ML19259B027
| ML19259B027 | |
| Person / Time | |
|---|---|
| Site: | 07100254 |
| Issue date: | 03/31/1978 |
| From: | Office of Nuclear Reactor Regulation |
| To: | |
| Shared Package | |
| ML19259B005 | List: |
| References | |
| NUDOCS 7901150242 | |
| Download: ML19259B027 (2) | |
Text
NEDO-11209 3-31 78 TOPICAL REPORT EVALUATI0f1 Report fiumber:
f1E00-ll209-04A, Nonproprietary Report
Title:
fluclear Energy Business Group BWR Quality Assurance Program Description Report Date: fiarch 1978 Originating Organization:
General Electric Company Reviewed by:
Quality Assurance Branch Sl!MMARY OF TOPICAL REPORT Topical report flEDO-ll209-04A describes the quality assurance (QA) nragram which General Electric (GE) applies to those design, procurement und fabrication activities involving safety-related structures, sysi. ems, and components of nuclear power plants within the GE scope of work.
fled 0-ll209-04A commits GE to comply with the requirements of Appendix B to 10 CFR Part 50 and to follow the Regulatory Position provided by the flRC in Regulatory Guides 1.28 (June 7,1972),1.30 (August 11,1972),
1.37 (f4 arch 16,1973),1.38-Revision 2 (May 1977),1.39-Revision 2 (September 1977), 1.58 (August 1973), 1.64-Revision 2 (June 1976),
1.74 (February 1974), 1.88-Revision 2 (October 1976),1.116-Revision 0-R (June 1976), and 1.123-Revision 1 (July 1977), as well as Af1SI f145. 2.12-1977.
GE has provided for our evaluation a detailed organizational description of those individuals and groups involved in carrying out activities required by the QA progran and a delineation of duties, responsibilities, and authority of those org:aizational elements involved in the QA program. f1EDO-ll209-04A contains a description of the measures used to carry out the GE QA program activities and describes how applicable requirements of Appendix B will be satisfied by :ne administration and implementation of these measures in QA manuals and crecedures.
SUMMARY
OF REGULATORY EVAL.UATIC:1 We have evalua ed the QA program and the organizations responsible for QA functions as descrihr ' in f1ED0-ll209-04A. We find that QA policy and direction originate at an acceptably high management level and are effectively communicated to other parts of the crganization. Those performing QA functions have responsibility and authority commensurate with their duties in implementing the QA program. We also find that measures have been established, to he implemented by written procedures and instructions, which address each of the criteria of Appendix B in an acceptable manner.
Based on our review and evaluation of NEDO-ll209-04A, we conclude that:
1.
The organizations and persons performing QA functions within GE have the required independence and authority to effectively carry out the QA program without undue influence from those directly responsible s
7 901 15 0c2 %2.
NEDO-11209 3-31 78 g for costs and schedules.
2.
The GE QA program contains requirements and controls which, when properly implemented, comply with the requirements of Appendix B to 10 CFR Part 50.
3.
The GE topical report, f1EDO-ll209-04A, "fluclear Energy Business Group BWR Quality Assurance Program Description" provides an acceptable description of the QA program for use in the design, procurement, and f abrication activities associated with nuclear power pl mts.
O O
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NEDO-11209 3-31 78 GENERAL ELECTRIC COMPANY 175 Curtner Avenue San Jose, C cornia 95125 March 31,1978 STATEMENT OF POLICY AND AUTHORITY It is the policy of the Nuclear Energy Business Group to achieve and maintain, through the composite of the quality of all products offered and work performed, a reputation in the nuclear energy business for timely and effective compliance with all quality requirements.
This document describes the BWR Quality Assurance Program whicit is to be used by the Nuclear Energy Business Group to fulfill this policy. All man-agers within the Nuclear Energy Business Group with quality-related responsi-bilities have full authority to implement the program within their respective areas of responsibility. Development of procedures to implement the Quality Assurance Program is a basic responsibility of each of the organizations within the Nuclear Energy Business Group.
The implementation of the Quality Assurance Program for the Boiling Water Reactor business has the unqualified endorsement and support of General Electr ic management.
b
)
R. H. Beaton Vice President and Group Executive Nuclear Energy Businest Group
-ix-/ x-
NEDO-11209 3-31-78 TABLE OF CONTENTO Page LIST OF ABBREVIATIONS -
xvil INTRODUCTION
.. xix 1
ORG ANIZATION.
1-1 1.1 General.,
.11 1.2 Organtrational Functions..
.11 1.3 OA Functional Responsibilities..
.13 1.4 OA Personnel Responsibdities and Quahlications..
.1-8 2
OUALITY ASSURANCE PROGRAM 2-1 2.1 General.
. 2-i 2.2 Ouakty System Docur.nentat.on.
.2-2 3
DESIGN CONTROL 3-1 3.1 General..
.3-1 32 Design Interf ace Con.01..
. 3-1 3.3 System Desic-
.3-2 3.4 Standard '.eactor Island Design.
.3-2 3.5 Dest.-
< Procured Engineered Equipment..
.3-3 3.6 P
of Reactor Equipment Components..
.3-3 3.7 p of Controls and Instrumentation..
.3-3 3.8 Design of Fuel..
.3-4 3.9 Design of High Density Fuel Storage Equipment..
.3-4 3.10 Design Venfication..
.3-4 3.11 Design Change Control.,
. 3-5 3.12 Field Change Control.
.35 3 13 Design Review Control..
.36 4
PROCUREMENT DOCUMENT CONTROL 4-1 5
INSTRUCTIONS, PROCEDURES, AND DRAWINGS.
5-1 6
DOCUMENT CONTROL.
6-1 7
CONTROL OF PURCHASED MATERIAL, EuulPMENT AND SERVICES 7-1 8
IDENTIFICATION A CONTROL OF MATERIALS, PARTS, AND COMPONENTS.-
8-1 9
CONTROL OF SPECIAL PROCESSES 9-1 10 INSPECTION -
10-1 11 TEST CONTROL 11-1 11.1 Product Test Program.
.11-1 11.2 Preoperational Testing.
.11-1 11.3 Startup Testing..
.11-1 12 CONTROL OF MEASURING AND TEST EQUIPMENT 12-1
-xi.
NEDO-11209 3-31-78 i
'i ABLE OF CONTENTS (Continued) g Page 13 HANDLING, STORAGE AND SHIPPING 13-1 14 INSPECTION, TEST, AND OPERATING STATUS 14-1 15 NONCONFORMING MATERIALS, PARTS, OR COMPONENTS.,.
15-1 15.1 General..
.15-1 15.2 Reporting of Nonconformances..
15-1 16 CORRECTIVE ACTION 16-1 17 OUALITY ASSURANCE RECORDS-17-1 18 AUDITS
..-... 18-1 O
O
-Xii-
NEDO-11209 3-31-78 g
LIST OF ILLUSTRATIONS Figure Title Page i
11 Nuclear Energy Business Group..
.1 11 1-2 NEBG QA Organizations and Customer Contact Points.
.1-12 1-3 Nuclear Energy Product and Ouality Assurance Operation..
.1-13 1-4 Nuclear Energy Projects Division.
.1-14 1-5 Nuclear Energy Engineering Division..
.1-15 1-6 Nuclear Energy Products Division..
.1 16 1-7 Nuclear Energy Programs Division..
,,1 17 1-8 Abridged Organization Chart Showing Key OA Positions and Relationships in the NEBG BMs Business..
.1-18
.xiii /.xiv.
NEDO-11209 3-31-78 LIST OF TABLES Table Title Page 11 BWR Ouality Assurance Organizational Responsibilities..
.1-9 1-2 BWR Responsibilities / Relationships Matrix.
.1-10 2-1 NRC Regulatory Guide Positions..
.2-7 2-2 Cross-Incex Table Showing Relationship of Key Ouality-Related Document Systems and Manuals with Each of the Cnteria of 10CFR50, Appendix B.,
.2-16 3-1 Design Reviews..
.3-7 5-1 Key QA Program Documentation Approval and Issuance Authority..
.5-2
-xv-/-xvi.
NEDO-11209 3-31 78 LIST OF ABBREVIATIONS AE Architect Engineer ANSI American National Standards Institute ASME American Society of Mechanical Engineers BWR Boiling Water Reactor BWRSD BWR Services Department (Proj. Div.)
BWRSED BWR Systems Engineering Department (Engr. Div i CBIN Chicago Bridge and Iron Nuclear CFR Code of Federal Regulations C&lD Control and Instrumentation Department (Prod. Div.)
CRD Control Rod Drive DDR Deviation Disposition Request ECN Engineering Change Notice EEPO Engineered Equipment Procurement Operation (Engr. Div.)
El Engineering instruction Engr. Div.
Nuclear Energy Engineering Division EOP Engineering Operating Procedures ESO Engineering Services Operation (Engr. Div.)
EWA Engineering Work Authorization FDI Field Disposition Instruction FDDR Field Deviation Dispu ition Request FPD Fuel Projects Department (Proj. Div.)
FPI Fuel Project Instructions GE General Electric GESSAR General Electric Standard Safety Analysis Report GEUMCO GE Uranium Management Corporation (Prog. Div.)
IR inspection Report LWR Light Water Reactor MR Material Request MPL Master Parts List MRO Material Review Board NEBG Nuclear Energy Business Group NEMD Nuclear Energy Marketing Department (Prog. Div.)
NFPA National Fira Pruection Association NRC Nuclear P..,auiatory Commission NSSS Nuclear Steam Supply System NTD Nuclear Technology Department (Engr. Div.)
OPG Organization and Policy Guide PAS Product Assurance Section (P&OAO)
PCO Program Control Operation (Proj. Div.)
POC Product Quality Certification P&OAO Nuclear Enc 7 oroduct & Ouality Assurance Operation Prod. Div.
Nuclear Enec / Products Division Prog. Div.
Nuclear Energy Programs Division Proj. Div.
Nuclear Energy Projects Division PSAR Preliminary Safety Analysis Report OA Quality Assurance OAEE&l Quality Assurance Engineered Equipment & Installation (Engr. Div.)
QAS Quality Assurance Sechon (P&OAO)
OC Ouality Control REO Reliability Engineering Operation (Engr. Div.)
RIS Requisition Instruction Sheet
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NEDO-11209 3-31-78 SFSO Spent Fuel Services Operation (Prog. Div.)
S&LO Safety and Licensing Operation (Proj. Div.)
STRIDE Standard Reactor Island Design VNC Vallecitos Nuclear Center WMD Wilmington Manufacturing Department (Prod. Div.)
xviii-
NEDO-11209 3-31-78 INTRODUCTION A Quahty Assur6nce (OA) Program is provided by the General Electric Nuclear Energy Business Group (NEBG) to assure the required effort, equipment, procedures, and management are directed toward satisfying the quakty objectWes of providing safe and rehable structures, systems, and components, and complying with the provisions of the following documents: Appendix B of 10CFR Part 50,"Quahty Assurance Cnteria for Nuclear Power Plants"; NRC Regulatory Guide 1.28, "Quahty Assurance Program Requirements"; ANS! N45.2-1971, "Quahty Assurance Program Requirements for Nuclear Power Plants" and apphcable sections of the ASME Boiler and Pressure Vessel Code.
The program herein desenbed is structured in accordance with the outline of the 18 cnteria of Appendix B of 10CFR Part 50, and NRC Regulatory Guide 1.70, " Standard Format and Content of Safety Analysis Reports for Nuclear Power Plants" - Light Water Reactor (LWR) Edition dated September 1975.
This document desenbes the OA Program which is apphed generally throughout the NEBG, but which is specifically apphcable to the safety-related functional aspects of systems and components within the domestic boihng water reactor (BWR) scope of supply. This scope of supply includes nuclear steam supply systems (NSSS), nuclear fuel, and the standard reac*or island design (STRIDE). Systerns and components included in the BWR scope of supply are classified "important to safety'" if they prevent or mitigate the consequences of postulated accidents that could cause undue risk to the health and safety of the public. The quakty of any systems or components not classified "important to safety" is controlled in accordance with the importance of the overall functions to be performed by these items.
The Nuclear Regulatory Commission (N RC) will be given notification of programmatic changes 'n the OA Program as desenbed herein, pnor to implementation, except changes which do not decrease the effectivaness of the program, or those that reflect organizational changes. Organizational changes affecting the OA Program will be reported to the NRC within 30 days af ter implementation. This OA Program description will be reviewed at least annually and revised, if necessary, to reflect programmatic and organizational changes.
The OA Progrom is designed to provide assurance that the quakty-related work elements for systems, components (including spares and replacement parts), and services included in the BWR scope of supply, are identifieo and controlled.
Specific responsibihbes of personnel and organizations are assigned and documented for quakty-related activities through-out the major steps of design and construction of the nuclear power plant projects, encompassing the L*
i phases of:
e Contract definition
'ehminary design e
Systems and components design and specification Supplier evaluation and selection e
Matenal and component procurement e
Fabncation and assembly of components and systems e
Inspection and testing e
Cleaning, packaging, and shipping e
!nstallation and erection of systems and components e
Preoperational and startup testing e
XIX-
NEDO 11209 3-31-7t in addition to the Nuclear Energy Product and Quality Assurance Operation (P&OAO) and the various line OA l
organizations, project management, engineering, procurement, manuf acturing and services organizations also have speci-fically designated OA responsibilities. Documented procedures require each such organization to administer its own activities and conduct self audits as required, in addition to audits of General Electric (GE) suppliers to assure compliance with the OA Program for their assigned scope of responsibilities. These audits in turn are augmented by audits of these organizations by P&OAO.
O O
-X X-
NEDO-11209 3-31-78 1
ORGANIZATION 1.1 GENERAL Organizational structuring and functional responsibility assignments in the NEBG are based on recognition of QA as an interdisciplinary function with quahty-rela:ed activities being performed by many organizational components and individu-als from top-level management down to individual contnbutors.
The authontres and responsibilities cf persons and organizations pe-forming quahty-related activities are established, assigned. and documented in formal document systems. Persons anc' organizations assigned QA functions are given appropnate and sufficient authonty and organizational freedom to: identil quality problems; initiate, recommend, or provide
/
solutions to quality problems; venfy implementations of the solutions, anc prevent further processing, delivery, installation, or utilization of nonconforming stems until proper dispositioning has occurred.
The organizational structure and functional responsibihty assignments are such that- (1) attainment of quaht/
objectives is accomphshed by individuals assigned responsibihty for specifying quahty or performing work to specifications; (2) venfication of conformance to estabhshed quahty requirements is accomphshed by those who do not have direct responsibihty for specifying producing. or expedit:ng products; and (3) personnelin key QA functions have direct access to top-level NEBG management.
1,2 ORGANIZATIONAL FUNCTIONS An abbreviated organization chart showing the NEBG, and specifically those organizational components concerned with supplying BWR systems and components, is shown as Figure 1-1. Figures 1-2 through 1-7 provide additional detail structunng of the NEBG organizations performing OA activities dunng design, procurement, manufactunng. cite construc-tion, and testing.
The Manager of P&OAO and the General Managers of the Nuclear Energy Engineenng Division (Engr. Div.), the Nuclear Energy Projects Division (Proj. Div.), the Nuclear Energy Products Division (Prod. Div.), nd the Nuclear Energy Programs Division (Prog. Div.) all report directly to the Vice President and Group Executive of the NEBG.
The P&QAO is a staff organization assigned responsibihty for estabhshing the NEBG-level quahty-related pohcies, instructions, and procedures, and for integrating, measunng, and auditing the various functional organizations involved in the BWR business. Procedures and practices are evaluated to assure conformance with applicable GE Corporate and NEBG quahty-related pohcies, instructions, and procedures, and to assure integration of individual quahty planning into an overall QA Program. The P&OAO is responsible for auditing comphance of the overall QA Program with apphcable codes, standards, and regulations. The P&QAO is also assigned the responsibikty for monitoring the technical excellence of the GE BWR by participating in management review boards independent of the comprehensive design verification and review programs carned out by the kne organizations. The Manager, P&QAO, is further assigned responsibihty for QA communica-tion to the QA line organizations within the NEBG by providing technical quidance, advice, and counsel based on current OA technology as it relates to the BWR business. This technical guidance, advice, and counselis directed toward specifying how the hne organizations are to comply with the NEBG Product Quahty Policy and related instructions and procedures. The QA communications relationships for the BWR business art, ?~~ in Figure 1-8.
The NEBG Group Executive has established a BWR Ouahty Council to aid in fulfdhng the assigned integration and QA communications responsibihties and to provide a communications medium within the NEBG and to the NEBG Group Executive on BWR quahty-related matters. One of the primary objectives of the Councilis to assure total quality system coverage, uniformity, con 3istency, and continu!ty, whde eliminating system deficiencies and redundancies. The Council is cnaired by the Manager-P&OAO and consists of the managers responsible for QA in each of the major organizations within the NEBG. The Council normally meets quarterly to review the status of quahty-related programs and projects and to plan future efforts. The Council provides OA managers in the hne organizations with direct access to top-level management and provides a forum for the review of quakty problems and corrective actions. Membership in the BWR Ouahty Councilis shown in Figure 1-8.
1-1
NEDO41209 3-31-78 The Engr. Div., Prod. Div., Proj. Div., and Prog. Div, are line organizations with responsibility for planning and implementing the OA functions performed within their areas of responsibility. Procedures require that tl/ 1etailed QA program planning and implementation performed by these hne organizations comphes with the overall t,. Jity system requirements which are estabhshed by P&OAO in the NEBG Product Quakty Pohey and quahty-related Instructions and Procedures. The QA activities related to design, procurement, manufacture and project management, as they are performed by the kne organiza"ons, are desenbed in the succeeding paragraphs.
Administrative control (salary review, hire / fire, position assigment) and technical OA direction of the activities of each department-level organization are the responsibility of the individual department-level managers. The individual QA mana-gers have the authonty, independence, and organizational freedom to identify quakty-related problems; initiate, recommend, or provide solutions to condit+ons adverse to quality; and to venty implementation of such s_!utions. Each OA manager is provided a direct line of communicat,on to his department-level manager on all quality-related matters (Figure 18).
