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{{#Wiki_filter:Attachment to PLA-506 FINAL REPORT ON PGCC/ACR PANEL CONNECTORS DESCRIPTION While implementing FDDR-KR1-506 (rework of termination cabinets), damaged insulation (cuts, knicks, shield solder connections, etc.)was discovered on the jumper wires connecting the field wiring terminal board to the cable connector in GE's T-Mods.This was reported in NCR-3030.Subsequently, similar insulation damage and deficient pin crimps were discovered in the PGCC/ACR panel connectozs.
{{#Wiki_filter:Attachment to PLA-506 FINAL REPORT ON PGCC/ACR PANEL CONNECTORS DESCRIPTION While implementing FDDR-KR1-506 (rework of termination cabinets), damaged insulation (cuts, knicks, shield solder connections, etc.) was discovered on the jumper wires connecting the field wiring terminal board to the cable connector in GE's T-Mods. This was reported in NCR-3030.
This was reported in NCR-3403.A sample inspection program was implemented to determine the extent of insulation damage and defici.ent pin crimps.A visual inspection (extracting all pins)and pull test of all conductors and pins was performed within each of 250 sample panel connectors.
Subsequently, similar insulation damage and     deficient pin crimps   were discovered in the PGCC/ACR panel connectozs.       This was reported in NCR-3403.
125 connectors in the ACR inner zing panels and 125 connectors in the relay and back row panels of Unit 1 were randomly selected for the sample.The sample sizes identifi.ed were based on MZL-STD-105DE 29 April 1963, Table I General Inspection Level ZI and Table ZZA Single Sampling Plans for Normal Inspection.
A sample   inspection program was implemented to determine the extent of insulation damage and defici.ent pin crimps. A visual inspection (extracting all pins) and pull test of all conductors and pins was performed within each of 250 sample panel connectors.       125 connectors in the ACR inner zing panels and 125 connectors in the relay and back row panels of Unit 1 were randomly selected for the sample.
The sample plan was based on a 0.65 percent AQL acceptance rate.The sample inspection determined that the Unit 1 ACR inner ring/relay/back row panel connectors did not meet a 0.65 percent QAL for insulation damage and deficient crimps.CAUSE The causes of the problems could not be posi.tively identified.
The sample   sizes identifi.ed were based on MZL-STD-105DE 29   April 1963, Table I General Inspection Level ZI and Table   ZZA Single Sampling Plans for Normal   Inspection. The sample plan was based on a 0.65 percent AQL acceptance   rate.
However, it is believed that the damage to the insulation,.consisting of nicks, cuts and abrasions, was caused during the pin inse tion process.The edge of the insertion tool can impact the conductor insulation and cause damage under the high forces required to insert pins into the connector dielectric.
The sample   inspection determined that the Unit   1 ACR inner ring/relay/back row panel connectors did not meet a 0.65 percent QAL       for insulation damage and deficient crimps.
The deficient pin crimps could have been caused by a combination of manfuactur'ng personnel ezror and crimping tool malfunction.
CAUSE The causes   of the problems could not be posi.tively identified. However, it is believed that the damage to the insulation,.consisting of nicks, cuts and abrasions, was caused during the pin inse tion process.         The edge of the insertion tool can impact the conductor insulation and cause damage under the high forces required to insert pins into the connector dielectric.
General Electric said that their QA program at the time did not provide for verifying the adequacy of the crimping tool prior to use each day.ANALYSIS OF SAFETY IMPLICATIONS The PGCC/ACR panel connectors do have safety-related control and instrumen-tation circuits.Zt is conceivable that improperly crimped pins could prevent circuits from performing their design safety-related functions.
The deficient pin crimps could have been caused by a combination of manfuactur'ng personnel ezror and crimping tool malfunction. General Electric said that their QA program at the time did not provide for verifying the adequacy of the crimping tool prior to use each day.
Also, damaged insulation, if uncorrected, could permit shorting oz intro-duction of external voltage sources into safety-related circuits which could prevent the circuits from performing the designed safety function.
ANALYSIS OF SAFETY IMPLICATIONS The PGCC/ACR panel connectors     do have safety-related control and instrumen-tation circuits. Zt is conceivable that improperly crimped pins could prevent circuits from performing their design safety-related functions.
Attachment to PLA-506 (cont'd)Since damaged panel connectors are a random occurrence and could occur in any safety-related circuit, the possibility of a failure exists.The simultaneous degradation and loss'of safety-related circuits could result in a safety hazard to the operation of the plant.Project Engineering has determined the PGCC/ACR panel connector deficiencies to be reportable under 10 CFR 50.55(e).CORRECTIVE ACTION GE issued FDI WJIQ, Rev.0 to initiate a 100 percent visual inspection and pull test of all Unit 1 inner ring/relay/back row panel connectors with No.20 AWG wire.FDI WJIQ, Rev.1 was later issued and expanded the 100 percent inspection to all Unit 1 inner ring/relay/back row panel connectors.
Also, damaged insulation,   if uncorrected, could permit shorting oz intro-duction of external voltage sources into safety-related circuits which could prevent the circuits from performing the designed safety function.
The inspection, repair/rework and testing for Unit 1 are 95 percent complete.The remaining five percent will be completed and tracked by NCR-3403.Unit 2, will utilize a sampling plan similar to that used for Unit 1.CONCLUSIONS Upon completion of the inspection program, the Unit 1 inner ring/relay/back row panel connectors will have been subjected to inspection, repair/reworks and testing to assure their functionability and the detection and repair of defects.Project Engineering has authorized a sampling plan for Unit 2, and Bechtel Construction and QC will document results and generate an NCR for any discrepancies.}}
 
