ML19347F247
| ML19347F247 | |
| Person / Time | |
|---|---|
| Issue date: | 03/06/1981 |
| From: | Kelley W, Whitesell D NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML19347F245 | List: |
| References | |
| REF-QA-99900054 NUDOCS 8105180057 | |
| Download: ML19347F247 (13) | |
Text
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g U. S. NUCLEAR REGUL4 TORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT REGION IV Report No.
99900054/81-01 Prograa No.
51300 Company:
Oresser Industries, Inc.
Industrial Valve Operations P. O. Box 1430 Alexandria, LA 71301 Inspection Conducted:
February 18-20, 1981 Inspector:
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Wm. D. Kelley, Coritractor Irjspector
' D&te Vendor Inspection Branch Li Approved
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D. E. Whi+,esel l, Chief
'Date ComponentsSection I Vendor Inspection Branch Summary Inspection on February 18-20, 1981 (99900054/81-01)
Areas Inspected:
Implementation of 10 CFR Part 50, Appendix B and applicable codes and standards including, design-document control, procurement control.-
evaluation of suppliers performance; manufacturing process control - machining; inspection and test - testing of completed products; control of special processes - special welding applications; training - welder qualifications; and audits - internal management.
Also, reviewed vendor activities and con-ducted an exit interview.
The inspection inve'.ved 20 inspector-hours on site by one NRC inspector.
Results:
In the seven areas inspected, no nonconformances or unresolved items were identified.
18105180 C
2 DETAILS
-A.
Persons Contacted D,resser Industries, Inc. - Industrial Valve Opentions
^J. W. Ashmore, Quality Assurance Engineer
- V. Beavers, Chief Inspector
- J. D. Beck, Chief Engineer
- L. M. Brown, Quality Assurance Engineer, Systems and Audits
- B. G. Brunson, Manager Quality Systems
- H. C. Christopher, General Product Manager
- G. D. Fitzpatrick, Manager of Purchasing
- K. Hare, Manager Planning and Administration
- R. S. Huffy, Product Engineer
- Y. S. Lai, Chief Development Engineer
- J. L. Markley, Manager Materials D. McKnight, Welding Inspector
- J. J. Nagel, Manager Manufacturing
- R. L. Schaus, Manager Plant Operations
- T. A. Shoup, Welding Engineer
- R. R. Thomas, Quality Assurance Engineer
- W. Tacy, Jr., Manager Product Engineering
- J. P. Watz, Principal Quality Assurance Engineer
- J. A. White, Manager Industrial Engineering Hartford Steam Boiler Inspection and Insurance Company (HSB)
- B. C. Dasher, Authorized Nuclear Inspector
- Denotes those persons who attended the exit interview (See paragraph J).
B.
General Review of Vendor's Activities 1.
The ASME resurveyed Dresser Industries (DI) the week of June 9, 1980 and issued the following Certificates of Authorization:
Certification No.
Symbol Product N-1746 N
Class 1, 2, & 3 valves N-2434 NPT Class 1, 2, & 3 valve parts and appurtenances N-1747 NV Class 1, 2, & 3 safety and safety relief valve
3 Certificates N-1746 and N-1747 expire on May 20, 1983, certificate N-2434 expires on September 8, 1983.
2.
There has been no change in the status of the authorized inspection agency or the authorized nuclear inspector as reported in NRC IE Report No. 99900054/79-01.
3.
DI's contribution to the nuclear industry represents approximately five percent (5%) of its total workload.
C.
Design-Document Control 1.
Objectives The objectives of this area of the inspection were to ascertain whether procedures had been developed and properly implemented to control the review, approval, release and issuance of design e
documents in a manner consistent with NRC rules and regulations, and the vendor's commitments in the ASME accepted Quality Assurance Program.
2.
