ML19319E136
| ML19319E136 | |
| Person / Time | |
|---|---|
| Site: | Rancho Seco |
| Issue date: | 03/01/1973 |
| From: | Dodds R, Hunter V, Spencer G NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION V) |
| To: | |
| Shared Package | |
| ML19319E131 | List: |
| References | |
| REF-QA-99900048 NUDOCS 8003310652 | |
| Download: ML19319E136 (9) | |
Text
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O U. S. ATOMIC ENERGY COMMISSION DIRECTORATE OF REGUIATORY OPERATIONS REGION V
,RO Vendor Inspection 2eport No. 99900048/73-02 Vendor:
Anchor Valve Company Docket No.
050-0112 24747 Clawiter Rd.
Constr. Permit No.
56 Hayward, California 94545 Category A-3 Licensee: Sacramento Municinal Utility District i
Facility: Rancho Seco-Type of Inspection: Vendor. Announced I
Dates of Inspection:
January 22 - 24, 1973 Dates of Previous Inspection:
July 14 - 16. 1977 Principal Inspect,or:
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g u R. T. DoddS, Reactor Inspector (Date)
Accompanying Inspectors:
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'V. H. Hunter, Reactor Inspector
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I (Date) l Other Accompanying Personnel: None
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,t 14ti4E L-Reviewed by: ~ S. Spenger, Chief, Reactor Construction (Date)
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SUMMARY
OF FINDINGS Enforcement Action None Vendor's Action on Previously Identified Enforcement Item A.
It was determined that written instructions have been placed at machining stations that require _part identity to be reestablished after machining, before returning the part to the lot, as stated in Pacific Gas and Electric Company's letter dated November 18, 1971.
(Paragraphs 4.a. 4.e and 9.)
Other Significant Findings Current Findings A.
Valve Motor Operators (Limitorque Division of Philadelphia Gear) - Anchor i
installs and functionally tests valve motor operators for compliance with j
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purchase order specifications prior to releasing the valves for shipment J
to the customer. All operators in the shop with the potential torque 4
switch deficiency have been identified. The switches will be replaced in accordance with limitorque instruction prior to being released.
Anchor conducted an audit of Limitorque in August 1972 and found signi-ficant deficiencies in several areas of quality assurance. Corrective action has been requested and a reaudit has been scheduled for February 1973.
(Paragraph 10.)
Management Interview l
The results of the inspection were discussed with the following licensee and vendor representatives:
i SMUD Quality Assurance Engineer W. Friedrich I
Bechtel Quality Assurance Engineer G. R. Oakes j
D. K. Dann Inspection Supervisor i
Anchor Valve Company (AVC)
President 3
'W. A. Benning-l D. P. Gilbert Quality Assurance Manager Quality Assurance Engineer J. W. Smith, Jr.
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- Limitorque Division of Philadelphia Gear Company District Representative L. J. Helmuth A.
The inspectors acknowledged the corrective action taken by the vendor to assure that material identification was being maintained throughout machining operatiore (Paragraphs 4.a., 4.e. and 9.)
B.
In response to in',.>
.. findings, AVC stated that additional procedures will be prepared
'de a detailed method of calibration and recording of calibration date u
.- gauges.
(Paragraph 4.d.)
REPORT DETAILS 1
Section I - Prepared by R. T. Dodds 1.
Persons Contacted AVC D. P. Gilbert QA Manager O
J. W. Smith, Jr.
QA Engineer
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E. Zavialoff Assistant Chief Engineer Project Engineer (SMUD)
P. Poirier E. Hook Project Engineer (PGE)
B. Tillman QA Clerk R. Gartner Toolroom Leadman F. Kabas Weld Shop Leadman J. Freitas Chief QC Inspector W. Morgenthaler QC Inspector SMUD W. Friedrich QA Engineer Bechtel R. Dann Inspection Supervisor 2.
General At the time of the inspection, AVC was manufacturing valves for SMUD in accordance with purchase orders for Class I valves in assorted sizes from 2-1/2 to 10 inches. AVC possesses "N" and "NPT" ASME Certificateo of authorization that are valid for the period of March 9, 1971 to March 9, 1974. Except for some minor documentation differences, all valves were being built to quality Class I specifications. The vendor only manufactures to special orders and does not stockpile valves.
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Quality Assurance Program The purchase order from SMUD requires AVC to have a QA program that meets the applicable requirements of Appendix "B" of 10 CFR 50.