The overall BWR system design and the detail design ofitems of equ:pment manufactured by the NEBG organizations are provided by the NEBG engineenng organizations. Detailed design of items of equipment fabncated by subcontractors for direct shipment to the reac or site is provided by NEBG engineenng or by a subcontractor, subject to NEBG approval. Detail design of the NEBG-supphed systems and components, whether f abncated by the NEBG or its subcontractors,is required to meet NEBG specified system design requirements by application of appropnate specifications and des,gn controls A continuity of engineenng controlis maintained from the conceptual design phase through material procurement, manuf actur-ing, field installation, and preoperational and startup testing To assure compatibility with Owner"/AE design scope, GE has identified specific interface requirements needed for input to GE designs in a series of fill-in questionnaire documents which are furnished to the Owner /AE for completion and return to GE engineering organizations dunng the design phase. The NEBG engineenng organizations have design change control responsibility for all NEBG-designed systems and compo-nents. Development engineenng organizations contribute to the overall quality system by providing basic technicalinforma-tion and advanced inspection techniques resulting from planned development programs and through performance of necessary development and quahfication tests.
The OA activities related to NEOG-manuf actured products are underthe direction of the various managers of OA. The Manager, Quality Assurance, Wilmington Manufactunng Department (WMD), is responsible for providing QA planning and QA Program implementation for equipment such as control rods. control rod drives (CRD's). steam separators, CRD hydraulic control modules, fuel bundles. channels, and fuel assembly components, which are manufactured in Wilmington, North Carolina. He is also responsible for providing OA planning and QA Program implementation for purchased material and equipment used in the manuf acture of WMD products. The Manager, Quakty Assurance, Control and Instrumentation Department (C&lD), is responsible for providing OA planning and OA Program implementation for equipment such as sensors, instrument panels, and racks, peripheral electrical sensing and control equipment, and reactor servicing tools and equipment which are manuf actured by C&lD in San Jose, Cahfornia. He is also responsible for providing OA planning and QA l
Program implementation for purchased matenal and services applied to the manufacture of C&lD products. These OA managers report directly to their respective department general managers and are at the same organizationallevel as other managers who have prcduc. ;,cheduhng, expediting. and fabricating responsibilities; however, their responsibihties are separate and independent from these other managers. Products are not re: eased for shipment without the approval of the OA manager or his designee.
The OA Program for procured engineered equipment is under the direction of the Manager, Quahty Assurance Engineered Equipment and Installation (O AEE&l), who reports directly ta the Manager, Engineered Equipment Pro ( irement Operation (EEPO), and is at the same organizational level as managers with procurement, product schedule g, and expediting responsibihties. The OA manager's responsibihties, however, are separate and independent from thesa other organizations. T he Manager-OAEE&lis responsible for defining O A requirements to supphers of engineered equipment and services and for assunng suppher comphance with NN requirements through surveillance, audits, and review and approval of quahty-related documentation. The NEBG quainj ceviews of Owner /AE/ Constructor field installation activities are performed by the OC Site Representative, under the direction of the Manager, OAEE&l. The purpose of such revcws is to venfy that NEBG systems and components nre properly received, handled, stored, and installed in compliance with NEBG requirements. These reviews are intended to satisfy NEBG interests relative to warranty fulfillment.
- The Owner of the nuclear power ;4 ant, also des,gnated as "appi. cant" in Append,x B of 10CFR Part 50 1-2
NEDO-11209 3-31-78 The O A Program for Spent Fuel Services Operation (SFSO) designed or procured equipment is under the direction of the Manager. Quahty Assurance, SFSO, who reports directly to the Manager, SFSO. The OA Manager is responsible for providing OA planning; for assuring that appropriate quahty requirements are included in the design, procurement, and instaFation of SFSO equipment, such as high density spent fuel storage racks; and, for assunng that all applicable regulatory, customer, and GE quahty requirements are met in SFSO products.
Liaison between the Owner and NEBG on all NSSS or Nuclear Island quahty-related matters is through the appropriate Project Manager. Liaison between the Owner and NEBG on nuclear fuel quahty-related matters is through the Fuel Project Manager. The NSSS, Nuclear Island, and Fuel Project Managers are responsible for assuring that unique contract requirements involving quakty-related matters are trsnsmitted to the affected kne organizations within the NEBG for planning and implementation. The Safety and Licensing Operation (S&LO) of Proj. Div. has the primary responsibihty for defining the BWR product safety standards and for assuring that applicable new regulatory requirements related to quahty and safety are made known to the cognizant functional organizations within the NEBG. Technical direction
- for field installation and preoperational and startup testing of NEBG-supphed systems and components is provided by the NEBG Resident Site Manager and statt. Quahty usurance planning and senaces are provided to the NEBG Resident Site Manager by the assigned NEBG QC Site Representat;ve from OAEE&l and other QA organizations, as needed. Installation.
l preoperational, anu startup testing engineers anJ speciahsts assigned to the NEBG Resident Site Manager have the responsibihty for planning and providing technical direction for the installation, preoperational, and startup testing activities.
Estabhshed QA communication relationsh4 within the NEBG, including a channel of communications directly between each of the various O A kne organizations and their department-level managers are shown in Figure 1-8. A separate channel of communications is also available for kne OA managers to the Manager, P&OAO, through the BWR Ouahty Council. This communication channel is estabbshed for developing common solutions to quahty-related problems, and for providmg a second kne of communication to NEBG management on such quahty-related matters as stop-work actions.
The tabulation in Table 1-1,"BWR Ouahty Assurance Organizational Responsibikties," identifies the NEBG organiza-tions having kne responsibihties for specifying, attaining, and venfying quakty requirements for NEBG-supphed systems, corrponents, and services. Additional detail responsibihties are further identified in other sections of this program description.
A summary of prime and contnbuting functional responsibihties for ear:h of the NEBG division-level organizations is shown in Table 1-2. A furt%r breakdown of functional responsibihties for NEBG OA organizations and other major organizations performing quahty-related functions for BWR systems and components is detailed in Subsection 1.3.
1.3 QA FUNCTIONAL RESPONSIBILITIES 1.3.1 Staff OA Organizations e
Quahty Assurance Section (P&OAO)
For the NEBG, the Quahty Assurance Section (OAS) of P&OAO has the responsibihty for coordinating and integrating the BWR Q A Program as related to manuf actunng, procurement, and construction, by appropriate means, including:
Developing the NEBG policies, instructions, and procedures related to manufacturing procurement, and l
e construction OA.
Representing the net 3G to customers, the NRC, ard other government authonties on matters regarding the e
manufacturing, procurement, and construction aspects of the overall BWR OA Program.
Auditing the NEBG manufacturing, procurement, and construction organizations for compliance with their approved quahty related procedures and instructions.
- Technical dwection is defined as technical guidance. adwce. and counsel based On current engineenng and instaliation practices. whsCh IS prOvded 'O the Owne(s staff.
1-3
NEDO-11209 3-31 78 Providing assistance to the NEBG marketing and legal organizations on manufactunng, procurement, and construction-related quahty system matters, as requested.
Administering a lending library of the various NEBG organizations' key QA manuals and quality-related procedures manuals for loan to customers and potential customers.
Provioing technical support and consultation to the NFRG licensing activities, as requested.
Providing quality system and auditing ponsultation services to the NEBG organizations, as requested.
Initiating stop-work recommendations to the affected NEBG manager, as necessary, to prevent further processing delivery, installation, or utilization of nonconforming or suspect items until proper dispositioning has occurred.
Product Assurance Section (P&QAO)
For the NEBG, the Product Assurance Section (PAS) of P&OAO has the responsibility for coordinating and integrating the BWR QA Program as related to project management and engineering by appropriate means, including:
Developing the NEBG policies, instructions, and procedures related to project management and engineering l
QA activities.
Representing the NEBG to customers, the NRC, and other governmental authonties on matters regarding l
project management and engineenng aspects of the overall BWR OA Program.
Auditing the NEBG engineenng and project management organizations for compliance with approved quahty systems, procedures, and instructions.
l Providing assistance to the NEBG marketing. legal, and projects organizations on engineering-related quahty system matters, as requested.
Initiating stop-work recomment
- 1s to the affected NEBG manager, as necessary, to prevent further processing, dehvery, installatbr.
utibzation of nonconforming or suspect items until proper dispositioning has occurred.
Providing guidance to line organizations on matters related to engineering OA activities.
Participating in selected design reviews.
1.3.2 Line Organizations - QA Quahty Assurance - C&lD, WMD, and SFSO For assigned product scope, assure conformance with applicable design and OA requirements by appropriate means, inciuding.
Developing and documenting a quakty system in compliance with the NEBG pohcies, procedures, and instructions, and applicable codes, standards, and regulatory requirements.
Conducting preproduction reviews with engineering to assure mutual understanding of design requiremeres and manufacturing capabihty.
Prepanng product and process quakty planning to assure conformance with applicable drawings, specifica-tions, and special instructions issued by design engineering organizations.
14
NEDO-11209 3 31-78 Providing control of purchased material and services, including necessary surveillance of supphers to assere l
that purchased materials and components are provided at proper qual:ty levels and that quahty-related procurement document requirements are satisfied.
Providing product and process control to assure that quahty planning is properly interpreted ar'.d implemented.
Providing required receiving. in-process, and final inspection and testing in accordance with OA documented inspection and test procedures.
Providing for the cahbration and control of measuring and test equipment.
Providing for the effective control of nonconforming materials, parts, and con ponents, including stop-work authority.
Assunng provision of programs for the required training. quahfication, a.1d certification of personnel.
e Assuring provision for control of handhng, storage, and shipping.
Assunng provision of a formal corrective action system.
Assunng provisions for generation, collection, transmittal or storage, maintenance and retrieval of all neces-sary quahty records.
Assunng provisions for audit and other measurements of the effectiveness of the quahty system, including suppher quality systems.
Providing product release control and certification of product quahty.
e Providing product quakty-related problem analyses and initiating or recommending appropriate action.
Quahty Assurance - Engineered Equipment and Installation (QAEE&I) e For procured engineered equipment and design services other than for Controls and instrumentation, assure suppher conformance with apphcable design and QA requirements by appropriate means, including:
Developing and documenting a quahty system in corrpliance with the NEBG quahty policies, procedures and instruct!ons, and appbcable codes, standards, and regulatory requirements.
Reviewing suppher QA Programs for adequacy.
Conducting pre-award evaluations to establish supplier quahfication.
e Conducting pre-procurement review with engineering and procurement, as necessary, to assure clear under-l standing of quahty requirements.
Providing quahty planning which defines supplier QA program requirements and check hsts which define audit requirements.
P,;viding audit / surveillance of supplier quahty-system and activities during manufacturing.
e Reviewing and approving identified supplier fabrication, test, and inspection procedures.
Providing for the accumulation, review, approval, and transmittal of suppher QA records to be transmitted to or retained for the Owner.
15
NEDO t1209 3-31 78 Providing for the review and approval or disapproval of supplier deviations from specified quality requirements.
e Assuring that all required supplier documentation has been reviewed, approved, and shipped to the site or e
stored, as required.
initiating stop work orders through procurement to prevent further processing, utilization, or shipment of e
nonconforming or suspect items until proper dispositioning has occurred.
For NSSS equipment, assure the Owner conforms with applicable NEBG installation requirements by appropriate means. including:
Reviewing and approving selected Owner /AE/ Constructor installation procedures.
Provioing site :urveillance planning for implementation by the NEBG Ouahty Control Site Representative.
Performing surveillance of Owner /AE conformance with NEBG-supplied installation and test documents.
Providing feedback and analysis of installation quality problems and implementation of preventive or corrective action to assure Owner compliance with NEBG requirements.
Quahty Assurance - BWR Services Department (BWRSD) e For BWRSD, develop, document, and maintain quality systems for quality-related activities which eff ectively meet the requirements of the overall BWR OA Program. This work is accomplished by appropriate means, including:
Providing functional guidance and direction to BWRSD managers and engineers in implementing applicable portions of the BWR OA Program, and in responding to both internal and external OA audits of BWRSD activities.
Planning and directing preparation of the OA input to customer bid specifications and purchase orders for BWRSD scope.
Integrating and coordinating the BWRSD OA responsibilities for material, equipment, and services supplied by BWRSD.
Recommending indoctrination and training programs to BWRSD management to assure suitable proficiency is achieved and maintained by BWRSD personnel for activities affecting quality.
Planning, directing, and executing periodic audits of BWRSD quakty-related activities and reporting findings to management, including recommended corrective action.
Quahty Assurance - Engineering Organizations e
For the BWR scope of supply, the NEBG engineering organizations are responsible for product design and design control by appropriate means, including:
Developing and documenting a quality system for engineering work in compliance with NEBG quality policies, instructions, procedures, contractual commitments, and applicable regulatory requirements.
Providing quality planning for engineering which defines engineering OA program and audit requirements.
Assun.tg incorporation of applicable regulatory requirements, codes, standards, cnteria, and design bases in the design.
Assunng incorporation of project design requirements into the design.
1-6
NEDO-11209 3-31-78 Translating the design information onto the appropriate design documents.
e Verifying design adequacy either through independent design review, the use of alternate or simpliied f
e calculational methods, or by the performance of a suitable testing program.
Coordinating design activities among interfacing design engineers and design organizations.
Reviewing, approving. assuing, and distnbuting design documents under a controlled document system.
Controlling design changes and changes to design documents in accordance with documented procedures.
Providing for the retention, storage, control and retrievabihty of design record documents.
e Taking corrective action as necessary to correct design errors and to improve the design control function.
Conducting penodic audits of design activities that affect product quality.
l Quality Assurance - Projects Organizations e
For Proj. Div., coordinate and integrate those OA-related activities essential for support of Project Management and resolution of Owner quahty-related problems by appropriate means, including:
Providing Proj. Div. Policies and Procedures concerning quality-related activities within the Division scope of responsibihty.
Assuring that utility owners and AE's are apprised of the BWR OA program dunng audits and that the GE responses to customer audit reports adequately descnbe the systems meeting the requirements of 10CFR50, Appendix B. and that appropriate corrective action is initiated when necessary, Conducting periodic audits of project activities that affect product quahty, e
Monitonng initiated corrective action for completion by the affected Proj. Div. organization.
e Providing quakty system services for project organizations.
1.3.3 Project / Program Management Organizations Project Managoment - NSSS or Standard Reactor Design (STRIDE) e The NSSS or STRIDE Project Manager maintains interface relationships with the Owner, Architect Engineer and Constructor, as well as cognizant GE personnel to assure provision cf licensing, engineering, QA, and equipment supply activities by appropriate means, including:
Directing the NBG performing organizations and others, as apphcable, as to the contract scope of supply and the basis definition, and changes thereto, Providing control of design interfaces with engineenng, the AE/ Constructor, the Owner, and in the case of e
STRIDE contracts. with the subcontractor-designer through STRIDE Project Management.
Monitoring to assure contract commitments are satisfied.
e Providing for coordination, integration, and project management cf requisition activities performed by contnbut-ing NEBG organizations.
Maintaining recognition of quality requirements for systems and components, and taking appropriate action to e
maintain consistent requirements.
17
NEDO-11209 3-31-78 Providing the Owner with appropnate information as to the status of the project and applicable revisions of project documentation as required by contract.
Project Management - Fuel Projects e
The Fuel Project Manager maintains interface relationships with the Owner for nuclear fuel contracts and assures provision of engineenng OA, and equipment supply activities by appropnate means, including:
Directing NEBG performing organizations and others, as applicable, as to the contract scope of supply and the basis definition, and changes thereto.
Monitonng to assure contract commitments are satisfied.
Providing for coordination. integration, and project management of fuel requisition activitres performed by e
contnbuting NEBG organizations.
Maintaining recenition of fuel quality requirements and taking appropriate action to maintain consistent e
requirements.
Providing the Owner with appropriate information as to the status of the project and applicable revisions of project documentation as required by contract.
Program Management - Spent Fuel Serwces e
The Program Manager maintains interface relationships with the Owner and assures provision of engineenng, OA, and equipment supply activities by appropnate means, including:
O Directing NEBG performing organizations and others, as applicable, as to the contract scope of supply and the e
basis definition, and changes thereto.
Mondoring to assure contract commitments are satisfied.
Maintaining recognition of applicable quality requirements and taking appropnate action to maintain consistent requirements.
Providing the Owner with appropnate information as to the status of the program and applicable revisions of program documentation as required by contract.
1,4 QA PERSONNEL RESPONSIBILITIES AND QUALIFICATIONS The responsibilities, education, and experience requirements of individuals assigned to OA-related managerial and individual contnbutor posnions are formally documented in the NEBG position quides which are approved and periodically reviewed by designated levels of management. The responsibilities and qdallflCation requirements of individuals performing inspection and testing operations are formally documented in job descriptions, which are also approved and periodically reviewed by designated levels of management. Qualification requirements for managers responsible for QA activities on BWR projects are shown below:
Staff Organizations Titles Qualification Requirements Manager, Quality Assurance, P&OAO; BS or equivalent qualifications; at least 15 years in responsible man-Manager, Product Assurance, P&OAO agerial or project-type assignments,10 years of which have been in quality-related work or equivalent experience in the design, construc-1-8
NEDO-11209 3-31 78 tion, or operation of a nuclear f acility; thorough knowledge of all aspects of the BWR OA Program.
Manager, Quality Systems, P&OAO; BS or equivalent qualifications; at least 12 years in responsible man-Manager, Quality Audits, P&OAO; agerial or project-type assignments, 7 years of which have been in Manager, Engineering Systems, P&OAO; quality-related work or equivalent experience in the design, construc-Manager, Engineering Systems Audits, P&OAO tion or operation of a nuclear facility; thorough knowledge of the BWR OA Program.
Line Organizations Titles Qualification Requirements Manager, OAEE&l, EEPO, Engr. Div.
BS or equivalent quakfications; at least 10 years in responsible man-Manager, OA, C&lD, Prod. Div.
agerial or project-type assignments, 5 years of which have oeen in Manager, OA, WMD, Prod. Div.
quality-related work, or equivalent experiences in the design, cc1struc-Manager, OA. REO, Engr. Div.
tion, or operation of a nuclear facility; thorough knowledge of the OA Manager, QC, ESO, Engr. Div.
Program for his area of responsibility.
Manager, OA&OM, PCO - Proj. Div.
