ML20214A274
| ML20214A274 | |
| Person / Time | |
|---|---|
| Issue date: | 11/17/1986 |
| From: | Merschoff E, Naidu K NRC OFFICE OF INSPECTION & ENFORCEMENT (IE) |
| To: | |
| Shared Package | |
| ML20214A272 | List: |
| References | |
| REF-QA-99900839 NUDOCS 8611190360 | |
| Download: ML20214A274 (7) | |
Text
.
ORGANIZATION: ROTORK CONTROLS, INCORPORATED ROCPESTER, NEW YORK REPORT INSPECTION INSPECTION NO.: 99900839/86-01 DATES: 09/09-12/86 ON-SITE HOURS: 24 CORRESPONDENCE ADDRESS:
Rotork Controls, Incorporated ATTN: Mr. W. H. Whiteley President 19 Jet Drive Rochester, New York 14624 ORGANIZATIONAL CONTACT:
D. Matla, CA Manager TELEPHONE NUMBER:
716-328-1550 NUCLEAR INDUSTRY ACTIVITY:
Fabrication of electric and pneumatic actuators for valves.
//['8[d ASSIGNED INSPECTOR:
M K. Naidu, Reactive Inspection Section (RIS)
Date OTHERIhSPECTOR(S):
[
n y g APPROVED BY:
E. W. Merschof f, Chief S, Vcndor Program Branch Date INS;'ECTION BASES AND SCOPE:
A.
BASES:
10 CFR Part 21 and 10 CFR 50 Appendi> B.
B.
SCOPE: Review of implementation of the Quality Assurance Program in selected areas.
PLANT SITE APPLICABILITY:
Fort St. Vrain (50-267), McGuire (50-369).
8611190360 861118 PDR GA999 EMVROTOR 99900839 PDR
ORGANIZATION: ROTORK CONTF0LS, INCORPORATED ROCHESTER, NEW YORK REPORT INSPECTION NO.: 99900839/86-01 RESULTS:
PAGE 2 of 7 A.
VIOLATIONS:
No violations were identified during this inspection.
B.
NONCONFORMANCES:
No nonconformances were identified during this inspection.
C.
UNRESOLVED ITEMS:
No unresolved items were identified during this inspection.
D.
INSPECTION FINDINGS AND OTHER COMMENTS:
1.
Background Information Rotork Controls, Incorporated (Rotork) manufactures electric and pneumatic actuators for valves. The operators were designed and components manufactured by the parent company, Rotork Controls, Limited, Bath, England. Potork imports selected components supplied by the parent company and assembles the actuators in the U.S.
In 1982, Rotork qualified their electric operators to the requirements of IEEE 382-1980, IEEE 323-1974 and IEEE 344-1975.
Rotork utili:es a modular construction with standard components consisting of the motor assembly, double acting thrust base, auxiliary switch contact assembly and terminal block assembly (synchroset) or reversing starter assembly (synchropack). The Potork actuator is designed with a minimum number of moving components. The drive train consists of a motor specially designed for valve actuators, a single gear reduction through a worm and worm wheel set, a center column, and the drive sleeve. The worm gear is machined directly into the motor shaft. The motor is constructed such that the torque switch spring pack is located at the end of the motor and is casily adjust-able. The motor assembly is sealed with an "0" ring. As such, space heaters are not considered to be necessary to prevent moisture condensation. The actuator body construction is such that the thrust is removed in a thrust base prior to the gear case. This arrangement permits the gear case / actuator to be of a lighter construction and allows the actuator to be serviced while the valve is in operation.
Lubrication for the drive train is oil. Manual operation is through a direct drive handwheel.
=
/
ORGANIZATION:
ROTORK CONTROLS, INCORPORATED ROCPESTER, NEW YORK REPORT INSPECTION NO.: 99900839/86-01 RESULTS:
PAGE 3 of 7 The electrical compartment in the Rotork actuator is ccmpletely sealed from the environment through the use of male / female joints and "0" rings. The auxiliary switch contacts and the motor leads are internally connected to a separate terminal compartment for field connections. This terminal compartment is a sealed enclosure separate from the main electrical compartment.
2.
