was the circuit breakers seismic qualification.
Alabama Power could not provide sufficient documentation to support either the seismic qualification or the use of these breakers in 600 volt applications.
l
-ORGANIZATION: SATIN AMERICAN CORPORATION SHELTON, CONNECTICUT i
REPORT INSPECTION NO.? 00001G04/R7-01 RFSUITS: PAGr 2 nf 7 l
The circuit breakers in question were originally manufactured by ITE and are of the Type HE molded case design. At one time, these breakers carried the 600 volt U.L. rating, but some years ago ITE moved their manufacturing facility and at that time decided to drop the 600 volt rating. Type HE breakers manufactured in subse-quent years carried a 480 volt U.L. rating. Review of U.L. standard 489 for molded' case breakers indicates that six main tests are required to be performed on sample breakers in order for the breakers to carry the U.L. rating.
The first test is a calibration check done at 135 percent and 200 percent of the breakers current carrying capacity. This check was performed only on selected sample breakers shipped to Farley.
The second test is an overload test to be performed at 600 percent of the breakers current carrying capacity at rated voltage. This test was not performed by Satin American Corporation.
The third test is a tungsten load test to be performed at rated current. This test was not performed by Satin American Corporation.
The fourth test is a tempreature test performed at rated current.
Satin American Corporation did not perform this test.
The fifth test is an endurance test at rated voltage. Satin American did not perform this test.
The sixth test is a dielectric test at 1000 volts plus twice rated voltage. Satin American Corporation did perform this test on all the breakers supplied to Farley.
In conclusion, the subject breakers were never subjected to tests two and five at the 600 volts in which they were to be ultimately ;
used. Additionally, due to the fact that no lot control was maintained by Satin American Corporation (the 200 breakers may have come from many different orignial manufacturing lots), the number one calibration check should have been performed on all breakers.
Also, Satin American Corporation has not audited the original manufacturer and therefore has no assurance that design changes which could have affected the breakers original seismic qualifica-tion were not made. Satin American Corporation procured the subject breakers commercial grade and received no certificate as to the breakers seismic qualification.
ORGANIZATION: SATIN AMERICAN CORPORATION
. SHELTON, CONNECTICUT REPORT INSPECTION NO.- 99901094/A7-01 RFS!!! TS : PAGF 4 mf 7 Documentation indicating that Satin American had informed Alabama Power that some of the 600 volt breakers they had ordered would only carry a 480 volt U.L. listing was presented during this inspec-tion.
- 2. Supply of overcurrent trips to Maine Yankee The inspectors reviewed documentation pertaining to the supply of three General Electric EC-1 Type Circuit breaker overloads to the Maine Yankee Atomic Power Plant, Although Maine Yankee did not indicate that these overloads were for a safety-related application, they did invoke ANSI N45.2.2 Level B and the Satin American Corporation QA program. The overloads were ordered under Purchase Order 47714-00 dated June 13, 1987 and were supplied by Satin American Corporation as being suitable for use in safety-related applications. The inspector reviewed test results that showed the overloads had received a thorough series of tests before being dedicated by Satin American Corporation as safety-related Class lE equipment. Calibration of the overloads to GE calibration curve GES-6000 was performed at 95%, 120%, and 300% of the long time pickup setting and at 250% of the short time pickup setting. Also the long time trip times were checked for pickups set at 80%, 120%,
140%, and 160% of the coil rating. The short time trip times were checked for pickups set at 400% and 1000% of the coil ratings. 4 Additionally, a reset time test was performed where current was j decreased from 300% to 80% of pickup and the overloads were observed to reset.
In conclusion, the testing done on the GE overloads appeared to I adequately serve as basis for a safety-related dedication. '
- 3. Refurbishment P0 from ConEdison i
The inspectors reviewed a Purchase Order from ConEdison (P0 709397) for refurbishment of a Westinghouse DB-75 breaker installed in their Indian Point 2 Nuclear Power Plant. The purchase order invoked 10 CFR Part 21 and the Satin American Quality Assurance Manual.
This breaker had not yet arrived at Satin American Corporation at the time of the inspection.
