ML18087A753

QA Training Program

ML18087A753
Person / Time
Site:	Salem
Issue date:	03/14/1983
From:	Public Service Enterprise Group
To:
Shared Package
ML18087A720	List: ML18087A719 ML18087A721 ML18087A722 ML18087A723 ML18087A724 ML18087A726 ML18087A727 ML18087A728 ML18087A729 ML18087A730 ML18087A732 ML18087A733 ML18087A734 ML18087A735 ML18087A736 ML18087A737 ML18087A738 ML18087A739 ML18087A740 ML18087A741 ML18087A742 ML18087A743 ML18087A745 ML18087A746 ML18087A747 ML18087A748 ML18087A749 ML18087A750 ML18087A751 ML18087A752 ML18087A753
References
PROC-830314-01, NUDOCS 8303160636
Download: ML18087A753 (24)

Text

GENERAL QUALITY ASSURANCE What is Quality Assurance?

A program for the control of all important activities.

What are Important Activities?

Those ~ctivities which may have an adverse affect on items required for safe operation and protection of the-public.

Why have Quality Assurance?

1. *It is a regulatory requirement.

2, Economically beneficial to accomplish an activity correctly the first time.

What is the QA Goal?

Provide confiden~e that equipment, structure and activities are accomplished in a manner consistent with the established requirements for the identified activities.

What are Established Requirements? -

Requirements contained in the issued procedure for the work activity or function.

The requirements are derived from many sources; regulatory commitments, industrial standards, and company imposed policies such as economics, reliability.

QA PROGRAM RESPONSIBILITIES EVERYONE HAS A RESPONSIBILITY FOR SOME ASPECT OF THE QA PROGRAM DOERS EXAMPLES:

Mechanics Technicians Engineers Designers Supervisors J Accomplish activity in accordance with the procedure Plan, schedule, implementation accountability Primary individuals for the quality of the work activity INDEPENDENT VERIFICATION QA Organizations Review Inspection Monitoring Audit Analysis -

Problem identification

WHY DO WE NEED PROCEDURES?

Define activity to be accomplished.

Provide the method to accomplish activity in a consistent manner.

. Note important characteristics or changes to prior methods.

Provide the method to document the a.. ctivity; Provide method to accomplish activity such that established requirements are met.

WHAT HAPPENS WHEN YOU DON'T HAVE A PROCEDURE, OR WHEN A PROCEDURE IS INADEQUATE?

Schedule delay due to inadequate tools or material.

Damaged equipment due to faulty disassembly-reassembly.

Lack of performance/failure due to incorrect part being used.

Personal hazards; radiation exposure etc.

Outage delay/extension a)

Fines, penalties b) replacement energy costs.

Potential of duplication of work exists.

CONTROL OF NONCONFORMING MATERIAL PURPOSE:

Prevent use of material which does not meet established requirements.

HOW:

l.

Identify

2.

Segregating/Tagging

3.

Disposition a)

. Repair b) c)

d)

Rework Use as is Scrap approved by appropriate Rep IMPLEMENTATION -

Accomplish disposition in controlled manner.

VERIFICATION

1.

Test

2.

Inspection 3

• Review

4.

Monitor

CORRECTIVE ACTION PURPOSE:

HOW:

To assure that activities adverse to quality are identified, reviewed and corrected.

1)

Identification:

Everyone is responsible for identify-

2)

Review:

ing to their supervisor areas which they feel require correction.

Supervision is responsible for reviewing and assessing the needed correction and assign action to correct (within the area of responsibility)

3)

Implementation:

Responsible organization reviews and determines method of accomplishing the correction and institutes action to correct.

EQUIPMENT HISTORY RECORDS PURPOSE:

Record all critical corrective and preventive action accomplished on equipment to assure reliable, dependable equipment performance.

Records must be traceable throughout the life cycle of the the equipment from manufacture, receiving, st9rage, installation test, operation, maintenance and scrap.

Activity A

Traceability Act.i vi ty B

Traceability Activity c

TRAINING Qualification formal education work history O.J.T.

Certification Statement from supervision indicating ability to perform.

Re-Training Maintenance proficiency

Commercial Catalog Item -

An item which complies with all of the following requirements:

(1)

The item is not unique to facilities or activities licensed by the NRC.

(2)

The item is manufactured in quantity to published manufactuer's fixed design and quality requirment.

