ML20004E525
| ML20004E525 | |
| Person / Time | |
|---|---|
| Issue date: | 01/22/1981 |
| From: | NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML20004E516 | List: |
| References | |
| REF-QA-99900334 NUDOCS 8106120290 | |
| Download: ML20004E525 (4) | |
Text
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r^s T'ransamerica Delaval Incorporated kJ Engine and Compressor Division
^
Docket No. 99900334/80-01 NOTICE OF DEVIATION Based on the results of an NRC inspection conducted on October 14-17, 1980, it appears that certain of your activities were not conducted in accordance with NRC requirements as indicated below:
Criterion V of Appendix B to 10 CFR 50 states:
" Activities affecting quality shall be prescribed by documented instructions, procedures, or drawings, of a type appropriate to the circumstances and shall be accomplished in accordance with these instructions, procedures, or draw-ings.
Instructions, procedures, or drawings shall include appropriate quantitative or qualitative acceptance criteria for determining that important activities have been satisfactorily accomplished." Deviations from these requirements are as follows:
A.
Section 10, dated June 30, 1979, of the Quality Control Manual, contains the following requirements:
1.
Paragraph 10.6.4 states, "New tools and gages will be identified with a tool and/or Gage Tryout Tag (Quality Control Form P-270).
This is a temporary tag reflecting the fact of dimensional acceptance of the tool and/or gage.
The temporary tag is removed and replaced with the calibration decal after the tool and/or gage accurately produces or accepts a first part."
2.
Paragraph 10.6.5 states, "All gages and equipment will be identified by Company name, gage or equipment name, part and/or cerial number, as applicable."
Contrary to the above, the gage used to measure, accept / reject the diameter and depth of the link rod dowel counterbore had not been identified with:
(1) A tool and/or Gage Tryout Tag; (2) A calibration decal; or (3) Company name, gage or equipment name, part and/or serial number, as applicable; although the gage has been in use since February 1980.
B.
Paragraph 7.1.1 in Section 7 of Quality Control Procedure I.P.-700 states in part, "... Quality Engineering will process Corrective Action Request Form P-260 when required by any of the following conditions:..
7.1.1.6 Internal and external failures to meet contract requirements."
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Contrary to the above, Quality Engineering did not process a Corrective Action Request Form with respect to customer identified Transamerica Delaval (TD) failures to meet weld quality contract requirements in ASME Section III Class 3 diesel generator piping (See DetailsSection II, para-graph B.4.a.(1)).
C.
Paragraph NO-5521(a)(2) in Section III of the ASME Code states, "The procedure (s) used for examination of Level I, II, and III nondestructive examination personnel shall be described in the Employer's written practice which is required by SNT-TC-1A, paragraph 5 and shall be referenced in the Employer's Quality Program." Paragraph NO-5521(a)(6) states, "For non-destructive examination methods not covered by SNT-TC-1A documents, per-sonnel shall be qualified to comparable levels of competency by subjection to comparable examinations on the particular method involved."
Contrary to the above:
1.
The TD written practice (Section 4 of Quality Control Procedure I.P.
-600, " Qualification-Certification of NDE Personnel") did not de-scribe the procedure (s) used for examination of Level III nondestruc-tive examination personnel.
2.
Personnel performing ASME Section III, Subsection NO and NF required visual examinations, ha. not been qualified by being subjected to an examination of comparable standard to methods covered by SNT-TC-1A documents.
O.
Paragraph NO-4321(a) in Section III of the ASME Code states, "Each Certi-ficate Holder is responsible for the welding done by his organization and he shall establish the procedure and conduct the tests required by this i
Article and by Section IX in order to qualify both the welding procedures and the performance of welders and welding operators who apply these procedures." Paragraph NO-4323 states in cart, "...Only welders and welding operators who are qualified in accordance with ND-4320 and Section IX shall be used."
Contrary to the above-1.
Shielded metal arc welding of a six (6) inch Schedule 40 ASME Section III Class 3 piping assembly (Shop Engine No. 2931, Shop Order No. 94302, Part No. 02-717-02 YR, Item F to Item F) was cbserved being perfirmed in the vertical up position (3G), al-though the welder had been qualified in accordance with ASME Section IX requirem :nts for the flat position (1G) only.
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Shielded metal are welding was identified to have been performed on a two (2) inch ASME Section III Class 3 piping assembly (Part No.
02-717-02 YE) by a welder who had been qualified in accordance with ASME Section IX requirements only for pipe outside diameters of 2 7/8 inch (2 1/2 inch nominal pipe size) and over.
