ML17138A550
| ML17138A550 | |
| Person / Time | |
|---|---|
| Site: | Susquehanna  |
| Issue date: | 01/26/1979 |
| From: | Robert Carlson NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I) |
| To: | Curtis N PENNSYLVANIA POWER & LIGHT CO. |
| References | |
| NUDOCS 7903210045 | |
| Download: ML17138A550 (11) | |
Text
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Docket No. 50-387 UNITED-STATES NUCLEAR REGULATORY COMMISSION REGION I 631 PARK AVENUE KING Ol PRUSSIAN PENNSYLVANIA 19406 JSIH 26 l9 Pennsylvania Power 8 Light Company ATTN:
Nr. Norman W. Curtis Vice President Engineering and Construction (N-4) 2 North Ninth Street Allentown, Pennsylvania 18101 Gentlemen:
Subject:
'amage to Wiring on. Termination Nodule Connectors for ACR Equipment (Your letter of January 15, 1979)
Thank you,for your letter, referenced
- above, which forwarded an interim report pursuant to 10 CFR 50.55(e) regarding the. subject matter.
Your report wi-ll-be reviewed and.evaluated; and should we require additional information concerning this matter, we will contact,you.
Your cooperation with us is appreciated.
Sincerely, I
Jl Robert T. Carlson, Chief Reactor Construction and Engineering Support Branch CC:
A. R. Sabol,
- Manager, Nuclear guality Assurance W. E. Barberich, Licensing Engineer
TWO NORTH NINTH STREET.
ALLENTOWN, PA.
18101 PHONE:
(215) 821-5151 NORMAN W. CURTIS Vice President. Engineering C Construction 821-5381 Januaxy 15, 1979 Mr. Boyce H. Grier Director, Region I U.S. Nuclear Regulatory Ccmnission 631 Park Avenue King of Pxussia, Pennsylvania 17406 SUSQUEHANNA STEM ELECTRIC STATICN SUPPXZ>KNTAL INFORMATION K) ~MM REPORT OF FABRICATION DAMAGE TO WIRING GN TERMINATIONMCIXKZ CONNECK)RS FOR ACR EQUIPMENT (REF PLA 301 r NOVEMBER 14 g 1978)
DCCran NO.:
50-397
. LICENSE NO.: CPPR-101 ER 100450 FIZE 840-4 PLA-313
Dear Mr. Grier:
This will sexve to confirm PPGL's report of 1/9/79 (A. R. Sabol, PPGL to NRC Reactor Inspector, A. Finkel) which conveyed supplemental infoxmation relative to the subject interim report.
The initial report advised that the deficiency, which was peculiar to termination module connector plugs, was under further investigation.
Sub-sequent1y, during the process of shen~ning PGCC cables, it was noted that a high percentage (apprcacimately 30%) of non-safety related cables also exhibited cuts and nicks similar to those reported for the T-mxlules.
These PGCC cables, which were also supplied by G.E., are used to interconnect the ACR pane1s and the texmination cabinets.
Specifically, the deficient conditions noted during the process of shortening the PGCC cables included the follcRring:
o Conductor insulation nicked or damaged o
Wires not properly instal1ed or criznped in the'onnectotr pins o
Improper'oldering (this involves carxying the cable shield through the connector plugs via a connector pin)
PENNSYLVANIA POWER 8
LIGHT COMPANY
Mr. Boyce H. Grier January 15, 1979 Cable shortening of safety-related cables has not yet started ard, there is no absolute evidence that they are so affected; however, due to pxoblans identified for the high percentage of non-safety related cables, the condition is being projected as generic and, therefore, potentially reportable under 10CFR50. S5 (e).
- 'he. conditions relative. to PGCC cable have been identified-by Bechtel and are
.being controlled under NCR-3231 even though the deficiencies concern non-
', safety. related circuits.
Bechtel has also documented the conditions i'n its,.
K2Z-1-29 (attached) and a January 2; 1979,, supplement thereto.
You willbe advised of further developnents as they occur.
Very truly yours, N. W.. Curtis Vice President-Engineering, 8.Construction ARS mcb cc:
Mr. J. G. Davis (15)
Acting Director-Office of Inspection 6 Enforcement U. S. Nuclear Regulatory Carimission Washington, D.C.
20555 Mr. G. McDonald, Directox (1)
Office of Management Information 6 Pxogram Contxol U. S; Nuclear Regulatoxy Ccmnission
'ashinIptmn,'.C.
20S55 Mr. Robert M. Gallo (1)
U. S. Nuclear Regulatory CcmnLssion P.
O. Box 52.
Shickshinny, Pennsylvania 18655 4
JOB NO.
8856 r
~ QUALITYASSURANCE PROGRAM MANAGEMENTcoRREOTtvE AOTioN REIIT OcT 4 7a D 9 3 7 8 9 MCAR-'I REPORT NO.
1-29 O NO.
30 ~ 0 DATE I *,DESCR IPTION (incltfding references):
NCR 3030 was issued 9-28-78 to identify damaged insulation on conductors installed in termination nadules located in termination cabinet 1TC621.
