ML19325C552

Part 21 Rept Re Unqualified Splices Identified in GE Supplied Instrument Racks Contructed by Huico,Inc.Drawings Supplied W/Racks Showed No Splices & No Maint Performed That Would Have Installed Splice.Prompt Attention Requested

ML19325C552
Person / Time
Site:	Cooper
Issue date:	06/08/1989
From:	Trevors G NEBRASKA PUBLIC POWER DISTRICT
To:	Brager D GENERAL ELECTRIC CO.
References
REF-PT21-86-106-000, REF-PT21-89-106-000 PT21-89-106, PT21-89-106-000, NUDOCS 8910170045
Download: ML19325C552 (3)

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June 8,1989 . ,. _ , .._

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Jr I b nw Mr. . David J. Brager - j,jd___ ~ ' " ,

e m Nuclear Services Manager ~i GE Nuclear Energy. . I. ~

11422 Miracle Hills Drive, Suite 304 0%a , NE' 68154-

Dear Mr. Brager:

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Subject:

.Possible 10CFR21' Reportable Defoct' -l i

, The purpose of this letter : is . to inform General Electric (CE) of facts relating to previously unidentified splices provided on GE supplied instrument.

o racks. This information is being provided Ic>r your evaluation with regard to ,

L s a potential generic manufacturing problem end the possible need to report this  ;

situation per the requirements af 10CFR21.

E During a recent plant walkdown of local instrument racks and associated cables ' ,

at C, coper Nucloac Station (CNS), unqualified splices were found in the conduit k running from the~reck mounted Barton switches to the terminal boxes mounted on

['4 Lthe samezrack. These findings appear' to be - isolated. to Barton. rack mounted .

switches only. The affected conduits'are all less-than 10. feet in length with most > being Oless than b' feet. Previous plant . walkoowns - had verified -. that qualified cables - were pre = enc at the rack mounted terminal boxes. Based on L the short run'of conduit t the ' instrument.s and the f.:ct that the EQ integrity >

l of the . instrument would have - to be broken to inspect the cable . terminationLat ,

the -instrument,- a reasonable: assumption was mads that- qualified cable existed if.~om the terminal- box to. the instrument. The discovered unqualified splices ,

are not shown on any existing drawingt for the instruments or the racks. The ')

f drawings for the- instruments. and - racks reference a General Electric - design- t l- ,  : specification for local instrument racks -(209A4351). This specification b , specifically states, "5.1.3.1 Connections to external devices are to be on  ;

Terminal ' Blocks located in NENA type 12 enclosed steel terminal cabinets."

Tharefore, CNS had no reason to . bslieve that splices - existed . inside the conduit.: Due to the non-conformances mentioned above,- an equipment history

search was performed to determine exactly where the, splices: originated.  ;

The , instrument racks listed on Attachment I were all supplied under NPPD Contract E66-31. This contract, " Nuclear Steam Supply System", covered a very

'large scope of equipment and consequently no specific requirements are given l' 4

'for the conscruction or connection of the instruments and racks. A review of

'the receiving files for this contract has provided fairly certain traceability back to the original rack manufacturer. The racks were constructed by HUICO Incorporated of Pasco, -Washington under a General Electric Purchase Order 8910170045 890608 pA PDR PT21 EUTNPPD

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Mr. D;vid J. Br:ger

_ June 8. 1989 sj:j Page 2

' 282.Y 7044 The. racks were constructed based on the GE 'pecification S

- 209A4M1.1 Rack construction and instrument installation drawings are listed on Attachment 1. The racks were completed in mid 1971 and shipped to CE under y a HUICO Certificate of Compliance to ths rack drawings and GE Specification mentioned above. General Electric has provided PQCs for the completed '

instrument racks _ which are dated in mid 1973. These PQCs certify that the racks were inspected- by CE and found acceptable. It - is not known vl.at happened to the racks at GE between 1971 and 1973. '

i The racks were installed under NPPD Contract E70 3 which made connections to the field side of~the terminal box. No records could be found to indicate the rack wiring was modified during original installation.

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. A maintenance history search was performed which identified approximately four

- switches which have been replaced since original installation. For these switch replacements it appears the incoming leads were disconnected . at tne ,

terminal . strips inside- the Barton switches and, _therefore, the splice.inside e the conduit was not discovered during replacentnt.

L A field walkdown of the existing equipment revealed that the instruments l

(except for the four mentioned earlier) have a stainless steel tag affixed to l the DP unit which identifies a GE purchase order number that matches the purchaw order number listed for the equipment in the HUICO Qt. documents i supplied as part of Contract E66 31.

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.f Based on the above, it is concluded that the splices existed in the conduit when the instrument racks were received at CNS. The drawings supplied with the racks did not show the splices and no maintenance has been performed that would have installed this type of splice. The Barton switches are supplied I. - with- pigtails and the configuration of the switches requires extensive

!- disassembly to get to the internal connections. It is therefore assumed that L the original contractor (HUICO) spliced the pigtails to the GE wire to avoid disassembling the switch for whatever reason, i

In view of the potential impact that this finding may have on other plants l with similiar insta ll a tions provided by CE, your prompt attention to this i matter would be appreciated. If you have any questions concerning this *

! matter, please contact Steve McClure or Lob Wilbur at our General Office in h Columbus.

Sincerely, G. . revors Division Manager Nuclear Support

. CAT /REW:cs L Attachment U cc: degionalOffice USNRC - Region IV l

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-ATTACHMENT 1  ;

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~ . t CNS Rack. Drawing No. CIC- Location-25-2 117C3304 RWCU-DPIS-170A R-931-NW [

kWCU-DPIS-170B 1 25-5 115D6009 NBI-LIS-101A R-931-NW NBI-LIS-101B' PC-PS-16 l 25 115D5010 NBI-LIS-101C- R-931-SE-NBI-LIS-101D -

NBI-PIS-52B 25-50 115D6011 HPCI-FIS R-859-SW

~25-52. 115D6013' NBI-PIS-52D 1R-903-SE- l r

25-56 -115D6014 MS-DPIS-116A,B,C,D R-903-SE

• MS-DPIS-117A,B,C,D ,

MS-DPIS-118A,B,C,D.

MS-DPIS-119A,B,C,D ,

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25-58 115D6015 RCIC-DPIS R-859-NE RCIC-DPIS ,

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