Table 1-1 BWR QUALITY ASSURANCE ORGANIZATIONAL RESPONSIBILITIES Manufacturing Type of Equipment Design Quality Requirements Process Procedures OA Compliance Verification Procured Engineered BWRSED and NTD Supplier
- OAEE&l Equipment and Design Services Nuclear Fuel BWRSED and NTO Fuel Process Technology WMD-OA (WMD)
Manufactured Reactor BWRSED and NTD Fuel Process Technology WMD-OA Equipment (WMD)
Manufactured Controls C&lD Engineering C&lD Manufacturing C&lD-OA and Instrumentation Procured Controls C&lD Engineenng Supplier
- CalD-OA and Instrumentatien Spent Fuel Storage Fuel Storage Suppher*
SFSO-OA Equipment Project Engineering
- oesignated supplier manufacturing procedures and design documents are revewed and approved by GE eng.neerus or OA organuations in accordance wth documented procedures i
1-9
NEDO-11209 3-31-78 O
Table 1-2 BWR RESPONSIBILITIES / RELATIONSHIPS MATRIX Engr.
Proj.
Act vity NEMD P&OAO Div.
Div.
C&lD WMD SFSO 1.
Initial contract negotiation P
C C
C C
C P
2.
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C P
C P
5.
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C C
P 6.
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P 7.
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8.
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C 9.
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C C
C C
110. Product quality C
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P P
P t 11. Quality systems P
P P
P P
P t 12. Product audits P
P P
P P
P t 13. Quality system r udits P
P P
P P
P
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C P
15 Manuf actunng (C&lD)
C P
- 16. Engineered equipment P
procurement
- 17. Installation and operating C
C P
C C
?"
plant servces Pnme responsibility P
=
C - Cor.inbuting responsibility / relationship t Each functonal organaation 6n the NEBG is respmsible for the quality of its own output.
- Control and instrumentation items only
" sFs0 items only 0
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NEDO-11kO9 3-31-78 0
2 QUALITY ASSURANCE PROGRAM 2,1 GENERAL An overall OA program is established, documented, and implemented which encompasses the collective activities and events with their associated responsibilities, efforts, equipment, procedures, interfaces, and management which are necessary to provide the means to meet product quality objectives.
Since many projects are being processed by design, procurement, and manufacturing organizations simultaneously, OA activities which are described in the OA Program are continuously being applied in support of the total BWR scope of responsibility and are applicable to each of the projects throughout those phases of activity for which the NEBG is responsible.
The OA Program desenbed herein applies those quality system elements necessary to provide assurance that NEBG-supplied systems and components meet the quality requirements of the Owner and applicable codes, standards, and regulatory agency requirements. This OA Program is documentea in formally controlled document systems and is im-plemented throughout all phases of nuclear power niant design and construction. All BWR systems and components classified "important to safety" are supplied in accoroance with this OA Program.
Training and expenence qualifications are defined for each position in GE. In addition, the program provides for indoctnnation and training of personne! oerforming activities affecting quality in order to provide assurance that appropriate proficiency is achieved and maintained. This indoctrination and training is carried out through vanous documented proce-dures, personnel contacts and meetings. These training programs encompass inspectors, testers, shop personnel and engineers, as appropria e. Quality assu rance, manufacturing, engineering, and project organizations each develop their own requirements fnr training and establish their own training programs. The purpose of the training is to assure that personnel responsible for quality-related activities are instructed as to the purpose, scope, and implementation of the quality-related manuals, instructions, and procedures. Personnel performing quality-related activities are trained and qualified in the pnnciples and techniques of the activity being performed.
The OA Program provides for conducting activities affecting quality under suitably controlled conditions, including the use of appropnate equipment, suitable environmental conditions, and assurance that prerequisites for the given activity have been satisfied. These prerequisites include cogsideration of special process controls and skills and the need for special inspection and test equipment where required for the venfication of quality.
The BWR quality system documentation derives its authority and is structured from the GE Corporate Product Quality Policy down through each organizational level of the NEBG. Responsibility for the final review and issuance of the overall BWR OA Program rests with the NEBG Group Executive. Responsible organizations and individuals within the NEBG are l informed of the mandatory nature of the vanous quality policies, manuals, and procedures through the NEBG Product Quality Policy, Instructions and Procedures issued by the NEBG management. Quality-related instructions, manuals, and imp;e-menting procedures assign responsibilities making them mandatory for quality-related administrative functions. Shop travelers, work orders, or other planning documents relative to specific projects, processes, or work stations are mandatory directives for personnelinvolved in hardware-related activities, such as production, inspection, and test personnel.
The OA Program provides for the regular management review, through audits or other appropriate means, of organizations participating in the BWR business, and of the status and adequacy of that part of the OA Program for which they have designated responsibility.
The BWR OA Program is structured to comply with the NEBG commitments to the quality-related regulatory guides and ANSI Standards as documented in Table 2-1. This OA Piogram provides for periodic modification and/or updating of NEBG commitments to comply with quality-related regulatory guides and ANSI Standards relating to the NEBG scope of supply. New or revised quality-related regulatory guides and referenced standards are evaluated and determinations are 2-1
NEDO-11209 3-31-78 made as to when, how, ano to what extent they will be implemented. The NEBG commitments to comply with regulatory positions, or NRC-approved alternate positions to qm hty-related regulatory guides, are then incorporated into the BWR OA Program documentation.
The NEBG commitments to comply with applicable regulatory guides not hsted in Table 2-1 are documented in the project hcensing documents for each nuclear power plant. The NRC-approved hcensing documents for a specific nuclear power plant project establish the NEBG regulatory guide or alternate position commitments for that project. The commit-ments to comply with regulatory guides issued or revised subsequent to NRC approval of the project licensing documents are documented in amendments to the NRC-approved project licensing documents.
9 Classification of structures, syste ns, and major components important to safety is documented in the project licensing documents and the Project Master Parts List (MPL), and is provided through cnntrolled documents to affected NEBG organizations for implementation. Replacement parts not identified in the project licensing documents are classified relative to safety importance using either onginal or current classification cnteria.
2.2 OUALITir SYSTEM DOCUMENTATION The NEBG quahty-related actrdties are documented in a series of planned and coordinated pohcies, procedures, manuals, and instructions defined as OA program documentation. Activities and events comprising the BWR OA Program appropnate to each NEBG organization are identified and documented in formally controlled document systems issued by each cognizant organization. Quahty Assurance system documents, including OA manuals, are distnbuted to a predeter-mined list of key personnel as controlled copies. % visions are distnbuted to the same hst with appropriate instruct:ons for replacement and disposition of obsolete documents.
Though the basic scope of the quakty system utilized by the various organizations within the NEBG is essentially the sarne each NEBG functional organization has its own system of guides, procecures, instructions, manuals, and other implementing documentation that presenbes the methods f or carrying outits portion of the overa'l BWR OA Program. Each of these systems is unique, relates to the activities of the particular organizations involved, anc is undergoing continuous review, upgrading, and improvement.
A cross-index table showing the relationship of the key BWR quahty-related document systems or manuals with each of the critena of 10CFR50, Appendix B, and identifying the system or manual section so related, is presented in Table 2-2. A bnef descnption of the purpose and scope of each of the key document types governing O A activities which demonstrate the implementation of the OA Program is presented below:
General Electric Corporate Product Quahty Pohcy (No. 20.9).
The General Electric Corporate Product Quanty Policy, issued by the Corporate Executive Office, states quakty considerations and requirements apphceble to all General Electric product-determining business components, and establishes the overall posture of the General Electric Company with regard to the quahty of products and services provided. The policy specifically requires that each product-determining business component issue, maintain, and operate in comphance with a product quahty pohcy. This pohcy must define the broad quahty objectives of its products, identify the key eierrents of the product quakty system, and assign pome responsibilities for their accomphshment. The product quahty pohcy must identify and provide reference to the supporting procedures which implement the pohcy.
Nuclear Energy Business Group Product Quahty Pohcy(No. 70-1).
The NEBG Product Quahty Policy issued by the Group Executive, interprets the Corporate Product Quahty Pokcy and provk1es implementing direction to the NEBG organizations.
This document, which is a part of the NEBG Organization and Policy Guide (OPG) documentation system, estabbshes tha quakty policy for NEBG products and services, assigns quahty-related responsibihties, and identifies interrelationships for policy implementation. The NEBG Product Quahty Policy is appbcable to all NEBG organizations and specifically requires that each NEBG nrganization be in full comphance with the applicable requirements of Company Policy 20.9, Product Quahty, and apphcable NEBG Instructions and Procedures referenced therein.
O 22
NEDO-11209 3-31-78 NEBG Ouality-Related Instructions and Procedures. The NEBG Instructions and Procedures which are issued by authority of the NEBG Group Executive and/or Division-level managers to establish procedures and practices for those l quality system elements requiring uniform consideration and application by several or all organizations within NEBG. These instructions and procedures are part of the NEBG OPG and are supplemental to the NEBG Product Ouality Policy. They provide implementing direction in those areas where a standardized, uniform approach is deemed necessary by the NEBG management. Listed below are the key quality-related NEBG Instructions and Procedures:
Standard Quality System Requirements (No. 70-11) e This instruction supplements NEBG Policy No. 70-1 and establishes the minimum quality system requirements to be implemented by NEBG organizations in fulfilling licensing commitments, contracts, and internal requisitions for the sale, lease, or transfer of NEBG products to a customer.
BWR Ouality Assurance Records (No. 70-12) e This instruction supplements NEBG Policy No. 70-1 and establishes the basic OA records requirements to be implemented by NEBG organizations for BWR products and services.
Quality Measurements (No. 70-14) e This instruction supplements NEBG Policy No. 70-1 and establishes minimum NEBG-level OA program measure-ment requirements which must be implemented by the identified NEBG organizations.
Analytical and Testing Laboratory Ccuncil(No. 70-20) e This instruction describes the implementation of the NEBG Analytical Laboratory Council pursuant to the require-ments of NEBG Policy 70-1 which directs P&OAO to establish uniform quality-related practices for NEBG organizations.
Analytical Laboratory Control (No. 70-21) e This instruction supplements NEBG Policy No. 70-1 and establishes the requirements for the analytical laboratory control programs needed to fulfill NEBG quality and safeguards assurance requirements.
Quality Assurance, Nuclear Safety, and Nuclear Material Safeguards Audits (No. 70-29) e This procedure supplements NEBG Policy No. 70-1 and Instruction No. 70-11 and estabLshes the requirements for the audit programs to be implemented by P&OAO and identifies the responsibilities of other NEBG organizations in support of these audit programs.
Personnel Proficiency in Quality-Related Activities (No. 70-30) e This procedure supplements NEBG Politv No. 70-1 and instruction No. 70-11 and establishes the minimum personnel proficiency requirements to be implemented within the NEBG in support of the BWR OA Program, OA Shipment Release and Product Quality Certification (No. 70-39) e This procedure supplements NEBG Policy No. 70-1 and establishes basic guidelines to be followed by applicable NEBG organizations when releasing prcJucts for shipment and certifying product quality.
Reporting Defects and Noncompliance (No. 70-42) e This procedure provides direction for NEBG compliance with the requirements of NRC Regulation 10CFR21 Reporting Defects and Noncompliance. Standard practices are established for all NEBG organizations for identifying, 2-3
NEDO-11209 3-31-78 documenting, evaluating. and reporting potential defects in any licensed nuclear facility or activity, or noncompliance with the provisions of an NRC regulatory requirement relating to a substantial safety hazard.
Quahty Assurance Program Manuals and Document Systemm Documents describing the BWR OA Program and prescnb-ing the detailed quahty-related activities of individual organizations are prepared, issued, and maintained by the responsible organizations, such as: engineering, manuf actunng, and quality assurance. Such documentation consists of, e g., engineer-ing operating procedures, OA plans and procedures, and inspection and test planning. Key manuals and document systems are:
ASME Ouahty Assurance Program Manual (NEBG):
e This manual descnbos the controlled engineering system which meets all of the applicable requirements of Section 111 of the ASME Boiler and Pressure Vessel Code for engineer:ng organizations. It has been accepted by the ASME as a basis for issuance of a Certificate of Auttorization.
BWR Engineering Operating Procedures Manual:
e This manual contains documentation of the BWR design control program. The cnteria of 10CFR50, Appendix B, are addressed in the procedures to the extent that engineenng activities are involved.
BWR Ouahty Assurance Manual (k T %586):
e This manual describes the BWR QA F im for the NEBG functional organizations that have a direct impact on BWR product quakty. This desenption addr as m how each organization's quality system meets the requirements of each of the 18 NRC OA Cntena. This manudi is etructured such that each cnterion is broken down into work elements and each of these work elements is addressed as to the method of accomplishment, followed by a listing of the implementing instructions.
BWR Services Department - Operating Practices and Procedures Manual:
e This manual contains documentation estabhshing uniform courses of acton for quality-related BWRS activities, and estabhshes interface requirements and responsibihties for activities related to the fulfillment of the BWRS charter.
This manual contains a detailed desenption of the C&lD manufactunng quality assurance program established in comphance with the requirements of the ASME Boiler & Pressure Vessel Code, Section Ill. It has been accepted by the ASME as a basis for issuance of a Certificate of Authorization.
C&lD Manufactunng Procedures Manual:
e This manual contains documentation defining responsibihties and systems relative to C&lD manufactunng activities where more than one section level C&lD organization is concerned.
C&lD Nuclear Quahty Assuranca Manual:
e This manual documents the OA Program utilized by C&lD organizations. The cnteria of 10CFR50, Appendix B, are addressed to the extent that they relate to the manufacture of control and instrumentation equipment.
Prof. Div - Pohcies and Procedures Manual:
e This manual contains documentation descnbing the Nuclear Energy Projects Division organizational interfaces and 2-4
NEDO-11209 3-31-78 responsibilities, as well as administrative and functional operating instructions, including product quality responsibilities.
e P&OAO Practices and Procedures Manual:
This manual contains documentation desenbing specific requirements and controls fcr performing activities for which P&OAO is responsible.
OA Engineered Equipment and Installation - Quality Assurance Manual:
o This manual contains documentation of the OA activities related to equipment procured for direct-to-site shipment.
The cnteria of 10CFR50, Appendix B, are addressed to the extent that they relate to this classification of equipment.
e SFSO Practices and Procedures Manual:
This manual contains documentation of administrative procedures and specific requirements and instructions for accomplishing the quality-relateo activities associated with spent fuel storage racks and related equipment.
SFSO Quality Assurance Plan:
e This OA Plan documents the OA program utilized by SFSO. The criteria of 10CFR50, Appendix B, are addressed to the extent that they relate to the design and manufacture of spent fuel storage racks and related equipment.
WMD - ASME Code Compliance Manual:
e This manual contains a detailed description of the WMD QA Program established in compliance with the applicable requirements of ASME Boiler and Vessel Code, SectK - ill and Section Vill. It has been accepted by ASME as a basis for issuance of Certificates of Authorization.
e WMD - Practices and Procedures:
These practices and procedures document the basic business policies, assigned responsibilities and administrative instructions established by WMD management.
Implementing Document Types. The document types listed below are representative of those used by the various NEBG organizations to implement the BWR OA Program.
Acceptance standards Audit plans and procedures Calibration procedures Corrective action procedures Design control procedures Engineering drawings and specifications Handling, storage, packing and shipping procedures inspection instructions inspector and tester stamp cor. trol procedures Material identification and control procedures Measuring and test equipment control procedures Nonconforming material control proca%re?
Preproduction quality evaluatior, procedures Process and personnel qualification procedures Process control procedures Product / process quality plans Purchased material quality control plans 2-5
NEDO-11209 3-31-78 Quality assurance document control procedures Quality assurance records spec:fications and instructions Quality control standard instructions Receiving inspection plans Shipment release control procedures Supplier evaluation and selection procedures Test instruM:ons A network of policies, document systems, manuals, and implementation documents is designed to provide the QA program procedures, specificat:ons, and documentation necessary to support the NEBG objectives of providing safe and reliable systems and components, and complying with the requirements of applicable codas, standards, laws and regulatory agency requirements.
O O
2-6
NEDO-11209 3-31-78 Table 2-1 NRC REGULATORY GUIDE POSITIONS NRC Regulatory ANSI Guide Standard NEBG Position 1.28 - June 7,1972, N45.2-1971 Comply with the provisions of Regulatory Guide 1.28 (June 7,
" Quality Assurance 1972) and the requirements and guidelines in ANSI N45.2-Program Requirements 1971, except as follows:
(Design & Construction)"
1.
Section 4.3, second paragraph, first sentence: This son-tence is not considered applicable since the first para-graph of Section 4.3 identifies three alternate methods for ventying or checking the adequacy of design. All other sentences of Section 4.3 will be complied with.
2.
Section 14, second paragraph, second sentence: This sentence is interpreted to mean that necessary handling tools and equipment will be used and controlled on work under GE jurisdiction. It does not mean that GE will necessanlyprovide handling tools and equipment. Tne provision of such tools and equipment is a contractual consideration.
3.
Section 18 fourth paragraph, first sentence: To the extent required by contract, GE will maintain records which correctly identify the "as built" condition of items fo, the life of the particular item, rather than for the life of the plant.
4.
Section 18, fourth paragraph, second sentence: This sentence is not considered applicable. Refer to the committed GE position on Regulatory Guide 1.88.
5.
Section 19, second paragraph, first sentence: This sen-ter.ce is revised to read, " Audits shall be performed, as necessary: (1; to provide.
6.
Section 19, second paragraph, second sentence: This sentence reviseu to read, " Followup action shall be taken, as needed. This action may include reaudit of deficient areas."
1.30 - August 11,1972, N45.2.4-1972 Implement regulatory position.
"Qua;ity Assurance Requirements for the insta'lation, inspection
& Testing of Instru-mentation & Electrical Equipment.*
2-7
NE DO-11209 33170 Tablo 21 NFIC FIEGULATOF1Y GUIDE POSITIONS (Continued)
NFIC Flegulatory ANSI Guido Standard NEDO Position 137 - March 10,1973.
N45 2.1 1973 Comply with the provisions of Flogulatory Guido 1.37, March
' Quality Anuranco 16,1973, including tho r oquiremonts and rocommondations in Floquironients for Cloarung ANSI N45 2.1 1973, except as follows: Sochon 5 sixth para-of Fluid Systoms &
graph, recommends that local rusting on corro aon resistant Anociated Components of alloys bo removed by mechanical mothods. This recommon.
Water-Cooled Nuclear Power dation shall bo interproted to mean that local rusting may bo Plants!
removed mochanically, but that it does not prortudo the uso of other tomovat means.
