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43 Pullman Power Products g
ESD-26S P
DOCUVENT NO.
h PREPARED BY: D, regee APPROVED BY:
DATE: 7-27-76 Pevised 4-11-7S d
TO BE USED PAGE ONLY. ON JOB
- 7177 NO.
-1 of 12 REY. --3/31/81 J. Brasher gc REV. 5 /27/81 P. Munns /
FIELD PROCEDURE FOR DEFICIEilT C0f!DITI0ll NOTICES (D.C.tl.)
gg%'AN
1.0 SCOPE
Y gg This specific'ation establishes procedures req
..p ement the re-quirements of KFP-10 Field Procedure !!onconfo. ties, KFPS-9 Pipe Support Field Procedure I;onconformities, and ESD-243 Pipe Rupture Restraints.
These procedures provide instructions to be followed when conditions are detected which indicate thata defielent condition exists 2.0 RESP 0tlSIBILITIES:
2.1 The Field QA/QC Hanager is responsible for assuring compliance with this procedure.
i 2.2 The Chief Engineer is responsible for reviewing conditions reported and the recommended disposition for compliance with the applicable
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code, procedures and contract.
I 2.3 The Field QA/QC ffanager or his designated representative shall'evalu-l ate a11 Deficient Condition :totices to detemine if the recommended
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dispositions are acceptable within the scope of the Quality Assurance
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Program.
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2.4 Field QA/QC Inspectors and/or Field Engineers shall generate all De.
ficient Condition Hotices, D.C.N. Fom F-129 see attachment #1.
The
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criginator shall formulate the recommended disposition for each re,+
ported condition.
3.0 Deficient Condition Notices shall be initiated to report:
incorrect or incomplete documentations deviations from prescribed procedures, codes or specifications: items or work processes which deviate from specified condi.
tions or requirements which can be corrected through the normal course of I
construction; out of specification or out of code piping or coyonents; j
damaged piping or comonents requiring welding to repair; a discrepancy that might, by itself, adversely affect performance, reliability or result
- I in malfunction. In process visual or fl.D.E. rejections are not considered 8
a reportable deficient condition unless there is evidence of the process f
'or program being out of control.
4.0 DEFICIEllT CO:lDITIO'lf0TICE PROCEDURES:
4.1 All known condi.tions which may be deficient shall be reported on a Defielent Condition Notice, F-129.
Field QA/QC Inspectors and/or Field Engineers shall originate the Deficient Condition Notice, see
/.ttach icntt#1.
5-2P-81 8603310003 SM123 PDR FOIA DIVIggg4-744 PDR
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- Pullman Power Products
{F CSD-269 DOCUVENT N3.
h PREPARED BY:
D. Ceske APPROVED BYt &[h -
DATE: 72779 REV. 3/31/81 J. Brasher #
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TO BE USED PAGE 2 of 12 ONLY ON JOB 8 7177 NO.
4.1.1 Each Deficient Condition flotice shall be assigned a number by the Field QA/QC Inspector concerned. The number shall be a six (6) digit number. The first three digits are the Fleid QA/QC Inspectors enployee number.
The last three are in nu-nerical sequenc-for each inspector. Hunbers shall be entered as follows: 053-001, indicating inspec.- 053's first report.
4.1.2 The notice shall be dated and signed by the originator on the day the notice is initiated.
4.1.3 The deficient condition shall be described in narrative form.
Include sketches with dimensions, if required, to communicate the total condition reported. An opinion of the cause of the condition shall be included.
4.1.4 The Field QA/QC Inspector shall affix a hold tag to all dis-crepant items reported on a Deficient Condition Notice until the notice has been dispositioned.
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4.1.4.1 The Hold. Tag shall reflect the Deficient Condition tiotice Number.
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4 4.1.4.2 The Hold Tag Number shall be entered on the Deficient
$h'N Condition Notice along with the inspector's initials and date.
4.1.4.3 When a Field Engineer originates a Deficient Condition Notice he shall obtain a number from a Field QA/QC Inspector. The inspector shall affix the Hold Tag, enter the Hold Tag Data on the !!otice Form, and enter the nutter on the Notice Form.
4.1.5 The Deficient Condition Notice ilumber and Hold Tag Ilumber shall be recorded on,the appropriate log, see attachment #2.
4.2 The originator of the Deficient Condition Notice af ter solicitating comments and suggestions from the appropriate Department as needed shall enter the recommended disposition.
