ML19259D551
| ML19259D551 | |
| Person / Time | |
|---|---|
| Issue date: | 07/11/1979 |
| From: | Hunnicutt D, Oller R NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML19259D547 | List: |
| References | |
| REF-QA-99900080 99900080-79-1, NUDOCS 7910250068 | |
| Download: ML19259D551 (15) | |
Text
U. S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT REGION IV Report No. 99900080/79-01 Program No. 51300 Company:
Copes Vulcan, Inc.
Post Office Box 377 Lake City, Pennsylvania 16423 Inspection Conducted: June 12-14, 1979 Inspector:
[
7/#/79 R. E. Oller, Contractor Inspector Date Vendor Inspection Branch Approved by:
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D. M. Hunnicutt, Chief, ComponentsSection II Date Vendor Inspection Branch Summary Inspection on June 12-14, 1979 (99900080/79-01)
Meas Inspected:
Implementation of 10 CFR 50, Appendix B criteria, other NRC requirements, and applicable codes and standards including action on the previous inspection finding; handling, storage, and shipping; general review of vendor's activities; nonconformances and corrective action; internal audits, material identification and control; and product acceptance. The inspection involved twenty-four (24) inspector-hours on site.
Results:
In the eight (8) areas inspected, no unresolved items were ident-ified and no deviations were identified in six (6) areas. The following were identified in the remaining two (2) areas:
Deviations: Action on Previous Inspection Finding: Regarding lifting devices, the six (6) month nondestructive testing of books and the monthly visual in-spections of cables, belts, slings and eyebolts were not performed as required by Revision 5 of CVI Procedure 61-5.1.1.
(See Notice of Deviation, Item A.)
Internal Audits: The completed corrective action for the discrepancy reported in CVI Audit Report No. 78-2, was not reaudited to verify that the discrepancy was corrected.
(See Notice of Deviation, Item B.)
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2 A.
Persons Contacted D. Badowski, Product Sales Manager
- J. Baker, Vice President of Engineering D. Garres, Receiving Inspector
- R. Lawson, Director of Engineering N. Mattson, Contract Engineer
- D. Mays, Quality Control Manager
- E. Pialet, Supervisor of QC Engineering C. Roney, Maintenance Foreman J. Schrieber, Welding Foreman
- D. Tripp, Vice President of Materials
- Attended the Exit Meeting.
B.
Action on Previous Inspection Findings 1.
(0 pen) Unresolved Item D.3.b (Report No. 78-01):
Failure to have available, the records of internal inspection for handling devices such as cranes, hooks, chains and slings.
The inspector found that the inspection records for 1978, now avail-able, consisted of a list of chains and straps inspected on Sept-ember 29, 1978, and a list of cranes inspected on December 19, 1978.
Neither of these records contained sufficient information to verify that the requirements of CVI Procedure 61-5.1.1 were met for non-destructive testing of hooks every six (6) months and a monthly visual inspection of cables, belts, slings and eyebolts. This failure to follow the procedure is also contrary to criterion V of Appendix B to 10 CFR 50 which requires that activities affecting quality shall be accomplished in accordance with written procedures.
These findings change the above condition to a deviation from com-mitments.
The inspector also found that procedure 61-5.1.1 was revised on
.farch 30, 1979, and implementation was required by the Plant Engi-
. eer's memorandum dated April 25, 1979, to start on May 7, 1979, and be completed by August 1, 1979.
Implementation of the revised procedure was not started at the time of the NRC inspection.
(See Paragraph C.)
C.
Handling, Storage and Shipping 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 requirements:
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3 a.
A written system has been established to assure that handling, storage and shipping activities are controlled in accordance with codes and standards.
b.
Instructions, procedures or drawings are used to control hand-ling, storag2, shipping, packaging and preservation of materials and items, to prevent damage, deterioration, or loss.
c.
Lifting devices are maintained, periodically inspected, and controlled in accordance with written procedures or instructions.
2.
Method of Accomplishment 1
The preceding objectives were accomplished by:
a.
Review of QA Manual Procedure No. 1-6.11, Revision 2, " Handling, Storage, Shipping and Preservation," to verify that controls for these activities are documented.
b.
Review of Procedure No. 61-5.1.1, Revision 5 and 6, " Maintenance -
Material Handling Equipment."
Revie9'o'f records of inspection for 1978.
c.
d.
Review of CVI internal memorandum dated Ap_11 25, 1979.
e.
Discussions with cognizant personnel.
3.
Findings a.
Deviations From Commitments See Notice of Deviation, Item A.
b.
Unresolved Item None.
D.
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 Accomplishment The preceding objectives were accomplished by:
a.
Discussions with cognizant personnel.
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4 b.
