ML20136H345
| ML20136H345 | |
| Person / Time | |
|---|---|
| Site: | Comanche Peak  |
| Issue date: | 11/21/1985 |
| From: | Jason Christensen, Hansel J, Hodges F EVALUATION RESEARCH CORP. |
| To: | |
| Shared Package | |
| ML20136H310 | List: |
| References | |
| ERC-CP-001, ERC-CP-1, NUDOCS 8511250089 | |
| Download: ML20136H345 (42) | |
Text
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DOCUMENT NO.: ERC/CP-001
<.. REVISION . 4 PAGE 1 of 38 EVALUATION RESEARCH CORPORATION l
(ERC)
MANAGEMENT PROGRAM PLAN FOR THE QA/QC REVIEW TEAM COMANCHE PEAK STEAM ELECTRIC STATION COMANCHE PEAK RESPONSE TEAM (CPRT)
Prepared by:,l*} I{..C [,/$I (ibr: reurco.cio/:*/r' Date: n bi/b #
4 J. D; Christensen 4 QA/QC Deputy Review Team Leader
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Approved by: ' u. c.ev /44 nrvue ,,/:./u) Date: -1/-(s' F. R. Hodges.
Energy and Environmental Sciences Division Manager of Quality Assurance Approved by: h(((t.MJ((ikrt. rita.e4 ,,/2e//>) Date: << [d , /7.s'
,L J. L. Hansel
[' QA/QC Review Team Leader .
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DOCUMENT NO t ERC/CP-001 REVISION: 4 MANAGEMENT PROG.uM PLAN FOR THE QA/QC REVIsr TEAM INDEX
1.0 INTRODUCTION
. Page 3 2.0 ORGANIZATION Page 4 3.0 QUALITY ASSURANCE PROGRAM Page 13 4.0 PROCUREMENT DOCUMENT CONTROL Page 26 5.0 INSTRUCTIONS, PROCEDURES, AND DRAWINGS Page 27 6.0 DOCUMENT CONTROL Page 29 7.0 CONTROL OF PURCHASE MATERIALS, EQUIPMENT AND SERVICES Page 30 8.0 INSPECTION Page 31 9.0 NONCONFORMING MATERIALS, PARTS OR COMPONENTS Page 33 10.0 CORRECTIVE ACTION Page 35 11.0 QA RECORDS Page 37 12.0 AUDITS Page 38 i
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MP Plan R^ vision 4
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1.0 INTRODUCTION
This Management Program Plan (MP Plan) has been prepared by Evaluation Research Corporation (ERC) for the purpose of desetibing the quality assurance program which will be applied to Comanche Peak Response Team (CPRT) QA/QC Review Team activities for which ERC has been assigned responsibility. The QA/QC Review Team's scope of work is described in detail in Appendix B of the CPRT Program Plan. Appendix B is titled Quality of Construction and QA/QC Adequacy Plan.
Because of the importance of ERC activities, they will be subject to applicable ERC Energy and Environmental Sciences Division (E&ESD) Quality Assurance Program requirements. Accordingly, this MP Plan requires the approval of the ERC Division Manager of Quality Assurance as well as the QA/QC Review Team Leader.
Division level ERC Quality Assurance Procedures are integrated with procedures prep 1 red by the QA/QC Review Team in order to ensure the proper control and completion of the overall QA/QC Review Team scope of work. The application of ERC quality assurance requirements provides the necessary assurance to the QA/QC RevEew Team Leader, ERC management, and Texas Utilities Generating Company (TUGCO) that the requirements of the CPRT Program Plan and this ERC MP Plan are being satisfactorily implemented, i
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MP Plan Rsvision 4 2.0 ORGANIZATION I
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2.1 Comanche Peak Response Team (CPRT) (
The CPRT organization and its functional responsibilities are s
-described in Section VI of the CPRT Program Plan. The CPRT is led by a Senior Review-Team which formulates policy and provides overall direction of CPRT activities. The QA/QC Review Team
' Leader, along with the Review Team Leaders for Design Adequacy; Civil, Structural, Mechanical; Electrical /
Instrumentation; and Testing Programs report to the Senior Review Team. A CPRT Program Director, who also reports to the Ser. lor Review Team, is responsible for monitoring the Review
' Team activities on a day-to-day basis.
- a. 2.2. QA/QC Review Team The QA/QC Review Team has been assigned the responsibility for the implementation of the Ouality of Construction and QA/QC Adequacy Plan, Appendix B of the CPRT Program Plan. ERC, under the direction of the QA/QC Review Team Leader, Mr. John Hansel, has been assigned the responsibility for managing and directing the QA/QC Review Team activities. He is assisted by a Deputy Review Team Leader, Mr. Jon Christensen who acts in his behalf when Mr. Hansel is away from the Site. Mr. Hansel is also assisted by a part-time consultant, Mr. Vic Hoffman.
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MP Plan R1 vision 4 Mr. Hoffman, an employee of Stone and Webster Engineering Corporation, is utilized because of his e tensive experience with the detailed planning and inplementation of sampling reinspection programs applied at other power stations.
