0CAN088314, Program Plan for Inadequate Core Cooling Sys - Unit 1: Reactor Vessel Monitoring Sys/Hot Leg Monitoring Sys;Unit 2:Reactor Vessel Monitoring Sys
| ML20076G861 | |
| Person / Time | |
|---|---|
| Site: | Arkansas Nuclear  |
| Issue date: | 08/26/1983 |
| From: | John Marshall ARKANSAS POWER & LIGHT CO. |
| To: | John Miller, Stolz J Office of Nuclear Reactor Regulation |
| References | |
| 0CAN088314, CAN88314, PROC-830826, NUDOCS 8309010152 | |
| Download: ML20076G861 (198) | |
Text
m
- - ~ _ ,
ARKANSAS POWER & LIGHT COMPANY ARKANSAS NUCLEAR ONE UNITS 1 AND 2 PROGRAM PLAN FOR INADEQUATE CORE COOLING SYSTEM UNIT 1: REACTOR VESSEL MONITORING SYSTEM HOT LEG MONITORING SYSTEM UNIT 2: REACTOR VESSEL MONITORING SYSTEM 8309010152 830826 PDR ADOCK 05000313 P PDR
TABLE OF CONTENTS Section Page
- 1. EXECUTIVE SUlifiARY 1-1
- 2. INTRODUCTION 2-1
- 3. SCOPE OF WORK 3-1 3.1 Overview 3-1 3.2 Phase I -- Confirnatory Test Progran 3-4 3.2.1 Phase I Progran Plan 3-4 3.2.2 Systen Functional Design 3-7 3.2.3 Confirmatory Testing 3-8 3.2.4 Pretest Analysis of Sensor Designs 3-21 3.2.5 Documentation 3-24 3.2.6 Licensing Submittals 3-26 3.3 Systen Developnant and Connissioning 3-27 3.3.1 Phase II Systen Detailed Design Specification 3-27 3.3.2 Sensor Design and Fabrication Process 3-31 3.3.3 Data Acquisition Hardware Development 3-37 3.3.4 Software Development - Basic Functions 3-44 3.3.5 Systen Acceptance Testing 3-46 3.3.6 Documentation and Training 3-47
- 4. QUALITY ASSURANCE 4-1 APPENDIX A - Background for and Experience with Radcal A-1 Ganna Thermoneters APPENDIX B - RGT Calibration B-1 APPENDIX C - Quality Assurance Manual C-1 ii
LIST OF FIGURES Fi gu re Page 2-1 ICC Probe Installation Configuration for ANO-1 2-3 Reactor Vessel Monitoring System 2-2 ICC Probe Installation Configuration for ANO-1 2-4 Hot Leg Monitoring System 2-3 ICC Probe Installation Configuration for ANO-2 2-5 2-4 Basic RGT Sensor Design 2-8 3-1 Generic Equipment Qualification Diagram 3-9 3-2 Prototype Sensor Designs 3-11 3-3 liancmeter Tube Design, ANO-1 3-16 3-4 ORNL Forced Convection Test Facility Schematic 3-18 3-5 Example RGT Fabrication Outline 3-32 3-6 Example Cable Pack Thermocouple Grouping 3-33 3-7 ANO-1 ICC Reactor Vessel Monitoring System Equipment 3-39 Qualification Diagram 3-8 ANO-2 ICC Reactor Vessel Monitoring System Equipment 3-41 Equipment Qualification Diagram 3-9 AND ICC Reactor Vessel Monitoring System Equipment 3-43 Cabinet layout A-1 Radcal Design Gamma Thermoneter with Axial Heat Flow A-3 A-2 Heat Flow in Axial-Flow Radcal Gamma Thermoneter A-5 A-3 Core Locations of Radcal Ganma Thermoneters in EdF Reactors A-6 i
l ii
{
l
LIST OF TABLES Table Page 3-1 Outline of Ganna Thermoneter Probe Testing 3-22 i
l l
iV
. e+ -
., i , +w-7-v- --,m, y - ,- - y --------mn --g,u -----.-----.
- 1. EXECUTIVE
SUMMARY
Arkansas Power and Light (AP&L) has developed the following program plan for a Radcal Gamma Thermoneter (RGT)-based inadequate core cooling (ICC) system program. The AP&L staff concluded that the RGT-based ICC system offered not only the capability to satisfy the regulatory requirements, but also net the operational needs of providing other useful accident management data. This systen is currently the preferred alternative chosen by AP&L to meet implementation order 0CNA128211 requirements for Arkansas Nuclear One, Units 1 and 2 (ANO-1 and-2). Therefore, AP&L developed a program plan for implementation of the RGT-based ICC system to satisfy the ICC needs for ANO.
The ganna thermoneter being proposed for the ANO system is similar in design to the RGT device developed by Scandpower in the mid-1970s. Much of the early effort for the RGT was directed toward the development of in-core local power monitoring systems to replace miniature fission chanbers and self-powered neutron instrumentation systems currently i being employed in light water reactors.
l l
Nunerous utility ganna thernoneter programs oriented towards both power I
monitoring and ICC nonitoring are ongoing currently. The majority of these efforts are in Europe (France, Germany, Sweden); however, programs are now starting in the U.S. with the Duke Power and Florida Power and Light power monitoring programs.
1-1
- . _ ._ .= - -
d 1-2
! The RGT device is a rugged instrument made from a series of composite stainless steel tubings swaged together to form a monoli'. hic structure.
The central tube contains a series of differential-type thermocouples
) and a central nichrome heater. The differential thermocouples are staggered along the length of the RGT unit such that the differential junctions form a set of distributed sensors. One junction of the dif-I ferer.tial thermocouple is insulated with an annulus of argon gas which i
forces heat from the central nichrome heater to flow in a controlled fashion around the argon annulus and through the composite tubing to the reactor coolant heat sink.
I The same general configuration is used for both power monitoring and ICC monitoring. When used for power monitoring, the heat generation at the j sensor is produced primarily by reactor gamma rays. For ICC application, the central heater is the primary heat source, since these devices are l used both above the core and in-core after shutdown where the gamma heating contribution is relatively low. For ICC monitoring, the RGT will sense changes in coolant heat transfer resistance which can be pro-
. cessed to determine the coolant level.
i
)
l The RGT unit is incorporated within a stainless steel manometer tube so that the device can sense collapsed water level (without voiding effects) above the reactor core. The collapsed level is more indicative l of core coolant inventory than the voided level. In the core the RGT
?
l will determine coolant heat transfer characteristics and coolant inven-tory, as well as monitor the core power af ter shutdown. This infor- -
l mation is of vital importance during an accident when the reactor core i
i
1-3 cooling is threatened. The same general configuration is used as for l
monitoring of coolant heat transfer and level in a stilled column tapped t
i from the reactor system hot leg.
On liarch 31, 1983, A.P&L presented the RGT-based ICC system approach to the Nuclear Regulatory Commission (NRC), including a schedule for i implementation. The objective of this meeting was to determine if the NRC would allow AP&L to respond to their implementation order (0CNA128211) for both ANO-1 and -2 with the RGT system as presented. As 4
a result of this presentation and follow-on discussions between AP&L and I
NRC staff, the NRC gave verbal approval for AP&L to respond to the order with the RGT-base <1 system. On April 15, 1983, AP&L provided a written
-description of the ICC system as presented on fiarch 31 as a formal 4
response to the order.
l Since this time, AP&L has developed the program plan presented herein, which describes in depth the RGT-based ICC system program. This program plan describes both Phase I (the confirmatory test program for develop-i ment of licensing support) and Phase II (system fabrication for both AN0-1 and -2).
The Phase I confirmatory test program as described herein nakes use of j thermal-hydraulic test facilities of Oak Ridge National Laboratory 1
(0RNL). AP&L and Technology for Energy Corporation (TEC) will conduct a series of tests to provide data for licensing support of the ICC system
- and to provide plant-specific (ANO-1 and -2) design data to be incor-porated into Phase II systen development. The Phase I program will be conducted under a detailed test plan developed jointly by AP&L, TEC, and ORNL. ~
'88% , *. I V k
<----e--~.----,_,m_ , _ , , , , , ,,, _
1-4 The Phase II program uses the test results of Phase I for finalization of system hardware and software design for ANO-1 and -2. The ICC system consists of the RGT sensor units, electrical connectors, cabling, penetrations, processing hardware and sof tware, display system, and interfacing systems to existing plant hardware.
There will be two RGT ICC nonitoring units above-core for ANO-1. These will be installed in the space acquired from removal of the central control rod drive assembly. These RGT units will have built-in manometer tubes for monitoring collapsed level. There will also be four ICC RGT units for in-core monitoring. The in-core monitors will replace existing self-powered neutron detector units through existing instrument thimble hardware. In-vessel monitoring for ANO-1 will be supplemented by a hot leg nonitoring system. One RGT unit per each hot leg will be installed in a stilled column of water associated with each hot leg.
This system will track system voiding above the reactor vessel level.
The ICC system for ANO-2 uses the existing instrument housing and l thimble assembly. Two RGT units will penetrate the done, upper plenun, and core regions. Existing done and plenum instrument thimbles will l
serve as the manoneter tubes to determine collapsed level above the core. Information from the ANO-2 ICC system will be supplemented by core exit thermocouple data processed through the ICC system processor hardware.
l l
l l
1-5 The connector, cabling, penetration, and processing system for both ANO-1 and -2 will all be qualified to 1-E requirements. A system description including the RGT and system support components for Phase II is given in Section 3.3.
- .- . =- _ _- . - - . _ _ - -. -- - -
- 2. INTRODUCTION l Following the accident at Three Mile Island, NRC identified the need for i additional instrunentation to detect ICC. As a result, all licensees 4
were required to install control room indication for displaying reactor coolant subcooling margin and core exit thermocouple data over an elevated temperature range. More recently, the NRC has indicated they
! will require all PWR licensees to install coolant inventory instrumentation that would provide the operators with a clear indication of void formation in the reactor vessel head and permit tracking of the coolant inventory in the vessel and the primary system piping.
]
The RGT-based ICC monitoring system is designed to detect void formation i in the reactor vessel upper head, hot leg piping system, and to track coolant inventory in accordance with the NRC requirements. In addition, it will provide coolant temperatures and heat transfer trending in 4
selected regions both above the core and in the core, indications of core uncovery (should it occur), and a measurement of post-shutdown power production in the fuel. This additional information will improve the ability of the plant operators to properly diagnose the onset of ICC I
l and to assess the adequacy of actions taken to restore core cooling.
! The RGT-based ICC system consists of redundant reactor vessel probes J
which contain RGT sensors located at selected intervals within the probe. The probe design is based on proven technology nearly identical to that used for local power measurements in several European reactors.
I 2-1
}
i l
2-2 Each probe consists of a cable pack of sheathed, single-difference ther-nocouples (one for each sensor), absolute thernocouples, and a heater cable; an annular core rod which contains the cable pack; and a jacket tube which surrounds the core rod / cable pack assembly.
The RGT installation differs somewhat for the two ANO reactor designs.
For ANO-1, the installation is conceptually represented in Figures 2-1 and 2-2. Redundant probes will be inserted through the top of the vessel, with access provided by renoving the central control rod drive assembly. The in-vessel portion of these probes will extend from the upper head to the fuel alignment plate. In-core monitoring will be accomplished by additional orobes which will be inserted through existing in-core instrunent ports in the botton of the vessel and will extend to the top of the core. Each hot leg will be nonitored for voiding by addition of a stillwell tube which extends from the vent piping at the top of the hot leg to a drain at the bottom of the cold leg. Each stillwell will contain a probe that will extend the complete length of the hot leg.
For the ANO-2 reactor, both above-core and in-core monitoring will be accomplished using redundant probes which traverse the entire region to be nonitored (see Figure 2-3). These probes will be inserted through the vessel head using existing instrunent ports.
l l
6 '
' 2-3
!Csit0'. RCD tt!YE MICHAA:54 rtAr.0E gi l l I i t t f
. - ~ ~
s L CNs w
m
~
f I - : ::mus: TAT cN
' 'I - " F04T5
\' \ l 3 I *"" l '
[ t B "/ i g-.; :Irr i
g 'y gg i
\ x s
/
l E1
,e I sus I Clrr t Q g j ,' '
sC!rr h
~+- y =gs jet,r -p r
'/ '
p1 THtRMMEitR
' /' i Na, t
FR06t$ *n
/
h'A \M
- p7 UPPG Pt[NL*
, PLA,5 C &". . ins Clrr PORT 5 C- l S
@ pas :rr 4 l b Nn.c:rr ' 77 -
\E E
s .'\ j'r -
.cwtt Pttut~
l } p g PLATt
/j ns i i.
. os .//,
T 1 l ll l ? /
, i ::rr
// :tre r
/
/ ,l /
/ ::r-
! i l l:rr y/
as . nsou:Tc / !
1 wa o:our.t '
{
- ,r, ; ; ,
l l::gr .y
- rr . c rrtats:t m s occurtt l
t j /
y3 ,1 , y3 7
- I i l I 9-t
/ crrr i i i i : rr coat
/
- rr
\
i l l i, ::rr
_//,
/ i i
,/ ; ; l l J "5 '
f , l ,
O E "5 d
'/ i l '/
'. 'A
./.
j 7
/
,/
r l \ i L.,
() .! l . A
- NGjM,,N bI '
- ss r.~ m 4:::.t j i q u s u )
1 I .
% o
% b Figure 2-1. ICC Probe Installatier. Configuration for ANO-1 Reactor Vessel Monitoring System
- -e.-, , . - , _ . , - _ . - - - - , _ , .
2-4 Val,
...~.
EXISTING HI. PT.
-} NO:-O>C -
VENT PIPING i e
I e
a m
-m STILLWELL ,a GAMMA THERMOMETER u HOT LEG PROBE "A" GAMMA '
, . THERMOMETER N SENSOR (TYPICAL) ,
S.G. '
"A" (TYPICAL) 70 RCP a ,
E
( )
7 e R.V. _' _
COLD LEG "A" l
. < / v g
Ji W .
),
TO EXISTING i i Y '
W%O DRAIN !
/ // / / / / / / / / // // / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / /
"B" NOTE: A COR GSPONDING PROBE AND STILLWELL WOULD EE INSTALLED FCR CHANNEL MEASUfe:NG HOT LEG "B" LEVEL .
=
i l
1 '
i Figure 2-2. ICC Probe Installation Configuration for ANO-1 Hot Leg Monitoring System 1
, _ . . , . . . , _ . - , . . , _ . _ _ _ , . _ _ _ . , _ _ _ _ , . _ _ _ , . . . , , . _ _ _. _ . _ _ , _ . , _ . .... _ ..__ _... ~_._ _ _
=., 2-5 bb:
ELECTRICAL CONNECTORS
. 33 W--as .
A- l uM=~N- iO HYDR AULIC ISOLATORS rTi mSbLE NON j
\ ".
es
=006:::I ., y COfA'AUNICATION CIFF x ,j j ! D PORT (Typic;L)
I IN CORE ll \.*Af
=
l 1
- M E(
INSTRUMENT UPPER GUCE j l i*m ,"_,,, k
/ ,gg.
- s l , l#l STRUCTURE PLATE
\GU!OE TUEE srg ,\ o Lqx 'Nll \a '
\
\ g Ml !-DIr r b.; [
l _
k * -l---l COMMU NIC ATION PORTS (TYPIC AL )
/ \ q 6' J j gN 1 l e, j N's h l/cippNl[' FUEL ALIGNMENT l
\ \
g NN j
- PLATE
/ *
^AE S /?II .r i
N 5 Il p f'\
- N 'N/s SENSOR "
, e LOCATION i [N -7'ih
'G AM M A i t! .
~
THERMCMETER ,! ji\Dlr../f'.l
, r c,c~:
" ~ '
l f;' A S S jl CORE
' a .
ij)OtFF(!j t
- !!.-A B S N[
I
! ,l l l l __
I I l h i g -
0
)
1 AES - AESOLUTE THERMDCCUPLE 0::F- C1. FERENCE THERMOCOUPLE
, UNIT- 2 REACTCR VESSEL r
I Figure 2-3. ICC Probe InsCallation Configuration for ANO-2.
i
0-2-6 In both facility installations, those portions cf the probes which traverse the region above the core are surrounded .y a nanometer tube. ,
This tube serves to hydraulically isolate the liquid adjacent to the probe, thereby enabling the probe to sense collapsed level. Hydraulic isolation for narrow-range (done vs. plenun) nonitoring is accomplished with insertion of an orifice plate within the nanometer tube.
The proposed ANO-1 hot leg level neasurenent systen is shown in simplified forn in Figure 2-2. The piping (tubing) section functions similarly to a manometer in that the water level in the stillwell will follow the level in the hot leg. The stillwell length, as a mininun, will be from the top to the botton of the hot leg (approximately 40-50 feet). As shown, a ganna thernoneter probe will be installed in the stillwell for detection of water level. The operation of the ganna thernoneter is identical to that of reactor vessel level monoto ri n g. The probe length will be the same as the stillwell with nultiple axial sensor locations. The spacing of these sensors will be closer along the upper three-to-four-foot portion of the probe than along the rest of the probe so that better accuracy and resolution of water level can be obtained in the critical upper portion of the hot leg.
The design of individual sensors will differ depending on their location in the probes, in the region above the core and the hot leg stillwell, the RGT sensors must indicate absolute coolant tenperature and collapsed level. Within the core, the sensors will be designed to trend heat l
l -
\ _ _ . _ - _ _ _
1 2-7 transfer coefficient, provide indication of core uncovery, and indicate axial coolant temperature distribution and post-shutdown heat production 4
in the fuel.
t The basic sensor design used for heat transfer coefficient trending is shown in Figure 2-4. During fabrication, an argon gas chamber is machined into the core tube at each sensor location prior to assembly of I the probe. When electrical current is applied to the heater, the insu-i lating effect of the gas chamber creates a temperature difference bet-ween the hot and cold junctions of the thermocouple. This difference is related to the heat transfer coefficient at the surface of the probe l adjacent to the sensor.
A The other sensor designs proposed for use in the probes are slight modi-l l fications of this design. For example, post-shutdown heat production is detected using a sensor design identical to that described above; I
however, the heater is not used for this function. The fission product decay gammas serve as the heat source, producing a temperature dif-ference that is proportional to shutdown power. All sensor designs are discussed in nore detail below in Section 3.2.3.2.
Signals from the RGT probes are transmitted outside containnent to a data acquisition system that will process the data to create ICC infor-nation and display it to the operator.
AP8L presented a discussion of the reactor vessel monitoring system and hot leg nonitoring system design concept to the NRC at a meetir.g l
e .
- 2.
2 *8
=
ii
?%
HEATER ELEMEhT CORE ROD !
N NF l
%r COLD LENGTH
\
K// ,
T cold \ ' !2 JACKET T2JBE V
i
,2 r b s -
sy [- INSULAhT N )
%./ d K6< h#
/ r g HEATED LENGTH OF Ig )4 /j:t. :f,r\, j HEATER CABLE g[@
b -
\ 3~ GAS C.%MBER s Nr JME Fi gu re 2- 4. Basic RGT Sensor Design.
2-9 held in Bethesda, Maryland on March 31, 1983. This was followed by a submittal to the NRC on April 15, 1983, which further described the general approach using the RGT concept.
The scope of work required for this project is described in Section 3.
The effort will consist of two phases. Phase I will involve the devel-opment of a system functional specification, and the fabrication and testing of partial-length prototype probes applicable to both ANO-1 and
-2. The results of this phase of the project will provide the basis for licensing of the systen by the NRC, and will also support the development of detailed system specifications. Phase II of the project covers the design, fabrication, qualification, and testing of the systems to be installed at ANO.
The Quality Assurance requirements to be used by TEC in completing the work previously outlined are covered in Section 4 l
- 3. SCOPE OF WORK 3.1 OVERVIEW The AND ICC system program consists of two phases. In Phase I, AP&L and TEC will design and carry out a development effort aimed at (1) finalizing the ANO RGT ICC system conceptual design described in Section 2 of this document, and (2) supporting system licensing by the NRC. In Phase II, the detailed desiens of the monitoring systems to be installed at ANO-1 and -2 will be developed using information obtained during Phase I, and both systems will then be fabricated, tested, and installed.
To accomplish the goals set for Phase I, partial-length prototype probes will be fabricated.
The partial-length prototype probes will be subjected to confirmatory tests using thermal-hydraulic test facilities at ORNL. Test objectives include e Confirmation that the RGT probes will detect ICC conditions, o Verification that the proposed nanometer tube design permits unambiguous collapsed coolant level determinations, and e Identification of the boundary conditions for unambiguous ICC indications.
As an integral part of the test program, multidimensional heat transfer analysis will be used to predict the baseline for the sensor response for conparison to test results, and to establish algorithms for system 3-1
i 3-2 software integration. In addition, these calculations will assist in the sensor designs and the sizing of the manometer.
At the conclusion of the test / analysis program, a report will be generated which summarizes the results of this effort and documents the
- findings and conclusions. This report will be used in licensing the system. It will also serve as the basis for further detailed design work in Phase II.
l Phase I of the program is a confirmatory test phase. The major tasks to be performed as a part of the Phase I effort are listed below.
- e Develop a detailed Phase I project plan e Develop a documentation plan for Phase I and II e Develop a Phase I test plan I
- e Develop a system functional specification f e Develop a system environmental qualification plan i e Design partial-length prototype probes and complete probe speci-fication
! e Specify and procure material e Prepare facility (TEC and ORNL) e Fabricate partial-length prototype probes ,
e Insertion and bending radius testing e Perform QA testing of probes
- Perform engineering analysis of probe performance during ICC events e Complete confirmatory testing of sensors for above-core and in-core applications e Report test results l
l l
( - . . - - . - . - - _ _ _ _ . . - _ - - - _ _ _ . _-__ _ _ _ _ _ _ __
i, 3-3 e Develop a final report to be used as a licensing document by AP8L, both as a decision-making tool and as the basis for licensing presentation A more detailed discussion of this work is provided in Section 3.2.
Phase II is the detailed design / implementation portion of the program.
The major tasks in this phase are listed below.
l
- Develop a detailed Phase II ANO-1 project plan e Develop a detailed Phase II ANO-2 project plan
- Develop detailed design specifications for all system components (ANO-1 and -2) t e Procure materials i
j e Fabricate full-length prototype probes e Complete insertion testing for ANO-1 and ANO-2 reactors '
I e Fabricate in-reactor probes e Integrate system components o Perform QA testing and calibration e Perform integrated system tests i
e Write final acceptance tests e Perform factory acceptance tests e Write manuals and assemble systen test documentation e Provide training support at ANO Detailed discussion of these tasks is provided in Section 3.3.
l-~. . _ _ _ _ . _ _ _ . _ _ _ _ . _ . , _ _ _ . . _ , _ _ . _ , _ , _ _ _ _ _
3-4 3.2 PHASE I - CONFIRMATORY TEST PROGRAM 3.2.1 Phase I Project Plan Upon initiation of the ANO ICC system program, a detailed project plan covering the work breakdown structure, schedule, task state-ments and assignments , and budget will be developed.
The project plan will address interin reporting to AP&L on the fabrica-tion and testing program,and identify the ongoing work and near-term nilestones.
A The initial effort in the AN0 ICC system development and design program will be fabrication and testing of prototype R,.GTs,to confirm the suita-bility of the RGT design for an ICC application in the ANO-1 and -2 reactors. The primary objectives of this prototype program are:
e Denonstrate that the desired neasurements - measurement of local reactor power, measurement of coolant absolute temperature, and indication of reactor vessel or hot leg heat transfer coefficient and level trending - can be acconplished by a single integrated instrunent, o Denonstrate that the RGT indicates local core coolant tem-perature and heat transfer conditions in an ICC event, and obtain data on how closely this reflects fuel cladding temperature, o Measure the effectiveness of the hot leg stillwell for ANO-1.
o Measure the effectiveness of the manometer tube designs for ANO-1 and -2.
- Provide data to determine the conditions where the gamma thermoneter will furction as an effective ICC system.
- Demonstrate that the RGT can monitor the effectiveness of natural circulation cooling.
3-5 e Provide data to confirm that the RGTs are relatively insensitive to competing effects in ICC events over the potential tem-perature and pressure environments.
e Demonstrate the robustness of the system by showing that the RGT probe can readily be installed and operated.
The scope of the prototype program covers the fabrication of RGTs of sufficient length and resolution to neet the full reactor ICC indica-tion requirements for both ANO-1 and -2.
The facilities available for testing the partial-length prototype RGTs are:
e TEC special test fixtures--basic sensor calibration e ORNL air-water entrainnent loop--manoneter evaluation tests e ORNL Forced Convection Test Facility (FCTF)--variable depressurization rates:
--Above-core
--In-core (including 3 x 3 fuel rod simulator array).
After the hardware requirements are established, a program test plan will be prepared and documented. Two types of testing address the objectives of the prototype program:
Separate effects testing e Temperature, o Pressure, o Vibration, e Probe flexure beyond elastic limit, o Probe insertion testing, ,
3-6 s Infrared scans of RGT, and e Electromagnetic interference of RGT signals.
ICC measurement confirmatory testing e Air-water mixture tests for manometer tube design optimization, e ICC confirmation-depressurization/reflood tests, e RGT response to fuel-clad and coolant temperature using fuel rod simulators, and e Determination of reactor conditions which allow for unam-biguous ICC monitoring.
Independent of the testing program, a plan for analysis of the RGT sen-sitivity and response will be prepared. This analysis program will predict the RGT probe behavior for the following uses:
e Residual core power monitoring, e In- and above-core absolute temperature measurements during ICC events, e In- and above-core heat transfer conditions, and e Above-core collapsed level.
e Hot leg stillwell level Upon completion of each test series, an interim report on the test response of the RGT probe will be prepared. Upon completion of the entire test program, a " quick-look" report on the testing results will be produced to provide an early indicaticn of the response of the RGT probe and a brief summary of what performance goals were accompl'shed.
This report will be followed by a more detailed final test and analysis report that documents and conpares the test results to the conputer predictions, and provides final conclusions and recommendations on the
3-7 performance of the RGT probe for ICC events. The report will summarize the conditions where the probe can be used to supply unambiguous data on ICC events, and will note any major corrective actions to the RGT speci-fication, fabrication plan, or probe design that would affect Phase II 3
of the program.
i 3.2.2 System Functional Design. In conjunction with the development of the Phase I program plan, a system functional design specification will be developed. This specification will be an elaboration of the concep-tual design previously presented to the NRC by AP&L.
3.2.2.1 Data acquisition development. The probe functional design will be matched with a data acquisition system functional design speci-fication development. This data acquisition system will be developed in
- Phase II to acquire data from each of the thermocouples in the RGT probe, and to digitize, process, and display the data as reactor level, temperature, and power information. The same system will control the sensor heaters and validate the data it acquires. The Phase I effort will be to develop the functional requirements of a data acquisition i
system using qualified or qualifiable components. The qualified com-ponents will include selection of cable connectors and cable con-1 figurations and the front-end data acquisition electronics.
3.2.2.2 Qualification. The qualification effort in this program, as it relates to Category 1E systems, is primarily a documentation gathering
! and cataloging task. As presented to the NRC during the fiarch 31 pres-i entation, the systen will be configured using components and materials
-t-nr-ener -e--tw w - +e e.w--.c.v--------,yw-wr --er- -, -m e- ew--------w, .__y-v-gy-i-ww---e-wwar -m or n,y-- < - -T yrw -W- * -- - *
- 3-8 that have undergone testing that qualifies those components and naterials for use in Category 1E systems.
In the case of the RGT sensor, the qualification will be based on pre-vious in-reactor use and on the additional confirmatory testing to be done in this program.
Before any components or materials are procured in Phase II for the final system design and assembly, the potential suppliers will be requested to provide a comprehensive qualification docunentation package for review by TEC prior to purchase. All qualification documents will be assembled as an integral part of the overall systen documentation for Phase I.
Since the Phase I testing program will use previously tested components, there are no plans to perform LOCA or main steam line break (MSLB) testing on any in-containment components. The design of the signal transmission system will take into account all interfaces from the sen-sor up to and including containment penetrations (see Figure 3-1).
Therefore, a reconnended installation will be provided to satisfy LOCA/MSLB concerns.
3.2.3 Confirmatory Testing A set of confirmatory tests will be conducted at ORNL under the direction of AP&L and TEC to verify that the reactor vessel monitoring system RGT units will perform adequately over the range of postulated in-reactor conditions. An initial detailed test plan will be produced natching the testing effort to the Phase I program objectives. The test plan will provide the necessary flexibility and direction to the probe
yo t y
l t
n e
g m j n n i s i s y a l s a t ae l n nc p o go s C i
i r Sl ' 0 o[ D d
e i
s t
u O
l l
a W
_ q'" +
t n
e a m
- i m
n r
g a
- n a i
< o - t D i e n
][ t c aa C o n o
> rf i
- t r t ee a nt c en -
i f
l' i
- i n l a
i o u s a Q s t i
m ' n l
as ,r ' ei nn m ga i l
i r ST t u n q e f m
i n
i c
a r
_ l t e ae n n 4 cc o e
] i a C G rrf ot r e 5_ sce d 1
_ net i
_ el n s -
r SEI n 3 I
- . e e r
_ 6 u
g
+ i y f e r a
d n
u o
B e
rg / es rg on un si e nr si st et et SS . ri PF
< r, c -
3-10 development testing and ICC measurement confirmation testing. A proto-type containing the various sensor designs (see Figure 3-2) will be sub-jected to depressurization and air-void entrainment tests at the ORNL FCTF and the ambient temperature air-water void entrainment loop, respectively.
i 3.2.3.1 Phase 1 partial-length prototype probes.
