ML20028B372

Final Deficiency Rept Re Class IE Wiring Terminations Crimped W/Less Pressure than Specified Due to Lack of Maint Program & Traceability for AMP Hydraulic Crimp Tools. Procedure 255.0 Revised to Require Maint Check Program

ML20028B372
Person / Time
Site:	Palo Verde
Issue date:	11/15/1982
From:	Van Brunt E ARIZONA PUBLIC SERVICE CO. (FORMERLY ARIZONA NUCLEAR
To:	Sternberg D NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION V)
References
10CFR-050.55E, 10CFR-50.55E, ANPP-22278-GHD, DER-82-37, NUDOCS 8211300329
Download: ML20028B372 (10)

Text

{{#Wiki_filter:.. \\ Dock K Ql&W) 50-528/529/530 t,'!! 50.55(e)G Report CE2 l@l 22 F3 I: pg Arizona Public Service Company PHOENIX, ARIZONA 85036 P.O. Box 21666. EES.T!,"/.'rj November 15, 1982 ANPP-22278-GIID/BSK U. S. Nuclear Regulatory Commission Region V i Creekside Oaks Office Park 1450 Maria Lane - Suite 210 Walnut Creek, California Attention: Mr. D. M. Sternberg, Chief Reactor Projects Branch 1 i

Subject:

Final Report - DER 82-37 4 A 50.55(e) Reportable Condition Relating to Class 1E Wiring Terminations Crimped With Less Pressure Than Specified, Due To Lack Of Maintenance Program And Traceability For AMP Hydraulic Crimp Tools File: 82-019-026 D.4.33.2

Reference:

(A) Telephone Conversation between T. Bishop and G. Duckworth on July 13, 1982 (B) ANPP-21591, dated August 10, 1982 (Interim Report) (C) ANPP-27139, dated October 28, 1982 (Time Extension)

Dear Sir:

Attached, is our final written report of the Reportable Deficiency, under 10CFR50.55(e), referenced above. Very truly yours, K.fgfg (L E. E. Van Brunt, Jr. APS Vice President Nuclear Projects Management ANPP Project. Director EEVILJr/GIID:db Enclosure cc: See Attached Page 2 Ep ' 8211300329 821115 PDR ADOCK 05000529 S PDR

U. S. Nuclear Regulatory Commission November 15, 1982 Attention: Mr. D. M. Sternberg, Chief ANPP-22278-Gild / BSK Page 2 cc: Richard DcYoung, Director Office of Inspection and Enforcement U. S. Nuclear Regulatory Commission Washington, D. C. 20555 T. G. Woods, Jr. J. A. Roedel D. B. Fasnacht G. C. Andognini A. C. Rogers B. S. Kaplan W. E. Ide J. Vorces J. A. Brand A. C. Gehr W. J. Stubblefield W. G. Bingham R. L. Patterson R. W. Welcher R. !!. Grant D. R. llawkinson L. E. Vorderbrueggen G. A. Flore111 Lynne Bernabei, Esq. liarmon & Weiss 1725 "I" Street, NW Washington, D. C. 20006 R. L. Greenfield i Assistant Attorney General Bataan !!cmorial Building Santa Fe, New Mexico 87503

T FINAL REPORT - DER 82-37 DEFICIENCY EVALUATION 50.55(e) ARIZONA PUBLIC SERVICE COMPANY (APS) PVNGS UNIT 2 I. DESCRIPTION OF DEFICIENCY As requested by an NRC inquiry, the operating pressures of hydraulic crimping tools used for electrical terminations were checked in accordance with the vendor's instructions. AMP Hydraulic Pump Crimping Tools, Catalog No. 69120, were found to be operating at 4500 psi, which is less than the 8200 psi specified by AMP in their Customer Manual CM1950. This condition was considered questionable because of the uncertainty as to whether the electrical terminations were adequately crimped to assure safety related functions. No program had been initiated to assure correct tool usage, assure periodic maintenance for these hydraulic crimp units (22), or provide traceability of specific tool applications used in conjunction with the lug terminations on wire sizes 2/0 through 750 MCM. AMP Special Industries has reviewed this condition and has conducted conclusive testing (see Attachments A & B) on samples taken from the ANPP Jobsite. Sample wire sizes 2/0, 4/0, 250 MCM, 350 MCM, and 700 MCM were terminated by Bechtel site personnel at 4500 psi and 8200 psi, and forwarded to vendor for tensile strength tests. The vendor also performed 1111-volt drop testing on additional wire samples of the same sizes but which were terminated by the vendor at 4500 psi and 8200 psi crimp pressures. The results of the tensile strength tests (summarized in Table I attached) demonstrate that ANPP samples crimped at 4500 psi well exceeded UL-486A and Military Specification !HL-T-7928G requirements. The Mil-volt drop tests show that little voltage drop difference occurs through termination lugs crimped at pressures ranging frou 8200 - 4500 psi. The results of these tests are summarized in Table II (attached). Although the tests were not performed at ampere loads provided in the !!IL-T-7928G Standard, the corresponding voltage drops for the maximum allowed wire ampacity figures per Project Design Criteria (slightly higher than the tested values) are not expected to exceed the maximum allowed by the MIL-T-7928G Standard. It is therefore concluded that the wire sizes 2/0 - 750 l 11CM, which were crimped with pressures of 4500 - 8200 psi are adequate for the intended purpose.

