ML20008F234
| ML20008F234 | |
| Person / Time | |
|---|---|
| Issue date: | 01/22/1981 |
| From: | Barnes I, Oller R NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML20008F230 | List: |
| References | |
| REF-QA-99900316 NUDOCS 8103120601 | |
| Download: ML20008F234 (11) | |
Text
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O U. S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT REGION IV Report No. 99900316/81-01 Program No. 51300 Company:
Gould Incorporated Valve and Fittings Division 6300 W. Howard St.
Chicago, Illinois 60648 Inspection Conducted:
January 6-8, 1981 Inspector:
2.4M-l~ N R. E. Oller, Contractor Insp ector Date ComponentsSection II Vendor Inspection Branch Approved by:
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[(l I. Barnes, Chief Date '
omponentsSection II Vendor Inspection Branch Summary Inspection on January 6-8,1981(99900316/81-01)
Areas Inspected:
Implementation of 10 CFR 50, Appendix B criteria; other NRC requirements, and applicable codes and standards including:
internal audits, design control, manufacturing process control, equipment calibration, and product acceptance.
The inspection involved 24 inspector-hours on site.
Results:
In the five (5) areas inspected, no deviations or unresolved items were identified.
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DETAILS SECTION A.
Persons Contacted
- S. Kunka, Vice President - Operations J. Furfey, QA Engineer R. Haines, QA Manager J. Misek, Tool & Gage Group Leader A. Pietramale, Manager Product Engineering D. Speckman, Project Design Engineer D. Takada, Project Engineer - Nuclear Products
- Attended the exit meeting.
8.
Internal Audits 1.
The objectives of this area of the inspection were to verify that the following items were controlled in accordance with the QA Manual and applicable NRC and ASME code requirements:
a.
A written system has been established to assure that internal audits are performed and controlled in accordance with applicable codes to verify compliance with all aspects of the QA program.
b.
Planned and periodic internal audits are performed in accor-dance with written procedures or checklists by qualified personnel not having direct responsibilities in the areas being audited.
c.
Audit results are documented and reviewed by management having responsibility in the area audited.
d.
Followup action, including reaudit of deficient areas, is taken where indicated.
2.
Method of Accomplishment The preceding objectives were accomplished by:
a.,
Review of the QA Manual Section 15.0, Revision 4, " Auditing".
b.
Review of " Internal Audit Schedule - Nuclear Program - 1980".
c.
Review of the following records of internal audits of the QA Program based on different QA Manual sections, with the audits being performed.in different months of 1980:
Y;
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(1) Assignment of Auditor Letters.
(2) Completed Audit Checklists.
(3) Audit Findings Summary Letters.
(4) Corrective Action Response Letters to Auditors.
d.
Review of the following records of the management audit of the QA Program performed on 12-11-80.
(1) Completed Audit Checklist.
(2) Corrective Action Letter, dated 1-5-81.
3.
Findings a.
Within this area of the inspection, no deviations or unresolved items identified.
b.
Other Findings - Followup Item The followup audit of the corrective action responses to the December, 1980, Management Audit Findings, will be performed during late January,1981.
This item will be followed-up on during a subsequent NRC inspection.
C.
Design Control 1.
Objectives The objectives of this inspection were to verify that the following items were controlled in accordance with the NRC and ASME require-ments and the QA Program:
a.
The QA program provides appropriate controls for the design activities; b.
Approved written procedures or instructions are available and are being implemented, to assure that the requirements of design specifications, codes, standards, and/or commit-ments, as applicable, are correctly translated into drawings, specifications, procurement documents, procedures and/or instructions; c.
That design documents are reviewed for compliance with design specifications and code requirements, and the reviews and checking are performed by qualified personnel other than those responsible for the original design;
4 d.
Revisions, changes and/or addenda to design documents are reviewed in the same manner as the original; The reviews and checks of design documents are appropriately e.
documented in a manner that is auditable; f.
Procedures are implemented for the review, approval, release and distribution of design documents including changes thereto by the responsible design personnel.
g.
Measures are established requiring that deviations from the design documents identified by in process or final inspections are to be reported to the responsible design personnel for review, evaluation &nd appropriate disposition.
2.
Method of Accomplishment The preceding objectives were accomplished by:
a.
Review of the QA Manual Section 5.0 " Order Initiation," and Section 6.0 " Design Engineering".
b.
Discussions with cognizant personnel.
Review of the following records to verify that the Engineering c.
and QA Departments activities related to valve Order Initiation review, were implemented and documented.