The QA/QC Review Team is made up of selected personnel from ERC, ERC direct hire consultants, and personnel from ERC subcontractors. The major ERC subcontractors are Stone and Webster Engineering Corporation, who in general provide engineering personnel, and Daniel Construction Company, who in general provide inspection personnel.
The QA/QC Review Team Leader has established an organization which is depicted in Figure 2.1. Reporting to the Review Team Leader are a Supervisor of Safety Significance Evaluation, a Supervisor of Programmatic Issues, a Supervisor of Hardware Issues, a Supervisor of Construction Reinspection /
Documentation Review Engineering, and a Supervisor of Inspection. These supervisors, along with the Review Team Leader, are responsible for the development and implementation of Issue-Specific Action Plans which govern QA/QC Review Team investigations and evaluations. They are supported by five staff positions in the areas of Administration and Clerical, Training and Certification, Records Management and Documentation, Procedures and Project Assurance, and Project Coordination. The following are descriptions of the responsibilities of each of these key positions and support functions.
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MP Plan Rsvision 4 g
2.2.1 Supervisor of QA/QC Progrannnatic Issues The Supervisor of QA/QC Programmatic Issues has a group I of quality assurance engineers and technicians reporting to him who are responsible for preparing and implementing Category 1 QA/QC Programmatic Issue-Specific Action Plans. They are also responsible for reviewing related Action Plans and results from other Review Teams. Individual members of the group are designated as Issue Coordinators. This group is also responsible for assisting the QA/QC Review Team Leader l l
in the collation and analysis of all Issue-Specific Action Plans results, including those from other Review l l
l Teams, in order to conduct a collective evaluation and reach final conclusions on the adequacy of the QA/QC Program and the adequacy of the quality of construction. In addition, this group provides j l
assistance to other Review Teams in determining root I causes and generic implications in their respective areas of concern.
2.2.2 Supervisor of Hardware Issues The Supervisor of QA/QC Hardware Issues has a group of discipline engineers reporting to him. This group is responsible for preparing and implementing the Category 1 QA/QC Hardware Issue-Specific Action Plans and for reviewing related Action Plans and results from other 6
I MP Plan l Rsvision 4 j l
Review Teams. As in the QA/QC Programmatic area, individual group members are designated as Issue Coordinators.
2.2.3 Supervisor of Construction Reinspection / Documentation Review Engineering The Supervisor of Construction Reinspection /
Documentation Review Engineering is responsible for implementing the Category 2 self-initiated Construction Reinspection / Documentation Review Program. Reporting to him are an Assistant Supervisor, a Lead Electrical Engineer, a Lead Civil / Structural Engineer, and a Lead HVAC/ Mechanical Engineer. These lead engineers in turn l' have discipline engineers reporting.to them as appropriate. The specific responsibilities of this group are to identify the safety related hardware i
populations which will be sample reinspected, select random samples, identify safety significant
! reinspection attributes, develop reinspection and documentation review instructions and checklists, L
. prepare field verification packages, assist in the evaluation and processing of reinspection I deviations, and evaluate reinspection / review results in t
order to reach conclusions on the construction adequacy of each population.
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MP Plan Revision 4 2.2.4 Supervisor of Inspection The-Supervisor of Inspection has a group of mechanical, electrical / instrumentation, and civil / structural inspectors reporting to him. The inspectors are organized into Electrical, Civil / Structural, Mechanical, and Piping subgroups, each led by a Level III discipline inspector. All inspectors are qualified g Level II or III in accordance with ANSI N45.2.6 and Regulatory Guide 1.58. The major responsibility of this group is to conduct the reinspections required by the self initiated construction reinspection /
documentation review program and to document and process the results. They are also responsible for conducting independent Third-Farty inspections or providing Third-Pabty monitoring of other inspections conducted in support of the QA/QC Review Team and other applicable Review Team activities.
2.2.5 Supervisor of Safety Significance Evaluation The Supervisor of Safety Significance Evaluation is responsible for evaluating hardware deviations identified by the QA/QC Review Team for safety significance. Reporting to him are a Lead I&C and I
L Electrical Engineer, a Lead Mechanical Engineer, a Lead Structural Engineer and a Lead Support Engineer. These l
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MP Plan R; vision 4 lead engineers have discipline engineers reporting to them as appropriate. In certain cases, responsibility for evaluations of deviations for safety significance ray be assigned to other Review Teams, particularly where deviations are in areas which are also under evaluation by the other Review Teams. Conversely, the SSEG may be requested to conduct evaluations for safety significance by other Review Teams.
2.2.6 Staff Support Functions In addition to the five line supervisory positions described above, there are five staff support functions which provide support to the QA/QC Review Team nctivities. These staff support functions are as follows Administration and Clerical - This group provides day to day general administrative support to the QA/QC Review Team including typing and filing, processing of time sheets and expense accounts, procurement of office supplies, etc.
