ML19253A495
| ML19253A495 | |
| Person / Time | |
|---|---|
| Issue date: | 06/21/1979 |
| From: | Relley W, Whitesell D NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML19253A492 | List: |
| References | |
| REF-QA-99900371 99900371-79-1, NUDOCS 7909100155 | |
| Download: ML19253A495 (11) | |
Text
U. S. NUCLEAR REGUI.ATORY COBD!ISSION OFFICE OF INSPECTION AND ENFORCEMENT REGION IV Report No.
99900371/79-01 Program No.
51300 Company:
Bristol Steel and Iron Works, Inc.
Corporate Offices 320 Piedmont Avenue Plant 2, 321 Morrison Boulevard Plant 3, Bristol Washington County Industrial Park Bristol, Virginia 24201 Inspection at:
Bristol, Virginia 24201 Inspection Conducted: June 4-6, 1979 Inspector:
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W. D. Kelley, Contractor Inspector
/ Date Vendor Inspection Branch Approved by:
8 d42.//7j D. E Whitesell, Chief, Components Section 1
/ Date Vendor Inspection Branch Summary Inspection on June 4-6, 1979 (99900371/79-01)
Areas Inspected:
Implementation of 10 CFR 50, Appendix B and applicable codes and standards including, manufactur:.ng process control, training, and auditing; also reviewed the quality assurance program and conducted an initial management meeting. The inspection involved twenty (20) inspector-hours on site by one (1)
NRC inspector.
Results:
In the five (5) areas inspected, no deviations or unresolved items were identified.
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2 Detail Section A.
Persons Contacted Bristol Steel and Iron Works, Inc. (BSIW)
- J. V. Barnes, Quality Assurance Manager K. F. Blevins, Chief Inspector Plants 1 and 2
- L. E. Collins, NDE Manager (Level III)
- J.
E. Corrin, Chief Engineer G. Long, Job Supervisor
- R. H. Smith, Quality Assurance Representative Hartford Steam Boiler Inspection and Insurance Co. (HSB)
- 0. K. Franks, Authorized Nuclear Inspector
- Denotes those perosas who attended the exit interview.
B.
Initial Management Meeting 1.
Objectives
.s, The objectives of this meeting were to accomplish the following:
a.
To meet with the Bristol Steel and Iron Works, Inc. (BSIW) management and those persons responsible for the administration of the ASME accepted Quality Assurance program, and to establish channels of communication.
b.
To determine the extent of the company's involvement in the commercial nuclear business.
c.
To explain NRC direct inspection program including the LCVIP organization, VIB inspection method and documentation.
d.
To describe the NRC evaluation of the ASME inspection system.
2.
Method of Accomplishment The preceding objectives were accomplished by a meeting at Bristol Steel and Iron Works, Inc. Corporate Of fices on June 6,1979. The following is a summary of the meeting:
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3 a.
Attendees were:
Bristol Steel and Iron Works (BSIW)
J. V. Barnes, Quality Assurance Manager L. E. Collins, Manager, NDE J. E. Corrin, Chief Engineer R. J. Corrin, Vice President Technical Services D. Faulkner, Manager Purchasing M. D. Fritz, Manager Projects and Engineering J. A. Hawkins, Vice President Sales
- 0. Hurt, Executive Vice President Newell, Vice President, Operations H. Smith, Quality Assurance Representative Hartford Steam Boiler Inspection and Insurance Co. (HSB)
O. K. Franks, Authorized Nuclear Inspector b.
The VIB organization was described and its relationship to NRC Region IV and the NRC Headquarters component of the Office of Inspection and Enforcement.
c.
The TLCVIP function was described including the reasons for its establishment, its objectives, its implementation structure, and the more significant program changes.
d.
The conduct of VIB inspections was described and how the inspec-tion results are documented and reported, and what the responses to reports, should include. How proprietary information is handled, the Public Document Room, and the White Book were also explained.
e.
The purpose, scope, and status of the NRC's two year program to evaluate the ASME inspection system as an acceptable independent third party was discussed.
f.
The company's contribution to the nuclear industry was discussed including current and projected activities, the status of the ASME certification of authorizatioc, and the third party inspection services.
3.
Results Management acknowledged the NRC presentation as being understood by them, and provided the inspector with the following information concerning the company's activities and products.
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4 The BSIW Plant No. 2 manufactures structural components subject a.
to 10 CFR 50 regulations.
b.
The ASMI issued the following Certificates of Authorization to BSIW Plant No. 3 to use their symbol.
Certificate No.
Symbol Product N-1293 N
Class 1, 2, or 3 and MC vessels and Class 2 & 3 storage tanks.
N-1294 NPT Class 1, 2, 3 and MC vessel parts and appur-tenances and component supports; Class 1, 2 &
3 piping subassemblies
& tublar products welded with filler metal; Class 2 & 3 storage tank parts and appurtenances; Class CB concrete reactor vessel parts & appurte-nances, and class CC
-- r e concrete containment parts and appurtenances.
c.
