ML18024A101

Letter Attaching a Report of Defects Discovered During Qualification and Manufacturing of Control Room Systems

ML18024A101
Person / Time
Site:	Susquehanna
Issue date:	07/19/1978
From:	Sherwood G General Electric Co
To:	Engelken R NRC/IE, NRC/RGN-V
References
MFN 297-78, WHD 176-78
Download: ML18024A101 (5)

Text

~ pg-063-DOS (Rg GENERAL:'i . ELECTRIC NUCLEAR ENERGY PRO SECTS DIVISION

NERAL ELECTRIC COMPANY, 175 CURTNER AVE.. SAN JOSE. CALIFORNIA 95125 HC 682, (408) 925-5040 July 19, '1978 MFN 297-78 MHD 176-78 Mr. Robert H. Engelken, Director Office of Inspection and Enforcement

'44 Nuclear Regulatory Commission Region 5 1990 North Calif'ornia Walnut Creek, CA 94596

SUBJECT:

REPORTING OF DEFECTS DI)COYERED DURING QUALIFICATION AND MANUFACTURING OF CONTROL ROOM SYSTEMS This is to advise the NRC staff of three defects reportable per 10CFR Part 21. As discussed with Hr. Lucien Vorderbrueggen by Walter H.

O'Ardenne, Manager - BWR Product Standards at 4 p.m. on July 15, 1978 these defects are in previously shipped control room systems and affect three projects under construction. This constitutes the written report pursuant to 10CFR Part 21.21.

These defects were determined to be reportable at 4:21 p.m. PDT on July 14, 1978. Attached hereto are reports of the defects as they apply to the specific licensees.

General Electric's Control and Instrumentation Department, the designer and manufacturer of these systems, has implemented changes to its,quality assurance program to prevent similar occurrences and have initiated corrective actions necessary to resolve the specific defects with the affected licensees. These and further actions to correct the issue are shown in the attachment.

Although the control syste'ms were shipped, we believe there is a high probability that these conditions would have been detected prior to plant operation. The plant preoperation and startvp tests and audi,ts conducted by General Electric are designed to detect and correct conditions such as described by the attached prior to plant operation.

Glenn G. Sherwood, Hanager Shfptv AnrI'Iic"ancona I flno~a+i~n GGS cc/29 (III; $

Attachment

V ATTACHMENT I. DEFECT IN CONTROL ROOM SYSTEM SUPPLIED FOR PENNSYLVANIA POMER LIGHT'S SUSQUEHANNA 1 PROJECT On July 14, 1978 room benchboard it was determined that a defect existed in a ontrol manufactured by the General Electric Company uclear Energy Business Group and supplied to Pennsylvania Power 8 ight for application on the Susquehanna 1 project.

The Reactor Protection System mode switch is a Rundel roduct manufactured by Gould, Inc.. The mode switch performs numerous s ety re1ated inter-lock and bypass functions and must be seismically alified to assure that plant conditions during and after a Safe Shu own Earthquake are not aggravated or that the probability of occurr nce of an analyzed plant event has not increased.

The seismic examination conducted by an ind endent laboratory concluded that the prototype switch had passed the s smic examination but exhibited some contact chatter.

• Based on that info mation; a safety-related

, control room benchboard containing the de switch was shipped to Su quehanna 1. During a subsequent in estigation for contact chatter at the GE Seismic Test Facility the pro type switch failed. The failure

~ mechanism was attributed to a to'1er nce buildup (due to electrical separation barriers) which caused he switches pr imary contact cam to separate from the contact cam in he adjacent contaot block. All contact blocks downstream of this separ ion ceased to function.

The following corrective act ns have been taken:

Pennsylvania Power 6 ight has been instructed to "red tag" the switch until the ap opriate corrective action is complete.

2. All inhouse'und Product mode switches have been removed from the affected benchb ards.

General Elec ic engineers are working with the vendor to effect a qualified s itch or a suitable alternate.

The following orrective actions are to be taken:

l. Seism examination of a fixed switch ...... ...... Aug. 4, 1978 (tentative)

Qu ify a controlled batch of switches d issue installation'nstructions ...... June 30, 1979 (tentative)

It 1 or 2 is unsuccessful then select and qualify new switch and issue installation instruction ...................................... Dec. 31, 1979

I I. DEFECT IN CONTROL ROOM SYSTEM SUPPLIED FOR WASHINGTON PUBLIC POMER SUPPLY SYSTEMS HANFORD NUClEAR STATION On July 14, 1978 it was determined that a 'defect existed in the power generation control complex (PGCC) manufactured by the General Flectric Company Nuclear Energy Business Group and supplied to Washington Public Power Supply System for application as a control room system in the Hanford 2 Nuclear Station. The PGCC is the nuclear steam supply system (NSSS) control room panels which are prewired and functionally verified by General Electric.

During an electr ical separation audit of engineering documentation utilized in the manufacture of the Hanford 2 PGCC several deviations were discovered that obviate compliance with the single failure criteria.

One such deviation affects the ability of the Reactor Protection System to per form i ts funct i on.

The following corrective actions have been taken:

l. Washington Public Power Supply System has been notified.

2. Effort initiated to check all panel wiring diagrams against actual manufacturing documentation:

The following corrective action is to be taken:

Issue'"from-to", (wire by wire) instructions to correct any discrepancies ...................... March 30, '/979

III. DEFECT IN CONTROL ROOM SYSTEM SUPPLIED FOR.PENNSYLYANIA POWER 8 LIGHT'S SUSQUEHANNA 1 PROJECT AND MISSISSIPPI POMER 8 LIGHT'S GRAND GULF 1 PROJECT On July 14, l978 it was determined that a defect, existed in the con ol room panels manufactured by the General Electric Company Nuclear Energy Business Group and supplied to Pennsylvania Power 6 Light (Susqy/hanna 1),

and Mississippi Power 5 Light (Grand Gulf 1) for application E a control room system.

GE-CR2940 control switch assembly requires a locking rin which secures the switch in place on the benchboar d face. An error 'anufacturing documentation utilized to manufacture control room p els depicted the GE-CR2940 control switch without its position locki g ring. Consequently the switches were installed without the locking r g. As a result, the entire switch body may rotate rathe~ than the o rator, thereby preventing the switch function.

GE-CR2940 control switches are utilized for safety related manual control functions. The above mentioned d viation could delay manual operation during an analyzed plant even such that technical specification limits could be exceeded. It is beli ed that manual operation could only be delayed since the plant. oper or would be informed by numerous

-diverse alarms and annuciators of e omitted manual action.

The fo'llowing corrective action . have been taken;

l. Pennsylvania Power 5 Li t and Mississippi Power & Light have been notified.

2. The manufacturing cumentation has been revised to assure installa-tion with the loc ng rings prior to further equipment shipment.

3. Locking rings d installation tools are ordered for on-site instal-lation at the Susquehanna 1 and Grand Gulf 1 site.

4. Issue ins llation instructions for 'Grand Gulf 1.

The followi corrective action is to be taken:

1. Iss e installation instructions for Susquehanna 1 ...Nov. 24, 1978.

JH cc/31-32, 30