ML20076N225

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Part 21 Rept Re Valve Seat Defect.Initially Reported on 830620.Risk of Seat Cracking Could Occur Under Torque. Bechtel Analysis Underway
ML20076N225
Person / Time
Site: Wolf Creek, Callaway, 05000000
Issue date: 06/21/1983
From: Barclay J
YARWAY CORP.
To: Gallo R
NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I)
Shared Package
ML20076N190 List:
References
REF-PT21-83-924-000 PT21-83-924, PT21-83-924-000, NUDOCS 8307210229
Download: ML20076N225 (11)


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June 21, 1983

. Nuclear Regulatory Commission Region 1 631 Park Avenue King of Prussia, PA 19406 Attention:

Mr. Robert Gallo

Reference:

Phone notification of. June 20, 1983 -

Re valve seat defect reportable under 10CFR21 Gentlemen:

Attached please find an analysis report dated May 26, 1983 made on twelve (12) 1-1/2" stainless steel Hydrop valves returned by Bechtel Power Corporation from Union Electric l

Company.- Calloway site.

As the report indicates that a risk of seat cracking could occur under torque Bechtel agreed to investigate based on application,reportability under 10CFR21.

A meeting was held at Yarway Corporation, Blue Bell, PA, June 14, 1983 attended by representatives of Yarway, Bechtel, Union Electric and Kansas Gas and Electric.

Agreement was reached that a) a visual-seat inspection would be made of all valves on the, sites to determine any further cracked seats b) as Hydrop valves are designed and used for throttling and not as stop valves, a stop collar would be installed on the stem to limit.the. applied torque c)

Bechtel would inform Yarway of reportability when their analysis was complete.

Yarway was informed by phone June 17, 1983 that Bechtel Engineering had determined that the cracked seats consti-tuted a significant reportable deficiency. ' Attached is a copy of the. telex received'on June 20, 1983 which is a summary of the information supplied by Bechtel to Regions

'3 and 4 of the NRC.

'0307210229 B30705 PDR ADOCK 05000482 S

PDR YARWAY CORPORATION," BLUE BELL, PENNSYLVANIA'19422, PHONE: (215) 825-2100. CABLE: YARWAY, TELEX: 844450

vuuaway Nuclear Regulatory Commission June 21, 1983 Page Two i

The. valves in question are unique in that they; a) were constructed using special SA 182 F316 bodies for the SNUPPS project b) were only supplied to two sites thirty-five (35) each 1-1/2" size to Calloway, Union Electric and Wolf Creek, Kansas Gas and Electric.

If any further information is required please contact W. A. Volger or R. G. Chew, Yarway Corporation.

Very truly yours, J. F. Barclay Vice President and General Manager North America Operations JFB:dbg Attachments cc:

J. Kroehler, Jr.

Project, Q.A. Mgr.

Bechtel Power Corp.

15740 Shady Grove Rd.

Gaithersburg, Maryland 20877-1454

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YaR.WEY May 26, 1983 BECHTEL POWER CORPORATION 15740 Shady Grove Road Gaithersburg, Maryland 20760 Attention:

Mr. Joseph Smith Project Engineering Manager Gentlemen:

Ref:

SNUPPS Project, Bechtel Job 10466 Purchase Order 10466-M-231B-1, 2 Subi:

Reporting of Defects per 10CFR21 This letter and its attached report confirm YARWAY's verbal defect notification given to J. Smith by Paul Abbott and-William Volger during a conference call placed at 1:55 pm on

~

May 13, 1983.

The reported defect involves cracking of seats in twelve (12)

Hy-drop Throttling Valves, and is explained in detail in the attached report.

Only the Union Electric, Calloway Site has reported this problem with the following /items affected..

P.O. ITEM NO.-

SERIAL NO(s)

VALVE PART NO.

14.04 B6586, B6587, B6589 105834-06 14.06 B6594', B6595 105834-08 17.01 B6546, B6547, B6550, B6551 105834-04 i

17'.02 B6568, B6569, B6570 105834-05 Since YARWAY does not know the exact location or use of its

'Hy-drop Thrcttling Valves in the plant design, we cannot evaluate.

whether a substantial safety hazard would exist in the event of i

product failure.

