ML20072A860

Rev 1 to Quality Verification Program Midland Nuclear Co Generation Plant Units 1 & 2

ML20072A860
Person / Time
Site:	Midland
Issue date:	05/24/1983
From:	CONSUMERS ENERGY CO. (FORMERLY CONSUMERS POWER CO.)
To:
Shared Package
ML20072A848	List: ML20072A844 ML20072A850 ML20072A860
References
PRO483-0014A-QL, PRO483-0014A-QL07-R1, PRO483-14A-QL, PRO483-14A-QL7-R1, NUDOCS 8306100272
Download: ML20072A860 (64)

Text

. .- 5 APPENDIX 1

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UNCONTROLLED o QUALITY VERIFICATION PROGRAM

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MIDLAND NUCLEAR C0 GENERATION PLANT UNITS 1 AND 2 Index of Topics

1. Purpose

2. Scope 2.1 Remedial Soils Activities 2.2 HVAC Activities 2.3 Cable Routing and Identification Reinspection 2.4 ASME Hanger Reinspection 2.5 B&W Construction Activities

3. References

4. Definitions

5. Program Content 5.1 Detailed Scope 5.2 Methodology 5.3 Identification of Deficiencies 5.3.1 Deficiencies Found During Reinspection of Accessible Attributes 5.3.2 Deficiencies Found During Reinspection of Inaccessible Attributes

6. Special Program Elements 6.1 Cable Reinspection 6.2 In Process Inspection Notices and Discrepancy Reports 6.3 Exceptions to this Plan 6.4 Purchased Material 6.5 Inaccessible Attributes l

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8306100272 830603 PDR ADOCK 05000329 A PDR l

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j - QUALITY VERIFICATION PROGRA'i MIDLAND NUCLEAR C0 GENERATION PLANT UNIIS 1 AND 2 Index of Topics

7. Documentation and Reports 7.1 Documentation of Results  ;

7.2 Documentation of Nonconformances 7.2.1 Trending 7.3 Reports 7.3.1 Reports to Executive Manager - MPQAD 7.3.2 Reports from Executive Manager - MPQAD 7.3.3 Reports to NRC and Construction Implementation Overview Team

8. Implementation 8.1 Organizational Responsibilities 8.1.1 MPQAD - BOP QA 8.1.2 MPQAD - BOP QC 8.1.3 MPQAD - Site Audit Section 8.1.4 MPQAD - QA Administration and Training i

9. Appendices

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A. List of PQCIs B. PQCIs to be Verified by Documentation Review C. Statistical Sampling Plan N

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1 UE0NTROLLED v) QUALITY VERIFICATION PROGRAM

-Midland Nuclear Cogeneration Plant Units 1 and 2 1.

Purpose:

To confirm through a verification program under the direction of Consumers Power Company, the acceptable quality status of safety related procurement and construction activities completed and inspected by the Engineer-Constructor quality control personnel prior to December 2, 1982.

2. Scope: This program will cover all closed Inspection Records of in-spections performed by the Engineer-Constructor quality control personnel on safety related material, systems, components and structures of the Midland Nuclear Cogeneration Plant Units 1 and 2 prior to December 2, 1982, except:

{j 2.1 Remedial Soils Work, which has been under the direction of Consumers Power Company Quality Assurance (QA) personnel since August, 1982.

2.2 HVAC work, which has been under the direction of Consumers Power Company QA personnel since the major reorganization in June 1981.

2.3 Verification of cable routing, identification and other accessible attributes which is being done on a 100% reinspection basis in accordance with PQCI E-4.0.

2.4 Verification of ASME hangers which will be done under a separate O- reinspection program as previously committed to the NRC on November '

15, 1982 and March 29, 1983. This program requires 100% reinspec-Rev. 1, 5/24/83 PR0483-0014A-QLO7

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.' 2 I k- tion of all hangers with closed IR's as of December 1982. This program will be conducted under the direction of Consumers Power

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Company QA personnel.

2.5 B&W Construction Company activities which have been performed under the B&W Quality Assurance Program.

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References:

3.1 Regulatory Guide 1.58, Rev 1, Qualification of Nuclear Power Inspection, Examination and Testing Personnel.

{} 3.2- MPQAD Procedure E-3M, Preparation and Approval of Project Quality Control Instructions

4. Definitions:

Population: The entire quantity of closed Inspection Records (IR) as of December

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2, 1982 relating to a specific PQCI.

Project Quality Control The document that provides Quality Instruction (PQCI): Control Engineers (QCEs) with specific direction as to attributes to be verifi-ed, how they are to be verified and the

- acceptance criteria.

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Inaccessible: An item or attribute of an item which, due to its physical location or config-uration, cannot be physically or visual-ly reinspected without removing and thereby invalidating installed work.

Under the Quality Verification Program, thisincludesthoseitemsorattributes normally inspected in process and which subsequent construction processing makes inaccessible, eg, piping fit-up, root veld and subsequent layers under the cover pass, anchor bolt hole drilling,

( internal cleanlinesc, embedment in concrete, etc. Inaccessible does not include those items which can reasonably be reached by scaffold erection, limited access (remote) areas which require the physical size of the inspection person-nel to be limited or those items that can be viewed by removal of access cover i

> or panels, eg, electrical consoles, cabinets, conduit boxes, etc.

The inaccessibility of attributes covered by insulation or coatings will be Rev. 1, 5/24/83 PR0483-0014A-QLO7

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b handled on a case by case basis. When such coverings can be practically removed and replaced and where their particular reinspection is required to establish an acceptable level of confidence of the quality of a particu-lar attribute, the coverings will be removed. Items which fall into this category and are scheduled for verifi-cation in accordance with plan require-ments will not be considered inaccessi-ble unless so approved on a case by case j

basis by the Executive Manager - MPQAD.

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Inspection Record (IR): A report that scopes the inspection to

, be performed, relating it to a specific

,e PQCI ar.d a system, component, structure or portion thereof and which records the results of inspections.

In Process Inspection A form previously used to record noncon-Notice (IPIN): forming conditions on work returned to construction forces for rework prior to completion of inspection activities for the unit in question.

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(' Discrepancy Report (DR): A form similar to the IPIN and used to report ir: process nonconformances.

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Nonconformance Report (NCR): A document used for reporting noncon-forming conditions.

Reinspection: As used in this Verification Program, reinspection means a complete review of requisite documentation and a physical or visual recheck of accessible in-spection attributes covered by a speci-fic PQCI or a review of applicable inspection records and related quality

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documentation where attributes are not accessible.

Inspection by Attributes: Inspection whereby the characteristic or item or attribute is classified simply as conforming or nonconforming without regard for the degree of nonconformance.

Nonconformance: A deficiency in characteristic, documen-tation or procedure which renders the quality of an item unacceptable or indeterminate.

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Verification: As used in this program, verification refers to the overall process of estab-lishing the quality acceptance of the total population of completed and inspected work through combinations, as applicable, of efforts such as re-inspec-tion documentation review, review of past efforts to investigate and resolve problems, analysis of past overin-spection results and, if necessary, NDE

~ techniques and destructive examination.

() 5. Program Content: As identified in Section 2, Scope, Consumers Power Company (CPCo) will conduct a Quality Verification Program of safety x

related procurement and construction work in which the prior 100% in-spections have been performed under the direct supervision of the Engi-neer-Constructor. Such inspections were performed in accordance with approximately 100 PQCIs, as listed in Appendix A, that specified the i

inspection requirements to be achieved by Ouality Control (QC) Personnel.

As noted in section 5.1, this listing includes all inspections completed by the Engineer-Constructor prior to December 2, 1982, including those excluded from this program for reasons stated herein. The Quality Verifi-cation Program has the purpose of establishing a quality baseline for the completion of construction of the Midland' Project.

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'O 5.1 Detailed Scope: The program will include approximately*100,930 irs:

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subject bo the Quality Verification Program, for which the Engi ,

neer-Constructor has a record of completed inspections as docuteent-

,, ^3 l ed by closed Inspection Records (IR) and for which no,other 2007,< l s s verification activity has taken place or is scheduled to take i N

l place. There are approximately 147,500 closed irs'oi which ap *

. l proximately 14,700 were for reinspections which occurred due to

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, s , m design change, construction rework, etc., and app'reximately 31,890 3 l \

t which are excluded, due to previous commitments onder the Remedial I

( e , x l Soil, HVAC, Cable routing and identification and ASME Hanger ~

j ql Programs. Where a reinspection has occurred on a epecific item or j i attribute the verification will relate to the latest IR. In I-.

