ML19282B471
| ML19282B471 | |
| Person / Time | |
|---|---|
| Issue date: | 12/11/1978 |
| From: | Agee J, Hunnicutt D, Mcneill W NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML19282B427 | List: |
| References | |
| REF-QA-99900294 NUDOCS 7903150038 | |
| Download: ML19282B471 (16) | |
Text
U. S. flVCLEAR REGULATORY COMMISSION OFFICE OF IriSPECTION AND ENFORCEMErlT REGION IV Report No.
99900294/78-01 Program No. 44075 Company:
Westinghouse Electric Corporation Medium Motor & Gearing Division Post Office Box 225 4454 Genesee Street Buffalo, New York 14240 Inspection Conducted: October 30-flovember 2, 1978 Inspectors:
I[ Mx
/4dPM/
J.,R'/ Agee,, Contractor Inspector, Vendor Date Iffspection Branch
$$hn /$n d' h? h* lb <Z
//W71 y
M. Mctie'ill,4 Contractor Inspector, Vendor Date fInspection Branch Approved by:
/
ruNa
/M;N/
D. M. Hunnicutt, Chief, ComponentsSection II, Date '
Vendor Inspection Branch Summary Inspection conducted October 30-November 2, 1978 (99900294/78-01)
Areas Inspected:
Implementation of the Quality Assurance (QA) Manual / Program including:
initial management meeting; customer contracts; design control /
design tests / production tests; document control; audits; inspection; receiving inspection; and procurement document control. The inspection involved fifty-four (54) inspector-hours on site by two (2) NRC inspectors.
Results:
In the nine (9) areas inspected, no apparent deviations or un-resolved items were identified in four (4) of the areas.
In the remaining areas, four (4) deviations and one unresolved item were identified and are described as follows:
790315004SS DETAILS SECTIO?! I (Prepared by J. R. Agee)
A.
Persons Contacted A. L. Beaman, Senior Design Engineer C. D. Carothers, Contract Administrator J. J.~ Courtin, Manager, Special Products Engineering
- C. J. Herron, Jr., Manager, Manufacturing
- D. L. Hoover, General Manager
- R. F. McKeever, Quality Assurance Manager
- L. E. Smith, Marketing Manager
- D. M. Stiglmeir, Engineering Manager Z. A. Tendorf, Senior Design Engineer
- J. F. Walsh, Senior Quality Assurance Engineer
- Attended Exit Interview.
B.
Initial Management Meeting An initial management meeting was conducted to acquaint the vendor's management with the NRC responsibility to protect the health and safety of the public and to inform them of certain responsibilities imposed on vendors by the " Energy Recrganization Act of 1974" (Public Law 93-438) and 10 CFR 21.
1.
Objectives The objectives of the Initial Management Meeting were to:
Meet with the vendor's management personnel and establish a.
channels of communication.
i b.
Acquaint them with their responsibilities under Section 206 of Public Law 93-438 and 10 CFR 21.
l j
Learn how the company operates and its policies and practices c.
i concerning quality assurance and quality control.
i d.
I Obtain information related to the company's contribution to the nuclear industry.
2.
Method of Accomolishment The preceding objectives were accomplished by:
Describing the historical events that indicated the need a.
for the Vendor Inspection Program (VIP).
i i
e
. b.
QA prgram meets contract, regulatory, and national standards requirements for the production of Class lE products.
QA Manual contains a management policy statement concerning c.
QA.
d.
QA organization is structured to achieve organizational independence and freedom to:
(1)
Identify quality problems.
(2)
Initiate appropriate resolutions.
(3) Verify corrective actions.
QA staff has access to a level of management that ensures e.
effective implementation of the QA program elements and authority to enforce positive and timely corrective action.
f.
Duties, responsibilities and authority of the QA staff are clearly delineated in writing.
g.
Program has provided detailed written procedures, properly 4
reviewed and approved, for control of quality activities.
h.
Program provides for indoctrination and training of personnel performing activities affecting quality.
2.
Method of Accomplishment The preceding objectives were accomplished by:
a.
Review of the Quality Assurance Manual, dated May 31, 1978.
b.
Review of Quality Control Instructions (QCI) Manual, revised September 16, 1974.
c.
Discussions with cognizant QA management personnel con-cerning the QA program activities.
d.
Examination of the Medium Motor and Gear Division (MMG) organizational structure for verification the QA Depart-ment has sufficient independence and authority to enforce effective implementation of the MMG Quality Assurance program.
This examination revealed the QA Manager reports to the Manager of Manufacturing.
_ d.
Review of customer motor specification number 36-823513 with design criteria N6-50-D707 and seismic criteria N6-50-D707.
e.
Review of Westinghouse document WCAP-9112, Equipment Qualification Data Package, Class lE Medium A.C. Motors, last revision May 1, 1978.
