ML19274E968
| ML19274E968 | |
| Person / Time | |
|---|---|
| Issue date: | 03/23/1979 |
| From: | Hunnicutt D, Oller R NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML19274E967 | List: |
| References | |
| REF-QA-99900314 99900314-79-1, NUDOCS 7906070031 | |
| Download: ML19274E968 (16) | |
Text
THIS DOCUMENT HAS tiOT BEEi REVIEWED FOR PROPRIETARY Sapecut UNITE D STATES INFORMATION AS DESCRIBED
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g NUCLEAR REGULATORY COMMISSION IN 10 CFR 2.790' __ _ _
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o REGION IV
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ARLINGTON, TEXAS 76011 2 6 MAR N Docket No. 99900314/79-01 Colt Industries Trent Tube Division of Crucible, Incorporated Attn: Mr. J. L. Wehrle QA Manager 141 Hammonds Street Carrollton, Georgia 30117 Gentlemen:
This refers to the QA Program inspection conducted by R. E. Oller of this office on February 25 - March 1,1979, of your facility at Carrollton, Georgia associated with the raanufacture of welded piping and to the discussion of our findings with you and members of your staff at the conclusion of the inspection.
This inspection was made to confirm that, in the areas inspected, your QA Program is being effectively implemented. The inspection effort is not designed to assure that unique quality requirements imposed by a customer are being implemented; nor to assure that a specific product, component or service provided by you to your customers, is of acceptable quali ty. As you know, the NRC requires each of its licensees to assume full responsibility for the quality of specific products, components or services procured from others.
You should therefore not conclude that the NRC's inspection exempts you from inspections by an NRC licensee or his agents nor from taking effective corrective action in response to their findings.
Areas examined during the inspection and our findings are discussed in the enclosed report. Within these areas, the inspection consisted of an examination of procedures and representative records, interviews with personnel, and observations by the inspector.
Within the secce of this inspection, we found no instance where you failed to meet NR(,
requirements.
In accordance with Section 2.790 of the Commission's " Rales of Practice,"
Part 2, Title 10, Code of Federal Regulations, a copy of this letter together with the enclosed inspection report will be placed in the Comission's Public Document Room.
If this report contains any informa-tion that you believe to be proprietary, it is necessary that you make a written application within thirty (30) days to this office to with-hold such information from public disclosure. Any such application must include a full statement of the reasons on the basis of which it is 790607003/
Colt Industries claimed that the information is proprietary, and should be prepared so that proprietary information identified in the application is contained in a separate part of the document.
If we do not hear from you in this regard within the specified period, the report will be placed in the Public Document Room.
Should you have any questions concerning this inspection, we will be pleased to discuss them with you.
Sincerely, NL y
Uldis tapovs, Chie Vendor Inspection Branch
Enclosure:
Inspection Report No.
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U. S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT REGION IV Report No.
99900314/79-01 Program No.
51300 Company:
Colt Industries Trent Tube Division of Crucible 141 Hammond Street Carrollton, Georgia 30117 Inspection Conducted:
February 26 - March 1,1979 M28
/
Inspector:
R. E. Oller, Contractor Inspector, Vendor Date Inspection Branch Approved by:
) fX j 8/A3/77' D. M. Hunnicutt, Chief, ComponentsSection II,
' Date' Vendor Inspection Branch Summary Inspection on February 26 - March 1, 1979 (99900314/79-01).
Areas Inspected:
Implementation of 10 CFR 50, Appendix B criteria, other NRC requirements, and applicable codes and standards including:
review of vendor activities; manufacture of SA-312 piping including manufacturing process control, fitup and welding, weld heat treatmerit, testing of completed products and ultrasonic examination.
The inspection involved twenty-seven (27) inspector-hours on site.
Results :
In the six (6) areas inspected, no deviations were identified.
The following unresolved items were identified:
Deviations:
None.
Unresolved Items Manufacturing Process Control: The QA Manual will be revised to clearly show that for operations such as forming, pickling, passivating, planishing and degreasing, the procedures and revision numbers do not have to be shown on the Mill Orders.
