ML20054M588
| ML20054M588 | |
| Person / Time | |
|---|---|
| Issue date: | 06/11/1982 |
| From: | Barnes I, Sutton J NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML20054M583 | List: |
| References | |
| REF-QA-99900289 NUDOCS 8207130642 | |
| Download: ML20054M588 (14) | |
Text
.
ORGANIZATION:
NUCLEAR VALVE DIVISION BORG WARNER CORPORATION VAN NUYS, CALIFORNIA ntP0H1 INSPECTION INSPECTION NO.:
99900289/82-01 DATE(S) 3/22-25/82 ON-SITE HOURS: 56 CORRESPONDENCE ADDRESS:
Nuclear Valve Division Borg Warner Corporation ATTN:
Mr. A. L. DuBrow, President / General Manager 7500 Tyrone Avenue Van Nuys, CA 91409 ORGANIZATIONAL CONTACT:
Mr. P. L. Milinazzo, Manager, Quality Assurance TELEPHONE NUMBER:
(213) 781-4000 PRINCIPAL PRODUCT: Nuclear Valves.
NUCLEAR INDUSTRY ACTIVITY: Commercial nuclear production of the Nuclear Valve Division of Borg Warner Corporation totals 50% of company production.
ASSIGNED INSPECTOR:
f l -II E l-on,ReactivegComponentProgramSection Date J.
OTHER INSPECTOR (S): W. D. Kelley, R& CPS APPROVED BY:
\\.
!h 4-/I 82 I, Banes, Chief,R&CQl Date INSPECTION BASES AND SCOPE:
A.
BASES:
B.
SCOPE:
This inspection was made as a result of the identification by:
(1) Duke Power Company of internal binding in 8-inch gate valves furnished to Catawba 1 and 2; and by (2) Tennessee Valley Authority concerning the specification on a Borg Warner drawing of excessive bolt torque for a flow control valve furnished to Bellefonte 1 and 2.
Additional areas included in the inspection were fcllowup on identified low torque values in bonnet to (cont. on next page)
PLANT SITE APPLICABILITY:
DESIGHTED ORIGINAL 50-413/414; 50-438/439.
\\
certified B7-8207130642 820614 PDR GA999 EMVBORG l
99900289 PDR
ORGANIZATION:
NUCLEAR VALVE DIVISION BORG WARNER CORPORATION VAN NUYS, CALIFORNIA REPORT INSPECTION NO..
99900289/82-01 RESULTS:
PAGE 2 of 7 SCOPE:
(cont.) body studs / nuts at Bellefonte 1 and 2, status of previous inspection findings, nonconformance/ corrective action, manufacturing process control / machining, and design control.
A.
VIOLATIONS:
None B.
NONCONFORMANCES:
Contrary to Criterion V of Appendix B to 10 CFR Part 50 and paragraph 3.5.3, in Section 3 of the Nuclear Products Quality Assurance Manual, required design changes were not made in the preparation of Drawing No. 80590 (12-inch,1500 pound, motor-operated gate valve) from Drav ing No. 80600 (14-inch, 1533 pound, motor-operated gate valve), as evidenced by the failure to reduce the 500 to 550 foot pound torque requirement listed by Drawing No. 80600, on changing the stud diameter to 3/4-inch from 1\\-inch.
C.
UNRESOLVED ITEMS:
During review of the identified problem concerning low bolting torque values in valves furnished to Bellefonte, the NRC inspector established that the Borg Warner Nuclear Valve Divisic.7 (BW-hv'D) nad used a minimum design seating stress of 4500 psi for spiral wound metal-asbestos filled l
This value was consistent with the requirements of the contrac-tually applicable Code (Winter 1975 Addenda), but was noted to have been subsequently raised to 10,000 psi by the Winter 1976 Addenda.
Paragraph 2.4.7 of Section 2 of the QA Manual requires the QA Manager to review new Code Addenda to maintain the adequacy of the QA Program Manual, but does not address how code changes in engineering requirements would be reviewed and incorporated into the QA program.
The NRC inspector was informed that the Engineering Department performed a review of new Code Addenda, but this was accomplished only on a verbal basis.
Insufficient time was available to verify that the Engineering Department was incorporating changes in code requirements into design criteria.
This subject and l
the specific example of change in design seating stress will be reviewed l
at the next scheduled inspection.
l
ORGANIZATION:
NUCLEAR VALVE DIVI 3 ION BORG WARNER CORPORATION VAN NUYS, CALIFORNIA REPORT INSPECTION NO.:
99900289/82-01 RESULTS:
PAGE 3 of 7 D.
