ML19247B515
| ML19247B515 | |
| Person / Time | |
|---|---|
| Issue date: | 05/10/1979 |
| From: | Agee J, Hunnicutt D NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML19247B512 | List: |
| References | |
| FOIA-80-502, REF-QA-99900277 NUDOCS 7908090237 | |
| Download: ML19247B515 (9) | |
Text
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U.S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT REGION IV Report No. 99900277/79-01 Program No.
Company: The Rockbestos Company A Member of the Marmon Group 285 Nicoll Street New Haven, Connecticut 06504 Inspection at: New Haven and East Granby, Connecticut Inspection Conducted: April 23-26, 1979 Inspector; ff;'
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,J. R. Agee, Contractor Inspector Crate /
Vendor Inspection Branch Approved by:
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d /0 77 D. M. Hunnicutt, Chief, Components D6te '
Section II, Vendor Inspection Branch Sumary Inspection on Aoril 23-26, 1979 (99900277/79-01)
Areas Inspected:
Implementation of 10 CFR 50, Appendix B and applicable codes and standards including: action on previous inspection findings; quality assurance manual / program involving auditing, training, receiving inspection, and nonconformances; design control; inspection and tests; and measureinent and calibration. The inspection involved twerty-five (25) inspector-hours on site.
Results:
In the five (5) areas inspected, no apparent deviations or unresolved items were identified.
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,o y90809023y Details Section A.
Persons Contacted R. C. Brown - Quality Engineer G. S. Buettner - Technical Director E. D. Ford - Quality Supervisor M. C. Goldberg - Contract Administrator
- G. G. Littlehales - Quality Assurance Manager J. M. Maganelli - Quality Control Manager E. S. Reed - Vice President and General Manager
- Attended the exit interview B.
Action on Previous Inspection Findings 1.
(Closed) Deviation (Inspection Report No. 77-01): The QA Manual does not require training for personnel performing quality related functions. The inspector verified by review of the QA Manual and related quality documents that a training program and a means for evaluating suitable proficiency has been implemented.
2.
(Closed) Deviation (Inspection Report No. 77-01): Manufacturing Instruction Tags (MITs) have been released for manufacture of products without approval by Manager of Standards Engineering.
The inspector verified by random sampling of subsequent MITs, that each had been approved by the Supervisor of Specification Engineering or his designee in compliance with the latest revision of the QA Manual.
C.
Quality Assurance Manual / Program 1.
Objectives The objectives of this area of the inspection were to verify that the:
a.
QA Manual had been maintained current per commitment.
b.
QA Program had been implemented in the area of auditing, training, receiving inspection, and nonconformances.
c.
Organizational structure and facility capabilities are suf-ficient to design and manufacture electrical cables for Class IE applications.
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Method of Accomplishment The preceding objectives were accomplished by:
a.
Discussions with the Quality Assurance Manager concerning the quality program for the New Haven and East Granby plants.
b.
Review of the QA Manual and determining that it had been revised January 1978 as Edition 14 with a format similar to 10 CFR 50, Appendix B.
Additional administrative revisions were made to the manual in April and November 1978.
Records indicate the manual has been reviewed semi-annually.
c.
Review of the Quality Procedure Q-25, Training, Revision 2, April 27,1978, and the QA Manager's training manual and training notebook which contain separate coverage for each job category, such as quality supervisor, electrical tester, electrical test helper, process inspector, working assistant, chief technician, technician and others.
d.
Review of QA Manual, Section 19, Audits, November 1,1978, and Quality Procedure Q-30, Outline of Requirements for Auditing of OA Programs, e.
Review of the audit schedule and records for 1978 and deter-mining that twenty-seven (27) of twenty-nine (29) audits scheduled have been completed. Seven (7) audits had been made of the East Granby plant. A review of random selection of the audit reports in such areas as:
organization and responsibilities; identification and control of materials, components and parts; procedures for tool and gage control revealed that several findings had been identified. The QA auditors had recorded several recommendations for improve-ments in the areas inspected. Where findings had been iden-tified, adequate responses had been provided.
Twenty (20) audits had been scheduled for 1979. As of April 24, 1979, two (2) of the scheduled audits had been conducted.
f.
