ML19309F639
| ML19309F639 | |
| Person / Time | |
|---|---|
| Issue date: | 02/29/1980 |
| From: | Ellershaw L, Hunnicutt D NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML19309F637 | List: |
| References | |
| REF-QA-99900705 99900705-80-1, NUDOCS 8004300222 | |
| Download: ML19309F639 (5) | |
Text
'O 8 " *8
- Dh U. S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPCTION AND ENFORCE N T REGION IV Report No. 99900705/80-01 Program No. 51400 Company:
ITT General Controls 801 Allen Street Glendale, CA.
91201 Inspection f
Conducted: Fet zy 15, 1980
]) bM i t [;
c)-O 7"N
\\
1 Inspector-
/
L. B. Ellershaw, Contractor Inspector Date ComponentsSection II Vendor Inspection Branch Approved by:
k/[
- s.,wu x< d[-
Id[17/F'd D. M. Hunnicutt, Chief
/ Date/
ComponentsSection II Vendor Inspection Branch Summary Special Inspection on February 13-15, 1980 (99900705/78-01)
Areas Inspected: Follow-up on two (2) 10 CFR Part 21 Reports which addressed incorrect material used for fabrication of springs for electro-hydraulic valve actuators, and selection nomographs furnished with actuators do not show actual operating parameters, such as friction and residual hydraulic forces were not considered. The inspection involved 17 inspector-hours on site.
Results:
ITT General Controls has complied with requirements of 10 CFR Part 21.
i
DETAILS SECTION (Prepared by L. E. E11ershaw)
A.
Persons Contacted R. L. Formella - Director, Quality Assuance and Reliability J. Harper - Contracts Administrator R. Kardell - Systems Analysis Supervisor K. Santarelli - Service and Applications Engineer R. Singh - Manag-, Heavy Industrial Products Engineering B.
Follow-up on 10 CFR Part 21 Report dated December 7, 1979 Introduction ITT General Controls (ITT GC) issued a 10 CFR Part 21 report to the Director, Office of Inspection and Enforcement, on December 7, 1979.
The report identified the use of incorrect material in the fabrication of a spring, part number 17443A, used in certain NH 90 Series Milliampere Hydromotor Actuators. The report included notices dated December 6, 1979 sent to 13 of their customers receiving these actuators.
A subsequent notice dated February 1,1980, was sent to 13 customers clarifying the original notice.
1.
Objectives The objectives of this follow-up inspection were to ascertain that the reporting organization had implemented the requirements in accordance with 10 CFR Part 21, and had:
Met the requirements for reporting the deficiency.
a.
b.
Parformed an evaluation of the condition, including making an assessment of generic implications.
i i
c.
Assigned responsibility for effecting corrective action and preventing recurrence.
I i
2.
Method of Accomplishment The preceding objectives were accomplished by:
Verifying that the requirements for reporting " reportable a.
deficiencies" have.been posted, and that procedures have been initiated to provide for the reporting process.
n
,,,,-r e-w---
2 b.
Review 10 CFR Part 21 report and associated documents including:
purchase documents, drawings, and certificates of conformance (C of C) supplied by ITT GC's vendor.
c.
Discussions with cognizant personnel.
3.
Findings ITT GC received a total of 1,621 defective, No. I springs from their supplier between October,1975 and March,1978. The Receiv-ing Inspection acceptance criteria for these springs consisted of a dimensional inspection and receipt of a C of C.
ITT GC's typical purchase documents to their vendor, state quantity, 17443 A (part number), Return Spring, per print through Change No. 12.
Also included is the statement, " submit with packing slip one copy of report showing compliance to material call out on print".
Drawing 17443 A states, " Material - SAE 5160 Steel".
All shipments received included the required C of C, which states, "This is to certify that (number) springs shipped on (date) have been manufactured in accordance with the specifications indicated on the Purchase Order and in accordance with the drawing." The C of Cs are signed by a representative of the spring manufs; curer.
l The problem was identified, when a ITT GC customer returned four actuator units because the springs had taken a permanent set.
