ML20148Q408
| ML20148Q408 | |
| Person / Time | |
|---|---|
| Issue date: | 09/27/1978 |
| From: | Hunnicutt D, Oller R NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML20148Q339 | List: |
| References | |
| REF-QA-99900268 NUDOCS 7811300029 | |
| Download: ML20148Q408 (12) | |
Text
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'(3 V
VENDOR INSPECTION REPORT U.S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT REGION IV Report No.
99900268/78-02 Program No. 44020 Company:
Armco, Incorporated Advanced Materials Division 13835 Beaumnt Highway Houston, Texas 77028 Inspection Conductea:
August 7-10, 1978 Inspector:
'2 FIS lT R. E. Oller, Contractor Inspector
'Oate Vendor Inspection Branch 2b'I Approved by:
1 D. M. Hunnicutt, Chief, ComponentsSection II Date Vendor Inspection Branch Summary Inspection on August 7-10, 1978 (99900268/78-02)
Areas Inspected _:
Inplementation of 10 CFR 50, Appendix B, criteria and applicable codes, including review of vendors activities, joint fitup and Welding, material forming, procurement control consisting of document control-source selection and supplier performance, equipment calibration and action on previous inspection findings.
The inspection involved 28 inspector-hours on site.
Results:
In the six (6) areas inspected, no deviations were identified in two [2T areas. The following were identified in the remaining areas.
Deviations:
Action on Previous Inspection Findings:
Four (4) Mill Orders were not revised to show appropriate procedure numbers.
Procurement control:
Three (3) material purchase orders did not contain the required statement,
" Materials are ordered according to ASME Code,Section III, requirements and are subject to inspection before shipping," in accordance with Criterion IV.
Fitup and Welding:
During in-process tack welding, filler wire was not used as required and the Argon shielding gas rate was 45 CFH instead of 20-30 CFH specified in Procedure 12.
Also, during an in-process weld repair of a weld metal defect cavity, the amperage range used was 420-450 instead of 460-520, 78M3006 @
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-2 in accordance with Criterion V.
Equipment calibration:
The requirements for calibration were not fully implemented for three (3) different types of nuasuring and testing devices in accordance with Criterion XII.
Unresolved Items None.
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I DETAILS SECTION A.
Persons Contacted L. Brizuela, Production Scheduler H. Bryant, Welder Operator D. Bynum, Welding Supervisor S. Crawford, Supervisor of Production R. Fisher, First Class Operator J. Fraysur, Chief Inspector
'H. Riley, Maintenance Supervisor
- R. Schultz, QA Supervisor
- C, Sprague, Plant Manager K. Wood, Laboratory Technician
- Attended Exit Meeting.
B.
Action on Previous Inspec_ tion Findings 1.
(0 pen) Deviation (Report No. 78-01):
Failure to show the appropriate procedure numbers for operations on four (4) in-process Mill Orders.
The inspector found that contrary to the corrective action commitment in Amco's Advanced Materials Division letter dated March 15, 1978, the four (4) above Mill Orders had not been revised to properly identify the operations to procedure numbers 12, 15, 10 and 4A.
(See Enclosure, Item A.)
2.
(Closed) Deviation (Report No. 78-01):
Failure to audit Welder Operators' use of procedure flo. 8 within the required time period of three months.
The inspector found the audit record " Welder
& Welding Operator Approval for ASME Code,Section III work" now shows that all welder operators' use of the procedures have been audited and the record is current.
3.
(Closed) Deviation (Report No. 78-01):
Failure to include pro-visions in Section 13 of the QA Manual for control of the distribution of QC and Standard Operating procedures.
The inspector found Section 13 of the QA Manual has been revised to provide for controlled distribution of QC and Standard Operating procedures.
Review of the distribution lists for the procedures verified that they are being maintained.
_4 C.
Review of Vendur's Activities 1.
Objective The objective of this area of the inspection was to assess the vendor's activities and their impact on future NRC inspections and identify the components supplied for nuclear facilities.
2.
Method of Accomplishment The preceding objective was accomplished by:
a.
Discussions with cognizant personnel.
b.
Review of the following ASME N-type symbol authorization to verify that it is current and identifies the product:
N-1717, NpT for Class 1, 2 & 3 Tubular products welded with Filler Metal.
Expires April 29, 1980, c.
Verbal review of principal contracts and projected work loads for impact on the NRC inspection schedule.
d.
Review of manufacturing processes, QA/QC activities, pur-chasing of materials - parts - services to evaluate the vendor's effectiveness in controlling the quality of the product.
3.
Findings Within this area of the inspection, no deviations or unresolved items were identified.
The QA supervisor indicated that effective July 1,1978, Armco Steel Company's name was changed to Armco, Incorporated.
D.
Weld Joint _ Fitup and Welding 1
1.
Objectives The objectives of this area of the inspection were to verify that the following items were controlled in accordance with applicable NRC and ASME Code requirements.
a.