Fitup and Welding:
(1) Procedure Qualification Records No. TWP-1-Q5 and No. TWP-1-QB, for welding procedure specification No. TWP-1B, did not show the labora-tory test numbers for traceability to tensile and bend test specimens.
(2) Startup weld data sheets for use with the welding procedure specifi-cations are not formalized and implemented.
e a
_M"N Details Section (Prepared by R. E. Oller)
A.
Persons Contacted H. Cook, Welding Operator
- D. Coppock, Industrial Engineer G. Hyatt, Welding Operator J. Mashburn, Ultrasonic Technician - Level II R. McDowell, Radiographic Technician - Level II M. Newsom, Records Coordinator J. Thompson, Furnace Operator
- J. Wehrle, QA Manager
- Attended exit meeting.
B.
Review of Vendor's Activities 1.
Objective The objective of this area of the inspection was to assess the vendor's activities and their impact on future NRC inspections.
2.
Method of Accomplishment The preceding objectives were accomplished by:
a.
Discussions with cognizant personnel, b.
Review of two (2) lists of Trent Tube's customers to whom SA-312 ASME Code,Section III, Class 1, 2 and 3 piping, and SA-358 ASME Code,Section III, Class 1, 2 and 3 piping had been supplied during 1978 and 1979.
c.
Review of the QA Manual to verify that it included the QA program necessary to assure product conformance to the ASME Code,Section III, Classes 1, 2, and 3, for welded tubular products welded both with and without filler metal.
3.
Findinas a.
During 1978 and 1979, Trent Tube manufactured SA-312, ASME Code, Class 1, 2 and 3 piping for approximately nine (.9) different distributors and/or fabricators. They also
_4_
manufactured SA-358, ASME Code, Class 1, 2 and 3 piping for nine (9) different distributors and/or fabricators.
b.
The QA Manual provides the QA programs required by ASME Code,Section III, NCA-3800 and NCA-4000 for material manufacturers and certificate holders.
c.
The Trent Tube Division of Crucible, Inc. located in Carrollton, Georgia has a valid Quality Systems Certificate (Materials) No. N-1781, and a valid certificate of Authorization No. N-2016 to use the NPT s',mbol.
d.
The Trent Tube Plant has capabilities to manufacture A-312 and SA-312 piping of standard sizes in nominal outside diameters of three (3) through thirty (30) inches with wall thickness of 0.083 through 0.378 inches; forty (40) through forty-eight (48) inches 0.D. with wall thickness through 0.500 inches, and can produce this type pipe in a sixty (60) inch 0.D. Capabilities for manufacturing SA-358 piping include piping of six (6) through thirty (30) inches 0.D. with wall thicknesses of 0.188 through 0.625 inches for selected 0.D.s.
C.
SA-312 Piping Manufacturina Process Control 1.
Objectives The objectives of this area of the insper. tion 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 manu-facturing processes are controllei in accordance with appli-cable codes.
b.
Measures have been established and implemented to control the manufacturing processes by use of process sheets.
travelers, checklists or procedures.
c.
The process sheets, travelers, checklists or shop procedures used included: the document numbers and revisions to which the processes, inspections or tests conformed; the results of completion of the specific operations; the signature, initials or stamp of the manufacturer's responsible represen-tative and date are shown for operations completed.
d.
The plant equipment and facilities are adequate to manufacture the product, and are laid out in such a manner as to provide an organized sequence of operations and inspections and preclude by-passing of required operations and inspections.
2.
Method of Accomplishment The preceding objectives were accomplished by:
a.
Review of the QA Manual Section: No. 12.0, " Process Control",
and No. 15.0, " Manufacturing Prc esses."
b.
Observation of the following equipment and facilities used in manufacturing SA-312 piping and discussions with cognizant personnel concerning the operations performed at the respective locations:
(1) Two (2) continuous type tube mills (one automatic Gas Tungsten Arc welding "GTAW" machine and one automatic combination Plasma Arc and GTAW welding machine) used for forming, welding and cutoff of three (3) through six (6) inch nominal 0.D. piping. Also, the calibra-tion status of ammeters and voltmeters for the I.D. and 0.D. torches and the flowmeters for proportioning the percentages of Helium, Argon and Hydrogen gases for torch shielding and trailing shielding.
