ML20210H604

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Rev 1 to Procedure CPP-027, Reinsp/Documentation Review of Purchased Safety-Related Matl & Equipment
ML20210H604
Person / Time
Site: Comanche Peak  Luminant icon.png
Issue date: 10/16/1986
From: Zill R
EVALUATION RESEARCH CORP.
To:
Shared Package
ML20210F162 List:
References
CPP-027, CPP-27, NUDOCS 8702110450
Download: ML20210H604 (17)
v • d • e


Text

o i Pago 1 of 12 EVALUATION RESEARCH CORPORATION UNCONTROLLED COPY COMANCHE PEAK RESPONSE TEAM PROJECT PROCEDURE FOR QA/QC ISSUE-SPECIFIC ACTION PLAN VII.a.9 PROCEDURE NO: CPP-027 REVISION: 1 ISSUE DAIE: 10/16/86 REINSPECTION / DOCUMENTATION REVIEW OF PURCHASED SAFETY-RELATED MATERIAL AND EQUIPMENT l

i Prepared by: 4/// E jr Date: A9 9- 86 l Approved by: Dater /d' I8 i

On-Site QA Repre atlVe / '

Approved by: fu[ Date [O [ [8 Q Re' view Tead Leader '

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8702110450 870126 PDR ADOCK 05000445 A PDR

CPP-027 Revision: 1 1.0 PURPOSE This pricedure describes the development of the reinspection / documentation review checklists, the preparation and assembly of verification packages, and the performance of the equipment / material reinspections and/or documentation reviews required by Issue-Specific Action Plan VII.a.9.

2.0 APPLICABILITY This procedure is applicable to purchased safety-related equipment and material received and QC-accepted at Conanche Peak Steaa Electric Station, l'r.its 1, 2 and Common.

3.0 REFERENCES

3.1 ISAP VII.a.9, " Adequacy of Purchased Safety-Related Material and Equipment."

3.2 CPP-001, " Preparation of Project Procedures and Quality Instructions."

3.3 CPP-012 "QA/QC Intarface with Constructor and TUGCO."

3.4 CPP-004, " Project Working Files."

l 3.5 CPP-010. " Preparation of Deviation Reports."

l 3.6 CPP-016. " Safety Significance Evaluations of Deviation <

Reports." '

3.7 CPP-020, "Out-of-Scope Observations."

4.0 GENERAL Separate verification packages are prepared for each equipment and material iten selected for evaluation. The verification packages include a reinspection / documentation review checklist which

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identifies, the attributes and accept / reject criteria to be verified for each selected equipment / material item. The results of the reinspection /documeccation review are documented on these checklists. This procedura ensures that the results of each twinspection/ documentation review are documented, reviewed and approved. Furtheitmore, any item which deviates from the established acceptance citeria is uniquely identified and controlled.

4.1. Responsibilities 4.1.1 QOC Deputy Program Manager of External Source Issues The Deputy Program Manager of External Source Issues has the overall responsibility for the implementation O of the Category I specific CPSES construction QA/QC

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issues that have been identified by External Sources.

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CPP-027

, Revision: 1 4.1.2 ISAP Issue Coordinator The Issue Coord' i nator is responsible for the following:

Review and approval of verification packages .

Assignment of identification numbers to verification packages.

Review and validation of deviation reports '

and program deviation reports.

Interface with constructor and TUGCO.

Final acceptance of completed verification package. '

Control of verification package and accumulation of records. -

4.1.3 ISAP QA/QC Engineers The engineers are responsible for the following:

Preparation of the verification package for each item included in the evaluation.

Interface with QC Inspector to resolve problems and provide technical guidance.

Review of deviation reports and program deviation reports.

i Review of verification package for accuracy and completeness 4.1.4 QA/QC Inspection Supervisor The QA/QC Inspection Supervisor ensures that verification packages are assigned to qualified inspectors and reinspection / documentation results are reviewed, and returned to the ISAP Issue Coordinator.

