ML20236M224

Notice of Nonconformance from Insp on 870914-18. Nonconformance Noted:Three Suppliers Not on Approved Vendors List & QC Dept Had No Listing of Calibr Stds

ML20236M224
Person / Time
Issue date:	11/10/1987
From:	NRC
To:
Shared Package
ML20236M218	List: ML20236M214 ML20236M219 ML20236M224 ML20236M229
References
REF-QA-99900064 NUDOCS 8711130007
Download: ML20236M224 (3)

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APPENDIX B

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Ingersoll-Rand Docket No. 99900064/87-01 _

NOTICE OF NONCONFORMANCE I

During an inspection conducted September 14-18, 1987, the implementation of the QA program at the IR facility in Phillipsburg, New Jersey was reviewed with  !

respect to the manufacture of components for nuclear pumps. The applicable QA requirements are 10 CFR Part 50, Appendix B, and IR's Quality Assurance l Manual (QAM), Revison 5, dated May 21, 1986. Based on the results of.this inspection, it appears that certain activities were not conducted in accordance with these requirements. The following nonconformances were identified:

1. Criterion VII of Appendix B to 10 CFR Part 50 and Subsection NCA-4134.7 of Section III of the ASME Code require that materials and services be i purchased from appraved suppliers.  ;

i Subsection 5.4.3 of Section N-10 of the QAM states, in part, " Purchasing procures materials, items and services only from suppliers listed on the Approved Vendor List...."

Contrary to the above, P0s were placed with Accutrex Products (571639),

TiniusOlsen(500052) and Nutley Equipment Repair Company (503413); but the three suppliers were not on the Appruved Vendors List. (87-01-03)

2. Criterion XVII of Appendix B to 10 CFR Part 50 and Subsection NCA-4134.17 of Section III of the ASME Code require that P0's be retained.

Subsection 5.5.3 of Section N-10 of the QAM states, in part, " Purchasing will maintain copies of the purchase documents as objective evidence...."

Subsection 4.9 of Section N-24 of the QAM states, in part, "The j following... Quality Assurance records shall be maintained for the ]

duration specified below, as a minimum: .. 4.9.5 Purchase orders - i 10 years...."

Contrary to the above, a copy of the following P0s could not be retrieved i by IR: 500052 (Tinius Olsen), 575638 (Vitco Nuclear Products), 579777  !

(Durametallic), 527545 (Carpenter Technology), 570857 and 575426 (IR - )

Foundry Division) and 548915 (Precision Heat Treatment). (87-01-04)  ;

3. Criterion II of Appendix B to 10 CFR Part 50 and Subsection NCA-4134.2 of '

Section III of the ASME require the indoctrination and training of personnel perforniing activities affecting quality.  ;

Subsection 3.0 of Section N-25 of the QAM states, " Training and indoctrina-tion is performed to ensure that all personnel performing quality related "

activities are familiar with the applicable Code requirements, company ,

policies, Quality Assurance Program requirements and the procedures, I forms and instructions necessitated during the performance of their i respective job functions." j l

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- Contrary to the above, it was noted: .(87-01-05) f

a. IR did not have records to show that welding personnel had been indoctrinated and trained regarding applicable code requirements, i company policies,-QA Program requirements and quality procedures.

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b. A review of records in.the QC Inspection Department revealed that the formal training. scheduled for this department for calendar year-1987 had not been accomplished as of the dete of the inspection, l

4. Criterion XII of Appendix B to 10 CFR Part 50 and Subsection NCA-4143.12 of Section III of the ASME Code require tha.t measuring and test equipment l be controlled and calibrated.

Section 4.5.2.1 of Procedure No. GXQ-1, " Gage Control Program," Revision 2,  !

states, in part, "A listing of Calibration Standards shall be maintained i by the Quality Control Department." )

Contrary to the above, the QC Department did not have the listing of  !

calibration standards. (87-01-06)

5. Criterion XVIII of Appendix B to 10 CFR Part 50 and Subsection NCA-4134.18 )

of Section III of the ASME Code requires that audits be performed to )

verify compliance with all aspects of the QA program.

Subsection 4.2.1 of Section N-10 of the QAM states, in part, " Survey /

Audits shall be conducted at the vendor's facility annually."

Contrary to the above, external audits were overdue for John Crane -

Hondaille and Durametallic who were both last audited in July 1986. .l (87-01-07)

6. Criterion VII of Appendix B to 10 CFR Part 50 and Subsection NCA-4134.7 of Section III of the ASME Code requires that purchased material as noted l by documentary evidence conforms to the procurement documents.

Subsection 5.3 of Section N-12 of the QAM requires that material made from i stock produced by a manufacturer whose quality system program has not been qualified under NCA-3800 be further tested for upgrading to nuclear:

l'ermont Yankee P0 25165 dated August 30, 1985 for an inpeller nut modifica-  ;'

tion imposed quality and 10 CFR Part 21 requirements upon IR.

IR's Certificate of Conformance dated April _ 10, 1986 stated that the items furnished on P0 25165 conformed to the contract requirements including quality requirements.

Contrary to the above, two items were purchased as stock material from ,

LivingstonWilbar(P0571638) and Accutrex Products (P0 571639), but j there was no documented evidence that the items had been upgraded per the I conditions noted in Section N-12 of the QAM. (87-01-08)

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7. Criterion IV of Appendix ~ B to 10 CFR Part'50 and Subsection NCA-4134'.4 of"Section III of-the ASME Code require that procurement documents' impose a QA program upon the vendor. ,

Subsections5/ .3.1 and 5.4.2 of Section N-10.of the QAM require that.QC.

review purchase requisitions (PR) for incorporation of a vendor's quality program approved by IR, and Purchasing prepares the P0 in' strict compliance to the QC approved PR, respectively.

Contrary to the above, the requirement for a vendor t'o have an approved.

QA program was not stated on P0s 502326 (January 19, 1986) to Grumman ~!

Aerospace, 571639(March 21,1986) to Accutrex Products, 500051 (July 22, 1987) to.Blanchette Tool.& Gage. -(87-01-09)  ;

a Criterion IV of Appendix B to 10.CFR Part 50 and-Subsection NCA-4134.4 of 8.

Section III of the ASME Code require that procurement documents.be .

controlled. J i

Subsection 3.1.3 of Section N-10 of the QAM requires that the Manager QA ~ '

approves prs and reviews P0s to assure compliance with the PR.

Subsection 5.3.1 of Section N-10 of the QAM requires that QC reviews prs for compliance with 10 different items.

Subsection 5.4.1 of Section N-10 of.the QAM requires that'all prs for Code and other controlled materials, items and services bear the approval of QC prior to preparation of the P0 by Purchasing.

Subsection 5.5.1.2 of Section N-10 of the QAM requires that QC reviews-and signs the P0 toshow compliance of the P0 with the PR.

Contrary to the above, it was noted that the Manager QA and/or the QC department did not review and approve the following documents: prs and P0s to Accutrex Products (571639), GrummanAerospace(502326)-and Blanchette Tool & Gage (500051); and P0s to Nutley Equipment. Repair.

(503413), and Vitco Nuclear Products (575055, 575657, 575427, 575422, and 575420). (87-01-10) i 9

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