ML19291C334
| ML19291C334 | |
| Person / Time | |
|---|---|
| Issue date: | 11/28/1979 |
| From: | Ellershaw L, Hunnicutt D, Roberds H NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML19291C330 | List: |
| References | |
| REF-QA-99900031 99900031-79-2, NUDOCS 8001240221 | |
| Download: ML19291C334 (13) | |
Text
U. S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT REGION IV Report No.
99900031/79-02 Program No. 51300 Company:
Bingham-Willamette Company 2800 N. W. Front Avenue Portland, Oregon 97210 Inspection Conducted:
October 29-November 2, 1979 h/,,2 w w d-M
[ 28/77 Inspectors: #
L. E. Ellershaw, Contractor Inspector
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ComponentsSection II Vendor Inspection Branch Ib 911 f
U/t8/7'1 8 H. W. Roberds, Contractor Inspector
/ Date/
f ComponentsSection II Vendor Inspection Branch Approved By:
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7/77 D. M. Hunnicutt, Chief
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ComponentsSection II Vendor Inspection Branch Summary Inspection on October 29-November 2, 1979 (99900031/79-02)
Areas Inspected:
Implementation of 10 CFR 50 Appendix B criteria, and applicable codes and standards including: weld material control; postweld heat treatment; heat treatment; control of joint fitup and welding; follow-up on construction deficiency report - LER No. 79/02L-026380; special process personnel qualification (nondestructive examination); nondestructive examination (liquid penetrant and magnetic particle); nondestructive examination (radiography); and manufacturing process control. The inspection involved fifty-six (56) inspector-hours on site by two (2) NRC inspectors.
1795 052 800124 2 11 3
2 Results:
In the nine (9) areas inspected, ten (10) deviations from commitment were identified. There were no unt' solved items.
Deviations: Weld Material Control - maintenance of welding materials relative to metellurgy was not in conformance with the requirements of Criterion V of Appendix B to 10 CFR 50 and the QA Manual (Notice of Deviation, Item A),
welding materials were issued to and used by production without being qualified and accepted by QA which is not in conformance with Criterion V of Appendix B to 10 CFR 50 and the QA Manual (Notice of Deviation, Item B); Post Weld Heat Treatment - use of one thermocouple on Motor Stands which precludes determining temperature differential within any fifteen (15) foot interval and within arS two (2) points on the weldment, is not in conformance with Criterion V of Appendix B to 10 CFR 50, Section III of ASME Code, and QA Manual (Notice of Deviation, Item C), postweld heat treat charts and welder and material records did not reflect actual conditions which is not in conformance with Criterion V of Appendix B to 10 CFR 50 and the QA Manual (Notice of Deviation, Item D);
Heat Treatment - the raising of temperatures exceeded the procedure limits which is not in conformance with Criterion V of Appendix B to 10 CFR 50 (Notice of Deviation, Item E); Special Process Personnel Qualification (NDE) - procedure does not address rules covering the duration of interrupted service which will require re-examination and re-certification which is contrary to Criterion V of Appendix B to 10 CFR 50 (Notice of Deviation, Item F); Manufacturing Process Control - inspection report sticker not attached to part for identification purposes, which is not in conformance with Criterion V of Appendix B to 10 CFR 50 and the QA Manual (Notice of Deviation, Item G); inspection did not review work orders to assure sign-offs and recording of heat numbers which is not in conformance with Criterion V of Appendix B to 10 CFR 50 and the QA Manual (Notice of Devia-tion, Item H); welder and material record not filled out to provide trace-ability to welder, weld procedure and welding material used, which is not in conformance with Criterion V of Appendix B to 10 CFR 50 and QA Manual (Notice of Deviation, Item I); unidentified material used for lifting lugs was welded to a part which is contrary to Criterion V of Appendix B to 10 CFR 50 and QA Manual (Notice of Deviation, Item J).
1795 053 0
3 DETAILS SECTION I (Prepared by L. E. Ellershaw)
A.
Persons Contacted G. Brumels, Production Control Scheduler G. Clark, Production Control Engineer D. A. Hensler, Assistant QA Manager L. Hinkle, Supervisor, Fabrication Shop S. Jensen, Process Control Engineer F. Lauren, Foreman, Plate Shop Tool Room R. J. Mellon, Supervisor, Nuclear Contracts J. L. Michel, Manager, Field Services R. J. Niiranen, Sales Engineer J. A. Odoms, Senior QA Engineer O. I. Rove, Manager, Quality Assurance C. Vanderbom, Senior QA Engineer A. Westcott, Foreman, Specialty Welds W. A. Young, QA Engineer B.
