ML19254D367
| ML19254D367 | |
| Person / Time | |
|---|---|
| Issue date: | 08/27/1979 |
| From: | Hunnicutt D, Oller R NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML19254D355 | List: |
| References | |
| REF-QA-99900267 99900267-79-2, NUDOCS 7910250400 | |
| Download: ML19254D367 (12) | |
Text
U. S. NUCLEAR REGULATORY C0t2iISSION OFFICE OF INSPECTION AND ENFORCEN3T REGION IV Report No.
99900267/79-02 Program No. 51300 Company:
Tube Turns Division of Chemetron 7100 Katy Road, Post Office Box 393 Houston, Texas 77001 Inspection Conducted: August 13-17, 1979 a
.(
Inspector:
b b yhM M
l R. E. Oiler, Contrac.or Inspector y'
D.Ite ComponentsSection I!
Vendor Inspection Branch Approved by:
I Nv h N ~17 D. M. Hunnicutt, Chief
(
Date ComponentsSection II Vendor Inspection Branch Summary Inspection on August 13-17, 1979 (99900267/79-02)
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, internal audits, manufacturing process control, radiographic examination, welding control consisting of welding procedures - welding :caterial control and welding heat treatment, and test of completed products.
The inspection involved twenty nine (29) inspector-hours on site.
Results:
In the seven (7) areas inspected, no deviations were identified in six (6) areas. The following were identified in the remaining areas.
1209 J06 7010250TCO e-,e a
2 Deviation: Welding; f ailure to maintain the humidity at a uaximum of 50%
in the welding materials storage building.
(See Notice of Deviation.)
Unresolved Items: Action on previous Inspection Findings:
Report 79-01,QA Manual Procedure TT22-213 was revised to provide for reporting of nonconforming material found at receiving inspection, bu* was not approved and submitte d to the AIA for acceptance.
Reporn 78-01, QA Manual Frocedur's were revised to include the training program in procedure TT22-200J and delete it from procedure TT22-214, but these revisiens were not approved and submitted to the AIA for acceptance.
(See Details Section paragraph B.3 and 4).
I 1209 007
2 DETAILS SECTION A.
Persons Contacted
- M. Barnes, Jr., Works Manager
R. Ganz, RT Technician - Level II P. Lazar, Production Manager
- Ar: ended the Exit Meeting B.
Action on Previou_ Inspection Findings 1.
(Closed Deviation (Report No. 79-01); Failure to include on four (4) purchase orders for plate materials, the required state-ment, "No weld repair permitted without the prior approval by Tube Turrs." The inspector found that current purchase orders for plate material contain the above statement. Review of a memorandum dated February 12, 1979, from the QC Department te the Manager of Order Service, verified that the preparers of purchase orders were requested to include the above subject state-ment on P.O.s.
2.
(Closed) Deviation B-2 (Report No. 78-01); Failure to calibrate, label and maintain calibration records for the weiding shielding gas flowmeter No. SN-R5007 used n making the weld root seal pass.
The inspector found that the practice of putting in a weld root seal pass has been discontinued. The new practi:e is to manually tackwe'd the pipe using procedure TTH0-12-0100 and then complete the weld using the automatic submerged arc process in accordance with welding procedures TTH0-14-0109, Revision 21, 22, or 23, as applicable. While the manual GTAW tacking procedure also requires the use of a welding gas f'.owmeter, the gas flow in manual GTAW process is a nonessential variable. Based on Code interpretation No.
III-1-78-213 issued July 21, 1978 and clarified on April 20, 1979, the subject matter is no longer considered a deviation.
3.
(Open) Unresolved Item (Report No. 79-01): The practice of rejecting nonconforaing purchased material found at receiving inspection by writing a rejection report and returning the material to the vendor, was not described in the QA Manual. The inspector found that a 1209 008 v
3 draft revision of Manual Procedure TT22-213 now requires that QC be advised of nonconforming material found by receiving inspection and tha* QC shall prepare a Rejection - Complaint Report. Tube Turr-Louisville Management will approve this manual revision, and it will be presented to the Authorized Inspection Agency's (AIA's) laspection Specialist for a ceptance.
