ML20128A177
| ML20128A177 | |
| Person / Time | |
|---|---|
| Site: | 05000051, 07100099 |
| Issue date: | 05/06/1992 |
| From: | FOSTER WHEELER ENERGY CORP. |
| To: | |
| Shared Package | |
| ML20128A171 | List: |
| References | |
| NUDOCS 9212030228 | |
| Download: ML20128A177 (169) | |
Text
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Date: Sib 8L O
FOSTER WilEELER ENERGY CORPORATION ENERGY APPLICATIONS, DIV.
QUALITY ASSURANCE MANUAL ASME SECTION III, DIVISION I; 10CFR 50 APPENDLX D; ANSI A45.2; ANSI /ASME NQA-1; ASME SECTION XI;10CFR72 SUDPART G AND 10CFR71 SUUPART II
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ASSIGNED TO O CONTROLLED 1
COPY NUMBER 3 UNCONTROLLED FOSTER WHEELER ENERGY CORPORATION ENERGY APPLICATIONS,DIV.
LOCATION:
78 CORPORATE PARK 200 CORPORATE DRIVE, LED ANON, NJ 08833 MAILING ADDRESS: PEIU1YVILLE CORPORATE PARK CLINTON, NJ 08809-4000 0
9212C30228 921123 PDR rilSC ew.c PDR 9212030225
N FOSTER WHEELER ENERGY CORPORATION n
Energy Applications Division i
Perryville Corporate Park, Clinton, NJ 08809-4000. Phone 908 2361401 August 7, 1992 TO:
MR. NICK F. MARQUEZ (AUTHORIZED INSPECTION AGENCY REPRESENTATIVE)
HARTFORD STEAM BOILER INSPECTION & INSURANCE COhiPANY Attached please find revised sections of the Foster Wheeler Energy Corporation's Qaality Assurance Manual. The sections that have been revised are indicated on the Master Index and the Section Index. Changes ha ve been highligh ted by Rx in the margin. Ifyou concur that these changes are acceptable with the Code, note your acceptance by signing the attached extra copy of this letter in the space provided.
Reference MasterIndex Rev #
7 The above sections have been reviewed and (accepted as noted), (not accepted) per ASME Code,Section III.
Signed:
Hartford $icam Miler Inspection & Insurance Company A copy of this letter signed and noted by you will be given to the " Authorized Inspecton.
Very truly yours, ENdRGY APPLICATIONS DIVISION FOSTER WHEELER ENERGY CORPORATION f.f%KWLN D. J. Lamvermeyet Manager, Quality Assurance l
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- Easter Wheeler Enerry corn.
Sectioru MasterIndex Energy Applications 7Div.I Pagt
_.A_. Rev.-
7 Ouality Assurance Manual Date:
5/6/92:
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MASTERINDEX S.cetion Index ReyislDa Section Ilile
_ Revialon_.
Date Title Page 7
5/6/92 Masterindex
-7 5/6/92-Policy & AuthorityStatement 6
5/6/92 Introduction 4-
-5/6/92 Definitio*.s 4
5/6/92 1
Organization 4
5/6/92 2
Quality AssuranceProgram 4
5/6/92 3
DesignControl 4
5/6/92 4
Procurement Document Control 4
5/6/92 5
Instruction Procedures and Drawings 3
-5/6/92 6
Tbcument Control 3
5/6/92-7 Control of Purchased Items 3
5/6/92 and Services 8
Identification and Control ofItems 2
.12/14/90 9
Controlof SpecialProcesses 2
12/14/90
'0 10-Inspection 2
12/14/90 11 Test Control 2
12/14/90 12 Control of Measuring & Test Equipment 2-12/14/90
-13 Handling, Storage & Shipping 2
12/14/90 14 Inspection, and Test Status
-2 12/14/90 15 Controlof_NonconformingItems 4
5/6/92 16 Corrective Action 4
5/6/92 17 Quality AssuranceRecords 6
5/6/92.
18 Audits 4
.5/6/92 19 Authorized NuclearInspection 2
12/14/90 APPROVED (IMUDriv9Ml v i.
Ip/J.Lamvermey Mgr. Quality Ass ance e
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FOSTER WHEELER ENERGY CORPORATION Energy Applications Division Perryville Corporate Park, Clinton, NJ 08809-4000 May 6,1992 POLICY AND AUTHORITY STATEhfENI EEV. 6 This Mar'ual covers the Quality Assurance Program of Energy Applications, Div. of Foster Wheeler Energy Corporation, governing the Design, Manufacture and Construction of '
Nuclear Components, parts appurtenances meeting ASME Code,Section III Division I for Classes 1,2,3, MC & CSitems and as a Material Supplier;10 CFR50 Appendix B; ANSIN45.2; ANSI /ASME NQA-1; 10 CFR71, Subpart H and 10 CFR72, Subpart G. In addition, for Maintenance tasks,it meets the Repair and Replacement requirements of ASME Code,Section XI.
Le Quality Assurance Manager is responsible for the implementation of this program and is therefore, responsible for all planned and systematic actions ne.essary to assure tasks are q
carried out in accordance with the Code and contract requirements at the Home Office, Subcontractors and Work locations. He has authority to (1) identify quality problems (2)
O initiate action which results in solutions and verifies implementation and (3) controls non-conforming items, deficiencies or unsatisfactory conditions until corrected, Le Quality Assurance Manager reports to the FWEC Director QA/QC and thereby has direct access to responsible management and is independent from the direct pressures of..
production. He reports regularly on the effectiveness of the QA Program and consults with -
management on matters of policy which are quality related.
Company management and personnel will support the program by carrying out requirements contained herein. Revisions to this Manual will be distributed by Quality -
Assurance to the holders of controlled copies. Each holder of this manual shallbe responsible for the proper maintenance of its contents.
l All personnel assigned to nuclear plant projects are required to become familiar with the.
i policy and procedure,in this manual. *Ihe provisions in this manual take precedence over,
any other procedu al documents. Any conflicts relative to this program that cannot be resolved by the Quality Assurance Manager, shall be brought to my attention for resolution with Code and Regulatory requirements and this manual's requirements.
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Sectioru hitroduction Energy Applications, Div.
Page 1 of1 Rev. _1_.
QualliyAlintance Manual Date:
5/6 92 O
INTROD_UCIlON This Manual describes the Energy Applications Div. of FWEC Quality Assurance Program for the Construction and Maintenance of systems, components and parts, and Maintenance Tasks include Modification, Alteration, Repair, and Replacement. This is a controlled document which meets the requirements of ASME Section III, Div.1;10CFR50, Appendix B; R4 ANSI N452; ANSI /ASME NQA-1;10CFR71 Subpart H; 10CFR72 Subpart G and applicable NRC Regulations and Regulatory Guides. For Maintenance Tasks it also meets the Repair, Replacement and modification requirements of ASME B&PV Code,Section XI.
Revision to this manual may be made from time to time in order to:
Conform to changes in the Code, Standards, and Regulatory requirements.
To clarify or correct items.
To improve the effectiveness of the QA System.
Revisions must be reviewed and approved by the Manager of Quality Assurance.
When Quality Assurance, Engineering, Project Management or Purchasing activities are specified in this Manual, the respective responsibilities, aetivities and requirements can c:ther be accomplished at the "Home Office" or " Work Location" dependent upon the needs of the specific Project / Task. Requirements specifically limited to a facility organizadon are preceded by either "Home Office" or " Work Location", e.g., " Work Location Quality Assurance", "Home Office Engineering", etc.
Due to the recent name change from "FW Energy Applications,Inc." to " Energy Applications Div. of Foster Wheeler Energy Corp.", some printed documents may still use pre-printed forms with the previous name. Examples would be purchase orders, Nuclear Quality Assurance Directives, etc. These forms may be utilized until the system has been completely purged of the outdated forms. However, care must be taken to use the current printed form.c with the correct organization name whenever possible.
This manual describes the Quality Assurance Program policy and is supplemented by a Manual of procedures which implements the Quality Assurance Program. The Procedures Manual shall not conflict with this Manual.
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Easter. Wheeler Energy _Com Section: Definitions Energy Applications, Div.
Page 1 of 5 Rev. L.
Quality _Assurancthianual Date:
5/6/92_
D.EEINITIONS The following definitions are provided to assure a uniform understanding of selected terms as they are used in this Manual:
AcceploLUsc-atis: A disposition permitted for a nonconforming item when it can be established the discrepancy will not effect the form, fit, and function ofit's intended use and the Code requirements are satisfied. This disposition requires a documented technical justification.
R4 ANSI / ash 1ENQA-1: For Section III work, the 1989 edition and la-1989 addenda applies as R4 modified and supplemented by NCA 4134. For Section XI work, the 1989 edition applies if specified by the owner.
App _utienance: An item intended to be attached to a completea and stamped component which has work performed on it requiring verification by an Inspector.
As-Ruilt Drawings: Drawings depicting the final as-built configuration of item including accepted non-conformances that occur during manufacture or installation. Any difference in the as-built drawings from the corresponding drawings used for design analysis, shall be reconciled with the Design Report by the person or organization responsible for the design.
Authorizedlnspector: Each entry in the Manual shall mean "Autimrized Nuclear Inspector" as required by the Code.
Audit: A documented evaluation performed to verify by examination of objective evidence, that those selected elements of a previously approved quality program have been developed, documented, and implemented in accordance with specified requirements. An audit does not includ e surveillance or inspection for the purpose of process control, or acceptance of ma terial items.
Certificate.sLCompliance (COCh A written statement attesting that the materials are in accordance with specified requirements.
CertificaterLConformance: A document signed by an authorized individual certifying the degree to which items or services meet specified requirements.
Certified MateriaLIest_ Report (CMTRh A document attesting that the material is in accordance with specified requirements, including the actual results of all required chemical analyses, tests and examinations.
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EostedYhecler Energy _Co:p.
Sect;on: Dcfluitions Energy Applicatiora, Div.
Page 2 of 5 Rev. L Qualliy_Asantance Manual Date:
51652.
V Code:ASME Section III, Div.1; For maintenance Tasks, the " Code" encompasses the Repair and Replacement requirements of ASME BP&V Section XI.
Companent: A vessel, piping system, pump, valve storage tank, or core support structure each of which requires a Data Report and Stamping.
R4 Computer Program. Sequence of instructions suitable for processing by a computer.
R4 Processing may include the use of an assembler, a compiler, an interpreter, or a translator to R4 prepare the program for execution as well as to execute it.
DAiR: Discrepant Material Report prepared by Field QC Pngineer, inspector, NDE Technician or Purchasing (as instructed by Field QC Engineer) to report a nonconforming condition or characteristic.
Design Input Dr>cuments: Documents which include those criteria, parameters, bases, or other design requirements upon which detailed final design is based. For this section, these include the Design Specifications and any other documenh referenced by it.
D_esigrLQutRut Documents: Documents such as drawings, specifications and other documents defining technical requirements of structures, systems, and components.For this section, these include documents such as Design Reports, Drawings, Calculations, Load (V3 Capacity Sheets, Design Report Summaries and Construction Specifications.
DianingEcriew and Approval Chart:The Project drawings are reviewed and approved in accordance with the Drawing Review and Approval Chart. This Form is subject to revision per Code and contract requirements. (Exhibit 35)
Desien Renort: The design document which shows that the allowable limits stated in the Code stress analysis or calculations are not exceeded for the loadings spe fied in the Design Specification. Design Report shall identify and describe the drawings used in design and construction. Design Reports for Class 1 components and supports;Oass CS structures; Class MC vessels and component supports; Class 2 vessels designed to NC 3200 or Gass 2 or 3 components designed to service loadings beyond Design Loadings are certified by a Registered Professional Engineer qualified by ANSI /ASME N626.31988. A Qass 2 Design Report shall be prepared for Cass i pipingl in. nominal pipe size or smaller which is designed in accordance with the rules of Subsection NC. (Ref. NCA 3551.1)
Design Specification: A document prepared by the Owner or Owner's designee which provides a complete basis for design in accordance with ASME Section III and is certified by a Registered Professional Engineer qualified by ANS1/ ASME N62631988.
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Eoiter Wheeler Encrev Corp, Section:- Definitions Energy Applications, Div.
Page S of 5 Rev._L.
Quality Assurance Manual Date: _5/M1 O
Engineering Tasks: Design and Engineering analysts work performed on Code and Safety Related Items.
BEA: Energy Applications Div. of Foster Wheeler Energy Corp. (FWEC).
nVEC: Foster Wheeler Energy Corporation liold_ Point: A designated stopping place during or following a specific activity at which inspection or examination is required before further work can be performed.
IlomeDIfice:
R4 Mailing Address location Foster Wheeler Energy Corp.
Foster Wheeler Energy Corp.
Energy Applications, Div.
Energy Applications Div.
R4 Perryville Corporate Park 78 Corproate Park R4 Clinton, NJ 08809-4000 200 Corporate Drive R4 Lebanon,NJ 08833 Identification and Verification PIogram: A system for positive identification of material during storage and handling and verification of identity of material on the accompanying f
Certified Material Test Report or Certificate of Compliance at the time of shipment both into and out of the Material Supplier's facility, items: An allinclusive term used in place of any of the following: appurtenance, assembly, component, equipment, material, module, part, structure, subassembly, subsystem, system or unit.
Maintenance Tasks: Design, Engineering, Procurement, Processing, Examination, Test or Inspection Operations perfonned for the Modification, Alteration, Repair, Replacement or continued operation of Nuclear Power Plant Components and Systems categorized as Code or Safety Related Items.
Materials: Metallic materials which are manufactured to an SA, SB, or SFA specification or any other material specification permitted by the Code.
Mechanical Design: The activity responsible for Code sizing calculations, material and service requisitions, drawings, and work releases.-
Momfor: To watch, observe, or check to ensure compliance with the Code and the requirements of the Owner's or Certificate Holders Quality Assurance Program. This activity is not necessarily documented or required to be on a centinoons basis.
Nantonformance: A deficiency in a characteristic, documentation or procedure that renders an item, or activity unacceptable or indeterminate.
Easter Whtslerlactgy_ Corp.
Section: Definitions Energy Applications,Div.
Page 4 of 5 Rev.._L.;
Quality _/Luurance Manual Date:
516/92 Nuclear Ouality>ssurance: Personnel assigned to Project Team as required by the Manager of Quality Assurance to assure by monitoring and audit that Code and Design Specification requirements are met in the FWEA engineering, design, procure nent, manufacture, construction and maintenance operations.
Nuclear _ Quality _AsturansLQirecoves: All NQAD transmittals 'o cognizant project personnel and FWEA management by Quality Assurance personne) are on consecutively number NQA directive forms. (Exhibit 3.4)
Earts: A partis attached to orbecomes a portion of a component o component supportbefore completion and stamping of the component or componut support. Parts have wmk performed on them requirinp r crification by an Aetheiaed Inspector.
ErpjecLManager_Instartion: The Project Manager Instructions (Exhibit 3.3) are formal documents directing project activity, and distributing authorized documents. PMI's ara consecutively numbered and sent to all cognizant project personnel.
Projectflan: The plan prepared by the Project Manager to define responsibilities for the project activitics and to define interfaces between participating organizations.
ErofesLSprcification List: The current list of first tier specifications used to inform the cc,gnizant project personnel of all reference documents whose requirements must be met to assure compliance with the contract. (Exhibit 3.1)(cover sheet).
Quality Assurance (OAh All those planned and systematic actions necessary to provide adequate confidence that items designec. and constructed are in accordance with the rules of the Code.
Quality contro11QCl: Measurement of the characteristics of an item or process to determine conformance to specified requirements.
Quality System Program: A system used to control material quality during manufacture or supply or by other work performed by the Material Manufacture or supplier to assure conformance to the basic material specification and special requirements of the Code.
Receiving Report: Standard form that is part of the original purchase order document prepared by Purchasing and provided to the Work Location to record receipt of Materials and Items.
Regulatory _ Requirements: As used in this manual,10CFR50 Appendix B; ANSI 45.2; R4 10CFR71, Subpart H; 10CFR72, Subpart C; ANSI /ASME NQA-1; and applicable NRC Regulations and Regulatory Guides as specified by the customer.
Foster Whetkr Enerev Corni Sectiom Definitions Energy Ap; lications, Div.
Page 5 of 5 Rev. 4 Quality Assurance Manual Date:
5/6/92.
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Release: Documented au thoriza tion and transmittal of documents i.e., drawings, procedures, specifications, etc. for work.
Rep >1t: The process of restoring a nonconforming characteristic to a condition such that an item complies with Code requirements. He disposition requires a documented technical justirication.
Review / Approval:As used in this manualis denoted by signature, initials or stamp, and date.
SNT-TC-1 A: Refers to the 1984 edition Rework: Le process by which an item is made to conform to original requirements by completion or correction and restored to a condition such that it complies with Code requirements. The disposition requires a documented technical justification.
Syrveillance: The act of monitoring or observing to verify whether an item or activity conforms to specified requirements.
Survev: A documented evaluation of an organization's ability to perform Code activities as verified by a determination of the adequacy of the organization's quality program and by a review of the implementation of that program at the location of the work.
Sysiem Noncompliante: An activity or procedure nonconformance that violates requirements.
Subcontractor A - ASME Certificate Holder Subcontractor B - Non certificate bolder approved by FWEA Task Authorization Form: Task responsibilities for portions of the contract requirements are defined and distributed to each Task Leader on Task Authorization Forms by the Project Manager (Exhibit 3.2).
Weld Development Laboratory: The authority for the engineering and control of Weld Technology including the procedures, methods and techniques to be utilized. It is responsible for the qualification of weld procedures as well as the correct application of weld procedures, joint configurations, methods and techniques. It is synonymous with " Weld Engineering".
Work L o ca ti o n: Location (s) where engineering, procurement, manufa eture, construction and maintenance operations are performed in the shop or field by FWEA Work Release: Work Releases (Exhibit 63) are formal consecutively numbered documents -
prepared by mechanical design and used to transmit and release documents to' Work -
Location (s) for the purpose of authorizing work.
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Sectieru 1._'
Energy Applications, Div.
Page 1 of 16' Rev._L..-
4
}O uHtv Assurance Manum 1.
Date:
s/6/92 1.0 - ORGANIZAT1DN
. INDEX PAGE INDEX 1
1.1 PUR/OSE 2-1.2 SCOPE 2
13 QUALITY ASSURANCE 2
R4 1.4 ORGANIZATION
-3 R4 1.5 AUTHORITY ANDRESPONSIBILITY 4
EXUIBITS R4 Exhibit 1.1 Organization Chart OVEA) 14-O Exhibit 12 Organization Chart (Quality 15 Assurance Department)
R4 Exhibt 13 TypicalWork Location 16 l~
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EnitedheelerIncrev Corp.
Sectiom 1
Energy Applications, Div.
Page 2 of16 Rev. 4 Quality Assurance Manual Date:
5/6/92 O
1.0 QRGANIZATION 1.1 P.ntp91c Toidentify the authority and responsibilities of the FWEA Quality Assurance program, de cribe the organizational structure utilized for its implementation and indicate their interface with sulcontractors to assure that quality is achieved by those responsible for the work and is verified by persons not directly responsible for the work.
1.2 Stops This section establishes the authority and responsibilities of Quality Assurance including personnel performing functions and activities affecting quality under the Code and Regulatory requirements at the Home Office, Subcontractor and at Work Locations, for establishing a Quality Assurance interface with:
1.
Construction of Code and Regulatory items at Work Locations.
2.
Installation of Code and Regulatoryitems.
3.
Field operations for the completion, alteration, repair of items constructed in O
subcontracted facilities.
4.
Other manufacturers subcontracted to manufacture Class i,2,3, MC and CSitems.
5.
Maintenance operations in the field for the repair, replacement and modification of items.
6.
Field fabrication of piping sub assemblies (Class 1,2 & 3).
7.
Supply of Code Materials.
1.3 Quality Assurance The Quality Assurance Manager is responsible for the planned and systematic actions necessary to assure that tasks are carried out in accordance with the Code Regulatory and contract requirements at the Home Office, Subcontractor B, and Work Loca tions.The Quality Assurance Manager has authority to:
'(1) identify Quality problems; O
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Foster Wheeler Enerry Corn.
Section:
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. Energy Applications, Div.
l Page 3 of 16 Rey, _L,-
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W 92-O (2)_ _ initiate action which results in solutions and to verify implementation; (3) control for further analysis, processing or installation of a nonconfornung item,
/eficiency or unsatisfactory condition including placanent of " Holds" when necessary, until properly dispositioned and/or the unsatisfactory condition has been corrected.
1.4 OIganizatinn 1.4.1 Authority for the execution of all tasks, referred to here-in as the Work Activities -
is under the direct responsibility of FWEA. The organization of personnel having Authority and Responsibility for quality and quality related function and activities is as shown in Exhibit 1.1. Those shown above the project organization retain -
overall authority for performance of functions in the designated areas. The R4 Manager, Nuclear Systems is responsible for Project Management, Manufacture, Construction or Maintenance Services. Manufacture, Construction and Maintenance capabilities required may be provided by subcontract service so as to provide the expertise, facilities or resources needed for performance of the work, R4-The Director of Engineering is responsible for Design, Structural, Thermal R4 Hydraulic analyses, System Engineering areas as well as Engineering Programs.
R4 The Director of Purchasing is responsible for Procurement.
1.4.2 For each task, a subordinate project organization is established to mcet the specified Code, Regulatory and contract requirements at the location (s) where the work is being performed (Home Office, Subcontractor and/or Work Locations). A Project Manager is assigned to head up the project with Task Leaders and other responsible individ uals assigned in the applicable areas for performance of the work required.
The Project Manager is respon.sible for implementing the project requirements including Quality Assurance 1.y issuing Project Manager Instructions indicating "when" and "what" is required. The responsibility for performance of functions -
as te "HOW" the work is performed,is retained by the responsible management that has overall authority in the organization for the required functional area (s).
- Detailed responsibilities required for the performance of individual tasks is -
described throughout the remainder of this Manual.
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Energy Applications, Div.
Page 4 of 16_ Rev. L Date:
5/6/92 Quality Assurance Manual N
1.4.3 The organization for Quality Assurance that is not directly responsible for performing the work is shown in Exhibit 1.2. The Quality Assurance Manager R4 reports to the FWEC Directoi QA/QC and thereby has direct access to responsible Management and is independer.t from the direct pressures of production. He reports regularly on the effectiveness of the QA Program and consults with Management on matters of policy which are quality related.
1.4.4 A QA/QC Supenisor designated by the Quality Assurance Manager is assigned when work is performed at a Work Location. The QA/QC Supervisor reports to -
the Quality Assurance Manager on quality related matters and is responsible for implementation and supervision of quality related activities at the designated Work Location. A typical organization at a work locations is shown in Exhibit 1.3.
1 A3 A Quality Assurance Task Leam is assigned for each Home Office project by the Quality Assurance Manager. He is responsible for performing and implementing Quality Assurance requirements as described by this Manual for the assigned project and its activities.
1.5 Authority And Responsibilities 1.5.1 The Quality Assurance Manager is responsible:
(1) For assuring that the Code and Regulatory Requirements are adhered to on Tasks and that the procedures outlined in this manual are followed.
(2) For the documentation of the Quality Assurance Program induding any changes.
(3) For assuring that an audit program is carried out during the project (s) to assure compliance with the Quality Assurance Program and to verify its effectiveness.
(4) For assuring that FWEA exercises direct responsibility and supenision of welding requiring Code Symbol stamping at the work location.
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Sectiom
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Energy Applicatio' Olv.
Page 5 of16 Rev. i_
Date: _ 5/6/92__
Qpality Assurance >fanual V
(5) For the survey and qualification of the Quality Assurance Programs of Materials Manufacturers and Suppliers and for issue of an Approved Vendor's List which designates acceptable vendors for procurement use.This responsibility may be considered to have been met if the Material Manufacturer or Material Supplier is a holder of a ASME Quality System Certificate (Materials).
(6) For designating qualified personnel to serve as FWEA "LevelIII" examiners in accordance with SNT TC-1 A and the Code tor the appropriate NDE.
(7) For designating qualified personnel to serve as Lead Anditors, Auditors and Field QC Engineers in accordance with Quality Assurance operating procedures.
(8) For maintaining an updated list of controlled Quality Assurance manual holders.
(9) For assuring that Quality Assurance and Quality Control personnel are qualified and that sufficient training is provided to assure the necessary level (q
of proficiency.
V (10) For survey and qualification of the Quality Assurance Programs of suppliers of subcontracted services including non-destructive examination and issuing an Approved Vendors List designating the acceptable suppliers for procurementuse.
(11) For assuring that Code Addenda are reviewed when issued, ana for approving additions and/or revisions as may be necessary to update and implement the Quality Assurance Manual within six (6) months of Addenda "date of issue".
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(12) For acceptance of proposed modifications to the Quality Assurance Programs for FWEA qualified Material Manufacturers and Suppliers; and suppliers of subcontracted services that do not hold ASME Quality System Certificates (Materials).
(13) For transmitting any proposed changes of the Quality Assurance Manual to O
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Foster Wheeler Encity Corp.
Sectioru l_
Energy Applications', Div. '
Page 6 of 16 Rev. 4 -
O Qualltv_ Assurance Manual Date:
5/6/92
- h the Authorized Inspection Agency Authorized Nuclearinspector Supervisor (ANIS) for acceptance and providing evidence of acceptance to the QA/QC supervisor so it is submitted to the Authorized Inspector at the Work Location after approval and prior to implementation.
(14) For verifying that required records are being maintained in accordance with this Program.
