ML19276G118
| ML19276G118 | |
| Person / Time | |
|---|---|
| Issue date: | 03/02/1979 |
| From: | Jerrica Johnson, Kelly W, Whitesell D NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML19276G115 | List: |
| References | |
| REF-QA-99900060 NUDOCS 7905150585 | |
| Download: ML19276G118 (15) | |
Text
{{#Wiki_filter:. U. S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT REGION IV Report No. 99900060/79-01 Program No. 44060 Company: Target Rock Corporat' ion 1956 East Broadhollow Road Inspection at: East Farmingdale, New York 11735 Inspection Conducted: February 6-9, 1979 Inspectors: / [ f 8(( 14 William D. Kelley~, Contragtpr Inspector, 'Date ' Vendor Inspection BranchJ Qm.(k~~ y-In J.1/1 Johnsonj Contractor Auditor, Vendor Date InspectioFBranch Approved by: / a /, ~ -7 7[79 D. E. ~Whitesell, Chief, Comppne es Section I, ' Da t'e / Vendor Inspection Branch I Summary Inscection on February 6-9, 1979 (99900060/79-01). Areas Inspected: Implementation of 10 CFR 50, Appendix B and other applicable regulations including design verification, procurement control - procedures, document and drawing control, control of special processes - heat treating, training, and audits. The inspection involved forty-eight (48) inspector-hours on site by two (2) NRC inspectors. Resul ts: In the six (6) areas inspected no deviations or unresolved items were identified. 7905.150575
. DETAILS SECTION I (Prepared by W. D. Kelley) A. Persons Contacted Tarcet Rock Corporation (TRC)
- G. A. Abruzzo, Manager Quality Assurance R. McIntyre, Design Manager F. Merichner, Level III, Product Quality Engineer A. Lloyd, Production Manager
- V. Liantonio, Manager of Engineering
- D. M. Pattarini, Vice President of Engineering
- Denotes those persons who attended the exit interview (See paragraph G).
B. Control of Soecial Processes (Heat Treatment) 1. Objectives The objectives of this area of the inspection were to verify that: a. Procedures had been prepared and approved by the vendor to prescribe a system for the heat treatment of material and parts which is consistent with NRC rules and regulations, ASME Code requirements, and the vendor's commitments in the ASME accepted Quality Assurance Program. b. The heat treatment procedures are being properly and effectively implemented by the vendor. 2. Method of Accomolishment The objectives of this area of the inspection were accomplished by: a. Review of the ASME accepted Quality Assurance Manual Revision 3, Change Notice No. 3, Section 9.0 Heat Treating. b. Review of the following procedures: (1) TRC QCI-2120 Revision C, Control of Special Processes - Heat Treating.
. (2) TRC Report 1312 Revision D, Heat Treating Requirements for Precipitation Harding Stainless' Steel (17-4 PH), to verify they had been prepared by the designated authority, approved by the responsible mr:1agement, and reviewed by the quality assurance staff. c. Review of the procedure referenced in paragraph b.2. above, and TRC certifications and heat treating furnace charts, to verify that the material heat treatment used to enhance the mechanical properties of high alloy steel is conducted in accordance with the approved procedure. d. Review of the procedures referenced in paragraph b. above, to verify: (1) The furnace atmosphere is controlled. (2) The furnace temperature distribution is measured, and the measuring and recording devices calibrated. (3) Thermocouples are installed on the parts to be heat treated. (4) The heating and cooling rate is specified. (5) Record and documentation requirements are specified. e. Review of the following certifications; (1) TR Certification 79-212, (2) TR Certification 79-312, and (3) TR Certification 79-313, to verify conformance with applicable procedures: ASME Code requirements, and contract requirements. 3. Findings a. The inspector verified that: (1) Procedures have been prepared by the vendor which prescribes a system for the heat treatment of material and parts which is consistent with NRC rules and
. regulation, ASME Code requirements, and the vendor's commitments in the ASME accepted Quality Assurance Program. (2) The heat treatment procedures are being properly and effectively implemented by the vendor. b. Within this area of the inspection no deviations or unresolved items were identified. C. Audits 1. Objectives The objectives of this area of the inspection were to verify that: a. Procedures have been prepared, and approved by the vendor, which prescribes a system for auditing which is consistent with NRC rules and regulation, ASME Code requirements, and the vendor's commitments in the ASME accepted Quality Assurance Program. b. The audit procedures are being properly and effectively implemented by the vendor. 2. Method of Accomplishment The objectives of this area of the inspection were accomplished by: a. Review of the ASME accepted Quality Assurance Manual Revision 3, Change Notice No. 3; (1) Section 1.0, General, (2) Section 6.0, Control of Vendors, and (3) Section 15.0, Audits, Corrective Action, and Training, to verify that the vendor has established procedures prescribing a system for audits. b. Review of the following procedures; (1) TR 1660 dated December 2,1975, Qualification of Audit / Survey Personnel;
