ML19276E805
| ML19276E805 | |
| Person / Time | |
|---|---|
| Issue date: | 11/13/1978 |
| From: | Ellershaw L, Hunnicutt D NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML19276E793 | List: |
| References | |
| REF-QA-99900286 NUDOCS 7903210124 | |
| Download: ML19276E805 (12) | |
Text
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VENDOR INSPECTION BRANCH U. S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFCRCEMENT REGION IV Report No.
999002S6/78-02 Program No. 44030 Company:
Gaulin Corporation 44 Garden Street Everett, Massachusetts 02149 Inspection at:
Everett, Massachusetts Inspection Comiucted:
October 23-27, 1973 p ry a.\\
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~7 8 Inspector:
L.' E. Ellershaw, Contractor Inspector, Vendor
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1 Approved by:
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D. M. Hunnicutt, Chief, QomponentsSection II, Da te Vendor Inspection Branch Summary Inspection on October 23-27, 1973 (99900286/78-02) 4 Areas Inscected:
Implementation of 10 CFR 50, Appendix B criteria, and applicable codes and standards, including the control of nonconformances and corrective action, design process management, indoctrination and training, weld heat treatment, qualification of NDE personnel (visual), heat treat-rrent, and previous inspection findings. The inspection involved thirty (30) inspector-hours on site.
Results:
In the seven (7) areas inspected, six (6) deviations from commit-ment and one (1) unresolved item were identified.
Deviations:
Previcus Inspection Findings (Manufacturing Process Control) -
Quality Control inspectors failed to indicate completion of inspection operations on the Standard Operation Sheet and subsequent operations were completed which is contrary to Criterion X of Appendix B to 10 CFR 50 (Enclosure, Item A); quality control inspectors failed to record required inspections as having been performed on the Quality Control Log Report, 7903210lcN
_2 which is contrary to Criterion X of Appendix B to 10 CFR 50 (Enclosure, item B); Heat Treatment - a subcontractor failed to accomplish heat treat-rrent in accorda"ce with the applicable heat treat procedures, and the heat treat procedure used, including revision was not documented on the furnance chart which is contrary to Criterion IX of Appendix B to 10 CFR 50 (Enclosure, Item C); Design Process Management - the Specification Review Committee failed to sign the cover cheets, indicating review and approval, of certain Change Notices to a Customer purchase order, which incorporated revisions to the Customer's Equipment Specification, which is contrary to Criterion III of Appendix B to 10 CFR 50 (Enclosure, Item D); Qualification of Nondestructive Examination Personnel (Visual Examiners) - a subcontractor, performing visual examination on ASME Subsection NF, Class 2 welds, failed to qualify the visual examiner in accordance with ASME requirements, which is contrary to Criterion IX of Appendix B to 10 CFR 50 (Enclosure, Item E);
Weld Heat Treatment - post weld heat treatment was performed by a subcontractor in which the weld procedure specifications used had not been qualified for postweld heat treatment (Enclosure, Item F).
Unresolved Item:
Heat treatment - a subcontractor's heat treatment procedure, used to perform heat treatment of a cylinder for a charging pump, does not appear to meet the requirements of the ASME Code.
(Details Section, paragraph D.3.b.).
. DETAILS SECTION (Prepared by L. E. Ellershaw)
A.
Persons Contacted R. E. Bopp, Manager, Quality Assurance W. Chaplis, Director of Engineering L. A. Olenchak, Supervisor, Quality Control J. Pickett, Engineering Records Center Clerk J. E. Richard, Contract Administrator C. J. Scarano, Assistant QA Manager R. Scott, Shop Foreman B.
Action on Previous Inscection Findinas 1.
(Closed) Deviation A. (Report No. 78-01): This item dealt with unidentified parts being found in the QA Hold Area and in which the disposition had been made to scrap.
Gaulin Corporation (GC) has implemented their committed corrective action in that a review of the Hold Areas indicated that material was being properly identified.
2.
(Closed) Deviation B. (Report No. 78-01):
This item dealt with the failure of Industrial Engineering to review and approve released procedures, and the failure to retrieve obsoleted procedures and drawings after current revisions had been distri-buted.
GC has implemented their committed corrective action in that a review of procedures and drawings revealed that procedures have been reviewed and approved, and no obsolete procedures or drawings were observed in the manufacturing ;raas.
3.
(Closed) Deviation C. (Report No. 78-01): This item dealt with certain inspection operations not being stamped and dated by QC inspectors, while subsequent operations were stamped off.
GC has implemented their committed corrective action in that the specific operations cited, were subsequently corrected.
However, it appears that the action taken to prevent recurrence has not been adequate in that a similar deviation has been i denti fied.
