Attachment C - NNFD-004 Work Control.pdf

DOCUMENT APPROVAL SHEET

DIVISION/FACILITY: NNFD

DOCUMENT TYPE: Administrative Procedure

DOCUMENT NUMBER: NNFD-004

REVISION NUMBER: 11

DOCUMENT TITLE: Work Control

Approver Name (Badge) Approval Role Approval Date

Pierce, Michael (36010) Final Approver 08/16/2021

Effective Date: 08/27/2021

This document has been electronically approved for use. Documentation of electronic concurrence and approval of this document is maintained in IDMS.

http://home.ornl.gov/cgi-bin/cgiwrap/ncsgroup/whos/whos.cgi?pagename=Detail&serverhost=wp2.ornl.gov&badge=36010

NONREACTOR NUCLEAR FACILITIES DIVISION Proc. No. NNFD-004 Work Control Page No. 2 of 36 Rev. No. 11

Modification Log

Change # or Rev.

Page

Section/

Step Description of Change

Effective

Date

Changed Facility Manager and Operations Manager to Facility

Management Group Lead and Operations Group Lead, respectively.

Acronyms were also updated to reflect these new titles. No revision bars included.

08/27/2021

10 4.2 Added a new step 4.2.6.3 to revise the work packages as necessary to incorporate feedback.

4.3

Added a new Note prior to Step 4.3.15 to indicate when a technical SME must be included as a reviewer/approver.

15 Added “physically or electronically” to Step 4.3.19

4.5

Added a note prior to step 4.5.8 indicating that signatures may be obtained electronically.

Added a 2nd note prior to Step 4.5.8 to indicate when a technical SME must be included as a reviewer/ approver.

This note in conjunction with the note added prior to step 4.3.15 satisfy ACTS Action 0.41151

19 Added “physically or electronically” to Step 4.5.10.4

21 4.7

Added a new Step 4.7.3 to ensure feedback is noted in the work order prior to closure.

This step in conjunction with the step added at 4.2.6.3 satisfy ACTS

Action 17735.1.1

27 App B

Deleted the following sentence from the general instructions section of the Work Package guidelines:

“Since MWPs and SMWPs have different revision requirements (FMGL can decide who needs to approve revisions) than SOWP and OWPs (all reviewers sign per DOE Order 422.1 and NNFD-001), it’s important to distinguish between the two.”

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Table of Contents

Section Title Page

1. INTRODUCTION

1.1 Purpose

1.2 Scope

1.3 Work Management

1.4 Work Management Processes

2. GENERAL INFORMATION

3. REQUIREMENTS

4. PROCESS

4.1 Work Identification

4.2 Work Screening

4.3 Work Planning

4.4 Work Execution

4.5 Work Package/Plan Changes

4.6 Post Maintenance Testing

4.7 Work Closure

5. REFERENCES

5.1 Source Documents

5.2 Performance Documents

6. RECORDS

7. APPENDICES

Appendix A, Definitions/Acronyms Appendix B, Work Package Guidelines Appendix C, Post Maintenance Testing

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1. INTRODUCTION

1.1 Purpose

The purpose of this procedure is to ensure a uniform graded approach to work management and establish the requirements and instructions for planning, scheduling, initiating, controlling, and documenting actions pertaining to work control within the Nonreactor Nuclear Facilities Division (NNFD).

1.2 Scope

The requirements, guidance and references in this procedure apply to operations (other than operational evolutions covered by a procedure approved in accordance with NNFD-001, Document Development, Review, and Approval), maintenance, and service work (e.g. new, corrective, preventative maintenance, predictive maintenance, calibrations, new construction, subcontract) performed within or affecting the NNFD facilities. This document establishes the controls and methodology for the administration of work related activities within or affecting all NNFD facilities.

This procedure provides a maintenance work control program that addresses identification of needed work, planning and preparation for work, evaluation of work hazards, development of hazard controls, establishment of conditions to perform work, return of system to operations (system control), and review of completed work records and document control.

Facility-specific operating procedures may be used in lieu of test plans, work control plans and packages.

No primary user is identified for this procedure. Since multiple users are responsible for performing portions of this procedure, user responsibilities are identified throughout this procedure.

1.3 Work Management

The process defined in this procedure is designed to implement work management that:

• Ensures the appropriate level of rigor is applied to work based on a graded approach.

• Provides a NNFD common approach such that work management is accomplished using the same structure and methodology in all areas.

• Provides the directions, tools, requirements, and references to create a total work management system.

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1.4 Work Management Processes

EMERGENCY WORK

When the need for emergency work (as defined in Appendix A, Definitions/Acronyms) is recognized, inform the Facility Management Group lead (FMGL) and follow Oak Ridge National Laboratory (ORNL) and NNFD notification requirements as applicable. Execute the work and using a blank Work Log and Pre-Job Brief, document the steps taken and approval of work by the FMGL and Division Director, or designee. After the hazard is controlled, submit a Work Request and scan and attach the forms to the Work Order for record.

URGENT WORK

When the need for urgent work (as defined in Appendix A, Definitions/Acronyms) is recognized, inform the Facility Management Group Lead (FMGL). Using a blank Work Log, document the steps to be taken including review and approval of work by the FMGL, Division Director or designee, and concurrence by Subject Matter Experts (SMEs) as determined by the FMGL along with the conduction of a Pre-Job Brief per NNFD-018. After the work is completed, submit a Work Request, scan the forms, and attach the forms to the Work Order for record. Compile Work Order and associated forms into Work Package. Obtain FMGL approval to close Work Package and document in the Work Log Section of NNFD-FRM-058, Work Package Forms. Forward the completed Work Package to Document Control Center (DCC) for record retention.