Fabrication process. A swaging process will be used to fabricate the partial-length prototype probes. This process consists of (a) grouping I
the thermocouples and segmented heater into a cable pack; (b) inserting the cable pack into a stainless steel tube designated as the core rod; (c) swaging of core rod onto the cable pack; (d) identifying the loca-tion of the terminal junctions of the thermocouples by x-ray and, in the 4 case of the gas-insulated sensor, machining the annulus in the core rod;
, and (e) performing the final swage of the jacket tube onto the core rod while flowing argon gas through the annular volume between the core rod l and jacket tube. The thermocouples and segmented heaters will be
(:xamined by performing loop and lead-to-sheath resistance measurements l prior to the assembly of the cable pack. The locations of the ther-m) couple junctions will be verified by heat tracing.
i l All prototype test specimens will be fabricated with at least three sen-sors and will be approximately eight feet long. The manometer tube for f
i ANO-1 will be made an integral part of the RGT sensor. The fabrication process for the eight-foot prototypes will be the same as that for the full-length prototypes and in-reactor units.
i
l l
3- 11 l
- =
I
, - .t
- / ?.
y ' COLD f- ,
.s ,
p '
GAS -W' CHAMBER _ ,
e e
)=
' HOT HEATER CABLE
/'
HEATER / e J ACKET +
CABLE CORE R0D 2 A B SLOW HEAT TRANSFER SENSOR / SIGNATURE OF UNCOVERY SENSOR RESIDUAL POWER SENSOR , ,
- Z ' COLD HEATER
~
CABLE
' HOT
- Z JACKET Z CORE ROD C
FAST HEAT TRANSFER SENSOR Fi gure 3-2. pec ctype Sensor Designs i 31199AOS
3-12 The details of the fabrication process for both the test specimens, prototypes, and in-reactor units are given in Section 3.3.2.
3.2.3.2 Sensor designs. The RGT probes are designed to trend the heat transfer coefficient and tenperature both above the core and in-core, sense changes in collapsed level above the core and in the ANO-1 hot leg, and indicate residual core power following shutdown. Four sensor designs will be assessed for providing this information.
Heat transfer coefficient trending; collapsed level indication. Two of the four sensor designs will be used in the prototype assenblies for these measurements. The sensors are shown in Figures 3-2A and 3-2C.
One sensor utilizes a gas-insulating chamber, while the other does not.
The principal difference between these two designs is in their response times. The sensor with the insulated heated junction responds more slowly than the uninsulated heated junction sensor to changes in the surrounding medium. Due to changes in the surface heat transfer, however, both sensors have a larger emf output when uncovered. The gas-insulating chamber, while having a slower response, has better noise-damping characteristics.
Signature of core uncovery. The RGT sensor used for this purpose will be fabricated with both the hot and cold junctions heated (see Figure 3-2B). This cable pack arrangement in which the cold junction is positioned axially above the insulated junction provides a distinct signature when the two junctions are uncovered in a sequential manner.
'y y -, - . . -
-- = -_-
3-13 The cold junction, which is not thermally insulated, heats up more I
slowly than the insulated hot junction, causing a transitory reduction in the emf output of the single difference thermocouple until the slower insulated hot junction drives the output back to an equilibrium value.
This signature is a function of both the rate of change in local surface heat transfer anu the input energy to the sensor.
Residual power. For this application, the sensor design is identical to that shown in Figure 3-2A. In the core, the sensor is heated by energy deposited as a result of absorption and scattering of gamma radiation I
from fission product decay in the steel body of the sensor. This thermal energy is transmitted from the sensor to the surraunding coolant.
Because of the gap surrounding one junction, a temperature difference is established between the two junctions. This difference is directly pro-portional to the volumetric heating of the rod and hence proportional to i
the local power level. (The heater is used only for periodic calibra-
! tion of the sensors.) The relationship between sensor response and core power is well established. However, specific correlation coefficients l
for ANO-1 and -2 will be developed during Phase I.
l 3.2.3.3 Separate effects testing. Separate effects testing will consist of collecting existing test data and inspection data obtained from the probe fabrication procedure to provide a basic picture of the gamma thermometer probes' sensitivity to any competing effects in ICC events.
A quality control calibration of each sensor of the fabricated RGT units will be conducted to determine sensitivity and time response charac-teristics, and to ensure that these parameters are uniform among sensors
- . = -_ _. __ _ - . -. - -
i 3-14 and within specification. (SeeAppendixB.) This information will be supplemented where required by simple tests integrated into the confir-matory testing. The data obtained will further confirm the prototype probe design and validate the ICC probe confirmation testing program as f
! specific tests of ICC phenomena.
l l 4
3.2.3.4 Air-water tests. After fabrication, testing, and calibration of sample probes, testing will begin at the ORNL test facilities, i
The first ORNL testing effort will take place at the atmospheric air-water test facility. The ORNL atmospheric air-water test loop is 4
i designed with provisions for:
e Supplying both direct current (joule) and heater cable power to the RGT sensors.
3
) e Producing boiling by slowly or rapidly lowering pressure above
- the test chamber, e Supplying constant dc current of 0-300 A in joule test mode and 0-10 A to heater cable.
e Recording of dynamic analog signals 0-10 mV, and a series of conventional current and voltage measuring instruments.
e Analog-to-digital conversion and multiplexer for sampling.
Tape recording equipment and computer access.
The objectives of these tests are:
! e To provide basic design data on the manometer tube stilling column and RGT assembly's performance, i
e To denonstrate that the final prototype manometer tubes and i probes are capable of making level measurements in a variety of void-water mixtures and flows (both ANO-1 and -2 configurations),
e To obtain basic performance data, response time, fill and drain rates of the manoneter tube-probe assemblies (ANO-1 and -2 l confiaurations),and rm,,,-r-, ,_ w,c, ,- ,, r , -, --m_ -n. -- - - ~ , -
., -n- , ,- - - --..~,------,-,---n, _ , _ _ ,
_ . . - - - . - - - ~ . - - . .
1I 3-15 e To determine the boundary conditions of flow and voiJ fraction under which the probe assembly can provide unambiguous data to a reactor operator.
This testing will be carried out by:
e Using several gamma thermoneter junction configurations,
- e Changing manometer tube and stilling column dimensions, hole i configurations, and I
e Altering probe dimensions to meet manometer tube requirements
! (ANO-2 RGT probe design).
! Air-water testing will provide performance data under a range of j conditions:
! e Varying void fraction, e Different flow rates, e Variable heater power, e Pressure changes to induce boiling around the probe, and -
e Changing loop fill and drain rates.
The conbination and number of these test parameters will be described in the test plan. Figure 3-3 illustrates the sensor types and the approach to manometer tube design for both ANO reactors.
l i
The nanometer and RGT dimensional parameters determined during these tests will provide the basis for the designs used in the ICC confirmation and depressurization tests. .
i 3.2.3.5 ICC Confirmation Tests in the ORNL FCTF. Depressurization j
tests of the ganna thermoneter will be conducted in the FCTF, which is capable of simulating pressure, tenperature, and flow conditions typical of a large PWR reactor during a small-break event.
4 P
- _-___.___.. ,__ .._ ... m._-.,. . . . _ - . . _ . . _ . _ . _ _ _ _ , . ~ , - - - _ , - . _ , . _ _ , _ _ . . - . _ . _ - _ _ . ~ . _ - _ _ - . . ~ .
3-16 "E.
T JACKET TUBE MECPMICAL SEAL MAN 0 METER ANNULUS r -- CORE TUBE
/
- O ~
/
- - c CABLE PACK
/,
~
' ' VEL SENSORS .
N~
+ DETACHABLE MANOMETER TUBE N N h
4
_ + EQUALIZ:NG PORTS l
(
4 L
Y i
l D~
l-Figure 3-3. !!anometer Tube Desion, ANO-l.
i l
I i
i 31190A04
..c , . _ . , . _ - _ - . . , . - . , _ _ . - , _ - _ - - - - - _ . - - - _ , , . - . _
y ) 4-
,p ,4 -, -
g ,.
it
\1 .
. 'm T
! >i Tt s t i s N
\
\ ,
, vr
. i Y ~'
, l - 3-17 s "
The test facility (FCTF) is a high pressure, high temperature, forced circulationwater,lochconfiguredasshowninFigure3-4. The' loop can s s. '
be, operated at pre-blowdown ~ temperatures up to 650 F at 2250 ps'ig,* with i ;
a' water flow through theft est section of up to 112 \gpm at variable test
)
section power inputs up to ~ 140 kW. All necessary plumbing, heat
's transfer equipment, instrumentation, and controls for leop ce"eration are
, t in place. However, the test secti6n'wili'be modified Eo inco?porate the
, _i RGT and fuel pin simulators. i
,V .. t
- } In order to onductthehotcal[brationofthegammatherm3meterasa leved.probh and an in-core probe, it wiil be necessary to make certain s.
1 modificatiens t(the test section. A Ceramaseal penetration iill be
\ ., u '; ;- ~
adied th the upper f]ange to allow juule heating of the body' of the a
X e gamma.thermomete? 'and the fuel pin simulator bundle.
4
- i. o
. 3 Instrumentation, identical or equivabnt in precision and accuracy to ,
that used in the RGT cold calibration process, will be used to measure l power to the internal heater, current during joule heating, voltage drops, temperatures, and tenperature differences.
The first program objectives to be accomplished with fabrication and
' installation of the prototype probe in the FCTF are:
~
- Tne loop can be operated at much higher temperatures with reduced pressure. The RGT probe is expected to see maximum local temperatures during FCTF blowdown of ~1000 F. Separate ef fects test on probe and thermocouple w111 be used to demonstrate probe survival at much higher l
temperatures t~ nan 1000 F.
i l
1
e 3-18
- 'si?
A
=
- - w w %
LOW HIGH E PRES $URE LOOP PRESSURE LOOS c:;
' m w
C C.
m m
M c .m- '8 we I I 5w I 'l I HEAT T w"
=s
~
+ (( EX:H/LNGER )
FLO O 7dN LINE E - d
,1, W Di =
- i i. ec E i_,-
j _ e, re _
v
[ _ _ _ _l E l DRAG ::sKs
- I u.
- m
" d :ENSITDM.ETER y l l 5
m Ci' 4 i g z'i'i 4
=
5 5 e I !
~
-9 20 e.pm _e $2 c.m.
~,
e u ea ---
5 e 5= -
= .
l , l-<-
i : -
I A
! F I
L f~ to: 2 I
. ..y l
=
a . v. . LJ 1 5 I :12 gr u
...- a w
. g 5 _.-
l 5
- ~
- 00 ;r i
t
- Fi gu re 3-4. ORfiL Forced Conve
- tion Test Facility Schematic. ,
f I l
, i i
l
. _ _ _ - , _ _ _ _ _ . . _ _ _ _ . _ . . . _ _ _ _ . _ _ . - _ _ _ _ _ m. , , _ - - , - _ - _ _ . . - - _ _ . . _ . . _ ,
3-19 e Demonstrate that a single gamma thermometer probe capable of measuring local reactor power can provide absolute temperature and vessel level measurements during a small LOCA.
e Show that the prototype gamma thermometer can readily be installed in a similar reactor test facility, and build a proto-type design operating history.
After installation, the FCTF testing program will accomplish the following objectives:
e Demonstrate that the prototype gamma thermometers can supply measurements to provide effective ICC monitoring of the entire reactor vessel and hot leg stillwell.
e Provide data to determine the boundary conditions on unambiguous gamma thermoneter ICC monitoring performance - depressurization rates (break size), flow rates (pumps off sensitivity), and refill repressurization.
e Confirm that the absolute temperature measurement provides a good indication of coolant temperature above and in the core in an ICC event, and obtain data on how closely this reflects fuel cladding temperature.
e Obtain data to help confirm that the gamma thermometer can moni-tor effectiveness of natural circulation cooling.
e Provide data to select the optimum sensor types and arrangements in the gamma thermometer probe for ANO-1 and -2.
i, The test plan will meet these objectives by allowing flexibi'lity in the test sequence to incorporate the results of the air-water testing and the initial depressurization tests. This flexibility is required by the l
Phase I and II program schedules and the feedback to the design process and sensor selection process that the testing provides.
Initial testing in the FCTF will provide baseline data on the gamma thermoneter probes' performance in a reactor-like environment, including
3-20 heatup data and flow sensitivity. After heatup, a depressurization test will be conducted. The rate of depressurization selected will be deter- .
mined using small-break LOCA requirements and the results of the air-water tests of.the gamma thermometer sensor types. The addition of reflood-repressurization testing is included. This sequence will provide upper plenum ICC and hot leg confirnation testing of the gamma ther-noneter sensor types along with the absolute thermocouples. Subsequent depressurization testing of this instrument configuration, varying depressurization rates, and, if necessary, the initial conditions and small levels of core flow will provide the boundary conditions for unam-biguous ICC monitoring in the reactor vessel upper plenum and hot leg.
^
Following the upper plenum testing, the most p'romising sensor con-
. figuration will be selected and installed in the core simulator bundle for in-core,1CC performance evaluation.
Testing will determine the relationship between probe absolute tem-perature measurement and simulator clad temperature, and demonstrate the probe's natural circulation monitoring features. Similarly, the rela-tionship between RGT heat transfer behavior measurenents and fuel rod simulator heat transfer conditions will be characterized to demonstrate the RGT's ability to determine ICC. Accuracy of heat removal rate data will also be evaluated along with low flow sensitivity, if required.
I In-core simulation testing will follow the same sequence as the upper l
l plenum testing. The test sequence will determine the effectiveness of i
! in-core ICC monitoring, subject to initial conditions and boundary
\ l t
conditions selected from the data obtained and lessons learned in the
{
upper plenum probe tests. Table 3-1 provides the general test sequence.
3-21 3.2.4 Pretest Analysis of Sensor Designs To determine the design parameters of the RGTs, existing multidimen-sional transient heat transfer codes in conjunction with the confir-matory tests will be used. These analyses will be used to characterize the behavior of each of the sensor types shown in Figure 3-2 in terms of heat transfer characteristics, sensitivity, and response time.
3.2.4.1 General approach. Thermal-hydraulic analyses of the expected test conditions will be performed with the RELAP-5 code, and heat transfer analyses of the gamma thermometer will be performed with the HEATING-5 code or equivalent. All results obtained from the codes will be verified by comparison to baseline test data.
3.2.4.2 Air entrainment test evaluation. The first step in the air entrainment test evaluation is to apply a two-dimensional R-Z HEATING-5 model or equivalent for the RGT sensor region. This model requires definition of the heat transfer conditions present in the air entrain-ment loop, which involves correlating the convective surface heat transfer coefficient to air void fraction. This will provide confidence in the prediction nodel for pretest analysis of the depressuriza' tion tests. A limited set of baseline analyses at zero void fraction and analyses of selected void fraction tests is planned. This will verify the HEATING-5 model and provide an additional check of hydraulic con-ditions of the design. The manometer design objectives will be addi-tionally met as described in the following section.
Table 3-1 OUTLINE OF GAMMA THERMOMETER FROBE TESTING Test Location Sensors Conditions Variables Object i ve Separate effects TEC-ORNL Air-water test spect- As achievable, integra- Temperature, pres- To measure sensitivity mens and upper plenum tion with air-water and sure, flexure, EMI of gamma thermometer probe prototypes ICC confirmation testing probe to ICC ef fects Air-water ORNL atmospheric Single test specimens Air-water forced f low Void fraction, flow To verify manometer test loop of all f our sensor with pressure control rate, fill & drain tu be st i l lwel l per-types and manometer tube rate, loop pressure, f ormance, sensor design verification heater power response time, and specimens void sensitivity of each sensor type og 9
depressurization FCTF Upper plenum 8 multisensor proto- Initial: 2250 psi Depressuri zat ion Conf irm ICC measure-types of each sensor 590*F, rate, toop flow ments, level, temp, type: both Junctions struttaneous prototype determine boundary heated (SU), single test i ng, l conditions for unam-Junction heated, and depressuri zat ion, blouous ICC monitoring no annulus with single no core simulator Junction heated. Each prototype to contain absolute TC's in-coro wIth Dependent on test As above with core As above with core As above plus probe-simulator pins results simulator and simulated simulator heat test- coolant-clad temp.
core heat Ing (scope subject heat transf er charac-to previous test ter relationships and results) natural cire. or flow sensitivity if pos-sible.
! l l l l
3-23 3.2.4.3 Design evaluation. The manometer-probe gap design will be evaluated relative to the expected in-reactor and in-test conditions.
4 This analysis will determine how the gap design affects the instrument's performance in single-phase as well as two-phase conditions. This eval-uation will be performed for both the ANO-1 vessel and hot leg and ANO-2 vessel type prototypes.
, 3.2.4.4 Depressurization test analysis. The first step in the l depressurization test analysis is to upgrade the RELAP model for the FCTF. This includes a brief review of past analyses of the facility for the ability to predict the various flow regimes. The RELAP results will be calibrated by evaluation of heater rod measurements.
Next, the RELAP code will be applied to each of the 12 selected depressurization transients (six in-core and six above-core), and the results will be used as boundary conditions for the HEATING-5 analysis j of the RGT response. The predicted response of the RGT to each of the 12 depressurization transients will be compared to actual test data, and any discrepancies will be resolved or further model refinement performed, if required.
The comparison of the test results by analysis and the repeatability of i the test results will meet the objectives of demonstrating the ability of the probe to neasure vessel level unambiguously, as well as clearly indicating the approach to ICC conditions for the expected range of con-ditions in a PWR.
4 f
3-24 3.2.4.5 Summary report. A report will be prepared which summarizes all aspects of these analyses, including model development, test results, conclusions, and recommendations.
3.2.4.6 LOCA licensing analysis. An analysis of the response of the probe to a series of ICC transients for each reactor unit (AN0-1 and -2) i is proposed. This analysis is not necessary to demonstrate the ability i
of the probe to discriminate between heat transfer or flow regimes, rather it would demonstrate the time at which the probe would provide a clear indication of the approach of ICC conditions for ANO-1 and -2. It is assumed that the results of a best-estimate, small-break ~LOCA analy-sis are available for each plant used for the demonstration.
3.2.5 Documentation At the end of the Phase I test program, a " quick-look" report will be l
prepared to provide a timely sunnary of the Phase I testing efforts.
l The report will assess the RGT's performance as an ICC monitor, and pro-vide early recommendations resulting from the design and testing efforts of Phase I. This will allow APSL additional review time of the Phase I progran results or an opportunity to commence with the Phase 11 program with a minimun of delay.
All test sequences and test data will be assembled as a final overall i
i test program report. Each test will be described in detail. The test sections will include the following information:
l
3-25 e Test objective i e Types of sensors to be tested i
i e Number and types of tests to be run, along with system diagrams j of the test setup I
e Acceptance criteria e Critique of test results e Recommendations
--Additional tests 4
--Design changes
--Continue to next test The summary report will also include recommendations covering Phase II design considerations and functional requirements for an RGT ICC moni-i toring system. The recommendation section will also address lessons learned that apply to system requirements for the following items:
e In-containment design (ANO-1 and -2)
!' e Designation of independent safety trains / channels (ANO-1 and -2) e Power sources e Signal conversion / transmission considerations a
! e Display formats and methods for 1E and non-1E displays e In-situ testing and calibration e Sensor location in the ANO-1 vessel and hot leg, ANO-2 vessel e Mechanical design considerations for in-reactor installation ANO-1 and -2 s Plant ERF computer interfaces i
l i
i
+y+ewep-- >----P-e-----p-p%-., ,--mee--------ww-m-mww g y 3-n-- , ,- c -----------w-%w,cw-,g.,p-wpi-,,,v 7 y-n-- r-wwti--, ag- -wesweg- y em.w-ge vew ww4-- p *e Mt
. .. _ .= - - - . - --
- 3-26 AP&L will work with reactor vendor personnel to resolve unit-specific requirements which are unique to the reactor type as well as to the facilities design. Additional reconnendations can be developed for integration of displays into the ANO control complex. This effort would be directed by credible human factors engineers, either employed by AP&L or subcontracted. All display design will be factored into the control roon design review effort.
1
- 3.2.6 Licensing Submittals Three steps in the licensing process are anticipated. Step 1 is to pre-pare and submit the confirnatory test program plan to the NRC and to receive approval fron NRC for scope of the testing program. Step 2
- would entail preparation of a draft report upon completion of the con-firmatory test program, meeting with the NRC if needed to review the
! preliminary results, and then preparing and submitting a final report.
\ .
Step 3 is to prepare and submit the final design description of the ICC monitoring system, including plant-specific information, and to receive i
approval from NRC for the final design.
! The confirmatory test program plan submittal will be of sufficient detail to demonstrate to the NRC that the test program is adequate and that the results of the test program will demonstrate conformance to l appropriate NRC regulations and criteria.
The Step 2 report will consist of two basic sections: (1) results of l the confirmatory test program, and (2) conformance of system and con-ponents to appropriate criteria, i
i i
3-27 3.3 SYSTEM DEVELOPMENT AND COMMISSIONING 3.3.1 Phase II System Detailed Design Specification The final functional design specification developed in the prototype testing phase will be used to develop a detailed design specification for the ICC system to be installed in the AP&L reactor vessels. The design effort will make use of the integrated RGT ICC monitors. The system design specification will be directed toward a simple, straight-forward installation in the plant with a minimum of retrofit and reactor internals modification. Documentation of the ANO ICC system will be accomplished through the detailed system design specification, which will be maintained under normal engineering procedures. The system detailed design specification provides the mechanism to guarantee that the system will perform the proper function and accomplish the ICC noni-toring goals for licensability and successful operation.
The following outline provides the general configuration of a potential system design specification including other system specification documents--the integrated fabication-testing plans, the quality assurance plans, and the detailed component specifications.
i
(
Modifications will be made to the system detailed design specification i
to account for the differences between ANO-1 and -2. The specific installation requirements for each reactor will be identified in the j specification.
l l
I - - - . - - - -
4 3-28 i TEC plans to design the ICC monitoring system as two independent chan-
- nels of instrumentation even though the ANO-1 system will have two to 1
four vessels and two hot le; RGT rods versus two RGT rods in ANO-2.
I Therefore, all in-containment designs for each reactor type will be dif-i
! ferent in physical configuration, with the signal processing and data i handling systen being identical for both reactor types.
i PHASE II SYSTEM DESIGN SPECIFICATION OUTLINE j I. FUNCTIONAL SPECIFICATIONS AND GENERAL SYSTEM DESCRIPTION II. RGT PROBE A. THERM 0 COUPLES
- 1. Dimensions
- 2. Materials
, 3. Detailed junction requirements
- 4. Resistance--leads and insulation
- 5. Mechanical constraints and performance B. HEATER CABLE
! 1. Segmentation requirenents
. 2. Dimensions
- 3. Materials
- 4. Resistance--heater and insulator
! 5. tiechanical constraints and performance
! C. RGT INTEGRATED FABRICATION AND TESTING PLAN
- 1. Swaging
- a. Steps--reduction
- b. Tooling requirements i
i c. Assembly--pressurization and annealing
) 2. Testing
- a. IR and lead resistance
- b. Surface requirenents l
I l.
I a
i
,--,-e, ,,-.-en--+-mm-,-mm-,-- v.--r-,-->--x- ,,,-wwm~e, m gaemm -y~.. -c-a
3-29
- c. Cleanliness requirements
- d. Mechanical performance
- e. Dimensional inspection techniques
- f. Radiography requirements
- g. Documentation requirements
- h. Leak testing--fill testing
- i. Storage / shipping
- j. Response testing
- k. TC calibration requirements
- 3. Materials Certification - QA Plan
- a. QA plan with naterial certificates
- b. Applicable specifications
- c. Traceability of testing equipment
- d. Certification of fabrication technicians
- 1. Configuration
- a. Thermocouple quantities
- b. Thermocouple locations
- c. Dimensions
- d. Materials
- e. Mechanical requirements and performance
- f. Electrical requirements and connector configuration 9 Manometer requirenents
- 2. Assembly integrated fabrication and testing plan
- a. Swaging
- 1. Steps--reduction
- 2. Tooling requirenents
- 3. Assembly requirements
' 4 Annealing I
- b. Testing
- 1. IR and lead resistance
- 2. Radiography requirement
- 3. Cleanliness requirements
- 4. Mechanical performance
- 5. Dimensional inspection techniques
- 6. Infared scanning requirements
- 7. Leak testing I 8. Calibration documentation
- 9. Storage / shipping requirements
- c. QA Plan
- 1. QA plan
- 2. Applicable specifications (if any)
- 3. Traceability of test equipment 4 Certification of technicians (fabrication)
- 5. Certification of technicians
- 6. Certification of QA inspectors
3-30 III. CABLE A. CONDUCTOR DIMENSIONS B. CABLE MATERIALS C. MAXIMUM LENGTH D. NUMBER CONDUCTORS E. CABLE CONNECTOR CONFIGURATIONS (EACH END)
F. APPLICABLE SPECIFICATIONS G. ENVIRONMENTAL REQUIREMENTS H. RELIABILITY / LIFETIME I. SHIELDING AND GROUNDING REQUIREMENTS / CONFIGURATION IV. CONTAINMENT PENETRATION A. NUMBER PINS B. PIN DIMENSIONS C. CONNECTION REQUIREMENTS - (NO CRIMP CONNECTIONS)
V. SIGNAL PROCESSING SYSTEM A. TERMINATION
- 1. Connectors
- 2. Thermocouple reference junction
- 3. Differential TC termination B. ANALOG-DIGITAL CONVERSION
- 1. Resolution
- 2. Range-span
- 3. Speed-sampling rate
- 4. Common mode capacity
- 5. Surge protection
- 6. Thermal sensitivity
- 7. Auto ranging - autogain
- 8. Noise requirenents and input filtering
- 9. Data quality and error correction capability
- 10. Number channels
- 11. Size-weight constraints
- 12. Environment
- 13. Availability
3-31
- 14. Applicable standards
- 15. Open transducer detection--self-diagnostics
- 16. Heater-process control interface requirements
- 17. EMI immunity C. DATA PROCESSING / DISPLAY
- 1. Availability
- 2. Memory requirements
- 3. Software requirements 3.3.2 Sensor design and fabrication process. The basic sensor designs chosen from Phase I testing (see Figure 3-5) will be utilized in the fabrication of the RGTs for the reactor vessel monitoring system.
The sensors will be designed for both above-the-core and in-core deployment.
Generally, the RGT will consist of a thermocouple-heater cable pack, a core rod, and a jacket tube. The assembly will be swaged to form a monolithic stainless steel unit.
Sensor fabrication procedure. Even though the internals of the various designs shown in Figure 3-2 are different, the fabrication steps (with the exception of sone minor deviations) are essentially identical. For example, in Figure 3-2B the location of the thermocouple junction designated as TH ot does not have the same tight positional requirements as that of Figure 3-2A or C. The fabrication procedure discussed below is for the designs of A and C, and can be easily extrapolated to that of Figure 3-28.
Cable grouping. The thermocouples and the internal heater will be grouped together before insertion into the core tube. The heater dianeter will be based on the required number of sensors in a gamma thermoneter string. Typically, a cable pack array will be as shown in
3-32 G.T. CROS5 SECTION SWAGI JAW SCFIM;,T:C 1 I 1.15 O g g
h Ce
$ - + Wi=.52 D e 2.21 O g.
WT=WA'.L TH;;KNESS l
T I I LI_I
@i 2.22 O g 2.17 :,g i., T, f
,', 2.IEE 0 3 L
"f n , ,
7 II h' 2.2: :Cn&y ldki'
?.
2.25 :.s 2.1 :.
A A i ' i.
9
@v . , ,
a..a .; $~%^-
.1 i' i y, h 2.12 O g 2.C5 -
f i i A'-
i !
(y))- 2.06 0,
~
li 3*1FGAC1 F i gu re 3-5. Example RGT Fabrication Outline.
i i
l 1
1 3-33 0.020" 0.D.
.056" 0.D. DIFFERENCE (HEATER) THERMOCCUPLES
\
,A .
.096" 9
Figure 3-6. Exam:le Cab'c Fack Therm:: curie Groupir,g.
l j e 7
/
3-34 Figure 3-6. A consideration in designing the RGT is to maximize the number of cables (sensors) to provide a better definition of the measured parameters (e.g. , level). The number of cables is limited by RGT diameter. The RGT diameter is limited by the inner diameter of the manometer or stilling column (hot leg).
Core rod assembly fabrication. In the sensor designs of Figure 3-2A and C, the hot junction location specification relative to the center line I
of the gas chamber is expected to be 0.025 inch. Tabs identifiable with x-rays will be placed at lower positions on the follower ends of the thermocouples to provide clear and unambiguous dimensional reference points for locating the hot junction of thermocouples. Experience has shown that, for a given mechanical interference between the cable assembly and the core tube inner diameter, there is a predictable amount of linear elongation of the core tube which can be compensated for in the assembly of the cable pack. The previously mentioned tabs will be used to provide verification of the elongation of the core tube. The fabrication swaging steps for assembly of the core tube are shown in I
Figure 3-5, along with the core-jacket tube swaging steps. The swaging steps presented in Figure 3-5 hold for sensor strings with and without l gas chanbers. In the final swage of the jacket tube onto the core rod, a uniform nechanical interference between then will be achieved.
Tne actual assembly process is composed of a series of steps involving resistivity measurements on both raw tube stock, assembled components, l
f and QA checkpoints. A generic assembly process is discussed below, f
d 3-35
- Assembly fabrication process. The fabrication process followed during the manufacture of the RGTs will be in accordance with well-defined i
procedures. An example of the first step of those procedures is as follows:
Step 1. Assembly of Gamma Thermometer o Clean with triclene, and inspect all stock materials.