Training and Certification - This group is l
l responsible for ensuring all personnel assigned to '
( the QA/QC Review Team are properly indoctrinated.
qualified, and certified as required. They are l
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MP Plan Rsvision 4 responsible for administering certification tests I- -and certifying /recertifying inspectors in
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accordance with ANSI N45.2.6 requirements.
1 Records Management and Documentation - This group is responsible for establishing and implementing documentation and records control systems for QA/QC Review Team activities. Large quantities of data and information will be developed during the implementation of the Quality of Construction and
- QA/QC Adequacy Plan and one of the prime responsibilities of this group will be to provide assistance to the QA/QC Review Team in controlling and processing these data.
Procedures and Project Assurance - This group is responsible for ensuring that all procedures, ;
instructions, and checklints which are required to j implement the CPRT Program Plan and this MP Plan ;
are identified and prepared. They are also the on-site representatives for the ERC Division l
Manager of Quality Assurance and as such, are responsible for reporting to him on the effectiveness of the quality assurance program l-being applied to QA/QC Review Team activities. .
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HP Pirn R vicion 4 They conduct ongoing surveillance of QA/QC Review Team activities and report the results to the QA/QC Review 5 i
Team Leader and the ERC Division Manager of Ouality !
Assurance.
Coordinating Engineer - This individual is responsible for assisting in the scheduling, coordination, and reporting of the status of activities being conducted by the QA/QC Review Team. He is assisted in these activities by a staff of planners and schedulers. He is the prime interface between the CPRT Scheduler and the QA/QC Review Team.
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MP Plan Rsvision 4 3.0 QUALITY ASSURANCE PROGRAM 3.1 QA/QC Review Team Quality Assurance Program Description The CPRT Program Plan, which has been developed by the Senior Review Team, provides overall direction for all CPRT activities. Appendix B, Ouality of Construction and QA/QC Program Adequacy Plan, of the CPRT Program Plan details the scope of work for QA/QC Review Team Activities. Appendix C of the CPRT Program Plan contains Issue-Specific Action Plans ;
(ISAPs) which specify how external issues and self-initiated programs are to be investigated, evaluated and/or performed by the CPRT Review Teams. ISAPs which are to be implemented by the QA/QC Review Team are referenced in Appendix B of the CPRT Program Plan. This MP Plan details the quality assurance requirenents which will be applied to the work conducted by the QA/QC Review Team. In the case of conflicts between this MP Plan and the CPRT Program Plan and its appendices, the CPRT Program Plan shall prevail. In order to implement the requiremento of the CPRT Program Plan ord its appendices and t
this MP Plan, implementing procedures and instructions have l
been established.
l l The following are descriptions of each of the series of implementing procedures and instructions. Also included is a ,
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MP Plan Ravision 4 description of the relationship of sections of the MP Plan and individual procedures and Instructions to QA program elements which are ap111 cable to QA/QC Review Team work.
3.1.1 ERC Quality Assurance Procedures (QAPs) o The ERC E&ESD Quality Assurance Program is defined in ERC QAPs. A number of these QAPs are directly applicable to QA/QC Review Team activities. In certain other cases, minor modifications are required to make existing QAPs applicable to the activities. Figure 3.1 is a list of QAPs which are applicable to QA/QC Review Team activities inc1 tiding those for which minor changes are required.
3.1.2 Comanche Peak Project Procedures (CPPs)
CPPs are . procedures which have been developed by the QA/QC Review Team. They are utilized to implement requirements of ISAPs and to imp 7ement requirements of the QA program which is being applied to QA/QC Review Team activities. Figure 3.2 is a list of CPPs I
currently being applied to the work.
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i 3.1.3 Quality Instructions (QIs) 2 QIs are inspection instructions which are utilized by l
ERC inspectors to conduct inspections or to overview
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i MP Plan Rsvision 4 l- ,
l inspections.- These instructions specify accept / reject ,
l criteria and provide checklists / forms ttilized to l
record inspection results. Figure 3.3 is a listing of QIs as of October 8, 1985. An up-to-date listing is maintained by the Records Management and Documentation
~ Croup.
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I 3.1.4 Relationship of Procedures to QA Program Elements '
The quality assurance program elements applicable to QA/QC Review Team activities are Organization; QA Program; Procurement Document Control; Instructions, Procedures, and Drawings; Document Control; Control of Purchased Material, Equipment, and Servichs; Inspection; Nonconforming Materials, Parts or Components; Corrective Action; QA Records; and Audits.
Figure 3.4 is a matrix which cross references each of -
the applicable QA Program elements to sections of this MP Plan as well as QAPs. CPPs, and QIs. Taken collectively, the sections of the MP Plan and the QAPs, CPPs, and QIs referenced in Figure 3.4 define the quality assurance program which is applied to the work.
3.2 Interface with Other CPRT Review Teams l
Overall coordination of CPRT activities is the responsibility of the Senior Review Team and the CPRT Program Director.
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MP Plan R3 vision 4 1
Appendix F of the CPRT Program Plan defines the interface between the QA/QC Review Team and the Design Adequacy Team.
