ML19352B116
| ML19352B116 | |
| Person / Time | |
|---|---|
| Issue date: | 04/08/1981 |
| From: | Barnes I, Herr R, Roberds H NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML19352B109 | List: |
| References | |
| REF-QA-99900744 NUDOCS 8106030127 | |
| Download: ML19352B116 (6) | |
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l U.S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT REGION IV Report No. 99900744/81-01 Program No. 51300 Company:
Johnson Controls, Inc.
Panel Unit Highway 59 Poteau, Oklahoma 74953 Inspection Conducted:
February 23-25, 1981 Inspectors: Id2 aud
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H. W. R6berds, Contractor Inspector
' Date Reactive Inspection Section Vendor Inspection Branch lSm 4'-/t/e')
A R. K. Herr, Investigator Date Approved by:
be 4-/r/7/
I. Barnes, Chief Date Reactive Inspection Section Vendor Inspection Branch Summary Inspection on February 23-25, 1981 (99900744/81-01)
Areas Inspected:
Implementation of 10 CFR Part 50, Appendix B, and applicable codes and standards including:
welder qualification material identification and control and equipment calibration, electrical test and fitup.
The inspec-tion involved 32 inspector-hours on site by one NRC inspector and one NRC investigator.
Results:
In the two areas inspected, five nonconformances were identified.
There were no unresolved items.
Nonconformance:
Welder Qua
'ication - Welders' requalification not performed as required by Criterion V of Appendix B to 10 CFR Part 50 and Section 10 of the QA Manual (Notice of Nonconformance, Item A).
Material Identification and Control - Tagging of materials and items to identify the acceptance status not in conformance with Criterion V of Appendix B to 10 CFR Part 50 and Section 15 of the QA Manual (Notice of Nonconformance, Item B).
Segregation of materials and items identified with hold tags not in conformance with Criterion V of Appen-
' dix B to 10 CFR Part 50 and Section 15 of the QA Manual (Notice of Nonconformance, Item C).
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Listing of material code numbers on material requisition slips not in conformance with Criterion V of Appendix B to 10 CFR Part 50 and Quality Assurance Standard QAS-903 (Notice of.Nonconformance, Item D).
Verification of materials released on requisitions not in conformance with Criterion V of Appendix B to 10 CFR Part 50 and Quality Assurance Standard QAS-903 (Notice of Nonconformance, Item E).
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3 DETAILS SECTION l
(Prepared by H. Roberds and R. Herr)
A.
Persons Contacted
- R. E. Searles, Operations Manager
- J. E. Jones, Cuality Assurance Manager
- R. L. Stankewicz, Quality Engineer W. L. Gann, Receiving Inspector R. Cottrell, Project Tecnnician E. McCullah, Project Engineer T. Qualls, Inprocess Inspector
- Attended Exit Meeting.
B.
Introduction On February 6, 1981, a telephone call was received by the Nuclear Regulatory Commission, Region IV, Vendor Inspection Branch, at Arlington, Texas.
The caller e>oressed concerns relative to products produced by Johnson Controls, Inc. Potecu, Oklahoma.
Specific identified subjects were maintenance of welder's q1alification, control of safety related and ASME Code items, electrical checkout of control panels, identification and calibration of gages, and aisalignment (fitup) of panel frames.
An inspection was conducted by the Vend (r Inspection Branch of the Poteau facility on February 23-25, 1980, to ascertain the validity of the preceding subject concerns.
C.
Welder Quali fication 1.
Objective The of jective of this area of the inspection was to determine if welde's and welding operators are qualified in accordance with Section IX of the ASME Code and the manufacturer's Quality Assurance program.
2.
Method of Accomplishment a.
Review of the Quality Assurance Manual, Section 10, " Control ef Special Processes."
b.
Review of seven welder performance qualification record packages.
c.
Review of production records to assure continuing qualification for the weld process used.
d.
Interviews with cognizant personnel.
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Findings a.
Nonconformances
-See Notice of Nonconformance, Item A.
b.
Unresolved Items
- None.
D.
Material Identification and Control 1.
Objective The objective of this area of the inspection was to verify that material identification and control during manufacturing is in accordance with the applicable regulatory, code and QA program requirements.
2.
Method of Accomplishment a.
Review of the Quality Assurance Manual, Section 9, "Identifi-cation & Control of Materials, Parts and Components."
b.
Review of procedure No. QAS-802, Revision 1 of 10/5/79 " Receiving Inspection."
Review of procedure No. QAS-903, Revon 0, of 3/6/79, " Release c.
of Materials for Manufacturing / Fabrication."
d.
Observation of storage areas.
e.
Interviews with cognizant personnel.
3.
Findings a.
Nonconformances (1) See Notice of Nonconformance, Item B.
(2) See Notice of Nonconformance, Item C.
l (3) See Notice of Nonconformance, Item D.
I In addition to tne identified nonconformance, it was also noted that there was no records to indicate that the material handler responsible for issuance of safety related and code items had received training in regard to procedures and QA l
Manual requirements.
(4) See Notice of Nonconformance, Item E.
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b.
Unresolved Item None.
E.
Equipment Calibration, E' t.ctrical Test and Fitup 1.
Objectives The objectives of this area of the inspection were to ascertain that:
a.
Systems have been established and maintained to provide for the control of measuring devices used in activities affecting quality and electrical test and fabrication fitup assembly activities.
b.
The systems have been adequately documented with approved pro-cedures and that these procedures are being implemented.
2.
Method of Accomplishment The preceding objectives were accomplished by:
a.
Review of Section 10 of the Quality Assurance Manual, " Process Control."
b.
Review of Section 11 of the Quality Assurance Manual, " Inspection."
c.
Review of Section 12 of the Quality Assurance Manual, " Test Control."
d.
Review of Section 13 of the Quality Assurance Manual, " Measuring and Test Equipment."
e.
Review of Section 15 of the Quality Assurance Manual, " Inspection and Test Status."
f.
Observation of shop equipment.
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3.
Findings a.
Within this area of the inspection, no nonconformances or unresolved items were identified.
i b.
Review of the Quality Assuran.e program indicated that appropriate guidance had been given to provide for the control of equipment calibration, electrical test and fitup assembly activities.
Specific implementation of program controls for the subject activities could not be verified during the inspection, however, as a result of an ongoing employee strike, which had commencea approximately six weeks prior to the inspection.
These activities will be further reviewed during a future inspection.
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Exit Meeting -
A post inspection meeting was held on February 25, 1981, with the management representatives denoted in paragraph A. above.
The inspectors-explained the background for the inspection and informed management that they had not been able to relate the expressed subjects (page 3) to any degradation of product quality. However, management was infonned of the inspection findings cited in the Notice of Nonconfonnance of this report, which could indicate a lack of understanding and/or enforcement of their Quality Assurance Program.
The inspectors explained, in detail, the three parts required in the response letter, relative to the findings.
The management representatives. informed the inspectors of the strike by the International Brotherhood of Electrical Workers and indicated they did not know when a settlement might 5e reached.
They also stated that approximately 10% of the production at the Poteau facility was safety related or ASME code items.
Management made no comments relative to the findings except for points of clarification.
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