Review of the QA Manual.
c.
Review of ASME Certificates of Authorization No. 1842 for N Class 1, 2 and 3 valves, and No. 1843 fot NPT Class 1, 2 and 3 valve parts and appurtenances.
d.
Review of lists of customers to whom Copes Vulcan, Inc., (CVI),
shipped ASME Class valves during 1978 and 1979.
e.
Verbal summary by the Product Sales Manager of valve manufactu-ring capabilities of the CVI Lake City plant.
3.
Findings a.
Deviations From Commitruents None.
b.
Unresolved Items None.
c.
Other Findings (1) The Copes Vulcan plant holds valid ASME authorizations for N Class 1. 2, 3 valves and NPT Class 1, 2, 3 valve parts and appurtenance. These authorizations expire August 19, 1979.
(2) During 1978 and 1979, the plant shipped ASME Class valves to twenty-one (21) customers.
(3) The CVI Lake City plant currently has capabilities to manufacture gate, check and control valves of the fol-lowing sizes, pressure classes and materials.
(a) Gate valves 3" through 14" nominal pipe size, 150, 300, and 1500 psi, austenitic stainless steel and carbon steel.
(b) Control valves 3/4" through 4" nominal pipe size, 11 pressure clasr s from 150-1500 psi, austenitic stainless steel and carbon steel.
(c) Three way control valves 1" through 3" of 304 aus-tenitic stainless steel.
(d) Steam isolation and control valves 6" through 12",
pressure class 900 psi for the secondary side of PWR systems.
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5 (e) Feedvater control valves such as feedwater startup 2" through 4",
900 psi, and main feedwater control valves,.12" through 18", 900 psi.
(f) Variety of special trim valves.
E.
Nonconformances and Corrective Action 1.
_C ectives Tee objectives of this area of the inspection were to verify that the following items were controlled in accordance with applicable NRC and ASME requirements.
a.
A written system hcs been established to assure the noncon-formances are controlled and corrective action is taken.
b.
Documented procedures or instructior:s are implemented for identification, documentation, segregation and disposition of nonconforming materials parts or components, and notifi-cation to affected organizations.
c.
Nonconforming items are reviewed and accepted, rejected, re-paired or reworked in accordance with documented procedures.
d.
Conditions adverse to quality are promptly identified and cor-rected.
The causes of significant conditions adverse to quality are e.
determined and corrected to preclude repetition.
f.
The condition adverse to quality, the cause and the corrective action are documented and reported to appropriate 1cvels of management.
2.
Method of Accomplishment The preceding objectives were accomplished by:
a.
Review of the following QA Manual procedures:
(1)
No. 1-6.17, " Nonconforming Materials or Items."
(2)
No. 1-6.18, " Quality Control Discrepancy Report."
(3)
No. 1-6.19, " Corrective Action."
b.
Observation in the shop of the locked cage type Reject Material Hold Areas and the Material Review Boerd's hold for disposition table.
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6 c.
Observation of two (2) ASME Class 3 cylinder type valve plugs SN 79-4 and SN 79-5 for Job 200530 on hold, and the following related process documents:
(1) Inspection Data Sheets.
(2) Hard Surfacing Record Procedure No. 2.1.5.4100, Revision 3.
(3) Operation and Route Sheet traveler.
(4) Quality Control Inepection Point tags.
(5) Reject Q Ticket.
d.
Observation in the weld shop of an ASME Section III Class 2, 1"-150 lb. valve body, being weld repaired for Job 20-95371, and the following related process documents:
(1) Operation and Route Sheet traveler.
(2) Welding Records including sketches and photographs.
(3) Reject Q Ticket.
e.
Review of the following nonconformance related records for valve SN 7720-95350-3-3 involving disposition by " Repair by Welding" for the valve body SN CV-603.
(1) Welding Record.
(2) Repair Welding Form and Sketch.
(3) Reject Q Ticket.
(4)
Inspection Report Data Sheet.
f.
Review of Inspection Report Data Sheets for nonconformances involving a valve bonnet SN R-1395, on Job 20-95350, cover-ing dispositions by iucept As Is" and " Rework."
g.
Review of the Reject Q Tickets involving nonconformances for a stem on Job 10-95281 and a cage on Job No. 20-95279, covering disposition by " Scrap."
h.
Review of following Quality Control Discrepancy Reports (QCDR) inc1hding the corrective action responses:
(1) Vendor QCDR No. 14-79IIIK8.
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7 (2) In-Process QCDR No. 9-79IIIE-2.
(3) Document Control QCDR No. 12-78IIIG-3.
i.
Discussions with cognizant personnel.
3.
Findings Within this area of the inspection, no deviations or unresolved items were identified.
F.
