ML20215E976
| ML20215E976 | |
| Person / Time | |
|---|---|
| Site: | Comanche Peak  |
| Issue date: | 07/17/1978 |
| From: | Geisler A MANAGEMENT ANALYSIS CO. |
| To: | |
| Shared Package | |
| ML20214X072 | List: |
| References | |
| NUDOCS 8610160039 | |
| Download: ML20215E976 (74) | |
Text
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QUALITYASSURANCEMANAGEMENTRNIEWBOARD QAMR8 AUDIT NO. 3 REPORT JULY 17,1978.
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c.w y-DATE OF AUDIT: JUNE 5 THROUGH 23, 1978 AUDIT TEAM LEADER: ALFRED H. GEISLER This report contains confidential infonnation on the activities of Brcwn &
Root and its suppliers.
Informaticn within this report may not be copied, distributad or shewn to unauthorized individuals without the express, writtan consent of Brown & Root, Inc.
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QUALITY ASSURANCE MANA(nIMENT REVIEW BOARD QAMRB AUDIT NO. 3 -
OF THE BROWN & ROOT QUALITY ASSURANCE PROGRAM
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SOUTH TEXA5 PROJECT
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CGIANCHE PEAK PROJECT INRODUCTION The third audit of the Brown & Root Quality Assurance Program was conducted for the Quality Assurance Management 3eview Board during,the peHod of June 5 through
, June 23. 1978.
The scope of the audit included a compliance with Nuclear Regulatory Commission quality assurance requirements and indust guidance as it applies to the deri procurement and constnsction activities re ating to the South Texas Project (Sk and to compliance with section III of the ASME Boiler and Pressure Vessel Code as it applies to Brown & Root activities on the Comanche Peak Project (CP5ES).
The audit team was led by Alfred H. Geisler Manager Nuclear Licensing. Brown &
Root. Team members were selected from vaHous organizations as follows:
R. M. K11 mist..B&R EngineeHng I. THbuch. B&R Operations
- L. W. Crowe B&R Construction R. J. Kingcaid. B&R Procurement N. W. Pressler. BAR Quality Assurance
@,Gr "J.M. Norms.ManagementAnalysisCorp.(MAC)
R. A. Romeo BAR Quality Assurance
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. Prior to the audit, all Brown & Root audit team members participated in an audit training program conducted by the Brown & Root Quality Assurance Department Audit Section.
The audit'was conducted by the team members in accordance with an r.idit plan and schedule (See Appendix A). The auditors used both standarized at:d specialized checklists, and interviews in performing the audit. Specialized diecklists con-sistad of questions formed by the team members from referencad documents assigned as part of the audit plan. The audit checklists, which consisted of nearly one thousand itses, are available from the Audit Team Leader. The week of June 5 was spent auditing the Brown & Root Home Offica activities for the STP project. The' week of June 12 was spend auditing activities at the STP Site. The week of June lg was spend auditing activities at the CP5ES sita and verifying findings' at the Brown & Root Home Office.
- R. Romeo substituted for I.THbuch duMng the audit of the.STP and Comanche Peak sita due to a conf 1tet of assignments for I. THbuch.
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' A. pre-audit.neating.wa's held at thb Brown & Root Home Offica on June 5,1978 in p.
C3 sixth floor conference room of the Engineering Southwest building.
In addi-tion to the..audie team, the following persons were in attendance:
- G. H. Bulcken, B&R Quality Assurance W. T. Greene. B&R Purchasing x
T. H. Gamon, B&R Quality Assurance 2
L. E. Hayden, BAR Engineering s
J. L Paden 8AR Engineering H. Paperno, B&R Quality Assuranca R. W. Peverley, 84R Enoineering R. A. Sanford, BAR Pro; act Management L A. Swarts, 81sR Engineering
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Separata pre-and post-audit meeting were held at the STP site on June 12 and June 18, respectively, with the fol'owing persons atending in addition to the audit team:
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post-audit Dean Mooney 84R Quality Assurance x
Jack Purdy 84R Quality Control x
Sid Rasnick BAR Construction Eng.
Jim Salvitti B&R Construction Mgat.
Tom Wamick BAR Quality Assurance C. W. Vincent 84R Quality Assurance R. A. Melivert 81R Quality Assurance Gary Euert BAR Quality Assuranca
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. Briefings.were held separately with T. H. Gamon and L. E. Hayden to discuss the results of the audit.
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A pre-audit me'eting was held at the CPSES Site on June 20.
In addition to the Tb-audit team, the following persons were in attendance:
H. Kirkland BAR Project Management U. D. Douglas, BAR Construction Management R. Scott, BAR Quality Assuranca P. Clarks. BAR Quality Assurance A briefing was held with R. Scott at the conclusion of the CPSES audit.
I SIM ERY OF FINDINGS j
The audit resultad in the generation of 33 Audit Deffciency Reports (ACR's).
all pertaining to activities on the South Texas Project. Such reports repre-
.sent noncompliances with requirements, whether imposed by the Nuclear Regulatory l
Commission, Industry Standards, or by Brown & Root manuals and procedures. The ADR forms are included as Appendix 8 to this report. The use of these foms has been instituted to provide a convenient means of closing out individual l
audit deficiencies on a timely basis.
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eiencies were rankek as to the nature o n
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of occurrence and the potential severity of consequence resulting from such deficiency. The more significant deficiencies are as follows:
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1.
ADR-1; Control of Identification and Changes to Design Inputs 2.
ADR-2; Control of Design Manuals
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3.
ADR-8; Record Retentien Systems 4.
ADR-16; Internal Audit Program 5.
ADR-19; Control of QA Program and Procedure Changes 6.
ADR-20. 21. and 22; Indoctrination and Training Records 7.
ADR-26; Designation of Storage Area Levels 8.
ADR-32; Designation of Housekeeping Zones Appendix C to this report provides a listing of concerns and recomendations as a result of the team members' observations during the course of this audit.
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QAMRB Audit No. 3 Plan June 5 through 23,1978
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QMWtB AUDIT Pt.AN.
HOUSTON - JUNE 5-9, 1978 STP SITE - JUNE 12-15. 1978 AUDIT ELEMENT 10CFR50 ANSI STANDARD AUDITORS APPENDIX B 4
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1.
Organization I
Geisler 2.
Quality Assurance II Geisler Progree 3.
Management Nevisiv II Geisler 4.
Indoctrination and -
II K11 mist Crowe Training 5.
Design control III N.45.2.11 (Sec. 2 to 8)
Norris, Kingcaid Design Document Control VI 6.
Instructions, Pro-V Norris, Kingcaid cedures, and Drawings,.
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Procurement Control IV, VII, VIII N.45.2.13 Pressler.Tribuch,Rc:
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Nonconformance and.
XV N.45.2.11 (Sec. 9) )
K11 mist Crowe 1
Corrective Action XVI N.45.2.13 (Sec. 8.9 1.
Records
.- t XVII N.45.2.9 K11 mist, Crowe N.48.2.12 Sec. 5) lh..)
N.45.2.13 Sec.11)
XVIII N.45.2.11 (Sec.11)
K11 mist, 'Crowe
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Audits N.45.2.12 N.45.2.13 (Sec.12)
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Packaging, Shipping.
. XIII N.45.2. 2 Pressler.
Receiving, Storage 1.nd 1
Handling 2.
Control of Measuring and XII
- Pressler, Test Equipment 3.
Housekeeping N.45.2.3
- Pressler,
!l4 Cfvil-Structural Cona X
N.45.2.5 Norris, Kingcaid struction/ Quality Control XI 4
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Mechanical Construc-X N.45.2.8 K11 mist, Crewe tion / Quality Control XI l
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k.'elding IX K11 mist, Crewe NOE IX K11 mist, Crewe 9
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~AUDITUR5 D
APPENDIX 8 18.
Paintings and Coatings Norris, Kingg*'t i
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Qualification of Inspec-X N.45.2.6 K11 mist, Crow. -
tion and Testing Per-XI sonnel
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Inspection. Test and VIII Pressler, Romeo Operating Status XIV
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Geotechnical Norris. Kingcaid l
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APPENDIX 8 AUDITORS
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I Geisler 1.
Organization
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Indoctrination II K11 mist, Crowe and Training 3.
Pield' Design Changes --
III N.45.2.11 (Sec. 8)
Romeo,Pressler 4.
Instructions, Pro..
'V Acmeo, Pressler cedures, and Drawings 3.
Procurement Control IV,VII..VIII N.45.2.13 Romeo, Pressler 5.
No'nconformance and XV N.45.2.11 '(Sec. 9)
K11 mist, Crowe Corrective Action XVI N.45.2.13 (Sec. 8, 9)
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Records XVII N.45.2.9 K11 mist, Crowe Document Centrol VI N.45.2.11 Sec. 7)
N.45.2.12 Sec. 5)
N.45.2.13 Sec.11)
Audits XVIII N.45.2.11 (Sec. 11)
K11 mist, Crewe
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N.45.2.13 (sec.12)
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ackaging,.5)iipping, c -
XIII N.45.2.2 Romeo, Pressler
' Receiving, Storage and Handling
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Control of Measuring.
XII Romeo, Pressler j
and Test Equipment
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Mechanical Construc-X N.45.2.8 K11 mist, Crowe tion / Quality Control XI l !.
Welding IX K11 mist, Crowe 1
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NDE IX Klinist, Crowe L.
Qualification of: :. <
X N.45.2.6 K11 mist, Crowe Inspection and Testing XI i
Personnel li.
Inspection. Test and.
VIII Acmeo, Pressler Operating Status XIV i
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_--..u-,-~..~m ggets AUDIT PURPOSE i m, l
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To datarmine conformance of the Brown & Root Quality Assuranca Program to 10CFR50, Appendix 8, and ANSI N45.2.
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To determine compliance of the Brown & Root Procedures to the Brown &
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Root Quality Assurance Program and the ANSI N45.2.XX Daughter Standards.
3.
To deternrine compliance of Brown & Root existing practicas to the Brown & Root Procedures.
4.
To deterstne if the Brown & Root existing practicas and procedures are the most logical. efficient and cost effective manner to meet the Brown & Root Quality Assurance F. g -
AUDIT TEAM NEMBERS A. N. Geisler - BAR Nuclear Licensing
- Audit Team Leader 1
J. M. Norris
- Management Analysis Co. - Auditor and Advisor R. M. K11 mist - 8AR Engineering
- Auditor I. Tribuch
- BAR Operations
- Auditor L. W. Crowe
- BAR Construction
- Auditor R. J. Kingcaid - BAR Procurement
- Auditar N. W. Pressler - BAR ua'i Assurance
- Auditor R. A. Romeo
- 8&R uaLi Assuranca
- Auditor i
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,MF.rM50 TITLE N.45.2-1977 Q.A. MANUAL Q.4. PROGRAM REY 2,6/77 M IX B
.ERION SECTION SECTION SECTION SECTION SECTION_
'.['l' Organization 3
1.0 5.1 17.1 17.1.1 B
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l'I Quality Assurance 2
- 2. 0 5.2 17.2 17.1.2B TI!
Design Control 4
3.0 5.3 17.3 17.1.38 IV Procurement Docu -
5 4.0 5.4 17.4 17.1.48 ment, control V
Instructions, U
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- 5. 5 17.5 17.1.5B Procedures and Orawings I
VI Document C'oniifol 7
6.0 5.6 17.6 17.1.6B VII Control of Purchas'ad 8
7.0 5.7 17.7 17.1.7B i
Material. Equipment.
Services VIII Identification and 9
8.0 5.8 17.8 17.1.88 Control of Material, Parts, Components
'IX Control of SpicialP 10
- 9. 0, 5.9 17.9 17.1.98 Processes -
NE Inspect 1on 11 10.0 5.10 17.10 -
17 1.108
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XI Test Contr61 P 12 11.0 5.11
-.17.11 17.1.11E XII control of Measuring 13 12.0 5.12 17.12 17.1.125 and Test Equipment XIII Handling, Storage,'
14 13.0 5.13 17.13 17.1.13E, Shipping 1
l XIV
'thspection Tist and. 15 14.0 5.14 17.14 17.1.14E Operating Status XV Nonconforming
- 16 15.0 5.15 17.15 17.1.15E Material Parts of T.omponentf ' '
XVI Cor.rective Aci! ion 17 16.0 5.16 17.16 17.1.16E XVII Quality Assuranca
18 17.0 5.17 17.17 17.1.175 Records XVIII Audits 10 13.0 5.18 17.18 17.1.18!