Weld Material Control 1.
Objectives The objectives of this area of the inspection were to verify that BWC had implemented the requirements for the control of welding materials 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, Subsection 9.2.5, " Weld a.
Material," Revision 10, dated January 1, 1979.
b.
Review of material test reports relative to welding materials observed being used.
c.
Observation of stored welding materials located in the Plate Shop Rod Storage Room.
d.
Observation of stored electrodes in the dry rod ovens.
1795.054
4 Review of Welder and Material Records, Form W005.
e.
f.
Discussion with cognizant personnel.
3.
Findings a.
Deviation from Commitments (1) See Notice of Deviation, Item A.
(2) See Notice of Deviation, Item B.
Purchase Order 1-55299 dated April 18, 1979, was placed with Quimby Welding Supplies, for E70T-1 wire. The initial shipment of wire (Heat Number H-7423) was received at BWC on June 13, 1979. The balance of the wire was received on June 29, 1979. The wire was placed on " hold" on July 2, 1979, due to lack of certifications. The certifications were received on July 3, 1979, with subsequent QA approval on July 5, 1979. The certifications were for as-welded condition only, thus BWC had testing performed in a postweld heat treated condition on August 22, 1979.
The records show that this material was used on Joint 1 of Motor Stand S.O. 00N03, on June 13, 1979.
b.
Unresolved Items None.
~
C.
Postweld Heat Treatment 1.
Objectives The objectives of this area of the inspection were to verify that BWC had implemented the requirements for the control of postweld heat treatment (PWHT) 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, Subsections 9.2.7, " Base a.
Metal Repairs," and 9.3, " Heat Treatment," Revision 10, dated January 1, 1979.
I795 055
5 b.
Review of PWHT records relative to ASME, Class 1 Motor Stands, S.O.s 00N03 and 00N04.
c.
Review of PWHT procedure D50.23, Revision 7, dated March 13, 1975.
d.
Discussions with cognizant personnel.
3.
Findings a.
Deviation from Commitments (1) See Notice of Deviation, Item C.
The weld which joins the motor.nounting flange to the motor stand has a circumference of 22.9 feet. With just one (1) thermocouple attached to the motor stand, the temperature difference between any two (2) points within any 15 foot interval on the weldment could not be determined.
(2) See Notice of Deviation, Item D.
b.
Unresolved Item None.
D.
Heat Treatment 1.
Objectives The objectives of this area of the inspection were to verify that BWC had implemented the requirements for the control of heat treat-ing in accordance with the QA Manual and applicable NRC and ASME Code requirements.
2.
Method of Accomplishment The preceding objectives were accomplished by:
a.
Review of QA Manual Section 9, Subsection 9.3, " Heat Treatment,"
Revision 10, dated January 1, 1979.
b.
Review of low temperature stress relief procedure D50.4, Revision 6, dated November 17, 1977, which was used in the performance of heat treating seal sleeves.
1795 056
6 c.
Review of heat treat charts and records for seal sleeves, S.O. 00N01/4.
d.
Review calibration status of furnace controllers and recorders.
Discussion with cognizant personnel.
e.
3.
Findings a.
Deviation from Commitments See Notice of Deviation, Item E.
b.
Unresolved Item None.
E.
Control of Joint Fitup and Welding 1.
Objectives The objectives of this area of the inspection were to verify that BWC had implemented the requiremaats for the control of joint fitup and welding in accordance with the QA Manual and applicable NRC and ASME Code requirements.
2.
Method of Accomplishment The preceding objectives were accomplished by.
a.
Review of QA Manual Section 9, Subsection 9.2.6, " Production Welding," Revision 10, dated January 1, 1979.
b.
Observation of in process submerged arc welding, gas tung-sten are welding, and shielded metal arc welding.
c.
Observation and review of calibration status of welding power sources.
d.
Observation of welder's performance relative to the para-meters stipulated on the welding procedure specifications.
e.
Discussion with cognizant personnel.
1795 057
7 3.
Findings a.
Deviation from Commitments None.
b.
