APPENDIX B

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APPENDIX B

1.0 INTRODUCTION AND SCOPE

At the time of project termination, the Thermionic Reactor Power System program activities were in a "pre-reactor experiment" contractual phase. The quality program plan reflects that program status and shows how quality assurance activities were to have been expanded to meet program needs.

This program plan applied to all activities affecting Thermionic Fuel Element (TFE) quality under Project 0018, Contract AT(04-3)-840, and is presented here as it would have been had the project continued.

2.0 MANAGEMENT AND PLANNING

2.1 The purpose of this quality program plan is to describe the work elements to be accomplished by GEES in assuring accomplishment of the Company policy regarding quality. That policy is: "The products created by Gulf Energy and Environmental Systems for its customers shall be of high quality in materials, workmenship, and performance. Inherent in this policy is the concept that creation of a product of high quality requires that features essential to product function and appearance be equal to or superior to similar features in the products of others available to a customer."

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2.2 This plan includes requirements and procedures that are currently needed and in use. Additional items will be included as the program evolves in a manner that will provide a comprehensive Quality Assurance Program for use on components manufactured for the Thermionic Reactor Experiment (TREX). The milestone chart (Figure B-1) portrays how the Quality Assurance Program is expected to evolve.

The quality assurance and reliability milestones on Figure B-1 are derived from schedule information contained in the "Thermionic Reactor Power System Development - Fuel Element Plan", Gulf-GA-C12307 and the "Thermionic Reactor Power System Development, Volume IV, Reactor Plan", Gulf-GA-C12308. The attached Quality Program Plan Implementation Schedule for TFE Qualification Testing (Table B-1) provides a schedule to prepare for passing a Quality Assurance Program audit covering manufacturing of thermionic fuel elements for 5,000 hour TFE qualification testing. Quality Assurance Plan revision will be accomplished on a yearly schedule to provide a document satisfactory for meeting Thermionic Reactor Space Power Systems milestones.

2.3 The organization chart (Figure B-2) illustrates organization alignments. Even though the prime responsibility for this Quality Program document lies with the GGA Quality Assurance Division, many groups such as Engineering, Testing, Material Control and Production are called upon to perform tasks related to quality. The Quality Assurance Division is responsible for performing audits to assure that all groups are performing their tasks as intended. The Quality Assurance Division also performs the Program Audits shown on the milestone chart (Figure B-1).

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2.4 There are examples of other AEC quality programs active within GEES. The HTGR reactor programs utilize 10CFR50 Appendix B "Quality Assurance Criteria for Nuclear Power Plants" and the HEDL program utilizes RDT Standard F2-2T, "Quality Assurance Program Requirements". Procedures available from these programs shall be used for the TFE program when applicable.

2.5 Significant developments and the status of the Quality Assurance Program shall be reported to GEES management and to SNS in the thirdly reports.

3.0 QUALITY REVIEWS OF TECHNICAL DOCUMENTS

3.1 Technical documents used shall be drawings, process specifications, material specifications, fabrication process specification (travelers), and cell rosters.

3.2 Reviews conducted shall be as follows:

Reviewing Process Mat’ls. Cell
Organization Drawings Specs. Specs. Travelers Rosters

Engineering x x x x
Fabrication x x x x
Q. A. Engineering x x
Configuration
Control Board x x
Testing x x
Materials x x

4 .0 TRACEABILITY AND IDENTIFICATION

Each Thermionic Fuel Element shall be given an identifying number and all fabrication and test results shall be identifiable to this number. The numbers shall be those appearing in the cell roster.

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4.2 Fabrication traceability from raw materials, detail parts through completed TFE's shall be maintained by the use of purchase order numbers, heat numbers where required, and traveler numbers.

5.0 PROCUREMENT

5.1 Purchasing of all materials and services shall be accomplished by means of a Procurement Requisition (PR), GEES Form 8, and a Purchase Order (PO), GEES Form 4. Technical documents shall be referenced on the PR and PO. Parts and materials shall be inspected upon receipt and deviations from PO requirements reported on an Inspection Report (GGA Form 663). Travelers shall reference PO number (and heat number, if any) for materials and parts.

5.2 PR’s shall be reviewed by Engineering before transmittal to Purchasing. PO’s shall be reviewed by Production Control to assure compliance with PR.

6.0 FABRICATION AND ASSEMBLY

6.1 Work shall be accomplished as prescribed on Fabrication Process Specifications (travelers). The travelers shall reference pertinent drawings and specifications.

6.2 Work shall be accomplished by technicians qualified by a documented training and certification program.

6.3 Special processes shall be qualified be a documented certification program.

6.4 Completed end items shall be final inspected, including a final check of the data package, prior to delivery to test.

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7.0 INSPECTION AND TESTS

7.1 Receiving inspections shall be conducted in accordance with requirements in PO's.

7.2 In-process inspections shall be accomplished in accordance with inspection points called out on travelers.

7.3 Final inspection shall be accomplished in accordance with instructions on travelers.

7.4 Testing shell be accomplished as specified on the cell roster. Significant test results shall be issued with the monthly contract progress report and in a test booklet after each reactor shutdown for neutron radiographs. Documentation of testing procedures is provided for in the Implementation Schedule.

8.0 NONCONFORMING ARTICLES AND MATERIALS

8.1 Deviating parts and materials shall be reported on an Inspection Report (IR).

8.2 The IR shall be processed as described in Quality Procedure QP-001, except that the Configuration Control Board (CCB) makes final "use as is" decisions.

8.3 Deviating parts and materials shall be conspicuously tagged and segregated until disposition is obtained on the IR. Reject materials shall be conspicuously marked and segregated to prevent inadvertent use on a production item. Rework shall be accomplished on a rework traveler.

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9.0 CALIBRATION AND STANDARDS

9.1 Electronic items shall be calibrated in accordance with Quality Procedure QP-016, "Maintenance and Calibration of Electronic Equipment".

9.2 Mechanical items shall be calibrated in accordance with Quality Procedure QP-017, "Calibration of Mechanical Measuring and Test Equipment".

10.0 STAMPS

10.1 Upon completion of inspections, the Q. A. Inspector shall stamp the traveler or PO with his stamp.

10.2 Inspection stamps, types used, issuance and control are described in Quality Assurance Directive QAD-006, "Issue and General Use of Inspection Stamp

11.0 HANDLING, PRESERVATION, PACKAGING, STORAGE AND SHIPPING

11.1 Parts and materials requiring special handling shall be so noted on the travelers.

11.2 Clean rooms shall be operated as described in Procedures HCR-l, HCR-2, HCR-3, HCR-4, HCR-5, and HCR-6.*

11.3 Completed TFE’s shall be shipped to testing in special containers in cooperation with the Office of Nuclear Material Control (ONMC).

*These exist in draft form only at the present time.

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12.0 STATISTICAL QUALITY CONTROL

12.1 Currently no sampling plans are used, however, in the event the need arises MIL-STD 105 or MIL-STD 414 shall be used if possible. If these two plans cannot be used, a special plan shall be prepared in writing and approved by the CCB.

12.2 Control charts and process capability studies will be used as pertinent.

13.0 DATA PACKAGE

13.1 The data package for completed TFEs shall be as follows:

13.1.1 Completed, stamped-off travelers.

13.1.2 A complete set of drawings used.

13.1.3 Completed IR's.

13.2 Additional TFE data shall be contained in:

Thirdly Reports

Cell Rosters

Test Summaries

Special Topical Reports

"H" Series Material Specifications

Fabrication and Engineering Documents (FED’s)

Process Specifications

Production Control Notebook

Purchase Order files (material test reports and certifications)

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