ML19270G238
| ML19270G238 | |
| Person / Time | |
|---|---|
| Issue date: | 04/06/1979 |
| From: | Sutton J, Whitesell D NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML19270G223 | List: |
| References | |
| REF-QA-99900306 99900306-79-1, NUDOCS 7906050177 | |
| Download: ML19270G238 (9) | |
Text
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U. S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT REGION IV Report No. 99900306/79-01 Program No. 51300 Company:
Leslie Company 401 Jefferson Road Parsippany, New Jersey 07054 Inspection Conducted: March 12-16, 1979 Inspector:
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!M f)W.Sutton,ContractorInspector, Vendor
/j0 ate
/ Inspection Branch Approved P it b d i9 D. W. Whitesell, Chief, ComponentsSection I, Date Vendor Inspection Branch Sumary Inspection on March 12-16, 1979 Areas Inspected:
Implementation of 10 CFR 50, Appendix B criteria, and applicable codes and standards; including the vendor's action on previous findings; calibration; testing of completed products, nondestructive Examination (NDE) Personal Qualifications; nonconformance and corrective action; and review of vendor activities. The inspection involved thir cy-four (34) inspector hours on site by one (1) NRC inspector.
Results:
In the six (6) areas inspected, no apparent deviations or unresolved items were identified in three (3) areas. The following was identified in the remaining three (3) areas.
Deviations: Calibration: master test gage not calibrated as prescribed.
(Enclosure, Item A); Testing of Completed Products: Assembly Instruction Procedure (AIP) not reviewed by QA Manager or ANI (Enclosure, Item B).
Unresolved Item:
Nonconformance/ corrective action: clarification of paragraph 7230 of the QA Manual required dispositioning nonconformances identified after split production orders are issued.
(Details, paragraph E.3.b.).
7906050177
. Details A.
Persons Contacted
- W. B. Buckman, Director QA
- J. T. Muller, Vice President, Engineering
- A. W. Philippy, Manager QA B. Horvath, Supervisor, Inspection and Test D. Powers, Lead Person, Tool and Gage H. Schichter, Foreman, Welding
- Denotes those present at the Exit Interview.
B.
Action on Previous Inspection Findings 1.
(Closed) Deviation (Report No. 77-01): QA Manual does not clearly define the organizational structure.
The inspector verified that the current QA Manusl, dated December 7,1978, clearly delineates the organizational structure including responsibilities.
2.
(Clcsed) Deviation (Report No. 77-01): The QA Manual does not provide for a formal training program for welders. The inspector verified that a formal training program for all personnel involved with quality related activities is in force, and is being documented. The current manual, Section 2100, outlines the current training program,.and internal audits of the program have been performed and documented.
3.
(Closed) Unresolved Item:
Designation of Level III NDE examiner by written test. All Level III NDE Personnel have been certified by written examinations in accordance with the SNT-TC-1A requirements.
C.
Calibration 1.
Objectives The objectives of this area of the inspection were to verify that; a.
Calibration activities are performed and controlled in accordance with the QA Manual cormiitments and the applicable NRC regulations and ASME Code requirements, b.
A system has been established, and is maintained, to assurt that tools, gages, instruments and other measuring devices used in activities affecting qui.ity are properly calibrated and adjusted at specified periods to maintain accuracy within the specified limits.
c.
Calibration records are kept for each instrument indicating the calibration results.
d.
The calibration system is being properly implemented.
2.
Method of Accomplishment The preceding objectives were accomplished by:
a.
Review of the QA Manual Section 7100, dated December 7, 1978, Calibration, to verify that provisions have been established to assure that equipment requiring calibration had been identified, the calibration frequency is specified, the calibration standards are identified, the traceability
'of standards is required, and a recall system is in effect.
b.
Review QIP 4201, Revision A, dated April 13, 1972, titled
" Pressure Gage Calibration."
c.
Review of the inspection use log.
d.
Review of the recall system.
e.
Review of the index system calibration record cards.
f.
Review of equipment certification for standards, Dead Weight Testers Nos. 460 and 472, and Gage Blocks Nu. 8-1092 and 8-1093.
g.
Inspection of the calibration facilities for mechanical and tastrument calibration.
h.
Review of the calibration records for the following:
(1) Micrometers No. 2-28-149-116-12 and 17.
(2) Vernier indicators and scales Nos. 142-139, 111, 110 and 45.
(3) Welding volt meters and ammeters.
(4) Surface plates Nos. 8-1014 and 8-1016.
(5) Pressure geges 100-31.
, (6) Review of QIPs Nos. 4101, 4002, 4103, 4104, 4105, 4106, 4107, 4108, and 4109 for calibration instructions.
i.
Discussions with shop personnel.
3.
Findings a.
Deviations See Enclosure, Item A.
During the inspector's review of the QIP for pressure gage calibration and calibration record cards for the pressure gages, it was noted that the 5,003# master pressure gage had not been calibrated correctly within a three (3) month period.
The Dead Weight Tester for the 5,000# gage had been sent out for calibration and was not available for longer than the three (3) month period specified.
During this time the 5,000#
master pressure gage was being calibrated using the 1,000#
Dead Weight Tester. This would invalidate the tests performed using the 5,000# master gage as the gage could not be calibrated at the mid point and at both ends of the scale as specified by the procedures.
b.
Unresolved Items None.
D.
Testing of Comoleted Products 1.
Objectives The objectives of this area of the inspection were to verify that:
a.