AVC's QA manual has been reviewed and approved by the ASME "N" stamp code committee. The manual has also been examined and approved for usage by SMUD.
An in-depth examination was made of the QA Manual and supporting
" Standard Procedure Inst' ructions." The program was compared to the 10 CFR 50, Appendix "B" requirements. No significant program deficiencies were identified.
4.
QA/QC Program Implementation a.
Inspection Tours Several tours were made to observe (1) receiving inspection and material storage areas, (2) nonconforming material control, (3) manufacturing processes, (4) valve inspection, (5) checks of QC test equipment, and (6) cleaning and preservation practices.
It was observed that the plant was reasonably clean for the activities In progress. Storage of parts and snhassemblica were neat and orderly. Many subparts were checked and found to be identified by purchase order number, part number and heat number.
All machines were attended where work was in progress.
" Major Part Routing Tickets" were noted to be with individual parts and the documentation on them appeared to be current. Coated low hydrogen filler metal electredes for welding were noted to be stored in locked holding ovens. Nonconforming material was found to be identified by appropriate tags and was stored in designated segregation areas. QC inspectors were observed to be performing QC activities including the witnessing of inspection hold points.
b.
Vendor Audits
,The examination of vendor audits performed by AVC disclosed that all approved suppliers (includes Limitorque Corporation) have been audited on schedule at least once within the last year. Written reports, including followup, were submitted to AVC management following each visit.* The records show that the auditors (QA/QC personnel) were being trained as appropriate in specialty fields.
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- See Paragraph 11 for the results of an audit of the valve motor operator
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supplier (Limitorque Division of Philadelphia Gear).
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Material Control It was verified during the tour of the facility that material with yellow " hold" tags had been stoted in segregated areas. According to the vendor, and as verified by sampling the SMUD records, the material was put on hold by the receiving inspecter until released for production by QA. QA must review the documentation for conformance to the specifications before releasing the material to production. Approved materials awaiting initial machine operations were noted to contain " release for production" green tags. A separate storage area was used for materials' tagged with red
" reject" stickers.
The Material and Nuclear Manufacturing Rejection Notices issued for 1972 and 1973 to date were examined. All notices appeared to have been dispositioned in accordance with QA program requirements.
d.
Inspection. Measuring Devices and Test Equipment The records pertaining to daily checks and periodic calibrations for the past year of test gauges, calipers and micrometers were
'N A documented check against standard sources was made
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examined.
each day the QC instruments were used. Quarterly calibrations
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were also being performed on time.
The quarterly relibrations included checks of individual machinist micrometsrs and calipers.
The standard gauges and test blocks were being calibrated annually by independent laboratories.
j Daily tests of a test pressure gauge, micrometer and caliper were witnessed.
Standard procedures had been prepared for the tests of the calipers and micrometers.
The inspector stopped at about
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five intervals to compare pressure readings during the check of the
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test gauge. However, the quarterly calibration program for pressure gauges was not detailed in that it did not require a record of comparative pressure readings nor did it specify the interval between comparative check pressures.
e.
Inprocess Control and Inspection About 25 routing tickets for major parts were examined and found to be current with the status of manufacturing operation in progress for the respective parts. Six travelers were checked in the welding area. The procedures being followed were the same as those required by the applicable Special Order Instructions. Material traceability by part and heat
,or lot number was being maintained for all materials including weld filler metal.
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s A check of work stations and machining operations disclosed that applicable drawings were available and apparently being used.
l The inspection of valve bodies was observed. Records were being made of minimum wall thickness measurements and other specified check points. The inspection records shewed the acceptance limits.
The dye penetrant testing of valve bodies and parts was also observed. Records were made of any discrepancies observed such as porosity in valve facings.
In the instance where this was noted.
the valve body was returned to manufacturing in accordance with a documented " Release for Rework" form.
f.
Cleaning and Packaging The cleaning and packaging of valves was observed. The specified cleaning and packaging procedures were available in the cleaning area and it was apparent that the procedures were being followed.
A check of the demineralized water used in the area showed it to contain less than 0.2 ppm chlorides (minimum sensitivity of test).
The records show that the portable demineralizers were checked by an independent laboratory (Signet Laboratory) prior to usage.
Section II - Prepared by V. H. Hunter 5.
