ML20072J478
| ML20072J478 | |
| Person / Time | |
|---|---|
| Site: | Midland |
| Issue date: | 06/10/1983 |
| From: | CONSUMERS ENERGY CO. (FORMERLY CONSUMERS POWER CO.) |
| To: | |
| Shared Package | |
| ML20072J434 | List: |
| References | |
| PROC-830610-01, NUDOCS 8306300112 | |
| Download: ML20072J478 (67) | |
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UNCONTROLLED o
QUALITY VERIFICATION PROGRAM MIDLAND NUCLEAR COGDiERATION PLAhl 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 Elecents 6.1 Cable F.cinspection-i 6.2 In Process Inspection Notices and Discrepancy Reporte 6.2.1 0 Forms l
6.3 E::ceptions to this Plan 6.4 Purchcscd Material 6.5 Inaccessibic Attributes O
0306300112 830610 PDR ADOCK 05000329 A
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01!AL11Y VERIFICATION PROGRAM LIEI /Fr Fl' CLEAR _ _C0 GENERATION PLANT L' LITS 1 AhL 2 Inde-a of Topics 7.
Documentation and Reports 7.1 Documentation of Results 7.2 Documcutation of Nonconferecnces 7.2.1 Trending 7.3 Reports 7.3.1 Repcrts to Executive Manager - MPQAD 7.3.2 Reports from Executive Manager - 1:PQAD 7.3.3 Reports to NRC and Construction Implementation Overvice Team 8.
Implementation 9
f"J) 8.1 Organizational Responsibilities 8.1.1 MPQAD - BOP QA 8.1.2 11PQAD - BOP QC 8.1.3 MPQAD - Site Audit Section 8.1.4 MPQAD - QA Administration and Training 9.
Appendices A.
List of PQCIs B.
PQCIc to be Verified by Documentation Review C.
Statistical Sampling Plcn
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lE0NIR0LLED 1
A QUALITY VERIFICATION PROGRAM Midland Nuclear Cogenerntien Plant Units 1 and 2 1.
Purpose:
To confirm throt.gh a verification progrna under the direction of Consumers Fower Company, the acceptah' quality status of safety related procurement and construction cctivities completed and inspected by the Engineer-Constructor quality control personnel prior to December 2, 1982.
2.
Scepe: This program will cover c11 cicsed Inspection Records of in-spections performed by th Engireer-Constructor quality control personnel on safety related naterial, systems, componente cnd structures of the Midland Nuclear Cogeneration Plant Units 1 and 2 prior to December 2, f^3 1982, except:
V 2.1 Retedici Soils Work, which has been under the direction of Con-sumers Power Cotrpany Quality Assurance (QA) personnel since August, 1982.
2.2 HVAC work, which has been under the direction of Consumers Power Company QA persor.ncl cince the major reorganizatien in June 1981.
2.3 Verification of cable routing, identification and other accessible attribute.s which is being done on a 100% reinspecticn basis in act-t o nce with PQCI E-l. 0.
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2.l Verification of ASME hangers which sil_ be done under a separate reinspection program as previously committed to the NRC on Nosctber 15, 1982 and March 29, 1983. 11.is progran requires 100% reinspec-tion of all hangers with closed IR's as of December 1982. This program will be conducted under the direction of Censumers Power Company QA personnel.
2.5 B&W Construction Company activities which have been performed under the E&U Quality Assurance Program.
3.
References:
3.1 Regulatory Guide 1.58, Rev 1, Qualification of Nuclear Power
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V Inspection, Examination and Testing Personnel.
3.2 MPQAD Procedure E-3M, Preparation and Approval of Project Quality Control Instructions 4.
Definitions: 0 A form previously utilized to Dccurent Walkdcun statusing on specified piping systems prior to Hydrostatic or Pneumatic Testin5-
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3 OV Discrepancy Report (DR):
A forn sinilar to the 1 PIN previously used to raport inprocess nonccnfer-cances.
Inaccessible:
An item or attribute of an item which, due to its physical location er config-uration, cannot be physically or visual-ly reinspected without removing and thereby invalidating installed scrk.
Under the Quality Verification Program, this includes those itens or attributes normally inspected in process and which
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subsequent ecnstruction processing rankes inaccessible, eg, piping fit-up, rcot wcld end subsequent layers under the cover pass, anchor bolt hole drilling, internal cleanliness, embedcent in concrctc, etc.
Inaccessible does not include those items which can reasonably be reached by scaffcid erection, limited access (renote) areas which require the physical size of the inspecticn person-nel to be limited or those items that can be viewed by removal of access cc,ver er panels, eg, electrical conscics,
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cabinets, conduit boxes, etc.
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When such coverings can be practically removed and replaced and where their particular reinspection is required to establish an acceptable level of con-fidence of the quality of a rarticu-lar attribute, the coverings will be re-noved.
Items which fall into this category and are scheduled for verifi-cation in accordance with plan require-fs ments will not be considered inaccessi-O ble unless so approved on a case by case basis by the Executive hanager - MPQAD.
In Process Inspection A form previously used to record noncon-I!ctice (IPIN):
forming conditiens en rcrk returned to construction forces for rework prier to completion of incpection activities for the item in question.
Inspection by Attributcc:
Inspection whereby the iter.cr attribute is classified sicply as conforming or nonconforming without
~s regard for the detree cf nonconformance.
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5 N, Y Inspection Recore (IL):
A report that scopes the inspcction to be perforted, relating it to a specific PQCI and a system, component, struc'ture or portion thereof and which records the results of inspections.
Nonconformance:
A deficiency in characterictic, documen-tation or precedure which renders the quality of an iten unacceptabic cr indeterminate.
