ML19347D087
| ML19347D087 | |
| Person / Time | |
|---|---|
| Issue date: | 01/19/1981 |
| From: | Barnes I, Foster W NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML19347D077 | List: |
| References | |
| REF-QA-99900399 NUDOCS 8103100741 | |
| Download: ML19347D087 (11) | |
Text
{{#Wiki_filter:. O U.S. NUCLEAR REGULATORY CCMMISSION OFFICE OF INSPECTION AND ENFORCEMENT REGION IV Report No. 99900399/80-01 Program No. 51400 Company: American Insulated Wire Corporation 36 Freeman Street Pawtucket, Rhode Island 02862 Inspection at: Pawtucket, Rhode Island and Attleboro, Massachusetts Inspection Conducted: October 27-30, 1980 Inspector: b 's 8 /' t /?' [ [ W. E. Foster, Contractor Inspector Date Component Section II Vendor Inspection Branch Approved by: I 8-
- iA74, I. Barnes, Chief Date Components Section II Vendor Inspection Branch Summary Inspection conductec oa ~ ^ er 27-30, 1980 (99900399/80-01).
Areas Inspected: Imp.. .. cation of 10 CFR 50, Appendix B criteria, and appli-caole coces and standards; including follow up on a regional request; implementa-tion of 10 CFR Part 21; control of measuring and test equipment; manufacturing process control; and change control. The inspection involved twenty-three inspector-hours on site by one NRC inspector. l Re.;ults: In the five areas inspected, the following violation, four deviations, [ and two unresolved itenis were identified: Violation: Implementation of 10 CFR 21 practice was not consistent with paragrapn 21.6 of 10 CFR Part 21 (See Notice of Violation). Daviations: _ Control of Measuring and Test Equipment practices were not con-sistent with: Criterior XII of Appendix B to 10 CFR 50 (See Notice of Deviation, Item A); Criterion V e Appendix B to 10 CFR 50, and paragraph 13.2.1 of the l Quality Assurance Manual, dated June 25, 1979 (See Notice of Deviation, Item B). l Manufacturing Process Control practices were not consistent with: Criterion V l of Appendix B to 10 CFR 50, and paragraphs 2.1, 2.2, and 2.3 of Quality Assurance Standards and Procedures No. 11.01, dated September 17,1979 (See Notice of Oeviation, Item C); and Criterion V of Appendix to 10 CFR 50, and paragraph 8108100 MI-I
2 6.1.1 of the Quality Assurance Manual, dated June 25, 1979, (See Notice of Deviation, Item 0). Unresolved Items: Control of Measuring and Test Equipment - an apparent lack of controls on equipment that is not clearly identified regarding calibration and functional status (See Details Section, paragraph 0.3.b). Manufacturing Process Control - the time is not recorded when wire / cable is immersed in water; consequently, it cculd not be determined that sufficient immersion time had been achieved (See Details Section, paragraph E.3.b). +
3 DETAILS SECTION A. Persons Contacted
- J. Barbosa, Manager - Quality Control, Pawtucket Plant A. Chaves, Leadman - Continuous Vulcanizing
- G.
R. Delisle, Production Controller A. Escobar, Inspector
- W. H. Firth, Manager - Quality Assurance I. Fonseca, Supervisor - Cabling R. J. Fortin, Elastomers Specialist - (Laboratory Inspection of Raw Materials, etc.)
E. Gaboury, Elastomers Specialist and Calibrator of micrometers and pin dial indicators
- H. S. Galkin, Vice President - Marketing and Sales
- H. Galkin, Plant Manager N. I. Levin, Engineer - Quality Assurance
- A. Madoian, Assistant Manager - Quality Assurance
- N. Morrissetti, Secretary - Quality Assurance
- M. C. Pacheco, Manager - Quality Control, Attleboro Plant T. Paolella, Manager - Engineering E. Rose, Engineer - Process (Extruder)
E. Wasilewski, Supervisor - Test (Electrical)
- Attended Exit Interview.
