ML20138P252

Rev 14 to Procedure CP-QP-16.0, Nonconformances

ML20138P252
Person / Time
Site:	Comanche Peak, 05000000
Issue date:	07/02/1984
From:	Vega A TEXAS UTILITIES ELECTRIC CO. (TU ELECTRIC)
To:
Shared Package
ML20138M609	List: ML20138M606 ML20138M651 ML20138M794 ML20138M800 ML20138M811 ML20138M820 ML20138M824 ML20138M832 ML20138M839 ML20138M847 ML20138M852 ML20138M864 ML20138M881 ML20138M892 ML20138M899 ML20138M915 ML20138M926 ML20138M943 ML20138M955 ML20138M959 ML20138M964 ML20138M970 ML20138M974 ML20138N671 ML20138N674 ML20138N677 ML20138N681 ML20138N686 ML20138N697 ML20138N700 ML20138N703 ML20138N708 ML20138N712 ML20138N716 ML20138N821 ML20138N861 ML20138N868 ML20138N872 ML20138N876 ML20138N888 ML20138N994 ML20138P014 ML20138P087 ML20138P090 ML20138P094 ML20138P098 ML20138P112 ML20138P114 ML20138P116 ML20138P122 ... further results
References
FOIA-85-59 CP-QP-16.0, NUDOCS 8511070021
Download: ML20138P252 (18)

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t ISSUE PROCEDURE PAGE

• REVISION DATE NUM8ER TEXAS UT1UTIES GENERATING CO

( CPSES 14 jut. 0 2 1984 1 of 9 CP-QP-16.0 A

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PREPARED - 2 FATE '

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NONCONFORMANCES APPROVED BY: / M- k u' -

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1.0 REFERENCES

1-A CP-QP-15.0, " Tagging System" 1-B CP-QP-17.0, " Corrective Act GENERAL DCOPy 2.0 C0 2.1 PURPOSE AND SCOPE The purpose of this procedure is to establish a method of docu:nenting the identification, resolution, and Itclosecut is the of nonconfomances as defined in Paragraph 2.2.

(- responsibility of all site employees to report items of

" nonconfonnance to their supervisor or to the TUGC0 Site QA Supervisor. The requirements contained herein are applicable to nonconfonnances identified for material s, services or items associated under with safety-related the jurisdictionstructures, of the systems and components not AS!E Code,Section III, Division 1. ,

I When nonconfomances are detected by inspection NOTE:

and testing, they shall be reported in accordance l describing l with quali ty procedures / instructions Where i the inspection or testing functions.

specific guidelines are not the given in quality provisions of this procedure / instructions, When a specific person procedure shall govern.

is assigned responsibility for an activity his/her designee may act in his/her place.

2.2 OEFINITION 2.2.1 Nonconfonnance

_A deficiency in characteristic, doctanentation, or procedure which renders the quality of an itan unacceptable or in-detenninate. 1 7

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t PROCEDURE WSION NWBER E PAGE TEXAS UTl!JTIES GENERATING CO.

CPSES CP-QP-16.0 14 2 of 9 lJUL O 2 $84 3.0 PROCEDURE 3.1 NONCONFORMANCE IDENTIFICATION 3.1.1 Field Identification When a nonconfonning condition as defined in Paragraph 2.2.1 is identified, the individual shall immediately apply a Hold Tag, when practical, (Reference 1-A) and note his name and telephone extension on the tag. He shall return and note on the Hold Tag the appropriate NCR neber when obtained from the TUGC0 NCR Coordinator.

NOTE: For electrical activities, the inspector may use his judgement to apply a Hold Tag to a nonconfonning internal c a ponent. For example, the inspector may apply a Hold Tag to a broken / damaged tenninal strip and note on the Hold Tag wording such as " Applied to Tenninal Strip Only." On the NCR the statement would be " Applied to Tenninal Strip Onl'y - other L unrelated activities may proceed."

