ML20023B966
| ML20023B966 | |
| Person / Time | |
|---|---|
| Issue date: | 04/15/1983 |
| From: | Phillips H, Alexandra Smith NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML20023B954 | List: |
| References | |
| REF-QA-99900283 NUDOCS 8305090413 | |
| Download: ML20023B966 (18) | |
Text
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ORGANIZATION:
BIW CABLE SYSTEMS, INC.
BOSTON, MASSACHUSETTS REPORT INSPECTION INSPECTION N0.-
999007R1/83-01 nATF(O 7/7A 1/d/A1 nN_RTTC unHD9 cp CORRESPONDENCE ADDRESS:
BIW Cable Systems, Inc.
ATTN: Mr. E. Manchester, Jr.
President 65 Bay Street Boston, Massachusetts 02125 ORGANIZATIONAL CONTACT: Mr. A. Sutkus, Quality Control Manager TELEPHONE NUMBER:
(617) 265-2102 PRINCIPAL PRODUCT:
Power, control, instrumentation, and other types of electrical cables.
NUCLEAR INDUSTRY ACTIVITY:
BIW Cable Systems, Inc. (BIW) has electrical cable manufacturing plants in Boston, Plymouth, and North Dighton, Massachusetts.
The corporate office is in Boston and the equipment qualification testing laboratory is in Plymouth.
The total company's current workload is approximately 10 percent nuclear.
b 4//S/EJ ASSIGNED INSPECTOR:
A. L. 5inith, Equipment Qualification Section ~ IQS)
Date OTHER INSPECTOR (S):
J. Benson, Sandia National Laboratories
/
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Y//5/85 APPROVED BY:
H. S. Phillips, Chief,' EQS Date INSPECTION BASES AND SCOPE:
A.
BASES: Appendix B to 10 CFR Part 50 and 10 CFR Part 21.
B.
SCOPE: This inspection consisted of:
(1) a review of the 18 criteria of 10 CFR Part 50, Appendix B described in the BIW Cable Systems Quality Control Manual and associated procedures; (2) verification that the applicable criteria of the QA program had been implemented in compliance with the commitments contained in the BIW Quality Control Manual and supplemental procedures; and (3) 10 CFR Part 21 inspection.
PLANT SITE APPLICABILITY:
Not identified.
h 8305090413 830420 PDR GA999 ENVBIWCS 99900293 PDR
ORGANIZATION: BIW CABLE SYSTEMS, INC.
BOSTON, MASSACHUSETTS REPORT INbPELilVN N0.:
99900283/83-01 RESULTS:
PAGE 2 of 8 A.
VIOLATIONS:
Contrary to Section 21.31 of 10 CFR Part 21, BIW procured safety-related testing services from Associated Testing Laboratories and Isomedix, Inc.,
without specifying in the procurement documents that the provisions of 10 CFR Part 21 applied.
B.
NONCONFORMANCES:
1.
Contrary to the requirements of Criterion V of Appendix B to 10 CFR Part 50 and paragraph 4.1 of the BIW Quality Control Manual (QCM), purchase order Nos. 2-2865, 1-3876, 830205773, and 820105013 which procured safety-related testing services did not contain evidence that they had been reviewed by the quality control department.
2.
Contrary to the requirements of Criterion V of Appendix B to 10 CFR Part 50 and paragraohs 4.2 and 18.5 of the BIW QCM, no documented evidence existed to reflect that vendor surveys or audits had been performed at Associated Testing Laboratories or Isomedix, Inc.
3.
Contrary to the requirements of Criterion V of Appendix B to 10 CFR Part 50 and paragraph 18.4 of the BIW QCM, followup audits were not always being accomplished within required time periods.
4.
Contrary to the requirements of Criterion V of Appendix B to l
10 CFR Part 50 and paragraphs 1.1 and 2.4 of the BIW Quality Control Procedure No. 1, " Collection, Control, Storage and Maintenance of QA Records for Nuclear Power Plants," some records for safety-related j
equipment qualification tests were not stored in fireproof cabinets.
5.
Contrary to the requirements of Criterion V of Appendix B to 10 CFR Part 50 and paragraph 16.2 of the BIW QCM, the corrective action taken to close out equipment calibration deficiencies outlined in the BIW internal audit report (Boston plant) of December 20, 1982, did not include correction to prevent or preclude recurrence.
6.
Contrary to the requirements of Criterion XI of Appendix B to 10 CFR Part 50, the BIW thermal aging and loss-of-coolant accident (LOCA) simulation laboratory facilities did not employ adequate instrumentation or data recording meth'.ds to assure that specified environmental and electrical conditions had been met, nor did the QCM require such.
ORGANIZATION:
BIW CABLE SYSTEMS, INC.
BOSTON, MASSACHUSETTS REPORT INSPECTION N0.:
99900283/83-01 RESULTS:
PAGE 3 of 8 l
7.
Contrary to the requirements of Criterion II of Appendix B to 10 CFR Part 50, the BIW quality assurance program did not provide necessary controls over the review and approval of safety-related equipment qualification test reports.
i 8.
