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NL A.EAFt REGULATORY COMMISSIOA o
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August 3, n983 Docket Mos: 50-329 t
and 50-330
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M MDRAWDUM FOR: James G.ixeppler, Regio'nel. Administrator, Region III FROM:
Darrell G. Eisenhut Ofweetor Division of Licensing,1NRR
SUBJECT:
NRRCOMMENTSON'MIDLANDd6W5TitUCTION COMPLETION PLAN In response to your memorandurn of June 23, 1983, Enclosure 1 provic'es NRR's connents on the Midland Construction Completion Program (CCP) submittal of June 10, 1983.
We understand that NRR and 1&E ceImments will be Combined with any Region III connents since March 28, 1983, and an NRC package of connents will be issued to CPCo. This will be followed by a public meeting which will be held prior to final NRC approval. CPCo will also be required to update the CCP to reflect NRC cosnents prior to final NRC approval.
We have reviewed I&E'e consents provided to R. Warnick on July 8,1983, and consider them' to be appropriate. In ' fact, two NRR convaentt, in (Connents 10 and 12)icorrespond to similar coments made by IAE.
We have also~ reviewed the $t9ne & Webster documents date:d April 1, April ll, and May 19, 1983, for Stone WWebster's acceptability as i
a third party overviewer of the CCP. -We conclude that Stone & Webster is i
appropriately independent and qualified. Earlier concerns abcut the qualifications of two individuals on the Stone & Webster team have teen resolved through the provision of missing pages from one of the submittals.
Should you have q estiens regarding Enclosure 1, contact Licensing i
Branch No. 4.
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I 4. lBN Ei u, director Darrell'G.-
'l Division of Licensing l
Office of Nuclear Reactor Regulation
Enclosure:
As stated t
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NRR Comments on Construction Completion Procram (J. W. Cook letter to J. Keppler dated June 10.:1983) e m (1)
Page 2: & 35
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Page 2 of CCP notes tnat " safety 4 relit,d systems and areas of the plant
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will be systematically reviewed.".CPCo should define or id*ntify wbat it means by safety-related sy$ tans.,
The brief discussion on the top of page 35 (dentifies a "sepa' rate organira-tion" to carry out a spatial:nystems. interaction ($$1) review, and notes that the SSI represents the Project.rvspanse to the generic licensing issue of "important to safety" that is being handled outside o? the CCP with NRC/NRR. CPCo should provide a,clearidefinition of systems "important to safety", but not safety-rel.ated.:and a description of the process they (CPCo) used to decide that.$ystems "important to safety" can be excluded from the CCP.
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(2)
Page 4 - Last paragraph
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This section notes that CPCo intends to schedule periodic reviews of Program status and progress with the NRC. Such meetings should be noticed and members of the public'and interested parties should be provided the oppor-tunity to attend as observers.
(3)
Page 4 4 34.
The scope of the CCP is not clear. The statement in the first paragraph of the Executive Sumary appears to. conflict with the penultimate paragraph on page 4'and the Description Section 9.3 on page 34. The relationship of the Quality Verification Program to the CCP is also not clear, althcugh it appears to be part of it.
(&)
Page 17 - Second paraoraoh Who will determine the need and extent for reinspection of the past work of an inspector failing any part of the recertification process? What criteria l
2re used for these decisions? What infonnation is provided to RIII to justify thc decision?
i (5)
Page 21 - Section 4.3.2.b.
Although not quantified, it woJ1d. appear that a significant portion of the CCP will be involved with verification of acceptability of inaccessible e
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attributes. This is predominately a paper work review, but "if required" will be supplemented by NDE.techiques and destructive examination. Define l
- if required". In view of past documentation problems and the extent of 1
inaccessible items, the CCP should include some NDE of inaccessible items on a sampling basis.
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O 2-a NRR further suggests that R131 consider auditing / supplementing the App 11-cant's NDE conclusions with its own findings based on use of the RC 1 NDE mobile van.
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Page 28 - Section 5.3.2 The composition 6f " site managenert". ' Project management", and," management
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team" should be defined if not already done elsedere.
(7)
Page 32_ - First paragraph Because we do not have access to the protocol for communications used on the soils remedial activities, we er+ unable to comment on the appropriate-ness of using that protocol in dealing with the C10 team.
(8)
Page 32 - Tinird paragraph 1
Will the overview of site construction activities include systems. excluded from the CCP?
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(9)
Page 32 - Fourth paragraph s ~
Justification should'be provided for the size of the S&W staff for tne CIO outlined in their April 1.1983,. letter to J. Cook. What criteria were used, and by whom, to establish the proposed number of S&W personnel? What restrictions and lead times would exist in the event S&W should identif'y the need to. increase its staffing levels?
(10) Qualifications of CIO Oventewers We reconenend that provisions be.made for the NRC to review the experience recoros 'of all personnel added to the S&L' Team in the future.
(11),Paje 34 - Section 9.3 d Item 1 under Stretion 9.3 excludes NSSS installation by B&W as part of the CCP. Staff acceptance of 'this exclusion has been noted in the hearing to depend upon results of a future NPC tudit of BW ttcrk arns. Staff accep-tance of this ite.e should be acknewledged to be corditional. In the interin, the basis for CPCof s oecision should be provided for NRC review.
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t (12) Page 35 - First paragraph and p.a' e 32 Third ' paragraph g
l The spatial systes Me'raction:tss!) is proposed to be overviewed by the C10, reviewer.,*,4W.
As indicated at an April 13, 1983, meeting. :the staff understands TERA will mediteportions of the $ystems' Interactions
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activities applicable to three systems. On:page.32, CPCo states that 7
the C10 will not include am.9verview of other third party evaluations being Conducted. CPCo shoul.d.starify to What extent the CIO effort will address the three systems in the TERA scope. They.should fu/ther verify l
whether or not TERA will audit.those portions oi' the 351 review applie-able to the three systems under the 7 ERA scope, s
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....e Docket Mos: 50-329 04, OL and 50-330 ON, OL EMORA!!DUM FOR: James G. Keppler, Regional Administrator.
Region III FROM:
Darrell G. Eisenhut, Director Division of Licensing, NRR
SUBJECT:
NRR COMMENTS ON MIDLAND CONSTRUCTION COMPLETION PROGRAM As requested in your memo of June 23, 1983, NRR has reviewed Consumers Power i
Company's Construction Completion program (CCP) dated June 10, 1983. Our comments follow:
1.
Page 2 of the CCP asserts that " Safety-related systems and areas of l
the plant will be systematically reviewed." The document does not indicate how CPCo defines or identifies safety-related systems.
2.
The top of page 35 identifies a " separate organization" to carry out a spatial system interactions (SSI) review which responds to the generic licensing issue of "important to safety" that is being handled outside of the CCP with NRC/NRR.
It is not clear how an SSI would enable identification of all systems important to safety.
Also, should not the CCP include all systems "important to safety" (as presently defined in H. Denton's memo to All NRR Personnel dated November 20,1981) and not just safety-related systems?
3.
Iht scope of the CCP is not clear. The statement in the first paragraph of the Executive Summary, which included "all systems"
.in the scope, appears to conflict with both the penultimate paragraph on page 4 and tSe Description section 9.3 on page 34.
4.
The relatienship of tne Quality verification Program (Appendix 1) to the CCP is also not clear.
We have also reviewed the Stone & Webster documents dated April 1. April 11, and i
n',ay 19, 1983, for Stone & Webster's acceptability as a thiid; party overviewer of Conse,ers' CCP. We conclude that Stone & Webster is appropriately indeptndent and qualified, with the exception of two individuals, to perfom.this function.
The
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two individuals excepted in qualifications are Messrs. J. P..Chawla and S. W.
Baranow whose experience records were rot included in any of'the transmittals.
The credentials of both should be reviewed by the NRC before approval is given for their inclusion on the inspection team. Additionally, we reconmend that provisions be made for the NRC to review the expe-tence records of all pgsonnel added to the 4
I Stone & Webster team in the future.
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[h James G, K:pplcr 2-Se umld like to arrange a meeting between Region III, NRR and I&E to discuss the
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acceptability or unacceptability of the CCP in view of NRC cornments. This tr.eeting would precede a public meeting in Midland to obtain public comments before a finalized flRC posf t1on is developed. -
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Darrell G. Eisenhut, Director Division of Licensing Office of Nuclear Reactor Regulation cc:
W. Johnston W. Houston J. P. Knight D. Muller F. Rowsone J. Tay1or L. Rubt:nstein D. Ziemann' 4
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MEMORANDUM FOR:
R. F. W6rnick, Director 0L
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l Office of Special Cases, Region III FROM:
James M. Taylor, Director Division of Quality Assurance, Safeguards, and Inspection Programs Office of Inspection and Enforcement
SUBJECT:
MIDLAND CONSTRUCTION COMPLETION PROGRAM (DOCKETNOS. 50-329/330)
We have reviewed the Consumers Power Construction Completion Program for Midland as requested in your June 23, 1983 memorandum. Our consnents are enclosed. The majority of the comments were discussed with J. Harrison on July 6, 1983.
In addition we have reviewed the Stone & Webster proposal to conduct the third party assessment of the Construction Completion Program. We have concluded that Stcne & Webster Engineering Corporation has sufficient independence and competence to perform the third party assessment of the Construction Completion Program. However, there is a concern that the size of the proposed Stone & Webster staff to perform the third party assessment is too small. Some assurance that an adequate staff will be available to conduct the third party assessment is needed.
If you have any questions abou; the connents please call.
1 J'
.' aylor, Director i
visio of Quality Assurance, Safeguards and Inspection Programs Office of Inspection and Enforcement
Enclosure:
i Comments h
cc w/ enclosure:
D. Eisenhut, NRR T. Novak, NRR l
E. Adensam, NRR jm,15 883 Ns.
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Consnents from Reactor Constructico Programs Bran {h A.
Consnents on Constru'ction Completion Program t
Ofconcernwa$theintegrationoftheQA/QCfunctionintothe 1.
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2 various teams.,We now understand that the MPQAD representative 3
,e is performing a liaison fuitetion between the team and MPQAD and actual inspections will not be perfonned by 'the MPQAD team representative. The CCP should be unambiguous concerning the
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function and ' duties of the team MPQAD representative.
2.
Page 11 and Page_12_
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Will completed ASME Code work, including N-stamp work, be U"'
subject to the reverification program? ' If so,-this should be clearly stated.
1 3.
Page 12 s
What are the differenc[s between (a) Quality Control inspection 1-u
. p(lads, (b) Project Quality Control Instructions (PQCI's) and F
c) Quality Work Plans (QWP) (referred to.on page 24)?
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Page 12 Under i: raining of MPQAD Personnel the statement is made "Early c
in 1983, MPQAD decided to terminate recertification of old PQCIs except in selected cases,...". What old PQCIs have a
been retained and will they:be used in the CCP program?
5.
Page 19
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"He assures validation of NCR's".
Please explain what this 1.
statement means.
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how will jncomplete items (system status) be documented?
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7 7.
Has Region IIISreviewed the three procedures listed in Figure 4-1, Page 267
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Page 28
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7 Under. Evaluation and Msdingeaent - Phase 2, need furthbr clari-fication'of'the meltdng of "The first anagementsreview for work release will-be done by the management team.
S'ub' sequent status 1
assessment results will-be released by site Aanalgement prior
.i to initiation of additional completion segmentst"' ~
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Page 33 System Layup - Is equipment requiring inert gas cover being checked and maintained as recommended by the manufacturer?
Is normal preventive maintenance (shafts rotated, heat applied, etc.) being perfonned on the equiprnent?
- 10. Page 36 l
For changas to the CCP does Region III feel being informed before implementation is adequate?
B.
Connents on Quality Verification Program (Appendix 1) 1.
Page 9 Need clarification of the statement " System / area reinspection will be supplemented by random plant-wide inspections as appropriate to establish a valid quality baseline on an expeditious basis."
2.
Page 9 Last line, insert between the words " reports" and "will" the following: "that have not been dispositioned". This is to clarify that the nonconforming condition need not be reported
-only if there is an open NCR on the same item.
3.
Page 10 Section 5.3.1, third-sentence, insert between the words " reports" and "as" the following: "that have not been dispositioned".
'l This is to clarify that the nonconforming condition need not be reported only if there is an open NCR on the same item.
4.
Page 13. Section 6.4
-i Are meterial traceability aspects to be covered by this
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program?
j C.
Connents on Appendix B l '.
Page 1-1 L}
Why are PQCIs associated with remedial soils program listed?
l The CCP excepts that activity..
II. Connents from Quality Assurance Branch Page four of the plan identi#Ss four major' safety-related work items
-j outside the scope of. the CCP. However, Section 9 of the plan (page 34)
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... i describes activities associated with these four areas. In this regard it is recommended that:
1.
The extent Section 9 is or is not part of the CCP be clearly stated.
2.
Additional information be provided which led Consumers Power to detennine that those activities identified in Section 9.3 (page 34) of the plan have demonstrated effectiveness in the Quality Program implementation.
3.
The quality assurance program and organization be described for controlling those activities identified in Section 9.3 (page 34).
(tonsucers Power could reference previously established commitments.)
If not already provided, Consumers Power should provide clear justification as to why the activities described in Section 9.3 need not be part of the CCP and why additional quality assurance controls are not necessary during the completion of these activities.
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R. F. Warnick,. Director Office of Special Cases, Region III PEMORA".00M FOR:
James M. Taylor, DirectorDivision of Quality Assurance 6. S FROM:
7 and Inspection Programs Office of Inspection and Enforcement.
MIOLAND CONSTRUCTION COMPLETION PROGRAM S'JiJECT:
(DOCKET N05. 50-329/330):
Program for l
- e have reviewed the Consumers Power Construction' Completion Our comments are 23,1983: rra:norandum.
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l'icland as recuested in your JuneThe majority of the cor:rnentsiwere en:losed.
Jaly 6; 1983.
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- r. addition we have reviewed the Stone & Webster proposal to We have i
C mpletion Program.
third party assessment of the Construct on. ocor.cluded th fficient independence and competence to perfom the.th rHowever, there is a concern t i
i d party si:e of the propcsed Stone & Webster staff > tc perfom the th Construction Completion Program.
dd assessment is too small.available;to conduct the third party assessm l
you have any questions about. the comments please cal.
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I 6., aylor, Director viiticw cf' Quality Assurance.. Safeguards l
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. and Ir.spection Programs-Off. ice of thspection and Enforcement E.cicsure:
C:r entsi
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. Eisenhut,f.RR T. f.ovak, f4RR s.
t E. Adensam, NRR i
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j CClo!ENTS'ON MIDLAND CONSTRUCTION. COMPLETION PROGRAM I
Comments from Reactor Construction hograms Branch A.
Corinents on Construction Completion Program j
1.
Of concern was the integration.of the. QA/QC function into the
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variousi teams. We now understand that the MPQAD representative
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is performing a liaison function between the team and MPQAD and actual inspections wil.1 not be performed by the MPQAD team representative. The CCP shouJd be unambiguous concerning the function and duties of the. team MFQAD representative.
2.
Page 11 and Page 12 l.
Will completed ASME Code work, including N. stamp work, be subject to the reverification program? If so, this should ba clearly stated.
3.
Page 12 t
What are the differences between (a) Quality Control inspection plans, (b) Project Quality Control Instructions (PQCI's) and (c) Quality Work Plans (QWP).(referred to on page 24)?
4.
Page 12 Under training of HPQAD' Persennel. the statement is made "Early in 1983, MPQAD decided to teminate recertification of old PQCIs except in selected. cases,...". What old PQCIs have been retained and will theyibe used in the CCP program?
5.
Page 19 In the discussion of the team MFCD repres,entative it is stated "He assures validation of NCR's".
Please u plain what this statement means.
6.
Paes.20 t
l Nonconformances are documented:in Nonconfomance Reports (HCP.s),
how will incomplete items (system status) be documented?
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Has Region III reviewed. the-thme procedures listed in Figure 4-1, Page 26?
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Unider Evalua*.ionianc Management:- Phase 2, need further clari-fi:ation a' the meaning' of "The first management review for work release wi 1 be done t y the management team. Subseque d status h
assessment.results will' be released by site management prior L
'.1 2 initiation of additio'ogl completioni segments."
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Pana 33 System Layup - Is equipme.nt requiringiinert gas cover being
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Is normal preventive maintenance. (shafts rotated, heat applied.
,j etc.) being performed om.the equipment?
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Fon changes to the CCP does Region III feel being informed ll,. u>a inu' before implementatiion is adequate?
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Cc:ments, on Quality Verification Program (Appendix 1) appne),.ll B.
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Page 9 i.
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';eed clarification of the statement " System / area reinspection will be supplemented by randon plant-wide inspections as appropriate to establish a valid quality baseline on an expeditious basis."
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Page 9 4
Last line, insert between the words " reports" and "will" the following:
"that have not been dispositioned". This is to clarify that the. nonconforming: condition need not be reported on1.y if there is an open,4CR on the same item.
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Page 10
-l Section 5.3.1, third sentence,. insert: between the words " reports" and "as" the following: "that-have not been dispositioned".
This is to clarify that the. nonconforming ccndition need not ne reported only.if there is an open NCR on the same item.
4 Face 13, Section 6.4 I.
Are material traceability aspects to be covered ::y this progran.?
C.
Cc=ents. on Appendix B 1.
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Why are PQCIs associated with remedial soils program listed?
The CCP excepts that activity..
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II. Coments fron Quality Assurance Branch
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However 5ection 9 of the plan (page 34)
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desi:rlbes activities associated with;these four areas.
In this regard it is recomended that:
- 1. ?The extent Section 9 is or is not part' of the CCP be clearly
- stated; " '
2.
Additional information be provided which led Consumers Power to j
.. determine that those activitiesiidentified'in Section 9.3 (page 34) 1 of the plan have demonstrated effectiveness in the Quality Program ir.plementation.
3.
The quality assurance program and organization be described for centrolling those activities identified in Section 9.3 (page 34).
(Ionsumers Power could referenceipreviously established commitments.)
If net already provided, Consumers Power should provide clear justification as tc :hy the activities described.in Section 9.3 need not be part of the C P and why additional quality assurance controls are not necessary i
durir.g the completion of these activ'ities.
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JUN 27 G83 Docket No. 50-329 Docket No. 50-330 i
Consumers Power ra=y==y ATDI: Mr. Jeans W. Cook Vice l' resident Midland Project 1945 h at Parnall Road Jack
,MI 49201 Gentlement ERC Region III has completed a preliminary review of your June 10 submittal regarding the Construction Coupletion Program (CCP).
, 1983, this review the Region has authorised r,====rs Power Company (CPCo) t Based on initiate CCP team training activities; this authorisation was made per o
teleconference to Mr. D. Miller of your staff by Messrs J. Barrison of my staff on June 20, 1983.
. R. Cardner and by the MRC prior to granting CPCo authorisation to furth Construction Completion Program.
by the NRC is at CPCo risk pending CCP approval.The team training that was authori Your cooperation with us is appreciated.
Sincerely,
' $U}i.]L0]. &Y Q-Q NAtuam f'"1R.F.Warnick, Director j
Offica of Special Cases i
ec w/Itr dtd 6/10/83:
see attached distribution list 1
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OFFICIAL RECORD COPY I
4 Consumers Power Company JUN 2 7 GS3 cc w/Itr dtd 6/10/83:
DMB/ Document Control Desk (RIDS)
Residuit Inspector, Rill The Honorable Charles Bechhoefer, ASLB The Honorable Jerry Harbour, ASLB
- The Honorable Frederick P. Cowan, ASLB The Honorable Ralph S. Decker, ASLB William Paton, ELD Michael Miller Ronald Callen, Michigan Public Service Consnission Myron M. Cherry Barbara Stamiris Mary Sinclair
-4 Wendell Marshall Colonel Steve J. Gadler (P.E.)
Howard Levin, TERA Billie P. Garde, Government Accountability Project Lynne Bernabei, Government Accountability Project 1
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O Jaenes W Ceek Vice hesadent - hojet:s, Engmernng and Cens,rmation o.a.,e om.=: ms w.= *-ami now. a.=a. m aeroi < sin tasoass June 10, 1983 Mr J G Keppler, Administrator, Region III Nuclear Regulatory Commission 799 Roosevelt Road Glen Ellyn, IL 60137 MIDLAND NUCIIAR C0 GENERATION PLANT MIDLAND DOCKET NOS 50-329, 50-330 t
CONSTRUCTION COMPLETION PROGRAM FILE 0655 SERIAL 23255
' Reference 1.
Letter to Mr J G Keppler dated January 3,1983, from Mr J V Cook regarding Construction Completion Program.
The enclosure to this letter is a revision to the Construction Co:npletion Program description submitted on June 3, 1983 (Reference 1).
The revisions incorporate the coceents and changes suggested by Region III staff.
NRC release points following Project. Management review of plans and i
performance on major activities are incorporated directly in the body of the text (Section 5).
In addition, an expanded description of special activities, I
such as installation of pipe hangers and watertight doors is provided (Sectiot.4.5). Other changes were made to provide clarification; the intent of Reference I has not been changed.
i slash to facilitate identification.
All changes are indicated wtth a margin The Quality Verification Progr:m which is included as an appendix to the Construction Completion Program tas been revised to provide a 100, verifica-
'l tion program for accessible portions of items associated with the use of the 0 form.
