ML20032D391
| ML20032D391 | |
| Person / Time | |
|---|---|
| Issue date: | 10/23/1981 |
| From: | Barnes I, Kelley W NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML20032D387 | List: |
| References | |
| REF-QA-99900058 NUDOCS 8111130727 | |
| Download: ML20032D391 (10) | |
Text
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ORGANIZATION: ROCKWELL INTERNATIONAL - FLOW CONTROL DIVISION RALEIGH, NORTH CAROLINA REPORT NO.: 9990008?8/81-02 INSPECTION DATE(S): kd$d'!k[h INSPECTION ON-SITE HOURS: 69 CORRESPONDENCE ADDRESS:Rockwell International Flow Control Division Attn: Mr. J. V. Grasso -
General Plant Manager 1700 South Sanders St.
Raleigh, North Carolina 27603 ORGANIZATION CONTACT:
Mr. R. A. Bandukwala TELEPHONE:
(919) 832-0525 PRINCIPAL PRODUCT: ASME Section III "N" Stamped Class 1, 2, and 3 Valves NUCLEAR INDUSTRY ACTIVITY: Rockwell International - Flow Control Division's contribution to the nuclear industry represents approximately 10 percent of its total workload.
ASSIGNED INSPECTOR: kkd'
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/c[77/kf' Wm. D. Kelley, Reactivy Inspection Section (RIS)
Date OTHER INSPECTOR (S):
H. L. Whitener, Reactor Inspector, Region II
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APPROVED BY:
- 1. Barnes, Chier, RIS Date INSPECTION BASES AND SCOPE:
A.
BASIS:
10 CFR Part 21 and 10 CFR Part 50, Appendix B B.
SCOPE:
This inspection was made as a result of:
(1) the issuance of a licensee event report by the Carolina Power and Light Company concerning a stem to stem disc separation in a main steam isolation valve installed at the Brunswick Steam Electric Station, Unit 2; and (2) the issuance of a licensee event report by the Georgia Power Company concerning a stem to stem disc separation in a main steam stop valve installed at the E. I. Hatch Nuclear Plant, Unit 2.
Additional areas included in the inspection included manufacturing process control, calibration, and records.
LEIC Tra ORIGII %
Cert'fi;d By_
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8111130727 811029 PDR GA999 EMVROCI 99900058 PDR
ORGANIZATION: ROCKt' ELL INTERNAT10NAL - FLOW CONTROL D1V!S?ON RALE 8GH, NORTH CAROLZNA REPORT NOa INSPECTION RESULTS:
PAGE 2 of 5 99900}58/81-02 A.
VIOLATIONS None 5.
NONCONFORMANCES Contrary to Criterion V of Appendix B to 10 CFR Part 50 and Rockwell International Flow Control Division (RI-FCD) drawings C-410354 and 0-408177, dimensional measurements of two spare stem discs and four spare stems, that had been furnished by RI-FCD to Carolina Pcwer and Light Company (CP&L)
Brunswick Steam Electric Station, showed that the female threads of both disc were oversized and that the male threads of three of the stems were undersized with respect to Class 3 requirements.
C.
UNRESOLVED ITEM CP&L Purchase Order No. 716707, dated September 4,1980, for spare stems,
stem discs, piston assemblies and discs for the Brunswick Steam Electric Station main steam isolation valves (24" x 20" x 24" Fig.1612 JMMNY), states they are to be manufactured in accordance with a quality assurance program which conforms to the applicable requirements of Appendix B to 10 CFR Part 50.
RI-FCD stated they had taken an exception to this requirement in their pro-posal; however a copy of the exception to the requirement of Appendix B was not available at the Raleigh plant.
The inspector was informed a copy of the exception would be requested from the RI-FCD area sales office and made avail-able to the inspector on a subsequent inspection.
D.
OTHER FINDINGS OR COMMENTS 1.
Inspection of Main Steam Isolation Valves at CP&L, Brunswick Steam Electric Station, Soutn Port N. C., on July 21-24, 1981 a.
There have been six main steam isolation valve failures, one in Unit 1 and five in Unit 2: (1) three of the failures were stem to stem disc separations; and (2) three of the failures were piston assembly to main disc separations.
b.
It was CP&L's understanding that all main steam isolation valves had been disassembled by construction craftsmen during plant test and startup because of excessive seat leakage.
No docu-l mentation of the disassembly, repair, and reassembly was avail-able to the inspector during the inspection.
The follow-up review of this documentation will be performed by NRC-IE-RII on a subsequent inspection.
c.
The original valve design required:
(1) the stem to stem dite con-nection to be preloaded with a toroue of 1000 foot-pound; (2) a single round antirotation pin to be inst:lled and captured with a plug weld; and (3) the piston assembly to main disc to be assembled with no specified preload and a single round antirotation pin installed and captured with a plug weld.