4.1.5 QA/QC Discipline Level III Inspector The.QA/QC Discipline Level III Inspectors receive and assign verification packages. The Level III Inspectors review completed packages for accuracy, ce=pict ness, consistency and proper documentation of deviations, approve the completed package and document their transmittal in accordance with this procedure.

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CPP-027 -

. Rsvision: 1 4.1.6 QA/QC Inspector The inspector is responsible for performing the reinspection / documentation Review, and completing the 'l specific checklist attributes contained in each reinspection / documentation review verification package.

4.2 Policy Activities performed under this procedure shall conform to the -

policies contained in the CPRT Program Plan, ERC Management Program Plan, and Issue-Specific Action Plan VII.a.9.

The ISAP Issue Coordinator and the QA/QC Inspection Supervisor may perform all activities designated to an individual under his or her supervision. The only exception being those activities under the supervision of the QA/QC Inspection Supervisor that are required to be performed by an individual certified as defined in ISAP VII.a.9.

Should an activity be~ designated as the responsibility of the Issue Coordinator or QA/QC Inspection Supervisor it may be delegated by the Issue Coordinator or the QA/QC Inspection Supervisor to an individual under his or her supervision.

4.3 Conflicts In the case of a conflict between this procedure and the

! documents referenced in Section 4.2, the latter shall govern.

) 4.4 Definitions 4.4.1 Verification Package A group of documents including, as required, the verification package contents list, the applicable reinspection / documentation review checklist, implementing inspection instructions, drawings, l documents, etc. which have been collected to enable the

Inspector to perform and to document the reinspectien/ documentation review of a given ites.
4.4.2 Checklist A tabulation of attributes including accept / reject criteria to be used to document the reinspection / documentation review of a piece of equipment or material.

l 5.0 PROCEDURE l

l 5.1 Preparation of Reinspection and Documentation Review Checklists for Equipment and Material '

Reinspection and documentation review prepared checklists are O assembled by the ISAP QA/QC Engineer for each evaluation ites.

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t e CPP-027 Revision: 1 O 5.1.1 Responsible ISAP QA/QC Engineers will obtain from TUGC0 a copy of the applicable design specification and amendments in effect at the time of shipment from the

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vendors' facility as well as a copy of the applicable design drawings including all authorized change -

documents. Discussions will be held as required, with Texas Utilities Generating Company Project Support personnel to obtain information and/or interpretation of design and fabrication documentatica, and with the QOC QA/QC Reinspection personnel as to the feasibility '

of inspecting identified attributes. The purpose ~and results of these discussions will be documented and maintained as memoranda in the ISAP working files. The ISAP Issue Coordinator will review each memoranda and provide his concurrence by signature on the memoranda.

5.1.2 The ISAP QA/QC Engineer utilizing the above information will develop a checklist (Attachment 6.1) for the-

, attributes that require reinspection and/or l verification through documentation review.

In some cases a piece of equipment selected for reinspection will have multiple occurrences of an attribute such as electrical terminations, bolting, etc. In these cases the ISAP Issue Coordinator may elect to employ. statistical sampling in lieu of reinspection of each occurrence in a selected piece of equipment.

Statistical sampling when performed will be as defined in accordance with Appendix D of the CPRT Program Plan.

The ISAP Issus Coordinator will obtain the approval of the QOC Deputy Program Manager for each proposed use [

statistical sampling. l Those physical characteristics (attributes) defined in

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, the applicable design specification and/or TUGCO/ vendor

design drawings that are not included in the checklist will be identified, including the justification for exclusion (i.e., inaccessible, does not affect the equipment (s) ability to perform its intended safety function, etc.), on a memorandum. These memoranda will be signed by the ISAP QA/QC Engineer and approved by the ISAP Issue Coordinator and QOC Deputy Program Manager and maintained in the ISAP working file.

The ISAP QA/QC Engineer will also prepare any required implementation instructions (Attachment 6.2) to aid the QA/QC Inspector in the performance of the reinspection or documentation review.

