CENTER FOR h LTCLEAR WASTE REGULAlORY ANALYSES 19/"r

NONCONFORMANCE REPORT

Project No. 20-01402-571 NCR NO. 2002-08 I

PART 1: DESCRIPTION OF NONCONFORMANCE: One of the Alloy 22 weld qualification specimens CNWRA Drawing 20-01402-571-025 machined by Texas Toolmakers was not machined correctly. A detailed description of the non conformance items is provided below:

1 . All plates: The 1 .OO inch dimension (plate thickness) was not machined. Thickness of machined specimens was left as the nominal plate thickness. 2. Plate S/N 003: The 0.250 inch dimension was not recorded on the dimensional inspection for plate S/N 003. 3. Plate S/N 006: Ther as machined too deep and has nearly penetrated through the weld joint surface.

Initiated by: Darrell S. Dun Date: 7/16/2002

PART 2: PROPOSED DISPOSITION AND CORRECTIVE ACTION 1 -

Disposition: Accept specimens as is.

Basis of Disposition: The missing dimensional inspection for the 0.250 inch dimension on plate S/N 003 (diameter of thermocouple hole) is an oversight during the dimensional inspection of this part. The nominal plate thickness which is slightly greater than 1 .OO inch is acceptable for the weld procedure qualification specimens. Plate S/N 006 was rejected on the basis of the incorrectly machined thermocouple bore. Repair of weld procedure qualification specimen S/N 006 will be performed if needed and all dimensions will be reinspected and documented.

Action to Correct Nonconformance: The three items listed in Part 1 were discussed with staff at Texas Toolmakers (Mike and Casey Ridgway).

Item #1: Plate thickness is not normally not machined for this type of specimen. Corrections to CNWRA Drawing 20-01402-571- 25 are recommended. The 1.00 +I- 0.010 inch dimension for plate thickness should be changed to 1 inch nominal thickness.

Item #2: The 0.250" hole diameter will6.e verified by SwRI staff and documented on dimensional inspection for Plate S/N. 003.

Item #3: No corrective action will be taken at this time. Plate will be tagged indicating out of tolerance dimensions. If weld procedure qualification specimen S/N 006 is used, it will be repaired and re machined. All repair work will be performed at SwRI or a vendor on the SwRI Approved Supplier List and documented.

4- 7!7/zpL.t

Q- Vq/i%w d3l d o d, j ' t % s v h

Proposed by: Darrell S. Dunn Date: 7/16/2002 a. 8#* Target date for completion:3CL8/2002

PART 3: APPROVAL

Element Manager: 7//6j 20-

Director of QA: Comments/Instructions:

Element Manager: 7//6j 20-

Director of QA: , Comments/Instructions:

L mz szp--- J .

CNWRA FORM QAP 9y1

3

CNWRA FORM QAP 9-1

Darrell S. Dunn

Phone: (210) 522-6090 Fax: (210) 522-5184 e-mail: ddunn@swri.org

SWRI-CNWRA

3.00 + 0.03" I

12.00 +/- 06'

3.00" +I, 0.03"

1

Alloy 22 1 Specimen CNWRA Ldwing 20-01402-571-25 All Dimensions t 0.01 0" unless otherwise specified Note: Detail A on Page 2

Page 1 of 2

6.00" +I- 0.03"

0 m

2 T i

Detail A n

Matenar:

Specimen Orientation: Heat: 2 2 7 3 - {-31&q

Other:

0.128" +/- 7 0.002"d ia

0.128 +I- 0.002"dia 7

01

I I I

I I I I I I I I

I I I I

5

b

%

t .oo

a 0.250" dia

4--

I

J/ta/zQL

wfoz

Initiated by. D. Dunn Date

bate

JL 18m QA Approval B. Mabrito Date

Bruce Mabrito

From: Sent: To: Subject:

Darrell Dunn [ddunn@cnwra.swri.edu] Monday, March 24,2003 11 :05 AM Bruce Mabrito; ’mark ehnstrom’ Repaired weld specimen

The repaired weld specimen which was the subject of NCR 2002-08 will not be used to qualify a welding procedure. The plate will be used as a practice piece for a fabrication shop to weld Alloy 22 with the current waste package weld joint design. The welded specimen will not be used for testing. The quality of the weld will be evaluated using radiographic testing (RT).

