ML19270H875
| ML19270H875 | |
| Person / Time | |
|---|---|
| Issue date: | 11/15/1979 |
| From: | Hunnicutt D, Oller R NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML19270H864 | List: |
| References | |
| REF-QA-99900316 99900316-79-2, NUDOCS 8001040197 | |
| Download: ML19270H875 (8) | |
Text
.
U. S. NUCLEAR REGULATORY C0&lISSION OFFICE OF INSPECTION AND ENFORCEMENT REGION IV Report No.
99900316/79-02 Program No.
51300 Company:
Gould, Incorporated Valve and Fittings Division 6300 W. Howard Street Chicago, Illinois 60648 Inspection Conducted: October 22-26, 1979 Inspector:
ik0tb Ib(b h Lgurl e
R. E. Oller, Cdntrac or' Inspector \\
Date ComponentsSection I Vendor Inspection Branch i
Approved by:
}&
J i@b ll-l C- ]
m D.~ M. Hunnicutt', Chi f g
Date ComponentsSection I Vendor Inspection Branch j
Summary Inspection on October 22-26, 1979 (99900316/79-02)
Areas Inspected:
Implementation of 10 CFR 50, Appendix B criteria, other NRC inspection,ts, and applicable codes and standards including:
requiremen action on previous findings, review of vendor activities, internal audits, manu-facturing process control, and equipment calibration. The inspection involved thirty (30) inspector-hours on site.
Results:
In the five (5) areas inspected, no deviations were identified in four (4) areas. The following were identified.
I Deviation: Equipment Calibration; calibration of the Bendix Profiloceter test plate was not recorded on a Tool and Gage Control Card.
(See Notice of Deviation)
Unresolved Items: Equipment Calibration; written instructions, covering the use of the Dead Weight Tester in calibrating the master pressure gage were located at Plant No. 1 instead of Plant No. 3 where the Tester was (See Details Section, paragraph F.y.M 1 3 0 2 located.
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2 i
DETAILS SECTION A.
Persons Contacted R. Cardamaone, Group Leader
- R. Haines, Quality Assurance Manager D. Jamrog, Inspection Manager i
T. Jose, QA Inspector I
- S. Kunka, Vice President - Operations R. Malone, QA Engineer J. Misek, Tool and Gage Group Leader R. Piotter, QA Inspector J. Pemperton, Forge Manager G. Simpson, QA Inspector j
S. Syed, Receiving Inspector R. Williams, QA Inspector
- Attended the Exit Meeting.
B.
Action on Previous Inspection Findings (Closed) Unresolved Item (Report No. 79-01): The hydrostatic test procedure for valves did not reflect the actual practice of rejecting all valves which showed any seat leakage and tagging them " Hold for QA Resolution." The inspector found that procedure ESN-309 " Hydrostatic Shell and Seat Integrity Test" was revised on July 20, 1979, to provide that as an alternate to measuring a valve test leakage rate, a valve assembly may be rejected at any leakage rate, and removed from the test stand without measuring the leakage rate.
C.
Review of Vendor's Activities 1.
Objective The objective of this area of the inspection was to assess the vendor's activities and their impact on future NRC inspections.
2.
Method of Accomplishment The preceding objective was accomplished by:
a.
Discussions with cognizant personnel.
b.
Review of the QA Manual.
c.
Observation of in process parts production and valve assembly operations.
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3 d.
Review of the Gould Valve and Fittings Division Procedure No. 9, Revision 0, for reporting 10 CFR Part 21 deficiencies.
3.
Findings a.
Deviations From Commitments None.
b.
Unresolved Items None.
c.
Other Findings - General (1) The nuclear valve workload of Plant No. 3 remains at about 25%, as it was during the prior NRC inspection.
(2) The Gould Valve and Fitting Division received an Authorized Nuclear Inspector Supervisor's audit in August, 1979, and an unannounced ASME audit on September 12, 1979.
(3) The ASME N, NPT and Quality Systems (material) authori-zations are still valid until the expiration date of March 1, 1982.
(4) The division has an approved procedure No. QCP-9 for reporting of any 10 CFR Part 21 deficiencies which might be found.
D.
Internal Audits 1.
Objectives The objectives of this area of the inspection were to verify that the following items were controlled in accordance with applicable NRC and ASME Code requirements:
A written system has been established to assure that internal a.
audits are performed and controlled in accordance with applicable codes to verify compliance with all aspects of the QA program.
b.
Planned and periodic internal audits are performed in accordance with written procedures or checklists by qualified personnel not having direct responsibilities in the areas being audited.
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4 c.
Audit results are documented and reviewed by management having responsibility in the area audited.
d.
Follow-up action, including reaudit of deficient areas, is taken where indicated.
2.
Method of Accomplishment l
The preceding objectives were accomplished by:
a.
Review of the QA Manual Section 15.0 " Auditing."
b.
Review of the " Qualified Auditor's List," dated Au8ust 15, 1979 and revised October 24, 1979.
c.
Review of records of educatio:.
training, experience and qualification for the person's identified on the " Approved Auditor's List."
d.
Review of records of the internal audits performed since January 1, 1979.
e.
Review of the "1979 Schedule of Nuclear Audits by Section of the Nuclear QA Manual."
i f.
Review of the record of " Management Audit" dated 1978.
g.
Review of internal audit assignment letters for the rest of 1979.
h.
Discussions with cognizant personnel.
3.
Findings a.
Deviations from Commitments None.
l b.