NON-EMERGENCY WORK

Identify Need - The need to perform a Task is identified by any staff member through the Facility Service Center electronic service request system, or directly into the Computerized Maintenance Management System (CMMS).

NOTE: For operations activities which will utilize an Operations Work Plan, Work Order creation and screening is not required

Validate Need – The electronic service request or Work Order is reviewed by the NNFD Facility Management Group Lead or designee and screened to validate the need for the work and establish the grade, priority and status. The work screener then ensures that the Work Order identifies the asset which is applicable to the activity. All NNFD Configuration Items have assets established in the CMMS. Other equipment may have assets identified in the CMMS as well. The work screener is required to link the work order to the asset when an asset is identified in CMMS. Attaching work orders to assets is necessary in order to maintain system and component maintenance history.

The grading criteria identified in SBMS, (Grade 1(A-H), Grade 2, Grade 3, Grade 4) provides the necessary graded approach that evaluates both the level of risk and rigor required to ensure that the proper controls are in place to conduct the work safely and effectively. All work performed in NNFD Nuclear Facilities is considered to be Grade 1 work and as such are assigned Grade 1 (A-H).

The work is then assigned to a task leader for planning and scheduling.

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1.4 Work Management Processes (cont)

Identify Resources and Requirements – Consists of determining scope, requirements, variables and constraints associated with the requested work.

Develop Work Package - A work package is developed by the work package/plan author to provide the proper prerequisite conditions, work instructions, post-maintenance testing, and data records necessary to resolve the requested work. Specific NNFD direction for Work Plan formatting and comment resolution is contained in Appendix B, Work Package Guidelines. NNFD required reviewers/approvers are indicated in the Work Package Reviewers Table section of NNFD-FRM-058, Work Package Forms and NNFD Post Maintenance Testing direction is provided in Appendix C, Post Maintenance Testing.

Assemble and Allocate Resources –Resources are allocated on a priority basis for NNFD based on safety, research priorities, and other factors. Craft resources are allotted by the Work Management and Maintenance group. This work prioritization is communicated to all involved personnel via the online scheduling system.

Hold Points –Hold points ensure the necessary safe work environment and prerequisite conditions for the workers to safely and effectively perform the requested work. Use of hold points should be limited to those steps, whose omission would result in injury to personnel, damage to equipment, or serious non-compliance to a requirement. Hold points require the signature or initials of the individual responsible for verifying the hold point requirements, and continuation in the work plan shall not occur until the required signatures are obtained.

Work Log – The Work Log Section of NNFD-FRM-058, Work Package Forms is a chronological log of significant events or findings such as work package review comments, revisions and approval, scope change, status of work for complicated packages, parts used, feedback comments, and changes that were made such that a person not involved with the task can understand what was done by reading the work package. For Standing Work Packages, it may also include daily start authorization, pre-job brief documentation, hold point approvals, and closeout authorization. A Work Log is required for inclusion in all work plans. The Work Log section of NNFD-FRM-058, Work Package Forms may be formatted to best meet work package requirements.

Conduct Work – This is the actual physical execution of the work to resolve the originator’s request. The assigned Task Leader has specific responsibility and authority to accomplish the work. The Task Leader coordinates all tasks and assumes responsibility for ensuring the tasks are performed accurately, safely and in compliance with the specified administrative and technical requirements. Pre-job briefs are conducted per NNFD-018, Pre-Job Briefs and Post-Job Reviews.

Additionally, the Task Leader ensures that post-maintenance testing (Appendix C) has been completed to ensure the proper functionality or operability of the system or component, as appropriate.

http://sbms.ornl.gov/sbms/SBMSearch/subjarea/wppc/SAdef.htm

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1.4 Work Management Processes (cont)

Closure and Feedback - This ensures the quality of all work meets NNFD and customer requirements and that a continuing improvement process is in place. Task Leaders are responsible and accountable for the functional and operational concerns associated with the work performed. Feedback is performed in accordance with NNFD-018, Pre-Job Briefs and Post-Job Reviews.

Closure reviews (Work Package Closure Checklist section of NNFD-FRM-058, Work Package Forms) are necessary for all completed work packages prior to archiving. The Task Leader is responsible for this closure review to ensure the completed work packages contain all the necessary items important to operations, safety, quality, engineering, configuration control, environmental protection and waste management concerns prior to final records retention. This may include the development and issuance of new or revised drawings, procedures, preventive maintenance, spare parts, and training.

Forms - Forms associated with this procedure are available on the NNFD website.

2. GENERAL INFORMATION

2.1 Individuals who serve as the Task Leader shall be qualified in accordance with the Qualification Card, Craft Supervisor/Task Leader/Work Planner.

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3. REQUIREMENTS

3.1 DOE Order 433.1, Maintenance Management Programs for DOE Nuclear Facilities, as implemented in the SBMS maintenance program description, requires that:

3.1.1 There is an assignment of roles and responsibilities for managing and conducting maintenance activities.

NNFD Facility Management Group Leads and task leaders must understand the administrative requirements and organizational assignments of this procedure to accomplish these functions.

3.1.2 A configuration management process is in place to ensure the integrity of nuclear facility Structures, Systems, and Components (SSC) using a graded approach.

All Personnel conducting work in Nonreactor Nuclear Facilities are responsible for ensuring that the requirements of NNFD-002, Change Control of Modifications and NNFD-023, Balance of Plant Modifications in NNFD Facilities, are followed during the course of work activities affecting Configuration Items in order to maintain system status and provide for proper configuration control.