- Perform resistance and mechanical measurements on tube stock.
' e Perform loop lead-to-sheath resistance measurement on thermocouple.
e Attach tabs to follower end of thermocouple for use as reference marks to aid in the location of hot junctions, i
' e Assemble thermocouples and heater into cable pack.
e Perform in-process inspections, e Assemble core tube and cable pack.
e Swage core tube onto cable pack, o Perform core rod resistivity mechanical measurements at five points on core rod.
- Perform in-process x-rays to determine hot junctions' locations using platinun tabs as references.
e Machine gas chamber annular rings, and inspect core tube assembly (step not included in fast heat transfer sensor design).
- Perform resistance and nechanical measurements on core tube assenbly.
e Dry jacket tube with argon bakeout at 356 F.
e Assemble core tube assembly and jacket tube, e Perform final assembly of gamma thermometer.
i e Perform in-process inspections and resistance mechanical neasurenents on finished ganma thermoneter.
j e Weld end plug and forward end of active portion of gamma thermoneter, and inspect welds.
1
. - . . ._ .. _ . ~ . _ . _ . _ _ _ . _ _ _ _ _ . . . _ _ . - _ _ _ . . _ _ , . _ . - - . _ _ . _ _ _ _ _ - .
]
3-36 e Stress relief anneal.
o- Calibration: joule heat 4ng.
e Return to ORNL for high depressurization and void entrainment.
Each of the major process operations will be subdivided into further process operations.
For example, in the assembly of the cable pack the steps will include:
o Clean with triciene and inspect all stock materials.
- e Inspect thermocouples
--Loop and insulation resistance checks to verify vendor's materials properties measurements, i'
--Junction location verification,
--IR scan of the heater, and
--Weld tabs onto follower sections.
i Nanometer designs and fabrication. In the case of the ANO-1, the in vessel manometer will be made as an integral part of the level-indicating RGT unit. The manoneter tube will be fabricated to be mechan-ically mounted on the RGT unit designed for collapsed level indication.
l The annular clearance will be designed based on the results of thermal hydraulic analyses from Phase I. Figure 3-3 shows a schematic drawing of a RGT manoneter tube arrangement.
For ANO-2, the manoneter tube will be the existing in-core instrument thimble. However, the RGT will have been properly sized during Phase I j testing to ensure optimun annular spacing.
! i 1
i
3-37 RGT standoffs between the RGT assembly and the manometer will prevent manometer-to-sensor contact. Orifice spacers will also be provided to hydraulically isolate the dome monitoring section of the manometer from the plenum section.
ANO-1 Hot Leg Stillwell The RGT probe and stillwell for each hot leg will be seismically sup-ported. The stillwell will be designed to meet the requirements of ASME Section III. All pipe or tubing hangers and supports also will be designed to withstand expected thermal and dynamic loads.
3.3.3 Data Acquisition Hardware Development and System Description The data acquisition hardware development effort of the Phase II reactor vessel monitoring system program will provide a qualified, highly reliable system fulfilling the requirenents of the system design specification. A detailed system design specification for the data acquisition system will be developed. Af ter the detailed system design is finalized, the system integration effort will begin. This effort will result in a verified system that will be acceptance tested t '.d shipped to ANO.
The following is a conceptual system configuration. The expected system scope will include the following features:
- LOCA-resistant connectors at the gamma thermoneter and at the reactor containnent penetration.
o Waterproof conduit (SS) between connectors, with flexible (SS) hose connection to each connector.
3-38 e Radiation-resistant (cross-linked poly) insulated thermocouple extension wires for the in-containment section between connectors.
e Two independent channels with noncommon fault redundance for-each reactor, using TEC 600 Data Acquisition and Display System Electronics with serial communications to the host computer.
e Optional nonqualifiable redundant circular data storage up to several hours.
1 e Optional data readout, graphics display, and circular ' data storage.
Each part of this scope is discussed below.
i .
i ANO-1 Reactor Vessel Monitoring System RGT units. The ANO-1 reactor vessel monitoring system consists of six gamma thermoneters, which can
- be thought of as two pair, each pair comprised of one top (done and i
plenum) and two bottom (in-core) gamma thermometers as shown in Figure 3-7. The above-core units have a built-in manoneter tube to provide '
collapsed level. Each gamma thermometer probe has its own connectors; i
i the containnent heater leads and thermocouple extension wires are run through conduit. Cables for each channel will pass through one reactor containment penetration and into a data acquisition and display system.
. The above-core gamma thermometers each are expected to have nine differential thermocouples (6T, TCs), one absolute thermocouple (ABS TC), and two heater leads. Cables for these probes will require ninteen alumel leads, one chronel lead, and two copper leads. The in-core units each are expected to contain five differential thermocouples, and four i
absolute thermocouples, and require cabling of fourteen alumel leads, i four chronel leads, and two copper leads.
i e
t
_v--y,9,n-. ,., .
yre,,.,m , .-~~r. . . - , -,.m , ,..,_r,,,,,,me,. .,m__,,_ _.,m_.y._,,e -er.__w m-
f*i, i;h!!i M
S6NAL PROCESSittG 3' wTOP c - ll)ms // mnO- 2
'e // ___ruc+0__lf2J Illa..
- g.,gg c__- .
g -
w ( ~ {xa //~ XIW(}r '
- IlOT LE6 ( "
llMW -// :X0:'.{]- // GAMMA EE TilERM0 METERS -- - J {- !/
- 5. ? -- Sl6tlAL SEttSOR ITNE1RATON // _
B~ TRAtiSMISSON ELECTRICAL litTERFACE // DISPLAYS INTERFACE /' Q m- "A SENSOR Coll!!ECTJR _ ,c [g -
~~
/p
^-
- fiTRING - ,
, e SIGNAL
$g l PROCESSING ";-. $ ' ll}733:Z// ~ ~~' nM-{lZ :
--- T O P (
'IIm m- Il- w = 0 =ifZ) : g
[g gngy cuaB=g x "' oa r tilma=ll o] llOT LE6 c___.._.._ f(J}sWW/__am{]=\"Zl- I fh QE3 UN RE RY
-- 1000 rr --yf-- . mori-f en1inc,s Ois,uss
.i O 8 - CABINET g I - 1f tSIDE CONTAINMENI --- ------- ~ ~ OUTSIDE CONTAINMENT CUtllAINMENT k/ALL
'l 4 3 3-40 ANO-1 Hot Leg fionitoring System RGT Units. The ANO-1 hot leg monitoring system is expected to consist of a single probe for each of two hot leg stillwell columns. The hot leg monitoring system probe is expected to f contain 15 differential thermocouples, one absolute thermocouple, and a single heater. Each hot leg will tie into a channel of the reactor vessel monitoring system processor. Thus the ANO-1 ICC system will con-sist of two channels, each with one above-core probe, two in-core probes, and one hot leg probe. Cable for each hot leg probe will consist of thirty alunel leads, one chronel lead, and two copper leads. ANO-2 Reactor Vessel Monitoring System RGT Units. The reactor vessel monitoring system consists of two gamma thermometers, each identical but in independent redundant channels as shown in Figure 3-8. The RGTs make use of existing instrumentation thimbles. Each unit is designed to cover done, plenum, and core regions. Each gamma thermometer has its own multipin connectors, which are connected via flexible conduit to raceways running to the reactor containment penetration, employing an ! identical connector as used on the gamma thermometer. Each cable will 4 contain the thermocouple lead wires and heater wires for one gamma thermometer from each ANO-2 type RGT probe. There is expected to be ten differential thermocouples, four absolute thermocouples, and one pair of heater leads in each cable bundle. This requires twenty-four alumel i leads, four chronel and two copper leads. I I For each gamma thermoneter, these leads will pass through a reactor containment penetration to a data acquisition and processing system.
- - _ - - - - - - . _ . . . _ _ . -_ . _ . ~ - _ _ _ _ _ _ . _ . _ . - _ - _ _ _ _
/
SIGNAL n ir -
/ PROCESSING
( WM
~
1 ZL. fXX iI
- ,s II l
'g h
/ CORE -
GAMMA -- - , ._ EXIT T/C'S
, s THERMOMETERS SENSOR ELECTRICAL PENETRATION w INTERFACE INTERFACE 5 CONNECTOR DISPLAYS SIGNAL -
4 {$ - SENSOR STRING __ __ TRANSMISSION _ _ .
- 3 ~4 AS CORE i ' / EXIT T/C3 A SIGNAL
$5 } .
_ l ,J M 4 2X*X
//-
Z PROCESSING s H "1
~f/
/ I
- Rg PRESSURE ~
y{ BOUNDARY FITTINGS 1000 FT4 - - - 500FT-- 0 - ca 2 l DISPLAYS i 5s g . 4 1 - a lC CABINET
/
i
~
INSIDE CONTAINMENT r * -ot/TSIDE 0]NTAINMDVT CONTAINMENT WALL a
3-42 Connectors. The maximum nunber of leads required is 34 for the ANO-1 hot leg nonitoring system version gamma thermometer probe, which is the limiting case cable configuration. Hence, a connector having a hexagonal close-pack arrangement supplying 19 pair (38 leads) was selected. This connector arrangement allows several spare pins. The ANO-1 probe will use the same connectors. Three companies, ITT Cannon, Veen Litton, and Kyle Technology Corporation, have been selected as possible vendors whose connectors can withstand the LOCA conditions in containment. The connectors will be selected to ensure waterproof seals to the gamma thermometer. Signal processing. The signal processing system is expected to be the TEC Model 2200 Isolation System which consists of a TEC Model 1480 Isolation Module Bin, a TEC Model 963-1 Isolation Bin Power Supply, and a thermocouple cold junction reference. These are shown in Figure 3-9. This TEC 2200 Isolation System will be mounted in a TEC Model 158 Seismic Cabinet. The thermocouple signals will be amplified about 1000 times to a 0.10-volt range for up to-16 channels in four TEC flodel 980-0 Analog Signal Isolators. Anplifiers. The absolute temperature thermocouples will be terminated at a cold junction tenperature reference, allowing the data acquisition system to compensate for changes in cable and cold junction temperature. This reference junction will be located in the same TEC 1480 with the TEC 980-D, along with a TEC Model 963-1.
c . w 3-43
^
+# TEC 158 CABINET -
t
.}:T 7 ,
~
PWR. SUPPLY DC FLOPPY DISC FLOPPY DISC. 1 (OPTIONAL SEPARATE CRATE FOR NON-QUALIFIEDf ITEMS) SIGNAL CONDITIONING AND ISOLATION (TEC 2200 SYSTEM) f MODEL ',4SO CRATE r TC - AMPLIFIERS
- TC RE F. ,
9800 980D 980D SBOD COLD JUNCTION 4 963-1 POWER SUPPLY - - - DATA ACQUISITION AND DISPLAY (TEC GOO SYSTEM) r C M S P* P' P* GOi P E C M M M IND ' U M C > POWER SUPPLY HEATE R HEATER POWER ?OWER SUP' PLY SUPPLY Applicaticr. Cepencent--actual number varies. Figure 3-9. ANO 1CC Reactor Vessel Monitoring System Cabinet Layout v --- - , - - . .n, , - , .-7-.--w,--w--- - - . - - . , ---,m--.- py-,-,. , . - - , - - . , . - -,-w--- . , ---w- .--%---7.. w--
J 3
% 1
- 3-44 Pr'ocessing of existing core exit thermocouples for ANO-2 can also be included with this systen. These thermocouples will be processed using
^
additional Model 980-Ds. Data acquisition will be through the system as discussed below. w Data-Ac3uisition and Storage. The data acquisition and storage unit is expected to be a TEC Model 600 which is a microprocessor-based data acquisition, data proce'ssing, data display, and control instrument. An additi5nal feature of the TEC 600 is that it can function in either a stand-alone mode or as a unit that communicates to a host computer. Since the TEC 600 is of modalar design, it can be configured to a specific system's ' requirements by utilizing ~particular combinations of its standard nodules. A typical block diagram is shown in Figure 3-9. The menory function'of the TEC 600 has built in the capability to
- electronically erase stored constants on command. This is a very useful feature during calibration and any future recalibrations.
The TEC 600 seismically is qualified to the IEEE Standard 344. It is also environnentally qualified to the IEEE Standard 323. 3.3.4 Software Development - Basic Functions Sof tware will be provided to acquire, process, and display data from the ICC sensces. The software will sanple signals from the absolute and differential ,thermocouples of the RGT sensors once per second. Heater current and reference junction temperature will also be sampled once per second. The raw data will be used to compute the heat transfer g - -_
3-45 coefficient at each differential thermocouple and the temperature at each absolute thermocouple. In addition, the input data will be validated by simple range checks on absolute value and rate of change. The final function of the data acquisition software is to update trend buffers in which the last 60 ten-second averages and the last 60 one-minute averages are maintained for each thermocouple input. Data processing involves six functions:
- 1. Estimate collapsed level using above-core RGT differential thermocouple data, 2.. Process data from the uppermost in-core RGT differential thermocouple for recognition of the "uncovery signature,"
- 3. Present coolant heat transfer trends above and in-core, 4 Conpute shutdown power from the in-core RGT sensors on operator request (heater turned off),
- 5. Calculate absolute coolant temperature distribution both above and in-core, and
- 6. Alarm checking and generation.
Alarms will be generated for the following conditions:
- 1. High absolute temperature,
- 2. Low heat transfer coef ficient,
- 3. Low collapsed water level, and
- 4. Core uncovery (determined by uncovery signature).
Two devices will be provided for operator input and data display. The primary device will be the safety parameter display synten (SPDS) computer displays. The backup display is expected to be a TEC Model 601
3-46 that has four 16-character lines available for display of alphanumeric data. Two lines will be used for display of input or computed parameters. The other two lines will be used for operator dialog. Currently displayed parameters will be dynamically updated. In addition to display callup, either display device will allow the operator to perform the following functions:
- Modification of selected calibration constants (under pass-word control),
e Modification of setpoints (under password control), e Heater control, and e Initiation of automatic thermocouple calibration checks. 3.3.5 System Acceptance Testing Overall systen acceptance testing will be performed in two stages. In the first stage, the data processing hardware and software will be verified using simulated input signals. Static and dynamic test cases will be defined to exercise all the functions described in Section 3.3.4. This stage will be deemed a design qualification test for the data pro-cessing subsystem, and will be performed for one channel configured for ANO-1 and one channel configured for ANO-2. l In the second stage, the sensor strings will be cabled into the data 1 processing subsysten, and the complete system will be checked out. In this test, the sensor strings will be tested for accuracy and time l l l l
3-47 response in TEC's flowing water loop where sensor calibration is normally perforned. All essential systen functions will be verified fron sensor to display. 3.3.6 Documentation and Trabiing 3.3.6.1 Documentation. A documentation plan will be prepared prior to Phase II. The documentation plan will contain a list of all required documents, a detailed description of each, and the production schedule for each document. This plan will be used to track the development and review status of all documentation. All documentation will be tracked carefully to maintain AP8L review status and scheduled milestones. The following documentation will be developed to provide sufficient information for the installation, operation, and maintenance of the AN0 ICC systen for Units 1 and 2: o Project plan s QA plan e Equipment qualification environmental report e Systen operation and naintenance manuals covering
--introduction
--theory of Operation
--operating Procedure
--naintenance
--installation
--specifications e Interface drawings ,
e Systen drawings e Components drawings 3.3.6.2 Training. The training programs for the RGT based ICC systen will be closely integrated with the operating, progranning, and main-tenance manuals. Each training course reviews and uses all appropriate
. - _ ~ -. _
3-48 manuals to ensure trainees are familiar with them. Training courses simulate expected plant and system activities, including failure modes to the extent possible or practical. On completion of the courses, eval-uation forms are employed to ascertain the trainee's comprehension of the course materials. Three separate training programs are proposed for system operators, personnel responsible for systen hardware maintenance, and personnel responsible for system software maintenance. These courses will be taught immediately following the factory acceptance test. Operator training. This is a multipurpose course designed to provide a general system overview from an operations standpoint. Block-diagram-level discussions of system architecture, system configuration, system startup, and alarm presentation provide the knowledge required to operate the systen from any operator device. Course curriculun also includes system-level tr.oubleshooting. Prerequisite: A basic knowledge of the system functional design. Objectives: Upon completion of this course, the trainee should be able to:
- Describe the operation of the system.
e Describe the configuration of the system, e Recognize systen operational problems.
- Troubleshoot systems to a subsystem level.
e Describe operation under various partial failure modes.
3-49 Content: Exact course content will be determined during Phase II. Duration: Course duration will be three eight-hour days. For maximum effectiveness and hands-on use, a class size of five and no more than ten is expected. The operations and maintenance manuals will be used as training manuals. Hardware maintenance training. This course will provide the trainee with an overview of the configuration and communication logic of the system, followed by intensive training on system maintenance, troubleshooting to a component level, and diagnostics. Emphasis will be placed on the actual hands-on skills required for these areas. Prerequisite: A basic knowledge of logic operations and devices. Objectives: Upon completion of this course, the trainee will be able to: e Describe the configuration and communication logic of the system. e Demonstrate system naintenance precedures, o Denonstrate procedures for troubleshooting to a component level. e Denonstrate procedures for performing diagnostic tests. Content: Exact course content will be determined during Phase II. Duration: Course duration is expected to be three eight-hour days. For maxinun effectiveness and hands-on use, a class size of five and no
3-50 more than ten is expected. The operations and maintenance manuals will be used as the training manual. Software maintenance training. This course will provide the trainee with an overview of the total system and the system software intervals. The system software architecture and data base philosophy will be cove red. Prerequisite: A basic knowledge of programming Objectives: Ability to operate all modules of the software progran Ability to run system diagnostics. Troubleshoot software problems. Content: Exact course content will be determined during Phase II. Duration: Course duration is expected to be two and one-half days. The class should be limited to four trainees. For maximun effectiveness, the operation and maintenance manuals will be used as the training nanual. i 1 I
- 4. QUALITY ASSURANCE Tne ANO ICC system shall be manufactured under the controls of the TEC Quality Assurance Program. This program addresses the requirenents of the American National Standards Institute, ANSI N45.2-1977 and sub-sequent, applicable daughter standards, and Title 10 of the Code of Federal Regulations, Part 50, Appendix B (10CFR50, Appendir T).
TEC is a sustaining member of the CASE Association, in which its repre-sentative, E. W. (Ted) Lyon, Jr. , TEC's Corporate QA Manager, is the Vice-Chairman of the Nuclear Section's Operations Committee. TEC has recently been submitted to the CASE Register by Consumer Power Company as a supplier found acceptable and implementing the QA requirements of ANSI N45.2. . . ~ TEC will apply the aforesaid QA program during the manufacture of the test specimens and during all phases of testing and IE qualification. Furthermore, this QA program shall apply to the nanufacturing and testing of the deliverable ANO ICC system to Arkansas Power and Light. The QA Manual, Corporate Engineering Procedure CEP-106, " Software Design and Control," and lower-tier departmental procedures will be implemented for the control of all software /programning work. In addition, qualifi-cation plans and procedures for all verification and validation requirenents and hardware qualification efforts will be documented. Qualification test reports will be provided with the docunentation. 4-1
4-2 All shipping, packaging, and handling will be performed in accordance with ANSI N45.2.2, Level B. Further details are in TEC's Corporate Quality Assurance Plan and Quality Assurance Manual. The QA Plan is available upon request. I i
sensors can be fabricated to have nearly identical sensitivities and that the sensitivity can be accurately determined before the instrument is installed. Table A-1 shows typical calibration data for several of the Ed~ Radcal strings. These calibrations were performed under reactor conditions in a hot, pressurized test loop at Renardier. As shown, for all of the sensors in these early production Radcals, the standard deviation is 3.0%. For maxin;n accuracy each sensor has its own calibration curve. However, since all sensors can have virtually iden-d tical sensitivities, there is a potential for simplifying the processing of RGT signals by using a single calibration curve. In the EdF installations, the RGTs replace traversing in-core probe (TIP) flux thimble tubes which normally provide access for reveable fission chambers. The evaluation of the RGTs includes comparisons of the RGT measured power to that obtained from a TIF in a symmetric assembly. Figure A-4 shows a typical comparison. Data processing routines, developed by EdF, have been used to reconstruct the axial power shape f rom the nine discrete RGT measu renents. The agreement is excellent, and the RGT provides the advantage of continuous, rather than periodic, axial power shape measu rements. The response time of the Radcal gamma thermometer has been shown to be greater than the response time for fission chambers but less than for self-powered neutron detectors (SPNDs). O ^-7
Table CALIBRATION DATA FOR EdF RADCALS (ASSUMES liANDB00K VALUES FOR ELECTRICAL RESISTIVITY) ____ __________. .________ ____ _ ____._____ _ _m _ _ m __________________________-.-____ ___.__________ Sensitivity ( C/W/g) Sensor Sensor Sensor Senso r Senso r Sensor Sensor Sensor Sensor Standard No. 1 No. 2 No. 3 No. 4 No. 5 No. 6 No. 7 No. 8 No. 9 Average Deviation (%) Canne 4 25.13 25.58 25.44 25.71 26.02 25.69 25.90 25.90 27.37 25.86 2.4 Canne 5 27.19 24.66 24.71 24.99 24.34 24.79 24.94 24.99 22.56 24.79 4.7 Canne 6 25.63 2 4 .12 24.17 24.02 24.87 24.74 21.57 24.61 22.97 24.08 4.9 Canne 7 25.90 25.71 26.27 25.80 25.99 25.88 2 5. 82 25.28 22.35 25.11 5.6 Canne 8 25.71 24.99 25.61 25.94 26.65 25.99 25.17 27.40 25.65 25.90 2.8
= _ ...._ - _______________________ _ ____________ _ -___ ______
25.15 3.0
r l O O . O ~! i 16 0 - i s
'o.
c ! 12 0 - i n 5 2 - I
- O N
3 i 80 - Q' E td y 3 -
)
O
- O.
, ?
j 40 - i TRICASTIN 3, CYCLE I i e r l _ A Gamma Thermometer !
- Axial Shape from GT [
i e TIP i. , 0 ' ' ' ' ' ' ' ' ' ' ' ' ' ' ' ' ' ' ' !-
-20 0 20 60 10 0 14 0 18 0 220 260 300 340 380
[ AXIAL POSITION (CM) . i , i FIG'JRE A-4 i COMPARISON OF RGT AND TIP MEASURED AXIAL PdWER SHAPE !
.i f
r
A.2.2 Other Programs Another recent test of RGTs was an accelerated irradiation program carried out at Oak Ridge National Laboratory (0RNL). Ten short speci-mens were irradiated in the Oak Ridge reactor (ORR) for nine conths, producing neutron exposure equivalent to three years in a PWR. This progran was designed to verify that the calibration characteristics of the RGT would be constant after significant PWR irradiation. The earlier heavy water reactor experience had empirically shown this to be t ru e. In addition to the 10 irradiated specimens, 5 were held as archive, non-i rradi ated specimens. Any changes in calibration were to be detected through time response plunge testing, pre- and postirra-diation. Unfortunately, a special ceramic connector used for the test O specimens became brittle during irradiation. Most of the connectors broke and nade it impossible to make electrical connections to the ther-noccuple leads. However, good data for one specimen was obtained. For this specinen, no change in sensitivity of the instrument was detec-table. The specimens are now being shipped to England where the CEGB hot labs at Berkeley will attempt to repair and re-plunge the specimens to obtain a core conplete data set. Other test and derenstration prograns are underway at several reactors in the United States and Eu ro pe. Prototype wet-type RGis will be installed in 1983 in a B&'.' reactor 1 (Oconee/ Duke Power), Forsnark (Swedish State Power Board), and Biblis (Rheinisch-Westf ali sches Elektrizitatswerk) . The Forsnark program will O A-10
be the first reactor installation for BWRs. A program for the applica-s v tion of RGTs to ronitor axial power shape was initiated in October 1982 by the Swedish State Power Board at its Ringhals PWR. A.3 INADEQUATE CORE COOLING The RGT is able to function as both an in-core power meter and an inade-quate core cooling (ICC) instrument above and in the core. The RGT can provide temperature heat transfer and water level measurements. These applications are being investigated in Sweden for the Barsebeck BWR and i Ringhals PWR. In the United States, ORNL has performed independent ana-lytical work,3 and a test is planned for early 1983 in the NRU reactor. TEC and ScP are now working with several U.S. utilities evaluating the use of the RGT as an ICC instrument meeting Regulatory Guide 1.97 requi rements . A.4 INTRINSIC ADVANTAGES OF RADCAL GAMMA THERMOMETERS A.4.1 Direct Measure of Linear Heat Generation Rate (LHGR) Forerost of the attributes of ganma therroneters is the direct relationship of the output signal to the local fuel power, upon which l all local power operating limits rest directly hinge [e.g., departure ! f rom nucleate boiling (DNB), maxinun linear heat generation rate (MLHGR), minim;n critical heat flux ratio (MCHFR), etc.]. 3 Thermal Hydraulic Analysis of the Dual-Function Ganma Therrometer, J. O. Johnson and T. J. Bu rns, ORNL/IM-8089, December 1981. O A-11
Both theory and experience show that the raw signals f rom all core gamma therroneters can be converted to surrounding local fuel power values by the application of a single constant with an accuracy of about 10% regardless of fuel burnup, core configuration, or control rod position, and that this ratio of fission heat to sensor heat holds constant inde-finitely. It is expected that when full-core systems of RGTs have been installed in PWRs, a simple summation of some 350 to 450 signals will yield a direct and quite accurate value for total reactor thermal power. The readout systems under development for RGTs enploy t>oth a " straight through" sigral channel and a "high accuracy" processing channel which employs normalization and obtains the highest possible accuracy of local powar measu rement f rom RGT sensors. A.4.2 gnstancy of Calibration SRP gamma thermoneters have exhibited constant calibrations with a fast fluence equivalent to five and one-nalf years in a PWR (with 1.5% calibration accuracy) . Halden gamma themometers have held constant calibration over seven years of irradiation in HBWR with no observable changes in signal relative to the power in surrounding fuel. At HBWR the fuel loading is so variable and heterogeneous that the uncertainty associated with this observation is larger than at SRP, and is estimated by the applicants to be 5%. A highly documented, well-controlled exposure test of RGT specimens has been undertaken in the ORR at ORNL. It has been calculated that the 10 l l O A- 12
6 specimens being irradiated therein will change calibration less than 5% af ter a fast neutron exposure of 6.2 x 1021 neutrons per cm2 (equivalent to three years in a PWR). The overall correlation of RGT signal to fuel LHGR is dependent first upon the sensitivity of the RGT, S , signal / watt / gram of sensor heating 3 (or its reciprocal K ),1 and second upon K2, the fission-to-ganma heating ratio prevailing (LHGR in fuel per watt / gram of RGT sensor heating). The term gamma heating is used for convenience. Actually, 7% of the heating in an LWR gamma therroneter is due to n,y reactions taking place in the sensor. Both of these ratios vary with time and core conditions within quite narrow bands ( 5% on K1 and 10% on K2 )- A.4.3 Accu rate Out-of-Pile Calibration The sensitivity of RGT signals to heating of the sensors can be measured in a laboratory by direct electrical heating or by time constant deter-mination. In practice, to date, a variation of 1.5% in mean sen-sitivity has been deronstrated by EdF. Individual chambers have shown high linearity of signal (correlation coefficient greater than 0.9999 to i the best fit straight line) in both room temperature and high-tem-l perature (300 C coolant) electrical heating calibrations. l A.4.4 Large Signals RGTs produce meaningful signals (i.e., affected less than 2% when cable resistance has fallen as low as 100,000 n). The signals can be fed directly to the control room without intervening electronics (at Halden the signals are taken di rectly rore than 103 neters). An average RGT O A-13 i
signal at full power is 1.6 millivolts (40 C) from a thermcouple. EdF L has reported usable RGT signals at 1% reactor power from prototypes in Bugey 5 with no noise problem. A.4.5 In-Core Recalibration Without TIP TEC has extensive experience in utilizing a process called " Loop Current Step Response" (originally developed at Oak Ridge National Laboratory) in which small current steps are imposed upon in-reactor thermocouples and resistance temperature detectors to obtain transfer functions which are "deconvoluted" to show the response of the devices to external sti-muli such as coolant temperature changes. This technique led to the use of heater cables in RGTs. TEC has performed tests using such heater cables in RGT specimens that gave calibration curves with linearity and scatter as good as those obtained by direct electrical calibration. In the application of the heater calibration technique, the heat being generated in any RGT string at any time (usually 0 to 3.0 W/g) is augmented by up to 3 W/g of electric heating via the mineral insulated nichrone cables imbedded in the cable pack. This full-range recalibra-tion can be done at any time requi red or desired, and at full or reduced reactor power. A.5 DRY RADCAL CONCEPT The progran described herein nakes use of the RGT in the " dry" con-fi gu ration . By d ry , i t is neant that the RGT is di rectly inserted into the existing flux thimble tubes as opposed to replacing these tubes with A-14
RGTs. The ganma therconeter denonstration programs to date used the RGT ! in the wet configuration with the diameter of the RGT equal to the thimble being replaced. In the dry configuration the RGT is snaller in diameter (0.185 in. vs 0.300 in.). The dry RGT is inserted into the j flux thimble with the sensor section held firmly in place by the use of ; 4 standoff nubs on the surface of the RGT. This creates an annular air > gap between the RGT and the flux thimble of approximately 71/2 mils. l Extensive evaluations by TEC have shown that the RGT sensitivity is unaf f ected by the presence of this annular gap. The time respor,se will be increased by 40%, but this is of little concern for flux napping i since the tine constant in the dry configuration is still less than 20 s. The primary advantage of applying the RGT in the dry configuration is
- the lack of retrafit required. The dry RGT avoids replacing the existing flux thinble tubes. Thus, the time-consuming and expensive task of pulling thimbles and replacing then with RGTs is not required.
j Another advantage of the dry RGT is that the existing pressure boundary f is left intact, and the RGT does not have to be qualified as a primary pressure boundary device. l l lO l A-15 i
1 i i I a i 1 I O , a i ! i 1 1 'l APPENDIX B i k RGT CALIBRATION L h l l I I !G i l - l ^ i l i l f I ( G , l
h 1 4 i TEC will perform electrical resistance measurements on core and jacket {} tubular stock to establish reference electrical properties for sub-l sequent calibration testing. Dimensional data measurements will also be ! performed on the core and jacket tubular stock to ensure that specifica- I I 1 j tion requi rements are met. Test equipment will be calibrated using National Bureau of Standards (NBS) traceable standards. TEC will per-i form resistance measurements on the finished RGT units at each sensor location using (1) a classical four-terminal technique and (2) the voltage and current information obtained during the low-temperature, 1 direct electrical calibrations. l l TEC will perform cold calibration of all RGT units, all test units, full-i length prototypes and in-reactor RVMS units, to measure instrument sen- ! [ () sitivity and time resporse. The electrical calibration will be per-forned in the TEC calibratior test loop. The test loop consists of an I electrical heating system, a water loop to provide sufficient cooling, a test section in which the ganma thermometer is rounted, and associated electronic instrumentation. Data to be recorded include date, time, sensor number, measurement number, water temperature before run, i current, voltage between probes, thermocouple reading with gain, amplifier gain, and water temperature after run. Again, pertinent test ; equipment is calibrated using NBS traceable standards. The primary variables of interest are the instrument sensitivity and time response to a step change in power. The sensitivity is defined as the measured r B-1 O r
l l b l i r signal (mV or 'C) from the difference thermocouples divided by the l l specific power generation at the sensor region, and the units of ' l l sensitivity are expressed as degrees Celsius per Watt per gram ! l l j ( CW-1g -1). l The effective time response is expressed as the time (seconds) required j for the signal to reach 63.2", of the maxinum value af ter initiation of f i the power-on transient, f l Because the RGT is sufficiently cooled in the calibration loop, the tem-perature of the instrument is expected to vary less than 10 C over the { i 1 entire range of currents (20 to 80A) applied. Thus, the thermal effects ! j on naterial properties as a result of current level are not a concern. , For this reason, the differential thermocouple signal versus power ! ! generated in the sensor region is expected to behave linearly [i.e., the sensitivity is not expected to be influenced by current (power) level]. l l Steady-state data are recorded for both the direct electric calibration ! and the heater cable calibration. The steady-state data will be recorded as noted above and input into an on-line conputer to determine the specific heating power (W/g) and sensitivity [ degrees Kelvin or degrees Celsius per (W/g)]. At least six (6) current levels (from 20 to 80A) will be applied to cover the entire in-core heating rate. For the heater cable calibration, current values of 0 to 3 amperes will be employed to cover the proper linear heating rates of 0 to 12 Wcn-l.