(2) Two (2) batch type automatic GTA welding machines. Also, the calibration status of the ammeters, voltmeters and gas flowmeters for these machines.
(3) The acid etching operation of the weld cross section for checking of weld penetration of pipes welded on the batch mill. Also the flattened ring test for piping welds made on the continuous mill.
(4) Alkaline degreasing tanks.
(5) Roller Hearth heat treatment furnace No. 723 equipped with water spray quenching apparatus, and the calibration status of the temperature recorder-controllers.
(6) The thirty-six (36) inch heat treatment furnace and the related recorder-controllers.
(7) The roller straightener mill.
(8) Three (3) hydrostatic testers.
(9)
Pickling and rinsing tanks and related equipment.
(10) Plate forming apparatus such as: the plate bending roller mill and the press brake forming mill.
(11)
Forging and roller planish lsq mills for cold working and smoothing the I.D. and 0.0. pipe weld beads.
(12) The 160 KV Fluoroscope x-ray machine used for pre-liminary examination of pipe welds.
(13)
Final dimensional inspection and nondestructive examination areas and facilities.
c.
Review of the following procedures (other than welding and ultrasonic tests) used in manufacture of SA-312 piping:
(1) No. QDP-015-C1, Recision 0, " Degreasing Procedure."
(2) No. QDP-014-C1, Revision 2, " Heat Treatment Procedure, Roller Hearth Furnace."
(3)
No. QDP-014-C2, Revision 1, " Heat Treatment Procedure, 36" Annealing Furnace."
(4) No. QDP-106, Revision 1, " Hydrostatic Pressure Test Inspections."
(5) No. PCS-020-C1, dated December 16, 1970, " Quality on Time Operating Procedure - Planishing."
d.
Review of in-process and completed Mill Order Travelers.
(The specific Mill Orders are identified in the report areas covering welding and ultrasonic testing).
3.
Findings a.
Deviations From Coi.'...i tments None.
b.
Unresolved Items
. The QA Manual paragraph 12.2 indicates that one function of the Mill Order (M.0.) travelers is to identify the procedures with revision numbers to be followed for the operations.
Review of M.0.s established that this was not being done for operations such as forming, pickling, passivating, planishing and degreasing.
The QA Manager indicated that it was not his intent to require that these operations be identified with a procedure number on the M.0., as they did not require a quality related documented report. The QA Manager indicated that he will revise the QA Manual to clarify the above requirement.
This item remains unresolved, pending revision during a subsequent f4RC inspection.
D.
SA-312 Piping Fitup and Welding 1.
Objectives The objectives of this area of the inspection were to verify that the following items were controlled in accordance with applicable f1RC and ASME Code requirements.
a.
A written system has been established to assure that welding is performed and controlled in accordance with applicable codes and procedure specifications.
b.
The work is conducted in accordance with a process control document such' as a traveler.
c.
Applicable qualified welding procedure specifications (WPS) and weld data sheets are used at the work stations, d.
The requirements of essential variables and other applicable WPS parameters are complied with to produce weldments having the required properties.
e.
The welding is being perfonned by properly qualified personnel.
f.
Weld joint geometry, fitup alignment, and surface pre-paration are as required by the applicable WPS and the Code.
g.
Tack welding is performed by qualified welders using qualified WPS.
h.
The welding equipment is in good condition and calibrated, where required.
1.
The completed weld meets code requirements for nondestructive examination suitability, undercut and other visual acceptance standards.
2.
Method of Accomplishment The preceding objectives were accomplished by:
a.
Review of the QA Manual Section 13.0, " Welding."
b.
Review of the following Welding Procedure Specifications (WPS) and their supporting Procedure Qualification Records (PQR) used in manufacturing SA-312 piping,. to verify that the procedures were developed and qualified in accordance with the ASME Code, Sections III and IX:
(1) WPS No. TWP-1B, Revision 6 and PQRs Nos. TWP-1-Q3 through Q14 for automatic batch type machine GTA welding.