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STP PROCEDURE APPLICABILITY
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AUDIT ELEMENT TU5.ITY ENGINEERING CONSTRUCTION PROCUREMENT PROJECT Q
ASSURANCE MANAGEMENT _.
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Organization ST-Q'AP-1.1 STP-GR-002
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Q.A. Program QSP-1.0 STP-GR-003 3.
Management -
ST-QAP-2.8 Review ST-QAP-7.2 D0-412 N
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Indoctrination ST-qAP-2.9 STP-PM-006 A040KPGCP-13
.STP-PP-0014 and Training 5.
Design Control ST-QAP-2.3 STP-DC-002 A040KPOCP-1 STP-PMO-021 Design Occu-ST-QAP-2.4 STP-0C-004 A040KPDCP-2 ment Control ST-QAP-2.10 STP-DC-005 A040KPOCP-3 l
ST-QAP-2.11 STP-0C-006 A040KPDCP-4 ST-QAP-3.1 STP-DC-007 A040XPDCP-5 ST-QAP-3.2 STP-DC-008 A040KPDCP-7 ST-CAP-6.2 STP-0C-010 A040KPGCP-21 1
ST-qCP-2.5 STP-0C-011.
STP-0C-012 s.
STP-0C-013 Y. T. -b i
STP-0C-014 i
STP-0C-015 5TP-0C-016
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STP-0C-023 STP-0C-024 STP-FM-005.
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STP-GR-004 6. Instructions.
ST-QAP-2.1 STP-DC-001 A040KPGCP-1 STP-PP-0001 Procedures, ST-QAP-2.2 STP-GR-001
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and Drawings i
7.' Procurement ST-QAP-4.1 STP-0C-024 A040KPGCP-2 STP-PP-0002 control ST-QAP-4.2 STP-AO-003 A040KPGCP-3 STP-PP-0003 ST-QAP-4.3 STP-AD-004 A040KPGCP-6 STP-PP-0004 ST-QAP-4.4 STP-AD-007 A040KPGCP-8 STP-PP-0005 ST-QAP-5.1 STP-FM-005 A040KPGCP-9 STP-PP-0006 QSP-1.0 STP-PM-010 A040KPGCP-11 STP-PP-0C07 QSP-2.0 A040KPGCP-12 STP-PP-0008 i
QSP-3.0 A040KPGCP-14 STP-PP-0009 QSP-4.0 A040KPGCP-15 STP-PP-0010 QSP-5.0 A040KPGCP-16 STP-PP-0012 QSP-6.0 A040KPGCP-17 STP-PP-0015 QSP-7.0 A040KPGCP-19 STP-PP-0020 I
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QSP-8.0 A040KPGCP-20 STP-PP-0D21 QSP-9.0 A040KPGPC-23 STP-PP-0022 m..,"
A040KPGCP-24 STP-PP-0023 A040KPGCP-2S STP-PP-0024 A040KPGCP-25 STP-PP-0025 A040KPGCP-27 STP-PP-0025 A040XPGCP-28 STP-PP-0027 STP-PP-0028 STP-PP-0030 STP-PP-0031 STP-PP-0032 STP-PP-0033 STP-PP-0034 STP-PP-0035 8.
Nonconformance 'ST-QAP-2 6 STP-DC-021 STP-PMO-022 and Corrective ST-QAP-2.7 STP-DC-022 Action QSP-7.0 9.
Records ST-QAP-6.1 STP-0C-009 A040KPDCP-6 STP-PP-0011 QSP-9.0 A040KPGCP-24 STP-PP-0016 STP-PP-0027
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Audits ST-QAP-7.1 l
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ST.-qCP-1.1 A040KPGCP-22 1
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Receiving.
A040KPMCP-5 Storage, and A040KPICP-1 Handling 12.
Control of.
ST4CP-7.1 A040KPICP-3 Measuring and Test Equipment 13.
Housekeeping ST-QCP-2.3 A040KPGCP-4 i 14.
Civil-Struc-ST-QAP-5.3 A040KPCCP-1 tural/ Con-ST-QAP-5.4 A040KPCCP-2 i
struction/
...ST-QAP-5.6 A040KPCCP-3 i
Quality ST-QAP-5.8 A040KPCCP-4
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i Control ST-GAP-5.9 A040KPCCP-5 ST-QCP-4.1 A040KPCCP-6 ST-QCP-4.2 A040KPCCP-7 ST'QCP-4.3 A040KPCCP-8 ST-QCP-4.4 i
ST-QCP-4.S A040KPCCP-10 ST-QCP-4.6 A040KPCCP-11 A040KPCCP-12 ST-QCP-4.8 A040KPCCP-13
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MANAGEMENT A040KPCCP-15
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A040KPCCP-17 A040KPCCP-18 A040KPCCP-19 A040KPCCP-20
- 15. Mechanical ST-QAP-5.5 A040KPMCP-1 Coistruction/
ST-QCP-3.2 A040KPMCP 1 Quality ST-QCP-3.3 A040KPMCP-4 i
. Control ST-QCP-3.4 A040KPMCP4 i
- 16. Welding ST-Qh-2.2 A040KPMECP-1 ST-QCP-2.4 A040KPMECP-2 ST-QCP-2.6 A040KPMECP-3 ST-QCP-3.4 A04CKPMECP-4 ST-QCP-4.1 A040KPWCP-1 A040KPWCP-2 A040KPWCP-3 A040KPWCP-4 A040KPWCP-5 A040KPWCP-6 A040KPWCP-7 s'
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57-NDEP-5.1 ST-NDEP-6.1 18.
Paintings ST-QCP-4.7 A040KPCPP-1 and Coatings A040KPCPP-2 A040KPCPP-3 19.
Qualification ST-QCP-2.2 A040KPICP-4 of Inspection and Test Personnel 20.
Inspection.
ST-QAP-5.10 Test and Operating Status c.9 21.
Geotechnical ST-QAP-5.11 STP-PE-002 p--
STP-PE-003 i
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OAMRB AUDIT DOCUMENTATION
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.. REGULAT. ION-1.
10CFR50, Appendix B, " Quality Assurance Criteria for' Nuclear Power Plants and Fuel Reprocessing Plants" g,. 2 B.
INDUSTRY ' STANDARDS AND REGULATORY GUIDES -
1.
ANSI N45.2 - 1977, " Quality Assurance Program Requirements for Nuclear Facilities" and Regulatory Guide 1.28. Revision 1, March,1978.
2.
ANSI N45.2.1.- 1973, " Cleaning of Fluid Systems and Associated Com-ponents During Construction Phase of Nuclear Power Plants" and Regu-latory Guide 1.37, March, 1973.
3.
ANSI N45.2.2 - 1972, " Packaging, Shippinf Receiving, Storage and Handling of Itasq for Nuclear Power Plants (During the Construction Phase)".and. Regulatory Guide 1.38. Revision 2. May,1977.
4.
ANSI N45.2.3 - 1973, " Housekeeping During the Construction Phase of Nuclear Power Plants" and Regulatory. Guide 1.39, Revision 2 September, 1977.
5.
ANSI N45.2.4 - 1972, " Installation. Inspection, and Testing Requirements for Instrumentation and Electric Equipment During the Construction of Nuclear.Powe.r Generating Stations" and Regulatory Guide 1.30, August, 1972.
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4.
-6.
ANSI N45.2.5.- 1974, " Supplementary Quality Assurance Requirements for
.M Installation, Inspection, and Testing of Structural Concrete and Struc-tural Steel.During the Construction Phase of Nuclear Power Plants" and Regulatory Guide 194 Revision 1. April,1976.
7.
ANSI N45.2.6 - 1973, " Qualifications of Inspection, Edamination, and Testing Personnel for the Construction Phase of Nuclear Power Plants" and Regulatory Guide 1.58, August,197.3.
8.
ANSI N45.2.8 - 1975, " Supplementary Quality Assurance Requirements for Installation, Inspection and Testing of Mechanical Equipment and Systems for the Construction Phase of Nuclear Power Plants" and Regulatory Guide 1.116. Revision 0-R, June,1976.
ANSI-Nd5.2.9 - 1974, " Requirements for Collection, Storage, and Main-I 9.
tenance of Quality Assurance Records for Nuclear Power Plants" and Regulatory Guide 1.88, Revision 2, October,1976.
- 10. ANSI Nd5.2.1'O - 1973, " Quality. Assurance Terms and Definitions" and Regulatory Guide 1.74, February,1974.
- 11. ANSI N45.2.11 - 1974, " Quality Assurance Requirements for the Design of Nuclear Power Plants" and Regulatory Guide 1.64, Revision 2, June,1975.
12.
m
. ANSI N45.2.12 - 1977, " Requirements for Auditing of Quality Assurance Programs for Nuclear Power Plants"
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Procurement of Items and Snrvices for Nuclear Power Plants" and Regu-latory Guide 1.123, July,1977.
C.
STP PROGRAM REQUIREMENTS 1.
Brown & Root, Inc. Quality Assurance Manual
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2.
STP Quality Assurance Program 3.
STP FSAR, Section 17.1.2, including Topical Report B&R-002A,. Revision
- 2. June, 1977
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5.
STP Non-nuclear Q.A. Manual' D.
STP CUALITY ASSURANCE PROCEDURES Organization 1.
ST-QAP-1,1, " Houston QA Organization" 2.
ST-QAP-1.2, "Sita QA Organization" Administration 3.
ST-QAP-2.1, " Preparation of Project. Program Documents" 4.
ST-QAP-2.2, " Control of Project Program Documents"
.u.,.
5.
ST-QAP-2.3, " Document Conhl" h
6.
ST-QAP-2.4 "QA Document Review" 7.
ST-QAP-2.6, "Noncenformances and Corrective Action" 8.
ST-QAP-2.7 "Stop Work" 9.
ST-QAP-2.8, "Mangement Review"
- 10. ST-QAP-2.9, " Personnel Training and Qualification"
- 11. ST-QAP-2.10. " Meetings and Telephone Conversations"
- 12. ST-QAP-2.11. "Foms Control" Encineerino
- 13. ST-QAP-3.1, " Engineering Quality Assuranca" 14.
ST-QAP-3.2 " Field Design Changes" Procurement 15.
ST-QAP-4.1, " Vendor Surveillance"
.. A 16.
ST-QAP-4.2, " Houston Purchasing"
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ST-QAP-4 3, " Field Purchasing" L
ST-QAP-5.1, " Subcontracted Quality Control Services" e,
- 21. ST-QAP-5.3, " Surveillance of Pittsburgh Testing Laboratory" ST-QAP-5.4.." Structural Integrity Test" 22.
- 23. ST-4AP-5.3, " Stainless Staal Tanks"
- 24. ST-QAP-5.6. " Post-Tensioning"
- 25. ST-QAP-5.8, " Containment Liner" 26.
ST-QAP-5.9.. "Stafitless Staal Liner"
- 27. ST-QAP-5.10. " Inspection. Test and Operating Status"
- 28. ST-QAP-5.11. "Sita Geotechnical Surveillanca" Records
- 29. ST--QAP-6.1, " Project QA Records"
- 30. ST-QAP-6.2 " Codification of Occuments" bD Auditino 31. 'ST-QAP-7.1, " Houston QA Audits"
- 32. ST-QAP-7.2, " Management Audits"
- 33. DQ-412. " Quality Assuranca Management Review Board" 34.
DQ-420, " Management Audits" E.
STP 00ALITY CONTROL PROCEDURES Procurement 1.
ST-QCP-1.1, " Receiving and Storage Inspection" Construction - General 2.
ST-QCP-2.2, " Welder and Welding Operator Qualificatien Verification" 3.
ST-QCP-2.3," Housekeeping" 4.
ST-QCP-2.4, " Weld Material Centrol"
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ST-QCP-2.5, " Surveillance of Controlled Documents" s
6.
ST-QCP-2.6, " Weld Procedure Qualification" l
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Constructicn - Mechanical
\\
7.
ST-QCP-3.2, " Field Fabrication - Miscellaneous Staal and Piping
.,])
8.
