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f'                     4Q       Pullman Power Products                                         XV - 2 y
f' 4Q Pullman Power Products XV - 2 y
00cOSA[ NT Nn,   1 PREPARED BY: J. Miller             APPROVED BY: A. A. Eck             _AAE h M 4/23/80 PERRY                   TO BE USED               '              PAGE PROJECT')ROCEDURE             ONLY ON JOB 8         V''               NO. 1 of 8       j l
00cOSA[ NT Nn, 1
PREPARED BY: J. Miller APPROVED BY: A. A. Eck
_AAE h M 4/23/80 PERRY TO BE USED PROJECT')ROCEDURE ONLY ON JOB 8 V''
PAGE NO.
1 of 8 j
LATEST REV. DATE 9-16-82 RECElVED
LATEST REV. DATE 9-16-82 RECElVED
                                                        ' PROCEDURE FOR HANDLING NOV - 31982             NONCONFORMANCES (FIELD)
' PROCEDURE FOR HANDLING NOV - 31982 NONCONFORMANCES (FIELD)
Docu= El b g Copyright 1982 PULLMAN POWER PRODUCTS
Docu= El b g Copyright 1982 PULLMAN POWER PRODUCTS
                                                                                        ~
~
HEADQUARTERS AT WILLIAMSPORT, PENNSYLVANIA pEvl510h   PREPARED BY     APPROVED BY INITIALS                     DESCRIPTION 7/25/77 J.Townsend       K. Swisher       KS     Initial Issue 4/21/78 J. Miller       K. Swisher       KS     Revised para. 5.1.2, 9.1, 10.1 Added para.
HEADQUARTERS AT WILLIAMSPORT, PENNSYLVANIA pEvl510h PREPARED BY APPROVED BY INITIALS DESCRIPTION 7/25/77 J.Townsend K. Swisher KS Initial Issue 4/21/78 J. Miller K. Swisher KS Revised para. 5.1.2, 9.1, 10.1 Added para.
5.1.5, 5.2, App. C, Fom J-Deleted para.11, 2/12/79 R.Hunnicutt N.Hol l erbus t.     NH     Extensively Revised Revised para. 6.1.2 and App. A. Nonconform-3/05/79 J. Miller        N.Hollerbust    NH ance Codes and Cause Codes App. B.
5.1.5, 5.2, App. C, Fom J-Deleted para.11, 2/12/79 R.Hunnicutt N.Hol l erbus t.
A. A. Eck               Extensively Revised 4/23/80 J. Miller                        AE Added para. 5.2.5, Appendix E and Fom AL.
NH Extensively Revised 3/05/79 J. Miller N.Hollerbust NH Revised para. 6.1.2 and App. A. Nonconform-ance Codes and Cause Codes App. B.
11/18/80 R.Hunnicutt J. Willis             JW Added 1.2, Rev. 5.2, 5.2.2, 5.2.3 5.4, 1/02/81 J. Miller        J. Willis        JW deleted 6.1.3, 6.1.4, 6.1.5, revised 6.1.6 and Added 6.6.
4/23/80 J. Miller A. A. Eck AE Extensively Revised 11/18/80 R.Hunnicutt J. Willis JW Added para. 5.2.5, Appendix E and Fom AL.
Revised para. 1.2, 5.4.1, 5.4.2, 6.1, 6.6, 6/16/81 R.Hunnicutt      J. Willis        JW 7.0, 8.1, 9.0, 10.0 Added Form AQ.
1/02/81 J. Miller J. Willis JW Added 1.2, Rev. 5.2, 5.2.2, 5.2.3 5.4, deleted 6.1.3, 6.1.4, 6.1.5, revised 6.1.6 and Added 6.6.
J.E. Miller J. Willis           JW     Revised para. 5.5.
6/16/81 R.Hunnicutt J. Willis JW Revised para. 1.2, 5.4.1, 5.4.2, 6.1, 6.6, 7.0, 8.1, 9.0, 10.0 Added Form AQ.
4/06/82                                           Revised Para 5.2.4 and 5.2.5; added Form 9/16/82    J.E. Miller J. Willis            (.d BP and Appendix G. Added 5.2.6, 5 2 7. Am 5 2.8 -                                   .
4/06/82 J.E. Miller J. Willis JW Revised para. 5.5.
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9/16/82 J.E. Miller J. Willis
(.d Revised Para 5.2.4 and 5.2.5; added Form BP and Appendix G. Added 5.2.6, 5 2 7. Am 5 2.8 -
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8309290086 830622 PDR FOIA HIATT83-199 PDR 7
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PREPARED BYr   J. Miller         APPROVED BY, A. A. Eck           AAE $1?N     4/23/80 PERRY                 TO BE USED       .c::p e     B       PAGE PROJECT PROCEDURE         ONLY ON JOB #   'g .       Q       NO. 2 Of 8 INDEX Title                                             Paragraph           Page Title Page                                           ---                1                1 Index                                                 ---                2                 1 Scope                                                 1.0               3 Policy                                               2.0               3                 j Responsibility                                       3.0               3 Unacceptable Conditions                               4.0               3                 )
Jg Pullman Power Products gp XV - 2 7
Nonconformances                                       5.0             3-5 Resolution of Nonconformances                         6.0             5-7 Distribution                                         7.0               7 Records                                               8.0               7 Steps to Prevent Recurrence                           9.0               7 Documenting                                         10.0               8 Review                                               11.0               8
DOCUMENT No.
  - ('
PREPARED BYr J. Miller APPROVED BY, A. A. Eck AAE
  .                  Nonconformance Codes                           Appendix A             1 of 1
$1?N 4/23/80 PERRY TO BE USED
~!                   Cause Codes                                   Appendix B             1 of 1 NR Information Sheet Instructions               Appendix C             1 of 1
.c::p e B
.j
PAGE PROJECT PROCEDURE ONLY ON JOB #
:                    NCR Torm Instructions Appendix D             1 of 2               i NCR Distribution                               Appendix E             1 of 1               l MPL Form Instructions                           Appendix F             1 of 1               '
'g.
NR Information Sheet                   .
Q NO.
Form               BP NR Review Stamp                                 Appendix G             1 of 1 Nonconformance Report                               Form               17 Field Process Sheet                                 Form               18 Field Weld Process Sheet                             Form               19 Field Weld Process Sheet / Repair                   Form               19A Field Multi-Weld Process Sheet                       Form               ISB Hold Tag                                             Form               22 Nonconformance Report Index                         Form                 J tiPL Report Index                                   Form               AL Interface Nonconformance Review Sheet               Form               AQ W
2 Of 8 INDEX Title Paragraph Page Title Page 1
Index 2
1 Scope 1.0 3
Policy 2.0 3
j Responsibility 3.0 3
Unacceptable Conditions 4.0 3
)
Nonconformances 5.0 3-5 Resolution of Nonconformances 6.0 5-7 Distribution 7.0 7
Records 8.0 7
Steps to Prevent Recurrence 9.0 7
Documenting 10.0 8
- ('
Review 11.0 8
Nonconformance Codes Appendix A 1 of 1
~!
Cause Codes Appendix B 1 of 1 NR Information Sheet Instructions Appendix C 1 of 1
.j NCR Torm Instructions Appendix D 1 of 2 NCR Distribution Appendix E 1 of 1 MPL Form Instructions Appendix F 1 of 1 NR Information Sheet Form BP NR Review Stamp Appendix G 1 of 1 Nonconformance Report Form 17 Field Process Sheet Form 18 Field Weld Process Sheet Form 19 Field Weld Process Sheet / Repair Form 19A Field Multi-Weld Process Sheet Form ISB Hold Tag Form 22 Nonconformance Report Index Form J
tiPL Report Index Form AL Interface Nonconformance Review Sheet Form AQ W


1
1
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Ig Pullman Power Products xV - 2 y
ooCUMENT No.
ooCUMENT No.
PREPAREo BY       J. Miller       APPROVED DY   A. A. Fck       AAF $$$U     4/23/80 PERRY             To BE USED         f"*'             PAGE No.     of 8 PROJECT PROCE0llRE         oNLY oN job #
PREPAREo BY J. Miller APPROVED DY A. A. Fck AAF
d 1.0 SCOPE 1.1 This procedure defines the actions recuired to orocess nonconfomances (NCR's) in accordance with Section XV of the Connany's Quality Assur-ance Manual.
$$$U 4/23/80 PERRY To BE USED f"*'
PAGE of 8 d
No.
PROJECT PROCE0llRE oNLY oN job #
1.0 SCOPE 1.1 This procedure defines the actions recuired to orocess nonconfomances (NCR's) in accordance with Section XV of the Connany's Quality Assur-ance Manual.
6/16/81 1.2 In additinn, this procedure defines the Comoany's resnonsibility in-volving " Interface Nonconformances". Interface Nonconformances are those nonconfomino conditions which are identified by PPP personnel against work perfomed by other contractors or aoainst items / material supplied by the owner, and/or those Nonconfoming conditions which have been added to the Company's scope of work.
6/16/81 1.2 In additinn, this procedure defines the Comoany's resnonsibility in-volving " Interface Nonconformances". Interface Nonconformances are those nonconfomino conditions which are identified by PPP personnel against work perfomed by other contractors or aoainst items / material supplied by the owner, and/or those Nonconfoming conditions which have been added to the Company's scope of work.
2.0 POLICY 2.1 Nonconformances in items may be detected at Source Inspection, Re-ceiving Inspection. In-Process Inspections, durino fabrication or in-stallation, at Final Inspection or during testino.
2.0 POLICY 2.1 Nonconformances in items may be detected at Source Inspection, Re-ceiving Inspection. In-Process Inspections, durino fabrication or in-stallation, at Final Inspection or during testino.
{                       2.2 To provide interface between the Company and the Client, specific
{
                                    " description" and "cause" codes on nonconfomities are included in this procedure. (Appendix A and B.)
2.2 To provide interface between the Company and the Client, specific
3.0 RESPONSIBILITY 3.1   It is the responsibility of the 0.A. Manaaer for the implementation of this procedure through his examination, inspection and testing personnel.
" description" and "cause" codes on nonconfomities are included in this procedure. (Appendix A and B.)
3.0 RESPONSIBILITY 3.1 It is the responsibility of the 0.A. Manaaer for the implementation of this procedure through his examination, inspection and testing personnel.
4.0 UNACCEPTABLE CONDITIONS 41 Unacceptable conditions which can be corrected at the time of dis-covery under the control and to the satisfaction of the inspector, and which can be made acceptable by controls imposed by operations as outlined on a previously approved Process Sheet are not considered nonconfoming.
4.0 UNACCEPTABLE CONDITIONS 41 Unacceptable conditions which can be corrected at the time of dis-covery under the control and to the satisfaction of the inspector, and which can be made acceptable by controls imposed by operations as outlined on a previously approved Process Sheet are not considered nonconfoming.
5.0 NONCONFORMANCES 5.1 Unacceptable conditions other than those outlined in the precedino paragraph are considered as nonconformances. The 0.A. Department shall use Fom 17 "Nonconformance Report" to document nonconfom-
5.0 NONCONFORMANCES 5.1 Unacceptable conditions other than those outlined in the precedino paragraph are considered as nonconformances. The 0.A. Department shall use Fom 17 "Nonconformance Report" to document nonconfom-ities.
                .                    ities.
h SF l.ot A (4-79)
h SF l .ot A (4-79)


