ML19284A621
| ML19284A621 | |
| Person / Time | |
|---|---|
| Issue date: | 01/23/1979 |
| From: | Agee J, Hunnicutt D NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML19284A620 | List: |
| References | |
| REF-QA-99900224 NUDOCS 7903150118 | |
| Download: ML19284A621 (8) | |
Text
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U. S. NUCLEAR REGULATORY COMMISSION OFFICE JF INSPECTION AtlD E!!FORCEMENT REGION IV Report No.
99900224/79-01 Program No.
51400 Company:
Bailey Controls Company 29801 Euclid Avenue Wickliffe, Ohio 44092 Inspection Conducted: January 8-11, 1979 Inspector:
Y db
//2 7/7f J.fA. Agee,iContractor Inspector Date Wendor Inspection Branch Approved by:
/ /2 7 /79
[y D. M. Hunnicutt, Chief, ComponentsSection II, Date Vendor Inspection Branch Summary Inspection on January 8-11, 1979 (99900224/79-01)
Areas Inspected:
Implementation of the quality assurance program to the approved QA Manual and 10 CFR 50, Appendix B, including audits-internal, design control, inspection and test and measurement.
The inspection involved twenty-eight (28) inspection hours on site by one (1) !!RC inspector.
Resul ts :
In the four (4) areas inspected, no apparent deviations or unresolved items were identified.
7903150113
. DETAILS SECTION A.
Persons Contacted
- R. J. Campbell, President V. C. Catalano, Manager, Quality Control J. D. Courtwright, Quality Coordinator Contract Engineering H. Howe, Contract Quality Engineer M. A. Keyes, Vice President, Engineering
- G. M. Kohl, Manager, Contract Quality Engineering
- H. L. Miller, Director, Quality Assurance D. E. Nelson, Contract Quality Engineer
- J. A. Pittman, Vice President, Marketing E. T. Shields, Supervisor, Engineering Documentation
- R. A. Walzer, Audit Coordinator
- Attended exit interview.
B.
Audits-Internal 1.
Objectives The objectives of thi area of the inspection were to verify that:
a.
Audits are conducted on a periodic basis.
b.
Audit procedures had been approved and implemented.
Sufficient audit training is provided to maintain qualified c.
auditors.
d.
Management reviews audit programs and reports.
2.
Method of Accomplishment The preceding objectives were accomplished by:
a.
Review of QA Manual Procedure 1768, Audits, Revision D.
April 21, 1978, and Procedure 1768-01, Internal Audits, Revision D, April 21, 1978.
b.
Discussions with QA Department management concerning audit activities.
. c.
Review of audit files including the " Audit Report 1977 Quality Assurance Program, Internal Audit."
In this report the QA department, using a prepared checklist completed an internal audit of all identified functions throughout the plant. This was an indepth audit covering implementation, application, usefulness, etc., of the existing primary, secondary, and tertiary procedures.
This audit resulted in the identification of three hundred forty-seven (347) deviations. As of the date of this inspection all but twenty:-five (25) of the deviations had been closed out and/or satisfied by correcting defecient or delinquent activities, by revising most procedures, by purging or adding other procedures, and retraining personnel in certain areas.
Resultant from the audit the QA Manual has been revised and reissued.
As a supplement to the 1977 audit a second indepth audit has been scheduled for 1979.
In this audit each department will be audited to the full QA program. The purpose is to ascertain that all quality functions needed to satisfy the criteria of ANSI N45.2 and 10 CFR 50, Appendix B, have been adequately addressed and covered.
d.
Review of the 1979 audit schedule which indicates all departments will be audited to the full QA program require-ments. The purpose of this is to purge any unnecessary QA practices and provide optimum QA coverage for the areas or QA functions required to provide nuclear and non-nuclear instrumentation and controls products to the industry.
e.
Review of audit training records which revealed that all new employees receive formal orientation training including a description of QA practices and an introduction to the codes and standards to which they must comply such as ANSI N45.2, 10 CFR 50, Appendix B, and MIL-Standards.
f.
Review of the records of department quality coordinators who are responsible for providing additional quality training, periodically and as needed, to personnel within the respective department.
g.
Review of the QA Training Manual'for Internal Auditors, Revision B, January 11, 1978.
h.
Review of the training records of fifteen (15) auditors who have been qualified to ANSI N45.2-23.
. 3.
Findings Within this area of the inspection no deviations and unresolved items were identified.
C.
Design Control 1.
Objectives The objectives of this area of the inspection vere to verify that:
a.
Customer contracts (purchase orders) for Class 1E safety related products and systems had imposed required codes and standards of the correct revision (vintage, date) for the nuclear power plant in which the products / systems will be used, b.
Products and systems manufactured for specific nuclear power plants comply with the specific codes and standards imposed by the contract.
c.
Products manufactured for Class 1E systems had been designed and qualification tested in compliance with applicable codes and standards and in compliance with approved design manufacturing and testing procedures and instructions.
2.
Method of Accomolishment The preceding objectives were accomplished by:
a.
Review of the following customer purchase orders for Class 1E safety related products and systems:
(1)
P. O. No. 023032 LJ, January 28, 1970.
(2)
P. O. No. 023033 LJ, January 28, 1970.
These purchase orders require equipment to be supplied in accordance with the licensee specification No. 9996, Revision 1, dated April 6,1970.
b.