Testing acitivities are controlled in accordance with the QA Manual comitments and applicable NRC regulations and the ASME Code requirements.
b.
Products are assembled in accordance with approved proce-dures and materials comply with approved specification.
c.
Functional tests of products are performed in accordance with epproved test documents.
d.
That the system is being properly implemented.
. 2.
Method of Accomplishment The preceding objectives were accomplished by:
a.
Review of the QA Manual:
(1) Section 3200, Inspection Plans.
(2) Section 5000, Final Parts Inspection.
(3) Section 6000, Assembled Items Test inspection.
(4) Section 7500, Acceptance Stamps.
b.
Review of the following Quality Control Instructions (QCI's):
(1) 3334, Test and Cleaning Inspection, Nuclear Strainers.
(2) 1203, Final Inspection of Parts.
(3) 2301, Assembly Inspection Plans.
(4) 2302, Parts Inspection Plans.
(5) 2903, Quality Instructions Nuclear Valve Body Wall Thickness Measurements.
c.
Valve Serial Log Book.
d.
Assembly and Test Plans for Orders No. 77-11530, Part Numbers 1461-1462, and 1481; No. 74-8239; No. 7706085010; and No.
77-16063; Part No. 1376, 1424, 1425.
e.
Review of the system for the control of the inspection and acceptance stamps.
f.
Inspection of the test equipment and certification of gages and instruments.
g.
Review of test reports to verify that test results are within the specified acceptance limits and are properly documented, and that the procedures are being properly implemented.
h.
Observation of shop activities.
, 1.
Discussion with shop personnel.
3.
Findings a.
Deviations See Enclosure, Item B.
b.
Unresolved Items None.
E.
Nonconformance and Corrective Action 1.
Objectives The objectives of this inspection were to verify that:
a.
A system for control of nonconformances and corrective actions has been established and is consistent with NRC regulttions, and the QA Program requirements; and b.
The system is properly implemented.
2.
Method of Accomplishment _
The objectives of'this area of the inspection were accomplished by:
a.
Review of the QA Manual, Section 7000, Nonconformance and Corrective Action.
b.
Review of the Material Review Board (MRB) Log Book.
c.
Review of twenty (20) MRB reports to verify appropriate disposition.
d.
Review of the Correction Action Request Book.
e.
Review of the scrap and rework reports.
f.
Review of QCI 1503 instructions reporting and documenting nonconformances, g.
Incpection of the segregation area.
. h.
Review of W0 63009-05-92, Part Numbers F 3111-1 and F 3111-2 to verify appropriate disposition of the identified nonconformances.
i.
Discussions with shop personnel.
3.
Findings a.
Deviations None.
b.
Unresolved Items Paragraph 7230, Disposition Decisions, requires clarification relating to the disposition and documentation of nonconforming items on split work orders.
F.
Nondestructive Examination (NDE) Personnel Qualifications 1.
Objectives The objectives of this area of the inspection were to verify that Leslie had developed and implemented detailed procedures for the qualification and certification of N9E personnel, in accordance with the QA Manual commitments and applicable NRC regulations and ASME Code requirements.
2.
Method of Accomolishment The preceding objectives were accomplished by:
a.
Review of the QA Manual, Section 7000, Special Process Controls, Nondestructive Examinations.
b.
Review of QCI 8004, Revision 2, Qualification of Level II or I NDE Personnel, c.
Review of audits performed for suppliers of subcontracted NDE work.
d.
Review of NDE personnel qualification and physical records.
e.
Review of SNT-TC-1A 1975, " Personnel Qualifications and Certification in Nondestructive Testing,"
. f.
Discussion with the Level III Examiners.
3.
Findings a.
Deviations None.
b.
Unresolved Items None.
c.
The documents retiewed demonstrated that the special processes are being perfonned by qualified personnel, using qualified procedures, consistent with the regulations, ASME Code and contract commitments.
G.
Review vi 'J r.dr 's Activities 1.
Objectives The objectives of this area of the inspection were:
a.
To review the nuclear activity and work load to assess their impact on future NRC inspections, b.
Evaluate the vendor's fabrication / manufacturing equipment and capabilities.
2.
Method of Accomolishment The foregoing objectives were accomplished by observing the manufacturing / fabrication in progress, and discussions with the cognizant vendor personnel.
3.
Findings The vendor has the capability to design, manufacture and test ASME Code Class 1, 2 and 3 nuclear control valves ranging in sizes from 1/2" to 12", and pressure ratings from 150 pounds to 2500 pounds. Also Class 1, 2 and 3 nuclear line strainers ranging in sizes from 1/2" to 8".
He has welding capabilities to perform manual, semi-automatic and automatic welding processes, including hard facing.
.g.
He presently subcontracts his heat treat activities and all nondestructive examinations, except for Liquid Penetrant (PT) examinations which are performed in-house.
The Vendor holds valid ASME Certificates of Authorization number N 2244 for use of the ASME "N" stamp and Certificate. number N 2245 for use of the ASME "NPT" stamp for class 1, 2, and 3 valves, fluid conditioning devices, parts and appurtenances. The current active nuclear contracts being processed represents approximately 10 percent of the present work load.
H.
Exit Interview The inspector met with management representatives ; denoted in para-graph A) at the conclusion of the inspection.
The inspector sum-i.'arized the scope and findings of the inspection. The maragement representatives had no comment in response to the items discussed by the inspector.
_