ML20055E575
| ML20055E575 | |
| Person / Time | |
|---|---|
| Issue date: | 06/28/1990 |
| From: | Potapovs U, Wilson R Office of Nuclear Reactor Regulation |
| To: | |
| Shared Package | |
| ML20055E542 | List: |
| References | |
| REF-QA-99901192 99901192-90-01, 99901192-90-1, NUDOCS 9007120121 | |
| Download: ML20055E575 (10) | |
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ORGANIZATION:
REUTER-STOKES CANADA L*
DIVISION OF FURST MANUFACTURING COMPANY REPORT INSPECTION INSPECTION NO.: 99901192/90-01 DATE: May 14-18, 1990 ON-S!TE HOURS: 66 L
CORRESPONDENCE ADDRESS: Mr. Ralph Menzies, General Manager Reuter-Stokes Canada Division of Furst Manufacturing Company 465 Dobbie Drive Cambridge, Ontario N1R SX9, Canada ORGANIZATIONAL CONTACT: Thomas A. Wagner, Quality Manager TELEPHONE NUMBER:
(519)623-4880 NUCLEAR INDUSTRY ACTIVITY: Sales volume is 80 to 90 percent nuclear.
Ontario Hydro and Combestion Engineering are the largest customers, for in-core instrumentation.
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ASSIGNED INSPECTOR: [G&lM?t/ 2) 77hdjr 6'.28-f8 y I). C. Wilton', 5dnior Reactor Engineer, Reactive Date Inspection Section No. 2 (Ris-2), VIB OTHERINSPECTOR(S):
R. N. Moist, QA Specialist, RIS-2 l
APPROVED BY:
W b 'M*"00
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U. Potapov,, Chief, RI5-4 Date
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t INSPECTION BASES AND SCOPE:
L A.
BASES:
10 CFR Farts 21 and 50 und Combustion Engineering Purchase Order Requirements.
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SCOPE:
Review documentation, interview personnel, and examine i
TacTTities and equipment related to supply of safety-related equipment for commercial U.S. power reactors.
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PLANT SITE APPLICABILlTY: All Combustion Engineering plants and other sites with Combustion Engineering services.
9007120121 900703 PDR OA999 EMVREUTS 99901192 PDC
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- - ORGANIZATION: REUTER-STOKES CANADA
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DIVISION OF FURST MANUFACTURING COMPANY j
KLVUKI INbVLLIAUM I
NO.: 99901192/90-01 RESULTS:
PAGE 2 of 10 1
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A.
VIOLATIONS:
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None B.
NONCONFORMANCES:
1 None I
C.
UNRESOLVED ITEMS:
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None D.- STATUS OF PREVIOUS INSPECTION FINDINGS:
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None. This was the first NRC inspection of this facility.
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INSPECTION FINDINGS AND f,THER COMMENTS:
===1.
Background===
Reuter-Stokes Canada (RSC) supplies metal sheathed, ceramic insulated instruments including thermocouples and associated enclosures and in-core neutron detectors to AAB Combustion 1i Engineering (C-E)foruseinU.S.-commercialnuclearpower plants.
For most U.S. applications, theromocouples and primary 1
system pressure boundary components are safety-related.
In-core neutron detectors, which are included in in-core instrument
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assemblies, are not safety-related, j
2.
Quality Assurance Program j
The Quality Assurance (QA) program at RSC is governed by two
'l manuals titled Quality Assurance Manual (QAM) and System Function ProceduresManual(SFPM). The QAM, Revision 11, dated May 1987,
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represents RSC policy statements and SFPM, Revision 06, dated May 1987, represents implementing procedures for the policy state-
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ments.
The RSC QAM was prepared using as a basis the following docu-ments: (a)10CFRPart50,AppendixB,(b)CanadianStandards-Z.299.2, Z.299.3, Z.299.4 all dated 1979, (c) Ministry of
- Consumer and Commercial Relations,(Providence of Ontaric Requirements for ASME Welding and d)10CFRPart21.
