ML20138J234
| ML20138J234 | |
| Person / Time | |
|---|---|
| Site: | South Texas  |
| Issue date: | 07/12/1985 |
| From: | BROWN & ROOT, INC. (SUBS. OF HALLIBURTON CO.) |
| To: | |
| References | |
| OL-I-CCANP-072, OL-I-CCANP-72, NUDOCS 8510290293 | |
| Download: ML20138J234 (19) | |
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'W/9 fa-10-17-75 1NTRODUCTION 9-16-30 1-1 Cgw =rga v-This 0;ality Assurance Manual defines the Brow 1.&-Root _ Power Group's It de$ct ibesins'io3fity d
0;ality Assurance Program for nuclear work.
assurance activities of Brown & Root's Engineering, Power Oper a tions, Constmetion, and 02ality Assurance Departments and Brown & Root's Purchasing, and Digineering Opem tion Group. It also provides for the establishment of specific detailed policies and procedures for use in the overall nuclear 02ality Assurance Progmm.
The O2ality Assumnce Program described in this mnual shall conform to all re;uirements of the American Society of Mechanical Engin ee rs Boiler and Pressure Vessel Code,Section III, Division 1, "Nu cl ea r Power Plant Components" (known hereinafter as the " Code") and of Title 10, Code of Federal Regulations, Part 50 (10 CFR 50) Appendix B, "02ality Assurance Criteria for Nuclear Power Plants and Fuel Reprocessing Plants."
The objective of this Assurance Program is to ensu re sa fe, reliable products and to p e confidence that all Code items as well as all other sa fety-rela ork are designed, fabricated, and installed in accordance with n21 established in the Code and regulatory re;uirements.
All Brown & Root procedures and document all meet the rej uirements of this manual; however, practices establist.
or agreed to in the contract for individual nuclear projects my, d these manual re uirements, provided such re;uirements de not negate any requirements of the Code. All changes that affect Code items : mist be accepted by the Inspection Specialist of the Authorized Inspection Agency in Houston before implementation.
In u se, this Q2ality Assumnce Program should be constantly reviewed for prospective changes that can simplify and improve the effectiveness of operations. Suggestions will be carefbily evaluated by Brown & Root 02ality Assurance and other appropriate Departments before final action.
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RUCLaaft RtCULATORY COMuluten 9/16/80 Jctket No-fficial Emb. Me Ola y Assubance Manager Date la the matter of Staff CE NT!FilD upiica nt _
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3.1 PURPOSE 4
5 This section establishes the measures to provide for control of s
design activities, whether performed by B&R Engineering or subcontracted to others for specialized services. For those contracts that encompass plant construction only, this section only establishes 9
measures for requesting design changes from the field.
10 11 3.2 CENERAL 12 13 Subsequent to a letter of intent or a signed contract, a, scope document shall be prepared. This document shall define the equipment,
,3 material, and services required to complete the work in accordance is with the conditions of the contract. This effort will be administered i,
by a Project Manager who is responsible for the prosecution of the is 19 entire engineering and design effort for the project, including 20 quality of work, and compliance with appropriate Codes, standards, 21 and regulations and owner's requirements. These activities are 22 carried out in accordance with Power Group Operations Department l
23 Procedures.
24 25 All design activities will be accomplished in accordance with written i
n procedures which are reviewed,. approved, and otherwise controlled by 27 B&R Engineering. These procedures will ensure that the sources of design information are traceable; adequate controls are maintained; j
designs are verified; and design changes are reviewed, approved and 33 documented.
3, 32 These procedures shall also provide a method for assigning t
33 34 appropriate safety classifications by the originator in accordance i
as with applicable Code class, standard, and regulatory requirements and l
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cc=mitments. The following factors will be considered in assigning 4
safety classificatiens:
5 6
The pessible effects of the failure of the ites en plant safety a.
7 or reliability 8
b.
The design and fabricatien co=plexity of the item o
The need for special controls and surveillance over processes or c.
