U. S. NUCLEAR REGUI.ATORY C0mlISSIONOFFICE OF INSPECTION AND ENFORCEMENT

REGION IV

Report No. 99900314/79-02 Program No. 51300

Company: Colt IndustriesTrent Tube Division of Crucible, Inc.141 Hammond St.Carrollton, Georgia 30117

Inspection Conducted: August 27-31, 1979

Inspector: U 8/'5 d'f/R. E. Oller, Contractor Inspector DeteComponents Section IIVendor Inspection Branch

Approved by: I 8' 8e

D. M. Hunnicutt,' Chief DateComponents Section IIVendor Inspection Branch

Summary

Inspection on August 27-31, 1979 (99900314/79-02)

Areas Inspected: Implementation of 10 CFR 50, Appendix B criteria and otherapplicable requirements including: action on previous inspection findings, reviewof vendor activities, nonconformances and corrective action, and equirmentcalibration. The inspection involved twenty-five (25) inspector-hours on site.

Results: In the four (4) areas inspected no deviations were identified in two

(2) areas. The following were identified in the remaining areas.

Deviations: Nonconformances and Corrective Action: Failure to maintain aRejection (rework) Tag with four (4) nonconforming stainless steel pipes.(See Notice of Deviations, Item A)

Equipment Calibration: (1) Failure to calibrate voltmeters on automatic girthwelding machine No. 718. (2) Failure to use heat treatment furnaces which weretemperature surveyed. (See Notice of Deviation, Items B, and C)

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Unresolved Item: Action on Previous Inspection Findings: The QA Manual hasnot been revised to include specific details regarding the exclusion ofprocedura and revision numbers on Mill Order travelers.for operations such as:forming, pickling and passivating, planishing and degreasing. Trent Tubewill revise the QA Manual by January 1, 1980, to clarify the above condition.(See Details Section, paragraph B.I.)

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DETAILS SECTION

A. Persons Contacted

P. Broughton, Welding OperatorH. Cook, Welding OperatorT. Cowart, Production Foreman

*C. Enos, An'_horized Nuclear Inspector, HSB I&I Co.W. Hill, Quality Projectr SupervisorM. Newsom, Records Coordinatcr

*L. Powell, Plant Manager*J. Wehrle, QA Manager-

* Attended the exit meeting.

'B . Action on Previous Inspection Findings

1. (0 pen) Unresolved Item (Report No. 79-01): Failure to clearly showin the QA Manual, that the procedure and revision numbers do nothave to be shown on the Hill Order travelers for operations such asforming, pickling, passivating, planishing and degreasing.

The inspector found that the QA Manual has not been revised to providethe needed clarification. Trent Tube management will revise theQA Manual and present it to the Authorized Inspection Agency and theASME for acceptance by January 1,1980. This item remains unresolved.

2. (Closed) Unresolved Item (Report No. 79-01): Failure to show thelaboratory test numbers for tensile and bend tests on the weldingprocedure qualification records (PQR) No. TWP-1-Q5 and No. TWP-1-Q8for welding procedure specification (WPS) No. TWP-1B. The inspectorwas notified by Trent Tube letter dated April 11, 1979, with attachedrevised PQRs No. TWP-1-Q5 and No. TWP-1-Q8, that the missing laboratorynumbers are now on the two (2) PQRs.

3. (Closed) Unresolved Item (Report No. 79-01): Failure to formalizeand implement the startup weld data sheets for use with weldingprocedure specifications.

The inspector was notified by Trent Tube letter dated April 11, 1979,with attached startup weld data sheets that a copy of these welddata sheets are now formalized and a copy is in use at the weldingmills.

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C. Review of Vendor's Activities

1. Objective

The objective of this ar(a of the inspection was to assess the vendor'sactivities and their impact on future NRC inspections.

2. Method of Accomplishment

The preceding objective was accomplished by:

Discussions with cognizant personnel with regard to currenta.work loads.

b. Review of the ASME N-type symbol and Quality Systems Certificate(Materials) authorizations to verify that they are valid andidentified the products.

Discussions with the QA Manager with regard to actions by Trentc.

