ML20062G006
| ML20062G006 | |
| Person / Time | |
|---|---|
| Site: | Midland |
| Issue date: | 07/26/1982 |
| From: | Bird W, Boos A, Mooney J CONSUMERS ENERGY CO. (FORMERLY CONSUMERS POWER CO.) |
| To: | |
| Shared Package | |
| ML20062G002 | List: |
| References | |
| MPQP-1, MPQP-1-R03, MPQP-1-R3, NUDOCS 8208120223 | |
| Download: ML20062G006 (23) | |
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MPQP-l' l .- REVISION 3 July 26, 1982 Page 1 O
V ATTACHMBIT 1 J
- l
, QUALITY PLAN FOR l UNDERPINNING ACTIVITIES j
A Effective Date July 26, 1982 O
Approved W Manager MPQAD v 4.
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Approved M - - , 5_ eeV Bechtel Assis(ant Project Manager (Y
Approved M NC N w
( Midland Projejt Office j
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miO382-4025a 141-8208120223 820809 PDR ADOCK 05000329 A PDR
MPQP-1 l -
REVISION 3 July 26, 1982 Page 2 4
. sP,i f" QUALITY PLAN FOR UNDERPINM NG ACTIVITIES
- 1. GENERAL All activities for the remedial soils work are covered by the existing Consumers Power Company and Bechtel Power Corporation Topical Reports 4
CPC-1-A and BQ-TOP-1, Revision IA, respectively. This Quality Plan provides a more detailed written description of the accomplishment of activities specific to certain soils remedial work. This Quality Plan was developed to describe how quality programmatic coverage is extended to encompass the underpinning subcontractors as required by the Quality Plan for Remedial Soils Work (MPQP-2).
i' The senior management, consisting of the Vice President of Projects, O En81 neerins end Construction. Consumers eewer ComPenv. and the Midlend l Project Manager, Bechtel Power Corporation (CP Co's contractor for the Midland Nuclear Plant), reviews and approves major decisions and design concepts regarding underpinning work. For CP Co, a Midland Project Office Executive Manager and an Assistant Project Manager, and for Bechtel, a Bechtel Assistant Project Manager, will manage the l
underpinning work. The Bechtel Site Manager manages overall field activities including the underpinning work.
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The Manager of MPQAD and the Civil Section Head will manage the MPQAD support of underpinning work with the overview of the Director of
.j Environmental and Quality Assurance.
- O j miO382-4025a-66-141
3pqp_i REVISION 3 July 26, 1982 Page 3 O QUALITY PLAN FOR UNDERPINNING ACTIVITIES i 2. SCOPE This Quality Plan is applicable to the auxiliary building and service
! water structure tInderpinning tasks. The "Q" list for this work is all i
inclu'sive and, as such, covers activities, items and structures beyond the requirements provided by the FSAR. This extension to provide Quality Assurance Program coverage over and above the coverage for safety related items provides an additional assurance that the non-safety related activities will not have an adverse affect on safety related structures.
The following major categories of the underpinning work are specifically covered by this Quality Plan.
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- 1. Underpinning of the Service water Pump Structure as delineated by Specification 7220-C-194(Q).
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- 2. Underpinning of Auxiliary Building (removal, replacement of fill, and
! underpinning beneath the feedwater isolation valve pit areas, i auxiliary building electrical penetration areas, control tower, and beneath the turbine building) as delineated by Specification 7220-C-195(Q). (Reference MPQP-1)
Any activity or structure which will be excluded from Quality Assurance Program coverage shall be specifically documented on an exception basis.
Assurance of NRC Region III concurrence with any general exclusion from the Quality Assurance Program is required prior to conducting any work activities in the excluded area, miO382-4025a-66-141'
'! MPQP-1 REVISION 3 July 26, 1982 Page 4 f-me QUALITY PLAN FOR UNDERPINNING ACTIVITIES Specifications, procurement documents, drawings and procedures are b O
specific as to the design attributes and activities which require quality verification. The need for verification shall be dictated by the following principal:
The Quality Assurance Program shall provide control over activities affecting the quality.of the identified structures, systems and components to an extent consistent with (a) their importance to safety; (b) their possible detrimental interaction or effect on safety related structures and items; or (c) assuring obtainment of the overall Project objectives.