Review of Bailey Controls Company (BCCo) letter dated January 26, 1972,
Subject:
(Customer) Order No. 023036LJ BMCo. Job No. 5198P, which states in part that BCCo.,
accepts the purchase order.
. c.
Review of BCCo letter dated January 26, 1972,
Subject:
(Customer) Order No. 023033L.J. BMCo Job No. 5199P, which states in part that BMCo accepts the purchase.
d.
Review of BCCo letter dated December 19, 1978,
Subject:
Qualification Letter of Promulgation, BCCo LOP Log No.
15001-02. This letter states that BCCo has qualified the NI/RPS equipment to meet the qualification require-ments of (Customer) documents and associated references (including revisions).
This letter represents the NI/RPS equipment that was shipped to a specific site in December 1978. This letter identifies all of the qualification and test reports for the individual components for the NI/RPS.
e.
Review of the BCCo Qualification Test Plan and Acceptance Criteria for N1BQ/KS Pressure Transmitters, Control No.
QP-3204-E21-20-TPAC, File No. Q220, dated August 29, 1977.
f.
Review of Qualification Test Laboratory document No.
OP-4100-SEIS, Seismic Qualification Test Procedure for Class IE Modules dated March 14, 1977.
g.
Discussions with QA management regarding the shipment of the equipment of item d., above. The equipment shipped is a cne-of-a-kind design and is identical to equipment that will be' supplied for other current contracts for NI/RPS equipment. No contracts have been negotiated that require qualification to current EEE standards 323-1974 and 344-1975. The equipment and systems shipped are hardwired and are not subject to adjustable software program controls.
Fi,qdi ngs i
3.
Within this area of the inspection no deviations or unresolved items were iderdified.
D.
Inspection 1.
Objectives The objectives of this area of the inspection were to verify that:
. a.
Controlled and documented inspection programs are maintained to assure quality conformance.
b.
Responsibilities for implementation of the inspection program are clearly defined and that inspections are conducted by personnel independent of activities being performed.
c.
Inspection points are identified for each activity and records are maintained for inspection made, d.
Receiving inspection requirements are identified and test instructions are appropriate for the complexity of the incoming product.
e.
Inspection and test procedures are maintained in the area where inspections are conducted.
2.
Method of Accomplishment The preceding objectives were accomplished by:
a.
Discussions with QA, receiving inspection, manufacturing, and test laboratory personnel regarding their respective inspection practices.
b.
Review of the QA Manual, Procedure 1760, Inspection Program, May 30, 1978; Procedure 1760-01, Inspection Program Support, August 17, 1978; Procedure 1760-02 Inspection Procedure, May 19, 1978; and Procedure 1764, Inspection Test and Operating Status of Parts During Fabrication.
c.
Inspection of manufacturing practices, inspection stations and tests stations for the rabrication of production products, examples: transfer relays, VDC Buffer relay, VDC Lat hing relay, Power Supply monitor, Analog Memory.
Although the above devices were not Class 1E products, the assembly, inspection and test stations, personnel and practices were the same as for production of Class 1E products.
d.
Inspection or receiving inspection practices including receipt of incoming products, omparison of invoices to purchase order, identification of discrepant parts,
. preparation of discrepant parts documentation, identifi-cation and storage of non-conforming materials, physical measurements of mechanical parts by calibrated gauges, testing of electronic products by calibrated instruments to latest product drawings, storage and retrieval of products and materials.
e.
Verifying that receiving inspection practices are conducted in compliance with controlled procedures.
3.
Findings Within this area of the inspection no deviations or unresolved items were identified.
E.
Measuring and est Equicment 1.
Objectives The objectives of this area of the inspection were to verify that:
a.
A program for control of measuring and test equipment had been implemented.
b.
All measuring and test equipment is controlled, calibrated, maintained and documented in compliance with written, approved procedures.
c.
All measuring and test equipment calibration data is traceable to the National Bureau of Standards.
2.
Method of Accomplishment The preceding objectives were accomplished by:
a.
Discussions with QA and calibration laboratory personnel concerning th= implemented reasurement and calibration control program.
b.
Inspection of the physical measuring instruments in the.
mechanical inspection stations in the manufactur 'qg and receiving inspection areas. Total of three (3) inspection s tations.
c.
Inspection of the electrical and electronics measuring instruments in product fabrication, receiving inspection and the calibration laboratory.
_a_
d.
Review of the data of the instrument calibration records maintained in the calibration laboratory. A total of twenty (20). instruments were identified in the areas of items b. and c., above, and compared with the data on the respective calibration data cards maintained in the calibration laboratory. All instruments were within the required calibration tolerances and were calibrated within the required calibration cycle.
No examples were identified where out-of-calibration instruments had been used in the measurement of production components or final products.
3.
Findings Within this area of the inspection no devi1tions or unresolved items were identified.
F.
Exit Interview The inspector met with management representatives (denoted in paragraph A) at the conclusion of the meeting of January 11, 1978.
The scope of the inspection was summarized concerning the following QA functions:
1.
Audits-Internal 2.
Design Control 3.
Inspection 4.
Measuring and Test Equipment Management acknowledged the statements made by the inspector.