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We trust that these revisions fulfill your request for clarification and incorporation of the NRC release points in the Construction Completion Program document.
aaas JWC/DMB/kle CC Atomic Safety and Licensing Appe Board CBechhoefer FPCowan, ASL3 JHarbour, ASL3 DSHood, NRC MMCherry RQfernan, NRC RJCook, Midland Resident Inspector TSKelley HRDenton, NRC kE!arshall i
WPaton, NRC JJHarrison, NRC-RWarnick, NRC BStamiris MSinclair LL3ishop I
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CONSt. :RS PO'.T.P. COMPAhY T
Midland Units 1 and 2 Docket No 50-329, 50-330 Letter Serial 23255 Dated June 10, 1983 At the request of the Commission and pursuant to the Atomic Energy Act of 1954, and the Energy Reorganization Act of 1974, as amended and the Commission's Rules and Regulations thereunder, Consumers Power Company submits Revision 1 to its Construction Completion Program.
CONSUMERS POWER CCMPAh7 i
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By N
i J V Cook, Vice President P
ects, Engineering and Construction Swornandsubscribedbeforemethis//
day of J_) 1983.
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Od Alva C Robinson - Notary Public Jackson County, Michigan 1
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My Commission Expires [6b'b /, [f[b i
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i miO683-4032c168
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O MIDLAND NUCLEAR CCGENERATION PLAST Docket No-50-329, 50-330 4
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l CONSTRUCTION COMPI.ETION PROGRAM d
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S TABLE OF CONTENTS Section Title Eagg
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Executive Summary 1
t 1.0 Introduction 5
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2.0 Preparation of The Plant 10 i-3.0 QA/QC Organization Cha ges 11 k
4.0 Program Planning 18 5.0 Program Implementation 27 I
6.0 Quality Program Review 30
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7.0 Third Party Reviews 31 8.0 System Layup 33 l
9.0 Continuing Work Activities 34
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10.0 Changes to The CCP 36 I
Appendix 1 Quality Verification Progras I
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1 CONSTRt CTION COMPIITION PROGRA.]
Executive Summarv The Construction Completion Program has been formulated te provide the planning and management of the construction and qualit ance in Ccgeneration Plant.necessary for corspletion of the construction of the Midland Nu y activities Construction completion is defined in this Plan as Company f@or component checkout and preoperation carrying treated in separate interactions between Consumers Pow The Construction c
s Nuclear Regulatory Commission.
ompany and the i
Background
The Construction Completion Program was developed in response to management concerns that have been identified during the period pr a number of initiation of the Program.
eceding the level of activity as it approached completion.The M dland Project had been proce most nuclear projects. construction to system completion, using punch lists, has which have been compounded due to the congested space a cult for numerous design changes, both generally attribotable u ng Project.
e status, increased emphasis on overall Project objectives as well as c focus of construction and inspection resources on completion of ontinued short-term milestenes and increased effort to cceplete engineering ah systems for field installation.
i ead of having met their exThe Midisad Project has been criticized by the.NTsc regi i
Assurance Program. pectations for implementation of the Pro ce as not l
often, during the menths preceding this Program, been in a reactive r than proactive pcsture with regard to quality assurance ather matters.
In recognition of these conditions, management has concluded that approach was needed to effectively complete the Project while maint a change in quality standards, aining high g
Obtectives The development of the Program has considered the status and probleas currently being experienced.
i of the
, following overall objectives were established under three general h The Program Must:
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l Isorove Project Information Status By:
Preparing an accurate list of to go work against a defined baseline.
Bringing inspections up-to-date and verifying that the quality of completed work is acceptable.
Maintaining a current status of work and quality inspections as the Project proceeds.
Imorove Imolementation of the OA Prearam Sv:
Expanding and consolidating Consumers Fever Company centrol of the quality function.
Improving the primary inspection process.
Providing a uniform understanding of the quality requirements a=eng all parties.
t Assure Efficient and Orderly Conduct of the Proiect Ev:
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Establishing an organizational structure censistent with the remaining work.
i Providing sufficient numbers of qualified personnel to carry out the program.
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Maintaining flexibility to modify the Plan as exparience dictates.
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Description I
The Construction Completion Program entails a number of major changes in the conduct of the final stages of the construction process and can be described in summary as a two phase process.
First, after certain necessary preparations, the safety-related systems and i
t areas of the plant will be systematically reviewed. This first phase will be carried out on an area-by-area basis, but will be accomplished mainly by tes=s organized with systems responsibility and a separate effort to verify the completed work. The product status of remaining installation work and a currentfrom this phase of the program will be i
i inspection status which providea grality verification of the existing work. The teams organized to 1
carry out this first phase will continue to function in the second phase as the responsible organizational units to complete the work.
In order to achieve its complete set of objec-ives, the Program contains a
. number of activities and elements that support and are linked to the two major phases described above.
4
-I in more detail in the balance of this report,The major components of the Plan, whic 3
can be described as fo11cus:
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A significant reduction in the construction activity in the safety-related portion of the plant, material removal and a general cleanup has been carried out in preparation for installation and inspection status assessment and quality verification activities.
A review has been made of equipment status to assure that the proper lay-up precautions have been implemented to protect the equipment until the installation work is completed.
The integration of the Engineer /Censtructor QC function into the Midland Project Qaality Assurance Department (MpQAD) under Censumers Power Company management has been completed.
HPQAD is carrying out a racertification program of QC inspectors, and review of the inspection procedures to be utilfred.
The completion teams are being organized, staffed and traiaed accerding to procedures developed to define the team's work process.
The completion teams will 1) accomplish installation and inspee:
1cn status assessment, 2) couplete installatics and ensurc quality inspections are performed and 3) determine that all require =ents have been met prior to functional turnover for test and operation.
Quality verification of completed work will be carried out in parallel with installation and inspectien status activities of the completien tea =s.
A series of management reviews are being carried out to carefully menitor the development and conduct of the Program and to revise the plan as appropriate.
i Review and resolution will proceed on outstanding issues related either to QA program or QA program implementation as raised by the NRC or third party overviews of the Project.
Third party reviews are being undertaken to monitor Project perfer=ance and to carry out the NRC's requirements for independen design verification.
Status The Program vas initiated on December 2,1962 by limiting certain ongoing safety-related work and starting preparations for the phase-one work of status assessment and quality verification activities. Since the Program also has incorporated a number of commitments made to the NRC during the period prior to December 2,1982, activities in support of these commitments such as QC integration into MPQAD and the racertification of QC inspectors, had been i
initiated prior to December.
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Milestones for each element of the Plan are enumerated in the text.
In general, preparation for the Phase 1 activities are in place and the Revision 1 miO683-4033a-66-168 i
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4 management reviews are being held. A pilot team is developing the procedures and training requirements. It is expected that the Phase I will begin shortly.
The Program provides for the Phase 1 results on an area, system, or partial system to be reviewed and evaluated prior to initiating Phase 2 system completion work on that system or partial system. Management will monitor both process readiness and Phase 1 evaluation result:..
The major areas of continuing safety-related work outside the Construction Cogletion Program are h'SSS construction as performed by B&V Construction Co, NVAC work under the Zack subcontract, the 6,tmedia? Soils Program and post-turnover punch list work released to Bechtel Construction by Consumers Power Company.
During the contir.uing implementation of the Program in 1983, the h'RC Region III can use the Plan to monitor safety-related construction activities 3
at the site. Since a subn antial portien of the Plan directly relates to i
commitments made to h1C me:.eges*.nt, consumers Power Company intends to schedule periodic reviews cf Program sta :us and pregress with the h7C.
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i 1.0. INTRODUCTION The Construction Completion Program has been formulated to provide the planning, and implementation of the construction a d guidance in Cogeneration Plant.necessary for completion of the construction of the Midland Nu quality activities n
carrying all systems to the point they are turned over to Cons Company for component checkout and preoperational testing. The Construction er Completion Program does not include the Remedial Soils Program whi h i treated in separate interactions between Consumers Pow c
s Nuclear Regulatory Concission.
er Company and the referred to as the Program in this document which contains the Pla Program development and implementation.
3 Beckrround i
The Construction Completion Program was developed in response to a nu management concerns that were identified during the period preceding th m er of initiation cf the Program.
l level of activity as it approached completion.The Midland Project had been procee e
construction to system coepletion, using punch lists, has been diffic lt fThe l
most nuclear projects.
which have been compounded due to the congested space an
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u or numerous design changes, both generally attributable to the age of the g
a Project.
These factors lead to the need for improved definition of work status, increased emphasis on overall Project objectives as well as conti focus of construction and inspection resources on completion of syst nued short-term milestones and increased effort to cceplete engineering ahead ems for field installation.
of The Midland Project has been criticized by the Nuclear Regulatory C regional office as not having met their expectations for implementation o=sission i
Project's Quality Assurance Program.
of the The result has been that the Project g
management has too often, during the acnths preceding 1
, been in a
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matters.
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change in approach is needed to effectively complete a a maintaining high quality standards.
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j Obiectives t
The development of the Program has considered the Project's current st recent history and attempts to address the underlying or root causes of th atus and probless currently being experienced.
folicwing overall objectives were established under three general hIn order e
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- The Program sust:
eadings.
Imorove Protect Information Status Svt Preparing an accurate list of to go werk against a defined baseline d
Revision 1 a10683-4033a-66-163 a,,
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Bringing inspections up-to-date and verifying that the quality of completed work is acceptable.
Maintainlag a current status of work and quality inspecticas as the Project proceeds.
Isorove Isolementation of the QA Proaras Sv:
i Expanding and consolidating Consumers Power Company control of the quality function.
Improving the primary inspection process.
t Providing a uniform understanding of the quality requirements among all parties.
Assure Efficient and Orderiv Conduct of the Proiect tv:
i Establishing an organizational structure consistent with the remaining i
work.
Providing sufficient numbers of qualified persennel to carry out the Program.
Maintaining flexibility to modify the Plan as experience dictates.
Plar. Contents h e Program was initiated on December 2, 1982 by limiting on-going verk on Q systems to pre-defined tasks and preparing the major structures housing Q-systees for an installation,and inspection status assessment and verification of completed work. The relationship of the major elements of j
the Plan is shown in Figure 1-1.
The sections of the Plan address the following major activities:
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The buildings are being prepared for a status assessment of incomplete work and verification of completed work, i
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A new quality organisation that integrates the QA and QC functicas under a Consumers Power Company direct reporting relationship has been established. As part of this transition, the Engineer / Constructor QC laspectors are being recertified to increase confidence in the quality inspection performance.
The overall Plan for the Program is being developed la two major phases.
The first phase includes:
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l A team organisation assigned on the basis of systees developed to determine present installation and inspection status. The installation status assessment includes a comparison of partially
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7 installed work to current design and identification of remaining i
work items for completion. The inspection status assessment t
includes the Team Quality Representative requesting MPQAD to perform additional inspections using recertified inspectors on partially completed or completed work to bring inspections up to date. A closely coordinated effort involving the i
Engineer / Constructor and Consumers Power Company (QA/QC, testing and construction) personnel will improve quality performance.
Separate teams are also being assigned to work area type consodities such as cable trays and doors.
(ie, commodities not related to a particular systes.)
i The quality verification of completed work initiated on a r
L 200*. basis using rs-certified inspectors.
I The second phase includes:
Work completion, following quality verification, installatica and inspection status assessment under responsibility of the tean organization.
An integration of the QC inspection process for new work with the completion work to ensure adequate quality perfor:snee.
I The first phase implementation of the P cgras will be initiated with a review of the process, procedures and team assignments that will be used. The plan for verification of completed work will be revir.ed t
separately. Verification of completed and previously inspected verk j
will be carried out by MPQAD in accordance tith the Quality Verification Plan, in coordination with the team effort. The teams will conduct the installation and inspection status assessment; as l
part of this effort MPQA3 will be requested to bring inspections up to j
date on partially completed or completed work. To11owing Phase 1 i
completion of the first verification and'rsatus assessoent segment, a
management review will be made of the evaluation of the initial Phase 1 results and the process and procedures for Phase 2 activities.
4 In second phase Program implementation, the assigned team will plas and carry out the remaining work needed for completion including QC inspections.
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The adequacy and completeness of the quality program will be reviewed.
as appropriate, on an ongoing basis, taking into considerati2n i
questions raised by NRC inspections and findings by third party 1
reviewets.
Independent assessments of the Midland Project will provide management and NRC with evaluations of Project performance.
~ The on going work to protect plant equipment and systess will be i
augmented as nacessary to provide adequate protection during implemer.tation of this Plan.
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Vork on Q-Systems has been limited to specific activities. This limitation permits important work to proceed outside of the Construction Completion Program while allowing building preparation for status assessment and verification activities on that work which is under the Construction Completion Program.
Summary The program is a comprehensive plan to complete the Midland Nuclear Cogeneration Plant in a manner that assures the licensibility of the plant when construction is complete. Ccst and schedule for completien of the Midland Project are also a concern for Consumers Power Company.
The Company believes that the most efficent way to project completion is to understand the current plant status, establish the requirements to finish the project and complete the work according to these requirements. Thus the these of the Constructien Completion Program t
to verify past sork and proceed on future work with improved performance is consistent with this philosophy.
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FIGb..E 1-1 CONSTRUCTION COMPLETION PROGRAM SCHEMATIC
-PHASE 1 PHASE 2
- SECTION PLANNING IMPLEMENTATION PLANNING IMPLEMENTATION.
PREPAR ATION -
7 OF THE PLANT i
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OA/GC 3
REORGANIZATION i
I PHASE 1 4
PHASE 2 PLANNING PLANNING
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VERIFICATION
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MANAGEMENT op j
REVIEW COMPLETED INSPECTIONS EVALUATION SYSTEMS 5
'AND COMPLETION i
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INSTALLATION REVIEW WORK MANAGEMENT AND REVIEW INSPECTION l
STATUS H
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8 QUALITY PROGRAM REVIEW l'
7 THIRD PARTY REVIEWS l
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SYSTEM LAY UP
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9 CONTINUING WORK ACTIVITIES 1
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l 10 2.0 PRIPARATION OF THE PLA.\\"r s
j 2.1 Introduction L
i The preparation of the Plant cleared the auxiliary, diesel generator and containment buildings and the service water pump structure of materials, construction tools and equipment and temporary
. construction facilities.
2.2 Objective l
To allow improved access to systems and areas for the Program I
activities.
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2.3 Description i
'The preparation ac!*vities minimize obstacles and interferences for i
the Program activi;
,s.
This is being accomplished through the following steps.
l 1.
Limitation of Q-work to specific activities and areas defined in Section 9 resulting in substantial work force reduction.
2.
Removal and storage of construction tools and equipment, and
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tesporary construction facilities (scaffolding, etc) from the buildings identified in Sectica 2.1.
3.
Removal, control and storage of uninstalled materials from the buildings identified in Section 2.1.
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Appropriate housekeeping of all areas following material and equipment removal.
The preparation for each area will be ' complete before initiating
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l lurther Program activity. The on going work described in Section 9 t
wi11' continue as scheduled during the preparation of the Plant for i
CCP activities.
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2.4 Milestones 1
i Complete preparation of affected areas of the plant.
(Complete) i i
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r 11 3.0 QA/0C ORGANIZATION CHANGES 3.1 Introduction Department (MPQAD) was expanded to assum uality Assurance j
project quality functions including Engineer /Constrect control of sit ASME.
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The new organization is described belowructor QC except
' Inspectors are being recertified as part of thi The transferred QC 4
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0biectives s transition.
3.2 Establish New OA/0C Ormanization Establish an integrated organization which incl d
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of Engineer / Constructor QC to MPQAD while accompli h following objectives:
u es the transition f
s ing the t,
t 1.
Establish direct Censumers Power Company cont t
inspection process.
rol over the QC i
2.
Departments in the integrated organizationEsta e QA and CC 3.
Use qualified personnel from existing QA a d QC contractors to staff key positions throughout thdepartoonts and n
organization.
e integrated Jtecertifv OC Insoectors Ensure that those Quality Control inspectio to MPQAD will be trained and recertifi d i n personnel transferring Procedure 3-SM-1.
e n acccrdance with MPQAD 3.3 Description Istablish New OA/0C Ormanizatio_n '
i A new organization was implemented under Cen has been described in the appropriate Topical Rsumers Power Com i
FSAR and quality progran manuals (Volume II eport (CPC-1A), the Changes to CPC-1A vere approved by NRC on Ma, SQAM and NQAM) i rch l'.
1983.
Features of the new organization include 1.
the MPQAD Executive Manager. Lead QC Supervisors ent who reports to Corporate QC and QA functions (except ASME N StAny required 1
is provided at the lesel of the MPQAD E I
amp activ i
xecutive Manager.ities) 2.
personnel in his department.The MPQAD Executive Man
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ormance of lead
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be responsible for the technical content and r s
a such plans.
QC will be responsible to implement these plans.
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QA will continue to monitor the Quality Control inspection process to insure that program requirements are satisfactorily implemented.
5.
MPQAD will continue to use Bechtel's Quality Control Notices Manual (QCNM) and Quality Assurance Manual (BQA!!) as approv for use on the Midland Project.
6.
will reasin with that contractor.ASME requirements imposed i
implementation of ASME requirements.MPQAD QA will monitor the An organization chart relationships is attached.(yig 3-1) showing current reporting 1
contained in project procedures.The official organization chart is t
j Trainine of MPQAD Personne_]
3 Engineer / Constructor QCE's (Inspectors) to existing P y all number of QCI's have been recertified under this process.A significant MPQAD decided to terminate recertificationK old P a
Early in 1983, in selected train and recertify to the new PQCIs.
, and then 4
MPQAD current plans are to re-train and re-certify all inspector revised PQCIs.
Instructions (PQCI) are undergoing a complete rev:ew to assu s to the Attributes that affect the safety and reliability of specific c systems and structures are identified for verification.
omponents, I
Accept / reject criteria are clearly identified.
Appropriate controls, methods, inspection and/or testing equipm specified.
i ent are i
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- Requisite skill levels are required per ANSI N45.2.6 or SNT-TC-1A i
i After the PQCIs are revised as necessary, Quality Co eers test to assure their proficiency in utilising the new inst n
emonstration successful completion, each inspector is being certified to perfora ruction. Upon l
inspections to those PQCIs in which he was trained I
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13 The adequacy of PQCIs prior to training is assured by the following programmatic requirements:
1.
The PQCI evaluation effort is being conducted under the direction of MPQAD QA personnel. MPQAD Procedure E-sM was issued April 11, 1983 and establishes the responsibilities and requirements for the preparation, revision, and control of PQCIs by QA personnel.
As a part of the initial PQCI revision process, Project Engineering does a review of the PQCI for MPQAD to assist in ensuring that attributes that affect safety have been identified for inspection, and further to ensure that the PQCI is consistent with the specification requirements and that clarifications are made to specifications'uherever necessary. The final responsibility for the content of the inspection plan remains with MPQAD-QA.
2.
Whenever a PQCI is revised, the revision is evaluated to determine if a pilot run for testing the implementing capability of the PQCI is required. If a pilot run is required, the PQCI is tested by a team from QA, QC and Training. Based on this pilot run, the PQCI may be further revised.
3.
Once the PQCI is ready for issue, an effectivity date is established in conjunction wit. the Training Deparssent.
A.
For PQCIs on which training was not previously conducted, the training and certification process is then started.
B.
For PQCIs on which training and/or certifica:Acn was previously i
conducted, a determination is made as to the need for retraining or recertification.,When a revised PQCI is issued, it is evaluated in accordance with established procedures to determine if retraining and recertificatien is required. Based on this evaluatica, appropriate action is taken.
4.
During the training process, student questions (see below) are solicited and monitored. Based on this, further revision to a PQCI l
may be initiated.
I Steps taken to ensure all questions raised during PCCI training sessions are
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resolved prior to certification includer 1.
The development of an MPQA Department " Statement of Training Policy." A copy of the turrent Policy is included as Tigure 3-2.
2.
The Policy Statement is handed out at the start of each class and reviewed with the trainees.
3.
Statement 2 of the Policy deals with student questions. Instructets handle many questions as a routine part of a class. However, when an instructor is faced with questfor.s he cannot answer, he makes note of them for subsequent resolutica with-the students.
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kien the instructor determines the need, a QA Engineer, Project / Resident Engineer or other resource person is scheduled to participate as part of the class and answer questions raised by the students.
t 5.
If there are unanswered questions at the end of the scheduled class time, an evaluation is made by the instructor as to whether training i
can nevertheless be considered complete and the examination given without jeopardizing the students opportunity to satisfactorily i
write the exas.
6.
Even if the examination can be given, prior to answering questions, the questions are still tracked and answered prior to certification.
7.
klen a trainee indicates that he is not prepared to take an examination or a performance demonstration, he shall not be administered the examination or performance demonstration until his i
specific concerns are resolved.
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Flouna 3-9 MPQAD OHGANIZATiON DECHTEL
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PRINCFAL MIDLAND PROJECT QUALITY ADVISOR OUALITY QC PROGRAMMATIC ASSURANCE DEPT.
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SUPPORT EXECUTIVE MANAGER ASME QUALITY q
ASSURANCE I
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.uNERAL OA SOILS QA/QC SITE QC K -- l l
& TRAINING SUPER!f4TENDENT SUPERINTENDENT SUPERINTENDENT 3 - - -
i b-l flVAC QA/OC QA ASSISTANT PIPEJMECH/ WELD
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ASSISTANT SUPERINTENDENT CIVIL O C ELEC1 DICAL OC OC i,:
SUPERINTENDENT (ASME)
I NOTE: TING CIIANT IS INTEt#0ER TO 800pICATE ONLY Tilf 8NTEGRATs0N OF Tilt SECIITTi. GC FUNCTION.
