ML19312E988
| ML19312E988 | |
| Person / Time | |
|---|---|
| Issue date: | 05/09/1980 |
| From: | Brown R, Whitesell D NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML19312E986 | List: |
| References | |
| REF-QA-99900304 99900304-80-1, NUDOCS 8006180303 | |
| Download: ML19312E988 (8) | |
Text
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VENDOR INSPECTION BRANCH U.S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT REGION IV Report No.
99900304/80-01 Program No. 51300 Company:
Progressive Fabricators, Inc.
St. Louis, Missouri Inspection l
Conducted:
April 28 - May 2, 1980 mum 4
Inspectors:
m Ross L. Brown, Contractor Inspector Date ComponentsSection I Vendor Inspection Branch g/5 //0 Approved by:
(topd 7
D. E. Whitesell, Chief Date ComponentsSection I Vendor Inspection Branch Summary Inspection on April 28-May 2, 1980 (99900304/80-01).
Areas Inspected:
Management meeting and implementation of 10 CFR 50, Appendix B including manufacturing process control, control of nonconformances and correc-tive action and audits.
The inspection involved thirty-two (32) inspector hours on-site by one NRC inspector.
Results:
In the four (4) areas inspected there was no deviations in any of the areas, no unresolved items were identified in three (3) of the areas, and one unresolved item was identified in the remaining area.
Unresolved Item: The Discrepancy Report number is not recorded on the Process Sheets (see Details Section, Paragraph C. 3. b.).
800618030 3
l DETAILS SECTION A.
Persons Contacted Progressive Fabricators, Inc. (Pro Fab)
- R. J. Casey, President
- A. Barton,-Assistant Plant Superintendent
- A. W. Buss, Quality Assurance Manager
- F. F. Felber, Nuclear Project Engineer
- G. E. Frizzelle, Quality Control Inspector (Level III)
- G. K. Lowery, Quality Assurance Supervisor
- T. E. Tharp, Purchasing Agent Kemper Instelnce Companies (Lumberman's Mutual)
- R. L. Erickson, Authorized Nuclear Inspector (ANI)
- P. C. Lahoti, Authorized Nuclear Inspector Supervisor
- Attended Initial Management Meeting.
- Attended Exit Interview and Initial Management Meeting.
B.
Initial Management Meeting 1.
Objectives The objectives of this meeting were to accomplish the following:
a.
To meet with the Progressive Fabricators, Inc. management and those persons responsible for administration of the company's QA program and to establish channels of communication.
b.
To determine the extent of company's involvement in the commerical nuclear business.
c.
To explain NRC direct inspection program including LCVIP organization, VIB inspection methods and documentatione,.
d.
To describe the NRC evaluation of the ASME inspection system.
2.
Method of Accomplishment The preceding objectives were accomplished by a meeting on April 29, 1980, with those persons identified in Paragraph A.
The following is a summary of the meeting:
. a.
The VIB organization was described and its relationship to NRC Region IV and the NRC Headquarters component of the Office of Inspection and Enforcement.
b.
The conduct of VIB inspections was described and how our in-spections are documented including the report, responses to reports, how proprietary information is handled, the Public Document Room, and the White Book.
c.
The purpose, scope, and status of the NRC's two year program for evaluation of the ASME inspection system as an acceptable indepen-dent-third party was discussed.
d.
The companies contribution to the nuclear industry was discussed including current and projected activity, status of ASME certiff-cates of authorization and third party inspection arrangements.
3.
Results The results of the meeting are as follows:
a.
The company has contracted with Kemper Insurance Companies to provide the inspection services required by the jurisdictional authority and the National Board, for ASME Code items.
b.
The authorized nuclear inspector is providing this service on a part-time basis, c.
The company holds ASME Certificate of Authorization No.'s - N-1434 and N-1435 to use the "N" and "NPT" symbol stamp, the current certificate expires on May 26, 1982.
The company also holds ASME Certificate of Authorization No. 5034 to use the "U" symbol stamp.
This certificate expires on December 31, 1982.
i d.
Information was obtained that the company's current domestic nuclear contracts include Class 2 tubular products welded with filler metal and Class MC Penetration Parts for two (2) nuclear facilities, however, neither contract is presently being worked.
e.
The company does not conduct any oipe design work, only shop de-tailing when required.
f.
The company has the capability to design and fabricate Class 2 and 3 vessels.
g.
No deviations from commitment or unresolved items were identified.
~
. C.
Manufacturing Process Control 1.
Objectives The objectives of this area of the inspection were to verify that:
a.
The manufacturer operates under a controlled system using process sheets or equivalent for all operations including inspections pertinent to component production.
b.
The system requires all processes and examination / tests to be performed by qualified personnel using qualified procedures.
c.
The process sheets are required to be prepared including docu-ment number and revisions to which production and examinations must be performed.
d.
The process sheets include provisions for the identification of hold / witness points and signoff and date.
2.
Method of Accomplishment The preceding objectives were accomplished by a detailed review of:
a.
The Pro Fab-Nuclear Quality Assurance Manual (NQAM) Procedure No. 5.1, " Process Sheet System," (travelers).
b.
Customer Purchase Order No.
78KA2-823188-2, contract date September 4,1978 and referenced Specification No. A2-823188 for Pipe and Fitting for Essential Service Water and Cooling Tower and Raw Service Water Piping Intake Pump Station."
c.
The quality Package for Pro Fab Job No. N-196, Customer Order No.
d.
The quality file for Pro Fab Job No. N-195-5-Customer Order No.
1092-487.
e.
