ML20207A158
| ML20207A158 | |
| Person / Time | |
|---|---|
| Site: | 05000000, Comanche Peak |
| Issue date: | 05/10/1979 |
| From: | Hudson W BROWN & ROOT, INC. (SUBS. OF HALLIBURTON CO.) |
| To: | |
| Shared Package | |
| ML20206S800 | List:
|
| References | |
| FOIA-85-59 QSP-7.0, NUDOCS 8607110433 | |
| Download: ML20207A158 (45) | |
Text
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J Brownf5' Root,Inc.
POWER DIVISION QUALITY ASSURANCE DEPARTMENT VENDOR SURVEILLANCE SECTION QUALITY SURVEILLANCE PROCEDURE CONTROL OF VENDOR NONCONFORMANCES PROCEDURE QSP 7.0 REVISIONS NO.
DATE
> APPROVAL PAGES REVISED I
W. W. Rudson Orieinal Issue O
12/3/76 1
8/15/77 W. W. Rudson All 2
9/8/78 W. W. Hudson All 3
5/10/79
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- 7. Su nd ese
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QSP 7.0 - 3 of 3
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3.2.2 Follow-Up I
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Af ter receiving the Vendor's notification of cocpletion of l
the nonconformances resolution, the action taken shall be either reinspected by a Surveillance Specialist to verify satisfactory co=pletion of resolution or the reinspection waived and verification accomplished during project receiving inspection or a subsequent Surveillance visit.
If verification is to be accomplished by project receiving inspection, they will be notified via interoffice memo by the Project Coordination Supervis or.
Verification performed by Surveillance Specialist will have the results documented on a Vendor Surveillance Report.
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QUALITY SURVEILLANCE PROCEDURE QSP 7.0 CONTROL OF VENDOR NONCONFORMANCES
- 1. 0 P_URPOSE "This procedure provides the systect to be used in establishing and documenting measures for the identification, control, and disposition of items, material, and services that do not meet procurement document requirements during the performance of Vendor Surveillance activities.
2.0 RESPONSIBILITY 2.1 VENDOR SURVEILLANCE SECTION MANAGER The Vendor Surveillance Section Manager has the overall respon-sibility to assure that the requirements of this procedure are fulfilled and properly documented.
- 2. 2 ASSISTANT VENDOR SURVEILLANCE SECIION MANAGER l
r-The Assistant Vendor Surveillance Section Manager has the l
actual responsibility to assure that the proper control of Vendor nonconformances is maintained in accordance with this procedure.
- 2. 3 REGIONAL SURVEILLANCE SUPERVISOR l
The Regional Surveillance Supervisor has been designated by the Assistant Vender Surveillance Section Manager the responsi-f, bility to assure that the requirements of this procedure are fulfilled and properly documented in his region.
V,-
-2.4 PROJECT COORDINATION SUPERVISOR g[, -
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The Project Coordination Supervisor has been designated by the
's Assistant Vendor Surveillance Section Manager the responsibility y'
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to generate, monitor, and assure timely follow-up and close-out p,
of all B&R Vendor Surveillance issued nonconformances and to assure L
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the nonconformances are handled in accordance with specific project i
y procedures,
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2.5 SURVEILLANCE SPECIALIST It is the responsibility of the Surveillance Specialist identi-fying the nonconfor=ance to assure that it is properly identified, l
C controlled, and documented in accordance wi e this procedure.
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45 Rev. No. 3
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QSP 7.0 - 2 of 3 O
2.6 VENDOR It is.the responsibility of the Vendor to maintain his Brown
& Root approved Quality Assurance Program, which shall include a system for identification and control of nonconformances, in effect during the life of the order.
- 3. 0 INSTRUCTIONS 3.1
. CONTROL OF VENDOR NONCONFORMANCES 3.1.1 General Section 3.2 of this procedure establishes the system for processing Vendor nonconformances and shall' be used unless one or more of the following conditions arise.
In such cases, the Project Coordination Supervisor shall be notified and he will generate a nonconformance report in accordance with the specific project nonconformance procedure, a) Action taken-by Vendor is insufficient or not in accor-dance with his approved nonconformance procedure.
b) The Vendor's proposed resolution is inadequate.
p c) The nonconformance appears to be a reportable deficiency.
Note: Specific Project Procedures are identified in the back of this procedure on different colored pages.
3.2 VENDOR CONTROL NONCONFORMANCES 3.2.1 Identification a) After detection of a nonconformance, the Surveillance Specialist shall assure that it is brought to the atten-tion of the Vendor's QA Organization, the appropriate Regional Surveillance Supervisor and Project Coordination Supervisor.
b) The Surveillance Specialist shall monitor the action taken by the Vendor Quality Assurance Organization to j
assure it is in accordance with their Brown & Root l
approved procedure for controlling nonconformances, c) The Surveillance Specialist shall document the noncon-l formance 1'n, the Vendor Surveillance Report, including the t
proposed resolution and resolution justification," if applicable.
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Rev. No. 3 5/10/79 l
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- r M After receiving the Vendor's notification of cocpletion of V
the nonconformances resolution, the action taken shall be either reinspected by a Surveillance Specialist to verify satisfactory completion of resolution or the reinspection waived and verification accomplished during project receiving inspection or a subsequent Surveillance visit.
If verification is to be accomplished by project receiving inspection, they will be notified via interoffice seco by the Project Coordination
' Supervisor.
Verification perforned by Surveillance Specialist will have the results docu=ented on a Vendor Surveillance Report
')
Rev..;o. 3 5/10/79 l
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13188 Brown & Root,Inc. "AR3S QUALITY ASSURANCE INDEXED RECEIVING INSPECTION REPORT UNIT SYSTEM COMPONENT IDENTIFICATION /SP DWG./ SPECIFIC ATION & REV.