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4.2.1 If Rework / Repair is required the Field E.ngineer shall enter the Production Department work steps required to correct the condition.
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4.2.2 The Field QC Inspector shall enter the inspection requirenents
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for work steps established above.
4.2.3 Reco-nended inspection requirenents shall be reviewed by the Level III prior to Field QA/QC ltanager's Review.
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y Pullman Power Products' EsD 268 DOCUVENT NO.
PREPARED BY, D. Geske APPROVED BYt,A 7-27-78 4-30-80 4/4 REV. 3/31/81 J. Brasher (&JO BE USED 7377 PAGE 3 of 12 ONLY ON JOB 4 NO.
4.3 After the Field Engineer and Field QA/QC Inspec;or have entered the recommended disposition, as required, the originator shall route the D.C.N. to the Chief Engineer for review and signature as required by paragraph 2.2 above.
4-30-80 4.4 After review and signature, the D.C.N. shall be forwarded to the Field QA/QC Level lli or Level 11 designated by the Field QA/QC Manager for review of the recommended inspection requi rements.
4-30-80 4.5 Af ter review by the Chief Engineer and the QA/QC Level lli or desig-nee, the D.C.N. shall be forwarded to the Field QA/QC Manager who shall conduct an evaluation as required by paragraph 2.3 above.
4.5.1 The Field QA/QC Manager may conduct, or cause to be conduct-ed, an Investigation of the reported condition, in no case shall the originator of the report or personnel previously involved in the condition be utilized as an Investigator.
4.5.1.1 Whan required, physical examination of the condition f')
and all supporting documentation shall be examined
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as needed, to arrive at conclusions regarding the condition to include cause.
4.5.1.2 When an Investigation of the reported condition is 4 h[
performed, the result of the Investigation shall be S
prepared and attached to the D.C.N.
Legible, hand-h written documentation shall be sufficient.
4.5.2 The Field QA/QC Manager or his designated representative shall review all available data, to include the Investigative report, and render an evaluation directed toward the Quality Assurance Program ef fectiveness.
4.5.2.1 The evaluation statement shall be in narrative form Indicating validity of the reported condition, de-gree of impact, i.e. Non-compliance or Non-conformance and cause of the condition.
4.5.2.2 Cause of the reported condition shall be determined as accurately as possible during the initial reporting phase of the D.C.N. process, verified by the investi-gator, if required.
The Field QA/QC Manager or his designated representative shall enter a cause code, selected from the attached list, attachment #3, on the report form.
4.5.3 The Field QA/QC Manager or his designated representative shall indicate the documentation vehicle by which the condition is to be corrected by checking the appropriate block.
SF 1 01 A (4 79)
y : Pullman Powcr Products Es0-2 a DocuvENT NO,
! PREPARED BYt O' C NC APPROVED BY DATE, 7-27-79
'~
REV 3/31/81 J. Brasher #
I TO BE USED PAGE ONLY ON JOB 817177 NO.
4 of 12 4.5.3.1 tion-Conformance - DR #
A.
A no,tice issued by a Field QA/QC Inspector ex.-
plaining any deviation from custoner or code re-quirenents and docunenting corrective action.
Under no circumstances shall corrective action permit a deviation from code requirements.
D.
See ESO-240 for reporting requirements and pro-Cedures.
4.5.3.2 Repair Order (Attachment #4) i A.
Required when the reported condition, verified l
.by investigation and evaluation, necessitates l
repair to correct the condition and is not a non-
.conformance per ESO-240.
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8.
Reference to the. D.C.H. number shall be included ~
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C.
The D.C.fl. shall be a'ttached to the Repair Order j
and both docu9ents shall be routed to the Engi-j neering Department for issue of the required process sheet (s).
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D.
Upon completion of the required repair and final
- inspection the D.C.l!. shall be closed.
Rework /Retnsnect o der (Attachment #5)
.5.3.3 r
A.
Reoufred when the reported condItian. verifled
- ,,, g by investination and evaluation, necessitates s ..
Tqs gha further work to deternine the extent of the con-dition, i.e., filing 'an are strike, g' rind a weld crown, remove bolts for anchor check, etc.
B.
Reference to the D.C.fl. number shall be included on the Rework / Reinspect Order and required pro-cess s.heet(s).
C.