Internal audits 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 requirements:
a.
A written system has been established to assure that internal audits are performed and controlled in accordance with ap-plicable codes to verify compliance with all aspects of the QA Program.
b.
Planned and periodic audits are performed in accordance with written procedures or checklists by qualified personnel not having direct responsibilities in the areas being audited.
Audit results are documented and reviewed by management having c.
responsibility in the area audited.
d.
Follow-up action, including reaudit of deficient areas, is taken where indicated.
2.
Method of Accomplishment The preceding objectives were accomplished by:
a.
Review of the QA Manual Procedure No. 1-6.22, " Internal Audits."
b.
Discussions with cognizant personnel.
c.
Review of records of management audits dated April 5, 1978, October 25, 1978, and April 18, 1979.
d.
Review of records of scheduled internal audits including the following:
(1) Internal audit schedule for the period of August,1971 through April, 1979.
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8 (2)
Internal memorandum dated June 6, 1979, regarding re-scheduling of the April, 1979, internal audit to be per-formed along with the scheduled June, 1979, audit.
(3) List of Audit Team Members for the period of August, 1971, through March, 1979.
(4) List of Auditors' participation in audits as part of their training.
(5) Record of Audit Reports Nos. 79-1, 78-3, 78-2 and 78-1.
(6) Record of Discrepancy Report No. 8-78III-E10 related to Audit Report 78-2.
3.
Findings a.
Deviation From Commitments Centrary to Criterion V of Appendix B to 10 CFR 50 and the QA Manual Procedure 1-6.22, Revision 6, the completed cor-rective action for the discrepancy in Audit Report No. 78-2, dated June 6, 1978, concerning failure by the machine shop to~ sign off on Operation and Route Sheets, was not reaudited to verify that the discrepancy had been corrected. Prior to the end of the NRC inspection, the acting Section III Spe-cialist provided records which showed that on June 13, 1979, the Machine Shop Foreman and the acting Section III Specialist performed an audit of in process Operation and Route Sheet Travelers for seven (7) valve bonnets in the machine shop and verified that the operations on these records were being signed off. This audit provided the corrective action for the failure to perform a followup audit. However, no method to preclude recurrence was provided.
b.
Unresolved Items None.
G.
Material Identification and 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 Requirements.
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9 a.
A written system has been established to assure that material identification and control is performed in accordance with ap-plicable codes.
b.
Documented measures have been used for identification and control of materials and items including partially fabricated assemblics.
c.
Identification is maintained either on the item or on records traceable to the item.
d.
Permanent or temporary identification marks or numbers are legible and are not detrimental to the item quality or interfere with the function of the item.
Welding and brazing materials are controlled.
e.
f.
All characteristics required to be reported appear on checklists or Certified Material Test Reports, and the CUTRs have been received, reviewed and found acceptable.
2.
Method of Accomplishment The preceding objectives were accomplished by:
a.
Review of the following QA Manual procedures:
(1)
No. 1-6.12, " Receiving Inspection."
(2)
No. 1-6.13, " Inspection and Documentation."
(3)
No. 1-6.14, " Assembly and Test."
b.
Observation of caged and locked areas for:
(1) Receiving Inspection.
(2) ASME Section III Material and Parts.
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10 c.
Observation of permanent identification markings on the following items, and the related Identification Tags, QA Inspection Point Tags, and other accompanying process and control records, where applicable.
(1) Receiving Inspection Area (a) Bar Stock for Job 20-95179.
(b) Valve Body Forging for Job 20-95393.
(c) Bonnet Studs for Job 952718.
(2) ASME Section III Storage Area (a) Bar Stock for Job 10-95160.
(b) Bar Stock for Job 20-95386.
(c) Valve Body Forgings for Job 10-95280 and for Job 20-95400.
(d) Valve Bonnet Forgings for Job 20-95371.
(3) Machining Area Bonnets for 8"-150 lb. valves for Job 20-95179.
(4)
Inspection Department (a) Valve stem for Job 20-95321.
~
(b) Valve Boncets for Job 20-95399.
(5) Weld Shop (a) Sealed cans of 8018 coated weld rods purchased on P0 813210-2 and released for use on MR-A10950.
(b) Packages of straight Inconel wire purchased on PO 503507-5 and released on KR-7305.
(c) Packages of hardsurfacing Stoody No. 6 rods.
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l 11 (d) Three inch valve bonnet for Job 20-95398.
(e) 1 1/2"-600 lb. valve body being veld repaired for Job 20-95178.
(6) Completed Valve Hold Area Two (2) assembled and tested ASME III Class valves with stamped code nameplate attached. The valve manufacturer's attached nameplates identifi.ed the valves as SN 7820-95394-2-6 and SN 7820-95394-4-5.
