ML19295G105
| ML19295G105 | |
| Person / Time | |
|---|---|
| Issue date: | 11/05/1980 |
| From: | Barnes I, Oller R NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML19295G100 | List: |
| References | |
| REF-QA-99900100 NUDOCS 8012180621 | |
| Download: ML19295G105 (9) | |
Text
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U. S. NUCLEAR REGUL1 TORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT REGION IV Report No.
99900100/80-02 Program 51400 Company: Limitorque Corporation 5114 Woodall Rd.
Lynchburg, Virginia 24501 Inspection Conducted: September 30 - October 3, 1980 Inspectors:
R 8-3-80 R. E. Oiler, Contractor Inspector Date ComponentsSection II Vendor Inspection Branch Approved:
l ' i' D I. Barnes, Chief ComponentsSection II Vendor Inspection Branch Summary Inspection on September 30 - October 3, 1980 (99900100/80-02)
Areas Inspected:
Implementation of 10 CFR 50 Appendix B criteria and other applicable requirements including:
action on previous inspection findings, nonconformances and corrective action, internal audits, qualification of special process personnel and procurement document control.
The inspection involved 25 inspector-hours on site.
Jesults:
In the five (3) areas inspected, no deviations were identified in three (3) areas. The following were identified in the remaining areas.
Deviations: Nonconformances and Corrective Action:
1.
Failure to include the Manufacturing Supervisor's signature on two Variation Reports which originated in the Machine Shop.
80121806M
2 2.
Failure to have all of the Material Review Board members in attendance at meetings, signoff on five (5) M.R.B. Reports.
3.
Failure to include a representative of the Manufacturing Engineering group at Material Review Board meetings, as shown by the list of attendees indicated in M.R.B. Report No. 022 and other M.R.B. Reports.
Internal Audits:
Failure to perform a follow-up audit on three (3)
Audit Deficiency Notification Items, Nos. G.3, F.5 and C.8 which had resulted from the July 29, 1980 audit of the Limitorque Manufacturing Plant.
(See Notice of Deviations, Items A-D.)
Unresolved Items None.
3 DETAILS SECTION A.
Persons Contacted J. Allen, Q. C. Supervisor
- H. Beers, Plant Manager
- K. Groome, Q. C. Manager K. Kurtz, Administrative Assistant to QC Manager
- T. Mignogna, Senior Vice President of Manufacturing D. Warsing, Technical Manager
- Denotes those attending the Exit Mc Ung.
B.
Action on Previous Inspection Findings 1,
(Closed) Deviation A (Report No. 80-01):
Failure to maintain a Tool and Gage Inspection / Calibration Record Card for the Wilson Rockwell Hardness Tester, and to include on a computer calibration list, the identity of an inside depth micrometer for Employee Clock No. 25 4.
The inspector found that in accordance with Limitorque's response letter dated April 28, 1980, that the above calibration record for the subject hardness tester is now being maintained. The employee's micrometer has been put on an " Add to List", dated March 9, 1980 for inclusica in the computer calibration list of employee tools.
To verify corrective action and provide prevention of recurrence the two (2) above areas were audited by Limitorque in July 1980.
2.
(Closed) Deviation B (Report No. 80-01):
Failure to complete Inspection Travel Cards at first piece, patrol and final inspection of parts, and failure to file the Inspection Travel cards daily as proof of asterial inspection. The inspector found that in accordance with Limitarque's response letter dated April 28, 1980, the QC Machine Shop Inspectors were notified by memorandum dated April 28, 1980, that the procedure for completing and filing the inspection travel cards must be followed. To verify corrective action and pro-vide prevention of recurrence, the above activity was audited by Limitorque during July 1980.
3.
(0 pen) Unresolved Item (Report No. 80-01).
The Standard Operating Procedure QCP-5.3 did not describe the recording of the final parts inspection on Form L-375, prior to placing the parts in the store room.
Discussion established that this procedure has not yet been revised. This item remains open.
4 C.
Nonconformances and Corrective Action 1.
Objectives The objectives of this area of the inspection were tu verify that the following items were controlled in accordance with applicable NRC and QA Program requirements.
a.
A written system has been establisned to assure that noncon-formances are controlled and corrcetive action is taken.
b.
Documented procedures or instructions are implemented for identification, documentation, segregation and disposition of nonconforming materials 7 arts or components, and notification to affected organizations.
c.
Nonconforming items are reviewed and accepted, rejected, repaired or reworked in accord 9nce with documented procedures.
d.
Conditions adverse to quality are promptly identified and corrected.
The causes of significant conditions adverse to quality are e.
determined and corrected to preclude repetition.
f.
The condition adverse to quality, the cause and the corrective action are documented and reported to appropriate levels of management.
2.
Method of Accomplishment The preceding objectives were accomplished by:
a.
Review of the QA Manual Section X " Control of Nonconforming Material and Corrective Action."
c.
Review of the following procedures:
(1) QCP-3, " Receiving Inspection Procedures", subprocedure QCP-3.D " Variation Report."
(2)
QCP-4, " Machine Shop Inspection Procedures," subprocedure QCP-4.E " Variation Report."