10 equipment it d.
The degree to which functional compliance can be de=enstrated by 12 inspection or test The quality, history, and degree of standardization of the item e.
15 A Project Quality Engineer (PQE) will be assigned within the project is engineering organization, reporting.'to the Engineering Project u
is Manager.
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20 The Project Quality Engineer will ensure that design activities are 2'
controlled through approved Project Engineering Procedures. The 22 Project Quality 'ngineer will participate in the development of E
23 Engineering Procedures and will monitor the implementation of the Engineering Procedures.
25 1s To ensure that design control is in accordance with the precepts of Corporate QA policy, the Project Quality Engineer coordinates with 29 interpretation of quality assurance requirements.
33 31 32 3.3 DESIGN INPUT 33 34 The design of a system will be conveyed'in one or more of the 35 following documents: system design descriptiens, technical reference 36 37 38 33
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3 documents, purchase specifications, construction specifications, 4
calculations, and drawings. These are classified as de:ign docu=ents 5
whose generation, review, approval, and distributien are controlled a
by project procedures. These docu=ents together constitute the
=inicum design for a system. The function of each is described in the following paragraphs.
9 to 3 3.1 System Design Descriptions u
12 The basis for the design of each system is contained in a docu=ent titled System Design Description (SDD). This document identifies the design inputs and their sources; applicable Code, standard, and/or 33 regulatory requirements; operating parameters, environmental 4
is conditiens;structuralandmechanica5 loadings, electrical l'
u 18 require =ents; and safety, quality assurance, material, fabrication, k
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and construction requirements. When the system design is initially 18 20 developed, the basic design requirements are published in an SDD 21 which is unique to that system. As the design is finalized, the
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design basis is reflected in the calculations, specifications, 23 technical reference documents, and drawings. The status of these 24 documents is tracked by the responsible disefpline in accordance with 2s project procedures. When the design reaches co=pletion, the SDD is revised to reflect the as-designed configuration. During design evolution, design interfaces are maintained through the specifications, technical reference docu=ents, and drawings.
30 si 3 3.2 Technical Reference Docueent 32 An SDD may be supported by one or more Technical Reference Documents, 23 24 which may cover more than one syste=. A Technical Reference Document 35 will not be an SDD but it may contain design criteria. In such cases, 36 the design criteria will aug=ent or supplement the design criteria 37 38 30 ao
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2 described above. Technical Reference Docu=ents =ay include, but are 3
not limited to, the following: design criteria (other than those contained in SDD's), standard attach =ents to purchase specifications, s
repcrts (including design reports, stress reports, test reports),
s lists (such as valve lists, line lists, etc.), B & R Standards, 7
special instructions, and Design Specifications. Technical Reference a
9 Docunents (or the abstract thereto) will be distributed on controlled
'O distribution to the holders of the SDD =anuals.
ti 12 3.3.3 Purchase Specifications 13 Purchase specifications will be prepared frc= the SDD for the purpose is of purchasing engineered equip =ent and/or services. All is specifications will be prepared to &Jstandard for=at and require the 11 review and approval of the B&R Quality Assurance Depart =ent and the Owner as well as Engineering. Bulk =aterial and sc=e =inor catalog ite=s =ay be purchased en a Bulk Material Specification Form. A copy 20 of this form is contained in Exhibit 3.1.
21 22
- 3 3 3.4 Construction Specifications 24 25 Ccnstruction specifications =ay be prepared by B&R Engineering to 26 provide require =ents for the construction of specific ite=s.
3' Construction specifications will be prepared fro: the SDD and may be presented in a for=at si=ilar to the purchase specification, which 29 would require the same CA review and approvals, or =ay be prepared in 33 the sa=e for=at as a technical reference docu=ent, which would 31 require QA review.