3.1.3 A prioritization process places proper emphasis on safety requirements, maintenance backlog, system availability, and requirements for those infrastructure elements identified as part of the nuclear facility safety basis.

NNFD Facility Management Group Leads are responsible for ensuring that all work in NNFD Facilities is properly screened for priority, grade and status.

3.1.4 A process for feedback and improvement based on the relevant information from the results of operations, maintenance and assessment efforts.

Task Leaders are responsible for obtaining feedback from workers following the completion of work.

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4. PROCESS

4.1 Work Identification

ALL PERSONNEL

NOTE 1: If conditions present a personnel safety risk, a TSR issue, OR may be ORPS reportable, the Facility Management Group Lead or designee shall be notified immediately.

NOTE 2: For operations activities which will utilize an Operations Work Plan, Work Order creation and screening is not required.

4.1.1 If a request for work is needed, submit a service request electronically using SBMS Subject Area, Electronic Service Request Process.

Anyone may identify a deficient condition or request needed work through NNFD by submitting a service request. A service request is simply a request for work that may come in different forms. Service requests might be a verbal request to the service provider, an electronic request through the electronic service request system or programmed maintenance request (QE&I inspections, calibrations, preventive maintenance and recalls) via the Computerized Maintenance Management System (CMMS). Service requests serve to identify the work.

NNFD FMGL/TL

4.1.2 If a request for work is submitted verbally, ensure that the request is entered into the electronic service request system.

4.2 Work Screening

NNFD FMGL/TL

4.2.1 Screen the work request for personnel safety, TSR issues, and immediate mission impact.

4.2.2 Screen the service request via the CMMS for grade, priority and status.

Screening (Graded Approach)

For NNFD the work screening is the process by which the NNFD Facility Management Group Lead or his/her designee performs the work screener function for a service request. The work screener considers funding, safety, and competing priorities prior to approving a work request. The purpose of this activity is to understand the specific work identified/requested. The screening function is comprised of categorizing the work by grade, (Grade 1 (A-H), Grade 2, Grade 3, Grade 4) by priority (1-8) by status (On hold for Additional information, Approved for Planning, or Deferred) or canceling the request. The work screener accomplishes this task by entering this information through the CMMS for the Work Order.

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4.2 Work Screening (cont)

4.2.3 If the request is rejected for any reason, notify the requester of the disposition.

FMGL

4.2.4 Approve the work order in the CMMS.

TASK LEADER

4.2.5 Serve as the work screener to:

4.2.5.1 Determine existence of a Standing Work Plan.

4.2.5.2 Determine access requirements to the area where the work is to be performed.

4.2.5.3 Identify the Work Authorizer for the work and whether additional work start authorizations are needed prior to starting work.

4.2.5.4 Review the work, for any special instructions/considerations that may be applicable to the work.

4.2.6 If the work is covered by a Standing Work Package, perform the following:

4.2.6.1 Identify the specific Standing Work Package and verify that it adequately addresses the requirements to accomplish the work requested, the Standing Work Package is appropriately graded for the work, and that plant conditions, scope, hazard controls and work instructions are still applicable for this job. Requirements of the Work Package Review Checklist section of NNFD-FRM-058, Work Package Forms should be used to informally conduct this evaluation.

4.2.6.2 Review all Work Packages every two years or prior to use if longer and document per the Work Package Review Checklist section of NNFD-FRM-058, Work Package Forms.

4.2.6.3 Revise the Work Package as necessary per Section 4.5, Work Package/Plan Changes to incorporate any feedback found during the biannual Work Package Review.

4.2.6.4 Provide the necessary planning information (work package, resources needed, duration of the need for resources and a logic sequence for the resources) to the appropriate Facility Supervisor.

4.2.6.5 Request resource loading using the online scheduling system.

4.2.6.6 Ensure USQ screening, for nuclear facilities, has been conducted by a USQ-qualified reviewer.

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4.2 Work Screening (cont)

NOTE: In some facilities the Operations Supervisor or delegate may sign the Work Log or similar for initial start and daily start after verifying that plant conditions, scope, hazards controls and work instructions are still applicable.

4.2.6.7 Ensure the Facility Management Group Lead has approved the work on the POD.

4.2.6.8 Conduct a pre-job brief per NNFD-018 prior to work start.

4.2.6.9 When work is complete, document job closeout in the Work Log Section of NNFD-FRM-058, Work Package Forms.

4.2.6.10 GO TO Step 4.6.1.

4.2.7 If the work is NOT covered by a Standing Work Plan, proceed to Work Planning and assign a work package plan/author, or perform the duties of the work package plan/author.

4.3 Work Planning

WORK PACKAGE PLAN/AUTHOR

NOTE: All Grade 1 (E-H) and Grade 2 work will require instructions/plans.

4.3.1 Define which type of jobs requires instructions/plans.

4.3.2 Use the electronic system, Work Plan System (WPS) for Operations, Maintenance, and Services to develop the work plan, ensuring that the Work Plan is graded appropriately for the activity to be performed as follows;

• Scope/Description shall be completed. The WPS system may be used to provide a sequential number for the Work Package Number.

• Work Flow per the WPS is required to change the status of the Work Plan.

• A Job Hazard Evaluation per the WPS shall be included in the Work Package.