Nonconformance Report (NCR):
A document used for reporting noncon-
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fopulation:
Ihe entire quantity of closed Inspection Records (IR) as of December 2,
1982 relating to a specific PQCI.
Project Quality Centrol The document that provides Quality Instruction (PQCI):
Centrol 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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O Reinspecticn:
fr uscd in this Verification Program, reinspection ecans a complete review of requisite documentatien cnd c 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 documentation where attributes arc not accessible.
Verification:
As used in this program, verification refers to the overall process of estab-w(J 11shing the quality acceptance of the total population of completed and inspected work through cot.binaticrs, er applicable, of efforts such as re-inspec-tion, documentaticn review, review of past efforts to investigate and resolve problems, cnclysis of past overin-spection results and, if necessary, NDE techniques end destructive examination.
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Program Content: As identified in Section 2, Scope, Consumers Pcwcr Company (CPCo) uill conduct a Quality Verification Fregram of safety related procurctent 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 FQCIs, as listed in Appendix A, that specified the inspection requirements to be achieved by Quality 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 frcm 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.
G 5.1 Detailed Scope: The program will include approximately 100,900 irs subject to the Quality Verification Program, for which the Engi-neer-Constructor has a record of completed inspections as docunent-ed by closed Inspection Records (lR) and for which ne ether 100%
verification activity has taken place or is scheduled to take place. There are approximately 147,500 closed irs of which ap-proximately 14,700 were for reinspections which occurred due to-design change, ccnstruction rework, etc., and approximately 31,900 which are excluded, due to previous commitments under the Eccedial Soil, HVAC, Cable routing and identification and AbhE henger Progrcas. 1:hore a reinspection has occurred en c. 9pecific iten or
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attribute the verification will relate to the latest IR.
In additien, prior to the use of PQCIs, Material Receipt Inspections (MRI), Field Inspection Plans (FIP) and Welding Inspecticn ER-5 forms were tred es quality. instructions and records. These al'so
'will be used for quality verification. Where applicable, the results of the inspections will be grouped with like PQCIs. Other-wise they will be treated as separate populations.
5.2 Methodology
This program will confirm the acceptable quality status of ccepleted work and establish the validity cf prior inspections. To cccomplish this, accessible attributes of items covered by completed irs will be reinspected to the lastest design requirements with PQCI's which have been reviewed and/or revised as -
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necessary to assure clarity of acceptance criteria and uniformity of implementation. For-inaccessible attributes, the original inspection documents will be reviewed for evidence of acceptn-bility, and justification will be developed as described in section 6.5 to establish hardware quality and support the validity of inspections associated with-such PQCIs. Each'IR relates to a specific PQCI. PQCIs are crganized by discipline and further i-structured to activities within-that discipline,He.g., there are separate PQCIs std ccrresponding' irs for preplacement, placement
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.and post-placement inspections of concrete.
Closed irs related to each PQCI provide a popt.lation of like. activities. Closed irs are l
those where the Engineer-Constructors'10G% inspection ofLccn-'
'l struction and insttiled hardware has been completed.
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LJ To assess the validity of these past completed inspections, and verify the hardwarc quality, CFCo will initiate a ;00% reirspection of the population to provide adequate cenfidence that safety related systems components and structures will herform satis-factorily in service.
The initial 100% reinspection effort will be based on a sys-tems/ area orientation to provide a quality baseline for subsequent construction completion activities.
System / area reinspecticns will be supplemented by random plant-wide inspections as appropriate to establish a valid quality baccline on an expeditious basis.
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At some future date, ence the quality level of completed work has t-been established, CFCo will make a determinaticn as to whether or not further verification efforts can appropriately be based on less than a 100% reinspection pregram.
When CPCo believes that sufficient justification exists for a reduction in the 100% commitment, it will reccamend such a re-duction to the SRC in accordance with the statistical sampling plan attached as Apperdix C.
sm 5.3 Identification of Deficiencies: Any nonconforming condition obsersed during the implementation of thic program other than those previously identified cn r.crecrfermance reports, will bh, idcutified
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all such irs will be treated as a unique population and will be reinspected 100%.
IPINs are no longer used in the inspection procecc. Discrepancy Reports (DF) were used prior to the use of the IPINs. They are no longer in ute, but are recorded and will be treated the same as the IPIN.
6.2.1 Attachnent 10 Forms: Attachment 10's were used in cen-junction with Hydrostatic / Pneumatic Test Procedures as a i
I punchlist for a defined Hydrostatic or Pneumatic Test, and included line numbers, drawing numbers and test boundaries.
The Attachment 10 was not intended to be the quality docu-ment that identified documented acceptance by the QCE of
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subsequent action taken to correct punchlist deficiencies
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identified during the walkdewn process. These deficiencies were intended to be tracked on other quality documents, such as Nonconformance Reports, Inspection Reports, etc.
In order to verify that this use of the Attachment 10 did not comprorise the quality of installed hardware, all completed hardware inspections documented on closed irs falling within the system boundaries identified on existing Attachment 10 forns will be 100% verified during the Quality Verification Program.
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13 qC 6.3 Exceptions to this Program: Excepcions to this Program shall not be taken unless such exceptions can be fully justified.
One such exaniple wculd be a case where objective evidence is available of a CPCo overinspection of the the Engineer-Constructor's inspections and which demonstrates effective quality control and provides the basis to verify acceptability of the iters or attributes covered by these past 1Rs.
Where such exceptions are propesed to be taken, a special report will be prepared by the MPQAD-QA Cereral Superintendent for review and approval of the Executive !!anager-MPQAD. This report will j
contain full justification for the exception and documentation of r^N objective evidence to support the exception. The Executive Mana-
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s 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 Material: Purchased safety related material and com-ponents whether source inspected or inspected upon receipt are subject to this Progran for verification of completed receipt i
inspections performed by the Ergincer-Constructor prior to December j.