(This is the document by which MMG quotes to customers for Class lE motors as evidence that its equipment is qualified.)
3.
Findings a.
Deviations None.
b.
Unresolved Items Design Assurance Procedures describing design assurance and the marketing / engineering / manufacturing interfaces have been compiled but not implemented.
Implementation of these procedures will be inspected in a future inspection.
E.
Design Control / Design Tests / Production Tests 1.
Objectives The objectives of this area of the inspection were to verify that:
a.
Written instructions had been implemented for design control.
b.
Adequate test facilities were used tc verify design of prototype products (motors).
c.
Test procedures have been implemented for qualification testing of all nuclear safety related motors.
d.
All design data, logs, analyses, engineering notebooks, style drawing books for all nuclear safety related motors are available for review.
e.
Qualified life of the nuclear safety motors has been determined and that this maets applicable national codes and standards.
. d.
Review of QA Manual,Section XVII, Design Control, dated September 23, '.;/7.
e.
Review of QCI fio. 36, Design Control and MI Review, dated March 27, 1978.
f.
Review of Westinghouse document, WCAP-9112, Equipment Qualification Data Package, Class lE, Medium A.C. Motors, last revision May 1, 1978.
(This document verifies that equipment complies with IEEE-Std. 323-1974.)
g.
Review of Test Specification 110299, Commercial Test for MAC Polyphase Induction Motors, dated December 5,1974.
Verified that production motors are tested to this specification.
h.
Review of Test Specification 986260, Complete Test for Polyphase Induction Motors, dated tiovemoer 29, 1977.
Verified that all motors, identified by contract as nuclear safety related, are tested to this specification.
i.
Review of Product Specification, Nuclear Safety-Related AC Motors, dwg. 4209A62, dated May 15, 1975.
j.
Discussions with contract administrator, design engineers, test engineers and engineering manager regarding the MMG design and manufacture of nuclear safety related motors.
3.
Findings Within this area of the inspection, no deviations or unresolved items were identified.
F.
Document Control 1.
Objectives The objectives of this area of the inspection were to verify that:
a.
Measures had been established to control the issuance of documents such as instructions, procedures, drawings, including changes thereto which prescribe activities affecting quality, b.
Measures had been established to assure that documents, including changes, had been reviewed for adequacy and approved for release by authorized personnel and are distributed where needed.
DETAILS SECTIOTI II (Prepared by W. M. McNeill)
A.
Persons Contacted P. J. Calleri. Buyer R. D. Frost, Buyer H. Hansen, QC Supervisor D. L. Hoover, General Manager R. Kubek, Manufacturing Engineering Manager R. F. McKeever, QA Manager J. G. Schraven, QC Supervisor M. W. Showers, Buyer E. Z. Malentynowicz, Purchasing Supervisor J. F. Walsh, QA Engineer B.
Audits 1.
Obiectives The objectives of this area of the inspection were to verify that:
a.
Procedures have been prepared and approved that describe a system for internal and external auditing which are consistent with the commitments of the QA program and Criterion XVIII of 10 CFR 50, Appendix B.
b.
Audit procedures are being properly and effectively implemented by the manufacturer.
2.
Method of Accomolishment The preceding objectives were accomplished by:
a.
heview of the Westinghouse Medium Motor and Gearing Division Quality Assurance Manual, revision 19, dated May 31, 1978, section XVII, which established the general requirements for audits.
b.
Review of the Quality Control Instructions; Audit (Patrol)
Inspection, QCI-5, undated; Final Assembly /In-Process Audit, QCI-10, undated; Finished Product Audit, QCI-24, undated; which established the specific requirements of audits.
. c.
Verification that the above procedures and manual were implemented by review of the final inspection of a motor, and the two inprocess inspection stations, shafts, and winding. At each station inspection operations were reviewed and observed. Check Lists, Station Inspection Guides, Delivery tags, inspector stamps, drawings, and specifications were reviewed at each of these stations.
3.
Findings a.
Deviation See Enclosure, Item B.
b.
Unresolved Items None.
c.
Qmments A number of fixed gages are used to check or inspect drawing requirements.
For example, key way slots are inspected with gage blocks. This policy of not calibrating fixed gages ignores the effects of wear, mishandling, etc.
The authorized gages are those that are assigned by the Gage Inspector to the inspection station.
The gages referenced in the deviation are snap gages used to measure critical shaft diameters.
D.
Receiving Insoection 1.
Objectives The objectives of this area of the inspection were to verify that; a.
Procedures have been prepared and approved that describe receiving inspection activities as appropriate to assure conformance of procured items and services to the identified requirements. These procedures are consistent with the commitments of the QA program and Criteria VII and X of 10 CFR 50, Appendix B.
b.
The above procedures are being properly and effectively implemented by the manufacturer.
. 2.
Method of Accomplishment The preceding objectives were accomplished by:
a.
