ML20205Q791

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Records & Records Retrieval
ML20205Q791
Person / Time
Site: Comanche Peak, 05000000
Issue date: 06/29/1984
From:
TEXAS UTILITIES ELECTRIC CO. (TU ELECTRIC)
To:
Shared Package
ML20204J134 List:
References
FOIA-85-59 NUDOCS 8606030304
Download: ML20205Q791 (42)
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TEXAS UTILIITES GENERATING-COMPA27v

.CCMA2iCHE FEAK STEAM ELECTRIC STATIhN RECORDS AND RECORDS RETRIEyAL June 29, 1994 l

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2 TABLE OF CONTENTS Page A. Introduction . . . . . . . . . . . . . . . . . . . . . 1 B. Overview of Quality Assurance Organisation . . . . . . 3

1. Construction Quality Assurance /

Quality Control . . . . . . . . . . . . . . . . . 3

2. Vendor Compliance . . . . . . . . . . . . . . . . 4 t
3. Quality Assurance Services . . . . . . . . . . . . 5 C. Overview of Crganization for Constructing CPSES . . . 5 D. Computer and Record Related Support Services and Facilities . . . . . . . . . . . . . . . . . . . . 7
1. Cn-Site Computer Services . . . . . . . . . . . . 7 '
a. Data Processing Facilities . . . . . . . . . 7
b. Computer Data Integrity . . . . . . . . . . 9
c. Computer Data Base Validation . . . . . . . 11
1. Checks for Keying Errors . . . . . . . 11
2. 100% Match of Manual Log a nd Computer Data Base . . . . . . . . 11
3. Activity Report to Record Comparison . . . . . . . . . . . 11
4. Electronically Linked Ccmputer Data Bases . . . . . . . . . . 12
5. Records Monitoring Group . . . . . . . . . . . . . . . . . 12

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2. Record Centers . 6 . .. . . . . . . . ' . .. . . 12
s. Document Control Canter -- ,

Construction . . .s , . . . . . * . . . . . 12 ,

b. Balance of Plant Vault , . . . . . . . . . . 14
c. Permanent Plant Record Vault . . . . . . . . 14
d. Operations Vault . . . . . . . . . . . . . . 15 E. Records Flow Progress . . . . . . . . . . . . . . . . 15
1. Introduction . . . . . . . . . . . . . . . . . . 15 6
2. Records Flow During Construction . . . . . . . . 16 i
4. Introduction . . . . . . . . . . . , . . . . 16
b. Inspection Reports . . . . . . . . , . . . . 18
c. Electrical Separation Oe ficiency Raport . . . . . .. . . . . . . 20
d. Non-conformance Reports . . . . . . . s . . 21
e. Master Data Base . . . . . . . . . . . . . . . 24  ;
3. Records Retention . . . . . . . . . . . . . . . . 26
4. Records Retrieval . . . . . . . . . . . . . . . . 26 i
a. Autemated Records Managemen* -

System (A.R.M.S.) Data Base . . . . . . . , 26 ,

b. DCA and CCC Data Bases . . . . . . . . . . . 29 t

Glossary of Terms

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A. Introduction .

Texap Utilities Generating Company (TUGCO) 'is responsible for ' ngineering, e design, procurement,  ;

P construction and quality assurance activities and will

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operate the Cemanche Peak Steam Electric Station (CPSES)

(FSAR, Section 17.0) : Gibos & Hill (G&H) is the '

Brchitect/ engineer and Westing}1ouse Electric Corporation ,

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is the nuclear steam supply system suppliere As shown in Figure A .1, TUGCO is functionally divided t

t t ince "Cngineering and Constructio'"n and "Op6:ations" components for the purpose of constructing and cperating .

CPSES. TUCCO Entineering f and Construction has assigned its Construction Managemen*. organisation responsibility fer plant construction. TUGCO Operations is responsible for plant operations following completion o# construction a well as quality assuranc6 for CPSES durihg construction.

As required by 10 C.P.R. Part 50, Appendi.t B. Criterion I,  !

quality assurance is organizationally independent of i i

construction and has independence frem cost and achedule. l An understanding of hcw construction sork is carried t out at Cemanche Peak through the Construction Management  ;

organisation (illustrated .in Figure A-2) is esseatial to an understanding of document distribution and records ,

I retrieval. The Construction Management organization  ;

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I Ficure A-1 1

TUGCO Functional Organization r

a TEXAS UTILITIES GENERATING CCFSA.W I

ENGINEERING CPERATIONS S CONSTRUCTICN I

I I CC!".ANCRE PEAK PLAST QUALITY CONSTRUCTION

- OPERATIC:;0 ASSURANCE MANAGDENT 4

(See Fig. 3-1) (see yig, A_2) l O

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Figure A-2 CPSES Construction Manacement Functional Orcanization CCMANCHE PEAK CCNSTRUCTION MANAGEMENT I I PROJECT SUILDING g3cIngggInc CONTROL /

PANAG E 47 MANAGEMENT ' "

FRCC1,RE.4;T CRGANIZATICN yygggg; (See Fig. C-1) l l PROJECT MANAGE,rr;T DOCUMENT ,

CCNTRCL CCNTROL I SYSTEMS CENTER i l

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o' Engineering Management -- a TUGCO organization responsible for managing engineering activities.

o Building Management Organization -- a TUGCO project orfanization created to facilitate construction and completion

. of major areas of the plant such as the reactor and auxiliary buildings.

o Project Control / Procurement Management

-- responsible for, among other things, the Document Control Center (Construction) which receives, processes, distributes, and stores certain construction and design documents and the Project Management Control Systems which is responsible for operating computer systems which support construction activities on site.

