ML20127N091

QA Program Insp Rept 99900289/85-01 on 850326-28.No Noncompliance Noted.Major Areas Inspected:Licensee & Vendor Interface Into Collection,Followup on Part 21 Repts & Status of Previous Insp Findings

ML20127N091
Person / Time
Issue date:	05/15/1985
From:	Merschoff E, Oller R NRC OFFICE OF INSPECTION & ENFORCEMENT (IE)
To:
Shared Package
ML20127N011	List: ML20127N007 ML20127N091
References
REF-QA-99900289 NUDOCS 8505230435
Download: ML20127N091 (14)

Text

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ORGANIZATION: BORG MARNER CORPORATION NUCLEAR VALVE DIVISION VAN NUYS, CALIFORNIA REPORT INSPECTION INSPECTION NO.: 99900289/85-01 DATE(S): 3/26-28/85 ON-SITE HOURS: 48 CORRESPONDENCE ADDRESS: Borg Warner Corporation Nuclear Valve Division '

ATTN: Ms. Norma Moore, Manager, Quality Engineering 7500 Tyrone Avenue, P. O. Box 2185 Van Nuys, California 91409 ORGANIZATIONAL CONTACT: Norma Moore, Manager, Quality Engineering TELEPHONE NUMBER: (818) 781-4000 PRINCIPAL PRODUCT: Nuclear valves and hydraulic valve operators.

NUCLEAR INDUSTRY ACTIVITY: Approximately 30%.

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ASSIGNED INSPECTOR: ((N/ s'//s/as-p;a.R.E.OllergeactiveInspectionSection(RIS) hte OTHER INSPECTOR (S): L. Vaughan, Program C; rdination Section APPROVED BY: 5 Ir[Pr-E. W. Merschoff ief, RIS, Vendor Program Branch Date INSPECTION BASES AND SCOPE:

A. BASES: 10 CFR Part 21 and Appendix B to 10 CFR Part 50.

B. SCOPE: The purpose of this inspection was to collect licensee and vendor interface information with regard to valve operation and main-tenance manuals and 10 CFR Part 21 notifications to customers.

Additionally, a followup was performed on a Borg Warner Nuclear Valve Division (BW-NVD) 10 CFR Part 21 report concerning Perry Station; a Bellefonte 50.55(e) report; a Comanche Peak 50.55(e) report and the status of previous inspection findinas.

PLANT SITE APPLICABILITY: As identified in this report.

8505230435 050521 PDR GA999 ENVBORO 99900289 PDR

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ORGANIZATION: BORG WARNER CORPORATION NUCLEAR VALVE DIVISION VAN NUYS, CALIFORNIA REPORT INSPECTION NO.: 99900289/85-01 RESULTS: PAGE 2 of 14 A. Subjects Inspected:

1. Collection of: (a) operation and maintenance manuals (OMM),

information for safety related valves (SRV), and/or valve operators (V0) shipped to various nuclear power plants (NPP) during the period of 1977 through 1984, and (b) identification of 10 CFR Part 21 notification letters to NPPs concerning potential generic deficiencies.

2. Potential gate valve guide problem at Perry NPP.

3. Over-torquing of valve motor operator studs at Bellefonte NPP.

4. Check valve malfunction due to broken tack welds at Comanche Peak NPP.

5. Status of previous inspection findings.

B. Supplementary Information:

Borg Warner, Nuclear Valve Division located in Van Nuys, California, manufactures nuclear valves and hydraulic valve operators for the nuclear industry. They hold ASME N and NPT type authorizations for this location.

C. Inspection Details:

1. The collection of information concerning OMMs furnished with SRV and V0 to various NPPs was accomplished by selecting SRVs and V0s for each plant site identified in the OMM log for the period of 1977 thr.ough 1984.

The information needed to identify NPP sites, OMMs and valves is '

shown in the following Table A.

4 ORGANIZATION: BORG WARNER CORPORATION NUCLEAR VALVE DIVISION VAN NUYS, CALIFORNIA REPORT INSPECTION NO.: 99900289/85-01 RESULTS: PAGE 3 of 14 TABLE A BW-NVD OPERATION AND MAINTENANCE MANUALS Project OMM No. Item Description Tag and Other I.D. Nos.

