ML19276E777
| ML19276E777 | |
| Person / Time | |
|---|---|
| Issue date: | 01/18/1979 |
| From: | Hunnicutt D, Oller R NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML19276E773 | List: |
| References | |
| REF-QA-99900267 NUDOCS 7903200600 | |
| Download: ML19276E777 (9) | |
Text
h U. S. tiUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND E?1FORCEMENT REGION IV Report No.
99900267/79-01 Program No.
51300 Company:
Tube Turns Division of Chemetron 7100 Katy Road, Post Office Box 393 Houston, Texas 77001 Inspection Conducted: January 3-5, 1979 M'fN/
Inspector:
'C R. E. Oller, Contractor Inspector, Vendor Date Inspection Branch Gb
/
/
Approved by:
e/
D. M. Hunnicutt, ' Chief, ComponentsSection II, Date Vendor Inspection Branch Summary Inspection on January 3-5, 1979 (99900267/79-01).
Areas Inscected:
Implementation of 10 CFR 50, Appendix B, criteria, other NRC requirements, and applicable codes and stindards including nonconformances and corrective action, material identificatica and control, procurement control consisting of document control - source selection and product acceptance, and action on previous inspection findings. The inspection involved twer.ty (20) inspector-hours on site.
Results:
In the four (4) areas inspected, no c'eviations were identified in three (3) areas.
The following was identiried in the remaming area.
Deviations:
Procurement Control:
Purchase orders for plate materials do not contain the statement, "no weld repair permitted without prior approval
~
by Tube Turns," as required by the QA Manual in accordance with Criterion IV.
Unresolved Items: Quality Control does not prepare Nonconformance and Corrective Action Reports for purchased materials found to be nonconforming during receiving inspection.
(Report Details, paragraph C.3.b.)
7903200 Wt Details Section (Prepared by R. E. Oller)
A.
Persons Contacted
- R. Avera, QC Specialist
- M. Barnes, Jr., P1 ant Manager
- P. Barkworth, Manager, Manufacturing Engineering
- Attended the Exit Meeting.
B.
Action on Previous Inspection Findings 1.
(Closed) Deviation A. (Report No 78-01); Failure to provide and use documented procedures to control the care and inspection activities for four (4) 10-ton and one (1) 20-ton overhead cranes, the related chains, hooks and slings, and other lifting devices used in the pipe shop. The inspector found that in accordance with Tube Turns response letter dated April 18, 1978, documented procedures, to control the above activities, were received from the Louisville plant on June 9, 1978. Review of reports of monthly inspections of the above lifting devices verified that the Louisville plant procedures were implemented at the Houston plant.
2.
(Closed) Deviation B-1 (Report No. 78-01); with regard to calibration of hydrostatic pressure gages:
Failure to label six (6) Master gages as " Master Gages", failure to maintain three (3) of the six (6) master gages within the required calibration frequency of three months and failure to attach the required calibration stickers with proper information on them to the six (6) gages.
The inspector found that in accordance with Tube Turns response letters dated April 18, 1978, and May 18, 1978, the following corrective and preventive actions were implemented. All the Master gages are now labeled as " Master" gages and have attached calibration stickers containing the proper information. The c?libration procedure TTHO-17-005 has been revised to require that crf..
the master gages will be calibrated on a three month frequency and the working gages will be calibrated prior to each series of tests by comparison to a master gage piped int, the test system. Observation of three master pressure gages and review of the related records verified that these gages were in calibration and the above requirement is being met.
3.
(0 pen) Deviation B-2 (Report No. 78-01); Failure to attach the required calibration label to the welding equipment shielding gas flow meter SN-R5007, and failure to provide the required calibration record card. The inspector found that in accordance with Tube Turns response letter dated April 18, 1978, plant management continues to search for an appropriate method to calibrate the above flow meter but have not resolved this deviation.
4.
(Closed) Deviation B-3 (Report No. 78-01); Failure to list the NBS X-ray step, Tablet Film Standard No. 1001, in the calibration instructions and schedules' contained in procedure TTH0-17-005.
The inspector found that in accordance with Tube Turns response letter ddted April 18, 1978, that procedure TTH0-17-005 has been revised and now includes the above standard in the calibration instructions and schedules part of the procedure.
