ML19290E276
| ML19290E276 | |
| Person / Time | |
|---|---|
| Issue date: | 01/04/1980 |
| From: | Hunnicutt D, Oller R NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML19290E272 | List: |
| References | |
| REF-QA-99900028 NUDOCS 8003100124 | |
| Download: ML19290E276 (12) | |
Text
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U.S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT REGION IV Report No. 99900028/79-02 Program No. 51300 Company: Tube Turns Division of Chtzetron Corporation 2900 W. Broadway Louisville, Kentucky 40201 Inspection Conduct:
December 3-7, 1979 Inspector:
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R. E Oller, Contractor Inspector Date Component Section II Vendor Inspection Branch
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Approved by:
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! - /4 - X'B D. R. Hunnicutt, Chtpf Date ComponentsSection II Vendor Inspection Branch Summary Inspection on December 3-7, 1979 (99900028/79-02)
Areas Insoected:
Implementation of 10 CFR 50, Appendix B, criteria, other NRC requirements, and applicable codes and standards including:
action on the previous inspection findings; review of vendor activities; nonconformances and c)rrective action; training; welding control, consisting of fitup and welding -
heat treatment and welder qualifications; and follow-up en two (2) different Part 21 Reports dated April 12, 1979, and June 7, 1979.
The inspection in-volved twenty-eight (28) inspector-hours on site.
Results:
In the seven (7) areas inspected, no deviations were identified in six (6) areas.
The following were identified in the remaining areas.
Deviations From Commitments:
Welding control; welding on a guard pipe sub-assembly f or a main steam penetration on Order Item 070195-001 was not per-formed within the amperage range and welding gas flow range required by the applicable welding procedure No. TT12-0114, Revision 0.
(See Notice of Deviation).
8003100
/2y
2 Unresolved Items: Nonconformances and Corrective Action; the Requests for Corrective Action documents were not generated by the Superintendent of Inspection based on a review of Nonconformance Reports, as described in the QA Manual.
(See Details Section, paragraph D.3.b).
3 DETAILS SECTION A.
Persons Contacted W. Barrett, Superintendent of Inspection P. Butler, NDE Engineer D. Carson, Welding Foreman
- W. Davis, Supervisor, Welding Engineering S. Grimm, Welder L. Hayden, Vice President of Engineering E. Massey, Welder
- J. Seay, Manager of Quality Control W.
Irent, Metallurgist
- S. Vitatoe, Section Manager, Quality Process Engineering
- Attended the exit meeting.
B.
Action on The Previous Inspection Findings (Closed) Deviation B (Report 78-02):
Failure to provide documented measures to calibrate the weld shielding gas flowmeters on welding machines numbers 32132, 32048, 32108 and others.
The inspector found that ASME Code Interpretation III-1-78-213, "Section III, Division 1, Calibration of Welding Machines and Gas Flow Regulators" originally issued July 21, 1978, had a clarification issued on April 20, 1979, which states, " Manual and semi-automatic welding equipment, as de-fined by Section IX, including auxil3ary 2quipment, such as gas flow regulators are not required by NCA-4134.12 to be calibrated." In consid-eration of this and other related circumstances, the above matter is no longer considered a deviation.
However, although Tube Turns' letter commitments to the NRC, dated February 27, 1979, to initiate calibration of the flow =eters no longer appears necessary, a written withdrawal of this commitment is needed.
Tube Turns' Manager of quality control indicated that he will issue the necessary letter to the NRC.
C.
General 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.
4 2.
Method of Accomolishment The preceding obj ectives was accomplished by :
Discussions with cognizant personnel regarding the plant a.
workload for nuclear compenents, and changes in plant management.
b.
Review of the proposed revisions to QA Manual Parts:
I - General Information; II - Standard Procedures, and III - ASME III Nuclear Power Plant Components, Division 1 and Division 2.
3.
Findings a.
Deviations from Commitments
- None, b.
Unresolved Items None.
c.
Other Findings (1)
Mr. L. D. hayden is now Vice President of Engineering, he replaced Mr. H. H. George who retired.
The organ-ization has been changed so the QC Manager reports directly to Mr. Hayden.
(2) The plant nuclear workload has declined and is now about five (5) percent of plant output.
D.
Nonconforaances and Corrective Action 1.
Objectives The obj ectives 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 noncon-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.
5 Nonconforming items are reviewed and accepted, rej ec ted,
c.
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:
Review of the QA Manual Procedure TT22-327, Revision 1, "Noncon-a.
formances and Corrective Action."
b.
Review of seven (7) Nonconformance Reports and related rework records such as Rework Routings, Manufacturing Orders, Component Weld Control Records, and Record of Repair of Welds.
c.
Review of 15 Requests for Corrective Action.
d.
Discussions with cognizant personnel.
3.
Findings a.
Deviations from Commitments
- None, b.
Unresolved Iqgn Review of the Requests for Corrective Action established that the requests are being generated in a different manner than that described in the QA Manual Procedure IT22-327, paragraph
- 7. 0.
The manual indicates the Superintendent of Inspection generates these requests af ter review of nonconformance reports.