(3)

The item part number i§ listed in the supplier's catalog as opposed to a manufacturer's bulletin or circular.

(4)

The item requires no supplier documentation.

(5)

The item is identifiable by physical marking, tagging or containerization and is maintained throughout storage.

Note:

For replacement (CCI) items, a document must exist which identifies the item (to be ordered) as an authorized replacement-in-kind for the original or existing item.

documents include the manufacturer's part list, bill of material, repair, maintenance or instruction manual or a PSE&G engineering list of replacement or interchangeable parts.

Any proposed substitution or authorized parts requires written engineerring approval.

Such

EXAMPLES OF CCI'S (1)

Electronic components and assemblies such as resistors, capacitors, integrated circuits, instrumentation.

(2)

Electrical items such as relays, lamps, fuses, transformers, switches, recorders.

(3)

Mechanical components - bearings, gaskets, packing, a-ring, non ASME code fittings, small nuts, bolts, stud.

NON-CCI ITEMS (1)

Any component with a unique requirement (i.e. special handing, selection, inspection or modification)

(2)

ASME boiler and pressure vessel code items The procurement of a CCI intended for use in safety related equipment may be procured without specific quality requirements.

The receipt inspection and subsequent installation test shall be sufficient to demonstrate proof of satisfactory component acceptability.

This method of procurement does not alter the function of a CCI, nor does it change the controls placed on the installation.

Items in the CCI category do not require imposition of 10 CFR part 21 on the supplier.

MATERIAL ORDER/

ITEM CLASSIFICATION FORM MOIC PURCHASING DEPARTMENT INITIATE PURCHASE ORDER PROCUREMENT INITIATION NUCLEAR QA NUCLEAR OP PROCUREMENT &

SUPPLIER CONTROL MATERIAL CONTROL ESTABLISH ITEM CLASSIFICATIO~ AND QUALITY REQUIREMENTS It NUCLEAR PROCUREMENT &

MATERIAL CONTROL PREPARE REQUISITION FROM COMPLETED MOIC I~

QA NUCLEAR OPS.

SUPPLIER CONTROL APPROVE REQUISITION &

RETURN TO NUCLEAR PROC. & MAT'L CONTROL p.-

~ -

NUCLEAR ENGINEERING ASSIST QA IN ITEM CLASSIFICATION &

APPROVE MOIC rel i::

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WORK ORDER SYSTEM CHANGES ALL NON-SAFETY RELATED WORK ORDERS ARE TO BE REVIEWED BY THE QA ORGANIZATION PRIOR TO ISSUANCE AND STAMPED IN THE SPECIAL INSTRUCTION BLOCK SIGNIFYING AGREEMENT.

NO NON-SAFETY RELATED WORK ORDERS ARE TO BE IMPLEMENTED WITIIOUT A QC INSPECTION STAMP.

GOOD PRACTICE TO MAINTAIN DEPARTMENT LOG OF ALL CONTACTS WITH SPONSOR ENGINEER.

SEE ATTACHED SAMPLE W.O.

.t.NT"

.CD SALEM IOF'l I

ICENTr..-rCATION

t.

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oaLEM/WORK DCS:CRIP'TION ctnun (2 O)

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REQUES~Y QAR~ED YU "-\\_18;co 0 1'I J'l,I P ROTE c:T I Ot; TES D MOD "ECIAI. INSTRUCTIONS

!EVI BY

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To:* (§_}

D MAIHT.

Cl.ASSl,.ICATION

. ELECTRICIAN* TECMNICIAN DOIL.ER REP'AIR MECMANIC llNGJAL' W9~2 iRoEo 5 G) 0

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D..., ** "'E~MISSION REQUIRED SSS/SS l'l:"MISllUON QA NOTl,.IC:ATION/REVIE~.

IQA)NAMI!:

(23)

TIME~--

DATE (QAI CIAJ'~"u; (23~

P'OLLOW-UP'/111 ETIEST R IEQU IRED MANPOWER REQUIREMENTS ESTIMATED NO.MEN Cl.OCK HOURS

{2 9 ESTIM"'-TED MAN HOURS ACTUAL MAN tlOU~~

ul'v. A~NED Tl.CHNICAI.

STATION MECHANIC* ASSISTANT

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TECHNICAi.

