ML19263E447
| ML19263E447 | |
| Person / Time | |
|---|---|
| Issue date: | 02/26/1979 |
| From: | Sutton J, Whitesell D NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML19263E443 | List: |
| References | |
| REF-QA-99900302 99900302-79-1, NUDOCS 7906180263 | |
| Download: ML19263E447 (9) | |
Text
.
VENDOR IflSPECTION REPORT U. S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT REGION IV Report No. 99900302/79-01 Program No. 44055 Company:
Western Piping and Engineering Company, Inc.
1485 Yosemite Avenue San Francisco, California 94124 Inspection Conducted: January 22-26, 1979 Inspector:
do
[r 62 -E4 - ff J. W. Sutton, Contractor Inspector, Vendor Date Inspection Branch
/
/
o Approve y.
reda.
pg. ft-ff D. E. Whitesell, ComponentsSection I, Vendor Date Inspection Branch Sumary Inspection on January 22-26, 1979 Areas Inspected:
Implementation of 10 CFR 50, Appendix B, criteria and applicable codes and standards, including action on previous inspection findings, QA Manual Review, Welding Procedure Specifications, Qualifica-tion of Personnel (NDE), Training, and Audits.
The inspection involved thirty-two (32) inspector-hours on site.
Results:
In the six (6) areas inspected, no apparent deviations or unresolved items were identified in one (1) area.
The following were identified in the remaining five (5) areas.
Deviations: Action on Previous Inspection Findings - Failure to take comitted corrective actions / preventive measures relative to designating responsibilities, level of authority, and lines of comunication for subcontractors (Enclosure, Item A.).
Welding Procedures Specification (WPS) packages did not contain required documentation (Enclosure, Item B.).
Qualification of Personnel (NDE), personnel records did not meet require-ments of Criterion V of Appendix B,10 CFR 50, and paragraphs 10.3.2 and 10.3.3. of the Quality Assurance Manual (Enclosure, Item C.).
Internal 2355 086 7906180f/p3 audits and personnel records not in accordance with Criterion V of Appendix B to 10 CFR 50, and paragraphs 18.5 and 18.12.1 of the Quality Assurance Manual (Enclosure, Item D.).
Unresolved Items None.
2355 087
. Details Section A.
Persons Contacted Western Piping and Engineering Company, Inc. (WP&E)
- K. A. Friedman, President
- J. C. Flaherty, Vice President
- H. R. Goldberg, QA Manager P. G. Sorenson, QC Manager Department of Industrial Safety, State of California J. Olesiak, Senior Safety Engineer R. M. Johnson, Safety Engineer
- Denotes those present at the Exit Interview.
B.
Action on Previous Inspection Findings 1.
(0 pen) Deviation (. Inspection Report 77-01):
The Quality Assurance Manual did not clearly define the responsibilities, level of authority, and lines of communication for subcontrac-tors involved.
The inspector found that, contrary to the corrective action commitment in the WP&E letter dated December 27, 1977, the QA Manual had not been revised to reflect this requirement.
This is a deviation from corrective action commitments (See Enclosure, Item A.).
2.
(Closed) Deviation (Inspection Report No. 77-01):
Records of certification of tests for liquid penetrants showing batch number and test results were not being maintained. The inspec-tor verified that test certification for liquid penetrants are being maintained. Materials are being stored in a designated controlled area.
3.
(Closed) Deviation (Inspection Report No. 77-01):
The Shop Travelers did not reference the welding procedure specification number and revision level to be used for tack welding.
The inspector verified that the QA Manual has been revised to indicate that tack welding would be considered as a separate operation on the shop travelers.
Review of shop traveler in use indicated that implementation of the commitment is being followed.
2355 088 C.
QA Program Review 1.
Objectives The objectives of this inspection were to ascertain whether the QA Program has been documented in writing, and if correctly im-plemented, will ensure that the completed components were manufactured in compliance with code requirements and meet the prescribed quality standards. Also, to ascertain whether the program is consistent with NRC regulations and Code requirements.
2.
Method of Accomolishment The preceding objectives were accomplished by:
a.
Review of the Quality Assurance Manual, Revision 1, dated January 10, 1979, to verify that it is consistent with NRC rules, regulations, and the Code requirements.
b.
Review of appropriate organization charts to verify that the QA staff is independent from the pressures of cost and scheduling and has access to upper management.
c.
Review of the documents concerning the authority, duties, and independence of the Quality Assurance staff to verify that they have the independence to identify quality problems and initiate appropriate corrective action, and the authority to stop work.
d.
Review of documents to verify that appropriate review and approval by authorized personnel are provided for.
e.
Interviews with cognizant personnel to ascertain whether they are knowledgeable in the procedures which control the activities for which they are responsible.
f.
Observation of work in progress to verify that the program is being implemented.
3.
Findings 2355 089 a.
Deviation See Enclosure, Item A.
b.
Unresolved Items None.
c.
General A complete revision from the original QA Manual reviewed during 1977, has been issued.
The current "N" and "NPT" certificates of authorization were issued on September 11, 1978, to expire in 1981. The current authorization are being used to control the current activities of fabricating containment penetrations and pipe suppo*ts for two (2) customers. The current activities account for approximately 80% of shop work in progress.
D.
C_ontrol of Special Processes, Weldino Procedure Soecifications Use, a_nd Control 1.
