ML19263C701
| ML19263C701 | |
| Person / Time | |
|---|---|
| Issue date: | 12/19/1978 |
| From: | Sutton J, Whitesell D NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML19263C698 | List: |
| References | |
| REF-QA-99900265 NUDOCS 7903010026 | |
| Download: ML19263C701 (9) | |
Text
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U. S. NUCLEAR REGULATORY C0'd14ISSION OFFICE OF INSPECTION AtiD ENFORCE!4ENT REGION IV Report No.
99900265/78-01 Program No.
44070 Company:
General Atomic Company Post Office Box 81608 San Diego, California 92138 Inspection Conducted: November 27 - December 1, 1978 Inspector:
.W.
rd
/2-/f-78 i W. Sutton, Contractor Inspector, Vendor Date Inspection Branch b
App.~oved b.
A//
/2*/9-78 D. E.'Whitesell, Chief, ComponentsSection I, Date Vendor Inspection Branch Sunmary Inspection on November 27 - December 1, 1978 Areas Inspected:
Implementation of 10 CFR 50, Appendix B criteria and applicable codes and standards including, action on previously identified items, calibration, testing of completed products, document control and nonconformance/ corrective action. The inspection involved thirty-two (32) inspector-hours on site by the NRC inspector.
Results:
In the five (5) areas inspected, no apparent deviations or unresolved items were identified in two (2) areas. The following were identified in the remaining three (3) areas.
Deviation: Testing of Comoleted Products. Equipment was not provided to monitor the temperature of the component and pressurizing medium during a low tempera'"re hydrostatic test of two (2) pressure vessels.
(See Enclosure.)
Unresolved Items:
(1) Calibration (Details Section, paragraph C.3.b.),
(2) Nonconformance corrective action, (Details Section, paragraph F.3.b.).
7003010 %
W DETAILS SECTION A.
Persons Contacted General Atomic Comoany (GAC)
- P. E. Bissonnette, General Manager
- E. V. Bak, Manager, Manufacturing Operations P. Boortz, QA Analyst T. R. Colandrea, Director, QA Division J. Fowler, Document Control
- E. D. Fogg, Manager, Manufacturing Engineering
- D. J. Harris, Manager, CMD/QA
- H. L. Hewitt, Manager, Administrative Control
- M. Hersey, QA Analyst C. Kerr, Data Analyst
- A.
J. Matt, Technical Advisor
- J. Rusk, Quality Operations Branch J. Rockstrow, Calibration Technician, QA State of California Division of Industrial Safety Authorized Inspection Agency J. Berggreen, Safety Engineer
- V Rez, Authorized Nuclear Inspector Supervisor
- Denotes those present at the Exit Interview.
B.
Action on Previous Insoection Findings (Closed) Deviation (Report No. 77-01):
(1) Failure to keep weld material holding ovens locked. The inspector verified that a revision to the QA Manual addresses the control of holding ovens.
(2) Failure to use correct welder qualification form, failure to approve heat treat procedure, and failure to record the NDE results on the specified form. The inspector verified that the QA Manual has been revised to correct these items and that the correct forms are being used.
The corrective action as stated in GAC letter of September 20, 1977, has been implemented.
- . C.
Calibration 1.
Objectives The objectives of this area of the inspection were to verify that calibrat on activities are controlled in accordance with the QA Manual and applicable NRC and ASME Code requirements:
a.
That 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 calibrated and adjusted at specified periods to maintain accuracy within the specified limits.
b.
That Calibration records are kept for each instrument indicating the calibration results.
c.
That the calibration system is being properly implemented.
2.
Method of Accomplishment The preceding objectives were accomplished by:
a.
Review of the QA Manual, Quality Procedure 12, Revision G, to verify that provisions have been included to assure that equipment requiring calibration is identified and a calibration frequency is specified. The calibration standards and traceability of standards is specificed and a recall system is in effect.
b.
Review of calibration procedures manual, Procedure 50-19.
c.
Review of qualifications of calibrators.
d.
Review of the inspection use record cards.
e.
Review of the recall system files.
f.
Review of calibration due notices and over due records.
g.
Review of the card index systems.
h.
Review of equipment certification standards for:
(1) Gage blocks Nos. 5, QC 9-138, QC 9-10.
(2) Thread wire, QC 9-122.
(3) Roughness, QA 9-78A.
. (4) Dead weight tester, TEC 19007.
(5) Thermocouple, K22-J-29.
(6) Leak rate (Helium), QC-16-7.
i.
Inspection of the calibration facilities for~ mechanical, electrical and instrument calibration.
j.
Review of the calibration records for the following:
(1) Micrometers, SV 111, SV 112.
(2) Dial indicators, SV-12-15-8-6-9.
(3) Electrical meters (weld machine), W-12-W-13-W-24.
(4) Surface plate, QC 13-1.
(6) Vernier scale, SV 2-12.
(7) Pressure gages, C-58025, 28092, 28091.
(8)
Impedance bridge, 14570, counter 19542.
k.
Discussions with cognizant personnel.
3.
Findings From the documents and records reviewed, and observation of the nuclear work in progress, it was determined that the system prescribed for control and calibration of gages, tools and instruments is consistent with the NRC Rules and Code require-ments, and that the system is effectively implemented.
a.
Deviations No.
b.
Unresolved Items Quality Procedure #12, Revision G, Section 3.11 requires clarification concerning its applicability to the services provided by outside calibration laboratories.
