ML18031A074

Interim Rept & Suppl on Termination Cabinet - Termination Modules Damaged Conductor Insulation. Describes Damage to Insulation on 200 Conductors in Termination Modules in Cabinet 1TC621 & 11 Cables.Correction Scheduled for 790215

ML18031A074
Person / Time
Site:	Susquehanna
Issue date:	01/04/1979
From:	PENNSYLVANIA POWER & LIGHT CO.
To:
Shared Package
ML18031A073	List: ML18031A072 ML18031A074
References
MCAR-1-29, NUDOCS 7901230194
Download: ML18031A074 (7)

Text

JOBNO.8856QUALITYASSURANCEPROGRAMMAlEMENTcoRREOTIUEAGTICNREPo~ti4'>E098789MCAR-0REPORWNO.QNo.30.0DATE'.DESCRIPTION(Includingrejerencet):NCR3030wasissued9-28-78toidentifydamagedinsulationanconductorsinstalledinterminationItcduleslocatedintexminationcabinet1'IC621.Thirty-nineterminationItcduleswereinspectedforcut,strippedordamagedinsulationonmoduleconductorsandthirty-threemoduleswerefoundwithdamagedccnductors.AnaverageoffourtofiveconductorsweredeterminedtobedamagedineachterminalItcduleconnector'nspected.TheterttunationcabinetsaresuppliedbyGEunder.the+-1NSSScontract.oRECOMMENDEDACTION(Optional)1.Constructiontoperformaninvestigationtodeterminetheextentofdamagedconductorinsulationinterminationmxiulesnotinspectedtodate.2.ConstructiontodocumentnonconfornencesidentifiedduringinvestigationrequestedinOneabove.3.ProjectEngineeringtoadviseQPregazdingreportabilityforthisdeficiencyunder10CFR50.55eby10-6-78.REFERREDTOXENGINEERINGQCONSTRUCTIONQPROCUREMENTQQAMANAGEMENTQISSUEDBProjectQAEngineerDateZf-~ZIIREPORTABLEDEFICIENCYIIICAUSEQYESNOTIFIEDCLIENT**DaterPsnagsateCORRECTIVEACTIONTAKENSeeattachedinterimreportandinterimreportsupplement.**PP&LnotifiedNRCperPLA-301AUTHORIZEDBYDateFORMALREPORTTOCLIENTIIIsectionIIAppiietICORRECTIVEACTIONIMPLEMENTEDVERIFIEDBYPtoj~.IQAEngineerSFP21130.RevI10/7ttDISTRISVTIQNDlv.QAMsnsgerMpr.ofQA-TPQDrv.ProcursmsntMar,ProtectMsnsgsrContructlonMsnsgcrengineeringMsnsgerProiecsEngineerPEOI.Supt./PEDI.COnSt.Mgr,OrProi.ProcurementMgr.chl~Iconst.QcEngineerorocsupervisororProcurementSuppherQuslltyMgr.sndDiv.SupplierQuslltvMgr.QaSupervisorClientOPQaAMgr.I.APDaaMgr.trots.Ihelnspecsprovidedsndattachrelerenredocument.DateDate7BDM3QIVg

t~.OFczl7a097546MCAR1-29INTER3ldREPORTTERMINATIONCABINET-TERMINATIONMODULESDAMAGEDCONDUCTORINSULATIONSUSQUEHANNASTEAMELECTRICSTATIONUNJTS1Ci2Preparedby:Weckedby:Approvedby:-ProspectEngineer-EngineeringMa'nagerSECHTELPOMEHCOHPOHATIONSanI'rancisco,UaiiforniaDecember19,1975(P5-20/1)

