ML20040D718
| ML20040D718 | |
| Person / Time | |
|---|---|
| Issue date: | 01/18/1982 |
| From: | Potapovs U NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML20040D715 | List: |
| References | |
| REF-QA-99900760 NUDOCS 8202020183 | |
| Download: ML20040D718 (4) | |
Text
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APPENDIX B
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NOTICE OF NONCONFORMANCE Stewart and Stevenson Services, Inc.
Docket:
99900760/81-01 Based on the results of an NRC inspection conducted on October 26-30, 1981, it appears that certain of your activities were not conducted in accordance with NRC requirements as indicated below:
A.
Criterion V of Appendix B to 10 CFR Part 50 states in part, " Activities affecting quality shall be prescribed by documented instructions, procedures, or drawings,... and shall be accomplished in accordance with these instructions, procedures, or drawings...."
Paragraphs 3.4, 3.5.1, and 3.5.2 of the Production Specification 008 (basic) issued December 20, 1976, titled, " Nonconforming Material (Rework)," state the following:
3.5, "The nonconforming item shall be inspected by Quality Control to verify rework and conformance to the original requirements."
3.5.1, "When determined that the rework is acceptable, the Nonconformance Report shall reflect Quality Control acceptance and be appropriately distributed."
3.5.2, " Quality Control will remove the red reject tag."
Contrary to the above, red reject tags 0248, 0967, and 2695 had not been removed from an electrical control panel (Work Order N75744) in the test berth.
The corresponding NCRs 920, 922, and 793 had been corrected and closed on May 5, 1981.
B.
Criterion V of Appendix B to 10 CFR Part 50 states in part, " Activities affecting quality shall be prescribed by documented instructions, procedures, or drawings,... and shall be accomplished in accordance with these instructions, procedures, or drawings...."
Engineering Specification ED007 (basic) issued December 15, 1976, ti tl ed,
" Design Document Retention and Control," requires that documents furnish documentary evidence of the design.
Contrary to the above, Installation Drawing 62240-1, Revision H,
" Commonwealth Edison Auxiliary Feedwater Pump Drive 16V-149T1," did not furnish documentary evidence of design, in that an air intake support, a support for the service water booster pump, and gussets which were added to eliminate an anomaly found during the seismic testing of Work Order 74505, were not shown.
8202020183 820118 PDR OA999 ENVSSS 99900760 PDR
Stewart and Stevenson Services 2
Inc.
C.
Criterion V of Appendix B to 10 CFR Part 50 states in part, " Activities affecting quality shall be prescribed by documented instructions, procedures, or drawings,... and shall be accomplished in accordance with these instructions, procedures, or drawings...."
Paragraphs 3.3, 3.4, 3.6, and 4.0 of Production Specification 005 (basic) issued December 27, 1976, titled, " Welding Machine Certification,"
state:
3.3 "Use a calibrated test meter to check the accuracy of each machine's meter."
3.4 " Verify that test meter is within calibration date."
3.6, " Enter the readings on the Report of Certification form."
4.0, " Records:
Record of Certification forms shall be retained in the Quality Control files for the life of the unit."
Contrary to the above, no documentary evidence of welding machine certification could be presented to the inspector.
4 D.
Criterion XIV of Appendix B to 10 CFR Part 50 states in part, " Measures shall be established to indicate, by the use of markings such as stamps, tags, labels, routing cards, or other suitable means, the status of inspections and tests performed upon individual items of the nuclear power plant... These measures shall provide for the identification of items which have satisfactorily passed required inspections and tests, where necessary to preclude inadvertent bypassing of such inspections and tests..
Contrary to the above, the established measures did not provide for identification of inspection and test status, as evidenced by the inspection signoffs on Inspection Point Program No.108 for Work Order No. N79905/6 (Marble Hill Auxiliary Feedwater Pump Drive, Fan Assembly Support) indicating assembly machining and postweld heat treatment operations being performed prior to the assembly being fabricated.
E.