Therefore, it was agreed that Bechtel,would l

determine the reportability under 10CFR21 I

p Yanway compoaAnON. BLUE DELL PENNSYLVANIA 19422. PHONE. (215) 852100. CA8LE: YA=WAY. TELEX-844450

- - - - - - - - - ~ - - - - - - - - -

vanwar Bschtal Powar Corporation SNUPPS Project, Bechtel Job 10466 Page two We appreciate your assistance.

Sincerely, YARWAY CORPORATION

. W $'

Paul F. Abbott, Supervisor Customer Engineering & Services PFA:ds cc: J. F..Barclay-D. J. Dillenback P. C. Neumann G.-Loos W. A. volger y T. Toter

.. G. Chew I

J. Paptzun J. R. Vogel

. R. Jones N. Blagbrough b

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REPORT

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ON SNUPPS PROJECT 1 " HYDROP VALVE FAILURES 7

SERIAL # 6546-4)l, 50,' 51, 68-70, 86-88, 94-95 Material Analysis Team - G. Paptzun, Product Development Engineer W. Volger, Manager, Q. A. Systems W. Toter, Welding Engineer SCOPE:

Twelve 1\\" stainless steel Hydrop valves were examined in an attempt to isolate the cause of cracks found in the seating areas.

All seats ex-amined exhibited cracks. Two typical fracture surfaces examined micro-scopically revealed.a cleavage, stress type fracture.

All valves revealed insufficient. braze behind the seat area. The exact cause for the in-sufficient braze and the exact relationship between the insufficient braze and the stress type fractures has not been determined at this time.

ther evaluation is continuing.

It is recosamended that a torque test and Fur-visual examination be performed in the field to all stainless steel Hydrops with seat pt. nos. 952097. In addition, all valves in batch 991-A must be returned as the wrong filler metal groove was used in that batch brazing operation.

It is recommended that the customer be supplied the serial numbers of the suspect valves in batch 991-A.

DISCUSSION:

Sectioning of the tweIve valves revealed that all seats had cracks.

Cracking varied from,one up to four occurrences in any one seat.

All cracks ran lon-gitudinally, none extended through the entire length of the seat.

Two seats were sectioned twice per Figure 1(B) for detailed analysis of the crack surface.

Sectioning on each side of the fracture showed no evidence of braze on the seating, side of the filler metal void.

These sections were removed and the fracture surfaces were examined at various magnifications up to 200X.

The cracks were cleavage in nature.

The surface exhibited a woody structure -

(typical of the Stellite #6 casting) with the initiation sites on the outside diameter of'the ring.

See Figure 2A. 'lhis indicates that failure occurred due. to stress from the mating seat surfaces.

Theoretical values for deter-mining fracture force to cause a seat supported below the filler groove to fail can be-estimated.

This estimates to a torque value of 46 ft.-lbs. for seat groove 952097, Rev. A, and 63 ft.-lbs. for seat groove 952097, Rev.

The fracture surfaces revealed no other significant indications which -

none.

would have contributed to the failure.

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l liardness readings were taken on the seat castings and the stainicss steel body, and revealed no unusual results. The hardness readings were as follows:

q Body Rb 73 Casting Rc 45 The most significant find was the lack of braze behind the seats in the areas that failed.

In addition, there is no evidence of braze at the top of the Third, two styles of filler grooves were uncovered.

seats.

1.ack of braze behind the seats can be a symptom of many conditions.

F.xcessive joint clearance, insufficient braze material, improper braze treatment, poor surface condition, or defective braze material could be possible reasons for this condition.

No conclusions can be reached at this time.An investigation of the items above is t

The fact that two styles of filler grooves in the seat castings were un-covered is easily traceable.

Valves with serial numbers were brazed in lot 589-A on the 31st of January,1[80.668-70,(86-88, 6594-95 3

These valves were brazed in accordance with Dwg. 103909, Rev. none, as specified by 955001-07, Rev. none. n ese contained the seat, Part Number 952097, Rev. A,.

with the filler groove at the top for brazing with the seat in the p position. However, valves - serial numbers 6546, 6550, and 6551%ei-7 brazed in lot 991-A on the 5th of March,1982. 'These valves were brazed to 103909, Rev. none, as specified by Dwg. 955001-07 Rev. none. These contained the seat part number 952097, Rev. 8, with the filler groove at the bottom for brazing to 103909; Rev. A.

