ML19259B003
| ML19259B003 | |
| Person / Time | |
|---|---|
| Site: | 07001201, 07100115 |
| Issue date: | 12/11/1978 |
| From: | Zeff D BABCOCK & WILCOX CO. |
| To: | NRC OFFICE OF NUCLEAR MATERIAL SAFETY & SAFEGUARDS (NMSS) |
| References | |
| NUDOCS 7901150210 | |
| Download: ML19259B003 (63) | |
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.m Babcock &Wilcox
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Power Generation Group
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.1 U P.o. Box 1260. Lynchburg Va. 24505 Telephone: (8o4) 384-5111
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December 11, 1978
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REFERENCES:
(1)SNft-1168, Docket 70-1201 (2) 10 CFR 71.51(a)
Gentlemen:
As required by 10 CFR 71.51(a) and as revised per Federal Register, Volume 43, flo.122, June 23,1978, we are forwarding, with this letter, two copies of the Shipping Container Quality Assurance Program ifanual for the Babcock & Wilcox Company, Commercial Nuclear Fuel Plant (SNM-1168).
Should questions arise during your review of the manual, I may be contacted at (804) 384-5111, Ext. 5211.
Sincerely, BABC0CK & UILCOX COMPANY COMf!ERCIAL NUCLEAR FUEL PLANT D. W. Zeff, !!w ger Safety, Licensing, and Safeguards DWZ:cmm Attachment (2) cc:
J. P. Watters
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7901150910
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The Sabccck & WJcox Corn::any / Established 1867
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.. : 3 THE BABCOCK &WILCOX COMPANY NUCLEAR MATERIAL.S DIVISION COMMERCIAL NUCLEAR FUEL PLANT SHIPPING CONTAINER QUALITY ASSURANCE PROGRAM MANUAL -
License No. SNM-Il68 Docket No. 7o-1201 Revision DQfe 12-11-78
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P THE BABC0CT, & WILC0X COMPAflY tlVCLEAR MATERIALS DIVISI0ft SHIPPIflG C0f1TAINER COMMERCIAL flUCLEAR FUEL PLAfiT QUALITY ASSURAf1CE PROGRAM MANUAL RECORD OF REVISI0fts CHANGE DATE REY.
PAGE/ PARAGRAPH DESCRIPTI0fl 12-11-78 0
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BABCOCK' 8 WILCOX SECTION No.
i NUCLEAR MATERIALS OlVISION COMMERCIAL NUCLEAR FUEL PLANT TABLE OF C0hTEf1TS SHIPPING CONTAINER QUALITY ASSURANCE MANUAL SNM-ll68:
PAGE 1
1 0F TABLE OF CONTEf4TS SECTION TITLE i
Table of Contents ii Introduction 1
Organization 2
Quality Assurance Program 3
Design Control 4
Procurement Document Control 5
Instructions, Procedures, and Drawings 6
Document Control 7
Control of Purchased Materials, Equipment, and Services 8
Identification and Control of Materials, Parts, and Components 9
Control of Special Processes 10 Inspection 11 Test Control 12 Control of Measuring and Test Equipment 13 Handling, Storage, and Shipping 14 Inspection, Test, and Operating Status 15 Non-conforming Materials, Parts, or Components 16 Corrective Action i
t 17 Quality Assurance Records r
18 Audits Appendix A Glossary of Terms CQiG 12-11-78
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BABCOCK' a WILCOX SECTION No.
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PAGE I
2 0F INTRODUCTION PURPOSE:
This manual defines the quality assurance program to be applied by the Commercial Nuclear Fuel Plant to the design, fabrication, testing, inspection, use, and re-pair of radioactive materials shipping containers subject to the QA requirements of 10 CFR 71.
SCOPE:
CNTP management policy incorporates high standards of quality not only relative to product, but also where employee and public safety is concerned. The Quality Assurance program is established to assure that shipping containers are designed, built, and used in an orderly manner and in accord with established criteria and regulations.
Shipments of radioactive material from the CNFP are of a relatively narrow oe, consisting chiefly of:
(1) Unirradiated, low enriched fuel assemblies (2) Unirradiated scrap and waste materials as UO2 powder, pellets, or contaminated material for burial.
(3) Sealed s/y emitting sources used for activation analysis, calibration, and other analytical purposes.
Consequently, radioactive material shipping containers anticipated to be used by the CNFP are relatively uncomplicated and the QA program has been limited to those 12-11-78 g.g Rev.
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BABCOCK' 8 WILCOX SECTION No.
NUCLEAR MATERIALS DIVISION ii COMMERCIAL NUCLEAR FUEL PLANT INTRODUCTION SHIPPING CONTAINER QUALITY ASSURANCE MANUAL SNM-Il68:
PAoE 2
OF 2 areas where manufacturing and use specifications impact on nuclear or radiological safety. Due to the variability between container designs and types, no attempt is made in this manual to define applicability of specific requirements to individual containers, (i.e., which components are safety related) and such decisions will be made on a case-by-case basis by CNFP management.
DISTRIBUTION AND APPROV/iS:
The following limitations will be applied to the distribution and use of this manual:
(1) The manual and revisions thereto will, at a minimum, be approved by the CNFP Plant Manager, Quality Control Manager, and Safety, Licensing, and Safeguards Manager.
(2) Distribution of the manual will be controlled by the Manager, Quality Control to provide assurance that there is adequate dissemination of infor-mation and maintenance of current versions in the distribution chain.
Subsequent sections of this manual describe the implementation of the criteria specified in Appendix E of 10 CFR 71. As noted above, individual consideration of the criteria is predicated on the imoortance of safety and proper use of a container, considering the level of risk involved.
Delegation of individual function specified within this manual may be undertaken by management in accord with established plant policy.
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9 BABCOCK 8
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6 0F ORGANIZATION 1.1 Scope The CNFP may fabricate containers internally or employ a vendor organization for either design or fabrication. Additionally, nuclear safety evaluations or other specialized functions may be delegated to consultant organizations.
This section provides, in general, the QA controls necessary to assure that final responsibility remains with the CNFP as the licensee, and that indi-vidual approval and QA functions within the CNFP maintain independence from the design, fabrication, and use functions.
1.2 Personnel Qualifications Personnel responsible for shipping container QA functions are deemed to be qualified in this area since current programs for the application of 10 CFR 50, Appendix B are in effect.
1.3 Oruanization Implementation and maintenance of the QA program for manufacture (if appropriate), use, and repair of radioactive material shipping containers utilized at the CNFP shall be the responsibility of CNFP management. CNFP organization (Figure 1) is such that the plant organizations reponsible for the QA program are functionally independent and have authority to approve procedures, implement changes or corrective actions, or terminate container use, if necessary until improper conditions have been completed and approved.
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6 og CJP Plant Manager u
y Control Ma u ing e ng 4 e pards LICE Ming GC Engineering Manufacturing f
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na,; a.saa t, inspection Figure 1 The principal responsibilities and authorities for the CNFP Quality Control Program are vested in the following positions within the Quality Control Section.
1.3.1 Manager, Quality Control The direct organizational responsibility for implementing the Quality Assurance program lies with the Manager, Quality Control.
He reports directly to the Plant Manager and is wholly independent of other plant operations thus assuring independence in carrying out the functions of checking, inspecting, auditing, or othenvise verifying that the work has been performed satisfactorily and that the product conforms to applicable specifications.
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6 op Specifically, the Manager of Quality Control is responsible for assuring the implementation of all quality related factors.
He is responsible for preparing the Quality Control Program relating to the purchase specifications, vendor quality, assurance requirements, vendor system audits, and inspections.
He is responsible for plant audits to assess the overall effectiveness of the quality program. He is responsible for the review and approval of all vendor quality assurance programs.
He has the authority to withhold from further processing or use any components, which do not meet the applicable specifications.
1.3.2 Supervisor, Data Evaluation The Supervisor, Data Evaluation reports directly to the Manager, Quality Control and has the primary responsibility for establish-ing and maintaining a release system for materials and/or parts purchased by or manufactured within the CNFP. This includes review of data from the Inspection Unit on incoming materials and/or components prior to release for fabrication or use. Also included in this release system is a review of inspection reports, data, and allied records to validate certification that a component was fabricated in accordance with contractual drawings and specifications. Other responsibilit.es include review and evaluation of design specifications and drawings for Quality Control Rev.
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BABCOCK 8 WILCOX SECTION No.
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0F requirements and inspections, and approval of CNFP vendor's facilities including their QA/QC programs.
