ML19309D034
| ML19309D034 | |
| Person / Time | |
|---|---|
| Issue date: | 02/21/1980 |
| From: | Kelley W, Whitesell D NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML19309D031 | List: |
| References | |
| REF-QA-99900075 99900075-80-1, NUDOCS 8004100005 | |
| Download: ML19309D034 (13) | |
Text
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l U.S. NUCLEAR REGULATORY COMMISSION l
OFFICE OF INSPECTION AND ENFORCEFINT l
REGION IV i
Report No. 99900075/80-01 Program No. 51300 Company: MCC-Pacific Valves 3201 Walnut St.
Long Beach, California 90007 Inspection Conducted: February 4-7, 1980 l
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1 Inspector:
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Wm. D. Kelley, Con' tractor faspector Date' ComponentsSection I
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Vendor Inspectica Branch Approved by:
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[s. 24 fedp D. E. %hitesell, Chief Date' '
ComponentsSection I Vendor Inspection Branch Summary Inspection on February 4-7, 1980 (99900075/80-01)
Areas Inspected:
Implementation of 10 CFR 50, Appendix B and applicable codes and standards including, design verification - computer programs, procurement document control, manufacturing process control - material identification and control and machining, training - welder qualification, inspection and test - magnetic particle examination, control of special process - heat treatment of materials and parts and forming and bending of pressure retaining materials; also, performed review of vendor's activities and action on previously identified items, and conducted exit interview.
The inspection involved twenty eight (28) inspector-hour on site by~one (1)
NRC inspector.
Results:
In the nine (9) area inspected, no deviations or unresolved items were identified.
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2 DETAILS SECTION A.
Persons Contacted MCC-Pacific Valves (MCC-PV)
- R. L. Audibert - Manager of Quality Assurance F. Clifford - NDE Level III T. A. Dunavan - Manager of Purchasing J. Fleming - Quality Assurance Engineer
- P. S. Grewal - Manager - Project Engineering W. J. O' Brian - Manager of Research and Development J. P. Pepe - Material Applications Engineer
- J. I. Rosen - Supervisor Quality Assurance Engineering
- Denotes those persons who attended the Exit Interview.
B.
General Review of Vendor's Activities 1.
The inspector verified that there had been no change of the status of ASME Certificates of Authorization, authorized Inspec-tion Agency or the authorized nuclear inspector as report ed in NRC RIV Report 99900075/79-01.
2.
MCC-PV's contribution to the nuclear industry for the morith of January 1980 represented approximately nine (9) percent of its total workload.
C.
Previously Identified Items (Closed) Deviation (Report No. 79-01 Item A):
Contrary to Criterion I of Appendix B to 10 CFR 50 and paragraph NCA-4134.1 of Section III to the ASME Code MCC-PV had established and manned two new positions, without the authority and duties of the new positions being clearly established and documented in writing for the new positions.
. in that neither of the positions were functionally described.
The inspector verified that the Quality Assurance Manual had been revised to clearly establish and document the authority and duties of two new positions and the revision had been accepted by the Authorized Inspection Agency's nuclear specialist.
(Closed) Deviation (Report No. 79-01, Item B) Contrary to MCC-PV's letter of December 21, 1978, the Quality Assurance Manual had not been revised to more accurately describe the quality training program.
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3 The inspector verified that the Quality Assurance Manual had been revised to more accurately describe the quality training program and the revision had been accepted by the Authorized Inspection Agency's nuclear specialist.
D.
Design Verification (Computer Programs) 1.
Objectives The objectives of this area of the inspection were to verify that:
Procedures had been prepared and approved by the vendor a.
to prescribe a system for design computer program verification which is consistent with NRC rules and regulations, and the vendor's commitments in the ASME accepted Quality Assurance Program.
b.
The computer design program verification procedures are properly and effectively implemented by the vendor.
2.
Method of Accomplishment The objectives of this area of the inspection were accomplished by:
Review of the ASME accepted Quality Assurance Manual Revision a.
1:
(1) Section 5.0 " Order Entry",
(2) Section 6.0 " Order Planning", and (3) Section 7.0 " Design Control" to verify the vendor had established procedures to prescribe a system for design verification.
b.
Reviewed PVSAP Revision 1/12/79 " Theoretical Manual," to verify that the measures provided for verifying the adequacy of the design computer program.