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l Jij Pullman Power Products XV-2 pi/
PREPARED BY:       J. Miller         APPROVED BY,   A. A. Eck           AAE oi s 4/23/80 PERRY                      TO BE USED        O u
DOCUMENT NO.
                                                                                .h4
PREPARED BY:
                                                                                '' "            PAGE NO.
J. Miller APPROVED BY, A. A. Eck AAE oi s 4/23/80 O
4 of 8 PROJECT PROCEDURE                 ONt.Y ON JOB #
.h PAGE 4 of 8 PERRY TO BE USED PROJECT PROCEDURE ONt.Y ON JOB #
u 4
NO.
5.0 NONCONFORMANCES (Cont.)
5.0 NONCONFORMANCES (Cont.)
9/16/82               5.2 All nonconformances except as identified in para. 5.4 (Interface Nonconformances), require the approvals of the Q.A. Manager, Chief Field Engineer, Authorized Nuclear Inspector and the Owner / Agent prior to proceeding with the proposed disposition.
9/16/82 5.2 All nonconformances except as identified in para. 5.4 (Interface Nonconformances), require the approvals of the Q.A. Manager, Chief Field Engineer, Authorized Nuclear Inspector and the Owner / Agent prior to proceeding with the proposed disposition.
5.2.1   Nonconformances may include, but are not limited to incorrect materials, incomplete or incorrect documentation or identifi-cation, improper dimensions, special process out of control or serious misalignment during installation.
5.2.1 Nonconformances may include, but are not limited to incorrect materials, incomplete or incorrect documentation or identifi-cation, improper dimensions, special process out of control or serious misalignment during installation.
5.2.2 When a nonconformance is discovered, the item (s) involved 1/2/81                                shall be segregated when possible. A Q.C. Inspector shall attach a " Hold Tag" to the item or adjacent to the operation, as in the case of welding.       Refer to " Hold Tag Usage" procedure.
1/2/81 5.2.2 When a nonconformance is discovered, the item (s) involved shall be segregated when possible.
  ,1h . 81                        5.2.3 Process sheets involved shall be withdrawn and returned to the point of issurance. The Q.C. Inspector will note on the Process
A Q.C. Inspector shall attach a " Hold Tag" to the item or adjacent to the operation, as in the case of welding.
                        -                  Sheet, the NCR number where and when applicable. Once the nonconformance has been resolved, the original Process Sheets, revised if necessary or new Process Sheet together with re-(
Refer to " Hold Tag Usage" procedure.
5.2.3 Process sheets involved shall be withdrawn and returned to the
,1h. 81 point of issurance. The Q.C. Inspector will note on the Process Sheet, the NCR number where and when applicable.
Once the nonconformance has been resolved, the original Process Sheets, revised if necessary or new Process Sheet together with re-(
vised drawings, if applicable, can be issued to resume work.
vised drawings, if applicable, can be issued to resume work.
Hold Tag shall be removed as set forth in the Hold Tag Pro-cedure.             ,
Hold Tag shall be removed as set forth in the Hold Tag Pro-cedure.
5.2.4 NR Information Sheets shall be initiated for all possible non-9/16/82                                conforming conditions in accordance with the attached instructions (Appendix C).
9/16/82 5.2.4 NR Information Sheets shall be initiated for all possible non-conforming conditions in accordance with the attached instructions (Appendix C).
5.2.5 The NR Information Sheet shall be reviewed by QA to determine 9/16/82 if the condition described is correct. The NR information sheet shall be forwarded to the QA Manager or his designee for their concurrence. If at any point it is determind that an NR coc-dition does not exist, the sheet shall be with drawn and the inspector notified so that the hold tag can be removed and the appropriate action, if any, taken..
9/16/82 5.2.5 The NR Information Sheet shall be reviewed by QA to determine if the condition described is correct. The NR information sheet shall be forwarded to the QA Manager or his designee for their concurrence.
5.2.6 After obtaining the concurrence required above, the NR Information 9/16/82                                Sheet shall be used to prepare a Nonconformance Report to be filled out in accordance to the attached instructions (Appendix D).
If at any point it is determind that an NR coc-dition does not exist, the sheet shall be with drawn and the inspector notified so that the hold tag can be removed and the appropriate action, if any, taken..
5.2.7   For Nonconformance Reports written against more than one item 9/16/82                            - of equipment, Form Al shall be used. This shall be filled out
9/16/82 5.2.6 After obtaining the concurrence required above, the NR Information Sheet shall be used to prepare a Nonconformance Report to be filled out in accordance to the attached instructions (Appendix D).
( ',     -
9/16/82 5.2.7 For Nonconformance Reports written against more than one item
- of equipment, Form Al shall be used. This shall be filled out
( ',
in accordance with the attached instructions (Appendix F).
in accordance with the attached instructions (Appendix F).
9/16/82                       5.2.8 With prior approval of the QA Manager, individuals may be allowed to submit nonconfonnances via the use of form 17 without the requirements of the NR Information Sheet.
9/16/82 5.2.8 With prior approval of the QA Manager, individuals may be allowed to submit nonconfonnances via the use of form 17 without the requirements of the NR Information Sheet.


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Pullman Power Products
: xy_,
DOCUMENT No.
DOCUMENT No.
PREPARED BY:       J. Miller _         APPROVED BY   A. A. Eck         AAE - oi?N 4/23/80 PERRY                     TO BE USED       py 'f 3   O         PAGE 5 of 8 PROJECT PROCEDURE                 ONLY ON JOB 8       gggQ               NO.
PREPARED BY:
                -                5.3 The Q.A. Manager shall evaluate all nonconformances for applicability for reporting under 10 CFR 50 55 (e) to the Customer. This evalua-tion shall also take into consideration the Company's obligation to
J. Miller _
                            ,          report defects or noncompliances under 10 CFR 21.
APPROVED BY A. A. Eck AAE - oi?N 4/23/80 PERRY TO BE USED py 'f 3 O
5.4 Interface Nonconformance 5.4.1     Nonconformances identified by Company, but involving other 6/16/81                                  site contractors or the Owner's vendors / suppliers, the report shall be filled out as set forth in Appendix C with the following exceptions:
PAGE 5 of 8 NO.
PROJECT PROCEDURE ONLY ON JOB 8 gggQ 5.3 The Q.A. Manager shall evaluate all nonconformances for applicability for reporting under 10 CFR 50 55 (e) to the Customer.
This evalua-tion shall also take into consideration the Company's obligation to report defects or noncompliances under 10 CFR 21.
5.4 Interface Nonconformance 6/16/81 5.4.1 Nonconformances identified by Company, but involving other site contractors or the Owner's vendors / suppliers, the report shall be filled out as set forth in Appendix C with the following exceptions:
a) The NCP. number will be assigned by the Customer.
a) The NCP. number will be assigned by the Customer.
b) Only complete lines 1 through 8, remainder of form to be completed by responsible organization.
b) Only complete lines 1 through 8, remainder of form to be completed by responsible organization.
c) If line 9 is known Proposed Disposition / Justification, it g                                               shall be attached to the NCR on a separate sheet.
c) If line 9 is known Proposed Disposition / Justification, it g
    ; 6/16/81                 -          5.4.2 Nonconformances which have been added to the company's scope
shall be attached to the NCR on a separate sheet.
* of work will be received by the company with the NR. filled out
; 6/16/81 5.4.2 Nonconformances which have been added to the company's scope of work will be received by the company with the NR. filled out through line 12.
                                ,"    .          through line 12.
4/6/82 S.5 In effort to keep the number of open nonconformances to a minimum, all nonconformances shall be closed within 30 days from approval of l
4/6/82                 S.5 In effort to keep the number of open nonconformances to a minimum, all nonconformances shall be closed within 30 days from approval of l                                       the resolution, when pos'sible.
the resolution, when pos'sible.
lj         ,
lj 6.0 RESOLUTION OF NONCONFORftANCES 8
6.0 RESOLUTION OF NONCONFORftANCES 8
6.1 Appropriate resolution of the nonconformance will be determined by
6.1 Appropriate resolution of the nonconformance will be determined by the Field Engineering Department inconjunction with Quality Assurance
'l the Field Engineering Department inconjunction with Quality Assurance the Customer and the Quality Engineering Group at Corporate Headquarters, In all cases, the final resolution shall be reviewed if necessary.
'l'                                        the Customer and the Quality Engineering Group at Corporate Headquarters, if necessary. In all cases, the final resolution shall be reviewed by the Q.A. Manager for Code compliance and concurrence shall be obtained from the Authorized Nuclear Inspector. It in this review the
by the Q.A. Manager for Code compliance and concurrence shall be obtained from the Authorized Nuclear Inspector.
                                  .      Q.A. Manager or Authorized Nuclear Inspector do not concur, the NCR will be returned to the originator for re-evaluation of the proposed   '
It in this review the Q.A. Manager or Authorized Nuclear Inspector do not concur, the NCR will be returned to the originator for re-evaluation of the proposed solution, except as noted in paragraph 5.4.
i solution, except as noted in paragraph 5.4.
i 6/16/81 6.1.1 For nonconformances which do not meet the Code, the item may be scrapped / returned for replacement, repaired or reworked to bring it within the Code requirements.
6.1.1   For nonconformances which do not meet the Code, the item may 6/16/81                                be scrapped / returned for replacement, repaired or reworked
6:1[2 'For nonconformances which do meet the Code, but deviate from l("
* to bring it within the Code requirements.
tustoner requiremen'ts, the item may be rejected and scrapped /
                      '-                    6:1[2 'For nonconformances which do meet the Code, but deviate from l("
    '                                              tustoner requiremen'ts, the item may be rejected and scrapped /
returned for replacement, reworked or repaired to bring it into specification or accepted to "Use-as-is".
returned for replacement, reworked or repaired to bring it into specification or accepted to "Use-as-is".