The D.C.fl. shall be attached to tt$e Rework /Re-inspect Order and both documents shall be routed to the Engineering Department for issue of the
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required process sheet (s).
D.
If Rework / Reinspection reveals the reported con-dition to be acceptable the D.C.?!. shall be closed.
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' Pullman Powcr Producto r
ESD-269 r
DOCUVENT NO.
PREPARED BY:
D. Ceske APPROVED DY: Mbe DATE: 7-27-79
-; REV. 3/31/81 J. Brasher //E TO BE USED PAGE ONLY ON JOB # 7177 NO, 5 of 12 E.
If Rework / Reinspection reveals the reported con-dition requires repair, the D.C.!!., with Rework /
Reinspect Order and process sheet (s) attached, shall be routed to the Field QA/QC !!anager or his designated representative for re-entry into the evaluation stage of the D.C.!!. process. See
. Paragraph 4.5 above. The Field QC Inspector shall attach a Hold Tag to the discrepant iten with reference to the D.C.fl. flumber.
4.5.3.4 Internal Audits (See ESD-263)
A.
!!ay be required when the reported condition, ver-ified by investigation and evaluation, identifies a condition which requires review of procedures, documentation, work processes, etc.
j B.
The D.C li. shall be attached to the Internal Aud-O itors documentation as the source and reference V
Docurrent. Cross-reference between the D.C.tl.
number and the audit geport shall be maintained.
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C.
Hold Tags shall be applied to all items of hard-D ware, if required.
D. ' Documentation of the audit findings shall close the D.C.fl. Corrective actions, if required, shall be controlled by the internal audit procedures.
4.5.3.5 All other condition which require corrective action, other than those indicated in paragraph 4.5.3.1 through 4.5.3.4 above, shall be documented as directed by the Field QA/QC flanager.
i 4.6 Af ter reviewing the Deficient Condition flotice and conducting an eval-uation the Field QA/QC Manager or his designated representative shall enter the Department and/or individual responsible for taking corree
- tive action. In addition, the date that corrective action is to be complete shall be entered.,
4.7 Steps to prevent recurrence shall be entered by the responsible su.
pervisor.
4.7.1 Development of the steps required to inprove the work process, work controls, documentation, procedures, etc., are the respon-sibility of the Department Supervisor. Changes to the esta-blished systen require Field QA/QC 'lanager review and approval.
t 1.
y Pullman Power Products eD-ass DOCUVENT No.
($ PREPARED BY n _ (%te, APPROVED BY Md ; -w DATE: 7-27-7S
- 4-30-80 REY. 3/31/81 J. Brasher,#C TO BE USED PAGE ONLY ON JOB # 7177 NO.
6 of 12
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4.7.2 Af ter steps to prevent recurrence have been entered the report shall be routed to the Field QA/QC itanager for approval.
The responsible supervisor shall implement the indicated steps Imediately, unless he is notified to the contrary by the F,ield QA/QC llanager. Signature by the Field QA/QC itanager indicates review and approval.
4.8 Upon completion of all work required to correct the reported condition I
the Field QA/QC flanager or his designated representative shall close
,.the Deficient Condition liotice by entering a signature and date.
.S 1 Furnish one copy. to each of the following as required.
- .t 4.8.1.1 Originator - May re-inspect the reported condition A
to assure corrective actions have been taken, hh 4.8.1.2 Field QA/QC Inspector 4.8.1.3 Field Engineer 4.8.1.4 Chief Engineer 5.0 DOCUIEllTATIO!1 C0tlTROL:
5.1 A log shall be established by the Field QA/QC llanager or his designated representative listing each Deficient Condition llotice received.
D.C.,il.'s shall be listed by originator's sequence number and will reflect corrective action required and date the D.C.fl. was closed, see attachment M.
5.2 The original copy of the Deficient Condition llotice shall be retained on file.in the QA Department.
30-80 5.3 WHen a Field QA/QC Inspector is terminated, then it becomes the Lead-man's responsibility to maintain the D.C.N. log of that Field QA/QC Inspector until all D.C.N.'s have been completed and signed off.
If the QA/QC Inspection Leadman terminates,then his D.C.N. log will be-come the responsibilty of the person assuming his position.
+30-80 5.4 All 0.C.N. logs that are completed and not active, will be filed in the closed out D.C.N. file of the same prefix number located in the Field QA/QC Office.