- 4. Supply of GE EC-1 overcurrent trip devices to Farley l
The inspectors reviewed Purchase Order QP-1240 dated October 14, 1986 from Alabama Power Corporation for purchase of ten GE-EC-1 over-current trip devices for use in their Farley Nuclear Plant. The I
ORGANIZATION: SATIN AMERICAN CORPORATION SHELTON, CONNECTICUT l
REPORT INSPECTION NO.- 99901094/A7-01 RFSlH TS! PAGF 4 nf 7 devices were specified as QA Code A (safety-related) by Alabama Power, however, 10 CFR Part 21 was not invoked.
Requirements of the Purchase Order specified Satin American Corporation provide a copy of their QA manual and a certificate of conformance stating that the overloads supplied are equal to the original devices in form, fit, and function.
Satin tested these overloads at 95%, 120%, and 300% of pickup for longtime and at 1200% of pickup for instantenous trips. Trip times were obtained from GE curve 0889B0484, Figure 44 and curve GES-6000.
Testing of these overloads appears to have been adequate for installa-tion into a safety-related application.
- 5. 10 CFR Part 21 Program The inspectors noted that applicable portions of 10 CFR Part 21 were posted as required both in the office and in the shop areas. A flow chart indicating Part 21 responsibilities was also posted in these areas.
- 6. Control of Purchased Material, Equipment, and Services Review of Section 6.0 of the Satin American Quality Assurance manual revealed the fact that vendors supplying components to Satin American were not required to be on their approved vendors list. Additionally, the manual did not state how materials could be procured from i vendors not on the approved venders list. Criterion VII of Appendix B to 10 CFR Part 50 requires measures be established to control purchased material. This deficiency is identified as Nonconformance '
87-01-01.
- 7. Control of Special Processes The inspectors reviewed Section 9.0 of the Satin American Quality Assurance Manual and verified that special processes such as welding, soldering, brazing, zinc chromate plating, silver cyanide plating and degreasing are controlled and accomplished by qualified personnel using qualified procedures.
When reviewing the qualifications for welders at Satin American, two personnel were listed as certified welders, when in fact they were not certified. Satin American stated these welders had not performed 4 any inshop welding, and that all welding was performed by outside contractors. This incorrect personnel qualification is identified as Nonconformance (87-01-02).
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ORGANIZATION: SATIN ~AMERICAN CORPORATION SHELTON, CONNECTICUT REPORT INSPECTION NO.* 09Qn1nC4/A7-n1 RFR111 T9
- par,r A nr 7 All other personnel qualifications and the procedures for controlling special procedures appeared adequate.
- 8. Audits of Satin The inspector reviewed an audit of Satin American performed on August 21-22, 1986 by Cygna Energy Servies for the Boston Edison Company. The auditors had documented four findings concerning supplier requalification, QA audit plans, manufacturing procedures, and training of personnel.
Corrective action to the above findings was implemented by Satin American in January 1987 and appears to have adequately addressed the auditors concerns.
Additionally, a survey report conducted August 26, 1986 by Southern Company Services was reviewed. No deficiencies were noted by the auditors during the survey.
- 9. Control of Measuring and Test Equipment The inspectors reviewed Section 12.0 of the Satin American Quality Assurance Manual for the Control of Measuring and Test Equipment. i The inspectors verified that the monthly calibration status for j test equipment and meter'ing devices had been documented as required.
The status reports from September 1984 until June 1987 were reviewed.
The inspectors went on a shop tour and randomly verified that pieces of test equipment such as clamp-on ammeters, high potential test sets, high current analyzers, megohmeters and voltometers were not i beyond their calibration due date listed on the calibration sticker l and on the calibration status report. The inspectors reviewed the I calibration dates for 8 measuring and testing devices and none I were beyond their due date. No Nonconformances were identified )
during this part of the inspection. 4
~10. Exit Meeting Following the inspection, an exit meeting was held where the findings of this inspection were discussed. The following were in attendance of the exit:
R. P. McIntyre, Reactor Engineer, USNRC l R. C. Martouich, QA Supervisor, Satin American Corporation i
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ORGANIZATION: SATIN AMERICAN CORPORATION SHELTON, CONNECTICUT REPORT INSPECTION NO.- 44Q01044/R7-01 RFSulTS: par,F 7 nf 7 4
J. B. Jacobson, Reactor Engineer, USNRC A. Nahahedian, Vice President, Satin American Corporation J. Satin, President, Satin American Corporation L. Gradin, Dir. Engr / President, EchoTech, Incorporated 3 i
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