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.8856QUALITYASSURANCE PROGRAMMAlEMENTcoRREOTIUE AGTICNREPo~ti4'>E098789MCAR-0REPORWNO.

QNo.30.0DATE'.DESCRIPTION (Including rejerencet):

NCR3030wasissued9-28-78toidentifydamagedinsulation anconductors installed intermination Itcduleslocatedintexmination cabinet1'IC621.Thirty-nine termination Itcduleswereinspected forcut,strippedordamagedinsulation onmoduleconductors andthirty-three moduleswerefoundwithdamagedccnductors.

Anaverageoffourtofiveconductors weredetermined tobedamagedineachterminalItcduleconnector

'nspected.

Theterttunation cabinetsaresuppliedbyGEunder.the+-1NSSScontract.

oRECOMMENDED ACTION(Optional) 1.Construction toperformaninvestigation todetermine theextentofdamagedconductor insulation intermination mxiulesnotinspected todate.2.Construction todocumentnonconfornences identified duringinvestigation requested inOneabove.3.ProjectEngineering toadviseQPregazding reportability forthisdeficiency under10CFR50.55eby10-6-78.REFERREDTOXENGINEERING QCONSTRUCTION QPROCUREMENT QQAMANAGEMENT QISSUEDBProjectQAEngineerDateZf-~ZIIREPORTABLE DEFICIENCYIIICAUSEQYESNOTIFIEDCLIENT**DaterPsnagsateCORRECTIVE ACTIONTAKENSeeattachedinterimreportandinterimreportsupplement.

• • PP&LnotifiedNRCperPLA-301AUTHORIZED BYDateFORMALREPORTTOCLIENTIIIsectionIIAppiietICORRECTIVE ACTIONIMPLEMENTED VERIFIEDBYPtoj~.IQAEngineerSFP21130.RevI10/7ttDISTRISVTIQN Dlv.QAMsnsgerMpr.ofQA-TPQDrv.Procursmsnt Mar,ProtectMsnsgsrContructlon Msnsgcrengineering MsnsgerProiecsEngineerPEOI.Supt./PEDI.

COnSt.Mgr,Or Proi.Procurement Mgr.chl~Iconst.QcEngineerorocsupervisor orProcurement SuppherQuslltyMgr.sndDiv.SupplierQuslltvMgr.QaSupervisor ClientOPQaAMgr.I.APDaaMgr.trots.Ihelnspecsprovidedsndattachrelerenre document.

DateDate7BDM3QIVg

t~.OFczl7a097546MCAR1-29INTER3ldREPORTTERMINATION CABINET-TERMINATION MODULESDAMAGEDCONDUCTOR INSULATION SUSQUEHANNA STEAMELECTRICSTATIONUNJTS1Ci2Preparedby:Weckedby:Approvedby:-ProspectEngineer-Engineering Ma'nagerSECHTELPOMEHCOHPOHATION SanI'rancisco, UaiiforniaDecember19,1975(P5-20/1)

ATTACHMENT sCsC21'P2O.ggg4gINTERIMREPORTMCAR1-29DescritionNCR3030wasissued9/2'/75toidentiQdamagedinsulation onconductors installed intermination moduLeslocatedintermination cabinet1TCb21.Thirtyninetermination moduleswereinspected forcut,strippedordamagedinsulation onmoduleconductors andthirty-three moduleswerefoundwithdamagedconductors..

Subsequently NCR3030wasrevisedtoidentifyapproxi-mately200damagedT-MODS.Anaverageoffourtofiveconductors werede-terminedtobedamagedineachterminaLmoduLeconnector inspected.

Thetermination cabinetsaresuppliedbyGEunaertheM-1NSSScontract.

CauseThecauseofthedamageisattributed tothemanualinsertion andextrac-tionofterminated pinsonconnector sheLLs.AnaisisoftheSafetImlications Thesystemdesignwasreviewedandthefollowing wasconcluded fortheworstcondition.