ST-QCP-3.3, " Hoisting, Rigging and Transportation" 9.
ST-QCP-3.4, " Weld Control-Mechanical"
- 10. ST-QCP-3.5, " Piping Installation" Construction - Civil
- 11. ST-QCP-4.1, "Wald Control - Structural and Misca11aneous Staal for Category I Structures"
- 12. ST-QCP-4.2 "Cadwelding"
- 13. ST-QCP-4.3, " Reinforcing S_tael"
- 14. ST-QCP-4.4, "Concreta Inspection" 15.
ST-QCP-4.5, " Structural Steel Erection"
- 16. ST-QCP-4.6, " Control of Grouting"
- 17. STM4.7, " Protective Coatings" f,'f.?j
- 18. ST-QCP-4.8 " Waterproof Membrane"
- 19. ST-QCP-4.9 "Vibrofl,otation" Measurina and Test Ecuipment, 20.
ST-QCP-7.1.," Tool and Equipment Calibration" F.
STP NONDESTRUCTIVE EXAMINATICN PROCEDURES Genera 1 1.
ST-NDEP-1.1, "NDE Procedure Qualification"
' ' '2.'
ST-NDEP-1.2, " Marking Requirements for NDE" Radiocrachic 3.
ST-NDEP-2.1, " Radiographic Examination" Visual 4.
ST-NDEP-3.1, " Visual Examination"
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ST-NDEP-4.1, '" Liquid Penetrant Examination"
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Macnetic Particle
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ST-NDEP-4.1, " Magnetic Particle _Examiriation" w
Ultrasonic 7.
ST-NDEP-6.1, " Ultrasonic Examination"
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G.
STP OUALITY SURVEILLANCE PROCEDURES i,
' 1.
QSP 1.0, " Vendor Suheillance Program" 2.
QSP 2.0, " Vendor Surveillance Organization"
'3.
QSP 3.0, " Control of Quality Surveillanca Procedures"
~
~
4.
QSP 4.0, " Vendor QA Program Evaluation" 5.
QSP 5.0, " Vendor Pre-award Survey" 6.
QSP 6.0, "Sourca Surveillance" 7.
QSP 7.0, " Control of Vendor Nonconfonnances" n
d 8.
QSP 8.0, " Vendor Audits"
....... "9.
'QSP_.,0
" Vendor Surveillanca Records" H.
STP PROJECT MANAGEMENT PROCEDURES 1.
STP-FMO-021. Revision 3. " Guidelines for Field Request for Engineering Action" 2.
STP-PMO-022. " Procedure for Evaluating and Reporting of Defects, Noncompliancas and Deficiencies" I.
STP ENGINEERING PROCEDURES Document Control 1.
STP-0C-001-F " Preparation of Project Procedure"
'2.
STP-0C-002-I, " Drawing Control" 3.
STP-0C-004-E, " Foreign Document Processing and Control" 4.
STP-0C-005-H, " Preparation and Control of Specifications" 5.
STP-0C-006-F, "Correspondenca and Ccmunicatien Control" i,
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76."STP-OC,007-F " Preparation and Control of System Design 0:scriptions" 3
7.
STP-0C-008-G, " Calculations" 8.
STP-DC-009-G, " File and File Storage" 9.
STP-0C-010-E, " Codification"
,,),
10.
STP-DC-011-C " Document DistMbution"
- 11. STP-0C-012-F, " Preliminary Safety Analysis Report (PSAR) Change Control"
- 12. STP-DC-01,3-C, " Document Change Notice Control"
- 13. STP-DC-014-E, " Document Review Comment Proces's"
~
- 14. STP-OC'-015-E, "Dasign Verification"
- 15. STP-DC-0,16-8, "Alara Review"
- 16. STP-DC-017-8, " Computer Program Documentation"
- 17. STP-DC-018-C, " Control of Industrial Security Documents"
- 18. STP-0C-019-D, " Technical Reference Control" 19.
STP-0C-021-8, " Engineering Design Deficiencies"
- 20. STP-DC-022-C, " Processing Deficiency and Disposition Reports"
- 21. STP-0C-023-F, " Field Requests for Engineering Action *-
a b i:
22'.
STP-DC-024-E, " Supplier Deviation Requests" Administra' tion
~
23 STP-AD-003-0, " Preparation of Inquiry Packages" 24.
STP-AD4004-C, "B'id Evalgation" 25.- STP-AD-007-8, "Preparatbn of Material Requisitions" Pro.iect Manacement 26.
STP-PM-005-F, " Interface Control"
)
27.
STP-PM-006-8, " Personnel Training" l
23.
STP-PM-010-C " Purchase Order and Subcontract Management" General Recuirements l
29.
STP-GR-001-B, " Manual Control" 30.
STP-GR-C02-C, "Proje,ct Engineering Organization" 31.
STP-GR-003-C, " Design Quality Program" 4
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. 32. STP-GR-004-D, " Preparation 'and Certification of ASME Section Documents" ~
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Project Enoineerino
- 33. STP-PE-002-B, " Administration of Geotechnical Field Activities"
.i'
- 34. STP-PE-003-B, "Geotechnical Field Engineering" J.
STP CONSTRUCTION PROCEDURES Civil 1.
A040KPCCP-1, Revision 2. " Construction Suneyt" t A040KPCCP-2, Revision 0, " Structural Backfill" 3.
A0400CCP-3, Rr. vision 7. " Pre'-Pour Inspection and Pour Card Sign Off" 4.
A040KPCCP-4, Revision 6. "Concreta Placement"
~
5.
A040KPCCP-5, Revision 4, "Concreta Patch'ing, Finishing, and Preparation of Construction Joints
- 6.
A040KPCCP-6,' Revision 3. " Grouting" 7.
A040KPCCP-7, Revision 2. " Reinforcing" Staal Activities" 8.
A040KPCCP-8, Revision 2. "Concreta Curing" g,
9.
A040KPCCP-10. Revision 1. " Rigging" n
- 10. A040KPCCP-11, Revision 2. "Rainforcing Steel Mechanical Splicing (Cadwelds)"
- 11. A040KPCCP-12. Revision 2. " Instal 1ation of Watenroofing Membrane Systas"
- 12. A040KPCCP-13, Revision 1. " Installation of Miscallaneous Embedded Matartals"
- 13. A040KPCCP-15. Revision 3. ", Fabrication of Miscallaneous Steel"
- 14. A040KPCCP-16. Revision 1 "Concreta Pre-Placement Planning"
- 15... A040KPCCP-17. Itavision 1. " Erection of Category I Structural Stael"
- 16. A040KPCCP-18, Revision 0, "Trumplate Assembly and Sheathing Installation"
~
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- 17. A040KPCCP-19 Revision 1, "Shotcreta"
- 18. A040KPCCP-20, Revisien 0, "ECW Pipe Excavatien and Backfill"
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Document Control
- 19. A040KPDCP-1, Revision 3. " Documents Control Centers General Procedures"
- 20. A040KPDCP-2, Revision 3, " Receiving Documents"
~
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- 21. A040XPDCP-3, Revision 3. " Distribution of Documents" y-
- 22. A040KPDCP-4, Revision 0, " Reproduction o,f Occuments"
- 23. A040KPDCP-5, Revision 3. " Recovery and Destruction of Superseded Documents" I
- 24. A040pDCP-6, Revision 1; " Central File System"
- 25. A040KPDCP-7, Revision 0, " Computerized Document Control System" General
- 26. A040KPGCP-1, Revision 3. " Preparation and Control of Quality Construction Procedures"
- 27. A040KPGCP-2, Revision 3. " Field Procurement"
- 28. A040KPGCP-3, Revision 1. " Field Purchasing of B&R Furnished Items and Services for B&R Account"
- 29. A040KkGCP4, Revision 0," Housekeeping"
- 30. A040XPGN-6, Revision 2. " Field-Sponscred Subcontracts (under $100,000.00)"
31. A040KPGCP-8, Revision 1. " Subcontractor Technical Conference"
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- 32. A040KPGCP-9.. Revision 2. " Bid Comparison /Recamendations and Draft of.
Field Subcontracts"
- 33. A040KPGCP-11, Revision 1. " Subcontract Close-out" l
l
- 34. A040KPGCP-12. Revision 1, " Subcontract Bidder Site Visit"
- 35. A040KPGCR-13, Revision 2 " Indoctrination and Training"
- 36. A040KPGCP-14. Revision 0, " Subcontract Backcharges" l
-37.
A040KPGCP-15. Revision 1. "Backcharges"
.:u
- 38. A040KPGCP-16. Revision 1. " Preparation and Issuance of Subcontract Inquiry Addendum"
- 39. A040KPGCP-17. Revision 2. " Field Expediting" I
40.
A040KPGCP-19. Revisicn 0,'" Site Subcontract Infor nation Records",
- 41. A040KPGCP-20 Revision 0,'" Subcontract Inquiry Preparation for Field-Sponsored Subcontracts"
- 42. A040KPGCP-21, Revision 5, " Field Request for Engineering Actien" and GM-34030, " Interim Procedure - Civil / Structural FREA's"
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' A040KPGCP-22. R~evision 7. General Material Receiving and Storage" 3
- 44. A040KPGCP-23 Revision 1
" Field Sponsored Subcontracts (over i
$100,000.00)"
- 45. A040KPGCP-24 Revision 0, " Site Subcontract Filing SysEem"
- 46. A040KPGCP-25. Revision 0, " Field-Sponsored Subcontract Change Orders"
- 47. A040KPGCP-26, Revision 1
" Approval of Vendor Drawings"
~
- 48. A040KPGCP-27. Revtsion 1. "Sidder Evaluation"
- 49. A040KPGCP-28. Revision 0, " Preparation of Field Requisitions"
~
InstH
.tation.
j
- 50. A040KPICP-1, Revision 1. " Receiving Functional Check, Storage and
'i Handling of Instrumentation" 51. A040KPICP-3, Revision 1."GeneralCalibrationProcedure"
~
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- 52. A040KPICP-4, Revision 0, " Qualification and Certification of Calibration Facility Personnel" Mechanical
- 53. A040KPMCP-1, Revision 0, " Trenching and Backfilling"
- 54. A040KPMCP-2, Revision 0, " Field Fabrication and Installation of ASME
~
Piping Systems and Components" A040KPMCP-3, Revisic' 1. " Handling Storag'e, Installation and Main-55.
n tenance of Pemanent Nuclear Equipment"
- 56. A040KPMCP-4, Revision 0,, " Mechanical Pipe Drafting" -
- 57. A040KPMCP-5, Revision 0, " Handling and Tagging of Piping Valves"
- 58. A040KPMCP-6, Revision 0, " Pressure Testing of Pipe Systems and/or Components" Painting
- 59. A040KPCPP-1, Revision 0, " Qualification of Application Perscanal (Service Level I)"
- 60. A040KPCPP-2, Revision 5. " Coating Senica Level I Steel"
- 61. A040KPCPP-3, Revision 3. " Coating Miscellaneous and Structural Steel" Hn6erisIn Gne neerina
- 62. A040KPMECP-1, Revision 6. " Qualification of Welders and Welding Operators"
- 63. A040KPMECP-2, Revision 1
" Field Fabrication and Erecticn of Structursi Steel to. the Requirements of AWS 01.1" 7w
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- 64. A040KPMECP-3, Revision 1, " Field Fabrication and Erection of Piping 4
t-
Systems and Components Non-Nuclear Systems" G
- 65. A040KPMECP-4, Revision 1. " Field FabMeation and Welding of Piping Sistems and Components (Nuclear Systems).
Weldino Centrol i
)
'66.
A040KPWCP-1, Revision 3. "ControT of Welding Materials" l
- 67. A040KPWCP-2, Revision 3, " Administration and Organization of Welding Engineering Department"
- 68. A040KPWCP-3, Revision 2. " Administration and Organization of Walder j
Qualification and Training Center"
- 69. A040KPWCP-4, Revision 5. " Administration and'0peration of Wald Data Control Center" 0.