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MRR CH ARACTERISTIC INSPECTION:
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NCR HOLD TAG APPARENT RESPONSIBILITY FOR UNSATISFACTORY ITEMS:
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-1195
.,-3-80 Brown,& Root.inc.
INTEROFFICE MEMO
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TO:
R. M. Klimist DATE: June 3, 1980 i
FROM:
J. T. Maxwell
SUBJECT:
CPSES, Job 35-1195 Source Inspection of Gulfalloy Corp., Houston, Texas May 28-29, 1980 y
The attached P.O. with items indicated was inspected to the require-ments of the Brown & Root P. O., referencing SA Specification, and released except as indicated below.
Item No. 5 on P.O. 35-1195-30448 consisting of 310.40 feet of 1" car-bon steel pipe was not authorized for shipment because the identity of the material was not in accordance with the Brown & Root P.O. and SA Specifi-cations.
Other items of concern were:
1.
Field inspection of material - a fi.cing of a different ht. lot was in shipment to Brown & Root that was not on the CMTR and B&R, Inc. QA Fom 045.
2.
The CMTR indicated items and quantities that were not en the B&R QA Fom 045.
. 3.
Some ht. lot nos. on the CMTR and B&R QA Fom 045 did not correspond with the chemistry analysis, destructive test, and/or Pressure Test Report.
These areas were, verified and corrected.
Frcm my discussion with Gulfalloy personnel, I feel they have very knowledgeable personnel, but I detected that the inspection personnel were weak in the piping receiving area.
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TRANSPORTER DATE DEFICIENCY DISCLOSED M'
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k' BVS 238 GULFALLOY (Houston)
I P.O. 35-1195-30448 Item 3 312 Ft.
Field Item 7 25 Ea.
Item 8 25 Ea.
A r
f Iu Item 5 310.40 Ft.
Did not authorize shipment Y
- 4 Item 10 12 Ea.
P.O. 35-1195-30442
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Item 8 147 Ea.
e-Item 10 3 Ea.
Source Inspection per
/y'a 'y 7 Item 11 1 Ea.
Brown & Root Purchase Item 13 50 Ea.
Order Specification Item 14 50 Ea.
Item 16 10 Ea.
Item 17 40 Ea.
P.O. 35-1195-30416 Item 16 2 Ea.
Item 33 20 Ea.
Item 34 37 Ea.
Item 35 20 Ea.
Item 36 15 Ea.
Item 37 20 Ea.
Item 39 10 Ea.
Item 40 30 Ea.
Item 41 20 Ea, Item 46 20 Ea.
Item 7 Item 8 Item 9 P.O. 35-1195-30449 Item 3 9 Ea.
P.0. 35-1195-30418 Item 2 1024.10 Ft.
Item 10 Item 12 Item 14 Item 16 l
Item 35 Item 37 Item 39 i
Item 11 Item 13 Item 15 Item 17 Item 36 Ihm 38 9$
.?"g!hf i *i P.O. 35-1195-30396 Item 17 4 Ea.
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). v INTEROFFICE MEMO TO:
T. Gamon/R. Bass DATE: June 13, 1980 3
FROM:
R. Klimist i
SUBJECT:
CPSES, Job 35-1195 Source pection of Gulfalloy Corp., Houston, Texas May 2 19 1980
' gcy n g-O Attached for y ur information is a copy of John Maxwell's coments, etc. regarding his inspection of Gulfalloy.
s k h/A /lA Ed /d R. M. Klimist Site Quality Assurance Manager 3
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e' CONFORMANCE CERTIFICATE j
PROJECT: COMANCHE PEAK JOB NO.:
CR0422 UNIT 1
PAGE.
7 OF 1
5
.3,vtNCOR 124 ADDHtSS 08 VE NUOR & ACILIT Y l
j GULFALLOY. INC.
4730 DARIEN HOUSTON, TEXAS (J e FyR CM AS E O R D E R NQ t ai SPECI F 4 CAT;ON NO, lREV.
l tSI D RA WI NG NQ.:
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35-1195-30442 S A-182 F-304 l NA NA l NA IGt T EM OL5CRIPTIONtSe (78 No. OF 11 E MS 1881NO.RELEAsiD 1
I SEE BELOW SEE BELOW i
SEE BELOW (93 COMPLE T E O vES E NO (106 SE Re AL OR BOCNTit ICATION NOISt.
Item 8: (147 ea.) 2" 3000# SW 90 ELL HT# NW 10: (3 ea.)
3/4" 3000# SW 90 ELL HT# FV 11: (1 ea.)
1" 3000# SW 45 ELL HT# IX 13: (50 ea.)
3/4"x3/8" 3000# SW RED INSERT HT# EBH 14: (50,ea.)
3/4"x1/2" 3000# SW REO INSERT HT# EDR 16:-(10 ea.)
3/4" 3000# SW TEE HT# JD 17- (40 ea.)
1" 30004 SW CPLG HT# EGR Resords checked (g[) be80w are being transmettee with thes cetteficate as remrets tav ene,tsrown & Root Document Cata Sheet.
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Y Mate *ial Certific ations Operating Elec. Test Recoros Veswal inspection R ecoros
.a-Heat Treat Recoros Non.coersteng E sec. Test R ecorus Dimensooral tnscoct. Recoros
$2 _ RT Feim & Recoros Pressure Test Records
- Cleanliness R ecoros
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PT/MT Recr.1s Saat Tigntness T est R ecords Painting R ecores
$3 UT Recoros Performance Test Records Pactogeng Recoros
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Acoroved Stress Report Weto. Personnet Qual. Corts.,
Sosee Parts List
- j Accroveo Oesegn Anaivses NDE Personnel Qual. Corts.