1.38 - Rov. 2. May 1977 N45 2 21972 Comply with the provisions of Ikgulatory Guido 1.30, llov,2.
Ouality Anuranco May 1977, including tho regulatory position relativo to ANSI Floquirements for N45.2 21972, excopt as follows:
Packaging. Stupping, Rocciving. Storago &
1.
Section 3.7.1(1): GE will uso cloated, sheathed boxes fiandling of items for up to 1000 lb rather than 500 lb. This typo of box is safo Water Cooled Nuclear for, and has boon tosted for, loads up to 1000 lb. Othor Power PlantsJ national standards allow this, coo F'odoral Specification PPP B 601. Spocml qualification testing may bo ro-quired for loads abovo 1000 lb.
O 2.
Section 3.7.2 Skids or runners shall be used on con-tainers with a grow woight of 100 lb or moro Skids or runners t. hall bo f abncoted frorn 3x4 inch nominal lumhor sito minimum and laid flat except where this is impractical because of tho r, mall dimensions of the containor.
l 3.
Section 4.3.4: Sinco titio to equipmont gonorally changos hands at tho timo it is moved off tho supplior's dock into the carrior, GE will mako thoso inspections
" mmodiately poor to loading" rathor than "aftor load-i ing.' as prosootly indicatr,d To havo this inspection, and powiblo repair performod after loadmg. prosonts legal complications, as onco the equipment ontors the trane. port vohklo. the carrior has some responsibility and our custornor has ownership 4
Appendix Soction A3 41(4) and (5). Dunng printing of tho standard, a transposition occurred botwoon the last sentence of (4) and (5) T he correct requiromonts aro as follows:
(4)
itowover, preservativos for inacconsible insido surfacos of pumps, valves, and pipo for systems containing roactor coolant water shall bo the water flushablo typo!
2H
NEDO-11209 3-31-78 Table 2-1 NRC REGULATORY GUIDE POSITIONS (Continued)
NRC Regulatory ANSI Guide Standard NEBG Position 1.38 (continued)
(5)
"The name of the preservative used shall be indi-cated to facilitate touchup.'
5.
Appendix Section A3.4.2(3): Inert gas blankets are cur-rently used on the reactor pressure vessel (RPV) and on some of the heat exchangers supplied by GE. Provi-sions are made for measuring and maintaining the RPV blanket pressure within the required range during ship ment and storage. Heat exchangers or tanks containing carbon steel which require an inert gas blanket will be inserted prior to shipment. During storage, provision shall be made for measuring and maintaining the inert gas blanket pressure within the required range within each pressurized purged item or container.
6.
Appendix Section A3.7.1(3) and (4). GE will work to the following requirement in lieu of items (3) and (4): Fiber-board boxe. tall be ecurely closed either with a water resistant adhe. i applied to the entire area of contact between the flaps, or all seams and joints shall be sealed with not less than 2-inch wide, water-resistant tape.
1.39 - Rev. 2 September N45.2.3-1973 Implement regulatory position.
1977, " Housekeeping Requirements for Water-Cooled Nuclear Power Plants.'
1.58 - August 1973, N45.2.6-1973 Comply with the provisions of Regulatory Guide 1.58, August
" Qualification of Nuclear 1973, including the requirements and recommendations in Power Plant inspection, ANSf N45.2.6-1973, except as follows: Section 2.2, taken Examination & Testing together with Table 1, indicates that a person who approves Personnel /
inspection and test procedures must be cartified as meeting Level lli capability requirements. Not all GE personnel who approve inspection and test procedures will be certified as meeting Level lli capability requirements. However, personnel who approve inspection and test procedures will be deter-mined by GE management, through evaluation of their educa-tion, training, and experience, to be fully qualified and compe-tent to approve such procedures. The basis for the determina-tion will be documented.
1.64 - Rev. 2, June 1976, N45.2.11-1974 Comply with the provisions of Regulatory Guide 1.64, Rev. 2,
" Quality Assurance June 1976, including the regulatory position relative to ANSI Requirements for the N45.2.11-1974, except for the following modifying provisions Design of Nuclear to the second paragraph of S ction 6.1 of ANSI N45.2.11-Power Plants.
1974:
2-9
NEDO-11209 33178 Table 21 NRC REGULATORY GUIDE POSITIONS i sntinued)
NRC Flegulatory ANSI Guido Standard NEDG Position 1.64 (continued) 1, if, in an exceptional circumstance, the designer's im-rnodiato r,upervisor is tho only technically quahlind inds-vnfual availablo in tho organization to perform a design verification by design review, th:s review may bo con-ducted by the supervisor, providing that:
(a) iho justification is individually documented and approvod in advanco by the supervisor's man-agoment, and (b) OA audits cover frequency and effoctivonoss of ur of supervisors as design vonfiers, to guard aga.ost abuso.
2.
An individual who contributed to a given design may participato in a group vonfication of that dosign provided that tho individual who contobuted to the dos'9n (a) does not vonfy his contobution to the design, and (b)does not servo as the chairman or loador of the group verification activity.
1,74 - February 1974, N45 2,101973 Irnplomont regulatory position.
"Quahty Assuranco Torms & Definitions '
I 88 - Rev 2, October 1976, N45 2.91974 Comply with tho provmons of Regulatory Guido 1.00, Rev. 2.
"Collottion. Str>rago a October 1976, including the regulatory position relativo to Maintenanco of Nuclear ANSI N4S 2.91974, except as fol!uws:
Power Plant Ouality Anuranco Records '
l.
Classification - As spocified in Soction 3 2 5, GA iecords will bo classified by NEDG as "lifotimo" or "non-permanent" in accordanco with 'ho dofinitions provided in Soction 2.2 of ANSI N45 2.9-1974. Tho supptomont*
to this alternato position identifies the classification 50 as,igned by NEUG for each OA record typo and is based on the guidanco furnishedin Apperviix A of ANSI NAS 2 9-1974.
2.
Procurement - In accordance with thn second son-tence of Section 12. ANSI N45 2 91974,the NEUG will identify in procuremont documents tho OA records which are to bo supplied to or maintained for the NEDG or the Owner by suppliors or subsupphors, including thoso GE organitations other than the NEUG O
- $na Supptomant 10 hn<,pattssy Guvfe 168 Aitommie Pond,onem p.wp 2 13 2 10
NEDO-11209 31-78 Table 2-1 NRC REGULATORY GUIDE POSITIONS (Continued)
NRC Regulatory ANSI Guide Standard NEBG Position 1.88 (continua d) 3.
Storage and Maintenance - Records classified as
" lifetime" will be furnished to tho Owner or stored and maintained in accordance with the provisions of Section 5 of ANSI N45.2.9-1974. In lieu of the requirements of Sections 5.2-5.6 for " nonpermanent" records, such records will be stored in metal file cabinets as permitted in NFPA-1975 for Class 3 records to prevent loss, dam-age, or deterioration and maintained in a manner de-signed to permit accurate retrieval. " Nonpermanent" records, listed in the supplement, which are generated by NEBG or provided to NEBG by NEBG suppliers in accordance with contract requirements, will be retained for periods of time as specified in the supp;ement to this alternate position. After elapsed retention times, "non-permanent" records may be disposed of at the option of the N EBG or the supplier. Concurrence with this disposi-tion of nonpermanent records by the Owner is through andorsement of the GE Topical Report NEDO-11209 by its reference in the Owner's Safety Analysis Report.
4.
Indexing "ihe NEBG will comply wit'i a substitute to paragraph 3.2.2 of ANSI N45.2.9-1974, which reads:
"Both lifetime and nonpermanent records shall t>e listed in an index or system of indexes. The index or system of indexes shall include, as a minimum, record retention times and the location of the records within the record system. Index systems used by organizations for the retention of records shall provide information which can be used to identify equipment or material /
5.
Special Processed Records-The NEBG will comply with a substitute to paragraph 5.4.3 of ANSI N45.2.9-1974, which reads: "Special Processed Records -
Provisions shall be made for special processed records (such as radiographs, photographs, negatives, and mi-crofilm) to prevent damage from excessive light, stack-ing, electromagnetic fields and temperature. These pro-visions will be delineated in NEBG internal instructions which will incorporate, or take into consideration availa-ble manufacturers' recommendations."
1.94 - Rev.1, April 1976.
N45.2.5-1974 Not applicable to standard BWR scope of supply.
" Quality Assurance Requirements for installation, inspection,
& Testing of Structural Concrete &
Structural Steel C.
the Construction Phase of Nuclear Power Plants!
2 11
NEDO-11209 3-31-78 Table 21 NRC REGULATORY GUIDE POSITIONS (Continued)
NRC Regulatory ANSI Guide Standard NEBG Position 1.116. Rev. 0-R, June 1976, N45.2.8 1975 Comply with the provisions of Regulatory Guide 1.116, Rev.
" Quality Assurance O-R, June 1976, including the regulatory 7 asition relative to Requirements for ANSI N45.2.8-1975, except as follows: Regulatory Position 3 Installation, inspection.
- comply with the implementation of Regulatory Guido 1.68
& Testing of Mechanical as described in GESSAR, Chapter 14. " Initial Test.'
Equipment & Systems" 1.123, Rev.1, July 1977 N45.2.13-1976 alement regulatory position.
" Quality Assuranco Requirements for Control & Procurement of items and Services for Nuclear Power Plants" Nono issued N45.2.12-1977 Comply with the requirements of ANSI /ASME N45.2.12 1977.
" Requirements for Auditing of Quality Assuranco Programs for Nuclear Power Plants" O
O 2 12
NEDO-11209 3-31-78 SUPPLEMENT TO THE ALTERNATE POSITION ON REGULATORY GUIDE 1.88 85L{j j
_E c SAFETY-RELATED AND/OR ASME CODE RECORD WPES, STORAGFJMAINTENANCE RESPONSIBILITY j
jj a:.8 AND RETENTION CLASSIFICATION g,g
=
E'$
0$
ma A.1 Design Records
$U Applicable Codes & Standards used in Design G
L As-Constructed Drawings N/A Certified Design Specifications - Code Equipment O"
L Certified Stress Reports - Code Equipment O"
L Design Calculations & Record of Checks (Design Verification)
G L
Design Change Requests (Engineering Change Notices)
G L
Design Deviations (Nonconformance Reports)
G L
Design Procedures and Manuals (EOP Manual)
G A
Design Reports (Nonproprietary)
O" L
Design Reports (Proprietary)
G L
Design Review Reports G
L Drawing Control Procedures (GE Drafting Manual) (EOP Manual)
G A
GE-Approved Supplier Drawings and Procedures G
L NDE Specifications G
L Operation and Maintenance Manuals O"
L Preoperation and Startup Test Specifications O"
L Purchase & Design Specifications & Amendments (including purchased part drawings for design and build orders)
O" L
Purchased Part Drawings for items used in NEBG Manufacture G
L QA System Audit Reports G
B Ouality Requirements Summary (NEBG Make Reactor Equipment)
O" L
Reports of Engineering Surveillance of Field Activity N/A Safety Analysis Report (GE Input)
O" L
Stress Reports G
L Systems Descriptions (Nonproprietary System Design Specifications)
O" L
Systems Descripticns (Proprietary System Design Specifications)
G L
Systems Process and instrumentation Diagrams (P&lD)
O" L
Technical Analysis, Evaluations, and Reports (Nonproprietary Topical Reports)
O" L
Technical Analysis, Evaluations, and Reports (Proprietary Topical Reports)
G L
A.2 Procurement Records (Procured Engineered Equipment)
Audit Reports G
B Procurement Procedures (OAEE&l OA Manual)
G A
Procurement Specification O"
7 Purchase Order (unpriced) including Amendments O"
7 Purchaser's (NEBG) Pre-Award QA Survey G
B Product Quality Certification O"
7 QA Records Binder (Specified Supplier Manufacturing Records)
O" 7
Receiving Records N/A 2-13
in DO 11209
) :11> 781 f.4 i sG
{f 4
GUPPLEMENT TO THE ALTERNATE POSITION
$f r,
d ON llEOULATOHY 0010E 1.110 (Conlinued) f,, y a
$f b
Vs 2
Gopphor% OA18tograin Mntumi O
O Wnteling I'rtn.euforno O
l.
A 'l Manufacturit.y fiercot<!n (f4LilO Mako)
Apphcnblo Cen!rt Dotn Itnport=
0" L
As tioill Dinwing= nrul lintonh (l' nth nrul Anontntily Drnwings)
O l
As buill Drawingo nori flnt.onk (Outhrin Ornwirige) 0" L
ASMI, Ge><!n ~ Porrnannnt hnemeth Itnins 0"
L Cortifit:nto of Irnpur tiort 4 lento Pnf ootinnt A Oonhfit.ntiori O
A Cnetifi(ntnu of Cannpliant n (Ptrs<fott Ounhty Cortifa.ntion) 0" L
Cinatung I'to<,nelotne G
10 1 (I'ly Cottnnt l'antninatiori Prot.n<!orn4 0
10 l'<!ily Conant I:snininatnin I uml itereott=
0 L
l.len.ttic.nl Control Vnnfu.ntl<nt inst flenults O
L I nrntn Inst Prta enjorem O
10 I utnto Tugt lineoita O
L l'rittning a linnating I' roc nelotn Quahter:ntions O
y liont Trnattnnot l'na enforug O
10 linat ironttrmat Itottnah O
l.
Hot lintuling Penreulotn O
10 in l'tu nn (I arml) linpn< tion A Itat finsultu O
to insp A Tent Irntr, A Toohng Cnkh I'ror n<forns A lin<. orth O
C t lituki l'anintrarit llsarrunntunt Pr<n nelorn O
10 L ngout l'onottorit 1:sarrutintnin I inal linnolta O
l I(n ation of Wohl I illor Matonal O
L Magontic Portir.to I.sarninntiori Pnir orlorn 0
10 Magontic l'arfu lo I sannnntion I anal flocotto O
l.
Major Octor.t ltopair Itotorch (natopt CAID Canin lintnn)
O L
Maior Dnfott Itupair Hen oath (CalD Co<to Itntno) 0" L
M.itorinto Ptolmstun Itutorals (nstopt CAID Canto itenna)
O L
Matnriato l'tripnttino line. orth (Calu Cr><fo Itnrnm)
O" L
f Jon<:onfortnant,n fininnh O
L l% kuging. line naving, norj Storngo Procneforno (natopt thomo contain nl les OA Manonis) 0 10 Untfortnan< n inst Pror.nclurn A linnolto lintonb O
L Pipes anel I itting 1.otation floptat O
L l'renworo Tont Ptor,nttorn 0
10 Pinenorn Inst Itnsults O
L Prosjus,t l'ajoiptonot Cabbrntion Pros nelurn O
C Pernfor:t I viosptnot t Cnhbrution lin<.ot<h O
C Perntor Quakty Clun.khst (WMO only) 0" i
Putthaso Onints f >r Matonal utml eni f JI 00 Makn llorno O
to Porthannr% (fJf'llO) Prn nwarrj OA Gorvny O
li 2 14
NLDO-11209 3-31-78 0
5E 8-E
,e i."o SUPPLEMENT TO THE ALTERNATE POSITION keg lis o a> li ON REGULATORY GUIDE 1.88 (Continued)
$j cr ma S
ua y v>
z OA System Audit Report G
B QA Manuals, Procedures & Instructions G
A Radiographic Procedures G
10 Radiographic Review Forms (except C&lD Code items)
G L
Radiographic Review Forms (C&lD Code items)
O" L
Radiographs (except C&:D Code items)
G E
Radiographs (C&lD Code items)
O" E
Receiving Inspection Records G
7t Safety-related items Log (C&lD only)
G L
Ultrasonic Examination Procedures G
10 Ultrasonic Examination Final Results G
L Suppher Certificates of Conformance accompanied by Special Specified Data G
L Suppher's OA Program Manual G
D Welding Matenals Control Procedures (except those contained in OA manuals)
G 10 Welding Personnel Quahfication G
7t Welding Procedure Quahfications and Data Reports G
7t Welding Procedures G
L Work Processing and Sequencing Documents G
10 seeiegend
" Where NEBG supplies OA records to the Owner NEBG mil normany retain copies as needed for NEBG business purposes. The NEBG records storage, however, should not be considered as Owner's second storage facility wDout NEBG agreement.
t For orders placed amer June 1,1978. this retenton pered is extended to to years from shapment of the product.
Legend Not applicable to NEBG (Owner or AE scope of Responsibility)
N/A
=
Retained by or for GE-NEBG G
=
Transmitted to Owner O
=
L Lifetime retention (life of the item)
=
7 years retention (from date of generation) 7
=
10 10 years retention (from date of generation)
=
A Retained for 3 years after being superseded or invalidated
=
B Retahed until corrective action is completed or 3 years (whichever is later)
=
C Retained until recahbrated
=
D Retained until purchase order is closed out
=
E Retained for lifetime per NRC request or until NRC permits their disposal
=
2-15
NEDO-11209 3-31 78 Table 2-2 CROSS-INDEX TABLE SHOWING RELATIONSHIP Os: KEY QUALITY-RELATED DOCUMENT SYSTEMS AND MANUALS WITH EACH OF THE CRITERIA OF 10CFR50, APPENDIX B Legend for Titles of Docarnent Systems and Manuals Abbreviations ASME - QAPM ASME - QA Program Manus! (NEBG)
BWR - EOPM BWR Engineering Operating Procedures Manual BWRSD - OP&PM BWR Services Department - Operating Policy and Procedure Manual CalD - ASME C/M Control and Instrumentation Department - ASME Code Quality Assurance Manual C&lD - MPM Control and instrumentation Department - Manufacturing Procedures Manual C&lD - NOAM Control and Instrumentation Department - Nuclear Quality Asc. irance Manual NEBG - OPG Nuclear Energy Business Group - Organization and Policy Guide Proj. Div. - P&PM Nuclear Energy Projects Division - Policy and Procedure Manual QAEE&l - OAM Quality Assurance - Engineered Equipment and installation - OA Manual SFSO - P/P Spent Fuel Services Operation - Practices & Procedures SFSO - OAP Spent Fuel Services Operation - Quality Assurance Plan WMD - ASME C/M Wilmington Manufacturing Department - ASME Code Con pliance Manual WMD - P&P Wilmington Manufacturing Department - Practices and Procedures Document System or Manual and Applicable Section 1.