32 33 3.3.5 Calculations 35 Calculations are prepared as a basis for each system design. When 36 co=pleted, calculations are verified and a copy retained in the 33 Docu=ent Control Center. Cc=puter progra=s used in conjunction with l
ss calculations are controlled and verified and shall be identified in so
'O the stress or design report.
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6 and construction requirements. Drawings will be prepared on a a
standard format and will be issued under a controlled distribution in 9
accordance with Section 5 of this manual.
to ti 34 DESIGN SPECIFICATIONS 12
'3 Design Specifications shall be prepared by the Engineering Depart =ent and shall contain sufficient detail to provide a ec=plete basis for design and construction in accordance with the Code.
16 The Design Specifications shall include, as a mini =u=:
is 19 1.
The functions of the ite=s, including any di=ensions upon which functional perfor=ance depends; 7,
2.
22 Design requirements, including mechanical and operating loads; 3
Envirer.= ental conditions, including radiations; 23 4.
Code classification of the ite=s; 24 25 5.
Definition of boundaries, including dimensional locations, 26 forces and coments, and structural requirements; 27 6.
Material requirements, where applicable; 2s 7.
When operability of a co ponent is required, reference shall be 29 made as to other documents where operating requirements are 30 defined; 8.
Applicable Code by year and addenda.
l 32 33 35 PROFESSIONAL ENGINEERING CERTIFICATION 34 35 All Division I Design Specifications and Stress Reports, Design 3,
Reports and Load Capacity Data Sheets for Class 1 Co:ponents, Class 2 3,
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Vessels, MO Vessels, MC Cc=ponent Supports, Class 1 Co=ponent Supports, and CS Core Support Structures will be certified by one or 5
= ore Registered Professional Engineers (RPE) co=petent in the applicable field of design. Certification =eans the application of 7
the Engineer's Seal to the cover page of specificatiens and reports, a
as applicable. The RPE will sign and date his seal.
9 to 3 5.1 Desien Specificatiens 3,
12 A copy of the Design Specifications shall be made available to the 33 g.
ANI prior to fabrication.
is A copy shall be filed at the location of the installation and made is 17 available to the enforce =ent authorities having jurisdiction over the is plant installation before co=ponents or appurtenances are placed in
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'S service. In the case of parts, piping subasse=blies, appurtenances and co=ponent supports the Design Specifications need not be made 2'
available to the ANI at the site. However, the applicable data from the Design Specifications which form the basis of fabrication shall n
be made available to the ANI at the site.
24 25 3 5.2 Stress Reports 26 27 The Stress Report shall be co=pleted, certified, and reviewed to the 28 extent necessary to deter =ine that it is based en the Design and 29 Service Loadings stated in the Design Specifications. B&R Engineering 3o shall certify that such a review has been conducted and that the si 32 applicable Stress Report is based on the Design and Service Loadings 33 stated in the Design Specifications. Copies of this certification 34 shall be attached to the copies of the Stress Report which are made 35 available to the ANI and a copy shall be filed at the location of the 36 installation and =ade available to the enforce =ent authorities having s,
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2 jurisdiction over tne nuclear power plant installatien. The 4
availability as stated above shall be the sa=e as that defined for s
the Design Specification in 3 5.1 above.
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The Stress Reports shall be sent to the Owner for review and approval y
ot be sent to the Owner y
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,o for approval if the Owner has assigned that responsibility to the B&R si Engineering Organization.
12 is 3.6 DESIGN ANALYSIS 14
'5 Engineering precedures for the preparation, review, approval, and
'8 control of desir. docenents shal] include provisions for appropriate
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design analyses. Appropriate design analyses shall include stress, is hydraulic, vibration, shielding, and ther=al analytical treat =ent, 19 and shall ensure that the design ce= plies with applicable Code, 20 standard, and regulatory require =ents. The design analyses shall ensure that the. design meets the design require:ents as included in the applicable design docu=ent and Design Specification and that the 23 design is adequate for the intended service.
