ML20024C080
| ML20024C080 | |
| Person / Time | |
|---|---|
| Issue date: | 06/08/1983 |
| From: | Hubbard G, Phillips H NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML20024C066 | List: |
| References | |
| REF-QA-99900326 NUDOCS 8307120236 | |
| Download: ML20024C080 (19) | |
Text
l ORGANIZATION:
D. G. O'BRIEN, INC.
SEABR00X, NEW HAMPSHIRE rw.rvru AH3Ft.t,I AUh IN5FtLi1UN NO.:
99900326/83-01 DATE(S) 4/4-8/83 ON-SITE HOURS:
58 CORRESPONDENCE ADDRESS:
D. G. O'Brien, Inc.
ATTN:
D. G. O'Brien, President One Chase Park Seabrook, New Hampshire 03874 ORGANIZATIONAL CONTACT: Mr. H. P. Hilberg, Engineering Manager TELEPHONE NUMBER:
(603)474-5571 i
l PRINCIPAL PRODUCT:
Electrical penetration assemblies (EPA).
NUCLEAR INDUSTRY ACTIVITY:
Approximately 10 percent of D. G. O'Brien's (DG0) manufacture and test activities deals with EPAs for nuclear power plant applications. Test activities included equipment qualification of safety-related EPAs.
ASSIGNED INSPECTOR: M-7. k
(///O G. T. Hubbard, Equipment Qualification Section
'Dete (EQS)
OTHERINSPECTOR(S):
A. L. Smit p
i APPROVED BY:
3 (o ah n__
fo-T43 H. S. Phillips, Chief,i QS' Date E
l INSPECTION BASES AND SCOPE:
A.
BASES:
10 CFR Part 21, and 10 CFR Part 50, Appendix B.
B.
SCOPE: This inspection consisted of (1) a review of the quality assurance manual (QAM) and supplemental procedures, (2) verification of the implementation of the QAM and supplemental procedures (18 criteria of 10 CFR Part 50, Appendix B), and (3) verification of the implementation of 10 CFR Part 21 requirements.
l l
PLANT SITE APPLICABILITY:
Not identified.
8307120236 830613 0
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ORGANIZATION:
D. G. O'BRIEN, INC.
SEABROOK, NEW HAMPSHIRE REPORT INSPECTION N0.:
99900326/83-01 RESULTS:
) AGE 2 of 7 A.
VIOLATIONS:
1.
Contrary to Section 21.6 of 10 CFR Part 21, DG0 failed to post Section 206 of the Energy Reorganization Act of 1974 in its facility.
2.
Contrary to Section 21.31 of 10 CFR Part 21, DG0 procured safety-related testing services from Isomedix and Wyle Laobratories without specifying in the procurement document that the provisions
,of 10 CFR Part 21 applied.
B.
NCNCONFORMANCES:
t 1.
Contrary to the requirements of Criterion V of Appendix B to 10 CFR Part 50, DG0 did not establish documented procedures to describe how deviations from approved test procedures are documented and controlled.
2.
Contrary to the requirements of Criterion V of Appendix B to 10 CFR Part 50 and paragraph 5.5, Section 15 of the QAM, dated August 11, 1982, replies to corrective action report Nos. 249, 247A, and 247B were not made within the required time frame.
l 3.
Contrary to the requirements of Criterion V of Appendix B to 10 CFR Part 50 and paragraph 3.3, Section 2 of the QAM, dated August 11, 1982, and the requirements imposed on DG0 by customer purchase orders Nos. 69758 and F12645-32, DG0 procured safety-related testing services from test laboratories without specifying the required quality assurance requirements.
4.
Contrary to the requirements of Criterion V of Appendix B to 10 CFR Part 50 and paragraph 8.1 of Section 15 and paragraph 4.6 of Section 2 of the QAM, dated August 11, 1982, DGO issued purchase orders to firms for safety-related testing services that were not listed on the qualified vendor list (applicable at the date of issuance).
5.
