ML19253B497
| ML19253B497 | |
| Person / Time | |
|---|---|
| Issue date: | 08/20/1979 |
| From: | Kelly W, Whitesell D NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML19253B484 | List: |
| References | |
| REF-QA-99900060 99900060-79-2, NUDOCS 7910160308 | |
| Download: ML19253B497 (11) | |
Text
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U. S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT REGION IV Report No.
99900060/79-02 Program No. 51300 Company:
Target Rock Corporation 1966 East Broadhollow Road East Farmingdale, New York 11735 Inspection Conducted:
August 7-10, 1979
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- 8 /10 /99 Iaspector:
D. Kel1ey, Contract 6r Inspector Ilate ComponentsSection I Vendor Inspection Branch
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N 4//.20/f9 Approved by:
7N D. E. Whitesell, Chief Date ComponentsSection I Vendor Inspection Branch Summary Inspection on August 7-10, 1979 (99900060/79-02)
Areas Inspected:
Implementation of 10 CFR 50, Appendix B and applicable codes and standards including, inspection and test-liquid penetrant examination, nonconformance and corrective action, and calibration. Also reviewed reported valve malfunction item and conducted exit interview.
The inspection involved twenty seven (27) inspector-hours on site by one (1)
NRC inspector.
Results:
In the four (4) areas inspected, no deviations or unresolved items were identified.
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2 DETAILS SECTION A.
Per3ons Contacted Target Rock Corporation (TRC)
- G. A. Abruzzo, Manager Quality Assurance J. Bocci, Manager Safety Relief Valves F. Goeco, Level I NDT N. Palmiotto, Inspection Supervisor
- D. M. Pattarini, Vice President of Engineering Commercial Union Insurance Company (CUI)
M. Kudera, Authorized Nuclear Inspector (N7169)
- Denotes those persons who attended the exit interview (See paragraph H).
B.
General Review of Vendor's Activities 1.
The ASME issued the following Certificates of Authorization to TRC to use their symbol:
Certification No.
Symbol Product N-1947 N
Class 1, 2 & 3 valves N-1948 NPT Class 1, 2 & 3 valve parts and appurtenances and pipe subassemblies N-1949 NV Class 1, 2 & 3 pressure relief valves These certificates expire on December 9, 1980.
2.
The authorized inspection agency is the Commercial Union Insurance Company.
The authorized nuclear inspector is an itinerant inspector.
3.
TRC's contribution to the nuclear industry represents approxi-mately fifty percent (50%) of its total workload.
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3 4.
The National Board will survey TRC on September 4 and 5, 1979, for the issuance of the "U" and "UV" Certificates cf Authorizations.
5.
TRC is currently manufacturing 8 inch by 10 inch safety relief valves to ANSI 2500# class and 8 inch check, globe, gate and regulator valves to ANSI 4500# class.
C.
QA Program Review 1.
Objectives The objectives of this inspection were to ascertain whether the QA program has been updated to the latest applicable code addenda, documented in writing, and if properly implemented, will ensure that the specified quality of completed components has been achieved in compliance with NRC rules and regulations and the commitments in the ASME accepted Quality Assurance Manual. Also, to ascertain whether the program provides for the following:
a.
Management's policy statements concerning QA.
b.
Delineates how the QA organization is structured, to achieve appropriate independence from scheduling and costs, the freedom and independence to identify quality problems, initiate appropriate resolutions, and verify corrective action.
c.
Whether the duties and authority of the QA staff is clearly delineated in writing, and they have access to a level of management that can ensure effective implementation of the QA program elements, and to enforce positive and timely corrective action.
d.
Detailed written procedures are properly reviewed, approved, released, and issued to control quality activities, as appropriate.
e.
A training and indoctrination program to improve or maintain the proficiency of personnel performing quality activities, and personnel verifying that quality activities have been correctly performed.
2.
Method of Accomplishment The preceding objectives were accomplished by:
a.
Review of the ASME accepted Quality Assurance Manual.
b.
Review of appropriate organization charts.
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Review of the docunents concerning the authority duties, independence and freedom of the Quality Assurance staff.
d.
Review of Statement of Authority, dated August 14, 1974, signed by the President and General Manager.
Review of iocuments to verify that they had been reviewed and e.
approved by authorized personnel.
f.
Review of the training and indoctrination program require-ments and documentation.
g.
Interviews with cognizant personnel.
h.
Observation of work and test in progress.
3.
Findings The evidence demonstrates that the QA program has been documented in writing, and clearly defines the duties, authority, and organizational independence and freedom of the QA staff. Detailed written implementing documents are appropriately reviewed, approved, released, and issued by authorized personnel. The QA staff has access to a level of management to ensure effective implementation of the program and timely and positive corrective action of enforcement items.