Thirty-nine termination axxlules were inspected for cut, stripped or damaged insulation on rmdule conductors and thirty-three mxiules were found with damaged ccnductors.
An average of four to five conductors were determined to be damaged in each terminal rreQule connector
'nspected.
The termination cabinets are supplied by GE und~. the M-1 NSSS contract.
~ RECOMMENDED ACTION (Optionai).
I 1.
Construction to perform an investigation to determine. the extent of damaged
~
conductor insulation in termination modules not inspected to date.
2.
Construction to document nonconformances identified during investigation requested, in One above.
3.
Pxoject Engineering to advise QA regarding ~portability for this deficiency under 10 CFR 50.55e by 10-6-78.
REFERRED TO QX ENGINEERING Q CONSTRUCTION Q PROCUREMENT Q OA MANAGEMENT Q
ISSUED B Project OA Engineer Oats
'l REPORTABLE DEFICIENCY
@NO I I I CAUSE Qx YES P o anage ate NOTIFIED CLIENT ** 1 4
Date CORRECTIVE ACTION TAKEN See attached interim report and interim report supplement.
ProjectMensger Contructlon Manager Engineering Manager Protect Englnecr Prof.Supt./Proj. Const.Mgr.or Prof.Proeurernent Mgr.
chief const. Qc Engineer or QE supervnor or Procurement Suppher Quality Mgr. snd Div. Supplier Ouslfty Mgr.
OA Supervisor Chant GPD QA Mgr.
EAPD QA Mgr.
FORMAL REPORT TO Cl IENT IlfSection li Applies)
CORRECTIVE ACTION IMPLEMENTED VERIFIED BY Project QA Engineer SFP 31130, Rsv I to/11j l:
+Des ribs In roses provided snd attach referenre document.
Oats Oats
MCAR 1-29 INTERIM REPORT TERMINATION CABINET - TERKlNATION'MODULES DAMAGED CONDUCTOR INSULATION SUSQUEHANNA STEAM ELECTRIC STATION UNITS 1 h 2 Prepared by:
ecked by:
Approved by:
- Prospect Engineer
- Rhgineer ing Manager
).i BECHThi POHEH CUHPOHATION San l'rancisco, California December 19, 1975 (P5-20/1)
ATTACHMENT gEc 2.1 '72 Q.g 7$ 4n INTERIM REPORT MCAR 1-29 Descri tion NCR 3030 vas issued 9/25/75 to identify damaged insulat;ion on conductors installed in termination modules located in termination cabinet 1TCb21.
Thirty nine termination modules were inspected for cut, stripped or danaged insuLation on module conductors and thirty-three modules were found with damaged conductors.
Subsequently NCR 3030 vas revised to identify approxi-mately 200 damaged T-HODS.
An average of four to five conductors vere de-'ermined to be damaged in each terminal module connector i'nspected.
The termination cabinets are supplied by GE under the M-1 NSSS contract.
Cause The cause of the damage is attributed to the manual insert;ion and extrac-tion of terminated pins on connector sheLls.
Anal sis of the Safet Im lications The system design was reviewed and the foLlowing was concluded for the worst condition.
The deficiency which involves damaged insulation of PGCC T-HODS if'ndetected or uncorrected could permit shorting or introduction of external voLtage sources into safety related circuits which couLd prevent the circuits from performing the designed safety function.. Since the occurrence of da-maged insulation is a random thing and could occur in any and all safety re-lated circuits the possibility of a coaznon mode failure exists.
The simuL-taneous degradation and loss of safety-relatea circuits could resuLt in a saf'ety hazard to the operation of the plant.
Project Engineering has determined the PGCC T-HODS def'iciency to be reportable under LOCFR 50.55(e).
Corrective Action GE San Jose is preparing a repair procedure for the T-MODS.
The first 32 are in the process of being totally reworked.
The remaining U5 will be shipped to GE San Jose for repair/rework per the above procedure upon-com-pletion of a report by GE on the same subject.
Conclusion Upon completion of'he repair/rework and re-test of the T-MODS per GE pro-cedures and criteria, the aef'iciency vilL have been corrected and the po-tential safety hazard will have been eliminated.
GE forecasts completion of this effort by February 15, 1979.'P5-20/2)
MCAR 1-29 INTERIM REPORT SUPPLANT ON
. TERMINATION CABINET -- TERMINATION MODULES DAMAGED CONDUCTOR INSULATION SUSQUEHANNA STEAM ELECTRIC STATION'NITS 1
5 2 Prepared by:
Checked by: /!
Approved by:
- Prc]ect Engineer ', '
Engineering Manager BECHTEL PO)KR CORPORATION San Francisco, California December 29, 1978 (P5-21/1)
gy2
'79 <097844 SUPPLEMENT TO INTERIM REPORT ON MCAR 1-29 Description of Related Cable Problems Subsequent to the issue of MCAR 1-'29 and during the investigation relative to the termination modules located in termination cabinet 1TC621, additional problems were identified.
