ML20137Z987
| ML20137Z987 | |
| Person / Time | |
|---|---|
| Issue date: | 09/27/1985 |
| From: | Merschoff E, Oller R NRC OFFICE OF INSPECTION & ENFORCEMENT (IE) |
| To: | |
| Shared Package | |
| ML20137Z951 | List: |
| References | |
| REF-QA-99900282 NUDOCS 8510080417 | |
| Download: ML20137Z987 (12) | |
Text
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ORGANIZATION:
ITT GRINNELL CORPORATION PIPE HANGER DIVISION WARREN, OHIO REPORT INSPECTION INSPECTION N0.: 99900282/85-01 DATE(S):
7/22-26/85 ON-SITE HOURS:
54 CORRESPONDENCE ADDRESS: ITT Grinnell Corporation ATTN: Mr. Arthur Laurenson Corporate QA Manager 260 West Exchange Street Providence, Rhode Island 02901 OPGANIZATIONAL CONTACT: Mr. A. Laurenson, Corporate QA Manager TELEPHONE NUMBER:
(401) 831-7000 PRINCIPAL PRODUCT: Component Supports NUCLEAR INDUSTRY ACTIVITY: The shock and sway suppressor manufacturing activities and quality records are being transferred to the Providence, Rhode Island facility. The Warren, Ohio plant is being permanently closed.
b
/-20:f8 ASSIGNED INSPECTOR:
4 R. E. Oller, Reactive Inspection Section (RIS)
Date OTHERINSPECTOR(S):
E. L. Burns, Brookhaven National Laboratory APPROVED BY:
77 E. W. Merschoff,
- f. RIS, Vendor Program Branch Date INSPECTION BASES AND SCOPE:
A.
BASES: Appendix B to 10 CFR P~ art 50 and 10 CFR Part 21.
B.
SCOPE: The purpose of this reactive inspection was to review the technical aspects of manufacturing deficiencies which have occurred in hydraulic shock and sway suppressors (snubbers) furnished by ITT Grinnell (ITTG) to nuclear power plants. Additionally, the status of previous inspection findings was reviewed.
PLANT SITE APPLICABILITY: Cooper, Diablo Canyon, Fitzpatrick, Millstone, North Anna, Palo Verde, Peach Bottom, Point Beach.
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ORGANIZATION:
ITT GRINNELL CORPORATION PIPE HANGER DIVISION WARREN, OHIO REPORT INSPECTION N0.: 99900282/85-01 RESULTS:
PAGE 2 of 10 A.
INSPECTION ISSUES 1.
Manufacturing deficiencies consisting of:
(a) leakage at seals; (b) leakage at fill port plug threads; (c) leakage at velocity and bleed adjustment screws; (d) velocity and bleed screw settings; (e) contamination through vent plug holes; (f) vibration of reservoirs; (g) reservoir materials; (h) snubber hardware; and (i) mounting bracket interference.
2.
Snubber related activities consisting of:
(a) repair and testing services; (b) maintenance reconnendations and space parts; and (c) snubber procurement.
B.
INSPECTION FINDINGS AND COMMENTS:
1.
Hydraulic Shock and Sway Suppressor (Snubber) Deficiencies:
a.
Background
Early in 1985, Brookhaven National Laboratory (BNL) performed a study for the NRC in which snubber manufacturing deficiencies, specific to each manufacturer of mechanical and hydraulic snubbers were identified. BNL also made other inspection recommendations which were common to all manufacturers of snubbers.
As a result of this study a Vendor Program Branch Inspection was conducted at the ITTG facility at Warren, Ohio.
b.
Findings (1) General Information Discussions with the Warren plant QA manager (QAM) and the Product Engineering Manager (PEM) revealed that the Warren plant is scheduled for permanent shutdown on or about August 16, 1985. Uncompleted snubber work and all quality records will be transferred to the ITTG, Providence, Rhode Island facility.
The only inprocess nuclear work observed during this inspection involved 8-inch bore hydraulic snubbers.
ORGANIZATION:
ITT GRINNELL CORPORATION PIPE HANGER DIVISION WARREN, OHIO REPORT INSPECTION NO.: 99900282/85-01 RESULTS:
PAGE 3 of 10 These snubbers were manufactured by Boeing Engineering.
