ML19318A493
| ML19318A493 | |
| Person / Time | |
|---|---|
| Issue date: | 04/15/1980 |
| From: | Kelley W, Whitsell D NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML19318A486 | List: |
| References | |
| REF-QA-99900371 99900371-80-1, NUDOCS 8006230223 | |
| Download: ML19318A493 (12) | |
Text
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U. S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT REGION IV Report No.
99900371/80-01 Program No. 51300 Company:
Bristol Steel & Iron Works, Incorporated P. O. Box 471 Bristol, Virgina 24201 Inspection Conducted: March 31, thro h April 3, 1980 Inspectors:
j f 80 William D. Kelle'y,'Contrac}6r Inspector
'Date ComponentsSection I y
Vendor Inspection Branch Approved b.
d M/6 D. E. Whitesell, Chief Date ComponentsSection I Vendor Inspection Branch Summary Inspection on March 31 through April 3, 1980 (99900371/80-01)
Areas Inspected:
Implementation of 10 CFR 50, Appendix B and applicable codes and standards including, design and document control-design input, procurement document control, inspection and test-liquid penetrant examination, equipment calibration, audits-internal management, quality assurance records, control of other special processes, and control of special process-heat treating.
Also performed a review of vendor's activities and conducted an exit interview.
The inspection involved twenty eight (28) inspector-hours onsite by one (1)
NRC inspector.
Results:
In the eight (8) areas inspected, no deviations or unresolved items were identified in seven (7) areas.
The following was identified in the re-maining one (1) area.
Deviation:
Quality Assurance Records (Details paragraph H)
Contrary to Criterion V of Appendix B to 10 CFR 50, paragraph 16.2.2 of the ASME accepted Quality Assurance Manual, and paragraph 5.3 of ANSI N45.2.9 the standard operating procedure SOP 9.2 does not require records removed from storage to be checked out with QA or provide for a method for maintaining control or accountability of records removed from storage.
80062302.2 3
2 DETAILS A.
Persons Contacted Bristol Steel & Iron Works, Inc.
M. Arnold - NDE Technician - Level II L. E. Collins - Plant Manager
- R. J. Corrin - Vice President Technical Services D. Faulner - Manager of Purchasing
- M. D. Fritz - Manager of Projects & Engineering
- J. W. Hagood - Sr. Purchasing Engineer
- 0. L. Hurt - Executive Vice President
- K. Liskey - Manager, Nuclear & Plate Products Division
- R. S. Shaidt - Quality Assurance Manager D. L. Swiney - Manager NDE - L4 vel III
- G. W. Roberts - Quality Assurance Representative Hartford Steam Boiler Inspection & Insurance Company
- 0. K. Franks - Authorized Nuclear Inspector
- Denotes those persons who attended the Exit Interview (See paragraph K)
B.
General Review of Vendor's Activit-'.es 1.
There has been no change in the status of the ASML Certification of Authorization, the authorized inspection agency, or the authorized nuclear inspector as reported in NRC IE:RIV Report 99900371/79-01.
I 2.
BS & IW's contribution to the nuclear inductry represents approximately ten percent (10%) of its total workload.
C.
Design and Document Control - Design Input 1.
Objectives The objectives of this area of the inspection were to verify that:
Procedures had been prepared and approved by the vendor to a.
prescribe a system for the control of the design inputs which are consistent with NRC rules and regulations and his commit-ments in.the ASME accepted Quality Assurance Manual.
3 b.
The design input procedures are properly and effectively im-plemented.
2.
Method of Accomplishment The objectives of this area of the inspection were accomplished by:
Review of the ash 2 accepted Quality Assurance Manual, Revision 9.
a.
(1) Section 1.0, " Control of Contract Specification" and (2) Section 2.0, " Control of Design Documents" to verify the vendor had established procedures to prescribe a system for control of design input.
b.
Review of standard operating SOP 9.2, Revision 4, " Collection, Storage, and Maintenance of Quality Assurance Records (ASME/
10CFR 50)" to verify that they had been prepared by the designated authority, approved by management, and reviewed by QA.
Review of the Customer design Specification Project 4840-P c.
Specification DC-300-13 Revision 8 to verify they had been properly and effectively implemented, the design input is correct, and had been verified and documented.
d.
Interviews with personnel to verify that they are knowledgeable in the procedures applicable to design input.
3.
Findings The inspector verified that BS & IW had only one contract for a.
nuclear containment that required design stress and seismic analysis. The design stress and seismic analysis was subcontracted to an engineering organization that had been surveyed and qualified as an acceptable vendor in accordance with the requirements of the ASME accepted Quality Assurance Manual.
