ML20211K062
| ML20211K062 | |
| Person / Time | |
|---|---|
| Site: | Comanche Peak  |
| Issue date: | 04/18/1984 |
| From: | BROWN & ROOT, INC. (SUBS. OF HALLIBURTON CO.) |
| To: | |
| Shared Package | |
| ML20211J491 | List:
|
| References | |
| FOIA-85-59 CP-QAP-11.1, NUDOCS 8606270139 | |
| Download: ML20211K062 (60) | |
Text
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NOTE: Major re-writs, no chings bars.
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NUMBER REVISION PAGE
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APR 181984 1 of, is TI g.
ORIGINATOR:
FABRICATION AND INSTALLATION REVIEWED BY:.
3_po W 0 ATE OR kND NG APPROVED BY:
O sit er m um a.
1.0 REFERENCES
2.0 GENERAL FOR INFORMATl0N ORY 2.1 PURPOSE This procedure delineates the responsibilities and general requirements for Quality Control (QC) inspection / surveillance
.of Nuclear Safety Class 1, 2 and 3 activities affecting quality.
The requirements contained herein are stipulated to ensure that QC inspection activities are accomplished and documented in accordance with applicable project design documents, codes, standards, regulatory requirements, and the B&R QA Manual.
1 2.2 SCOPE The requirenents delineated herein or in subordinate instructions apply to quality activities performed by B&R at CPSES.
Procedures / instructions issued by depa rtments other than the Quality Assurance (QA)/QC Department shall not 'be used to impose constraints or requirements upon QC surveillance / inspection activities.
Similarly, all QA/QC procedures / instructions shall delineate only QC surveillance / inspection criteria and/or attributes to be used while perfonning surveillance or inspection.
2.3.
RESPONSIBILITY j
The Site QA Manager is responsible for all Safety Class 1, 2 and 3 inspection and surveillance activities. He is also
'l responsible for ensuring adequate procedures and instructions
- {
are available for the performance of activities affecting j,
quali ty.
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ISSUE
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CPSES NUMBER REVISION DATE PAGE JOB 35-1195 CP-QAP-11.1 4
2 of 16 g ig g 2.4 HOLD POINTS Hold points.are defined as any operation in the production process that requires QA/QC/ANI inspection release before further processing. Hold point acceptance is indicated on the appropriate process control document.
Operational Traveler (OT)' hold points shall be assigned by Quality Assurance (QA) as deemed necessary to assure that the quality of the item being installed is in compliance 7
. with applicable requirements.
Hold points designations are as follows:
'[
a.
Monitor (M) - conformance verification by physically observing a task being.perfomed on a periodic or random basis.
The inspector must be notifed prior to
-]
implementing work activities.
b.
Verify (V) - conformance verification by physically inspecting an iten after perfomance of an operation, does not require physical observation of the work being perfomed; or, by reviewing objective evidence attesting to the fact that the operation was performed and satisfactorily.comple ted.
The inspector shall be notified subsequent to the performance of an operation.
c.
Witness (W)~ - confomance verification by physically observing the entire operation being performed.
The inspector shall be notified prior to commencenent of work.
2.5 TRAINING AND CERTIFICATION Personnel perfonning inspection and surveillance of activities affecting quality shall be trained and certified in acconiance with CP-QAP-2.1.
3.0 PROCEDURE l
3.1 QC INSPECTION / SURVEILLANCE INSTRUCTION PREPARATION QE, as directed by the Site QA Manager, shall review applicable specifications, drawings and procedures. They shall prepare quality documents that delineate adequate, concise attributes, actions and acceptance criteria for accomplishing inspection activities.
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ISSUE CPSES NUMBER REVISION DATE
.PAGE J08 35-1195 ygh 3 of 16 CP-QAP-11.1 4
3.2 PERFORMANCE OF INSPECTION /SURVEIll.ANCE Inspections and surveillance of activities affecting quality shall be accanplished in acconiance with applicable Qualit;y Procedures, and subordinate instructions.
3.2.1 Inspection Reports Inspection Reports will be generated and controlled in accordance with Attachment 1.
s 3.2.2 Repair of Base / Weld Metal Defects Evaluation and repair of base metal damage and arc strike removal shall be perfonned in accordance with Attachment 2.
3.3 DOCUMENTATION QC inspections /surveillances shall be doctsnented and dispostioned as delineated in applicable procedures and instructions.
3.4 REPORTING 0F DEFICIENCIES /NONCONFORMANCES Deficiencies /nonconfonnances shall be reported and doctanented in accordance with the requirements described in Attachment 1.
3.5 CORRECTIVE ACTION l
Corrective action, when required, shall be initiated and documented in accordance with CP-QAP-17.1.
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ISSUE CPSES NUMBER REVISION DATE PAGE J08.35-1195 APR 181CJ844 of.16 CP-QAP-11.1 4
ATTACHMENT 1 REPORTING DEFICIENCIES /N0NCONFORMANCES 1.0 GENERAL The purpose of the Inspection Report (IR, Figure 1) is to establish a method of documentin.g field inspections performed by QC personnel.
NOTE:
IR's shall not be used to docuent any deficiency
~
related to an N stamped component, or any deficiency defined after final QC acceptance as defined in Paragraph 2.3.2 of this Attachment.
2.0 PROCEDURE
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2.1 PREPARATION /USE, The IR shall completely and accurately describe the item or activity observed.
Questions regarding inspection characteristics should be directed to the QC Lead /QC Supervisor.
o 2.2 NUMBERING Satisfactory inspections reported on an IR do not require a log number.
The QCI shall enter sufficient applicable identification on the IR to maintain traceability to the item being inspected and N/A the IR log number space.
When completed, the IR shall become part of the item's documentation package.
QC Systems (Clerical) shall preassign Inspection Report numbers, for unsatisfactory inspection reports, to the QC Report Log (Figure 2)p shall in turn maintain an Inspection Groups.
Each QC Grou to prevent duplication of nebers and provide traceability.
The Quality Control Inspector (QCI) shall obtain the serial number for an "Unsat" IR from the QC Lead.
Prior to ' assigning the "Unsat" IR number the QC Lead
,l' shall review the "Unsat" IR and obtain pertinent information l[
from the "Unsat" IR to complete the necessary entries on the j;
IR Log.
QC Lead shall assign the applicable deficiency j'
trend code (See Figure 3) to the Unsat IR and log the trend j
. code in the a
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S,ROWN & ROOT, INC.
ISSUE CPSES NUMBER REVISION DATE PAGE JOB 35-1195 CP-QAP-11.1 4
APR 181984 5 of 16 ATTACHMENT 1 (Continued) comments section of the IR Log. "Unsat" Inspection Reports shall be nunbered as follows:
EXAMPLE: AM - 00001
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ECHANICAL ASME g
2.3 REPORTING DEFICIENCIES 2.3.1 '
In-Process Deficiencies If a deficiency is observed during in-process inspection, the QCI shall "unsat" the " Hold Point" on the appropriate process control documentation, enter the "Unsat" IR number and sign and date the entry.
The original "Unsat" Inspection Report describing the nature of the deficiency shall be returned to the organization responsible for resolving the deficiency. The copy shall be retained by the QC Lead until the satisfactory resolution of the IR has been completed.
An "Unsat" IR shall automatically generate an appropriate inspection " Hold Point" on the process control document (s) issued by the responible organization used to correct the deficiency.
When the deficient item (s) are found satisfactory, the QCIk shall close the previously generated "Unsat" IR and sign-off I the process control documentation.
The closed IR shall be retained with the process control documentation. QCI shall 1
infonn the Lead of the closed status of the IR to update the )
IR Log.
NOTE:
Except as defined in Paragraph 2.3.2 of this Attachment, any deficiency may be documented on an "Uns a t" IR.
When intergrated Task groups are established to complete an activity, the QCI shall return any package with an "Unsa t" IR to the responsible QC Lead /QE, who shall route the package to the organization responsible for resolving the problem.
I 2.3.2 Nonconformances When a deficiency which cannot be resolved by an "Unsat" IR
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BROWN & ROOT, INC.
