ML19296D118
| ML19296D118 | |
| Person / Time | |
|---|---|
| Issue date: | 07/12/1979 |
| From: | Barnes I, Hunnicutt D, Roberds H NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML19296D080 | List: |
| References | |
| REF-QA-99900039 99900039-79-1, NUDOCS 8002290368 | |
| Download: ML19296D118 (17) | |
Text
.
U. S. NUCLEAR REGULATORY CO.TIISSION 9
OFFICE OF INSPECTION AND ENFORCEMENT REGION IV h ~ c No.
99900039/79-01 Program No.
51300 Company:
Rhine-Schelde-Verolme Zware Apparatenbouw b.v Heijplaatstraat 4, P. O. Box 221 Rotterdam, The Netherlands Inspection Conducted: May 28 - June 1, 1979
,/91 7/M/If Inspectors:
I. Barnes, ContracFor Inspector, CSII Date Vendor Inspection Branch
(
ud M
H. W. Roberds, Contractor Inspector, CSII
/,Date Vendor Inspection Branch Approved by:
N 7 2!7[
D. M. Hunnicutt, Chief, ComponentsSection II Date Vendor Inspection Branch Summary Inspection on May 28 - June 1, 1979 (99900059/79-01)
Areas Inspected:
Implementation of 10 CFR 50, Appendix 8, criteria and applicable codes and standards, including action on previous inspection findings, joint fitup and welding, welding material control, special welding applications, welder qualifications, material identification and control, manufacturing process control, special processes personnel qualification (nondestructive examination), liquid penetrant examination, magnetic particle examination, ultrasonic examination and radiographic examination. The inspection involved seventy (70) inspector-hours on site by two (2) NRC inspectors.
Results:
In the twelve (12) areas inspected, no deviations or unresolved items were identified in seven (7) areas, with the following deviations being identified in the remaining areas:
S () O ld ~ 9 (J N
2 Deviations: Action on Previous Inspection Findings - No evidence available to confirm performance of special course on ASME Code welding qualification requirements required by corrective action commitments (Notice of Deviation, Item A).
Special Welding Applications - Welding positions permitted by WPS PS-36.23, Revision 4, not in accordance with Criterion V of 10 CFR 50, Appendix B, and position essential variable requirements of QW-281.2(d) in the ASME Section IX Code (Notice of Deviation, Item B).
Performance of submerged arc buildups and shielded metal arc overlay not consistent with Criterion V of 10 CFR 50, Appendix B, and certain requirements of applicable welding documents (Notice of Deviation, Item C).
Joint Fitup and Welding - Absence of instructions on geleidekaart relative to welding of certain thermocouple nut temporary attachments, not consistent with Criterion V of 10 CFR 50, Appendix B, Sub-Chapter 8.1 and paragraph NB-4231.2 in the ASNE Section III Code (Notice of Deviation, Item D).
Special Pracesses Personnel Qualification (Nondestructive Examination) - Absence of rules in procedure No. 9.09.01(E) relative to duration of interrupted service for NDE personnel requiring reexamination and recertification, not in accordance with Criterion V of 10 CFR 50, Appendix B, and paragraph 9.7.3 of SNT-TC-1A, 1975 Edition (Notice of Deviation, Item E).
- lanufacturing Process Control - Sign off of an inspec in operation for a weld that had not been accomplished was not in accordance with Criterion V of 10 CFR 50, Appendix B, and Chapter 6 of the QA Manual (Notice of Deviation, Item F).
3 DetailsSection I (Prepared by I. Barnes)
A.
Persons Contacted
- F. C. Smit, Managing D? rector
- M. Lodder, Manager, Quaiity Assurance
- G. J. Van Der Vlies, Heat. Project Management
- P. C. De Ruiter, Shop Supe rintendent
- J. H. Van Eldik, QA Enginee'
- C. Klootwyk, QA Shop Enginei-A. Van Haasen, Manager, Mar > acturing J. Poort, Engineering Manage:
A. Waasdorp, Assistent QA Project Engineer
- P. D. Quinlan, Quality Assurance Representative, General Electric Company
- N. C. Theis, Authorized Nuclear Inspector, Hartford Steam Boiler Inspection and Insurance Company
- Attended exit meeting.
B.
Action on Previous Inspection Findings 1.
(Closed) Deviation (Item A, Enclosure, Inspection Report No. 78-01):
Performance of first layer shielded metal arc overlay cladding at an amperage range above that permitted by the applicable welding procedure specification.