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-.a. a i M "c N ~ S ' n^ T c"M c N i O r-. R AINING POLIC'/
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,e is :ha objee:ive og g3,s,w g3 2eets:heneedsofthetra1[ses, 3
- E* ::t:: C provide ::aining 3,
- a policies apply:
P 8*ec chose needs the follcut g 1.
Persensel who cr. cquired to.:tted claasr:es etsini g shall not b adriuistered a= ex4=ination without e
acts =d:=ce is definad.a 1007. classroom at:e= dance.
ICC" abecacas for brief periods of time.tocci c.laccroom ti=e Issa instrue:or excused Trai=i=g Supe:* riser.is writing by the trainees supgrvisce and approved by th ropriate 2.
Een trainees have e'-<
subject =a:ter the
- l*** *
- h* ***i3123 ss:
cr h1 or obtain the ansvers and provide ch e m er the questions
==a=i=a-ion or certificatics as appro riate i**l 3.
The ti== required for self-study prior to exa=i=a'tton shall be de:er i and scheduled by the appropriate Training Cocrdisa:or, based on the
= =ed duratics of the lessen and ce=plexity of the subject.
4 The i=structor vill review the class evaluatio= sheets er deter-i== the accepeabili:7 of the trai=ing price to ad=i=istering th c =posi:e :o i
exam to the class.
isterait until appr=priate action has been taken.If judged unacceptable, 'the exa=
s U-W en a trai=ee i= dica es -ha-h i
- r a p* for:ance demonstration he sha
- i"**i**
i ac-d -<
C,:: or perfor=a=ce de=ces tra:1on u--* 1 his spec.< U..e con *ce rn,,*,,****,,',*7y,
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17 Recertifv QC Insnectors The training and racertification process for QC Inspectors as just discussed satisfies commitments made during the September 29, 1982 public meeting with the NRC. Those inspectors transferred from the Engineer / Constructor to MPQAD are trained and examined in accordance with MPQAD Procedure B-3M-1.
Upon satisfactory completion of the training end examination requirements, inspection personnel will be certified for the Project Quality Control Instruction (s) (PQCI(s))
they are to implement. Inspection personnel are certified on a schedule which supports or. going work and system completion team activities.
Where individual inspectors fail any part of the recertification process an evaluation will be made of the cause of the failure and based on that evaluation, a determination will be made of the need
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and extent for reinspection of th's individual inspecter's past wc k.
3.4 Milestenes Establish New Organization Transfer the Bechtel QC Organizatien to MPQAD.
Cc=plete Submit changes to Topical Reports and quality program manuals to NRC.
Ceeplete Recertifv QC Inseectors Specify the revised training and exa=inatien requirements for certification (B-3M-1)
Ceeplete
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r-18 4.0 PROGRAM PLANNING 4.1 Introduction The detailed planning for the major portion of the Construction Completion Program is described in this section. Planning in support of Phase 1 consists of the activities to set up a team organization, process and procedures to assess the installation and inspection status of Q-systems, Q-components and Q-structures (Section 4.2) and to verify the quality status of hardware installed and inspected prior to December 2,1983, (Section 4.3). The Phase 2 planning effort covers the process and procedures that will be used by the team organization for completion work (Section 4.4). The procedures te. integrate the quality program requirements with completion work are covered (Section 4.5). 4.2 Team Orranization (Phase 1) 4.2.1 Introduction The planning for team organization consists of procedures preparation and team organizatica and training for an installation and inspection status assessment. 4.2.2 Obiectives 1. Establish and implement a team organization ready to inspect and assess work for installation and inspectica status. 2. Develop the organizational processes and procedures l necessary to implement the team approach for status assessment. 4 3. Provide training to enstre required inspection and installation status assesseant activities are satisfactorily performed. 4.2.3 Descriotion Team Ormanization The team organization structure will vary depending upon tr.e assigned scope of work. The assigned scope of werk will be made on the basis of systems, specific items such as hangers and commodities thzt are installwd and tracked on an area . l basis such as conduit, cable tray supports and watertight l doors. (For example, see Rechtel Field Procedure TPG9800, l " Bulk Ranger Organization Charts".) The organization will .i. Revision 1 m10683-4033a-66-16A i' '. i s-I Y l' e ' ^ -se. ~ -< -
^ 4 19 consist of a team supervisor and personnel as appropria:e from field engineering, planning, craft supervision, project engineering, MPQAD and Consumers Power Company Site Management Office. The team may be augmented by procurement personnel, subcontract coordinators and turnover i coordinators. Teams are assigned a specific scope of work and held accountable for status assessment and overall completion within this scope. The scope includes the requirements to develop a viable working schedule and insure early i identification and resolution of problem areas. Project i processes and procedures are being reviewed and modified to i incorporate the taam organization. The team MPQAD representative is responsible for providing the QA/QC support for the team. He receives scheduling direction froo the Taa: i Supervisor but receives all other direction from and reports .f to management wi:hin MPQAD. To support the team, he analyzes the quality requirements and plans the QC activities to integrate them with the team effort. He assures the i necessary PQCI's and certified inspection persennel are 1 available for performing the inspections. Ee assures validation of NCR's. He maintains cognizance of the quality i status of the verification activities. Pilot teams are being utilized to develop and tes processes and procedures during the development stage to assure tha: Program objectives can be me:. This also provides practical i field input to assure that efficient and workable methods are used. Team members are physically located together to the ex:en: practicable to improve com=unication, status assesement, } problem identifica: ion and problem resolu:ica. The MPQAD 4 representative, however, will centinue to reper to MPQAD management and will maintain a permanent physical assignmen: within the MPQAD area. Team Training The construction training procedure (TPG-2.000) has been revised to incorporate the training require =ents of the CCP. The procedure sets down specific requirements for type of training and subject matter fer each organization element. d The training requirements by type and subject are defined in a matrix for each organization, managemen: and staff level including craftpersons. The training matrix vill be approved by Consumers Power Company. h 'I d Revision 1 ' 'j miO683 *.033a-66-168 fj i 1 1 4
20 The team training includes the major elements described below: 1. General training will be provided in A. Quality requirements for nuclear work t B. Requirements of the CCP C. Safety orientation D. Inspection and work procedures Training in Items (A) through (C) and selected parts of (D) will be conducted in a formal setting and will be given to all personnel including the craftpersons. In eddition, a " tool box" training session will be conducted at least monthly for the craftpersons by the foreman. l The subject matter will be developed by the training coordinator, and will include information .I regarding quality issues across the job. 2. Training in the procedures used to govern the parfermance of work will be conducted for designated field l engineering, support personnel and craft personnel as defined in the training matrices. Formal training vill be conducted for identified procedures that define the centrol of designated werk processes, procedures for centrol of special processes and requirements for inspection and acceptance of completed work. Formal training includes classroom er field demonstration / discussion sessions. Documentation of Nonconformances Non-conformances on the finished portion of partially completed work identified during the status assessment will be documented on Non-conformance Reports (NCR's). J 4.2.4 Milestones Complete assignment of team supervisors and Complete members to_ designated systems. Complete organization description and pro-Complete cedures for team functions. Set up training program for teams. Revision 1. miO683-4033a-66-168 -) i .L__ 3 k-- _ .,~ .i' ~* "h :
. ~. 21 4.3 Quality Verification (Phase 1) 4.3.1 Introduction The verification program is the activity undertaken to establish, using a variety of methods, that the hardware installations completed and inspected prior to Decenber 2, 2 1982 have an acceptable quality status and that prior inspections were performed in an acceptable manner. 4.3.2 Obiectives The objectives of the verification program are to: I Develop and implement a verification inspection plan using reviewed / revised PQCI for completed and inspected work which considers: il' } Re-inspection of accessible ite=s for quality a. verification. s' b. Verification of acceptability of inaccessible attributes by a review of documentation, over-inspection results and past corrective actions and supplementary to these reviews, if required, by NDI techniques and destructive examinatien. 4.3.3 Quality Verification Program Descrittien The Quality Verification Program is provided in Appendix 1 ef this document, i .) The quality verif1 cation program is based on a 100% reinspection of accessible attributes and review of documentation for inaccessible attribe:es. At some future i date, once the quality level of completed work has been j established, Consumers Power Company will make a determination as to whether or not further verification efforts can appropriately be based on less than a 100% reinspection program. d 'ihen Consumers Power Company believes that sufficient justification exists for a reduction in the 100% com=itment, it will recommend such a reduction to the NRC in accordance. with.the statistical sampling plan described in an appendix to the Quality Verification Program. 4.3.4 Milestone Issue Quality Verification Plan Ccmplete s . e' i Revision 1 l miO683-4033a-66-168 i, lf -J ~ ^
22 4.4 Comoletion Planning (Phase 2) 4.4.1 Introduction Establish completion processes, prepare procedures and expand training to cover completion work. 4.4.2 Ob3ective The objectives cf completion planning are as follews: Establish processes and interfaces for work completion. Prepare procedures defining tasks of each completion team. Train team members by expanding upon training received previously for inspection and status assessment. Establish scheduling methods to be used during completion activities. 4.4.3 Descriotion The team organization (developed in Section 4.2) and the processes and procedures will be extended to acco=plish the completion work. Training will be conducted to assure that supervisers understand the team objectives and their role. Emphasis will be placed on completion of all work in accordance with the design and procedural reouirements, and the change process to be used when the-design or the procedures must be =odified. t Co=pletion work will be identified and released for construction using a controlled process to ensure that new work does not cover up existing nonconformances or items that have not been inspected or re-inspected. This process is i described in Section 4.5.3 and 4.5.4 I-4.4.4 . Milestone Complete team procedures and training program for initiation of completion work. 4.5 QA/DC Completion Plannina (Phase 21 4.5.1-Introduction J The QA/QC completion activity covers the planning to support completion work. . I, Revision 1 ~ miO683-4033a-66-168
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s. 23 4.5.2 Objectives Establish in process inspection program and complete review and modification of PQCIs. t 4.5.3 Descriotion i l The QC in-process inspection program will be directly coordinated with construction work plans for new work to insure that inspection points are integrated with the installation schedule. The identification of applicable PQCI's and required inspection points will be used by syste= completion teams to insure that QC inspections are adequately scheduled into the process. The completion team quality representative will be responsible for providing the intsrface between the completion team and MPQAD to insure that quality requirements 'are satisfied. Procedure fer Control and Release of New Verk The process for release of work will be controlled by procedures that ensure that the requirements of the 1 Construction Completion Program are met prior to initiatic: of new work. The requirements for release of work include; checking, review and approval to ensure that verification and i status assessment activities are completed and that the new i work activity will not cover up (make inaccessible) items that have existing nonconformances. These procedures are identified in Figure 4-1. They define the overall process for identification and approval prior to release of work. These procedures require an identification of equipment or items that may be, affected by the new work package and a check to see that there are no existing nonconformances or j incomplete inspections on these items. The interactions between project management, the completien team and the QA/QC organization are as follows. Prior to l Phase 1, quantification of Q items will be performed by the completion team. The completed items will be identified to the QA/QC organizaticn for the association of clcsed irs and a subsequent verification during Phase 1. The remaining items t. will be placed in an incomplete category and will be the basis for the status assessment by the ecmpletion team during Phase '1. 'A commodity list will be prepared as the Phase 1 verification and status assessment activities are carried out L and will result in a documented status for each system / area. it i This documented status will form the basis for site l
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management review prior to release for Phase 2 completion l 3 vork. Construction work plans (C'a*Ps) for new work will be prepared based on the lists as they are developed. .i L i. Revision 1 l l miO683-4033a-66-168 } l{ t .+ ~ ,,,-...-.,G
w-24 Thera are several major steps in the preparation and approval 1 of the CWP. Each CVP will have a comparable Quality Work Plan (QWP) that defines the quality activities. Inspection hold points will be identified and included in the CVP. Following initial preparation of the CVP, the package is taken by the team quality representative. The inspection hold points are reviewed and approved according to MPQAD procedure and a QWP is initiated for this work activity. The QWP contains the inspection records that will be required for that work activity. A review will be performed to ensure existing nonconformances or uninspected work are not covered up. The resieu will be based on the steps in the three i procedures identified in Figure 4-1. After the CWP is returned to construction, and the QWP is prepared, work can proceed. 4.5.4 Soecial Procedures l As the detailed planning fer CCP implementation has / developed, it has become apparen: that certain activities involving installation of some bulk commodities ca= be performed most efficiently if performed by a specialized tea = s j set up for that specific cocmodity. A team organization for status assessment and subsequent installation of pipe hangers has been formed. This tea = will work under procedures that provide for meeting all conditions imposed on the system team organization. The same procedure for control and release of new work described in I Section 4.5.3 will be in effect for this activity. Since the f status assessment and verification of all items in an area [ will not be complete prior to initiating hanger work, the area release contains special provisions to ensura existing non-conformances or uninspected work is not covered up. Es-sentia11y, each Construction Work Plan (CVP) will contain a specific review and check that the new work will not effect l status assessment or verification for existing installation. I The installation of water tight doors can also be performed outside the system team organization but will be governed by .the same procedures for control and release of new work. These procedures will ensure that there is no coverup of j existing non-conformances or uninspected work. It will also be desirable to allow installation of specific items on systems critical to the turnover schedule prior to l full release of an area for Phase 2 work. In these limited l cases, the procedures identified in Tigure 4-1, provide for a full examination in the CWP of each item and identification l of items that might be covered up. This icformation will be used by MPQAD and the team organizations to ensure each iten l Revision 1 miO683-4033a-66-165 I I' .Iri ~ ~ .. - ~. . +.
25 that might be covered up will be status assessed and/or inspected and completed prior te release of the CWp. In each of the cases described above, management reviews will be held, third party and NRC release points identified in, Section 5.0 will be adhered to. These activities all meet the requirements identified in Section 10.0 for CCP scrivities. 4.5.5 Milestone Complete procedures for integration of inspection points with construction work process. Complete procedures for control and release of new work. i I i t \\ 'l t Revision 1 n10683-1033a-66-168 I .y
26 FIGURE L-1 Procedures for Controlling Release for New Work Procedure Organization Furnose Area Release Construction for Construction (FIG 7.500) nese three procedures together ensure proper coc:pletion of verification c:d status assessnent Construction Vork Construction activities prior to initiation Plans (FPG 7.300) of new work and ensure no cover-up of existing nonconformances Control, Release and MPQAD Handling of Construction Work Plans and Quality Work Packages (T-3) i 4 l .' { f 4 Revision 1 miO683-4033a-66-168 i j O
27 5.0 PROGRAM IMPLEMEh' RATION 5.1 Introduction The. implementation of the Phase 1 Construction Completion Program activities will be initiated after management reviews of the overall process insures that Project performance and quality objectives have been addressed. The Phase I work will then be carried out by the various teams and inspection personnel in accordance with the procedures described in the preceding sections. The verification and installation and inspection status assessment of an area, system or partial system will be followed by a review of results and a second management review before initiating the Phase 2 completion work. NRC hcid points have been placed in the process. These hold points have been established to give the NRC confidence in the effectivaness of the CCP implementation. Third party (Section 7.0) hold points will be determined after the NRC has approved the contractor. 5.2 Obiectives The objectives to be met are: Establish the present installation completion and quality status. Integrate the construction and quality activities for all remaining work. ~ l, Improve performance in demonstrated cenformance to quality goals I in all system completion work. .I Establish a management involvetent that ensures program i committments are properly defined and carried out. I e Provide NRC with confidence in the projects ability to complete 5.3 Descrietion The preceding sections have objectives that establish the i prerequisites for the implementatica of the Construction Completion Program. The Project Management reviews (identified in Tigure 1-1) .( and NRC release are described in this section. l a i 5.3.1 Management Review - Phase 1 l Project management will conduct formal reviews of the plans for implementation activities prior to initiation of team activities for the Phase I work. Each major activity i (systems and area completion, pipe hangers, etc) described in 4 Section 4.0 will be reviewed.,These reviews will ensure that identified project management and quality issues have been-adequately addressed by specific actions and that Program Revision 1 u_ siO683-4033a-66-168 e --~^ -- - ~'~~ l, 'Ql' m . _ _ _, _., ~..
28 objectives are met. The reviews will cover the process for both 1) the verification of completed inspection activity and
- 2) the installation and inspection status activity.
i NRC Hold Point Upon completion of each Phase 1 management review and resolution of open items, NRC will release the activity to i proceed. This process will allow the Project to establish l NRC confidence in the project's preparation and ability to proceed. Phase 1 Implementation The existing installation and inspection status and } L verification of completed work will be established in j accordance with the plan presented in Section 4. .5.3.2 Evaluation and. Management Reviews - Phase 2 i The installation and status assessment will be performed en a system and/or area basis. Prior to the start of Phase 2 a review will be held of the CCP activities to date and of the results of the initial verification and status assessment activities. In addition, the plans and procedures for Phase 2 implementation will be reviewed. This evaluation I assures management that the project is prepared to release new work. The first managemen: review for work release will be done by the management team. Subsequent status assessmen: 4 l results will be released by site management prior to initiation of additional completion segments. Reports will be made to Project management at regularly scheduled } meetings. l i NRC Hold Point I 4 ~ NRC will release Phase 2 activities to preceed following j completion of the Phase 2 management reviews and releases j described above. 1 Phase 2 Imelementation 1 This activity starts ccepletien for turnover. k*ork will be scheduled as installation and inspectica status assessments are completed and reviewed. Correction of identified problems will be given priority over initiation of new work, as appropriate, and the completion teams will schedule their work based on these priorities. The plant will be divided into many distinct modules and the CCP sequence will be applied to each module. As a result, t a there will be situations in the plant where Phase 2 activities will be occurring immediately adjacent to an area undergoing Phase 1 activities. 4 Revision 1 i ziO683-4033a-66-168 j. i i + 4 - ~ - s r6,+, , -. - - + --n. ~.. .---.r
29 Third Party Construction Imolementation 0cerview The Phase 1 management reviews and the initial Phase 2 management review will be audited by the Construction Implementation Overview Third Party as described in Section 7.3. 3.4 Milestones Complete Management review and initiate implementation of plan for verification of completed inspections. Complete Management review and initiate implementatien of plan for status assessment. 5 Complete Management review of initial verification and installation and inspection status results and initiate . systems completien work. Satisfy the NRC hold points. l Establish third party hold points. 1 1 1 s }' ' Revision 1 L -J a10683-a033a-66-166 4 I i ' i l 6 k
30 6.0 OUALITT PROGRAM REVIEW 6.1 Introduction The adequacy and completeness of the quality program is reviewed as part of the ongoing Project managemen: attention to quality. These reviews consider questions raised by NRC inspections or findings raised by third party evaluations. 6.2 Obiective Address issues raised by internal audits, NRC inspections and third j party assessments. Program changes, if needed, will be evaluated 1 and, as findings are processed, will be factored into the Project work. i l 6.3 Descristien Consumers Power Compcny believes Midland QA program is sound. From time to time, questions arise on detailed aspects of the progra= or i j program implementation. The normal process of addressing these issues ensures that all necessary information is provided to NRC and l that internal confidence in the program is maintained. i l The recent inspection of the diesel generator building has raised i several issues of programmatic concern. These are in the areas of material traceability, design control process, Q-system related requirements, document control and receipt inspection. Project management has directed that an expeditious evaluation of these issues to be considered as part of the managemen: review prior to initiation of Phase 2. Items identified in the NRC D/G Bldg inspection report are addressed and being resolved through t).e normal process of closing the inspection findings. Any correc ive j action c program changes will be implemented as appropriate in Project work on a schedule provided in the inspection report response. The Project will also receive, frem time to time, findings fre= third party assessments (Section 7). These findings or recommendations may also result in program modification er adjustments. Corrective action taken by the Project will be implemented on a schedule stated in the response to these findings. 3 } / .l i .i j Rovision 1 'z } - aiO683-4033a-66-168 , -a il b q
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31 1 7.0 THIRD PARU REVIIVS 7.1 Introduction l This section describes third party evaluations and reviews that are planned to assess the effectiveness of design and construction activity implementation. Third party reviews being conducted as part of the Recedial Soils Program are not included in this ' activity. 7.2 Obiectives To assist in improving Project implementation and assessment of Midland design and construction adequacy, consultants will be utilized in order to: Provide continuous monitoring and feedback to Manageoen: of P:oject performance. Identify any activities or organizational elements needing improvement. 4 Improve confidence (including the NRC's and the public's) in overall Project adequacy. 7.3 Descriction The use of consultants to overview Project design and construction activities with particular emphasis on construction is part of the effer: } to improve the Project's imple=entation of the quality Specifically, the plan overview employs the use of program. consultants for three separate functions: (1) To carry out a self-j initiated evaluation (SIE) of the entire Project under the INPO Phase I program, (2) to utilize a third party Construction i l Implementation Overview (CIO) of ongoing site construction activities to provide monitoring of the degree of implementation success achieved under the new program and (3) to conduct a third l party Independent Design Verification (IDV) Program. Only the CIO is described in this section. j Construe: ion Imslementation Overviev A. third-party Construction Implementation Overview (CIO)is being undertaken using, as a model, the program developed specifically for the underpinning portion of the soils remedial work. The overview was initiated by retaining an independent firm, having considerable experience and depth of personnel in the nuclear construction field. The consultant's overview team is located at the Midland Plant site and observe the work activities being conducted in accordance with this Plan. si The overview will continue until Consumers Power and the i NRC have confidence in the adequacy of the implementation of the Consumers Quality Assurance Prog;as fo: the Midland Project. I l Revision 1 ?! miO683-4033a-66-168 l It A ,e
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32 Findings identified by the installation overview team will be made available to the NRC in accordance with established procedures. The protocol for communications between the parties will be the same as used on the soils remedial activities. In order to ensure the Project's readiness to undertake the major steps in the Construction Completion Program (CCP), the CCP includes provisions for management review at key points in the process. The review will examine plans for future implementation and ensure tha: programs and processes are thorough, complete and cerrect. To provide the NRC with additional assurance that the CCP processes have, in fact, been and will be implemented as described, the duties 4 of the third party CIO will include responsibility for audits of Project performance of these management reviews of the CCP process. The CCP implementation will not proceed beyond these points until i the third party overviewer has documented their satisfaction with cur readiness to proceed, including satisfaction with our initial response to any audit findings, in their weekly reports or other memoranda. - i The CIO will also overview site construction activities while in residence, although the significant focus will be on the implementation of the CCP. The exception is that the CIO will not include an overview of the other third party evaluations being conducted. Consumers Power Company has proposed that Stone and k*ebster (SF.*) be the organization to perform the CIO. This is based on the fac: tha: S&*=* is considered technically capable to perform the activities both l in terms of the individual team proposed and in the corporate depth to support this effort. They are presently conducting an independent overview of the soils re=edial activities and have been found acceptable by the NRC for corporate independence. 7.4 Milestones l Construction Implementation Overview Define scope Select consultant Cc=plete Mobilize CIO Team Complete 1 Complete I.- I 1* i I l Revision 1 1. siO683-4033a-66-168 L -i-r ~ t ~ .L2
= l 33 8.0 SYSTEM LAYUP i 8.1 Introduction Perform system lay-up activities to protect plant equipm2nt. 8.2 Obiectives Expand the protection of completed and partially completed plant systems and components until plant start-up, to take into account any special considerations during the status assessment. 8.3 Description 4 Procedures and instructions are provided in the Testing Program Manual to protect equipment during the on-going installation and test work. These were extended to cover special considerations associated with the Program implementation. Both the pre-and pest-turnover periods are covered. System and compenent integrity is ensured through existing programs and implementation of control and i verification procedures. In summary, these procedures and instructions require: Test Engineers to complete walkdowns of Q-Systems (in the auxiliary, diesel generator and containment buildings and the service water pump structure), paying particular attention to systems /compenents that are open to the atmosphere (eg open ended pipes, open tanks, missing spools, disconnected instrument lincs, etc). Systems that have been hydrotested but are not currently in controlled layup require action to place the system in layup. Layup consists checking to ensure that system water conditions are within j specification followed by moisture removal and closing the systa= j from the atmosphere. 8.4 Milestones Complete the layup preparation valkdown Complete ?-j. Ii .l. ~! t 4 i 4 Revision 1 miO683-4033a-66-168 .i .1 A t p --,. - g., ...,.-m,.g ..,ws,--g g-e-. my p-gy.,ge,%9-9
St. i I 9.0 CONTINUING WORK ACTIVITIES 9.1 Introduction This section describes the activities that are pro'ceeding in ~ 4 accordance with previcosly established commitments during the implementation cl ti. frogram. 9.2 Obiectives Maintain installation and support effort that will alleviate work interference in congested portions of the plant and fa:111 tate completion and protection of equipment on systems turned over te Consumers Power Ccmpany. Meet previous NRC commitments on activities which do not impede the execution of the Program. Provide design support for orderly system completion work and resolution of identified issues { 9.3 Descriotien Those activities that have demonstrated effectiveness in the Quality Program implementation will continue during implementatien of the l Construction Program. d These are: J 1. NSSS Installatien of systems and components being carried out by B&W Construction Company. 2. HVAC Installation work being performed by Zack Company. Velding 5 activities currently on hold will be resumed as the identified problems are resolved. 3. Post system turnover work, which is under the direct centrol cf Consumers Power Company, will be released as appropriate using established work authorization procedures. 4. Hanger and cable re-inspections which will proceed acccrding to j separately established commitments to NRC. ~1 p j 5. Remedial Soils work which is proceeding as authorized by NAC. J 6. Design engineering which will continue for the Midland Plant as j will engineering suppcrt of other project activites. ~'ij Other programs that are not a part of the Construction Completion Program (CCP) will be integrated with the CCP effort as required for {l overall project coordination and control by Midland Project Site { Management Office. l i Revision 1 siO683-4033a-66-168 ,1, i _ -. _. ~ _. _... _
O 35 l i A separate organization of design engineers (presently existing) will carry out spatial systems interaction (SSI) review and examination. Although not part of the CCP, this will be done in coordination with the activities of the CCT. The conduct of the SSI is not a prerequisite to either Phase 1 or Phase 2 of the Construction Completion Progra=. This program is being overviewed by the CIO as described in Section 7.3. The SSI represents the Project response to the generic If c.ensing issue of "important to safety" and is being handled outside of the CCP with NRC NRR. 9.4~ Milestones i .l These activities are proceeding with schedules that are independent of this Plan. i i l i d l l t l t .I .i Revision 1 miO683-4033a-66-168 .k _J.