Unresolved Item None.
F.
Follow-up Inspection of Construction Deficiency Report -
LER No. 79/02L-026380 1.
Introduction A "stop work" order dated March 29, 1979, was imposed on BWC by Duquesne Light Company (DLC) and Stone & Webster Engineering Corporation (S&W) because BWC was unable to demonstrate comp-liance with specification requirements for postweld heat treat-ment, weld procedure specification, qualification, nondestructive examination documentation, material certifications, and pump operational test requirements for the quench spray, recirculation spray, and auxiliary feedwater pumps purchased for Beaver Valley, Unit 2.
2.
Objectives The objectives of this follow-up inspection were to review corrective actions and to determine generic implications.
3.
Method of Accomplishment Review of reports relative to the "Stop work" order.
a.
b.
Discussion with cognizant personnel.
4.
Findings The following S&W purchase orders, with dates and items ordered, were placed with BWC, imposing the 1971 edition of the ASME Code through the Summer, 1972 addenda,Section III, Class 2:
2BV-24, June 13, 1972, Quench Spray Pumps 2BV-15, August 30, 1973, Recirculation Spray Pumps 2BV-208, January 14, 1974, Auxiliary Feedwater Pumps 1795 058
8 S&W requirements included:
their review and approval of BWC welding procedure specifications (WPS); use of welders qualified to Section IX of ASME Code; documented nondestructive examinations (NDE) including the use of qualified personnel; records of solution annealing heat treatment performed after repair welding to preclude sensitization of austenitic stainless steel; certificates of conformance (C of C) based upon certified material test reports (CMTR), and successful performance of pump operational tests.
The only parts / components under a controlled, documented program at that time, were pressure boundry/ retaining, parts / components.
Base plates and pump internals therefore, were not included under the controlled, documented program.
BWC submitted only those WPSs dealing with welding on pressure boundry parts. Welding was performed on base plates without benefit of WPSs. Welding was performed on internals, using WPSs that did not address all ASME Code variables, therefore when BWC subsequently submitted these procedures, S&W would not accept them.
The use of qualified welders, WPSs and personnel performing NDE on non pressure boundary parts could not be verified by BWC as these items did not go through the shop on a Code type traveler.
Therefore, none of the information was documented.
BWC did not have records pertaining to solution annealing heat treatment of austenitic stainless steel parts, after repair welding, to assure that sensitization had not occurred. BMC has developed a procedure based upon Regulatory Guide 1.44, to test the affected parts.
BWC indicated that a material problem regarding a restriction bushing in a seal, was the primary reason for the poor operational test performance. A new material has been substituted and other operational tests will be performed after all required repairs and replacement of parts have been accomplished.
S&W required C of Cs from BWC, supported by CMTRs. BWC assumed that C of Cs from their suppliers would be adequate. Subse-quently, they attempted to obtain CMTRs from their suppliers, but were only partially successful.
As a result of the above, BWC agreed to the following:
1795 059 -
9 Replacement of parts on which welding was performed a.
without documentation to verify the WPS used and the welder identity.
b.
Replacement of parts on which welding was performed without fully qualified WPSs.
Replacement of parts for which CMTRs could not be pro-c.
vided.
d.
Test austenitic stainless steel components to assure sensitization has not occurred.
Perform operational tests after all fixes have taken place, e.
with a tentative test date of February / March,1980, with S&W to witness.
BWC has submitted, after agreeing to the above, a Nonconformance and Deviation Request to S&W. This is a mechanism by which the findings of S&W and DLC, as documented in their joint quality assurance audit of BWC on May 7-11, 1979, can be appropriately resolved.
Based on the above, the "stop work" order was removed on August 8, 1979.
It would appear that this problem was a result of interpretation of contract requirements, which appear to be more stringent than ASME Code requirements. Further, it does not appear to be a generic problem based upon the information available, but a contract-unique problem.
G.
Exit Interview The scope and findings of this inspection, including the follow-up of the 10 CFR 50.55(e) report, were summarized at the conclusion of this inspection on November 2, 1979, with the following management reprecenta tives:
V. Hindley, Senior QA Engineer
- 0. I. Roves, Manager, Quality Assurance W. E. Tharp, President C. Vanderbom, Senior QA Engineer Management acknowledged the statements relative to the findings.