D.
Testing of Comoleted Products 1.
Objec tives The objectives of this area of the inspection were to verify that testing activities are controlled in accordance with the QA Manual and applicable NRC and ASME Code requirements:
a.
Products are assembled in accordance with approved proce-dures and materials comply with approved specification.
b.
Functional tests of products are performed in accordance with approved test documents.
c.
That the system is being properly implemented.
2.
Method of Accomolishment The preceding objectives were accomplished by:
a.
Review of the ASME accepted QA Manual, Procedure Nos. 10, Revision F,11, Revision G, and 14, Revision H, to verify that it meets the requirements of 10 CFR 50, Appendix B, and other applicable codes.
b.
Review of Hydrostatic Test Procedures for Pressure Vessels QD1-HT-3801,- Issue ~B, to verify that inspection and tests are perfomed using documented approved procedures.
c.
Review of Shop Travelers Nos. 19467, 19480, 19481, and 19482 for pressure dampners, to verify that the documents contain or reference the requirements and acceptance limits, in addition, that documents had been signed by authorized personnel.
d.
Review of the qualification records of test personnel.
Review of the system for control of inspection and acceptance e.
stamp.
f.
Inspection of :tu test equipment and certification of gages and instruments.
g.
Review of the test report foms to verify that test results are properly documented, and that the procedures are being properly implemented.
. h.
Discussions with cognizant shop and test personnel.
3.
Findings From the documents and records reviewed, and observation of the nuclear work in progress, it was determined that the system prescribed for testing of completed products is consistent with the NRC Rules. However, during the hydrostatic test of two (2) pressure dampers, it was observed that equipment had not been provided to monitor the temperature of the components and the pressurizing medium, in accordance with Paragraph NB6212,Section III of the ASME Code requirements for Test Medium and Test Temperatures. and in accordance with the QA program commitments.
a.
Deviations See Enclosure.
b.
Unresolved Items None.
E.
Document Control 1.
Objectives The objectives of this area of the inspection were to verify that:
a.
The vendor's document control system for manufacturing, and quality assurance d]cuments is consistent with regulatory requirements.
b.
The document control system includes all drawings, specifi-cations, procedures, instructions, etc. which affect quality.
c.
The system is being properly implemented.
2.
Method of Accomplishment The preceding objectives were accomplished by:
a.
Review of the QA Manual, Quality Procedure No. 6, Revision G, which established the general requirements for document ccntrol.
b.
Verified that two (2) design drawings, specifications and manufacturing documents were controlled and distributed in accordance with the Document Control Procedure.
. c.
Review of the individual Component Manufacturing Division locator report issued November 30, 1978.
d.
Reviewed the following:
(1) Document control record card system.
(2) Master travelers drawing filo.
(3) Document control notification log.
(4) Master log for velum drawings.
(5) Reviewed three (3) change notices.
(6) Reviewed document recall notification system.
To verify that the document control system included all designated documents that would effect quality and that they were on file.
e.
Discussion with cognizant personnel.
3.
Findings From the documents and records reviewed, and observation of the
.iuclear work in progress, it was determined that the system for document control is consistent with the NRC Rules and Code requirements, and is being properly implemented.
Within this area of the inspection no deviations or unresolved items were identified.
F.
Nonconformances and Corrective Actions 1.
Objectives The objectives of this area of the inspection were to verify thnt these activities were controlled in accordance with the QA Manual and applicable NRC and ASME Code requirements:
a.
The manufacturer's system contains sufficient measures to provide reasonable assurance that nonconforming materials, parts, or components are not inadvertently utilized and that prompt corrective actions are taken.
b.
To verify that the system is properly implemented.
.g_
2.
Method of Accomplishment The preceding objectives were accomplished by:
a.
Review of the QA Manual, Quality Procedures Nos. 15, Revision H and 16, Revision E, which established the general requirements for control of nonconformances and corrective actions.
b.
Review of six (6) nonconformance reports to verify that the nonconformances were appropriately dispositioned and that; (1) The assigned responsibilities are carried out by designated persons.
(2) The system for identifying and reporting nonconforrances, and for evaluating and enacting corrective action, is timely and effective.
(3) That nonconforming items are properly disposed of.
(4) That corrective action follow-up was properly perforced.
(5) That management participation is effective in minimizing recurrence.
c.
Review of the nonconformance log book.
d.
Inspection of the segregation system.
e.
Verification that repair / rework performed on the above NCRs was in accordance with the QA procedures.
f.
Discussions with cognizant personnel.
3.
Findings From the documents and records reviewed, and observation of the nuclear work in progress, it was determined that the system for controlling nonconformances anc corrective action is consistent with the NRC Rules and Code requirements, and is being properly implemented.
a.
Deviations None.
.. b.
Unresolved Items Quality Procedure #15, Revision H, Sections 2.2.1(b), 3.1.2, and 3.2.2.1 needs to be clarified as to the method to be used to notify the ANI in areas requiring his concurrence and review.
The ANI is an itinerant inspector on call when required by the vendor.
G.
Exit Interview The inspector met with management representatives (denoted in p=.agraph A) at the conclusion of the inspection. The inspector sunnarized the scope and findings of the inspection.
The management representatives had no comment in response to the items discussed by the inspector.
The inspector reviewed the format to be used by the company when responding to inspection findings which requires corrective action to be initiated.
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