The inspector verified that plugs had been installed on manual power sources and that checking of amperage with digital ammeters had been implemented. A review was also made of Weld Records for Spherical Ring 010 longitudinal seams in Order No. 30823 (Black Fox Unit 2) to establish that frequency of production welding checks was consistent with corrective action commitments.
2.
(Closed) Deviation (ltem B, Enclosure, Inspection Report No. 78-01):
Qualification of interpass temperature on overlay WPS No. PS-36.22 Revision 2 and voltage range on overlay WPS No. PS-36.22 Revision 2 not in accordance with ASME Code Section IX requirements for essential variables.
This finding has been closed on the basis that actions were taken to reconcile the differences between the permitted essential variable
4 ranges and the qualified values for the cited welding procedure specifications. During the inspection, however, a deviation from corrective action commitment was identified, pertaining to no documentation being available to confirm a committed training course on ASME Code welding qualification requirements had been performed.
(See Notice of Deviation, Item A) 3.
(Closed) Deviation (Item C, Enclosure, Inspection Report No. 78-01):
Presence of Inconel electrodes in certain bake and holding ovens, which were not identified on the outside of the respective ovens.
The inspector verified by examination of the welding materials storage area, that current storage practices were fully consistent with the requirements of Quality Procedure No. 9.08.03.
4.
(Closed) Deviation (Item D, Enclosure, Inspection Report No. 78-01):
Ferrite content in single layer cladding on Ring 005 for Contract No. 30822 established to be below customer specification requirements at localized positions in two beads.
The inspector' verified that the committed revision of the deficient computer program used for ferrite calculation had been performed and that a re-evaluation had been performed of ferrite contents derived from the deficient computer program.
5.
(Closed) Deviation (Item E, Enclosure, Inspection Report No. 78-01):
Qualification of forming procedure No. PS-51.21 Revision 2 not performed prior to forming of rings on Contract No. 30822 and 30823.
The inspector verified by review of qualification, BPQ-002, that PS-51.21 Revision 2 had been qualified in accordance with applicable ASME Code Section III requirements.
6.
(Closed) Deviation (Item F, Enclosure, Inspection Report No. 78-01):
Certain phases of the QA Manual not audited at the six month frequency required by the QA Manual.
The inspector verified that current internal audits were being performed of the RSV Zware Apparatenbouw b.v. (RSV-A) QA program in a cycle consistent with corrective action commitments and QA Manual require-ments.
7.
(Closed) Deviation (Item G, Enclosure, Inspection Report No. 78-01):
Yearly management audit of QA activities not performed in 1977.
The inspector verified that the 1978 management audit had been performed and that preparations were being made for performance of the 1979 audit.
5 8.
(Closed) Deviation (Item H, Enclosure, Inspection Report No. 78-01):
Failure to remove certain vendors no longer considered qualified from the Approved Nuclear Vendors List.
The inspector verifed that current control of the Approved Vendors List was in accordance with the revised format and change system described in the corrective action response.
9.
(Closed) Deviation (Item I, Enclosure, Inspection Report No. 78-01):
The inspector verifed that the present revision of the QA Manual addresses segregation of nonconforming materials in the receiving inspection area.
10.
(Closed) Unresolved Item (DetailsSection II, B.3.b., Inspection Report No. 78-01):
Use of subjective wording in Chapter 14 of the QA Manual relative to requirements for Manager QA evaluation of Nonconformity Reports.
This item was resolved on the basis of amendment of the QA Manual and verification of performance of review of Nonconformity Reports.
11.
(Closed) Unresolved Item (DetailsSection II, D.3.b., Inspection Report No. 78-01):
Inability to inspect calibration control program owing to applicable calibration procedure being written in the Dutch Language.
This item was resolved on establishment that the calibration control procedure, 9.10.01(E), had been translated into the English language.
C.
Special Welding Applications 1.
Objective The objective of this area of the inspection was to determine if special welding applications such as weld overlay cladding conform with the additional requirements established by ASME CodesSection III and IX and the RSV-A QA program.
2.
Method of Accomplishment The preceding objective was accomplished by:
a.
Review of Chapter 8, Sub-Chapter 8.1 Revision 6, of the QA Manual, " Welding."
b.
Observation of shiel/.ed metal arc and submerged arc weld overlay operations with respect to welder and welding operator compliance with applicable Wr.1 ding Instructions.
6 Comparison of Welding Instruction content with the applicable c.
Welding Procedure Specification.
d.