4.3.3 Identify the need for and obtain the services of appropriate Subject Matter Experts (SMEs) to prepare necessary designs, permits, Qualitative Exposure Assessments, and other documentation. Personnel/Disciplines to consider include (but are NOT limited to):

• Facility or System Engineering;

• Waste Management;

• Nuclear Safety;

• Nuclear Criticality Safety;

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4.3 Work Planning (cont)

• Nuclear Quality Representative (NQR);

• Environmental, Safety, Health, & Quality (ESH&Q) Representative;

• Hoisting and Rigging (H&R) Supervisor;

• Radiological Protection;

• Transportation;

• Industrial Safety/ Industrial Health Representative;

• Utilities; and

• Fire Protection.

4.3.4 Identify job related hazards and controls by using the “Typical Hazards to be Considered in a Job Hazard Evaluation”, contained in the Work Plan System with the involvement of associated subject matter experts as appropriate.

Identify and prioritize any conflicting requirements that might be encountered during execution of work (e.g. response to evacuation alarm versus security requirements).

Identify specific facility TSR mode requirements, if applicable.

4.3.5 For Operations Work Plans, review the work scope with facility management, Operations Group Lead, or Operations Safety Board (OSB) Chairman to determine if the work scope needs to be reviewed by the OSB prior to Work Plan Approval. Operations work scope requiring this review may include but are not limited to:

• Legacy radioactive material;

• Hazard(s) and Control(s) are not easily or readily defined (in relation to nuclear safety, industrial safety, radiological control, and fire protection);

• Impact to TSRs; and

• Operational activities that effect readiness for review approval, safety basis, and division level corrective actions.

4.3.6 Write instructions in the format defined in Appendix B, Work Package Guidelines (using the WPS or equivalent forms), or document work instructions in an approved, job-specific Internal Operating Procedure (IOP).

NOTE: The level of detail provided in the work instructions should result in a high probability that the job will be successfully completed. The preparer shall consider the significance of the work, personnel and nuclear safety risk, skill of the craft, experience of the work participants, complexity of work, and adjust the instruction detail accordingly, assuring that instructions fully and accurately address the scope of the work to be performed, the hazards associated with the job, and defines the controls necessary to prevent accidents, injuries, and property damage.

4.3.7 Provide step-by-step instructions for accomplishing the activity with specific detail of required final conditions whenever possible. For “troubleshoot and repair” type activities, exact work steps may not be identified at the time of work plan creation. NNFD-FRM-068, Troubleshooting Activity/Evaluation Log may be used in lieu of specific work steps in the work plan.

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4.3.8 Arrange the steps in the order required to logically and safely complete the work and consider the following general work steps for inclusion in all work instructions.

4.3.8.1 Identify the correct equipment requiring maintenance and direct workers to verify identification labeling is present and correct, as necessary, prior to starting and following completion of work.

4.3.8.2 Perform the stated work scope in logical order while ensuring hazard controls are maintained via work sequence and required hazard mitigation and controls.

4.3.8.3 Provide specific detail as necessary to ensure accurate performance of the work scope and ultimately desired final conditions (e.g. required belt tension, required bolt torque, required fan speed, required pump discharge pressure or flow rate).

4.3.9 When developing work instructions, involve representative workers and associated SMEs in the evaluation of both the work and hazards associated with the job, as appropriate.

4.3.10 Ensure that Hold Points appropriate for identifying and maintaining personnel and equipment safety are identified with appropriate signature blocks.

4.3.11 Ensure the Work Package/Plan documentation is included in accordance with Work Package Index section of NNFD-FRM-058, Work Package Forms. Work Package content location within the package is provided for guidance.

4.3.12 If a modification is associated with the work request, perform the following:

4.3.12.1 Ensure appropriate forms from NNFD-002, Change Control of Modifications or, as required, NNFD-023, Balance of Plant Modifications have been approved through modification approval and any requirements are implemented.

NOTE: Work may proceed prior to modification approval provided the System Engineer authorizes the work and a Hold Point is included in the work plan requiring modification approval.

4.3.12.2 If necessary to approve the work package and start work AT RISK prior to modification approval per 4.3.12.1 being completed, request the System Engineer to determine the order within the work instruction sequence for placement of a hold point (the extent of work permitted prior to modification approval).

https://recordsmgmt.ornl.gov/DMS_ORNL/Reporting/Rpt_Division_Summary.cfm https://recordsmgmt.ornl.gov/DMS_ORNL/Reporting/Rpt_Division_Summary.cfm

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4.3.13 If a procurement is associated with the work request, perform the following:

4.3.13.1 Ensure appropriate forms from NNFD-010, Procurement, Receipt Inspection, and Commercial Grade Dedication for NNFD Supplies and NNFD-017, Fabrication Control have been approved.

NOTE: Work may proceed prior to procurement documentation approval provided the System Engineer authorizes the work and a Hold Point is included in the work plan requiring procurement documentation approval.

4.3.13.2 If necessary to approve the work package and start work AT RISK prior to procurement documentation approval per 4.3.13.1 being completed, request the System Engineer to determine the order within the work instruction sequence for placement of a hold point (the extent of work permitted prior to procurement approval).

NOTE: Informational copies of procurement documentation may be kept with the work package for convenience.

4.3.13.3 Ensure original procurement documentation (completed per NNFD-010) is forwarded to the DCC for retention.

4.3.13.4 If the work plan is Grade 1-G/H, ensure the procurement file number is entered in the Work Package Index section of NNFD-FRM-058, Work Package Forms

4.3.13.5 If a fabrication package was utilized, list the fabrication package number in the Work Package Index section of NNFD-FRM-058, Work Package Forms.

4.3.14 Ensure a review is performed in accordance with SBMS, Unreviewed Safety Questions (USQ) Process for Nuclear and Facility Safety for nuclear facilities.

