ML19269E559
| ML19269E559 | |
| Person / Time | |
|---|---|
| Issue date: | 01/31/1979 |
| From: | Barnes I, Hunnicutt D NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML19269E532 | List: |
| References | |
| REF-QA-99900355 99900355-79-1, NUDOCS 7906290282 | |
| Download: ML19269E559 (11) | |
Text
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U. S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT REGION IV Report No. 999000355/79-01 Program No. 51300 Company: Hirata Valve Industry Co., Ltd.
15, Hisamoto, Takatsu-Ku Kawasaki-City, Kanagawa-Pref., Japan Inspection Conducted: January 12, and 16-18, 1979 Inspectors-ff 7 bt
' % 3/j / 777
'I. Barnes, Contractor Inspector, Vendor
\\
Date Inspection Branch g
b biYif 0
31/971' l
D. M. Hunnicutt, Chief, ComponentsSection II, f/
Date Vendor Inspection Branch Approved by:
M 9//j b b t IL 3 /j M7'i D. M. Hunnicutt, Chief, ComponentsSection II, 1
Date8 l
Vendor Inspection Branch
- Sumary, Inspection on January 12, and 16-18,1979 (999000355/79-01)
Areas Inspected:
Implementation of 10 CFR 50, Appendix B, criteria and applicable codes and standards; including initial management meeting, control of welding, weld heat treatment and design control. The inspection involved fifty-eight (58) inspector-hours on site by two (2) NRC inspectors.
Results :
In the four (4) areas inspected, no deviations or unresolved items were identified in two (2) areas; the following deviations and unresolved item were identified in the remaining areas:
Deviations:
Control of Welding - Qualification of hardfacing welding procedure specifications not consistent with Criterion IX of 10 CFR 50, Appendix B, and the essential variable requirements of "ections III and IX of the ASME Code (Enclosure, Item A): absence of weave bead restrictions in shielded metal arc welding procedure specifications not in accordance with Criterion V of 10 CFR 50, Appendix B, and customer specification 2146 042 79062902 M
l i
i 9779-41, Revision 38 (Enclosure, Item B); failure to qualify a heat of SFA 5.18, E70S-G using the production welding WPS interpass temperature not consistent with Criterion IX of 10 CFR 50, Appendix B, and Section III of the ASME Code (Enclosure, Item C'3; absence of identification on CMTR WPS used by casting vendor for defect repairs not in accordance with i
Criterion IX of 10 CFR 50, Appendix B, and Section III of the ASME Code f
(Enclosure,ItemD).
I Unresolved Item: Weld Heat Treatment - Adequacy of casting vendor heat treatment procedure could not be established because the available document was written in Japanese (DetailsSection I, 0.3.b).
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DETAILS SECTION I (Prepared by I. Barnes)
A.
Persons Contacted
- T.
Hirata, President
- M. Hirata, Vice President, Marketing
- Y. Hirata, Vice President, Kawasaki Division
- S. Tanimoto, QA Manager
- K. Shimuzu, Operations Manager
- S. Iizuka, Key Person, Atomic Power Team
- M. Ogasawata, Acting as Translator
- T. Hatakeyama, Acting as Translator
- K. Nakamura, Deputy Factory Manager
- H. Toyota, Manufacturing Section Chief l
A. Shinohara, Engineering Section Chief
- S. Hirano, Inspection Section Chief l
- M. Ryn, QE Section, Documentation
- S. Nakamura, Business Development Section, Nuclear Energy Department, Nissho-Iwai Co., Ltd.
- Attended Initial Management Meeting and Exit Meeting.
- Attended Exit Meeting.
B.
Initial Management Meeting 1.
Objectives The objectives of this meeting were to accomplish the following:
a.
To meet with the Hirata Valve Industry Co., Ltd. (HVI)
{
managemer.t and those persons responsible for the administra-tion of the HVI QA Program and establish channels of 4
communication.
b.
To determine the extent of company involvement in the U. S. commercial nuclear business, c.
To explain the NRC direct inspection program including the Licensee Contractor Vendor Inspection Program (LCVIP) organization, Vendor Inspection Branch (VIB) inspection i
i methods and documentation.
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. 2.
Method of Accomplishment i
The preceding objectives were accomplished by a meeting on January 12, 1979, with the attendees denoted in paragraph A above.
The following is a summary of the subject matter covered:
a.
The VIB organization was described and its relationship to NRC Region IV and other components of the Office of Inspection and Enforcement.
b.
The LCVIP was described including the reasons for its establishment, its objectives, and implementation methods and criteria used.
c.
The conduct of VIB inspections was described and how inspections are documented including the report, responses to reports, how proprietary information is handled, the Public Document Room, and the White Book.
d.
The company contribstion to the nuclear industry was discussed, including current and projected minufacturing activity for the U.S.A., status of ASME Certificates of Authorization and third party inspection arrangements.
3.
Findings a.
HVI management informed the inspectors that HVI currently had contracts for the supply of forged and cast austenitic stainless and carbon steel valves to four (4) U. S. nuclear i
projects i.e., Washington Public Power Supply System (WPPSS)
Project Nos. 1, 3, 4, and 5.
b.
