ML19320D345
| ML19320D345 | |
| Person / Time | |
|---|---|
| Issue date: | 05/23/1980 |
| From: | Brown R, Whitesell D NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML19320D336 | List: |
| References | |
| REF-QA-99900390 99900390-80-1, NUDOCS 8007210264 | |
| Download: ML19320D345 (6) | |
Text
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O VENDOR INSPECTION REPORT U. S. NUCLEAR RIGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT REGION IV Report No.
99900390/80-01 Program No.
51300 Company:
Irwin Steel Fabricatiors 1S45 Whipple Road S. W.
Canton, Ohio 44708 Inspection Conducted:
May 13-16,1980 Inspectors:
w 3
d Ross L. Brown, Contractor Inspector Date ComponentsSection I, VIB N
[/AS/#3 Approved by:
3 D. E. Whitesell, Chief Date ComponentsSection I, VIB Suninary Inspection on May 13-16, 1980 (99900390/80-01)
Areas Inspected:
Implementation of 10 CFR 50, Appendix B including control of non-confonnances and corrective action, weld control, audits and action on previous inspection findings. The inspection involved twenty six (26) inspector hours on-site by one NRC inspector.
Results:
In the four (4) areas inspected there were no deviations or unresolved items
'dentified.
8007210 M
c Detail Section A.
Persons. Contacted
- E. J. Jaquay, Quality Assurance Manager
- G. Knierien, Quality Assurance Engineer
- Attended Exit Interview B.
Action on Previous Insoection Findings (Closed) Unresolved Item (Report No.
79-01). The inspector verified that the certification of examination form has been revised and requires the qualified j
technician to include the approved procedure number and addenda prior to j
their signature.
C.
Control of Nonconformances and Corrective Action 1.
Objectives The objectives of this area of the inspection were to verify that proce-dures have been established and implemented for:
a.
Disposition of nonconformances that provide for:
(1) The control of nonconforming materials, parts, or components to prevent their inadvertent use or installation.
(2)
Identification, documentation, segregation, and disposition of nonconforming items and notification to affected organizations.
b.
Corrective Action that provides for:
(1) Review and evaluation of conditions adverse to quality to determine the cause, extent, and measures needed to correct and prevent recurrence.
(2) Reporting these conditions and the corrective action to management.
(3) Assuring that corrective action is implemented and maintained.
2.
Method of Accomolishment The above objectives were accomplished by a review of the following docu-ments.
a.
Irwin Steel Fabricators (ISF) Nuclear Quality Assurance Program, Revision 8, date May 5,1978 (QAP) Faragraph 15.0, "Nonconformities and Corrective Action."
l
-74
(
i b.
Inspection Reports for Nonconforming Material (IRNM) Numerical Log.
c.
IRNM - No 's 300 through 321.
3.
Findings No deviations or unresolved items were identified in this area of the inspec-tion.. The following information was obtained.
a.
The QAP defines nonconfomities, assigns the responsibility for the identification, disposition, approvals, and distribution of IRNM's.
The procedure also requires the Quality Assurance Manager (QAM) to initiate correct..<e action to preclude repetition, and the QAM shall periodically review with the General Manager, all corrective actions to detemine if possible trends can be noted that would re-quire additional preventive measures, b.
The Numerical Log lists IRNM numbers and appropriate shop order numbers.
c.
The IRNM reports identifies the discrepant item and describes the non-confomity. The reports also specifies the deficiency correction and action to prevent recurrence.
1 The General Manager initialed many of the reports, signifying he has reviewed the significant discrepancies and concurs with the disposi-tion and more especially the described preventive action to be taken as assigned by the QAM.
D.
Weld Control 1.
Objectives The objectives of this area of the inspection were to verify that:
- a.. Welding Material Control (1) The manufacturer has established procedures and instructions for purchasing, receiving, storing, disbursing, and handling of welding materials including welding electrodes, filler material, consumable inserts, fluxes and gases.
(2) The welding materials are clearly identified at all times in accor-dance with approved procedures.
(3) The ASME code required tests are perfomed on each lot of covered, flux cored or bare electrodes, rod, or wire, for each heat of consumable inserts and for each combination or bare electrodes and dry blend of flux mix to be used for welding.
, (4) The welding material storage procedures contain requirements for environmental (moisture) control.
(5) The disbursement of welding materials is controlled in accordance with approved procedures, b.
Weld Heat Treatment (1) The approved procedures are available for weld joint preheating when required by a welding procedure specification.