TUGCO's Quality Assurance organization is discussed in Section B. TUGCO's Construction Management .

organization is discussed in Section C. Important computer and record related support services and facilities are described in Section D. These discussions provide the framework for the discussion in Section E of how work is documented and hcw this documentation is retained and retrieved. The scope of these discussions is congruent with inquiries suggested by the CPSES Atomic  !

1 Safety and Licensing Board in its January 30, 1984, Board Memorandum (Records Retrieval), LBP-84-8 ("LBP-84-S").

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A B. Overview of Quality Assdrance Organization TUGCO's Quality Assurance organization is illustrated in Figure B-l.

It.is responsible for. sits ~ construction quality assurance and control; vendor compliance; and quality assurance services, which include quality assurance audits, CA program review, and training. This .

organization has primary responsibility for providing quality assurance for CPSES (including the programs of the vendors.and organizations participating in the design and construction of CPSES) as described in Chapter 17 of the FSAR.

For purposes of responding to questions raised by the Board concerning document distribution and retrieval, only the site construction quality assurance / quality control, vendor compliance, and quality assurance services components of the quality assurance organization are relevant. These are the only components of the QA organization directly involved with records of the type discussed in L3P-84-8. Each of these components is discussed below.

1. Construction Quality Assurance /Cuality Control TUGCO has overall responsibility for quality assurance / quality control activities during the construction phase at'CPSES. This, responsibility has been implemented through direct (Non-ASME) and~ indirect (ASME) l l

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Figure B-1 TUGCO Quality Assurance Functional Organization TUCCO QUALITY ASSURANCE I I SITE CONS E CU CN WO VENDOR ASSURANCE CCMPLIANCr~ QUALT-v ASSURANCE / SERVICES QUALITY CONTROL F - - -- '"- '- - t PERMANENT ASME SCOPE PLANT RECORD OPEN Pf E ERO W & RCOT VAULT RECORD VAULT (PPRV)

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4-management of the quality assurance / quality control functions, as described in Chapter 17 of the FSAR.

Functional responsibilities assigned to the TUGCO site construction quality assurance organization include direct management of ccmpleted quality assurance records (both Non-ASME and ASME). These records are stored in the Construction Permanent Plant Records V3 ult (see Section D). TUGCO Construction Quality Assurance also monitors ,

the statusing and tracking of incomplete Non-ASME /

4 inspection records, which are temporarily stored in an  ;

area referred to as the Open Plant Records Vault or within the Building Management Organisations (see Section C). /

2. Vendor Compliance The vendor compliance group performs in-process and release inspections at the facilities of vendors providing safety-related components for CPSES. These vendor control activities are in addition to the quality control services required to be provided by the vendor (and as verified by the TUGCC audit function). As part of these inspection activities, TUGCO vendor ccmpliance personnel verify that vendor documentation (required by the procurement specifications) is ccmplete and available to accompany a vendor's product to the CPSES project site.

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3. Quality Assurance Services Quality assurance' services is responsible for, among other things, auditing design and construction compliance activities. Design audits are performed both on site and at the offices of the Architect / Engineer or other contractors providing design services. It is also responsible for qualifying vendors, reviewing vendor quality assurance program manuals and performing vendor audits to verify conformance to applicable requirements.

Each of these audit activities includes verification that required documentation is being maintained.

C. Overview of Organization for Constructina CPSES Construction activity at CPSES (Unit 1) is being managed by up to four TUGCO Building Management Organizations (BMO) to facilitate completion of major portions of the plant.1 The four BMOs are:

1. Reactor Building
2. Auxiliary Building
3. Safeguard and Diesel Generator Buildings
4. Electric Control Building and all other buildings and areas A typical SMO structure is depicted on Figure C-1.

1 Prior to creation of the BMOs, construction activity at CPSES was managed on a plant wide basis by the Area Management Organization. As work progressed and major 4 plant structures neared completion, the BMOs replaced l

Area Management as construction or completions manager.