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3.
UNDERPINNING WORK ORGANIZATIONS Organizations involved with the underpinning are defined in the l l
Functional Matrix, Attachment I and as follows:
CP Co Project Management Sets policy, coordinates licensing review, and submittals to the NRC. l CP Co Safety and Licensing l
Performs licensing reviews and coordinates FSAR revisions.
CP Co Design Production .
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Provides client design input and performs reviews of and comments on
) Bechtel Design Documents.
mt0382-4025a-66-141
MPQP-1 REVISION 3 July 26, 1982 Page 5
/~T QUALITY PLAN FOR UNDERPINNING ACTIVITIES I
CP Co Site Management Provides overview and direction as necessary for underpinning activities for compliance with NRC commitments. Monitors underpinning activities with respect to commercial type items, construction activities (such as l equipment care, labor and production).
4 Bechtel Project Management Coordinates with client and sets project policy for Bechtel organizations.
Bechtel Project Engineering
.(:) Establishes design criteria and reviews input from non-Bechtel sources.
Originates and issues design documents for construction.
Bechtel Project Geotechnical Engineer Functions as Project Engineering's Geotechnical representative on p roj ect. Performs geotechnical reviews related to design criteria and procedures. Interfaces with Geotech Services and Resident Geotechnical i
Engineer.
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2 MPQP-1 REVISION 3 July 26, 1982 Page 6 5 ("T
,' (s QUALITY PLAN FOR UNDERPINNING ACTIVITIES Bechtel Site Management Performs the overall on-site management of all construction activities including coordination between Bechtel, CP Co and Subcontractor.
Includes a Construction Remedial Soils Group who is responsible for coordinating the activities of the underpinning subcontractors.
Geotech Services Provides design and field geotechnical services as requested by Project 4
Engineering.
Resident Geotechnical Engineer
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Performs foundation inspection and on-site geotechnical monitoring of underpinning activities. Interfaces with the Project Geotechnical Engineer.
I Resident Structural Engineer Represents Project Engineering on site and provides structural expertise ,
for the underpinning activities. Receives and evaluates data from the underpinning instrumentation systems.
Bechtel Quality Control (QC)
Performs first-line inspection and verification, of items under the Quality Assurance Program. Reviews construction procedures, drawings and n
(_) specifications for inclusion and establishment of inspection criteria.
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miO382-4025a-66-141
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MPQP-1 REVISION 3
. . July 26, 1982 Page 7 j QUALITY PLAN FOR UNDERPINNING ACTIVITIES i
! Midland Project Quality Assurance Department (MPQAD)
Provides the quality assurance for all underpinning work including work i done by Bechtel and Bechtel Subcontractors. Develops quality plans, reviews design documents and construction procedures. Performs over-inspections and pre planned audits.
l Subcontractor Perform construction activities as contracted for, within the framework of the Midland Project Quality Program.
l i Consultant j
Provides advice to Bechtel Project Engineering or Bechtel Construction on construction methods, design, instrumentation or geotechnical items,
,1 i 4. DESIGN CONTROL Design Control for the underpinning of the Auxiliary Building (Electrical Penetrations and Control Tower Structure), Feedwater Isolation Valve Pit i
'l i fill material replacement and Service Water Pump Structure underpinning j
will be provided by Project Engineering. Engineering Department Procedures (EDPs), Engineering Department Project Instructions (EDPIs),
and Project Engineering Procedures (PEPS) provide the controls for Engineering activities which are responsive to the Quality Program requirements of MPQP-2.