ISSUE CPSES NUMBER REVISION DATE PAGE JOB 35-1195 APR 18198k 6 of 16 CP-QAP-11.1 4
ATTACIDENT 1 (con't)
)
or any deficiency related to an N-Stamped Camponent, or any i
deficiency which is identified after final acceptance of piping systen or support in accordance with CP-QAP-12.1 (i.e., Hydro Release or VCD/DRD walkdown including document review), shall be reported on an NCR in accordance with CP-QAP-16.1.
When an NCR is issued against an "Unsat" IR, the QCI shall enter the NCR nisnber on the "Unsat" IR. The "Unsat" IR with the NCR number referenced on it, shall be closed by the QCI.
2.4 "U.NSAT" INSPECTION REPORT CLOSEOUT An "Unsat" IR shall be closed by the QCI when one of the following is accomplished:
a.
All UNSAT itens have been reinspected and found SAT, or b.
An NCR has been issued for UNSAT items in accordance with CP-QAP-16.1, After closeout of the "Unsat" IR, the responsible QC Lead /
Supervisor shall update the Inspection Report Log.
2.5 UNSAT INSPECTION REPORT TREND ANALYSIS.
e 1
At the end of each quarter, the responsible QC Lead shall send a copy of the completed IR Log to QE for Trend Analysis, i
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ISSUE CPSES NUMBER REVISION DATE PAGE JOB 35-1195 CP-QAP-11.1 4
g gjgg4 7 of,16 j ATTACHMENT, 1(continued)
FIGURE 1
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l COMANCHE PEAK STEAM ELECTRIC STATION asserr as INSPECTION REPORT lNo.
TTEM ON 10ENTFICAT10N NO.
5Y5TEner5TRUCTufE DESIGNATION a
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segP. MguLTS Q INSPGCTION ColdPLETED. ALL APPUCAALE ITBAS SAT 1SPACTORY Oc essPEcTon oAra Q 6 CX39tETW3, LpeSATWACTORY 1795 LISTED MLOW
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ISSUE CPSES NUMBER REVISION DATE PAGE JOB 35-1195 ygh 8 of 16 CP-QAP-11.1 4
i ATTACHMENT 1 (Continued)
FIGURE 1 (Continued)
Block 1:
Enter IR Number only for unsatisfactory inspection.
N/A for satisfactory inspections.
Blocks 2 &3:
Record sufficient infonnation to uniquely identify the item or activity observed.
Block 4:
Record the system and/or structure designation g
sufficient to specifically locate the item.
Blocks'5 & 6: Record the governing specification number and revision.
Block 7; Record the Quality procedure and/or instruction and revision number.
Block 8:
Record the M&TE nunber(s) of the calibrated instrument used to verify an inspection attribute and the calibration due date.
Block 9:
Check the type of inspection perfonned.
Block 10:
Check the appropriate block and sign and date in the space provided.
Blocks 11 & 12: Describe the characteristics to be observed.
(A characteristic is a property which can be appraised in tenns of whether it does or does not exist.)
Block 13:
Sign and date this block after satisfactory correction of. the "UNSAT" characteristic. Do not use this block for
" SAT" characteristic.
Block 14:
Reference all applicable docunentation such as drawing numbers, specification, DCA's, CMC's, etc.
Block 15:
Record all applicable NCR nunber(s), if applicable.
d Block 16:
Upon satisfactory completion of unsatisfactory characteristic (s), check the "IR Closed" block, sign and date the report.
Do not use this block if all the attributes are " SAT".
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ISSUE CPSES:
NUMBER REVISION DATE PAGE JOB 35-1195 APR 181984 9 of 16 CP-QAP-11.1 4
1 l
ATTACHMENT 1(Continued)
FIGURE 2 s
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ISSUE l
CPSES NUMBER REVISION DATE PAGE JOB 35-1195 CP-QAP-11.1 4
APR 18 t984 10 of 16 i
ATTACHMENT 1 (Continued)
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FIGURE 3 IR DEFICIENCY TREND CATEGORIES A - Valves B - Bulk Material C - Compeaent Supports a.
D - Piping r
E - Equipment F - Flange / Mech. Joints G - Sway Struts / Snubbers j
H - Tanks / Vessels i
I - General / Miscellaneous i
NUMBER IDENTIFIER 1.
Shipping Damage l
2.
Incomplete / Incorrect Vendor Documentation 3.
Handling / Storage 4.
Maintenance / House Keeping 5.
DWG/ CMC (Incomplete / Incorrect) 6.
. Documentation (Incomplete / Incorrect) 7.
Procedure / Specification Violation 8.
Hold Point Violation 9.
Material Traceability s
10.
Material (Damage / Incorrect) 11.
Fabrication (Incomplete / Incorrect) 12.
Installation (Incomplete / Incorrect) 13.
Alignment (Equip./ Piping, Etc.)
14.
Malfunction (Equip./ Valves, Etc.)
15.
Cleanliness / Contamination 16.
Welding 17.
Welding Procedure 18.
Welder Qualification 19.
Weld Filler Material
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20.
NDE (Results/ Methods) 21.
Arc Strikes, Base Metal Defects, Min. Wall Violation
'I 22.
Heat Treatment 23.
Hydro / Pneumatic Testing i
j 24.
Coating / Painting & Insulation 25.
Mishandling 26.
Construction Fabrication / Installation - Damage 27.
Calibration / Instrumentation 28.
Inspection Surveillance 29.
Miscellaneous 30.
Generic i
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ISSUE CPSES NUMBER REVISION DATE PAGE JOB 35-1195 CP-QAP-11.1 4
APR 181984 111'of16 l
ATTACHMENTl 2 _.
1.0 BASE METAL DAMAGE AND ARC STRIKE REPAIR ON THE BASE METAL -
1.1
. REPAIR OF ARC STRIKES AND BASE ETAL DAMAGE ON ASME CODE CLASS 1 (NB) PIPING a.
Arc strikes on ASME code class 1 itens shall be removed by grinding or buffing.
The ground area shall. be blended uniformly into the surrounding area and shall be examined by PT or MT.
Pipe wall thickness shall be 6
checked after grinding or blending to assure that I
minimum wall thickness requirements have not been violated, per Table 1.
b.
Mechanical marks, abrasions or other surface defects 3
including cable marks, tool' marks or pits, deeper than 1/16 inch, shall be removed by grinding and blending followed by PT or MT to assure removal of the defect.
I Also, surface defect no deeper than 1/16 inch if of abrubt nature and becomes a stress riser, shall be removed by grinding and blending followed by PT or MT to assure removal of the defect. The defect area shall be minimum wall thickness examined to assure that the i
requirements, per Table 1,
have not been violated.
{
NOTE:
Surface defects no deeper than 1/16 inch need not be removed if the defect is unifomly blended into the surrounding area and does not encroach on minimum wall.
1.2 REPAIR OF ARC STRIKES AND BASE ETAL DAMAGE ON ASME CODE CLASS 2,(NC) AND CLASS 3 (NO) PIPING I
a.
Arc strikes on P-1 Carbon Steel shall be vi sually inspected for linear indications such as cracks or unacceptable undercuts or crater.
(Surface may require preparation by filing or application of abrasive paper to provide a surface suitable for visual inspection.)
If linear indications are found, they should be lightly ground and blended then visually inspt eted and followed by a minimum wall thickness examination to assure that t
the requirements per Table 1 for class 2 and 3 piping have not been violated.
Arc strikes on all steel.
other than P-1, shall be removed by grinding and visually inspected to assure that it has been removed.
After grinding and blending, wall thickness shall be l
checked to assure the minimum wall.
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ISSUE CPSES NUMBER REVISION DATE PAGE JOB 35-1195 CP-QAP-11.1 4
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ATTACHMENT 2 (Continued) i; b.
Mechanical marks, abrasions or other surface defects including cable marks, tool marks, or pits, deeper than 1/16 inch, shall be removed by grinding and blending followed by a visual inspection. Also, surface defect no deeper than 1/16 inch.if of abrubt nature and becomes a stress riser, shall be removed by grinding and blending followed by a visual inspection.