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Figure C-1 Typical CPSES Buildine Manacement Organization SITE  ;

COMANCHE PEAK C0:3STRUCTIOi l CONSTRUCTION QUALITY MANAGEMENT ASSURANCE /

QUALITY CO:iTROL BUILDING MANAGER

g PLA CIING PA?ER FLCiJ SCHIOULING -

ENGINEERING CRAF- QA/QC GROUP ADMINIST?a!IVE i

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Each BM3 is headed by a Building Manager. Reporting to the Manager are the following groups:

1. Planning / Scheduling / Administrative
2. Paper Flow
3. Engineering
4. Craft The Planning / Scheduling / Administrative Group monitors construction progress and schedules work assignments as well as provides general administrative support. The Paper Flow Group (PFG) is responsible for preparing or L' .. " -

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obtaining, assembling, routing and tracking the docunents required to perform work assignments in accordance with the established, approved project procedures. The Engineering Group provides the field engineering services needed for the completion of work assignments. The Craft Group performs the construction work needed to complete the various assigmaents.

TUGCO Quality Assurance has assigned certain of its representatives responsibility for the CA/QC work - - - - - - - -

pertaining to each BMO. The Building QC organizations

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report to CA/QC Management and not to Construction Management.

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D. Computer and Record Related Support Services and Facilities The record of work completed at CPSES consists of paper records, scme of which have been photographed and reduced to microfilm for convenient storage. Retrieval depends on filing methods and indices. Some of the indicas are manual (e.g.,. manual logs). Others are computericed. This section discusses (1) the computer (data processing) services used to index these records and l

(2) the facilities where records are retained. The role i

of these ecmputer and records retention facilities in I

terms o f records flow, retention and retrieval is t

discussed in Section E.

1. Cn-Site Computer Services
a. Data Processing Facilities At CPSES certain data processing facilities are used to support construction. Others are used to support operatiens. The facilities are illustrated in Figure C-1.

The computers supporting construction activities are operated by TUGCO's Project Management Control Systems (PMCS) organization. The ccmputer which supports operations (including its maintenance activities) is operated by TUGCO Operations and is located in a different building from that housing construction computers. 1 Terminals which access these ccmputers are located at various work areas around the site, ' cut they can access l

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Piyure D-1 CPSES Computer Equipment Configuration e Construction Activities Support Operationn ,

I terminals i Data General 350 l (George I) l l periplierals I

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I terminals terminals I

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Data General 8000 Data General 8000 l (George 11) (George III) terminal I

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,. I terminals Data General 8000 l

I i l 1 peripherain terminals I

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only that computer to which they are connected. All terminals illustrated in Figure D-1 connected to the computers (both construction support and operations 1

! support) are identical. Terminals connected to the construction computers, however, cannot access the operations ccmputer and vice versa.

The construction computers consist of a Data General 3 50 (George I) and twin Data General SCOO's (George II and George III) with associated terminals, tape drives, and disc storage as shown. George I (accessed

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only by PMCS) is used primarily for program development  !

and keypunching. It is also used by FMCS keypunchers to type data to be processed on other on-site computers when this is requested. In this circumstance, the tape prepared on George I is physically transferred to George II or III or to the operations computer (see below) .

George II and George III are used to maintain and process administrative, engineering, financial, procurement, construction and quality assurance data associated with construction. The data processing load is distributed between these computers each of which is capable of j operating any of the programs. High speed printers, disc storage and tape drives (i.e., peripherals) are shared.

Terminals located around the site are used both for data entry and retrieval.

1 The operations computer, formerly a Data General 330 and now a Data General 8000 with associated peripherals serves the needs of the operations staff. It processes maintenance, schedular, personnel, financial, and other data associated with operations. It also

' processes certain computerized quality assurance data in the Automated Records Management System (A.R.M.S.)2

b. Cometter Data Intecrity The integrity of the computer systems used at CPSES is assured by computer' security measures which prevent unauthorized changes to programs and data.

Physical security is provided by locating ccmputer hardware (with the exception of terminals and designated printers) in secure facilities that are protected to reduce the risk of damage by fire, heat, humidity, and dust. Access to these facilities is restricted to a small.

number of data processing operators. Terminals and designated printers are located in office areas which are subject to the physical controls provided for each area.

Access to the constrhetion computers (George II and III) is controlled by PMCS. PMCS uses CSCRIpT, a security program, to limit access to the various data bases in accordance with instructions and procedures of the organization responsible for each data base. It 2 A.R.M.S. is discussed below in connection with Site Construction Cuality Assurance.

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provides numerous levels of security. CSCRIPT can limit access by a given user (password) to specific data bases or portions thereof, to certain rights for handling data (e.c., read only, update only), to specific portions of computer records or to ccmbinations of these ILsitations.

The same CSCRIPT controls can also be applied to specific terminals. When a password is used to access George II and/or III, it is compared to the profile (access limitations) programmed into CSCRIPT for this password.

An exact match is required before processing can proceed.

Administrative policies provide additional security. PMCS policies require that cnly the organization responsible for a particular data base (i.e.,

the data base " owner") can authorize the PMCS ,

administrator to change programs or CSCRIPT security profiles. They also require the owner to establish a list of people authorized to request printouts. Authorized individuals must sign for requested printouts. The deletion of a password f cm CSCRIPT effectively denies access to those no longer authorized.