(Detail Section, paragraph C.).
4_
C.
Previous Insoection Findings (Manufacturino Process Control) 1.
Objec;ives The objectives of this area of the inspection were to verify that Gaulin Corporation (GC) had implemented their committed corrective action, including actions to prevent recurrence, as delineated in their response letter to NRC, dated April 27, 1978.
2.
Method of Acccmolishment The preceding objective was accomplished by:
a.
Review of QA Manual Section 5, " Process Control", dated April 11, 1976.
b.
Review of Standard Operation Sheets.
c.
Review of Quality Control Log Reports.
d.
Discussions with cognizant personnel.
3.
Findinas a.
Deviations From Commitments (1)
It was determined that Gaulin Corporation's action to prevent recurrence were not adequate, in that a devia-tion similar to one reported in Inspection Report No.
78-01 was identified.
See Enclosure, Item A.
(2) Additionally, a new deviation was identified.
See Enclosure, Item B.
b.
Unresolved Item None.
D.
Heat Treatment 1.
Objectives The objectives of this area of the inspection were to verify that GC had implemented the requirements for the control of heat treatment of pieces and materials in accordance with the QA Manual and applicable NRC and ASME Code requirements.
. 2.
Method of Accomolishment The preceding objectives were accomplished by:
a.
Review of QA Manual Section 8, " Heat Treating", dated April 11, 1976.
b.
Review of P.O. 20868 to a subcontractor, invoking the use of Heat Treat Procedure No. GNV-42, Revision 2.
Review of the furnace charts for a suction and discharge c.
flange, relative to P.O. 20868.
d.
Review of the subcontractor's Report of Physical Tests and Chemistry, which stated that the suction and discharge flanges were heat treated in accordance with procedure GNV-42, Revision 2.
e.
Review of Heat Treat Procedure GNV-42, Revision 2.
f.
Discussions with cognizant personnel.
3.
Findinas i
a.
Deviation From Commitment See Enclosure, Item C.1. and C.2.
b.
Unresolved Item ASME Code,Section III, Subsection NB, NC, ND, NF, paragraph 2180 states, "When heat treating temperature or time is required by the material specification and the rules of this Subsection, the heat treating shall be performed in temperature-surveyed and -calibrated furnaces or shall be performed with thermocouples in contact with the material or attached to blocks in contact with the material.
Heat I
treating shall be performed under furnace loading conditions such that the heat treatment is in accordance with the material specification and rules of this Subsection."
Paragraph 1.3 of a subcontractor's heat treat procedure (HTP-11, Revision 2, dated August 12,1977) which was used to heat treat a cylincer for charging pump, S/N 78H001, states in part, "... temperature is measured by six (6) thermocouples
. (Chromel-Alumel) per furnace placed six (6) inches above hearth level and continually checked and recorded on multiple point recording Honeywell instruments."
There was no evidence to substantiate whether or not the subcontractor's furnace had been tetrperature-surveyed, and the wording of the procedure is such that the thermocouples may or may not have been in contact with the material or attached to blocks which are in contact with the material.
E.
Desinn Process Management 1.
Objectives The objectives of this area of the inspection were to verify that GC had implemented the requirements for design process management in accordance with the QA Manual and applicable NRC and ASME Code requirements.
2.
Pethod of Accomolishment The preceding objectives were accomplished by:
a.
Review of QA Manual Section 2, " Design Control", and Section 3, " Order Entry", both dated April 11, 1976.
b.
Review of Customer's P.O. 546-CAG-240790 BN and subsequent Change Notices.
c.
Review of Customer's Equipment Specification 952320, Revision 0, and interim change numbers 8 and 11.
d.
Review of the cover sheets to the Customer Design Specifica-tions to verify review and approval by GC's Specification Review Committee.
e.
Discussions with cognizant personnel.
3.
Findings Deviation From Commitment See Enclosure, Item D.
Unresolved Item None.
. F.
Qualification of Nondestructive Examination (NDE) Personnel - Visual Examiners 1.
Objectives The objectives of this area of the inspection were to verify that GC had implemented the requirements for assuring that subcontractor's nondestructive examination personnel were qualified in accordance with the QA Manual and applicable NRC and ASME Code requirements.
2.
Method of Accomolishment The preceding objectives were accomplished by:
a.
Review of QA Manual Section 6, " Nondestructive Examination",
dated April 11, 1976.
b.
Review of a GC purchase order to a subcontractor (P0 22057 dated August 30, 1977), requiring Visual Inspection of welds.
c.
Review of the subcontractor's documentation relative to their performance of the requirements of P.O. 22057.
d.
Review of the subcontractor's NDE certification record relative to a visual examiner.
e.
