ML19291C251
| ML19291C251 | |
| Person / Time | |
|---|---|
| Issue date: | 11/26/1979 |
| From: | Sutton J, Whitesell D NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML19291C247 | List: |
| References | |
| REF-QA-99900281 99900281-79-1, NUDOCS 8001230218 | |
| Download: ML19291C251 (7) | |
Text
.
U.S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT REGION IV Report No. 99900281/79-01 Program No. 53100 Company:
Allis-Chalmers Corporation York Plant Valve Division Box M93 York, Pennsylvania 17405 Inspection Conducted: October 16-19, 1979
/
a Incpectors:
lt/ M v'
M J. W. Sutton, Contractor Inspector Date
$omponentsSection I Vendor Inspection Branch
)e Approved b.
h/24/fp D. E. Whitesell, Chief Date ComponentsSection I Vendor Inspection Branch Summary Inspection on October 16-19, 1979 Areas Inspected:
Implementation of 10 CFR 50, Appendix B and applicable codes and standards, including action on previous inspection findings, manufacturing process control, ANI interface, nonconformance and corrective action and review of Vendor's activities.
The inspection involved twenty one (21) inspector-hours on site by one NRC inspector.
Results:
In the five (5) areas inspected no deviations or unresolved items were identified in four (4) areas. The remaining was identified in the remaining area.
Deviation: Manufacturing process control: QA/QC sign off areas of the manu-facturing process sheets were being signed off by manufacturing personnel.
(Notice of Deviation.)
Unresolved item: The QA manual does not clearly delineate the requirements of a product testing program as required by 10 CFR 50, Appendix B, Criterion XI, and the ASME Code, paragraph NCA 3134.11.
(Details Section, Paragraph C.3.b.)
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2 DETAILS SECTION A.
Persons Contacted Allis Chalmers Corporation, Valve Division (AC)
- R. G. Carlson, General Manager R. Randall, Manufacturing Production Engineering
- K. L. Sheaffer, QA Manager
- J. C. Thompson, Senior Analyst, QA Hartford Steam Boiler Inspection and Insurance Company (HSB)
- J. L. Warren, Assistant Regional Manager, Special Inspection Service.
- Indicates those who attended exit interview.
B.
Action on Previous Inspection Findings (Closed) Deviation (Report No. 77-01) NDE Qualification Records not being maintained by QA Department. The inspector verified that the QA manual, Section N7.1, had been reissued and that records of NDE personnel qualifications are now available when NDE work has been or will be subcontracted out to a subvendor.
(Closed) Unresolved Item (Report No. 77-01) a.
Procedures for control of welders symbols were not available.
b.
Procedures for notification of gages out of calibration were not available.
The inspector verified that the AC/QA manual has been revised and now contains instructions to control the use of welders symbols and for notification of gages / instruments found to be out of calibration.
C.
Manufacturing Process Control 1.
Objectives The objectives of this area of the inspection were to ascertain whether the manufacturing process is controlled in a manner which is consistent with the applicable regulatory code and contract require-ments, and is effective in assuring product quality.
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Method of Accomplishment The foregoing objectives were accomplished as follows:
I
3 Review of AC QA manual, Sections N5.1, " Manufacturing Control,"
a.
N5.2, " Identification and Control of Material and Items," and N5 3, "7dentification of Inspection Status," to determine the vendor's method and approach for controlling and verifying the various activities included in his manufacturing process. Also, to ascertain who, when, and how the process sheets were prepared, reviewed, and released to production.
b.
Review of the following process docznents, (1) Specification 8031-M-70 for HVAAC isolation valve.
(2) Drawing 049518 dated 6-30-78, manufacturing order 74077.
(3) Material Traceabilities Summaries.
(4) Review of various material tagging systems.
(5) Review of weld record sheets, 080 and 110.
The foregoing documents were reviewed to verify that the code classification, material, inspection, and test requirements are properly covered.
Review of various Process Sheets to verify that traceability is c.
provided to the customer, and the purchase order. Also, to verify that the Process Sheets provide for the following:
(1) Identifies the sequence of activities.
(2) Where an activity is controlled by detailed written pro-cedure, (ie; LP examination, Hydro test, etc.) that the procedure is identified by number, and revision, on the Process Sheet.
(3) Space is provided for the stamp, or initial, and date to indicate the completion of each activity, and the verifi-cation of the acceptability of completed activity.
(4) Space is provided for both the customer and the MI to identify their hold points and initial, sign, or stamp, and date, to document their acceptance of the activity.
d.
Observed the manufacturing of components being processed on the shop floor, to verify that the work was progressing in the estab-lished sequences, and where activities were controlled by detailed written procedure, verified that the procedures were available and that the activity was performed in accordance with its require-ments.
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4 3.
Findings a.
Deviation See Notice of Deviation, b.
