ML20150D992
| ML20150D992 | |
| Person / Time | |
|---|---|
| Issue date: | 10/22/1978 |
| From: | Brown R, Hunnicutt D NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML20150D971 | List: |
| References | |
| REF-QA-99900335 NUDOCS 7812110067 | |
| Download: ML20150D992 (9) | |
Text
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i VENDOR' INSPECTION REPORT i
l U. S. NUCLEAR REGULATORY COMMISSION I
g 0FFICE OF INSPECTION AND ENFORCEMENT REGION IV Report No.
99900335/78-02 Program No. 44070 Company:
Boeing Engineering and Construction A Division of The Boeing Company l
Seattle, Washington i
Inspection Conducted:
September 11-14, 1978 7[
Inspectors :
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l Rdss L. Brown, Contractor Inspector, Vendor Date i
Inspection Branch l
1 Observer:
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D. M. Hunnicutt, Chief, ComponentsSection II tate' Vendor Inspection Branch i
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/B//2/76' Approved by:
f D. M. Hunnidutt, Chief, Components Section 11 eate '
Vendor Inspection Branch Summary Inspection Conducted September 11-14, 1978 (99900335/78-02)
Areas Inspected:
Implementation of 10 CFR 50, Appendix B criteria including:
control of nonconformances and corrective action, indoctrination and training, manufacturing process control and equipment calibration.
This inspection involved twenty-seven (27) inspector-hours on site.
~ Resul ts :
In the four (4) areas inspected, no unresolved items were noted and no apparent deviations were identified in two (2) areas; the following i
I deviations were identified.in the remaining two (2) areas.
Deviations:
Indoctrination and Training - the vendors quality program was I
not in compliance with the requirements of Criterion V of 10 CFR 50, 7 812110 0 Col l
t
l Appendix B.
(Enclosure, flotice of Deviation, Item A.) Manufacturing Process Control - the vendors " Integrated Record System Orders" were not consistently.in conformance with the program requirements (Enclosure, I
flotice of Deviation, Item B).
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DETAILS SECTION A.
Persons Contacted 4
1 V. L. Boyt, Lead Technician, Calibration Laboratory J
L. B. Herrington, Line Examiner 1
- K. 5. Maiwald, Quality Engineer
- P. O. Webster, Quality Assurance Manager
- Attended Exit Interview.
4 B.
Control of Nonconformances and Corrective Actions 1.
Objectives The objectives of this area of the inspection were to verify:
a.
That procedures exist, for the identification, documentation, segregation and disposition of nonconforming items.
4 b.
That procedures exist, for the determining of cause and j
assignment of responsibility, preventive measures (corrective action), and " follow-up" to establish ~ effectiveness of preventive actions taken.
I c.
That repaired or reworked items were reinspected as stated in applicable approved procedures.
d.
The items dispositioned by "use as is" were properly accepted and documented including the as-built condition.
l e.
That summarizes of nonconformities and preventive actions are provided to upper management.
4 2.
Methods of Accomolishment The preceding objectives were accomplished by:
I Tho review of the Boeing Engineering and Construction, (BEC) a.
Quality Assurance Manual, Revision E, (QAM) Section 15.0 -
Nonconformance.
b.
The review of the QAM, Section 16.0 - Corrective Action.
c.
The review of the Nonconformance Record Log (NPSQF 15-1) for 1978.
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d.
The review cf fifteen (15) Nonconformance Records
~(NPSQF 15-2) to verify discrepancy discription and disposi-tion also corrective action assignment.
The review of ten (10) Nonconformance Records to verify e.-
ANI concurrence.
f.
Review of eight (8) monthly " Quality Assurance Assessment Reports" from the QA manager to the Director of Nuclear Power Systems, copies of this report is distributed-to each department manager.
3.
Findings:
No deviations or unresolved items were identified in this area l;
of the inspection.
C.
Indoctrination and Training 1.
Objectives The objectives of this. area of the inspection were to verify that the following items were controlled in accordance with the QA Manual and applicable NRC and ASME Code requirements:
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A written system has-been established to assure that in-a.
doctrination and training of personnel performing activities -
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affecting quality is implemented in accordance with applicable t
codes.
b.
Appropriate written agenda are used.
Records'of training sessions agenda and attendance are c.
' maintained.
d.
-The ' agenda includes subject matter adequate to provide an l
understanding of the general and detailed aspects of the-QA a
program, codes, standards and applicable technical disciplines.
2.
Methods of Acccmolishment The preceding objectives were accomplished by:
l Review of QAM, Section 2.0 - Quality Assurance Program.
a.
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b.
Review of NDE training procedures for MT, PT, RT, and UT.
1 c.
Review of two (2) Level II, MT, PT, RT, and UT examination parers.
d.
Review of one (1) Level III, MT, PT, RT, and UT examination papers.
e.
Review of 1977-1978 training session attendance lists.
f.
