ML20141G166

Notice of Nonconformance from Insp on 860106-10

ML20141G166
Person / Time
Issue date:	02/25/1986
From:	NRC OFFICE OF INSPECTION & ENFORCEMENT (IE)
To:
Shared Package
ML20141G124	List: ML20141G119 ML20141G145 ML20141G166 ML20141G192
References
REF-QA-99900053 NUDOCS 8602260174
Download: ML20141G166 (5)

Text

_ . _ . __ -_ .

APPENDIX B l Anchor Darling Valve Company Docket No. 99900053/86-01 NOTICE OF NONCONFORMANCE j Based on the results of an NRC inspection conducted on January 6-10, 1986 it appears that certain of your activities were not conducted in accordance with NRC requirements.

Criterion V of Appendix B to 10 CFR Part 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 drawings. Instructions, i

procec'ures, or drawings shall include appropriate quantitative or qualitative

, acceptince criteria for determining that important activities have been satisfactorily accomplished."

Noncor.ftrmances with these requirements are as follows:

1. Section 10.4.5.1 of the Quality Assurance Manual (QAM), Revision A states, in part, "The condition requiring [ weld] repair shall be l described on a Rework Ticket." >

Section 10.4.5.2 of the OAM states, in part, "The Inspector...shall also initiate a Repair Welding and Hardfacing Record Form... including sketch of repair."

Contrary to the above, there was no documented evidence of a Rework Ticket for two defects repaired on a Weld Repair Record dated

September 4, 1985 for the globe body on Shop Order No. E-6534; and 1 a Repair Welding and Hardfacing Record dated October 31, 1985 did not contain a sketch for the disc on Shop Order No. E-6534. (86-01-02)

2. Section 6.5 of STD No. MQCS-2 " Nonconforming Material & MRB Disposition,"

Revision W states, in part, "...each Board member shall signify acceptance by a si Notice]gnature, initial or stamp and date on the MRN [ Material Rejection Contrary to the above, the member from QA had not signed, initialed, or stamped the MRBA block on MRN No. 9419 dated April 3, 1985, relating to the bonnet on Shop Order No. E-6534-001. (86-01-03)

3. Section 5.3.4 of STD No. QAS-9 " Nondestructive Examination Personnel Qualification and Certification," Revision D and Section 9.6.1 of SNT-TC-1A (June 1980 Edition) requires that the qualification records of the certified individuals include a statement indicating satisfactory completion of training in accordance with AD's written procedure.

999000 5

I .

Contrary to the above, a review of qualification records for seven nondestructive examination (NDE) personnel (one-Level III and six-Level II) revealed that the qualification records did not contain a statement indicating satisfactory completion of training in accordance with STD No. QAS-9. (86-01-04)

4. Section 9.4.4 of the QAM, Revision A states, in part, " Approved procedures shall be filed by the Quality Engineer by shcp order and vendor."

Section 3.0 of STD No. MPDS-7 " Control of Vendor Procedures," Revision C states, in part, "... Quality Assurance - Responsible for maintaining file of Final Approved Vendor Procedures by shop order and vendor...."

Contrary to the above, there was no documented evidence that such a file existed for Section III valves on Shop Order Nos. E-6534, E-6516, and E-3256; and the file for E-3326 did not contain a copy of Cann & Saul heat j treat Procedure No. 1023 Revision 4 which was used on the bonnet material.

(86-01-05)

! 5. Section 5.4.2 of STD No. QAS-10 " Gage Control Procedure," Revision G, 4

states, in part, "A ' calibration' label shall be affixed to all gages and

, instruments which have been calibrated and issued for use...."

! Section 5.4.3 states, in part, "A 'do not use' label shall be affixed to i gages and instruments which have been taken out of calibration cycle and are not used. . . ."

Section 5.4.3.1 states, "The label shall show the gage serial number; the

~ date it was taken cut of the cycle; the reason; and the initials or stamp of the gage laboratory technician."

i j Contrary to the above, during an inspection of the shop and the calibration laboratory, it was noted that two spring gages (S/N 0154 and 0395) were not labeled properly to indicate that they had been calibrated; and the balance scales, surface plate, and dead weight tester were not correctly labeled to indicate that they had been taken out of service. (86-01-06)

6. Section 4.4.4.1 of the QAM states in part, "...A11 nonconforming or suspect material shall be segregated from acceptable material...."

Section 5.1.1 of STD No MQCS-2 " Nonconforming Material & MRD Disposition,"

Revision W requires that all nonconforming material be segregated from acceptable material in a hold area.

Contrary to the above, during an inspection of the shop, it was noted that acceptable seat rings (i.e., 24" - 900 HT E6685-1, 14" - 300 HT P8023-122, 16" - 300 HT P8023-144, and 28" - 150 HT P8157-1) were in

)

a nonconforming material hold area with nonconforming material.

