ML20087M600
| ML20087M600 | |
| Person / Time | |
|---|---|
| Site: | Midland |
| Issue date: | 03/20/1984 |
| From: | Palmer B CONSUMERS ENERGY CO. (FORMERLY CONSUMERS POWER CO.) |
| To: | STONE & WEBSTER, INC. |
| References | |
| CIO-0014, CIO-14, NUDOCS 8403300090 | |
| Download: ML20087M600 (46) | |
Text
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, .I g O /lld BRINCIPAL STAFF s 6-RA* '42 ;PRP O/RA DE A/RA DP14SF
<C OR*4A , g PF0 5CS DOCUMENTATION TRANSMITTAL (P]I(Q 5tJA ML _/
EriF F1 to %
To: Stone & Webster - CIO Transmittal No: CIO-dolY PO Box 1963 Date: 3/20/84 Midland, MI 48640 32 9/MO Attention:
The documentation listed below X is provided herc rith, t.as previously provided on ; as requested by .ine+ m d. .
Documentation
Description:
Minutes of Management Review for Construction Completion Plan Quality Verification Program, April 29, 1983, with attachments..
CIO ' has X has not been placed on routine transmittal for the described documentation.
p a p,y N^' d-AhMM 11gnatute l
CC RJCook, NRC Site (w/a, unless voluminous) )
JJHarrison, NRC Region III (w/a, unless voluminous)
DDJohnson, SMO (w/o) _ ~
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'\JGKeppler,NRC.RegionIII(((w/a,unlessvoluminous) I BHPeck, SMO (w/o)
NIReichel, SMO (w/o)
RAWells, MPQAD (w/o) i CMThompson - File 24.2 (w/a, unless voluminous) ' N k M' M10384-0001A-QLO6 3 gogo n
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.N MINUTES OF MANAGEMENT REVIEW POR CONSTRUCTION COMPLETION PLAN QUALITY YERIFICATION PROGRAM
- April'29, 1983 .-
Purpose and Agenda -
The puirpost of the meeting was'-to determine whether; the Quality verification: Program (QVP) was ready for implementation as required by the principles of the Con-struction Completion Plan (CCP).
Information was presented and discussed according to the attached agenda.
Attendees The CCP Management Team was present: J W Cook - Chairman J A Rutgers D B Miller R A Wells
~0ther attendees, including the thi'rd party C0D staff, were as indicated on the C>** o attached attendance list.
Discussion
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A. Agenda Item II - Description of-QVP: The details-of the QVP were presented according to the information in Attachment 1. Significant discussion items were:
- 1) QVP needs to contain an approved project level definition "
of " Inaccessible Attribute" before implementation. I
- 2) The list of PQCI/ irs needs to be verified.
- 3) Scheduling of initial qualifiestion efforts needs to be d
coordinated with project schedule priorities. . ._
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- 4) Paragraph 5.9 of Appendix F, treatment of r.onconforming conditions, needs to b's. fully discussed'and clarified with
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project engineering. .
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- 5) The quality verification phase results need to be carefully l analyzed and dccumented with full justification- for '
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. treatment of.any observed nonecnforming conditions.
- 6) QVP findings should be appropriately grended and an adequate program in place prior to implementation of l QVP. (Commitments made in response to INPO Construction
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Evaluation sho'uld be' reviewed in-this regard). '
- 7) Issues associated with IPIN, DR and Attachment 10 should be resolved prior to implementation of QVP.
8-) A derarmination needs to. be made that drawings are current and acceptable prior to implementing the QVP, particularly
. noting redlines and attachments.
B. Agenda Item III - Implementation Procedures required to support,the QVP were discussed per Attachment 2. -
Significant discussion items were:
- 1) All QVP requirements, as well as other related project commit-ments,must be identified and procedures written as necessary.
e
, 2) QVP implementing procedures must be in place prior to QVP r
s, implementation.
C. Agenda Item IV: PQCI Review, Revision and Training The process was explained per the information in Attachment 3 and 4.
Significant discussion items were:
- 1) Need to verify method for. establishing effectivity dates for PQCI including changes prior to QVP implementation.
- 2) Need,c,o review Project Engineering's role in PQCI revision )
processLprior to QVP implementation. (Note.Ed Hughes letter 4/15/83).
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- 3) Need to insure that PQCI signature process is clearly
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, identified by procedure.(Note PQCI 4.10 issue noted in BHP i
4/25/81.meno regarding.NRC_ exit) prior to QVP implementation.
- 4) Verify requirement and accomplishment of Project Engineering sign-off on PQCI prior to training..
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- 5) The ability to complete recertification of inspectors to new- ,
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'PQCIs by June l'was questioned. ' Appropriate schedule' statust '
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information will be provided to the CCP management team to track this activ'ity.
