ML20148B506
| ML20148B506 | |
| Person / Time | |
|---|---|
| Issue date: | 09/06/1978 |
| From: | Kelley W NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML20148B373 | List: |
| References | |
| REF-QA-99900049 NUDOCS 7810310262 | |
| Download: ML20148B506 (11) | |
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VEND 0R INSPECTION REPORT U. S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT REGION IV Report No. 99900049/78-01 Program No. 44060 Company: Atwood & Morrill Co. , Inc.
285 Canal Street Salem, Massachusetts Inspection Cor. ducted: July 24-26, 1978 Inspector:
Wm. D. Kell' y,
'Contractorffnspector, Vendor f/tk /97[
Inspecti, ranch U
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Approved by /w%e2[,' e6)/ d 8 7f
? E. Whitesell, Chief, ComponentsSection I, Date Vendor Inspection Branch l
Summary Inapection on July , 1-26, 1978 (99900049/78-01) 2 Areas Inspected: Iniplemen5ation of 10 CFR 50, Appendix B and applicable codes and standards including, design document control, evaluation '#
suppliers performuce, manufacturing process control machining, sp welding applications; and audits and vendor's action on previous -
findings. The inspection involved 20 inspector-hours on site by -
inspector.
Results: In the five (5) areas inspected, no apparent deviatic unresolved items were identified in two (2) areas. The follow ~,
were identified in the remaining three (3) areas.
Deviations: Evaluation of Suppliers Performance (Detail Section, t.
graph D.3.a.)
Unresolved Items: Design Document Control (Details :setion, paragraph C.3.a.,
Evaluation of Suppliers Performance (Detads Section, paragraph D.3.b.),
and Audits (Details Section, paragraph G.3.b.)
781031026>
V DETAILS SECTION A. Persons Contacted l
l Atwood & Morrill Co., Inc. (A&M)
- J. M. Cowley, Vice President Engineering
- F. Crippen, Vice President Manufacturing
- W. F. Emerson, Quality Control Manager T. P. Gates, Welding Engineer F. R. Smagala, Manufacturing Supervisor A. J. Talbot, Project Engineer
- V. W. Toneatti, Quality Assuranw Manager
- Denotes those persons who attended Exit Interview (See Paragraph H).
B. Action on Previous Inspection Findings (Closed) Unresolved Item (Report 77-02): A&M has used a gasket factor and minimum design sealing stress that differs from ASME Code require-ments which is based on data they have developed.
The inspector verified that the A&M is now using the gasket factor and minimum design sealing stress as specified in the ASME Code,Section III, 1977 Summer Addendum.
(Closed) U w solved Item (Report 77-02): A&M were rewriting their entire welding p r; um and revising the welding procedures to meet ASME Code,Section IX, 1977 Edition.
The inspector verified that procedures are being reviewed, revised and requalified in accordance with a prescribed schedule.
(Closed) Unresolved Item (Report 77-02): A&M had developed a training program master plan and was in the process of developing the implementing procedures.
The inspector verified that training implementing procedures had been developed and training sessions in accordance with these procedures have been held.
(Closed) Deviation (Report 77-02): Contrary to ASME Code Section
'III; paragraph NA-4133.6.
- a. The Liquid Penetrant Procedure 90-67-015 was not available during the' penetrant examination at the work station.
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- b. The Shop Process Order for Order No.13824 required the part to be liquid penetrant tested in accordance with Liquid Penetrant Inspection Procedure _ 90-67-015 and Liquid Penetrant Procedure 90-67-014 was in the' Shop Traveler Package at the work station.
The inspector verified that tha. personnel involved in nondes-tructive testing had been instructed that they must verify that the correct procedure are available at the work stations.
(Closed) Deviation (Report 77-02): Contrary to the ASME Code, Section'IX, paragraph QW-214.1, Welding Procedure Qualification 90-C 021 and 90-61-027 were qualified on 1 inch material and the procedures state the qualifications range is 3/16 inch and over.
The inspector verified that the welding procedures were requalified in accordance with the ASME Code Section IX requirements.
(Closed) Deviation (Report 77-02): Contrary 1 the Welding Procedure Spacif' cation 90-61-021 and 90-61-027, there was no documentary evidence that the interpass temperature had been verified by the quality control inspector.
The inspector verified that the quality control supervisors and inspectors had been instructed in the requirements of verifying and documenting interpass temperatures. The interpass temperature veri-fication is specified on Shop Process Orders and in addition inter-pass temperature is verified during welding on a random basis.
C. Design Document Control
- 1. Oj ectives_
The objectives of this area of the inspection were to ascertain whether procedures had been developed and properly implemented to control the review, approval, release and issuance, of design documents in a manner consistent with NRC rules and ,
L regulations, ASME code requirements and the vendor's QA program commitments.