Review of three (3) NDE training sessions class agenda.
g.
Review of BEC written practices.
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h.
Review of Level I, II, and III examiner qualifications.
3.
Findings a.
Deviation See Enclosure, Item A.
l This deviation is relative to the indoctrination and training of personnel other than the nondestructive testing individuals, however, the vendors has conducted training sessions for all division personnel, but a procedure outlining the activity was not a part of or referenced in the QAM.
b.
Unresolved Item None were identified.
D.
Manufacturing Process Control 1.
Objectives The objectives of this area of the inspection were to verify:
a.
That manufacturing / fabrication operates under a controlled system such as process sheets, travelers, or equivalent procedures.
b.
That the system requires the process sheet to be prepared including document numbers and revisions to which inprocess and final examinations and tests must be performed.
c.
That the system provides for the Authorized Nuclear Inspectors (ANI) review and his establishment of witness /
hold point as code requirements.
. d.
That the system requires inspection and/or hold points to be signed and dated, e.
That the system requires inspection / test results to be documented.
2.
Method of Accomplishment The preceding objectives were accomplished by:
a.
Review of the BEC, QAM, Section 4.0 - Fabrication Control.
b.
Review of forty-five (45) " Integrated Record System Orders" (IRS 0)
(traveler) to verify the following:
(1)
Required documents and revisions are identified.
(2)
IRS 0 review and approval.
(3) ANI hold points are specfied and signed.
(4)
That the inspection / test results were documented, signed, and dated.
c.
Review of IRSO Master File to verify the use of latest documents.
d.
Review of " Documentation Log"(2) welding procedures were t to determine if four (4) referenced drawings and two latest revision.
3.
Findings a.
_ Deviation See Enclosure, Item B.
_M b.
Unresolved Item Hone identified.
E.
Ecuipment Calibration 1.
Objectives The objectives of this inspection was to verify that:
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. Tools, gauges, instruments and other inspection, measuring, a.
and testing equipment and devices used in activities affecting quality are of the proper range, type, and accuracy.
b.
These devices are calibrated and properly adjusted at specified periods or use intervals in accordance with written procedures.
c.
The calibration is performed against certified measurement standards which have known relationship to National Standards.
d.
The control measures include provisions for test equipment l
identification and calibration status by equipment marking or on records traceable to the equipment.
e.
The Manufacturer determined and implemented corrective action for materials and items checked using measurement or testing equipment later found to be out of calibration.
2.
Method of Accomplishment The preceding objectives were accomplished by:
a.
Review of BEC, QAM, Section 13.0 - Measurement and Test Equipment Control.
b.
Review of Boeing Aerospace Company (calibration subcontractor)
Quality Instructions QI-800-591
" Certification / Verification Activities."
c.
Review of the Index Report form DZ-5378-1 to verify the following:
(1)
Equipment name and number.
(2)
Location (owner).
3 (3)
Parameters (dimensional, pressure, etc.).
(4)
Calibration procedure number and revision number.
(5)
Shelf life (storage between calibration and use).
(6)
Accuracy cycle (schedule time between calibrations).
1 d.
Review of secondary standards calibration certification.
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Review of calibration tags on the following equipment:
(1) Two(2)weldingmachines.
(2) Three (3) welding gas flowmeters.
(3) Seven (7) inspection tool in shop inspection cabinet.
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(4) Four (4) inspection tools in calibration laboratory.
f.
Review of BEC Survey Report of Boeing Aerospace Company -
Calibration / Certification Laboratory.
3.
Findings All tools, gages, instruments, and other measuring and a.
testing devices used by Boeing Engineering and Construction are calibrated, repaired and schedule controlled by Boeing Aerospace Company (BAC) Calibration Laboratory, b.
All reference standards used by the BAC Calibration Laboratory 1
are calibrated by Boeing Metrology Laboratory.
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In this area of the inspection no deviations or unresolved items I
were iden'.'.fied.
F.
Exit Interview 1.
In addition to those denoted in paragraph A, the inspector met with the following management representatives at the conclusion of the inspection on September 14, 1978.
l J. W. Baxter, Engineering Manager 1
R. W. Clark, Supports Program Manager J. D. Donnell, program Controls C. M. Finkbiner, Procurement A. R. Hathaway, Project J. E. Lally, Manufacturing Manager l
C. H. Parker, Material Manager.
G. W. Folta, Authoiized Nuclear Inspector, State of Washington, (AuthorizedInspectionAgency) 2.
The following subjects were discussed.
a.
The scope of the inspection.
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b.
The deviations in the areas of indoctrination and training and manufacturing process control.
c.
The response to the deviations in accordance with the three (3) conditions described in the inspection report cover letter.
3.
Management's comments were generally related to clarification of the finding, except they did ask the status of 10 CFR 21.
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Mr. Hunnicutt stated that 10 CFR 21 is being revised and will 4
be reissued in the near future.
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