ML19269F443
| ML19269F443 | |
| Person / Time | |
|---|---|
| Issue date: | 09/05/1979 |
| From: | Barnes I, Hunnicutt D, Roberds H NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML19269F414 | List: |
| References | |
| REF-QA-99900036 99900036-79-2, NUDOCS 7912210036 | |
| Download: ML19269F443 (12) | |
Text
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U. S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT REGION IV Report No.
99900036/79-02 Program No. 51300 Company:
Combustion Engineering, Inc.
911 West Main Street Chattanooga, Tennessee 37402 Inspection Conducted: August 13-17, 1979 Inspectors:
II h
M I. Barnes, Contractor Inspector Date ComponentsSection II Vendor Inspection Branch ll (b
b H. W. R6berds, Contractor Inspector
/ ' Date ComponentsSection II Vendor Inspection Branch Approved by: (
1 M7
[fY D. M. Hunnicutt, Chief Date ComponentsSection II Vendor Inspection Branch Summary Inspection on August 13-17, 1979 (99900036/79-02)
Areas Inspected:
Implementation of 10 CFR 50, Appendix B criteria and applicable codes and standards including; manufacturing process control, joint fitup and welding, special processes personnel qualifications (nondestructive examination), radiographic examination, and nondestructive examination (liquid penetrant and magnetic particle). The inspection involved fif ty-five (55) inspector-hours on site by two (2) NRC inspectors.
Results:
In the five (5) areas inspected, no apparent deviations or unresolved items were identified in three (3) areas; the following deviations being identi-fied in the remaining areas:
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2 Deviations:
Joint Fitup and Welding - Welding was being perform ne 2G position although the weld procedure allowed only the 1G pasition (Fatice of Deviation, Item A).
Welding operations observed were not in accordance with certain requirements of DWPS.
(Notice of Deviation, Item B).
Unidentif-ied alignment and tie strap material were observed welded to certain vessel assemblies and piping subassemblies (Natice of Deviation, Item C).
Nondestructive Examination (Liquid Penetrant and Magnetic Particle) Certain drawings had not been updated and reissued by Design Engineering (Notice of Deviation, Item D).
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3 DETAILS SECTION I (Prepared by I. Barnes)
A.
Persons Contacted
- J. T. Rich, General Manager - Nuclear Manufacturing
- W. A. Stone Jr., Manager, Nuclear Quality Assurance J. A. Anderson, Lead Quality Engineer
- T. L. Bailey, Manager, FPSM Quality Assurance
- B. J. Bates, NQA Audit Coordinator B. G. Carlton, Welding Engineer G. S. Cushman, Manager, Nuclear Component Manufacturing kJ. P. Fava, Section Manager, Inspection /NDE
- R. J. Ferester, Manager, suclear Production Control
'dD. Gomien, NDE Examiner
- T. Halvorsen, Component Engineering, Technical Assistant to Director
- L. A. Hoenig, Supervisor Standards, Component Engineering
- L. C. Miller, Section Manager, Quality Engineering
- C. Rigsby, Superintendent, Manufacturing
- T. J. Wood, Senior Quality Engineer, FPSM W. Worley, Quality Engineer, FPSM
- J. N. Garrett, Authorized Nuclear Inspector, Hartford Steam Boiler Inspection and Insurance Co.
- Attended exit meeting.
B.
Joint Fitup and Welding 1.
Objective The objective of this area of the inspection was to determine if production welding was controlled in accordance with the Combustion Engineering, Inc. (CE) QA program and applicable ASME Code require-ments.
2.
Method of Accomplishment The preceding objective was accomplished by:
a.
Review of System No. 9, Revision D, of the QA Manual, " Control Of Special Processes."
b.
Review of QC Procedure No 9.2, Revision C, " Welding Control."
c.
Review of QC Procedure No. 9.4, Revision E, " Preheat Control."
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4 d.
Observation of production stcip cladding operations and shielded metal are process use (temporary and permanent attachments, back cladding, safe end weld repair, back welding of pressure boundary seams) vith respect to:
(1) Compliance with traveler instrue. ions relative to welding procedure specification (WPS) selection.
(2) Availability of welding procedures in work areas.
(3) Presence of welding material requisition card copies at welding stations for welding operations in progress.
(4) Quali fication of personnel for operations witnessed.
(5) Verification that welder technique, welding position, electrical parameters, welding materials and preheat temperatures were in accordance with WPS requirements.
e.
Review of Inspection welding surveillance program records relative to QA program commitments.
f.
Examination of original copy of welding material requisi-tion cards for one production shift relative to program requirements for documentation of WPS understanding.
g.
Verificaticn of calibration status of meters on automatic welding equipment.
3.
Findings a.
Deviations from Commitment (1) See Notice of Deviation, Item A.
(2)
(a) DWPS SAA - 1.8-105-1 requires submerged are strip cladding to be performed with 250 F minimum preheat and respective amperage and voltage ranges of 900-1100 and 28-29.