The records showed they were generated by Internal Auditors and/or Monitors of production for deficiencies in activities such as welding and heat treating.
The QC Manager indicated he wished to continue this additional method of generating Requests for Corrective Action.
He
6 indicated the QA Manual will be revised to include the current practice.
This item remains unresolved pending revision of the QA Manual.
E.
Training 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 indoctrin-ation and training of personnel performing activities affecting qualicv is imp'_wented in accordance with cpplicable codes.
b.
Appropriate written agenda are used.
Records of training sessions agenda and attendance are c.
maintained.
d.
The agenda includes subject matter adequate to provide an understanding of the general and detailed aspects of the QA program, codes, standards and applicable technical dis-ciplines.
The instructors are suitably qualified.
e.
2.
Method of Accomplishment The preceding objectives were accomplished by:
Review of the QA Manual Procedure TT22-329, Revision 1, "Indoc-a.
trination and Training," and Procedure TT22-325, Revision 1,
" Nondestructive Examination."
b.
Discussions with cognizant pe rsonnel.
Review of the agenda records of training for 1979 for the c.
following groups of personnel:
(1)
Internal Auditors (2) Vendor Auditors (3)
Nondestructive Examination personnel in the techinques of:
(a) Penetrant Inspection
7 (b) Magnetic Particle Inspection (c) Ultrasonic Examination (d)
Radiographic Examination (4) Hydrostatic Test Inspectors (5) Visual Inspectors (6) Personel in QC, Sales, Engineering, Purchasing and Production with arsigned functions identified in the QA Manual.
(7)
Foreman and hourly employees whose work related to heat treatment and metallurgy.
3.
Findings a.
Within this area of the inspection, no deviations or un-resolved items were identified.
H.
Welding Control 1.
The objectives of this area of the inspection were to verify that the following activities were controlled in accordance with ap-plicable NRC and ASME Code requirements.
a.
A system has been established to assure that welding is controlled in accordance with the applicable codes.
b.
The weld joint fitup alignments meet requirements.
c.
The requirements of essential variables and other procedure parameters are concurred with during welding.
d.
The welders are qualified in accordance with the ASME code.
e.
The post weld heat treatment, specified by the welding procedures, is performed in accordance with an approved procedure, consistent with Code requirements.
2.
Method of Accomplishment The preceding objectives were accomplished by:
Review of the QA Manual Procedures TT22-333, Revision 1, " Welding a.
Operation Control," and IT22-324, Revision 2, " Heat Treating."
8 b.
Observation of in-process ASME Code welding on a main steam penetration guard pipe using welding procedure TT12-0114, Revision 0.
c-Review of records of welder qualifications covering four (4) welders _ sing the different processes of Gas Tungsten Arc Welding-Manual (GTAW-MA), ".
. Flux Core Arc Welding (FCAW),
." Shielded Metal Arc Weldin3-Manual (SMAW-MA) and Submerged Arc Welding-Mechanical (SAW-Mech.).
d.
Review of a weekly computer printout welding " Process Usage Record" used to maintain the 3 month ASME Code welder quali-fication requirements, e.
Review of records, of a local postweld ".
(11500 F) stress relief of an ASME Code weld on a process pipe penetra-tion 20" OD x 1.03" wall x 36' long, including the Manufactur-ing Order traveler sheet, Supplemental Routing Sheet, Weld Control Record and heat treatment time-temperature recorder chart.
f.
Review of records of furnace postweld normalizing heat treatment of an ASME Class 2, WPB-W concentric reducer SN-10537, including the following records:
(1) Heat Treatment Procedure TIO9-001, Revision 4.
(2) Manufacturing Order No. 053324, Item 001.
(3) Time-Temperature Charts with the accompanying record " Heat Treatment Confirmation or ".
. Sample Submission Report."
(4) Component Weld Control Record.
(5) Welding Procedure IT14-0107, Revision 8 (for required postweld heat treatment).
(6)
Detailed Analysis Report for Order Item 53324-001.
g.
Review of the calibration and furnace survey records in effect for May, 1979 for furnace No. 24145 used in heat treating of the concentric reducer SN-10537.
h.
Observation of the two zones recorder-controllers for furnace No. 24145.
1.
Discussions with cognizant personnel.
9 3.
Findings a.
Deviation from Commitments See Notice of Deviation.
b.
Unresolved Items None.
I.
Continuing Followup on Part 21 Report Dated April 12, 1979
==
Introduction:==
This Part 21 Report involved incorrect pipe fitting ma-terial included in fittings marked lot W6719 which were supplied by the Tube Turns Louisville Plant during the period of March, 1978 to March, 1979 to various distributors for use in both nuclear power generating plants and non-nuclear use.
Tube Turns reported this matter to the liRC by letter dated April 12, 1979, and an NRC followup inspection was per-formed in May, 1979.
(See Report No. 99900028/19-01)
Tube Turns imple-mented a corrective action recall program to account for all of the W6719 fittings including those for use at nuclear power generating site.
The recall program was in process during the May, 1979 NRC inspection.
