ML19309B188
| ML19309B188 | |
| Person / Time | |
|---|---|
| Issue date: | 01/04/1980 |
| From: | Ellershaw L, Hunnicutt D NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML19309B177 | List: |
| References | |
| REF-QA-99900342 99900342-79-2, NUDOCS 8004030244 | |
| Download: ML19309B188 (9) | |
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AU U.S. NUCLEAR REGUIATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT REGION IV Report No. 99900342/79-02 Program No. 51300 Company:
Lakeside Bridge & Steel Company 5300 North 33rd Street Milwaukee, Wisconsin 53209 Inspection Conducted:
December 10-14, 1979 v
lblTO Inspectors:
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L. E. Ellershaw,' Contractor Inspector bach ComponentsSection II Vendor Inspection Branch 1
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Approved by:
D. M. Hunnicutt, Chi 3f j
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ComponentsSection II Vendor Inspection Arcnch Summary Inspection conducted December 10-14, 1979 (99900342/79-02)
Areas Inspected:
Implementation of 10 CFR 50 Appendix B Criteria, and applicable codes and standards including: Pervious inspection findings; follow-up on 10 CFR 21 report; joint fitup and welding; welder qualifi-cations; nondestructive examination (NDE) personnel qualifications; wela material control, and procurement source selection.
The inspection in-volved 35.5 inspector hours on site.
Results:
In the seven areas inspected, two deviations from commitment were identified.
There were no unresolved items.
Deviations: Joint Fitup and Welding - welding was being performed without the welders being equipped to measure interpass temperatures, a supple-mentary essential variable (See Notice of Deviation, Item A); Procurement Source Selection - certain vendors are shown on the AVL as being fully approved, but certain pertinent areas for which they were qualified are shown in the Vendor Evaluation Report _, not having been evaluated.
(See Notice of Deviation, Item B).
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DETAILS SECTION (Prepared by L. E. Ellershaw)
A.
Persons Contacted F. Cullen - Welding Foreman W. E. Jonas - NDE Level III Examiner l
R. Kubit - Chief Structural Engineer R. T. Rozek - Director, Quality Assurance Y. T. Smith - Welding Engineer E. Soref - Welding / Engineer, Manufacturing R. Weber - Weld Material Cage Attendant L. Webster - Weld Material Cage Attendant A. J. Wos - Quality Assurance Engineer B.
Action on Previous Inspection Findings 1.
(Closed) Item A (Report No. 79-01): This item dealt with final dispositions of nonconformance reports (NCR) not being presented to the Authorized Nuclear Inspector (ANI) prior to implementing the disposition.
Lakeside 3 ridge & Steel Company (LB&S) has implemented their committed corrective action in that all NCRs involving Code items have been presented to the ANI prior to implementing the disposition.
2.
(Closed) Item B (Report No. 79-01):
This item' dealt with the failure to control the return or use of welding electrodes.
LB&S has implemented their committed corrective action in that welding electrodes are being controlled and a written warning was given to the particular welder.
3.
(Closed) Item C (Report No. 79-01): This item dealt with welding not being performed in accordance with the qualified welding procedure specifications.
LB&S has implement 6d their committed corrective action relative to the specifically identified deviation, in that QA has in-creased in-process welding surveillance, and an assessment of the identified conditions was made.
However, a similar deviation was identified during this in-spection.
(Notice of Deviation, Item A).
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(Closed) Item D (Report No. 79-01):
This item dealt with post-weld heat treatment (PWHT) being performed on pipe assemblies, in which the welding procedure specifications (WPS) used, were not qualified for PWHT.
LB&S has implemented their committed c.orrective action with in-creased emphasis by Quality Assurance Pre-Planning.
Additiona'ly, a WPS which is qualified in the PWHT condition was found to be identical to the WPS used, but which had not been qualified.
Therefore, the error was in specifying the wrong WPS on the Manufacturing Process Sheet.
5.
(Closed) Unresolved Item (Report No. 79-01):
This item dealt with meters on automatic welding equipment not being included in the calibration program.
LB&S has revised and implemented the calibration procedure to include meter electrical checks.
C.
Follow-up On 10 CFR 21 Report 1.
Introduction Tennessee Valley Authority (TVA) reported by telephone to NRC Region II on September 12, 1979, that reactor pressure vessel studs had received improper heat treatment relative to batch size and that all studs had been recalled for testing of addi-tional samples and possible re-heat treatment.