(86-01-07)

7. Standard No. M-240 " Carbon, low alloy, and stainless steel castings,"

Revision M requires that wheels, files, and brushes used on stainless steel be marked in yellow, a Contrary to the above, it was noted that dedicated stainless steel burr wheels located in a cabinet for grinding equipment were not marked in yellow. (86-01-08) i 8. Section 10.4.4.3 of the QAM, Revision A states, in part, "At the end of each shift or completion of the job, each welder shall return all unused and used filler metal...to the storage area."

Section 5.4 of STD No. EMS-1, Revision M, states, in part "At the end of i the shift or completion of a job, each welder shall police his station to insure that all used electrodes stubs and unused welding materials are removed from the area."

Section 5.2.2 of STD No. EMS-1 states, in part, " Bare rod...shall be storec' in a clean dry area and shall not be removed from the original i contair.?r until issued... holding ovens for low hydrogen electrodes shall be maintained at 225*F to 325"F...."

Section 5.2.3 of STD No. EMS-1 states, in part, "... unused spools or

coils may remain on the wire feeder providing they are... covered to maintain cleanliness and dryness."

l l Contrary to the above, during an inspection of the manufacturing and l

welding material storage area, it was noted: (86-01-09) i

, a. An unmarked box of Sandvik electrodes (E308L-16 in three different sizes) was left in the weld area after the completion of a job.

b. Unmarked stellite rods were not in containers in the welding material storage area.

I c. Bare wire remaining on a wire feeder after usage was not covered,

d. The temperature in an oven containing E309L electrodes (Lot nos.

12039-1-1 and 90194-1-3) was below 275"F on two occasions (150*F

in the morning and 180*F in the afternoon of the same day).

9. Section 9.4.2.5 of the QAM, Revision A states, in part, "All vendors for Category 1 materials shall be subject to an audit... Frequency shall not exceed twelve months for NCA-3800 qualified vendors...."

i Section 9.4.2.1 of the QAM states, in part, "The Approved Vendor List is issued by the Purchasing Manager and approved by the Quality Assurance Manager. It identifies NCA-3800 compliance and limitations or restrictions on the vendor."

l 1

t .

i ,

! Section 4.4.5 of STD No. MQCS-2 " Nonconforming Material and MRB Disposition" Revision W requires Purchasing to forward Vendor Material Discrepancy Reports (VMDR) to the vendor and when returned with appropriate corrective action to distribute VMDRs.

Section 4.2.7 of STD No. MQCS-2 requires Quality Assurance to audit corrective actions to ensure implementation and report on outstanding items.

Contrary to the above, a review of the Approved Vendor List (AVL) dated January 6,1986 and six vendor audit reports for Cann & Saul Steel, Quaker Alloy Casting, Dodge Foundry & Machine, Effort Foundry, R.E.C., and LTV Steel indicated the following: (86-01-10)

a. Vendor corrective action, as indicated on VMDRs, were not audited for implementation by Quality Assurance.

b. The restriction (i.e., Effort Foundry be re-audited prior to acceptance of any Category 1 material), resulting from the January 1985 vendor audit was not identified in the AVL.

c. R.E.C. located in Mt. Vernon, NY was not audited within the twelve month frequency.

10. Section 6.5.4 of STD No, MQCS-2 " Nonconforming Material and MRB Disposition" Revision W, states, in part, "MRN's related to vendor

! deficiencies will be handled in the following manner: After disposition is assigned and the Quality Engineer determines that corrective action is applicable, the QE shall...give the entire VMCR to the Purchasing Representative of the MRB who will have ten (10) working days to obtain cause and corrective action."

Contrary to the above, a review of the QA Department MRN Log Book and purchasing vendor files for 373 VMDRs issued during 1985, indicated that 19 were still open having passed the ten working day requirement for a response. (86-01-11)

11. Section 1.6 of the QAM states, in part, " Training and indoctrination shall include... periodic meetings and discussions of the QA Manual, i related procedures...This shall be repeated for each QA Manual revision to update personnel...."

Contrary to the above, a review of training and indoctrination records for manufacturing personnel indicated no objective evidence of training on the QAM revisions dated November 1, 1984 and December 3, 1985 for the Manufacturing Manager, Engineer, and Planner; Assembly Department Supervisor; Store Supervisor; and Machine Foreman. (86-01-12) i a

v

12. Section 6.7 of Procedure No. OPER-1 " Notification and Resolution of Abnormal Occurrences Report" dated December 16, 1985 states, in part, "Upon notification of the existence of an abnormal occurrence, the Technical Director shall initiate an investigation to determine if the occurrence could create a substantial safety hazard...Each abnormal occurrence report shall be evaluated and documented on Form OPER-1-2...

The OPER-1-2 form shall be attached to the OPER-1 form and maintained by Tech Staff."

Contrary to the above, a review of Tech Staff files identified 17 Abnormal Occurrence Reports (A0R) issued in 1985, but only three A0Rs (Nos. ABW-85-7, ABW-85-10, and ABW-85-14) had an evaluation performed and documented on Form OPER-1-2. (86-01-13) 1

- - . _ . . - . ., _ , _ . . - _ , _