Review of GE Specification 21A9477 Revision 7 with respect to definition of requirements for weld overlay cladding.
e.
Examination of welding procedure specifications, applicable to production welding operations witnessed, in terms of ASME Code Section IX qualification of essential variables in the supporting procedure qualification records.
3.
Findings a.
Deviations from Commitment (1) See Notice of Deviation, Item B.
(2) See Notice of Deviation, item C.
b.
Unresolved Items None.
D.
Joint Fitup and Welding 1.
Objective The objective of this area of the inspection was to determine if production welding was controlled in accordance with the RSV-A QA program and applicable ASME Code requirements.
2.
Method of Accomplishment The preceding objective was accomplished by:
Review of Chapter 8, Sub-Chapter 8.1 Revision 6, of QA Manual, a.
" Welding."
b.
Observation of nozzle weld and closure head weld repair on Black Fox Units 1 and 2, respectively, in terms of:
(1) Completeness and correctness of traveler documentation.
(2) Availability of welding procedures and instructions at work stations.
7 (3) Correctness of assignment of applicable welding procedure specifications (WPS) with respect to essential variable qualifications of the WPS for the specific applications.
(4) Mea :urement of preheat and interpass temperatures in use and comparison with WPS requirements.
(5) Verification that cavity preparation and examination had been performed in accordance with procedure and ASME Code requirements.
(6) Verification that welder technique, welding position, electrical parameters, welding materials have scope of interpass cleaning were in accordance with WPS requirements.
Review of traveler documentation for welding documentation relative c.
to attachment of temporary attachments (thermocouple nuts) on Black Fox Unit 1, Suborder 61000.
3.
Findings a.
Deviation from Commitment See Notice of Deviation, Item D.
b.
Unresolved Items None.
c.
General Comment Absence of automated welding and fitups for pressure boundary welds precluded review of all current processes in current usage during this inspection.
This area will be further examined during a future inspection.
E.
Welding Material Control 1.
Objective The objective of this area of the inspection was to determine if welding material purchase, acceptance, storage and handling was in accordance with the RSV-A QA program and applicable ASME Code requirements.
2.
Method of Accomplishment The preceding objective was accomp'.ished by:
8 a.
Review of Chapter 8.0, Sub-Chapter 8.1 Revision 6, of the QA Manual, " Welding."
b.
Examination of process specification, PS-30.21 Revision 4,
" Receiving inspection of welding materials."
c.
Examination of welding materials storage procedure, 9.08.03, with respect to traceability and moisture control provisions.
d.
Review of welding material requisition cards for production welding operations witnessed.
e.
Examination of electrode ovens for material identification and temperature control.
f.
Verification of welding materials approval for application on lilack Fox Units 1 and 2.
g.
Verification that unused welding materials were returned and appropriately processed.
h.
Examination of procurement and material test information for the following categories of approved welding materials:
(1) Submerged arc wire and flux combinations for use in pressure boundary applications.
(2) Submerged arc wire and flux combinations for strip cladding applications.
(3) Ferritic coated electrodes for use in shielded metal arc pressure boundary applications.
(4) Austenitic stainless steal coated electrodes for use in overlay applications.
3.
Findings Within this area of the inspection, no deviations from commitment or unresolved ite,':s were identified.
F.
Welder Qualifications 1.
Objective The objective of this area of the inspection was to determine if welders and welding operators were qualified in accordance with Section IX of the ASME Code and the RSV-A QA program.
9 2.
Method of Accomplishment The preceding objective was accomplished by:
Review of Chapter 8.0, Sub-Chapter 8.1 Revision 6, of the QA a.
Manual, " Welding."
b.
Review qualifications for welders and welding operator observed performing production welding relative to procedure require-ments.
Examination of system used for maintenance of welder qualifications.
c.
3.
Findings Within this area of the inspection, no deviations from commitment or unresolved items were identified.
G.
Manufacturing Process Control 1.
Objectives The objectives of this area of the inspection were to verify that:
A system had been established for the control of manufacturing a.
processes, which was consistent with applicable regulatory and ASME Code requirements.
b.
The system was implemented.
2.
Method of Accomplishment The preceding objectives were accomplished by:
Review of Chapter 6.0 Revision 7 of the QA Manual, " Process a.
Control and Material Identification."
b.
Examination of purchase orders and receiving inspection reports for Black Fox Unit I closure head materials.
c.
Examination of material forming practices, heat treatment practices, test sample location, testing practices and results relative to ASME Section III Code and customer requirements.
d.
