ML20151F873

Notice of Nonconformance from Insp on 880307-11. Nonconformance Noted:Matl Being Upgraded for Westinghouse Purchase Orders Lacked Required Number of Tensile Tests Needed to Meet ASME Boiler & Pressure Vessel Code

ML20151F873
Person / Time
Issue date:	04/15/1988
From:	Office of Nuclear Reactor Regulation
To:
Shared Package
ML20151F868	List: ML20151F864 ML20151F873 ML20151F880
References
REF-QA-99900735 NUDOCS 8804190027
Download: ML20151F873 (3)

Text

..

APPENDIX A 1

Southern Bolt & Fastener Corporation Docket No. 99900735/88-01 NOTICE OF NONCONFORMANCE During an inspection conducted on March 7-11, 1988, the implementation of the Southern Bolt & Fastener Corporation (SBF) Quality Assurance (QA) program at the Shreveport, Louisiana facility was reviewed with respect to the fabrication of large studs, nuts, and other fasteners used in nuclear applications. The SBF QA Manual, Revision 0, dated November 13, 1986 describes the QA program being implemented at SBF. .This QA pro ASME Boiler and Pressure Vessel (BPV) gram Code, is based Section on the requirements III, Subsection NCA-3800. of the Based on the results of this inspection and in accordance with the NRC Enforce-ment Policy of 10 CFR Part 2, Appendix C, the following items of nonconfomance were identified.

1. Paragraph NCA-386'i.4(e) of Section III of the ASME BPV Code states, in part, "The Material Manufacturer who certifies material made from stock produced by a manufacturer whose Quality System Program has not been qualified under NCA-3800 may accept certification of the requirements of the material specification which must be performed during the melting and of the heat analysis from the manufacturer of the stock provided the requirements of (1) through (4) below are met. (1)(a)TheMaterial Manufacturer performs or subcontracts all other requirements of the material specification on each piece of stock material."

Paragraph 1.A. of Section 65.0 of the SBF QA Manual, Revision 0, dated November 13, 1986 states, in part "SBF shall perfom or subcontract all other requirements of the material specification on each piece of stock."

Contrary to the above, material being upgraded for Westinghouse purchase order PE 21815 MSA, dated March 26,1987(SBFProductionOrder4097)and for Westinghouse purchase order MN 83129D, Supplement 3 (SBF Production Order 4016) lacked the required number of tensile tests needed to meet the ASME BPV Code. In each case, tensile tests were performed on two out of three pieces of stock material; the requirement of the Code being, tensile tests performed on each piece of stock. The material for each order has been shipped to the purchaser (88-01-01).

2. Paragraph NCA-3867.3 of Section III of the ASME BPY Code states, in part, "Nonconforming material shall be identified and reviewed for acceptance, rejection, or repair. . . ."

Paragraph 2 of Section 110.0 of the SBF OA Manual, Revision 0, dated November 13, 1986 states, in part, "Nonconformances discovered during receiving inspection, in-process inspection or final inspection are identified by a "hold tag" on the nonconforming matertal...."

8804190027 880415 PDR OA999 EMVSOUBF 99900735 DCD

n . .. _ -- . . _. . . -.

Paragraph 3 of Section 110.0 of the SBF QA Manual states, in part, "The Quality Department is responsible for preparing and documenting a detailed  ;

nonconformance report and initiating further disposition of the material." '

t Paragraph 4.5.2 of Section 410.01 of the SBF Procedure Manual, Revision 2, dated January 31, 1985, states, "In all cases of nonconforming units that do not occur by routine or typical causes and for all nuclear parts, place the defectives in "HOLD" status, prepare an "NCR" (see CP 460.01) and formal disposition shall be determined by SBF via the "NCR" process which upon completion of its evaluation will be either "accept-as-is" (as agreed by SBF and/or the customer, if necessary), or "repair and reinspect," or "

"reject ano scrap," totally depending upon the specific circumstances involved."

a. Contrary to the above, no nonconfomance report (NCR) was written for bolts, nuts and studs received from Texas Bolt which required rework. The rework was performed due to various nicks and dings which were observed on the threads during the final / receipt inspec-  ;

tion performed by SBF. The results of the rework and reinspection j were documented on the SBF "Finished Fastener Receiving Inspection Report"(88-01-02).

b. Contrary to the above, no NCR was written for two measurements of lateral expansion (Charpy Impact test results) for SBF Production Order 4218, which did not meet the minimum value specified in Section NB-2333-1 of the ASME BPV Code. The finished parts were shipped to Hub Inc. (purchase order T-8027103) with one of the out of speci-fication values recorded on the Certificate of Test. The other out of specification value had been erroneously transcribed onto the Certificate of Test as a valid number (88-01-03).

c. Contrary to the above, no NCR was written for material for SBF Production Order 4218 which contained a high carbon content and was rejected by the purchaser, Hub Inc. The rejected material is currently in the SBF controlled warehouse (88-01-04).

3. Paragraph NCA-3867.3 of Section III of the ASME BPV Code states, in part, "In order to prevent the inadvertent use of material which does not conform, adequate control measures shall be established to preclude nonconfomances with the requirements of this Section."

Paragraph 3 of Section 110.0 of the SBF QA Manual Revision 0, dated November 13, 1986 states, in part, "The Quality Department is responsible for preparing and documenting a detailed nonconformance report...Noncon-fomance Reports are logged by QC...on the Nonconfomance/ Corrective Action Report Log...."

Paragraph 6 of Section 110.0 of the SBF QA Manual states, "Further processing of nonconforming material pending disposition is not permitted."

Paragraph 9 of Section 110.0 of the SBF QA Manual states, in part. "The Corrective Action Report will be issued...with a response required within 30 days. The follow-up will be conducted...within 30 days of the response."

Contrary to the above, NCRs 1345 and 1352, dated August 15, 1987 and August 16, 1987 respectively, could not be located by SBF. The material was shipped to the purchasers and it is not known, due to the missing paperwork, what type of nonconformance was identified or if either NCR was dispositioned. Additionally, a number of NCRs initiated in 1987 have not been closed out and some NCRs were signed by the fonner QA manager as being closed out, but no disposition was indicated on the NCR (88-01-05).

4. Paragraph NCA-3861(a)(3) of Section III of the ASME BPV Code states, in part, "The Material Manufacturer shall be responsible for: surveying, qualifying, and auditing the suppliers of subcontracted services...."

Paragraph 4 of Section 50.0 of the SBF QA Manual, Revision 0, dated November 13, 1986, states, in part, "Services provided shall be completed in accordance with the SBF approved system...."

Paragraph 8 of Section 50.0 of the SBF QA Manual states, in part, "Procure-ment of Code materials must be from vendors who are approved. Approval is shown on the A.V.L. (Approved Vendor List)...."

Contrary to the above, Metallurgical Services was not listed as evaluated and approved for an NCA-3800 program on the A.V.L., although it is used by SBF to provide chemical analysis of ASME Section III material (88-01-06).

5. Paragraph 10 of Section 50.0 of the SBF QA Manual, Revision 0, dated November 13, 1986 states, in part, "Each vendor on the A.V.L. will be evaluated annually, or more often when considered necessary.... Any vendor not evaluated and ap;.oved within twelve (12) months from the date of the last approval will be removed from the A.V.L. or be re-evaluated...."

Contrary to the above, four suppliers listed en the A.V.L. were being evaluated every three years as opposed to the required annual evaluation (88-01-07).