ML19250C623
| ML19250C623 | |
| Person / Time | |
|---|---|
| Issue date: | 09/10/1979 |
| From: | Ellershaw L, Hunnicutt D NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML19250C614 | List: |
| References | |
| REF-QA-99900204 99900204-79-1, NUDOCS 7911280477 | |
| Download: ML19250C623 (12) | |
Text
.-
U. S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT REGION IV Report No.
99900204/79-01 Program No.
51300 Company:
P. X. Engineering Company, Inc.
225 Merrimac Street Woburn,PLA 02810 Inspection Con ed:
August 13-16, 1979
$).E.E11ershaw,PrincipalInspector EQhgtD
/0 C?k Inspectors:
1 hate /
ComponentsSection II Vendor Inspection Branch Approved by:
e /E
[/8
/
D. M. Hunnicutt, C)iief Date ComponentsSection II Vendor Inspection Branch Summary Inspection on August 13-16, 1979 (99900204/79-01)
Areas Inspected:
Implementation of 10 CFR 50 Appendix B Criteria, and applicable codes and standards, including: nonconformances and corrective action; audits; qualification of personnel performing special processes; radiography; procedure, document, and drawing control; weld material control; joint fitup and welding; weld procedure specifications, and material identification and control. The inspection involved thirty-two (32) inspector-hours on site.
Results:
In the nine (9) areas inspected, six (6) deviations from commitment were identified.
No unresolved items were identified.
1410 257 49%
7911280....
2 Deviations:
Procedure, Document, and Drawing Control - revisions to documents and drawings, other than what was specified by the Document / Drawing Status Report, were found in the fabrication shop which is contrary to Criterion V of Appendix B to 10 CFR 50 (Notice of Deviation, Item A.1.); Weld Material Control -
electrodes had not been placed in the rebake oven by the foreman after being returned by the welder as required, which is contrary to Criterion V of Appendix B to 10 CFR 50 (Notice of Deviation, Item A.2.) and electrodes had been issued to a welder without a Weld Wire Requisition slip being filled out, which is contrary to Criterion V of Appendix B to 10 CFR 50 (Notice of Deviation, Item A.3.); Joint Fitup and Welding - Welders were not welding in accordance with the specified welding procedure specifications which is contrary to Criterion V of Appendix B to 10 CFR 50 (Notice of Deviation, Item A.4.); Welding Procedure Specifications - a SAW and FCAW WPS did not address certain essential and non-essential variables, which is contrary to Criterion V of Appendix B to 10 CFR 50 (Notice of Deviation, Item A.S.); Material Identification and Control - measures have not been established to maintain identity of welding electrodes after being placed in intermediate holding ovens which is contrary to Criterion VIII of Appendix B to 10 CFR 50 (Notice of Deviation, Item B.)
1410.258
3 DETAILS SECTION A.
Persons Contacted
- R. L. Carbone - Manager, Quality Assurance D. Descheneaux - QA Technical Assistant L. A. Hinthorne, Sr. - Manager, Nondestructive Examination
- J. Infantino - Plant Superintendent
- L. Mauriello - Manager, Quality Control
- G. S. Scruton - Vice President Operations C. Speight - Level II, NDE Examiner
- Indicatec attendees at exit interview. See paragraph K.
B.
Nonconformances and Corrective Action 1.
Objectives The objectives of this area of the inspection were to verify that P. X. Engineering Company, Inc. (PKE), had implemented the require-ments for the control of noncomformances and corrective actions in accordance with the QA Manual and applicable NRC and ASME Code requirements.
2.
Method of Accomplishment The preceding objectives were accomplished by:
Review of QA Manual revision 5, Chapter 13, "Nonconformances a.
and Corrective Action."
b.
Review of the Nonconformance Report Log, which lists noncon-formance report (NCR) numbers, dates, and disposition dates.
Review of ten (10) closed and five (5) open NCRs.
c.
d.
Observation of parts identified by NRC Log as being nonconform-ing to assure the parts were identified as such.
Review of NCRs to assure th:
they had been submitted to the e.
Authorized Nuclear Inspector.
'f.
Review of corrective actions to assure that causes had been identified and actions taken to prevent recurrence.
g.
Discussions with cognizant personnel.
1410 259
4 3.
Findings a.
Deviation From Commitments
- None, b.
l'atesolved Item None.
C.
Audits 1.
Objectives The objectives of this area of the inspection were to veri.., that PXE had implemented the requirements for the scheduling and conducting of internal audits in accordance with the QA Manual and applicable NRC and ASME Code requirements.
2.
Method of Accomplishment The preceding objectives were accomplished by:
a.