Approximately twenty (20%) of the cast valves for Project No. I had been completed with the remainder in the
. manufacturing process. Materials had been received for the manufacture of valves for Project No. 4, and Project No. 3 was in the material procurement stage. Activity had not yet started on valves for Project No. 5.
c.
HVI was resurveyed by ASME in 1978, with the current Certificate of Authorization expiring on August 4,1981.
d.
HVI has a contract with the Hartford Steam Boiler Inspection and Insurance Co. to act as their Authorized Inspection Agency and are presently served on an itinerant basis by an Authorized Nuclear Inspector.
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. t C.
Control of Welding 1.
Objectives The objectives of this area of the inspection were to verify that measures had been established to assure the control of l
welding in accordance with ASME Code, contract and regulatory j
requirements.
i 2.
Method of Accomolishment The preceding objectives were accomplished by:
a.
Review of Section 5, Revision 6, of the QA Manual,
" Welding Quality Assurance."
b.
Review of material and fabrication requirements in United Engineers and Constructors (UE&C) Specification, 9779-41, Revision 38, "ASME III Valves," applicable to WPPSS Project Nos. 1 and 4.
c.
Review of material and fabrication requirements in Ebasco
{
Specification, 3240-41, " Station Valves 21s" and larger, Contract 3240-418," applicable to WPPSS Project Nos. 3 and 5.
d.
Observelion of welding materials storage area and review of welding materials approval and release system.
i e.
Review of temperature control and electrode segregation in electrode ovens.
f.
Review of calibration status of welding equipment to be utilized for U. S. commercial nuclear fabrication.
g.
Review of specification, NAF-37, Revision 2, " Calibration Procedure Relating te Nuclear Valves for WPPSS Nuclear Projects No. 1 and 4."
h.
Examination of purchase orders, purchase specifications, receiving inspection reports and Certified Material Test Reports for eight (8) consumables (shielded metal arc, gas tungsten arc, and oxyacetylene), which had been approved for use on WPPSS Project Nos. I and 4.
l i.
Examination of welding procedure specifications (WPS) and supporting procedure qualification records (PQR) designated for use on WPPSS Project Nos. I and 4.
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j.
Examination of vendor documentation and procurement documents relative to control of repair welding by suppliers of austenitic stainless and carbon steel castings.
3.
Findings i
l a.
Deviations from Commitment (1) See Enclosure, Item A.
(2) See Enclosure, Item B.
(3) See Enclosure, Item C.
(4) Sub-paragraph 1 in paragraph 5.7 of Hirata Purchase Specification No. NPS-0012, Revision 1 (applicable to procurement of SA 216, Grade WCB disc castings), states in part, " Repair welding the following categories are subject to Hirata's approval on the documented proce-dures preliminarily furnished by the supplier...
d.
After excavating the wall to remove the defect i
exceeding 3/8 in. (9.5 mm) deep or 10*.' of the nominal wall thickness whichever smaller."
Contrary to the above, repairs were made to Disc No. 0208, Charge No. 3E15742, to a depth of 11 mm without preliminary submittal of a repair welding procedure by the casting vendor or approval by HVI i.e., no information was made available to the inspector to show either identity of welding procedure used or its receipt and approval by HVI.
1 The inspector noted that the vendor repair records j
showed the use of an HVI procedure, NAF-18, Revision 0, for performance of weld repair:;. This procedure addressed general requirements for performance of weld repairs j
and was not a welding procedure specification.
Paragraph 4.5 of this procedure specifically prohibited use of this procedure by non-HVI personnel unless HVI welding equipment and specifications were used, which was not the case in this instance.
Copies of Certified fjaterial Test Reports for welding materials used by the vendor were also not in the possession of HVI, precluding determination of the adequacy of the material qualifications.
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e e
f a :
Review of other repair documentation for SA 216, Grade WCB bodies and discs from the same casting vendor showed the same situation existed.
i b.
Unresolved Items None.
c.
General Comment No welding operations were performed on U. S. nuclear valves during this inspection, precluding direct observation of production welding compliance with QA Program and contract requirements.
D.
Weld Heat Treatment 1.
Objectives The objectives of this area of the inspection were to verify that heat treatment applicable to weldi.ig was specified and performed in accordance with QA Program, ASME Code and regulatory requirements.
2.
Mechod of Accomplishment The preceding objectives were accomplished by:
a.
Review of Section 6, Revision 6, of the QA Manual, " Heat Treatment."
l b.
Examination of calibration status and records for the temperature recorder for the production heat treat furnaces.
c.
Examination of casting vendor postweld heat treatment charts i
relative to committed temperature cycle.
d.
Discussions with cognizant personnel.
3.
Findings a.
Deviations from Commitment None.
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b.
Unresolved Item Casting vendor procedure, P-NE-00007, Revision 0, " Heat Treatment Standard for the Carbon Steel Castings," was available only in Japanese, precluding review of methods used to assure control of metal temperature, and metal temperature uniformity. This item will remain unresolved j
pending availability of an English language translation.
l c.