2.
Objectives 4
The objectives of this area of the inspection were to verify that LB&S had implemented the requirements for:
reporting the defi-ciency; performing an evaluation of the condition including making an assessment of generic implications, and assigning responsi-bility for effecting corrective action and preventing recurrence.
3.
Method of Accomplishment The preceding objectives were accomplished by:
Review of 10 CFR 50.55(e)/10 CFR 21 preliminary report.
a.
b.
Review of all correspondence relative to the reported deficiency; i.e., correspondence between the licensee (TVA) and LB&S, and between LB&S and Acimet Manufacturing (a subcontractor to LB&S).
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Discussions with cognizant personnel.
4.
Findings LB&S placed Purchase Order (P.O.) SC9225 with Acimet Manufacturing Company (AMC), procuring 756-' 3 inch Reactor Pressure Vessel, Anchor Bolts, material specification SA-540, in accordance with ASME Code NF-2000.
AMC subcontracted the heat treatment of the bolts to Addison He _ Treat Company (AMC's P.O. dated 1-18-79),
in accordance with SA-540.
The material was sent to Addison in lots of 10,000 pounds.
Af ter the P.O. was issued, the require-ment for 6,000 pounds maximun size heat treat lot per ASME Code Section III, NF-2000 was identified, and verbally transmitted from AMC to Addison in February 1979.
A formal change notice was not issued.
After completion of heat treatment, a Certification of Heat Treatment was provided by Addison to AMC.
It was at this time the heat treat lot size error was discovered.
The actual heat treat lots were from 9,000 to 13,000 pounds.
Subseque-'
charpy impact tests failed the 25 mills minimum lateral expansion requirements.
AMC notified LB&S by telephone on August 8, 1979, with written notification following on August 14, 1979, including AMC Noncon-formance Report (NCR) No. 170.
It was determined that 126 of the 756 bolts had been shipped to the site (Hartsville).
LB&S submitted their NCR (No. 562-25) and a TVA NCR (S-10) to TVA on August 16, 1979.
LB&S identified their NCR as a 10 CFR 21 notification.
LB&S's proposed disposition was to obtain the return of the 126 bolts and to re-heat all of the material after normalizing, in 6000 pounds maximum heat treat lots, including all required testing.
TVA and General Electric Company (Reactor Vessel Manufacturer) accepted the proposed disposition with final sign-off on September 18, 1979.
AMC conducted a review of previous nuclear orders requiring both SAS40 and ASME Section III, NF-2000 material, to ascertain generic implications.
It was determined that all previous orders had been properly heat' treated.
The review was documented to LB&S, by letter dated September 20, 1979.
LB&S summarized to TVA, all of the above by letter dated October 19, 1979.
The 126 bolts were returned from the site, rc ueat -eated by Nettleton Heat Treat Conpany, tested, and re-shipped to the site.
The remaining 630 bolts have been replaced with r aw
- material, f
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5 D.
Joint Fitup and Welding 1.
Obj ectives The objectives of this area of the inspection were to verify that LB&S had implemented the requirements for the control of joint fitup and in-process welding in accordance with the QA Manual and applicable NRC and ASME Code requirements.
2.
Method of Accomplishment The preceding objectives were accomplished by:
a.
Review of QA Manual Section 10, dated October 25, 1978.
b.
Observation of the following welding being performed on Contract 9152 and review of the applicable welding pro-cedure specifications (WPS):
(1)
Flux Core Arc Welding (FCAW) on Reactor Support, Mark l
No. 2-0-1-6.
(2) FCAW on Reactor Support, Mark No. 2-0-1-3.
c.
Review of the applicable Manufacturing Process Sheets and drawings for the above in-process welding.
d.
Discussions with cognizant personnel.
3.
Findings s.
Deviation From Commitment See Notice of Deviation, Item A.
The base material being welded, was A-588, Grade A.
The Sargent and Lundy specification Y-2797, amendment 2, dated 10-25-78 for Contract 9182 imposes Charpy impact require-ments. Where Charpy impact requirements are imposed, inter-pass temperatures become a supplementary essential variable for the FCAW process.