Individual ISAPs also define interfaces internal to and external of the QA/QC Review Team. All CPRT ISAPs are reviewed by the QA/QC Review Team to verify complete coverage of all QA/QC program and related hardware concerns. In addition, all ISAP result reports are reviewed by the QA/QC Review team during the collective evaluations of QA/QC program and hardware adequacy. The interface between TUCCO/ Brown and Root and the QA/QC Review Team is defined in CPP-012, QA/QC Interface with Constructor and TUCCO.
3.3 Indoctrination, Training and Certification of QA/QC Review Team Personnel Overall requirements for CPRT perpornel qualifications and training are contaired in section III.R of the CPRT Progran Plan. Detailed requirenents for the indoctrination, training, i and certifiestion of QA/QC Review Team personnel are contained in CPP-003, Indoctrination. Training and Certification of Personnel. The following is a brief summary of the requirements contained in CPP-003.
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3.3.1 Personnel Conducting Inspection Activities All QA/QC Review Team inspection personnel shall be certified Level If or III in accordance with ANSI
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MP Plan ,
Revision 4 i 4
N45.2.6 and Regulatory Guide 1.58. Subcontractor {
certifications are accepted based on the following {
conditions: !
Subcontractor is on the ERC Approved Suppliers List.
The individual has either demonstrated proficiency to ERC Level III personnel at the Braidwood Site or ,
the individual has successfully completed an ERC Ceneral and Specific Examinations.
3.3.2 Personnel Other Than Inspection Personnel l
Qualifications of personnel other than inspection personnel (excluding clerical and administrative personnel) are reviewed by the QA/QC Review Team Leader to verify that education, experience, and qualifications are adequate to perform the assigned
! tasks.
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3.4 Review of the Adequacy of the QA/QC Review Team Quality l
l Program i l
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The Procedures and Project Assurance Group is responsible for monitoring the compliance of the QA/QC Review Team to CPRT Program Plan and MP Plan requirements. This Group has a 1
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r i MP Plan R; vision 4 s.
dual reporting relationship in that they report to both the QA/QC Review Team Leader and the ERC Division Manager of l'
Quality Assurance. They are the on-site representatives of the Manager of Quality Assurance and are responsible for i identifying and reporting on the status of the quality program to both the QA/QC Review Team Leader and the Manager of Quality Assurance. This group is responsible for scheduling l and conducting surveillance of QA/QC Review Team activities in accordance with ERC-QA-15, Performance of Project Specific l Surveillance. The results of these surveillances shall be documented and reported to the QA/QC Review Team Leader and the Manager of Quality Assurance. The QA/QC Review Team
, Leader is responsible for resolving any problems or l
l deficiencies noted during the surveillances.
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! In addition to the surveillance activities described above, l
the Manager of Quality Assurarce conducts periodic audits of l QA/QC Review Team activities. These audits are conducted in accordance with ERC-QA-18, Administration of Quality Assurance l Auditing and ERC-QA-20, Conduct of Programmatic Audits.
Should major problems be identified during the course of the work, the Manager of Quality Assurance issues Corrective Action Requests in accordance with ERC-QA-07 or Stop Work Orders in accordance with ERC-QA-24.
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MP Plcn R3 vision 4 1
FIGURE 3.1 ERC ENERGY AND ENVIRONMENTAL SERVICES DIVISION QA PROCEDURES APPLICABLE TO QA/QC REVIEW TEAM WORK Procedure Number Title ERC-QA-01 Preparation, Maintenance, and Control of E&ESD Quality Assurance Manual ERC-QA-02 Preparation, Maintenance, and Control of Project Specific Quality Plans ERC-QA-04 Quality Assurance Program Management Review Meetings ERC-QA-05 Activity Planning ERC-QA-07 Corrective Action Requests ERC-QA-12 Preparation, Review, and Approval of QA Procedures ERC-0A-13 Quality Assurance Review of Procurement Documents
- ERC-QA-15 Performance of Project Specific Surveillance ERC-QA-17 Quality' Assurance Participation in Preparation of Approved Source Lists ERC-0A-18 Administration of Ouality Assurance Auditing ERC-QA-20 Conduct of Programmatic Audits
- ERC-0A-21 Preparation, Transfer, Receipt of Project Specific Quality Records ERC-QA-24 Stop Work Orders ERC-QA-27 Preparation, Maintenance, and Control of E&ESD Projectized QA Procedures
- Procedures modified to make applicable to QA/QC Review Team activities, i
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! MP Plan Ravicion 4 FIGURE 3.2 CPRT PROJECT PROCEDURES Procedure Number Title CPP-001 Preparation of Project Procedures and Quality