3.1.2 Reporting Nonconfonning conditions shall be reported on the NCR fonn (Attachment 1). Supporting documentation, e.g., Inspection Reports, NDE reports, drawings shall also be attached to or referenced on the NCR where appropriate. The location of I

, the nonconforming condition (structure, room neber, elevation and area code) and the systen/subsysten number shall be recorded on the NCR form.

NOTE: The systen/subsystec number is not required for discrepancies relating to conduit, cable trays, protective coatings, cable tray hangers or anchor bolt locations provided that the structure is identified.

3.1.3 Numbering the NCR Before sending the NCR to the appropriate Package Flow Group (PFG) the individual reporting the nonconfonnance shall obtain a nunber fram the TUGC0 NCR Coordinator. This neber shall be noted on the NCR and on the Hold Tag per Reference 1- A tha t is applied to the nonconfonning iten/ equipment.

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j PROCEDURE ISSUE y NUMBER REVISION PAGE DATE i TEXAS UTILITIES GENERATING CO.

CPSES 4

CP-QP-16.0 14 JUL 0 21984 3 of 9 4 .  : ;

The TUGC0 NCR CooNinator shall assign numbers as follows:

i e.g. NCR M -

80 - 100214 sequential NCR ntsnber

, for that year Issued to Unit 1 and common. '

- 2XXXXX is issued to Unit 2.

year Mechanical , Electrical Discipline (Tnstrumentation, Civil) ,

t l For NCR's on items / components turned over to TUGCO, the '

i TUGC0 NCR Coordinator shall add the letter "S" after the NCR nisnber and forward a copy to TUGC0 Startup for

. information.

The TUGC0 NCR Coordinator enters the NCR number and brief

\ description of the nonconfor1ning condition in the NCR Log (Attachment 2) for Unit 1 and common or Unit 2 as appropriate.

NOTE: The PFG NCR Coordinators shall periodically review their NCR Log (at least monthly ) to ensure q accuracy and agreement wi th the TUGC0 NCR Log.  !

l , 3.2 PROCESSING NONCONFORMANCE REPORTS j 3.2.1 Draft NCR -

4 The inspector signs and presents the NCR to the QC Supervisor for review. The QC Supervisor indicates his review by i

' initialing after the inspectors signature. The inspector forwards the NCR to the appropriate PFG NCP. Coordinator who ,

logs and forwards the NCR to the appropriate Quality j Engineer. Wien individuals assigned to departments other than QA/QC or QA/QC persons outside the Unit 1 and Unit 2 j management organization are reporting a nonconforming

' condition, they shall forward the draft Nonconformance Report 1 i to the Unit 2 (PFG) NCR Coordinator for processing in i accoNance with this procedure.

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3.2.2 Pre-Issuance Review and Preparation

' The reported nonconformance shall be evaluated by the

' ' Quality Engineer for clarity, accuracy, validity, spectficity

and legibility.

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, PROCE00RE ISSUE

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NUMBER REVISION PAGE DATE TEXAS UTILITIES GENERATING CO.

CP-QP-16.0- ,,

14 llil0 2 584 4 of 9 3.2.2.1 NCR's may be voided at any time if it is detennined that nonconfonning conditions do not exist, the nonconformance was previously reported on another NCR or other similar conditions exist. In the event that an NCR is detennined to be invalid, " Void" shall be entered in bold letters in the disposition block with the reason and justification for voiding the NCR. Any pertinent supporting doctanentation shall be attached to the NCR and referenced in the reason 1 '

and jus tification statenents. Vo iding of NCR's shall be approved by the QE Supervisor or his designee. The original voided NCR will be forwarded to the (PFG) NCR Coordinator.

, 3.2.2.2 If the NCR is determined to be valid, the reviewer assigns

' an " Action Addressee" and signs and forwards the draft NCR to the (PFG) MCR Coordinator.

3.2.3 NCR Issue

-s The PFG NCR Coordinator enters the da te issued in the NCR Log, maintains a. copy and forwards the original NCR to

,the " Action Addressee".

3.2.4 Disposition ,

3.2.4.1 Final Disposition (Rework, Repair, Scrap, Use-as-is)

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The " Action Addressee" i 3 hall evaluate eache reported nonconfonning condition ard detennine an appropriate disposition to correct and/or resolve the nonconfonnance.

