ML19250C619
| ML19250C619 | |
| Person / Time | |
|---|---|
| Issue date: | 09/10/1979 |
| From: | NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML19250C614 | List: |
| References | |
| REF-QA-99900204 99900204-79-1, NUDOCS 7911280472 | |
| Download: ML19250C619 (3) | |
Text
.
P. X. Engineering Company, Inc.
Docket No.
99900204/79-01 NOTICE OF DEVIATION Based on the results of an NRC inspection conducted on August 13-16, 1979, it appeared that certain of your activities were not conducted in full compliance with NRC requirements as indicated below:
A.
Criterion V of Appendix B to 10 CFR 50 states in part, " Activities affecting quality shall be prescribed by documented instructions, procedures, or draw-inga, or a type appropriate to the circumstances and shall be accomplished in accordance with these instructions, procedures, or drawings 1.
QA Manual Chapter 6, paragraph 6.1, states in part, "... It is the responsibility of the Quality Control Manager to prepare a Document /
Drawing Status Record (DDSR) for each order.
The original of the DDSR is maintr.ined in the Quality Control Work Package. The DDSR defines the number of documents and drawings distributed to specific locations throughout the plant and the latest change in effect.
. Whenever a document change is issued, the Quality Control Manager will assign one of his inspectors the task of distributing the latest change to the applicable areas and retrieving the out-of-date document or drawing.
The inspector who retrieved the out-of-date document or drawing will make a verification entry on the Quality Control work package original of the DDSR."
Contrary to the above, DDSRs showed certain revisions to weld procedure specifications and sketches had been issued to the fab shop but a re-view of the fab shop packages and the associated work areas revealed they either did not contain those revisions, or obsolete revisions were still in the packages.
In addition, a revision to a drawing and a traveler was found in a fab shop package and the DDSR did not show them to have been issued.
(See Details Section, paragraph F.3).
2.
QA Manual Chapter 9, paragraph 9.1.5.9, states in part, "If coated electrodes are not consumed prior to the time shown by the Foreman on the requisition, they will be returned to the Foreman for re-baking in accordance with Quality Control Standard Practice No. 011.
Standard Practice No. 011, paragraph 3.0, states in part, "... Using the weld wire requisition with which the electrodes were originally issued, the job foreman will place the electrodes in containers in the holding ovens marked with the heat number and material grades of the electrodes.
Electrodes returned for rebaking shall be br6ed at a minimum of 500 F for 2 hours2.314815e-5 days <br />5.555556e-4 hours <br />3.306878e-6 weeks <br />7.61e-7 months <br /> or 250 F for 20 hours2.314815e-4 days <br />0.00556 hours <br />3.306878e-5 weeks <br />7.61e-6 months <br />, or required by manufacturers specifications."
1410 254 7911280 2
2 Contrary to the above, a weld wire requisition showed twenty-five (25) 1/8", 7018 electrodes, Heat No. 92013A, were issued to welder No. 78 for Job 555-6B at 7AM, with eighteen (18) electrodes being returned at 11:00 A.M.
Observation of the holding oven at 11:30 A.M.
revealed the job foreman had not placed the electrodes in the holding oven for rebaking.
3.
QA Manual Chapter 9, paragraph 9.1, states in part, " Coated electrodes shall be issued from intermediate holding ovens by the cognizant Shop Foreman or his quclified designee.
. using the Weld Wire Requisition (Which identifies data for the issued electrodes).... A cognizant Shop Foreman will fill out the requisition in duplicate.
The Foreman will transmit the original requisitions to the Quality Control Manager at the end of each day."
Contrary to the above, the inspector observed welder number 15 with two (2) sizes (1/8" and 5/32") of type 7018 electrodes in his pos-session during in process welding on job 615-B and only one (1) Weld Wire Requisition had been filled out, and that being for the 5/32",
7018 electrodes.
The electrodes had been issued at 7 A.M., and this condition was noted at 10 A.M.,
at which time a slip was made out.
4.
QA Manual Chapter 9, paragraph 9.1.4.4, states in part, "All welding including tack welding on AStE Code work will be performed by qualified welders or operators using qualified procedures.
Weld Procedure Specification (WPS) W-59, shielded metal arc welding (SMAW), being used on job 613 stipulated the following parameters:
250 F. maximum interpass temperature, and 180-220 amperes.
WPS W-59, SMAW, being used on job 615B stipulated the following parameters: 400 F. maximum interpass temperature, and 110-160 amperes.
WPS W-39 (flux cored arc welding) being used on job 613 stipulated the use of CO shielding gas with a flow rate of 36-40CFH.
2 Contrary to the above, welding was not being performed in accordance with the above WPSs, in that interpass temperatures were not being determined, welders were welding with amperages outside of the amperage range, and CO flow rate was not being complied with.
(See 2
Details Section, paragraph H.3.)
5.
QA Manual Chapter 9, paragraph 9.1, states in part, ".
. All welding procedure specifications will be prepared and qualified in accordance with the requirements of Section III and Section IX of the ASlE Boiler and Pressure Vessel Code."
1410 255
\\
3 Paragraph QW-2C1.1,Section IX, of the ASME Code states in part, "The welding procedure specification (WPS) shall cover details which are important to the production of sound welds. This shall include.
variables described for each welding process as either essential or nonessential (See QW-252 through QW-281)."
Contrary to the above:
WPSc W-44 revision 1 and W-44 revision 5, submerged arc welding a.
for jobs 613 and 564 respectively, do not address interpass temperature, which is an essential variable.
b.
WPS W-39 revision 0, flux cored arc welding for job 615A, does not address flow rate of C0 shielding gas, which is a nonensential variable. The WPS states, gGas-shielding Gas shall be Linde CO 2
or equivalent." Procedure Qualification Record W-39B states, CO at 25-35 CFH".
2 B.
Criterion VIII of Appendix B to 10 CFR 50 states in part, " Measures shall be established for the identification and control of materials, parts, and com-ponents.
These measures shall assure that identification of the item is maintained by heat number, part number, serial number, or other appropriate means Contrary to the above, measures have not been established to maintain con-trol and identity of welding electrodes once they have been placed in inter-mediate holding ovens prior to distribution to welders.
(See Details Section, paragraph J.3.).
I410 256
-