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PREPARED BY:             J. !! iller       APPROVED BY   A. A. Eck     _
f~
AAC  $$ N 4/23/80 PERRY                           TO BE USED                     et       PAGE PROJECT PROCEDURE                         ONLY ON JOB #                           NO.     6 of 8 6.0 RESOLUTION OF NONCONFORMANCES (Cont'd)                                   ,  ,
ig Pullman Power Products XV-2 p
6.1.3 Submittal and approval of nonconformances involving changes to or deviations from design, permits the Owner or his Agent
DOCUMENT NO.
                    "                        to review the proposed change for reconciliation of the Design Report without the initiation of a Deviation Report.
PREPARED BY:
J. !! iller APPROVED BY A. A. Eck
$$ N 4/23/80 AAC PERRY TO BE USED et PAGE PROJECT PROCEDURE ONLY ON JOB #
NO.
6 of 8 6.0 RESOLUTION OF NONCONFORMANCES (Cont'd) 6.1.3 Submittal and approval of nonconformances involving changes to or deviations from design, permits the Owner or his Agent to review the proposed change for reconciliation of the Design Report without the initiation of a Deviation Report.
6.2 Scrap 6.2.1 The Q.A. Engineer-Materials shall identify the material " Scrap" and segregate it in the designated scrap area or return for replacement, as required.
6.2 Scrap 6.2.1 The Q.A. Engineer-Materials shall identify the material " Scrap" and segregate it in the designated scrap area or return for replacement, as required.
6.2.2 The Chief Field Engineer will initiate the required documents for replacement, if necessary.
6.2.2 The Chief Field Engineer will initiate the required documents for replacement, if necessary.
6.2.3   For Owner furnished material, the Chief Field Engineer will forward the NCR to the Owner for approval of the proposed dis-
6.2.3 For Owner furnished material, the Chief Field Engineer will
.(
.(
. -                                           position. Upon return of the NCR from the Owner, the Q.A.
forward the NCR to the Owner for approval of the proposed dis-position. Upon return of the NCR from the Owner, the Q.A.
j Engineer-Materials will either arrange for return to the Owner
Engineer-Materials will either arrange for return to the Owner j
                                  ~
~
                                              .or " Scrap" and segregate in the designated scrap area at the direction of the Owner. The st'ps     to prevent recurrence shall e
.or " Scrap" and segregate in the designated scrap area at the The st'ps to prevent recurrence shall direction of the Owner.
be the Owner's responsibility.
e be the Owner's responsibility.
6.3 Rework                           ..
6.3 Rework 6.3.1 When rework is the resolution, the Chief Field Engineer shall indicate, on the NCR, the bxtent to the rework.
6.3.1   When rework is the resolution, the Chief Field Engineer shall indicate, on the NCR, the bxtent to the rework.
6.3.2 The Q.A. Manager shall review the, solution 'for compliance to the Code, Customer specification and obtain concurrence from the Authorized Nuclear Inspector.
6.3.2 The Q.A. Manager shall review the, solution 'for compliance to the Code, Customer specification and obtain concurrence from the Authorized Nuclear Inspector.     ,
6.3.3 The Chief Field Engineer shall prepare instructions, drawings, Process Sheets and other documents which may be required. All such documents will be controlled in accordance with approved procedures.
6.3.3 The Chief Field Engineer shall prepare instructions, drawings, Process Sheets and other documents which may be required. All such documents will be controlled in accordance with approved procedures.                        .
6.4 Repair
6.4 Repair
                                ~
~
6.4.1 'Where repairs are required, the NCR and supporting documen-tation shall be submitted to the Customer /0wner for approval.
6.4.1 'Where repairs are required, the NCR and supporting documen-tation shall be submitted to the Customer /0wner for approval.
The Authorized Nuclear Inspector shall be notified and his e                       6.4.2 r''
6.4.2 The Authorized Nuclear Inspector shall be notified and his e
L                                            concurrence received prior to repair. .
r''
concurrence received prior to repair..
L


l l-Pullman Power Products p9 C                                                                                                XV-2 l
l l-C 9
DOCUMENT No. _     i PREPARED 8v     J. Miller           APPRoVEo 8Y   A. A. Eck           AAC $1IN   4/23/80         l 0
Pullman Power Products XV-2 p
PROJEC      ROCEDURE                  oNa a         !h* h h             NO.
DOCUMENT No. _
6.0 RESOLUTION OF NONCONFORMANCES (Cont'd)                                                   ,
i PREPARED 8v J. Miller APPRoVEo 8Y A. A. Eck AAC
6.4.3 The Chief Field Engineer shall prepare instructions, drawings, Process Sheets and other documents which may be required. All such documents will be controlled in accordance with approved procedures.
$1IN 4/23/80 oNa a
6.5 Use-As-Is 6.5.1     When an item conforms to the Code, but deviates from Cus-tomer specifications, the Chief Field Engineer shall obtain approval from the Owner to "Use As Is".
!h* h h 0
6.6 Interface Nonconformances are the Project Organization's respon-sibility to review and approve.       NCR's, which affect ASME Code items and which will be added to the Company's scope of work to perform proposed disposition, shall be reviewed and concurrence
PROJEC ROCEDURE NO.
6.0 RESOLUTION OF NONCONFORMANCES (Cont'd) 6.4.3 The Chief Field Engineer shall prepare instructions, drawings, Process Sheets and other documents which may be required.
All such documents will be controlled in accordance with approved procedures.
6.5 Use-As-Is 6.5.1 When an item conforms to the Code, but deviates from Cus-tomer specifications, the Chief Field Engineer shall obtain approval from the Owner to "Use As Is".
6.6 Interface Nonconformances are the Project Organization's respon-sibility to review and approve.
NCR's, which affect ASME Code items and which will be added to the Company's scope of work to perform proposed disposition, shall be reviewed and concurrence received from the Q.A. Manager, Chief Field Engineer and the ANI
(
(
received from the Q.A. Manager, Chief Field Engineer and the ANI
on Form AQ prior to commencement of the work.
''                                  on Form AQ prior to commencement of the work.
7.0 DISTRIBUTION 7.1 ' Distribution shall be in accordance with Appendix E, except for those NR's identified in paragraph 5.4.1.
7.0 DISTRIBUTION
The printed distribution list at the battom of Form 17 shall not be used.
:!                            7.1 ' Distribution shall be in accordance with Appendix E, except for those NR's identified in paragraph 5.4.1. The printed distribution list at the battom of Form 17 shall not be used.
8.0 RECORDS Records of all nonconformances and their disposition except for 8.1 those identified in paragraph 5.4.1 shall be maintained under the supervision of the Q.A. Manager. NCR's shall be easily retrievable for review.
8.0 RECORDS 8.1    Records of all nonconformances and their disposition except for those identified in paragraph 5.4.1 shall be maintained under the supervision of the Q.A. Manager. NCR's shall be easily retrievable for review.
8.1.1 In cases where the decision is made to " Scrap" all associated records for the scrapped item, shall be properly noted to disposition and retained.
8.1.1 In cases where the decision is made to " Scrap" all associated records for the scrapped item, shall be properly noted to disposition and retained.
8.1.2   In all cases where return for rep 1'acement is decided, the records shall be returned with the item.
8.1.2 In all cases where return for rep 1'acement is decided, the records shall be returned with the item.
9.0 STEPS TO PREVENT RECURRENCE 9.1    The Q.A. Manager or his designee shall initiate and record the necessary steps to prevent recurrence of all nonconfonnities.               _
9.0 STEPS TO PREVENT RECURRENCE The Q.A. Manager or his designee shall initiate and record the 9.1 necessary steps to prevent recurrence of all nonconfonnities.
,br                                   except for those identified in paragraph 5.4.1, as required.
,br except for those identified in paragraph 5.4.1, as required.


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I
                                ,G Pullman Power Products                                       xv - 2 y                                                           ooc *.fvENT No.
,G Pullman Power Products xv - 2 s
ArPRoVED BY   A. A. Fck       AAF     l31)N 4/23/8G PREPAREo BY: J. 19111er PERRY             To BE UsED                           PAGE PROJECT PROCEDURE            oNLY ON Joe #    Q'g,                 No. 8 of 8 10.0 DOCUMENTING                                               ,                          ,
y ooc *.fvENT No.
6/16/81                   10.1 Nonconforrance Reports shall be assioned an NCR number, except those identified in paracranh 5.4. All NR's except those iden-tified in paranraph 5.4.1 shall be indexed on Fom J. The Index (Form J) shall contain the NCR number, the revision number, the initiator, a brief description, and the status.
PREPAREo BY: J. 19111er ArPRoVED BY A. A. Fck AAF l31)N 4/23/8G PERRY To BE UsED Q'g, PAGE No. 8 of 8 PROJECT PROCEDURE oNLY ON Joe #
10.0 DOCUMENTING 6/16/81 10.1 Nonconforrance Reports shall be assioned an NCR number, except those identified in paracranh 5.4.
All NR's except those iden-tified in paranraph 5.4.1 shall be indexed on Fom J.
The Index (Form J) shall contain the NCR number, the revision number, the initiator, a brief description, and the status.
11.0 REVIEW 11.1 In order to control and eliminate the possible recurrence of a nonconfomance, the 0.A. Manaaer shall review the NCR's on a monthly basis. See " Corrective Action Procedure".
11.0 REVIEW 11.1 In order to control and eliminate the possible recurrence of a nonconfomance, the 0.A. Manaaer shall review the NCR's on a monthly basis. See " Corrective Action Procedure".
11.1.1 In cases of repeated nonconformances, the 0.A. Manaaer shall report in writino to the Director of Duality As-surance explaining the corrective action taken to stop
11.1.1 In cases of repeated nonconformances, the 0.A. Manaaer shall report in writino to the Director of Duality As-surance explaining the corrective action taken to stop recurrences of specific nonconfomances and solicit the recomendations of the Director of Ouality Assurance.
  '                                          recurrences of specific nonconfomances and solicit the recomendations of the Director of Ouality Assurance.
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C                 Aj Pullman Power Products                                           xv-2 y                                                               DOCUMENT NO.
C Aj Pullman Power Products xv-2 y
PREPARED BY     J. Miller       APPROVED BY     A. A. Eck       AAE   oIIN 4/23/80 PERRY PROJECT PROCEDURE TO BE USED Onty on ;oB -
DOCUMENT NO.
7026                  PAGE
PREPARED BY J. Miller APPROVED BY A. A. Eck AAE oIIN 4/23/80 7026 PAGE PERRY TO BE USED
                                                                                        ~o. i er i APPENDIX A
~o.
* NONCONFORMANCE CODES CONCRETE                                     ELECTRICAL 001 Materials                               050 Tagging / Labeling 002 incorrect Mix                           '051   Improper Installation 003 Physical Properties                     052 Cable Pulling Tension (Slump, Air Temp, Strength,           053 Condult/ Tray Fill Permeability)                           054 Separation Criteria 004 Olm or Location                         055 Hanger / Support / Mounting 005 Placement Technique (Vibrator,           056 Minimum Sending Radius Placement Rate)                       057 Welding 006 Curing                                   058 Cable / Wire
i er i PROJECT PROCEDURE Onty on ;oB -
;                  007 Post Pour Visual (Voids,                               "
APPENDIX A NONCONFORMANCE CODES CONCRETE ELECTRICAL 001 Materials 050 Tagging / Labeling 002 incorrect Mix
Honeycomb,etc.)
'051 Improper Installation 003 Physical Properties 052 Cable Pulling Tension (Slump, Air Temp, Strength, 053 Condult/ Tray Fill Permeability) 054 Separation Criteria 004 Olm or Location 055 Hanger / Support / Mounting 005 Placement Technique (Vibrator, 056 Minimum Sending Radius Placement Rate) 057 Welding 006 Curing 058 Cable / Wire 007 Post Pour Visual (Voids, Honeycomb,etc.)
TESTING EXAMINATION 061   Instrument / Certification /Calibra-tion
TESTING EXAMINATION 061 Instrument / Certification /Calibra-(-
(-           MECHANICAL 062 Olmension/Visua!
MECHANICAL tion 020 Material Identification 062 Olmension/Visua!
020 Material Identification                 063 Operator Certification /Quali fica-021  Identification, Tagging 022 Installation                                 tion                                   ' .
021 Identification, Tagging 063 Operator Certification /Quali fica-022 Installation tion 023 Equipment Alignment 064 Hydro / Leak Test 024 Welding 065 Radiographic 025 Mininum Wall 066 Ultrasonic 026 Missing or inadequate Hangers, 067 PT/MT Supports, or Snubbers 068 Hechanical Operational Test 069 Megger/HI-POT Test / Continuity STRUCTURAL STEEL MI5CELLANEOUS AND GENERAL 040 PhysIcol/ Chemical 041 Identification (Missing Tags) 100 Testing 042 Rus t/ Contamination 101 Qualification 043 Olmensional 102 Calibration 044 Fabrication 103 Documentation 045 Erection Technique 104 Inspection 046 Jointing (P.tveting, Bolting, 105 Storage and Hand!!ng Welding) 106 Cleanliness 107 Damage (including Porous Concrete Contamination) e
023 Equipment Alignment                     064 Hydro / Leak Test 024 Welding                                 065 Radiographic 025 Mininum Wall                           066 Ultrasonic 026 Missing or inadequate Hangers,         067 PT/MT Supports, or Snubbers                 068 Hechanical Operational Test 069 Megger/HI-POT Test / Continuity STRUCTURAL STEEL 040 PhysIcol/ Chemical                       MI5CELLANEOUS AND GENERAL 041   Identification (Missing Tags)         100 Testing 042 Rus t/ Contamination                     101 Qualification 043 Olmensional                             102 Calibration 044 Fabrication                             103 Documentation 045 Erection Technique                       104 Inspection 046 Jointing (P.tveting, Bolting,           105 Storage and Hand!!ng Welding)                               106 Cleanliness 107 Damage (including Porous Concrete Contamination) e
_..___ y 1.01AJ4-79)
_ ..___ y 1.01AJ4-79)