Tube to assure that double welded A-312 and SA-312, ASME CodeClass 1, 2 and 3 austenitic stainless steel pipe, is free oflack of weld are penetration through the pipe wall, prior toits shipment.

d. Observations in the shop of double welded pipe, and sampling -examination and flattening teits, to assure freedom from lackof penetration.

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e. Review of records of welding.

f. Observation of the etched weld cross section ends of numerousA-312, T-304 double welded pipes in the stock storage area.

3. Findings

a. Deviations from Commitments

None.

b. Unresolved Items

None.

c. Other Findings

(1) Trent Tube holds a valid ASME Authorization to use theNPT symbol for Class 1, 2 & 3 piping subassemblies and

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tubular products, welded with filler metal. This author-'

ization expires on February 24, 1980. They also hold a validquality system certificate (Materials) as a " Manufacturerof low Allow, stainless steel, high nickel and otherspecialty alloy pipe and tubular products welded withoutfiller metal . . ." This certificate expires on June 6, 1980.

(2) The plant nuclear pipe manufacturing work load (numberof customer orders) shows a slight decline since theprior NRC inspection. (See Report No. 79-01)

(3) Discussions and observations of in process welding ofA-312 piping without filler metal on two continuous mills(automatic welding machines), verified that for schedule5, 10 and 40 piping a ring is cutoff at every fifth lengthof pipe (approximately 20 ft.) while on heavier wall pipe,a ring is cut off at every third of pipe. The weld crosssection on these rings are etched, while hot from cutting,and examined for lack of weld are penetration. The ringis then reverse bent to check weld for stretch defects.For SA-312 pipes with a wall thickness range of 0.125-0.500inch and double welded on the batch mill, with the platelength being precut, a v-notch is cut at the end of everythird pipe and while the cut surface is still hot, it isetched and examined for lack of penetration between thebeads.

Further discussion disclosed that visual examination atfinal inspection and contractual code required nondestructiveexamination such as radiographic and ultrasonic examinationsare the other means of assuring that the double weldedlongitudinal welds in SA-312 and A-312 piping are freeof lack of penetration. Review of records of welding showedthe footage amount of scrap was identified, but not the reasonfor being scrapped. The weldability on these cecords wasindicated as good, fair or poor.

Discussion also established that while longitudinal pipewelds required by contract to be radiographed were alsoexamined by fluoroscope immediately after welding, the useof the fluoroscope was limited to pipes with internaldiameters over six (6) inches due to the size of thex-ray unit which is put inside the pipe.

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D. Nonconformances and Corrective Action

1. Objectives

The objectives of this area of the inspection were to ver'fy thatthe following items were controlled in accordance with rpplicableNRC and ASME requirements.

a. A written system has been established to assure that noncon-formances are controlled and corrective action is taken.

b. Documented procedures or instructions are implemented foridentification, documentation, segregation and disposition ofnonconforming materials parts or components, and notificationto affected organizations.

Nonconforming items are reviewed and accepted, rejected,c.repaired or reworked in accordance with documented procedures.

d. Conditions adverse to quality are promptly identified andcorrected.

The causes of significant conditions adverse to quality aree.determined and corrected to preclude repetition.

f. The condition adverse to quality, the cause and the correctiveaction are documented and reported to appropriate levels ofmanagement.

2. Method of Accomplishment

The preceding objectives were accomplished by:

Review of the QA Manual Section 18.0, "Nonconformities anda.

Corrective Action."

b. Observation of facilities in the following indicated plant areasfor segregation of nonconforming items; also examination of theitems therein such as plate, sheet or pipe.

(1) Receiving Inspection Segregation Area.

(2) Hold Racks for Rejected In procesa Pipe in the weldplanishing area, cut-salvage arr_a and the final inspectionarea.

Review of the following "Cause and Corrective Action Reportsc.

(C&CA) No. 035 through No. 103 for the period of Janurary 10,1978, to August 23, 1979, to identify the basis for the problemsinvolving noncor formances.

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d. Review of four (4) Inspection Tally Sheets common to C&CAReports Numbers 039, 042, 048 and 101.

