ML19269D967
| ML19269D967 | |
| Person / Time | |
|---|---|
| Issue date: | 01/26/1979 |
| From: | Barnes I, Hunnicutt D NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML19269D956 | List: |
| References | |
| REF-QA-99900038 99900038-79-1, NUDOCS 7906210344 | |
| Download: ML19269D967 (11) | |
Text
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U. S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT REGION IV Report No. 99900038/79-01 Program No. 51300 Company:
Ishikawajima-Harima Heavy Industries Co., Ltd.
Nuclear Power Division 1, Shin-Nakahara-Cho Isogo-Ku, Yokohama, Mail No. 235, Japan Inspection Conducted: January 8-12, 1979 Inspectors:
8.- e
/ - 2 6 - ~/ 7 I. Barnes, Contractor Inspector, Vendor Date Inspection Branch
/ Swm i - 2 6 - ~i y
[4-c D. M. Hunnicutt, Chief, ComponentsSection II, Date Vendor Inspection Branch Approved by:
- 8ae,
/-2c.-
77 p,
D. M. Hunnicutt, Chief, ComponentsSection II, Date Vendor Inspection Branch Summary Inspection on January 8-12, 1979 (99900038/79-01)
Areas Inspected:
Implementation of 10 CFR 50, Appendix B, and applicable codes and regulations; including initial management meeting, control of welding, weld heat treatment, material forming, material identification and control, and procurement document control. The inspection involved sixty-eight (68) inspector-hours on site by two (2) NRC inspectors.
Results:
In the six (6) areas inspedt', ne deviations or unresolved items were identified in five (5) W '.v. tha following deviations being identified in the remaining erer..
Deviations:
Control of Welding Calibration Procedure E91-014(E),
Revision 4, not consistent with Criterion XII o* 10 CFR 50, Appendix B, and Section 13 of the QA Manual relative to assuring accuracy of welding 2264 169 79J6210Tff.
. equipment (Enclosure, Item A); certain welding procedure specifications not in accordance with Criterion IX of 10 CFR 50, Appendix B, and the voltage supplementary essential variable requirements of the ASME Code,Section IX (Enclosure, Item B).
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. DETAILS SECTION I (Prepared by I. Barnes)
A.
Persons Contacted
- M. Amano, General Manager, Nuclear Power Division
- K. Takagi, Deputy Division Manager, Nuclear Power Division
- J. Asai, General Superintendent, Yokohama No. 3 Works
- K. Tomita, Manager, Quality Assurance Group, Quality Assurance Department, Nuclear Power Division
- Y. Kikuchi, Deputy Manager, Production Engineering Department, Yokohama No. 3 Works
- H. Kumano, Section Manager, Quality Assurance Group, Quality Assurance Department, Nuclear Power Division
- A. Kurokawa, Section Manager, Quality Assurance Group, Quality Assurance Department, Nuclear Power Division
- M. Maeda, Welding Engineer, Production Engineering Department, Yokohama No. 3 Works
- K. Maki, QA Engineer, Quality Assurance Group, Quality Assurance Department, Nuclear Power Division
- Y. Shinohara, Welding Engineer, Production Engineering Department, Yokohama No. 3 Works
- T. Takahashi, Design Engineer, Nuclear Equipment Design Department, Nuclear Power Division
- S. Nakamura, Business Development Section, Nuclear Energy Department, Nissho-Iwai Co., Ltd.
- C. E. Cannon, Supervisor for Japan, Royal Indemnity Insurance Co.
Dr. Y. Yamazaki, Department Manager, Production Engineering Department, Yokohama No. 3 Works K. Futagawa, QA Engineer, Quality Assurance Group, Quality Assurance Department, Nuclear Power Division
- Attended Initial Management Meeting.
- Attended Exit Meeting.
- Attended both Initial Management Meeting and Exit Meeting.
B.
Initial Management Meeting 1.
Objectives Tne objectives of this meeting were to accomplish the following:
To meet with the Ishikawajima-Harima Heavy Industries Co.,
a.
Ltd., Nuclear Power Division (IHI) management and those persons responsible for the administration of the IHI QA Program and establish channels of communication.
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. b.
To determine the extent of company involvement in the U. S. commercial nuclear business.
c.
To explain the NRC direct inspection program including the Licensee Contractor Vendor Inspection Program (LCVIP) organization, Vendor Inspection Branch (VIB) inspection methods and documentation.
2.
Method of Accomplishment The preceding objectives were accomplished by a meeting on January 8,1979, with the attendees noted in paragraph A.
above.
The following is a summary of the subject matter covered:
a.
The VIB organization was described and its relationship to NRC Region IV and other components of the Office of Inspection and Enforcement.
b.
