ML20197C667
| ML20197C667 | |
| Person / Time | |
|---|---|
| Issue date: | 11/03/1986 |
| From: | Merschoff E, Naidu K NRC OFFICE OF INSPECTION & ENFORCEMENT (IE) |
| To: | |
| Shared Package | |
| ML20197C642 | List: |
| References | |
| REF-QA-99901066 99901066-86-01, 99901066-86-1, NUDOCS 8611060334 | |
| Download: ML20197C667 (5) | |
Text
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ORGANIZATION:
ROTORK CONTROLS L1MITED BATH, ENGLAND REPORT INSPECTION INSPECTION N0.: 99901066/86-01 DATES: 09/09-10/86 DN-SITE H0llRS:
14 CORRESPONDENCE ADDRESS:
Rotork Controls Limited ATTN: Mr. T. Eassie Chief Executive Bath, BA13JQ England ORGANIZATIONAL CONTACT:
G. Hawkins TELEPHONE NUMBER:
(0225) 28451 f
NUCLEAR INDUSTRY ACTIVITY:
Fabrication of electric and pneumatic actuators for valves.
ASSIGNED INSPECTOR:
A4'
/*h3(f K. R. laiTju, Reactive Inspection Section (RIS)
Date OTHERINSPECTOR(S):
//
gr APPROVED BY:
E. W. Merschoff, Chief
, Vendor Program Branch ate INSPECTION BASES AND SCOPE:
A.
BASES:
10 CFR Part 21 and 10 CFR 50, Appendix B.
B.
SCOPE:
Review of implementation of the Quality Assurance Program in selected areas.
PLANT SITE APPLICABILITY:
FortSt.Vrain(50-267);McGuire(50-369).
8611060334 861103 PDR GA999 EMVROTOR 99901066 PDR
ORGANIZATION:
R0TORK CONTROLS LIMITED BATH, ENGLAND REPORT INSPECTION QQQn10AA/AA n1 RESULTS-PAGE 2 of 5 NO A.
VIOLATIONS:
No violations were identified during this inspection.
B.
NONCONFORMANCE'S:
No nonconformances were identified during this inspection.
C.
UNRESOLVED ITEMS:
No unresolved items were identified during this inspection.
D.
INSPECTION FINDINGS AND OTHER COMMENTS:
1.
Background Information:
Rotork Controls Limited (Rotork) designs and manufactures electric and pneumatic operators for valves. Rotork operators are being used in nuclear power plants located in England and other European countries.
Rotork supplies subassemblies to Rotork Incorporated (Rotork Inc.) located in Rochester, New York, who use the sub-assemblies to manufacture electric operators for use in domestic nuclear power plants.
This inspection was performed as a followup to an inspection at Rotork Inc, conducted during September 9-12, 1986. During this inspection, the implementation of the quality assurance program was verified in selected areas.
2.
Plant Tour:
The inspector toured the plant in the areas of assembly, storage of purchased material, paint shop, incoming receipt inspection and test area.
The inspector interviewed component assemblers, in-process inspectors, incoming receipt inspection supervisor and test technicians, and determined that the individuals interviewed were knowledgeable in the work they performed.
3.
Review of Design Control:
The inspector verified the implementation of design control by reviewing the processing of the purchase orders (PO) received by Rotork. The P0s are sorted in two categories, standard and non-standard products. The standard product order is processed on l
ORGANIZATION:
ROTORK CONTROLS LIMITED BATH, ENGLAND REPORT INSPECTION Nn - ooon10AA/RA n1 RFStil TS -
PAGE 3 of 5 white paper. The nonstandard product order which is used to distin-guish operators for nuclear and special applications is processed on pink paper and requires the signatures of individuals 'from contracts, technical, engineering and quality control to sign the appropriate places to indicate that they reviewed the product request order and concur that the individual components of the operator are correct and that it will meet the relevant technical requirements. All operators intended for nuclear power plants are processed as non-standard products. A Certificate of Compliance (CoC) is prepared for the signatures of the managers of contracts, engineering and quality assurance certifying that the actuator / assembly / component with the relevant specification subject to exceptions (if any) plies (as applicable) when used on the valve identified therein, com documented on the CoC. The inspector reviewed two processed nuclear product orders and determined that the three managers signed them in compliance with the quality assurance program requirements. Changes.
and modifications to the products undergo the same review cycle.