The defect 2
area shall then be minimum wall thickness examined to g
assure that the requirements per Table 1 for class 2 and 3 piping have not been violated.
NOTE:
Surface defects no deeper than 1/16 inch need not be reoved if the defect is unifomly blended into the surrounding area and does not encroach on minimum wall.
l 1.3 REPAIR OF ARC STRIKES AND BASE METAL DAMAGE ON NF Ct. ASS 1 HANGERS 1.3.1 NF Class 1 Hangers
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a.
Arc strike on Class 1 items shall be reoved by grinding and ground area shall be examined by VT.
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i The grinding and detennination of possible weld repair shall be in accordance with Table 2.
a b.
Mechanical narks, abrasions, cable marks, tool marks J
or pits shall be removed by grinding if it violates section minimum wall and ground area shall be examined by VT.
Detennination of possible weld repair shall be.in accordance with Table 2.
1.3.2 NF Class 2 and 3 Hangers a.
Arc strike on P-1 carton steel shall be vi sually inspected for linear indications such as cracks or unacceptable undercuts or crater. (Surface may require H
preparation by filing or application of abrasive paper 1
to provide a surface suitable for visual inspection.)
d If linear indications are found the arc strike shall be l]l removed by grinding and area shall be visually examined.
Deterurination of possible weld repair shall be in accordance with Table 2.
Arc strike on all other steel (i.e., other than P-1) shall be removed by grinding and vi sually examined.
Determination of possible weld repair shall be in accordance with Table 2.
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ISSUE CPSES NUMBER REVISION DATE PAGE JOB 35-1195 i 13 of 16 CP-QAP-11.1
'4 APR 181984 l
ATTACHMENT 2 (con't) b.
Mechanical narks, abrasion or other surface defects l
including cable marks, tool marks or pits may be removed,by grinding if it violates section minimum l
wall thickness per Table 2.
The defect may be removed i
by grinding and visually examined.
Detennination of possible weld repair shall be in accordance with Table 2.
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ISSUE CPSES NUMBER REVISION DATE PAGE JOB 35-1195 APR 181984 I
CP-QAP-ll.1 4
14 of 16
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fATTACHMENT'2 (con't)~
, { TABI.E_ #1 Minf== Acceptable Wall Thickness,. _.-..._. -
for piping PIPE 0.D.
SG.
SG.
SG.
SG.
SG.
STD.
SG.
SIZE INGES 55 105 10 20 30 40 1/8 I
.405
.043
.043 l
.060 060 1/4 !
.540
.057
.057
.077
.077 3/8 l
'.675
.080
'080 i
.057
.057 1/2
.840
.057
.073
.073
.095
.095 3/4 1.050
.057
.073
.073
.099
.099 g
1 1.315
'.057
.095
.095
.116
'.116 Ik 1.660
.057
.095
.095
.122
.122 14 l
1.9
.057
.095
.095
.127
.127 2
l 2.375
.057'
.095
.095 i'
.135
.135 l
24
! 2.875
.073
.105
.105
.178
.178 3
l 3.5
.073
.105
.105
.189
.189 34 I
4.0
.073
.105
. 105
.198
.198
.207
.207 4
4.5
.073
.105
.105 4
5 5.563
.095
.116 116 h
.226
.226 6
6.625
.095
.116 116
.245
.245 I
. 8 8.625
.095
.130 130
.21'
.242
.282
.282 10 10.750
.116
.145 145
.219
.269
.319
.319 12 l 12.750
.136
.158 158
.219
.289
.328
.355 14 l14.00
.136
.164 219
.273
.328
.328
.383 16 16.00
.145
.164 219
.273 328,
.328
.438 18 18.00
.145
.164 219
.273
.383
.328
.492 20 20.00
.164
.191 l.219
.328 438
.328 l.519 22 22.00
.164
.191 l.273
.328 438
.328
.519 24 l 24.00
.191
.219 l.273
.328 l
492
.328
.601 26 26.00 l
l l.273
.438 i.328 l-l 28 I 28.00 l
.273
.438
.547
.328
- 3 30 l 30.00
.215
.273 273
.438 547
.328 32 l32.00 273
.438 l
547
.328
,.601
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l 34
!34.00 l
l.273 l
438 l
547 l.328 l.601 36 l 36.00 l
273 l.438 l
547
!.328
!.656 if 42 l42.00 l
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l.328 l-CCN TO.
NOTE: Use only for pipe specified by nominal wall thickness.
Do not use for pipe specified by minimum wall thickness, Specification defines minimum acceptable wall thickness.
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ISSUE CMES NUMBER REVISION DATE PAGE CP-QAP-11.1 4
15 of 16 h
ATTACIGiENT 2 (con't)
/TABUU#1Contd.
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i Minimum Acceptable Wall Thickness for piping.
P1PE SG.
EXT.
SG.
SG.
SG.
SG.
SG.
XX.
l SIZE 60 STRONG 80 100 120 140 160 STRONG 1/8
.083
.083 f
I l
1/4 l
.104
.104 l
l 3/8
.110
.110 l
l 1/2
- l. -
.129
.129
.164
.257 l
.191
.270 l
3/4
.135
.135 1
.157
.157
.219
.313
. l ik
.167
.167
.219
.334
.175
.175 l
1h
.246
.350 e
i 2
.191
.191
.300
.382 2
l
.242
.242 l
.328 483 3
l
.262
.262 l
.383
.525 l
.557 34
.278
.278 1
4
.246
.295
.295
.383 465 r.590
.328 l
.328 5
.438
.547
.656
- 6
.629
.756 l
.378
.378
.492 8
.355 438
.438
.519
.629
.710 l
.793
.766 10 438
.438
.519
.629
.738 I
.875 l
.984 12 l
.492
.438
.601
.738
.875
.984 l 1.148 l
14 l
.519
.438
.656
.820
.956 J 1.094 1.230 16 l
.573 438
.738
.902 1.066 1.258 1.393 e
18
.656
.438
.820 1.012 1.203 1.367 1.558 l
20
.710
.438
.902 1.121 1.312 1.531 l 1.722 I
22 l
.766 l
.438
.984 1.203 1.422 1.641 l 1.86 l
24
.847
.438 1.066 1.340 1.586 1.804
! 2.050 l
26 l
.438 l
I
- 1 28 l
.438 l
l I
30 I
.438 l
- j 32 I
.438 I
1 j
34 I
I
.438 l
1 I
I 36. -. !._
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.438 l
l l
l 42 l
l 438 l
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ISSUE
+
CPSES NUMBER REVISION DATE PAGE 0B 35-W 5 g ygg
' ! 16 of 16 CP-QAP-11.1 4
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ATTACHMENT 2 (con't) t TABLE 2 Arc strikes and base metal defects on NF component supports may be repaired without weld build up provided the following conditions are met:
A.
The damaged / defect area ground is well faired without abrupt changes in contour and shows no visual indication of being previously repaired.
g B.
The depression produced by grinding does not exceed an area 2 inches in diameter.
C.
The depth of the depression produced by grinding does not exceed the following:
a.
Structural Shapes 1.
1/32 inch for naterial less than 3/8 inch in thickness.
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2.
1/16 inch for 3/8 to 2 inches inclusive in thickness.
3.
1/8 inch for naterial over 2 inches in thickness.
j; b.
Tube Steel 1.
10% of the nominal wall thickness.
c.'
Plate 1.
7% of the nominal plate thickness up to a maximum of 1/8 inch.
If the above requirements cannot be met, the damaged /
defected area shall be repaired by welding and grinding i
unless otherwise approved by engineering.
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Quality Assurance Department NCR NO. M 139 5 Z-a QA RECORD
-uconformance Report (NCR)
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DATEa CPSES-35-1195 PAGE I
0F
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l DRAWING / IDENTIFICATION (REV)
TAG /ID NUMBER LOCATI.ON OR ELEVA RIR NO.
