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{{#Wiki_filter:AttachmenttoPLA-506FINALREPORTONPGCC/ACRPANELCONNECTORSDESCRIPTIONWhileimplementingFDDR-KR1-506(reworkofterminationcabinets),damagedinsulation(cuts,knicks,shieldsolderconnections,etc.)wasdiscoveredonthejumperwiresconnectingthefieldwiringterminalboardtothecableconnectorinGE'sT-Mods.ThiswasreportedinNCR-3030.Subsequently,similarinsulationdamageanddeficientpincrimpswerediscoveredinthePGCC/ACRpanelconnectozs.ThiswasreportedinNCR-3403.Asampleinspectionprogramwasimplementedtodeterminetheextentofinsulationdamageanddefici.entpincrimps.Avisualinspection(extractingallpins)andpulltestofallconductorsandpinswasperformedwithineachof250samplepanelconnectors.125connectorsintheACRinnerzingpanelsand125connectorsintherelayandbackrowpanelsofUnit1wererandomlyselectedforthesample.Thesamplesizesidentifi.edwerebasedonMZL-STD-105DE29April1963,TableIGeneralInspectionLevelZIandTableZZASingleSamplingPlansforNormalInspection.Thesampleplanwasbasedona0.65percentAQLacceptancerate.ThesampleinspectiondeterminedthattheUnit1ACRinnerring/relay/backrowpanelconnectorsdidnotmeeta0.65percentQALforinsulationdamageanddeficientcrimps.CAUSEThecausesoftheproblemscouldnotbeposi.tivelyidentified.However,itisbelievedthatthedamagetotheinsulation,.consistingofnicks,cutsandabrasions,wascausedduringthepininsetionprocess.Theedgeoftheinsertiontoolcanimpacttheconductorinsulationandcausedamageunderthehighforcesrequiredtoinsertpinsintotheconnectordielectric.Thedeficientpincrimpscouldhavebeencausedbyacombinationofmanfuactur'ngpersonnelezrorandcrimpingtoolmalfunction.GeneralElectricsaidthattheirQAprogramatthetimedidnotprovideforverifyingtheadequacyofthecrimpingtoolpriortouseeachday.ANALYSISOFSAFETYIMPLICATIONSThePGCC/ACRpanelconnectorsdohavesafety-relatedcontrolandinstrumen-tationcircuits.Ztisconceivablethatimproperlycrimpedpinscouldpreventcircuitsfromperformingtheirdesignsafety-relatedfunctions.Also,damagedinsulation,ifuncorrected,couldpermitshortingozintro-ductionofexternalvoltagesourcesintosafety-relatedcircuitswhichcouldpreventthecircuitsfromperformingthedesignedsafetyfunction.
{{#Wiki_filter:AttachmenttoPLA-506FINALREPORTONPGCC/ACRPANELCONNECTORSDESCRIPTIONWhileimplementingFDDR-KR1-506(reworkofterminationcabinets),damagedinsulation(cuts,knicks,shieldsolderconnections,etc.)wasdiscoveredonthejumperwiresconnectingthefieldwiringterminalboardtothecableconnectorinGE'sT-Mods.ThiswasreportedinNCR-3030.Subsequently,similarinsulationdamageanddeficientpincrimpswerediscoveredinthePGCC/ACRpanelconnectozs.ThiswasreportedinNCR-3403.Asampleinspectionprogramwasimplementedtodeterminetheextentofinsulationdamageanddefici.entpincrimps.Avisualinspection(extractingallpins)andpulltestofallconductorsandpinswasperformedwithineachof250samplepanelconnectors.125connectorsintheACRinnerzingpanelsand125connectorsintherelayandbackrowpanelsofUnit1wererandomlyselectedforthesample.Thesamplesizesidentifi.edwerebasedonMZL-STD-105DE29April1963,TableIGeneralInspectionLevelZIandTableZZASingleSamplingPlansforNormalInspection.Thesampleplanwasbasedona0.65percentAQLacceptancerate.ThesampleinspectiondeterminedthattheUnit1ACRinnerring/relay/backrowpanelconnectorsdidnotmeeta0.65percentQALforinsulationdamageanddeficientcrimps.