The di sposition shall be ~ citarly ana concisely reconfed in the ." Disposition" space son each NCR according to the following: '

a. The respective dishosition block (s) shall be checked (i.e., Rework, Repair, Use-As-Is and/or Scrap).

b. Rework Dispositions shall specify the rewort actions required to correct the nonconfonning conditions and bring the affected itens into compliance wi th the specified requirements. '

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CP-Q P-16.0 14 JUL0 2 $84 5 of 9 l

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c. Repair Dispositions shall specify the repair actions required to bring the nonconfaming characteristic (s) to a condition such that the capability of the affected item to function reliably and safely is unimpaired, even though the iten still may not confom to specified requirements. Repair dispositions shall also include appropriate Engineering technical justification for acceptance of the iten with characteristics that do not canply with specified design requirenents. 1

d. Use-As-Is Dispositions shall include sufficient Engineering technical justification to establish that the nonconfoming characteristic will result in no adverse conditions and that the affected iten will continue to meet all Engineering functional requirements, including perfomance, maintainability, fit and safety.

e. Scrap Dispositions shall be made when it is detemined

that an iten is unsuitable for its intended purpose

\ and cannot be feasibly or economically reworked or

, repaired.

3.2.4.2 Temporary Waiver For those nonconfoming itens which Construction / Engineering desires to continue to process on a " risk removal" basis, authorization shall be requested in the NCR disposition. In order to receive this authorization to continue the proci:ss, the following conditions sust be satisfied:

1

a. The NCR disposition shall include sufficient infoma-tion and direction for accomplishing the wort. Detail shall be provided to pemit adequate evaluation of potential impact to affected parties (i.e., construction, engineering, QA/QC, records, start-up and operations);

b. Engineering Review / Approval shall be by the Engineering Group Supervisor or above;

c. Quali ty Engineering Review / Approval shall be by the Discipline Level III QE or above.

After approval of the disposition a Blue Temporary Waiver Tag, per Reference 1-A, shall be affixed to the item. The NCR number shall be noted on the Temporary Waiver Tag.

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! PROCEDURE ISSUE

• REVISION PAGE NUMBER DATE TEXAS UTILITIES GENERATING CO.

CPSES  :

CP-Q P-16.0 14 E0 2 W 7 of 9 L

3.2.9 Verification /Closu re The appropriate QC Supervisor shall ensu re that the NCR disposition work items are verified and/or witnessed by QC.

shall docunent their inspections (via inspection QC '

reports, checklists, travelers, etc. as required). The QC Supervisor shall ensu re that all documents required for closure shall be either attached to or referenced on the NCR and forward the NCR to the QE for closure.

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The QE, shall close the NCR by signing the. " Verification" block of .the original .

The closed NCR will then be transmitted by the PFG NCR Coordinator to the Pennanent Plant Records Vault (Unit 1 and common) or when the data package is complete, to the Interim Records Vault (Unit 2) and the date entered in the NCR log.

Copies of closed NCR's are transmitted to the TUGCO . NCR coordinator for closure of the TUGC0 NCR log. ,

k 3.3 CORRECTIVE ACTION Copies of NCR's shall be transmi tted daily to the QA Supervisor for evaluation of the need for corrective action.

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3 PROCEDURE REVISION ISSUE NUMBER DATE PAGE  !

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CPSES l t CP-QP-16.0 14 JUL0 2 W 6 of 9 I  !

3.2.5 Action Addressee Review /Appr' oval Only the authorized representative of the Action Addressee -

may sign the Engineering Review / Approval block. l 3.2.6 Quality Assurance Review l

i The NCR disposition shall be reviewed by the Discipline Level III Quality Engineer for adequacy and confonnance to applicable specifications , code requirenents and current  :

drawing / design change.

J If the disposition is satisfactory the PFG NCR Coordinator 'l-i enters the date on the NCR log and puts the NCR into the 4

data package. If the disposition is not satisfactory, the Quality Engineer shall resolve all comments with the Engineer j who dispositioned the NCR. i

' Upon Quality Engineering approval of the disposition, and prior to beginning any rework / repair, QC shall. remove the

( red hold tag and blue waiver tag (if applicable).

