ML20039D243
| ML20039D243 | |
| Person / Time | |
|---|---|
| Issue date: | 12/08/1981 |
| From: | Mcneill W, Potapovs U NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML20039D225 | List: |
| References | |
| REF-QA-99900033 NUDOCS 8112310453 | |
| Download: ML20039D243 (14) | |
Text
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ORGANIZATION: WESTINGHOUSE ELECTRIC CORPORATION ELECTR0-MECHANICAL DIVISION CHESWICK, PENNSYLVANIA REPORT NO.:99900033/81-02 INSPECTION DATE(S): 9/21-25/81 INSPECTION ON-SITE HOURS: 60 CORRESPONDENCE ADDRESS: Westinghouse Electric Corporation Electro-Mechanical Division ATTN: Mr. F. R. Bakos General Manager Cheswick Avenue Cheswick, PA 15204 ORGANIZATION CONTACT:
Mr. C. E. Owens, Product Assurance Manager TELEPHONE:
(413) 363-8700 PRINCIPAL PRODUCT:
Pumps, Control Rod Drives, and Valves NUCLEAR INDUSTRY ACTIVITY: About 55% of the sales is nuclear.
ASSIGNED INSPECTOR:
( ), )J'/.
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W. M. McNeill, Components Section (CS)
Date~
OTHER INSPECTOR (S):
W. D. Kelley, Reactive Inspection Section (RIS)
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APPROVED BY:
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U. Potapovs, Acting Chief, CS Date '
INSPECTION BASES AND SCOPE:
A.
BASES:
10 CFR 21 and Westinghouse Topical Report WCAP-8370, Revision 9A.
8.
SCOPE: This inspection was made as a result of the issuance of 10 CFR Part 50.55(e) reports by Florida Power and Light Company (St. Lucie, Unit 2) and SNUPPS (Wolf Creek and Callaway, Units 1 and 2) concerning an identified potential failure of 3-inch thru 18-inch gate valves to close under flow conditions at maximum pressure differential.
QA programmatic areas included in the inspection were audits, nonconformances and corrective actions, calibration, design input, design verification, and design document control.
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WESTINGHOUSE ELECTRIC CORPORATION ORGANI!ATION: ELECTR0-MECHANICAL DIVISION CHESWICK, PENNSYLVANIA REPORT NO.: 9990003: /81-02 INSPECTION RESULTS:
PAGE 2 of 4 A.
VIOLATIONS:
None B.
NONCONFORMANCES:
1.
Contrary to the Water Reactor Divisions Policy / Procedure Manual, Section 18.0, paragraph C and Section 5 of the Topical Report, internal audit procedures did not require preaudit and postaudit conferences.
2.
Contrary to Procedure EIM-26, paragraph 8 and Section 5 of the Topical Report, nonconforming parts were not being properly identified, in that a part was found with an incorrect Material Review Report (MRR) referenced.
3.
Contrary to Procedure EIM-23, paragraph III.7 and Section 5 of the Topical Report, there was no evidence of QA approval of the deletion of an inspection step.
4.
Contrary to Procedure EIM-41, paragraph 3.2 and Section 5 of the Topical Report, a plug gage was accepted, even though it was outside the specified calibration band.
C.
UNRESOLVED ITEMS:
None D.
OTHER FINDINGS:
1.
Audits - The three internal audits performed this year were reviewed in detail. The independence of the team and their qualifications were inspected. The qualification records of the lead auditor and three auditors were insp'ected. The use of checklists and the reporting of findings were verified.
The corrective action and follow up of corrective action were verified on four findings and observations.
The Nuclear Energy System annual management audit was also reviewed.
In this area, nonconformance No.1 was identified.
2.
Nonconfonnance and Corrective Actions - Nine MRRs and four Error Correction Tags (ECTs) were reviewed of hardware found inprocess.
The review, approval, and disposition of each were verified.
In the area of identification of nonconforming hardware, nonconformance No. 2 was identitied.
The MRR in question identified a step on an inside diameter of the part which had been dispositioned accept-as-is.
This step was not observed, and the part was remeasured.
The measured diameter did not agree with the MRR.
It was within tolerance.
This part has been a member of a larger lot.
The balance had been shipped to an outside plating shop.
