ML19305A057
| ML19305A057 | |
| Person / Time | |
|---|---|
| Issue date: | 10/31/1978 |
| From: | Hunnicutt D, Potapovs U NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML19305A056 | List: |
| References | |
| REF-QA-99900080 99900080-78-1, NUDOCS 7901020205 | |
| Download: ML19305A057 (10) | |
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VENDOR INSPECTION REPORT U. S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT REGION IV Report No.
99900080/78-01 Program No.
44060 Company:
Copes Vulcan, Incorporated Post Office Box 577 Lake City, Pennsylvania 16423 Inspection Conducted: October 16-20, 1978
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Inspector:
R. E. ON er, Contractor Inspector, Vendor Date Inspection Branch Approved by:
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D. M. Huhnicutt, Chief, Compcnents Section Date II, Vendor Inspection Branch Sumr g Inspection on October 16-20,' 1978 (99900080/78-01)
Areas Inspected:
Implementation of 10 CFR 50, Appendix B criteria and applicable codes and standards including:
training, handling - storage and shipping, liquid penetrant examination, testing of completed products, and action on previous inspection findings. The inspection involved 26 inspector-hours on site.
Results:
In the five (5) areas inspected, no deviations were identified.
The following unresolved item was identified:
Unresolved-Item: Handling - Storage and Shipping - The records of internal inspection for the handling devices, i.e., cranes, hooks, chains, sling and other devices, were not available due to the absence of the Maintenance Foreman, who maintains these records (Details Section, para-graph D.3.b.)
790102 cad 5
.. DETAILS SECTION (Prepared by R. E. Oller)
A.
Persons Contacted
- J. Baker, Vice President - Engineering A. Balczon, Plant Engineer
- N. Bruce Manager - Manufacturing J. Butler, Manager - Electronics Development T. Dzikowski, QC Inspector K. Logan, QC Inspector C. Lyons, Manager - Contracts Engineering
- D. Mays, Manager - Quality Control J. Niskanen, Receiving & Material Handling Supervisor
- P. Petersen, Manager - Inspection
- D. Tripp, Vice President - Materials
- Attended the Exit Meeting.
B.
Action on Previous Inspection Findings 1.
(Closed) Deviation (Report No. 77-01):
Failure to provide traceability by serial number of a privately owned 0-7 inch vernier caliper used in final inspection.
The inspector found the above caliper has been assigned a serial number to provide traceability.
2.
(Closed) Deviation (Report No. 77-01):
Failure to include three (3) different types of electrical measuring instruments in QC Procedure 50-5.07.03, Revision 11 to assure they are calibrated on a six (6) months cycle. The inspector found that in accordance with Copes Vulcan letter dated October 6, 1977, procedure No. 50-5.07.03 has been revised to include the above three (3). types of devices, i.e. temperature recorders,
-digital thermometer and tong testers.
Discussion with the Electronics Development Manager verified that he was aware of the need to revise the procedure when calibrated devices are added or removed from service.
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. C.
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 in-doctrination and training of personnel, performing activities affecting quality, is implemented in accordance with appli-cable codes.
b.
Appropriate written agenda are used, c.
Records of training sessions agenda and attendance are 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 disciplines.
e.
The instructors are suitably qualified.
2.
Method of Accomplishment The preceding objectives were accomplished by:
a.
Review of the QA Manual procedures No.1-6.08 " Indoctrination and Training of Personnel ' and No.1-6.22 " Internal Audits",
to verify that measures to control indoctrination and training are documented.
b.
Review of the following procedures to verify that these procedures contained provisions to implement the QA Manual and to identify personnel to receive training and indoctri-nation:
(1)
Procedure No. 50-5.27.30, Revision 3, " Indoctrination and Training of Quality Control Personnel in ASME III Requirements."
(2) Procedure No. 50-5.27.22, Revision 2, "SNT-TC-1A Nondestre-tive Testing Personnel Certification Procedure On Requirements for Training, Examination and Certifi-cation (LiquidPenetrant)."
. (3) Procedure No. 50-5.27.23, Revision 2, "SNT-TC-1A Hon-destructive Testing Personnel Certification Requirements for Training, Examination and Certifi-cation (Radiographic)."
(4) Procedure No. 50-1.1.43, Issued May 5, 1977, " Guide for Indoctrir.ation and Training of Engineering Department Personnel for ASME III Contracts."
(5) Procedure No. 50.1.1.41, Issued September 30, 1976,
" Guide for Training Contract Engineers for ASME III Contracts. "
c.