- Sone RGT units will receive partial calibration. The partial calibration will provide a statistically significant indication that the RGT is performing as dasigned. Above core RGT's will utilize a multi-sensor calibration technique.
B-2
q The temperature difference between the hot and cold junctions is obtained by extracting the steady-state dif ference thernocouple signal (converted to C) in response to the applied-ste;- change in power. This value is divided by the calculated specific power generated at the sensor. This l calculation (part of the TEC RGT interpretive software package) requires precise knowledge of as-f abricated material resistivities in order to determine the correct portion of current passing through the sensor region (i.e., the material directly under the-argon annulus). For the Cdse of heater cable calibration, the power generated by the heater cable is divided by the linear nass of the core section in calculating the sensitivity value. The data points are input into TEC's VAX 11/780 to calculate the specific power (Wy-1) generated within the sensor section and hence the sen-s i ti vi ty . TEC software will also perform statistical data analyses pro-viding linear correlation coefficient, standard deviation, and variance f rom the "best tit" sensitivity line for each sensor. TEC will also neasure time constants for at least three (3) current levels for direct electric calibration and at current levels correspond-
- ing to equivalent heating rates for the heater cable as independent checks on the real sensitivity of the instrunents. The time constants are neasured from the signal response to current cut-off.
Strip chart traces will be used to document the data, time, full-amplitude scale, current level, and turn-on and nf f locations. The entire cold electrical calibration will be repeated after the gamma g thermoneter specinen is stress-relief annealed. U B-3
t f 4 }i Calibration will be rechecked for the test specimen prototypes during j the hot testing campaign (depressurization tests) to determine cold-to-i l-hot calibration constants. 3 l
- TEC will also design and f abricate 12-ft dianeter spools, which will be ;
! used as nounts for the completed gamma thermometers. ,The spools will i i [ include latching devices to secure the RGTs in place and will be , designed for vertical mounting in a stand to ensure ease of installation i into the existing TIP system thimble tubes. The 12-ft diameter spools ) provide a neans of storage and protection without exceeding the RGT naterial elastic limit. l i i i ,1 I I l I I i 2 I i B-4 , t
s O~ QUALITY ASSURANCE MANUAL TECHNOLOGY for ENERGY CORPORATION 10770 DUTCHT0WN ROAD KN0XVILLE, TENNESSEE 37922 Manual Number Organization I Representative Title Date Issued I # m4
# 4 .
*w ' '*
g REVISIONS TO TEC'S OUALITY ASSURANCE PROCEDURES Revision By TEC Other No. Date Page(s) of Revision Appr. Approvals A JWR 2/27/79 JWR TEC-QA-1.2, pages 1 and 2 TEC-QA-2.3P, pages 1 and 2 TEC-QA-2,4P, page 1 TEC-QA-4.1P, page 3 TEC-QA-6.2P, page 2 TEC-QA-7.1P, page 2 TEC-QA-8.1P, page 2 TEC-QA-8.2P, page 1 TEC-QA-11.2P, page 1 TEC-QA-12.1P, pages 2 and 3 TEC-QA-13.1P, page 2 .- TEC-QA-14.1P, pages 3 and 4 TEC-QA-14.2P, pages 1 and 2 TEC-QA-15.1P, pages 1 thru 4 TE C-QA-16.1P , pages 1 and 2 TEC-QA-17.1P, page 1 B 1/18/80 JWR TEC-QA-1.3, pages 1 and 3 TEC-QA-1.1, page 2 TEC-QA-1.2, page 2 TEC-QA-2.1P, page 3 TEC-QA-2,2P, pages 1 and 2 TEC-QA-2.3P, pages 1 and 2 TEC-QA-1.0, pages 1 and 2 TEC-QA-3.1P, page 1 TEC-QA-3.3P, page 1 TEC-QA-4.1P, page 3 TEC-QA-6.2P, page 2 TEC-QA-7.5P, pages 1 and 2 TEC-QA-9.1P, page I p TEC-QA-11.1P, page 1
, TEC-QA-11.2P, page 1 1
s REVISIONS TO TEC'S OUALITY ASSURANCE PROCEDURES N By
- Date ppr. Page(s) of Revision Ap o als B JWR 1/18/90 JWR TEC-0A-12.1P, pages 1 thru 4 TEC-QA-13.1P, page 2 TEC-QA-14.1P, pages 2, 3, and 4 TEC-QA-15.1P, pages 2 and 4 TEC-QA-17.1P, pages 1 and 2 TEC-QA-18.1P, pages 1 and 2 TEC-QA-18.2P, page 1 TEC-QA-10.1P, page 3 Figure 1.2-1, pages 1 thru 5 Figure 12.1-1 Figure 13.1-2 Figure 15.1-6 Figure 18.1-1, pages 1 and 2 C EWL 9/18/80 EWL N/A Total fianual -
All Pages D EWL 12/15/81 EWL N/A Total I4anual - All Pages p D .
OUALITY ASSURANCE PROCEDURES TABLE OF CONTENTS
- 1. ORGANIZATION 1.1 Statement of TEC's Quality Assurance Policy 1.2 Quality Assurance: Organization, Authority, and Responsibilities 1.3 Glossary of TEC Quality Assurance Terms
- 2. TEC OUALITY ASSURANCE PROGRAM 2.1 Preparation, Issuance and Revision of Quality Assurance Manual 2.2 Project Quality Assurance Administration 2.3 Project Qulity Assurance Plans 2.4 Division of QA Responsibility
- 3. DESIGN CONTROL 3.1 Quality Assurance in Design Control 3,2 Quality Assurance in Design Review 3.3 Design Revisions
- 4. PROCUREMENT DOCUMENT CONTROL 4.1 Quality Assurance Participation in Procurement Document Review
- 5. INSTRUCTIONS, PROCEDURES AND DRAWINGS 5.1 Quality Assurance Procedures 5.2 Group, Division and Departmental Procedures i
- 6. DOCUMENT CONTROL i 6.1 Document Review 6.2 Control of Documents 6.3 QA Manual Controlled Deviations
- 7. CONTROL OF PURCHASED MATERIAL, EQUIPMENT AND SERVICES 7.1 Vendor Qualification and Surveys 7.2 Qualified Vendors List
(\ , 7.3 Procurement Quality Assurance - Inspection Planning 7.4 Procurement Quality Assurance - Source Inspection 7.5 Procurement Quality Assurance - Receiving Inspection 1
TABLE OF CONTENTS (Continued)
- 8. IDENTIFICATION AND CONTROL OF MATERIALS, PARTS, AND COM?0NENTS 8.1 Identification at Receiving 8.2 Serialization of Materiai 8.3 Control and Issuance of Material
- 9. CONTROL OF SPECIAL PROCESSES 9.1 Qualification of Personnel 9.2 Control of Special Processes and Nondestructive Examination Methods
- 10. INSPECTION 10.1 Quality Assurance in Inspections 10.2 Quality Assurance Review of Process Sheets and Production Packages
- 11. TEST CONTROL 11.1 Product Acceptance Test 11.2 Field Test
- 12. CONTROL OF MEAS'JREMENT AND TEST EQUIPMENT 12.1 Instrumentation and Mechanical Equipment Calibration
- 13. HANDLING, STORAGE, AND SHIPPING l 13.1 Packaging and Shipping Verification
- 13.2 Procedures for Packing, Shipping, Storage, and Handling l
j
- 14. INSPECTION. TEST. AND OPERATING STATUS 14.1 Routing Sheets and Manufacturing Methods Packages
- 15. HONCONFORMING MATERIALS, PARTS. OR C0"PONENTS 15.1 Nonconformances
(,, 15.2 Design Deviation Request V ,
- \
TABLE OF C0tlTEtiTS (Continued)
- 15. CORRECTIVE ACT10tl 16.1 Corrective Action Processing '
l s *[*, N-1 17. QUALITY ASSURANCE RECORDS s i .
. - 17.1 - Quality Assurance , Record identification and Retention 18.. AUDITS -
18.1 Audits 18.2 PQAA Surveillance Activities 4 a l I e 1
+
T b G 4
TITLg NO. p 1.0 ORSANIZATION TEC-QA-1.1 i == F- - REV. Tecnnology for Energy Corporation O APPROVED BY DATE DATE QU ALIT'Y ASSUR ANCE M ANU AL {(;% a. _gf 12/15/81 a y 1.0 ORGANIZATION 1.1 STATEMENT OF TEC'S OUALITY ASSURANCE POLICY It is the policy of Technology for Energy Corporation to prodece and market prod-ucts and services which meet or exceed all specifications and applicable standards of performance, reliability, and quality. The plan of Technology for Energy Corporation is to establish and maintain a reputation as a leader in product and service quality. The quality assurance (QA) program, is the administration and documentation that implements this policy. TEC's QA program parallels the 18 criteria defined in 10 CFR 50 Appendix B. The procedures used in TEC's quality assurance program are contained in a controlled quality assurance manual, and they comply with Ai!SI standard N45.2 insofar as it is applicable to the project requirements. TEC's QA program applies to all contracts or purchase orders designated by TEC's customers as having quality i assurance requirements invoked. 1.1.1 0A References A. Appendix 3 to 10 CFR 50, Quality Assurance Criteria for Nuclear Power Plants and Fuel Reprocessing Plants. B. ANSI N45.2, Quality Assurance Program Requirements for Nuclear Power Plants. C. ANSI N45.2.2, Packaging, Shipping, Receiving, Storage and Handling of Items for Nuclear Plants. D. ANSI N45.2.4, Supplementary Quality Assurance Requirements for Installation, Inspection and Testing Requirements for Instrumentation and Electrical Equipment during the construction of the Nuclear Power Generating Stations. l E. ANSI N45.2.6, Qualification of Inspection, Examination and Testing Personnel for the Construction Phase of Nuclear Power Plants. F. ANSI N45.2.8, Supplementary Quality Assurance Requirements for Installation, Inspection and Testing of Mechanical Equipment and Systemt for the l Construction Phase of Nuclear Power Plants. G. ANSI M45.2.9, Requirements for Collection, Storage, and Maintenance of Quality Assurance Records for Nuclear Power Plants. i H. ANSI N45.2.10, Quality Assurance Terms and Definitions. l Page 1 of 101 l l ..__ j
TITLE NO. l l == 1.0 ORGANIZATION TEC-QA-1.1 i ) REV. Technology for Energy Corporation APPRCWED BY DATE DATE QUALITY ASSUR ANCE M ANUAL gp' J % 12-15-81
.s 11 23-si J. ANSI N45.2.12, Requirements for Auditing of Quality Assurance Programs for Nuclear Power Plants.
ANSI N45.2.13, Supplementary Quality Assurance Requirements for Preparation of Procurement Documents for Nuclear Power Plants. K. ANSI N45.2.14, Quality Assurance Program Requirements for the Design and Manufacture of Class 1E Instrumentation and Electric Equipment for Nuclear Power Generating Stations. L. AllSI N45.2.22, Supplementary Requirements for Inspection of Dimensional Characteristics. f1. ANSI N45.2.23, Qualifications of Quality Assurance Program Audit Personnel for fluclear Facilities.
- 1.1.2 Endorsement The above QA policy and the quality assurance program described in this QA manual has the unqualified support of our company and management.
r1
- i '/ /
7 / '
/ l l l 0& L$4, . / C,h/Lll$$G( , b lh Sl i Preside t , '
Date l l I b, . l Page 2 of 101 J
TITLE NO. j i e 1.0 ORGANIZATION i TEC-QA-1.2 ( ) REV. Technology for Ener2y Corporation 0 APPROVED BY s DATE DATE QUALITY ASSUR ANCE M ANUAL eO %&A ( _ v . 12-23-2 / 12-15-81 1.0 ORGANIZATION 1.2 OUALITY ASSURANCE: ORGANIZATION, AUTHORITY AND RESPONSIBILITIES This section describes the organization, responsibilities and authority of the Quality Assurance Office of Technology for Energy Corporation (TEC). 1.2.1 Organization The TEC Quality Assurance (QA) program is administered by the Corporate Quality Assurance Manager (CQAM) who is appointed by and reports to the President. The CQAM is responsible for insuring that the QA program is implemented in all corporate activities, as appropriate. All technical contract activities at TEC are performed as g projects under the direction of a Project Manager who is appointed by the Director of j Project Management. All QA activities at TEC will be carried out under the TEC QA program. A Project Quality Assurance Administrator (PQAA) will be assigned for each project who will report to the CQAM and assist the project manager in assuring that all QA requirements called for in the project are met through adherence to the TEC QA program and the project QA plan. The TEC organization chart is attached as l Figure 1.2-1. 1.2.2 Statement of Authority l The President of TEC has directed the CQAM to implement the QA program. The CQAM has responsibility for assuring campliance to all QA procedures. He is assigned the responsibility for checking, auditing, inspecting, or otherwise verifying that engineering, purchasing, document control, and manufacturing activities are being carried out in compliance with QA procedures. His efforts shall be completely inde-pendent of the individual or group directly responsible for performing the specific l acti vi ty. The CQAM has the authority to stop work on any activity where adherence to QA procedures is found to be inadequate and to require conformance to applicable QA procedure before work is resumed. l The CQAM shall have the authority to initiate new procedures or corrective action that will result in solution to QA problems and prevent nonconforming work from being incorporated into the final product. He shall verify that corrective measures have been implemanted and have successfully resolved the QA problem. O . Page 3 of 101
)
TITLE , NO. 1.0 ORGAtlIZATI0tl TEC-QA-1.2
==
{ l ! lI REV. O Technology for Energy Corporation APPROVED BY DATE DATE QUALITY ASSurt ANCE MANU AL [g g,n_g, 12-15-81 v i-1.2.3 Corporate Ouality Assurance Manager: Responsibility The CQAM will be responsible for the administration of the TEC QA program under the review of the President. The CQAM or his staff shall prepare all QA procedures and conduct QA audits and inspections. The CQAM shall be audited as outlined in TEC-QA-18.1. The Corporate QA Mana.or reports weekly to the President on the status of the QA program or more often as required (these meetings are not normally documented). The CQAM shall prepare a quarterly status report, addressed to the TEC President, with the TEC Executive Committee on distribution, for management review of the state of TEC's QA program. 1.2.4 Project Quality Assurance Administrator: Resoonsibility l The PQAA is responsible for assisting the project manager in seeing that all QA b requirements and projectapplicable QA plan. Allto projects the project andare met project hence throughmanagers adherence andto PQAA's the TECare QAaudited program
'r' as outlined in TEC-QA-18.1. The PQAA's functionally report to the CQAM.
1.2.5 Training l The CQAM, his staff, and the PQAA's shall receive training so that they can ade-quately perform their QA duties. All employees of TEC engaged in design, procurement, or manufacturing activities covered by QA program shall receive training in its requirements. Each project manager is responsible for ensuring that all employees in their project understand the requirements of the QA manual as they apply to the project. 1.2.6 Attachment Figure 1.2-1: TEC Organization Chart r l ! A u.) , Page 4 of 10! J
O e' o Figure 1.2-1 TEClitl0 LOGY FOR ENERGY CORPORATION ORGANIZATION CHART President ' Horbert J. Ackermann, Jr. TECilNICAL DIRECTOR Vice President Julian E. Mott f FINAllCE OFFICE Vice President n Ronald D. Brenner S CORPORATE QUALITY ASSURANCE 3 Manager Edward W. Lyon, Jr. Project Quality Assurance Administrators ENGINEERIl1G GROUP OPERATI0flS GROUP PRODUCTS GROUP Vice President Vice President Vice President James C. Robinson Anthony R. Buhl Ronald Nutt Rev. D: 12-15-81 m.
. 1 8
5 1 2 1 D v e R N O EI VS I I n TV a AI e RD D T SS . & I E P T NC GN I I . NE MV R I M DR TP t
. AE EO d S FKL i ORE m AV h
) l EME c C D S d I E e P l FTS .
u Uth E FAS F n Onu C y 0RE i R eB R e ON . t Gd U! ! n PI P n i . OO s RS o SsR SI i OU C N e ES D CB ( Ory RI I P n V . 1 T o l l I A
- Aeh AD 2 Rct M .
Ei n U J 1 PVA l I O e r u g i F S E _ C I s V i Rl t h _ E0 t SI a S M
. LI AV .
CI V I D N . _ li M C E T T l l _ E _ M n E o G s . Al t l
! 0 i AI W
. MS _ I . TV W CI ED . J J O R P 28
- o
]o C
APPENDIX A BACKGROUND FOR AND EXPERIENCE WITH RADCAL GAMMA THERM 0 METERS 9 G
.=._.._- -
A.1 BACKGROUND <~~ Gamma thernneeters have been used in heavy-water reactors at the Savannah River Plant and Halden for over 20 years. That experience showed that the gamma thermometer signals were proportional to local fuel power and that, unlike neutron-sensitive devices, the sensitivity of the instruments was affected very little by fuel burnup and insigni-ficantly by irradiation effects such as depletion of fissionable materi al . Gamma therrumeter operation depends upon the heating of a metal mass by gamma radi ation. That gamma heating is proportional to local fuel power. The heat produced in the metal mass is allowed to escape to the reactor coolant along a controlled heat path. The resultant temperature e difference along the heat path is measured by thernocouples to produce an output signal which is proportional to the gamma heating and hence also proportional to the fuel power. Several different variations on gamma thermoneter designs were used suc-cessfully in the Savannah River Plant (SRP) and the experimental Halden heavy-boiling-water reactor (HBWR) . Also, ganma thercometers of the Halden design were used in the core of the Otto Hahn ship reactor. While successful in obtaining accurate measurements of fuel power, these early designs were not easily adaptable to use in conmercial light water reactors (LWRs) because they were single-sensor devices and, thus, not compatible with LWR rulti-sensor installation requirements. f) U A-1
The Radcal design has been developed by Scandpower (ScP) beginning in (')N (_ 1976.2 Technology for Energy Corporation (TEC) has been actively engaged in the process development, fabrication, and testing of gamma thermoneters since 1979. The various design features of Radcal are covered by patents granted and pending in the United States and abroad. The Radcal gamma thermometer (RGT) design is illustrated in Figure A-1. In the usual design where the RGT unit replaces the existing flux thimble, the unit appears from the outside as a long, thin rod (7.5 mm in diameter and up to 34 m in length of which approximately 4 m contain sensors). The device consists of three primary elements: (1) the jacket tu be, (2) the core rod, and (3) the central cable pack. For instruments
/~N used in reactors to date, the jacket tube and core rod have been
(_) stainless steel. An annular chamber is nachined into the core rod during fabrication so that a gas gap is created when the jacket tube is drawn or swaged down in an argon atmosphere. The cable pack consists of a number of thermocouple leads, and in nost l designs, a Nichrone heater cable. The thermocouples each contain two j junctions so that a temperature difference between the two junctions is measu red. The heater cable is provided to enable in-reactor calibration l of the device. 2Ganna Thermoneter Developnents for Light Water Reactors, Leyse and S mi th , IEEE Volune NS-26, No.1, F ebruary 1979. i O. A-2 t 2
s: __ . _ _ _ . . . .._. .. _. ... ___ .. . . . . . . - . . . . . x....____.- _; ; . _ ,_ ,m m A G
- ACTIVE SECTION ~ 4m -
LENGTH UP TO 30 m
,m ,,\ ~ =\ f C (l::::
y s_-
)
,/,/ ,// d
. INSIDE VIEW (Cross Section)
[ JACKET TUSE--* - ARGON CHAM 5ER O CORE ROo a CABLE PACK-- - > e t' FIGURE A-1 RADCAL DESIGN GAMMA THERMOMETER WITH AXIAL HEAT FLOW
~
O A-3 l i
1 In operation, gamma radiation results in nearly uniform heating (~N () throughout the body of the instrument. The annular gas chamber creates a region of relatively low heat transfer to the coolant so that the heat generated in that part of the core rod mJst flow axially toward the ends of the chamber, as shown in Fi gure A-2. The RGT design parameters are varied to accommodate particular material or dimensional requirenents: the outside diameter can be made smaller or larger than 7.5 mm; the material of construction can be changed, to Zircaloy or Inconel, for example; and the chamber length can be varied to provide appropriate signal size for the gamna heating available in a particular reactor design. Also, designs with only radial heat flow, rather than both axial and radial heat flow, .have been developed. Tnese radial heat flow designs provide simpler construction and faster response, but have a greater sensitivity to surf ace cooling conditions. A .2 EXPERIENCE WITH RADCAL GAMMA THERMOMETERS (RGTs) A .2 .1 Experience of Electricite de France (EdF) RGTs of the design illustrated above have been in place in EdF PWR reac-tors since June 1979. Eighteen sensors (two strings) were installed in Bugey 5 at that time and are still in-reactor and operating. Thi rty-si x l more sensors (4 strings) were installed in Tricastin 2 in June 1980, and another 36 in Tricastin 3 in October 1980. The locations of these Radcal strings are shown in Figure A-3. The data obtained from these RGTs have provided the primary data available on the application of gamma thernoneters in LWRs. The out-of-l l g reactor calibrations performed on the EdF Radcals have shown that the 1 ) A4 i t
. . . . . .. _.. .- . . . . . _ . . . . . _ . . ._ .. .. . _ . . . . . . . . . . , .....m.,..... . . . . . . _ . _
--]
O dy THOT
.. AT TCOLD I
l i I f g, _ . . . , . .
, .. - g .
y L. M ' :.
' jd. . -
O , _. o-
.I.
.4
$y
~
j~ '
.g
, g.M. d,j ,
i i - - o I i
= AT r' I
TbT H TcoLo FIGURE A-2 HEAT FLOW IN AXIAL- FLOW
- RADCAL GAMMA THERMOMETER O
A-5
,. . . , . - _ _ . . . . . . . . .. . .. . .. . % (1 c. i t. A... ....-'~._.....
O 8 T2 T2 T3 T3 - T3 T2 B T3 T2 8- BUGEY 5 T2- TRICASTIN 2 T3- TRICASTIN 3 i FIGURE A-3 i CORE LOCATIONS OF RADCAL GAMMA THERMOMETERS IN EDF REACTORS l l O A-6
( Figure 1.2-1 (Continued) i . PRODUCTS GROUP Vice President Ronald Hutt l . Special Consultants ) i 2' .- 4 E y PRODUCT MANAGEMENT PRODUCT DESIGN MANUFACTURING , DIVIS10H DEPARTMENT DIVISION E; , ~ W. F. Hartman J. W. Rizzie J. K. Milam I 4 i l l i I ! Rev. D: 12-15-81
1 Figure 1.2-1 (Continued) I l l TECilNICAL SERVICES DIVISION 1 - 1 Director M. V. Mathis Special Consultants i aeg 2 1 .- m j j% EllGINEERIllG DRAFTING & COMPUTER
- DEVELOP 11ENT DESIGil SERVICES OPERATIONS
- S LABORATORY DEPARTMENT SECTION I
j J. T. Smith F. J. Fox R. R. Mayhew q ._ j i i
^
. Rev. D: 12-15-8I i 1 . l
1 Figure 1.2-1 (Continued) MANUFACTURING CORPORATE QA DIVISION MAllAGER Director E. W. Lyon l J. K. Milam i I I l o DETECTOR PRODUCTION CONTROL PRODUCTION QUALITY CONTROL & 3 SECTI0tl DEPARTMENT l DEPARTMENT TESTING DEPARTMENT 1 e G. L. Ogle J. W. Stinnett H. E. Dunn ] S
~
. - I
~
QC Testers QC Inspectors Note: QC/TD Manager and Corporate QA Manager interface functionally on all QA/QC matters. Also the QC/TD i Manager has stop work authority. If and when this stop work authority is invoked, the CQAM is imme-diately notified and the stop work activity is monitored by the CQAM's office. I l i l Rev. D: 12-15-81 1 i
TITLE NO. l 1.0 ORGANIZATION TEC-QA-1.3
==
REV. D Tecnnology for Energy Corocration APPROVED BY DATE DATE
! QUALITY ASSUR ANCE M ANU AL v n_n-s t 12-15-81 v .
1.0 ORGANIZATION 1.3 GLOSSARY OF TEC OUALITY ASSURANCE TERMS The purpose of this section is to clarify QA terms and titles that should be emphasized because of their importance in understanding the documents and procedures contained in TEC's QA program. A complete glossary of QA terms is given in ANSI N45.2.10.
- 1. Controlled Document: A document that requires specified reviews and approvals as well as all changes thereto, and is distributed in accordance with a specified distribution list, including all changes or revisions.
l 2. Corporate Quality Assurance Manager (C0AM): A TEC employee who is responsible to the president for implementing and maintaining the TEC QA program.
- 3. Corrective Action Reoort (CAR): A method used to document the need for correc-tive action for significant conditions adverse to quality, other than by means of an audit report or nonconformance report. A CAR can be requested by anyone.
l
- 4. Design Deviation Reauest (DDR): A TEC internal form, used during the design phase, sent to tne Contracts Department manager requesting that a TEC customer either authorize a design deviation to the customer's drawing (s) or specification or approve a technical change to the contract. This form is used prior to a -
deviation. l 5. Corporate Engineerina Procedures Manual: A controlled manual categorizing the engineering procedures used at TEC.
- 6. Field Change Reauest (FCR): A form used to request a design change from the field or from tne installation site.
- 7. Inspector (OC): Personnel assigned to the Quality Control and Testing Department (QC/TO) wno have been trained in the areas of assigned inspection, and are inde-pendent of production pressures. The inspector is a person other than the one who performed the activity being inspected.
- 8. Manufacturing Methods Package (MMP): Folders that contain routing sheets, method sequence sneets, wire preparation instructions, PCB set up, wiring sequence, TEC bill of material, test instructions, special manuf acturing procedures, and any other documents required to accomplish the manufacturing objectives.
Page 10 of 1U1
/
TITLE NO.
- 1.0 ORGANIZATION TEC-QA-1,3
=
l l
,li REV.
O Technology for Energy Corporation APPROVED B DATE DATE QUALITY ASSURANCE MANUAL Ch y v LL LAa r us il-2:t- A i 12-15-81
- 9. Nonconformance Report (NCR): Form used ko identify, document and disposition any material or documentation nonconformance, reportable to the customer or that results in significant conditions adverse to quality.
- 10. Preaward Vendor Survey Evaluation Report: An appraisal of a vendor's quality system capability and company status.
- 11. Production Packaae (PP): Folders that contain engineering drawings, test proce-dures or instructions, engineering process sheets and TEC and/or customer inspec-l tion " Hold points" (if applicable) as a minimum. These packages are prepared by the Product Design Department and assist the Production Department in preparing MMPs.
- 12. Process Sheets (PS): This is an engineering document, prepared by the Products Design Department, to be used as a guide by the Production Department in pre-paring routing sheets.