A viable training and indoctrination program has been provided for upgrading, and maintaining, the profi-ciencies of pe:sonnel involved in quality activities.
Within this area of the inspection no deviations or unresolved items were identified.
D.
Inspection and Test-Liquid Penetrant Examination 1.
Objectives The objectives of this area of the inspection were to verify that; a.
The liquid penetrant examination procedures used by the vendor are consistent with the NRC rules and regulations, the ASME code requirements, and the commitments in the ASME accepted QA manual.
b.
The liquid penetrant examinations are being conducted by prop-erly qualified personnel in accordance with approved and qualified procedures.
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Method of Accomplishment The objectives of this area of the inspection were accomplished by:
Review of the ASME accepted Quality Assurance Manual, Revision 3, a.
Change Notice #3.
(1) Section 7.0 " Process Control" (2) Section 10.0 " Nondestructive and Examination;" and (3) Section 4.0 Design, " Drawing, Specification & Procedure Control" to verify that the vendor had established procedures for performing the liquid penetrant examinations.
b.
Review of the following procedures:
(1) TRP 1303 D Liquid Penetrant Inspection Acceptance Standards (2) Report No. 868a, Addenda 1 through 11, Liquid Penetrant Inspection Procedure to verify that the procedures had been approved, certified, and issued in accordance with the vendor's ASME accepted Quality Assurance Program commitments.
Review of Report No. 868a to verify that it is currently c.
being used, and that it defines the significant examination variables, and that these variables are controlled within the limits specified by the ASME code.
d.
Review of the documents referenced in paragraph a and b to verify they provide for the requalification when changes are made to surface preparations or change in penetrant materials.
e.
Observed the performance of a liquid penetrant examination using Report No. 1196A Liquid Penetrant Procedure, and verify whether the personnel performing and evaluating the exrmination were qualified, and that the examination was conducted in accordance with all of the procedures parameters.
f.
Verified that any indication revealed by the examination are evaluated in accordance with the procedure and the results reported in the prescribed manner.
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6 g.
Interviews with personnel performing liquid penetrant examination to verify they are knowledgeable in the applicable procedures.
3.
Findings a.
The inspector verified that (1) The liquid penetrant examination procedures used by the vendor met NRC rules and regulations and the ASME Code requirements; (2) The liquid penetrant examination witnessed was conducted by properly qualified personnel, in accordance with approved and qualified procedures.
b.
Within this area of the inspection no deviations or unresolved items were identified.
E.
Equipment Calibration 1.
Objectives The objectives of this area of the inspection were to verify that:
A system has been established and is maintained, to assure that a.
tools, gages, instruments, and other measuring devices, used in activities affecting quality, are properly controlled, calibrated, and adjusted at specified periods to maintain accuracy within the specified limits.
b.
The system is adequately documented with approved procedures and that the procedures are being implemented.
2.
Method of Accomplishment The objectives of this area of the inspection were accomplished by:
Review of the ASME accepted Quality Assurance Manual, Revision 3, a.
Change Notice No. 3, Section 12.0 Control of Calibration of Gages, to verify that the vendor has established procedures which prescribes a system for equipment calibration.
b.
Review of the following procedures; 1.
QCI 1100, Revision F, " Calibration and Maintenance of Measuring and Test Equipment,"
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MILI STD-120, Change Notice 1, " Gage Inspection,"
3.
MIL-C-45662A " Calibration System Requirements,"
to verify they have been prepared by the designated authority, approved by responsible management and reviewed by quality assurance.
Review of the documents referenced in paragraphs a. and b. to c.
verify that they identified the items included in the calibration program, the frequency of calibration, method and precision of calibration, and provided data sheets for recording the cali-bration results.
d.
Review of the calibration records of the following items:
1.
Gage Blocks - 254A 2.
Thread Wires - 338 3.
Ring Master - 317 4.
Micrometer Standards - 287 to verify that they provided all pertinent information pertaining to the calibration history, identification of item, standards used in calibration, calibration due date and interval, and the location for use.
Review of standards used in the calibration process to verify e.
they have been properly calibrated and certified.
f.
Review the calibration records of the items listed in paragraph d.
te verify the calibration procedures had been implemented.
g.
Interviews with personnel responsible for the calibration program to verify they are knowledgeable in the applicable procedures.
3.
Findings a.
The inspector verified that:
(1) A system has been established and is maintained to assure that tools, gages, instruments and other measuring devices used in activities _ff.ecting quality are properly controlled, calibrated, and adjusted at specified periods to maintain accuracy within specified limits.
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8 (2) The system is adequately documented with approved procedures and the procedures are being properly implemented.
b.