-The WPS being used on both welds, was 30-B-U3-GF, revision 1, 0
dated June 8,1978, which required a 500 F maximum interpass temperature. - The welds were multiple layer welds and the welders were not equipped to measure the interpass tempera-ture.
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b.
Unresolved Item None.
E.
Welder Qualifications 1.
Objectives The objectives of this area of the inspection were to verify that LB&S had implemen:ed the requirements for qualifying and main-taining the qualifications of welders in accordance with the QA Manual and applicable NRC and ASME Code requirements.
t 2.
Method of Accomplishment The preceding objectives were accomplished by:
a.
Review of QA Manual Section 10, dated October 25, 1978.
b.
Review Record of Performance Qualification Tests and comparison to ASME Code requirements.
c.
Review current list of qualified welders.
d.
Observation of welders and review of Welder Qualification Record.
e.
Discussions with cognizant personnel.
f.
Review of Procedure 5.4.1, '* Welder and Welding Operator Performance Qualification," revision 1.
3.
Findings a.
Deviat ion From Commitment None.
b.
Unresolved Item None.
F.
Nondestructive Examination (NDE) Personnel Qualifications 1.
Obj ectives The objectives of this area of the inspection were to verify that LB&S had implemented the requirements for qualification of NDE i
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personnel in accordance with the QA Manual and applicable NRC and ASME Code requirements.
2.
Method of Accomplishment The preceding objectives were accomplished by:
a.
Review of QA Manual Section 14, dated October 25, 1978.
b.
Review of SNT-TC-1A and ASME Code requirements.
c.
Review of NDE personnel qualification records.
d.
Discussion with cognizant personnel.
3.
Findings a.
Deviation From Commitment
- None, b.
Unresolved Item None.
G.
Weld Material Control 1.
Objectives The objectives of this area of the inspection were to verify that LB&S had implementad the requirements for the control of weld mater-ial including qualification, storage and issuance, in accordance with the QA Manual and applicable NRC and ASME Code requirements.
2.
Method of Accomplishment The preceding objectives were accomplished by:
Review of QA Manual Section 10, dated October 25, 1978.
a.
b.
Review of Procedure 5.1, " Weld Material Issue Procedure,"
revision 7.
Observation of weld material located in storage areas in-c.
cluding storage ovens, i
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Observation of weld material issued to welders / welding operators.
e.
Review of weld material certifications, f.
Discussions with cognizant personnel.
3.
Findings a.
Deviation From Commitments None.
b.
Unresolved Item None.
H.
Procurement Source Selection 1.
Objectives The objectives of this area of the inspection were to verify that LB&S had implemented the requirements for procurement source selection in accordance with the QA Manual and applicable NRC and ASME Code requirements.
2.
Method of Accomplishment The preceding objectives were accomplished by:
a.
Review of QA Manual Section 8, dated October 25, 1978.
b.
Review of Approved Vendors List (AVL),
c.
Review of five Vendor Evaluation Reports to assure chac the pertinent activities for which the vendor is qualified, as shown on the AVL, have been evaluated for procedures aad procedure implementation.
d.
Discussions with cognizant Personnel.
3.
Findings a.
Deviation From Commitment See Notice of Deviation, Item B.
9 The AVL shows that Florida Steel Corporation was fully ap-proved on February 16, 1979, for the following activities:
steel fabricators; welding, and NDE.
The Vendor Evaluation Report dated February 16, 1979, shows them to be conditionally approved.
In addition, nearly all sections of the Report dealing with procedure implementation relative to fabrication, welding, and NDE are blank.
The AVL shows Siemens - Allis as being fully approved on July 11, 1979, for the following activities:
calibration; fabrication; NDE; machining, and stress relieving.
The Vendor Evaluation Report dated July 11, 1979, dealing with procedures and procedure implementation relative to NDE and stress relieving, is blank.
b.
Unresolved Items None.
I.
Exit Inter 41ew A meeting was held at the conclusion of this inspection on December 14, l
1979, with the followir.; management representatives :
i G. Behnke - Vice President, Marketing A. Jurevics - Vice President, Engineering R. Kubit - Chief Structural Engineer W. T. Langer - Director of Purchasing R. T. Rozek - Director of Quality Assurance Y. T. Smith - Welding Engineer J. Watts - Vice President, Manufacturing A. J. Wos - QA Engineer The scope and findings of this inspection were summarized.
Manage-ment acknowledged the statements relative to the findings.
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