ML19247B132
| ML19247B132 | |
| Person / Time | |
|---|---|
| Issue date: | 07/17/1979 |
| From: | Hunnicutt D, Oller R NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML19247B131 | List: |
| References | |
| REF-QA-99900316 99900316-79-1, NUDOCS 7908080006 | |
| Download: ML19247B132 (10) | |
Text
U. S. NUCLEAR REGUIATORY COMMISSION OFFICE OF INSPECTION AND ENFORCE'!ENT REGION IV Report No.
99900316/79-01 Program No. 51300 Company:
Gould Incorporated Valve and Fitting Division 6300 W. Howard Street Chicago, Illinois 60648 Inspection Conducted:
June 26-29, 1979 Inspector:
4 7
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R. E. Oller, Contractor Inspector Date Vendon Inspection Branch Approved b -
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- f.LohaAD 7/77[
DI M.~Hunnicutt, Chief, ComponentsSection II
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Vendor Inspection Branch 1
Summarv Inspection on June 26-29, 1979 (99900316/79-01)
Areas Inspected:
Implementation of 10 CFR 50, Appendix B criteria, other NRC requirements, and applicable codes and standards including: action on previous inspection findings, review of vendor activities, nonconformances and corrective action, training, material identification and control, and testing of completed products. The inspection involved twenty five (25) inspector-hours on site.
Results:
In the six (6) areas inspected, no deviations were identified.
The following unresolved tem was identified.
Unresolved Item Testing of Completed Products: The hydrostatic test procedure for valves requires that any seat leakage will be measured, recorded and reported. Dis-cussions with the QA Inspector, performing the seat test, established that seat leakage is not measured nor recorded. The practice is reject all valves showing any seat leakage and tag them " Hold for QA Resolution".
Gould manage-ment indicated they would review this matter and revise the procedure if such revision is considered appropriate.
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2 DETAILS SECTION A.
Persons Contacted
- R. Haines, QA Manager P. Ioakimidis, Stock Room Group Leader
- S. Kunka, Vice President of Operations
- M. McKay, Plant Superintendent
- R. Malone, QA Engineer
- A. Pietramale, Manager of Product Engineering G. Simpson, QA Inspector B. Trinidad, QA Receiving Inspector R. Williams, QA Inspector
- Attended the Exit Meeting.
B.
Action on Previous Inspection Findings 1.
(Closed) Deviation A (Report No. 78-01): Failure to include in Purchase Orders No. C-40425 and No. C-34846 for calibration services, the quality requirement that certificates of calibration be furnished for calibration of optical ccmparators, and hardness testers and their standards.
The inspector found that in accordance with Gould's response letter dated January 9,1979, paragraph 12.5 of the QA Manual was revised to include the requirement that " Purchase Orders shall include instructions to supply Certificates of Calibration". This change was accepted by the ANI prior to its implementation.
2.
(Closed) Deviation B (Repcrt No. 78-01):
Failure to include Receiving Inspection Reports in the Receiving Inspection Packages for internal orders No. VM-22 and VM-11.
The inspector found that in accordance with Gould's response letter dated January 9, 1979, procedure QCP-2 has been revised to include instructions in preparation of Receiving Inspection Packages. Review of three (3) current packages established that they contained the Receiving Inspection Reports.
C.
Review of Vendor's Activities 1.
Cbjective The objective of this area of the inspection was to assess the vendor's activities and their impact on future NRC inspecticns.
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3.
2.
Method of Accomplishment The preceding objective was accomplished by:
a.
Discussions with cognizant personnel.
b.
Review of the QA Manual.
c.
Review of the following ASME Certificates of authorization:
(1)
No. N-1357 for N Class 1, 2, & 3 valves.
(2)
No. N-1358 for NPT Class 1, 2 and 3 valve parts and appurtenances.
(3) Quality Systems Certificate (Materials) No-1359.
d.
Review of a list of Gould Valve and Fitting Division's customers to whom ASME Class 1, 2 or 3 valves and nuclear fittings were supplied during 1978 and 1979.
3.
Findings a.
Deviations from Commitments None b.
Unresolved Items None c.
Other Findings (1) The Gould Inc., Valve and Fitting Division manufactures ASME Class manual operated instrumentation and manifold valves below 2" nominal pipe size, of austenitic stainless steel, Inconel and Monel materials, up to 2500 lb. pressure class.