Contrary to the above, submerged arc strip clad-ding using DUPS SAA - 1.8-105-1 was observed being performed on Contract No. 73474, Job and Control No. 766722-044, with 200 F preheat temperature, 1100-1200 amperes and 26.5-27 volts.
In addition to the above, a similar observation with respect to arc voltage control was made in 2166 0'8
5 the use of this process for the overlay cladding of a pressurizer shell.
Cladding was observed being performed at 26 volts on Contract No. 9779, Job and Control No. V61615-310, using DWPS SAA 3.8-124-0, which also requires an are voltage range of 28-29 to be maintained.
In this particular in-stance, use of this voltage value was not verified by accompanying CE personnel.
(b) DWPS SMA-1.3-109-1 states in part with respect to seld preparation cleaning, "As required to pro-dcce groove and adjacent surface free of dirt, grease or other contaminants.
Contrary to the above, shielded metal arc welding using DWPS SMA-1.3-109-1 was observed being per-formed on Contract No. 74474, Job and Control No.
767741-017, without removal of contaminants from the weld preparation surface, i.e., whip restraint lugs were fitup on primary piping ano velding started without local removal of the rust film and other foreign matter on the piping surface.
(See Notice of Deviation, Item B.)
(3) Paragraph 2.1 in QCP 9.2, Revision C, provides criteria for the control of welding of temporary attachments.
Specific requirements for attachment material identi-fication are net included in this procedure. However, general provisions are made in the procedure for use of appropriately qualified personnel, procedures and welding materials.
Implemer.tation of these controls could not be verified for those items identified in the Notice of Deviation, in that:
(a) Sequence 010 on the traveler for Contract No.
75174, Job and Control No. 768141-006, addresses fitup of the lower vessel assembly, which was being completed during the inspection. This sequence requires tie straps to be welded to the internal vessel surfaces in accordance with tooling drawing E694-656. An appropriate DWP was assigned for welding the tie straps to the austenitic stainless steel weld cladding surfaces.
The specific attachments observed by the inspector were welded to the ferritic outer vessel surfaces, for which there were neither instructions or identification of existence in both the traveler 2166 019
6 and tooling drawing. The inspector was unable to ascertain the identity of the welder (s), welding procedure or welding materials used for naaking these attachments, in that welding material requisition cards applicable to the operation could not be located prior to the end of the in-spection.
(b) Operation 0740 on the traveler for Contract No.
74474, Job and Control No. 767741-019. includes fitup of whip restraint lugs on primary piping and was signed off by the fitting operator, QC Inspector, and Authorized Nuclear Inspector on August 7, 1979. A DWP for this operation was not assigned on the traveler. The inspector was verbally informed that the same DWP used for per-forming the restraint lug seam welds was applicable to the fitup operation.
The inspector was unable to verify this information or establish the identity of welder (s) and welding materials used, in that appropriate welding material requisition cards could not be located by the Fossil Power Systems Quality Engineering staff assigned to nuclear piping manufacture.
(c) Connecting strapping of two subassemblies from Contract No. 74474, Job and Control Nos. 767711-021 and 767711-022, was not a defined manufacturing operation, in that the operation was not refer-enced in either of the two (2) applicable travelers.
Welding material requisition cards could not be located for the attachment welding operations, precluding identification of personnel, welding materials and welding procedure used.
(See Notice of Deviation, Item C.)
b.
Unresolved Items None.
c.
Comments The inspector observed, that the ammeter and voltmeter applicable to the strip cladding equipment used in primary piping overla; operations, were installed overhead at a sufficient distance from the control panel, to preclude ready observation of the developed amperage and voltage by the welding operator.
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7 C.
Manufacturing Process Control 1.
Objectives The objectives of this area of the inspection were to verify that:
a.
A system had been established for the control of manufacturing processes, which was consistent with applicable regulatory and ASME Code requirements.
b.
The system was implemented.
2.
Method of Accomplishment The preceding objectives were accomplished by:
a.
Review of System No. 5, Revision E, of the QA Manual, "Instruc-tions, Procedures, and Drawings."
b.
Review of System No. 5, Revision D, of the QA Manual, "Instruc-tions, Procedures and Drawings (Modifications for Nuclear Work Performed by Fossil Power Systems)."
c.
Review of System No. 6, Revision F, of the QA Manual, " Document Control."
d.
Review of System No. 7, Revision D, of the QA Manual, " Control of Purchased Material, Items, and Services."
e.
Examination of material forming and heat treatment practices used in pipe manufacture relative to applicable ASME Section III requirements and appropriateness of material test informa-tion.
f.
Examination of traveler documentation for vessel and piping subassemblies with respect to:
(1) Definition and control of sequencing of manufacturing operations to provide for compliance with ASME Code Section III fabrication requirements.
(2) Compliance with designated hold points.
(3) Performance of required ASME Code nondestructive exam-inations and at appropriate times of examination.
(4) Completeness of operation signoff.
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o a 8
(5)
.vidence of fabrication inspection definition and per-formance consistent with QA program commitments.
(6) Use of qualified welding personnel relative to assigned welding operations.
3.
Findings Within this area of the inspection, no deviations from commitment or unresolved items were identified.