(See DetailsSection II, paragraph B.4.a.(3)).
E.
Paragraph 5.5.4 in Section 5 of Quality Control Procedures I.P.-500 states in part, " Rod shall be issued from the storage area to the welder.
The welder will return unused rod to the storage area within four hours of issuance...."
Centrary to the above, unused rod was not being returned to the storage area within four hours of issuance, as evidenced by the following examples:
1.
On October 11, 1980, rods were returned by three (3) welders after respective issue times of 5 hours5.787037e-5 days <br />0.00139 hours <br />8.267196e-6 weeks <br />1.9025e-6 months <br /> 55 minutes, 4 hours4.62963e-5 days <br />0.00111 hours <br />6.613757e-6 weeks <br />1.522e-6 months <br /> 20 minutes and 4 hours4.62963e-5 days <br />0.00111 hours <br />6.613757e-6 weeks <br />1.522e-6 months <br /> 30 minutes.
2.
On October 14, 1980, rods were returned by a welder afte. an 8 hour9.259259e-5 days <br />0.00222 hours <br />1.322751e-5 weeks <br />3.044e-6 months <br /> imte time.
F.
Paragraph 4.2.4 in Section 4 of Quality Control Procedure I.P.-500 states,
" Verification of weld procedure and welder will be accomplished by pro-viding space on the Route Sheet for entrance of the weld procedure number and welder identification.
Records of each weld including welding and weld rod, will be provided by the Weld Report."
Contrary to the above, although space was provided on the Route Sheet for welder identification, verification of the use of certain welders could not be accomplished, in that:
1.
Welding of Item F to Item F, Shop Engine No. 2931, Shop Order No.
94302, Part No. 02-717-02YR, was observed being performed by a different welder than the individual identified on the Route Sheet.
2.
Welding on Operation 140 of the Route Sheet for Shop Engine No.
(
2957, Shop Order No. 94583, was observed being performed by a l
different welder than the individual identified on the Route Sheet.
3.
Welding records were not provided, in that Weld Reports had not been prepared as of the inspection for the operations observed.
(See DetailsSection II, paragraph B.4.a.(5)).
G.
Paragraph 10.3.2 in Section 10 of Quality Controi,.*ocedure I.P.-500 states in part, "All in process and completed components, parts or piping
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subassemblies found to be defective will be immediately rejected and documented on an Inspection Report and placed in Bond.
The Material Review Board will review all defective components, parts or piping sub-assemblies...."
Contrary to the above:
1.
A defective weid (Item F to Item F, Shop Engine No. 2931, Shop Order No. 94302, Part No. 02-717-02YR) was rer.oved and replaced without rejection and documentation on an Inspection Report.
2.
Disposition was made by Quality Control supervision of a dimensional nonconformance in Shop Engine No. 2931, Shop Order No. 94749, Part No. 02-540-07-B7, without submission of the Inspection Report to the Material Review Board for review.
H.
Paragraph 11.2 in CF Braun & Co. Project 4840-P Specification 164-03 states in part, ".
. Fillet welds shall be of the specified size with full throat cnd legs of uniform size.... "
Drawing 02-540-07B7, Revision d requires the weld of Item A to Item B (Roof to Sidewall Joint) of the Shop Engine No. 2931 Tank Lube Oil Sump Inlet Compartment to be a single full penetration weld with 1/4 inch fillet.
Contrary to the above, the identified weld was observed to contain an area with less than a 1/4 inch fillet resulcing from a fitup condition where the tank roof and sidewall were almost flush.
(See DetailsSection II, Paragraph B.4.a.(7)).
I.
Paragraph 4.3.1 in Section 4 of Quality Control Procedure I.P.-500 states, "All components, parts and pi7ing subassemblies manufactured in accordance l
with ASME Section III, Class 3 will be inspected during the process of fabrication after each manufacturing operation is complete.
The item l
will be examined for adherence to specification for each individual l
characteristic affected by the operation.
- f the item is acceptable at l
the operation inspected, the inspector will enter his inspection stamp
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in the space provided on the Production Roccing Sheet."
l Contrary to the above, performance of required inspections for completed Operation Nos.10 through 130 on the Production Route Sheet for the Shop Engine No. 2931 Tank Lube Oil Sump Inlet Compartment could not be
. verified; in that neither inspection acceptance stamps had been entered for the operations on the Production Route Sheet, nor had Inspection Reports been prepared to denote a rejected condition after inspection.
(See DetailsSection II, paragraph B.4.a.(8)).
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