ML20054C345
| ML20054C345 | |
| Person / Time | |
|---|---|
| Issue date: | 03/25/1982 |
| From: | Barnes I, Kelley W NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML20054C330 | List: |
| References | |
| REF-QA-99900100 NUDOCS 8204200403 | |
| Download: ML20054C345 (11) | |
Text
ORGANIZATION:
LIMITORQUE CORPORATION LYNCHBURG, VIRGINIA REPORT INSPECTION INSPECTION NO.
99900100/82-02 DATE(S) 1/27-28/82 ON-SITE HOURS: 12 CORRESPONDENCE ADDRESS:
Limitorque Corporation ATTN:
Mr. T. Mignogna President 5114 Woodall Rd.
Lynchburg, VA 24506 ORGANIZATIONAL CONTACT:
Mr. K. Groome, Quality Control Manager TELEPHONE NUMBER:
(804) 528-4400 PRINCIPAL PRODUCT: Electric Motor Actuated Operators NUCLEAR INDUSTRY ACTIVITY: Limitorque Corporation (LC) supplies electric motor actuated operators for valve operation.
LC nuclear involvement represents approximately 10 percent of their total production.
// m ASSIGNED INSPECTOR: / /d -*
7 - 2. C-n -
[-<-Wm. D. Kelley, Reactive & Component Program Section Date (R& CPS)
OTHER INSPECTOR (S):
m APPROVED BY:
4 = ~-,
7 F 2-I. Barnes, Chief, R& CPS Date l
INSPECTION BASES AND SCOPE:
A.
BASES:
B.
SCOPE:
This inspection was made as a result of: (1) Construction deficiency l
reports by: (a) Consumers Power Company concerning the installation of under-I rated terminal blocks on component cooling water and service water system electric motor actuated valve operators at the Midland Nuclear Power Plant, i
Units 1 and 2; and (b) Louisiana Power and Light Company concerning the furnishing to Waterford Generating Station, Unit 3, of valve operators which (SCOPE cont. on next oace)
PLANT SITE APPLICABILITY:
DESIGNATED ORIGINAL Docket Nos. 50-329; 50-330; 50-382; 50-361; and $ N d.d D WW 1 i
8204200403 020401 PDR GA999 EMVLMIT 99900100 PDR
ORGANIZATZON:
LIMITORQUE CORPORATION LYNCHBURG, VIRGINIA REPORT INbFtbl1UN NO.:
99900100/82-02 RESULTS:
PAGE 2 of 8 SCOPE: (Cont.). contained motor pinion keys that had been made from a wrong material; and (2) a 10 CFR Part 21 report by Bechtel Power Corporation concerning the furnishing to Southern California Edison San Onofre Nuclear Generating Station, Units 2 and 3, of original and replacement motor pinion keys which had been made from a wrong material.
A.
VIOLATIONS:
None B.
NONCONFORMANCES:
1.
Contrary to Criterion II of Appendix 8 to 10 CFR Part 50 the quality assurance program did not provide for indoctrination and training of personnel performing activities affecting quality, other than those personnel reporting directly to the Quality Control Manager; i.e.,
training was not addressed for engineers, parts and shipping personnel, purchasing agents, order processors, and field service personnel associated with nuclear orders.
2.
Contrary to Criterion V of Appendix B to 10 CFR Part 50 and paragraph A.2 of Section IV of the Quality Assurance Manual, a telephone order for five " Keys - Motor Pinion Gear," Drawing Number 60-563-0154-1, Revision A, was received and the parts shipped without the order being routed through the File Department.
3.
Contrary to Criterion XVI of Appendix 8 to 10 CFR Part 50, the cause and corrective action to preclude recurrence were not documented in regard to:
a.
Furnishing of incorrect carbon steel keys with Certificates of Compliance indicating them to be 4140 alloy steel; b.
Installation of improper terminal blocks by a Field Service Engineer.
4.
Contrary to Criterion V of Appendix B to 10 CFR Part 50 and paragraph D.la of Section IX of the Quality Assurance Manual, the Shipping Department Supervisor did not ensure that all material shipped to a customer was properly identified, as evidenced by the shipment of 1030 carbon steel keys for an order (WKM Valve Division) requiring 4140 alloy steel keys.
ORGAN 1ZAT10N:
LIMITORQUE CORPORAT10N LYNCHBURG, VIRGINIA REPORT INSPECfl0N NO.-
99900100/82-02 RESULTS:
PAGE 3 of 8 C.
UNRESOLVED ITEMS:
None D.
OTHER FINDINGS OR COMMENTS:
1.
Construction Deficiency Report by Louisiana Power and Light Company (LPLC) - Problem reported was the discovery, as a result of the LPLC follow up of NRC IE Information Notice 81-08, that 10 LC valve operators furnished to Waterford Generating Station had keys of the wrong material holding the pinion gear to the electric motor shaft.
a.
