ML20011A999
| ML20011A999 | |
| Person / Time | |
|---|---|
| Issue date: | 10/14/1981 |
| From: | Oller R, Potapovs U NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML20011A996 | List: |
| References | |
| REF-QA-99900221 NUDOCS 8111030504 | |
| Download: ML20011A999 (12) | |
Text
ORGANIZATION:
CONSOLIDATED CONTROLS CORPORATION BETHEL, CONNECTICUT REPORT NO.: 99900221/81-01 INSPECDON DATE{Sh 8/25-27/81 INSPECTION ON4TTE HOURS: 24 CORRESPONDENCE ADDRESS: Consolidated Controls Corporation ATTN: Mr. John Engelberger Vice President / General Manager 15 Durant Ave.
Bethel, CT 06801 ORGANIZATION CONTACT:
Mr. L. E. Goodsell, Jr., QC Manager TELEPHONE:
(203) 743-6721 PRINCIPAL PRODUCT: Electronic Instrumentation and Control Systems NUCLEAR INDUSTRY / CTIVITY: Consolidated Controls has manufacturing plants in Bethel and Danbury, Connecticut, engaged in the manufacturing of commercial nuclear electronic instrumentation and control systems.
The output of both plants is 16% for the consnercial nuclear industry.
ASSIGNED INSPECTOR:
/8" N-[/
R. E. Oller, Components Section (CS)
Date OTHER INSPECTOR (S):
(
APPROVED BY:
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[C-Ik-dl U. Potapovs, Acting Chiej, CS Date
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INSPECTION BASES AND SCOPE:
A.
BASES:
10 CFR Part 50 and 10 CFR Part 21.
B.
SCOPE: Status of previous inspection findings; manufacturing process control; change control; nonconformances and corrective action; and 10 CFR Part 21 implementation.
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ORGANIZATION:
CONSOLIDATED CONTROLS CORPORATION BETHEL, CONNECTICUT REPORT NO.: 99900221/81-01 INSPEGON RESULTS:
PAGE 2 of 5 A.
VIOLATIONS:
None B.
NONCONFORMANCES:
None C.
UNRESOLVED ITEMS:
Ncire D.
STATUS OF PREVIOUS INSPECTION FINDINGS:
1.
(Closed) Deviation A (78-01):
Failure by the QC Department to review, approve, and enter Q.C.R. and initials on Purchase Order No. 56922-7, dated May 5,1978, and the related order cards.
The inspector verified that in accordance with the CCC response letters, dated September 1, 1978, and October 31, 1978, that current purchase orders are reviewed by QC and approved by stamping with Q.C.R. FB., while the order requisition cards are reviewed and approved by stamping Q.C.R.,
FB., C of C.
2.
(Closed) Deviation 8 (78-01):
Failure to identify the document "Authori-ties and Duties of the Quality Control Staff" as Appendix 1 in the QC Manual No. 2, as committed to in Consolidated Controls Corporation's corrective action response letter, dated December 20, 1977.
The inspector verified that in accordance with the CCC response letters, dated September 1, 1978, and October 31, 1978, the document " Duties of the Quality Control Staff" was added to the Table of Contents of Revision 4 of QCM No. 2, and was denoted as being.available on request.
3.
(Closed) Deviation C (78-01):
Failure to add Test Procedure KGD 1315 to the manufacturing routing for conducting dielectric and insulation resistance tests on the 9N30 assembly, as committed to in the CCC correc-tive action response letters, dated August 25, 1977, and September 22, 1977. Also, failure to identify the dielectric and insulation test procedure on the manufacturing routing Revision D, dated May 27, 1977, for Assembly No. 9N28.
The inspector verified that in accordance with the CCC response letters, dated September 1, 1978, and October 31, 1978, CCC has changed the manufacturing routing sheets for assemblies 9N28 and 9N30 to include the test procedures numbers KGK-1315 and KGD-1315, respectively, for the operations covering the dielectric and insulation test.
Also two current routing sheet records had the required test procedure numbers KAF-7315 and KBG-7317 opposite the operation covering the Hi. Pot and I.R. tests.
ORGANIZATION:
CONSOLIDATED CONTROLS CORPORAT10N BETHEL, CONNECTTCUT REPORT NO.: 99900221/81-01 INSPECTION RESULTS:
PAGE 3 of 5 4.
(Closed) Deviation D (78-01):
Failure to list by number in the tooling column of the manufacturing routing, dated September 15, 1977, the correct harness board for Assembly No. 9N38-6, as committed to in the CCC response letter, dated September 22, 1977, and to properly identify harness boards.
The inspector verified that in accordance with the CCC response letters, dated September 1, 1978, and October 31, 1978, the item of concern was incorrectly identified by CCC as a harness board, but was actually a manufacturing aid called an " Easel Wiring Fixture." The identification of this item was corrected for Panal Type 9N38-6, and was correctly listed in the routing tooling column. Also, the incorrectly identified harness boards were properly identified as No. 7N186.
5.
(Closed) Deviation E (78-01): Failure to provide evidence of CCC inspec-tion and proper identification of acceptance of 40 relays, Parts Nos.
KHF-431A and KliE-431A located in the assembly / test area of Plant No. 2, as committed to in the CCC corrective action response letter, dated September 22, 1977.
