ML20050C360
| ML20050C360 | |
| Person / Time | |
|---|---|
| Site: | Hatch, Brunswick, 05000000, Black Fox |
| Issue date: | 03/18/1982 |
| From: | Barnes I, Kelley W NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML20050C342 | List: |
| References | |
| REF-QA-99900058 NUDOCS 8204080435 | |
| Download: ML20050C360 (12) | |
Text
.
ORGANIZATION:
ROCKWELL INTERNATIONAL FLOW CONTROL DIVISION i
RALEIGH, NORTH CAROLINA REPORT INSPECTION INSPECTION I
NO.:
99900058/82-01 DATE(S) 2/8-11/82 ON-SITE HOURS: 60 l
CORRESPONDENCE ADDRESS:
Rockwell International Flow Control Division ATTN:
Mr. J. V. Grasso, General Plant Manager 1900 South Saunders Street l
Raleigh, NC 27603 ORGANIZATIONAL CONTACT:
Mr. R. A. Bandukwala TELEPHONE NUMBER:
(919) 832-0525 PRINCIPAL PRODUCT: ASME Section III Class 1, 2, and 3 valves.
NUCLEAR INDUSTRY ACTIVITY: Rockwell International - Flow Control Division's con-tribution to the r.uclear industry represents approximately 10% of its total work load.
3//6[BZ ASSIGNED INSPECTOR:
a W. D. Kelley, Re' active g Components Program Section Odte '
(R& CPS)
V OTHER INSPECTOR (S): I. Barnes, Chief, R& CPS 7/////2 APPROVED BY:
I. Barnes, Chief, R& CPS Date INSPECTION BASES AND SCOPE:
A.
BASES:
B.
SCOPE:
This inspection and the inspection documented in Inspection Report No.
99900058/81-02 were 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 (continued on next page)
__ -,,, u n, i
uw).a- - - - -
, b PLANT SITE APPLICABILITY:
. Certified By L d-@'gia c Records identified with the following nuclear facilities were examined during this inspection: 50-324; 50-325; 50-366; and 50-557.
8204000435 820323 PCR GA999 EMVROCI 99900058 PDR
ORGANIZATION:
ROCKWELL INTERNATIONAL FLOW CONTROL DIVISION RALEIGH, NORTH CAROLINA REPORT INSPEJIION NO.:
99900058/82-01 RESULTS:
PAGE 2 of 5 SCOPE (cont.) 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.
The areas included in this inspection were the manufacturing process control provisions utilized in the manufacture of main steam isolation valves, with specific emphasis placed on controls for assembly, pin insertion and plug welding.
A.
VIOLATIONS:
None B.
NONCONFORMANCES:
1.
Contrary to Criterion V of Appendix B to 10 CFR Part 50 and Section 9, Revision 8, of the QA Manual, review of the Valve Route Card for a completed and shipped 26" 1612 (WCC) JMMNTY main steam isolation valve (Black Fox Nuclear Project 2, Serial No. PI-38) showed the following examples of the failure of applicable personnel to sign and/or date operations to dano'.e completion:
a.
Sequence No. 070 was not signed by either manufacturing or Quality Assurance personnel.
b Sequence Nos. 050, 060, 090, 100, 110, 120, 130, and 260 were not signed by supervisory personnel to denote verification of opera-tion completion.
Personnel performing the operations were identified on the Route Card, but dates of completion had not been entered.
c.
Sequence No. 160 was not signed by a Rockwell Inspector and Sequence Nos. 170, 260, 280, 290, and 311 had been signed but not dated by a Rockwell Inspector.
2.
Contrary to Criterion V of Appendix B to 10 CFR Part 50 and Section 6, Revision 7, of the QA Manual, the Valve Route Card applicable to the ASME Section III Code Class 1 valve identified in B.1 above did not indicate the correct Method Specification number to be used for assembly of the stem to stem disc and assembly of the main disc to piston assembly; i.e. Method Specification 7736LR was listed on the Route Card to be used for the assembly operations, whereas Method Specification 7718, Revision 0 was the applicable issued specification.
l
ORGANIZATION:
ROCKWELL INTERNATIONAL FLOW CONTROL DIVISION RALEIGH, NORTH CAROLINA REPORT INSPECTION NO.:
99900058/82-01 RESULTS:
PAGE 3 of 5 3.
Contrary to Criterion V of Appendix B to 10 CFR Part 50 and paragraph NB-4432 in Section III of the ASME Code (1971 Edition), locking pins were welded to stem discs and main discs (pressure parts) in main steam isolation valves which had been furnished to E. I. Hatch, Unit 2, without specification or evidence of use of welding procedures that had been qualified in accordance with Section IX of the ASME Code.
C.
UNRESOLVED ITEMS None D.
STATUS OF PREVIOUS INSPECTION FINDINGS:
1.
(0 pen) Notice of Nonconformance, Inspection Report No. 81-02:
Furnishing of spare stems and discs to the Brunswick Steam Electric Station with oversized disc female threads and undersized stem male threads in regard to Class 3 requirements.
