ML20199H955
| ML20199H955 | |
| Person / Time | |
|---|---|
| Site: | Palo Verde  |
| Issue date: | 06/24/1986 |
| From: | Jan Brunt E, Van Brunt E ARIZONA PUBLIC SERVICE CO. (FORMERLY ARIZONA NUCLEAR |
| To: | Kirsch D NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION V) |
| References | |
| REF-PT21-86, REF-PT21-86-255-000 ANPP-37140-EEVB, DER-86-06, DER-86-6, PT21-86-255, PT21-86-255-000, NUDOCS 8607080018 | |
| Download: ML20199H955 (10) | |
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Arizona Nuclear Power Project P.O. BOX 52034
- PHOENIX, ARIZONA 85072-2034 June 24, 1986 ch ec 4,k$
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N U. S. Nuclear Regulatory Commission (o
Region V 1450 Maria Inne - Suite 210 Walnut Creek, California 94596-5368 Attention:
Mr. D. F. Kirsch, Acting Director Division of Reactor Safety and Projects Palo Verde Nuclear Generating Station (PVNGS)
Units 1, 2, 3 Docket Nos. 50-528, 529, 530
Subject:
Final Report - DER 86-06 A 50.55(e) and 10CFR21 Reportable Condition Relating to Inadequate Wiring Lug Terminations File: 86-006-216; D.4.33.2
Reference:
(A)
Telephone Conversation between R. C. Sorenson and D. R. Larkin on February 21, 1986 (Initial Reportability - DER 86-06)
(B)
ANPP-35655, dated March 25, 1986 (Interim Report - DER 86-06 and DER 86-07)
(C)
ANPP-36357, dated April 22, 1986 (Time Extension - DFR 86-06)
(D)
ANPP-36582, dated May 14, 1986 (Time Extension - DER 86-06)
Attached, is our final written report of the Reportable Deficiency under 10CFR50.55(e) referenced above. The 10CFR21 evaluation is also included.
Very truly yours,
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E. E. Van Brunt, Jr.
Executive Vice President Project Director EEVBJr/DRL:kp Attachments cc: See Page 2 O
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June 24, 1986 ANPP-37140-EEVB/LAS/DRL-92.11 DER 86 Final Report Mr. D. F. Kirsch Acting Director Page Two ec:
Mr. J. M. Taylor, Director Office of Inspection and Enforcement U. S. Nuclear Regulatory Commission Washington, D. C.
20555 A. C. Gehr (4141)
R. P. Zimmerman (6295)
Records Center institute of Nuclear Power Operations 1100 circle 75 Parkway - Suite 1500 Atlanta, Georgia 30339 l
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FINAL REPORT - DER 86-06 DEFICIENCY EVALUATION 50.55(e)
ARIZONA NUCLEAR POWER PROJECT (ANPP)
PVNGS UNITS 1, 2, 3 I.
Description of Deficiency During the NRC CAT Inspection conducted in February, 1986, several deficiencies were discovered with vendor wiring in the battery chargers (Power Conversion Products) and the diesel generator control panels (Cooper Energy Services).
Special CIP 698.0 and SWA 6742 were initiated to inspect vendor wire termination attributes that could affect safety in battery chargers 3EPJAH11, 3EPKBH12, 3EPKCH13, 3EPKDH14, 3EPKAH15 and 3EPKBJ16.
Special CIP 696.0 was initiated to inspect wire termination attributes that could affect safety in diesel generator control panels 3JDGAB01, B02, B03 and 3JDGB01, B02 and B03.
The results of the inspections are documented on the Special CIP.
Deficiencies are noted in the following:
NCR's EG-7196 EG-7561 EG-7388 EG-7387 EG-7375 EG-7593 EG-7349 EG-7372 SWA-6868 I
The types of deficiencies discovered include the following:
a.
Wire extended past the end of the lug so that it interfered with proper seating of the screwhead or washer.
b.
Terminals not securely attached.
c.
Nicked or cut conductor strands (control wire only).
d.
Improperly crimped lugs.
e.
Loose pin connections.
f.
Improper size of lug g.
Lugs bent in excess of 90'.
h.
Improper solder termination.
1.
Relay missing spring fasteners or having springs not fastened.
- j. Insufficient separation between Class "Q" and non-Class "Q" cables.
k.
Broken or damaged lugs.
DER 86 Final Report Page Two Evaluation A.