This continues to be an unresolved item.
4.
(0 pen) Unresolved Item (Report no. 78-01): The subject " Training Program" appplicable to all personnel performing activities affecting quality, was improperly included in the QA Manual pro-ce' 3 TT22-214 " Audit Procedure."
The inspec*.or found that a draf t revision of the QA Manual Pro-cedure TT22-200J has been written to provide measures for a training program and a draft revision of TT22-214 deletes the training provisions. Tube Turns Louisville Management will approve these manual revisions and they will be presented to the AIA's Inspection Specialist for acceptance.
This continues to be an unresolved item.
C.
General Review of Vendor's Activities 1.
Objective The objective of this area of the inspection was to assess the vendor's activities and their impact on future NRC inspections.
2.
Method of Accceplishment The preceding objective was accomplished by:
a.
Discussions with cognizant personnel.
b.
Review of a list of the Tube Turns Houston plant's customers from whom orders for ASME SA-155 Class Welded piping were received during the past twelve (12) months.
c.
Review of the draft status of QA Manual revisions.
d.
Review of the ASME Authorization No. 1807 for NPT Class 1, 2, 3 and MC Vessel Parts and Class 1, 2, 3 Piping Sub-assemblies and Tubular Products welded with filler metal.
1209 009'
4 3.
Findings a.
Within this area of the inspection, no deviations or unresolved items were identified.
Other Findings (1) The Tube Turns Houston plant has capabilities to manufacture welded carbon steel pipe 20 through 60 inches nominal 0.D. with wall thicknesses of 3/8 through 3 inches for nuelcar service. They also can manufacture carbon steel yoke closures in diameters of 20 through 48 inches diameter for nuclear service.
(2) The ASME NPT Authorization expires July 15, 1980.
(3) The Authcrized Nuclear Inspector services are provided by the Houston Office of HSB-I & I Company on a noti-fication basis.
D.
Internc1 Audits 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 internal audi 3 are performed and controlled in accordance with appi-cable codes to verify compliance with all aspects of the QA program.
b.
Planned and periodic internal audits are, erformed in accordance wi.h written procedures or checRists by qualified personnel not having direct responsibilities in the areas being audited.
c.
Audit results are documented and reviewed by management having responsibility in the. area audited.
d.
Followup action, including reaudit of deficient areas, is taken where indicated.
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5 2.
Method of Acccmplishment The preceding objectives were accomplished by:
a.
Review of the QA Manual Procedure TT22-214 " Audit Procedure."
b.
Review of the schedules of internal audits for the period of June,1978 through May,1979 and for the period of June, 1979 through May, 1980.
c.
Review of records of eleven (11) internal audits performed during the period of July, 1978 through July, 1979.
d.
Discussions with cognizant personnel.
3.
Findings Within this area of the inspection, no deviations or unresolved items were identified.
E.
Manufacturing Process 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 requireme.cs.
a.'
A written system has been established to assure that mann-facturing processes are controlled in accordance with appli-cable codes.
b.
Measurer have been established and implemented to control the manufacturing processes by use of process sheets, travelers, checklists or procedures.
c.
The process sheets, travelers, checklist or shop procedures used included:
the document numbers and revisions to which the processes, inspections or tests conformed; the results of completion of the specific operations; the signature, initials or stamp of the manufacturer's responsible representative and date were shown for operations completed, and the signature,
6 initials or stamp of the authorized inspector aud uste, were shown for activities he witnessed.
2.
Method of Accomolishment The preceding objectives were accomplished by:
a.
Review of the QA Manual Procedure TT22-202 " Production and Process Control."
b.