Drawing No. 35869, Rev.5. Valve Containment Assembly, Job No. 195-5.
f.
Weld Procedures 59A, Rw. 1 and 60.A. Rev.l.
9 Liquid Penetrant Procedure No. 720, Rev. 4.
3.
Findings a.
No deviations from commitment, or unresolved items were ide.itified in this area of the inspection.
. b.
The following information was verified:
(1) The NQAM describes the generation, 'orovals and controls of the two (2) types of process sheets (production type and non-pro-duction type jobs).
It also includes the assignment of veri-fication and witness points.
(2) The customer documents identifies the procedures instructions, etc. that must be submitted for customer approval.
(3) The quality package for Job No. N-196 includes the following documents related to the production order (routine) for appro-ximately 16,000 feet of 30 inch OD and 180 feet of 48 inch OD Pipe:
Process Sheet,ASME Form NPP-1 Data Report, ASME Form NM-1 Data Report, and inspection and test reports.
The process sheets were approved by QA and the ANI also the iden-i tified hold points on the sign-off sheet were signed by the ANI j
and Pro Fab QA.
1 (4) The quality file for Job No.
N-195-5 includes the following quality documents related to the ASME Section III.
Class MC-Valve Containment Assembly (non-Production type job):
Process Sheets (that defines the operations sequences which includes the Pro Fab inspection points and ANI and customer hold points),
Form N-2 Partial Data Report and the required quality documents.
The process sheets and quality document were approved by the appropriate responsible persons.
(5)
The weld procedures were satisfactorily qualified in accordance with the requirements of ASME Code,Section IX.
D.
Control of Nonconformances and Corrective Action 1.
Objectives The objectives of this area of the inspection were to verify that pro-cedures have been established and implemented for:
a.
Disposition of nonconformances that provide for:
(1) The control of nonconforming materials, parts, or components to prevent their inadvertent use or installation.
(2)
Reporting these conditions and the corrective action to management.
(3) Assuring that corrective action is implemented and maintained.
1
. 2.
Method of Accomplishment The above objectives were accomplished by a review of the following documents:
a.
NQAM - Procedure No. 's 12.1, "Nonconformities," 12.2
" Resolution of Nonconformities" and 12.3
" Corrective Action."
b.
Discrepancy Reports (DR) No.'s 334, 341, 242, 247, and 246.
c.
Six (6) QA manager sumary reports to the President.
d.
Material Review Board Reports (MRB) No.'s 1869, 1912, 1368, 1870, and 1889.
3.
Findings
)
a.
Deviation No deviations from commitment were identified, b.
Unresolved Items The discrepancy reports numbers for minor discrepancies are not recorded on all process sheets.
Pro Fab management stated that discrepancy reports are issued for all discrepancies identified during in-process inspections, minor deficiencies, etc. these were never intended to be recorded on the process sheets.
The inspector verified that DRs are written for all minor deficiencies identified prior to presenting the component for final inspection.
Ccmpany management also stated that Procedure 12.1 of the NQAM will be reviewed and revised as necessary to clarify the requirement.
This area will be inspected during a subsequent inspection, c.
The following information was verified:
(1) The three (3) NQAM procedures assigns the responsibilities for the identification, documentation, evaluation, disposition, and approval of all nonconformities.
(2) The discrepancy reports were complete, appropriate approvals signature and date (including ANI).
. (3) The MRB reports; identifies the discrepancy, describes the corrective action and preventive measures and include appro-priate signature and date (including ANI).
(4) The QA Manager's summary report to the company President iden-tifies the trends and actions taken to prevent recurrence.
E.
Audits 1.
Objectives The objectives cf this area of the inspection were to verify that the following items w6ie controlled in accordance with the QA Manual and applicable NRC and ASME Code requirements:
a.
A written system has been established to assure that audits are per-formed and controlled in accordance with applicable codes to verify compliance with all auditable aspects of the QA program.
b.
Planned and periodic audits are performed in accordance with written procedures or checklists by qualified personnel not having direct i
responsibilities in the areas being audated.
c.
Audit results are documented and reviewed by management having responsibility in the area audited.
d.
Followup action, including reaudit of deficient areas, is taken 4
where indicated.
2.
Methods of Accomplishment The preceding objectives were accomplished by:
a.
Review of NQAM Procedure No.
1.5 " Description of Internal Audit System."
b.
Review of 1980 audit schedule.
c.
Review of two (2) audit checklists.
d.
Review of six (6) internal audit reports.
\\
e.
Review of three (3) follow-up audit reports.
3.
Findings No deviations or unresolved items were identified in this area of the inspection.
The following information was obtained:
.... a.
The QAM assigns the responsibilities for the performance of audits.
b.
The company Vice President is responsible for the performance of audits of the Quality Control Department.
c.
The QAM requires the audits to be conducted in accordance with a prepared checklist by trained and qualified personnel.
d.
The audit results are required to be documented and corrective action taken when required.
e.
The audit reports were conducted in accordance with a prepared check-list that covered the Quality Control activities throughout all sections of the Quality Assurance Manual.
f.
All audit reports were transmitted to the President.
g.
The identified nonconformances were corrected and area reaudited and signed off by assigned auditor.
h.
The assigned auditors were approved by the President prior to the audit.
F.
Exit Interview The inspectors conducted an exit meeting with the Pro Fab management representatives at the conclusion of the inspection.
Those persons indicated by an asterisk in Paragraph A. above were in attendance.
The inspector discussed the scope of the inspection and the details of the finding identified during the inspection.
The Pro Fab management's comments were for clarification only.
_ _ _ _