Review of traveler documentation with respect to:
(1) Definition of and a method of sequencing of manufacturing operations to provide for compliance with ASME Section Code fabrication requirements.
10 (2) Compliance with designated hold points.
(3) Performance of all nondestructive examinations required by the ASME Section III Code and at correct times of examination.
(4) Completeness of operation signoff.
(5) Use of approved welding, examination and heat treatment procedures.
(6) Verification of compliance of qualifications.
(7) Review of welding procedures with ASME Code Section III and IX requirements.
(8) Review of accumulated postweld heat treatment time relative to welding procedure and welding materials qualifications.
3.
Findings Within this area of the inspection, no deviations or unresolved items were identified.
H.
Exit Meeting A post inspection exit meeting was held on June 1, 1979, with the manage-ment, Authorized Inspection Agency and customer representatives denoted in paragraph A above.
The inspectors summarized the scope and findings of the inspection. Management acknowledged the statements of the inspectors with respect to the findings as presented to them and affirmed their commitment to the quality assurance program.
11 DetailsSection II (Prepared by H. W. Roberds)
A.
Persons Contacted K. Fun, Quality Assurance Engineer P. Bomers, Quality Assurance Systems Engineer C. Klootwyk, Quality Assurance Shop Engineer R. W. v. Mourik, Quality Assurance Engineer H. llornis, Assistant Quality Assurance Shop Engineer A. Waasdorp, Assistant Project Engineer B.
Special Processes Persennel Qualification (Nondestructive Examination) 1.
Objectives The objectives of this area of the inspection were to verify that:
The employer, Rhine-Schelde-Verolme Zware (RSV-A) has developed a.
a written practice for control and adminstration of NDE personnel training, examination and certification in accordance with applicable NRC and ASME Code requirements.
b.
Personnel records are complete and are current.
c.
Personnel performing nondestructive examinations are qualified for the method used and have current eye examinations as defined in SNT-TC-1A.
2.
, Method of Accomplishment The preceding objectives were accomplished by:
a.
Review of Chapter 9.0 of the Quality Assurance Manual, "Non-destructive Examinatirn", Revision 9.
b.
Review of Quality Procedure No. 9.09.01(E) Revision 1, 1978-03-14,
" Qualification and Certification Nondestructive Examination Personnel."
c.
Review of five (5) personnel certfication and qualification record packages including results of eye examinations.
12 d.
Interviews with cognizant personnel.
3.
Findings a.
Deviations from Commitments See Notice of Deviation, Item E.
b.
Unresolved Items None.
C.
{LiuidPenetrant) 3 1.
Objectives The objectives of this area of the inspection were to verify that:
a.
Nondestructive examination is performed in accordance with approved procedures.
b.
Nondestructive examination procedures meet tl.e requirements of the - 'ME Code and applicable NRC requirements.
Test results are interpreted by qualified personnet.
c.
2.
[lethod of Accomolishment The preceding objectives were accomplished by:
a.
Review of Chapter 9.0 of the Quality Assurance Manual, "Non-destructive Examination", Revision 9.
b.
Review of NDE Procedure No. PS-24.25 " Liquid Penetrant Examination of Welds, Weld Metal Cladding and Build-ups."
c.
Review of material certifications with respect to percentage of sulfur and halogen content for th-following items:
(1)
Penetrant, batch No. PG 1986.
(2)
Penetrant, batch No. 2199.
(3) Penetrant remover, batch No. PG1830.
(4) Developer, batch No. 2120.
13 d.
Interviews with cognizant personnel.
3.
Findings Within this area of the inspection, no deviations from commitments or unresolved items were identified.
4.
Conunents Due to the limited production activity, the observation of the inspection technique used in this discipline of NDE in deferred to a future inspection.
D.
Nondestructive Examination (Magnetic Particle) 1.
O_bjectives The objectives of this area of the inspection were to verify that:
Nondestructive examination is performed in accordauce with a.
approved procedures.
b.
Nondestructive examination procedures meet the requirements of Section V of the ASME Code and applicable NRC requirements.
c.
Test results are interpreted by qualified personnel.
2.
Method of Accomplislunent The preceding objectives were accomplished by:
a.
Review of Chapter 9.0 of the Quality Assurance Manual, "Non-destructive Examination", Revision 9.
b.
Review of NDE Procedure No. PS-23.24 " Magnetic Particle Examin-ation of Welds and Weld Metal Build-ups", Revision 1.
c.