Examination of the Calibration Certificate for the standard showed that it was purchased in October 1978, to meet the revised procedure requirements.
5.
(Closed) Deviation B-4 (Report No. 78-01); Failure to provide a calibration record card for the calibrated Linde gas metal arc welding machine No. 51033, as required by procedure TTH0-17-005.
The inspector found that in accordance with Tube Turns response letter dated April 18, 1978, that an inventory of all welding machines was performed which included the above equipment.
Serial number WMG-4006 was assigned to this machine and was traceable to a calibration record card.
6.
(0 pen) Unresolved Item (Report No. 78-01): The subject, " Training program" applicable to all personnel performing activities affecting quali~ /, was improperly included in the QA Manual Section TT22-214, " Audit Procedure." The inspector found that the QA Manual has not been revised to include the subject activity in an appropriate part of the QA Manual. Tube Turns QA Manager indicated this condition will be corrected.
C.
Nonconformances and Corrective Action 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 requirements.
a.
A written system has been established to assure that ncncon-formances are controlled and corrective action is taken.
b.
Documented procedures or instructions are implemented for identification, documentation, segregation and disposition of nonconforming materials, parts or components, and notification to affected organizations.
c.
Nonconforming items are reviewed and accepted, rejected, repaired or reworked in accordance with documented procedures.
d.
Conditions adverse to quality are promptly identified and corrected, e.
The causes of significant conditions adverse to quality are determined and corrected to preclude repetition.
f.
The condition adverse to quality, the cause and the corrective action are documented and reported to appropriate levels of management.
2.
Method of Accomplishment The preceding objectives were accomplished by:
a.
Review of the QA Manual Section TT22-213, "Nonconformances and Corrective Action."
b.
Review of the "Nonconformances" log maintained in the QA office, to verify that all material nonconformances are accounted for by QC personnel.
c.
Review of the following Nonconformance and Corrective Action reports and related process control documents cc:amon to the indicated material lot numbers, to verify that the noncon-forming items were identified, documented, reviewed, rejected, accepted or reworked and accepted, in accordance with the QA Program.
(1) Pipe lot No. J-2580-HC (a) Nonconformance and Corrective Action Report.
(b) Production Routing (traveler).
(c) Rework Routing (traveler).
(d)
Nonconformance Report and Record of Repair.
(2) Pipe Lot No. J-2294-HA (a) flonconformar. 'e and Corrective Action Report.
(b) Final Inspection Report.
(c) Supplemental Production Routing.
(3) Pipe Lot Nos. J-1903-HB, J-2043-HA, J-2013-HA, and J-2018-HL (a) Nonconformance and Corrective Action Report for four (4) pieces.
(b) Production Routing for piece J-1903-HB.
(c) Rework Routing for piece J-1903-HB.
(4) Pipe lot Nos. J-2267-HK and J-2267-HT Nanconformance and Corrective Action Report.
d.
Discussions with cognizant personnel.
3.
Findings a.
Deviations from Commitments
- None, b.
Unresolved Items The QA Manual requires that upon discovery of nonconforming purchased material at receiving inspection, that quality control shall be advised of the matter and they shall prepare a Nonconformance and Corrective Action Report and present 't to Purchasing or the Manager-Order Processing who will contact the vendor for disposition of the material. Discussion established that this activity was not the actual practice which is to write a rejection report and return the material to the vendor.
By telephone conversation on Januar, 18, 1979, Tube Turns QA Manager stated he will revise the QA Manaual to show the actual practice in use for disposition of nonconforming material found during receiving inspection.
This item remains unresolved pending Tube Turns corrective action and review of their action during a subsequent NRC inspection.
D.
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 applicable codes.
b.
Documented measures have been used for identification and control of materials and items, including partially fabri-cated assemblies.
c.
Identification is maintained 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 inter-fere with the function of the item.
e.
All characteristics required to be reported appear on Checklists or Certified Material Test Reports (CMTR), and the CMTRs have been received, reviewed, and found acceptable.
2.
Method of Accomplishment The preceding objectives were accomplished by:
a.
