ML20206P513

Insp Rept 99901045/86-01 on 860623-26.Nonconformance Noted: Measures to Control Review & Approval of Document Changes Inadequate & Audit Sys to Verify Compliance W/All Aspects of QA Neither Established Nor Implemented

ML20206P513
Person / Time
Issue date:	08/20/1986
From:	Merschoff E, Petrosino J NRC OFFICE OF INSPECTION & ENFORCEMENT (IE)
To:
Shared Package
ML20206P493	List: ML20206P489 ML20206P506 ML20206P513
References
REF-QA-99901045 99901045-86-01, 99901045-86-1, NUDOCS 8608270227
Download: ML20206P513 (14)

Text

{{#Wiki_filter:__ - - _ _ -. ORGANfZATION: CONTROL PRODUCTS CORPORATION GRAFTON, WISCONSIN REPORT INSPECTION INSPECTION DATES: June 23-26, 1986 OM-SITE HOURS: 50 N0.: 99901045/86-01 l CORRESPONDENCE ADDRESS: Control Products Corporation ATTN: Mr. R. J. Bertling, President 1000 Hickory Street Grafton, Wisconsin 50324 ORGANIZATIONAL CONTACT: D. J. Schaeffer, QA Manager TELEPHONE NUMBER: (414) 377-0800 NUCLEAR INDUSTRY ACTIVITY: Control Products Corporatior, manufactures three types of Agastat electrical control relays which are sold and marketed ex-clusively by the Amerace Corporation. The three types of nuclear' designation Agastat relays are: magnetic latching type (EML), general purpose (EGP) and timing relays (ETR). II / ASSIGNED INSPECTOR: f 4.de !7 8McM(, / dte J. y? Pe osino, Reactive Inspection Section (RIS) D OTHER INSPECTOR (S): T. P. Guilfoil, en' National Laboratory g[e.h APPROVED BY: E. W. Merschoff, , RIS, Vendor Program Branch 'Date el INSPECTION BASES AND SCOPE: A. BASES: Appendix B to 10 CFR Part 50 and 10 CFR Part Pl. B. SCOPE: Verify QA program implementation as a follow-up cf a recent UTST Nuclear Regulatory Commission safety system modification inspec-tion at the Dresden nuclear power plant. Additionally, the implemen-tation of the 10 CFR Part 21 program was reviewed. \\ PLANT SITE APPLICABILITY: All nuclear power stations that use Agastat electrical control relay series EGP, ETR, and EML. i 8608270227 860821 GA999 EMVCTLPC PDR PDR 99901045 1

~ CONTROLPRODUCTSd0'RPORATION ~ ORGANIZATION: GRAFTON, WISCONSIN REPORT INSPECTION N0.: 99901045/86-01 RESULTS: PAGE 2 of 8 P A. VIOLATIONS: None. B. NONCONFORMANCES: 1. Contrary to Criterion VI, " Document Control," of Appendix B to 10 CFR Part 50, CPC failed to establish adequate measures to control the review end approval of document changes. Out of 28 quality-assurance (QA) procedures, 21 were found to have been revised without current revision review and approval. (86-01-01) 2. Contrary to Criterion VII, " Control of Purchased Material, Equipment, and S'ervices," cf Appendix B to 10 CFR Part 50, no pre-award survey or periodic vendor survey had been performed for the procurement of seismically oualified relay base plates from the Overseas CCA company (Chauvin-Avnoux). (86-01-02) 3. Contrary to Criterion XVIII, " Audits," of Appendix B to 10 CFR Part 50, CPC failed to establish or implement an audit system to verify compliance with all aspects of its QA program. (86-01-03) C. UNRESOLVED ITEMS: None. D. STATUS OF PREVIOUS INSPECTION FINDINGS: None. E. OTHER FINDINGS OR COMMENTS: 1. 10 CFR Part 21 The Control Products Corporation (CPC) Procedure QI.23.0, a. revision dated February 25, 1986, was reviewed for its adequacy to provide compliance with 10 CFR Part 21 reporting requirements. In addition, the procedural implementation of the posting requirements (10 CFR Part 21.6) were evaluated by inspecting ~ the manufacturing areas. This review found CPC Procedure Q1.23.0 lacking clarity because it did not provide assurance that CPC would notify l