(3) Review of procedures QCP-13, Material Review Board Procedure."
5 c.
Review of the computer print-out listing variation reports for August 1980.
d.
Review of 16 variatica reports, selected from c.e above list.
Review of five (5) Material Review Board reports, including the e.
related variation reports.
f.
Observation of the methods of physical segregation of noncon-forming parts in the shop receiving inspection and machine shop areas.
g.
Discussions with cognizant personnel.
3.
Findings a.
Deviations from Commitments See Notice of Deviations, Items A, B and C.
b.
Unresolved Items None D.
Internal Audits 1.
Objectives The objectives of this ares of the inspection were to verify that the following items were controlled in accordance with the QA Manual and applicable NRC requirements:
a.
A written system has been established to assure that internal audit 1 are performed and controlled in accordance with applicable requirements to verify compliaace 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.
c.
Audit -esults are documented and reviewed by managcment having
_esponsibility in the are audited.
d.
Follnw-up action, including reaudit of deficient areas, is taken where indicated.
6 2.
Method of Accomplishment The preceding objectives were accomplished by:
a.
Review of the QA Manual Section I, Subsection C " Audits."
b.
Review of procedure QCP-14, Revision 3 " Internal Audit Procedure."
c.
Review of records of the internal audit of the Manufacturing Plant performed on July 29, 1980 consisting of the following-(1)
Internal Audit Checklist dated July 29, 1980.
(2) Summaries of deficiency findings dated July 29 and July 30, 1980, from the two (2) auditors to the Senior Vice President.
'3) Audit Deficiency Notifications (ADN) from the auditors to the responsible persons.
(4) Checklists of Internal Audit Follow-up for the ADN items.
d.
Review of records of the internal audit of the Engineering department performed on February 20, 1980, consisting of:
(1)
Internal Audit Checklist dated February 20, 1980 (2) Summary of the deficiency findings dated March 10, 1980 (3) Audit Deficiency Notifications e.
Discassions with cognizant personnel.
3.
Findings a.
Deviation From Commitment See Notice of Deviations, Item D.
b.
Unresolved Items None E.
Qualification of Soecial Process Personnel 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 QA Program requirements:
7 a.
A written system has been established to assure that =easures to control the qualification of personnel performing special processes has been docu=ented.
b.
The above system has been implemented such that the subject personnel are properly qualified in accordance with NRC and the =anufacturer's require =ents.
2.
Method of Acce=olishment The preceding objectives were accemplished by:
a.
Review of the QA Manual Section VI "Special Processes."
b.
Review of the following standard operating procedures :
(1) QCP-12. A, " Heat Treating".
(2) QCP-12. F, "'4elding".
(3) QCP-11. A " Nondestructive Testing Qualification and Certification Procedure".
(4)
QCP-8, " Paint Procedure".
c.
Review of records of training from Carbo 11ne Company for two (2) Limitorque painters.
d.
Review of records of SNT-IC-1A eynmination (including visual) qualification and certification of L1=itorque personnel in Liquid Penetrant Ernmination, consisting of one (1) Level III Exa=iner and one (1) Level II technician.
e.
Review of the records of '4 elder Perfor=ance qualifications for the welding processes of Flux Core Arc '4elding (semi-automatic) and Shielded Metal Arc Welding (manual).
3.
Findings Within this area of the inspectica ac. irc.-iations or unresolved items were identified.
8 F.
Procurement Document, Control 1.
Obiectives The objectives of this area of the inspection were to verify that:
A written system has been established to assure that procurement a.
document control is performed in accordance with NRC and QA Program requirements.
b.
Written procedures have been prepared and approved by the cc p:ny to provide control of procurement documents for materials equipment and services, as applicable.
The above procedures are being effectively implemented.
c.
2.
Method of Accomplishment The preceding objectives were accomplished by:
Review of the QA Manual Section III, " Vendor Procurement Control."
a.
b.
Review of the follow..'g procedures:
(1)
QCP-10.A, " Purchasing Policy".
(2)
QCP-10.B, " Request for Quotation" (3)
QCP-10.C, " Standard Material-Purchase Orders".
(4)
QCP-10.D, "Special Material - Purchase Orders".
(5)
QCP-10.E, " Approved Vendors".
c.
Review of the Approved Vendor List (computer-run) dated September 29, 1980.
d.
Review of traveling requisitions and purchase orders for critical components as follows:
(1) Housing Castings - Lynchburg Foundry.
(2) Drive Sleeves - Walker Machine and Foundry.
(3) Worm Gears - AMPCO Metals Inc.
(4) Special Electric Motors - Reliance Electric Company.
9 3.
Findings Within this area of the inspection, no deviations or unresolved items were identified.
G.
Exit Intervieu 1.
The inspector met with management representative denoted in paragraph A. above, at the conclusion of the inspection on October 3,1980.
2.
The following subjects were discussed:
a.
Areas inspected.
b.
Status of corrective and preventative ac. ion fuc the previous outstanding items.
c.
The deviations identified in this report.
3.
Ine manufacturer's representatives were requested to formulate their corrective and preventative action response to deviations in accordance with the three (3) conditions identified in the inspection report cover letter.
4.
Management's questions related to clarification of the above items.