ML19289G108

QC Procedure QCP-M-012 for Final Acceptance Insp

ML19289G108
Person / Time
Site:	Crane
Issue date:	05/04/1979
From:	GENERAL PUBLIC UTILITIES CORP.
To:
References
QCP-M-012, QCP-M-12, NUDOCS 7906260332
Download: ML19289G108 (20)

Text

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%q-[j sh'WQ U17(, w WwJ u J- ~~ c _ t<_ Transe:::al of Procedure ) _m Rev. No. n QCP-M-012 Final Acceptance Inspection d ic LocatOn Three Mi1e Island G. Walton i US - !aC, I&E Attached pless e find a copy of the subject procedure for your immediate use. Please sign the botic: portion of this transmittal indicating re-ce:pt of the r. e w revision; detach it, and return it to us together with the cid revis ien. \\ ,k L 4 5Fus: cA Eng:neer =rc-- To: r.PUSC QA

Subject:

seceipt o f F r o c e<'.u r e O c ? lu. ; il Re. No. r A:: ached please find our copy of the old revision of the subj ect procedure. he will use the new revision as of (DATE) Co., Title, and care > l. t J _) u S i GPU 5emce Cerccraaon is a sucs c.ary o' General P c ic U:e : es Oc corai.c- 't 906 2 60'3f[ " f o[9*w 7 7-9f

Rev. 0 ~ Date: May 4, 1979 QPU SERVICE CORPORATION QUALITY CONTROL PROGDURE QCP-M-012 FOR j FINAL ACCEPTANCE INSPECTION THREE MILE ISLAND - UNIT 2 (MODIFICATION) CCNCURRED BY: h te5/U/7f franage N Qualit, s e/ /' / Metropolitan Edn. Ceepany Date4\\rl *$ APPROVED BY _ L im TM 2 Modificatnyns l C QA Manager 3 i.'

Rev. 0 Date: May 4, 1979 GPU SERVICE CORPORATION QUALITY CONTROL PROCEDURE QCP-M-012 FOR . TANCE INSPECTION FINAL ACJ 1. SCOPE This procedure is applicabe to nuclear and nuclear safety related systems and structures, part of the TNI-2 Modifications Program. This proce3ure shall be used during pre-eperational checkouts, through cc=pletion of the =odification, including checks for func-ticnal or operational tests. Modificatica related checks include hydrostatic tests, flushing, meggering, continuity checks, and n-tor starring-tests, and all items identified in the procedure for testing, and checks of mechanical and electrical equipment. II. GENERAL A. P_tuso s e The purpose of this procedure is to outline the method for determining the Quality status, and acceptance of co=pleted modifications to syst-=s, sub-systems, components and struc-tures, part of the TMI-2 Modificati'sns Program. B. Reference Documents F The requirements of all applicable GPUSC QC procedures and the following reference documents shall apply to all items covered within the scope of this document.

1. Engineer Specifications (B6R)

2. Tes t Procedures

3. Test Instructions

4. ANSI N45.26 - Qualification of Inspection 5 Test P e rs o nn e l.

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.N..,,. [ s N,; . h, (:4,..,[,. ym.... - Ri v. O Date:May 4, 1979 .i ~I II. GENERAL - Continued 5 C. Check Lists = } The reference to check lists (Attach =ent "A") in this pro- [ cedure shall apply to a written list of the require =ents specified by drawings, equip =ent =anuals, syste= specifica- } ticus, vendor installation procedures and operating =auuals, and other instructions that =ust be ce= plied with to assure } the integrity and quality of =aterials and work =anship of 7 J the equip =ent, syste=, and/or sub-syste= being inspected for final acceptance. D. Final Accentance Inseection Descriori n Final accepta..-- inspection shall be conducted as follows: I 1. Final Int ection - A visual inspection of the cc=pleted f syste=, or part thereof, and review of quality assurance l documentation to assure that all required work and 9 [ docu=entation is s' tis factorily ce=pleted, and that this h syste=, sub-syste=, or structure is ready for turnover to Met-Ed QC and Met-Ed/GPU Start-Up. E. De fini tion s ? Verify: - as used in this proce iure requires that a quality Control Inspector will observe and assurc that the work n 7 k T acco=plished on equip =ent within the scope of this docurent h is in accordance with specifications and procedures. y r. ?' III. RESPONSIBILITY s The sequence and schedule of final inspection shall be ~ Ai coordinated by the CPUSC Lead Quality Control Engineer and r ] the Craft Supervisors of the applicable contractors upon 2 notice of scheduled cc=pletion of the construction activity. I Met-Ed/GPU Start-Up is responsible for providing the Lead s -4 Quality Control Engineer with advance notice of test schedules. i = 4= 1 m i_ ij .g. 5 r, /-), m. v.+ ^ -l =.

