ML19294B110
| ML19294B110 | |
| Person / Time | |
|---|---|
| Issue date: | 12/07/1979 |
| From: | NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML19294B107 | List: |
| References | |
| REF-QA-99900086 99900086-79-2, NUDOCS 8002270154 | |
| Download: ML19294B110 (2) | |
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Hopkinsons Limited Docket No. 99900086/79-02 NOTICE OF DEVIATION Based on the results of an NRC inspection conducted on November 12-16, 1979, it appears that certain of your activities were not conducted in accordance with NRC requirements as indicated below:
Criterion V of Appendix B to 10 CFR 50 states:
" Activities affecting quality shall be prescribed by documented instruction, procedures, or drawings, of a type appropriate to the circumstances and shall be accomplished in accordance with these instructions, procedures, or drawings.
Instructions, procedures, or drawings shall include appropriate quantitative or qualitative acceptance criteria for determining that important activities have been satisfactorily accomplished." Deviations from these requirements are as follows:
A.
Paragraph 4.5.7 in Section 4 of the QA Manual states, " Operations may be performed in a sequence other than that specified on the Operation Chart only by approval of the Quality Assurance Manager, with the charts amended to indicate the change prior to making such a change, and the Authorized Nuclear Inspector shall be informed of such changes."
Contrary to the above, welding operations were performed on Works Order Nos. 17/SM 5634 and 24/SM 5224 in a sequence other than that specified on the Operation Charts, without either the approval of the Quality Assurance Manager or prior amendment of the charts to indicate the changes (See Details C.3.a.(1)).
B.
Paragraph 5.5.3 in Section 5 of the QA Manual states with respect to acceptance of castings from the Hopkinsons Ltd. Foundries Division, "Q.A. Department, in conjunction with Metallurgical Department shall ensure that the documentation is correct and complete before the casting is accepted for manufacture."
Contrary to the above, the body casting for Manufacturing Work Order No.
11/SM 5640 was accepted by QA for manufacture, without ensuring that the documentation was correct with respect to performance of repair welding (See Details C.3.a.(2)).
C.
Paragraph 6.2.4 in Section 6 of the QA Manual states, "The welding pro-cedure to be used for each application shall be as stated on the Special Test Specification Sheet for the part concerned.
It shall be the respons-ibility of Welding Supervision to ensure that the procedure is available to, and that all parameters are followed by, the welder."
Contrary to the above, Velding Supervision did not ensure that all para-meters of welding procedures were being followed by welders for the repair of castings, as evidenced by the following observations made with respect to repair of the body casting for Manufacturing Work Order No.12/SM 5630:
A
2 1.
Flux core arc welding repairs were made to the outside of the casting using a different wire size to that required and at twice the weld bead width permitted by the applicable welding procedure.
2.
Shielded metal are welding repairs were made to the inside of the casting using a different arc voltage range to that required and without verification of compliance with the maximum interpass temp-erature requirements of the applicable welding procedure (See Details, D.3.a).
D.
Paragraph 5.3.2 in procedure, N6-1 Revision 4, states in part, " Records shall be maintaincd on form 60440 by the foreman of the issue to welders of welding materials. The information recorded shall include the following... (d) Identity of weld for which material is issued... "
Paragraph 5.3.3 states in part, "Only material to perform one welding p.ocedure and sufficient for approximately four hours welding shall be issued at one time...."
Contrary to the above, materials were issued for Manufacturing Works Order No. 17/SM 5634 to perform two welding procedures (Operation Nos.110 and 120) and the identity of the welds for which the materials were issued was not recorded.
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