Also, that the measures pro-vided for the design verification to consider importance to safety, identify method of performing the design verification, identify the items to be addressed during design review, and prescribes the requirements for performing verification.
4 Reviewed design computer program verification; PVSAP Revision c.
January 12, 1979 " Program Verification," to verify that the computer design verification procedures are being properly implemented.
d.
Interviews with personnel to verify they were knowledgeable in the procedures applicable to computer design verification.
3.
Findings The inspector verified that:
A Manual had been prepared and approved by the vendor to a.
prescribe a system for design computer program verification which is consistent with NRC rules and regulations, and the vendor's commitments in the ASME accepted Quality Assurance Program.
b.
The design computer progrr.m verification procedure was properly and effectively implemented by the vendor.
Within this area of the inspection no unresolved items were identified.
E.
Procurement Document Control 1.
Objectives The objectives of this area of the inspection were to verify that:
Procedures had been prepared and approved by the vendor that a.
prescribes a system for procurement document control which is consistent with NRC rules and regulations, and the vendor's commitments in the ASME accepted Quality Assurance Program.
b.
The procurement document control procedures are properly and effectively implemented by the vendor.
2.
Method of Accomplishment The objective of this area of the inspection was accomplished by:
Review of the ASME accepted Quality Assurance Manual, a.
Revision 1, Section 9, " Procurement Control" to verify that the vendor had established a procedure that prescribed a system for procurement document control.
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5 b.
Review of the procedures referenced in paragraph a. to verify they have been prepared by the designated authority, approved by responsible management and reviewed by the QC.
c.
Reviewed these selective documents:
(1) Three Shop Job Instructions (2) Ten Purchase Orders to verify that the scope of work to be performed is identified, the technical requirements are specified, test and inspection criteria is identified, special instructions and requirements identified, suppliers are required to have a documented QA program, and procurement documents are reviewed prior to release for bid and/or contract award.
d.
Review of the following selective documents:
(1) Four (4) Procurement documents (2) Three (3) Purchase requisitions (3) Seven (7) Purchase orders to verify the procurement procedures are being properly and effectively implemented / interface control of procurement documents is effectively and properly performed in accordance with procedures, and distribution list for procurement docu-ments had been established and are current.
Interviews with personnel to verify they were knowledgeable e.
in the procedures applicable to procurement document control.
3.
Findings a.
The inspector verified that:
(1)
Procedures had been prepared and approved by the vendor that prescribed a system for procurement document con-trol which is consistent with NRC rules and regulations, and the vendor's commitments in the.ASME accepted Quality Assurance Program.
(2) The procurement document control procedures were properly and ef fectively implemented by the vendor.
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6 b.
The inspector noted that changes had been made to the following purchase documents:
(1) Requisition for Purchase Order 33349 for valve stem forgings had, Notes (2) and (3) deleted and a new Note (2) added without the change apparently being approved by the Quality Assurance Engineer.
The requisition had been signed by Quality Assurance Engineer and dated.
(2) Shop Job Instruction for Purchase Order 34363N had been for Shop Job order 7E0171N and had been changed to Shop Job Order 4Z5006N without the change apparently being approved by the Quality Assurance Engineer. The Shop Job Instruction had been signed by the Quality Assurance Engineer and dated.
The Supervisor Quality Assurance Engineering verified that these revisions had been made prior to the signiature of the Quality Assurance Engineer and his approval included the changes:
However, the Supervisor concurred that this practice was confusing and did not lend itself to the tracking of the approval. He took immediately corrective action by instructing the Quality Assurance Engineer to initial and date all changes made on documents before his approval.
F.
Manufacturing Process Control (Material Identification and Control) 1.
Objective The objective of this area of the inspection was to verify that material identification and control during marrufacturing is ir accordance with NRC rules and regulation, and the vendor's.om-mitments in the ASME accepted Quality Assurance Progre..
2.
Method of Accomplishment The objective of this area of the inspection was accomplished by:
a.
Review of the ASME accepted Quality Assurance Manual Revision; (1) Section 7.0 " Design Control,"
(2) Section 9.0 " Procurement Control," and
7 (3) Section 11.0 " Process Control."
to verify that procedures had been established for material identification and control during manufacturing.
b.
