ML19270G241
| ML19270G241 | |
| Person / Time | |
|---|---|
| Issue date: | 04/05/1979 |
| From: | Kelley W, Whitesell D NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML19270G227 | List: |
| References | |
| REF-QA-99900049 99900049-79-1, NUDOCS 7906050182 | |
| Download: ML19270G241 (8) | |
Text
..
U. S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT REGION IV Report No. 99900049/79-01 Program No. 51300 Company:
Atwood and Morrill Company, Inc.
285 Canal Street Inspection at: Salem, Massachusetts 01970 Inspection Conducted: March 21-23, 1979 Inspector:
Y Ar>-
04-6L6-19 Wm. D. Kelley, Contfractor Inspector, Vendor Date Inspection Branch M
,46r' hdw,'c.i d4-o5'/9 O
/
Approved by:
D. E. Whitesell, Chief, ComponentsSection I, Date Vendor Inspection Branch Summary Inspection on March 21-23, 1979 (99900049/79-01)
Areas Inspected:
Implementation of 10 CFR 50, Appendix B and applicable Codes and standards, including manufacturing process control, training, and audits, also, reviewed previously identified items. The inspection involved seventeen (17) inspector-hours on site by one (1) NRC inspector.
Results:
In the three (3) areas inspected, no apparent deviations or unresolved items were identified in two (2) areas. The following was identified in the remaining area.
Deviation: Manufacturing Process Control (Se Notice of Deviation enclosure.)
7906050t$>,
Details (Prepared by Wm. D. Kelley)
A.
Persons Contacted Atwood and Morrill Company, Inc. (AM)
- J. M. Covey, Quality Control Engineer
- F. A. Crippen, Vice President of Manufacturing W. A. Doyle, Manager of Systems and Procedures
- W. F. Emerson, Quality Control Manager M. D. Lyons, System Analysis
- E. H. Morency, Quality Control Super <isor
- A. Niciewsky, Quality Assurance Engineer
- V. W. Toneatti, Corporate Quality Assurance Manager Hartford 5 team Boiler Inspection and Insurance Comoany_
- R. E. Feigel, Engineer
- G. Pivie, Authorized Nuclear Inspector
- Denotes those persons who attended Exit Interview (See paragraph G.).
B.
General Review of Vendor's Activities 1.
The ASME issued AM Certificates of Authorizations N-1766 and N-Dei 7, authorizing the use of t! e "N" sym ol for Class 1, 2, and 3 valves and the use of the "NPT" symbol for Class 1, 2, and 3 valve parts and appurtenances and piping subassemblies.
The authorizations expire May 20, 1980.
2.
AM has the design and machining capabilities for manufacturing gate, globe, and check valves from 21/2 inch to 72 inch in size and 150# to 2500# ANSI pressure ratings.
3.
The authorized inspection agency is Hartford Steam Boiler Inspection and Insurance Ccmpany.
The authorized nuclear inspection is a full time resident inspector.
4.
The AM Company, Inc., (Salem and Washington plants) were purchased by Xomox Corporation of Cincinnati, Ohio, from Foster-Wheeler Corporation in the last quarter of 1978.
5.
It is estimated that the production of components for the nuclear industry accounts for approximately 75% of the vendor's work load.
. 6.
The Quality Assurance Manager of the Salem plant has been promoted to Corporate Quality Assurance Manager and now reports directly to the President of AM. A Quality Control Manager is now responsible of the administration of the Quality Assurance Program at the Salem plant and reports to the Corporate Quality Assurance Manager.
C.
Previously Identified Items 1.
(Closed) Deviation (Report No. 78-01):
Contrary to the require-ments of Criterion VII of Appendix B to 10 CFR 50 and vendor's QA Program commitments, the records demonstrated that audits of AM's yproved casting suppliers were not being perfonned within the prescribed time period.
