ML19260C046
| ML19260C046 | |
| Person / Time | |
|---|---|
| Issue date: | 10/15/1979 |
| From: | Hunnicutt D, Oller R NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML19260C022 | List: |
| References | |
| REF-QA-99900314 99900314-79-2, NUDOCS 7912180273 | |
| Download: ML19260C046 (10) | |
Text
U. S. NUCLEAR REGUI.ATORY C0mlISSION OFFICE OF INSPECTION AND ENFORCEMENT REGION IV Report No. 99900314/79-02 Program No. 51300 Company:
Colt Industries Trent Tube Division of Crucible, Inc.
141 Hammond St.
Carrollton, Georgia 30117 Inspection Conducted: August 27-31, 1979 Inspector:
U 8/'5 d'f
/
R. E. Oller, Contractor Inspector Dete ComponentsSection II Vendor Inspection Branch Approved by:
I 8'
8 e
D. M. Hunnicutt,' Chief Date ComponentsSection II Vendor Inspection Branch Summary Inspection on August 27-31, 1979 (99900314/79-02)
Areas Inspected:
Implementation of 10 CFR 50, Appendix B criteria and other applicable requirements including: action on previous inspection findings, review of vendor activities, nonconformances and corrective action, and equirment calibration. The inspection involved twenty-five (25) inspector-hours on site.
Results:
In the four (4) areas inspected no deviations were identified in two (2) areas.
The following were identified in the remaining areas.
Deviations:
Nonconformances and Corrective Action: Failure to maintain a Rejection (rework) Tag with four (4) nonconforming stainless steel pipes.
(See Notice of Deviations, Item A)
Equipment Calibration:
(1) Failure to calibrate voltmeters on automatic girth welding machine No. 718. (2) Failure to use heat treatment furnaces which were temperature surveyed.
(See Notice of Deviation, Items B, and C) 1613 051 z7F j1so
2 Unresolved Item: Action on Previous Inspection Findings: The QA Manual has not been revised to include specific details regarding the exclusion of procedura and revision numbers on Mill Order travelers.for operations such as:
forming, pickling and passivating, planishing and degreasing. Trent Tube will revise the QA Manual by January 1, 1980, to clarify the above condition.
(See Details Section, paragraph B.I.)
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~m
3 DETAILS SECTION A.
Persons Contacted P. Broughton, Welding Operator H. Cook, Welding Operator T. Cowart, Production Foreman
- C. Enos, An'_horized Nuclear Inspector, HSB I&I Co.
W. Hill, Quality Projectr Supervisor M. Newsom, Records Coordinatcr
- L. Powell, Plant Manager
- J. Wehrle, QA Manager
- Attended the exit meeting.
'B.
Action on Previous Inspection Findings 1.
(0 pen) Unresolved Item (Report No. 79-01): Failure to clearly show in the QA Manual, that the procedure and revision numbers do not have to be shown on the Hill Order travelers for operations such as forming, pickling, passivating, planishing and degreasing.
The inspector found that the QA Manual has not been revised to provide the needed clarification. Trent Tube management will revise the QA Manual and present it to the Authorized Inspection Agency and the ASME for acceptance by January 1,1980. This item remains unresolved.
2.
(Closed) Unresolved Item (Report No. 79-01): Failure to show the laboratory test numbers for tensile and bend tests on the welding procedure qualification records (PQR) No. TWP-1-Q5 and No. TWP-1-Q8 for welding procedure specification (WPS) No. TWP-1B. The inspector was notified by Trent Tube letter dated April 11, 1979, with attached revised PQRs No. TWP-1-Q5 and No. TWP-1-Q8, that the missing laboratory numbers are now on the two (2) PQRs.
3.
(Closed) Unresolved Item (Report No. 79-01): Failure to formalize and implement the startup weld data sheets for use with welding procedure specifications.
The inspector was notified by Trent Tube letter dated April 11, 1979, with attached startup weld data sheets that a copy of these weld data sheets are now formalized and a copy is in use at the welding mills.
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4 C.
Review of Vendor's Activities 1.