A040KPWCP-5, Revision 3 " Administration and Organization of Field Weld Technical Center"
~
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- 71. A040KPWCP-6, Revision 2. " Functional Check of Electrode Ovens"
- 72. A040KPWCP-7., Revision 1. " Maintenance of Welding Power Supplies" Weldino EnoineeHno Standards -
- 73. A040KSWES-1, Revision 1. " Stud Welding"
^
- 74. A040KSWES-2, Revision 1. " Calibration and Operation of Oxygen
~
Indicators"
- 75. Aca0KSWES-3, Revision 0, " Field' Welding of Main Ste'am condenser *
- 76. A040KSWES-4, Revision 0, " Field Welding of Aluminum-Bronze Pipes (InspectionPlan)"
K.
STPPROCdREMENTPROCEDURES 1.
STP-PP-0001
" Procedure for PrepaHng Purchasing Proca'dures" 2.
ITP-PP-0002, "Precedure for ' Handling InquiMes for Engineered Equipment and Bulk MateHa14" 3.
STP-PP-0003, " Procedure for PrepaHng Purchase Orders ~ for Engineered Equipment" 4.
STP-PP-0004, " Procedure for Preparing Purchase Orders for Bulk Materials" 5.
STP-PP-0005, " Engineered Equipment Purchasing Procedure" 6.
STP-PP-0006, " Bulk Materials Purchasing Procedure" 7.
STP-PP-0007, " Procedure for PrepaHng Purchase Change Orders for Engineered Equipment" 8.
STP-PP-0008, " Procedure for PrepaHng Purchase Change Ordars for Bulk MateM als"
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STP-PP-0009, 'Pibcadu're for Purchasing Review and Evaluation of Bids"
- 10. STP-PP-0010. " Procedure for Purchasing Evaluation of Vendors"
~
- 11. STP-PP-0011. " Procedure for Purchase Order F1Thanization"_ _
~
12.
STP-PP-0012. " Procedure for Developing-Edipment and Material Lead-Times"
- 13. STP-PP-0014. " Procedure for. Personnel Indoctrination and Training" 14.'
STP-PP-0015. " Procedure for the Control of Procurement Do.curleitts"
- 15. STP-PP-0016, " Procedure for Purchase Order and Subcontract File Storage and Safskeeping".
- 16. STP-PP-0020. " Procedure for Handling Inquiries - Engineered and Field Subcontracts"
- 17. STP-PP-0021. " Procedure for Preparing Engineered Subcontracts"
- 18. STP-PP-0022. " Procedure for Preparing Field Subcontracts"
- 19. STP-PP-0023. " Engineered Subcontract Purchasing Procedure"
- 20. STP-PP-0024. " Field Subcontract Purchasing Procedure"
- 21. STP-PP-0025. " Procedure for Preparing. Purchase Change Orders for Engineered Subcontracts"
~
- 22. STP-PP-0026. " Procedure for Preparing Purchase Change Orders for Field Subcontracts"
- 23. STP-PP-0027. " Procedure for Subcontract Flie Organization"
- 24. STP-PP-0028, " Engineered / Field Subcontracts Latter of Intant Purchasing Procedure" 25.
STP-PP-0030. " Procedure for Expediting Purchase Orders and Subcontracts"
- 26. STP-PP-0031. " Procedure for Reporting Material and Equipment Status"
- 27. STP-PP-0032. " Procedure for Traffic Function"
- 28. STP-PP-0033, " Procedure for Field Purchasing"
~ :
' 29. STP-PP-0034, " Procedure for Field Purchasing of Non-Safety Related
. Materials"
- 30. STP-PP-0035, " Procedure for Field Purchasing of B&R Furnished Itams and Servicas*
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Sub.iect Resconsibility
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control of Identification and Changes to Design EngineeHng T'.'
Inputs 2
Contro.1 of Design Manuals EngineeHng J.4 3
Approval of Civi1-Structural FREA's Engineering
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4 Design Verification of FREA's Engineering
..,/
5 FREA's Used for Disposition of Non-confomancas Enginsedng Quality Assurance Construction 6
Incomp.fets FREA's Filed in Site Q.A. Vault QualityAssurancets.i.
7 Incorrect Attachment to Engineering Procedure Engineering d 4. /
STP-DC-23-F 8
Record Retention System Quality Assurance Engineering Procurement Construction 9
. Procurement Review and Approval of SDR's Engineering 10 Expf~rsfTnginsedng Procedure STP-0C-017-B EngineeH ng 1
11 Correct Procedures for Piping Fabrication Construction 12 Concreta Sampling Point Quality Assuranca 0-13 Performance of Concreta Compressive Strength Quality Assurance.r..
Tests 14 Painter Qualification Records Construction 3
15 DDR Resol.ution Quality Assurane A Quality Assurance
- 16 Internal Audit Program 17 ADR' Resolution Quality Assuran"i'f)
--18 bips.of Quality Assuranca Document' Quality Assuranc #
Transmittal Acknowledgement 19 Centrol of Quality Assuranca Program and Quality Assuranca Procedure Changes 20 EngineeH ng Training Records Enginsedng 21 Quality Assurance Training Records Quality Assurance 22 Procurement Training Program and Records Procurement 23 Receiving Inspection of Owner /Other Supplied Quality Assuranca 24 Promptness of Quality Receiving Inspection Quality Assuranca 25- ~
Notification of ANI for Receiving Inspection Quality Assuranca 26 Definition of Storage Area Levels Construction 27 Construction Release of " Hold" Equipment Construction 28 Exptred. Quality Assuranca Procedure ST-QCP-7.1 Quality Assuranca 29 Approval of Lengthening Calibration Intervals Quality Assurance Construction
-- --f.eli ; ratter. Interval of Pressure Gages
. Construction 31 Qualification of Outside Calibration Quality Assurance g,
32
- Desia"? tion of Housekeeping Zones Constructicn 33 Housekeeping Surveillance Inspections Quality Assuranca
---and-Repo rts
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l sag muconsasapesariosess Provide required identification, documentation, approval and control of design inputs and changes thereto pMor to translation of these inputs into design output documents (i.e. specifications, drawings, calculations, etc.). Expeditously update design input documentation for existing final design and re-verify that design to assure com-I.-.
.1 pliance with design inputs.
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Page 2 of 3 Occument Violated and Paracraoh (Citeh i
ANSI N45.2.11. " Quality Assurance Requirements for the Design o'f Nuclear Power y
i P1 ants" A.
Section 2.2
" Procedures shall be employed to assure that design activities are carried out in a planned, controlled, orderly and correct manner.
Pro-gram procedures shall cover the following as applicable:-
8.
Identifying appropriate design inputs."
5.
Section 3.1
" Applicable design inputs; such as design bases, regulatory requirements, codes and standards, shall be identified, documented and their selection reviewed and approved. Changes from specified design inputs including the reasons for the changes shall be identified, approved, documented and controlled.
The design input shall be specified on a timely basis and to the level of detail necessary to permit the design activity to be carried out in a correct manner and to provide a consistent basis for making design deci-siens, accomp1.ishing design verification measures, and evaluating design changes."
C.
Section 4.1
" Design activities shall be prescribed and accomplished in accordance with procedures of a type sufficient to assure that applicable s
3 design inputs are correctly" translated into specifications, drawings, nea* =
a-4==+*uctions.
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D.--,Section.-6.4
" Measures shall be applied to vertfy the adequacy of design.
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Design verification is the process of reviewing, confirming, or substan-
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~~~ 1ating the desicin by one or more methods to provide assurance that the t
, design meets the specified design inputs."
The following definitions apply to the cited paragraphs:
A.
Design - Technical and management processes which ccamence with identifi-cation of design input and which lead to and include the issuance of design
...___..._ output documents.
n_
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<n. rnnn+. N*e criteria, parameters, bases or other design require-ments upon which detailed final design is based.
C.
Design Output - Documents such as drawings, specifications and other documents defining technical requirements of structures, systems and j
components.
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--CFTNai ges1gn - Approved design output documents and approved changes
_ thereto.
i Observations-
~t being identified, approved,
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anner as required
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The B&E Q.A. Manual a~nd Engineering Procedure STP-0C-007-F define the System Design Descriptions (SD0's) as the documents containing the design inputs and their sources. The SD0's are defined as the basis for developing the design output documents (i.e., Purchase Specifications, Construction Speci-fications, Calculations and Drawings).
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- AUDIT DEFICIENCY REPORT I
A PacuscT: South Texas Pro,fect Jos NO.
UNIT:
PA23:
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If the SDD's and ancilliary documents constituta the Interim Design. Manuals rigorously enforca its definition and maintenance within each discipline such that a completa and up-to-data description of design bases can be provided for members of the l
discipline and interfacing disciplines.
~
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Page 2 of 2 -
N Doe"=nt Violated _and paracraoh (Cite):
~
f STP-0C-007-F, paragraph 2.8 "The STP Design Manual is the ecmposite of all.
the completed and approved 500's. This is inclusive of these ancillary docu-
~
.a ments (specifications, calculations, drawings, etc~.) that have been approved and controlled during the interim.
... Each OPE will maintain a ecmpleta controlled copy of the STP Design Manual in a place that is readily accessible to members of his discipline."
STP-0C-007-F, paragraph 31 "Each 500 is the STP sourca document in'which the '
design bases for a structure, system or component are descr.ibed and their design inputs / origins described."
Observations:
being con-ti; ' 'ad ~ 4-+ '- ', _...... o n nes = T= ui reo oy edure.
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9
-" r, design SLu
+**en'*^**
_ a..winea in tne ancillary documents b.
"-aa=*
m (spar 4*4c=tiens. crawines. calculations. etc.) are not being controlled and
..fcussions maintainec as part u we air uesign Manuat. ns me rus
. w.
with vardem OPE's. it became evident to tha ="d**-~
- hat the. definition of designhses Witstac in varww.. w..:nts in multi-locations add it was doubtful that a clear, concise,ccmole+= ' '. '
'"- d-Hotion of hsystem's design
- bases coula oe. p. w.....wn these various documedfs..
. dnable time.
In
--d
'G its and pieces one instanca, these desim ' ---
throus m e
-an*" and "would be more troubla *n ra-didata in one place anu mintain up-to-cata r.a.u
....uv we suo 's current.$ While all
....r control, Q
dad 4 -d their confidenca +*=++6-b") disciptinaaitty4s no{syiden_t to tne auair. ors unac tnere was established clearly defined a
control mechan u
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-'N wi+ win **- - d a--Mng discipline.,
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N QUAUTY AkihuMAnut uerAM: man s AUDIT DEFICIENCY REPORT Pnoascr: South Tava* 8'mjeC9 JCe NO.:
UNIT:
PAGE: I ' OF I
3 (11 Awestant oneAs.esatsen tal Auss? see.
(at Asse me.
tel Aem coes 8&R Engineerini _- _--
QAMRS-3 3
i,i...sw s= -irm.
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poi cavseeavi R. Peverlev J. Norris, R. Xinecaid L
6 / 7/ 78 IOtti C28, 7888 t : oocuneaar vsei.Arso Ano pamAenAree scar:3 l
Attachment to A040KPGCP-21 Revision 5. " Interim Procedure Civil-Structural FRhi*
(Revised 5-18-78), paragraph 3.8 "Upon receipt of an FREA that has been approved as a deviation to a safety-related drawing by the PSE, the required signature cycle
_ grou_gh_the E_PM di n_c,1 u_d_,i n_g t_h_e.d.f_esign_ve,t lerl m_u s t_be_ cap 1.g.ted. "
tf ii.
Ari.
Following review of the Civil-Structural FREA's for May,1978, there was no h
objective evidence of timely compliance with the cited requirement on site e
approved deviations to safety-related drawings.
Esangles are the following 2
FREA's:
2; 1-C-1021,1-C-1026, 2-C-1029, 2-C-1030,1-C-1034,1-C-1035,1-C-1036, 2-C-1050, 1-C-1052, 1-C-1057, 1 -C-1059.
is s3 poTaseTIAh asposeTA a a carissancy O v==
3==
l al sescossesamoATseso.e 1.
Review previously site-approved FREA's and provide required signatures.
2.
Re.*ise procedure to require timely signature approval of FREA's.
1I Y d D l"_.Q"oCedure.
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pi e mars.
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To be ampleted by audited crynnizatices siri s===== rive Acri = =_ _ _. sw u s es,
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last puesvaserAveva Acrieses gasosa.wes assessua.se coasphsTless 0A753 las4 su. ass 7Tsus eve jtaas oATas i
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To be cornaleted by B&R Quality Amtrance (239 8tEVIEW Op.gspq3mese (241 flsV.EW EED Ev.
