ML20151F880
| ML20151F880 | |
| Person / Time | |
|---|---|
| Issue date: | 04/15/1988 |
| From: | Abbate C, Baker E Office of Nuclear Reactor Regulation |
| To: | |
| Shared Package | |
| ML20151F868 | List: |
| References | |
| REF-QA-99900735 NUDOCS 8804190034 | |
| Download: ML20151F880 (8) | |
Text
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ORGANIZATION:
SOUTHERN BOLT & FASTENER CORPORATION SHREVEPORT, LOUISIANA REPORT INSPECTION INSPECTION NO.: 99900735/88-01 DATES: 03/7-11/88 IW u Tr m oe.
53 CORRESPONDENCE ADDRESS: Mr. Thomas Goin, Vice Fresident Quality Assurance Southern Bolt & Fastener Corporation Post Office Box 7196 Shreveport, Louisiana 71137 ORGANIZATIONAL CONTACT: Mr. Walt Oehlkers, QA Coordinator TELEPHONE NUMBER:
(318) 221-4251 NUCLEAR INDUSTRY ACTIVITY:
Supplier of large studs, nuts and fasteners.
ASSIGNED INSPECTOR: b_Ud A4,
)
C. M. Abbate. Program' Development and Reactive at InspectionSection(PDRIS)
OTHERINSPECTOR(S):
C. Czajkowski, Consultant APPROVED B 5
. T. faker, Acting Chie~f, PDklS, Vendor Inspection Branch ate INSPECTION BASES AND SCOPE:
A.
BASES: ASME BPV Code,Section III, Subsection NCA-3800, 10 CFR Part 21.
B.
SCOPE:
This inspection was performed to review Southern Bolt & Fastener's QA progran and its implementation. Areas examined during the inspection included the procurement program, the calibration system, the NDE program, the heat treating program, upgrading of ASME material, nonconforming item control and finished product packages.
The inspection consisted of obser-vation of work and review of rarnrde PLANT SITE APPLICABILITY: Multiple plants.
8804190034 880415 PDR QA999 EMVSOUBF 99900735 DCD
ORGANIZATION:
SOUTHERN BOLT & FASTENER CORPORATION SHREVEPORT, LOUIS!ANA REPORT INSPECTION NO,: 99900735/88-01 RESULTS:
PAGE 2 of 8 A.
VIOLATIONS:
There were no violations identified during the inspection.
B.
NONCONFORMANCES:
1.
Contrary to Paragraph NCA-3367.4(e) of Section III of the ASME Boiler and Pressure Vessel (BPV) Code and Paragraph 1.A. of Section 65.0 of the SBF QA Manual, Revision 0, dated November 13, 1986, material being upgraded for SBF Production Orders 4016 and 4097 lacked tFe required number of tensile tests needed to meet the ASME BPV Code requirements. The material has been shipped to the purchasers (88-01-01).
2.
Contrary to Paragraph NCA-3867.3 of Section Ill of the ASME BPV Code, Paragraphs 2 and 3 of the SBF QA Manual, Revision 0, dated November 13, 1986, and Paragraph 4.5.2 of Section 410.01 of the SBF Procedure Manual, Revision 2, dated January 31, 1985; a.
No nonconformance report (NCR) was written for studs, nuts and bolts which required rework.
The rework was performed due to various nicks and dings which were identified during a SBF final / receipt inspection (88-01-02).
b.
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 (88-01-03).
c.
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. (88-01-04).
3.
Contrary to Paragraph NCA-3867.3 of Section 111 of the ASME BPV Code and Paragraphs 3, 6, and 9 of the SBF QA Manual, Revision 0, dated November 13, 1986, NCRs 1345 and 1352, dated August 15, 1987 and August 16, 1987 respectively, could not be located by SBF; a number of NCRs initiated in 1987 have not been closed out; and some NCRs have been signed as closed out, but no disposition was recorded (88-01-05).
4.
Contrary to Paragraph NCA-3861(a)(3) of Section III of the ASME BPV Code and Paragraphs 4 and 8 of Section 50.0 of the SBF OA Manual.