Organization Section 2, Responsibility for QAP Organization ASME - CAPM e
Section 20, Organization and Function BWR - EOPM Section 2.0, Organization BWRSD - OP& PM Section 4.0, Quality Assuranca and Safety Section 1.0, General CalD - ASME C/M Section MPS, Quality Assurance C&lD - MPM Section 1.0, Organization C&lD - NOAM O
2-16
NEDO-11209 3-31-78 Table 2-2 CROSS-INDEX TABLE SHOWING RELATIONSHIP OF KEY QUALITY-RELATED DOCUMENT SYSTEMS AND MANUALS WITH EACH OF THE CRITERIA OF 10CFR50, APPENDIX B (Continued)
Document System or Manual and Applicable Section (Continued) 1.
Organization NEBG - OPG Section 70, Nuclear Safety & Quakty Assurance Section 150, Organization Section 160, Functional Directives Proj. Div. - P&PM Section 14, Functional Responsibilities Section 80, Product Quality OAEE&l - OAM Organization Chart OC Standing instructions OC Plans & Index SFSO - OAP Section 1.0, Organization SFSO - P/P Section 10 Practices and Procedures Systems Section 20. Organization, Function, Responsibilities WMD - ASME C/M Section 1.0, Organization WMD - P&P Section 30, Management II.
Quality Assurance Program ASME - OAPM Section 1, Introduction a
BWR - EOPM All Sections BWRSD - OP& PM All Sections C&lD - ASME C/M All Sections C&lD - NOAM e
Section 2, Quahty Assurance Program NEBG - OPG e
Section 70, Nuclear Safety & Quahty Assurance Section 150, Organization Section 160. Functional Directives Proj. Div. - P&PM Section 12, Organization Section 14 Functional Responsibihties Section 80. Product Quahty Section 110 General OAEE&l - OAM All Sections SFSO - CAP All Sections SFSO - P/P Section 70, Quality Assurance WMD - ASME C/M Section 2 0 Quahty Assurance Program 2-17
NEDO-11209 3-31-78 Table 2-2 CROSS-INDEX TABLE SHOWING RELATIONSH.P OF KEY OUALITY-RELATED DOCUMENT SYSTEMS AND MANUALS WITH EACH OF THE CRITERIA OF 10CFR50, APPENDIX B (Continued)
Document System or Manual::nd Applicable Section (Continued)
Section 30, Management WMD - P&P e
- lli, Design Control BWR - EOPM e
Sections 20 through 75 BWRSD - OP&PM Section 3.0, Administrative Section 4.0, Quality Assurance and Safety Section 3, Design Control CalD - NOAM e
Section 16, Interdivisional Interfaces Proj. Div. - P&PM Section 20, Marketing and Proposals Section 30, Project Definition OC Standing Instructions OAEE&l - OAM Section 3.0, Design Control SFSO - OAP e
Section 3.0, Design Control WMD - ASME C/M WMD - P&P e
Section 60, Procurement Control Section 70, Quality Control Section 80, Product Control IV.
Procurement Document Control BWR - EOPM Section 45, Procurement Section 65, Safety and Licensing Section 4.0, Quality Assurance and Safety BWRSD - OP&PM C&lD - ASME C/M Section 3.0, Procurement Control Section 4, Procurement Document Control CalD - NOAM Section 30, Project Definition Proj. Div. - P& PM Section 80, Product Quality OA Requirements O AEE&l - OAM OC Standing Requirements Section 50 Material and Facilities Management SFSO - P/P Section 4.0, Procurement Document Control SFSO - CAP e
Section 4.0, Procurement Document Control WMD - ASME C/M Section 60, Procurement Control WMD - P&P Section 70, Quality Control Section 80, Product Control 2 18
NEDO-11209 3-31-78 Table 2-2 CROSS-INDEX TABLE SHOWING RELATIONSHIP OF KEY OUALITY-RELATED DOCUMENT SYSTEMS AND MANUALS WITH EACH OF THE CRITERIA OF 10CFR50, APPENDIX B (Continued)
Documwnt System or Manual and Applicab'e Section (Continued)
V.
Instructions, Procedures, and Drawings Section 15. Engineering Operating Systems e
BWR - EOPM Section 30 Poduct Definition and Control Section 40. Engineering Technology and Design Section 60, Document Control BWRSD - OP&PM Section 4.0, Quality Assurance and Safety C&lD - ASME C/M Section 2.0, Drawing & Specification Control C&lD - NOAM e
Section 5.0, Instructions, F iocedures, and Drawings NEBG Drafting All Sections Manual Proj. Div. - P&PM Section 110 General QAEE&l - QAM OA Requirements OC Standing Instructions SFSO - OAP Section 5.0. Instructions, Procedures, and Drawings WMD - ASME C/M Section 5.0, Instructions, Procedures, and Drawings WMD - P&P Section 10. Structure Section 30 Management Section 70, Quality Control Section 80 Product Control VI.
Document Control BWR - EOPM Section 40. Engineenng Technology and Design Section 60 Document Control e
BWRSD - OP&PM Section 1.0. Statement of Policy Section 4.0, Quality Assurance and Safety CalD - ASME C/M Section 2.0, Drawing & Specification Control C&lD - NOAM Section 6 Document Control Proj. Div. - P&PM Section 30 Project Definition e
Section 40 Project Funding & Work Control Section 110. General QAEE&I - OAM QA Requirements OC Standing Instructions 2 19
NEDO-11209 3-31-78 Table 2-2 CROSS-INDEX TABLE SHOWING RELATIONSHIP OF KEY QUALITY-RELATED DOCUMENT SYSTEMS AND MANUALS WITH EACH OF THE CRITERIA OF 10CFR50, APPENDIX B (Continued)
Document System or Manual and Applicable Section (Continued)
Section 6.0, Document Control SFSO - OAP WMD - ASME C/M Section 6.0, Document Control Section 10, Structure WMD - P&P Section 30 Managemerit Section 70, Quality Control Section 80, Product Control Vll.
Control of Purchased Material, Equipment, and Services Section 45, Procurement BWR - EOPM Section 4.0, Quality Assurance and Safety BWRSD - OP&PM Section 3.0, Procurement Control CalD - ASME C/M Section 7.0, Control of Purchased Material Equipment, C&lD - NOAM and Services OA Requirements CAEE&l - OAM OC Standing Instructions Section 70, Quality Assurance SFSO - P/P Section 7.0, Control of Purchased Matenal, Equipment, SFSO - CAP and Services Sect:on 7.0, Control of Purchased Material, items and Services WMD - ASME C/M Section 60 Procurement Control WMD - P&P Section 70, Quality Control
- Vill, Identification & Ccntrol of Materials, Parts, and Components Section 30, Product Definition and Control BWR - EOPM Section 40 Engineenng Technology and Desgn C&lD - ASME C/M Section 4, Process Control Section 8, Identification & Control of Material, Parts C&lD - NOAM and Components OA Requirements CAEE&l - OAM OC Standing Instructions Section 80, Identification and Control of Materials, SFSO - CAP e
Parts, and Components Section 8.0, Identification and Control of Materials WMD - ASME C/M and items Section 30 Management WMD - P& P Section 70, Quality Control 2-20
NEDO-11209 3-31-78 Table 2-2 CROSS-INDEX TABLE SHOWING RELATIONSHIP OF KEY OUALITY-RELATED DOCUMENT SYSTEMS AND MANUALS WITH EACH OF THE CRITER.A OF 10CFR50, APPENDIX B (Continued)
Docum.at System or Manual and Applicable Section (Continued)
IX.
Control of Special Processes BWR - EOPM e
Section 40 Engineering Technology and Design Section 75, Product Ouality Section 5.0, Welding / Brazing Quality Assurance C&lD - ASME C/M e
Section 6.0, Nondestructive Examination Section 8.0, Heat Treatment C&tD - NOAM Section 9.0, Control of Special Processes OAEE&l - OAM OA Requirements OC Standing Instructions SFSO - OAP Section 9.0, Control of Special Processes WMD - ASME C/M e
Section 9.0, Control of Construction Processes WMD - P&P Section 30 Management Section 50, Preproduction Section 60, Procurement Control Section 70, Quality Control Section 80, Product Control Section 90, Traffic X.
Inspection BWR - EPOM Section 35. Product Development Section 75, Product Quality C&lD - ASME C/M Section 4.0, Process Control CalD - NOAM Section 10, inspection OAEE&l - OAM OA Requirements OC Standing instructions SFSO - OAP e
Section 10.0, inspection WMD - ASME C/M Section 10. Examinations, Tests, and inspections WMD - P&P Section 30, Management Section 60, Procurement Control Section 70, Quality Control Section 80 Product Control XI.
Test Control BWR - EOPM Section 35. Product Development Section 65, Safety and Licensing 2-21
NEDO-11209 3-31-78 Table 2-2 CROSS-INDEX TABLE SHOWING RELATIONSHIP OF KEY QUALITY-RELATED DOCUMENT SYSTEMS AND MANUALS WITH EACH OF THE CRITERIA OF 10CFR50, APPENDIX B (Continued)
Document System or Manual and Applicable Section (Continued)
Section 4, Quality Assurance and Safety BWRSD - OP& PM Section 5. Startup and Test CalD - ASME C/M e
Section 4, Process Control Section 11, Test Control C&lD - NOAM OC Standing Instructions OAEE&l - QAM Section 11.0, Test Control SFSO - OAP Section 11.0, Test Control WMD - ASME C/M Section 70, Quality Control WMD - P&P Xil.
Control of Measuring and Test Equipment Section 35. Product Development BWR - EOPM Section 7, Calibration of Measuring & Test Equipment C&lD - ASME C/M Section 12, Control of Measuring & Test Equipment C&lD - NOAM QA Requirements OAEE&l - OAM OC Standing Instructions Section 12.0, Control of Measunng & Test Equipment SFSO - OAP Section 12.0, Control of Measuring & Test Equipment WMD - ASME C/M Section 30, Management WMD - P&P Section 70, Quality Control Xill.
Handling, Storage, and Shipping Section 40, Engineering and Design BWR - EOPM Section 4, Process Control C&lD - ASME C/M Section MPS, Quality Assurance C&lD - MPM Section 13. Handling, Storage, and Shipping C&lD - NOAM e
OA Requirements QAEE&l - QAM e
OC Standing Inductions Section 13.0, Handling, Storage, and Shipping SFSO - OAP Section 13.0, Handling, Storage, Shipping, and Preservation WMD - ASME C/M Section 60, Procurement Control WMD - P&P Section 80, Product Control Section 90, Traffic 2-22
NEDO-11209 3-31-78 Table 2-2 CROSS-INDEX TABLE SHOWING RELATIONSHIP OF KEY OUALITY-RELATED DOCUMENT SYSTEMS AND MANUALS WITH EACH OF THE CRITERIA OF 10CFR50, APPENDIX B (Continued)
Document System or Manual and Applicable Section (Continued)
XIV.
Inspection, Test, and Operating Status C&lD - ASME C/M Section 4, Process Control C&lD - NOAM Section 14, inspection. Test & Operating Status OA Requirements OAEE8! - OAM SFSO - OAP e
Section 14.0, inspection. Test, and Operating Status Section WMD - ASME C/M Section 14.0, Examination or Test Status WMD - P&P Section 30. Management Section 70, Quahty Control Section 80, Product Control XV.
Nonconform;ng Material, Parts, or Components Section 40. Engineering Technology and Design BWR - EOPM Section 45 Provarement Section 50, Manufacturing Section 55, Change Control Section 4.0, Quality Assurance and Safety BWRSD - OP&PM e
C&lD - ASME C/M e
Section 11, Nonconformities and Corrective Action Section 15, Nonconforming Materials, Parts, or C&lD - NOAM Components Section 70, Product Safety Proj. Div. - P& PM Section 80, Product Quakty OA Requirements OAEE&l-OAM OC Standing instructions Section 15.0, Nonconforming Materials. Parts, and Components SFSO - OA o WMD - ASME C/M Section 15.0, Nonconforming Material or items WMD - P&P e
Section 30, Management Section 60, Procurement Control Section 70, Quahty Control Section E0, Product Quahty XVI.
Corrective Actiori BWR - EOPM Section 45 Procurement Section 50, Manufacturing Section 55, Change Control e
Section 75, Product Quakty 2-23
NEDO 11209 3-31-78 Table 2 2 CROSS-INDEX TABLE SHOWING RELATIONSHIP OF KEY OUALITY RELATED DOCUMENT SYSTEMS AND MANUALS WITH EACH OF THE CRITERIA OF 10CFR50, APPENDIX B (Continued)
Document System or Manual and Applicable Section (Continued)
BWRSD - OP& PM e
Section 3.0, Administrative Procedures Section 4.0, Quahty Assurance and Safety Section 5.0, Startup and Test CalD - ASME C/M e
Section 11.0, Nonconformities & Corrective Action Section MPS, Quahty Assurance CalD - MPM CalD - NOAM e
Section 16, Corrective Action Section 80, Product Quahty Proj. Div. - P&PM e
OA Requirements OAEE&l - OAM OC Standing instructions SFSO - OAP Secm.' 16.0, Corrective Action WMD - ASME C/M e
Sectica 16.0, Corrective Action Section 30, Management WMC - P&P e
Section 60, Procurement Control Section 70, Quahty Control Section 80, Product Control XVil.
Ouality Assurance Records BWR - EOPM e
Secton 40 Engineering Technology and Design Sec* on 60. Document Control Secmn 75, Product Quahty BWRSD - OP& PM e
Secti.r13.0, Administrative Sectio - 4.0, Ouahty Assurance and Safety C&lD - ASME C/M e
Section 9.0, Documentation and Certification C&lD - NOAM Section 17 Oiaakty Assurance Records Proj. Div. - P&PM Section 14 Functional Responsibihties e
Sect;on 80, Product Quahty OA Requirements OAEE&l - OAM e
OC Standing instructions Section 70, Quahty Assurance SFSO - P/P e
Sectdn 30, Ma.lagement SFSO - OAP e
Section 70, Quahty Control Section 17.0, Quahty Assurance Records WMD - ASME C/M Section 30 Management WMD - P&P Section 70, Quakty Control 2-24
N EDO-11209 3-31-78 Table 2-2 CROSS-INDEX TABLE SHOWING RELATIONSHIP OF KEY QUALITY-RELATED DOCUMENT SYSTEMS AND MANUALS WITH EACH OF THE CRITERIA OF 10CFR50, APPENDIX B (Continued)
Document System or Manual and Applicable Section (Continued)
XVill.
Audits Section 20. Organization and Function BWR - EOPM e
Section 75, Product Quality BWRSD - OP&PM e
Section 4.0, Ouality Assurance ar.d Safety CalD - ASME C/M Section 12, Audits CalD - NOAM e
Section 18, Audits Proj Div. -- P&PM Section 80, Product Quality e
OAEE&l - OAM OC Standing Instructions SFSO - OAP e
Section 18.0, Audits WMD - ASME C/M Section 18.0, Audits Section 30, Management WMD - P& P e
Sectio i 60, Procurement Control 2-25/2 2G
NEDO-11209 3-31-78 3
DESIGN CONTROL 3.1 GENERAL The design of structures, systems, and components is controlled within the various design organizations to assure safe and rehable performance of products and services to be supplied. The design control processes are documented by practices and procedures which estabhsh the responsibilities and interfaces of each organizational unit that has an assigned design responsibihty. The practices and procedures include measures to assure the following:
design requirerrants are defined and design activities are carried out in a planned, controlled, and orderly e
manner;
'ppropriate quahty requirements and standards are specified in design documents; e
suitable matenals, components, and processes are specified on design documentation; e
appropriate design verification methods are selected and implemented by individuals or groups not having e
direct responsibikty for the original design; and design changes are controlled to the same level as was apphed to the original design, including review and e
approval by the same organization that performed the orioinal review and approval unless another responsible organization is designated by NEBG management.
Each GE BWR offered for sale is of a ct.nent product line which has been engineered as a " Standard Plant" design.
Tl:e " Standard Plant"in its several ratings, and chanlos thereto,is reviewed for coniormance to GE product safety standards ano to the apphcable NRC regulations independant of sales commitments, and is updated as necessary to assure its compliance with changes to these requirements. Modifications to the " Standard Plant" for a padicular sale are made only pursuant to the contract with he Owner, provided safety and warranty conditions are not adversely affected. Since each nuclear system sale (called " project" after sale is made) is based on a " Standard Plant," it is not necessary to repeat the review of the " Standard Plant" for each project, bt t anly to review the mod,fications, if any, for each project.
The NEBG engineenng organizations define and document acceptable and approved materials, parts, equipment and processes. The definition is documented in controlled design manuals and standards specifications. Standard "off the shelf" commFcialitems are included. The standards specificatioris are retiewed, approved, and issued in accordance with l the engineering review system. In addition, all equipment designers have available to them direct consultation services of matarials cugineers dunng the design action and design review phases. Application 3etoction of matenals is based upon this review sys;em, and review for suitabihty occurs during th9 engineering review for design venfication action. Where engineenng experiace identifies a need for testing confirmation, suitab:e controlled quahfication tests are performed.
Each discrete design for the GE BWR Nuclear System is subject to the NEBG design control system. The NEBG design control measures are apphed to: analyses for performance parameters; reactor physics; stress; thermal; hydraulic; l radiation; accidents; compatibihtv of materials; accessibihty f ar in-service inspection, maintenance, and repair; and specifica-tion of criteria for inspection and test.
The contractual design basis and data unique to a specific project is defined to the engineering organizations by the project or program manager.1 he information is documented in the appropnato pryy.t/ program release document, e g., the Engineenng Work Authorization (EWA), which authorizes and initiates the engineering and licensing work for the project.
3.2 DESIGN INTERFACE CONTROL To provide assuance of structure, system, and component interface compatibihty, NEBG design documents are distnbuted for information, review, and coordination by affected design organizations. The responsible engineer is required to have his design documents reviewed for interface compatibihty by individuals having responsibihty for the interfacing 3-1
NE DO-11209 3-31 78 documentation in order to assure that there is no confhct in the design objectives and that the product resulting from the interfacing designs will function as planned. Design documents are also furnished to the Owner and/or his agents to provide for interface compatibility review and coordination by Owner / agent design organizations.