. addition, prior to the use of PQCIs, Material Receipt Inspections

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j (MRI), Field Inspection Plans (FIP) and Welding Inspection WR-5 , y i / -

t forms were used as quality instructions and records.:s These also '

l s will be used for quality verification. Where applicable, the results of the inspections will be~ grouped vidh like PQdI's. Other-v 1l

• wise they will be treated as separate populations.

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5.2 Methodology

This program will provide assurance of the quality:of (

q completed work and establish the validity of prior inspect!1ons. To j accomplish this, accessible' attributes of item'scoveredjycom-

1. t pleted irs will be reinspected to the lastest design, requirements '

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with PQCI's which have been reviewed and, revised to assuta clarity . y. .

of acceptance criteria and uniformity of implementation. $'or ,

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X.) 5 , inaccessible attributes, the original inspection document will be reviewed for evidence of acceptability, and justification will be developed as described in section 6.5 to establish hardware quality and support the validitySof inspections associated with such PQCIs.

Each IR relates to a specific PQCI. PQCIs are organized by disci-

! pline and further structured to activities within that discipline,

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e.g., there are separate PQCIs and corresponding irs for pre-placement, placement' and post-placement inspections of concrete.

' Closed irs related to each PQCI provide a population of like activities. Closed irs are those where the Engineer-Constructors i 100% inspection of construction and installed hardware has been

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completed. 'N Os.

{JToassessthevalidityofthesepastcompletedinspections,and 9 m l

j verify the, hardware quality, CPCo will initiate a 100% reinspection

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of the pfpulation to provide adequate confidence that safety l

l related systems components and structures will perform satis-

, s-factorily in service. .N i

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[ u,. The' initial 100% reinspection effort will be based on a sys-

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, tems/ area orientation to provide a quality baseline for subsequent -

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l construct'.on completion activities. sSystem/ area reinspections will H _ 5.

! be supplemented by random plant-wide inspections as appropriate to i

establish a valid quality baseline on an expeditious basis. i (h

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been established 'CPCo will make'a determination as,to whether or

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not further verification efforts can' appropriately be based on less than a 100% reinspection program. t When CPCo believes that sufficient just.ification exists for a reduction in the 100% commitment, it will recommend such a re-duction to the NRC in accordance with the statistical sampling plan attached as Appendix C.

5.3 Identification of Deficiencies: Any nonconforming condition observed during the implementation of this program other than those O Previe 17 1ae=tiziea e co rer e ce rePerte. w111 de ia titiea by a nonconformance report and will be dispositioned in accordance with established procedures.

5.3.1 Deficiencies Found During Reinspection of Accessible Attributes: Reinspections will be conducted in accordance with PQCIs which have been reviewed or revised since imple-mentation of the Construction Completion Program (CCP) and in accordance with current design drawings and specifi-cations. An acceptable reinspection will validate both the hardware quality and the prior IR. Any deficiencies, other than those previously identified on nonconformance raports as a result of prior inspections, will be identified on a Rev. 1, 5/24/83 PR0483-0014A-QLO7

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10 nonconformance report which will be traceable to both the verification and original IR and the item or attribute in question. When a nonconformance documents a difference between the as built condition of the unit and the refer-enced design drawing or specification, a further check will be made to determina. the design basis against which the IR wac originally completed, as well as the current stage of construction, to further establish the validfty of the original 1R.

5.3.2 Deficiencies Found During Reinspection of Documentation for Inaccessible Attributes: The verification process for

() . inaccessible attributes is discussed in Section 6.5. As noted in that section, any documentation deficiencies will be recorded on the new IR, entered on a nonconformance report and cross referenced to the original IR.

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6. Special Program Elements 6.1 Cable Reinspection: As noted in Section 2, Scope, reinspection of routing and identification of installed cables is underway and is being performed 100% for all accessible attributes per PQCI E-4.0.

Other electrical work, including cable tensioning and terminations, on which inspections have been completed by the the Engineer-Con-structor will be handled in accordance with this program. This gg V

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( includes PQCIs E-1.0, E-1.1, E-1.60, E-2.0, E-2.1, E-3.1, E-5.0, E-6.0, E-6.2, E-6.6 and E-6.6.1. These PQCIs are further defined and affected quantities of irs are shown in Appendix A.

6.2 IPIN and DR: In accordance with approved procedures the QC inspec-tion process has used in the past In Process Inspection Notices (IPIN) and Discrepancy Reports (DR) rather than Nonconformance Reports (NCR) to record nonconforming conditions noted by the inspector on work returned to construction for rework. The process required that IPINs be dispositioned before the Inspection Record could be closed. Because the use of IPINs and DRs raises the possibility that a complete inspection may not have been performed on items or_ attributes covered by irs with associated IPINs or DRs,

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all such irs will be treated as a unique population and wi31 be reinspected 100%. IPINs are no longer used in the inspection process. Discrepancy Reports (DR) were used prior to the use of the IPINs. They are no longer in use, but are recorded and will be treated the same as the IPIN.

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6.3 Exceptions to this Program: Exceptions to this Program shall not be taken unless such exceptions can be fully justified. One such example would be a case where objective evidence is available of a CPCo overinspection of the the Engineer-Constructor's inspections and which demonstrates effective quality contrel and provides the basis to verify acceptability of the items or attributes covered by A

kl these past irs.

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(~'r 52 Where such exceptions are proposed to be taken, a special report will be prepared by the MPQAD-QA General Superintendent for review and approval of the Executive Manager-MPQAD. This report will contain full justification for the exception and docurentation of objective evidence to support the exception. The Executive Mana-ger-MPQAD will inform the NRC Region III whenever he has made a decision to allow such an exception to the Program prior to imple-menting the exception.

6.4 Purchased Materia _1_* Purchased safety related material and com-ponents whether source inspected or inspected upon receipt are subject to this Program for verification of completed receipt

{} inspections performed by the Engineer Construction prior to Decem-ber 2, 1982. In many cases, purchased items have been installed f and are not fully accessible for reinspection; however inaccessible t

interfaces will have been demonstrated and their functional accepta-bility proven through installation and subsequent testing. Access-t ible features will be reinspected in accordance with this Program, 1

i The total number of irs associated with PQCI R-1.00, Material l

l Receiving Inspection, is approximately 12,000. In addition, prior l to the introduction of PQCI R-1.00, approximately 150 MRIs and 20 l

FIPs-were used for receipt inspection, covering approximately 700 items. Based upon further review, receipt inspections covered by I MRIs will either be grouped with like items covered by PQCI R-1.00 or be reinspected separately. FIPs were also us2d for construction l

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-O activities and will be treated separately under this plan. Wherc ,

materials such as rebar, certain structural members or features of I components are inaccessible fcr reinspection, documentation will be reviewed in accordance with this Program.

6.5 Inaccessible Attributes: There are 57 PQCIs which cover activities that appear to be ineccessible for reinspection. These include rebar installed in placed concrete, containment building tendon reinspection, and PQCIs relating to surveillance of subcontractor actions. A complete listing of these is given in Appendix B to j this Program. A brief statement as to why attributes of these irs are considered inaccessible and why verification by documentation

() review is appropriate appears in Appendix B. Documentation re-lating to these PQCIs will be reviewed as indicated in this Pro-

gram, in accordance with a revised PQCI or checklist specifically developed for review of documentation. These PQCIs, either in-dividually or by groups, will be reviewed and specific detailed justification will be developed to verify the quality status of l associated hardware. This will be done by a combination of meth-ods, applied as necessary to achieve verification, including valid-ation of prior inspections through documentation review, rein-spections of attributes that may still be accessible, a review of

_ _y-past overin:pections, a review of past activities to resolve problems, and if required, application of NDE techniques or limited destructive examinations. This justification, or recommendations O

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V for additional verification activities, where this justification cannot be established, will be provided by the MPQAD-QA General

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Superintendent to the Executive Manager-MPQAD for decision and approval. Deficiencies in documentation will le reported on nonconformance reports, the disposition of which will determine further actions necessary. These actions will include special testing programs as required to satisfactorily establish the quality acceptance of this category of PQCIs.

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7. Documentation and Reports:

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7.1 Documentation of Results: Results of reinspections and document

() reviews will be recorded on new irs opened specifically for this purpose. Each such new IR will be cross-reference to the closed original IR. A proper notation will be made on the new IR to identify whether the existing original inspection covered by the IR was validated, rejected or is indeterminate. The new IR will j provide the basis to document the quality status of the items or attributes b ing reinspected.

7.2 Documentation of Nonconformances: Nonconforming conditions ob-l served during reinspection activities will be documented on a

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j nonconformance report and apprcpriately analyzed for management l

attention. This includes instances where a design or construction modification has occurred since the Inspection Record was closed I

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and a new IR not yet opened. (Note discussion in Section 5.3.1) l Rev. 1, 5/24/83 PR0483-0014A-QLO7

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. 7. 2.g Trending: Deficiencies noted during the verification process will be trended cs appropriate for analysis and management information.

