U-600778, Final Deficiency Rept 55-86-08 Re Improper Installation of Raychem Insulation on Splices in Class 1E Circuits.Initially Reported on 860902.Defective Splices Reworked & Repaired

Final Deficiency Rept 55-86-08 Re Improper Installation of Raychem Insulation on Splices in Class 1E Circuits.Initially Reported on 860902.Defective Splices Reworked & Repaired

ML20215C077
Person / Time
Site:	Clinton
Issue date:	12/06/1986
From:	Hall D ILLINOIS POWER CO.
To:	James Keppler NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III)
References
55-86-08, 55-86-8, U-600778, NUDOCS 8612150017
Download: ML20215C077 (5)

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d/n 16 l U-600778 Ll4-86 ( 12-06 )-L 1A.120 ILLINOIS POWER COMPANY CLINTON POWER STATION. P.O. BOX 678. CLINTON. ILLINOIS 61727 DEU G 1986 Docket No. 50-461 Mr. James G. Keppler Regional Administrator ,

Region III U.S. Nuclear Regulatory Commission 799 Roosevelt Road Glen Ellyn, Illinois 60137

Subject:

Reportable 10CFR50.55(e) Deficiency 55-86-08: Improper Installation of Raychem Insulation on Splices in Class lE Circuits

Dear Mr. Keppler:

On September 2, 1986, Illinois Power Company (IP) notified Mr. R. Knop, NRC Region III (Ref: IP Record of Coordination Y-203113, dated September 4, 1986) of a potentially reportable deficiency under the provisions of.

10CFR50.55(e) concerning improper installation of Raychem insulation on splices in Class lE circuits. Nonconforming Material. Report (NCMR) No. 1-2508 was initiated to document deficient Raychem splices where the splice sleeve does not entirely overlap the splice shim as required by the equipment qualification. This initial notification was followed by one (1) interim report (Ref: IP Letter U-600724, D. P. Hall to J. G. Keppler, dated October 3, 1986). Our investigation of this matter is complete.

Illinois Power has reviewed and evaluated the findings associated with this investigation and has determined that the improper installation of Raychem insulation on certain splices invalidated the environmental qualification of the affected splices. Extensive engineering evaluations would be required to determine the effects of the deficient splices on the associated systems to perform their intended design function. On this basis, tbe matter was evaluated to be reportable under the provisions of 10CFR50.55(e).

Illinois Power is currently in the process of reworking /

repairing those Raychem splices identified as being deficient. The remaining corrective action associated with this issue will be completed prior to initial criticality.

This letter represents a final report in accordance with the l requirements of 10CFR50.55(e). Attachment A provides the details of our investigation.

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We trust that this1finalLreport.provides you. sufficient' background information to-perform a general assessment 1of' this reportable deficiency and' adequately describes.-~our

-overall approach to resolve thisfissue.

Sincerely yours, D. . Hall Vice President

RLC/bsa:

Attachment cc: -NRC. Resident Office-

. Illinois Department.of: Nuclear Safety

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1ATT CHMENT A) ,

' ILLINOIS POWER COMPANY '

~ 'Clinton: Power" Station'

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' Docket.No.'50-461 ReportableL10CFR50.'55(e) fDeficiency 55-86-08: Improper: Installation ~of

" Raychem Insulation on~ Splices'in: Class lE1 Circuits FINAL-REPORT-Statement of-Reportable ~ Deficiency / Background On' September 2,'1986,-Illinois-Power Company (IP) notified =Mr.,R.: Knop, NRC Region III-(Ref: .IP. Record of .

.CoordinationxY-203113, dated-SeptemberL4,c1986) of~a ,

.potentially reportable deficiency.-under the provisions:of 10CFR50.55(e)Leoncerning improper installation of_Raychem insulation onts'plices in Class lE circuits. Nonconforming a terial'-Report (NCMR) No. 1-2508 was initiated.to document M'

deficient Raychem splicesLfor.which the splice sleeve does z

notfentirely overlap'the splice. shim as required by the equipment ~ qualification (Ref: -Qualification Report No.

EQ-CLO48).

