ML18031A316

Final Deficiency Rept Re Panel Inserts Wiring & Device Damage.Caused by Manufacturing Personnel Error & Crimping Tool Malfunction Resulting from Inadequate Qa.Connector Pins Repaired,Reworked & Tested

ML18031A316
Person / Time
Site:	Susquehanna
Issue date:	10/30/1979
From:	Hollingshaw H, Sisesta J BECHTEL GROUP, INC.
To:
Shared Package
ML18031A315	List: ML18031A314 ML18031A316
References
REF-PT21-79-159-001 MCAR-1-33, NUDOCS 7912040353
Download: ML18031A316 (50)

Text

SCAR 1-33 SDPPUMNT PENAL RZPOar PANEL OC653 .

INSERTS 72C and 73C

%RING AND 1KFECE DAMAGE SUSQUEHANNA SIKAN ELEVIBXC 8MECN UNZXS I5 2 Prepared by:

Checked by:

Approved by".

- Pro5ect Zhgineer BRUMMEL PCS CORPORATXCN San Francisco, CaUfornfa OCXGBER 30, 197/

(P22B-12/1)

PINAL REPOHT MCAR 1-33 Sunoleaant

~Sub ect Panel OC653 Inserts 72C and 73C Des creation The forego~ is a supplement; to MCAR 1-33, reference BLG-2082, issued by site Quality Assurance an 5-1-79. Subsequent to the retuzn of Insert Modules 72C and 73C lcm General ELectric an 7-20-79, Construction attempted to. per-form the tasks delineated an H)I WJEA. Twa problems of significance were noted:

1. Insert Module 72C:

PuL1 in tes~ af the J connectors resulted in the replacement af all pins eleven af the thirtaen connectors installed in Insert Nodule 72C.

Refer to details in Canponent Control Report (CCR) 38.

2. Insert Module 73C:

Euring the cantiruity test af Panel OC653 to Insert Module 730 wiring, was noted that the inccadzg feeder breaker switches were functioning it incorrectly. Switch numbers HS-00030B, -31B, -32B, -34B and -36B provided continuity throug'n their contacts in the open position (before switch actu-ation). The replacement switch furnished by General ELectric for HS-00036B did not provide continuity through the switch contacts in the closed (after switch actuation) position. These switches were manufactured by the ELec-troswitch Corporate.an, Waymount, MASS. Refer to detKLLs in CCR 43 and NCR 4326.

The subject inserts were repaired/reworked and checked out at the Jobsite.

(P22B-m'2)

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C, Final Report MCAR 1-33 Supplement 3

Zt was deteradzmd that a canbination of manufacturing personnel error and crimping tool aalfunction as a result of inadequate QA was respon-sible for the defective c~.

Zt was determined that selected ELectroswitch controls used for an indicating light circuit did not make before break.

is of Safe ~cations

1. The defective connector pin crimps are part of the off-site power system feeder 4.16kV circuit breaker controls and the four standby AC Diesel Generator 4.16kV feeder breaker controls.

Cate affsite power feeder breakers are required to trip upon loss of voltage at each of the four 4.16kV standby AC bus. Simultsne- ~

omIy the under voltage condition of each bus starts its respective standby AC QLesel Generator. %hen rated speed and voltage are reached each DLesel Generator Circuit breaker is automatically closed into a dead bus disconnected fran both offsite power sources.

Ghese buses serve redundant N.rgency core cooling pumps and related equi~ (i.e. HHR, Core Spray, etc.) and are requiM for emer-gency shutdown+

Inserts 72C and 73C contain the two offsite power supply feeder breaker controls switches and syndmeniziz~ switches to each of the four 4.16kV buses and the four diesel Generator breaker can-trols and related synduenizing switches, in addition to non-safety related cangonents.

ot¹r We deficiency reported identified a condition where the 4.16kV standby AC bus circuit breakers could be rendered inoperable fran the main control room.

The deficiency described above if uncorrected could preclude operator action to redistribute load or restore offsite power when available.