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On other current contracts the customers have furnished to BS & IW their approved design drawing and BS & IW developed l
their own shop fabrication drawing from these drawings.
l b.
Within this area of the inspection, no deviations or unresolved items were identified.
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4 D.
Procurement Document Control 1.
Objectives The objectives of this area of the inspection were to verify that:
Procedures had been prepared and approved by the vendor that a.
prescribes a system for procurement document control which is consistent with NRC rules and regulations, and the vendor's commitments in the ASME accepted Quality Assurance Program.
b.
The procurement document control procedures are properly and effectively implemented by the vendor.
2.
Method of Accomplishment The objectives of this area of the inspection were accomplished by:
Review of the ASME accepted Quality Assurance Manual, Revision 9, a.
(1) Section 6.0, " Control of Material Before Fabrication," and (2) Section 8.0 " Control of Purchased, Materials, Items and Services."
to verify that the vendor had established procedures that prescribed a system for procurement document control.
b.
Review of the following procedures (1) Standard Operating Procedure S0P 3.1 Revision 4, " Vendor Retention and Approval (ASME/10CFR 50)," and (2) Standard Operating Procedure S0P 3.2 Revision 3, " Procurement of Materials, Parts, Services, and Welding Material (ASME/
10CER 50)"
to verify they have been prepared by the designated authority, approved by responsible management and reviewed by the QA c.
Reviewed these selective documents (1) Approved Vendor List (2) Order Acknowlegment l
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5 (3) Material Specification MS 350.1 Revision 0 Carbon and Alloy Steel Forged and Rolled Flanges, Forged Fittings, Valves and Parts.
(4) " Advance Bill of Materials" to verify that the scope of work to be performed is identified, the technical requirements are specified, test and inspection criteria are identified, special instructions and requirements are identified, suppliers are required to have a documented QA program, and procurement documents are reviewed prior to release for bid and/or contract award.
d.
Review of four (4) sets of purchase documents which included (1) Purchase requisitions (2) Purchase Orders (3) Technical Documents to verify that the procurement procedures are being properly and effectively implemented, the interface control of procurement documents is effective and properly performed in accordance with procedures, and the distribution list for procurement documents had been established and are current.
Interviews with personnel to verify they are knowledgeable in e.
the procedures applicable to procurement document control.
3.
Findings a.
The inspector verified that (1) Procedures had been prepared and approved by the vendor that prescribed a system for procurement document control which is consistent with NRC rules and regulations, and the vendor's commitments in the ASME accepted Quality Assurance Program.
(2) The procurement document control procedures were properly and effectively implemented Jy the vendor, b.
Within this area of the inspection no deviations or unresolved items were identified.
E.
Inspection and Test-Liquid Penetrant Examination i
6 1.
Objectives The objectives of this area of the inspection were to verify that; The liquid penetrant examination procedures uced by the vendor a.
are consistent with the NRC rules and regulations, and the commitments in the ASME accepted QA manual.
b.
The liquid penetrant examinations are being conducted by prop-erly qualified personael in accordance with approved and qualified procedures.
2.
Method of Accomplishment The objectives of this area of the inspection were accomplished by:
Review of the ASME accepted Quality Assurance Manual, Revision 9 a.
(1) Section 8.0 " Control of Purchased Materials, Items and Services," and (2) Section 14.0, " Examination and Testing" to verify that the vendor had established procedures for per-forming the liquid penetrant examinations.
b.
Review of the following procedumes:
(1) Standard Operating Procedure S0P 7.1, Revision 11, "Qualifi-cation and Certification of Nondestructive Testing Personnel;"
(2) Project Procedure PT-0109-1, Revision 4, " Liquid Penetrant Examination in Accordance with ASME Section V, Article 6; "and (3) Procedure C0AT-109-1, Revision 1, " Surface Preparation, Cleaning and Painting Procedure."
to verify that the procedures had been approved, certified, and issued in accordance with the vendor's ASME accepted Quality Assurance Program commitments.
Review of Project Procedure PT-0109-1, Revision 4 to verify that c.
it is currently being used, and that it defines the significant examination variables, and that these variables are controlled within the limits specified by the ASME Code.
7 d.
Review of the documents referenced in paragraph a,and b.to verify they provided for the'requalification when changes are made to surface preparations or change in penetrant materials, e.
Interviews with personnel performing liquid penetrant examination to verify they are knowledgeable in the applicable procedures.
3.
Findings a.