. (2) QCI-2500 Revision E, Quality Monitoring, and Internal Audit Program; and (3) QCI-1802 Revision H, Evaluation and Selection of Sub-contractorr; to verify they had been prepared by the designated authority, approved by responsible management, and reviewed by the quality assurance organization. c. Review of the procedures referenced in paragraph b. above, to verify that they identified the organization responsible for auditing, established audit personnel qualifications, provided for training and indoctrination of audit personnel. Also, to verify that the essential elements of the audit system have been established and provides audit schedules or controls to assure coverage of all elements of the quality assurance program, and that the results of audits are docu-mented and that follow-up audits are required to verify that corrective action has been implemented. d. Review of approximately twenty (20) audit reports to verify that the procedures and other audit documents were available to the auditing personnel, and that the procedures are being properly and effectively implemented. 3. Findings a. The inspector verified that: (1) Procedures had been prepared and approved by the vendor which prescribes a system for auditing which is consistent with NRC rules and regulation, ASME Code requirements, and the vendor's commitments in the ASME accepted Quality Assurance Program. (2) The audit procedures are being properly and effectively implemented by the vendor. b. Within this area of the inspection no deviations or unresolved items were identified.
. D. Procurement Control (Procedure, Document, and Drawing Centrol) 1. Objectives The objectives of this area of the inspection were to ascertain whether procedures have been developed and properly implemented to control the review, approval, release and issuance, of proce-dures, documents, and drawings, in a manner consistent with NRC rules and regulations, ASME Code requirements, and the vendor's commitments in his ASME accepted Quality Assurance Program. 2. Method of Accomolishment The objectives of this area of the inspection were accomplished by: a. Review of the ASME accepted QA Manual, Revision 3, Change Notice 3; Section 4.0 " Design, Drawing, Specification, and Procedure Control" to verify that the vendor had established procedures which prescribes a system for procedure, document, and drawing control. b. Review of procedure OCI 1500, Revision E, " Release and Control of Engineering Drawings" and " Maintenance of Engineering Files" to verify that they had been prepared by the designated authority, approved by management, and reviewed by QA. c. Review of the procedure referenced in b. above, to verify that it identifies the personnel responsible for preparing, reviewing, approving, and issuing procedures, documents, and drawings; and that the review and approval of significant changes are performed by the same personnel. Also, to ascertain whether minor changes to design drawings that do not require design approval, are identified. d. Review of the following documents; (1) TR QC Form 54A-Revision 5-20-77, Engineering Release Sheet-Drawing, (2) TR QC-72-1, Revision B, Specification Data Sheet, and (3) Defective Trend Analysis,
. to verify that the distribution list is current, and that the proper documents are identified, accessible, and are being used. e. Interviewed personnel to verify whether they are knowledgeable in the procedures applicable to procedure, document, and drawing control. 3. Findings a. The inspector verified that procedures had been developed and properly implemented to control the review, approval, release and issuance of drawings, procedures and documents in a manner consistent with NRC rules and regulation, ASME Code requirements, and the vendor's commitments in his ASME accepted Quality Assurance Program. b. Within this are of the inspection no deviations or unresolved items were identified. E. Manufacturing Process Control 1. Objectives The objectives of this area of the inspection were to verify that the vendor's manufacturing processes are: a. Performed under a controlled system which meets the NRC rules and regulation, ASME Code requirements, the vendor's commitments in his ASME accepted Quality Assurance Program, and contract requirements. b. Effective in assuring product quality. 2. Method of Accomolishment The objectives of this area of the inspection were accomplished by: a. Review of the ASME accepted Quality Assurance Manual, Revision 3, Change Notice No. 3; (1) Section 2.0, Authorized Nuclear Inspector, (2) Section 5.0, Material Control,