1 36 I 10.0 CHANGES TO THE CONSTRUCTION COMPIITION PROGRAM 10.1 Introduction The mechanism for obtaining approval to initiate activities that do not meet the requirements of the CCP is described in this section. t + 10.2 ' Objectives Istablish a sanagement control to ensure that any activities that do not meet the requirements of the CCP are reviewed and approved prior to initiation. '10.3 Description A procedure (MPPM-19) is being issued to co. trol changes to the CCP. The procedure will provide that Q vork activity outside the exceptions defined in Section 9.0 will meet the requirements of the CCP. Any changes to the defined CCP process will receive management review and approval for any deviation from the CCP requirements. The requilaments that must be maintained for work activities under the CCP are: A. Manegement reviews are scheduled and held of (1; activity planning for verification and status assessment and (2) results of status assessment and planning prior to new work activity. B. A process is in place to ensure that no existing nonconformances will be covered up by new work activities. C. g l Procedures to control work definition and release including definition of inspection requirements and inspection hold points are in place. t D. Inspection and constructier. personnel involved must have received all required training. I Any work activity that does not meet these conditiens will be considered a change. A change will be reviewed by the j Ccastruction Implementation Overviewer. The hitC Aegten?HT i @ will JutMnfMasit prior to implementation. .tqu ? ve %...y cz is he cet i 4 Revision 1 - j miO683-4033a-66-168 a k i S'
g] p.g8 ) 1 l y APPENDIX 1 .o - gv [it . \\1 " E l
=== Eu' l 3 ,0UALITY "ERIF: CATION PROCRAM l MIDLAND N1*CLEM CCGCiU;.s*JM;N PluT L%ITS 1 /SJ 2 Inde:c of Tepics 1; Purcose. + 2. Secee 2.1 Remedial Soils Activities 2.2 EVAC Activities 2.3 Cable Routing and Iden:1ficatien keinspecti n 2.4 ASME Eanger Rcinspecticn 2.5 3r.' Constructier. Activities 3. References 4 Definitions 5. Fregram Centent 5.1 retailed Scope 5.2 Me:hedelegy 5.3 Identifica:1on ef Deficiencies 5.2.1 Leiiciencies 7ound Luring I. inspection of Accersible A::ribu:cr. t i 3.2.0 Leficiencies Found During 7. cia. spec:ica of Inaccessib;u A::rit.t.:cs 6. Special Freer.: rictents itj 6.1 Cstic F.cintraction i i 6.2 In Process Ins;e::1cn Ectices and Discrepancy Laper.r i i' ~ 6.2.1 A :achnen: 10 For:t 6.3 I::ceptiens to this Plan 6.4 Purchssc4 Material j 6.5 Inaccessitis A::ribu:es a i Rev. O, 6/1CiL1- } Ph0;L3-LCI-.-C.lf7 .i 1 n M (" 7~ntili o 29 > il
~ II I Chl.1TY ViiKIFICA*105 ?RCC':AM s ).III/5r >TCIFAR COCD; ERAT:CN P.'.;3T L'LlTS 1 DL 2 Index cf Tepics i 7. Docurentatien and Reports e i 7.1 Documentation of Results 7.2 Documentation of Nencenfer:cnces t 7.2.1 Trending i 7.3 Repor:s j 7.3.1 Repcrts te Executive Manager - MPQA 1 7.3.2 T.cports frc: Executive Manager - ::?(AD 7.3.3 Reperts to NRC and Construction I:;1e=entation Cvervice Ter.e 8. Ierlementa ien i j. 8.1 Orgcnizatienal Respensibilities E.1.1 N?;AD - 30P CA 8.1.2 M?QAD - 10? QC 6.1.3 E?QAD - Si:e Audit Sectic 8.1.4 M?QAD - QA Ad=inistraticn and Training 9. Attendices ~ A. List of.?QCIs B. 'PQCIs to ha Veritied by Dccu=entatien Retice C. S:ctistical Sa:P ing Plan l I 1 l
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I dE0NIROLLED QUAL.ITY V~RI7IC.CICN PROGR.O! Midland Nuclear Corener.-tien Plan: Units 1 and 2 1.
Purpose:
Tc ccnfirm through a verification prog:s= under the direction of Consu=srs Power Cc=pany, the acceptable quality status of safety related procurenent and constructien activi:ies cc:pleted and inspa:ted by the Ingineer-Censtructcr quality cont:cl persennel prior to Deceche: 2, ICE 2. f 2. Scepe: This progran vill ecver t11 c1 coed Inspec:1on Records of in-spections peric:ced by the Ir.gi:eer-Censtructs: quality cent cl persennel t i on safety relcted caterial, sys:e=s, ce=ponen:r t.r.d structures of the Midland Nuclear Ccgeneratien Plant Units I and 2 pric: to Dece:ber 2, 1982, except: f 2.1 7.ar.edicI Scils k'c:k, which has been unde: the cirection cf Con-I susers Power Ccepany qu li:y As surance (QA) persenr.el since Augus:, 1952. 2.2 HVAC verk, which has been under the di.cc:icn cf Censumers ?cver I Company CA ;ersc nc1 tince the =ajor reorganizatien it. 2cr.e icgi, l 2.3 Verifica:1er. cf ccble routing, identifica:ier. c.C cther accessible attribu:ss which is being donc en a 1002 reirs;cc:ic: tesis it. cecordance vi:h PqC! I-L.r. k I Rev. 2, 6/10/F3 ??.01E 2-0C 1.'. A-CiC; \\
2 2.4 Verifica:ica of ASME hangers shici. si~l be dene under a separate reinspection program as p cvicusly cct=itted to the 57.C on No.c te: 13, 1951 and March 29, 1983. 11.is p cgre.n requires 100% reinspec-tion of all hangers with closed IP.'s cc cf Lect =her 1962. This program vill be ccnducted under the directien of Censumers Pcver Company QA personnel. 2.5 304 Construe:icn Compan-/ ac:iv:: es which have been perfer:cd under st= IC.: Quality Assurance P cgra=. 3. T.eferences: 3.1 Regulatory Guide 1.58, P.ev 1. Quclificatien cf Nuclear Peuar Inspectien, E.xaminctien and Tes: irs Perrennel. 2.2 E?qA: Procedure I-2::, F:cparction and Approval of ? e.e cc: (uali:;. Centrol Instructions 4 Definitions: A::a:h:en: ;C a tors ;;e icusly u:ilized :: Ice.rcr: 1 I Wa;kdcut statusing en specified p; ping systa:s pric: :e Eyd:csta:ic cr Pnetratie it.stit.. t l 4 t r 4.tv., s.., 0;,.e. -} .. r.9 h E* *w.h e # A*k-mN e -- i-e..w t 1 'l 4 - - ~. - -. - ~ -. -
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I 1 l \\ E ecrepctcy Report (DR): A forn siniler te :he !?l:; previcusly used tc :.pc:: inp;ccess noncenfe:- i =ances. r Inaccessible: An iten er a: tribute of an 1:en which, due to its physical loca:1cn er ecnfig-utsticn, cannet be physi: ally c visual- + f 17 :cinspected without rarevi:g a d thereby invalidcti:g ins:-iled sc k. Under the L;.c11:7 Yeri"5:stien Progran, this includes thcee 1:cne c tt:ribu:es nor: ally inspec:ed in_ precess and which subsequent ccestrue:1; processing nakes in:ccessible, eg, piping fi:-up, ::c: vcid ett subse cent layc.:s under :he cever pess, at: hor belt hcie drilling, internal cleanliness, enhednt:- in cere:ttc, etc.' intecessible do s net e include these i:c=s thich ccn raatc:tily be :eached by serffeld erectien, linited acce'as' (ren::c' aists which require the , [hysical si:e of the inspec:icn ;ctsen- -_ l nel.:c le 11 : ed er these itens the: l .'l.
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e L The inaccessibility cf tt:ributes ec c:cd by ::.sulation or coatings will be handled on a case by case br. sic. . When such ccve:ings can be practicnlly
- ce.eved and replaced and where their part:cular reinspec:ien is requiref :e establi t an ecceptable level cf ect-fidence cf the quality of a p : ir.u-la; attribute, the ceverings vill be re-acved. Itens uhich fa*1 ir.:e this 4
) i ca:escry a:.d 4:e scheduled fer verifi-ca:icn in accordance with plan require-nar.ts vill ne: be cenmidered inaccessi-b*e unless se np;;cred en a case by case i basis by the I:<ecu:ive ha:.ata - ::?Cjr. In 7:c:cs: Ier.:ectien ' A fern previcusly usad :: re:::d.cr.::.-
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fermir.; cer.dittcer e t ::. 4*.uenue te cer.s :ue:ic. f::ces fe: enc h ;;fer te I l cenple:1:n cf ine ec:ict activi:1es f:: l the 1:en in ques:1en. Ii l Inspec: ion by A:triturer: Inspecti:n wherchy the fren er i fj a:::ibt:4 is citreffied sin;1y as t cCnds'l"I*I C nEnd::.f4**/ning VIIIfut i
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s 6 .g a .h. s b Inspectics Recc:c (11/,: A =cport ih's: secpes the irspection te s be pe,ric;::cd, : cit.tir.r it to a specific P(CI asdgsysten, cc=penen:, strue:ure c pc:cien thereof and uhich recc:ds :ht re.sults of inspectiet.a,. !cncc.fernarec: ' ' ' A deficiency in characteris:ic, cccunen-I tatidi c: ;rtetdure which renders the quality ef an iten un.cceptailc c: -ingeter=inate. 4 s i s !!cce.fornanceNeport (NCR): ' A docu=snt.. u'sec f e:. re;c :ing ncnce:. ' e, f c =ing cer.ditient,. i. t a o i Tepulatien: ite entirc qu ntity of
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Inspac:1ct. T.c cerd t l' ?.) as cf ::ece:he , t,~ s O, 1932s rela:ing te 'a s;teific ?C.C!. t ~ P cject (ual ty Centrel The docunent that pre.-5fer (cr.li:;- Ins::ucticn (?(CO : Cer.trel Ingineers (CCit' Eith cpccif:.c ~ s 'directicn ns to a:cribu:as t: ha vc ;ii-3 i m -ed how they a + " '.a,"a ificc anc :he a .1 tCc
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N 6 Reinspectier: 1. used in this Verifica icn ?:cs;kt, reinspection sc:. a cc plete review cf .i requisite decuments:fer : d a pl.ysica; or visu:1 rccheck of acesssible in-spection attributes covered by a speci- { fic PQCI cr a review of applicable inspection records and related qu lity docu=cetatics whe:e at:ribu:ca ::c r.et t accessible. Verification: As uswd in this p:cg:as, verific tic 1 1 refers to the everall ;;ccess cf estat-s 11shing the quali:y. ccep:ance cf :he l tct:1 pe;ulation ef cc pletaf a-d .s } inspec:ed vc:k th:cu;h cct line:iert, er { applicable, cf effer:s such as re-ins;e:- 4 l tics, cect:c::stic review, :eviev ef l i I pest effer:s :c intestig::e d rescive p cbic=s, cr. !yrft ef pss: everin-spectic: csults and, i: :.e cacc::y, :::I s tech.ie,uer tid destrue:ive e.:::ir. :i::. a L ?* .' I, i 4 4 3 E. sey. 6,.. C.,. e. y ?KL 52-CC;-i.-QLC7 '.) a < j c' h-
5. Pretram Centent: As identified it. fcctien 2, Scope, Ccnse:ers Pever Company (C?Co) vill cencuct a Quality Verifiestic: Fregrar of safety related procurement and cons::uctien work in which the prier '00% in-specticas have been pc for:ad under the direct su;c:visier of the Engi-neer-Cens t ru ct or. Such in:pections were perfor:ed in accc:dence with approxica:aly 100 PQCIs, as listed 1: 1.ppendi A, th : specified the inspection requirerents :c be achieved by Quality Cen :cl (QC) Personnel. As ne:ed in scetien 5.1, this listing includes c11 inspections enzpleted by the Engineer-Censtructc; prie to Cece:bar 2,1982, inclucing these e::cluded frem this preg:sm for ressor.s sta:cd herein. The Quality Verifi-estic: Program has the purpose cf establishing a quali:y baseline fer the ce=pletien of ccustruction of the Midland Project. 5.1 Detailed Secee: The program vill include a;;rctititely 100,900 irs cubject to the Quality Verificctic Pregrce, for which :he Engi-neer-Ccastructor hrs a rccc d of completed 1: spec:icr.s as dccuten - ed by elesed ~nspectic: Records (!R) ced !c: which te ether 10C% verific tic: activi:y has taken place er is scheduled to take i place. There are apprev'--:ely 147,5CC closed irs of which ap-l i proxima:cly 14,700 were for reinspectier.s whi:5 cccurred due t: - I j design chcrge, censtrue:1cn revnrk, c::., cec t;;;cxica:ely 3.',900 which are excludec, due te previous cc==1:=ents under the F.credial Soil, EVAC, Cable reuting and iden:ifier.:ic and,.1).I Eazger 1:: grass. !!he r.: s rai= spec:icn has eccurred cr. t >;.se_fic ite c; i i i t ? ? Rev. 2, 6/10/5) a PRC4E -CC14/-CLC7 a m. .m. 4 ,p Y =- ,e.-
s j i 0 st:ribute the verifica: ice vill rc;cre te the latest IE. In additien, pric to the use of ?QC s, Ma:erial Receipt Inspecticas (MRI) Field Inspectie: Plans (IIP) and k'elding Ins;c: tie 1T.-1 forms were tred ss e,tality instructions and :ceerds. ihese also vill be used for quali:y verificatien. Vhere applicable, the results of the inspecticas vill be grcuped with like FCCIs. 0:hc - vise they will be t ccted as separats populations. 5.2 Methode1ce : This pres:s vill cenfirm the accep:able quality i status ef cceple:cd work cad es:ablish the validity cf prier inspections. c cccLzpiish this, accessitie &:::itutes ef items i l ccve:ed by ccupleted IKs will be reinspec:cd :: the las:es: design requirements with PQCI's which have tae: reviewed and/c revi:ed as i necessary to assu:e clarity cf accep:cuce criteria and unifer:1:7 4 cf it;1erenta icn. For inaccessitie attritt:es, the eriginal inspectica docu:er.:s vill to reaieved fer evidence cf secc;:c-bility, and justificc:1cn vill be devalered ac d=>c: ted in sa:tien 6.5 cc estat ish hc:dvare quality and sup;er: :hc validi:y of il inspec:icts assccis:cd with such PCCIs. Ecch IR cic:es :c A specific ?QC!. ?QCIs are c:gcnized by ciscipline anc further strue:::ed te activities within tht: dis:1;11:e, e.g., there cre . separate FCCIs a:d cc res;.cnding IEs fc preplac nen:, piccemen: f and post-placcect.L. ins;ecticns cf cen::e:e. Cicsed IEs reic:ed :e ) each P(CI p ctide a pcpulatic ef like actisitite. Clesed irs are ~ these where :he Insinect-Cons::seters 2C01 inspectir.: cf..ct-V s:: ::1c: s:c instt;lic' hn dec e has teen cen;1e:et. .s. , b,.. t......ca II.C l i.~-C C 1;;-CLC 7 3 .g. 21 I i
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1 1 1 O. To assest tre vr.lidi:y el :hese pas: comple:sc 1:s;te:1 ens, and verify the harivare gut.11ty, CICo v11* initiate a ICC:: cirr;e: ica ef the popula: ion to provide adequa:. cetfidence tha: safe:v i related systems competents d struc:cres will perfer: sctis-factorily in service. The 1:1tial 100% <1nspection effor: vill be bered cr. a ryr- .ii e tt / area orienta: ion to provide a eta ity baseline for subsequent 3 ccar::vetics completion ac:1vities. Systa=/crea reinsp=::ie:r vi:1 -be ru;;;e wn=ed by randon plan:-vf fe ins;ecticas as ap;;opria:e te 3r i establish a valid quality besc11:.. c i an expediticus basis, J.t sore future da:e, cace the quali:y level of cc ;1e:ed verk 1:r bec es:ablished, CFCe vill make a de:ermina:icr. 44 :o whe:her c: not further scrift:stic efforts can a;;;e;;ictcly tu bened c: less than a 100% reinspectici. ;;ct:ar. t I ~ l.
