ML19305D078
| ML19305D078 | |
| Person / Time | |
|---|---|
| Issue date: | 11/15/1979 |
| From: | NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML19305D056 | List: |
| References | |
| REF-QA-99900047 99900047-79-2, NUDOCS 8004140040 | |
| Download: ML19305D078 (3) | |
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Westinghouse Nuclear Components Division, Tampa Plant 99900047/79-02 NOTICE OF DEVIATION Based on the results of an NRC inspection conducted on October 15-19, 'J79, 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 instructions, 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 2.17 in Standard Division Procedure PQ3-006.2 states, " Stores Attendants are responsible for requistioning weld materials, for baking electrodes, for issuance of welding materials to welders, for sorting returned electrodes and re-baking electrodes.
They are also responsible for filling in form WC-1."
Contrary to the above:
1.
Form WC-1 was not filled in on October 17, 1979, relative to the return of electrode stubs from a pressurizer clip welding operation.
2.
Form WC-1 was observed at 4.40 p.m. on October 17, 1979, being filled in by a welder and not by the Stores Attendant.
3.
Returned 5/32 inch Inconel 182 electrodes were observed mixed, i.e.,
Heat Nos. 0049 and 0058, in a canister on top of an electrode holding oven.
It was cdditionally noted that three (3) different heats of 1/8 inch Inconel 182 electrodes, i.e., 0046, 0073 and 0074, were pre-sent mixed together in the same holding oven, which was identified by Test Number as containing only 1/8 inch Inconel 182 electrodes from Heat No. 0046.
(See Details I, B.2.).
B.
Paragraph 9.4, sub paragraph 9.4.4, in Section 9 of the QA Program Manual states in part, "All welding operations are performed as indicated in Manufacturing Line-ups in conformance with Process Specifications..
Contrary to the above, submerged arc, shielded metal are and automatic gas tungsten are welding operations were observed, which were not being per-formed in full conformance with the electrical parameter requirements of the applicable Process Specifications.
(See Details I, C.3.a.)
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2 C.
Paragraphs NB/NC/ND-2410 in the ASME Section III Code state in part with respect to welding materials used in the construction and repair of com-ponents, "... In addition, welding material shall conform to the re-quirements stated in this Subarticle.
Paragraphs NB/NC/ND-2431.1(c) in the ASME Section III Code state in part with respect to the general test requirements for weld metal,
. Coupons shall be tested in the as-welded condition, or they shall be tested in the applicable postweld heat treated condition when the production welds are to be postweld heat treated.
Contrary to the above, 1/8 inch E-9018M electrodes were procured with testing performed only in the postweld heat treated condition, although used in applications not receiving a subsequent postweld heat treatment, i.e. temper bead repairs after final postweld heat treatment (See Details I,D.3.a.(2)).
D.
Paragraphs QW-281.2 and QW-281.3 (Corrosion Resistant Weld Metal Overlay) in the ASME Section IX Code require for the shielded metal are welding (SMAW), process that a WPS be set up as a new WPS and completely re-qualified, when welding positions other than those already qualified are added and when changes are made in the nominal electrode diameter used for the first layer of deposit.
Contrary to the above, SMAW WPS, PS 82121UW Issue 1, permitted both changes in welding position and changes in nominal electrode diameter used for the first layer of deposit, relative to the qualifications submitted to the inspector on October 18, 1979, as the appropriate PQRs for the WPS.
(See Details I, E.3.a.)
E.
Paragraph 9.10 in Section 9 of the QA Program Manual states in part,
" Weld repairs and base metal repairs shall be in accordance with
- 12. 3. 7... " Paragraph 12.3.7 in Section 12 of the QA Program Manual states, "If repair disposition is determined, Industrial Engineering prepares an M.R.R.T which is reviewed for completeness by Quality Assurance.
The M.R.R.T delineates the proper manufacturing and inspection operations l
necessary for the repair, and references the P.S.I. or H.D.I. applicable for the process. Quality Assurance distributes the M.R.R. and M.R.R.T.
to the applicable persons or departments, including the Authorized Nuclear Inspector for his information or insertion of Notification of Hold Paints if required."
Contrary to the above, weld and base metal repairs were observed being performed in the longitudinal seam run-off tab area of a steam generator shell (Order No. PCGT 2583, Assigned Item AAA, Upper Shell Barrel - Cone End), without preparation, review and distribution of an M.R.R. and M.R.R.T.
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3 F.
Nuclear Power Components Dye Penetrant Examination Process Specification No. 84350 JA, paragraph VI, states in part, "... materials including cleaning agents shall be certified not to contain more than 1% sulfur or total halogens by weight'."
Contrary to the above, materials (penetrant) could not be certified not to contain more than 1% sulfur or total halogens by weight, in that the penetrant containers used by production were observed to contain rags and other foreign materials.
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