Review of the procedures:
(1) QAS-4, Revision 1, " Standard for the Issuance and Control of Heat, Serial and X-ray Numbers" (2) QAS-7, Revision 3, " Receiving Inspection Standard," and (3) QAS-10, Revision 5, " Material Certification Review Procedure."
to verify they provided for the identification and control of purchased materials, requires positive identification of materials throughout the manufacturing cycle, and provide for the segregation and disposition of nonconforming materials.
Examined representative material in various stages of manu-c.
facturing and verified that the identification, and trace-ability to the certified mill test report, was being main-tained.
d.
Interviews with personnel to verify they are knowledgeable in the procedures applicable to material identification and control.
3.
Findings The inspector verified that the material identification and a.
control during manufacturing was consistent with NRC rules and regulations, and the vendor's commitments.
b.
Within the area of the inspection no deviations or unresolved items were identified.
G.
Manufacturing Process Control - Machining 1.
Objectives
8 The objectives of this area of the inspection were to verify that:
The machining operations were performed under s. controlled system of manufacturing which meets NRC rules and regulations and the vendor's commitments in the ASME accepted Quality Assurance Program.
The controlled system of manufacturing was effective in assuring product quality.
2.
Method of Accomplishmint The objectives of this area of the inspection were accomplished by:
a.
Review of the ASME a cepted Quality Assurance Manual, Revision 1:
(1) Section 6 " Order Planning,"
(2) Section 8 " Process Planning," and (3) Section 11 " Process Control."
to verify that procedures had been established to prescribe a control system of operation.
b.
Review the following procedures:
(1)
MES-1, Revision 3, "Preperation and Use of Work Order,"
(2) QAS-2, Revision 2, "Nonconformance Reporting and Process Standard," and (3) MES-21, Revision 2, "Preperation and Use of Rework Work Orders" to verify that they had been prepared by the designated authority, approved by management, and reviewed by QA, and are consistent with NRC rules and regulation and the vendor's commitments.
c.
Review of the following documents:
(1)
Fifteen (15) Operation and Routing Sheets, (2) Seven (7) Drawings, L
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(3) Certified Material Test Reports, to verify that they provide drawing / document control in the shop, and also provides for part identification and trace-ability, in process and final inspections, identification and segregation of defective items, the resolving of noncon-forming items, and that the gages and measuring devices are under a controlled calibration system.
d.
Examine three (3) representative samples of finished machined parts to verify that they were properly identified and machined to conform to the drawings and specifications.
Examined the documents of the following parts:
e.
(1) Disc - Heat No. ZR45, Serial No. XN738 (2) Body - Heat No. 21J0, Serial No. D206-9 (3) Body - Heat No. 2508, Serial No. XN771 (4) Assembled Valve-Tag No. 3CE-V30SAB-1 (5) Assembled Valve-Tag No. 3CH-V1075B-1 to verify compliance with applicable documentation require-ments.
3.
Findings a.
The inspector verified that:
(1) The machining operations were performed under a controlled system of manufacturing which meets NRC rules and regu-lations and the vendor's commitments in the ASME accepted Quality Assurance Program.
(2) The controlled system of manufacturing was effective in assuring product quality.
b.
Within this area of the inspection no deviations or unresolved items were identified.
MCC-PV is currently revising their standard WES-1, Revision 2 c.
" Welding Procedure and Welder Performance Qualification Testing" to describe in detail the minimum on-the-job training a welder must have before performance qualification
10 testing and identify the supervisor who will make the training evaluation. The inspector will review the reviewed standard on a subsequent inspection.
H.
Inspection and Test - Magnetic Particle Examination 1.
Objectives The objectives of this area of the inspection was to verify that:
The magnetic particle examination procedures used by the a.
vendor meets the applicable NRC rules and regulations, and the vendor's commitments in the ASME accepted Quality 1
t Assurance Program.
b.
The magnetic particle examinations are performed by properly qualified personnel in accordance with the procedures.
2.
Method of Accomplishment The objectives of this area of the inspection were accomplished by:
Review of the ASME accepted Quality Assurance Manual Revision a.
(1) Section 4.0 " Quality Assurance," and (2) Section 13.0 " Nondestructive Examination" to verify that procedures had been established for magnetic particle examination.
b.
Review of the following procedures (1) QAS, Revision 6, " Nondestructive Examination (NDE)
Personnel Qualification and Certification," and (2) QAP-0046, Revision 0, " Dry Powder Magnetic Particle Procedure" to verify that they had been reviewed, approved, and qualified, in accordance with the quality assurance program and Code requirements, and accepted by the Authorized Nuclear Inspector.