ITTG had reconditioned them due to seal leaks and was painting them. These snubbers will be sent to the Providence, Rhode Island facility for functional testing.
Due to the closing of the Warren plant, this inspection effort was focused primarily on the technical aspects of the ITTG hydraulic snubber deficiencies and special related activities recommended for inspection in the BNL report, instead of the QA program administration at the Warren, Ohio plant. The QA/ manufacturing areas which were reviewed, consisted of traveler process control and functional test records. No nonconformances were identified in these areas. The snubber deficiencies and related activities were discussed and evaluated with the PEM.
2.
Snubber Deficiencies:
a.
Fluid Leakage From Reservoirs Due To Polyurethane Seals The PEM attributed this deficient condition to the lack of knowledge in sealing technology in the early 1970's. The original use of polyurethane seals proved to be unsuitable for containing the snubber hydraulic fluid due to the inability of the seal compound to continually withstand environmental conditions including the effects of radiation, temperature and humidity.
ITTG utilizes General Electric (GE) fluid SF-1154 as the hydraulic medium for the nuclear snubbers. The PEM indicated that there was no chemical incompatibility between this fluid and the polyurethane compound.
In June 1974, ethylene propylene seals became available and were adopted for use in all ITTG hydraulic snubbers due to the superior endurance capability of this
- material, b.
Fluid Leakage and Air Entering Cylinder at Fill Port Plug Due to NPT Threads The PEM indicated that the use of standard pipe threads on the hydraulic snubber fluid fill port was discontinued in mid-1976. This was accomplished by design incorporation of SAE threads on the plug and port in conjunction with an 0-ring and groove.
O ORGANIZATION:
ITT GRINNELL CORPORATION PIPE HANGER DIVISION WARREN, OHIO REPORT INSPECTION NO.: 99900282/85-01 RESULTS:
PAGE 4 of 10 c.
Fluid Leakage at Velocity and Bleed Adjustment Screws The PEM provided the clarification that the leakage was ultimately eliminated by the use of both a Parker thread seal and a washer between the seal and the lock nut. To date, this configuration has proved to be satisfactory.
d.
Improper Valve Calibrations For Velocity And Bleed Settings During discussions on this problem, the PEM indicated that these settings are typically 8-inches-per-minute and 4-inches-per-minute for the velocity and bleed settings, respectively. The values are specified based on predicted piping system dynamic response characteristics.
ITTG ensures these settings for nuclear application snubbers by use of their procedure No. PHD-5434-1, entitled "... Filling, Purging & Calibration Procedure for 11" through 8" Bore Models...PH-76N...."
This procedure governs factory settings of the lockup velocity and bleed rate on a vacuum test machine. Prior to mid-1975, filling and calibration was performed on a flow bench which allowed air entrainment into the hydraulic fluid. This air entrainment would often result in incorrect snubber response calibration settings.
e.
Breather Filters Used In Place Of Open Reservoir Vent Plugs To Avoid Contamination This problem was formerly believed due only to sand blasting the snubbers in the field.
The PEM indicated that sand / grit blasting operations prior to snubber final assembly in the shop may also have contributed to the problem of hydraulic fluid contamination. To eliminate the problem in the field, the original reservoir design was revised to include a breathable filter in place of the standard vent plug. A review of ITTG production drawing Figure 200/201, which specified the breathable filter, indicated that the use of the vent plug was terminated on May 20, 1976.
f.
Reservoir Secured Directly To The Cylinder To Avoid Loosening By Vibrations
ORGANIZATION:
ITT GRINNELL CORPORATION PIPE HANGER DIVISION WARREN, OHIO REPORT INSPECTION N0.: 99900282/85-01 RESULTS:
PAGE 5 of 10 The ITTG hydraulic snubber is available for nuclear application with either a reservoir integrally mounted on the cylinder or remotely mounted. The selection is dictated by the system design specification and snubber bore size. The integrally mounted reservoir configuration has been seismically qualified as evidenced by ITTG Test Reports No.