ATTACHMENTsCsC21'P2O.ggg4gINTERIMREPORTMCAR1-29DescritionNCR3030wasissued9/2'/75toidentiQdamagedinsulationonconductorsinstalledinterminationmoduLeslocatedinterminationcabinet1TCb21.Thirtynineterminationmoduleswereinspectedforcut,strippedordamagedinsulationonmoduleconductorsandthirty-threemoduleswerefoundwithdamagedconductors..SubsequentlyNCR3030wasrevisedtoidentifyapproxi-mately200damagedT-MODS.Anaverageoffourtofiveconductorswerede-terminedtobedamagedineachterminaLmoduLeconnectorinspected.TheterminationcabinetsaresuppliedbyGEunaertheM-1NSSScontract.CauseThecauseofthedamageisattributedtothemanualinsertionandextrac-tionofterminatedpinsonconnectorsheLLs.AnaisisoftheSafetImlicationsThesystemdesignwasreviewedandthefollowingwasconcludedfortheworstcondition.ThedeficiencywhichinvoLvesdamagedinsulationofPGCCT-MODSif'ndetectedoruncorrectedcouldpermitshortingorintroductionofexternalvoltagesourcesintosafetyrelatedcircuitswhichcouLdpreventthecircuitsfromperformingthedesignedsafetyfunction.Sincetheoccurrenceofda-magedinsulationisarandomthingandcouldoccurinanyandalLsafetyre-latedcircuitsthepossibilityofacoarnonmodefailureexists.Thesimul-taneousdegradationandlossofsafety-relatedcircuitscouLdresuLtinasafetyhazardtotheoperationoftheplant.ProjectEngineeringhasdeterminedthePGCCT-MODSdef'iciencytobereportableunderIOCFR50.55(e).CorrectiveActionGESanJoseispreparingarepairprocedurefortheT-MODS.Thefirst32areintheprocessofbeingtotallyreworked.%heremainingU5willbeshippedtoGESanJoseforrepair/reworkpertheaboveprocedureuponcom-pLetionof'reportbyGEonthesamesubject.ConclusionUponcompletionoftherepair/reworkandre-testoftheT-MODSperGEpro-'ceduresandcriteria,theaef'iciencywiLLhavebeencorrectedandthepo-tentialsafetyhazardwillhavebeeneliminated.GEforecastscompletionofthiseffortbyFebruary15,1979.(P5-20/2)

MCAR1-29INTERIMREPORTSUPPLANTONTERMINATIONCABINET-TERYiINATIONMODULESDAMAGEDCONDUCTORINSULATIONSUSQUEHANNASTEAMELECTRICSTATIONUNITS1h2Preparedby:Checkedby:/,/'-)~Ci:.wApprovedby:-ProjectEngineer'iclV.~~,>.i:'~-EngineeringManagerBECHTELPO>lERCORPORATIONSanFrancisco,CaliforniaDecanber29,1978(P5-21/1)

SUPPLEMENTTOINTERIMREPORTONMCAR1-29DescriptionofRelatedCableProblemsSubsequent.totheissueofMCAR1-29andduringtheinvestigationrelativetotheterminationmoduleslocatedinterminationcabinet1TC621,additionalproblemswereidentified.InletterBCLPC-5105,datedOctober3,1978,SFHODocumentControlNo.094517,theFieldConstructionManager,Mr.S.SchoenenbergerinformedPP&L,thatonPGCC/ACR,duringimplenentationofGeneralElectric'sFDDR-KR1-521,Rev.0(GenericCableRetrofit)rework,itwasnotedthatnumerousinsulationdamages(cuts,nicksandshieldsolderconnections,etc.)werefound.Duetothehighpercentageofdamagedcable,thequalityofallterminationsisrenderedindeterminate.Belowisalistofthosecableswhichwerefounddamaged:1)7442/C94A-4082)7442/C94A-4103)7442/C94A-4124)7442/C94A-4095)7119/C94A-7156)4111/C94A-8227)4113/C94A-7448)4113/C94A-7149)4119/C94A-73610)4128/C94A-80611)41.12/C94A-733InletterBCLPC-5106,datedOctober3,1978,SFHODocumentControlNo.094517,theFieldConstructionManager,Mr.S.Schoenenberger,alsoinformedPP&L,thatonthePGCC/ACR,duringimplementationofGeneralElectric'sFDDR-KR1-521,Rev.0,(GenericCableRetrofit)rework,itwasnotedthat.onecable'.4108/C94A-712wasfoundtohavefour(4)con-ductorspulledoutofitspinconnectors.Thequalityofthiscableisrenderedindeterminate.Theabovenotedletters,plusBCLPC-5104,datedOctober3,1978-basicallydescribingthesameproblemgivenintheMCARdescription-wereforwardedtoProjectEngineeringbyIOMQK-4056,datedOctober17,1978,SFHODocumentControlNo.094517,fromtheFieldConstructionManager.TheIOMwasprovidedasanassistindeterminingpossiblereportabilityofcabledeficienciesfoundinthePowerGenerationControlComplex/AdvancedControlRoom,(PGCC/ACR).AnupdatedstatusonT-MODinspectionwasprovidedinTWXCME-2044,dated10/30/78,toJ.R.SchmiedelfromS.Schoenenberger.Acopyisattached.This7ÃXprovidesadditionaldetailonBechtelinspectionresultsoftheT-MODsinUnit1.NonconfomanceReport(NCR)3231wasgeneratedtodocumenttheadditionalitems/problemswithinthePGCC/ACRcomplex.GeneralElectric(GE)isintheprocessofpreparinganFDIwhichistodetailacompleteinspectionplan(F5-21/2)