. (3) Section 7.0, Process Control, and (4) 13.0, Nonconforming Parts, to verify that procedures had been established which prescribes a system for the control of the manufacturing processes. b. Review of the section of the Quality Assurance Manual referenced in paragraph a. above, to verify that the control system provides for the use of shop travelers or process control check list, containing document numbers and revisions to which the process must conform, and requires that all processes and test to be performed by qualified personnel using qualified procedures. c. Review of the shop traveler or process control check lists,, to verify that it has spaces for reporting the results of specific operations, or reference to other documents where the results are maintained. Also verify that space is provided for signoff indicating the date on which the operation or test was performed, and that space is provided for the signoff and date by the authorized nuclear inspector for these activities which he witnesses, d. Review of selective shop travelers on Project No.; (1) 77-DD, and (2) 76-BADD to verify the implementation of the above referenced proce-dures and the overall QA program documentation requirements, including the establishment of mandatory hold points by the authorized nuclear inspector. e. Interviews with personnel to verify they are knowledgeable in the procedures applicable to manufacturing process control. 3. Findinol a. The insoector verified that the vendor's manufacturing processes are: (1) Performed under a controlled system which meets NRC rules and regulations, ASME Code requirements, the
-g-vendor's commitments in his ASME accepted Quality Assurance Program, and contract requirements. (2) Effective in assuring the specified product quality. b. Within this area of the inspection no deviations or unresolved items were identified. F. Training 1. Objectives The objectives of this area of the inspection were to ascertain whether: a. Procedures have been develcped and approved, which prescribes a system for training personnel performing quality related activities, in a manner consistent.with NRC rules and regulations, ASME Code requirements, and the vendor's QA program commitments. b. The training procedures are being properly and effectively implemented. 2. Method of Accomplishment The objectives of,this area of the inspection were accomplished by: a. Review of the ASME accepted QA Manual Revision 3, Change Notice No. 3; (1) Section 1, General, and (2) Section 15, Audits, Corrective Action and Training to verify that the vendor has established procedures which prescribe a system for training personnel whose activities affect quality. b. Review of the following procedures: (1) TR 1660 dated December 2,1975, Qualification of Audit / Survey Personnel, (2) Procedure No.1439, Revision A, Qualification Procedure - Inspection Personnel, Production Test Personnel,
- (3) QCI-2800, Revision F, Training of Inspection and Test Personnel, and (4) QCI-2140, Revision B, Destructive and Nondestructive to verify that they had been prepared by the designated authority, approved by management, and reviewed by QA, and that they provide formal training for new employees; and retraining to improve or maintain tne proficiency of inspection and testing personnel, personnel performing special processes, audit personnel, and personnel involved in quality related design and procurement activities. c. Review of the following procedures; (1) TRC Repcrt No.1932A NDE Personnel Examint. ion /Qualifica-tion Procedures for ASME Section III, and (2) Report No. 2036, Revision 0, Memorandum - Indoctrination and Orientation Engineering Department to verify that they provided for the indoctrination of the technical requirements of the product, the codes and standards to be used, and the quality assurance / control elements that are to be employed. Also, verify that they provided for testing the capability and proficiency of nondestructive testing personnel, and retraining and recertifying if required. d. Review of training records of inspectors, nondestructive testing personnel, auditors, designers and quality assurance and procurement personnel to verify the procedures and necessary training documents were available to the personnel performing the training and the training procedures were being properly and effectively implemented. e. Interviewed personnel to verify whether the training performed was commensurate with the persons assigned quality affecting duties. 3. Findinas a. The inspector verified that: (1) Procedures had been developed, and approved, prescribing a system for training personnel, whose activities affect
. quality, in a manner consistent with NRC rules and regulations, ASME Code requirements, and the vendors commitments in the ASME accepted Quality Assurance Program. (2) The training procedures are being properly and effectively implemented. b. Within this area of the inspection no deviations or unresolved items were identified. G. Exit Interview At the conclusion of the inspection on February 9,1979, the inspectors met with the company's ~ management, identified in paragraph A, for the purpose of informing them as to the results of the inspection. The company's management acknowledged the inspector's comments as being understood, but had no additional comments.
- DETAILS SECTION II (Prepared by J. M. Johnson) A. Persons Contacted
- G. Abruzzo, Quality Assurance Manager
- V. Liantonio, Engineering Manager, Code Products M. S. McClintock, Project Engineer
- Denotes those present at exit meeting.