The status of this nonconformance was not reviewed durirg this inspec-tion, as a result of correspondence not having been completed on this item.
2.
(0 pen) Unresolved Item, Paragraph C, Inspection Report No. 81-02:
Applicability of Appendix B to 10 CFR Part 50 to the procurement of spare stems and discs by Carolina Power and Light Company (CP&L).
The NRC inspectors were informed, that a copy of an exception to the CP&L Purchase Order No. 716707 specification of Appendix B to 10 CFR Part 50 as being applicable for the supply of spare stems and discs, had not been located.
Resolution of this i,;m has been deferred pending completion of the response to the nonconformance identified in 1. above.
E.
OTHER FINDINGS OR COMMENTS:
1.
Assembly of Main Steam Isolation Valves Furnished to Brunswick, Units 1 and 2, and E. I. Hatch, Unit 2 a.
The NRC inspectors were unable to review the assembly history of these valves, as a result of being informed by Rockwell personnel that Route Cards were only used for oiece manufacture in the time frame these valves were produced.
l l
l l
ORGANIZATION:
ROCKWELL INTERNATIONAL FLOW CONTROL DIVISION RALEIGH, NORTH CAROLINA REPORT IN5PtL610N N0.:
99900058/82-01 RESULTS:
PAGE 4 of 5 b.
Examination of Special Engineering Instructions 408 which contained the Rockwell requirements for manufacture of the E. I. Hatch, Unit 2, valves, revealed no specific criteria for valve assembly.
One nonconformance was identified (see paragraph B.3) in regard to the failure to specify the use of a qualified welding procedure for welding of locking pins to the stem disc and main disc.
2.
Current Assembly Practices Used for Main Steam Isolation Valves a.
A review was made of the Valve Route Card for a 26" 1612 (WCC)
JMMNTY main steam isolation valve, Serial No. PI-38, which had been furnished to Black Fox Nuclear Project 2 during 1981.
This review was made in order to determine the current assembly process control provisions for this design of valve, and to ascertain compliance with specified requirements during manufacture.
This inspection showed a difference existed in assembly method
' rom that utilized for the Brunswick and E. I. Hatch valves; i.e., locking pins were retained by mechanical staking and not by plug welding.
The NRC inspector was informed that this method had been utilized for valves shipped since early 1979.
During this review, one nonconformance (see paragraph B.2) was identified pertaining to the identity of the Method Specification utilized for staking of locking pins.
Method Specification 7736LR was listed on the Valve Route Card as the applicable specification to be used for stem to stem disc to piston assembly.
Sequence Nos. 080 and 110 were signed off by a Rockwell Inspector indicating acceptance of these assembly operations in accordance with Method Specification 7736LR.
On request to see this Method Specification, the NRC Inspector was informed that this pecification had been replaced at customer request by inserting the content in Method Specification 7718, Revision 0.
No information w..s provided in regard to the failure to revise the Route Sheet, or the basis for sign off by the Rockwell Inspector.
An additional nonconformance (see paragraph B.1) was identified in regard to t'he failure to comply with the QA program manu-facturing process control requirements in existence at the time of manufacture of this valve.
Review of the current QA program requirements for manufacturing process control (Section 9,
ORGANIZATION:
ROCKWELL INTERNATIONAL FLOW CONTROL DIVISION RALEIGH, NORTH CAROLINA REPORT INSPECTION NO.:
99900058/82-01 RESULTS:
PAGE 5 of 5 Revision 9 - September 3, 1981) showed a change had been made in sign off requirements.
The present revision now requires Quality Assurance personnel to sign off only inspection operations listed on the Route Card and not all operations.
Review of Standard Operating Instruction (S0I) 40-19-05, dated December 3, 1981, which pertains to documentation gathering and processing for nuclear valves, indicates it is a Quality Assurance responsibility to review Route Cards for completeness and correctnesu (after performance of indicated operations) prior to moving material to stores.
No operation was listed, however, on Piece Route Cards which clearly required the Rockwell Inspector to perform this function; i.e., the final inspection operation prior to moving material to stores required the Rockwell Inspector to only visually and dimensionally inspect the part.
An operation requiring review for completeness was entered on the Valve Route Card which is used for assembly.
b.
An inspection was performed with respect to the calibration status of five micrometers, one dial bore gage, and all current torque wrenches used in valve assembly.
No nonconformances were identified in this area of inspection.
It was established, however, that the present calibration program did not include a torque multiplier used with torque wrenches in valve assembly.
The NRC inspector was informed that this device would be included in the calibration program to assure necessary accuracy.
A follow-up will be made on this subject at a future inspection.
The NRC inspector additionally noted that the reasons for return of devices for repair were not always entered in the cali-bration records.
As a result, positive verification that a repair was not related to device accuracy could not be accoa-plished.
3.
Manufacturing Process Control-Present Work An inspection was performed in regard to the compliance of eight parts in manufacture during the inspection, with respect to QA program process control and customer specification requirements.
No noncon-formances were identified in this area of inspection.
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