ML20199C886
| ML20199C886 | |
| Person / Time | |
|---|---|
| Issue date: | 06/11/1986 |
| From: | Conway J, Merschoff E NRC OFFICE OF INSPECTION & ENFORCEMENT (IE) |
| To: | |
| Shared Package | |
| ML20199C876 | List: |
| References | |
| REF-QA-99900346 NUDOCS 8606180291 | |
| Download: ML20199C886 (18) | |
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ORGANIZATION: VELAN VALVE CORPORATION WILLISTON, VERMONT INSPECTION INSPECTION REPORT . N0.: 99900346/86-01 DATE: 3/24-27/86 ON-SITE HOURS: 54 CORRESPONDENCE ADDRESS: Velan Valve Corporation ATTN: Mr. E. I. Francois Vice President, Quality Assurance Avenue C, Griswold Industrial Park Williston, Vermont 05495 ORGANIZATIONAL CONTACT: Mr. E. I. Francois TELEPHONE NUMBER: 802-863-2562 NUCLEAR INDUSTRY ACTIVITY: Velan's nuclear product line consists of cast and forged steel gate, globe, ball, and check valves. ASSIGNED INSPECTOR: Wh 8( J. V. Conway, React Inspection Section, (RIS) Date J OTHER INSPECTOR (S): J. Harper, RIS L. Vaughan, Pro ram Coordination Section APPROVED BY: Ivfb f M E. W. Merschoff, Chi ~ef, RIS,Mendor Program Branch Date INSPECTION BASES AND SCOPE: A. BASES: 10 CFR Part 21 and 10 CFR Part 50, Appendix B. B. SCOPE: This inspection was made as a result of the receipt of 10 CFR Part 50.55(e) reports from Gulf States Utilities Company (GSUC) relating to oversized springs in piston check valves, torque switch settings and high stall torque on operators and motors supplied with motor-operated valves (M0V), short hanger block bolts, and leaking swing check valves; (continued on next page) PLANT SITE APPLICABILITY: Oversized springs, high stall torque, short bolts, and leaking swirig check valves - River Bend (50-458/459); antirotation stop (continued on next page) 8606180291 860613 PDR GA999 EMVVEL.AN 99900346 PDR
~ ORGANIZATION: VELAN VALVE CORPORATION WILLISTON, VERMONT REPORT INSPECTION NO.: 99900346/86-01 RESULTS: PAGE 2 of 11 SCOPE: (continued) and 10 CFR Part 21 reports from: (a) Toledo Edison re-lating to check valve disc binding and (b) Tennessee Valley Authority relating to incomplete disc openings for stop check valves. In addition, the inspec-tion was conducted to review manufacturing records and gather data on design changes, recommended maintenance programs and vendor / licensee interface per- . taining to swing check valves. PLANT SITE APPLICABILITY: (continued) Davis Besse (50-346); disc op.enings - Bellefonte Units 1 and 2 (50-438/439) and modified torque switch settings - River Bend (50-458/459) and Seabrooke Units 1 and 2 (50-443/444). A. NONCONFORMANCES:
- 1. Contrary to Criterion V of Appendix B tr 10 CFR Pari 50 and Section 7.9 of Procedure No. VELW-QC-156.7, one of the compartments of holding oven No. W385 was identified with a heat number instead of a lot number (86-01-01).
- 2. Contrary to Criterion V of Appendix B to 10 CFR Part 50 and Subsection NCA-4134.5 of the ASME Code, the procedure for cleaning and packaging of stainless steel valves and valve components, VEL-P-64, does not adequately centrol the identification and segregation of carbon steel grinding wheels from stainless steel grinding wheels. This is evidenced by the fact that unmarked and unsegregated carbon steel grinding wheels were found in a room marked " Stainless Steel Only" and an operator was grinding carbon steel valve bodies in the room (86-01-02).
B. OPEN ITEMS: None. C. STATUS OF PREVIOUS INSPECTION FINDINGS:
- 1. (Closed) Violation (83-01): A current copy of 10 CFR Part 21 was not posted in the area where section 206 was posted.