The LCVIP was described, including the reasons for its~
establishment, its objectives, and implementation methods and criteria used.
c.
The conduct of VIB inspections was described and how inspections are documented including the report, responses to reports, how proprietary information is handled, the Public Document Room, and the White Book.
d.
The company contribution to the nuclear industry was discussed, including current and projected manufacturing activity for the U.S. A., status of ASME Certificates of Authorization, and third party inspection arrangements.
3.
Findings a.
IHI management informed the inspectors that IHI had recently completed work on mechanical penetration assemblies for Washington Public Power Supply System (WPPSS), Project Nos. 1 and 4.
Final fabrication of the assemblies was to be performed by an ASME Certificate Holder in the U.S.A.
b.
Materials had been procured for fabrication of mechanical penetration assemblies for WPPSS Project Nos. 3 and 5 and a contract for an airlock was in the design stage, c.
IHI ASME Certificates of Authorization for use of the N and NPT stamps, N-1393 and N-1394, respectively, expire on May 26, 1979.
Resurvey by ASME was expected by IHI to be perfonned during April 1979.
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. d.
IHI has a contract with the Royal Indemnity Insurance Co. to act as their Authorized Inspection Agency, and are presently served on an itinerant basis by an Authorized Nuclear Inspector.
C.
Control of Welding 1.
Objectives The objectives of this area of the inspection were to verify that measures had been established to assure the control of welding in accordance with ASi1E Code, contract and regulatory requi rements.
2.
Method of Accomplishment The preceding objectives were accomplished by:
a.
Review of Section 7, Revision 3, of the QA Manual, " Welding Control."
b.
Review of Section 13, Revision 5, of the QA Manual,
" Facilities and Equipment."
c.
Examination of welding records applicable to Job No. 5501-408 (Washington Public Power Supply System (WPPSS) Nuclear Project Nos. 1 and 4).
d.
Observation of welding materials storage area and review of welding materials approval and release system.
e.
Review of temperature control and electrode segregation in electrode ovens.
f.
Review of calibration status of welding equipment to be utilized for U.S.A. commercial nuclear fabrication.
g.
Review of procedure, E91-002(E), Revision 5, " Measuring Instruments Calibration Control Program."
h.
Review of procedure, E91-014(E), Revision 4, " Maintenance Control Procedure of Welding Machine."
i.
Examination of purchase orders, purchase specifications, and Certified Material Test Reports for six (6) consumables (shielded metal arc, gas tungsten arc, and submerged arc),
which hcd been approved for use on Job No. 5501-401 (WPPSS Nuclear Project No. 3).
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. j.
Review of Ebasco Penetrations Specification No. 3240-54, WPPSS Classification - Quality Class 1, dated January 20, 1976, for material and fabrication requirements applicable to WPPSS Nuclear Project Nos. 3 and 5.
k.
Review of Ebasco Specification No. 884-WA-77, Revision 2,
" Supplementary Requirements For Welding of Nuclear Pressure Components."
1.
Examination of thirteen (13) welding procedure specifications (WPS) and applicable supporting procedure qualification records.
3.
Findings a.
Deviations from Commitment (1) See Enclosure, Item A.
(2) See Enclosure, Item B.
b.
Unresolved Items None.
c.
General Comment At the time'of the inspection, shop fabrication had not started on WPPSS Nuclear Project Nos. 3 and 5, precluding direct observation of production welding compliance with QA Program and contract requirements.
D.
Weld Heat Treatment 1.
Objectives The objectives of this area of the inspection were to verify that heat treatment applicable to welding was specified and performed in accordance with QA Program and applicable NRC and ASME Code requirements.
2.
Method of Accomplishment The preceding objectives were accomplished by:
.a.
Review of Section 8, Revision 3, of the QA Manual, " Heat Treatment Control."
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. b.
Review of Post Weld Heat Treatment Procedure No. 062 K055, dated November 11', 1977.
c.
Review of procedure, QT502-17, Revision 0, "Postweld Heat Treat Procedure for Class 2 Components."
d.
Examination of postweld heat treatment chart and heat treat records applicable to items fabricated for WPPSS Nuclear Project flos. I and 4, relative to thermocouple placement, temperature uniformity during heat treatment, heating and cooling rates, hold time at temperature and IHI review and approvals, e.
Examination of accumulated postweld heat treatment time relative to qualification times of applicable welding procedure and welding materials.
f.
Examination of calibration status and records for furnace used to heat treat U.S.A. commercial nuclear items and review of system used to assure accuracy of thermocouples.
3.
Findings a.
Within this area of the inspection, no deviations or unresolved items were identified.
b.