3.2.7 Revision of Nonconformance Reports When changes are required to the nonconfonning condition or disposition, the NCR shall be revised. This revision -

shall be denoted on the NCR number and the reason (s) .for revision included in the comments section. The necessary 4

approvals shall be obtained in accordance with this procedure for the portion affected by revision.

3.2.8 Implementation ofge Disposition l '

NCR's shall be sent by the PFG NCR Coordinator to the appropriate department responsible for implementation of the disposition.

g For NCR's identified with an "S" after the NCR ntsnber, an infonnation copy will also be sent to TUGC0 Startup. l 1

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NONCONPORMANCE REPORT (NCR)

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,f u,)S /W PREPARED f lv>AN J D

ex EAR' NONCONFORMANCES

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APPROVED BY:- v' -

1.0 REFERENCES

1-A CP-QP-15.0, " Tagging Systen" C'ONTROLLED 1-B CP-QP-17.0, " Corrective ActiorrCONTROL NOSGco_.

2.0 GENERAL 2.1 PIRPOSE AND SCOPE this procedure is to establish a method t The purpose of of documenting the identification, resolution, It is the and close of nonconformances items of all siteas defined intoParagraph 2.2. I amployees report responsibility of to their supervisor or to the TUGC0 Site

• noncenfonnance The requirements contained herein are QA Supervisor. nonconfonnances identified for materials, i applicable to services or itens associated with safet I ASE Code.Section III, Division 1.

inspection ,

i NOTE: When nonconformances are detected b describing ,

with quality procedures / instructions functions. Where ,

the inspection or testing j specific guidelines are the not given inofquality provisions this ,.

procedure / instructions, When a specific person f e

procedure shall govern.is assigned responsibility l

• designee may act in his/her place. l 2.2 OEFINITION 2.2.1 Nonconfonnance_

A deficiency in characteristic, docunentation, ble or in- or proc which renders the quality of an iten unaccepta determinate.

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t PROCEDURE ISSUE PAGE

• REVISION DATE NUMBER TEXAS UTILITIES GENERATING CO.

CP-QP-16.0 14 JUL 0 21984 2 of 9 t

3.0 PROCEDtRE 3.1 NONCONFORMANCE IDENTIFICATION 3.1.1 Field Identification When a nonconforming condition as defined in Paragraph 2.2.1 is identified, the individual shall immediately apply a Hold Tag, when practical, (Reference 1-A) and note his name and telephone extension on the tag. He shall return and note on the Hold Tag the appropriate NCR nisnber when obtained from the 11)GC0 NCR Coordinator.

NOTE: For electrical activities, the inspector may use i his judgement to apply a Hold Tag to a nonconforming internal camponent. For example, the inspector my apply a Hold Tag to a broken / damaged terminal strip and note on the Hold Tag wording such as " Applied to Terminal Strip Only." On the NCR the statement would be " Applied to Terminal Strip Onfy - other t unrelated activities may proceed."

3.1.2 Reporting Nonconforming).

(Attachment 1 conditions Supporting shall be reported documentation, on the NCR form e.g., Inspection Reports, NDE reports, drawings shall also be attached to 'or i referenced on the NCR where appropriate. The location of 3

j the nonconforming condition (structure, roam number, elevation and area code) and the system / subsystem number shall be recorded on the NCR fonn.

NOTE: The system /subsysten number is not required for discrepancies relating to conduit, cable trays, protective coatings, cable tray hangers or anchor bolt locations provided that the structure is identified.

3.1.3 Numbering the NCR Before sending the NCR to the appropriate Package Flow Group (PFG) the individual reporting the nonconfonnance shall obtain a ntsnber from the TUGC0 NCR Coordinator. This ntsnber shall be noted on the NCR and on the Hold Tag per Reference

' 1-A that is applied to the nonconforming iten/ equipment.

