ML20204G309

Summary of 830422 Meeting W/Westinghouse in East Pittsburgh, PA Re Reactor Trip Breaker Problems.Changes in Mfg Controls & QA Program Planned.Attendance List Encl

ML20204G309
Person / Time
Issue date:	04/28/1983
From:	Potapovs U NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV)
To:	NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV)
References
REF-QA-99900330 NUDOCS 8305020420
Download: ML20204G309 (4)

Text

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gg 281983 MEMORANDUM FOR:

Docket File 99900330, Westinghouse Switchgear Division FROM:

U. Potapovs, Chief, Vendor Program Branch, Division of Vendor and Technical Programs

SUBJECT:

MEETING ON REACTOR TRIP BREAKER PROBLEMS On April 22, 1983, a meeting was held at the Westinghouse Switchgear Division, East Pittsburgh facility between T. Ippolito, R. LaGrange, and U. Potapovs of NRC and Westinghouse personnel identified in the attached attendance list to discuss possible contributing factors to the recent malfunctions of Westinghouse Reactor Trip Breakers with under voltages (UV) devices.

This memorandum addresses primarily the quality assurance and manufacturing process control aspects of the items discussed.

Over the past several years there has been a gradual tightening of QA measures within the Switchgear Division including both procurement and manufacturing controls for Class 1E equipment.

This process is still continuing and some of the recently adopted measures have not yet been finalized in a formal QA program document with implementing procedures.

As an example, during the pre-Salem supply period, the only major difference in procurement of commercial and Class 1E switchgear components was that a certificate of compliance was issued for the 1E devices.

The significance of this certificate was primarily that special care and attention was given to these parts during assembly and testing although no additional processing or inspection requirements were applied or documented for these items as compared to parts manufactured for commercial application.

Nuclear orders (1E) could be identified by "YN" designation'in the order number.

This designation, however, was applied to the. entire-switchgear assembly and not necessarily to the UV devices.

During the manufacturing and assembly of these devices all inspections including dimensional were performed on a sampling basis only.

(NOTE: At least some of the recent functional problems were directly attributed to improper dimensions).

During the " post-Salem" period, the following changes were instituted in the procurement and manufacturing practices for 1E equipment:

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Memo to Docket File 1.

Batch parts traceability system adopted for manufacture of 1E components including UV devices. Parts assembled and identified (YN designation) for specific orders.

No preassembled shelf items used.

2.

Requirements for configuration control added (1981) to processing and approving design and dimensional changes (NOTE:

In at least one instance, unseated shaft retaining rings, the problem could have.been avoided by effective configuration control).

3.

Critical dimensions identified for individual parts and assemblies which are required to be 100% inspected during the manufacturing process for Class IE components.

While the above changes are reportedly being implemented, formal QA program /

procedural modifications have not been completed at this time for all of these items.

Additionally, based on a policy letter dated April 21, 1981, all orders for Class 1E equipment, including replacement parts are cycled through the Westinghouse Nuclear Service Integration Division (NSID).

All 1E orders placed by utilities or others directly with the Switchgear Division are returned to the originator with instructions to reorder through NSID who then provides a technical /QA overview for the procurement of these items.

NSID treats the Switchgear Division essentially as an.outside vendor in the procurement process in that they conduct QA audits,~ product surveillance audits, and execute QA releases for specific' items prior to the shipment of these items to the user.

Historically, all DB undervoltage devices (manufactured from 1950 on) have been assembled at the East Pittsburgh plant while all DS type devices (manufactured since 1970) have been assembled at the Puerto Rico facility with Switchgear Division providing the overall QA management function.

In summary, it would appear that the outlined changes in the manufacturing controls and QA program, if properly iniplemented should provide reasonable assurance that the manufactured equipment will be capable of performing its intended function.

One item that appears to be essential in the procurement of these devices appears to-be.the need for the purchaser to clearly identify them as Class 1E otherwise the order may well be filled from commercial stock.

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Memo to Docket File s s

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Additionally', the list of critical ~ dimensions designated for 100% inspection should be~ broadened to include configuration verification (ex., proper installa-tion'and seating of retaining rings).,as well as at least a visual verification of the absence of significant defects in critical areas such as the cold formed

' tab on the trip bracket stsmping.

mangest Sgned by U. POTAP0YS" Uldis Potapovs, Chief Vendor Program Branch-

Attachment:

As Stated cc:

T. Ippolito R. LaGrange bcc: J. T. Collins R. L. Bangart J.'E. Gagliardo I. Barnes I

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