Arkansas Nuclear 1063 2" C.S., M.0., Tag Nos. 2"-CBA-GB-MO ,

One - Unit 2 Y-Globe Valve CV2815-ANO-1, 2"-CBA-GB-M0-CV2816-ANO-1 Beaver Valley 2099 16"x10"x16", 900 LB., Tag Nos. 2 FWS-HYV 157A, Unit 1 C.S. FW. Iso. Valve B and C Bellefonte 2227 6" & 10", LP, CS & TVA Mark No.

S.S. Globe Valve 3 AWO412-ND-60 3 AWO416-NS-20 3 BWO456-KC-45 Byron /Braidwood 2023 16"x10"x16", 900 LB., Tag Nos. 1FWOO9A,-8,&C; Units 1 and 2 C.S. FW. Iso. Valve 2FWOO9A,-8,&C Catawba 2239 2", 1635 LB., 5 S Duke It. No. 9J-244 Gate Valve, Air List No. CN-1500-10 Op., Fail Close. Order No. A98528.

Comanche Peak 2337 4", 300 LB., S.S. Tag Nos. 1FP-591; Units 1 and 2 Gate Valve, M.0. 1FP-592; 2FP-449, 2FP-450; Type No.

4G B1605 BHMO.

Ginna 1082 2"-Y Type, C.S. P.O. 73622-1302 Lift Check Valve Valve I.D. No. V-5 Valve Item V-5 Grand Gulf 1086 1/2 thru 2 inch Bechtel P.O. 9645-M Station S.S. & C.S., M.0. -250.2 Y-Type Globe Valves Limerick Station 1036 1-1/2 & 2 inch, ID No. 1-1/2-CCD-GB Units 1 and 2 Y-Type Globe Valve, ID No. 2-CCD-GB S.S.

l 1

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ORGANIZATION: BORG WARNER CORPORATION NUCLEAR VALVE DIVISION VAN NUYS, CALIFORNIA REPORT INSPECTION NO.: 99900289/85-01 RESULTS: PAGE 4 of 14 TABLE A (Continued)

Project OMM No. Item Description Tag and Other I.D. Nos.

I McGuire Station 2246 4", 1500 LB, C.S., Item 6H-102, Gate Valve, M.0. List No. MC-900-12 Order No. A98513 Monticello 2232 1 " & 2"; 1500 LB., Tag No. 2"-CCA-GB-AO-Station S.S. Globe Valve ZS-1 through -4; Air Op. Tag No. 1"-CCA-GB-AO-ZS-1 through -4.

Nine Mile Point 2187 2", 1500 LB., C.S. Tag Nos. 44.2-15; Unit 1 Globe Valve Air 44.2-16; 44.2-17, Op. 44.2-Spare; and 44.2-Spare Oconee Station 2078 4" & 8", LP, S.S. & Duke Item 28-468; C.S. Gate Valves, and 58-266;

' M.0. List Nos. CN-0150-12 and CN-0150-10; Order Nos. A98521 and A98528.

Palo Verde 2346 6", 1500 LB, S.S. Tag Nos. RC130 and Globe Valve, M.0. RC131.

PASNY 2207 1", 150 LB., C. & Unique No. WLD-MOV-505 S. Gate Valve, M.0.

Perry Units 2010 28", 900 LB, M.0. Tag Nos. RNN229 and 1 and 2 Gate Valve RNN268.

Pilgrim Station 2364 1", HP, Diaphragm Tag No. 1-CCC-YGB-S-Unit 1 Y-Type Globe, (R, S)

Valve, S. S.

Rancho Seco 2340 2", 1500 LB, Lift Tag Nos. V2167; V2168; Check, Valve, S. S. V2169 and V2556 l

ORGANIZATION: BORG WARNER CORPORATION

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NUCLEAR VALVE DIVISION VAN NUYS, CALIFORNIA REPORT INSPECTION NO.: 99900289/85-01 RESULTS: PAGE 5 of 14 TABLE A (Continued)

Project OMM No. Item Description Tag and Other I.D. Nos.

