ML19270G877
| ML19270G877 | |
| Person / Time | |
|---|---|
| Issue date: | 03/30/1979 |
| From: | Hunnicutt D, Oller R NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML19270G876 | List: |
| References | |
| REF-QA-99900057 99900057-79-1, NUDOCS 7906210059 | |
| Download: ML19270G877 (10) | |
Text
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U.S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT REGION IV Report No. 99900057/79-01 Program No. 51300 Company:
The William Powell Company Plant No. 2 3233 Colerain Avenue Cincinnati, Ohio 45214 Inspection Conducted: March 12-15, 1979 Inspector h[
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C R. E. Oller, Contractor Inspector Date /
Vendor Inspection Branch b
Approved by:
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.3d 77 D. M. Hunnicutt, Chief, ComponentsSection II Date '
Vendor Inspection Branch i
Summary Inspection on March 12-15, 1979 (.99900057/79-01)
A Implementation of 10 CFR 50, Appendix B criteria, other r as Inspected:
NP, requirements and applicable codes and standards including:
action on pievious inspection findings; general review of vendor activities, handling, storage and shipping; material identification and control, and procurement document control. The inspection involved twenty-five (25) inspector-hours on site.
Results:
In the five (5) areas inspected, no deviations or unresolved items were identified.
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. Details Section (Prepared by R. E. Oller)
A.
Persons Contacted R. Cochran, Metallurgical Technician L. Carboina, Bonded Area Inspector R. Eveslage, Gage Inspector F. Hornbeck, Supervisor of Welding Department L. Jackson, Weld Shop Foreman
- H. Knock, QA Manager D. Mowery, Manager of Technical Services G. Murray, Supervisor of Shipping
- J. Williams, Project QA Engineer
- E. Winterfeldt, Corporate QA Manager A. Winteride, Chief Inspector i
- Attended the exit meeting B.
Action on Previous Inspection Findings 1.
(Closed) Deviation A.1 (Report 78-01):
Failure to calibrate the Argon welding gas flow meters in the first floor weld shop and third floor hardfacing department and failure to have a procedure in effect to assure that the calibration requirements were met for these devices. The inspector found that the welding gases flowmeters have been added to the calibration procedure specifi-cation PS-104.6 with an assigned calibration frequency of once every three (3) months. All of the flowmeters have been cali-brated and calibration record cards are being maintained for these flowmeters. The Chief Inspector issued a memorandum dated September 15, 1978, to the Gage Inspector, advising him of the calibration record card system to be used and his responsibility concerning this activity.
2.
(Closed) Deviation A.2 (Report 78-01):
Failure to provide docu-mented evidence that five (5) welding generators were calibrated against standards which have known relationship to National Stan-dards. Copies of the subcontractor's calibration certificates were provided prior to the end of the inspection which closed the corrective action for this deviation.
However, the preven-tative action for this deviation was not completed.
The inspector found that welding machine ammeters and voltmeters have been added to the calibration procedure specification PS-104.6 2240 155
. with an assigned calibration frequency of once every three (3) months.
Calibration record cards are being maintained for these meters.
The Chief Inspector's, previously referenced, memorandum to the Gage Inspector included ameters and voltmeters.
3.
(Closed) Deviation A.3 (Report 78-01):
Failure to calibrate the Sargent Welch Standard Thermometer used in calibrating surface pyrometers, and have a procedure in effect to assure that cali-bration requirements were met.
Prior to the end of the inspection, the above thermometer was calibrated. However, the preventative action for this deviation was not completed.
The inspector found that the above themometer has been added to the calibration procedure specification PS-104.6 with an assigned calibration frequency of once a year. A calibration record card is being maintained for this thermometer. The Chief Inspector's, previously referenced, memorandum to the Gage Inspector included this thermometer.
4.
(Closed) Deviation A.4 (Report 78-01):
Failure to have available calibration procedures for the " Black Light" fluorescent lamp and the ultraviolet reference meter No. J-221, used in the process of fluorescent dye penetrant inspection. The inspector found that in accordance with Powell's response letter, Powell Specification PS-104-78 includes provisions for checking the " Black Light" and calibrating the ultraviolet reference meter No. J-221 at biennial intervals. Meter J-221 has also been added to Calibration Procedure Specification PS-104.6 with an assigned calibration frequency of every two (2) years.
A calibration record card is b'ing maintained for Meter J-221.
The Chief Inspector's, previ-c sly referenced, memorandum to the Gage Inspector included Meter J-221.
5.
(. Closed) Deviation B (Report 78-01):
Failure to document the training sessions which were conducted for the in-process and final dimensional inspectors. The inspector found that the training sessions are now being documented by the Chief Inspec-tor's signing of the minutes of the inspection meeting training sessions and the attendees signing of attendance sheets. Written instructions concerning proper documentation of training sessions were issued on September 18, 1978, by the Chief Inspector to the inspection office personnel.
6.