7.3 Reports

7.3.1 -Reports to Executive Manager-MPQAD: A weekly status report will be made jointly by the CPCo BOP Quality Control (QC)

Superintendent and Quality Assurance (QA) General Super-intendent to the Executive Manager - Midland Project Quality Assurance Department (MPQAD) summarizing the results of the program. The report will note the completed Inspection (G/

Reports by the unique PQCI number, Nonconformance Reports issued and identification of attribute (s) causing the l nonconformance(s).

l 7.3.2 Reports from Executive Manager-MPQAD: The Executive Mana-ger-MPQAD will inform the CPCo' Site Manager, the Engineer-Constructor Project Manager, and the Vice President, Pro-jects, Engineering and Construction, of the status of the quality verification program on a biweekly basis and will provide them with a formal monthly report of the verifi-cation effort. As appropriate, he will also report on the acceptability of completed work as it may be impacted by nonconformances.

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/m O, 7.3.3 Reports to NRC and Construction Implementation Overview Team: The Executive Manager-MPQAD will provide copies of the monthly reports noted in section 7.3.2 to NRC Region III and the Construction Implementation Overview Team.

8. Implementation: This program will be implemented under the direct control of MPQAL through procedures approved and issued according to normal programmatic requirements.

8.1 Organizational Responsibilities: The Executive Manager-MPQAD has total overall responsibility and authority for the development and implementation of all quality related aspects of this verification

() program. He will be responsible for seeing that the implementation phase _of the program is coordinated with other project departments as required to assure proper support for this plan commensurate with overall project goals.

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8.1.1 MPQAD - BOP QA: is responsible for the programmatic elements of the verification program including, but not limited to, i

procedure development, PQCI review and approval, nonconfor-mance review, analysis of results, justification for docu-l l ment review, verification of Inaccessible attributes, program content modifications and certifying that the verification has been completed for a given area or system, l

1 and performing management overview of the reinspection l

process with appropriate documentation of results.

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17 l 8.1.2 MPQAD - BOP QC: is responsible for program implementation

j. including, but not limited to, conducting the reinspection L activities with QC personnel that satisfy Regulatory Guide l

f 1.58, Rev 1, which requires personnel certification in accordance with ANSI N45.2.6 (no person will reinspect activities for which he performed the original inspection),

reporting results to the Executive Manager-MPQAD, reporting

, s nonconformances to MPQAD-BOP QA, and coordinating with I

i Construction Services and Consumers Site Management Office to establish schedule priorities for reinspection activi-l I

ties.

l /~T - 8.1.3 MPQAD - Site Audit Section: is responsible for formal audits l %)

l of the overall verification program implementation.

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8.1.4 lMPQAD'- QA Administration and Training: MPQAD Procedures

,- will be developed in accordance with programmatic require-ments to direct implementation of this plan.

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5/24/83 A LIGT OF ALL PQCI'S WITH QUANTITY AND REINSPECTION INFORMATION PQCI # PQCI TITLE QUANTITY DOC'T llARDWARE REMARKS C-1.02 Compacted Backfill 181 Hardware & documentation ttnder remedial soils program @

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C-1.09 Inspection of Crack for BWST Hardware & documentation under remedial soils program Foundation Ring Wall 5 C-1.10 Insp of Grouting Surface condition and --4 and Dry Packing 1833 documentation c=>

C-1.11 Erilling & Grouting Rebar 66 i x C-1.20 Concrete Preplacement Inspection of remaining Inspection 767 i 1 unplaced concrete areas plus past documentation C-1.21 Inspection of Inspection of accessible Reinforcing Steel 259 i rebar plus past documentation C-1.22 Inspection of Reinforcing Inspection of accessible Steel at Construction rebar at remaining joints Joints 19  ! plus past documentation PR0483-0014F-QLO7 KEY:

1 Document-Review documentation for completeness

! Hardware-Reinspect accessible attributes x Hardware-Attributes not acessible for reinspection

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5/24/83 i

A LIST OF ALL ?QCI'S WITH QUANTITY AND REINSPECTION INFORMATION PQCI # PQCI TITLE QUANTITY DOC'T HARDWARE REMARKS C-1.30 Concrete Placement i Inspection ,

780 x C-1.31 Inspection of Concrete Activities 246 i x C-1.40 Concrete Post Inspection of concrete Placement Inspection 1002 1 i surfaces plus documentation i C-1.50 Installation and Testing Inspection for proper --

of Expansion Anchors 4982 installed condition ,

C-1.51 Retest Verification of

Drop In Expansion Anchors 54 x

i' C-1.52 Reinspection of Seismic Category I Pipe Support Expansion Anchors 294 3 x C-1.53 Reinspection of 4 Expansion Anchors for Seismic Cat I Support 0 PR0483-0014F-QLO7 KEY:

! 1 Document-Review documentation for completeness

! Hardware-Reinspect accessible attributes x Hardware-Attributes not acessible for reinspection

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5/24/83 A LIST OF ALL PQCI'S WITH QUANTITY AND REINSPECTION INFORMATION PQCI # PQCI TITLE QUANTITY DOC'T HARDWARE REMARKS C-1.56 Reinspection of Rock Bolt Installation 20 x C-1.60 Concrete Drilling and Cutting Reinforcing Steel 325  : x &

C-1.70 Installation of Pressured Concrete Pipe 2 x C-1.80 Installation of Concrete Unit Masonry 102 x C-1.81 Installation of Concrete Unit Masonry 139 i x C-1.90 Installation of SWI Sluice Cates 0 .

C-2.00 Plant Area Dewatering 59 Hardware and documentation under remedial soils program PR0483-0014F-QLO7 KEY: /t i Document-Review documentation for; completeness Hardware-Reinspect accessible attributes x Hardware-Attributes not acessible for reinspection

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• APPENDIX A R2v 1 4 of 20 5/24/83 A LIST OF ALL PQCI'S WITH QUANTITY AND REINSPECTION INFORMATION PQCI # PQCI TITLE QUANTITY DOC'T HARDWARE REMARKS C-2.02 Permanent Gravel Hardware and documentation Packed Wells 17 under remedial soils program C-2.03 Drawdown Recharge One time test under remedial Test I soils program I

C-2.05 Drilling Q-Listed

] Areas for Underpinning i Operations 14 Remedial Soils Program C-2.10 Structural Steel Inspection of accessible Erection 121 1 attributes plus documentation

! C-2.11 Installation of Watertight and Airtight Doors O C-2.20 Field Fabrication of Miscellaneous Steel 1502 x C-2.21 Field and Offsite Fabrication of Reinforcing Steel 0 PR0483-0014F-QLO7 KEY:

1 Document-Review documentation for completeness

! Hardware-Reinspect accessible attributes x Hardware-Attributes not acessible for reinspection

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5/24/83 A LIST OF ALL PQCI'S WITH QUANTITY AND REINSPECTION INFORMATION PQCI # PQCI TITLE QUANTITY DOC'T HARDWARE REMARKS C-2.56 Load Monitoring of the Remedial Soils Program _,

Feedwater/ Isolation Valve Pit Rod & Rock Bolt 0 C-3.01 Installation Inspection Inspection of accessible of Spent Fuel Storage attributes plus documentation Racks 20 C-3.02 Installation Inspection Inspection of accessible of Spent Fuel Storage attributes plus documentation Racks 8 1 1 C-3.03 Inspection of Test for Acceptability of the Spent Fuel Rsck Cells 0 ,

N C-4.10 Batch Plant Inspection 929 x C-5.10 Shear Connector Installation 503 1 x C-6.00 Mechanical Splicing of Reinforcing Bars 787 i x PR0483-0014F-QLO7 KEY:

1 Document-Review documentation for completeness i Hardware-Reinspect accessible attributes x Hardware-Attributes not acessible for reinspection

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6 of 20 5/24/83 A LIST OF ALL PQCI'S WITH QUANTITY'AND REINSPECTION INFORMATION

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PQCI # PQCI TITLE DOC'T QUANTITY HARDWARE REMARKS C-7.00 Erection of Reactor Building Liner Plate 10 x C-8.50 Inspection of Surface Preparation Application Touch Up & Repair of Coating 908 1 x C-8.51 Inspection of Inspection of surface Decontamination Coat condition plus documentation for Concrete 17 i  !