The authorized inspection agency is Hartford Steam Boiler Inspection and Insurance Company. The authorized nuclear inspec-tor is a resident inspector.
d.
BSIW contribution to the nuclear industry represents approxi-mately fif ty (50) percent of Plant No. 3 workload.
C.
QA Program Review 1.
Objectives The objectives of this inspection were to ascertain whether the QA program has been documented in writing, and if properly implemented, will ensure that the specified quality of completed components has been achieved in compliance with NRC rules and regulations, code and contract requirements and the commitments in the Quality Assurance Manual. Also, ascertain whether the program provides for the following:
a.
Management's policy statements concerning QA.
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5 b.
Delineates how the QA organization is structured, to achieve appropriate independence from scheduling and costs, the free-dom and independence to identify quality problems, initiate appropriate resolutions, and verify conrective action.
c.
Whether the duties and authority of the QA staff is clearly delineated in writing, and that they have access to a level of management that can ensure effective implementation of the QA program elements, and to enforce positive and timely corrective action.
d.
Detailed written procedures are properly reviewed, approved, released, and issued to control quality activities, as appropt' ate.
e.
A training and indoctrination program to improve or maintain the proficiency of personnel performing quality activities, and personnel verifying that cuality activities have been correctly pe rfo rmed.
2.
Method of Accomplishment The preceding objectives were accomplished by:
Review.of the ASME accepted Quality Assurance Manual.
a.
b.
Review of appropriate organization charts.
c.
Review of the documents concern: 2g the authority duties, independence and freedom of the Quality Assurance staff.
d.
Review of Statement of Authority, e.
Review of documents to verify that they had been reviewed and approved by authorized personnel, f.
Review of the training and indoctrination program requirements and documentation.
g.
Interviews with cognizant personnel.
h.
Observation of work and test in progress.
3.
Findings The evidence descastrates that the QA program has been documented in writing and clearly def tnes the duties, authority, and organizational independence and freedom of the QA staff.
Detailed written c :- ? wra as ?,4 (,... 4'c t
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6 implementing documents are appropriately reviewed, approved, released, and issued by authorized personnel.
The QA staff has access to a level of management to ensure effective implementation of the program and timely and positive corrective action of enforce-ment items.
A viable training and indoctrination program has been provided for upgrading, and maintaining, the proficiencies of personnel involved in quality activities.
Within this area of the inspection no deviations or unresolved items were identified.
D.
Manufacturing Process Control 1.
Objectives The objectives of this area of the inspection were to verify that the vendor's manufacturing processes were:
Performed under a controlled system which meets the NRC rules a.
and regulations, ASME Code requirements, the vendor's commitments in his ASME accepted Quality Assurance Program, and contract requirements.
b.
Effective in assuring product quality.
2.
Method of Accomplishment The objectives of this area of the inspection were accomplisuec by:
a.
Review of the ASME accepted Quality Assurance Manual, for ASME Section III Nuclear Plant Components, Revision 7 and Quality Assurance Manual for 10 CFR 50 Nuclear Power Plant Safety Related Items, Revision 5; (1) Section 6, Centrol of Material Before Fabrication, (2) Section 7, Control of Fabrication, and (3) Section 10, Welding, to verify that procedures had been established which prescribes a control system of the manufacturing processes.
b.
Review of SOP 4.5, Revision 3, Control of Fabrication Router, to verify that the control system requires shop travelers or process control check lists, to be prepared which identifies the document numbers and revisions to which the process must c-,
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7 confo rm.
Also to verify that all processes and tests are to be performed by qualified personnel using qualified procedures.
c.
Review of the shop traveler, or process control check lists, to verify that spaces are provided for reperting the results of specific operations, or reference to other docudents where the results are maintained. Also that it includes space for the signoff by the vendor, indicating the date on which the operation or test was performed, and space for signoff and date, by the authorized nuclear inspector, to document his acceptance of activities that he has selected as mandatory hold points, d.
Review of selected shop travelers; (1) F-0109D-41, (2)
F-0044-7-11.42, (3) F-0044-7-33.21 & 23, and (4)
F-0109F-1.6.9, to verify their compliance with the above referenced procedures, and the overall QA program documentation requirements, including the establishment of mandatory hold points by the authorized nuclear inspector.
Interviews with personnel to verify they are knowledgeable in e.
the procedures applicable to manufacturing process control.
3.
Findings a.
The inspector verified that the vendor's manufacturing processes are performed under a controlled system which is consistent with the NRC rules and regulations, the Code requirements, the Quality Assurance Program commitments, and that the system is effective in achieving the specified product quality.
b.
Within this area of the inspection, no deviations or unresolved items were identified.
E.
Training 1.
Objectives The objectives of this area of the inspection were to ascertain:
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Whether procedures had been developed and approved by the vendor prescribing a system for training personnel whose activities affect the quality of their products in a manner consistent with NRC rules and regulatio'as, and the vendor's QA Program commitments.
b.
