ML19261B788
| ML19261B788 | |
| Person / Time | |
|---|---|
| Issue date: | 11/22/1978 |
| From: | Hunnicutt D, Oller R NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML19261B781 | List: |
| References | |
| REF-QA-99900029 NUDOCS 7903060012 | |
| Download: ML19261B788 (9) | |
Text
.
VENDOR INSPECTION REPORT U. S. NUCLEAR REGULATORY COMMISSION OFFICE OF IftSPECTION AND EilFORCEMENT REGION IV P,eport tio.
99900029/78-02 Program No.
44020 Compar.y:
Youngstown Welding & Engineering Company 3700 Oakwood Avenue Youngstown, Ohio 44509 Inspection Conducted: November 2-3, 1978 Inspectors:
[
/bo
//-ff-7/
R. E. Oller, Contractor Inspector Date Vendor Inspection Branch O h/
musOAY
//fLLl7Y D. M. Hunnicutt, Chief, ComponentsSection II Date/
Vendor Inspection Branch Approved by:
h'[)
v7daJd
///IX/78' D. M.~ Hunnicutt, Chief, ComponentsSection II
/Date' Vendor Inspection Branch Summary Inspection on November 2-3, 1978 (99900029/78-02)
Areas Insoected:
Implementation of 10 CFR 50, Appendix B, criteria, other NRC requirements, and applicable codes and standards including: management meeting, manufacturing process control, welding control consisting of welding procedure specifications-welding material control and welder qualifications, and action on previous inspection findings. The inspection involved twenty-eight (28) inspector hours on site by two (2) inspectors.
Results:
In the four (4) areas inspected, no deviations were identified in three (3) areas. The following was identified in the remaining area:
7903060 0/1
_z_
Deviations:
Corrective action has not been taken for the failure to audit Tive (5) areas of the QA Manual and these areas are still not audited, preventive action was not taken to assure that the ANI reviews the monthly audit reports, and preventive action was not taken to assure that the training and indoctrination schedule is followed.
Unresolved Items:
flone.
9 '
DETAILS SECTION (Prepared by R. E. Oller and D. M. Hunnicutt)
A.
Persons Contacted J. Evans, Shop Superintendent D. Lasko, Tube Mill Superintendent
- D. Lewis, QA Manager K. McMillin, Vice President and Treasurer G. Mitchell, Storeroom Receiver E. Pekarovic, QA Secretary
- E. Sigle, Vice President H. Smith, Sales Manager
- R. Yahn, Vice President, Sales
- Attended Exit Meeting.
B.
Action on Previous Inspection Findings 1.
(0 pen) Deviation (Report No. 78-01):
Failure to audit on a semiannual basis, the QA Manual areas of Nos. I, " General";
VIII, " Heat Treating"; X, " Authorized Inspector"; XI, "Non-conformities"; and XII, " Audits." Also, failure to review with the Authorized Inspector the monthly audit reports for February 1978 and for March 1978. The inspector found the following condi-tions existed with regard to the corrective and preventive action commitments in YW&E's response letter dated June 16, 1978:
a.
The preventive action with regard to the above five (5) areas of the QA program has been taken.
These areas are included in the QA Manual Audit Checklist revised on August 10, 1978.
This part of the deviation is closed.
b.
The corrective action with regard to the above five (S) areas had not been taken in that these areas have not been audited.
This part of the deviation is open and is a deviation to the conmitment in YW&E letter dated June 16, 1978.
c.
The corrective action with regard to the AI review of the above February and March audit reports had been taken.
These reports were signed and dated on February 28, 1978, by the Authorized Nuclear Inspector as having been reviewed.
This part of the deviation is closed.
d.
The preventive action with regard to AMI review of the monthly audit reports has not been taken.
The activity of ANI review of ifonthly Audit Checklists has not been added as an internal audit item to the identhly Audit Checklist revised on August 10, 1978.
This part of the deviation remains open and is a deviation to the comitment in YW&E letter dated June 16, 1978.
2.
