ML19340E682
| ML19340E682 | |
| Person / Time | |
|---|---|
| Issue date: | 11/14/1980 |
| From: | Brown R, Whitesell D NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML19340E679 | List: |
| References | |
| REF-QA-99900057 NUDOCS 8101150381 | |
| Download: ML19340E682 (7) | |
Text
U.S. NUCLEAR REGULATORY CCMMISSION OFFICE OF INSPECTION AND ENFORCEMENT REGION IV Report No.
99900057/80-02 Program No. 51300 Ccmpany:
The William Powell Ccmpany Plant No. 2 3233 Colerain Avenue Cincinnati, Ohio Inspection Conducted:
October 27-31, 1980 h
/3 9d Inspector:
w Ross L. Brown, Contractor Inspector, Date Ccmponent Section I, Vendor Inspection Branch Approved by:
d[
////4/84
- 0. E. Whi tesell, Chief,
Date '
Component Section I, Vendor Inspection Branch Summary Inspection en October 27-31, 1980 (99900057/80-02)
Areas Ins::ected:
Followup of deficiency reported in 10 CFR 21 Report date November 12, 1979 and implementation of 10 CFR 50, Appendix B iaciading equipment calibra-tion and welding procedures and personnel qualifications. The inspection involved twenty-nine (29) inspector hours on site by one NRC inspector.
Results: No deviation from comitments or unresolved items were identified.
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Details Section A.
Persons Contacted R. N. Cochran, Metallurgical Technician R. Eveslage, Tool & Gage Inspector D. O. Holte, Welding Engineer R. E. Howard, Project Engineer
- H. Knock, QA Manager, Plant No. 2 J. F. Loftus, Corporate Chief Engineer
- D. W. Mowery, Sr., Manager Technical Services
- J. C. Williams, Project QA Engineer
- E. E. Winterfeldt, Corocrate Manager of Quality Assurance
- Attended Exit Meeting B.
General Vendor Information The William Powell Company (WPC) has contracts for approximately 750 ASME, Class 1, 2, and 3 valves for nuclear installations.
These contracts ex-tend into 1983.
The WPC contract with Hartford Steam Boiler Inspection and Insurance Ccmpany presently is for part time inspection service on an as need basis.
C.
Follow-Uo of the 10 CFR 21 Recorted Deficiency 1.
Objectives of this area vf the inspection were to verify:
a.
That the valve contracts that specified seismic requirements have been re-evaluated using the latest computer program.
b.
That the corrective action has been evaluated to deternine its adequacy and proposed modifications have been submitted to the client for review and approval, c.
That the repair / rework method (s) and procedures have included the QA l
participation.
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2.
Methods of Accomolishment The preceding objectives were accomplished by a detailed review of the following documents and discussions with cognizant personnel related to t
the WPC nuclear valves contracts:
a.
Intra-Canpany Correspondence date May 16, 1980,
Subject:
Natural Fre-cuency Evaluation of Nuclear Valves for Plants other than Mississippi Power & Light.
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- b.
Intra-Company Correspondence, date November 15, 1979,
Subject:
Natural Frecuencies for Detroit Edison Valves using deficient Computer Program NFREQ.
c.
WPC letter to Cetroit Edisen Company, date May 2, 1980.
Subject:
P. O.
IE-86734, All. Release Revised Seismic Reports.
d.
Chart comparing the frequencies originally recorted for the Cincinnati Gas & Electric Company (Zimer Plant) valves and the values rescrted using *he most recent canputer program.
3.
Findings No deviaticns frem cxinitment er unresolved items were identified. The inspector verified the folicwing information; a.
Grand Gulf Units 1 and 2 (1) WPC has completed the seismic re-analysis of all the valves for these units.
(a) The results have been subnitted to the customers for review and acceptance. WPC requested scme valves with less than the recuired frequency to be accepted as is.
The customer has accepted valves tnat have a frequency of 33 cps or higner as stated in the technical specification.
(b) Drawings showing the mcdifications to valves that recuire the yoke arm to be strengthened have been submitted to the cus-tomer for acceptance.
(c) WPC has notified the client that some of the valves will recuire auxiliary supports.
(d) The inspector observed develcpment work under the direction of a welding engineer, to establish welding precedures and l
techniques to minimize distortion and assure weldability.
(e) WPC management stated that the design (seismic) verification testing by the Medal method has been completed on two (2) valves, and two (2) additional valves are being prepared for testing. This testing will be completed during the first quarter of 1981.
(2) The customer has recuired WPC to cerforn ccerability testing at new specified c icads of 6.0 horizontal and 5.0 vertical instead of the original requirements of 3g's in two (2) directions. WPC managemerir stated that nine (9) of the recuired fourteen (14) valves have been satisfactcrily tested by WPC personnel and ob-
. served by WPC-QA management.
b.
Detroit Edison Comoany - Fermi 2 WPC management stated that on October 27, 1980 Detroit Edison (DECO) management contacted WPC to request seismic analysis reports for the Fermi valves.
The Purchase Order IE-86734 equipment specification did not require calculations for valve natural frequency, however, calculations were performed using a computer program that contained the error as re-ported to NRC in the Part 21 Report on November 12, 1979.
WPC contacted DECO management in November,1979 informing them of the potential error in the frequency reports for six (6) valves. DEC0 manegement stated that the reported natural frecuencies have not been used for any evaluations.
It was agreed to revise the valve reports by deleting the frequency portion of the rcports.
The revised reports were transmitted to DECO by letter dated May 2, 1980.