Review of the Westinghouse Medium Motor and Gearing Division Quality Assurance Manual, Revision 19, dated May 31, 1978, section XV, which established the general requirements for receiving inspection.
b.
Review of the Quality Control Instructions Receiving Inspector, QCI-3, undated, Receiving Inspection, QCI-3A, undated and Inspection Coding, QCI-1, dated January 1, 1977, which established the specific requirements of receiving inspection.
c.
Verification that the above procedures and manual were implemented by review of four (4) recent receiving lots, bearings, 10-31-74, insulation, 10-27-313, bolts, 10-26-322, and varnish, 10-27-96.
d.
Verification that the above procedures and manual were implemented by review of the Purchase Orders, Inspection Codes, Vendor Compliance Report Codes, Sample Record Cards, Advice of Delivery tags, Test Reports, and vendor certifications associated with the above lots.
3.
Findinas a.
Deviations See Enclosure, Item C.
b.
Unresolved Items None.
c.
Comments A number of observations were made of this area of the inspection.
(1) A number of materials are received in a bulk form e.g.
resins, varnish, paint, etc. Yet the program did not address how these items were to be handled in regards to sampling.
The sampling program in use was desig-nated for discrete units.
. c.
Verification that the above manual was implemented by review of the 1978 Audit Schedule, April 1978 audit and October 1978 Audit and their associated findings.
d.
Verification that the above procedures were implemented by review of four Patrol audits in 1978 and one Finished Product Audit dated April 15, 1978.
3.
Finding; a.
Deviation (See Enclosure, Item A.)
b.
Unresolved Items flone.
C.
Inspection 1.
Objectives The objectives of this area of the inspection were to verify that:
a.
Procedures have been prepared and approved that describe the inspection system which is consistent with the ccm-mitments of the QA program and Criterion X of 10 CFR 50, Appendix B.
b.
Inspection procedures are being properly and effectively implemented by the manufacturer.
2.
Method of Accomolishment The preceding objectives were accomplished by:
a.
Review of the Westinghouse Medium Motor and Gearing Division Quality Assurance Manual, Revision 19, dated May 31, 1978, sections III, IV, V, X, and XIII which established the general requirements for inspection.
b.
Review of Quality Control Instructions, Inspection Stamps, Use and Control, QCI-22, dated January 30, 1975, Gage Control, QCI-14, dated October 16, 1970, Final Assembly In-Process Final Assembly Audit, QCI-11, undated, First Piece and Recurrent Inspection, QCI-4, undated, which established the specific requirements of inspection.
, (2)
Bearings were ordered to one of two drawings. Bearing drawing 2736D20, Revision 15, was found in Receiving Inspection.
Revision 17 was issued on June 18, 1978.
This drawing contained all the technical and quality requirements for bearings. Also, it was ncted that lot 9-21-03 was received and the material used.
The Procurement Document Specification requires the vendor to submit a certification of the material (rolled steel).
No records could be found of a certification.
(3) Significant characteristics of received material are verified via independent tests by Westinghouse's own laboratory.
In review of the test reports from the lab, it was noted in some cases that nonconformances to specification requirements were not being processed properly. Let 96 of varnish was observed which did not conform to the specification on gel time and viscosity. Contrary to established procedures acceptance of the lot was noted by the laboratory supervisor on the test report with a verbal concurrence by engineering.
E.
Procurement Document Control l.
Objectives The objectives of this area of the inspection were to verify that:
a.
Procedures have been established for the preparation and review of procurement documents which are consistent with the commitments of the QA program and Criteria IV of 10 CFR 50, Appendix B.
b.
The above procedures are being properly and effectively implemented by the manufacturer.
2.
Method of Accomolishment The preceding objectives were accomplished by:
a.
Review of the Westinghouse Medium Motor and Gearing Division Quality Assurance Manual, Revision 19, dated May 31, 1978, section XIV, which established the general requirements for procurement document control.
, b.
Verified that the above ~anual was impleaented by review of purchase orders for rolled steel, 20F1010ZNKFTZ-6C, shaft steel, 20F10105AD02250-70, cable, 20Z63711 AL 3RE-6C, wire, 20ZX21500-C, and bearings 20XPZOO74-C.
c.
Verified that the above manual was implemented by review of the drawings, specifications, and certifications an a
~
recent lot of the above purchase orders.
/
3.
Findings
(
a.
Deviations See Enclosure, Item D.
b.
Unresolved Items None.
c.
Comments Most products purchased, with a few exceptions e.g. bearings, are purchased to Procurement Document Specifications (PDS).
The PDS details all the technical and quality requirements.
Some purchase orders e.g. 20Z63711AC 3RE-6C did not document the revision of the PDS that was applicable. Some certifications received on purchase order 20F10105AD02250-7D did noc detail the PDS revision.