ML19254D445
| ML19254D445 | |
| Person / Time | |
|---|---|
| Issue date: | 09/25/1979 |
| From: | Barnes I, Hunnicutt D NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML19254D417 | List: |
| References | |
| REF-QA-99900066 99900066-79-1, NUDOCS 7910250541 | |
| Download: ML19254D445 (7) | |
Text
U. S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT REGION IV Report No. 99900066/79-01 Program No. 51300 Company:
Texas Pipe Bending Company Post Office Box 5188 Houston, Texas 77012 Inspection Conducted: May 7-11, 1979 Inspector:,
k k F /777 I. Barnes, Contractor Inspector, Vendor
/ Dafe Inspection Branch 2/f b AI/777 Approved by: y D. M. Hunnicutt, Chief, Components Section.II, V Date' Vendor Inspection Branch Summary Inspection on May 7-11, 1979 (99900066/79-01)
Implementationof10CFR50,AppendixB,c(riteriaand Areas Inspected:
applicable codes and standards, including joint fitup and welding; procedure, document and drawing control; nonconformances and corrective action; and heat treatment. The inspection involved thirty-five (35) inspector-hours on site.
Results:
In the four (4) areas inspected, no apparent deviations or unresolved items were identified in one (1) area; with the following deviations and unresolved items being identified in the remaining areas:
Deviations: Procedure, Document and Drawing Control - Assembly under engineering hold for revision not moved to a designated hold area, as required by Criterion V of 10 CFR 50, Appendix B, and Section 2 of the QA Manual (Enclosure No. 1, Item.
A); changes made to a shop drawing, which were not in accordance with the require-ments of Criterion V of 10 CFR 50, Appendix B, and Section 4 of the QA Manual (Enclosure No. 1, Item B).
Joint Fitup and Welding - Qualification of a subcerged are welding procedure not consistent with Criterion V of 10 CFR 50, Appendix B, and the postweld heat treat requirements of the ASME Code,Section III (Enclosure, Item C).
Unresolved Items: Joint Fitup and Welding - Abseace of defined controls relatiye to' hot re-rolling of welded pipe (Details Section, C.3.b).
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Heat Treatment - Status of corrective actions for nonconforming solution annealing heat treatments incomplete as of this inspection (Details Section, D.3.b.(1));
compliance with AS.'E Code requirements for metal temperature and metal temperature uniformity could not be established for the pipe mill furnace, owing to absence of documentation of practices to be followed (Details Section, D.3.b.(2)).
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3 DETAILS SECTION A.
Persons Contacted
- G. R. Shepherd, Vice President, Contracts and Procurement
- A. T. Cureton, Vice President, Manufacturing
- W. S. Smith, Manager, Quality Assurance
- L. W. Hensley, Manager, Power Engineering
- W. W. Trujillo, Assistant Manager, Quality Assurance
- B. V. Kielman, Supervisor, Quality Control
- H. Garza, Quality Control Engineer M. J. Hewlett, Welding Engineer
- D. Snider, General Foreman, Pipe Mill M. R. Wood, Supervisor, Documentation
- Attended exit interview.
B.
Procedure, Document and Drawing Control 1.
Objectives The objectives of this area of the inspection were to:
a.
Ascertain that a system has been established for the control of procedures, documents and drawings, which is'ponsistent with the QA Program and customer dasign requirements. (
b.'
The system has been established and is operating effectively.
2.
Method of Accomolishment The preceding objectives were accomplished by:
a.
Review of Section 2 of the QA Manual, revision dated May 18, 1978,
" Engineering & Design Control."
b.
Review of Section 4 of the QA Manual, revision dated May 18, 1978, "In-Process Control."
c.
Examination of customer specification, 9645-M-201.0, Revision 23, relative to document submittal and approval requirements for Job No. N1789.
d.
Review of customer approved procedures for Job No. N1789.
e.
Verification that applicable custcmer approved revisions of procedures were available at work stations.
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4 f.
Review of six (6) Sh'op Drawings in shop use for the referenced contract, in terms of specification of and use of approved procedures.
g.
Verification that drawings in shop use were the correct revisions required by the Engineering Department and had received appropriate approvals.
h.
Examination of control system utilized for in process fabrication affected by revisions in customer requirements.
3.
Findings a.
Deviations frem Commitment (1) See Enclosure No. 1, Item A.
(2) See Enclosure No. 1, Item B.
b.
Unresolved Items None.
C.
Joint Fitup and Welding 1.
Objective
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The objective of this area of the inspection was to determine if pr6 duction welding was controlled in accordance with the manufacturer's QA Program and applicable ASME Code and regulatory requirements.