- 'her. C?Ce belicies that sufficient f u=: fice.tica e::ists for a e
redue:ien in the 100% cc :1::c :, i: v-11 recc: end such a re-duction to the 51C in cccc:d::cc vi:h the statis:'c:1 sart:ing -1:n at: ached ::.*.;perdin C. .i 4 i 5.3 Identificatica_cf Leficiencies: Any :::::sferrin; cc:.di:icn xtse: sed during the-ir.ple.tenta:ien of th's ;;: ran c:he: :han :h:ta g prav:cusly iden:ific; c:. r erecife: 2::e reper:s, ti be ic.:.....: q. s ,n la. O, 6/.10/53 ,j. .,w., . e.. -,. s.t p.., i E' i a i .-w. .m.. ) w p 4
l 10 by a nencenforaance report and vill be dispeci:ioned in accordance with established procedurcc. 5.3.1 Deficiencies reund curine reinsreetion of Accessible ii i Attributes: Reinspections will be condue:cd in acccrdance with PQCIs which have been reviewed and/c: reviccd since i implementation of the Constructic Ceepletien Prcgra: (CCP) cnd in seccrdance with current design drasings and specifi-cations. i.n acceptable reidspec:icn vill velidc:c toth the t } hardware quali:y and the 7.rier I?.. Any deficiencies. c:hcr ~ than these previeusly identified on nonce formance repc::s as a result of prior inspections, vill be identified en a ncncenfor:snee repert which vi'1 he ::acenble te both the verificatien and criginal IE and the ite: cr attribute in questien. tihen a nencenfermance dece er.:c c diff erence batveen the as buil: conditien cf the u-!: and the refe:- enced desirs drawing c specifica:1cn, a ft :her chtch vill be =ade te de:4:rinc ti.e ces.;n bEzis c;ains: which thc IF was originally cenpic:cd, as tell as the current s:rge cf construe:icn, te further establish the validity cf the I. criginal IR. -f 3.3.2 24'iciencier Feu-d Durft Reins ectien cf Oces.r.cnts:1en fer Inaccessible attai,butes: Tht. verifica:ic precess fc: 4 -i i:.r.ccett*FJe a::: butes is dienurrod i:. f=6aic: 6.f. As 1
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s T i. 64 noted in that section, any decu::enta:ica deficiencies v.. be racerdsd on the nev ;R, entered en a ncncenferrance t report and c css stercnced to :he original IR. t, T o. Syvcic1 Program Ele =ents 6.1 Cable Reinspection: As no:e4 in See:icu 2. Scope, reinspection cf i routing and identificc:icn of installed cables is underway cnd is f; being perferred 10C% fc: all accessible a:::ibutes ;er ?qc1 E-1.C. t 0:her elec::ical sc h, including cabic tensienitz c.nd erni attens, on which ins;cc icnr have been con;1sted by :he En; inca: Cen-structo: vill be handled in accc dance vi:h this pregran. This 4 includes ?(Cis E-1.0, E-1.1, E-;.60, E-2.0, E-2.1, E-3.1, E-5.0, E-6.0, E-6.2, E-6.6 a:d E-6.6.;. ! Lese ?QCIs are fur:her defined and aff ac cd quantities cf !!.s cra shcr-in / rerdf:e A. f f.2 !?IN and DR:
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!... usad in :he pas: : 7:c:cas 1. ;ce.fe-Tc: ices (IPIF) and Discre;ancy Repor:s (DK) ra hs: chcn Nen.:enfernance Repc :s (NCR) te record.cr.ctr.fc: sing ccndi:icns ne:ed by the l inspec:or en work returnac ce constructien fe rework. The ;;ccerr i cquired thr: : PINS be disperi:1cted 1cic:e the Ins;ec:ica lecc c could 'ce cicose. Icc.tuse the use,cf IPINs and D?.s raiter t!.e pcssibi.1:y thc: e cen;'cre int;e::icn nay not he. a tcc:. ;tticined s i c.1:6Lc c: a : '.S ::es ce teren by IPs vitt ertxci..: 2.?;::s er D:.s, I - 1 Ret.-2, 6/10/13 l
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1. all such irs will te ciec:ed as a unique pcpulatten and vill ha reinspected IC0%. IPI5: are cc longer used in the inspecticn ptocccc. Discrepancy Re;c :s (DF) verc c:ed prio :o the use ci the IFI5s. They are no longer in ute, but are recc:ded and vill he treated the same as the IPIN. 6.2.1 Attechtent 10 Forms: A::ac'.:ene 10's were used in ect-junction with hyd:cs:stic/?necratic Tes: Procedures as a punchlist fer a defined Eyd estt:ic er Fneutz:ic Tcst, and included line numbers, drawing nenhers tr.d test beundsries. The Attach =ent 10 was not in:cnded te le the qua'ity decu-ment that identified docu:ented acce;:ance by the CCI cf subsequent acticn :skan to ec::act punchlis: deficien:ict identified during the vc1kder: 7 ocess. These deficienciaa vere in:cnded te he ::acked c: c:her quality cec ne:.:s, su:h as Xencenformance Repc :s, Inspectic: Ke;c :s, a:c. In J order to verify that this use of the /.::ac'.nen: 10 did nc: cer;;crire the qrt.'ity cf ins:alled harevaru, c'* cerple:ei l harciare inspec:1en: dccurented en closed ils fa*1ing vithin the syste: beundaries idsttified on e::isting At:achnen: 10 I fc :s vill be ICC" verified d.rin; the Qur.lity "Jeri::ca:ic: u 7:ogra:. 2 ( 4 e ?1 r.e.. 1, e f :r..<:3 3 rRots:-ce:,.-et:-
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\\ 13 6.3 Excercices to this Program: Excep:icns to this Program shall no: be taken unless such exceptiens can be fully justified. One such exa pic veuld be a case where objective evidence is available of a C?Co overinspectice of the the Engineer-Cons::uctc 's inspectic s and which de=enstrates effective quality control and p cvides the basas to verify accep: ability cf the iters or at::ibutes covered by these past IKs. Ii j '"here such exceptic s cre prepesed :c be taken, a specici rc;cr: ui1* be ;;epared by the MPQAD-01. Gerer:' fuperintendent for revicv and c; proval of the Exe:utive M::ccer-M?(A1. This report will contain full justificatien fo: :he exception and dece:entatien cf objective evicence to supper: the exce;;ics. The Executive Mc a-ger-MPRAD vill infer = the :RC Regien Ill whenever he has =ade a decision to aller such cr. ei.ce;tien :c :he Progran pric: tc 1 7 e-1 j eenting the exceptien. i i i 6.4 ?ctchased Material: Furchased safety related tt:s:ici and cc -
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j incpectic s perfor=ed by the Irgincc -C: s::ucto ;rio: :o lacerto: 1
- 1. 1551. In many cases, purchased i:c c have been ins:alled and are net fully accorribic fc reins;e::1cn; however inacccccible interfa:ss VIli EEia'baan de:ensira:ed a C thc'ir foretichkl ~cee;:
c 1-bility preven thret.ph intitalla:1:n and su': sequent :usti ;. Ac:es:- ) 1510 fu.sturus vi.; iv. ins;ected in cacerc.*tt -ter -tis ?::; ce. r 4 1 l <j ?.ov. 1, 6/10/83 J' re.C-s i-L t 141.-QLO7 i i t i k I'v e.-%- b
14 The totti nuther of irs associated with ?qc* ?.-l.CC, Materici Receiving Inspecticn, it c;prcxicately 12,000. In additien, prier Le the introduction of PQCI R-1.00, s.;p ct.ic:ately 15C MRIs and 20 II?s were used fer receipt inspectien, cevering apprcxi=ately 700 iters. Based upon further revicu, receip: inspec:1ons cevered by MF.!s vil* utther be grouped with like 1:ene cevered by ?QCI R-1.30 or be reinspected scperately. FIPs were also used for ccnstrue: ice f s { activities and vi'1 be treated separately under this p2ce. Where i materisir cuch as rebar, cer:ain structural cctburs er features of t cerpenents a:e inacce::iL.*e ict reinspection, decunen:c:ict vill be i reviewed in accc:dence with this ?:cgran. i i 6.5 ' Inaccessibic 1.:tributer: There are 37 PQCIs which ecyc: cctivities that s e deered to be inaccessibis der reins;ectien. These include rebar installed in pl::cd cc:.w ste, cent:1:nen: buildint tendon reinspecticn, u.d P.QCIs rela:ing te surveillance ei sch-4 3 centrac:e cetivities. A ccep ete lis:ing cf t!.ese is given in A;pencia * :: his 7::g cs. A brief s:ata ar: ar :: ht; a:::ibutes i of these Ils are considered intecessible and why verificctic:. ty i dccunantatien :eview is apprepriate t;;.us:s in A;;endix 3. 1ccu- ..ntatic: :e-lating to there ICCIe vill be revievel as indica:cd in A this Fro-gran, in seccid nco vi:h a revised PQCI or che:klis: 't specificc*.*y devele;ed for review of decentntet'er. These PQCIs. either in-di idual*y er by ;r:ups, vi1.* be :=vi6ted d spreific j de eiled :r** Tic:.:1.2. sill b. de.e* c;cd :c vsv; ;
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15 56ctus of nasociated hardware. This vill ta der.e by a ce=bina: ion methods, applied as ne:esscry te achieve verificatien, includir.g c: vclidatien of prior inspectices thrctsh dccutenta: ion review, rei - specticas cf attributes ths: c:7 etill be accessible, a reviev ef past everinspectienz, a review cf past activities to resc1ve problets, cnd if required, applica:1cn of NDE techricuer er limited destructive er.rtinctions. This jus:ificatien, or reccerendatiens for additien:1 verificaticn ac:ivities, where thic furtifica ic car:ct be estab_'ished. Vill be provicec by the lOR.C-QA General l Superintenden: to :he I::ccutive ).a.ager-X?qA3 for decisic: r.nd I approval. Deficiencies it. dcct:catetien vill be reper:ed c ncnce foretnce reperts, the diz;ositic. cf which vill determine further ac:1cus necesscry. These acti s vill include specisi testing prog:= s n required to satisfactoril: er::tlish the \\ quali:y acceptance cf :Li> categcry cf P(Cis. i 7. Decument::ior. Enc Rererts: 1 7.1 Documentatien cf Results: ?.esults cf reinspecticas a d dect:.4:.: I reviews will be recorded en r.ev I5s c;aned specifica*1y for this a l' pc: pose. Each such nov 17. vill be c cst-:sference te :he elesef i ~, l e:igitti IR. t A proper cc:stien vill be ade en the nev 17. te identify whether the a::isting crigina' inspectica covered hr the !R 8 vos validated, rejec ec cr is inde:c -in.ite. The new IP. v111 i I
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l l-3 t i i 16 i L 7.2 Docur.entatien ef Xencenferr.snees: Scacenferrir;, cceditices eb-served duris.g rei=spection activities vill Ec; dectracted c a i nonconferer.nce :=per: and appropris:ely a al;. zed fer nanagemen: attention. This includes instancas where a design er cer.ttrue:ic: t modificatien has occurred since the Inspec:ic Re:c d was clcsed and a new IR not yet cpened. (Ne:e discussict in See:ien 5.2.1) t i
7.2.1 Trendine
Deficiencies noted durir.g the verificaticn process vill be trended as a;; c; 13 c ft: ar.alysis c d e.anage:ct: infor:a: ion. t e' 7.3 Resor s: 7.3.1 Re;erts te Executive Maneger-::1CLI: A vaskly status repc : vill be race scin:1;* b: the C?Ce 20P Quali:7 Centrel (C,C; t Superintend.n: cr.d.Ruality Assurance (QA) Canc x; tu;6:- 1 intenden: to the Executive Mr.nc;cr - 1:idland Projec: quali:y 1 Assur..ncu Le; art =en: (M?QAO) su :sricir;; tre resul:s cf :he pres:A. The repo : vill no:e :he cc:;1e:cd Inspectien Peperts by the unique PQCI nu bor, tenectic :ance Repo::s 4 I I issued and id :ificatice of a:::ibu:e(s) crurf.nc. :!.e i nonconic :anca:.s'f. I, 5 }l ~ Rev. 2, 6/10/f5 PRC'33-0014A-(*;7 't a..,.. -~.; c-+,- ~. - - -+-4 - - - * + - -+-
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7.2.' T.c orts f rom I:cacutive Sanscer-?:PCAD: "he Ixecutive Mana-ger-MPCAD will infor= the C?Co Sice ).anager, the Engineer-Censtructor Itcject Manager, and the Vice President, I c-jects, Engineering cr.d Cerstruction, of the statu: cf t!.e quality verification pregra: en a biveckly basis and vill previde cl.sm with a fc =al ncnthly repc : cf the verifi-l cation effert. As appropriate, hc vill also re;c t on the i cceeptr.bility of ccepleted verk as it cc, he impacted by nenconfermances. i t. i 7.2.3 Peterts te NRC and Cens: uctiu. It-lenentatien C.'erviev Team: The Executive Manager-MPQ/O will ;; ovide cepies of the monthly :eperts r.oted in settien 7.3.2 to NRC Regier.111 ar.d the Constructien I=ric antaticn Overview Tea =. ), 3. Inelete.taticn: This pregram vill be i=placented under the dir m cen:::1 ef >JU.: th cugh precedures appreved and issued occc: ding to norta:. pres:a:satic requircecntr. f.1. Crranizatteesi Restensibilities: The Ir.ecutive Mr..sger-::TQr.L has tota
- cverall responsibility and sucherit: fc
.!.e develo;ce.: and i, .:ple,entati sn of all qualiti re2rted sapects ef this *:e:ifics.ti6: p r ectr.r.. He will be responsible fer ecuitt, t!.4t the implacentatier.
- . t. cf the ;rcatas is cecidir.e
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s 18 3 8.1.1 MPQ.C - BOP CA: is res;casibia for the p;cgte. :ic ele =erts of the verification prog := includir.g. tu: re lici:ed te, 1 i E,. precedure devalepnent, PQCI review ar.c ap;.rsvel, scnce fe:- i mance revie., analysis cf results, justification fc dccu- =ent review, verificction of inaccessible a:::1bu:es, 3 i i progra=,ccr.: cst redificaticas and certifying tht.: the tF l verificatien has been ece;1c:cd for a given area c systar. t-l cnd ;crfort:.:t ranagement overviau cf the reinspectien i
- ocess vi
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- a cocu:en:c:fo. of results.
1 t E.1.2 EPc/D - 30P CC: is res;ctsi::le f e: ;;cg:ar. 1 p;<.:c : tiet including, bu: not li:ited tc, cceducting the reinspectics ac:i*1 ties with CC persettel tha: se:icfy T.epla:ory Guide l 1.$C F.ev 1, whi:h requires ;arser:cl es :i' ice. tic in cccc:danta sith /d;S! :;.5.::.6 f.r.c ;arre vill reinspa:: activities fe; thich !. perfor:ad the origi:a; :.syce:ien), t re; citing res:lt: te Ll.a i::etutiva !.ar.ager-!.1UO rc;c :;rg i nonconformances to :ty.;-I G C). A.d coordita:ing with Cons uctien Services and Cct.auters $1:i ::u.t.a zen: Cffice te as:stlish sciedule pricri:ias for reinspec:ic a::ivi-i ties. 6.1.3 !?OAL - fits Audit ferties: i t. :ta;.nsible :or it *.m.1 4.t.f.1:s e cf the overall vstifiertic. ;;rt :.- 1 ;1ents:stier. 1 l T.c'. ;. u,R/si FTC4! -C014A-Q!.07 - -..- -. -, -. ~.. -.-~;- - -~--m ' ; '. $ m.9 y",, y, e. 'i' e. .?, y...._ - s
19 6.1.4 1000 - QA Adeinistra:1ce and Trainine: h?qc Trecedures will be develeped in accorda ce with p:cg: u.:4: c require-mer.:s to direct implere ttticr of this pla.. 1 f t ?, i 1 1 t 1 s. hav. ". 6/*0/53 3 Pkt-63-GCi!.A-CLO7 m. .-4..e**.g.ye-.1 =uss,
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a_.----- i APPFNDIX A Page I of 20 A I.1ST OF Al.I. PQCI'S WITil QllANTITY ANil llEINSPECTION INFORMATION i Pf)CI I PQCl TITI.E QllANTITY DOC'T llARDWAR F. REHARKS C-l.02 Compacte1 Itackfil t lill Ilardware & documentation under remedial soils prograai i C-l.09 Inspection of Ilardware & ilocumentation ass.n Crack for P.WST in stor remedial #; oils program d Fnnnilatlon Ring Unll 5 O C"3 C-1.10 insep of Croint ing Surface condition and v,g;fm and Dry Packing 1811 1 1 docur.cntation ,g WCW C-1.1I ler11IIng & CroutIng .m ) Relia r 66 1 x gLa n
- g. uaam C-l. 2fl Concrete Preplacement inspection of remaining gMy lin;pec t lon 767 2
i unpinced concrete arens m plua past documentatinn C-l.21 Int:pcet ion of Inspection of accessilite Reinforcing Stect 259 i i reliar plus past docismen t a t ion C-l.77 innpectinn of Reinforcing inspect leni of accessil>Ie Steel at Contitruction relear at remaining. joints .inintn 19 i i pins past documentatlon llev. 7, I./1ti/WI PI:04Wi-on l 4 r-ys.f11 3:EY: 1 Oncoment-Review stocumentation for completeness ? Ilaretwarc-1:elns:pect arrettslisle att ributes x II.es dwat e-At t r il utes not aresutbic Inr reinespection +
.. w J. z._ ~ - Al'I'ENDIX A Page 2 of 2fl e A I.1ST OF AI.I. Pt)CI'S WITil ()flANTITY ANH HEINSPECTION INFORHATTON Pt)CI # Pf)CI TITI.E ()HANTITY DOC'T llANpWARE NEMARKS C-l.30 Concrete Placement inspectioin 780 1 x .] C-1.31 Inspectline of Concrete Activitlen 246 1 x C-l.40 Concrete Por;t Inspection of concrete M acemen t Inspection 1002 1 i surf aces plus elocumentation C-1.50 Installation anil Testing Inspection for proper of Expansion Anclinrn 4917 i i installeral coniHtion _. = - - C-l.51 keterst Ver!!Ical lon ol' firop in Expansion Antliors 54 1 x C-l.52 Reinspectlon of Sels;mic CatcP.ory l Pipe Support Expansion Ancisors 294 i x C-1. "> 3 Reinnpection of Expaur:lun Aeielsorts for Seirinile C.it i Suppnet 0 Ncv. 2, f./ IU/ft'l PI:04fft-tWil 4 F-Ql.0 7 KQ: 1 Ilocument-Review slocinnentation for completeness i lla rifwa rc-Reinspec t accesulls t e at t rilint en x II.orifware-At t rilent es not acenntlile for reinnpect ion
,l' 1 ). 0 i 2 su A I f t X o m s c l a s e il nr e p N' og n s i E e i o c n P g t r i i P a ap cse Ar t i er ns pt el mnr mi ol o e S uo cif cs r N K O R o rt e I A dl ot l a f al e T li l A F a l i nl nes M R i R ae o
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m c i I F ee t I r N rr as a a t s I lwr net N e eco i O ri mc n n I la ua n I i c n T E lot e C ct a P E ei n S R w pi N A eslno W x x x x x vit i I E I D R R eet ) l R RA A I l N t cc A nr r eaa mww Y T a l I. T 'C i r r r i 1 1 1 1 i I
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)N i i A I y_p l l N i ll Ki ! x )( Y l T iT I T 5 2 9 l i N 0 2 0 1 9 l A l 2 3 2 1 ) O 's S l 1 ( I C Q P l e l. c e l r t A u e d s y r g F k n s r c n O c ag e n n I i o n r o o W r T M n gi P s C S e S o nc a t I. fi i r f f H f f a ot l o o o o o w l a l f e t c A nl i n nr s ny s p i s e nl ri ni nn or oe s E. a e i i F i il I l t a l i es I t t R t f t i o t a e T co e ae ne as aC r I ep t g i l t I t l e A T pI es l e I e l : l H e l s ril ar nr a ac t I nt ct e t c t c t t t l n C I i nt e si nn si se a n ) co out e o l' Ml CCS l C se o nn nt l e f e l i I i S P l I I f. 7 M. M. 9 t. e. o H l 0 i t I I N t 1 i l. e l l 1 l l l 2 t q / e. P C C C C C C s y ( tI 4 /. l i f f is .t-i 7 t .u l vf et rr t
J 0 n 2 o A n i t f m l o s c X o a a i s e I nr i t e p D4 og d a n s N i o e et e n E e t r m l n P g ap e m e ese t i s P a t r a l m i l er AP ns r su pt el r g sc mnr mi e o eo ol o i uo d r cd cif S cs n P c r N K o u as rt e O R dl s u ot t I A a t m l f l i f al T H di sa l op i A E nd er o nes M R ae t g S ns ot s R m o oe i i e O ee er i jt l t i c F rr mp n t u asa N a i i cl e t s wr t s d ei net I d e l e pr eci N rd ei m st mci n O I ian no e nt ua l u os R i a T c s E ot e E s ce et t I' E n w pl i S R eni N A i nr I W 2 x vit a E D e et R t R RA l A D l t cc l ~ N A nrr eaa Y T mww ~. 'C s l T d i e r i s I 1 2
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N D Y.,D I la T O llA l' I I K1 i x Q Y l T iT I 2 I T n 1 W N 7 4 2 5 A S I 1 I 1 1 1 I O I I Q I C Q P I. I A gn F i f O n ol n e T e di ne e I S l g ep t ot r c I. e r t r c f i S t e 1 v a se e od s t nf t a h
- l. d t.