Thedeficiency whichinvoLvesdamagedinsulation ofPGCCT-MODSif'ndetected oruncorrected couldpermitshortingorintroduction ofexternalvoltagesourcesintosafetyrelatedcircuitswhichcouLdpreventthecircuitsfromperforming thedesignedsafetyfunction.

Sincetheoccurrence ofda-magedinsulation isarandomthingandcouldoccurinanyandalLsafetyre-latedcircuitsthepossibility ofacoarnonmodefailureexists.Thesimul-taneousdegradation andlossofsafety-related circuitscouLdresuLtinasafetyhazardtotheoperation oftheplant.ProjectEngineering hasdetermined thePGCCT-MODSdef'iciency tobereportable underIOCFR50.55(e).

Corrective ActionGESanJoseispreparing arepairprocedure fortheT-MODS.Thefirst32areintheprocessofbeingtotallyreworked.

%heremaining U5willbeshippedtoGESanJoseforrepair/rework pertheaboveprocedure uponcom-pLetionof'reportbyGEonthesamesubject.Conclusion Uponcompletion oftherepair/rework andre-testoftheT-MODSperGEpro-'ceduresandcriteria, theaef'iciency wiLLhavebeencorrected andthepo-tentialsafetyhazardwillhavebeeneliminated.

GEforecasts completion ofthiseffortbyFebruary15,1979.(P5-20/2)

MCAR1-29INTERIMREPORTSUPPLANTONTERMINATION CABINET-TERYiINATION MODULESDAMAGEDCONDUCTOR INSULATION SUSQUEHANNA STEAMELECTRICSTATIONUNITS1h2Preparedby:Checkedby:/,/'-)~Ci:.wApprovedby:-ProjectEngineer'iclV.~~,>.i:'~-Engineering ManagerBECHTELPO>lERCORPORATION SanFrancisco, California Decanber29,1978(P5-21/1)

SUPPLEMENT TOINTERIMREPORTONMCAR1-29Description ofRelatedCableProblemsSubsequent.to theissueofMCAR1-29andduringtheinvestigation relativetothetermination moduleslocatedintermination cabinet1TC621,additional problemswereidentified.

InletterBCLPC-5105, datedOctober3,1978,SFHODocumentControlNo.094517,theFieldConstruction Manager,Mr.S.Schoenenberger informedPP&L,thatonPGCC/ACR, duringimplenentation ofGeneralElectric's FDDR-KR1-521, Rev.0(GenericCableRetrofit) rework,itwasnotedthatnumerousinsulation damages(cuts,nicksandshieldsolderconnections, etc.)werefound.Duetothehighpercentage ofdamagedcable,thequalityofallterminations isrenderedindeterminate.

Belowisalistofthosecableswhichwerefounddamaged:1)7442/C94A-408 2)7442/C94A-410 3)7442/C94A-412 4)7442/C94A-409 5)7119/C94A-715 6)4111/C94A-822 7)4113/C94A-744 8)4113/C94A-714 9)4119/C94A-736 10)4128/C94A-806 11)41.12/C94A-733 InletterBCLPC-5106, datedOctober3,1978,SFHODocumentControlNo.094517,theFieldConstruction Manager,Mr.S.Schoenenberger, alsoinformedPP&L,thatonthePGCC/ACR, duringimplementation ofGeneralElectric's FDDR-KR1-521, Rev.0,(GenericCableRetrofit) rework,itwasnotedthat.onecable'.4108/C94A-712 wasfoundtohavefour(4)con-ductorspulledoutofitspinconnectors.

Thequalityofthiscableisrenderedindeterminate.

Theabovenotedletters,plusBCLPC-5104, datedOctober3,1978-basically describing thesameproblemgivenintheMCARdescription

-wereforwarded toProjectEngineering byIOMQK-4056,datedOctober17,1978,SFHODocumentControlNo.094517,fromtheFieldConstruction Manager.TheIOMwasprovidedasanassistindetermining possiblereportability ofcabledeficiencies foundinthePowerGeneration ControlComplex/Advanced ControlRoom,(PGCC/ACR).

