ML20005A206
| ML20005A206 | |
| Person / Time | |
|---|---|
| Issue date: | 04/20/1981 |
| From: | Mcneill W, Whitesell D NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML20005A200 | List: |
| References | |
| REF-QA-99900387 NUDOCS 8106300038 | |
| Download: ML20005A206 (7) | |
Text
-
h U.S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT REGION IV Report No. 99900387/81-01 Program No. 31400 Company:
General Atomic Company Post Office Box 81608 San Diego, California 92138 Inspection Cuducted: March 30 - April 3, 1981 Inspectors 2/
.4,,-
c4/re///
W. M. McNei11, Contiactor Inspector Date Components Section Vendor Inspection Branch n D m ? L,ffv
~
c //h ///
9 7.d C; Approved by:
- 0. E. Whitesell, Chief Date Components Section Vendor Inspection Branch Summary Inspection on March 30 - Acril 3,1981 (99900387/81-01)
Areas Insoected:
Implementation of 10 CFR 50, Appendix B, including design controls; periodic management neeting and iction on previous inspection findings.
The inspection involved 30 inspector hours on site by one NRC inspector.
Results:
In the three areas inspected, no r.onconformances or unresolved items were identified in two of the areas.
The following tnree nonconformances were identified in the remaining area.
Nonconformances:
Document Control - travelers did not fully control the sequences of operations, operations required, and dating of operations performed contrary to the Manufacturing Operations Manual, Section 14, paragraph 4.1 and Appendix B (Notice of Nonconformance, Item A).
Design Control - conformance to contract requirements was not fully inspected in the areas of pneumatic +.ests, skid mount nuts, motor performance, and signal reproducibility contrary to the Contract Specification and Appendix B (Notice of Nonconformance, Item B).
8106800 o %
- l
....~.
2 4
?
2 g
4 Document Control - some ' documents were ont controlled in particular Wire Lists contrary to the Quality Manual, Section 6, paragraph 2.0 and Appendix B (Notice of Nonconformance, Item C).
t 0
e i
i e
J G
i i
8 t
I
..-.----..z..-.
3
)
OETAILS SECTION A.
Persons Contac'.ed B. Asamoto, Qualification Engineer
- P. Bissonnette, General Manager
- T. Colandrea, QA Division Director
- W. Compas, Director Electronic Systems Division J. Hawkins, Planner F. Frame, Supervisor Technical Publications R. Jacob, Head Test Techican E. Jones, Supervisor Print Room "J. Kelly, Quality Department Manager P. Kline, QC Supervisor
- R. Morrison, Manufacturing Engineering Department Manager T. Malligan, Quality Engineer C. Newsom, Quality Enc'nwer C. Phipps, Productior. Manager C. Poe, Drafting Supervisor
- 0. Schaffer, Manuft:turing Liason Engineer
- F. Thrombley, Manufacturing Department Manager P. Vader, Inspector B. Ward, Design Engineer
- 0. Weis, Project Manager
- J. Winso, Project Manager E. Woodward, Oraftsman
- Denotes those attending exit interview.
B.
Action on Previous Insoection Findings (Closed) Violation (Report 79-01):
Part 21 posting requirements were not followed.
A review of the fabrication and engineering areas established that 10 CFR Part 21 procedures were posted with the reporting requirements.
General Atomic (G. A.) does agree at this time that it does supply equip-ment to which 10 CFR Part 21 is applicable.
(Closed) Jeviation (Report 79-01):
Travelers did not identify test proce-dures by number.
An inspection of travelers found all testing to be performed identified with a test procedure by number.
1
1 4
(Closed) Deviation (Report 79-01):
Crimping was not qualified as required by the Workmanship Inspection Standard.
Crimping tools are now qualified by pull tests and are included as part of the calibration program.
Proce-dure QCI 414 has been written and implemented to control this activity.
o The Quality Manual has also been revised, also to address this requi,rement.
(Closed) Deviation (Report 79-01):
Changes to travelers were not properly L'
approved.
A -aview travelers 'n us.:4 currently found no improper changes.
(Closed) Deviation (Report 79-01):
Orawing and procedure revisions were not approved by the required personnel.
The Quality Manual, Section 6, has been revised.
A review drawings and procedures established all had the approvals required.
(Closed) Deviation (Report 79-01):
Reference Specifications were not approved by the appropriate personnel.
A review of current Reference Specifications found there issuance and change control to be in accordance with the current Quality Manual.
(Closed) Unresolved Item (Report 79-01):
The Manufacturing Operations Manual has been issued.
