ML19225A652
| ML19225A652 | |
| Person / Time | |
|---|---|
| Issue date: | 05/07/1979 |
| From: | Kelley W, Whitesell D NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML19225A644 | List: |
| References | |
| REF-QA-99900058 99900058-79-1, NUDOCS 7907190742 | |
| Download: ML19225A652 (10) | |
Text
U. S. NUCLEAR REGULATORY COB 1ISSION OFFICE OF INSPECTION AND ENFORCEMENT REGION IV Report No. 99900058/79-01 Program No. 51300 Company:
Rockwell International Corp.
Flow Control Division 1900 South Saunders St.
Raleigh, North Carolina 27603 Inspection Conducted: April 17-19, 1979 Inspector F
?2Y 05/c9/79 kh. D. Kelley, Contra'ctor Inspector, Vendor Date Inspection Branch Approvedbyb
/>Il e5/or/79 c
D. E. Whitesell, Chief, ComponentsSection I, Date '
Vendor Inspection Branch Summary Inspection on April 17-19, 1979 (99900058/79-01)
Areas Inspected:
Implementation of 10 CFR 50, Appendix B and applicable codes and standards, including design verification - computer program, control of special processes - weld heattreat and visual examination of welds, inspection and test - radiographic examination, and training -
qualification of personnel porfomance speed processes; also, reviewed previous identified items.
The inspection involved twenty-two (22) inspector-hours on site by one (1) NRC inspector.
Results:
In the five (5) areas inspected, no apparent deviations or unresolved items were identified.
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q907190 ~r Details Section A.
Persons Contacted Rockwell International - Flow Control Division (RI-FCD)
- S. L. Adams, Design Engineering Supervisor J. B. Abernethy, Welding Engineer R. A. Bandukwala, Manager, Quality Assurance
- 3. Carothers, Supervisor, Metal Process Control
- J. J. Cushing, Manufacturing Career Development Pa;ticipant
- K. Exner, Supervisor, Engineer E. L. Green, Chief Inspector
- F. D. Johnson, Supervisor, Materials Engineering
- R. D. Norden, Product Engineering Manager
- W. G. Rains, Supervisor, Quality Assurance Engineering
- R. D. Timbrook, General Plant Manager T. E. Toothman, Production Superintendent B. R. Yeargin, Quality Assurance Engineer Lumberman Mutual Casualty Company C. D. Adams, Authorized Nuclear Inspector
- Denote those persons who attended Exit Interview (See paragraph 1).
B.
General Review of Vendor's Activities 1.
The ASME issued RI-FCD Certificates of Authorization N-1562 and N-1563, authorizing the use of the "N" syr bol for Class 1, 2, and 3 valves and the use of the "NPT" symbol for Class 1, 2, and 3 valve parts and appurtenances.
The authorizations expire on November 26, 1979.
2.
RI-FCD has the design and machining capabilities for manu-facturing gate, globe, check, stop-check, and argle valves from 24 inch to 32 inch in size and 600# to 4500# ANSI pressure ratings.
3.
The authorized inspection agency is Lumbermens Mutual Casualty Company.
The authorized nuclear inspector is a full time resident inspector.
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It is estimated that the production of components for the nuclear industry accounts for approximately 75^', of the vendor's work load.
5.
RI-FCD is aware of the developing shortage of cobalt.
C.
Previously Identified Items (Closed) Deviation (Report flo. 78-02):
Contrary to Criterion VI of Appendix B to 10 CFR 50 and paragraph tiCA-4134.6 of Section III to the ASME Code, the ASME accepted Quality Assurance Manual did not provide for the control, review, approval for release, and issuance of the RI-FCD Plant Internal Operating Pr ocedures.
The inspector verified that subsection 2.4 and 2.6 of the ASME accepted Quality Assurance Manual were revised to address the review, approval for release, and the issuance of the RI-FCD Plant Internal Operatin1 Procedures; also, the revised manual was submitted to and
.ccepted by the Authori. red Inspection Agency's Inspection Specialist.
(Closed) Unresolved Item (Report t;o. 78-02).
The vendor's welding procedure specifications qualification records did not record the actual valves for amperage, voltage, travel speeds, preheat, and interpass temperatures.
The inspector verified that RC-FCD does record the actual,anges for amperage, voltage, travel speeds, and the actual preheat and interpass temperature during the qualification of a welding proce-dure specification.
D.
Design Verification (Computer Programs) 1.
Objectives The objectives of this area of the inspection were to verify that:
Procedures had been prcpared and approved by the vendor to prescribe a system for computer design program verification which is consistent with flRC rules and regulations, and the vendor's commitments in the ASME accep'_ed Quality Assurance Program.
b.
The cemputer design orogram verification procedures are properly and effectively implemented by the vendor.
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3/3 2.
Method of Accomplishment The objectives of this area of the inspection were accomplished by:
a.
