ML20141H823
| ML20141H823 | |
| Person / Time | |
|---|---|
| Issue date: | 12/13/1985 |
| From: | Harper J, Merschoff E NRC OFFICE OF INSPECTION & ENFORCEMENT (IE) |
| To: | |
| Shared Package | |
| ML20141E221 | List: |
| References | |
| REF-QA-99900054 NUDOCS 8604250049 | |
| Download: ML20141H823 (2) | |
See also: IR 05000930/2010004
Text
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ORGANIZATION: DPESSER INDUSTRIES, INC.
ALEXANDRIA, LOUISIANA
CEPORT INSPECTICN INSPECTION
NO.-
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99900054/85-01 DATE(S): 09/30/85-10/04/85 ON-SITE HOUPS: 50
' CORRESPONDENCE ADDRESS: Dresser Industries, Inc.
ATTN: B. G. Bronson, OA Manager
Post Office Box 1430
Alexandria, Louisiana 71301
ORGANIZATIONAL CONTACT: Mr. B. G. Bronson, QA Manager
TELEPHONE NUMBER: (318) 640-2250
PRINCIPAL PRODULT: Nuclear Safety arid Sdfety Relief Valves
NUCLEAR
business is INDUSTRY ACTIVITY:
supplying valves Less facilities.
for nuclear than 5% of Dresser Industries ( Alexandria)
ASSIGNED INSPECTOR: \i r,m
c .t #
J. Cd Harper, Reactiv6 Inspection Section (RIS) Date
OTHER INSPECTOR (S): L. D. Vaughan, Program Coordination Section (PCS)
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APPROVED BY: / --
re . , 3 6-
E. W. MerschofVfhief, RIS Date
INSPECTION BASES AND SCOPE:
A. BASES: 10 CFR Part 21 and 10 CFR Part 50 Appendix B.
B. SCOPE:
To ensure that valves, model 7150 and 7250, Class 1 and 2 are
being supplied to Fort Calhoun in accordance with established comitments.
In addition, to ensure that valves and valve spare parts are supplied by
Dresser to the nuclear industry in accordance with established QA
procedures, applicable codes ( ASME Section III) and standards (Appendix
B to 10 CFR Part 50.)
PLANT SITE APPLICABILITY:
Fort Calhoun, 50-285; Perry Nuclear, 50-440, 50-441;
Davis-Besse, 50-346;'Diabl'o Canyon, 502275, 50-323.
kop20o49e60413
999000$99 ENVDagy
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ORGANIZATION: CRESSER INDUSTRIES, INC.
ALEXANDRIA, LOUISIANA
REPORT INSPECTION
NO.: 99900054/85-01 RESULTS: PAGE 2 of 7
A. Inspection Issues
The inspection was conducted to determine whether rodels 7150 and 7250
Class 1 and 2 valves are being fabricated and supplied to Fort
Calheun in accordance with the established Dresser QA and CC
commitments. Dresser is supplying these valves as part of the Fort
Calhoun outage work package. During the inspection, observations were
made on the fabrication of other valves and valve spare parts that are to
be supplied to the nuclear industry. The survey consisted of ensuring
that there is proper implementation of Dresser QA procedures, applicable
codes ( ASME Section III) and standards ( Appendix B to 10 CFR Part 50.)
B. Inspection Findings
1. Violations .
\
Contrary to section 21.21 of 10 CFR Part 21, evaluations of
defects are not being performed adequately to determine if they
merit reporting in accordance with 10 CFR 21. A review of
Dresser's Part 21 procedure (#003.00 dated March 28, 1984) and
Part 21 evaluation files for 1984 and 1985 concluded that as a
result of an inadequate evaluation on file no. 84-01, Dresser
failed to notify the NRC or its customers of a reportable Part 21
item (85-01-01).
2. Nonconformances
a. Contrary to Criterion VII of Appendix B to 10 CFR Part 50,
and Dresser Industries QAM, Section 6 paragraph 6.,1 and 6.2,
Dresser procured services from two sources that were not on an
approved vendors list (85-01-02),
b. Contrary to Criterion V!1 of Appendix B to 10 CFR Part 50,
and Dresser Industries procedure QTI-13, paragraph 3.6,
Dresser failed to perform receiving inspection on 4
containers of type 7018 nuclear weldina rods (85-01-03).
c. Contrary to Criterion XII of Appendix B to 10 CFR Part 50,
and Dresser Industries procedure QIT-33, paragraoh 9.0b,
calibration of the Charpy V-Notch Impact Testing Machine has
not been performed during the last five years (85-01-04).
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ORGANTZATiON: CRESSER INDUSTRIES, 'NC.
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ALEXANDRIA, LOUISIANA
REPORT INSPECTION
NO.: 99900054/85-01 RESULTS: PAGE 3 of 7
d. Contrary to Criterien XII of Appendix B to 10 CFP Part 50,
and Drerser Industries procedure QTI-76, paragraph 2.1, the
calibration certifications (*1343, *6141) for torque
devices had no documentation of a standard serial number.