WPC management stated that the majority of the seismic calculations for the DECO valves were performed using the method that predated the erro-raneous program, however, they are not sure how many reports are avail-able.
If the reports are not available it might be possible to run com-parisons against similar valves of known frequencies.
c.
Cincinnati Gas & Electric Comoany-Zimmer (CG&E)
WPC management performed a re-analysis of all CG&E valves using the most recent program, these calculations identified a number of valves that have a frequency lower than the 33 cps as required by the tech-nical specification. WPC management stated that the reports will be submitted to the custaner for their acceptance of the valves.
These valves were originally analyzed using the computer program that predated the erroraneous program, these calculations showed a number of the valves with a frequency below the specified 33 cps.
These valves were apparently accepted at the time by CG&E.
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Natural Frecuency Evaluation of Valves for other Plants Sucolied by WPC The Intra-Company Correspondence dated May 16, 1980 states in part:
The natural frequency evaluation of valves furnished for the follow-ing plants has been completed and all valves have a frequency higher l
than the critical frequency stated in the respective technical speci-fication: Toleda Edison, North East Utilities (Millstone), Alabama, Georgia Power, Arkansas, Boston Edison, Metropolitan Edison (TMI),
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_4.
Commonwealth Edison (Zion), Arkansas / Louisiana and TVA (Watts Bar).
e.
10 CFR 21 Interim Reoort Powell Valve Comoany will submit an interim report to the NRC by December 31, 1980.
D.
Ecuimnent Calibration 1.
Objectives The objectives of this inspection where to verify that:
a.
Tools, Gauges, instruments and other inscection, measuring, and testing equipment and devices used in activities affecting quality are of the proper range, type, and accuracy.
b.
These devices are calibrated and properly adjusted at specified periods or use intervals in accordance with written procedures.
c.
The calibration is performed against certified measurement standards which have known relationship to National Standards.
d.
The control measures include provisions for test equipment identification and calibration status by marking or on records traceable to the equip-ment.
e.
The Manufacturer determined and imolemented corrective action for materials and items checked using measurement or testing equipment later found to be out of calibration.
2.
Methods of Accomolishment The preceding objectives were accomplished by a detailed review of the following documents and discussion with cognizant personnel:
a.
The William Powell Company (WPC) Quality Assurance Manual for Nuclear Power Valves, Change Notice No. 6, date October 25,1979 (QAM) Article 6, Paragraph 6.4 l
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Specification PS-104-6, " Inspection Gage & Measuring Equipment."
c.
Calibration Records File 3.
Findino l
No deviations from commitment or unresolved items were identified.
The inspection verified the folicwing:
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_ _ - _ _ a.
The QAM article requires all tool, gages, instruments, etc. including personnally owned equipment used in manufacturing affecting quality to have unique identification numbers and shall be calibrated at specific periods or use intervals.
The manual also requires the type and serial number of tools, gages, etc., used for final inspection to be entered on the inspection report for traceability.
b.
Specifications PS-104-6 and PS-104-lC established the frecuency and method of calibration of inspection tools and gages.
They also establish the color code procedure used to indicate calibration status.
c.
The calibration record files includes the card file for each inspection tool and certification of measurement standards.
These records were complete in accordance with the applicable standards.
E.
Weld Control 1.
Objectives The objectives of this area of the inspection were to verify that:
a.
Weldino Procedure Soecification (1) The manufacturer has established procedures or instruction for preparation, qualification approval / certification distribution and revision of welding procedures specifications (WPS).
(2) The WPS define all essential variables supplementary essential variables and nonessential variables in accordance with the applicable editions of Section IX and III of the ASME Code.
(3)
Each of the above procedures has been qualified in accordance with Section IX and III of the ASME Code and that the support-ing Procedure Qualification Records (PQR) are on file.
(4) Any changes or revisions of the WPS essential variables are supported by reoualification of the original WPS or a new WPS.
(5) Any changes in the WPS nonessential variables are properly identified anc documented either as revisions to the original WPS or a new WPS.
b.
Welder Cualifications (1)
The manufacturer has established procedures for qualification of welders and welding operators in accordance with Section IX of the j
ASME Code.
.. (2) The manufacturer has a workable system for maintaining a con-tinous record of the qualification status of all welder? and welding operators and that this system is effectively utilized and accurate.
2.
Metheds of Acccmolishment The preceuiny sject.ivac were accomplished by a review of the following documents:
a.
QAM-Article 5, paragraph 5.5.2, " Qualifications" b.
Welding procedure numbers 2/21602, 2/13101 and 2/13601.
c.
Two (2) welder qualifications for each welding procedure No. 's.
2/13101, 2/13601, and 2/34001.
3.
Findinas No deviations from comitment or unresolved items were identified.
The inspector verified the following:
a.
The QAM requires welders, welding procedures and hardfacing proce-dures and operator qualification tests to be conducted in accordance with the applicable requirements of ASME Code Section IX and III.
It also requires the records to be approved by the manager Technical Service.
b.
The procedures for shielded metal arc, flux core (with post weld heat treatment (PWHT)) and flux core (without PWHT) welding were in accordance with the requirements of ASME Code and QAM.
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The welder qualification records were in accordance with code and QAM requirements.
F.
Exit Interview The inspector conducted an exit meeting with The William Powell Company manage-ment representatives at the conclusion of the inspection. Those persons indi-I cated by an asterisk (*) in paragraph A above were in attendance.
The inspector discussed the scope of the inspection and stated that in the areas inspected no deviations from comit:nent or unresolved items were iden-l tified.
The WPC management's coments were for clarification only.
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