nr as I oS A rs c n nao cn f l Cl e - D o n i o O ng E. l R Q s I i t t e rn t e O r c on b n l I i I T nW n goo r n agt aa nt c l i I e w nfl o l i e Fl aar ee l T n1 o i r t l l t g l cn ae d l sa ct ari d e I I l mk wt l ar uc t et ic l r n e l C rc as iee r e st r cs cl i i Q ea r e rrp t r nai J l l ae P PP DT PAO SE I WA Fl FFR I 2 1 5 l 0 l l 1 1 0 0 0 I. 2 2 0 l I 3 C 2 2 2 2 2 2 2 NQ t le / - P C C C-C C C C F s t'l q ll ~ t a e H f 21 H . 4 vl - i e R rP 2 j li
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-~' ~ ~ ~~~~ ~' ' ~ ~ ~ ' ' ~ ' ~ ' ~ ~ ~ APPEllillX A Page 5 of 20 A 1.157 OF AI.I. Pf)CI'S litTil QllANTITY AllD REINSPECTl00f INFfMINATIOli Pf!CI I IT!CI TITI.F. ()llAlfTITY ll0C'T llARIMJARE ItEMARKS C-2. 5fe I.aad Monitoring ol' tioe Fecelwater/Isolatics Remedial Solis Program Valve Pit Rod A Rock Rolt O 3 C-3.nl Instal lat inst Inspection of Spent Fuel Storace Inspectfan of eccessible Itacks attrilvietes plus documentation 70 t i C-3.07 Installat tene inspection of Spent Fasel Storage Inspection of accesaf tsle Racks attril.utes plus documentation 8 1 1 C l.03 Inspect loss of Tent Ior i' Accept al.f i f t y nt' s lie Spent Fenel Rack CelIs 0 C-4.lO Rate le Plant Innpectinn 979 2 e' r x C-5.lO Sleca r C..nucc t o r Installation 503 i x C-6.00' Mecleanical Splic.f sig of . Reisifoe ring Barn 787 2 x Rev. 2, f /Its/r. ) l'RD4M 1-t18814 F-8,5f.fl7 KEY: I~~ llorosaceit-Re wIcw driciassental lon for complet esecsa i llarelwarc-Reinspect acccusilite nitrileutes x liaralwarc-At trlieuten isnt acenntlif e f or relunlicct ion k h'. i
--.~ _. ArrEleplX A Page fe of 20 A l.lST OF AI.I. Pf)CI'S WITil QllAttTITY AND REINSPECTitWI INI'ORMATinti PflCI I Ff)CI TITI.E QllANTITY DOC'T llARilWAR E REMARKS C-7.00 Erectinee of Reactor lheitelinC l. leser Plate 10 t x C-8.50 laspection of Surface Preparatton Applfratinn l Tancle lip & Repair of Coating 908 i x i'. C-4.51 Inspection of Inspection of surface i prenatamination Coat enndition plus documentation for concrete 17 i I:-4.fO Inspec t lent of Surface l Pe crarat ion Applications Toncieesp & Repair of Coat ings Reartar Niilg 1.Incr Plate 0 l I:-9.00 installatinn-rnst Tennlineing Cnenpanents 40 2 x i C 't. I R Post Tenslensing Systcom Etrenning in't x t l urv. . c.IInint PRf 4Cb eso 14 F-fSt.fl1 R EY: ? Ikicisment-Review einc. wntat ton f e r completencrste ! liardwarc-Meinspect arresallele at t rileutes t z liarelwase-Att rilisates not arcsnll lc for relen:pect ion i 1
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4_._._.2,__1_... APPFJelltX A Page 7 of,20 A l.lST (W AIJ. Pf)CI'S WITil f)llAlfTITY Atell RElstSPFCTints' iteFoltHAT1006 t PelCI # Pt)CT TITI.E ()tIA88TITT senC'T IIARiaWARE RFMARKS C-9.26 Costaisement ridg Tensiese Reinsp Il 1 x CW-I.See Welding & IIDE Inspection of surface of "t)" 8.1sted lion cond1 tion and raelf ographs . A.9eE I t ems 381 1 1 plies dociementation E-1.0 lastellation of Inspection of accessible Casidai t Roses and attritmtes plies documentation Supports 471 T> 1 1 l'-l.1 lustallation of Inspection of accessible Anses 9 1 i attributes plus elocumentation E-l.f.O In Process Inspection of Elcetrical Itts Installatlam 25 1 x E-2.0 installation of inspect loss of accessilite Cable Tray and at t rlh.st es pins documentat ion Wireway 1%8 i E-2.I Inntallation of Inspection of accessible Teay Supparen 799 1 1 attrilintes pins documentation rev. 2. f./ledit t !E: B Efl4N l-8 Mil 4 F-Ql.0 / ? Ilocument-Review dornmentation for rnepletenens ! liardware-Reinspect arressilite at t r.II.uten a liarelwa rc-At t rilient er. not. arcanil.ic for ref unpect lain
APPENilIX A Page 8 of 20 A I.lST OF AI.I. PQCI'S WITil QllANTITY AND REINSPEl' TION INFORHATION Pf)C1 # 'Pf)CI TITI.E ()llANTITY 10C'T llARDWARE RF. MARKS E-3.0 Final Electrical Area Completion Activity 0 E-1.1 Electrical System Turnover Activities 108 2 x E-4.0 installation of Inspections of accessIhle Electric Cables 7954 1 x attriheites has been accomplished under cable routinc,& 10 prograni E 's. it Ceible Terminntloitti 121til 1 inspection of accennible nttributes pliis docinementation E-fi. 0 Isistallation of Inspection of accennihte Electric Equipement avid attributen plans documentatlois I nst renaeus at t on 14(. i 1 E-(i. I Hodiffration of Comb ine wi t te RW l.10 Elect ric Erpilpment 209 1 i inspect accessible attributes plus documentation Rev. 7. fi/10/ill Pt:t:4 fi l-tasi14 F--#!I.t:1 KEY: i Dorisment -3:cylew sincument at inn f or rompletenents ! liardwarc-Reine.pect accessible attributes x liarifwarc-At I ributes not ncensible for relen.pect lon
~ _ - _..__..___..2 -c ---~ APPENplX A l' age 9 of 20 A 1.15T OF AI.I. POCI'S WITil ()flANTITY ANil itEINSPECTION INFORMATION 16)Cl I Pt)Cl TITI.E ()tIANTITY IMIC'T IIARDWARE REHARKS E-fi.2 Installarton of Inspect accessible Terasinal nomen 103 2 2 attributen plus documentation E-fi. f. Installation of Inspect accessible Electric renetrations 127 1 2 attriliantes plus documentations E-fi.fi.I installation of Feed inspect accessible + Thranse,h Assy's for attributes plais doctimentation Elec resectration 3HH 2 2 { E-6.7.I Installation of Inspect accessible P.atterlen & Racks 9 2 1 at t ributes plus dncomentation NW-l.10 Hodificatlost to Comblue with E-6.1 Electrical Equipment 144 1 i inspection of accessible attributes plus docus:entation t 1-l.10 Installatloss of Inspection of' accessible lies t rumesit s 1 *>9 1 2 attrilnotes plies clocumentation Il-l.fMI Installation of Innpection of acccasible Hechanical Equelpment Il i ? att ribules plus documentat ion
- cv. 7. s./Its/31 l't.fl47t I-tesileir-s}l 3/
Kl.y : Tiiocuencnt-Review documentation for completenens liarIwarc-Reinspect accenn hic ntIrJhistes x liariluarc-Attributen not acennihic for reinnpect ion C
_u.._ 4-i APPL 3felX A = Page 10 of 20 A l.IST OF AI.I. l'I)CI'S WITil I!IIANTITY AND REINSPECTION INFORNATION P Pf)Cl # Pt)Cl TITI.E QUANTITY llOC'T 11ARIMiARE REMARKS H-2.00 instaliallon of 78 i i Notating Eqisipament inspection of accessible l at trlhutes plus elocuraentation H 't.10 installatime of Cranen Inspection of accesallite I i i att ributes plus elocumentation H-4.00 Complete Installatipun of Heclutnical inspectJon of accensible Eeleil pment attributes plus elocuanentation e' 1 2 HI*-l.fM) hinassembly Mennsemisly nnel Huellficat tem of Inspectlen of accennllsle attribulcu plus elocuamentation Systems anel Compiments 4 2 ? ^ Hil-l.00 Weleling neul NI)E 8:ev I of Hechanical Equipment U j l'-l.DH Piping Completeel inspection of necessible I.Jne Installation 80 2 2 attributes plus elocumentation P-l.10 Piplog Nuhasnemisty inspection of accessible Fielil Installation Rif 185M i 2 at trilmtes plus elocumentat lam -Rev. 7. 6/in/RL l*RH48 l--0014 F-yl.fl? _K_EY..: t thicument-Review elocumentation for completenenn
- liaralware-Reinspec t accesull ic nti rlhuten x Ilarifwarc-At t ributes unt accasil le for reinnpect Ion 6
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_a APPENist,X t. 4 18 of 70 llare A 1.IST OF AI.I. I'IF:l'S WITil (pIANTITY AND I:EINSPECTION__INFOIHATION re)t:1 # PtF*l TITI.E OIIANTITY Dt X*.' T llARlWARE NFNARKS P-l.20- Piping Suliassen.I,1y Inspection of accessible Siwip Fal. f.1;cworb 994 1 i att rilneten plieu docum.cs. tat ion P-l.30 Valve asul laillne Inspection of acccuullste Coimponent Install 1747 2 i as tributen plus doennientntleen I - l. t:0 in Piocess insp Feale/lin;teillat Ice rrwo rir of Piping i f.7 1 x P-2. fMI Pipe Coimponent ine:pect ion of access!!sle Suppos-tr. Flesal Setting 5 1 1 nt t ribenten plun docuenciatation r-2. I tl P.Ipc (Consponent) Supiner t installation iifsi' P. 2.211 l'i e C:tantanient) linepect.Jon of accessible l Sieppests. T l. sir.elion 4 4e.H 1 1 at trilusteia pitan dncuementntlosi
- r. 2.1r Pipe (t's,p ment )
Closed IR's froom P-7.In and Userg+e t til9/PI29 P-2.2H will I.c reinrpectcal Walkdown in to rc<luiresments of l*-2.30 where I ns t 4e l l eil res. 2. e.i les/s..I IAY: sTt:4:: t-tits l 4 8..e}I.ill i loucum. cut-P *v. lev docusment at ion for completenenn 2 Ila n dw.e. -Fr leis pec t accensilsic 4st I rlima ee. x II:irdwarc-At t rilme rs; su.I arennil.le for s e in: spec t ion
~ APPENDIX A rate 12 of 20 y A I.1ST OF AI.I. rQt'I'S WITil QllANTITT Anis REINSP8tCTinit INFORMATI0ll t a FQCI # PQC1 TITI.E QllANTITY DOC'T NARDWARE REHARKS s ~ PF-l.IO ripe FImage Installatirws Innpection of accessible seed Rework A20 1 1 attributes plus documentation s PI-l.40 Fjeld Fabrication and Inspectjon of accessible Installatten of FIptng attributes plies docinecntation Relateel Instrumentat line 204 1 2 PI-7.40 of f-Site' Fabricatiews/ Inspectirws of accesulhie Ucid of Pipe Related att rlhutcu plus elocienceitation Inst reinen-( Supporta P4 1 2 9 PIU - WeIJlag and lenE of Inspection of accessible '~ l. 11 0 Isist ressmer.t Teebleig and, att rlhutes plus doctementation Fittings 642 1 t =% PU-l.hG Fab / Weld / Neat Treat inspection of accessible
==I IIIW. ni AsME III attrilaisten plus docussentatinn ripinr. 19014 1 1 R-l.00 Esterial Recciw1pg inspection of meressible ^ Inspection 17tKl7 i 2 attrileutes plies docessientation r> j-s l d l Rev. 7. f./Ist/83 Pkt:4M14 mil 4 F-4)(R 7 KEY: t nacument-Review docuinentatton for compteseness ! II.ardwarc-Reinsperr.irecss thle at t ribut es i '. ~ x Ilardu. orc-At t ril.uten not arcsnitete for relianpcet f un
Arrt31HII A 2 Page 13 of 2n A 1.IST or AII. Pf)CI'S WITH ()tIANTITY AIID kEINSPECTIDII INFORMATI006 ,IVI I FW)CI TITEX. EMIANTITY DOC'T HARDWARF. Rt36 ARKS R-l.fO Receiving Area an.1 Storage Facilities Walk throngle of existing conditions plies documentation Inspection 45 2 x i R-2.00 Receiviens Inspect Ion for NSSS Esgulpment 198 2 x t R-2.lO Receivisic Inspectines for ~ i MSSS Esguipoent 42 2 x l R-2.2ts Rcreiving Inspectlon Inr N555 Fqnipoent piecument at f use 287 i x ( 9 5-l.n0 Storage Areal Walk througle of Facilitics Surv (37 2 x existing conditions plass review of elocumentation ., 7 SC-l.05 Matertal TestIsig Services 3n(> 1 x rev. 7, e.Itu/s) Frelin :-ntl!4 F-QtDI KET: T liocuement -Review elocissmentat it..e f o r. comp le t eness ! Itae dwarc-Reinspect accenslisle at t rilust ess a liardwarc-At t riinit es not acessil.le for reinspection S
L__ - L -- r APPENDIX A i Page 14 of 20 i 4~ ; A 1.lST OF AI.I. Ps)CI'S WITil f)llANTITY ANel REINSPECTION INFORMATION .i .t f*f)CI # Pf)CI TITI.E f)llANTITY IXtC'T - IIARlWARE RFHARKS Q:- 3 -- SC-l.06 Recoating Work of Cent [ }- til Ig I,Incr Plate, ty .Hinc Steel, an1 Pipe ~ .i llanger Atraclimenti 0 }. j SC-l.07 Agreement for Tecle -{ Servicen for Soils ' t.alearatory Tenting O . i, ~ 'i SC-l.10 F.n rthweirk. Siebcent rroc t ~ t' Surveillant.c 0 .?-.-- 8C-1. I I' roncret e anel lini t.. Hn:sonry Sarface Suli/ I 3 Contract Surv 4 tif-1 x r: w .) u. SC-l.14 Sulerontract Surveillaure of lunsallatinn of t .g. Houlcrpinning n 4 s f*C-1.16 Flulet Frectcil Storar,c Tankn/!:nt.enne raer 1 !:n rve i l lance-1 011 1 x ~ I I:e'v. 2, f /lfi/fil ~ l'I'04H l-Of tl4 F-til.01 K EY: TDurisment-Review alocumentation for completeness j i liarsivarc-Reinspect acres.silele attrll.nt es j W x II:grelw. ire-As t rll.seren not nresnilite for relnnpect tnn P-+
) 02 Af s o i X in T 5 t S1 s c N n e E e e p P g n s P a e e n s A l' a t i 0 r eue g cs l o pa r S mmr N P ol ai K O R s r ci f I A l rt - T H s A E ot l l M o f al e t R S I i O n e s. F l ol r N a i e e l i t i c I d ana N e t n O m net e eco I T R mcn C ua F c s P E ot e l S R s ct N A eu w pl e I l E H x x x x x eni I R R i nr D lA vI t ecl l N HRA A ee t Y T nr r T ean 'C mwu I T O 1 nl l i e a N D i r r s 1 i o a a. A l l Y.l l t Q El I i l Y K! ! x i T JIT I TN 8 H 8 3 0 I S lA ? 1 l 5 3 0 3 H Q 1 8 2 C 1 I I Q P I. I se A n e t nn e c k c e o c F g i naa r n n eTl o a O nyt ga n l i rc nl oei n l c l T vf s t ac r o e st p nni mrv I l pge S si I u c ean one our d nv o l. S n i k e r Trn I ii v CS u ear ok v oi A rice di al u dr a S a ot nD n t t r t S t Tu c t ar n n. e l aic a S ees cn r e l F el Cg i n t t t i ot n t ot cae ri c nn I nl n Ct a nC c eWn b t a oa t c T ral i nnl e I t t ur e a r r i el V rr aar T nsno r oi Egt Fl cl ou t upe I u nn l 1 t i l n ul ,A o di o d ao S e l cl l i sI v t c i l c l t c - v C i l l n nnr adh eol cnl E r Q uf oo et u cnn i i P S nSM HES aS FCS l' I M NS s l ou i nu u l D I I I I I N M 3 4 7 I. l. 0 0 1 1 I M 0 ? 1 a F l f. l l l l G E l'8 i S H H W / - 1 M M f t f
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n y a._2. __ _ L- _j.- J APPFNRTI A e 'Page l(n of 20 j A 1.15T tlF AI.I. Pf)CI'S UlTil f)llANTITY AND REINSPECTION INFokHATION IMM:t I 11)C I TI TI.E ()l'ANTITY IX1C'T llANDWARE NDIAkKS ( T-1.00 l'ydrontat ic and Pncesmat Ic I.eak Testing 460 i x T-l. l f! Final Cleaning of interior Surfaces of Piping Hecle Equipment anel Instrumentat Ion 0 A T-5.DU l.ift Test for Crnnen 0 ? W-l.00 Welding, ifcat Treat-ment and Non llestructIve Inspection of accesalble i attrilouten, raillography plus Examinat!on 20251 i i documentation .i U-l. fiO Area inspectton Of In l'rocess Activlticn For ~' Uciding t}-l.Inteel And ASilE III Itens 1(i4 i x C-l.01 Excavation in s}-Soll Arca NA. Remedial Soils Program t B*c v. /*, te/lil/A1 1, 1*k H ' H'l-HO l 4 V-t}l.H 7 -_l'_Y : E 2 Document -Revicv elocument at lon for romplet eness i liarelwarc-Reinspect accessile le a t t r itiut en x llatelwarc-At t ril.ut en unt ncesslinic for reinspect inn I a 3a m-
j ) 02 ni. Af s l o ie a s t s m ia n r: X n l a l 7 er a a n e 8 e er er e p H1 rg r r g r g n n 1 ao a ao ao e n F e wr ws wr wr P g lip m i l l t i P a r a ti r ri p es e d p f AP as r so ias ias pt l er hl g i s l l mir l s l l i o l i ol o d o r dl d a i o cif e l S ns p na nc ns r N K a al a a rt e O R l s l i l l i I A na l ne na na f ali a t l T 4 oi e l om oi oi A F) id o i e id id n e r. H R t e S t r t e t e ol n t am l a as am l e s o t e l t r t e t e t l r e t F nr a nem nr nr a :. a N e i ed a e e t s I mr d s ug s e ue e c n m nr mr mr net s ue e e i I ~ N cd m c o cd cd mc e on e osr on on ua l s Du M Dip nu D u c s i T ~ C ot c E t ri P E s e n. S R w pI N A esI ~ W I nr i E D vi l R R eel A RN A ) I H N t ee A ns s ea a Y T mwu T udl 'C i I cr r T o oa a N i Y Dii l l l A E H K t I x O l Y T iT I T 4 I W N 2 7 8 A l S lA 2 G N e 1 7 t 1 I t Q l ~ ~ y f P r l e I. a d s cg ii i I t ,n i n A l l u ri n i l a i F_ ne r t f d l r nt o O s o n n i cis F l o o s l T P y l nl cJ g C i E S n m S e oe e t u u r o c l l. W i e Tnl f rq f en i i 1 t t ik oeA od o t n l aS f cc l. ni a y i A e c O na i ina nil i l t i t naS k i g iJ nl o E. c r n n t a I r n i as i e a i e arL n t rD ei i e I I l rD n T P ac t l l e1 o no s F a Tgt ~ e Fr I ca' t t I I F g i q l T o l t I nm sA ni l e df ewea nxl c ae ei a v i n p1 vr l t oa t t l 6 t a l nl C a ei scl e sI u r nl t ini l s i Q r l e n e e. p i iy naa aiq s e l G FN I e FVO l &PS Cb cPA l i i I 2 5 l i D. 2 0 I. f. 0 7 l s I. l 4 5 1 c 2 2 3 ll l l / - 8Q l iEC C C F. E E i F l l f 4 l /l i te H t 23 M i . 4 v0 eI : R P n k j '.' '*e
..L....._.. -.. a- -.- -~--- - - - - ~ ~ .[. Al'PENIllX A '4 Page 18 of 7tl A l.lST OF AI.I. Pf!CI'S UlTil f)llANTITY ANI) ItEINSPF.CTION INFORHATION Pf!CI f Pf)CI TITI.E t}llANTITY DOC'T llARinWARE NEHARKS t ^ IM-6.9 Installation Of instruements Docessentation and liardware is For Under Planing imder remedial soils program Data Arpsinitions System 2 's l Ell-6.1 Installation of instruenent-Documentation and liardware les l Supports For Unider under remedial soils program Pinning Data Aquisitttms {. System 29 1C-l.0 Instrument Clieckoist 67 Documentation and liarelvare is tmder ressedial solls program t i NH-l.lMI Steirage & Hafntenance Remedial soils program of Halcrial Released j To Mergentine NA i { MS-l.lMI !;torage A Halnt enance Remedial solls progroei tif Haterisel Releas:cd To Spencer, NA White A Prent is Nev. 7, is/lH/lil l PRil4fl.l-Du l 4 V-t)1 f t?; KFY: 't"6acument-Review docismentation for c.ompletenesrs 8 1 Ilarduzirc-Heinspect accensilele nit ribieten x Ilariluarc-At tril.ut en not acessilele for reinspection h..