2.
Method of Accomplishment The preceding objective was accomplished by:
a.
Review of Section 5 of the QA Manual, revision dated April 10, 1978, " Welding."
b.
Observation of production shielded metal arc, submerged are and gas tungsten arc welding operations with respect to:
(1) Work being performed in accordance with Shop Drawing require-ments and referenced instructions.
(2) Verification that applicable welding procedure specifications were available at the work stations.
(3) Verification that procedure assignment was in accordance with ASME Code essential variable requirements.
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5 (4) Establishing correct, approved welding materials were in use and welding personnel were complying with the parameters required by the applicable welding procedure specifications.
c.
Examination of control practices for use and removal of temporary attachments.
d.
Verification that control program utilized for assuring required accuracy of welding equipment was in effect.
e.
Review of welding personnel qualifications for operations witnessed.
f.
Examination of the manufacturing control system in the pipe mill, with respect to welding procedure specification qualification relative to manufacturing practices in use.
g.
Verification that sub-asse=bly fitup was in compliance with ASMS Code requirements.
3.
Findings a.
Deviation from Commitment See Enclosure No. 1, Item C.
b.
Unresolved Items
.j Operation 16 on the Manufacturing Control Sheet for Job No. M1112N, Item 2, Piece 1, permitted re-rolling of welded pipe to be performed with hot or cold, without any formalized definition of the term
" hot" being in existence with respect to required practice and temperature range.
Shop utilization of temperatures above the material lower critical temperature for re-rolling would invalidate existing welding qualifications.
It was additionally noted that the QA Manual specifically excludes plate hot rolling as a special process requiring QC monitoring for compliance with approved procedures.
This item is considered unresolved pending development of docu-mented criteria for the control of hot re-rolling.
D.
Heat Treatment 1.
Objectives The objectives of this area of the inspection were to:
a.
Verify that procedures have been established for the heat treat-ment of materials and parts and that these procedures were con-sistent with applicable regulatory, ASME Code and contract require-ments.
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6 b.
Verify that heat treatment operations are corducted in accordance with these procedures.
2.
Method of Accomplishment The preceding objectiv.es were accomplished by:
a.
Review of Section 4 of the QA Manual, revision dated May 18, 1978, "In-Process Control."
b.
Review of solution annealing heat treat procedure, EAWQ-1788, Revision 0.
c.
Examination of vendor heat treat records relative to solution annealing of bends on Job No. N1788A.
d.
Review of heat treat vendor survey report relative to audit criteria used.
Review of postweld heat treatment procedure, HSRCS-2, Revision 0, e.
which was approved for use in the pipe mill, with respect to ASME Code requirements.
3.
Findings a.
Deviations from Commitment A
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None.
b.
Unresolved Items (1) Solution annealing of stainless steel bends was performed by a heat treat vendor, which was not in co=pliance with the applicable procedure requirements in respect to holding time at temperature and certification of actual elapsed cooling time to 800 F.
This matter was identified by Texas Pipe Bending Company on Nonconformance Reports, but corrective action and steps to preclude recurrence had not been finalized as of this inspection.
This item is considered unresolved pending completion and review of corrective actions.
(2) Documented means were not available as of this inspection to enable verification, that postweld heat treatments performed in the pipe mill furnace, would be in compliance with respect to ASME Code requirements for assuring metal te=perature and metal temperature uniformity. As of this inspection, no ASME Section III piping had been heat treated in the pipe mill furnace.
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7 This item is considered unresolved pending verification of practice compliance with applicable ASME Code requirnents.
E.
Nonconformances and Corrective Action 1.
Objective The objective of this area of the inspection was to verify that a system for control of nonconformances and for assuring effective corrective actions has been established and implemented.
2.
Method of Accomplishment The preceding objective was accomplished by:
a.
Review of Section 9 of the QA Manual, revision dated April 10, 1978, "Nonconformances."
b.
Examination of five (5) nonconformance reports with respect to:
(1) Identification of item and description of nonconformance.
(2) Identification of reporting party and personnel responsible for resolution.
(3) Disposition of nonconformances in accordance with program commitments.
(
(4) Eviden'ce of management participation in conconformance report and corrective action review.
(5) Analysis of nonconformances and determination of required corrective action.
(6) Assigned responsibilities are carried out in an effective manner.
3.
Findings Within this area of the inspection, no deviations from commitment or unresolved items were identified.
F.
Exit Interview The inspector met with the managment representatives denoted in paragraph A above on May 11, 1979, at the conclusion of the inspection. The scope of the inspection and the findings were discussed with managment representatives present. Management acknowledged the statements of the inspector and had no specific questions relative to the findings.
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