ML20137Q202
| ML20137Q202 | |
| Person / Time | |
|---|---|
| Issue date: | 01/24/1986 |
| From: | Merschoff E, Trottier E NRC OFFICE OF INSPECTION & ENFORCEMENT (IE) |
| To: | |
| Shared Package | |
| ML20137Q190 | List: |
| References | |
| REF-QA-99901036 99901036-85-01, 99901036-85-1, NUDOCS 8602060081 | |
| Download: ML20137Q202 (8) | |
Text
{{#Wiki_filter:.. ORG NIZATION: ILLIN0IS FABRICATORS, INC. BRADLEY, ILLIN0IS REPORT INSPECTION INSPECTION N0,: 99901036/85-01 DATE(S): 11/6-8/85 ON-SITE HOURS: 40 CORRESPONDENCE ADDRESS: Illinois Fabricators, I = ' ATTN: Mr. R. A. Hawke ehaYt' 265 South Kinzie Bradley, Illinois 60915 ORGANIZATIONAL CONTACT: Mr. Charles R. Hawker, Vice President TELEPHONE NUMBER: (815) 939-3551 PRINCIPAL PRODUCT: Custom fabricated steel, specializing in battery trays and instrument control panels. NUCLEAR INDUSTRY ACTIVITY: None since November, 1980 m. (( [ /IV186 ASSIGNED INSPECTOR: E. H. Trottier, Reactive Inspection Section (RIS) Date OTHER INSPECTOR (S): Jeffrey B. Jacobson, RIS APPROVED BY: / Nduf6 .W.MerschofffQMief,RIS,VendorProgramBranch Date INSPECTION BASES AND 5 COPE: A. BASES: 10 CFR 50 Appendix B and 10 CFR Part 21 B. SCOPE: This inspection was performed to evaluate the allegation received by the Region III office of the Nuclear Regulatory Commission on September 25, 1985 concerning fabrication of two safety-related containment ventilation control panels without benefit of a OA program. PLANT SITE APPLICABILITY: Clinton Power Station (50-461). 8602060091 860131 PDR GA999 ENV***** 99901056 PDR - ---r.
0 ORGANIZATION: ILLIN0IS FABRICATORS, INC. BRADLEY, ILLIN0IS REPORT INSPECTION NO.- 99901036/85-01 RESULTS: PAGE 2 of 5 A. Inspection Issues The issue that resulted in this inspection was the allegation received by Region III of the Nuclear Regulatory Commission on September 25, 1985. The allegation related to the quality assurance controls in effect at Illinois Fabricators, Inc. where two containment ventilation control panels were fabricated. The panels were fabricated for MCC Powers who designed, engineered and installed the completed control panels at Illinois Power Company's Clinton Power Station near Clinton, Illinois. This inspection sought to establish whether an appropriate quality assurance program was in place at the Illinois Fabricators, Inc., the company that fabricated the panels. B. Inspection Findings Although Illinois Fabricators did not have a quality assurance program in place that would meet the requirements of 10 CFR 50 Appendix B, the safety related werk was performed under the control of MCC Power's quality assurance program and, as such, war properly controlled. Specifically, the inspector verified that Illinois Fabricators received and accepted all quality-related requirements referenced by and attached to the purchase order for fabrication of the panels as follows: 1. Packaging Equipment and material were required to be shipped in containers "... in keeping with good commercial practices to prevent damage during shipment and storage at buyer's [MCC Powers, Inc.] warehouse." m. The inspector reviewed the Receiving Inspection Report for each panel (IPL43JA and B). The overall appearance of each panel was inspected by a member of the MCC Powers QA staff and accepted on 12/2/80. In addition to overall appearance, the Receiving Inspection Report verified conformance to four other criteria. These criteria were: a. Fabrication in accordance with approved drawings. b. No evidence of distortion from cutting / punching operations. I c. No evidence of significant paint defects. d. No missing hardware, gaskets or accessories. l l [ 1 l
/ ORGANIZATION: ILLIN0IS FABRICATORS, INC. BRADLEY, ILLIN0IS REPORT INSPECTION Nn.- 99901036/85-01 RESULTS: PAGE 3 of 5 The inspection accepted each criterion separately and noted acceptance by individual check marks in appropriate boxes. Tne Receipt Inspection Report was signed by a member of the MCC Powers QA staff. 2. Source Inspection The panels were "... subject to source inspection at the supplier's [ Illinois Fabricators] plant by MCC Powers Quality Assurance representative,... one week before fabrication...." began. The inspector reviewed the Vendor Surveillance Peport (source inspection) performed by the Manager of Quality Assurance for MCC Powers on November 11, 1980 at the Illinois Fabricators facility in Bradley, Illinois. The summary section of the report cites the MCC Powers purchase order and job numbers, and clearly identifies the ultimate destination of the panels as "the Clinton Nuclear Power Station,.... " The summary section concludes with the following statement: "It is the opinion of MCC Powers that Illinois Fabricators is an established, viable, and competent manufacturer fully capable of supplying MCC Powers with an acceptable product line with appropriate design support and documentation evidence." The final section of the source inspection report is titled " Objective Evidence." In it, the Manager of QA for MCC Powers summarized his plant tour, reviewed panel base material purchase orders (including Certificates of Conformance), and welder qualification records. 