ML20141F399
| ML20141F399 | |
| Person / Time | |
|---|---|
| Issue date: | 12/27/1985 |
| From: | Merschoff E, Petrosind Jj NRC OFFICE OF INSPECTION & ENFORCEMENT (IE) |
| To: | |
| Shared Package | |
| ML20141F380 | List: |
| References | |
| REF-QA-99900871 NUDOCS 8601090311 | |
| Download: ML20141F399 (7) | |
Text
ORGANIZATION: ELGAR CORPORATION SAN DIEG0, CALIFORNIA REPORT INSPECTION INSPECTION NO.- 99900871/85-01 DATE(S h 09/17-19/85 ON-SITE HOURS- 44 CORRESPONDENCE ADDRESS: Elgar Corporation ATTN: Mr. P. A. Zecos Vice President and General Manager 9250 Brown Deer Road San Diego, California 92121 ORGANIZATIONAL CONTACT: Mr. C. B. McVicker - QA Manager TFIFPHnNF NllMAFQ- /610 a90 DORS
- PRINCIPAL PRODUCT: Uninterruptible Power Supplies NUCI EAR INDUSTRY ACTIVITY: Approximately 2%
Current in house nuclear orders: Vogtle, Indian Point and WPPSS ASSIGNED INSPECTOR: /2/e er f.aJ. J. Petrosino active Inspection Section (RIS) Date OTHER INSPECTOR (S): E. H. Yachimiak, RIS APPROVED BY: te/er/rr
'E. W. Merschof fff#iief, 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: (1) Obtain information in regard to Elgar inverters originally sold to TVA (Hartsville) which were recently purchased by Ft. Calhoun Station; (2) Review an Elgar problem evaluation concerning a recent River Bend fuse block stud problem, which was identified (continued on page 2)
PLANT SITE APPLICABILITY: Elgar mode! #UPS-253-1 (fuse block stud problem):
Beaver Valley #2 (50-412), Comanche Peak 1 & 2 (50-445/446), Millstone #3 0601090311 851227 PDH GA999 ENVE O R
C ORGANIZATION: ELGAR CORT 0 RATION SAN DIEGO, CALIFORNIA REPORT INSPECTION NO.: 99900871/85-01 RESULTS: PAGE 2 of 5 B. SCOPE: (continued) on an Elgar 25 KVA inverter; and (3) Evaluate the Elgar quality assurance program for adequacy and implementation of applicable requirements.
PLANT SITE APPLICABILITY: (continued)
(50-423),NineMilePoint#2(50-410), River Bend #1 (50-458), Seabrwk #1 (50-443), South Texas #1 & 2 (50-498/499), Vogtle #1 & 2 (50-424/425) and WPPSS #3 (50-508)
A. INSPECTION ISSUES:
- 1) Obtain information to support an NRC inspection of refueling outage modifications at the FT. Calhoun nuclear station.
- 2) Review Elgar's evaluation of a fuse block stud problem which was reported to the NRC by the River Bend station as a 10 CFR Part 50.55(e) concern.
- 3) Evaluate the adequacy of Elgar's implementation of its Quality Assurance Program.
B. INSPECTION FINDINGS:
- 1) Contrary to Criterion V cf Appendix B to 10 CFR Part 50 and Section 2, " Quality Assurance Program", of ANSI N45.2-1977, no quality assurance manual requirements or records were in evidence to assure that all Elgar personnel performing activities affecting safety were indoctrinated as to the QA program requirements (85-01-01).
- 2) Contrary to Criteria III and V of Appendix B, to 10 CFR Part 50, a review of the circumstances surrounding a 25 KVA inverter fuse block stud deficiency revealed the following (85-01-02):
a) No documents were in evidence to assure that the design basis for current carrying ccnductors associated with the P-2660 fuse holder were correctly translated into specifications, drawings, procedures, or instructions.
b) No instructions, procedures, or drawings were in evidence to assure that the interconnection assembly of a 400 ampere I fuse holder (858-P266D), a 400 ampere shunt resistor
, (857-PR4), and a bus bar (943-390-20) were sa*.isfactorily l
accomplished for Elgar static inverter model 253-1 filter panel assembly.
l l
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ORGANIZATION: ELGAR CORP 0PATION SAN DIEGO, CALIFORNIA REPORT INSPECTION NO.: 999008/1/85-01 RESULTS: PAGE 3 of 5 C. OTHER COMMENTS:
- 1) Discussions with Elgar Corporation (Elgar) personnel and a review of selected records concerning Elgar's 7.5 KVA (model
- 752-1) and 10 KVA (model #103-1), were performed. Areas that were discussed included; seismic testing, possible equipment requalifications, pre-operational testing, structural attachments, and storage. General Electric (GE) was TVA's agent for the original procurement of the inverters, which were purchased in 1980 for the Hartsville nuclear station.
Omaha Public Power District (OPPD) recently purchased the inverters from TVA for use in their uninterruptible power supply systems (UPS).
The inverters will be installed at the Fort Calhoun nuclear station during the current refueling outage. The UPS system will contain two 7.5 KVA inverters and one 10 KVA inverter for each power train,.
for a total of six inverters.