Plant Tour The insoector toured the plant in the areas of assembly, storage of material, painting shop, incoming receipt inspection and test area.
The inspector interviewed operator assemblers and test technicians and determined that the individuals were knowledgeable in the work they performed.
3.
Review of Purchase Orders The inspector reviewed four purchase orders (P0) received by Potork to determine whether the engineering, manufacturing and ouality assurance personnel reviewed and accepted the technical requirements. The inspector determined that the managers of engineering, manufacturing and quality assurance review the purchase documents and indicate their concurrence by their signatures on a Certificate of Conformance that the operators will meet the specification requirements including IEEE 323-1974, IEEE 344-1975 and IEEE 382-1980. The following purchase orders were reviewed.
a.
P0 P29631-77 dated May 29, 1986 issued by Mill Power Supply Company (PPS) for two 16HA1 type actuators rated for 575 volts, 60H Hz and 57 revolutions per minute (rpm). The P0 stated that MPS is the agent for Duke Power Company (Duke) and that the actuators are safety related items intended for installation at the McGuire Nuclear Power Plant. The P0 required Rotork to comply with 10 CFR Part 21 and the Rotork quality assurance program which was previousl'y approved by Duke. The P0 required a quality release for the components prior to shipment. A Certificate of Conformance dated June 6,1986 was signed by the managers of engineering, contracts, and quality assurance, in accordance with their QA manual requirements, to acknowledge that they reviewed the purchase specification requirements and that the Rotork operators would meet the appropriate technical requirements. The inspector reviewed the corresponding Potork job number (J0) 09743 and determined that the technical require-ments were translated to manufacturing specifications.
ORGANIZATION: ROTORK CONTROLS, INCORPORATED ROCHESTER, NEV YORK REPORT INSPECTION NO.: 99900839/86-01 RESULTS:
PAGE 4 of 7 b.
P0 P24352-13 dated August 20, 1986 issued by MPS for the supply of five add-on-packs type NSK-10008. The add-on-packs contain components to increase the number of auxiliary switches on existing operators to provide additional indications or functions.
Each add-on-pack contains 12 add-on-switches, I wire harness,1 potentiometer,1 adaptor,1 cover and a set of bolts. During the design review of the P0, a discrepancy was identified in the purchase specification relative to the number of individual components. Rotork clarified this discrepancy with MPS and MPS issued a change to the P0 resolving the discrepancy.
The P0 was being processed during the inspection.
Public Service Company of Colorado issued P0 N7103 dated July 16, c.
1926, for the supply of one type 30NA1, 5 rpm actuator, and one type 70 NA1, 29 rpm actuator, both rated for 3 phase, 460 volt, 60 herz. Both operators were required to have water tight enclosures classified as safety related Class 1E. An attachment to the P0 titled standard P0 Document and Clause requirements required Rotork to implement a quality assurance program meeting 10 CFR 50 Appendix B requirements during the manufacture of the actuators and required Rotork to comply with 10 CFR Part 21 defect reporting requirements. Rotork was to provide a Certificate of Conformance (CoC) stating that the actuators meet IEEE 323-1974 and IEEE 344-1975 requirements. The inspector reviewed a CoC prepared and signed by the managers of contract, engineering and quality assurance to acknowledge that they reviewed the specification requirements and the Rotork actuators would meet all the requirements except paragraph 1.2 of the specification.
Paragraph 1.2 required Rotork to supply assembly drawings to facilitate assembly of components.
Rotork stated that they would provide outline drawings, nuclear maintenance manual ( AE 5/6) and A-Range maintenance manual (AE 5). The inspector reviewed Rotork J0 B 09820 dated July 30, 1986 and determined that the J0 reflected the P0 requirements, d.
Anchor Darling Valve Ccmpany (AD) issued purchase order (PO)
E-1709 dated June 19, 1986 to Rotork to supply five 7NA1 type actuators which met Duke Power Company specification for nuclear safety related gate, globe and check valves CNS-1205-01-00-0003 Revision 5.
