ML20033A935
| ML20033A935 | |
| Person / Time | |
|---|---|
| Issue date: | 11/10/1981 |
| From: | Barnes I, Ellershaw L NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML20033A928 | List: |
| References | |
| REF-QA-99900754 NUDOCS 8111300181 | |
| Download: ML20033A935 (8) | |
Text
{{#Wiki_filter:. ORGANIZATION: ACIMET MANUFACTURING CLEVELAND, OHIO REPORT NO.: 99900754/81-01 INSPECTION DATE{S): 9/14-18/81 INSPECTION ON-STTE HOURS: 31 CORRESPCNDENCE ADDRESS: Acimet Manufacturing ATTN: Mr. L. L. Logan Genercl Manager 1710 Clarkstone Road Cleveland, Ohio 44112 ORGANIZATION CONTACT: Mr. T. E. Solomon, Manager, Quality Assurance TELEPHONE: (216) 692-2250 PRINCIPAL PRODUCT: Nuclear Fasteners - Bolts, Studs, and Nuts NUCLEAR INDUSTRY ACTIVITY: Acimet Manufacturing (Ali) is currently providing fhstener materials to at least five nuclear power generating stations. I I q ASSIGNED INSPECTOR: h[. E. EHershw, Reactive Inspection S u ct //- /0 -T/ Date OTHER INSPECTOR (S): APPROVED BY: c/ // - AL f f I. Barnes, Chief, RIS Date INSPdCTION BASES AND SCOPE: A. Basis: 10 CFR Part 50, Appendix B. B. Scope: This inspection was r'de as a result of a 10 CFR Part 50.55(e) written notification by Tennessee Valley Authority pertaining to dimensional and marking deficiencies in studs and nuts provided to the Phipps Bend and Hartsville Nuclear Plants. Areas selected for irspection included: procure-ment control; heat treatment; equipment calibration; internal audits; and material identification and control. . ~.., ~ C C:'- '~ ~ 8111300181 811116 P DR O A9 99 EMV* * * *
- 99900754 PDR
ORGANIZATION: ACIMET MANUFACTURING CLEVELAND, OHIO REPORT NO.: 99900754/81-01 INSPECTION RESUt.TS: PAGE 2 of 4 A. VIOLATIONS: 1. Contrary to paragraph 21.6 of 10 CFR Part 21, posting of Section 206 of the Energy Reorganization Act of 1974 or an appropriate notice had not been accomplished. 2. Contrary to paragraph 21.21(a) of 10 CFR Part 21, procedures had not been Edopted to provide for: (a) evaluating deviations or informing the licensee or purchaser; and (b) assuring that a director or responsi-ble officer was informed if the supplied basic component (i) failed to comply, or (ii) contained a defect. B. NONCONFORMANCES_: 1. Contrary tc Criterion V of Appendix B to 10 CFR Part 50, QA Manual Section VII and paragraph NCA-3867.4(e) in Section III of the ASME Code: a. Acimet Manufacturing (AM) purchased finished bolting products for use in ASME Code Section III applications from an AM approved bolting material manufacturer. The material used came from a stock material manufacturer, through a material supplier, both of which had not been audited by AM nor were they holders of ASME Quality System Certificates. b. Verification of compliance of these materials with the material specification requirements had not been accomplished in accordance with the provisions of NCA-3857.4(e) in Section III of the ASME Code. 2. Contrary to Criterion V of Appendix B to 10 CFR 50 and Heat Treat Procedure No. 4.1, time in and time out was not recorded for hardening (austenitizing) and draw (tempering) phases of heat treatmer.t, nor could it be verified that parts are not permitted to come to room temperature prior to tempering. 3. Contrary to Criterion V of Appendix B to 10 CFR Part 50 and QA Manual Section XII: a. Inspection equipment has not been calibrated at scheduled intervals; e.g., at least 12 working plug gages, scheduled for calibration in July 1981, had not been calibrated as of September 16, 1981, and were still in service. b. Master Jill Block Set No. 17 was scheduled for annual cali-bration during February 1981; however, it was not calibrated until June 8, 1981. The records showed that this set was removed from service on February 20, 1981, and not returned until June 10, 1981. However, review of calibration cards for working plug gages show that certain gages were calibrated by the use of Set No.17 during April and May 1981.
ORGANIZATION: ACIMET MANUFACTURING CLEVELAND, OHIO REPORT NO.: 99900754/81-01 INSPECTION RESULTS: PAGE 3 of 4 c. Master Jill Block Set No. 89 was scheduled for annual calibration on May 1, 1981. The record showed that Set No. 89 was removed from the system on May 19, 1981, and calibrated on June 1, 1981. However, review of records for 16 working plug gages show that these gages were calibrated by the use of Set No. 89 after May 19, 1981, and before June 1, 1981. d. Calibration of certain setting plugs could not be traced to National Bureau of Standards because AM failed to record the master set numbers used in calibrating these plugs. e. Calibrction record cards showed that actual, recorded calibration dimensions of at least six plug gages were out of tolerance, yet they were noted as being "0.K.," were not removed from service, and nonconformance reports were not generated. 4. Contrary to Criterion V of Appendix B to 10 CFR Part 50 and QA Manual Section XVII, the seven internal audits conducted during August 1981 were performed by the General Manager who had not been trained as an observer on previous audits, nor had he received any other documented instructions or training by the Quality Assurance Manager. C. Unresolved Items: None D. OTHER FINDINGS OR COMMENTS: 1. 10 CFR Part 50.55(e) Construction Deficiency Report All identified discrepant material supplied by AM to the Hartsville and Phipps Bend Nuclear Plants has been reworked and/or replaced. AM's failure to identify the defects was a result of not performing specifi-cation review and the required inspections. The actions taken by AM to preclude recurrence included the following: termination of the responsi-ble quality control personnel; incorporation into the QA Manual of document control and specification review requirements; and the establish-ment of acceptance criteria, prior to order entry, regard'ng gaging and inspection. The generic aspects could not be determined 1 ring this inspection due to the very limited amount of nuclear work seing processed. However, the items identified in B.3 could have allowed the processing of other dimensional nonconformances. 2. Procurement Control This area of the inspection consisted of a review of: five purchase orders placed by AM with various vendors; vendor audits performed by AM; certified material test reports related to the material received against the five purchase orders; and customer imposed requirements plac i on AM. Nonconfomance, Item B.1 was identified.
ORGANI2.ATION: ACEMET MANUFACTURING CLEVELAND, OH10 REPORT NO.: 99900754/81-01 INSPECTION RESULTS: PAGE 4 of 4 3. Heat Treatment This area of the inspection consisted of a review of heat creat vendor qualifications, temperature uniformity survey records, heat treatment procedure for A193 Grade 87 bolting material, and heat treat charts. Nonconformance, Item B.2 was identified. 4. Equipment Calibration This area of the irepection was performed by reviewing the Calibration Record Cards of 40 working plug and ring gages, and 2 mester gage sets. Traceability of the master gage sets to National Bureau of Standards was established. Nonconformance, Iter B.3 was identified. 5. Internal Audits This area of the inspection was performed by reviewing the internal audits performed during 1981 (all of which were performed in August). The NRC inspector expressed concern about the internal audits, partic-ularly the one dealing with equipment calibration, in which some of the very same elements that were identified by the NRC inspector as being nonconforming were checked off as being okay by AM's auditor. Nonconformance, Item B.4 was identified. 6. Material Identification and Control This area of the inspection was performed by observation of stored bar stock, in-process material and finished products, and comparing the associated documentation with the identifying markings on the material / parts. There were no nonconformances or unresolvad items identified.
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