CAUSEThecausesoftheproblemscouldnotbeposi.tivelyidentified.However,itisbelievedthatthedamagetotheinsulation,.consistingofnicks,cutsandabrasions,wascausedduringthepininsetionprocess.Theedgeoftheinsertiontoolcanimpacttheconductorinsulationandcausedamageunderthehighforcesrequiredtoinsertpinsintotheconnectordielectric.Thedeficientpincrimpscouldhavebeencausedbyacombinationofmanfuactur'ngpersonnelezrorandcrimpingtoolmalfunction.GeneralElectricsaidthattheirQAprogramatthetimedidnotprovideforverifyingtheadequacyofthecrimpingtoolpriortouseeachday.ANALYSISOFSAFETYIMPLICATIONSThePGCC/ACRpanelconnectorsdohavesafety-relatedcontrolandinstrumen-tationcircuits.Ztisconceivablethatimproperlycrimpedpinscouldpreventcircuitsfromperformingtheirdesignsafety-relatedfunctions.Also,damagedinsulation,ifuncorrected,couldpermitshortingozintro-ductionofexternalvoltagesourcesintosafety-relatedcircuitswhichcouldpreventthecircuitsfromperformingthedesignedsafetyfunction.
AttachmenttoPLA-506(cont'd)Sincedamagedpanelconnectorsarearandomoccurrenceandcouldoccurinanysafety-relatedcircuit,thepossibilityofafailureexists.Thesimultaneousdegradationandloss'ofsafety-relatedcircuitscouldresultinasafetyhazardtotheoperationoftheplant.ProjectEngineeringhasdeterminedthePGCC/ACRpanelconnectordeficienciestobereportableunder10CFR50.55(e).CORRECTIVEACTIONGEissuedFDIWJIQ,Rev.0toinitiatea100percentvisualinspectionandpulltestofallUnit1innerring/relay/backrowpanelconnectorswithNo.20AWGwire.FDIWJIQ,Rev.1waslaterissuedandexpandedthe100percentinspectiontoallUnit1innerring/relay/backrowpanelconnectors.Theinspection,repair/reworkandtestingforUnit1are95percentcomplete.TheremainingfivepercentwillbecompletedandtrackedbyNCR-3403.Unit2,willutilizeasamplingplansimilartothatusedforUnit1.CONCLUSIONSUponcompletionoftheinspectionprogram,theUnit1innerring/relay/backrowpanelconnectorswillhavebeensubjectedtoinspection,repair/reworksandtestingtoassuretheirfunctionabilityandthedetectionandrepairofdefects.ProjectEngineeringhasauthorizedasamplingplanforUnit2,andBechtelConstructionandQCwilldocumentresultsandgenerateanNCRforanydiscrepancies.  
AttachmenttoPLA-506(cont'd)Sincedamagedpanelconnectorsarearandomoccurrenceandcouldoccurinanysafety-relatedcircuit,thepossibilityofafailureexists.Thesimultaneousdegradationandloss'ofsafety-relatedcircuitscouldresultinasafetyhazardtotheoperationoftheplant.ProjectEngineeringhasdeterminedthePGCC/ACRpanelconnectordeficienciestobereportableunder10CFR50.55(e).CORRECTIVEACTIONGEissuedFDIWJIQ,Rev.0toinitiatea100percentvisualinspectionandpulltestofallUnit1innerring/relay/backrowpanelconnectorswithNo.20AWGwire.FDIWJIQ,Rev.1waslaterissuedandexpandedthe100percentinspectiontoallUnit1innerring/relay/backrowpanelconnectors.Theinspection,repair/reworkandtestingforUnit1are95percentcomplete.TheremainingfivepercentwillbecompletedandtrackedbyNCR-3403.Unit2,willutilizeasamplingplansimilartothatusedforUnit1.CONCLUSIONSUponcompletionoftheinspectionprogram,theUnit1innerring/relay/backrowpanelconnectorswillhavebeensubjectedtoinspection,repair/reworksandtestingtoassuretheirfunctionabilityandthedetectionandrepairofdefects.ProjectEngineeringhasauthorizedasamplingplanforUnit2,andBechtelConstructionandQCwilldocumentresultsandgenerateanNCRforanydiscrepancies.}}
}}

