ML19270G881
| ML19270G881 | |
| Person / Time | |
|---|---|
| Issue date: | 04/03/1979 |
| From: | Agee J NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML19270G879 | List: |
| References | |
| REF-QA-99900240 99900240-79-1, NUDOCS 7906210069 | |
| Download: ML19270G881 (8) | |
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U.S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT REGION IV Report No. 99900240/79-01 Program No. 51400 Company: Westinghouse Electric Corporation Industry Systems Division 200 Beta Drive pittsburgh, Pennsylvania Inspection Conducted: March 6-8, 1979 Inspector:
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- d. R. @~e, Contractor Inspector Date Vend 6r Inspection Branch i
Approved by:
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D. M. Hunnicutt, Chief, Components Date Section II, Vendor Inspection Branch l
Summary Inspection conducted on March 6-8, 1979 (99900240/79-01)
Areas Inspected:
Implementa' tion of 10 CFR 50, Appendix B, criteria and customer requirements including inspection of QA Manual / Program, design control, and customer contracts. The inspection involved twenty-four (24) inspector hours on-site by one NRC inspector.
Results:
In the areas inspected, no apparent deviations or unresolved items were identified.
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. Details Section A.
Persons Contacted T. F. Brozick, Contract Administrator J. A. Davis, Quality Control Supervisor
- A. G. Fitch, Manager, Operations Department E. J. Madera, Manager Nuclear Control of Protection Systems R. M. Paterni, Engineer
- J. A. Pesavento, Manager Product Assurance G. W. Remley, Chief Programer
- H. G. Schecstel, Quality Assurance Manager
- H. E. Six, General Manager
- attended exit interview B.
Quality Assurance Manual / Program 1.
Obj ectives f
The objectives of this area of the inspection were to verify i
that the:
i a.
QA Manual has been maintained current per comitment.
b.
QA Program has been implemented in the areas of auditing, training, receiving inspection, nonconformances, and others.
e c.
Organizational structure and facility capabilities are sufficient to design and manufacture Class IE products and systems.
2.
Method of Accomplishment The preceding objectives were accomplished by:
a.
Review of the QA Manual and determining that it had been maintained current according to Technical Publication (TP) 122.
b.
Review of QA Manual, TP 120, Section 10 Quality Assurance Audit Program which requires that certain areas and func-tions be audited twice annually.
Two (2) areas were selec-ted for inspection: Development Engineering, and Manufac-turing. Audit files revealed these areas had been audited 2240 167 oc
. as required, with approved checklists. No open findings existed. Where findings had been identified, follow-up action had been made within the required sixty (60) days.
c.
Review of QA Manual, TP 122, Section 1 ISO (Industry Sys-tem Division) Product Assurance Charter, paragraph 1-6 Audit and Inspector Personnel Training which states that training will be provided as required through corporate, as well as outside sources.
Records of six (6) manufac-turing inspectors were reviewed which revealed that each inspector had received required on-the-job training in such areas as soldering, crimping, printed circuit (PC) board assembly, wire processing assembly, and printed current inspection.
d.
Review of records of six (6) Froduct Assurance Department personnel including managers, auditors, and engineers.
The records for these six (6) personnel revealed that each had a baccalaureate degrae and had several years experience in quality assurance, quality control, auditing, product reliability and related engineering.
e.
Review of the QA Manual, TP 123 Purchasing Operating Pro-cedures, Section 4.0 Defective Material. The review determined that procedures for handling of nonconformance (rejected) items had been implemented.
f.
A review of incoming material receiving inspection prac-tices, where accepted materials are transferred to stock and rejected (nonconforming) materials are segregated and stored on the rejected materials shelves located in the purchased materials inspection area.
Inspection of the rejected materials revealed each rejected item or parcel of rejects.t materials had a DIN (Discrepant Item Notice) Tag attachei. The rejected materials shelves were identified by the lame of the specific purchaser, who becomes a member of the 4terial Review Board (MRB) for disposition of those rejected materials, g.
Inspection of twelva (12) DINS on which the initially rejected materials had been reviewed by the MRB and marked as: Scrap, Rework-in-house, Rework by Vendor, or Use as Received, as required by i? 123.
h.
Review of the computer printout containing data from the DIN forms that is used as a qualified vendor list (QVL) and for vendor rating.
Vendors with less than an acceptable rating are required to improve performance or are removed from the QVL.
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Findings Within this area of the inspection, no deviations or unresolved items were identified.
C.
Design Control 1.
Objectives The objectives of this area of the inspection were to:
a.
Review the status of the design of a specific integrated protection system (IPS).
b.
Verify that sufficient documentation had been prepared or identified for preparation that will provide traceability of the project from system and hardware / software conceptual design to qualification testing and certification of the final hardware / software system will meet customer speci-i fications and applicable codes and standards required for i
Class IE applications.
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2.
Method of Accomolishment The preceding objectives were accomplished by:
a.
Discussions with engineering management, contract adminis-trator and engineering personnel concerning the status of the IPS prototype projects. These discussions revealed the conceptual design for the IPS was obtained from the customer document WCAP-9153 Integrated Protection System, Prototype Verification Program which also establishes the design principles and the verification programs that will be used during the development, test and operations phase of the prototype model.
b.
Review of the Equipment Specification E-953230 which ref-erences codes, standards and technical and environmental requirements that must be addressed as part of the total IPS rJEsf n.
i c.