1.3.3 Chief Inspector The Chief Inspector reports directly to the Manager, Quality Control and is responsible for the preparation and execution of inspection procedures to define the techniques and methods for performing inspections required to assure component compliance with applicable specifications and drawings pertaining to dimensional, visual, and non-destructive inspection requirements.
Additionally, he is responsible for performing all necessary Quality Control inspections in accordance with written procedures.
He is resptasible for preparing procedures for the qualification of inspection equipment and personnel for Quality Control at the CNFP and for maintaining a gage control program for the periodic certification of inspection tools, gages, and quality related instruments at the CNFP.
1.3.4 Supervisor, Quality Control Engineering The Supervisor, Quality Control Engineering reports directly to the Manager, Quality Control and is responsible for the preparation of inspection procedures and sampling plans that properly interpret applicable design specifications for safety related items. He is responsible for the sampling plans for all 12-11-73 Rev.
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6 op other inspections in which a sampling technique is utilized.
He is responsible for approving techniques utilized in analytical tests and metallographic examinations performed in-house or by vendors.
Additionally, he is to review and approve CNFP vendor Quality Control plans arid perform audits of vendors to evaluate their Quality Control / Quality Assurance systems for fabricating product (s) to meet applicable specification and drawing requirements.
Internally, he is to evaluate design / fabrication document.s (specifications, drawings, special instructions) and offer comments relative to their adequacy, correctness, and completeness.
He is to administer the corrective action review and the internal audit program at the CNFP in accordance with Sections 16 and 18 of this manual.
1.3.5 Heal th-Safety Health-Safety personnel report directly to the Manager, Safety, Licensing, and Safeguards and are responsible for preparing and executing procedures that control nuclear and radiological safety.
Typical Health-Safety responsibilities include: appropriata inspections, radiation surveys, proper labeling of shipping container and vehicle, proper generation and retention of Health-gg 12-11-7a Rev.
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1 NUCLEAR MATERIALS DIVISION COMMERCIAL NUCLEAR FUEL PLANT ORGANIZATION SHIPPING CONTAINER QUALITY ASSURANCE MANUAL SNM-Il68:
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3 OF Safety documentation and overall enforcement of health physics and nuclear safety standards. Health-Safety has the freedom and authority, if necessary, to terminate the use of a shipping container if the nuclear or radiological standards are not met.
The Manager of Safety, Licensing, and Safeguards is responsible to assure that container design and us~e is in compliance with regulatory criteria.
In the ecse of new container design atid fabrication, the Manager, Safety, Licensing, and Safeguards will be responsible for coordinating and approving nuclear and radio-logical safety evaluations necessary to assure safety.
1.4 Interrelationships Interfaces within the QA program are outlined in Figure 2.
QA Program Pesponsibility Technical & C plias..e :,upport f
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BABCOCK ~ 8 WILCOX SECTION No.
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0F 3
QUALITY ASSURANCE PROGRAM 2.1 Scope The CNFP QA program applicable to the packaging and transport of radio-active material relative to nuclear and radiological safety criteria is described in this manual. The program described in this manual is established and approved by CNFP management with future revisions requiring equivalent approval.
Implementing procedures are also approved in writing by plant manogement as are revisions.
Functional CNFP organizations with primary responsibility for implementing and accomplishing the QA program are as follows:
- Safety, Licensing, and Safeguards in areas generally involving nuclear or radiological safety evaluations and licensing for new or modified containers, including design coordination and approval in safety related areas, preparation of operational procedures and checklists for in-spection of containers for compliance with certificates and other regulatory criteria.
- CNFP Quality Control in areas involving initial and "in-use" container inspections, verification that containers are fabricated in accord with approved specifications, and application of appropriate QC procedures relative to material control / traceability, vendor QA programs and audits.
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BABCOCK a WILCOX SECTION No.
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3 PAoE 0F SNM-ll68 As oescribed in Section 1 of this manual, both of the above organiza-tions report independently to the Plant Manager.
In addition to the above, shipping containers "in use" may, on occasion, I
be inspected by other plant components for routine in-use inspection (such as Manufacturing).
In these cases, the inspection shall be conducted only in accord I
with written procedures or checklists approved by Safety., Licensing, and Safeguards or QC management and inspection data will be forwarded to Safety, Licensing, and Safeguards and Quality Control for review and retention.
2.2 Requi rements Implementation of the Quality Assurance program will incorporate the follow-ing areas:
2.2.1 Personnel training and familiarization with QA, QC, and regulatory requirements as defined by management as requisite for effective control and compliance.
2.2.2 Periodic audits of the QA program to assure continuing compliance with its provisions and intent.
2.2.3 Designation, through procedures, or equally effective means, of responsibilities for operation of the QA program.
2.2.4 Requirements for the approval of procedures, manuals, design specifications, and other documents affecting safety or regulatory compliance.
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BABCOCK WILCOX SECTION No.
2 NUCLEAR MATERIALS DIVISION COMMERCIAL NUCLEAR FUEL PLANT QUALITY ASSURANCE PROGRAM SHIPPING CONTAINER QUALITY ASSURANCE MANUAL 3
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PAoE OF 2.2.5 Identification, based on the specific concainer involved, of safety related components. Typically, these may include, but are not limited to:
- Structural requirements for maintenance of geometric controls or container integrity.
- Neutron absorbants.
- Radiation shielding.
2.2.6 Procedures and controls shall be maintained, as appropriate, by vendor or consulting organizations and are applied as intended.
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BABCOCK WILCOX SECTION No.
3 NUCLEAR MATERIALS DIVISION COMMERCIAL NUCLEAR FUEL PLANT DESIGN CONTROL SHIPPING CONTAINER QUALITY ASSURANCE MANUAL 1
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PAGE OF DESIGN CONTROL 3.1 Scope This section describes the system by means of which effective control is exercised throughout the design of new or modified containers.
3.2 Responsibility Responsibility for design control as related to interpretation of regula-tory criteria and nuclear and radiological safety is the responsibility of the Manager, Safety, Licensing, and Safeguards. Project control, as related to the design program as a whole, is the responsibility of a design group designated by CNFP management. The Manager, Safety, Licensing, and Safeguards will coordinate nuclear, radiological, and licensing aspects closely with the design group.
In case of disagreement in these areas, the position of the Manager, Safety, Licensing, and Safeguards will prevail.
Following completion of the design, specifications and requirements for fabrication will be transmitted to the QC Manager for incorporation in the QA program as necessary. Those specifications relating to safety will be identified by the Manager, Safety, Licensing, and Safeguards or a qualified designee.
3.3 The design control program will include provision for the following:
3.3.1 Independent verification of nuclear or radiological safety cal-culations.
3.3.2 Design review by the CNFP Managers of Quality Control and Safety, Licensing, and Safeguards and written approval of drawings Ccie 12-11-78 Rev.
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BABCOCK ~ a WILCOX SECTION No.
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PAGE OF and specifications prior to release for fabrication.
3.3.3 The review shall consider the following as appropriate:
3.3.3.1 Adequacy of calculations.
3.3.3.2 Compliance with applicable provisions of the Code of Federal Regulations.
3.3.3.3 Accident evaluations.
3.3.3.4 Inspection, maintenance, and repair criteria.
3.3.3.5 Structural design, materials. of construction, and purchased parts relative to maintenance of safety.
3.3.4 Review and approval of proposed modifications or revisions affect-ing safety by the Manager, Safety, Licensing, and Safeguards.
3.4 When proposed design changes may affect safety limitati'ans or controls, dasign review criteria equivalent to that described above will be implemented.
3.5 The following activitics will be documented in writing:
3.5.1 Detailed nuclear and radiological evaluations and acceptance thereof.
3.5.2 Specific safety criteria upon which container design is based.
3.5.3 Results of final design evaluations, identification of " problems",
or questionable areas and their resolution.
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BABCOCK 8
WILCOX SECTION No.
4 tJUCL E AR MATE AI ALS DIVISION COMMERCIAL huvLEAR FUEL PLANT PROCUREMEflT DOCUMENT C0flTROL SHIPPING CONTAINER QUALITY ASSURANCE MANUAL SNM-Il68:
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OF 3 PROCUREMENT DOCUMENT CONTROL 4.1 Scope This section describes the method of control exerciseo at the CNFP to assure that all requirements relative to nuclear and radiological safety and container structural integrity are suitably included or referencad in documents used to procure materials, components, and services. Quality Control shall verify that the procurement documents for shipping containers which have been transmitted to the supplier are complete with respect to technical and quality requirements defined in the applicable specifications and drawings. Any changes to procurement documents shall be handled in like manner. Procedures shall be established to assure that CNFP Quality Control and Safety, Licensing, and Safeguards approve procurement documents prior to issuance.