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CPP-027

, Rsvision: 1

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5.1.3 After preparing the checklist and implementation O, instructions the ISAP QA/QC Engineer will prepare a memorandum to the ISAP Issue Coordinator including as attachments: -

The Reinspection Checklist, and any i implementing instruction. 6 A list of the source documents (including revision numbers) for each attribute -

included; and The memoranda written in accordance with

, 5.1.1 and 5.1.2 above.

4 NOTE: The documentation review of materials may include or be limited to on-site construction testing as the basis for determining material j . acceptability. If this is the case the ISAP '

QA/QC Engineer will document the following:

l basis of need to use the on-site testing as verification of the materials compliance with procurement / design requirements. -

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Explanation of the construction test (s),

including the parameters of the procurement design requirements specified, identification of the point in the construction process testing was performed, and a description of how discrepancies were identified, documented and resolved. '

The documentation review checklist attributes to be verified by the QA/QC inspector.

5.1.4 On receipt of the memorandum, the ISAP Issue Coordinator will review'the documents for accuracy, completeness and conformance with this procedure. The ISAP Issue Coordinator will review the checklist and exclusion memorandum to determine that the attributes selected for review will provide reasonable assurance that the physical characteristics of the equipment / material comply with the applicable design specification and TUGCO/ vendor design drawings. Upon satisfactory review the ISAP Issue Coordinator and the QOC Deputy Program Manager will sign the transmittal l memorandum, the checklist and implementing instruction.

, The original documents will be filed in the ISAP working file and copies of the checklist and -

implementing instruction (identified as " Verification Package Copy") will be returned to the ISAP QA/QC t

Engineer for inclusion in the verification package.

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CPP-027 l'

. Rsvision: 1 5.1.5 Changes to approved checklists and implementing instructions require the approval of the ISAP Issue Coordinator and the QOC Deputy Program Manager. The l changes shall be processed in the same manner described in paragraph 5.1.3 above. In addition the memoranda shall state the reason for change and what effect the change will have on the reinspection effort (i.e., Redo completed reinspection). If the reinspection checklist contains information previously entered by the QA/QC Inspector and this information is not affected by the -

revision, the information will be transferred to the new reinspection checklist.by the original QA/QC inspector and approved by the QA/QC Issue Engineer. If the original QA/QC Inspector is not available to make this transfer of information, the information will be transferred by the QOC Issue Coordinator and reviewed and approved by the QOC Deputy Program Manager.

l 5.3 Preparation of Material / Equipment Verification Packages Verification packages are prepared by the ISAP QA/QC Engineer for each evaluation ites.

5.3.1 The ISAP Issue Coordinator will establish a unique number for each material / equipment verification package. The verification number is determined as in the example below.

O I-M-VII a.9-0,01, Q -

A three (3) digit unique number The ISAP number Discipline

-Type of checklist Discipline: M = Mechanical E = Electrical S = Structural C = Civil W = Welding Type of Checklist:

I = Equipment D = Material O

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CPP-027 Revision: 1 g'^ The ISAP Issue Coordinator will maintain a log of i

verification packages numbers issued including revisions to the verification package. Revisions to

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the verification packages will be identified as in the example below.

I-M-VII.a.9-001-01.

A two (2) digit suffix indicating the number of the '

revision to the originally issued package.

5.3.2 The ISAP QA/QC Engineer assembles the Verification Package which includes a Verification Package Contents Form (Attachment 6.3) listing the documents needed to perform the reinspection and/or documentation review (see Attachment 6.3).

The verification package should include all documentation required to perform the reinspection / documentation reviews. If the documentation can not be included in the reinspection package, the ISAP QA/QC Engineer will identify the location of the document (s) in the Implementing Inspection Instruction.