NOTE: For operations work packages utilized inside hot cells or other primary confinement areas, a Technical SME shall be included as a Reviewer/Approver.

4.3.15 Ensure the Work Package is reviewed by the individuals defined in the Work Package Reviewers Table section of NNFD-FRM-058, Work Package Forms including any applicable SMEs or their representative identified in Step 4.3.3 that are involved in the work beyond simple reference or for hazards not fully controlled or implemented by required permit(s) or controlled via work plan direction in lieu of permit.

4.3.16 If the work is high impact as defined in Appendix A, Definitions/Acronyms, ensure the Work Package is reviewed by the Division Director, or designee.

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SUBJECT MATTER EXPERTS

4.3.17 Review and concur on the work packages that:

• have specific action steps to mitigate hazards or ensure compliance with regulatory/contractual/ORNL requirements in their area of expertise.

• require exemptions, variances, or formal interpretations of regulatory/contractual/ORNL requirements in their area of expertise.

• initiate or require mandatory review of an activity through the requirements of another Subject Area, Management System, procedure, policy, or guideline [e.g., Radiological Work Review Checklist, Laboratory Space Manager Program, generating a new Data Quality Objective (DQO), establishing a Satellite Accumulation Area (SAA)].

• provide input on prioritization of hazard control requirements in cases of abnormal situation response or conflicting requirements.

TASK LEADER

4.3.18 Resolve and incorporate comments per Appendix B, Work Package Guidelines.

NOTE: By signing as Reviewer, Concurrence, or Approver, personnel are authorizing the Work Package as written.

4.3.19 Obtain “Review/Approver” signatures (electronically or physically). Documents required to be complete prior to Work Package Approval are indicated in the Work Package Index section of NNFD-FRM-058, Work Package Forms.

4.3.20 Ensure that the NNFD Facility Management Group Lead and Operations Group Lead or designees concur on the work package and obtain “Work Package Concurrence” signatures.

4.3.21 When the Work Package is ready for work (all required documentation, permits, hazard evaluations, drawings, reviews, approvals and concurrences) and materials (tools, equipment, parts, etc) are available, provide the necessary planning information (resources needed, duration of the need for resources and a logic sequence for the resources) to the NNFD Facility Supervisor.

4.3.22 Request resource loading via the online scheduling system as needed

The work package/plan or job-specific IOP, once approved, serves as the certification of hazard assessment for the specification of personal protective equipment for operations, maintenance, and service activities at Oak Ridge National Laboratory.

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4.4 Work Execution

TASK LEADER/FMGL

NOTE: The NNFD and facility Plan-of-the-Day/Week provides the mechanism to coordinate, allocate resources, schedule, plan, prioritize work and interface between the facility and operations for all work, operations and testing in the complex.

4.4.1 Ensure that, prior to conducting any work in NNFD Facilities, that it is listed on the Facility Plan of the Day. This verification must be performed each day/shift the work is being performed.

TASK LEADER and FMGL

NOTE: The Facility Management Group Lead Start Work Approval is an acknowledgement of the work plan being in an active phase, and the potential interface with facility conditions. For SOWP and SMWP start work approval may be signed utilizing the Work Log Section of NNFD-FRM-058, Work Package Forms. The Work Authorization must be signed for the Work Package initially on the Document Review Authorization Page.

4.4.2 Sign the work package for work start authorization verifying:

• The work package/plan has been reviewed and approved.

• All documents required for work start are completed and in the work plan per Work Package Index section of NNFD-FRM-058, Work Package Forms

• Work authorizer and workers share common understanding of the complete work scope, hazards associated with the work, and controls necessary to prevent accidents, injuries and property damage.

• Subject Matter Experts were used in the identification and mitigation of hazards, controlling and monitoring exposure to hazards, and execution of work if the task leader lacked the necessary familiarity, work experience, or training to ensure that hazards were identified, controlled, and monitored.

• Conditions are appropriate for work to proceed.

4.4.3 Ensure that, prior to beginning work, that a pre-job briefing is performed in accordance with NNFD-018, Pre-Job Briefs and Post-Job Reviews.

4.4.3.1 If the work is covered under grade 1A-B and 4 SMWP, document the pre-job brief and work scope MJR or WO in the Work Log Section of NNFD-FRM-058, Work Package Forms.

4.4.4 Ensure, for Grade 1C-1H work, that the work instructions including drawings and all documentation are taken to the job site and used to execute work in accordance with work instructions. Work instructions and associated drawings and documentation for Grade 1A-B and Grade 2 work should be available for reference in the field as necessary.

4.4.5 Determine if work instructions need to be present at the job site for Grade 3 work.

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4.4 Work Execution (cont)

4.4.6 Ensure that the appropriate level of written direction and detail, craft familiarity and skill, and work oversight are provided to complete the work scope while maintaining hazard mitigation commensurate with the hazard consequences and risk.

4.4.7 Record daily progress/work execution in the Work Log Section of NNFD-FRM-058, Work Package Forms.

WORKERS

4.4.8 Execute the work in accordance with the work instructions, including prompt notification of the task leader of any unexpected conditions, inspection/testing results, observed equipment reliability issues, and any parts utilized that were not provided by the task leader or previously identified/documented in the work plan.

4.4.9 If the planned work scope or hazard changes or an issue arises concerning the safe execution of the planned work during work execution, suspend work and notify the task leader.

4.4.10 Ensure the task leader is updated on the work status (execution, hazards, and work site condition) at the end of each shift or following work stoppage for the day.

4.4.11 Notify the task leader prior to leaving the work site of any need to complete work in an alternate work location (e.g., shop).

