ML19345H320
| ML19345H320 | |
| Person / Time | |
|---|---|
| Issue date: | 03/23/1981 |
| From: | Oller R, Whitesell D NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML19345H318 | List: |
| References | |
| REF-QA-99900104 NUDOCS 8105200106 | |
| Download: ML19345H320 (12) | |
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U.S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT REGION IV Report No. 99900104/81-01 Program No. 51300 Company:
Westinghouse Electric Corporation Nuclear Components Division, Pent.acola Plant P.O. Box 1313 Pensacola, Florida 32596 Inspection Conducted:
February 23-27, 1981 Inspector:
Ar af/23/A/
R. E. 011er, Contractor Inspector Date Components Section Vendor Inspection Branch Approved by:
Bf//////
- 0. E. Whitesell, Chief Date Components Section Vendor Inspection Branch Summary Inspection performed February 23-27, 1981 (99900104/81-01)
Areas Inspected:
Implementation of 10 CFR Part 50, Appendix B criteria other NRC requirements, and applicable codes and standards including:
action on previous inspection findings, general review of vendor activities, internal audits, radiographic examination, procurement source selection and weld joint fitup and weldiag.
The inspection involved 27 inspector hours on site.
Results:
In the six areas inspected, no nonconformances or unresolved items were identified.
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810520010(o
2 DETAILS SECTION A.
Persons Contacted "J. Abernathy, General Supervisor - Welding J. Allen, QA Engineer D. Boykin, Welding Engineer
- "G. Callender, Manager - QA Engineering
- "M. Ferguson, QA Engineer A. Furth, Welding Engineer H. Glover, Radiographer P. Jacob, Welding Supervisor "R. Latta, Manager - Manufacturing Planning "K. Mastron, Manager - Purchasing & Traffic
- T. Miller, Manager - Product Assurance J Peterson, Welding Supervisor "L. Willey, ANI Inspection Supervisor
- Attended the preinspection meeting.
" Attended exit meeting.
B.
Preinspection Meeting A preinspection meeting was held on February 23, 1981, with the above denoted m1tnagement representatives.
The NRC inspector defined the scope of the inspection, designated a date and time for the exit interview, and discussed changes in the Vendor Inspection Branch, vendor inspec-tion documentation, and identification of deficiencies.
C.
Action on Previous Inspection Findings l
1.
(Closed) Deviation A (Report No. 80-01):
Failure to follow l
Welding Procedure Specification (WPS) PAW-MA-385, Revision 3 l
for the voltage range of 14-18 volts and the shielding gas flow j
rate of 50 CFH during hard facing weld metal overlay welding on Shop Order PCZL 454.
The inspector found that f, accordance with Westinghouse Pensacola Plant (WPP) letter dated 6-6-80, that corrective action has been taken by reinstructing all welders that the essential varialles of welding procedures must be adhered to.
The training sessions were documented.
In addition, for '.he affected production weld overlay, a special WPS, containing values of the two out-of-specific.ation i
essential variables, was written and qualified to assure that the weld overlay met code requirements.
Preventive action was provided by including routine observation by patrol inspection of the use of required welding parameters during subsequent hard surfacing appli-cations.
These patrol inspections were also documented.
3 2.
(Close) Deviation 8 (Report No. 80-01):
Failuru to attach and use two thermocouples during the intermediate postweld heat treatment of a pressurizer nozzle for Shop Order No. ~./4, nozzle SN. W664-A01, as required by Procedure No. DMP-15-4-5524, Revision 4.
The inspector found that in accordance with WPP letter dated June 6,1980, that corrective action was provided by training the welder who performed the subject heat treatment, in the r ; quire-ments of the procedure. To provide preventive action, a program in stress relieving instruction was implemented for all welders who perform stress relieving.
It was verified that this training was documented.
D.
General Review of Vendor's Activities 1.
Objective The objective of this area of the inspection was to assess the vendor's activities and their impact on future NRC inspections.
2.
Method of Accomplishment The preceding objective was accomplished by:
a.
Discussions with cognizant personnel.
b.
Revirs of the following ASME N-type symbol authorizations to veriy that they are current and identify the products that are required to be stamped:
l (1) No. N-1669 for use of the "N" symbol.
