ML20203H964
| ML20203H964 | |
| Person / Time | |
|---|---|
| Issue date: | 08/01/1986 |
| From: | Conway J, Gormley O NRC OFFICE OF INSPECTION & ENFORCEMENT (IE) |
| To: | |
| Shared Package | |
| ML20203H915 | List: |
| References | |
| REF-QA-99901032 99901032-86-01, 99901032-86-1, NUDOCS 8608050141 | |
| Download: ML20203H964 (9) | |
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ORGANIZATION: CONSOLIDATED PIPE & VALVE SUPPLY, INC.
MISHAWAKA, INDIANA INSPECTION [NSPECTION REPORT )N-SITE HOURS: 34 NO.- 99901032/86-01 DATE: 6/16-18/86 CORRESPONDENCE ADDRESS: Consolidated Pipe & Valve Supply, Inc.
ATIN: Mr. Maurice Polis Chief Executive Officer 1210 North Willow Street Mishawaka, Indiana 46544 ORGANIZATIONAL CONTACT: Mr. Bernard Blanda, Vice President (2191 255-9667
_ TELEPHONE NUMBER: '
NUCLEAR INDUSTRY ACTIVITY: Material supplier of pipe, valves, and fittings.
(
// r ASSIGNED INSPECTOR:
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' Date J. TT 'Gdnway, Rfctive Inspection Section (RIS)
OTHER INSPECTOR (S): 0. P. Gorm1 y, Pr gram rdination Section
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APPROVED BY: Date E. W. Merschoff, Chie IS, Vendor Program Branch INSPECTION BASES AND SCOPE:
A. BASES: 10 CFR Part 50, Appendix B and 10 CFR Part 21.
B. SCOPE: The purpose of this inspection was to conduct a programmatic evaluation of the implementation of the QA Program in the areas of train-ing, control of purchased material and services, control of measuring equipment, audits, and reporting of defects.
PLANT SITE APPLICABILITY:
10 CFR Part 21 material supplied to D.C. Cook, (50-315/316) and Midland (50-329/330).
8608050141 E;60801 PDR GA999 Et1VCOPS 99901032 PDR
ORGANIZATION: CONSOLIDATED PIPE & VALVE SUPPLY, INC.
MISHAWAKA, INDIANA REPORT INSPECTION RESULTS: PAGE 2 of 7 ,
NO.- 99901032/86-01 ~i A. VIOLATIONS:
- 1. Contrary to Sections 21.6 and 21.21 of 10 CFR Part 21: (86-01-01) a) Copies of 10 CFR Part 21 and Section 206 were not posted in a conspicuous area.
b) Appropr W procedures to evaluate deviations or inform the '
licenseu or purchaser of the deviation did not exist.
- 2. Contrary to Section 21.31 of 10 CFR Part 21, a review of procurement /
documentation packages for nuclear material revealed that customer purchase orders (P0s) to Consolidated specified 10 CFR Part 21 as an applicable requirement, but Consolidated P0s to the following suppli-ers/ manufacturers did not similarly specify that 10 CFR Part 21 would apply:),Kilsby-Robert (three Tube (two), Ametex (one), Quality Pipe P Stainless Products (two), Robvon Backing Ring (one), and Jones &
Laughlin (one). (86-01-02)
B. NONCONFORMANCES:
- 1. Contrary to Criterion V of Appendix B to 10 CFR Part 50 and Section 5.4 of the Quality Assurance Program Manual (QAPM), a review of docu-mentation packages (DP) for nuclear orders from American Electric Power (AEP) revealed that a Nuclear Class Material Receiving Report was missing for material on Consolidated Pipe and Valve Supply (CPVS) work order Nos. 4201, 4308, 4330, and 4815. (86-01-03)
- 2. Contrary to Criterion V of Appendix 8 to 10 CFR Part 50 and Section 5.4 of the OAPM, it was noted during a review of DPs for nuclear orders the " NUCLEAR" stamp was not used on numerous documents which included CPVS P0s, certificate of compliances, and receiving reports.