TASK LEADER and FMGL

4.4.12 If any staff member sees an unsafe act, activity or condition that creates an imminent danger, exercise stop work authority.

4.5 Work Package/Plan Changes

NOTE: Work may continue during the processing of an MWP change providing:

• The pending change is noted in the Work Log Section of NNFD-FRM-058, Work Package Forms;

• Work can be reversed prior to declaring the affected system operable or returning the system to service;

• Work does not include any increase in personnel safety hazards; and

• The FMGL provides verbal approval that the previous USQD/USQDSCREEN bounds the change.

WORK PACKAGE/PLAN AUTHOR

4.5.1 Make a clear and executable change in the work instructions, either handwritten, page replacement, or section replacement.

4.5.2 Mark each change with “R” followed by the change number (e.g. R1).

4.5.3 Retain any superseded sections in the Work Package marked through with the R# noted.

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4.5 Work Package/Plan Changes (cont)

4.5.4 Add signoffs as required to the work package body for new work or repeated steps.

4.5.5 If the revision results in numbered steps NO longer being sequential, renumber the applicable steps, or leave the steps in non-sequential order (numbers skipped or reused) with an explanation included in the Work Log Section of NNFD-FRM-058, Work package Forms.

4.5.6 Maintain a clean paper trail with directions that are clear and can be followed without confusion.

4.5.7 Include the revision number and a short statement of what the change is and any relevant background necessary to understand the change in the Work Log Section of NNFD-FRM-058, Work Package Forms.

Example: Revision 1: AJ-112 VOG Exhaust Fan Motor outboard bearing found to be degraded, added steps to replace.

NOTE 1: Approval signatures may also be obtained electronically.

NOTE 2: For operations work packages utilized inside hot cells or other primary confinement areas, a Technical SME shall be included as a Reviewer/Approver.

4.5.8 Include approval lines on the next free lines in the Work Log (i.e., following the revision number and short statement) by stating “Approval:” and the acronym of the approver’s title.

Example: Approval: TL Signature & Date FMGL Signature & Date.

NOTE: A non-intent change is any change that has no reasonable potential to change work scope or process such as editorial or format changes, correcting typos, spelling, or grammatical errors, adding signoff blanks, and adding minor wording to clarify understanding.

4.5.9 If the change is non-intent, obtain TL and FMGL approval.

NOTE: An intent change is any change NOT meeting the criteria for a non-intent change.

4.5.10 If the change is intent, perform the following:

4.5.10.1 Obtain a USQD/USQDSCREEN and document the results on the Work Log Section of NNFD-FRM-058, Work Package Forms.

FMGL

4.5.10.2 Determine required approvals for the intent change (TL and FMGL required at a minimum).

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4.5 Work Package/Plan Changes (cont)

4.5.10.3 Ensure compliance with the review requirements of NNFD-002, Change Control of Modifications and NNFD-023, Balance of Plant Modifications.

WORK PACKAGE/PLAN AUTHOR OR TASK LEADER

4.5.10.4 Obtain required approval signatures (physically or electronically).

4.5.10.5 Document review of Job Hazard Evaluation (JHE) and Pre-Job Brief.

4.5.11 Update the electronic copy in the Work Planning Tool.

4.6 Post Maintenance Testing

TASK LEADER

4.6.1 Develop Post Maintenance Testing (PMT) requirements, referring to Table 1 of Appendix C, Post Maintenance Testing, as needed.

4.6.2 IF the work scope is of a “troubleshoot and repair” type, THEN put a step in the work instructions to complete the PMT identification document requirements.

NOTE: Multiple PMTs may be required on one job to test stages of work or multiple components, to allow testing at the end of each stage or on each piece of equipment.

4.6.3 Determine the necessary PMT(s) based on the PMT requirements and per Appendix C, Post Maintenance Testing.

NOTE: Systems may be operated for testing or run-in as part of the maintenance activity. Work packages may be used to give operational direction for equipment and/or systems if the affected system is not operable (to satisfy TSRs) and system interactions cannot adversely impact nuclear safety.

Services delivered by the equipment (such as compressed air, cooling water flow, or ventilation) may be used by the plant while operating under this configuration but the equipment cannot be used to satisfy TSR equipment requirements.

4.6.4 Complete the PMT by performing the following:

NOTE: The “Required Plant Condition/Test Requirements/Procedures” field shall be completed by writing specific steps and actions or listing procedures or written instructions which will be used as PMT to satisfy the stated acceptance criteria. If applicable, the test shall be related back to the step in the work package where it is required.

4.6.4.1 Record the PMT#, Work Order # (if applicable), and any Required Plant Conditions/Test Requirements/Procedures on the Post- Maintenance Testing Section of NNFD-FRM-058, Work Package Forms or NNFD-FRM-067, Post Maintenance Testing.

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4.6 Post Maintenance Testing (cont)

NOTE: Post Maintenance Testing should be completed in a timely manner following work execution. If any required PMT cannot be completed within a reasonable period of time from work execution as determined by the Facility Management Group Lead, facility operations shall place an administrative tag on the equipment controls indicating “PMT required.”

4.6.4.2 Perform each test.

4.6.4.3 WHEN the testing is finished, THEN record the test results (“SAT” or “UNSAT”) and relevant remarks on the Post-Maintenance Testing Section of NNFD-FRM- 058, Work Package Forms or NNFD-FRM-067, Post Maintenance Testing.

4.6.4.4 Complete the “Performed By” and “Date” fields of the Post- Maintenance Testing Section of NNFD-FRM-058, Work Package Forms or NNFD-FRM-067, Post Maintenance Testing.