Unresolved Item During the inspectors review of the manufacturing process and the QA manual, it was noted that there is no clear indication, or reference, in the QA manual to completely control the testing of the completed products. Reference is made throughout the manual that tests will be performed. Procedures for Hydro and NDE testing of products are contained in the manufacturing operation manual, but are not identified in the QA Manual.
Management informed the inspector that they would review this area of concern, and that whatever steps are required will be taken to clearly identify the implementing procedures in the QA manual.
D.
Authorized Nuclear Inspector (ANI) Interface 1.
Objectives The objectives of this area of the inspection were to ascertain whether procedures had been prepared and approved, which describes the system to be implemented for the achievement of interface activities with the ANI, and that the identified activities are consistent with the NRC rules, Code requirements, and the QA Program commitments.
2.
Method of Accomplishment The objectives of this area of the inspection were accomplished as follows:
Review of Allis Chalmers(AC), Valve Division QA Manual to as-a.
certain whether the system provides for interface with the ANI to make the Design Specification available for his review, and to assist him as necessary to provide the inspection services, to ensure that all code items are designed, manufactured, inspected and tested in compliance with code requirements.
s
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5 b.
Review of nonconforming reports to verify that changes in the customer's design specifications (DS) are reviewed with the ANI to inform him of the status of the inspections and tests of the items when it is removed from the manufacturing process.
Review of QA Manual, to verify that measures have been provided c.
to make available Material Certifications and the QC Source and/or Receiving Inspection Reports, for review by the ANI, and that such reviews are documented.
d.
Review of QA Manual, to verify that a system has been provided to maintain the identification of materials, and that the iden-tification is transfered when it becomes necessary to divide the material, also, to verify that the ANI is provided the opportu-nity to verify that the identification of material is properly maintained and documented e.
Review of QA Manual; to a,eertain whether measures have been established for the ANI to witness any welding procedure, and/or any welder performance qualification tests, and to request the requalification of any procedure or welder, to ensure proper qualification and/or acceptable welding performance.
f.
Review of QA Manual, to verify that the program provides for the application of the code stamp only with the authorization of the ANI after acceptable pressure testing, and the certification of the Manufacturer's Data Report, and only in the presence of the ANI.
g.
The Daily Log Book maintained by the ANI was reviewed, to verify that AC is making its QA/QC documents available to the ANI for his review, to provide assurance that the code requirements are complied with and that the product quality has been achieved.
3.
Findings The ANI activities as documented in his bound log book, and by docu-ments reviewed, supports a finding that the vendor is properly imple-menting its interface responsibilities with the ANI in a manner con-sistent with the NRC rules, Code requirements, and its QA program com-mitments. The ANI at this vendor is an itenerant inspector, on call by the vendor.
E.
Nonconformance and Corrective Action 1.
Objectives The objectives of this inspection were to verify that:
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6 a.
A system for control of nonconformances and corrective actions has been established and is consistent with NRC regulations, and the QA Program requirements; and b.
The system is properly implemented.
2.
Method of Accomplishment The objectives of this area of the inspection were accomplished by:
Review of the QA manual, Sections N12.1," Manufacturing Loss a.
Ticket" (MLT), and N12.2, " Corrective Action System," dated June 26, 1979.
b.
Review of MLT Nos. 48713, 48737, 48251 and 49044.
c.
Review of the MLT Log Book.
d.
Review of the Corrective Action Requests (CAR) log.
Review of the QA managers monthly reports on CAR standings.
e.
f.
Inspection of the segregation and scrap areas.
3.
Findings In this area of the inspection no deviations or unresolved items were identified.
F.
Review of Vendor's Activities 1.
Objectives The objectives of this area of the inspection were:
a.
To review the nuclear activity and work load to assess their impact on future NRC inspections.
b.
Evaluate the vendor's fabrication / manufacturing equipment and capabilities.
2.
Method of Accomplishment The foregoing objectives were accomplished by observing the manu-facturing/ fabrication in progress, and discussions with the cognizant vendor personnel.
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7 3.
Findings The vendor has the capability to design, manufacture and test ASME Code Class 2 and 3 nuclear velves of the Butterfly type to 168" and cone type to 60" sizes.
The vendor is capable of both manual and automatic machining oper-ations on valves and parts from plate, castings, forgings and bar stock.
The vendor subcontracts all NDE activities. Visual and Hydrostatic tests are performed by the vendor's personnel.
The vendor holds valid ASME Certificates of Authorization "N" 1530 and "NPT"-1531 for class 2 and 3 valves and appurtenances. Completed products are shipped by both truck and rail.
The vendor is currently processing four (4) nuclear contracts con-taining approximately two hundred (200) different size Butterfly valves. This represents approximately eight (8) per cent of the total commercial nuclear work load for domestic use.
G.
Exit Interview The inspector met with management representatives (denoted in paragraph A) at the conclusion of the inspection. The inspector summarized the scope and findings of the inspection. The management representatives had no comment in response to the items discussed by the inspector.
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