Battery Chargers After evaluating the identified deficiencies, the following deficiencies were determined to be safety significant due to the potential for these deficiencies to cause a malfunction of the battery chargers:
Item a) Wire Extended Past Lug Wire extending past the end of the barrel may interfere with complete surface to surface contact between the lug and the terminal. This could result in localized heating which could further deteriorate the connection and possibly cause an open circuit.
Item b) Terminals Not Secured Loose terminations may not provide adequate contact between lug and terminal.
This could also result in circuit malfunction.
Item c) Nicked or Cut conductors Strands Wire with nicked or cut conductor strands can break away from the lug during additional handling caused by rework or maintenance on the panel. This would result in an open circuit.
Item d) Improperly Crimped Lugs Improperly crimped lugs can result in damaged or loose terminations with the same consequences as discussed above.
Item e Loose Pin Connections loose pin connections can increase the electrical resistance of the circuit. This could affect the control signals and cause malfunction of the equipment.
Based on the above evaluation of the Unit 3 battery charger deficiencies, on March 7, 1986 EER 86-PK-008 was initiated to walkdown and evaluate vendor wire terminations in the Unit 1 and 2 battery chargers. The Bechtel Resident Engineer, Power Conversion Products (PCP) Engineer, and ANPP Operations Engineer all participated in the walkdown. Though minor findings were discovered, the terminations were found to be functionally sound and presented no safety-significant risk. This is docurented on a PCP memorandum dated April 8, 1986.
E' DER 86 Final Report Page Three B.
Diesel Generator Cabinets The following deficiencies were determined to be safety significant since these items could cause a malfunction of the diesel generators:
Item a) Wire Extended Past Lug Wire extending past the end of the barrel may interfere with complete surface contact between the lug and terminal. This could result in localized heating which could further deteriorate the connection and possibly cause an open circuit.
Item b) Terminals Not Secured Loose terminations may not provide adequate contact between lug and terminal.
This could also result in circuit malfunction.
Item c) Nicked or Cut Conductor Strands Control wires with nicked or cut conductor strands can break away from the lug caused by additional handling while performing rework or maintenance on the panel.
Ihis would result in an open circuit.
Item d) Improperly Crimped Lugs Improperly crimped lugs can result in damaged or loose terminations with the same consequences as discussed above.
Item e) Loose Pin Connections Loose pin connnections can increase the electrical resistance of the circuit.
This could affect the control signals and cause misoperation of the equipment.
Item f) Improper Size Lug Use of improper size of lug can result in damaged or loose terminations with the same consequences as discussed in item e above.
Item h) Improper Solder Termination Improper solder termination can increase the electrical resistance of the circuit.
This could affect the control signals and cause misoperation of the equipment.
DER 86 Final Report Page Four Item 1) Relays Missing Spring Fasteners Relays missing spring fasteners or having springs not fastened do not meet seismic requirements.
Item n)
Cable Separation The cable separation condition identified is between a non-Class 1E wire bundle entering the top of diesel generator panel 3JDGBB01 and a Class 1E wire way. A minimum of 6" separation is required.
Item p) Broken or Damaged Lugs Broken or damaged lugs or peeling of a contact surface may not provide adequate contact between lug and terminal. This could result in circuit malfunction.
Based on the above evaluation, ANPP initiated EER 86-DG-024 to walkdown and evaluate the Unit 1 and 2 Diesel Generator Control Panels. There were no significant deficiencies noted. Similar defects, as listed in the Unit 3 EER, were previously identified during Construction and Startup and had been corrected.
One minor Class 1E wiring separation deficiency, identifed on EER-86-DC-005, had not been corrected at the time of the walkdown. This deficiency is scheduled to be corrected by Work Order #00135626 during the first available outage.
C.
Root Cause Analysis The root cause of the deficiencies was determined to be a breakdown in the vendor program to assure equipment met specification requirements, and in addition, a breakdown in vendor source inspection and site receipt inspection programs.
D.
Transportability In light of these findings, the Project evaluated the potential for other safety-significant deficiencies in vendor terminations.
The program for vendor supplied equipment relies primarily on the vendor to perform acceptable work in accordance with specifications.
No specific onsite program for inspection of vendor wiring exists, but the quality of vendor terminations is confirmed by the combination of Construction QC, Startup Testing and Engineering examinations to resolve field questions. The several tiers of examination have revealed equipment from approximately 36% of the vendors of electrical cabinets where potential deficiencies have been identified and these have been addressed fully.
DER 86 Final Report Page Five No widespread functional testing problems have been discovered during startup u operation due to bad terminations other than as indicated in attaohment 1.
No widespread functional testing problems have been discovered during startup or operation due to bad terminations other than as indicated in attachment 1.