A written system has been established to assure that welding is performed and controlled in accordance with applicable codes and procedure specifications.
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l b.
The work is conducted in accordance with a process control document such as a traveler.
c.
Applicable qualified welding procedure specifications (WPS) and weld data sheets are used at the work stations.
d.
The requirements of essential variables and other applicable WPS parameters are concurred with to produce weldments having the required properties.
e.
The welding is being performed by properly qualified personnel.
f.
Weld joint geometry, fitup alignment, and surface prep-aration are as required by the applicable WPS and the Code.
9 Tack welding is performed by qualified welders using qualified WPS.
h.
The welding equipment is in good condition and calibrated, where required, i.
The completed weld meets Code requirements for nondestruc-tive examination suitability, undercut and other visual acceptance standards.
j.
Repairs by welding are performed in accordance with Cods requirements.
2.
Method of Accomplishment The preceding objectives were accomplished by:
a.
Review of the QA Manual, Section 8, " Welding Quality Assurance," to verify that adequate controls for welding i
are documented.
b.
Review of in-process welding Procedure No. 12, " Tack Welding Procedures for Stainless Steel Pipe Using the Manual Gas Tungsten Arc Welding Process with...
Addition of Filler Metal" and the procedure qualification records for this procedure, to verify that the required procedure was being used to tack weld a 12" 0.0. X0.875" wall stainless steel pipe.
Also, to verify that the procedure and welder operators were qualified.
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, c.
Observation of the press closure alignment and tack welding of the above pipe to verify that the procedure parameters were being complied with.
)
d.
Review of the " Salvage Rework" sheet traveler for Mill Order j
Sfl7-9871-1, 3P, for the repair of the long seam of a 12" 0.0.
X1.25" wall pipe to verify that the welding repair operation was controlled and identified by the procedure number on the traveler.
e.
Review of the in-process automatic submerged arc welding procedure flo. 5 for the above traveler operation; the related procedure qualification record dated June 15, 1975, and the welder operator's performance qualification record to verify that the required procedure was being used, and that the procedure and the welder operator were qualified in accordance with the ASME Code,Section IX.
f.
Observation of the repair welding of a defect cavity in the outside of the long seam of the above pipe on Mill Order Stl7-9871-1, 3P, using procedure flo. 5 to verify that the proce-dure's parameters were being complied with, g.
Observations of the condition of the welding equipment and facilities.
h.
Discussions with cognizant personnel'.
3.
Findings a.
Deviations from Conmitments See Enclosure, Item B.
1 b.
Unresolved Items None.
E.
Material Forming 1.
Objectives The objectives of this inspection were to verify that an approved procedure to control forming or bending of pressure retaining materials had been developed and was consistent with ASME Code, l
t1RC requirements, and industry practices.
Also, that this opera-tion was performed in accordance with the procedure by qualified personnel.
1 2.
, Method of Accomplishment i
The preceding objectives were accomplished by:
a.
Review of the QA Manual, Section 7, paragraph 7.3, " Mill Order Release," to verify that controls for the forming operation were documented.
b.
Review of the approved standard operating procedure No. 15, Revision 0, " Pipe Forming 6"-30"," greater than 0.375" wall,"
to verify that the procedure contents were consistent with i
Code requirements and industry practices.
c.
Observations of forming markings on material ready for forming and on materials for which forming was completed, to verify that the material conditions were consistent with the above Procedure No. 15.
No forming was in process.
4 d.
Discussions with cognizant personnel.
3.
Findings Within this area of the inspection, no deviations or unresolved items were identified.
F.
Procurement Control 1.
Objectives The objectives of this area of the inspection were to verify that the following items were controlled in accordance with applicable 1
NRC and ASME Code requirements.
J a.
A written system has been established to assure that all applicable aspects of procurement are controlled.
b.
Procedures have been prepared and approved by the company to l
prescribe systems for the following activities which are consistent with the commitments of the QA program.
(1)
Procurement Document Control.
(2)
Procurement Source Selection and Contract Award.
.(3)
Evaluation of Supplier Performance.
c.
The above procedures are being properly and effectively implemented by the company.
. 2.
ththod of Accomplishment The preceding objectives were accomplished by:
a.
Review of the QA Manual, Section 5, " Procurement Control",
to verify that adequate controls for procurement document control, source selection and evaluation of supplier performance are documented.
b.
Review of the following Armco material purchase requisitions and purchase orders to verify that the purchase uder require-ments were developed in accordance with the QA program and the orders were awarded to qualified vendors:
(1) Requisition No. V-0957, dated June 7,1977, for T-304 stainless steel plate and test plates, and the related Purchase Order No. VRM-265696.
(2) Purchase Order No. VRM-286481, dated November 23, 1977, for T-304 stainless steel plate and test plates.
(3) Purchase Order No. VRM-292794, dated April 26, 1978, for T-304 stainless steel plate and test plates.