The English language version of the procedure used to control calibration frequency of thermocouples had not been revised to reflect the requirements of the current Japanese language revision.
E.
Material Forming 1.
Objectives The objectives of this area of the inspection were to verify that existing process control provisions included the control of forming or bending, and that these operations were performed in accordance with applicable ASME Code requirements.
2.
Method of Accomplishment The preceding objectives were accomplished by:
a.
Review of procurement requirements imposed upon a vendor utilized for plate forming operations on Job No. 5501-408.
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. b.
Examination of process sheet, PR-408-2, Revision 0, relative to sample removal for verification of toughness properties after forming.
Review of sample toughness properties to verify that they c.
met established acceptance limits.
3.
Findings a.
Within this area of the inspection, no deviations or unresolved items were identified.
b.
The methods used to control forming or bending in accordance with ASME Code provisions were not specifically described in or referenced by the ASME accepted QA Manual.
F.
Material Identification and Control 1.
Objectives The objectives of this area of the inspection were to verify that material identification and control during manufacturing were in accordance with applicable regulatory, Code, and contract requi rements.
2.
Method of Accomplishment The preceding objectives were accomplished by:
a.
Review of Section 4, Revision 4, of the QA Manual,
" Procurement Control."
b.
Review of Section 5, Revision 3, of the QA Manual,
" Material Control."
Examination of WPPSS Nuclear Project No. 3, SA 240, c.
Type 316 bellows material, and SA 516, Grade 70 neck rings for material identification.
d.
Comparison of identity and material sizes relative to receiving inspection reports.
e.
Review of procurement documents and Certified Material Test Reports for the referenced materials.
f.
Verification that the materials were procured from an approved vendor.
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_9_
g.
Review of welding material storage area practices relative to identity control of electrodes, wire and flux.
h.
Verification that the welding materials were procured from approved suppliers and were in compliance with the applicable procurement documents.
3.
Findings Within this area of the inspection, no deviations from commitment or unresolved items were identified.
G.
Exit Meeting An exit meeting was held on January 12, 1979, with the management representatives denoted in paragraph A. above.
The inspectors summarized the scope and findings of the inspection and requested that the response be prepared with separate corrective action and steps to preclude recurrence statements for each finding.
Management affirmed its commitment to the quality assurance program and stated all necessary actions would be taken to satisfactorily correct the observed discrepant conditions.
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. DETAILS SECTION II (Prepared by D. M. Hunnicutt)
Procurement Document Control 1.
Objectives a.
To ascertain that procedures have been prepared and approved by Ishikawajima-Harima Heavy Industries Co., Ltd. (IHI) that prescribe a system for procurement document control, which is consistent with the IHI commitments of their Quality Assurance Program (QAP).
b.
To determine that the procurement document control procedures are being properly and effectively implemented by IHI.
2.
Method of Accomplishment The preceding objectives were accomplished by:
a.
Review of Section 4, " Procurement Control," of IHI Quality Assurance Manual (QAM), Document No. Q11-904, Revision 4, dated August 1, 1978.
b.
Review of ASME B&PV Code,Section III, Division 1, Subsections NC and NE, including addenda up to 1975 (winter).
c.
Review of Welding Material Purchase Specifications and related Purchase Orders (P0) for containment Mechanical Penetrations for WPPSS Nuclear Projects Nos. 3 and 5 for the following:
(1) WEL-MIG-308L, Revision 1, dated August 15, 1978.
(2) WEL-MIG-109, Revision 1, dated August 15, 1978, Drawing Code No. 062 K252A.
(3) WEL-MIG-316L, Revision 1, dated August 15, 1978, Drawing Code No. 062 K250A.
(4) BL-76, Revision 0, dated June 14, 1978, Drawing Code No. 062 K259.
(5) Y-DM3, Revision 0, dated June 14, 1978, Drawing Code No. 062 K258.
(6) YF-15, Revision 0, dated June 14, 1978, Drawing Code No. 062 K258.
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. (7)
LB-52N, Revision 3, dated February 6,1978, Drawing Code No. 062 K074C.
d.
Review of the following Certified Material Test Reports (CMTR):
(1) flo. NR-55 for Heat flo. 35 426.
(2) No. NR-43 for Heat flo. A5778.
(3) No. NR-42 for Heat flo. A5743A.
(4) tio. H. N1264 for Heat No. DF8J03.
(5) No. H. N1264 for Heat No. DF8J29P.
(6) No. Rill-4-0-1 for Wire Lot No. L35211.
(7) No. RIN-4-0-1 for Flux Lot flo.1-2.
~e.
Discussions with cognizant QA and management personnel.
3.
Findings No deviations or unresolved items were identified in this area of the inspection.
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