ML18030A013

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Final Deficiency Rept Re Power Generation Control Complex/ Advanced Control Room Cable Connector.Insp Program Nearly Complete.All Unit 1 Cable Repairs Will Be Completed Prior to Fuel Load.Unit 2 Cables Will Be Installed & Repaired
ML18030A013
Person / Time
Site: Susquehanna  Talen Energy icon.png
Issue date: 09/29/1980
From: CURTIS N W
PENNSYLVANIA POWER & LIGHT CO.
To: GRIER B H
NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I)
References
10CFR-050.55E, 10CFR-50.55E, PLA-545, NUDOCS 8010070086
Download: ML18030A013 (6)


Text

REGULATI-'JFORHA I'IOlTIDISTRIBUT IO'ISTEI(RIDS)ACCESSIO'I NOR'8010070086 DOC~DATE'0/09/29 iIOTARIZEO'uO DOCKET¹FACIL;Susquehanna SteamElectricStationpUnitlpPennsylva 05000387"38Susquehanna SteamElectricStationEJnit2iPennsylva 05000388AUT~AUTHOR4FFILIATIONCURTIS',8

~Pennsylvania PowerItLightCo.~P[lRECIP~u4'4ERECIPIE'JT AFFILIATIO'JGRIEREB,n.Region1iPhi1adelphiaiOfficeoftheDirector

SUBJECT:

Finaldeficiency reptrepowergeneration controlcomplex/advancedcontrolroomcableconnector, Insoprogramnearlycomplete.A11 Unit1cablereoairswillbecompleted orio,rtofuelloadsUnit2cableswillbeinstalled 5reoaried.

DISTRIBUTION CODE:B019SCOPIESRECEIVED:LTR gENCLgSIZE:MTITLE:Construction Deficiency Report(10CFR50~55E)NOTES:Send IEE3copiesFSAR4allamends'5000387 05000388RECIPIETTITIDCODE/.'PATE ACTIOI':A/0LICEuSNG04RUSHBROOKP'DID 06INTERNAL:

AD/RCI/IE17ASLBP/J~HARDEDO4STAFF19IiYD/GEOBR22LICQUALBR12'JRCPDR02REV13EGFI!-E0l7ORDSDEV21ICOPIESL.rTRENCL11,11-1111111111111111RECIPIETVTIDCODE/'VANE YOUNGBLOODEB 05STARKPR~07AEOO18D/DIHHUMFAC15EQUIPQUALBR11ICE09!DIPA20OELD21QABR14RUTHERFORDEH

~IECOPIESLTTRETJCL1111111112211111111EXTERiuaL:

ACRSEISIC16161608111PDR03TOTAL'IU'LIBEJJOFCOPIESclEQVIRED:LTTR40EVCL40I P"L.TWONORTHN1NTMSTREEt,ALLENTOWN, PA.1810)PHONE;(215)821~5151September 29,1980.'!r.BoyceH.GrierDirector, RegionIU.S.NuclearRegulatory Commission 631ParkAvenueKingofPrussia,Pennsylvania 19406SUSQUEPANNA STEP~MELECTRICSTATIONFINALREPORTOFADEFICIENCY ONPGCC/ACRCABLECONNECTORS ERs100450/100508 FILE840-4/900-10 PLA-545

References:

PLA-437datedJanuary8,1980PLA-301datedNovember14,1978

Deari!r.Grier:

ThisletterservestoprovidetheCommission withafinalreportofa'deficiency onPowerGeneration ControlComp1.ex/Advanced ControlRoom(PGCC/ACR) cableconnector deficiencies originally reportedinPLA-301.Theinformation isfurnished pursuanttoPP&L'sobligations underthe'rovisions of10CFR50.55(e).

Theattachment tothisletterdescribes thedeficient condition alongwithitssafetyimplications andthecorrective actionbeingtakentoachieveresolution.

HetrusttheCommission willfindtheinformation forwarded bythislettertobesatisfactory.

'erytrulyyours,N,.CurtisVicePresident-Engineering

&Construction-Nuclear Attachment FLU'.jmk//IPENNSYLVANlA POWER8,LIGHTCOMPANY0XOopnpqg i'fr.BoyceH.GrierSeptember 19,1980':ello(15)D'".=.ctor-~'fiice ofInspection

&Enforcement

uclearRegulatory Commission DC20555;.YcDonald, DirectorOf='.'eof!!anagement information

&ProgramControlL'.S.NuclearRegulatory Commission 4'asnington, D.C.20555Nr.Robert.'f.GalloU.S.nuclearRegulatory Commission P,Q.Box52Shc!:.sninny, Pennsylvania 18655 ATTACHbKNT TOPLA545Page1of3PGCC/ACRCABLEPROBLEh/S FINALREPORTC/ACRCab'cP:oblemsDESCRIPTION InlettersfromBechtelConstruction datedOctober3,1978,PP5Lwasinformedthatduringimplementation ofGeneralElectric's FDDR-KR1-521, Rev.0(GeneralCableRetrofit) rework,itwasnotedthatnumerouscasesof-'nsulation damageswerefoundandthatonecablewasfoundtohavefour(4)conductors pulledfromtheirpinconnectors.

Duetothehighpercentage ofdamagedcable,thequalityofallterminations wasrenderedindeterminate.

NCR-3231wasgenerated todocumenttheproblemswithinthePGCC/ACRcomplex.t,wasagreedtobyPP5L,BechtelandGeneralElectric, thatGE>>ouldpreparanFDIwhichshouldhavedetailsofacompleteinspection planandanapprovedrepairprocedure.