Seabrook 2027 18", 900 LB, C.S. Tag Nos.1FW30, -30, Units 1 and 2 FW, Iso. Valve -48, -57 and 2FW30,

-39, -48, -57.

Shearon Harris 2026 16", 921 LB, C.S. Tag Nos. 2FW275AB-1, Units 1-4 Gate, Valve 2FW285- AB-1,-2 Hydraulic Operator 2FW27S- AB-2,-3 2FW285-AB-3,-4 2FW27S-AB-4 2 FW265- AB-1,-2,- 3,-4.

SNUPP 2086 1", 1500 LB, C.S., Bechtel Tag No.

Callaway and Gate Valve, M.0. 1-CBC-GTE-Q-W-MA-K Wolf Creek -

South Texas 1074 1-1/2" C.S. Gate Tag Nos. 01-1/GH22SS3 Project Valves -ABC; 01-1/2 GH25SS3 Units 1 and 2 -ABC; 01-1/2 GH25SS3A-C St. Lucie 1043 3", S.S., Gate Valve Item No. 9; Unit 2 Tag Nos. V-1441,-2,-3,

-4 Code No. 31-14-55-0622 Susquehanna 1042 2", S.S., M.0., Item Nos. 29.1.1 and Units 1 and 2 Y-Type Globe 29.2.1 Valve Equip. Nos.

2-CCA-GB-MO-FV-12603-P 2-CCA-GB-M0-FV-22603-P Vogtle Project 2372 Electro-Hydraulic Fisher Controls /

1C Operator Bechtel P.O. No.

S181972 WPPSS Unit 2 2345 3", 150 LB, C.S. Tag Nos. FDR-V-219, Gate Valve, Air -220, -221, -222, Op., Fail Close -394, -395

i ORGANIZATION: BORG WARNER CORPORATION

, NUCLEAR VALVE DIVISION VAN NUYS, CALIFORNIA REPORT INSPECTION NO.: 99900289/85-01 RESULTS: PAGE 6 of 14 l

2. Collection of information also included customer notification ,

letters sent by BW-NVD, concerning 10 CFR Part 21 reports in which  !

the potential defects were generic to several NPPs. Review of seven 10 CFR Part 21 reports identified four which were generic in nature.

These reports are identified in the following Table B.

TABLE B 10 CFR PART 21 CUSTOMER NOTIFICATIONS BY BW-NVD Report Date Customer / Site Valve ID Deficiency 2/7/80 Duke Power / Tag Nos. 9J-239, Qty 6 Inadequate gate guides Catawba / and 9J-221, Qty 6 in valve under test McGuire at Duke Power. Needs rework.

Bechtel/ Tag No. ACA-GT-M0 Same Arkansas -2CV4698-1-PL, and Nuclear One 3ACA-GT-M0-2CV4697-2-PL Unit 2 TVA/Bellefonte Tag No. 38WO456-K-30 Same Qty. 16.

Combustion Tag Nos. SI604 and Same Engineering / SI609, Qty. 4.

Palo Verde 5/23/80 WSH/B0 ECON / Serial Numbers: Stem nuts or extensions GERI/WPPS-2 26210 thru 26216, may become loose 22337 thru 22339, during operation of 22355, 26727, and valve. Needs stem 35653 thru 35656 modification and staking.

l ORGANIZATION: BORG WARNER CORPORATION NUCLEAR VALVE DIVISION VAN NUYS, CALIFORNIA REPORT INSPECTION l NO.: 99900289/85-01 RESULTS: PAGE 7 of 14 TABLE B (Continued)

Report Date Customer / Site Valve ID Deficiency Combustion Unit #1 - Qty 20 Same Engineering / - Unit #2 - Qty 17 Palo Verde Unit #3 - Qty 10 ,

See BW-NVD letter dated 5/29/80 to Cleveland Electric Illuminating for serial numbers.

Bechtel/ Grand Units 1 and 2, Qty 93; Same Gulf (BPC) see BW-NVD letter dated 5/30/80 to BPC for Tag Nos.