(1) Portland General Electric (PGE) P.O. No. N-17318 dated 7-22-80 for instrument valve J-9N2.
(2) Order Approval Sheets, approved with comments by the Design Project Engineer and QA Manager.
(3) PGE Supplement No. 1 (change order) to P.O. N-17318, covering the Gould comments.
(4) Order Approval Sheets, approved by the Design Project Engineer and QA Manager for the above Supplement No. 1 to P.O. N-17318.
d.
Review of specification OS 101, Revision 9A dated 7-18-80, for shutoff valves prepared by Gould Design Project Engineer for the above PGE order to verify that the specification and
-the reviews, approvals and routing were in accordance with the requirements of the QA program and ASME Code.
5 Review of the " Order Index" dated 12-2-80 for PGE Order N-17318, e.
to verify it was developed by the Design Project Engineer, accepted by the QA Manager and released by the Manager Product Engineering.
f.
Review of a " Marked Up" drawing for the above valve order, submitted by the Design Project Engineer to Drafting.
g.
Review of the " Assembly Drawing Log Book" and " Suffix Cards" used for assigning drawing numbers traceable to specific customer's orders.
h.
Review of the " Design Calculation" design report for Instru-ment Valves on PGE order N-17318 to verify the signoffs of the preparer and reviewer were in accordance with the QA Manual.
i.
Review of a design report " Stress Report No. 2" for an ASME Section III Division I, Class I Valve For Bailey Meter P.O.
M0099, to verify that the report was prepared by the Design Project Engineer, reviewed by a different Project Engineer and certified by a registered Professional Engineer.
j.
Review of Engineering Change Request (ECR) No. 277 dated 10-15-80 and the related Engineering Change Notice (ECN), to verify that the ECR the preparer, was the Design Project Engineer, the change was accepted by the QA Manager, and the ECN was prepared and approved by drafting.
k.
Review of an "As Built" Drawing No. 3002001, F and the related Dimensional Inspection Checklist (DIC) and other valve part drawings and DICs to verify that the Design Project Engineer had reviewed each valve part drawing and approved it for "As Built" dimensions by stamping and sign-ing off on each drawing.
1.
Review of eight engineering standards ESNs osed in procuring materials and processing valve parts and valve assemblies, to verify that the ESNs were prepared by the Project Engineer, reviewed and accepted by the QA Manager and approved by the Manager - Product Engineering.
m.
Review of an Orcer Index for Gould Order No. T-81752, to verify that all ESNs, with applicable revision level, were identified.
6 n.
Review of a revised ECN to verify that the change was identified on the ECN and the change was reviewed and signed by the Manager Product Engineering in the same manner as for the original.
o.
Review of six drawings approved by Brown & Root, to verify that the drawings and transmittal letters were properly controlled oy signoff and routing.
3.
Findings a.
Within this area of the inspection, no deviations or unresolved items were identified.
b.
Other Findings - Comments Design Control practices were consistent with the current QA manual procedures for the design report generated in 1976, as well as current design work.
D.
Manufacturing Process Control 1.
Obj ectives The objectives of this area of the inspection were to verify that the following items were controlled in accordance with the QA Manual and applicable NRC and ASME code requirements:
a.
A written system has been established to assure that manu-facturing processes are controlled in accordance with appli-cable codes.
b.
Measures have been established and implemented to control the manufacturing processes by use of process sheets, travelers, checklists or procedures.
c.
The process sheets, travelers, checklists or shop procedures used included:
the document numcers and revisions to which the processes, inspections or tests conformed; the results of completion of the specific operations; the signature, initials or stamp of the manufacturer's responsible representative and date were shown for operations completed, and the signature, initials or stamp of the authorized inspector and date, were shown for activities he witnessed.
2.
Method of Accomolishment The preceding objectives were accomplished by:
7 a.
Review of the QA Manual Section 10.0 " Process Control".
b.
Observations of valve bodies being manufactured and review of the accompanying Process Inspection Sheets to verify that the sheet identified the item being manufactured; the sequence of process steps and QC inspections were identified; the sheet was appropriately signed for release to production, and the completed inspections were signed by the QC inspector.
c.
Observations of 3-valve manifold and instrument valve assemblies on hold in the final assembly area, and review of the accompany-ing Assembly Travelers, Hydro-static Test Reports, and Name Plate Marking Sheets, to verify that the travelers contained the following:
the required valve information; sequences of operations and inspection steps with procedure identity; releases for assembly, and signoffs for operations, inspec-tions and tests completed and accepted.
d.