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- ORGkNIZAT10N:
REUTER-STOKES CANADA
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L' DIVISION OF FURST MANUFACTURING COMPANY 1
MLVUKI IM5FLGilUM NO.: 99901192/90-01 RESULTS:
PAGE 3 of 10 l
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Two C-E Purchase Orders (P0s) to RSC for in core instrument i
assemblies were selected to verify that the RSC QA program met I
the C-E PO requirements. C E P3 0812458-001 (for Palo Verde i
NuGear Power Station) and C-E PO 0721268-001 (for $t. Lucie
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Nuclear Power Station) imposed C-E Quality Assurance Specifi-cation WQC-11.1, Revision E, dated June 1988, for Palo Verde and Revision D dated October 1974, for St. Lucie. The changes f rom i
I Revision D to E were primarily. administrative; for instance, j
" vendor" changed to read " subcontractor." WQC-11.2 outlines the i
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minimum quality requirements that RSC has to meet for safety-j related items and su) plies. The NRC inspectors reviewed RSC's QAM and determined t1at it met the minimum quality requirements of WQC-11.1. Revision E.
The above CoE P0s to RSC were selected L
to verify implementation of the RSC QA program.
The following i
discusses each QA progrem area reviewed during this inspection, l
a.
Organization - The NRC inspectors verified that the quality manager roports directly to the general manager of RSC on
-J quality related matters, that all the responsibilities and authority of each section of the quality department were well defined in Section 1 of the QAM, and tiat quality and i
training requirements were identified. Qualification records for six quality control (QC) inspectors were j
reviewed to verify that each record edequately documented l
the inspector's skill level. Also eye examination records were reviewed for the six inspectors.
No anomalies were identified in this area.
q b.
MeasuringandTestEquipment(M&TL)-ThreeitemsofM&TE used by QC personnel were selected to evaluate RSC's system for control and calibration of M&TE. The items selected were an RSQ 12-4 pressure gage used for the primary hydro-test, an RSQ 4-1 !aegohm bridge used for testing of insulation resistance and continuity, and an R$Q 56-1 digital multimeter uied for measuring thermocouple resistance. Calibration L
records for each item were reviewed to verify that the
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l' record identified calibration results including accepie ce criteria, date calibrated, date due, frequency of celi-bration, maintenance requirements when applicable, cal'-
bration procedures, signatures of individuals who calibrated R
the equipment and standards used for calibration.
Five standards (RSS-2-3,RSS-3-3,RSS-4-3,RSS-14-3,and RSS-15-3)wereverifiedastraceabletotheNationalResearch Council of Canada or to the U.S. Institute of Standards and l
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- ORGANIZATION: REUTER-STOKES CANADA DIVISION OF FURST MANUFACTURING COMPANY j
p KLVUKl IMbFLcil0N NO.: 99901192/90-01 RESULTS:
PAGE 4 of 10 1
1 Technology (formerly known as the National Bureau of
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Standards). After reviewing the records of the three items j
above, the NRC inspectors verified that the information on the calibration sticFers affixed to the equipment matched l
the calibration record information. The procedures i
addressed what action RSC takes when M&TE is found out of calibration.
The NRC inspectors also reviewed an equipment i
calibrCion report which identified the status and due date o
i of the equipment selectad above. An inactive equipment calibration list was reviewed to verify that the RSQ 43-1 micrometer was included on the list since a nonconformance 1
report was generated by QA questioning the dependability of j
the micrometer.
No anomalies were identified for the control and talibration of M&TE.
c.
Inspection Status - RSC QC inspectors annotate their signatures for acceptance on QC records relating to receiving, inprocess and final inspection. The NRC inspectors reviewed several receiving, inprocess and final l
inspection records for appropriate QC signstures. The QA supervisor also signs every inprocess and final inspection QC record. Annotation of the QA supervisor signature was verified on several QC records.
No anomalies were identi-
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fied in this area.
d.
NonconformingMaterial-RSCusesrejectionnotices(RNs) 3 to document nonconformances identified during inprocess and receiving inspection. The status of RNs is controlled by the QC 030 log.for inprocess and QC 032 log for receiving inspection. The RN is a three part form. Part 1 identifies 1
the nonconformance, Part 2 identifies the disposition and Part 3 identifies the follow-up and corrective action response when applicable.