Ob;ervm.. ion of two (2) in process 32" 0.D., SA-155 pipes No. 4 of 22 and 5 of 22 for Order HPM4-27793, Item 001, completed through the radiographic examination, also review of the accompanying Production Routers to verify that the routers were properly released to production; operations were properly identified by procedure and revision number or instruc-tions; the ANI and Tube Turns QC holdpoints were identified, and all completed operations and inspections were initialed and dated as required, by the operator, QC inspector and ANI, as applicable.
c.
Observation of in process pipes No. 21 of 22 and 8 of 22 for Order NO. HPM4-27793, Item 001, completed through the heat treatment, also review of the acco.npanying Production Routers to verify that the required information was on the routers and that completed operations and incpections were appropriately initialed and dated.
d.'
Review of the welding record " Weld Record Pipe" for pipes 1 through 8 of 22 for Order HPM4-27793, Item 001, also the approved welding material sheet for the same order.
Review of the following related work and inspection records for e.
orders: HPM4-27778, Item 001, Pipe 1 of 1; HPM4-27615, Item 001, Pipe 1 of 1, and HPM4-27611, Item 001, Pipes 1 through 5 of 5.
(1) Tube Turn's Customer Purchase Orders (2) QC Order Analysis Sheet (3) Production Routings (travelers)
(4) Weld Record Pipe, (records)
(5) Weld Material Approved List (6) Hydrostatic Test Records (7) Radiographic Reports (8) Detailed Analysis Reports (alias CMTRs) 1209 ]l2
7 3.
Finding Within this area of the inspection, no deviations or unresolved items were identified.
F.
Radicerschic Examination I.
Objectives The objectives of chis 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 radiographic examination (MT) is performed in accordance with applicable codes.
b.
Final acceptance RT is performed in accordance with detailed written instructions or proct.res which delineate require-ments and acceptance standards.
c.
The RT procedures meet the requirements of the ASME Code and are qualified.
d.
The RT is performed and the results interpreted by certified personnel.
e.g Test results are documented and evaluated to assure that the component or material examined contain no rejectable defects.
f.
Appropriate instruments are used, and the instruments are calibrated, waere required.
2.
Method of Accomplishment a.
Review of the QA Manual Procedure TT22-208 " Nondestructive Examination."
b.
Review of approved procedure TT-03-372, Revision 3, " Procedure for Radiographic Examination to the Requirements of ASME V".
c.
Observation of the radiugraphic setup for one x-ray film exposure on the long weld seam of pipe 9 of 12 for Order No. 4-27809, a 30 inch Q.D. by 2.500 inch wall carbon steel pipe, to verify that procedure TT-03-372, Revision 3 was being followed.
0 E l} } }
8 d.
Examination of the developed RT film for the above pipe.
e.
Observation of the radiographic equipment and facilities including the density step tablet film reference stancard.
f.
Review of the following radiographic examination related records for five (5) pipes (Nos. 1, 2, 3, 6 7, of 22) on Order HPM4-27793:
(1) QC Order Analysis (2) Production Routings (3) Detailed Analysis Report 3.
Findings Within this area of the inspection, no deviations or unresolved items were identified.
G.
Welding 1.
Th2 objectives of this area of the inspection were to verify that the following activities were controlled in accordance with applicable NRC and ASME Code requirements.
a.
A system has been established to assure that welding is controlled in accordance with appl.:able codes.
b.
The welding procedure specifications (WPS) used in production welding are prepared, qualified and controlled in accordance with the QA Program.
c.
The welding materials purchase, acceptance, storage, issuance and use are controlled and documented in accordance with detailed procedures.
d.
The post weld heat treatment, specified by the welding procedures, is performed in accordance-with an approved procedure, consistent with code requirements.
2.
Method of Accomplishment The preceding objectiven were accomplished by:
1209
>)14
9 a.
Review of the QA Manual Procedures: TT22-206 " Welding Operation Control," and TT22-210 " Heat Treatment."
b.
