ML19290C902
| ML19290C902 | |
| Person / Time | |
|---|---|
| Issue date: | 12/14/1979 |
| From: | Ellershaw L, Hunicutt D NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML19290C886 | List: |
| References | |
| REF-QA-99900104 99900104-79-2, NUDOCS 8002150025 | |
| Download: ML19290C902 (9) | |
Text
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U.S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT REGION IV Report No. 99900104/79-02 Program No. 51300 Company:
Westinghouse Electric Corporation Pensacola Plant P. O. Box 1313 Pensacola, Florida 32596 Inspection Conducted: November 26-30, 1979 Inspectors:
N]
/Mf!77 L. E. Ellershaw, Contractor Inspector
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ComponentsSection II
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Vendor Inspection Branch Approved by:
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D. M Hunnicutt, Chief
' Da t'e ComponentsSection II Vendor Inspection Branch Summary Inspection performed November 26-30, 1979 (99900104/79-02).
Areas Inspected:
Implementation of 10 CFR 50 Appendix B Criteria and applicable codes and standardf including:
nonconformances and corrective action; quali-fication of personnel performing special processes (NDE); welding material control; welding procedure specifications; and manufacturing process control.
The inspection involved thirty two (32) inspector-hours on site.
Results:
In the five (5) areas inspected, five (5) deviations fram commitment were identified in three (3) areas. No unresolved items were identified.
Deviations: Welding Material Control - different types and heats of welding electrodes were intermingled within several holding ovens (Notice of Deviation, Item A.); the Weld Wire Inventory Log showed one heat number of electrodes was issued to three different welders, but the welders had more than one heat number in their possession (Notice of Deviation, Item B.); welding material has been received, accepted, and released, without its being in conformance to purchase order and specification requirements (Notice of Deviation, Item C.);
Welding procedure specifications do not address all ASME Code required 8002150 bh
2 nonessential variables (Notice of Deviation, Item D.); Manufacturing Process Control - a wrong welding procedure specification (WPS) was called out on the route sheet and the welder subsequently signed-off the operations indicating he had performed to that WPS, and NDE operations had been deleted from a route sheet without QA sign-off (Notice of Deviation, Item E.).
3 DETAIL SECTION A.
Persons Contacted G. E. Callender - Manager, QA Engineering K. M. Carlson - QA Records / Inspection Supervisor J. E. Cooper - NDE Level III Examiner M. L. Ferguson - QA Engineer A. H. Furth - Sr. Welding Engineer R. Gibbons - Welder J. Hobbs - Supervisor, Assembly Area P. G. Jacob - General Welding Supervisor D. E. Lohr - Supervisor, Welding Area W. Underwood - Welding Engineer B.
Nonconformances and Corrective Action 1.
Objectives The objectives of this area of the inspection were to verify that Westinghouse Electrical Corporation, Pensacola Plant (WPP) had implemented the requirements for the control and reporting of non-conformances and corrective action in accordance with the QA Manual and applicable NRC and ASME Code requirements.
2.
Method of Accomplishment The preceding objectives were accomplished by:
Review of QA Manual Section 13.0, "Nonconformance Control,"
a.
dated 2/19/79, and Section 14.0, " Corrective Action," dated 8/19/77.
b.
Review of open and closed Material Review deports (MRR).
Observation of nonconforming material / parts to assure the items c.
are identified as being nonconforming by use of Hold Tags.
d.
Discussion with cognizant personnal.
3.
Findings a.
Deviation From Commitment None.
r 3
4 b.
Unresolved Item None.
C.
Qualification of Personnel Performing Special Processes (NDE) 1.
Objectives The objectives of this area of the inspection were to verify that WPP had implemented the requirements for qualification and certifi-cation of personnel performing NDE in accordance with the QA Manual and applicable NRC and ASME Code requirements.
2.
Method of Accomplishment The preceding objectives were accomplished by:
Review of QA Manual Section 9.0, " Nondestructive Examination, a.
Qualification and Control," dated 2/19/79.
b.