The inspector verified that the liquid penetrant examination procedures used by the vendor meet NRC rules and regulations and the commitments in the ASME accepted QA Manual.
b.
The inspectcr did not witness liquid penetrant examination because there was no LP examination being performed during the period of this inspection.
c.
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:
Procedures had been prepared and approved by the vendor to a.
prescribe a system to assure that tools, gages, instruments 1
and other measuring devices used in activities affecting j
quality are properly controlled, calibrated and adjusted at specified periods to maintain accuracy within specified limits which is consistent with NRC rules and regulations and the vendor's commitments in the ASME accepted Quality Assurance Program.
b.
The equipment calibration procedures are properly and effectively implemented and the results adequately documented.
2.
Method of Accomplishment The objectives of this area of the inspection were accompli hed by:
a.
Review of the ASME accepted Quality Assurance Manual, Revision 9, Section 11.0, " Control of Measuring and Test Equipment" to verify that the vendor had established procedures which prescribes a system for controlling equipment calibration.
b.
Review of the following procedures;
8 (1) Standard Operating Procedure S0P 6.1, Revision 6,
" Calibration and Verification of Measuring and Testing Equipment," and (2) Standard Operating Procedure S0P 6.2 Revision 2, " Ultrasonic Instrument Certification / Calibration Procedure" to verify that they had been prepared by the designated authority, approved by management, and reviewed by Quality Assurance. Also to verify that the procedures identifies the items to be calibrated, the frequency, method, and method of documenting the calibration.
Review of the equipment recall schedule, calibration results, and c.
the calibration records, to verify that the results, interval, and the procedures and standards use for calibration, are properly implemented.
d.
Tracking' ten (10) instruments, gages, and meters, through the calibration process, to verify that they had been properly calibrated and certified.
3.
Findings a.
The inspector verified that:
(1) Procedures had been prepared and approved by the vendor which prescribes a system to assure that tools, gages, instruments, and other measuring devices used to verify the acceptability of nuclear items, are properly controlled, calibrated, and adjusted at specified periods to maintain accuracy within specified limits, and that the system is consistent with NRC rules and regulations, and the vendor's commitments in the ASME accepted Quality Assurance Program.
(2) The equipment calibration procedures are properly and effectively implemented and the results are adequately documented.
b.
Within this area of the inspection no deviations or unresolved items were identified.
G.
Audits (Internal Management) 1.
Objectives The objectives of this area of the inspection were to verify that:
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9 Procedures had been prepared and approved by the vendor to a.
prescribe a system for perfor' ing internal management audits m
which is consistent with NRC rules and regulation, and the vendor's commitments in the ASME accepted Quality Assurance Program.
b.
The audit procedures are being properly and effectively implemented by the vendor.
2.
Method of Accomplishment The objectives of this area of the inspection were accomplished by:
Review of the ASME accepted Quality Assurance Manual, Revision 9 a.
(1) Section 8.0, " Control of Purchased Materials Items and Services,"
4 (2) Section 15.0, " Audits," and (3) Section 16.0, " Documentation" to verify the vendor had established procedures which prescribe a system for internal management audits.
b.
Review of the following documents (1) Standard Operating' Procedure S0P 3.1 Revision 4, " Vendor Selection Procedure and Approval (ASME/10CFR 50),"
(2) Standard Operating Procedure S0P 3.6 Revision 3, " Vendor Selection and Approval (10CFR 50)," and I
-(3) Standard Operating Procedure S0P-10.1, " Auditing" to verify that they had been prepared by the designated authority, approved by responsible management, and reviewed by the quality assurance function, Review of the documents reference in paragraphs a. and b.
c.
to verify that they identify the organization responsible for auditing, establishes the audit personnel qualifications, provides for training and indoctrination of audit personnel, establishes the essential elements of the audit system, provides for audit schedules to assure coverage of all elements of the quality assurance program, and requires reporting to and follow-up corrective action by both the audited and the auditing organizations.
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10 d.
Review of six (6) audit reports to verify whether the procedures and the necessary audit system documents, are available to the auditing personnel; and whether the procedures are being properly and effectively implemented.
Review of Approved Suppliers List e.
3.
Findings a.
The inspector verified that:
(1) Procedure had been prepared and approved by the vendor which prescribes a system for performing internal manage-ment audits consistent with NRC rules and regulation, and the vendor's commitments in the ASME accepted Quality Assurance Manual.
(2) The audit procedures are being properly and effectively implemented by the vendor.
b.
Within this area of the inspection no deviation or unresolved item were identified.
H.
Quality Assurance Records 1.