Revision 0, dated November 13, 1986, Metallurgical Services was not
ORGANIZATION:
SOUTHERN BOLT & FASTENER CORPORATION SHREVEPORT, LOUISIANA REPOP.T INSPECTION NO.-
99900735/88-01 RESULTS:
PAGE 3 of 8 listed as evaluated and approved for an NCA-3800 program on the Approved Vendor List (A.V.L.) although it is used by SBF to provide chemical analysis of ASME Section !!! material (88-01-06).
5.
Contrary to Paragraph 10 of Section 50.0 of the SBF QA Manual.
Revision 0, dated November 13, 1986, four suppliers on the A.V.L.
were being evaluated every three years as opposed to the required annual evaluation (88-01-07).
C.
UNRESOLVED ITEMS:
No unresolved items were identified during the inspection.
D.
STATUS OF PREVIOUS INSPECTION FINDINGS:
1.
(Closed) Nonconfomance (Item A, 81-01):
Cont *ary to Subsection NF-2300 of the ASME BPV Code and Section 130.0 at the SBF QA Manual, records did not exist to substantiate that calibration had been perfomed on temperature instruments or the impact test machine.
The calibration program in place at SBF was reviewed during the inspection. A sample of ring gages, plug gages, and other test equipment used at SBF was examined to verify calibration at the correct frequencies and to verify that the calibutions were perfomed by qualified calibration vendors. The inspectors also observed the calibration of the Charpy Impact machine.
No noncon-formances were identified in this area and further details can be found in Section 3 of the report.
This nonconformance is closed.
2.
(0 pen) honconfomance (Item B, 81-01):
Contrary to Paragraph NCA-3867.4(e) of the ASME BPV Code, Section !!!
and Section 60.0 of the SBF QA Manual, certain materials used in ASME Code Section 111 applications had been received from unqualified venoors and verification of compliance of these materials with material specifications had not been accomplished in accordance with the provisions of NCA-3867.4(e).
Accitional ncnconfomances were identified during the inspection in these areas, therefore, this nonconformance is closed. This item will be tracked as 88-01-01.
ORGANIZATION: SOUTHERN BOLT t, FASTENER CORPORATION SHPEVEPORT, LOUISIANA REPORT INSPECTION NO.: 99900735/88-01 REslHTs.
Der a gr o E.
OTHER FINDINGS AND COMENTS:
1.
Entrance and Exit Meetings An entrance meeting was conducted on March 7,1988 at the SBF facility in Shreveport, Louisiana.
The purpose and scope of the inspectior.
were discussed during this meeting.
During the exit meeting, conducted March 11, 1988, the inspection findings and observations were sumarized.
2.
Observation of Work Throughout the inspection, the inspectors observed work being performed at SBF. The inspectors observed tensile tests, the calibration of the Charpy Impact machine and ocasurements of the lateral expansler, of test specimens (results o' impact tests).
The inspectors also observed hold tags in use, heat treating being performed and production order packages accompar ying material on the shop floor, It was observed that the appropriati revisions of the procedures were present at the work stations and the personnel were knowledgeable of the procedures.
The inspectors also examined the controlled warehouse. This is where stock material which is traceable back to certifications is kept.
The inspectors selected four control numbers from items in the warehouse and reviewed the certifications. All four certifica>
tions were readily available for review and correctly identified the stock material.
3.
Calibration Program The inspectors examined the calibration program in place at SBF.
Section 120.0 of the SBF QA Manual and Section 430 of the SBF Proce-dure Manual were reviewed. The inspector selected at random a nurrber of ring gages, plug gages and go-no-go gages in the controlled test equipment cabinet to ensure proper calibration. All of the celected equipment was marked with a serial number, last date calibrated and calibration due date.
The equipment serial number was traceable to the calibration log which listed the same information.
Also reviewed were the calibration results received by SBF fror, the calibration vendors.
If a piece of equipme'it was found to be out of calibration, it was pulled from service and the information was noted in the log and on the piece of equipment.
7 ORGANIZATION:
SOUTHERN BOLT & FASTENER CORP 0PATION SHREVEPORT, LOUISIANA REPORT INSPECTION NO.: 99900735/88-01 RESULTS:
PAGE 5 of 8 The equipment examined was properly calibrated and the records reviewed were kept in accordance with the QA manual and the procedure, thus closing out Ponconformance item A in inspection report No. 81-01.