Review of Procedure PE-12-04-001, revision 5, dated 8/20/79,
" Nondestructive Personnel, Training, Qualification, and Certification."
Review qualification records of the Level III Examiner, c.
including test results and eye examinations.
d.
Review qualification records of twelve (12) Level II Examiners, including test results and eye examinations.
Discussions with cognizant personnel.
e.
3.
Findings a.
Deviation From Commitment None.
b.
Unresolved Item None.
D.
Welding Material Control 1.
Objectives The objectives of this area of the inspection were to verify that WPP had implemented the requirements for the control of welding
5 material in accordance with the QA Manual and applicable NRC and ASME Code requirements.
2.
Method or Accomplishment The preceding objectives w.s accomplished by:
Review of QA Manual Cection 8.0, " Welding-Quality Assurance,"
a.
dated 2/19/79.
b.
Review of Procedure PE-15-04-019, revision 4, " Shop Control of Welding and Brazing Materials."
Observation of weld filler metal storage areas including holding c.
and baking ovens.
d.
Review traceability of observed weld filler metal including Certified Material Test Reports (CMTR).
e.
Review purchase orders relative to the weld filler metal and associated specifications; i.e., Westinghouse Tampa Division Specification 2655A71, " Material: Steel Welding Electrode -
ASME SFA 5.5 Type E - 9018 M."
f.
Discussion with cognizant personnel.
g.
Review of Weld Wire Inveatory Log.
3.
Findings a.
Deviation From Commitments (1) See Notice of Deviation, Item A.
(2) See Notice of Deviation, Item B.
Empbasis was not placed on the control and segregation of electrodes br heat number even though each electrode is identified by a heat / lot number. This was evidenced through observation of electrodes in the holding ovens.
(a) Oven IP 644, identified as containing type 308 elec-trodes, exhibited the following:
the bottom shelf con-tained intermingled 5/32", type 308L-15 electrudes, heat numbers 9504 and 9530, while the top shelf contained intermingled 1/8", type 309-10, 308L-16, and 308L-15 electrodes, heat numbers 8515, 8538 and 8533, respectively.
6 (b) Oven LP 794, identified as containing type 309 elec-trades, exhibited the following: Bottom shelf - inter-mingled 5/32", type 309-15 and two heats of type 309-16 electrodes, heat numbers 8537, 8550 and 7560, respectively.
Middleshelf-intermingled 1/8", type 309-16 and 308L-16 electrodes, heat numbers 8515 and 8538, respectively. Top shelf - intermingled 1/8" type 309-15 electrodes, heat numbers 8547 and 8532.
(c) Oven LP0 6713, identified as containing type 7018 elec-trodes, exhibited the following:
Bottom shelf - inter-mingled 3/16", type 9018M and 7/32", type 7018 electrodes, heat numbers 7262 and 9038, respectively. Bottom middle shelf - intermingled 1/8", type 7018 electrodes, heat numbers 9157 and 9039.
(d) The bake oven exhibited the following:
Top shelf -
intermingled 1/8", type 7018 electrodes, heat numbers 8038, 9157, 8227 and 9039.
As a result of the above, electrodes have been issued to welders in an intermingled condition, with just one heat number recorded on the Weld Wire Inventory Log, thus creating a serious problem weld material trace-ability.
(3) See Notice of Deviation, Item C.
WPP placed purchasa orde -
54-3-M-47028, dated 1/13/78, with Westinghouse, Montevello.
Division, ordering 500 pounds of 3/16", type 9018M electrodes (SFA5.5).
Change notice 01, dated 1/27/78, imposed Westing-house Tampa Division Specification 2655A71 and the require-ment for material certifications to contain statement of test results.
Specification 2655A71 requires, in addition to meeting SFA 5.5, the testing of deposited weld metal which has undergone different postweld heat treatments (PWIIT).
PWHT "A" requires 1125 +25 F for 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br />.
PWHT "B" requires 1000 +25 F for 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br />. The specification further requires fracture toughness, tensile and ductility properties from specimens which have been subjected to PWHT "A" and. specimens which have been subjected to PWHT "B".
