ML19318A798
| ML19318A798 | |
| Person / Time | |
|---|---|
| Issue date: | 04/29/1980 |
| From: | Agee J, Hunnicutt D NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML19318A779 | List: |
| References | |
| REF-QA-99900378 99900378-80-1, NUDOCS 8006240172 | |
| Download: ML19318A798 (6) | |
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U.S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT REGION IV 4
Report No. 99900378/80-01 Program No. 51400 Company: NAMCO Controls Div.
ACME Cleveland Corp.
149 Cucumber Street Jefferson, Ohio 44047 Inspection at:
Cleveland and Jefferson, Ohio Inspection Conducted: February 11-14, 1980
[49/[C Inspect r:
2ff,7 J. R. Agae, Contractor Inspector
" Dets A
ComponentsSection II
]
Vendor Inspection Branch Approved by:
9 74 M%Eaf-k/29/80 l
D. M. Hunnicutt, Chief
/ Dat'e ComponentsSection II Vendor Inspection Branch Summary Inspection on February 11-14. 1980 (99900378/80-01)
Areas Inspected:
Implementation of 10 CFR 50, Appendix B criteria and appli-cable codes and standards, including:
action on previous inspection findings, limit switch shaft failure and quality. assurance program implementation. The inspection involved twenty-seven (27) inspection hours on site.
Results:
In the three (3) areas inspected, one (1) deviation and no unresolved items were identified.
Deviation: QA program implementation - written procedures had not been compiled and implemented in areas whose activities affect quality (See Notice of Deviation).
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2 DETAILS SECTION A.
Persons Contacted J. R. Bendokaitis - Project Engineer J. A. Bentley - Manager, Administration & Supply F. M. Bishop - Manager, Shipping Receiving J. Buzogany - Chief Engineer D. J. Hetzer - Manager, Manufacturing / Industrial Engineering W. J. Kocianic - Manager, Sales Service, Cleveland Site
- R. E. Loomis - Quality Assurance Manager
- D. E. Russel - Quality Assurance Engineer R. A. Varner - Chief Inspector
- Attended exit meeting.
B.
Action on Previous Inspection Findings 1.
(Closed) Deviation (Report 79-01):
Certain NAMCO Purchase Orders did not require a Certificate of Conformance on materials purchased.
By inspection of random selection of twelve (12) purchase orders (P0s),
issued since the last inspection, dated September 1979 te February 1980, the inspector verified each purchase order required the supplier to provide a Certificate of Conformance with materials shipped.
2.
(Closed) Deviation (Report 79-01):
Certain pieces of testing and inspection equipment had not been calibrated.
The inspector veri-fied that current inspection and testing equipment had been cali-brated by an outside calibration and servicing equipment company.
In contrast to the previous inspection, each instrument in use, had a current calibration label affixed.
3.
(Closed) Deviation (Report 79-01):
No training sessions had been conducted and/or documented since the publication of the QA-2-101 procedure. The inspactor verified that five (5) one-hour training sessions on 10 CFR 50 Appendix B and 10 CFR Part 21 involving seventy (70) hourly and salary personnel had been conducted. Also, training sessions had been conducted on several quality contre.1 procedures including:
instructions, procedures and drawings; assembly and inspection records; identification and control of dedicated products and sampling procedures.
C.
Limit Switch Shaft Failure 1.
Objectives The objectives of this area of the inspection were to determine if generic construction deficiencies exist in the manufacture and
3 shipment of NAMCO safety-related limit switches, type EA180-31302.
2.
Method of Accomplishment The preceding objectives were accomplished by:
a.
Review of detail and fabrication drawings of the EA180-31302 limit switch including:
(1) EA180-11302 limit switch (2) EA086-00097 Shaft b.
Examination of the mechanical and electrical operational char-acteristics of an EA 180-31302 limit switch.
Inspection of the plant practices for inspecting incoming c.
materials.
d.
Inspection of plant practices for receiving / inspection of materials to MIL-Std. 105-D sampling criteria.
Inspection of limit switch shafts, part No. EA086-00097, dedi-e.
cated for assembly into nuclear limit switches.
f.
Examining and measuring, while using a set of recently calibrated calipers, the shaft plug holes and o-rin; grooves of approximately twenty-five (25) limit switch lever shafts dedicated for assembly into nuclear limit switches.
g.