No magnetic particle examination is currently being performed c.
by MCC-PV; however, the inspector did verify that:
11 (1) A copy of the procedure is available at the work station.
(2) The personnel that may perform the magnetic examinations are properly qualified.
i' (3) The indications are to be evaluated in accordance with the procurement requirements, and the results reported in the prescribed manner.
d.
Interviews with personnel to verify they are knowledgeable in the procedures applicable to magnetic particle examination.
3.
Findings I
The inspector verified that the magnetic particle examination a.
procedures used by the vendor meets the applicable NRC rules and regulations, and the vendor's commitments in the ASME accepted Quality Assurance Program.
b.
MCC-PV does not currently perform magnetic particle (MT) inspection in house.
b' hen NT is required by the design specification or customer contract requirements it will be done by a vendor that has been surveyed, qualified and placed on the approved vendors list in accordance with the requirements of the ASME accepted quality assurance program and in accordance with MCC-PV procedure QSP-0046.
Within this area of the inspection no deviations or unresolved c.
items were identified.
P I.
Control of Special Processes - Heat Treatment of Materials and Parts 1.
Objective The objectives of this area of the inspection were to verify that:
i Procedures have been established for heat treatment of a.
materials and parts and these procedures are consistent with NRC rules and regulations and the vendor's commitments in the ASME accepted Quality Assurance Program.
i b.
The controlled system of heat treatment of materials and parts was effective in assuring product quality.
2.
Method of Accomplishment The objectives of this area of the inspection were accomplished by:
Review of the ASME accepted Quality Assurance Manual, Revision a.
1, Section 9, " Procurement Control.
12 b.
Review of the Approved Vendors List Interviews with personnel to verify they were knowledgeable c.
in the procedures applicable to heat treatment of parts and material.
3.
Findings The inspector verified that the heat treatment of materials a.
acd parts meets the applicable NRC rules and regulations and the vendors commitments in the ASME accepted Quality Assurance
- Program, b.
All materials requiring heat treatment are purchased from a vendor in the heat treated condition that has a ASME Quality Systems Certification (Materials) or who has been surveyed, qualified and placed on the approved vendors list in accordance with the requirements of the ASME accepted Quality Assurance Program and in accordance with a MCC-PV approved procedure.
All parts requiring heat treatment are heat treated by a c.
vendor that has been surveyed, qualified and placed on the approved vendors list in accordance with the requirements of the ASME accepted Quality Assurance Program and in accordance with a MCC-PV approved procedure.
d.
Within this area of the inspection, no deviations or unresolved items were identified.
J.
Control of Special Processes - Forming and Bending of Pressure Retaining Materials 1.
Objectives The objectives of this area of the inspection were to verify that:
The forming and bending of pressure retaining materials were a.
under a controlled system of fabrication which meets NRC rules and regulations and the vendor's commitments in the ASME accepted Quality Assurance Programs, b.
The controlled system of forming and bending of pressure retaining materials was effective in assuring product quality.
13 2.
Method of Accomplishment The objectives of this area of the inspection were accomplished by:
I Review of the ASME accepted Quality Assurance Manual a.
Revision 1, Section 9.0, Procurement Control.
b.
Review of the Approved Vendor's List Interviews with personnel to verify they were knowledgeable c.
in the procedures applicable to forming and bending of pressure retaining materials.
3.
Findings The inspector verified that the forming and bending of a.
pressure retaining materials meets the applicable NRC rules and regulations, and the vendor's commitments in the ASME accepted Quality Assurance Program.
b.
The only forming or bending of pressure retaining material performed for MCC-PV valves is the bending of the by pass piping which is performed by a vendor that has been surveyed qualified and placed on the approved vendors list in accordance with the requirements of the ASME accepted Quality Assurance Program and in accordance with a MCC-PV approved procedure, Within this area of the inspection no deviations or unresolved c.
items were identified.
K.
Exit Interview At the conclusion of the inspection on February 7, 1980, the inspector met with the company's management, identified in paragraph A, for the purpose of informing them as to the results of the inspection.
During this meeting management was informed no deviations or unresolved items were identified.
The company's management acknowledged the inspector's statement and had no additional comments.
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