InFebruarv, 1979,GEissuedFDI-NJGORev.0toperforma100'oinspection ofallGEsuppliedSITS/FITS cablesusedintheSusquehanna 1ACRcontrolroom,upperrelayroomandlowerrelayroomfordamagedinsulation andsuspectpincrimps.ApprovedmethodsofrepairfordamagedPGCC/ACRcableconnectors identified duringtheinspections performed underFDI-t'fJGO wereaccomplished inaccordance withGEFDDR-KRl-526.

ThisFDDRwasoriginally issuedonSept.6,1978tocontroltherepairofPGCC/ACRpanelconnectors.

ThePanelCcnnector problemswereexplained inourPLA-506datedJuly8,1980.Theinspections, repair/rework andtestsforthecablesunderFDI-ÃJGO, FDDR-KR1-526, theirrevisions and'ddendums arenearlycomplete.

Atotalof1762cableshavebeeninspected.

Theresultsoftheinspection areasfollows:~Dameeguuantit1.Nickstoconductor insulation 264Cutstoconductor insulation Damagedornoshrinktubing346265Pinspulledoffduringpulltestorfelloffduringdepinning 58."otpinnedinaccordance withwirelistorass."..blymethod78V~F!iledcontinuity 21 CAUSE{a}and",nicksandcutstoconductor insulation; afterhavinginves-=!~'..";~'.:,"-'arced con"uctor insulation withintheT-'.lODwiring"oaconne."sr,:.'~;e".."..ired byGEthatduringreassembly (i.e.,pininsertion andez-trac"icnuingthestandardAmphenoltoolingforthetermination modules)continual difficulty wasexperienced.

Theferruleedgeduringextraction andthesharpinsertion tooledgeduringassemblyimpactedonthedenselypackedwresattheconnector areacausingnicks,cutsandabrasions.

(b)It~..3,damagedornoshrinktubing,canbebrokenintotwo(2)parts:(1)thedamagedshrinktubingcouldhavebeencausedatthefactoryduringasse...bly ofthecableorattheconstruction siteduringinstallation; and(2)thelackofshrinktubingwasduetoanoversight inmanufacturing.

(c)Item4,pinspulledoffduringpulltestorwhichfelloffduringdepinning; itwasdetermined thatacombination ofmanufacturing personnel errorandcr-'mping toolmalfunction, duetoinadequate QAcoverage, wasresponsible fordefective crmps.Thiswouldaccountforpinsfailingpulltestsorfallingoffduringdepinning.

(d)Item5,notpinnedinaccordance withwirelistorassemblymethod,isamanufacturing error;i.e.,theconductor mightbepinnedinholeAinaconnector butinholeBintheconnector ontheoppositeendofthecable.(e)Item6,failedcontinuity, isadirectresul'toftheconductor notpinnedinaccordance withthewirelistorassemblymethod(Item5).ANALYSISOFSAFETYDPLICATIONS AsthevariousproblemsareofarandomnatureandthereareanumberofClass1Ecablesinvolved, theSafetyAnalysisispresented onanitembyitembasisasfollows:(a)Initems1,2and3,nicksandcutstoconductor insulation anddamagedornoheatshrinktubing,ifbarecopperwireisexposedandleftuncorrected, i'ouldpermitshortingofwiresorintroduction ofexternalvoltagesintosafetyrelatedcircuits.

Anyoftheseconditions couldpreventthecircuitsfromperforming thedesignedsafetyfunction.

(b)Items4,5and6,pinspulledoffduringpulltestorfelloffduringdepinning, notpinnedinaccordance withwirelistorassemblymethodandfailedcontinuity, couldaffectthedesignedsafetyfunctions.

Ifduringaseismicevent,theconductor vibrateslooselyinthepinsothatthereissporadicornocontinuity betweenthepinandconductor, oriftheconductor isnotpinnedcorrectly suchthatthereisnocontinuity betweentheproperconnector pinsateachendofthetable,theoperation ofthecircuitcouldbeadversely affected.

ProjectEngineering hasdetermined thattheaboveitemsarereportable under10CF?5C.55(e).,

-3>>CORRECTIVE ACTIONSThe100%inspection programforPGCCcableconnectors andrepair/rework fortheproblemslistedinNCR-3231isnearlycomplete.

...."='.opreventrecur'rences oflikepoh's~".:t.~;ei'GCCcoucheconnectors',

andwhicharealsoapplicable totheSusquehanna PGCC/ACRUnit2cables,areindicated byGEtobe:t(1)Appropriate trainingofpersonnel involved.

(2)'Revision offabrication techniques.

(3)Increased/revised inspection activities.

(4)GEhasdeveloped asupplemental reinspection instruction (GEInspection Instruction CA-006)toidentifydamagedornonconforming connectors priortoshipment.

Satisfactory completion ofthiscablereinspection onSusquehanna Unit2cableswasreverified byPPRLauditonSept.9-11,1980attheGEmanufacturing facilityinSanJose,CA.Inaddition, faultycrimpingtoolswererepairedorreplacedandperiodictestingofcrimpingtoolswasincreased.

Construction sitepersonnel havebeengivenfurtherinstructions inthehandlingandinstallation ofcables.Thesiteelectricians havebeeninstructed touseasteadypull(notayank)whenmakingpulltestsandthespringtestersarecalibrated every30daysorsoonerifdeemednecessary.

CONCLUSIONS Therepair/rework andtestingoftheUnit1PGCC/ACRcablesisnearlycomplete.

AllUnit1PGCC/ACRcableswillbecompleted priortofuelload.TheUnit2PGCC/ACRcableswillbeinstalled andrepairedorreworkedasnecessary.

Discrepancies willbedocumented onanNCR.ForUnit2PGCC/ACRcables,fieldinspections oftheequipment andadditional GEfabrication personnel

training, inspection andrevisedfabrication techniques shouldprecluderecurrence ofsimilarproblems.