The inspector verified that the AM casting supplier had been audited. Also, that a new procedure," Standard Operating Inspec-tion for Approved Vendor List QC-214-1," had been writtt:n, ap-proved, and issued by the Quality Assurance Department to prevent recurrence.
2.
(Closed) Unresolved Item (Report No. 78-01): Ther6 was no evi-dence that the procedures developed by AM to control design activities had been reviewed for adequacy and approved for re-lease by the authorized personnel.
The inspector verified that AM Procedure No. 20-71-04, Controlling Design Products under ASME Section III had been revised and approved by management, and had been issued for implementation.
3.
(Closed) Unresolved Item (Report No. 78-01): AM is currently redefining the responsibilities of the Systems Department and will revise their Quality Assurance Manual and its implementing procedures, and will present them to the Authorized Inspection Agency's Specialist for acceptance.
The inspector verified that a procedure (Policy No. 2) had been written and approved by management, that redefines the responsi-bilities of the Systems Department, and the Quality Assurance Manual had been revised to include the new procedure. The Manual revision had been reviewca and accepted by the Authorized Inspec-tion Agency.
4.
(Closed) Unresolved Item (Report No. 78-01): AM is currently reviewing their vendor evaluation for receiving inspection re-quirements, and will reviso the applicable sections of the Quality Assurance Mar.ual, as necessary.
The revised documents will be presented to the Authorized Inspection Agency for accep-tance.
, The inspector verified that the receiving inspection departmcat has been realignest, and the Quality Assurance Manual revised to reflect the realignment, and the revision accepted by the Auth-orized Inspection Agency.
5.
(Closed) Unresolved Item (Report No. 78-01): AM does not presently reference the implementing audit procedure in its Quality Assurance Manual. AM will reference the implementing procedures in its QA Manual, and prtsent it to the Authorized Inspection Agency for acceptance.
The inspector verified that the audit section of the Quality Assurance Manual had been appropriately revised and +' e revision had been and accepted by the Authorized Inspection Ax.ncy.
D.
Manufacturing Process Control 1.
Objectives The objectives of this area of the inspection were to verify that the vendor's manufacturing processes were:
a.
Perfonned under a controlled system which meets the NRC rules and regulations, 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 accomplished by:
a.
Review of the ASME accepted Quality Assurance Manual, Issue 4,Section III, " Procurement Control,"Section IV,
" Process Control,"Section II, "Nonconformances," to verify that procedures had been established to prescribe a control system for the manufacturing processes.
b.
Review of the following procedures No. 20-67-01, date effective May 26, 1978, Receiving Inspection by Quality Control, No. 40-65-02, date effective May 23, 1978, Preparing and Processing Routine Sheets for Pressure r
. Retaining parts under the jurisdiction of ASME Code, to verify that the control system requires shop travelers, or process control check list, to be prepared continuing document numbers and revisions to which the process must confonn, and requires all processes, and test, to be per-formed by qualified personnel using qualified procedures.
c.
Review of the shop process order list to verify that it has spaces for reporting results of specific operations, or reference to other documents where results are main-tained, that it includes provisions for sign off by the vendor, indicating the date on which the operation or test was completed, and that it provides for sign off by the authorized nuclear inspector for those activities which he witnesses, including the date of witnessing.
d.
Review of shop process orders No.14008, Item 75, No.13952, Item 05, No.14008, Item 81, to verify that they comply with the above referenced procedures, and the overall QA Pmgram documentation requirements, including establishment of mandatory hold points by the authorized nuclear inspector.
e.
Interviews with personnel to verity they are knowledgeable in the procedures applicable to manufacturing process control.
3.
Findings Deviation, see Notice of beviation enclosure.
a.
b.
Within this area of the inspection, no unresolved items were identified.
E.
Training 1.
Objectives The objectives of this area of the inspection were to ascertain:
a, Whether procecures had been developed and approved by the vendor prescrhing a system for training personnel whose activities affect the quality of their products in a manner consistent with NRC rules and regulations, and the vendor's QA Program commitments, b.
