ML20235H268

Insp Rept 50-219/89-02 on 890117-20.Violations Noted.Major Areas Inspected:Licensee Activity Re Info Notice 86-053 (Raychem Splices)

ML20235H268
Person / Time
Site:	Oyster Creek
Issue date:	02/03/1989
From:	Anderson C, Paolino R NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I)
To:
Shared Package
ML20235H235	List: ML20235H233 ML20235H244 ML20235H268
References
50-219-89-02, 50-219-89-2, IEIN-86-053, IEIN-86-53, NUDOCS 8902230542
Download: ML20235H268 (5)

See also: IR 05000219/1989002

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U.S.. NUCLEAR REGULATORY COMMISSION

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REGION :I -

Report ^No. 50-219/89-02

. Docket No; 50-219

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. License No. DPR-16' Priority -

Category. C'

1 Licensee: GPU Nuclear Corporation

1. Upper Pond Road

Parsippany, New Jersey 07054

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Facility Name: Oyster Creek Nuclear Gen (ting Station

Inspection At: P1 ant Site

Inspection Conducted: January 17-20, 1989

' Inspector: N> 'O # > E7

R. J/. Paolino, Senior Reactor Engineer, date

EB, PSS

Approved by: '

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C. J. Anderson, Chief, Plant Systems

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.date

Section, EB, DRS

Inspection Summary: Inspection on January 17-20, 1989 (Inspection Report

No. 50-219/89-02)

' Areas Inspected: Routine, unannounced inspection of licensee activity

. relating to Information Notice 86-53 (Raychem Splices).

Results: 10 CFR 50, Appendix B violation identified pertaining to installed-

splice configuration that are not in accordance with established procedures

for qualified splices.

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DETAILS

1.0 Persons Contacted , l

1.1 General Pcblic Utilities (GPU) j

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R. Barrett, Plant Operations Director 1

-T. Barton,-Deputy Director.

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• M. Bradley, Job Coordinator  ;

G. Busch, Licensing Manager '

R. Fenti, Manager - QA Mod / Ops ,

P. Fischler, MC&F

M. Heller, Licensing Engineer i

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R. Hillman, Manager, Plant Chemical

J. Kowalski, Manager Plant Training 1

• C. Lefler, Tech Functions- 1

R. Lewis, I&C Instructor  !

D. MacFarlane, Site Audit Manager

B. Mahoney, Training Coordinator, Plant Engineering

P. Manning, Supervisor Field QC Inspection

E. Pagan, EQ Manager 1

D. Ranft, Manager Plang-Engineering {

A. Rone, Director of Plant Engineering l

D. Robillard, QA Auditor j-

• T. Snider, Manager Plant Maintenance

P. Thompson,: QA Auditor i

R..Thoms, QA Engineering Manager

J. Williams, Training Supervisor

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• denotes personnel not in attendance at exit meeting of January 20, 1989.

2.0 Introduction

Several licensees discovered in 1986 that a substantial amount of Raychem

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cable splices previously installed at their facilities.did not conform to.

the vendor's installation requirements in one or more of the following

ways:

• Improper diameters

• Improper overlap length or wire insulation

a Use of tubing directly over the fabric cover of the wire

• Improper bending of tubing / wires inside junction boxes.

On June 26, 1986 Information Notice 86-53 was issued to alert licensees

to this potential generic safety problem and to inferm them to consider

appropriate actions, if applicable, to prevent or correct similar problems

at their facilities.

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3.0 Corrective Actions by Licensee

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In response to Information Notice 86-53, the licensee issued a memo, i

dated August 22, 1986, stating that all splicing and terminations j

involving use of heat shrinkable tubing shall be accomplished in accord- j

ance with Site Procedure 732.2.009 or appropriately approved engineering  !

instructions. As a further measure to determine if Oyster Creek had the I

problems identified in the Information Notice, QC was required to establish

a checklist (IN-048) for inspection of electrical components utilizing

information provided in the Notice.

QC completed its investigation of Raychem Splices, based on various

inspections and document reviews, in November 1986. Deficiencies were

identified in the line drive box No. TB-NR-108C. Tape of an indeterminate

origin was found on the cable under the Raychem splice. A Deviation

Report (DR #86-529) was issued and the splices (4) were repaired. SF #38123,

Attachment F, covered work done to TB-NR-108A, B and D. SR #38414,

Attachment G, covered work done on TB-NR-108C.

Except for the deficiencies noted, the licensee determined the results of

both the field inspections and document reviews to be acceptable. No

other problems with Raychem splices were disclosed by their review. The

licensee QC report of January 19, 1987, concluded that the deficiencies  ;

noted above were isolated.  ;

4.0 Physical Inspection

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The NRC inspector selected a sample of four Limitorque actuators and two

Hycal temperature sensors for visual inspection. Items selected include

Limitorque MOV Nos. V-14-30, V-14-31, V-14-36, V-14-37 and sensors

TE-057-2A and TE-059-28. Following licensee established procedures, the  !

equipment was tagged out and the covers removed for close inspection of

the terminations and splice configurations.

