ML20136H336
| ML20136H336 | |
| Person / Time | |
|---|---|
| Issue date: | 01/03/1986 |
| From: | Jocelyn Craig, Robert Pettis NRC OFFICE OF INSPECTION & ENFORCEMENT (IE) |
| To: | |
| Shared Package | |
| ML20136H326 | List: |
| References | |
| REF-QA-99900337 NUDOCS 8601090442 | |
| Download: ML20136H336 (7) | |
Text
ORGANIZATION:
PAUL-MUNROE ENERGY PRODUCTS DIVISION ORANGE, CALIFORNIA REPORT INSPECTION INSPECTION N0.: 99900337/85-01 DATE(S):
8/14-16/85 ON-SITE HOURS: 26 CORRESPONDENCE ADDRESS: Paul-Munroe Energy Products Division ATTN: Mr. Mark P. Schneider, P.E.
Corporate Director of Quality Assurance 1701 W. Sequoia Avenue Orange, California 92668 ORGANIZATIONAL CONTACT:
TELEPHONE NUMBER:
(714) 978-9600 PRINCIPAL PRODUCT:
Vesign and manufacturer of fluid power components.
NUCLEAR INDUSTRY ACTIVITY: Major supplier of hydraulic shock suppressors (snubbers) and related^ testing services.
ASSIGNED INSPECTOR:
/ %
gt.R. L. Pettis, Jr., Special Projects Inspection Date Section (SPIS)
OTHERINSPECTOR(S):
E. Trottier, Reactive Inspection Section (RIS)
M. Subudhi, Brookhaven National Lab APPROVED BY:
tui
/- 3 -n tp J. Y. Craig, Chief, SPIS, Vendor Program Branch Date INSPECTION BASES AND SCOPE:
A.
BASES:
10 CFR Part 50, Appendix B; 10 CFR Part 21.
B.
SCOPE:
Follow-up on previously reported deficiencies involving shock suppressor design, testing and maintenance.
Review of 10 CFR Part 21 system, reports of corrective action and the procurement process.
PLANT SITE APPLICABILITY:
Sequoyah, Units 1 and 2 (50-327/328); Arkansas, L* nit 2 (50-368).
i I
~
8601090442 860103 PDR GA999 EMVMUNH 99900337 PDR
ORGANIZATION:
PAUL-MUNR0E ENERGY PRODUCTS DIVISION ORANGE, CALIFORNIA REPORT INSPECTION NO.:
99900337/85-01 RESULTS:
PAGE 2 of 7 A.
VIOLATIONS:
None.
B.
NONCONFORMANCES:
1.
Contrary to Paul-Munroe (PM) Quality Assurance Manual (QAM)
Section 7.4(f), " Control of Purchased Items and Services,"
documentation was unavailable to support quarterly reviews of Nonconforming Material Reports (NMR) for the second and fourth quarters of 1984, and the first and second quarters of 1985.
(85-01-01)
C.
UNRESOLVED ITEMS:
None.
D.
STATUS OF PREVIOUS INSPECTION FINDINGS:
None.
E.
Other Findings or Comments:
1.
Anker-Holth and E-Systems Affiliation Recently, PM acquired the engineerng and design rights to the Anker-Holth (AH) snubber line, which was earlier effiliated with McDowel-Wellma1, in addition to expanding their snubber repair and spare parts business activities. As a result, all snubbers previously manufactured by AH will be serviced by PM with damaged units to be replaced with the PM design.
In addition to AH, PM has a similar contract with E-Systems, whose snubber assemblies were primarily supplied to BWR facilities designed by the General Electric Company.
According to this agreement, PM will provide all service and sales for the E-System product line.
PM has been supplying the nuclear industry with primarily large capacity hydraulic snubbers used in conjunction w m the seismic support of such equipment as steam generaton and reactor coolant pumps,
ORGANIZATION:
PAUL-MUNR0E ENERGY PRODUCTS DIVISION ORANGE, CALIFORNIA REPORT INSPECTION NO.: 99900337/85-01 RESULTS:
PAGE 3 of 7 Most parts and products used in the design are manufactured at REMC0 Hydraulics outside San Francisco, California, while the marketing, engineering, and assembly are performed at PM's headquarters in Orange, California.