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- MPQP-1 REVISION 3 July 26, 1982 Page 8 O QUALITY PLAN FOR UNDERPINNING ACTIVITIES Design criteria will be developed from input from consultants, the Midland Plant Safety Analysis Report, 50.54(f) responses submitted to the NRC staff, meetings with and submittals to the NRC staff, and testimony during the ASLB Soils hearing.
Design documents, including specifications, drawings and material
! requisitions, shall be specific as to what is required to ascertain that processes, activities and final products meet their design requirements.
Design documents, including specifications and drawings (as well as changes and revisions to these documents), will be reviewed and checked for compliance to design requirements by Bechtel Project Engineering.
() Design documents will be reviewed by Quality Control and MPQAD. The MPQAD review applies to all design documents. (MPQAD Procedure M-11)
MPQAD will act as the focal point for the assurance of the resolution of quality related comments.
Technical specifications and revisions thereof will be generated, reviewed, approved, and controlled by Bechtel Project Engineering in accordance with EDP 4.49. Initial specifications will also be reviewed i
- by CP Co Design Production and comments submitted to Bechtel Project Engineering. Specificatica Change Notices (SCNs), used as interim change documents between revisions of the specification, will receive the same level of review and approval by Bechtel Project Engineering as the basic 3 specifications. Specification Change Notices shall be administered and
. s) controlled in accordance with EDPI 4.49.1. -
miO382-4025a-66-141
MPQP-1 REVISION 3 July 26, 1982 l Page 9 QUALITY PLAN FOR UNDERPINNING ACTIVITIES ,
Project Engineering prepares, reviews, approves, issues and controls design drawings in accordance with EDP 4.46. Changes to engineering drawings receive the same level of review and approval as the basic j drawing and are administered in accordance with EDP 4.47 and EDPI 4.47.1.
Bechtel design calculations are originated, checked, approved, controlled and documented by Project Engineering in accordance with EDP 4.37. All design calculations submitted by the consultant are checked, reviewed and approved by Bechtel Project Engineering in accordance with EDPI 4.25.2.
Bechtel Construction shall request from or notify Project Engineering of changes to design documents by Field Change Requests (FCRs) and Field
() Change Notices (FCNs), respectively. The FCRs will be reviewed, evaluated, dispositioned, controlled and administered in accordance with l EDP 4.62. FCNs will allow Bechtel Construction to initiate field changes I
in design documents within the allowable guidelines of Field Procedure FPD-2.000 and Specification G-34 (Q) as provided by Project Engineering.
FCNs will be reviewed, evaluated, dispositioned, controlled and administered according to EDP 4.62.
The design interface for the underpinning activities between Project Engineering, project groups, technical support groups and consultants shall be administered as illustrated in Attachment 2, Design Document Interface Flowchart. Geotech Services will receive design for review in accordance with EDPI 4.25.2. The Subcontractor receives design documents rx
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MPQP-1 REVISION 3
-July 26, 1982 .,
Page 10 {-
QUALITY PLAN FOR UNDERPINNING ACTIVITIES from Bechtel Construction in accordance with FID 1.100. The Resident i
Structural Engineers duties on site are defined in PEP 2.14.9.
i j Inspections are performed by Bechtel QC to verify that construction is being performed to the latest revisions of the design documents. Audits and/or overinspections are conducted by MPQAD. Field geotechnical activities, including subgrade acceptance, are accomplished in accordance with EDPI 2.14.8.
- 5. PROCUREMENT AND RECEIVING t
Procurement of items and services for the remedial underpinning work is ,
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j performed by Bechtel employing the technical and quality requirements iO established in the specifications and drawings. Q-material requisitions are originated by Bechtel Construction in accordance with FPG-8.000.# -
Bechtel Construction is responsible for assuring that applicable Quality.
Program requirements, design bases, specifications, procedures and drawings are included and referenced in the material requisitions.
Bechtel Field Procurement Department initiates formal purchase orders and ' , '
will be respousible for ensuring that the procurement package conforms to '
the material requisit' ion. MPQAD reviews and approves procurement documents in accordance with MPQAD Procedure M-5 to assure that necessary Quality Assurance Program requirements are included.