179506d I
10 DETAILS SECTION II (Prepared by H. Roberds)
A.
Persons Contacted J. A. Odoms, Senior Quality Assurance Engineer W. A. Young, Quality Assurance Engineer G. Miller, NDE Leadman D. Smith, Quality Assurance Engineer K. Crossley, Welding Engineer G. Hade, Quality Assurance Engineer D. Larsen, NDE Level II B.
Special Processes Personnel Qualification (Nondestructive Examination) 1.
Objectives The objectives of this area of the inspection were to verify that:
The employer, Bingham-Williamette Company (BWC), has deve-a.
loped a written practice for control and administration of NDE personnel training and examination in accordance with applicable NRC and ASME Code requirements, b.
Personnel records are complete and are current.
Personnel performing nondestructive examinations are-qualified c.
for the method used and have current eye examinations as defined in SNT-TC-IA.
2.
Method of Accomplishment The preceding objectives were accomplished by:
Review of the Quality Assurance Manual, Section 9, " Control a.
of Manufacturing and Installation Processes".
b.
Review of procedure No. H29.6, Revision 5, " Certification of Nondestructive Examination Personnel".
1795 061
11 Review of five (5) personnel certification and qualification c.
record packages including results of eye examinations.
3.
Findings a.
Deviations from Commitments See Notice of Deviation, Item F.
b.
Unresolved Items None.
C.
Nondestructive Examination (Liquid Penetrant and Magnetic Particle) 1.
Objectives The objectives of this area of the inspection were to verify that:
Nondestruction examination is performed in accordance with a.
approved procedures.
b.
Nondestructive examination procedures meet the requirements of Section V of the ASME Code and applicable NRC requirements.
Test results are interpreted by qualified personnel.
c.
2.
Method of Accomplisument The preceding objectives were accomplished by:
Review of the Quality Assurance Manual, Section 9, " Control a.
of Manufacturing and Installation Processes."
b.
Review of procedure No. H11.15, Revision 0, " Magnetic Particle Inspection (Dry Powder Method)."
Review of procedure No. H10.3, Revision 9, " Color Contrast c.
Liquid Penetrant Inspection."
d.
Observation of inspection of production components.
3.
Findings Within this area of the inspection, no deviations or unresolved items were identified.
1795 062
12 D.
Nondestructive Examination (Radiography) 1.
Objectives The objectives of this area of the inspection were to verify that:
Nondestructive examination is performed in accordance with a.
approved procedures.
b.
Nondestructive examination procedures meet the requirements of Section V of the ASME Code and applicable NRC requirements.
Test results are interpreted by qualified personnel.
c.
2.
Method of Accomplishment The preceding objectives were accomplished by:
Review of the Quality Assurance Manual, Section 9, " Control a.
of Manufacturing and Installation Processes."
b.
Review of procedure No. H12.6, Revision 2, " Radiographic Inspection."
Observation of radiography performed on shop order No. 6A235 c.
Dwg C-443, weld seam WJ-9.
d.
Review of ten (10) production radiographs for shop order No. 6A235, Dwg C-443, weld seam WJ-9.
Review of twenty five production radiographs for sales e.
order No. 00N1/4, HT No. P4718, stuffing box casting.
3.
Findings Within this area of the inspection, no deviation from commitment or unresolved items were identified.
E.
Manufacturing Process Control 1.
Objectives The objectives of this area of the inspection were to verify that:
Manufacturing is performed under a controlled system.
a.
b.
Certain processes are accomplished by qualified personnel using approved procedures.
1795 063
13 Results of specific operations are reported and/or recorded.
c.
2.
Method of Accomplishment The preceding objectives were accomplished by:
Review of the Quality Assurance Manual, Section 9, " Control a.
of Manufacturing and Installation Processes."
b.
Review of Work Order Preparation and Use Procedure D50.12, Revision 8.
Review of procedure No. D50.92, "Use of Temporary Attachments c.
on ASME Section III Component and Materials."
d.
Review of work order at various stages of the manufacturing process.
Observation of a machining operation on work order No. 6A235, e.
part No. 3003A.
3.
Findings a.
Deviations from Commitments (1) See Notice of Deviation, Item G.
(2) See Notice of Deviation, Item H.
(3) See Notice of Deviation, Item I.
(4) See Notice of Deviation, Item J.
b.
Unresolved Items None.
1795.064
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