- 2. gthod of Accomplishment The objectives of this area of the inspection were accomplished by: ,
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- a. Review of the ASME accepted Quality Assurance Manual Issue 3, Revision 0. ;
i (1) Section 2, Order Processing and Engineering. l (2) Section 9, Documentation.
To verify'that the vendor hied established procedures to describe his system for design document control.
- b. Reviewed these selective A&M procedures.
(1) 20-71-03, 'date effective May 18, 1978, Preparing and I Process Print Requisition.
(2) 10-82-02, date effective February 11, 1977, Maintaining Files of Standard Manufacturing Procedures.
(3) Internal Memorandum dated July 17, 1970, and attach-ment.
To verify they had been prepared by the designated authority, .
approved by management, and reviewed by QA, and released and issued as. prescribed. i l
- c. Review of A&M procedure 10-82-02, date effective February 11, .
1977, titled, Maintaining Files o.f Standard Manufacturing I Procedures, to verify it provided for identification of. !
'ersonnel responsible for preparing, reviewing, approving, -l and issuing design documents; review and approval of signif- )
icant changes by the same organizational personnel; delineation of types of minor changes to design. documents that do not require review and approval.
- d. Review of A&M Internal Memorandum dated June 17, 1970, and ]
attachment to verify the distribution lists are current i and that the proper documents are identified, accessibly and being used-
- e. Interviewed personnel to verify they were knowledgeable in the procedures applicable to design document control.
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- 3. Findings -
- a. ,Within this area of the inspection no deviations were identified.
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- b. Unresolved Items (1) There was no evidence that the procedures developed by A&M to contro1 ' design activities had been reviewed for adequacy and approved for release by the authorized personnel.
l The inspector will review the quality assurance program implementing procedures on a subsequent inspection to ascertain. the personnel authorized to review and approve l procedures for the contt ol of design activities.
(2) A&M is currently redefinirig the responsibilities of the Systems Department and will revise their Quality Assur-ance Manual and its implementing procedures and will ;
present them to the Authorized Inspection Agency's j Specialist for acceptance. The inspector will review 1 the revised documents on a subsequent inspection. l D. Evaluation of Supplier Performance
- 1. Objectives !
The objectives of this area of the inspection were to verify that procedures had been prepared and approved by the vendor .
to prescribe a system for evaluation.of supplier performance which is consistent with the commitments of the Quality Assurance Program; also, verify that the evaluation of supplier performance procedures is being properly and effectively implemented by the vendor. 1 1
- 2. Method of Accomplishment 'l The objective of this area of the inspection was accomplished by:
- a. Review of the ASME accepted Quality Assurance Manual, Issue 3, Revision 0. .
(1) Section 3, Procurement Control.
(2) Section 12, Audit.
.To verify the; vendor had established procedures for effecting evaluation' of . suppliers.
- b. Review these selective A&M procedures.
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4 (1) 20-67-02, date effective May 26, 1978, Preparing and Processing the Nonconformance Report.
(2) 40-65-07, date effective March 15, 1978, Receiving Incoming Materials and Services.
To verify procedures for evaluation of . suppliers performance had been prepared by designated authority, approved by management, and reviewed by the QA functions.
- c. Review of six (6) sets of documents applicable to three (3) suppliers to verify the procedures and necessary procurement documents were available to the person respon-sible for performing the qualii.y affected activity, and the supplier procedures were prop. rly implemented.
- d. Review of vendors audit schedule for suppliers.
- e. Interviews with personnel to verify they were knowledgeable in the procedures applicable to evaluation of suppliers performance.
- 3. Findings I
- a. Deviation ,
1 See Enclosure. !
- b. Unresolved Items I A&M is currently reviewing their vendor evaluation for receiving inspection, and.will revise the applicable section of the Quality Assurance Manual & Implementing ,
> procedures as necessary. The revised documents will l be presented to the Authorized Inspection Agency"s l Specialist for acceptance. '
The inspector will review the revised documents on a sub-sequent inspection.
E. Manufacturing Process Control - Machining
- 1. Objective.
The objective of this area of the inspection was to verify j that the machining operations are performed under a controlled I system of manufacturing which meets the ASME Code requirements, I j
NRC regulations, and contract requirements, and is effective in assuring product quality.
- 2. tiethod of Accomplishment The objective of this area of the inspection was accomplished by:
- a. Review of the ASME accepted Quality Assurance Manual, Issue 3, Revision 0.
(1) Section 4, Process Control.
(2) Section 9, Documentation.
(3) Section 11, Nonconformances.
To verify that procedures had been established to describe a control system of operation, and manufactu,ing process,
- b. Review these selective AM procedures:
(1) 40-65-02, effective date May 23, 1978, Preparing and Processing Routing Sheets.
(2) 40-65-06, offective date March 17, 1978, Preparing and Processing Shop Process Orders by Control Department.
(3) 90-67-001, effective date August 6,1973, Transferring Material Identification During Fabrication.