Since the occurrence of defective pin crimps is randaa and could occur in any and all Diesel Generator feeder breaker circuits the possi-bility of loss of operator control exists.

t Report NCAR 1-33 Supplement 4

Pro5ect Engineering has deteanined the Insert to be reportable under 10CPH 50.55(e).

72C defective ~ crimps

2. It has been detemdned that the cited discrepancy of 'a contact used in the circuit breaker control indicating light circuit medcLng before bre~g does not represent a safety i~ard. As a result there can be a mmntary flicker of the indicating lights if the operator slowly nuves the switch handle fran one position to another. In the nodal method of operation, it is doubtful that the light f1icker would be noticable and is not considered operationally significant-Pro5ect Zhp~ring has determfned that the above condition is not reportable under 10CPR 50.55 (e)-

Corrective Action Insert 72C connector pins were re~~d/reworked and tested. We faulty ELectroswitches were replaced. Eoth ~erts 72C and 73C were 100$

visua11y inspected, 100$ pin pull tested and functiona11y checked by PL-Integrated Start-Up Group for circuit continuity, operation, quaLLty and verified by'Quality Control.

Engineerizg has deterndzed that the use of El.ectroswitch switches are limited to General Electric control roan equipnent.

Attachnents: 1. GP-79-122 GB-79-241 CCR-38 CCR<3 NCR-4326 AB/fy (P22B-12/4)

GENERAL j ELECTRlC NUCl.EAR POWER SYSTEMS DlVlSION GENERAL ELECTR1C CCMPANY, 175 CVRTNER AVESAN JOSE, CAUFORNfA 95125 HC 394, (408) 925-3005 October 22, 1979 Responds to: BLG-2171 GB-79-241 Hr. J. R. Schmfedel Bechtel Corporation P. 0. Box 3965 San Francisco, CA 94119

SUBJECT:

SUSQUEHANNA 1 4 2 INSER'TS 72C AND 73C You were provfded a copy of our letter GP-79-122 dated October 3, 1979 transmitting a copy of aur report to the NRC regarding the defective pin crimps on insert 72C. This conditfan has been reported per 10CFR 50 Part 21.

Me have reviewed the questions you raised regarding Electroswftches used on insert 73C. Further discussions with Bechtel personnel have ascertained that the nature of the problem constitutes a failure of the contacts to make before break fn this appl1cation. As a result there can be a momentary flicker af the indicating lights slowly moves the switch handle from one position to another. In the if the operator normal method of operation, 'ft fs doubtful that the 11ght would even flicker, fn either case the condition fs not operatfanally significant.

Further, we have reviewed the Bechtel schematics which cover these switches. These are E103 sheets 16, 19, 21, 22 and 24. These documents .

do not specify a make before break function. Therefore, the switch function described {s not a part of the design freeze base supp11ed to GE.

Based an the abave discussion, we have decided that a reportable condition does not exist with regard to the Electroswftch.

If you have any further questions, please contact Dick Lockett.

V truly yours, i 1 1 ar d Project Manager Susquehanna Project JWM: mn/1487 cc: E. A. Gustafson R. J. Shovl1n ffle 16.14 and 7.7

9 9 ~~QQU<4 g CT GE-NEHA!, 'LE'CIRlc NVCLKAN IIOWER IYITKNS OIVlstON QEMERAL, EMCTRlC COMPANY, 17d CURTNER AVE, SAN JOSF CAUFORNIA 95125 dddd Act lntn Copy hdt m ISA, (ee) m-3OOS ~ lip, Ref. Cay, SAN AW 0

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e October 3, 4979 Responds to NlA gp- 19-122 fee Sgr.

Vl lKSPC Nr. L J. Shovl5n SsicasL 0

hss5stant Prospect 15rector Susquehanna DOT Pennsylvan5a Pover 4 L5ght Coepany Tvo North N5nth Street hllentchm, PA . )8101..