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/
                                                                                                                \
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(                              Pullman Power Products                                     XV-2 h7F ooCUMENT No.
h7 Pullman Power Products
PREPARED BYr     J. Miller     APPROVED BY   A. A. Eck           AAE   $1%N 4/23/80 To BE UsED                 9         . PAGE No. 1 of 1 oNLY oN job #
(
PERRY PROJECT PROCEDURE                      g[
XV-2 ooCUMENT No.
APPENDIX "B"                       .
F PREPARED BYr J. Miller APPROVED BY A. A. Eck AAE
CAUSE CODES GENERAL (Cont'd)
$1%N 4/23/80 To BE UsED 9
PAGE No. 1 of 1 PERRY PROJECT PROCEDURE oNLY oN job # g[
APPENDIX "B" CAUSE CODES GENERAL (Cont'd)
OPERATIONS _
OPERATIONS _
30 Inadequate Documentation 01 Operator Error                           31 Lack of Identification 02 Inadequate Indoctrination &
30 Inadequate Documentation 01 Operator Error 02 Inadequate Indoctrination &
Training                              32 Improper Cure 03 Unqualified Personnel                   33 Equipment 34 Does I;ot Meet Specification 04 Insufficient Personnel                          Requirements 05 Incorrect / Inadequate Planning 06 Poor Workmanship                         35 Violation of Procedure 36 Does Not Meet Drawing Requirements 07 Carelessness                             37 Intertninate/ Unknown I''         DESIGN                                     FUNCTIONAL 10 . Wrong Material Called Out             40 Failed Test On Drawing 11 Specification - Wrong Revision           EQUIPMENT 12 Specification - Misinterpretation
31 Lack of Identification 32 Improper Cure Training 33 Equipment 03 Unqualified Personnel 04 Insufficient Personnel 34 Does I;ot Meet Specification 05 Incorrect / Inadequate Planning Requirements 06 Poor Workmanship 35 Violation of Procedure 36 Does Not Meet Drawing Requirements 07 Carelessness 37 Intertninate/ Unknown I''
                            "    ~                            51 Inadequate or Incorrect Tools /
DESIGN FUNCTIONAL 10. Wrong Material Called Out 40 Failed Test On Drawing 11 Specification - Wrong Revision EQUIPMENT 12 Specification - Misinterpretation 51 Inadequate or Incorrect Tools /
h       ,    _      te p ta ion g Device out of Calibration
h
                              '9                                52 ot   tal per rawing (Interference)                         SUPERVISION 17 Imprcper Installation (Drawing or Specification)                                   '  te     r       n 18 Hanger, Support, Mounting Problem 19 Inadequate Information on Drawing h          r so 63 Supervisor Failed to Follow 20 Incorrect Dimensions / Tolerances               Instructions on Drawing GENERAL                                       ,
~
21 Environmental 22 Damage - By Others 23 Malfunction / Failure of Construction.
te p ta ion
Inspection, or Test Equipment 25 Vendor Supply Problem
'9 52 g Device out of Calibration ot tal per rawing (Interference)
              -    26 Material Inadequate 27 Mishandling
SUPERVISION 17 Imprcper Installation (Drawing or Specification) te r
{'.           28 Improper Storage 29 Inadequate Status Control SF 1.ot A (4-79)
n 18 Hanger, Support, Mounting Problem h
r so 19 Inadequate Information on Drawing 63 Supervisor Failed to Follow 20 Incorrect Dimensions / Tolerances Instructions on Drawing GENERAL 21 Environmental 22 Damage - By Others 23 Malfunction / Failure of Construction.
Inspection, or Test Equipment 25 Vendor Supply Problem 26 Material Inadequate 27 Mishandling
{'.
28 Improper Storage 29 Inadequate Status Control SF 1.ot A (4-79)


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(                    y          Pullman Power Products                                         xy_,
Pullman Power Products
(
: xy_,
coCUMENT NO.
coCUMENT NO.
PREPARED BY,    d. Miller          APPROVED BYr    A. A. Eck             AAE $lyf 4/23/80 PERRY PROJECT PROCEDURE TO BE usED ONLY ON JOB #
A. A. Eck AAE
rar (r (b  G 9 gQ  U PAGE NO. I of 2 APPENDIX C 9/16/82                                                                       ,
$lyf 4/23/80 PREPARED BY, d.
Nonconformance Information Sheet Instructions Instructions Enter Spec. number and current revision to the Spec.
Miller APPROVED BYr rar (b 9 Q PAGE PERRY TO BE usED PROJECT PROCEDURE ONLY ON JOB #
STATUS - Enter installed or hold based on present disposition of item (s) being identified .
(r G g U NO.
Line 1      ITEM ID        -    Enter complete identification of items (s).
I of 2 APPENDIX C 9/16/82 Nonconformance Information Sheet Instructions Instructions Enter Spec. number and current revision to the Spec.
Note: If quantity of item is more than one, then enter "See MPL" and complete multiple problem list in conjunction with NR Information Sheet.
STATUS - Enter installed or hold based on present disposition of item (s) being identified.
l' Line la      ITEM NAME      -    Enter a description of item (s).
Enter complete identification of items (s).
Examples given on NR Information Sheet.
Line 1 ITEM ID Note:
i Line Ib      QUANTITY
If quantity of item is more than one, then enter "See MPL" and complete multiple problem list in conjunction with NR Information Sheet.
                                                -  Enter number of items, if more than 1, complete in           -
l' Enter a description of item (s).
j                     .
Line la ITEM NAME Examples given on NR Information Sheet.
conjunction with Line 1.            .    .
i Enter number of items, if more than 1, complete in Line Ib QUANTITY j
Line Ic      LOCATION        -  Identify building - elevation- azimuth when applicable.
conjunction with Line 1.
Line 2        ISSUED BY      -  Name of individual identifying condition on NR Information Sheet.
Identify building - elevation-azimuth when applicable.
ITEM MAT'l          Enter name of company, vendor or Owner of material Line 3                         -
Line Ic LOCATION Name of individual identifying condition on NR Line 2 ISSUED BY Information Sheet.
being identified.
Enter name of company, vendor or Owner of material Line 3 ITEM MAT'l being identified.
Line 4       RESPONSIBLE         Identify who is responsible for causing the condition.
Line 4 RESPONSIBLE Identify who is responsible for causing the condition.
ORGAN!ZATION -
ORGAN!ZATION -
Category:     (1) Possible significance (10 CFR 21)
Category:
Line 5-NCR TYPE         -
(1) Possible significance (10 CFR 21)
(2) Major                                       ;
Line 5 NCR TYPE (2) Major (3) Minor Type:
(3) Minor Type:       Self-explana tory Line 6       GOVERNING       .  (1) Acceptance Criteria (2) Line spec.
Self-explana tory Line 6 GOVERNING (1) Acceptance Criteria P.EQUIREllENT (2) Line spec.
P.EQUIREllENT (3) Iso.
(3) Iso.
                ~
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i C                   Jg p Pullman Power Products                                   XV-2 oOCUMENT NO.
i C
PREPARED BY     J. Miller       APPROVED BY: A. A. Eck           AAE SION 4/23/80 PERRY                TO BE USED          [4 :], () d       PAGE PROJECT PROCEDURE           ONI.Y ON JOB #
Jg Pullman Power Products XV-2 p
i g Lv G V NO. 2 of 2 9/16/82                                       - Enter a total description. Give length, depth, Line. 7        NR DESCRIPTION width when identifying a defect or when applicable.
oOCUMENT NO.
PREPARED BY J. Miller APPROVED BY: A. A. Eck AAE SION 4/23/80
[4 :], () d PAGE PERRY TO BE USED i
NO.
2 of 2 g Lv G V PROJECT PROCEDURE ONI.Y ON JOB #
9/16/82 Line. 7 NR DESCRIPTION
- Enter a total description. Give length, depth, width when identifying a defect or when applicable.
If necessary, attach a sketch to aid in the under-standit'g of the condition.
If necessary, attach a sketch to aid in the under-standit'g of the condition.
Line 8         CAUSE OF NR       - Identify     what or who caused the condition also when, where and why if applicable.
Line 8 CAUSE OF NR
Line 9         PROPOSED         - Corrective action needed to correct the condition.
- Identify what or who caused the condition also when, where and why if applicable.
DISPOSITION         This can't be N/A'd.
Line 9 PROPOSED
Line 10         STEP TO PREVENT     What action is needed to prevent this type of condition from happening again.
- Corrective action needed to correct the condition.
RECURRENCE
DISPOSITION This can't be N/A'd.
(          COMMENTS: Use back of form for any additional comments or information.
Line 10 STEP TO PREVENT What action is needed to prevent this type of RECURRENCE condition from happening again.
I i                   .
(
i l                                                         .
COMMENTS: Use back of form for any additional comments or information.
I i
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4 I
4 I
C                               g'')               Pullman Power Products                                                                  xv-2 DOCUMENT No.
Pullman Power Products C
PREPARED BY, J. Miller                                   APPROVED BY     A. A. Eck                     AAE--       El%U 4/23/80~
g'')
To BE UsED                                               PAGE PERRY PROJECT PROCEDURE                               oNLY ON job #                                             No. 1 of 2 APPENDIX D Nonconformance Report Form Instructions Line No.                                                               Instructions 1
xv-2 DOCUMENT No.
PREPARED BY, J. Miller APPROVED BY A. A. Eck AAE-- El%U 4/23/80~
To BE UsED PAGE PERRY PROJECT PROCEDURE oNLY ON job #
No. 1 of 2 APPENDIX D Nonconformance Report Form Instructions Line No.
Instructions 1
Enter NCR number and revision sheet number, numerical identification of item, name of item, and quantity.
Enter NCR number and revision sheet number, numerical identification of item, name of item, and quantity.
2                                         Self-explanatory 3                                         Source: Vendor, Owner, or Company as applicable.
2 Self-explanatory 3
4                                         Enter the Company Name and applicable Spec. No, and Revision.
Source: Vendor, Owner, or Company as applicable.
I'                                                                                         Possible Significance (10CFR 21) 5                                        Category:
4 Enter the Company Name and applicable Spec. No, and Revision.
                                -                                                              Possible Owner Review Board Action Primarily Quality Program Concern Type:   Self-explanatory 6                                         Enter specification, code procedure, etc. applicable.
I' 5
Category:
Possible Significance (10CFR 21)
Possible Owner Review Board Action Primarily Quality Program Concern Type:
Self-explanatory 6
Enter specification, code procedure, etc. applicable.
7 As found description-clear and concise. Enter NC code (refer to Appendix A)..
7 As found description-clear and concise. Enter NC code (refer to Appendix A)..
8                                         Detailed cause of nonconfonnity, enter Cause Code.
8 Detailed cause of nonconfonnity, enter Cause Code.
(Refer to Appendix B.).
(Refer to Appendix B.).
9                                         Indicate disposition by checking. Justification shall define specific disposition method and required actions.
9 Indicate disposition by checking. Justification shall define specific disposition method and required actions.
10                                        Describe in detail the corrective measures taken or to be taken to prevent reoccurrance of the nonconformance.
Describe in detail the corrective measures taken or to 10 be taken to prevent reoccurrance of the nonconformance.
11                                         The following shall review and approve:
11 The following shall review and approve:
Chief Field Engineer Field Quality Assurance Manager Authorized Nuclear Inspector (when required).
Chief Field Engineer Field Quality Assurance Manager Authorized Nuclear Inspector (when required).
m
m
      )                   .
)
t
t
_ _ _ _ .      _ sF_ _ l .o t A (4-79)__
_ sF_ _ l.o t A (4-79)__