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DISPOSITION:
t A-REWORK B-REPAIR C-USE AS IS YY D-SCRAP E-RETURN TO VENDOR 1
i Final Dim rev is merely a key for the inspector in the field to make him
' aware that he is'to verify the BRP per the latest rev.
If at any time this box is not filled out a person;cou d check date on BRP versus the date j
Thiswouldassurean-}g j
QCI inspected.
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rev to which the inspector accepted this in fiel fore, i is s tion, it y
I is acceptable not: po have a rev in the block.
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1 1 DATE:
TUGC0 QA REVIEW / APPROVAL:
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ATTACIDENT A CP-SAP-16 s.
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1 Revision 8
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TEST DEFICIENCY REPORT Page 8 of 8
. 4 se Startup Sys No.
Component Tag No.
'TDR' No. ' '
Page t o'f f
1701 C pt H0 AMP-er /c 2 0%0 De ciency Identified during:
If during test, est.
Operation Other (Circle One)
Test No: ICA AT-fszI Deficiency
Description:
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If NO: CP-SAP-5 Auth. No.
@/ NO (Circle.One)
STA-605 Clearance No.
Engineering Evaluation required to determine Corrective Action:,@ NO (Circle One)
Ref. Correspondence for Engineering Eval: pf [////g
- ~~~~DeficiFndy Reportedly:Qy[{1g Date: g/gg Corrective Action:
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Corrective Action Approved By:
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Required Retast Approved By:
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Corrective Action Complaced:
Date:
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Date:
Distribution: Original to Log TUCCO QA Startup/ Turnover Surveillance Supervisor MSP Group TUSI Engineering Mgr.
Initiator Operations Support Engineer 1
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..s -s suss TEXAS UTHJTIES GENERATING COMPANY OFFICEMEMORANDUM T.-
M.~R.' McBay
.gamm asas.T-May 24.'1984 TDR 2768 Please evaluate the subject TDR and provide the appropriate correction action.
Notify TUGC0 Startup of your findings at your earliest convenience.
[
U T. P. Miller
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TPM/gr t.iAY 20 n24 cc:
A. C. Lilly J. E. Wooten
, Ie:as Utilities GS. 3 3.ir.5 03-(78[3 (f.$.18,3NIsi b5V-
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.g st-84458 TEXAS UTILITIES GENERATING COMPANY OFFICEMEMORANDUM M. R. McBay Glen Rose. Texas May 24, 1984 l
To TDR 2768 Please evaluate the subject TDR and provide the appropriate correction action.
Notify TUGC0 Startup of your findings at your earliest convenience.
cA'rit2/w T. P. Miller TPM/gr cc:
A. C. Lilly J. E. Wooten l
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TXX-4180 g) -
5/25/84 l
N Allegation No. 24
,j It has been alleged that there is constant pressure, by craft and management,'on QA/QC inspectors not to write non-conformance reports.
Evaluation of Validity' This allegation.is not valid.
The procedures' governing initiation and
~
processing of Nonconformance Reports have been established to preclude anyone (including management or supervisors) from stopping an inspector from initiating a Nonconformance Report if in his judgment, such a report is warranted. The inspector has ooly to call a clerk to obtain an NCR number,, and the report 'must then be entered into the system and resolved.
CPSES also uses other methods to document ' conditions not in compliance with specified requirements, specifically. Inspection Reports or in the case of electrical separation or some final. inspections, Deficiency Reports (listing of work items required to be completed to achieve conformance with specified requirements).
The basic difference between i
I the use of these documents and a Nonconformance Report is that t'hese latter documents do not routinely involve the use of " Hold Tags." If items identified in this manner canhbt be made to conform to requirements, a Nonconformance Report wiIl be issued and the matter y
resolved per established procedures.
3 Additionally, there have been a series of 01 investigations within the past year relative to this same subject and none of these investigations has indicated a practice similar to the allegation.
There has never been any pressure on QA/QC inspectors not to report nonconforming conditions in the manner and on the proper form prescribed by procedures.
Nonconforming conditions may be reported and documented on Nonconformance Reports, Inspection Reports, and Deficiency Reports.
There have been instances when QC inspectors have l $.,
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i, been reminded by QC management of the need to comply fully with procedures, including the need for inspectors to report nonconforming conditions on 'the appropriate form.
There hav'e been instances when inspectors have been instructed to report nonconforming conditions on Inspection Reports, and not on Nonconformance Reports, because the procedure provided for the use of Inspection Reports. These instances were motivated by management's desire to assure that reporting requirements are met, and certainly not by any desire to have nonconforming conditions go unreported.
Relative to alieged craft pressure. QC Inspectors are totally independent of the construction (craft) organization. Thus, " pressure" cannot be provided.
It is possible however, to have exchanges of feelings from time to time between craft and QC, and all levels of TUGC0 and Brown and Root management have demonstrated that such exchanges are controlled.. The best example of this control can be seen through a review of Section VII of the CAT report for CPSES.
i Safety Significance None
~~
Generic Implications'of Other Systems or Contractors Not applicable l
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POST CONSTRUCTION VERIFICATION DEFICIENCY REPORTS
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hP-16,193 i TEXAS UTILITIES SERVICES INC.
OFFICE MEMORANDUM To C. K. Moahlmsm ca.a no T
May 30. 1984 i
subj et CWANGE PEAK STEAM Fm'rRIC STATION 00RRECIIVE ACTION FOR TDR 2768 REF:
SU-84458 The referenced correspondence is attached for your use. 'IUGC0 has requested our assist:mce in evaluating and specifying corrective action for the identified TDR. CPPE is expected to provide all assistance nece'ssary to respond quickly. In addition, your review should iel ua an evaluation to detennine if this itan is reportable t
per 10CFR50.55(e).
We would like to forward our response to Start-Up no later than June 13, 1984 Please advise if this response date is not attainable. Your response should be forwarded to R. E. Camp via CPPA.
L. M. Poppfewen Project Engineering Manager WP/RPB/cp e
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CPPA-39,344' l
TEXAS UTILITIES GENERATING COMPANY OFFICE MEMOR ANDUM
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To R.E. Camo cien the Texa. June 7. 1984 subject COMANCHE PEAK STEAM ELECTRIC STATION TDR-2768 In reference to the two (2) deficiencies reported:
- 1) Condensate only overpowers the Heater Drain Pumps because the additional PSIA from the Extraction Steam from the H.P. Turbine is not present during cold testing. At approximately 25% Turbine Generator load one Heater Drain Pump will be brought into service.
At this time there is approximately 48 PSIA Extraction Steam from the H.P. Turbine in addition to the PSIA resulting from the difference in elevations of the equipment. The Condensate Pumps would be over-powered assuring minimum flow rate. The second pump is put into service at approximately 50% rated ' power. At this time the Extraction Steam PSIA is increased further and achieving minimum flow rate is 4
not a problem.
- 2) Minimum recirculation is required when flow falls to 1400 GPM or less. Both pumps do not operate until 50% rated power is reached.
At no time will a recirculation mode occur with both pumps running simultaneously and valve ILV-2592 closed. Testing has proved, suf-ficient minimum recirculation has been obtained with one pump oper -
ating.
In sumary it should be noted that these problems will not exist during normal operation. However, operations should take note of the possible damage to the pumps if they are ran simultaneously with valve ILV-2592 closed.
l This is not a reportable item per 10CFR50.55(e).
M CKM:JKS:
- tw
.K. Moehlmah ' '
(
Project Mechanical Engr.
cc: ARMS i
L.M. Popplewell i
TUGC0 Operations I
FOR INDRsflJ ONLY i
a i------- __ ~-_l Z ----- Mi___ __ -.__ _ _ _
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l, o FOLDER NO.
36 Draft No.
Date COMANCHE PEAK ALLEGATION WORK PACKAGE QA/QC Category 1 - NCR Activities AllegationNumbers:hAO-30.AQ-31,AQ-32,AQ-34.A0-36 A0-37!AQ0-8,AQO-AQ0-10, AQO-11, AQO-12, AQO-13, AQE-1, AQE-4, AQE-5, (-4, y4(3,c AQP-1, AQH-2
) y,gggggg,,
Statement of Allegation: Various concerns involving Nonconformance Report (NCR) program including:
a.
