ML19289C645

Interim Rept on Discrepancies Found in Inboard Terminal Box Electrical Penetration Assemblies.Recommends Determining If There Was Breakdown in Vendor QC Program.Another Rept Will Be Transmitted on or Before 790131.Related Correspondence

ML19289C645
Person / Time
Site:	Midland
Issue date:	01/15/1979
From:	Howell S CONSUMERS ENERGY CO. (FORMERLY CONSUMERS POWER CO.)
To:
References
HOWE-16-79, NUDOCS 7901220057
Download: ML19289C645 (7)

Text

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/ Stephen H. Howell Senior Vice l'renfent Gener al Of fices: 1945 West Parnail fload, Jackson, Michigan 49201 * (517) 788 0453 January 35, 1979 lieve 16-79 f1r J G Keppler, Regional Director Office of Increetion and Enforcetent U3 liuelear Rogulatory Corzniscion Region III

• (99 Roocevelt End Glen Ellyn, IL C0137

!!IDLAI!D !!UCLFAR PLANT -

UIllT I:0. 1, DOCKI:T I:0. 50-329 U!!]T !!O. 2, DOCKET ::0. 50-330 ELEC'1 RICAL 1 E!!iTRATION AS&"t!4LY In accordance with the requiremente of 10 CFR 50 55(e), thic letter conctitutec an interim report on the statun of dicererancien found in the inboard terminal boxen of Unit 1 and 2 electrical penetration accenbliec.

A deceription of the dicerepancy, potential cafety implications, investication and planned corrective actionn are documented in the attachments to thin letter.

Another report, either it.terin or fin tl, will be cent on er before 'tarch 31, 1979

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Attachment:

1. Q u'111t:. Accurance Procr:tm, !!nnunement Corrective Action Report,

!! CAR-1, Hoport 26, dated December 19,19'(8.

2. Letter, P. A. Ihrtinea to G. C. Keeley. BLC 6993, MCAR-26, Interin Report #1, with attached repors CC- Director of Office Inspection 'ind Enforcerent Att: Mr. John G. Davic, Iseting Di rector, UC::RC (15)

/irector of. Office of !Snngement Information and Program Control, USI:RC (1) 790122005 ] g

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p Bechtel Associates Professional C.orporation OAR 26 1!:TERIM REPORT 1

%;e3 Janery 8, 1979 Attachtect to BLC-6993 Safety Implication Most of the discrepancies identified arc of a nature that would be suspect to a fallure mode. The failure mode would most likely be an electrical circuit disruption. The discrepancies were identified in penetration assemblics for Class lE circuits. Therefore, a circuit disruption would be classified as a failure of the electrical penetration assembly to perform its intended safety function.

Eased on 'c potential failure modo and resulting safety implication, these deficiencies are considered to be reportable as stated in the MCAR.

Forecast Date on Corrective Action A schedule for

• the corrcctive actions will be pr'ovided in Interim Report -

1 j Submitted by v[ , ..

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Approved by:}f[ .-?. Q Y %d7 M' Concurrence by: . d d) J t t LA JK/j s 1/5/4

Bechtel Associates Professional Corporation HCAR 26 Ih7ERIM REPORT 1 Pccc 2 -

January 8, 1979 Attachment to BI.C-6993 Probabic Caus_c Electrical connections are visually checked at random by Bechtel Supplier Quality Representative (SQR) as part of inprocess inspection. Electrical connections are subjected to a 100% cicetrical check according to the supplier's acceptance test procedure. Electrical tests are randomly witnessed by Bechtel SQR. All verification documents, including the required electrical tests (insulation resistance and continuity) are checked by Bechtel SQR prior to rc1 casing material for shipment. Further investigation is being made to determine why the random check by the SQR did not discover any discrepancies.

The crimping tools ubich vere used for the Midland work were subjected to regular calibration checks and pull tests to verify calibration.

Pull tests uere randomly witnessed by Bechtel SQR. The records for the calibration and' pull test were rechecked in late Deccaber 1978 by Bechtel SQR and found satisfactory.

The supplier's QA manual and their acceptance test procedurcs require inspection and verification of each manufacturing operation. Based on this requirement and in view of the discrepancies identified, it would appear that there war a breakdown in the supplier's quality control program. The supplier (Bunker Ramo-Amphenol Sans Division) will be requested to provide their own assessacnt of the probabic cause of the apparent breakdown in their quality control program.

Corrective Action Although al' of Midland's presently known electrical penetration assemblics have been delivered to the jobsite, the supplier will be notified to identify corrective action to be taken to prevent recurrence for potential add-on orders.

With regard to the assemblies on the site, investigate the inboard terminal boxes on all penetrations for inadequate terminations and docunent the finding:. Each individual nonconforming termination will be dispositioned accordingly. It is noted that of the total 92 electrical penetration assemblies (46 per unit), 26 assemblics (13 per unit) are designated for Class 1E circuits.