I 1
I I
I                      7     Pullman Power Products                                           xv-2 DOCUMENT No.
7 Pullman Power Products xv-2 DOCUMENT No.
PREPARF.D BY: J. Miller       APPROVED BY:         A. A. Eck         AAF   SINI     4/23/80 TO BE USED                                     PAGE PERRY PROJECT PROCEDURE     ONLY ON job #                                   NO. 2 of 2 APPENDIX D                 .
PREPARF.D BY:
Nonconformance Report Form Instructions Line No.                                         Instructions 12                     Review required - check as required.
J. Miller APPROVED BY:
A. A. Eck AAF SINI 4/23/80 TO BE USED PAGE PERRY PROJECT PROCEDURE ONLY ON job #
NO.
2 of 2 APPENDIX D Nonconformance Report Form Instructions Line No.
Instructions 12 Review required - check as required.
Decision - leave blank.
Decision - leave blank.
PNPP Review Board Signatures - leave blank.
PNPP Review Board Signatures - leave blank.
13                     Self-explanatory.
13 Self-explanatory.
1' 0
1' 0
a S
a S
s i
s I
l I
SF 1.01 A (4-79)
SF 1.01 A (4-79)


l Pullman Power Products
l
(                         .}:                                                       ,
(
xv-2 DOCUMENT NO.
.}:
                                    .        er         APPRSVED BY: A. A. Eck           AAE $ISU 4/23/80 PREPARED BY.
Pullman Power Products xv-2 DOCUMENT NO.
Perry                       TO BE USED ONLY ON JOB 8 bh U V dief PAGE NO. 1 of 1 Project Procedure APPENDIX E NCR DISTRIBUTION Af ter. Internal Review /Acoroval:
er A. A. Eck AAE
$ISU 4/23/80 PREPARED BY.
APPRSVED BY:
Perry TO BE USED bh PAGE Project Procedure ONLY ON JOB 8 U V dief NO.
1 of 1 APPENDIX E NCR DISTRIBUTION Af ter. Internal Review /Acoroval:
Original to C.E.1.
Original to C.E.1.
Copies to:
Copies to:
Q.A.
Q.A.
Engineering Q.C. Supervisor Q.A. Supervisor Responsible Field Engineer Training Officer ANI Af ter C.E.1. Review /Aporoval :
Engineering Q.C. Supervisor Q.A. Supervisor Responsible Field Engineer Training Officer ANI Af ter C.E.1. Review /Aporoval :
i'                                             Original to Q.A.
i' Original to Q.A.
Coples to:
Coples to:
Engineering
Engineering Q.C. Supervisor Q.A. Supervisor Responsible Field Engineer
                    .-                                Q.C. Supervisor Q.A. Supervisor Responsible Field Engineer
, ANI Af ter' Comoleti on/ Dispos i tion:
                                                      , ANI
                                  $              Af ter' Comoleti on/ Dispos i tion:
Original to Q.A.
Original to Q.A.
Copies to:
Copies to:
Line 297: Line 378:
I
I
(-
(-
g") Pullman Power Products xv-2 coCUMENT No.
Pullman Power Products xv-2 g")
PREPAREo BY:       d. Miller     APPROVED BY:   A. A. Eck       AAE-_ $1?N 4/23/80 PROJE       OCEDURE         ht.Yo[$8 -           7026             "#.'          2-1 APPENDIX F i     11/18/80                                         .
coCUMENT No.
Contractor Instructions For Fillitig Out MPL Attachment Form       -
PREPAREo BY:
instractions l                             1. Use fom only when NR is written against more than one item of equipment
: d. Miller APPROVED BY:
: 2. Line One should correspond to the information filled out on the
A. A. Eck AAE-_ $1?N 4/23/80 PROJE OCEDURE ht.Yo[$8 -
                        .      . NR fom.
7026 2-1 APPENDIX F i
: 3. Fill in:the MPL number on Lines 2 thru 29 as required for each
11/18/80 Contractor Instructions For Fillitig Out MPL Attachment Form instractions l
(                             item of equipment.
1.
: 4. Submit a m of the attachment tooether with the original of the NR to the OA Doc. Center for logging anj distribution. Retain the original of the attachment.                          ..
Use fom only when NR is written against more than one item of equipment 2.
: 5. As each item of equipment is fixed (according to the review board approved disposition), fill in the date the item (s) was (were) either scrapped, repaired, or reworked (as applicable) in the
Line One should correspond to the information filled out on the NR fom.
                                    " Item Comp. Date" block.
3.
: 6. A responsible person within the contractor's organization authorized to sign off the NR's should sign his name on each line for each item when the fix has been made. The date this authorized person signs his name should be filled in to the right of his signature. Submit a copy of the attachment to the QA Doc. Center as ea'ch item of equipment is fixed.
Fill in:the MPL number on Lines 2 thru 29 as required for each
: 7. When all items of equipment have been fixed according to the approved disposition, the original of the NR attachment with all applicable sign-offs should be submitted to the QA Doc. Center together with the closed-out NR.                     ;
(
item of equipment.
4.
Submit a m of the attachment tooether with the original of the NR to the OA Doc. Center for logging anj distribution. Retain the original of the attachment.
5.
As each item of equipment is fixed (according to the review board approved disposition), fill in the date the item (s) was (were) either scrapped, repaired, or reworked (as applicable) in the
" Item Comp. Date" block.
6.
A responsible person within the contractor's organization authorized to sign off the NR's should sign his name on each line for each item when the fix has been made. The date this authorized person signs his name should be filled in to the right of his signature. Submit a copy of the attachment to the QA Doc. Center as ea' h item of equipment c
is fixed.
7.
When all items of equipment have been fixed according to the approved disposition, the original of the NR attachment with all applicable sign-offs should be submitted to the QA Doc. Center together with the closed-out NR.
W 4
W 4
m 9
m 9
GR_fL800 ((4-79)
GR fL800 ((4-79)


l l
l
(                               49               Pullman Power Products                                                                               rorm BP XV - 2 W                                           ,
(
49 Pullman Power Products rorm BP XV - 2 W
00CUMENT NO.
00CUMENT NO.
PREPARED BY               J. Ililler                         APPROVED BY, A. A. Eck                               AAE     oI*N 4/23/80 6f         ON dvph M V PERRY                                           TO BE USED                                                     PAGE ONLY ON JOB 8                                                  NO.             I of 1 PROJECT PROCEDURE f '~} -
PREPARED BY J. Ililler APPROVED BY, A. A. Eck AAE oI*N 4/23/80 ON PAGE 6f ph M V PERRY TO BE USED dv NO.
NR INFORMATION $HEET l     Safety 44/47 or Augmented Non-Safety 45 (P54-N64) 9/16/82                          l $P NO..
I of 1 PROJECT PROCEDURE ONLY ON JOB 8 f '~} -
Status                        Installed or on hold?
NR INFORMATION $HEET 9/16/82 l $P NO..
l
l Safety 44/47 or Augmented Non-Safety 45 (P54-N64)
                                                      #                Complete identification required. (i.e. G-RH-231 RB)
Status l
: 3. f "                          l la.                            l    Description (spool, hanger, valve, etc.)                                                       .
Installed or on hold?
                                                ""                  Number of items involved in the nonconformance?
: 3. f "
Ib.                         l
l Complete identification required. (i.e. G-RH-231 RB) l Description (spool, hanger, valve, etc.)
                                              '*"                      Building. Elevation, etc.
la.
Ic.                                                                                                                      .
l Number of items involved in the nonconformance?
I       2.         Issued By       l     (name of person writing NR)                                                                                 .
Ib.
3.lItemMat*1                     (name of Vendor. Owner, etc.)
Ic.
Building. Elevation, etc.
I 2.
Issued By l
(name of person writing NR) 3.lItemMat*1 (name of Vendor. Owner, etc.)
l (ContractorWho caused the NR)
*(~
arsoonsiple
arsoonsiple
  *(~
}._
  }._                             4.       Organuation           l (ContractorWho caused the NR)
4.
  !                                                                cai. coa,.                                      'O     e *,emi-   ~ - O i eu. e.i-
Organuation
                                                                          , ,,,. gO'a ,'aois.e',s* s.o
'O e
                                                                                                    ,.'.. -i -
*,emi-
s j                             . 5. l NCR Type                                         .ou...               O" ' 'a sr a u a v io. -  4
~ - O i eu. e.i-cai. coa,. O','aois.e',s s.o. i -
                                                                                                                                          'Oia' ==o====            -
s j
(11 A"""t       'M ''d *
. 5. l NCR Type 4 'Oia'
  !                                            Governing                    -
 
: y. 9.n
==o====
    ;                              6.         non.,tro   n,         . (2) Line soce.                      .
,,,,. g a
.ou...
*,.'. - O" ' 'a sr a u a v io. -
(11 A"""t
'M ''d *
: y. 9.n Governing 6.
non.,tro n,
. (2) Line soce.
g y.lNRDescription l (Give length, depth, width when applicable)
g y.lNRDescription l (Give length, depth, width when applicable)
(Who,what,where,when.why)
: 3. l Cause of HCR l
: 3. l Cause of HCR l l
(Who,what,where,when.why) l I
I l
l Propos TH15 CANNOT BE N/A'd ni e nn e 4,ed fin datai? what we will do to correct the !ml 9.
Propos                     TH15 CANNOT BE N/A'd                                                                           *
4n, l
        .                          9.          ni e nn e 4,ed 4n,                fin datai? what we will do to correct the !ml l
'l0TE:
                                          'l0TE:     1. liore than (1) { tem may be placed on a single NR as long as the NR condition is
1.
(                                                         the sare for eacn.                                                                                                         ~
liore than (1) { tem may be placed on a single NR as long as the NR condition is
: 2. Use sketches when ever possible to aid in location and description of the NR.
(
I                 ~
the sare for eacn.
: 10. Steps to
~
            ~
2.
Prevent
Use sketches when ever possible to aid in location and description of the NR.
                                    , , Recurrence C0fft[NTS:               PLEASE Il5E BACK OF SHEET.
I
~
~
: 10. Steps to Prevent
,, Recurrence C0fft[NTS:
PLEASE Il5E BACK OF SHEET.