Objective The objective of this ar(a of the inspection was to assess the vendor's activities and their impact on future NRC inspections.
2.
Method of Accomplishment The preceding objective was accomplished by:
Discussions with cognizant personnel with regard to current a.
work loads.
b.
Review of the ASME N-type symbol and Quality Systems Certificate (Materials) authorizations to verify that they are valid and identified the products.
Discussions with the QA Manager with regard to actions by Trent c.
Tube to assure that double welded A-312 and SA-312, ASME Code Class 1, 2 and 3 austenitic stainless steel pipe, is free of lack of weld are penetration through the pipe wall, prior to its shipment.
d.
Observations in the shop of double welded pipe, and sampling -
examination and flattening teits, to assure freedom from lack of penetration.
e.
Review of records of welding.
f.
Observation of the etched weld cross section ends of numerous A-312, T-304 double welded pipes in the stock storage area.
3.
Findings a.
Deviations from Commitments None.
b.
Unresolved Items None.
c.
Other Findings (1) Trent Tube holds a valid ASME Authorization to use the NPT symbol for Class 1, 2 & 3 piping subassemblies and 1613 054
5 tubular products, welded with filler metal. This author-ization expires on February 24, 1980.
They also hold a valid quality system certificate (Materials) as a " Manufacturer of low Allow, stainless steel, high nickel and other specialty alloy pipe and tubular products welded without filler metal..." This certificate expires on June 6, 1980.
(2) The plant nuclear pipe manufacturing work load (number of customer orders) shows a slight decline since the prior NRC inspection.
(See Report No. 79-01)
(3) Discussions and observations of in process welding of A-312 piping without filler metal on two continuous mills (automatic welding machines), verified that for schedule 5, 10 and 40 piping a ring is cutoff at every fifth length of pipe (approximately 20 ft.) while on heavier wall pipe, a ring is cut off at every third of pipe. The weld cross section on these rings are etched, while hot from cutting, and examined for lack of weld are penetration. The ring is then reverse bent to check weld for stretch defects.
For SA-312 pipes with a wall thickness range of 0.125-0.500 inch and double welded on the batch mill, with the plate length being precut, a v-notch is cut at the end of every third pipe and while the cut surface is still hot, it is etched and examined for lack of penetration between the beads.
Further discussion disclosed that visual examination at final inspection and contractual code required nondestructive examination such as radiographic and ultrasonic examinations are the other means of assuring that the double welded longitudinal welds in SA-312 and A-312 piping are free of lack of penetration. Review of records of welding showed the footage amount of scrap was identified, but not the reason for being scrapped. The weldability on these cecords was indicated as good, fair or poor.
Discussion also established that while longitudinal pipe welds required by contract to be radiographed were also examined by fluoroscope immediately after welding, the use of the fluoroscope was limited to pipes with internal diameters over six (6) inches due to the size of the x-ray unit which is put inside the pipe.
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6 D.
Nonconformances and Corrective Action 1.
Objectives The objectives of this area of the inspection were to ver'fy that the following items were controlled in accordance with rpplicable NRC and ASME requirements.
a.
A written system has been established to assure that noncon-formances are controlled and corrective action is taken.
b.
Documented procedures or instructions are implemented for identification, documentation, segregation and disposition of nonconforming materials parts or components, and notification to affected organizations.
Nonconforming items are reviewed and accepted, rejected, c.
repaired or reworked in accordance with documented procedures.
d.
Conditions adverse to quality are promptly identified and corrected.
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 levels of management.
2.
Method of Accomplishment The preceding objectives were accomplished by:
Review of the QA Manual Section 18.0, "Nonconformities and a.
Corrective Action."
b.
Observation of facilities in the following indicated plant areas for segregation of nonconforming items; also examination of the items therein such as plate, sheet or pipe.
(1) Receiving Inspection Segregation Area.
(2) Hold Racks for Rejected In procesa Pipe in the weld planishing area, cut-salvage arr_a and the final inspection area.
Review of the following "Cause and Corrective Action Reports c.
(C&CA) No. 035 through No. 103 for the period of Janurary 10, 1978, to August 23, 1979, to identify the basis for the problems involving noncor formances.
