ML19309C820
| ML19309C820 | |
| Person / Time | |
|---|---|
| Issue date: | 01/31/1980 |
| From: | Hunnicutt D, Oller R NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML19309C802 | List: |
| References | |
| REF-QA-99900268 99900268-80-1, NUDOCS 8004090299 | |
| Download: ML19309C820 (9) | |
Text
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O U. S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT REGION IV Report No. 99900268/80-01 Program No. 51300 Company: Armco Incorporated Advanced Material Division 13835 Beaumont Highway Houston, Texas 77028 Inspection Conducted: January 14-18, 1980 Inspectors:
(.
2 h 3/~ '[f' R. E. Oller, Contractor Inspector Date ComponentsSection II Vendor Inspection Branch Approved by:
hf M4((
/[S//80 D. M. Hunnicutt, Chief
' Date ComponentsSection II Vendor Inspection Branch Summary Inspection on January 14-18, 1980 (99900268/80-01)
Areas Inspected:
Implementation of 10 CFR 50, Appendix B criteria, other NRC requirements and applicable codes and standards including:
action on previous inspection findings, internal audits, qualifications of NDE personnel, and welding control consisting of welding procedure specifications -
welding material control and welding heat treatment. The inspectioa involved twenty-nine (29) inspector-hours on site.
Results:
In the four (4) areas inspected, no deviations were identified in one (1) area. The following were identified in the remaining areas:
Deviations:
Internal Audits:
Deficiencies reported in the March, 1979 Audit Reports were not resolved as required by the QA Manual.
(See Notice of Deviations, Item A).
Qualifications of NDE Personnel: Records of current eye examinations were not on file at AMD for one AMD NDE technician and a subcontractor's four (4) NDE technicians as required by the QA Manual.
(See Notice of Deviations, Item B).
8004090 1
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I Welding Control: Certain postweld heat treatment furnace chart records were not identified with the Mill Order and Piece Numbers of the heat treated piping.
(See Notice of Deviations, Item C).
U.1 resolved Items None.
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3 DETAILS SECTION A.
Persons Contacted
- L. Barrington, QA Supervisor D. Bynum, Welding Supervisor
- J. Fraysur, Chief Inspector D. Lankford, Production Foreman
- R. Moon, Plant Manager H. Riley, Maintenance Supervisor R. Schultz, Senior Applications Engineer K. Wood, Laboratory Technician
- Attended the exit meeting.
B.
Action on Previous Inspection Findings 1.
(Open) Deviation A (Report 79-02): Welding procedure specifications (WPS) No. 10 and No. 11 were revised and requalified by the pro-duction welding supervisor, who was not properly authorized to perform these activities. The inspector found the QA Manual (QAM) is being revised. The applicable revised parts of the QAM will show that revision and requalification of WPSs are the responsibilities of the welding supervisor.
In addition, the preventive action measures to audit this area during the February, 1980 internal audit are still in effect. This item remains open pending AMDs final approval of the revised QAM and its acceptance by the Authorized Inspection Agency.
2.
(Closed) Deviation B (Report No. 79-02):
The final disposition and corrective action entered on nonconformance report NCR No. 197 was not signed and dated by all members of the Material Review Board to indicate acceptance, nor was it signed and dated by the ANI to show concurrence. The inspector found that in accordance with AMD's response letter dated October 10, 1979, a meeting of the MRB was held to review procedures for handling nonconforming reports. A procedure No. 0.P.-25 " Procedure for Handling Nonconforming Material" has been written and is in draft status. This procedure provides guidance in routing, signoff and dating of the acceptance of the disposition of NCRs by members of the MRB and signoff and dating of the concurrence by the Authorized Nuclear Inspector, when applicable. This procedure will be approved for use in a timely manner.
4 3.
(Open) Deviation C (Report No. 79-02): Failure to arrange training programs on a monthly basis. The inspector found that in accordance with AMD's response letter dated October 10, 1979 a procedure has been written and is in draft status.
