ML19308A245
| ML19308A245 | |
| Person / Time | |
|---|---|
| Issue date: | 10/12/1978 |
| From: | Hunnicutt D, Oller R NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML19308A244 | List: |
| References | |
| REF-QA-99900314 44020, NUDOCS 7901230313 | |
| Download: ML19308A245 (12) | |
Text
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VENDOR INSPECTION REPORT U. S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT REGION IV Report No.
99900314/78-01 Program No. 44020 Company:
Colt Industries Trent Tube Division of Crucible Inc.
141 Hammonds Street Carrollton, Georgia 30117 Inspection Conducted:
September 18-21, 1978 Inspector:
/Y R. E. Oller, Contractor Inspector, Vendor Date Inspection Branch Approved by:
J hf
- T
/0//2 /77 D. M. Hunnicutt, Chief, ComponentsSection II Cate/
Vendor Inspection Branch Summary Inspection on September 18-21, 1978 (99900314/78-01)
Areas Insoected:
Implementation of 10 CFR 50, Appendix B criteria, and applicable codes and standards including general review of vendor activities, Authorized Nuclear Inspector Interface, weld joint fitup and welding, weld heat treatment, liquid penetrant examination, radiographic examination, and action on previous inspection findings.
The inspection involved twenty-seven (27) inspector-hours on site.
Results:
In the seven (7) areas inspected, no deviations or unresolved items were identified.
790123D 5/3
DETAILS SECTION (Prepared by R. E. Oller)
A.
Persons Contacted
- W.
Hill, QC Inspector G. uvatt waiaina na--
+--
d.
Masnoorn, level II, NDE Technician R. McDcwell, Level II, NDE Technician M. Nawsom, Records Coordinatcr J. Leadue, Welding Technician
- L. Powell, Plant Manager B. Smith, Level II, NDE Technician C. Toegal, Authorized Nuclear Inspector HS3 I&I Company
- J. Wehrle, QA Manager
- Attended the exit meeting.
B.
Action on previous Inscection Findinos 1.
(Closed) Deviation (Report No. 77-01):
Failure to develop a training schedule in cooperation with department heads concerned.
The inspector found that a written training scnedule and program for 1973, has been developed anc the first two sessions have been conducted.
2.
(Closed) Deviation (Report No. 77-01):
Failure to provide evidence of Authorized Insoector ( AI) concurrence fcr the proposed resolutions of nonconformances involving repair denoted en Rejecticn Tag numcers 0961, 0025, a.d C327 for tube TA-024.
The inspector found that in accordance with Trent Tube letter dated February I6, 1978, paragraph 18.9 of the QA Manual has been revised to require AI concurrence on proposed resolutions involving base retal repair.
In additicn, review of the acove three (3) Rejection Tags verified that the Authorized Nuclear Inspector has now initiaied and dated them as evidence of his concurrence of the proposed resolutions.
3.
(Closed) Deviation (Repcrt No. 77-01):
Failure to place the procedure and revision number fcr oparat10ns in the "Special Instruction" blocks of three (3) in-prccess Mill Orders (travelers).
The inspector found that in accordance with Trent Tube letter dated February 16, 1978, paragraph 12.2 of tne QA M.anual was revised to allow applicable procedure numbers to be put in the Mill Order travelers after the operaticn er in the "Instructicn Block" if there is insufficient space after the operation description.
Review of a current Mill Order Traveler, No. 0-05-40559-8, verified that the applicable procedure number and revision were entered after the operation.
4.
(Closed) Deviation (Report No. 77-01): Failure to identify procedure numbers and revisions on in-process Mill Order No. 3-C5-50714-7, Item 0, Tube TA-022.
The inspector found that in accordance with Trent Tube letter dated February 16, 1978, that paragraph 2.1(b) of the QA Manual has been revised to state that the special processes such as welding, heat treatment, hydrostatic testing and NDE will be identified on the traveler.
5.
(Closed) Deviation (Report No. 77-01):
Failure to indicate on Mill Order No. 6-C5-50713-7, Item 0, Tube TA-024, the Rejection Tag numbers 0961, 0025, and 0027, which were the documents that covered further operations on the item which was unsatisfactorily completed at the radiographic operation.
The inspector found that in accordance with Trent Tube letter dated February 16, 1978, the QA Manager issued a letter to inspection and laboratory personnel and the Production Superintendent issued a letter to production personnel.
Both of these letters instructed the affected personnel that Rejection Tag numbers and the corresponding disposition must be entered on the Mill Order Travelers.
