ML19351E855
| ML19351E855 | |
| Person / Time | |
|---|---|
| Issue date: | 09/02/1980 |
| From: | Kelley W, Whitesell D NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML19351E847 | List: |
| References | |
| REF-QA-99900262 NUDOCS 8012190446 | |
| Download: ML19351E855 (9) | |
Text
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O U. S. NUCLEAR REGUI.ATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT REGION IV.
Report No.
99900262/80-01 Program No. 51300 Company:
Babcock & Wilcox Control Components, Inc.
2567 S. E. Main Street Irvine, California 92714 Inspection conducted:
August 5-6, 1980 Y us
/b u, E'l M 0 G Inspe-tors:
William D. Kelley, CcTutractor paspector pate Vendor Inspection Branch r 'h
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D. E. Whitesell, Chief Date Components Section i Vendor Inspection Branch Summary Inspection on August 5-6, 1980 (99900262/80-01)
Areas Inspected:
Implementation of 10 CFR 50, Appendix B and applicable codes and standards including, design and document control; procurer::ent control -
evaluation of supplier performance; manufacturing process control - machining; control of special processes - special welding applications; and testing of completed products; also reviewed vendors activities and conducted an exit in-terview. The inspection involved sixteen (16) inspector-hours on site by one (1) NRC inspector.
1 Results:
In the six (6) areas inspected, no deviations or unresolved items l
were identified in five (5) areas. The following were identified in the re-maining one (1) area.
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Deviation: Design and Document Control - Contrary to Criterion V of Appendix
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3 to 10 CFR 50, paragrapa NCA-4134.5 of Section III to the ASME Code, and paragrapn 5.0 of Section 5 of the ASME accepted Quality Assurance Manual re-vised procedures were not being processed as required prior to release and implementation.
(See Notice of Deviation enclosure.)
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2 DETAILS A.
Persons Contacted Babcock & Wilcox - Control Components Inc. (B-WCC)
R. Allen - Quality Engineer
- D. Capps, Senior Quality Engineer
- J. F. Gardner - Controller
- C. E. Fleming - Director of Manufacturing
- D. W. Smeller, Manager Contract Engineering
- R. E. Topping, Director of Quality Assurance
- Denotes those persons who attended the Exit Interview.
3.
General Review of Vendor's Activities 1.
The inspector verified that there has been no change in the status of the ASME Certification of Authorization, the authorized inspection agency, or the authorized nuclear inspector as reported in NRC-IE-RIV Report No. 99900262/79-01.
2.
B-WCC's contribution to the nuclear industry represents approximately five percent (5%) of its total workload.
C.
Design and Document Control 1.
Objectives The objectives of this area of the inspection were to ascertain whether procedures had been developed and properly implemented to control the review, approval, release and issuance, of design do-cuments in a manner consistent with NRC rules and regulations, and the vendor's commitments in the ASME accepted Quality Assurance Program.
2.
Method of Accomplishment JIhe objectives of this area of the inspection were accomplished by:
a.
Review of the ASME accepted Quality Assurance Manual, Revision 4:
(1) Section 3, " Design Control," and (2) Section 5, " Instructions, Procedures and Drawing;"
to verify that the vendor had established procedures to prescribe a system for design document control.
b.
Reviewed the following procedures:
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(1) 1704-01 " Design Control" (2) 1708-05 " Engineering Graphics Control of Nuclear Documents,"
(3) 1707-03 " Quality Assurance Procedures and Specifications,"
(4) 1704-06 " Design Review for New Product and/or Graphics Design Change for Retrofit,"
to verify that they had been prepared by the designated authority, approved by management, and reviewed by QA.
c.
Review of the documents listed in paragraphs a. and b. to verify that they provided for identification of personnel responsible for preparing, reviewing, approving, and issuing design documents; and that the review and approval of significant changes were performed by the same personnel. Also to ascertain whether minor changes to design documents, which do not require review and approval, are identified.
d.