4.6.5 IF the PMT result was “UNSAT”, THEN perform the following:

4.6.5.1 Follow any procedure specific directions in the procedure for failure.

4.6.5.2 Add a new PMT task for retest to the PMT instructions.

4.6.5.3 When deficiencies have been corrected, re-perform the necessary

PMT.

4.6.6 Repeat Step 4.6.4 and 4.6.5, as necessary, to complete all PMT(s).

4.6.7 WHEN all PMT is completed, THEN perform the following:

4.6.7.1 IF applicable, THEN record Work Package/Plan # and Title on the Post- Maintenance Testing Section of NNFD-FRM-058, Work Package Forms or NNFD-FRM-067, Post Maintenance Testing.

4.6.7.2 Record the total number of PMT(s) performed and any final remarks on the Post-Maintenance Testing Section of NNFD-FRM-058, Work Package Forms or NNFD-FRM-067, Post Maintenance Testing.

4.6.7.3 Sign and date the Task Leader field, AND request the System Engineer/Facility Management Group Lead/Facility Supervisor to sign and date on the Post-Maintenance Testing Section of NNFD-FRM-058, Work Package Forms or NNFD- FRM-067, Post Maintenance Testing.

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4.6 Post Maintenance Testing (cont)

4.6.8 If PMT is performed in another procedure (e.g. Surveillance Procedure), and if referenced in the PMT form/section of the work package, document requirements and results in the implementing procedure.

4.7 Work Closure

4.7.1 Perform work package closure activities per the Work Package Closure Checklist section of NNFD-FRM-058, Work Package Forms.

4.7.2 Document via the Work Log Section of NNFD-FRM-058, Work Package Forms or via a specific step within the closeout section of the work instructions for the Review of any observed abnormal indications encountered during work execution.

4.7.3 Ensure equipment condition feedback is noted in the work order prior to work order closure, AND initiate additional work orders as necessary to address condition feedback.

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5. REFERENCES

5.1 Source Documents

5.1.1 DOE Order 433.1, Maintenance Management Program for DOE Nuclear Facilities

5.1.2 NNFD-001, Document Development, Review, and Approval

5.1.3 SBMS Subject Area, System Engineering

5.1.4 SBMS Subject Area, Work Control

5.2 Performance Documents

5.2.1 NNFD-001, Document Development, Review, and Approval

5.2.2 NNFD-002, Change Control of Modifications

5.2.3 NNFD-003, Document Control and Records Management

5.2.4 NNFD-018, Pre-Job Briefs and Post-Job Reviews

5.2.5 NNFD-023, Balance of Plant Modifications

5.2.6 SBMS Subject Area, Unreviewed Safety Question (USQ) Process for Nuclear and Facility Safety

6. RECORDS

Completed Work Packages, including NNFD-FRM-058, Work Package Forms, shall be forwarded to the NNFD Document Control Center for retention in accordance with NNFD-003, Document Control and Records Management and the Records Inventory and Disposition Schedule (RIDS).

7. APPENDICES

7.1 Appendix A, Definitions/Acronyms

7.2 Appendix B, Work Package Guidelines

7.3 Appendix C, Post Maintenance Testing

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APPENDIX A

Definitions/Acronyms

ACRONYMS

1. ACTS - Assessment, Commitment, & Tracking System

2. ASME - American Society of Mechanical Engineers

3. BOP - Balance of Plant

4. BOPM - Balance of Plant Modification

5. CCP - Configuration Control Package

6. CMMS - Computerized Maintenance Management System

7. DCC - Document Control Center

8. DID - Defense-in-Depth

9. DOE - Department of Energy

10. DQO - Data Quality Objective

11. DSA - Documented Safety Analysis

12. FMGL - Facility Management Group Lead

13. HAZWOPER - Hazardous Waste Operations

14. HVAC - Heating, Ventilation, & Air Conditioning

15. IH - Industrial Hygiene

16. IOP – Internal Operating Procedure

17. IS - Industrial Safety

18. JHE - Job Hazard Evaluation

19. MWP - Maintenance Work Package

20. NCS - Nuclear Criticality Safety

21. NNFD - Nonreactor Nuclear Facilities Division

22. ORNL - Oak Ridge National Laboratory

23. ORPS - Occurrence Reporting and Processing System

24. OWP - Operations Work Package

25. PdM - Predictive Maintenance

26. PEP - Performance Evaluation Plan

27. PJB - Pre-Job Briefing

28. PM - Preventive Maintenance

29. PMT - Post Maintenance Testing

30. POD - Plan of the Day

31. POW - Plan of the Week

32. QA - Quality Assurance

33. QEA - Qualitative Exposure Assessment

34. QE&I - Quality Engineering and Inspection

35. R - Revision

36. RCT - Radiological Controls Technician

37. RIDS - Records, Inventory, & Disposition Schedule

38. RWS - Required for Work Start

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39. SAA – Satellite Accumulation Area

40. SBMS - Standards-Based Management System

41. SC - Safety Class

42. SMWP - Standing Maintenance Work Package

43. SOWP - Standing Operations Work Package

44. SS - Safety Significant

45. SSC - Structures, Systems, and Components

46. TL - Task Leader

47. TSR - Technical Safety Requirements

48. USQ - Unreviewed Safety Question

49. USQD - Unreviewed Safety Question Determination

50. WPS - Work Planning System

51. WPT - Work Planning Tool

52. WO - Work Order

DEFINITIONS

1. Approved for Planning - Job is ready to be planned. A Job is normally placed in this status by the NNFD Facility Management Group Lead when the job is ready to be sent to the task leader for planning.