ITT GC made some hardness checks, to verify that proper heat treat-ment for the material had been performed. The hardness checks did not correlate.
ITT GC then sent the springs out for heat treatment, and upon return, made additonal hardness checks. The hardness checks remained the same. At this time, ITT GC sent the springs to a lab for material analysis. The analysis showed the material to be 1060/
1070 steel, not 5160 steel.
After determining the quantity of springs involved (1,621), a review was made as to how many had been used in the NH 90 Series actuators.
It was found that 368 had been used in NH 90 Series actuators which had been shipped to a total of 13 customers.
The customers were notified on December 6, 1979. The notice stated that because of the incorrect material used, the springs would not meet the design strength and will, upon actuation of a greater than three inch stroke, take a permanent set. This would result in a decreased force output of approximately 160 lbs. at all compressed postions.
3 Based upon additional review, a subsequent notice dated February 1, 1980, was sent to their customers clarifying the decreased force output. These notices state the minimum decreased force output could be 40 lbs., 80 lbs., 100 lbs., or 160 lbs., depending on spring combinations used and any adjustments made to the actuators by the customer.
ITT GC is now procuring springs from another supplier who will be supplying certified material test reports.
A procedure is being developed, which will specify that one (1) spring out of each received lot will be sent out for load characteristics and hardness checks, to verify proper material is being received.
It was also stated that the procedure would be relaxed, regarding frequency, once a confidence level had been reached.
In most cases, the end use and final destination of the actuators are not known by ITT GC.
C.
Follow-up on an initial letter dated February 1,1980, and a 10 CFR Part 21 Report dated February 5,1980 Introduction ITT GC issued a 10 CFR Part 21 report to the Director, Office of Inspection and Enforcement, on February 5,1980. The report identified a problem with the data contained in the Selection Nomographs provided to customers purchasing NH 90 Series electro-hydraulic actuators.
The existing data will provide forces, derived from the chart, which represent actual spring and/or hydraulic force only. The effects of friction and residual hydraulic force are not included. As a result, customers utilizing the NoTographs may have incorrectly sized the actuatars. All NH 90 Series actuators are affected. All purchasers of NH 90 Series actuators were notified by registered mail dated February 1,1980.
1.
Objectives the objectives of this follow-up inspection were to ascertain that the reporting organization had implemented the requirements in accordance with 10 CFR Part 21 and had:
a.
Met the requirements for reporting the deficiencey.
b.
Performed an evaluation of the condition, including making an assessment of generic implications.
l 1
l l
l
{
i 4
l c.
Assigned responsibility for effecting corrective 'ction and a
preventing recurrence.
2.
Method of Accomplishment The preceding objectives were accomplished by:
Verifying that the requirements for reporting " reportable a.
deficiencies" have been posted, and that procedures have been initiated to provide for the reporting process.
b.
Review 10 CFR Part 21 report and associated documents including customer procurement documents to ITT GC and final test and acceptance procedures.
Observation of a final acceptance test.
c.
d.
Discussions with cognizant personnel.
3.
Findings An approximate total of 1338 NH 90 Series hydramotor actuators have been shipped to 22 cutomers, beginning in 1975.
The final test / acceptance criteria for actuators consisted of dimensional inspection and actual spring and hydraulic forces.
It has been determined that the actuators can have about 100 lbs.
of friction and an additional 40 lbs. of residual hydraulic pressure which was not taken into account when developing the selection nomograph charts. Therefore, customers may have selected the wrong actuator or improperly sized the actuator to fit his application without taking into consideration the inherent friction and residual hydraulic forces which reduce the stated function of the actuator.
l A test program is currently under way, to include these forces, in which the test data being developed will provide specific operating i
l parameters for a given actuator series model number.
The test program and evaluation is expected to be completed by mid-March, 1980.
l t
5 A review of certain purchase orders to ITT GC from their customers, shows a number of the actuators are designated as safety related.