Background
NRC IE Information Notice 81-08, dated March 20, 1981, was issued as a result of the failures of the key holding the pinion gear on the motor shaft of the LC valve operators at the following plants:
(1) Nebraska Public Power District - Cooper Nuclear Station (2) Boston Edison Company - Pilgrim Nuclear Power Station, Unit 1 (3) Georgia Power Company - E. I. Hatch Nuclear Plant, Units 1 & 2 (4) Power Authority of the State of New York - James A. Fitz-patrick Nuclear Power Plant.
LC responded to the notice by notifying all of their customers by letter dated June 3, 1981, of their recommendation to replace all 1018 keys on their Size SMB-3 and SMB-4 valve operators equipped with motors that developed 150 foot pounds torque or greater, I
and all size SMB-5 valve operators.
LC's letter stated that the replacement keys and their material certificate of compliance would be provided at no cost.
ORGANIZATION:
LIMITORQUE CORPORATION LYNCHBURG, VIRGINIA REPORI IN5etcaluN NO.-
99900100/82-02 RESULTS:
PAGE 4 of 8 b.
Findings LC informed NRC IE:HQS in their letter of June 9,1981, that they had reviewed their design calculations and had found the stresses in the keys of the 1018 material to be acceptable for normal valve operator service; however, the use of a 4140 key increased the ability of the valve operators to withstand impact and shock loads imposed by frequent reversal of the valve travel and/or the stalled motor condition.
LC stated verbally it was their engineering judgment that the key failures were aggravated by the operation of valves without the flowing media in the pipe lines, sudden reversal of the valve travel, and/or electrically jumping the torque switch to effect a tight shutoff of leaking valves.
As stated in LC letter of June 3, 1981, to their customers, no records were available prior to May 25, 1981, that would identify which key material was used on a particular order.
Prior to this date LC had purchased their keys in bulk lots and performed inventory by weight count once a year.
The inspector verified that LPLC had been notified by LC of their recommendation to replace the keys of 1018 material with keys of 4140 material.
2.
Construction Deficiency Reoort by Southern California Edison (SCE) -
Problem reported was the discovery that the keys purchased from the WKM Valve Division of ACF Industries, Inc., for holding the pinion gear on the valve operator motor shaft, were 1030 carbon steel material and not the 4140 alloy steel indicated by the certificate of compliance.
a.
Background
Bechtel Power Corporation (BPC) reported to NRC RIV by letter dated November 29, 1981, of improper key material in LC valve
ORGANIZATION:
LIMlTORQUE CORPORATION LYNCHBURG, VIRGINIA REPORT itutu iun NO.-
99900100/82-02 RESULTS:
PAGE 5 of 8 operators installed on WKM valves at the SCE-San Onofre Nuclear Generating Station.
Replacement keys of 4140 material were ordered from WKM who in turn ordered the keys from LC by TWX dated June 4, 1981.
The NRC RIV inspector was informed by LC personnel that these keys were subsequently lost in the mail between WKM and San Onofre Nuclear Generating Station.
WKM requested by telephone for LC to ship replacement keys and confirmed the order with a telecopy of their purchase order on July 21, 1981.
The keys were withdrawn from stock and (with an accompanying material certificate of compliance) were shipped on August 19, 1981.
Prior to installation, the replacement key material was analyzed by an unnamed independent laboratory
.who determined the key material to be 1030 carbon steel.
b.
Findings The NRC inspector observed that the keys of 4140 material are identified by a part number which is affixed to the front of the storage bin.
The bin was observed to be adjacent to a bin containing keys of identical size of 1018 material.
The keys do not have a material identification marking and keys of both materials were available to the employee withdrawing the keys for the WKM replacement order.
The Manager of Quality Control issued a material certi-ficate of compliance stating the keys were 4140 material.
The NRC inspector reviewed the limited number of documents l
available pertaining to the keys which consisted of the i
material certificate of compliance, the part drawing, a shipping list and an acknowledgment of the purchase order.
The NRC inspector requested to see a copy of the noncon-formance and corrective action documentation, and was informed corrective action had been implemented, but i
I neither the nonconformance and corrective action, nor the retraining of the employee had been documented.
Three nonconformances were identified.
c.
Items Requiring Follow-up Inspection - The LC Material l
Review Board did not meet and decide the required corrective l
action with respect to identified cause of furnishing incorrect key materials to nuclear customers; i.e., material
ORGANIZATION:
LIMITORQUE CORPORATION LYNCHBURG, VIRGINIA REPORT 1re r tt i tua N0.-
99900100/82-02 RESULTS:
PAGE 6 of 8 identified as 1030 steel and 1018 steel were shipped to SCEC, San Onofre Nuclear Generating Station and LPLC, Waterford Generating Station repectively, as 4140 steel.
A detailed evaluation of the LC quality assurance program provisions for material control will be made at a subsequent inspection, in order to assure compliance with Criterion VIII of Appendix B to 10 CFR Part 50.
3.
Construction Deficiency Report by Consumer Power Company (CPC) -
Problem reported was the discovery of underrated terminal blocks in LC valve operators that had been furnished by valve manufacturers to the Midland Nuclear Power Plant.
a.