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7 d.
Review of four (4) Inspection Tally Sheets common to C&CA Reports Numbers 039, 042, 048 and 101.
Review of Rejection Tags and related records such as Inspection e.
Tallys and Mill Orders (travelers) for five (5) completed customer orders.
3.
Findings a.
Deviations from Commitments See Notice of Deviation, Item A.
The four (4) 21 foot long stainless steel pipes observed in a reject material rack without an accompanying Rejection Tag and Mill Order, were identified to a Rejection Tag No. 4647, in the production file for Mill Order OC3-01243-9.0, a stock item available for upgrading for nuclear use.
This rejection tag showed that twelve (12) pipes had been rejected but the quantity twelve (12) had been crossed out and changed to eight (3). The final Inspection Tally sheet dated August 16, 1979 for this mill order showed that eight (8) pipes had been repaired and accepted by final inspection. The corrective action for the above four (4) pipes was completed during the inspection by completion of Reject (rework) Tag No. 4969 dated August 29, 1979 and placing it with the pipes.
b.
Unresolved Items None.
E.
Equipment Calibration 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 equipment calibration is performed and controlled in accordance with applicable codes.
b.
A written procedure has been developed and approved which contains provisions to assure that tools, instruments and other inspection, measuring and testing equipment and devices used in activities affecting quality, are of the proper range, type and accuracy, and are calibrated and properly adjusted at specified periods or use intervals.
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8 The devices are identified in a documented system and/or c.
procedure and are calibrated in accordance with the system and procedure.
d.
The calibration is performed against certified measurement standards which have known relationship to National Standards, where such standards exist, 1he control measures include provisions for test equipment e.
identification and calibration status by marking, or on records traceable to the equipment.
2.
Method of Accomplishment The preceding objectives were accomplished by:
Review of the QA Manual Section 17.0, " Calibration."
a.
b.
Review of the Equipment Calibration Log sheet record and calibration procedures for individual measuring devices, contained in a calibration log book.
Observation of the calibration status of the following types c.
of devices located in the shop.
(1) Heat Treatment Furnaces' Instruments (recorders and controllers)
(2) Analytical Balance (3) Micrometers (4) Vernier Calipers (5) Ultrasonic Test Units (6) RT Penetrameters (7) Dial Indicators (8) Hydrostatic Test Pressure Gages (9) Automatic Welding Machine Voltmeters, Ammeters and Flowmeters.
(10) Optical Pyrometer i611 OL58 (11) Surface Pyrometer
9 (12) RT Densitometer and Step Tablet Density Film Strip (13) Thermco Hydrogen Analyzer (14) Mini Proportioners (for Hydrogen and Argon welding gases.)
(15) Smith Mixers (for Argon and Helium Welding gase mixing.)
d.
Review of the Trent Tube calibration record cards and sub-contractor's Certificates of calibration for the above devices.
Review of heat treatment records, i.e., " Operators Report and c.
Furnance Report" and furnace charts for completed pipe on Mill Order No. IC5-45150-9 and IC5-41199-8.
These mill orders were for SA-358 Class 1, ASME Code Class 1 and 2, T-304 pipe, respectively.
f.
Review of a Leeds and Northrup letter dated August 13, 1979, certifying that during the service visit on April 11, 1979, a calibration check was made to the instruments in the plant which were adjusted to original specified accuracies with a L&N Millvolt Potentiometer traceable to the National Bureau of Standards.
g.
Discussions with cognizant personnel.
3.
Findings a.
Deviations from Commitments See Notice of Deviations Items B, and C.
b.
Unresolved Items None.
F.
Exit Interview 1.
The inspector met with management representatives denoted in paragraph A, at the conclusion of the inspection on August 31, 1979.
2.
The following subjects were discussed:
a.
Areas inspected.
b.
Status of previously identified unresolved items.
c.
Deviations and unresolved items identified during this inspec-tion.
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10 3.
The manufacturer's representatives were asked to formulate their corrective action response to deviations in accordance with the three (3) conditions identified in the inspection report cover letter.
4.
The manufacturer representative's questions related to clarification of the above items.
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