4.2 Requirements 4.2.1 For fabrication of shipping containers, a bill of materials shall be prepared by the responsible engineering group which consolidates such information as drawings and specifications, and special test requirements. The responsible engineering function may also prepare a purchased materials list (if required) for those items which are to be procured. Both documents, i.e., the bill of materials and the purchased materials list are reviewed for conformance with applicable 12-11-73 Rev.
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BABCOCK WILCOx SECTION No.
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PAGE OF specifications, and these specifications shall be clearly defined to the supplier.
4.2.2 Technical requirements normally are contained in the applicable drawings and specifications. The technical requirements can be supplemented or defined completely by supplemer.*ary documents prepared by the design group. Supplementary documents shall not modify the design or functional requirements specified by the applicable drawing or specification.
4.2.3 Quality requirements are contained in the applicable drawings and specifications. Specific quality requirements may be supplemented, detiri d, or amplified by a Quality Control Require-ment ("QCR") prepared by CNFP Quality Control. The QCR shall not modify the quality requirements specified by the applicable drawing or specifications.
4.2.4 Engineering and quality requirements which apply to the procure-ment of materials or components shall be specified in the purchased materials list.
4.3 Materials Control snall prepare a purchase requisition for transmittal to the Purchasing Department. The requisition shall denote all of the technical and quality requirements covered in this list along with such schedular information as quantities and delivery dates.
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BABCOCK a
WILCOX SECTION No.
4 NUCLEAR MATERIALS DIVISION COMMERCIAL NUCLEAR FUEL PLANT PROCUREMEtlT DOCUMEflT C0fiTROL SHIPPING CONTAINER QUALITY ASSURANCE MANUAL SNIA-Il68:
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0F 3 4.4 The Purchasing Department shall prepaa a purchase order for transmittal to an approved vendor from the information contained in the purchase requisi tion. The purchase order shall be checked to verify that the technical and quality requirements in this procurement document are satis factory.
4.5 In general, the major purchased materials, components, and services shall be procured only from vendors who have been evaluated and audited for acceptability with respect to manufacturing and/or technical capability, and their quality assurance program. Such vendors shall be noted on approved vendor list which is maintained by Quality Control and submitted to the Purchasing Department for use in their procurement activities.
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BABCOCK ~ 8 WILCOX SECTION No.
NUCLE AR MATERIALS OlVISION
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5 COMMERCIAL NUCLEAR FUEL PLANT INSTRUCTIONS, PROCEDURES, & DRAWINGS SHIPPING CONTAINER QUALITY ASSURANCE MANUAL 1
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PAGE OF INSTRUCTIONS, PROCEDURES, & DRAWINGS 5.1 Scope Effective control of fabrication and use of radioactive material shipping containers necessitates the use of approved written procedures and equiva-lent documentation such as user instructions, drawings, and specifications.
This section provides general criteria for use and content of instructions, procedures, and drawings.
5.2 Requirements Procedures, instructions, or drawings, as applicable, will be used for the following QA related activities:
5.2.1 In-house ' fabrication of shipping containers or components (if applicable) 5.2.2 Qualification testing of containers or components.
5.2.3 Inspection and audit of fabrication activities (at CNFP or 'endor facility).
5.2.4 Periodic audit of CNFP shipping container QA program.
5.2.5 Routine in-use inspection of shipping containers.
Procedures, instructions, and drawings will contain sufficier.t informa-tion relating to regulatory requirements, specifications, and acceptance criteria to allow complete and effective application by user personnel.
Existing CNFP systems provide detailed requirements for the content and organization of procedures such that format standardization assures comprehensive coverage, logical sequencing, and appropriate approvals.
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PAGE 0F CUFP policy prohibits implementation of procedures prior to receipt of all required approvals.
Date 12-11-78 Rev.
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BABCOCK' &
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6 NUCLEAR MATERIALS DIVISION COMMERCIAL NUCLEAR FUEL PLANT DOCUMENT C0fiTRCL SHIPPING CONTAINER QUALITY ASSURANCE MANUAL SNM-Il68:
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0F 3 DOCUMENT C0ffTROL 6.1 Scope The control of instructions, procedures, or drawings within the CNFP is the responsibility of the originating unit. This section describes the system whereby such documents, relating to QA, are maintained in a current status and are properly approved and distributed.
6.2 Requirements 6.2.1 Prior to issue, design specification, construction drawings, procurement documents, and design change requests will be approved by the Managers of Quality Control and Safety, licensing, and Safeguards. Prior to approval, responsible managers will take any necessary steps to assure themselves that the document it correct and, if applicable, that proposed revisions do not alter safety criteria.
6.2.2 The shipping container QA Manual and revisions thereto will be approved by the Plant Manager, Quality Control Manager, and Manager, Safety, Licensing, and Safeguards.
6.2.3 Operating instructions and procedures will be approved by the Manager of the originating section and if other than Quality Control or Safety, Licensing, and Safeguards, by the Managers of those sections.
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PAGE 2 0F 3 6.2.4 Non-conformance findings are reported to the Quality Control and Safety, Licensing, and Safeguards Managers for review and, by consultation with er r riate design or operating personnel, determination of t _,.ss i ti o n. Non-conformance reports and sub-sequent actions shall be documented. Containers in a non-conformance status will be identified.and withheld from use or further fabrication until resolution is obtained.
6.2.5 The section assigned responsibility for preparing a document is also responsible for obtaining the required approval signatures, controlling the distribution, initiating modifications as required, and assuring that pages that have been superseded are removed from the revised document.
6.2.5.1 The originating CMFP section shall be responsible for transmitting to individuals / sections on distribution those documents for which they have sole responsibility of main-taining and having the individual /section acknowledge receipt by signature.
6.2.5.2 Once receipt is made it then becomes the responsibility of the document recipient to distribute the new or revised document as necessary and remove and destroy all obsolete documents.
(Files wherein outdated documents.
specifications, and drawings are retained for historical purposes are exempt from this requirement.)
b.
O Date 12-11-72
BABCOCK' 8 WILCOX SECTION No.
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PAGE OF 6.2.5.3 The section responsible for originating the document is also responsible for assuring that changes to docu-ments have the same reviewing and approval authority as the original issue.
Date 12-11-73 Rev.
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BABC0CK~ a WILCOX SECTION No.
7 NUCLEAR MATERIALS DIVISION COMMERCIAL NUCLEAR FUEL PLANT CONTROL OF PURCHASE MATERIAL, SHIPPING CONTAINER EQUIPMENT, AND SERVICES QUALITY ASSURANCE MANUAL SNM-Il68:
PAGE I 3
0F CONTROL OF PURCHASED MATERIAL, EQUIPMENT, AND SERVICFS 7.1 Scope To assure that purchased material, equipment and services conform to purchase specifications, specific evaluations of vendor capabilities are made consistent with the importance, complexity, and quantity of the product or services. This is accomplished through an evaluation of the vendor's quality program and inspection of the product received at the CNFP.
7.2 Requirements 7.2.1 Prior to procurement of items considered as critical to safety an on-site evaluation shall be made of the vendor's facilities with respect to his quality program assuring that he can effec-tively demonstrate the controls within his own plant and those of this subcontractors to provide the quality that is required.
The vendor's Quality Manual outlining the quality plan to be in effect requires CNFP approval prior to commencing production of B&W purchased material.
7.2.1.1 The evaluation is performed in accordance with a check list.
7.2.1.2 Vendors who have been adjudged as being acceptable per this evaluation are then placed on an Approved Vendor's Li s t.
Rev.
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DABCOCK a WILCOX SECTION No*
7 NUCLEAR MATERI A LS DIVISION COMMERCIAL NUCLEAR FUEL PLANT CONTROL OF PURCHASE MATERIAL, SHIPPING CONTAINER E UIPMENT, AND SERVICES QUALITY ASSURANCE MANUAL SNM-Il68:
PAoE 2 0F 3 7.3 Vendors supplying material, components, or services shall be audited during periods of procurement or fabrication activities in accordance with written procedures for the purpose of ensuring that quality requirements are being met and maintained.
The audits shall be conducted in accord with a planned agenda covering such vendor operations as QC program implementation, inspection activities, QC records, etc., as covered by the applicable Quality Control Requirement.