3 (131 O ATs.
Q Satistx cry C Unnrisfactorv f
//
lael.ssukrs er vengpgCA71ome (3:3vs.0FiED ev.
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YORQgg,;ggw;a.gaw;;.w.w.ve.mm:rd n m m AUDIT DEFICIENCY REPORT PO 3
,,s. JECT: South Texas Project Joe NO.
tJNIT:
PAGE:
I OP I
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isi....r i. e -.....
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B&R Engineering QAMRS-3
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- .T-i.l occuseSMr VIG6ArEo As.O PAR Adm Apee ic3rt3.
STP-0C-023-F, paragraph 2.2
" Field requests... that fall within the criteria s,,,
of Table I require formal engineering approval prior to implementation."
STP-DC-015-E, paragraph 2.3.5 "FREA's require verification to the same d
s the g,_egree.a,.,,g,or_i gi.nal_do.c.ument_. " _ _ _ _ _ _ _
The following sampling of FREA's were not doctmen.ed as having had a design
>y verffication:
E 1-E-0001,1-E-0002,1-E-0006.1-E-0009,1-E-0011.' 1-E-0012.1-E-0098 3
1-C-1025.1-C-1035, 2-C-1050.1-C-1052,1-C-1057.
i a
i
.: si perusers.t.as, ear..e a os,scaancy Q ves
$ so.
isas masonesesp.oarson..
Ccmply wi'h the procedure.
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QUALITY ASSURANCE DEPARTMENT -
AUDIT DEFICIENCY REPORT l
PnoJacT: South Texas Project Jos NO.:
UNIT:
PAGE: I oF 2
toi musetse omeamesai swi, gal Aust? me, gag men me.
(46aos cons B&R Engineering / Quality Assurance / Construction OAMRS-3 5
1.losseuesso aff as getmaposrvan ave g(71 OAfsa (el CATseenvs R. Peverley J. Norris, R. Xinecaid 6 / 7 / 78 Otii Otaf
- i. o.sunsa,v.. urs..no,.m m.- ic.vai.
.j B&R Quality Assurance Manual. STP Supplement Section 15.3 "Upon identification of a nonconformance.... the DDR shall be originated by B&R Quality Assurance for such findings."
y,,_,,,,_,,,,,_._____.___________________
t; FREA's are being utilized for disposition of nonconformances.
Examples are the following FREA's from May, 1978:
E g
0-C-1018. 0-C-1025, 0-C-1033, 1-C-1034, 1-C-1038, 2-C-1040, 1-C-1051, 2-C-1055, 1-C-1057. 1-C-1063, 2-C-1064.
a e
4 -== -
i t 3 povanrnas naposrvAa6a asricssacy C van hme taas necessassmearsomee- -
(seeattachment)
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L. Hayden/H. Pacerne/
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Reconnendations:
I Discussions revealed that the FREA is used in lieu of 00R's because of built in
'.'t delays in the initiation and processing of the 00R's.
It is recen= ended that the procedure for disposition of nonconfomances be simplified to provide rapid initiation and disposition of nonconformance of all items.
It is also recomended that the FREA procedures be revised to remove "nonconfomance" as a form of FREA disposition and instead provide a mechanism for Construction to identify non-confomances to Site Quality Assurance for initiation of 00R's. '
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AUDIT DEFICIENCY REPORT
- g. PnoJacr: South Tcxas Project JC3 NE:
UNIT:
PAGE:
I CF l
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88R Cuality Assurance (site)
QAMRB-3 6
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$90 G.CuMENT V4. BATE. AM. PAR A. A Appe (G37Els B&R Q.A. Manual. Section 17.4 "All Q.A. Records, after being stamped; 'shall bv.?
reviewed for validity, legibility, completeness, and traceability..."
g,,y,,g,,,___-__________----,_____-
The following FREA's are examples of FREA's filed.in the site Q.A. Vault as l
completed but lack formal approval through the complete signature cycle:,
w E
1-C-0792, 1 -C-0793, 1-C-0796, 1-C-0802, 1-C-0814,* 1-C-0830, 1-C-0834.
Wc rii T..T..
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..........no...
Only maintain records in the Site Q.A. Vault that.are completa. Sita Q.A. Vault personnel should be instructed to reject records that are incompleta.
8 J
inas
._ -- _ we Auqainau pn ea T..
ii.: 4, vs..v.
pi.e ars.
~'i f nc 7 f t./
i Ta be completed by audited orpaniastica iiF) 6 83 64 ACTi.as m-
- -_a iasuga AA.S ***a-maabs. 6.eSebETi.Se. ATW3 r.
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li.i P895WENTATIVE ACT1.se. (8seca.M.E SCMS wks. C.espbgfi.88. ATE)
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To be comcleard by B&R Cuality Assurancs last asvesw or maspose.es Last nav.sws..v j (ast GATES j
Q Satisfactorv Q Unserisfac:crv f
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l lael8853u4.73 yvengP CAT 1.Me iB71 VgniFig. 73 j (188 GATES Q Satafactorv Q Unsetnfae cry l
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_-B M y.p,. G.,- L i g,g w p ;. z a r:z o m. w wm9M
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. nw AUDIT DEFICIENCY REPORT PROJECT: Ssuth TexasiProject Jos NO.:
UNIT:
PAGE: 1 OF 1 q
(sl Awestas emeasseaarnese las Auss? pee.
(ataan me.
(43 Asa coes B&R Enoineering._.__
CAMRB-3
'7. -
(seosesuessa.stus get papestvse ers g(73 sATas istCATESe#ve J. E. Paden J. Norris, R. Xinecaid 8
6
/ 9 / 78 Ossi Otai O
- i..e.u -.av vio u r A.....As..,.ei. 73, ANSI N45.2, Section 7 "Those participating in an ' activity shall be made aware of
~
and use proper and current instructions, procedures, drawings and engineering requirements for perfoming the activity."
g g,,_,,,
STP-0C-023, Attachment A "STP-PMO-021. Rev. 3. GUIDELINES FOR FIELD REQUESTS FOR l
ENGINEERING ACTION." The attachment to this procedure is stated to be Rev. 3; where in fact the cover page noted Rev.,.2.
All following pages, however, are m9 titied Rev. 3. - However, when these pages are compartd with the actual procedure lh in the PMO manual (STP-PMO-021. Rev. 3), it is noted these are two different c
procedures.
t 1
(t e3 novant:Aa, mare mTAen.s osricas <v j
O v== '
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Revise procedure to provide correct attachment.
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f AH Qtelotaa.a 7 /12/ T8 c ows (t s: Appseeves eve j(sel sA?ns 6
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%Q1 To be completed by audited organiastion (979 GSee#eET3WE ACTless RemseOSs 8teeShuSE 98306844E3 SteerbETlem SATE 4 e
(l88.IdeessTTEIB Sv s
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0 last anseestTTus eve 4333OATE:
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,0..
s sa..viewso v.
,iasi aarus Q Satisfac cry Q Unntisfactory I
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Q Satisfac: cry C Unstisfactorv l
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. QUAUTY ASSURANCE DEPARTMENT -
'./~
AUDIT DEFICIENCY REPORT
~
g enoJacT: South Texas 9 roject Jos NO.:
UNIT:
PAGE: I OF 4
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.a B&R Q.A./Engrg./ Procurement / Construction OAMRS-3 8
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(see attachment) ines smv 7 s.sose_. _
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Q Satisfactory Q Unansfactorv
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~
Document Violated and Paracraoh (Cite):
10 CFR 50, Appendix B, Criterion XVII
" Sufficient Records shall be maintained
- to furnish evidence of activities affecting quality.
... Records shall be identifiable and retrievable.
Consistent with applicable regulatory requirements, the applicant shall establish requirements concerning record retention, such as duration, location and assigned responsibility."
Observations:
~
n correlated records retention sy nd ANSI N.45.2.9.
I Str ra* " 1.
. 1
- Ci.37.iG6"*** "** Jr.d * * *" '"heen' tracts.
=
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-......y annecords retention systam.
lae.,,,., e so m e-4-
n Ju,E 56e-DC-000 ="I """ ' '" ' ""m nce e naoTi~i rdention m+-d-- _..mtr conflict as to Yhich organr:$-
p - -o
' tion was r=sonn***' - ~~ &m"' ~ a.- accuments.
'1 * "'
.z,..i @ Assurance Manual, no system ano no icenti-m
_ find r=+=ntion responsibil4*4 ae f _ I P _- '
.ne n t 4100 Clinton w. We.
_ n' 2
"--aa-e.,, v.111 ance j
s was of tne coinion QA
....m no or r,~e--
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- a personnea assured tha
="dd + -
=m rds was at f - r.m m..u i t.
% na veut+
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- ._:- M v site-keeps only "cuar m der w nesa.
a-a eaa4naaringsays it
- - - - - - "e")- <a- -+ - - t generatad 9 reu ou,_
- + ser.=.,tstien is already at
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p.archasino does not micro-Tl im; QA mie~#"~
,..,, y reet ana rrame. w....,c a,.%.ineering
.4,-
m,,,,. 4 s - -. 4 < <.
..1 1
,1 ws retrievability.,
Pur su4 3...... :.. ; '"-- hv TPNS number 3
y,,,..,....... m.u...
ane v="A"-
-... ~. -.. -.
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.anuur uccwnen ci 4re iww renumcertu.x.,us are filed i
bv_ - -
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Recomendations ---"
The records problem for South Texas Project does ngt, at present, lend itself h
to an orderly turnover of documents to the owner.
This will, if left unchecked,
/
very likely have impact on the acquisition of the operating license. Were sufficiently decisive actions taken imediately, this problem could be routinely solved, but would involve a number of manhours in order to assiare physical presence of the necessary documentation. To delay in this effort will prove costly.
One of the most difficult aspects of turnover is the vaHous possible. encodes-being used-
~
o TPMS:- Engineering and vendor documentation o
TPMS (vaHes scmewhat from Engineering TPNS) - QA documentation o
Vendor codes - Vendor Surveillanca docunentation
'o General Memoranda (and filing technique)
~
.- QA Engineering j
Construction Procurement.
a e v
o correspond,ance (and filing technique - alpha pair. acronym accass) qK
((
gy,-ineering Construction o
Purchase / Subcontract Number - Procurament/ Subcontracts i
' Subject File Cada - Hl.AP o
A second aspect is that each STP organization has set up its own filing technique
without-reel w..e.d-ration given to same function being performed by a sister organization.
Example:
00R's; Engineering files by GM number; QA by CDR
- number, t.xample: weld Procedures; Engineering files by GM number; QA could not retrieve; Construction by GM number.
Document locations &re indeterminate. Responsibilities for retention must be datamined so that backfitting can be done suecassfully to assure presence and completaness of documentation.
Frequently, necessary data are attached to
- correspondence-ee-memoranda (as noted above). This of itself is not a prcblem, but computer entries in the " subject" field do not shew a relevant doc =a+ """ e r Of any--Icind, uni [.n abbreviated or "first" weM antry. me- --%CM7
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.-w page 4 of 4 Cross-referencing of documentation in. the QA vault was not in evidence duHng this audit. The vaTaTt' supervisor indicated that this practice was not done since theirs was a repository function only.
Mcwever, this should not be the case since ANSI N45.2.9 requires visibility, traceability and retrievably.
'~' A matrix of the various codes used on relative documentation should be developed
~
in order to successfully pull together the necessary data packages from all sources.
Texas Utilities' Comanche peak Station is well into a significant records turn-over program. Retrievab111ty is excellent. Tracking through matrices to data package location is done through computer with a manual backup.
It'is a rele-vant and simple system being pulled together by knowledgeable p'ersons in an orderly and sensible manner. Currently, the turnover program is.about five months behind the actual construction effort; the program was started in January 1978.
Serious consideration of this turnover method for application to STP should be given.
Further, It is recomended that the STP microfiche be properly indexed and housed in cartridges t3~ fit 1nto readers located in DCC areas as well as in the field.
~
This provides a better control of documentation to assure that current data are being implemented across the board. Again, Comanche Pead DCC uses this technique m
and it is proving very useful and appears to be easier to control the access and use of control-led documentatien.