To assure maintenance of computer data bases and programs in the event of a ccmputer system failure, duplicate safeguard copies are made regularly and stored on magnetic tapes. Access to these duplicates is restricted to PMCS.

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c. Computer Data Base Validation Validation that information has been entered into a data base accurately is the responsibility of the originating organisation. Validation is acccmplished in a number of ways, including the following:
1. Checks for Keying Errors Programs are designed to check for certain types of keying errors. When the operator is advised of a keying error the system will not allow the operator to continue until the error is corrected.
2. 100% Match of Manual, Log and Computer Data Base Manual logs have been, and in scme instances continue to be, kept to index records at CPSES.

When a manual log is converted to a computerized data base, a one-to-one ecmparison is made of each, element of

, the manual log and the ccmputer data base.

3. Activity Report to Record Comparison Activity reports (printouts of changes made to a ecmputer data base during a specified period) are compared to the actual documents to validate the accuracy of changes made to the data base, i.e., to assure that the computer data base matches the record.

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4. Electronically Linked Computer Data Bases Certain related data bases (e.g., the "DCC:DB" and "DCA:DB" data bases discussed in Section E.4.b. of this Report) are electronically linked so that a change in one is autcmatically flagged in the other.
5. Records Monitoring Group The construction management organization includes a records monitoring group which spot-checks computer index.information against items in controlled records packages in various records centers discussed below.
2. Record Centers There are four record centers at CPSES which maintain the paper and microfilm records pertaining to construction and operation of CSPES. These four record centers, the Document Control Center - Construction, the Balance of Plant Vault, the Permanent Plant Record Vault, and the Operations Vault, are discussed belcw.
a. Document Control Center - Construction The Document Control Center - Construction is responsible for controlling instructions, procedures and drawings required for plant construction. The DCC

(hereinafter referred to as "DCC-Construction"), is part of the Project Control Procurement Management organization (see Figure A-2).3 The types of documents maintained by DCC-Construction include the following:

1. Drawings in microfilm aperture card form;
2. Specifications;
3. Construction procedures and instructions;
4. Vendor equipment instruction manuals; 1 5. Design Change Authorisations (DCAs);4
6. Component Modification Cards (CMCs).5 In August, 1983, five DCC-Construction satellite control centers were established to support more efficiently design, construction and inspection activities. These satellite centers are primarily discipline-oriented. Each separate center is devoted, with seme overlap, to a different discipline, i.e., civil, 3

The DCC-Construction should not be confused with the Document Control Center, commonly referred to as the operations Vault, which is a part of TUGC0 Cperations.

See PSAR, Section 17.2 and Section D.2.d. of this 4 . Report for a discussion of the function of the operations Vault.

4 See Glossary for a description of the purpose of DCAs.

5 12e Glossary for a description of the purpose of CMCs.

b D electrical, instrumentation and control, mechanical and pipe support. The satellites contain only copies of documents distributed to them by DCC-Construction to support the disciplines they service,

b. Balance of Plant Vault The Balance of Plant (BOP)6 Vault receives, indexes and stores documents generated during the construction of CPSES pertaining to non-safety related components. This group is part of the construction l organization.
c. Permanent Plant Record Vault The Permanent Plant Record Vault (PPRV) is a i

TUGCO Quality Assurance facility which serves as the prime repository for documents generated during plant construction that reflect the actual conditions of completed construction or manufacturing activities for .

safety related structures, systems or components. Such records are referred to as verification records and are stored in the PPRV. The PPRV is the prime data collection point for the Automated Records Management System (A.R.M.S.)7 and is also the checkpoint for the 6

Balance of Plant (30P) as used by TUGCO in this context refers to non-safety related systems and components throughout the plant which do not require QA/CC inspection.

7 A.R.M.S. is discussed in Section E.4.a. of this' Report.

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.~a accountability of records prior to plant operation. PPRV records will eventually be' turned over to the Operations Vault.

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d. Oeerations Vault The Operations Vadit is in a permanent strucsur,e located on the southern side of the CPSES site. The Operations Vault is also known as the TUGCO Operations Document Control Center and is referred to as such in the FSAR. The Operations Vault is independent of the DCC-Construction and its satellites which support construction activities. The Operations Vault will be the ultimate repository of records during the operational lifetime of the plant (except permanent plant drawings which will be retained by the cognizant engineering organization).

TUGCO currently is in the process of transferring records generated during the manufacturing and construction phases to the Operations Vault.

E. Records Flow Process

1. Introduction An overview of the records flew process at CPSES is

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shown in Figure E-1. Design is initiated in engineering.

The resulting design documents (e.g., drawings) are transmitted to the Document Control Center-Construction for distribution. Copies are distributed to the appropriate DCC satellite which acts as the control point.

Piiltire C- 1 CPSES Work at d Records Flo'.e I rocenn i.