UTILITY MECHANIC* HICl.l'Elll UMP NO./PROCEDU"E NO.

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P'.O.ta.C. NO.

INTRODUCTION The NRC requires in 10CFRSO that all activities which contribute to (a) preventing accidents that could cause undue risk to the health and safety of the Public or (b) mitigating the consequences of such accidents should they occur be performed in accordance with a quality assurance program.

The necessary elements of such a program are described in 10CFRSO App. B.

The P.S. Quality Assurance Program is described in the Quality Assurance Manual and the~FSAR.

The Salem Q-List lists those systems and programs which are subject to the Q.A. Program described above.

Part of the Q-List is a docu~

ment called the Master Equipment List, or the MEL.

The MEL lists specific plant equipment components which were procured and installed under the Q-Program.

It is not currently complete with respect to systems which have been added to the Operations Q-Program subse-.

quent to installation, e.g. spent fuel cooling.

TNT 10 March 1983

HISTORY OF MEL During the design development of Salem, each Engineering division was responsible for classifying equipment and maintaining records of the classifications.

During construction, the Salem Project Manager prepared a consoli-dated list of the classification of all safety-related equipment.

This list, Project Directive No. 7 (PD-7), was developed from the purchasing records of the equipment.

In 1978 the NRC, during an inspection, noted that PD-7 was in need of revision.

Since the responsibility for the list had been trans-ferred to the Engineering Department and since PD-7 was geared more for construction, a commitment was made to develop a Master.

Equipment List (MEL) to provide a convenient list of the classifi-cation of all safety-related components.

The Unit No. 2 MEL was issued on November 3, 1980 with a Revision 1 issued on January 27, 1981 to incorporate fire protection components and instruction sheets on the various fields of information.

The Unit No. 1 MEL was issued on July 15, 1981.

The MEL is. some cases used existing computerized engineering data files, and so may list more than just safety-related components.

LAR 10 March 1983

UTILIZATION OF MEL Physically, the MEL is a composite of printouts of six computer files which were used by engineering during plant design and pro-curement of equipment.

These six sections are:

The Mechanical Section, which includes mechanical equipment, manual and motor operated valves, and cranes; T_h_e Structural Section; The Electrical Section; The Controls Section, which is composed of 3 subsections:

ControJsValves (Air & Solenoid & Damper)..

Controls Instruments Controls Equipment.

One additional section of MEL has recently been added -

a listing of systems subject to the QA Program, and whether these systems are on the list because of their safety-related, security, or fire protection classification.

Each section of the list has a variety of information about the listed equipment, and includes common fields denoting the seismic class, nuclear code class (if applicable), safety-related status, and applicabiiity of the Quality Program.

The Controls Equipment list also has a column designating if the item was procured as a Commerical Catalog Item (CCI).

(Reference QAI-2-1)

UTILIZATION OF MEL - Cont'd.

For Station personnel use, only five columns may be used as sources of information for decisions relative to Quality related activities:

1.

Safety-Related

2.

QA Applicability 3.

CCI

4.

Nuclear Class

5.

Seismi.c Class All other fields are engineering data subject to interpretation by engineering.

For use in classifying work orders as to safety-related status and QA Program applicability, Station pe~sonnel shall con~ult the system's list of the MEL, not the component listing.

All work on any of the listed systems shall be performed based on the classification of the system as a whole, not the individual component in question.

For use in classifying items on procurement documents, both the MEL systems listing and the MEL component listing shail be consulted.

Use of the information shall be as follows:

if the item is on the MEL component listing and its system is on the system list, the classification on the component list may be used on an MO/IC

- if the item is not on the component listing and its system is not on the systems listing, the item may be assumed to be non-safety related with no QA program requirements.

UTILIZATION OF MEL -

Cont'd.

- if the item is not on the component listing but its system is on the system listing, the Nuclear Engineering Department should be consulted regarding its true classification

- if an item is found on the MEL component listing but its system is not on the systems listing, this is an error, and Nuclear Engineering should be consulted to effect MEL revision.

For items on the MEL component listing, the safety-related and QA applicability columns may be used verbatim, unless the item is listed CCI "Yes".

In this case, care should be exercised as the classificat.:ionfor safety-related and QA Program applicability of "No" refer only to procurement, and in reality should be regarded as "Yes" for ail other activities.

TNT 10 March 1983

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