I- 13. Project Ouality Assurance Administrator (POAA): A TEC employee, reporting to the GAM, wno aevelops specific project quality assurance plans and assures that the project work is being carried out according to the project QA plan, POAA Surveillance Report: A TEC form used by PQAAs to document random sur-l j 14. veillance activity and to report both positive and negative results to the CQAM.
- 15. Quality Assurance (0A): "Are we doing the right things?"
l l 16. Quality Assurance Manual (0AM): The QA binder, revision sheet (s) and table of l contents that contains the documents and QA policy for a QA program. i
- 17. Qu'ality Assurance Plan: A set of documents that define the QA responsibilities, organization structure, and specific or unique customer requirements for a given project.
- 18. Quality Assurance Procedures (0AP): Generic procedures, delineating instructions supplementing the QA manual to accomplish specific quality related activities (e.g., procurement, receipt inspection, record storage, etc.)
- 19. Quality Control (0C): "Are we doing things right?"
- 20. Quality Control and Testing Department (OC/TD): The department comprising the l QC/TD manager and trained and certified inspection and testing personnel, respon-sible for quality related inspections, testing, and maintaining records at TEC.
l Q 21. Quality Control Test Procedures (OCTP): These procedures supersede all QAPP's and are test procedures used by the QC/TD for testing and inspecting all TEC and 1 sunolier cuality related material and products prior to shipment. , Page 11 of 101 1
r TITLE NO. 1.0 ORGANIZATION TEC-QA-1.3 REV. D Technology for Energy Corporation APPROVED 8 DATE DATE QUALITY ASSUR ANCE M ANUAL (( n.p.g, 12-15-81
- 22. Qualified Vendors List (0VL): A List of' vendors which produce products accep-table to TEC specifications and standards (this includes both the Aerospace and Huclear Sections of the CASE register).
- 23. Reauest for Corrective Action (RCA): A TEC form that can be initiated by all TEC personnel to report any suspected condition adverse to quality. The RCA is sub-l mitted to the CQAM, and, if by investigation by the CQAM, is found to be a valid condition adverse to quality, a CAR will be initiated.
- 24. Reauest for Quote (RF0): A written request for a vendor to submit a purchase price for equipment, material or service.
- 25. Routing Sheet (RS): A TEC Production Department form used to route a TEC product through all steps in manufacturing and testing.
l 26. Stoo Work: The authority given to the CQAM, PQAA or QC/TD Manager to stop manu-facturing or operations if he/she feels that product quality is not being main-r tained according to the project QA Plan, drawings, or approved procedures.
- 27. Task Leader: TEC engineers or technicians assigned by the project engineer to accomplisn a specific work function for a project; also, sometimes called a lead engineer.
- 28. TEC Project Engineer: TEC engineer assigned the responsibilities for imple-menting project management and Quality Assurance activites.
- 29. TEC Project Manager: TEC manager designated by the Director of Project Management to De responsible for the management of a project and assuring project quality assurance.
l I l l Page 12 of 10I J
r TITLE NO. p y 2.0 TEC QUALITY ASSURANCE PROGRAM TEC-QA-2,1 6 '
=
REV. Technology for Energy Corporation O APPROVED BY DATE DATE QUALITY ASSUR ANCE M ANU AL V(l&wts O 12-2 3 -p / 12-15-81 2.0 TEC OUALITY ASSURANCE PROGRAM 2.1 PREPARATION, ISSUANCE, AND REVISION OF QUALITY ASSURANCE MANUAL 2.1.1 Puroose l The CQAM prepares and verifies implementation of the Quality Assurance Manual for performing the assigned QA functions, forming a nucleus for the QA Program. This manual delineates the Quality Assurance Policy and philosophies for Technology for Energy Corporation (TEC). 2.1.2 General Reauirements l The CQAM shall be responsible for preparing, approving, maintaining, and inter-facing all portions of the QA manual. He shall be responsible for controlling the { issuance of the QA manual and all changes thereto. Prior to issuance of any revisions to the QA Manual, the CQAM shall assure that the revision has been reviewed by and concurred with by the corporate Procedures Review Committee. TEC's QA Manual shall be
, reviewed biennially by the CQAM to determine whether a revision is required or at i shorter intervals as deemed necessary by the CQAM.
2.1.3 OA Manual Control Controlled manuals are identified with a controlled number and registered to a person _who is responsible for maintaining the location and up-to-date status of the Controlled QA manuals are assigned to the company president, CQAM, all pro-l manual. ject managers, PQAAs, and all top level administration, operations, engineering, and products management. Controlled copies of TEC's QA manual will be sent to organiza-l tions outside TEC on request and need (customer, regulatory agency, etc.). It shall be the project manager's responsibility to maintain the project QA manual, to make it i available to all personnel within his project and to assure that the sections are l read, understood, and followed. 2.1.4 Quality Assurance Manual Revision Revised QA manual sections shall be processed in the same manner as the original . When a section is revised, the revision number and date is placed on each page that has been revised. Also, a vertical line is placed in the left margin denoting the current revision. A complete listing of revisions is maintained in the front of the ((]QAmanual. w
=-
Dage 13 of 101 1
r TITLE NO.
- 2.0 TEC QUALITY ASSURANCE PROGRAM
=
TEC-QA-2.1 ( ) REV. Technology for Energy Corporation D APPROVED BY DATE DATE QUALITY ASSUR ANCE MANUAL u h ]p_]5_g] c (tiTwu h L i 2-n-p i e i_ Controlled copies of TEC's QA manual will be reviewed by the assignee after l receipt of revised sections as distributed by the CQAM. Receipt of the QA nanual revision will be verified by the assignee by returning the acknowledgement form with the assignee's signature and date that the QA nanual was revised. The acknowledgement l will be returned to the CQAM. 2.1.5 Format The QA Manual will usually consist of several major sections, each of which is further divided into subsections. Major sections shall be numbered in sequence using a single arabic numeral. The title or heading of a major section shall be in capital letters and shall summarize the content of the section. The first division of a major section shall be identified by arabic numerals separated by a decimal point. Each lesser section shall be identified by a similar (e} decimal system. Indentation, spacing, and margins shall be as indicated by this section. Revision block paper will be used for all pages except for attachments (i.e., figures and tables). However, attachments shall indicate figure or table number, page number (e.g., page 2 of 5) and revision level and revision date. 2.1.6 Sections Numbers The Quality Assurance Manual is comprised of sections, tables, and figures I covering the following topics or areas of quality assurance. The manual section num-l bers and subjects shall be: SUBJECT SECTION l Organization 1 TEC Quality Assurance Program 2 l Design Control 3 i Procurement Document Control 4 Instructions, Procedures, and Drawings 5 Document Control 6 Control of Purchased Material, Equipment, and Services 7 Identification and Control of Materials, Parts, l and Components 8 Control of Special Processes 9
)
Page 14 of 101
TITLE NO. 1 l 2.0 TEC QUALITY ASSURANCE PROGRAM TEC-QA-2,1 h : I EEE REV. D Technology for Energy Corporation APPROVED 8 OATE DATE QUALITY ASSUR ANCE M ANU AL 12-15-81 SUBJECT SECTION Inspection 10 Test Control 11 Control of Measuring and Test Equipment 12 Handling, Storage, and Shipping 13 Inspection, Test, and Operating Status 14 Nonconforming Materials, Parts, or Components 15 Corrective Action 16 Quality Assurance Records 17 Audits 18 2.1.7 Personnel Indoctrination and Training Program l The CQAM shall conduct periodic documented training sessions with personnel involved in QA activities. The purpose of this training is to e assure that required personnel are aware of all QA Manual changes. All new TEC personnel shall receive indoctrination and training in the total QA program. l l p) f l Page 15 of 101 1
, TITLE NO. 2.0 TEC QUALITY ASSURANCE PROGRAM TEC-QA-2.2 m^r _/ l
=
Technology for Energy Corporation D APPROVED BY DATE DATE QUALITY ASSUR ANCE MANUAL { . /2-27-# / 12/15/81
" v 2.0 TEC QUALITY ASSURANCE PROGRAM 2.2 PROJECT OUALITY ASSURANCE ADMINISTRATION 2.2.1 Purpose This section defines the activities of a Project Quality Assurance Administrator (PQAA).
?.2.2 Assianment and Training For each project, the CQAM shall assign a PQAA. All PQAAs will receive training so that they can perform their quality related activities. PQAA training and qualifi-cation will be the responsibility of the CQAM. The PQAA shall report to the CQAM.
E
'J 2.2.3 P0AA Responsibilities
! The activities for which the PQAA is responsible include the following:
Obtaining and reviewing all documents related to the program. These shall include, as appropriate: The Customer Contract Customer Drawings and Specifications TEC Drawings, Specifications, and other design related documents i TEC Procurement Documents (i.e., purchase requisitions) NOTE
?
Customer Inquiries, and Bid Invitations, shall be routed to the CQAM for review and comment. Cost Estimates of Quality Assurance effort shall be prepared by the CQAM or his designee. Preparing and processing of the project QA Plan in accordance with TEC-QA-2.3.
'/l k/
l. Page 16 of 10I
TITLE NO. __l '
- d 2.0 TEC QUALITY ASSURAllCE PROGRAM TEC-QA-2.2
{ ) 1-REV. Technology for Energy Corporation APPROVED SY DATE DATE QUALITY ASSUR ANCE M ANUAL { r, (2%2/
]g ]g,g) l2.2.3 P0AA Responsibilities Coordinating with involved groups external to QA, such as engineering, production, and purchasing regarding project QA plan changes, interpretation, and problems.
Monitoring, throughout the life of the contract, the effectiveness of and confor-mance to the project QA plan in each area of QA activity involved. Preparing any contractually required QA reports or documents. l Keeping the project manager and CQAM informed of any potential QA related problem areas. NOTE l The PQAA shall have "stop work authority" for the project to which the PQAA is assigned.
f)
~
Maintaining a complete project QA file of all incoming and outgoing correspon-dence related to the project QA plan or to any QA actions related to it. The file shall contain applicable engineering documents (drawings, specifications, engineering j instructions, etc.), applicable contract documents, DDRs and 11CRs and adequate records
- of applicable test actions and results that are related to QA.
On completion of the project, compile a record of the entire QA action on the l program containing the following: l _ Pertinent correspondence, l Contractual and engineering documents, l QC test records, l An analysis of QA problem areas and recommended solutions applicable to future programs, 1 i At the end of the project, transmit the QA file and all of the above mentioned records l l to the CQAM for disposition. 1 (]- 1 Page 17 of 101 i
TITLE NO. I l ___
} 2.0 TEC QUALITY ASSURANCE PROGRAM TEC-QA-2.3 REV.
Technology for Energy Corporation D APPROVED SY DATE DATE QUALITY ASSURANCE MANUAL 2.0 TEC OVALITY ASSURANCE PROGRAM 2.3 PROJECT OVALITY ASSURANCE PLAN 2.3.1 Purpose This section defines the purpose and basic requirements of a project QA plan and l defines the PQAA's responsibilities in preparing the QA plan. 2.3.2 Definition of a Quality Assurance Plan A QA plan is a set of documents which define the QA responsibilities in the pro-ject organization and provides a method of defining the QA procedures and other QA information required to meet the project QA. h, V 2.3.3 Resoonsibilities and Reouirements for a 0A Plan The PQAA and Project Manager will prepare the QA plan. The plan will identify ll the total QA efforts necessary to meet the project requirements. The QA plan will i contain as a minimum:
- 1. Project organizational chart
- 2. Division of QA responsibility (TEC-QA-2.4)
- 3. Design control assignments (TEC-QA-3.1)
- 4. List of design review procedures (TEC-QA-3.3)
- 5. List of document control procedures (TEC-QA-6.2)
- 6. Special requirements by customer (reports, field test results, etc.)
- 7. List of reference documents
- 8. Document Distribution List The QA plan shall be approved by the project manager, project engineer (s), and j the CQAM. Revisions to a QA plan shall be reviewed and approved by the same proce-dures as the original plan. Each QA plan and subsequent revisions, shall be l controlled by the PQAA as a support document to the specific project.
2.3.4 Distribution and Control of the 0A Plan The PQAA will control the distribution and revision of the QA plan. An approved (n) copy will be sent to the CQAM. Pano 18 of 101
)
I TITLE NO. f jg 2.0 TEC QUALITY ASSURANCE PROGRAM TEC-QA-2.3 ; REV. Technology for Energy Corocration APPROVED JY DATE DATE QUALITY ASSUR ANCE MANUAL kEl + # 2 2 2-/V 12/15/81 l The PQAA shall distribute a copy of the project QA plan to the project manager, project engineer (s), project task leaders and appropriate support functions. He or she shall assure that these responsible project people understand the QA requirements to which they are committed in the project QA plan. (O l I
'O .
w 1o ee
g TITLE . NO. l (A 2.0 TEC QUALITY ASSURANCE PROGRAM TEC-QA-2.4 kJ 1-REV. Technology for Energy Corporation ' APPROVED SY- CATE DATE QUALITY ASSUR ANCE MANUAL Q g2-23-s/ 12/15/81 2.0 TEC QUALIT0 ASSURANCE PROGRAM. 2.4 DIVISION OF 0A RESPONSIBILITY 2.4.1 Purpose This section defines the QA requirements to which a TEC project and its contractors shall conform. 2.4.2 Ouality Assurance Program Recuirements l Each PQAA shall be responsible for defining which QA program requirements will apply to the primary project as well as all support organizations involved in the l project. The PQAA wili list the TEC groups and TEC contractors who are associated with his project. He/she will then identify with an X (see Table 2.4-1) the QA {O program requirements for TEC and TEC's contractors. A copy of Table 2.4-1 will be included in the QA plan (see TEC-QA-2.3). 2.4.3 Attachments Table 2.4-1, Quality Assurance Program Recuirements Pace 20 of 101 _. .
.-. _. .~. . - - . _ _ - - . - - . - .
TABLE 2.4-1 ' _QUALITY ASSURANCE PROGRAM REQUIREMENTS Page of
~ ' '
PROJECT , VErlDOR 5 - l PROGRAF 1 REQUIREMEllTS TEC l
- 1) Quality Assurance Organization
- 2) Documented Quality Assurance Program and Procedures .
- 3) Design Control ~
~
4
- 4) Control of Procurement Documents u 5) Instructions, Procedures, and Drawings ~
I$
- 6) Document Control y -
i
- 7) Control of Purchased Items - '
- m .
~
a) Source Evaluation
'% b) Snurce Selection
- ~ c) Source Inspection and Audit - i S d) Receiving Inspection '
- 8) Identification and Control of Materials, Parts, 3 and Components l 9) Control of Special processes
! 10) Inspection Program i 11) Test Control
- 12) Control and Calibration of Measuring Equipment
! 13) Procedures of llandling, Storage, Shipping, and Preservation
- 14) Inspection, Test, and Operating Status
- 15) Control of,ilonconforming Materials, Parts, and Components
- 16) Corrective Action
- 17) Maintenance of Quality Records
; 18) Audits Rev. D: 12-15-81 4
i
f g TITLE NO. ___ 3.0 DESIGN CONTROL TEC-QA-3.1 REV. Technology for Energy CorporaHon 0 APPROVED BY DATE DATE QUALITY ASSUR ANCE M ANU AL g
~ n 3.0 DESIGN CONTROL 3.1 00ALITY ASSURANCE IN DESIGN CONTROL 3.1.1 Purpose The purpose of the section is to define the mechanism for ensuring that applicable reguiatory requirements, customer specifications and quality assurance requirements are correctly reflected in TEC sprcifications, drawings, procedures and instructions.
3.1.2 Project 0A Plan i The PQAA and Project Manager shall prepare a QA plan, which shall identify the organizational structure within which the project is to be implemented, and shall define the authorit/ and responsibility of each person and ' organization involved in performing quality related design. The plan shall identify the items and services and the specific activities specified in ANSI N45.2.11 (see Table 3.1-1) The design responsibility and interfaces among the contributing organizations, both internal and l external to the project, shall be identified. Design verification shall be accomplished independent of those persons assigned the responsibility for the design. l The PQAA shall review and evaluate the effectiveness of the plan in achieving quality objectives (see TEC-QA-3.2). 3.1.3 Comoliance with ANSI N45.2.11 - 1974 l The PQAA shall ensure that the proper procedures from the TEC Corporate Engineering Procedures Manual are being used for design and design verification and that design input requirements and design verifications are being documented by Engineering. Design specifications,- drawings, and other design documents shall be approved by functional managers as prescribed by the aforesaid procedures. ANSI N45.2.11 - 1974 will be used as a guide for reviewing the Engineering efforts. l Deficiencies will be reported to the project manager and CQAM in accordance with TEC-QA-3.2. The general design control elements for TEC and TEC's contractors will be defined in the QA plan as shown in Table 3.1-1. This table will be used as a basis for QA design review and audit. 3 .1.4 Attachment C - Table 3.1-1 General Design Control System Elements Page 22 _ of 101
s TABLE 3.1-1 GEtlERAL DESIGil CONTROL SYSTEM ELEMEtlTS
- 1) Design Planning
- 2) Prepare Design Documents (which address, as applicable: reactor physics, stress, thermal hydraulic, and accident analysis, compatibility l of materials, and accessibility for in-service inspection, maintenance, and repair and delineation of I acceptance criteria for inspection i
and test)
- 3) Identify and Resolve Internal Design Interfaces
- 4) Identify and Resolve External Interfaces
- 5) Perform Design Verification
- 6) Review Design (Regulatory Requirements, Codes and Standards, Quality Requirements, Performance, Material Application, Test Requirements, Acceptance Criteria, Inservice Inspection, Maintenance, Special Processes)
- 7) Control Design Changes
- 8) Provide Design Specs and Stress Reports
- 9) Review Subcontractor and Vendor Design Documents
- 10) Audit Design Control System b .
D: 12/15/81 Page 23 of 101
TITLE N O. p _ i 3.0 DESIGN CONTROL TEC-QA-3.2 l REV. Tcennology for Ener2y Corporation APPROVED ,SY DATE DATE QUALITY ASSURANCE MANUAL f0-
- u. <-.m ; 12-25-p/ 12/15/81 3.0 CESIG$ CONTROL 3.2 OUALITY ASSURANCE IN DESIGN REVIEW 3.2.1 Purpose This section defines requirements and responsibilities for PQAA participation in design review functions including the review of specifications and drawings.
3.2.2 Definitions Design Verification - The process of reviewing, confirming, or substantiating the design by one or more methods (i.e., design reviews, alternate calculations, or quali-fication testing, or any combination of these three) to provide assurance that the f design meets the specified inputs. OL' Design Review Board (DRB) - Formalized design review to assure that critical reviews to orovide assurance that design documents such as drawings, calculations, analyses or specifications are correct and satisfactory. A DRB assures proper con-sideration of significant factors that affect performance, reliability, safety, cost, the ability to produce, inspect, operate and maintain, and overall value throughout the life of a component or system and to emphasize the application of appropriate codes and standards in the design. The chairman of the DRB shall be appointed by the department manager responsible for the design. 3.2.3 ' General l The PQAA shall monitor the design verification process. i The CQAM shall be notified of all scheduled DRB's and he or his designee shall ' I attend selected DRB meetings of his choice. The attendee shall prepare a report for j the project QA file for DRB meetings attended. l 3.2.4 P0AA Responsibilities l The PQAA shall have the following responsibilities: Review data packages or DRB agenda furnished by the DRB coordinator prior to the sche-( A duled DR3 meetings. Dependent upon the review phase represented by the data package, V the M review will consider the following factors, as applicable. Page 24 of 101
TITLE NO. _g t . - - [ D i 3. 0 DESIGil C0tlTROL TEC-QA-3.2 q == i [ d - li rl E V . 9 Tccanology for Energy Oorcoration APPROVED QY DATE DATE CU ALITY ASSUR ANCE M ANU AL 12/15/81 4 ,7.n_ c f v . Review inspection and test requirements and adequate product acceptance criteria as related to overall program objectives. Assure that proper selection and application of codes, standards, materials, and processes; and use of standardized and previously qualified components are being used wherever possible. l Address the need for special inspection and test equipment and procedures, and need for specially trained and certified fabrication and inspection personnel. Identify potential cuality problems and their possible solutions. Discuss the definition of special identification, documentation, configuration, and traceability requirements. l Attend and participate in DRR meetinas as directed by C0AM. Accept, investicate, and report back to the DRB chairman on assigned 0A action items.
\
v Maintain a file on DRR reports which verify the completion of action items requested by or assiqned to OA. l 3. 2. 5 PDAA Reauirements and Resoonsibilities for Soecification Reviews fl0TE If specification review is applicable, this shall be accomplished prior to design review. The POAA shall review the followina TEC specifications applicable to his/her assioned pro.iect: l Component, material, process, and/or naterial processinq specifications Other specifications within the scope of this document when QA review is a contrac-
+ual requirement.
l DOAA revies of specifications, and specification chances, shall assure inclusion of the following, as applicable: Adequa*.e provisions for product inspection and testing and for determining and controllinn product or process cuality. t O - Paqe 25 of 101 L
, TITLE NO.
l _ 3.0 DESIGti C0tlTROL TEC-QA-3.2 REV. Technology for Energy Corocration 0 APPROVED BY DATE DATE QU ALITY ASSUR ANCE M ANUAL h f 6 I%No v . f2-2=-4/ 12/15/81 Adequate instructions for packing, storing, and packaging for control of cleanli-ness of fabrication, assembly, test areas, special processes, and for customer storage requirements. Special inspection and/or test equipment requirements, including special instru-ment calibration requirements. Provisions for product identification and traceability such as serialization, lot control, and heat numbers or part numbers. Use of materials and components which have been qualified as determined from the Qualified Vendor Lists, preferred parts lists, or feedback information from simi-lar items. Provisions for documentation of inspection and test data when required. l t) . o=m 76 of 101
TITLE N O. l l' 3.0 DESIGN CONTROL TEC-QA-3.3 R E V. Technology for Energy Corocration D APPROVED BY DATE - DATE QUALITY ASSUR ANCE MANUAL p 12-za -s / 12/15/81 v - 3.0 DESIGN CONTROL 3.3 DESIGN REVISIONS 3.3.1 Puroose l This section defines PQAA requirements to assure that design changes are controlled. 3.3.2 Recuirements l Corporate Engineering Procesure CEP-110, " Design Change Control," shall be used by all personnel to provide methods for incorporating design changes in approved design documents including field changes. These changes shall be justified and sub-jected to design control measure commensurate with those applied to the original {g design. 3.3,3 Method of Control The PQAA shall include design review procedures in the project QA plan to assure that the reouirements of this section are met. ANSI N45.2.11 - 1974 Section 8 will be used as guide for these review procedure requirements. (/3 v . Dace 27 of 101
TITLE NO. 4.0 PROCUREMENT DOCUMEllT CONTROL TEC-QA-4.1 < ,m e-Q 'l b R E V. Technology for Energy Corporation APPROVED (Y DATE DATE QUALITY ASSUR ANCE MANUAL g (, \ _p, 13713731 4.0 PROCUREME)TD0CUMENTCONTROL 4.1 OUALITY ASSURANCE PARTICIPATION IN PROCUREMENT DOCUMENT REVIEW 4.1.1 Purpose l This section defines requirements and responsibilities of the PQAA in reviewing procurement documents applicable to quality related procured items and services. 4.1.2 Reouirements and Resoonsibilities ! l 4.1.2.1 POAA The PQAA shall review purchase requisitions on items directly related to the pro-
- l ject prior to their transmittal to vendors to assure inclusion of the following, as applicable.
Supplier selection based on the Qualified Vendor List (QVL). Requirements for the supplier's use of QVL sources in his subcontracting. Application of the appropriate government, customer, or TEC quality assurance / ins;,ection system specification. Requirement for supplier to have QA program consistent with pertinent sections of 10 CFR 50, Appendix 3. The suppliers QA program will be reviewed during the ven-dor qualification / audit process. Customer source inspection requirements. TEC source inspection plan and source inspection hold points. Product serialization and material traceability requirements. Supplier data submittal requirements. Requirements for qualification of supplier fabrication and inspection processes, procedures, and personnel. purchasing Codes or other special requirements which affect quality. u) . Page 28 of 101
TITLE N O. __ 4.0 PROCUREMEtlT 00 Cut 1EllT C0!1 TROL TEC-QA-4.1 1 REV. Technology for Energy Corporation APPROVED BY DATE DATE QUALITY ASSUR ANCE MANUAL N CIr b b ,1 - n -a s 12/15/81 v e Reference to drawings, specifications, codes and standards by applicable revision letter or date (drawings and specifications referenced on purchase requisitions shall be released by engineering instructions). Requirements for supplier control of special processas. Information indicating the quantity of items ordered is sufficient to provide for any required TEC destructive acceptance test. Requirement for supplier to extend applicable quality requirements to his subtier supplier ( s) . 4.1.2.2 Source Inspection The PQAA or the cognizant engineer shall establish, with the concurrence of the CQAM, the need for TEC source inspection based on the following guidelines - any one of which, when applicable, normally requires source inspection. (O Inspection at another point requires product disassembly or destructive testing or requires replacement of costly packaging materials and/or containers. Products are to be shipped directly from a supplier to a site other than TEC. Specific processes, inspections, and test performed by a supplier cannot be verified as adequately accomplished except at the time of accomplishments. Special equipment or facilities required for inspection or tests are available only at a supplier's facility. Schedules do not permit loss of time due to a supplier's shipment of unacceptable items. i 4.1.2 Recuirements and Responsibilities 4.1.2.3 Hold Points The PQAA shall establish, with the concurrence of the CQA'1, TEC source inspection hold ooir.t requirements when applicable and include these requirements on the purchase requisition. Hold points for complex procurements requiring extensive source inspec-tion planning nay otherwise be identified in the supplier's manufacturing plan during its review by QA or in the TEC inspection plan. I Page 29 of 101
TITLE N O. __ 4.0 PROCUREMENT DOCUtiENT CONTROL TEC-QA-4.1 REV. Technology for Energy Corocration 0 APPROVED BY DATE DATE QUALITY ASSUR ANCE M ANUAL
~ r 4.1.2.4 OA Review The PQAA shall indicate evidence of QA review of procurement documents by signing and dating the purchase requisition for items directly related to product quality.
Purchase orders for nuclear safety related materials will be identified by anno-tating " NUCLEAR SAFETY RELATED" on the first page of the purchase order. NOTE For all purchased material, parts and components that have the possibility of being shipped to a customer and/or which are incorporated into a l customer's product, the QC/TD Manager shall receive a copy of the purchase , order. 1 l l , 4.1.3 Procurement Procedures ANSI N45.2.13 - 1976 will be used as a guide for the development of procedures for control of procured items. All changes to procurement documents require formal revisions, and these l revisions shall receive the same reviews and approvals as the original procurement I documents. 4.1.4 10 CFR Part 21 Reference to part 21 shall be made on TEC Purchase Order if required by the rules in 10 CFR 21.31 and/or the customer's contract. Dv - Page 30 of 101 i
TITLE N O. I l l lll= 5.0 (g - INSTRUCTI0flS, PROCEDURES, AND DRAWINGS TEC-QA-5.1 REV. Technology for Energy Corporation ' O APPROVED BY OATE DATE OUALITY ASSUR ANCE MANUAL f b M ,h;<;. (2 -2 L p/ 12/15/81 v ,- 5.0 INSTRUCTIONS, PROCEDURES, AND DRAWINGS 5.1 00ALITY ASSURANCE PROCEDURES 5.1.1 Purpose This section establishes the requirements for the preparation, approval, issuance and control of Quality Assurance Procedures. ~ 5.1.2 Definition Quality Assurance Procedures (QAP's) are generic procedures delinating instructions, supplementing the QA Manual sections to accomplish specific quality
,l related activities (e.g., procurement, document control, record storage, etc.).
n (U 5.1.3 Quality Assurance Procedure (0AP's) QAP's shall be prepared and approved by the CQAM or his designee. QAP's shall be controlled by the CQAM and issued internally to those persons directly affected on an "as-needed" basis. 5.1.4 Format for 0AP's l QAP's should be organized into the following titled sections in the order listed: Section 1 - Purpose of QAP Section 2 - Applicability Section 3 - Requirements Section 4 - References, Definitions, Abbreviations and Forms 5.1.4.1 Puroose of 0AP This section shall contain the purpose and scope of the procedure. 5.1.4.2 Apolicability
~
5 This section shall list all TEC departments in which the QAP is invoked. Page 31 of 101
. TITLE NO. A 5.0 ItJSTRUCTI0tlS, PROCEDURES, TEC-QA-5.1
![] !
l
=
AtlD DRAWIrlGS R E V. Technology for Energy Corporation D QUALITY ASSUR ANCE MANUAL APPROVED B( DATE _ DATE f h)qtw c . .()w n -z3- p / 12/15/81
~ i 5.1.4.3 Reauirements This section contains the actual procedural steps to be completed and their order of accomplishment. This section, when required, may be broken down into more descrip-tive sub-headings, but arranged in a logical sequence.
5.1.4.4 References, Definitions, Abbreviations and Forms ' This section shall list referenced documents, define terms and abbreviations, and list forms applicable to the QAP. h') v Page 32 of 101
TITLE N O. ! e l i 5.0 INSTRUCTIONS, PROCEDURES, TEC-QA-5.2
==
lg l AtlD DRAWINGS hl REV. Technology for Energy Corporation APPROVED BY DATE DATE QUALITY ASSUR ANCE M ANU AL f (, ,1 , ., ., n _ , 12/15/81 w y 5.0 INSTRUCTIONS, PROCEDURES, AND DRAWINGS 5.2 GROUP. DIVISION AND DEPARTMENTAL PROCEDURES 6.2.1 Purpose This section establishes the requirements for the preparation, approval, issuance and control of Group, Division and/or Departmental operational procedures hereaf ter referred to as unit operational procedures. Unit operational procedures are those administrative procedures deemed necessary by the unit manager to instruct personnel on the day-to-day operations of the unit. 5.2.2 Reauirements and Responsibilities G 5.2.2.1 Once a unit operational procedure is prepared, it shall be submitted to the
'd Group representative to the Corporate Review Committee (CPRC) to determine whether the procedure crosses any Group interface boundaries.