QCF-M-012 Rev. O Date: May 4, 1979 IV. PROCEDURE A. Scheduling of Final Acceptance Inspection Schedules for final acceptance inspection shall be based on the following:

1. Scheduled co=pletion of work by the contractor as defi ted in the specification, work order, contract, o r p ur-chase order.

2. Scheduled completion of work as reported by the Craf t S up -

ervisor, Jo:e Engineer, or Proj ect S up erin t end en t.

3. Scheduled co=pletion of pre-operational checks and inspec-tion and/or turn over for functional testing.

Note: Checks which require verification by Quality Control, but were conducted without Quality Control participa-tion, shall be rescheduled and re-run. B. Precaration of Check Lists

1. Prior to scheduled final acceptance inspection the Quality Control Engineer will prepare a check list for use during the inspection (see sample format - Attach =ent "A").

Gen-eral type check lists =ay be prepared for final inspection of similar syste=s components or sub-syste=s, however, unique or special situations which are not covered by gen-eral check lists will require preparation of a special ~ check list be. ore final inspection is scheduled.

2. The check lists referenced herein require review and approval by the T.er.a Quality Control Engineer. After his e

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QCP-H-012 Rev. 0 Date: ?.ay 4, 1979 IV. PROCEDURE - Continued B.

2. - Continurd approval is given, the check lists are submitted to the GPUSC Site QA Nanager for final approval, prior to use.

Quality Control shall furnish the cogni: ant Craf t Super-a visor with a copy of the approved check list prior to performing the inspection. Ite=s to be considered for check points include the following:

a. Verification of available documentation for materials, in-process inspection, tests, welding, (Vendor docu-

=entation as well as on-site documentation) Tie-In Authori:ation form, etc.

b. Verification of compliance with applicable revision of drawings, specifications, procedures, and B6R opera-tions procedures.

Visual inspection to verify satisfactory completion of t. work.

d. Verification that either all Deviation Reports & Hold Tags have been cleared and that tnere are no outstanding items, or they are dccumented on a punch list.

e. Verification of cleanliness Icvels as specified by Engineering Specification.

f. Verification that any temporary ins tallations, connect-tions, or disasse=bly has been restored to design re-quir ments.

g. Verification of required identification and =arkings.

h. Verification of the physical integrity, i e.,

lack-of-damage. ~ Lao v' 6 _ 'I

Rev. 0 Date:May 4, 1979 IV. PROCEDURE - Continued 3.

2. - Continued

1. - Continued Ite=s identified as recairing QC checks in the applicable test procedure.

j. System description developed and distributed.

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k. Operating procedures developed and distributed.

1. Check point ite=s that are rejected or declared not applicable and are =arked NA, require explanation in the remarks section of the check list.

3. The check lists may be supplemented by QC records of tests such as the Leak Test Report prepared for hyrostatic tests and the Inspection Report prepared for final flushing.

C. Final Acceptance Inspection

1. Prior to scheduling final inspection:

a. The cognizant Craft Supervisor will perform the neces-sary check: and_ final inspection of th turnover ite=s to assure all required work or tests have been completed.

b. The checks and inspection of the designated work shall be documented by the cogni: ant supervisor certifying comple-tion of ccnstruction and transmitted to the Lead Mechanical QC Engineer. This will include a cecplete list of turnover ite=s, marked up drawing or other sketch which will clearly identify the inspection boundary.