Copies of Elgar and GE specifications, purchase orders, procedures, requirements, and other associated records were obtained from Elgar.
These will be utilized by an NRC inspection team at Fort Calhoun station for a selective verification to assure the equipment conforms to all applicable requirements and is traceable back to Elgar.
- 2) The NRC was notified of a deficiency located inside class 1E uninterruptible power supplies furnished by Elgar and installed at the River Bend nuclear station. The deficiency involved a loose stud on a 450-600 Amp rated fuse block located on a " filter panel assembly", inside a 25KVA Elgar static inverter, model number OPS 253-1, which is part of the class 1E UPS system. The loose stud was identified on the side of the fese block which was mechanically connected to a bus bar, which subsequently was connected to a shunt type resistor. This involved a straight line connection of the components, with the bus bar in between the resistor and the fuse block.
During discussions with assembly line personnel and observations of how the components were actually assembled, it was revealed that no fabrication drawings or instructions had been generated for that activity.
Subsequent discussions with engineering and quality assurance personnel revealed that engineering had not performed any design analysis to allow for the nontypical utilization of the fuse block terminal stud as a current carrying conductor.
ORGANIZATION: ELGAR CORPORATION SAN DIEGO, CALIFORNIA REPORT INSPECTION NO.: 99900871/85-01 RESULTS: PAGE 4 of 5 Normal industry practice is to have direct physical contact between the bus bar and the fuse, whereas Elgar's configuration utili:es the stud and stud hardware as a current carrying conductor.
Discussions with the fuse block manufacturer determined that the fuse block stud is a copper alloy which is tin plated, while the nuts and washers could be stainless steel or plated steel alloys. The manufacturer also indicated that the bus bar and fuse should make direct mechanical contact to reduce high heat conditions created by using the stud hardware as a current carrying conductor (see page 1 for affected plants).
The safety significance of this problem is that during a loss of offsite power, an inverter failure could result in the loss of a 120 volt ac class 1E power supply for plant control and instrumentation.
Elgar Corporation is currently evaluating all the circumstances surrounding this problem pursuant to 10 CFR Part 21. However, it was noted by the NRC inspector that Elgar's evaluation of the deficiency did not take into consideration any root cause areas other than licensee induced stud damage. Currently, Elgar is evaluating the lack of design documents and lack of in-process manufacturing controls as a potential root cause of the reported deficiency (Nonconformance 85-01-02).
- 3) Abriefqualityassurance(0A)programimplementationreviewwas conducted. Areas that were specifically reviewed included; measuring and test equipment, and training and indoctrination.
A sample of approximately twelve electrical crimping tools were examined for unique identification, calibration control, records of calibration, and traceability back to the National Bureau of Standards. All aspects of this area were satisfactory.
The QA manual adequately addressed the 18 criteria of Appendix ,
B to 10 CFR 50 and ANSI N45.2. Within the individual sections, the area of indoctrination and training of personnel who perform activities affecting safety was reviewed. It was noted that an effective program of training and indoctrination was documented and appeared to be adequately implemented for the QA/QC and manufacturing personnel. However, no program was in place which would indoctrinate other personnel who performed activities af fecting quality. Areas for which the program did not address indoctrination were engineering, design, procurement, customer services, and all management positions other than QA (Nonconformance 85-01-01).
i
ORGANIZATION: ELGAR CORPORATION ,
i SAN DIEGO, CALIFORNIA REPORT INSPECTION NO.: 99900871/85-01 RESULTS: PAGE 5 of 5
- 4) Plant Tour:
A plant tour was conducted which included all manufacturing aspects of Elgar's facility at San Diego. Material receipt inspection, material control, in-process quality control functions, and wave soldering processes, were some of the areas which were observed.
No deficiencies were noted during this part of the inspection.
D. PERSONS CONTACTED:
Name Title Company Susan Pritzi Program Administrator Elgar "
Ed Noble Supervisor 0A Test /Insp. Elgar Clyde B. McVicker QA Manager Elgar *"
Mike Murray OA Engineer Elgar *"
Gilbert Cota QA Inspector Elgar Vernon Lawson Supervisor - Magnetics Elgar Clydine Ford Supervisor - Boards Elgar Sue Zorich QC Inspector - Boards Elgar Steve Sedio Engineering Manager Elgar Josie Smith Training Specialist Elgar Phyllis Kelly Supervisor - Production Elgar Debbie Nason Human Resources Elgar Fred Welch Sr. QA Technician Elgar Vice President / Gen. Manager Elgar "
P. A. Zecos Elgar **
Tom Erickson Vice President Human Pos.
George Seibert Electrical Engineering Dept. Stone & Webster (1)
Thomas Crouse OA Manager - River Bend Station GulfStatesUtl.(1)
Rnbert Stafford Director - Quality Services Gulf States Utl. (1)
Al Wilkinson Manager Applications Engineer Gould Inc. (1)
" Exit meeting only
- " Entrance and exit meeting (1) telephone contact only i
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