2. Cancel – the work order is rejected. If the request for service is rejected for any reason, then the Work Screener shall notify the requester of the reason for canceling.

3. Deferred - Work items or facility deficient conditions that are deferred (due to: lack of funding, life cycle, etc.). Gives representation of true facility condition and provides a method to track and review.

4. Emergency Work – Work required to mitigate an imminent or existing nuclear or personnel safety hazard.

5. GRADE 1 - Work that could affect the operation of a CAT 1, 2, or 3 Nuclear Facility. Grade 1 tasks are subdivided into 8 types (A-H) based on the definitions in the table below. These types are driven by the documentation and review requirements for work being performed. All work in NNFD CAT 1, 2, OR 3 nuclear facilities are considered Grade 1.

Work Type Description

A May not effect operation of facility, however facility management determines that work Requires Facility

Management Group Lead Attention

B Experiment Systems Maintenance

C Non-Safety Related (SC/SS/DID)* Preventive Maintenance (PM), Calibrations, or Routine Operations

D Non-Safety Related (SC/SS/DID) Corrective Maintenance (CM), Trouble Shooting/Testing, or Routine

Operations

E Safety Related (SC/SS/DID) Preventive Maintenance (PM), Calibrations, or Routine Operations

F Safety Related (SC/SS/DID) Corrective Maintenance (CM), Trouble Shooting/Testing or Routine Operations

G Non-Safety Related (SC/SS/DID) Facility Modification

H Safety Related (SC/SS/DID) or TSR Related Facility Modification

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6. GRADE 2 - Work that could not affect the operation of a CAT 1, 2, or 3 Nuclear Facility. (Life Safety) Non-nuclear functional features relative to fire, storm, collapse, crowd behavior, and other related safety considerations within a structure or facility. (High Rigor Equipment) Equipment for which maintenance or repair requires a higher degree of rigor in work planning, performance and documentation, as specified in regulations or standards due to potential for serious injury. This systems/equipment may have defined work protocols required by OSHA, a nationally recognized standard such as ANSI or ASME, or by the equipment manufacturer. Examples: cranes, fork lifts, man lifts or work platforms, pressure vessels, high pressure systems, etc. (Facility Modifications) Significant changes to a facility that are governed by Building, Fire, or other recognized codes or standards. NOTE: Additional guidance is provided in the procedure “Implement Work Control for Operations, Maintenance, and Services” (see Work Grading Guidance).

7. GRADE 3 - Work that could not affect the operation of a CAT 1, 2, or 3 Nuclear Facility. Work activities not classified as Grade 1 or 2 that require job specific permitting for personnel safety or a high level of coordination due to the fact that the work might have a significant impact on laboratory operations. NOTE:

Additional guidance is provided in the procedure “Implement Work Control for Operations, Maintenance, and Services” (see Work Grading Guidance).

8. GRADE 4 - Work that could not affect the operation of a CAT 1, 2, or 3 Nuclear Facility. Work activities that can be completed and controlled effectively through skill-of-the-craft. NOTE: Additional guidance is provided in the procedure “Implement Work Control for Operations, Maintenance, and Services” (see Work Grading Guidance).

9. High Impact – Work that involves lifting of, or maintenance on (with risk of permanent damage) equipment with replacement costs and labor valued at or over 10 million dollars, emergency work, non-routine transportation of quantities of nuclear material > Category 3.

10. Hold Point – A Hold Point is a step in the Work Plan that identifies the necessary safe work environment and prerequisite conditions for the workers to safely and effectively perform the requested work. A Hold Point requires facility conditions to be verified or changed and require a signature from the cognizant discipline (i.e. FMGL, RCT, IH, Quality) prior to proceeding in the work plan.

Hold points are placed at the discretion of the work plan author and used to identify critical steps, changes in operating or safety conditions, or other instances where proceeding beyond the hold point without having accomplished the requirements of the hold point would produce dire results.

Hold points require the signature or initials of the individual responsible for verifying the hold point requirements, and continuation in the work plan shall not occur until this has been accomplished.

• Example – A work plan requires a specific system alignment for work to continue. This would require a Hold Point which would only be released by the Facility Management Group Lead’s signature, once the system alignment is complete.

• Example – A work plan requires intrusion into a potentially contaminated system. This would require a Hold Point which would only be released by a Radiological Control Technician’s signature, once the work area has been surveyed to meet the specifications in the work package.

11. Materials – tools, equipment, parts, etc. staged for job.

12. On Hold for Additional Information – This status is assigned to a service request that does not provide the initial information needed to correctly grade and disposition the work.

13. Ready to Work - Paper work complete – Job Hazard Evaluation, Permits, Work Instructions, reviews and approvals.

14. SMWP - Standing Maintenance Work Package – A work package that is used to perform corrective, preventive, or predictive maintenance and is intended to cover more than one occurrence of the work scope.

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15. Urgent Work – Work necessary to maintain continued operation of, or address an identified deficiency that may result in a nuclear or personnel safety hazard, or other abnormal condition in a nuclear facility that cannot be addressed in a timely manner through the normal work control process without undue risk, hazard exposure, or consequence.

Priorities

1 Correction or mitigation of imminent safety hazards: This category includes industrial safety, radiological safety, environmental protection, security (physical, nuclear material) situations where direct action is needed to correct, mitigate, prevent risk to the public, workers, or the environment.

2 Corrective and preventive maintenance of nuclear safety-class and safety significant configuration items and comparable systems/items for other hazardous materials: This category includes maintenance of systems and components that are necessary to…