The NRC inspector verified the posting of current copies of 10 CFR Part 21, Velan Part 21 procedure, and Section 206 at two locations in the plant.
- 2. (Closed) Nonconformance (83-01): Two field service reports from a Velan Service Engineer dated April 25 and May 23, 1983, and relating to the jamming disc on 21 inch stop check valves at the Bellefonte nuclear site were not in the files of the Engineering Supervisor at Plant 3.
ORGANIZATION: VELAN VALVE CORPORATION WILLISTON, VERMONT REPORT INSPECTION NO.: 99900346/86-01 RESULTS: PAGE 3 of 11 I i The NRC inspector reviewed copies of the Field Service Reports related to the jamming disc on the 21" stop check valves which had been given to the Engineering Supervisor at Plant 3.
- 3. (Closed) Nonconformance (83-01): An eye examination report was absent for three Level II personnel - employee no. 70 for 1980 and '
the Manager QC and employee no. 86 for 1981. The NRC inspector verified that employee no. 70 was qualified in 1980 for limited NDE certification for liquid penetrant examination under the provision of procedure VEL-QCI-565. Recent eye examinations for employee no. 86 and the QC Manager indicate they have acceptable eyesight. Velan has established a file for all personnel requiring eye examinations so that the supervisors are notified approximately one month before the eye examination date. The qualification records of two Level III and three Level II examiners were reviewed and found to meet the requirements of SNT-TC-1A.
- 4. (Closed) Nonconformance (83-01): Revised procedures contained in Revision 7 to the QA manual were not reviewed by the following personnel: NDE Level II examiner (employee No. 70), welders (Nos.
WA54, WA57, WA55, and WA62), inspectors (Nos. 2, 51, 73, and 88), and the company metrologist. The NRC inspector verified that employee Nos. 70, WA54, WA57, WA55, , WA62, 2, 51, and 73 were trained and qualified. The Vice President - QA also issued a memo to the supervisors regarding their responsi-bility to perform training in a timely manner.
- 5. (Closed) Nonconformance (83-01): Four companies (Precision Inspec-tion, Aviation Electric, Canadian Marconi, and Canadian Central Gauge) had supplied calibration services, but none of the companies were approved by Velan.
The NRC inspector verified that QC procedure VEL-QCI-762 for Vendor Qualification (Calibration Services) was written and approved in December 1983. It was also noted that Velan performed audits on Aviation Electric and Canadian Marconi in February 1984 and Canadian Control Gauge in January 1984. Precision Inspection is no longer used by Velan as a calibration service vendor.
ORGANIZATION: VFLAN VALVE CORPORATION WILLISTON, VERMONT REPORT INSPECTION N0.: 99900346/86-01 RESULTS: PAGE 4 of 11
- 6. (Closed) Nonconformance (83-01): There was no indication that the Quality Assurance Administrator had reviewed and/or initialed three NDE procedures and training / qualification records from Trutom who had performed radiographic and ultrasonic testing services for Velan.
The NRC inspector verified that paragraph 2.3 of Procedure VELW-QC-156.2 was revised to reflect that the company Level III examiner shall review and approve all subcontractor NDE procedures and verify qualifications of personnel. D. OTHER FINDINGS AND CO$MENTS:
- 1. Swing Check Valves Velan currently manufactures three types of bolted-bonnet swing check valves. The main difference is the configuration in which the hanger is attached to the valve body. For the 21", 3", 4", and 6" (high pressure) valves, the hanger is attached to a bracket which is an integral part of the seat. For the 6" (low pressure) to 12" valves, the hanger is attached to a ring that is bolted into three brackets which are welded on the body. For valves greater than 12",
the hanger is also attached to a ring, but the ring is bolted into machined lands on the body. All three types are designed to have the disc suspended in the flow path at full flow. Forgings are used for the body, bonnet, and disc, and a hardfaced seat is welded into the body. The seal areas of the ' disc are also hardfaced. The attachment of the disc to the hanger is with a nut that is locked with a cotter pin to the stem of the disc. The NRC inspector reviewed the QA records for 24 orders of nuclear swing check valves. Records consisted of customer purchase orders (P0) and technical specifications and Velan Order Writeups (0W) and Data Packages (DP). The P0s referenced technical specifications and the requirements of Section III of the Code and 10 CFR Part 21. The 0W is generated by the Contract Administrator in Montreal upon receipt of a customer order. The 0W, which references requirements contained in the P0 and applicable drawings, is sent to Plant No. 3 in Williston, Vermont. For nuclear orders, the QA department at Plant No. 3 receives not only a copy of the 0W but also copies of the customer's P0 and design specification.