~~SUPPLEMENTTOINTERIMREPORTONMCAR1-29PAGETN'O~Je2"7>~097844andanapprovedrepai'rprocedure(referenceIOMDocumentControlNo.097038toH.LillighfromC.Turnbow-copyattached).Fortypesofproblemsfoundseepages3,4,5,and6oftheattachedNCR3231.ThePennsylvaniaPowerandLightCompany(PP&L)issuedalettertoProjectEngineering,datedNovember10,1978,SFHODocumentControlNo.096038,statingtheirrequirementsforresolvingthePGCCT-MODproblems.Acopyisattached.ProjectEngineeringrespondedtoPP&LwithaletterBLP-10055,datedNovember21,1978,DocumentControlNo.096266,providingaBechtelinspectionprogramasrequestedbyPP&L.Acopyisattached.CauseThecauseofproblemsassociatedwiththePGCC/ACR,accordingtoGEisestablishedasrelatedtoinadequatefabricationtechnique.AnalysisofSafetyImplicationsThesystemdesignwasreviewedandthefollowingwasconcludedfortheworstcondition.ThedeficiencywhichinvolvesdamagedPGCC/ACRcableconnectorsifundetectedoruncorrectedcouldpermitshortingorintroductionofexternalvoltagesourcesintosafetyrelatedcircuitswhichcouldpreventthecircuitsfromperformingthedesignedsafetyfunction.Sincetheoccurrenceofdamagedcableconnectorsisarandomthingandcouldoccurinanyandallsafety-relatedcircuits,thepossibilityofacommonmodefailureexists.Thesimultaneousdegradationandlossofsafety-relatedcircuitscouldresultinasafetyhazardtotheoperationofthe'lant.ProjectEngineeringhasdeterminedthePGCC/ACRdeficiencytobereportableunder10CFR50.',55(e).CorrectiveActionsCorrectiveactionsintheformofInspectionprogramsbyBechtelandGEareidentifiedincorrespondenceindicatedinthe'abovedescriptionandinPP&LlettertoProjectEngineering,PLB-9354,datedDecember14,1978,SFHODocumentControlNo.097413.Acopyisattached.Correctiveactionsto-datehavebeenbasicallytheinitiationofthein-spectionprogramandrepair-reworkprocedures.ItiscurrentlyanticipatedthatrepairorreworkofalldeficientUnit1PGCC/ACRcablesarescheduledforcompletionbyFebruary15,1979.(P5-21/3)

SUPPLEMB1T'TOINTERlMREPORTONSCAR1-29PAGETHREECorrectiveactionstopreventrecurrencesoflikeproblemsinthefutureincludingUnit2facilitiesareindicatedbyGEtobe:1)Appropriatetrainingofpersonnelinvolved,2)Revisionoffabricationtechniques,3)Increased/revisedinspectionactivities,4)AssessallUnit2PGCC/ACRtoassureagainstsimilarproblems.ConclusionsUponcompletionoftherepair/reworkandre-testofthePGCC/ACRitemsperGEproceduresandcrite.ia,thedeficiencieswillbecorrectedandthepotentialsafetyhazardwillbeeliminated.GEforecastscompletionofrepair/reworkeffortbyFebruary15,1979.AdditionalGEfabricationpersonneltraining,inspectionandrevisedfabricationtechniquesshouldprecluderecurrenceofsimilarproblemsinthefuture.