(15) For assuring Jiat FWEA Quality Assurance authority has been established with other manufacturers subcontracted to manufacture or install items for FWEA.
(16) For the audit of Quality Assurance Programs of subcontracted organizations during the period of the subcontract (s).
(17) For assuring that a Subcontractor "A" organization has a current AShE Certificate of Authorization (as applicable) covering the Scope of Work required by FWEA.
(18) For auditing Tasks to verify that applicable requirements of Design Specifications and the Code are correctly translated into specifications and g
drawings.
(19) For auditing to assure that internal design reviews are performed by individuals or groups other than those having responsibility for the performance of the design and that reports of the design reviews c.re issued.
(20) For auditing the activities of FWEA to assure that design documents are prepared and checked as required.
(21) For assuring by audit that to the extent necessary, the Code and Regulatory Requirements have been included in the purchase orders for procurement of materials, items and services for the subcontracted manufacture or installation ofItems.
(22) For review and approval of procurement requisitions for adequacy in meeting Code, regulatory, and contract requirements and assuring they are used as the single method of authorizing a purchase order for subcontracted 1
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Emler Whecht_Enctev Coro.
Secti:n:
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Energy Applications, Div.
Page 7 of 16 Rev. _L.,
Qualitydnurance_ Manual Date:
5/6/92 pV Manufacturing, Construction or Maintenance of items and procurement of -
material, items and services. The requisition and purchase order shall save the function of authorizing sub contracted work.
(23) For inspections, examinations and tests associated with receiving, installation, shipment, repair, or replacement of material or items at the Work Location.
(24) For assuring that inspectors and the Authorized Inspector have access where Nuclear work is being performed Mduuing all subcontractor locations.
(25) For resiew and approval of Drawings, Design Reports, and other design documents.
(26) For approval of weld, heat treatment and NDE procedures and assuring that personnel performing these special processes a. qualified in accordance with the Code and Regulatory Requirements.
(27) For review and approval of Vendor drawings, plans, procedures, certifications and other documents specified by the purchase order to be submitted for approval.
(28) For certifying FWEA Certificates of conformance and/or compliance after assuring that Codes, Regulatory, and Contract requirements, as applicable have been met for the completed work.
(29) For the control and issuance of National Board Serial numbers. Records for issuance, date issued, item type and manufacturer's Serial number shall be maintained.
(30) For Indoctrination and Training of Home OtSce Personnel.
(31) For Qualification of Quality Assurance program audit personnel.
1.5.2 QA/QC Supervisoris responsible:
(1) For reporting to the Quality Assurance Manager on all quality reted matters.
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Energy Applications, Div.
Page 8 of 16 _ Rev. _i_
Qualityhurance Manual Date:
5/6/9L (2) For carrying out the responsibilities delineated in (3), (4), (7), (9), (14), (15),
(16), (17), (18), (23), (24), (26), (27), of 1.5.1 above at the Work Location when so designated and delegated by the Quality Assurance Manager.
(3) For Training and Indoctrination of Work Location Quality Assurance and Quality Control personnel.
(4) For supervision of Work Location Quality Control personnel including inspection and examination personnel.
(5) For reporting results of examinations, inspections or tests.
(6) For establishing or verifying that in process and final examinations and tests are included in process instructions along with orevision for the Authorized Inspector's Hold Points.
(7) For documentation and identification of non-conforming items as well as verifying that non-conforming items have been dispitioned.
(8) For controlling further processing, delivery, or installation of an non-conforming item, deficiency, or unsatisfactory condition until proper disposition has been made.
(9) For the maintenance of an adequate control program for calibration of Measurement and Test Equipment in accordance with the Code and RegulatoryRequirements.
(10) For the maintenance of and access to quality records.
(11) For making an approved controlled copy of the Quality Assurance Manual available to the Authorized Inspector.
(12) For maintaining Procedures for the performance of inspections at the work locations.
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Foster Wheeler Enerev Cog.
Secti:n:" J 1 -
Energy Applications, Div.
Page 9 of 16_ Rev. 1 -
Date: -. 5/&92 Oum11ty Assur=are Manual-
-(13) For advising the Manager of Quality Assurance of adverse quality-performance of subcontractors, including Materials Manufacturers and:
Material Suppliers and suppliers of services, so appropdate corrective action can be taken.-
(14) For certifying FWEA Certificates of Conformance and/or compliance after -
assuring that Codes, Regulatory and Contract requirements, as applicable,-
have been met for work completed at the Work location.-
13.3 Field QC Engmeer is responsible:
(1). For evaluation of vendors as directed by the Manager of Quality Assurance.
(2) For performance of inspections at subcontractor facilities.
(3) For assuringby surveillance that applicable requirements of FWEA Puria e Order (s), Drawings, NDE and Quality Assurance requirements arebeing met -
at the subcontractors facilities.
1.5.4 Quality Assurance Lead Auditors are responsible for:
(1) PerL rming audits utilizing audit plans, preplanned check lists and Audit o
- reports, (2) Annually auditing all aspects of this program for conformance with the Quality Assurance Program and the Code and Regulatory requirements.
(3) Re auditing deficient areas.
'Ihe Lead Auditor of the Quality Assurance Department shall be independent of -
R4
- Quality Assurance and be appointed by the FWEA Director.
R4 15.5 The Project Manager reports to the Manager, Nuclear Systems and is responsible for the overall performance of the project. He is responsible for implementing Contract requirements including Quality Assurance requirements. Other quality --
related responsibilities under his direction include:
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Foster Wheeler Enerev Corp.
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_1_.
Energy Applications, Div.
Page 10 of16 Rev _i_
Quality Assurance Manual Date:
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-V 1.
Distribution and implementation of client specified specifications, standards andCodes,includingdistributionof theDesignSpecificationssoitisavailable to the ANI prior to fabrication.
2.
Distribution of project documentation to project personnel and to the client / owner / customer.
3 Release of design documents (i.e., drawings, specifications, plans, procedures) and instructions for operations at the Work Location.
4.
Preparation of project distribution lists and maintaining records of the distributions.
5.
Submittal of Data Reports to the customer.
6.
Maintaining project documentation as Quality Assurance Records as directed by the Quality Assurance Manager.
R4 1.5.6 The Director of Purchasing is responsible for purchase of materials and subcontracted services, t
R4 The Senior Buyer or Work Location Buyer (as applicabM is responsible:
1.
For placing orders based on procurement requisition, with acceptable
- vendors who are listed on the FWEA Approved Vendors List for procurement of materials,ittms and services.
2.
For establishing the interface between Engineering and subcontracted manufacturers, installers or others performing services at the Work Location.
The interface will include measures to control the issuance and distribution of documents (drawings, plans, procedures) used for manufacture and installation operations or maintenance tasks.
3.
For maintaining all vendor or subcontractor contracts.
T.53a-1)
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Eorar WheeletEnergyIoan Section:
L.
Energy Applications, Div.
Page 11 of16 Rev. L.
Quality.A.uurance. Manual Date:.5/992.
4.
For maintaining vendor supplied Quality Assurance records as directed by -
Manager of Quality Assurance or QA/QC Supervisor.
5.
For control of all Material Supply activities.
1.5.7 The Director of Engineering reports to the Director RVEA, and is responsible for all Engmeeting activities.
Responsible engineering activities include:
1.
The preparation of procurement requisitions (technical specifications) for procurement of materials, items arid services.
R4 2.
Review of design drawings and their revision for manufacture, installation and maintenance.
3.
Preparation of Work Releases for the transmittal of documents to the Work Location (s) for the purpose of release and authorization of work.
6.
Preparation of plans, procedures and process instruction sheet for Tasks at the Work Location.
5.
Performing Design Reviews and designatug qualified individuals to be Design Reviewers.
6.
Having revisions of design documents checked by the design activity responsible for the criginal design.
7.
Assuring Registered Professional Engineer (RPE) who certifies Design Reports, Drawings, and Load Capacity Data Sheets comply with ANSI /ASME N626.31988 qualifications requirements based upcn review at a 3 yr. Max. interval.
8.
Preparation of RPE qualification procedures and maintenance of RPE qualification and tri-annual review records.
9.
Preparation of Design Reports and Load Capacity Sheets as applicable.
R4 1.5.8 Manager, Nuclear Systems, reports to the Director FWEA and is responsible for the technical direction of all projects. Responsibilities include:
(1) Technical Direction of all Project Managers.
(
(2) Director of Manufa:turing, Cons truction and Maintenance Operations.
51 5 -1)
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. Energy Applications, Div.
Page 12 of16 Rev.._4_;
QumHtv Aamurance Manual -
Date:. 5/6/92-1.5.9 The Manager of Manufacturing, Construction or Maintenance Services'is respectively responsible for supervision'of craftsmen required by the work activities as follows:
1.
Performance of the Work in accordance with current released authorized procedures andinstructions.
1 2.
For coordination of all Work Location activities.
3.
For ob'aining the necessary lifting and handling equipment; tools; gages; instruments, and calibrated measurement and test equipment to perform the assigned tasks.
4.
- For cbtaining direction from Chief Radiation Control Engineer for control of radiation of personnel under his control when work is being performed at a Nudear Power Plant facility.
5.
For obtaining the nmessary qualified personnel for carrying out the Tasks.
6.
For directly supervising welding for construction tasks requiring certified Code Symbol stamping.
7.
Maintaining traceability of the Materials and items during processing. -
8.
Maintaining process and Quality Assurance records as directed by the QA/QC Supervisor.
9.
Complying with the requirements of the. Quality Assurance Program as -
~
described by this Manual throughout the execution of the work.
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Section:
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Energy Applications, Div.
Page 13 of16 Rev.1
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Quality Assuranee Manual Date:
5/6/92
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QUALITY - ASSURAkE DEPARTMENT b
MANAGER Quality Assurance I
AUL.QR Quality Assurance QAlQC Engineers Supervisor "f"g,I Inspectors g,,, g,,,
TieM QC Engineers AUDITOR Personnel Work Location Exhibit 12 Page 15 of 16 -
5tW4s.
Rev. 4
TYPICAL WORK LOC rtION ' ORGANIZATION t
I DIRECTOR -
MANAGER Tech Center QualityAssurance i
PROJECT MANAGER ii i
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MANAGER Construction
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I WO
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Superintentent Weld Engineer '
Sur os-1 Foreman NOTE:
Normally located at the Home Office.
Dotted lines show functionallines of Authority.
Craft Solid lines show Administrative lines of Authority.
Labor Exhibit 1.3 Page 16 of 14.-
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East.:r Wheeler Enerev Corr,_
Section:
._2._
Energy Applications, Div.
Page 1 of10 Rev._L-A Guality Assurance.hianual Date: S/6/92_
2.0 QUALrrY ASSURANCE PROGRAM INDEX EAGE INDEX 1
2.1 PURPO3E 2
2.2 SCOPE 2
23 PROGRAM REQUIREMENTS 2
2.4 MANUAL CONTROL 4
R4 2.5 TRALNING AND INDOCTRINATION PROGRAM 7
2.6 MANAGEMENT REVIEW 8
EX11mlIS:
O V
Exhibit 2.1 Typical transmittalletter for distribution 9
of revisions to the Quality Assurance Manual Exhibit 2.2 Typical transmittal letter for.' uthorizca Inspection 10 Agency acceptance of prcposed changes to the Quality Assurance Manual O
5155s-D
Easter Wheeler Enerev Corn, Secti:n:
1.
i Energy Applications, Div.
Page _2 of10 Rev._L.
Quality Assurance Manual Date: s/&92 =
2.0 QUAMDULSSURANCEPROGRAM L
2.1 f.urpose To describe the elements of the Quality Assurance Program and identify the l
controls necessary for its implementation.
2.2 Scope This section describes the elements of the Quality Assurance Program established 3
to assure Construction and Maintenance Tasks are performed in accordance with contract, Code and Regulatory Requirements.
23 P2ogram Requirements -
The FWEA Quality Assurance Program establishes controls for activities.
performed on Code and Regulatory items. These controls are utilized by Quality l
Assurance / Quality Control and Project personnel induding the craft, man on the r
job in accordance with polides and procedures e:tablished herein to ensure that a comprehensive and integrated Quality Assurance Program is achieved and maintained.
23.1 ControLof.Speelfied Contract Documents During the course of the work, the program requires Design Specifications, Drawings, and Contract requirements to be semdnized and reviewed by Project Management with Quality Asst 4:ance approval prior to project -
implementation to assure Cr 4e, Regula tory, and contract requirements arc not violated or negated. Disusbution of these documents, as approved and -
released for uJe, is er.. trolled by listings in the Project Specification List.
This list is approved by Quality Assurance and is distributed to all project particir uts as the necessary authority for document use. Decument changes are reflected by changes in the Project Specification Ust which are approved and processed tht same as the original.
23.2 Eneineering DesigtL=nd hulysis Design controls are irr. posed on Design activities to assure the Client's requirements inclyding the Code a.nd Regulatory Requirements are correctly translated into drawings, specifications, reports and procedures _
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Secti:m _2-Energy Applications, Div.
Page _3 of 10 Rev._L.
Quality.AssurancellanuAl Date: 5!OL (q)
'Ihe desip documents are checked by competent, qualified personnel other than person who prepared the document and approved by the responsible Engineering or Mechanical Design and Quality Assurance Task Leaders. Changes are processed the same as the original document.
Equipment designs are subjected to " Design Reviews" whereby qualified personnel other than these who developed the designs formally review the Designs at Design Review meetings to assure client requirements have been met and appropriate matcrials, parts and processes and acceptance criteria have been selected and specified. Design documents are certified by a qualified Registered Professional Engineer where required by Code.
233 Erecurcment Procurements of Material, items and Services are controlled to assure client, Code and Regulatory requirements are met and the required traceability is maintained. Procurement requisitions and their changes are prepared by Mechanical Design and checked by a quallfled person other than the preparer; reviewed and approved by Project Manager and responsible Mechanical Design, and Quality Assurance Task Leaders.
Potential procurement sources,1.e., Material Manufacturers and Suppliers;
(
Manufacturers, Installers and Subcontractors of Services are evaluated by Quality Assurance Survey prior to order placement. Ilased on these evaluations, vendors utilized for procurement are selected from a
" Approved Vendor's List" which is prepared and maintained by Quality Assurance. Procured material and items may be source inspected at the vendors facilities as determined by the Quality Assurance Manager but are also subject to recuving inspection.
23.4 Worklocation Tasks are controlled to assure utilization of correct and approved procedures, instructions, qualified personnel; and suitable equipment.
Drawings, procedures, and changes are prepared and checked by a competent qualified person other than the preparer in accordance with established procedures to assure client, Code and-Regulatory Requirements havebeenincluded. Distributionofdocumentsnecessary for the perfonnance of the work is made by authorized release. Personnel are qualified and trained, as necessary, to meet job, Regulatory and Code requirements. Special processes, i.e., welding, heat treatment and O
foster.WheelerIncigy. Corp.
Secti:ru
_2_.
Energy Applications, Div.
Page 4 of10 Rev. L.
QualityJusurutte.hianual Date: _516/92..
non destructive examination are performed by qualified personnel utilizing qualified procedures under suitably controlled conditions.
Measurement and test equipment which have been calibrated and controlled to meet job requirements is utilized, inspections and tests are performed and documented to verify specified, Code and Regulatory Requirements have been met. l landling, storage, pa ckaging, and shipment is perfonned under controlled conditions utilizing qualifhd personnel.
2.3.5 Nonconformance and Records Nonconformances are detected and reported and discrepant material controlled to preven t their inad vertent use. Discrepant material reports are dispositioned by Engineering and cleared by Quality Control prior to further processing. Tunely, positive corrective actions is taken to prevent recurrence of discrepancies determined to be significant by Quality Assurance. Imemal audits are performed at scheduled intervals to assure and verify requirements of this Program are being met throughout the project. Quality Assurance Fecords which must be retained are identified for each project and the responsibility for collection and maintenance established by a records checklist issued from Quality Assurance. Records are retained and controlled to verify that contract, regulatory and Code requircments were met.
2.4 hianual Control A copy of this manual shall be made available to the Authorized Inspector of record by Q.A. Manager for his use in evaluating and monitoring the Quality Assurance Program. Quality Assurance Manager is responsible for control of manual distribution and revision which shallinclude the following:
2.4.1 Revision Notntions - Revision Notation "Rx" in the left hand margin of the pages indicate paragraph or line changes that have been made as part of the current revision. When the entire section is changed revision nc.tation will not be used, and control will be by the section revision.
2.4.2 Section Revisions - This manual shall be revised by Section. 'Ihe revisions of the r.ection is indicated in the upper corner of each section page and on O
V eus..
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[gater Wheeler Engrav Coro.
Sedi:n:
._2_
Energy Applications, Div.
- Page 5 of 10 Rev.._(_
Quality Assurance Manual Date: _5/6/92 the section indices. This revision identification indicates the section revision status which may d81fer from the manualissue revisio.- Section revisions which comprise the manual issue revision are 11:, in the Manual Master Index.
2.4.3 Indices - The Master Manual Index reflect the section revision currently in -
t force.Section revisions are indicated by revision number in the upper right hand corner of the section pages,in the section indices, and in the Master i
ManualIndex.
l 2A 4 Log File Listing of all proposed changes are logged in FWEA log file by consecutive numbers. While changes are in process of development, correspondence is logged in the file. When proposed changes result in accepted changes, copies are sent to the controlled manual holders.
74.5 Control Manual Listing 'Ihis listing identifies each person to whom a controlled manual has been issued and indicates title, assigned manual l
number, date issaed, and the revision Uncontrolled manuals are so identified on the title page and shall not be used for the performance of work.
2.4.6 Review of Code Addenda-The Quality Assurance Manager is responsible -
for reviewing Section III Code Addenda within six months of Addenda "date of issue" ann documenting proposed changes to the Quality
^
Assurance Manual. Manual revision and implementation shall be accomplished within this period.
2.4.7 Rest,onsibility - The Quality Assurance Manager is responsible for approving the manual and manual changes transmitting proposed changes to the ANIS for acceptance and distributing revised secdons to holders of controlled manuals. Revisions are distributed with a transmittal letter similar to that shmyn on Exhibit 2.1 and a copy of the ANIS acceptance letter shown in Exhibit 2.2.
i The manual revisions shall be implemented at all locations within 60 days, of the - date that the ANIS accepted the revision. Internal acknowledgements, training, procedural changes shall be completed within this period. Manuals will be downgraded to " Uncontrolled" if
~
acknowledgement of cantrolled receipt of the revisionis not received from -
ths centrolled Manual Holder within 60 days except for internt.1 and Authorized Inspection Agency manuals.
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Energy Applications,Div.
Page _6 of 10 Rev._4 Qualliy_Asnurance.hianual Date: 5/6/92-j'{
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2.4.8 Uncontrolled manuals may be distributed external to FWEA by Q.A.
]'l Manager who shall maintain a log of distribution date and to whom l
distributed, 2.49 A copy of the accepted Authorized Inspection Agency (ANIS) letter (Exhibit 2.2)is sent to the QA/QC Supervisor at the Work Location for presentation to the Authorized Nuclear Inspector of record at the Work Location prior to implementation.
l 2.4.10 Audita Receipt of signed transmittal letters (see Exhibit 2.1) will be used as evidence that revisions of controlled copies have been received by manual holders. Audits will be made to insure that controlled manuals within FWEA are being adequately controlled.
2.4.11 Uniquc}iarual Changca - An amendment to this manual may be issued, J
should a unique minual change become necessary for a particular project or contract at a Work Location. Unique manual changes shallbe subject to the review and approval of the Manager of Quality Assurance, and the acceptance of the Authorized Inspection Agency (ANIS) with jurisdiction at the Work Location and Home Office.
O 2.4.11.1 De Manager of Quality Assurance is responsible for formally transmitting proposed unique changes to this manual to the Authorized Inspection Agency (ANIS) for acceptance prior to implementation. Proposed changes shall be transmitted by a formletter. A copy of the accepted letter shallbe sent to the Work Location QA/QC supervisor so he can make it available to the Authorized Inspector at the Work Location as evidence of acceptance of the unique changes that apply only to that particular Work Location prior to implementation.
2.4.11.2 ne accepted unique change shallbe printed on blue paper and issued only to controlled manual holders at the applicable Work Location and to those associated with the Work Location.
2.4.11.3 The unique pages shall have their three mounted holes punched in the right margin so that each unique page maybe inserted opposite, and with the print facing the page which ccatains the paragraph being revised. Each unique page shall list the applicable project number, contract number or Work Location to which the change applies, and the section, page and revision of the sheet which contains the paragraph being replaced.
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S:cti:n: _2
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Page 7 of 10 Rev._L Date:
5/6/92 Qo!ity A3smiance Manual f-2.4.11.4 The contents of unique pages shallidentify the paragraph being replaced by its number.The unique paragraph being added shall use the same paragraph number as the original paragraph and shall be shown on the new page. Revisions of unique pages shall be identified by letters in alphabetical order hyphenated with the revision number of the original manual page. The first unique page shalllave a hyphenated A af ter the revision number.
2.4.11.5 An index of amendments shall control the effectivity of unique pages at a specific Work Location and shall be identified as
" Work Location" Amendments for (Work Location Name).
2.5 Ilaining and IndoctrinationItagram The training program for personnel performing activities affecting quality are outlined herein; for training of I..d Auditors and Auditors, see Section 18; for training of Inspectors and Test personnel, see Section 10.
2.5.1 Program Plan - The training and indoctrination program for QA and QC personnel both at the Home Office and Work Location performing I
activities affecting quality shallinclude the fotlos Ang elements. Elements (b) through (e) or portions thereof, may be waived by the Manager of Quality Assurance, d epending upon the individual's previous educational or work experience, or by proven "on the job" performance.
(a)
Orientation (Familiarization Training with FWEA Quality Assurance Program)
(b)
InstructionalTraining (c)
Written and /or Practical Exarnination (d)
On-the Job Training (e)
Refresher (in Service) Program 2.5.2 The Quality Assurance Manager is responsible for training and indoctrina tion of Home Office QA personnel while the QA/QC supervisor is responsible to train and indoctrinate Work Location QA/QC personnel.
Personnel shall be reviewed annually by Q.A. Manager or QA/QC Supervisor to assure that suitable procciencyis achieved and maintained,
'nds review shall be documented in Training record file. Training records shall be maintained at the Home Office or Work Location, as applicable.
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Secti:ru _1 Energy Applications, Div.
Page 8 of10 Rev. L Quality _AssuranceAlanual Date: =5/6/92-2.5.3 The QA Manager shall be responsible for training and indoctdnation of other pers< nnel performing activities affecting quality such as management, design, engineering, procurement and supervisory R4 personnel.1his is accomplished by the QA Manager reviewing and R4 approving the appropriate training plan and schedule prior to its R4 cxecution. The manager responsible for the person's activities is also R4 responsible for carrying out the training and shall assure that the training and indoctrination is accomplished by udlizing a written planned and scheduled training program approved by the Q.A. Manager. Ihis activity shall be documented.
2.5.4 Quality Assurance will assure the above is performed by audit.
2.5.5 Documentation of training willinclude date, subject, instructor, length of time of the sessions, and attendance. The documentation shall be certified by tlw instructor.
2.5.6 When there are major changes in the Quality Assurance Program, additional indoctdnation is reviewed by the Quality Assurance Manager and Supplemental training is conduded for QA/QC or other affected personnel. When job responsibilities change, the necessary indoctrination and training shall be performed.
2.6 hianagement. Review 2.6.1 The FWEA Director is responsible for assigning Management personnel (independent of Quality Assurance and a lead auditor) to. periodically audit (minimum, annually) the Quality Assurance Program for compliance with requirements of the Code, Regulatory Requirements and this Manual. The assigned personnel are also responsible for reauditing any deficient areas found. A report of the review including an; nnaings will be documented and distributed for review and action, as necessary.
Appropriate corrective action will be taken and verified by reaudit of the deficient area (s).
2.6.2 The FWEA Director also reviews the Quality Assurance Program by:
1.
Reviewing management reports.
2.
Review the results of internal and external audits.
3.
Reviewing Annual Quality Assurance Assessment Report.
CL%D
c Fester Wheeler Enetgy Ccrporati:n Energy Applications Division Perryville Corporate Park-Cllnion, NJ INTER OFFICE CORRESPONDENCE EXHIBIT 2.1 PAGE 9 of10 REV.
-4 DATE S/6/92 TO:
(Controlled Copy Manual # )
Attached please find the followGg revised sections to the FWEA Quality Assurance Manual.
Section hgt Revision Please place these new sections in your manual and remove and destroy the old pages. Indicate O
that this has been accomplished by endorsing one (1) copy of this memorandum and return it to the writer.
Very truly yours,
- Manager, QualityAssurance The above revised pages have been placed in my controlled copy of the manual and the old pages have been destroyed.
-(Signature)
(Date) h i
0155eD 1,.
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FOSTER WHEELER ENERGY CORPORATION t
O Energy Applications Division Perryville Corporate Park, Clinton, NJ 088094000
- Phone 908 2361401 Exhibit 2.2 Page 10 of 10 Rev.
4 Date 5/6/92 TO:
(AUTHORIZED INSPECTION AGENCY REPRESENTATIVE)
HARTTORD STEAM BOILER INSPECTION & INSURANCE COMPANY Attached please find revised sections of the Foster Wheeler Energy Corporation's Quality Assurance Manual. The sections that have been revised are indicated on the Master Index and the Section Ind ex, Changes have been highlighted by Rx in the margin. If you concur tha t these changes are acceptable with the Code, note your acceptance by signing the a ttached extra copy of this letter in the space provided.