Review of training, examination and certification records for Liquid Penetrant Examination personnel to verify that they were trained, examined and certified in accordance with above procedure 50-5.27.22.
d.
Review of the examination and certification records for the Level III Examiner in radiography to verify that he was examined and certified in accordance with the above proce-dure 50-5.27.23.
e.
Review of the records of training and certification for the QC engineer and QC final inspectors to verify that these persons were trained and certified in accordance with the above procedure 50-5.27.30.
f.
Review of the records of training and certification of Contract Engineers to verify that these persons were trained and certified in accordance with the above proce-dure 50.1.1.41.
g.
Discussions with cognizant personnel.
3.
Findings Within this area of the inspection, no deviations or unresolved items were identified.
D.
Handling, Storage and Shipping 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:
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. a.
A written system has been established to assure that handling, storage, and shipping activities are controlled in accordance with codes and standards.
b.
Instructions, procedures or drawings are used to control handling, storage, shipping, packaging and preservation of materials and items, to prevent damage, deterioration, or losc c.
Access to stcrage areas is controlled.
d.
Periodic inspections and audits are performed to verify the integrity of the stored items.
e.
Completed items are cleaned, inspected and appropriately sealed, packaged or protected for shipment, and that the items are suitably blocked, anchored, braced and/or cushioned to prevent damage, f.
The shipping document packages are reviewed for completeness, before shipment.
g.
Lifting devices are maintained, periodically inspected, and controlled in accordance with written procedures or instruc-tions.
2.
Method of Accomplishment The preceding objectives were accomplished by:
a.
Review of QA Manual Procedure No.1-6.11, Revision 2,
" Handling, Storage, Shipping and Preservation," to verify that controls for these activities are documented.
b.
Review of the following procedures to verify that written instructions are used to control inspection of handling devices, and the handling, storage and shipping of valves and their parts.
(1)
Procedure No. 61-5.1.1, Revision 5, " Maintenance -
Material Handling Equipment."
(2) Procedure No. 50-5.19.01, Revision 1, "Haterial Handling."
(3)
Procedure No. 5.2.114, Revision 3, " Carton & Crate Construction for Packaging Commercial Valves for Nuclear Service."
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. c.
Observations of the physical condition and inspection status tags of the overhead cranes, hooks, chains and other lifting devices located throughout the shop, to verify that the above procedure No. 61-5.1.1 was being implemented.
d.
Review of outside source visual inspection records, dated February 20, 1978, for chains, hooks, nylon slings, and other items to verify that these type items were being maintained.
e.
Observations of finished and seni-finishrd valve parts contained on and in skids, boxes, and beskets for rovement from department to department for processing, to verify that the above procedure No. 50-5.19.01 was being implemented, f.
Observations in the shipping department of the various types of packaging and crating used fe' shipping different sizes of valves to verify that the above procedure No.
5.2.114 was being implemented.
g.
Discussions with cognizant personnel.
3.
Findings a.
Deviations From Connitments
- None, b.
Unresolved Item With regard to handling devices such as cranes, hooks, chains and others, procedure No. 61-5.1.1, paragraph 2, requires that all material handling equipment will be serialized and records on each serial number will be maintain-ed by the Maintenance Foreman as to the date of the last inspection.
paragraph 5 requires that all identified hooks will be nondestructive tested on a six (6) month basis.
Paragraph 6 requires that cables, belts, slings and eyebolts shall be visually inspected on a monthly basis.
Cables and chains attached to cranes shall be visually inspected on a monthly basis.
In response to the inspectors request to review records of the above inspections, the Manager of Manufacturing explained that the Maintenance Foreman, who had possession of the records, was absent from the Copes Vulcan, Inc. plant this week (10/16-20/78).
CVI management indicated they will secure these records for the NRC inspector to review during a subsequent inspection, t
. l This item remains unresolved pending review of the subject records during a subsequent NRC inspection.
E.
Liquid Penetrant Examination 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 liquid penetrant examination (PT) is performed in accordance with applicables codes.
b.
Final acceptance PT is performed in accordance with detailed written instructions or procedures which delineate require-ments and acceptance standards.
c.
The PT procedures meet the requirements of the ASME Code and are qualified.
d.
The PT is performed and the results interpreted by certified personnel.
e.
Test results are documented and evaluated to assure that the componer.L or material examined contain no rejectable defects.
f.
Appropriate instruments are used, and the instruments are calibrated, where required.
2.
Method of Accomplishment The preceding objectives were accomplished by:
a.