4.
Review of Purchased Material and Services:
The inspector reviewed compliance to established quality assurance procedures relative to the purchase of material and services. Vendors are qualified through surveys, audits or previous history of performance.
Successful vendors are listed on an Approved Vendors List. The inspector determined Rotork purchased components and calibration services from approved vendors.
Rotork effectively implements a vendor rating system which controls the quality of components received. The system enables Rotork to take appropriate action when nonconforming components are identified during receipt inspections. The inspector reviewed the control of the procurement of electrical motors, auxiliary switches, wiring harnesses, and worm and wheel gears and identified no unacceptable findings.
5.
Review of Identification and Control of Materials and i
components:
All components used in actuators intended for nuclear power plants are identified with a prefix N and stored in an enclosure, the access to which is controlled by quality control. The enclosure is partitioned into bins of appropriate size to accommodate components.
Each bin is adequately identified with the component number and contained the necessary documentation to identify the origin of supply. Retrieval of components for use is controlled by computer printout sheets.
ORGANIZATION: ROTORK CONTROLS LIMITED BATH, ENGLAND REPORT INSPECTION Nn_-
QQQO10FA/R6 01 RF911l T9 -
PACF d nf A The components are used to assemble modules such as switch mechanisms, synchropacks, add-on-packs and motors.
Each module is tested for correct operation on specially designed test fixtures'after assembly and placed in the nuclear storage area. A CoC is issued for each module listing the components used in the assembly. When an operator is assembled, the individual CoCs for the modules are attached to a single CoC. This CoC certifies that the individual modules were assembled and that the performance of the actuator meets the relevant specification.
If a module is subsequently repla'ced, the current CoC for the module is attached to update the CoC of the actuator.
The inspector witnessed the assembly and testing of selected modules, interviewed the craft performing the work and determined that the individuals were knowledgeable in the work they performed.
6.
Review of Inspections:
j The inspector reviewed the implementation of the following inspections:
a.
Incoming Receipt Inspections:
Quality Control Inspectors performed inspections on purchased material received.
Inspection checklists were used to document the results of inspections. Unacceptable material was identified, segregated and a nonconformance report was generated.
The gears received were inspected for surface finish, surface hardness, gear form, backlash, tooth to tooth accumalative errors and bearing pattern. The inspector verified the calibration of three hardness testing machines and determined that the calibrations were current and that the calibration certifications were acceptable.
Rotork supplied selected suppliers with inspection tools to enable them to inspect the material prior to shipment. Rotork reinspects the material during receipt inspections.
b.
In-process Inspections:
In-process inspections are conducted on individual components prior to assembly into the respective modules. As indicated in paragraph 3 of this report, the completed modules are tested
ORGANIZATION: ROTORK CONTROLS LIMITED BATH, ENGLAND REPORT INSPECTION NO.-
44901066/R6-01 RFSUITS-PArJ 9 nf R after assembly utilizing specially designed fixtures to simulate the intended function, c.
Final Test:
Every actuator is subjected to routine electrical and mechanical tests. The results are documented on a test certificate. Unacceptable performances are documented in a deficiency report which is reviewed by quality control and J
engineering for suitable disposition.
7.
Review of Corrective Action:
The inspector reviewed the implementation of corrective action.
Conditions adverse to quality identified in the factory are documented in deficiency reports which require review and disposition by engineering and quality control.
Conditions adverse to quality 1
identified after the operator is delivered are identified in Service Engineer's Reports on Site Problems Defect Feedback Reports. These reports are reviewed by quality control to determine the nature of the problem and whether the problem meets the reportability criteria of 10 CFR Part 21.
The inspector reviewed twenty-five Service Engineers Reports and determined that the identified problems did not reflect inadequate quality control inspections. Acceptable corrective action was taken on identified problems.
E.
EXIT INTERVIE:
The inspector met with Rotork representatives mentioned in Section F and discussed the scope of the inspection and findings.
F.
PERSONS CONTACTED:
- T. Eassie, Chief Executive
- G. Hawkins, Quality Assurance Manager
- G. Malcolm, Engineering Director
- N. Bellworthy, Senior Quality Control Engineer J. Granger Quality Control Engineer
- Denotes those individuals who were present at the exit interview at the conclusion of the inspection.
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