ML20148C086
| ML20148C086 | |
| Person / Time | |
|---|---|
| Issue date: | 09/06/1978 |
| From: | Hunnicutt D, Oller R NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML20148C045 | List: |
| References | |
| REF-QA-99900028 NUDOCS 7811010094 | |
| Download: ML20148C086 (10) | |
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l VENDOR INSPECTION REPORT U. S. NUCLEAR REGULATORY COMMISSION 0FFICE OF INSPECTION AND ENFORCEMENT REGION IV 3
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Report No.
99900028/78-02 Program No.
44020 i
Company:
Tube Turns Division of Chemetron-Corporation 2900 W. Broadway Louisville, Kentucky 40201 Inspection Conducted: August 22-25, 1978
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val-aM' 7 [77 InspectorhR.E.01ler,.ContractorInspector, Components j
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Section II, Vendor Inspection Branch e i
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.J Approved by:
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'Date-D. M. Hunnicutt, Chief, Components Section -II i
Vendor Inspection Branch i
L Summary Inspection on August 22-25, 1978 (99900028/78-02)
Areas In'spected:
Implementation of 10 CFR 50,. Appendix B criteria, and applicable codes; including general review of vendor activities, equipment l
calibration, tests of completed products, procurement control consisting of document control-source selection. and supplier performance, and action on previous inspection findings.
The inspection involved twenty-six (26) inspector-hours on site.
Results:
In the five -(5) areas inspected, no deviations were identified in four (4) areas.- The following were identified in the remaining ~ area.
Deviations:
Equipment Calibration:
Calibration requirement pertaining to serial numbers, calibration stickers and subcontra'ctor's' certification, were not implemented ~for five (5) measuring and/or testing devices in accordance with Criterion XII.
No~ measures were in effect to provide for control and calibration of flow meters for weld shielding gases in'accordance with
'7811010o95
Criterion XII. A procedure requiring assignment of a unique serial number to each piece of equipment under the calibration program, was not followed with regard to a Dead Weight Tester and an ammeter in accordance with Criterion V.
Unresolved Items:
None.
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DETAILS SECTION (Prepared by R. E. 011er)
A.
Persons Contacted R. Barrett, Maintenance Superintendent R. Bachting, Master Inspector F. Crawford, Purchasing Director J. Evans, Senior Inspector E. Forrester, Electrical Maintenance Foreman
- H. George, Vice President of Engineering
- J. Seay, Quality Control Manager L. Settle, Inspection Superintendent J. Spears, Senior Inspector J. Thomas, Inspection Foreman
- W. Trent, Chief Metallurgist
- S. Vitatoe, Specifications Supervisor t
- M. Wakefield, QA Consultant
- Attended the Exit Meeting.
B.
Action on Previous Inspection Findings 1.
(Closed) Deviation (Report No. 78-01):
Failure to provide a l
formalized frequency schedule to control. inspections of eleven (11) l overhead cranes used in handling of bellows penetration assemblies and parts.
The inspector found that documented inspection frequency schedules for overhead. cranes in each department have been developed and implemented.
2.
(Closed) Deviation (Report No. 78-01):
Failure to use the required
-" Corrective Action Request" forms for resolving major and repetitive The inspector found a new " Request for Corrective Action" errors.
form is now in use for resolving major and repetitive errors.
Previously used interoffice memorandums are no longer being used for this purpose.
C.
General Review of Vendor's Activities 1.
Obj ective The objective of this crea of the inspection was to assess the l
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_4 vendor's activities and their impact on future NRC inspections and identify the components supplied for nuclear facilties.
2.
Method of Accomplishment The preceding objective war, accomplished by:
a.
Discussions with cognizant personnel.
b.
Review of an ASME letter extending the prior N type symbol authorizations until August 31, 1978, pending the committee review of the ASME survey, 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, purchasing of materials - parts - service to evaluate the vendor's effec-i tiveness in controlling the quality of the product.
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3.
Findings Within this area of the inspection, no deviations or unresolved i
items were identified.
D.
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 requirements:
a.
A written system has been established to assure that equip-ment calibration is performed and controlled in accordance with applicable codes.
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.
i c.
The devices are identified in the documented system and/or procedure and are calibrated in accordance with the system or procedure.
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The calibration is performed against certified measurement standards which have know relationship to National Standards, where such standards exist.
e.
The control measures include provisions for test equipment identification and calibration status by marking, or on records traceable to the equipment.
2.
Method of Accomplishment The preceding objectives were accomplished by:
4 a.
Review of the QA Manual procedure TT-22-326, Revision 1,
" Calibration of Measuring and Test Equipment," to verify that controls for calibration are documented.
b.
Review of the following procedures to verify that approved written instructions are available to provide for the control, i
calibration, and documentation of measuring, testing, and inspection devices at specified periods or use intervals.
(1)
Procedure TT-25-001, Revision 9, " Instrument Control."
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(2)
Procedure TT-17-005, Revision 9, " Gage Crib Instructions."
(3)
Procedure TT-17-048, Revision 0, " Calibration Recall
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Sy stem. "
c.
Examination of the following measuring and testing devices to verify that they were controlled, calibrated, and identified as required by the ASME Code and the QA Program.
(1) Mechanical measuring devices such as protractors, calipers, micrometers, and Pi tapes.
(2) Working and Master hydrostatic test pressure gages.
j (3) Ammeters, voltmeters, and weld shielding gas flow meters, on manual and automatic welding machines.
(4) Temperature controllers and chart recorders on heat treatment furnaces.
(5) Spare thermocouples for furnaces.
l (6) Working Optical Pyrometers and the Master Reference Optical Pyrometer.
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Dead Weight Testers.