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In many cases, purchased items have been installed and are not fully accessible for reinspection; however inacccccible interfaces difi~1 Evebeen dcmonst' rated and' thEir~ fiinctional accepta-
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bility proven thrcuph installation and subsequent tesring. Access-
/'m, ible featurcu will be reinspected in accordancc virF rFis Program.
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The total nut:ber of irs associated with PCCI R-1.00, Material Receiving Inspection, ic approximately 12,000.
In additicn, prior to the introduction of PQCI R-1.00, approximately 150 MRIs and 20 FIPs were used for receipt inspection, covering approximately 700 items. Based upon further revfeu, receipt inspections covered by MRIs will either be grouped with like itens covered by PQCI R-1.00 or be reinspected separately. FIPs were also used for ccnstruction activities and will be treated separately under this plan. Where materials such as rebar, certain structural members or features of components are inaccecaible for reinspection, documentatien will be reviewed in accordance with this Program.
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7.2 Documentation of Nencenformances: Nonconforrirg cenditions ob-served during reinspection activities will be.decerented on a nonconferrance report and appropriately analyzed for nanagement attention. This includes instances where a design or ccnctruction modification has occurred since the Inspection Record was closed and a new IR not yet opened.
(Note discussion in Section 5.3.1) 7.2.1 Trending 1 Deficiencies noted during the verification process will be trended as appropriate for analysis and managecent information.
7.3 Reports
n 7.3.1 Reports to Executive Manager-MPQAD: A weekly status report will be made jointly by the CPCo BOP Quality Contrcl (QC)
Superintendent nnd Quality Assurance (QA) General Super-intendent to the Executive Mannger - Midland Project Quality Ascurance Lepartment (MPQAD) sunnarining tre results of the progrnm. The report will note the completed Inspection Peports by the unique PQCI nuuber, Kcnconformance Reports issued and identification of attribute (s) crusing the nonconformance (s).
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7.3.2 Reports from Executive Manager-MPQAD: The Executive Mana-ger-MPQAD will inform the CPCo Site hanager, the Engineer-Constructor Project Manager, and the Vice President, Pro-jects, Engineering cnd Construction, of the statuc of the quality verificatien 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 neceptability of completed work as it uay be impacted by ncnconformances.
7.3.3 Reports to NRC and Construction Implementation Overview Team: The Executive Manager-MPQAD will provide copies of the t'%
monthly reports noted in section 7.3.2 to NRC Region 111 and
!.j the Construction Irrplcncntation Overview Team.
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Implementation: This program will be implemented under the direct control of EFQAD through procedures approved and issued according to normal programmatic requirements.
8.1 Organizational Responsibilities: The Executive Manager-MFQAD has total overall responsibility and authcrity for the development and implementation of all quality reIcted aspects of this verificntion program. He will be responsible for seeing that the implementation phase of the program is coordinated teith other project departments as required to assure prer.cr 1,upport for this plan commensurcte p
with overah project gccls.
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8.1.1 MPQAD - BOP QA: is responsible for the pregistmatic elements of the verification program including, tut rot limited to, precedure development, PQCI review and approval, nonconfor-mance review, analysis of results, justification for docu-ment review, verification of inaccessible attributes, program content modifications and certifying thct the verification has been ccepleted for a given area or system, and performing management overview of the reinspection process with appropriate documentation of results.
8.1.2 MPQAD - BOP QC: is responsible for program implementatien including, but not limited to, conducting the reinspection n(_)
activities with QC personnel that satisfy Regulatory Guide 1.56, Rev 1, which requires personnel certification in accordance with ANSI 1;45.2.6 (no person will reinspect activities for which he performed the original inspection),
reporting results to the E:<ecutive Kanager-hFQAD, reperting nonconformances to hkQAD-IOP QA, and coordinating with Construction Services and Consumers Site lianagement Office to establish schedule priorities for reinspection activi-ties.
8.1.3 MPQAD - Site Audit Section: is responsible for fornal audits of the overall verification program implementation.
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O 8.1.4 IGQAD - QA Administration and Training: h?QAL Frecedures l
I will be developed in accordance with prograt.aaatic require-ments to direct inplerentction of this plan, i
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APPENDIX A Page 1 of 20 A LIST OF ALL PQCI'S WITH QUANTITY AND REINSPECTION INFORMATION PQCI # PQCI TITLE QUANTITY DOC'T IIARDWARE REMARKS C-1.02 Compacted Backfill 181 Hardware & documentation under remedial solis program C-1.09 Inspection of Hardware & documentation Crack for BWST under remedial soils program Foundation Ring Wall 5
O Cll3 C-1.10 Insp of Grouting Surface condition and and Dry Packing 1833 1
1 documentation
=s=s C-1.11 Drilling & Grouting Rebar 66 i
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C-1.20 Concrete Preplacement Inspection of remaining M
Inspection 767 unplaced concrete areas plus past documentation C-1.21 Inspection of Inspection of accessible Reinforcing Steel 259 rebar plus past documentation C-1.22 Inspection of Reinforcing Inspection of accessible Steel at Construction rebar at remaining joints Joints 9 19 1
1 plus past documentation Rev. 2, 6/10/83 PR0483-0014 F-QLO7 KEY:
1 Document-Review documentation for completeness i Hardwarc-Reinspect accessible attributes x Hardware-Attributes not acessible for reinspection
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APPENDIX A Page 2 of 20-A LIST OF ALL PQCI'S WITH QUANTITY AND REINSPECTION INFORMATION
'PQCI # PQCI TITLE QUANTITY DOC'T HARDWARE REMARKS C-1,30 Concrete Placement 4
Inspection 780 x
C-1.31 Inspection of Concrete Activities 246 x
4-C-1.40 Concrete Post Inspection of concrete Placement Inspection 1002 1
1 surfaces plus documentation C-1.50. Installation and Testing Inspection for proper d'
of Expansion Anchors 4982 1
1 installed condition 3
C-1.51' Retest Verification of Drop.In Expansion Anchors 54 x
C-1.52 Reinspection of Seismic Category I Pipe Support
. Expansion Anchors 294 1
x C-1.53 Reinspection of Expansion Anchors for Seismic Cat I Support.
