ML20030C505
| ML20030C505 | |
| Person / Time | |
|---|---|
| Site: | Satsop |
| Issue date: | 07/09/1981 |
| From: | Leddick R WASHINGTON PUBLIC POWER SUPPLY SYSTEM |
| To: | Faulkenberry B NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| References | |
| 10CFR-050.55E, 10CFR-50.55E, 10CFR50.55E, GO3-81-2217, NUDOCS 8108260177 | |
| Download: ML20030C505 (20) | |
Text
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Docket Nos. 50-508/509 l
Washington Public Power Supply System Box 1223 Elma, Washington 98541 (206)482-4428 v_ t.
5 7[JUL 13 Ita!
4 July 9,1981 SEPW, g G03-81-2217 Fu...
INSTEC3c8 g Nuclear Regulatory Commission, Region V ENTGCEMENT 4 Suite 202, Walnut Creek Plaza
/
T 1990 N. California Boulevard Walnut Creek, California 94596 Attention:
Mr. B. H. Faulkenberry Chief, Reactor Construction Projects Branch Gentlemen:
Subject:
PROJECT NOS. 3 AND 5 NRC INSPECTION OF WNP-3 AND WNP-5 DOCKET NUMBERS 50-508 AND 50-509 INTERIM REPORT OF P0TENTIAL 50.55(e)
PIPE HANGER STIFF CLAMPS On June 11, 1981 your office was notified of a problem we considered to be potentially reportable under the requirements of 10CFR50.55(e).
Attached please find a copy of the Engineers Interim Report on this subject.
We will provide a final report on this subject by October 1, 1981.
Should you have any questions or desire further infonnation, please feel free to contact me directly.
V ry truly yottrs,
. S. Leddick Program Director, WNP-3/5 At+'chments cc:
J. Adams - PP&L D. Smithpeter - BPA Ebasco - New York WNP-3/5 Files - Richio.;d 76N 8108260177 810709 PDR ADOCK 05000508 S
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'a ATTACS ENT M0E-81-67, dated July 3, 198:
WASHINGTON PUBLIC POWER SUPPLY SYSTEM WPPSS NUCLEAR PROJECTS NO. 3 & 5 t.:';INEERING INTERIM REPORT ITT GRINNELL STIFF CLAMPS DEVIATION /NON-CCMPLIANCE 031 JULY 3, 1981 l
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INTRODUCTION On May 20, l981 the installing contractor reported significant tie rod bending on the ITT Grinnell Figure 215 stiff clamp assembly (MK No. FDC-ll51 Rl/R2) when installed in accordance with the manufacturer's instructions.
Engineering assessment confirmed the tie rod bending and further revealed that a relaxation of the specified 240 ft. lb. torque had occurred after installation.
Failure to achieve full and equal tension in the strap loop around the trunnion was also evident, as well as apparent binding between the tie rod and trunnion which resulted in a bending moment that caused deformation of the tie rod.
(See Attachment 1) These noncon-forming conditions reoccured in other stiff clamp assemblies during mockup installations performed under the supervision of the Engineer and ITT-Grinnell at the site on June 1 and 2, 1981.
Failure :o achieve and maintain proper pretensioning of :he straps will reduce the rigidity of the stiff clamp assembly thus impairing it's abtlity to perform i*'s design function. The Grinnell Figure 215 Stiff Clamp assembly is designed to provide a stiffness five (5) times greater than that of a snubber assembly.
In the event that the stif f clamps do not function as designed the integrity of the eiping system cannot be substantiated by the dynamic analysis methods utilized for the WNP 3/5 Project. Approximately 4,000 stiff clamp assemblies are employed in the design of safety and non-safety related support systems for each unit.
These supports are located throughout the Turbine Building, Reactor Auxiliary Building and Reactor Building.
On June 4, 1981 the Engineer initiated NCR No. 14020 :o formally notify the supplier of the non-conforming conditions (See Attachment 2).
On June ll, 1961 the NRC was notified of the deficiencies in accordance with the provisions of 10CFR 50.53 (e).
A.
POTENTIAL PROBLEMS AND REFERENCE TO THE NOTIFICATION The potential problems associated with the ITT-Grinnell Figure 215 Stiff Clamp have been identified in NCR No. 14020 and notification was made to the NCR in accordance with the requirements of 10CFR 50.55 (e).
These potential problems are summarized below, l.
BENDING 0F THE TIE RODS Tie Rod bending was identified during installation of inital a.
stiff clamp assemblies and confirmed during subsequent noc<ups at the site.' 3ending was attributed to high friction betueen the strap loop and the trunnien.