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AUDIT DEFICIENCY REPORT s
PnoJacT: South Texas P.roject Joe NO.:
UNIT:
PAGE: 1 OP I t s 8 Ae.sts. e so. AsstamTr --
(38 Av.ft see.
IatA.. me.
tol A.R Cesas B&R Engineering QAMRS. 3 9
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jet GeCu assMT veOL.ATED AMO,AAAeA A,te (C87Els STP-0C-024, paragraph 2.3 and Figure 1 "Fonn 200.60 is submitted by the supp1'ier to the Engineering Project Manager (EFM).
Engineering, with the assistance of Purchasing, is responsible for the review and disposition of SDR's in a timely i
_ _anner cons _isynt, wi_th_tha en,lgin,eerjn.g, an,,,,d cyngt.ry,gtignJqhedg]e.".
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2; There'was no objective evidence presented to docunent that Purchasing is invol'ved 2,
in the review'of Supplier Deviation Requests
g oval spot for Purchasing as required g
by STP-0C-024, Figure 1.
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(sas escoesassseoArioees.-
Comply with the procedure and revise Forn 200.60 to include a place for the approval signature of purchasing.
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pass navsawso evs jiaal cars:
Q Sarishetorv Q Unsatishctcrv l
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.c PROJECT: South Texaf Nject 'J03NO.:
UNIT:
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STP-0C-001-F, paragraph 2.7.1
" Review drafts may be issu'e'd simultaneously for interim use and review. The expiration date of the interim use will be shown on the cover sheet, and is usually 60 days from the date of approval."
p,,y,g,,,_,,_:-_____________----__-
h Engineering Procedure STP-0C-017-8 " Computer Program Occumentation", has been issued for " Interim Use and Review" since 2/13/78. No expiration date of the
=
E interim use is shown on the cover sheet.
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AUDIT DEFICIENCY REPORT g,, PncuecT:. Stuth Texas Project JoiNO.:
UNIT:
PA2e: 1 OF l 3
top avesfu.emeassesavnese tal Avest no.
tal Aan me.
tel Ae# C888 E&R Quality Assurance (sik)
OAMRB-3 12 a.i e-wrra.
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i.i carseeave J. Norris, R. Kingcaid
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/15 / 78 Oini Oisi Ci
$91 De4WasSMT Viet.ATED Ame PAmmemAppe (CETEls i,.,
ANSI N45.2.5. Section 4.8
" Pumped concrete mQst be sampled frem the pump line discharge."
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During the placement of concrete for lifts CI-1-W28, 28A and 33,.' he PTL t
l inspector was taking samples at the truck discharge (i.e., the pimp line intake)..
3 a
Es 3 3 povasevame. msPOftTASt.& OSFIC4SMCv O vas
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Ta be completed by audited organiastfors' inn viv.4r==.
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AUDIT DEFICIENCY REPORT PnCJECT: South Texas.Projcet Joe NO.:
UNIT:
PAGet I dF I
O sii e.v=.
a.
a._vea _.
sai avoiv ees.
in e== a==.
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B&R Constructinn QAMRS 11 ~
isiesesuseas ws7Ms geg as.esy?so ave g73o*Ts:
isi catseesevs l
R. Tavior L. Crowe, R. K11 mist 6 /15 / 78 Oiii O isi,Q. -
iS0 occusesset weehatso aseo panaamapee iC&Tais g
ANSI N45.2. Section 7 "Those participating in an activity shall be made awaC f
and use proper and current instructions, procedures, drawings and engineering
, requirements. for performing the activity."
7,,_
3,.,,
There is no objective evidence that any continuity exists for the fabrication and/or g
installation of pipes i.e.
45 ft. long by 30 in, diameter aluminum-bronze pipe is moved to the pipe fabrication shop where it is being double joined to a total 1migth I
of 90 ft. by 'the use of powered turning rolls and automatic weld equipment. The ni shop foremarr' stated that he was fabricating pipe in accordance with construction a
procedure A040KPMECP-4, which he had at his work station. The pipe superintendent '
stated that this' pipe was being installed because there is no cost code for fabri-cating pipe over 21s in. diameter. The Senior Mechanical Engineer stated that this pipe was being installed and the work was being performed in accordance with con-struction procedure A040KPMCP-2..This procedure was not available in the pipe -
fabrication shop.;
,,,,,,,,,,,,,,,,,,,,,,,,,,,o.,,.,,,,
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Provide the cirNet procedures to the working level penannel. Assure that the involved supervision understand the process and procedures which apply to work being performed in their areas.
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To be completed by santiend orgwriandoor (171 emanesTiviLAaviese mampe. esses iisses.use====aa.se see. 6sysese savus l'gies oatas i.ee eu.amef russ sve 7 7 138.Lesesvssevative actiose. eisessues assessus.se gossesaviese says inte sweaseTTan sv
, saas oaras
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QUAUTY ASSURANCE DEPARTMENT *
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AUDIT DEFICIENCY REPORT m
encJacT: South Texas _P.r.oject Jos No.:
unir:
paan: 1 op 2
- . ~iv
,s...
iii
(
B&R Ouality Assurance (site)
QAMRS-3
~
13 isi.
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i c.rs avi s R. Parrish R. Kinacaid, J. Norris 6 /15/78 Out Ol' iSt 4Wa.S., v b.vs3 Am. pam m.p., iC8753.
ANSI N45.2.5, Section 4.8 "In-process tests shall be performed during the course of construction... A list of the required in-process tests is -contained in Table 8...
l Material
~
Recuirement Test Methods
.. Test Freou'ency Concreta._,.. Compressive ASTM C39 Two cylinders for 28-day test from a
_. J.trengths each 100 car. yd. or a minimum of 9
one set / day for each class of e
~
o concreta (1D) Observations:-
A review of the daily compressive strengths register as maintained in the Quality Assuranca Vault.gave no objective evidence of compressive strengths test perfonned on concreta for the days of May 1, 2, 4 and 5.
Pours were verified as being made on these days.and are listed on the attached sumary.
o is vusevia s==,.
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Comply with the requirements of ANSI N.45.2.5.
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SUMMARY
During a_.._-ranted --_
_ _..,.. -44ma_ __.... _..: DA Vaul tC '2"~it was noted cae S, press &n@EE~*p.-F;ed jfad,dffn'g~BiTSe"datas an fys i c W a d i - & - '"
~f"r4MCalg;r 8, were foVi.;i =-x w ih i t r;.
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=~=. aard.iFwefe sitnessed to be sa.Eh " ;.i j.s R-U ntMi f s.-J.
wam--~" - ~ZM -
.....,..- or Pittsburgh 1
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Parrish sf.aitiR1 ae w
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pe was to phone back late
~W ta Si phcx..
=.sn, he was ad
}:i tas stw a a r d *h bthay were probably
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engTer,-.c i=s ts.
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_ n 22Cr _...- md4NNri Allan Hamens and determined l
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'...:-; nt.';. the dyr in question:
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C;t; Four Number
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(9:.:)
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~v 5/1/78 ME2MM1-PS
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5/2/78 ME2 MMS-PS 5/2/78 FH2W12-C
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5/2/78 FH152RL
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5/2/78 MEWOO7-03 l
5/2/78 ME1-WOO 1-1CD y
5/4/78 ME1-WO12-06
.o 5/4n8 ME1-WO11-01 2
5/5/78 MEl-WOO 4-04 i
~
5/5/79 MEl-WOO 1-04C 1
5/5/78 RYS-1 (Grouting) 5/5/78 RYS-2 i
5/5/78 RVS-3 l
5/5/78 RYS-4 i
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QUAUTY ASSURANCE DEPARTMENT-AUDIT DEFICIENCY REPORT PROJECT: South Texas Project Joe NO.:
UNIT:
PAGe:
1 OF 2 g,,
i i i
... -....=4 ri..
- .u.er iii i.e4=.c===
B&R Construction QAMRS-3 14 i.e.=v
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its o.CW.88.T WI.bArEO A.O PA. A..assee (g4733.
A040KPCPP-1, paragraph 3.1.1
" Prior to qualification testing, Journeyman Applicators will attend an application school provided by those paint manu,
facturers specified for containment and other safety related areas."
7,,y y -_
Applicator's. qualification records provided in the Q.A. Vault contained no objective g
evidence that P. Rackowitz or E. Longoria were quali ed by Ameron for either Dimetcota 6 or Amercoat 90. Applicators Coating for RCS #1 - Shell Liner-l (Amercoat 90Fdated 3/27/78 indicated P. Rackowitz applicator. Applicators lg Coating Records for RCS #1 shell (Amercoat 90) wall dated 3/28/78 indicated E. Longoria was applicator. Applicators Coating Records for RCS #1 - Shell Liner c
(Dimetcota 6) dated 3/19/78 indicated E. Longoria was applicator.
=
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comply with the precad' re.
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pi e oars...s A M ^*. *, " '
77.: " 3B f
J. Monroe '__
To be completed by audited organiation v ~- w
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$3 4 PUIEv8MTATIv4'AgT).asa }&MCa.M.4 3C346344.53 C.esph.TI.se OArsi i
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saan oars.
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lasi naview, assp. sa.
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Q Satisfactorv Q Unsatisfac:crv f
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.--- RELATED CONCERM
,f The QA Vault contained a record of applicators attendance and certification-o
(
}
from Amaron (Dimatecte 6 and Amercoat 90).
However, this certification by 4-~ '-- nimetcote 6 and a duplicate A pm -as-
.....e.
r,...,
.. T_s 5. The names contained on tin (by nameW'"
- nst
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- ^ ~ ' ~ ^ t these s f o i se-orig i.m..n e - 3 ;,.g.. car. orsi ova an* **=vad an this oroject since n
August 1S n _z -
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QUAUTY ASSURANCE DEPARTMENT,
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AUDIT DEPICIENCY REPORT l
+
Pnoascr: South Texas Project Jos NO.:
UNIT:
PAGa:
I OF 2
i.e uerr.
3.vi..
isi....,
isi a...
i.
B&R Quality Assurance QAMRS-3 15 l
ist ose uss wetne geim nvasseve giri..tsa ielCATEG.Rv.
A. Holbrook R. K11 mist, L. Crowe 9
6 / 9 / 78 Otii Otr
,'.8 8 L 899
.u8e.MT VI.e.ArE. AM.,44 A.M.,
i.3TEj e (seeattachment) g y-Adequate measures have not been established to assure that conditions adverse to y quality are promptly corrected.
l On the data of the Audit, June.9.1978, twenty-one (51)'open DOR's were listed on the g Houston DDR Log.-- Of these 21 DDR's, fourteen (14) had been open for a period longer.
than 60 days, with two (2) cpen for 9 months.
In the May Monthly Progress Report c
(dated June 6,1978), forty-six (46) open DDR's were listed on the Sita DDR Log.
Of i
these 46 DDR's, twenty-three (23) DDR's stated that the resolution status was " Dis-position Overdue".
d inni v ria.
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is as necessamano.rs.ne.
Provide procedural requirements for prcmpt response and resolution of 00R's.
Assure upper management involvement in 00R's which are not resolved expeditiously.
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glasi caras Q Satisfactorv Q Unsatisfactory t
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10 CFR 50 Appendix B, Criterion XVI
" Measures shall be established to
+-
assure that conditions adverse to quality, such as... are promptly iden-tified and corruted.
In the case of significant conditions adverse to quality, the measures shall assure that the cause of the condition is deter-mined and correct!ve action taken to preclude correction action."
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AUDIT DEFICIENCY REPORT D.
PROJECT:
South Texas Project JOSNO.:
UNIT:
PAGE: 1 CF 2 1
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Document Violated and paracraoh (Citelt ANSI N.45.2.12 Section 4.3.2.1
'" Checklists or procedures shall be used to ensure depth and continuity of audits. The audit checklist is intended for
',7 use as a guide and should not restrict the audit investigation when findings...,, raise ANSI N.45.2.12. Section 4.3.2.3
" Selected elements of the quality assurance program shall be audited to the depth necessary to detemine whether or not they are being implemented effectively."
. Obsdrvations:
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- M ementatgon.
In reviewing the checklists, findings and concerns from aucit repoMs BR-15, BR-18, BR-21. BR-25 and BR-28 there is a clear indication that the audit checklists have been prepared with a min that the ion manager for y-
~C.i __. - ? - -_ 'n_ot audi ted"
"" eu mee-ar+-that.-T e is, fro drfomed.