Reference MasterIndex Rev.#
ne above sections have been reviewed and (accepted), (accepted as noted),(not accepted) per O
ASMECode,SectionIII.
Signed:
Hartford Steam Boiler.
Inspecion & Insurance Company -
i A copy of this letter signed and noted by you will be given to the " Authorized Inspector",
Very truly yours, ENERGY APPLICATIONS DIVISION FOSTER WHEELER ENERGY CORPORATION D.J Lameermeyer Manager, Quality Assurance i
f O
Foster Wheeln Enerry Cgg.
. Sectirn:._3 Energy Applications,Div.
Page 1 of 18 Rev.1_
l Oumilty Annurance Manaami Date:
5/& 92 i
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3.0 DESIGN CONTROL INDEX a
PACE
[
INDEX 1
3.1 PURPOSE 2-3.2 SCOPE 2
33 ENGINEERING RESPONSIBILITIFS 2
t R4 3.4 ENGINEERING CONTROLS 10
.j DOIIBITS:
Exhibit 3.1 Project Specification List 14 Exhibit 3.2 Task Authorization 15 Exhibit 33 Project ManagerInstruction 16 Exhibit 3.4 Nuclear Quality Assurance Directive 17-Exhibit 3.5 Drawing Review & ApprovalChart 18 l
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S:ction: _3,_
Energy Applications,Div.
Page 2 of18 Rev._L O_uality Anurante Manual Date:
5/6/92 O.-
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3.0 DESIGN CONTROL 3.1 Eurpsic his section outlines the Quality Assurance System and Controls maintained throughout the engineering of nuclear power plant components to meet Code and Regulatory Requirements, it is the policy of Energy Applications, Div.,(RVEA) to design nuclear components in strict accordance with the Code and Regulatory Requirements and the Design Specifications which constitute the contractual agreement between the Owner and his Agent and RVEA.The effective application of this policy requires systematic design planning, defined objectives, careful checking, thorough analysis, effective quality assurance monitoring, design reviews, and complete records.
3.2 Scope This section includes the Design Engineering features at FWEA affecting quality assurance from receipt of the Design Specification through construction and provides for the establishment and control of the interfaces with the Manufacturer, materials manufacturer, and/or installer.
3.3 Engineering Responsibilities ne engineering design of nuclear projects or items is performed by a task -
organization selected to suit the specific project requirements. The task organization responsible for the engineering design and conformance to the Code, Regulatory Requirements and Design Specification, normally includes the following task groups, each with its Task leader:
1.
Project Management 2.
Thermal /HydraulicEngineering 3.
MechanicalDe3ign 4.
StructuralEngineering 5.
Procurement 6.
Nuclear Quality Assurance As a minimum, the project group will include 1,3,4, & 6.
U Details of their responsibilities follow:
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Energy Applications, Div.
Page 3 of 18 Rev. L.
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O 33.1 hojectManagement
'Ihe Project Manager is the FWEA management representative responsible for the total project including the following:
33.1.1 Obtaining the Owner or Owner's Agent's Desi m Specification for the l
project's components certified by a Recistered Professional Eneineer or other design input such as design basis, performance requirements, regulatory requirements, Codes, and standards.
33.1.2 Providing the design input to the responsible design organization by Project ManagerInstruction.-
3.3.13 Controlling the design input to permit the design activity to be carried out in a correct manner and to provide a consirtent basis for making design decision, accomplishing design measures and evaluating design changes.
. Maintains a current Project Specification List releasing it to Task.
a.
Leaders to define applicable specifications, standards, Code Class and Code cases. (Exhibit 3.1) b.
Provides contract specified interface data such as nozzie pipeloads, anchor bolt layout to appropriate Engineering Task Leaders or other plant contractors as required.
Authorizes the issue of work releases by Mechanical Design to start c.
key fabrication operation.
d.
Authorizes Mechanical Design issuance of requisitions for code-items, materials and sub-contracted services.
33.1.4 Plans and conducts Design Reviews when used for design verification or -
required by Code contract. These design reviews will be documented by design review minutes.
O
Entier Whaler Enerry Corn.
Secti:ru 1 Energy App" cations, Div.
Page 4 of 18 Rev._L.
Quality Am. qance Manual Date: _- 5/dV92 O
33.1.5 Assures that the Design Report is certified by a Registered Professional Engineer (See Para. 33.4) as required in the Code for each Gass 1 component and component supports, Class CS core support structure, Cass MC vessel and component supports, Class 2 vessels designed to-NC3200 and Class 2 and 3 components designed for specified service loadings.mter than Design loadings as defined in the Code. A Class 2 Design Reprt shall be prepared for Class 1 piping 1 in, nominal pipe size or smaller which is designed in accordance with the rules of Subsection NC.
33.1.6 Submits to the Owner for his review a copy of the completed Design -
Report for all coraponents and supports. 'Ihe copy of the Owners review documentation will be attached to the Design Report and will be made available to the Authorized Inspector prior to the Al stamping.
33.1.7 Releases the Project Plan to the cot,nizant Task Leaders and other project -
personnel along with authorization to perform tasks. See Task Authorization Form (Exldbit 3.2).
33.1.8 Issues instructions during the project to implement project tasks. See Project Manager Instructions (Exhibit 33).
33.1.9 Lists the Design Reviewers for a spedfic project d esigna ted by the Director of Engineering on the Drawing Review and Approval Chart (Exhibit 3.5).
Releases the chart to Task Leaders and Cognizant project personnel.
33.1.10 Transmits Design Report (s) and the documentation of review by the Owner or his designee to the QA/QC supervisor so they are available to -
the ANI prior to stamping the component.
33.2 Thermal /HydraulleDesien The T/H design group initiates the concept design, performs the thermal and hyd.aulic design analysis and optimizes the design configuration per the Design.
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-2_._i..
E02ict.WheelcLEnergy. Corp.
S:ct1:n:._L.
Energy Applications, Div.
Page 5 of 18_ Rev.,_L QualliyAssurAttte.hiAmtAl Date: J/fdL O
Specification. The T/H Task Leader is responsible for the use of the correct analytical methods, verified computer codes, valid design drawings and the conformance of the design components to the thermal and hydraulic requirements of the certified Design Specification and the Code, including but not limited to the following:
33.2.1 Perfonns the thermal / hydraulic analysis referencing the drawings, data, specifications and Code released for this analysis.
33.2.2 Reviews and transmits to the Structural Engineering and to the Mechanical Design Groups, the fluid pressures, temperatures, and velocities, (using Code or more conservative Coeffidents of Thermal Conductivity and Thermal Diffusivity) referencing the design drawings, where available. This data will be the basis far Structural Analysis, Material Selection, and the determination of corrosion and erosion allowances if not defined in the certified Design Specifications.
33.23 Presents the thermal /hydraulle design at the Design Review rneeting(s).
33.2.4 Reviews all revisions of drawings referenced in the Thermal / Hydraulic O
analysis to assure that the Thermal Hydraulic Report is in accordance with final drawings.
33.2.5 Reviews fluid flow data including operational environment,if required, for erosion and corrosion determination.
33.3 hiechstnicalDesign The Mechanical Design group prepares the project du.ign drawings, the Code sizing calculations, the material, fabrication and installation service requisitions, discrepant material and item dispositions; and the work releases.
Material selection is also performed with consideration of metal temperature, the structural requirements, weldability and other metallurgical considerations.
OV (5153s 3)
EndetWheelm Fnerey Corn.
Section:,,1, Energy Applications, Div.
Page 6 of 18_ Rev._L Quality Amaurance Manual Date: _ 5/&92_
O Specifically, the Mechanical Design Task Leader is responsible for the activities identified below:
33.3.1 Incorporates the requirements of the certified Design Specifications and the Code and Regulatory Requirements, on the drawings and Specifications, as defined by the Project Specification List. Obtains necessary information for completion of drawings from other Task Leaders. Drawings are transmitted to the cognizant Task Leader by Transmittal Form with explanatory notes as required and with a Master Drawing List showing the latest revhin.
333.2 Distributes drawing for structural analysis, thermal / hydraulic analysis, non destructive examination planning, welding methods, handling, storage and shipping methods and installation planning as required.The drawings are checked against characteristics which include requirements of the Code and Certified Design Specifications.
3333 Directs assignment of the part numbers to detail drawing for positive identification and traceability. All detail drawings include adequate identification to derme materials procured for each part in accordance with the FWEA Operating Manual.
33.3.4 Releases the design output documents for design reviews as coordinated -
by the Project Manapr per the Drawing Review and Approval Chart; presents design drawings in the Design Review (s). (See Exhibit 3.5).
3335 Reviews the material selections specified by the Certified Design Specificatbn, and defines any conflicts including those associated with code materialrequirements.
33.3.6 Definesanynecessaryspecialenvironmentssuchastemperature,inertgas, specific moisture levels required for handling, storage and shipping-without conflicting with requirements dermed in the Certified Design Specification.
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EailcGhrcletEnergyIorp.
S:cti:n: _L.
Energy /.pplications, Div.
Page 7_of18 Rev. L QMAllly.Anutance Martual Date:
s/6/92 O
\\
3.3.3.7 Releases the approved requisitions for the required material and sut>-contracted services except engineering services in accordance with the Code and Regulatory Requirements.
3.3.3.8 Releases the checked and approved drawings for fabrication by Work Release or by requisitions (if fabrication is not by FWEA) after Project Manager Authorization.
3.3.3.9 Reviews proposed revisions to client specifications and drawings and submits comments to the client via the Project Manager.
3.3.3.10 Maintain ~ the following current lists which include all planned drawings, and materials, and release them to co5nizant Task Leaders when prepared i
and when revised, Master Drawing List and Master Procedure List a.
b.
Bill of Materials with Requisition and Purchase Order references.
3.3.3.11 Reviews for approval, all changes to the project drawings proposed by the manufacturing or installation org;.nizations.
3.3.3.12 Dispositions with the cooperation of the cognizant project Task Leaders, Discrepant Material Reports invoMng non-conformances in accordance with the requirements of Section 15 of this Manual.
3.3.3.13 When the item is completed, Mechanical Design reviews Process Instruction Sheets, DMR Log & DMR's and prepares as built drawing to reflect the as built configuration and includes a list of the drawings.
3.3.4 StructuralEncineering The Structural Engineering group prepares and certifies the Design Report in accordance with the certified Design Specification and the Code.
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P fo11st.1YheclcLEnergy_ Coly.
Sectiom _ 3 Energy Applications, Div.
Page 8 of 18_Itev. L.
Quality _AStulanCc. Manual Date: J/R2L The Stmetural Engineering Task Leader is respont.ible for the use of the correct analytical methods, verified computer codes, valid design drawings, and the conformante of the designed components to the structural and the dynamic analysis requirements of the certified Design Specification and the Code.
Specifically, the Task Leader is responsible for the activities below:
3.3.4.1 Preparation, checking and approval of a Design Report for Class 1 components and component supports; Class CS core support structures, Class MC Vessels and component supports, Class 2 vessels designed to NC 320 and Class 2 and 3 components designed for specified service loadings greater than design loadings as defined in the Code.
'Ihe Design Report must identify and describe drawings used for design and construction and stress analysis calculations.The computer program used in the calculations shall be identified:
The computer type, program, revision, inputs, outputs, evidence of program verificdon and the basis supporting application to the analysis.
The report is to be checked by competent personnel who did not prepare the structurel analysis being checked.The report is to be cer tified for Code Conformance by one or more registered Professional Engineers.
3.3.4.2 Preparation, checking, approval and certification of the Design Reports for purchased parts and appurtenance to be attached to a component referenced in Paragraph 3.3.4.1.
3.3.4.3 Preparation of the Design Report for Class 2 and 3 components or supports that are not required to be certified by a Registered P.E.
3.3.4.4 Reconciliation of the Design Report to the "as built" drawings. After reconcillation,a Structural Engineershallprepareand approvea revision or addenda to the Design Report and obtain a RPE certification when O
FositLWhecinInergy_ Corp.
Section: _1 Energy Applications, Div.
Page 9 of 18_Rev. _i_
Date:
51 & 9 2 QuAlltyl83ErABCC11Anut]
O V
required and transmit the approved Design Report to the Project Manager for submittal to the Owner.
33.4.5 Presentation of the structural analysis results in the In-process and Final Design Reviews.
336 Qualitylsaurance
'Ihe Quality Assutance Task Leader is independent of Project Task leaders except for his recognition of the priorities of th.: project actkities.
The Quality Assurance Task Leader has the responsibility to identify quality assurance problem areas, organizational freedom to recommend and initiate -
corrective or preventative action and verify the cucution of problem resolution.
Corrective or preventative action is initiated with the Task Leaders. S;wcifically, the Qu ality Assurance Task Lead er is responsible for the actWities id entified below:
33.6.1 Reviews and approves drawings, requisitions, Design Reports and work releases for compliance with Design Specifications and signs off documents which he approves.
33.6.2 Reports the findings of audits he cond ucts to the management responsible for the group being audited and recommends corrective action. This is done by Nuclear Q.A. Directive (See Exhibit 3.4). Copies of the audit R4 reports shall be provided to the FWEA Director.
33.63 Follows up to verify the implementation of the corrective actions.
33.6.4 Approves each revision of the Project Specification I.ist, released by the Project Manager.
33.65 Approves design output documents of a project that require design verliication i.e. design review, Qualification testing or alternate calculations after the design verification process has been satisfactorily
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L
i FalcLWhederIncrgy_ Corp.
S:ctl:m _L Enesgy Appilcations, Div.
Page 10 of 18 Rev,.L Quality. Assurance _ Manual Date: Jilm L m
completed and action items assigned as a result of the design verification have been closed ow.
3.3.6.6 Surveys and qualifies the capabilities and Quality Assurance Programs of outside vendors to insure complianee with project, Code and Regulatory Requirements.
3.3.6*/
Par ticipates in design reviews to assure all quality related informa tion has been included in drawings and specifications and that independent checks have been performed. Issues conunents to project Task Leeders and other cognizant personnel on consecutively numbered NQA directives through the use of a log.
3.3.6.8 Prepares, approves and releases requisitions for sub contracted non-destructive examination services.
3.4 Engineering. Controls Engineering control of design activities and design documents is maintained to assure conformance with the Certified Design Specifications, the Code and Regulatory O
Requirements. 'Ihese controls are maintained by the Project Manager and the Task Leaders and they are monitered and audited by Nuclear Quality Assurance.
3.4.1 Design Coordination - The design is initiated by the transmittal of the following documents by Project Manager Instruction:
Project Specification List Certified Design Specifications Task Authorization Form The design development is coordinated by the distribution of Certified Design Specification, drawings, procedures, analysis, requisitione and releases to all cognizant project personnel and by the review of the design in preplanned Design Review meetings, using written paredui e for conducting a Design Review. A copy of the Certified Design Specifications is released to the QA/QC Supervisor (via work release) who will make it available to the Authorized laspector.
O
fat'etWheelerInergyforp.
Sectioru L.
Energy hypycatluns, Div.
Page11 of18 Rev L.
Dater 5/ML Qualityluurance. Manual p.3 h
3.4.2 DeshnVetification 3.41'.
Drawings and Design Reports shall be subjected to Design Review as a means of verification to assure design adequacy; design conformance with the Code and Regulatory Requirements; and conformance with the Certifini Design Specification. Other design output documents are i
subjected to design review at the discretion of the Project Mana;;er. As part of the review, supporting des.lgn analyses and development testing cavits, when applicabk, are evaluated for correctness and adequacy.
3.4.2.2 Design reviews are planned end schedtded by the Project Mr. nager to support milestones for a specific project that typically includes verification of adequate design definition and capability for release to procure materials, release to manufacture or other milestone design reguliements.
3.4.2.3 The Director of Engineering designates and assigns competent individual (s) to be d esign reviewer (s). Selection is based upon having the necessary qualifications and competence in the areas required as well as
" " ' " ' " ' " " ' ' " " " ' " " ' " " " " " " " " ' ~ " ' ' " " " " ' ' " ' ' ' ' " ' ' '
CiiJ R4 may serve provided he has not made a contribution to the design R4 approach or established the design inputs used in the design and is the R4 only individual in the organization competent to perform the design R4 re dew.
3.4.2.4 Internal Design Reviews are planned and conducted by the Project Manager and the cognizant task leaders. Each design is reviewed for meeting requirements including an evaluation for manufacture. Each reviewer critically reviews the adequacy of the design independent of other reviewers and presents his comments at the Design Review Meeting.
The review shall address the following items, as applicable:
Were the design inputs correctly selected?
a.
t.
Are assumptions necessary to perform the design activity
. adequately described and reasonable? Where necessary,are the
_. ~. _ _ -. _. - _.. _ - _.. _.. _ _ _ _ _ _ _.
Epster Wheeler Energy Corp.
Szcticru )
Energy App!! cations, Div..
Page 12 of 18 Rev. L..
Quality Assurance Manual Daes 5/& 92 l
s 4
v assumptions identified for subsequent reverifications'when the I
. detailed design actiY!tles are Completed?
c.
Was an appropriate design method used?
d.
Were the der 4m inputs correctly in<:orporated into the design?
Is the design output reasonable compared to design inputs?
e.
i f.
Are the necessary design input and verification requirements for..
interfacing organizations specified in the design documents or in' supporting procedures or instructions.
3.4.2.5 Other methods of design verification may be utilized as established by the l
Director of Engineering such as alternate calculations or qualification testing, he method of design verification, if other than design review, shall be stated in the design report.
i 3.4.3 Resign Changea - Design Specification changes are reviewed for acceptability by the cognizant project personnel. Accepted design changes are issued by Project i
Manager Instructions (PMI) with the revised specification, q
Design changes originating within FWEA or the subcontract manufacturer are directed to Mechanical Design for evaluation and acceptance.
l All design changes are shown on the affected dravdngs, reports, and other FWEA documents which are prepared, checked, reviewed, audited and released with I
appropriate revision identification as described herein.
3.4.4 Design Nonconformance;- Material, items and processes that do not conform, to Design Specifica tions, the Code, project d rawings and proced ures when detected are recorded, segregated and dispositioned in accordance with Section 15 of this Manual. Responsibilities of Mechanical Design, Project Management, Quality.
Assurance, and other participating Task Leaders in performing the required i
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Page 13 of 15] Rev. _i_
I DJJtlityls1MIAntt.hlanUAl Date:
5/6/12_
O activities are further defined under applicable paragraphs of this Section.
3.4.5 MaterialTraceability For RVEA fabrication & installation actidties, the Bill of Material which identifies the location where material was used, by part number, provides required traceability.The item part number is listed on Certified Material I
Test Reports. The subcontractor shall identify documentation which prov' des traceability between the CMTR and the location of the materialin the fabricated assembly. This shall be available for review by RVEA.
O O
ENERGY APPLICATIONS Contract No.
FOSTER WIIEELER ENERGY CORP.
Page of Revision-Date PROJECT SPECIFICATION LIST FOR This current List of ASME Codes, Code Addenda, Code Classes, Code Cases, Certified Design Spedfications, First Tier Specification & Standards,is the basis of the Project Design and Construction.
REVISIONS, AUTHORIZATIONS AND APPROVALS Resision No.
Date Project Manager Quality Assurance Rev. Authorization Exhibit: 3.1 Page:
14 of18 Rev.:
4 Date:
5/6/92 l'\\
(-)
em.4,
FAGE OF FOSTER WHEELER ENERGYCORPORA'!10N
- [
ELT;RGY APPLICATIONS DIVISION TASKAUTHORIZATION l
f To:
(TASK !8.ADER)
DATE:
CC:
_ (TASK LEADER'S SUPERVISOR)
CONTRACT NO.:
COST CODE:
REVISION No.:
PROJECT:
TASK DESCRIPTION:
4 (Continue on next page,If necessary) 1 B(JDGET. IIRS TIMEINTERVAL TOTAL DISCIPLINE
.t
- O l
-NOTE: Task Leaders r s not to exceed either total budget or rate of expenditures indicated.
EXHIBIT -
3.2 PAGE 15 0F 18 -
REY.
4 DATE-
% 92 OT11ER COSTS MATERIALS:
.OTHER:
COMPUTER:
REMARKS:
(1) Reproduction to be charged to Cost Code 8810.
(2) Travel te be charged to Cost Code 7300 (each trip requires prior approval by Project Manager).
_ THE FOU.OWING REPORTS WLi.BE REOUIRED:
SIGNED:
APPROVED:
O PROJECT MANAGER DEPARTMENT MANAGER (5158A) a
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O FWEC - ENERGY APPLICATIONS DIV.
i PROJECT MANAGER INSTRUCTIONS Contract No.
PMINo.
Charge No.
Date*
1 Project Manager Page1of To:
Copies:
Subject:
1 O
Exhibit: 3.3
- Page:
16 of18 Rev.:
4 Date:
5/6/92-O F15%41
. =. - _ _
NUCLEAR QUALITY ASSURANCE DIRECTIVE ENERGY APPLICATIONS DIVISION ;
FOSTER WHEELER ENERGY CORP.
PROJECT:
A JCLEAR PERRYVILLE CORPORATE PARK i
CLINTON, NJ 08809 1
CONTRACT:
NO.
JOB #:
DATE:
PAGE:
OF TO:
cc:
j
SUBJECT:
REFERENCE:
O i
6 Exhibit: 3.4 Page:
17 of 18 Rev,:
4 Date:
5/6/92 D. J.Lamvenneyer Mgr., Quality Assurance _
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FWEC Applications. Div.
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Perryville Corporate Park tute ClintodNJ 08SO9-4000 intAupa. un vit(* L ArtsqvAI. DIAu1~
Hochanical Neign (1)
Weluar (3)
Project Owner Drdtoman Checker Design Task letr ileview (2) 5sality Aasur.
Hansger or Ilis Agent
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Dwgs. and as spec 1 fled by the Project Manager or the mechanical Ibstgn Task leader for deta11 dwgs.
Yes for 4
Approve Trt.ntmit
- 2) Design Heview members, approved by ti.e Int rett or of Engineer ing (le)
(L) the project, arv listed belows 5$55 a..rs3: Eg Helease (la)
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- 3) heviows ur.it apprve=s.Jiowings for compliance un th specifica-Lions and signs off those Wiich he agigerovos.
Is)lWA Drawing with Owner er his agent's connants.
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fosicLWheeletIncrgy_Corg S e ti:ru _ L Energy Applications, Div.
Page 1 of 10 Rev._L Quality Asinunce Manual Date: 5/6/92 4.0 PROCUREMENT DOCUMENT CONTRQL INDEX PAGE INDEX 1
4.1 PURPOSE 2
4.2 SCOPE 2
4.3 RESPONSIBILITIES 2
4.4 PURCHASE ORDER REQUIREMENTS 3
R4 4.5 APPROVED VENDORS LIST 6
4.6 VENDOR SUBMITTALS 7
EXLilllIIS Exhibit 4.1 ProcurementRequisition 9
Exhibit 4.2 Purchase O* der 10
EndeWhiclet.EnctgyIorp.
Srctirru
_4_
Juergy Applications, Div.
Page 2_of 10 Rev._f_
Date: 5/6/92 Quality A2surance Manv>J 4.0 PRO _CUREMENT DOCUh1ENT CONTROL 4.1 P.grpsic To establish measures to assure that documents for procurement of materials, items and services are in accorhnce with the Code, Regulatory and contract requirements.
4.2 Stops This section describes the requirements for the preparation, review, approval and use of procurement documents at the Home Office and Work L. ation.
43 Responsibilitics 43.1 Mechanical design, or his designee, is responsible for preparation of procurement requisitions utilizing client specification; and drawings; FWEA drawings and Bill of Materials; the Code, Regulatorj and Contract requireme.ts, p
43.2 Quality Assurance and the Project Manager are responsible for requisition review and approval.
433 Home Office Quality Assurance is responsible fc,r preparation of an Approved Vendors List, and issuing it to Purchasing for use. Purchasing shall utilize the Vendor's list for procurement of Material, Items and Services.
43.4 Quality Assurance is responsible for the approval of vendor submitted drawings, plans and procedures for meeting purchase order, Code and Regulatory requirements.
43.5 Purchasing is responsible for prepara tion of the Purchase Order utilizing the procurement requisition as the specification of technicairequirements.
43.6 Purchasing is responsible for receipt and distribution of vendor submitted documents.
43.7 Purchasing and the Project Manager are responsible for defining the commercial requirements which sre the basis of the purchase order.
Easter Wheeler Enercy_ Corp.
Secti:ru __L Energy Applications, Div.
Page 3 of 10 Rev._4_.
Date: 5/6/92 Quality Assurance Manual O
4.4 Eurchase_OrdetRequirements 4.4.1 The following requirements shall be specified in the procurement requisition and be included in the purchase orders for the material, item or service being procured, as applicable. (See Exhibit 4.1)
(1) ScoperLWork-A complete description of the materials and services required and the quantity, toleranced size (as applicable) item no.,
and item identification including part number shallbe clearly stated.
Each line item to be of the same heat / lot.
F (2) Technical Requirements - A cot ensive description of the technical requirements shall be specihed. Applicable specifications, drawings, procedures design criteria, Regulatory and Code requirements shall be listed or referenced. Document issue date and/or revision as well as the Code issue, Class, Addenda and Applicable Code Case designations shall be clearly stated.
Definitions of ASME Section Il " Basis of Purchase" options (as applicable) and supplementary requirements of ISVEA, Code, and the Owner (client),if any, which do not relax the Code shall also be included.