If the procedure crosses these boundaries, it must be submitted for CPRC review, and this review documented. If no Group boundaries are crossed, then only internal Group organizational approvals are required. 5.2.2.2 The preparing organization shall have internal procedures describing the
- format, review and approval and revision cycle, and the issuance and control of unit operational procedures.
l I ( G( ' Page 33 of 101
TITLE NO. g _- 6.0 00CUMEllT C0tlTROL TEC-QA-6.1 i) ! REV. Technology for Energy Corporation APPROVED BY DATE DATE QUALITY ASSUR ANCE MANUAL F(, 4 % \ n . m, , 12/1s/81 6.0 DOCUMENT CONTROL 6.1 DOCUMENT REVIEW 6.1.1 Purpose This section defines QA requirements and responsibilities for reviewing quality related documents such as specifications, procedures and their revisions. 6.1.2 Reautrements and Resoonsibilities Specifications and procedures and changes thereto in the following categories, shall be reviewed by QA: ( Component and material procurement specifications as applicable. V3 V Other specifications within the scope of this document when QA review is a contractual or legal requirement. The assigned PQAA is responsible for reviewing documents applicable to a specific project. The CQAM is responsible for reviewing documents of a general nature l within the scope of those provisions of ANSI N45.2, its daughter standards and TEC's quality assurance programs. The reviewer shall assure that the documents include provisions for the following, as applicable: Product inspection and testing to determine and control product or process quali ty. Control of cleanliness of fabrication, assembly and test areas, special
- processes, and preservation and packaging for storage or shipment.
l Special inspection and/or test equipment, including special instrument calibrations. Product identification and traceability, such as serialization, lot control and heat numbers. Use of materials and components which have been qualified as determined from Qualified Vendor Lists, or feedback information from similar itens. Documentation of inspection and test data.
\(V3 Definition of personnel qualification requirements and personnel training.
Page 34 of 101
\
TITLE NO.
~
I I 6.0 DOCUMENT CONTROL TEC-QA-6.1 ll R E v. O Tecnnology for Energy corocration QU ALITY ASSUR ANCE M ANU AL 9 , 12/15/81 Evidence of QA review for component and material procurement specifications, as applicable, shall be by means of the PQAA signature on the purchase requisition to which the procurement specification is attached. For internal specifications and procedures, incorporated in production packages, evidence of QA review shall be by means of the PQAA Surveillance Report (see Figure 18.2-1). ( C 1.] Page 35 of _101
TITLE N O. 6.0 DOCUMENT CONTROL TEC-QA-6.2 4 i (J REV. Technology for Energy Corporation APPROVED SY DATE DATE QU ALITY ASSUR ANCE M ANUAL C t (U h s.,,m h-TR-p / 12/15/81 6.0 DOCUMENYCONTROL 6.2 CONTROL OF DOCUMENTS 6.2.1 Purpose This section provides direction for the control of standard TEC released docu-ments such as engineering drawings, specifications and procedures applicable to pro-ducts produced by TEC. The purpose of document control is to assure that the fabrication, processing, inspection and testing of products are performed in accor-dance with the current drawings, procedures, and specifications. The disposition of obsolete doc"ments shall be the responsibility of the issuing organization. They shall recover or direct disposition of obsolete documents or notify holders of obso-lescence and distribute new documents in accordance with the document control procedure. (G 6.2.2 Document Control Document numbers and revision status for standard TEC released documents shall be assigned by the issuing organizations. The issuing organization shall maintain a Document Index and Revision Status Log (see Figure 6.2-1 for typical format), indicating the document identification and description, and revision level and effective date, and index number. Also, document distribution shall be controlled by a Document Control Log (see Figure 6.2-2 for typi-cal format) which indicates the control number, Document identification (description and number), document assignee, document revision level issued to ass'gnee, and issuance date, and acknowledgement of receipt. The index number listed on Figure 6.2-2 corresponds to index number column on Figure 6.2-1. Document control procedures shall be incorporated in the project QA plan that will control issuance of project documents and changes theretc. These procedures shall assure that documents, including changes, are reviewed for adequacy and approved for release by authorized personnel and are properly distributed. ANSI N45.2.11 Section 7 will be used as' a guide in preparation of these procedures. (O mJ Page E of [_1_
TITLE NO. l 6.0 DOCUtEtlT C0tlTROL TEC-QA-6.2 l ___
~
REV. Tschnology for Energy Corporation APPROVED BY DATE DATE QUALITY ASSUR ANCE M ANU AL gbu>LL4=%,h,'
, !? -? a st /
12/15/81
~ "
l 6.2.3 Project Documentation Index At the commencement of all QA projects, the PQAA shall establish a document index for each project, based upon the document submittal requirements delineated in the customer's specification or purchase order. Upon completion of the project, this index shall be used as a checklist to assure that all specified documents are available and retrievable, thereby enabling the records package close out. Once the documents become records, they shall be handled in accordance with QAP-1006, "QA Records Storage Procedure." 6.2.4 Attachments
- 1. Figure 6.2-1 Document Index and Revision Status Log
- 2. Figure 6.2-2 Document Control Log l l r
! LD l f 1 bv Page 37 of 101
, - i-1 _
- _ /8 _
5 1 f / o _ 2 1 D e g a v P e R
)
e l E p T m A a D S ( D g lA o L L E s V u E t L a f t f 1 S O
- I 2 n S o I 6 i V s E e i R r v u
g e R i F d n a N x O e I d T n P I I R t C n S e E m D u c T o N D E M U C O D T R I l EE I B J M t cU oN D T.. l UO I N D _ _ - uu g g O% 5-
- t 1!l i.lI , :j:l ll <
l
] : , !
- ,' i ( 'r , t , i;[ ,. I
@ FE T T I
- 1 SA -
3 fD / T 5 1
/
2 1 K : C D A - v e R Y E R EE UT SA
)
SD = I e l p m a - S . ( K g C 2 A o 2 L _ 6 l o e r . r t Y OiCF u g t n o E R 1 n e m u c o D _ E
- 4 t
. e A l N t i T t n e m - u c o D z - . 0
~10 -
1 1 x MON i l
- ~
e l _ -
~ _
i d I n ~C nO owm u* O .g I ,11 1 1! . . Ii! lJl -
TITLE NO. 6.0 DOCUMENT CONTROL TEC-QA-6.3 REV. Technology for Energy Corporation APPROVED BY \ DATE QUALITY ASSUR ANCE M ANUAL 9r Ld WSN %
\ DAITT:/15/81 11-23-P /
6.0 DOCUMENT CONTROL 6.3 OA MANUAL CONTROLLED DEVIATIONS 6.3.1 Purpose The purpose of this section is to provide measures for limited, but controlled deviations from the QA Manual from time to time as circumstances may require, or for a means to revise a limited section prior to a major QA Manual revision. 6.3.2 General All TEC personnel shall comply with all sections of the QA Manual unless a deviation has been requested and approved in accordance with this section. Such a
, deviation may be (1) a limited deviation from an approved manual section for a (es specific period of time or activity, or (2) the implementation of a change of the v approved section in advance of the formal issuance of the revised section, or the issuance of a new section which incorporates the change.
QA Manual Deviation Request (QAMDR), once approved shall be issued to all TEC QA Manual internal recipients. The approved QAM3R, together with the referenced QA Manual Section constitutes the authority to perform the activ;ty as described by these documents with the limita-tions as approved by the QAMDR. Any record made of the activity performed under the authority of the QAM3R shall either include a copy of the approved QAMDR or a reference to the QAM3R by number. l l 6.3.3 Reauirements and Responsibilities l l 6.3.3.1 Limited Deviation Reauest The individual requesting a limited deviations shall prepare a QAM3R, (see Figure 6.3-1) describe the requested deviation, the reason for such a deviation, how long a period of time the deviation is required, or he/she shall specify the activity (s) involved and how many times he/she intends to deviate from the approved QA Manual Section. 1 l Page 40 of 101 L
, TITLE NO. l 6.0 00CUMEllT C0tlTROL TEC-QA-6.3 (-) 4
=
REV. Technology for Energy Corocration APPROVED SY DATE DATE QUALITY ASSUR ANCE M ANU AL 13j13731 4 o-6.3.3.2 Advance Imolementation Deviation Request The individual requesting authorization to implement a change in advance of its formal issuance shall prepare a QAMDR, describing the change, the reason for requesting the advance implementation authorization, and he/she shall include any available references to, or status of, the change approval activity that would assist the Corporate Procedure Review Committee in their evaluation of the request. 6.3.3.3 0AMDR Control [ The CQAM shall issue a sequential control number from the QAMDR log (see Figure 3 6.3-2) once the QAMDR has been approved, i
< 6.3.3.4 0AMDR Review and Approval i
e' The individual requesting the QA Manual deviatinn shall submit the completed QAM3R to the CQAM. If the COAM determines that the request is not in violation of 10 CFR 50, Appendix 3, AtlSI f445.2-1977 or subsequent daughter standards, or other TEC QA
.I commitments, he shall submit the QAMDR to the Corporate Procedures Review Committee j for their evaluation. The CQAM shall resolve any comments, and then signify his approval of the QAMDR by his signature and date. The date of his signature shall be ; the effective date of the QAMDR.
If the CQAM determines the QAMDR to be a violation of TEC QA commitments, he shall return the QAM3R to the requestor, disapproved, indicating the reason for disapproval. I 6.3.3.5 OAMDR Issuance and Distribution Approved QAMDRs shall be distributed to all TEC internal QA Manual recipients
; with instructions to insert the QAM3R in their QA Manual in front of the affected j section.
6.3.4 Attachments
- 1. Figure 6.3-1. 0A Manual Deviation Request (OAMDR) l 2. Figure 6.3-2: 0AMDR Control Log
!Dv Page 41 of 101
_ _ _ _ . . . - _ . . . . . - _ .. _- . . _ _ - _ . = _ _ -. .- - .. i b Figure 6.3-1 QA MANUAL DEVIATION REQUEST No. QA Manual Section
Title:
QA Manual Section Rev.: t 4 Describe Deviation / Change: 1 I. Attachment C l
- Reason for Request
J J Attachment Q Requested by: Date: ) Limited Deviation Q Activity Affected: Advance Implementation Q Number of Deviations: l How Long Required: Status of QA Manual Section Revision: . Approved: O Yes Q No Reason for Disapproval: l l Approved By: __
'Date:
- CQAt4 Signature Rev. D
- 12/15/81 f Page 42 of 101
. . - - - - - . . - _ . - - _ . , . - - . . . - _ . . - - - - . . . - - . - , . , . - - - - . . . , , . . , _ _ _ , , - _ _ - - . . , , - ~ , . -
Figure 6.3-2 0A Manual Deviation Reauest Control Log QAPDR QA lianual Effective No. Section Date OAMDR Description Rev. D: i (o 1 > , Page 43 of 101 12/15/S1 l l
TITLE NO.
-p ;
il 7.0 CONTROL OF PURCHASED tiATERI AL, TEC-QA-7.1 d EEE EQUIPMENT A!!D SERVICES
.I N g g y, Technology for Energy Corporation APPROVED SK DATE DATE QUALITY ASSUR ANCE M ANU AL cf_ ig/13fg1 7 u %, s n . 7x_ p f 7.0 CONTROL OF PURCHASED MATERI'AL', E0VIPMENT AND SERVICES 7.1 VENDOR OUALIFICATION AND SURVEYS 7.1.1 Purcose Vendor QA preaward surveys are conducted to verify the existence of systems, procedures, and equipment which are adequate to assure products and services are in accordance with TEC and TEC's customer's standards of quality. This section defines l the CQAM's responsibilities for conducting vendor surveys.
7.1.2 Responsibili ty l Vendor surveys will be conducted by the CQAM or his designee. Technical assistance will be requested of other TEC organizations, as required. O( 7.1.3 Procedure for Vendor Surveys _ 7.1.3.1 Initiation and Scheduling Vendor surveys may be conducted of selected vendors furnishing material, equip-ment or services covered by TEC specifications, or other than commercial, standard catalog, off-the-shelf items. Vendor surveys will not necessarily be required when the vendor has a record of satisfactory performance in delivering similar products to contract requirements over a substantial period of time. Vendor performance records shall support this conclusion and shall be based upon the QC/TD vendor history and NCR file. l TEC qualification testing and receiving inspection can be used jointly in lieu of vendor QA preaward surveys. The survey of a given vendor will normally be requested by either purchasing, the l PQAA, or the Project Manager as procurement needs or product quality dictate. The l scheduling of an initial survey shall be coordinated with purchasing and Project Management. ) Dage 44 of 101
, TITLE NO. I - 7.0 C0tlTROL OF PURCHASED MATERIAL, TEC-QA-7.1 __-_. EQUIPMEtlT AllD SERVICES I REV. D Technology for Energy Corporation APPROVED BY DATE DAT QUALITY ASSUR ANCE M ANU AL ( 15/81
~
7.1.3.2 Survey Conduct The CQAM survey team shall appraise the vendor's quality system by completing the TEC QA Vendor Survey Checklist. The CQAM shall maintain the Vendor Survey File and distribute a summary of the vendor acceptability to purchasing, the applicable PQAA, and applicable project personnel. 7.1.3.3 The Vendor Ouality Evaluation Report After each appraisal, a Vendor Quality Evaluation Summary Report shall be l completed by the CQAM. The data package shall contain the following: QA Vendor Survey Report and Vendor Quality Evaluation Summary Report. Company administration, products, or bulletins, (if available). A " Qualified Vendor List" shall be maintained by the CQAM based on the evaluation i of the above reports. 7.1.4 References
'TEC Lead Auditor's Training Course r
J . page 45 of 101
TITLE NO. 7.0 CONTROL 0F PURCHASED MATERIAL, TEC-QA-7.2
===
EQUIPMEllT AtlD SERVICES REV. D Technology for Ettergy Corporation APPROVED DATE DATE QUALITY ASSUR ANCE M ANUAL
& It Y L.'.,
17 - 2 % P / 12/15/81 7.0 CONTROL 0FPURCHASEDM/TERfNL,EQUIPMENTANDSERVICES 7.2 OVALIFIED VENDORS LIST 7.2.1 Purpose A Qualified Vendor's List (QVL) provides information for purchasing and the purchaser in determining whether adequately qualified suppliers are available to supply the parts or services required. An adequately qualified supplier is one whose quality program meets the level required for the complexity of the supply needed. 7.2.2 Qualified Vendor's List (OVL) 7.2.2.1 Supplier Survey A QVL shall be maintained by the CQAM. The QVL and changes thereto, shall be issued by QA which is based on surveys, the CASE Register data reports or supplier hi story. Whenever a new certified supplier is required, QA shall coordinate a visit through purchasing and Project management to the supplier for purposes of conducting a vendor survey. 7.2.2.2 Suoplier Quality Evaluation Report Af ter each survey a Vendor Quality Evaluation Summary Report (see TEC-QA 7.1) shall be completed and approved by the CQAM. The CQAM shall then include the approved supplier on the QVL. The QVL shall be reviewed annually by the CQAM and reviewed as required. Controlled copies of the QVL shall be distributed to PQAAs, Manufacturing Methods, and Purchasing by the CQAM when additions or deletions have been made. 7.2.2.3 Coordinating Agency for Sucolier Evaluation (CASE) Register The Nuclear and Aerospace Sections of the CASE Register shall be considered as an extension to the TEC QVL for ALL " catalog, off-the-shelf" items, and these suppliers so listed do not require a pre-award survey. b . Page 46 of 101
TITLE NO. 7.0 CONTROL OF PURCHASED MATERIAL, TEC-QA-7.2 {yg EEE EQUIPMENT #1D SERVICES l -- REV. Technology for Energy Corporation D APPROVED BY DATE DATE QUALITY ASSUR ANCE MANUAL g , ,1, _p, 12/13/g1 u /* N0'TE For any procurements requiring design or development on the part of the vendor for TEC, either a copy of the survey report, substantiating the CASE Nuclear Section listing, or a pre-award survey performed by TEC, qualification testing and receipt inspection performed by TEC, or supplier history evaluation by TEC is required. l l l [ Page 47 of 101
l i TITLE N O. , _ _- s l I l l 7.0 C0?lTROL OF PUPCHASED fiATERI AL, TEC-0A-7.3
===
l l E0'JIPMEf'T AND SERVICES l 1 ---- ! REv. Tecnnology for Energy Oorcoration APPROVED RY DATE D A TE QU ALITY ASSUR ANCE M ANU AL gp { , y ) _gg v I-7.0 CONTROL OF PURCHASED ftATERIAL. E0llIPMENT, AND SERVICES 7.3 PROCllREMENT O!!ALITY ASSURANCE - INSPECTION PLANNING P 7.3.1 Purpose This section delineates the requirements for inspection olanning as it pertains to source and receiving inspec tion. 7.3.2 General Reouirements The inspection plan will establish the inspection actions necessary to neasure conformance of the procured items or services. Basic inspections required for each receint,.includinq source inspected items are: (} Identification verification Evidence of damage Proper packaqina Compliance with purchase order requirements Review of certifications and test reports for completeness, correctness, and con-formance of reported results to specified requirements. 7.3.3 OC/TD Responsibilities Prepare aeneric receivina inspection procedure addressing the above general requirements. Assure that procedures are prepared, anproved, issued and implemented as reouired for both source inspections and special functional tests for received itens. Assure that inspoction actions required to neasure conformance o' an iten or ser-vice are referred or listed in the inspection procedures. l Each characteristic requirino inspection - verification shall be identi fied accor.1-incl.v (i.e. , visual exanination, measure, test, verify docunentation, or other) .
\_/ .
l l 48 of 101 Pace
TITLE N O. q i .I ; 7.0 CONTROL OF PURCHASED t1ATERIAL, TEC-0A-7.3 ll == ! EOUIPME!!T AND SERVICES t ii, - f -- REV. Technology for Ener3y Oorcoratton APPROVED SY DATE DATE CU ALITY ASSUR ANCE M ANU AL 4 N tt: 1 %.as w 27-9, 12/15/81 Assure that procedures require the following docunentation: A copy of .the purchase order Applicable drawings and specifications Inspector training requirements (See ANSI N45.2.6-1973)
~For procured items under specific TEC qualification programs, ensure that proce-dur,is exist, addressinq reverification of acceptance to the qualification proqran on a case by-case basis.
Where statistical sanolina is u',ilized for receipt inspection, TEC-0A-10.1 shall be utilized. l I l
/
Page 49 of 101
m
$ TITLE NO.
H 7.0 CONTROL OF PURCHASED MATERIAL. TEC-QA-7.4 g == EQUIPMENT AND SERVICES i- REV. D Tectmology for Enerny Corocration
=
APPROVED B DATE DATE QUALITY ASSUR ANCE M ANU AL 12/15/81 7.0 CONTROL OF PURCHASED MATERIAL. EQUIPMENT, AND SERVICES 7.4 PROCUREMENT OUALITY ASSURANCE - SOURCE INSPECTION 7.4.1 Purpose This section defines QA requirements and responsibilities for inspection of pro-cured items and -services at a supplier's facility. 7.4.2 Reauirements and Responsibilities 7.4.2.1 Inspection Reauirements The TEC Quality Control / Testing Department (QC/TD) inspector shall review the purchase order requirements and the source inspection procedure with the supplier prior to visiting his facility to assure mutual understanding of inspection, test, and source inspection hold points requirements. The TEC inspector shall coordinate with purchasing and Project management and perform source inspections as specified in the inspection procedure including: Verification that the supplier's measuring instruments used for acceptance pur-poses can measure to the required accuracy and are in a current state of accepted calibration traceable to the National Bureau of Standards or other approved standards. Verification that special processes and inspection methods requiring qualified proceCures and certified personnel are Mrformed using procedures approved by TEC. Verification that supplier insper - : r or 1 sting personnel have been trained to perform the inspection. Verification that components and assemblies are cleaned, preserved, packed and identified in accordance with TEC's specification and the supplier's approved procedures. The TEC inspector shall initiate a Nonconformance Report MCR) to document non-conforming conditions in accordance with TEC-0A-15.1 and trUsmit the ICRs to the CQAM, PQAA, project manager, and QC/TD Manager. i n
%)
- l i
I ( Page 50 of 101
, TITLE NO.
1 ( == 7.0 CONTROL OF PURCHASED MATERIAL, TEC-QA-7.4 ( ) EQUIPMENT AND SERVICES REV. Technology for Energy Corocration APPROVED SY '3 DATE QUALITY ASSUR ANCE MANU AL e y D ATf 2/15/81 C (f i WF., t . g.L n-zw.g Authorize shipment of acceptable products'in accordance with purcnase oraer requirements by initiating Vendor's Approval for Shipment tags and signing l Vendors Inspection forms, if applicable. If the TEC inspector is resident at the supplier facility, he shall prepare periodic status reports, source inspection accomplishments, results obtained, and pro-duct shipments made by the supplier during the reporting period. He shall forward l copies of reports to the appropriate PQAA. He shall compile and maintain source inspection and contractually required The TEC l supplier residentrecords inspector attesting will forward to the acceptability records of the products to the appropriate PQAAorforservices. final review and filing upon completion of the purchase order. l 7.4.3 OC/TD Responsibilities l QC/TD source inspection responsibilities are as follows: (h Process NCP,s submitted by source inspectors for disposition of nonconforming pro-cured items in accordance with TEC-QA-15.1. Initiate a Request for Corrective Action form for recurring non-conformances in accordance with TEC-QA-16.1. Review source inspection status reports for compliance of inspection actions to planned requirements and take necessary action to resolve problem areas. Distribute status report copies to the Purchasing Department buyer, CQAM, PQAA and to the Project Manager. Review completed procurements inspection and test records for adequate evidence of acceptability of procured items and services, and maintain a file or reference to a file, of completed records. l i x ,' . Page 51 of 101
TITLE NC. y h 7.0 CONTROL 0F PURCHASED t1ATERIAL, TEC-QA-7.5 ___ EQUIPMEllT AND SERVICES t! REV. 0 Technology for Energy Corporation l APPROVED BY DATE DATC QUALITY ASSUR ANCE M ANUAL I(INLuf%,dA
- W -2 x - A. /
17/15/81 7.0 CONTROL OF PURCHASED MATERIALS, EQUIPMENT. AND SERVICES 7.5 PROCUREMENT OUALITY ASSURANCE - RECEIVING INSPECTION 7.5.1 Purpose This saction dafines the quality Control and Testing Department's (QC/TD) respon- . sibilities for inspection and testing of incoming procured items and services. 7.5.2 Requirements and Responsibilities 7.5.2.1 Trained inspectors shall inspect and document inspection results of all incoming items that have the possibility of being sold, or incorporated into
- systems to be sold to TEC customers. Receiving inspection shall be performed in accordance with QC/TD procedure DOP-103.
l 7.5.2.2 The QC/TD Manager and responsible engir.ers, when applicable shall determine those items that require functional testing, and shall assure that this i
' testing is accomplished using approved procedures prepared by the appropriate project engineer when required. The QC/TD Manager shall also determine which items require 1003 receiving inspection, and which items can be statistically sampled for acceptance using appropriate receiving inspection sampling guide-lines or project QA Plan.
7.5.2.3 The QC/TD shall maintain copies of purchase orders, invoked specifications i and drawings and controlled procedures in the Receiving Inspection files in I order to accomplish incoming inspection and testing. 7.5.2.4 Inspected items shall be tagged, and associated inspection records shall be g completed prior to release of the inspected items. Where suppliers test reports and/or certifications are required by TEC procurement documents, I these reports / certifications shall be filed with the receiving records by the QC/TD. Acceptance of multiple small items shall be indicated by an inspec-tion tag attached to the container (box or bag). 7.5.2.5 Honconforming conditions shall be documented by means of the'Nonconformance Report (NCR) (see Section TEC-QA-15.1) and copies of the ICR shall be l transc'iitted to the CQAM, appropriate PQAA and, if appropriate, Purchasing for subsequent processing. Nonconforming items shall be placed in a segregated ( area or readily identified as nonconforming. Page 52 of 101
, TITLE N O.
r \' l 7.0 CONTROL OF PURCHASED MATERIAL, TEC-QA-7.5
==
{ } l EQUIPMENT AND SERVICES l REV. Technology for Energy Corporation APPROVED BY DATE DATE QUALITY ASSUR ANCE M ANU AL
"%~>>'..
> s, y2 9/ 12/15/81
" t 7.5.2.6 Completed receiving inspection records shall be filed in Receiving Inspection files.
7.5.2.7 QC/TD personnel shall be trained and certified using Procedure CP-101,
" Procedure for Certification and Qualification of Technical Personnel", and ANSI N45.2.6-1973 as a guide.
7.5.2.8 Revisions to receiving inspection procedures shall be controlled in the same manner as the original issue to these procedures. Page 53 of 101
TITLE NO. l 8.0 IDENTIFICATI0t! AND CONTROL TEC-QA-8.1 EEEE le) l l. OF t%TERI ALS PARTS AMD COMP 0MENTS ,_ n c ,/. Technology for Energy Corporation APPROVED BY DATE DATE QUALITY ASSUR ANCE MANU AL T FuLk
~gjpgjgy i
O -n-v I
- I 8.0 IDENTIFICATION AND CONTROL OF MATERIALS PARTS AND COMP 0NENTS 8.1 IDENTIFICATION AT RECEIVING 8.1.1 Purpose The purpose of this section is to defir, how materials, parts and components, that have the possibility of being shipped t. 1 customer and/or which are incorporated into a customer's product, are identified at aceiving and how their identity is .11ain-tained during transfers to storage or production.
8.1.2 General The Receiving /!nspection Report form (Figure 8.1-1) is a two-section, multiple part form (six page, color coded form) used both for material identification at material receiving, and for material inspection by the QC/TD
, 8.1.3 Purchase Item Identification i
When the consignmen't is received, the material is verified against the packing list, and the packing list is verified against the ?urchase order. The receiving sec-tion of the Receiving / Inspection Report (R/I Report), is completed by the Production and Inventory Control Department and this form is affixed to all boxes or crates. Distribution is as follows: e White Copy - Purchasing o Light Yellow Copy - Requisitioner
- l. o Pink Copy - Receiving l
l The material is stored in a segregated receiving area until transferred to QC/TD l for receiving inspection and/or testing. Once the item has been inspected and either accepted or rejected, the Inspection section of the R/I Report is completed, and the following distribution is made: a Green Copy - QC/TD 2 Blue Copy - Accounting
- Dark Yellow Copy - Affixed to material G
v . l l Page 1 of 101
TITLE NO. e f I
= 8.0 IDEtlTIFICATION AND CONTROL TEC-QA-8.1
! OF MATERI ALS PARTS AND li COMP 0MENTS REv.
Technology for Energy Corporation APPROVED SY DATE DATE QUALITY ASSUR ANCE MANU AL (M n 2 5-si 12/15/81 8.1.4 Identification After OC/TD Receiving Inspection 8.1.4.1 Acceptable Material If material is found to be acceptable to the Dark Yellow copy of the R/I Report, once completed is affixed to the material, and the material is placed in the " accepted material" area outside the stock room. 8.1.4.2 Unacceptable Material If material is found to be discrepant (either hardware or documentation), this is annotated on the R/I Report, an NCR (Figure 15.1) is issued, the NCR number is entered on the R/I Report, and a TEC red "Honconforming Material" tag (Figure 8.1-2) is affixed to the discrepant material. NOTE I The " Nonconforming Material" tag shall be removed only by_ the QC/TD inspector. The material shall be moved to a segregated storage area, if physically feasible, 8.1.4.3 Removal of R/I Report, Material Copy and " Nonconforming Material" Tag R/I Report - When accepted items or material enters the stockroom, the R/I Report is removed and discarded by Production and Industry Control personnel. Documentation associated with items serial numbered for traceability will be removed by QC/TD and filed. When these items are shipped to the customer this documentation will be removed from the QC/TD file and sent with the shipment as required by the contract. Nonconforming Material Tag - When the rejected item or material disposition is implemented, this tage is removed by the QC/TD inspector and discarded. 8.1.4 Attachments
- 1. Figure 8.1-1, Receiving / Inspection Report
- 2. Figure 8.1-2, Nonconforming Material Tag Pace 55 of 101
Figure 8.1-1 Receiving / Inspection Report N TEI: acceivisaeinspecTiou aeaoaT-00a02 RECElvmC SECTON DATE P.O.
- VENDOR VENDOR'S REOutSk ROUTE TO RECElvED MvosCE
- INSPECTION REQUAEC TsONER OYES O NO ITE gO f MFC. PART NO. l TEC PART NO.DESCRIPTION l I CONTRACT WBS g,y g
CTY, O . I I I l t 1 i l l 1 I i l l 1 I i I 1 l l I i 1 I i l l i i i I l i i t i i # l ' l I I i l i i l i I l 1 i i i i I i i
! I i i l l I I RECEIVWG SIGNATURE MSPECTON SECTON MFC, PART NO.l TEC OWG. NO. C OT C REV.f PROCEDURE l REV.f p p WS]DATE gy i i i I '
i l 7 I i i i i l I I l l l l l l ' I i i i l I l l l i i i I I i i ' I i i i i i I I I i ' f I I i ' I l !
. i l i i l i i !
REMARKS TEST EQUIPMENT O' CENERAL PROCEDURE) OC/TD APPROVED NCR NOJDATE SK; NATURE a
. .or . ~r.