W - 4 09 contract administrator files and documentatien, P
) termination that all subsystems were identified with 4,
ated drawings and most drawings had assigned revision
".umberL Mote: drawings with assigned revision numbers represented hardware that was approved for production and use while drawings withcut revision numcers represented hardware still in the development stage.
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- d.
Review of customer purchase order number 546-LP-273768XN dated March 7,1978, for the IPS prototype project.
e.
Review of random selection of five (5) electrical drawings from approximately one hundred (100) drawings from the contract administrator IPS files. These drawings repre-senting individual components, circuits and integrated systems for the IPS were approved.
f.
Review of a random selection of approved drawings that are typical for the hardware (PC cards) for the IPS proto-type. The PC boards represented have been seismically qualified to meet customer requirements for Class IE appli-cations and have been approved for production. The drawings include:
(1) NSC Signal Converter Drawing Number 2837A10G03 (2) NCH Function Generator Drawing Number 2837A11G01 (3) NAL Comparator Drawing Number 2837Al'sG01 (4) NSA Summing Amplifier Drawing Number 2837A14G01 (5) NRC Relay Card Drawing Number 2837A87G04 g.
Review of the draft TP 172 Nuclear Control and Protection System, Software Application Procedure which will be imple-mented for the QA documentation of software development and appl!:ations projects, including the IPS prototype project.
3.
Findings Within this area of the inspection, no deviation or unresolved items were identified.
Comment: The purchase order, item d. above, is for one (1) channel integrated protection system. The concept of the IPS represents a new design trend in the development of safety sys-tems for nuclear power plants. The trend involves the use of programmable digital computers as components of the safety sys-tem.
The conceptual design has been generated to meet criteria and requirements of the custcmer topical report which establishes en i P.'.
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. design principles and the verification programs for development, test, and operations phases of the prototype model. The NRC Office of Nuclear Reactor Regulation (NRR) is currently reviewing and evaluating the progressive design, development and qualifi-cation testing phases of the prototype model.
Quality assurance requirements of 10 CFR 50, Appendix B, have been imposed on the project and should be implemented parallel with implementation of the IpS program plan.
Inspection to the QA documentation requirements for several general functions will continue in subsequent inspections. Those functions in-clude: system requirements, software requirements, preliminary design, detailed design, code and debug, integration and test, and operation and maintenance.
D.
Customer Contracts 1.
Objectives l
The objectives of this area of the inspection were to:
1 a.
Identify customer contracts (purchase orders) for Class IE systems and hardware that have not been reviewed during pre-vious inspections.
b.
Verify tha'. the customers had imposed adequate codes and standards for,the hardi;are and systems purchsed.
c.
Verify that the hardware to be provided has' been qualifi-cation tested to applicable codes and standards, specif-ically IEEE standards.
d.
Verify that the contracts had imposed quality assurance requirements to meet the intent of the criteria of 10 CFR 50, Appendix B.
2.
Method of Accomolishment The preceding objectives were accomplished by:
a.
Discussions with QA and contract administrator personnel responsible for nuclear projects for cor=ercial nuclear power generating stations.
b.
Review of the following contracts (purchase orders) for upgrading protection and surveillance systems:
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P.O. No. 546-GIG-236591-BN (2)
P.O. No. 546-GIG-236592-BN (3)
P.O. No. 546-CLJ-288037-BB (4)
P.O. No. 546-CLJ-291972-BN These contracts require technical upgrading of previously designed and approved Class IE systems for nuclear appli-cations. Each of these contracts required compliance to the W PWRSD QA document QCS-1, Revision 7, and applicable Class IE IEEE standards.
c.
Review of TP (Technical Publication) 136, Contracts Proce-dures Manual concerning contract administration interface with other Westinghouse departments. A comparison of this procedure with the current contract administration files and practices for the IPS Prototype project indicated the files and documentation have been implemented in compliance with TP 136.
d.
Review of PARS (procurement advisory releases) containing engineering data and documentation for the IPS Prototype
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project. Examples and types of data include:
(1) PAR 18,, letter P.O. No. 546-LN-250499, May 8, 1976, containing engineering letter SD-IPLS-496, S.0. MFTP-32, (a) Arming of ILC (Integrated Logic Control)
(b) Anning of Safeguards Logic for Maintenance.
(2) PAR 19, letter November 21, 1977, IPS Prototype, N-Subsystem Requirements and Specification Sheets.
(3) PAR 20, letter May 18, 1976, 414 Integration Protec-tion System, Verification Test Outline.
(4)
PAR 20, letter January 27, 1978, (a) Fiber Optics Cable Installations (b) Fiber Optic Separation.
e.
Review of (W) ISD Process Control Systems Document NO. NPC-003, I\\{
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Revision 2, March 13, 1978, entitled, (W) ISD Standard Ex-ceptions to (W) PWRSD Control and Electrical Systems (C&ES)
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Standards. This document describes the technical position (W) ISD takes in support of its design of electronic compon-ents.
3.
Findings Within this area of the inspection, no deviations or unresolved items were identified.
E.
Exit Interview At the conclusion of the inspection on March 8, 1979, the inspector met with the company's management, identified in paragraph A. for the purpose of discussing the details of the scope of the inspection.
During this meeting, the inspector identified the following areas or QA functions that were inspected:
-QA Manual Program including audits, training, receiving inspection, and nonconforming items
-design cortrol
-customer cuntracts Management acknowledged statements made concerning the details of the inspection.
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