3.3 SYSTEM DESIGN Design specifications and data sheets containing design basis and other data for a specific contract are developed by the design engineer based on the appScable project / program release document and issued to the responsible design organizations in the early months following the receipt of an order. Design controlhng documents, responsive to these data sheets, are then prepared by the responsible engineers. The design controlling docume its provide the basis for detailed systems, structure, and component design and typically include the system and structure design specificat:ons, piping and instrumentaPon diagrams, process diagrams, functional control diagrams, and instrument engineenng diagrams.
The design specifications, data sheets, and design controlling documents incorporate the design and safety require-ments for each plant. The designs are subject to a design verification review within engineering and to a review for project appbcation by the project engineer pnor to being issued as a basis for component design. The project engineer and project manager assigned to the particular project are responsible for overall project coordination, but are not directly responsible for the preparation of the engineenng design or the documentation issued for the project. The vanous engineering organizations of the NEBG are responsible for the design and design control activities for the GE BWR. Engineenng personnel are authorized to define and prepare performance parameters and to document the design of systems and equipment. They obtain necess try internal engineenng interface consultation and services as required. They provide final design approvalin accordance with documented engineenng practices and procedures. Responsibility for internal design document controlis vested in the engineenng services organizations of the NEBG. Responsibihty for interface control with the Owner is ass'gned to the cognizant project or program manager, In add, tion to the design specifications, data sheets, and design control documents, engineenng organizations issue general standard design specifications which establish standard requirements for designing components which satisfy the system and structures requirements. These standard design specifications identify apphcable codes, standards, regulations, and other requirements to be utilized to assure comphance with safety cntena, quahty levels, and other specific requirements which havs. been imposed to obtain acceptable quakty, safety, and rehabihty. These design specifications are subject to design venfication review poor to issue. The onginal issue and any subsequent changes to the document for the project are subjected to review for project apphcation by the project engineer.
3.4 STANDARD REACTOR ISLAND DESIGN The design documentation for Owner-purchased components within the Reactor Island scope consists of one or more of the following documents: equipment procurement specifications which specify general requirements including codes, l matenals, processes, workmanship, and acceptance cnteria; purchased part drawings which show the authne and interf ace requirements; and specific data sheets or project sheets which define the project unique requirements of the equipment. The responsible oesign engineer prepares the specifications, drawings, or data sheets and is responsible for assunng that they conform to the requirements of the project EWA, the data sheets, structured system design control documents, the general l design specificat;ons, and apphcable codes, standards and regulations, and that these documents are all compatible. Initial issues of purchase specifications are reviewed by O AEE&l pnor to issuance to the subcontractor. The purchase specification identifies the engineenng documents, such as drawings, procedures, calculations and test data which must be submitted by subcontractor-designer for review and documented approval by apphcable STRIDE Froject Management and transmitted to the Owner as required by contract. The actual design work is accomphshed by a quahfied subcontractor who has an l acceptable OA program in conformance with apphcable cnteria of 10CFR50, Appendix B, and other NEBG specified requirements.
Design documentation is subject to design venfication review by the subcontractor-designer, after which it is submitted to the STRIDE Project organization for review and acceptance. Practices are in place for review, resolution, and reissue of design documents mquinng change following NEBG review and comment. Any subsequent changes to the approved suppher documents are also fnrmally reviewed and require documented approvalin the same manner as the onginal design documentation.
3-2
NEDO-11209 3-31-78 The detail design makes use of standard products and purchased components which have been procured in accordance with approved functional specifications, and qualified for performance and design adequacy in accordance with documented procedures by a separate testing group. Design requirements, qualification test reports, calculations, and other design data are reviewed for design adequacy in accordance with documented procedures. Product requirements are transmitted from l CalD Engineering to the CatD Matenals organization through issuance of controlled El's or RIS's which specify applicable drawings, specifications, and project unique requirements. Changes to the control and instrumentation documents after release to manufacture are controlled as descnbed in Subsection 3.11 " Design Change Controlf 3.8 DESIGN OF FUEL Nuclear system performance requirements and design bases for nmicar fuel are specified by the BWRSED. Detailed fuel drawings and specifications are prepared and are subjected to a design venfication review by Reactor Design Engineering. These documents are reviewed with WMD Manufacturing and OA personnel to assure compatibility with manufacturing and quality control technology and capability pnor to release for manufacture. Changes to drawings or specifications are made through the use of ECN's that are reviewed for consistency within cognizant BWRSED and WMD organizations, and are approved by the engineenng organization that approved the onginal design. Design changes affecting system design or the design of non-fuel components are reviewed for system interface compatibility with other affected organizations in the NEBG.
Product requirements are transmitted from BWRSED to WMD through issuance of controlled El's which specify applicable drawings and specifications. The Fuel Projects Department also specifies other project unique requirements to WMD through the issuance of controlled Fuel Project Instructions (FPI's).
Design review, design release, and design change control systems are forma ;y documented and implemented for all designs of fuel components and assemblics.
3.9 DESIGN OF HIGH DENSITY FUEL STORAGE EQUIPMENT The system design controlling documentation for high density fuel storage equipment consists of design specifica-tions and drawings supplemented by procass specifications necessary to fabncate, inspect, test, and install the equipment.
The responsible engineer assures that the design conforms to the design basis, as well as to all corporate and 7gulatory requirements. The design documents are subjected to a design venfication review by cogr.zant personnel, as well as a review by SFSO-OA.
The GFSO has established a system of Spent Fuel Services Instructions which detail the design and venfication processes and descobe interfaces and responsibilities for accomplishment of the design work.
3,10 DESIGN VERIFICATION Venfication or checking of design adequacy is perfor med using one or more of the following: design review, the use of alternate or simplified calculational methods, or the performance of a suitable qualification test. A design review by one or more qualified individuals is normally performed, supplemented by altemate or simplified calculations and qualifcation testing, if necessary. When qualification testing is used as the sole means of ventying design adequacy, a prototype or initial production unit is tested under the most adverse design conditions for the unit being tested.
In addition to the design venfication made prior to issue of design documents, a system design review is made of the engineenng work after the design documents have been issued and the Owner has had an opportunity to review them for
, adherence to the contract requirements and to provide interf ace design date from the balance of plant design. The system design review is made by a design review team coordinated by the review team chairman, and covers the data sheets, the design controlling documents, and the general standard design specifications descnbed above. The team includes the project licensing engineer who participates in the review of the documents against requirements of the PSAR and any applicable amendments, and the responsible engineers who participate in the review to provida necessary design informa -
tion and to initime and to follow through on any required changes.
3-4
NEDO-11209 3-31 78 3.5 DESIGN OF PROCURED ENGINEERED EQUIPMENT The design documentation of NEBG-purchased components (other than instrumentation and controls and matenals used in the f abncation of NEBG-manuf actured components) consists of one or more of the following documents; equipment procurement specifications which specify general requirements, including materials, processes, workmanship, and accep-tance cntena, purchased part drawings which show the outhne and interface requirements; and specific data sheets or project sheets which define the project unique requirements of the equipment. The responsible engineer prepares the specifications, drawings, and data sheets and is responsible for assunag that they cc nform to the require *nents of the p.oject EWA, the nuclear system data sheets, system design control documents, interface control drawings, the gene al design specif> cations and apphcable codes, standards and regulations. The designs are subjected to design venfication review and, in add: tion. are reviewed by the project manager to assure that the design documents meet any unique project requirements, Initial issues of purchase specifications for engineered equipment are reviewed by Procurement and OAEE&l pnor to suppher bidding Changes to the documents after the purchase order is placed, are controlled as descnbed in Subsection 311. " Design Change Controlf The pu rchase specification identifies the documents, such as d:awings, procedures. calculations, and test data which must be submitted by the suppher for review and approval by Engineenng and/or QAEE&l.
Product design and quahty requirements are transmitted from Engineenng to Procurement through controlled asuance of Matenal Requests (MR s) which identify the product and specify apphcable drawings, spec!fications, and QA req.orements. Initialissuance and rev:sions to the MR s are controlled by written procedures.
3.6 DESIGN OF REACTOR EQUIPMENT COMPONENTS Design documentation for reactor equrpment manufactured by WMD consists of specific detailed product drawings augmented by design and process specificat:ons necessary to fabncate inspect, and test the finished product The responsible engineer assures that the design documents conform to the project EWA. the nuclear system data sheets, the system design control documents, the general design specifications, and the applicable codes. standards, and regulations beiore release to Manufactunng. The design documents are subjected to a design venfication review and a review by cognizant matenals eng:neers Reviews are also conducted by BWR Systems Engineenng Department (BWRSED) with WMD Manufactunng Engineenng and Quahty Assurance to assure compatibihty witt manufactunng and quahty control techno!ogy and capahihty. Changes initiated after this point are controlled as desCnbed in Subsection 3.11. " Design Change Control '
Product requirements are transmttted to WMD through issuance of controlled Engineenng Instructions (EI) from BWRSED, or in the case of spare and renewal parts orders, by Requisition Instruction Sheets (RIS)f rom BWRSD. The El cr RIS specifies the appbcable drawings and specifications 3.7 DESIGN OF CONTROLS AND INSTRUMENTATION The system design controlhng documentation for controls and instrumentatron consists of design specifications.
instrument eng:neenng diagrams, f unctional control drawings, and general controls and instrumentation specifications which incorporate the general functra.ial, environinental. matenal. and test requirements The responsible engrnaer obtains interface review of the documents he has initiated and assures that they meet the requirements of the project EWA, apphcable nuclear system data sheets, system design control documents. interface control drawings, and general design specificat.ons. as well as the apphcable codes, standards, and regulations. Reviewers include the project engineer and other eng neers responsible for systems or equipment with which there exists a design interf ace. In add, tion. a design venfication review is performed to assure correctness and completeness of design, including specification of the appropriate quahty requirements.
The detail desiga of controls and instrumentat:on by CalD Engineenng and subcontractor designers encompasses the generation of system elementary diagrams and connection diagrams, panel and rack arrangement drawings, purchased part drawings, instrument data sheets. manuf actunng drawings, and instruction manuals. The instrument data sheets define the charactenstics of the measurable parameters, the instrument environment ranges, accuracies, set points, and locations of instruments required by the system design. These detail design documents are subjected to design venhcation review.
33
NEDO 11209 3-31-78 Following implementation of any changes required as a result of the review, the design is considered frozen and further changes to the design documenta' ion wul only be made for the following reasons. (1) requestn by the Owner for changes from tne or:ginal plant as sold. (2) changes to meet r
~rements of apphcable codes, standar Js, cnd regulatory agencies. (3) feedback from recent p! ant startup testing or operating plant experience, or (4) Other information identifying changes required to make a system or equipment funct'on proj s and safely. Resu "s of design reviews are documented and filed in a controlled manner for future reference in accordance with appbcable codes, standards, and regulations. For identification of those positions or organizations responsible for the various types of design reviews held in NEEG. refer to Table 3-1.
3.11 DESIGN CHANGE CONTROL Followirg issuance of engineenng documente, a design change control procedure is implemented with controls commensurate wth those apphed to the original design. Measures for documenting and dispositinning errors and deficien-cies in 'he design J 76 'or determining and implementing corrective actions are descnbed n this sec n as well as in Subsection 3.12. Field O :nge Contror and in Subsection 3.13. " Design Review Contrel." The end result, after all changes have been incorporateo. is reflected in accurate drawings, specifications and other documents which f ully descnbe the fin.11 design for equipment supphed The controi procedure requires documentation of the change, desigr. venfication review Of the r* ange, approval by the responsible eng;neer, aM in specified cases, final review by the project ent incer. The resk,nsible engineer is charged with the responsibil,ty foi defining all other dergn documents affected by the ci ange. and for resolving and coordinat.ng changes with other eng coers whose documena are affected The Engineent g Change Notice (ECN) is used for documenting and record >ng approval for the change.
The ECN's are identified. issued. and controlled in accordance with documented procedures. Copies of the ECN are distr;buted to design interf ace perscnnel, including the responsible engrneer who approved the change, the project manager, and to eng:neenng. manuf actunng, procurennt, and O A personnel in other organizations, as a pprognate. Design changes l affecttng interf ace conditions between the Owr.er-supphed and N EBG-supphed equipment are ident fied and reviewed by the project manager with the Owner or his designated representative.
3.12 FIELD CHANGE CONTROL Af te dehvery of equipment and dunng the installation and startup phases at the plant site, field n os that become necessary fallinto two general classes: first, those generated by design changes, and second. those initiatec in the field as a result of unique field conditions. In order to accomplish a field change on NEBG-furnished components, the responsible engineer processes a design change in accordance with Subsection 3.11. " Design Change Control' and issues a Field D:sposition Instruction (FDl) w hich Ider.tifies the components affected, the changes to be made, the parts to b3 replaced the source of replacement parts. the disposition of parts replaced, the procedures to be fo!! owed in making the change, and the quahty requirements to be met The responsible engineer is also responsible for providing instructions for the manuf acture or procurement of the replacement parts, as cpohcable, and for assuring that instructions are issued for other projects requinng such changes. The design documentation supporting the FDI is sub ected to a design venfication review and is reviewed by the project engineer. The field change is then authorized by the project manager poor to distnbut;on of the FDI. For l components furnished by the Owner or his agent, which are based on NEBG component design documentation, FDl's are issued in a similar manner to effect changes.
l Changes initiated by field organizations generally are the ecsult r' deviations from the planned construction or preoperational conditions. In order to initiate action to accomphsh a field change on NEBG furnished comp nents. the field organization generates a Field Deviation Disposition Request (FDDR) which ideltifies the deviation and the proposed changes to correct or compensate for the deviation. The Engineenng and Project Management organizations review the FDDR for comphance with the estabhshed design cntena ar.d fm safety. performance, and f unctional design requirements. If the proposed method is found to be satisfactory, the FDDR is men reviewed and released for field implementation. If the proposed method for correction does not comply with tne es'ablished cntena and requirements, the responsible engineer l disapproves the FDDR. and an alternate solution is presented by modification of the FDDR or t y issuing an approved FDI If an FDDR results in a design change documents are changed by use of the ECN. When an FDDR :ndicates an inhment problem which affects mor-than one, roject, the responsible engineer issues appropnate ECN s to effect changet to the design documents for all plants affected. The FDl's, FDDR's, and ECN s are formatly identified. prepared. and controlled in accordance with documented procedures 35
NEDO 11209 3-31 78 The NEBG installation engineers a^d technical speciahsts provide technical direction of Owner implemented field changes dunng the installation, preoperational and startup testing phases. Also, venfication of fieh' change implementation l during the ir'stallation phase is accomplished by NEBG surveillance of NEBG-supplied systems and components.
3.13 DESIGN REVIEW CONTROL The system for assuring controlled changes in the design has been described in preceding sections of this OA l Program desenption. In addition, designs with significant design related conditions adverse to quakty and safety, when identified, are documented and reviewed by appropriate management through a review board for identification of necessary corrective action and application to affected projects. Following ri iagemerit decision to apply the corrective action to specific projects, the responsible eng..ieer makes the necessary 3 sign document changes and issues FDl's, where appropriate, to meet the changed requirements. As a result, corrective action is applied to all nuclear plants where action to correct the c'3use of the condition is deemed appropriate. The five basic types of design reviews being practiced by the NEBG engineer >ng organizations are bnefly desenbm in Table 3-1, " Design Reviews.'
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NEDO-11209 3-31-78 Table 3-1 DESIGN REVIEWS Responsible Review Type F.eview Scope Organization or Individual 1.
Engineer's Cesign Review Correct translation of design Designated cognizant interface prior to issue of design onto design. Design component, system design documentation and changes verification; internal design engineer, or responsible thereto.
interfaces; O A aspects of engineering manager.
purchase specs /manuf drawings, producibility (conceptual proto-type, trial prod ction).
2.
Project Application Review.
Incorporation of contract Project Engineer for each requirements.
project.
3.
Design Review and Freeze Design / contract / licensing Responsible Design, Licensing to finalizo BWR design.
compatibility.
and Project Engineers.
4.
Vendor Design Review for Vendor compliance with require-Each Design Engineer responsible compliance with procurement ments; design adequacy.
for the equipment design.
specifications.
5.
Design Review for changes Application of new safety, Board for management review h
to final design.
licensing, or operational and application of corrective (9
requirements to other action to affected projects.
projects.
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NEDO-11209 3-31-78 4
PROCUREMENT DOCUMENT CONTROL Merzures are established and documented for the preparation, review, approval, and control of procurement docurn,snts to provide assurance that regulatory requirements, design bases, and other requirements which are necessary to assure the requisite level of quality are included or referenced in the documents for procurement of items and services, including spare and replacement parts and subcontractor design services. Design quality requirements, such as those documented in drawings and specifications are prepared, reviewed, approved, and issued by the appropnate engineering organizations, prior to order placement. Additional quality campliance requirements, such as supplier QA Program and documentation requirements, and provisions for source surveillance and audit, are prepared, reviewed, approved, and issued by OA organizations for inclusion in the procurement document packages. Reviews of procurement documents by OA personnel are made to provide assurance that quality requimments are complete and correct:y stated and that they can be controlled by the supplier and verified by NEBG OA personnel. Purchase Specifications are reviewed and signed off by QA on an Engineering Review Memorandum prior to issuance.
The NEBG documents for EEPO procurement of engineered equipment are approved by the responsible engineer and released by Engineenng Services Operation (ESO). The OAEE&l develops OA requirements which are applied to each Material Request for engineered equipment or services and @ch be ome a part of the purchase contract. A copy of each purchase order for engineered equipment is sent to QAEE&l for plan. nc wrposes.
Quality-related changes in procurement documents are subject to the same levcl of control as was exercised in the preparation of the onginal procurement documents. The NEBG Procurement organizations close out purchase ceders only after ascertaining that all equipment and documentation has bec 1 received and that the pertinent records accure,fy reflect the procurement actions. The pertinent records are then stored and maintained in a systematic and controlled manner in designated record retention areas for the length of time specified by contract or legal requirements.
The following information and requirements are included in procurement documents, as deemed appropnate by NEBG OA engineers:
GE Supplier Quality Assurance Program - Identification of the requirements of the QA Program to be developed and implemented by the suppher, such as design control, document preparation and control, purchased material control, control of matenals, special process controls, inspection and test control, control of measunng and test equipment, handling, storage, and shipment control, inspection and test status control, nonconforming material control, corrective action, auditing, etc.
Basic Technical Requirements - Drawings, specifications, codes, industnal standards, and the apphcable requirements of those Regulatory Guides and ANSI Star.dards identified in Table 2-1, with applicable revision data, test and inspection requirements, including test equipment, special instructions, anc requirements such as for designing, f abacating, cleaning, packaging, handling, shipping, and normal or extended storage in the field.