That the training procedures were being properly and effectively implemented by the ven6r.
2.
Method of Accomplishment The objectives of this area of the inspection were accomplished by:
a.
Review of the ASME accepted Quality Assurance Manual, Issue 4,Section I, paragraph 1.8, Indoctrination and Training,Section VI, paragraph 6.3.1.1, Personnel and Training, to verify the vendor had established procedures to prescribe a sys:em for training personnel whose activities affect the quality of their products.
b.
Review of the following documents:
Employee Training Plan; Master Training Plan - QC Department 1979; Quality Assurance Training Matrix; 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 perfoming special processes, audit personnel, and personnel involved in quality related design and procurement activities.
c.
Review of the following procedures QC-C-2, Section A, Program for Qualification Certification of Personnel in Nondestructive Testing, Schedule of Instruction Seminar - QC Department, Lesson - Plan - Training Program, Drafting, QA Training in Manafacturing to verify that they provided for the indoctrina-tion 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 testing personnel and retraining and recertification if evaluation of perfomance shows individual capabilities are not in accordance with specified acceptance limits.
d.
Review of training records of inspectors, nondestructive testing personnel, auditors, designers, and quality assurance and procurement personnel to verify that the procedures ar.d necessary training documents are aulable to the personnel perfoming the training, and the tra.aing procedures are being properly and effectively implemented.
e.
Interviewed personnel to verify whether the training perfomed was commensurate with the persons assigned quality related duties.
. 3.
Findings The inspector verified that (1) procedures had been developed and approved by the vendor which prescribe a system for training personnel performing quality related activities, that are consis-tent with NRC regulation, code and contract requirements, and (2) the training program is properly implemented and is effective.
Within this area of the inspection, no deviations or unresolved items were identified.
F.
Audits (Internal Management) 1.
Objectives The objectives of this area of the inspection were to verify that:
a.
procedures had been prepared and approved by the vendor to prescribe a system for auditing (Internal Management) which is consistent with NRC rules and regulation, and the vendor's commitments in the ASME accepted Quality Assurance program, b.
The audit procedures are 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, Issue 4, Section 1, paragraph 1.4, " Audit of QA Manuals,"
Section XII, " Audits," to verify the vendor had established procedures which prescribe a system for internal management audits.
b.
Review of the AM System Department procedures No.1, Revi-sion 0, to verify that it had been prepared by the designated authority, approved by responsible management, and reviewed by the quality assurance function.
4 c.
Review of the AM 1978 QA Manual, Audit-pre-Audit Meeting, dated July 26, 1978, to verify it identified the organization responsible for avd; ting, established audit personnel quali-fications, prov'aed for training and indoctrination of audit personnel, est, ;"9ed the essen" ' elements of the audit
e
. system, provides audit schedules to assure coverage of all elements of the Quality Assurance Program, and requires reporting and follow-up corrective action by the auditing organizations.
d.
Review of the Audit of #4 Quality Assurance Manual, dated November 11, 1978, to verify that the procedures and the necessary audit system documents, are available t'o the auditing personnel, and that the procedures are being pro-perly, and effectively implemented.
3.
Findings a.
The inspector verified that:
(1) Procedure had been prepared and approved by the vendor which prescribes a system for auditing consistent with NRC rules and regulation, ASME Code and contract re-quirements, and the vendor's commitments.
(2) The audit procedures are being properly and effectively implemented by the vendor.
b.
AM conducted a comprehensive in depth management audit of the implementation of the entire Quality Assurance Manual.
The findings and data presented in the audit report were definitive and complete.
G.
Exit Interview At the conclusion of the inspection on March 23, 1979, the inspector met with the company's management, identified in paragraph A, for the purpose of informing them as to the results of the inspection.
During this meeting the identified deviation was discussed and the evidence which supported the findings were identified.
The company's management acknowledged the findings and supporting evie.nce as being understood, but had no additional canments.
1.