Review of Nondestructive Examination Report No. 2380, MT of weld preps.
d.
Interviews with cognizant personnel.
3.
Finding Within this area of the inspection, no deviations'or unresolved items were identified.
14 4.
Comments Due to the limited production activity, the observation of the inspection technique used in this discipline of NDE is deferred to a future inspection.
E.
Manufacturing Process Control 1.
Objectives The objectives of this area of the inspection were to verify that:
a.
!!anufacturing is performed under a controlled system.
b.
Certain processes are accomplished by qualified personnel using approved procedures.
c.
Results of specific operation are reported.
2.
Method of Accomplishment The preceding objectives were accomplished by:
a.
Review of Chapter 6.0 of the Quality Assurance !!anual, " Process Control and Material Identification", Revision 7.
b.
Review of Master Travelers at various stages of the manufacturing
- process, c.
Review cf calibration for yoke Y5, ID 362.
d.
Interviews with cognizant personnel.
c.
Observation of clad welding of safe ends.
3.
Findings a.
Deviation froin Commitments See Notice of Deviation, Item F.
b.
Unresolved Items None.
F.
Nondestructive Examination (Radiography) 1.
Objectives
15 The objectives of this area of the inspection were to verify that:
a.
Nondestructive examination is performed in accordance with approved procedures.
b.
Nondestructive examination procedures meet the requirements of the AStiE Code and applicable NRC requirements.
c.
Test results are interpreted by qualified personnel.
2.
Method of Accomplishment The pi-ing objectives were accomplished by:
Review of Chapter 9.0 of the Quality Assurance Manual, "Non-a.
destructive Examination", Revision 9.
b.
Review of NDE Procedure N). PS-22.24 Revision 1 of May 11,1976,
" Radiographic examination of welds and base material weld repair using the Linear Accelerator."
c.
Review of twelve (12) production radiographs for nozzle weld No. 20303, film No. FX 83, for Black Fox 2 project.
d.
Review of radiograph report No. 30823-61500-105-000-0470, dated April 18, 1979.
Interviews with cognizant personnel.
e.
3.
Fiuding3 Within this area of the inspection, no deviations from commitments or unresolved items were identified.
G.
Nondestructive Examination TUltrasonic) 1.
Objectives The objecti.
af this area of the inspection were to verify that:
a.
Nondestructive examination is performed in accordance with approved procedures.
b.
Nondestructive examination procedures meet the requirements of the ASME Code and applicable NRC requirements.
16 c.
Test results are interpreted by qualified personnel.
2.
Method of Accomplishment The preceding objectives were accomplished by:
a.
Review of Chapter 9.0 of the Quality Assurance Manual, "Non-destructive Examination", Revision 9.
h.
Review of NDE Procedure PS-21.27, Revision 1 " Ultrasonic examination of full penetration pressure retaining welds 2h inches and greater in thickness, and repair to base metal which exceed 3/4 inch in depth."
c.
Observation of ultrasonic examination of inlet recirc. nozzle weld 30823-o1500 pc 105 nozzle No. 20303.
d.
Interviews with cognizant personnel.
3.
Findings Within this area of the inspection, no deviations from commitments or unresolved items were identified.
4.
Comments Due to the limited production activity, the observation of the inspection technique used in this discipline of NDE is deferred to a future inspection.
M.
Material Identification and Control 1.
Objectives The objectives of this area of the inspection were to verify that:
a.
Procedures were established for the identification and control of purchased materials and are consistent with ASME Code and NRC require.:ents.
b.
A system has been established for retaining identification after cutting or dividing materials during the manufacturing process.
c.
Positive identification of all materials for a finished component are traceable to a certified material test report.
d.
A system has been developed for control of nonforming materials to prevent their inadvertent use.
17 2.
Method of Accomplishment The preceding objectives were accomplished by:
a.
Review of chapter 5 of the Quality Assurance Manual, Revision 9
" Procurement Control."
b.
Review of chapter 6 of the Quality Assurance Manual, Revision 7
" Process Control and Material Identification."
Review of chapter 13 of the Quality Assurante Manual, Revision 8, c.
" Control of Nonconformities."
d.
Observed identification of twelve (12) nozzles on lower shell of Black Fox, unit one, traced identification through the system to the certified material test reports.
Observation of material storage area for conforming and non-c.
conforming materials.
f.
Interviews with cognizant personnel.
3.
Findinga Within this area of the inspection, no deviations from commitments or unresolved items were identified.