PM snubbers utilize TEFZEL, a unique seal material qualified for a 40 year life, in contrast to other manufacturers who use EPR or VITON material, which PM suggests should be replaced at 5 year intervals.
In the case of large capacity snubbers (1000-2200 kips), the fluid reservoir is a remote type which supplies several snubbers used as supports for such equipment as steam generators and reactor coolant pumps.
In these applications, tubing is used to deliver hydraulic fluid to each snubber and is supported seismically according to normally accepted engineering practice, and without the aid of a rigorous seismic analysis.
Earlier PM snubber units utilized a Reed valve design wnich experienced fluid leakage problems. This problem has been corrected by PM with the incorporation of a control valve. According to PM, the only operating plant which may still have older PM units incorporating the Reed valve design is the Sequoyah Nuclear Station.
2.
Review of PM Stress Analysis
~
An overall review of the stress analysis supporting the design of the PM shock suppressor was performed by the NRC inspector for a typical 1000 kip (1,000,000 pound load capacity) unit.
Calculations were performed by PM using standard empirical equations which normally result in conservative values.
Static seismic calculations were performed since it was demonstrated that the snubber assembly possessed no natural frequency below 33 cycles per second with snubber overall buckling demonstrated at the faulted load (ASME Level D) condition.
The PM units incorporate an integral fluid reservoir, located inside the main body, when used primarily as a seismic support for piping systems.
3.
Repair and Test Services PM is active in the repair and functional testing of snubbers to meet the needs of the nuclear industry.
To accomplish such testing PM developed, TESTAN, a portable console unit which connects l
hydraulically to an installed snubber. This equipment is capable l
t
ORGANIZATION:
PAUL-MUNROE ENERGY PRODUCTS DIVISION ORANGE, CALIFORNIA REP 0PT INSPECTION N0.: 99900337/85-01 RESULTS:
PAGE 4 of 7 of testing the entire range of PM snubbers and is used to verify parameters such as performance under faulted load conditions, and spring, bleed and lockup rates.
In addition, mobile laboratories dedicated to snubber testing and repair for on-site outage services, have also been developd by PM and toured by the NRC inspectors.
4.
10 CFR Part 21 The procedure adopted by PM to comply with 10 CFR Part 21, Quality Assurance Manual (QAM) Section 20.0 " Code of Federal Regulations, 10 CFR 21," was reviewed and found adequate by the NRC inspector. The posting of this procedure, 10 CFR Part 21, and Section 206 of the Energy Reorganization Act of 1974 were also verified.
Although the documentation reviewed was adequate, the NRC inspector.
found instances where it was difficult to clearly identify potential Part 21 issues and follow their final disposition.
No violations or nonconformances were identified during this part of the inspection.
5.
Refurbishment of Arkansas #2 Snubbers A review of PM's 10 CFR 21 records indicated the failure of several spherical bearings during functional testing performed by REMC0 Hydraulics, in April 1985.
The bearing, which failed at full faulted load of 250 kips during the bleed test, was observed to have experienced a failure of the outer race.
Further visual examination indicated the crack may have been in the bearing for some time.
At the request of AP&L, all 16 units tested were outfitted with new bearings, manufactured by the Torrington Company, rated at 400 kips each. The failed bearings were shipped to AP&L, at their request, so a complete metallurgical evaluation could be performed.
Snubber bearing failures were discussed in NRC Information Notice 84-73, dated September 14,1984, "Downrating of Self-Aligning Ball Bushings Used in Snubbers." This notice pertained to both mechanical and hydraulic snubber types utilizing spherical ball bushings and reported end housing stresses, in some cases, exceeding the material yield. As a result, load reductions were initiated by the
ORGANIZATION:
PAUL-MUNR0E ENERGY PRODUCTS DIVISION ORANGE, CALIFORNIA REPORT INSPECTION NO.: 99900337/85-01 RESULTS:
PAGE 5 of 7 manufacturer, the Torrington Company, based on a more conservative analysis than that previously used to establish the bearings load rating.
6.
Snubber Maintenance Snubber seal and fluid problems were discussed with the PM staff for both PM and Anker-Holth models.
Several weaknesses were identified with respect to the Technical Instruction Manual for seal and fluid maintenance of these snubbers. At present, the manual is not current with respect to normally accepted industry standards and lacks specificity with regard to overall snubber maintenance.
As a result, PM is planning to notify all owners of snubbers of such concerns prior to revising the Technical Manual.
