IR 05000930/2010004

Insp Rept 99900054/85-01 on 850930-1004.Violations Noted: Evaluation of Defects Not Being Performed Adequately. Nonconformances Noted:Svcs Procured from Two Sources Not on Approved Vendors List

ML20141H823
Person / Time
Site:	07000371, 05000930
Issue date:	12/13/1985
From:	Harper J, Merschoff E NRC OFFICE OF INSPECTION & ENFORCEMENT (IE)
To:
Shared Package
ML20141E221	List: ML20141E216 ML20141H810 ML20141H815 ML20141H819 ML20141H823
References
REF-QA-99900054 NUDOCS 8604250049
Download: ML20141H823 (2)

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ORGANIZATION: DPESSER INDUSTRIES, IN 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, In 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 facilitie 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: BASES: 10 CFR Part 21 and 10 CFR Part 50 Appendix SCOPE:

To ensure that valves, model 7150 and 7250, Class 1 and 2 are being supplied to Fort Calhoun in accordance with established comitment 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, 50-32 kop20o49e60413 999000$99 ENVDagy PDR

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ORGANIZATION: CRESSER INDUSTRIES, IN ALEXANDRIA, LOUISIANA REPORT INSPECTION NO.: 99900054/85-01 RESULTS: PAGE 2 of 7 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.) Inspection Findings Violations .

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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). Nonconformances 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), 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). 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, 'N .

ALEXANDRIA, LOUISIANA REPORT INSPECTION NO.: 99900054/85-01 RESULTS: PAGE 3 of 7 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 numbe Therefore, the calibration load cell and readout devices used as the standard for calibration cannot be traced as required (85-01-05). 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). 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). 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). Unresolved Items Nor 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 commitment The nonconformances found during the inspection did not involve the fabrication of valve models 7150 and 725 ' ,

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. i ORGANIZATION: DRESSER INDUSTRIES, IN t ALEXAMDRIA, LOUISIANA REPORT INSPECTION NO.: 99900054/85-01 RESULTS: PAGE 4 of 7 CFR Part 21 Reauirement 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 ope It also leaked severely because the disc was not seated properl resser 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 initiate 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 inspectio .__

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ORGANIZATION: DRESSER INDUSTRIES, IN ALEXANDRIA, LOUISIANA REPORT INSPECTION NO.: 99900054/85-01 RESULTS: PAGE 5 of 7

. 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. 85-0 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 n , 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 of pr.ocedure no. 003.001 to substantiate an investigatio 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 deviatio Nonconformance 85-01-08 was identified during this part of the inspectio . Purchase Requirements An examination was made of 20 purchase orders (P.O.) from Dresser for outside calibration services for gages, testing and measuring device 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 furnace '

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ORGANIZATION: ORESSER INDUSTRIES, IN 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 inspectio . 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 inspecte Weld rod containers were stored in either locked cabinets or locked weld rod oven 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-abilit 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 correc ,

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Nonconformance 85-01-03 was identified during this part of the inspectio l

1 4 Manufacturing Process Control

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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 documente No nonconformances were noted in this are . Calibration The NRC inspector found that torque devices calibration certifications l

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 measuremen Nanconformance 85-01-05 was identified during this part of the inspectio .

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ORGANIZATION: DRESSER INDUSTRIES, IN 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 rod Nonconformance 85-01-07 was identified during this part of the inspectio 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 standard 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 essentia Nonconformance 85-01-06 was identified during this part of the inspectio 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 material Operations observed appeared to be well planned and progressing in an orderly fashio i 1

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