4 Approved Vendor List (A.V.L.)
The A.V.L. was acquired from SBF personnel to ensure the require-ments of Section 50.0 of the SBF QA Manual and Section 440 of the SBF Procedure Manual were being met. Various production orders were reviewed to identify what suppliers SBF procures material from and if the suppliers are qualified and on the A.V.L.
During this review, i
it was noted that Metallurgical Services had not been evaluated and approved for an NCA-3800 program. Metallurgical Services is used by SBF to perform chemical analysis on Code and non-Code production orders.
4 Also identified during this review was the fact that four vendors who hold Quality System Certificates (OSC) were being evaluated every three years instead of being evaluated annually.
The three year evaluation schedule by SBF corresponded to the three year interval of the QSC.
Because a QSC can be terminated during the three year period, the suppliers need to be evaluated on a yearly basis.
During the NRC inspection, SBF contacted the four suppliers to ensure the QSCs were still in effect.
honconformances 88-01-06 and 88-01-07 were identified in this area.
5.
Review of Production Order Packages Several production order oackages were reviewed during the inspec-tion.
The review consisted of completed production orders and in-process production orders.
The packdges included the purchase order to SBF, purchase orders to suppliers, Certificates of Test, heat treatment reports, NDE reports NDE personnel qualifications, results of chemical analyses, test data reports, and Certificates of Compliance.
During this review, it was noted that rework had been performed en bolts, studs, and nuts received from Texas Bolt (purchase order 20011) without an NCR written to identify the nonconformance.
Various nicks and dings were identified on the threads of the finished parts during a SBF final / receipt inspection.
The nicks and dings required rework which would require an NCR to be written. The results of the rework and reinspection were noted on the SBF "Finished Fastener Receiving Inspection Report.
ORGANIZATION:
SOUTHERN BOLT & FASTENER CORPORATION SHREVEPORT, LOUISIANA REPORT INSPECTION NO.: 99900735/88-01 RESULTS:
PAGE 6 of 8 Nonconformance 88-01-04 was identified in this area.
During the review of the package for Production Order 4218 (purchase order T-8027103 from Hub, Inc.), it was noted that the Test Data Sheet (Lab order No. 05302) had two measurements of lateral expansion (Charpy Impact test results) which did not meet the minimum value specified in Section NS-2333-1 of the ASME BPV Code.
The raterial was accepted by SBF QA without an NCR being written. The finished parts were shipped to the customer with one of the out of specifica-tion values noted on the Certificate of Test. The other out of specification value was apparently transcribed erroneously cnto the Certificate of Test and appeared as an acceptable value.
During the NRC inspection, SBF issued NCR 1525 and required the t..ree test coupons be remeasured for lateral expansion. The NRC inspectors observed the remeasuring performed as a result of NCR 1525 and these measurements were significantly different from the original measure-ments. The second set of measurements fell within the acceptable values, thus rendering the r.aterial acceptable. Because of the large variation in results between the original measurements and the second set of measurements, SBF is conducting a search for previously inspected impact test specimens to perform a reinspection of those specimens. This is being done to develop a level of confidence in the data taken by the inspector who measured the first set of values.
Nonconformance 88-01-02 was identified in this area.
6.
Upgrading of Stock Material for Co6e Work A total of four packages which contained material upgrades were reviewed. Two of the four packages met the requirements of the ASME BPV Code, Section NCA-3867.4(e).
The two remaining packages failed to meet certain requirements of that section.
Production Order 4016 was for 144 manways studs and nuts being manu-factured for Westinghouse under purchase order MN 83129. AISI 4140 material was being upgraded to ASTM-A-193 Grade B7 material. The Code requires that a tensile test be performed on each piece of stock material.
For this order there were three pieces of stock used, but only two pieces of stock had tensile tests performed on them.
SBF cannot trace which studs and nuts came from which piece of stock and therefore plans on notifying the customer that the material was not properly upgraded.