(0 pen) Deviation (Report flo. 78-01):
Failure to include in the training program outline and conduct training for the areas of Product Familiarization, Inspection Techniques and Safety Practices as required by the QA Manual Section 1, paragraph 1.2.3.1.
The inspector found that a new QA program training outline matrix dated August 11, 1978, has been developed and supersedes the out-line containing the above areas, and meets the intent of YW&E's corrective action comitment letter dated June 16, 1978.
This part of the deviation is closed.
However, with regard to the preventive action comitment, that the training and indoctrination outline would be followed for QA progran areas identified in the new outline, no training has not been performed. This matter becomes a deviation to comitments in YW&E's letter dated June 16, 1978.
3.
(Closed) Deviation (Report flo. 78-01):
Failure to provide certificates of calibration showing traceability to national standards for calibration standards used in calibrating three (3) different types of measuring and testing devices. Also, failure to include four (4) measuring and testing devices in the " Tool
& Gage Manual." The inspector found that corrective and preven-tive actions have been taken. The appropriate certificates of calibration for the above devices are now available and the secondary standards have been audited to assure proper certifica-tion.
4.
(Closed) Unresolved Item (Report No. 78-01): This item involved index record sheets, " Check-off Lists for I! aster File QA Records,"
on which records such as Vendor fide Reports and Inspection Reports (UT, PT & X-Ray) appeared to be misidentified as being in the record packages, when, in fact, they were not in the packages.
YW&E QA management indicated they would revise the list to provide an accurate description of records maintained in the packages. The inspector found that the record package index, " Record Checklist
& Index," was revised on March 1,1978, and now provides an ac-curate description of the records.
. C.
Management Meeting 1.
Objectives The objectiver of this flanagement Meeting were to meet with Plant Management to discuss the purpose and intent of the Vendor Inspection Branch (VIB) direct inspection and resolve any questions the plant management might have.
2.
Method of Accomplishment The preceding objectives were accomplished by the inspector's presentation and the resulting discussions covering the following:
a.
flRC policies and organization.
b.
VIB program objectives and how these objectives are to be accomplished.
c.
VIB organization.
d.
Inspection areas to be covered.
e.
Basic inspection techniques of the VIB.
f.
Enforcement procedures applicable to vendors, including Part 21 of 10 CFR.
g.
The White Book.
h.
Questions.
3.
Findings flo unusual questions or discussions developed or occurred during the initial management meeting.
Plant Management identified the nuclear products manufactured, as longitudinal seam welded piping and supplied information on nuclear contracts in the plant.
D.
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 applicabla 'MC and ASME Code requirements.
a.
A written system has been established to assure that manu-facturing processes are controlled in accordance with applicable codes.
N _l :
1
- m
- w _ ?.N L J L A x -. -_L a'
... L*
c 6
/
b.
Measures have been established and implemented to control the manufacturing processes by use of process sheets, travelers, checklists or procedures.
n c.
The process sheets, travelers, checklists or shop pNcedures used included:
the document numbers and revisions to which the processes, inspections or tests confomed; the results of completion of the specific operations; the signature, initials or stamp of the manufacturer's responsible representa-D tive and date were shown for operations completed, and the signature, initials or stamp of the authorized inspector and 1
date, were shown for activities he witnessed.
2.
Method of Accomplishment a
The preceding objectives were accomplished by:
a.
Review of Section V, Instructions, Procedures and Drawings, of the Quality Assurance Manual (QAM).
c a
b.
Review of Section VIII, Identification and Control of Materials, of the QAM.
c.
Review of Section IX, Contr.,1 of Construction Processes, of the QAM.
d.
Review of Section X, Examination, Text and Inspections, of the QAM.
1 c.
Revie.1 of Contract No. 2995 (iluclear Order) for 12 inch, schedule 20 pipe, Heat No. 740279, type SA 312; Contract tio.1104 (Nuclear Grder) for 10 inch, schedule 10, pipe type SA 312; Contract 1109 (Nuclear Order) for 0.375 inch wall y
pipe, 24 inch OD, type SA 312; and Contract rio. 2960 (Nuclear Order) for 14 inch, 0.375 inch wall, type SA 312, including the test records file for each of these four (4) contracts, the test results for the tensile strength of test coupons
+ -
and the Radiographic results (RT) of the welds for ten (10) 1 random films for this welded sean pipe.