Speesat Nanchng Instruc.
Nameoiste Facsermie Operating Manuais Code Data Reoortis) 1 Leeviat oas-None Listeo Below s,
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E THE V ENOOR CE RTIFIES that one esemesi nesca.ried anove are in conf ormance wenn tne reoverements of tne Brown & Root Soecie. cat..a
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anc. ae. c... anet of sr.ec.fied cuanty A Ccov os enis comp.etec Conscernance Certificate weh me incawood eviin ene ein of essene enn sn.fiuce.
ev8t" Ine it.*rais) to Erown & Root. Inc at the acceess assennates *n tne procuren ent occuments
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R. M. Klimistas DATE: June 27, FROM:
J. Hawkins
SUBJECT:
CPSES, Job 35-1195 QA/QC Program Audit, CB&I, Salt Lai:e City, Utah Facility A QA/QC program audit was perfonned at subject facility on June 18-19, 1980.
t The results of this very thorough audit of. the entire CB&I system was very satisfactory.
A release inspection of TUSI-procured pipe whip restraints was per-fonaed during this same^ time frame by TUGC0 QA, Dallas personnel, with all inspections satisfactory.
I visually looked at approximately ele'een moment restraints being
"~fiiFn~ished by CB&I on B&R purchase order and they looked equally as satis-factory as the pipe whip restraints.
The audit report will be issued very scon by TUGC0 QA covering this audit.
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TEXAS UTILITIES GENERAT]NG COMPANY aom saumwea.o u.a.mamm QXX-616 July 1, 1980
,3 ;
Mr. Darwin Christofferson
/
-h Superintendent Welding & QA A
/
Yy Chicago Bridge & Iron l,
550 West 17th Street gag Salt Lake City, Utah 84110 COMANCHE PEAK STEAM ELECTRIC STATION QUALITY ASSURANCE AUDIT TCB-1 CHICAGO BRIDGE & IRON G&H SPEC. SS-16B y
QA AUDIT FILE: TCB-1
Dear Mr. Christofferson:
Attached is the TUGC0 QA Audit Report No. TCB-1 describing the results of cur audit of Chicago Bridge & Iron performed ~on June 18-19,1960 by Jim Hawkins (Acting Team Leader), Susan Spencer, and Danny Leigh (Auditor-in-Training).
Attacb ent A to this audit report centains concerns observed during this audi t.
Please address each of these concerns by July 30,19E0.
Thank you for your cccperation during the audit. Should you have questions, please contact Jim Hawkins at 817-897-4881.
Very truly yours, TEXAS UTILITIES GENE?.CIN3 CO.
. 6 Manager, Qu lity Assurance s;:r CNC/AV/SLS: sis r-O V 1P U)bkb5P b-ad Attachrent I@l cc:
R. G. Tolsen L' d J. T. Merritt R. E. Heim H. h. Acck N. N. Keddi.,
E. Zadina J. V. Hawkins Rose K1 hist
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Audit Findings I
Audit Nu. ber TCB..-1 t
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Audit No. TCB-1 Concern No.,1 Numerous shop sketches in checklist packages require MT of Welds A-T, when in fact Chicago Bridge & Iron (CB & I) does not use weld numbers 0 and Q.
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Four deficiencies identified during CB & I's first internal audit of 1979 have fiot been properly closed.
These are finding nur.bered 5.2.1, 6.2.2, 6.2.4, and 6.2.6.
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Audit No. TCE-1 Concern No.
3 The a'uditor qualification file for 5. Leroy Huffaker was reviewed.
It did contain his Certification of Qualification; however, all the required back-up documentation was not available.
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4 The Print Control Record is a master list of drawings and their revisica level s.
However, several drawings listed on Print Control Record FC-2, Revision B, (Centract 82105), have no revision level.
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5 Several weld procedures were reviewed to determine whether : hey had been approved by Brown & Rcot. The BRV letter number was referenced on the procedure; hcwever, the letter itself was not available for review.
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6 Contrary to the attached rem, the assembly drawings are not part of the dottarentation included with each ship ent. This was evidenced by the review of the data package during the June 19, 1950 Release Inscection.
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bTCf.'D([bCCI.!UC. Post Office Box 1001, Glen Rose, Texas 76043 July 3,1980 8.9/-11686 Gulfalloy, Inc.
4730 Darien Street Hcuston, Texas 77052 ATTN: Mr. Phil Glass Mr. G. W. Gross Texas Utilities Services, Inc.
Comanche Peak Steam Electric Station 1981-83 2300 MW Installation B&R QA Audit G303-3 Gentlemen:
This letter is to confim the telecon between Mr. Gross and Mr.
Meissner concerning a Brown 8.Rcot Quality Assurance audit of Gulfalloy, Inc., Houston, Texas facility en Wednesday, July 9,1980.
The purpose of this audit will be to verify compliance with the re-quirements of:
a.
ASME Section III (NCA 3800) b.
ANSI 45.2 c.
Gulfalloy's QA Program d.
Applicable Purchase Orders The audit team will consist"of Mr. Joe Burks (Lead Auditor), tr.
John Maxwell (Auditor) and Mr. Tony Valdez (Observer).
The proposed audit schedule will be as follows:
July 9,1980 8:00 a.m.
Pre-audit Meeting July 9,1980 Audit and Surveillance of Applicable P.O.'s July 9, 1980 Post-audit..eeting
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- e Your cooperatic-during this audit will be appreciated.
If there are any questions re;arding this audit, please contact D. D. Bedding-field a+. 817/897-43E;, Ext. 495.
Sincerely, BROWN & E00T, IllC.
3 3. M.