30 5.5 An inactive D.C.N. log will be returned to the original QA/QC inspector should he be reinstated.
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43 Pullman Powcr Producta.
I ES0-269 DOCUVENT NO.
h PREPARED BY't D. Ceske APPROVED BY: NA DATE: 7-27-7S m-; ;
h REV. 3/31/81 J. Brasher A TO BE USED PAGE ONLY ON JOB #7177 NO.
7 of 12 Few F-t 29 Ru.uAN PonEe Fkoeve.rs bEiCIENT ConDir[oH Norice.
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. my Pullman Powcr Prcducta y
ESD-263 DOCUMENT NO.
- $ PREPARED BYr D.'Cc5ke APPROVED BY: W J-
- h h REV. 3/31/81 J. Brasher #dc.
DATE, 7-27-7S TO BE USED PAGE ONLY ON JOB 87177 No.
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Attachment M2 e
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hg Pullman Powcr Prcducts.
ESD-269 r
DoctNENT NO.
h PREPARED BYr O. CCSkB.
APPRONED BY: h#
DATE: 7-27-79 t
E REV. 3/31/81 J. Brasher n I
TO BE USED PAGE ONLY ON JOB 8/177 NO.
9 of 12
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s CA'FI treti
- 1. Progt w Ocficiency e
2.
Itaterlal Defielency 3.
Individual Error 4 Dresing J
S.
Tools and Equienent 6.
Supervisory 7.
Envirorcental 8.
Other Attachment l'3 t
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Pullmcn Powcr Producta p
ESD-2tB 00CUMENT NO.
D. Ceske PREPARED BY APPROVED DY: M # --;;_
DATEt REV. 3/31/81 J. Brasher d k
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TO BE USED PAGE ONLY ON JOB 87177 NO.
13 of 12 Form F.81 TMt M.W. F.tLLC:C CtMP4 W Wit 0 FF P,*.8R_ (PDra
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0.0 DATE R.T.'t0 WLD Inks.
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CODE CLASS JOS #
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AREA ELEVA?l01 COLtMN Vt Lf,tt NYDRO O
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- 2. Ipotify Area Q.A.
Insp. Prior to starting ork.
Date Oy Date fy 3at e By
- 3. Add als erneeduceu to Proces; $8.ec t Date By Cate by hte _ _8y
- 4. Regvest R.T. of a
repair area.
Cate By Date ty 3 ate ty pst Revtast sire rea tar..u s Attach ent f4
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Pullman Power Products.
ES0-269 DOCV/ENT NO.
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h PREPARED BY, D. Ces'<e APPROVED BYr M e _- 4 DATE: 7-27-7E h REY. 3/31/81 J. Brasher ge:.
TO BE USED PAGE ONLY ON JOB #7177 NO.
11 of 12
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Pullman Powcr Products y
ESD 268 DOCUMENT NO.
f,f.,, f[/d'o! !f 7_p7_79 PREPARED BY: D. Geske APPROVED BY: ti, irampp REY.1-26-82 P. Schalvit:: #6 TO BE USED PAGE ONLY ON JOB
- 7177 NO.
12 of 12 PJLLMAkJ POMiR' PRODUCTS FORM F-131 D.C.M LOG c* * * " " "
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ATTACEMENT #6 SF 1.01A (4-79)
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-129 PULLMAN POBER PRODUCTS h
DETICIENT CONDITION NOTICE UNIT f AREA ELEV.
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FIE.D ENGINEER RECOMMENDED DISPOSITION:
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FIELD QA/QC MANAGERS EVALUATION:
AFFROVED AS RECOMMENDED OTHER 00.*"urNT3 CAusE CODE NON-CONFORMANCE - D.R.!
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REPAIR ORDER REWORK /REINSFECT 1
INTEFliAL AUDIT
] OTHER DATE FIELD CA/CC MANAGER CORRECTIVE ACTION REQUIRED BY:
NOT LATER THAN:
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APPROVED AS RECOMMENDED OTHER CAUSE CODE COMMENTS.
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F M 129 PULLMAN POWER PRODUCTS DEFICIENT CONDITION NOTICE UNIT i AREA ELEY.
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CAUSE CCDE l
NON-CONFORMANCE - D.R.!
REPAIR ORDER REWORK / REINSPECT INTERNAL AUDIT
] OTHER DATE FIELD QA/0C MANAGER CORRECTIVE ACTION REQUIRED BY:
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