D.
Exit Meeting A post inspection exit meeting was held by the lead inspector on August 17, 1979, with the management and Authorized Inspection Agency representatives denoted in paragraph A. above.
The inspector summarized the scope and findings of the inspection. Management acknowledged the statements of the inspector and had no specific questions in regards to the findings as presented to them.
~
21 66 022
,e 9
DETAILS SECTION II (Prepared by H. W. Roberds)
A.
Perscns Contacted D. A. Gomien, NDE Level III Examiner R. W. Scott, Design Engineer T. D. Cabe, NDE Lavel III Examiner T. J. Wood, Senior Quality Engineer
- 0. L. Butler, General Foreman NDE E. Kleinhesselink, 1st Shift Foreman NDE B. G. Robinson, 2nd Shift foreman NDE S. A. Whittenbarger, NDE Level II MT M. R. Welch, NDE Level II, RT B.
Special Processes Personnel Qualifications (Nondestructive Examination) 1.
Objectives The objectives of this area of the inspection were to verify that:
The employer, Combustion Engineering, has developed a written a.
practice for control and administration of NDE personnel training, examination, and certification in accordance with applicable NRC and AStfE Code requirements.
b.
Personnel records are complete and are current.
Personnel performing nondestructive examination are qualified c.
for the method used and have current eye examinations as defined in SNT-TC-1A.
2.
Method of Accomplishment The preceding objectives were accomplished by:
Review of thc Quality Assurance Manual, System 9, Revision D, a.
" Control of Special Processes."
b.
Review of the Quality Assurance Manual, System 5, Revision E,
" Instructions, Procedures, and Drawings."
Review of QC Procedure, Number 2.4, Revision D, " Documented c.
Certification Program."
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.,em e
e e
y 10 d.
Review of twelve (12) NDE personnel certification and qualifi-cation record packages including results of eye examinations.
e.
Interviews with cognizant personnel 3.
Findings Within this area of the inspection, no deviations from commitments or unresolved items were identified.
C.
Ncndestructive Examination (Radiography) 1.
Objectives The objectives of this area of the inspection were to verify that:
a.
Nondestructive examination (RT) is performed in accordance with approved procedures.
b.
Nondestructive examination procedures meet the requirements of ASME Code and other applicable requirements.
c.
Work is accomplished by, and the test results are interpreted by appropriately qualified personnel.
2.
Method of Accomplishment The preceding objectives were accomplished by:
Review of the Quality Assurance Manual, System 9, Revision D, a.
" Control of Special Processes."
b.
Review of the Quality Assurance Manual, System 5, Revision E, "Instrt.ctions, Procedures, and Drawings."
c.
Review of Process Specification for Radiographic Examination of Commercial Nuclear Components, Specification No. N-2.4.1.3 (f) of Sept. 25, 1975.
d.
Review of twenty-four (24) production radiographs for job Fo.
722-741-050 and job No. 750121-115.
e.
Interviews with cognizant personnel.
3.
Findings Within this area of the inspection, no deviations from commitment or unresolved items were identified.
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11 3.
Nondestructive Examinatic iquid Penetrant and Magnetic Particle).
1.
Objectives The objectives of this area of the inspection were to verify that:
Nondestructive examination (MT & PT) is performed in ac ~rdance a.
with approved procedures.
b.
Nondestructive examination procedures meet the require..ents of ASME Code and other applicable requirements.
Work is accomplished by and test results are interpreted by c.
appropriately qualified personnel.
2.
Method of Accomplishment The preceding objectives were accomplished by:
Revicw of the Quality Assurance Manual, System 9, Revision D, a.
" Control of Special Processes."
b.
Review of the Quality Assurance Manual, System 5, Revision E,
" Instructions, Procedures and Drawings.
Review of QC Procedure No. 6.2., Revision E, " Chattanooga c.
Nuclear Operations Review and Control of Drawings."
d.
Review of Magnetic Particle Inspection (Dry) Procedure No.
N-2.4.2.4(e) with addendum 2(a).
Review of Liquid Penetrant Inspection Procedure No. N-2.4.3.9(F) e.
with addendums 2(a) and 3(a).
f.
Review of Process Specification Drawing No. B-74374-662-002, Revision 01.
g.
Observation of a magnetic particle examination on job No.
767651-010.
h.
Interviews with cognizant personnel.
3.
Findings a.
Deviation from Commitments 2166 025 See Notice of Deviation, Item D.
12 Even though the drawing had not been reissued by Design Engineering, Quality Engineering proceeded to make an unauthorized change to the inspection copies of drawing No. B-74374-662-002 to include the modification to M&P specification No. N-2.4.2.4(e).
It appears that the cauce of this deviation is created by conflicting statements, relative to the release of revisions to Process Specification Drawings, found in QC Procedure 6.2.
Paragraph 2.6.3 states that revised process specification drawings shall not be released by emergency memo. Also the procedure does not clearly define who is authorized and responsible to initiate the emergency memo for the release of process specification drawing revisions.
b.
Unresolved Items None.
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