(                             1           Pullman Power Products                                                                                           xv-2 pv                                                                                                                         DOCUMENT NO.
(
PREPARED BY,          J. Mller                            APPROVED BY,              A. A. Eck                             AAE       l,{jyf 4/23/80 PERRY                                                                         -    O                         I TO BE USED                                                                 PAGE b At                                                    1 of 1 9
1 Pullman Power Products xv-2 pv DOCUMENT NO.
PROJECT PROCEDURE                                   onLy On jos a                                                               NO.
A. A. Eck AAE l,{jyf 4/23/80 J. Mller APPROVED BY, PREPARED BY, PERRY O
APPENDIX G I                                               -
I PAGE TO BE USED PROJECT PROCEDURE onLy On jos a b At 9
9/16/82         i
1 of 1 NO.
                                                                                                          . . . .h I
APPENDIX G I
s .. .            . - - - . . . . .
9/16/82 i
4I                                                                                                                                                           .
.h Is...
  .' ~                                             .
4I
                    .                                      .. c-      c      -..~__.__c-,.
.' ~
_m
_m
                                                                  ,j                      NCR REVIEW                           (
-..~__.__c-,.
ACCEPT                           ]
c-c NCR REVIEW
                                                                                                                                  ~
(
I                               INITIALS                                                                  .
,j ACCEPT
5                                                                                                           -
]
ENG.ICONST:
INITIALS
4 QA/QC                 -
~
                                                    .              j COMMENTS:                                                                                   .
I 5
                                                ~~
" ENG.ICONST:
1                                                             e                                             .
4 QA/QC j COMMENTS:
~~
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                                                                                                                                                                -                    d
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                                                                                                                                          .                              . ,        8 e
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j                                                       ,
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(                                            y                      Pullman Power Products                                                                                                                       gaan u DOCUMENT NO.
Pullman Power Products gaan u
PREPARED BY,                                d. Miller                                  APPROVED BYt                            A. A. Eck                             AAE               $1?N           4/23/80 PERRY                                                                                                                                                                   P PROJECT PROCEDURE                                                                     $ BE o                    9                                                                      NO.         10F 1 4
(
                                                                                                            .        /           Puttman Power Products                                             .
DOCUMENT NO.
                                    ''"'                                                                                                                                                      NONCONFOftf.tANCE REPORT NO. 415112 REv.12 77
A. A. Eck AAE
                                                                                                                                                                                                              ..=....
$1?N 4/23/80
                                                                                                                    .r      o
: d. Miller APPROVED BYt PREPARED BY, PERRY P
                                                                                                                                                  .             _e .. ..
PROJECT PROCEDURE
s g e .
$ BE NO.
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Puttman Power Products NONCONFOftf.tANCE REPORT NO. 415112 REv.12 77
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(                                              Pullman Power Products                                                                               ronM 18 yY                                                                                                                   DOCUMENT NO.
Pullman Power Products ronM 18 yY
PREPARED BY              J. Miller                 APPRovco oy             A. A. Eck                               AAE       $1?N 4/23/80 PERRY PROJECT PROCEDURE TO BE USED ONLY ON JOB W hhQ G N/ fo            r 8      PAGE NO.         1 Of 1
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                                                                  . .      ~       .        . . . . .
DOCUMENT NO.
Fullman Power Products                 ,g                 g                               ......... , ....
J. Miller APPRovco oy A. A. Eck AAE
                                                                                                                                                                                                ~
$1?N 4/23/80 PREPARED BY PERRY TO BE USED hhQ 8
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PAGE 1 Of 1 PROJECT PROCEDURE ONLY ON JOB W G N/ for NO.
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l p
l Pullman Power Products rorm is p
Pullman Power Products                                                                                   rorm is DOCtNENT NO.
DOCtNENT NO.
PREPARED BY:    J. fHiler                                       APPROVED RY: A. A. Eck                                       _AAE $lIN     4/23/80         )
J. fHiler APPROVED RY: A. A. Eck
Perry                                                TO BE USED                                      s                PAGE Project Procedure                                              ONLY ON JOB
_AAE
[d [(                           NO. I DI I h
$lIN 4/23/80
)
PREPARED BY:
[d [(
s PAGE Perry TO BE USED NO.
I DI I Project Procedure ONLY ON JOB h
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IICR No.                                                     Rev.         Date Review Coments                               ,
J. Miller APPROVED BY, A. A. Eck AAF
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Latest revision as of 21:51, 14 December 2024

Procedure XV-2 Procedure for Handling Nonconformances (Field)
ML20080K281
Person / Time
Site: Perry  FirstEnergy icon.png
Issue date: 09/16/1982
From: John Miller
PULLMAN POWER PRODUCTS CORP. (FORMERLY PULLMAN, INC.)
To:
Shared Package
ML20079G896 List:
References
FOIA-83-199 NUDOCS 8309290086
Download: ML20080K281 (26)


Text

-

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f' 4Q Pullman Power Products XV - 2 y

00cOSA[ NT Nn, 1

PREPARED BY: J. Miller APPROVED BY: A. A. Eck

_AAE h M 4/23/80 PERRY TO BE USED PROJECT')ROCEDURE ONLY ON JOB 8 V

PAGE NO.

1 of 8 j

LATEST REV. DATE 9-16-82 RECElVED

' PROCEDURE FOR HANDLING NOV - 31982 NONCONFORMANCES (FIELD)

Docu= El b g Copyright 1982 PULLMAN POWER PRODUCTS

~

HEADQUARTERS AT WILLIAMSPORT, PENNSYLVANIA pEvl510h PREPARED BY APPROVED BY INITIALS DESCRIPTION 7/25/77 J.Townsend K. Swisher KS Initial Issue 4/21/78 J. Miller K. Swisher KS Revised para. 5.1.2, 9.1, 10.1 Added para.

5.1.5, 5.2, App. C, Fom J-Deleted para.11, 2/12/79 R.Hunnicutt N.Hol l erbus t.

NH Extensively Revised 3/05/79 J. Miller N.Hollerbust NH Revised para. 6.1.2 and App. A. Nonconform-ance Codes and Cause Codes App. B.

4/23/80 J. Miller A. A. Eck AE Extensively Revised 11/18/80 R.Hunnicutt J. Willis JW Added para. 5.2.5, Appendix E and Fom AL.

1/02/81 J. Miller J. Willis JW Added 1.2, Rev. 5.2, 5.2.2, 5.2.3 5.4, deleted 6.1.3, 6.1.4, 6.1.5, revised 6.1.6 and Added 6.6.

6/16/81 R.Hunnicutt J. Willis JW Revised para. 1.2, 5.4.1, 5.4.2, 6.1, 6.6, 7.0, 8.1, 9.0, 10.0 Added Form AQ.

4/06/82 J.E. Miller J. Willis JW Revised para. 5.5.

9/16/82 J.E. Miller J. Willis

(.d Revised Para 5.2.4 and 5.2.5; added Form BP and Appendix G. Added 5.2.6, 5 2 7. Am 5 2.8 -

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8309290086 830622 PDR FOIA HIATT83-199 PDR 7

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Jg Pullman Power Products gp XV - 2 7

DOCUMENT No.

PREPARED BYr J. Miller APPROVED BY, A. A. Eck AAE

$1?N 4/23/80 PERRY TO BE USED

.c::p e B

PAGE PROJECT PROCEDURE ONLY ON JOB #

'g.

Q NO.

2 Of 8 INDEX Title Paragraph Page Title Page 1

Index 2

1 Scope 1.0 3

Policy 2.0 3

j Responsibility 3.0 3

Unacceptable Conditions 4.0 3

)

Nonconformances 5.0 3-5 Resolution of Nonconformances 6.0 5-7 Distribution 7.0 7

Records 8.0 7

Steps to Prevent Recurrence 9.0 7

Documenting 10.0 8

- ('

Review 11.0 8

Nonconformance Codes Appendix A 1 of 1

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Cause Codes Appendix B 1 of 1 NR Information Sheet Instructions Appendix C 1 of 1

.j NCR Torm Instructions Appendix D 1 of 2 NCR Distribution Appendix E 1 of 1 MPL Form Instructions Appendix F 1 of 1 NR Information Sheet Form BP NR Review Stamp Appendix G 1 of 1 Nonconformance Report Form 17 Field Process Sheet Form 18 Field Weld Process Sheet Form 19 Field Weld Process Sheet / Repair Form 19A Field Multi-Weld Process Sheet Form ISB Hold Tag Form 22 Nonconformance Report Index Form J

tiPL Report Index Form AL Interface Nonconformance Review Sheet Form AQ W

1

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Ig Pullman Power Products xV - 2 y

ooCUMENT No.

PREPAREo BY J. Miller APPROVED DY A. A. Fck AAF

$$$U 4/23/80 PERRY To BE USED f"*'

PAGE of 8 d

No.

PROJECT PROCE0llRE oNLY oN job #

1.0 SCOPE 1.1 This procedure defines the actions recuired to orocess nonconfomances (NCR's) in accordance with Section XV of the Connany's Quality Assur-ance Manual.

6/16/81 1.2 In additinn, this procedure defines the Comoany's resnonsibility in-volving " Interface Nonconformances". Interface Nonconformances are those nonconfomino conditions which are identified by PPP personnel against work perfomed by other contractors or aoainst items / material supplied by the owner, and/or those Nonconfoming conditions which have been added to the Company's scope of work.

2.0 POLICY 2.1 Nonconformances in items may be detected at Source Inspection, Re-ceiving Inspection. In-Process Inspections, durino fabrication or in-stallation, at Final Inspection or during testino.

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2.2 To provide interface between the Company and the Client, specific

" description" and "cause" codes on nonconfomities are included in this procedure. (Appendix A and B.)

3.0 RESPONSIBILITY 3.1 It is the responsibility of the 0.A. Manaaer for the implementation of this procedure through his examination, inspection and testing personnel.

4.0 UNACCEPTABLE CONDITIONS 41 Unacceptable conditions which can be corrected at the time of dis-covery under the control and to the satisfaction of the inspector, and which can be made acceptable by controls imposed by operations as outlined on a previously approved Process Sheet are not considered nonconfoming.

5.0 NONCONFORMANCES 5.1 Unacceptable conditions other than those outlined in the precedino paragraph are considered as nonconformances. The 0.A. Department shall use Fom 17 "Nonconformance Report" to document nonconfom-ities.

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DOCUMENT NO.

PREPARED BY:

J. Miller APPROVED BY, A. A. Eck AAE oi s 4/23/80 O

.h PAGE 4 of 8 PERRY TO BE USED PROJECT PROCEDURE ONt.Y ON JOB #

u 4

NO.

5.0 NONCONFORMANCES (Cont.)

9/16/82 5.2 All nonconformances except as identified in para. 5.4 (Interface Nonconformances), require the approvals of the Q.A. Manager, Chief Field Engineer, Authorized Nuclear Inspector and the Owner / Agent prior to proceeding with the proposed disposition.