Attachment to PLA-506 (cont'd)
Since damaged panel connectors are a random occurrence and could occur           in any safety-related circuit,     the   possibility of a failure exists. The simultaneous degradation and loss'of safety-related circuits could result in a safety hazard to the operation of the plant.
Project Engineering has determined the       PGCC/ACR panel   connector deficiencies to be reportable under 10       CFR 50.55(e).
CORRECTIVE ACTION GE issued FDI WJIQ, Rev. 0 to initiate a 100 percent visual inspection and pull test of all Unit     1 inner ring/relay/back row panel connectors with No.
20 AWG wire. FDI   WJIQ, Rev. 1 was     later issued   and expanded the 100 percent inspection to     all Unit 1 inner ring/relay/back row panel connectors.
The   inspection, repair/rework   and testing for Unit 1 are 95 percent complete. The remaining   five percent will be completed and tracked     by NCR-3403.
Unit 2,   will utilize a   sampling plan similar to that used     for Unit 1.
CONCLUSIONS Upon   completion of the inspection program, the Unit 1 inner ring/relay/back row panel connectors   will have been subjected to inspection, repair/reworks and testing to assure their functionability and the detection and repair of defects.
Project Engineering has authorized a sampling plan for Unit 2, and Bechtel Construction and QC will document results and generate an NCR for any discrepancies.}}

Latest revision as of 00:46, 22 October 2019

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)
v • d • e


Text

Attachment to PLA-506 FINAL REPORT ON PGCC/ACR PANEL CONNECTORS DESCRIPTION While implementing FDDR-KR1-506 (rework of termination cabinets), damaged insulation (cuts, knicks, shield solder connections, etc.) was discovered on the jumper wires connecting the field wiring terminal board to the cable connector in GE's T-Mods. This was reported in NCR-3030.

Subsequently, similar insulation damage and deficient pin crimps were discovered in the PGCC/ACR panel connectozs. This was reported in NCR-3403.

A sample inspection program was implemented to determine the extent of insulation damage and defici.ent pin crimps. A visual inspection (extracting all pins) and pull test of all conductors and pins was performed within each of 250 sample panel connectors. 125 connectors in the ACR inner zing panels and 125 connectors in the relay and back row panels of Unit 1 were randomly selected for the sample.

The sample sizes identifi.ed were based on MZL-STD-105DE 29 April 1963, Table I General Inspection Level ZI and Table ZZA Single Sampling Plans for Normal Inspection. The sample plan was based on a 0.65 percent AQL acceptance rate.

The sample inspection determined that the Unit 1 ACR inner ring/relay/back row panel connectors did not meet a 0.65 percent QAL for insulation damage and deficient crimps.

CAUSE The causes of the problems could not be posi.tively identified. However, it is believed that the damage to the insulation,.consisting of nicks, cuts and abrasions, was caused during the pin inse tion process. The edge of the insertion tool can impact the conductor insulation and cause damage under the high forces required to insert pins into the connector dielectric.

The deficient pin crimps could have been caused by a combination of manfuactur'ng personnel ezror and crimping tool malfunction. General Electric said that their QA program at the time did not provide for verifying the adequacy of the crimping tool prior to use each day.

ANALYSIS OF SAFETY IMPLICATIONS The PGCC/ACR panel connectors do have safety-related control and instrumen-tation circuits. Zt is conceivable that improperly crimped pins could prevent circuits from performing their design safety-related functions.

Also, damaged insulation, if uncorrected, could permit shorting oz intro-duction of external voltage sources into safety-related circuits which could prevent the circuits from performing the designed safety function.

Attachment to PLA-506 (cont'd)

Since damaged panel connectors are a random occurrence and could occur in any safety-related circuit, the possibility of a failure exists. The simultaneous degradation and loss'of safety-related circuits could result in a safety hazard to the operation of the plant.

Project Engineering has determined the PGCC/ACR panel connector deficiencies to be reportable under 10 CFR 50.55(e).

CORRECTIVE ACTION GE issued FDI WJIQ, Rev. 0 to initiate a 100 percent visual inspection and pull test of all Unit 1 inner ring/relay/back row panel connectors with No.

20 AWG wire. FDI WJIQ, Rev. 1 was later issued and expanded the 100 percent inspection to all Unit 1 inner ring/relay/back row panel connectors.

The inspection, repair/rework and testing for Unit 1 are 95 percent complete. The remaining five percent will be completed and tracked by NCR-3403.

Unit 2, will utilize a sampling plan similar to that used for Unit 1.

CONCLUSIONS Upon completion of the inspection program, the Unit 1 inner ring/relay/back row panel connectors will have been subjected to inspection, repair/reworks and testing to assure their functionability and the detection and repair of defects.

Project Engineering has authorized a sampling plan for Unit 2, and Bechtel Construction and QC will document results and generate an NCR for any discrepancies.

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