STATUS OF PREVIOUS INSPECTION FINDINGS:
1.
(Closed) Nonconformance 1 (Report No. 81-02):
Welder observed not maintaining electrical characteristics specified in approved welding procedures during valve hardfacing operations.
The inspector reviewed the corrective action taken by NVD to correct this item.
The revised welding procedure, qualification of the revised procedure and documentation of welders' training were reviewed to substantiate the corrective action.
2.
(Closed) Nonconformance 2 (Report No. 81-02):
Special Review Board for 10 CFR Part 21 was not convened to review reported Part 50.55(e) report by Duke Power Company as required by the QAM.
The inspector reviewed the revised organizational changes which NVD indicated in their response of January 4, 1982, would prevent recurrence of an item of this type.
The inspector concurs that the organizational change made by NVD will prevent recurrence.
E.
OTHER FINDINGS OR COMMENTS:
1.
Duke Power Company (DPC):
Catawba Nuclear Station, Units 1 and 2 -
Problem reported was inoperability of 8-inch gate valves used for isola-tion of the essential from nonessential loads, due to internal binding.
a.
Background
DPC notified the NRC on July 1, 1981, that BW-NVD Valve 1KC230 failed during dry cycling due to the valve disc becoming wedged between the body guides.
The problem was subsequently identifiea to result from sharp leading edges on the gate guides producing gouging, and was established by testing to be liable to occur with the valve installed in a system with the stem between 22h and 157 from vertical.
This subject was initially followed up at BW-NVD during the October 5-9, 1981, inspection (Report No. 99900289/81-02).
ORGANIZATION:
NUCLEAR VALVE DIVISION BORG WARNER CORPORATION VAN NUYS, CALIFORNIA REPORT INSPECTION NO.:
99900289/82-01 RESULTS:
PAGE 4 of 7 b.
Findings The NRC inspected the gate valve used in the operability test of the valve in various positions in a horizontal pipe line.
The square edges of the guide groove in the gate had been ground to assure a generous radii.
The inspector reviewed the opera-bility test data of the valve with the modified gate in a vertical pipe line.
The test data verified no binding during operation.
BW-NVD has received answers from their customers regarding the installed position of the valves in service; however, some of the valve's positions were assumed from information taken from the piping and instrumentation drawing.
This item will be further reviewed during a followup inspection.
2.
Tennessee Valley Authority (TVA) - Bellefonte Nuclear Plant, Units 1 and 2 - Problem reported was improper torquing of valve body to bonnet studs.
a.
Background
TVA notified BW-NVD by TLX dated January 6,1982, that their field forces had found the body to bonnet studs torqued to values less than the torque specified on the BW-NVD assembly drawings.
TVA stated that the cause of the deficiency could De due to TVA's construction forces dismantling the valves and their failure to properly torque the studs during reassembly; however, valves stored in the site warehouse were uncrated, torque checked, and found to be deficient.
TVA informed BW-NVD that this nonconformance had been evaluated as a significant co9dition and had been reported to the NRC under both 10 CFR Part 50.55(e) and 10 CFR Part 21.
b.
Findings Paragraph 10.0 of TVA Contract 77K38-86163-8, dated July 7, 1976, states in part, "The edition, revision and/or addenda in effect when the contract is awarded shall apply unless I
later revisions are agreed by both parties." BW-NVD designed l
their valves for this purchase order in accordance with 1975 Winter Addendum of Section III to the ASME Code. Table i
l XI-3221.1-1, Appendix XI of Section III states that the mini-mum design seating stress (y) for spiral wound metal-asbestos l
filled gaskets is 4500 psi; however, the 1976 Winter Addendum subsequently raised this minimum design seating stress to 10,000 psi.
t
ORGANIZATION:
NUCLEAR VALVE DIVISION BORG WARNER CORPORATION VAN NUYS, CALIFORNIA REPORT INSPECTION NO.-
99900289/82-01 RESULTS:
PAGE 5 of 7 After BW-NVD received TVA's TLX 910-495-1726 dated January 6, 1982, they contacted the gasket manufacturer, who recommended that a design seating factor of 15,000 psi be used for their spiral wound metal-asbestos filled gaskets.
BW-NVD reviewed the design of the body to bonnet bolting of their 150 and 300 pound class check and gate valves, and determined that the bolting met ASME Code requirements with the higher gasket seating factor; however, the torque values had to be increased.