7.4 As deemed necessary when it is either impractical or undesirable to inspect purchased item (s), the supplier shall furnish to the B&W inspector necessary facilities, equipment, or data to meet the required inspection criteria.
CNFP may elect to perform inspection at supplier's plant wherever:
7.4.1 Required inspection of the item before fabrication is desired.
7.4.2 Rejection subsequent to receipt at the CNFP, would result in either ultimate delivery delay or increased cost or both.
7.4.3 Inspection of a larger quantity of identical items or a'small percentage of a large quantity can be performed more efficiently at supplier's plant.
7.4.4 First-piece inspection at the supplier's facility is desired.
7.4.5 At the discretion of the Manager, Quality Control or Manager, Safety, Licensing, and Safeguards.
U 7.5 Incoming materials and components shall underco a receivino inscection prior to ' release of such items for use. These inspections shall be in accord with written procedures and instructions which cover the type of DCie 12-11-73 Rev.
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I BABCOCK WILCOX
${-CTION No.
7 NUCL E AR MATERIALS DIVISION COMMERCIAL NUCLEAR FUEL PLANT CONTROL OF PURCHA5E MATERI AL, SHIPPING CONTAINER EQUIPMENT, AND SERVICES QUALITY ASSURANCE MANUAL 3
3 SNM-Il68:
PAGE OF test or inspection applicable to the item.
7.5.1 Concurrent with the appropriate inspections, all QC documentation which the vendor is required to submit shall be reviewed for completeness and compliance with applicable drawings and specifi-cations by Quality Control.
7.5.2 Items which have been determined to comply with the receiving inspection and QC documentation requirement shall be released by means of a Material / Components P.elease issued by Quality Control.
7.6 Results of audits and any follow-up activities shall be retained on file by Quality Control.
i Date 12-11-73 Rev.
O
BABCOCK ~ a WILCOX SECTION No.
8 NUCLE AR MATERIALS DIVISION COMMERCIAL NUCLEAR FUEL PLANT IDENTIFICATION AND CONTROL OF SHIPPING CONTAINER MATERIALS, PARTS, AND COMPONENTS QUALITY ASSURANCE MANUAL SNM-il68:
PAGE 1
0F 3 IDENTIFICATION AND CONTROL 0F MATERIALS, PARTS, AND COMPONENTS 8.1 Scope This section describes the techniques used by CNFP to identify and control radioactive material shipping containers and materials, parts, or components where fabrication is at the CNFP to provide traceability and to assure that only acceptable parts are utilized in the fabrication of radioactive material shipping containers where specification of those parts or materials is based on safety or licensing requirements.
3.2 Requi rements 8.2.1 Incoming Material, Parts, and Components 8.2.1.1 The Material Control section of Manufacturing is respon-sible for the receipt of all incoming radioactive naterial shipping containers and material, parts, and components at the CNFP.
The receipt shall be documented and a copy of the receiving notification shall be forwarded to Quality Control.
I 8.2.1.2 Upon receipt of this notification, the QC Data Evaluation Unit shall prepare and submit a request to the Inspection Unit delineating the type of inspection, i.e., dimensional, visual, chemical analysis, etc., and the Quality Control procedure to be applied in the inspection.
8.2.1.3 The results of this inspection shall be reviewed along with the vendor certification of physical, chemical, non-destructive testing, and dimensional inspection as 12-11-78 Rev.
O gg
BABCOCK ~ &
WILCOX SECTION No.
8 NUCLEAR MATERIALS DIVISION COMMERCIAL NUCLEAR FUEL PLANT SHIPPING CONTAINER IDEtlTIFICATI0ft At1D C0t1 TROL OF MATERIALS, PARTS, AtlD COMP 0f4EtlTS QUALITY ASSURANCE MANUAL 2
3
' SNM-Il68:
PAGE OF specified in the purchase order for compliance with the applicable specifications and drawings by the Data Evalua-tion Unit. Quality Control shall prepare a material release docum2nt.
8.2.1.4 Upon completion of all required inspections and certiff-cations at the CNFP, the Quality Control and Safety, Licensing, and Safeguards groups shall be advised as to the acceptability of the material or components in question. Both groups shall review for compliance with the required specifications. Non-conforming parts, materials, and :omponents will be handled as prescribed in Section 15 of this QA manual.
8.3 Traceability 8.3.1 The program used to control and identify material and components is based on distinguisning between two (2) general categories; bulk traceability and unit traceability.
8.3.1.1 All sub-components which are identified with a serial number or other specific identifier shall be subject to unit traceability.
8.3.1.2 All sub-components which are manufactured from common material, as for example, container shells, shall be subject to bulk traceability through final inspection g,gg 12-11-78 Rev.
0
DAB' COCK' a WILCOX SECTION No.
8 NUCLEAR MATERIALS DIVISION COMMERCIAL NUCLEAR FUEL PLANT IDENTIFICATION AND CONTROL 0F SHIPPING CONTAINER MATERIALS, PARTS, AND COMPONENTS QUALITY ASSURANCE MANUAL SNM-Il68:
PAGE 3 op 3 prior to comitting such components to manufactu:ing operations.
8.3.1.3 Unit traceable components can be produced by utilizing bulk traceable iterrs from lots of acceptable material as, for example, a fuel assembly shipping container.
8.3.2 Unit traceability may be used in lieu of bulk traceability at the option of the CNFP and/or the vendor.
8.4 Inspection - completed components are withheld from use until the follow-ing actions have been completed:
8.4.1 All inspections have been completed and the results of these inspectio.ns have been reviewed for compliance with applicable specifications and drawings.
8.4.2 All documentation has been verified for completeness and accuracy.
8.4.3 Prior to first use of a shipping container all necessary safety, nuclear and radiological inspections must be completed and documented by the responsible group as being released for use.
8.5 Non-conforming containers shall not be used until:
8.5.1 The non-conforming condition or item has been repaired, replaced, or reworked in accordance with approved procedures to restore it to the design specification and/or drawing requirements.
8.5.2 The non-conforming condition has been approved by the cognizant engineering organization with design responsibility and Safety, Licensing, and Safeguards.
Date 12-11-7s Rev.
O
BABCOCK' 8 WILCOX SECTION No.
9 NUCLEAR MATERIALS DIVISION COMMERCIAL NUCLEAR FUEL. PLANT CONTROL 0F SPECIAL PROCESSES SHIPPING CONTAINER QUALITY ASSURANCE MANUAL SNM-Il68'.
PAGE 1 0F 2 CONTROL 0F SPECIAL PROCESSES 9.1 Scope This section sets forth the measures taken to assure that special processes necessary where the required level of quality cannot be assured by inspec-tion alone are controlled and accomplished using qualified personnel and procedures. Quality Control shall be responsible for qualifying those processes under their direct cognizance that are so complex or specialized in nature, or so critical to the product, that more than routine measures are necessary in training personnel and implementing the process.
9.2 Requirements Curing the review of design specifications and drawings which are to be released for fabrication purposes. Quality Control and the appropriate design group shall:
9.2.1 Identify what production and inspection processes shall require procedure, equipment and/or personnel qualification to assure quality of the final product.
9.2.1.1 Qualification shall be required to:
(a) Comply with design requirements.
(b) Comply with Quality Assurance program require-ments for the control of special processes.
12-11-78 Rev.
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BADCOCK 8
WILCOX SECTION No.
9 NUCLEAR MATERIALS DIVISION COMMERCIAL NUCLEAR FUEL PLANT CONTROL 0F SPECIAL PROCESSES SHIPPING CONTAINER QUALITY ASSURANCE MANUAL SNM-Il68:
PAGE 2 0F 2 (c) Validate sampling plans, methods revisions or condition optimization which provide for manufacturing economies.
9.2.2 Direct the vendor to prepare procedures for the qualification of personnel and equipment.
9.2.2.1 Direct the qualification in.conformance with the procedures.
9.2.2.2 Evaluate and determine the acceptability of the results in relation to the appropriate acceptance cri teria.
9.2.2.3 Records of the qualification procedure and the qualified equipment, process, and/or personnel shall be maintained by the CNFP or by the vendor's Quality Control organization.
Rev.
O Ddie 12-11-73
BABCOCK ~ 8 WILCOX SECTION No.
10 NUCLE AR MATERIALS DIVISION COMMERCIAL NUCLEAR FUEL PLANT INSPECTION SHIPPING CONTAINER QUALITY ASSURANCE MANUAL SNM-ll68:
PAGE 1 3
0F INSPECTION
- 10. 1 Scope The CNFP inspection program is conducted in accor ance with standards and documented procedures which incorporate the quality requirements defined in applicable specifications and drawings. The procedures encompass the necessary inspections setting forth minimum requirements for acceptance.