(8) Rockwell Hardness Testers.
(9) Tensile Tester and the Baldwin Universal Testing Station equipment.
(10)
Impact Tester.
(11) Gage Blocks Reference Standards d.
Review of the Tube Turn's calibration record cards, In-strument Calibration Log Sheets, Calibration Schedules, and Master File Addition Sheets for the above devices. Also, outside sources' certificates of calibration for those devices not calibrated ~ internally by Tube Turns, to verify that Tube Turns implements and maintains a documented calibration, identification, and recall system for measuring and testing devices, and that calibration standards have known treaceability i
to National Standards, were such standards exist.
i e.
Discussions with cognizant personnel.
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Findings a.
Deviations
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See Enclosure, Items A, B, and C.
l b.
Unresolved Items f
None.
E.
Testing of Completed Products 1.
Objectives The objectives of this area of the inspection were to verify that the following items were controlled in accordance with the ap-plicable NRC and ASME Code requirements, a.
A written system has been established to assure that final pressure tests are controlled in accordance with applicable procedures and process control documents.
b.
Final pressure tests are performed in accordance with approved t
procedures, instructions, and process control documents.
. c.
The results of tests are documented and reviewed for acceptability.
d.
The test equipment is calibrated where required.
e.
The tests are performed by qualified personnel.
2.
Method of Accomplishment The preceding ebjectives were accomplished by:
a.
Review of the QA Manaul procedure TT-22-325, Revision 1,
" Nondestructive Examination," to verify that adequate controls for final testing of bellows penetration assemblies are doc-umente'd.
b.
Review of approved procedure TT-08-025, Revision 0, " Hydrostatic Testing of Bellows Expansion Joints," to verify that this procedure (used for the following observed hydrostatic test of a bellows penetration) prescribed a system for this test which was consistent with the commitments of the QA Program.
c.
Observation of a demonstration hydrostatic test of a bellows assembly for Manufacturing Order, Order-Item No. 071932-002, Part SN56921, and review of the controlling Manufacturing Order (traveler) and the " Pressure Test Report" fonn to be completed on fornial final testing, to verify that test activ,,
ities were controlled as required.
.d.
Observation of the calibration status of the pressure gages used for the above test, to verify that the gages were calibrated.
I e.
Review of the completed Manufacturing Orders (travelers) and I
Pressure Test Reports for items on Tube Turns Order 73331, Item 4, and Tube Turns Order 72331, Item 5, to verify that l
the traveler entries were properly completed by Tube Turns and the Authorized Nuclear Inspector, and that the test reports were properly completed and signed.
3.
Findings l
Within this area of the inspection, no deviations or unresolved j
l items were identified.
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F.
Procurement Control 1.
Objectives
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i 8-r 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 all applicable aspects of procurement are controlled.-
i b.
Procedures have been prepared and approved by the company to prescribe systems for the following activities which are consistent with the cannitments of the QA' Program.
(1) ' Procurement Document. Control.
(2)
Procurement Source Selection, Bid Evaluation and Contract-Award.
(3)
Evaluation of Supplier Performance.
c.
The above procedures are being properly and effectively i
implemented by the company.
2.
Method of Accomplishment The preceding objectives were accomplished by:
a.
Review of the following QA Manual procedures to verify that provisions for procurement control are documented:
(1) TT-22-323, Revision 1, " Procurement Control."
(2) TT-22-328, Revision 1, " Audits."
(3)
TT-22-327, Revision 1, "Nonconformance and Corrective Action."
6.
Review of the following material purchase orders, the related purchase order requisitions and material specifications to verify that the QA Program requirements were included in developing these procurement. documents.
(1)
P. O. No. 23435, dated November 1, 1977, Requision No. 69956, and specification No. 70195-CS-17-109, Revision 0.
(2)
P. O. No. 26667, dated July 12, 1977, Requisition No. 749555, and specification CS-P-111, Revision 1.
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P. O. No. 25951, dated May 11, 1978, and Requisition 9
No. 71898.
(4)
'P. O. No. 26990, dated August 2,1978, and Requisition No. 75347.
c.
Review of four (4) Interplant Transfers for materials to verify that the method for procuring materials from other Tube Turns Division plants was consistent with the QA Manual provisions.
d.
Review of reports of material vendor surveys including three (3) Mannesmann Plants to verify that source selection activ-ities,were in accordance with the ASME Code, NCA-3800 require-ments.
e Review of six (6) raw material receiving inspection reports dealing with rejected materials to verify that Inspection, Engineering, and QC participated in this aspect of evaluation i
of suppliers' performance.
f.
Review of internal memorandums dealing with vendor's pe"'rm-ance ratings based on receiving inspection reports having l
nonconformances, to verify that this activitiy was performed as verbally described by the Tube Turns representative.
g.
Discussions with cognizant personnel.
3.
Findings l
l Within this area of the inspection, no deviations or unresolved items were identified.
G.
Exit Interview 1.
The inspector met with management representatives denoted in paragraph A, at the conclusion of the inspection on August 25, 1978.
2.
The following subjects were discussed:
a.
Statuc of corrective action for previous inspection findings.
b.
Failure to implement calibration requirements pertaining to proper serial numbers, calibration stickers, and subcontractor's certifications were required for five (5) measuring and/or testing devices.
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10-Failure to provide and implement measures t6 calibrate the c.
weld shielding gases flow meters.
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Failure to follow procedure requirements to provide a unique d.
serial number for a Dead Weight Tester and an ameter.
The manufacturer's representatives were asked to formulate their 3.
corrective action response to deviations in accordance with the three (3) conditions identified in the inspection report cover letter.
Management's coments were generally related to clarification of 4.
the findings.
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