(2) No. N-1670 for u;e of the "NPT" symbol.
c.
A verbal review of the inshop domestic nuclear orders and type of components manufactured at the Westinghouse Pensacola l
i Plant (WPP).
d.
A walk through observation of plant facilit'es and in process work.
3.
Findings a.
Within this area of the inspection, no nonconformances or unresolved items were identified.
b.
Other Findings - Comments (1) The WPP ASME N-type symbol authorizations are for the use of the "N" and "NPT" symbols.
The certificates appear to properly 1
4 describe the products being manufactured which require code stamping.
Both of the authorizations expire on March 11, 1983.
The plant also has an ASME "U" symbol authorization.
(2) Currently the products being manufactured are:
reactor vessel internals and associated hardware, reactor fuel racks, miscellaneous tanks, and main coolant pump casings.
(3) The current nuclear work load includes contracts for reactor internals and associated hardware for four domestic nuclear power plant units.
E.
Internal AuM ts 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 internal audits are performed and controlled in accordanca with appli-cable codes to verify compliance with all aspects of the QA program.
b.
Planned and periodic internal audits are performed 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 responsibility in the area audited.
l d.
Followup action, including reaudit of deficient areas, is taken where indicated.
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2.
Method of Accomplishment The preceding objectives were accomplished by:
l a.
Review of the QA Manual Section 18.0 " Audits".
l b.
Review of approved procedure PE-12-03-003, Revision 8, " Internal Audit of Quality Program, System and Procedures," including the following exhibits and Appendix I:
(1) Exhibits A "QA Engineering Checklist".
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5 (2)
Exhibit B, Notification letter to the department to be audited.
(3) Exhibit C, Notification letter to the department audited, with attached " Audit Nonconformance Reports," (ANR) and/or
" Audit Recommendation Reports," (ARR) to be completed for cause, corrective action and preventive action.
(4) Exhibit D, Letter covering audit personnel contacted.
(5) Exhibit E, " Audit Recommendation Report."
(6)
Exhibit F, " Audit Nonconformance Reports."
(7)
Exhibit G, Notification letter tc the reaudited department for corrective action.
(8) Exhibit H, " Departments Involved in Implementation of the Pensacola Plant QA Manual."
(9) Appendix I, " Qualification of Lead Auditors."
c.
Review of records of qualification for nine (9) Lead Auditcrs.
d.
Review of the Internal Audit Schedules for 1980.
e.
Review of the followin; records of the internal audit of the QA Engineering Department performed on July 8 and 9, 1980.
(1) Notice of familiarization and training session.
(2) Notice of proposed audit of the QA Engineering Department.
1 (3) Audit Checklist.
(4)
Letter dated 7-1E-80 to the affected department requestir.g that completion of Section II "Cause, Corrective and Preventive Actions" of the attached ANRs and ARRs within 15 working d=vs.
(5) Four ANRs and eight ARRs resulting from the above l
audit, to verify that proper entries were made, and the l
reports sections were completed by rs?ponsible persons for:
cause, corrective action, preventive action, lead auditor review of corrective and preventive actions, and the required signoffs and dates.
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3.
Findings a.
Within this area of the inspection, no nonconformances or unresolved items were identified.
b.
Other Findings - Comments Review of the qualification record for the lead auditor, who performed the July 8-10, 1980 audit of the QA Engineering Department, indicated that this auditor worked in the QA Engineering during the the above audit.
Discussions with the QA Engineering Department representative established taat the record was incorrect as the. lead auditor had been reassigned from QA Engineering to the Contracts '.ad International Support Department in 1979.
Prior to the end of the inspection, this lead auditors' qualification record was corrected.
F.
Radiographic Examination 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 radio-graphic examination (RT) is performed in accordance with applicable codes.
b.
Final acceptance RT is performed in accordance with detailed written instructions or procedures which delineate requirements and acceptance stancards.
c.
The RT procedures meet the requirements of the ASME Code and are qualified.
d.
The RT is performed and the resu interpreted by qualified and certified personnel.
e.
Test results are documented and evaluated to assure that the component or material examined contain no rejectable c'efects.
f.