Review of the QA Manual Section 8, Receiving Inspection, Quality Procedure Q-7, Receiving Inspection Procedure -
New Haven, Revision 18, August 14, 1978, and inspection of receiving inspection practices.
Incoming materials for several purchase orders were traced for disposition.
An example includes P0 #89249 for KL-486-0 material:
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Date Received Date Lab Test Acoroval 211133-211197 4/18/79 4/20/79 253419-253450 4/12/75 4/12/79 199836-199900 3/19/79 3/21/79 188586-188588 4/4/79 4/5/79 Each container for each lot of the above materials was appropriately stamped in compliance with applicable receiving inspection quality procedures.
Other materials containers that were stamped indicating acceptance based on laboratory testing and/or vendor certi-fication include: silicone elastomer composition, flame-retardant cross-linkable polyethylene, EPR, neoprene and hydrogen compounds.
Several containers of some of the above type raw materials had been identified as nonconforming and were placed in the locked Quality Control Hold Area.
Each had been rejected with attached Raw Material Rejection Report forms pending ultimate disposition.
3.
Findings Within this area of the inspection, no deviations or unresolved items were identified.
D.
Design Control 1.
Objectives The objectives of this area of the inspection were to verify that:
a.
Cabling products are designed and manufactured to meet customer specifications and applicable codes and standards.
b.
Cable designs are reviewed and approved in compliance with implemented procedures.
c.
Prototypes of new cable and revised cable design are quali-fication tested for compliance to established national codes and standards.
2.
Methods of Acccmolishment I.
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The preceding objectives were accomplished by:
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Discussions with the Technical Director concerning cable a.
designs, qualification programs and compliance to national cable codes and standards.
b.
Review of customer purchase orders and :,pecifications for cabling for Class IE application, including P0 No.10407 ~.
EM-058, dated October 4,1976, for 600V copper power cable, safety related quality Class Q, flame resistant.
Attachment to the P0 includes Specification No.13-EM-058 which states in part, "... All cables shall be manufactured and tested in accordance with all applicable requirements of IPCEA Standard 5-19-81..
5-66-524... All cable shall be qualified in accordance with all applicable requirements of IEEE 383-1974 and IEEE323-1974... The Project Quality Assurance Program is governed by NRC Regulation 10 CFR 50, Appendi B... and splicable provisions of ANSI N45.2-1971 Records indicate Rockbestos made several waiver requests to the customer on this contract, including:
Waiver Identification Customer Approval and Date and Date W/28(7/18/78) 8/15/78 W/29 (7/18/78) 8/15/78 W/29A(7/27/78) 9/5/78 W/30 (7/18/78) 8/15/78 W/31(7/18/78) 8/15/78 W32A (8/8/78) 8/21/78 W33 (8/8/78).
10/23/78 8/21/78 W35 (10/19/78)
W36A (10/23/78) 10/24/78 W37 (2/5/79) 2/23/79 W38 (4/3/79) 4/4/79 Review of the following Rockbestos documents which had been c.
submitted to various customers representing their qualified product to meet Class IE applications:
(1) Qualification of Firewall III, Class IE Electric Cables, dated July 7, 1977.
(2) Qualification of Firewall III, Class IE Electric Cables, dated June 7, 1978.
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d.
Review of document, Rockbestos Firewall III, Electric Cable, Prototype Test Data, dated September 13, 1978, which provides test data for single conductor cable in the following areas:
insulation characteristics; jacket characteristics; type tests including long tem physical aging, themal and radiation exposure, LOCA, main streamline break condition, flame; special moisture exposure; jacket abrasion resistance test; corrosive effects tests; insulation cut-through test and insulation crush test.
3.
Findings Within this area of the inspection, no deviations or unresolved items were identified.
Coment: While the cable qualification test data supplied appears to satisfy the contents of customer specifications, the data pre-sented is based on tests of single conductor cable and not on multicanductor cable. The qualification data specifically ad-dresses criteria of IEEE-383 (1974), IPCEA 5-19-81 and 5-66-524 with references to selected sections of IEEE-323 (1974) and rela-ted Arrhenius Plots. Multiconductor cables are currently fully qualified to IEEE-323 (1974); however, ongoing testing and in site aging provides supportive data concerning the integrity of t0e cables.