Gear Sob:

SUMECT: SUSQUEHAtAA 1 4, 2 REPORT Ta NRC INSERT 7'EFECTIYE CRIMPS A copy of our letter to Nr. Robert H. &gelken report5ng the defect5ve p5n cr(ops on Insert 72C as a reportabla cond5t5on per 10CFR Part 21 vas telecop5ed to you on the afternoon of September 28. An additional copy 5s being forvarded herev5th for the pro)ect record. ~

GK v511 5ssue FDI VJIg 'to cover the Susquehanna Insert connector 5nspec-t5on and tepa5r progran>>

I v511 cont5nue to keep you 5nforled of developeents 5n th5s area as they occur.

Very truly yours,

. 15llard Pro/act Manages Susquehanna Pro)act .

AS: bgrj1 182 Enclosure cc: g. A. Custafson

~J. I. Schafedel F5le: 7.7

'GENERALO ELECTRIC NVCLIAR IOwcR SYSTEMS OlVl$$ ON ggK%4 KLKCTRtC CCN$ ANY, sfs CVRTNE8 AVC 8AM JOSE, CAUPQRMA N>&-

SC,682, (40S) 925-504O September 23, 1979 i QPN 243 iQ t

1 Ilr. Robert H. Kngelken Office of Inspection and Enforcement Q. S. Nuclear Regulatory Coankssfon V 'cg)on 1900 North Calffornfa Street walnut Creek, CA 94596

Dear Nr. Engelken:

SUSJECT: REPORTABLE COND!TION CONNECTOR PIN CRIMPING DEFECTS ON PANEL INSERT P853 72C Th)s $s to advise the NRC of a reportable condition per 10CFR Part H~

It was reported to Mr. Bobby Faulkcnberry of your office by Halter H.

O'Ardennc, Manager. Safety Evaluation Programs on September 25, 1979.

The defect is $ n p4 crimps fn Panel H12-P853 Insert 72C. Thc defect was fudged to be reportable on September 24, 1919. Attached $ s a

'cport of the defect.

General Electric (GE) as the supplier of ihc subject insert All conform the util)ties affected and advise thea of GE's <nspectlon and repair pro'ram.

g Clr&f  !

G. Sherwood, Manager afety 4 L,kcens)ng Operat)on GGS:pcs/847 Attachment .

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I PNEL H12 P853 !NS~ 72C OEFECTIYE CONNECTOR PIN CRIMPS Oefective crimps wert found on pins used in connectors $ n the 72C insert for panel 812-PB53 5r the Susquehanna plaht. This panel is conmon to

. both Uni't 1 and Unit'2. It was determined'that a combination of manufacturing personnel error and crimping tool malfunction as a result of inadequate gA was responsible for the defective crimps. The defect consists of a crimp which ca~not meet the required pull force.

The defective crimps do not create a safety hazard on this particular panel. However, the defective crimps could have occurred on other panels including one that could have caused a substantial safety hazard.

Thus the 'condition $ s reportable.

GE has identified a time period for this gA breakdown. The plants identified that map have similar problems are Grand Gulf 1 t 2 Limerick 1 4 2, and Hanford 2.

GE has established an inspection program to determine whether thfs deviation exists on the above mentioned plants. Thc plants idcntifiod will be notified of GE's prospect plans for inspection.

This inspection will be completed by January 18, 3980. Mhere rework and/or repair is found to be required", GE will establish a repair/rework schedule consistent with schedule requirements. Also manufacturing and gA procedures have been modified to piecludc defective crimping 5n the future.

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4y NONCONFORMANCE REPORT (CONT'0) I. PAOS~FX+ I ~ .N III 4326 COND 0 0 ELEAS In order to malntaln schedule, feeder bkr. switches are released for Installation In accordance with the applicable design documents, Traceablllty and I,O, to ba maln-talned by Q.CD hold tags. Items can be removed or corrected at a later date without dame e or contamination to other equlpmant or structures, APPED VA 0 COND 0 LEAS PF PFgCE OATK I

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G Eo H E D ~ COWCllRREliCE DATE 8 /3 E. A. Gus a f ~on SlTE NQLLGKR Ext. 242

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