PHD-6507-4R, Revision 1, dated 6/8/78 for 4, 5, and 6-inch bore snubbers, and No. PHD-6507-5R, dated 3/14/80, for 8-inch bore snubbers. These snubbers were tested to Wylie test procedure No. 43505-1 with amendments 1 through 3, for compliance to General Electric Document No. 21A3502, Revision 2.
The PEM indicated that while in the process of qualifying the snubbers to the excitation levels required by the GE specification.
ITTG determined that the reservoir to snubber connection needed more restraint and that this could be achieved by the addition of end block tabs. This design change consisted of the addition of L-shaped supports welded to both sides of the reservoir and bolting the supports to the cylinder. A review of production drawing Figure 200, entitled " Shock and Sway Suppresor End Block with Tabs,"
indicated that ITTG hydraulic snubbers manufactured since August 22, 1977, included the additional supports.
The PEM also indicated that remote reservoirs are available as an option for large bore snubbers. These reservoirs were originally specified by designers for ensuring simultaneous snubber lockup on large equipment (e.g., steam generators).
The use of a single remote reservoir has been largely discontinued as a result of improved calibration techniques.
However, remote reservoirs continue to be specified when needed due to space limitations. The PEM indicated that seismic qualificatitn of the remote reservoir arrangement has been analytically verified for a specific length of stainless steel feed line, but unique field configurations must be individually evaluated, g.
Stainless Steel Reservoirs Verses Carbon Steel Models The PEM indicated that all of the ITTG snubber reservoirs are manufactured by Oil-Rite Corporation.
Integrally mounted reservoirs are available only in carbon steel, but remote reservoirs can be furnished made of either carbon or
ORGANIZATION:
ITT GRINNELL CORPORAT10N PIPE HANGER DIVISION
' WARREN, OHIO REPORT INSPECTION N0.: 99900282/85-01 RESULTS:
PAGE 6 of 10 stainless steel. With regard to remote reservoirs, certain licensee NPP's, including North Anna and Diab 13 Canyon have specified remote reservoirs made of Type 304 stainless steel due to corrosion problems. Stainless steel remote reservoirs, made by Oil-Rite, have been available only since 1978.
h.
Improper Valve Block Machining Problems This deficiency has been addressed in NRC Report No.
99900282/84-01 and therefore it was not discussed during this inspection.
i.
Wrong Hardware Sup) lied By ITT Grinnell For Mechanical Snubbers Manufactured By Otlers The PEM indicated that ITTG had supplied mechanical snubbers manufactured by Pacific Scientific Company which were equipped at the Warren, Ohio plant with various support hardware items. The subject deficiency related to mechanical snubbers furnished to Palo Verde NPP, and it was fully addressed in the NRC inspection report No. 99900282/84-01.
For this reason it was not reviewed during this inspection.
j.
Snubber Interferance With Mounting Brackets s
Prior to April 1980 there were some instances where the ITTG hydraulic snubber end piece would bind due to the oversize fillet welds in the end support bracket. The PEM indicated that this condition was corrected by development of an inspection and rework procedure for the support bracket welds. This procedum was furnished to all of the affected NPP's for their use in correcting the problem. A change was also made in the bracket design to reduce the interferance.
k.
Generic Aspects Of Failure Of Large Hydraulic Snubbers On Steam Generators At Palisades NPP This problem was fully reviewed in NRC inspection report No.
99900282/84-01 and was not discussed during this inspection.
3.
Snubber Related Activities:
ORGANIZATION:
ITT GRINNELL CORPORATION PIPE HANGER DIVISION WARREN, OHIO REPORT INSPECTION NO.:
99900282/85-01 RESULTS:
PAGE 7 of 10 a.
Snubber Repair and Testing Hydraulic snubber repair and testing is accomplished in accordance with Section 4.0 of ITTG's procedure No.
PHD-6511-76N, entitled " Inspection ar.d Maintenance."
Snubber rebuild and calibration services will be administered in the future by the ITTG Providence, Rhode Island, Field Operations Group.. According to the PEM, snubber initial testing as well as re-calibration can be satisfactorily accomplished only with the ITTG vacuum testing equipment. A test report checklist is utilized to document the calibration process and is intended primarily for ensuring that lockup velocity of 8-inches-per-minute and bleed rate of 4-inches-per-minute have been attained.