They also manufacture small diameter pipe fittings of carbon steel, low alloys, high alloys, copper and copper alloys materials. Fittings are manufactured at Plant No. I while N-stamped valves are manufactured at Plant No. 3.
(2) During 1973 and 1979 the plants supplied nuclear class valves and fietings to fourteen (14) domestic customers consisting of architect-engineers, constructors, electric utility companies and a nuclear steam system supplier.
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4 (3) The Authorized Inspection Agency is Factory Mutual Insurance Company. The ANI visits Plant No. 3 on a notification basis.
(4) The Gould Valve and Fitting Division has valid N, NPT and Quality Systems authorizations.
These certificates expire on March 1, 1982.
D.
Nonconformances and Corrective Action 1.
Objectives The objectives of this area of the inspection were to verify that the following items were controlled in accordance with applicable NRC and ASME requirements.
a.
A written system has been established to assure that nonconformances are controlled and corrective cution is taken.
b.
Documented procedures or instructions are implemented for identi-fication, documentation, segregation and disposition of noncon-forming materials, parts or components,.and notification to affect-ed organizations.
Nonconforming items are reviewed and accepted, rejected, repaired c.
or reworked in accordance with docuuented procedures.
d.
Conditions adverse to quality are promptly identified and corrected.
The causes of significant conditions adverse to quality are c.
determined and corrected to preclude repetition.
f.
The condition adverse to quality, the cause and the corrective action are documented and reported to appropriate levels of management.
2.
Method of Accomplishment The preceding objectives were accomplished by:
a.
Review of the QA Manual Section 14.0 "Nonconformities".
b.
Review of the approved procedure No. QCP-1, dated September 13, 1978, " Procedure for Handling Neoconformances".
c.
Review of the approved procedure No. QCP-2, dated January 4, 1979,
" Procedure for Receiving Inspection *'
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5 d.
Review of Receiving Inspection Rejection Reports No. 0609 dated May 3, 1979, and No. 0610 dated June 14, 1979, covering subvendor nonconfo rmances.
Observation of the marking, tagging and documents for the following e.
material reject report items resulting from process work errors.
(1) Seven (7) manifold type valve bodies and Material Reject Report No. 817.
(2) Valve bonnet nuts and Material Reject Report No. 813.
(3) Five (5) manifold type valve bodies and Material Reject Report No. 810.
(4) Forty-one (41) valve bodies, Material Reject Report No. 026, and the Rework Tra reler.
3.
Findings Within this area of the inspection no deviations or unresolved items were identified.
E.
Training 1.
Objectives The objectives of this area of the inspection were to verify that the following items were controlled in accordance with applicable NEC and ASME Code requirements:
a.
A written systen. has been established to assut-that indoctrination and training of personnel performing activities a f fecting quality, is implemented in accordance with applicable codes.
b.
Appropriate written agenda are used.
c.
Records of training sessiois agenda and attendance are maintained.
d.
The agenda includes subject matter adequate to provide an under-standing of the general and detailed aspects of the QA program, codes, standards and applicable technical disciplines.
e.
The instructors are suitably qualified.
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6 2.
Method of Accomplishment The preceding objectives were accomplished by:
a.
Review of the QA Manual Section 18.0 " Training".
b.
Review of the training program records for 1978 and 19 79, for all personnel whose duties affect quality, entitled " Nuclear QA Training Program Personnel Requiring Training". This record included the QA Manual areas covered; the attendees and the dates of training.
c.
Review of the 1979 Training Schedule.
d.
Review of records of special training for QA personnel.
e.
Discussions with cognizant personnel.
3.
Findings Within this area of the insoection, no deviations or unresolved items were identified.
F.
Material Identification and Control 1.
Objectives The objectives of this area of the inspection were to verify that the following items were controlled in accordance with applicable NRC and ASME Code Requirements.
a.
A written system has been established to assure that material identification and control is performed in accordance with applicable codes.
b.
Documented measures have been used for identification and control of matcrials and items including p^rtially fabri-cated assemblies.
c.
Identification is maintained either on the item or on records traceable to the item.
d.
Permanent or temporary identification marks or numbers are legible and are not detrimental to the item's quality or will interfere with the function of the item.
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7 e.
All characteristics required to be reported appear on Checklists or Certified Material Test Reports, and CMTRs have been received, reviewed and found acceptable.
2.
Method of Accomplishment The preceding objectives were accomplished by:
a.