5.2.1 Nonconformances may include, but are not limited to incorrect materials, incomplete or incorrect documentation or identifi-cation, improper dimensions, special process out of control or serious misalignment during installation.

1/2/81 5.2.2 When a nonconformance is discovered, the item (s) involved shall be segregated when possible.

A Q.C. Inspector shall attach a " Hold Tag" to the item or adjacent to the operation, as in the case of welding.

Refer to " Hold Tag Usage" procedure.

5.2.3 Process sheets involved shall be withdrawn and returned to the

,1h. 81 point of issurance. The Q.C. Inspector will note on the Process Sheet, the NCR number where and when applicable.

Once the nonconformance has been resolved, the original Process Sheets, revised if necessary or new Process Sheet together with re-(

vised drawings, if applicable, can be issued to resume work.

Hold Tag shall be removed as set forth in the Hold Tag Pro-cedure.

9/16/82 5.2.4 NR Information Sheets shall be initiated for all possible non-conforming conditions in accordance with the attached instructions (Appendix C).

9/16/82 5.2.5 The NR Information Sheet shall be reviewed by QA to determine if the condition described is correct. The NR information sheet shall be forwarded to the QA Manager or his designee for their concurrence.

If at any point it is determind that an NR coc-dition does not exist, the sheet shall be with drawn and the inspector notified so that the hold tag can be removed and the appropriate action, if any, taken..

9/16/82 5.2.6 After obtaining the concurrence required above, the NR Information Sheet shall be used to prepare a Nonconformance Report to be filled out in accordance to the attached instructions (Appendix D).

9/16/82 5.2.7 For Nonconformance Reports written against more than one item

- of equipment, Form Al shall be used. This shall be filled out

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in accordance with the attached instructions (Appendix F).

9/16/82 5.2.8 With prior approval of the QA Manager, individuals may be allowed to submit nonconfonnances via the use of form 17 without the requirements of the NR Information Sheet.

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Pullman Power Products

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DOCUMENT No.

PREPARED BY:

J. Miller _

APPROVED BY A. A. Eck AAE - oi?N 4/23/80 PERRY TO BE USED py 'f 3 O

PAGE 5 of 8 NO.

PROJECT PROCEDURE ONLY ON JOB 8 gggQ 5.3 The Q.A. Manager shall evaluate all nonconformances for applicability for reporting under 10 CFR 50 55 (e) to the Customer.

This evalua-tion shall also take into consideration the Company's obligation to report defects or noncompliances under 10 CFR 21.

5.4 Interface Nonconformance 6/16/81 5.4.1 Nonconformances identified by Company, but involving other site contractors or the Owner's vendors / suppliers, the report shall be filled out as set forth in Appendix C with the following exceptions:

a) The NCP. number will be assigned by the Customer.

b) Only complete lines 1 through 8, remainder of form to be completed by responsible organization.

c) If line 9 is known Proposed Disposition / Justification, it g

shall be attached to the NCR on a separate sheet.

6/16/81 5.4.2 Nonconformances which have been added to the company's scope of work will be received by the company with the NR. filled out through line 12.

4/6/82 S.5 In effort to keep the number of open nonconformances to a minimum, all nonconformances shall be closed within 30 days from approval of l

the resolution, when pos'sible.

lj 6.0 RESOLUTION OF NONCONFORftANCES 8

6.1 Appropriate resolution of the nonconformance will be determined by

'l the Field Engineering Department inconjunction with Quality Assurance the Customer and the Quality Engineering Group at Corporate Headquarters, In all cases, the final resolution shall be reviewed if necessary.

by the Q.A. Manager for Code compliance and concurrence shall be obtained from the Authorized Nuclear Inspector.

It in this review the Q.A. Manager or Authorized Nuclear Inspector do not concur, the NCR will be returned to the originator for re-evaluation of the proposed solution, except as noted in paragraph 5.4.

i 6/16/81 6.1.1 For nonconformances which do not meet the Code, the item may be scrapped / returned for replacement, repaired or reworked to bring it within the Code requirements.

6:1[2 'For nonconformances which do meet the Code, but deviate from l("

tustoner requiremen'ts, the item may be rejected and scrapped /

returned for replacement, reworked or repaired to bring it into specification or accepted to "Use-as-is".

i s

f~

ig Pullman Power Products XV-2 p

DOCUMENT NO.

PREPARED BY:

J. !! iller APPROVED BY A. A. Eck

$$ N 4/23/80 AAC PERRY TO BE USED et PAGE PROJECT PROCEDURE ONLY ON JOB #

NO.

6 of 8 6.0 RESOLUTION OF NONCONFORMANCES (Cont'd) 6.1.3 Submittal and approval of nonconformances involving changes to or deviations from design, permits the Owner or his Agent to review the proposed change for reconciliation of the Design Report without the initiation of a Deviation Report.

6.2 Scrap 6.2.1 The Q.A. Engineer-Materials shall identify the material " Scrap" and segregate it in the designated scrap area or return for replacement, as required.

6.2.2 The Chief Field Engineer will initiate the required documents for replacement, if necessary.

6.2.3 For Owner furnished material, the Chief Field Engineer will

.(

forward the NCR to the Owner for approval of the proposed dis-position. Upon return of the NCR from the Owner, the Q.A.

Engineer-Materials will either arrange for return to the Owner j

~

.or " Scrap" and segregate in the designated scrap area at the The st'ps to prevent recurrence shall direction of the Owner.

e be the Owner's responsibility.

6.3 Rework 6.3.1 When rework is the resolution, the Chief Field Engineer shall indicate, on the NCR, the bxtent to the rework.

6.3.2 The Q.A. Manager shall review the, solution 'for compliance to the Code, Customer specification and obtain concurrence from the Authorized Nuclear Inspector.

6.3.3 The Chief Field Engineer shall prepare instructions, drawings, Process Sheets and other documents which may be required. All such documents will be controlled in accordance with approved procedures.

6.4 Repair

~

6.4.1 'Where repairs are required, the NCR and supporting documen-tation shall be submitted to the Customer /0wner for approval.

6.4.2 The Authorized Nuclear Inspector shall be notified and his e

r

concurrence received prior to repair..

L

l l-C 9

Pullman Power Products XV-2 p

DOCUMENT No. _

i PREPARED 8v J. Miller APPRoVEo 8Y A. A. Eck AAC

$1IN 4/23/80 oNa a

!h* h h 0

PROJEC ROCEDURE NO.

6.0 RESOLUTION OF NONCONFORMANCES (Cont'd) 6.4.3 The Chief Field Engineer shall prepare instructions, drawings, Process Sheets and other documents which may be required.

All such documents will be controlled in accordance with approved procedures.

6.5 Use-As-Is 6.5.1 When an item conforms to the Code, but deviates from Cus-tomer specifications, the Chief Field Engineer shall obtain approval from the Owner to "Use As Is".

6.6 Interface Nonconformances are the Project Organization's respon-sibility to review and approve.

NCR's, which affect ASME Code items and which will be added to the Company's scope of work to perform proposed disposition, shall be reviewed and concurrence received from the Q.A. Manager, Chief Field Engineer and the ANI

(

on Form AQ prior to commencement of the work.

7.0 DISTRIBUTION 7.1 ' Distribution shall be in accordance with Appendix E, except for those NR's identified in paragraph 5.4.1.

The printed distribution list at the battom of Form 17 shall not be used.

8.0 RECORDS Records of all nonconformances and their disposition except for 8.1 those identified in paragraph 5.4.1 shall be maintained under the supervision of the Q.A. Manager. NCR's shall be easily retrievable for review.

8.1.1 In cases where the decision is made to " Scrap" all associated records for the scrapped item, shall be properly noted to disposition and retained.

8.1.2 In all cases where return for rep 1'acement is decided, the records shall be returned with the item.

9.0 STEPS TO PREVENT RECURRENCE The Q.A. Manager or his designee shall initiate and record the 9.1 necessary steps to prevent recurrence of all nonconfonnities.

,br except for those identified in paragraph 5.4.1, as required.

I

,G Pullman Power Products xv - 2 s

y ooc *.fvENT No.

PREPAREo BY: J. 19111er ArPRoVED BY A. A. Fck AAF l31)N 4/23/8G PERRY To BE UsED Q'g, PAGE No. 8 of 8 PROJECT PROCEDURE oNLY ON Joe #

10.0 DOCUMENTING 6/16/81 10.1 Nonconforrance Reports shall be assioned an NCR number, except those identified in paracranh 5.4.

All NR's except those iden-tified in paranraph 5.4.1 shall be indexed on Fom J.

The Index (Form J) shall contain the NCR number, the revision number, the initiator, a brief description, and the status.

11.0 REVIEW 11.1 In order to control and eliminate the possible recurrence of a nonconfomance, the 0.A. Manaaer shall review the NCR's on a monthly basis. See " Corrective Action Procedure".

11.1.1 In cases of repeated nonconformances, the 0.A. Manaaer shall report in writino to the Director of Duality As-surance explaining the corrective action taken to stop recurrences of specific nonconfomances and solicit the recomendations of the Director of Ouality Assurance.

. een.. = = =

d a

O b

C Aj Pullman Power Products xv-2 y

DOCUMENT NO.

PREPARED BY J. Miller APPROVED BY A. A. Eck AAE oIIN 4/23/80 7026 PAGE PERRY TO BE USED

~o.

i er i PROJECT PROCEDURE Onty on ;oB -

APPENDIX A NONCONFORMANCE CODES CONCRETE ELECTRICAL 001 Materials 050 Tagging / Labeling 002 incorrect Mix

'051 Improper Installation 003 Physical Properties 052 Cable Pulling Tension (Slump, Air Temp, Strength, 053 Condult/ Tray Fill Permeability) 054 Separation Criteria 004 Olm or Location 055 Hanger / Support / Mounting 005 Placement Technique (Vibrator, 056 Minimum Sending Radius Placement Rate) 057 Welding 006 Curing 058 Cable / Wire 007 Post Pour Visual (Voids, Honeycomb,etc.)

TESTING EXAMINATION 061 Instrument / Certification /Calibra-(-

MECHANICAL tion 020 Material Identification 062 Olmension/Visua!

021 Identification, Tagging 063 Operator Certification /Quali fica-022 Installation tion 023 Equipment Alignment 064 Hydro / Leak Test 024 Welding 065 Radiographic 025 Mininum Wall 066 Ultrasonic 026 Missing or inadequate Hangers, 067 PT/MT Supports, or Snubbers 068 Hechanical Operational Test 069 Megger/HI-POT Test / Continuity STRUCTURAL STEEL MI5CELLANEOUS AND GENERAL 040 PhysIcol/ Chemical 041 Identification (Missing Tags) 100 Testing 042 Rus t/ Contamination 101 Qualification 043 Olmensional 102 Calibration 044 Fabrication 103 Documentation 045 Erection Technique 104 Inspection 046 Jointing (P.tveting, Bolting, 105 Storage and Hand!!ng Welding) 106 Cleanliness 107 Damage (including Porous Concrete Contamination) e

_..___ y 1.01AJ4-79)

/

\\

h7 Pullman Power Products

(

XV-2 ooCUMENT No.

