ML19309G838
| ML19309G838 | |
| Person / Time | |
|---|---|
| Issue date: | 02/29/1980 |
| From: | Hunnicutt D, Oller R NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML19309G824 | List: |
| References | |
| REF-QA-99900267 NUDOCS 8005070641 | |
| Download: ML19309G838 (9) | |
Text
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8 005 0 70 ($>'I [
U. S. NUCLEAR REGULATORY COMMISION O
OFFICE OF INSPECTION AND ENFORCEMENT REGION IV Report No.
99900267/80-01 Program No.
51300 Company:
Tube Turns Division of Chemetron 7100 Katy Road, P. O. Box 393 Houston, Texas 77001 Inspection Conducted:
Februa ry 19-22, 1980 Inspector:
2 Y Y' /[
R. E. Oller, Contractor Inspector Date ComponentsSection II Vendor Inspection Branch 1
Approved by:
kg )
wucaM 2,h '//?O D. M. Hunnicutt, Chief Date ComponentsSection II Vendor Inspection Branch Summary Inspection on February 19-22, 1980 (99900267/80-01)
Areas Inspected:
Implementation of 10 CFR 50, Appendix B Criteria, other NRC requirements and applicable codes and standards including:
action on previous inspection findings, noacomformances and corrective action, training, welding control consisting of joint fitup and welding-visual examination of welds and welder qualifications, and equipment calibration.
The inspection involved twenty five (25) inspector hours on site.
Results:
In the five (5) areas inspected, no deviations were identified in four (4) areas. The following were identified in the remaining area.
Deviations: Welding Control:
(1) Production tack welding was observed being performed on the seam weld of a pipe for Order HPM 49-3251, Item 001, with-out the designated welding procedure TT11-1803, Revision 3 being available at the welding station.
(2) The Weld Rod Control Material issuance records i
for wire and flux being used in production welding on a pipe for order HPM 49-3256, Item 002, indicated that the material was issued for Order HPM 48-7845, Item 001. (See Notice of Deviation Items A and B.).
l Unresolved Items: None
2 Details Section A.
Persons Contacted
- R. C. Campbell, Quality Control Manager
- A. A. Freeman, Plant Manager R. Granz, NDE Technician P. Lazar, Production Manager F. Muesse, Inspection Foreman
- Attended the Exit Meeting B.
Action on Previous Inspection Findings 1.
(Closed) Deviation (Report No. 79-02): Failure to maintain the humidity within a maximum of 50% in the welding materials storage building as required by shop procedure TTH0-24-001, Revision 1.
The inspector found that in accordance with Tube Turns response letter dated September 17, 1979, that the welding material storage building humidity control equipment has been corrected. Observa-tion by the inspector established that the building is being maintained at 40% humidity.
2.
(Closed) Unresolved Item (Report No. 79-02): The QA Manual revised Procedure TT22-213, which requires that QC be advised of noncon-forming material found by receiving inspection and that QC shall prepare a Rejection-Complaint Report, had not been approved by management and submitted to the AIA's Inspection Specialist for acceptance. The inspector found that the above QA Manual revision was approved and submitted to the Authorized Inspection Agency on August 22, 1979, and accepted by the AIA Inspection Specialist on August 29, 1979.
3.
(Closed) Unresolved Item (Report No. 79-02): The revised QA Manual TT22-200J, which provides measures for a training program had not been approved by management and submitted to the AIA Inspection Specialist for acceptance.
The inspector found that the above QA Manual Revision was approved and submitted to the Authorized Inspection Agency on August 22, 1979, and was accepted by the AIA Inspection Specialist on August 29, 1979.
C.
Nonconformances and Corrective Action 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 requirements.
3 a.
A written system has been established to assure that noncon-formances are controlled and corrective action is taken.
b.
Documented procedures or instructions are implemented for identification, documentation, segregation and dispostion of nonconforming materials parts or components, and notification to affected organizations.
Nonconforming items are reviewed and accepted, rejected, re-c.
paired or reworked in accordance with documented procedures.
d.
Conditions adverse to quality are promptly identified and corrected.
e.
The causes of significant conditions adverse ta quality are determined and corrected to preclude repetition.
f.
The condition adverse to quality, the cause and the corrective action are documented and reported to appropriate levels of management.
2.
Method of Accomplishment The preceding objectives were accomplished by:
Review of the QA Manual procedure TT22-213 "Nonconformances a.
and Corrective Action."
b.
Review of records of corrective actions for nonconformances which occured during the period of May through October, 1979, consisting of Nonconformance and Corrective Action Reports, and Rework Routings.
c.
Discussions with cognizant personnel.
3.
Findings Within this area of the inspection no deviations or unresolved items were identified.
4 D.
Training 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 indoc-trination and training of personnel performing activities affecting quality, is implemented in accordance with applicable codes.
b.
Appropriate written agenda are used.
c.
Records of training sessions agenda and attendance are maintained.
d.
The agenda includes subject matter adequate to provide an understanding of the general and detailed aspects of the QA program, codes, standards and applicable technical disciplines, The instructors are suitably qualified.
e.
2.