Contrary to the requirements of Criterion X of Appendix B to l
10 CFR Part 50, the BIW quality assurance program did not provide for necessary inspection activities affecting quality in the BIW Plymouth plant laboratory which performs safety-related equipment qualification testing. There was no evidence to indicate that the quality control department had been or was involved in this safety-related test effort.
C.
UNRESOLVED ITEMS:
During the review and verification of Criterion IV of Appendix B to 10 CFR Part 50, the NRC inspector determined that Ebasco Services, Incorporated had issued a purchase contract (NY-403659, dated October 4, 1979) to " Design, fabricate, and furnish refueling disconnect and missile shield cable assemblies - Class 1E and Nanclass 1E, seismic Cat.
I."
This purchase contract invokes the Ebasco Specification LOU 1564.269D, Revision 2, dated September 26, 1979. During this inspection BIW quality control and process laboratory personnel could only locate Revision 1 of I
this specification.
Section 10 of Revision 1 contains requirements for seismic qualification. Two completed BIW qualification test reports (82L006 and 82K020) issued under this contract were reviewed; however, they contained no reference to seismic testing.
In addition, Attachment 1 to Ebasco letter LW3-567-87, states that BIW is to respond to seismic qualifi-cation by April 22, 1982.
The NRC inspector tried to determine if seismic qualification was or was not a requirement, and if so, what was the status.
However, the BIW employee responsible for this area was out of town; hence, no conclusions could be made. This item will be reviewed during a subsequent inspection.
D.
OTHER FINDINGS OR COMMENTS:
1.
Quality Assurance Manual: The NRC inspection team performed an in-depth review / evaluation of the BIW QCM to assure that the BIW written quality assurance program addresses and is consistent with all applicable regulatory requirements. The basic BIW QCM, consisting of 26 sections, is written to meet the requirements of 10 CFR Part 50, Appendix B, 10 CFR Part 21, ANSI N45.2, and MIL-Q-9858A.
The basic QCM is supplemented by a number of quality control procedures, 1
l ORGANIZATION:
BIW CABLE SYSTEMS, INC.
BOSTON, MASSACHUSETTS REPORT INSPECTION N0.:
99900283/83-01 RESULTS:
PAGE 4 of 8 l
l each of which is a limited scope detailed procedure addressing a specific area of the quality operation. The NRC inspection team also r
performed a detail review / evaluation of each supplemental procedure that related to nuclear work.
The NRC inspection team identified the nonconformances discussed in paragraphs B.7 and B.8 above during the review of the BIW written quality assurance program.
2.
Quality Assurance Program Implementation:
The NRC inspection team verified the implementation of the BlW QCM and supplemental procedures by examining representative documents and records, interviewing inspection and test personnel, and by visual observations and inspections.
Comments concerning the implementation review, keyed to each individual criterion of Appendix B to 10 CFR Part 50, are as follows:
a.
Organization:
The BIW organizational structure was reviewed as well as the organizational authorities and responsibilities.
The i
current staffing pattern was compared to the organization charts contained in Section I of the BIW QCM.
The quality control manager reports to the manager, engineering operations, and has the authority to stop all nonconforming work.
~
No nonconformances were identified within this area.
b.
Quality Assurance Program: The NRC inspection team evaluated this criterion by verifying the implementation of:
(1) the other 17 criteria of Appendix B to 10 CFR Part 50, and (2) the requirements contained in 10 CFR Part 21.
Training and indoctrination records for two individuals were reviewed to l
establish that the training program had been implemented in accordance with the QCM procedures.
One violation and six nonconformances (all related to program l
implementation) were identified.
They are discussed in I
paragraphs A and B above.
c.
Design Control:
The NRC inspector determined that BIW designs safety-related equipment, test fixtures, and translates l
applicable design requirements to test plans / procedures.
Eight test plans were examined to determine that design requirements were translated into the plans in accordance with the BIW QCM.
ORGANIZATION: BIW CABLE SYSTEMS, INC.
BOSTON, MASSACHUSETTS REPORT INSPECIl0N NO.:
99900283/83-01 RESULTS:
PAGE 5 of 8 No nonconformances were identified within this area; however, one item (paragraph C above) remains unresolved.
d.
Procurement Document Control:
The NRC inspector reviewed 14 BIW purchase orders, all related to nuclear equipment, to verify that BIW was processing procurement documents in accordance with the QCM and supplemental procedures.
Within this area, one nonconformance (paragraph B.1 above) and one violation (paragraph A above) were identified.
The violation concerned the failure of BIW to include 10 CFR Part 21 requirements in purchase orders issued for safety-related testing services; however, it should be noted that the latest purchase order issued for like services did include 10 CFR Part 21 requirements.
e.
Instruction, Procedures, Drawings: The NRC inspector verified implementation of the BIW procedures, as they relate to this criterion, by reviewing seven test plans / procedures and related test reports and data.
No nonconformances were identified within this area.
f.