This friction locks the trunnion within the scrap loop and prevents the trunnion from maintaining true alignment with the :ie rod as the assembly is tightened.
The trunnion rotates with the strap loop as the assembly is drawn together causing the trunnion to impar: a bending mcment to :he tie rod.
b.
Tie Rod bending was observed by ITT-Grinnell during qualification testing.
ITT-Grinnell has deemed this condition to be insigni-ficant provided the tie rod does not interfere with the pipe, as b.
(con't) this bending does not effect t: e stiff clamp function.
2.
TOROUE RELAXATION a.
Torque relaxation was identified during initial installation and subsequent mockups at the site.
Apparent cause of this reiaxation is attributed to the high friction between the trunnion and the strap and between the rocker washer and strap.
This high frict'.cn does not allow the strap loop to achieve equal loading beyond the points of tangency with the trunnion and rocker washer.
Subsequent slippage of the strap between the trunnion and rocker washer will result in torque relaxa-tion, and consequential reduction in stiff clamp rigidity.
b.
ITT-Grinnell has stated that torqua relaxatioc did not occur during original qualification testing.
3.
3ROKEN STRAPS Strap failures (breaks) have occurred during the mockup testing a.
at the site and during recent investigative tests conducted by ITT-Grinnell at their facilities as follows.
(1) One (1) 0.080" thick Aeroquip strap failed during mockup testing at the site.
The failure occurred at less than specified torque on a non-lubricated assembly during installation in accordance with prescribed procecures.
(2)
Recent tests by ITT-Grinnell at their Warren facilities have resulted in failure of 0.080" Aeroquip and RICO straps at less than specified torque values when lubricants were applied to friction surfaces other than tie rod thread surfaces. No failures occurred at specified torque values when lubricants were not used.
b.
All breaks occurred at the line of shear pins.
c.
The break described in 3.a (1) above is characterized by consider-able necking down of the scrap in the area between the shear pin holes consistant with a tensile overload. Tensile tests of the broken strap material resulted in yield and ultimate strengths as required by the material specification (SA366 TF 630 age hardened at 10750F for four (6) hours).
d.
ITT-Grinnell has advised that no strap failures occurred at less than specified torque and rated load during original qualifi-cation :ests which were conducted with lubri oced trunnions.
k.
EDGE INDICATIONS Crack-like indications have been observed in some straps at both :he site and in the ITT-Grinnell shop. ~
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4 EDGE INDICATIONS (con't) a.
These indications are found on the outer edge of the strap in I
line with the shear pins.
b.
Indications have been observed with the unaided eye and only in 0.080" thick straps supplied by Aeroquip.
I 3.
APPROACH TO THE RESOLUTION OF THE PROBLEM l.
BENDING OF TIE RODS Bending of the tie rods is being resolved by adoption of a modified design with elimination of rocker washer and development of appropri-ate installation procedure.
(See Attachment 3) 2.
TORQUE RELAXATION Torque relaxation is being resolved by the modified design described in 3.1 above.
Based on qualification tests conducted to date by ITT-Grinnell for this modified design, significant reductions in specified torque values (Approximately Sc%) produce the design stiffness.
3.
3ROKEN STRAPS Broken straps will be resolved by:
a.
Metallurgical evaluation to confirm no basic material problem associated with broken stra+.
b.
Confirmation that edge inc t..; ions did not contribute to strap failures.
c.
Review of Aeroquip manufacturing procedures and methods to confirm proper fabrication.
d.
Adaptation of modified design as described in 3.1 and 3.2 abc'ce.
L.
EDGE INDICATIONS Edge indications are to be resolved by the following.
a.
Visual inspecticn of straps at che ITT-Grinnell Warren facility.
This work is completed with results as shown in Attachment 4 5.
Visual inspection of straps at the site as follows:
(l)
Inspect all 0.080" Aeroquip straps.
(2)
Inspect 120 Aeroquip 0.040" straps.
(3)
Inspect 120 RICO 0.080" straps.
(a)
Inspect 120 RICO 0.040" straps.
-4_
b.
(con't)
(5)
If indications are found in (2), (3) and (4) straps, the need for additional sampling will be r' assessed.
Performance of metallurgical evaluation to confirm edge indica-c.
tions are edge surface conditions only and do not exist in the 1
area of the shear pin holes.
d.
Review of Aeroquip manufacturing procedures and methods to confirm proper fabrication.