Upon receipt of Q-material, inspections are performed by Quality Control in accordance with PSP G-5.1 to verify items comply with the procurement
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package requirements and quality verifications packages are complete.
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MpQp.1 a REVISZON 3 l July 26, 1982 j
Page 11 +.
.} QUALITY PLAN FOR UNDERPINNING ACTIVITIES .
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Quality verification packages are reviewed for availability, traceability ,b b '
and legibility by Bechtel QC and audited by MPQAD (MFQAD Procedured 1M){
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, , In addition, a technical review.v;ill be performed by Bechtel QC in quality verification packages for,non jhop s inspected items. ' ,
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, 1 i 6. PREPARATION AND It.'PLEMENTAT1cNe DF FROCEDURES/ INSTRUCTIONS t ,
4 Written, instructions to dae Subcontractor are in tb form of engineering
{ specif{c ti.e.ns, drawing g and apptoved changes thereto.
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i ? Tae1,0-321D form (controlled by EDP 4.58) xitached to the specifications 4
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identify the procedures and other vendor submittals, whi.yh are the r
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marimum ' ragtired N be submitted by the 'Eubcontractor prior to the start O \;. %
of fabrication and construction.
Theseprocedures2relogged, q ,
contrplied,anddistributedbythe'i'ieldDocumentControlCenterand !
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reylewed y(
- by Project Engineering, Bechtel QC and p'PQAD.
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e u Engineering dafines the specific quality attributes of each proce$ure.
.t,he procedures will be specifically reviewc(by MPQAD for appropriate
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inclusion of quality requirements. (MFQAD Procedure M-10) j These procedures, when approved by Bechtel QC, MPQAD, and Bechte] '
oject Engineeridg, provides authorization for fabrication / construction s ,
p ro cee'd.
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, MPQP-1 REVISION 3 July 26, 1982 Page 12 O
QUALITY PLAN FOR UNDERPINNING ACTIVITIES
- 7. INSPECTION, EXAMINATION, TEST AND CALIBRATION Quality verification, inspection and testing of Subcontractor activities is performed by Bechtel Quality Control, independent of the Subcontractor and Bechtel Construction. Bechtel QC will prepare inspection plans (in accordance with PSP G-6.1) utilizing inputs from technical specifications, design drawings and Subcontractor procedures. Project Quality Control Instructions (PQCIs) are prepared to cover all Subcontractor quality related activities. Existing PQCIs are adapted for standard construction activities such as concrete batching, placement and testing, and reinforcing steel installation. Additional PQCIs are developed as necessary to verify new underpinning activities such as O temporary support installation, load transfer and threaded reinforcing l
connectors. All PQCIs are subject to MPQAD review and approval according to MPQAD Procedure E-2M. In addition, inspection and test activities are monitored by MPQAD through the use of overinspection plans based on an independent evaluation of design and procurement documents per MPQAD Procedure E-1M. The Subcontractor is indoctrinated to Bechtel QC and MPQAD procedures and inspection planning to assure that hold points, l included as an integral part of the Subcontractor's procedures, are adhered to. For site construction activities, the detailed implementing procedures shall utilize integrated construction planning, as follows:
a) Hold points shall be clearly identified in the procedures.
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MPQP-1 REVISION 3 July 26, 1982 Page 13 O QUALITY PLAN FOR UNDERPINNING ACTIVITIES b) The procedures shall provide for QC/QA signoff to record the completion of the inspection holdpoints prior to proceeding with the further execution of subsequent procedural steps.
Tests are performed to qualify, demonstrate or assure that the quality of procured items or completed construction is as defined in applicable engineering drawings and procurement documents.
Calibration, maintenance and control of measuring and test equipment is provided by an approved agency which will be pre qualified by MPQAD.