Review of the ASME accepted Quality Assurance Manual, Revision 6, Section 1.0, General; Section 2.0, Control of Inquires, Order Entry, Product Dcsign, Engineering Documents, and Specifications, to verify the vendor had established procedures to prescribe a system for computer design program verification.
b.
Reviewed the following documents, RI-FCD, VER Research Department, Report No. 2573-01-21-14, Revision 3, Find-Astress Analysis Program, Axisymmetric Finite Elements; RI-S0I 70-16-101, Revision 0, Engineering Computer Program; and Procedure RI-FCD, VER Reasearcii Department, Report No.
2573-80, Revision 1, FEDCODE-A-Post-Processer Computer Program for Finite Element Data, to verify that they had been prepared by the designated authority, approved by management, and reviewed by QA.
c.
Reviewed the documents referenced in paragraph b. above, to verify that the measures provided for verifying the adequacy of the computer cesign orogram. Also that the measures provided for the design verification to consider tje importance to safety, identify the method of perfoming the design verification, identify items that are to be addressed during the design review, and prescribes the requirements for performing the verification by alternate calculations or by qualification test.
d.
Reviewed design verifications RI-RAL-10109, CG Calcula-tions for size 6, Figure 7502 HHTY; and RI, Design Report No. RAL-2039, 26 inch, Figure 1612Y-B21F022 and B21F028, to verify proper implementation of the computer design program verification procedures.
e.
Interviews with personnel to verify that they are knowledge-able in the procedures applicable to the computer design verification program.
3.
Findings a.
The inspector verified that:
(1)
Procedures had been prepared and approved by the
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, vendor prescribing a system for the computer design G@
45i 314 verification program, which is consistent with the NRC rules and regulations, the ASME Code requirements, and the vendor's commitments in the Quality Assurance flanual and that,
'2) The computer design verification program procedures are properly and effectively implemented.
b.
Within this area of the inspection, no deviations or unresolved items were identified.
E.
Control of Special Processes-Weld Heat Treatment 1.
Objectives The objectives of this area of the inspection were to verify that the heat treatment ielated to welding is specified, and that it is performed in accordance with the NRC rules and regulations, and the vendor's commitments in the ASME accepted Quality Assurance Manual.
2.
Method of Accomplishment The objectives of this area of the inspectica were accomplished by:
a.
The review of the ASME accepted Quality Assurance Manual, Revision 6, Section 5.0, " Welding Quality Assurance;" and Section 8.0, " Heat Treating," to verify that the vendor had established procedures to prescribe a system for weld heat treatment.
b.
Review of RI-FC0 procedure, f15-P1-111N, Revision 1, " Repair Fillet and Attachment Weids" with PWHT in accordance wii.h ASME,Section III, to verify that it had been reviewed, approved, and properly qualified.
c.
Reviewed the following documents, " Manufacture Route Card;"
and RI-FCD, MS-1703, Revision 5, " Post Weld Heat Treatment" (1100-12500B), and Furnace Chart, to verify that the heat treatment of welds was performed in accordance with the procedure requirements for the heat-up und cool-down rates, and that the time-at-temperature were complied with, d-Observed i.he weld heat treatment, to verify that the weldments are properly instrumented, the furnace atmosphere is controlled, and temperature variations do not exceed
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W 3< 5 ASME Code requirements, and measures are taken to avoid sensitization of austenitic stainless steel.
Interviews with personnel to verify they are knowledgeable e.
in the procedures applicable to weld heat treating.
3.
Findings The inspector verified that the heat treatment, relative a.
to welding, was specified and wcs being performed in accordance with the f;RC rules and egulations, and the vendor's commitments in the ASME accepted Quality Assurance fianual.
b.
Within this area of the inspection, no deviations or unresolved items were icentif ied.
F.
Control __of Special Processr.s-Visual Examination of Neld:
1.
Objective The objective of this area of the inspection was to verify whether completed welds met the visual standards established by Section III of the ASME Code and the vendor's ASMI accepted Quality Assurance Manual.
2.
Method of Accomplishment The objective of this area of the inspection was accomplished by visual examination of welds to verify that:
Weld reinforcement of butt welds, and the size and shape a.
of fillet welds, met the ASME Code and the vendor's drawing requirements.
b.
Joint configurations of attachments, transitions between parts of different inside diameters, and the wal' thicknesses met the ASME Codes and the vendor's drawing requirements.
c.
The weld surfaces finish was correct, and that the surface was free of defects, including cracks, laps, lack of penetration, 1cck of fusion, porosity, slag, oxide film, and undercut.
d.
Temporary attachments, arc strikes, and weld spatter are properly removed.
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Findings a.
The inspector verified that completed welds meet the visual acceptance standards established by Section III of the ASME Code and the ASME accepted Quality Assurance Program.
b.