E.
Inspection and Tests 1.
Objectives The objectives of this area of the inspection were to verify that:
a.
Manufacturing activities are inspected and controlled for each progressive stage af prcduction.
b.
Manufacturing activitias are conducted in compliance with approved and established procedures.
c.
Manufacturing inspection is conducted by quality control inspectors.
d.
Electrical and laboratory tests are completed on the products in various stages of production and in conjunction with final inspection of the finished product.
2.
Methods of Acccmolishment The preceding objectives were accomplished by:
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Discussions with QC management, manufacturing and inspection personnel for both the New Haven and East Granby plants.
b.
Review of the QA Manual, Section 11, Inspection, dated January 3,1978, and Section 12, Test Control dated April 17, 1978.
c.
Examining the inspection and test practices and activities at both the New Haven and East Granby plants and verifying that one hundred per cent (100%) production testing is made on single conductor cables, that the terting is completed in compliance wiht implemented procedures, and that func-tions such as dielectric strength, insulation resistance, continuity, spark test, etc., are completed in compliance with IPCEA/IEEE standards criteria.
3.
Findings Within this area of the inspection, no deviations or unresolved items were identified.
F.
Measurement and Calibration 1.
Objectives The objectives of this area of the inspection were to verify that:
a.
A system has been established and is maintained to assure that tools, gages, instruments and other measuring devices used in activities affecting quality are properly controlled, calibrated, and adjusted at specified periods to maintain c.ccuracy within specified limits.
b.
Calibration records are kept for each instrument and that calibration labels are affixed to, or located with the instru-ments.
2.
Methods of Accomolishment The preceding objectives were accomplished by examining a randem selection of quality measuring instruments located in the New Haven and East Granby plants for calibration labels and data.
Instru-ments identified included the following:
a.
Calibration and footage counter T-209.
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Peschel Instrument Model K24-508 24KV - 50KVA c.
Insulation Resistance Tester Hypotronics
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MGA Megohmeter 50/100/500V d.
Kelvin Bridge L&N No. 4287 Range 0.0001 to 110.1 ohm e.
Digital Voltmeter Model 8000A f.
Hypotronics Inc.
Insulation Tester Model 230DC g.
Hypotronics Inc.
Multi Reel Tester Model 7075-75 h.
Hypotronics Inc.
DC Insulation Test Set, 2A-060-1005 1644 Megahm Bridge and General Radio A.C. Dielectric Test Set No. 75-21641.
i.
PI Peschel Instrument Inc.
No. 5766 Note:
The instruments listed above are mounted on the electrical final test panels or are used independently in conjuction with final testing of conductors and cables at the final test panels. They are not used as portable in-struments.
3.
Findinas Within this area of the inspection, no deviations or unresolved items were identified.
Comments : As of the date and week of this inspection, the Rockbestos Company was converting the maintenance and calibration responsibilities from the Rockbestos Company to a recognized electrical testing laboratory. New calibration labels with the identity of the testing laboratory, dated April 1979, were affixed to the listed instruments.
Remnants of the Rockbestos calibra-tion labels were still affixed to the instruments. Data obtained n ' 9,
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.- from the Rockbestos calibration records for the listed instru-ments revealed that the instruments with the testing laboratory labels affixed were scheduled for recalibration, during April 1979.
Cross reference data from old to new calibration data was com-patible. Since the instrument calibration and record maintenance responsibilities are in a transition stage, the revised program will be further inspected in a future inspection.
G.
Exit Interview At the conclusion of the inspection on April 26, 1979, the inspector met with the Quality Assurance Manager, at the East Granby plant, and summarized the scope of the inspection concerning the following areas:
1.
Closure of the previous inspection findings.
2.
Quality Assurance Manual / Program including: auditing, training, receiving inspection, and nonconformances.
3.
Design Control.
4.
Inspection and tests.
5.
Measurement and calibration.
Records and data concerning items 2, 4, and 5 above, that were not conveniently available during the course of the inspection, were made available to the inspector and clarifications completed during the exit meeting.
The Vice President and General Manager who was unable to attend the exit meeting at the East Granby plant was subsequently contacted by telephone c,ncerning the summary of the inspection.
Management acknowledged the inspector's sumary of the inspection.
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