C-8.60 Inspection of Surface Preparation Application Touchup & Repair of Coatings Reactor Bldg Liner Plate 0 l C-9.00 Installation-Post

( Tensioning Components 40 x l C-9.10 Post Tensioning l

System Stressing 309 1 x l

PR0483-0014F-QLO7 KEY:

1 Document-Review documentation for completeness i Hardware-Reinspect accessible attributes x Hardware-Attributes not acessible for reinspection

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APPENDIX A Rev 1 7 of 20 -

5/24/83 A LIST OF ALL PQCI'S WITH QUANTITY AND REINSPECTION INFORMATION I

PQCI # PQCI TITLE QUANTITY DOC'T HARDWARE REMARKS C-9.20 Containment Bldg Tension Reinsp 11 1 x CW-1.00 Welding & NDE Inspection of surface of "Q" Listed Non condition and radiographs ASME Items 381 i plus documentation E-1.0 Installation of Inspection of accessible Conduit Boxes and attributes plus documentation Supports 4716 1 E-1.1 Installation of Inspection of accessible Boxes 9 i attributes plus documentation E-1.60 In Process Inspection .

of Electrical Item Installation 85 x E-2.0 Installation of Inspection of accessible Cable Tray and attributes plus documentation Wireway 1368 i  !

E-2.1 Installation of Inspection of accessible Tray Supports 799 i attributes plus documentation PR0483-0014F-QLO7 KEY:

1 Document-Review documentation for completeness i Hardware-Reinspect accessible attributes x Hardware-Attributes not acessible for reinspection

O O lAPPENDIX 0 A, Rrv 1 8 of 20 .-

5/24/83 A LIST OF ALL PQCI'S WITH QUANTITY AND REINSPECTION INFORMATION PQCI # PQCI TITLE QUANTITY DOC'T HARDWARE REMARKS ll

, E-3.0 Final Electrical l Area Completion Activity 0 ,

E-3.1 Electrical System.

Turnover Activities 108 i x l

E-4.0 Installation of Inspection of accessible

Electric Cables 7954 x attributes has been accomplished under cable routing & ID program i

, E-5.0 Cable Terminations 12361 1 Inspection of accessible j attributes plus documentation l E-6.0 ( Installation of Inspection of accessible attributes plus documentation Electric Equipment and Instrumentation 346 i i

E-6.1 Modification of Combine with RW 1.10 Electric Equipment 209  ! 1 Inspect accessible l attributes plus documentation l

PR0483-0014F-QLO7 KEY:

1 Document-Review documentation for completeness i Hardware-Reinspect accessible attributes x Hardware-Attributes not acessible for reinspection l

O O O .-

APPENDIX A. Rav 1 9 of 20

, 5/24/83 A LIST OF ALL PQCI'S WITH QUANTITY AND REINSPECTION INFORMATION PQCI # PQCI TITLE QUANTITY DOC'T HARDWARE REMARKS

/ l E-6.2 Installation of Inspect accessible Terminal Boxes 108 i attributes plus documentation t

E-6.6 Installation of Inspect accessible I?caq %g

~

Electric Penetrations 127 i attributes plus documentation s

E-6.6.1 Installation of Feed Inspect accessible Through Assy's for attributes plus documentation Elec Penetration 388 1 1 E-6.7.1 Installation of Inspect accessible Batteries & Racks 9 i attributes plus documentation RW-1.10 Modification to Combine with E-6.1

. Electrical Equipment 144 i Inspection of accessible attributes plus documentation I-1.10 Instal 3ation of Inspection of accessible Instruments 159 1 attributes plus documentation i

j M-1.00 Installation of Inspection of accessible Mechanical Equipment 11 1 1 attributes plus dscumentation i

PR0483-0014F-QLO7 KEY:

> 1 Document-Review documentation for completeness i Hardware-Reinspect accessible attributes x Hardware-Attributes not acessible for reinspection

O O O  ;

APPENDIX A, Riv 1 -

10 of 20 5/24/83 A LIST OF ALL PQCI'S WITH QUANTITY AND REINSPECTION INFORMATION PQCI # PQCI TITLE QUANTITY DOC'T HARDWARE REMARKS M-2.00 Installation of 28 i Inspection of accessible Rotating Equipment attributes plus documentation M-3.10 Installation of Inspection of accessible Cranes 1 attributes plus documentation I

M-4.00 Complete Installations Inspection of accessible of Mechanical attributes plus documentation Equipment 2 i MP-1.00 Disassembly Reassembly Inspection of accessible and Modification of attributes plus documentation Systems and Components 4 1 1 4

i MW-1.00 Welding and NDE Rev 1 of Mechanical Equipment 0 P-1.00 Piping Completed Inspection of accessible Line Installation 80 i attributes plus documentation P-1.10 Piping Subassembly Inspection of accessible Field Installation RW 1858 1 attributes plus documentation PR0483-0014F-QLO7 KEY:

Document-Review documentation for completeness i Hardware-Reinspect accessible attributes x Hardware-Attributes not acessible for reinspection

O' O O APPENDIX A. L7 1 .-

11 of 20

~

5/24/83 A LIST OF ALL PQCI'S WITH QUANTITY AND REINSPECTION INFORMATION I

l PQCI # FQCI TITLE QUANTITY DOC'T HARDWARE REMARKS

, P-1.20 Piping Subassembly Inspection of accessible Shop Fab & Rework 994 1 i attributes plus documentation

) P-1.30 Valve and Inline Inspection of accessible Component Install 1247 i  ! attributes plus documentation 3

P-1.60 In Irocess Insp

Fab / Installation i Rework of Piping 167 i x i

P-2.00 Pipe Component Inspection of accessible Supports Final Setting 5 1 i attributes plus documentation P-2.10 Pipe (Component) Inspection of accessible Support Installation 7057 i attributes plus documentation P-2.20 Fipe (Component) Inspection of accessible Supports Fabrication 6460 attributes plus documentation -

P-2.30 Pipe (Component) Closed IR's from P-2.10 and Support P119/P129 P-2.20 will be reinspected Walkdown 0 to requirements of P-2.30 where installed PR0483-0014F-QLO7 KEY:

1 Document-Review. documentation for completeness

/ 1 Hardware-Reinspect accessible attributes x Hardware-Attributes not acessible for reinspection

r_. _ _ _ _ _ _ . _ _ - . _ _ _ _ _

73 3 Q ). ~~

APPENDIX A. Riv i 12 of 20 5/24/83 A LIST OF ALL PQCI'S WITH QUANTITY AND REINSPECTION INFORMATION PQCI # PQCI TITLE QUANTITY DOC'T HARDWARE REMARKS PF-1.10 Pipe Flange Installation Inspection of accessible and Rework 820 attributes plus documentation PI-1.40 Field Fabrication and Inspection of accessible Installation of Piping attributes plus documentation .

Related Instrumentation 204 i PI-2.40 Off-Site Fabrication / Inspection of accessible Weld of Pipe Related attributes plus documentation Instrument Supports 84 PIW- Welding and NDE of Inspection of accessible 1.00 Instrument Tubing and attributes plus documentation Fittings 642 1 PW-1.00 Fab / Weld / Heat Treat Inspection of acceusible and hDE of ASME Ill attributes plus documentation Piping 31014 1 i R-1.00 Material Receiving Inspection of accessible Inspection 12007 1 1 attributes plus documentation PR0483-0014F-QLO7 KEY:

Document-Review documentation for completeness i Hardware-Reinspect accessible attributes x Hardware-Attributes not acessible for reinspection

O O -

O  :

APPENDIX A. Riv i 13 of 20 5/24/83 A LIST OF ALL PQCI'S WITH QUANTITY AND REINSPECTION INFORMATION POCI # PQCI TITLE -

QUANTITY DOC'T HARDWARE REMARKS R-1.60 Receiving Area and Walk through of existing Storage Facilities conditions plus documentation Inspection 45 x R-2.00 Receiving Inspection for NSS Equipment 198 i x R-2.10 Receiving Inspection for NSSS Equipment 42 i / x R-2.20 Receiving Inspection

, for NSSS Equipment Documentation 217 i x S-1.00 Storage Area / x Walk through of Facilities Surv 67 '

i - 'x, existing conditions plus

\ \ review of documentation s \

SC-1.05 Material Testing Services 306 x PR0483-0014F-QLO7 KEY:

1 Document-Review documentation for completeness i Hardware-Reinspect accessible attributes x Hardware-Attributes not acessible for reinspection

O '

O .O  ;

APPENDIX A, Rav 1 i 14 of 20 5/24/83 A LIST OF ALL PQCI'S WITH QUANTITY AND REINSPECTION INFORMATION .