Persons Contacted Bechtel Corporation G. R. Oakes Quality Assurance Engineer j
R. K. Dann Inspection Supervisor l
SMUD W. Friedrich Quality Assurance Engineer Limitorque 1
L. J. Helmuth District Represen'tative AVC W. A. Benning President D. P. Gilbert Quality Assurance Manager J. W. Smith' Quality Assurance Engineer
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Rocurement control AVC Purchase Order No. 1701 to the Vulcan Steel Company for the procure-ment of material for valve bodies and discs intended for valves to be used at Rancho Seco was reviewed.
Contained in the purchase order were the appropriate references to AVC's customer purchase order and pertinent requirements and specifications such as (1) SMUD's Purchase Order Number 4476, (2) heat number must be stamped and cast on each part, (3) radiography in accordance with the applicable ASME and ASTM references, (4) charpy V-Notch tests per NB-2300, etc.
Compliance with these purchase specifications was verified by examination of the one completed valve data package.
7.
Drawing and Procedure Control A shop traveler form in the fabricating area was selected which referenced Drawing 1892-3, Revision B.
The drawing was then compared with the drawing coordinators master drawing card file which indicated that it was of the most recent revision and had the approval stamp from the AVC customer. Three additional stations were similarly checked and found to have the latest drawings.
8.
Nondestructive Testing (NDT)
AVC's NDT procedures, techniques and personnel qualiff :ations were examined.
It was noted that AVC radiographic procedure number 1327-1 contained appropriate references to nechtel specifications 6478-M-504 and that the procedure had been submitted and approved for use by SMUD on November 9, 1972. The radiographic portion of AVC's NDT program has been subcontracted to the X-Ray Engineering Corporation (XEC).
Both AVC and XEC NDT personnel qualifications were reviewed and found to be in accordance with'SNT-TC-1A requirements.
9.
Docu'entation Control The documentation packages pertaining to valve and/or electrical motor operators being manufactured to the requirements of SMUD Purchase Order 4476 were reviewed. During this review, it was noted that the Bechtel l
" Data Requirements" form was present in each data package with each supporting data sheet being readily retrievable.
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Material Identification CO Report No. 071-01, Dockets Nos. 050-0275 and 050-0323, (Pacific Cas and Electric Company's Diablo Canyon 1 & 2) had indicated that there was a lack of an inspection point at the machine operations where material identification was being removed. AVC correction (as outlined in Pacific Gas and Electric Company's latter of response dated November 18, 1971) was to issue a directive to all affected personnel incorporating an inspection hold point whenever there was more than one heat of material on a routing ticket. In addition to the above, the directive niso stated that these requirements would be included in the AVC QA manual at the-next revision.
i Three machine operation points were checked and verified to have the j
referenced directive present and being implemented. It was also noted that the AVC Standard Procedure Instruction (SPI) was in the process of being modified to incorporare these requirements.
11.
Valve Motor Operators a.
Documentation AVC documentation for electrical motor operators was reviewed. No anomalies were identified in the documentation for valve motor operators to be placed outside of the containment building. It was noted that valve motor operators for use inside of the containment building were presently on hold status due to inadequate supporting documentation from the Limitorque Corperation.
The inspector reviewed an AVC audit report of the Limitorque Division of Philadelphia Cear that was conducted on August 30, 1972.
l The report cited Limitorque for the following deficiencies in their l
quality assurance program:
4 (1) No material release system.
i (2) No formal syrtem for drawing control and planned order control, including checkit.d.
(3) No in-process documented hold points.
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(4) Final parts inspection not documented.
(5) No internal audits.
1 (6) No dccumented gage control.-
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(7) " No test program for' testing completed motor operators.
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. Corrective action has been requested by AVC with followup audit of Limitorque to be performed during first half of 1973.
b.
Torque Switches The torque switch problem, as outlined in Directorate of Regulatory Operations Bulletin 72-3, was discussed with Anchor Valve and the following information c,bcained.
(1) AVC became aware of the problem through notification from Limitorque.
(2) As of the date of notification (1-15-73), AVC has not shipped any motor operators within the affected serial number range (SMB-00 to SMB-000) without performing the modifications required by Limitorque.
(3) AVC has performed an inhouse review and ascertained that i -
motor operators within the affected serial number range are oot present in stock.
Cj (4) AVC is assisting all customers in identifying all motor operators within the affected serial number range that have been shipped to date.
(5) It is the opinion of AVC technical personnel that the problem, as outlined in Bulletin 72-3, would have been detected during the 100% functional test program conducted by AVC.
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