D. D. Beddingfield Surveillance / Audit Supervisor-DDB/pb
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P. Bulten 9\\s R. Meissner J. Burks J. Maxwell T. Valdez (TUGC0 Dallas)
T. Vega J. Gore Houston QA File 9
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QUALITY ASSURANCE DEPARTMENT
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AUDIT CHECKLIST 35-1195 UNIT 1b2
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, sos no,:
PAGE OF PROJECT:
AUDITED O RG ANIZ ATIOP4:
AU DIT NO.:
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Gulfalloy, Inc. - Houston, TX G303-3 7-9-80 D EP A R TM ENT; CT IVIT Y t Annual Audit AUDIT TE AM:
TEAM LEADER:
J. Maxwell, T. Valdez J. Burks AUDIT CODE S = SATISFACTORY U = UNSATISFACTORY N = NOT AUDITED X = NOT APPLICABLE NO.
CH AR ACTERISTIC & DESCRIPTION
'40 D EI REMARKS l'.
0AM Section 6.0 Verify change of para. 6.1 as per ADR G303-2.2 (color code).
s 2.
Section 2.4 Organizational Chart clearly states QA Mgr. and QA members and their assigned duty?
S 3.
2 ct.i.qn _1.l _ _ _ _ _ _ _ _ _ _ _ __
QA figr. periodically audits material sources at least annually?
s 4.
3.4 Current list of approved procurement sources for materials is maintained by 0A fior.?
S 5.
Section 4 Customer orders are TEvTe5Te'd'hy-QT!~
S 6.
Section 4.9 Reviewed orders are compien'sntscVa-signed QA checklist?
S 7.
Section 5 K Tis'ts75TE materiaT grace r S
8.
S c_t. ion 5 P.O. spec. sheet is part of Receiving Inspection Report?
S 9.
A q.t_ ion 5.8 fio direct shipment made at this time Source inspection requirements are de-termined prior to direct shipments?
per QA Manager X
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[1 to"7 TerTfTes CIIIfto P.O.
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requirements - signs / dates Cf1TR and
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QA file consists of original copy of CliTR and RIR?
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CPSES job No:
35-1195 UNIT 1A2 PAGE
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OF 3 A CTIV IT Y :
AUDIT NO:
D ATES(S)
Gulfallov Annual Audit G303-3 7 o on NO. I CH AR ACTE RisTIC L DESCRIPTION ICODEI REMARKS
- 12. All incoming material is receipt in-Section 6 spected for identity and spec. and P.O. marking requirements?
S 13.
When material is cut, QC verifies Section 6 marking transfer prior to cutting?
S
- 14. Marking is legible and done to re-Section 6 quirements? (contamination, etc.)
S 15.
Material is handled in receiving, Section 7 storing, and shipping as required by QAM Section 7.
S 16.
Written statement on delivery ticket Section 7.3 for specific tests and test reports requi red?
- 17. Nonconforming material is grouped by Section 8 grade, type, size, etc., tagged and stored in N/C material control area?
S 18.
laterial on which traceability has Section 8.1 been lost for any reason, is scrapped?
S 19.
Nonconformance Report is generated on; Section 8.2 all customer rejected material?
S
- 20. Annual internal audits utilize audit Section 9 checklist and covers all aspects of
]A program?
S See attached list of concerns
- 21. Audit is done by personnel not having' Section 9 direct responsibility in area audit-ed?
S
- 22. 't&TE items are serio.ized and a cali-5!ction 10 bration log is kept for each?
...onCM $$d S
- 23. Calibration is done on first Monday Se < g %'jbM" of each month by QA coordinator?
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- 24. Calibration gage blocks, etc., are Section 10 traceable to National Standards?
S See attached list of concerns _
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QUALITY ASSURANCE DEPARTMENT l
AUDIT CHECKLIST l
3 CPSES
- ogno; 35-1195 unit 1&2 pace 3 or PROJECT
AtJDIT NO:
D AT ES(S):
A CTIVIT Y:
Gulfallov - Annual Audit G303-3 7-9-80 N O.
CH AR ACTE RisTIC & DESCRIPTION QCODEl REM ARKS
- 25. NDE personnel are certified to SNT-Section 11 TC-1A? File will have exam scores and re-certification dates?
I' For Sub-Contract NDS ADR G 303-3.1
- 26. Gulfalloy subcontractor NDE proce-Section 11 dures will be on file?
s
- 27. Gulfalloy material certification con-Section 11 tains quality systems cert. number, expiration date & original CliTR?
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- 28. Training session records are on file Section 13 for all employees?
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- 29. Documents are controlled by QA Mgr.?
Section 14 (Code, Addenda, Procedures) s
- 30. 1979 audit concern does NCR log in-G303-2 clude closure date?
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INTEROFFICE MEMO IM-19334 TO:
R. M. Klimist DATE: July 14, 1980 FROM:
T. B. Maxwell SUSJECT: CPSES, Job 35-1195 Source Surveillance / Inspection of Gulfalloy on July 9 & 10,1930 The folicwing purchase orders with items indicated were inspected as per P.O. and SA requirements, deficiencies are noted by P.O. and item numbers.
P.O. 35-1195-30448
.' $ $ A N Item 21-Not authorized for shipment, no CMTR. C Item 12-1. CMTR not signed.
- 2. B&R QA-045 not signed.
- 3. B&R QA-045 did not indicate all P.O. recuirements.
Deficiency 1, 2 and 3 were corrected and material released for sniement.
Item 20-Material supplied had two HT. numcers. N95547a was very poorly marked, authori:ed shipping.
P.O. 35-1195-30418 Item 18-1. CtTR not signed.
- 2. S&R QA-045 not signed.