The end use and final destination could not be ascertained in many instances.
D.
Exit Discussion The scope and findings were discussed at the conclusion of this inspection with Mr. R. L. Formella. Subsequent to the conclusion of this inspection, additional information was obtained which it incorporated into this report.
UNITEISTATES NUCLEAR CEGULATORY C0ammasaON g,ay,N,a,C r,y,,
WSPECTIOM & ENFORCEMENT -STATISTICAL DATA y
1 C Gll >> e aW suC 0535) g F ACILITY NAME J TT /34.M.L4nM M l.M'"I f INSPECTOR (S)
PRINCIPAL INSPECid LICENSEE, VENDOR REVIEWER MVnd LI TRANS-DOCKET NUM8ER (A)
REPORT NO.
DATES INQ/ INVEST /INSP REGION ACTION FROM CONDUCTING 9
19 24 ACTIVITY TYPE 1919le 101olHo I4 (Cilt'lal / I Al57 d r
i "
15 18 M M oo Y Y si "o'Ng"
~
AE 034 LICENSE NO. (8Y PRODUCT) iMOIOI/ I TO C o***
2 to 25 30 D.,
IIIIIIIIIIIIII alota1/IstW OI M M O O Y Y
$NSPECTsON 8ERFORUED SY*
1 REGIONAL OFFICE STAFF 2 C RESIDENTINSPECTOR 32 F
3 C PERFORMANCE APPRAISAL TEAM TYPE OF ACTIVITY CONDUCTED 8 CHECK ONE BOX ONLYi 3334 INSPECTION OTHER
' 14 C INQUIRY G
05 C MANAGEMENT AUDIT 09 C MATL ACCT.
13 C IMPORT C2 C SAFETY r uANAGEMENT VislT 10 C PLANT SEC.
I 15 C INVESTIGATION 03 C INCIDENT 07C SPEC %
11 C INVENT. VERIF.
l sip sNvtsT. ALsc CHECK 04 C E' VRCEMENT 08DENDOR 12 C SHIPMENT / EXPORT g BLOCKsi NSPECTION O R INV ESTIG ATION WA RNING :
% NNOUNCEO 20 UNANNOUNCED g
SPECTION SHWT:
1 DAY SHIFT 2 COFF SHIFT 3 C WEEKEND /HOL!OAY INSPECTION /tNvtSTIG ATION NOTm4 CATION ICHECK ONE BOX ONLYl J
31 10591 2 NEGIONAL OFFICE LETTER 30 REFERRED TO HOS FOR ACTION 4 0 REGION LETTER & HOS FOR ACTION INSPECTION / INVESTIGATION FINDINGS (CHECK ONE 90X ONLYl K
58 INLEAR 2 C NONCOMPLI ANCE 3 C DEVIATION 4 C NONCOMPLIANCE & DEVIATION L l ENFORCEMENT CONFERENCE HELD: 1039
'0 M
NUMBER OF NONCOMPLIANCE ITEMS IN LETTER TO LICENSEE:
NOTE: C> amos uusT sE sueuiTTED IOlk oN 704 Un4ENEVER PREviousLY 4 43 CITE D ITEM OF NONCOMPU ANCE N
NUMBER OF DEVIATION ITEMS IN LETTER TO LICENSEE:
is OFFICIALLY OELETED FRoM THE RECORD.
44 45 O
NUMBER OF LICENSEE EVENTS l g g 461NSPECTION FEE 1 C NON. ROUTINE / VENDOR INo Ful 2 C ROUTINE INo Feel 3 C ROUTINE (Feel 4 C ROUTINE (Fee Reduced) 0 47 CONTENTS 2.7900 sNFORMATION O T YES REGIONAL OFFICE LETTER OR REPORT TRANSMITTAL DATE FOR INSPECTION OR INVESTIGATION 591 OR LETTER ISSUED TO LICENSEE REPORT SENT TO HQS FOR ACTION IMMEDIATE ACTION LETTER R
48 53 54 59 60 OATE 65 lo O DltMl81 IIIIIII I II III I M M O 'O Y Y M M O O Y Y MM O O Y Y SU8 JECT OF INVESTIGATION (CHECK ONE 80X ONLY) 6667 TYPE A 10 CFR 20.403 TYPE 8 10 CFR 20.405 MISC.