Method Accomplishment The preceding objectives were accomplished by:
Review of the QA Manual procedure TT22-200J " Indoctrination a.
and Training."
b.
Review of approved procedure TTH0-26-002, dated 1/2/80,
" Inspector Training Prograa."
Review of training records for personnel who perform the c.
following quality related activities:
(1) Hydrostatic Testing (2) Final Inspection (3)
Internal Auditing d.
Discussions with cognizant personnel.
5 3.
Findings Within this area of the inspection, no deviations or unresolved items were identified.
E.
Welding 1.
Objectives 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 weld joint fitup alignments meet requirements.
The requirements of essential variables and other procedure c.
parameters are concurred with during welding.
d.
The completed welds meet visual acceptance standards of the program.
The welders are qualified in accordance with the ASME code.
e.
2.
Method of Accomplishment The preceding objectives were accomplished by:
Review of the QA Manual procedure TT-22-206 " Welding Operation a.
Control."
b.
Observation of production fitup and tack welding of the longitudinal seam weld in a carbon steel pipe for Order HPM 49-3251, Item 001.
Observation of production outside seam automatic submerged c.
are welding of a longitudinal seam weld in a 28 "0D, 1.25" wall carbon steel pipe for Order HPM 42-7845, Item 002.
d.
Observation of production inside seam automatic submerged are welding of a longitudinal seam weld in a 25 "0D,1" wall carbon steel pipe for Order HPM 49-3256, Item 002.
Review of the production order travelers and the welding e.
procedures and procedure qualification records for the above three separate items.
6 f.
Review of the qualification records for 12 currently active welders and welding operators who are qualified for the process of shielded metal are welding, submerged are welding, and gas metal arc welding.
g.
Review of the " Welder's Qualification Log-Pipe Mill," main-tained for use in control of welders 90 day code requalifica-tion requirements.
h.
Discussions with cognizant personnel.
3.
Findings a.
Deviations From Commitments See Notice of Deviation Items A and B.
b.
Unresolved Items None F.
Qualification of NDE Personnel 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 measures to control the qualification of personnel performing non-destructive 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:
a.
Review of the QA Manual procedure TT-22-208 " Nondestructive Examination".
7 b.
Review of the records SNT-TC-1A eye examinations, qualifica-tions and certification of seven (7) nondestructive exam-ination technicians for the test techniques of dye penetrant, magnetic partical, radiography and ultrasonics.
Discussions with cognizant personnel.
c.
3.
Findings Within the area of the inspection, no deviations or unresolved items were identified.
G.
Equipment Calibration 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 written system has been established to assure that equip-a.
ment calibration is performed and controlled in accordance with applicable codes.
b.
A written procedure has been developed and approved which contains provisions to assure that tools, gages, instruments and other inspection, measuring and testing equipment and devices used in activities affecting quality, are of the proper range, type and accuracy, and are calibrated and properly adjusted at specified periods or use intervals.
The devices are identified in the documented system and/or c.
procedure and are calibrated in accordance with the system and procedure.
d.
The calibration is performed against certified measurement standards which have known relationship to National Standards, where such standards exist.
The control measures include provisions for test equipment e.
identification and calibration status by marking, or on records traceable to the equipment.
8 2.
Method of Accomplishment The preceding objectives were accomplished by:
a.
Review of the QA Manual procedure TT-22-209 " Calibration of Measuring and Test Equipment."
b.
Review of approved procedure TTH0-17-005 Revision 3, "Calibra-tion Instructions."
c.
Observation of the calibration status of the following types of devices located in various areas of the shop.
(1) Laboratory Furnace Recorder-Controller (2) Charpy-V Impact Tester (3) Tensile Tester (4) Charpy-V Test Thermometer (5) Magniflux Machine (6) Micrometers (7) Micrometer Standards (8) X-ray Step Tablet Density Film Strip (9) Radiographic Penetrameters (10) Ultrasonic Transducers (11) Hydrostatic Test Pressure Gages (12) Sauder Heat Treatment Furnace Recorder-Controllers, Mutipoint Recorder, and High Temperature Limit (13) Four Automatic Welding Machines Meters (14) Manual Welding Machine (15) Air Arc Grouging Machine Meters (16) Tong Tester Ammeters (17) Simpson Standard Voltmeter (18) Micrometer Rod Standards (19) Laboratory Percentage Gage j
(20) Tensile Tester Elongation Gage Punch d.
Revies of the shop calibration record cards and subcontractor certificates of calibration, where applicable, for the above measuring devices.
Review of the record of the Sauder Furnace Temperature e.
Uniformity Survey dated 1-8-80.
f.
Discussions with cognizant personnel.
1
9 3.
Findings Within this area of the inspection, no deviations or unresolved items were identified.
H.
Exit Interview 1.
The inspector met with management representatives denoted in paragraph A. at the conclusion of the inspection on February 22, 1980.
2.
The following subjects were discussed.
a.
Areas inspected.
b.
Status of corrective action for the previously identified deviation and unresolved items.
c.
The deviations identified in this report.
3.
The manufacturer's representatives were asked to formulate the corrective action response to the deviation in accordance with the three (3) conditions identified in the inspection report cover letter.
4.
Management's comments were related to claritication of the findings.
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