- 3. CMTR QA-045 did not indicate all P.O. recuirements.
Ceficiency 1, 2 and 3 were corrected, material released.
Item 19-Same as item #13 Item 40-same as item d18 1:em 30-Same as item d13 Item 41-The physical dimensicn cf the fitting and the C4TR v
indicated a different size. This item was not autheri:ed for shipoing.
P.O. 35-1195-30513 Item 2-CMTR and CA-045 were not signec and cid not show all P.O.
recui rements. This was c:rrected and material released.
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Item 10-Authorized shipment Item 15-Authorized shipment
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Item 19-CMTR and QA-045 were not signed. QA-045 form did not indicate UT & PT reports. Corrections made and material released for shipping.
Item 21-Did not authorize shipment.
I" Heat lot number or fitting and CMTR did not correspond.
P.O. 35-1195-30442 Items 38, 39 & 21-CMTR and QA-045 were not signed. Correction made and material released.
Item 19 & 20-CMTR and QA-045 were not signed. CMTR and QA-045 did not show all P.O. recuirements. Correction made -
material released for shipping.
P.O. 35-1195-30449 Items 5, 8, 9, 13, & 6-CMTR and CA-045 were not signed.
CMTR and QA-045 did not indicate all P.O. recuire-ments. Correcticn made, material released for shipping.
In my inspection of this shipment and my last inspection, the number of croblem areas seems to have increased.
This ceuld be because, Sulfalloy nas new personnel in key' areas of re-ceiving, QA Review $ QA Administrative.
- discussed this in generzl with Mr. Phillio Glass, the new QA Coordi-nator. He seemed co.1cerr.ed with Gulfalloy problems and was interested in getting these types of creblems corrected.
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D. 3eddingfield R. Meissner
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JUL E o 1350 35-11 7-22-80 E.L MANN!NO Brown &RootJnc. Post Office Sox 1001, Glen Rose, Texas ;TQOg
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,n R-July 22,1980 BRV-11820 I
Gulfalloy, Inc.
4730 Darien Street Houston,. Texas 77052
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ATTN: Mr. G. W. Gross Texas Utilities Services, Inc.
Comanche peak Steam Electric Station 1981-83 2300 MW Installation Brown & Root QA Audit Report G303-3 And Source Surveillance Inspection Report IM-19334
Dear Mr. Gross:
Attached are the resuits of tne subject audit / surveillance which was conducted at your Houston facility on July 9th and 10th,1980. One (1)
Audit Deficiency Report (G303-3.1) was cresented in draft fom. please complete line Items 17 through 22 of the ADR, respond to the concerns and Source Surveillance Report IM-19334, by August 1,1980.
Gulfalloy will remain as Brown & Root's " approved" sucplier contin-gent uoan satisfactory corrective and preventative action of the discreo.
ancies cited on these reports.
Your attituce and cooperation during the surveillance and annual au-dit were accreciated.
If you should have any questions concerning the reports, please feel free to contact me.
Sincerely, ERC'al & ACGT, INC.
15D. ~LbN&" 'U
- 0. O. Bedcingfield Site Surveillane/ Audit Supervisor DCB/pb
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L. A. Ashley i'
K. M. Brocm D. Frankum R. Bass F0E NOMM CIM
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~ QUALITY ASSURANCE AUDIT REPORT (Organiz: tion:
D Gulfalloy - Houston Audit Numbar:.G 303-3
, Date of Audit: 'j-9/10-80 C-y Su;;
'so Audst Tesn P.Sornbor(s)
J. Pa vvoll Mr I
.. Beddinofleid,
T Valdo, _ Oheorver Audit Tca.n Leader:
J: Burks J. /Ada
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CONTENTS SECTION 1 Exnm ary...
SECTION 2 Pre-mdit Meeting Attendance..
SECTION 3 Postchdit f.kcting Attendance......
SECTION 4
. Audit Deficiency Reports....
SECTION 5
. List of Concoms _....
Canes. N o.
O A 644 2
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m 7-18-80 BrownCTRoot.inc.
BROWN & ROOT CPSES ASME AUDIT GULFALLOY INC., HOUSTON AUDIT
SUMMARY
The annual audit of Gul.falloy facility, Houston was conducted on July 9 &
10,1980.
AUDIT PURPOSE:
This annual Vendor Audit was conducted as an ASME requirement to verify that Gulfalloy's QA Program was being implemented as required by contract-ual agreement.
AUDIT SCOPE:
The scope of this audit is the Quality Assurance Requirements delineated in:
- 1. ASME Section III, Division 1 NCA 3800
- 2. Gulfalloy.QA Manual,
- 3. Brown & Root contract & purchase orders
- 4. ANSI N45.2 itiemd!L was cunduci.t:d 'uy F.c. J. Burks ( Team Leader) J. Maxwell ( Auditor) and T. Valdez ( Observer). ;
The pre-audit & post audit meeting information is on the attached audit meeting attendance sheets. '
AUDIT RESULTS:
The audit team deeply appreciates the cooperation & courtesy extended by each individual member of the Gulfalloy QA Department.
Only one deficiency was cited and these results were discussed at the post-audit meeting. Mr. P. Glass, assistant QA Manager, was presented with a draf t copy of the resultant audit checklist and the ADR ( #G303-3.1).
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While the overall QA program implementation looked good, one ADR was writ-ten & four. concerns were noted.
It is suggested that these concerns be considered as deficiencies to be corrected, and upon completion, please report the corrective action taken.
O s*
9 J. Burks Team Leader 0
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FOR INF0F;MA!!DN ONLY
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OCi QUALITY ASSURANCE DEPARTMENT AUDIT MEETING ATTENDANCE SHEET 8
E Pre-audit O Post audit 7 / f / /S l TIME: 8,W AA FjYI'*F r.1EETarJG:
oATE:
NAME ORG ANIZATION TITLE b
V h e:, w a er/ i s'.