(86-01-04)
- 3. Contrary to Criterion V of Appendix B to 10 CFR Part 50 and Section 9.0 of the CAPM, a review of gauge calibration ccrds and calibration certificates revealed that the working and master gauges all exceeded their calibration frequencies as noted by the following: (86-01-05)
The working caliper (No. X90-952) and working micrometer (No. 112-273) were calibrated in December 1982 by an employee of CPVS and in July 1984 by Tri-State Instrument Service (TSIS).
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ORGANIZATION: CONSOLIDATED PIPE & VALVE SUPPLY, INC.
MISHAWAKA, INDIANA REPORT INSPECTION RESULTS: PAGE 3 of 7 NO.- 99901032/86-01 The master caliper (No. X90-17), master micrometer (No.101), and gauge block (No. 611201-23) were calibrated in December 1981 and in July 1984 by TSIS.
- 4. Contrary to Criterion V of Appendix B to 10 CFR Part 50 and Section 4.0, G of the QAPM, a review of QA records revealed that 0A/QC manuals from approximately 21 manufacturers / suppliers were missing from the files of CPVS. (86-01-06) ,
- 5. Contrary to Criterion V of Appendix B to 10 CFR Part 50 and Sections 4.0 A and H of the 0APM, a review of nuclear orders between 1983-1985 revealed that 13 CPVS P0s were issued to five vendors who were not on the Approved Vendor List ( AVL). (86-01-07)
- 6. Contrary to Criterion V of Appendix B to 10 CFR part 50 and Section 3.2 of the QAPM, records were not available to verify that audits were performed between 1982 and 1986 on 26 of 35 vendors on the AVL. Docu-mented in-house evaluations were also not available. (86-01-08)
- 7. Contrary to Criterion V of Appendix B to 10 CFR Part 50 and Section 1.3.4 of the OAPM, internal audits were not performed on schedule in 1984 and 1985. (86-01-09)
- 8. Contrary to Criterion V of Appendix B to 10 CFR Part 50 and Section 4.0 I of the QAPM, training reccrds or other evi'dence of qualification were not available for the persons who performed audits. (86-01-10)
- 9. Contrary to Criterion V of Appendix B to 10 CFR Part 50 and Section 8.0 of the QAPM, nine corrective action reports did not address the I causes of the condition, and reports from vendors were not available.
(86-01-11)
- 10. Contrary to Criterion V of Appendix B to 10 CFR Part 50, Section 4.0 E of the QAPM, and Section 15.2 of specification SA-182, it was noted that CPVS accepted material from: (86-01-12) t a) Six vendors without the required quality program certification
! on the certified material test reports (CMTR).
b) Two vendors for which the CMTRs did not contain the heat treat-ment statement.
ORGANIZATION: CONSOLIDATED PIPE & VALVE SUPPLY, INC.
MISHAWAKA, INDIANA REPORT INSPECTION NO.- 99901032/86-01 RESULTS: PAGE 4 of 7 C. UNRESOLVED ITEMS:
None.
D. OTHER FINDINGS OR COMMENTS:
- 1. Personnel Contacted
- Morris Polis, Chief Executive Officer
- Bernard Blanda, Vice President
- Mike Clayton, Inspector
- Attended exit meeting.
- 2. Documentation Packages (DP)
The NRC inspector reviewed the Nuclear Work Order Log Book which listed nuclear orders from June 1980 to the present. During this time period, CPVS had aoproximately 182 nuclear orders (169-Indiana
& Michigan Electric (IME),10-Nebraska Public Power District (NPPD),
two-Consumers Power (CP), and one-Florida Power Corporation). Ap-proximately three percent of CPVS sales are nuclear.
Fifty-five DPs (51-IME, two-NPPD, one-FPC and one-CP) were reviewed.