The inspector verified that in accordance with the CCC response letters, dated September 1, 1978, and October 31, 1978, the items of concern had been transferred from Plant No. I to Plant No. 2 without the inspection acceptance tag covering the inspection acceptance of Plant No. 1.
To prevent this type of oversight, CCC had initiated the use of a multipart inspection tag for release from accepted stores in both plants.
The use of this multipart tag was short as CCC was unable to secure further supply of tags and reverted to the use of a one piece tag.
The current practice is to ship parts designated for use in Plant No. 2 directly to Plant No. 2, where they are inspected on receipt.
For any items trans-ferred from Plant No. 1 to Plant No. 2, a duplicate acceptance tag is made out and attached to the items before transfer.
6.
(Closed) Deviation F (78-01):
Failure to provide measures to assure that rented measuring and testing equipment used in activities affecting quality were properly controlled, calibrated, and adjusted at specified periods, in accordance with Criterion XII of Appendix B to 10 CFR Part 50.
The inspector verified that in accordance with the CCC response letters dated September 1, 1978, and October 31, 1978, paragraph 9.6 was added to Revision No. 4 of the QC Manual No. 2, to provide for an inspection copy of the purchase order for rental-lease or loan of test equipment, to be sent to the CCC calibration laboratory personnel, who would provide control and verification of calibration of the equipment when it was sent to the designated department. The manual revision also provided for recall of the equipment, under the CCC calibration system, if it was kept beyond the recalibration due date.
OHGANIZATION:
CONSOLIDATED CONTROLS CORPORATZON BETHEL, CONNECTICUT REPORT NO.: 99900221/81-01 INSPECDON RESULTS:
PAGE 4 of 5 E.
OTHER FINDINGS OR COMMENTS:
1.
Manufacturing Process Control The inspector reviewed three sections of the QC Manual QCM No. 2, Revision 6, which were applicable to the assembly, test, and inspection of printed circuit board assemblies and assembly and test of control cabinets.
Observations were made in Plant No. 2 of the in-process work on circuit board module assembling, wave soldering, electronic testing, final inspec-tion, and control cabinet assembling.
Review included one in-process assembly route sheet (traveler) with related documents and records, and one completed assembly.oute sheet (traveler) document and record package for printed circuit board logic modules Part No. 6N309. The related documents and records reviewed included:
three related, but separate, soldering and cleaning procedures and an acceptance standard; parts list; drawings; cabinet module loading list; engineering instructions for functional tests; QC instructions for electronic testing; inspection procedures; inspection and test reports; reject tags; and a customer purchase order quality requirement specification.
Within this area, no nonconformances to NRC, customer order, or the QC program requirements were identified and no unresolved items were identified.
2.
Ci,ange Control The inspector reviewed Section II of the QC Manual QCM No. 2, Revision 6, which was applicable to changes in design, procurement, and manufacturing documents.
To verify that changes in design documents were controlled, a review was made of: a revised printed wiring board (P.W.B.) assembly drawing No. 6N306, Revision C, the related engineering change notice (C/N)
No. S-2733, and three requests for action (R/A) which were incorporated i
into the C/N S-2733; the revised parts list Module PL-6N306, Revision E; the related C/N S-3167; and a six page handwritten engineering memorandum list of changes to be incorporated into C/N S-3167.
Also reviewed were an engineering biweekly list of open R/A's, dated August 10, 1981; the notes of the meeting of the Design Review Committee, dated August 27, 1981; and a Data List, Revision X, dated May 2, 1981, of all required documents for cabinets 9N48 and 9Nt9.
To verify that changes in procurement were controlled, the inspector reviewed a current purchase order involving Change Notice No.1.
Within this area, no nonconformances to NRC, customer order, or QC Program requirements were identified, and no unresolved items we; _ identified.
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ORGANIZATION:
CONSOLIDATED CONTROLS CORPORATION BETHEL, CONNECTICUT REPORT NO.: 99900221/81-01 INSPECTION RESULTS:
PAGE 5 of 5 3.
Nonconformances and Corrective Action The inspector reviewed four sections of the QC Manual QCM No. 2, Revision 6, which were applicable to the control and disposition of deficiencies in procured items and in-process items and those deficient items requiring corrective action requests.
To verify that nonconforming items were reviewed and accepted, rejected, repaired, or reworked, and that conditions adverse to quality, including the cause, are promptly identified and corrected, a review was made of:
six current Discrepancy Reports; a current monthly Summary of Discrepancy Reports with Material Review Board Action; a current monthly Summary of Discrepancy Reports for Internal Departments; three current Corrective Action Request for Procured Materials, and two current Quality Audit /
Corrective Action Requests for Internal Department Discrepancies.
Within this area, no nonconformances to NRC, customer order, or QC program requirements were identified, and no unresolved items were identified.
4.
10 CFR Part 21 The inspector reviewed the Standard Instruction No. 1563.031, dated January 6,1978, " Reporting of Defects and Non-Compliances," to verify that documented measures were available to meet the reporting requirements of 10 CFR Part 21.
Obseev3tions were made, in the final inspection area, of the posted copies of 10 CFR Part 21, Article 206 of the Energy Reorganization Act of 1974, and the above CCC Procedure No. 1563.031.
Within this area, no violations were identified.
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