At the end of this inspection, Westinghouse I
WESTINGHOUS ELECTRZC COMPANY
- ORGANIZATION:
ELECTR0-MECHANICAL DIVISION CHESWICK. PENNSYLVANIA REPORT NO.: 99900033/81-02 INSPECTION RESULTS:
PAGE 3 of 4 was attempting to find the part on MRR at the outside plating shop.
The summarization and trend analysis of MRRs, ECTs, etc., were reviewed.
The identification of a recent Licensee Event Report was traced through the Field Deficiency Report system including its evaluation.
One data package for a recent shipment of valves was reviewed to verify inclusion of all Deviation Notices (DNs) and the DNs customer review and approval.
In review of ECT 872951 nonconformance No. 3 was identified.
ECT 872951 had been voided by manufacturing engineering by changing the work instructions.
It appears the inspection was not necessary, however, there was no evidence of QA approval of the inspection deletion.
3.
Calibration - A sample of 20 gages and instruments were inspected. The frequency, serialization, labeling, and inspection records were verified.
The use of NBS traceable standards and acceptable transfer ratios were verified. The connuter printouts of gage and instrument status were inspected.
In this area, nonconformance No. 4 was identified.
The gage in question had a calibration band of nominal,.0004. The MRR accepted this gage as.0002 undersize.
The gage had worn an additional.0002 and beer, accepted on April 18, 1980, and April 3, 1981, as is by the cali-brction inspectors.
4.
Design Input - The inspector reviewed WCAP-8370 Quality Assurance Plan; design report for Westinghouse Class 1 Nuclear Valves; meeting minutes of the first, second, and third design review of the valves; and four layout drawings of gate and check valves to verify that the design input procedures were effectively implemented.
One follow-up item concerning pressure build up in the bonnet with the gate valves in the closed position was identified. The Westinghouse EMD gate valve design permits a pressure rise in the bonnet if the valve is closed in the cold condition and the sys'em start-up increases the valve temperature.
Westinghouse EMD stated this had been evaluated and would present their evaluation to an inspector on a subsequent inspection.
5.
Design Verification - The inspector reviewed the ASME accepted QA Manual, the design report for Class 1 nuclear valves, the auxiliary valve develop-ment test program, the minutes of three design review meetings, supple-mentary test requirements, stress report for Class 1 nuclear valves, and curve of closing load versus number of cycles to verify that the design verification procedures had been implemented.
6.
Design Document Control - The inspector reviewed the ASME accepted QA Manual, WCAP-8370 QA Plan, test curves, test program, supplementary test i
requirements, four drawings, three customer design specifications, design report, stress analysis, three design meeting minutes, and minutes of safety review committee to verify that the design document control pro-cedures had been implemented.
I
WESTINGHOUSE ELECTRfC COMPANY OWNNON:
ELECTR0-MECHANICAL DIVISION CHERWICK. PENNSVIVANTA REPOffr NO.: 99900033/81-02 INSPECTION RESULTS:
PAGE 4 of 4 7.
Deficiency Report - The NRC inspector reviewed the Westinghouse EMD data pertaining to the identified potential failure of 3-inch thru 18-inch gate valves to close under flow conditions with system pressure differential across the disc.
The test fixture used to verify the friction coefficient of the gate sliding on the seat ring when the valves are operated was inspected, and the test data retiewed.
The NRC inspector reviewed the design report to verify that the friction factor used in the original design calculations was less than the friction factor subsequently established by testing.
Three Westinghouse EMD letters to a licensee informing them of their evaluation of the failure of the gate valves to close and the presentation on the Westinghouse EMD gate valve closure problem were reviewed.
2.a inspector reviewed the Westinghouse EMD plant / project valve modification program and verified that the licensees have been notified, and corrective action had been planned for all affected sites. Westinghouse EMD was currently conducting functional tests of their gate valves (selective sizes 3-inch thru 18-inch) to confirm their revised design assumptions.
The NRC inspector will review the test data and design assumptions on a subsequent inspection.
Westinghouse EMD had notified all of the purchasers of their gate valves of the potential failure to close under flow condition at maximum pressure differential, were evaluating each gate valve flow / pressure condition, and planned to advise their customerr in regard to required operator modification or replacement. The NRC inspector will review the scope and adequacy of the Westinghouse EMD corrective actions in a subsequent inspection.
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Procedure 7.
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QA Manual 8.
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Revision (If applicable)
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