This agency provides for the traceability to national standards, the unique identification of each instrument or equipment requiring
() calibration, the maintenance of calibration frequencies, and the identification of calibration status. Calibration records are maintained by the agency and transmitted to Bechtel Construction for review. At tne completion of the subcontract, these records will be turned over to Bechtel Quality Control. Performance and effectiveness of the agency is verified by MPQAD audits and/or overinspections in accordance with MPQAD Procedures F-1M and E-1M, respectively.
- 8. HANDLING AND STORAG_EE All Q-list material is stored and handled in accordance with general Field Procedures FPG 4.000 and 5.000 and supplemented by the Subcontractor's procedure. Storage and handling of material and
-- equipment is subject to Bechtel QC inspection and verification according U
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m10382-4025a-66-141
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s MPQP-1 REVISION 3 July 26, 1982 Page 14 (T
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QUALITY PLAN FOR UNDERPINNING ACTIVITIES to PSP G-5.1 and MPQAD overinspections and/or audits per MPQAD Procedures E-1M and F-1M, respectively.
- 9. DOCUMENT CONTROL AND QUALITY RECORDS Subcontractor documents which are to be submitted for review and comment by Bechtel Project Engineering, Bechtel QC and MPQAD are controlled by the Field Document Control Center (FDCC) in accordance with Bechtel Field Procedure FPD 1.000. Prior to the start of work, the Subcontractor submits construction procedures, drawings, purchase orders, as required by the specifications, to Bechtel Construction. Bechtel Construction and the FDCC distributes the procedures for review and approval as defined in
((} the Quality Plans included with specifications 7220-C-194 and C-195.
Bechtel Project Engineering and/or Resident Enginee. ring, as designated, is responsible for resolving review comments.
All quality records are controlled by EDPs 5.16 and 5.24, Bechtel QC Procedure PSP G-7.1 and MPQAD Procedures F-11M and F-12M. These procedures prescribe the requirement for preparation, control, distribution and transmittal of all Q-related procedures, specifications, drawings and inspection records.
- 10. NONCONFORMING ITEMS AND CORRECTIVE ACTION Nonconformances discovered during construction inspection activities are documented and controlled by Bechtel QC in accordance with PSP G-3.2 and
]j MPQAD in accordance with MPQAD Procedure F-2M. These procedures provide miO382-4025a-66-141 ~
MPQP-1 REVISION 3 July 26, 1982 Page 15 O
V QUALITY PLAN FOR UNDERPINNING ACTIVITIES for the identification and documentation of the nonconforming item, identify the authority for and disposition of the nonconforming condition, and provide for documenting the reinspection and closeout of the nonconformance. Bechtel QC and/or MPQAD will be involved in the specific wording of non-conformance reports to assure an accurate description of the condition. Dispositions to non-conformance reports will be reviewed by MPQAD to assure that the disposition is acceptable, that engineering rationale is adequately documented and that quality planning is available for the verification of the disposition. Bechtel QC and/or MPQAD will inspect and provide verification of disposition implementation prior to closing of the non-conformance report. '
O Within the Midland Project Quality Program, the identification of reportable items is accomplished by Bechtel QC and MPQAD through the review of nonconformance reports, supplier surveillances and quality assurance audits. Corrective action for quality problems will be controlled by Bechtel PSP G-3.2 and MPQAD Procedure F-3M.
In the design phase, investigation of cause and action taken to preclude recurrance of design deficiencies will be accomplished through EDP 4.65.
Design deficiencies include those items which are not identified in the course of design development and which ultimately require changes..
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MPQP-1 REVISION 3 -
, July 26, 1982 i
Page 16 QUALITY PLAN FOR UNDERPINNING ACTIVITIES
- 11. AUDITS Audits are performed by MPQAD to verify conformance to quality requirements. MPQAD Procedure F-1M includes provisions for the i
identification of deficiencies, the determination of corrective action, and the necessary follow up to verify that timely and effective action is taken.
- 12. TRAINING AND CERTIFICATION i
All inspectors and quality auditors are trained and certified in i
accordance with PSP G-8.1 or MPQAD Procedures B-2M and/or B-3M.