To verify they had been prepared by the designated authority approved by management, and reviewed by QA.
- c. Review the selective procedures in paragraph b. above to verify they provide drawing / document control in the shop, provide for part identification and traceability, and inprocess and final inspection control. Also that the identification and removal of defective items are provided for, and a system is established for resolving nonconfonning items. Also"to verify that gages and measur-ing devices are under a controlled calibration system.
- d. Examine finished machined parts to verify that they were properly identified, and machined in conformance with the specifications and drawings.
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- e. Examined these selective documents.
(1) Routing Sheets.
(2) Shop Process Orders.
(3) Drawings.
To verify compliance with applicable documentation require-ments.
- 3. Findings Within this area of the inspection no deviations or unresolved items were identified.
F. Special Welding Applications
- 1. Objective The objective of this area of the inspection was to verify '
that special welding specifications (cladding, hard surfacing, seal welding, and weld repair without postweld heat treatment) conform with the requirements established by ASME Code, Sections III and IX, NRC regulations and the vendor's QA program.
- 2. Method of Accomplishment The objective of this area of the inspection was accomplished by:
- a. Review of the ASME accepted Quality Assurance Manual, Issue 3, Revision 0.
(1) Section 5.0, Welding.
(2) Section 8.0, Heat Treating.
r To verify the vendor had established procedures to prescribe O a system for the development and qualification of special welding specifications and for qualifying welders and/or machine operators.
- b. Review these selective A&M documents.
, (1) 90-61-013, effective date March 1,1976, Procedure Specifications for Shielded Metal Arc Hardsurfacing on Carbon Steel.
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(2) 90-61-016, effective date October 4,1976, Gas Metal Arc Welding of Low Alloy Steel (P4 Material) with Stainless Steel Overlay.
To verify that special requirements governing hard surfacing procedures and the performance qualification imposed by ASME Code regarding test sample size, examination of test sample, and special essential variables are satisfied.
- c. Interviews with cognizant personnel to verify that they were knowledgeable in the procedures applicable to hard surfacing.
- 3. Findings Within this area of the inspection no deviations or unresolved items were identified.
G. Audits
- 1. Objectives The objective of this area of the inspection was to verify that procedures had been prepared and approved by the vendor that prescribed a system for auditing which is censistent with the commitments of the ASME accepted Quality Assurance Manual.
Also, to verify that the audit procedures were being properly and effectively implemented.
- 2. Method of Accomplishment The objectives of this area of the inspection were accomplished by:
- a. Review of the ASME accepted Quality Assurance tianuel Issue 3, Revision 0.
(1) Section 1, General, subsection 1.4, Audit of QA Manuals.
(2) Section 12, Audits.
To verify that procedures are established that prescribes a system for auditing.
- b. Review of these selective A&M procedures (Check List).
(1). Audit Section 2, dated May 17, 1977.
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(2) Man.ual Section 3, dated April 29, 1077.
-(3) Manual Section 3, dated March 27, 1978. :
J To verify they had been prepared by the designated authority, approved by management, and reviewed by quality assurance.
- c. Review of these selective A&M documents.
(1) QC-218-2, Date 28, 1977, Quality Assurance Auditor Training.
(2) Memo to File, Dated June 29, 1978, List approved auditors. l
. i To verify that they identify the organizations responsible l for auditing and delineates it's responsibility; establishes )
their audit personnel qualifications and training; and that 1 the audits are performed by qualified personnel; and that '
the' essential elements of the aadit system are established.
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- d. Review of the audit schedules to assure that the audits I of quality activities during design, procurement and manu- l facture are planned, documented, and are conducted in a 1 manner that assures adequate coverage of all aspects of )
the quality assurance program requirements.
- e. Review of selective audit reports to verify that the written plan, team selection, team orientation, audit notification, pre-audit conference, audit performance, s
and post-audit conference are consistent with the pre-scribed requirements.
- f. Review of selective audit reports to verify that they are distributed to management and the audited organization',
and that followup audits regarding identified corrective action are conducted.
9 Review of selective internal and external audit reports to verify that the applicable procedures were available to the audit team personnel, and that the audit procedures .
were properly and effectively implemented.
- 3. Findings
- a. Within this area of the inspection no deviations from commitments were identified.
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- b. Unresolved Item A&M does not presently reference the implementing audit procedures in its ASME accepted Quality Assurance Manual. A&M will reference the implementing procedures-in its Quality Assurance Manual, and present it to the Authorized Inspection Agency Specialist for acceptance.
The inspector will review the revised documents on a sub-sequent inspection.
H. Exit Interview Theinspectormetwithmanagementrepresentatives(denotedin paragraph A.) at the conclusion of the inspection on July 26, 1978.
The management representative acknowledged the statements by the inspector concerning the deviations and unresolved items identified this inspection. l 1
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