(3) On nlity Assurance Program Recu1rements - The requirement for the contractor to have, a fully implemented quality assurance system consistent with the Code and the applicability of quality assurance requirements for sub-tier contractors shall be specified. The control, maintenance, and retention of records effecting quality shall also be specified.
(4) Documentation Reauirements - The documentation required ' o be t
submitted for review and approval, including required drawings, plans, procedures (i.e. Welding, NDE, Heat Treatment, Handling, Stora ge, Test, Shipping, Fmal Cleaning, Packaging, etc.), and reports shall be specified.
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Foster Wheeler Enerev Coro.
Secti:n:
._L.
Energy Applications, Div.
Page 4 of 10 Rev. _ 4 Ouality Assurance Manual Date: - 5/6/92
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(5) Access. Insyction and surveillance Provisions - Right of access of customer / client represer tative, FWEA Quality Assurance representative and Authorized Inspector, as applicable, shall be specified. Access is required to permit audit of the Vendor's Quality Assurance Program; perform inspections, and establish hold points.
Requirements for purchaser inspection, witness and hold points as well as notification provisions for selected inspection and test points shall also be specified.
(6) 10CFR Part 21 The applicability of 10CFR Part 21 " Reporting of Defects and Noncompliance" shall be specified along with the-requirements for extension of the provision to sub tier contractors.
(7) CertiRcation Recuirements - The certification documents required for the Material, item or Service being ordered shall be specified. These may include CMTR, Certificates of Compliance /Conformance, non-destructive examination reports, ASME data reports, etc.
Cenification that the supplier or manufacturer of Code Material and services was controlled under his accepted quality system by inclusion of his QSC No. and it's expiration date or if he has no QSC, by his
(
Manual revision and revision date accepted by Energy Applications -
Div. shallbe included.
(8) Sub-Contractor Responsibilities - Description of the responsibilities of the sub-contractor for activities which are a combined effort of FWEA and the sub-contractor.
(9) ElVEA's Requirements for Reporting and Discositioning Non-conformances Description of responsibilities and procedure for repo: ting and dispositioning non-conformar cet.
4.4.2 Requisition Preparation and Approval Requisitions are prepared by Mechanica! Design or his designee (except for NDF services which are prepared by Quality Assurance Manager) l l
' O etssim
- Foster Wheeler Fa.revrarn.
- Sictirru-d_.j Energy Applications, Div.
Page 5 of 10 Rev._.L.;
Ouality Assurance Manual.
L Date: 5/6/92 O
utilizing the Client's specifications and drawings, as defined on the Project _-
Specification List; FWEA drawings, Bills of Material, the Code, and Regulatory requirements. After the requisition has been checked by a -
qualifad indkidual other than the preparer.'for completenesi, and accuracy and all comments have been satisfied, it is forwarded to the L Mechanical Design Task Leader for approval. Final approval requires -
review and approvalby the Project Manager and Quality As urance.-
In cases of urgency, the Project Manager is permitted to review and approve requisitions for other project personnel with the exception of Quality Assurance.
4.4.3 The Project Manager transmits the approved requisition to Purchasing for preparation of the Purchase Order.
4.4.4 Revisions to requisitions shall be prepared, reviewsd, approved and distributed the same as the original issue.
1.4.5 Purchasing shan include the contents of procurement requisition, as-issued by Mechanical Design, in the Purchase Order as the specification-O-
of technical requirements for the Purchase Order.shall describe requirements for commercialitems and terms only (Exhibit 4.2).-
4.4.6 The purchase order is checked by an individual other than the preparer and this is documented on the purchase order by signature and date.
4.4.7 Vendor bids shall be evaluated by the Purchasing Manager who signs and -
dates the Purchase Order. When Vendors take exception to purchase :
order requirements, the exceptions will be resolved with those who are responsible _for establishing _these requirements and~' project documentation shall.be revised as necessary to reflect any.
accommodation of these exceptions.
4.4.8 Purchasing shall place orders with vendors listed on the-Approved Vendor List.
4.4.9 Si>. (6) copies of the Purchase Order are made:
a.
Vendor Copy
-e p-
1 S:ction:._L Eo11er WheeletEnerev Corp, Energy Applications, Div.
Page 6 of 10_ Rev. _ 4 Date: _S/6/92 Qyality Assurance Manual
,/3 U
b.
AcknowledgementCopy c.
Purchase Order File Copy d.
Receiving Department Copy (Receiving Report)
Distribution Copy -Project Mgr.
e.
f.
Accounting DepartmentCopy 4.4.10 The Purchasing Mgr. is responsible for distributing the copies hsted as
- follows, Vendor copy and Acknowledgemeni copy to Vendor, a.
b.
Purchase Order file copy to his purchase order file, Receiving Department copy to the work location receMng the c.
me.erial.
d.
Accounting Department copy to the Accounting Depatment.
Distribution copy to Project Manager.
e.
4.4.11 Purchase Order Change 4.4.11.1 Changes to the purchase order willbe n epan ^ and distributed in the same manner as the original purchase clar.
i 4.4.11.2 A change number is typed on a change order form to indicate the revision to the original order. Purchase Order revisions are consecutively numbered.
4.5
& toved Vendors List 4.5.1 The Approved Vendors List and its revisions are prepared and issued by the Quality Assurance Manager and distributed to Purchasing and the QA/QC Supervisor in person for their use. Copies of the superseded list (s) are collected and destroyed. Additions arc made by issue of the satisfactory Vendor Survey report. Deletions and changes of status are made by revision of the Approved Vendors List on a annual (min.) basis or if vendor status warrants. Vendor additions will be added when Approved Vendor List is revised. The List shallinclude:
(1) Vendor category i.e. Material Manufacturer, Material Supplier, Equipment Manufacturer >, Fabricators, Suppliers of subcontracted senices, etc.
q 0133e 4)
4
~..
Foster Wheeler Enenv Coro.
S:ction: _L.
- Energy Applications, Div. - _
Page 7 of10 Rev. L.
Quality Assurance ManRAI Date: 5/6S2 (2). Scope of Material, item or Service to be provided; i.eu Forgings,-
Machining and Forming Services, Code fabrication, etc.-
.(3) Vendor Name and Plant and Address ofit's location.
(4) ASME Quality System Certifica te No. or Certifica te of Authorization Number. Type (N, NPT, NA, etc.) as applicable, and' expiration dates. For material manufacturers, material suppliers and suppliers -
of services without a QSC, the accepted manual revision and date shall be included.
(5) Status of Approval, whether fully approved or conditionally.
Purchase Orders can only be pla'ced' to conditionally approved -
vendors contingent on the basis of satisfying the conditions of R4 approval. The corrective actions and committments made to satisfy R4 the conditions of approvalshall be fully approved by FWEC Quality -
R4 Assurance prior to actual start of work on the order.
(6) Survey evaluation report number, as applicable.
(7) Limitations,if any.
-(8) Expiration of Audit date.
4.6 Vendor Submittals 4.6.1 Vendor documents including drawings, plans, procedures, sketches, 4
reports, etc. required by Purc%se Order to be submitted to FWEA are received and internally distributed by Purchasing. Purchasing logs the -
documents, including revision or date of issue and distributes copies to
- Quality Assurance, Project Manager and specialist reviewers responsible _
q for document being evaluated; i.e.,; weld procedure - weld engineer;:
drawings-design engineer,etc.
4.6.3 Quality Assurance reviews the submittals, comolidates comments from -
other. reviewers and prepares a Quality Consolidated Comments Report __
4 indicating: Approved, Approved with Comments, and Disapproved =
status for each' document. The report is approved by_ the Quality Assurance Manager or his designee and returned to the Vendor through -
' Purchasing for action and review, as necessary. The reports are reviewed with the Project Manager prior to issue.
O
. -. ~
Foster Wheeler Enerrv C4::
SIction: f _i_, -
Energy Applications, Div,.
Page 8 of 10 Rev. i_. '
Oualltv Assurance Manual Date: 5/6M2J
~
, -p 4.6,4 Documents shall continue to be resubrnitted until " Approved". A final -
list of approved procedures shall be included in the purchase order and used by the vendor to certify compliance to procedures actually used.
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-MATERIAL REQUISITION FWEC - ENERGY-APPLICATIONS DIV.
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5/6/92 ACOM84 Copt.905ect TO ATT Acht0 AcKNOWttDG4'!NT MUST BE $1uNED AND RETURNF.D wtTHIN 10 D AYS ac6.cano.v svacan.no ct*t eG4 P O he nes Ch.
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S:ctign: _L.
Energy Applications,'Div.
Page 1 of 7 - Rev.1 QualigAAAurance Manual Date:
s/&92 O
5.0 INSTRUCTIONS PROCEDURES AND DRAWINGS INDEX PAGE-INDEX 1
5.1 PURPOSE 2
5.2 SCOPE 2
5.3 RESPONSIBILITIES 2
5.4 DRAWINGS 3
55 PROCEDURES 4
5.6 INSTRUCTIONS 4
EXIIIDIIS R3 Exhibit 5,1 -
BillOf Material 6
R3 Exhibit 5.2 ProcessInstruction Sheet 7 --
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Foster V(heelet ncrev Corn.
Section : Ji -
E Energy Applications, Div. -
Page 2 of 7_ Rev.JL Ouality Astutance Manual Date: _5/6/92.
5.0 INSTRUCTION
S. PROCEDURE
S A@ DRAWINGS 5.1 Pmpmc To establish measures to assure that activities affecting quality are prescribed by -
appropriate documented Instructions, Procedures and Drawings.
5.2 Stops his section describes the methods and responsibilities used for preparation, review and approval of Draw'ngs, Procedures and Ins tructions which are required for Code and Regulatory activities.
53 Respanaihilities 53.1 Mechanical Design is responsible for preparation, checking end obtaining all approvals of Drawings established by requirements on the Design Specifications and Drawings.
53.2 he Weld Development Laboratory is responsible for preparation and approval of weld procedures. The weld engineer is responsible for
\\
preparation of weld instructions and obtaining approval from Quality Assurance.
533 The Quality Assurance Manager or his designee is responsible for preparation and approval of NDE, Quality Assurance and QualityControl procedures. Level II or III personnel shall be utilized for the preparation of NDE procedures. LevelIII personnel shall approve NDE procedures.
53.4 Engineeringisresponsibleforpreparationandapprovalof testprocedure.
53.5 Project Mgr., or his designee,is responsible for preparation and approval of process procedures and Process Instruction Sheets.
53.6 Project Manager is respon>ible for issuance o f Project ManagerIns tructions as an internal directive to project teata members for issuing instructions -
and transmitting authorized do:uments.
53.7 Mechanical Design is responsible for the preparation of Work Releases (Exhibit 6-3) which shall be used for transmittal of documents to the work location (s) for the purpose of release and Authorization of work. Work Releases shallbe approved by the Project Manager and Quality Assurance
(
prior to issue.
5155a4)
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Fnater Wheelerfnerav Corn.
Secti:n: ' i_
- Energy Applications, Div..
. Page,3_qfjL Rev.'._3_.
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Quality Assuranceldannal Date:
5/&97_
4 53.8
_ Quality Assurance is responsible for review and approval of Drawings; Process, Weld and Test procedures; Weld Instruction Sheets, and Work i
Releases that are used to transmit documents to the Work Location for the ~
q purpose of release and Authorization of Work. The QA/QC supervisor is "j
responsible for review and approval of Process Instruction Sheets.
53.9 The QA/QC Supervisor is responsible for reviewing Process Instruction :
Sheets, and necessary drawings, procedures and instructions with thC Authorized Inspector so he may designate his hold points prior to issbe.
The ANI willindicate his review by signature and date on the Process Instruction Sheets.
53.10 The originator of each document is responsible to maintain the document and its revisions on file and provide copies to the Project Manager as needed for controlled distribution to the Project (See Section 6 of this-manual, Para.6.6.1).TN Project Manager shall maintain a file of all Project Documentation for Project Records.
5.4 Drawings
'O Q
5.4.1 Drawings necessary for the Task (s) are prepared by Mechanical Design -
and include the arrangements, configurations and details to define the design requirements specified by the applicable client specifications, drawings, standards, etc. listed on the Project Specification List.
N 5.4.2 Drawings shall specify the material specifications, the required non-destructive examinations; the Code or Regulatory item andl weld joint (s) identification, applicable weld procedures; test requirements and any other special procedures i.e., heat treatment, handling, packaging, cleanliness, etc. required. Acceptance criteria for the required inspections and examiations shall be provided on the drawing or included in the referenced procedures.
5.43 A Bill of Material (Exhibit 5-1) is prepared by ' Mechanical Design _for control of the Materials and Items on a given project. It ~ 'shall include alisting of the Material and Items required along with their respective :
assigned part numbers that are - utilized for identification. 'The applicable material type and specification; purchase order;J and -
procurement O
h Secti:n:
_5_.
Easter Wheeler Energy corn.
Energy Applications,Div.
Page 4 of 7 G ev. _3_.
Date: _5/&92_
QumHtv Assurance Manual N
requisition and drawing (as applicable) tabulated for each part, subassembly and assembly shall also be included.
5.4.4 Drawings and Bills of Material shall be reviewed by a checker other than the preparer for accuracy and completeness and forwarded to the Mechanical Design and quality assurance Task Leaders for review and approval. See Section 3 of this Manual for additional requirements applicable for drawings and Specifications prepared for FWEA developed Designs.
L 5.5 frocedurca 5.5.1 Activities affecting quality shallbe prescribed by written procedures and instructions and accomplished in accordance with these documents.
Procedures not available as standard procedures are developed to meet Code, Regulatory and contract requirements and contain appropriate quantitative or qurhtative criteria for satisfactory completion of the prescribed activity.
55.2 Procedures shall be prepared by the party responsible for its operational s
control. Weld procedures by Weld Development Laboratory, in accordance with Section 9 of this Manual; NDE procedures by NDE Engineer who is qualified to SNT-TC-1 A Level II or III requirements in accordance with Section 9 of this Manual; Process and test Procedures by Engineering; Quality Assurance / Quality /ControlproceduresbyQuality Assurance Manager or his designee. General Quality Assurance Procedures (not project specific) and revisions shall be approved and issued by Mgr. of Quality Assurance.
55.3 Procedures when revised shall be revised in their entirety. Each page of the proced ure shallinclud e page number, total pages and revision number.
5.6 Instructions 5.6.1 Project Manager Instructions (Exhibit 3-3) are consecutively numbered formal documents prepared by Project Management to direct project _
activity, transmit information, or transmit authorized documents.
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i' Energy Applications,Div,-
- Page 5 of 7 : Rev._3._E
=
- OumHtv Assurance M2nual.
Date: - 5/&92 L
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5.6.2 ' l>rocess Instruction Sheets shall be prepared by Project Manager, or his designee, to describe the sequence of detail process and inspection steps required to carry out operations at the Work Location (Exhibit 5-2).
Information required includes, as applicable:
1.
Sequence of the operations to be performed.
2.
Contract, project and line information.
3.
Identification of material and component to be used.
4.
Inspection, witness and Hold points required by Quality Control, the Authorized Inspector and the Customer.~
5.
Instructions for performing the operation including the standard, -
drawing and special procedures required, along with space to record q
revisic ns used.
6.
Instructions for heat treatment control.
7.
Reference to welding procedures to be used.
8.
Applicable contract information may be referenced, if necessary.
9.
Tool and equipmentinformation.
- 10.. Inspection and NDE procedure references.
- 11. Acceptance criteria.
12; Spaces for Quality Control inspector's or NDE technician's initials, acceptance stamp or rejection stamp and date, and ANI signature and date, as applicable for prescribed Inspection, Examination and test pofpts.
~
~
5.6.3.
The Process Instruction Sheet shallbreak operations down to step by step _
processes clearly describing the work in logical sequence.
5.6.4 Process Instruction Sheets are i eviewed and approved by Engineering and i
=
QA/QC Supervisor prior to use. Revisions are processed the same as the -
original (s).
5.6'.5 Revision (s) of procedures, standards, drawings, etc. utilized shall be-recorded on the Process Instruction Sheet at the beginning of operation by the operator or his supervisor. Quality Control will verify correct revision used by comparing with the released Master Drawing List and/or Master !
Procedure List at each inspection and doc umented byinspection signature l
and date on the Process Instruction Sheet.
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Eoiter Wheeler Enerev Corpi
. Secti ru fi_
- Energy Applications, Div.
Page 1 of 10 Rev.._3_
Onality Assuranceldanual Date: 5/6M2 e
6.0 DOCUMENT CONTROL INDEX PAGE INDEX 1
6.1 PURPOSE 2
62 SCOPE 2
6.3 DOCUMENT CONTROL 2-6.4 DOCUMENT REVIEW AND APPROVAL 3
65 DOCUMENTSTATUS ANDCONTROL 4
6.6 DOCUMENT DISTRIBUTION AND RELEASE 4
6.7 DOCUMENT REVISIONS 6
6.8 CUENT/CUSTOMERFURNISHEDDESIGN/
6 CONSTRUCTION SPECFICATIONS AND DRAWINGS EXHIBITS R3 Exhibit 6.1 Master Drawing List 7-R3 Exhibit 62 Master Procedure List 8
Exhibit 6.3 Work Release 9-Exhibit 6.4 TransmittalRecord Sheet 10 i
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'l Easter Wheeler Energy Com, Section:
_f_.
Energy App!! cations, Div.
Page2 of10 Rev._1.
Date: _5/6/92 Onllt.v A1MHaar1 Manual v
6.0 DDfUh1ENT CONTROL 6.1 httpose To establish the controls necessary for release of authorized project documents for performance of Construction and Maintenance Tasks in accordance with Code, Regulatory and contract requirements.
6.2 S1991 This section describes the measures established for control, distribution, and release of documents for projects at the Home Office and Work Location (s).
6.3 Document Control The design drawings, specifications, reports, procedures, requisitions and instructions are subject to the following document controls:
6.3.1 Document Markines - Documents are assigned unique identification numbers, and arelogged for record.
O a)
Drawing Numbers (Example 271295-1-150) include the job number (27-1295) and the consecutive number assigned to that single drawing (150). Special drawing numbers that do not conflict with the FWEA system can be used to accommodate the requirements of the client or his Agent.
b)
Requisitions are assigned numbers established for each contract by Mechanical Design by use of a Log. The contract number and the project number (charge number) also appear on the iequisition.
c)
Engineering Reports are assigned document numbers and are-logged for record and reference by Engineering. Design Report numbers (Example: EA-81/4) include the corporate identification (EA), the year issued (81), and a consecutive number assigned that year to that single report (4). The contract number also appears on the Design Report.
O v
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Foster Wheeler Energy Corpa Sectinu fi Energy Applications,Div.
Page 3 of 10 Rev._3_
Date: 5/6/92 Onlity Assurance Manual
]
d)
Project Manager Instructions and Work Releases are consecutively numbered for each project, e)
Procedures (i.e., Cleaning, Identification, Inspection, etc.) are pre assigned numbers by Engineering. Number (Example!
IEN 1000-4?*7) includes the type (IEN-Nuclear), a four dign consecutive number 0000) and project number (4397).
f)
Weld Procedures are assigned numbers by the Weld Development.
Laboratory. The assigned numbers (Example: 8 8-A-20-439?)
includes P-type materials being welded (8-8) weld process being utilized (A SMAW, B GTAW, E-SAW, etc.), a consecutive individually assigned number (20) and project number (4397),
g)
Non destructive Examination Procedures with the exception of Radiography carr* f.ie number of the generic procedure (i.e. PT-2 for liquid penetrant; MT-1 for magnetic particle, etc.) with an addenda number and project number assigned by Quality Assurance for a specific project (eg., PT-2 with Addenda 4-4397).
Radiographic procedures, when used for individual weld joints, are V
assigned a designator to indicate the type weld hint, a consecutive number and project number (Example: CS-4397-02) (CS-Circle seam, 4397 Project Number, and 02-assigned consecutive number).
6.4 Document Review And Approval 6.4.1 FWEA documents and their revisions shall be reviewed in detail for completeness and accuracy by competent _ personnel other than the preparer and subsequently reviewed and approved by _the assigned responsible Task Leader and Quality Assurance. Document details, incomplete or unchecked, are conspicuously marked " Hold" if the document is otherwise noted to be checked.
6.4.2 When customer review and approval is required, the Project Manager transmits the document and obtains his approval. When review and acceptance is required by the Authorized Inspector, Quality Assurance -
will obtain the acceptance. FWEA approvals and authorizations are substantiated by Signature or initials and date of the' approving or
/3 U
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- ~ _.
A E ater Wheeler Enerry Coro.-
Section: _6
- Energy Applications, Div.
- Page 4 of10 Rev._3_
Oualliy Assurance Manual -
- Date:.i!682 =-
N authorizingperson(s) Cystoe-anprovaland AuthorizedInspector(for -
drawings) acceptance are substantiated - / contract documentation (i.e, -
q approved Approval Requests, or other correspondence.)-_
6.5 Dncument. Status And Control 6.5.1
'lle status of drawings and procedures is maintained cunent by the; Mechanical Design Task Leader via the Master Drawing List (Exhibit 6.1),
and the Mast er Procedure List (Exhibit 62).These respectivelylist project drawings and procedures by identification number and current change letter. Updated lists ase issued whenever a change or addition is made.
List distribution is in accordance with the project distribuuon list and i project personnel are individually responsible (c. insuring that their work is based on current drawings and procedures as shown by these master--
lists.
6.5.2 Engineering reports and calculations are issued with identification.
'+
numbers, logged by the Director of Engineering to a controlled distribution established by the Project distribution list. Changes are distributed to holders of the original report and controlled by the; distributionlist.
6.6 Document DistributionAnd Release 6.6.1 hoject Managemeat is responsible for project document distribution. At project inception, a list is prepared to' define the distribution of oocumentation to personnel for the project (see GQ 6.1). Dunng the project, the project documentation shall be distribu ted in accordance with this list. Distribution will-be made to the area where work is being -
performed and shall always include the Project Manager and Qualityf Assurance.
6.6.2 Work Releases (Exhibit 6.3) are' consecutively numbered formal-documents prepared by Mechani al Design to transmit documente to the '
work location (s) for the purpose of release and authorization of work.-
~
Work Releases shall be directed and approved by the Project Manager and apprwed by Quality Assurance prior to issue, h
7
..m-,
Eoster Wheeler _tinttgy.CC.0L Section:
6 Energy Applica' ions, Div, Page 5 of 10 Rev.1, Date: _.516a2._
Quality Assurants Manud l
(V 6.6.3 Drawings, Procedures, Specifications, Master Drawing Lists, Mauer Procedure Lists, and Bills of Material shall be released to a subcontract manufacturer or installer by means of a procurement requisition in accordance with Section 4 of this Manual, 6.6.4 A work package consisting of, but not limited to, the following, as applicable, shall be assembled and distributed by Project Manager or his designee to Operations at the Work location:
1.
Process InstructionSheets 2.
Drawings 3.
Weld Procedurer, and Instruction Sheets,if required 4.
Weld Record Sheet,if required 5.
Procedures and Other Instructions 6.
Master Drawing and Procedure Lists 7.
Transmittal (See Exhibit 6,4) 6.6.5 The work package shall be released and transmitted to the work area by means of consecutively numbered transmittal forms (Exhibit 6.4) with one
'q copy retained by Work Location Quality Control. The transmittal form shall list the work package documents with revision and/or date ofissue v
and accounts for the copies distributed. After distribution has been made, one copy of the transmittal record is returned to the Home Office as verification that distribution of work package documents has been completed.
6.6.6 Documents that are not released may be transmitted by the following forms, as required, to communicate instructions, com ents, etc. during the course of a Project.
a)
Inter-Office Memo b)
Project ManagerInstruction c)
Task LeaderInstruction d)
Nuclear Quality Assurance Directive 6.6.7 Unapproved documents may be distributed internally within the project for design review, comment, etc. purposes, provided they are marked
" Preliminary" with date of issue in large letters or stamp on title page.
" Preliminary" or unreleased documents are strictly forbidden from being distributed to work areas at the Work Location (s).
! O V
l-enss.4
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4 Secti::ru,Jt_ '.. _.
Easter Wheeler Enerry Corp.
i, Energy Applications, Div.
Page 6 of10 Rev.W-j Date: - 5/6/92 O. Quality Assurance Manual
'e 6.7 l'lantment Revisions 6.7.1; Revisions to documents other than drawings shallbe prepared, approved, released and distributed the same as the odginal. Drawing revisions are prepared, approved and dis tributed the same as the original, bu t approval l by.other Task Leaders on the project is limited to those areas of their.
1 responsibility which are affected by the revision. Only current revisions of released documents shall be used for execution of work or opc
- ons.
6.7.2 Minor changes invoking inconsequential editodal corrections or typo.
errors do not require that revised documents receive the same review and :
approval as the original document. Au thority from the Quality Assurance -
Mgr., or designee, shall be obtained to omit such a review and approval..
In such cases, the QA Mgr., or designee's initials and date along with line -
thru changed correction shall appear and indicate minor change approval, 6.7.3 Previously distributed copies of rrleased documents utilized for. Work Location operations that have been superseded shall be collected and destroyed by'QA/QC supervison at the Work Location.' Recall, destruction-and recording of destruction shall be accomplish'ed' and O
documented utilizing the transmittal record sheet (Exhibit 6-4) and 'shall be the responsibility of QA/QC Supen isor.