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ORGANIZATION: VELAN VALVE CORPORATION WILLISTON, VERMONT REPORT INSPECTION RESULTS: PAGE 5 of 11 NO.: 99900346/86-01 , A DP consisted of a QC check list, Velan's Certificate of Conformance (CC), nondestructive examination (NDE)/hydrotest certification, Data Report, certified material test reports (CMTR), weld record, wall thickness report, seismic certification., assembly routing sheet (i.e., traveler), and assembly & final inspection check list. The QC check list identified the material specifications and the NDE, hydro, cleaning, and wall thickness procedures. The CC and NDE/ hydro certification were signed and dated by both the QC Documentation Manager and the Authorized Nuclear Inspector (ANI). The Data Report and the CMTRs were for the bonnet fasteners and the pressure retaining parts.(i.e., body, bonnet, and disc). There was also a CMTR for the material used to weld in the seat and for hard-coating the seat and disc. Section III, swing check valves manufactured by Velan include approx-imately seven bolted bonnet (BB) type to Public Service Electric & Gas, 167 BB and 12 pressure seal (PS) type to GSUC, two 88 to Duquesne Light, one BB and eight PS to Cornell & Underhill, 39 BB to United Engineers & Constructors (UE&C), 57 BB and eight PS to Niagara Mohawk Power (NMP) and five PS to Baltimore Gas & Electric.
- 2. Valve Disc Binding 1
In esponse to NRC IE Notice 83-06 and INP0 SER 20-83, Velan notified ten customers in August 1983 of a potential problem with anti-rotation stops in swing check valves. The concern was related to a disc hanging up on the anti-rotation stops on the disc and hanger arm thus preventing proper seating of the disc. The recommendation was to remove the stops on the cast disc and the hanger arm and use a locking nut which acts as the anti-rotation device. In approximately 1975, a new design was developed by Velan to use a ( I forged disc having one welded stop versus two stops on the original
- cast disc. Another change was made in 1985 to prevent disc malfunc-tion on the anti-rotation stops. The modification, which could be made in the field, included grinding down the stops on the disc and hanger armCustomers and inserting (a pin in a drilled hole between the disci.e.,
i and the arm. UE&C, Consolidated Edison, and NMP) having 3", 4" and 6" swing check valves were notified of this proposed fix by Velan in November 1985.
A ORGANIZATION: VELAN VALVE CORPORATION WILLISTON, VERMONT REPORT INSPECTION RESULTS: PAGE 6 of 11 NO.: 99900346/86-01 The NRC inspector was told by the Corporate Manager of Engineering that currently all replacement discs are forged and contain a welded stop. In addition, all valves which are greater than 4" have a hanger arm in which a hole is drilled to capture the welded stop in the forged disc.
- 3. Modified Torque Switch Settings During preoperational testing in July 1985, of MOVs at River Bend, it was noted that the torque switch limiter plate had been modified on some operators, and the torque switch settings in two cases exceeded the maximum allowable value established by the motor operator manufacturer, Limitorque Corporation (LC).