ORGANIZATION: ROCK!! ELL INTERNATIONAL - FLOW CONTROL DIVISION RALEIGH, NORTH CAROLINA REPORT NO.: 99900058/81-02 INSPECTION RESULTS:
PAGE 3 of 5 d.
The removal of the antirotation pins for maintenance by drilling became a problem and RI-FCD recommended the use of square pins with an interference fit be used to prevent rotation during the drilling operation.
e.
History of valve failures:
Valve Failure Unit Tao No.
Date Event Discussion 1
2 2-821-F022D 7/3/76 Dropped Main disc to piston Disc assembly separated; and antirotation pin not installed deep enough into disc.
2 2
2-B21-F022A 1/29/79 Dropped Stem to stem disc Disc separated ana the antirotation pin sheared; and piston assembly-main disc pin deformed.
3 2
2-821-F028C 1/15/81 Dropped Main disc to piston Disc assembly separated; and no evidence that an antirotation pin had been installed.
4 1
1-B21-F022C 3/30/81 Dropped Stem to stem disc sepa-Disc rated; pin not recovered; and evidence of plug weld and hole damage indicates an antirotation pin had been installed.
5 2
2-B21-F022C 7/81 Dropped Stem to stem disc sepa-Disc rated; stem antirotation pin hole clean; and stem 0
threads damaged 180 from stem pin hole.
6 2
2-821-F022D 7/81 Dropped Main disc to piston as-Disc sembly separated; no crest left on either male or female threads; pin fell out and not recover-ed; and plug weld did not fuse end of antirotation pin.
I
ORGANIZATION: ROCKWELL XNTERNAT80NAL - FLOW CONTROL DIVISZON RALElGH, NORTH CAROL 1NA REPORT NO.99900058/81-02 INSPECTION RESULTS:
PAGE 4 of 5 f.
The two spare discs and four spare stems were inspected and one nonconformance identified.
g.
Repair of Valves 2-821-F028C and -F022D The two spare stem discs with oversized female threads were returned to the RI-FCD Raleigh plant and two new stems made to fit.
The stems and stem discs were returned to the Brunswick Steam Electric Station and CP&L proposed that:
(1) the stem to stem disc connection be pinned with three 3/8 inch diameter antirotation pins of increased length; and (2) the piston assembly to main disc connection be pinned with two 1/2 inch diameter antirotaticn pins of increased length.
RI-FCD concurred with the rroposed modification and the spare parts were assembled and installeu in the valves by CP&L personnel with RI-FCD representatives present in accordance with an approved CP&L maintenance instruction. The assembly of the spare parts was witnessed by the NRC inspector.
The stems, stem discs, piston assemblies, and main discs removed from the valves were shipped to the CP&L Shearon Harris Energy and Environmental Center for evaluation.
2.
Inspection of Valve Internals at the CP&L Shearon Harris Energy and Environmental Center, New Hill, N. C., on August 11, 1981 The NRC inspector visually ex? mined the failed stems, stem discs, piston assemblies and main discs that had been removed from the main steam isolation valves (2-B21-F022C & 2-821-F022D).
The stem to stem disc connections had been sectioned and thread wear was clearly discernible.
3.
Inspection at the RI-FCD Plant, Raleigh, N. C., on August 10-14, 1981 a.
Presentation of RI-FCD Technical Report The NRC inspector met with RI-FCD personnel and discussed their Technical Report entitled, "MSIV Stem-Disc and Disc-Piston Disassemblies During Plant Operation." The NRC inspector was unable to determine from review of the contents of this report that either a determination had been made of the specific reasons for the valve failures, or that necessary actions to preclude t
recurrence of future failures had been established.
b.
Calibration The NRC inspector reviewed the calibration records for the gages, wires, and micrometers which had been used to measure the threads of the spare parts supplied to CP&L, in order to verify that their calibration was current during the period in which the parts were manu factured.
I
ORGANIZATION: ROCKWELL TNTERNATE0NAL - FLOW CONTROL DIVISION RALEIGH, NORTH CAR 0LIllA REPORT NO.: 99900058/81-02 INSPECTION RESULTS:
PAGE 5 of 5 c.
Records The NRC inspector reviewed the records (certified mill test reports and nondestructive test reports) for valves 2-821-F022C and 2-B21-F0220 and the CP&L purchase documents for the spare stems and stem disc.
One unresolved item was identified.
d.
Manufacturing Process Control The NRC inspector reviewed the shop travelers for valves 2-821-F022C and 2-B21-F0220 and the CP&L purchased spare parts and verified that the applicable documents had been referenced, inspection points established, and that the dimensional inspection had been signed off by a RI-FCD inspector.
e.
Item Requirina Follow-Up Inspection Review of the design utilized to prevent disassembly of the stem disc from the stem and the main disc from the piston assembly indicates that the antirotation pins can potentially be insuffi-ciently inserted to perform the required incking function.
The process controls used to assure proper assembly, pin insertion, and plug welding were not reviewed, however, during this inspection. This subject will be further reviewed during a future inspection.
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