Criterion IX of Appendix B to 10 CFR Part 50 states in part, " Measures shall be established to assure that special processes, including...
heat treating... are controlled and accomplished... in accordance with applicable... specifications, criteria, and other special requirements."
l Stewart and Stevenson Services 3
Inc.
Quality Control Specification QCS 001, Revision 8 states in part, with respect to heat treatment furnace requirements, "... For the purposes of this inspection a suitable furnace is one in which exploratory thermocouples will indicate no greater temperature differences from the average than 25 at any point within the furnace volume...."
Contrary to the above, measures were not established to assure that heat treating was controlled in accordance with specification requirements, as evidenced by:
1.
Placement of a heat treatment vendor, Houston Heat Treating Company, on the Qualified Vendor List without evidence of capability to comply with heat treatment specification requirements.
4 2.
Use of the vendor for postweld heat treatment of Marble Hill auxiliary feedwater pump diesel engine drive subassemblies without verification of the temperature uniformity of the furnace that was used for the heat treatment cycles.
F.
Criterion V of Appendix B to 10 CFR Part 50 states in part, " Activities affecting quality shall be prescribed by documented instructions, procedures, or drawings,... and shall be accomplished in accordance with these instructions, procedures, or drawings...."
Quality Control Specification QCS 017, Revision F, identifies that Category B vendors; i.e., those vendors who design or build products for "off the shelf" commercial application, can be placed on the Qualified Vendor List by review and approval of either their Quality Program Manual, history of performance, or survey.
Contrary to the above, review of the Qualified Vendor List showed no basis for inclusion of 411 Category B vendors from a total of 555 such vendors.
G.
Criterion V of Appendix B to 10 CFR Part 50 states in part, " Activities affecting quality shall be prescribed by documented instructions, procedures, or drawings,... and shall be accomplished in accordance with these instructions, procedures, or drawings...."
Paragraph T-661 in Section V of the ASME Code, Article 6 states in part, "When it is not practical to make a liquid penetrant examination within the temperature range of 60 to 125 F... the examination procedure at the proposed temperature requires further qualification...."-
1 Stewart and Stevenson Services 4
Inc.
Contrary to the above, Liquid Penetrant Examination Procedure QCS 003, RevisfonG,hadnotbeenqualifiedattheminimumexaminationtemperature of 50 F permitted by the procedure.
H.
Criterion V of Appendix B to 10 CFR Part 50 states in part, " Activities affecting quality shall be prescribed by documented instructions, procedures, or drawings,... and shall be accomplished in accordance with these instructions, procedures, or drawings...."
Paragraph 12.2 in Quality Control Specification QCS 003, Revision G, states in part, " Acceptable parts / welds shall be recorded on a Quality Control Liquid Penetrant Inspection Report.
This Report should include the following information:
12.2.1 Part Number, 12.2.2 Drawing Number, 12.2.3 Works Order Number, 12.2.4 Test Material Used, 12.2.5 Level of qualification of personnel performing and evaluating the test.
Contrary to the above, liquid penetrant examination of Clinton, Ohio, Unit 1 emergency diesel generator set cooling system piping welds was signed off on May 23, 1980, in the Final Assembly Inspection Point Program (IPP 100, Works Order No. N75744) as being complete, but had not been recorded on a Quality Control Liquid Penetrant Inspection Report as of the date of this inspection.
I.
Criterion IX of Appendix B to 10 CFR Part 50 states in part, " Measures shall be established to assure that special processes, including...
nondestructive examination... are controlled and accomplished by qualified personnel...."
Paragraph ND-5521(a) in Section III of the ASME Code (Winter 1975 Addenda) states in part, " Personnel performing nondestructive examination shall be qualified in accordance with SNT-TC-1A-1975, except as required in (1), (2), and (3) below.
(1) Certification of Level III nondestructive examination personnel by examination for technical competence is required...."
4 Contrary to the above, a Level III examiner was appointed by Stewart and Stevenson on December 4, 1978, and not certified by the required examination for technical competence.
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