PQCI f PQCI TITLE QUANTITY DOC'T HARDWARE REMARKS i

SC-1.06 Recoating hork of Cont Bldg Liner Plate, Misc Steel, and Pipe l Ha ger Attachment 0 SC-1.07 Agreement for Tech Services for Soils ,

Laboratory Testing 0 SC-1.10 Earthwork Subcontract Surveillance O SC-1.11 Concrete and Unit Masonry Surface Sub/

Contract Surv 406 x SC-1.14 Subcentract Surveillance

of Installation of Underpinning 0 SC-1.16 Field Erected Storage Tanks / Subcontract Surveillance 108 i x

! PR0483-0014F-QLO7 KEY:

1 Document-Review documentation for completeness Hardware-Reinspect accessible attributes x Hardware-Attributes not acessible for reinspection .

APPENDIX A, Rrv 1-4 15 of 20 -

5/24/83 A LIST OF ALL PQCI'S WITH QUANTITY AND REINSPECTION INFORMATION PQCI # PQCI TITLE QUANTITY . DOC'T HARDWARE REMARKS SC-8.00 Subcontractor Surv of Installation of Soil and Crack Monitoring Devices 58 Remedial Soils Program SE-1.00 Measuring and Testing Equipment Laboratory -

Surveillance Inspection 31 1 x ,

i SM-1.03 Heat Ventilation and Air Conditioning "

D j Subcontact Surveillance 828 x i

i s

SM-1.04 Field Erected Component Cooling Water Surge Tanks Subcontracts Surveillance 108 x i

SM-1.17 Field Fabricated Incore-

! Installation Tanks l Subcontract Surveillance 183 x SW-1.01 NDE-Subcontractor Surveillance 120 i x PR0483-0014F-QLO7 KEY:

1 Document-Review documentation for completeness

, i Hardware-Reinspect acceseible attributes l

x Hardware-Attributes not acessible for reinspection

- . . - . . ~

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APPENDIX A, Rav i 16'of 20 5/24/83 A LIST OF ALL PQCI'S WITH QUANTITY AND REINSPECTION INFCRMATION PQCI f PQCI TITLE QUANTITY DOC'T HARDWARE REMARKS T-1.00 Hydrostatic and Pneumatic Leak Testing 460 x T-1.10 Final Cleaning of Interior Surfaces of Piping, Mech Equipment and Instrumentation 0 T-5.00 Lift Test for Cranes 0 W-1.00 Welding, Heat Treat- Inspection of accessible ment and Non Destructive attributes, radiography plus Examination 20251 1  ! documentation W-1.60 Area Inspection Of In Process Activiti - For Welding Q-Listed And ASME III Items 164 1 x C-1.01 Excavation in Q-Soil ,

Area NA RemedialSoil'sbrogram

- / i

\

ty.PR0483-0014F-QLO7 KEY:

' ' 94* 1 Document-Review documentation for completeness

~

4- Hardware-Reinspect accessible attributes

• %% x Hardware-Attributes not acessible for reinspection

,9 ,

x J kJ .

APPENDIX A, Rav 1 17 of 20 -

5/24/83 A LIST OF ALL PQCI'S WITH QUANTITY AND REINSPECTION INFORMATION PQCI f PQCI TITLE QUANTITY DOC'T HARDWARE ' REMARKS C-2.01 Gravel Packed Wells 224 Documentation and hardware is under remedial soils program C-2.22 Field Fabrication Of O' Reinforcing Steel C-3.05 Inspection of The Remedial Soils program Feedwater Isolation Valve Pit Jacking Operation NA EU-1.0 Installation Of Conduit Documentation and hardware

& Box For Under is under remedial soils Pinning Data Aquisitions program System 61 EU-4.0 Installation Of Electrical Documentation and Hardware is Cables For Under Pinning under remedial soils program Data Aquisition System 117 EU-5.0 Cable Termination For Under Documentation and Hardware is Pinning Data under remedial soils program Aquisition System 178 PR0483-0014F-QLO7 KLY:

Document-Review documentation for completeness Hardware-Reinspect accessible attributes x Hardware-Attributes not acessible for reinspection

O O O  :

APPENDIX A R v 1

!' 18 of 20 -

5/24/83 1 -

A LISI 0F ALL PQCI'S WITH QUANTITY AND REINSPECTION INFORMATION

+

! PQCI # PQCI TITLE QUANTITY DOC'T HARDWARE REMARKS EU-6.0 Installation Of Instruments Documentation and Hardware is

. For Under Pinning under remedial soils program Data Aquisitions System 25 EU-6.1 Installation Of Instrument Documentation and Hardware is Supports For Under under remedial soils program 3 Pinning Data Aquisitions

! System 29 i

i 1 IC-1.0 Instrument Chectnut 67 Documentation and Hardware is under' remedial soils program RM-1.00 Storage & Maintenance Remedial soils program Of Material Released To Mergentine NA RS-1.00 Storage & Maintenance Remedial soils program Of Material Released To Spencer, NA White & Prentis i

4 i

PR0483-0014F-QLO7 KEY:

Document-Review documentat' ion for completeness Hardware-Reinspect accessible attributes x Hardware- Attributes not acessible for reinspection l

O O APPENDIX A, Rev l' Ch  :

19 of 20 ' I

• 5/24/83 m

,q A LIST OF ALL PQCI'S WITH QUANTITY AND REINSPECTION INFORMATION

/-

( .

PQCI # PQCI TITLE QUANTITY DOC'T HARDWARE REMARKS SCM-1.0 Crack Monitoring Of Documentation and Hardware is The Feedwater Isolation under remedial soils program Valve Pits Sub-Contract Surveillance 36 ,

SD-1.0 Monitoring, Reducing and Documentation and Hardware is' Reporting I'nder Pinning under remedial soils _ program

~ -

Instrunc.:. Data Sub-Contracts Surveillance 189 UP Documentation and Hri'rdware is C-1.004 Welding And NDE Of under remedial soils program "Q" Material 8 UP Documentation and Hardware is C-1.008 Excavation And Lagging under remedial soils program I

Of Access Pits Piers and Drifts For UP 1 /

1 UP Documentation and Hardware is C-1.010 Field Fabrication Of Steel under remedial soils program Sets For Under Pinning Of Aux Bldg

& FIVP 5 x

PR0483-0014F-QLO7 KEY: \

1 Documeh -Review.s documentation for completeness Hardware-Reinspect accessible attributes x Hardware-Attributes not acessible for reinspection L__ . .

O O O  :

I APPENDIX A, Rrv 1.

I 20 of 20 .

5/24/83 A LIST OF ALL PQCI'S WITH QUANTITY AND REINSPECTION INFORMATION t

The Remedial Soils' Program has initiated the following additional PQCI's for which there are no Engineer-Constructor IR's, Inspections have all been conducted by CPCo supervision UP-C-1.002 UP-C-1.011 UP-C-1.019 SD-2.0 UP-C-1.003 UP-C-1.012 UP-C-2.003 UP-C-1.005 UP-C-1.013 UP-C-2.004 UP-C-1.006 UP-C-1.014 UP-C-2.005 UP-C-1.007 UP-C-1.015 UP-C-2.007 UP-C-1.009 UP-C-1.016 UP-C-2.008 UP-C-1.011 UP-C-1.017 UP-C-2.009 UP-C-1.019 UP-C-1.018 UP-C-2.010 i UP-C-1.020 UP-C-2.019 UP-C-1.023 UP-C-2.042 UP-C-2.150 UP-C-3.001 4

RM/RS-1.00 i

i KEY j i Document-Review documentation for completeness

i Hardware-Resinspect accessible attributes x Hardware-Attributes not accessible for Reinspection PR0483-0014F-QLO7

. - _ _ _ _ _ _ _ _ _ . _ _ _ _ _ _ _ _W

UNCONTROLLED PQCIs To Be Verified by Review of Documentation Only , j The following PQCIs are deemed inaccessible for attribute reinspection.

Hardware acceptability will be established by documentation validation where possible and by supplemental verification efforts where document-ation review alone does not establish hardware acceptability:

1. Remedial Soils Program C-1.02 - Compacted Backfill C-1.09 - Inspection of Crack for BWST Foundation Ring Wall C-2.00 - Plant Area Dewatering C-2.01 - Gravel Packed Wells C-2.02 - Permanent Gravel Packed Wells C-2.05 - Drilling in Q-Listed Areas for Underpinning Operations EU-1.0 - Installation Of Conduit and Boxes For UP Data Acquisition System EU-4.0 - Installation Of Electrical Cables for UP Data Acquisition System EU-5.0 - Cable Termination for UP Data Acquisition System i EU-6.0 - Installation Of Instruments For UP Data Acquisition System EU-6.1 - Installation Of Instrument Supports For UP Data Acquisition System IC-1.0 - Instrument Checkout For UP Data Acquisition SCM-1.0 - rack Monitoring Of FW Iso Valve Pits Subcontractor Surveillance v)

Rev 1, 5/24/83 PR0483-0013A-QLO7 Page 1 of 10

A ls / SD-1.0 - Monitoring, Reducing and Reporting UP Inst. Data Subcontractor Surveillance UP-C-1.004 - Welding And NDE of Q-Material UF-C-1.008 - Excavation & Lagging of Access Pits, Piers and Drifts Fct UP UP-C-1.010 - Field Fabrication Of Steel Sets for UP Of Aux. Building and FIVP.