Source Surveillance and Audit - Provisions for access to the plant facihties, records, and documentation necessary for source surveillance or audit by the NEBG, the Owner, or his agent personnel when the need for such access has been determined.
Document Requirements - Identification of suppher documents and records to be prepared, controlled, retained, maintained, subm:tted, or made available for NEBG review and/or approval. Such records include:
drawings; specifications; procedures; procurement documents; inspection and test records; personnel and procedure qua'ifications; material, chemical and physical property test results; and Product Quality Certifications.
Lower Tier Procurement - Extension of applicable requirements of procurement documents to lower tier suppliers.
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9 NEDO-11209 3-31-78 5
INSTRUCTIONS, PROCEDURES, AND DRAWINGS Documented instruchons, procedures, and drawings are utihzed to communicate quahty requirements throughout all phases of design, procurement, manuf acturing. and construction Activities affecting quakty, including methods of complying with 10CFR50, Appendix B, are dehneated, accomphshed. and controlled by such documents as pohcies, procedures, operaterg instructions, design specifications, shcp drawings, planning sheets, test and inspection procedures, and standmg instructions. Each organization performing OA-related functions, such as eng>neering, manuf actonng and QA is responsible for the preparation, review, approval, release, apphcation, and matntenance of its own docun entation.
Components, assembhes, and systems furnished by the NEBG are inspected or tested in accordance with instruc-tions and/or check lists wntten for the purpose of communicat,ng quahty requ<rements and inspection and test methods to quahty control (OC) inspection and test personnel. These instruct!ons may be included on a shop traveler or be documented on a special inspection or test instruction, depending on the nature or complexity M the quahty control operation to be performed. The documents define or reference appropnate quantitative cr tena sus h as dimensions, toleranc as, and operating limits or quahtative critena such as comparative workmanship samples or visual standards for determin ng that important activities have been satisfactonly accomokshed The associated shop traveler or QA record provides space for recording or stamping identification of the individual perform,ng the inspection or test end is the record of the quahty Control operat:on This document serves as evidence of completion of the operation and certification of the acceptance status of the item (s) being inspected. Other sections of this OA Program description contain more detailed informat on concerning the specific documents employed in prescnbing quahty-related activities.
Approval and issuance authority for the vanous document types is in accordance with Table 3-1.
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NEDO-11209 3-31-78 O
Taule 5-1 KEY QA PROGRAM DOCUMENTATION APPROVAL AND ISSUANCE AUTHORITY
- NEBG Division Dept.
Mfg.
Group Level P&OAO Level Engr.
QA Engr.
Document Type Executive Managers Manager Managers Managers Managers Managers NEBG Policy and instructions X
NEBG Procedures X
BWR-CA Manual and Program
~
Description X
Division-level Policies and Procedures X
Department-Level Procedures X
Safety Analysis Report OA input X
Design input X
Product Design Documentation X
OA Planning, Instructons.
Procedures and Manuals X,
Manuf acturing Process instructions and Procedures X
- Approvat and issuance authority may be delegated by the respective managers.
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NEDO-11209 3-31-78 6
DOCUMENT CONTROL Procedures and practices are established, documented, and implemented to control the issuance and use of documents which prescnbe activities affecting quality, including: design basis speci'ications; procurement specifications; test a nd inspection instructions; manuf actunng, construction, and installation drawings; operating procedures; and O A plans and manuals. These measures provide astsurance that documerits, including changes, are reviewed for adequacy and approved for release by authorized personnel and are promptly distnbuted for une at the location where the prescribed activity is perfe med. Changes to documents are reviewed and approved by representatives of the same organization that approved the original document unless another orgrnization is specifically designoted by appropriate management. The designated reviewing individual (s) has access to pertinent background information upon which to base t.ie review, and is determined by the NEBG management to have an adequate understanding of the requirements and intent of the original document.
Through established distribWion and communication systems, those participating in an activity are furnished or apprised of current applicable instructions for performing the activity. Participating organizations have dncumented proce-dures for control of these documerJts, and the changes thereto, to assure use of the proper documents and to preclude the possibility of use of outdated or inappropriate documents.
The NEBG eng neenng services organizations are assigned responsibility for the initial distnbution, safeguarding of l
onginals and future retneval of design documents. Controlled distnbution lists are maintained to assure that distnbution is to responsible individuals and organizations. The NEBG organizations utilize a cesign record retention / retrieval system based on prints made from microfilm / microfiche. When a document is issued or revised, :he engineering services organ;Zation replaces the prior revision microfilm and relocates it to an obsolete file.
The NEBG OA related documents such as the Project Master Parts List, Engineering Work Authorizations, Engineer-ing Instructions. Shop Travelers Work Orders, OA Plans, OA Procedures and those document's identified in Subsection 2.2 are controlled in accordance with the following provisions:
Individuals or organizations responsible for prepanng, reviewing, approving, and issuing documents and their e
revisions are identified by higher level procedures with appropnate authonty for such delegation of responsibility.
Interface documents are developed, coordinated, controlled, and require mutual agreement between the interfacing organizations.
Assurance that proper documents are being used is ascertained by cognizant supervisors and venfied by OA through inspection and audits.
Distnbution lists are established by the issuing organization and include those individuals or organizations with e
a need to know in order to fulfill their assigned responsibilities.
Revised documents are distnbuted to those on controlled distnbution of the onginal or prior revision of the e
document. Distnbution of changes or additions to issued manuals and other OA documents is made to a contrciled distnbution list with instructions to the recipier.t as to the disposition of the obsolete documents.
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NEDO-11 3 7 CONTROL OF PURCHASED MATERIAL, EQUIPMENT AND SERVICES Procedures and practices are estabhshed and documented to provide assurance that purchased items and services.
whether purchased direct;y or through subcontractors. conform to the procuremeet document requirements. These mea-sures include p.ovisions as appropnate, for the following source evaiuation and 5 election, review of procurement require.
ments. OA or engineenng review of suppher documents; appropnate objective evidence of quahty furnished by the suppher; surveillance, inspection, or aud,t at the source; and ex amination or review of iter.s or services upon dehvery or completion Documentation of such requirements is originated and maintained by the cognizant OA organizations. Spare and renewal parts tnat pertnrm safety-related functions are procured to a level of quahty standards and controls that are at least as stringent as those employed for the procurement of the onginal equipment.
Measures for evaluation, certificat:on. or quahfication, and selection of procurement sources by engmeenng and OA personnelinclude the use of historical quahty performance data, source surveys (including a review of tne suppher s OA Program). or source quahfication programs Specific provisions for Q A review, concurrence and audit of NEBG supphers' O A Programs are dehneateu in purchase orders for safety-re;ated equipment or services. Supphers of enqmeered equipment l
and services are required to document their OA Program in accordance with the apphcable elements of ANSI N45 2 and to submit their documented QA Program to the NEDG for review. Those comments affecting componcnt quahty are resolved poor to commencement of any work which could be affected by the comments The NEBG supphers are subject to audit / evaluation by NEBG OA persont el for evaluation of the sufficiency of the suppher's O A Program and for adequacy of implementation. Each suppher of safe'
.. lated equipment or services is a udited or evaluated initially to determine acceptabihty of their QA Program If acceptable, the suppher is placed on an approved suppher hst. Following placement on the approved suppher hst, t7e suppher is either. (1) audited annually to determine the continued acceptabihty of the suppher's program, or (2) evaluated annually to dotermine if an audit is required dunng the upcoming year. When an eva!uation is performed, the results are documented and approvcd by responsible OA personnel.
This evaluation considers pertinent f actors, such as: the results of previous audits; history of performance of product and/or purchased service, effectiveness of implementation of the suppher's OA Program; and the importance, complexity, and quahty requirements of the item or service concerned Regardless of the results of evaluations, supphers are audited at least every 3 years?
Source inspection or surveillance is performed by NEDG OA organizations as necessary to assure the required quahty of an item or service. The OA organizations may elect not to perform source inspection or surveillance of suppher activities when the quahty of the item or service is to be venfied by some other method such as review of test reports, inspection or review upon receipt, or by the performance of acceptance or installation tests The OA representatives responsible for suppher audit and surveillance are typically assigned responsibihties as follows:
l Review purchase specifications and drawings to assure a clear understanding of quahty requirements.
Participate in preproduction reviews with suppher personnef to assure mutual understanding of quakty requirements.
Review mpphers' detailed fabocation process sheets to assure proper sequencing and adequate in-process inspection, test, and control.
Witness and audit vanous quahfications, tests, inspections, and nondestructive examinations.
Audit heat treatment, welding, cleaning. preserving. packing, and packaging activities.
Review suppher QA records for comphance with requirements.
- May te sapfed by AsVE survey
=
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NEDO-11209 3-31-78 Audit suppher conformance with established procedures, such as:
e Use of approved drawings and procedures Use of approved product and process quality planning e
Use of inspection and test personnel who are organizationally independent from production and e
scheduling personnel Document change control Nonconforming material control e
Material identification and traceability control Control and calibration of measuring equipment Control of welding Complete Product Quality Certifications prior to release of equipment for direct-to-site shipment.
e A Product OuMty Certification (POC) is transmitted with the equipment whenever items important to safety are shipped to a nuclear power plant. The POC certifies that the items identified therein are in conformance with the procurement quality requirements, including apphcable codes, standards, and specifications as identified in documents referenced on the POC. Any nonconformances to procurement quality requirements that may exist on modu!cs being shipped are identified or referenced on the POC. (Reference Subsection 15.2, Reporting of Nonconformances.")
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NEDO-11209 3-31 F 8
IDENTIFICATION AND CONTROL OF MATERIALS, PARTS, AND COMPONENTS Procedures and practices are established and documented which provide for the identification and control of materials, parts, and components, including partially fabncated subassemblies. The identification and control measures are documented in engineering, manufactunng, and OA-originated documents, and are implemented by the appropriate manufactunng and QA organizations. Equipment components, including subassemblies or parts, are identified and con-trolled by senal numbers, part numbers, or heat numbers in accordance with GE, ASME Code or regulatory requirements.
These measures provide means for assuring that only correct and ac:eptable items are used dunng manufacture.
Physical identification is specified and utilized to the maximum extent practical. When physical identification is either impractical or insufficient, physical separation, procedural control, or other appropriate means are specified. Identificat:on may be either on the item or on records tracEJble to the item. Where identification marking of an item is employed, the marking will be clear, unambiguous and indelible, and will be applied in such a manner as not to af f ect the function or quality of the item. Markings are transferred to each part of an item when subdivided so as not to be obliterated or hidden by surf ace treatment or coatings, unless other means of maintaining identification are utilized. The identification and contrc' measures pmvide for relating an item of production (batch, lot, part or assembly) at any stage, from material receipt through fabncation and shipment to an applicable drawing, specification, or other control document.
Matenals, parts, or components classified as "important to safety" are processed through and released by OA Inspection. Inspections and tests of matenal received from suppliers are conducted in accordance with the engineenng drawing and/or receiving inspection instructions or plans developed by OA to assure venfication of material to the requirements of the purchase order. Material is marked or identified in accordance with OA planning to identify inspection status and maintain identification. As applicable, materials traceability is provided in accordance with documented proce-dures specifically required by the ASME Boiler and Pressure Vessel Code.
Matenals organizations are responsible for maintaining raw material, purchased components, and in-process matenal in a manner which preserves the identification of the items while in the storage areas. Material identification is venfied by the Materials organizations poor to release for assembly or installation. Final venf; ;ation of correct id"entification is accomplished by OA personnel prior to release for shipping.
Items shipped to the Owner are normally identified by nameplate or other identification marking on the item. In those instances when it is not practical to provide nameplate or identification markings on individualitems, identification information is provided in shipping paperwork ihat is transmitted with each shipment.
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NEDO-I t 209 3-31-78 9
CONTROL OF SPECIAL PROCESSES Procedures and practices are established and documented to provido assuranco that special processes such as welding. heat troating, and nondestructivo examination are accomplished under controlled conditions. Theso special processes arn accomplished in accordance with applicable codes, standards, regulations, specifications, design cntena, and other special requiremonts. using qualified personnel, procedures, and equipment.
Requirements for special processos such as welding, heat treating and nondestructive examinations are specified on design documentation by the engineer responsible for tho design. Appropnato inspections and tests to assure control of these special processes are designated in test and inspection procedures.
Manuf acturing and QA personnel, proceduros, and equipment involved or utilized in the execution of control of special processes ato qualified to tho requirements of applicable codos and standards. Documented evidence of the validity of such qualifications is rnaintained fcir all such personnel, procedures, and equipment in accordance with applicablo codes and standards. Each cogr,izant OA organization has the responsibility of penodically monitoring those records to assure the continued validity of all such qualifications. For special processes not covered by existing codos or standards, or whero product requirements exceed the requirements of established codes or standards, the necessary qualifications of personnel, procedures, or equipment are defined in appropnato documents.
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NEDO-11209 3-31-78 10 INSPECTION Inspection of matenals, equipment, processes, and services is defined and executed in accordance with established OA plans, procedures, or instructions to provide assurance that the items coniform to applicable drawings, specifications, codes, standards, and regulations.
Examinations or measurements are performed on items in process for each work operation where necessary to provide assurance of quakty. Final quahty venfication inspection activities (for release to inventory or shipping), and in-process inspection of operations which are inaccessible during final inspection, are performed by OC personnel who are organizationally independent from the Manufactunng personnel who performed the work being inspected. These personnel report to the various OA managers and include inspectors, test technicians, and QA representatives who have t.een trained to meet established performance standards and are periodically evaluated to assure their competence in applicable quality control technologies.
Required accuracy of inspection and measuring d" vices specified is dependent on the charactenstic to be measured and the design tolerances specified. If direct inspection tf processed items is impossible or impractical, indirect control by monitonng of processing methods, equipment and personnelis utilized. A combination of direct inspection and process monitoring is provided when control is inadequate without both. Modifications, repairs and replacements are inspected in accordance with original inspection enteria or alternate approved enteria. Samphng is pnmanly used to venfy process parameter control and to venfy acceptabihty of items or lots where a high degree of confidence can be assured through use of statistically significant samphng plans.
Deuumented OA plans, procedures, or instructions are reviewed and approved by QA personnel and provide fc the following, where applicable:
identification of characteristics or activities to be inspected.
e identification of those responsible for performing the inspection operations.
e Acceptance or rejection criteria.
Method of inspection.
Recording evidence of completing an inspection operation.
e Identifying the inspection or data recorder and the results of the inspection operation.
e Quahfications requirements of individuals performing inspections and examinations. (R efer to Table 2-1 for the e
commitment to compliance with ANSI N45.2.6.)
Specification of any mandatory inspection points beyond which work cannot proceed without appropriate e
inspector action.
Such information is documented in planning documents which are appropriate in the activity and have been issued for utihzation by inspection or examination personnel.
Inspection results are documented and evaluated by QA personnel pr;or to release of a product for shipment to provide assurance that inspection requirements have been satisfied and that proper records have been prepared.
10-1/10-2
NEDO-11209 3-31-78 11 TEST CONTROL 11.1 PRODUCT TEST PROGRAM A product test program is estabhshed to provido assurance that all testing required to demonstrate that the product will perforte satisf actonly in service is identified, performed, and documented. Product testing is performed in accordance with OA or engineenng test procedures which incorporate or reference the test requirements and acceptance limits contained in apphcable engineenng and OA documents. Test requirements and acceptance cnteria are normally provided by the organization responsible for the design of the product. The proc'uct test program covers all required tests, including, as appropnate. development testing, prototype quahfication testing, cahbration testing of instruments, hydrostatic tetJng of pressure boundary components, quahfication testing of procured components, in-procc;s testing of ruanufactured compo-nonts, or final acceptance testing of completed products.
Test procedures for NEBG-manuf actured equipment are normally developed by OC engineers and/or development engineers in accordance with specified test requirements and reviewed by the cognizant design engineer. These test procedures include provisions for assunng that prerequisites for the given test have been met for mandatory hold points (where apphcable), for acceptance and teJection cntena, and fe, appropriate methods of documenting test results. Prerequi-sites include sucn items as appropnate and cahbrated test equipment, trained test personnel, completion status of the item to be teued, suitable environmental conditions, and provisions for data acquisition and storage.
Test procedures for procured equipment are based on engineenng design and ASME code requirements and when prepared by the suppher, are approved by assigned NEBG engineenng or QA personnel.
Product test results are documented, reviewed, and evaluated by designated QA or engineenng personnel prior to release for shipment to assure that test requirements have been satisfied.
11.2 PREOPERATIOrJAL TESTING The nuclear system is made operational by the Owner with technical direction provided bs "'EBG personnel. The NEBG provides preoperational test specifications and instructions for NEB 3-supphed systems and components.
Prooperational test spec:fications identify the systems and components which must be tested and state the require-ments of the tests necessary to assure safe performanca dunng testing Test specifications are reviewed and approved by the appropnate engineenng component poor to release.
Preoperational test instructions provide the necessary information ar'd the essential steps to be taken to fulfill the requirements of the preoperational test specifications.
The NEBG supphes field engineers and technical speciahsts with extensivc product kncwledge snd preoperational testing expenence to provide technical direction of the preoperational tects.
Upon completion of preoperational tests, the NEBG Resident Site Manager and the Owner's representative formal,1y document that the tests have been completed and that the results are in accordance with apphcable specifications and instructions.
11.3 STARTUP TESTING In:t;al f uelloading, nuclear system startup, and operational testing are performed by the Owner with technical direction nrovided by NEBG personnel. To facihtate technical direction of initial fuel loading and power testing, startup test specifica-tions and instrucsons are provided by the NEBG.
Startup test specifications define the minimum test program for safe and efficient startup and authorize and require the performance of the descnbed tests. The specifications limit and define the freedom for changes dunng the startup test activities. The specifications are r' viewed and approved by responsible NEBG engineenng personne! and each required test is performed to the extent specified.
11-1
NEDO-11209 3-31-78 Startup test instructions contain the recommended test method and desenbe the steps necessary to perform the test as required by the startup test specification. Other test methods may be employed; however, the resulting data must be equivalent in all respects to the data which would result from the recommended test method. The results of analyses made to facilitate startup testing activities requ' red by the startup test specifications are included in the startup test instructions. The startup test instructions also contain cnteria for judging the test results, where applicable, and data and calculation sheets for analysis of the data on the site.