2. Inspector (s) fro = the Quality Control Group will be assigned by the Lead Qaality Control Engineer to inspect the designated work. Quality Control will then schedule and initiate the final inspection using the applicable ap-proved check list (s).

In situations where Quality Control has advance information from the Craft Supervisor that a system /sub-system is being -s-2s2 Ub/ n l

Rev. 0 Date: May 4, 1979 IV. PROCEDURE - Continued C. Final Acceptance Inspection - Continued

2. - Continued checked for completion and will be submitted for final inspection, the Lead Quality Control Engineer

=ay direct the Quality Control Inspector to prepare for turnover the anticipated inspection by: performing pre-liminary inspections, familiarizing himself with the sys-tem equipment, assembling records for the data package, check for ince:plete work, review records to assure there are no outstanding Deviation Reports and other actions that can be performed expediently in advance of the sched-u]ed final inspection.

3. Final Inspection consists of:

a. Visual inspection of cocpleted work and other inspec-tion requirements as specified by the applicable check list.

b. Review of Quality Assurance Records to assure documents are complete and adequate for the completed work.

c. Review of Quality Control records to assure that re-quired construction related inspections have been com-pleted and docm=ented.

A list of all Deviation Reports and Nonconfor=ing Inspection Reports shall be developed, and those which are not cleared shall be listed on the Quality Control Final Acceptance Punch List (A ttachment "B"). When a nonconforming report is listed as a punch list item, the Quality Control Engineer shall note on the original report the turnover package na=e/ number and the punch list item nc=ber and include this report in the package. For closed NCR's/DR's, the list shall indicate the 'nu=ber of the Inspection Report that closed them out, i i 252 058 ._m m-am-mm*

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que-n-uti Rev. 0 Date: May 4, 1979 IV. PROCEDURE - Continued C. Final Acceptance Insoection - Continued

3. - Continued

d. Co=plete check list (s) and Quality Control Final Acceptance punch list (Attach =ent "3") and asse=ble together with the docu=entation and boundary identifi-cation provided by the Craf t Supervisor for turnover package.

e. Mark-up of syste=, iso =etric, etc., by the QC Engineer to show status of inspection of the syste=.

This status shall be =aintained current by Quality Control.

f. Co=plete Quality Control portion of the Turnover Agree =ent (Attach =ent "C") for turnover to Met-Ed/GPU Start-Up and Met-Ed QC.

g. The Turnover Agree =ent shall be transmitted to the assigned QA Engineer for auditing using Attach =ent "F" which will becc=e a per=anent part of the agree =ent.

If the audit results in any co=:ents and/or discrepancies, they shall be identified on Attach =ent "F" and the agree =ent returned to Quality Control for resolution. When all ce==ents and/or discrepancies are resolved to the satisfaction of QA, Attach =ent "F" will then be signed in the applicable area.

h. After QC and Start-Up acceptance of ibe turnover agreement, the syste= boundaries will be tagged by the Start-Up De pa r t=ent to show the portion of the syste= under Start-Up control.

4. The inspector should give particular attention to co=pleting the check list to assure that the nature and location of punch list ite=s and incomplete and te=porary items are adequately described in the inspection check list.

Entries =ust be clearly stated for subsequent use of the check list by the Lead Start-Up Quality Control Engineer, craft, and Start-Up personnel.

5. The Lead Quality control Engineer or his designate shall review the crr=pleted Turnover Agree =ent (Attach =ent "F"),

checklist, and any deviation, punch list ite=, or ince=plete or te=porary ite=s that =ay have been docu=ented and take the following action- " c7 bb e w - e amm e a mummmmme w w e ae ese e ee e h g

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Qcy-M-v u Rev. 0 Date: May 4, 1979 IV. PROCEDURE - Continued C. Final Accentance Insnection - Continued

5. - Continued

a. Review the checklist and assure that all outstanding punch list ite=s and incomplete or te=porary ite=s are identified in the appropriate section.