The above Mill Order had been shipped with other records to the customer and was not avail-able for review.
6.
(Closed) Deviation (Report No. 77-01):
Failure by the QA Manager to sign a quality related procedure, No. PCS-015-C1, " Degrease" to show it had been reviewed for adequacy and approved for release.
The inspector found that the above procedure was signed and dated August 14, 1978, by the QA Manager as evidence of review and approval.
7.
(Closed) Deviation (Report No. 77-01):
Failure to include a
" Smith Proportional Mixer" Model S-299-006-3 in the Calibration tog and failure to calibrate this device. The inspector found the above device was calibrated by a subcontractor on January 25, 1978, and the device has been entered in the Calibration Log and assigned an annual calibration frequency.
8.
(Closed) Deviation (Report Nc 77-01):
Failure to include two (2)
Airco " Mini Proportioners" (SN-124 and SN-193) and a Thermco
" Portable Mixer Analyzer" (SN-6404) in the calibration log and failure to provide certificates of calibration for these calibrated devices. The inspector found that Trent Tube had received a letter from Airco certifying that the Mini Proportioners were tested and conforms to Airco Test Procedures.
The above analyzer was calibrated by Trent Tube using a certified hydrogen-argon gas mixture from Matheson and a procedure provided by Thermco. The Mini Propor-tioners and the Thermco Mixer Analyzer have been added to the Calibration Log and assigned an annual calibration frequency.
9.
(Closed) Deviation (Report No. 77-01):
Failure to prepare and maintain calibration cards for a gage block set, SN-137R, and a dial indicator, SN-14, w+.ich were listed in th : Calibration Log.
The inspector found that a calibr. ion card has been prepared e
for the gage block set and is being properly maintained.
The card for the dial indicator had been misplaced, but had been found and is being properly maintained.
10.
(Closed) Deviation (Report No. 77-01):
Failure to list on the qualified vendor list two (2) subcontractors providing calibra-tion services for equipment which they did not manufacture.
The inspector found that in accordance with Trent Tube's letter dated February 16, 1978, paragraph 17.7 of the QA Manual was revised to delete reference to manufacturers of the equipment or device and instead requires that calibration subcontractors shall provide a certificate of calibration for the device checked and reference the certified measuring standard used.
Review also verified the two above subcontractors are now listed on the qualified vendors i
list.
11.
(Closed) Unresolved Item (Report No. 77-01):
Failure to provide appropriate storage conditions for final inspection measuring devices and ultrasonic test equipment. The inspector observed that a clean storage cabinet is now being used in final inspection area for storing measuring devices and ultrasonic test transducers.
12.
(Closed) Unresolved Item (Report No. 77-01):
Failure to properly maintain a radiographic McBeth Density Step Tablet calibration film strip No. PN-2900678.
The inspector found that a new National Bureau of Standards, NBS-1008, Photographic Tablet density strip-film for use in calibrating the densitometer has been secured and is in use in place of the old step tablet film.
c.
General Review of Vendor's Activities 1.
Objective The objective of this area of the inspection was to assess the vendcr's activities and ineir impact on future NRC inspections and identify the components supplied for nuclear facilities.
2.
Method of Accomolishment
-5 The preceding objective was accomplished by:
a.
Discussions with cognize.nt personnel.
b.
Review of the following ASME N-type symbol authorization to verify that it was current and identified the products:
NPT, N-2016, Class 1, 2, and 3 Piping Subassemblies and Tubular Products, welded with filler metal.
Expires February 24, 1981.
c.
Verbal review of principal contracts and projected work loads for impact on the NRC inspection schedule.
d.
Review of manufacturing processes and QA/QC activities to evaluate the vendor's effectiveness in controlling the quality of the product.
3.
Findings Within this area of the inspection, no deviations or unresolved items were identified.
D.
Authorized Nuclear Inspector Interface 1.
Objectives The objectives of this area of the inspection were to verify that the following items are controlled in accordance with applicable NRC and ASME Code requirements.
a.
A written system has been established to assure that controls by the manufacturer are adequaLa to facilitate the inspection activities of the Authorized Nuclear Inspector (ANI).
b.
The ANI has direct contact with the cognizant plant QA/QC representative.
c.
The ANI has free access to all parts of the plant concerned with supply or manufacture of ASME Code work.
d.
All applicable documents are available to the ANI for review.
e.
The ANI identifies and signs off on witness hold points on process control documents and witnesses qualification of special NDE procedures.
f.