ITT-Grinne~.1 has performed tests using clamp.with all four straps e.
having edge indications. All clamps so tested with edge indications achieved uneir load rating.
ITT-Grinnell reports that these edge indications have no. detectable effect on the ability of the clamps to perform their intended function.
f.
ITT-Grinnell has inspected 2759 Aeroquip straps 0.080" thick.
Of these 1796 were found to have edge indications.
In accordance with MIL-STD-105-D level 2, ITT-Grinnell has inspectc 1272 straps selected at random from the 1796 and found no indications within the area of the shear pins.
g.
It is ITT-Grinnell's opinion that unless the indications extend into the pattern of the shear pin holes they will not affect the performance of the clamps, and are therefore not significant.
C.
STATUS OF PROPOSED RESOLUTION i
The status of the proposed resolutions to those ITT-Grinnell stiff clamp l
problems identified and defined in A) and 3) of this report are as follows:
t L.
Resolution of the tie rod bending problem is contingent upon ITT-Grinnell's verified load test qualifications for the modified clamp design. Approximately 507 of these tests have been performed, with a projected completion date of July 30, 1981.
The smallest and largest pipe diameter si:e for each frame si:e (Frame size 1 through 6) will constitute these qualification tests.
2.
Resolution of the unequal strap tensioning and torque relaxation problem is centingent upon completion and verification of the same qualification tests identified in C.1) above.
3.
Resolution of the strap failure problem is contingent upon ITT-Grinnell's successful test verification of the ;aodified clamp design, which they are confident wil'. eliminate the strap overloading condition.
L.
The cause, extent and significance of edge indications on the Figure 213 0.080" Aeroquip strcps is currently under evaluation by ITT-Grinnell. Metallurgical tests, load qualifications and review of manufacturing processes and procedures are now in process, with a projected completion date for these test results and findings by July 30, 1981. l t
i D.
REASONS WHY THE FINAL REPORT WILL 3E DELAYED j
The final report cannot be issued until the following actions are completed, evaluated and compiled.
i 1.
Qualification tests for modified design configuration.
1 2.
Review of supplier's detailed procedures and manufacturing processes.
3.
Definitive cause ci strap failure.
t 1
4 Source, extent and significance of edge indications.
1 3.
Revised installation procedure for modified clamp design.
I 6.
Evaluation of collective data relative to preparation of final report.
E.
PROJECTED CCMPLETION OF CORRECTIVE ACTION AND SU_BMITTAL DATE OF COMPLETE REPORT All corrective actions necessary to prevent reoccurence of the identified stiff clamp def ciencies listed in this report will be finalized by August 15, 1981. The complete report will be submitted to the Supply System by September 15, 1981.
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ATTACHMENT LISTING FOR l
ENGINEERING INTERIM REPORT ATTACHMENT #1:
ITT-Grinnell original Figure 215 Stiff Clamp Design ATTACHMENT #2:
Stiff Clamp NCR No. 14020 ATTACHMENT 23:
ITT-Grinnell modified Figure 215 Stif f Clamp Design ATTACHMENT da:
Results of IIT Inspection at Warren ATTACHMENT #5: Criteria / Guidelines Used for Inspection of Aeroquip and Rico Scraps 4
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ATTACEENT 11 ITT-GRINNELL FIGURE 215 STIFF CLAMP ASSEMBLY I
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'I. RECOMMENDED CISPOSITION 02)
OESIGN OCCUMENT CHANGE REOUIRED (is)
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( 14 ) O uSE. As. iS O REPAIR O REWCRK CN PREPURCH ASED ITEMS WITHCUT AP8 l',[
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CORRECTIVE ACTION :
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/s All *?!P-3/5 succor:s and restraints involvine I~"T-GRINNELL Fi:. 215' stiff cla: asse=blies are to be identified and marked as non-confer =in2 ite=s until vendor resolutien has been
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NCR Attachrents d2 & #3 (ee. &&5 of 5) shall be used fer identifica:
,of non-cenfermine iters.
Non-clanc cortions of af fected su: ports and restraints can be i-e 211ed to final condi:fon.
Final installa:1cn of clares shall be ecceleted and verified in accordance with the accreved final discostion of this NCR.
ACTIO N TC PREVENT RECCCURRENCE (IF APPLICABLE ): tir) Vendor Engineering to provide appreeriate course o f action includine nec'essarv orocedures, nodifications, etc. recuired to prevent reoccurence.
t RE*0wu tWCE o VE RIFICaTICM SY* (88)
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eld se ( _T A-l'0101-27 J T T '.
?+.