Within this area of the inspection, no deviations or unresolved items were identified.
G.
Training - Qualification of Personnel Perfonning Special Pror, esses 1.
_ Objectives The objectives of this area of the inspection were to verify that:
a.
The vend 7r's Quality Assurance Program for qualification of personnel performing special processes, other than welding, meets the applicable NRC rules and regulations and the ASME accepted Quality Assurance Manual; and b.
All personnel performing special processes are properly qualified in accordance with the requirements the regulations and of the Quality Assurance Manual commitments.
2.
Method of Accomplishment The objectives of this area of the inspection were accomplished by:
a.
Review of the ASME accepted Quality Assurance Manual, Revision 6, Section 1.0, " General;" Section 5.0, " Welding Quality Assurance;" Section 6.0, " Nondestructive Examination;"
and Section 8.0, " Heat Treating," to verify that the vendor had established procedures for the administration and control of the training and certification of the qualifications of personnel performing special processes, and nondestructive exami.iation.
b.
Review of the following procedures, RI-FCD-RAL, Heat Treat Manual, Revision 3; RI-PIOP 55-40-02-U4, Training Qualifica-tion, and Certification of "ondestructive Testing Personnel, to verify they are consistent with ASME Code and ASNT Recomnended Practice No. SNT-TC-1A requirements and NRC regulations for level of qualif,ication, education and experience levels, written expmiqations.and practical
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. examinations for certification, period visual acuity and color vision examination, and periodic recertification.
c.
Review of the following procedures, Welder Training Programs; and RI-FCD-RAL, Heat Treat Manual, Revision 3, to verify the vendor had established procedures for training, indoctrination and qualification of personnel performing special processes, d.
Reviewed the training, examination, and certification records of Level III, NDT, Heat Treating Operator, Testing
- Hydrostatic to verify they were trained, examined, and certified in accordance with the ASME accepted Quality Assurance Program requirements.
e.
Interviewed personnel performing the following special processes, Heat Treating, Welding - Hard Subfacing; Testing
- Hydrostatic; and Nondestructive Testing, to verify that they are knowledgeable in their assignments, and that the infonaation in the certification recort's was accurate.
3.
Findings a.
The inspector verified that:
(1)
The vendor's Quality Assurance Program is consistent with the NRC rules and regulations, and the Vendor's commi tments.
(2) All persor.nel performing special processes are properly qualified in accordance with the requirementi of the codes, contracts, and the vendor's ccmmitments.
b.
Within this area of the inspection, no deviations or unresolved items were identified.
H.
Inspection and Test-Radiographic Examination 1.
Objectives The objectives of this area of the inspection were ta verify that:
a.
The radiographic examination nrocedures used by the vendor meets the applicable NRC rules and regulations, the code requirements and the commitments in th_ ASME ac.epted Quality Assurance Manual.
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b.
The radiographic examination was being conducted by qualified personnel in accordance with the qualified procedures.
2.
Me t hod o_f___Ac.ompl i shmen t The objectives sf this area of the inspection were accomplished by:
a.
Review of the ASME accepted Quality Assurance Manual, Revision 6, Section 6.0, Nondestructive Examination.
b.
Review of the following radiographic examination procedures to verify that they had been certified and issued in accordance with the vendors Quality Assurance Program, RI-FCD, MS-1026 NE, Revision 6, " Radiographic Requirenents for Gamma-Ray Examination of Valve Bodies and Valve Components for Nuclear Applications;" and RI-FCD, MS-1026 NE-W, Revision 1, " Rad f agraphy Requirements for Gamma-lay Examination of Welds and Circumferential Butt Welds to ASME Section III."
c.
Review of the radiogra,.ic examination procedures listed in paragraph b. to verify that significant examination variables are defined, and are controlled within the limits specified by the ASME Code and contract documents.
d Reviewed uccepted radiographs to verify that they mret the ASME Code and one interpretation is accurate and correctly recorded.
Also, verify that the personnel performing radiographic evaluation are properly qualified.
e.
Interviews with personnel to verify they are knowledgeable in the procedures applicable to radiography, and radiographic
.ilm processing, and interpretation.
3.
Findings a.
The inspector verified that:
1.
The radiographic examination p: ]cedures used by the vendor are consitent with the applicable NRC rules and regulations, and the ASME Code requirements and the Quality Assurance Manual commitments.
2.
The radiographic examination is being perforned by qualified personnel, in accordance with the approved procedures.,c.
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. b.
Within this area of the inspection, no deviation or unresolved items were identified.
I.
Exit Interview At the conclusion of the inspection on April 19, 1979, the inspector met with the company's management, identified in paragraph A, for the purpose of informing them as to the results of the inspection.
Dur ng this meeting, management was informed, that no deviations or i
unresolved items had been identified.
The company's management acknowledged the inspector's statement.
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