Reconsnendations:
Detailed management review should be perfomed of the effectiveness of our audit program. This review should include evaluations of audit management;
~
schedule and frequency of audits; scope and depth of audits; qualifications of auditors not only in auditing techniques but also in knowledge of regula-tions, standards and implementing procedures relative to the areas being OW. audited; and adequacy of manpower within the audit group in order to provide
-Q a complete and effective audit program.
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'QUAUTY ASSURANCE DEPARTMENT AUDIT DEFICIENCY REPORT
^
PROJECT: SoutIT-Tuxas irvject joe NO.:
UNIT:
PAGE:
I. OP I
iii.
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B&R Ouality Assiirariis (Audits)
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10 CFR 50. Appendix B. Criteria XVI
" Measures shall be established to assure that conditions adverse to quality... are promptly identified and corrected.
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At the time: of'the audit, seventeen (17) ADR's were unresolved or still out-1 M
standing. Two (2) of these are over.12 months old (ST-6.1. 57-6.2); two (2) g are 7 months old (ST-8.1 ST-8.5); and 5 others are over ninety (90) days old (BR-24.1.
2.
3,.4 and.5).
The majority of these were noted to be " awaiting 3
implementation." However the closing out of these are not being performed in a i
timely fashion.
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Recommend that acceptance of corrective actions be predicated upon more timely implementation of corrective measures and that action to verify implementation be expedited.
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AUDIT DEFICIENCY REPORT PnoJacT: South Texas Project JtD NO.:
UNIT:
PAGE: 1 OP I
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- STP-QAP-2.2, paragraph 5.2.3 "Approximately thirty days after an' issue has been released, the Program Document Log Record shall be reviewed and document holders who have not acknowledged receipt of the transmittal shall be contacted to assure that the trans.mi.t.tal was received."
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' maintained. Procedure Revision Log for Document Transatttal Acknowledgements is Clericalt personnel stat:d 2nd Noticas of Acknowledgements were not being w
Q sant' as the receipients were abusive of the 2nd notica. QAP Transmittal #29, t
Correspondence #STQ 2395, noted 4 outstanding acknowledgements. QAP Transmittal #39 i
Correspondence #STQ 2629,' noted 5 outstanding acknowledgements. QAP Transmittal #30, Correspondence #STQ 2330, noted 2 outstanding acknowledgements. NDE Procedure Transmittal #5, Correspondenca #STQ 2456, noted 3 outstanding acknowledgements.
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QUAUTY ASSURANCE DEPARTMENT -
ll AUDIT DEFICIENCY REPORT i I PnoJecT: Soutfi Texas Project Joe NO.:
UNIT:
PAGE:
I OF 2
3 ni 4. eves e e.34riem_.__
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taimeasees B&R Quality Assurance QAMRB-3 19 isi...su se =rv=.
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[IIl peTastflA4. Aspe.TTAet.s e=Flessaev 0 ves 8ne
- n..sse no.riea..
1.
Perform a complete inter-department review of the Q.A. Manual to determine'if it accurately reflects the present methods and resolve any inconsistancies, (this should be done prior to the ASME Audit in September,1978).
2.
Revise 0,A. Pro.cadure ST-QAP-2.1 to provide a more expediti.ous method of preparation, review and approval of Q.A. Program Occuments.
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Occumented Violated and paracracit (Citeh 10 CFR 50 Appendix B, Criterien II "The applicant shall establish at the earliest practicable time, censistent with the schedule for acccmolishing the activities, a quality assurance program which cceplies with the requirements of this appendix. This program shall be documented by written policies, procedures, and instructions and shall be carried out throughout plant life in accordance with those policies., procedures or instructions."
Observations:
w wo these i
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an extended pe vised.
These type M ted.
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AUDIT DEFICIENCY REPORT 5:uth Texas' Project JO3 mo.:
um:T:
PAGE: I OP 2
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B&R Engineering QAMRB-3
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Review and update all qualification training files to assure their completeness.
If necessary, provida supplementary training to backfit the requirements of 1
STP-PM-C06-C.
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Document VioTateo and'Paracraoh (Cite):
- 7. B&R QA Manual, Section 2.3 f tem c. " Personnel qualification records shall be c maintained by the responsible department."
STP-PM-006-C. paragraphs 2.5. 2.6. 2.7. 2.8 requires specific documentation of personnel indoctrination and training be filed in EDCC.
STP-0C-015-E. paragraph 3.1. requires specific documentation of personnel quali-fications including training records, be filed in EDCC.
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' AUDIT DEFICIENCY REPORT t
PnoJacT: 5:uth Texas Project J03 NO.:
UNm
'PAGet I
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B&R Q.A. Manual, Section 2.3., item c
" Personnel qualification records shall be maintained by the responsible department."
' j 7,,_
The auditor found numerous qualification training files incomplete. The g
following examples are provtded:
J File of:
Documentation Miss'ino u.
L E
C. W. Vincant--
Q.A. Indoctrination Program, Resume, Relevant Certifications G. T. Warnick Q.A. Indoctrination Program L. W. Perry Q.A. Indoctrination Program, Resume P. Pelengaris Replacement Level II Certification (due 5/30/78)
P. Shah Replacement Level II Certification (due 5/30/78) on v.,ri.a..
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l Review and updata all qualification training files to assure their completaness.
If necassary, provide supplementary training.
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h.-~ peoJact: South Texas Project Joe NO.:
- UNm PAGet I CP 2 iii n.
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Revise Procurement Procedure STP-PP-0014 to establish a ecmplete training program as.. required by the B&R QA Manual.
Implement the revised procedura and provide documentation of personnel qualification and training.
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Page 2 of 2 Occument Violated and paracraoh (Cite):
~
.m B&R Q.A. Manual. Section 2.3, item c
" Brown & Root personnel are indoctH-nated and trained... to ensure suitable proficiency and understanding of the requirements of the Project Procedures, the QA Manual, the Code and appli-cable regulatory requirements.
Each department or group shall develop pro-cedures, manuals, or instructions which identify the material to be presented, methods of presentation,- schedules for conducting sessions, and the.~ individuals, by job title, to be trained... Personnel qualification records shall be maintained by the responsible department."
observations:
There is no objective evidence that suitable and sufficient indoctrination and training of project procedures. QA Manual, the Code and regulatory require-monts is being performed within the Procurement Department. Procurement Procedure STP-PP-0014. " Personnel Indoctrination and Training", does not provide sufficient detail to datamine the adequacy of the program. As a minimum, Procurement personnel should be required to attend the Quality Assurance Introductory Program, PQA-X01-HT. Additional training programs should be developed on the requirements and methods of implementation of ANSI N.45.2.13, " Quality Assurance. Requirer.ents for Control of Procurement of Items and Services for Nuclear Power Plants" and of the project Procurement procedures and interfacing Engineering, Qualiv/ Assurance and Constructicn pmcedures. Personnel Qualification Training Records should be maintained to provide evidence of existing training of individuals.
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AUDIT DEFICIENCY REPORT P
SouthTexasP_roject Joe NO.:.
UNITr PAGE I
CP I
Y nOJacr:
i......
B&R Quality Assurance _(Site)
QAMRS-3 23 i.:.e v
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Contran to the above, owner or other supplied items as per ST-QCP-1.1, M
Paragraph 5.1.5. last paragra'ph requires only a receipt inspection of the g
document package to assure verification of confbraance certificate on material supplied by owner or others.
~
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- 1.
- Revise procedure to include complete inspection for traceability.
4 2.
Review all past, owner or other supplied items, and inspect and
'S document on RIR inspection for traceability.
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1 00C11 MENT VI0t.ATEtrANtr PARAGRAPH (CITE):
~
A.
ANSI N45.2.2. Sectica 5.2.2 "These inspections and examinations shall in-(
clude the following as appropriate:
1.
Identification and Markins' - Verification that identification and markings are in accordance with applicable codes, specifications,.
purchase orders, drawings, and this standard."
8.
BAR QA Manual. Section 7.5 "The QC Receivirig 5dpervisor shall inspect the ites(s) to determine the condition of the ites, to confirm that identifica-tion and traceability requirements have been met. *and to confirm that the required documentation as specified in the P.O. is attached or on Site."
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QAMRB-3 24 l
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ANSI N45.2.2 Section 2.2
" Procedures and instructions shall be generated, used and maintained current; these shall contain sufficient detail to provide... a l
basis for...
receiving... implementation thereof, and inspection, in
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- 1. Revise the B&R QA/QC receiving inspection procedure.
- 2. Review and process any items which have been received which QC has not yet processed.
- 3. Replace alt Construction placed Receiving Hold Tags which completed QC signed
_._ tags..
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ADR 24' q
Paga 2 of 2 Observations:
1.
ST-QCP-1.1, paragraph 4.1.3, does not define QC inspection requirements for (
the Inspector; i.e., after he is notified by Construction when does the Inspector perform his inspection, how long can an item remain in a receiving area before QC is required to perform the receipt inspection, and what is the status of the item until QC arrives at the inspection area.
l 2.' If during QC receipt inspection a receiving inspection requirement is not
~
satisfactory, the QC Inspector does not put a Receiving Hold Tag on the item until he completes the total inspection and all paper work is complete, which in some cases has taken days. The items may already have a Receiving Hold Tag which Construction has placed on during receipt. There is no pro-cadure requirement for this activity by Construction nor should this be a Construction activity.
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AUDIT DEFICIENCY REPORT
^
PnoJacy.- South-Tatas-Project h3 NO.:
UNIT:
PAGet I CF I m~Y sis
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B&R Ouality-As^surane d Siteh QAMRS-3 25 isi.
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6 A 6 / 78 Citi Ot88 0888
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-v B&R Q.A. Manual. Section 7.5 "The insliection shall be-documented on a Receiving Inspection Record (RIR)..."
B&R Q.A. Manual, Section 7.5 "For code items, the Authorized Inspector shall be
{
notified by_the,,Pr,,o&ct__Q.A,. Manager,.of, thy.tsca,1v.iggj nspe.q,ti.g,p Agtd,yi.ty. ".,.
a ii
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1.
ST-QCF-1.1 does not require a " Receiving Inspection Report" (Eshibit 57-7.9 in l
the BAR QA ManualJ to be completed but requires a " Storage Inspection Report" g
(ST-QCP-1.1. Att. 6-A) to be completed.
3 2.
The ANI was not notified or did the report require ANI notification on Reports 5-280-1, 5-280-1A, 5-280-2 and 5-280-2A (Ref. P.O. 6014).
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Revise ST-QCP-1.1 to include the " Receiving Inspection Report".
2.
Review previous inspections to assure that the ANI was notified and correct as necessary.
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wn, - w.,-n AUDIT DEFICIENCY REPCRT PROJECT: South Texas Profect JoeNO.:
UNIT:
PAGe: I CF l S'
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iii 26 B&R Construction QAMRB-3
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A r A.. P A. A.. Ap.e I C BT..
t ANSI N.45.2.2, Section 2.2
" Procedures and Instructions shall be generated, uss and maintained current; these shall contain sufficient detail to provide... a basis for.... storage and handling procedures, implementation thereof, and inspec-tion, in accordance with this standard."
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j Construction procedures should designate warehouses, areas in warehouses, or storage areas for the segregation of items falling into categories of Level A, Level B., Level C, Level 0. storage requirements.
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AODiT DEFibiENd9'NENAf~
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gi_ PnoJacre South Texas _ Project JOJNO.:
UNIT PAGE I
CP I
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g BAR Constr0ction Procedure A040XPGCP-22, paragraph 3.16.1, allows. equipment or antarials on " Hold" status to be released for installation if approved as per HL&P QA P1arr Section 3.8.8.
This is not in accordance with BAR approved p W ures and the HL&P rqferenced decisment paragraph does not-cover the subject of release.
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..rm Revist. B&R Construction procedure to reference B&R QA procedures.
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ADR 27 O
Page 1 of 2 5%,
Documeni: Violated and Paracraoh (Citel:
B&R Q.A. Manual Section 14.5 "If an item is found unacceptable but requested D,
e to be used under controlled conditions by the Construction Project Manager as a" /
noted in Section 15.0 of this manual, a " Waiver" tag or sticker (Exhibit 14.1) shall be attached to the item by a QC Inspector next to the " Receiving Hold" tag. A temporary waiver may be granted under the fc11owing conditions:
a.