Review of QA Manual revision 5, Chapter 15, " Audits."
b.
Review of audit schedules and completed audit records.
c.
Review records of training sessions conducted by the QA Manager for the audit team prior to performing the audits.
d.
Review of audit records to assure that complete QA program is audited on a semi-annual basis, c.
Review of annual management audits of entire QA Program, con-ducted under the supervision of the President of PXE.
f.
Review audit records to assure that identified, deficient areas have been responded to and reaudits have been conducted.
g.
Discussions with cognizant personnel.
3.
Findings a.
Deviation From Commitment i 410 260 None.
5 b.
Unresolved Item Nonc.
D.
Qualifications of Personnel Performing Special Processes -
Nondestructive Examination (NDE) 1.
Objectives The objectives of this area of the inspection were to verify that PXE had implemented the requirements for qualifying personnel per-forming NDE in accordance with the QA Manual and applicable NRC and ASME Code requirements.
2.
Method of Accomplishment The preceding objectives were accomplished by:
Review of QA Manual revision 5, Chapter 9, " Control of Special a.
Processes."
b.
Review of the Training and Qualification Manual, which contains the written practice in accordance with the requirements of SNT-TC-1A.
Review of qualification records of six (6) NDE examiners, c.
including eye examinations.
d.
Discussions with cognizant personnel.
Review qualification records of subcontractor's personnel per-e.
forming NDE for PXI.
3.
Findings a.
Deviations From Commitment None.
b.
Unresolved Items i410 261 None.
6 E.
Radiography (RT) 1.
Objectives The objectives of this area of the inspection were to verify that PXE had implemented the requirements for the control of RT in accordance with the QA Manual and applicable NRC -and - AS$'
Code requirements.
2.
Method of Accomplishment The preceding objectives were accomplished by:
a.
Review of QA Manual revision 5, Chapter 9, " Control of Special Processes."
b.
Review radiography procedure, RT-016 revision 1, dated 2-1-79.
c.
Observation of set-up for. radiography to be performed on a repair weld on job 606.
d.
Review of technique sheet established for the above repair weld.
e.
Review production radiographs, including the radiographs showing the unacceptable weld and the repair weld.
f.
Discussions with cognizant personnel.
3.
Findings a.
Deviations From Commitments None.
b.
Unresolved Items None.
F.
Procedure, Document, and Drawing Control 1.
Objectives The objectives of this area of the inspection were to verify that PXE had implemented the requirements for the control of procedures, documents, and drawings in accordance with the QA Manual and ap-plicable NRC and ASME Code requirements.
1410 262
7 2.
Method of Accomplishment The preceding objectives were accomplished by:
Review of QA Manual revision 5; Chapter 6, " Document and Drawing a.
Control."
b.
Review of four (4) Document / Drawing Status Records (DDSR), for the applicable in process jobs.
Comparison of DDSRs with the actual documents / drawings which had c.
been issued to the various departments, including the fabrication shop.
d.
Discussions with cognizant personnel.
3.
Findings a.
Deviations From Commitments See Notice of Deviation, Item A.1.
The following conditions were observed:
(1) The DDSR for job 615 required the use of WPSs W-6, W-79, and W-88, all revision 1, and sho ed that they had been issued to the fab shop. The abot.e WPSs could not be located in the fab shop packager or in the associated work areas.
(2) The DDSR for job 612A showed that sketch No. 4 revision 1, was the latest change in effect and tha'. it had been issued to the fab shop, with revision 0 being recalled. However, revision I could not be located and revision 0 was found to still be in a work area.
In addition, revision 2 of drawing 612B, sheet 5 of 6, was found in the fab shop package, however, there was no revision 2 of the DDSR to reflect that this drawing revision had been issued.
(3) The DDSR for job 613 showed that revision 0 to the Traveler was the latest, approved and issued, change. However, the fab shop package contained revision 0 and 1 to the Traveler.
b.
Unresolved Items
'None.
1410 26,3
8 G.
Weld Material Control 1.
Objectives The objectives of this area of the inspection were to verify that PXE had implemented the requirements for the control of welding materials in accordance with the QA Manual and. applicable NRC and ASNE Code re-quirements.
2.
Method of Accomplishment The preceding objectives were accomplished by:
Review of QA Manual revision 5, Chapter 9 " Control of Special a.
Processes."
b.
Review of Quality Control Standard Practice No. 011, revision I dated November 13, 1978, " Recovery and Rebaking of Flux and Coated Electrodes."
c.
Observation of central stocage areas, intermediate holding ovens, rebake ovens, and welding stations.
d.
Review of Weld Wire Reqcisition slips for issuance of weld materials to welders.
Review of weld material certifications for certain electrodes, c.
wire, and wire and flux combinations.
f.