- Bechtel Associates ProfessionalCorporation Attachr.cnt to DLC-6993 Page 1

SUBJECT:

MCAR 26 (Issued 12/19/78)

Electrical Penetration Assembly, Inadequate Wire Terninations INTERIM REPORT 1 DATE: January 8,1979 PROJECT: Consumers Power Company Midland Plant Units 1 & 2 Bechtel Job 7220 Introduction This report is submitted to advisc regarding the' interim status and course of action required pursuant to MCAR 26 and CPCo ::CR M-01-4-8-107.

Description of Discrepancy Field inspection by CPCo of three installed electrical penetration assemblics revealed the following discrepancies associated with wire terminations located in the penetration assemblics' inboard terminal boxes: .

1. Inadequate crimping of lugs - wires pulled out easily

2. Inadequate cri:rp .g of lugs - crimps not tight

3. Inadequate crimping of lugs - wires not fully penetrating lug barrel

4. Inadequate crimping of lugs - crimps caught the very tip of w cc S. Inadequate crimping of lugs - barrel of lug collapsed, preve :ing full vire compression

6. Incorrect type of lug used - insulated lugs specified, but uniasu-lated types found on some terminations

7. Inadequate termination of lug to terminal block - connections loose on terminal blocks

ATTAClDlWf 2 Howe 16 '(9 Bechtel Power Corporation 7,77 East Etenhower Parkway ;Ms Ann Arbor, f.hchigan .+

vaaAvaress P.O. Box 1000. / in Arbor, Michigan 4S10G January 10, 1979 s

BLC-6993 Mr. G. S. Keeley Project l'anager CO:;SUMERS PO*..'UR CO:!PA ;Y 1945 West Parnall Road Jackson, liichigan 49201 Midland Units 1 and 2 Consurers Pouer Ccrpany Bechtel Job 7220 l' CAR '26 II;TERIM REPORT 1 Files 2417/2801 , m . - ,.

Dear Mr. Keeley:

Trans:nitted for your information and use is the first interin report

+ubmitted for the elcetrical penetration assembly inadequate wire terminations (MCAR 26) .

The next interin report is scheduled for March 15, 1979.

Very truly yours, 3fGO2YlE<^'>

-[a / P. A. Martinez Project Manager PMt/AEB/pp cc: Mr. R. C. Bauran Mr. U. R. Bird Mr. J. L. Corley Attachrent (3 pagen).

J AN I 11979 QUAUiY I;8SliR?f.CE t

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11 CAR Report flo. 26 Page 2 f Description (continued) ,

3. Terminal box for 2Z113 n) Terminals B-17 and K-4 wirce pulled easily out of teminal lugs.

b) Temina3 s L-3 and L-8 connections were very loose on terminal bloch.

2. Terninal box for 1Z129 n) Teminals F-1, L-1 and E-15 uires pulled easily out of terminal lugs.

b) Teminals C-15 and E-19 have uninsulated lugs installed.

3. Teminal box for 1Z131 n) Teminal G-10 uire pulled casily out of teminal lug.

b) Teminals J-10, K-1, K-2, K-3, and K connections ucre very loose on teminal block.

In addition to these discrepancies, approxinate3y 20 of the wiring in the three teminal boxes exhibited the following:

1. Wires not fully penetrating lug barrel

2. Crir ps not tight

3. Crimps caught very tip of wire

4. llarrel of lug collapsed preventing full wire cenpression.

l'o te : There are no field inspections required to verify vendors vorFranchip.

After the penetrations are released fron the vendors and accepted by Ecchtel's shop inspectors the penetrations are shipped to the site for installation.

Reconmended Actirn: (continued)

4. Determine if there was a breakdown in the vendor quality control progran and/or the Bechtel shop inspection prograu.

4

UUAlli Y ASSUl( AtJCL l'l{UGit AM . ATTACIL':EtJT 1 Hm 16-U

> 1 .h f.iAN AGEf.iENT CORRECTIVE ACTION REPORT g Re-typed frem tele / copy received t,iCAR 1 REPORT f40* 2 f' 12/20/78 signed by E. Smith on 12/19/78 JOB f10. 2220 O IJO. ~4 . 0 0 ') D AT E .Dncenbr r 10 - 107R l' DESCRIPTIOlJ (including referencesi:

A client inspection of three installed electrical penetrations revealed inadequate crimping of wires located in the penetrations inboard terminal boxes. *;his has been documented in CPCo UCR M-01-4-8-107 issued 12/19/78. These terminations were done by t'ic ranufacturer Amphenol ' ans/Eunher Raao prior to shipment. This inspection as witnessed by Ecchtel Field Engineerfug and Quality Control, identified the following discrepancies:

(sce page two)

• HECOMMEf4DED ACTIOrJ (Optional)

1. Determine Uhat effect these discrepancies, if gone undetected, vould have on plant safety.

2. Investigate the inboard terminal boxes on all peretrations for inadequate terninations and correct accordingly.

3. Deternine the root cause of the discrepancies and tche appropriate corrective action to preclude recurrence.

(see page two)

REFERRED TO v EfJGif4ELRif4G COflSTRU ilOf! { OA fA AfJAGEidEtJT O PROCUREMEtJT ISSUED BY - M 12 M" Project Engineer b

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FORMAL REPORT TO CLIEtJT

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