ML20040F137
| ML20040F137 | |
| Person / Time | |
|---|---|
| Issue date: | 12/30/1981 |
| From: | Barnes I, Kelly W NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML20040F135 | List: |
| References | |
| REF-QA-99900053 NUDOCS 8202080361 | |
| Download: ML20040F137 (11) | |
Text
B ANCHOR DARLING VALVE COMPANY ORGANIZ/JdON:
WILLIAMSPORT, PA REPORT NO.: 99900053/81-01l:NSPECTION DAgS): 10/26-39/81' INSPECTION ON-StrE HOURS: 30
, CORRESPONDENCE ADDRESS: Anchor Darling Valve Company ATTN:
Mr. J. W. Marlatt General Manager 701 First Street Williamsport, PA 17701 ORGANIZATION CONTACT:
Mr. G. W. Kneiser, Quality Assurance Manager TELEPHONE:
(717) 323-6121 PRINCIPAL PRODUCT:
Nuciear Vahes NUCLEAR INDUSTRY ACTIVITY:
Ancnor Darling Valve Company's contribution to the nuclear industry represents approximately 60 percent of it,s total work load.
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3o -PI ASSIGNED INSPECTOR: & Wm. D. Kelley, Reactive Inspection Section (RIS) Date 4
OTHER INSPECTOR (S):
APPROVED BY:
8-m
/2 3o -PJ I. Barnes, Chief, RIS Date e-INSPECTION BASES AND SCOPE:
A.
BASrS:
10 CFR Part 21 and 10 CFR Part 50, Apoendix B.
B.
SCOPE:
This inspection was made as a result of the issuarce of licensee event reports by:
(1) Arkansas Power and Light Company concerning both the discovery of missing parts in a four inch swing check valve which had been instalied in the Arkansas tit; clear One, Unit 2 facility, and the identification from the retrieved parts of the use of a lock wire in assembly rather than a drawing specified cotter pin; and (2) Southern California Edison Company concerning the failure of San Onofre Unit I double disc parallel seated gate valves to open upon receipt of a valid safety injection signal.
Additional areas selected for inspection included design control, testing of completed products and records.
DESIGNATED ORIG 113AL 3 a cu t d 3:bd
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8202080361 820119 PDR QA999 EMVANDV 99900053 PDR
ORGANIZATIM: ANCHOR DARLING VALVE COMPANY WILLIAMSPORT, PA REPORT NO.: 99900053/81-01 INSPECTION RESULTS PAGE 2 of 5 A.
VIOLATIONS:
None B.
NONCONFORMANCES:
1.
Contrary to Criterion V of Appendix G to 10 CFR Part 50 and Ancnor Darling Valve Ccmpany (ADVC) Drawing No. 9362F, two 30 x 24 x 30 inch parallel seated gate valves on Order No. 1024-001-001 for Washington Public Power Supply System Nuclear Project R were shipped with the by pass installed on the opposite side of the valves to that specified by the drawing.
2.
Contrary to Criterion V of Appendix B to 10 CFR Part 50 and paragraph 4.2.1.10 in Westinghouse Equipment Specificatica 675198, it could not be verified that the yoke mounting flange,in Sen Onofre Unit 1, 14 x 10 x 14 inch gats'7alves was deiigned to withstand the specified
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seismic loading and applied stresses, 'in that an incorrect equation was used for performing the analysis.'
C.
UNRESOLVED ITEMS:
Review of assembly drawings for the ADVC double disc, parallel seated, gate valves showed that required disc-seat clearances had not been included.
As a result of the 1977 start up history, it vauld appear that the adequacy of controls for these dimensions may be insufficient.
A review of stacked dimensional tolerances for the cemponent parts will be made at the next scheduled inspection, in order to ascertain whether this had been a contributory factor to the idantified failure of the valves to open at San Onofre.
D.
OTHER FINDINGS OR COMMENTS:
1.
Licensee Event Report By Arkansas Power and Light Company - Problem reported was the discovery of missing disc nut, wasner, cotter pin, and stud of a four iach swing check valve th:at had been furnished to Arkansas Nuclear One, Unit 2; also, the retrieved parts indicate a tack welded lock wire had been used instead of the cotter pin specified on the assembly drawing.
The valve was manufactured in the ADVC Hayward, California plant which was subsequently closed (September 1981), and all l
records transferred to the Williamsport, Pennsylvania plant.
The assembly drawing specifies that the nut and stud be pinned with a 1/8 inch diameter by 1 inch long cotter pin and the stock requisition indicated that this cotter pin was requisitioned; however, the assembly l
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ORGANIZATION:
ANCHOR DARLING VALVE COMPANY WILLIAMSPORT, PA REPORT NO.: 99900053/81-01 INSPECTION RESULTS:
PAGE 3 of 5 l
inspection traveler line had the traveler line item, " Tack Welds and l
Set Screws Secure," signed off and dated.
During the time frame in l
which this valve was assembled, the Hayward plant used lock wires in the assembly of Navy, marine and some commercial valves.
Shop travelers were not retained by ADVC as part of the permanent records; however, the NRC inspector was informed that these travelers would not have shown if the assembler had substituted a lock wire with a tack weld for the cotter pin.
ADVC supplied new replacement parts for the valve to the licensee with a recommendation that the nut and stud be drilled and pinned and the pin be captured by peening.
No further corrective action is planned by ADVC.
2.
Licensee Event Report by Southern California Edison - Problem reported was the failure of the 14 x 10 x 14 incn ADVC double disc parallel seated gate valves which had been furnisned to the San Onofre Nuclear Generating Station to open upon a valid Safety Injection System signal.
a.