(0 pen) Unresolved Item (Report 78-01):
Contracted calibration surveys for heat treatment furnaces Numbers 5550, 5437, 5784, 5533, and 5777 in Plant 2 had not been completed at the time of the inspection.
The inspector found that temperature uniformity e.
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. surveys have been completed for furnaces No. 5437 on August 3, 1978, and for No. 5777 on January 29, 1979, by a contracted ser-vice.
Thc records of survey and calibration are on file at Powell Plant No.
The other three (3) furnaces have not been surveyed but are still under contract to be surveyed. This item continues to be unresolved pending completion of the surveys and verifica-tion of the action during a subsequent NRC inspection.
C.
General Review of Vendor's Activities _
1.
Objective J
The objective of this area of the inspection was to assess the vendor's activities and capabilities, and their possible impact on future NRC inspections.
2.
Method of Accomplishment The preceding objective was accomplished by:
a.
Discussions with cognizant personnel, t
b.
Review of the "N" and "NDT" certificates of authorization.
c.
Review of the Plant 2 QA Manual.
3.
Findings a.
The William Powell Plant No. 2 manufacturing activities include valves for nuclear application and valve parts for gate, globe and check valves.
Size ranges in nominal pipe size are from 2h inches through 48 inches. Materials include carbon steel, low alloy and austenitic stainless steel.
b.
Discussions established that the current nuclear class valve workload involves completion of orders for three (3) cus-tomers.
It is estimated that these orders will be completed in mid-1979. Any material for new valve orders would not be in production for approximately 9-12 months, c.
Plant 2 holds ASME "N" symbol certificate No.1578 for Class 1, 2, and 3 valves, and "NPT" symbol certificate No.1579 for Class 1, 2, and 3 valve parts.
Both of these certifi-cates expire on December 23, 1979.
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_. _. _ _ D.
Handling, Storage and Shipping 1.
Objectives The objectives of this area of the inspection were to verify that the following items were controlled in accordance with applicable NRC and ASME Code requirements:
a.
A written system has been established to assure that hand-ling, storage, and shipping activities are controlled in eccordance with codes and standards.
b.
Instructions, procedures or drawings are used to control handling, storage, shipping, packaging and preservation of materials and tems, to prevent. damage, deterioration, or loss.
c.
Access to storage areas is controlled.
d.
Completed items are cleared, inspected and appropriately sealed, packages are protected for shipment, and that the items are suitably blocked, anchored, braced and/or cushioned to prevent damage, e.
Lifting devices are periodically maintained, inspected, and controlled in accordance with written procedures or instruc-tions.
2.
fiethod of Accomplishment The preceding objectives were accomplished by:
a.
Review of the QA Manual Article 2: paragraph 2.15, " Assembly, Testing and Shipping;" and Article 5, paragraph 5.7, " Cleaning, Precervation and Packaging."
b.
Review of Process Specification PS-129, dated September 16, 1976, "l'oisting Equipment Program."
c.
Observation of overhead cranes, hoists and chain sling to verify that lifting equipment used for movement of nuclear valves and valve parts was identifiable, showed rated load capacities and was appropriately maintained.
d.
Review of recordt of monthly inspections of twenty-seven (27) cranes of over three (3) ton capacity; records of
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- annual inspection of 285 hoists and cranes of three (3)
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_ tons and under capacity, and records of annual inspection of 447 chain slings, to verify that the lifting equipment was inspected and tested in accordance with above specifi-cation PS-129.
e.
Observation of raw and finished controlled materials in the bonded storage areas.
f.
Review of the standard procedure " Manufacturing Practice, Packaging of Nuclear Valtes for Shipment."
9 Observation of packaging practices including construction of skids, pallets, crating, blocking, and banding of valves weighing 1500 to 17,000 pounds, h.
Discussions with the responsible shipping supervisor con-cerning selection of the sizes of steel banding and sizes and types of lumber for packaging.
1.
Discussions with other cognizant personnel.
3.
Findings Within this area of the inspection, no deviations or unresolved items were identified.
E.
Material Identification and Control 1.
Objectives The objectives of this area of the inspection were to verify that the following items were controlled in accordance with applicable NRC and ASME Code Requirements.
a.
A written system has been established to assure that material identification and control is performed in accordance with i
applicable codes.
b.
Documented measures have been used for identification and control of materials and items including partially fabri-cated assemblies, c.
Identification is reaintained either on the item or on records traceable to the item.
d.
Permanent or temporary identification marks or numbers are legible and are not detrimental to the item quality or do not interfere with the functicn of the item.
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. 2.
Method of Accomglishment The preceding objectives were accomplished by:
a.
Review of the QA Manual Article 2, paragraphs:
2.12, "Re-ceiving;" 2.13, " Receiving Inspection; 2.14, " Manufacturing;"
and 2.15, " Assembly, Testing, Shipping."
b.