4 II. ANALYSIS OF SAFETY IMPLICATIONS This condition is evaluated as not safety significant, However, it is evaluated as reportable under the requirements of 10CFR50.55(e) because this condition represents a' breakdown in the Quality Assurance Program. The lack of surveillance to enstire compliance with established. vendor requirements for proper crimping in accordance with the electrical specification (13-EM-306) is considered an " extensive deviation" as defined by the regulation. III. CORRECTIVE ACTION Work Plan Procedure / Quality Control Instruction 255.0 has been revised to require that a maintenance and check program for the hydraulic crimp units be implemented. This procedure is applicable to Units 1, 2 and 3. Each Hydraulic Crimp Unit shall be serialized to allow traceability of tool application, to casure that terminations are performed at specific crimping pressures and that correct dies have been utilized in accordance with the vendor's instruction as outlined in their Customer Manual CM1950. All future lug terminations for the subject wire sizes shall therefore be crimped at 8200 psi. The serial no. will be included on each applicable EE-530 card. The referenced NCR will be dispositioned use-as-is since the terminations already completed are adequate. l

~ DER 82-37 TABLE I Test UL-468A MIL-T-7928G Wire Size Tensile Strength Tensile Strength Tensile Strength Pounds Pounds (Min) Pounds (min) 2/0 943-300 750 4/0 2243 450 875 250MCM 1859 500 1000 350MCM 1819 600 1125 500MCM 2821 800 1500 709MCM 4939 1000 2000 l Summarization of Tensil Strength Test Results on Wire Samples Termined by Bechtel Crimping Tools at 4500 psi - See Attachment A e ] ~- __9. a_. r +,r'"

m TABLE II Conductor Allowable Ampacity (Project Test Current Design Criteria) by Amp Corresponding max. Mil-(Amps) volt Drop Results MIL-7-7928G '.Jire Size (Amps) At 8200 psi At 4500 psi Test Current Mil-volt Drop (Arms) (Max.) 2/0 182 150 1.47 1.44 283 4 4/0 249 225 2.36 2.12 380 6 250MCM 281 250 2.63 2.54 540 6 300McM 343 300 2.99 2.96 670 6 500McM 427 400 2.50 2.34 860 6 700MCM 517 500 2.74 2.58 1190 6 Summarization of Mil-volt Drop Test Results on l Bechtel Wire Samples terminated by Vendor g Crimping tools at (1) 4500 psi and (2) 8200 psi O u (See At tachment 11)

A3TAfA\\MV RT A WGT \\ oV 2. h.r1"SPECIAL AMP DER 82-37 ' B.,8 i Edd li4DUSTRIES -~ Ve%y Forge. Peara 19.:82 (215'647 1000 It y July 20, 1982 f 4 Bechtel Power Corporation .f Palo Verde fluelear Generating Station '8 P.O. Box 49 Phoenix, Arizona 85343 Attention: Mr. Bill Saylor Ocar Mr. Saylor, The sample wire that you submitted to my attention and the trriinntions i t_ha t you made on the site have been tested in ra-arde r 3 Tc:6.ile. The terminations and terminals identi fied by wi re markers, the recort and the samples are being submitted to your attention. We are taking the testing one (1) step further: We crieped on your wire I an submittinq on one end at 4500 P.S.I. and the other end at 8200 P.S. I. these sampics, a total of twelve (12), two each of: 2/0, 4/0, 350, 250, 500 I and 700 MCM to our Environmental Test Lab in Harrisburg, Pevevivania for and as soon as T hr^'

• astinn I placed an urgency on this request SMIL-T receive the results, I will call you prior to forwarding the recorts.

I would like to mention, one (1) of your samples, 500 MCM was crimped in the Another sample, 750 McM was criuped wi th the wrong die, reverse position. In all cens. snWat 4500 P.S.I. vell exceeded the Ut 800 MCH. and Milita ___W ifth tione ith the exceotion or onelli sa3pfe: Z/0, 56, The reduction in Tensile was contributed to the wire not dTrcled 680 pounds. being inserted to its fullest. So, actually, #6 could be ignored. It just goes to show you how inportant it is to have the wire all the way in the terminal barrel. please do not If you have any further questions in regards to this report, hesitate to contact me.

Regards, AMPpPECIALINDUSTRIES ff, T7p-( ){f b($t'

1. ,Ted Updegrgve,

j Manager, Qbality Assurance 3;j;

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AMP DER 82-37 t - SPECIAL INDUSTRIES Wuey Forge. Nnna 19482 (2151647 1000 August 17, 1982 Bechtel Power Corporation P.O. Box 49 Palo Verde, Arizona 85343 5 Attention: Bill Saylor Subj ect : Millivolt Drop on Cable Terminations: 2/0, 4/0, 250, 350, 500 s 700 ~ Terminated at: 8200 P.S.I. & 4500 P.S.I.

Dear Bill,

The tests conducted at AMP Environmental Lab, Harrisburg, Pennsylvania, are attached. As mentioned in the subject of this memo, we terminated six (6) cable sizes supplied by you with the Hydraulic Unit set at 8200 P.S.I. and the same amount of samples terminated at 4500 P.S.I. As you will notice by the report, there was little dif ference, between the two (2). The test currents used are those defined in the MIL-T-7928G Specification. This report along with the Tensile data previously submitted to you, I hope will be of great value. There is no charge for these two (2) test reports. I am sorry for any inconvenience you have encountered and hope we can main-tain a good customer / vendor relationship and continue to supply you with high quality products. Should you have any comments or questions regarding these test reports, please contact me at your convenience.

Regards, 9

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