BW-NVD's 10 CFR Part 21 Review Board Committee convened on February 16, 1982, and concurred with the engineering analyses that the low torque condition was a result of the valve body /
bonnet gasket having taken a permanent set during storage, thus, reducing the gasket load on the studs and nuts and contributing to the low torque condition.
BW-NVD evaluated the low torque condition as not being ".
a defect which could create a substantial safety hazard...."; therefore, a report was not made to NRC by BW-NVD.
As a result of the BW-NVD engineering analyses of the reported condition, all torque values of the bolted bonnet valves were revised to exceed the current ASME Code requirements and meet the gasket manufacturer's recommendation, in order to reduce the j
effects of " gasket set" that could occur after shop hydro-l static test and storage on site.
Presently, all customers l
who have purchased bolted bonnet valves have been notified of the new torque recommendation for their valves and the torque valves on all assembly drawing are to be corrected and approved, and the revised assembly drawing sent to the customers.
3.
Tennessee Valley Authority: Bellefonte Nuclear Plant Unit 1 & 2 - Problem reported was excessive torque specified on 8W-NVD drawing for the studs affixing the adapter to the yoke of a residual heat removal isolation valve.
a.
Background
i TVA notified NRC on January 5,1982, that during torquing in the field of the bolting for assembly of the motor operator adaptor to the yoke of a Bellefonte Nuclear Plant residual heat removal isolation valve, the 3/4-inch bolts became overstressed.
ORGANIZATION:
NUCLEAR VALVE DIVISION BORG WARNER CORPORATION VAN NUYS, CALIFORNIA REPORT INSPECTION N0.:
99900289/82-01 RESULTS:
PAGE 6 of 7 The BW-NVD assembly drawing number 80590 stated the torque for these bolts should be in the 500-550 foot pound range.
TVA contacted BW-NVD and was informed that the drawing was in error, with the correct torque being in the 120 to 140 foot pound range.
b.
Findings BW-NVD Drawing Number 80590 for the TVA Bellefonte Nuclear Plant, Units 1 and 2, 12-inch, 1500 pound, motor-operated gate valves was made by reproducing the mylar master of Drawing No. 80600 for a 14-inch, 1533 pound, motor-operated gate valve.
Drawing 80600, Revision F, requires eight 1h-inch ASTM A564, Type 630, studs (Item 30) torqued to 500 to 550 foot pounds, to affix the adaptor (Item 18) to the yoke (Item 15).
When the repro-duction was modified to meet the design requirements for the 12-inch, 1500 pound gate valve, the size of the studs was changed to 3/4-inch diameter, but note 32 on the drawing which specified the torque was not changed.
Subsequent to the notification by TVA that the studs were over-torqued, BW-NVD QA informed engineering of the problem.
The project engineer reviewed the drawing, noted and revised the torque requirement on Drawing No. 80590 on October 15, 1981, instituted a computerized check for all customers that had received 1500 pound gate valves, and verified that the correct torque values were specified on all assembly drawings except drawing number 80590.
One nonconformance was identified.
4.
Design Control - Reviewed three sections of the QA Manual, three drawings, the analysis report for the hydraulic modulating operator, one system description, four schematic diagrams, and the qualification test procedure for a pneumatic-hydraulic modulating operator.
Verified procedures had been implemented to control review, approval, release and issuance of design documents.
5.
Nonconformance/ Corrective Action - The inspector reviewed NVD's QA Manual Section 15-16, 13 material review reports, 15 material group tickets, and associated documentation to determine compliance to QA/QC requirements / procedures.
The corrective action taken to prevent recurrence was examined for implementation.
Segregation
ORGANIZATION:
NUCLEAR VALVE DIVISION BORG WARNEii CORPORATION VAN NUYS, CALIFORNIA REPORT INSPECTION NO.-
99900289/82-01 RESULTS:
PAGE 7 of 7 areas designated for storage of nonconforming items were inspected.
Relative to the documents examined, the inspector determined that activities relating to the control and disposition of nonconforming items complied with NVD's QA/QC program requirements.
6.
Manufacturing Process Control - The inspector reviewed NVD's QA Manual Section 9, 13 machine drawings, 9 shop outlines, 2 manufac-turing outlines, and associated documentation to determine if designated controls of the machining operations were being implemented.
The inspector also observed machining operations on 10 production machines.
As a result of this review, the inspector determined that the machining operations of NVD were being controlled as required by QA/QC requirements.
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