Disposition of 4 deviations shall be processed in accordance with i Paragraph IV.D. below. Incomplete ite=s unacceptable for turnover shall be returned by Quality Control to the responsible craft supervisor and doce=ented on Equipment Turnback Sheet (A ttachment "D"). The reason for turnback shall be clearly identified on the Turn-back Sheet.

b. Establish that Final Acceptance Inspectiot has been cc=pleted.

c. Authorize turnover of the syste=, sub-syste=, or equipment using the Turnover-Agree =ent (Atta ch=ent "C").

6. The Lead Quality control Engineer shall maintain syste=

> ketches =arked-up to show inspected syste=s and sub-syste=s. Revisions =ade to drawings of turned over syste=s shall be shown by mark up of the turnover status drawings maintained by QC or the revised drawing =ay be marked up to show the status of turnover. D. Disnosition of Renorted Deviations

1. All non-confor=ing ite=s disclosed in the Final Acceptance,

Inspections must be dispositioned per QCP-M-004 and corrected by the responsible contractor, subcontractor, or craft activity. Inco=plete work ite=s listed on final inspection check lists which are scheduled for future co=pletion to specification require =ents need not be handled per QCP-M-004. t s rJ n /c) O m

QC?-M-012 Rev. O Date: May 4, 1979 V. RE'a'ORK, REPAIR OR MODIFICATI0!{ A. The status of final acceptance inspection of eqt_ip=ent/ systems / portions of systems shall be negated when crafts or contractor personnel perfor:2 repair, rework, or cake modifications. The exception is when the contractor is performing work to resolve punch list items or responding to approved design changes. (Paragraph V.B below. ) 1. If, as a result of rework, r epair or modification, the final acceptance inspection status is to be negated with a turnback to the contractor, the turnback shall be made in accordance with the applicable Test Instruction. A copy of the turnback shall be given to the Lead Mechanical Quality control Engineer prior to work being performed. 2. Upon co=pletion of the work perfor=ed during a turnback, the Quality Control Inspector shall perform an inspection of the affected syste= (or portion of a system), co=po-nent, etc. A supplement to the original Turnover agree =ent shall be prepared and will include a Turnover agree =ent check list (if applicable), punch lists, and any other applicable docu=entation. The Equip =ent No./ Inspection Boundary section of the Turnover Agree =ent shall clearly identify the inspection boundaries. All applicable docu- =entation shall be =ade a part of the per=anent quality control file by the Quality Assurance group. B. The following require =ents apply to work performed by the 5 contractor.on punch list ite=s and design changes: I i { I

Rev. 0 Date:May 4, 1979 V. REWORX, REPAIR OR MODIFICATION - Continued B. - Continued

1. It shall be the responsibility of the contractor's Super-visor to notify the Lead Mechanical Quality Ccatrol Engineer of all work proposed to resolve punch list ite=s reported during the inspections and all work performed per approved design changes.

2. The Quality Control Inspector shall perform an inspection of work resulting from resolutions to punch list itens and the approved design changes using a check list or inspection re-port as applicable.

3. All work and inspection resulting frc= these resolutions shall be documented and will be cade part of the eqt-ipment/syste:

file. Inspection Reports of cleared punch lis: items shall be attached to the data package. Check lists specially pre-pared and approved for use during inspection of systems, ces-ponents, etc. affected by design changes will also be made p art of the Turn-Over data package. All applicable docu=en-tation shall be made a part of the permanent quality control record file by the Quality Assurance Group. 4. If a system has been turned over to Met-Ed/GPC Start-Up and there are punch list ite=s re=aining open that do not affect the integrity or previous testing of the system (i.e., installation of hangers, clean-ep, painting), these may continue to be worked by the Con-tractor without a Turnback notification. Quality Control, upon notification, shall perform an inspection of the work resulting from resolutions to punch list items and doctent the results using a checklist and/or inspection report as applicable. 9 ~~ 'g } } { ]