Contrary to the requirements of Criterion V of Appendix B to 10 CFR Part 50 and paragraph 2.9 of quality procedure SS-QA-150, Revision A, dated June 26, 1979, there was no documented objective evidence that training for all applicable areas of the QAM, as defined by the engineering department training matrix, had been l
given engineering department employees during the required 6-month time period.
l l
l
f ORGANIZATION:
D. G. O'BRIEN, INC.
SEABROOK, NEW HAMPSHIRE REPORT INSPECTION N0.:
99900326/83-01 RESULTS:
3 AGE 3 of 7 C.
UNRESOLVED ITEMS:
None D.
OTHER FINDINGS OR COMMENTS:
1.
QA Manual Review: The QAM is a quality procedures manual consisting of 18 sections and 9 appendices that establish the procedures necessary to comply with the requirements of the 18 criteria of 10 CFR Part 50, Appendix B.
The NRC inspectors' review of the QAM consisted of an examination of all 18 sections and the appendices to the manual.
The NRC inspectors did not identify any nonconformances during the manual review.
2.
QA Program Implementation:
The NRC inspectors verified the implementation of the QAM procedures by examining representative records and files, conducting interviews with personnel, and making visual inspections and observations.
Comments concerning the implementation review as related to the 18 criteria of 10 CFR Part 50, Appendix B are as follows:
a.
Organization:
The NRC inspector reviewed DG0's organizational structure including functional responsibilities and authorities.
This review included examination of the company organization l
chart, the QA organization chart, and Appendix 8 to the QAM.
l The inspector determined from the above examinations and l
discussions with the QA engineer that the QA manager reports directly to the president of the company and has the authority to stop work pending resolution of quality matters.
No nonconformances were identified, b.
Quality Assurance Program:
The NRC inspector evaluated this criterion by verifying that a QA program was established by the QAM, and by verifying the implementation of the 18 criteria of 10 CFR Part 50, Appendix B.
The NRC evaluation of training included an examination of one procedure, training files for 16 personnel, and one training matrix as well as discussions with 3 personnel. One nonconformance for this criterion l
was identified in the area of training (see nonconformance described in paragraph B.5).
ORGANIZATION:
D. G. O'BRIEN, INC.
SEABROOK, NEW HAMPSHIRE REPORT INSPECTION NO.:
99900326/83-01 RESULTS:
) AGE 4 of 7 c.
Design Control: The NRC inspector verified the implementation of the QAM design control procedures by the examination of 1 specification, 3 engineering change orders (ECO), 1 drawing, 2 test reports, and 11 procedures.
Included as part of the inspector's verification were discussions with one QA and two engineering personnel.
The NRC inspector determined that design effort for product and equipment qualification (EQ) testing were being controlled by review and approval systems as described in the QAM.
The inspector recommended to DG0 management that they clarify their procedures to more clearly identify responsibilities relative to design control of EQ test activities.
DG0 management agreed to revise the procedures as recommended. The revised procedures will be reviewed during a future NRC inspection.
No nonconformances were identified.
d.
Procurement Document Control:
The NRC inspector verified that DGO was complying with QAM procedures by examining six incoming purchase orders (PO), two P0 changes, two customer specifications, nine outgoing P0s, and one procedure.
The inspector's examination identified one violation (see nonconformance described in paragraph B.3).
e.
Instructions, Procedures, and Drawings:
The NRC inspector verified implementation of the DG0 procedures as they relate to this criterion by reviewing two DG0 test procedures / plans and the related specifications and test reports.
No nonconformances were identified.
f.
Document Control: The NRC inspector reviewed three test plans, two job folders, two customar specifications, and two drawings to verify review, approval, and issuance.
In addition, the NRC inspector visited four work areas and interviewed the supervisor of D00 document control.
No nonconformances were identified.
g.
Control of Purchased Material, Equipment, and Services: The NRC inspector verified implementation of the DGO procedures, as they relate to this criterion, by reviewing three nuclear vendor files, the DG0 qualified vendor list, three DG0 purchase orders, two receiving inspection reports, and three certificates of conformance. Within this area the nonconformance discussed in paragraph B.4 was identified.
ORGANIZATION:
D. G. O'BRIEN, INC.
SEABROOK, NEW HAMPSHIRE REPORT INSPECTION NO.:
99900326/83-01 RESULTS:
) AGE 5 of 7 Identification and Control of Materials, Parts, and Components:
n.