- Instructions CPP-002 Control of Correspondence and QA Review Team Documents CPP-003 Indoctrination Training, and Certification of Personnel CPP-004 Project Working Files CPP-005 Establishing Populations CPP-006 Sample Selection CPP-007 Ptaparation of Checklists and Data Base Reports CPP-008 Preparation of Verification Packages CPP-009 Performance of Reir.qpections and Documentation Reviews CPP-010 Preparation of Deviation Reports CPP-011 Evaluations of Adverse Trend Analyses, Safety Significant Deficiencies, and QA/QC Program Deficiencies CPP-012 QA/QC Interface with Constructor and TUCCO CPP-013 Collective Evaluation of the Quality of Construction CPP-014 Collective Evaluation of Construction QA/QC Program CPP-015 Special Evaluation Team (SET)
CPP-016 Safety Significance Evaluations of Deviation Reports CPP-018 QA/QC Interface with the Design Adequacy Program 20
MP Plan R vicion 4 FIGURE 3.2 (Cont'd)
CPRT PROJECT PROCEDURES Procedure Number Title CPP-019 Cluster Sampling for Issue Specific Action Plan VII.b.1 CPP-020 Out-of-Scope Observations CPP-022 Supplementary Evaluation of Visual Welding Inspection Techniques 21
MP Plcn R3vicion 4 FIGURE 3.3 QUALITY INSTRUCTIONS FOR COMANCHE PEAK QUALITY ASSESSMENT PROGRAM ,
Instruction Number Title 001 Procedure for Class 1E Cable Terminations Inspection-CPRT Action Item I.a.4 002 CPRT Action Item I.a.2, Inspection Report on Butt Splices and CPRT Action Item I.a.3, Butt Splice Qualifications 003 Procedure for Class IE Heat Shrinkable Cable _,
Insuistion Sleeves- CPRT Action Item 1.a.1 004 CPRT Action Item I.b.1- Flexible Conduit to Flexible Conduit Separation CPRT Action Item I.b.2 Flexible Conduit to Cable Separation ,
005 Procedure for Evaluation of Inspector Performance 006 Reinspection of Type 2 Skewed Welds 007 Reinspection of Plug Welds 008 Reinspection of Conduit /I-E-CDUT 009 Document Review of Conduit /R-E-CDUT 010 Reinspection of Electrical Equipment /
I-E-EEIN 012 Reinspection of Instrumentation Equipment /
I-E-ININ L 013 Documentation Review for Instrumentation Equipment /R-E-ININ 014 Reinspection of Cables /I-E-CABL l l
015 Documentation Review of Cables /R-E-CABL 016 Reinspection of Cable Trays /1-E-CATY 017 Documentation Review of Cable Tray / R-E-CATY 018 Reinspection of Previously Disassembled Vr.1ves 22
MP Plan R3 vision 4
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FIGURE 3.3 (Cont'd)
QUALITY INSTRUCTIONS FOR COMANCHE PEAK QUALITY ASSESSMENT PROGRAM Instruction Number Title 019 Reinspection of Small Bore Pipe Supports 020 Documentation Review of Small Bore Pipe Supports 021 Reinspection of Piping System Bolted Joint / Materials 022 Documentation Review of Piping System Bolted Joints /Meterial 023 Reinspection of HVAC Equipment Installation 025 Reinspection of Large Bore Piping Configuration 026 Reinspection of Small Bore Piping Configuration 027 Inspection Procedures for Large Bore Pipe l Supports-Rigid 028 Documentation Review of large Bore Pipe Supports-Rigid 029 Inspection Procedures for Large Bore Pipe Supports-Non Rigid 030 Documentation Review of Large Bore Pipe Supports-Non-Rigid 1 031 Reinspection of Containment Liner and Tank Stainless Steel Liner l
033 Reinspection of Fuel Building Fuel Pool Liners 037 Reinspection of Pipe Supports TRT Issues -
Pipe Supports in Rm 77N, Safeguards Bldg.,
Unit 1 039 Reinspection of HVAC Ducts and Plenues 23
MP Plan R2 vision 4
'd FIGURE 3.3 (Cont'd)
QUALITY INSTRUCTIONS FOR COMANCHE PEAK QUALITY ASSESSMENT PROGRAM Instruction Number Title 041 Reinspection of Field Fabricated Tanks 043 Reinspection of Concrete Placement 045 Reinspection Procedures for Structural Steel 047 Reinspection of Small Bore Piping and Instrument Tubing / Piping Welds / Material 051 Reinspection of Pipe Whip Restraints 053 Reinspection of Category I Conduit Supports /
I-S-COSP 055 Reinspectio.n of Instrument Pipe / Tube Supports /1-S-INSP 057 Documentation Review of Fill and Backfill Placement 058 Reinspection of 42 Pipe Supports-TRT Issues a
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MP Plan R2vicion 4 o
FIGURE 3.4 CPRT QA/QC REVIEW TEAM QUALITY ASSURANCE MATRIX l
QA Program Elements Management ERC QA Comanche Peak Comanche Peak Applicable to QA/QC Program Plan Procedures Project Procedures Quality Instructions Review Team Activities (MP Plan) (QAPs) (CPPs) (QIs)
Organization 2.0 N/A N/A N/A QA Program 3.0 QA-01 CPP-003 N/A QA-02 CPP-012 QA-04 CPP-018 QA-05 QA-15 QA-27 Procurement Document Control 4.0 QA-13 N/A N/A In:truction, Procedures 5.0 OA-02 CPP-001 N/A and Drawings QA-12 CPP-007 CPP-008 Document Control 6.0 QA-02 CPP-002 M/A QA-27 Control of Purchased R:terial, Equipment, cnd Services 7.0 QA-17 CPP-003 N/A I
In pection 8.0 N/A CPP-008 All CPP-009 Nonconforming Materials, Parts, 9.0 N/A CPP-010 N/A or Components CPP-011 CPP-016 Corrective Action 10.0 QA-07 N/A N/A QA-24 QA Records 11.0 QA-21 CPP-004 N/A Audits 12.0 QA-18 N/A N/A QA-20 25
MP Plan R2 Vision 4 4.0 PROCUREMENT DOCUMENT CONTROL The QA/QC Review Team has established measures to assure that appropriate quality assurance requirements are included in procurement documents for services relating to QA/QC Review Team activities .