Discussions with cognizant personnel.
3.
Findings a.
Deviations From Commitments (1) See Notice of Deviation, Item A.2.
(2) See Notice of Deviation, Item A.3.
b.
Unresolved Items None.
1410 264
9 H.
Joint Fitup and Welding 1.
Objectives The objectives of this area of the itspection vere to verify that PXE had implemented the requirements fo-the control of joint fitup and in process welding in accordance witt the QA Manual and applicable NRC and ASME Code requirements.
2.
Method of Accomplishment The preceding objectives were accomplished by:
Review of QA Manual revision 5, Chapter 9, " Control of Special a.
Processes."
b.
Observation of in process shielded metal arc and flux cored arc welding being performed at various times by six (6) different welders, on four (4) different jobs.
Review of WPSs applicable to the above in process welding.
c.
d.
Observation and verification of the calibration status of ammeters and voltmeters associated with the power sources being used.
Discussions with cognizant personnel.
e.
3.
Findings a.
Deviations From Commitments See Notice of Deviation, Item A.4.
The following conditions were observed relative to the above noted deviation:
(1) interpass temperatures were not being determined, as the welders were not equipped to do so.
(2) Welder number 33, using W-59 on job 613, was welding with an amperage value of 150 as shown by the power source ammeter. A tong meter was then utilized to check the amperage, and a value of 165 amps was obtained.
(3) Welder number 15, using W-59 on job 615-B, was welding with a power source ammeter reading of 175 amps.
1410 265 e
10 (4) The flow rate of the CO, shielding gas as shown by the flow meter, was 75 CFH.' It was further ascertained that the flow meter was not in a condition to accurately measure the flow rate.
b.
Unresolved Items None.
I.
Weld Procedure Specifications 1.
Objectives The objectives of this arca of the inspection were to verify that PXE had implemented the requirements for the qualification and control of weld procedure specifications (WPS) in accordance with the QA Manual and applicable NRC and ASME Code requirements.
2.
Method of Accomplishment The preceding objectives were accomplished by:
a.
Review of QA Manual reivsion c, Chapter 9, " Control of Special Processes."
b.
Review of six (6) WPSs and their applicable Procedure Qualifi-cation Records (PQR) c.
Review of Section IX of the ASME Code relative to essential and non-essential variables for the above six noted WPSs.
d.
Discussions with cognizant personnel.
3.
Findings a.
Deviations From Commitments See Notice of Deviation, Item A.S.
b.
Unresolved Items None.
1410 266
~~m--
11 J.
Material Identification and Control 1.
Objectives The objectives of this area of the inspection were to verify that PXE had implemented the requirements for the identification and control of materials in accordance with the QA Manual and applicable NRC and ASME Code requirements.
2.
Methed of Accomplishment The preceding objectives were accomplished by:
a.
Review of QA Manual revision 5, Chapters 8 and 9 " Control of Special Processes," and " Identification, Inspection and Control of Materials, Parts, and Components," respectively.
b.
Observation of materials and parts, and a review of their associ-ated documentation.,
c.
Discussions with cognizant personnel.
3.
Findings a.
Deviation From Commitment (See Notice of Deviation, It.em B.).
Documented instructions / procedures were not available to describe how identification control is maintained on weld materials located in intermediate holding ovens.
All canisters of electrodes were identified with heat / batch numbers on one end. However, there were loose electrodes which were deter-mined to be type 316, size 5/32", that could not be identified.
In
~
addition, the personnel responsible for the intermediate holding ovens had devised an informal method of maintaining electrode identification, which turned out to be inaccurate.
A listing of the electrodes con-tained in the oven had been affixed to the oven and apparently had not been updated as needed. The listing showed the following elec-trodes as being in the oven:
1/4", 7018, HT #901751000 3/16", 7018, HT #920072000 5/32", 7018, HT #92003A 1/8", 7018, HT #92013A jjjg 9(f 3/32", 7018, HT #900712107 17 IU LU/
12 1/8", 308L, HT #8F17B
- 5/32", 308L, HT #8E9A 5/32", 309L, HT #8M23B
- There were none in the oven.
In addition, two (2) canisters of electrodes, identified as 1/8",
316-16, HT #2297588 and 1/8", 309L, HT #8H23B, were found in the oven, but not shown on the listing.
b.
Unresolved Items None.
K.
Exit Interview A meeting was held at the conclusion of this inspection on August 16, 1979, with the following management representatives:
P.X. O'Neill - President Additional attendees are denoted by an asterisk in paragraph A.
The scope and findings of this inspection were summarized.
Management acknowledged the statements relative to the findings.
1410 263
.