Within this area of the inspection no deviations or unresolved items were identified.
F.
Nonconformance and Corrective Action 1.
Objectives The objectives of this area of the inspection were to verify that:
Procedures have been developed and approved by the vendor which a.
prescribes a system for the control of noncomformances, and assures effective corrective action, in a manner which is consistent with NRC rules and regulations, and the vendor's commitments in the ASME accepted Quality Assurance Program.
b.
The nonconformance and corrective action procedures are properly and effe.ctively implemented by the vendor.
2.
Method of Accomplishment The objectives of this area of the inspection were accomplished by:
Review of the ASME accepted Quality Assurance Manual, Revision 3, a.
Change Notice No. 3; (1) Section 13.0 " Nonconforming Parts," and (2) Section 15.0 " Audits, Corrective Action, and Training" to verify that the vendor has established procedures which prescribes a system for identifying and reporting nonconformances and requires corrective action.
b.
Review of the following procedures; (1) QCI-1300, Revision E " Handling and Storage of Nonconforming Parts and Assenblies,"
(2) QCI-2010, Revision B, " Final Inspection of Detail Parts,"
(3) QCI-2020, Revision E, " Final Inspection of Assemblies" to verify that the yatem for nonconformances, provides for the identification of inspection points, identifies the personnel responsible for the identification, inspection method, li__
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9 acceptance criteria, personnel responsible for reviewing nonconformance reports and for the resolution, and segregation of item, and the distribution of the report.
c.
Review of the following procedures; (1) QCI-1840, Revision B, "Correcive Action Requirements for Discrepant Parts Manufactured by Subcontractors,"
(2) QCI-2400, Revision G, " Internal Corrective Action," and (3) QCI-2500, Revision F, " Quality Monitoring and Internal Audit Program" to verify that the corrective action procedures, have been approved, and are consistent with the ASME accepted Quality Assurance Program, and identifies the responsibility for the receipt and analysis of nonconformance reports, recommending corrective action, approving corrective action, and follow-up to assure corrective action is effective and precludes recurrence.
Also, verify the corrective action procedures provide for management participation in nonconformance report and corrective action review.
d.
Review of fifteen (15) nonconformance reports to verify that the nonconformance, and corrective action procedures were properly implemented, the assigned responsibilities were achieved.
Also to verify that out, the identification, reporting nonconformances, and the evaluation and implementation of corrective action, were timely and effective. Also to determine whether nonconforming items were properly dis-positioned, and of the corrective action follow-ups were per-formed, and management's participation was effective.
Interviews with personnel to verify they are aware of, and e.
have access to the nonconformance, and corrective action proce-dures.
3.
Findings a.
The inspector verified that:
(1) Procedures had been developed and approved by the vendor which prescribed a system for the control for nonconformances and to assure effective and timely corrective action, in a manner consistent with NRC rules and regulation and the vendor's commitments in the ASME accepted Quality Assurance Program.
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10 (2) The nonconformance and corrective action procedures were properly and effectively implemented by the vendor.
b.
Within this area of the inspection no deviations or unresolved items were identified.
G.
Follow-up on a Reported Valve Malfunction 1.
Objectives The objectives of this area of the inspection were to review the information available regarding the cause of a TRC safety relief valve on Carolina Power and Light's Brunswick Unit 2 plant operating without cause on July 17 and 19, 1979, and evaluate if it was generic to other plants.
2.
Method of Accomplishment The objective of the area of the inspection was accomplished by review of the information furnished by the manager-safety relief valves, pertaining to the removal, disassembly, repair, setting and testing of the CP&L Brunswick Unit 2 safety relief valve, and discussions with knowledgeable personnel.
3.
Findings The inspector was informed that the failure of the CP&L Brunswick Unit 2 safety relief valves (TRC Model No. 67F, Serial Number 191) was due to wire drawing of the 3rd stage seat, which permitted gross leakage which resulted in the actuation of the safety relief valve.
The valve was removed from service and shipped to Wyle Laboratory, in Huntsville, Alabama, where it was tested in the presence of a TRC representative in the "As found" condition.
The valve was disassembled repaired, and reassembled. Wyle Laboratory then performed all of the required tests on the valve, and shipped it back to the Brunswick site in early August.
Wire draw is a common type of failure of valve seats, in steam, or pressurized hot water service. The problem is not generic.
H.
Exit Interview At the conclusion of the inspection on August 10, 1979, the inspector met with the company's management, identified in apragraph A, for the purpose of informing them as to the results of the inspection. During
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4 11 this meeting management was informed no deviations or unresolved items were identified.
The company's management acknowledged the inspector's statement and had no additional comments.
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