Method of Accomplishment The objectives of this area of the inspe: tion were accomplished by:
Review of the ASME accepted Quality Assurance Manual and the a.
following procedures:
(1) QA0P4-1, Revision 4, " Design Review and Control," and (2) QA0P4-2, Revision 3, " Product Drawing Changes and Release;"
to verify that the vendor had established procedures to prescribe a system for design document control.
b.
Review of the following procedures:
(1) QA0P4-4, Revision 1, " Deviation from Engineering Drawings,"
(2) OT1-65, Revision 2, " Initiation and Use of the Contract Document Control Checklist...," and (3) QT1-18, Revision 4, " Control of Nuclear Order Documents ;"
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to verify that they had been prepared by the designated authority, approved by management, and reviewed by QA.
c.
Review of documents referenced in paragraphs a. and b.
to verify that they provided for the identification of personnel responsible for preparing, reviewing, approving, and issuing design documents; and that the review and approval of significant changes were performed by the same personnel.
Also to ascertair. whether minor changes to design documents, that do not require review and approval, are identified.
d.
Review of QT1-18, Revision 4, " Control of Nuclear Order Documentation" to verify that the distribution lists are current and that the proper documents are identified, accessible, and are being used.
e.
Interviewed personnel to verify whether they were knowledgeable in the procedures applicable to design document control.
3.
Findings a.
The inspector verified that procedures had been developed and properly iinplemented to control the review, approval, release and issuance cf design documents in a manner consistent with NRC rules and regulations and the vendor's commitments in the ASME accepted Quality Assurance Program.
b.
Within this area of the inspection no nonconformances or unresolved items were identified.
D.
Procurement Control-Evaluation of Supplier Performance 1.
Objectives The objectives of this area of the inspection were to verify that:
a.
Procedures have been prepared and approved by the vendor for evaluation of suppliers performance which are consistent with NRC rules and regulations, and the vendor's commitments in the ASME accepted Quality Assurance Program, b.
Procedures for evaluation of supplier's performance are being 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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5 a.
Review of the ASME accepted Quality Assurance Manual, QA0P8-1, Revision 6, " Vendor Quality Surveys and Audit, to verify the vendor had established a procedure for the evaluation of suppliers and that it's requirements are con-sistent with NRC rules and regulations and ASME Code requirements.
b.
Review of six sets of documents applicable to three suppliers to verify that the procedures, and necessary procurement documents, were available to the persons responsible for performing the quality related activities, and that the procedures were available and were being properly implemented.
c.
Interviews with personnel to verify whether they were knowledgeable in the procedures applicable to evalua-tion of the supplier's performances.
3.
Findings a.
The inspector verified that:
(1) Procedures have been prepared and approved by the vendor for the evaluation of suppliers performances in a manner consistent with NRC rules and regulations, and the vendors commitments in his ASME accepted Quality Assurance Program.
(2) Procedures for the evaluation of supplier's performance are being properly and effectively implemented by the vendor.
b.
Within this area of the inspection
,is nonconformances or unresolved items were identified.
' E.
Manufacturir.g Process Control - Machining 1.
Objectives The objectives of this area of the inspection were to verify that a.
the machining operations are performed under a controlled system of manufacutring which meets NRC rules and regulations and the vendor's commitments in the ASME accepted Quality Assurance Pro-gram.
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6 b.
The controlled system of manufacturing is effective in assuring product quality.
2.
Method of Accomplishment The objectives of this area of the-inspection were accomplished by:
a.
Review of the ASME accepted Quality Assurance Manual and the following procedures:
(1)' QA0P3-2, Revision 1, " Material Identification,"
(2) QA0P4-3, Revision 3. "Use and Control of Manufacturing Drawings,"
(3) QA0P10-2, Revision 4, " Manufacturing Routings Initiations and Control;" and (4) QA0P11.1, " Final Product Inspection Assembly, Test and Final Release;"
to verify that procedures 'iad been established which prescribes a system for the control af the manufacturing operations.
b.