ORGANIZATION: CONTROL PRODUCTS CORPORATION GRAFTON, WISCONSIN REPORT INSPECTION N0.- 99901045/86-01 RESULTS: PAGE 3 of 8 the Commission in accordance with 10 CFR Part 21.21(b)(1). CPC's procedure passed the responsibility of reporting to the Amerace Corporation. A procedure revision was being processed by the CPC at the time of the exit meeting. A revicw of this procedure will be accomplished during a future NRC inspection. b. The provisions of 10 CFR Part 21 were not imposed on CPC by the Amerace Corporation for the CPC manufacture of nuclear grade Agastat electrical relays. Tnis failure of - the Amerace Corporation to impose 10 CFR Part 21 was dis-cussed with Amerace and CPC personnel. Both companys agreed to rectify the oversight immediately. Follow-up of this issue will be performed at the Amerace Corporation offices in the near future. 2. Procedure Revision Control CPC Procedure A-100 was reviewed and the implementation of procedure control was evalbated by reviewing 28 CPC procedures. Procedure A-100 was adequate with regard to the 10 CFR Part 50, Appendix B requirements. However, the area of revision control was found to need clarification. This area was discussed with CPC personnel and was under evaluation at the time of the exit meeting. Of the 20 p'recedures reviewed, 21 had been revised after the review ond approval signature date. Several of these procedures had been revised two or three times follwing original review and approval dates. The procedures listed below were found to deviate from 10 CFR Part 50, Appendix B requirements (see nonconformance 86-01-01). Inspect on Instructions i Q2.6.1 Q2.7.2 Control of Inspection Instructions C2.7.10 Certificate of Ccmpliance and Test Q2.10.1 Process Control 02.11.1 First Piece Inspection' 02.11.2 Peceiving Inspection Q2.13.1 Control of Measuring and Test Equipment Q2.14.1 Handling, Storage and Shipping 02.15.1 In-process Inspection, Test and Audit 02.16.1 Control of Non-conforming Material or Items Q2.16.2 Problem Evaluation Q2.16.3 Notification of Custoners, Users and/or Agencies

~ ORGANIZATION: CONTROL PRODUCTS CORPORATION GRAFTON, WISCONSIN REPORT INSPECTION NO.- 99901045/86-01 RESULTS: PAGE 4 of 8 Q2.17.1 Corrective Action Request Q2.18.1 Control and Filing of Records in Quality Assurance 02.18.2 Traceability Records for "E" and "F" Products Q2.19.1 Internal Audits E900 Deviation Request and Authorization E1000 Engineering Stop/ Rescind Order E1100 "C" Sheet-Special Product Information P100 Supplier Selection and Evaluation PS100 Customer Return Procedure 3. Approved Vendors CPC Procedure P-100 relating to supplier selection and evaluation was reviewed and implementation of vendor survey and evaluation requiremer,ts were evaluated (see nonconformance 86-01-02). This review revealed that: Section 5.2.1 of Procedure P-100 requires the QA department a. to send out QA pre-award survey form EN206 for a potential supplier to complete and send back to CPC. Only two EN206 forms were on file with one EN206 pending return from a vendor out of nine vendors who were on the CPC approved vendors list. The vendors who had completed EN206 forms were Pennsylvania Pressed Metals, Cosmo Plastics; the pending files were for Trico Products, b. Section 5.2.2 of Procedure P-100 requires the CPC QA department to complete a supplier evaluation form EN207, sign and date, and insert in each suppliers file for a vendor status refer-ence, and final supplier selection af ter internal CPC reviews are complete. Out of nine vendors who were on the approved vendors list, only Pennsylvania Pressed Metals had a form 207 on file. It should be noted that a review of the components that each vendor supplies indicated that Overseas CCA (Chauvin-Avnoux) is the only vendor that supplies other than commercial grade items to CPC.

l CONTROLPRODUCTS$0'RPORATION ORGANIZATIONr GRAFTON, WISCONSIN REPORT INSPECTION NO.- 9n901045/86-01 RESULTS: PAGE 5 of 8 4. Audits The CPC Procedure Q2.19.1, " Internal Quality Audits," was reviewed to evaluate the implementation of planned and periodic audits. This review revealed that: The QA Manager had not established an overall plan for periodic a. audits of CPC's internal functional areas and activities as-required by Section 4.1 of CPC Procedure Q2.19.1 and ANSI N45.2. b. CPC management did not assure that periodic audits were per-formed with established procedures as required by Section 3.1 of CPC Procedure Q2.19.1. (See nonconformance 86-01-05.) However, a QA program implementation audit was performed by the CPC QA manager in May of 1985. 5. Quality Assurance Manual CPC's QA Manual was reviewed for compliance with 10 CFR Part 50, Appendix B, and ANSI N45.2-1977. The manual was in compliance with these documents. The manual had been issued by the QA Manager in June of 1985, was signed by the Vice-President of manufacturing and was approved by the President. Although all revisions to the manual entered since the manual was issued had been properly entered, the method of documenting revisions to the manual sections was confusing and required clarification. This matter was discussed with the OA Manager. This review resulted in no adverse findings. 6. Receiving Inspections \\ The methods required by QA Procedure A2.11.2, " Receiving Inspection," to be followed for the inspection and disposition of production material received at CPC were reviewed for compliance. Areas examined included: a. Procedures for the processing of all incoming production material used in "E" series products before the material is transferred into stores or to the manufacturing floor. l