That the training procedures were being properly and effectively implemented by the vendor.
2.
Method of Acyomplishment The objectives of this area :
the inspection were accomplished by:
a.
Review of che ASME accepted Quality Assurance Manual, for an ASME Section III Nuclear Power Plant Components Revision 7, paragraph Indoctrination and Training and Quality Assurance Manual for 10 CFR 50 Nuclear Power Plant Safety Related Items, Revision 5 paragraph Indoctrination and Training, to verify the vendor had established procedures to prescribe a system for training personnel whose activities affect the quality of their products.
b.
Review of the follcwing Standard Operating Procedures; (1)'" SOP 1.2, Revision 2, Indoctrination and Training, (2) S0P 10.2, Revision 3, Qualification and Certification of Auditing Personnel, (3) SOP 7.1, Revision 10, Qualification and Certification of Nondestructive Testing Personnel, and (4) S0P 12.6, Revision 1, Qualification and Certifications of Inspection Personnel, to verify that they had been prepared by the designated authority, approved by management, and reviewed by QA. Also that provisions are made for formal training and retraining of new employees, inspection and testing personnel, personnel performing special processes, audit personnel, and personnel involved in quality related design and procurement activities.
c.
Review of the Standard Operating Procedures referenced in paragraph b, to verify that they provided for the indoctrication with the technical objectives of the product, Codes and standards to be used, and the quality assurance / control elements that are to be employed. Also, to verify that they provided for the testing of the capability and proficiency of nondestructive c.' ' t**
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9 testing personnel and retraining and recertification if evaluation of performance shows individual capabilities are not in accordance with specified acceptance limits.
d.
Review of training records of inspectors, nondestructive testing personnel, auditors, deoigners and quality assurance and procurement personnel to verify the procedures and necessary training and the training procedures were being properly and effectively implemented and appropriately documented.
e.
Interviewed personnel to verify whether the training performed was ccamensurate with the persons assigned quality related activities.
3.
Findings a.
The inspector verified that the vendor had developed and approved procedures that prescribed a system for the training of personnel whose activities affected the quality of their product in a manner consistent with NRC rules and regulations and his commitments in the ASME accepted Quality Assurance Program.
b.
The inspector verified that the training procedures were being properly ~ and effectively implemented by the vendor at the time of this inspection.
c.
Within this area of the inspection, no deviations or unresolved items were identified.
F.
Audits 1.
Objectives The objectives of this area of the inspection were to verify that procedures had been grepared and approved by the vendor that prescribed a system for auditing which is consistent with NRC rules, Code requirements, and the commitments of the ASME accepted QA Manual.
Also, to verify whether these audit procedures were being properly and effectively implemented by the vendor.
2.
Method of Accomplishment The objectives of this area of the inspection were accomplished by:
a.
Review of the ASME accepted Quality Assurance Manual, for ASME Section III Nuclear Power Plant Components and Quality Assurance Manual for 10 CFR 50 Nuclear Power Safety-Related Items, Revision 5; o q <: ". 'l v u ei - '
10 (1) Section 8.0, Control of Purchased Materials and Services, and (2) Section 15.0, Audits, to verify that procedures had been established to prescribe a system for auditing, which is consistent with NRC regulations.
b.
Review of the following standard operating procedures; (1) S0P 10.1, Revision 5, Auditing, and (2) S0P 10.2, Revision 3, Qualification and Certification of Auditing Personnel, to verify they had been prepared by the desinated authority, approved by management, and reviewed by QA.
c.
Review of the standard operating procedures referenced in paragraph b, to verify they identify the organizations responsible for auditing and their responsibilities; establishes audit personnel qualifications and training, and that the audits are performed by qualified personnel. Also, to verify that the' essential elements of the audit system is established.
d.
Review of the audit schedules to assure that the audits of quality activities during design, procurement and manufacture are planned, documented, and conducted in the prescribed maaner, and assures coverage of aspects of the QA program.
e.
Review of selective audit reports to verify that they include provisions for written plans, team selection, team orientation, audit notifications, pre-audit conferences, audit performances, and post-audit conferences.
f.
Review of selective audit reports to verify that they are properly distributed to management and the audited organization; and that follow-up audits to verify corrective action is required.
g.
Review of selective internal and external audit reports to verify the applicable procedures were available to the audit team personnel, and that the audit procedures were properly and effectively implemented.
3.
Findings a.
The inspector verified that:
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11 (1) Procedures had been prepared and approved by the vendor which prescribes a system for auditing consistent with NRC rules and regulation, ASME Code and contract require-ments, and the vendor's commitments.
(2) The audit procedures are being properly and effectively implemented.
b.
Within this area of the inspection no deviation or unresolved items were identified.
G.
Exit Interview At the conclusion of the inspection on June 6,1979, the inspector met with the company's management, identified in paragraph A, for the purpose of infor=ing them as to the results of the inspection.
During this meeting management was informed no deviations or unresolved items were identified.
The company's management acknowledged the inspector's statement and had no additional comments.
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