A review of QA records revealed that the motor operators were shipped in 1980 from LC to Velan with the proper torque switch settings. During hydrotesting of the MOVs, Velan discovered tnat certain valves could not be tested satisfactorily without changing the torque switch setting. Velan informed LC of the testing conditions and requested authorization to change the settings. LC granted Velan permission to change the torque switch setting to 2.25 provided that Velan testing proved that the switch would open and the motor would not stall at 80 percent voltage. In completing the Documentation Check List packages, the technician listed both opening and closing voltage at 2.25 rather than recording the actual test setting. Although Velan modified the limiter plates, Velan did not replace the existing calibration stickers with new stickers indicating the higher maximum allowable setting. This problem was also discovered to exist at the Seabrook facility. In both cases, Velan was given proper authorization from LC to modify the limiter plates in Velan's facility. LC was contacted and provided with the modified torque switch settings so that the correct stickers and limiter plates could be sent to the Uver Bend and Seabrooke nuclear plants.
- 4. MOVs - High Stall Torque The NRC was notified in December,1984 by GSUC that four motors of certain M0Vs were supplied by Velan with a stall torque (80 f t.-lb.)
greater than the specification (60 f t.-1b.). While resolving this problem, it was discovered that the valves supplied with the speci-fied 60 ft.-lb. motors exceeded the valve safety limit. l
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ORGANIZATION: VELAN VALVE CORPORATION WILLISTON, VERMONT REPORT INSPECTION N0.: 99900346/86-01 RESULTS: PAGE 7 of 11 The NRC inspector examined QA records and noted that Velan had origin-ally ordered SMB-3 operators with 60 ft.-lb. motors. LC mistakenly placed 80 ft.-lb. motors on.these operators. Velan did not identify the discrepancy during receipt inspection of the operators, nor upon final inspection of the MOVs prior to shipment to the customer. To supply the valves within the safety limits, LC recommended reducing the maximum operating differential pressure from the original 500 psi to 250 psi to allow a reduction in the size of the motor to 40 ft.-lb. However, LC did not inform Velan that they had discontinued manufacturing SMB-3 operators with 40 f t.-lb. motors. In November 1984, LC requested Velan to re-evaluate the operator selection with regard to operator size and suitable motor and compatible stall torque. LC also recommended the use of 40 ft.-lb. motors on SMB-2 operators which would satisfy the safety limit requirement. In December 1984, GSUC and Velan agreed to use 40 ft.-lb. motors on - SMB-2 operators, and Velan issued a new P0 to LC for these replacement operators on January 22, 1985.
- 5. Stop Check Valves - Incomplete Disc Opening In February 1983, during flushing operations of the makeup and purification and high pressure injection systems at the Bellefonte Plant, seven of nine 21" 1500 lb. Velan stop check valves intermit-tently failed to fully open and/or showed indication of excessive pressure drop. The cause of the malfunction is the lack of or an insufficient number of equalizing holes in the valve disc.
A review of QA records revealed that the deficiency of equalizer holes resulted from a drawing change. This deficiency existed in 21" to 6" stop check and piston check valves. All drawings for these valves were reviewed and modified by Velan in November 1983. As a result of the investigation, Velan notified UE&C in September 1984 that five stop check valves supplied to the Seabrooke Station could malfunction due to the deficiency of equalizer holes. Velan provided drawings showing the quantity, size and location of the holes which should be drilled in the disc to make the valve perform satisfactorily. The five discs from the affected valves were sent I to Velan who machined the holes, and the modified discs were returned to the Seabrook Station.
- 6. Piston Check Valves - Oversized Springs l
ORGANIZATION: VELAN VALVE CORPORATION WILLISTON, VERMONT REPORT INSPECTION N0.: 99900346/86-01 RESULTS: PAGE 8 of 11 In June 1985, GSUC notified the NRC of piston check valves for the reactor plant floor drain system supplied by Velan with springs which were out of specification. A review of QA records indicated that GSUC had ordered 12 piston check valves with springs (Part No. 7975-030) rated at a cracking pressure of 2.5 psi. However, Velan supplied 12 valves with springs (Part No. 7975-022) with a cracking pressure of 25 psi. Velan supplied the wrong springs because the incorrect spring part was referenced on the assembly drawing. It was noted that these piston check valves are supplied with springs rated at 2.5 psi (Part No. 7975-030),20 psi (Part No. 7975-023),and 25 psi (Part No. 7975-022). Prior to May 1985, the three springs were referenced on the same parts list. Velan is currently referencing each spring on a separate parts list, and the assembly drawing reflects the applicable part number. In July 1985, the NRC was notified that GSUC had completed their evaluation of the piston check valves with the oversized springs and determined that it would not adversely affect the safe operations of the plant and thus is not reportable under 10 CFR 50.55(e). However, new springs were supplied by Velan and installed by GSUC in the affected valves.