7/21/80 Duke Power / Mk Item No.28-396 Possible " worst case" Catawba SNs 35557 and -8, tolerance buildup Mk Item No.28-393 condition in which SNs 31755 thru 31764. gate could disengage from guide when valve is in backseat position.

5/2/83 Gibbs & Hill / Total 53 affected Potential swing check Comanche Peak valves. See list of valve malfunction due Units 1 and 2 valves attached to to possible broken BW-NVD trip report tack weld securing

, dated 2/1/83. disc to operating arm.

Requires reinspection and rework.

Arkansas Total of 12 affected Same Nuclear One valves. See BW-NVD '

(AN0) letter dated 5/2/83 to ANO for serial numbers.

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ORGANIZATION: BORG WARNER CORPORATION NUCLEAR VALVE DIVISION VAN NUYS, CALIFORNIA REPORT INSPECTION NO.: 99900289/85-01 RESULTS: PAGE 8 of 14 TABLE B (Continued)

Report Date Customer / Site Valve ID Deficiency Mill Power / Affected valves: Same Catawba / Catawba Qty 19 McGuire/ McGuire Qty 14 Oconee Oconee Qty 1.

See BW-NVD letter dated 5/2/83 to Mill Power for customer tag nos.

Pacific Gas Total of 7 affected Same

& Electric / valves. See BW-NVD Diablo Canyon letter dated 5/2/83 to PG&E for serial numbers.

Rochester Gas Total of 4 affected Same.

& Electric valves. See BW-NVD Corp./Ginna letter dated 5/2/83 to RG&E for serial numbers.

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ORGANIZATION: BORG WARNER CORPORATION NUCLEAR VALVE DIVISION VAN NUYS, CALIFORNIA REPORT INSPECTION N0.: 99900289/85-01 RESULTS: PAGE 9 of 14

3. Misalignment of Valve Body Guides and Inadequate Fillet Welds in 20 Inch Valves for Perry Units 1 and 2.

a. Introduction On November 21, 1984, BW-NVD notified the NRC by means of a 10 CFR Part 21 report, of two deficiencies in 20 inch gate valves supplied to Perry Station Units 1 and 2. The first deficiency involved ten valves wherein a misalignment occurred in the fabricated valve body guides which could cause the gate to stick. The second problem involved inadequate fillet welds used for welding in the previous mentioned guides in the bodies of certain valves which might be subject to a differential pressure in excess of 600 psi during cycling of the valve.

This second defect was determined to affect four of the previous ten valves furnished to the Perry Station.

b. Findings By review of records and interviews with BW-NVD personnel, the NRC inspectors verified that information supplied in the November 1984, 10 CFR Part 21 report was accurate and complete in regard to the identified deficiencies.

During the shop processing of ten 20 inch gate valve body castings, the cast-in guides were found to contain unacceptable porosity. To correct this condition, BW-NVD removed these cast guides and replaced them with welded-in fabricated guides. During this change the shop failed to use welding fixtures and this resulted in potential lineal distortion of the guides. Furthermore, engineering failed to include lineal dimensions for the welded-in guides on the fabrication drawing No. 80996. As a result, these guides were not properly inspected after installation.

The second problem concerned the fillet welds on the guides in four of the above valves. During the November 1984 site inspection of the valves by BW-NVD engineering personnel, they observed that the guide fillet welds in the valve flow' path might be inadequate for certain of the 20 inch

ORGANIZATION: BORG WARNER CORPORATION NUCLEAR VALVE DIVISION VAN NUYS, CALIFORNIA REPORT INSPECTION NO.: 99900289/85-01 RESULTS: PAGE 10 of 14 valves which would be subject to operating conditions where the differential pressure exceeds 600 psi.

This deficiency was verified by stress calculations, and BW-NVD recommended that the welds in the a'rected valves be built up.

Cleveland Electric s11uminating Company (CEI) determined that the inspection anJ rework of the valve guides would be done at the Perry site by CEI. BW-NVD determined that the two problems were unique to the Perry order and had no generic implications.