Review of the following approved production welding procedure specifications (WPS) and the related procedure qualification records (PQR):
(1) brS TIHO-0109, Revision 21, and PQR H0-1-418A.
(2) WPS TTH0-0109, Revision 22, and PQR H0-1-418B.
(3) WPS TTH0-0109, Revision 23, and PQR HO-1-418C.
(4) WPS TT-11-0106, Revision 11, and PQR No. 5329 (Repair Procedure).
(5) WPS TTH0-12-0100, Revision 3, and PQR No. H0-1-6.
(Used for GMA tack welding.)
c.
Review of approved procedure No. TTH0-24-001, Revision 1,,
" Control of Welding Supplies."
d.
Observation of the welding material receiving area and the temperature / humidity controlled welding material storage building.
e_
Retiew of the welding Material Approved list for Order KPM4-22793, ' tem 001, located in the welding material storage building.
Review of tuo (2) Weld Material Control issuanca sheets for Order HPM4-27787, and the Welding Material Qualification Sheet, Test H0-I-416.
g.
Review of the welding certificate book used for numbering and logging of Welding Material Test Reports.
h.
Observation of the heat treating furnace and facilities including the calibration status of the four (4) zones recorder - controllers, the multipoint recorder and the high temperature limit control.
i.
Review of the records of the furnace temperature uniformity survey performed on July ' and 6, 1979, including the calibration certificates for the furnace controls and recorder.
1209 015
10 j.
Review of the following approved postwe d heat treatment procedures:
(1)
No. TTH0-01-005, Revision 1.
(2)
No. ITHO-05-006, Revision 1.
(3)
No. TTH0-39-006, Revision 2 "A".
K.
Review of the following related production heat treatment records for pipes on Order HPM4-27770, Item 001, Order HPM4-27777, Item 001, and Order HPM4-27793, Item 001:
(1)
Q. C. Order Analysis Sheet.
(2) Production Rcuters (3) Form NM-1 Data Reports (4) Detailed Analysis Reports 3.
Findings a.
Deviations from Commitments See Notice of Deviations.
b.
Unresolved Items None.
H.-
Testing of Corpleted Products 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 ISME Code requirements.
a.
A written system 'aas been established to assure that final presse e tests are. controlled in accordance with applicable procedures and codes.
b.
Final pressure tests are performed in accordance with approved procedures.
c.
The results of tests are documented and reviewed for acceptability.
d.
The test equipment is calibrated where required.
e.
Tests are performed by qualified personnel.
1209 216
11 2.
Me: lod of Accomplishment The preceding objectives were accomplished by:
a.
Review of the QA Manual Procedure TT22-208 "Nondeutructive Examination."
b.
Review of approved test procedure TTH0-013, Revision 3,
" Hydrostatic Testing of Pipe."
c.
Observation of the hydrostatic test iscilities, including the calibration status of the pressurn gages.
d.
Observation of the in process hydro <.catic test of pipe No. 4 of 22 for Order EPM 4-27793, Item 001.
Review of the completed hydrostatic test operation step e.
on five (5) Production Routings (travelers), and the Hydrostatic Test Record for five (5) po es on order No.
EPM 4-27611, Item 001.
3.
Findings Within this area of the inspection, no deviations or unresolved items were identified.
I.
Exit Interview 1.
The inspector net with manag ent representatives denoted in paragraph A. at the conclusion of the inspection August 17, 1979.
2.
The following subjects were discussed:
a.
Areas inspected.
b.
Status of corrective action for the previously identified deviations and unresolved items.
c.
The deviation identified in this report.
1209 017
12 3.
The manufactu:ar's representatives were asked to formulate the corrective action response to the deviation in accordance with the three (3) conditions identified in the inspection repr,rt cover letter.
4.
.fanagement's comments were related to clarification of the findings.
h 0
,jg cu.