The NRC inspector noted that one of two Limitorques (V-14-30) located in

the Reactor Building (elevation 75'-0", Building Zone 15) contained three

splices with seal lengths less than the two inch length specified by the

manufacturer and referenced in the licensee's installation procedure

number A100-SME-3780-03. The installed seal length measured h inch (1) ]

and h inch (2) on one end of the splice. The overall splice length was

four inches, the length normally used in a non-harsh environment. {

Six inches is the qualified length specified for a harsh environment.

The Raychem heat shrink splice was used to extend the power leads in

order to provide sufficient length to terminate the power leads on a

terminal block. Records (including photographs) of a licensee walkdown

inspection of EQ related splices in November 1986 did not reveal or indi-

cate the presence of splices in Limitorque V-14-30. However, the licensee

did locate records (short form #7135) on January 24, 1989, after the

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inspection. These records indicate the splices were installed by Plant

Engineering in April 1983.

q. The licensee's procedures and the splice manufacturer specify'a two inch

. seal length on each end of the splice. The NRC inspector determined this

item to be a violation of 10 CFR 50, Appendix B, Criterion V, which states

in part, that " Activities affecting quality . . . shall be prescribed . . .

and "shall be accomplished in accordance with the instructions, procedures

.... (50-219/89-02-01). In discussions with the licensee, it was

determined that other data is available which indicates splices of various

seal' lengths less than the originally qualified seal length of two inches

have been qualified. The licensee reviewed the three deficient splices

considering.this additional data. Their prelin:inary review indicated

that two of the splices are qualifiable based on this data. For the

third splice, they are performing an evaluation to establish operability

of the splice. Since the inspection, the three deficient splices wcre

replaced.

As a result of the above splice deficiencies, the inspector ' questioned

the adequacy of the licensee's previous inspection of Raychem splices. In

response, the licensee evaluated their splice inspection sampling process

based on Mil STD-105D. They indicated that this review supported

their inspection sample size. The licensee noted that since their 1986

inspection, the number of Raychem splices identified in EQ applications ,

has grown. For these additional splices that were installed before 1986, '

the licensee plans an inspection of the splices that are readily

accessible. In addition, as equipment containing EQ splices is opened in

the future for maintenance activities, the splices will be inspected.

During this visual inspection of installed splices the NRC examined

several EMRV - valve monitoring systems (Dwg. No. 3E~664-40-001, revision 0)

which were being assembled in the instrument shop. The Monitoring Systems

contained several in-line splice configurations. All of the splices

exhibited the required inspection characteristics (established checklist

No. IN-048) for determining acceptability except for the primary splice

(WCSF-070-N) which provides the environmental seal to the components.

This splice did not have the bead normally formed by the red sealant

material at the end of the splice to ensure proper flow of materials

(adhesive). Examination of similar Raychem Splice Kits issued for this

application provided one possible explanation for not having the bead at

the end of the splice. All of the heat shrink tubing in the kit appeared i

to have a heavy coating of red adhesive material on the I.D. of the heat  !

shrink tubing except for splices designated WCSF-070-N. The red sealant

adhesive was barely visible on the inside diameter (I.D.) of the heat

shrink tubing indicating very little adhesive materials to effect an

environmental seal. The concern raised by the inspector is whether the

apperent reduction in red sealant material is the result of a change in

the manufacturing process to reduce the amount of red sealant and if

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qualification data existed to support changes in the splice material.

The licensee indicated that they contacted the manufacturer and determined

that no changes were made in-the splice material. .Therefore, the original

qualification data is acceptable. The manufacturer. indicated for the

small splices in question, .one would not necessarily expect to see a red

bead-of sealant at the splice end. The inspector had no further

questions.

5.0 Training

The NRC inspector examined personnel training records to determine the

adequacy of. licensee splice training. Prior to March 1985, the licensee

provided no formal training for installing splices. After establishing

a training program, the first splice training class was held on

December 23, 1985. Training was based on a seminar on " splice instal-

lations" by the. splice manufacturer. Electrical ard Instrumentation and

Control personnel received specialized training at this session. The

' training program (File No. 903.0.05) includes a Videotape, Raychem Nuclear

Products Guide, National Electric Code - 1987 Edition, Oyster Creek

Procedure for Splices and Terminations (No'. 700.5.031 and A100-SME-3780.3).

A large portion of the training is based on an NUS Videotape " Cables and

Conductors, Splices and Terminations Unit One and Two" and GPU "Raychem

Splices and Terminations." The inspector determined the training to be

adequate. .

6.0 Exit Meeting

The NRC inspector met with licensee representatives on January 20, 1989

at the Oyster Creek site. The inspector discussed the scope of the

inspection findings. At no time was written material given to the

licensee or his representatives.

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