5.3.3 The ISAP QA/QC Engineer obtains the documents necessary to be in the verification package, assembles the package and forwards the assembled verification package to ISAP Issue Coordinator for review.

i 5.3.4 The ISAP Issue Coordinator reviews the verification package for completeness and accuracy, and approves the package, if satisfactory, accepts the package by l signing the Verification Package Contents Form.

5.3.5 The ISAP Issue Coordinator transmits the approved Verification Packages to the QA/QC Inspection Supervisor. The ISAP Issue Coordinator documents the transmittal in a memorandum which specifies:

The Verification Package Number; The Unit designation; and The equipment tag / spin number.

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CPP-027 Revision: 1 l-5.4 Performance of Reinspections and Documentation Reviews 5.4.1 Upon-receipt of the Verification Package, the QA/QC Inspection Supervisor ensures that the verification packages are logged and then forwarded to the responsible QA/QC Discipline Level III Inspector. The QA/QC Discipline Level III Inspector confirms that any necessary equipment and/or services requested per '

Reference 3.3 have been provided and assigns the package to an QA/QC inspector. -

5.4.2 The responsible QA/QC inspectors perform the field reinspections and/or documentation reviews, using the checklists and implementing instructions in the verification package. i As required, the QA/QC inspector denotes the completion of the documents used to record the results of the reinspection / documentation review by signing and dating the forms included in the verification package.

The Inspector also completes the Verification Package Contents Form by entering the date he sr she completed the forms in the "DATE" column.

5.4.3 When inspection tools and measuring devices are used y for reinspection, the inspector (s) will do the following:

Use commercial, off-the-shelf tools and -

measuring devices, unless special tools or devices are specified by the ISAP QA/QC Engineer in the implementing instructions.

Ensure that if a specific degree of measurement accuracy is required by the I

checklist and/or implementing instruction, appropriate measuring devices are used.

Ensure that special measuring devices and devices whose indicated measurements are subject to change have received specified calibration.

NOTE: When such devices are used, the QA/QC Inspector will record in the remarka section of the checklist, the device serial number and the calibration due date.

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CPP-027 Revision: 1 N -

In some cases it may be necessary to verify s, an attribute by such methods as field s, surveys UT results, Hi-Pot /Meggar Test, etc.

which are provided by TUGCO. When such methods are used, the results are documented l

and included in the verification package as supportive evidence of the conclusions reached. i 5.4.4 Inspectors record the result of the reinspection and/or -

documentation review on the checklist. Based upon each ,

accept / reject criterion, the Inspector denotes the equipment / material acceptability by initialing the appropriate " Accept" or " Reject" column on the checklist and dating the annotation. When a condition on the equipment / material being evaluated is checked reject, the Inspector will initiate a Deviation Report (DR) in accordance with Reference 3.5, and will do the following:

Enter its number in the remarks column of the checklist.

File it in the verification package.

Enter the DR number and " Deviation Report" on

'( ) the Verification Package Contents Form, then initial and date the entry.

NOTE: Enter "NA" in the "DATE" column when the DR is superceded prior to being (in) validated by the second reviewer (see Reference 3.4) and indicate that it is " Superceded".

If in the course of performing a reinspection / documentation review where the applicability or accessibility of an attribute is questioned by the QA/QC Inspector, the QA/QC Inspector i will bring this question to the attention of the applicable QA/QC Issue Engineer. If the QA/QC Issue Engineer agrees that the attribute is not applicable or is inaccessible he will revise the checklist in accordance with paragraph 5.1.5 above. ,

l When the inspection / documentation review is completed, I the QA/QC Inspector will sign and date the " Inspected BY". block on the applicable checklist.

l The Inspector forwards the verification package with l the completed checklists to the QA/QC Discipline Level l

III Inspector for review and approval.

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CPP-027 -

Revision: 1 O 5.4.5 The QA/QC Discipline Level III Inspector reviews the verification package to ensure that reinspection / documentation review results are clear and

, complete.

Upon completion of each satisfactory review, the QA/QC Discipline Level III Inspector signs and dates the checklist in the appropriate block and forwards it to the responsible ISAP QA/QC Engineer via the QA/QC Inspection Supervisor.