B. Follow-uo on Regional Requests
===1. Background=== The Tennessee Valley Authority (TVA) reported that an American Wire Gauge size 6 single conductor cable had not been flame tested as required by the contract. This information had been supplied to the Office of Inspection and Enforcement, Region II. 2. Objectives The objectives of this area of the inspection were to verify that adequate corrective actions and preventive measures had been taken regarding flame testing required by contrrcts; and generic consider-ations had been assessed. 3. Methods of Accomplishment The preceding objectives were accomplished by: a. Reviewing the following documents to determine the requirements: (1) TVA Purchase Order No. 79K7-825687, dated April 3, 1979, and d
4 (2) TVA Standard Specification No. 25.016, Tentative Revision date January 22, 1979. b. Reviewing the following documents to determine TVA's current position regarding the problem: (1) TVA's Supplier Nonconformarge Report No. 18-1, dated September 26, 1979, and (2) TVA's Memoranda dated April 17 and 18, 1980, To: J. L. Parris, Form: F. W. Chandler,
Subject:
Sequoyah Nuclear Plant. c. Discussions with cognizant personnel to determine corrective and preventive actions taken or planned. 4. Findinas a. Comments (1) TVA had concluded that the cable which had been supplied set the contractual requirements. (2) American Insulated Wire Corporation has elected to conduct a vertical tray flame test on the smallest size wire of all orders specifying IEEE Standard 383. b. Deviations From Commitment None. c. Unresolved Items None. C. Implementation of 10 CFR Part 21 1. Objectives The objectives of this area of the inspection were to verify that suppliers of safety related equipment had established and implemented procedures in accordance with 10 CFR 21. 2. Me,thods of Accomolishment The preceding objectives were accomplished by: a. Reviewing the following customer orders to verify the equipment . as safety related and 10 CFR 21 had been invoked: w (1). Bechtel Power Corporation's Purchase Order No. 8856-E-130A, Revisions 16 and 17, dated December 10, 1979, and October 9, 1980, respectively, and their attendant specifications and related documents, and __r.- , _ _., ~,
5 (2) Tennessee Valley Authority's Purchase Order No. 79K7-825687, dated April 3, 1979, and its attendant specification. b. Reviewing Quality Assurance Standards and Procedures No. 21.01, dated December 8, 1978, entitled - Procedures For Compliance with Title 10, Code of Federal Regulations, Part 21, to verify that internal procedures had been established. c. Observing bulletin boards and other locations where postings were evident to verify that posting had been accomplished. 3. Findings a. Violation See Notice of Violation. The only location that displayed posting regarding Part 21 was outside the QA Manager's office at the Pawtucket Plant. The posting consisted of: (1) 10 CFR Part 21, and (2) a notice to employees. b. Deviations From Commitments None. c. Unresolved Items None. D. Control of Measuring and Test Equioment 1. Objectives The objectives of this area of the inspection were to verify that measures had been established to assure that tools, gages, instruments, and other measuring and testing devices used in activities affecting quality had been properly controlled, calibrated, and adjusted at specified periods to maintain accuracy within necessary limits. 2. Methods of Accomolishment The preceding objectives were accomplished by: a. Reviewing the following documents to verify that the objective had been satisfied: (1) Quality Assurance Manual, dated June 25, 1979, Section 13, entitled - Control of Measuring and Test Equipment, and
6 (a) 13.01, dated August 30, 1979, entitled - Pin Dial Calibration Procedure, and (b) 13.02, dated October 18, 1979, entitled - Micrometer Calibration Procedure. b. Reviewing the following documents to verify that the established measures had been implemented: (1) Calibration Log Books, (2) Electrical Calibration Laboratory Report No. 79027, dated December 17-21, 1979, and (3) Physical Testing Equipment Services, Incorporated is Certifi-cates of Calibration, dated November 11, 1979, for Testing Machines: B-1460, 4703, B-11779, B-7729, 53489, and S-48779. c. Observing various items of test and measurement equipment, and process instrumentation at the following locations to verify that the established measures had been implemerted: Continuous Vulcanizing; In-Process Inspection; Rewind; Jacketing; and Cabling. 3. Findings a. Deviations From Commitment (1) See Notice of Deviation, Item A. (2) See Notice of Deviation, Item B. Itan A - Procedures had been established to control, calibrate, and adjust a variety of test and measurir.g equipment; but failed to include instrumentation used in the continuous vulcanizing process and wire measuring devices, b. Unresolved Items The NRC inspector observed that: (1) Micrometer, Identification No. 27, bore the adhesive backing sf a color dot but no identifi-able color to indicate calibration status, and (2) pin dial indi-cators, Identification Nos. 36 and 38 did not display evidence that they were within calibration. Number 38 displayed a calibra-tion label which reflected a due date of October 6,1980, and the inspector was informed that No. 36 was inoperative. The Calibration Log Books revealed that the micrometcr and pin dial indicators were within the current calibration cycle. It was not apparent to the NRC inspector that adequate controls had been established to ensure that: (1) test and measurement equip-ment display positive evidence of the current calibration cycle,