Certain procurements for services were accomplished prior to the establishment of this MP Plan. For these cases, the ERC Division Manager of Quality Assurance has reviewed the procurement documentr and verified proper inclusicn of quality assurance requirements.
Procurement documents prepared af ter the issuance of this MP Plan are reviewed by the ERC Manager of Quality Assurance in accordance with ERC-QA-13, Quality Assurance Review of Procurement Documents.
They are also reviewed for proper technical content by the QA/QC Review Team Leader. The reviews conducted by the Manager of Quality Assurance and the QA/QC Review Team Leader are '
appropriately documented.
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MP Plan Ravision 4 i
5.0 INSTRUCTIONS, PROCEDURES, AND DRAWINGS A series of plans, procedures, and instructions as described in Section 3.1 of the MP Plan have been established to define how QA/QC Review Team activities are to be conducted. Where appropriate, these documents include acceptance criteria. The following are brief descriptions of the specific procedures which govern the preparation, review, and approval of the applicab e plans, procedures, and instructions.
5.1 ERC-QA-02, Preparation, Maintenance, and Control of Project Specific Quality Plans This procedure specifies the requirecients for the preparation, review, and approval of this MP Plan.
5.2 ERC-QA-12 Preparation, Review, and Approval of OA Procedures.
The preparation and approval of QAPs are covered . in this procedure, j 5.3 CPP-001, Preparation of Project Procedures and Quality l Instructions I
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The preparation and approval of CPPs and QIs are covered by this procedure. !
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m MP Plan R2 vision 4 5.4 CPP-007, Preparation of Checklists and Data Base Reports This CPP covers certain information, including checklists, which is required to be placed in QIs governing population inspections and documentation reviews related to ISAP VII.c.
5.5. CPP-008, Preparation of Verification Packages Instructions for the preparation, distribution, and control of packages containing documentation, inspection instructions, and checklists necessary to conduct reinspections related to ISAP VII.c are contained in this CPP.
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MP Plan
! Ravision 4 s-6.0 DOCUMENT CONTROL The QA/QC Review Team has established a Records Management and l
Documentation Group for the purpose of controlling the issuance of the various plans, procedures, instructions, and other l
documentation applicable to the work. CPP-002, Control of Correspondence and QA Review Team Documents, specifies the applicable controls for assuring that the latest revisions of documents are utilized by QA/QC Review Team personnel- for conducting the work. The procedures referenced- in Section 5.0 of 1
this MP Plan require changes to documents to receive the same review as the originals. ERC-QA-02, Preparation, Maintenance, and
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Control of Project Specific Plans, covers control of this !IP Plan.
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! ERC-QA-27, Preparation, Maintenance, and Control of E&ESD l
. Projectized QA Procedures, covers the control of ERC QAPs - which I
have been modified for QA/QC Review Team activities.
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MP Plan -
R; vision 4 7.0 CONTROL OF PURCHASED MATERIAL, EQUIPMENT. AND SERVICES ERC has established a QA/QC Review Team organization as described in Section 2.0 of this MP Plan which is made up of personnel from ERC and other subcontractors. Purchases relating to QA/QC Review Tetim activities are limited to acquiring personnel from the various subcontractors to work within the established organization. ERC does not issue contracts to organizations supplying personnel until such time as the organizations have been placed on the ERC Approved Source List in accordance with the requirements of ERC-QA-17, Quality Assurance Participation in Preparation of Approved Source Lists. Pre-award surveys of prospective contractors are also conducted. In addition to the qualifications of subcontractors described above, qualifications of each individual assigned to the QA/QC Review Team from subcontractors are reviewed in accordance
- with the requirements of CPP-003, Indoctrination. Training, and Certification of Personnel.
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e MP Plan Rsvision 4 8.0 INSPECTION
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The nA/QC Review Team has an Inspection Group which is described in
. paragraph 2.2.4 of the MP Plan. The inspections conducted by the QA/QC Review team are not inspections for acceptance of hardware and do not, therefore, fall under the requirements of 10CFR50, Appendix B or the TUCCO QA Program. .However, the QA/QC Review Team has established a controlled inspection system utilizing inspectors qualified Level II or III in accordance with ANSI N45.2.6 and Regulatory Guide 1.58. A series of procedures and instructions have been established to define the inspection system.