'l-03 1)Subsecuent to issuance of orizinal NCR. Sucecr: MS-27 R2 was tested by the Enz. :
6-1-31.
knile bein2 tercued :: desi;. lead :f 240 f t/lbs :he stiff cla:p strap br:ke.
Failure occured at 225 ft/lbs. 23 On 6-10-81 another stif f clare meck-ue installa:icn was :erf erned bv the 11.
RECCMMENDED DISi:CSITION :
CESIGN CCCUMENT CHANGE oEOUIREC YES l]No
[ USE - AS -IS REPAIR 4EWORK CN PoE?UR':MASEC ITEMS WITHCUT
[ REJECT x CTHER REWCRK CCRRECTIVE ACTION: INTERIM DISPOSITICN:
This rediscesitien is to pr:vife additi:nal documentation cencerning the cresentiv identified F12ure 215 (?E-41 series) stiff clamp croblem.
Referenced claws shall be scranped af ter proble= is resolved by vender.
Ill. EV ALU ATlON OF DISPOSITION:
3g3 g,t.,,,,
g, c,,,,,,,,3 tnrerim discosition is acceetable.
ANI CCNCURRANCE / W, a tt.::t a t:
O f y w=cr at uuet:
,n p
- p. -
, q
-n f-
. c os e l,IS S t r e n lev / Le ac .a.,:.n e. o, i tir;t
- Art c,b pp,.y:5 sr gcu W
b - 225
._6Wt rt?Lt ATE C_Ud?t$ o UY5.IIt'dv., Ctsstl Z :,vauty asstip-es
} 9,or ta tuf=cai:t: *tes===t; I 7:? to aut-ce::t: et.as w=tt
..=cweeyrs, vddfs
\\..Idi :s=*r-/~
c t im rg
- n=)= CAL
- ... t, t i
- sti 1 +'. 4 6% A. M, 4
- A r t JME j aart i ;,M t s
j $/I (b2 '2
/
! dr -l$-)?{
I b ~ 'h h i::t,-ts c
=c. teras l C ne: trets c et.terts
.g a =t.tcet:
!'-r4::cete :.t.t: to
= 4:c t e tm air = ::== t = r s I C ac:terts.ir= c:==t es I c aceterts
.c:terte vira ::= = t= rs O.::t rt: *ir
- = = tar IV. CONFIRM ATION OF COMPLETION OF APPROVED DISPOSITICN N..v t. s;GN r.TuRE. CCvP.NY 1.NC CONTR:.CT No.
TIT' i
- rE V.
VER!?iCATICN OF COMPLETION OF APPROVED DISPOSITION:
_ _ _ nr.vi,s:sNr.ru=E, CCvo:NY ANC CCNTRACT No.
~ ' ~ '_ E
.i
-41..-.=........ ~.. < N..N,,
SY SIGN ATU R E
' _i TE CS. AC. 464C 09 9 80) H ((I i9. SC) R2 (12.11.80)
tsa s:: st=v$ts iwe:anca47 :
ggs,-
,e,,,
'20
==ps/t 3...
7 u r.
J.
. s.
,4..Asaiti SITE M NCO NFCR M.'.NCE REPCG T
- q-...,. 3 i.
4
..,..,4 L,,,.
, v.,,
sn _
..m O
..n t
INS Ur lONS ; (sgg 3:0< 0; ?;:u) r in i
o 3
3.,
n.
- E 3: n. F s C 3r Cas s sym u i4 c_..,. e... c _= * -. _ o... _ :o = t % : N. a u f, : s
- 33. e.c e.u. a..,
,;;srgq g g1.od A
.e..
.r.e.
, a s e s e / s w '- *'.x.e, $ Ta = A s a es
_.c,.e.
i A
.l.' 0.f D ;' '<',
..c.s
- 9. = 0' ' 6 &
y.
..s e
= E s ec = si e t t ::=Teac: 1
)
- .47.q
- s p zou =c ;;=rcn i.,ct
,e,
, 3, m ;. w I do jAnj=.ag (.)
1.. i-vaul. w u t :
3,,, 0.,, g,m0 3,,
t...;
- .e vi-Reason for Dispestion:
(con't)
Erzineer.
Two (2) clanos - 16" CC-179 R2, Rev 1 and l'" FS '2F Re 2, were u:ili:ed by
- akin
- vo (2) straos fr:: each assembly, cerbining these wi:h FS-12R 1 " :lan; ycke and at: aching this asse=bly :o a 1!+" pipe spool.