(2) Approved procedures are available for the conduct of postweld heat treatment (PWHT) and that the fabricator has a system capable of meeting the heating and cocling rates, metal temperature, tempera-ture uniformity and control limits specified in Section III of the ASME code.
(3) The PWHT temperature and holding time is specified, is adhered to and is consistent with ASME code requirements based on the material i
type and wall thickness.
(4) Measures are taken to avoid sensitization of austenitic stainless steel and high-nickel alloys.
2.
Method of Accomolishment The above objectives were acccmplished by a review of the following documents:
a.
QAP - Paragraph 8.0 " Welding Quality Assurance."
b.
Standard Operating Procedure S0P No.12, Revision 7, " Welding Material Control for Manufacturing Under ASME Section III Division 1 and Division 2."
c.
Six (6) Certified Welding Material Control Cards.
d.
Three (3) Material Test Reports (MTR).
e.
Oe Wire-Flux Combination qualification report.
f.
QAP - Paragraph 9.0 " Heat Treating."
g.
One post weld heat treating (PWHT) procedure.
h.
Two (2)
PWHT furnace temperature charts.
- i. Four (4) shop orders (traveler).
I
o
. 3.
Findings No deviations from commitment or unresolved items were identified. The inspector obtained the following information in this area.
a.
QAP - Paragraph 8.0 states in part, "all welding material shall be controlled in strict accordance with ISF's S0P No.12 Rev. 7...."
b.
SOP No.12 defines a procedure to assure proper receiving, inspection, storage, handling, and dispensing of all welding material through the point of actual use.
c.
The dispensing of all welding materials is controlled by the welding supervisor by issuing a request (via a Certified Welding Material Control Card) for the appropriate welding material.
The control card identifies as a minimum; the assigned welder, elec-trode size and type, electrode heat and/or lot number, amount dis-pensed and returned (if applicable) and date and time of material issue and return.
d.
The MTR's includes the chenical characteristics and physical properties (including Charpy "V" Notch, Drop Weights and ferrite percentage as appropriate).
The MTR's includes the suppliers ASME - Certificate number and expira-tion date.
e.
ISF performs the majority of the wire-flux ccmbination qualification and certification of weld material used in their shop.
f.
QAP - Paragraph 9.0 requires all PWHT to be performed in accordance with an approved written procedure that includes as a minimum: Handling, protection, loading, thermocouple location, time, temperature, heating and cooling rate, and holding time at temperature, g.
The travelers identifies if and when a PWHT is required.
E.
Audits 1.
Objectives The objectives of this area of the inspection were to verify that the j
following items were controlled in accordance with the QA Manual and applicable NRC and ASME Code requirements:
a.
A written system has been established to assure that audits are per-formed and controlled in accordance with applicable codes to verify compliance with all auditable aspects of the QA pregram.
i i
~..
~
. e b.
Planned and periodic audits are perfonned in accordance with written procedures or checklists by qualified personnel not having direct responsibilities in the areas being audited, c.
Audit results are documented and reviewed by management having respon-sibility in the area audited.
d.
Followup action, including reaudit of deficient areas, is taken where indicated.
2.
Methods of Accomplishment The preceding objectives were accomplished by:
a.
Review of QAP - Paragraph 16.0 " Auditing the Quality Assurance Program.
b.
Review of the audit checklist.
c.
Review of two (2) internal audit reports.
d.
Review of audit report distribution list.
e.
Review of three (3) follow-up audit reports.
3.
Findings No deviations or unresolved items were identified. The following infonna-tion was verified:
a.
QAP - Paragraph 16.0 requires a periodic audit of the quality program in accordance with a prepared checklir!. by qualified personnel not having responsibility in the area (s) being audited.
It also esta-blishes the audit schedule.
b.
The audit reports dated August 1979 and February 1980 were signed by the responsible auditors, QA Supervisor and General Manager.
The ISF management stated the audit report fonn will be revised to clearly state the areas of the program audited by each auditor.
c.
The follow-up audits of identified deficiencies were perfanned by the assigned auditors. The reports were signed by and distributed to the management personnel as the original report.
F.
Exit Interview The inspector conducted an exit meeting with the Irwin Steel Fabricators manage-ment representative at the conclusion of the inspection.
Those persons indi-cated by an asterisk in Paragraph A. 'above were in attendance.
In addition, the following were present:
. P. T. Irwin, President J. C. McArdle, General Manager The inspector discussed the scope of the inspection and the details of the finding identified during the inspection.
The ISF management's consnents were for clarification only.
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