(2) WPS No. TWP-6A, Revision 3 and FQR No. TWP-6-Q1 for automatic batch type machine GTA welding.
(3) WPS No. TWP-7A, Revision 3 and PQR No. TWP-7-Q1 for automatic continuous type machine GTA welding.
(4) WPS No. TWP-22A, Revision 2 and PQR No. TWP-22-Q1 for automatic continuous type machine welding using both the Plasma Arc (PA) and GTA welding processes.
(5) WPS No. TWP-3C, Revision 2 and PQR No. TWP-3-Q3, for manual tack welding using the PA process.
(6) WPS No. TWP-38, Revision 2 and PQR No. TWP-3-Q2 for manual tack welding using the GTAW process.
c.
Review of a draft copy of startup weld data sheets specific to each WPS used for welding on different automatic welding machines, to verify that strict control is provided for welding parameters in relation to pipe wall thicknesses.
d.
Review of Trent Tube " Welder Operator Qualification Record" for January, 1979, to verify that the welder operators performing welding were qualified.
e.
Observation welding of T-304, SA-312, ASME Code, Class 2, 14" nominal 0.D. pipe No. GJ-931 on batch mill No. 717
. (automatic GTA welding machine) using WPS No. TWP-1B, Revision G, to verify that the procedure was being complied with.
f.
Observation of welding of T-304, SA-312, ASME Code Class 2, 5" nominal 0.D. piping in 41'- lengths, Bundle No. 26, M.0.
3-C5-41203-5-0, on the continuous mill No. 715, usin'g the combination PA and GTA welding procedure TWP-22A, Revision 2, to verify that the procedure was being complied with.
g.
Review of the following records of related mill orders (M.0.) and Welding Reports (WR) to verify that the M.0.
traveler identified the WPS and Revision number and the signoff of the completed operations, and that the welding report properly documented the welding:
(1)
M.0. Sheet No. 7-C5-45033-9-0, and the WR dated February 28, 1979, for Tube No. 933, welded on February 28, 1979.
(2)
M.0. Sheet No. 2-C5-40937-8-0, and WRs for nine (9) tubes Nos. GJ-612 through GJ-621, welded on October 18, 1978, and October 19, 1978.
(3)
M.0. Sheets No. 6-C5-40821-8-0, and WRs for 25 tubes Nos. GJ-408 through GJ-432, welded on August 17, 1978, and August 18, 1978.
(4)
M.0. Sheets No. 2-C5-40535-8-0, and WRr or 2 tubes Nos. MA-841 and MA-842, welded on June 6, 1978.
h.
Observation of a Fluoroscope examination of a seam weld in a T-304, A-312 stainless steel pipe.
i.
Discussions with cognizant personnel.
3.
Findings a.
Deviations From Commitments
- None, b.
Unresolved Items (1) Review of procedure qualification records ho. TWP-1-Q5 and No. TWP-1-Q8 for welding procedure specification
. No. TWP-1B, showed that these PQRs did not contain the laboratory test numbers for traceability to tensile and bend test specimens. Trent Tube will correct these records.
(2) The startup weld data sheets for use with welding procedure specification are not formalized and imple-mented. Trent Tube will complete the necessary action for these welding parameter control sheets.
The above two (2) items remain unresolved pending Trent Tubes corrective action and review during a subsequent NRC inspection.
E.
SA-312 Piping Weld Heat Treatme A 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 rystea has been established to assure that heat treatment of weids is performed and controlled in accordance with applicable codes.
b.
Documented procedures are available and are implemented, when required by welding procedure specifications to control postweld solution annealing heat treatment in accordance with ASME Code requirements.
c.
The weld heat treatments are suitably documented, were required.
d.
The heat treating equipment is calibrated where required.
e.
The weld heat treatment is performed by qualified personnel.
2.
Method of Accomplishment The preceding objectives were accomplished by:
a.
Review of the OA Manual paragcaph 15.1, " Heat Treating."
b.
Review of procedure QDP-014-C1, Revision 2, " Heat Treatmerit Procedure, Roller Hearth Furnace-723."
i
. c.