Discussions with cognizant personnel.
3.
Findings Within this area of the inspection, no deviations or unresolved items were identified.
E.
Equipment Calibration 1.
Objectives The objectives of this area of the inspection were to verify that the following items were controlled in accordance with the QA Manual and applicable NRC and ASME Code Requirements:
a.
A written system has been established to assure that equipment calibration is performed and controlled in accordance with applicable codes, b.
A written procedure has been developed and approved which contains provisions to assure that tools, gages, instruments and other inspection, measuring and testing equipment and devices used in activities affecting quality, are.of the proper range, type and accuracy, and are calibrated and
_ properly adjusted at specified periods or use. intervals.
c.
The devices are identified in the documented system and/or procedure and are calibrated in accordance with the system and procedure.
8 d.
The calibration is performed against certified measurement standards which have known relationship to National Standards, where such standards exist.
e.
The control measures include provisions for test equipment identification and calibration status by marking, or on records traceable to the equipment.
2.
Method of Accomplishment The preceding objectives were accomplished by:
a.
Review of the QA Manual Section 12.0 " Calibration."
b.
Review of the approved Procedure QAP-404, Revision 2, " Control of Gages, Tools and Mechanical Test Equipment," along with Attachment A " Mechanical Calibration Frequency," to identify the equipment under the calibration program and its frequency of calibration.
c.
Observation of the calibration of the following types of devices located in Plants No. 1 and No. 3.
(1) Torque Tester (For calibration of torque wrenches).
(2) Optical Comparators (3) Rockwell Hardness Testers (4) Torque Wrenches (5) Hydrostatic Test Gages (6) Astral Surface Plates (7) Contour Projector (8) Vernier Calipers (9) Thread Gages (10) Plug Gages (11) Ring Gages (12) Depth Gages (13) Outside Micrometers i
9 d.
Review of the Gould Calibration History cards and applicable subcontractor's Certificates of Calibration, for the above devices.
e.
Discussions with cognizant personnel.
3.
Findings a.
Within this area of the inspection, no deviations or unresolved items were identified.
b.
Other Findings - Item To Be Followed-Up On During the examination of the calibration status of inspection measuring devices, several plug gages, which were not cali-brated or documented, were observed in cabinet drawers in the First Piece Inspection Crib at Plant No. 1.
A search by the Tool and Gage Group Leader established that these gages were from a defunct department and the gages had been put in the First Piece Inspection crib by error.
Action was taken prior to the end of the inspection to move these gages to the Tool and Gage room, where they will be identified, cali-brated and entered in the calibration system.
This corrective action will be followed up on during a subsequent NRC inspec-tion.
F.
Product Acceptance 1.
Objectives The objectives of this area of the inspection were to verify that the following items were controlled in accordance with applicable NRC and ASME Code requirements and the QA program.
A written system has been established to assure that product a.
acceptance activities related to procurement of items and services, are controlled.
b.
Procedures have been prepared, approved and implemented by responsible personnel to control the subject activities, c.
The results of product acceptance activities are documented and reviewed for acceptability by responsible personnel.
2.
Method of Accomplishment The preceding objectives were accomplished by:
10 a.
Review of the QA Manual Section 9.0, " Material Control."
b.
Observations in the Receiving Inspection Department.
c.
Review of the Receiving Inspection Report No. 196 for valve manifold bodies Heat Mark (HMS) Symbol P-32.
d.
Observation of Tee Forgings and review of the following records comprising the Receiving Inspection Document Package for the tee forgings identified by HMS G-99 received from a heat treating subcontractor.
(1) Gould Purchase Order to Jero Steel Treating Company.
(2) Receiving Inspection Report Form.
(3) Jero's Certificate of Heat Treating.
(4) Heat Treatment Temperature Charts.
(5) Traveler for processing the tee forgings.
f.
Review of Receiving Inspection Report for raw bar stock from Crucible Steel Company to verify the following requirements were included.
(1) Records of stamping of material identification marking, and Material Certifications.
(2) Dimensional check of two Bars from each bundle.
(3) Copy of the purchase order no. 59739 approved by the QA Manager on 12/20/79.
3.
Findings Within this area of the inspection, no deviations or unresolved items were identified.
.G.
Exit Interview 1.
The inspector met with management representatives denoted in paragraph A, at the conclusion of the inspection of January 8, 1981.
2.
The following subjects were discussed.
11 a.
Areas inspected.
b.
This inspection's findings.
3.
The manufacturer's representatives indicated that they did not have any questions.
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