It is the responsibility of the Quality Control Section to assure that these requirements are fulfilled.
10.2 Requi rements 10.2. 1 Source or Receiving Inspection All purchased items which effect quality of the final product shall be either source or receipt inspected by Quality Control or the vendor under an approved B&W procedure. Such inspection shall consist of the following:
10.2.1.1 Review of vendor certification and test reports to as-certain conformance to the CNFP requirements.
10.2. 1.2 Sampling for receiving inspection operations, when needed, shall be in accordance with MIL-STD-105D or an alternate plan approved in a manner consistent wi'th the product quality requirement. Samples shall be selected at random for lots, batches, or groups of components.
10.2. 1. 3 Any non-conforming components shall be processed per
%fe 12-11-73 Rev.
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DABCOCK 8
WILCOX SECTION No.
10 NUCLE AR MATE RI ALS DIVISION COMMERCIAL NUCLEAR FUEL PLANT SHIPPING CONTAINER QUALITY ASSURANCE MANUAL SNM-Il68:
PAGE 2
0F 3 Section 15 of this manual, "Non-Conforming Materials, Parts, or Components." Non-conforming components shall not be released for production until the defective condition is either corrected or the deviation is accepted in the manner outlined in Section 15.
10.2. 1.4 Components shall also be f aspected for cleanliness, proper identification, and other CNFP/ Vendor requirements.
10.2. 1.5 Following the receipt and satisfactory review of all necessary reports, and subsequent verification that the material or parts are acceptable, formal acceptance shall be made as defined in Section 8 of this manual.
10.2. 1.6 The CNFP Quality Control and Safety, Licensing, and Safeguards Sections shall be responsible for decisions affecting B&W acceptability of product, except in such instances where Section 15 of this manual may be invoked.
10.2. 1. 7 All components scheduled for non-destructive testing shall be tested in accordance with the limits set forth in applicable specifications and drawings, or more extensive testing as determined by Quality Control.
10.3 Final Inspection i
Final inspection shall be performed by the Inspection Unit on completed components prior to use in the following manner:
gfg 12-il-73 Rev.
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BABCCCK a WILCOX SECTION No.
10 NUCLEAR MATERIALS DIVISION COMMERCIAL NUCLEAR FUEL PLANT INSPECTION SHIPPING CONTAINER QUALITY ASSURANCE MANUAL 3
3 SNM-Il68:
PAoE OF 10.3. 1 Components shall be inspected according to detailed inspection procedures, prepared to insure the verification of all specified quality requirements.
- 10. 3. 2 All as-built dimensions shall be compiled and forwarded to the cognizant design agency as required by specifications.
- 10. 3. 3 All acceptable components shall be released for further processing upon completion of final inspection.
- 10. 3. 4 All deviated components shall be treated in accordance with Section 15 of this manual.
10.3.5 All final inspection data shall be maintained and stored as defined in Section 17 of this manual.
10.4 If witness or mandatory hold points are listed in the documents as a con-dition of release for further fabrication, such points shall be included in the Inspection process outline. The cognizant design or procurement agency shall be notified as required in order to allow such agency to perform the specified surveillance.
Ccte 12-11-73 Rev.
0
BABCOCK a
WILCOX SECTION No.
11 NUCLEAR MATERIALS Ol'!!SIO N COMMERCIAL NUCLEAR FUEL PLANT TEST CONTROL SHIPPING CONTAINER QUALITY ASSURANCE MANUAL SNM-II68:
PAoE 1 0F1 TEST CONTROL 11.1 Scope The components manufactured at or for the CNFP are inspected for compliance with design specifications and drawings by one or a conbination of the following techniques:
11.1.1 Various methods of metrology to verify dimensional requirements.
11.1.2 Verification of mechanical properties and chemical requirements to meet material requirements.
I 11.1.3 Additionally, a program shall. naintained to assure that all testing activities affecting quality and serviceability of nuclear material shipping containers are identified and performed as prescribed in procedures. These testing activities include but are not necessarily limited to those tests which are per-formed on new shipping container designs to evaluate the Jurability end integrity as originally specified.
11.2 Requi rements 11.2.1 Testing 11.2.1.1 Any prerequisites that are essential for the proper exe-cution of a given test will be outlined in appropriate procedures. Acceptance criteria shall be incorporated in test procedures.
11.2.1.2 Adequate test instrumentation will be available and used as required in procedures.
gg 12-11-73 Rev.
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BABCOCK' 8 WILCOX SECTION No.
u NUCL E AR MATERIALS DIVISION COMMERCIAL NUCLEAR FUEL PLANT TEST CONTROL SHIPPING CONTAINER QUALITY ASSURANCE MANUAL SNM-Il68-PAGE 2
op 2 11.2.1.3 Tests will be performed under conditions suitable to give representative test results as stated in procedures and required by applicable regulations.
11.3 Documentation Essential testing will be performed by the design and/or fabrication vendor and will be documented and final evaluation shall be performed by Quality Control and Safety, Licensing, and Safeguards to assure test requirements have been satisfied.
Q c{3 _ 12-11-73 Rev.
o
d BABCOCK WILCOX SECTION No.
12 NUCLEAR MATERIALS DIVISION COMMERCIAL NUCLEAR FUEL PLANT CONTROL OF MEASURING AND TEST EQUIPMEtlT SHIPPING CONTAINER QUALITY ASSURANCE MANUAL SNM-Il68:
PAGE 1 0F 4 CONTROL OF MEASURING AND TEST EQUIPMENT 12.1 Scope This section sets forth measures in effect at the CNFP to assure that all measuring and test equipment used in activities affecting quality and safety are properly controlled, calibrated and adjusted to maintain accuracy within necessary limits.
It is the responsibility of Quality Control and Safety, Licensing, and Safeguards to assure that proper procedures are followed for active gages, measuring devices, and inspection fixtures under their respective control.
12.2 Requirements - Quality Control Equipment 12.2.1 New or Reworked Equipment 12.2.1.1 When applicable equipment used as media of inspection for quality verification shall be initially calibrated against available known standards traceable to the National Bureau of Standards. The Inspection Unit shall be responsible for filing the certifications of all measuring standards and the institution of re-certification and re-calibration shall be in accordance with a detailed written procedure.
12.2.1.2 For the inspection equipment wherein standards traceable to the National Bureau of Standards are not available, the manufacturer's certificate of accuracy shall be g ge 12-11-78 Rev.
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BADCOCK a WILCOX SECTION No.
12 NUCLEAR MATERIALS DIVISION COMMERCIAL NUCLEAR FUEL ' PLANT CONTROL OF MEASURING AND TEST EQUIPMENT SHIPPING CONTAINER QUALITY ASSURANCE MANUAL SNM-Il68:
PAGE - 2 OF 4 retained in the files of the Inspection Unit. The manufacturer's recommendation as to the manner and frequency of calibration shall be utilized.
12.3 Storage of Equipment 12.3.1 When equipment must remain permanently in the work area, adequate means for protection and cleanliness will be provided within the limits of work requirements.
12.3.2 Provision will be made to assure proper protection and cleanliness of all equipment not in actual use.
12.3.3 Any gage to be repaired shall be immediately placed in the Gage Control detention area, under the sole control of the Calibration Control Technician until such time as it has been repaired, re-calibrated and formally released for use by Gage Control.
12.3.4 When the inspections are performed by vendors, any equipment used shall be stored and protected in a manner that will meet the limits of work requirements. Any malfunctioning equipment will immediately be taken to a proper detention area and remain there until it is properly repaired, recalibrated, and released for use.
12.4 Periodic Inspection of Equipment 12.4.1 All inspection gages shall be examined, calibrated, and/or serviced at scheduled intervals specified in detailed procedures gg 12-11-78 Rev.
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BABCOCK a WILCOX ETION No.
12 NUCLE AR MATERIALS DIVISION COMMERCIAL NUCLEAR FUEL PLANT CONTROL OF MEASURING AND TEST EQUIPMENT SHIPPING CONTAINER QUALITY ASSURANCE MANUAL SNM-Il68:
PAGE 3
op 4 by personnel who are specifically charged with the responsibility of maintaining accurate gage and related records.
12.4.2 Additional gage inspection stiall be made when there is evidence of excessive wear, suspected or actual instrument damage.