6.8 Client /CustomerFurnished Design / Construction Specifications And Drawings 6
Review and distribution of customer furnished or specified specifications, Codes, Regula tory requirements, s tand ard s, dra win gs, and other con tra ct d ocuments shall be controlled in accordance with Section 3 of this Manual.~
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FOSTER WHEELER ENERGY CORPORATION ENERGY APPLICATIONS DIVISION MASTER DRAWING LIST MDL-REV. _- D ATED Page of FOR PROJECT Checked By:
Prepared By:
FWEA STATUS LEGEND:
nr = not reviewed a = approved c = comments d = disapprove MDL REV. NOJCurrent Dwg. Rev. Ltr.
WR No.
Drawing No.
Sht 0
1 2
3 4
5 6
7 8
u Drawina Title 5
Exhibit 6.1 Page 7 of10 Rev.
3 Date 5!6/92 eMA-M
FOSTER WHEELER ENERGY CORPORATION ENERGY APPLICATIONS DIVISION MASTER PROCEDURE LIST MPL-REV. ___ - D ATED Page,__of_ _
FOR PROJECT Prepared By:
Checked By:
FWEA STATUS LEGEND:
nr = not reviewed a = approved c = comments d = disapproved MDL REV. NOJCurrent Dwg. Rev. Ltr.
WR No.
Procedure No.
0 1
2 3
4 5
6 7
8 p
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Exhibit 6.2 Page 8 of 10 Rev.
3 Date -
5/6/92 mum
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- Foster Wheeler Energy Corporation
.. pg, ;
Energy Applicatins Division DATE Perryville Corporate Park Cllnton, NJ 08809-4000 -
Page No.
- of TO; Contract No.
Charge No.
l CUSTOMER:
MATERIAL:
DESCRIPTION Exhibit 6.3
.Page 9 of 10 -
Rev.
3 Date:
5/6/92 PREPARED BY:
APPROVED BY:
Mechanical Design
. Quality Assurance
. Project Manager I
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n Eastcr_WheeletEnczgyIogh Secti:n:
- Energy Applications,Div.:
Page 1_of16 Rev. J_
Qualltv Assur 'nce Manual Date: J/(381.
7.0 CONTROL OF PURCHASED ITEMS AND SERVICES INDEX
.EAGE -
INDEX 1
7.1 PURPOSE 2
7.2 SCOPE 2
R3 73 RESPONSIBILITIES 2
7.4 PROCUREMENTPLANNING ANDSOURCE 3
SELECTION AND EVALUATION 7.5 SURVEY EVA',UATION
-3 7.6 SOURCE SURVEILLANCE 6
7.7 VENDOR NONCONFORMANCES 7
O R3 7.8 MATERIAL RELEASE 8
7.9 RECEIVII4GINSPECTION 8
7.10 SUPPLY AND CERTIFICATION OF CODE MATERIAL 11 EXHIBITS Exhibit 7.1 Request And Confirmation -
13; ForI.spection Exhibit 7.2 MaterialStatus/ field 14-InspectionReport Exhibit 73 Nuclear Product Approved 15 Weld Materials List Exhibit 7.4 ReceivingReport 16
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Secti:n:
7 E0Aler Wheeler Energy.Earp, Energy Applications, Div.
Page 2 of 16 Rev. _3 Date:
5/6/92.
Quality hsutanc-Mannal O_
7.0 CONTIlOL OF PURCIIASED ITEMS (,c SERVICES 7.1 Purpose To as=ure purchased material, equipment and services conforra to the Code, Regulatory, and contract requirements as specified by the FWFA Purchase Order.
FWEA shall not use the small product exclusions permitted by NX-2610b.
7.2 Scope This section defines the responsibilities and controls necessary '.o assure that purchased material, items and services meet the purchase order requirements.
73 Resp:msih'liisa.
73.1 Purchasing is responsible for placement of purchase orders for Materials, Items and Services with vendors listed on the Approved Vendor List.
Vendors who do not +ake corrective action requested as a result of noncompliance with Code, Regulatory and/or purchase order requirements are removed from the List as directed by the Quality Assurance Manager. For subcontract activities requiring an ASME p/
Certifica te of Authorization, orders are only placed with AShE Ce: tificate L
Holders.
R3 73.2 Senior Buyer, or designee, is responsible for contact with the vendor for purposes of:
- 0) Establishing corrective action when necessary (2) Arranging Timely procedure submittals and approvals (3) Receiving surveillance and/or inspection notifications 73.3 Quality Assurance is responsible for performing source inspection / surveillance. Results chall be documented in the Field Inspection Report (FIR) (Exhibit 7.2).
73.4 Home Office Quality Assurance is responsible for survey and audit of FWEA vendors who do not hold AShE Quauty System Certificates (Materials) or suppliers of subcontracted services. These vendors shall be audited at a minunum frequency n once per year and resurveyed at a minimum frequency of once eve-
- years.NoncertiEcd vendors not audited or surveyed within the requencyshallberemoved rrom p
G etss.n
15terEhtticIIncigy_Co:p.
Sectioru _2 Energy Applications,Div.
Page Lof_1.6_ Rev. _3.
Quality _Assurancellanual Date:.51(d91 O
v the Approved Vendors List, and resurveyed prior to placement of a I
Purchase C rder. Vendors holding ASME Quality System Certificate or 'N' Certificate of Authorization that have expired shall be removed from the Approved Vendors List.
73.5
!!ome Office Quality Assurance is responsible for audit and survey of ITVEA vendors holding ASME Quality System Certificates or 'N' type Certiticates of Authorization as deemed necessary by the Quality Assurance Manager.
73.6 Purchasing is responsible for transmitting documents to vendors to perr,9t adequate receipt and control of I4VEA supplied Materials and items transferred to vendors for further processing. In such cases, documentation required by the Code, and Regulatory Requirements such as CMTR, inspection reports, purchase order, receiving reports, etc. are transmitted to the Vendor recching the material or items.
73.7 Quality Assurance is responsible for evaluation and approval of Subcontractor B authorized to procure Materials or items,in such cases, the subcontractor's purchase orders shall be approved by 14VEA Quality Assurance Manager prior to the procurement.
73.8 Mechanical Design, or designee, is responsible for specifying that Subcontractor B purchase orders regt.tre 14VEA approval prior to procurement when a subcontractor !ms b~. authorized to procure Materials and items.
7.4 Procutement_Elanning2niSouIcdelecilon AtidEYAlua11on llome Office Quality Assurance shall issist Purchasing h
.e sei t an of procurement sources. Selection shall be nude on the basis of demonstrated capability to provide a consistently Idgh quality product, process, or service in accordance with specified requirements of the Code, and Regulatory Requirements. The prospective vendor shall hold a ASME Quality System Certificate or 'N' type Certificates of Authorization or shallbe surveyed by liome Office Quality Assurance prior to order placement or the Purchase Order shall be contingent upon satisfying audit finding. Acceptable vendors shall be placed on an Approved Vendor's List prepared in accordance with Section 4 of this manual.
7.5 Surtcy_Ev3luation Home 01fice Quality Assurance shall determine the ability of the prospecti.
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I Easter _W.heeletEnergyIorp.
Section: _7 Energy Applications, Div.
Page 4 of16 Rev. 1.
Quality. Assurance M= aunt Date:.5/65t2.
l O
vendor's Quality Program to meet the Code and Regulatory Requirements, ne Vendor Program shall be documented in a Manual and shall rcquire:
7.5.1 Vendor surveys ne FWEA QA Manager shall anange for survey of candidate vendors assigning a lead auditor (Fef. Section 18) to perform the survey.
)
The lead auditor shall designate his audit team which shall consist of qualified auditor (s) and/or lead auditer(s) and prepare an audit plan which shall identify: audit 5 cope, requirements, audit personnel, activities to be audited, organizations to be notified, applicable documents, schedule, and shall provide the audit checklist. Tha audit plan shall include the lead auditor's concurrence that the designated audit team is adequate for performance of the audit. Le audit plan shall be approved by the QA Manager, he audit team performs the survey at the vendor's facility. The lead auditor prepares, signs, and dates the audit report which willinclude the following information as appropriate:
O (a) Description of the audit scope (b) Identificationof theauditors (c) Identification of persons contacted during audit acivities (d) Sununary of audit results, including a statement on the effectiveness of the quality assurance program elements which were audited l
(e) Description of each reported adverse audit finding in sufficient detail to enable corrective action to be (Aen by the audited organization The audit report shall include notification letter (s) for vendor correction of any noted deficiencies The QA Manager approver the audit report.
If the vendor is approved, the QA' Manager adds the vendor to the FWEA l
Approved Vendor List -If deficiencies exist, the QA Manager shall l
forward the deficiency letters to the supplier for correction. Ecsun'ey or -
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Entu. Wheeler.Enctgy Corp.
Sectirru Z
Energy Applications, Div.
Page.Sof 16 Rev.._3_.
QualityJLuurmnee hianual Date:.5&92.
other documented follow up is required to verify correction of the deficiendes prior to vendor approval.
7.5.2 YendorAudits FWEA approved vendors shall be audited at least annually except as provided for in 7.3.5 far Subcontractor A vendors.
The QA Manager shall assign a lead auditor to perform each vendor audit.
The lead auditor shall prepare an audit plan containing the plan information requir<d by paragraph 7.5.1 above. The lead auditor shall select areas to be audited through an evaluation of the vendors performance (DMR's, receiving reports, etc.). He shall document in the audit plan, the basis for selection of the areas to be audited, he audit team conducts the audit in acwrdance with the audit plan and checklist. The lead auditor prepares, signs and dates, an audit report which shallinclude the audit report information requirements "a through e" listed in paragraph 7.5.1 above. The QA Manager shall approve the audit report.
Prior to leaving the vendors facilities, the lead auditor shall obtain the vendor's written proposal of corrective action for any defidencies noted during the audit. De vendor's corrective action shallinclude:
(a) Cause of deficient conditions (b) Actions to correct and prevent reoccurrence of each deficiency.
(c) Schedule for implementation of corrective action.
Unsatisfactory vendor corrective aetion shall result in an immediate "stop work' order from the purchasing manager.
7.5.3 Material Suppliers who perform any functions or operation required by the basic matedal specifications which are not covered in his Quality System Certificate, shall be surveyed, evaluated and qualified in accordance with the requirements of 7.5.1 and 7.52 in this section.
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IoatetWheeletIncrgy Corpa Sectirn: - 7 Energy Applications, Div.
Page 6 o[L6, Rev. L.
Qualliy. Assurance Manual Date:.5/fdl 7.5.4 Survey reports shall be issued to Purchasing indicating approval or if conditionally approved; the corrective actions necessary for approval.
These reports shall be maintained on file as records by llome Office Quality Assurance. The Survey Report and Approved Vendor's List shall indicate the reason for conditional approval. Prior to placement of P.O.,
the Quality Assurance Mgr. shall resolve unacceptable quality conditions.
Upon satisfactory resolution, the vendor status will be upgraded to
" Approved" 7.5.5 When the Quality Assurance Program of a vendor who does not hold an ASME Quality System Certificate or *N" Certificate of Autlwrization has been approved, the vendor shall notify MVEA of proposed revisions to his Quality Assurance program and obtain approval prior to implementa tion. 'Ihis shall be specified in the purchase ord er.' Controlled copies of the Vendor's Quality Assurance Manuals shall be avallable for RVEA review.
7.6 SaurtcJiurycillance 7.6.1 RVEA vendors shall furntsh quality assurance information, documents, records, material samples and other information as specified by the purchase order and the Code. MVEA approval does not relieve the Vendor of his responsibility for meeting specified requirements.
7.6.2 Representatives of MVEA, the Authorized Inspection Agency, und the Customer, or his Agent, shall have access to the vendors plant facilities and equipment for the purpose ofinspecting work and materials.
7.6.3
'Ihe Quality Assurance Manager or his designee shall assign Field QC Engineers or other qualified specialists to perform source surveillance or evaluation as notified by or requested by Purchasing.
7.6.4 Source surveillance implementation shall include consideration of the complexity, and quality of items being procured and shall provide a means for determining the effectiveness of the vendor's quality program.
7.6.5 Source surveillance and inspection may be minimized when the quality of an item can be verified to conform to specifications or drawings by review of certified test reports or inspection upon receipt. The Quality Assurance Manager or QA/QC Supervisor shall provide documented notice when source surveillance is waived. (See Exhibit 7.1) The affected O
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. I InsicLWheclerIncagy_Com.
Secti:su _2 l
Energy Applications, Div.
Page 'Lo116. Rev.
l.,
l Qua11tyhurance Mmanal Date:
5/fd2.
O vendor shall be notified of the waived condition and a copy of the documentation shall be taaintainM by Purchasing in the app!! cable purchase order file. Source surveillance shall not eliminate the l
requirement for receiving inspection.
i i
7.6.6 The following classes of materials and services are subject to source inspection:
(a) Codeitems or material; (b) Subcontracted fabrication and installation; (c) Materials, fabrications, or parts shipped directly to work locations; I
(d) Subcontracted NDE and tests, i
7.6.7 During the course of a procurement, the Quality Assurance Manager may assign personnel to the Vendor's faciltites to check, examine or witness the receiving, processing, examination and testing of material or items at
(
R2 any stage to assure the vendor's conformance to committed Code, Regulatory and Qut11ty Assurance requirements.
7.6.8 Areas of vendor non conformance will be brought to the vendor's l'
attention by Quality Assurance through Purchasing.
i 7.7 Yendor.Non:Conformance.
7.7.1 Non<onformances detected by the Field QC Engineer are documented on a Material Status / Field Ir.spection Report (Exhibit 7.2) which is issued to the vendor (with copies distributed as indicated on the form).
7.7.2 -
In addition, the field QC engineer shall report the nonconformity directly l
R3 (verbally) to Home Office Quality Assurance or Project Manager who will prepare a DMR and transmit its number and if available,its disposition.
back to him for inclusion in the Material Status / Field Inspection Report, 7.7.2.1 Vender DMRs shall be piocessed in accordance with the.
requirements of Section 15 of this Manual, and transmitted by R3 Home Office Quality Assurance or Pro}ect Manager to the vendor for appropriate action.
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Secti:m
_2_
i Energy Applications,Div.
Page 8 of16 Rev. _1_
Quality AasurancrE==1 Date:.5/W92.
l O
7.7.2.2
'Ihe completed DMR with its disposition shall be maintained by R3 Quality Assurance as a record and sent to the applicable area (Home Office or Work location) to be included in the records -
documentation package. Material shall not be accepted if it fails to conform to the Code, Regulatory or design requirements.
1 R3 7.7.2.3 Non-conformance detected by the vendor and reported to Quality Assurance shall also be recorded on a DMR.'Ihe DMR j
R3 shall be prepared by Quality Assurance and processed per Par agraph 7.7.2.l and 7.7.2.2 above.
i 7.8 Malcrialliclease 7.8.1 Acceptable material will be released for shipment using Material Status / Field Inspection Report (Exhibit 7.2). Released material that has been source inspected shall be receipt inspected at the work location for shipping damage, identifi:ation, and documentation requhements.
7.8.2 Source inspection may be waived by the Quality Assurance Manager when the facility (vendor or work location) receiving the materia or item has been shown by audit to have an acceptable receipt inspection-capability.
7.9 Recclying. Inspection. -
7.9.1 Rescomibilitics 7.9.1.1 Tlu Project Manager shallbe responsible for receipt of material at the work location and completing the Receiving Report to account for the material received.
7.9.1.2 The QA/QC Supervisor shall be responsible for receipt inspection of Material and Items in accordance with requirements stated in the purchase order. Inspection stall be
. performed in accordance with written receiving inspection checklist. (Exhibit 81).
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foatcr.WheeletIncigy. Corp.
Secti:ru
_2.,.
Energy Applications, Div.
Page tof_1(L Rev 3 Quality.AasuranccAianual Date:.5/6/92.
7.9.1.3 Engineering shall be responsible for making receipt inspection an operation on the Process Instruction Sheets, providing spaces for Inspection and the Authorized Inspector, a s necessary, to sign or stamp off and date.
7.9.1.4 The QA/QC Supervisor shall be responsible for documenting acceptable welding materials m the Acceptable Nuclear Weld Materials Status Report indicating any restrictions to their use singularly or in combination with other materials and issuing it for use (Edibit 7.3).
7.9.1.5 Mechanical Design shall be responsible for issuing process instructions to the Welding Engineer for qualification testing of untested combinations of wire and flux and other welding material and issuing instructions for the qualification required.
"9.1.6 The QA/QC Supervisor shall be responsible for indicating inspection status of Materials or Items (" accept", " hold", or
" reject"). Color codes by painting or tagging are used to indicate receipt inspection status. Colors are green for " accept", yellow for " hold", and red for " reject".
7.9.1.7 The Quality Assurance Manager shall be responsible for the transmittal of inspection reports for FWEA materials shipped directly to a subcontracted Manufacturer or Installer The subcontracted Manufacturer or Installer shall verify that the material meets the requirunents of the FWEA purchase order and was not damaged in shipment. Damage shall be considered a nonconformance.
7.9.1.8 When FWEA receives customer supplied matedal for use, pertinent Code information such as Certified Material Test Reports, Inspection Reports, Purcha:e Orders, or other information shall be provided to FWEA by the customer to permit adequate receipt and control.This documentation willbe provided by the Project Manager. For Code work, the customer shall be surveyed and audiSd and put on the approved vendor's
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fosicr_Whec1stEnergy_ Corp.
Secthru J__
Energy Applications,Div.
Page 10 of16 Rev.,_3_,
Quality _Aasurancelianual Date:.5/fdl.
O list. When the customer is a "N" Certificate Holder, he may supply matenal for his own work without FWEA survey and audit.
7.9.2 Requirementy 7.9.2.1 The Work location material man verifies cuantity vsing a Receiving Report,(Exhibit 7.4), to account for a 1 purchase order items received.
7.9.2.2 Using the drawing, as applicable, and a receiving Inspection Check List, (Exhibit 8.1), work location Quality Control personnel, as a minimum, shall inspect for:
Shipping damage a.
- b. Identificationmarking 7.9.2.3 The QA/QC Supervisor or designee shall review Certified Material Test Reports or Certification of Compliance, as applicable, for compliance with the Purchase Order, Code, R egula tory, and M a terial Specifica tion Requiremen ts and record results on the receiving inspection check list.
7.9.2.4 Work location Quality Control personne1 shall indicate inspection status (" accept" or " reject") and shall sign or stamp off and date the Process Instruction Sheets as acceptable before the Material and Item is released for st.bsequent operations.
7.9.2.5 The QA/QC Supervisor shall providc the Authorized Inspector the opportunity to inspect the material or item and verify that the cutification records conform to the Code, Regulatory, and Purchase Order Requirements. He is also responsible for submitting certified reports of the results of all required tests and examinations performed in accordance with material specifications and the requirements of the appilcable material articles of the Code to the Authorized Inspector.
7.9.3 Nonconformances
All materials reaching the work tocation and found to be defective and not already rejected and-documented by the Field QC Engineer per Paragraph 7.7 above shall be rejected and a DMR processed in accorda nce with Section 15 of this Manual.
O
EasterWhccletIncrgy.. Corp.
Secti:ru 7
Energy Applications,Div.
Page 11 of 16 Rev. L Quality _AssuranceAianual Date:.5/6/92.
O 7.10 IJpgtadcmLCudeStockhlatedal 7.10.1 Code Material u pgraded from stock material puduced by a manufacturer who does not have a quality system program meeting the requirements of the Code may be supplied by RVEA with the following provisions:
A.
Certification from the stock material manufacturer certifying to the following be obtamed:
1.
Material specification requirements specified for melting.
2.
Ileat analysis requirements.
3.
No welding had been performed on the material.
B.
RVEA performs or subcontracts all requirements of the Material Specification on each piece of stock material. Alternately, RVEA may perfonn or subcontract all other requirements of the material specification on each heat and tot of material provided t iceability has been established at the Stock Material Manufacturer,'oy RVEA Suney and Audit.
O C.
RVEA shall perform a subcontract product analysis to verify the product composition of each piece of stock material.
7.10.2 Mechanical Design determines what tests are required for the stock material after reviewing the material specification and the special requirements of the Code. This information is issued as a Requisition to Purchasing for the performar.cc of tests.
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1 Easter. Wheeler Enczgy_Cp Sectitsu 7
Energy Applications, Div.
Page 12 of16 Rev. L.
Dumiltv Assurance Manual Date:
5/& 92
]
7.10.3 Mechanical Design shall issue a Material Requisition for tlie stock material whichincludes:
a)
Requb ed stock manufacturers certification for the requirements of.
the material specification widch must be done during the melting I
process and of the heat analyt.is, b)
Required certification that no welding was performed on the stock material.
7.10.4 The above Material Requisitions shall be approved by Quality Assurance to verify compliance to the material specification.
7.10.5 Quality Assurance will prepare CMTR's which contain the FWEA Certificate of Authorization Number with its expiration date.FWEA shall furnish this CMTR with stock material manufacturers certification as listed in 7.103 above and the data from subcontractors performing tests, examinations and trea tments with the material supplied identified to each piece.
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C ONF1RM ATION Exhibit 71 Page 13 of 16 REQUEST FOR INSPECTION Rey,3 Date: 5/6/92 (1)
TO; MAN AGER - QUALITY CONTROL DEPARTM ENT DATE P.O. NO.
CONTRACT NO.
VENDOR ADDRFE6 MATERIAL TO llE INSPECTED REQUIRED SHIPMENT DATE OFINSPECTION TYPE OFINSPECTION INSPECTION AT REFERENCE NO.
(2)
INSPECTION YES O NO O INSPECIOR INSPECTION DATE PER DATE NOTE:
I (1)
Info to be supplied by Purchasing (2)
Response from Q.C.
Purchasing Department Equipment Division O
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ENERGY APPLICATIONS DIVISION Exhibit 7 2 FOSTER WiiEELER ENERGY CORPORATION Page 14 of 16 ReV. 3 MATERIAL STATUS / FIELD INSPECTION REPORT NO.
- Date: 5/6/92 DATE OF REPORT 1.
VENDOR __
DATE OF VIStr 2.
IM PURCILASE ORDER NO.
LATESTCHANGE NO.
3.
PART NAME MATERIAL 4.
PART IDENTIFICATION
_ HEAT NO.
SERIAL NO.
5.
INSPECTION PERIORMED ( ) OR WTTNESSED(
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LNSPICTION DRAWINGS, PROCTDURf $, RUTRENCE DOCUMDIT (INCE RIVJ ACCiff RQtCT DOCUMENTATION NOTT; CorY,OF DOCUMINT A110N AVAll.A Dt.1 FROM PURC11 AEINC 6.
ETESULTSOFINSPECTION:
( )
ACCEITED, VENDOR TO SIIIP AS DIRECID BY FW CORP. PURCilASE ORDER O\\
( )
ACCEITED SUBJECT 10 CONDITIONS INDICATED ON ATTAOIMDC OR BEIDW
( )
RE}ECTED SEE ATTAGIMDfT OR COMMDITS BEIDW IOR DETAILS
( )
PARTIAL RIJECT, SHIP TTIMS INDICATED
(
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llOLD MATERIAL IOR IURTIIER INTORMATION, SEE ATT ACi tMDIIS OR COMMENTS }OR DETAll.S
(
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GDIER COMMENTS:
SIGNED 7.
DISIOSmON OFMATERIAL:
REFERENCE DMk REJECT-NOT USEABLE DY IOSTER W1IEELER CORP. SIGNED VENDOR IS NOTTO SIIIP REWOFX ACCORDINGTOINSTRUCTIONSOF ATTACliMENT DEIT.
ACCEPT AS IS(COMMENTON ATTAOIMENT)
DEIT.
8.
ADDITIONALCOMMENTS ATTA IED; YES._ NO_ (TOR RESULTS SEE ATTAOIMENT) 9.
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Section:.JL.
Energy Applications,Div.
Page LelZ Rev.._2_.
Qualliy.Assurvice_hianual Date: 12n4/90 8.0 IDENTIELCATION AND_CONTitOL OFITfhiS INDIX EAGE R2 INDEX 1
8.1 PURPOSE 2
8.2 SCOPE 2
8.3 IDENTIFICATION REQUIREMENTS 2
8.4 CONTROL OF MATERIALS AND ITEM IDENTIFICATION 2
8.5 WELD MATERIAI.S 4
8.6 CONTROL OF SUBCONTRACTORS 5
EXHIBIT 8.1 ReceivingInspection Check Liu 7
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EastLWatrier.Intigy_ Corp, Section:
fL.
Energy Applications, Div.
Page2.offl Rev.1.
Qualitylasurance Manual Date: 12/1 M 0 8.0 IDENTIFICATION AND CONTROL OFITEMS l
S.1 Birpnic.
To assure that the identification of Materials and items are controlled throughout R2 procurement and operations ht accordance with Code, Regulatory and Contract requirements.
8.2 Stoss.
R2 This section describes the requirements for the identification and control of Materials and Items so positive traceabMy is maintained throughout construction and maintenance tasks.
83 IdentificatinnRequhements 83.1 Mechanical Design is responsible for assigning part numbers to materials and items on Drawings and/ or Bills of Materials.
83.2 Individual Items, including weld materials, shall be assigned part numbers and when combined with contract project number, provide a Os unique serial number that is utilized for identification. Dash numbers, i.e,
-1, 2, etc. are added to serialize multiple items that have the same part number-project number combination. Welds are Yentified by a general type designator;i.e., C-Circle seam; L-Long seam, A Attachment, etc.,in combination with an assigned indMdual consecutive number (A-10, C-5, etc.).
833 Part and Project Numbers shall be specified in the Procurement Requisition for the Material (s) of Cons truction so that delivered items have positive traceability to applicable CMTR, standards and heat / batch or lot.