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The various organizations which are responsible for activities supporting plant construction gather the

documents required to complete the work. Upon completion of the work activity, records' are distributed te various ,

l records centers and control points.

j 2. Records Flew During Construction

a. Introduction  !

j Drawings, specifications, procedures and design.

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! change informacion required for construction are develcped I j by TUGCO's architect engineer, field engineers and/or . ,

equipment vendors. This information is transmitted to DCC-Construction which is responsible for the control and i

eventual distribution of this iriformation to those ~ ]

responsible for construction and inspection.

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Upon receipt of documents by CCC-Construction,

! information such as document number, title, revision, (

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etc., la entered into appropriate indices. After the indexiag information is entered, the dccuments are I prepared for filing. Specifications, procedures and t

instructions, correspondence, Design Change Authorizations '

(DCA), and Component Modification Cards (CMC) are filed j nunerically. Drawings are microfilmed and their aperture cards are filed by drawing number. Revisions to drawings are proceased and filed in the same manner.

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l . The DCC satellite centers do not-have any of the original documents stored in DCC-Construction. Copies of main DCC documents are made and distributed to the satellite centers to support the work they service. The l ' satellites maintain icgs of each document or document 1 package issued for construction thus providing a means to ,

update the documents in the event subsequent design

! changes are required.

Comanche Peak's Construction Management organization is responsible for construction planning and scheduling. Consistent with scheduled milestones, specific construction work is accomplished through the use of work packages or work processing documents. The I

affected craf t obtains from the satellites or paper flow groups, as appropriate, design documents required to carry out specific work. Control of the design documents is maintained through the satellites.

CA/QC obtains required design documents, performs the required inspections, and completes the necessary inspection documentation. Inspection i documentation, including inspection reports and non-conformance reports, is discussed below.

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b. Inspection Reports An Inspection Report ("IR") is used to record field inspections performed by field QA/QC personnel. It is a checklist of inspection attributes and has an area for recording any deviations identified during an j inspection. It is completed to document the results of an inspection, regardless of whether the inspection identified any discrepancies. The status of irs has been and is monitored from the time they are assigned an IR -

! number to the time they are closed and transferred to the PPRV for storage. Prior to the establishment of the Building Management Organizations, each non-ASME CC discipline was responsible for tracking and closing the inspection reports within its scope of work.8 In late 1983, steps were taken to centralize the open IR monitoring function so that the on-going tracking of irs would be integrated with project scheduling and S irs are used by ASME CC in connection with tha inspection of pipe supports, threading, ar' closure of non-conformance reports (NCRs ) . In thesa cases the IR would be part of a package which itsel' is tracked.

With respect to a pipe support, the hanger IR is part of the hanger package. Similarly, an IR documenting the inspection of threading would be part of the spool package. Lastly, irs used for NCR closure are part of the NCR package. A missing IR in either a hanger or spool package would be detectad by document review and would cause an NCR to be ge".erated. An IR used for  ;

NCR closure documents tha*. closure, and without it, the NCR is not closed. In addition, irs are used to report unsatisfactory in-process inspections. These i

irs are tracked manually and are evaluated for trends adverse to quali ty. ,

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would more efficiently utilize resources. In the process of doing so, manual icgs that had been maintained by each non-ASME QC discipline were audited. IR documents referenced in each log were accounted for, and their status (open or closed) was confirmed. The manual logs were then closed, and all information on open irs was entered into the Open IR Tracking Data Base. Thus the validity of the data in this computer data base was confiened. About the same time, the BMos were established. The "Open Plant Record Vault" (OPRV)9 was assigned responsibility to maintain QA accountability independent of the EMoc for open irs .

, Unsatisfactory (or open) inspection reports document inccmplete or non-conforming construction .

activities. In those instances where the quality control inspector and the craft determine that the work can be brought into compliance by additional effort that does not require engineering evaluation and disposition, the work is completed, reinspected, and the inspection report is closed.

9 The "Open Plant Record Vault" is not, in fact, a vault that stores completed QA records. Ra ther , it is an organization concerned with monitoring open irs and NCRs within the non-ASME QA scope until their completion and transmittal to the PPRV. The OPRV is located in the main construction administration building.

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a Where an open inspection report requires engineering evaluation and disposition, such evaluation is documented on an NCR, a DCA, or a CMC. These documents 1

provide a record of identifying, documenting, resolving and closing out the unsatisfactory condition reflected on

the IR.

As work activities are completed (following I inspections), documents related to each activity are distributed to the appropriate records center. Design documents are returned to DCC-Construction. Inspection reports,' other safety-related quality assurance records (e.g., ASME N-5 data reports, weld data cards) and construction records are sent to the Permanent Plant Records Vault for indexing and filing. Records verification is being completed to assure that irs are f

closed.

c. Electrical Seearation Deficiency Recort In certain areas of plant construction,

" deficiency reports" (or "punchlists") were used in addition to irs and NCRs. These lists were used to facilitate comunication between QC and Craft. A deficiency report was used during the walkdown of Unit 1, during which physical separation of electrical cables was checked. The walkdown teams consisted of electrical discipline representatives from engineering, construction i i r

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and CA/QC. When a separation deficiency was detected, it was noted on the Electrical Separation Deficiency Report.