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j PROCEDURE ISSUE PAGE REVISION DATE 4 NUMSER i T_E_X.AS UTluTIES GENERATING CO.

CPSES CP-QP-16.0 14 JUL 0 2 E84 3 of g i

The IUGC0 NCR Coordinator shall assign nebers as follows:

e.g. NCR M - 80 - 100214 sequential NCR neber for that year Issued to Unit 1 and common.

2XXXXX is issued to __ _

Unit-2. ,,,,

year _.___. .. .

Nechanical, Electrical Discipline (Instrumentation, C,ivil)

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For ER's on items / components turned over to TUGCO. the TUGC0 NCR Coordinator shall add the letter "S" after the NCR nu ber and forward a copy to TUGC0 Startup fo r_ _.

. infonnation.

'~i The TIED NER raardinator enters the NCR nuber and brief

" ~ ' "

description of the nonconforming condition in the NCR Log-N (Attachment 2) for Unit 1 and common or Unit 2 as appropriate. _

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NOTE: The PFG NCR Coordinators shall periodically " - '

review their NCR Log (at least monthly ) to ensure' accuracy and agreement with the TUGC0 NCR Log.

3.2 PROCESSING NONCONFORMANCE REPORTS 3.2.1 Draft NCR The inspector signs and presents the NCR to the QC Supervisor for review. The QC Supervisor indicates his review by initialing after the inspectors signature. The inspector forwards the NCR to the appropriate PFG NCR Coordinator who t logs and forwards the NCR to the appropriate Quality i Engineer. )#ien individuals assigned to departments other i than QA/QC or QA/QC persons outside the Unit 1 and Unit 2 management organization are reporting a nonconforming condition, they shall forward the draft Nonconformance Report to the Unit 2 (PFG) NCR Coordinator for processing in accordance with this procedure. l 3.2.2 Pre-issuance Review and Preparaticn The reported nonconfonnance shall be evaluated by the  :

Quality Engineer for clarity, accuracy, validity, specificity l and legibility.

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PROCEOURE ISSUE PAGE l [ REVISION DATE NUMBER TEXAS UTILITIES GENERATING CO.

'8 4 of 9 l CP-QP-16.0 14 JUL0 2 884

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3.2.2.1 NCR's may be voided at any time if it is determined that nonconforming conditions do not exist, the nonconformance -

was previously reported on another NCR or other similar conditions exist. In the event that an NCR is determined to be invalid, " Void" shall be entered in bold letters in the disposition block with the reason and justification i ,

for voiding the NCR. Any pertinent supporting doceentation i , shall be attached to the NCR and referenced in the reason and justification statments. Voiding of NCR's shall be l

i approved by the QE Supervisor or his designee. The original voided NCR will be forwarded to the (PFG) NCR Coordinator.

[ 3.2.2.2 If the NCR is determined to be valid, the reviewer assigns

an " Action Addressee" and signs and forwards the draft NCR 1

to the (PFG) NCR Coordinator.

3.2.3 NCR issue The PFG NCR Coordinator enters the date issued in the .

, m NCR Log, maintains a copy and forwards the original NCR to the " Action Addressee".

3.2.4 Disposition 3.2.4.1 Final Disposition (Rewort, Repair, Scrap. Use-as-is) 9 The " Action Addressee" shall evaluate each reported nonconforming condition and determine an appropriate disposition to correct and/or resolve the nonconformance.

The disposition shall be clearly and concisely recorded in the " Disposition" space on each NCR according to the following: .

a. The respective disposition block (s) shall be checked (i.e., Rework, Repair Use-As-Is and/or Scrap).

b. Rework Dispositions shall specify the rewort actions required to correct the nonconforming conditions and bring the affected itms into compliance with the j specified requirements.

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1 PROCEDURE ISSUE PAGE l REVISION DATE l NUMSER i TEXAS UTluTIES GENERATING CO.