F PREPARED BYr J. Miller APPROVED BY A. A. Eck AAE

$1%N 4/23/80 To BE UsED 9

PAGE No. 1 of 1 PERRY PROJECT PROCEDURE oNLY oN job # g[

APPENDIX "B" CAUSE CODES GENERAL (Cont'd)

OPERATIONS _

30 Inadequate Documentation 01 Operator Error 02 Inadequate Indoctrination &

31 Lack of Identification 32 Improper Cure Training 33 Equipment 03 Unqualified Personnel 04 Insufficient Personnel 34 Does I;ot Meet Specification 05 Incorrect / Inadequate Planning Requirements 06 Poor Workmanship 35 Violation of Procedure 36 Does Not Meet Drawing Requirements 07 Carelessness 37 Intertninate/ Unknown I

DESIGN FUNCTIONAL 10. Wrong Material Called Out 40 Failed Test On Drawing 11 Specification - Wrong Revision EQUIPMENT 12 Specification - Misinterpretation 51 Inadequate or Incorrect Tools /

h

~

te p ta ion

'9 52 g Device out of Calibration ot tal per rawing (Interference)

SUPERVISION 17 Imprcper Installation (Drawing or Specification) te r

n 18 Hanger, Support, Mounting Problem h

r so 19 Inadequate Information on Drawing 63 Supervisor Failed to Follow 20 Incorrect Dimensions / Tolerances Instructions on Drawing GENERAL 21 Environmental 22 Damage - By Others 23 Malfunction / Failure of Construction.

Inspection, or Test Equipment 25 Vendor Supply Problem 26 Material Inadequate 27 Mishandling

{'.

28 Improper Storage 29 Inadequate Status Control SF 1.ot A (4-79)

l y

Pullman Power Products

(

xy_,

coCUMENT NO.

A. A. Eck AAE

$lyf 4/23/80 PREPARED BY, d.

Miller APPROVED BYr rar (b 9 Q PAGE PERRY TO BE usED PROJECT PROCEDURE ONLY ON JOB #

(r G g U NO.

I of 2 APPENDIX C 9/16/82 Nonconformance Information Sheet Instructions Instructions Enter Spec. number and current revision to the Spec.

STATUS - Enter installed or hold based on present disposition of item (s) being identified.

Enter complete identification of items (s).

Line 1 ITEM ID Note:

If quantity of item is more than one, then enter "See MPL" and complete multiple problem list in conjunction with NR Information Sheet.

l' Enter a description of item (s).

Line la ITEM NAME Examples given on NR Information Sheet.

i Enter number of items, if more than 1, complete in Line Ib QUANTITY j

conjunction with Line 1.

Identify building - elevation-azimuth when applicable.

Line Ic LOCATION Name of individual identifying condition on NR Line 2 ISSUED BY Information Sheet.

Enter name of company, vendor or Owner of material Line 3 ITEM MAT'l being identified.

Line 4 RESPONSIBLE Identify who is responsible for causing the condition.

ORGAN!ZATION -

Category:

(1) Possible significance (10 CFR 21)

Line 5 NCR TYPE (2) Major (3) Minor Type:

Self-explana tory Line 6 GOVERNING (1) Acceptance Criteria P.EQUIREllENT (2) Line spec.

(3) Iso.

b.

~

i C

Jg Pullman Power Products XV-2 p

oOCUMENT NO.

PREPARED BY J. Miller APPROVED BY: A. A. Eck AAE SION 4/23/80

[4 :], () d PAGE PERRY TO BE USED i

NO.

2 of 2 g Lv G V PROJECT PROCEDURE ONI.Y ON JOB #

9/16/82 Line. 7 NR DESCRIPTION

- Enter a total description. Give length, depth, width when identifying a defect or when applicable.

If necessary, attach a sketch to aid in the under-standit'g of the condition.

Line 8 CAUSE OF NR

- Identify what or who caused the condition also when, where and why if applicable.

Line 9 PROPOSED

- Corrective action needed to correct the condition.

DISPOSITION This can't be N/A'd.

Line 10 STEP TO PREVENT What action is needed to prevent this type of RECURRENCE condition from happening again.

(

COMMENTS: Use back of form for any additional comments or information.

I i

i l

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4 I

Pullman Power Products C

g)

xv-2 DOCUMENT No.

PREPARED BY, J. Miller APPROVED BY A. A. Eck AAE-- El%U 4/23/80~

To BE UsED PAGE PERRY PROJECT PROCEDURE oNLY ON job #

No. 1 of 2 APPENDIX D Nonconformance Report Form Instructions Line No.

Instructions 1

Enter NCR number and revision sheet number, numerical identification of item, name of item, and quantity.

2 Self-explanatory 3

Source: Vendor, Owner, or Company as applicable.

4 Enter the Company Name and applicable Spec. No, and Revision.

I' 5

Category:

Possible Significance (10CFR 21)

Possible Owner Review Board Action Primarily Quality Program Concern Type:

Self-explanatory 6

Enter specification, code procedure, etc. applicable.

7 As found description-clear and concise. Enter NC code (refer to Appendix A)..

8 Detailed cause of nonconfonnity, enter Cause Code.

(Refer to Appendix B.).

9 Indicate disposition by checking. Justification shall define specific disposition method and required actions.

Describe in detail the corrective measures taken or to 10 be taken to prevent reoccurrance of the nonconformance.

11 The following shall review and approve:

Chief Field Engineer Field Quality Assurance Manager Authorized Nuclear Inspector (when required).

m

)

t

_ sF_ _ l.o t A (4-79)__

I I

7 Pullman Power Products xv-2 DOCUMENT No.

PREPARF.D BY:

J. Miller APPROVED BY:

A. A. Eck AAF SINI 4/23/80 TO BE USED PAGE PERRY PROJECT PROCEDURE ONLY ON job #

NO.

2 of 2 APPENDIX D Nonconformance Report Form Instructions Line No.

Instructions 12 Review required - check as required.

Decision - leave blank.

PNPP Review Board Signatures - leave blank.

13 Self-explanatory.

1' 0

a S

s I

SF 1.01 A (4-79)

l

(

.}:

Pullman Power Products xv-2 DOCUMENT NO.

er A. A. Eck AAE

$ISU 4/23/80 PREPARED BY.

APPRSVED BY:

Perry TO BE USED bh PAGE Project Procedure ONLY ON JOB 8 U V dief NO.

1 of 1 APPENDIX E NCR DISTRIBUTION Af ter. Internal Review /Acoroval:

Original to C.E.1.

Copies to:

Q.A.

Engineering Q.C. Supervisor Q.A. Supervisor Responsible Field Engineer Training Officer ANI Af ter C.E.1. Review /Aporoval :

i' Original to Q.A.

Coples to:

Engineering Q.C. Supervisor Q.A. Supervisor Responsible Field Engineer

, ANI Af ter' Comoleti on/ Dispos i tion:

Original to Q.A.

Copies to:

C.E.1.

Engineering Q.C. Supervisor Q.A. Supervisor Responsible F' eld Engineer ANI emu G

SF 1.01 A (4-791

I

(-

Pullman Power Products xv-2 g")

coCUMENT No.

PREPAREo BY:

d. Miller APPROVED BY:

A. A. Eck AAE-_ $1?N 4/23/80 PROJE OCEDURE ht.Yo[$8 -

7026 2-1 APPENDIX F i

11/18/80 Contractor Instructions For Fillitig Out MPL Attachment Form instractions l

1.

Use fom only when NR is written against more than one item of equipment 2.

Line One should correspond to the information filled out on the NR fom.

3.

Fill in:the MPL number on Lines 2 thru 29 as required for each

(

item of equipment.

4.

Submit a m of the attachment tooether with the original of the NR to the OA Doc. Center for logging anj distribution. Retain the original of the attachment.

5.

As each item of equipment is fixed (according to the review board approved disposition), fill in the date the item (s) was (were) either scrapped, repaired, or reworked (as applicable) in the

" Item Comp. Date" block.

6.

A responsible person within the contractor's organization authorized to sign off the NR's should sign his name on each line for each item when the fix has been made. The date this authorized person signs his name should be filled in to the right of his signature. Submit a copy of the attachment to the QA Doc. Center as ea' h item of equipment c

is fixed.

7.

When all items of equipment have been fixed according to the approved disposition, the original of the NR attachment with all applicable sign-offs should be submitted to the QA Doc. Center together with the closed-out NR.

W 4

m 9

GR fL800 ((4-79)

l

(

49 Pullman Power Products rorm BP XV - 2 W

00CUMENT NO.

PREPARED BY J. Ililler APPROVED BY, A. A. Eck AAE oI*N 4/23/80 ON PAGE 6f ph M V PERRY TO BE USED dv NO.

I of 1 PROJECT PROCEDURE ONLY ON JOB 8 f '~} -

NR INFORMATION $HEET 9/16/82 l $P NO..

l Safety 44/47 or Augmented Non-Safety 45 (P54-N64)

Status l

Installed or on hold?

3. f "

l Complete identification required. (i.e. G-RH-231 RB) l Description (spool, hanger, valve, etc.)

la.

l Number of items involved in the nonconformance?

Ib.

Ic.

Building. Elevation, etc.

I 2.

Issued By l

(name of person writing NR) 3.lItemMat*1 (name of Vendor. Owner, etc.)

l (ContractorWho caused the NR)

  • (~

arsoonsiple

}._

4.

Organuation

'O e

  • ,emi-

~ - O i eu. e.i-cai. coa,. O','aois.e',s s.o. i -

s j

. 5. l NCR Type 4 'Oia'

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  • ,.'. - O" ' 'a sr a u a v io. -

(11 A"""t

'M d *

y. 9.n Governing 6.

non.,tro n,

. (2) Line soce.

g y.lNRDescription l (Give length, depth, width when applicable)

3. l Cause of HCR l

(Who,what,where,when.why) l I

l Propos TH15 CANNOT BE N/A'd ni e nn e 4,ed fin datai? what we will do to correct the !ml 9.

4n, l

'l0TE:

1.

liore than (1) { tem may be placed on a single NR as long as the NR condition is

(

the sare for eacn.

~

2.

Use sketches when ever possible to aid in location and description of the NR.

I

~

~

10. Steps to Prevent

,, Recurrence C0fft[NTS:

PLEASE Il5E BACK OF SHEET.

(

1 Pullman Power Products xv-2 pv DOCUMENT NO.

A. A. Eck AAE l,{jyf 4/23/80 J. Mller APPROVED BY, PREPARED BY, PERRY O

I PAGE TO BE USED PROJECT PROCEDURE onLy On jos a b At 9

1 of 1 NO.

APPENDIX G I

9/16/82 i

.h Is...

4I

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-..~__.__c-,.

c-c NCR REVIEW

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,j ACCEPT

]

INITIALS

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" ENG.ICONST:

4 QA/QC j COMMENTS:

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A. A. Eck AAE

$1?N 4/23/80

d. Miller APPROVED BYt PREPARED BY, PERRY P

PROJECT PROCEDURE

$ BE NO.

10F 1 o

9 4

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Puttman Power Products NONCONFOftf.tANCE REPORT NO. 415112 REv.12 77

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Pullman Power Products ronM 18 yY

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DOCUMENT NO.

J. Miller APPRovco oy A. A. Eck AAE

$1?N 4/23/80 PREPARED BY PERRY TO BE USED hhQ 8

PAGE 1 Of 1 PROJECT PROCEDURE ONLY ON JOB W G N/ for NO.

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