Craft later performed necessary corrective action after which the work was then reinspected. When CC determined that an area was complete and acceptabic, an IR was prepared listing all raceways inspected, and the relevant i

partion of the deficiency report (s) were attached to the IR. The IR was then processed as discussed in the lr preceeding section. Both the IR and the attached deficiency report ( s) constitute the record of completed  ;

work. There are procedural controls governing this list, and a historical record of it exists.  ;

d. Non-conformance Reports l An NCR is used to document nonconforming conditions where the use of another document is not  !

specifically prescribed by inspection instructions. f The TUGCO NCR Coordinator reporting to TUGCO Cuality Assurance is responsible for monitoring unresolved [

(i.e., "open") NCRs related to non-ASME scope activities. ,

The office of the non-ASME NCR Coordinator is currently '

located in the main construction administration building.

The Brown & Root NCR Coordinator reporting to B&R Cuality Assurance is responsible for monitoring open NCRs related O

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to ASME scope. ThatofficeislohatedontheNorthIsland (near the main construction gate) away from the t administration building.

i To find an open NCR, it is necessary to go co the office ( ASME or non-ASME) monitoring the NCR.10 The i

format of the NCR number will indicate whether the item i

falls within ASME cr non-ASME secpe and, thereforo, will  !

indicate which office monitors the UCR. At each step in j the disposition of an NCR, a copy is cent to the ,

j appropriate office so that thu status cf ?.he. NCR is >

)<

updated and to assure that its files reflect the curren+

I status of the NCR. If the number of the NCR is not known, i

it is necessary to check both officas. ,

Both NCR offices use a nunerical filing scheme for open NCRs. Therefore, if the NCR number is known, i

, direct rer.rioval of the record frcm their file is the nest ,

4

, ef ficient nethod to obtain the NCR. In most caces, the l i,

NCR number is known from references to it on other records (e.g. inspection reports) or indices (e.g., status 1

reports).

If the NCR number is not known, a variety of j sources are available to identify the number. Within the j ASME scope, NdR numbers are manually logged at the time l

10 closed NCRs are sent to the PPRV and may be retriev.ed I by using the Automated Records Managenent systen Data '

Base (A.R.M.S.) discussed in Section E,4.a., below. I I 1 1 ,

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( .. -

j .

i

t the non-conforming condition is identified and the NCR is issued. For each NCR, the log includes an NCR number, f '

i description, trend category, location information, and I status for each step in the disposition process. Similar 1

information is also logged for non-ASME NCRs at the time '

f the NCR is created.

The NCR logs have been automated using the Non-conformance Report Tracking Data Base. The programs for i the NCR Tracking Data Base are processed on George II/III. I Access is restricted, via CSCRIPT, to QA/CC staff working

}

} with the NCR . Coordinator and to keypunch staff working in j

the computer center. The primary output from the ecmputer system is a periodic status report of open NCRs. The NCR i

I Coordinator validates the accuracy of this report by j comparing it to the items on file and distributes the

I i

report to all parties who have responsibility for closing

}

items which are on the list.

The list is used as the primary mechanism for identifying numbers of open NCRs for i subsequent retrieval from the files. The keypunching i
staff has no need for this report since they are not j involved in retrieval, only d*ta entry.ll ,

i j

l i 11 The only occasion when an NCR will be open and not I

1 appear on the status report is when it has been-opened since publication of the report. Should this be the

)

  • case, it is possible to ascertain the status of the J NCR by looking in the appropriate NCR log book.

1 l

.---eemt-we&w -- esp +g.m, e n w -r*- m v --- t re ~ -w----r- .b'-n~+r-~arwe-*m *-*r Y W~" " * - -M'**^-""""w"e '+'-*T'****t""^'"T"W*~*

. . . . _ , . _ , . _ . . . . . . _ . . _ _ . _ . . . _ _ . ~ . _ _ _ . - . . . . .

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t It is possible to access the NCR Tracking Data '

[

Base on the computer terminal. To do so the following 4

conditions must be met: ,

1. a terminal connected tp George  !

II/III must be used.

2. an authoriz,ed password must be used by a trained indi'iidual.

i 3. the ccmputer programs must be

! operational. ,

4 Having determined the correct NCR number fram one of the 1

I above sources, retrieval of the paper record is possible f

by going directly to the record files. ,

e. Master Data Base ,

i The Master Data Base (MDB) was developed early in the project as a log to identify remaining construction

work activities which could affact plant cenpletion.' The r

MDB programs are currently processed on the George II/III '

, ccmputers. The icg includes information identifying work  !

items, the affected system or plant area, the initiator of l the work item, the organization responsible for completion

of the work and the status of the item (i.a., open or closed).