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1 Document-Review documentation for completeness 1 Hardware-Reinspect accessible attributes j
.x Hardware-Attributes not acessible for reinspection
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A LIST OF ALL PQCI'S WITH QUANTITY AND REINSPECTION INFORMATION j
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 f
Steel 325 x
C-1.70 Installation of Pressured l'
Concrete Pipe 2
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i C-1.80 Installation of
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Concrete Unit Masonry 102 1
x C-1.81 Installation of Concrete Unit Masonry 139 i
x C-1.90 Installation of SWI Sluice Cates O
C-2.00 Plant Area Dewatering 59 Hardware and documentation under remedial soils program l
Rev. 2, 6/10/83 PR0483-0014F-QLO7 KEY:
1 Document-Review documentation for completeness 1 Hardwarc-Reinspect accessible attributes x Hardware-Attributes not acessible for reinspection
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A LIST OF ALL PQCI'S WITil QUANTITY AND REINSPECTION INFORMATION
-PQCI # PQCI TITLE QUANTITY' DOC'T llARDWARE REMARKS' C-2.02 Permanent Gravel liardware and documentation Packed Wells 17 under remedial soils program C-2.03 ' Drawdown Recharge' One time test under remedial Test I
soils program C-2.05-Drilling Q-Listed Areas for Underpinning 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
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-C-2.20 Field Fabrication of Miscellaneous Steel 1502 x
C-2.21 ' Field and Offsite Fabrication of 1 Reinforcing Steel-0 Rev. 2, 6/10/83 PR0483-0014 F-QLO7 KEY:
Document-Review documentation for completeness i 11ardware-Reinspect accessible attributes x liardware-Attributes not acessible for reinspection f
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A LIST OF ALL PQCI'S WITil QUANTITY AND REINSPECTION INFORMATION t
i PQCI # PQCI TITLE QUANTITY DOC'T llARDWARE REMARKS C-2.56 Load Monitoring of the Remedial Soils Program Feedwater/ Isolation Valve Pit Rod & Rock Bolt 0
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C-3.01 Installation Inspection Inspection of accessible of Spent Fuel Storage attributes plus documentation Racks 20 i
C-3.02 Installation Inspection Inspection of accessible of Spent Fuel Storage attributes plus documentation Racks 8
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C-3.03 Inspection of Test for Acceptability of the Spent Fuel Rack Cells O
C-4.10 Batch Plant Inspection 929 i
x C-5.10 Shear Connector Installation 503 x
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C-6.00' Mechanical Splicing of Reinforcing Bars 787 i
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i liardware-Reinspect accessible attributes x Ilardware-Attributes not acessible for reinspection
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A LIST OF ALL PQCI'S WITH QUANTITY AND REINSPECTION INFORMATION PQCI # P'QCI TITLE QUANTITY DOC'T HARDWARE REMARKS C-7.00 Erection of Reactor Building Liner Plate 10 1
x C-8.50 Inspection of Surface Preparation Application Touch Up & Repair of Coating 908 x
C-8.51 Inspection of Inspection of surface Decontamination Coat condition plus documentation for Concrete 17 1
i C-8.60 Inspection of Surface Preparation Application Touchup & Repair of Coatings Reactor Bldg Liner Plate O
C-9.00 Installation-Post Tensioning Components 40 1
x C-9.10 Post Tensioning System Stressing 309 x
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a APPENDIX A Page 7 of 20 A LIST OF ALL PQCI'S WITil QUANTITY AND REINSPECTION INFORMATION PQCI # PQCI TITLE QUANTITY DOC'T llARDWARE REMARKS C-9.20 Containment Bldg Tension Reinsp 11 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
1 E-1.1 Ins;911ation.of Inspection of accessible Boxes 9
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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 E-2.1 Installation of Inspection of accessible Tray Supports 799 1
1 attributes plus documentatien Rev. 2, 6/10/83 KEY:
PR0483-0014F-QLO7 1 Document-Review documentation for completeness i liardware-Reinspect accessible attributes x liardware-Attributes not acessible for reinspection
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APPENDIX A Page 8 of 20-A LIST OF ALL PQCI'S WITH QUANTITY AND REINSPECTION INFORMATION q...
l PQCI # PQCI TITLE QUANTITY DOC'T HARDWARE REMARKS E-3.0 Final Electrical Area' Completion Activity.