ORGANIZATION:
SOUTHERN BOLT & FASTENER CORPORATION SHREVEPORT, LOUISIANA REPORT INSPECTION NO.:, 99900735/88-01 RESULTS:
PArJ 7 M F This problem was previously identified during an ASME accreditation survey and SBF was in the process of responding to the ASME survey team's finding.
Production Order 4097 was for 32 trunnion bolts being manufactured for Westinghouse under purchase order PE 21815 MSA.
Thii material was being upgraded from ASTM-A-193 Grade B16 to SA-540 Grade B21.
As with Production Order 4016, the code required a tensile test be performed on each piece of stock material.
Three pieces of stock naterial were used for this order while only two pieces were tensile tested. The individual bolts cannot be traced to the piece of stock used to manufacture the bolts. At the time of the inspection, SBF stated they plan on notifying the customer of the improper upgrading.
Nonconformance 88-01-01 was identified in this area.
Nonconformance 88-01-03 was identified in the upgraded material package for Production Order 4218.
In this package, material had been upgraded, but contained a carbon content value in excess of that allowed by the chemical specifications.
The purchaser Hub, Inc.(purchaseorcerT-8027103), rejected the material in a letter to SBF, dated November 5, 1987, due to the high carbon content. No NCR was written to identify the disposition of the material.
During the NRC inspection, SBF issued NCR 1523 and the NRC inspectors verified that the material was being kept in the controlled ware-house with the proper certification available for review.
7.
Nonconforming item Ocntrol The SBF nonconfoming item control program was reviewed. Section 110.0 of the SBF QA Manual and Section 460.01 of the SBF Procedure Manual describe the requirements of the program and were reviewed by the NRC inspectors. NCRs, corrective action reports and the noncon-formance/ corrective action report log were reviewed. During this review, it was noted that a numbe. of NCRs which were initiated in 1987 had not been closed out. Additionally, upon review of several NCRs, it was noted that the former QA Manager had signed NCRs as being closed out, but no disposition had been indicated on the NCR.
Two NCRs, 1345 and 1352, dated Aagust 15, 1987 and August 16, 1987 respective.;, were written on nuclear production orders and could not be located by SBF.
The nonconfomance/ corrective action report log indicated that they had not been closed out, but the material has been shipped to the purchasers, it is not kncwn what type of noncon-famance existed for these two NCRs nor is it known what disposition,
ORGANIZATION: SOUTHERN BOLT & FASTENER CORPORATION SHREVEPORT, LOUISIANA REPORT INSPECTION NO.-
99000735/88-01 RESULTS:
PAGE 8 of 8 if any, was performed.
SBF indicated that an effort is being made to correct problens associated with the NCR program.
honconformance 88-01-05 was identified in this area.
8.
Heat Treatment The inspectors examined SBF's heat treating facilities. The equip-ment was calibrated and the latest revision of the procedures were available at the work station.
The SBF personnel were knowledgeable of heat treatment and the procedures.
Heat treatment charts which were included in production order packages were also reviewed to ensure the material was kept at the correct temperature for the appropriate amount of tine as specified in the Code.
9.
Nondestructive Examination (NDE)
The inspectors reviewed the certifir.ation for NDE personnel and found them in accordance with SBF's written practice, which meets the requirements of SNT-TC-1A.
The inspectors also reviewed the certifications of the material used at SBF for magnetic particle testing and liquid penetrant testing. This was done to ensure that contaminants were not present in the material. NDE test reports were reviewed in acdition to inspecting the facilities used for NDE.
Based on the review, the NDE program is being performed in accordance witn the SBF QA Manual and the accompanying SBF procedures.
10.
Internal Audits The inspectors reviewed the SBF internal audits for 1986 and 1907.
Both audits were performed with checklists and in accordance with Section 260.0 of the QA Manual and Section 450 of the SBF Procedure Manual. Corrective action was taken for deficient areas identified during the audits and follow-up was performed.
F.
PERSONS CONTACTED:
Thomas A. Goin, Vice President, Quality Assurance Peter Lillys, Vice President Technology E. W. Nelson, President Walter G. Oehlkers, Quality Assurance Coordinator R. Pettway, Forge Foraman G. Sepulvado, Chief Inspector J. Williams, Warehouse Foreman A. J. Wilson, Supt. Heat Treating
.