IR 05000498/1987036

Insp Repts 50-498/87-36 & 50-499/87-36 on 870518-22.No Violations Noted.Major Areas Inspected:Program for Insp & Rework of Electrical Splices Using Raychem Heat Shrinkable Tubing

ML20215J205
Person / Time
Site:	South Texas
Issue date:	06/12/1987
From:	Ireland R, Norman D NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV)
To:
Shared Package
ML20215J177	List: IR 05000498/1987036 ML20215J175
References
50-498-87-36, 50-499-87-36, IEIN-86-053, IEIN-86-53, NUDOCS 8706240361
Download: ML20215J205 (7)

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, .. i APPENDIX U.S. NUCLEAR REGULATORY COMMISSION

REGION IV

NRC Inspection Report: 50-498/87-36 Construction Permits: CPPR-128 CPPR-129 Dockets: 50-498 50-499 Licensee: Houston Light & Power Company (HL&P)

P. O. Box 1700 Houston, Texas 77001 Facility Name: South Texas Project, Units 1 and 2 Inspection At: Bay City, Texas Inspection Conducted: May 18-22, 1987 Inspector: [, b // 4//2/P^7 '

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D.~E. Norman, Reactor Ihspector, Engineering

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Da'te Section, Reactor Safety Branch Approved: d - MM, 4//2/577 R. E. Ireland, Chief, Engin'eering Section, Reactor

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Safety Branch Inspection Summary Inspection Conducted May 18-22, 1987 (Report 50-498/87-36)

Areas Inspected: Routine, announced inspection of the program for inspection and rework of electrical splices using Raychem heat shrinkable tubing. The inspection included actions relative to IE Information Notice 86-53 (improper installation of heat shrinkable tubing), previously identified NRC findings, i and the 10 CFR 50.55(e) identified by Incident Review Committee (IRC)

number 36 Results: Within the area inspected, no violations or deviations were

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Inspection Conducted May 18-22, 1987 (Report 50-499/87-36)

Areas Inspected: No inspection of Unit 2 was conducte Results: Not applicabl PDR ADDCK 0500 G .

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DETAILS l'

! Persons Contacted HL&P and Contractors 0.. Herring, Lead Electrical Engineer'--Bechtel

• K..Deska,. Electrical Engineer - Bechtel G. McCulley, QC. Inspector - Ebasco

• R. Ulandsy. EQ Engineer - Bechtel .!'

• B. Hernandez, Project QA" Analysis HL&P

• J.. Johnson, Project QA Supervisor'- HL&P,

• M.' Duke, Lead Electrical Engineer, I&C-HL&P

• S. Head, Lead Licensing' Engineer, HL&P

• W. Evans, Project Compliance Engiaeer, HL&P NRC

• C, Johnson, Senior. Resident Inspector, Construction

• Denotes those present at.the. exit interview on May 22, 198 ' Inspection Summary

'This inspection was performed to' follow up on the applicants activities taken in response to IE Information Notice (IEN) 86-53 and related activities which have,'or are being' taken in respect to Incident Review

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Committee'(IRC)36'(10CFR50.55e)whichreportedonRaychemsplice

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problems identified at the STP by the NRC and subsequently by the applicant. The. inspection scope included the following: . Review of Applicant's Actions Regarding Deficient Splices (1) As a result of the discovery of incorrectly installed Raychem I

. splices by the NRC staff reivew, and reinspection by HL&P based on concerns raised by the NRC during subsequent discussions, a 100 percent reinspection of splices was. initiated. The status of the reinspection as of May 22, 1987, was as follows:

(a) Reinspection 99 percent complet (b) 28 percent of splices did not comply with Raychem qualified configuration and required Nonconformance Reports (NCR).

I (c) 94 percent of NCRs dispositioned, with 39 percent identified for repair or rework, and 61 percent identified for use-as-i >

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. 1 In addition, splices in 37 Conax Electric Conductor Seal l Assemblies (ECAS) will not be reinspected because they are not !

accessible.' However, documentation for'those splices.had been reviewed and the splices appeared to be satisfactor NCR's had been documented on.all splices-for which-the

. documentation review and/or inspection identified ueviations from the Raychem splice configuration which had been tested and qualified or which had other workmanship-discrep ecies. The-majority of discrepancies fall in the following categories: j 7 Heat shrink tubing was oversized (or shim was rot used as i required).

. Holdout was exceeded (Substrate 0.D./Fu11y Recovered I.D.).

-Bend radius'was less than allowabl Seal length was insufficien L(2) Splices with workmanship deficiencies and some splices which did not comply'with Raychem configuration were either reworked or repla'ced. 0ther splices'which did not comply with Raychem configuration were accepted based on test reports.and calculations'which showed the installed configuration to be qualified for 40 years in the.STP environment. A summary of those reports are:

(a). Wyle Report 17859-02P dated March 11, 1987, qualified several Raychem NPKB~ splice configurations for the

. Commonwealth Edison Company. The report and Calculation E-6317-6 supported qualification of the following configuration' at' STP:

Overlap of.3/4 inch with .05-inch oversize tubing t0verlap of 1/2' inch with .066-inch oversize tubing Overlap of 3/4 inch with .065-inch oversize tubing Overlap of 1/2 inch with .008-inch oversize tubing and a bend radius ratio of.2.7.'