- 7. Leaking Check Valves In November 1984, GSUC notified the NRC of containment isolation check valves leaking beyond the acceptable limits for a specific test being conducted. The valves in question were purchased in June 1979 to Stone & Webster (S&W) specification No. RBS 228.211 dated January 1975. Initially, hydrostatic testing was to be in accordance with NX-6000 of the ASME Code for the shell test and specification MSS-SP-61 for the seat test. Since MSS-SP-61 does not include a differential pressure check, S&W added in November 1980 a pneumatic seat leakage test (ref. Engineering & Design Change Request No.
P-10331) to specification No. RBS 228.211. The NRC inspector reviewed Hydro / Air Test Data reports for seven swing check valves tested by Velan in August and December 1981 and March 1982 and later shipped to the River Bend station. These valves (2-20" 900 lb., 3-10" 150 lb., and 2-12" 15 lb.) were tested at an air pressure of 45 psi for 15 minutes, and all passed the maximum permissible leakage rate specified in the revised specifi-cation No. RBS 228.211.
O ORGANIZATION: VELAN VALVE CORPORATION WILT.ISTON, VERMONT REPORT INSPECTION N0.: 99900346/86-01 RESULTS: PAGE 9 of 11 In a 1984 telephone conversation, Velan's Corporate Manager of Engi-neering made a recommendation to GSUC's Project Manager regarding the containment isolation valves which did not pass the test at River Bend. The recomendation was to lap the seat area of the disc or replace the hard coated (stellite) disc with a soft seated disc. GSUC has lapped the leaking valves which were retested to acceptable resul ts .
- 8. Hanger Block Bolts In May 1984 GSUC notified the NRC of short cap screws (11/4" versus 11/2" requirement of ANSI Bl.1) for the hanger block bolts in swing check valves supplied by Velan. Velan investigated the problem and notified S&W via a telecopy dated December 19, 1984 that a shorter thread engagement was satisfactory due to the application of the bolts. Velan postulated that the assembler used 1 1/4','. bolts because the 11/2" bolts were not in stock for a short period of time.
Following this incident, Velan placed the bolt length for hanger brackets on the inspection checklist. The NRC inspector reviewed the " Assembly and Final Inspection Checklist" for bolted cover swing valves and verified that item No. 10 on the assembly inspection was to check that " Hanger Screws [are] correct size." Velan is currently investigating a method for identifying bolt size on the bolt head to confirm the size of the bolt used without necessitating its removal.
- 9. Welding The NRC inspector reviewed the qualification records of 12 welders who had welded on Section III valves. The Welder Continuity Log is certified on a quarterly basis by the Vice President Quality Assurance that an individual has welded to a particular process during that period. Welder Qualification Tests certify that an individual has made a weld which is tested per the requirements of Section IX of the ASME Code. A review of these records for welder Nos. WA-73, -57,
-42, -66, -54, -62, -55, -59, -41, 50 and -53 indicated that all the welders were qualified to weld with the apolicable Welding Procedure Specification (WPS). Eight Procedure Qualification Records were reviewed, and it was verified that the eight WPSs used to weld the seat ring into the body and to apply the hard facing on the sealing surfaces were all qualified.