Review of the procedures reference in paragraph a. to verify that they had been prepared by the designated authority, approved by management, and reviewed by QA, and are consistent with NRC rules regulation, ASME Code requirements, and the vendor's commitments in the ASME accepted Quality Assurance Program.
c.
Review of the following documents:
(1) Ten Operation and Routing Sheets; (2) Twelve Drawings, and (3) Two Receiving Logs; to verify that they provide drawing / document control in the shop, and also provides for parts identification, traceability, in process and final inspections, identification and segrega-tion of nonconforming items, the resolving of nonconforming items, and that the gages and measuring devices used for in-process and final intpections, are under a controlled calibration system.
7 d.
Examine three representative samples of finished machined parts; (1) Base Assembly, PN 4228501-NC045, (2) Nozzle, PN 5135301-NC045, and (3) Body Assembly, PN 7105502-NC049; to verify that they were properly identified and machined to conform to the drawings and specifications:
e.
Examined the finished machined parts identified in paragraph d above, to verify compliance with the specified documentation.
3.
Findings a.
The inspector verified that:
(1) The machining operations are 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 rs nonconformances or unresolved items were identified.
F.
Inspection and Test - Testing of Completed Products 1.
Objectives The objectives of this area of the inspection was to verify that valves are assembled in accordance with approved procedures and drawings, and that all materials complied with the specifications.
Also that the functional test of the products were performed in accordance with customer's design specifications and the specified acceptance limits.
2.
Method of Accomplishment The objectives of this area of the inspection were accomplished by:
a.
Review of test documents PT-10-NC051, Revision 0,
" Instructions for Setting and Testing Types 1970 and 1975 Portable Relief Valves and the Type 1980 Series Safety Relief Valves", and PT-65-NC0-45, Revision 2, " Steam Testing and m
8 Setting Instruction 31700 Pressurizer Safety Valves with Elevation Temperature Compensation," to verify that:
(1) Test procedures and/or instructions were available at the test station and had been approved by engine:aring and quality assurance.
(2) The tests had been performed in accordance with the procedures and/or instructions.
(3) Changes made to test procedure had been approved by engineering and quality assurarce, and had been followed.
(4) The test data was documented and evaluated in accordance with the procedure and/or instructions.
(5) The limits of acceptability of test results, had been established and were being used to determine the acceptability of the product.
b.
Review of test instruments used to_ verify that they are as specified by the procedure, and/or instructions, and were properly calibrated.
3.
Findings a.
The inspector verified that valves are assembled in accordance with approved procedures and drawings, and the materials complied with the specifications.
Also that the functional tests were performed in accordance with customer's design specifications and met the specified acceptance criteria.
b.
Within this area of the inspection no nonconformances or unresolved items were identified.
G.
Control of Special Processes - Special Welding Applications 1.
Objectives The objectives of this area of the inspection were to verify that special welding procedure specifications (WPS) for cladding, hard surfacing, seal welding, and weld repair without postweld heat treatment, conform to the requirements established by Sections III and IX, of the ASME Codes, NRC rules and regulations, and the commitments in the vendor's Quality Assurance Program.
9 2.
Method of Accomplishment The objectives of this area of the inspection were accomplished by:
a.
Review of the ASME accepted Quality Assurance Manual and the following procedures; (1) QA0P10-1, Revision 2, " Preparation and Use of Master Control Document for Processing Nuclear Orders," and (2) QA0P10-2, Revision 4, " Manufacturing Routing Instruc-tions and Control;"
to verify that the vendor has established procedures to prescribe a system for the development and qualification of special welding procedure specifications, and for qualifying welders and/or welding machine operators.
b.
Review of the following welding procedure qualifications:
(1)
L*S-65, " Automatic Plazma - Arc Hardsurfacing," and (2) WPS-94, Revision 1, " Gas Tungsten-Arc Tack Welding;"
to verify that the special requirements governing special welding application procedures and performance qualification imposed by ASME Code regarding test sample size, examination of test sample, and special essential variables had been satisfied.