R2 Part number and Project Number are to be listed on the CMTR coaesponding to the heat number. 'Ihis identification shall be maintained throughout subsequent operations by physical markings. -
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Inster.WheelerIncrgy_Com secti:ru,JL Energy Applications, Div.
PageLoll Rev. _2 1
QualityMutance Manual Date: 12/MSQ
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83.4 Markings shall be utilized to maintain positive traceability. Either low stre,s die stamp or electrochemical etch markings or other methods slall le used in areas that will not interfere with the functional or quality aspects of the items in locations shown on the drawing. When the size of material or item precludes physical marking, identification shall be labeled or tagged. Weld materials shall be labelled or tagged. Tags exposed to the weather shall be weather resistant;i.e., metallic tags or j
enclosed in plastic to preclude loss of identification.
83.5 Customer furnished material or iteins for which FWEA is responsible shall be identified and controlled in accordance with tids section of the manual.
83.6
~Ihe identification shall be maintained on the Process Instruction Sheets traceable to Material or item (s) throughout operations. Identification markings shall be controlled to assure traceability is maintained.
83.7 When material is to be divided, the material identification shall be transfened prior to dividing, and verified by Quality Control, who signs and dates the Process Instruction Sheet.
8.4 Controlmihiatedal andltemldentification 8.4.1 Materials and items shallbe receiptinspected to requirements of a Receipt Inspection Checklist (Exhibit 8.1) in accordance with Section 7 of this Manual.*Dds shall verify:
(1) The correct markings and identification; (2) Certifications (i.e., CMTR's and COC's) are properly identified and provide traceability to material heat and/or lot numbers, when required by Code. Weld wire and flux combinations shall be traceable to the heat / lot nurnber of the combination.
8.4.2 Acceptable Material and items shall be coded with Green tag or tape and ProcessInstruction Sheet stamped or signed off and dated by Inspection O'
O n..
I
foalcLWhtclerIncIgy. Corp.
Sectinu L
Energy Applications, Div.
Pageig[.2 Rev._L QualityhutanccA1Anual Date: 12(1M0 to release for Work Operations. Material and items are stored, when not being processed,in a suitable protected designated dry, clean, Storage Area.
8.4.3 Non conforming Materials shallbe coded with Red Tagoridentified with hard red copy of the DMR. Controls for the5e materials shall be in accordance with Section 15 of this Manual.
8.4,4 Material on "llold" because of documentation, sample, or testing deficiencies shall be coded with Yellow Tag or tape and remain in the designated area until cleared.
8.4.5 1 der.tification that is unsubstantiated shall be processed as a nonconformance in accordance with Section 15 of this Manual.
8.5 Weld.Maierial.
8.5.1 Only acceptable weld materials tha t have been receipt inspected and listed on the acceptable Nuclear Weld Material Status Report (Exhibit 7 3)in accordance with Section 7 of this Manual shall be used for welding.Each packa ge shallbe clearly identified as to type, size, grade and classification, O
applicable specification, heat and /or lot number, and vendor.
8.5.2 Customer furnished Materials are receipt inspected in accordance with R2 Section 7 of this Manual for meeting the Code, Regulatory, and contract requirements and re-identified as required by 8.3.2, if necessary, by Quality Control to the requirements of this section prior to use.
8.5.3 Weld Materials shallbe stored in a clean, dry designated Storage Area that is temperature controlled. Low Ilydrogen electrodes are only stored in hermetically sealed containers or in controlled rod ovens, labelled with type, size and heat number. A temperature of not less than 2507 but not more than 3507 is to be maintained in the rod oven.
O l
e
fristetWheeletIncigyroxp.
Sectiom.JL Energy Applications,Div.
Page}fp12 Hev._2 i
QualityJiasurance.hianual Dste: 12/1160 O
87).4 Weld Materials shall only be issued upon written request (procedure) f from the weld foreman. 'Ihe request shall indude the type, size, heat or lot number,}ob identification, and quantity of material issued, as well as, the welder receiving the materials, and be documented. The approved Weld Material List (Exhibit 7.3)is used in the preparation of the request.
Records are maintained to account for all materialissued and to verify the identification of any returned materials.
8.5.5 Only one heat and /or lot, of each type weld material shall be issued to a welder at a time. Welders may be issued both bare wire and electrodes of type and material spedfication corresponding to the same matedal l
desification. Quantitles of electrodes shall be limited to the amount required for a shift's work tmless covered ekcrcxies are issued in suitably calibrated portable ovens. Ifissued in portable ovens, weld material heat or lot number and size shall be labelled or tagged on the outside of the oven.
8.5.6 Only flux from a lot qualified for use with a specified heat or lot of weld wire as indicated on Axeptable Material List shall be issued.
8.5.7 Unused weld materials shall be returned to the issue area by the welder at the end of each shift. Retumed n 'crials shall be checked by the supervisor in control of the area for traceability and positive identifica tion.
8.6 ContratoLSubcontractors.
R2 8.6.1 Subcontractor D organizations are required to identify and control R2 Materials and items to meet Code, Regulatory, and contract rquirements.-
R2 When Subcontractor B is required to process or supply Materials or items, Mechanical Design shall specify in the applicable procuremen t requisition that a marking and traceability procedure is required to be submitted for FWEA approval prior to use. This procedure describes the marking and traceability requirements and assures that acceptable and correct Material -
er Items are utilized.
7..
featcLWheeler EncIgy Cogh Stxtioru.JL Energy Applications,Div.
Pagef.pfl Rev. 1.
i l
QualityAnulanr.cldanval Date: 12/200 e
k 8.6.2 PnudureReviemandAppicyal Submitted procedures are reviewed by Quality Assurance and engineering, as necessary, and those found acceptable, approved for use.
The procedures are scrutinized for meeting Code and contrael tequirements for:
(a) Maintenance of identification and traceability of materials and components for receipt throughout fabrication and processing i
including storage and packaging for shipment. Transfer or traceability of identification is required to be contrdled and maintained during all operations.
(b) Items being identified for traceability to applicable material certifications.
(c) Documentation of individual items such that similar items in different lots or ba tches are readily dis tinguished elther by marldngs on the item (s) supplied and by documentation traceable to the Item (s).
(d) Completion and maintenance of material certification records.
(e) Verification of Material markings, as received, to provide assurance of positive identification prior to release for manufacture.
(f) Items not identified are reported and controlled as non-conformance materials.
O
EXHI817 8a1 N D4XN APPLICATICE3, DJ V.
1.F.N. 100-5047 73cg7 og 7 Rtetiv!N; 11:$ 710710'4 CMI J 1.1,57 I
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DAtt 12/14/90 TOR F.C. No.
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NO. DE*S i
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Title Pare Rei.s.r-section 1.0 MATERIAL RICI:'.**SC 1
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1.1 Purchase Order :sformation 1
1.2 cameral 1
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1.3 Marka.=g 1
1.4 Archive 6 Oversteck Samples 1
1.3 Remarks 2.0 MATIR1A1. TEST RDOR; 2
2.1 Ceneral 2
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2.2 Melting Practice
)
2.3 Chemis tr7 2
2.6 Metallographic lxa=tnatten j-2.3 Best-Traatsent 3
2.6 Mechanical Fr:perties 3
4
~ ;
2.7 Hydrostatit ' Test Requirements 2.8 Archive 6 Overe.eck Specimen 4
2.9 Miscellaneous Destructtve & Veld Tests 2.10 Hon-Destrucuve Tests 5
- 2. 7.1 Miseeilaneous 3
2.12 R ema r's.s 3
J 3.0 MATERI.AL INS?EC 0N 3.1 lasic Data 6
t 3.2 Genera.1 6
h
-3.3 Df.mansional 7
3.4
- Rema rks y
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4 4
L fo11ct1YhedetEnergy_Com.
Srcti:ru 9
linergy Applications, Div.
Page 1 of itLRev._2_
.QRAlltyA1Autancellahual Date: 12aEiK1 c
9.0 CONTROL _OF SPECIALEW. CESSES INIlEX l
PAGE R2 INDEX 1
9.1 PURPOSE 2
9.2 SCOPE 2
9.3 WELDING CONTROL 2
9.4 HEATTRFATMENT 8
9.5 NON DESTRUCTIVE EXAMINATION 9
9.6 OTHER SPECIAL PROCESSES 13 EX1111!IIS Exhibit 9.1 Weld Joint Record 14 Exhibit 9.2 WeldingInstruction Sheet 15 Exhibit 9.3 Weld Instruction Sheet Notes 16 Exhibit 9.4 Welder and Weld Operator Qualification Record 17-Exhibit 9.5 Operator Qualifications 18
~
O 0151a *)
Section:
_9
[01ttLWhtclulinergy_ Corp, Energy Applications, Div.
PagelplifLRev. _L.
Date: 12dLH Qualitylsinianct. Manual 9.0 CONIBQL OF SPECI AlflLQCLSSIS.
9d Purpose To establish measures for the control of welding, heat treatment, non destructive examination and other special processes to assure that only qualified personnel and qualified procedures under suitable conditions are utilized in accordance with R2 Code, Regulatory and contr act requirements.
9.2 S. cops.
This section describes the requirements provided to control welding, heat treatment, non destructive examination, bending and forming and other spedal processes, at a Work Location, during manufacturing, or at installation.
9.3 W_cidingf.qnimi 9.3.1 Weldflanning (a) The Design Engineer determines what items should be joined by welding and obtains welding process and weld joint O
recommendations, as necessary, from the Weld Engineer.
(b) Engineering includes the selected welding procedures and }aint styles on detail drawings.
9.3.2 Weld prncedute The Weld Engineer is responsible for:
(a) Providing a formal welding proced ure describing the methods to be used in obtaining the required weld including the essential, non-essential and supplemental essential variables, prescribed by the Code.
R2 (b) Qualifying the wela procedure in accordance with ASME Sections III and IX; supervising the preparation of the test specimen and documenting the qualification parameters and test results on the Procedure Qualification Record; and certifying of the Procedure Qualification Record.
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, _.. _ ~,
TssletEhtclcLEncigy_ Cup, Srcti:ru
_S_
Energy Applications,Div.
PageJSL]i_Rev. _L Q1tality.Aawrance.hianu21 Date: 12/1 0 0 (c) Defining the parameters critical to the performan:e of quality welding; (d) Assuring that the. Authorized. 4spector has the opportunity to witness procedure qualifications and test.
9.3.3 1 Veld Procedure AppInal (a) Customer approval of the weld procedure, if required by the contract, shall be obtained by the Project Managen Approved procedures are released for processing in accordance with Section 6 of this Manual.
(b) Quality Assurance submits procedures and Qualification records to the Authorized Inspector for review and acceptance.
1 R2 (c) Weld Procedures submitted by Subcontractor A for manufacturing R2 and installation of Code items and Subcontractor B for safety related R2 items shall be reviewed e.nd approved by the weld Engineer and R2 Quality Assurance prior to use.
9.3.4 lyciding Ooerations The Manager of Work Location Manufacturina or Construction is responsible for:
R2 (1) Qualification of Welders and Welder Operators including R2 supervision of the Welders and Welder Operator's preparation of R2 the test specimen and arrangement of the required testing of the R2 specimen.
R2 (2) Documentation of the Welder and Welder Operator qualification R2 parameters and test results on the WPQR (QW 484) and certification R2 of the Welder / Welder Operator qualification.
R2 (3) Utilization of only qualified welders, procedures, material and weld materials for welding operations.
R2 (4) Assurance that the Authorized Inspector has the opportunity to witness welder qualification and tests.
5151a4)
EnAledheelcIInuev Corp, S:cti:ru t_
Energy Applications, Div.
PageloLifL.Rev. _1_
O.ualliy_AnturanceManual Date: 12/100 g
R2 (5) Assigning and supervising c ualified welders and welding operators i
for welding u sing the WPQR (QW484) and the Qualified Welder and Welding Operator list.
R2 (6) Ensuring that welding procedures / instructions are readily available, understood and followed by the welders and welding operators.
R2 (7) Maintaining the qualified Welder / Welder Operator list and R2 updating it monthly (Exhibit 9.4)ldentifying the welding processes used by the Welder or Welder Operator in the preceeding month.
The criteria for maintenance of the qualifications are as follows:
a)
The Welder must have used the process within the last 3 months.
b)
The qualification may be extended for an additional 90 day period if a welder has been welding with another process.
R2 c)
If the welder has not welded in any process for tluce months, R2 all qualifications lapse including those extended by (b) above.
Requ alification shall be in accordance with QW322 of ASME Section IX.
R2 (8) ne Manager of Manufacturing and Construction issues Welder Identification Stamps to qualified Welders / Welder Operators and maintains a log of the issue. If the Welder / Welder Operator is tenninated or reassigned to a non welding function, the stamps are retrieved and not reassigned for at least 6 months.
9.3.5 Weld OualigAssurance /Ouality Control (a) The QA/QC supervisor will assign qualified inspectors to ensure R2 that welding conforms with the applicable Code, Regulatory, and R2 specification requirements.
(b) Inspector shall perform specified inspections to insure product
- quality, b
o em.e 1
~v----
,e,
f2sicI_ Wheeler.Incity Corp.
S:cti:n:
L.
Energy Applications,Div.
Page 5 of 1LRev..l QualityAullunte.h!Amtal Datet lataQ O
R2 (c) The Weld Engineer shall prepare weld instructions, as necessary, to assure weld operations conform with the parameters and quality level established by the required weld procedure. Weld instructions shall be approved by the QA/QC Supervisor. (Exhibit 9.2).
9.3.6 Eeld Materialdt.Munibilitica (a) Mechanical Design is responsible for preparing the procurement R2 specification for the weld material (s)in accordance with para 4.4.
(b) Quality Control as part of Receiving Inspection is responsible for ensuring that required qualifications have been performed on weld materials; will notify engineering for performance of qualifications for materials which have been received untested or need additional qualifications. (See Paragraph 7.9.1.5) 9.3.7 Wcld Practice Requit.cments (a) Processes used for weldingCode items are limited to those specified R2 by the Code ca pable of producing welds in accord ance with the Weld R2 Procedure Qualification regrirements specified by the Code.
(b) Weld Materials utilized shall be controlled, stored and distributed in accordance with Section 8 of this Manual.
(c) Work shall be protected from contamination, rain, snow, and wind during welding Welding shall not be performed on wet surfaces.
(d) Weld joints shall be fitted, aligned and retained in position by clamps, Jacks, tack welds, temporary attachments or other appropriate means within the tolerance specified on the drawing, or weld procedure.
(e) Tack welds and temporary attachments shall be welded utilizing R2 qualified welders and' weld procedures,and specified on the Process R2
, Instruetion Sheet.
f O
i fmler Wherletfnergy.Cupa S:cttrn: _jt._
Energy Applications, Div.
Pagei oL1(__ Rev..L Owlity_Aumnre Manual Date: 12/1430 i
O (O
Applicable preheat, inter pass and post weld heat treatment requirements shall be implemented in accordance with weld l
procedare requirements.
9.3.8 Wsiding Records R2 (a) Manager of Manufacturing or Construction shall maintain WPQRS R2 qualification for welders and welding operators qualifications, including reference to the qualified weld procedures and process
- utilized, d
(b) Consumed weld materials for each weld joint or cladding weld shall R2 be recorded on a weld joint record or weld map. The welding supenisor shall record the type, size, heat or lot number of weld material utilized at the time of issuanc'. The map shall airo include welder identification; weld procedure / revision; and weld identification that will be recordeu by the welder. The record is reviewed and approved by the welding Supervisor / Manager and Weld Engineer. Following approval, the rec s shallbemaintained as Quality records and made availa!
mn request, to the Authorized Inspector. (See Exhibit 91).
(c) Weld procedures / instructions shall be kept on file as records by tlie Weld Engineer. Current procedures 11sted on the Master Procedure List shall be maintained.
9.3.9
} Veld Rep 2it Weld repair shallb performed in accordance with instructions contained on the Process Instruction Sheet. Weld repairs are authorized by disposition of the DMR per Section 15. For weld repair of base metals sxceeding the depth of thelesser of 3/8" or 10% of the section thickness a weld map shall be prepared by the QA/QC Supervisor. The Weld Map shril includelocation and size of the prepared cavity, the welding material identification, the welding procedure, the heat treatment and the examination results.
O v
em.e.
f.nstetlYhecletIntrgyJCorp2 S:cti:ru L
Energy Applications, Div.
Page f_of_1LRev._2.
QMAlltyA&ERIARCAManual Date: 12/14/90 43.10 SubcontracuYrdding RVE \\ may engage individuals by contract for their services as welders or welding operator at the Work Location provided the following requirements are met:
A.
Le work to be done by welders and welding operators is witMn the scope of the FWEA Certificate of Authorization.
D.
RVEA approved welding procedures qualified by RVEA are used.
C.
FWEA has qualified the welders and welding operators.
D.
The QA/QC Supervisor has the responsibility for quality surveillance of the welding operations.
E.
De Manager of Mfg., Construction or Maintenance has contractual and tecimical centrol of the welding operations,induding authority to assign or remove welders and welding operators.
F.
De ANIS of the Authorized Inspection Agency has accepted the 7m actual program joo control of the welding performed by the welders and welding c,perators.
C.
RVEA is responsible for Code compliance of the completed item or installation and the data report being properly executed and countersigned by the AI, including Code stampingif required by the Code and contract.
Q V
0131a 8)
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- 4a-
settion:
9 Micr_ Wheeler Encigyrorpa Energy Applications,Div.
Page 8 of 18 Rev.._2_
Date: 12/14/90 Quality Assurance Manual 9.4 11 cat Treatrnent 9.4.1 b eening R2 (a) Heat Trea ting shall only be performed in ten 2ture recording and R2 surveyed furnaces or with thermocouples attached to metallic R2 surfaces or attached to blocks attached to metallic surfaces by R2 sources approvM by Quality Assurance and listed on the Approved Vendor List.
(b) Meche.ical Design is responsible cifying heat treatment requirements. The heat treater shar,..cpare a procedure based on these requircrr.ents whu describes:
The equipment and its required calibration; the Ic iing;
}
temperature (s); time at temperature; thermocouple loution requirements; rate of heating and cooling; atmosphere contro! (as required); and other applicable requirements of the design or as specified by the Code, Regulatory and contract. Requirements for test coupons shall also be included. The procedure shall be h
submitted to Quality Assurance for approval prior to use.
(c) Portable heat treatment may be carried out with controlled heat pads, thermocouple and insulated conditions, as required, to prevent harmful temperature gradients in the heated and adjacent areas.
(d) A temperature recording chart shall be maintained for each heat treatment. The follow ng information shall be recorded on the chart i
and certified by the subcontractor or operator:
Subcontractors name Temperature Time, including heat and cooling rates 0:te Heat and Job Numbers Description i vinding item identification Number of..
s 1
Location and identification of thermoccuples Furnace or equipment identification Loading chart Heat treating procedure & revision O
Ol31a 4)
Sectione 9
Foster Whitler EnergyIQip2 Energy Applications,Ei.
Page 9 of 18 __ Rev..jL Date: 12n4190 Ouality_AlintancellAnul
,s
/
T LJ (e)
Quality Control shall review the charts for compliance wth applicable specifications, procedures and the Code. Cumulative heat treatment time and temperature records for items are reviewed to assure they are within the limits qualified by simulated test coupons for the material, weld material and/or.
weld procedures, as required. Identification of the heat treat procedure shall be included on vendor certification. Charts and certificates shall be maintained by QC and made available to the Authorized Nuclear Inspector upon request.
9.5 NDn-lleilnictive EundnatiDB.
ES.1 General (1) All non-destructiv< examination required by the Code shall be performed by and results evaluated by non-destructive examination personnel qualified to SNT-TC-1 A and the Code.
(2) Level Ill personnel shall be qualified by examination administered R2 by the FWEA QA Manager, ASNT or an outside agency in R2 accordance with Code requirements. If basic and method ff; examination is administered by ASNT or outside agency, the FWEA QA Manager shall administer the specific examination.
(3) Individuals performing Non-destructive Examination shall be qualified and certified in accordance with the FWEA written practice for the me thod used per SNT-TC-1 A and the Code. (These R2 requirements meet or exceed NQA-1 Supplement 2S-2.)
(4) For Non-destructive Examinations not covered by SNT-TC-1 A personnel shall be qualified to comparable levels of competency by appropriate examination on the particular method and technique involved as specified in the FWEA written practice.
R2 (5) The practical portion of the qualification for Level I & II shall be performed using the procedures and parts representative of wastruction and/or repair to be conducted and approved by the Level III.
(6) The emphasis shall be on the individual's ability to perform the Non-destructive Examination in accordance with the applicable procedure for the intended application.
/3 V
5151a 4)
Foster Wheeler Encrev Corn, Secti:n:.JL Energy Applications, Div.
Page 10 of 18 Rev. 2_
Quality Aasurance Manual Date: 12/14!90
-p J
(7) Classification of Personnel-The requirements of this section are applicable to the following categories of personnel:
(a) Magnetic Particle Test Personnel, Levels I, II and m (b) Fluorescent Penetrant Test Personnel, Levels I, II and m (c) Dye Penetrant Test Personnel, Levels I,II and m (d) Radiog aphie Test Personnel, Levels I,II and m (e) Ultrasonic Test Personnel, Levels I,11 and III (f) Helium Leak Test Personnel, Levels I, II and m (g) Visual Examination Test Personnel, Levels I,II, and m (h) Gas bubble formation, and Halogen detection leak test-personnel, Levels I,II and E (8) Qualified Non-destructive Level II or m Examination personnel
_,q shall demonstree NDE procedures to the satisfaction of the
~
V Authorized Inspector. Prior to first use of tl procedure, the ANI signs and dates the Qualification record, 9,5.2 Oualificalion of NDE Personnel (1) The Quality Assurance Manager shall certify Level _ III non-destructive examination personnel by examination as required by the Code and SNT-K-1 A.
(2) " Level m" personnel will qualify personnel in accordance with the FWEA written practice prepared and approved by the Level M and approved by the QA Manager which meets the requirements of the Code and SNT "C-1 A. Limited or restricted qu21ifications shall be noted on certificates.
(3) Level m personnel are responsible for preparing and maintaining written procedures for training and qualifying Non-destructive Examination Personnel.
n 0151a 4)
~,
Foster Wheeler Enflev Coro.
- Secti:n:? 1 Energy Applications, Div.
Page 11 of 18 Rev.',_2._ -
- Quality Assurance Manual
- Date: 12/14/90 (4)- The QA/QC Supervisor shall have. Code Non destructive Exam 6ations performed and results of examinations evalu_ated by qualifieti non-destructive Examination personnel of-Level II or =
higher.
(5) Level III personnel are responsible for providing the Authorized Inspector the opportunity to witness and verify the certification of operators in accordance with 1e written practice, and to audit th'e; program, ne Authorized Inspector may require requalification'of an operator if he has reason to question the' pc formance of that operator.
R2 (6) As a minimum, a Level D or III person shall prepare NDE procedures.
in accordance with the Code and submit them to LevelIII personnel R2 and QA Manager for approval.
9.5.3 Eersonnel Training and Certification (1) NDE personnel are certified by LevelIII personnel who are qualified by examination.
^
(2) Certification Data - A record of the dates and qualification tests for' Non-destructive Examination Personnel shall be maintained. ne.
records shallinclude:
- r (1) Name of certified individual.
(2) Level of certification and test method..
(3) Educational background and experience of. certified-individuals.
(4) Statement indicating satisfactory completion of tranung in -
accordance with the employer's written procedure.
R2 (5)_ Results of the physicalexamination R2 (6)1 Current examination copy (s) or evidence of successful completion of the examinations.
- R2 (7)' Composite grade (s) or suitable evidence of grades.
R2 (8) Daies of certification and/or recertification and the dates of -
assignment to NDT.
R2 (9) Signature of the Quality Assurance Manager, s
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F sterWheelcI. Energy _COIp2 S:cti ru 9
Energy Applications, Div.
Page 12 of 18 Rev.' 2 Quality _Aaanrance.hianual Date: 12/14/90 0
R2 (3) Recertification is required at least every three years for LevelI or 11 R2 personnel and every five years for Level III personnel. A record of R2 recertification shall be maintained that includes signature of the R2 Quality Assurance Manager. Recertification shall be based upom R2 (1) Evidence of continuing satifactory performance R2 (2) Satisfactory re-exunination of those portions of examinations R2 deemed necessary by the reponsible designated Level III R2 person.
R2 (3) NDE personne may be re-examined at any time at the R2 discretion of the employer and have their certifications R2 extended or revoked.
R2 (4) NDE personnel shall not be recertified without examination if R2 the dura tion of interrupted service has exceeded six (6) months.
9.5.4 Nandestructive Examination Proculures.
O) Non-destructive Examination will be performed in accordance with
(^
a written qualified procedure. The Level III person certifies the
(
Proced ure is in accord ance with the Cod e on the qu alification record.
(2) Records - Copies of procedure and personnel qualification data and reports of test results (or radiographs with re iew forms) shall be R2 maintained as required by the Code and Regulatory requirements.
Access shall be provided for the Autharized Inspector to these records.
(3) Special Application - When special materials or configurations are encountered requiring modified methods or techniques, such soecial~ procedures or combinations of methods will be uemonstrated to the Authorized Inspector (See Paragraph 9.5.1.8).
(4) All proced ures and personnel records, sha11 be at the Work tocation.
O
Egater Wheeler Encrev Corp, Secti:n:
9 Energy Applications, Div. -
Page 13 of 18 Rev._2_
.Qudity AssurABCe_Mamtd Date: 12/14/90 (5) The Authorized Inspector may require requalificatiori of an NDE R2 procedure or personnel when a specific reason exists.