The above PQCIs relate to the remedial soils program which has been established as a separate project and .for which inspections have been performed under the direction of MPQAD since August 1982. Soils work and related documentation have been reviewed by MPQAD for acceptability and corrective measures-instituted where required.

13 V

2. Reinspection of Expansion Anchors and Rock Bolt Installation.

C-1.51 - Retest Verification of Drop In Expansion Anchors C-1.52 Reinspection of Seismic Category 1 Pipe Support Expansion Anchors.

C-1.56 - Reinspection of Rock Bolt Installation The above PQCIs relate to reincpections which have been completed and results reported to the NRC.

3. In-Process Activities.

O Rev 1, 5/24/83

, PR0483-0013A-QLO7 Page 2 of 10

~

~ u - - -

r;;

1 .

f,. .. .

O E-3.1 - Electrical System Turnover Activities E-1.60 - In Precess Inspection of Electric Item Installation R-1.60 - Receiving Area and Starage Facilities Inspection W-1.60 - Area Inspection Of In Process Activities For Welding Q-list.ed and Af,ME III Items S-1.00 - Storage Area / Facilities Surveillance P-1.60 - In Process Inspection of Fabrication / Installation Rework of Piping The above PQCIs relate to in-process activities where affected work would now be completed and any reit.spection would be of completed work covered by other PQCIs, e.g., PQCIe E-6.0, W-1.00 and PW-1.00. In the' cases of O R-1.60 and S-1.00, these are an inspection or surveillance of general facilities maintenance which can be repeated, but not on a basis which would have any meaning relative to conditions existing when the in-spections were made. In short, a singla inspection can attest to con-ditions existing today without relation to past conditions.

\

4.. Surveillance of Subcontractor Activitie2.

N SC-1.05 - Material Testing Services SC-1.ll - Concrete and Unit Masonry Surface Subcontract Surveillance SC-1.16 - Field Erected Storage Tanks Subcontractor Surveillance O

Rev 1, 5/24/83 l PR0483-0013A-QLO7 Page 3 of 10 l

L. ~.

- SC-8.00 - Subcontractor Surveillance of Installation of Soil and Crack Monitoring Devices SE-1.00 - Measuring and Testing Equipment Laboratory Surveillance Inspection

.SM-1.03 HVAC Subcontract Surveillance SM-1.04 - Field Erected Component tooling Water Tank Subcontractor Surveillance SW-1.01 - NDE Subcontractor Surveillance SM-1.17 - Field Fabricated Incore Installation Tank Subcontractor Surveillance The above PQCIs all relate to surveillance of subcontractor activities.

Where work han not been completed, such surveillance activities can be pJ repeated when safety related work resumes. Otherwise, they can be evalu-ated only by a review of documentation and a single walk down of affected areas for assessment of current inplace conditions, but not of past activities. In addition, SM-1.03 - HVAC Subcontractor Surveillance, relates to activitica outside the scope of this quality verification i

program. ,In depth participation by CPCo continues in this work.

l l S. Hydrostatic and Pneumatic Leak Testing.

I l

l T-1.00 - Hydrostatic and Pneumatic Leak Testing

(

CPCo has already conducted an extensive evaluation of hydrostatic and

' pneumatic leak testing and corrective actions relative to such evaluation l

are being conducted separately from this reinspection program.

Rev 1, 5/24/83 PR0483-0013A-QLO7 Page 4 of 10

-O V 6. Special "One Time only ' Test.ing.

C-2.03 - Drawdown Recharge Test.

This is a test required to have been performed once and which demonstrated acceptable results. The remedial soils prcgram which is not within the scope of this verification program would provide any necessary justifi-cation for a repeat of such a test.

7. Previously Documented Responses to the NRC.

C-6.00 - Mechanical Splicing of Reinforcing Bars r

k This PQCI relates to necessery inspections of the "Cadweld" process of mechanically splicing reinforcing steel. The constructor' rocesses were the subject of extensive Investigation by the NRC in 1973 and '1974 : hich f

determined that corrective action had been identified and. implemented including requalification of personnel, review of work instructions for Class I work, CPCo QA review of work procedures, and audits of Class I work. Affected mechanically spliced rebar is now inaccessible due to concrete placement. CPCo overinspection of any continued use of this process in remaining construction will be a continuing process.

C-7.00 - Erection of Reactor Building Liner Plate O

Rev 1, 5/24/83 PR0483-0013A-QLO7 Page 5 of 10

J

(_) This PQCI relates to the preparation and installation of steel plates which provide the inner surface for the containment building. The liner is now accessible only from one side, being backed up by reinforced concrete on the outside. Extensive review was made by CPCo in 1974 of the accuracy of liner plate records. Centrols implemented after NRC investi-gation were evaluated and found satisfactory. In 1977, a deformation of liner plate occurred due to ireezing of an embedded construction water line. This resulted in extensive removal and replacement of steel liner plates. Quality of the liner plate installations have been verified through radiography, and extensive CPCo involvement in the installation and repair. The NRC has reviewed actions taken and closed its reports on the installation of steel liner plates.

O C-1.11 . Drilling and Grouting of Rebar This PQCI provides documented instructions for the drilling and grouting of reinforcement steel and in itself is a corrective action for previously cited deficiencies that such a procedure did not exist. Its usage is documented evidence of the implementation of corrective action.

C-5.10 - Shear Connector Installation This PQCI is used to assure that the proper installation of shear connect-ors has bden accomplished which tie the supporting beams, steel and concrete floor decking into a composite structure. Since the shear Rev 1, 5/24/83 PR0403-0013A-QLO7 Page 6 of 10

connector serves as concrete reinforcement, it is not visible once the concrete is placed. NRC reviewed corrective actions relative to in-stallation' problems with Nelson stud shear connectors and closed reports relative to this problem. PQCI 5.10-7Rs document accomplishment of required inspections.

C-8.50 - Inspection of Surface Preparation Application Touch Up and Repair of Coating This PQCI addresses the preparation of concrete surfaces and the appli-cation of'a coating to seal the surface to prevent contamination being absorbed into the concrete. Once the coating is applied, the surface preparation cannot be examined. The final coating can be examined for presence but not for the process steps that applied the coating.

C-1.60 - Concrete Drilling and Cutting Reinforcing Steel This PQCI describes the quality control steps necessary in drilling concrete to minimize cutting of reinforcing steel. Completion of the PQCI-IR identifies whether proper inspections were made and results encountered and documented. Since the holes will have been drilled, and l items either mounted in the holes or the holes grouted, it is not possible L to physically inspect the concrete or the reinforcement. This is par-- i l

ticularly true where expansion anchors have been used which cannot be  ;

nondestructively removed.

O Rev 1, 5/24/83 PR0483-0013A-QLO7 Page 7 of 10

-, eIf

8. Post Tensioning Requirements, f

I C-9.00 - Installation-Post Tensioning Components C-9.10 - Post Tensioning System Stressing C-9.20 - Containment Building Tension Reinspection These PQCIs document the re-routing of tendon sheathing, tendon install-ation and tensioning. CPCo identified a problem to the NRC in 1977 indicating the misplacement of two tendon sheaths and the omission of two sheaths. The misplacement of the two sheaths brought about approved re-routing of the tendons. The omitted sheaths were replaced. The NRC

~

conducted a special investigation of the corrective measures in May 1977 and deemed them acceptable. A final 50.55(e) report was issued by CPCo in August 1977.

9. Concrete Placement Activities.

C-1.30 - Concrete Placement Inspection \

C-1.31 - Inspection of Concrete Activities The PQCIs relate to inspections during placement-of concrete. Where concrete has been placed, inspections will be m E in accordance with

~

C-1.40 " Concrete Post Placement Inspection." Where concrete has not been placed, a preplacement inspection will be required betore placement when construction is resumed.

4 O Rev 1, 5/24/83 i

PR0483-0013A-QLO7 Page 8 of 10

t A

s- C-1.80 Installation of Concrete Unit Masonry C-1.81 Installation of Concrete Unit Masonry Thesa PQCIs relate to the installation of concrete block valls many of which have been removed as a result of subsequent plant modifications.

The remaining walls can be inspected for presence of the wall and visual quality but not for the process controls necessary to properly erect them.