The ANI maintains a log of activities reviewed and or witnessed.
2.
Method of Accomolishment The preceding objectives were accomplished by:
a.
Review of the QA Manual Section 21.0 " Contacts with ASME and Authorized Inspection Agency," to verify that these provisions were adequate to facilitate the inspection activ-ities of the ANI.
b.
Discussions with the ANI with regard to:
notification for ANI inspection services, plant contact, freedom of access, availability of necessary documents, establishing and sign-off of ANI Hold Points, and review by the ANI of procedures and personnel qualification records.
c.
Review of the ANI's daily inspection log.
3.
Findings Within this area of the inspection, no deviations or unresolved items were identified.
E.
Weld Joint Fitup and Welding 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 welding is performed and controlled in accordance with applicable codes and procedure specifications.
b.
The work is conducted in accordance with a process control document, such as a traveler.
Applicable qualified welding procedure specifications (WPS) c.
and weld data sheets are used at the work stations.
d.
The requirements of essential variables and other applicable WPS parameters are concurred with to produce weldments having the required properties.
e.
The welding is being performed by properly qualified personnel.
f.
Weld joint geometry, fitup alignment, and surface preparation are as required by the applicable WPS and the Code.
g.
The welding equipment is in good condition and calibrated, were required.
h.
The completed weld meets code requirements for nondestructive examination suitability, undercut and other visual acceptance standards.
2.
Method of Accomplishment The preceding objectives were accomplished by:
a.
fieview of the QA Manual, Section 13.0, " Welding" to verify that adequate controls for welding are documented.
b.
Review of Mill Order Traveler, No. 2-C3-00388-8, for manufacture of a 14" diameter, 0.375" wall, T-304 stainless steel pipe 20'6" long to verify that the welding coeration was controlled and identified by procedura and revision number on the traveler.
c.
Review of the welding Procedure Specification (WPS) No.
TWP-SB, Revision 1 for the above traveler operation, the related procedure qualification record (PQR) No. TWP-5-Q11, Revirion dated July 24, 1978, and the welding operator qualification record dated April 3,1977, to verify that the required WPS was being used; that the WPS was approved and qualified and the the welding operator was properly qualified.
d.
Observation of the in-process automatic gas tungsten arc welding (GTAW) with filler metal added of *,he above pipe to verify that the procedure's essential variables and other parameters were being complied with.
e.
Review of general procedure No. QDP-159, Revision 0, " Repair of Austentic Stainless Steel Pipe or Tubes" to assure that a general repair procedure for weld metal or base metal had been prepared and approved for use.
f.
Review of automatic GTAW WPS No. T-4A, Revision 1, " Machine-Repair" and the related PQR No. TWP-4-Q1 to assure that a properly qualified automatic repair WPS was available for use.
g.
Review of manual GTAW WPS No. TWP-48, Revision 1, and the related PQR TWP-4-Q2 to assure that a properly qualified manual repair WPS was available for use.
h.
Observation of the calibration status of the above batch automatic welding equipment to verify that the calibration was under control.
i.
Review of the following welding records to verifv that completed welding was properly controlled and documented.
a.
Mill Order Traveler for M.0.-0C5-40559-8.
b.
Welding Report Sheets TWP-3T and TWP-5 for welding for the above Mill Order.
c.
Welding Wire Release No. 5 dated June 6, 1978 for welding on the above Mill Order.
j.
Discussions with cognizant personnel.
3.
Findings Within this area of the inspection, no deviations or unresolved items were identified.
F.
Weld Heat Treatment 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 heat treatment of welds is performed and controlled in accordance with applicable codes.
b.
Documented procedures are available and are implemented, when required by welding procedure specifications to control weld preheat, interpass temperature and postweld heat treatment (solution annealing heat treatment) in accordance with ASME code requirements.
c.
The weld heat treatments are suitably documented, were required.
d.
The heat treating equipment is calibrated where required.
e.
The weld heat treatment is performed by qualified personnel.
2.
Method of Accomplishment The preceding objectives were accomplished by:
a.
Review of the QA Manual Section 15.0, subsection 15.1 " Heat Treating" to verify that controls for post weld heat treatment are documented.
b.
Review of approved procedure QDP-014-C1, Revision 2, " Heat Treatment Procedure Roller Hearth Furnace-723" and approved procedure QDP-014-C2, Revision 1, " Heat Treatment Procedure, 36" Annealing Furnace" to verify that documented measures were prov ided to control the postweld solution annealing heat treatment of all sizes of seam welded austenitic stainless steel pipes in accordance with the ASME Code.
c.
