ML19310A938
| ML19310A938 | |
| Person / Time | |
|---|---|
| Issue date: | 05/06/1980 |
| From: | Kelley W, Whitesell D NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML19310A913 | List: |
| References | |
| REF-QA-99900340 99900340-80-1, NUDOCS 8007010051 | |
| Download: ML19310A938 (9) | |
Text
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O 13.S. NUCLEAR REGULATORY COMMISSION
./FICE OF INSPECTION AND ENFORCEMENT REGION IV Report No. 99900340/80-01 Program No. 51300 Company:
Yarway Corporation Blue Bell, Pennsylvania 19422 Inspection Conducted: April 22-24, 1980 7
/
Inspecto v%duid. f.b es/co/go m
Wilflam D. Kelley, Cohtractor Inspector Date ComponentsSection I Vendor Inspection Branch I
d n t' Approved.'
(gera o%/oo/6a D. E. Witesell, Chief Date ComponentsSection I Vendor Inspection Branch Summary Inspection on April 22-24, 1980, (99900340/80-01)
Areas Inspected:
Implementation of 10 CFR 50, Appendix 3 and applicable codes and standards including, design and document control - design verifi-cation, manufacturing process control - machining and material identification and control, inspection and test - magnetic particle examination, and training -
welder qualification. Also performed review of vendor activities and conducted an exit interview.
The inspection involved twenty (20) inspector-hours on site by one (1) NRC inspector.
Results:
In the five (5) areas inspected, no deviations or unresolved items were identified in four (4) areas. The following were identified in the remaining area.
Deviation:
Inspection and Test - Magnetic Particle Examination; 'ontra ry to criterion V of Appendix B to 10 CFR 50, and Article T-732 of c ction V of the ASME codes; the vendors QA inatructions to control magnetic particle examinations did not contain all of the information specified by the code.
(See Details paragraph F).
8007010
- 2 DETAILS SECTION A.
Persons Contacted Yarway Corporation (YC)
- W. D. Clinton, Vice President of Manufacturing H. I. Gregg - Senior Development Engineer J. Hynam - Quality Assurance Engineer R. D. Schmitt - Manager, Power Plant Technology
- W. A. Volger, Manager, Quality Assurance
- Denotes those persons who attended the Exit Interview (See paragraph H).
B.
General Review of Vendor's Activities j
1.
There has been no change in the status of the ASME Certificates of Authorization, the authorized inspection agency, or the authorized nuclear inspector as reported in IE RIV Report 99900340/79-01.
2.
YC's contribution to the nuclear industry represents approximately five percent (5%) of its total workload.
3.
Three ASME "N" stamped valves had been returned to YC by a customer because the border around the "N" symbol had not been imprinted on the name plate on one side, due to the curvature of the valve body.
C.
Design and Document Control Design Verification 1.
Objectives The objectives of this area of the inspection were to verify that:
a.
Procedures had been prepared and approved by the vendor which prescribes a system for controlling design verification in a manner consistent with NRC rules and regulations, and the-vendor's commitments.
b.
The design 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:
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Review of the ASME accepted Quality-Assurance Manual, Revised a.
11/15/79, J
(1) Section 2, " Design, Specification and Document Ccatrol" and (2)
Section 3,." Customer Order Control,"
to verify that the vendor had established procedures to pre-scribe a system for design verification.
b.
Reviewed the documents referenced in paragraph a. to verify that they contained measures to verify the adequacy of design, require that the results of the design verification to be documented, require that the design verification consider the importance to safety, identify the method of performing the design verification, identify items to be ~ addressed during the design review, and prescribes the requirements for performing verification by alternate calculations, or by qualification test.
Reviewed the following documents:
c.
(1) Nuclear Control Plan (Class 1) 016-952221, (2) Minutes of Task Force Meeting 2/11/80, (3) Seismic Analysis of Yarway Corporation.
. Manual Valve Figure 5515B-SA105, (4) Seismic Analysis of Yarway Corporation.
. Piston Check Valve Figure 5561-SA105, and (5) Design Reports 948880 and 949325 to verify that the design verification procedures are being implemented.
d.
Interviews with personnel to verify that they are knowledgeable in the procedures applicable to design verification.
3.
Findings a.
The inspector verified that:
e (1) Procedures have been prepared, 1b* ap;, roved by the_ vendor 3
prescribing a system for desist v w:' cat on which is consistent with NRC rules anu :egu.,.49ns, and the vendor's commitments, and i
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4 (2) The design verification procedures are properly and effectively implemented.
b.
Follow-up Item The project engineer does maintain a log of the transmittal and' approval of documents from receipt of the invitation to bid to the development of the nuclear control plan for an order; however, the ASME accepted Quality Assurance Manual does not address or require the log to be maintained.
YC will review the need of describing the method of maintaining the logs in their quality assurance manual and the inspector will review YC action cn a subsequent inspection.
D.
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 manufacturing is in accordance with NRC rules and regulation, and the vendor's commitments.
2.
Method of Accomplishment The objective of this area of the inspection was accomplished by:
a.
Review of the ASME accepted Quality Assurance Manual, Revised 11/15/79 i
(1) Section 4, " Procurement Control" and (2) Section 5, " Process Control;"
to verify that procedures had been established for material identification and control during manufacturing.
i b.
Review of the following Quality Assurance Instructions:
(1) QAl-051, Issued 1/3/75, " Receiving Inspection Procedure for Incoming Material for Raw Storage,"
(2) QAl-057, Revision 1, " Material Check Analysis Procedure," and i
(3) QAl-027, Revision 2, " Flange Dimensions and Casting Pressure Markings;"
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to verify that they provided for the identification and control of purchased materials, requires the identification of materials to be maintained throughout the manufacturing process, and provides for the segregation and disposition of nonconforming materials.
