ML20148K376
| ML20148K376 | |
| Person / Time | |
|---|---|
| Issue date: | 09/22/1978 |
| From: | Hale C, Potapovs U, Whitesell D NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML20148K369 | List: |
| References | |
| REF-QA-99900637 NUDOCS 7811170129 | |
| Download: ML20148K376 (4) | |
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AUDIT REPORT U. S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT REGION IV
- Report No. 99900637/78-02 Program No. 44106
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Organization: State of California Division of Industrial Safety ATTN: Mr. Paul J. Carosella Principal Safety Engineer P. O. Box 603 San Francisco, California 94101 .
Dates of n Audit: September 12-13, 1978 Inspectors ,8 sv.5/- v/ 4 D'. E. Whitesell, Chief. ComponentsSection I Date Vendor Inspecti n Branch Reviewed by: -)[~77 C. J. (aleJ Chief, Projects Section, Vendor Date Inspe rion Branch Approved by: 3@~
Uldis Potapovs, Chie4 Vendor Inspection Branch h'Date lO
. Summary:
Audit Conducted: September 12-13, 1978 (99900637/78-02) concurrently with the inspection of Ametek - Straza Division' facility at El Cajon, California.
Areas Audited: ANI-Qualification and Duties; Evaluation of the ASME Inspection System.
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DETAILS A. Persons Contacted The Authorized Nuclear Inspector (ANI).
B. General The ANI is employed by the California Division of Industrial Safety, as a Safety Engineer. Since April of 1978, he has been assigned to provide inspection services, on an itinerant basis, to the Ametek -
Straza Division ( A/S), in El Cajon, California. Also to ensure that the size and class of the nuclear components manufactured by them are within the scope of the ASME Certifica';e of Authorization, complies with the California Boiler and Pressura Vessel laws and that the prescribed quality class has been achieved.
A/S manufactures mechanical penetrations, core supports, and Class 1, 2, 3, and MC piping subassemblies, vessel parts, core supports, and metal parts only of Concrete Containments (CC) under ASME Certificates of Authorization Nos.1663 N and 1664 NPT stamps.
t C. Qualifications The ANI informed the NRC representative that he is 58 years old, and a high school graduate, with supplemental home study technical courses, and trade school courses. He also claims 20 years experience and appropriate training relating to Boilers and Machinery in the US Navy. ,
A portion of his home study courses included California's safety laws and orders, and shop problems which culminated in his successfully I passing the California Civil Service written examination to qualify l for employment with the California Division of Industrial Safety, as a Safety Engineer. After his employment, he received training in Code Shop work, NDE theory and methodology, welding and welding repairs. .
After successfully passing the required written and oral examinations, l he received his California Certificate of Competency No.1022.
In addition to his 20 years experience in the Navy, he also claims five (5) years experience as an authorized Inspector with an A/A Insurance Company and holds valid certificates of competency in .
I Pennsylvania, # WC 1612; and Ohio, dated May 15, 1967. To qualify cs an ANI, he attended the National Boards Special training courses at Ohio State University. which included training in Welding, Metallurgy, NDE methodology and theory, Code requirements established by Section III, V, and IX of the ASME codes. He successfully passed the written examination-at the conclusion of the course which qualified him as an ANI National Board Commission No. N1975. j
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i He stated that he is familiar with the A/S OA program and maintains a controlled copy of the QA Manual on his desk. He also accompanies his supervisor during the periodic audits of the QA program as prescribed by ANSI 626. The NRC representative observed that a 4
controlled copy of the A/S QA Manual was available on the desk assigned -
to the ANI.
D. Performance of Duties The ANI explained that when a contract is received by A/S for nuclear code items, he is notified verbally by the QA Manager, and the customer's Design Specifications (DS) and supporting data sheets, drawings, etc.;
are made available for his review, usually by the assigned Project Engineer, prior to release by Engineering, which was verified .to be in accordance with the QA Manual. However, there was no evidence available that these reviews are documented.
The NRC Inspector searched the ANI Daily. Log Book from June 1976, e through 1977, to September 12, 1978, to ascertain whether there were '
any entries to document the' review of DS by the ANI, none were found.
Also DS # DC-400-09 dated June.2,1976, code items for TVA and DS # 13-MM-500 dated December 9,1976, code items for Palos Verdes;
, were reviewed to ascertain whether the ANI might have documented his review on the DS cover Sheets. He had_not signed eff or otherwise documented his review of these.DS. It was ascertahed that the DS 1 were properly certified by PE signatures, saals, and dates, and that the size and class of the code items were within the scope of A/SL '
certificates of authorization.
The Manager of QA verified that the ANI did review the DS, drawings, data sheets, and all changes thereto, but did not know whether the ANI documented these reviews.
t The ANI also explained that he verified the acceptability.of materials by reviewing certified material test reports (CMTR) and documents such verification in his Daily Log Book (DLB) and by signing and dating the CMTR. This statement was verified by review of the CMTR for SA 516, grade 70 pressure vessel plates, for heat numbers 367269; 97498; 22875; 45083; and 33964. Also the CMTR for weld filler metal SFA 5.9, Type ER 308 L,' heat numbers 743106, 760427-and 760428, also grade 309 L, Nat number 741994. On. each of the foregoing CMTRs, it was verif that the ANI had documented his review by signing and dating the CM It was further verified that he had documented his review of the f oregoing CMTRs in his DLB by heat numbers under the date the review occurred.
The ANI informed the NRC Inspector that the shop travelers for controlling the-manufacture of code parts were reviewed by him to l
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select and identify his hold points, prior to releasing the travelers
'to the shop. The NRC Inspector reviewed shop traveler 7-050158-2 for a Head Forging and verified that the ANI had signed off on Operation
- 70, his 'd point on August 31, 1978. It was also verified that the AM. ma also documented this inspection activity under the appro-priatc '
in his DLB.
The Aki : ) 4ed that noconformances are documented on Inspection Report ( s snd that he reviews all irs to verify that the corrective action does not negate code requirements. To verify this, IR numbers 43505, 46040, .44702, and 43491 were audited and it was verified that the ANI had reviewed each of them and had also documented his review
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in his DLB.
The ANI explained that he reviews welding and NDE procedures and procedure qualifications, and performs roving inspections during welding operations to verify proper fit-up, cleanliness, visual quality of welds, undercuts, excessive crown, etc. . .and spot chec.ks base metal, thickness and other parameters established by the qualified welding procedures.
Also he verifies that the nondestructive examinations are conducted in accordance-with qualified procedures and that the results are evaluated to the acceptance standards established by the appropriate section or
( subsection of the code. He also verifies that the welding and NDE procedures used in production work are' the procedures identified on the shop travelers. He also claims to witness all hydrostatic tests, and review the complete documentation package, prior to signing the manufacturers data sheets.
The NRC Inspector verified that all of the above ANI activities are identified in his DLB and that sufficient information is included to provide traceability to the applicable material, part, or document involved.
During the detail review of the DLB, it was noted that the periodic audits of the QA program were documented. However, there was no record or indication concerning the results of these audits.. The ANI stated that he did'not know whether his ANIS prepared a formal report concerning these audits.
The QA Manager informed the NRC Inspector that he had not received any formal report concerning these audits.
E. Follow-up Items
- 1. A system to formally document the review of Design Specifications.
- 2. A system to document the results of the ANI surveillance of the implementation of the several guality activities prescribed by the QA Manual.
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