In letter BCLPC-5105, dated October 3,
- 1978, SFHO Document Control No. 094517, the Field Construction Manager, Mr. S. Schoenenberger informed PP&L, that on PGCC/ACR, during implementation-of General Electric's FDDR-KR1-521, Rev.
0 (Generic Cable Retrofit) rework, it was noted that numerous insulation damages (cuts, nicks and shield solder connections, etc.) were found.
Due to the high percentage of damaged cable, the quality of all terminations is rendered indeterminate.
Below is a list of those cables which were found damaged:
- 1) 7442/C94A-408
- 2) 7442/C94A-410
- 3) 7442/C94A-412
- 4) 7442/C94A-409
- 5) 7119/C94A-715
- 6) 4111/C94A-822
- 7) 4113/C94A-744
- 8) 4113/C94A-714
- 9) 4119/C94A-736
- 10) 4128/C94A-806
- 11) 41.12/C94A-733 In letter BCLPC-5106, dated October 3,
- 1978, SFHO Document Control No. 094517, the Field Construction Manager, Hr. S. Schoenenberger, also informed PP&L, that on the PGCC/ACR, during implementation of General Electric's FDDR-KR1-521, Rev. 0, (Generic Cable Retrofit) rework, it was noted. that one cable
~~4108/C94A-712 was found to have four (4) con-ductors pulled out of its pin connectors.
The quality of this cable is rendered indeterminate.
The above noted letters, plus BCL?C-5104, dated October 3, 1978 - basically describing the same problem given in the MCAR description - were forwarded to Project Engineering by IOM QK-4056, dated October 17,
- 1978, SFHO Document Control No. 094517, from the Field Construction Hanager.
The IOH was provided as an assist in determining possible reportability of cable deficiencies found in the Power Generation Control Complex/Advanced Control Room. (PGCC/ACR).
An updated status on T-MOD inspection was provided in TMX CWE-2044,,
dated 10/30/78, to J.
R. Schmiedel from S. Schoenenberger.
A. copy is attached.
This TMX provides additional detail on Bechtel inspection results of the T-MODs in Unit 1.
Nonconformance
- Report, (NCR) 3231 was generated to document the additional items/problems within the PGCC/ACR complex.
General Electric (GE) is in the process of preparing an FDI which is to detail a complete inspect,ion plan (P5-21/2)
SUPPLEMENT TO INTERIM REPORT ON MCAR 1-29 PAGE THO
~ F2
'~~ ~09784<
and an approved repair procedure (reference IOM Document Control No. 097038 to H. Lilligh fr om C. Turnbow - copy attached).
For types of 'problems found see pages 3, 4, 5, and 6 of the attached NCR 3231.
The Pennsylvania Power and Light Company (PP&L) issued a letter to Project Engineering, dated November 10,
- 1978, SFHO Document Control No. 096038, stating their requirements for resolving the PGCC T-MOD problems.
A copy is attached..
Project Engineering responded to PP&L with a letter BLP-'0055, dated November 21,
- 1978, Document Control No. 096266, providing a Bechtel inspection program as requested by PP&L.
A copy is attached.
Cause The cause of probleas associated with the PGCC/ACR, according to GE is established as r elated to inadequate fabrication technique.
Analysis of Safety Implications The system design was reviewed and the following was concluded for the worst condition.
The deficiency which involves damaged PGCC/ACR,cable connectors if undetected or uncorrected could permit shorting or introduction of external voltage sources into safety related circuits which could prevent the circuits from performing the designed safety function.
Since the occurrence of damaged cable connectors is a random thing and could occur in any and all safety-related circuits, the possibility of a common mode failure exists.
The simultaneous degradation and loss of safety-related circuits could result, in a safety hazard to the operation of the'lant.
Project Engineering has determined the PGCC/ACR deficiency to be reportable under 10CFR 50.55(e).
Corrective Actions Corrective actions in the form of Inspection programs by Bechtel and GE are identified in correspondence i'ndicated in the'above descript,ion and in PP&L letter to Project Engineering, PLB-9354, dated December 14,
- 1978, SFHO Document Control No. 097413.
A copy is attached.
Corrective actions to-date have been basic.'ally the initiation of the in-spection program and repair-rework procedures.
It is currently anticipated that repair or rework of all deficient Unit 1 PGCC/ACR cables are scheduled for completion by February'15, 1979.
(P5-21/3)
~
~
~
r SUPPLEMENT'TO INTERIM REPORT ON MCAR 1-29 PAGE. THREE e2
'7~ ~097844 Corrective actions to prevent recurrences of like problems in the future including Unit 2 facilities are indicated by GE to be:
1)
Appropriate training of personnel
- involved, 2)
Revision of fabrication techniques, 3)
Increased/revised inspection activities,
--')
Assess all Unit 2 PGCC/ACR to assure against simi.lar pr oblems.
Conclusions Upon completion of the repair/rework and re-test of the PGCC/ACR items per GE procedures and criteria, the deficiencies will be corrected and the potential safety hazard will be eliminated.
GE forecasts completion of repair/rework effort by February 15, 1979.
Additional GE fabrication personnel training, inspection and revised fabrication techniques should preclude recurrence of similar problems in the future.
Ir
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