The NEBG supplies field engineers and technical specialists with extensive product knowledge and startup experi-ence to provide technical direction for the startup test progran,. Results of the startup tests are analyzed at the reactor site as the data becomes available and periodic reports of the results of the program are issued dunng the course of testing activities.
Upon completion of startup testing, the NEBG Resident Site Manager and the Owner's representative formally document that the startup tests have been completed and report that the results have met the intent of the specifications, calculations, and instructions.
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NEDO-11209 3-31 78 12 CONTROL OF MEASURING AND TEST EQUIPMENT A measuring and test equipmant control program is established and documented to provide assurance that tools, gauges, inttruments, and other inspection, measunng, and testing equipment and devices used in activities effecting or evaluating quahty are of the proper range and type, with measurement error limitations necessary to verify conformance to estabbshed requirements. Documented instructions and procedures, which establish and specif/ the control program for measunng and test equipment, are prepared, maintained, and implemented by the responsible OA or engineenng organizations.
Measunng and test equipment and reference standards are stored and cahbrated in environments which will not adversely affect their accuracy. Environmental factors which are considered include, but are not limited to: temperature, humid ty, vibration, electromagnetic interference, background radiation, @st, cleanness, and fumes. To assure precision and accuracy, inepection, measunng and test equipment is identified and controlled in accordance with documented procedures. Certified standan s having known valid relationships to national standards are utilized in performing the cahbration and adjustment whe e such standards exist. If no national standards exist, the basis for cahbration is dvumented, instrument cabbration irelude venfication that the instrument works in accordance with the manufacturer's instruction manual when such manual ex sts. When practical and within the hmitations of the state-of-the-art, the reference standards u&d for cahbration of measur ng and test equipment shall have tolerances no greater than 25% of the allowable tolerance for the equipment being cahbrued. Reference standards shall be cahbrated against higher level standards of closer tolerance.
The accuracies of the rreasunng and test equipment and the reference standards are chosen such that the equipment being cahbrated can be cahorated and maintained within the required tolerances. Cahbration measu res are not employed for rulers, tape measures, levels, and other such standard devices, since their use is limited to rough measuring functions.
Cahbration and maintenance of measuring and test equipment are performad at appropriately specified intervals. The method and interval of cabbration for each item of equipment is defined and ex:umented and is based on the type of equipment, stabihty charactenstics, required accuracy, and other conditions affect.ng measurement ccntrol. Special calibra-tion is performed when accuracy of the equipment is suspect or when other conditions warrant it. When inspection, measunng, or test equipment is found to be significantly out of cahbration (as determined by the responsible engineer from the area where the suspect equipment was last used), an evaluation is made and documented to determine the validity of previous inspection or test results and the disposition to be made of items previously inspected or tested. If any inspection, measunng, or test equipment is found to be worn and consistently out of cahbration, it is repaired or replaced.
Records are maintained of cabbration and maintenance activity, and items of measunng and test equipment arc suitably and uniquely identified by the responsible OA organization to 9tovide for the traceability to their cabbration test data and for visual determination of their cahbration status. It is the responsibikty of each person utihzing inspection or test equipment to assure himself that such equipment is within the cahbration due date prior to performing an inspection or test operation. Test and inspection superv sion is responsible for enforcement of this provision.
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NEDO-11209 3-31-78 13 HANDLING, STORAGE AND SHIPPING Procedures and practices are established, documented, and implemented in accordance with apphcable codes, standards and regulations to provide control of handhng, storage, cleaning, packaging, preservation, shipping release, and shipping of material and equipment to prevent damage, deterioration, or loss during manufacture and shipment. When necessary for a particular item, special covenng, special equipment, or special environmental conditions, such as inert gas atmosphere, specif:c moisture content levels, and temperature levels are specified by the cognizant engineering organiza-tion, and their existence is venfied by OA. As required, special markings or instructie ;s are supplied to identify, maintain, and preserve a shipment, including indication of the presence of special environmee M or the need for special control.
Where necessary to control quahty, instructions or guidance for site inspection, hand l:ng, preservation, storage, and special controls are prepared and are transmitted to the Owner prior to, or at the time of compor.ent shipment.
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NEDO-11209 3-31-78 14 INSPECTION, TEST, AND OPERATING STATUS Procedures and practces are established and documented to assure identification of inspection and test status.
These procedures and practices provide for assurance that required inspections and tests are performed and that the acceptability of items with regard to inspections and tests performed is readily apparent throughout the manufactunng cycle and is venfied by OA prior to shipment to the Owner. Nonconforming items are segregated and/or clearty identified as such and are controlled in accordance with the conforming matenal control measures desenbed in Section 15.
The inspection and test status of items is maintained through the use of separate physical locations or status indicators such as: tags, markings, shop travelers, stamps, or inspection records. Measures provide for assuring that only items that have successfully completed the required inspectione and tests are used in manufacturing or are released for shipment. When operations or inspections are perf ormed out of planned sequence, limit points are established beyond which work cannot proceed until required operations or inspections have been performed. The instructions for control of status indicators, including the authority for application and removal of tags, markings, labels, or stamps are documented in manufactunng or GA procedures.
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NEDO-11209 3-31 78 15 NONCONFORMING MATERIALS, PARTS, OR COMPO,NENTS 15,1 GENERAL Procedures and practices are established and documented to provide for positive control of items which do not conform to specified requirements in order to prevent their inadvertent use dunng manufacturing, or their release for shipment. Proceduces have been issued within the NEDG to provide for determining the cause of significant nonconfor-l mances, for the identification, documentation, segregatron, and disposition of such items, and for the notification of responsible and other affected organizabons. These procedures alsG delineate the responsibility and authonty for establish-ing disposition of nonconformances after appropriate review.
Nonconforming items are either accepted for use as is, repaired, rewo ked, returned to the supplier, or scrapped in accordance with a properly documented disposition. Nonconforming items dispositioned as " rework" or " repair" undergo reprocessing and reinspection in accordance with the original operational planning and inspection instructions or special planning approved by the resporwible engineer and QA. Reworked material must fully comply with drmvings and sper: fica-tions and final acceptability documentatun is required :vr items which have becn reworked or repaired.
For procured engineered equioment provided by supp.,ere for direct to-site shipment, deviations are processed on a Deviation Disposition Requed (DDR) form, or an equivalent form approved by the NEBG. The supplier descnbes the deviation on the DDR and recommends the GE disposition. The deviations are reviewed by the cognizant Design Engineer, Quality Control Engineer, and Buyer, who cosign the DDR and indicate the GE disposition.
Completed nonconformance reports identify the nonccnformbg item, descnbe the nonconformance, specify the disposition of the nonconformance, prescnbe any specialinspection or test requirements, and include signature approval of the disposition.
A disposition decision to "use as is" or to " repair" a nonconforming item is made only after careful review and approval by a Matenal Review Board (MRB) consisting of a minimum of two technically competent perscns selected by engineering and QA management. Before making disposition, the engineenng representative must determine that utilization of the item in the "m is" or " repaired" condition will not inf nnge upon the capability of the item to satisf actorily perform its intended functions and must document the rationale for acceptance. Items dispositioned a t scrap are deformed. defaced, or clearly identified as unfit for sheir intended use and removed from the processing area as soon as practicable.
Procedures and instructions are in place, which prevent or I:mit further processing of nonconforming items pending a decision on their disposition. The OA managers have authonty for stopping work in process when such action is necessary to assure requisite quality.
Physical segregation of nonceniorming items within hold areas is used where practical until d:sposition is made; otherwise, tagging, marking, cr other positive means of identification are used to effect control and to prevent inadvertent use.
A system is established by each OA organization to penodically or continuously analyze nonconformances through review of MRB action and scrap and rework, to determine trends. Apprnpriate action is taken relative to recurring defects and their cause, and the effect of corrective actions taken. Reports of these analyses are documenteJ and submitted to appropnate management.
15.2 REPORTING OF NONCONFORMANCES For safety-related equipment manufactured or purchased by the NEBG, the NEBG will identify and report to the Owner at the time of shipment, through completion cf the Product Quality Certifiation and attachments, those nonconfor-mances to procurement requiraments affecting end use* of modules which are dispositioned "use as is" or " repair." A
- Nonconformances affecting end use of moduces am those nonconformances that may han a potential adverW effect on the safety, operabsty. rehabety, integr ty or maintainabdity of the f*odule 15-1
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3-31-78 module is defined as an assembled device, instrument, or piece of equipment identified by ss 41 number or other identifcation code, having been evaluated by inspection and/or test for conformance to procurement requirements regard-ing end use.
Modules or components of modules which are fabncated according to the requ:rements of applicable codes must satisfy the requirements of the codes and applicable code cases. Identification and description of nonconformances of these parts are furnished to the Owner in accordance with code requirements.
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NEDO 11209 3-31 78 16 CORRECTIVE ACTION Procedures and practices are established and documented which provide assurance that conditions adverse to quality or nonconformances such as: failures, malfunctions, deficiencies, and deviations :n matenal and equipment are promptly identified, documented, and corrected or otherwise handled in accordance with establisned procedures. Corrective action followup and closeout procedures provide for assunng that corrective action commitments are implemented in a systematic and timely manner. Results of such fc'lowup and closcout activities are periodically reported to appropriate levels of management. Corrective action documentation and request forms or formalletters are used to document the corrective-action-related requests, responses and followup.
Procedures provide for significant conditions adverse to quahty to be identified, their causes to be determined, and for corrective action to be taken. Pertinent information is then documented and reported to responsible management through estabhshed communication systems.
Each cognizant NEBG OA organization is responsible for the following:
Identifying. diagnosing, and determining the causa of chronic quality problems.
e Transmitting relevant information to the individual responsible for taking corrective action.
e Veri?,ing to assure that corrective action is taken which w.ll preclude repetition of the problem or satisfactorily e
control the cause of the problem.
Continuous surveillance of operating BWR performance is maintained. Periodic contact by BWRSD personnel with plant operations personne: provides detailed information on statistical performance of the plant, as well as narrative reports of equipment malfunctions or f ailures. Automatic data handkng systems record and analyze the statisticalinformation. This information is analyzed by the cognizant design components and carefully monitored for significant cr ge-anc equipment weakness. This provides feedback to the responsible design component to avoid repetition of the same problems. Prompt communication to a!! operators of similar equipment is provided whenever significant or avoidable problems are discovered.
Implementation of appropriate design changes to assure corrective action is accomplished in accordance with procedures descobed in Subsection 311, " Design Change Control," and Subsection 3.13. " Design Review Control /
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NEDO 11209 3-31-78 17 QUALITY ASSURANCE RECORDS Procedures and practices are established and documented to provide assurance that eufficient records are prepared and accurnulated as work is performed to furnish documentar, evidence that the quality of items is satisfactory and that other closely related activmes have been performed satisfactorily. Requirements and responsibilities for record generation, accumulation, transmittal, retention, and maintenance are documented in these procedures. The Q A records are consistent with the requirements of applicable codes, standards, regulations, specifications, and contract requirements and are adequate for use in effective management of the OA Program.
The OA records include such docurrentation as the results of design reviews, inspections, tests, material analyses, etc. These records also include closely-related data such as qualifications of personnel, procedures, and equipment and other documentation required by applicable codes and regulations. Inspection and test records, as a minimum, identify tne complets te uate of the inspec on or test, the inspector or data recorder, the type of observation, the results, the acceptability u
of the item, and the action taken in connection with any nonconformanco noted. The OA records are identified, collected, stored, and maintained in a systematic and controlled manner and are retrievable consistent with the applicable NEBG and regulatory requirements.
Each functional N EBG organization is responsible for collecting, filing, transmitting and/or maintaining and controlling those quality-related records which they generate or cause to be generated in accor 'nce with documented procedures.
Nonconformance reports (IR's and DDR's) are filed and maintained by the cognizant line OA organization. Corrective action reports and audit reports prepared by P&OAO are filed and maintained by P& OAF. These reports are made available to the Owner and NRC personnel for audit and review at GE facilities upon request.
For those items for which there are no code requirements for record retention or transmittal, designated QA records, such as outline drawings, purchase specifications, material property records or inspection and test data are svided to the Owner or maintained for him in accordance with the contractual agreement with the Owner.
Records which identify the "as built" condition of safety-related items furnished by GE shall be transmitted to, or retained for, the Owner for the life of the items.
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NEDO-11209 3-31-78 18 AUDITS A comprehensive system of planned and documented audits is carned out to venfy product quahty and cornphance with the OA Program. This audit program is designed to assure comphance with all aspects of 10CFR50, Appendix B.
including. as a minimum, the quahty-related aspects of design, procurement, manufacture, storage, shipment, and GE-supphed services at reactor sites. These audits are conducted at scheduled intervr.ls as documented in audit schedule planning or on a random unscheduled basis, or both, as appropriate. The NEBG Instructions require that GA audits be conducted using pre-estabbshed wntten procedures or check hsts by appropriately trained personnel not having direct responsibikties in the areas being audited Audit resu!ts are documented by the auditors and transmitted for review and committnent of corrective action by management having responsibihty in the area audited. Audit data are penodically analyzed and reports indicating performance trends and the effectiveness of the OA Program are prepared and issued to responsible management for revieu and assessment Af ter evaluation and agreement on aud;t findings, the responsible managers take whatever action is necessary to correct any noncomph. ace revealed by the audit. The audit program provides for followup action, including any necessary reaudit of deficient areas, to assure that corrective actico has been taken. Audits are performed to de!3rmine the fohowing, as appropnate:
The adequacy of documented QA-related pohcies, procedures, instructions and practices to meet their e
intended purpose of assunng product quahty Compliance with quahty-related pohcies, procedures, instructions, and practices.
The adequacy of work areas. activities, processes, items of equipment, documents, and records.
Product comphance with apphcable enginef nng Wawings and specifications.
e implementation of corrective action in accordance w:th apphcable procedures.
e The P&OAO, by delegation from the NEBG Group Executive through the NEBG OPG, has the responsibikty for conducting OA audits of each of the Department-level organizations that affect product quahty for the purpose of appraising the quahty of the products and the efft.ctiveness of the quahty system. The Quakty Assurance and Product Assurance Sections of P&OAO are required to prepare plans, prior to the hrst of each year, for the conduct of audits which will assure that the quahty system estabbshed by such Department-level organization is audited at least annually.
Department-level organizations are required by the NEBG OPG to perform annual self-audits to determine the effectneness of, and venfy comphance with, assigned portions of the BWR OA Program. Each organization prepares plans for the conduct of intemal audits prior to February 1 of each year so that cunng the course of each year all aspects of the BWR OA Program are included in at least one self audit in addition to the P&OAO audits. More frequent audits or measuremen's may be conducted when dictated by any of the following circumstances: (1) When significant changes are made in functional areas of the OA program; (2) when a systematic, independent assessment of program effectiveness or product quahty or both is considered necessary; or (3) when it is necessary to venfy implementation of required corrective actions.
The N EBG supphers' quahty-s elated systems, procedures, processes, operatons, in-process and finished products, and documentation are subject to audit by the cognizant NEBG G A organizations. Audits are used to assess the adequacy of quahty-related systems and procedures and comphance thereto, and to evaluate the effectiveness of nspection operations and other product controls. "OA Requirements," which are included as part of the purchase spec'fications for engineered equipment important to safety, require NEBG suppliers to grant access to the NEBG OC Representatives for audit and review of apphcable design, manufacturing and quahty control records, reports, and documents.
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NEDO-11209 3-31-78 Audits of NEBG auppliers of safety-related engineered equipment are conducted by OA Representatives at least every 3 year s, or me'e frequentif, based on the following: (1)lmportance, complexity, and quahty requirements of the item er service: (2) the results of prevcus audits; (3) history of per formance o' product a nd/or purchased service; or (4) effectiveness j
of implementation cf the supplier's OA Program. For those years wnen an audit is not planned, a formal evaluation of the suppher is performed to determine if a re-audit is required during the upcoming year (refer to Section 7,"Controlof Purchased Material, Equipment, and Services").
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NUCLEAR ENEFtGY DIVISIONS e GENERAL ELECTRtc COMPANY SAN JOSE, CxL!FORNIA 95125 GENER AL h ELECTRIC TECHNICAL INFORMATION EXCHANGE TITLE PAGE AUTHOR SUBJECT TIE NL'.J8ER 78NED 116 Nuclear Science L. G. Marquis DATE and Technology March 1978 TITLE GE CLASS Nuclear Energy Business Group I
BoilingWater Reactor GOV ERNMENT CLO SS Quality Assurance Program Description REPRODUC.BLE COPY FILED AT TECHNICAL NUMBER OF PAGES SUPPORT SERVICES, R&UO, SAN JOSE, gg CALIFORNIA 95125 (Mail Code 211)
SUMMA 3Y A Ovality Assurance (QA) Program is provided by the General Electr;c Nuclear Energy Business Group (NEBG) to assure the required effort, ec;uip-ment procedures, and mariagement are directed toward satisfying the quakty objectives of providing safe and reliable structures, systems, and components, and complying with the provisions of the following documents: Appendix B of 100FR Part 50, " Quality Assurance Cntena for Nuclear Power Plants"; NRC Regulatory Guide 1.28 "Quahty Assurance Program Requirements", ANSI N45.2-1971 "Quahty Assurance Program Requirements for Nuclear Power Plants and applicable sections of the ASME Boiler and Pressure Vessel Code.
The program herein desenbed is structured in accordance with the outline of the 18 critena of Appendix B of 10CFR Part 50, and NRC Regulatory Guide 1.70, " Standard Format and Content of Safety Analysis Reports for Nuclear Power Plants"- Light Water Reactor (LWR) Edition dated September 1975 This document describes the OA Program which is applied generally throughout the NEBG. but which is specifically applicable to the safety-related fur.ctional aspects of systems and co.nponents within the domestic boiling water reactor (BWR) scope of supply.
By cutting out this rectangle and folding in half, the above iniorrnation can be fitted into a standard card file.
DOCtJMEfC NtJMBER N E DO-11209-04A INFORMATION PREPARED FOR __ Nuclear Energy Business Group ECTION Qua'.ity Assurance BUILDING AND ROOM NUMBER L-2990
_ M AIL CODE 368 NED.914 Min)
O G E N ER A L h E LECT!110 9
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