12.4.3 The inspector, when using relatively simple gages such as micro-meters, which can be checked readily for accuracy, shall check them with known standards during usage of such gages.
12.4.4 Any gage or equipment utilized in the inspection process which is determined to exceed the established calibration accuracy limits shall be subject to the following action.
(a) Removal from service and stored in an appropriate detention area.
(b) Determine disposition of the gage, i.e., rework, recalibrate or scrap and replace.
(c) Reworked gages shall be recalibrated prior to return to service. The corrective action for the reworked and/or recalibrated gages shall be recorded on the calibration record card.
12.4.4.1 All components measured with a gage or equipment that has exceeded the established calibration accuracy limits shall be reinspected with correctly calibrated equipment.
This reinspection shall cover all components, asserrblies, etc. inspected with the gage or tool to the last acceptable calibration.
Date 12-11-7a Rev.
0
BABCOCK a
WILCOX SECTION No.
12 NUCLEAR MATERIALS OlVISION COMMERCIAL NUCLEAR FUEL PLANT CONTROL OF MEASURING AND TEST EQUIPMENT SHIPPING CONTAINER QUALITY ASSURANCE MANUAL; 4
4 SNM-Il68:
PAGE OF 12.5 Requirements - Radiation Monitoring Equipment 12.5.1 Radiation Survey and Analysis Equipment Such equipment shall be calibrated and maintained as specified in SNM-1168.
t Ccte 12-11-78 Rev.
0
BABCOCK' 8 WILCOX SECTION No.
13 NUCLE AR MATERIALS DIVISION COMMERCIAL NUCLEAR FUEL PLANT HANDLING, STORAGE, AND SHIPPING SHIPPING CONTAINER QUALITY ASSURANCE MANUAL SNM-Il68:
PAGE 1
0F 2 HANDLING, STORAGE, AND SHIPPING 13.1 Scope This section sets forth measures in effect at the CNFP to control the cleanliness, preservation, packaging, shipping, and storage of components and asserblies to prevent damage or deterioration from start of fab-rication through receipt by customer.
It is the responsibility of all operating CNFP sections to follow detailed process procedures which will establish the methods and techniques to be followed to prevent damage to components. Specifically, the Quality Control Section shall verify that the components are adequately protected according to procedures listed below.
4 13.2 Requirements General 13.2.1 All assembly operations shall be carried out in an area adequate to permit the attainment of the final cleanliness level specified.
13.2.2 After completion of final visual and dimensional inspection, the cleanliness of acceptable components shall be maintained by suitable means to comply with the cleanliness requirement of applicable specifications.
13.3 Handling of Major Components 13.3.1 All major handling devices such as cranes, slings, and other devices used for the purpose of lifting or transporting major Date 12-11-78 Rev. o
BABCOCK 8
WILCOX SECTION No.
13 NUCLEAR MATERIALS OlVISION COMMERCIAL NUCLEAR FUEL PLANT HANDLING, STORAGE, AND SHIPPING SHIPPING CONTAINER QUALITY ASSURANCE MANUAL 2
2 SNM-il68:
PAGE OF components shall be subject to periodic inspections in accordance with written procedures.
13.3.2 Major components shall be defined as individual shipping containers.
13.3.3 Prior to each use, shipping containers are inspected for compliance with applicable regulatory controls including certificates of com-pliance and the Code of Federal regulations. The inspection shall be by persons other than those responsible for loading the container.
Ddte 12-11-78 Rev.
o
BAB' COCK a
WILCOX SECTION No.
14 NUCLE AR MATERIALS DIVISION COMMERCIAL NUCLEAR FUEL PLANT INSPECTION, TEST, AND OPERATING SHIPPING CONTAINER STA m QUALITY ASSURANCE MANUAL SNM-ll68:
PAGE 1 0F 3 INSPECTION, TEST, AND OPERATING STATUS 14.1 Scope This section sets forth measures in effect at the CNFP to indicate the status of inspections and tests performed on shipping container.
14.2 Requirements The status of inspection operations for components which are to be supplied to or used by the CNFP shall be documented.
14.2.1 New Container Inspection 14.2.1.1 Receiving inspection on incoming containers shall be performed in accord with approved Quality Control and Safety, Licensing, and Safeguards procedures.
If the items are found to be acceptable, appropriate documenta-i tion shall be generated to indicate acceptability.
14.2.1.2 Any items determined to be non-confonning shall have a i
" Hold" tag attached to the item.
If the assessment of the non-conforming condition established that rework is permitted, a " Rework Required" tag shall be attached to the item. Only the Inspection Unit shall remove any
" Hold" or " Rework" tags from an item.
14.2.1.3 Any item deemed to be unacceptable and assessed to be not subject to rework or repair shall have a " Reject" tag attached to it and shall be segregated from conforming units to await final disposition.
Dcie 12-11-78 Rev.
n
BA'BCOCK' a WILCOX SECTION No.
14 NUCLEAR MATERIALS DIVISION COMMERCIAL NUCLEAR FUEL PLANT INSPECTION, TEST, AND OPERATING' SHIPPING CONTAINER s141os QUALITY ASSURANCE MANUAL
' SNM-Il68:
PAGE 2
0F 3 14.3 Final Inspection 14.3.1 Containers which have completed the final inspection operation shall have ar. " Inspection Complete" tag attached by the Inspection Group.
This tag will indicate that all inspection operations are complete and the data has been submitted to the Data Evaluation Group for appropriate certification and documentation. The tag may be removed when container is placed in service If rework is necessary a
" Rework Required" tag shall be attached. Only the Inspection Group shall remove rework tags.
14.3.2 Under no circumstances shall a non-conforming component which has been processed through final inspection be used until the discrepant condition has been corrected.
14.4 In-Use Inspection 14.4.1 In-use inspection shall be performed by Quality Control and Safety, Licensing, and Safeguards in accordance with approved procedures.
14.4.2 Any item or component found to be non-conforming during in-use inspection shall have a " Hold" tag attached to it indicating a deviation which may require a repair, rework, reject, or, use as is, disposition.
14.4.2.1 If rework is required, a " Rework Required" tag shall be attached to the component by the Inspection Unit. This tag can be removed only by this unit from the defective component.
Rev.
0 Dcte 12-11-78
BABCOCK a
WILCOX SECTION No.
14 NUCLEAR MATERIALS DIVISION COMMERCIAL NUCLEAR FUEL PLANT INSPECTION, TEST, AT1D OPERATItiG SHIPPING CONTAINER s1arus QUALITY ASSURANCE MANUAL SNM-Il68:
PAGE 3
3 op 14.4.2.2 Any component classified as reject shall have a
" Reject" tag attached to it and shall be processed per paragraph 14.2.1.3.
4 m
2-"-78 Me Psev.
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BABCOCK' a WILCOX SECTION No.
15 NUCLEAR MATERIALS DIVISION COMMERCIAL NUCLEAR FUEL PLANT NON-CONFORMING MATERIALS, PARTS, OR SHIPPING CONTAINER COMPONENTS QUALITY ASSURANCE MANUAL I
SNM-Il68:
PAGE 0F NON-CONFORMING MATERI ALS, PARTS, OR COMPONENTS 15.1 Scope
-This section sets forth the measures taken by the CNFP to control shipping containers or components which do not conform to requirements in order to prevent subsequent use until the non-conformance is corrected.
It is the responsibility of CNFP Quality Control to asstire that the following require-ments are fulfilled cn non-conforming units.
15.2 Requirements General 15.2.1 All non-conforming components shall be documented by Quality Control.
15.2.2 All non-conforming components shall be separated from conforming components and identified (tagged, marked) as being non-conforming.
15.2.3 Sufficient data shall accompany the non-conforming component to identify its non-conforming condition.
(Such data is not required for any component or item which has been assigned to be scrapped.)
15.2.4 Safety, Licensing, and Safeguards and Quality Control shall recommend the disposition of the non-conforming components.
15.3 Non-Co ormance Disposition 15.3.1 lomponent non-conformance at receiving or in use shall be documented.
The report shall be prepared by Quality Control for submittal to the Design Group and Safety, Licensing, and Safeguards.
Dcte 12-11-73 Rev.
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BABCOCK' 8 WILCOX SECTION No.
15 NUCLEAR MATERIALS DIVISION COMMERCIAL NUCLEAR FUEL PLANT NON-CONFORMING MATERIALS, PARTS, OR SHIPPING CONTAINER COMPONENTS QUALITY ASSURANCE MANUAL 2
3 SNM-Il68:
PAGE OF 15.3.2 The Design Group and Safety, Licensing, and Safeguards shall review the completed report and recommend disposition.