_.i. _. ;. I. - - -- - - ~ ~ ~ ~ " ~ ~ ~ ' APPENDIX A Page 19 of 20 e i* y A 1.lST OF Al.f. PQCI'S WITil QllANTITY AND REINSPECTION INFORMATION i 14)CI I PQCl TITI.F. QllANTITY DOC'T 11ARDWARE 217tAltKS 5C11-1.0 Crack Honitoring of i Tlic Feeilwater Isolation Documentation and liardware in Valve Pits Sule-under rensedial solin program j Contract !;urveillance 3(i 511-1.0 Honitoring, Reducing and Neportlug lInder Pinning Docuanentation and liardware is Instrument flata Suli-under remedial soils program Contracts Surveillance 189 lir C-l.004 Welding Anel NDE Of , Documentation and liardware is under remedial soils program "Q" fla t e r ia l 8 IIP f:-l.00R Excavation And I.agr,ing Documentation and liardware is Of Access Pita under remedini soils progran Piern anel llrlIts For IIP 1 IIP C-l.Illo Field Friliricat ion of f; teel !!ocumentation anel liardware is
- 1ctra For iluder under remedial soils program Pinselng Of Aux Hisig A FIVP 5
I!cv. 7. ti/Itt/H1 l'I:llf il l-IID 14 P-Ql.fil e K EY: Tilorument-Review elocumentat ion for completenens t liarsivas e-Reinspect accessilile at t rili.ilets x Ilas dvarc-At t rileut es not arensil.lc for s elnnpect ion
..e-_ - a._ .-m t APPF.NolX A Page 20 of 20-A 1.15T flF AI.I. PI)CI'S WITil QilANTITY ANil HEINSPECTION INFORHATION The kemedial !;nlin Progrne lias leIltlated'the following adelltional Pf}CI's for wlitcle tliere are no Enginecr-Constructor ik's, inspections have all been conducted ley CPCo supervinfon i IIP-C-1.002 IIP-C-I. 011 IIP-C-I.019 S0-2.0 i llP-C-1.003 IIP-r-i.012 IIP-C-2.003 til'-C-I.005 IIP-C-I. 013 tir-C-2.0fM 'ilP-C-l.006 11P-C-l.014 IIP-C-2.005 III'-C-I.007 IIP-C-I.015 IIP-C-2.Ou1 IIP-C-l.009 IIP-C-1.016 IIP-C-2.008 IIP-C-l. 011 IIP-C-l.017 IIP-C-2.009 IIP-C-1.019 IIP-C-3. 018 IIP-C-2. O lli a llP-C-1.020 IIP-C-2.Ol9 IIP-C-1.fl21 ilP-C-2.042 IIP-C-2.I50 llP-C-3.001 ilH/MS-l.00 f I 1 Pcv. *r, (./10/H1 Pitfl4l1 1-fl014 F-f)l.fl7
s k APPENDIX B Page 1 of 10 APPENDIX B POCIs To Be Verified by Review cf Docunentation Oniv l The folleving PQCIs are deened inaccessible fer attribute reinspection. Eardware a:ceptability will be established by documentation validation where possible and by supplanental verification efferts where docunent-ation review alone does net es:ablish hardware acceptability: 1. Retedial Soils Preeran C-1.02 - Compacted Eackfill C-1.09 - Inspection of Crack for E"ST Tounda: ion King Vall C-2.00 - Plant Area Devatering C-2.01 - Gravel Packed Wells C-2.02 - Permanen: Cravel Packed Wells C-2.05 - Drilling in Q-Listed Areas fer Underpinning 0; era:1 ens i EU-1.0 - Installatten Of Cendui: and Ecxes Per UP Cata Acquisitic: Sys:e: EU-1.0 - Installatien Of Electrical Cables for U? Data Acquisitien Sys:e-4 EU-5.0 - Cable Terminatien for UP Data Acquisitien Sys:en t i EU-6.0 - Inttallatien of Instrunen:s For UP Data Acquisitien Syste= IU-6.1 - Installation Of Instrunent Supper:s P:r t? Data Acquisitien i Systen 1 IC-1.0 - Instrumen: Checkcu: For UP Data Acquisition -,. SCM-1.0 - Cra:k Menitoring Of 'R7 Iso. Valve.Pi:s Subcentractor Surteillance i I e-P.sv 2, 6/10/33 j Pit'53-0013A-QLO7 4 e - ~ w
3 APPINDIX B Page 2 of 10 SD-1.0 - Monitoring, Reducing and Reporting U? Iast. Data Subcontractor Surveillance UP-C-1.004 - Welding And NDE of Q-Material OP-C-1.005 - Excavation & Lagging of Access Pits, Piers and Drif ts For UP UP-C-1.010 - Tield Tabrication of Steel Sets for U? Of Aux. Building and TIVP. The abcve PQCIs relate to the recedial so'ils progra: which has been established as a separate project and for which inspections have been perfor=ed under the direction of MPQAD since August 1982. Soils work and related documentation have been reviewed by MPQAr f or acceptability and corrective ceasures instituted where required. 2. Reinsrec-ien ef Exransien Anchers and Rock 3elt Installatien. C-1.51 - Retest Verification cf Drop In Expansien Anchors C-1.52 - Reinspecticn of Seisnic Catercry 1 Pi;e Suppert Expansien Anchors. C-1.56 - Reinspection of Rock Bolt Installatien The abcVe PQCIs relate.to reinspectiens which have been ccepleted and results reported te the NRC. l 1 f 3. In-Process Acti.ities. i q 1 _I Rev 2, t/10/i3 J PRCAS3-0012A-CLO7 ' d -2. 1 b
s l APPE; DIX B Page 3 of 10 E-3.1 - Electrical System Turnover Activities E-1.60 - In Process Inspection of Electric Item Insta11atien R-1.60 - Receiving Area and Sterage Facilities Inspection V-1.60 - Area Inspection Of In Process Activities Fer Welding Q-listed and ASME III Itens 5-1.00 - Storage Area / Facilities Surveillance P-1.60 - In Process Inspection of Fabrication / Installation Kework of Piping The above PQCIs relate to in-precess activities where affected verk veuld now be conpleted and any reinspection vould be of cenpleted verk covered by other PQCis, e.g., PQCIs E-6.0, W-1.00 and PW-1.00. In the cases cf R-1.60 and S-1.00, these are an inspection or surveillance of general facilities maintenance which can be repeated, bu: not en a basis which veuld have any meaning relative to cenditions existing when the in-spections were made. In shcrt, a single inspection can -2::est to ec=- ditions existing today without relation to past ccnditiens. 4. Surveillance of Subcontracter Activities. f { SC-1.05 - Material Tes:ing Services ~ 1 SC-1.11 - Concrete and Uni: Masenry Surface Subcentract Surve111cnce SC-1.16 - Field Erected 5:orage Tanks Subcentracter Surveillance i .. 1 Rev'2. 6/10/83 - j PK04E3-C013A-QLC7 4-M , ~ A
s APPINDIX E Page 4 of 10 i SC-8.00 - Subcontractor Surveillance of Installation cf Soil and Crack Honitoring Devices SI-1.00 - Measuring and Testing Iquipnent Laboratory Surveillance 4 Inspection SM-1.03 - EVAC Subcontract Surveillance SM-1.04 - Tield Irec:ed Co:penent Cooling Wa:er Tank Subcontractor 1 Sur'eillance i t SW-1.01 - NDI Subcentractor Surveillance i SM-1.17 - Tield Tabricated Incore Ins:alla:ica Tank Subcontracter Surveillance 1 The above PQCIs all relate to surveillance of subcontractor activities. i Where work has no: been co=placed, such. surveillance activities can be repeated when safety related work resu=es. Otherwise, they can be etalu-j ated only by a review of docu=en:atic and a single walk devr. of affected i j areas for assessnent of current inplace conditione, but no: ef pas: activities. In additien, SM-1.03 - EVAC Subcor.::ac:cr Surveillance, j relates to ac:ivities outside the scope of this quality Jerifica:1cn program. In dep:h par:icipation by CPCo continues in this verk. 't 5 5. Hvdrostatic and ?ne::stie Lenk Testine. T-1.00 - Hydrostatic and Pneutetic Leak Testing C?Co has already candue:ed cr. exter. site evalua:icn of hydres:::1: and q }
- neunatic lesi testing and co
- ective ac: lens relative te cuch evalue:ien
, f .are being ecndue:ed separately fren this reinspecti n pr: gram.
- j -
Rev 2, 6/10/83 4 'PK04*3-0013A-Qi07 .i- .m + + A-M j g q e e y-w. e
s APPENDIX 3 l Page 5 of 10 I 6. Special "One Ti:e Oniv" Testing. C-2.03 - Dravdown Recharge Test. This is a test required to have been perfor=ed once and which de=enstrated acceptable results. The re=edial soils progra: which is not within the i scope of this verification program would previde any necessary justifi-i cation for a repeat of such a test. 4 7. Previousiv Decumented Restonses to the Unc. C-6.00 - Mechanical Splicing of Reinforcing Ears i Thir PQCI relates te recessary inspe:ticas of the "Cadveld" precess et mechanically splicing reinforcing steel. The crnstructor's ; recesses were the subject of extensive investigation by the NRC in 1973 and 1974 which deter ined that corrective a:tien had been identified and 1:ple:ented including requalification of personnel, review cf verk instructiens for { Class I verk, C?Co QA review cf work precedures, and audits of Class I work. Affected cachanically spliced rebar is nev inaccessible due to cencrete placanent. CPCo everinspectica cf any centinued use cf this i process in renaining constructien vill be a centinuing prccess. i-1 1 C-7.00 - Irectien of Recctor Icildit: tiner Plate j i i t i j' r Rev 2, 6/10/53 1 PK0aS3-0013A-QLG7 .n I ~ 4
APPEGIX 3 Page 6 of 10 This PQCl relates to the preparstion and installttien of steel plates which provide the inner surface for the coctain=ent building. The liner is nov inaccessible, being backed up by reinforced concre:e en the out-side and nuclear coated on the inside. Extensive review was cade by CPCo in 1974 of the accuracy of liner plate records. Controls i=ple=ented - 4 after NRC investigation were evaluated and found satisfactory. In 1977, a defor=ation of liner plate occurred due to freezing of an e= bedded con-structien water line. This resulted in selec:ed removal and replace =en: of steel liner plates. Quality of the liner plate installa:1 ens have been verified through radiography, and ex:ensive C?Co involve:en: in the installation and repcir. The NRC has reviewed actions taken a:d closed its reports en the installation cf steel liner plates. C-1.11 - Drilling and Creuting of Rebar This PQCI prevides documen:ed instructions for the drilling and grou:ing of reinforcenant steel and in itself is a cc::ective acticn for previcusly cited deficiencies that such a procedure did no: e::is t. Its usage is documented evidence of the implacentation cf cerrective acticn. . j I C-5.10 - Shear Connector Installation This PQCI is used to assure that the proper in.sta11ation of shear connec:- c:s.has been accccplished which tie the supporting bea:s, steel and , i concre:e fleer deckin; into a ce=posite s: rue:::e. Sin:e the shear i i. 4 i j'~ PROLS3-0013A-QLO7 ] ?.ev 2. 6/10/83 N. 'k[ .p*
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~ APPINDIX B Page 7 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-irs document accomplishment of required inspections. 4 C-8.50 - Inspection of Surface Preparation Application Touch Up and i Repair cf Coating This PQCI addresses the preparation of concrete surfaces and the appli-cation of a coating to seal the surface to prevent conta=ination being absorbed into the concrete. Once the coating is applied, the surface preparation cannot be exa ined. The final coating can be examined for presence but no: for the process steps that applied the coa:ing. C-1.60 - Concre:e Drilling and Cu :ing Reinforcing 5: eel This PQCI describes the quality contrel steps necessary in drilling i j concrete to mini =1:e cutting of reinforcing steel. Corpletien of the 1 j PQCI-IR identifies whether p cper inspecticus were made and results 1 .l encountered ar.d documen:ed. Since the holes will have been drilled, and b:, items either neunted in the holes or the holes grouted, 1: is no: pessible to physically inspect the cor. crete or the reinforcement. This is par-ticularly.true where expansien anchors have been used which' car.r.ct be ncndestructively ce:.ed. I t 6 l Rev 2, 6/10/83 i PR0453-0012A-QtC7 .i ....__.,__..._-.1,. 6 y 9 gg
APPI'QIX E Page 6 of 10 8. Post Tensiening Recuirements. C-9.00 - Insta11atien-Post Tensiening Cc peten:s C-9.10 - Post Tensiening Sys::: Stressing C-9.20 - Centainment Building Tension Reinspection These PQCIs document the re-routing of tenden sheathing, tendo: ins:all-atien and tensioning. CPCo identified a pr ble: to the !!RC in 1977 ? 1 indicating the =isplacement of two tende: sheaths and the c=ission cf tve sheaths. The =isplace=ent of the :ve sheaths b:cush: abcu: appreved re-routing cf the tendens. The emitted shea:hs were replaced. The !;RC conducted a special investigation of the ec::ective ressures in May 1977 and dee=ed the: acceptable. A final 30.55(e) repe:: vas issued by C?:e in August 1977. 9. Cencrate Place:en: Activities. C-1.30 - Ce:cre:e Pla:e:ent Inspectien C-1.31 - Inspectien cf Cencrete Activities g 1 - ? The PCCIs relate te intpecticus during pla:eten: ef ee:cre:e. *.ere 3 concre:e has been placed, inspections vill be made in accordance with C-1.40 "Cencrete Pes Placement Inspection." Where cen::e:e h:s c: been placed, a preplacement inspectic vill be required befera picetran: when c::structien is resumed. .a . + . j j. Rev 2. s/;0/83 - l PT.C'.S3-001 A-QLO7 i .q -.~--------~~---~~3 - -~ -'~ ^ '~ ~; kw L- \\' 'l
i l l APPENDIy. I ? age 9 of 10 C-1.80 Insta11atien of Concrete Uni: Masonry C-1.81 Installation of Concrete Unit Masenry These PQCIs relate to the installatien of cencrete block valls nany cf which have been renoved as a result of subsequen: plant nodifica:icns. The remaining valls can be inspected for presence of the vall and visual quality but not for the process controls necessary to properly erect : hen. I r C-4.10 - Ba:ch Plant Inspectien I-This PQCI was prepared for necessary cont:cis of concrete ba:ch plan: ) j activities. The batch plant has now been removed fren :he site. Cencrete s i necessary for cenpletion of the plan: is procured f:cm an offsite suppli-er. Curren:ly ccccrete is procured only fc: the Scils p :gra and fer i ncn-Q constructien. Reinspec: ion is limited to review cf decunen:s of 1 .3-past operations. Adherer.ce to this PQCI will be enferced en p ccured concre:e for balance of plan: safety related ec.strue:icns when cen-l s::uction is resumed. 4 i
- 10. Field Fabricatien C-2.20 - Tield Fabrication cf Miscellaneous S:ecl.
This PQCI addresses fchrication cf steel which vill h:va been censened and .ll - erec:ed into 1:ers which uill be inspee:cd if ac:essib's. unda: c:he ?QCIs. .Rev 2. 6/1C/83 .?R0453-CC13A-QLO7 m t. .my.-- --y .: }. t t {
APPENDIX E page 10 cf 10
- 11. NSSS Receiving Inseection Activities, i
? l R-2.00 - Receiving Inspection for NSSS Equipcent R-2.10 - Receiving Inspection for NSSS Iquipment R-2.20 - Receiving Inspection for NSSS Equip =ent Documentatics These PQCIs address the construe:cr's receiving inspectice of cc:penen:s and materials used by the NSSS supplier c'enstructor. In general, :he ite=s vill have been installed by that cen:: actor. Any accessible a:::1-butes will have been confir:ed by activi:1es of :he MSSS construe:cr. i
- 12. Other.
C-1.70 - Installation of Pressured Cencrete Pipe This PQCI covered the installation cf the main veter line fre the ri.a: 1 te the coeling pond. This line is now sub=erged as the pend is full. i I Inspectien of internal surfaces ceuld be perfer:ed threugh use of divers. j Integrity has been de enstrated through use cf the sys:en. i) 1
- s E-4.0 - Installation of Electrical Cables t
N one hundred percer.: reinspectien of ins:alled cables has been es=ple:ed and reper:ed under a separate pregram. Decumen:ctier. has no: ye: teen .i r t "etieJed. 1 t I .-l j^ -t Kev 2. 6/10/E3 JJ ?E0153-0013A-QLO7 lc d
m 3 3 3 5 =3 34 m h si i il 4 39 0 g jM ,g 'n.a. .8 A?PD DIX C y J. $ 3 354-b Wad Page 1 of 16 STATISTICAL SA2IPLINC PLAN INDEX OF TOP:CS 1.0 Purpose 2.0 secoe 1 1 3.0 References 4.0 Defini:iens i 5.0 Plan Centent 5.1 Detailed Scope i 5.2 Description of Saepling 5.3 Sa:pling Process 5.4 Sampling Tables 5.5 Deter = ins: ion cf Lo: Si:es 5.6 Sample Selection 5.7 Substitutien 5.3 increased er Reduced Sampling 5.9 Treatment of Reinspectien Deficiencies 1 5.10 Deficiencies Tecnd During ?.einspec:1en cf Dccu=e=ta:1en i i 6.0 Decurentatien and Reser:r } 6.1 Documentation of Kesults 6.2 Documentatien of Konconformances 6.3 Reports 2 7.0 I=olerentation i i Rei. 2. 6/10/53 l ?K0
- 32-00143-QLO.7
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APPE:: DIX C Page 2 of 16 SAMPLING PLAN FOR CPCo 0:'ALITY VIPITICATIO!! PF.0CR.M: 1. Purpose To provide a statistically valid method, under the directien of Consumers Power Ceepany.' of confirming the acceptable quality status of safety related precurement and censtruction activities ce=pleted and inspected by the Engineer-Constructor Quality Control persennel prior to Dece:bar 2. 1982. 2. Scope: This plan applies to c1csed Inspection Records (IR's) related to specific Project Quality Centrol Instructions (PRCI's) where the quantity of closed IT.'s is in excess of one hundred and for which there are an other ongot g or planned pregra=s to confirs quality. 3. Refere cerr MIL-STD-10!D Change Setics 2 (Merch 1964). Sa:p11rg Procedures and Tables for Inspection by Attributes, US NRC I&E Bulletin 79-02. Reinspection of Anchor Bolts. i l MIL-F.3EK-53-1A 1 TIB 1982 - Geide for Attribute 1:t Sr.r.pling and-MIL-STD-105. t f 4 Definitienst 'l .l Population: The entire quantity of clese' ( R's) reltting to a s;ctift: PRCf. l' i
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s APPENDIX C Page 3 of 16 Ti=e Centered: The ter= used to describe the ordering of lots, and ite=s vi:hin a lot, based i upon the tice sequence in which an IR was initiated j Ec=ogeneity: Honogenei:y i= plies tha: a series of i units of product should be alike or i si=ilar in nature. Eccegeneity under this plan vill be achieved by utilizing specific project Quality Cen:rol In-struction (PQCI) categeries covering like activities and generally vi:hin a defined ti=e period. A:ceptance Nuther (AC). 4he nu=ber of ncnconfor:ances per=i::ed .i I to be found in a sa:ple of a lo: withou: rejecting the'let for a specific accept-sble quality level. Rejection Nu:bar (Re): The number of nenecnfer:ances fcund in a sa:ple of a lo: that requires rejec:i:n cf the lo: fer a specific accep:able quality level. 1 .g 1 A 1,. 'Rev. 2, 6/10/E3 PT.0483-00145-Q'.07 . ~,., e ~~w y w -n .s ~" ']
s I APPECIX C Page 4 of 16 Acceptable Quality Level (AQL): The AQL is the maxi =u: percent of nonconfor cnce.s that, fer the purpcse cf - i sa pling inspectien, can be censidered i satisfactory as a process tverage. Attribute: An attribete is a characteristic or property which is appraised in ter=s of i f whether,it does er does net comply with 4 a given recuire=ent. 1 i [ Inspection by Attributes: Inspectica for which the ites er attribute is classified si= ply as ccnfor=ing er noncenfor=ing witheu: regard fe the degree cf nenecafernan:e. Li=1 ting Quality (LQ): ' The ter: applies to sampling plans ths: f } provide to: less than a specified i i percentage of quclity p:::ee:icn. I i 4 Consurers P:ver Cc:pany hcs selec:ed an 4 LQ of five percent which p:c 21 des 95!. confidence tha: at leas: 95% of inspe:- ti;n elements cf the lo:/pepulatien t.ill be accep:able. . 1 . ) ? - t Rev. 2, 6/10/!3 PT.0463-00143-QLO7 s e N w W we
APPCDIX C Page 5 of 16 t Lot: A quantity of items, such as ccepleted inspection reccrds covering the same activity, equal to or less than the total population and representing a subdivision of that population. t Konconfor=ance: A deficiency in characteristic, docu=en-tation or precedure which renders the quality of an ite= unacceptable or indeterminate. Pa - Probability of Acceptance: The p;cbability of accepting a lot with s predeter=i,ned percent defective, when a given sa:ple plan is used. t Rando: Sample: ~ A sacple taken frc= a pcpulatien er let i t 4 in ukich each of the items has an equal chance of being selected, regardless cf f ~j its quality. If the units in a lot have been arranged withcut bias at te their 1 quality a sa:ple drawn anywhere in the let will =eet the requirer.ents fer i randocness *. PQCI's are legged in j accc; dante with the date they vara j i cpened, tttally independent ef the ') (1
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APPC:LIX C Page 6 of 16 resulting quality, thus sa:pling by logged date or other steans meets this requirement. f i Sampling Plan: A sampling plan indicates for a given lot size the nu:-ber of ite:s or ec=po-nents fres each lot (sample size er a i series of sa=ple sizes) which are to be inspected from the let and the criteria for deter:ining the ac:eptability of the lot. i -l i {- . t -' l j i I >I Fev. 2. 6/10/63 PR0183-00143-Q1,07 %i, y y y w t=> WWb-k# C ' * ^' e 4
s AFPINDIX C Page 7 of 16 5.0 Plan Content 5.1 Detailed Scese: This sampling plan applies to closed Engineer-Constructor IR's related to specific Project Quality Control Instruction (PQC1's) for Balance cf Plant saf ety related materials, components, sys:ers and strue:ures, which are not covered by other ongeing progra=s to confirm quality. It is applicable to closed IR's where the quanti:y of clcsed irs fc a given PQCI is in excess of 100 and where it has been de=enstrated by one hundred percent inspecticn of a significan: per:icn cf each population that the ac:ep:ed quality level of that pcpulatica has been established. The specific FQCIs and quantities of closed irs that make up this total pcpula:icn are identified in Appendix A. That appendix also indicates whe:hcr beth hardware and document-ation are planned to be verified or whe:her docu en:a:ien alene'is planned to be tr.ieved because of inac:essibility ef hardware features. E i 5.2 Descristien ef Sampling: Sampling inspec:ics is that type of i activity in which units of product are selected a: randc= and f examined for one or =cre quality at:ributes. Sar;1ing inspe::icn is an acceptable way cf determining the conformance er ncncon-forsance of ite=s to specified quality.requirc en:s. he amoun: ef ' l inspection can be increcsed where the ;r: duct cuality is de:erier-i ating c: redu:ed where :he 1e.el of quali:y is high'. ( !!il-Edbk 1A) 1 i Rev. 2, 6/10/83 l ?R0123-00:13-Qt07 9w .e assus - "*4 /
o APPINDIX C Page 8 of 16 Statistical sampling =ethods force cne hundred percent verification l of quality whenever the required quality level has not been at-tained. The statistical =ethods proposed herein are designed to provide 95 percent confidence that the inspectable ele =ents of the entire population are acceptable based upon the accep: ability of items or attributes previously 100 percent i=spected to provide a f satisfactory quality baseline. This is censistent with past NRC reco==endations related to reinspections cf safety related 1:e:s3 and vill produce results at least ecuivalen: to these enpected fr:: l 100% inspection. El l The statistical quality control matheds p cposed are in accerdance t j t. vi:h MIL-STD-10$D Tables I, IIA and VI A. MIL-STO-10$D is pro'cably the = cst videly used sa ;1ing standard in the L'nited 5:a:es. This Progra: is a rigorous applicatien of s:stis:ical quali:: cer.::cl me: hods to assess the quality of nuclear power plant censtructien. i l (3 NCR I I Eulletin 79-02, Appendi>: A) - t I i-- a 1 1 t 0-i 1 s Iev. 2, 6/10/63 1RC113-00113-Q107 + s-hp T +, -, - y 3 , + -
APPE% IX C Page 9 of 16 5.3 Emeplinz Precess: The application of statistically valid sampling plans requires lot sizes to be large enough to per=it taking cf a sample quantity sufficient to li=it the risk ef accepting nen:en-forming ite=s. When quantities are not large enough, one hundred peretn: reinspection will be performed. Because of the Limiting Quality planned to be used, populations cf PQCI ice:s are recuired to be greater than 50 to be eligible for sa:pling further; however, CP Co has committed to perfor=ing 100 percen: inspec:ien of PQCIs F 1 having 100 or less Ils. In addition, ;cpulations :o be sampled must be first qualified by having demens::ated accep:ahle quali:y levels through one hundred percent inspection of a quan:i:y cf items sufficient to p;cvide adequate confidence the existing quality level is acceptable. When 10C: inspections have estab-11shed this confidence CPCo will consider that the ene hundred percent inspection of a significant portien of each ?QC: has established a valid basis 'for statistical sampling of an:' re: sin-t I ing quantities. i The statistical sa:pling plan vill be co: ducted as fellows: Two lots for each ?QCI will be sampled a: nor:al sampling levels in l accordance with MIL-STD-105D, Tables I, l'A and VI:A :e a lititing quality of 5 percent at a 95 percent cenfidence level. If these two successive lots validate that the required level cf quality has i been maintained, rear.ining lets will be sa: pled to the same crit-eric, bu: at reduced sa:pling levels per MIL-S!2-1030, Table I!A. i t ] Rev. 2, 6/10/63 PRCit3-C0143-Qt07
APPENDIX C Page 10 of 16 The Executive Manager cay recc==end to the NP.C discontinuance of further sampling where quality levels have demanstrated that pas: Engineer-Constructor inspections have previded ac:eptable centrol i of quality.