Background
These valves were purchased from ADVC by Westinghouse Electric Ccmpany Atomic Power Division (W-APD) on their purchase order 54-J-45425B dated December 8, 1964.
The W-APD purchase order specified that the valves meet ASA B16.5 and W-APD Equipment Specification E-675198, Revision 1.
No manufacturing or test records were required to be or actually retained for the valves, and a Seismic Report was the only available design document at the time of this inspection.
In 1975, prior to start up of the San Onofre Nuclear Generating Station, SCE requested ADVC to submit a proposal for changing the closing time of the SIS valves from 10 seconds to 5 seconds.
The request asked for the proposal to include both the Liniitorque (LC) electric motor operators and the Greer Hydraulics Inc. (GHI) hydraulic actuators.
ADVC supplied both manufacturers the required thrust (33160#) to open the valves (851A&B and 852A&B) based on a friction factor of 0.2.
ADVC recommended their valves be equipped with a LC motor operator.
On December 8, 1975, ADVC sent TLX677268 to SCE which stated, "A/DC assumes no responsibility for Greer Operators."
1 l
ORGANIZATION: ANCHOR DARLING COMPANY WILLIAMSPORT, PA REPORT NO.: 99900053/81-01 INSPECTION 7ESULTS:
PAGE 4 of 5 SCE elected to accept she proposal for the GHI actuators; therefore, ADVC designed a yoke in accordance with ASME Section III, 1974 Edition with Summer 1974 Addendum, to mount the GHI actuators on the exisitng vaive bodies.
The yokes, stems, and adapters were manufactured at ADVC and shipped to SCE San Onofre, Unit 1, and installed in late 1976 with ADVC field service engineers and manager of engineering on site for assistance and technical advice during assembly.
b.
Valve Problems During Plant Start Up During plant start up in January 1977 it was found that the GHI actuators were unable to open some of the SIS valves with the design pressure differential across the valve discs.
Disassembly of the valves revealed the following defective conditions:
(1) the bridge in the bottom of the valves and the bridae on the bottom of the lower wedge were defo %ed (brinnelled) where they made centact; (2) the stellite contact surfaces on the back of the wedges did not make contact when the valves were in the closed position; (3) the pinned screwed connection between the stem and top wedge was loose on ome valves; (4) axial misalignment of the actuator and valve stem on valve 851A; and (5) cracks in the back-seats of valves 851A&B, and 8528.
A program was established to recondition the valves which included polist.ing the stem surfaces, reworking the stem-to-upper pinned connections to prevent motion, reworking the upper wedge elongated disc oin holes, reworking the stellite bearing curfaces of the wedg0s to ensure cantact, reworking and modifying the lower wedges to reduce bearing stresses, refinishing the discs to restore them to as-new condition, refinishing the valve seat ring stellite surfaces, and replacing cracked back-seats.
The valves were reassembled and the startup testing of the SIS was continued.
Valve 851B operated progressively slower in the opening stroke for five cycles of operation and failed to open on the sixth cycle.
The valve was disassembled and inspection revealed a damaged downstream disc and seat ring and an inadequate clearance between the disc-wedge assembly and the seat rings.
The ADVC assembly drawing for the SIS valves do not specify the clearance but depend on the stacked tolerance of the parts during assembly to provide the necessary clearance.
The othar seven valves in the SIS were disassembled and the clearance in six valves was less than the ADVC recommended clearance of 0.10 to 0.13 inches and had damaged stellite seating surfaces
ORGANIZATION: - ANCHOR DARLING VALVE COMPANY WILLIAMSPORT, PA
' REPORT NO.! 99900053/81-01
'NSPECTION RESULTS:
PAGE 5 of 5 on the discb and seat rings.
The clearances between the stacked discs and wedges and the seat rings were increased to bewteen 0.10 and 0.13 inches by machining the disc stellite faces.
The seat rings and disc faces were relapped and the valves reassembled and successfully passed the startup test.
One nonconformance and one unresolved item were identified.
c.
Corrective Actions SCE has issued a design specification (Mini-Specification SI-M-8185-V-1) for replacement valves for the safety injection system using a stored onergy activation system.
The design specification requires each representative valve-actuator design combination to be tested 100 cycles in such a way that the design differential pressure will be developed across the disc.
d.
Items Requiring Follow Uo Inspection Review of the Seismic Report applicable to these valves showed that a friction factor of 0.2 had been used in the calculations.
The validity of this factor could not be established during the inspection for contacting stellite to stellite surfaces, and will be further reviewed during a subsequent inspection.
3.
Design Oncument Control - Reviewed one section of the ASME accepted QA Manual, four engineering standards, four drawings and one set of calculations.
Verified procedures had been impicmented to control review, approval, release and issuar.ce of design documents.
4.
Inspection and Test - Testing of Completed Products - Reviewed one section of the ASME accepted QA Manual, one quality assurance standard, three engineering' process standards and the test stations.
Verified:
(a) test procedure was available at test station; (b) test data had been documented; (c) test had been performed in accordance with procedure; and (d) test instrumentation had been calibrated.
One nonconformance was identified.
d 5.
Records - Reviewed one section of the ASME accepted QA Manual, one engineering material standard, one records retention standard, and three valve data packages.
Verified:
(a) records tnat must be retained were identified; (b) procedure identified how and where records are to be stored; (c) the procedures and necessary resources were available to the personnel identifying and filing quality assurance records; and (d) the records were filed and protected in accordance wi'.h the QA Manual and procedure requirements.
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PERSONS CONTACTED
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