ML19296F260

Part 21 Deficiency Rept Re Defect in Control Room Sys, Supplied & Mfg by Ge.Caused by Manufacturer.Effort Initiated to Check All Panel Wiring Diagrams Against Actual Manufacturer Documentation

ML19296F260
Person / Time
Site:	Columbia
Issue date:	07/19/1978
From:	Sherwood G GENERAL ELECTRIC CO.
To:	Engelken R NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION V)
References
REF-PT21-78-063-000 MFN-297-78, WHD-176-78, NUDOCS 8010200787
Download: ML19296F260 (5)

Text

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G E N E R A L 2p E L E CT R I C NUCLEAR ENERGY ,

PROJECTS DIVISION NERAL ELECTRIC COMPANY 175 CURTNER AVE.. SAN JOSC CAUFORNIA 9s12s MC 682, (408) 925-5040 July 19, 1978 MFN 297-78 ,

WHD 176-78 -

Mr. Robert H. Engelken, Director Office of Inspection and Enforcement Nuclear Regulatory Commission Region 5 1990 North California Walnut Creek, CA 94595 -

Dear Mr. Engelken:

SUSJECT: REPORTIN^ OF DEFECTS DISCOVERED DURING QUALIFICATION AND MANUFACTu. TING OF CONTROL ROOM SYSTEMS This is to advise the NRC staff of three defects reportable per 10CFR Part 21. As discussed with Mr. Lucien Vorderbrueggen by Walter H.

D'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 systems were shipped, we believe there is a high probability that these conditions would have been detected prior to plant operation. The plant preoperation and startup tests and audits conducted by General Electric are designed to detect and correct conditions such as described by the attached prior to plant operation.

Glenn G. Sherwood, Manager Safetv and f irancina nna-=+ <an GGS:cc/29 Attachment gu10zon '(V 9

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DEFECT IN CONTROL ROOM SYSTEM SUPPLIED FOR PENNSYLVANIA POWER LIGHT'S SUSQUEHANNA 1 PROJECT On July 14, 1978 it was determined that a defect existed in a fdontrol roem benchboard manufactured by the General Electric Company N/ uclear Energy Business Group and supplied to Pennsylvania Power & Light for application on the Susquehanna 1 project. ~

TheReactorProtectionSystemmodeswitchisaRundelfroductmanufactured by Gould, Inc.. The mode switch performs numerous spfety related inter-lock and bypass functions and must be seismically qvalified to assure that plant conditions during and after a Safe Shupdown 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 nad passed the seismic examination but exhibited some contact chatter. Based on that info mation, a safety-related control room benchboard containing the. da switch was shipped to Susquehanna 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 toler nce buildup (due to electrical separation barriers) which caused /he switches primary contact cam to separate from the contact cam in .he adjacent contact block. All contact blocks downstream of this separ oicn ceased to function.

The following corrective act' ns have been taken:

1. Pennsylvania Pcwer & ight has been instructed to " red tag" the switch until ti,e appropriate corrective action is complete.

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

3. 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:

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

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

3. If 1 or 2'is unsuccessf ul then select and qualify new switch and issue installation instruction ...................................... Dec. 31, 1979

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7H 63 -000 DEFECT IN CONTROL ROOM SYSTEM SUPPLIED FOR WASHINGTON PUBLIC POWER II.

SUPPLY SYSTEMS HANFORD NUCLEAR STATION On July 14, 1978 it was determined that a defect existed in the power generation cor. trol camplex (PGCC) manufactured by the General Electric 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 electrical separation audit of engineering documentation utilized in the r,anufacture 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 perform its function. .

The following corrective actions have been taken:

1, 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: -

1. Issue "from-to" (wire by wire) instructions to correct any discrepancies ...................... March 30, 1979 4

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III. DEFECT IN CONTROL RODM SYSTEM SUPPLIED FOR .PENNSYLVANI A POWER & -

. LIGHT'S SUSQUEHANNA 1 PROJECT AND MISSISSIPPI POWER & LIGHT'S GRAND GULF 1 PROJECT On July 14, 1978 it was determined that a defect ex'.sted in the contfoi room panels manufactured by the General Electric Company Nuclear fdergy Business Group and supplied to Pennsylvania Power & Light (Susquehanna 1) and Mississippi Power & Light (Grand Gulf 1) for application a( a control room system. ,

GE-CR2940 control switch assembly requires a locking rin,g wisich secures the switch in place on the benchboard face. An error *n manufacturing

. documentation utilized to manufacture control room pan;els depicted the GE-CR2940 control switch without its position locki,pg ring. Consequently the switches were installed without the locking rjng. As a result, the entire switch body may rotate rather than the o 'ator, thereby preventing the switch function. -

GE-CR2940 control switches are utilized for safety related manual control functions. The above mentioned deviation could delay manual operation during an analyzed plant event / such that technical specification limits could be exceeded. It is belic/ed that manual operation could only be delayed since the plant.operafor would be informed by numerous diverse alarms and annuciators of h'e omitted manual action.

The following corrective action have been taken:

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

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

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

4. Issue ins 11ation instructions for Grand Gulf 1.

The follovi corrective action is to be taken:

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

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10 CFR PART 21 REPORT !DErJT( :ATIOrt AND

- RECORDir4G OF IE ACTIONS PARf 21 IDENTIFICATION NO. -

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. IE ACTIONS - CHECK OR PROVIDE DATA AS APPROPRIATE L!ST OTilER NRC OFFICES INFORMED DISCUSSED WITil INITI ATOlt? REPORT IS REQUIRED DATE: tJN DTR pat;T 217 REQUEST MADE FOR ADDITIONAL INFO 7 l .

INQ UIRY7 DATE RECEIVED:

. PRESS RELEASE (S) INSP ECT1 AN7 REVIEWED FOR POTENTIAL Af O' ( MC 1110) Da m!GATION7 DATE:

TRAN!FFRED TO OTilER NRC OFFICE 7 l ENFORCEL :NT7 BULLETIN ISSUEU? NO. CORRECTn'T. ACTION TAKEN7 DATE OF CLOSEOUT: CIRCULAlt ISSUED?

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