Generation of NCR's i
b.
Disposition of NCR's c.
Voiding of NCR's d.
Use of inspection reports instead of NCR's 1
Reference Documents:
See source documents marked on attached pages.from. allegation list.
Source of Allegation: Various - see allegations list Date Received: Various - 1980-1984 The above information prepared by R. Wessman/0. Hunnicutt 6/14/84 Name Date Group Leader Name Date Assigned Team Members Date Assigned 2
Date Assigned 4
I' Date Assigned i
Date Assigned
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I ISSUE PROCEDURE C'.EVCON p4gg NU WER DATE texas UTIUTIES GENERATING CO CPSEs 1 of 9 CP-QP-16.0 14 JUL 0 2 W4 i
I
[z.o m-I
'I o' PREPARED W
r C
BATE NONCONFORMANCES APPROVED BY:
/-
M
'DATE
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1.0 REFERENCES
W Y
1-A CP-QP-15.0, " Tagging System"
~
1-B CP-QP-17.0, " Corrective Action" CONTR0nED COPY 2.0 GENERAL
,gg CONTROL 2.1 PURPOSE AND SCOPE The purpose of this procedure is to establish a method of documenting the identification, resolution, and closeout of nonconfomances as defined in Paragraph 2.2.
It is the responsibility of all site employees to report items of nonconfomance to their supervisor or to the TUGC0 Site QA Supervisor.
The requirements contained herein are applicable to nonconformances identified for materials, services or itens associated with safety-related structures, systems and camponents not under the jurisdiction of the ASE Code Section III Division 1.
NOTE:
neien nonconfomances are detected by inspection and testing, they shall be reported in accordance l
with quali ty procedures / instructions describing the inspection or testing functions.
Where specific guidelines are not given in quali ty procedure / instructions, the provisions of this procedure shall govern.
When a specific person is assigned responsibility for an activity his/her designee may act in his/her place.
2.2 DEFINITION 2.2.1 Nonconfonnance A deficiency in characteristic, docisnentation, or procedure l
which renders the quality of an iten unacceptable or in-i detenninate.
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ISSUE PROCEDURE REVISION PAGE NUM8ER DATE TEXAS UTILITIES GENERATING CO.
- i CP-QP-16.0 14 JUL 0 21984 2 of 9 i
3.0 PROCEDtRE 3.1 NONCONFORMANCE IDENTIFICATION 3.1.1 Field Identification When a nonconfoming condition as defined in Paragraph 2.2.1 is identified, the individual shall immediately apply a Hold when practical (Reference 1-A) and note his name and i
Tap, hone extension on the tag.
te ep 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 judmnt to apply a Hold Tag to a nonconfoming interna' c aponent.
For example, the inspector my ll apply a Hold Tag to a broken / damaged teminal strip l
and note on the Hold Tag wording such as " Applied to Teminal Strip Only." On the ER the statement would be " Applied to Teminal Strip Only - other unrelated activities may proceed."
3.1.2 Reportino Nonconfoming). conditions shall be reported on the NCR fonn (Attachment 1 Supporting documentation, e.g., Inspection l
Reports, NDE reports, drawings shall also be attached t or i
referenced on the NCR where appropriate.
The locatior. sf j.
and area code) g condition (structure, room neber, elevation the nonconfomin and the systm/subsysten neber shall be recorded on the NCR fom.
NOTE:
The system /subsysten peber is not required for discrepancies relating to conduit, cable trays, protective coatings, cable tray hangers or anchor e
bolt locations provided that the structure is identified.
3.1.3 Numbering the NCR I
Before sending the NCR to the appropriate Package Flow oup 6
(PFG) the individual reporting the nonconformance :.all I
obtain a neber fra the TUGC0 NCR Coordinator. This neber shall be noted on the NCR and on the Hold Tag per Reference j
i 1-A that is applied to the nonconfonning iten/ equipment.
I j
I TUGCO CA T ~
. -.n
I REVISION l ISSUE PROCEDURE PAGE NUM8ER DATE TEXAS UTILITIES GENERATING CO.
if CP-QP-16.0 14 lJUL02584 3 of 9
- l
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!i The TUGC0 NCR Coordinator shall assign nebers as follows:
100214 80 e.g.
NCR M
. sequential NCR nunber l
for that ysar Issued to i
Unit 1 and common.
2XXXXX is issued to Unit 2.
year Discipline (_ Mechanical J,lectrical
_Tnstrumentation..C_ivil)
For NCR's on itens/ components turned over to TUGCO, the TUGC0 NCR Coordinator shall add the letter "S" after the
!; j i
MCR number and forward a copy to TUGC0 Startup for I'
infomation.
The TUGC0 NCR Coordinator enters the NCR number and brief it description of the nonconfoming condition in the NCR Log (Attachment 2) for Unit 1 and common or Unit 2 as appropriate.
NOTE:
The PFG NCR Coordina' ors shall periodically 9
review their NCR Log (at least monthly ) to ensure M-accuracy and agreement with the TUGCD NCR Log.
i 3.2 PROCESSING NONCONFORMANCE REPORTS 3.2.1 Draft NCR
.f 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
- 1 i-logs and forwards the NCR to the appropriate Quality Engineer.
When individuals assigned to departments other 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 Nonconfonnance Report to the Unit 2 (PFG) NCR Coord stor for processing in accordance with this procedure.
1.
- l 3.2.2 Pre-Issuance Review and Preparation l
The reported nonconfonnance shall be evaluated by the Quality Engineer for clarity, accuracy, validity, specificity and legibility.
TUGCC OA
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x PROCEDURE-REVISION ISSUE PAGE NUM8ER DATE TEXAS UTILITIES GENERATING CO.
8 i
CP-QP-16.0 14
'JUL 0 21984 4 of 9 3.2.2.1 ER's may be voided at any time if it is detemined that nonconfonning conditions do not exist, the nonconformance was previously reported on another ER 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 and justification statenents.
Voidino of NCR's chall ha 8
g annenved hv the OE Supervisor or his designee. The original
.f voided NCR will be fomarded to the (PFG) NCR Coordinator.
3.2.2.2 If' the ER is determined. to be valid, the reviewer assigns an " Action Addressee" and signs and fomards the draft NCR to the (PFG) NCR Coordinator.
3.2.3 NCR Issue-The PFG NCR Coordinator enters the date 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)
The
" Action 4dressee" shall evaluate each reported nonconfo ming
.ondition and detemine 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 rework actions required to correct the nonconfonning conditions and bring tt affected itens into compliance with the i
specifiec equirements.
Penn ses s
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ISSUE PROCEDURE REVISION PAGE NUMBER DATE TEXAS UTIUTIES GENERATING CO.
"8 CP-QP-16.0 14 JUL0 ? $84 5 of 9 1
c.
Repair Dispositions shall specify the repair actions required to bring the nonconfonning characteristic (s) to a condition such that the capability of the affacted item to function reliably and safely is unimpaired, even though the iten still may not confonn to specified requirements.
Repair dispositions shall also include appropriate Engineering technical justification for acceptance of the iten with characteristics that do not comply 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 I
adverse conditions. and that the affected itan will continue to meet all Engineering functional requirements, including perfonnance, maintainabilit;y, fit and safety.
e.
Scrap Dispositions shall be made when it is detennined that an iten is unsuitable for its intended punose and cannot be feasibly or economically reworked or repaired.
3.2 4.2 Temporary Waiver For those nonconfonning itms which Construction / Engineering desires to continue to process on a " risk removal" basis, 7 authorization shall be requested in the NCR disposition.
In I:
. order to receive this authorization to continue the process, the following conditions sust be satisfied:
I:
a.
The NCR disposition shall include sufficient informa-tion and direction for acceplishing the work.
Detail r iall be provided to pennit adequate evaluation of ptential impact to affected parties (i.e., construction, engineering, QA/QC, records, start-up and operations);
1, b.
Engineering Reviev/ Approval shall be by the Engineering Group Supervisor or above; j
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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 ne ber shall be noted on the Temporary Waiver Tag.