Therefore, the calibration load cell and readout devices
used as the standard for calibration cannot be traced as
required (85-01-05).
e. Contrary to Criterion XII of Appendix B to 10 CFR Part 50,
and Dresser Industries QAM, Section 12, paragraph 5.1,
calibration of the WR-12 Carbon Determinator (used for analysis
of carbon and sulfur content) was not traceable to national !
standards or equipment manufacturer's recommended standards
(85-01-06).
f. Contrary to Criterion XII of Appendix B to 10 CFR Part 50,
and Dresser Industries procedure QTI-13, paragraph 3.1,
Dresser quality control failed to certify calibration
completed on June 6,1984 for the nuclear welding rod oven l
bi-metal thermometers TG-2, TG-4, TG-6, TG-8, TG-11, TG-20,
TG-21 (85-01-07).
g. Contrary to 10 CFR 21, paragraph 21.21, and Dresser's Part 21
procedure, *003.00, paragraph 3.2, Dresser did not identify / list
the pertinent data to ' substantiate an investigation for
Part 21 file no. 85-01 (85-01-08).
C. Unresolved Items
Nore.
D. Other Findings and Comments
The NRC inspector reviewed the parts and travelers for Class 1 and 2
Dresser /Hancock 7150 and 7250 model valves to verify that heat number
stamping, nondestructive testing, correct calibration of gages,
subcontractor agreements were r'et, and appropriate sign offs were
completed according to Dresser commitments.
The nonconformances found during the inspection did not involve the
fabrication of valve models 7150 and 7250.
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ORGANIZATION: DRESSER INDUSTRIES, INC. t
ALEXAMDRIA, LOUISIANA
REPORT INSPECTION
NO.: 99900054/85-01 RESULTS: PAGE 4 of 7
1. 10 CFR Part 21 Reauirement
a. A review of Dresser's Part 21 files for 1984 and 1985 noted
that Part 21 file no. 84-01 was not adequately evaluated in
accordance with 10 CFR Part 21 Section 21.21. File no. 84-01
identified a problem with the failure of the disc collar on
model 3707RA safety valves. The file stated this problem was
not reportable since "The failure is an isolated case. Since
1971, Dresser QA system has improved to preclude this failure
mode." However, a letter dated July 2,1984 in the same file
states this failure has happened twice since 1971 once in
August 1981 at Toledo Edison / Davis-Besse and again at Diablo
Canyon in May 1984
Information in file no. 84-01 indicates that in May 1984,
during blowdcwn testing by Wyle Laboratories, Huntsville,
Alabania, on the mai'n steam safety valves from Pacific Gas &
Electric /Diablo Canyon 2 (Dresser valve type 3707RA), valve
S/N BN 1741 lifted with simultaneous shearing of the disc
collar / spindle threads and cotter pin. This occurred during
the first actuation, at approximately 1065 psig. The disc and
spindle deflected sidewise upon closing and the disc became
wedged between the nozzle seat area and the bottom of the disc
.hol de r. The valve became mechanically jammed and could not open.
It also leaked severely because the disc was not seated properly.
2resser was asked about the blow-down problems that they
are presently experiencing on the 3700 series safety relief
valves undergoi'ng testing at Wyle Labs in Huntsville, Alabama
for Toledo Edison / Davis Besse. Specifically, Dresser was
asked whether an investigation / evaluation was done or is
planned to compare the problem experienced with the 3700
series safety relief valves to the problems documented in
file no. 84-01. Dresser's response was "no evaluatinn has
been performed." During a subsequent conference call on
October 10, 1985, Dresser (Mr. J. Watz and Mr. B. Brunson)
stated that " Dresser has performed an evaluation / comparison of
file no. 34-01 and the valves being tested by Wyle Labs and
determined the failure modes were similar. File no. 84-01 will
remain closed, however, a new file, no. 85-04, will be initiated.
This file (85-04) will reference file no. 84-01 and will be
reported as,a Part 21".
Violation 85-01-01 was identified during this part of the
inspection.
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ORGANIZATION: DRESSER INDUSTRIES, INC.
ALEXANDRIA, LOUISIANA
REPORT INSPECTION
NO.: 99900054/85-01 RESULTS: PAGE 5 of 7
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b. A review was made of Dresser's Part 21 evaluation and reporting
procedure " Evaluating and Reporting of Deviations and/or
Noncompliances Affecting Safety Related to NRC Regulation 10 CFR
Part 21" dated March 28, 1984 and Part 21 evaluation files for
1984 and 1985. This review noted that Dresser did not identify /
list the pertinent data called for in their procedure to
substantiate the investigation for Part 21 file no. 85-01.
This Part 21 file identified a problem with Dresser's model 3050
diaphragm valves sticking partially open or closed. The problem
was reported to the NRC by the Cleveland Electric Illuminating
Co., Perry Nuclear Power Plant. According to Dresser file no.
85-01, the problem was not reportable per 10 CFR 21 since
Dresser had "no knowledge in power plant system design."