Subcontractor field supervisory and engineering personnel are
'O indoctrinated to the Midland Project Quality Program. This indoctrination includes an introduction to the quality system, inspection activities, nonconformance control, NRC activities, field and engineering design changes and site organizations and interfaces. The indoctrination is initially completed prior to any Q-listed work proceeding. Additional l training sessions will be scheduled by MPQAD to indoctrinate personnel i
which are assigned after the initial indoctrination. The Subcontractor j is required to implement training for the procedures covering the Subcontractors Q-listed activities.
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miO382-4025a-66-141
MPQP-1
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REVISION 3 July 26, 1982 Page 17 O
u
. LIST OF APPLICABLE Q PROCEDURES 1
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miO382-4025b-66-27
3 MPQP-1 REVISION 3 List of Applicable Procedures July 26, 1982 Page 18 r
M v MIDLAND PROJECT QUALITY ASSURANCE DEPARTMENT PROCEDURES B-2M Personnel Training B-3M Qualification and Certification of Inspection and Test Personnel E-1M Site Inspection Planning and Site Inspection E-2M Review of Site Inspection Planning Prepared by others than MPQA F-1M Audit F-2M Nonconformance Reporting, Corrective Action and Statusing F-3M Resolution of Significant Quality Problems F-11M Documentation Control F-12M Quality Records 1
M-5 QA Review of Bechtel Field-Originated Procurement Documents
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M-10 MPQAD Review of Subcontractor Procedures and Instructions for Underpinning Related Activities M-11 MPQAD Review of Bechtel Design Specifications, Drawings and Procedures for Underpinning and Related Remedial Activities.
ENGINEERING DEPARTMENT PROCEDURES EDP - 4.37 Design Calculations EDP - 4.46 Project Drawings EDP - 4.47 Drawing Change Notice EDr.- 4.49 Project Specifications EDP - 4.58 Specifying and Reviewing Supplier Engineering and Quality Verification Documentation EDP - 4.62 FCR/FCN EDP - 4.65 -Design Deficiency miO382-4025b-66-27
MPQP-1 REVISION 3 List of Applicable Procedures July 26, 1982 Page 19 D'
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EDP - 5.16 Supplier Document Control EDP - 5.24 Document Distribution Control Center O
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MPQP-1 REVISION 3 List of Applicable Procedures July 26, 1982 Page 20 O
-FIELD PROCEDURES I
l FPG-8.000 FMRs FPD-2.000 Field Change Request / Field Change Notice FPG-4.000 Storage Maintenance / Inspection of Equipment and Materials FPG-5.000 Maintenance / Inspection of Material and Equipment Released for Construction FID-1.100 Vendor Document Review FPD-1.000 Field Documentation of Correspondence Control PROJECT SPECIAL PROVISIONS PSP G-3.2 Control of Nonconforming Items PSP G-5.1 Material Receiving and Storage Control
() PSP G-6.1 Inspection Planning PSP G-7.1 Document, Records and Correspondence Control PSP G-8.1 Qualification, Evaluation, Examination Training and Certification of Construction Quality Control Personnel ENGINEERING DEPARTMENT PROJECT INSTRUCTIONS EDPI - 2.14.8 Resident Geotechnical Engineer for Midland Remedial Underpinning Operation.
EDPI - 4.1.1 Preparation of Design Requirements Verification Checklist.
EDPI - 4.25.2 Interface Control Design Documents for Remedial Soils Underpinning Operation.
EDPI - 4.47.1 Interim Drawing Change Notice for the Midland Project 7220 EDPI - 4.49.1 Specification Change Notification
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miO382-4025b-66-27
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MPQP-1 REVISION 3 List of Applicable Procedures July 26, 1982 Page 21 PROJECT ENGINEERING PROCEDURES -
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MPQP-1
. REVTSION 3 JULY 26, 1982 PROJECT FUNCTIONAL MATRIX = = "," ..
FOR UNDERPINNING ACTIVITIES a
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