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ISSUE PROCEDURE REVISION q PAGE 4
NUM2ER DATE
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TEXAS UTILITIES GENERATING CO.
N jl CP-QP-16.0 14 JUL 0 2 EM 6 of 9 If l1 3.2.5 Action Addressee Review / Approval Only the authorized representative of the Action Addressee may sign the Engineering Review / Approval block.
3.2.6 Quality Assurance Review The ER disposition 'shall be reviewed by the Discipline Level III Quality Engineer for adequacy and confomance to applicable specifications, code requirments and current drawing / design change.
~
If the disposition is satisfactory the PFG ER Coordinator enters the date on the. ER log and puts the ER into the data package.
If the disposition is not satisfactory, the i,
Oc lity Engineer shall resolve all comments with the Engineer i
' i ea I
- i who dispositioned the ER.
u Upon Quality Engineering appraval of the disposition, and red hold tag and blue waiver tag (pair, QC shall remove the prior to beginning any rework /re
- i if applicable).
3.2.7 Revision of Nonconfomance Reports
',j When changes are required to the nonconforming condition l'
or disposition, the ER shall be revised.
This revision shall be denoted on the ER neber and the reason (s) for revision included in the comments section.
The necessary approvals shall be obtained in accordance with this l.
procedure for the portion affected by revision.
3.2.8 Implementation of the Disposition i
E R's shall be sent by the PFG ER Coordinator to the appropriate department responsible for implementation of i
the disposition.
i For ER's identified with an "S"
after the NCR neber, an information copy will also be sent to TUGC0 Startup.
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ISSUE
~
PROCEDURE REVISION PAGE i
NUMBER DATE TEXAS UTILITIES GENERATING CO.
l CP-QP-16.0 14 02W 7 of g i
3.2.9 Verification / Closure The appropriate QC Supenisor shall ensure that the ER disposition work itms are verified and/or witnessed by QC, QC shall doc uent their inspections (via inspection reports, checklists, travelers, etc. as required).
The QC Supenisor shall ensure that all docuents required for closure shall be either attached to or referenced on the NCR and forward the ER to the QE for closure.
The QE, shall close the ER by signing the " Verification" block of the original.
The closed ER will then be transmitted by the PFG ER Coordinator to the Pemanent Plant Records Vault (Unit 1 and comen) or when the data package is emplete, to the Interim Records Vault (Unit 2) and the date entered in the ER log.
Copies of closed ER's are transmitted to the TUGC0 ER i
coordinator for closure of the TUGC0 ER log.
A 3.3 (DRRECTIVE ACTION l
Copies of ER's shall be transmitted daily to the QA Supervisor for evaluation of. the need for corrective action.
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CP-Q P-18.0 19 JUL10 23 1 of 13
' PREPARED BY:
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1.0 REFERENCES
1-A CP-QP-16.0, "Nonconfonnances" 1-B CP-QP-17.0, " Corrective Idti INF01MATON ONLV
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2.1 PtRPOSE
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The pumose of this procedure is to establish a method of documenting field inspections perfonned by Quality Control personnel.
2.2 TYPES OF INSPECTION 2.2.1 Monitor (OCI-M)
To assure that a specific operation is be.ing perfonned. in accordance with applicable requirements.
Conformance verification by sonitoring is accomplished by physically observing a task being perfonned on a periodic or randam basis.
The QC inspector nonitoring an operation nust
.detennine the extent of physical observation required during the perfonnance of an operation based on variables associated with the operation.
The QC inspector must be notified prior to an operation being perfonned that has a "QCI-M" designation.
2.2.2 Verify (OCI-V)
To assure that, a specific operation has been perfonned to meet applicable requirements. This type inspection does not l-require the QC inspector to physically observe an operation h
being performed, but allows the inspector to physically inspect an item after perfonnance of an operation.
The QC i
inspector must be notified subsequent to performanc.e of an operation with "QCI-V" designated.
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CPSES i
CP-QP-18.0 19 a1094 2 of 13 l
2.2.3 Witness (OCI-W)
To assure an operation is being perfonned in accordance with applicable requirements.
Confonnance verification by witnessing requires the inspector to physically observe the entire operation being perfonned. The QC inspector must be notified prior to beginning the operation and shall be present during performance of an operation with "QCI-W" designated.
3.0 PROCEDIRE 3.1 PREPARATION OF INSPECTION REPORT The Inspection Report shall be completed in black ink and be legible.
The Inspection Report (IR) shall completely and accurately-describe the its or activity observed and refeFence any other appilcable doctments. The attributes listed on the IR shall be pre-detennined although additional conditions may be noted.
When any block of the IR is not applicable, i
N/A shall be marked in that block. The Inspection Report must be signed by the QC Inspector in the appropriate spaces 1
.on the report. Initialing is not acceptable except for corrections.
Corrections shall be made by a single line drawn through incorrect entries, with the correct entries made legible and accompanied by the initials of the correcting individual and the date.
The following l.
explanations refer to the various blocks on the Inspection l
Report (Figure 1).
An Inspection Report Supplemental Sheet (Figure 2) should be used when the IR does not provide adequate space for the at-tributes.
NOTE:
No changes, such as additions or deletions to a closed I.R., will be made by personnel other than the originator except as authorized by the Site QA Manager.
In cases where the originator is no longer employed at
- CPSES, the responsible i
supervisor can have appropriate changes made, with adequate justification.
Addi tional corrections n
a shall be initialed and dated.
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CP-Q P-18.0 19 JUL 101984 3 of 13 i
Block 1:
IR numbers shall follow an alphantaneric sequence, such as:
Example: 2 5-2-0000001 Report Number One Unit 2 (1 for Unit 1 & Common)
Discipline Code (for Unit 1 & Canmon only)
Discipline Codes:
BP -Base Plate C - Civil CT - Cable Tray Hanger Backfit Unit 2 Only DG - Diesel Generator E - Electrical EC - Electrical Cables ET - Electrical Terminations FP - Fire Protection (Thenno. lag 4
Installation).
- e I - Instrianentation
,W M - Mechanical ME - Mechanical Electrical MH - Mechanical Hilti Bolts MS-Class 5 Hangers MI - Mechanical Equipment MS - Structural Misc./ Steel PC - Protective Coating PCIT-Protective Coating Inspection Traveler (Unit 1)
PCR-Protective Coating Reinspection
.t PCV-Post Construction Verification PS - Plant Surveillance I
PSI-Preservice Inspection Report PSS-Plant Surveillance Separation SL - Steel Liners
~
TC - Unit 2 Tray Clamp Reinspection TW - Tack Weld NOTE:
Protective Coatings Inspection Travelers are handled in accordance with QI-QP-11.4-28.
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The PFG IR Clert maintains the IR Log and assigns the IR neber to the Inspection Report.
NOTE:
The Unit 2 PFG is responsible to cooniinate the processing of inspection reports initiated by receiving inspection or other inspection groups j
outside the Unit 1 and Unit 2 organizations.
An IR may be voided by the appropriate QC Supervisor.
The QC Supervisor shall state in the comments section of the IR i
the justification for voiding the IR.
- The IR is marked
' VOID', the IR Log is. updated to show the IR voided, and the IR is forwarded to the PPRV or mturned to the data package for later submittal to the Interim Vault as appropriate.
In the event that it 'becomes necessar to issue a new sequence of Insp)ection Report nebers(y for example, a new discipline code the new code shall be issued by the Non-ASE QE Supervisor and incorporated into the next revision of this procedure.
Blocks 2 & 3:
Record sufficient infonnation to uniquely identify the itan or activity abserved.
Example:
Itan Description Identification No.
Pressure Transmitter PT-458 i
Block 4:
Record the systen and/or structure i
designation, including unit, building, elevation, room neber, and area code, as appropriate, to specifically locate i
,a the ita.
Example:
System / Structure Designation SW EL. 832 Service Water Intake Structure q
Blocks 5 & 6:
Record the governing specification b:
neber and revision.