Appropriate instruments are used, and the instruments are cali-brated, where required.
2.
Method of Accomolishment The preceding objectives were accomplished by:
7 a.
Review of the QA Manual Section 9.0, paragraph 9.4 " Control of Nondestructive Examination."
b.
Observation of the radiographic setup for the intermediate x-ray of a girth weld between a skirt and support plate of a 4-Loop reactor internal assembly for Shop Order GAZL423, Assembly SN. 67571, Drawing 6115E83, Item G01, Issue 11R, to verify the ASME Code and WPP procedure QIP-8222, Revision 2 requirements were being met.
c.
Review of the Route Sheet traveler for the above Shop Order item.
d.
Review of the WPP RT procedure QIP-8222, Revision 2, used for the above operation.
e.
Examination of the final Radiographic Report and the 31 films for a girth weld similar to the above assembly but for a different work order, on Assembly SN67152, to verify that the films and report met ASME Code requirements.
f.
Review of the RT procedure QIP-8203, Revision I, used in making the above radiographs in item e.
g.
Review of the personnel qualification and certification records, including eye examination, for the two radiographers who per-formed the x-ray on tiie above two shop orders.
h.
Discussions with responsible personnel.
3.
Findings Within this area of the inspection, no nonconformances or unresolved j
items were identified.
G.
Procurement Source Selection l
1.
Objectives The objectives of this area of the inspection were to verify that the l
following items were controlled in accordance with NRC and ASME Code requirements.
a.
A written system has been established to assure that procurement I
source selection is controlled in accordance with code require-ments.
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8 b.
Procedures have been prepared, approved and implemented which will assure that procurement source selection includes integrated action by one or more responsible groups or departments such as quality assurance, purchasing and/or engineering.
c.
Evaluation of subcontractors include such measures as:
onsite survey of subcontractor's capabilities including a quality assurance program; acaptance based on a subcontractor being a holder of a valid ASkE certificate of authorization applicable to the items or services to be supplied; a history of subcontractors' performance, and evaluation of other applicable requirements specific to the purchaser.
2.
Method of Accomplishment The preceding objectives were accompliched by:
a.
Review of the QA Manual Section 7.0, paragraph 7.2, " Supplier Evaluation and Selection."
b.
Review of the following approved procedures:
(1) No. PE-06-02-004, Revision 2, " Qualified Supplier List."
(2) No. PE-12-01-006, Revision 6, " Supplier Surveillance Program," including the attached " Supplier Evaluation Plan" exhibit.
c.
Review of vendor recoro files r;:aintained at WPP for the following suppliers.
(1) Capital Pipe & Steel, Carnagie, Pennsylvania.
(2) Carbon Steel Products, Elizabeth, New Jersey.
(3) Carpenter Technology, Reading Pennsylvania.
d.
Review of the " Qualified Vendor List" dated 2-20-81 (Computer Printout) including the " Vendor Evaluation Plan" for the following suppliers to determine the method of supplier I
control:
(1) ARMCO Steel Corporation, Houston, Texas.
l (2) ARMCO Steel Corporation, Atlanta, Georgia.
1 (3) Capital Pipe & Steel, Carnagie, Pennsylvania.
(4) Carbon Steel Products, Elizabeth, New Jersey.
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(5) Carpenter Technology, Reading, Pennsylvania, e.
Review of computer printout sumcary sheet, " Qualified Supplier Review List" dated 2-16-81, to verify that suppliers on the QVL whose approvals will expire within 12 months, are identi-fied.
f.
Review of the "WPP 1981 Supplier Audit Schedule."
3.
Findings a.
Within the area of the inspection, no nonconformances or unresolved items were identified.
b.
Other Findings - Followup Item Review of the " Supplier Evaluation Plan" part of the " Approved Vendor List", dated 2-20-81, (computerized), established that it was significantly different from Exhibit B " Supplier Evalu-ation Plan" of the controlling procedure No. PE-12-01-006, Revision 6.
The QA Department representative indicated that the procedure had been revised and was in a draft comment status.
He then presented a draft copy of Revision 7 of the procedure for the NRC inspector's review.
The final approved revision to this procedure will be reviewed during a subsequent NRC inspection.
