ML20028B079
| ML20028B079 | |
| Person / Time | |
|---|---|
| Issue date: | 11/05/1982 |
| From: | NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML20028B066 | List: |
| References | |
| REF-QA-99900782 NUDOCS 8211290430 | |
| Download: ML20028B079 (3) | |
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APPENDIX B Raymond Control Systems A Brunswick Company Docket No. 99900782/82-01 NOTICE OF NONCONFORMANCE Based on the results of an NRC inspection conducted on August 9-13, 1982, it appears that certain of your activities were not conducted in accordance with NRC requirements as indicated below:
Criterion V of Appendix B to 10 CFR Part 50 states:
" Activities affecting quality shall be prescribed by documented instructions, procedures, or draw-ings, of a type appropriate to the circumstances and shall be accomplished in accordance with these instructions, procedures, or drawings.
Instructions, procedures, or drawings shall include appropriate quantitative or qualitative acceptance criteria for determining that important activities have been satis-factorily accomplished."
Nonconformances with these requirements are as follows:
A.
Paragraph 4.4 of the Quality Assurance Manual, dated April 10, 1979, states in part, " Review of work instructions shall be accomplished by the responsible department.
Quality assurance shall perform review including but not limited to the following..
- 3) Specification and drawing callout." Paragraphs 5.1 and 5.2 state in part, " Work instructions shall be documented as follows: Manufacturing Process Sheet."
Contrary to the above, Quality assurance had not reviewed work instructions as evidenced by the lack of indication of review in ine fol-lowing Process Sheets which were being used in the manufacturing process:
(1) dated August 6, 1982, for Part No.20-157, Revision 0; and (2) dated September 6, 1980, for Part No. 88-93, Revision C.
Also, it was noted that the latter Process Sheet was attached to Drawing No. 88-93, l
Revision E.
B.
Paragraph 11.2 of the Quality Assurance Manual, dated April 10, 1979, states, " Inspection stamps are provided to inspection personnel and shall be used to indicate inspection action completed and accepted."
l Ct.ntrary to the above, inspection stamps had not been used to indicate completion of inspection action and acceptance.
This was evidenced by:
l (1) written inspection stamp number on 12 Test Data Sheets, dated January 1981, for Sales Order No. 63479; and (2) no indication of inspection on the Torque Test Sheet, dated October 27, 1981, for Sales Order No. 70265.
8211290430 821105 PDR GA999 EMV** ***
99900782 PDR
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. C.
Paragraph 5.1 of the Quality Assurance Manual, dated April 10, 1979, states in part:
Work instructions are documented directives issued by Raymond Control Systems to assure the maintenance and proper performance of contract or purchase order re-quirements. The work instructions define requirements to accomplish operations of the processing cycle from entry to purchasing, manufacturing, special processing,
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inspection, testing, packaging, and shipping.
Contrary to the above, work instructions had not been issued to assure that proper performance of assembly operations had been accomplished.
D.
Paragraph 1.1 of Quality Assurance Requirements No. 001, dated May 30, 1978, states, "All new, replaced or repaired tooling must be checked and verified by Quality Assurance prior to acceptance and usage.
Upon acceptance, the acceptance shall be recorded on the tool inspection card."
Contrary to the above, acceptance of Torque Wrench, Serial No. 2338-4 (0-500 foot pounds) had not been recorded on a tool inspection card.
The torque wrench displayed a current calibration label; however, there was no information to justify affixing the calibration label.
E.
Paragraph 2.1 of Quality Assurance Requirements No. 001, dated May 30, 1978, states:
All new, replaced or repaired electrical test equipment must be by a certified source, and accompanied by a certi-fication of calibration.
The certification shall be reviewed for compliance and accuracy prior to acceptance and usage.
Upon acceptance the results of the inspection shall be recorded on the Calibration Record Card.
Contrary to the above, certification of calibration of new, replaced, or repaired electrical test equipment, used for acceptance testing of elec-trical actuators, had not been reviewed for compliance and accuracy prior to its acceptance and usage.
This is evidenced by failure to include elec-trical test equipment in the calibration program.
F.
The first paragraph of Quality Assurance Requirements No. 001, dated May 30, 1978, states in part, "All inspection tools and instruments are to be verified periodically by suitable equipment to insure their accuracy."
Contrary to the above, the Plug Gauge Set, Serial No. 1334-1 had not been verified periodically to insure its accuracy, as evidenced by the affixed calibration label and tool inspection card which indicated that calibration was due July 9, 1982.
. G.
Paragraph 7.1 of the Quality Assurance Manual, dated April 10, 1979, states:
It is the responsibility of the Quality Assurance Depart-ment to initiate an effective corrective action program.
This will be established to eliminate repetitive errors on internally manufactured parts, components and assem-blies, and specialized purchased material and services.
Paragraph 7.4 states in part:
Corrective Action is also instituted as a result of customer supplied data in the form of corrective action requests on quality complaints.
On September 16, 1981, Raymond Control Systems cnmmitted to take the following actions in order to prevent recurrence of inadequate crimping of wire terminations on actuators for nuclear power plants:
(1) perform wire pull tests of each lot prior to start of assembly wiring; (2) review correctness of crimping technique of wiring personnel prior to start of assembly wiring of each lot; and (3) perform instrument loaded wire pull tests at Final Inspection on samples from each lot.
Contrary to the above, the actions to prevent recurrence had not been taken as evidenced by the lack of:
(1) documented procedures for accom-plishing the tasks; (2) records to substantiate task accomplishment; and (3) documented procedures for controlling crimping tools and scales used in the performance of assuring adequate crimped wire terminations.
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