9.6 Other cpecial Processes (a) Engineering, the Quality Assurance Manager or designee shallidentify other processes which may affect critical characteristics of materialitems and cannot.
be di4 ectly examined to verify conformance. These shall also be considered as specialprocesses.
(b) When so identified as a special process, the applicable parameters that effect critical characteristics shall be controlled by appropriate process controls including qualified procedures and personnel.
(c) Procedures developed to control the significant process variables shall be-qualified by the necessary testing and evaluated by Engineering in accordance R2 with the Design Specification, Code Regulatory and Quality Assurance requirements. The procedures shall be approved by Engineering and Quality Assurance.
(d) Personnel utilized shall be verified by Engineering, as necessary, for competence to perform the 1equired tasks. When special skills or experience is required, only qualified personnel that have received the necessary training, or qualification shallbe rtilized.
(e) Copies of procedure and personnel qualification data and reports of test results shall be maintained as records, as required by the Code. Record access shall be maintained for the Authorized Inspector.
(f) Bending and forming procedures and qualification shall be performed as required by the Code.
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- . ua,...: x..
EXHIBIT 9.2 l
... ' " ~ ~.
y PAGE 15 or 18
(.
REV. 2
- +
WEL33IO DIST?.DCTICl! SEIT DATE 12/14/90-E00 F 8-33-4397 8-8-BAI-75-4397-3 W.P. Date 9/11/73
- 0. ".pti:n I.uo 6 ereove welds W.?. Rev.
5 Material a.nd Fi2.ler W1re Base material P-8 Type
?rshoat and Interrass e 316 stainless steel 60 F min.
350# max.
i304 or gMe al ER-316 BWt I-316-16 covered electrode riller Cup Sise bacxup Gas 1 5hieldi.ng GTAW-Argon /SAW Sandvik 34WF flux Argon back purge 5,6 or 7
?rocess anc Polarity
! Wolo Fosition 5
riat (1G)
GTAW-DCSPs SMAW, SAW-DCRP i
i.
ef@
i s
\\
9 f
MSGo t
r v
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meas w e.ui r we r Mate r:.a._
h.t nT, Vcl age 2 avel 3
Descriotica Sec.!
No.+ P-ecess l S :ev Tyre 1(A m )
(Volts)
(ir:n) l Set-up & weld 1
1 GTAW 5/32 Dt316 "I3 "
120-130 12-14 f
Root pass
. Manual Fill 2
2-7 SMAW 1/8 E-316-16 130-140 22-24 l
1 5/3:
150-170 22-24 I
8 3alance 3
8-end SAW 1/16 ER-316 290-320 29-31 6-14 ii l
t I
i are acorex mate anc ael: dure rns or may, as rec;.r rec. acc or suotract ir.cicated nu=cer.
O, '.sCNAI, INFC2MATIC31 m
GTAW - use 10-20 cfh argon for backpurge and thru torch.
1 aW - Torch angle approx. 7 toward sidewall, wire to sidewall spacing approx. 1/16" 0
wire feed speed controls at:perage l
Tip-to-work distance 1"
}-
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Septeaber 6. 1983 W.I.S. 8-8-BAE-25-4397-3
- EXillBIT 9.3 PAGE 16 0F 18 WM ECON C MS REV. 2 12/14/90
~
T'.!C TCI'E.4DC INSmCCT CNS NLC ADSWC"TD.RCM W.P. 8-8-BAE, AE, E-25-4439 FCa N;OLTICNAL CC" AILS, 'IUC LCHN. 2RCC2:uaE iPCC:F!C.WICN biCLLU Liu CCS$U.:.n.C.
1.
A hign frog'.:ency star: sr.all he 'ased to *T.L iate tne arc.
2.
Crind a11 stcpu ci,d starts to ensuro cottaicto fusion of previcus triccs.
3.
Cxi.da scale shall ha reeved frcm the surface of each head wita a s"inless stect br,mn before dercsititxj ttc next sucrossive wid lusu.
4.
T.ither a travel spd ir41catcr er a step vatcr. and scale shall be used c ecastro trsvol speed.
5.
On joints wclded frem boca s; des, bacX gr:.rd to scurd actal prior to tac.t welding.
S.
The finished surface of the reinforecaent Of all butt wclded,oints ; ray he flush with the plato or ray have reascnt.bly unifcz:n cr::rons. The tctal reinfer:2rrant of both sides anal'1 nce exceed the fc11cvL77 thickness:
Plat:n Thic'cass Max. _-'etal of Reinfer a: ent Up to 1/2" inc1.
1/15" Cve.r 1/2" := '.
3/32" Cver l" to 2" 1/8" d
7.
Canersi C'*a--c, 3nis ni..c ar.d G - -d i -~
s-- - -as:
A) Clean by v1 ping atth an acct.ne (tech:.:. cal Trade er hat e.r),. cu aned (nct saturntad) cisan, lint-f.'se cicen.
3)
. ~ser vi-e 5:.ishi-c rust he fcilcwed.y.,ri: ding where pe.ecra.: 1sg-tien is cc::; u.~.
2n.shes enust be sr.2:r.less steel.
C) Gr -d* -- d* ses. wenels. Ste es, etc., :us: he rasir. ': :ded alu-.1 a::: Oxide.
?c11cu 7: rd:.nq s.:n Vactura clean:nq.
Cl
- cJl.s., t.'at c=c :.n centec: w:.:n jcb ra:aruis must he clear.ed red ::s-g nct cave been prav:.cusly used en any ratarul c:..e:
2n s :L nless s:23..
C)
P:cdue:1cn welds sna11 bc kep: d:/ (f::: f:cm -at.2r) durf..g ar4 aftar
~olding as an aid in c.ravent:.nq ccc Osten.
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Jan. 1984 OPERATOR QUALIFICATIONS ARD CLASS IA
_l-A-1 Shielded Metal Arc 1%" Sch. 80 pipe & 6 5/8" 00 pipe assemblies, 2G & SG positions
'3-A-1 Shielded Metal Arc 2" Sch. 160 pipe Horiz. & Horiz. Fixed positions STANDARD CLASS I 1-1-A-1 Shielded Metal Arc l\\" Sch. 80 pipe - 2" Sch e assem., 2G & Spec. Shop pos.
B-8-A-1 Shielded Metal Arc 2* Sch.160 pipe FG pi
$) \\,i ahop pos.
V SECTION 9 STANDARD CLASS 2 EXHIBIT 9.5 l-1-A-1 Shielded Metal Arc 3/4" plate, Hor
. Up position PAGE 18 0F 18 KEV. 2 ADDITIONAL QUALIFICATIONS:
DATE 12/12/90_
Clasm No.
Procedure LA 5~~
1-1-BA-2 1Coen root TIC & SMA fill, all oos. cual. 2C SG, lh" Sch 80 & 2" Sch 160
=
=
1A 2 l 8-8-BA-1 lOcen root TIG & SMA fill, 1A 3 I l-1-BA-2
' TIG (ES) insert & SMA fill "
=
LA 4 i B-8-BA-2 TIG (EB) insert & SMA fill
- 1A 5 i B-8-B-2 TIB (EB) insert & TIG fill "
1A l6 i 5-8-BA-1 IOcen root TIG & SMA, MS oice, Hor. & Ro r. Fix ed, "
~
LA i 7a 1 5-8-A-3 Ishielded Metal Arc all oos., 1/16" to 7/8" cual."
1 i 7b i 5-B-A-3 i Shielded Metal Arc 2"Sch.160 cipe. Shoe oos. only" j open root CO Shielded Short Arc,1/8" pit., Vert. Up, Down & Hori2.
2 l8 l l-1-C-2 2 Shielded Short Arc,1/8" pit., Overhead position 2
l Ba l 1-1-C-2 lCpen root CO2 2
18b i 1-1-C-2 IOcen root C-25 Shielded Short Arc, 1/8" olt., Hori2. & Vert. Down 2
19 1 1-8-A-1 I Shielded Metal Arc (Into A) 3 /8" olt., Horir. & Vert Oc cos.
_2 i 9a i 1-8-A-1 iShielded Metal Arc (Inco A) 3/8" olt., Horir, cos. oniv
[
)s i 10 l 6-6-B-2 ITIG (ES) insert & TIG fill, lh" CD X.105" Wtube, Shco cos. Uo
\\s /
I 11cl 1-1-T-5 iSemi-auto flux cored wire, cas snield (CO, & C25) Hor. & Vert. CD ec5 L4 1 11el 1-1-T-5 Isemi-auto flux cored wire, gas shield (C25) 6G oosition 2
1 12 1 34-34-A-1 I Shielded Metal Arc. h" olt., CuNi (70-30), 45* Uo sicoe 2
6 13 i 3 4 - 3 4 -C-1 i Semi-auto Inert Gas Metal Arc, h" olt, CuNi (70-30) Flat oos.
2 i 14 1 1-1-B IOcen root TIG, 1/8" MS cit., Roriz. & Vert. Do cos.
2 i 15 i 8-8-B-3 ICoen root TIG, 1/ 8 " CRIS el t., Socie. & Vert. 00 cos.
1 1 16 I 8-8-A-1 I Shielded Metal Arc, 2" Sch. 160 eice MS cioe. Hori2. oosition LA i 17 I 5-8-BA-2 ITIG (EB) insert & SMA fill, 14" OD X.165" W tube, Shoe oos. Uo 2
l 18 1 1-3 3 -C -1 isemi-auto, inert cas MIG, fillet weld SiBr (P-33 to P-1)
B-8-A-1 I Shielded Metal Arc, 3/8" MS elt., Hori:. & Vert. Uo cos.
2_
1 19 i
2 1 19al S-8-A-1 i Shielded Metal Arc, 3 /8" MS cit., Moris, cos. oniv 2
i 20 I 1-34-A-1 I Shielded Metal Arc. H* olt., 45' Uo sloce LA i 21 1 5-8-3-2 iTIG (EB) toot & TIG fill, 5" CD X h"W eice. Horir. '2G) oos.
2 l 22 I l-3 4 -C-X jSemi-auto. MIG, inert gas, h" olt. nickel wire, flat 2
4231 1-35-C-X lSemi-auto. MIG, inert gas, 3/4" olt., aluminum bronze, flat All 1 26 l 1-8-T ISemi-auto. Flux cored wire, cas shield CO. (1G) Flat oos.GJiGr FE-2)
All i 27 I 8-8-C-X iSemi-auto. (1025) shielded short are tvoe' MIG, vertical Down All i 29 1 1-8-T-1 iSemi-auto, flux cored _ are, Plat sosition (Stoody SOS 309L) l Semi-auto. 87% Arcon 13% Relium shielded, MIG, flat oos. (EN 82BW)
All i 29 8 1-4 3 -C-X 30 1 51-51-B-16 iAutomatic Inert Gas ?unestan Arc SG 2
31 } 1-1-A-1 4F Overhead structural fillet weld & welder loader r$)
All 132 1 1-1-E-5 Autcrfetic submerced are weldine All 33 l 1-1-E-5 Semi-auto, submerged are weldinc
_(\\ \\bs All 34 I 23-23-B-1 1 Aluminum (TIG) 1/S" clate, Morir. cos rX(NN\\\\ \\\\ >
WELDING ?ROCEDURE AND PROCEDURE VARIATION IDENTIFICAT V($BIR QUALIF. RECORDING i
\\
Mtomatic TIG (for AIG)
A Shielded Metal Arc (stick electrode) hs g-g 9
)
B Manual TIG s
C Semi-auto. CO sh rt are type M C (Manual)
Automitic mig (for AlG) 2 E
Sub-arc T
Flux cored wire welding 3
Automatic flux cored wire 5
Sub-Arc (non-code) welding (for AIG)
- ) {-
Foster Wheeler Enerav Coro.
. Sectiiru ~ 10_.
Energy ApplicationsTDiv. '
- Page 1 of 4 Rev.
2_.
Ouality Assurance Manual-
' Date: 12/1W90
-}
10.0 INSPECTION INDEX
'PAGE R2 INDFJ 1
10.1 PURPOSE 2
10.2 SCOPE 2-10.3 RESPONSIBILITIES
-2:
10.4 REQUIREMENTS 3.
10.5 CONTROLPROGRAM 3
10.6 QUALIFICATION OF INSPECTION & TEST PERSONNEL 4
O Y
4 5
0 0
_ _m i
m E9 ster Wheeler Encrev Corn, Stcticn: _10_
Energy Applications, Div. -
Page 2 of 4 Rev._L,.
Quality Assurance Manual
- Date: 12/14/9Q 10.0 INSPECTION
,10.1 parp.oie.
To establish a controlled program for inspection, examination and testing of R2 material and items in accordance with Code, Regulatory, and Contract Requirements.
10.2 Scope This section describes the responsibilities and controls for in-process and final inspections, examinations and tests in conformance with released drawhigs,.
R2 procedures, instructions, the Code, and Regulatory Requirements.
10.3 Respnnsibillites 10.3.1 The QA/QC Supervisor is responsible for designating inspection points and reviewing and approving Process Instruction sheets to assure all inspections, examinations and tests required by released documents and the Authorized Inspector are provided.1 103.2 The QA/QC Supervisor is responsible for assuring that ' qualified-inspection personnel perform all inspection and tests and providing indoctrination and training as required in accordance with Section 2 of this Manual. Personnel performing Non-destructive Examination shall be qualified in accordance with Section 9.0 of this Manual.
10.3.3 The QA/QC Supervisor is responsible for notifying _the Authorized Inspector a reasonable time in advance when his presence is required at :
a Hold Point as indicated on the Process Instruction Sheet (s).
.R2 103.4 The inspector or NDE Technician is responsible for initialing or stamping off and dating operations inspected and found acceptable in the space R2 provided in the Process Instruction Sheets.The Serial Number of Measure R2 and Test equipment used shall be recorded on Process Instruction Sheet -
at the operation sequence. Rejected items shallbe processed in accord ance with Section 15 of this Manual.
f 10
.15151a.14
,4
Epster Wheeler Enerev Corp 2 Srctioru
._10_.
Energy Applications, Div.
Pagelo_f 4_ Rev.1
. Ouality Assurance Manu~al Date: 12/14/90 10.4 Requirements 10.4.1 Requirements specified in released documents are translated by engineers into In-process and final inspection, examination and test line items on -
Process instruction Sheets. Released drawings provide the nondestmetive examination reqeit'.ments foritems and welds as well as dimensional and other special and test procedure information required. Other g
requirements shall be incorporated as specified in released procedures, R2 and as required by the Code and Regulatory Requirements.
10.4.2 Prepared Procest Ins truction Sheets are reviewed by personnel other than preparer and approved by the QA/QC Supervisor in accordance with Section 5 of this Manual.
10.4.3 The Av thorized Inspector shall review process instru ction sheets covering
.. ems required by the Code so that he can designate his holdpoints.
Holdpoints are incorporated into the Process Instruction Sheets as line items.
10.5 Control Program nU 10.5.1 Inspection, test and non-destructive examination points specified on the process instruction sheet are points beyond which work cannot proceed tmtil accepted and cleared by Work Location Quality Control. When rejectable results are obtained, a DMRis issued (See Section 15).
10.5.2 Inspections and Tests are to be performed onlyby qualified personnel and R2 in accordance with approved procedures. If inspection personnel are not R2 qualified, or determined not to be capable of meeting specified -
requirements, they shall be removed from the work location.
R2 10.5.3 Non-destructive examinations are to be performed by certified personnel R2 and qualified procedures in accordance with Section 9.0 of this Manual.
10.5.4 Test will be included as line items on the Process Instruction Sheet (s) and special test results and data will be reported on pre-planned data sheet (s) that are included with the released test procedure.
R2 10.5.5 The Authorized Inspector shtllbe notified forhis designated Hold points.
As a minimum, he shall witness final hydrostatic, pneumatic, or leak test
q EasterEheelcr. Energy _Cerp.
S:ctt:n.. 10.
Energy Applications, Div.
Page 4 of 4 Rev._1_
Qs11tv Assunutec Manuni Date: 12/M/90 (g) required by the Code. Witnessing of final testing by the Authorized R2 Inspector is required prior to certification of Data Reports and Stamping.
10.5.6 The record of inspections for an Item (Process Instructions Sheets) will be reviewed by the inspector's supervisor for completeness and assurance of resolution of all non-conforrnances prior to final acceptance. The QA/QC supervisor shallinitial or sign off and date the process instruction sheet toindicate his acceptance.
10.6 Qnll(ication.ofhupection & Test Personnel R2 10.6.1 The QA/QC Supervisor shall prepare a procedure which defines the areas that require qualified inspection and test personnel and the minimum requirement for such personnel. The procedure shall include requirements for indoctrination, training, determining initial capability, evaluation of performance and certification of qualifications (records)and physical requirements. The procedure shall be approved by the QA Manager as complying with NQA 1, supplement 2S 1.
R2 10.6.2 The QA /QC Supervisor shall maintain a record, on a 3 year max interval, O
R2 to document the performance of each qualified persons in the qualified areas. Personnel who have not performed activities in their qualified areas at least annually shall be reevaluated by the same criteria as initial-capabilitydetermination.
10.6.3 The QA/QC Supervisor shall maintain Certification records which shall include:
(a) employer's name; (b) identification of personbeing certified; (c) activities certified to perform; (d) basis used for certification, which includes such factors as:
(1) education, experience, and training (2) test results, where applicable (3) results of capability demonstration R2 (e) ruults of annual evaluation; (f) results of physical examination, when required; (g) signature of QA/QC Supervisor or QA Manager who are responsible for certification R2 (h) Date of certification and expiration v
S151s 14
Foster Wheeler Enetry Core,
. Sectitru.,_11_ _
Energy Appilcations, Div..
Page 1 of 5 Rev._2_,
Date: 12/14/90
_ O
- Ouality Assurance Manual 11.0 TEST COPEROL INDEX PAGE.
R2 INDEX 1-2 11.1 PURPOSE
-. 2 -
11.2 SCOPE 11.3 RESPONSIBILITIES.
2 11.4 TESTPROGRAM 2
11.5 TEST MONITORING AND WITNTSSING 4
EXHIBIT EXHIBIT 11-1 Hydrotest Data Sheet O y
O s
Ecater Wheeler Energy _ Corp 2 Secti ru _11_
Energy Applications, Div.
Page 2 of 5 Rev. _2_,
Quality Assunnte. Manual Date: 12/14/90 V
11.0 TEST CONTROL 11.1 Eurpsic.
To assure that the program for testing materials and items to demonstrate compliance with specification requirements is in accordance with Code, Regulatory and Contract requirements.
11.2 Ssope.
This section establishes the program for planning, procedure preparation, and implementation of required tests.
11.3 Responsibilitics.
11.3.1 Mechanical Design is responsible for preparation of test plans and procedures including the incorporation of requirements and acceptance limits as contained in the applicable design documents.
R2 11.3.2 Quality Assurance is responsible for assuring that Code, Regulatory and m
R2 contract requirements are specified in the test plans and procedures and f
(
that test are conducted in compliance with approved procedures required on Process Instruction sheet.
11.3.3 QA/QC supervisor is responsible for the training and qualification of test personnel,(See para 10.6)
R2 11.3.4 Mechanical Design and Quality Assurance Manager are responsible for review and approval of test procedures submitt-d by subcontractors.
11.4 Test Program 11.4.1 Test procedures shall be prepared by Mechanical Design when required R2 by contract or when needed to supplement planning for complicated equipment or complex operations. The type, sequence, frequency and required procedures are to be specified in the plans. Quality Assurance shall review and approve test plans to assure Code and contract requirements have been met. Test procedures shall be presented to the Customer as required and to the Authorized Inspector so they can designate any hold points that may be required.
m 6 1514 11)
Eutcr1YheeletEnergyIorp, secti:ru
._11_.
Energy Apptkations,Div.
Page 3 of 5 Rev._1_
Date: 12/14/90 Ouality_Assuranceldannal
,nv) 11.4.2 Mechanical Design shall prepare test procedures incorporating design requirements and acceptance limits required by the Client's R2 3pecir; cations, Drawings, the Code, Regulatory and contract. Specific items to be addressed, as applicable, shall include:
Test set up description including sketches, as necessary, to delineate a.
test requirements, a
b.
Equipment and instrumentation required.
Test measuring instrumentation calibration requirements, c.
d.
Step by step instruction.
Provisions for data acquisition with data forms required to collect c.
specialdata and test results, f.
Erwironmental conditiora including those to simulate design and funct onal requirements and conditions required to satisfactorily i
conduct the test.
g.
Provisions for tests to be conducted and evaluated by qvalified personnel.
i R2 h.
Code, Regulatory, specification an?. standard references.
3 i.
Quality Assurance witness, and/or monitoring points.
11.4.3 Prepared test procedures are reviewed by personnel other than preparer and approved by Quality Assurance Manager.
11.4.4 Personnel conducting tests and evaluating results shall be qualified in accordance with Section 10 of this Manual. Only qualified personnel are utilized for test performance and evaluation.
)
f
\\
V 61Sla4 D
Eniter Wheeler EnergySerg, Secti:n:
_11_
Energy Applications, Div.
Page 4_of 5 Rev.._2_.
Quality Assutance Manual Date: 12/1480 f
v 11.4.5 Process Instruction Sheets in accordance with Section 5 of this Manual shall be utilized to implement and document test-procedures and requirements and record test results data sheet Exhibit 11 1.
11.5..dionitoringand. Witnessing.
115.1 Inspection points specified in the procedure for monitoring test requires prior notification of Quality Assurance. A Quality Assurance representative shall be present unless waived in writing. Quality Assurance shall give sufficient notice to the Authorized Inspector so he has the opportunity to witness his designated hold points.
11.5.2 If functional, performance or special testing is being conducted, an engineering representative as directed by Engineering may also be assigned to witness the testing.
O O
Cf151e 11)
O EXHIBIT 11-1 PAGE 5 of-5 REV. 2 12/14/90 PROC -IEN-I-1234-5221 REV. 3 HYDROTEST DATA SHEET FOR TEST DATE 11/9/87 CFMT TANK P/N 3500 Mist Eliminator Buttom Head Half Jacket Heel Removal Assembly Required Pressure 250 psig Gage No.
1234 Required Hold time 30 min Ambien Observations (psig)' Temp.(g )
Pressure Test F
or remarks Time Reading Sequence 1-1/2 Test Pressure 1:05 125 68 2-Initial Test 1:15 250 68 Pressure 3-Hold 4-Final Test Pressure 1:46 250 68 5-Reduce Test Pres-1:50 170 68 sure by 1/3 (if applicable) d/(I&
Accepted by FWEA-Quality Control (O)
Easter Wheeler Enerry Corn.
Stctionr 12._
- Energy Applications, Div.
Page 1 of 4 Rev.,_2_ -
Date: 12/14/90 0
Onntity Assurance Manual-12.0 h1EASURING AND TEST EOUIPMENT CONTROL INDEX EAGE R2 INDEX 1
12.1 PURPOSE 2
12.2 SCOPE 2
12.3 RESPONSIBILITIES 2
. CONTROL PROGRAM 3
- O Oi
,. Cn51. t.
' ' ~
~
foster Wheeler _IncIgy Corp.
S:ctitru 12._
Energy Applications, Div.
Page 2 of 4 Rev._2_.
Quality Assuance Manual Datc: 12/11/SQ 12.0 hiEASURING AND_ TEST EOUIPMENT CONTROL 12.1 P_urpoic To establish the requirements necessary for maintaining measuring and test R2 equipment within necessary accuracy limits to meet Code, Regulatory and Contract requirements.
12.2 S.cogc_
This section describes the system utilized for the control and calibration of measuring and test equipment.
123 Ecsponsibilities The QA/QC Supervisor is responsible for:
123.1 Assuring that the required calibrated measuring and test equipment is available, and are of the proper range, type and accuracy to verify conformance to the specified requirements.
123.2 Calibration of equipment against certified national standards. Where such -
standards do not exist, calibration shall be performed using manufacturer's recommended standards.
R2 123.3 Maintr'ning a controlled calibration system for measure and test equipment and providing procedures for its implementation.
R2 123.4 Subcontracting calibration to an approved outside laboratory when required.
123.5 Evaluating previous results of measuring and test equipment found out-of-calibration to determine appropriate corrective action in accordance with FWEA approved procedure.
R2 123.6 Conducting internal periodic audits to ensure compliance with the established system per Section 18.
1 O
Sma-13
1-Ecstar Wheeler Energv Corn.
Section:
._11_
Energy Applications, Div. -
Page 3 of 4 Rev. 2_
Quality Assurance Manual Date: 12/14/90 f3 V
12.4 Control Plogram.
R2 12.4.1 Each measurement and test equipment device utilized shall be uniquely identified (serialized) by the QA/QC supervisor who maintains a log and ha each device calibrated to maintain limits of accuracy required for verification of the speofied inspection and test requirement. When size or functional characteristics limit the application of labels, an identifymg symbol shallbe applied to theinstrument and container which reflects the identification and due date for next calibration.
12.4.2 Measurement and test equipment shall be calibrated at scheduled intervals against certified standards traceable to National '.andards.
Where these standards do not exist, alternate standards based on manufacturer's recommendations shall be used and their use documented.
12.4.3 Records shall be maintained that indicate thelast and next due calibration dates and shall be traceable to the calibrated equipment item by marking or labeling to indicate by whom it w. 4 calibrated and the next calibration date.
(s 12.4.4 The calibration interval established by FWEA procedure for each item shall be based on the type of equipment, required accuracy, use and other conditions affecting measurement control.