14 JUL 0 21984 5 of 9 CP-QP-16.0

c. Repair Dispositions shall specify the repair actions required to bring the nonconforming characteristic (s) l to a condition such that the capability of the affected its to function reliably and safely is unimpaired, even though the its still may not conform to specified requirements. Repair dispositions shall also include appropriate Engineering technical justification for

• acceptance of the itse with characteristics that do not caply with specified design requirments.

d. Use-As-Is Dispositions shall include sufficient i Engineering technical justification to establish that

'the nonconforming characteristic. will result in no adverse conditions and that the affected item will continue to meet all Engineering functional requirements, including performance, maintainability, fit and safety.

e. Scrap Dispositions shall be made een it is determined

] that an its is unsuitable for its intended purpose and cannot be feasibly or economically reworked or 1 t

\ repaired, 3.2.4.2 Temporary Waiver 4

For those nonconforming itms which Construction / Engineering

' desires to continue to process on a " risk removal" basis, authorization shall be requested in the NCR disposition. In order to receive this authorization to continue the process, the following conditions sust be satisfied:

a. The NCR disposition shall include sufficient informa-l tion and direction for accamplishing the work. Detail ,

shall be provided to permit adequate evaluation of i potential impact to affected parties (i.e., construction, j' engineering, QA/QC, records, start-up and operations);

i

b. Engineering Revie#/ Approval shall be by the Engineering i

Group Supervisor or above; l

c. Quality Engineering Review / Approval shall be by the Discipline Level III QE or above.

After approval of the disposition a Blue Temporary Waiver Tag, per Reference 1-A, shall be affixed to the item. The NCR number shall be noted on the Temporary Waiver Tag. ,

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• PROCEDURE I REVISION PAGE

$ TEXAS UTILITIES GENERATING CO.

! CMS M 0 21984 7 of g CP-Q P-16.0 14

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3.2.9 ' erification/Closu re The appropriate QC Supenisor shall ensure that the NCR disposition work itens are verified and/or witnessed by QC. ,

shall docunent their inspections (via inspection QC reports, checklists, travelers, etc. as required). The QC Supenisor shall ensure that all documents required for

., closure shall be either attached to or referenced on the NCR and forward the NCR to the QE for closure.

The QE, shall close the NCR by signing the " Verification" block of the original.

The closed NCR wili then be transmitted by the PFG NCR 2 Coordinator to the Perinanent Plant Records Vault (Unit I and 4

' comunn) or when the data package is complete, to the Interim

- Records Vault (Unit 2) and the date entered in the NCR log.

Copies of closed NCR's are transmitted to the TUGC0 _ NCR ..

coordinator for closure of the TUGC0 NCR log. ,

\ 3.3 Q)RRECTIVE ACTION Copies of NCR's shall be transmi tted daily to the QA Supervisor for evaluation of the need for corrective action. ___

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. CPSES CP-QP-16.0 14 JUL 0 2 E84 6 of 9 a

3.2.5 Action Addressee Review /Apor' oval l

Only the authorized representative of the Action Addressee l may sign the Engineering Review / Approval block.

3.2.6 Quality Assurance Review The NCR disposition shall be reviewed by the Discipline l Level III Quality Engineer for adequacy and conformance to

applicable specifications, code requirenents and current drawing / design change.

1 If the disposition is satisfactory the PFG NCR Coordinator enters the date on the NCR log and puts the NCR into the data package. If the disposition is not satisfactory, the Quality Engineer shall resolve all comments with the Engineer l I

who dispositioned the NCR.

Upon Quality Engineering approval of the disposition, and j

prior to beginning any rework / repair, QC shall. remove the red hold tag and blue waiver tag (if applicable).

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,; 3.2.7 Revision of Noncon"ormance Reports When changes are required to the nonconfonning condition i

or disposition, the NCR shall be revised. This revision shall be denoted on the NCR ntaber and the reason (s) .for revision included in the comments section. The necessary approvals shall be obtained in accordance with this procedure for the portion affected by revision.

l 3.2.8 Implementation of the Disposition NCR's shall be sent by the PFG NCR Coordinator to the appropriate department responsible for implementation of

the disposition. g i

For NCR's identified with an "S" after the NCR ntaber, an information copy will also be sent to TUGC0 Startup.

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