0 E-3.1 Electrical System Turnover Activities 108 i
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E-4.0 Installation of-Inspection of accessible
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Elo~c t ric ' Cables 7954 i
x attributes has been t
accomplished under cable routing & ID program L
E-5.0 dable' Terminations 12361 1
Inspection of accessible attributes plus documentation u
E-6.0 Instaliation of Inspection of accessible
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, Electric Equipment-and attributes plus documentation
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_g7 Instrumentation 346 i
E-6.1 M dification of Combine with RW 1.10 Electric Equipment' 209 Inspect accessible 1
attributes plus documentation
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APPENDIX A Page 9 of 20 A LIST OF ALL PQCI'S WITil QUANTITY AND REINSPECTION INFORMATION PQCI # PQCI TITLE QUANTITY DOC'T liARDWARE REMARKS E-6.2 Installaf 1A 2 i Inspect accessible Terminal Boi, 108 1
attributes plus documentation E-6.6 Installati*
Inspect accessible Electric Penetratioos 127 2
attributes plus documentation E-6.6.1 Installation of Feed Inspect accessible Through Assy's for attributes plus documentation Elec Penetration 388 1
E-6.7.1 Installation of Inspect accessible Batteries & Racks 9
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attributes plus documentation RW-1.10 Modification to Combine with E-6.1 Electrical Equipment 144 1
1 Inspection of accessible attributes plus documentation 1-1.10 Installation of Inspection of accessible
-Instruments 159 attributes plus documentation M-1.00 Installation of Inspection of accessible Mechanical Equipment 11 1
1 attributes plus documentation Rev. 2, 6/10/83 PR0483-0014 F-QLO7 KEY:
1 Document-Review documentation for completeness i llardware-Reinspect accessible attributes x liardware-Attributes not acessibic for reinspection
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APPENDIX A Ai Page 10 of 20 A LIST OF ALL PQCI'S WITil QUANTITY AND REINSPECTION INFORMATION PQCI # PQCI TITLE QUANTITY DOC'T HARDWARE REMARKS M-2.00 Installation of 28 1
1 Inspection of accessible Rotating Equipment
' attributes plus documentation M-3.10 Installation of Inspection of accessible Crancs 1
1 attributes plus documentation M-4.00 Complete Installations
. Inspection of accessible of Mechanical attributes plus documentation Equipment 2
1 i
^
MP-1.00 Disassembly Reassembly Inspection of accessible and Modification of attributes plus documentation Systems and Components 4
1 1
MW-1.00 Welding and NDE Rev 1 of Mechanical Equipment 0
P-1.00 Piping Completed Inspection of accessible Line-Installation 80 1
1 attributes plus documentation P-1.10 Piping Subassembly Inspection of accessible Field Installation RW 1858 1
attributes plus documentation Rev. 2, 6/10/83 PR0483-0014F-QLO7 KEY:
1 Document-Review documentation for completeness
! Ilardware-Reinspect accessible attributes x Hardwarc-Attributes not acessible for reinspection
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APPENDIX A Page 11 of 20-
-A LIST OF ALL PQC1'S WlTH QUANTlTY AND REINSPECTION INFORMATION PQCI # PQCI TITLE
~ QUANTITY DOC'T HARDWARE
' REMARKS-P-1.20 ' Piping Subassembly Inspection of accessible Shop Fab & Rework' 994 1
attributes plus docun.cntation P-1.30 Valve,and Inline Inspection of accessible-I Component Install 1247 i
attributes plus documentation
-P-1.60' In Process Insp Fab / Installation Rework.of Piping 167 1
x
'P-2.00 Pipe Component Inspection of accessible
+
Supports Final Setting 5
i attributes plus documentation P-2.10 Pipe (Component)
R SupportElnstallation 7057
'P-2.20 -Pipe (component)
' Inspection of accessible
'Supporte fabrication 6460 i
attributes plus documentation r-2.30 Pipe (Component)
Closed IR's from P-2.10 and
-Support F119/P129 P-2.20 will be reinspected Walkdown'
,0
_ to requirements of P-2.30 where installed Rev. 2, b/10/u3 KEY :
PR0483-0014F-QLO7 -
1 Document-Review documentation for completeness i Hardwarc-Reinspect accessible attributes
. x Hardware-Attributes not acessible for reinspection I
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%J APPENDIX A Page 12 of 20 1
A LIST OF ALL PQCI'S WITH QUANTITY AND REINSPECTION INFORMATION
_PQCI # PQCI TITLE QUANTITY DOC'T HARDWARE REMARKS 1
1 PF-1.10 Pipe Flange Installation Inspection of accessible
~
and Rework 820 1
attributes plus d: umentation i,
PI-1.40 Field Fabrication and Inspection of acc.ssible Installation of Piping attributes plus documentation s
Related Instrumentation 204 1
1 h
PI-2.40 Off-Site Fabrication /
Inspection of accessible Weld of Pine Related attributes plus documentation l
Instrumee. Supports 84 1
i PIW I Welding and NDE of-attributes plus documentation Inspection of accessible 1.00 1 Instrument Tubing and J.
1 Fittings 642 PW-1.00 Fab / Weld / Heat Treat Inspection of accessible I
and NDE.of ASME III attributes plus documentation Piping 31014 R-1.00. Material Receiving Inspection of accessible Inspection 12007 1
attributes plus documentation Rev. 2, 6/10/83 PR0483-0014F-QLO7 KEY:
! Document-Review documentation for completeness i Hardware-Reinspect accessible attributes x Hardware-Attributes not acessible for reinspection
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APPENDIX A~
Page 13 of 20 A LIST OF ALL PQCI'S WITH QUANTITY AND REINSPECTION INFORMATION PQCI #' PQCI TITLE QUANTITY DOC'T HARDWARE REMARKS R-1.60 ' Receiving Area and.