Due to the requirement for utilizing ITTG testing equipment, snubbers requiring re-calibration must either be shipped to the factory, or reworked by the Field Operations Group on-site.
In some instances, licensees have purchased and installed ITTG vacuum test equipment for performing snubber performance evaluation and re-calibration with in-house personnel at the NPPs.
b.
Snubber Maintenance Recommendations And Spare Parts The PEM indicated that, as a minimum, licensees should comply with the recommendations given in maintenance instruction No. PHD-6511-76N. This instruction is for hydraulic snubbers of all sizes furnished by ITTG. Each customer receives the above instruction with the snubbers.
An abbreviated summary of these recommendations is as follows:
(1) Check hydraulic fluid levels annually.
(2) Visually inspect connecting pins for signs of wear on a periodic bases.
(3) Frequently remove and inspect the reservoir breathable filter.
(4) Periodically examine piston rods for signs of scoring.
(5)
Replace ethylene propylene seals every five years.
ORGANIZATION:
ITT GRINNELL CORPORATION PIPE HANGER DIVISION WARREN, OHIO REPORT INSPECTION NO.: 99900282/85-01 RESULTS:
PAGE 8 of 10 As part of the qualification test for compliance with GE specification 21A3502, ITTG environmentally qualified nuclear application snubbers to Wyle test procdure No.
43505-1. Based on this evaluation, the PEM indicated that ethylene propylene seal replacement is recomended at five year intervals for environments up to 200*F.
ITTG purchases seals from several approved suppliers for the initial manufacturing as well as for inclusion in maintenance kits. The ethylene propylene seals have a shelf life of five years and an actual endurance limit of seven years in the 200 F environment. Purchasing agreements with suppliers require that cure dates and compound batch numbers be documented. Other spare parts are also made available for purchase as required.
ITTG recommends maintaining a 10 percent spare snubber and seal replacement kit inventory.
Within the inspection area of spare parts and maintenance, a review was made of typical procurement packages for calibration services, seal kits and miscellaneous hardware orders for Peach Bottom, Millstone, Fitzpatrick, and Cooper nuclear NPPS.
No deficiencies were identified.
c.
Snubber Procurement Within this area, a representative package for Point Beach NPP (P.O. No. B44157S, dated 03/20/84) was examined. This package contained the following documentation:
(1) Assembly Inspection Checklist (2) Calibration Test Record (3) Magnetic Particle Examination Report (4) Packing List (5) Quality Control Checklist This order for 4-inch bore hydraulic snubbers, required I
compliance with Point Beach Engineering Specification No.
PB-110, Rev. O, dated 06/08/81.
Significant design aspects of the specification were noted as follows:
(1)
... snubbers will be located inside containment...."
ORGANIZATION:
ITT GRINNELL CORPORATION.
~
PIPE HANGER DIVISION' WARREN, OHIO REPORT INSPECTION NO.: 99900282/85-01 RESULTS:
PAGE 9 of 10 (2)
" Snubbers must have a qualified life of forty (40) years... based on 100% use.
...for those items that can not withstand forty (40) years, frequency of parts replacement shall be specified."
(3)
" Snubbers may be required to withstand the following environment:
(a) piping temperature of 680 F, (b) ambient temperature of 40 -300 F, (c) 100% relative humidity, and (d) 100 Roentgen /hr. (gama).... "
(4)
" Shock suppressors shall be capable of operating for a minimum of one (1) year without maintenance or inspection."
(5)
... snubbers shall be calibrated for a locking velocity of 6-20 1pm and a slip (bleed) velocity of 5 ipm...."
(6)
... pin-to-pin movement shall not exceed plus or minus 0.040" for dynamic cyclic loading up to 33 Hz."
(7) " Snubbers must be capable of restraining a one time load up to 150% of catalog rated load."
The FEM indicated that ITTG snubbers meet or exceed all of the PB-110 specification requirements.
C.
STATUS OF PREVIOUS INSPECTION FINDINGS:
1.
(Closed) Violation (Report No. 84-01): The vendor failed to impose 10 CFR Part 21 requirements on six purchase orders for welding material and steel bar stock ordered under their quality standard QAV-002 as ASME Code Section III material.