Examined representative material in various stages of manu-c.
facturing and verified that the identification, and traceability to the certified mill test report, was being maintained.
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 being implemented in a manner consistent with NRC rules and regulation, and the vendor's commit-ments.
b.
Within this area of the inspection no deviations or unresolved items were identified.
E.
Manufacturing Process Control - Machining 1.
Objectives The objectives of this area of the inspection were to verify that:
The machining operations were performed under a controlled a.
system of manufacturing which meete NRC rules and regulations and the vendor's commitments in the ASME accepted Quality Assurance Program.
b.
The controlled system of manufacturing was effective in assuring product quality.
2.
Method of Accomplishment I
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The objectives of this area of the inspection were accomplished by:
Review of the ASME accepted Quality Assurance Manual, Revised a.
11/15/79, l
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(1)
Section 5, " Process Control,"
(2) Section 6, " Welding / Brazing Quality, Assurance" and (3)
Section 8, " Control of Measuring and Test Equipment;"
to verify that procedures had been established to prescribe a control system of operation.
b.
Review these selective f:uality Assurance Instructions:
(1) QAl-053, Revision 2, " Standard Minimum Wall Thickness Veri-fication Procedure for Figure 5500 Series Nuclear Wel-bond Valves,"
(2) QAl-069, Issued 5/31/77, " Standard Manufacturing Practices and Tolerances," and (3) QAl-14, Issued 2/8/71, " Drawing Interpretation;"
to verify that they had been prepared by the designated I
authority, approved by management, and reviewed by QA, and are consistent with NRC regulation, and the vendor's commitments.
Review of the following documents for three in-process orders:
c.
(1) Production Order Route, (2) Drawings, (3) Receiving Logs, (4) Certified Material Test Reports, and (5) Nuclear Control Plan.
to verify that they provide drawing / document control in the shop, and also provides for part identification and traceability, in-process and final inspections, identification and segregation of defective items, the resolving of nonconforming items, and that the gages and measuring devices are under a controlled calibration system.
Y 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.
3.
Findings a.
The inspector verified that:
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.7 (1) The machining operations were performed under a controlled system of manufacturing which meets NRC rules and regulations 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.
F.
Inspection and Test - Magnetic Particle Examination 1.
Objectives The objectives of this area of the inspection were to verify that:
a.
The magnetic particle examination procedures used by the i
vendor meets the applicable NRC rules and regulations, and the vendor's commitments in the ASME accepted Quality Assurance Program.
1 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:
a.
Review of the ASME accepted Quality Assurance Manual, Revised 11/15/79 (1) Section 5, " Process Control" and (2) Section 7, "Non-Destructive Examination;"
to verify that procedures had been established for magnetic particle examination.
b.
Review of YC NDE procedure numbers j
(1) 100-021-002, and 100-021-008 " Procedure for Dry Powder Magnetic Particle Inspection" and to verify that they had been reviewed, approved, and qualified, in accordance with the quality assurance program and Code require-ments, and accepted by the Authorized Nuclear Inspector.
c.
Verified that:
(1) The applicable traveler specified the appropriate test procedure,-and that a copy of the procedure is available at the work station.
8' (2) The personnel' performing the examinations are properly qualified.
- (3).The test equipment has been calibrated and materials surfaces to be examined had been properly prepared.
(4) The test parameters are specified in the examination procedure.
(5) The indications are evaluated in accordance with the procurement requirements, and the results reported in the j
. prescribed manner.
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Interviews with personnel to verify they are knowledgeable in the procedures applicable to magnetic particle examination.
3.
Findings a.
The inspector verified that for the direct magnetization method (1) The magnetic particle examination procedures used by the vendor meets the applicable NRC rules and regulations, Code requirements, and the vendor's commitments in the ASME accepted Quality Assurance Program.
(2) The magnetic particle examinations are performed by properly qualified personnel in accordance with the procedures.
b.
Deviation See Notice of Deviation.
G.
Training - Welder Qualification 1.
Objective i
The objectives of this area of the inspection were to verify that the welders and welding operators are qualified in accordance with NRC rules and regulations, and the vendor's commitments in the ASME accepted Quality Assurance Program.
2.
Method of Accomplishment The objectives of the inspection were accomplished by:
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a.
Review of' the ASME accepted' Quality Assurance Manual, Revised 11/15/79:
(1)' Section 1, " General,"~and
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(2) Section-15, " Training and Certification of Personnel;"
to verify that procedures had been established requiring the qualification of welders and welding operators.
b.
Review of the Record of Performance Qualification tests of
-welders.and welding operators, to verify that they are in-conformance with ASME Code requirements.
c.
Review of welders qualification log, to verify that the vendor has provided a system for maintaining a continuous record of the welder qualifications; and that the welders have been, and are currently, qualified to weld under the prescribed pro-cedures.
d.
Interviews with personnel to verify they are knowledgeable in' the procedures applicable to welder qualification.
3.
Findings The inspector verified that the welders.and welding operators a.
were qualified in accordance with NRC rules and regulations, and the vendor's commitments.
b.
The inspector verified the welders receive "on-the-job" training.
Personnel applying for the position as a welder receive a formal performance evaluation of past experiences before acceptance and periodic formal review during training. After performance of the qualification test the coupons are tested and a formal.
performance evaluation made of the welder and recorded.
c.
Within this area of the_ inspection no deviations or unresolved items were identified.
H.
Exit Interview At the conclusion of the inspection on April 24, 1980, the inspector met
.with the company's-management, identified in paragraph A, for the pur-q pose'of informing them as-to the results of the inspection.
During this 1
' meeting the identified deviation was discussed and the evidence which i
supported the finding was identified.
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The company's management acknowledged the findings and supporting evidence as_being understood, but had no additional comments.
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