His revision of 103909 calls for brazing in the inverted position. These seats should not have been applied to the valves brazed in the upright position in batch 991-A.

The part drawings were revised; the control plan was not.

It should be noted that both seats, with groove locations for brazing in the inverted or the upright position, failed to allow the braze to flow up and support the seat.- Groove location did not seem to have any relationship to the lack of braze.

Each seat casting, however, was brazed tight below the filler metal groove. This would indicate that brazing in the inverted position would correct this problem, as the capillary flow would be assisted by gravity.

The fact remains, however, that braze is not evident on the failed valves at the top of the seat. This is. indicative of a'possible problem. However, it should be noted that it is very difficult to detect, with the naked eye, if braze is evident or not.

The radius corner on the upper bore diameter can deceivingly appear to be braze material when, in fact, it is not.

In addition, not seeing braze material with the naked eye from the top,. does not always indicate that there is no braze present. The converse, however, does apply. When a reservoir of braze is evidet at the top of the seat, we can be sure that braze material is present.

To check this, bodies were pulled from existing stock; again, a reservoir of braze was not always evident at the top of the seat. However, getting a ' clear picture of this requires that the braze be sectioned and examined.

One body, brazed to 103909, Rev. B (inverted position) was assembled and torqued to 110 ft.-lbs.

The seat cracked at 80 ft.-lbs. Sectioning re-vealed that the braze was not 100% behind the seat. A similar body was pulled which showed a reservoir of braze at the top of the seat. His was torqued to 120 ft.-lbs. (yield limit of the stem) and did not crack the seat.

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"l RESULTS:

As can be observed from the twelve valves received, and from the prelim-inary investigation of the bra:ing procedure and seat strength, bodies which do not exhibit a reservoir of braze at the top of the joint run :

some risk of not having bra:e behind the seat ring.

Bodies without braze behind the seat run a risk of cracking under torque.

The evidence has clearly indicated that the valves have passed visual and hydro inspection withur clear evidence of brase at the top of,the seat.

Thus, all stainless steel Hydrop valves with this seat design may be subject to the potential cracking preblem. Fractures of this nature would only re-sult in valve leakage and would not violate the integrity of the contain-It is therefore recommended that all stainless steel Hydrop valves ment.

be checked by a torque test and visual inspection to assure sufficient braze behind the seat ring. This will avoid service failures. Valves brazed in batch 991-A should be returned as the rings used in this batch violate the limitations of overlap for. vertical upflow qualified for Bra ing Procedure Specification 103909, Rev. none.

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Manager, Product Development Power Products and Processes T

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Manager, Quality Assurance Systems Ik Bill Toter Welding Engineer l

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. VALVES HAVING CRACKED SEATSEYARWAYM' ETTER uTOTBECHTEL', T" DATED..

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! C OPERATION.. INSPECTION-OF.',THE" FAILED VAL 9ES;.REVEALEIT:1983 DESCR l

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THAT THE ACCEPTANCE l CRITERIA 'OF.' THE? BRAZINGi PR,0CEDURE"HAD"NO.T

BEEN SATISFIED. THE VALVE SEAT IS. MADE FROM: A. SINTERED. STELLITE "--

' MATERIAL THAT IS EXTREMELY.:HARD AND BR.ITTLEi'.A'D THE.1O:,M..).

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-SEAL INJECTION LINE. SEVERAL OTHERS WERE IN THE REACTOR COOLANT SAFETY INJECTION LINES. THE VALVES ARE, SET TO PROVIDE A PREDETERMINED FLOW RATE AND'ARE NOT USED FOR SHUTOFF.

IF THE DAMAGED VALVES HAD NOT BEEN DISCOVERED, FLOW INDUCED VIBRATION COULD HAVE CAUSED THE CRACKS TO PROPAGATE.

ULTIMATELY, PIECES OE THE BRITTLE SEAT MATERIAL COULD BREAK LCOSE WITH THE FOLLOWING RESULTS:

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