This procedure identifies subject matter and personnel to be trained as well as how the program will function. The scheduled February internal audit of this area of the QA program is firm. This item remains open.
4.
(Closed) Deviation D (Report No. 79-02): Failure to follow Operating Procedure No. 35, Revision 2, relative to the use of the Foxboro recorder during in process hydrostatic testing using the continuous hydro tester. The inspector found that in accordance with AMD's response letter dated October 10, 1979, operating procedure No. 35 has been revised to delete reference to use of the Foxboro recorder and instead identifies the use of the working and master pressure gage during hydrostatic testing. This closes the corrective action on this item.
The preventive l
action, by means of review and correcting, if needed, of two (2) operating procedures during each internal audit will be implemented in February, 1980.
5.
(Closed) Unresolved Item (Report No. 79-02):
The serialized and calibrated flowmeters had the following deficiencies; (a) Two (2) flowmeters located on the No. 3 Continuous Mill (automatic welding machine) had the same serial number (WG-031),
and the Argon flowmeter on the Batch Mill and the Argon flowmeter on the Hun 4 welding machine had the same serial number (WG-017).
(b) The record of. calibrations for working flowmeters showed the flow readings at the calibrated flow settings of 100%, 50%
and 10% for flowmeters WG-012, WG-016 and WG-017, were extensively out of calibration by as much as 20 CFH, in comparison with the reference calibrated flowmeters, without the above three (3) flowmeters having been tagged out-of-service.
The inspector found that the permanent serial numbers on the above flowmeters have been corrected.
In addition, the calibration records show that the above out of calibration flowmeters have been cleaned and recalibrated.
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5 C.
Internal Audits 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 internal audits are performed and controlled in accordance with applicable codes to verify compliance with all aspects of the QA program.
b.
Planned and periodic internal audits are performed in accordance with written procedures or checklists by qualified personnel not having direct responsibilities in the areas being audited.
Audit results are documented and reviewed by management having c.
responsibility in the area audited.
d.
Follow-up action, including reaudit of deficient areas, is taken where indicated.
2.
Method of Accomplishment The preceding objectives were accomplished by:
a.
Review of the QA Manual Section 16 " Audit."
b.
Review of the approved QC Procedure No. 12, Revision 2,
" Procedure for Controlling Internal Audit.
Review of records of QA program internal audits performed c.
on March 29, 1979 and in December 1979, and of the Management audit performed on February 28, 1979.
d.
Discussions with cognizant personnel.
1 3.
Findings 4.
Deviations From Commitments See Notice of Deviations, Item A.
b.
Unresolved Items None.
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6 D.
Qualification of NDE Personnel 1.
Obj ectises The objectives of this area of the inspection were to verify that t'ae following items were controlled in accordance with applicable NRC and ASME Code requirements:
a.
A written system has been established to assure that measures to control the qualification of personnel perfonning nondestructive examinations (NDE) has been documented.
b.
The above system has been implemented such that the subject personnel are properly qualified in accordance with NRC, ASME and the manufacturer's. requirements.
2.
Method of Accomplishment The preceding objectives were accomplished by:
Review of the QA Manual Section 9, paragraph 9.3 " Nondestructive a.
Examination (NDE)."
b.
Review of records of examination and certification for eight (8)
AMD NDE personnel having various SNT-TC-1A ratings of Level I, II and III in the techniques of radiography, dye penetrant inspection and ultrasonic examination.
c.
Review of records of examination and certification for four (4) subcontracted ultrasonic examination personnel having SNT-TC-1A ratings of Level II and III.
d.
Discussions with cognizant personnel.
3.
Findings a.
Deviations From Commitments See Notice of Deviations, Item B.
b.
Unresolved Items None.
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E.
Welding 1.
The objectives of this area of the inspection were to verify that the following activities were controlled in accordance with applicable NRC and ASME Code requirements, A system has been established to assure that welding is a.
controlled in accordance with the applicable codes.
b.