B. Design Document Control 1. Objectives The objectives of this area of inspection were to examine the establishment and implementation of quality-related procedures to determine whether design activities were defined and implemented; purchase order requirements including design inputs and QA and ASME Code requirements were followed; design docu-ments were controlled; final design incorporated design inputs; design verification methods were documented; and testing was performed to procedures and was evaluated. 2. Method of Accomolishment The preceding objectives were accomplished by an examination of the following documents related to 2" HPSI (High Pressure Safety Injection) valves and 3" HLI (Hot Leg Injection) valves supplied for five (5) nuclear plants: a. Target Rock Corporation Quality Assurance Manual, Revision 2 (scope was for pressure boundary components) and Revision 3 (scope also included essential non-pressure boundary components) effective August 21, 1974, and Change Notices 1, 2, and 3: Section 4 (Design, Drawing, Specification and Procedure Control) and Section 7 (Process Control) which includes testing and QA document package requirements. These were examined to determine that QA design process requirements were in accordance with the objectives stated above for original manufacture and subsequent modification.
I b. Documents related to 71J valves to assure implementation of design process requirements: (1) Purchase Order No. 9101861 to Target Rock dated June 14, 1371, and Supplements 1 through 12. The purchase order included the following invoked documents: . WQC 11.1, Revision C dated flovember 30,1970,(QA Requirements attachment). . Project Technical Specification 6370-PE-705 which includes design inputs and Data Sheet showing required operational parameters including a C of 12-14. y (C is the flow coefficient). y (2) Target Rock Design Report No. 2085 (Calculation of Maximum Torque Capability of Valve Stem for 71J-002). (3) Target Rock Flow Test Procedure - Report No. 1373, approved and dated June 13, 1973. (4) Target Rock results of flow test and their transmittal to buyer by CN 2010 dated August 20, 1973. (5) Buyer's TWX dated September 13, 1973 indicating approval of Target Rock flow test results. (6) Target Rock Certificate of Compliance dated November 26, 1973. (7) Certificates of Equipment dated January 15, 1974, and October 8, 1975, signed by seller and purchaser representatives. (8) Target Rock letter dated August 30, 1977, to buyer concerning specification and test data and system requirements. (9) Target Rock letter dated October 24, 1977, documenting telecon with buyer representative who requested a C of y 14-18 (preferably on the high side) at Target Rock to give a later installed C of 12-16 at the site. y (10) Addendum 1 to Report flo. TRP 2053 - C Test Results y for Valve 71J-002 showing . Original test results (1973) - C of 13. y
.. Test results after plug was modified to obtain higher C (1977) - C of 22. y y . Test results after further modification adding stellite guide vanes for stability (1977) - C V of 18. c. Documents related to 75C valves to assure implementa-tion of design process requirements: (1) Project Specification 1370-PE-705, Revision 3, (invoked by P.O. 9403351) including Valve Data Sheet and Code Edition and Addenda. (2) Target Rock Design Report No. 1905 (Minimum Wall Thickness and Strength of Bonnet / Body Threads) dated May 11, 1977. (3) Drawing No. 75C, Revision E - Globe Valve Assembly. (4) Performance Test 1818A. (5) Test results dated August 30, 1977. (6) ASME Code NPV-1 forms dated April 15, 1977, and January 26,1979, (after modification) showing design pressure, temperature, hydrotest pressure, Code Edition and Addenda, and Professional Engineer Number on Certificate of Design. (7) Buyer's Certificates of Equipment dated Apri'l 21, 1977, and January 29,1979 (after modification). d. Documents related to 71L, 75A, and 74R valves to assure implementation of design process requirements: (1) Engineering Drawing Release Sheet for 71L valves. (.2 ) Engineering Procedure Release Sheet for 71L valves. (3) Materials Release Sheet for 71L valves. (4) Drawing 74R - 002, Revision G - 2" BW Globe "Y" Pattern Valve. (_5 ) Drawing 71L - 002, Revision 14 - Assembly Drawing.
.. e. Test results (pertaining to valves 71L, 75C, 74R, and 75A) from the tests performed on a larger test loop at another facility to permit approximation of fuli flow and zu) conditions. These tests were performed on July 31, 1978, for 2" Y valves, 2" T valves and 3" Y valves, and a later second test was performed on the 3" Y valves. 3. Findings In this area of the inspection, no deviations and no unresolved items were identified. S =}}