4. Overtorqued Valve Operator Studs at Bellefonte Station

a. Introduction In November 1983, the NRC was notified by a TVA/Bellefonte Station 50.55(e) report that motor operator studs on a 6 inch gate valve could not be torqued to the 140-165 ft. Ib.

value specified on the BW-NVD Drawing No. 79760. As a result of this report, this item was inspected.

b. Findings By review of records and interviews with cognizant personnel, the NRC inspectors determined that the above condition was due to a BW-NVD drawing error which specified the wrong torque values. At the request of TVA, BW-NVD engineering performed a review of all drawings related to TVA contracts.

This review was documented on Customer Specification Discussion sheets. This review verified that the error was isolated to BW-NVD drawing No. 79760. This drawing was then revised to provide the proper torque values of 60-70 ft. Ib.

5. Broken Tack Welds in Swing Check Valves at Comanche Peak Station

a. Introduction In February 1983, Comanche Peak Station notified the NRC by a 50.55(e) report, of a malfunction of a swing check valve due to loose parts resulting from a broken tack weld.

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ORGANIZATION: BORG WARNER CORPORATION 4 NUCLEAR VALVE DIVISION l VAN NUYS, CALIFORNIA REPORT INSPECTION NO.: 99900289/85-01 RESULTS: PAGE 11 of 14 This tack weld connects the disc stud to the operating arm.

As a result of this notification, this item was inspected at BW-NVD.

b. Findings By review of records and interviews with cognizant personnel, the following information was obtained. Prior to 1977, tack welds joining the valve disc stud to the operating arm were the standard design used by BW-NVD for the subject valve.

In 1977 the tack weld was changed to a fillet weld. When notified of the tack weld failure at Comanche Peak in January 1983, BW-NVD visited the site. During this visit the affected valves were inspected and a repair procedure -

was discussed. Since this problem had generic implications BW-NVD performed a review of all swing check valves which they had manufactured. The swing check valves manufactured up to the 1977 date of the design change plus six months were considered suspect by BW-NVD and were identified in the notification letters sent to five purchaser's of the valves, including Comanche Peak. In addition to the lists of valves, BW-NVD sent each customer an inspection and rework procedure which utilized fillet welds in place of the tack welds. BW-NVD personnel indicated that all of the affected customers had responded by telephone to the notification letters. In May 1983, BW-NVD submitted a 10 CFR Part 21 report to the NRC.

A copy of the report, notification letters and lists of affected valves are maintained for reference in the VPB Reactive File.

D. Persons Contacted P. L. Milinazzo, QA Manager, Borg Warner, NVD.

M. N. Rielly, Project Engineer, Borg Warner, NVD.

W. R. Wheaton, QA Specialist, Borg Warner, NVD.

E. Documents Reviewed

1. Drawing No. 80996 Rev. D, 5/31/79, Body Assembly, 20", 900 lb.,

Gate Valve, C.S. (Ref. NR-0007).

2. Drawing No. 81040 Rev. H, 3/12/85 Valve Assembly Gate, 20",

900 lb. , C.S. , w/ Gear Operator.

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ORGANIZATION: BORG WARNER CORPORATION NUCLEAR VALVE DIVISION VAN NUYS, CALIFORNIA REPORT INSPECTION NO.: 99900289/85-01 RESULTS: PAGE 12 of 14

3. Drawing No. 79558, Rev. B, 8/6/79, Body Casting Commercial, 20", 900 lb. Gate Valve, C.S.

4. Parts List, No. PL-810-40, Rev. C, Valve Assembly, 20", 900 lb.,

C.S. , Gear Operated, Class 1.

5. Engineering Change Notice No. 81040, Rev. B, Valve Assembly, 20", 900 lb., C.S., Gear Operated, Class 1.

6. Engineering Change Notice No. 80996, Rev. B., 3/28/79, Body Assembly, 20", 900 lb. , Gate Valve, C.S.

7. TWX,2/6/85;ClevelandElectricIlluminating(CEI)Inc.to BW-NVD, i.e., schedule for valve disassembly of 5 valves.

8. TWX, 2/7/85; BW-NVD response to CEI TWX dated 2/6/85.

9. Letter, 11/14/84; CEI to BW-NVD, notification of nonconforming conditions.

10. Letter, 12/14/84; BW-NVD to CEI, providing additional information/

investigation into nonconforming conditions.