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Date: May 4, 1979 V. REWORK, REPAIR OR MODIFICATION - Continued B. 4. - Continued A supplement to the original Turn-Over shall be prepared and will include a Turn-Over Agree =ent, checklists (if applicable) and the Inspection Report (s) that indicates those punch list ite=s that have been resolved. If additional ite=s are noted + during the inspections that have not been previously punch listed, they shall be included in the package. C. I: the Constniction turnover package includes syste= drawings and/ or erection drawings, the applicable Craft Supervisor should main-tain a log of those drawings, as required. If, as a result of re-pairs, rework, modifications, etc., revisions are made to any of these drawings, the Craf t Supervisor shall notify the Lead QE that such revisions have been made. The Lead QCE, or his desig-nate, shall review the revised drawings to determine if any por-tions of the turned over systems are affected by the drawing chan ge. The Lead QCE or his designate shall note any such chang-es to turned over syste=s in his syste= file log (See Attachment "E").

1. The QC inspector shall inspect the affected portion of appli.

cable component / system, as shown on the drawing revision, and shall indicate inspection status and initial and date the ap-plicable drawing revision in the syste= file log.

2. For changes made to drawings which do not affect the turned ov-er portion of the syste=s, the Lead Quality Control Engineer, or his designate, shall nott his review of the revised draw-ing in the syste= file log.

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QCP-M-012 [ Rev. O Date:May 4, 1979 VI. SUBCONTRACTORS A. Subcontractors shall notify the cognizant superintendent cr supervisor when an item, system, etc. has been ec=pleted and is ready for turnover. Af ter review of the turnover, the Superintendent or Supervisor shall then notify the Lead Mechanical Quality Control Engineer in writing that the item, system, etc. is ready for final inspection. } B. The Lead Mechanical Quality Control Engineer shall initiate the necessary actions to perform final inspection. VII. OUALIFICATION A. Quality Control Inspectors sho are responsible for inspections of test and checks during Fre-operational Start-Up and Operational phases of the plant shall be qualified to ANSI-N45.2.6 for a Level I or Level II. In addition, the Quality Control Engineers shall meet the recoc= ended educa-tional and experience requirements and the level of capability for Level II or III as speci fied in ANSI-N45. 2. 6. The capabilities and proficiency of Quality Control personnel qualified in accordance with ANSI-N45.2.6 shall be determined by suitable performance de=onstration and a written or oral examination. Certification records, as required by ANSI-N45.2.6 for Quality Control Level personnel, shall be maintained on file. A documented evaluation vill be nade at least once yearly. I / [, ) O f.i u a __

QCP-M-012 Unit No, GPU SERVICE CORPORATION Rev. 0 ' Sheet of QUALITY CCNTROL FINAL ACCEPTANCE INSPECTION CHECK LIST Approved by: Equipment / System Lead Q.C. Engr./ Date Sub-system Nomenclature GPUSC Q. A./Date Weld Map /Insp. Boundry INSPECTICN ACC-REJ REMARKS

1. Verify that inco=plete work, docu=entation and outstand-ing deviations have been re-solved as follows:

a. Verify that hold tags have been cleared.

b. Verify that required out-standing documentation re-quired by bill of =aterials has been received.

c. Verify that all construction related inspections are com-plete.

d. ..rify that installation is as per latest drawing and specification revision. (SAMP LE) Inspector Date J B (Attachment "A") [ ,c; l' -~.

sm. v.. Rev. v Date: May 4, 1979 GPU SERVICE CORPORATICN OUALITY CONTROL PU'2CH LIST TITLE: DRAWING NO. SYSTdM/SUB-SYSTEM NO. 4 EQUIPMENT NO./ INSPECTION BOUNDARY REFEFINCE SPEC. NO. PREPARED EY: QUALITY CONTROL INSPECTOR DATE: REVIENED BY: LEAD QUALIT( CONTROL E'iGINEER DATE: DISTAIBlTTION : DATE ISSUED: SHEET 1 0F PLNCH LIST ~ A preli::tinary inspection and documentation check has been completed. The following ite=s were found to require additional work: Ite= No. Descriution of item ') I 9 h h :) <_ J c. e e e 3 (A tta ch=ent "B") . ~