(Closed) Unresolved Item (Report 79-01):
Calibration tables have been applied to equipment calibrated outside G. A. to assure calibration status.
(Closed) Unresolved Item (Report 79-01):
Subcontracted calibration services are provided only by subvendors on the Supplier List.
Most calibration is currently dore in-house.
(Closed) Unresolved Item (Report 79-01):
Travelers which required the test procedure to be recorded on were found to be filled in completely.
G.A. maintains that only current revisions of tests procedures etc. are used and the date of an operation determines the revision used.
C.
Design Controls 1.
Objectives The objectives of this area of the inspection were to verify that:
a.
The manufacturer's design control activities are conducted in such a manner as to provide assurance that appropriate safety-related technical requirements have been implemented during the design of electrical equipment.
i I
i l
i i
l
.i
5 l
b.
The manufacturer's design control program, including its imple-mentation, meets the requirements of codes, staridards, customer requirements and Appendix B to 10 CFR Part 50.
2.
Method of Accomolishment The preceding objectives were accomplished by:
a.
Review of the Electronic Systems Division Quality Manual, E-307-642, Revision F, Section 3, Design Control, which established the general requirements for design control.
b.
Revicw contract 2258 and its associated specifications and Change Order Notice.
This review included Specification Y2827 and its appendixes.
c.
Re few of the Work Project Notification of job 2258.
Inspection of some of the drawing, subvendor purchase orders, test prece-dures, material certifications, hardware, seismic test report, and performance specification associated with the electrial equipment i.e., area gas monitors and process line-liquid monitors currently under production.
d.
The above documents were inspected to verify the translation of customer requirements, codes, standards, and etc. into design documents, fabrication drawing, inspection requirements, or subvendor requirements.
3.
Findings a.
Monconformances (1) A traveler for Detector Skid Assembly, 366-2001-01, S/N 8 was in the fifth operation / inspection step although the second and fourth steps, inspection steps, were neither performed nor signed off.
The routing for this and similar equipment was changed duri ; this inspection.
A lot of 10 P.C. boards, 357-2050-44, S/N's 10 to 19, were found in fabrication without a traveler.
Before the end of this inspection a " Clean Up Sheet" was issued to document the fabrication steps performed on these boards.
The fabrication steps were rework to up grace the boards to a new drawing revision.
1
- ~. -
6 A traveler for 0358-3811-00 parts was found which had the fabrication s'..ip signed off but undated.
The fabrica-tion drawing had been changed since the issuance of the traveler and it is not possible to know if the parts were fabricated to the most recent revision because of the lack-of dates on the sign off.
(2) The out of date Wire List 0358-2120-00 was removed from the floor during this inspection. Wire Lists are a recent manufacturingtechnique for control of fabrication.
The Quality Manual is to be revised to addres. Wire Lists which it does not presently.
b.
Unresolved Items None c.
Comments None D.
Periodic Management Meeting 1.
Obiectives The objectives of this meeting were to accomplish the following:
a.
To meet the company management and those oersons responsible for administrative of the General Atomic, Quality program and to reestabl'ish channels of communication.
b.
To redetermine the extent of the company's involvement in the commerical riuclear business.
c.
To explain NRC direct inspection program including VIB organiza-tion, inpsection methods and documentation.
l
l l-l 7
2.
Method of Accomplishment The preceding objectives were accomplished by a meeting with Mr.
W. J. Compas, General Manager.
7 The following is a sumary of the meeting:
a.
The VIB organization was described and its relationship to NRC Region IV and the NRC Headquarters component of the Office of Inspection and Enforcement.
b.
The VIB was described including the reasons for its establishment, its objectives, its implementation structure.
c.
The conduct of VIB inspections was described and how our inspactions are documented including the report, responses to reports, how proprietary information in handled, the Public Document Room, and the White Book.
d.
The company's contribution to the nuclear industry and inspec-tion history were discussed including current and projected activity.
e.
The company quality assurance program was discussed.
3.
Findings The Electronic System Division fabricates for the nuclear industry gas or area radiation monitors and liquid or process radiation monitors and their supporting microprocessors and instrumentation.
Currently G.A. has about 60 contracts (50 domestic).
Some of this equipment is class 15.
Generally 150 units are used at a site.
About 20 percent of the fabrication in done in-house, it is general assembly.
Last year about 120 liquid monitors were shipped and about 80 gas monitors.
Some assembly generally PC boards is done in a Mexican plant site.
About 170 people are employed at the San Diego plant.
G.
Exit Interview The inspectors met with management representatives (denoted in paragraph A) at the conclusion of the inspection April 3, 1981.
The inspectors summarized the scope and fincings of the inspection.
5
.