l 7 and (2) inoperable test and measurement equipment be tagged, removed from the production area, etc. E. Manufacturing Process Cnntrol 1. Objectives The objectives of this area of the inspection were to verify that measures had been established and documented to control manufacturing, inspection and test activities. Also, to verify these activities had been accomplished in accordance with the established and documented measures. Additionally, verification of indication of mandatory hold points in appropriate documents. 2. Methods of Accomolishment The preceding objectives were accceplished by: a. Reviewing the following documents to verify measures had been established and documented to control manufacturing, inspection and test activities: (1) Quality Assurance Manual, dated June 25, 1979, Sections - (a) 6, entitled - Instructions, Procedures, and Drawings, (b) 9, entitled - Identification and Control of Materials, Parts and Components, (c) 11, entitled - Inspection, (d) 12, entitled - Test Control, and i (e) 15, entitled - Inspection, Test and Operating Status. (2) Quality Assurance 5tandards and Procedures - (a) 9.01, dated June 27, 1978, entitled - Traceability of Class IE Cable, (b) 11.01, dated September 17, 1979, entitled - Process Extrusion Inspection, (c) 11.02, dated August 19, 1980, entitled - Daily Electrical In-Process. Inspection, and .(d) 12.13, dated February 26, 1980, entitled - Procedure For Operation of Tray Flame Test Chamber. b. Reviewing the following records to verify that the established and documented measures had been implemented: ,~
8 (1) Daily Electrical Test Reports dated October 1-29, 1980, (2) Extrusion Order No. 65367, dated June 10, 1980, and the attached Engineering Specification No. 09678, Revision 2, dated September 2, 1980, (3) Daily Dimensional and Physical Worksheets dated from August 8 - October 28,1980, and (4) Factcry Order No. 16988, dated July 23, 1980, and its attendant Engineering Specification No. 10102, Revision 0, dated July 23, 1980. c. Observing the following activities to verify implementation of the established and documented measures: Extruding, Inspecting, Jacketing, Cabling, and Testing. 3. Findings a. Deviations From Commitment (1) See Notice of Deviation, Item C. (2) See Natice of Deviation, Item D. Item C - The Daily Dimensional and Physical Worksheet (00PW) reflects the following: " Required Temperature: Zone:1 - Zone:2 - Zone:3 - Zone:4 - Die-Required Running Speed: Required Steam Pressure:" Filed copies of 00PWs that were reviewed, on completed tasks, did not contain information relative to temperature, speed or pressure. Ites 0 - Machine set-up (temperatures, die size, speed, steam pressure) is accomplished by referring to Continuous Vulcanizing Data Sheets which provides information from previous processing. Pre-determined requirements had not been documented. I-I l e c-w +
9 b. Unresolved Item Dielectric tests are conducted after wire / cable has been immersed in water for a period of six hours. The time of immersion and tests is not recorded. As a res"It of the foregoing, the NRC inspector was not able to determine that the wire / cable had been immersed for the required time. F. Change Control 1. Objectives The objectives of this area of the inspection were to verify that measures had been established to control changes to software and hardware. Also, to verify the measures for software changes included provisions for review, approval, and distribution to and usage at the location where the prescribed activity is performed. An additional phase was to verify the measures had been implemented. 2. Methods of Acccmolishment The preceding objectives were accompliched by: a. Reviewing the following documents to verify measures had been established to control changes to software and hareware: (1) Quality Assurance Manual, dated June 25, 1979, Sections - (a) 4, entitled - Design Control, (b) 5, entitled - Procurement Document Control, (c) 7, entitled - Document Control, and (d) 16, entitled - Non-conforming Items. (2) Quality Assurance Standards and Procedures - (a) 7.01, dated May 16, 1979, entitled - Internal Document Distribution and Control, and (b) 8.01, dated Marc'h 1, 1978, entitled - Purchase Order Procedure. (3) Quality Assurance Directive, dated September 10, 1980,
Subject:
List of Authorized Personnel.
10 b. Reviewing the following Engineering Specifications to verify approval by authorized personnel: (1) 10102, Revision 0, dated July 23, 1980, (2) 07675, Revision 6, dated September 26, 1980, (3) 07680, Revision 4, dated June 24, 1980, (4) 07676, Revision 6, dated September 26, 1980, (5) 08035, dated August 2, 1976, (6) 08036, dated June 7, 1978, (7) 08037, dated June 7, 1978, (8) 09678, Revision 2, dated September 2, 1980 (9) 10075, Revision 1, dated August 5, 1980. 3. Findings a. Comments The NRC inspector lacked sufficient time to complete this area of the inspection. b. Deviations From Commitment None. c. Unresolved Items None. G. Exit Interview ~ 1. .The inspector met with management representatives denoted in paragraph A at the conclusion of the inspection on October 30, 1980. 2. The following subjects were discussed: a. Areas inspected. b. Violation identified. c. Deviations identified. d. Unresolved Items identified. 4 ~ v-v -e'
e 11 e. Contractor response to the report. The contractor was requested to structure his response under headings of corrective action, preventive measures, and dates for each defi-ciency and deviation. Additionally, management representatives were requested to notify
- he Commission in writing if dates require adjustment, commitments require modification, etc.
3. Mar.agement's comments generally, related to clarification of some findings. o 4 e e =W}}