Review of the distribution lists to verify that they are current and that the proper documents are identified, accessible, and are being used.
e.
Interviewed personnel to verify whether they were knowledgeable in the procedures applicable to design document control.
3.
Findings a.
The inspector verified that procedures had been developed to control the review, approval, release and issuance of design documents in a manner consistent with NRC rules and regulations and the vendor's commitments in the ASME accepted Quality Assurance Program.
b.
Deviation:
B-WCC procedure 1704-01 had been released and imple-mented prior tc the specified reviews and approvals of the revised procedure.
c.
Within this area of the inspection no unresolved items were identified.
D.
Procurement Control-Evaluation of Supplier Performance 1.
Objectives The objectives of this area of the inspection were to verify that:
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Procedures had been prepared and approved by the vendor to a.
prescribe a system for evaluation of suppliers performance which 4
is consistent with NRC rules and regulations and the vendor's commitments in the ASME accepted QA Program.
b.
Procedures for evaluation of suppliers performance are being properly and effectively implemented by the vendor.
2.
Method of Accomplishment The objectives of this area of the inspection were accomplished by:
a.
Review of the ASME accepted Quality Assurance Manual, Revision 4, Section 7, " Control of Purchased Materials, Items and Services" and B-WCC procedure 1708-03, " Subcontractor Selection, Evaluation and Approval-Nuclear" to verify the vendor had established pro-cedures for effecting evaluation of suppliers.
b.
Review of six (6) sets of documents applicable to three (3) 1 suppliers to verify that the procedures, and necessary procure-ment documents, were available to the persons responsible for j
performing the quality affected activities, and that the pro-cedures were properly implemented.
c.
Interviews with personnel to verify whether they were knowledge-able in the procedures applicable to evaluation of the suppliers' performances.
3.
Findings a.
The inspector verified:
(1) Procedures had been prepared and approved by the vendor to prescribe a system for evaluation of suppliers' performance which is consistent with NRC rules and regulations and the vendor's commitments in the ASME accepted Quality Assurance l
Program.
(2) Procedures for evaluation of suppliers were being properly and effectively implemented by the vendor.
1 b.
Within this area of the inspection no deviations or unresolved
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items were identified.
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E.
Manufacturing Process Control - Machining 1.
Objectives The objectives of this area of the inspection were te verify that:
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5 The machining operations were performed under a controlled system a.
of manufacturing which meets NRC rules and regulations and the vendor's commitments in the ASME accepted Quality Assurance Program.
b.
The controlled system of manufacturing was effective in assuring product quality.
2.
Method of Accomplishment The objectives of this area of the inspection were accomplished by:
a.
Review of the ASME accepted Quality Assurance Manual Revision 4:
(1) Section 5, " Instructions, Pr2cedures and Drawings,"
(2) Section 8, " Identification and Control of Material and Items,"
(3) Section 9, " Control of Manufacturing Processes," and (4) Section 13, " Handling, Storage, Shipping and Preservation,"
to verify that procedures had been established to prescribe a control system of operation.
b.
Review these selective specification and procedures:
(1) 1706-01, " Traveler Issue - Nuclear,"
(2) 1707-03, " Quality Assurance Procedures and Specifications,"
and (3) 1709-02, " Marking and Identification of Mechanical Parts,"
to verify that they had been prepared by the designated authority, approved by management, and reviewed by QA, and are consistent with NRC rules, regulations, and QA commitments.
c.
Review of the following documents:
(1) Operation and routing sheets,
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(2) Drawings, (3) Receiving Logs, and (4) Certified Material Test Reports.
6 to verify that they provide drawing / document control in the shop, and also provides for part identification and traceability, in-process and final inspections, identification and segregation of defective items, the resolving of nonconforming items, and that the gages and measuring devices and under a controlled calibration system.
d.
Examine three (3) representative samples of finished machined parts to verify that they were properly identified and machined to conform to the drawings and specifications.
e.