Emphasis will be placed on maintenance measures which will increase seal life through the periodic investigation of snubber fluid, reservoir level, viscosity, cleanliness and water content of the snubber fluid.
The main thrust will be to recommend to PM customers that seal replacement be performed at 5 year intervals, since experience has demonstrated that degradation of EPR and VITON A seal material occurs much faster than earlier predicted.
PM believes increased seal degradation is due to such factors as compression set, aging and service temperature.
PM's snubbers incorporate a TEFZEL seal material integrated with stainless steel springs inside a plastic jacket, referred to by PM as the " LIFE-0F-PLANT" seal design and guaranteed for 40 years without replacement. AH snubbers upgraded with this seal design in addition to PM designed units will be exempt from concerns identified above.
7.
Procurement Process The inspector selected three vendors from the Paul-Munroe Approved Vendor List (AVL) for review of their qualifications. One vendor had a current and valid QSC certificate with the remaining two vendors being recently audited by Paul-Munroe.
In addition, Section 7.4 of the PM QAM was reviewed which states, "The Qualit engineer reviews the Nonconforming Material Report (NMR)y Assurance log quarterly." The results of this review by the NRC inspector produced the following:
ORGANIZATION:
PAUL-MUNR0E ENERGY PRODUCTS DIVISION ORANGE, CALIFORNIA REPORT INSPECTION
-NO.:
99900337/85-01 RESULTS:
PAGE 6 of 7 Year Quarter Review Status of NMR Log 1985 2
Review of NMR log not conducted 1985 1
Review of NMR log not conducted 1984 4
Review of NMR log not conducted 1984 3
Third quarter, 1984, reports were reviewed for significant trends on October 5, 1984.
1984 2
Review of NMR log not conducted 1984 1
First quarter,1984, reports were reviewed for significant trends on January 29, 1984.
Nonconformance 85-01-01 was identified during this part of the inspection.
A new logging and tracking system for NMRs was developed by Paul-Munroe in July, 1985. To date, 15 entries have been made, but insufficient information existed to establish any trends.
F.
PERSONS CONTACTED:
- J. M. Raymont, Jr.
- M. P. Schneider
- W. F. Holub F. U. Erlach
- R. C. Fisher A. Shelcoviz R. Galantine R. Estes G.
DOCUMENTS EXAMINED:
1.
QAM, dated December 18, 1984, Paul-Monroe QA Program Manual.
2.
IOM, Tech Instruction Manual for 1200K Hydraulic Shock Suppressors.
3.
IOM, dated July 1978, Snubber & Accessories - Recirculation System (E-Systems).
ORG6NIZATION:
PAUL-MUNROE ENERGY PRODUCTS DIVISION ORANGE, CALIFORNIA REPORT INSPECTION N0.: 99900337/85-01 RESULTS:
PAGE 7 of 7 4.
Report, document no. PA87776, Revision B, dated November 16, 1985, Design Report PMH-2200.
5.
Report, document no. A-690734, Revision 0, dated September 7, 1977, Stress Report, SAYAG0, 1000K Snubber.
6.
Report, document no. A-690623, Revision 0, dated October 27, 1976, Stress Report, Multiplant 11, 1000K Snubber.
7.
Report, document no. A-690624, Revision 0, dated January 29, 1977, Stress Report, Multiplant 11, 1300K.
8.
QAM, Revision A, December 18, 1984, QA Program Manual.
9.
AVL, Revision 0, dated May 10, 1985, Approved Vendor List.
10.
INM, NDE Training Records (Qualifications).
11.
INM, Equipment Calibration Records.
12.
Report, Nonconforming Material Report (NMR) 1984 & 1985.
13.
INM, General (New Employee) Training Records.
14.
P.0., document no. E-19121, dated June 24, 1985, AC Fasteners.
15.
P.0., document no. E-15163, dated June 21, 1985, Kosmos Engineering.
16.
P.0., document no. E-15280, dated July 16, 1985, Bowman Plating.
17.
P.O., document no. E-15476, dated August 8, 1985, A&G Engineering.
18.
P.0., document no. E-15096, dated June 17, 1985, Bowman Plating.
19.
P.O., document no. E-15105, dated June 18, 1985, Bowman Plating.
20.
P.0., document no. E-14052, dated May 6, 1985, Dragon Valves.
.