The welding procedure specifications (WPS) used in production welding are prepared, qualified and controlled in accordance with the QA program.
That welding materials purchase, acceptance, storage, issuance c.
and use are controlled and documented in accordance with detailed procedures.
d.
The post weld heat treatment, specified by the welding procedures, is performed in accordance with an approved procedure, consistent with code requirements.
2.
Method of Accomplishment The preceding objectives were accomplished by:
Review of the following QA Manual sections:
a.
(1)
No. 7 " Process Control," paragraphs 7.6 " Welding" and 7.7 " Heat Treating."
(2)
No. 8 " Welding Quality Assurance."
(3)
No. 10 " Heat Treating."
b.
Observation of the ASME code welding material storage facilities.
Examination of the welding material issuance control log.
c.
d.
Tracing of the issue of 1/8" and 3/32" diameter welding wire Heat Number 21296 and approved flux ST-100 Lot 58S from the issue recorded in the log to its use in welding pipe S.N. 9-7420, 9P-4 on Mill Order 9-7420.
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l Review of the A.M.D. " Physical and Chemical Test Report" e.
No.79-326 covering the qualification of the previously identified welding wire and flux.
f.
Review of the following production welding procedure specifications (WPS) and the individually related procedure qualification record (PQR).
(1) WPS No. 1 Revision 1 and PQR Lab Test No. 72-323.
(This WPS is used in making manual welding repair.)
(2) WPS No. 2 dated September 1974, and PQR Lab Test No.74-789.
(This WPS is used for inside diameter weld repair using the automatic GTAW process.)
(3) WPS No. 5, Revision 2 and PQR Lab Test No.74-852.
(This WFS uses the automatic SAW process.)
(4) WPS No. 8, dated February 15, 1975 and PQR Lab Test No. 75-1348. This WPS is a combination procedure using the automatic SAW process for the ID seam weld and GTAW for the 0.D. seam weld.)
(5) WPS No. 10, Revision 2 and PQR Lab Tests No.79-147 and No.79-196.
(This WPS is a simultaneous ID and OD welding method using the automatic GTAW process.)
(6) WPS No. 11, Revision 1 and PQR Lab Tests No.79-331 and 79-330.
(This WPS is used for manual tack welding using the GTAW process.)
g.
Observation of three (3) L&N recorder-controllers on the three (3) zones of the carbotton heat treating furnace and of the two (2) L&N recorder-controllers on the continuous furnace for the calibration status.
h.
Observation of the production optical pyrometer SN-1779208, for the calibration status, i.
Review of the L&N' certificate of calibration dated June 10, 1979 for five (5) recorder-controllers, and the L&N certificate of calibration dated January 12, 1979 for the above optical pyrometer.
J.
Review of calibration procedure No. QC 12, Revision No. 1.
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k.
Review of the furnace temperature uniformity survey records dated January 26, 1978 for the two (2) above furnaces.
1.
Review of eight (8) selected furnace recorder temperature chart tracings and the related daily furnace log sheets covering post-weld solution heat treatment of various mill orders of seam welded pipe in the carbottom furnace during the period of January through November,1979.
Review of six (6) selected furnace recorder temperature chart m.
tracings and the related daily furnace log sheets covering postweld solution heat treatment of various mill orders of seam welded pipe in the continuous roller hearth furnace during the period of January through June,1979.
Discussions with cognizant personn'el.
n.
3.
Findings a.
Deviations From Commitments See Notice of Deviations, Item C.
b.
Unresolved Items None.
F.
Exit Interview 1.
The inspector met with management representatives denoted in paragraph A at the conclusion of the inspection on January 18, 1980.
2.
The following subjects were discussed:
a.
Areas inspected.
b.
Status of corrective and preventive action for the previously identified deviations and unresolved items.
c.
Deviations identified in the report.
3.
The manufacturer's representatives were asked to formulate their corrective action responses to deviations in accordance with the three (3) conditions identified in the inspection report cover letter.
4.
The manufacturer representatives' questions related to the inspection findings.
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