24 2s 2s Design analyses, when performed by B&R Engineers, shall be docu=ented 27 in the form of calculations, drawings, specifications and etc. Design 2s analyses shall be detailed enough so that a person technically 29 qualified in the subject can review and understand the analyses and 33 can verify the adequacy of the results. Design analyses will be 31 reviewed by interfacing disciplines and approved by the Discipline 32 Project Engineer.
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3 37 DESIGN VERIFICATION 4
5 Design verification will be performed by individuals or groups other s
than those who performed the original design. The Discipline Project Engineer, as the Supervisor, may not perform the design verification, s
9 Design verification will be conducted to ensure that the design meets to spec $fied input requirements and that the design is correct and sat $sfactory. The type and depth of design verification depends on safety, complexity, and standardization of the system or item under
,3 rev$ ew. Brown & Root Engineering Procedures detail the methods and steps to follow for design verification. When design verification is 33 complete, the individual assigned the responsibility for coordination is of the verification shall complete'the "$esign Verification" Document 17 is Review Form (Exhibit 3.2).
19 20 Design reviews will be the primary method of design verification. For 21 documents that do not involve interfacing disciplines, such as most 22 calculations, the review may be performed by a single technically 23 qualified individual. Where interfacing disciplines are involved, an inter-discipline review will be conducted. The review findings shall 25 be documented on a Documen'. Review Form (Exhibit 3 3). The Docume as Review Form shall provide objective evidence of the extent and findings of the review and how the findings were resolved.
3 29 Where design reviews are not possible, des 2gn verification may be in 33 the form of alternate design or calculational techniques or as 33 32 qualification testing. These will be 1dentified, documented, and as performed to demonstrate adequacy of perfor=ance under design 34 conditions. Such tests will be done to detailed, approved procedures 35 and controlled as described in Section 11.0 of this manual. The 36 Docu=ent Review Form (Exhibit 3 3) is used for each verification to 37
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describe the action taken or required.
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3 Reports of in-process er final design verifications will be reviewed by Engineering Project Manage =ent.
s 3.8 DESIGN CHANGE SUPERSEDED - RECGRD CCN i
8 Brown & Root will i=ple=ent procedures to ensure that all design changes, including field changes, are reviewed, approved, and docu=ented in the sa=e =anner as the original design.
12 If the organization originating the design has been released fro = its 33 responsibilities, the design change will be reviewed and approved by i.
an alternate organization. This organization will have access to all is background infor=ation, have de=enstrated cc=petence in the specific is 17 design area of interest and have an adequate understanding of the is require =ents and intent of the original design.
'I 19 2o Design changes may be acco=plished by revision to the design 21
_ docu=ents or docu=ented on a Docu=ent Change Notice (Exhibit 3 5).
2' DCN's are reviewed and approved by the Discipline Project Engineer, 23 the Project Quality Engineer and the Engineering Project Manager 24 before i=ple=enting the change. All approved design changes are 25 issued through the Engineering Docu=ent Control Center (EDCC). The nu=ber of DON's that =ay be issued against any drawing before a total p
revision is required is five (5). If five DCN's do not accrue within 28 90 days of the original issue date, the drawing =ust be revised and 29 outstanding DNC's incorporated. When pages of docu=ents (other than so drawings) have been revised and issued to docu=ent holders as part of si 32 the DCN, the docu=ent holders will incorporate the revised pages in 33 the docu=ent and there is no ti=e or nu=ber li=itations. Change bars 34 will be used to identify changes and individual pages will be
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35 1g7dentified, as, having been revised.
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2 B&R Construction personnel at the construction site may request 3
that design changes be made by use of the Field Request for Engin-eering Ction (FREA) Form (Exhibit 3.4).
The applicable portions 6
of this form will be completed by construction personnel and will be transmitted from the Site Document Control Center (SDCC) to the a
Engineering Document Control Center (EDCC) for further distribution 9
to the Responsible Discipline.
After review of the request for the io change, the form will be completed by Engineering.