C-4.10 - Batch Plant Inspection This PQCI was prepared for necessary controls of concrete batch plant activities. The batch plant has now been removed from the site. Concrete necessary for completion of the plant is procured from an offsite suppli-er, Currently concrete is procured only for the Soils program and for non-Q construction. Reinspection is limited to. review of documents of past operations. Adherence to this PQCI will be enforced on procured concrete for balance of plant safety related constructions when con-struction is resumed.

10.. Field Fabrication C-2.20 - Field Fabrication of Miscellaneous Steel.

l l

This PQCI addresses fabrication of steel which will have been consumed and I.

erected into items which will be inspected if accessible, under other

~O PQCIs.

Rev 1, 5/24/83 PR0483-0013A-QLO7 Page 9 of 10 L

O' 11. NSSS Receiving Inspection Activities.

R-2.00 ---Receiving Inspection for NSSS Equipment R-2.10 - Receiving Incpection for NSSS Equipment R-2.20 - Receiving Inspection for NSSS Equipment Documentation These PQCIs address the constructor's receiving inspection of components and mater.tsis used by the NSSS supplier constructor. In general, the items will have been installed by that contractor. Any accessible attri-butes will have been confirmed by activities of the NSSS constructor.

12. Other.

C-1.70 - Installation of Pressured Concrete Pipe This PQCI covered the installation of the main water line from the river to the cooling pond. This line 'is now submerged as the pond is full.

Inspection of internal surfaces could be performed through use of divers.

Integrity has been demonstrated through use of the system. '

l E-4.0 - Installation of Electrical Cables One hundred percent reinspection of installed cables has been completed

! and reported under a separate program. Documentation has not yet been reviewed. l Rev 1. 5/24/83

( PR0483-0013A-QLO7 Page 10 of 10

APPENDIX C, Rav 1 Pags 1 of 16 STATISTICAL SAMPLING PLAN INDEX OF TOPICS 1.0 Purpose 2.0 Scope 3.0 References I

4.0 Definitions 5.0 Plan Content 5.1 Detailed Scope 5.2 Description of Sampling 5.3 Sampling Process 5.4 Sampling Tables 5.5 Determination of Lot Sizes 5.6 Sample Selection

() 5.7 Substitution 5.8 Increased or Reduced Sampling 5.9 Treatment of Reinspection Deficiencies 5.10 Deficiencies Found During Reinspection of Documentation 6.0 Documentation and Reports

(

1 6.1 Documentation of Results 6.2 Documentation of Nonconformances 6.3 Reports 7.0 Implementation O -

5/24/83 PR0483-0014B-QLO7 l .,'_--..

APPENDIX C, Rev 1 Paga 2 of 16 SAMPLING PLAN FOR CPCo QUALITY VERIFICATION PROGRAM 1.

Purpose:

To provide a statistically valid method, under the direction of Consumers Power Company, of confirming the acceptable quality status of safety related procurement and construction activities completed and inspected by the Engineer-Constructor Quality Control personnel prior to December 2, 1982.

2. Scope:

This plan applies to closed Inspection Records (IR's) related to specific Project Quality Control Instructions (PQCI's) where the quantity of closed IR's is in' excess of one hundred and for which there are no other ongoing d /

or planned programs to confirm quality.

3.

References:

/ ,

MIL-STD-105D Change Notice 2 (March 1964), Sampling Procedures and Tables r

for Inspection by Attributes.

US NRC I&E Bulletin 79-02, Reinspection of Anchor Bolts.

MIL-HDEK-53-1A 1 FEB 1982 - Guide for Attribute Lot Sampling and MIL-STD-105.

4. Definitions:

Population: The entire quantity of closed -

(IR's) relating to a specific PQCI.

O 5/24/83 PR0483-0014B-QLO7

APPENDIX C, Rev 1 Pagn 3 of 16 Time Centered: The term used to describe the ordering of lots, and items within a lot, based upon the time sequence in which an IR ~

was initiated Homogeneity: Homogeneity implies that a series of units of product should be alike or similar in nature. Homogeneity under this plan will be achieved by utilizing specific project Quality Control In-struction (PQCI) categories covering like activities and generally within a defined time period.

Acceptance Number (AC): The number of nonconformances permitted

- to be found in a sample of a lot without rejecting the lot for a specific accept-able qtality level.

Rejection Number (Re): The number of nonconformances found in a sample of a lot that requires rejection of the lot for a specific acceptable l quality level.

O 5/24/83

, PR0483-0014B-QLO7

b a " A * " - - '-

APPENDIX C, R;v 1 1 Paga 4 of 16  ;

O(_/ Acceptable Quality Level (AQL): Tite AQL is the maximum percent of nonconformances that, for the purpose of sampling inspection, can be considered satisfactory as a process average.

Attribute: An attribute is a characteristic or property which is appraised in terms of j whether it does or does not comply with a given requirement.

Inspection by Attributes: Inspection for which the item or attribute is classified simply as conforming or nonconforming without regard for the degree of nonconformance.

Limiting Quality (LQ): The term applies to sampling plans that l

provide not less than a specified l

percentage of quality protection.

Consumers Power Company has selected an LQ of five percent which provides 95%

confidence that at least 95% of inspec-tion elements of the lot / population will be acceptsble. -

5/24/83 PR0483-0014B-QLO7

.- APPENDIX C, Rav 1 Pegs 5 of 16 Lot: A quantity of items, such as completed inspection records covering the same 7

activity, equal to or less than the total population and representing a subdivision of that population.

Nonconformance: A deficiency in characteristic, documen-tation or procedure which rendere the quality of an item unacceptable or indeterminate.

Pa - Probability of Acceptance: The probability of accepting a lot with a predetermined percent defective, when a given sample plan is used.

Random Sample: A sample taken from a population or lot in which each of the items has an equal N.

- chance of being selected, regardless of its quality. If the units in a lot have been arranged without bias as to their x quality a sample drawn anywhere in the lot will meet the requirements for randomness . PQC1's are logged in accordance with the date they were opened, totally independent of the O

(1 Mil-Hdbk 1A Para 12.2) 5/24/83 PR0483-0014B-QLO7

.- APPENDIX C, Rav 1 Page 6.of 16 resulting quality, thus sampling by logged date or other means meets this requirement.

Sampling Plan: A sampling plan indicates for a given lot size the number of items or compo-i nents from each lot (sample size or a series of sample sizes) which are to be inspected from the lot and the criteria for determining the acceptability of the lot.

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.+ APPENDIX C, Rev 1 Pegs 7 of 16

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-\ / 5.0 Plan Content 5.1 Detailed Scope: This sampling plan applies to c1csed Engineer-Constructor IR's related to specific Project Quality Control Instruction (PQCI's) for Balance of Plant safety related materials, components, systems and structures, which are not covered by other ongoing programs to confirm quality. It is applicable to closed IR's where the quantity of closed irs for a given PQCI is in excess of 100 and where it has been demonstrated by one hundred percent inspection of a significant portion of each population that the accepted quality level of that population has been established. The specific PQCIs and quantities of closed irs that make up this total population are identified in Appendix A.

That appendix also indicates whether both hardware and document-ation are planned to be verified or whether documentation alone is planned to be reviewed because of inaccessibility of hardware features.

5.2 Description of' Sampling: Sampling inspection is that type of activity in'which units of product are selected at random and examined for one or more quality attributes. Sampling inspection is an acceptable way of determining the conformance or noncon-formance of items to specified quality requirements. The amount of inspection can be increased where the product quality is deterior-ating or reduced where the level of quality is high .

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APPENDIX C, Rsv 1 Pags 8 of 16 Statistical sampling methods force one hundred percent verification of quality whenever the required quality level has not been at-tained. The statistical methods proposed herein are designed to provide 95 percent confidence that the inspectable elements of the entire population are acceptable based upon the acceptability of items or attributes previously 100 percent inspected to provide a satisfactory quality baseline. This is consistent with past NRC recommendationn related to reinspections of safety related items and will produce results at least equivalent to those expected from 100% inspection.

The statistical quality control methods proposed are in accordance n

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with MIL-STD-105D Tables I, IIA and VIIA. MIL-STD-105D is probably the most widely used sampling standard in the United States. Thgs

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Program is a rigorous app,lication of statistical quality control methods to assess the quality of nuclear power plant construction.

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(3 NCR I&E Bulletin 79-02, Appendix A)

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... APPENDIX C, Rev 1

'Pagt 9 of 16 b

V 5.3 Sampling Process: The application of statistically valid sampling plans requires lot sizes to be large enough to permit taking of a s:tmple quantity sufficient to limit the risk of accepting noncon-forming items. When quantities are not large enough, one hundred percent reinspection will be performed. Because of the Limiting Quality planned to be used, populations of PQCI items are required to be greater than 50 to be eligible for sampling further; however, CP Co has committed to performing 100 percent inspectica of PQCIs having 100 or less irs. In addition, populations to be sampled must be first qualified by having demonstrated acceptable quality levels through one hundred percent inspection of a quantity of itama sufficient to provide adequate confidence the existing quality level is acceptable. When 100% inspections have estab-lished this confidence, CPCo will consider that the one hundred percent inspection of a significant portion of each PQCI has established a valid basis for statistical sampling of any remain-ing quantities.