3. Certifications and Test Reports Copies of applicable documents required by MCC Powers under this item were to be "... signed by a responsible memiser of the supplier's [ Illinois Fabricators] Quality Assurance function." and forwarded to MCC Powers. i l The inspector reviewed the "QW-484 Manufacturer's Record of Welder or Welding Operation Qualification Tests" for both Illinois Fabricators welders designated to undergo qualification. The inspector was advised by Illinois Fabricators that although the lead welder had been selected and did perform the welding, a backup or j alternate welder was also qualified. The inspector's review of each l welder's QW-484 form verified that all information was entered and l the form signed by the Vice President of Illinois Fabricators. l l
ORGANIZATION: ILLIN0IS FABRICATORS, INC. BRADLEY, ILLIN0IS REPORT INSPECTION NO - 99901036/85-01 RESULTS: PAGE 4 of 5 The inspector reviewed both the "QW-482 Welding Procedure Specification (WPS)" documented on ASME Form E-6, and the "QW-483 Procedure Qualification Record (PQR)" for the welding procedure used on the panels. Each form was completed as required, with the physical tests associated with the PQR performed by Pittsburgh Testing Laboratory and signed by their manager of the Chicago District. 4. Certification of Conformance Illinois Fabricators was required to "... certify that all materials and furnished items supplied under this order were inspected and/or tested and conform with all requirements of the published specifications and requirements of this [ purchase] order." The inspector reviewed the statement of certification by "I *nois Fabricators, Inc. that "... all materials and finished items supplied under P. O. 377-10870 conform with specifications received with the purchase order." The certification was signed by the President of Illinois Fabricators, Inc. In addition to verifying Illinois Fabricators' conformance to the requirements established by MCC Powers, the inspector reviewed the Contract Spccification governing HVAC controls. The Contract Specification was written "... by Baldwin Associates on March 22, 1978 by and between MCC Powers, a unit of Mark Controls Corp.,... and Baldwin Associates,... for HVAC Controls, complete for Clinton Station." The inspector found no weld-related requirements in Article 112, Codes and Standards, Division 1 - General Requirements. It was noted, however, that the subarticle dealing with control panels found in Division 3 - Technical Requirements, states, "Each panel shall be 3/16 inch steel plate, all welded-construction and built and reinforced in such a manner that no deflection will occur due to the weight of instruments, other apparatus, etc." A review of the material referenced in the Welder Qualification Tests (QW-484) and the Welding Procedure Specification (QW-482) referenced in item 3 above, verified the thickness range as "1/16 - 3/8 [ inch]," with the actual test plate being "5/16 [ inch] thick." The base metal specified in QW-482 is " Commercial Quality Mild Steel," and " carbon steel plate" in QW-483. Thus, all available records indicate that Illinois Fabricators, Inc. fully satisfied the material and performance requirements specified by MCC Powers, Inc.
ORGANIZATION: ILLIN0IS FABRICATORS, INC. BRADLEY, ILLIN0IS REPORT INSPECTION NO - 99901036/85-01 RESULTS: PAGE 5 of 5 C. Other Observations and Comments The inspector noted that Illinois Fabricators, Inc. established a c~iorehensive Quality Assurance Program in support of expected participation in the construction of the now inactive Farble Hill Nuclear Generating Station. Revision 0 to the 0A manual that was to have been used is dated 6-13-83 and contains 19 sections that appropriately address the eighteen criteria of Appendix B to 10 CFR 50. The inspector examined purchase orders and other documents for items that would be required to support the fabrication and supply of safety-related components for the Marble Hill Station. These documents included calibration certificates for measuring and testing equipment, and welder certifications. No deficiencies were noted. a,___
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