ML19270E850
| ML19270E850 | |
| Person / Time | |
|---|---|
| Issue date: | 11/16/1978 |
| From: | Hunnicutt D, Iller R NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML19270E846 | List: |
| References | |
| REF-QA-99900018 99900018-78-2, NUDOCS 7901020263 | |
| Download: ML19270E850 (8) | |
Text
.
L VEflDOR IfiSPECTION REPORT U. S. fiUCLEAR REGULATORY COMMISSI0fl 0FFICE OF IflSPECTION AND FilFORCEMENT REGION IV Report No.
99900018/78-02 Program No.
44020 Company:
Flowline Corporation P. O. Box 860 flew Castle, Pennsylvania 16103 Inspection Conducted:
October 31 - November 1, 1978
.0 Inspectors:
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o -v 1 VL-II' lHO R. E. Oller, Contraci;or Inspector,1 Vendor Date Inspection Branch f
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D. M. Hunnicutt, Chie,f, Components lection II, Date Vendor Inspection Branch i
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Approved by:
/fCA, '\\ x A OM "IL-II' I k ~l O D. M. Hunnicutt, Chief,) Components Sec$ ion II, Date Vendor Inspection Branch Surrmary Inspection on October 31 - flovember 1, 1978 (99900018/78-02)
Areas Inspected:
Implementation of 10 CFR 50, Appendix B criteria, other 11RC requirements and applicable codes and standards including: managerren t 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-four (24) inspector-hours on site by two (2) inspectors.
Re sul ts_:
In the four (4) areas inspected, no deviations were identified.
The following unresolved item was identified.
Unrevolved Item:
Review of " Welder's Log" sheets maintained by the welding superintendent for 1977 and 1978, established that on several occasions the procedures used were misidentified in the log in that 790102o m
_2_
stainless steel welding procedure specifications flo. Ir.iT-55-71-Fit lio. 55-7-61 were entered as having been used for welding of nicke', monel and aluminium.
Flowline management will take action to correct the current rect ds and preclude the recurrence of this condition.
(Report Details, pa. graph E.3.b.).
t.
DETAILS SECTION (Prepared by R. E. Oller and D. M. Hunnicutt)
A.
Persons Contacted
- E. H. Leimbacher, Vice President and QA Manager
- R. K. Mohn, Assistant QA Manager J. Simon, Welder
- Attended Exit Meeting.
B.
Action on Previous Inspection Findings 1.
(Closed) Deviation (Report flo. 78-01):
Failure of the Flowline calibration record cards to show the subcontractor's last cal-ibration of February 17, 1978, and the name of the calibrator for three recorders on heat treatment furnaces, an optical pyrometer and a potentiometer.
The inspector found that the dates of calibration for the above items are being entered on the cards and the cards are being kept current.
2.
(Closed) Deviation (Report No. 78-01):
Failure to include in the Calibration Procedure Q. A.4., revised April 24, 1978, the Helium-Argon welding gases Ratio Proportioner and the Vernier Caliper and their respective calibration frequencies as required by QA Manual paragraph 10.4.2-1.
The inspector found that in accordance with Flowline's letter dated June 5,1978, Procedure Q.A.4. was revised on May 16, 1978, to include the above devices and assigned calibration frequencies.
3.
(Closed) Deviation (Report flo. 78-01):
Failure to use a Flowlf -
procedare to calibrate Vernier Caliper flo. 701.
The inspector founr' that in accordance with Flowline's letter dated June 5, 197f, that a calibration procedure was issued on May 16, 1978, to control the calibration of Vernier Calipers.
4.
. Closed) Deviation (Report No. 78-01):
Failure to provide a written approval for release of the procedure " Calibration of Plug Gauges" prior to its issuance to the Chief Inspector.
The inspector found that in accordance with Flowline's letter dated June 5,1978, the subject procedure has been initialed by the QA Manager as evidence of review and approval.
_4-C.
f4anagement fleeting 1.
pbjectives Objectives of this Management f4eeting were to meet with Plant fianagement to discuss the purpose and intent of the Vendor Inspection Branch (VIB) direct inspection program and to discuss areas previously identified by Plant flanagement that were of specific interest to Flowline flanagement.
2.
f4ethod of Accomolishment The preceding objectives were accomplished by the Section Chief's presentation and the resulting discussions covering the following:
a.
VIB program objectives and how these objectives are to be accomplished.
b.
VIB organization.
c.
Inspection areas to be covered.
d.
The contents of the White Book.
e.
Items covered in previous Flowline response letters to VIB.
f.
Questions.
3.
Findings No unusual questions or discussions developed during this flanagement ideeting.
Plant flanagement identified nuclear products manufactured, and supplied information related to 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 applicable flRC and ASME Code requirements.
a.
A written system has been established to assure that manu-facturing processes are controlled in accordance with appil-cable codes.
k b.
Measures have been established and implemented to control the manufacturing processes by use of process sheets, travelers, checklists or procedures.