Review of Rejection Tags and related records such as Inspectione.Tallys and Mill Orders (travelers) for five (5) completedcustomer orders.

3. Findings

a. Deviations from Commitments

See Notice of Deviation, Item A.

The four (4) 21 foot long stainless steel pipes observed in areject material rack without an accompanying Rejection Tagand Mill Order, were identified to a Rejection Tag No. 4647,in the production file for Mill Order OC3-01243-9.0, a stockitem available for upgrading for nuclear use. This rejectiontag showed that twelve (12) pipes had been rejected but thequantity twelve (12) had been crossed out and changed toeight (3). The final Inspection Tally sheet dated August 16,1979 for this mill order showed that eight (8) pipes had beenrepaired and accepted by final inspection. The correctiveaction for the above four (4) pipes was completed duringthe inspection by completion of Reject (rework) Tag No. 4969dated August 29, 1979 and placing it with the pipes.

b. Unresolved Items

None.

E. Equipment Calibration

1. Objectives

The objectives of this area of the inspection were to verify thatthe following items were controlled in accordance with applicableNRC and ASME Code Requirements:

a. A written system has been established to assure that equipmentcalibration is performed and controlled in accordance withapplicable codes.

b. A written procedure has been developed and approved whichcontains provisions to assure that tools, instruments andother inspection, measuring and testing equipment and devicesused in activities affecting quality, are of the proper range,type and accuracy, and are calibrated and properly adjustedat specified periods or use intervals.

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The devices are identified in a documented system and/orc.procedure and are calibrated in accordance with the systemand procedure.

d. The calibration is performed against certified measurementstandards which have known relationship to National Standards,where such standards exist,

1he control measures include provisions for test equipmente.identification and calibration status by marking, or onrecords traceable to the equipment.

2. Method of Accomplishment

The preceding objectives were accomplished by:

Review of the QA Manual Section 17.0, " Calibration."a.

b. Review of the Equipment Calibration Log sheet record andcalibration procedures for individual measuring devices,contained in a calibration log book.

Observation of the calibration status of the following typesc.of devices located in the shop.

(1) Heat Treatment Furnaces' Instruments (recorders andcontrollers)

(2) Analytical Balance

(3) Micrometers

(4) Vernier Calipers

(5) Ultrasonic Test Units

(6) RT Penetrameters

(7) Dial Indicators

(8) Hydrostatic Test Pressure Gages

(9) Automatic Welding Machine Voltmeters, Ammeters andFlowmeters.

(10) Optical Pyrometeri611 OL58(11) Surface Pyrometer

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(12) RT Densitometer and Step Tablet Density Film Strip

(13) Thermco Hydrogen Analyzer

(14) Mini Proportioners (for Hydrogen and Argon welding gases.)

(15) Smith Mixers (for Argon and Helium Welding gase mixing.)

d. Review of the Trent Tube calibration record cards and sub-contractor's Certificates of calibration for the above devices.

Review of heat treatment records, i.e., " Operators Report andc.

Furnance Report" and furnace charts for completed pipe onMill Order No. IC5-45150-9 and IC5-41199-8. These mill orderswere for SA-358 Class 1, ASME Code Class 1 and 2, T-304 pipe,respectively.

f. Review of a Leeds and Northrup letter dated August 13, 1979,certifying that during the service visit on April 11, 1979,a calibration check was made to the instruments in the plantwhich were adjusted to original specified accuracies with aL&N Millvolt Potentiometer traceable to the National Bureauof Standards.

g. Discussions with cognizant personnel.

3. Findings

a. Deviations from Commitments

See Notice of Deviations Items B, and C.

b. Unresolved Items

None.

F. Exit Interview

1. The inspector met with management representatives denoted inparagraph A, at the conclusion of the inspection on August 31,1979.

2. The following subjects were discussed:

a. Areas inspected.

b. Status of previously identified unresolved items.

c. Deviations and unresolved items identified during this inspec-tion.

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3. The manufacturer's representatives were asked to formulate theircorrective action response to deviations in accordance with thethree (3) conditions identified in the inspection report coverletter.

4. The manufacturer representative's questions related to clarificationof the above items.

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