The nonconformance may be corrected by receipt of Vendor's documenta-tion and procurement has received a constitment of submittal of such documentation.
b.
The nonconforming itas can be removed or correcded at a later data (prior to operation) without chang's to, or contamination of the associ-ated permanent plant equipment or structures.
I c.
Traceability and identification as a nonconfonnance is maintained by tagging.
d.
Authorized Nuclear Ins actor concurrence with waiver is obtained
("ASME Code Items" on1 ).
The waiver shall be approved by the B&R Project QA Manager, the Owner and when applicable the NSSS Supplier and the Authorized Nuclear Inspector."
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' AUlitT DEFICIENCY REPORT
_g*.
eoJacn outh. Texar.P_roject Joe NO.:
UNIT:
PAGEr 1 0F l
P S
- A n
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A
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i., A.....
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BM Quality.A">>cnce (Site)
'QAMRB-3 29 i
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- j (9) OOCuessMT viebATED AMO pamag. Appe (C&TEls 10 CFR 50, Appendix B, Criteria V
" Activities affecting quality shall be prescribed by documented precedures."
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_ _ _ - _ _ _ -. L B&R QA Procedure. ST-QCP-7.1. " Tool and Equipment Calibration."J evision dated R
2 l
6/14/77.'which is now in effect is in noncompliance with the calibration system as defined.in the BAR QA Manual Section 12. This is due to the fact that QA w
E Procedure ST-QCP-7.1. Revision Interim Change dated 12/7/77, was an intarim In 7
change for oAly a 60-day partod (STP Memo STQ-2647). To date no new procedure has been issued to comply with the B&R Q.A. Manual.
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Issue revised precedure which complies with the B&R QA Manual.
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last puesvaseTA71vE ACTIOfes (80864.MOS SSpeSSWhES COespbETiese SATE) lassswaterrtus eve j taas oATus
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To be completed by B&R Cuality Asatrance taal navsaw or essponssa taag msveswam ave ilas4OATEs Q Satisfactorv._-.
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N QUALITY ASSURANCE DEPARIMkNI 2
AUDIT DEFICIENCY REPORT PRCUECT: South. Texas; Project Joe NO.:
UNIT:
PAGE:
1 O F' I
tal AwesTse emeA8eszAftese (38AWOf? foe.
(31 AO R 84e.
- l. ASM COG E B&R Ouality A:surance451te)/Constructicn OAMRB-3 2.9 se si cu
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im =Arsi isi CAv=aa av' R. A. Rcmeo, N. W. Pressler :
6/1978 Om Gia: " ')
(St eeCuasSMT veO6ATED A849,A A AGRAp.e iC17.j s I
B&R QA Manual, Section 5.4
" Instructions, procedures and drawing documents shall be reviewed...
Reviews shall be mada for technical content... and conflict or redundancy with other documents approved for the project."
p,,g _ Tr The Quality Assurance and Construction procedures are 'inconsista'nt.'QA Procedure g
ST-4CP-7.1, paragraph 4.7. states "the Project QA Manager.is authorized, when requestad, to extend the use of equipment beyond its. calibration due data by 9
issuing a memorandum to the responsible department identifying the equipment..."
lg Construction Procedure A040KPICP-3, paragraph 3.23.1, states "the Senior Instrument Engineer, is authorized to extend.the use of equipment beyond its o
calibration due data by issuing a memorandum to the responsible department (copy to QA) ident,1fying the equipment..."
~
(84) POTsMT3A4. ASpe RTAet E oE,1CJEMCY O v==
$1 ao Isaa maconseesseo arseresa Revise procedures to assure consistency.
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AUDIT DEFICIENCY REPORT PnoJacT: South Texai Rroject Jos NO.:
' UNIT '
PAGE: I CP 2
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,,0 BM Construction _;.
QAMRB-3 30 i
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BM Construction Procedure A040KPICP-3 " General Calibration" Revision 1 h
January 23..1978 is in noncompliance with the BM QA Manual in the following.
e,,,,,
g 1.
The intervals for pressure gauge calibration as shown on the Master
.se:
Index is not in accordance with the BM QA Manual and ASME.
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=.u.aricas.<v Q vs.
99 4 s a3.ss.aeassse.473.se Revise the BM Construction precedure to reflect the above requirements.
Review all past records to assure pressure gauges were calibrated at prescribed intervals.
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To be carnoletrd by B&R Quality Assurance last.sysaw.c.ssr. asses taag.sysawass.vi i tast. 7sa Q Satishe:civ Q Unntahcrorv
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ADR 30 Page 2 of 2 Occument Violated and Paracrach-(Cfte):
.~,,
1.
B&R QA Manual, Section 12.4 "All measuring and test equipment shall be s
calibrated and properly adjusted at specified periods or use intervals so that accuracy is maintained within specified limits."
2.
B&R QA Manual, Section 12.4 "For Code items, the following M&TE shall be recalibrated at the speci~ied intervals:
f c.
Pressure Gauges - Before each test or series of tests. A series of tests is that group of tests using the same pressure test gauge or gauges which are conducted within a period not exceeding two weeks."
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. ADDIT DEFICIENCY REPQRf'~'
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Mc :en hath Texas Profcet Joe No.:
UNff PAGE:
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QAMRS-3 31 680 esecuh wsTMs-.-
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6A558 0:n Ots: 088'
- i. o cu===v vs. u r==.......... i sv.is B&R Q.A. Manual Section 12.8 "If B&R elects to use standard testing laboratories to perform calibration services, they shall be approved by the B&R Q.A. Depart:r.ent before award of contract...*
7,,g,g,,g,, _
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outside calibration laboratories have not been reviewed and approved by the BAR Quality Assurance Department.
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( 9) POTENTIA 6. AEPORTAat.s asFIC4EseCY O v==
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lsa8 AEComessameA73.n=-
Qualify outside calibration laboratories in accordance with Q.A. Manual requirements.
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pa.g waveswso ove j gast parts Q Satisfac: cry Q Unserisfac civ l
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ta71 v5NIFIED SY isel oATEs g
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AUDIT DEFICIENCY REPORT T
nOJacT: South Texas Project Joe NO.: -
P UNIT:
PAGet I OF 2
ns..
34ri..
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.a B&R Construction QAMRB-3 31 i.isessum na.
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o-on i si o. cum.ent v 64rso me.o passa.m p., scarsi.
1 (see attachment) 7,,yg,,_,,,,_
l Although equipment installation work has started. Construction Procedure A040KPGCP-4 has.not been revised' to address the remaining segments of the Q
housekeeping pmgram including designation of zoner, establishment of training 3
program for parsonnel assigned to work in Zones I. II or III. and controlling Q
equipment and personnel within these zones.
ii 3 p.7 wria manosrtaan a ospicasmcv O vas d.l =.
i, s i.e Comply with the requirements of ANSI N.45.2.3.
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.ADR 31 Page 2 of 2 Occument Violated and Parterach (Cite):
1; ANSI N.45.2.3, Section 2.2 "The procedures and instructions for housikeeping practices shall be prepared and may be issued in segments to confom with-the project construction schedule. The first segment establishing regulations for control of site area, site preparaticn, fire prevention and protection, and records shall be in force with the start of construction activities. The re-
'maining segments shall be prepared and approved no later than the start; of equipment installation work."
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APPENDIX C QUALITY ASSURANCE MANAGEMENT REVIEW BOARD
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QAMRB AUDIT NO. 3
~
08SERVATICNS. RECOMMENDATIONS, CONCERNS
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1.
Ac s exchanga of information betwetn the South Texas Project and the Comanche' Peak Project would be desirable. Many Quality Assurance and Construction programs are similar at both sites, thus a cross-review of O
procedures, instructions and specifications would be beneficial toward standardizing the B&R implementation of the Qua.1-ity Assurance Program.
Scheduled coordinationmeetings and site visits between Project, Construc-tion and Quality Assurance management of the two sites would provide opportunity to discuss comon conditions and problems.
2.
The Procurement Department should assign a full-time " Project Purchasing Representative" for the South Texas Project to coordinate all procurement activities. At p' resent, the Power Purchasing Department Manager also is assigned as the " Project Purchasing Representative *.
3.
Although some procedure simplification and consolidation has occurred, considerably more should be considered. At present, there are approxi-mately 250 STP procedures describing the Brown & Root implementation of the 18 Criteria of 10CFR50, Appendix B.
Project procedures covering all departments'-activities regarding specific subjects could be developed.
For example, the 5 existing department procedures for initiation, review, approval and-implementation of field changes could be consolidated into one cohesive project procedure, thus eliminating the problems of duplication of responsibility and assuring accurate interfaces which exist with the present system.
m 4.
Matrices should be developed to provide a cross-reference indexing between tKe is criterla or iOCFR50, Appendix B; the Quality Assurance Manual; the.
ANSI _N.45.2.xx series of industry standards; and the Brown & Root pro-
=Q:rh cadures.
This emss-reference indexing would provide assurance of pro-w am el mm.g m quality program requirements and also highlight those areas of procedure duplication.
5.
Training courses should be developed on.the requirements and method of implementation for each of the ANSI N.45.2.xx series of standards.
Attend-ance at these trainings ~ programs should be those personnel required to perform the functions of the standard (i.e., a training program on require-ments and implementation of ANSI N.45.2.11. " Quality Assurance Requirements for the Design of Nuclear Power Plants", would be attended by all project engin ring n. mnnnel).
6.
On South Texas Project, there is a lack of formal definition of the require-ments for a specific' placement of concrete and of formal coordination be-tween the crafts, quality control engineers, field engineers, and area engineers. The result of this is a redundant review of drawings, speci-fications, and 1rocedures by each of the organizations to detennine the parameters of t1e pour, pre-requisites including engineered compactions,
. vapor har"4.m : robar placement, penetrations, block-outs, embedments
.... _ _... and curing requirements.
On a single placement the review of five procedures, four standards and two or more drawings /specificaticns are required to assure that current acceptance cti_ter.ia, methods and standards are being implemented.
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reylews are n.of_cpydinated in any formal manner.
3rraddNiedtiefi.1 P lack ofevidence'of efestTye-.wus.go.hitit.desiga.engin:ering', sin [e t
cLr.,. rscefve+at sf te"rfter concreta-placement hadaEcomp4eted.
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While the B&R procedures can be interpreted as meeting the literal require-ments of ANSI N.45.2.5 relative to instructions and procedures, they do not provide a well coordinated plan for concrete placement.
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'v 7.
The STP concrete construction specification, CS-028, should be revised and reissued by Engineering incorporating all applicable DCN's and FREA's.
The present revision of this document currently has 13 DCN's and 33 FREA's.
This document is frequently used by Construction Engineering and Quality Control.
The current state of this document does not provide for ease of locating and verifying current requirements.,
8.
Numerous concrete blockouts are located throughout STP Unit 1 Mechanical-
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Electrical Auxiliary and Fuel Handling Buildings. The blockouts were made on Unit 1 to assure access into cubicles for piping, conduit and ductwork which had not been routed at the time of constmetion of these areas.
Unit 2 is apparently making the same blockouts, in the same locations and of the same size as Unit 1 even though the definition of need and size on Unit I has been finali::ed.
In some cases there are 12 inch by 12 inch blockouts with 3 one-inch conduits routed through.
This could easily be corrected on Unit 2 by providing 3 one-inch sleeves.
Mcwever, as stated to the auditor, these blockouts are being made so that the drawings would not require revision or change.
Engineering should consider a simplified means of revising the drawings such that construction would not be required to spend the additional time necessary to form and place concrete around unnecessary Unit 2 ~ block-outs. A similar situation exists with the number and location of embedded plates.
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9.
A program should be established between Vendor Surveillance or Expediting
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and Construction or Quality Control Receiving personnel whereby receiving personnel are notified of shipments from the vendors such that they can plan in advance for receipt inspection of the material and assure, appro-priate storage area.
i 10.
Westinghouse needs to p'rovide to Bren & Root a ecmplete 1.ist identiifying storage levels for the NSSS ecuipment.
Presently the list that exists is incomplete thus requiring kown & Root to obtain from Westinghouse after receipt inspection starrge levels 'for the unidentified equipment on a case by case basis.
In some cases, this has required up to one month.
11.
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