Recent inspections of vendor panels, 3J-HPB-E02, 3J-HPA-E02, 3J-SDB-C08, 3J-SDB-C09, 3J-SBB-C03, and 3J-SBD-C03, as a result of CAR S-86-25, found no significant deficiencies with vendor terminations in Unit 3.
This equipment had no records of past jobsite inspections or deficiencies, the latter of which was confirmed by these inspections.
The CAT audit findings were prior to complete operational acceptance of Unit 3 equipment.
The preponderance of information from the onsite quality proErams provides a justification for the position that there are no safety significant residual wiring deficiencies in the equipment for which there are no documented findings. This conclusion is supported by the fact that all equipment has been installed, tested, turned over, inspected, and operated in the same manner for all units.
II.
Analysis of Safety Implications A. Unit 3 Based on the above, this condition is evaluated, for unit 3, as reportable under the requirements of 10CFR 50.55(e), since if this condition were to remain uncorrected it would represent a significant safety condition.
l The project has also evaluated this condition, for Unit 3, as I
reportable under 10CFR Part 21.
This report addresses the l
reporting requirements of 10CFR21.21(b)(3) with the exception of l
sub part (vi), regarding the number and location of such components supplied to other facilities.
B.
Unit 1 and 2 Based on the walkdown of the Unit 1 and 2 Diesel Generator Control l
Panels, which found no cignificant defects in vendor wiring, and the minor termination deficiencies found in the Unit 1 and 2 battery chargers, it has been determined that these deficiencies are not reportable under the requirements of 10CFR21 since, if this condition were to remain uncorrected, it would not adversely j
affect the safety of operations.
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DER 86 Final Report Page Six III. Corrective Action A. Unit 3
- 1) Unit 3 nonconforming items determined to be unacceptable will be reworked under NCR's:
EG-7196 EG-7375 EG-7387 EG-7388 EC-7349 EG-7593 EJ-7372 EG-7561 All work will be completed prior to fuel load.
- 2) The inspection and rework discussed above resolve all vendor wiring workmanship problems in the Unit 3 diesel generator control panels. Any future wiring in the panels will be performed by Bechtel/ANPP in accordance with the appropriate requirements and inspected by Quality Control. No additional action is required by the vendor to prevent recurrence.
- 3) A Quality Talk was presented on March 4, 1986, to all Bechtel
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onsite personnel to further reemphasize quality standards when working in electrical panels.
B.
Unit 1 and 2 The following Work Orders have been issued to correct minor termination deficiencies in the following battery chargers:
Equipment #
Work Order #
1EPKAH11 00143381 2EPKAH11 00143824 2EPKBH12 00143825 2EPKCH13 00143826 2EPKDH14 00143827 2EPKAH15 00143829 2EPKBH16 00143830 C.
ANPP Quality Program i
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To prevent recurrence of these type problems, ANPP has upgraded the Procurement Program to provide detailed " implementation audits" of suppliers of safety-related equipment. Actual equipment being supplied to ANPP is examined and verified to be handled in accordance with the supplier's approved program. In addition, suppliers of equipment which require fabrication processes that can not be verified through documentation review or site receipt inspection, as well as suppliers with identified
- _ ~,__
DER 86 Final Report Page Seven weaknesses in their quality program, have source inspection and/or source surveillance imposed. For these vendors, specific and unique inspection / surveillance plans are developed and implemented against criteria which includes inspection for items such as those noted. Finally, all safety-related items procured for ANPP are subjected to a detailed receipt inspection process which provides specific criteria for workmanship inspections as well as other inspections for specific electrical items. Although performed previously, revisions to procedures are being generated to include termination criteria and separation criteria requirements into the recefot inspection process. These revisions will be completed by July 31, 1986.
Attachment
" DER History for Vendor Internal Wiring" l
DER 86-06 DER History for Vendor Internal Wiring The workmanship of vendor internal wiring has been investigated for the following equipment:
Equipment Supplier Reference a.
Diesel Generator Cabinets Cooper Energy DER 82-36 (4/0 power cables)
Service b.
Switchgear General Electric DER 82-41 Corp.
c.
Main Control Board Consip, Inc.
DER 82-43 d.
Chiller Control Panel Carrier Air DER 82-78 Conditioning Corp.
e.
Loadcenter Brown Boveri DER 82-44 Electric Co.
f.
Auxiliary Relay Cabinet Harlo Corp.
DER 83-43 g.
Emergency Response Facilities Energy Incorporated DER 86-13 Data Aquisition and Display Panels l
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