D .* Agenda Items I and VI - Organization and Manpower These items were discussed per information in Attachments 5 and 6.
l There were no open discussion items.
E. Agenda Item VII - Program Reviews No attachment for this item '
Significant discussion items were:
- 1) Determine whether a PQCI is needed for equipment in storage that has been receipt inspected prior to QVP implementation.
- 2) Need to determine if equipment previously' received an'd installed requires verification in addition to ongoing programs. Detarm'ine I if this needs to be included in QVP before implementation.
- 3) Ongoing programmatic reviews in design change control, design documentation control, receipt inspection, Q-ness and material I traceability need not delay QVP implementation although the project. should strive to resolve its position on material trace-1 ability before implementation. l
- 4) Process inspection control.should;be established as appropriate prior to QVP implementation.
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F. Agenda Item VIII - Project Coordination No attachment for this item Discussion indicated that.although it was essential to coordinate QVP activities with project schedules that this coordination was not a part of the QVP itself. This coordination will be handled through other mechanisms.
G. Agenda Item I - Management Team Review G. Slade and his team presented a detailed report which will be prepared and submitted to the CCP Management Team separate from these minutes.
The general conclusion of the teams, however, was that the QVP was not ready for implementation at this time but that it should be presented to the NRC for their review.
H. Agenda Item II - Project Management Conclusions After consideration of the above information, the CCP Management Team concluded that: .
- 1) The QVP should be finalized for presentation to the NRC.
- 2) QVP implementation should not occur at this time.
- 3) Action items need to be pursued per Attachment 7.
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qvP Manaamanrr RavIxv ,'//m /
.. ACTION ITEMS .
FORECAST RESPONSIBLE INDIVIDUAL COMPLETION ITEM
- DATE
[ SUPPORT)
Define inaccessible attribute (A1) B. Palmer (J. Norris or 5/04/83 .
. D. Harris)
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Diset$ss nonconforming conditions with'- Rt Wells /J. Rutgers (Staff) 5/29/83 proj eng (A4) ,-
. Set up trending program (A6) B. Palmer (M. Curland) 5/13/83
. Resolve IPIN, DR and Attachment 10 (A7) R. Wells (B. Palmer, M. 5/06/83 Curland)
. Verify adequacy of drawings (A8) B. Palmer 5/13/83
., Identify QVP related commitments (31) B. Palmer 5/13/83 (SMO)
. Issue procedure (B2). K. Cill 5/13/83 PQCI effectivity dates (C1) .H. Leonard- 5/06/83
- d. Review proj eng role in PQCI review (C2) H. Leonar'd 5/06/83
. Clarify PQCI approval process (C3 and C4) ,
H. Leonard 5/06/83
- d. Provide schedule status to management (CS) R. Wells 5/05/83 Determine need for PQCI for review of B. Palmer (J. Norris or 5/13/83
, equipment in storage (E1) D. Harris)
- 13. Determine need for additional verifica-
' B. Palmer (J. Norris or 5/13/83' tion of equipment received'and installed
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D. Harris)
(E2) d g G). Try to resolve material traceability (E3)
R. Wells (J. Rutgers) 5/20/83-
. Establish process inspection control (E4) B. Palmer,(M. Curland) 5/13/83 Finalize QVP (H1) J. Norris (B Palmer) 5/03/83 Initiate NRC discussions on QVP (H1) R.' Wells 5/04/83 O
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. .v AGENDA FCR MANAGEMENT REVIEW CF QUALITY VERIFICATION PLAN flf fg I Introduction Wells II Description of Plan Norris A. Scope B. Exceptions C. 100% Inspection '
D. Potential Exemptions frcan Plan E. Accessible / Inaccessible Attributes F. Initial Inspection Plan G. Sampling Concepts .
H. NRC Role I. Potential NRC Concerns Potential CP Co Concerns
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III Implementation Taggart A. Procedures
- 1. Status
- 2. Schedule IV PQCI Review and Revision Verderosa A. Process
- 1. QAE/QCE Roles
- 2. Project Engineering
- 3. Process Flow Chart B. Training and Recertifying Process Ewert C. Schedule Ewert V Crganization Wells A. QC Integration B. ECP-QA Realignment C. Verification Plan Responsibilities VI Manpower Needs and Plans Wells A. Manpower Curves .