Observation of in-process solution annealing of T-304, A-312 piping using the above furnace No. 723. Also, observation of the calibration status of the recorder-controllers for this f"rnace.
d.
R siew of the following records of Mill Orders (M.O.) and related heat treatment reports (HTR) for solution annealing of T.304, SA-312, ASME Code, Class 2 piping, to verify that the neat treatments were identified and signed off on the M.0.s and properly documented on reports and furnace charts.
(1)
M.0. Sheets 6-05-40829-8-0 and the related furnace chart and " Operator Report and Furnace Report", dated September 8,1978 for twenty-five (25) tubes.
(2)
M.0. Sheets 2-C5-405J5-8-0 and the related furnace chart and " Operator and Furnace Report", dated June 23, 1978 for Tubes No. MA-841 and MA-842.
(3)
M.0. Sheets 2-C5-40937-8-0 and the relate.d furnace charts and " Operator and Furnaca Reports", dated October 23, 1978 and October 25, 1978 for ten (10) tubes.
e.
Discussions with cognizant personnel.
3.
Results Within this area of the inspection, no deviations or unresolved items were identified.
F.
SA-312 Piping Testing of Comoleted Products 1.
Objectives The objectives of this area of the inspection were to verify that the following items were controlled in accordance with the applicable NRC and ASME Code requirements.
a.
A written system has been established to assure that final pressure tests are controlled in accordance with applicable procedures, specifications and codes.
b.
Final pressure tests are performed in accordance with approved procedures, instructions or specifications.
. c.
The results of tests are documented and reviewed for acceptability.
d.
The test equipment is calibrated where required.
e.
The tests are performed by qua~iified personnel.
2.
Method of Accomplishment The preceding objectives were accomplished by:
a.
Review of the QA Manual paragraph 15.4, " Pressure Testing."
b.
Review of the approved procedure No. QDP-106, Revision 1,
" Hydrostatic Pressure Test Inspections."
c.
Review of the following records of Mill Orders (M.O.) and related hydrostatic test reports (HTR) of T-304, SA-312, ASME Code, Class 2 piping,-to verify that the hydrostatic tests were identified and signed off on the M.0.s and properly documented in reports:
(1)
M.0. Sheets 6-C5-40829-8-0 and the related Hydrostatic Test Reports dated September 25, 1978 for twenty-five (25) tubes.
(2) M.0 Sheets 2-C5-40535-8-0 and the related Hydrostatic Test Report dated June 29, 1978 for Tubes MA-841 and MA-842.
(3)
M.0. Sheets 2-C5-40937-8-0 and the related Hydrostatic Test Reports for ten (10) tubes.
d.
Observation of the three (3) hydrostatic testers.
e.
Discussions with cognizant personnel.
3.
Findings Within this area of the inspection, no deviatio'ns or unresolved its.s were identified.
G.
SA-312 Piping Ultrasonic Examination 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 ultrasonic examination (UT) is performed in accordance with applicable codes.
b.
Final acceptance UT is performed in accordance with detailed written instructions or procedures which delineate require-ments and acceptance standards, c.
The UT procedures meet the requirements of the ASME Code and are qualified.
d.
The UT is performed and the results interpreted by certified personnel.
e.
Test results are docunented and evaluated to assure that the component or material examined contain no rejectable defects.
f.
Appropriate instruments are used, and the instruments are calibrated, where required.
2.
Method of Accomplishment The preceding objectives were accomplished by:
a.
Review of the QA Manual Section 14.0, " Nondestructive Examinati on. "-
b.
Review of the following six (6) ultrasonic examination procedures use.d in examining stainless steel SA-312 ASME Code, Class 1 and 2 piping and stainless steel plate used in the manufacture of SA-312 piping, to determine if these procedures provided the following information and require-m'nts in accordance with ASME Code:
1.
Requirements a.
The type of instrument and its frequency range, linearity and signal attenuation accuracy.
b.
The extent of coverage (beam angles, surface scanning rate and direction) and the scanning technique.
c.
The calibration requirements, including the calibra-tion block type, size and material and location and size of UT reflectors.
, d.