Background
CPC-Midland Nuclear Power Plant notified Region III of the NRC by letter dated February 13, 1981, of a defective item reportable under paragraph 50.55(e) of 10 CFR Part 50.
The attachment to the letter states in part, "..
The other 10 operators inspected had Marathon Series 300 blocks which were initially rated by Marathon for 600-Volt Service and have subsequently been derated to 300 volts by their catalog 10M79 b.
Findings LC stated in their letter to the Henry Pratt Co., dated January 21, 1981, that Marathon Special Products (MSP) had an Under-writer's Laboratory (UL) approval on the MSP 300 Series terminal block which specified that the terminal block rating was based on dimensional requirements and not on breakdown voltage.
Currently the MSP 1979 catalog shows the 300 Series terminal block as carrying a UL rating of 300 volts.
The LC letter i
referenced an article in the April 7, 1977 issue of Machine Design which states that most manufacturers rate their terminal blocks at one third of the breakdown voltage.
The NRC inspector verified that the MSP rating sheet for their 300 Series terminal block states the line to line breakdown voltage is 9,000 volts and the line to ground breakdown voltage is
ORGANIZATION:
LIMITORQUE CORPORATION LYNCHBURG, VIRGINIA REPORT INSPECTION NO..
99900100/82-02 RESULTS:
PAGE 7 of 8 11,200 volts.
It is LC's position based on past experience and the actual breakdown voltage that the MSP 300 series terminal blocks are suitable for service in their valve operators because the motors operate on 460 volts.
4.
Construction Deficiency Report by Consumer Power Company (CPC) -
Problem reported was the discovery of terminal blocks for 120 volt service installed on LC valve operators for 460 volt service at the Midland Nuclear Power Plant.
a.
Background
CPC-Midland Nuclear Power Plant notified Region III of tne U.S. Nuclear Regulatory Commission by letter dated February 13, 1981, of a defective item reportable under para-graph 50.55(e) of 10 CFR Part 50.
The letter states an investigation revealed that eight out of 18 LC valve operators had MSP Series 100, Clinch Jones Series 140, or Beau Products terminal blocks, which are underrated for 460 volt service.
b.
Findings A newly hired LC Field Service Engineer from the Willowbrook, Illinois, Service Center arrived at the CPC Midland Nuclear Power Plant on November 21, 1977, to make architect-engineer requested field changes of the terminal blocks on LC valve cperators.
The change requested was the replacement of five i
terminal blocks on 71 valve operators.
The architect-engineer l
had requested the change to permit one vacant terminal between l
the three 460 volt terminals connected to the motor and the I
two 120 volt terminals connected to the motor heater.
Some of the motorized valve operators were modified at the Henry Pratt Company.
The LC Lynchburg plant shipped 66 MSP 300 Series terminal blocks to the LC Willowbrook Service Center on l
November 16, 1977.
Some of the terminal blocks were damaged in shipment, so an additional 20 Clinch Jones Series 140 terminal blocks were shipped on November 28, 1977; however, these terminal blocks could only be used in 120 volt i
control circuits and not the 460 volt power circuits.
LC stated in their letter of January 21, 1981, to CPC that, "The field service engineer that performed the required terminal strip changes was a new employee and did not I
know at the time that the Clinch Jones terminal strips l
were not adequate to be used for power connections."
l i
l
ORGANIZATION:
LIMITORQUE CORPORATION LYNCH 8URG, VIRGINIA RtPORT itor tt. i t ua NO.
99900100/82-02 RESULTS:
PAGE 8 of 8 At LC:s request terminal blocks were removed from several installed valve operators, and in addition to finding Clinch Jones Series 140 terminal blocks installed, a terminal block which appeared to be an MSP Series 100 was found installed on a valve operator supplied on LC Order 3A2337-B.
LC examined their records and could not find any record where they had purchased MSP 100 Series terminal blocks, and therefore, concluded that it was possible that the inex-perienced LC field service engineer obtained this terminal block locally at the job site.
The inspector reviewed one LC letter, one service call report, two lists of LC motorized valve operators, two shipping lists, one customer order acknowledgement and one shipping memo.
One nonconformance was identified.
c.
Item Requiring Follow up Inspection - Section 1 of the LC Quality Assurance Manual states that it is the intent of the manual with its supporting procedures to meet the applicable provision of Appendix 8 to 10 CFR Part 50.
Criterion I of Appendix 8 requires the individuals assigned the responsibility for assuring effective execution of any portion of the quality assurance program to have direct access to such levels of management as necessary to perform this function.
The Quality Assurance Manual splits the authority and responsibility for the imple-mentation and enforcement of the quality assurance program between the Quality Assurance Administration, who reports to the Vice President Admimistration, and the Quality Control Manager, who reports to the Plant Manager.
There are no documented lines of communication between the Quality Assurance Administration and the Quality Control Manager.
A detailed evaluation of the l
LC organization will be made at a subsequent inspection, in order to assure compliance with Criterion I of Appendix B to l
10 CFR Part 50, with respect to plant quality personnel having required auchority and organizational freedom.
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