~
01 O INTE RN AL OVE R EXPOSURE 06 C 11 C INT. OVEREXPOSURE 15 0 CRITICALITY 210 EQUIP. FAILURE C2 C EXTERNAL OVEREXPOSURE 07 C 12 C EXT. OVEREXPOSURE 16 C LOSS / THEFT 22C ALLEGATION /
S 03 C RELEASE TO UNREST. AREA 08 C 13 C EXCESS R AD. LEVELS 17 C MUF COMPLAINT 04 C LOSS OF FACILITY 09 C 14 C EXCESS CONC. LEVELS 18 C TR ANSPORTATION 230 PU8LICINTEREST 05 C PROPERTY DAMAGE 50 0 19 C CON'AM/ LEAKING 24C SABOTAGE SC%RCE 250 ABNORMAL OCCUR.
20 C '.NVIRONMENTAL EVENT 260 OTHER HEADQUAR TERS ENTRIES y
MO$ ACTION ON INSP/ INVEST REFERREO 8Y REGION:
~. - ~
lIl 6Lthis
.a 70 75 NOTE: SL K TO N MU BE O
DATE HOS ENFORCEMENT LETTER. NOTICE. ORDER ISSUED:
l l l l l l l M M D 0 Y Y WHENEVER ENTRIES ARE M QE IN 8 LOCKS T, U Ar.O V V
CIVIL PENALTY ISSUED:
1IIII TS DATE 766 ENTERED INTO CCMPUTER FILE (MO/YRh y y y y p
1
_-.______________l 9
t tiu 34.tse04.s.,A: siat h.LemO O
.ENIL MOTi08 NI NWOteS HLOMUN NMULOC ENIL 64 44 84 04 13 M.
33 23 92 82 32 42 81 71 63 41 31 31 01 4
3 2 I
._ J D
U
_v
__ l _
1_
1_
M he eh.
_N_
E_
t
,8
_h i"
a m.g i =
h.
M M-6'_-b6__
N h._
m_._j.m
.em
__h
_N N'
h'-
N i__
ey LGG B 3 0 7 0 3 )
ie"
.m N
'e J em
.me b f o B b t 7 3 1 2 D
=
I V
V V
V V
- J 9* 8" a
o 2 a
psapa s
a o2 a
g ETAD SHlT DE w
2 E I 4 I
N*
S't aI LOOC
[
LOOC E
EDOC E
EDOC E
EDOC y
I #
I S
S 5
S
-%z $
Q 01 DNEPXE
$ 68
.% $ Q.u 3
3 D
ETELP SRte NAM a
g=
PUWO t tOF [;
m MOC 7aOfff 4
CC8 EN C/N C/N C/N 8-PSHL
.+.-
ECNAliPMOCNON
~
DER EtuOOM TCEatb~
7PSNI.ON E tuDOM
~~
NOIT AMROFNI GNIKCAHT ELUDOM
'h E
/
YLNOh
} NOliCASNAHT SetiT NEPOLtf P l
008 03
)
'810129 SI D ETC fPSNI
(
3 NEPO LVAE 4 & NLPO tti L f
& 307 03,,207 03 DNA SERJtDECOHPi A
E tiMII(M NEliW Y tN)hSJ NLW( NIAME4101 KNALH
)I&SO lC C.-
GNH883401tf E LJtDOM.ElON[
I
.GNIDOC SUI A IS, t t ON f ATAD LACITSITATS TNEMECHOFNE f NOITCEPSNI - CHNSU 2 kDeb -eeF emes.anuF
_ _ - - _ _ _ _ _ _ _ _ _ _ _ - - _,