Review of the following sections of the QA Manual:
(1)
No. 9.0 " Material Control".
(2)
No. 10.0 " Process Control".
(3)
No. 11.0 " Assembly and Testing (For Valves)".
b.
Observation of nuclear barstock stamping, color coding and tagging in the receiving-storage area of Plant No. 1.
c.
Observation of rough forgings Heat Mark Symbol E-18, for nuclear tee fittings, in the QA Receiving Inspection Area of Plant No. 1; discussions with the QA Receiving Inspector and review of the following Receiving Inspection Package records:
(1) Purchasing Department Shipping Order PDS0-0003, dated February 2, 1979, for the heat treating of a Lot consisting of 11,715 stainless steel tee forgings in accordance with Gould procedure ESN 202, Revision 4 and 5.
(2) Subvendor's Certification of heat treatment dated March 29, 1978, and the furnace chart, for the above items.
(3) Goulds Receiving Inapection Report, dated April 2, 1979, for the above E-18 heat treated forgings.
(4) The T.A. Traveler signoffs fcr the abc'e forgings.
(5) The attached material specifications known as ESNs.
(6) The Order Index.
d.
Review of the Heat Mark Symbol (HMS) logs at Plant No. I and at Plant No. 3.
e.
Review at Plant No. 3 of the following Receiving Inspection Package records for manifold type valve bodies for Order No.
VM-42:
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8 (1) Order Authorization (2) Receiving Inspection Report (3) Order Index (4) ESN Materia? 2pecifications (5) Design Drawings (6)
T.A. Traveler f.
Observation of shop presses used for stamping and electrolytic etching of the HMS identification on valve parts.
g.
Observation of HMS identification on valve parts being assembled for Order No. 4147, and review of the HMS entries on the accompany-ing traveler.
h.
Discussions with cognizant personnel.
3.
Findings Within this area of the inspection, no deviations or unresolved items were identified.
G.
Testing of Completed Products 1.
Objectives' The objectives of this area of the inspection were to verify that the following items were controlled in accordance with the applicable NRC and ASME Code requirements.
a.
A written system has been established to assure that final pressure tests are controlled in accordance with applicable procedures, specifications or drawings.
b.
Final pressure tests are perfonned in accordance with approved procedures, instructions, specifications or drawings.
c.
The results of testa are documented and reviestd for,.ccept-ability.
d.
The test equipment is calibrated where required.
e.
The tests are performed by qualified personnel.
%?t000
9 2.
Method of Accomplisbanent The preceding objectives were accomplished by:
a.
Review of the QA Manual Section 11.0 " Assembly and Testing (For Valves)'
b.
Review of approved procedure ESN-309, Revision 2, "IIydrostatic Shell and Seat Integrity Test".
c.
Observation of the hydrostatic shell and seat leakage tests of two-way manifold valves.
d.
Observation of hydrostatic test equipment and f.acilities.
Review of the Design Drawing No. 30129000 dated August 14, 1978, e.
applicable to the above valves being tested, which showed that the valves were ASME III Division I, Class 2 Components.
f.
Reviewed records of hydrostatic tests " Test Log" which documented the items, the test conditions and the test results.
g.
Review of the Assembly and Test Traveler for the above valves, c'
' Numbers 18787-188111.
h.
Review of completed travelers and NPV-1 data forms for completed valves SN 24113 through 24137 of Customer Order No. 63668-N19731 and N19732.
3.
Findings a.
Deviations from Commitments None b.
Unresolved Item Eracedure ESN-309, Revision 2, with regard to tF ydrostatic t
sert test, requires that any seat leakage will
- measured, recorded and reported to Quality Assurance and the Engineering Department.
In discussions with the QA inspector, performing the hydrostatic test, it was learned that the allowable seat leakage of 2cc/hr for the valves being tested, was such a small amount that no attempt is made to collect and measure seat test leakage.
The practice is that if a valve shows any seat leakage it is rejected and tagged " hold for QA disposition" Gould 5853S0
10 Inc. Valve and Fitting Division management indicated that they will review this matter and revise the procedure if it is con-sidered appropriate to do so.
II.
Exit Interview 1.
The inspector met with management representatives denoted in para-graph A at the conclusion of the inspection en June 29, 1979.
2.
The tollowing subjects were discussed:
a.
Areas inspected.
b.
The unresolved item in paragraph G.3.b. of this report.
3.
Management's questions related to the above subjects.
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