Gm,n/ A,,a,v - dw,x.y 1.2-%td ~7%wd/
Sk... n /n, f P4, r as.&
,,_--;-r B h w d l $ 7"
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0 5'
kfd bihberYNab kor#Y 4.
5.
e.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
( To be Compteted Following Post audit Meeting)
STATEMENT OF A REEMENT Draft copies of deficiency reports were presented to tne audited organization. -Deficiencies stated within each report'were discussed at tne post audit meeting. and based upon current information it was the opinion of those in attendance that the reports were accurate. Accordingly,it has been agreed that a written response to each deficiency will be submitted to Brown & Root Quality Assurance no later than days after receipt of a formal written audit report.
Signed B< oVAUTY ASSUR ANCE Signed l
WVo8 TED O 4G ANI.* A riCN n s. r e.:. n
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%d.s W QUALITY ASSURANCE DEPARTMENT AUDIT MEETING ATTENDANCE SHEET TYPE oF MEETING:
j D AT E:
TIME:
O Pre sudit Ltf Post. audit 7 // O / [6 3I30 M
.NAME ORGANIZATION TITLE h ! ~ N 2. L L' //, /&&
$b oN k.M45 n~n/WRn 1.
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7.
8.
9.
10.
11.
12.
13.
14.,
15.
16.
17.
18.
19.
20.
( To be Completed Following Post. audit Meeting)
STATEMENT OF AGREEMENT Draft copies of
[
deficiency report (were prJsented to the audited organization. Deficiencies stated within each report were discussed at the post audit meeting, and based upon current information it w:s the opinion of those in attendance that the reports were accurate. Accordingly,it has been agreed that a written response to each deficiency will be submitted to Brown & Root Quality Assurance no later than A6 days after receipt of a formal written audit report.
Signed 64E B&R CU ALITY ASSURANCE g
Signed AUCI T E 0 0r4G AM c A flO.4
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QUALITY ASSURANCE DEPARTMENT AUDIT DEFICIENCY REPORT PROJECT:
JO B N O.:
UNIT:
PAGE:
OF (Il AWOt?EO Om4 Ants A7 tem (3) AWOt? MO (3l AOm me tal Aom COOC
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7
/10 / 80 ICin Oisi Oin' (88 Decuassm? vrebATED Ano PAmAsmarm (C17Els Gulfalloy Q/A Manual para. 11.2 Personnel records will be =aintained for all NDE Personnel, Delineating their Qualifications Level in accordance.with. SNT-TC-1A, their Exa=inations, Scores, &
Racertification dates, p
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Gulafalley P.O. # 22-27-15571 & -15572 for Gibbs & Hill had =aterial with U.T.
at Southwest Labs, Inc., Houston. The U.T. Report was signed by D. Childers ASNT W
Level III.
y Ccatrary to above Gulfalley Q/A Manual require =ents, no docu=entary evidence g
cocid be produced by Culfalley Q/A Dept. to confir= Mr. Ch11dres was a certified Inspector. ( Exa=s. Scores, & Re-Certification Date) t e lp PO T E N TI A4. m spo mT AS bs e stscas mCT C vss O ma 6938 msCOnsess= GAT 4emGs 1.
Acquire Required docu=entation 2.
If docu=entation can not be produced take appropriata =eadures regarding
=aterial involved.
in st mesponse Assiento vo:
p.. m E,s,mo n s a o w s pesi A movsa evi piioArt c~
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To be completec by audirec crganization t a ts co mm EcTtv s AcTiose asseomes.asackwas scmsow6so comensvion oavsa 18 89 SW Shs ITT ED S V i
,(191 OATE, f
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LSSI Pm E w Em ? A fiw 8 ACTIQ 4: simC hados SCME DWbs0 CQas %sTIQm O A TE3 (3 0 0 Su SeetTT ED e v t t aal G A T E.
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To be comotered by B&R Cudity Aswrance 18 38 m EVIEW O F N ESPo n ts.
,tagg Ga f E G krisfacters C unutisfxterv l Y m 1 W ' W 1571,W G Miti
/ /
ines mEsui.rs or v Emersc Afion.
[ tars vsvarisO.e ws s talg ;J 8(J s1 Vish.qtasecart C krisfactors C Unwtisfactcr/
l t
/ /
ta tt m a ne a m u s.
4 386 GbO S ED S T tatsDATE 4 A.e A a
1 i
s I
_ Ccacerns:
Ref: ADR G 303-3 1.
Texas Indicator, Calibration Facility, has confusing and inconsistant l
calibration & re calibration dates on documentation and calibration stickers.
2.. Internal Audit checklist does not cover all aspects of Q/A Progras in that it does not address training or M & TE Control.
3.
Inter =al Audit checklist has e.rror at 3-b.
The reference to section 6 of QA Manual should be Sec. 7 - for Handling & Storage.
4.
Q/A Manual is not specific as to where.sub-contract NDE files are to be r.aintained i.e.,
at Gulfalley or at sub-contractor facilict:
it implies Gulfalley.
l I
IBR k,eBegna BM l
l
\\
k
Audit 7/22-23/80 CONCERNS A310-10 QA Audit Checklist Item:
5.
Indeteminate: No documentation was available with ANI signature to verify witnessing the operations during the actual testing and "N" stamping of the components as per C.B.&I. QAM Div. 3, Para. 2.3.3.
NOTE: The shop release for shipment checklist (Fonn No. G0-681) is signed by the ANI stating all code contract requirements and code requirements have been met.
6.
Ko objective evidence to confinn audits conducted by ANI since Oc-tober, 1979.