Observation of material identification stamping with the unique Controlled Material Number (CM-No.) and review of the related controlling documents such as inspection tags and router travelers for items denoted as follows at the locations indicated:
(1) Raw Material Bonded Area (a) 2h" gate valve body, CM-1135B (b) Swing check valve disc, CM-1502B (2)
Finished Material Bonded Area (a) 14" - 600 pound gate valve body, CM-8945
(.b) 16" x 14" x 16" - 900 pound check valve body, CM-25488 (c) Valve parts assembly package consisting of:
two (2) bodies, CM-2890 and CM-2891; two (2) bonnets, CM-33108 and CM-3311B; two (2) discs, CM-3162 and CM-3161B; studs marked EQ-45 and EF-6; and nuts marked EQ-4.
(3) Boring Mill Area (a) 6" - 150 pound gate valve body, CM-3324B (b) 6" - 900 pound check valve body, CM-3308B (cl 6" - 150 pound gate valve body, CM-1174A (4) Assembly Area
(.al Parts for a valve being assembled consisting of body CM-30968, bonnet CM-1203, disc CM-9103, studs ET, and nuts EV.
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. (b) Parts of an assembled valve consisting of body CM-3113B, bonnet CM-30348, studs LL-38, and nuts LL-19.
(5) Hydrostatic Test Area Parts of a completed 20" - 19003 W. E. Gate Valve consisting of body CM-19108 and bonnet CM-3103B.
(6)
Final Inspection Area A completed and partially crated 4" - 1500 pound gate valve, code name plate SN-69379-1 stamped "N" Class 2, built in 1978.
c.
Review of records of the "NPV-1, N Certificate Holder's Data Report," and the " Documentation Checklist" for the above valve, SN-69379-1, to verify that all of the parts and i
related documents were accounted for.
d.
Review of the documentation package for the above valve, SN-69379-1, to verify that records for each part in the valve, were identified by part CM-Number and the valve serial num-i ber.
e.
Review of the documentation package for a completed valve,
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SN-68503-?, to verify that the records for each part in the valve were identified by part CM-Number and the valve ser-ial number.
f.
Discussions with cognizant personnel.
3.
Findings Within this area of the inspection, no deviations or unresolved items were identified.
F.
Procurement Document Control 1.
Objectives The objectives of this area of the inspection were to verify that the following items were controlled in accordance with NRC and ASME Code requirements.
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a.
A written system has been established to assure that pro-curement document control is performed in accordance with applicable codes.
- b. ~ Procedures have been prepared, approved and implemented which will assure that procurement documents suitably in-clude or reference necessary requirements for procurement of materials, equipment and services.
c.
The procurement documents, to the extent necessary, require subcontractors to provide a quality assurance program appro-priate to their activities.
d.
Suitable documentation is maintained which verifies that the procurement document centrol system is being properly and effectively implemented.
2.
Method of Accomplishment The preceding objectives were accomplished by:
a.
Review of the QA Manual Article 4, " Material Procurement and Inventory Control."
b.
Review of the following purchase orders (P.O.) and the re-lated Quality Requirement Supplements (QRS) for base mater-ials, welding materials, and services, to verify that the QA program requirements were being complied with in devel-oping and processing these documents:
(1)
P.O. No. 618N, dated January 16, 1979, for a 10" - 1500 pound gate valve thrust ring, and the QRS dated January 10, 1979.
(2)
P.O. No. 4726-2, dated June 7,1978, for services of solution annealing heat treatment of test bar No. 100579 for a 4" - 1500 pound gate valve bonnet, and the QRS dated June 5,1978.
(3)
P.O. No. 593-N, dated July 31, 1978, for a 6" - 300 pound valve solid disc, and the QRS dated July 19, 1978.
(4)
P.O. No. 595-N, dated August 2, 1978, for a 6" - 150 pound gate valve body, and the QRS dated July 19, 1978.
(5) Review of the following three (3) P.O.s for welding filler rod materials, and the related QRS's:
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(a)
P.O. No. 435-2, dated June 7, 1978, for 3/16",
1/8" and 5/32" diameter electrodes to specifica-tion SFA 5.4, Class E-308-16, and QRS dated June 7, 1978.
(b)
P.O. No. 433.2, dated September 7,1978, for 5/32" diameter electrodes to specification SFA 5.1, Class E-7018, and the QRS dated June 7, 1978.
(.c)
P.O. No. 429-2, dated May 1,1978, for 5/32" and 3/16" diameter electrodes to specification SFA 5.4, Class E-502-16, and the QRS dated May 1, 1978.
c.
Review of the current " Approved Controlled Material Suppliers
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List," Revision 9 with 13 attached addendums, to verify that the suppliers for the above P.O.s were approved and on the list.
d.
Discussions with cognizant personnel.
3.
Findings Within this area of the inspection, no deviations or unresolved items were identified.
G.
Exit Interview 1.
The inspector met with management representatives denoted in paragraph A, at the conclusion of the inspection on March 15, 1979.
2.
The following subjects were discussed:
a.
Areas inspected, b.
Status of corrective and preventative action for previous inspection findings.
3.
Management's comments were generally related to clarification of above items.
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