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These configurations were shown to be qualified in all-areasLof,the containment except for the reactor' cavity, pressurizer enclosure, and inside ine CRDM shroud; and outside containment except for rooms MAB-037, 039, 041, ;

059, and 244A- l

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(b) Wyle Report 17859-02B, dated March 11, 1987, qualified several Raychem WCSF splice configurations for Commonwealth '

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i Ediso The report and Calculation E-6317-7 supported qualification of the following configurations at STP: ;

i Tubing oversize by .06 inch Undersize tubing with holdout of Overlap of 2 inches.with a bend radius ratio of These configurations were shown to be qualified in all areas both inside and outside containmen (c) Action. Test Lab Report 22414-87N, dated August 27, 1986, qualified Raychem WCSF splice configuration for Toledo Edison. The report and Calculation E-6317-5 supported-qualification of splices with various overlaps and an undersize tubing with a holdout of 3.6 for use outside I containment and also outside rooms M054 and M244A through T l outside_ containment. Qualified life is also restricted to 30 years in rooms M037, M039, and M04 (3) During the NRC inspection the following items were identified which were not resolved during the inspection and warrant

! additional followup by the applicant and NRC:

(a) Each configuration qualified by the above reports usually qualified one or two attributes which were different from the configuration qualified by Raychem. If a combination of the attributes were included in a single splice (i.e.,

holdout of 3.6 and bend radius ratio of .5) the configuration may not be qualified. Pending review of records by the applicant to determine if unqualified configurations exist and further review by the NRC, this is considered to be an unresolved ite (Unresolved Item 498/8736-01)

(b) Splices qualified by report 17859-02P were supported by Calculation E-6317-6 for 40 years in a 120 F environmen Several areas outside the containment were at 135 F and there were no restrictions on using the splices in those areas. A calculation was subsequently performed by the applicant at 135 F and it was found that qualification could not be supported in rooms MAB-037, 039, 041, 054, and 244A through T. The applicant is expected to review :

appropriate documentation to determine if splices qualified by Report 17859-02P were used in any of those area This is considered to be an unresolved item pending further review by the NR (Unresolved Item 498/8736-02)

b. Review of Generic Considerations - The applicant has investigated the splice problems and found the root cause to be a failure to follow

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the requirements of the design specification and the instructions for

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termination of electrical cables presented in Procedure-SSP-2 As mentioned pr_eviously in this report, many existing splices which

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do not conform to the. configuration specified by Raychem have been !

determined to be qualified and have been dispositioned to use-as-i l However, any new splices installed in the plant will be to the i Raychem specified configuratio The following actions have been '

taken to ensure proper splice construction:

(1) Revision of SSP-26 (2) 100 percent in process QC' inspection of splices (3) Use of a splice detail design drawing for each scheduled splice and a field change request with details for all other (4) Use of a termination and installation card / termination inspection record.for each splic ,

(5) Retraining of engineering, inspection, and craft personne i IRC 364 will remain open pending completion of in process corrective actions and closure by the applican c. IEN 86-53 (Closed) .IEN 86-53, " Improper Installation of Heat Shrinkable Tubing," was issued to alert licensees and applicants to a potentially generic safety problem involving improper installation of heat shrinkable tubing over electrical splices and termination Problems involving improper installation of heat shrinkable tubing !

manufactured by Raychem were identified at a number of plants. This part of the NRC inspection was performed to followup on the applicants activities regarding problems addressed in the IEN and to provide additional information pertaining to the effectiveness of corrective actions being taken with regard to problems identified j previously in this repor The inspection scope included the ,

following:

(1) Procedures Review - Standard Site Procedure (SSP-26), Revision 1 dated March 20, 1987, " Termination of Electrical Cable" presents instructions for the installation, inspection, and documentation of electrical terminations, including splice It includes the provision that all vendor supplied Raychem kits will be installed per vendors instructions and that splices made from i bulk material provided by Raychem (should be constructed from l material selected from Raychem) instruction sheets. The material is then recorded on an EE580 termination card, which also includes an inprocess inspection record to be completed by a QC inspector for each splice. Details of each splice, based on vendor instruction, have been translated onto a splice detail drawing to be used by craft and inspection personne l

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When properly. implemented, it appears that the instructions should result. in splices that comply with qualified Raychem configuration.-

(2) Data Review - A random sample of splices, located in various devices (i.e., penetrations, pumps, solenoid valves, terminal .!

boxes,~ motor. operated valves, resistance temperature detectors I and pressure transmitters) was selected for this inspectio The sample included splices from several safety-related systems and was used in the selection of data to be reviewed and splices to be inspected during the walkdow The following data wa reviewed for the sample:

Original installation and inspection records .

Rework installation and inspection records Records for 100 percent reinspection NCR's resulting from reinspection Qualification records for personnel observed making and inspecting splices  ;

This review indicated that deviations from Raychem specified I splice configurations, observed as a result of record review and walkdown inspections, had been noted on reinspection records and then documented as a nonconformance on an NC Where test reports were available to demonstrate qualification of a particular configuration, the splice was dispositioned as acceptable and no rework was require When test reports were not available to support a splice, or a workmanship deficiency existed, the splice was replaced or reworked to bring it into i conformanc (3) Walkdown Inspection - The NRC inspector performed an inspection of the sample, which consisted of approximately 140 splice The splice inspection record completed by the applicant during his walkdown was used as a checklist;, therefore, the inspection record and splices were reviewed concurrently. During the walkdown inspection, the following two discrepancies, which were considered to be isolated cases were identified by the NRC inspector:

The bend radius of the Raychem splice in cable .

D1MS11C2PA-2, located in device D1MSPT025, is approximately l 1/4 inch, which is less than any configuration qualified by i'

test report The outer shrink tubing on the splice in cable  ;

B1FWO7C5SF-1, located in device B1FWPA008 has a small cut, i

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The discrepancies were documented on NCRs SE06367 and SE06368, respectively. Disposition had not been made by the end of this

' inspection, therefore,, disposition will be reviewed during a subsequent inspection. This is considered an open item (498/8736-03). Exit Intervie The NRC inspectors met with the applicant representatives denoted in !

paragraph 1 on May 22, 1987, and summarized the scope and findings of the inspectio .

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