However, Dresser's customers were notified. File 85-01 did
not identify / list the information called for in paragraph 3.2
of pr.ocedure no. 003.001 to substantiate an investigation.
In addition, a review of the purchase order and specifications
for valves ordered by the Perry Nuclear Power Plant was performed
by the NRC inspector. This review identified documents which
listed valves as " active" and "non-active", " safety related"
and "non-safety related" and "ASME Class 1, Class 2 or Class 3"
valves. With this information Dresser should have been able to
determine the safety significance of the deviation.
Nonconformance 85-01-08 was identified during this part of the
inspection.
2. Purchase Requirements
An examination was made of 20 purchase orders (P.O.) from Dresser
for outside calibration services for gages, testing and measuring
devices. Dresser was found to have purchased calibration and
certification services for thermocouples TG-2, TG-4, TG-6, TG-8,
TG-11, TG-20, TG-21, from two vendors that were not on Dresser's
approved vendors list. Calibration of the thermocouples was
performed by Honeywell-Houston on August 13, 1980 - Dresser order
- 26229-6'; on October 19, 1982 - Dresser order 848879-6; and, on
December 4, 1984 - Dresser order 447671-6. Likewise, Honeywell -
Ft. Washington, PA performed calibration and certification of the
thermocouples on February 25, 1982 - Dresser order #41201-6. These
thermocouples were used to monitor the temperature of the heat
treating furnaces. '
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ORGANIZATION: ORESSER INDUSTRIES, INC.
ALEXANDRIA, LOUISIANA
REPORT INSPECTION
NO.: 99900054/85-01 RESULTS: PAGE 6 of 7
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Nonconformance 85-01-02 was identified during this part of the
inspection.
3. Control of Special Processes
Heat treating and weld rod ovens were inspected and were found
to be adequately calibrated and functioning according to Dresser
procedures. The nuclear welding rod storage area was inspected.
Weld rod containers were stored in either locked cabinets or locked
weld rod ovens. The Section III weld rod ovens were marked " Nuclear."
All rods were stored in the metal containers received and were marked
wit.1 rod specification, lot and/or heat number to maintain trace-
ability. However, four cases were found where containers of Type
7018, nuclear welding rods, lot 3c504YOZ, heat #76175, were not
stam. red (verified) by the receiving inspection personnel. Receiving
Inspection is essential in verifying that cans are properly sealed,.
and that identificatior. numbers, material type, and quantity ordered
are correct. ,
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Nonconformance 85-01-03 was identified during this part of the
inspection. l
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4 Manufacturing Process Control
)
The NRC Inspector reviewed the parts, travelers, and drawings for
four shop orders and verified that specified requirements such as:
(a) heat number stamping, (b) nondestructive testing, (c)
authorized nuclear inspector sign off, (d) final inspection, (e)
calibration of gages, (f) serial number assignment, and (g) heat
treatment had been completed and correctly documented. No
nonconformances were noted in this area.
5. Calibration
The NRC inspector found that torque devices calibration certifications
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81343 and #6141 had no documentation of a calibration standard serial l
number. Therefore, there is no objective evidence that the torque '
devices were checked using a traceable load cell and readout device
as the standard for measurement.
Nanconformance 85-01-05 was identified during this part of the
inspection.
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ORGANIZATION: DRESSER INDUSTRIES, INC.
ALEXANDRIA, LOUISIANA
REPORT INSPECTION
NO.: 99900054/85-01 RESULTS: PAGE 7 of 7
The NRC inspector found that calibrations of nuclear welding red
oven bi-metal thermometers (TG-2, TG-4, TG-6, TG-8, TG-11, TG-20,
and TG-21) completed on June 7,1984 were not certified by quality
control. Accurate continuous monitoring of the nuclear weld rod
ovens (between 250 and 300* F) is essential for low hydrogen
electrodes. The temperature range of 250* to 300 F has to be
maintained in order to reduce moisture or hydrogen absorption of the
weld rods.
Nonconformance 85-01-07 was identified during this part of the
inspection.
The NRC inspector reviewed the calibration and procedure requirements
involved in the operation of the WR-12 Carbon Determinator. Dresser
was not able to show that the calibration standards used for
calibrating the carbon determinator are traceable to national
standards or the equipment manufacturer's recommended standards.
The WR-12 Carbon Determinator is used to determine material carbon
and sulfur content. For applications where high levels of carbon
and sulfur are detrimental to impact strength and low levels of
ca.rbon are desirable (i.e., some corrosive environments), accurate
analysis of carbon and sulfur level is essential.
Nonconformance 85-01-06 was identified during this part of the
inspection.
10 Plant Tour
A tour of Dresser's facility was performed by the inspectors. The
activities observed were receiving, nuclear material storage area,
nuclear weloing rod storage area, heat treating furnaces, stock
rooms, valve assembly clean room, calibration records area, and the
metallurgical laboratory. The storage, laboratory and work areas
were neat, clean and free of extraneous materials. Operations
observed appeared to be well planned and progressing in an orderly
fashion.
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