Objectives The objectives of this area of the inspection were to verify that:
Procedures had been prepared and approved by the vendor that a.
3rescribed a system for control of quality assurance records which is consistent with NRC rules and regulations and the
~ASME accepted Quality Assurance Program b.
The quality assurance record procedures are properly and effectively implemented by the vendor.
2.
Method of Accomplishment i
The objectives of this area of the inspection were accomplished by:
Review of the ASME accepted Quality Assurance Manual Revision 9 a.
(1) Section 1.0, " Control of Contract Specification," and (2) Section 16.0, " Documentation"
11 to verify that the vendor had established procedures that prescribed a system for contr'ol of quality assurance records.
b.
Review of Standard Operating Procedure S0P 9.2, Revision 4,
" Collection Storage and Maintenance of Quality Assurance Records (ASME/10 CFR 50) to verify it had been prepared by the designated authority, approved by responsible management and reviewed by QA.
c.
Review of the following procedures (1) Standard Operating Procedure S0P 9.2, Revision 4, " Collection, Storage, and Maintenance of Quality Assurance Records (ASME/10CFR 50)"
(2) PN-SOP 9.2, Attachment 7.1, " Guideline for Establishment and Disposition of typical QA Project Files,"
(3) PN-SOP 9.2, Attachment 7.2, "QA Record Retention List," and (4) PN-SOP 9.2, Attachment 7.3, Form TR4, "QC Documentation Transmittal,"
to verify they identify the records that are to be retained, where and how they are to be stored for preservation and safe-keeping, provide for their retrieval without undue delay.
d.
Review of the following quality assurance records.
(1) QA Record Files, (2) Customer Design Specification Project 4840-P, Specification 300-13 Revision 8, (3) Ten (10) Certified Mill Test Reports and (4) Five (5) Approved Drawings to verify that the vendor's procedures pertaining to quality assurance records were properly and effectively implemented.
e.
Verify that the procedures and necessary resources are available to the personnel identifying and filing quality assurance do-
- cuments, f.
Interviews with personnel to verify they were knowlegeable in the procedures applicable to the identification and filing of quality assurance documents.
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12 3.
Findings:
a.
Deviation: See Notice of Deviation b.
Within this area of the inspection no unresolved items were identified.
I.
Control of Other Special Processes 1.
Objectives The objectives of this area of the inspection were to verify that a.
Procedures had been prepared and approved by the vendor to prescribe a system for control of special processes (other than welding, nondestructive testing and heat treating) which are consistent with NRC rules and regulations and the vendor's commitments in the ASME accepted Quality Assurance Program.
b.
These,special processes are accomplished in accordance with these procedures by qualifed personnel.
2.
Method of Accomplishment The objectives of this area were accomplished by:
Review of the ASME accepted' Quality Assurance Manual, Revision 9, a.
b.
Review of contracts, and l
c.
Interviews with personnel knowledgeable in the contract requirements.
3.
Findinas a.
BS & IW is a fabricator of plate and structural shapes and their customer contracts and specification do not require an special process other than welding, nondestructive testing and heat treating.
b.
Within this area'of the inspection no deviations or unresolved items were identified.
J.
Control of Special Processes-Heat Treatment 1.
Objectives l
13 The objectives of this area of the inspection vere to verify that:
a.
Procedures had been established for the heat treatment of materials and part (other than stress relieving) which are con-sistent with NRC rules and regulations and the vendor's commitments in the ASME accepted Quality Assurance Manual.
b.
The heat treatment operations are conducted in accordance with these procedures.
2.
Method of Accomplishment The objectives of this area of the inspection were accomplished by:
Review of the ASME accepted Quality Assurance Manual, Revision 9, a.
b.
Review of contracts, and
. Interviews with personnel knowledgeable in the contract require-c.
ments.
3.
Findings GS & IW is a fabricator of plate and structural shapes, and a.
purchases the material in accordance with the requirement of their customer's contract requirements and specifications, from material suppliers that have been surveyed and qualified and placed on an approved vendors list in accordance with the re-quirements of contract commitments.
Procedures are not required for solution annealing heat treatment, or quenching and tempering of materials.
b.
Within this area of the inspection no deviations or unresolved items were identified.
1 K.
Exit Interview At the conclusion of the inspection on April 3, 1980 the inspector met with the company's management, identified in paragraph A, for the purpose of informing them as to the results of the inspection. During this
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j meeting the identified deviation was discussed and the evidence which supported the finding was identified.
l The company's management acknowledged the findings and supporting l
evidence as being understood, but had no additional comments.
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