7 f.
Observations in the shop of three (3) pieces from each of these orders, including heat number permanently stamped on each piece, material specifications for each heat number, acceptance stamp (YlGE and ANI) on each completed piece and the individual serial number identifying each niece of L
each order.
~
7 E.;
e 4'
g.
leview of shop travelers for twelve (12) pieces and for each order, rer2ipt inspection reports for twelve (12) selected pieces, forming record of these twelve (12) pipes (tubes) formed, and welding records of seam welds for each pipe (tube) selected for review.
h.
Discussions with cognizant QA and production perscnnel.
3.
Findings Within this area of the inspection, no deviations or unresolved items were identified.
E.
Welding Control 1.
The objectives of this area of the inspection were to verify that the following activities were controlled in accordance with applicable flRC and ASME Code requirements.
a.
A system has been established to assure that welding is controlled in accordance with the applicable codes.
b.
The welding procedure specifications (WPS) used in produc-2 tion welding are prepared, qualified and controlled in accordance with the QA program.
c.
That welding waterials purchase, acceptance, storage, issuance and use are controlled and documented in accordance with detailed procedures.
d.
The welders are qualified in accordance with the ASME Code.
2.
Method of Accomplishment The preceding objectives were accomplished by:
a.
Review of the QA Manual Section IX, paragraph 9.5, " Welding,"
to verify that measures for welding control are documented.
b.
Observation of welding materials and their storage facilities including spools of code welding wire and boxes of bare welding rod, to verify that the facilities were appropriate and the materials were properly marked.
c.
Review of fluclcar Storeroom Requisitions controlling issuance of weld materials to production to verify that the releases properly identified the material and were signed by the welding supervisor.
g.
d.
Review of QA Receiving Reports for two (2) heats of welding wire, No. D-41441-308 and flo. Y3819-308 to vert fy that these r.aterials were accepted by the QC Engineer prior to storage.
e.
Review of supplier's " Certification of Tests" for the two (2) above heats of wire to verify that the certifications met Code requirements, all data was complete and that QA reviewed and accepted these materials.
f.
Review of purchase orders Nos. 192035 and 192036 for the above materials to verify that the P0s contained the required specifications and that the P0s were reviewed by the QA manager prior to release to the supplier.
g.
Review of the following welding procedure specifications (WPS) used for ASME Code welding of stainless steel and the related procedure qualification records (PQR) to verify that these procedures used for the tube mill welding were approved and contained the required essential variables, other required welding parameters and postweld heat treatment, and that these WPSs were qualified in accordance with the ASME Cc'e Section IX.
(1) WPS No. 720, Revision 6 (Gas Tungsten Arc welding -
automatic) and the supporting PQR No. PQT-199.
(2) WPS No. P-225, Revision 2 (Gas Tungsten Arc welding -
manual) and the supporting PQR No. 7530-1.
h.
Review of performance qualification records for eight (8)
Tube Mill welders and welder operators to verify that they were qualified to the above procedures for the two (2) processes used in pipe welding in accordance with the ASME Code Section IX.
i.
Review of " Performance Logs" for July, August, and September, 1978, for the above eight (8) welders to verify their con-tinued use of these processes.
J.
Discussions with cognizant personnel.
3.
Findings sithin this area of the inspection, no deviations or unresolved items were identified.
. F.
Exit Intervie'.1 1.
The inspectors met with management representatives denoted in paragraph A. at the conclusion o' the inspection on November 3, 1978.
The following SJbjects were discussed:
c.
a.
Areas inspected.
b.
Status of corrective action for previous inspection findings.
c.
Failure of YW&E to implement all of the corrective and preventive action commitments stated in their June 16, 1978, response letter for identified deviations from the previous inspection.
3.
The manufacturer was asked to formulate his corrective action response to deviations in accordance with the three (3) condi-tions identified in the inspection report cover letter.
4.
Management's comments were generally related to clarification of the findings.
,