Darrell S. Dunn Center for Nuclear Waste Regulatory Analyses Southwest Research Institute 6220 Culebra Road San Antonio, TX 78238-5166 Phone: 210-522-6090 Fax: 210-522-5184 e-mail: ddunn@swri.org

1

PURCHASE REQUISITION

specimens CNWRA drawing 20-01402-571-125 749.00 -+-! 20 ‘ 01402 571 100 6/12/02

~-

VTERYAL MOTES TO BUYER

Quality & Technical Requirements: Specimens as per ZNWRA drawing 20-01402-li71-025. Dimensioral - - - IS required. +OL 3Il-023 ~ . ~ _ _

~

- -___-

I I-;_

~

1. Government Project?

IF YES, CHECK THE APPROPRIATE PROPERTY TYPE (SEE BACK FOR EXPLANATION OF PROP- ERTY TYPES)

a G- i CONSUMABLE

b 0 G-2 DELIVERABLE

c 0 G-3 ACCOUNTABLE / REPORTABLE

I

IS GOVT. PROPERTY RElNG SENT TO SUPPLIER?

a YES

0 NO :ONTRACT REVIEW APPROVAL

2. Ql lALlTY ASSURANCE? a a ASLREQUIRED?

BUYER SIGNATURE

3. SOURCING NOTES IF YOU HAVE SELECTED A BRAND NAME OR PARTICULAR MANUFAC- TURER, WOULD AN EQUIVALENT BRAND OR PRODUCT ALSO SATISFY YOURNEED?

IF YOU HAVE SUGGESTED A SUPPLIER, AND NO OTHER SUPPLIER WILL MEET YOUR NEEDS, PLEASE AlTACH A MEMO OF EXPLANATION.

REQUESTORS SIGNATURE EXT. NO.

Darrell Dunn 6090 DEFT. / DIVISION APPROVAL

DATE

I

1 TOTAL 1 4. REPAIRS

TI IS THIS REQ. FOR A REFA197

mpg b IS THE REPAIR ON OR OFF CAMPUS?

m m c IF OFF CAMPUS PROVIDE SHIPPING TICKET b

Y NO.

1 SEE INSTRUCTIONS ON REVERSE SIDE

)arrell S. Dunn

'hone: (210) 522-6090 ax: (210) 522-5184 -mail: ddunn@swri.org

i WR I-C N WRA

1 3.00 + 0.03"

00" +/- ,6"

3.00 +I. 0.03"

1

Alloy 22 Id Specimen CNWRA Drawing 20-01402-571-25 All Dimensions 5 0.010" unless otherwise specified Note: Detail A on Page 2

Page 1 o f2

6.00" +/- 0.03"

tail A n

3% To L ,omDleted at time of order: - Material: /QLLOY' QJLZ

Heat: 2 2 7 3 - / - 3 1 6 q Specimen Orientation:

Other:

0.128" +I- - 0.002"d ia

0.128" +/- 0.002"d ia -

01

2 , I

I I I

I I I I

k

I I ik

I I I

,0.250" dia

,0.250" dia

I 1 .OO" I

24&!/abL Initiated by. D. Dunn Date

QA Approval B. Mabrito Date

Iarrell S. Dunn

'hone: (210) 522-6090 -ax: (210) 522-5184 ?-mail: ddunn@swri.org

SWRI-C N WRA Alloy 22 .Ad Specimen CNWRA Drawing 20-01402-571 -25 All Dimensions 2 0.005" unless otherwise specified Detail A identified on Page 1

Page 2 of 2

Detail A

6' +I- 0.5'

-1

\ -

"33 s To L. ,omDleted at time of order:

Material: ACLO Y 2%

Heat: 2273-/-3lL4 Specimen Orientation:

Other:

I Dimensions specified in 20-01402-571-25 page 1

z+t Reviewed by ki Jain Date

f

Danell S. Dunn

Phone: (210) 522-6090 Fax: (210) 522-5184 e-mail: ddu nn@swn .org

S wRI-CNWRA ' Refert. ,e drawing for weld precedure

qualification specimens CNWRA Drawing 20-01402-571-026 No dimensional tolerances

+ - a Y/& - To

Material: Allov 22

comcdeted at time of order:

Heat: 2277-1-3164 Specimen Orientation: As Shown

Other:

I I I I I I I I I I I I I I I

I I I 1 I I I I I I I I I I I I

I

1 w - 4

Date Initiated by. D. Dunn

QA Amroval B. Mabrito Date

M a y 21 02 09:31a I t X H S I U U L M H K E H S , I N U

CUSTOMER WORK ORDER / QUOTE Job No.: Quote No.: Date Opened: Delivery Date: Customer No.: Job TakedQuoted by:

Customer; Quote Good For. Terms: SOUTHWEST RESEARCH IhYSTITUTE

6220 CULEBRA DARRELL D W

Item aty Part No. Rev Part Name ByTau Price ESI. ' TOW

1650 2-3 WEEKS ARO 01 11 I MlKE RIDGWAY

90 DAYS Customer P.O.: Contact:

Phone No.: Fax No.:

%% 10 NET 30

S A N ANTONIO, TEXAS 78238 210-684-511 I 2 10-522-5 184

1 6 20-01402-571-25 ALLOY 22 WELD SPECIMEN 749.00 $4,494.00

21 U - 4 U 2 - 0 3 t i Y

Pagelsheet - of

3uality kquimments: 0 None 0 As noled below

JateriaVProcess Cenification: Dyes W I Certificate of Compliance: 6 ONO I source lnspedion a y e s 6 locumenled Dimensional Inspection: &S DNo: If Yes: 1) OSpecified Dimensions Only, 2) d p l i n g ,

ruthonzed 7 7 1 Representative: Date: 5/21/02

3) ~ 1 0 0 %

:ustomsr Acceptance: Date: Customer Comments (id app6cable):

Vote: price($ may be a3ecied vscope 05 wnrW~nspection is deviatedfrom that quoted

beviewed by: Date: I Dyes DNo

P.O. provided at time of review: - F ~ T f i u ~ O n ) y -

TI? FmOF-030101

AII quotations and agreements are contingent upon strikes, fires, availability of materials, and all otfier causes Beyond our ContTol. Prices are subject to change by seller before final acceptance FOB: TEXAS TOOLMAKERS, INC.

Rev 2

9

.... Ju1-16-02 , .. . 0 6 : 5 1 A P - 0 2

11411 East Coker Loop 6an Antonio, Tern 78216

bmw- taraatoolmakem.com '(310) 494-3651 * Fm (210) 494-6139 A8306 IS0 m 2

CERTIFICATE OF CONFORMANCE

TO: So- Research Institute 6220 Culebm Road San Antonio, Tx. 78238-5168

CUSTOMER P.0, 286716S

mJoB #: 33484

DESCRIPTION 5 €3. PIN 20-01402-571-25 ALLOY 22 WELD SPECIMEN

W E CERl'ZFY THAT 7TE mM(S) ON "HE ABOVE REFERENCED PURCHASE ORDER HAVE BEEN PROCESSED ANDJOR MANUFACTURED IN ACCORDANCE W7T?T:

Drawings

RECORDS ARE ON FlLE AT THIS FACILITY, WHICH VE"Y OUR PROCESS CONTROLS, AND AVNLABLE FOR REVIEW UPON REQUEST. TEST RESULTS ARE AS FOLLOWS;

ACCEPTED

Q.C. Tispector , , . ~ - - .... . TITLE:

DATE : 711 8/02 , .

NSlONAL INSPECTION REPORT

TTI Form QF-100201 Rev 2

DIhllENSIONAL INSPECTION REPORT "$A TEXAS TOOLMAKERS, LNC.

TTI Form QF-100201 Rev 2

s-

DIhl[ENSIONAL INSPECTION REPORT 291 TEXAS TOOLMAKERS. LNC.