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- "8 JUll0 W fg CP-QP-18. 0 19 5 of 13 i
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l Block 7:
RecoM the quality procedure and/or instruction and revision number.
Example:
Ref. QC Doc. & Rev. No.
QI-QP-11.8-5 Rev. 10 1
Block 8:
Record the M&TE number (s) and the 1
calibration due date of the calibrated instrument used to verify an inspection
. attribute.
^
Block 9:
Check the type of inspection perfonned.
l Block 10:
Check the appropriate block and sign (do 2 not initial) and date in the space J
provided when the inspection is complete and all items marked sat or unsat.
1 Block 11 & 12:
Prior to perfonning the inspection, list 1@
the attributes to be observed.
(An
.j attribute is a
characteristic or property which can be appraised in tenns i
of whether it does or does not exist.)
5 3
Indicate the acceptability of the q
attribute by checking either ' Sat' or
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' Unsa t'.
I NOTE:
The acceptability of the 8
attribute is to be noted
.j rega M1ess of elapsed time
'a before correction of the
]
'Unsat' condition.
Block 13:
Sign (do not initial) and date this block after satisfactory correction of
- ,' ]
the "UNSAT" attribute.
Do not use this block for " SAT" attributes.
Block 14:
Reference all applicable documentation i
such as drawing numbers, specifications, DCA'S, CMC'S, e tc. and revisions as applicable.
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Block 15:
Record any applicable NCR ntsnber.
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CPSES JUL10 M 6 of 13 CP.QP-18.0 19 Block 16:
Upon satisfactory completion of unsatis-factory attributes, or issuance of an NCR, or superseding IR, check the "IR CLOSED" block, sign and date the report. Put NA in this block if all the attributes are
" SAT".
If a DCA or CMC has been issued dich makes the unsatisfactory condition acceptable, the DCA or CMC will be noted in the comments section and the IR marted " SAT" and closed out.
Unsatisfactory Inspection Reports may be -
superseded by the issuance of another IR authorized by approved procedures /
instructions.
In these cases the unsatisfactory IR nimber shall be referenced in the remarks section of the
. (9 new or superseding IP. and the origirwal v
unsatisfactory IR closed with the following (or similar) statement in Block 14: "The UNSAT attributes of this IR have been added to IR f and l
this IR is closed). The QC Inspector shall then close the IR by checking the IR closed block, signing and dating Block 16.
3.2 INSPECTION REPORT PROCESSING 3.2.1 Unit 1 and Common The QC Inspector perforrs the inspection, prepares the IR in accordance with Section 3.1, and forwards the IR to the IR Clert for further processing.
The IR Clerk records the required information from the IR into the IR Log.
If no unsatisfactory conditions are noted, the IR is then forwarded to the PPRV.
If unsatisfactory conditions are noted: the original Unsat IR is maintained by the IR Clert and copies of the Unsat IR are forwarded to the craft for correction of the unsatisfactory condition.
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REVISION PAGE NUMBER DATE TEXAS UTILITIES GENERATING CO.
, li CP-QP-18.0 19 R 10 S4 7 of 13 CPSES When all unsatisfactory conditions have been corrected and reinspected and accepted, or when an NCR or superseding IR has been prepared for the unsatisfactory condition (s) per approved procedures / instructions, the QC Inspector shall Block 16).
The closed IR shall then be forwarded to the PPRV by the IR Clerk.
}
NOTE:
Deficiencies for items which have been accepted by final inspection (unless an IRN has been issued) j as delineated by Quality Instructions, or deficiencies for which a "use-as-is" or non standard repair disposition is requested, shall t
be documented in accordance with Reference 1-A.
I
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Inspection Reports for Class 5 hangers and Class 5 hanger hiltis remain with the hanger package for f
transfer to the PPRV.
3.2.2 Unit 2 PFG iO Inspection Report roms are piaced into the wo,*,ackage for
~
i the applicable component prior to the package being issued.
to the field.
The IR Fom shall be nunbered (Reference Section 3.1) and all applicable heading or identification infomation filled in by the PFG.
j A cover sheet (Figure 4), may be used when more than one inspection is required.
When a cover sheet is used, the 4
various inspection reports attached to it are listed as pages under one IR number.
Upon completion of each inspection report, the cover sheet is' signed as well as the IR or marked NA if the specific inspection was not required. Men all required inspections are complete, the Lead or Level II Inspector in the appropriate discipline shall verify the inspections are complete and all required signatures affixed to the inspection reports and the cover sheet. He/she shall then sign the cover sheet indicating the IR is closed. When the package is presented to QC for inspection, the QC inspector shall complete the fonn based on inspection results. The package shall then be returned to the PFG.
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CP-QP-18.0 19 JUL 101984 8 of 13 j
NOTE:
In the event heading infonnation is not complete and/or requires further clarification, the inspector shall add any required infonnation to the IR.
In the event an IR is required to doctment an inspection and one is not contained within the component package; the 1
QC Inspector shall obtain a prensbered report from the PFG for placement in the data package.
When all unsatisfactory conditions have been corrected, and
.1 reinspected and accepted, or when an NCR or superseding IR has been prepared for the unsatisfactory condition (s) per
- l.,
approved procedures / instructions, the Discip(line
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Inspector shall close the original unsat IR refer to Paragraph 3.1, Block 16), and the PFG IR coordinator shall close the IR log.
1
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Deficiencies for itms which have beert aci:epted
..i @
by final inspection as delineated by Quality j
Instructions, or deficiencies for which a
"use-as-is" or non standard repair disposition is
- required, shall be docimented in accordance with Reference 1-A.
3.3 INSPECTION REPORT LOGS IR Logs are unintained by the appropriate PFG.
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The infonnation required on the Inspection Report Logs is h 1 self explanatory and obtained directly fran the IR except e
as follows:
a.
If an NCR has been issued, recorti the NCR nLaber in the Identification Section.
b.
If an IR is superceded, the new IR nLaber is recorded in the Identification Section.
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i 3.4 CORRECTIVE ACTION TREND ANALYSIS At the end of each
- quarter, the PFG Coordinator will send a report of inspections perfomed to the QE Supervisor for trend analysis in accordance with Reference 1-B.
These reports shall include the ntaber of Inspection Reports worked and the ntaber of unsatisfactory reports for each type of report (Mi, E. ET EC, etc.)
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REVISION PAGE NUMBER DATE TEXAS UTILITIES GENERATING CO.
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Leat Wask; Thic Wesk Construction to Startup O
Subsystems 331/ 325/ 323 331/326/323 1
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Custody Transfer to Operations Subsystems 331/ 259/ 239 331/253/233 Areas 423/ 177/ 177 423/177/177 Final Acceptance (STA-802)
Subsystem 331/ 183/ 75 331/156/ 63 Areas 423/ 117/ 98 423/117/ 98 D.
Preop / Accept Tests:
(Test / Retest /Reperform)
Totals:
199 / 38 / 37 199 / 38 / 37 To Go:
Procedure Issue for Comment 0/
0/ 0 0/
0/ 0 Procedure Issue for Approval 1/
0/ 0 1/
0/ 0 Procedure Approval 1/
0/ 0 1/
0/ 0 Start Test 14 /
1/ 7 15 /
1/ 7 Field Testing Complete 35 /
4/ 9 43 /
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Data Package Issue for Reviev 52 / 16 / 12 55 / 17 / 14 i
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Draft 1 - 9/17/84 AQ-116/CP2A COMANCHE 1-EAK OPEN ISSUE ACTION PLAN Task: AQ-116 Ref. No.:
Characterization: Procedure changes resulting in inappropriate review of ASME documentation.
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Could result in inadequate review to determine if required work was completed.
Source:
Approach to Resolutions:
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Review procedure changes to determined reason for changes.