Review of the qualification report, " Qualification of NAMCO Control Limit Switch, Model EA-180, to IEEE Standards 344('75),
323('74) and 382('72), Revision 1, " dated September 5, 1978,"
which certifies that the EA 180 limit switch tested, operated satisfactorily under the simulated environmental and electrical load conditions of the required test criteria.
h.
Review of Inspection Reports (IR ) concerning problems, rejects, defects, failures and field operating deficiencies concerning the standard commercial and nuclear snap-lock limit switch. Note:
Inspection Reports (irs) are discrep-ancy reports written to identify and record the various types of material and equipment problems that require Material Review Board (MRB) review for disposition.
3.
Findings Within this area of the inspection, no deviations or unresolved items were identified.
4 a.
General In this inspection, the administrative and documentation programs and practices from procurement to receiving / inspection to assembly, functional testing and shipment of the nuclear limit switches were examined.
All irs generated since September 1979 plus a random selection of approximately twenty-five (25) irs dating back to 1975 were reviewed.
None of the irs identified problems relating to fracture of the limit switch lever shaft.
According to the project development engineer for the nuclear limit switch, no problems have ever been identified relating to fracture of the limit switch lever shaft.
A review of the engine-ering data revealed that the limit switch is designed to actuate at fif ty (50) inch-pounds directional force on the actuating arm and shaft assembly.
Engineering test data revealed that eight hundred (800) to nine hundred (900) inch-pounds force are required to fracture a lever shaft.
Test data revealed that as forces in excess of fif ty (50) inch-pounds were applied to tha lever shaf t fractured or sheaved before the lever shaft could be damaged.
b.
Comments From the review of limit switch drawings and engineering test data, examination of receiving and storage practices and exam-ination of assembly, testing and packaging activities the inspec-tion did not detect any activities in the manufacture and ship-ment activities that would contribute to generic field problems with the limit switch.
c.
Deviations and Unresolved Items Within this area of the inspection, no deviations or unresolved items were identified.
D.
Quality Assurance Program Implementation 1.
Obj ectives The objectives of tune area c:? the inspection were to verify that
)
the QA program had been updated since the last NRC inspection to more adequately meet customer requirements to provide a QA program that meets 10 CFR 50, Appendix B or ANSI N45.2 criteria.
2.
Method of Accomplishment The preceding objectives were accomplished by:
a.
Review of the QA Manual Sections:
.-=
5 (1) 2.0 QA Program (2) 3.0 Design Control.
(3) 4.0 Procurement Document Control.
(4) 7.0 Control of Purchased Material, Equipment, and Service.
(5) 12.0 Control of Measuring and Test Equipment (6) 13.0 Hant'ing, Storage and Shipping (7) 15.0 Nonconforming Materials, Parts, or Components (8) 17.0 QA Records b.
Review of the inspection practices in the following areas:
(1)
Receiving (2)
Receiving inspection (3)
Stockroom (4)
Shipping (5) Manufacturing Discussions with the following management personnel concerning c.
QA program requirements for providing written procedures describing the quality functions performed in their respective departments: quality assurance; supply and administration including purchasing, receiving, materials control and shipping; engineering; and manufacturing engineering.
d.
Verifying that the QAP QA-2-101, Addenda to QA Manual, that had been implemented for a specific customer had been dis-continued.
3.
Findings a.
Deviation See Notice of Deviation, i
.a 6
b.
Comments The inspector found that the implementation of the NAMCO QA Pro-
. gram failed to meet the criteria of Appendix B to 10 CFR for the supply of Class IE products for the commercial nuclear industry, in the area of written procedures for functions affecting quality as listed in Section C.2.c above.
Inspection Report No. 99900378/
79-01, Section C.3.c, page 5, states in part, "In light of the incompleteness of the NAMCO QA program at the time of the August 8-9, 1979 inspection, a subsequent inspection will be scheduled to verify that NAMCO has complied with its commitment to provide qualified safety-related limit switches to its customers under a QA program that meets 10 CFR 50, Appendix B criteria."
Inspection of the NAMCO QA Program during this inspection (Febru-ary 11-14, 1980) indicated that very slight progress in upgrading the NAMCO QA Program to meet NRC QA Criteria during this seven mot.th period had been made.
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