Examined the documents of the following parts:
(1) Body, Part No. 120101138 (2) Plug, Part No. 320604134xx (3) Plug, Part No. 320601040 (4) Body, Part No. 923801625 to verify compliance with applicable documentation requirements.
3.
Findings a.
The inspector verified that:
(1) The machining operations were performed under a controlled system of manufacturing which meets NRC rules and regulations and the vendor's commitments in the ASME accepted Quality Assurance Program.
(2) The controlled system of manufacturing was effective in assuring product quality.
b.
Within this area of the inspection no devia.tions or unresolved items were identified.
F.
Control of Soecial Processes-Special Welding Applications 1.
Objectives The objectives of this area of the inspection was to verify that
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special welding specifications (cladding, hard surfacing, seal welding, and weld repair without postweld heat treatment) conform with the additional requirements established by ASME Code, Sections III and IX, NRC rules and regulations, and the vendor's ASME accepted Quality Assurance Program.
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7 2.
Method of Accomplishment The objectives of this area of the inspection were accomplished by:
a.
Review of the ASME accepted QA Manual, Revision:
(1) Section 4, " Procurement Document Control," and (2) Section 9, " Control of Manufacturing Processes,"
to verify the vendor had established procedures to prescribe a system for the development and qualification of special welding specifications, and for qualifying welders and/or welding machine operators.
b.
Review of the following welding procedures.
(1) ES-277, Rev. J, "Hard-Surfacing Procedure By the Automatic Plasma Transferred ARC Process," and (2) WS-211, Rev B, " Submerged Arc Welding of Automatic 5.3...."
to verify the special requirements governing special welding application procedures and performance qualification imposed by ASME Code regarding test sample size, examination of test sample, dnd special essential variables are satisfied.
c.
Interviews with personnel to verify that they were knowledgeable in the procedures.
3.
Findings a.
The inspector verified that special welding specifications conform with the additional requirements established by ASME Code, Sections III and IX, NRC rules and regulations, and the vendor's ASME accepted Quality Assurance Program.
b.
Within this area of the inspection no deviations or unresolved items were identified.
f c.
Follow-up Item The inspector observed that weld procedure qualification records f
had been corrected n:,4tp, " White-out." None of the customer specifi-cation have imposed the' requirements of ANSI /ASME N45.2.9 on 3-WCC; hccever, 3-WCC stated the practice of using " White-out" to l
make corrections would be discontinued.
G.
Testing of Completed Products l
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8 1.
Objectives The objectives of this area of the inspection was to verify that products are assembled in accordance with approved procedures and drawings, all material complied with the specifications, and the functional test of the products were performed.
2.
Method of Accomplishment The objectives of this area of the inspection was accomplished by:
Review of test documentation to verify:
a.
(1) Test procedures and/or instructions were available at the test station and had been approved by engineering and quality assurance.
(2) The test had been performed in accordance with the procedure and/or instructions.
(3) Changes made to test procedure had been approved by engineer-ing and quality assurance and they had been followed.
(4) The test data was documented and dispositioned in accordance with the procedure and/or instructions.
(5) The limits of acceptability of test results had been estab-lished and were being used for rejection or acceptance of the product.
b.
Review of test instrumentation used to verify they are as specified by the procedure and/or instruction and were in cali-bration.
3.
Findings a.
The inspector verified that products are assembled in accordance with approved procedures and drawings, all material complied with the specifications and the functional test of the products were performed.
b.
Within this area of the inspection no deviations or unresolved items were identified.
c H.
Exit Interview At the conclusion of.the inspection on. August 6, 1980, the inspector met with the company's management, identified in paragraph A, for the purpose i
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9 of informing them as to the results of the inspection.
During this meeting i
the deviation was discussed and the evidence which supported the finding 6
was identified.
The company's management acknowledged the finding and supporting evidence as being understoodd, but had no additional comments.
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