Observation of two (2) furnaces including the water spray /
fog quenching facilities and the calibration status of the recorder / controllers to verify that the facilities maintained.
d.
Review of the following heat treatment records for completed Mill Orders No. 0-C5-40559-8 and No. 7-C5-40336-8, to verify that the applicable procedures were used and the completed the operation was documented on a report and the furnace charts in accordance with the QA program.
(1) Mill Order Travelers.
(2) Operator's Report and Furnace Reports.
(3)
Furnace Charts.
3.
Findinas Within this area of the inspection, no deviations or unresolved items were identified.
G.
. 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 acceptance standards.
b.
Final acceptance PT is performed in accordance with detailed written instructions or procedures which delineate requirements 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 component or material examined contain no rejectable defects.
2.
Method of Accomplishment The preceding objectives were accomplished by:
a.
Review of the QA Manual Section 14.0 " Nondestructive Examin-ation" to verify that controls for dye penetrant inspection are documented.
b.
Review of approved procedure No. QDP-102-C5, Revision 1,
" Procedure For Liquid Penetrant Testing of Welds In Stainless Steel Pipe and Tubing - Solvent Removable Method" to verify that the procedure was in accordance with the ASME Code and contained appropriate acceptance criteria.
c.
Observation of the application of procedure No. QDP-102-C5 for a dye penetrant examination on longitudinal welds in two (2) stainless steel pipes to verify that the procedure was followed.
d.
Examination of the batch numbers and type numbers on the penetrant, developer and cleaner containers, to verify that the materials were treaceable and were of the type specified in the above procedure.
e.
Review of the certification and physical (eye) examination records for two (2) Level II NDE Technicians to verify that these NDE personnel were qualified in accordance with SNT-TC-1A standards, as required by the ASME code.
f.
Review of the " Penetrant Examination Report" and the Mill Order Traveler for completed dye penetrant examination of work for Mill Order No.1-C5-40532-8, Tube GI-154, to verify that the penetrant examination was controlled and the results were documented in accordance with the QA program, g.
Discussions with cognizant personnel.
3.
Findinas Within this area of the inspection, no deviations or unresolved items were identified.
H.
Radiographic 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 ra-diographic examination (RT) is performed in accordance with applicable codes.
b.
Final acceptance RT is performed in accordance with detailed written instructions or procedures which delineate requirements and acceptance standards.
c.
The RT procedure meet the requirements of the ASME Code and is qualified.
d.
The RT is performed and the results interpreted by certified personnel.
e.
Test results are documented and evaluated to assure that the component or material examined contains no rejectable defects.
f.
Appropriate instruments are used, and that the instruments are calibrated, where required.
2.
Method of Accomplishment The preceding objectives were accomplished by:
a.
Review of the QA Manual Section 14.0 " Nondestructive Examin-ation" to verify that controls for radiographic examination are documented.
b.
Review of approved procedure No. QDP-101-C4, Revision 1,
" Procedure For Radiographic Examination of Welds-Without Filler Metal" and approved procedure No. QDP-101-C3, Revisioc.
1, " Procedure For Radiographic Examination of Welds-Filler Metal" to verify that these procedures were in accordance
with the ASME Code and contained appropriate acceptance criteria.
c.
Observation of the application of procedure No. QDP-101-C4 for the radiographic examination of the longitudinal weld in a stainless steel pipe on Mill Order No. 4-C5-40645-8 to verify that the procedure was being followed.
d.
Observation of radiographic x-ray facilities including the densitometer and NBS Film Step Tablet to verify that the equipment was maintained and calibrated where required.
e.
Review of the Radiographic Examination Report and the Mill Order Traveler for completed radiographic work for Mill Order No. 7-C5-40336-8, Tube TA-033 to verify that the above radiographic examination was controlled and the results were documented in accordance with the QA program.
f.
Review of the certification and physical (eye) examination record for the Level II NDE technician performing and interpreting the radiography to verify that the technician was qualified in accordance with SNT-TC-1A standards, as required by the ASME Code.
g.
Discussions with cognizant personnel.
3.
Findings Within this area of the inspection, no deviations or unresolved items were identified.
I.
Exit Interview 1.
The inspector met with management representatives denoted in paragraph A, at the conclusion of the inspection on September 21, 1978.
2.
The status of corrective action for previous inspection findings was discussed.
3.
The plant management was informed that no deviations or unresolved items were identified in the areas inspected.
4.
Management's comments were related to the above items.
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