]

! The MDB is used by management tot

1. authorize the commencement of workt

, 2. track the status of work in progressi l:

l 12 The MDB is not intended to be a comprehensive list of NCRa, as that function is handled by the NCR Tracking l Data Base discussed earlier. It should be noted, 3 (footnote continued) 1 )

1 1

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3. acknowledge the completion of work; and
4. plan future work.

The primary output of MDB are printouts of selected portions ci t?,a data base in the most efficient order required to facilitate work ficw. For example, open work items which affect a given system can be sorted and printed by the responsible department to assure that required work is completed prior to the scheduled test system date. The various printouts of outstanding work

. items are ccmmonly referred to as "punchlists" (e.g.

Construction Punchlist, Completions Punchlist and the Paster punchlist) and snould be distinguished frem the Electrical Separation Deficiency Report, described above.

These punchlists are status documents and, although controlled by administrative procedures, are not QA documents.

As iteras are acknowledged to be complete as evidenced by the completion of required documentation, the status on the MOS is changed to " closed." Closed items 1 will not appear on punchlists, although a historical J l

report could be generated which would include only closed items.

(footnote continued frem previous page) ,

however, that if the disposition of an NCR involves an  !

spen work item, that work item will be included in MDB, along with a reference to that NCR. 1

  • V. .
3. Records Retention TUGCO complies with the requiremeTts of ANSI N.45.2.9-1974 (Draft 11) and the ASME Code,Section III (1974) for collecting, storing and maintaining quality assurance reecrds for CPSES. These records include the following:
1. design
2. procurement
3. installation and construction
4. preoperational and startup test
5. operation phase and activity records Some of these records are to be maintained for the life of the plant; o thers are considered non-permanent with minimum specified retention periods, depending on the record type.
4. Records Retrieval As noted in Section D, indices (including manual legs and indices generated from various computer data bases),

are used to facilitate retrieval of documents and records frcm record centers at CPSES. The more important of these indices and lists are discussed below,

a. Automated Records Management System (A.R.M.S.) Data Base The Automated Records Management System (A.R.M.S.) data base, a computer index of verification records, is used to facilitate retrieval of completed

_ _ _ _ _ _ _ _ ______'-__ _---- - - - _ - - - - - - - - - - - - - - - - - - - = - - - - - - - - - - - - - - - ------ --- "

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records. A verification record is any document that is retained as proof that permanent plant structures, systems, components and work functions are manufactured, installed, inspected or acccmplished in compliance with design and construction requirements.

TUGCO Operations is responsible for A.R.M.S.

The programs used by A.R.M.S. are processed on the Operations Computer. For QA verification records

. generated during plant construction, receipt by the PPRV triggers the process of A.R.M.S. indexing. First, a filing 1ccation is assigned to the record. A coding step is performed to index lengthy records by consolidating the A.R.M.S. indexing information onto a single page coding sheet. For reasons of proximity to PPRV, A.R.M.S. index data is keypunched from the coding sheets or directly frem QA records into the George I computer. Once a day, the key-punched data is collected on ecmputer tape and delivered to TUGCO Operations and added to A.R.M.S.

Periodically an activity report is generated of changes m'ade to A.R.M.S. during the previous key punching cycle.

The activity report is compared item by item to the CA records to assure the accuracy of A.R.M.S. Differences detected at this point are corrected and appear on subsequent activity reports until A.R.M.S. and the CA records match.

s 6 Access to A.R.M.S. is restricted to one terminal in the PPRV, one terminal in the TUGCO QA offices in Dallas, terminals in the operations Vault, and terminals in PMCS. In addition, printouts are provided to authorized QA/CC individuals. Use of any of these sources will direct the requestor to the filing location of the records selected. Retrieval is completed by going to the appropriate file location and pulling,the record.

b. DCA and DCC Data Bases There are two ecmputer data bases used for control and distribution of documents received by DCC-Construction: "DCC DB" and "DCA:DB."

The DCC:DB is a computer data base that is used to store information pertinent to drawings, specifications, procedures, and other materials. It is used by DCC to control, distribute and assure the accountability and traceability of these records. The data base includes information such as doccment number, revision number and the distribution list. This data base is controlled by DCC-Construction so that changes to the data base cannot be made without authorisation by DCC- I j

1 Construction management. Access to this data base is l

l

c controlled by a CSCRIPT13 password so that unauthorized persons cannot access the data base to change the information it contains.

The DCA:DB is a data base for the control and distribution of design change information (DCAs/CMCs) .

This data base is a shared system between engineering and DCC-Construction with engineering having the authority and responsibility to make changes to the data base. The DCA:DB is electronically linked to DCC:DB so that when engineering information is entered into the DCA:DB, DCC-Construction is alerted to the fact that a change has been made to a design dccument. When the actual design change document is received by DCC-Construction, it enters additional information into DCA:DB such as a document number and date. At this point the design package can be released to the craft for construction. This system was set up to assure that the latest design information and any changes are made available to the craft performing the construction work. Access to the data base is controlled by the CSCRIPT password system described earlier.