NOTE: Correspondence is on file frem district ANI stating a semi-annual audit would be conducted in February,1980 - no record of the audit having been performed.
- 26. Welder Symbols - PN is certified to weld 1-G position only (flat).
NOTE: On assembly 34-A welding identification symbols CC, AD and PN welded on this assembly which encompassed flat, vertical and horizontal positions. No objective evidence to verify or identify which welds were made by each welder.
33.
Records are filed and maintained as required; however, numerous records cannot be authenticated as permanent records as described in ANSI N45.2.9, para. 3.2.1, line 12, etc. Many original records are not accepta-ble, having entries written in lead pencil.
F O R li W 0 PiiA.E l M K i Akw.d
[J,jJohn T' B. Maxwell FO!A-85-59 Y
o{l2 t
'\\
Y July 28, 1980 AUDIT NO.
G303-3 AREA'S OF CONCERN 1.
Texas Indicator, Calibration Facility has confusing and inconsistant calibration and re-calibration dates on documentation and calibration stickers.
(1)
REPLY:
The calibration in question is on Gauge Block Set S/N 773647 and was a typo-graphical error which has now been correct-ed.
2.
Internal audit checklist does not cover all aspects of Q/A Program in that it does not address training or M & TE Control.
(2)
REPLY:
Training is covered in Q/A Manual, Section 13 and M & TE Control is covered in Section 5.
On the next revision, the inter-nal audit checklist will be revised to in-clude the training and M & TE Contrcl.
3.
Internal audit checklist has error at 3-b.
The re-ference to Section 6 of the Q/A Manual should be Section 7 for Handling & Storage.
(3)
REPLY:
This will be corrected on the next
~
revision of the manual.
4.
Q/A Manual is not specific as to where cub-contractor NDE files are to be maintained i.e.,
at Gulfalloy or at sub-contractor facility; it implies Gulfalloy.
(4)
REPLY:
This will be corrected on the next revision of the manual.
The NDE files will be maintained by the sub-contractor, with the exception of the Level III designate.
Sincerely, f
GULFALLOY, OC.
Sc.W
.r cL./
l G. W. " Bill'I Gross l 03 7...,f'i.!n, firs +! M,.9 c.
.s :..
i Manager of Quality Assurance g,
4730 Danen Street
- P. O. Dos 52.518
- Houseon. Texas 77052
- Telephone (713) 672 7451 WAT5 Ec.2.313262. TWX 910 8a1 11ts e
EiiiA
]
July 28, 1980
?
Brown and Root, Inc.
P. O. Box 1001 Glen Rose, Texas 76043 Attention: Mr. D. D. Beddingfield Site Surveillance / Audit Supervisor Subj ect :
Brown and Root QA Audit Report G303-3 Source Surveillance Inspection Report IM-19334
Dear Sir:
Attached are the results of the audit and surveillance which was conducted at our facility on July 9th, and July 10th.
1980 and Gulfalloy's response.
Gulfalloy is always happy to have audits and surveillance at our facility.
As you are aware the audit was on such short notice that it was impossible for me to be in town.
Mr. Glass had just been promoted to QA Coordinator and this s'
\\
was his first audit.
The attitude and cooperation of Brown and Root's audit team and surveillance was very much appre-i ciated.
If you should have any questions concerning my re-i spense, please contact me at 800/231-3262.
j'",] N 3 g, c.,~
rp Sincerely, GULF LLOY, INC.
G W
'Bi oss Manager Quality Assurance C!Q h h h I
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4730 Danen Street P O Bos $2518 + Houseon, Texas 77052
- Telephone (7U) 672-7451 I
WATS 8041313262. TWX 9148al.11ts
'@g Brown & Root,Inc. "'" "' "
14874 QUALITY ASSURANCE ARMS RECEIVING INSPECTION REPORT
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_m Brown &RootJnca T'
QUALITY ASSURANCE DEPARTMENT CONFORMANCE CERTIFICATE PROJECT: COMMANCHE PEAK Jos No.: CR0422 UNIT.
I PAGE l
OF l
e la VL NDOR 121 ADD RE SS OF V E ** DO R F ACILIT Y GULFALLOY, INC.
4730-DARIEN STREET HOUSTON, TEXAS IJi Pust CH ASE ORDE R NO las SeE CIFICA T.ON NO
[REV.
($) O R AWI NG NO.
p= t V l
1 35-1195-30418 i ASME SA105 lN/A N/A N/A teil IT EM OE SC RIPTIONESI 173NO.OF ITEMS 4(S) NO. R E LL ASE O I
I SEE BELOW SEE BELOW
, SEE BELOW (9) COMPLET E hNO YES (103 S E RI A L QH IDEN TI F IC ATION NO LSI.
ITEM 18:
12-6 x 3/4 3000# SOCK 0LET (15 ea.)
HT#P970 l TEM 19:
5-4 x 1 3000# SOCK 0LET (20 ea.)
HT#P973 ITEM 40:
5-3 x 3/4 3000# SOCK 0LET (100 ea.)
HT#P960 ITEMilll M-3 X /
Mo** m K W L & &ed MM Resoetas checked (
) below are besPg transmitted wetm this Certificate es reprol by she Brown & Root Occument Gats Sheet.
h Materies Certifications Operating Elec. T est R scords Visual Inspection R ecords c*
Heat Treet Records Non Operating Elec. Test R ecotus Oimensional I nspec t. R ec or ds f2 RT Film & Records Pressure Test Records Cleanliness Records h{
PT/MT Recoros Saat Teghtness Test R ecords Painting Records UT Records Performance Test R ecords Packaging Records hh Approved Stress Report W eed Personnel Owel C erts.