AnupdatedstatusonT-MODinspection wasprovidedinTWXCME-2044, dated10/30/78, toJ.R.Schmiedel fromS.Schoenenberger.

Acopyisattached.

This7ÃXprovidesadditional detailonBechtelinspection resultsoftheT-MODsinUnit1.Nonconfomance Report(NCR)3231wasgenerated todocumenttheadditional items/problems withinthePGCC/ACRcomplex.GeneralElectric(GE)isintheprocessofpreparing anFDIwhichistodetailacompleteinspection plan(F5-21/2)

~~SUPPLEMENT TOINTERIMREPORTONMCAR1-29PAGETN'O~Je2"7>~097844andanapprovedrepai'rprocedure (reference IOMDocumentControlNo.097038toH.LillighfromC.Turnbow-copyattached).

Fortypesofproblemsfoundseepages3,4,5,and6oftheattachedNCR3231.ThePennsylvania PowerandLightCompany(PP&L)issuedalettertoProjectEngineering, datedNovember10,1978,SFHODocumentControlNo.096038,statingtheirrequirements forresolving thePGCCT-MODproblems.

Acopyisattached.

ProjectEngineering responded toPP&LwithaletterBLP-10055, datedNovember21,1978,DocumentControlNo.096266,providing aBechtelinspection programasrequested byPP&L.Acopyisattached.

CauseThecauseofproblemsassociated withthePGCC/ACR, according toGEisestablished asrelatedtoinadequate fabrication technique.

AnalysisofSafetyImplications Thesystemdesignwasreviewedandthefollowing wasconcluded fortheworstcondition.

Thedeficiency whichinvolvesdamagedPGCC/ACRcableconnectors ifundetected oruncorrected couldpermitshortingorintroduction ofexternalvoltagesourcesintosafetyrelatedcircuitswhichcouldpreventthecircuitsfromperforming thedesignedsafetyfunction.

Sincetheoccurrence ofdamagedcableconnectors isarandomthingandcouldoccurinanyandallsafety-related

circuits, thepossibility ofacommonmodefailureexists.Thesimultaneous degradation andlossofsafety-related circuitscouldresultinasafetyhazardtotheoperation ofthe'lant.

ProjectEngineering hasdetermined thePGCC/ACRdeficiency tobereportable under10CFR50.',55(e).

Corrective ActionsCorrective actionsintheformofInspection programsbyBechtelandGEareidentified incorrespondence indicated inthe'above description andinPP&LlettertoProjectEngineering, PLB-9354, datedDecember14,1978,SFHODocumentControlNo.097413.Acopyisattached.

Corrective actionsto-datehavebeenbasically theinitiation ofthein-spectionprogramandrepair-rework procedures.

Itiscurrently anticipated thatrepairorreworkofalldeficient Unit1PGCC/ACRcablesarescheduled forcompletion byFebruary15,1979.(P5-21/3)

SUPPLEMB1T'TO INTERlMREPORTONSCAR1-29PAGETHREECorrective actionstopreventrecurrences oflikeproblemsinthefutureincluding Unit2facilities areindicated byGEtobe:1)Appropriate trainingofpersonnel

involved, 2)Revisionoffabrication techniques, 3)Increased/revised inspection activities, 4)AssessallUnit2PGCC/ACRtoassureagainstsimilarproblems.

Conclusions Uponcompletion oftherepair/reworkandre-testofthePGCC/ACRitemsperGEprocedures andcrite.ia,thedeficiencies willbecorrected andthepotential safetyhazardwillbeeliminated.

GEforecasts completion ofrepair/rework effortbyFebruary15,1979.Additional GEfabrication personnel

training, inspection andrevisedfabrication techniques shouldprecluderecurrence ofsimilarproblemsinthefuture.