ORGANIZATION: CONTROL PRODUCTS CORPORATION ~ GRAFTON, WISCONSIN REPORT INSPECTION NO.? 99901045/86-01 RESULTS: PAGE 6 of 8 b. Review of on file Receiving Reports (EN 24 forms) for com-pleteness and proper distribution. Review of Quality Control Vendor Record Data cards (EN 25 c. forms) for completeness and proper documentation. d. Review of First Piece Inspection Records (EN 64 forms) for completeness. Inspection of areas designated for segregating material that e. has not been inspected or that has been inspected but rejected to prevent its inadvertent use in production. This review resulted in no adverse findings. 7. Control of Nonconforming Materials or Items The methods required by QA Procedure Q2.16.1, " Control of Noncon-forming material or items," to ensure that material or items which are nonconforming are properly identified, segregated, documented, reviewed and disposed of were reviewed for compliance. Areas examined included: Procedures used to stop work on material found.to be noncon-a. forming. b. Methods used to physically isolate the nonconforming material from acceptable material. Review of Defective Material Report (DMR) committee findings c. on DMRs associated with material furnished by tre nine suppliers listed in Section E.3 of this report. The DMR review committee consisted of representatives from Manufacturing, Engineering. Purchasing, Production Control, and Quality Assurance. d. Review of Purchasing Department files for DMRs, vendor notifi-cation and follow-up to obtain vendor response, if required, Review of incomplete DMRs to ensure interim copies were e. distributed as appropriate. f. Rrfiew of completed DMR file to ensure completed DMRs were properly closed out. This review resulted in no adverse findings.

CONTROLPRODUCTSCbRPORATION ~ ORGANIZATION: GRAFTON, WISCONSIN 1 INSPECTION REPORT PAGE 7 of 8 NO.- 99901045/86-01 RESULTS: 8. Problem Evaluations The methods required by QA Procedure 02.16.2, " Problem Evaluation," to be followed when an in-plant problem arises that cannot be handled by a DMR or a problem develops in the field were reviewed. This review resulted in no adverse findings. 9. EGP Series Power Relay Assembly Technical specifications, process specifications, bills of materials, and floor supervisor copies of routing sheets were reviewed. The actual assembly process required for "E" series GP power relays was cbserved. This review and observation resulted in no adverse findings.

10. Test Procedures for EGP Series Power Relay In process test procedures TP-GPR-01, " Test Procedure for GP and TR Series and TP-GPR-02, Dielectric Testing of GP Series Relay Coils,"

were reviewed and the test procedures observed to Verify proper testing of the "E" series GP power relay. QA Procedure Q2.13.1, " Control of Measuring and Test Equipment," was reviewed and its applicability and use to the test equipment used in testing the "E" series GP power relay was verified. Calibration procedures, records and periodicity for the test equipment used in testing the "E" series GP power relay were reviewed. This review and observation resulted in no adverse findings. 11. Production Control Equipment and material used during the production of GP series power relays as well as the production control practices were observed during the inspection. The GP series power relays were being manu-factured in accordance with industry standards.

GRGANIZATION: CONTROLPRODUCTSEORPORATION GRAFTON, WISCONSIN REPORT INSPECTION NO - 99901045/86-01 RESULTS: PAGE 8 of 8 F. PERSONS CONTACTED:

• R. J. Bertling President, CPC
• T. L. Nemec Vice-President, CPC
• D. J. Schaeffer QA Manager, CPC S. Sanfelippo Production Control Manager, CPC R. Hillenbrand Production Supervisor, CPC E. Lesnik Material Manager, CPC

~

• J.

Ferguson QA Manager, Amerace Corporation

• Attended exit meeting.

_,e-

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