15.4 Contract Variation Approval Notice (CVAR) 15.4.1 To obtain approval of a non-conforming item, a CVAR shall be pre-pared by Quality Control listing ti a detaih relevant to the devia-tion.
15.4.2 The CVAR shall be evaluated by the Design Group and a recommended course of action indicated on the CVAR.
15.4.3 Upon completion of this evaluation, the Design Group shall forward the CVAR to the Data Evaluation Group of CNFP Quality Control for formal submittal to the cognizant design agency fnr disposition.
15.4.4 Upon receipt of the dispositioned CVAR, Quality Control shall notify the proper personnel of the final decision and appropriate steps to take consistent with the decision, whether it be to reject, accept, or repair according to an cpproved procedure.
15.5 Repair of Non-Conforming Components 15.5.1 In the event of a repair, the CNFP or vendor facility shall cite either an existing repair procedure or prepare a special procedure. All CNFP repair procedures shall be reviewed and approved by Quality Control.
15.5.2 After the repair has been completed, the component shall be inspected for conformance to the applicable CVAR disposition or design criteria or both.
12-11-78 Ra o
g
-a h
BABCOCK' &
WILCOX SECTION No.
15 NUCLEAR MATERIALS DIVISION COMMERCIAL NUCLEAR FUEL. PLANT NON-CONFORMING MATERIALS, PARTS, OR SHIPPING CONTAINER
~ COMPONENTS QUALITY ASSURANCE MANUAL SNM-Il68:
PAGE 3
3 op 15.5.4 Inspection of reworked components shall be to the applicable design criteria and shall be documented.
15.6 Reject or Non-Conforming Components 15.6.1 Material and components which have been rejected shall be tagged by Inspection and placed on Hold in a designated area.
15.6.2 Materials and components which are to be returned to the vendor shall be processed in the following manner:
15.6.2.1 Data Evcluation will fill out a claim report for transmittal to the vendor by the Purchasing Department.
15.6.2.2 The Design Group shall review &nd indicate corrective action required by the ver.ior on the form.
15.6.2.3 Purchasing shall fill out tha remainder of the claim report form and fonvard to the vendor along with non-conforming components. A ccpy of the completed form shall be sent to CNFP Quality Control.
@ ta 12-11-78 Rev.
0
BABCOCK a WILCOX SECTION No.
16 NUCLEAR MATERIALS DIVISION COMMERCIAL NUCLEAR FUEL PLANT CORRECTIVE ACTION SHIPPING CONTAINER QUALITY ASSURANCE MANUAL 1
2 SNM-Il68:
PAGE t,
CORRECTIVE ACTION 16.1 Scope This section sets forth the measures in effect at the CNFP to assure that conditions adverse to quality in safety related areas such as defective material, non-conformances to design specifications and drawings, deficiencies, and non-compliances to approved procedures are. promptly identified and corrected.
It shall be the responsibility of the Quality Control Section and Safety, Licensing, and Safeguards to bring to the attention of CNFP plant management, any condition adverse to quality and to verify that the appropriate corrective action has been taken to preclude its repetition.
16.2 Requi renents Non-Conformance Review 16.2.1 All Contract Variation Approval Notices covering non-conforming components shall be analyzed by a Review Board including represen-tatives from the Supervisory and/or Manageme nt Levels of Quality Control and Safety, Licensing, and Safeguards.
16.2.2 This review shall be conducted periodically as scheduled by the Manager of Quality Control.
16.2.3 The purpose of the review shr 9 to analyze the deviated conditions for chronic recurrence, determinatior, of cause, and to recommend the corrective action to be implemented. Also, follow-up shall be performed on corrective action established Date
. 2-11-78 Rev.
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BABCOCK' a WILCOX SECTION No.
16 NUCLEAR MATERIALS DIVISION COMMERCIAL ' NUCLEAR FUEL PLANT CORRECTIVE ACTION SHIPPING CONTAINER QUALITY ASSURANCE MANUAL 2
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PAGE OF at previous meetings to ascertain the status and effectiveness of the measures taken.
16.2.4 Quality Control shall be responsible for documenting the results of the meetings and listing all CVAR's and component discrepancy reports on a CVAR summary and corrective action report along with the corrective action taken on each. Also, included in the report shall be the follow-up performed on previous corrective actions.
16.2.5 The Manager, Quality Control and Manager, Safety, Licensing, and Safeguards shall review and sign-off the report.
- 16. 3 Operational Reviews 16.3.1 Operational use shall be monitored through inspection and audit activities by approved Quality Control and Safety, Licensing, and Safeguards procedures.
- 16. 3.2 Findings shall be brought to the immediate attention of the plant management to:
16.3.2.1 Determine if use of the container should be terminated.
16.3.2.2 Assess the risk involved with proceeding.
16.3.2.3 Establish the corrective action and its implementation.
Rev.
0
@te 12-11-78
BABCOCK' 8 WILCOX SECTION No.
17 NUCLEAR MATERIALS DIVISION COMMERCIAL NUCLEAR FUEL PLANT QUALITY ASSURANCE RECORDS SHIPPING CONTAINER QUALITY ASSURANCE MANUAL 1
1 SNM-Il68:
PAGE OF QUALITY ASSURANCE RECORDS 17.1 Scope This section sets forth measures in effect at the CNFP for the preparation and maintenance of Quality Assurance records.
It is the responsibility of the Quality Control and Safety, Licensing, and Safeguards sections to assure that adequate tests and inspection records are maintained to verify compliance with the provisions of this QA program.
17.2 Requi rements 17.2.1 Inspection forms, test reports, and other pertinent records shall be completed by personnel assigned the responsibility to perform such inspections and tests and shall be dated and initialed to verify their completion.
17.2.T Inspection forms, test reports, and records shall indicate any deviation from requirements per Section 15 of this manual.
17.2.3 The CNFP shall retain Quality Assurance records for a minimum period from first use shipment to removal from use.
17.2.4 After this period, the necessity for longer storage of the records shall be reviewed. Final disposition of the records shall be con-tingent on concurrence that they are no loncer required.
g Psev.
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BABCOCK &
WILCOX SECTION No.
18 NUCLEAR MATERIALS DIVISION COMMERCIAL NUCLEAR FUEL PLANT AUDITS SHIPPING CONTAINER QUALITY ASSURANCE MANUAL SNM-ll68:
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OF 4 AUDITS 18.1 Scope This section sets forth the audit program (intercal and supplier) in effect at the CNFP.
Internal audits are performed to verify compliance with the Quality Assurance Program and to determine the overall effective-ness of the program. Supplier audits are performed to monitor quality programs in effect at CNFP vendors while they are supplying material or components to current purchase orders. The audits shall be conducted by personnel who have experience or training in auditing using a checklist and/or other appropriate audit forms.
It is the responsibility of the CNFP Quality Control Section to administer the audit program outlined below.
18.2 Requirements Internal Audits 18.2.1 A comprehensive system of planned and c;cumented audits of the Quality Control program shall be conducted as a minimum at least twice each year at an interval of approximately six (6) months.
10.2.2 A team consisting of at least two (2) members shall perform the audit. One (1) representative of the team shall be assigned from the Quality Control Section.
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4 0F 18.2.2.1 For those activities relating specifically to the Quality Control Section, the member (s) conducting the audit shall not have any direct responsibilities in Quality Control.
18.2.3 A follow-up shall be performed on corrective actions resulting from findings on previous audits.
18.2.3.1 The audit shall consist of observations of processes, products, and physical areas of the plant.
Interviews with cognizant supervisory personnel and a review of records and other documents shall be made as team functions during the audit.
18.2.3.2 All findings resulting from the audit shall be reported individually on an internal audit finding report form.
18.2.4 The completed audit forms along with a summary shall be submitted as a report to the Manager, Quality Control. Copies of this report shall also be distributed to the Manager, Safety, Licensing, and Safeguards.
18.2.5 If there are findings the Supervisor, Data Evaluation shall request corrective action from each responsible representative notified with the target completion date.
18.2.6 The Supervisor, Data Evaluation shall review corrective action for timeliness and effectiveness noting that it is either satisfactory or unsatisfactory.
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op 4 18.2.7 The Supervisor, Data Evaluation shall transmit to the Manager, Quality Control all completed internal audit reports for concurrence on corrective action taken.