8.1 CPP-008, Preparation of Verification Packages s
This CPP provides for the preparation of a complete package of information for the conduct of a reinspection or documentation review related to Action Plan VII.c. The packages include or reference all necessary drawings and related changes, i
inspection instructions, inspection accept / reject criteria and checklists, and forns for documenting the inspections.
8.2 CPP-009 Performanco of Reinspections and Documentation Reviews This CPP provides overall direction for the administration and i control of reinspections and documentation reviews being I
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MP Plan Rtvision 4 conducted under ISAP VII.c. It also addresses requirements I' for utilizing calibrated inspection equipment for the reinspections.
8.3 Comanche Peak Quality Instructions QIs provide instructions to QA/QC Review Team inspectors for conducting inspections and documentation reviews. They are utilized for all inspections and documentation reviews conducted by the QA/QC Review Team Inspection Group including those for ISAP VII.c, other QA/QC Review Team ISAPs, and ISAPs from other Review Teams for which the QA/QC Review Team is providing third party inspection or inspection overview services. These ISAPs also address necessary requirements for calibration of inspection equipment.
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MP Plan Rsvision 4 9.0 NONCONFORMING MATERIALS, PARTS, OR COMPONENTS Nonconforming hardware and documentation identified by the QA/QC
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Review Team during th'eir evaluation and reinspection activities are documented on Deviation Reports (DRs) as specified in CPP-010, Preparation of Deviation Reports. These DRs are used only for QA/QC Review Team evaluation purposes. Copies of all DRs are submitted to TUCCO for evaluation, documentation, and processing under their nonconformance control system. Any requit-ed segregation, rejection, repair, or rework of components takes place under the controls of the TUCCO QA program. The following is a brief description of the QA/QC Review Team system for identifying and evaluating deviations.
~9.1 CPP-010 requires all identified deviations to be documented on a DR form and to undergo an evaluation to verify validity.
Copies of valid' deviations are transmitted to the QA/QC Review Team Safety Significance Evaluation Group (SSEG) and TUGC0 QC.
Controls are established to ensure that, where applicable, hardware rework or repair is not conducted by TUGC0 until such time as the SSEG has completed their evaluation of the deviations.
9.2 The SSEG ' conducts evaluations of deviations that are potentially safety significant in accordance with CPP-016, Safety Significance Evaluations of Deviation Reports. Should l
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it be determined that a deviation, if uncorrected, would result in the ~ loss of capability of the affected system, structure, or component to perform its intended safety function, the deviation is reclassified as a safety significant deficiency and returned to the responsible Issue Coordinator for root cause and generic implication analysis.
In certain cases the QA/QC Review Team Leader may designate other Review Teams responsible for conducting evaluations for safety significance in lieu of the SSEG.
9.3 CPP-Oll, Evaluations of Adverse Trends Analyses Safety Significant Deficiencies, and QA/QC Program Deficiencies specifies requirements for conducting root cause and generic implication analyses of safety significant deficiencies. It also specifies requirements for the review and evaluation of DRs for the ' purpose of identifying adverse trends which indicate a potential . for safety significant deficiencies in areas not previously evaluated. In addition, CPP-011 identifies requirements for sample expansion.
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- 10. CORRECTIVE ACTION
-The QA/QC Review Team identifies problems, deviations, and deficiencies relating to TUGCO's QA Program and the station hardware during the course of the QA/QC Review Team activities.
These problems, deviations, and deficiencies are documented as identified in Section 9.0 of the MP Plan or in ISAP Results Reports and collective evaluation reports (CPP-013, Collective Evaluation of the Quality of Construction and CPP-014, Collective Evaluation of . Construction QA/QC Program). Recommendations for corrective action are provided to TUGC0 and they are responsible for documenting, evaluating, and implementing corrections under the TUGC0 QA Corrective Action Program.
The QA/QC Review Team has an internal corrective action system covering QA/QC Review Team activities. As described in Section 3.4-of this MP Plan, the QA/QC Review Team Leader is responsible for correcting problems identified during surveillance activities conducted by the Procedures and Project Assurance Group. The ERC Division Manager of Quality Assurance monitors this process and also conducts his own surveillance and monitoring activities.
Should identified problems not receive adequate or timely correction or if serious problems are identified, he issues a Corrective Action Request to the QA/QC Review Team Leader in accordance with ERC-QA-07, Corrective Action Requests. The Manager of Quality . Assurance also has the authority in extreme cases to stop work in accordance with ERC-QA-24, Stop Work Orders. Work is 35
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only to be . stopped in the area related to the problem and is not i
resumed until agreed to by . the QA/QC Review' Team Leader and the- ~'
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- 11. QA RECORDS The QA/QC Review Team includes a Records Management and Documentation Group which is described in Section 2.2.6 of this MP Plan. Records relating to QA/QC Review Team activities and evaluation results are collected and maintained in accordance with CPP-004, Project Working Files. At the completion of the work, QA/QC Review Team records shall be turned over to the CPRT Program Director. ERC also retains copies of certain records in E&ESD files in accordance with ERC-QA-21, Preparation, Transfer, Receipt of Project Specific Quality Records.