Investigation-Results/ Corrective Action "

Illinois Power's investigation into this matter has

_ determined that the nonconforming splices are associated with-work which was performed in conjunction with certain

Engineering Change. Notices (ECNs)'which changed the method for terminating certain electrical components from terminal blocks to splices. A sample inspection was performed of additional splices associated with these ECNs. The results of these inspections confirmed that the same nonconforming condition existed.as described by NQHR No. 1-2508 The configuration of the Raychem sleeve not entirely overlapping the shim was evaluated and found acceptable per l Calculation No. CDQ-012390, Rev. 06. Equipment

-Qualification Report No. EQ-CLO48 was revised to incorporate the acceptability of this configuration.

A review was performed of safety-related electrical

. installation travelers to identify those installations located in a harsh environment which utilized Raychem heat shrink in safety-related circuit splices. In addition, a computer search was conducted of Maintenance Work Requests (MWRs), Nonconforming Material Reports (NCMRs), and i Condition Reports (CRs) to further identify locations where

~ Raychem splices were utilized.

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m' M  ; ATTACHMENT-A

LILLINOIS POWER COMPANY

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iClinton Power Station-MWRs C-31401! throtight C-31431 -and :C-11780 were issued Leo -

-inspe'ct and rework / repair,jas:necessary, the,approximately

=370 devices:which_were suspected of utilizing.Raychem-

-splices.. The adequacy of the Raychem installations 1was-idetermined bysinspection of the visible attributes of the fsplice. (InspectionJdetermined;that approximately 80%,.of the 1370 devicesJutilized Raychem splices and.approximately-25%

'of ' the identifie'd devices had deficient Raychem . .

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installations.- 1The~ deficient' splices are currently being reworked / repaired,'and will be-completed prior to initial criticality.

During the inspections of the installed Raychem

. splices, a condition was identified involving.Raychem heat shrink tubing; installed over braided Bostrand Wire that is utilized-for termination of the transformer conductors in

the junction boxes _of the Hydrogen Igniters. The-supplier of theLHydrogen Igniters _(Morrison-Knudsen, Company, Inc.)

H provided:RaychemLheat shrink tubing with the Hydrogen Igniters for the purpose of terminating the transformer.

= conductors to the field cables. .The installation instructions for the Hydrogen Igniters did not specify removallof the braided material from.the'Bostrand Wire prior to application of.the;Raychem heat shrink tubing. However, the removal.of certain porous woven or braided substrate material, prior to application of the heat shrink tubing ist a requirement of Raychem. Raychem provided clarification of this requirement in a letter to the Public Service Company of Colorado, dated 11-27-85. The letter states that the ,

requirement for removal of woven or braided substrates applies to porous, non-solid materials which do'not provide a solid substrate to seal against. The.Bostrand Wire is considered to provide an adequate substrate, against which the Raychem heat shrink can be sealed since it is impregnated with an organic coating. This termination configuration was utilized in the qualification of these

- units and meets tha design purpose, which is to provide insulation over the connection similar to the overall cable jacket to prevent a gross short to ground. Based on the above, it was concluded that the Raychem splice installations on the Bostrand Wires (transformer conductor)

. in the Hydrogen Igniter junction boxes are qualified for L

their desigr. purpose.

Root Cause The root cause of the deficient Raychem installations j

is attributed to a lack of understanding and/or adherence to Raychem's installation instructions and requirements by the Constructor, Baldwin Associates. In addition, the Baldwin Associates' QC checklist has been reviewed and found not to L

have specific attributes for verification of the installation and is thus considered to have contributed to this deficiency.

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E ATTACHMENT A ILLINOIS POWER COMPANY Clinton Power Station s

Corrective action to preclude recurrence by the r Constructor is not applicable, since the Constructor is no longer on site. However, the Raychem installation requirements and QA/QC hold / witness points are now provided in Clinton Power Station (CPS) Procedure 8492.01. IP Plant Staff training is provided on Procedure 8492.01 in accordance with Maintenance Standing Order MSO-26.

Appropriate QA/QC personnel have also been trained to this

[ procedure. The Raychem manual (BAK-2999-9-0001) has been revised to include additional information to assist IP Plant

, Staff in the proper installation of Raychem heat shrink tubing.

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E Safety Implications / Significance i Illinois Power's investigation of this matter is complete. IP has reviewed and evaluated the findings t associated with this investigation and has determined that _

the improper installation of Raychem insulation on certain l>

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splices invalidated the environmental qualification of the

? affecced splices. Extensive engineering evaluations would be required to determine the effects of the deficient splices on the associated systems to perform their intended design function. On this basis, the matter was evaluated to be reportable under the provisions of 10CFR50.55(e).

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