Discussions with cognizant personnel.
3.
Findinos a.
Deviation From Commitment GC placed purchase order 22057 with a subcontractor, to weld and perform visual examination of the welds in accordance with ASME Boiler and Pressure Vessel Code,Section III,1974 Edition up to and including the Winter,1975 addenda, Sub-section NF, Class 2 (Component Support - Pump Pedestal). The subcontractor subsequently performed the welding and visual inspection, and submitted the required documentation to GC.
The Certificate of Compliance from the subcontractor, dated October 24, 1977, states in part, "All welders and examina-tion personnel are qualified in accordance with ASME Section III."
. The subcontractor's Weld Data Report stated that weld joint numbers 1 through 12 were welded and inspected on October 11, 1977 and October 13, 1977 (some of the welds had to be removed, rewelded and re-inspected).
However, a review of the subcontractor's Quality Control Inspection Report dated October 24, 1977, stated "NDE Welding Inspection-M/A" (not applicable).
Also, the subcontractor's NDE Certification Record for the person who performed the visual inspection states in part, Name:
- EJC, Date:
October 3, 1977, NDE Method - Visual Examination Level:
(No level indicated)
NDE Experience:
PT and MT Examination - Actual Grade:
General N/A Specific N/A Practical N/A Percentile Weight Factor:
General N/A Specific N/A Practical N/A This form was signed by the subcontractor's Level III Examiner on October 3, 1977. Thus, it appears that visual examination of welds as required by ASM.E Subsection NF, Class 2 Component Supports, was performed by a visual examiner that had not been qualified in accordance with the ASME Code, which requires that NDE personnel be qualified by written and practical examinations.
See Enclosure, Item E.
b.
Unresolved Item None.
G.
Weld Heat Treatment 1.
Objectives The objectives of this area of the inspection were to verify that GC had implemented the requirements for the acccmplishment of weld heat treatment in accordance with the QA Manual and applicabSe NRC and ASME Code requirements.
. 2.
Method of Accomolishment The preceding objectives were accomplished by:
a.
Review of QA Manual Section 8, " Heat Treating", dated April 11, 1976.
b.
Review of GC purchase order 22057 to a subcontractor.
c.
Review of weld procedure specifications (WPS) and the applicable procedure qualification records (PQR).
d.
Review of the subcontractor's Certification of Ccmpliance relative to the performance of the purchase order require-ments.
e.
Review of subcontractor's procedure number SP9315-650, Revision 2, "Postweld Heat Treatment", which is identified by GC number GNV 51, Revision 2.
f.
Review of subcontractor's furnace chart shcwing postweld heat treatment.
g.
Discussion with cognizant personnel.
3.
Findinas a.
Deviation From Commitment GC placed purchase order 22057 with a subcontractor, to perform the following operations in accordance with the ASME Code,Section III, Subsection NF, Class 2:
"1.
Weld in accordance with GNV-33, Revision 1 and/or GNV-34, Revision 1 (which was subsequently changed to GNV-32, Revision 0 - Gas Metal Arc Welding, and/or GNV-35, Revision 1 - Shielded Metal Arc Welding, in Revision 1 to the purchase order).
2.
Visual Inspection of Welds.
3.
Material Certification of Compliance is required.
4.
Authorized Nuclear Insoector must be notified - Code Date and NPT stamp must be supplied.
5.
Stress Relieve and sand blast."
. c.
Discussions with cognizant personnel.
3.
Findings a.
Deviation From Commitment None.
b.
Unresolved Item None.
I.
Nonconformances and Corrective Action 1.
Objectives The objectives of this area of the inspection were to verify that GC had implemented the requirements for the control of nonconfor-mances and corrective action in accordance with the QA Manual and applicable NRC and ASME Code requirements.
2.
Method of Accomolishment The preceding objectives were accomplished by:
a.
Review of QA Manual Section II, "Nonconformities", dated April 11, 1976.
b.
Observations and review of nonconforming parts and related documentation, as identified in the designated " hold" areas.
c.
Review of " Nonconforming Material Reports. '
d.
Review of Material Review Board activities.
e.
Review of "In-House Corrective Action Reports."
f.
Discussions with cognizant personnel.
3.
Findings a.
Deviation From Commitment None.
~
a b.
Unresolved Item fione.
J.
Exit Interview A meeting was held at the conclusion of this inspection on October 27, 1978, with the following management representatives in attendance:
R. E. Bopp, Manager, Quality Assurance D. G. Colony, President R. H. Cooper, Executive Vice President C. J. Scarano, Assistant Quality Assurance Manager The scope and findings of this inspection were summarized.
Management acknowledged the statements relative to the findings.
.