The sizes and frequencies of search units.
e.
The beam angles.
f.
The method of compensation such as a distance amplitude correction (DAC) curve or electronic DAC.
g.
The reference reflectors for accomplishing transfer.
h.
The reference level for monitoring discontinuities is defined and the scanning gain setting is specified.
1.
The levels or limits for evaluation and recording of indications.
j.
The method of recording significant indications and the reporting requirements.
k.
The acceptance limits.
2.
Procedures (a) No. QDP-110-C1, Revision 0, for examination of welds in 3"to 48" OD stainless steel pipe with
. wall thickness to 1", in accordance with ASME Code Section III,1974 Ed. and Winter 1976 Addenda.
(b) No. QDP-110-C1, Revision 1, for examination of welds in 3" to 48" 0.0. stainless steel pipe with wall thickness to 1", in accordance with ASME Code,Section III, 1977 Ed. and 1977 Summer Addenda.
(c) No. QDP-110-C2, Revision 1, for examination of 300 series stainless steel plate under 1" thick, in accordance with ASME Code,Section III, 1977 Ed. and 1977 Summer Addenda.
(d) No. QDP-110-C3, Revision 1, for examination of stainless steel pipe of 3" to 48" OD and wall thickness up to 1", in accordance with ASME Code,Section III,1977 Ed. and Summer 1977
~ Addenda.
4
a
. (e) No. QDP-110-C3, Revision 2, for examination of stainless steel pipe of 3" to 48" 0D and wall thickness up to 1", in accordance with ASME Code,Section III, 1977 Ed. with Addenda through the Winter 1978 Addenda.
(f) No. QDP-110-C5, Revision 2, for 100 percent' volumetric examination of pipe 6 3/4" diameter and under, requiring circumferential and axial scanning, in accordance with ASME Code,Section III, 1977 Ed. with Addenda through Winter 1978 Addenda.
c.
Observation of a demonstration of ultrasonic inspection by a Trent Tube Level II UT operator of the longitudinal weld in a 12.750" OD 0.375" wall, T-304, A-312 pipe using procedure QDP-110-C1, Revision 1, Calibration was performed using a working reference standard and m Automation Industries UM-771 ultrasonic device. The search unit was a 2.25 MHZ 0
45 shear wave transducer ir. combination with a lucite saddle adapter. The weld was scanned from both sides in a circumferential direction.
d.
Discussions, observations of work and review of Mill Order travelers to verify that the in shop ultrasonic examination of pipe is performed on piping after it has been pickled and passivated and wipe clean prior to examination.
e.
Review of the following records of Mill Orders (M.O.) and related ultrasonic examination reports (UER) of T-304, SA-312, ASME Code, Class 2 piping, to verify that the ultrasonic examinations were identified and signed off on the M.O.s and properly documented in reports:
(1)
M.0. Sheets 6-C5-40829-8-0 and the related Ultrasonic Examination Report dated September 27, 1978 for twenty-five (25) tubes.
(2)
M.0. Sheets 2-C5-40535-8-0 and the related Ultrasonic Examination Report dated July 6, 1978 for tubes MA-841 and MA-842.
(3)
M.0. Sheets 2-C5-40937-8-0 and the related Ultrasonic Examination Reports dated November 3, 1978 and November 8, 1978 for ten (10) tubes.
., f.
Review of the required records of training, qualification eye examination and certification for Trent Tubes Level III UT Examiner, and the Level II UT Technicians who perform the UT of al' SA 312, ASME Code, Class 1 and 2 piping, g.
Review of the " Record of Demonstration" of capability for Procedures QDP-110-C1, Revision 0, QDP-110-C2, Revision 0, and QDP-110-C5, Revision 0.
h.
Discussions with cognizant personnel.
3.
Findings a.
Deviatione From Commitments
- None, b.
Unresolved Items None.
H.
Exit Interview 1.
The inspector met with management reprasentatives denoted in paragraph A, at the conclusion of the inspection on March 1, 1979.
2.
The following was discussed:
a.
Areas inspected.
b.
The unresolved items identified in the report.
3.
Management's questions related to clarification of the above items.
.