Document Control: The NRC inspector reviewed test plans, job orders, and related changes to verify proper review, approval, and issuance. Two work areas were observed to verify that current documents were being used.
No nonconformances were identified within this area.
g.
Control of Purchased Material, Equipment and Services:
The NRC inspector reviewed nuclear vendor files, the approved nuclear vendor list, and applicable certifications of conformances for testing.
No vendor files or other documented evidence was available to reflect that BIW had reviewed the quality assurance programs of two firms which had performed safety-related testing services for BIW.
Within this area the nonconformance discussed in paragraph B.2 was identified.
h.
Identification and Control of Materials, Parts and Components:
The NRC inspector verified the implementation of the BIW QCM l
ORGANIZATION:
BIW CABLE SYSTEMS, INC.
BOSTON, MASSACHUSETTS REPORT INSPECTION N0.:
99900283/83-01 RESULTS:
PAGE 6 of 8 procedures relating to this criterion by selecting one specimen from the thermal aging laboratory and one specimen from the LOCA simulation laboratory.
The identification i
and traceability of each specimen were verified.
No nonconformances were identified within this area.
i.
Control of Special Processes:
BIW does not perform special l
process work at this time; herce, this criterion does not apply.
j.
Inspection: As indicated in pcragraph B.8 above, BIW had not established the required inspection program for inspection of activities affecting quality in ti. air equipment qualification laboratory.
The NRC inspector examined test logs and data sheets to verify that the quality control department had not documented their participation in or review of actual tests.
No nonconformances were identified in this area as related to program implementation.
However, as noted above one nonconformance was identified relating to the establishment of written procedures in paragraph B.8.
l k.
Test Control:
BIW manufactures cable and cable assemblies and i
performs thermal aging, flame, and LOCA simulation testing.
l The NRC inspector reviewed eight test plans and related test l
methods to verify that applicable standards were included.
i The completed test reports for five test programs were reviewed to verify that required test prerequisites were met.
In addition, one test that was in progress during this inspection was observed by the NRC inspector.
During the NRC inspector's review of BIW Report B915, " Flame and Radiation Resistance Cables for Nuclear Power Plants,"
dated November 11, 1980, and a BIW report entitled "Long Thermal Aging of Insulation and Jacket Material for Electrical Cable," dated June 1981, questions concerning BIW's treatment of a possible phase change in the ethylene propyne rubber were raised.
This item is being evaluated by NRC consultants and will be reviewed during a subsequent inspection.
Also during this part of the inspection it was determined that BIW was in the process of establishing a new certification l
program for test personnel.
Verification of the program will be accomplished during a subsequent inspection.
ORGANIZATION: BIW CABLE SYSTEMS, INC.
BOSTON, MASSACHUSETTS IITUlT INSFtL UUN NO.:
99900283/83-01 RESULTS:
PAGE 7 of 8 Within this area the nonconformance discussed in paragraph B.6 above was identified.
1.
Control of Measuring and Test Equipment: The NRC inspector evaluated the implementation of the BIW QCM procedures relative to this criterion to determine if measuring and test equipment was being controlled.
Three calibration records were reviewed.
Two equipment calibration procedures were evaluated and four items of test equipment were examined to verify status of calibration.
No nonconformances were identified within this area.
m.
Handling, Storage, and Shipping: The NRC inspector verified that BIW was following their written procedures by examining two specimens from the laboratory and observing that each specimen was adequately identified and stored.
No nonconformances were identified within this area.
n.
Inspection, Test, and Operating Status: The NRC inspector verified that BIW was following their written procedures in this area by performing observations in the laboratory areas for status of testing and nonconformances.
No nonconformances were identified within this area.
o.
Nonconformance Material, Parts, or Comments:
The NRC inspector verified that BIW was following their written procedures by reviewing two nonconformances and determining that they had been reviewed, approved, and dispositioned in accordance with established procedures.
No nonconformances were identified within this area.
p.
Corrective Action:
The NRC inspector examined four identified deficiencies that required corrective action to verify that BIW was following their written procedures.
Within this area the nonconformance discussed in paragraph B.5 above was identified.
i
ORGANIZATION:
BIW CABLE SYSTEMS, INC.
BOSTON, MASSACHUSETTS REPORT INSPECTION N0.:
99900283/83-01 RESULTS:
PAGE 8 of 8 q.
Quality Assurance Records: The NRC inspector examined a sample of test records to establish that BIW was complying with their written procedures.
l Within tnis area the nonconformance discussed in paragraph B.4 above was identified, i
r.
Audits: The NRC inspector examined two internal audit l
reports, two reaudit or followup reports, and two lead auditor i
qualification folders to verify that BIW was complying with their written procedures.
l Within this area the nonconformance discussed in paragraph B.3 above was identified.
l 3.
Implementation of 10 CFR Part 21: The NRC inspector observed the physical posting of required material at both the Boston and Plymouth plants to verify that BIW was in compliance with both regulatory requirements and their written procedures.
1 l
Within this area the violation discussed in paragraph A. above was identified.
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