Objectives The objectives of this area of the inspection were to verify that welding procedure specifications used for production welding were controlled and used in accordance with WP&E QA Program and NRC and ASME Code requirements.
2.
Method of Accomplishment The preceding objectives were accomplished by:
a.
Review of the QA Manual Sections 8.3, Revision 1, titled,
" Control of Welding Materials," and Section 9.4, Revision 1, titled, " Control of Welding Processes."
b.
Observation of welding activities at two (2) welding stations.
c.
Review of Shop Traveler 15826, dated January 2,1978.
d.
Examination of welding procedures used in witnessed welding operation.
e.
Review of the following welding procedures for content and control.
P-091-1-001, Revision 6, P091-1-003, Revision 5, P-091-1-005, Revision 5, P091-1-006, Revision 1, P-091-1-009, Revision 4, P091-8-002, Revision 5, P-091-8-003, Revision 5, 091.8-0025.
f.
Review of the current list of qualified weldors and system used to maintain qualifications.
2355 090 g.
Review of material certification for filler metal, Heat No. 346206.
h.
Examination of material storage areas and review of welding materials approval and release system. Review of weld material log.
i.
Review of temperature control and electrode segregation in electrode ovens.
J.
Review of calibration status of meters on welding equipment utilized for operations witr.nsed.
k.
Discussions with shop personnel.
3.
Findings a.
Deviations See Enclosure, Item B.
b.
Unresolved Items None.
c.
General During the inspectors review of the master file of WPS records it was noted that documentation required to be included in the master file such as supplementary welding information recorded during welding qualifications testing and required certified reports of mechanical test results of weld material test coupons were not included in the master files. Unofficial copies of these records were found in the shop area. These records are not part of shop requirements.
E.
Nondestructive Examination (NDE) Personnel Qualifications 1.
Objectives The objectives of this area of the inspection were to verify that WP&E had implemented the requirements for the qualifica-tion and certification of NDE personnel in a:cordance with the QA Manual and applicable NRC and ASME Code requirements.
2355 091 2.
flethod of Accomolishment The preceding objectives were accomplished by:
a.
Review of the QA Manual, Section 10.3, Revisian 1, titled,
" Nondestructive Examination."
b.
Review of available NDE Certification Records.
c.
Review of SNT-TC-1A,1975, " Personnel Qualification and Certification in Nondestructive Testing."
3.
Findings a.
Deviations From Commitment See Enclosure, Item C.
b.
Unresolved Item None.
c.
General During the inspectors review of available records of Nondestructive Testing personnel, it was noted that the requirements of paragraph 9.6.1. of SNT-TC-1A were not being met.
Paragraph 9.6.1. requires that personnel records include the following as a minimum: educational background and experience, completion of training, results of physical examination, and copies of current examinations and grades. The only record available was a certification that the person was qualified as a Level I, II, or III, in a given NDE Inspection Technique.
F.
- Training, 1.
Objectives The objectives of this area of the inspection were to ascertain whether approved procedures have been established for the indoctrination and training of personnel performing quality related activities, and that the procedures are consistent with the NRC regulations and applicable Code requirements and the QA Program comitments. Also, ascertain whether the indoctrina-tion and training procedures are in place and are effectively implemented.
2355 092
- 2.
Method of Accomplishment The objectives of this area of the inspection were accomplished by:
a.
Verification that the training program is implemented as described in the QA Manual by review of the records of subjects covered for each discipline.
The following documents were reviewed:
(1) ASME QA Manual, paragraph 2.5, titled " Training Program."
(2) General training reccrds of personnel.
3.
Findings The evidence reviewed demonstrated that a training and indoctrina-tion program has been implemented under the revised QA Manual in specific areas of expertise. The present program is in an early stage of implementation but positive action to expand and improve the training program is being formulated.
Within this area of the inspection, no deviations or unresolved items were identified.
G.
Audits 1.
Objectives a.
To ascertain that procedures have been prepared and approved by the company to prescribe a system for auditing which is consistent with the commitments of the QA Program.
b.
To determine that the audit procedures and schedules are being properly and effectively implemented by the company.
2.
Method of Accomplishment The preceding objectives were accomplish d by:
a.
Review of the QA Manual, Section 18.0, titled " Audits" Internal and Management to verify that:
(1) Procedures and policy documents identify organizations responsible for audits and define their responsibilities and authorities.
2355 093
_g_
(2) Measures have been established to assure that auditors are independent of any direct responsibility for performance of activities which they are auditing.
b.
Review of the current audit program files for audits per-formed by corporate and QA auditors, to verify that:
(1) Audits are performed in accordance with approved pro-cedures and instructions.
(2) Corrective actions are taken for deficiencies identified by audits.
(3) Provisions have been_made for re-audit of deficient areas.
(4) Audits are scheduled and performed in accordance with approved checklist.
(5) Provisions exist for reporting on the effectiveness of QA Program to responsible management.
c.
Review of the current audit schedule.
3.
Findings a.
Deviations See Enclosure, Item D.
b.
Unresolved Items None.
H.
Exit Interview The inspector met with management representatives (denoted in para-graph A.) at the conclusion of the inspection.
The inspector sum-marized the scope and findings of the inspection.
The management representatives had no coament in response to the items discussed by the inspector.
The inspector reviewed the format to be used by the company when responding to inspection findings which require corrective action to be initiated.
2355 094