H.
Weld Joint Fitup and Welding 1.
Objectives The objectives of this area of the inspection were to verify that the following items were controlled in accordance with applicable l
NRC and ASME Code requirements.
i a.
A written system has been established to assure that welding is performed and controlled in accordance with applicable codes and procedure specifications.
b.
The work is conducted in accordance with a process control document such as a traveler.
c.
Applicable qualified welding procedure specifications (WPS) and weld data sheets are usea at the work stations.
d.
The requirements of essential variables and othse applicable WPS parameters are concurred with to produce weldments having the required properties.
10 e.
The welding is being performed by properly qualified personnel.
f.
Weld joint geometry, fitup alignment, and surface preparation are as required by the applicable WPS and the Code.
g.
The welding equipment is in good condition and calibrated, were required.
h.
The completed weld meets code requirements for nondestructive examination suitability, undercut and other visual acceptance standards.
i.
Repairs by welding are performed in accordince with code requirements.
2.
Method of Accomplishment The preceding objectives were accomplished by:
a.
Review of the QA Manual, Section 9.0, paragraph 9.3 " Weld and Brazing Processes."
b.
Review of the in process Route Sheet traveler for a 3 3. cop core barrel girth weld for Shop Order KGZL350, Assembly SN 54269, Drawing 6121E32, Item G01, Issue 048, to verify that inprocess welding operation was controlled and identified by procedure and revision numbers.
c.
Review of the Weld Status Input Sheet (for computer input).
d.
Review of the automatic welding procedure specification (WPS)
GTAW/AU-234-4, which was identified on the traveler and located at the welding station.
e.
Observation of the weld joint and automatic welding of the above joint using WPS GTAW/AU-234-4, to verify that the specified procedure parameters were being adhered to.
f.
Observation of the calibration status of the ohmmeter, voltmeter and wire feed speed control indicator, g.
Review of the in process Route Sheet traveler for welding of radial keys to the Core Barrel Support for Shop Order TWZL333, Assembly SN.51172, Orawing 6121E62, Item G01, Issue 01B, to verify that the inprocess welding operation was controlled and identified by procedure and revision numbers.
h.
Review of the manual WPS SMAW/MA-618, Revision 5, which was identified on the traveler and located at the welding station
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for the welding in above item g.
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Observation of the weld joint and manual welding of the radial keys to the core barrel, using WPS SMAW/MA-618, Revision 5, to verify that the specified procedure parameters were being adhered to.
j.
Review of the procedure qualification rect.rds (PQR) No. GTAW/AU-157, j
dated February 19, 1975 for WPS GTAW/AU-234-4, and PQR No. 160 for WPS SMAW/MA-618, Revision 5.,
to verify that both of the l
WPSs were qualified in accordance with the ASME Code Section IX.
k.
Review of the Welder Performance Qualification Records for:
Welding operator No. 5195 (one of two operators) who performed the automatic welding of tha girtn weld and for welder No. 8020 (one of four welders) who performed the manual welding of the radial keys to the core barrel support, to verify that they were qualified in accordance with the ASME Code Section IX.
1.
Discussions with welding operators, welders and welding supervisors.
3.
[indings a.
Within this area of the inspection no nonconformances or unresolved items were identified.
b.
Other Findings - Followup Item l
During the manual welding of radial keys to the core barrel I
support on Shop Order TW2L333, Assembly SN 51172, using welding specification No. SMAW/MA-618, Revision 5, it did not appear that the weld metal interpass temperature was being checked with a temperature indicator The WPS specifies a 6
maximum interpass temperature of 350 F.
Discussion with the welder and a welding supervisor indicated that no interpass temperature checks with a temperature indicator were made.
This matter was discussed in the exit interview, and its correction will be followed during a subsequent NRC inspection.
I.
Exit Interview l
1.
The inspector met with management representative denoted in paragraph A. above, at the conclusion of the inspection February 27, 1981.
2.
The following subjects were discussed:
l a.
Areas inspected.
a 4
t 12 b.
Status of corrective and preventative action for the previous outstanding items.
j c.
The items to be followed up on, identified in this report.
3.
Management's questions related to clarification of the above items.
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