Records relating to qualification, indoctrination, training, and certification of QA/QC Review Team personnel are maintained by the Training and Certification Group (see Section 2.2.6 of the MP Plan)
?.n accordance with CPP-003, Indoctrination, Training, and Certification of Personnel, l-L i
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- 12. AUDITS The ERC Division Manager of Quality Assurance schedules and I conducts planned and periodic audits of QA/QC Review Team activities as defined by the CPRT Program Plan and Appendices, this Et MP Plan, applicable QAPs, CPPs, and QIs. These audits are conducted in accordance with ERC-QA-18, Administration of Quality
. Assurance Auditing, and ERC-QA-20, Conduct of Programmatic Audits.
Findings are directed to the QA/QC Review Team Leader for resolution.
k'he re required, the Manager of Quality Assurance also conducts audits of ERC . sub' contractors and conducts audits of other third party inspeccion agencies being utilized by other CPRT Review Teams. These audits are also conducted in accordance with ERC-QA-18 and ERC-QA-20.
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t Rsvision: 0 Page 7 of 14 APPENDIX G (Cont'd)
ATTACHMENT 3 DESIGN ADEQUACY REVIEW TEAM QUALITY ASSURANCE PROGRAM I
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POLICY STATEAENT in conjunction with the Comanche Peak Response Team Program Plon, this Design Adequacy Program Guality Assurance Program has been prepared to establish the measures necessary to provide odequate confidence in and ossurance of the quality of services to be provided in the performance of octivities involved in the conduct of the CPRT Design Adequocy Program. To
! that end, the quality assurance / quality cortrol methods, procedures, and instructions estelished herein shall be implemented, as applicable, by those individuals assigned responsibility for the activities requiring quality assurance
- and control as identified herein. Any deviations, exceptions, or other nonconformances shall be brought to my attention for resolution.
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- Howard A~. Levin Review Team Leader CPRT Design Adequocy Program TN-85-6262 10/8/85
,-m-4 Rev 2: October 28,1985 TABLE OF CONTENTS Revision Date POLICY STATEMENT - 10/8/85 TABLE OF CONTENTS 2 10/28/85
. QUALITY ASSURANCE PROGRAM 0 10/1/85 DISCIPLINE INSTRUCTIONS (See Discipline Instruction Tob)
DESIGN ADEGUACY PROCEDURES DAP-1 PREPARATION AND REVIEW OF CRITERIA LISTS I 10/27/85 DAP-2 DOCUMENTA flON AND TRACKING OF ISSUES AND DISCREPANCIES 0 9/9/85 DAP-3 DEVELOPMENT AND VALIDATION OF SELF-INITI ATED REVIEW SCOPE O 9/9/85 DAP-4 PREPARATION OF CHECKLISTS I 10/24/85 DAP-5 REVIEW OF CALCULATIONS, EVALUATIONS AND OTHER IMPLEMENTING DOCUMENTS 0 10/4/85 DAP-6 REVIEW OF DRAWINGS, SPECIFICATIONS, AND OTHER DESIGN OUTPUT DOCUMENTS 0 10/4/85 DAP-7 TRENDING AND GENERIC IMPLICATIONS (Later) (Later) t.
DAP-8 PREPARATION OF ENGINEERING EVALUATIONS I 10/27/85 DAP-9 PREPARATION AND APPROVAL OF DISCIPLINE SPECIFIC RESULTS REPORTS AND DAP COLLECTIVE Es'ALUATION REPORT 0 10/4/85 J
Rev 2: October 28,1985 TABLE OF CONTENTS Revision Date ,
DAP-10 DEVELOPMENT AND USE OF DAP PROCEDURES AND DISCIPLINE INSTRUCTIONS 2 10/27/85 DAP-lI . DOCUMENT CONTROL i 10/24/85 DAP-12 DAP INTERFACES AND COMMUNICATIONS 0 10/23/85 DAP-13 PREPARATION OF CALCULATIONS 0 10/4/85 DAP-14 DESIGN ADEQUACY PROGRAM RECORDS 0 10/4/85 DAP-15 TRAINING AND QUALIFICATIONS 0 10/4/85 DAP-16 AUDITS 0 10/4/85 DAP-17 ' CORRECTIVE ACTIONS 0 10/4/85 DAP-18 CONTROL OF SUBCONTRACTORS (Later) (Later)
DAP-19 PROCESSING AND REVIEW OF INFORMATION BETWEEN THE QUALITY OF CONSTRUCTION, GA/OC ADEOUACY PROGRAM AND THE DESIGN ADEQUACY PROGRAM i 10/24/85 l
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