Review of the QA Manual Sections: TT22-202, paragraph 4.0,
" Control of Production"; TT22-205, paragraph 4.0, " Receiving and Release of Purchased Material"; and TT22-207, paragraph 2.0, "In-Process Inspection."
b.
Observations of material markings in the receiving inspection area and discussions with the receiving inspector to verify that the identification and marking of plate materials was conducted in accordance with the QA program.
Review of the Lot Number Log book to verify that all incoming c.
materials were controlled and accounted for.
d.
Observation of the low stress steel stamping identification data on plates at the trimming area and at the final inspection area to verify that permanent identification was maintained throughout the manufacturing process.
e.
Review of records of Final Inspection Reports, Production Routings, and Rubbings of Code Identification Stampings for Pipe Lot Nos. J-2580-HD and J-2580-H3 to verify that these inspection and process records provided the proper identi-fication and control of these materials.
f.
Discussions with other cognizant personnel.
3.
Findings Within this area of the inspection, no deviations or unresolved items were identified.
F.
Procurement 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 all applicable aspects of procurement are controlled, b.
Procedures have been prepared and approved by the ' company to prescribe systems for the following activities which are consistent with the commitments of the QA program.
(1) Procurement Document Control.
(2) Procurement Source Selection.
(3) Product Acceptance.
c.
The above procedures are being properly and effectively implemented by the company.
2.
Method of Accomplishment The preceding objectives were accomplished by:
a.
Review of the QA Manual Section TT22-205, " Procurement Control."
b.
Review of the following material purchase orders and QC Order Analysis records, to verify that these documents were developed, approved, and issued in accordance with the QA Program requirements.
. (1)
P.O. No. 9816-P, dated October 23, 1978, for plate material and the related QC Order Analysis for TT order HPM-437760, dated October 2,1978.
(2)
P.O. No. 9818-P, dated October 23, 1978, for place material.
(3)
P.O. No. 9828-P, dated November 14, 1978, for plate material.
(4)
P.O. No. 1608-P, dated November 14,1978, for 36,000 lbs. welding filler wire.
(5)
P.O. No. 8746-P for plate material and the related QC Order Analysis No. 427740.
c.
Review of the following purchase orders and a contract for calibration and maintenance services to verify that these documents were developed, approved, and issued in accordance with the QA program requirements.
(1)
P.O. No. 8643-Q1, dated April 10, 1978, for calibration and certification for three (3) pressure gages.
(2)
P.O. No. 7979-Q1, dated January 16, 1978, for calibration and repair of eight (8) pressure gages.
(3)
P.O. No.' 6510-M, dated July 14, 1974, for maintenance service on Honeywell instruments on the Sauder heat treatment furnace per the Maintenance Service Agreement.
(4) Review of the Maintanence Service Agreement No. 925-101506-77046, dated August 11, 1977, covering:
furnace surveys to be conducted every 6 months and calibration of furnace controls and recorders every 3 months, d.
Review of the " Approved Vendor List," dated October 1,1978, to verify that vendors of materials and services to the Tube Turns Houston Plant are qualified and approved in accordance with the ASME Code and the QA Program.
e.
Review of records of surveys by the TT Houston Plant manu-facturers from whom Tube Turns purchases plate material, to verify that the surveys were properly conducted.
f.
Review of the Materials Receiving Reports, Receiving Report Supplements, and Certified Material Test Reports for plate
. materials purchased on P.O. Nos. 9810-P and 9807-P to verify that these materials were received, inspected, evaluated, and accepted by QA in accordance with the QA program.
g.
Discussions with cognizant personnel.
3.
Findings a.
Deviations From Commitments See Notice of Deviation.
b.
Unresolved Items None.
G.
Exit Interview 1.
The inspector met with management representatives denoted in paragraph A. at the conclusion of the inspection on January 5, 1979.
2.
The following subjects were discussed:
a.
Areas inspected.
b.
Status of corrective action for previously identified deviations.
c.
The deviations identified during the inspection.
3.
The manufacturer's representatives were asked to tormulate the corrective action response to the deviation in accordance with the three (3) conditions identified in the inspection report cover letter.
4.
Management's comments were related to clarification of the finding.