Unresolved Items None.
c.
Other Findings (Comments)
The checklist records of internal audits, performed during 1979, were not dated or signed in all cases by the auditors.
The QA Manager indicated this omission will be corrected for future audits.
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5 E.
Manufacturing Process Control 1.
Objectives The objectives of this area of the inspection were to verify that the following items were controlled in accordance with applicable NRC and ASME Code requirements:
a.
A written system has been established to assure that manu-facturing processes are controlled in accordance with appli-cable codes.
b.
Measures have been established and implemented to control the manufacturing processes by use of process sheets, travelers, checklists or procedures.
c.
The process sheets, travelers, checklists or shop procedures used included: the document numbers and revisions to which the processes, inspections or tests conformed; the results of completion of the specific operations; the signature, initials or stamp of the manufacturer's responsible representative and date were shown for operations completed, and the signature, initials or stamp of the authorized inspector and date, were shown for activities he witnessed.
2.
Method of Accomplishment The preceding objectives were accomplished by:
a.
Review of the QA Manual Section 10.0 " Process Control."
b.
Review of the parts traveler for valve bodies, Part No.
30099901, Heat Mark Symbol E-70, in machining.
c.
Review of two (2) assembly travelers for two (2) lots of 25 valves each, for Item 80961870, valve assemblies prior to hydrostatic testing.
d.
Review of assembly travelers for Item 806187C, Assemblies SN-20515 through 20539 for valves af ter hydrostatic test; also the related Hydrostatic Test Log Sheet dated October 25, 1979, for these valves.
e.
Review of the contents of the traveler package prior to release to production for customer order 63072-N1974315, covering manufacture of 5-way manifold valves.
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6 3.
Findings Within this area of the inspection, no deviations or unresolved items were identified.
F.
Equipment Calibration 1.
Objectives The objectives of this area of the inspection were to verify that the following itens were controlled in accordance with applicable NRC and ASME Code requirements:
a.
A written system has been established to assure that equip-ment calibration is performed and controlled in accordance with applicable codes.
b.
A written procedure has been developed and approved which contains provisions to assure that tools, gages, instruments and other inspection, measuring and testing equipment and devices used in activities affecting quality, are of the proper range, type and accuracy, and are calibrated and pro-perly adjusted at specified periods or use intervals.
c.
The devices are identified in the documented system and/or procedure and are calibrated in accordance with the system and procedure.
d.
The calibration is performed against certified measurement standards which have known relationship to National Standards, where such standards exist.
1 e.
The control measures include provisions for test equipment identification and calibration status by marking, or on records traceable to the equipment.
2.
Method of Accomplishment l
The preceding objectives were accomplished by:
a.
Review of the QA Manual Section 12.3 " Calibration."
b.
Review of Quality Procedure No. 8, Revision 0, " Control of Gages, Tools and Mechanical Test Equipment."
c.
Observations of the follow measuring devices located in Plant No. I and Plant No. 2, for identification numbers traceable to records of calibration and/or certification:
l i
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7 (1)
Infrared Pistol Optical Pyrometers (2) Outside and Depth Miccc.neters (3) Vernier Calipers (4) Rockwell Hardness Testers (5)
"Go - No Go" Thread Gages (6) Pipe Thread Ring Gages (7) Plug Gages (8) Optical Comparators (9) Profilometers (10) Kodak Contour Projector (11) Surface Plates (12) Hydrostatic Test Gages on Test Branch (13) Dead Weight Tester and Weights.
d.
Discussions with QA Inspectors in Plant No. I and No. 3.
e.
Review of calibration records consisting of Tool and Gage Control Cards and subcontractor's certificates of calibration for the above devices.
3.
Findings a.
Deviations From Commitments l
See Notice of Deviation enclosure.
b.
Unresolved Item i
Written calibration instructions for calibrating the master pressure gage using the dead weight tester, were in Plant No. 1 instead of Plant No. 3 where the pressure gage and dead weight tester were located. This item remains unresolved pending Gould's posting of the procedure in the work location and verifying this action during a subsequent hTC inspection.
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8 c.
Other Findings - Comments (1) The precision measuring mechanical tools such as micro-meters and calipers used in Plants No. I and No. 3 have old superseded QA and QAV calibration control numbers on them in addition to newly assigned calibration control numbers.
It could not be determined by talking to the assigned QA Inspectors which of these numbers were the current calibration control serial numbers.
(2) Measuring devices such as hardness testers, are identified by the device manufacturer's serial numbers which are in-accessible and not clearly or conspicuously displayed on the device for calibration identification purposes.
(3) A certificate of calibration supplied by Argle Engineering for five (5) hardness testers contained errors in the serial numbers shown on the certificate.
(4) The calibration label on the optical comparator in Plant No. 3 contained the wrong calibration date of September 28, 1979, instead of June 28, 1979, as shown on the Certificate of Calibration.
The OA manger indicated that he will have the above conditions corrected.
G.
Exit Meeting 1.
The inspector met with management representatives denoted in para-graph A, at the conclusion of the inspection on October 26, 1979.
2.
The following subjects were discussed:
a.
Areas inspected.
b.
Status of Corrective Action for the previous inspection finding.
c.
The deviation, unresolved items, and comment findings identified in this report.
3.
The manufacturer's representatives were asked to formulate their corrective action responses to the deviation in accordance with the three (3) conditions identified in the inspection report cover letter.
4.
The manufacturer representatives questions related to clarification of the inspection findings.
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