(4) Purchase Order No. VRM-291032, dated January 18, 1978, for T-316L plate and test plates.
(5) Purchase Order No. VRM-292752, dated May 22,1978, for T-316 plate and test plates.
c.
Review of Armco's " Approved Vendor List," dated July 20, 1978, for m.ttorials and services to verify that the vendors were approved in accordance with ASME NCA-3800.
d.
Review of reports of survey for one material manufacturer on June 26-27, 1978, and one calibration contractor on July 13, 1977, to verify that the surveys were conducted in accordance with the QA program, e.
Review of QC Procedure No. 16, dated October 26, 1976,
" Procedure for Approving Vendors Who Supply Plate, Sheet and Strip or Other Services for Nuclear Application," to verify that Armco had documented instructions for approving vendors.
f.
Review of material nonconformance reports dated May 10, 1978, and June 27, 1978, for rejected materials furnished by two (2) vendors to verify that nonconformnce reports were Armco's means for evaluation of supplier performance as indicated by Armco's representative.
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_9 g.
Discussions with cognizant personnel.
3.
Findings a.
Deviations from Coranitments See Enclosure, Item C.
b.
Unresolved Items _
None.
G.
Equipment Calibration 1.
Objectives The objectives of this area of the inspection were to verify that the following items were controlled in accordance with applicable NRC and ASME Code requirenents:
A written system has been established to assure that equip-a.
t ent calibration is performed and controlled in accordance with applicable codes.
4 b.
A written procedure has been developed and approved which contains provisions to assure that tools, gages, instruments and other inspection, measuring and testing equipment and devices used in activities affecting quality, are of the proper range, type and accuracy, and are calibrated and properly adjusted at specified periods or use intervals, c.
The devices are identified in the documented system and/or procedure and are calibrated in accordance with the system and procedure, d.
The calibration is performed against certified measurement standards which have known relationship to National Standards, where such standards exist.
The control measures include provisions for test equipment e.
identification and calibration status by marking, or on records traceable to the equipment.
f.
The Manufacturer determined and implemented corrective action for materials and items checked using measurement or testing equipment later found to be out of calibration.
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. 2.
Method of Accomplishment The preceding objectives were accomplished by:
a.
Review of the QA Manual, Sections No. 10, paragraph 10.3,
" Calibration of Furnace Controls," and No. II, " Qualification cf Gauging, Measuring and Testing Equipment," to verify that controls for calibration are documented.
b.
Review of QC Procedure No.12, " Procedure For Periodic Calibration of Production Facilities," to verify that additional controls for celibration ure documented, c.
Examinatica of the following mear. ring and testing devices to l
verify that they were controlled and calibrated, and identified in the QA Manual or QC Procedure No.12:
(1) 0.D. Micrometers.
(2)
I.D. Micrometers.
(3)
Depth Micrometers.
l-(4)
Severn Gage S.H. 2408.
(5)
LTN Optical Pyrometer.
(6) Standard Gage Bl0cks and Rods for Micrometer Calibration.
(7) Padiographic Densitometer and Step Tablet Film Strip.
(8) Radiagraphic Penetrameters.
(9) Voltage and amperage meters on five (5) welding machines.
(10) Master Pressure Gages.
(11) Tensile Machine and Extensometers.
(12) Hardnes, Tester No. 7271 and Reference RC and RB Hardneas Blocks.
(13) Roller Hearth Furnace Recorder Controllers.
(14) Car Bottom Furnace Recorders.
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. (15) Continuous Hydrostatic Tester Foxboro Recorder Model 40.
(16) Tong Tester Ammeters.
(17) Simpson Reference Volt-Ohm Meter.
d.
Review of the Armco calibration records or outside sources' certificates of calibration for the above.levices to verify that Armco maintains and implements a documented calibration, identification and recall system for measuring and testing devices, and that calibration standards have known traceability to National Standards, where such standards exist.
e.
Discussions with cognizant personnel.
3.
Findings a.
Deviations from Commitments See Enclosure, Jtem D.
b.
Unresolved Items None.
H.
Exit Interview 1.
The inspector met with management representatives denoted in paragraph A. at the conclusion of the inspection on August 10, 1978.
2.
The following subjects were discussed:
a.
Status cf corrective action for previously identified i
l deviations including Armco's failure to revise Mill Orders to proparly include procedures numbers 12,15,10, and 4A i
l contrary to the commitment in Armco's letter dated March 15, 1978, to make the above revisions.
l b.
Failure to include on purchase orders, the statement,
" Materials are ordered according to ASME Code,Section III, requirements and are subject to inspection before shipping."
c.
Failure to follow welding procedures No.12 and No. 5 during in-process welding.
?
i d.
Failure to fully implement the calibration program for three(3)typesofmeasuringdevices.
3.
The manufacturer's representatives were asked to formulate their corrective action responses to deviations in accordance with the three (3) conditions identified in the inspection report cover letter.
4.
The manufacturer's representatives' questions related to clarification of the above items.
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