A DP consisted of a customer P0 and specification; CMTRs from manu-facturers; and CPVS P0, CC, receiving report, and invoice. Thirty P0s from IME and one from CP specified the requirements of 10 CFR Part 21. Twenty-nine of the orders from IME were for stainless steel flanges (ASTM /SA 182), and CPVS purchased the flanges from Golden Gate Forge & Flange (GGFF). The order from CP was for Section III, Class 1 flanges which were also purchased from GGFF. CPVS P0s passed on the requirements of 10 CFR Part 21 to GGFF and required a CMTR, but they did not specify that the flanges were to be manufactured under a QA program which was approved by CPVS or their customer.
The P0s for nuclear material from both IME and CP specified that the vendor (i.e., CPVS) should have a QA program which was previously approved by the buyer. Following a request to review customer audits of CPVS, the NRC inspector was told Florida Power & Light (FPL) was the only licensee or company to perform an on site audit / survey of CPVS. FPL did not place an order with CPVS.
Forty-six CPVS P0s from 1983 to 1986 to 25 manufacturers / suppliers of nuclear material and services were reviewed to assure that applicable technical and quality requirements were included or referenced in pro-
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ORGANIZATION: CONSOLIDATED PIPE & VALVE SUPPLY, INC.
MISHAWAKA, INDIANA REPORT INSPECTION RESULTS: PAGE 5 of 7 NO.: 99901032/86-01 curement documents. It was noted that 10 CFR Part 21 requirements were not passed on to Kilsby-Robert Tube (Nos. 2325-2 and 2730-4),
Ametex (No. 2113-1), Quality Pipe Products (Nos. 4215-7, 4313-2, and 4829-2), Flange Fittings & Forgings (No. 4313-3), Tube Sales (No. 4424-5), Virginia Stainless Products (Nos. 4412-1 and 41213-3),
Robvon Backing Ring (No. 4706-3), and Jones & Laughlin (No. 41213-7)
In addition, nine of the 12 P0s noted (see Violation 86-01-02).
above were not stamped " Nuclear" (see Nonconformance 86-01-04). ,
Nuclear Class Material Receiving Reports were reviewed to assure that receipt inspection was performed on nuclear material. It was noted that receiving reports were missing on material supplied on work orders No. 4201 (P0s EX 665 to Middle East Tube and 4208-1 to Standard Fittings), No. 4208 (P0 4313-2 to Quality Pipe Products), No. 4330 (P0s 4204-2 to Sharon Tebe and 4412-1 to Virginia Stainless Products),
and No. 4815 (P0 4829-2 to Quality Pipe Products). (see Nonconfor-mance 86-01-03)
A review of vendor QA manuals revealed that CPVC did not have a manual for 21 of the 25 manufacturers / suppliers of nuclear material and services (see Nonconformance 86-01-06). It was also noted that the manuals for Standard Fittings, Hackn.ey, WFI, and Capital Pipe were uncontrolled copies and several years old.
- 3. Control of Measuring Equipment The inspector reviewed applicable sections of the 0APM, gauge calibra-tion cards, and certifications to assure that measuring equipment is properly identified, controlled, and calibrated at specified intervals.
It was noted that two working instruments 6" dial caliper (No.
X90-952) and 0-1" micrometer (No. 112-273) - did not have a calibra-tion sticker on the instrument or its container. The gauge calibra-tion cards for four measuring instruments and the gauge block indicated that the caliper (No. X90-952) and micrometer (No. 112-273) were calibrated in December 1982 at CPVS, and the master caliper (No. X90-17), master micrometer (No. 101), and gage block (No. 611201-23)were calibrated by a vendor in December 1981.
Records indicated that initial calibration for the four instruments and gauge block was performed in June 1980. Two Certificates of In-spection indicated that TSIS calibrated and inspected all five items in July 1984. The certificates indicated that the reference standards were traceable to the National Bureau of Standards. No other records were made available to the NRC inspector. (see Nonconformance 86-01-05) 1
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ORGANIZATION: CONSOLIDATED PIPE & VALVE SUPPLY, INC.