1.
Objective The objective of this inspection was to review the status of the recall program relative to those W6719 fittings which were supplied for use in nuclear sites.
2.
Method of Accomplishment The preceding objective was accomplished by discussions with Tube Turns QA consultant and review of a process recall recorda.
3.
Findings The part of the recall program dealing with '.6719 fittings supplied for use in nuclear sites is nearly complete.
The list of nuclear sites to which the W6719 fittings were shipped now identifies more sites than were identified in Tube Turns letter dated May 10, 1979, to the NRC.
The NRC inspector recommended to the Manager of Quality Control that he submit an interum or final report, including a new list of affected nuclear sites, to the NRC when Tube Turns is assured that all of the W6719 fittings shipped to nuclear sites have been accounted for.
10 J.
Follown" on Part 21 Report dated June 7, 1979
==
Introduction:==
The Tube Turns Division of Chemetron plant management located in Louisville, Kentucky, called the NRC Region II assigned in-spector on June 5, 1979, and then submitted a 10 CF" Part 21 Report, dated June 7, 1979, to NRC Region II regarding a certain sleeve to con-tainment liner insert weld in fif teen (15) subassembly sleeve penetra-tions, wherein the welds had not received a required stress relief heat treatment.
These subassembly sleeves had been shipped to Carolina Power and Light Company for use in the Shearon Harris Nuclear Generating Station.
Tube Turns initiated corrective action through the purchaser, Ebas co Services, to have all fif teen (15) subassemblies returned to the Louis-ville plant for stress relieving.
Ebasco, the Architest.-Engineer, and the Owner, Carolina Power and Light, were made aware of th< conditions.
Tube Turns also reported by letter dated June 21, 1979, to NRC Region II that their Engineering Departmen'. had reviewed all orders for nuclear power plant f abrications and der armined that, other than ene shearon Harris unit, only one assembly had bee? made that included part of tae containment liner, and they had confirmed that the subj ect weld was stress relieved.
Carolina Power and Light also reported this deficiency to NRC Region II, by letter dated August 3, 1979, with attached Final Report, as a 10 CFR 50.55(e) construction deficiency.
1.
Obj ectives The objectives of this follow-up inspection were to ascertain that the reporting organization had implemented the requirements of 1C CFR Part 21 and had:
a.
Met the requirements for reporting the deficiency.
b.
Performed an evaluation of the condition, including making an assessment of generic implications.
Assigned responsibility and implemented a plan of corrective c.
action.
d.
Reviewed preventive action measures.
2.
Method of Acccmplishment The preceding objectives were accomplished by:
a.
Discussions with cognizant personnel covering the cause of deficiency; its correction and generic consideration.
b.
Review of Tube Turns approved procedure TT21-002, dated December 2,1977, " Tube Turns Procedure to Report Deviations In Accordance with 10 CFR Part 21."
11 c.
Review of Tube Turns Part 21 Report letter dated June 7, 1979, to verify the following:
(1)
The reporting requirements of 10 CFR Part 21 were met.
(2) The deficiency was properly evaluated and an assessment of generic implications was made.
(3) Adequate corrective action was implemcnted in a timely manner.
d.
Review of Ebasco Services letter dated June 11, 1979, wherein fif teen (15) penetrations returned to Tube Turns, were identi-fled.
e.
Review of Tube Turns Drawing No. 76924-C7.2, Revision 4, " Con-tainment Wall Sleeve for Type I Penetration" which identified the subject subassembly.
f.
Review of Tube Turns letter dated June 21, 1979, to NRC Region II wherein Tube Turns verified that only the Shearon Harris subassemblies were involved in the problems of failure to stress relieve.
g.
Review of the following Tube Turns' records of stress relief heat treatment covering the fif teen (15) subassemblies :
(1) Time-Temperature Stress Relief Chart for eleven (11) sub-assemblies, dated June 8 and June 9, 1979.
(2) Time-Temperature Stress Felief Chart for four (4) subassem-blies, dated June 15, 1979.
(3) Fif teen (15) Tube Turns Certificates of Conformance for the heat treated subassemblies.
h.
Review of Tube Turns pro _edure IT-09-0?.7, Revision 2, used in stress relieving the subject subassemblies.
3.
Findings a.
Deviations None.
b.
Unresolved Items None.
12 c.
Other Findings - Comments Discussions and review of documents established that the Tube Turns 10 CFR Part 21 Report dated June 7, 1979, met the require-ments of 10 CFR Part 21.
The subsequent correct 1ve action provided the ASME Code required stress relief of the shop welds in the fifteen (15) penetrations.
The review of generic con-siderations verified that the problem was limited to only the Shearon Harris Unit.
K.
Exit Inte rview 1.
The inspector met with management representatives, denoted in paragraph A, at the conclusion of the inspection on December 7,1979.
2.
The following subj ects were discussed:
a.
Areas inspected.
b.
Status of corrective and preventative actions for the pre-viously identified deviation.
c.
Findings identified in this report, including Tube Turns 10 CFR Part 21 reporting letters.
3.
Management's comments related to clarification of the above items.