ML18031A074

Interim Rept & Suppl on Termination Cabinet - Termination Modules Damaged Conductor Insulation. Describes Damage to Insulation on 200 Conductors in Termination Modules in Cabinet 1TC621 & 11 Cables.Correction Scheduled for 790215

ML18031A074
Person / Time
Site:	Susquehanna
Issue date:	01/04/1979
From:	PENNSYLVANIA POWER & LIGHT CO.
To:
Shared Package
ML18031A073	List: ML18031A072 ML18031A074
References
MCAR-1-29, NUDOCS 7901230194
Download: ML18031A074 (7)

Text

QUALITYASSURANCE PROGRAM MAlEMENT coRREOTIUE AGTICN REPo~ti 4 '>E 09 87 8 9 MCAR-0 REPORWNO.

JOB NO. 8856 Q No. 30.0 DATE '

.DESCRIPTION (Including rejerencet):

NCR 3030 was issued 9-28-78 to identify damaged insulation an conductors installed in termination Itcdules located in texmination cabinet 1'IC621. Thirty-nine termination Itcdules were inspected for cut, stripped or damaged insulation on module conductors and thirty-three modules were found with damaged ccnductors. An average of four to five conductors were determined to be damaged in each terminal Itcdule connector The terttunation cabinets are supplied by GE under. the+-1 NSSS contract. 'nspected.

o RECOMMENDED ACTION (Optional)

1. Construction to perform an investigation to determine the extent of damaged conductor insulation in termination mxiules not inspected to date.

2. Construction to document nonconfornences identified during investigation requested in One above.

3. Project Engineering to advise QP regazding reportability for this deficiency under 10 CFR 50.55e by 10-6-78.

REFERRED TO X ENGINEERING Q CONSTRUCTION Q QA MANAGEMENT Q Q PROCUREMENT ISSUED B Date Zf-~Z Project QA Engineer II REPORTABLE DEF ICIENCY NOTIFIED CLIENT Date r

Q YES P snags ate III CAUSE CORRECTIVE ACTION TAKEN See attached interim report and interim report supplement.

• • PP&L notified NRC per PLA-301 AUTHORIZED BY Date DISTRISVTIQN Dlv. QA Msnsger Mpr. of QA-TPQ FORMAL REPORT TO CLIENT Drv. Procursmsnt Mar, Protect Msnsgsr III section II Appiiet I Date Contructlon Msnsgcr engineering Msnsger Proiecs Engineer PEOI.Supt./PEDI. COnSt.Mgr,Or Proi.Procurement Mgr.

chl ~ I const. Qc Engineer or oc supervisor or CORRECTIVE ACTION IMPLEMENTED Procurement Suppher Qusllty Mgr. snd Div. Supplier Quslltv Mgr.

Qa Supervisor Client OPQ aA Mgr.

I.APD aa Mgr. VERIFIED BY Ptoj ~

.I QA Engineer Date trots .Ihe ln specs provided snd attach relerenre document.

SFP 21 130. Rev I 10/7tt 7BDM3 QI Vg

t

~

.OFc zl 7a 097546 MCAR 1-29 INTER3ld REPORT TERMINATION CABINET - TERMINATION MODULES DAMAGED CONDUCTOR INSULATION SUSQUEHANNA STEAM ELECTRIC STATION UNJTS 1 Ci 2 Prepared by:

Wecked by:

Approved by:

- Prospect Engineer

- Engineering Ma'nager SECHTEL POMEH COHPOHATION San I'rancisco, Uaiifor nia December 19, 1975 (P5-20/1)

s CsC 21 'P2 O.g gg4 g ATTACHMENT INTERIM REPORT MCAR 1-29 Descri tion NCR 3030 was issued 9/2'/75 to identiQ damaged insulation on conductors installed in termination moduLes located in termination cabinet 1TCb21.

Thirty nine termination modules were inspected for cut, stripped or damaged insulation on module conductors and thirty-three modules were found with damaged conductors.. Subsequently NCR 3030 was revised to identify approxi-mately 200 damaged T-MODS. An average of four to five conductors were de-termined to be damaged in each terminaL moduLe connector inspected. The termination cabinets are supplied by GE unaer the M-1 NSSS contract.

Cause The cause of the damage is attributed to the manual insertion and extrac-tion of terminated pins on connector sheLLs.

Anai 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-MODS 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 coarnon mode failure exists. The simul-taneous degradation and loss of safety-related circuits couLd resuLt in a safety hazard to the operation of the plant.

Project Engineering has determined the PGCC T-MODS def'iciency to be reportable under IOCFR 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. %he remaining U5 will be shipped to GE San Jose for repair/rework per the above procedure upon com-pLetion of' report by GE on the same subject.

Conclusion Upon completion of the repair/rework and re-test of the T-MODS per GE pro-

'cedures and criteria, the aef'iciency wiLL 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 - TERYiINATION MODULES DAMAGED CONDUCTOR INSULATION SUSQUEHANNA STEAM ELECTRIC STATION UNITS 1 h 2 Prepared by:

/,/

Checked by:

'-) ~Ci:.w Approved by:

- Project Engineer '

iclV.

- Engineering Manager

~

~,

>.i:'~

BECHTEL PO>lER CORPORATION San Francisco, California Decanber 29, 1978 (P5-21/1)

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 implenentation 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 7) 4113/C94A-744

2) 7442/C94A-410 8) 4113/C94A-714

3) 7442/C94A-412 9) 4119/C94A-736

4) 7442/C94A-409 10) 4128/C94A-806

5) 7119/C94A-715 11) 41.12/C94A-733

6) 4111/C94A-822 In letter BCLPC-5106, dated October 3, 1978, SFHO Document Control No. 094517, the Field Construction Manager, Mr. 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, was noted that. one cable'.4108/C94A-712 was found to have four (4) con-it ductors pulled out of its pin connectors. The quality of this cable is rendered indeterminate.

The above noted letters, plus BCLPC-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 Manager. The IOM 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 TWX CME-2044, dated 10/30/78, to J. R. Schmiedel from S. Schoenenberger. A copy is attached. This 7ÃX provides additional detail on Bechtel inspection results of the T-MODs in Unit 1.

Nonconfomance 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 inspection plan (F5-21/2)

~ Je2

~ ~

"7> ~097844 SUPPLEMENT TO INTERIM REPORT ON MCAR 1-29 PAGE TN'O and an approved repai'r procedure (reference IOM Document Control No. 097038 to H. Lilligh from 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-10055, 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 problems associated with the PGCC/ACR, according to GE is established as related 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 shor ting or introduction of external voltage sour ces 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 indicated in the'above description 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 basically 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)

SUPPLEMB1T'TO INTERlM REPORT ON SCAR 1-29 PAGE THREE Corrective actions to prevent recurrences of like problems in the futur e 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,

4) Assess all Unit 2 PGCC/ACR to assur e against similar problems.

Conclusions Upon completion of the repair /rework and re-test of the PGCC/ACR items per GE procedures and crite. ia, 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.