MISHAWAKA, INDIANA REPORT INSPECTION RESULTS: PAGE 6 of 7
_ NO.- 99901032/86-01
- 4. 10 CFR Part 21 During a physical inspection of the facility, it was noted that the applicable documents specified in Part 21 were not posted. The NRC inspector was also told that CPVS did not have a procedure to evaluate deviations or defects and subsequently notify the customer. (see Vio-lation 86-01-01).
- 5. Approved Vendor List ( AVL)
The AVL is included in Revision 3 of the QAPM dated February 1, 1985.
AVLs were not available for previous years, and working documents for an AVL update were not available. In 1985, 10 orders were placed with three vendors who were not on the AVL as follows: Capitol Manu-(5418-2, 5701-8, 5910-3 1003-10), Capital Pipe and Steel facturing(550S-1,059-09-5,51003-5,1003-12),
Products Jones and Laughlin Steel (4820, 32-8-00105). In 1983, three orders were placed with two vendors not on the AVL as follows: Waterman Machine and Manufacturing (310-1), and Virginia Stainless Steel Nipple (3210-2, 3830-3). Other Ametek (1/84),
orders to vendors not on the AVL were noted as follows:
Dodson Steel Products (12/84), Calumet Testing Services (6/84), and I TSIS (7/84). (see Noncomformance 86-01-07)
- 6. External Audits Supplier evaluation was an area of weakness identified in a 1983 FPL audit of CPVS, and it continues to exist. Audit reports consist of limited check lists containing "yes, no, or N/A boxes." The audit reports do not identify the auditor and frequently fail to include In addition, there were no the date or name of the company audited.
records to show that 26 of the 35 suppliers on the AVL had been audited on the required schedule or that other evaluations had been conducted as required (see Nonconformances 86-01-08). Approved vendors for which audits were not available included: Anvil Products of Pennsylvania and Texas, Bonney Forge, Borg Warner, Custom Alloy, Flanges Fittings and Forgings, Hackney Iron and Steel, Ideal Consol-idated, Robert James Sales, LTV Steel, Kerotest Manufacturing, Kilsby-Robert Tube, Middle East Tube, Midland Ross, William Powell, Quality Pipe Products, Robvon Backing Ring, Sharon Tube, Southern Fluid Products, United States Steel of Ohio and Pennsylvania, Virginia Stainless Steel Nipple, Velan Valve, and WFI.
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m ORGANIZATION: CONS 0LIDATED PIPE & VALVE SUPPLY, INC.
MI5HAWAKA, INDIANA REPORT INSPECTION RESULTS: PAGE 7 of 7 NO.- 99901032/86-01
- 7. Training / Qualification Records were not available pertaining to the qualifications of per-sonnel (e.g., QA Manager, Auditor, Inspector, and Training Instructor) performing quality related activities. Records of training available provided no insight into the material covered. All instructors were within the company, and the instructor often signed as a trainee.
Records were not available pertaining to the training and qualifica-tion of the personnel who performed the external and internal audits.
(seeNonconformance 86-01-10)
- 8. Certification Material Test Reports (CMTR)
CPVS accepted CMTRs which lacked the required quality program certif-ication. This condition was observed on six P0s in 1985 as follows:
Sharon Tube (4209-2), Capital Pipe and Supply (5505-1), Quality Pipe Products (5509-3), Middle East Tube (EX706), Standard Fittings (5520-3), and Stainless and Alloy Fittings (5716-11).
CPVS accepted CMTRs which did not have the required heat treat statement. Two orders observed in the review of DPs in 1983 were Standard Fittings (41213-1/ heat codes V20, VAAA) and Midco Pipe and Tube (4110-4/ heat code ACF). (see Nanconformance 86-01-12) l
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