- 10. Audits
j i ORGANIZATION: VELAN VALVE CORPORATION WILLISTON, VERMONT REPORT INSPECTION NO.: 99900346/86-01 RESULTS: PAGE 10 of 11 The NRC inspector reviewed: applicable sections of the QAM, one proce-dure, 19 vendor audit reports (included eight performed on calibration service vendors),17 internal audit reports, Quality Systems Certifi-cates for nine vendors, qualification records of four lead auditors and the Approved Vendor List (AVL) to verify external and internal audits are being performed as required. This review noted that all vendor and internal audits are being conducted in accordance with the QAM and approved procedures by qualified personnel.
- 11. Spare Parts Procurement The NRC inspector reviewed applicable sections of the QAM, eleven vendor audit reports, eighteen P0s and the AVL to verify that procurement of spare parts from domestic and foreign suppliers are being conducted in accordance with QA program requirements.
It was noted that Plant No. 3 in Williston, Vermont procures material and components from both U.S. and Canadian vendors while Plants No. 1 and 2 in Montreal, Quebec utilize vendors in Canada, Japan, Spain, and the U.S. During a review of records at Plants No. 2 and 3, it was verified that procurement activities and vendor audits are being conducted in accordance with the requirements of the QA program. Per discussions with Velan's purchasing personnel, it was noted that less than 3% of the nuclear procurement orders from Plant No. 3 are with Canadian vendors, and approximately 66% of nuclear procurement orders from the Canadian plants are with overseas vendors. Japan Steel Works (JSW) and Forjas DeLazcaro (FD), are the major foreign vendors. JSW is an ASME Certificate holder (No. 487 which expires in April 13,1987), and FD was audited by Velan in May 1984 and May 1985.
- 12. Plant Tour The NRC inspector toured the manufacturing areas of Plant No. 3 in the company of Velan officials. The activities witnessed included welding, cleaning of components, and Nondestructive Examination (NDE).
The welding and NDE areas were clean and free of extraneous materials. Activities observed appeared to be well planned and progressing in an orderly fashion. Current copies of welding and NDE procedures were at the applicable stations. Up to date calibration stickers were on the volt and amp meters (welding machines) and the black light (filtered and unfiltered) and ultraviolet meter at the magnetic particle testing station. In the weld material control area, electrodes were retained in four ovens. All the ovens were
ORGANIZATION: VELAN VALVE CORPORATION WILLISTON, VERMONT REPORT INSPECTION NO.: 99900346/86-01 RESULTS: PAGE 11 of 11 operating at approximately 290 F and had stickers indicating that the temperature recorders were calibrated. It was noted in furnace no. W385 that a certain lot of electrodes was incorrectly identified on the oven grid (See Nonconformance 86-01-01). In the component cleaning area, it was noted that unmarked and unsegregated carbon steel grinding wheels were present in a room marked " Stainless Steel Only," and an operator was grinding carbon steel valve bodies in the same room. A review of procedure VEL-P-611,
" Cleaning and Packaging of Stainless Steel Valves and Valve Compo-nents", states that brushes and abrasives are to be reserved for use on stainless steel but does not describe how this is to be accomp-lished. From the observations made it is obvious that simply lab-eling the room " Stainless Steel Only" has not worked, and VEL-P-611 has not adequately addressed the subject (See Nonconformance 86 02).
- 13. 10 CFR Part 21 The procedure for ' reporting defects was reviewed, and it was found to be adequate. It was noted that Velan had complied with the posting requirements of the regulation in that the applicable documents were posted in two locations of the fabrication shop in Plant No. 3. A review of five P0s to both foreign and domestic vendors indicated that Part 21 requirements were imposed on the suppliers.
E. PERSONNEL CONTACTED J. Farrell, Corp. Mgr. Engineering Z. Palko, QA Mgr. (Plant 2)
*D. Haseldine, Engineering Supervisor
*E. Francois, VP - 0A
*B. Bleau, Mgr. QC Documentation L. West, Purchasing Mgr.
R. Coutinho, Project Adm. Mgr. O. Morad, Purchasing Mgr. (Plant 2) D. Snalen, Foremen - welders
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