18.2.8 If corrective action is satisfactory, the Manager, Quality Control shall return the internal audit finding (s) to the Data Evaluation Supervisor for filing.
If corrective action is unsatisfactory, a meeting shall be arranged with the applicable representative of the audited section and/or supervisor 'for the purpose of resolving differences in the proposed corrective action.
18.3 Supplier Audits 18.3.1 Quality Control is assigned the prime responsibility of developing a vendor audit schedule prior to release of a fabrication program.
The schedule shall identify the audit team for the vendor, the audit fre-quency and suggested approximate audit date(s).
18.3.2 Once the audit schedule has been completed it shall be submitted to the Manager, Quality Control for approval.
18.3.3 An audit agenda shall be developed to satisfy those requirements which have been imposed on the vendor by QCR through the purchase order. However, additional items may be added to the agenda, e.g., follow-up on corrective actions from previous audits, quality problems the vendor may be having, etc. The agenda shall be submitted to the vendor prior to the audit.
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0F 4 18.3.4 Prior to and at the conclusion of each audit a meeting shall be held with vendor plant management. At the beginning of each audit the detail plan of how the audit will be accomplished shall be presented to allow the vendor to schedule personnel and activities that will be involved in the audit. Once the audit has been completed, a post-audit critique shall be held where each finding of the audit is discussed along with recommended corrective action.
18.3.5 After the audit is completed, an audit report shall be prepared and submitted to the vendor for his information and action.
18.3.6 The vendor shall be requested to reply to each finding indicating the corrective action he proposes to take with the target com-pletion date for the implementation of each corrective action.
18.3.7 If the corrective action is considered adequate the vendor will be notified accordingly and follow-up will be performed at the next regular scheduled audit to determine its effectiveness.
18.3,8 If the corrective action is deemed insufficient, further negotiations will be necessary with the ver. dor to achieve a mutually acceptable solution. The necessity for an immediate re-audit will be determined at this time.
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SHIPPING CONTAINER QUALITY ASSURANCE MANUAL ROSSARY OF TERMS' SNM-Il68:
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0F 6 As used in this manual, the following terms shall mean:
ACCEPTANCE CRITERIA The limit, or limits, associated with established values, used to determine whether or not an item is satisfactory.
APPROVAL The act of endorsing or assi ning C
positive authorization, or both.
AS-BUILT DATA Documented data that describe the condition actually achieved in a product.
ASSEM3LY A conbination of subassemblies or components or both fitted together to form a unit.
AUDIT An activity to determine through investiga-tion, the adequacy of, and adherence to, established procedures, specifications, codes, and B&'d-fiPGD procurement document requirements, and the effectiveness of implemen tation.
CERTIFICATE OF CONFORMANCE A written statement, signed by a qualified party, certifying that items or services comply with specific requirements.
CERTIFICATION The action of determining, verifying, and attesting in writing to the quali-fications of personnel or material.
CHARACTERISTIC A physical, chemical, visual, functional, or other identifiable property of an item, process, or service.
CLEAHLINESS A state of being clean in accordance with predetermined standards, and usually implies freedom from dirt, dust, rust, oil, or other contaminating impurities.
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0F 6 CORRECTIVE ACTION Measures to identify and correct conditions adverse to quality or safety; for example, defective equipment, deviations to design specifications, and other non-compliances.
DESIGN GROUP That section which helps to control, initiate, recommend, revise, or approve various aspects of shipping container design, fabrication, or use.
DOCUME.iT Any written or pictorial information des-scribing, defining, specifying, reporting, or certifying activities, requirements, procedures, or results.
DOCU.tENTATION A compilation of those documents concerning a specific function, activity, or project.
EXA:11 NATION An element of inspection consisting of investigation of materials, components, supplies, or services to deteimine confor-mance to those specified requirements which can be determined by such investigations.
Examination is usually non-destructive and includes. visual, simple physical manipula-tion, gaging, measuren.ent, and written documentation.
HANDLING An act of physically moving and/or lif ting items by hand or mechanical means.
HOLD An action ~wherein a component, item, assembly, or part is withheld and segregated from further processing until a disposition has been defined and imposed.
INSPECTION A phase in which by means of examination, observation, or measurement determines the conformance of i tems, processed, or services to predetermined requirements.
Inspection may involve the use of special 3
equipment tools, procedures, or documentation.
It is performed by qualified personnel whose Qfe 12-11-78 Rev.
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op 6 duties include verification of quality related activities and who is independent of the activity being verified.
ITEM Any level of unit assembly, including sys tem, subsystem, subasse:rbly, component, or material.
thTERIAL A substance or combination of substances used to form pieces, parts, caponents, items, etc.
NON-CONFORPN4CE A deficiency in characteristic, documenta-tion, performance of procedure which renders the quality of an it m unacceptable or in-determinate. Examples of non-conformances include:
physical defects, incorrect or inadequate documentation; or deviation from design standards, prescribed processing, in-spection or test procedures, and procurement document requirements.
PART An item which has work performed on it and which is attached to, and becomes an element of a component.
PROCEDURE A document which specifies instructions for performance of a particular task.
It includes methods to be employed, description of equipment or material to be used, sequence of operations, etc.
PROCESS One or more operations, methods, functions,
procedures, or other specified actions,
which result in the desired end item or res ult.
FROCUREMEi4T DOCUMENT A cont acturally binding document, includ-ing attachments, identifying the requirements which items or services must meet prior to acceptance. Also includes purchase requisi tions.
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PAGE 4 0F 6 QUALIFICATION A demonstration of those characteristics (PERSONNEL) or abilities of an individual, gainea through training and/or experience, that enable him to perform specific functions.
QUALIFIED EQUIPMENT Equipment which has been evaluated by sufficient testing to assure performance within specified parameters.
QUALIFIED PARTY OR A person or organization competent and INDIVIJUAL recognized as knowledgeable to perform certain functions.
QUALIFIED PROCEDURE A procedure which incorporates all applicable code and standard requirements, manufacturing parameters and engineering specifications, and which has been proven adequate for the intended purpose.
QUALITY The properties or characteristics, con-stituting those requisites of specifications, codes, standards, industrial practices, other recognized methods and/or acceptance criteria, by which an item is judged.
QUALITY CONTROL Those quality assurance actions which pro-vide a means to control the characteristics of an item, process, or facility to established requirements.
REJECT A disposition which may be imposed on a non-conforming item providing for its withdrawal and isolation from further processing pending an evaluation to repair, rework, use-as-is, or scrap.
REPAIrl The process of restoring a non-conforming characteristic to a condition such that the capability of an item to function reliably and safely is unimpaired, even though the item still may not conform to the original requirement in every aspect.
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op 6 F. WORK The process by which a non-conforming item is made to conform to a prior specified requirement by completion, remachining, reassembling, or other remedial means.
(Cutting off excess metal is rework; welding on an extension is repair.)
SCRAP A disposition which may be imposed upon a non-conforming item when it has been established that the discrepancy renders the item unfit for its intended use and it is not economically or otnemise feasible to repair or rework it. Scrap may also be excess material, or damaged material, remain-ing from fabrication operations which is un-suitable for further use.
SHIPPIllG CONTA':!ER That which is used to contain radioactive material for either off-site shipments, or in-house movement as it applies to the CNFP operations (i.e., unirradiated low enriched fuel assertlies, unirradiated scrap U0,
contaminated material, or scaled s/y ebitting sources used for calibration or analytical purposes).
SOURCE INSPECTION A review, observation, inspection, or in-dication for the purpose of verifying that an action has been accomplished as specified at the location of procurement or manufacture.
SPECIFICATION A concise statement of a set of requirements to be satisfied by a product, a material, or process indicating, whenever appropriate, the procedure by means of which it may be determined whether the requirements given are satisfied.
SUPPLIER Any organization under contract for furnish-ing items or services.
It concludes the terms vendor, contractor, subcontractor, fabricator, and subtier levels of these where appropriate.
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PAGE OF TRACEABILITY Pertains to bulk and unit traceability as it applies to parts, materials, or com-ponents.
It is a program used to control and identify materials, parts, or com-ponen ts.
Typically, unit traceability utilizes concepts as unique serial numbers for each item. Bulk treceability includes those materials fabricated from common material, steel plate, cheat, rods, etc.
USE-AS-IS A disposition which may be imposed upon non-conforming items when it has been established that the discrepancy does not affect the intended use and that the item will conform to functional requi rements.
VERIFICATION The act of confirming, substantiating, and/or assuring that an action has been performed or a condition achieved in conformance with specified requirements.
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