Nonconforming material is identified by.a red tag indicating that it cannot be used until disposition is identified, whereas a blue tag indicated the material is on hold for material review or the j
material has been dispositioned for further processing.
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Nonconforming material is placed in rejected material quarantine (locked cabinets) or otherwise segregated from good material. The NRC inspectors selected four RNs--030-1252,030-126850,030-126950,and030-127050(twocompleted and two inprocess)--for review to verify that Quality l
Engineering annotated Part 2 and Part 3 of the RNs, that 4
material was properly tagged and segregated, and that adequate corrective action was identified.
No anomalies were identified in this area.
ORG'ANIZATION:
REUTER-STOKES CANADA DIVISION OF FUk3T MANUFACTURING COMPANY KLVUK)
IMbVL L,I I VM NO.: 99901192/90-01 RESULTS:
PAGE 5 of 10 e.
Incoming Inspection - Upon receipt of a product, production controlissuesaQ112 Form (Form 1)fortheproductwhenthe P0 states that incoming inspection is required or when certifications are required. Quality engineering is responsible for specifying incoming inspection require-ments on the process sheets. The receiving inspector is responsible for acceptance or rejection of the product and for generating RNs for rejected incoming material. The NRC inspectors selected two P0s, 794 and 719, to verify imple-mentation of incoming inspection requirements.. The NRC inspectors verified that a Form I was initiated for each P0, j
that a Q130 (Quality Control Record Sheet) listed all the applicable inspection criteria, that the inspection procedure used was adequate, that the inspection results were approved by QA engineering when the primary receiving inspector performed the inspection or by the primary
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receiving inspector when another inspector inspected the product, and that QA engineering reviewed certifications, to anomalies were identified in this area.
f.
Inprocess Inspection - The NRC inspectors reviewed several l
QA records to verify that inspections or tests were l
performed as required, that test equi) ment used and calibration due date were listed on tie QA record, that a quality procedure was listed, that the inspection and test results met the acceptance criteria listed on the QA record, and that the results were approved by the QA supervisor. No 1
anomalies were identified in this area.
g.
Final Inspection - The NRC inspectors reviewed Work Order 601-8512-01 Operation 530 and associated Form Q130 to verify i
that an inspection proccuure and applicable inspection criteria were listed. Attributes such as visually checking for oxides on welds and brazes, checking assembly for damage and checking for contaminants were listed on Form Q130.
No anomalies were identified in this area.
h.
Shipping Inspection - The NRC inspectors reviewed Work Order 601-8512-01 Operation 540 and associated Form Q130 to verify that an adequate final inspection was performed in accor-dance with the QA procedure.
It was determined that the QA procedure was followed, that the QA record final inspection results were reviewed and approved, and that inspection criteria were listed on the QA record.
No anomalies were identified in this area.
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ORGkNIZATION:
REUTER-STOKES CANADA DIVISION OF FURST MANUFACTURING COMPANY REPORT INSPI.GT 10N NO.: 99901192/90-01 RESULTS:
PAGE 6 of 10 1.
Identification and Traceability - The NRC inspectors selected two Form l's, 10951 and 10883 for the calibration tubeplug.anditsbarstocktoverifyIdentificationand-traceability of the material. The NRC inspectors verified that the material selected was in the RSC strek room and.
identified with a form 1, and that the storage conditions were adequate. No anomalies were identified in this area, J.
Internal Audits - The NRC inspectors reviewed the latest internal audit that was performed in 1989.
It was deter-mined that a checklist ras used listing all the sections of the QAM and SFPM and th6t any anomalies identified were closed out prior to the NRC inspection. The NRC inspectors reviewed qualification records of the auditors and deter-mined that each had adequate capability to perform internal audits.
k.
Special Processes - Weld Procedure Specifications 028-0020 for header braze and 028-4210 for seal plug to header weld were selected for review, since both provide either primary or secondary pressure boundary seals. Special Process Qualification Program 034-0008 was also reviewed by the inspectors in order to determine the criteria for indi-viduals performing the above work. RSC qualification
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records for the two selected individuals satisfied the requirenents of the C-E Specification SYS80-FEA-6100, Revision 03. ' No anomalies were identified in this area.