The NRC inspector verified the implementation of the DGO procedures relating to this criterion by selecting one specimen designated for testing and by establishing the identification and traceability of the specimen.
In addition, one work area was selected and the identification and traceability of two flanges were verified. No nonconformances were identified.
1.
Control of Special Processes:
The NRC inspector verified the implementation of QAM requirements of this criterion by examining four procedures, two special process inspection records, and four training files.
Special processes used by DG0 during EQ testing include dye penetrant inspection and helium leak testing. No nonconformances were identified.
j.
Inspection: The NRC inspector verified the implementation of the DG0 procedures relative to this criterion by observing the main DG0 inspection area / laboratory and by verifying that the quality or inspection function was being performed by employees who were not responsible for the manufacturing effort / work.
Two QA/QC records for two 12-inch flanges were reviewed. No nonconformances were identified.
k.
Test Control:
The NRC inspector evaluated DG0's implementation of the QAM test procedures which included requirements for test i
fixtures, conditions, and instrumentation.
The inspector's evaluation included a review of 2 test reports, 11 test procedures, and 2 ECOs for test procedures.
The inspector's examination determined that the QAM and test procedures were being implemented; however, the inspector did recommend clarification of the procedures with respect to responsibilities.
DG0's management agreed to revise their procedures to more clearly identify individual responsibilities under this criterion.
The revised procedures will be reviewed during a future NRC inspection.
No nonconformances were identified.
1.
Control of Measuring and Test Equipment: The NRC inspector l
evaluated DGO's calibration system by examining one procedure, four calibration cards, four calibration data sheets, and the file for nonconformances of calibrated test instruments. The evaluation verified calibration and identification of three test instruments and the traceability of four instruments to the National Bureau of Standards.
No nonconformances were identified.
ORGANIZATION:
C. G. O'BRIEN, INC.
SEABROOK, NEW HAMPSHIRE REPORT INSPECIl0N N0.:
99900326/83-01 RESULTS:
JAGE 6 of 7 m.
Handling, Storage and Shipaing:
The NRC inspector verified the implementation of the UGO procedures relating to this criterion by reviewing two receiving records, visiting the bonded storage room and examining three EPAs (that were ready for shipping), and by verifying that they were properly preserved and marked.
No nonconformances were identified.
n.
Inspection, Test, and Operating Status:
The NRC inspector verified that DGO was following their written procedures in this area by performing observations in two work areas and establishing that the travelers for four items showed inspectirn and manufacturing status.
No nonconformances were identified.
o.
Nonconforming Materials, Parts, or Components: The NRC inspector verified the implementation of the QAM procedures for this criterion by examining four discrepancy reports and two test reports.
The inspector determined that QAM procedures were being implemented and test procedure deviations were documented. However, the review of implementing procedures identified one nonconformance (see nonconformance described in paragraph B.1).
p.
Corrective Action:
The NRC inspector verified that the QAM procedures for corrective action (CA) were implemented by review of five CA reports. The NRC inspector determined that the reports were completed according to the requirements of QAM procedures. No nonconformances were identified.
q.
Quality Assurance Records: The NRC inspector examined inspection records, completed test reports, material certificates, and observed the record storage area to verify that DG0 was complying with their written procedures. No nonconformances were identified.
r.
Audits:
The NRC inspector examined four internal audits, three CA reports resulting from audit findings, and two auditor qualification folders to verify that DG0 was complying with their written procedures.
Within this area the nonconformance discussed in paragraph B.2 was identified.
l l
I
ORGANIZATION:
D. G. O'BRIEN, INC.
SEABROOK, NEW HAMPSHIRE REPORT INSPECTION NO.:
99900326/83-01 RESULTS:
) AGE 7 of 7 3.
Implementation of 10 CFR Part 21: The NRC inspector reviewed eight customer purchase orders, and nine purchase orders issued by DG0 to verify that 10 CFR Part 21 requirements were being specified to subcontractors. The DG0 work area was also visited to verify that the required documents had been posted.
Within this area the violations discussed in paragraphs A.1 and A.2, above, were identified. With regard to violation A.1 (Failure to Post Section 206 of the Energy Reorganization Act of 1974), it should be noted that DG0 posted this document during the inspection and the NRC inspector verified such.
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