3.
Findings Within this area of the inspection, no deviations or unresolved items were identified.
H.
QA Records 1.
Objectives The objectives of this area of the inspection were to verify that the following items were controlled in accorcance with applicable NRC and ASME Code requirements:
a.
A written system has been established to assure that record control is performed in accordance with applicable codes.
b.
A written procedure has been developed, approved and implemented I.i which provides for the following:
7 (1) Classification of QA records as pe.rmanent or temporary.
p,$ c.
(2) A QA record index.
- 17.
(3) Adequate storage, preservation and safe keeping.
(4) Periodic audit of the storage system.
Ms (5) A system for timely retrieval of QA records.
.f,,
c.
Records required for quality assurance, fabrication and trace-
~."
ability are maintained.
., A) 9,-
d.
The file contains documents such as records of materials, manu-
. ~ *T facturing, examination, and test data taken before and during manufacture, and the procedures, specifications, stress reports, and drawings used, fully identified by pertinent material or
. item identification numbers, revision numbers, and issue dates.
1213 105
12 The file also includes related data such as qualification of c.
personnel, procedures, equipment and related repairs.
f.
Adequate measures are provided to suitably protect the files from deterioration and damage.
2.
Method of Accomplishment The preceding objectives were accomplished by:
a.
Review of the QA Manual Procedure 1-6.20, " Contract Records."
b.
Review of copies of the following Data Package permanent records supplied to the customer and balance of records maintained by Copes Vulcan for a 2"-150 lb. diaphragm operated control valve SN 7410-95327-1-1, to verify that the records therein were as specified by the customer and as required by the ASME code and the QA Manual.
(1) Data Package Records (a) Heat Treatment.
(b) Certified Material Test Reports.
(c) Code Compliance Form MPV-1.
(d) Dye Penetrant Examination Procedures and Verification
, j Reports.
(e) Hydrostatic Test Report.
s:.'
jp' (f) Dimensional Inspection Report,
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(e) Mechanical Tests.
t, ~.
'b (2) Records Maintained by CVI (a) Master Valve Index.
(b)
" Build Sheets" for Valve Assembly.
T
~ ll
/
(c) Final. Visual Inspection Record.
L t
]
(d) Welding Records.
1213 106 J,
13 (c) QC Material Releases.
(f) Customer Approved Prints.
(g) Engineering File Prints.
(h) NDE Tables with Document Control Sheets.
(i) QC Inspection Point Plan.
(j) Special Procedures (k) Shop Orders and Changes.
(1) Control Valve Specifications.
(m) Customer Specifications and Correspondence.
(n) CVI Subvendor Purchase Orders.
(o) Other Procedures.
(p) NDT Qualifications.
(q) Welder Qualifications.
(r) liardsurfacing Record.
(s) Document Transmittal Forms.
c.
Discussions with cognizant personnel.
3.
Findings Within this area of the inspection, no deviations or unresolved items were identified.
I.
Product Acceptance 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 requirements.
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14 a.
A written system has been established to assure that product acceptance activities related to procurement of items and services, are controlled.
b.
Procedures have been prepared, approved and implemented by responsible personnel to control the subject activities.
c.
The results of product acceptance activities are documented and reviewed for acceptability by responsible personnel.
2.
Method of Accomplishment The preceeding objectives were accomplished by:
a.
Review of the QA Manual Procedure No. 1-6.12, " Receiving Inspection."
b.
Observations in the Receiving Area, (Previously discussed in paragraph F.1, " Material Identification and Control" of this report).
c.
Review of the following documents used by Receiving Inspection to verify that material meets purchase re-Fuirements and could be released to production:
l (1) Barstock (a) PO No. 712887, Item 3 for 3 3/4" diameter bar.
(b) Certificate of Test from the supplier.
(c) Ultrasonic Test Report..
(d) CVI Quality Material Release No. A-4384 for the purchased material for Job 20-95386.
(2) Two (2) 8"-150 lb. Bonnet Castings (a) P0 NO. 811197, Item 2.
(b) Material Test Report.
(c) CVI's QC Material Release No. A-10460.
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15 3.
Findings Within this area of the inspection, no deviations or unresolved items were identified.
J.
Exit Meeting 1.
The inspector met with management representatives denoted in para-graph A, at the conclusion of the inspection on June 14, 1979.
2.
The following subjects were discussed:
a.
Areas inspected.
b.
Status of Corrective Action for the previous inspection findings.
c.
The deviation identified in the area of internal audits.
3.
The manufacturer's representatives were asked to formulate their corrective action responses to deviations in accordance with the three (3) conditions identified in the inspection report cover letter.
4.
The manufacturer representatives' indicated they had no questions related to the above items.
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