Space Parts List
- j Approved Design Annivses N D E P er sonnel Owal. Certs Special Handling Instruc.
Nameplate F actermde Operating Manweis Code Data Report (s)
Deviations.
None Listed B elow v
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THE VENDOR CE RTIFIES that the itemise c escrioeo soove are in contormance with tne recworements of tne Brown & Root Sper c a tien
-3 with the approved oeviations hated soove. ses esitaoie 'or the purpose intendeJ. are free f rom detects en design, workmansMio and m a e iais j4 ancs are new ania of specified quality. A cops of th.s completed Conf ormance Cer;ificate wit 8 De included with the bdl of lading sna s%pwas Z;
witn the stemit! to Br1wn & Root. Inc et the esdress designated in the procurement documents V ENDOR A
~ i E D SIG P A U RE.
[ TIT LE:
jogyg-
!0.A. COORDINATOR 7 [# b l
N O
_ e The Veh oe h e -[c e r t i f ieJinat the siems auc.e meet ait contractuai recuirements Brown & R oot h as reviewed evidence sucpor ting tr is 2
Cen tincat e aart e. cept as noten unene. "R e a s s" anove, has venhed con f ormance to r eawnements This Ceetificate does not waive aav r.am s j
Prown & Root may have undee the Paecnase C.ier inc aucing the r *gh t to
- etec t the item 6 sl woo n c escover y o f dehciencies du ing or site s e...e r
as etestination g P
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Taylo'r-Bonney Division Lo9 No. 315-7 p, g,'
1 of 1 Energy Proc'ucts G.oup GULF - WESTS.PN MANUFACWqlNG COMPANY g
CUSTOMER: GULFALLOY Date JUNE 9, 1980 CUSTOMER'S Order No.: 22 17202 Bonney Order No. 85088 SHIPPED TO: GULFALLOY Mark 4730 DARIEN HOUSTON TX 77052 g poaja 9 4 gf
- 90735-//93-SoV/J
( OW 29 -DS/SWf I
MeM ecmcation No.
~
1: :t Quanuty Bonney N 2.
No.
Lot No.
Chem > cat an.iysis. Physical Procerties, Remaras:
I SA105 I
t Soc)<b.eti.22[
12 -
X 3/ 3000 1
15
{P970 C.28 Mn.82
.008 S.022
/
ITEM!18 j
1 T/S 80,555 Y/S 49,242 El 32 Ra 59.5V e
l20
! P973
/
0#fckole 5-4X13 2
T/S86,294[Y/S52,030[El28Ra56 C.28 Mn.82
.008 S.022 Si.22 ITEM; 19 3 /X 3/4 3000 Socko et 3
100 3960 5
j C.28 Mn.82
.00S S.022 i.22 ITEM 40 l
T/S 80,303 Y/S 47,980 El 32 Ra 61 1
4
!,14 P469 3 1/3 - 3 X 1 3000# Sockolet ITEM'.41 C.32 Mn.79 P.009 S.022 51.21 l
T/S 86,097 Y/S 52,296 El 28 Ra 55.5 4
6 P943 E
3 1/2 - 3 X 4. 30f# Sec'.olet f
79,591./S50,386El32[Ra64.5 C. 2 7 Mn. 94
006 S.021 $1.23 ITEMj41 7
T/S This is to certify,that:
l Tlie fittings sulpplied are in ecmplete accordance with the ASME Boiler and
~
1.
Pressure vessel Code,Section III, Class 2, 1974 Edition thrit Sumner 1974 Addelida, SA105, and the purchase order.
l l
2 The material included on this test report was nanufactured under ASME Quality Systems Certificate (Materials) No. N-22S6-1, expires March 30, 1952.
I I
i we cemtv tea: tne cata en :.s s. ee: s a r.e :::v tam trw cur recor:s :#.ma:e e. urnisnec us :v - e :. couren r,in. er as c:.a.ce::= nemerai.a:.: a : v :.en:
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- Z BROWN.& ROOT, INC.
ISSUE CPSES NUMBER REVISION DATE PAGE JOB 35-1195 Chr5 N hr"'
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QG A.L AShtf / k.a &,
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Problems encountered.
(hh 6.
Identification of components inspected by unique nanufac-tuer's number.
4.4 SPECIAL ACTIVITIES This section of the Vendor Surveillance Plan is used to document activities not included in the basic surveillance plan, such as:
witness of qualification testing, verification of effective implementation of the vendor's corrective action to an ADR, qualification survey finding or nonconfomance report.
4.5 FINAL SURVEILLANCE 4.5.1 Perfomance When required by the Vendor Surveillance Plan or as detemined by the SQAM/SSAS, a Final Surveillance shall be perfomed before shipment of the material / item to verify adequacy of shipment preparation. The Surveillance Team shall review the required documentation, (i.e., Material Test Reports, NDE Reports, radio-graphs, etc.) at the vendor facility to assure acceptability and compliance wi+.h the purchase order or subcontract and cited codes and standards.
The Quality Assurance Confomance Certificate shall be signed by the Surveillance Team Leader as authorization to proceed with shipment.
4.5.2 Documentation The Surveillance Team shall document final inspections in a Vendor Surveillance Report.
to cona da '
ZA' to - z :-
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, ' 4. 6 NONCONFORMANCES FOUND DURING SURVEILLANCE Any deviation or discrepancies identified by the Surveillance Tean during a source surveillance shall be reported and processed in accordance with CP-QAP-16.1.
4.7 HOLD, SURVEILLANCE AND WITNESS P0INTS The vendor shall notify B&R Quality Assurance of a pending sur-veillance or hold point. The SSAS shall assure that the surveil-lance hold point is either perfomed, or waived.
.g QQ&&00 0N
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.