Interviews with personnel to verify that they are knowledgeable c.
in the special welding procedures, and that the procedures are available at the work stations.
3.
Findings The inspector verified that the special welding specifications a.
conform with the requirements established Sections III and IX, of the ASME Code, NRC rules and regulations, and the commitments in the vendor's Quality Assurance Program.
b.
Within this area of the inspection no nonconformances or unresolved items were identified.
H.
Trai ling - Welder Qualifications l
1.
Objectives
10 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 commitments in the vendor's Quality Assurance Program.
2.
Method of Accomplishment The objectives of the inspection were accomplished by:
a.
Review of the ASME accepted Quality Assurance Manual and the following procedures; (1) QAOPl.4, Revision 9, " Indoctrination and Training,"
(2) QA0P16.2, Revision 2, " Qualification of Welding Procedures", and (3) QA0P16.3, Revision 3, " Qualification of Welding Operations;"
to verify that procedures had been established requiring training and qualification of the 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's qualifications; and that the welders have been, and are currently, qualified to weld under the procedures prescribed on the shop travelers.
d.
Interviews with personnel to verify they are knowledgeable in the procedures applicable to welder qualification.
3.
Findi'm1 a.
The inspector verified that the welders and welding operators had been qualified in accordance with NRC rules and regulations, and the commitments in the vendor's Quality Assurance Program.
b.
Within this area of the inspection no nonconformances or unresolved items were identified.
I, Audits (Internal Management) 1.
Objectives
11 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 internal auditing which is consistent with NRC rules and regulation, and the commitments in the vendor's Quality Assurance Program.
b.
The audit procedures are being properly and effectively implemented by the vendor.
2.
Method of Accomplishment The objectives of this area of the inspection were accomplished by:
a.
Review of the ASME accepted Quality Assurance Manual, and the following procedures; (1) QAOP 1-4, Revision 9, " Indoctrination and Training of Personnel,"
(2) QAO? 1-6, Revision 8, " Internal Systems Audits," and (3) QA0P 1-8, Revision 0, " Training, Certification and Examination of Auditors;"
to verify the vendor had established procedures which prescribe a system for internal audits, and provides appropriate training and qualification of personnel conducting the audits, b.
Review of the following documents:
(1) QA0P1-6, Revision 8, " Internal Systems Audits,"
(2) QA0P1-7, Revision 11, " Corrective Action," and (3) QA0P7-2, Revision 6, " Material Review Board;"
to verify that they had been prepared by the designated authority, approved by responsible management, and reviewed by the Quality Assurance staff.
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12 c.
Review of the documents referenced in paragraph a. and b.
to verify that they identify the organization responsible for auditing, establishes the audit personnel qualifications, establishes the essential elements of the audit system, provides for audit schedules to assure coverage of all elements of the quality assurance program, and requires reporting to and follow-up corrective action by both the audited and the auditing organizations.
i d.
Review of all audit reports for 1980, as follows; (1)
Indoctrination and Training, (2) Management Review of the Status and Adequacy of Quality Program, (3) Design Control - Document Control, (4) Welding and Heat Treat, (5) Annual Internal Audit, and (6) Audits - Corrective Action to verify whether the procedures and the necessary audit system documents, are available to the auditing personnel; and whether the internal auditing procedures are being properly and effectively implemented.
3.
Findings a.
The inspector verified that:
(1)
Procedure had been prepared and approved by the vendor which prescribes a system for auditing which is consistent with NRC rules and regulation, and the commitments in the vendor's Quality Assurance Program.
(2) The audit procedures are being properly and effectively implemented by the vendor.
b.
Within this area of the inspection no nonconformances or unresolved items were identified.
J.
Exit Interview At the conclusion of the inspection on February 20, 1981, the inspector met with the company's management, identified in paragraph A, for the
13 purpose of informing them concerning the results of the inspection.
During this meeting management was informed that no nonconformances or unresolved
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items had been identified.
The company's management acknowledged the inspector's statement and offered no comments.
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