Amendment #1 dated June 27, 1986 to the P0 required five drive busings to be included in the supply. AD specified the technical requirements of the valve such as the seat mean diameter and area, line design pressure, design differential pressure, disc thrust, stuffing box load, total stem thrust, stem
ORGANIZATION: ROTORK CONTROLS, INCORPORATED ROCHESTER, NEW YORK REPORT INSPECTION NO.-
99900839/86-01 RESULTS:
PAGE 5 of 7 diameter and thread, steam factor stem torque, disc total travel in inches, required drive sleeve rpm, and maximum voltage reductior..
In compliance to the Rotork OA Manual, a Certificate of Compliance dated July 10, 1986 was prepared and signed by the managers of contracts, engineering and quality assurance to acknowledge that they reviewed the specification reauirements and that the Rotork actuators would meet the P0 requirements including the IEEE 382-1972, IEEE 323-1974 and IEEE 344-1975 standards which were specified. Additionally, it was highlighted that these actuators were intended for 3 phase, 208 volts 60 herz (and not the usual three phase 575 volt 60 herz for Duke).
Rotork internal JO B09789 translated the AD specifications for manufacture of the operators.
4.
Review of Quality Assurance Records The inspector reviewed the quality assurance documents relative to Duke P0 P2963-77 for two 16NA1 type actuators which had been shipped recently. The records are considered typical for each operator and consisted of the following:
a.
A Nuclear Quality Approval Checklist indicating that the following attributes were verified and determined acceptable:
(1)
Inspection of various modules prior to assembly to procedure QC 136.
(2) Pressure test was performed to procedure QC 129.
(3) Verification of Grit Blast to procedure CC 130.
(4) Examination of Grit Blast to procedure QC 127.
(5) Elcometer readings (thickness measurement) verified to procedure QC 126.
b.
Quality Assurance records on the external coatings applied to the operator which included the following:
(1) Surface preparations.
(2) Batch numbers of Carbozinc II, Phenoline 305 and their expiration dates.
ORGANIZATION: ROTORK CONTROLS, It!CORPORATEC ROCHESTER, NEW YORK REPORT INSPECTION N0.: 99900839/86-01 RESULTS:
PAGE 6 of 7 (3) Temperatures at which they were stored.
(4) Details of paint application and measurements of thickness of the paint coating.
(5) Product identity and quality assurance certification records on the metallic gray final coating.
Final test certificate indicating that the following tests were c.
performed:
(1) Circuit continuity was verified to meet the wiring diagram.
(2) Insulation resistance was verified by applying 2KV.
(3) The motor operated at 575 volts 3 phase 60 herz.
(4) Verification of the gear ratio (60:1) and speed (57 rpm).
5.
Review of Rotork Purchase Orcers to Vendors The inspector reviewed purchase orders issued by Rotork to their vendors to determine whether Rotork specified applicable quality and technical requirements therein. The inspector determined that Rotork procuras the majority of components from their Bath, England plant.
Items such as primers, paint and special alloy castings are procured domestically.
Review of the purchase orders indicated that Rotork specified the applicable cuality and technical recuirements.
6.
Review of Control of Measuring Equipment The inspector selected several measuring equipment used on the assembly and test areas, verifico their respective calibration documents and determined that the calibration of the equipment was current. The records indicated'that the ecuipment was calibrated to standards traceable to the National Bureau of Standards.
7.
Review of Audits Performed The inspector revieweo five audits performed by Rotork OA manager a.
on various activities such as drawing control, procurement, assembly and testing. Timely respcnses were provided to cuoit findings and all the findings had been closed.
CRGANIZATION:
ROTORK CONTROLS, INCORPORATED ROCHESTER, NEW YORK REPORT INSPECTION NO.-
99900839/86-01 RESULTS:
PAGE 7 of 7 b.
The inspector reviewed three audits performed by licensees on Rotork and determined that corrective action had been completed for all adverse findings.
E.
EXIT INTERVIEW:
The inspector met with Rotork representatives mentioned in Section F and discussed the scope of the inspection and findings.
F.
PERSONS CONTACTED:
W. H. Whitley, President R. Arnold, Vice President, Engineering D. R. Brown, Manager, Manufacturing D. C. Matla, QA Manager M. R. Saltzer, Manager, Purchasing C. Warnett, Vice President, Sales m-n a
,,-