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Design Control - The NRC inspectors reviewed several t
Engineering Change-Notices and determined that they were-
. i generated, dispositioned, approved and distributed in accordance with RSC Standard Function Procedure SFP-29. The 1
NRC inspectors determined that changes to the drawings received the same approvals as the original drawings. No anomalies were identified in this area.
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10 CFR Part 21 - Section 21 of the QAM requires posting of
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the RSC reporting procedure for 10 CFR Part 21.
The NRC inspectors verified that the procedure was posted on two bulletin boards and that it adequately covered reporting requirements. RSC considers Part 21 to be a legal require-ment, since it is imposed by the Connecticut C-E contracts.
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ORG'ANIZATION: REUTER STOKES CANADA DIVISION OF FURST MANUFACTURING COMPANY MLVUhl INbVLL,I l UM NO.: 99901192/90-01 RCSULTS:
PAGE 7 of'10 i
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Procurement Practices - The NRC inspectors reviewed RSCs i
System Function Procedure (SFP) STP-3, Revision 06, dated May1987, titled" Purchasing"rocuremen,tDocumentControl" Revision 11. date and QAM May 1987, Section 3 titled P and Section 6 titled " Purchased Materials and Services" to verify that the requirements of WQC 11.1.QA specification were met. RSC's suppliers are classified, evaluated and approvedforplacementonRSC'sApprovedVendorList(AVL) by three different classifications. Class A suppliers are audited prior to acceptance of product., Only two suppliers were listed on the AVL as Class A.
Class B suppliers are assessed by an evaluation of a sample product. No suppliers were identified on the AVL as Class B.
Class C i
suppliers are assessed by an evaluation of 100 percent of an initial batch of product at receiving inspection which includes specified tests and inspections. An exception
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for Class C suppliers allows waiver of receiving inspection q
analysis for brand reame or generic products. The NRC inspectors noted that the use of this exception for items j
procured from unaudited suppliers and intended for safety-i related applications could violate the requirements of 10 CFR Part 50, Appendix B.
The inspectors also noted that, although the RSC QAM and STP Manuals had been accepted by C-E as meeting their WQC-11.1 QA specification, C-E has recently issued a revision to this specification which j
addresses commercial grade procurement and dedication and that RSC is working on Revision 12 of their QAM in response to this revision.
The NRC inspectors selected two reports of audits that were
'l performed by RSC on their Class A suppliers. The two i
suppliers selected were Strite Industries Limited, which.
performs machining operations, and VAC-Aero International i
Inc., which performs heat treatment operations for RSC.
.The NRC inspectors determined that appropriate attributes were selected by RSC to perform an adequate implementation audit of the-suppliers in accordance with C-E specification 1
WQC-11.1 and that adequate documentation was available in 1
the file to support placement of the suppliers on RSCs AVL.
The NRC inspectors verified that the personnel performing j
the supplier audits had adequate training as shown in their qualification records. The NRC inspectors selected one source inspection file for Plymouth Tube, a Class C supplier, j
The RSC source inspector witnessed ultrasonic testing and 1
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~ ORGANIZATION: REUTER-STOKES CANADA DIVISION OF FURST MANUFACTURING COMPANY I'
KLVUMI IMPLLilVN l
NO.( 99901192/90-01 RESULTS:
PAGE 8 of 10 l
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performed final inspection during the inspection. The NRC inspectors verified that adequate source inspection was per-formed by RSC based on the documented evidence in the source inspection file.
l-The NRC inspiiturs examined in detail the procurement
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l practices employed for two types of material purchased from Class C suppliers for the in-progress Palo Verde P0, C-E Number 0812458-001 dated February 9,1989. Selected were materials used for reactor primary system pressure boundary parts, and for the thermocouple sensing junction and lead
- wires, i
Material for three different pressure boundary parts was obtained from a total of four sup)11ers as follows:
Seal plug.1.6 inch-diameter by 10 inc1 long ASTM A-479 type 347 j
stainless steel bar, certification B-0203; calibration tube, 0.28 inch-outside diameter ASTM B-163 inconel 600 seamless tubing, Certification T-0420; and calibration tube plug,1.6 i
inch-long ASTM-B-166 inconel 600 rod and bar, Certifications B-0155 and B-0205.