General Comment During this inspection, the inspector ascertained that i
postweld heat treatment had not been performed to date by HVI during valve manufacture. Welding procedure specifica-tions and materials utilized by HVI for U. S. nuclear valves l
were observed to have been qualific only in the as welded d
condition. The inspector was inforr.ed that all necessary repairs of castings had been performed by the casting vendor and necessary postweld heat treatment cycles performed at the same facility. Review of this subject in the time available, in terms of welds made by both HVI and casting vendors, revealed no instance where ASME Code required i
I postweld heat tre tment had not been performed. This subject will, however, be examined in greater detail during a future inspection.
E.
Exit Meeting The inspectors met with the management representatives denoted in paragraph A above on January 18, 1979, at the conclusion of the inspection. The scope of the inspection, the deviations from commitment, and the unresolved item were discussed with the management representitives present. The lead inspector requested l
that the response be prepared with separate statements of l
corrective action an1 steps to preclude recurrence for each deviation from commitment. Management was also informed that a response to the unresolved item was voluntary and not obligatory.
Management had no comments or questions regarding the findings as reported by the inspector.
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i DETAILS SECTION II (Prepared by D. M. Hunnicutt)
A.
Persons Contacted A. Shinohara, Engineering Section Chief S. Iizuka, Key Person, Atomic Power Team T. Hatakeyama, Acting as Translator i
i B.
Design Control i'
1.
Objectivg a.
To ascertain that measures have been established with respect to definition of a system for the control of the design process and design verification and documents.
b.
To determine that the measures have been implemented in a manner consistent with QA Program coninitments.
2.
Methods of Accomplishment The preceding objectives were accomplished by:
a.
Review of Hirata Valve Industry Co., Ltd., Kawasaki Division, QAM, Section 2, " Design, Drawing, and Specification Cuntrol,"
Revision 6, dated July 26, 1978.
I I
b.
Review of United Engineers and Constructors, Inc., Division l
15, Section 15A, Specification 9773-41. and % ision 20, Section 20A, Specification 977; ti, including Revision 39, for ASME Section III valves, Contrac'. No. 41 for WPPSS Nuclear Project No. I and 4.
I c.
Review of Washington Public Power Supply System (WPPSS),
Nuclear Projects No. 3 and 5 (1976), Specification 3240-41, Station Valves 2h: and Larger, Contract 3240-41B and addenda.
d.
Review of Stress Analysis Mathematical Model, Specification No. SRC-003, Revision 1, March 16, 1977.
e.
Review of Stress Report No. NSR-0021, Revision 1, Customer Purchase Order No. WPPSS-9779-41A, dated October 27, 1977, for results of analyses for valve body, bonnet, disc, stem, yoke, and joint bolt, and the complete valve and comparison 2146 050
9 i i of calculated stresses with allowable values as specified in WPPSS Design Specification 9779-41, Division 15, Section i
15A, and Division 20, Section 20A.
f.
Review of Stress Report No. NSR-0020, Revision 1, Drawing No. NT-20047, Revision 3, for one 4 inch - 2500 lb. Gate Valve, ASME Code Class 1, Valve No. RCS-V-34, Hirata I.D. No. N0075, No. 186.
g.
Review of ASME Code 1974 Edition (including addenda through Winter 1975) for ASME Code Class 1 valves.
h.
Observation of a computer run of a standard valve calculation and a rerun of a calculation of a 4" valve stress analysis and printout of the completed calculation results and comparison of the two sets of calculations for accuracy.
I 1.
Review of Drawings and Material Certifications for 4" -
2500 lb. Gate Valve No. RCS-V-34, Hirata I.D. No. N0075, i
No. 186, ASME Code Class 1, as follows:
Valve Component Drug No.
Material body N013-30020 ASME SA-351 Gr. CF8 bonnet N025-30001 ASME SA-182 Gr. F304 disc N043-30019 ASME SA-351 Gr. CF8 stem N063-40017 ASME SA-182 Gr. F6 seat ring N055-40018 ASME SA-182 Gr. F304 gasket retaining ring N202-40001 ASME SA-182 Gr. F304 yoke 182-31092 ASTM A-216 Gr. WCB canopy N029-40001 ASME SA-182 Gr. F304 bonnet lifting ring 159-40069 ASTM A-351 Gr. CF8 gasket 712-40281 18%Cr - 12% Ni-Mo S/S i
J.
Physicel inspection of components for 4" - 2500 lb. Gate Valve, %SME Class 1, Valve No. RCS-V-34, Hirata I.D. No.
0075, Nc'.186, as follows:
1.
body 2.
disc 3.
stem 4.
canopy for evidence of material identification, weld repairs, general workmanship, completeness of shop travelers, storage, and handling.
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, k.
Tour of facility fabrication, testing, assembly, and i
storage areas.
l.
Discussions with cognizant personnel.
3.
Findings Within this area of the inspection, no deviations or unresolved items were identified.
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