QCP -M- 012 Rev. 0 GPU SERVICE CORPORATION Date: May 4, 1979 TURNOVER AGREEMENT DRAWING NO. TITLE SYSTEM /SUB-SYSTEM NO. EQUIPrnNT NO./ INSPECTION BOUNDARY REFERENCE SPEC. NO. Quality Control has completed the applicable Final Inspectic-on the above equip:nent/ syste= in accordance with the attached Inspection Check List. We certify that this equip- =ent/syste: has been built in accordance with pertinent plans and specifications, except for the incomplete ite=s and deviations listed on the Check List. Punch List Attached No Punch List Attached PREPARED BY-QUALITY CONTROL INSPECTOR DATE INSPECTICN CCMPLETED: QUALITY CONTROL ENGINEER _DATE REVIEWED: DATE LEAD QUALITY CONTROL ENGINEER ne Start-Up Department accepts the above equipment / system for pre-operational testing. We agree to abide to all Quality Control requirements specified on the Quality Control Pre-Operational Testing Check Lists and to notify the Lead Start-Up Quality Control Engineer of any impending repairs, rework or modifications to the co=ponent/syste. ACCEPTED BY: MET-ED/GPU START-UP DATE ACCEFrED BY: DATE MET-ED QA ' ;: a o ~ [ U,( 3 (Attachment "C") e e -IS-

~ QCP-M-012 Rev. O ? GPU SERVICE CORPORATION Date: May 4, 1979 THREE MILE ISLAND NUCLEAR GENERATING STATICN EQUIPMENT TURNBACK SHEET Unit No. From: Dept. System: To: Dep t. Date: The following equipment is transferred for jurisdictional purposes for work to be perfor=ed as no t ed. EQUIPMENT DESCRIPTION ACCEPTED BY SIGNED FOR DEPT. FOR DEPT. From: Dept. Date: TD: Dept. The work as described has been completed and the equipment is transferred for jurisdictional purposes. EQUIPMENT DESCRIPTION OF WORK DWG. REV. DATE T u / f1 [' '~p LJL

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= ACCEPTED BY; SIGNED DEPT. FOR FOR:_ (Attachment "l)") _16- ~

Kcv. U GPU SERVICE CORPORATION Date: May 4,1979 SYSTEM DRAWING REVISION LOG Syste: No. Inspection Inspection Required Status Dwe. No. Rev. YES l NO ACC. I REJ. Insnector Date Re= arks e .e i 9 e I G fr p ea u._ V '. l l 'y ,A l g i e (Attachment "E ") + @ M

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-n-v u GPU SERVICE CORPORATION Rev. O Date May 4 ' 1979 QA/QC TRANSMITTAL FOPO! FOR TURNOVER AGREEMENT TITLE DWG. NO. SYS EM/ SUE _ SYSTEM NO. EQUIPMENT NO./ INSPECTION BOUNDARY REFERENCE SPEC. NO. In accordance with QCP-M-012, subject Turnover Agreement is being sub -itted to Quality Assurance Ior audit. LEAD Q.C. EhGINEER/Date Subject Agree =ent is being returned to Quality Control for resolution of the below listed comments and/or discrepancies. GPUSC Q.A. ENGINEER / Date The above listed comments and/or discrepancies have been resolved and the Agreement is - now satisfactory. s GPUSC Q. A. ENGINEER / Date SITE Q.A. MANAGER GPUSC/Date Subj ect Agreement has been audited by Quality Assurance with no comments and is satis-factory. GPUSC Q. A. ENGINEER / Date SITE Q.A. MANAGER GPUSC/Date , n) 1: <I r,. ,u-o L (Attachment "F") ~ -18_ -}}