Walk through of existing Storage Facilities conditions plus documentation Inspection 45 i
x-R-2.00 Receiving Inspection i
l for NSSS Equipment 198 x
I R-2.10 Receiving Inspection for NSSS Equipment 42 x
i R-2.20 Receiving Inspection for NSSS Equipment Documentation 217 i
x e
i-S-1.00. Storage Area /
Walk through of Facilities Sury 67 x
existing conditions plus review of documentation t-
- ~
SC-1.05' Material Testing-Services 306 x
Rev. 2, 6/10/83 PR0483-0014 F-QLO7 KEY:
1 Document-Review documentation for completeness
! Hardware-Reinspect accessible attributes x Hardware-Attributes not acessible for reinspection y-
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APPENDIX A Page 14 of 20
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A LIST OF ALL PQCI'S WITil QUANTITY AND REINSPECTION INFORMATION PQCI # PQCI TITLE QUANTITY DOC'T llARDWARE REMARKS SC-1.06 Recoating Work of Cont Bldg Liner Plate, Misc Steel, and Pipe IIanger 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 1
x SC-1.14 Subcontract Surveillance of Installation of Underpinning 0
SC-1.16 Field Erected Storage "anks/ Subcontract S.rveillance 108 t
x t
Rev. 2, 6/10/83 PR0483-0014F-QLO7 KEY:
1 Document-Review documentation for completeness liardware-Reinspect accessible attributes x liardware-Attributes not acessible for reinspection Y
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..Y APPENDIX A Page 15 of 20 C
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 x
SM-1.03 Heat, Ventilation and Air Conditioning Subcontact Surveillance 828 1
x SM-1.04 Field Erected Component Cooling Water Surge Tanks
. Subcontracts Surveillance 108 x
SM-1.17 Field Fabricated Incore Installation Tanks Subcontract Surveillance 183 i
x SW-1.01 NDE-Subcontractor Surveillance 120 x
Rev. 2, 6/10/83 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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APPENDIX A Page 16 of 20 A LIST OF ALL PQCI'S WITil QUANTITY AND REINSPECTION INFORMATION PQCI # PQCI TITLE QUANTITY DOC'T IIARDWARE REMARKS T-1.00 llydrostatic 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,lleat Treat-Inspection of accessible ment and Non Destructive attributes, radiography plus Examination 20251 1
documentation W-1.60 Area Inspection Of In Process Activities For Welding Q-Listed And ASME III ltems 164 1
x C-1.01 Excavation in Q-Soil Area NA Remedial Soils Program Rev. 2, 6/10/83 PR0483-0014 F-QLO7 KEY:
1 Document-Review documentation for completeness i Ilardware-Reinspect accessible attributes x Ilardwarc-Attributes not acessible for reinspection
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APPENDIX A Page 17 of 20 A LIST OF ALL PQCI'S WITH QUANTITY AND REINSPECTION INFORMATION PQCI # PQCI TITLE QUANTITY DOC'T IIARDWARE REMARKS C-2.01 Gravel Packed Wells 224 Documentation and hardware is under remedial soils program C-2.22 Field Fabrication Of 0
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 Rev. 2, 6/10/83 PR0483-0014 F-QLO7 KEY:
1 Document-Review documentation for completeness i Hardware-Reinspect accessible attributes x Hardware-Attributes not acessible for reinspection
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.(y APPENDIX A Page.18 of 20 A LIST OF ALL PQC1'S UITil QUANTITY AND REINSPECTION INFORMATION PQCI # 'PQCI TITLE QUANTITY DOC'T IIARDWARE REMARKS EU-6.0 Installation Of. Instruments Documentation and Hardware is For Under Pinning under remedial soils program r
Data Aquisitions System 25 EU-6.1.. Installation Of Instrument Documentation and liardware is Supports For Under under remedial soils program Pinning Data Aquisitions System 29 IC-1.0 Instrument Checkout 67 Documentation and liardware is under remedial soils program RM-1.00 Storage & Maintenance Remedial soils program i
Of Material Released-To Mergentine NA RS-1.00. Storage & Maintenance Remedial soils program Of Material Released.
To Spencer, NA' White'&-Prentis Rev.'2, 6/10/83 I
KEY:
PR0483-0014F-QLO7 1 Document-Review documentation for completeness i llardware-Reinspect accessible attributes l
x Hardware-Attributes not.acessible for reinspection
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Page 19 of 20-
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i i
i A LIST OF ALL PQCI'S WITH QUANTITY AND REINSPECTION INFORMATION I
PQCI # PQCI TITLE QUANTITY DOC'T HARDWARE REMARKS SCM-1.0 Crack Monitoring Of Documentation and liardware is The Feedwater Isolation under remedial soils program Valve Pits Sub-Contract Surveillance 36 SD-1.0 Monitoring, Reducing and Documentation and liardware is Reporting Under Pinning under remedial soils program Instrument Data Sub-Contracts Surveillance 189 UP Documentation and liardware 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 Of Access Pits Piers and Drifts For UP 1
UP Documentation and liardware is C-1.010 Field Fabrication Of Steel under remedial soils program Sets For Under Pinning Of Aux Bldg
& FIVP 5
Rev. 2, 6/10/33 PE0483-0014F'-QLO7 KEY:
1 Document-Review documentation for conpleteness i liardware-Reinspect accessible attributes x Ilardware-Attributes not acessible for reinspection
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APPENDIX?A' LPage 20'of 20 A LIST OF-ALL PQCI'S WIT 11 QUANTITY AND REINSPECTION INFORMATION -
Thc[ Remedial Soils' Program'has initiated the following additionalLPQCI's ' for which there are no Engineer-Constructor :
- 1R'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
.UP-C-1.020-UP-C-2.019
,j
~UP-C-1.023
.UP-C-2.042-UP-C-2.150 UP-C-3.001 1RM/RS-1.00 i
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PR0483-0014F-QLO7 t
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r-APPENDIX B Page 1 of 10 APPEhTIX B v
PQCIs To Be Verified by Review of Documentation Only 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 n
C-2.01 - Gravel Packed Wells v
C-2.02 - Permanent Gravel Packed Wells C-2.05 - Drilling in Q-Listed Areas for Underpinnir.g 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 Systen EU-5.0 - Cable Termination for UP Data Acquisition System 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 - Crack Monitoring Of,FW_ Iso _ Valve _.P_its Subcontractor Surveillance l
l 0
Rev 2, 6/10/83 PR0483-0013A-QLO7
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APPENDIX B Page 2 of 10 O
SD-1.0 - Monitoring, Reducing and Reporting UP Inst. Data Subcontractor Surveillance UP-C-1.004 - Welding And NDE of Q-Material UP-C-1.008 - Excavation & Lagging of Access Pits, Piers and Drif ts For 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.