If a change to 11 the design document proper is required, a DCN or revision to the 12 affected document will be initiated to accomplish the required change.
12 Otherwise, the completed and approved FREA form constitutes the documentation of the deviation. The FREA will be returned to the
'6 originator through EDCC and SDCC.
For projects encompassing only the construction phase, Field Requests for Engineering Action will be processed through the Site Document Control Center to the Owner; 18 who, in turn, coordinates these requests with their engineer. A 20 supplier of engineered equipment may request changes to or devia-tions from a purchase document through the use of the Supplier Devia-22 tion Request (SDR) form (Exhibit 3.6).
These forms will be submitted 23 to B&R Engineering by the supplier.
Authorization for the change 2
or deviation is by return of the approved form to the supplier. SDR's 23 and FREA's require the approval of the same organizational entities 26 that approved the Document against which the change was made except 27 as defined in subparagraph 3 of paragraph 3.8.
28 29 20 3.9 DESIGN INTERFACE 31 The initiative for design interface action and activities within B&R or with external program participants will be the responsibility 33 of the congnizant Discipline Project Engineer, acting for or with 3
the approval of the Engineering Project Manager, in accordance with 35 appropriate engineering procedures. The Discipline Prcject Engineer as will ensure that proper documentation of all design activities is at 3?
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5 5
3.10 ENGINEERING CONsutTANTs 7
Before the award of contract the Houston Coordinator will evaluate 9
the prospective consultant's quality assurance program to ensure that to it meets with the requirements of the Brown & Root QA Progra= and the it Code. The Houston Coordinator will confer with the Project enginecaing personnel as necessary to ensure that a cutual
,3 understanding exists or design interfaces between B&R and prospective engineering consultants, including such =atters as the scope of work, 33 Code and regulatory requirements, an,d procure =ent procedures for is proposed subcontracts for design ser' vices.
17 18 is j
All docu=ents prepared by a Consultant will be sub=itted to the 20 responsible B&R Project Engineer for review and approval. On ite=s 25 designed to Code requirements, the Stress Reports will be certified 21 by an assigned Registered Professional Engineer of the Consultant to 23 verify co=pliance to the Code and Design Specifications. This action does not relieve B&R of final responsibility for the Stress Reports.
25 26 3.11 CUALITY ASSURANCE REVIEWS AND AUDITS I
27 28 1
The B&R QA Department will review all Engineering procedures and 29 those design decuments stipulated in Project Procedures as requiring 3e review by the B&R QA Department and shall enter any ce==ents on a QA 3,
Department Docu=ent Review For= (Exhibit 3.3). The Houston 32 Coordinator (QA) will ensure that those docu=ents reflect:
33 34 35 36 37 38 30
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3 Require =ents contained in the Engineering Procedures a.
b.
Require =ents of applicable Code, standards, and regulatory 5
agencies Appropriate q.ality assurance require =ents c.
7 d.
Inspection and test require =ents a
Acceptance criteria sufficient to allow verification that e.
s activities have been satisfactorily acco:plished f.
Confor=ance to the applicable Design Specification 32 g.
Approval of the docu=ent by appropriate Engineering disciplines 13 The B&R CA Department will conduct external and internal audits i.
pertaining to design activities being perfor=ed for the Project. The is E&R QA Depart =ent will audit the B&R Engineering organization and 16 17 c3nsultants en a scheduled basis to
- ensure ec=pliance with is Engineering Procedures, the Code, regulatory require =ents, and the QA
'(
Progra=. Corrective action on deficiencies shall be coordinated 19 20 directly with the Project Quality Engineer or in the case of external 21 audits, with the censultant's assigned representative.
22 3 12 EXHIBITS 24 25 31 Bulk Material Specification Form 3.2 27 Document Review (Design Verificatien) For=
3.3 Docu=ent Review For=
29 34 Field Request for Engineering Action 33 3.5 Document Change Notice 31 3.6 Supplier Deviation R. quest Form 32 33 34 35 x
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