The statistical sampling plan will be conducted as follows:

Two lots for each PQCI will be sampled at normal sampling levels in accordance with MIL-STD-105D, Tables I, IIA and VIIA to a limiting quality of 5 percent at a 95 percent confidence level. If these two successive lots validate that the required level of quality has been maintairied, remaining lots will be samplad to the same crit-eria, but at reduced sampling levels per MIL-STD-105D, Table IIA.

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APPENDIX C, Rav 1 Pega 10 of 16 The Executive Manager may recommend to the NRC discontinuance of further sampling where quality levels have demonstrated that past

-Engineer-Cons'tructor inspections have provided acceptable control j of quality.

5.3.1 Suitching

The sampling plan will include switching pro-cedures to provide Consumers Power Company the protection provided by the tightened plan, when evidence that the desired quality level is below prescribed levels and the advantage of the reduced plan, when evidence that the desired quality level has been achieved. Due to the known quantities of spccific PQCI's available for sampling (non-continuous production run) the following switching rules will be implemented:

o Establish acceptable base quality level through 100%

reinspection.

o Single normal plan for two lots.

o From single normal, switch to single reduced, after acceptance of two consecutive lots. Switch back to single normal after the first rejected lot.

o From single normal, switch to single tightened, after the first rejected lot for two consecutive lots, then switch back to single normal if both lots are acceptable. If either or both of the single tightened lots are rejected switch to 100%

, () inspection of lots, until two consecutive lots are accepted.

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'l N APPENDIX C, Rev 1 f Pcgm 11 of 16 hs#

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(V~h 5.4 Sampling Tables: The following tab es indicate sampling inform-l l

I atiort for Single Normal, Single Reduced and Single Tightened sampling plans:

1 SINGLE NORMAL j Population Sample Accept Rej ect Lot Size Size Number Number N n _ic Re

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2-50 ALL 0 1 51-500 50 0 1 501-1200 80 0 1 1201-3200 125 2 3 3201-10,000 200 3 4 10,001-00 315 7 8 SINGLE REDUCED 2-50 ALL to 20 0 1 51-500 20 0 1 501-1200 32 0 1 1201-3200 50 1 2 3201-10,000 80 1 2 10,001-00 125 3 4 SINGLE TIGHTENED

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! 0-80 All 0 1 l 80-500 80 0 1 j 500-1200 125 0 1 1201-3200 200 3 4 3201-10,000 315 5 4 10,001-00 500 10 A I

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APPENDIX C, Rsv 1 Pggs 12 of 16 (O_ ,/ The specific PQCIs and total quantities of closed Inspection Records to which these lot and sample sizes apply are included in Appendix A to the Quality Verification Program.

5.5 Determination of Lot Sizes: A reinspection lot is a collection of units of product (closed inspection records of like activities) from which a semple is drawn and inspected to determine conformance with the acceptance criteria and may differ from a-collection of units designated as a lot for other purposes such as production or procurement'. Iba size of the lot is one of the factors that determines the sample size to be used in sampling inspection. For this prograu the formation of each lot is planned to be at least equal to the normal sample size for the entire population; thus for s

a population of 1000, the minimum lot _ size would be 80; the op-timal lot size would be 281 or greater.

Normally the total quantity of the population will not be a direct multiple of the lot size. After dividing the population quantity (4 Mil-Hdbk - 53 Para 6.4.1)

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APPENDIX C, Rev 1 Pags 13 of 16 A

js.) by the lot quantity, any residual quantity may be combined with the last lot, or be treated separately'for sampling ccnvenience so long as the sample size is in accordance with MIL-STD-105D. Lots will be tima centered. The purpose of this is to further enhance homoge-neity for each lot and to identify and isolate conditions which may

.t have occurred in specific time periods during construction of the Midland Plant. This method of stratifying samples and lots, yields l

more information for corrective action than sampling the entire population. Quantities used for determining lot sizes will exclude inspection records where reinspections have occurred, since this will preclude counting the same item twice. A limited number of PQCI's cover like actEv~ities. These will be grouped, where appro-

! priate, to provide a single population. An example of such group-ing would be PQCI's E-6.1 and RW-1.00, " Modification of Electrical Equipment."

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5.6 Sample Selection: Samples will be selected by dividing the lot size by the sample size indicated by MIL-STD-105D Tables I and IIA for normal sampling. For example, for a lot of 500, the sample

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size is 50. In this case any of the first 10 irs and every tenth IR for a specific PQCI would be selected for reverification. This assures randomness, since the manner of filing is totally indepen-dent of the quality of the item and of the person selecting the sample, and all irs have an equal chance of selection. It also provides a cross section as related to time, since the irs are O

5/24/83 PR0483-0014B-QLO7

1

, ' - APPENDIX C, Rev 1 Pags 14 of 16 logged by the date they were opened. Where there are multiple lots of the same size, the same method may be used, so that each sequent-ial lot is time centered with the preceding lot and each item sampled is time sequenced within the lot.

5.7 Substitution

Where accessibility is found to inhibit inspection of attributes of a specific item intended for sample reinspection, the Executive Manager-MPQAD has sole authority to direct the selection of a substitute random item for reinspection from the same lot, or in the event that no item (s) is accessible for rein-spection, a documentation review of the inaccessible item (s).

Justification for this substitution will be documented.

O 5.8 Increased or Reduced Sampling: The Executive Manager-MPQAD has authority to direct 100% reinspection at any point where the ability to conduct a valid sample reinspection is determined to be impractical. Switching to reduced or tightened sampling will require prior approval by the Execut!.ve Manager-NPQAD in accordance with criteria described in this plan.

l 5.9 Treatment of Reinspection Deficiencies in Verification Sampling Program: Deficiencies identified by refuspections will be recorded l on a nonconformance report and promptly reported to MPQAD-QA and others for processing per procedure. The party responsible for recommending the initial disposition of the nonconformance will O .

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APPEPDIX C, R;v 1 i ' '

Pigs 15 of 16 m

U review the intended disposition with MPQAD-QA prior to further processing of the nonconformance. The purpose of this MPQAD-QA review is to insure proper treatment of the nonconformance in the sampling analysis. Deficiencies determined to be acceptable to "use as is" will be evaluated by Project Engineering to determine whether the design criteria requirement which the attribute failed to meet will be modified to clarify the inspection requirement. If Project Engineering modifies the requirement on a generic basis, the deficiency will be considered " acceptable" for purposes of sample analysis. The final decision as to whether the deficiency constitutes a sample defect will be made by the Executive Man-ager-MPQAD. This decision and its justification will be docu-

,r) mented.

LJ 5.10 Deficiene Found During Reiftspection of Documentation for Inaccessible Attributes: The verification process for inaccessible

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attributes is discussed in Section 6.5 of the Quality Verification Plan. As noted in that section, any documentation deficiancies will be noted on the verification IR, entered on a nonconformance l

report and cross referenced to the original IR. The treatment of sampled lots containing nonconformances will be determined on a l case by case basis and further verification requirements will be i

i determined taking into account the disposition of the nonconform-l ing condition.

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UNCONTROLLED =='

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b)3 6.0 Documentation and Reports i

I 6.1 Documentation of Results:

Results of sampling rainspection will be i

documented on IR's and statused to apecifically identify the PQCI, j the lot utmber, the quantity in the lot, the quantity inspected, the quantity found acceptable, the NCR's identifying any deficien-cies and the results of the nonconformance disposition, and accept-ability of the lot.

6.2 Documettation of Nonconformances: Nonconforming conditions will be reported and dispositioned in accordance with approved procedures.

Disposition of the nonconformances will include necessary actions

,pJ to be taken on the balance of the lot; e.g., screen balance of the lot for the rejected attributes, or 100% inspect the balance of the lot.

6.3 Reports

The results of the s mpling plan for each lot related to each PQCI will be included in reports made by the CPCo BOP Quality l

i Control Superintendent and the Quality Assurance General Super-intendent QA as described in section 7.3 of the Quality Verifi-cation Program.

7.0 Implementation

This plan will be implemented as directed by the Executive Manager MPQAD. The organizational responsibilities are the same as shown in section 8 of the Quality Verification Program. In addition, MPQAD BOP Quality Control shall have the responsibility of selecting the IR's to be sampled from lot sizes predetermined by MPQAD-QA.

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