11. Letter, 11/28/84; BW-NVD to CEI explaining guide rail problem and BW-NVD notification to NRC, i.e., NR0007.

12. QA Manual, Rev. 7,12/4/84.

13. Letter, 2/26/85; BW-NVD to CEI, covering recommendations for reworking the tack welds, and justification for accepting same welds.

14. Letter, 11/19/84; BW-NVD to NRC, Notification of N.R. 0007 concerning gate valve, 20", 900 lb., body guide rail problem.

15. Letter, 4/6/83; BW-NVD to NRC, notification of N.R. 0006, concerning sensitivity and density variations in radiographs of valve welds,

16. Letter, 5/2/83; BW-NVD to NRC Region V, Interim notification report for N.R. 0005, concerning failure of tack welds in swing check valves.

17. Trip Report, 2/1/83; BW-NVD QA Manager's trip to Comanche Peak to investigate cause of tack weld failures.

ORGANIZATION: BORG WARNER CORPORATION

. NUCLEAR VALVE DIVISION VAN NUYS, CALIFORNIA REPORT INSPECTION N0.: 99900289/85-01 RESULTS: PAGE 13 of 14

18. Letter, 5/2/83; BW-NVD to Arkansas Nuclear One, notification of possible hardware problem of tack welds in swing chedk valves.

19. Letter, 5/2/83; BW-NVD to Mill Power, notification of possible tack weld problem in swing check valves for Catawba, McGuire and Oconee.

20. Letter, 5/2/83, BW-NVD to Pacific Gas & Electric (PG&E), noti-fication of possible tack weld problem in swing check valves for Diablo Canyon.

21. Letter, 5/2/83; BW-NVD to Rochester Gas & Electric (RG&E),

notification of possible tack weld problem in swing check valves for Ginna.

22. Procedure, 5/2/83; BW-NVD Procedure for Reinspection and Rework of NVD Swing Check Valves.

23. Letter, 7/22/80; BW-NVD to NRC OIE, notification of N.R. 0003, concerning possible tolerance buildup condition on gate valve stems.

24. Letter, 7/22/80, BW-NVD to NRC Region V, notification of N.R. 0003 and including corrective action to be taken.

25. Letter, 5/30/80; BW-NVD to WPPS-2, notification of N.R. 0002 concerning loosening of stem nuts and extensions on Globe valves with SCM operators.

26. Letter, 5/30/80; BW-NVD to Bechtel Power / Grand Gulf, notification of N.R. 0002 concering loosening of stem nuts and extensions on globe valves with SCM operators.

27. Letter, 6/11/80; BW-NVD to WPPSS-2, recommended corrective action for loosened stem nuts.

28. Internal Memorandum; 6/10/80; BW-NVD, consisting of instructions for documenting field modifications on valve stems.

29. Letter, 2/12/80; BW-NVD notification to NRC concerning N.R. 0001, possible failure of gate valves to close due to inadequate guides.

30. Letter, 2/12/80; BW-NVD to Combustion Engineering /Palo Verde, notification of possible hardware problem due to inadequate guides in gate valves.

c ORGANIZATION: BORG WARNER CORPORATION NUCLEAR VALVE DIVISION VAN NUYS, CALIFORNIA REPORT INSPECTION NO.: 99900289/85-01 RESULTS: PAGE 14 of 14

31. Procedure P-77910. Rev. A, 10/7/80; BW -NVD Assembly Procedure to Upgrade Four Valves in Line at C.E. (Palo Verde).

32. Procedure No. 11-8, Rev. O, 5/25/84, Reporting of Defects and Noncompliances to the NRC.

33. Drawing No. 79760; Valve Assembly, 6 Inch Gate Valve, 150 lbs.,

C.S., M.0.

34. Engineering Change Notice, 1/16/84; Change modifying Drawing No.

79760, Note 37 added.

35. Specification, 6/19/84; BW-NVD Customer Specification Discussion Sheets for TVA specifications.

36. Letter, 7/26/83; BW-NVD to NRC Region V, i.e., all affected valves rework completed, see NR-0004.

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