A: 200 ft./lbs torque ene (1) 16" s::ap frc:
the c.C-te9 paren: asseroly :a,.ec.
6
. CA. t. A - 4 @ 4 til ( 7 t) 'm M 1 LUAant_ _________ __ ___ _____ ___z
ATTACHMENT 13 ITT-GRIN' ELL MODIFIED FIGifRE 213 STIFF CLAMP ASSEMBLY I
}
I
/,
\\
ATTACHIENT FIN
_ - - - - -.. -/
YOKF i
i e
.e, t
i_,
h I
i II
\\
\\)
fl 1
\\
\\/
I i
J l
l t
1 Nim-C bb F
TIE RCD WASHER, i
s y
TIGHTENING & LOCK NUT lm T"dbjd l
TIE ROD'
\\
l STRAP (Loop Section)
TRtJ'iNIONS l -
=
-. -~
ATTACHMENT #4 l
RESULTS OF ITT INSPECTION AT WARREN
- iTI?? CLAMP STRAPS (Individac1 Straps)
ARE00UIP (Inspcetion completed 6-29 al)
ECO Size Good Bad Total Size Goed Bad Total
)
fi;l - 3" 16 2
16 Ill - 3" 3
0 3
l
./l - 4" 2
0 2
11 - 4' C
O 4
.:42 - 3" 0
0 0
l/2 - 8" 12 0
12
~!
l.,-
'12 - 3" :nr: 14'
- 125 0
- 125
- 2 - 3" chru 14" 0
3 0
}
jd3-20" 143 0
143
- 3 20" 1
0 1
g/3 - 24" 34 0
34 13 - 24" O
0
^
4 i
A e
Ild4 - 3" 0
12 72
- 4 - 3" 0
0 0
l l#4-4" 17 11 28
- 4 - 4" O
G 0
d4 - 6" 191 0
191
- 4 - 6" 115 3
115 j
i 1
i j
ii5 - 3" 223 34 2"
- 5 - 8" 0
0 0
j15-10" 137 58 195 15 - 10" C
0 0
l, '", l15 - 12" 190 660 850 10 - 12" 38 0
38
!05-14" 0 397 397
- 5 - 14" 61 0
f,1 i
i I
i l#6 - 16" 146 90.
236 16 - 16" 6
0 6
- d6 - IS" 3
52 55
- 6 - 18" 0
0 0
'46 - 20" 135 123 258 16 - 20" 49 0
40 l
{06 - 24" 3 134 137
- 6 - 24" 1
0 1
,\\
- NOTE - 2,459 PCS. OF THESE SIZES SH0iiN JN DiVENTORY.
Q.C. INSPECTED A l
SAMPLZ OF 125 PCS.
ALL PCS. WERE ACCEPTABLE.
- 10 3ICO S~Iu.PS NOTED.
- ANY EDGE INDICATION
~
- " PROCEDURE VE-I USED FOR INSPECT g g g i
j l
.ARECCGI?:
_A
_R.
_I.
RICO:
_A
_R
_T j
1365 1631 2996 286 0
286 l
54.4" Reject 0" Raj ect I
f i
AERCOUI?
RICO
_A R_
_T A
_R
_T 0&O Material 320 0
320 0
16 0
16 0
CSO Material 1046 1631 2676 61 270 0
270 0
t
- 4 cc:
- 3. acaell
- 3. Gast
,---n
,--+.,..,-n-
, -,,.--,_,-~,.,r
.,,..,,_,,,,,,__n,,_,,,
gn,,.--,.
,,_,,n.
- e
_o ATTACHMENT #5 I
CRITERIA /GUIDLINESS TO 3E USED FOR INSPECTING AER00UIP AND RICO STRAPS 3
FURNISHED TO WPPSS SITE FOR ITT GRINNELL STIFF CLAMP FIC 215 3
i' i
i i
j 1)
Inspection will be visual examination with no magnification.
)
2)
Identification of Rico vs. Aeroquip straps must be maintained.
i 3)
Identification of scrap thickness (either.040 or.080) must be i
maintained.
i
- 4) Mark numbers and NPT serial numbers of clamps inspected =ust be maintained.
I j
- 5) A three (3) levol inspection criteria should be used -
f A.
Any strap with edge indications will be identified.
i 3.
Any strap with indications on inside face (area that bears against pipe) will be identified.
j C.
Straps with "no" indications will be identified.
A separate list for each type of finding will be caintained.-
i i
1 4
I l
)
i 4
T 1
... ~
,m.~- -,,
i~-.w--t
-~+-n
-