B. Status
,C, Tcrocast VII Prograrmatic Reviews Wells i
A. I.7act on quality Verifiestion Plan B. Status 90214469
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2 VIII Coordination with Project Schedules Wells A. Priorities - SMO
- B. Impact of Sampling
- l C. Option - 100% Inspection by Modules, to " Start!, '
D. MPQAD Input
's . Qualification Sampie
- 2. Verification Smuple
- 3. Coordination
- Construction
- Teams
- X Recomunendations Wells A. Management Approval of Quality Verification Plen B. Submit QVP to NRC C. Continue Preparation for Implementation, considering findings fre Management Audit
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EXHIBITS Procedures , Taggart Training Ewert
- Lesson Plan
- Class Review Fozu
- Policy Failure Evaluation (Example) ' ' "-
- Process Flow Chart w
PQCI Norris
- cid, with support dr-a_ts
- New organization Chart We'1s 1
Manpower / Budget / Schedule Wells quality Verification Plan Norris-1 i
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v. nn New Procedures to Support Verification N-1 Control of the Quality Verification Program Document N-2 Quality Verification Program Exceptions N-3 Quality Verification Organization Charter N-5 Verification Program - Purchased Items N-6 Processing of Third Party Identified Deficiencies v-Nell Verification Program Sampling l
,M-12 Inspection Verification N-13 Requests for Construction Services Support N-16 Reporting of Verification Results .
N-19 Construction Completion Monitoring Program 5 4 e l -
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Y. Summarv of New MPQAD Procedures for Verification - Procedure No. Title & Purpose N-1 Control of the- Quality Verificat' ion Program Document i
- Ao establish the requirements and responsibilities for preparing, reviewing, epproving, revising and distributing the Quality Verification P'rogram Document. -
N-2 Quality Verification Program Exceptions To establish the requirements and responsibilities for Midland Project Quality Assurance Department documenting and reporting exceptions to the Midland Quality Verification Program. - N-3 QualityVer[ficationOrganizationCharter To define the charter of and the responsibilities for the Midland Project Quality Assurance Department Quality Verifi-cation Organization during Phase I Quality Verification-activities. N-5 Verification Program - Purchased Items To establish the requirements and responsibilities for the Midland Project Quality Assurance Department verification of the quality of purchased safety-related material and components. , N-6 Processing of Third Party Identified Deficiencies To, establish the requirements and responsibilities for Midland Project Quality Assurance Department processing of corrective actions resulting from third party identi fied deficiencies.
- N-ll Verification Program Sampling To establish the requirements and responsibilities for Midland Project Quality Assurance Department sampling of previously accepted items for verification by reinspection.
N-12 Inspection Verification l
. _. . To.establi,sh,the requirements,,and responsibilities for Mid. land
, Project Quality Assurance Department verification of th's l acceptability of previously accepted items by reinspecting the items or reevaluating the Inspection Records of the selected items. l l i* t
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Procedure No. Title & Purpose N-13 Requests for Construction Services Support To establish the requirements and responsibilities for requesting Construction Services support. N-16 Reporting of Verification Result's To establish the requirements and responsibilities for providing verification reports on the Midland Project Quality
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- Assurance Department Quality Verification Program.
l N-19 Construction Complet' ion Monitoring Program ! To establish the requirements and responsibilities for hidland l Project Quality Assurance Department monitoring of the CP Co
! Construction Completion Program.
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a # Basis to Evaluate and Update Verification Procedures (2nd Phase Development)
- Finalized Quality Verification Program Document (Assume final 4/29/83)
- CP Co Serial Lettar 22027 dated April 22, 1983
- Results & Recommendations from Management Review Conducted April 27-29, 1983 Recent Organizational Changes to Support Verification 90214493 d
. 'l 5 . CONSUMERS MIDLAND PROJECT AFAN 7 1 poggg .
QUALITY ASSURANCE PROC NO E-3M j)Mek COMPANT DEPAR'!' MENT PROCEDURE PAGE 6 of 30 RETISION 0 DATE 4/6/83 PREPARATION AND APPROYAL OF PROJECT QUALITT ' CONTROL INSTRUCTIONS b ar ' Revision
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- CD wY PQCl REVISION OBJECTIVES .
3a CD l , k ( j' A) All attributes important to the safety and Feliability .
, of specific components, systems, and structures are identified for verification. j B) Accept / reject criteria are clearly identified. !
' ~ C) Appropriate controls, methods, inspection and/or i* testing equipment are specified.
- l. D) Requisite skill levels are required per ANSI N45.2.6 or
- SNT-TC-1A. ,
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V , ei 1 N e m PCCI REVISION TEAM MAKE UP ' is , i 4 Quality Assurance Ehgineering (QAE), i Quality Control Engineering (QCE), and Training J. I 1 *: o 1 ; s 4 - 4 1 - $ l l 4 e g l
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r. m W W v1 PQCl REVISION - TEAM MEMBER RESPONSIBILITIES QAE - overall technical / programmatic responsibility " Project Manager" for the effort. ' QCE - verification of the " workability" of the PQCI from an inspection viewpoint.
- overall inspection expertise input.