During this inspection it was verified that ITTG provided corrective action for the above violation by revising their procurement standard No. QAV-002 to Revision 2, effective 12/06/84 to include the requirements that, "USNRC 10 CFR Part 21 is effective for all QAV-002 requirements." Review of two randomly selected purchase orders, No. P-16442, dated 05/31/85 and No. 16631, dated 07/19/85 for ASME Code steel plate material
ORGANIZATION:
ITT GRINNELL CORPORATION PIPE HANGER DIVISION WARREN, OHIO REPORT INSPECTION NO.: 99900282/85-01 RESULTS:
PAGE 10 of 10 verified that Revision 2 of the QAV-002 standard is being implemented.
2.
(Closed) Nonconformance A (Report No. 84-01): The vendor's January and April 1984, Service and Material Report calibration certificate for the controls and recorder on the heat treat furnace, and the 1984 certificates of calibration for the ultrasonic test units Models USL-38 and S-301, did not contain a statement for traceability to the National Bureau of Standards.
During this inspection it was verified that a certificate of calibration, dated 07/02/84, for the furnace controls and recorder was received from Honeywell. This certificate showed traceability to NBS standards.
Concerning the ultrasonic test equipment, it was verified that these instruments were calibrated as part of the maintenance for veritical and horizontal linearity to the ASTM E-317-79 standard. Traceability to NBS standards was not required. The ITT Grinnell procedure No. 10A011, which specified the NBS traceability requirement, was voided by the QA manager by a notation on the document to the Lead Documentation Analyst.
3.
(Closed) Nonconformance B (Report No. 84-01): The vendor placed a purchase order with a sub-vendor for whom the yearly required audit by ITTG was six weeks overdue.
In addition, yearly required audits were one month late for five other vendors on the Approved Vendor List (AVL).
During this inspection, review of the audit / survey records verified that the Hilti Company, with whom the P.O. was placed, was reaudited and evaluated on 04/06/84 by ITTG, but was not placed on the Approved Vendor List (AVL) until June 1984.
Concerning the five vendors on the AVL whose reaudits were overdue, review of records verified that they were reaudited and evaluated during the period of June through August of 1984.
PAGE 1
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g, s. O//e r (Mc)
INSPECTOR:
E.
L. Burns (BNL)
DOCKET NO.:
99900282 SCOPE:
(ITT-Grinnell Snubbers)
REPORT NO.:
85-01 DOCUMENTS EXAMINED ITEM TYPE OF DOCUMENT NO.
DOCUMENT NO.
REY.
DATE TITLE / SUBJECT 1
PRO 5434-1&2 7
1977 Filling. Purging, and Calibration Procedure 2
DWG Fig 200/201 5/20/7f Breatheable Filter Production Drawing 3
RPT 6507-4R 1
6/8/78 4,5, and 6-inch Bore Suppressor Test Report 4
RPT 6507-5R 3/14/80 8-inch Bore Suppressor Test Report 5
DMG Fig 200 8/22/7]
Shock & Sway Suppressor End Block with Tabs 6
PRO 6511-76N 2
1978 Inspection and Maintenance Procedure 7
P.O.
210555N 6/11/85 Philadelphia Electric / Peach Bottom (seal kit) 8 P.O.
841039 4/23/85 Northeast Utilities / Millstone (misc. parts) 9 P.O.
853469 5/30/85 PASNY/Fitzpatrick (thread seals) 10 P.O.
242105 7/10/85 Nebraska Public Power / Cooper (misc. parts & seals) 11 QAM Sec. 4.0 11 6/12/8d In-Process Control Procedure 12 QAM Sec. 7.0 11 6/12/84 Calibration Procedure 13 P.O.
B44157S 3/20/8d Wisconsin Electric / Point Beach (4-bore hyd.)*
TYPE OF DOCUMENT:
(Snubber Eng. Spec. PB-110, Rev. O, 6-8-81)
DWG - Drawing LTR - Letter SPC - Specification (f'7 - gehorf PRO - Procedure QAM - QA Manual QCD - QC Document P.O.- Purchase Order INM - Internal Memo 2,
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