6 Page 56 of 101 Rev. D: 12-15-81
1 h rigure 8.1-2 rionconformino Material Tag NONCONFORMING MATERIAL (Hold for proper disposition) Nomenclature P. O. # Fart # Quantity Rcported By Date
Description:
Disposition: See reverse side NCR # - D!SPCSITiON INSTRUCTIONS Disposition is being deterrnined unless a box is choche:d belov., O Pcturn to O Ehat/ork by O Repa;r by C Ur -?s's.
] '. '_,ra D 0 Gthcr Date NCR # -
I 1 l Page 57 of :01 Rev. D: 12/15/81
- l. . _ . . _ - - _ _ - - . -- - - - - - - - - -- - - - - - ^ - - - - - - - - - - - -
TITLE N O. 8.0 IDENTIFICATION AND CONTROL TEC-QA-8.2
=== OF t%TERIALS PARTS AND
{cI I COMP 0NENTS i REV. D Technology for Energy Corporation APPROVED Sh DATE DATE I QU A LIT'Y ASSURANCE MANUAL 12/15/81 l F b_L ~ . a\ a is-23-c; 8.0 IDENTIFICATION AND CONTROL'0F MATERIALS PARTS AND COMPONENTS 8.2 $ERIALIZATION OF MATERIAL 8.2.1 Purpose This section describes TEC's serialization system and defines manufacturing and QA responsibilities associated with the assignment, application and control of serial numbers applied to components, assemblies, and systems. 8.2.2 Serialization System Serial numbers are applied to parts, components, subassemblies, assemblies, and systems so that these items can be distinguished for individual control and for the e establishment of records. Serialization of an item shall be required whenever: W Traceability of the item is required by engineering drawing, specification call-out or contractual requirement. Serial numbers for TEC fabricated items shall be specifically assigned, either on an individual or lot basis by the Production Control Manager who shall j also maintain a master record of such assignments. l On TEC fabricated items requiring serialization for traceability or for fabrica-l tion and inspection status control, the specific assigned serial numbers shall be assigned by the Production Control Manager on the Production Assembly Release to Manufacturing Methods form (see TEC-QA-14.1). Physical application of serial numbers on items shall be accomplished by Production personnel at some point during the fabrication. At the time of product inspection, the QC/TD inspector shall verify that the items are correctly marked with the assigned serial numbers. On supplier fabricated items requiring serialization, applicable purchase orders must contain provisions for serialization, including a list of serial numbers to be applied by the supplier. The PQAA shall assure the inclusion of such provisions during review of purchase requisitions. Receiving or source inspection, as applicable, shall verify that the item are correctly marked with the assigned serial nunbers.
'D U
Page 58 of 101
TITLE No. , y j l l 8.0 IDEt!TIFICATI0tl AND CONTROL. TEC-QA-8.3 EEE I i, 0F t%TERIALS PARTS AND l [ l COMPONENTS ggy, Technology for Energy Oorcoration 8 AP.90VED Y gArg .oA7E QUALITY ASSUR ANCE M ANU AL e Ov% ..s n _n _, , 12/15/81 8.0 IDENTIFICATION AND CONTROL OF MATERIALS PARTS AND COMPONENTS 8.3 CONTROL AND ISSUANCE OF MATERIAL 8.3.1 Purcose The purpose of this section is to establish a control system for the issuance of material from the TEC stockroom. 8.3.2 Control System The Production & Inventory Control Department shall issue written procedures for the issuance and control of material from the TEC stockroom which shall address as a minimun, .the following: 3 o Controlled access to be the stockrooms and material W storage areas for authorized personnel only. o Material handling and storage to prevent damage, contamination and/or loss. t o That when material is issued from stock, a TEC manufacturing routing sheet (shop traveler), identifying any supplier certifications, or test reports, as applicable, are required. O Page 59 of 101
TITLE NO.
,.. t l l l 9.0 CONTROL OF SPECIAL PROCESSES TEC-0A-9.1
== i l REV.
n 76cnnology for Energy Oor:: oration APP 90VED BY OATE DATE QUALITY ASSUR ANCE M ANU AL {$ 12/15/81 9.0 CONTROL 0FSPEC}ALPROCESSES 0.1 OUALIFICATION OF PERSONNEL 9.1.1 purpose This section defines, for 0A related work, the training and aualification requirements for personnel who perform special processes, inspections, and tests, or who participate in the approval of procedures, the handling of data or test results, or the control of reports and records. The qualification and training of manufac-turina personnel, such as assemblers and solderers shall be the responsibility of the Quality Control and Testing Department. 9.1.2 Appl icabil ity l This section applies to all TEC personnel who participate in quality assurance U related projects. 0.1.3 Pesponsibility It is the responsibility of the COAM, and/or Supervisors to assure that only those personnel within their oraanization who neet the requirements of ANSI Na5.2.6-1973 and/or CP-101 are permitted to perfarn special processes, inspections, evaluations, and testina activities that result in, or assure the attainment of quality. 9.1.4 Method of Qualification The ceneral reauirements for qualification, qualification level s, performance, and records are defined in ANSI N45.2.6-1973. The COAM shall qualify audit personnel usina A'!SI N45.2.23-1978 as a guide d oc ument . Qualification documentation shall he maintained by the CQA'M in the COAfi's office. Paae 60 of 101
TITLE NO. lll _ 9.0 CONTROL OF SPECI AL PROCESSES TEC-QA-9.2 ('> ! == ; I REV. Technology for Energy Corporation D APPROVED SY DATE DATE QUALITY ASSUR ANCE MANU AL gg n.n.gr 12/15/81
" t 9.0 CONTROL OF SPECIAL PROCESSES 9.2 CONTROL OF SPECIAL PROCESSES AND NONDESTRUCTIVE EXAMINATION METHODS 9.2.1 Purpose The purpose of this section is to define the system for the control of special processes (which, at TEC include: welding, painting, soldering) and Nondestructive examination methods.
9.2.2 Control of Special Processes Written procedures are established for the control of welding, painting and soldering which address the following as applicable and as a maximun: e e The special process is identified e Requirement that applicable gages, instruments, and other devices used in controlling special processes be subject to TEC's calibration program, and that these calibration records are maintained o Requirement that personnel and equipment for special processes are approved or certified when applicable e Where TEC utilizes subtier suppliers for special processes and/or NDE, these suppliers be qualified and listed on the TEC QVL in accordance with TEC-QA-7.2. i ! kO \ us' l . i t Pace 61 of 101
TITLE NO. e 9.0 CONTROL OF SPECI AL PROCESSES TEC-QA-9.2 REV. Technology for Energy Corporation APPROVED BY DATE DATE QUALITY ASSUR ANCE M ANUAL
-(le us4... t,.7%-B/ 12/15/81
~
9.2.3 Nondestructive Examination Methods ,- Written procedures are established for NDE methods (when performed at TEC) which address the following as applicable: o NDE method identified o Requirement that NDE personnel be qualified and certified to the requirements of SNT-TC-1A or ASME B&PV Code, as applicable o Requirement that personnel resumes and qualifica-tion records of NDE personnel are on file in the QC Department o Requirement that records of all NJE are maintained in the QC Department k') o Establishment of NDE i cceptance criteria. v. (G
*L) =
Page 62 of 101
t TITLE NO. e l 10.0 ItJSPECTION TEC-QA-10.1 k> i REV. O Technology for Energy Corocration APPROVED SY DATE DATE QU ALITY ASSUR ANCE M ANU AL (, ,,q 12/15/81 u i 10.0 INSPECTION 10.1 OUALITY ASSURANCE IN INSPECTIONS 10.1.1 Purpose This section establishes Quality Assurance requirements and responsibilities for implementing and maintaining a Statistical Quality Control receipt Inspection Program for large quantities of small items such as electronic components. Inpsection planning, source inspections and receiving inspection procedures are covered in Section 7 of this QA manual . 10.1.2 Reauirements and Resoonsibilities 10.1.2.1 Statistical Samoling Programs The Quality Control and Testing Department (QC/TD) Manager shall develop establish, and maintain statistical sampling programs to determine quality levels, identify quality trends, justify reduced or tightened inspection, establish process controls, and provide a basis for initiation of corrective action which will improve quality performance. The QC/TD Manager shall: Research, develop and improve sampling plans utilized by 'nspection with the exception of customer developed sampling plans. Determine the need for applying sampling plans. Assist in the preparation of detailed inspection instructions for use of the plans, including selection of the appropriate inspection levels and acceptable quality levels. t Develop, implement, and coordinate the various aspects of statistical sampling ( programs. Assure that sampling plans or portions thereof applicable to specific materials, parts, components, etc., are identified, referenced, or explained on the appli-cable record. Coordinate nonstandard sampling plans with the customer prior to use. Train and qualify sampiing personnel . v Page 63 of 101
. TITLE N O. I
- 10.0 INSPECTION TEC-QA-10.1 lh REV.
O Technology for Enercy Corporation APPROVED BY DATE oATE QUALITY ASSUR ANCE MANU AL bb4\ s. r 12 2.h ci 12/15/81 10.1.2.1 Statistical Sampling Programs Establish program requirements for statistical sampling during receiving inspec-tion and source inspection. Review supplier sampling plans prior to their use by the supplier, if such review is contractually required. Develop statistical process control techniques and charts and implement them as
- requi red.
Monitor statistical quality control charts to identify any adverse conditions. Establish and implement detailed procedures for inspection personnel use of sta-tistical sampling plans and process control charts for supplier-furnished items (as required). ( Specify article quality characteristics as either critical major, or minor. I g Critical characteristics shall receive 100% inspection. Select and specify appropriate inspection level and applicable acceptance quality levels for major and minor article quality characteristics. 10.1.2.2 Inspection Results The inspectors will document and transmit inspection data or analysis to the QC/TD Manager. The QC/TD Manager will perform analyses of the inspection results. i d Page 64 of 101
TITLE NO. l 10.0 INSPECTION TEC-QA-10.2 ;
! EEE I O R Ev.
D Technology for Energy Corporation APPROVED EY DATE QUALITY ASSUR ANCE M ANU AL D A {2/1b[OI 10.0 1NSPECTION 10.2 0A REVIEW 0F PROCESS SHEETS & PRODUCTION PACKAGES 10.2.1 Purpose This section defines the responsibilities of the PQAA in assuring that various documents contained on Production Packages (PP) have been approved for issuance, that process sheets, if applicable, are complete and address contractual " hold points", and that all applicable engineering drawings have been "baselined". 10.2.2 General Manufacturing ilethod Packages (31P) (see Section TEC-QA-14.1) shall be prepared
' only from approved and issued Production Packages that are issued by Product Design Department (PPD) or the Engineering Group.
10.2.3 Requirements The PQAA shall review applicable Engineering / Product Design Department production packages prior to release for proper production procedures, completed process sheets, if applicable, and verification that all applicable drawings have been "baselined". The process sheets are intended for guidance to the Production Department describing suggested sequence for manufacture and fabrication. The process sheet also specifies TEC and/or customer " hold points" and in-process and final inspection requirements, if applicable. NOTE Process sheets are required to be included in the production package if any of the following conditions are applicable: , o Useful information is to be transferred between the Product Design Department and Manufacturing Division. o The project specification requires QA hold points. ! a The production package defines a base design. C When used, process sheets will be referenced on the cover sheet of the production package. Page 65 of 101
TITLE NO. 10.0 INSPECTION TEC-QA-10.2 REV. Technology for Energy Corporation O QUALITY ASSUR ANCE MANUAL qg ,,_ _ef 12/15/81 10.2.4 Production Package Review Procedure The PQAA review shall assure that the documents called for in the production ' packages (which are prepared and approved in accordance with Product Design Department procedure, PDD-OP-02) are adequate to determine product compliance to QA requirements. The production package shall contain as a minimum: j Engineering drawings ( Approved and "baselined") Test procedures (or reference listed) Engineering process sheets, if applicable TEC and/or customer inspection " hold points" Acceptable production packages shall be signed by the PQAA prior to Jse. 10.2.5 Revisions to Production Packages Revisions to approved production packages shall be reviewed by the PQAA. If acceptable, the PQAA shall so indicate by his/her initials being placed on the record of revisions. Prior to revising the production package cover sheet, the PQAA shall make a copy of the cover sheet, and place this copy in the applicable project file for record pur-pose of the project "as-built" conditions. The PQAA shall be responsible for inserting revised documents into the production packages and logging these changes on the PP coversheet. Superseded or obsolete docu-ments shall be removed by the PQAA and destroyed. I i l i
!!D y.>
l Page _66_, of 101
TITLE N O.
,e q 11.0 TEST CONTROL TEC-0A-11.1 I I I aEv.
o Technology for Energy Corporation APPROVED BY DATE DATE QUALITY ASSUR ANCE M ANUAL S, y L V) % W \ 12/15/81 11-7:1-F f 11.0 TEST *dONTROL 11.1 PRODUCT ACCEPTANCE TEST 11.1.1 Purpose This section defines requirements and responsibilities of the QC/TD in performing acceptance tests on TEC manufactured parts, subassemblies, assenblies, subsystems and systems. 11.1.2 Recuirements and Resonnsibilities Items shall be acceptance tested in accordance with applicable specifications, test procedures and contract requirements. Tne OC/TD Manager shall review and concur with all OC test procedures and their w revisinns. The preparation of these test procedures, meeting the format requirenents of OCTP-001-000, shall he the responsibility of the cognizant engineer, who shall insure that all applicable specification and contractual requirenents are incorporated. The resonnsible department manaqer shall approve all QC test procedures and their revisions. The OC/TD Manaqer sF . i assure that the test procedures address the following: The requirement that all prerequisites for the given test have been met (prerequisites shall include: the use of calibrated equipment; qualified and l certified persons; suitable environnental conditions; acceptance criteria and provisions for data acquisition) . That adequate instrumentation is available and used That necessary monitoring is performed The OC/TD Manaaer shall also assure that: All test results are documented and evaluated by hin or other qualified personnel to assure that test requirenents have been net (all entries shall be recor.1ed in ink).
- q L.)
- Page 67 of 101
g TITLE N O. r _ 11.0 TEST CONTROL TEC-QA-11.1 I l REV. Technology for Energy Corporation APPROVED B DATE DATE QUALITY ASSUR ANCE M ANU AL f'IU 184Su i t-i t - c / l 12/15/81 Test personnel are trained, qualified and certified in accordance with TEC-QA-9.1. If modifications, repairs or rework are determined to be necessary as a result of acceptance testing, these actions shall be accomplished by the Manufacturing Organization and approved by Engineering, as applicable (during the testing activity, QC/TD personnel may trouble shoot a nonconforming item to determine the problem, but SHALL NOT perform any rework or repair on the item). Any items requiring rework or repair shall be reinspected and retested to the extent necessary, using approved procedures, to verify item acceptability. Originals of test result documents shall be retained by the QC/TD. Copies of l test result documents shall be distributed to the PQAA for QA record purposes. Also, the necessary number of copies shall be distributed to the Contracts Department Manager, who shall transmit them to the customer, if required by contract. (h 11.1.3 Certificate of Inspection and Conformance Product acceptance is complete when the QC/TD Manager and Project Manager, and customer's inspectors (if required by contract) have signed and dated the Certificate l of Inspection and Conformance. The PQAA shall review the completed form and signify approval by his/her signature and date. This completed document and the TEC Shipping Request form is forwarded to the Contracts Department Manager to be processed in accordance with TEC-QA-13.1. 11.1.4 Attachment Figure 11.1-1, Certificate of Inspection and Conformance h V . Page 68 of 101
Figure 11.1-1 s Lt.KI Ir 1GA1 r. UF TECHNOLOGY FOR ENERGY CORPORATION INSPECTION AND CONFORMANCE QUALITY RELATED ITEMS PRODUCT: QUANTITY: SERIAL NO.: CUST0MER: SPECIFICATION TITLE: SPECIFICATION NUMBER: REV.: i NAME OF CUSTOMER's FACILITY: PROJECT OR JOB P2 UMBER: CUSTOMER'S CONTRACT NO.: CERTIFICATION OF CONFORMANCE I CERTIFY THAT THIS PRODUCT HAS BEEN INSPECTED AND/0R TESTED BY ME OR MY DESIGNATED INSPECTOR AND THAT IT MEETS OR EXCEEDS THE QUALTIY CONTROL REQUIREMENTS IDENTIFIED IN THE AB0VE SPECIFICATION OR TEC'S WORKMANSHIP STANDARDS. CERTIFIED BY: TITLE: QUALITY CONTROL AND TESTING DATE: DEPARTMENT MANAGER I CERTIFY THAT THIS PRODUCT HAS BEEN FABRICATED ACCORDING TO THE QUALITY ASSURANCE REQUIREMENTS AS IDENTIFIED IN THE AB0VE SPECIFICATI0!1S. CERTIFIED BY: TITLE: PROJECT MANAGER DATE: PQAA APPROVAL: DATE: i i CERTIFICATION OF INSPECTION i I CERTIFY THAT I HAVE INSPECTED THIS PRODUCT, REVIEWED THE ACCEPTANCE TEST RESULTS AND THAT IT HAS BEEN FABRICATED ACCORDING TO THE AB0VE SPECIFICATIONS, ALL HOLD POINTS HAVE BEEN VERIFIED, AND ALL DOCUMEtlTS HAVE BEEN CHECKED AND ARE IN PROPER ORDER. THIS PRODUCT IS~ ACCEPTABLE FOR SHIPMEllT PER THE AB0VE CONTRACT SHIPPING INSTRUCTIONS. CERTIFIED BY: TITLE: CUSTOMER'S INSPECTOR DATE: Rev: D 12/15/81 . Page 69 of 101
TITLE NO. y 11.0 TEST CONTROL TEC-QA-11.2 I l, REV. O Technology for Energy Corporation QUALITY ASSURANCE MANUAL 4 - 12/15/81 s 11.0 TEST CONTROL 11.2 FIELD TEST 11.2.1 Purpose The purpose of this section is to define the QA requirements for field test and other services performed for TEC customers in the field. 11.2.2 Requirements and Responsibilities Field test and other services (field training, etc.) which involve quality-related work will be controlled by written test prccedures and shall have a QA plan as l described in TEC-QA-2.3. Each service project will be assigned a project manager, PQAA and field team. The PQAA will prepare a QA plan that will satisfy the TEC and I customer QA requirements. The project manager will instruct engineering to prepare a test procedure in accordance with the applicable requirements of the contract. QA inspections of field service will be verified in accordance with the aforesaid test procedure by the PQAA. Nonconformances will be processed as described in the QA manual. Test procedures and their revision shall be reviewed by the PQAA. Personnel performing field test and other quality related field services shall be trained and qualified in their service according to CP-101 and ANSI N45.2.6 - 1973. 11.2.3 Test Report A test report will be prepared by the testing personnel and it shall be reviewed by the PQAA and approved by the responsible manager. The test report shall be distri-buted by the responsibic manager, and the original transmitted to the PQAA for record purposes. 11.2.4 Field Change Recuest Changes in engineering documents which are requested from the field will be made through a Field Change Request (FCR). The use of this engineering document is described in the engineering procedures. The PQAA will revies the FCR for QA conflicts. The project manager will review and dispositan the FCRs. h) N . Page 70 _ of 101
l TITLE NO. 1 e 12.0 CONTROL 0F MEASUREMENT TEC-QA-12.1 l
=== l ll AND TEST EQUIPMENT IlI REV.
D Technology for Energy Corporation APPROVED SY DATE DATE QUALITY ASSUR ANCE MANUAL c( t. U l W%%s 1r-7s-9/ 12/15/81
~
\
12.0 CONTROL OF MEASUREMENT AND TEST EQUIPMENT 12.1 INSTRUMENTATION AND MECHANICAL EQUIPMENT CALIBRATION 12.1.1 Purpose ~ This section defines requirements and responsibilities for the calibration, certification, and control of electrical and mechanical measuring equipment used in quality-related field measurements and manufacturing. 12.1.2 Definition Electrical measuring equipment are devices typically of the following types used in TEC inspection, manufacturing, and field measurements operations: ( g Voltage, resistance, current, and frequency meters / analyzers. Function generators. Oscilloscopes. Pulse generators. Laboratory power supplies. Variable band pass filters. Voltage and current sources. Mechanical measuring equipment are devices typically of the following types used in TEC inspection, manuf acturing, and field measurements operations: Special measuring devices. Jigs, fixtures, and assembly control tools used either exclusively by Inspection or jointly by Production and Inspection to regulate the dimensions (geometry) of a product. Pressure gauges. Torque wrenches. Calipers. Scales. Balances. Micrometers. Precision hand tools. j}v page 71 of 101
l l . TITLE NO. hEEE 12.0 CONTROL OF MEASUREMENT TEC-0A-12.1 AND TEST EOUIPMENT REV. D Technology for Energy Corporation APPROVED BY DATE DATE QUALITY ASSUR ANCE M ANUAL
\
i) f r* % s 17 7% 9: 12/15/31 12.1.3 Ouality Control - Reouirements a'nd R'esponsibilities 12.1.3.1 Calibration of Electrical or Electronic Eauipment The calibration facility operated by the Enqineering Develoonent Laboratory (hereafter called TEC Calibration facility) shall maintain and control or otherwise have access to primary standards of sufficient accuracy to assure satisfactory calibration of secondary, working, or other lower echelon standards. Primary stan-dards shall be traceable to and periodically calibrated and certified by the National Bureau of Standards or other approved calibration laboratory. Calibration standards shall have errors normally less than one fourth of the tolerance of the equipment being calibrated. Greater uncertainties may be allowed when linited by the state of the art. In situations where it is impossible to comply with the above, a calibration standard of less accuracy shall be allowed providinq the conditions are documented, I'g l authorized by the COAM, and can he shown to be within the tolerances and accuracy of the requirements of the equipment being calibrated. The TEC Calibration facility shall establish and naintain calibration procedures if they have not been included in the instrunent operating manuals, certificates of calibration, instrument history / repair records, and other documents necessary to main-tain traceability of calibration standards. Calibration frequency will be per the manufacturer's recommendations or as TEC personnel deem necessary. The TEC Calibration facility shall establish and naintain calibration procedures, schedules, records and identification of electrical and electronic equipment. Calibration methods defined by an appropriate qovernment agency or professional society shall be utilized wherever possible. When no suitable documents in these categories exists, a TEC procedure shall be prepared by the user. 12.1.3.2 Calibration of Mechanical Measurino Eauionent The TEC Calibration facility shall procure, maintain and control or otherwise have' access to primary standards of sufficient accuracy to assure satisfactory calibration of secondary, workino, or other lower echelon standar ts. Primary stan-daris shall be traceable to and periodically calibrated and certified by the Nacional 9ureau of Standards or other anproved calibration lahoratory. pa ce 72 of 101
TITLE NO. l 12.0 CONTROL OF tEASUREMEllT TEC-QA-12.1
; == AND TEST EQUIPMEtlT REV.
D Tecnnology for Eriercy corocration APPROVED BY DATE QUALITY ASSUR ANCE M ANU AL D AI!/15/81 g ine TEC Calloration racility siial H esnau t isn ena niolatalo cai tara ce va proccuura, schedules, records and identification of mechanical measuring equipment. Calibration standards shall have errors normally less than one fourth of the tolerance of the equipment being calibrated. Greater uncertainties cuy be allowed when limited by the state of the art. In situations where it is impossible to comply with the above, a calibration standard of less accuracy shall be allowed providing the conditions are documented and authorized by the CQAM and can be shown to be within the tolerances and accuracy of the requirements of the equipment being calibrated. The TEC Calibration facility shall establish and maintain calibration procedures, certificates of calibration, instrument history / repair records, and other documents necessary to maintain traceability of calibration standards. Calibration frequency shall be established per the manufacturer's recommendations or as TEC Calibration Facility Management deems necessary. Calibration methods defined by an appropriate government agency or professional society shall be utilized wherever possible. When no suitable documents in these 9 categories exist, a TEC procedure shall be prepared by the user. The initial frequency of calibration for each item of mechanical measuring equip-ment shall be quarterly unless otherwise specified by the CQAM. NOTE For mechanical measuring equipment that is not in use, this equipment may be held in CONTROLLED STORAGE for up to one year before calibration is due. Once checked out from CONTROLLED STORAGE, it shall be calibrated quarterly. 12.1.3.3 Certification and Control The calibration status of items of electrical and mechanical measuring equipment shall be indicated by a decal, a tag, or a periodic inspection nameplate, as applicable, attached to the item. The decal, tag, or nameplate shall as a minimum specify the calibration date, the next calibration due date (or calibration void date) and the stamp and/or name of the individual or laboratory which performed the calibration. Where outside calibration facilities are utilized, a TEC decal, tag, or nameplate shall be affixed to the measuring and test equipment in addition to that of the outside calibration facility. b%.) Page 73 of 101
TITLE NO. I 7 l 12.0 CONTROL OF IEASUREMENT TEC-QA-12.1 i
' ___--~ AND TEST EQUIPMENT ll l I
RE v. 3 Technology for Enercy Corporation APPROVED BY DATE QUALITY ASSUR ANCE MANUAL \ \ D A17-/15/81 eS T , tw % n-n-ri a v Records of calibration, maintenance, repair, and location shall be maintained for each item of measuring equipment. Calibration and certification records provided by the National Bureau of Standards or other approved calibration laboratory shall be maintained on file. The TEC Calibration facility shall perform or have performed by outside labora-tories initial and periodic calibration, maintenance and repair of measuring equipment in accordance with established procedures and schedules. Calibration of primary measurement standards shall be performed by the National Bureau of Standards or other approved calibration laboratory in accordance with established schedules. Items which are not calibrated shall be clearly marked "Not Calibrated." When a piece of inspection / test equipment is suspect, a special calibration will be performed. Should an item be found to be out of calibration, an investigation will be made of the material inspected and where necessary, reinspection will be conducted. If the equipment or manufactured item has been shipped to the customer, the customer shall be notified and appropriate action taken. 12.1.4 Attachment Figure 12.1-1 Equipment Property and Calibration Labels DV Page 74 of 101
l l 1 1 Figure 12.1-1 Equipment Property and Calibration Labels. ' PROPERTYOF TECHNOLOGY FOR ENERGY CORP. KN0XVILLE, TN 37922 tocauBRATEIR. 8Y DATE DUE C AllB R ATIO N NOT REQUIRED l 1 l l l l l Rev. D l 12/15/81 lb ( Page 75 of 101
+ , TITLE NO.
e 13.0 HANDLING, STORAGE, AND TE C -0 A-13.1 g l == SHIPPING REV. D Technology for Energy Corporation APPROVED BY OATE DATE QUALITY ASSUR ANCE M ANU AL
?ha ,LM*Qr v 11-n 21 12/15/81 13.0 HANDLING,' STORAGE, AND SHIPPING-13.1 PACKAGING AND SHIPPING VERIFICATION 13.1.1 Purpose This section defines the responsibilities for the verification of packaginq and the preparation for shipnent of TEC products.
This section applies to apolicable products reouirino 0A' acceptance that are shipoed from TEC to a TEC custoner includinq source inspected items shipped by a supplier direct tn a TEC work site or to a TEC customer. 13.1.2 Responsibilities ( 9 hv the OC/TD as follows: Packaging and preparation for shipment of applicable products shall be ver i Verify that applicable shippino documents are properly completed; i .e., part number, part description, quantity, item serial nunbers (if any) , etc., are included. Inspect applicable items for ohysical dar.aoe, completeness, proper identifica-tion, evidence of orior inspection and acceptance and/or other requirenents as j sepcified by applicable drawings, specifications, purchase ordcr, or contract. 1
~Verif.y that aDolicable containers, pac'<aqing material, and preservation safe-l Quards are in accordance with requirements of the purchase order, drawings, specification, or contract.
NOTE When packaging specifications or packing reauirements are not specified on apoli-cable documents, itens will be pac'<ed, inspected, and shipped in accordance with TEC shinoinq standards. Veri fy that all containers are identified and marked in accordanc e <;i th requi re-ments of the purchase 3rder, drawings, sneci fications, nr contract. Verify that all shippinn documents have been siqned and dated. O oane ?6 of 101 _ o
., TITLE NO. I
'l e
13.0 HANDLING, STORAGE, AND TEC-QA-13.1 EEE SHIPPING REV. Technology for Energy Corporation D APPROVED BY DATE DATE QUALITY ASSUR ANCE MANU AL ggy , ,,, 12/15/81 Verify that all nonconformances that have been reported by an NCR have been dispositioned. The OC/TD Manaaer shall assure that these verifications are documented and a copy of the documentation is forwarded to the P0AA. f h O Pa ce 77 of 101
- TITLE NO.
__i~ r i 13.0 HANDLING, STORAGE, AND EEE TEC-QA-13.2
) i SHIPPING REV.
Technology for Energy Corporation n QUALITY ASSUR ANCE MANU AL ()- V ( O
, , 12/15/31 13.0 HANDLING, STORAGE, AND SHIPPING 13.2 PROCEnURES FOR PACKING. SHIPPING, STORAGE AND HANDLING 13.?.1 Purpose This section defines the requirements for the preparation of packing, shipping, storaqe, and handlina.
13.2.2 Responsibility 13 ?.2.1 Production Control Department The Production Control Depart:nent prepares and implements qeneric procedures for (] 1 Dacking, shiocina, storaqe, and handling of TEC products. Ar;SI N45.2.2-1972 and pro-cedure FIN-003 " Ship lent of Products and Property" will be used as a guide for the preparation of these procedures, flormallv, a 24 hour notice is to be given to the PQAA prior to shippinq so that the necessary certificates of confornance can be prepared and issued. l l
- O Page 78 of 10
' TITLE NO.