5.3.1 Switching
The sampling plan vill include switching pro-cedures to provide Consumers Pever Co=pany the protection provided by the tightened plan, when evidence that y the i i desired quality level is belev prescribed levels and the advantage of the reduced plan, when evidence that the desired quality level has been achieved. Due to the kncwn quantities of specific PQCI's available for sa=pling (non-continuous production run) the folleving switching rules will be imple=ented: Establish acceptable bas'e quality level through 100C o reinspection. 1 Single ner=al plan for two lots. o ~ o Trom sir.gle normal, switch to single reduced, af ter accept'ance i cf two conse:utive lots. Switch back to single n:real after the first rejected lot. Tros single ner=al, switch to singin tightened, after the first o rejected let for two consecutiva Iota, then svi:ch back to i single ner=al if both lots are acceptable. If either er both of the single tightened lots are redected svitch te 100* I inspe: tion f Icts, until two cense:utive Icts c e ac:eptsd. i s Rev. 2. 6/10/S3 i PRC483-00I43-CLC7 i ~~ ~ E # 2 ,d
APPENDIX C Page 11 of 16 5.4 Sacclina Tables: The follcuing tables indicate sa=pling infore.- i. ation for Single Nor:al, Single Reduced and Single Tightened sampling plans: SINGLE NOR:!Al Pepulation Sample Accept Reject Lot Size Size Nu=ber Nu=ber 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 i SINGLE REDUCID 2-50 ALL.:o 20 0 1 51-500 20 C 1 501-1200 32 0 1 1201-3200 50 1 2 3201-10,000 80 1 2 l 10,001-00 125 3 4 l r SINCI.E T!CETE::q 0-80 All 0 1 80-500. 80 0 1 500-1200 125 0 1 1201-3200 200 3 3201-10,000 315 5 6 10,001-00 500 10 11 [ r 1 1 1 Re*. 2, 6/30/83 j PR0483-001LE-QLO" E m
O APPCGIX C Page 12 of 16 The specific PQCIs and total quantities of closed Inspecticn Records to which these lot and sanple sizes apply are included in Appendix A to the Quality Verificatien Progra=. 5.5 Deternination of Lot sizes: A reinspection lot is a ecliectic: ef units of product (closed inspectica records of like activities) -[ free which a sanple is drawn and inspected to deter =ine confer =ance s* vith the acceptance criteria and may differ frc= a collecticn of ~ units designated as a lot for other purposes t.uch as production.or 4 procuranent. 'The size cf the lot is cas of the' factors that deter =ines the sa:ple si:e to be used in sa=plir.; insper.tien. For this progra the for:stien of each lot is plar.nad to be at least equal to the nornal sanple site _fer the entire pcpulatien;, thus for ~ a populatien of 1000, tha =ini=u:. lot si:a vould be 10; the ep? ti=al lot size vould be 281 er greater. 1 i Norna11y the to:a1 quar.tity ef the ;cpulatien vill not he a direct s =ultiple. 'c! the lot si:e. After dividing the pcpulatien quantity 4 4 1 - I q (4 Mil-Edbk - 53 Para 6.4.1) l ~ s l } r. ~. / N i .1 W -} .Rev. 2, 6/10/E2. 1 PR04E3-00143-QLO7c \\' .n, ~ -., ,e' ...~,,,y ~~~-%ss~r-,&~- m. ed..~.---~-. ,~ ~.~' r
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I APPENDIX C Page 13 of 16 by the lot quantity, any re,sidual quantity =ay be cochined with the last lot, or be treated separately for saepling cons..ience so long j as the sample, size is in accordance with MIL-STD-105D. Lots vill ) be time centered,. The purpose cf this is to further enhance he:cge-neity for each lot and to identify and isolate conditions which =ay have etcurred in specific time periods.during constructica cf the Midland Plant. This method of stratifying sa=ples and lots, yields i more information,for corrective actien than sampling the entire population. Quantities used fer deter ining lot sizes will e::clude inspection records where reinspections have occurred, since this vill preclude ccunting the sa:e ite twice. .A limited nu=ber of PQCI's cover like activities. These vill be grouped, where appro-l priate, to provide a single populatien. An exa:71e of such group-ing would be PQCI's E-6.1 and Ri'-1.00, "Modificatien of Electrical Equipment." { 5.6 Sa ele Selection: Samples vill be selected by dividing the let size by the sample si:e indicated by MIL-STD-105D Tables I and IIA for ner=al sampling. For example, for a lot of 500, the sa:ple size is 50. In this case any cf the first 10 irs and every tenth 1 Il IR for a specific PQCI would be selected for reverificati:n. This assures randemness, since the manner of filing is totally indepen-4 dent of the quality of the ites and of.the persen select.ng the n "Ij sample, and all irs have an equal chance of selection. It aise ~ j provides a cross sectica as related to time, since the IT.s are J '.s l Rev.f2, 6/10/83-l j - PRCit3-00113-QLO7 k{ A J- ? y ) 9 f ?, n 5 \\ m
l l APPENDIX C [ Page 14 of 16 logged by the dates 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 itec t sampled is t'ine s'equenced within the lot.
5.7 Substitutten
Where accessibility is found to inhibit inspectice i of attributes of a specific ites intended for sa:ple reinspection, f the Executive Manager-MPQAD has sole authority to direct the selection of a substitute rando: ite: for reinspection free the same lot, or in the event that no item (s) is accessible for rein-spection, a documentation review of the inaccessible ite:(s). Justificarica for this substitution vill be documented. i I 5.8 ,;eressed er Reduced Sateling: The Executive Manager-MPCAD has ~ authority to direct ICO: reinspection at any point where the f ability to conduct a valid sample reinspectien is deter ined to be impracticsl. Switching to reduced er tightened sampling vill i require prior approval by the Executive Manager-MPQAD in accordance with criteria described in this-plan. 5.9 Treatment of Reinssectien Deficiencies in Verifiestien Satelint Progra=: Deficiencies identified by reinspections will be recorded on a nonconfor=ance report and preeptly reported to XiQA3-QA and others fcr processing per procedure. The pcrty responsible for recc=nending the initial disposition cf the nonctnferrante will l i i Ik 3 Rev. 2, 6/10/53 7104S3-00143-QLO7 4 g, p+*O +M-4*"*8 -P***"
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\\ T l I i APPENDIX C Page 15 of 16 review the intended disposition with MPQAD QA processing of the nonconfor=ance. prior to further The purpose of this XPQAD-QA review is to insure proper treat:ent of the r sampling analysis. enconforma~nce in the Deficiencies deter =ined to be acceptable t "use as is" will be evaluated by Project I o ngineering to determine whether the design criteria requirenant whi h the attribute failed c te meet will be modified to clarify the inspection require =ent. Project Engineering rodifies the requiren If the deficiency will be censidered " ent on a generic basis, sa=ple analysis. ateeptable" for purpcses of The final decision as to whether the defi i constitutes a sample defect will be made by the E c ency xecutive Man-ager-HPQAD. This decision and its justification will b e docu-mented. 5.10 Deficiencies Found During Reinsenetien Inaccessible Attributes: of Docunentation fer c The verification process fer inaccessibic attributes is discussed in Section 6.5 of th e Quality Verificatien Plan. As noted in that sectien, any decumentati I on deficiencies will be noted on the verification IR i entered en a nencenfor=ance report and cross referenced to the originci IR i The treatnent of ( sampled lots containing nencenfor ances vill be d etermined en s case by case basis and fur.her verificatien req i t 1 u rements vill be deternined taking into accour.t the dispositi ing ccedition. cs of the nonconfor=- t - t i e l i 'Rev. 2, 6/10/83 ~! -P10433-00148-QLO7 I. m. e we g s. w
APPENDIX C Page 16 of 16 6.0 Documentation and Reports 6.1 Documentation of Results: documented on IR's and statused to sResults of sa=p c the lot number, the quantity in th pecifically identify the PQCI, e lot, the quantity found acceptable the quantity inspected, cies and the results of the nonconformance di, the ability of the lot. sposition, and accept-6.2 Documentation of Nonconfernances: reported and dispositioned in accordance wi hNoncon Disposition of the nonconfor:ances will approved procedures. t to be taken on the balance of thinclude necessary actions e lot; lot for the rejected attributes e.g., screen balance of the 3 , or 10C% inspect the balance ef the lot. I
6.3 Reedres
The results of the sampling plan for { each PQC1 will be included in reports c d each lot related to Control Superintendent and the Qualit a e by the CPCo 50P Quality
- ntendent QA as described in section 7 3y Assurance General S i
\\ cation Program. of the Quality Verifi-
7.0 Inolenentation
I This plan vill be implenented as dir i Executite Manager MPQAD. ected by the~ as sheen in-section S of the Quality VerifiThe organiza re the sane cation ?regra=. MPQAD 3CP Quality Centrol shall have th In additien, IR's to be sanpled from lot aires pred e respensibility ef selectin; the t* R5v. 2, 6/10/83 eterninad by MPQAD-QA. PR0183-00145-QLO7
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f I '[ 'g UNITED STATES NUCLEAR REGULATORY COMMISSION o I REGION lli o 790 ROOSEVELT ROAD GLEN ELtVN, ILLINOIS 00137 Sete* AU6 1 9 1983 Docket No. 50-329 Docket No. 50-330 Consumers Power Company ATTN: Mr. James W. Cook Vice President Midland Project 1945 West Parnall Road Jackson, MI 49201 Gentlemen: By letter dated June 10, 1983, Consumers Power Company (CPCo) submitted its proposed Construction Completion Program (CCP) for the Midland Nuclear facility. The program as submitted was a compilation of all prior CPCo submittals with revisions incorporated. The NRC has completed a review of the June 10, 1983, CCP submittal. As a result of this review, the following comments were developed. Prior to final approval of the CCP, the responses to these comments must be incorporated into the CCP. A. Comments on Construction Completion Proaras 1. Executive Summary The scope of the CCP is not clear. The statement in the first paragraph of the Executive Summary appears to be in conflict with the penultimate paragraph on page 4 and the Description Section (9.3) on page 34. In addition, the relationship of the Quality Verification Program to the CCP is not clear. Clarify the scope of the CCP and define the relationship of the Quality Verification i Program to the CCP. 2. Pase 2 i Page 2 of the CCP states that, " safety-related systems and a. l areas of the plant will be systematically reviewed." Define i or identify what is meant by the term " safety-related ~! systems and areas." i b. As stated in the CCP, phase 1 implementation will be on an area-by-area basis, but will be accomplished mainly by teams 3 organized with systems responsibility. Our concern deals with the interface between the area-by-area basis and the systems basis. Provide assurance that all safety related systems and components of the plant are covered during phase 1. .1 b. y + .9...e
^ Consumers Power Company AUG 1 9 E63 i 3. Pane 3 The description of the major components of the CCP does not include NRC Hold Points. Describe the NRC Hold Points to be covered prior to initiating phase 1 and phase 2 actidities. 4. Pane 4 a. As stated in the CCP, the major areas of continuing safety-related work outside the CCP includes post-turnover punch list work. Provide assurance that these post-turnover list activities are minor and not major, b. This section states that CPCo intends to schedule periodic reviews of Program status and progress with the NRC. Provide assurance that such meetings will be noticed such that members of the public and interested parties will be provided the 4 opportunity to attend as observers. 5. Pane 7 As stated in the CCP, during phase 2 implementation the assigned team will plan and carry out the remaining work needed for comple-tion including QC inspections. Since we understand that QC inspections will not be performed by the CCP teams, clarify the teams involvement in QC inspection activities during phase 2. 6. Pane 8 In describing the limitation to work on Q-Systems, the CCP states that this limitation permits important work to proceed outeide the CCP. Describe the measures to be taken to prevent nonconforming items, in areas covered by the CCP, from becoming inaccessible due j to ongoing work. i 7. Finure 1-1 l The CCP schematic does not identify the NRC Hold Points. Revise j this schematic to include the phase 1 and phase 2 Hold Points. 8. Pane 11 - Section 3.1 ) As stated in the CCP, MPQAD was expanded to assume direct control of QC except ASME. Clarify the boundaries of MPQAD and CCP controls ~ over "N" stamp activiti.ts and non "N" stany activities. i l o g 9 1 1 9*
l i l Consumers Power Company -3 AUG 1 9 EST 9. Pane 12 - Section 3.3.5 As stated in the CCP, MPQAD will continue to use Bechtel's Quality Control Notices Manual (QCNN) and Quility Assurance Manual (BQAM). Provide clarification as to the decision not to use the Consumers QA manual. In addition, describe the measures taken to provide assurance that the Bechtel and Consumers manuals are in agreement. 10. Pane 13 - Paranraph 2 and Paraaraph 3.B, Regarding the revision to PQCI's, identify in the CCP: That the documentated basis for the determination of the need' a. (or lack thereof) for pilot runs will be available for review by the NRC. b. That the documented basis for the determination of the need (or lack thereof) for retraining or recertification of affected QC inspectors will be available for review by the NRC. 11. Pane 17 Describe the criteria to be used in determining the need and extent for reinspection of the past work of an inspector failing any part of the recertification process. Also identify who will make the o determination and the manner in which the determination will be documented. 12. Pane 19 As stated in the CCP, the scope of team work activities a. includes the requirements to ensure early identification and resolution of problem areas. In view of the fact that phase 1 i allows only the identification (and not the resolution) of problems, clarify this statement. t b. In the discussion of the team MPQAD representative, it is stated, "He assures validation of NCR's." Explain what this statement means. i 13. Pane 20 As stated in the CCP, tool box training sessions will be a. conducted at least monthly. Address the adequacy of the tool box training sessions and the manner in which the sessions will be documented. 4, 4 i k 0 m'*
=- Consumers Power Company *g } g b. As stated in the CCP, nonconformances are documented in nonconformance reports. Identify how incomplete items (system status) will be documented. 14. Pane 21 - Section 4.3.2.b Although not quantified, it would appear that a significant portion of the CCP will be involved with verification of acceptability of inaccessible attributes. This'is predominantly a paperwork review, but "if required" will be supplemented by NDE techniques and destructive examination. In view of past documentation problems and the extent of inaccessible items, explain why the CCP should not include some NDE of inaccescible itema on a sampling basis. Also define "if required." 15. Pene 24 - Section 4.5.4 Identify the critical systems referred to in this section. 16. Pane 28 Identify the composition of project management, site management and management teams. Also clarify the scope of the phase 2 management reviews. i 17. Pane 32 Identify whether the CIO review of site construction activities will include systems excluded from the CCP. 18. Pane 33 Clarify the extent of measures taken to mainta' in and protect equipment in system layup. f t } 19. Pane 34 - Section 9.2 li Clarify the second sentence. 20. Pane 35 t Clarify the extent to which the _ third party CCP overview will n. address the three systems in the TERA scope and revise, if necessary, the statement on page 32 of the CCP which states that the CIO will not include an overview of the other third party evaluations being conducted. t I ( i = t + w .---y.. -ev---, .m-p
Consumers Power Company.AUS 1 9 G83. b. Provide your rationale for not including in the CCP systems and equipment that are important to safety but that are not i safety-related. 1 Provide a definition of your understanding of the term c. 2 " systems Luportant to safety." 21. Pane 36 - Section 10.3 i Clarify this section to provide assurance that changes to the CCP will not be implemented without prior NRC review and approval. B. Comments on Quality Verification Pronram (QVP) 1. Pane 1 - Section 2 Clarify the scope of the QVP in regards to the implementation a. of IPIN's in Soils, HVAC, and B&W work activities. i b. Clarify the reinspection requirements for partially completed IR's. l i 2. Pase 9 i Cisrify the statement " System / area reinspection will be s. supplemented by random plant-wide inspections as appropriate to establish a valid quality baseline on an expeditious basis." b. As stated in the CCP, any nonconforming condition observed during the implementation of this program other than those previously identified on nonconformance reports will be identified by a nonconformance report. Clarify this statement to provide assurance that the nonconforming condition need not be documented only if there is an open NCR on the same item. f, 3. Pane 10'- Section 5.3.1 f As stated in the CCP, any deficiencies, other than those previously i identified on nonconformance reports as a result of prior inspec-tions, will be identified on a nonconformance report. Clarify this statement to provide assurance that the deficiency need not be documented only if there is an open NCR on the same item. j 4. Pane 13 - Section 6.4 i Identify whether material traceability aspects are to be covered by this program. t-i i 4 F l
EE3' Consumers Power Company C. Comments on Appendix B 3 2. Pane 2 l 1 Provide clarification as to the reason why PQCI's associatad with the remedial soils program are listed since the CCP ext +,cs that f activity. Should you have any questions regarding this letter please contact Mr. R. F. Warnick of my staff. t Sincerely, ^^ ^s JamesG.Keppid)) Regional Administrator DMB/ Document Control Desk (RIDS) ec: Resident Inspector, RIII The Honorable Charles Rechhoefer, ASLB The Honorable Jerry Harbour, ASLB The Honorable Frederick P. Cowan, ASLB The Honorable Ralph S. Decker, ASLB William Paton, BLD Michael Miller Ronald callen, Michigan Public Service Commission Myron M. Cherry Barbara Stamiris Mary Sinclair Wendell Marshall Colonel Steve J. Gadler (P.E.) Howard Levin (TERA) l Billie P. Garde, Government Accountability Project l Lynne Bernahei, Government r Accountability Project I i t 4 i i i, s I i ,}}