Revision as of 00:50, 18 May 2018

Final Deficiency Rept Re Insulation Damage & Deficient Pin Crimps in Power Generation Control Complex/Advanced Control Room Panel Connectors.Cause Unidentified.Visual Insp & Pull Test Initiated on Unit 1
ML18030A128
Person / Time
Site: Susquehanna  Talen Energy icon.png
Issue date: 07/08/1980
From:
PENNSYLVANIA POWER & LIGHT CO.
To:
Shared Package
ML18030A127 List:
References
PLA-506, NUDOCS 8007140179
Download: ML18030A128 (2)


Text

AttachmenttoPLA-506FINALREPORTONPGCC/ACRPANELCONNECTORSDESCRIPTIONWhileimplementingFDDR-KR1-506(reworkofterminationcabinets),damagedinsulation(cuts,knicks,shieldsolderconnections,etc.)wasdiscoveredonthejumperwiresconnectingthefieldwiringterminalboardtothecableconnectorinGE'sT-Mods.ThiswasreportedinNCR-3030.Subsequently,similarinsulationdamageanddeficientpincrimpswerediscoveredinthePGCC/ACRpanelconnectozs.ThiswasreportedinNCR-3403.Asampleinspectionprogramwasimplementedtodeterminetheextentofinsulationdamageanddefici.entpincrimps.Avisualinspection(extractingallpins)andpulltestofallconductorsandpinswasperformedwithineachof250samplepanelconnectors.125connectorsintheACRinnerzingpanelsand125connectorsintherelayandbackrowpanelsofUnit1wererandomlyselectedforthesample.Thesamplesizesidentifi.edwerebasedonMZL-STD-105DE29April1963,TableIGeneralInspectionLevelZIandTableZZASingleSamplingPlansforNormalInspection.Thesampleplanwasbasedona0.65percentAQLacceptancerate.ThesampleinspectiondeterminedthattheUnit1ACRinnerring/relay/backrowpanelconnectorsdidnotmeeta0.65percentQALforinsulationdamageanddeficientcrimps.CAUSEThecausesoftheproblemscouldnotbeposi.tivelyidentified.However,itisbelievedthatthedamagetotheinsulation,.consistingofnicks,cutsandabrasions,wascausedduringthepininsetionprocess.Theedgeoftheinsertiontoolcanimpacttheconductorinsulationandcausedamageunderthehighforcesrequiredtoinsertpinsintotheconnectordielectric.Thedeficientpincrimpscouldhavebeencausedbyacombinationofmanfuactur'ngpersonnelezrorandcrimpingtoolmalfunction.GeneralElectricsaidthattheirQAprogramatthetimedidnotprovideforverifyingtheadequacyofthecrimpingtoolpriortouseeachday.ANALYSISOFSAFETYIMPLICATIONSThePGCC/ACRpanelconnectorsdohavesafety-relatedcontrolandinstrumen-tationcircuits.Ztisconceivablethatimproperlycrimpedpinscouldpreventcircuitsfromperformingtheirdesignsafety-relatedfunctions.Also,damagedinsulation,ifuncorrected,couldpermitshortingozintro-ductionofexternalvoltagesourcesintosafety-relatedcircuitswhichcouldpreventthecircuitsfromperformingthedesignedsafetyfunction.

AttachmenttoPLA-506(cont'd)Sincedamagedpanelconnectorsarearandomoccurrenceandcouldoccurinanysafety-relatedcircuit,thepossibilityofafailureexists.Thesimultaneousdegradationandloss'ofsafety-relatedcircuitscouldresultinasafetyhazardtotheoperationoftheplant.ProjectEngineeringhasdeterminedthePGCC/ACRpanelconnectordeficienciestobereportableunder10CFR50.55(e).CORRECTIVEACTIONGEissuedFDIWJIQ,Rev.0toinitiatea100percentvisualinspectionandpulltestofallUnit1innerring/relay/backrowpanelconnectorswithNo.20AWGwire.FDIWJIQ,Rev.1waslaterissuedandexpandedthe100percentinspectiontoallUnit1innerring/relay/backrowpanelconnectors.Theinspection,repair/reworkandtestingforUnit1are95percentcomplete.TheremainingfivepercentwillbecompletedandtrackedbyNCR-3403.Unit2,willutilizeasamplingplansimilartothatusedforUnit1.CONCLUSIONSUponcompletionoftheinspectionprogram,theUnit1innerring/relay/backrowpanelconnectorswillhavebeensubjectedtoinspection,repair/reworksandtestingtoassuretheirfunctionabilityandthedetectionandrepairofdefects.ProjectEngineeringhasauthorizedasamplingplanforUnit2,andBechtelConstructionandQCwilldocumentresultsandgenerateanNCRforanydiscrepancies.