,. Triittitig - verification of- the' "trainability" of- the PQCI. ( l
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PROJECT ENGINEERING EVALUATION I
, e A) Resolving any problems with inspection criterJa identified -
i during the PQCI generation process - including the generation of inspection criteria document changes, as required. B) . Verification that the PQCI does, in fact, include all attri-butes important to the safety and reliability of the subject inspection area. l Verification that the PQCI does not contain extraneous criteria C) I not important to the safety and reliability of the subject in-spection area. j . k. l 4 a l , 0
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POCl PLDW CHART' ; N O m i. CLARIFICATION REVIEW ., COMMENTS s i f APPROVALS
; REVIEW ) PILOT J4 REVIEW. : & '
, DEVELOPMENT i ISSUES QAE AQAES QAE AQAES AQANSH QCE PFQCE OCE PFOCE PFQCE l .
l TRAINING PQAE(ASME) TRAINING PQAE(ASME) PQAE(ASME) \ - COMMENT l l m l+
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"I O PQCI E-6.6 i N O m n INSPECTION ACTIVITY 2.5 a.i. BEFORE c E-20-102 , Inspect flanged installation connections for: para. 3.6 IfV) I1,,n.p. 2.5 lioli inn
- a. CorrectlortentattonI lllV)
- b. Correct bolting material ILV) nei..r.:
e ' i' c. Correct 0-rings II V) 18:1 -7H ^
- d. Proper matching of bolt holes 109)
- e. Gasket surf aces free of damage ILV) l'-
- f. Bolt threads 'and nut washer faces are not lubricated IfV)
- p. Unifona contact over entire flange area 11 V)
- h. Ihreads fully chgaged and nut face, facing the flange ll;H)
- 1. Bolts have been properly tightened (torqued. or elongated to required sequence ().
i thelcorrect values lin accordance with the ty humber and 3 NOTE: Record torque, torque wrench ident ~ calibration due date on the Flange Bolting Record, f ,s l
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ACTIVITY 2.14 i r
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NOW i 2.14 t.ssu m e that the bolts / nuts have been torqued to the values listed E 20-102 W, Flange H. Iring Inc l e.w . Through balta must be torgijed in a diametricly opposite sequence. 3.6.4.3.4 lloid Ht i niil 3.6.3.3.4 Polus 7 nn/s o n HofE: Record torque, torque wrench identity number'and calibration Appendix "D"
, due date on the Flange Balting Record, i 7/8" Bolt / Nut - 500 forch-pounds minimum /42 foot-pounds
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l I/4" Bolt / Hut - 2,800 inch-pounds minimum /235 f oot-pininds Onp Screw - 1,200 inch-poundo/100 font-pounds ' !. Cap Screw Not - 600 inch-pounils/50 funt-pounds I thel 1 Point: QCE must be present during the torqueing*of holts. 4 ,i i. h
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NOW t . 2.12 Verify that the following bolting material was used connecting the E 20-102 I(V) header plate to the flange. Location of lock and flat unshers shall 3.6.3.3.4 (H)
- he as shown in attachment "A". Bolta may be oriented in either direction. 3.6.4.3.4 FIC 3-3 ,.
1 . FIC 3-13 Hedium Voltage Bolt - 1 1/4" (coarse three ')::5.25" long . Hut - 1 1/4" ' Flat & Lock Washer
; 12 Bolts Required 4 Low Voltage's Bolt - 7/8" (coarse thread)x4.5" long , Nut - 7/8" Flat & Lock washer
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REINSPECTION SCOPE AND ASSUMPTIONS SCOPE
- 139,000 CLOSED IR'S REPRESENT POPULATION
- CcMBINED PQCI'S
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- RECEIPT INSPECTION
- DOCUMENT REVIEW
- OVERINSPECTIons PREVIOUSLY DONE
- 101,500 CLOSED IR'S SUBJECT TO VERIFICATION (EST)
. - 79,500 HARDWARE REINSPECTION
- 22,000 PRIMARILY'DOCUMENTATI0il REVIEW ASSUMPTIONS
- PLANNING BASED UPON 45,000 UNITS OF REINSPECTION
- 4 INSPECTION HOURS PER UNIT (avg) REQUIRED FOR REINSPECTION
- WORK FORCE OF 250 TO 350 ' INSPECTORS
- SCHEDULE BASED UPON 7 DAY WEEK AND 5 INSP-HOURS PER DAY
- NRC APPROVAL OF CCP IN MAY 90214507
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. - 4 sA CUMULATIVE REINSPECTION MAN ll0URS N
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FOR VER'IFICATION PHASE 500 - I [. . 8106,000 MAN-llRS l 400- maximum / j i , , 350 INSPECTORS A jj hI ---
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250 INSPECTORS , . . 8 _ I !. 1 . i 5 b' 180,000 INSP-HRS E' 200 - E - Pl.AN M . . t
- 88,000 INSP-HR$
- E -' MINIMUM
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