!i di 14.0 INSPECTION, TEST, AND l, [ Es=
'l OPERATING STATUS TEC-QA-14.1 l h REV.
D Technology for Enerty corporation QU ALITY ASSUR ANCE M ANU AL p 12/15/81 14.0 INSPECTION, TEST, dND OPERATING STATUS 14.1 Routing Sheets and Manufacturing Methods Packages 14.1.1 Purpose The purpose of this section is to define the Production Department's respon- ' sibilities in preparing Routing Sheets (RS) and Manufacturing ilethods Packages (4tP), the QC/TD responsibilities for inspecting and testing products and assemblies manufac-l tured by the Production Department, and the PQAA's responsibilities in assuring QC/TD and Production Department's compliance to this section. 14.1.2 General e The RS is an approved method for transmitting instructions to Production and b Quality Control and Testing Department (QC/TD) personnel, and it serves as an authori-T zation for labor expenditures and for the movement of material. The RS authorizes the I release of material from storage and serves as a summary record for TEC fabricated I products. l The Manufacturing Methods packages (MMP) are folders that contain or reference the written inspection and testing instructions, production procedures, assembly ' drawings, routing sheets and other QA, engineering, and production documents, as required to accomplish the manufacturing objectives. Applicable documents, such as l standard production procedures or inspection and/or testing procedures do not have to l be contained in the It1P but must be referenced on the Methods Sequence Sheet if not included in the fitP. 14.1.3 Responsibilities and Reouirements 14.1.3.1 Production Department Once approved Production Packages are received the Product Design Department, Manufacturing Methods Section prepares Manuf acturing Methods Packages .(41P) which shall contain the following items, as applicable: O Page 79 of _101
TITLE NO. h, 14.0 IllSPECTION, TEST, AtlD TEC-QA-14.1 {y l
== OPERATING STAT'JS I --
aEv. 3 Technology for Eeercy Corporation APPROVEo SY CATE oATE QUALITY '. SUR ANCE M ANU AL b t N +.4 6 I?-2 3-E t 12/15/31 Routing Sheet fiethod Sequence Sheet Wire Preparation Instructions PWB Set Up Wiring Sequences TEC Bill of I4aterial Any Test Procedures (Instructions) (or reference to these procedures by number and title) Special fianufacturing Procedures / Instructions When the Production Control Department issues a " Production Assembly Release to fianufacturing !!ethods" form, which also assigns batch serial numbers, if required, Production Department commences production as described by the It4P. After manufac-turing requirements are completed as specified by the Routing Sheets and the !!4P, the product is routed to QC/TD where all QC inspections and tests, both in process and final, are accomplished in accordance with written procedures.
- Items found to be acceptable are routed to either TEC stock or to the Shipping Department for processing and shipping to the customers.
Items found to be discrepant (as described in TEC-QA-15.1) shall have an NCR form prepared, and based on the NCR disposition, shall be handled accordingly. For those items dispositioned repair or rework, they shall be routed to Production Department and then rerouted to QC/TD for reinspection or retesting. Items with defects (as described in TEC-QA-15.1.4, Note 2) shall be as noted on the defect reports and shall be routed to the Production Department for rework. Items which require repair shall be routed to the Production Department where the item (s) will be repaired in accordance with written instructions received from PDD and/or QCTD personnel, as appropriate. 14.1.3.2 Quality Control and Testing Department The QC/TD shall assure that all items are inspected and/or tested in accordance with inspection / test procedures and/or instructions contained or referenced in the it'4P . The QC/TD shall issue flCRs for all items found to be nonconforming, and shall tag with a nonconforming materials tag (see TEC-QA-3.1) and place these items in a segre-gated area, if physically feasible. The QC/TD shall reinspect and/or retest all items in which the NCR is n dispositioned, rework or repair, once the rework or repair is completed. I V Page 80 of 101
TITLE NO.
- ] ggs j[
, 14.0 INSPECTION, TEST, AND TEC-QA-14.1 q OPERATING STATUS l ll -- ! aEv.
D Technology for Energy Octocration APP 90VED B OATE DATE QU A LITY ASSUR ANCE M ANU AL g , , 12/15/81 14.1.3.3 Ouality Assurance The POAA shall perform, in addition to defined hold points, random surveillances during manufacturing and OC inspection and testing, and document these surveillances by means of the POAA Surveillance Report (see TEC-0A-18.2, Figure 18.2-1). QJality Assurance notification of the commencement of production and/or testing activity shall be by means of the PQAA attendance at manufacturing production meetings. 14.1.4 Manufacturing Methods Package The MMP shall accompany the item (s), to which it applies, throughout all phases of nanuf acturing and inspection / testing. Once the item (s) is accepted, and either routed to TEC stock or shipping, the MMP is returned to Manufacturing Methods Section. Copies of the completed Routing Sheet are distributed as follows: fO Quality control and Testing Department Manager Production Control Manager The original Routing Sheet is maintained in the Manufacturing Methods files. Pa ge 81 of g
~
l TITLE N O. 1 l j i 15.0 NONCONFORMING MATERIALS, TEC-QA-15.1
/% s EEE l PARTS OR COMPONENTS l --
R EV. D Tecnnology for Ener2y Corcoration APP 90VEo BY OArg DATE QU ALITY ASSUR ANCE M ANU AL g 1 g7157g1 15.0 NONCONFORf1INGMATEkIALS,PARTSORCOMPONENTS 15.1 NONCONFORMANCES 15.1.1 Purpose The purpose of this section is to define how TEC manufactured item and vendor product nonconformances, whether hardware or documentation, are reported to TEC mana-genent and to the customer, as required by contract, to prevent nonconforming items f ron being incorporated into TEC products. Also, this section defines TEC's method for dispositioning identified nonconformances. 15.1.2 Responsibility Quality Assurance and QC/TD personnel have the responsibility for the administra-tion of this procedure. 15.1.3 Definition of Nonconformance A deficiency in characteristic, documentation, or procedure which renders the quality of an iten unacceptable or indeterminate. Examples of nonconformance include: physical defects, test f ailures, incorrect or inadequate documentation, or deviation f rom prescribed processing, inspection or test procedures. 15.1.4 Nonconformance Hold Procedure When materials, parts, components, modules, or systems, or the documentation for any of the aforesaid itens, are suspected of being nonconforming to TEC or customer specifications, drawings, etc. , the nonconforming item shall be immediately tagged with a nonconforming material tag (see Figure 8.1-2) which is filled out by QC/TD per-sonnel questioning the quality of the iten(s). This nonconforming material tag shall l be renoved by the QC/TD manager or his designee ONLY. The QC/TD Manager or his designee shall have "stop work" authority. Production Department shall stop work on any items under their control bearing the nonconforming naterial tag, or QC hold tag until tne resulting Nonconformance Report (NCR) is dispositioned. Pa ge 82 of 101
TITLE NO. l H 15.0 NONCONFORMING MATERIALS, TEC-QA-15.1 l PARTS OR C0ftP0NENTS g==ll O aEv. D Technology for Energy Corporation APPROVED BY DATE DATE QUALITY ASSUR ANCE MANUAL Tx q g0 g> um 17 7<.91 12/15/81 l All items tagged with the nonconfoYmirlg material tag shall be removed from their existing areas, and segregated in an area having controlled access, if physically feasible. After the item is tagged, an NCR shall be initiated by the QC/TD Manager or his designee. The QC/TD Manager shall maintain the NCR Log. The NCR form will be completed in accordance with QC/TD procedure 00P-100, " Instructions for Processing Honconformance Reports." The QC/TD tianager, after the NCR form is completed, shall approve the required disposition. NOTE 1 Recommended dispositions of " Repair" and "use-as-is" require PDD and, if appropriate, customer action. PDD shall maintain documentation supporting their dispositions of " Repair" and "use-as-is". Recommended dispositions of Return to Supplier require Purchasing Department and supplier action. NCRs forwarded to the customer shall be via the Contracts Department Manager. 9 NOTE 2 Small component failures, such as defective I.C. chips, resistors, diodes, etc., or manufacturing errors, such as bad solder joints, wiring errors or shorts, do not constitute a test failure requiring an NCR to be written. These problems shall be documented on the back of the Routing Sheets, the item returned to the Production l Depe -tment for rework and the item reinspected by the QC/TD. If, cither the PQAA, by means of random surveillances, or the QC/TD manager during QC inspections / tests deter-l mine that a trend is being set, the QC/TD Manager or his designee shall then issue an NCR describing these failures. After a UCR is prepared, tne QC/TD tianager shall forward a copy of the NCR to the l CQAM and appropriate PQAA, if applicable in accordance with D0P-100. l After the NCR final disposition is determined, (in tae case of repair /use-as-is, both the Design Engineer and his/her department manager shall sign and date the NCR) l the NCR disposition shall be approved by the QC/TD tianager. Once the disposition is implenented, the QC/TD Manager shall verify implemen-l tation and close out the NCR. When the NCR requires customer action, before final disposition is implemented, customer approval is required. G
. A copy of all closed out NCRs shall be distributed to the CQAM and PQAA, if (I/ applicable.
Page 83 of 101
, TITLE NO.
!l l 15.0 NONCONFORMING fMTERIALS, TEC-QA-15.1
== PARTS OR COMP 0tlENTS i ll REV.
D Tecnnology for Energy Corporation APPROVED BZ DATE DATE QUALITY ASSUR ANCE M ANUAL 12/15/81 { NOTE 3 A copy of all closed out flCRs for TEC purchased items shall be forwarded to Accounts Payable. 15.1.5 Nonconformance Report Summaries . At the beginning of each month, the QC/TD Manager shall prepare a summary of flCRs issued the previous month stating the NCR number, and the NCR status and forward same l to the CQAM. For any NCRs not closed within 30 days of initiation, the QC/TD tianager shall state the reason why on the summary sheet. 15.1.6 Attachments Figure 15.1-1 Nonconformance Report Page 84 of 101
1 s Figure 15.1-1 Nonconformance Report l l
=nsen,,non w r eronet a, l (F#'fn9 i Proiect! Contract: P. O. # i Reportei hy: Date: Supolter: I I
Nnmenclature: Part #: Sertal a I nate Received: Invoice
- I Drawino specification (No): . Rev. Quantity: <
Nonennfomance nescription: l i DC/TD Review: Date: steffnf4 ft Disposttien racemended ny the OC/in: [ReturntoSupo11er. [ Use as is'. [Scrao. CRenair'. [ Rework. [ Cther NnTE: ***ouires appropriate approval sf onature in Section !!!. Coev to: [CCAM. [POAA. [ Finaace. [nther v trCffnN fif nisonsition Acoroved: CReturntosucolier. [ Use as is. [ Rework. O Scrap. [oeocir. [ Other Co w nts: Discosition Actio4 Recutred Bv: . T.c oa rtmen t -ate Reoa1*/IIse as is acorovals: Deston Engineer: . Date: (if acolicable) Department Mananer: . Date: Customer: . Date: Disposition Aceroved Ry (OC/TD) . Date: , Copy to: ]COAM. [70AA. [ Purc%astaa. [ Engineer. [Custoaea. i [ Supolter. [ protect *%nacer. [ Production. [ Production Ctrl. [ Ot*** . [ Other l l trering Tv ntsoosition tantemented: [Returnedtosupolter. [tJsedasis. [ 8 ewe-t e , [ Scracoed. [ Repaired, nther i ni s onsi tion trot...nted ev: , nate: 51Onature NCR c1nsen by OC/73: . nate: l-l ( Coov to: [ CoAM. [ 90AA. [ Ft nance. [ otne-l (> . Page 85 of 101 Rev. D: 12/15/81 i
g TITLE NO. II l 15.0 NONCDNFORMING MATERIALS, TEC-0A-15.2
===
g PARTS OR COMFONENTS R EV. D Technology for Energy Corporation APPROV E( B Y DATE DATE OUALITY ASSUR ANCE MANUAL y A n_ gf 12/15/81
* \
15.0 NONCONFORMING MATERIALS, PARTS OR COMPONENTS 15.2 nESIGN DEVIATION RE0 VEST (DDR) 15.2.1 Purpose The purpose of this section is to define the use of the DDR and its implementation. 15.2.2 Definition of DDR A DDR is a Desiqn Deviation Request form (see Figure 15.2-1) which is a TEC internal form sent to the Contracts Department Manaaer, requesting that a TEC customer either authorize a desian deviation to the customer's drawing (s) or specification or approve a technical chanae to the contract. A DDR is used during the design phase of a product and is used before a deviation is accomplished. It is not intended to be used "after-the-fact," whicn would be a nonconformance. 15.2.3 Responsibilities The Project Manaaer is responsi51e for controlling, coordinating and distributing all DDRs. I The POAA shall review all DDRs pertainina to 0A projects for possible impacts on
' contractual quality requirements.
15.2.4 Procedure Once a DDR is initiated, the Project Manager shall obtain the Desian Engineer's and Project Engineer's approval sianatures on the DDR form. The Project Manaaer will approve the DDR and, if the project is QA applicable, route the DDR to the POAA for review. The POAA shall return the DDR to the Project Manaaer after sianinq the DDR. The Proioct Yanacer now assions a DnR Nun 5er which shall be as follows: e.a., 3n036 - 1 n / / V 30N number Sequential number Daqo 86 of 101
l TITLE NO. 15.0 fl0NCDtlFORMIfiG MATERIALS, TEC-QA-15.2
===
l PARTS OR COMP 0tiENTS REV. Tecnnology for Energy Corporation APPROVED BY DATE DATE QUALITY ASSUR ANCE M ANUAL u, 3 3, 12/15/81
~
g The Pro.iect Manager shall maintain a 100 of DDR's which shall show assigned date, status and date closed-out. A copy of the DDR shall now he forwarded to the Contracts Department Mananer, who shall utilize the information on the DDR in preparing a letter to the customer. If the custoner approves, the Contracts Department Manager shall issue a revision to the PON and the Pro.iect Manager shall annotate this PON revision and date on the original to the DnR, signifyinq customer approval. If the custoner does not approve, the Contracts Department Manager shall send a copy of the disapproval letter to the Pro.iect Manager. The Project Manager shall annotate the letter number (if any), the date and person siqning the letter, on the DDR oriqinal, sianifyinq customer disapproval. 15.2.5 Dis'tribution of ComDieted DDR { ) Oriqinal - Pro,iect Manager l Copy - POAA 15.2.6 Attachments Figure 15.2-1 Desinn Deviation Reouest r - P80e 87 of 101
5 DESIGN DEVIATION REQUEST DDR NO : CllSTOMER : PON flUMBER: DRAWINGS: Drawino Number Revision Level SPECIFICATION flUMBER: ,
- DESCRIPTION OF DEVIATION:
i O [ Attachment APPROVALS: DESIGN ENGINEER: DATE: PROJECT ENGINEER: DATE: PROJECT MANAGER: DATE: POAA REVIEW: DATE: , CilSTOMER APPROVAL: [ Yes Q No Fiqure 15.2-1 Rev. D: 12/15/81 Page 88 of 101
TITLE NO. 16.0 CORRECTIVE ACTION TEC-QA-16.1 REV. O Technology for Enercy Corporation APPROVED BY DATE oATE QUALITY ASSUR Af4CE M ANU AL
, 12/15/81
% i-16.0 CORRECTIVE ACTION 16.1 CORRECTIVE ACTION PROCESSING 16.1.1 Purpose The purpose of this section is to define the methods used to assure that correc-tive action is taken for conditions adverse to quality, as identified by this manual, which includes actions taken to prevent recurrence.
16.1.2 Requirements 16.1.2.1 Initiating the Reouest for Corrective Action Form
/ Any TEC personnel can initiate a request for corrective action (see Figure b 16.1-1). It is the responsibility of all TEC personnel to assure the attainment of quality at TEC. This includes request for corrective action against the Quality Assurance Department.
I Any area of concern or apparent discrepancy pertaining to quality should be iden-tified by means of a Request for Corrective Action (RCA) form. Anonymity shall be preserved, if requested (as indicated on the RCA form). The initiator of the RCA form shall forward the completed form to the CQAM for processing. Once the CQAM has determined the request to be a valid request, the CQAM will sign the RCA, return same to the requestor, and initiate a Corrective Action Report (see Figure 16.1-2). If the request is determined to be outside the scope of quality assurance, or the request is not valid, the RCA shall be returned to the i requestor with the reason for rejection so stated. l 1E.1.2.2 Corrective Action Report l If the RCA requestor wishes to remain anonymous, the CQAM or his designee shall sign the " Reported By" space on the Corrective Action Report (CAR) form, i The CQAM or his designee shall complete items one through six on the CAR, which includes the identification of the condition, as well as assign the organization and individual responsible for taking the necessary corrective action, q r
) ,
l l Page 89 of 101
TITLE NO. t . 16.0 CORRECTIVE ACTION TEC-QA-16.1
==
REV. O Technology for Energy Corporation - QUALITY ASSUR ANCE MANUAL 9 gh,( ,.,,., yf 12/15/81 The assigned individual shall determine the cause of the discrepancy and state the corrective action to prevent recurrence of the condition adverse to quality. The l CQAM or his designee shall review the corrective action proposed or taken, release the stop work action, if applicable, and close-out the CAR once verification of corrective action is accomplished. Periodic follow-up is taken to verify the effectiveness of corrective actions taken to correct significant adverse conditions. This follow up shall be documented by means of the PQAA Surveillance Report forms (see TEC-QA-18.2). 16.1.2.3 CAR Log l indicate the status of all CAR's at all times.The CQAM shall maintain a log of Corrective Actio 16.1.2.4 CAR Summaries The CQAM shall issue a CAR Summary report on a monthly basis or at a frequency h determined by the CQAM, commensurate with CAR activity listing all outstanding CAR's and identifying any corrective action over 30 days delinquent. Copies of the CAR Summaries shall be distributed to the TEC President, applicable Group Vice President (s) and other affected organizations. I 16.1.2.5 Attachments
- 1. Figure 16.1-1 Reauest for Corrective Action
- 2. Figure 16.1-2 Corrective Action Report p
V , Page 90 of 101_
. - - . _ . = .. . - . .-
l RE00EST FOR CORRECTIVE ACTION RE0llESTOR : DATE: Do vnu prefer to remain anonymous? Yes [ No 0 DESCRIPTI0fl 0F APPARENT DISCREPANCY: i l 4 l l i l 1 i I ( RECOMMENDED CORRECTIVE ACTION (IF ANY): !O i < i l C0AM REVIEW: C Aporoved: DATE: CAR NO. COAM Signature l { C Disapproved: DATE:
- l CQAM Signature REASON FOR REJECTION
1 i Fiqure 16.1-1 Rev. 0: 12/15/81 O ' i Page 91 of 101 l-.-.,,-..-. . _ . - - . . - . - . . . . - - . _ . - _ . - . . - . .. .-. . . - . . - . - . , . . - . _ . . . . . . - - ..
1 CORRECTI0fl ACTION REPORT
- 1. CAR N0.:
- 2. REPORTED RY: DATE:
! 3. ORGANIZATION AFFECTED:
4 DESCRIPTI0tl 0F APPARENT DISCREPANCY: 4
- 5. RESULTS OF INVESTIGATION:
[ Attachment 6 IMPOSEn RESTRICTIONS: C None C Stop work OOther (J ACTIVITY /0RGANIZATION RESTRICTED: DATE IMPOSED: th l C0AM SIGNATURE: RESTRICTI0ff DETAILS: 4 q 7 ASSIGilED RESPONSIBILITIES: ORGANIZATI0ft: IflDIVIDUAL DETERMINED CAUSE OF DISCREPANCY: CORRECTIVE ACTION (PROPOSED OR IMPLEMENTED): l COAM REVIEW: DATE: STOP WORK RELEASED BY: DATE: C AR CLOSE OUT: DATE: Fiqure 16.1-2 O. , Rev. D: 12/15/81 Page 92 of 101
TITLE NO. I l _ l 17.0 QUALITY ASSURANCE RECORDS TEC-QA-17.1 ( > 1
- l. l REv.
D Technology for Energy Cor: oration APPROVED BY DATE DATE QUALITY ASSUR ANCE M ANU AL { , , 12/15/81 17.0 OUALITYASSURdNCERECORDS 17.1 OVALITY ASSURANCE RECORDS IDENTIFICATION AND RETENTION 17.1.1 Puroose The purpose of the section is to assure that sufficient records are maintained to furnish evidence of quality and to satisfy customer contract requirements. This sec-tion shall define requirements concerning record retention, duration, location, and assigned responsibility. 17.1.2 Resoonsibility l The CQAt4 or PQAA shall be responsible for the administration of the functions in this section. 17.1.3 Applicable Quality Assurance Documents TEC and Vendor's documents which are designated as Quality Assurance documents shall be identified for each project on the project record index. Prior to the com-mencement of manufacturing on any quality assurance project, the congnizant PQAA shall prepare a QA record's index and file the same in the record storage area. This index shall be compiled from the contractual records submittal requirements. Records designated as Quality Assurance Records by the customer shall be iden-l tified in the customer's contract and so identified on the project record index. 17.1.4 Retention Duration and Locatio_n _ Quality assurance records shall be retained as outlined in QAP-1006. The reten-l tion duration of quality assurance records shall be as stated in customer's contract or as defined in NiSI N45.2.9-1974. Permanent and non-permanent quality assurance records shall be stored in file l cabinets having controlled access. TEC shall maintain a duplicate remote storage system as follows: Primary storage - Active projects - files located in a designated area under the cognizant PQAA having controlled access. pd , Completed projects - files located in a designated area under the cognizance of the CQAti. Page 93 of 101
W TITLE NO. I
; I 17.0 QUALITY ASSURANCE RECORDS TEC-QA-17.1 l == i l l l REV.
O reennology for Energy corooration CUALITY ASSUR ANCE M ANU AL
,t33f 12/15/81 Secondary storage - to be located, as designated in TEC QA p rocedure, QAP-1006 i Access to these files shall be through the CQAM or the President's office l (secondary storage and completed projects) and PQAA office (active projects). Records removed from the QA files shall be withdrawn in accordance with QAP-1006.
17.1.5 Record Quality Quality assurance records (drawings, documents, and data sheets) shall be legible and reproducible. Reduced quality assurance records, if implemented, shall be on microfiche, 35mm Aperture Cards or microfilm. l I l l
'M (M
l - pa ge 94 of 101
TITLE NO. I 18.0 AUDITS TEC-QA-18.1 l ==
\ l REV.
D Technology for Energy Cor:2 oration APPROVED SY DATE DATE QUALITY ASSUR ANCE M ANU AL 12/15/81 18.0 AFDITS 18.1 AUDITS 18.1.1 Purpose The purpose of this section is to define the requirements for performing TEC l internal audits of the QA program, TEC Management audits of the CQAM function, and external vendor audits. 18.1.2 General Requirements Auditors shall meet the requirements of a lead auditor in accordance with ANSI N45.2.23-1978 and TEC's Lead Auditor's Training Course prior to performing audits
,I independently, for internal audits and external audits (excluding TEC management j g audi ts) .
TEC internal audits shall be performed as scheduled by the TEC Internal Audit l Schedule prepared by the CQAM. TEC external vendor audits shall be performed as required by contract or based on vendor history problems. l TEC Management audits shall be performed once during the calendar year. The TEC QA Manual, procedures and customer contracts shall be used as a checklist for internal audits. The QA Manual shall be used as the checklist for Management audits. 18.1.3 TEC Internal Audits These audits shall be performed in accordance with the annually established audit schedule. This schedule is divided into individual criteria to achieve depth during l each audit. Each criteria shall be audited at least once each calendar year. Audit reports shall be issued within 30 days of the audit completion, and shall be addressed to the President of TE' and distributed to the audited organization (s). Deficient areas shall be reaudited to verify implementation of corrective action to findings. Page 95 of 101
TITLE NO. I l 18.0 AllDITS TEC-0A-18.1 k a s v. Tecnnaiocy for Energy Corporati D APPROVED BY DATE DATE QUALITY ASSUR ANCE MANUAL fL n n cf 12/15/81 Audit reports shall be prepared, as described in the TEC Lead Auditor'3 Training Course, which shall list the audit scope and audit summary. Findings shall be written on the TEC OA Audit Evaluation Sheet (see Fiqure 18.1-1) . 18.1.4 TEC '4nacement Audits These audits shall be performed by selected Vice-Presidents at TEC that have been l certifled as Auditors. They are responsible for auditing the C0AM functions to deter-mine compliance to the TEC OA program. Assurance of corrective action shall be the responsibility of the COAM. Al though this is the C0AM responsibility, actual corrective action shall be routed to the audi-tors for their approval. The audit renort shall be addressed to the President of TEC and distributed to the TEC Executive Committee. 18.1.5 External Vendor Audits, The vendor QA manual shall be utilized as the audit check list. The audit report shall be prepared within 30 days of completion of the audit. The TEC Lead Auditor's i Training Course shall be used in preparing the audit report. Audits shall be conducted at least once during the contract or annually, if deemed necessary by the COAM by qualified Lead au.iitor(s) . 18.1.6 Attac hments Finure 18.1-1 TEC OA Audit Evaluation Sheet ()J Page 96 of 101
Figure 18.1-1 TEC AUDIT NO. QUALITY ASSURAtlCE EVALUATION AUDIT SHEET NO. AUDITED ORGANIZATION LOCATION C0tlTROL ELEMENT REQUIREMEllT(s): OBSERVATION (s): CONTRACT (s): REPORTABLE O Yes C No AUDITOR (s): DATE: AUDITED ORGANIZATION REPRESENTATIVE DATE: TITLE: SIGNATURE SIGNIFIES UNDERSTAtlDING, NOT NECESSARILY AGREEMENT Rev. D: 12/15/81 ( y Page 97 of 101 (^'J
's_
i5 Figure 18.1-1 (cont.) dl AUDIT NO. FINDING NO. 1 CORRECTIVE ACTION PROPOSED BY AUDITED ORGANIZATION: ) (Including Scheduled Implementation Dates) i i i AUDITOR COMMENTS: l CORRECTIVE ACTION VERIFIED: (CQAM Use Only) I
- Auditor
Date: I - Rev. D: 12/15/81 i ( Page 98 of 101 i
TITLE NC-
,_.r i l' 18.0 AUDITS TEC-QA-18.2
( == l i, f REV. D reennaiocy for Energy corocration QUALITY ASSUR ANCE M ANU AL i7_ 3 7, 12/15/81 18.0" AUD'ITS ; l 18.2 P0AA SURVEILLANCE ACTIVITIES 1E.2.1 Purpose l The purpose of the section is to delineate the requirements for the PQAA sur-veillance of project activities and the reporting of the same. 18.2.2 Procedure l During the weekly activities of the PQAA function, the PQAA shall make randon surveillances of his/her project to assure compliance to the contract, QA Plan and TEC QA Manual.. { These surveillances shall be documented by means of the PQAA Surveillance Report (see Fi gu re 18.2.1) . Both satisfactory and unsatisfactory findings shall be bx documented. If a negative finding is not significant and can be corrected on the spot, this need only to be addressed on this form. Otherwise, an NCR needs to be pre-pared in accordance with TEC-0A-15.1P. 8 The PQAA Surveillance Report shall be submitted to the CQAM no later than the Monday af ter the preceeding week in which the surveillance was performed, with infor-mation copies to personnel affected. The PyAA Surveillance Number is obtained by the PQAA from the P0AA Surveillance Report log, naintained by the C0AM. 18.2.3 Attachments l Fi gure 13.2-1 P0AA Surveillance Reoort g Fi gure 18.2-2 P0AA Surveillance Report Log (
,q
-)
Page 99 of 101
/
, POAA SURVEILLANCE REPORT SURVEILLAriCE NO.: PROJECT NO.: CONTRACT NO.: SURVEILLANCE DATE: PREPARED BY: OBSERVATION: STATUS: Sa tisf actory ] PQAA SIGNATURE:
,. Unsatisfactory ] (Corrective Action Below)
NCR Required: ]Yes ] No IF YES, NCR NO.: CORRECTIVE ACTION: CORRECTIVE ACTION COMPLETED: DATE: PQAA Signature REVIEWED BY: DATE: CQAM l Fi gu re 18.2-1 ['/ 8._ Rev. D: 12/15/81 Page 100 of 101
]
ARKANSAS POWER & LIGHT COMPANY POST OFFICE BOX 551 LITTLE ROCK. ARKANSAS 72203 [501)371-4000 August 26, 1983 OCAN088314 2 Director of Nuclear Reactor Regulation ATTN: Mr. J. F. Stolz, Chief Operating Reactors Branch #4 Division of Licensing U. S. Nuclear Regulatory Commission Washington, DC 20555 Director of Nuclear Reactor Regulation ATTN: Mr. James R. Miller, Chief Operating Reactors Branch #3 Division of Licensing U. S. Nuclear Regulatory Commission Washington, DC 20555
$UBJECT: Arkansas Nuclear One - Units 1 & 2 Docket Nos. 50-313 and 50-368 License Nos. DPR-51 and NPF-6 Program Plan for ICC Systems i
Gentlemen: 1 Our two Inadequate Core Cooling submittals dated April 15, 1983, (1CAN048308 and 2CAN048306) committed to providing a program plan by August 26, 1983. Our ICC program plan is attached. This plan documents our approach to developing and implementing the Inadequate Core Cooling instrumentation systems which will be installed in compliance with the NRC's Order for Modification of License dated December 10, 1982 (0CAN128211). The plan discusses some aspects of our proposed system in greater detail than our April 15, 1983 submittals; however, it is not intended that this document contain descriptions or commitments which cannot be modified during the performance of our program. Ver truly yours, hw . I hohnR. Marshall Manager, Licensing l JRM:JK: s1 Attachment 0
,a
( Mt '.'E2E n M ODL E SOU T H UT. LIT *E S Sv STEM
.}}