For Certification B-0203 the original supplier provided chemical and physical certifications; RSC subsequently obtained chemical and ultrasonic tests from i
local laboratories.
For Certification T-0420 the original supplier provided chemical and physical certifications and RSC later tested for straightness.
For Certification B-0155 the original supplier provided chemical and physical certifications; RSC subsequently obtained chemicals and i
j physicals from a local laboratory.
For Certification B-0205 the' original supplier provided chemical certification; RSC subsequently obtained chemicals, physicals, radiography, and liquid penetrant testing from local laboratories. The B-0203 material was worked by a Class A vendor who certified j
chrome plating. Most of the material was supplied through dis-tributors. The calibration tube supplier had an Appendix B program, but the procurement was Class C.
Chromel and alumel thermocouple wires were obtained from Hoskins Alloys of Canada, Ltd., the trademark holder. The inspectors noted that RSC Purchasing Procedure SFP-3 in Section 3.5.9.2 requires Quality Enginaering to assign receiving inspection instructions.
N oming inspection Procedure SFP-4 in Section 4.5.3. states that the Test Instructions section of Form 1 (used for receiving inspection) q p
shall be suf ficient to satisfy the requirements of the r
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' ORGANIZATION:
REUTER-STOKES CANADA DIVISION OF FURST MANUFACTURING COMPANY l
i MLVUKl JN5PLG110M NO.: 99901192/90-01 RESULTS:
PAGE 9 of 10
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Process Sheets and RSC ordering documentation. The Process Sheets and related Work Orders invoke QC Standard Procedure 038-0019 " Receiving Inspection of Wire Rev. 00" dated 4
April 27, 1989, which specifies several tests including comparing the measured resistance of a cut sample of wire with the value calculated for the wire dimensions.
Purchase Order 0556, dated January 23, 1989 invoked " Supplemental Purchase Information" Nunber SPI-TW-3, dated January 31 1974 for type K thermocouple wire; this document specifies a calibration reference, accuracy, cleanliness and related i
properties, and requires material and accuracy certifications l'
which were provided by Hoskins.
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In addition to the thermocouple wire testing covered above, for each manufacturing lot of thermocouples the Process Sheet and Work Order require fabrication and calibration of t
L prototypes. This is because fabrication significantly
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affects calibration, and RSC seeks confidence through prototype testing that production thermocouples will meet contract calibration requirements. The file contained calibration data from the National Research Council of L
Canada for four prototype units.
Based on the examination described above for certain critical materials, the inspectors determined that accep-1 table procurement criteria appear to be employed for the safety-related thermocouple assemblies.
However, the inspectors noted that the applicable procurement / procedural requirements would pmntt procurement practices as stated above, at 1 cast for W ass C procurements, which would not j
comply with 10 CFR Part 50, Appendix B.
The inspectors recommended that RSC re-evaluate the existing procurement procedures in view of this concern.
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Test Control - The NRC inspectors reviewed acceptance test
.l data for the C-E Palo Verde purchase order.against the requirements of "SYSCO-FEA-6100 Revision 03, Engineering Specification for In-core Instrument Assemblies for System 80 Standard Design," dated August 27, 1983, (this was a l
contract for spares using the original equipment procurement 3
specification). Approximately 3/4 of the specification s
requirements were selected for checking; the 34 detectors shipped to date were shown by test data sheets to meet all checked requirements.
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ORGANIZATION: REUTER-STOKES CANADA l
DIVISION OF FURST MANUFACTURING COMPANY I
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KLrUKl IN5FLGIl0N NO.: 99901192/90-01 RESULTS:
PAGE 10 of 10 3
F.
PERSONS CONTACTED:
e R. Menzies, General Manager j
+1 J. Hayashi,' Plant Manager
. F. M. Smith,-Engineering Manager
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S. S. Ahluwalia, Chief Engineer
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T. A.' Wagner, Quality Manager.
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- 1. Wilson, Quality Supervisor W. Humphrey, Quality Technician
-J. Gingrich, Stockroom Supervisor e
Attended: entrance meeting on May 14, 1990
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+ Attended' exit meetir.g on May 18, 1990 l
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