The'QA/QC Discipline Level III Inspector documents the transmittal in a memorandum which includes:

Verification package number.

Inspector's initials.

Data the reinspection / documentation review was completed.

5.4.6 The ISAP QA/QC Engineer will review the verification package to ensure that the reinspection / documentation review was conducted in accordance with the checklist and implementing instructions. .

4 The ISAP QA/QC Engineer will evaluate each DR written

, against a verification package to determine which of

, the following are applicable:

The identified deviation was the result of an authorized modification (NCR, DCA, etc.) that was not identified at the time the verification package was prepared; or The identified deviation can reasonably be l attributed to on-site construction or testinF activities; or The deviation most likely existed at the time of receipt and was not detected and corrected l during manufacturing inspection, vendor surveillance, and receipt inspection.

The ISAP QA/QC Engineer will invalidate (in accordance with Reference 3.5) those DRs that identify deviations that were previously authorized. The DR including the justification for invalidation will be l submitted to the ISAP Issue Coordinator for approval.

The ISAP Issus Coordinator will indicate his approval of the invalidation by co-signing the appropriate block on the DR with the ISAP QA/QC Engineer.

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CPP-027 Revision: 1

'T . The QA/QC Issue Engineer will document those deviations determined to be the result of on-site construction or testing as "Out of Scope" (in accordance with Eeference 3.5). The ISAP Issue Coordinator will indicate his approval by co-signing the appropriate block on the DR with the ISAP QA/QC Engineer.

The ISAP QA/QC Engineer will process the remaining DRs in accordance with Reference 3.5 and indicate the date

  • the DR was (in) validated in the "Date" column of the Verification Package Content Form. , ,

5.4.7 Upon completion of each satisfactory review, the ISAP QA/QC Engineer initials and dates the " Accepted by" block on the Verification Package Contents form and forwards the completed verification package to-the ISAP Issue Coordinator. The ISAP Issue Coordinator indicates his acceptance of tha verification package by signing and dating the " Accepted by" block on the Verification Package Contents form.

6.0 ATTACHMENTS 6.1 Checklist (Sample) 6.2 Implementing Inspection Instructions (Sample and Instructions) '

6.3 - Verification Package Contents Form (Sample)

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Attachmsnt 6.1 CPP-027 Revision: 1 Page 1 of 2 CHECKLIST Comanche Peak Response Team - .

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Documentation Review Checklist Comenon Equipment / Tag No. Venficatsen Pkg. fee.

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Attachment 6.2 CPP-027 Revision: 1 Page 1 of 2 IMPLEMENTING INSPECTION INSTRUCTIONS FORM i Comanche Peak Response Team implementing inspection instructions venfiution Phg. No. EqWpment / Tag n (7) (7)

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, ,Attachtsnt 6.2 CPP-027 Revision: 1 0 -

INSTRUCTIONS FOR COMPLETING CPP-027.2

" IMPLEMENTING INSPECTION INSTRUCTION" ISAP QA/QC Engineer (1) Enter. Verification Package number. -

, , (2) Enter equipment mark / tag number.

(3) Enter the applicable attribute number.

(4) Enter the information. As required, indicate where the l

reinspection / documentation review results associated with the

! Implementing Inspection Instruction are to be entered on the .

! checklist.

(5) Reference any source documents.

(6) Provide a list of any documents needed to perform the reinspection or document review required by each Inspection Instruction, and indicate their location, i.e., attached or available at ....

(7) Enter page number and total of pages in this instruction.

(8) Enter signature and date.

Issue Coordinator After ensuring that the Instruction is necessary, completa, clearly understandable, and consistent with this procedure, the Issue Coordinator enters:

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(9) Signature and date.

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.. Attachmint 6.3 CPP-027 Revision: 1 Page 1 of 1 VERIFICATION PACKAGE CONTENTS FORM f Comanche Peak Response Team -

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