The process sheets, travelers, checklists or shop procedures c.
used included:
the document numbers and revisions to which the processes, inspections or tests conformed; the results of cornpletion of the specific operations; the signature, initials or stamp of the manufacturer's responsible representative and date were shown for operations completed, and the signature, initials or stamp of the authorized inspector and date, were shown for activities he witnessed.
2.
Method of Accomplishment The preceding objectives were accomplished by:
Review of Section 8, " Process Control," of the QA Manual (QAM).
a.
b.
Review of Specifications, Drawings and NDE requirements for nuclear quality elbows.
Review of Purchase Order No. 59675, dated October 10, 1978, c.
with naterial check list and verification that QA had approved and signed the P.O. prior to issuance.
s d.
Review of Purchase Order No. 59299, dated October 27, 1978, for 24 inch, schedule 20 elbows and verification that QA and the ANI had reviewed and approved the purchase order and established holdpoints as required.
Review of th." current Approved Vendor List (AVL).
e.
f.
Ouservation of shop operations to verify compliance with QAM requirements and appropriate specifications related to nuclear o' ality elbows in various stages of manufacture.
9 Examination of three (3) shop travelers to verify that materials, holdpoints, and shop operations were performed (or being performed) and that holdpoints and completed operations were signed off by the appropriate QA and ANI personnel, as required.
h.
Verification that identifying numbers (heat numbers) were stamped on each piece and that the stamps were low stress type.
e i.
Verification that shop travelers provided controls for each operation as it is completed and that the completion or holdpoint is signed off and dated, as required, and that manufacturing progresses in accordance with the " Production Order" or shop traveler.
3.
Findings _
fio deviations or unresolved items were identified in this area of the inspection.
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 specification (WPS) used in production welding are prepared, qualified and controlled in accordance with the QA program.
c.
That welding materials purchase, acceptance, storage, issuance and use are controlled and documented in accordanca 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 Sections flo.13, " Welding Wire Control" and No. 14, " Welding Control," to verify that measures for welding control are documented.
b.
Observations of welding materials and the storage facilities including spools of code welding wire, boxes of bare welding rod and tanks of Argon and Helium welding gases to verify that the facilities were appropriate and the materials were properly marked.
c.
Review of records of QA releases (Welding Electrode Certification) to production welding for seven (7) heats of welai..g wire and bare rod to verify that these materials were accepted by QA.
- d.
Review of supplier certifications for the Argon and Helium welding gases to verify that these gases were certified to acceptance standards and were of known percentage ourity.
Review of the following records of purchasing and certifica-e.
tions for two (2) heats (flo. 2413 and flo. 74599) of the above welding wire and rod to verify that the material was procured to code requirements and verified by Flowline as meeting purchase specifications.
(1)
P.O. flo. 50489 and flo. 58142.
(2)
Supplier's Material Certifications.
(3)
Flowline's subcontracted laboratory chemical analysis reports.
(4)
Flowline's determination of delta ferrite percent contents in the supplied wire and rod.
(5)
Quality Assurance Department's copy of the Welding Electrode Certifications (Receiving Inspection Report).
T Review of two (2) records of welding material issuance (Filler Metal Record) to verify that the issuance to production of code weld filler materials was controlled in accordance with the QA program.
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 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 Code,Section IX.
(1)
IqPS fio. HWT-55-71-FM, revised August 8,1978, WPS
"... For Gas Tungsten Arc Welding-GTAW, Semi-Automatic Welding."
(2)
WPS flo. 55-7-61, revised September 12, 1978, UPS
"... For Gas Tungsten Arc Welding-GTAW, Manual Welding."
h.
Review of performance qualification records for three welders to verify that these welders were qualified in accordance with the ASME Code,Section IX.
- i.
Review of the " Welder's Log" sheet records of welding by four (4) welders for 1977 and 1978, to verify that records of welder usage of procedures and processes were maintained in accordance with the QA program.
j.
Discussions with cognizant personnel.
3.
F_i n_di,njls a.
Deviations From Comaitmens, None.
b.
Unresolved Items The QA Manual Section 14, " Welding Control," paragraph 14.3.3.
requires that the Welding Superintendent maintain a " Welder's Log" (A-26) listing individual welders with a record of procedures used.
Review of these " Welder's Log" sheets for 1977 and 1978, established that on several occasions the procedures used were misidentified in the logs in that proce-dures No. HWT-55-71-FM and No. 55-7-61 for welding austenitic stainless steel, were entered as having been used for welding base materials such as nickel, monel and aluminum.
r'awline's management will correct the current records and it c t to prevent recurrence of this condition.
This item remains unresolved pending verification of Flowline's corrective action during a subsequent NRC inspection.
F.
Exit Interview 1.
The inspectors mat with management representatives denoted in paragraph A at the conclusion of the inspection on November 1,1978.
2.
Th. following subjects were discussed:
a.
The areas inspected.
b.
Status of corrective action for the previous inspection findings.
The apparent misidentification of welding procedures in the c.
" Welder's Log" sheets for 1977 and 1978.
d.
The absence of deviations in the areas inspected.
3.
Management's comments were related to clarification of the above finding.