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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 reinspections which have been completed and results reported to the NRC.
3.
-In-Process Activities.
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APPENDIX B Page 3 of 10 e
O E-3.1
- Electrical System Turnover Activities E-1.60 - In Process Inspection of Electric Item Installation R-1.60 - Receiving Area and Storage Facilities Inspection W-1.60 - Area Inspection Of In Process Activities For Welding Q-listed and ASME 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 reinspection would be of completed work covered by other PQCIs, e.g., PQCIs E-6.0, W-1.00 and UJ-1.00.
In the cases of
(}
R-1.60 and S-1.00, these are an inspection or surveillance of general u-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 single inspection can attest to con-ditions existing today without relation to past conditions.
4.
Surveillance of Subcontractor Activities.
SC-1.05 - Material Testing Services SC-1.11 - Concrete and Unit Masonry Surface Subcontract Surveillance SC-1.16 - Field Erected Storage Tanks Subcontractor Surveillance O
N.
Rev 2, 6/10/83 PR0483-0013A-QLO7
n 1
APPENDIX B Page 4 of 10 l')
\\s 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 Cooling 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.
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Where work has not been completed, such surveillance activities can be repeated then 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, activities outside the scope of this quality verification program.
In depth participation by CPCo continues in this work.
5.
Hydroststic and Pneumatic Leak Testing.
l l
T-1.00 - Hydrostatic and Pneumatic Leak Testing i.
CPCo has already conducted an extensive evaluation of hydrostatic and
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pneumatic Icak testing and corrective actions relative to such evaluation are being conducted separately fron this reinspection program.
Rev 2, 6/10/83 PR0483-0013A-QLO7-
APPENDIX B Page 5 of 10 A' v '
6.
Special "One Time Only" Testing.
C-2.03 - Drawdown Recharge Test.
This is a test required to have been performed once and which demonstrated acceptable results. The remedial soils program 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 01 v
This PQC1 relates to necessary inspections of the "Cadweld" process of mechanically splicing reinforcing steel. The constructor's processes were the subject of extensive investigation by the NRC in 1973 and 1974 which 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 j
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 2, 6/10/83 PR0483-0013A-QLO7
=
APPENDIX B Page 6 of 10 rhU This PQCl relates to the preparation and installation of steel plates which provide the inner surface for the containment building. The liner is now inaccessible, being backed up by reinforced concrete on the out-side and nuclear coated on the inside. Extensive review was made by CPCo in 1974 of the accuracy of liner plate records. Controls implemented after NRC investigation were evaluated and found satisfactory. In 1977, a deformation of liner plate occurred due to freezing of an _mbedded con-struction water line. This resulted in selected 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.
,m 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 been accomplished which tie the supporting beams, steel and concrete floor decking into a composite structure. Since the shear OO Rev 2, 6/10/83 PR0483-0013A-QLO7
APPENDIX B Page 7 of 10 n
v 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-irs 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 items either mounted in the holes or the holes grouted, it is not possible to physically inspect the concrete or the reinforcement. This is par-ticularly true where expansion anchors have been used which cannot be nondestructively removed.
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Page 8 of 10 k-)
t 8.
Post Tensioning Requirements.
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.$5(e) report was. issued by CPCo in August 1977.
9.
Concrete Placement Activities.
C-1.30 - Con. crete 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 made in accordance with
-C-1.40 " Concrete Post Placement Inspection." Where concrete has not been placed, a preplacement inspection will be required before placement when construction is resumed.
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F APPENDIX B Page 9 of 10 hN)
C-1.80 Installation of Concrete Unit Masonry C-1.81 Installation of Concrete Unit Masonry These PQCIs relate to the installation of concrete block walls 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.
j l
This PQCI addresses fabrication of steel which will have been consumed and erected into items which will be inspected if accessible, under other r~s-
! y PQCIs.
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APPENDIX B Page 10 of 10 s
- 11. NSSS Receiving Inspection Activities.
R-2.00 - Receiving Inspection for NSSS Equipment R-2.10 - Receiving Inspection for NSSS Equipment R-2,20 - Receiving Inspection for NSSS Equipment Documentation These PQCIs address the constructor's receiving inspection of components and materials used by t'.ie 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.
O C-1.70 - Installation of Pressured Concrete Pipe This FQCI 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.
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.
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PR0483-0013A-QLO7
UNCONTFl0LLED=e16 O
%J STATISTICAL SAMPLING PLAN INDEX OF TOPICS 1.0 Purpose 2.0 Scope 3.0 References 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 retermination of Lot Sizcs
+
5.6 Sample Selection m
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 6.1 Documentation of Results 6.2 Documentation of Nonconformances 6.3 Reports 7.0 Implementation (D
m)
Rev. 2, 6/10/83 PR0483-0014B-QLO7
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APPENDIX C Page 2 of 16 7-)'
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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 or planned programs to confirm quality.
3.
References:
MIL-STD-103D Change Notice 2 (March 1964), Sampling Procedures and Tables for Inspection by Attributes.
US NRC ISE Bulletin 79-02, Reinspection of Anchor Bolts.