Review of the QA Manual Procedure No.1-6.09, paragraphs 3.3, " Inspection Prior to Welding" and 3.6, " Inspection of Welds, and Procedure No.1-6.20, " Contract Records" to verify that controls for liquid penetrant inspection are documented.
L b.
Review of. approved in-process procedure No. 50-5.9.12, l
Revision ll, " Liquid Penetrant Inspection - Solvent Removable l
" and No. 50-5.9.17, Revision 3, " Liquid Penetrant l
and Magnetic Particle Inspection Acceptance Standard" to
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verify that the procedure and acceptance standard were in accordance'with the ASME Code.
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, c.
Observation of the application of procedure No. 50-5.9.12 for a~1iquid penetrant examination of machined surfaces and a drainline weld preparation in a stainless steel 2-2 inch 900/1500# valve bonnet to verify that the procedure was followed.
d.
Review of the Operation and Route Sheet traveler and the
" Inspection Report Data Sheet" for the above valve bonnet on Order No. 10-95321 Part No. 166142FU to verify that the observed penetrant examination was controlled by the traveler and the results were documented in accordance with the QA program.
c.
Examination of the batch and type numbers on the containers for penetrar.t dye, developer and remover to verify that the materials were traceable to certifications and were of the type specified in Procedure No. 50-5.9.12.
f.
Review of the certification card for the NDE technician who performed the liquid penetrant examination to verify that he was qualified and certified in accordance with ASME Code requirements.
g.
Review of approved proceiure No. 50-5.9.13, Revision 5,
" Liquid Penetrant Insoettion Visible Water Wash Method" to verify that en approved procedure was available for the water soluble methed of penetrant inspection.
h.
Review of Operation and Route Sheets and Inspection Report Data Sheets for completed work on two (2) valve bodies for:
Orders No. 95378, Part 170100FU and Order No. 95390, Part 182383, to verify that these liquid penetrant examinations were controlled and the results were recorded in accordance with the QA program.
1.
Discussions with cognizant personnel.
3.
Findings Within this area of the inspection, no deviations or unresolved items were identified.
G.
Testing of Completed products 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 final assembly, pressure tests, and functional tests are controlled in accordance with applicable procedures, specifications, drawings and codes.
b.
Final assembly, pressu.'e tests and functional tests are performed in accordance with approved procedures,instruc-tions, specifications or drawings, c.
The results of tests are documented and reviewed for acccptability.
d.
The test equipment is calibrated where required.
e.
_The assembling, tests and inspections are performed by qualified personnel.
2.
Method of Accomplishment The preceding objectives were accomplished by:
a.
Review of the QA Manual Procedures No.1-6.14, Revision 3,
" Assembly and Test," and No.1-6.15, Revision 3, " Final Pressure Test (Hydrostatic)" to verify that adequate controls for final assembly and testing of valves are documented.
b.
Review of approved Procedures No.1.2.1.87, Revision 10
" Assembly of D-100 Valves and Actuator," and No. 4.4.451, Revision 1, " Production Test Procedure for Commercial Feedwater Bypass Valves Intended For Nuclear Service" to verify that these procedures prescribed a system fo-the assembly and test of the valve observed under test.
c.
Observation of a demonstration hydrostatic test of 4"-900#
. globe valve, SN-7720-95390-1-3, using the above procedure No. 4.4.451, to verify that the procedure was being followed.
d.
Review of the following processes cor'.*ol documents for a 4"-900# globe valve, SN-7720-95390, which was in the assembly stage to verify that the assembly operation was controlled.
(1) Shop Order.
(2) Assembly Route Sheet Traveler.
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- l (3) Assembly Drawing No. D-175864, Revision 1.
(4) Assembly Procedure No.1.2.1.87, Revision 10.
(5)
Final Test Procedure No. 4.4.451.
e.
Observation of the hydrostatic test facilities including the calibration status of the presssure gages to verify that the equipment was adequate and the gages were in calibration.
f.
Review of " Inspection and Test Reports" contain in record packages for two (2) completed valves SN-7720-95390-1-1 and SN-7620-95378-223-4, to verify that final hydrostatic test, seat and packing leakage tests, and functional tests results were. recorded.
g.
Discussions with cognizant personnel.
3.
Findings Within this area of the inspection, no deviations or unresolved items were identified.
H.
Exit Interview 1.
The inspector met with management representatives denoted in paragraph A, at the conclusion of the inspection on October 20, 1978.
2.
The following subjects were discussed:
a.
Areas inspected.
b.
Status of corrective action for previous inspection findings, c.
The unavailability of the inspection records for the cranes and other handling devices.
3.
Management's comments were generally related to clarification of the above findings.
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