The specification requires the test reports to show all results of chemical and physical testing.
The material was received by WPP on 3/6/78 and released to the Welding Supervison on 3/20/78 as shown by Quality
7 Release (QR) 143842.
The Test Reports did not reflect the test results required by the specifications.
This was subsequently detected and a Material Rejection Notice, No. 800377, was generated on 3/20/79 (one year later). The disposition was acceptable, with the comment "SFA 5.5 of Section II, Part C requires material to be capable of meeting RT (radiography) and mech. tests. Quantitative values do not have to be listed. They are listed upon request." This disposition was approved by Manufacturing Engineer on 4/2/79 a.nd QA Engineer on 4/3/79. An amended test Report was received on 3/28/79, reflecting satis-factory RT results.
However, all of the required testing and results have still not been documented.
Therefore WPP has received, accepted, and released to manufacturing, unqualified weld material.
b.
Unrecolved Item None.
E.
Welding Procedure Specifications (WPS) 1.
Objectives The objectives of this area of the inspection were to verify that WPP had implemented the requirements for the qualification and control of WPS in accordance with the QA Manual and applicable NRC and ASME Code requirements.
2.
Method of Accomplishment The preceding objectives were accomplished by:
Review of QA Manual Section 8.0, " Welding - Quality Assurance,"
a.
dated 2/19/79.
b.
Observation of in-process gas tungsten are and gas metal arc welding and a review of the associated WPSs and their Procedure Qualification Records (PQR).
Review of Procedure PE-15-4-020, " Working Welding Procedures,"
~
c.
revision 4, dated 10/22/79.
d.
Discussion with cognizant personnel.
3.
Findings a.
Deviation From Commitment See Notice of Deviation, Item D.
The 3pecific working WPSs involved are GTAW 4050, GTAW 689, and GMAW 4046-1. The
8 nonessential variables not addressed, include:
a change in the method of initial and interpass cleaning, a change in the method of back gouging, and a change in the contact tube to work dis-tance.
b.
Unresolved Item None.
F.
Manufacturing Prc:ess Control 1.
Objectives The objectives of this area of the inspection were to verify that WPP had implemented the requirements for the control of manufacturing processes in accordance with the QA Manual and applicable NRC and ASME Code requirements.
2.
Method of Accomplishment The preceding objectives were accomplished by:
Review of QA Manual Section 6.0, " Manufacturing Planning and a.
Control," dated 2/19/79.
b.
Observation of in process manufacturing operations and a review of the associated route sheets and manufacturing documents.
c.
Discussions with cognizant personnel.
3.
Findings a.
Deviation From Commitments See Notice of Deviation, Item E.
It was subsequently determined that the route sheet for the tank weldment, Shop Order 115, S/N 48283, was in error. The correct working WPS should have been 689-6, which is the manual mode for GTAW. This involved oper-ation 470 - weld shell to top head, and operation 480 - weld shell to bottom head. However, welder 8014 performed and signed-off the route sheet, attesting to his performance in accordance with the route sheet requirements (whidh were in error) on 11/28/79.
Operations 60 and 90 on the route sheet for the pressurizer upper head assembly, identified as IWSL 172, S/N 48844, were NDE Operations that had been deleted on 11/16/79, without evidence of quality assurance review.
9 b.
Unresolved Item None.
G.
Exit I.sterview The scope and findings of this inspection were summarized at the con-clusion of this inspection on November 30, 1979, with the following management representatives and the Authorized Nuclear Inspector (ANI):
K. D. Boenitz - Marketing W. R. Bullivant - QA Engineer G. E. Callender - Manager, QA Engineering K. M. Carlson - Supervisor, QA Records /Intpection M. L. Ferguson - QA Engineer A. H. Furth - Sr. Welding Engineer R. E. Goss - Manager, Operations F. B. Hyland - Manager, Product Assurance P. G. Jacob - General Welding Supervisor R. F. Latta - Manager, Manufacturing Planning C. K. Starks - Plant Manager T. Zwick - ANI, Lumbermens Mutual Casualty Company Management acknowledged the statements relative to the findings.
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