MIL-HDBK-53-1A 1 FEB 1982 - Guide for Attribute Lot Sanpling and MIL-STD-105.
4.
Definitions:
Population:
The entire quantity of closed
'(IR's) relating to a specific PQCI.
./
Rev. 2, 6/10/83 PR0483-0014B-QLO7 L
APPENDIX C Page 3 of 16 7_
V 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 Ilomogeneity :
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 73(j 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 quality 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 quality level.
',,E Rev. 2, 6/10/83 PR0483-0014B-QLO7
F 7
APPENDIX C Page 4 of 16 3
(G Acceptable Quality Level (AQL):
The 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 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 O) conforming or nonconforming without
(_
regard for the degree of nonconformance.
Limiting Quality (LQ):
The term applies to sampling plans that provide not less than a specified 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 acceptable.
(~).
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APPENDIX C Page 5 of 16
,r 3 V
Lot:
A quantity of items, such as completed inspection records covering the same 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 renders 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 chance of being selected, regardless of its quality. If the units in a lot have been arranged without bias as to their quality a sample drawn anywhere in the lot will meet the requirements for randomness PQCI's are logged in accordance with the date they were opened, totally independent of the
.g
- J (1 Mil-Ildbk 1A Para 12.2)
Rev. 2, 6/10/83 FR0483-0014B-QLO7
F -~
APPENDIX C Page 6 of 16 ss 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-nonts from cach 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 Page 7 of 16 O
5.0 Plan Content 5.1 Detailed Scope: This sampling plan applies to closed 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 FQCIs and quantities of closed irs
) C 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.
j 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 Page 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 acceptabic based upon the acceptability of items or attributes previously 100 percent inspected to provide a satisfactory quality baseline. This is consistent with past URC recommendations related to reinspections of safety related items and will produce results at least equivalent to those expected from 100% inspection.
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The statistical quality control methods proposed are in accordance O
with MIL-STD-105D Tables I, IIA and VIIA. MIL-STD-105D is probably the most widely used sampling standard in the United States. This Program is a rigorous application of statistical quality control methods to assess the quality of nuclear power plant construction.
(3 NCR ISE Bulletin 79-02, Appendix A)
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APPENDIX C Page 9 of 16 ba 5.3 Sampling Process: The application of statistically valid sampling plans requires lot sizes to be large enough to permit taking of a sample 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 inspection of PQC!c 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 items sufficient to provide adequate confidence the existing
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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 PQC1 will be sampled at normal sampling 1cvels 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 raintained, remaining lots will be sampled to the same crit-eria, but at reduced sampling levels per MIL-STD-105D, Table IIA.
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I APPENDIX C Page 10 of 16 The Executive Manager may recommend to the NRC discontinuance of further sampling where quality levels have demonstrated that past Engineer-Constructor inspections have provided acceptable cont'rol of quality.
5.3.1 Switching
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 specific 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 I
of the single tightened lots are rejected switch to 100%
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inspection of lots, until two consecutive lots are accepted.
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APPENDIX C Page 11 of 16 5.4 Sampling Tables: The following tables indicate sampling inform-ation for Single Normal, Single Reduced and Single Tightened sampling plans:
SINGLE NORMAL Population Sample Accept Rej ec t Lot Size Size Number Number N
n Ac Re 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 QJ 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 0-80 All 0
1 80-500 80 0
1 500-1200 125 0
1 1201-3200 200 3
4 3201-10,000 315 5
6 10,001-00 500 10 11
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The specific PQCIs and total quantities of closed Inspection Records to which these lot and sample cizes 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 sample 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 The size of the lot is one of the factors that determines the sample size to be used in sampling inspection. For i
this program the formation of each lot is planned to be at least p) k-equal to the normal sample size for the entire population;. thus for 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 Page 13 of 16 v
by the lot quantity, any residual quantity may be combined with the last lot, or be treated separately for sampling convenience so long as the sample size is in accordance with MIL-STD-105D. Lots will be time centered. The purpose of this is to further enhance homoge-neity for each lot and to identify and isolate conditions which may have occurred in specific time periods during construction of the Midland Plant. This method of stratifying samples and lots, yields 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 activities. 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."
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 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 l
provides a cross section as related to time, since the irs are
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APPENDIX C Page 14 of 16 mU 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.
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 Executive Manager-MPQAD in accordance with criteria described in this plan.
5.9 Treatment of Reinspection Deficiencies in Verification Sampling Program: Deficiencies identified by reinspections will be recorded 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
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F APPENDIX C Page 15 of 16 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-mented.
5.10 Deficiencies Found During Reinspection of Documentation for Inaccessible Attributes: The verification process for inaccessible attributes is discussed in Section 6.5 of the Quality Verification Plan. As noted in that section, any documentation deficiencies will be noted on the verification IR, entered on a nonconformance report and cross referenced to the original IR.
The treatment of sampled lots containing nonconformances will be determined on a case by case basis and further verification requirements will be determined taking into account the disposition of the nonconform-ing condition.
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6.0 Documentation and Reports 6.1 Documentation of Results: Results of sampling reinspection will be documented on IR's and statused to specifically identify the PQCI, the lot number, 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.
i 6.2 Documentation of Nonconfornances: Nonconforming conditions will be reported and dispositioned in accordance with approved procedures.
Disposition of the nonconformances will include necessary actions
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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 sampling plan for each lot related to cach PQCI will be included in reports made by the CPCo BOP Quality 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 FTQAD. The organizational responsibilities are the same as shown-in section 8 of the Quality Verification Program.
In addition,
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MPQAD BOP Quality Centrol shall' have the responsibility of selecting the IR's to be saepicd' from lot sizes predetermined by MPQAD-QA.
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