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4 1975 - 1976 START OF PROJECT - DESIGN BY GIBBS & HILL BY DRAWING & DE/CD ISSUANCE -
SITE DESIGN CHANGES ISSUED BY:
DC/DD - SAFETY RELATED CLARIFICATION FICR FPAR
- NON-SAFETY 1978 IDGIBBS&HILLDESIpNCHANGESONDCAFORM ALL FIELD
% 4 f w ~- fy f u en~-gD~2 JUNE 1978
- COMPONENT MODIFICATION CARD (CMC) INITIATED JUNE 1980
- DESIGN CHANGE TRACKING GROUP (DCTG) FORFED IN COMANCHE PEAK PROJECT ENGINEERING (CPPE) TO FORMALLY TRANSMIT DESIGN CHANGES (DCA'S & CMC'S)
TO GIBBS & HILL, NEW YORK FOR DESIGN REVIEW MAY 1982
- BEGAN ESCALATED DRAVING UPDATE PROGRAM -
GIBBS & HILL DCA/ CMC MASTER INDICES UTILIZED AS THE MAIN INFORMATION SOURCE OCTOBER 1982
- TRANSFER OF INITIAL DCA/ CMC DATA TO CPSES SITE COMPLETE - BEGAN MAINTAINING SITE DCA/ CMC COMPUTER SYSTEM IN PARALLEL WITH GIBBS & HILL, NEW YORK PRONOUNCED TUGC0 NUCLEAR ENGINEERING (TNE) AS THE
. OCTOBER 1982 PERMANENT SITE ENGINEERING ORGANIZATION -
ASSIGNED RESPONSIBILITY FOR RETENTION OF THE ENGINEERING RECORD NOVEMBER 1982 - TRANSFERRED RESPONSIBILITY FOR DRAWING UPDATE ADMINISTRATION AND DCTC FUNCTIONS TO TNE DECEMBER 1982 - BEGAN PHYSICAL TRANSFER OF UNIT 1 DESIGN DRAWINGS AND UPDATE RESPONSIBILITY FROM GIBBS & HILL, NEW YORK TO TNE APRIL 1983
- SET UP GIBBS & HILL SITE DESIGN REVIEW TEAM OCTOBER 1983
- DCTG COMPUTER SYSTEM UTILIZED BY THE SITE DOCU>ENT CONTROL CNETER FOR DESIGN CHANGE LOGS$' 7 w &kWQ s 3 m a n m u 'f v ~/ ', _ N / ~ s ? I (
C0!!ANCHE PEAK i ENGINEERING - DOCU11ENT CONTROL INTERFACE _ _ _ _ _.,C0!@!U!!ICATION LINE
- DISTRIBUTION LINE 3.N ENGIllEERING DOCUMENT CONTROL CRAFT & OTilER USERS' 1
l GIBBS & IIILL/TNE PREPARE DRAWING & SPECS RECEIVE, REPRODUCE & DISTRIBU.TE rRECEIVE IIARD COPY DRAWINGS, p-SPECIFICATIONS, VENDOR DRAWINGS, b PREPARE DESIGN CllANGES DCA'S & Ct!C'S FR0!! DOCUMENT l CONTROL t L_. VENDOR DRAWING REVIEW 6 DESIGN VERIFICATION p _. f l i l_ + DESIGN CIIANGE/DRANING _ _ _ _ _ __-, DESIGN CilANGE LOGS FOR elARD COPY LOG DISTRIBUTION l PROGRA!! ADMItilSTRATION GIBBS & llILL/ VENDOR DRAWINGS WITil DRAWINGS / SPECS C0!iPUTER INTERFACE l COMANCllE PEAK PROJECT j ENGINEERING (CPPE) f CRAFT INTERFACE l PREPARE DESIGN CNANGES RECEIVE, REPRODUCE & DISTRIBUTE RECEIVE IIARD COPY DRAWINGS, ._ pDRAWINGS, SKETCllES, DCA'S & CMC'S
- nCA'S, CMC'S & DESIGN CllANGE PREPARE SITE ORIGINATED
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O TUGC0 NUCLEAR ENGINEERING DRAWINGS UPDATE ACTIVITIES April, 1984 _ ~... .m-.m,,--.~,-.. -n,--
Page 1 of 2 In support of plant operations, the following drawings are targeted for update to incorporate all outstanding design changes prior to Unit 1 Iuel load: 1. Mechanical Flow Diagrams (M1-200 and 300 series). 2. Electrical One-Line Diagrams, three-line diagrams, electrical wiring and connection diagrams (El-001 through El-200 series). 3. Instrument and Control Diagrams (M1-2200 and 2300 series). 4. Instrument Equipment List (M1-2400). 5. Instrument Location Drawings and Tabsheets (M1-2500 and M1-2600 series). 6. Safety Related Vendor Drawings. Drawings identified above with outstanding design changes remaining at fuel load will be added to the Master Data Base for update prior to commercial operation. In addition to drawings required to support plant operation, the following listing of drawings will be updated, however the entire effort will not complete until after commercial operation: 1. Electrical Physical Drawings (El-300 through El-800 series). Note: These drawings will be used for future engineering and construction work associated with plant cable tray and conduit modifications. 2.- Electrical Fire Protection / Detection Drawings and other miscellaneous drawings in the El-2000 series. 3. Plant Architectural Drawings (all G&H "A" prefix drawings). 4. Non-Safety Related Vendor Drawings. 5. Electrical Lighting Drawings (El-900 series). l 6. Electrical Material List (El-1800 series). 7. Computerized Cable and Raceway Schedule (El-1700) and other ( miscellaneous El-1700 series drawings. 8. Instrument Rack Wiring Diagrams (El-2800 series). 9. Instrument Installation Details (M1-2100 series). age o
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i-Page 2 of 2 The following drawings will not be updated for the reason stated: 1.- Piping Composites (M1-400 through M1-800 series). Update-is not required as Flow Diagrams and Piping Isometrics satisfy plant needs. HVAC composites.(M1-450, 550, 650, 750, and 850 series) will be updated Post Fuel Load in absence of Isometric drawings. 2. Instrument Rack Drawings (M1-2800 series). As-Built condition will be documented via photograph per CPPA-24167. 3. Instrument Air Piping Diagrams (M1-2700 series). As-Built Flow Diagram will suffice. 4. Plant Structural and Cable Tray Support Drawings (all G&H "S" Prefix and El-XXXX-XX "S" Drawings). Selected Cable Tray Support Drawings have been updated to aid final inspection, however no wholesale update of structural drawings will be accomplished. Architectural drawings will be used to locate / relocate equipment. New drawings will be issued to modify / add cable tray supports or equipment foundations. i s . -. - ~... -... .w-..,.
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~-.. : 1 SUBSYSTEM NO. S/N i N-5 SUBSYSTEM CHECKLIST See if any BRP's previously certified require amendment. If so, amend and send to ANI with subsystem data report. Verify all equipment within boundries of subsystem. Verify all equipment is supported (ie, pumps, tanks, heat exchangers, etc.) N-F support by manufacturer (NF-1 Data Report) Support' by Brown and Root (Appropriate Documentation) Documentation for installation activities (if applicable) Verify that no open NCR's exist on equipment, piping, hangers, etc. Verify that supports which have been certified on Partial N-5's have not been pulled out of the vault for rework. ( Verify that there is no open documentation on ISO's previously certified (ie,RPS's, Hydro's, Travelers,etc.) Verify all punchlist items are closed as applicable. 1-l Verify Design Conditions of piping have hanged fro that certified on Partial N-5 Data Reports. erify all applicable orifice pl.ates have been certified on the applicable Partial N-5 Data Reports. Status any modification work accomplished on penetrations. COMPLETED BY o 7
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. ~ ZT=--- -T --- - - ~ _m. BRP NO. S/N l I N-5 CHECKLIST Check for open NCR's Check for documents at QES Check for latest flange traveler and for s/n if applicable. Check line list for accuracy Check for Attachment 3 Y Check for base metal repairs If BMR are present make sure that they are shown on IS0's in hydro pkg. Make sure hydro is complete Make sure HITS printout matches BRHL and/or GHH Make sure weld attachments are shown on Hydro ISO in vault If theneare threaded connections shown on ISO,' list threaded IR number Check welding engineering printout for outstanding documents Check data reports (NPV-1, N1, NIA etc.) for completeness and accuracy (sign-offs, pressure and temperature). COMPLETED BY DATE _}}