Rev 2

13

ffected by tolerance block

TTI F o ~ QF-100201 Rev 2

NSlONAL INSPECTION REPORT

TTI Form QF-100201 Rev 2

'3 z/s--4 DIMENS1 ONAL INSPECTJON REPORT TEXAS TOOLMAKERS, LNC.

Job No.. IRev. No.: IP.0. No.:

CENTER FOR NUCLEAR WASTE REGULA i 0 R Y ANALYSES

M E M O R A N D U M

August 30,2002

TO: Nonconformance Report (NCR) 2002-08 File f i

FROM: Bruce Mabrito, Director of CNWRA QA

SUBJECT: StatusExtension on NCR 2002-08

This memorandum to the NCR 2002-08 file is an explanation of the progress to date on closing out this NCR and provides for an extension in the target dates for completion.

NCR 2002-08 describes Alloy 22 specimen preparation shortcomings to be used in the CNWRA weld qualification process.

The subject target date for completion of NCR 2002-08 was first extended to August 3 1,2002. Item No. 3 on this NCR will have to be further extended until a decision is reached on whether specimen SN 006 is going to be utilized in the CNWRA process. If used, further repair and machining is required.

Item No. 2 on the NCR, examination of a 0.250-inch hole, has been performed and is acceptable. Item No. 1, drawing revision has not been performed but is not a quality-affecting hold point for close out of NCR 2002-08 .

Based on this information and the currently anticipated activity in the CNWRA, I am extending the formal target date for completion of NCR 2002-08 - to September 13, 2002.

cc: B. Mabrito D. Dunn M. Ehnstrod30 T. Mayces/30 M. PadilldCNWRA QA

WELD JOINT FABRICAT, iY RECORD

Weld Joint No. 4/14 Fab. Oper. Record Seq. No. d(,h- Wps No. c 22- 6 7A ul

Base Plate A: Material f fl-s 7r BasePlateB: Material / / /A Thickness #/A

#. L h4RI No. &I# =&:* Filler Metal: Type Size

Root FR/lrr'CR /nod 4 Root S / 3 t N Fill ER Ah C R M ~ - I o Fill 3/32 " Flux # /A

Fill Flux

SwRI Lot No. Root H/# Joint Design f l @ d ~ / ; r i J M Z I

Fit-Up: Accepted By #/A . Date:

I 1 1 I

Inspections: (Circle As Required) Root: MT: PT: V'RAcceptedBy Date Find: MT: PT: VT:AcceptedBy Date

UT: RT: Accepted By Date

Repair k t- I / I I

ED 18.05-14a

P

Q

Darrell S. Dunn

Phone: (210) 522-6090 Fax: (210) 522-5184 e-mail: ddunn@swri.org

SWRI-C N WRA

b

-T 3.00 +I 0.03" I

1

12.00" +/- 0.06

3.00" +I 0.03"

Alloy 22 V 1 Specimen CNWRA Didwing 20-01402-571-25 Rev. 01 All Dimensions 5 0.01 0" unless otherwise specified Note: Detail A on Page 2

Page 1 of2

To be mpleted at time of order:

Material:

Heat: Specimen Orientation:

Other:

0.128" +/- 0.002"dia 7

0.128" +/-

0.002"dia 7

/

I I <

,0.250" dia

- _ -

,0.250" dia

- - -

1 'I nominal thickness

/

9h/WL Date

q r q o t 'Date

QA Approval B. Mabrito Date QA Approval B. Mabrito Date

I

I

Darrell S. Dunn

Phone: (210) 522-6090 Fax: (210) 522-5184 e-mail: ddunn@swri.org

SWRI-CNWRA

1

Alloy 22 Weld Specimen CNWF; lrawing 20-01402-571-25 Rev. 01 All isions & 0.005" unless otherwise specified Detail A identified on Page 1

Page 2 of 2

Detail A

- To h3 COmDlekd at time of order:

Ma , ial:

Heat: Specimen Orientation:

Other:

6' +/- 0 5'

-1

Dimensions specified in 20-01402-571-25 Rev. 01 page 1

9 / f / b z - Initiated by. D. Dunn Date