13 See discussion of CSCRIPT in Section D.1.b. of this Re port .

a o a GLOSSARY OF TERMS

1. Accept (Use-As-Is) -- A disposition permitted for a non-confdrming item when it can be established that thd item'is satisfactory for its intended use.
2. Activity Report -- Printouts of changes made to a computer data base during a specified time period.
3. Aperture Card -- a piece of 3 5 mm microfilm mounted on a card used to store large records such as drawings and their revisions.
4. A.R.M.S. - Automated Records Management System -- A computer index used to facilitate retrieval of completed documents. -
5. BMO - Building Managemant Organization -- A group chartered with the responsibility of completing construction work within a specific area of the plant.
6. BOP - Balance of Plant -- Non-safety related systems and components throughout the plant which do not require QA/CC inspection.
7. BOP Vault -- A facility which receives and stores documents generated during the construction of CPSES that pertain to non-sa4ety related components.
8. CMC - Component Modification Card -- A document that authorizes changes to a specific component or system.

A CMC is generally used to authorise drawing changes.

9. Corrective Action -- A measure taken to rectify conditions adverse to quality and, where necessary, to preclude repetition. -
10. CSCRIPT -- A computer program used to administer security functions on the Geroge II/III computers. l
11. DCC - Document Control Center-construction -- A facility which controls instructions, procedures and drawings required for construction.
12. DCA:DB - Design Change Authorization Data Base -- A computer data base that is used to assure accountability and traceability of DCA's and CMC's. l

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13. DCC:DB - Document Control Center Data Base -- A computer data base that is used to assure accountability and traceability of controlled copies of instructions, procedures and drawings required for construction.
14. Deviation -- Departure from a previously approved method, sequence or standard.
15. DCA - Design Change Authorization -- A document that authorizes changes to design documents. A DCA is generally used to authorize specification changes.
16. Disposition -- A decision made by an authorized person of the action to be taken to resolve a non-conforming condition. This action can be either:

accepted (use-as-is), rework, repair or scrap.

17. Electrical Separation Deficiency List -- A list (now called Electrical Separation Deficiency' Report) of electrical cables or raceways which do not meet required specifications for physical spacing.
18. " George" -- A slang term used to refer to varicus onsite computer equipment.
19. Inspection -- A quality control activity in which the conformance of materials, supplies, components, parts, appurtenances, systi's, processes or structures to predetermined quality requirements is determined by examination, observation or measurement. ,
20. IR - Inspection Report -- A document used to record field inspections performed by quality control personnel.
21. Logs -- A manual or computer generated listing of informatic1 in a logical sequence to facilitate access to and retrieval of records and documents.
22. MDB - Master Data Base -- A ccmputerized list of work activities which are outstanding.

234 N-5 Data Report -- A record utilized by the ~ installer of piping systems to certify that - the installation of the system is acceptable and in accordance with the ASME Code. l O D

e J A 111 -

24. Non-Conformance -- A deficiency in characteristic, documentation, or procedure that renders the quality of an item or activity unacceptable.
25. NCR - Non-Conformance Report -- One means of documenting a nonconformance.
26. N-5 Procram -- A program developed by Brown & Root (as the holder of the ASME Code Certificate of Authorication) to describe the methods of cenducting and documenting piping system installation in accorrlance with the ASME Code.
27. Open Items -- TNose activities or items of work that need to be ecmpleted.
28. Operations Vault -- A f acility within TUGCO Operations which will be Ehe ultimate repository of records during the operational lifetime of the plant.
29. OPRV - Open Plant Record Vault -- A group responsible for the accountacility of in-process inspection reports.
30. " Owner" of Computer Data Base -- The group which has the authority for controlling access and maintaining a computer data base.
31. PFG - Paper Flow GroQp -- A group responsible for preparing, obtaining, assembling, routing and tracking documents required by a BMO to perform construction work activities.
32. PPRV - Permanent Plant Record Vault -- A facility wnich serves as the prime repository of completed CA verification records during construction.
33. Funchlist -- A generic term for any list of open items.
34. QA Record -- A document that furnishes evidence of the quality of items and/or activities affecting quality. A document is considered to be a reco~rd when it has been completed and closed.
35. " Sat" --

A slang term used to identify an inspection checkpoint or report that has been completed satisfactorily.

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36. Satellite -- A subdivision of DCC-Construction which provides DCC services in areas convenient to construction workers.
37. Tracking -- Monitoring the status of an item.
38. Trending -- The evaluation of deviations or non-conformances by source and frequency as one basis for determining the need for corrective action to preclude repetition. e
39. "Unsat" --

A slang term used to identify an inspection checkpoint or report indicating that construction of an item is inccmplete or unsatisfactory.

40. Verification -- The act of assuring that an activity or condition has been implemented in conformance with the specified requirements.
41. Walkdown -- A tour of an area of the plant done for a variety of reasons, including inspections and construction progress reports.

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