12.4.5 Quality Assurance may provide their own services or use those of an approved gage laboratory for the calibration oi measuring and test equipment devices. Certificates of calibration will be obtained and maintained on file for equipment items calibrated by outside laboratories.
12.4.6 When special measuring and test equipment is required for use in a process inspection, examination or test,it shallbe specified by the Process Instruction Sheet or Test Procedure.
12.4.7 Equipment that has not been properly maintained or calibrated in accordance with a specified schedule shallbe identified with a hold tag and removed from service. Any equipment suspected of being out of calibration shallbe recalibrated.
5151e4D
Foster Wheeler Energy Corn.
Section:
_11_
Energy Applications,Div.
Page 4 of 4 Rev,_2_
Quality Assurance Manual Date: 12/14/90 (L
12.4.8 Material and Items checked with equipment which is out of calibration shall be considered unacceptable until Quality Assurance determines that applicable requirements have been met.QA/QC supervisor shall review the Process Instruction Sheet to determine the items and materials by which the defective device was used since the last valid calibration. The affected items and materials shall be identified on a DMR which is processed per Section 15.
12.4.9 Calibration records shall identify the serial number of device, d escription, procedure and revision used, date of calibration, acceptance limits, R2 frequency required, standards used, as found conditions, and per.,on performing the calibration. The records shall also indicate any adjustments or repairs made to the equipment.
12.4.10 Pressure gages shall be calibrated against a standard deadweight tester or a calibrated master gage prior to each test or series of tests. A series of tests is a group of tests using the same gage or gages and conducted within a two week period.
12.4.11 Temperature instruments used to control temperatures of Charpy-t V-notch impact test specimens shall be calibrated at least once in each V
three-month period.
12.4.12 Charpy V-notch impact test machines shall be calibrated at least once in each one-year interval using methods outlined in ASTM #23-72 and R2 employing standard specimens obtained from the N.I.S.T.
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$151e-tD
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Sectioru 13 Energy Applications, Div. -
Page 1 of 4 Rev, _1_J Date: 12/14/90 Oualltv Assurance Manum 1 13.0 HANDLING. CLE ANLINE S S. PRES ERVATION. PA CKAC ING.
SHIPPING AND STORAGE INDEX j
PAGE R2 INDEX 1
.5 13.1 PURPOSE 2
13.2 SCOPE 2~
13.3 RESPONSIBILITIES 2
13,4 CONTROLPROGRAM 3
13.5 MATERIALSUPPLIER' 4
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5t11a 13).
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l Fnaler Wheeler Encrev Corn.
~ Section:
13._
- l Energy Applications 7Div. '
Page 2 of 4 Rev,'_2_c
- l Date: 12/14/911 QualityAssurance M=nual-13.0 IIANDLING, CI EANLINESS. PRESERVATION. PACKACING SHIPPING AN]2 SIDRAGE 13.1 P_urpose To assure that the handling, cleanliness, preservation, packaging, shipping and R2 storage provisions for Material and items meet design. Code, Regulatory and contraet requirements.
13.2 Scops This section contains provisions of control for handling, cleanlinc, preservation, packaging, shipping and storage to prevent damage, deterioration, contamination orloss ofidentification.
133 Responsibilities __
133.1 Mechanical Design is responsible for, preparing procedures and instructions for control of handling cleanliness, preservation and shipment to prevent damage, deterioration, and contamination of material during processing, storage and shipment.
O 133.2 Mechanical Design is responsible for review of Material and Items for lifting and handling equipment requirements.
1333 The Manufacturing or Construction Manager is responsible for the.
storage and handling of material, and inspection of handling equipment and ihe removal of defective bandling equipment from service.
133.4 The Manufacturing or Construction Manager is responsible for the training and qualification of personnel performing lifting and handling operations.
133.5 The Manufacturing or Construction Manager is responsible for R2 designating appropriate areas for.the storage of materials, and.
maintaining the areas in satisfactory condition to prevent contamination, deterioration, damage orloss.
O (5151a-13 4
y-
1 Easter Whec1er Itnergy_ Corp.
Sects:ru 13._
Energy Applications,Div.
Page 3 of 4 Rev._2_
Qualliy.Aasurance Martual Date: 12/14/90 Q) 13.3.6 The QA/QC Supervisor is responsible for the review and approval of procedures and instructions to assure:
R2 (a) Cooe, Regulatory and Contract requirements have been met; (b) Storage, handling, preservation, and deanliness requirements are induded, as necessary, and R2 (c) Adequate inspection requirements are specified induding a final inspection prior to shipment.
R2 13.3.7 Quality Control is responsible for verifying by inspection that specihed handling, stcrage, packaging, and shipment requirements of procedures are followed.
13.3.8 Mechanical Design and Quality Assurance are responsible for resiew and approval of handling, cleanliness, preservation, packaging, storage and shipping procedures required to be submitted by subcontractor's of manufacturing, installation or sersices.
f')
13.4 Controllrogram.
V 13.4.1 Mechanical Design and Quality Assurance review designs and incorporate special handling features such as lifting lugs or fixtures, and protective features such as inert gas environment, surface finish protectors, special coverings, temperature and humidity controls to meet Code, Regulatory and contract requirements. When special features are not required, the use of standard handling and storage procedures are used to assure the prevention of damage or deterioration.
13.4.2 Mechanical Design prepares handling, storage, packaging and shipping instructions and procedures. Procedures are required when critical, environment sensitive, perishable, or high value items are being handled, stored, packaged or shipped. Procedures are to indude the following provisions,as applicable:
(a) Provisions of handling, storage and packaging to maintain cleanliness and integrity.
(b) Provisions for maintenance of identification throughout storage, packaging and shipment.
b) t enswim.,
Easter Wheeler Enerev Coro:
Section:
13_...
Energy Applications, Div..
Page 4 of 4 Rev.
2_.
Oum11tv Assurance Manual Date: 12/14/90 (c) Specifying acceptable modes of shipping and the securing ofitems
_ _ l' during shipment to prevent damage.
P (d) Certification of lifting and handling equipment to rated capacity.-'
prior to service and periodic inspection for deterioration and damage during service.
(e) Special procedures (para 13.4.1) are listed =on Process Instruction Sheets and verified by the QA/QC sunervisor.
13.5 Material Supplier When RVEA functions as a Material Supplier of Code Materials the following shall -
apply:
The customer's purchase order shall be reviewed, signed and dated, by the a.
Project Manager and the QA/QC Supervisor, b.
The Material shall be procured and controlled per Section 4,7,13.
Mechanical Design shall prepare and issue a Process Instruction Sheet in c.
accordance with Section 5, except AI review is not required. Manual Sections i
1,2,5,6,10,14,15,16, and 18 are applicable.
d.
QA/QC Supervisor shall inspect the Material as specified on the Process Instruction Sheet and verify materialidentification and marking.
The QA/QC Supervisor shall obtain copies of the applicable. Material; e.
Manufacturer and RVEA Certified Material Test Reports (CMTR) and
~
forward same to the QA Manager.
R2 f.
QA Manager shall prepare the FWEA Certificate of Conformance which identifies the material by heat number, material specif,c : Bon, grade,~ quantity.
and shalllist the RVEA N-(Subcontract) Certificate of Authorization numberj and expiration date. CMTR(s) are attached to the RVEA C of C and furnished -
to the customer with the Material.
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Eo11cGhecirtEncigyInrp, Sectioru _1L Energy Applications, Div.
Page,1 of 3 Rev. L Qualliyliturantelianual Date: 12/1 0 0 14.0 INSEECflON> ND.TERISTAIUS INDEX 1%GE R2 INDEX 1
14.1 PURPOSE 2
14.2 SCOPE 2
14.3 PE9PONSIBILITIES 2
14.4 CONTROL PROGRAM 2
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0151a44
EoiteLlYhttitLEncigySprp, Sectiosu liL Energy Applications, Div.
Page 2 of 3 Hev.
2.,
QuAlliy_ASManCfldARUAl Dalet 12/l G O
14.0 INSPECTIONAND TEST STATI)S 14.1 Purpoic.
R2 fc establish measures necessary for rnalntaining and repor ting inspection, test and R2 manufacture / construction status to assure Code, Regulatory and contract requirements are being met.
14.2 Scop _e This section contains provisions for the control and reporting of inspection, test R2 aus manufacture / construction status.
14.3 Ressmnsihililler.
14.3.1 Inspection or NDE personnel ate responsible for indicating the inspection er test status of material and item (s), physically by tag or on records traceable to the material and/or item (r).
14.3.2 Inspection and test status shall be indicated by Signature (s) and/or initial (s) (date of signature) of the qualified personnel performing O
inspections or tests, 14.4 Control Program 14.4.1 Process Instruction Sheets are used to record inspection and test status of designated inspection and test points. Inspection or test points shall not be passed until the designated test or inspection r>oint has been completed and is signed and dated.
R2 14.4.2 The responsibic manufacture / construction.upervisor will request inspection for each inspection and test point designated on the Process Instruction Sheet by notifying the QA/QC Supervisor. The QA/QC R2 Supervisor will assign an inspector and notify the Authorized Inspector and/or Customer Representative, as required, for those designated hold points. Further processsing is withheld until the designated inspection or test point has been satisfactorily completed, signed and dated by the inspector or test personnel.
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1 InsletWheelcrIncigy. Corp.
Secti: u _1L Energy Applications,Div.
Page 3 of 3. Rev.
2_.
Date: 12/11t90 Quality _ Assurance Manual When the spec fied inspection or test has been completed and results are 8
14.4.3 acceptable, the inspector, or NDE technician will enter his initials or assigned stamp and date in the designated inspection space. If results are unsatisfactory, a rejection will be noted by DMR number on the process sheet or the receMng inspection check list if the discrepancy is found during receMng inspection. A Discrepant Material neport Number will be logged and prepared (See Section 15 of the Manual). Only through reinspection, as required, and clearance of the non-confonnance will the initials and date of the inspector or NDE person be entered to indicate completion and acceptance of the inspection or test.
14.4.4 Color codes shall be used to indicate inspection or test status at receipt inspection. A Green code is used to indicate acceptable materials or item, while yellow color indicates the material or item is not to be processed (put on hold) and is awaiting documentation or further instructions before fu rther processing. Red cod e or hard (red) copy of DMRindicates material or item is rejected and is not to be processed until the applicable discrepant condition has been cleared. Color codes are applied and removed by Quality Control personnel.
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End., wheeler F=,egvfarp.
Sedi:n:
15 Energy Applications, Div.
Page3 of 7. Rev._L, g..mIItv Astur^a'* M*atal Date
.5/M2.
O 15.0 CONTROL OF NONCONEO_RMING ITEhiS INDEX 11GE INDEX i
15.1 PURPOSE 2
15.2 SCOPE 2
15.3 RESPONSIBIU11ES 2
R4 15.4 FWEANONCONFORMANCES 3
R4 15.5 VENDOR ANDSITENONCONFORMANCES 4
EX111111TS Exhibit 15.1 Discrepant Material Report 7
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lostcLWhcclerEnergy. Corp.
Section:
15_.
Energy Applications, Div.
Pay,e 2 of 7 Rev._L.
Date:.51fd2.
QualityJasurancc11anual O
15.0 CONTROLDENONCONEORMING.IIEMS 15.1 Purpose.
This section defines measures to control and identify nonconformances. A nonconformance is a deficiency in a characteristic, documentation or procedure that renders an item, or activity unacceptable or indeterminate.
15.2 Scopc_
'Ihis section desoibes the responsibilities and activities involved in the detection, documentation, segregation, and disposition of noncenformances.
153 Respansibillites.
153.1 All cognizant personnel are responsible to report any suspected nonconformance in writing by use of Field Inspection Report, DMR or NQAD, as required to the Project Manager, Quality Assurance Manager, and cognizant discipline supervisor.
153 2 Quality Assurance / Quality Control are responsible for detecting and reporting nonconformances at a subcontractor's facilities during source inspections.
1533 Subcontractors are responsible to report any nonconformances of Materials and items to RVEA Purchasing.
153.4 The QA/QC Supervisor is responsible for identifying, reporting, and segregating nonconformances; concurring with the disposition (s);
presenting dispositions to the Authorized Inspector for his review; and re-inspecting repaired or reworked items.
153.5 Quality Assurance is responsible for surveying vendor Quality Assurance programs to assure that vendor nonconformances are:
(1) reviewed against the RVEA purchase order, Code and Regulatory Requirements (2) reported to FWEA for review, concurrence and disposition and O
Secticn:
15_
foatetWheelerIncigy_ Corp.
Energy Applications, Div.
Peg 22plZ Rev. L.
Date
.5/ M 2.
1 Qualliy. Assurance Manual O
(3) segregated where practical and properly identified to prevent their unauthorized use or shipment.
i 153.6 Mechanical Design is responsible for review of nonconfonnances and determining disposition; i.e., accept as is, repair, rework, scrap.
i 153.7 Quality Controlis responsible for maintaining records of Manufacture, Construction or Maintenance Task nonconformances.
R4 153.8 Quality Assurance is responsible for (dentifying discrepancy reports of vendor reported nonconformances with a FWEA DMR number and maintairj " n as -cords.
'sible for reviewing internal reported 153.9 Quality WWN w
nonconfon wrc 5 i d.4evidons f or verification and to concur with their dispositions.
153.11, The Project Mani ger is responsible for obtalrdng client approval of nonconformances when materials and items do not conform to client certified design specification and drawing requirements.
O The Quality Assurance Manager or his designee is responsible for
~
153.11 evaluating nonconformances and having the Project Manager place a
" Hold" on applicable parts or tasks wl :,e a nonconformance occurs.
153.12 The Mechanical Design Manager is responsible for evaluating deviations.
He shall document his evaluation by memo to the Project Manager if there is a " substantial safety hazard".
153.13 The Project Manager is responsible for ensuring FWEA compliance with 10 CFR 21, " Reporting of Defects and Noncorr.pliances"; and reporting Deviations that are found to create a " substantial safety hazard" to the NRC within two (2) working days.
15.4 MEANonconfonnances i
15.4.1 Cognizant engineering, manufacturing and maintenance personnel are required toreportbyNQAD,totheProject Manager, Quality Assurance Manager and cognizant supervisor, any suspected nonconformance or deviation to project specifications, standards, design criteria,
l'ostetWhedetEnergy Corp.
Secti:ru J5_
Energy Applications, Div.
Pagelpfl Rev._1.
Qualliylssurance. Manual Date:.5/ M 2.
O the Code; and Regulatory Requirements or this Quality Assurance Program detected during review of drawings, calculations, analytical models, engineering reports, procedures, instructions or their execution.
15.4.2 Quality Assurance shall review nonconformances and verify that the reported unacceptable conditions exist.ne results of this determination shall be documented by Nuclear Quality Assurance Directive.
15.4.3 The Qaality Assurance Manager or his designee shall review nonconformances. The Project Manager shall place a " Hold" on the applicable part of the task that is non-conforming.
15.4.4 he Quality Assurance Manager shall report the system noncompliance and appropriate recommended corrective action on a Nuclear Quality R4 Assurance Directive and issue it to the MVEA Director and FWEC Director QA/QC and other cognizant Directors for their immediate review and aetion. (Ref. Exhibit 16.1).
15.5 Yendotand_WmklocationNonconfonnances.
15.5.1 Nonconformances shall be reported by inspection or as a result of a O
submitted Vendor discrepancy report. Vendor nonconformances may be reported on the Vendor's nonconformance report form which has been R4 asigned a Discrepant Material Report (DMR) number by Quality Assurnance The DMR number is recorded on a log. (See Exhibit 151).
Nonconformances reported by Mspection shall be identified by DMR nurnber on the process sheet or receipt inspection at a Work Location report as applicable. DMR's shall be processed in accordance with this Section.
15.5.2 The nonconformance description shall identify the item by contract, }ob, part and serial number; location and contain a concise description of the location and nature of the discrepancy and what acceptance standard was violated. The description must be sufficient in detail to allow an independent third party to evaluate the defect without access to the discrepant condition.
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festgghter Encagy. Corp.
Secti:n: _11.
Energy Applications,Div.
PageJ_pf.Z Rev._L.
Qamnty Amautance Manual Date:
5& 92 0
15.5.3 All nonconforming Matenal and items shall t>e identified and segregated to prevent intermingling with conforming Materials and items.
Identification shall include affixing the hard copy of the DMR to the nonconforming material or item. Where possible, the Material or Items, shall be segregated by secuting them in an appropdate " Discrepant Material Area".Only authorized Quality Contrcl Personnel are pennitted to remove nonconformance identification from Materials and Items after they are cleared.
15.5.4 When nonconforming Material or Items are customer fumished, the QA Manager shall notify the customer's representative by issuance of a copy of the DMR so that he may partidpate in the inspection.
15.5.5 M echanical Design shall disposition nonconforman ces: accept as is; scrap; rework; or repair by reviewing applicable documentation including _
drawings, specification, and procedures and describing action required on the DMR.
15.5.6 Repair or rework dispositions shall require a supplemental process sheet to be prepared with the same controls as established for the original.'lhe qV supplemental process sheet shall detail the sequence of repair, inspection -
requirements, weld procedures and NDE procedures requ' sed.'De ANI shall establish his hold points in the supplemental process sheei. Base metal defects which are to be repaired shall be reported in accordance.
with paragraph 93.8d.
15.5.7 Disposition of " accept as is" (use as is) and repair requires a technical justification on the DMR by Engineering. " Accept as is" (use as is) and
" repair" shall be approved by the Project Manager and Quality Assurance -
Manager or his designee.
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Sectioru 15 Energy Applications, Div.
. Pagejg(2 Rev.' L.,
l Oualltv AssuranCc. Manual Date NO2.
j O
15.5.8 Dispositioned DMR's affecting Code requirements are presented to the Authorized Inspector by QA/QC supervisor prior to implementation for l
his review and concurrence and for designation of any " Hold" points he dwms necessary.
- i 155.9 DMR's are cleared by indicating a completed disposition action on the DMR Form (bottom line) and indicating acceptance on the Process Instruction Sheet. Repairs are always reinspected before completion.
" Accept as is" items are closed out by indicating "Not Applicable" in the disposition action completed the.
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Exhibit 15-1 Rev. 4 DISCPIPANT MATERIAL PIICRT SERIAL NO.
Page 7 of 7
$/6/92 CONTRACT NO.
JOB NO.
P.O. NO.
RIV*
MTERIAL DEAVING STATUS:
CAUSE O Def ective Katerial O in Proceae VmDOR O Tinal tvg. or Spec. "equirement DESCRIPTION (ACTUAL CONDITIONS)
Ref. Document b
DATE Q.A. AUT110RITY INSPECTED BY:
Q YES O NO D
CUSTOMER'S APPROVAL PIQUIprn O
DISPOSITION OF DISCREPANT MATERIAL IDG po.
O Acc Pr As Is O PIPAIR OSCPAP OsEE scLcu O
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EACRCHARGE VENDOR FOR RIWOFX Q TIS O NO RETURN POR VENDOR REWORK QTES D NO HAI. ALLOVASLE REWOFX CHARGES
~ PURCHASING VENDOR FITURN AUTHORIf.ATION NO.
Approvals l Dated Other Approvals Dated
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Mechanical Design O*
Project Manager Quality Assurance DISPOSITION ACTION COMPWw AW ACu.nw Acknowledged and Accepted Na a and Title Date Signatura
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Itatu_Wheela Faerev Cogh Sectie m _1 L i
Energy Applications,Div.
Page1 ofJ Rev. L Quality Aasur== M===*1 Date:.5M2.
16.0.COlmECnYEACDON INDEK PAGE l
INDFX 1
16.1 PURPOSE 2
16.2 SCOPE 2
R4 16.3 RESPONSIBILITIES 2
R4 16.4 CORRECTIVE ACTION PROGRAM 2
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EX111111I EXHIBIT 16.1 FORMAT 4
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EasterEhecletInergy Corp.
Sectiom _16_
Energy Appiltations, Div.
Page 2 of 4 Rev._L.
Qualliylssunncchianual Date:.5/681.
O 16.0 CORRECTIVIiACEION 16.1 Purpose.
This section defines measures and system requirements for reviewing nonconformances for determination of trends and action to be taken to prevent recurrence.
16.2 Scopc_
This section establishes controls which provide assurance that significant conditions adverse to quality are identified and actions are taken to preclude recurrence.
163 Responsibilitics.
163.1 Quality Assurance is responsible for review of reported nonconforma nces,id en tifying trends, and initia ting corrective a etion with the management identified as being responsible. The review shall be R4 documented by a NQAD sent to the FWEA Director.
163.2 The responsible management shall determine the cause of the problem, provide a recommended corrective action and scheduled completion date. The QA Manager shall review the proposed corrective action and if acceptable, sign and date to show his concurrence.
1633 Quality Assurance is responsible for follow-up to assure adequate corrective action has been completed and for maintaining corrective action records.
16.4 ConectiveActionhogram.
R3 16,4.1 Qual;ty Assurance shall review FWEA reported nonconformances for R3 significant problem areas at six month intervals to establish the need for R3 corrective action. The Project 'lanager and other responsible R3 management are consulted, as needed, to conduct the review. An NQA R3 Directive indicating the findings is issued by Quality Assurance stating R3 the cause of problem with recommended corrective action.The format R3 shown in Exhibit 16.1 shall be followed.
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InstetWheeletEncIgy_ Corp, Secti:su _16_
Energy Applications, Div.
Pageaof 4 Rev._L Quality.Aasmance.hianual Date:
5/6/92 0_
16.4.2 An NQAD issued by Quality Assurance describing the problem and the cause with the plantied corrective action and completion date shall be submitted to the management responsible for the problem with copies to R4 the FWEC Director, Project Manager and Quality Assurance.
16.4.3 Quality Assurance shall follow-up the conunitted corrective aetion within 30 days of the scheduled completion date to assure corrective action has been taken. When the corrective action has been found to be satisfactorily completed, Quality Assurance shall so indicate an NQAD by signature and dateindicating close out.
16.4.4 Quality Assurance shall review subcontractor nonconformances for significant problems. When a trend has been identified, the Quality Assurance Manager shall initiate a letter requesting cause and corrective action be sent to the vendor via Purchasing. Purchasing shall maintain a log of corrective action requests and the log shall provide for a record of request status. ' Die letter shall describe the nonconformance and recommend corrective action to prevent recurrence. Implementation and effectiveness of the corrective acuan shall be verified at the next scheduled audit or source hospection. Failure of a vendor to respond to a request for corrective action shall be cause for removal from the Approved Vendor List.
5151a 19
Page 4 of 4 Rev. 4 5/6/92
- 1) HQA DIRECTIVE TO:
CC:
SUBJECT:
REFERENCE:
PROBLEM:
R3 CAUSE:
PROPOSED CORRECTIVE ACTION:
COMPLETION DATE:
R3 QA APPROVAL:
DATE:
CORRECTIVE ACTION TAKEN:
FOLLOW UP:
ACCEPTABLE UNACCEPTABLE CLOSE OUT:
DATE:
R3 QA APPROVAL:
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Easter.Wheelez.EnergyIorp.
Secti:n: _11 Energy Applications, Div Page1 of 5 Rev._fi_
Date:
5/02.
QnAllty3Saurance Manual O
17.0 QUALITY ASSURANCE.llECORDS INDEX PAGE INDFJ 1
17.1 PURIOSE 2
17.2 SCOPE 2
R6 17.3 RESIONSIBIIITIES 2
R6 17.4 RECORDS 2
R6 17.5 REVIEWOFRECORDS 4
17.6 STORAGE 4
17.7 VALIDATION 5
17.8 MATERIALSUPPLY 5
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foster.Whccler.Enczgy_ Corp.
S:ctirru
_12._
Energy Applications,Div Page 2 of 5 Rev._fL QualityJssurance Manual Date:
5W92.
17.0 QUALIIYASSURANCERECORDS 17.1 Purpose.
To establish basic requirements for the colkrtion, distribution, s etention, retrieval and review of Quality Assurance records.
17.2 S. cope.
This section describes the procedures used in the FWEA Quality Assurance Program for the maintenance of Quality Assurance records to meet Code, Regulatory and contract requirements.
17.3 Respatuihilitiet 17.3.1
'Ihc Quality Assuranm Manager is responsible for initiating a record index at the surt of the job for the collection, retention and transmittal of recor ds ao required by the Owner. Quality Assurance is responsible for:
Assuring that records are either originals or are legible copies, a.
properly identified and in satisfactory condition.
b.
Providing access to records for management; the client, the customer; the Authorized Inspector or other Authorized Personnel, Assuring that records are maintained in such a manner that they are c.
protected from deterioration and damage.
d.
Maintaining a system for retrieving records includin.
ctification of the storagelocation.
R6 17.3.2 Quality Assuranm is also responsible for collecting and retalning legible records from vendors.
17.4 Recuds 17.4.1 Records shall be maintained as required by contract and shall be distributed to the Owner or his agent.
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EastcLWhccicLEncIgy_Com Sectiom
._12_
C Energy Applications,Div Page 3 of 5 Rev._fL, QuAlllyd$lulante. Manual Dates.J/fa!9L 17.4.2 Records shall be identified with part, serial (as required) and job numbers so as to be traceable to the items and activities to which they apply.
17.4 3 The lifetime record file shall include those records required by the Code for Classes 1,2, MC and CS, and thos.c designated by the Owner Client for Quality Assurance, Manufacture, Maintenance and traceability.ney shall be maintained for thelife of the item and shallinclude,but need not belimited to:
a.
Index b.
Code Data Reports c.
Design Specification d.
Designdocumentse.g. Certified designreportanddesigndrawings Certified as built drawings and Master Drawing 1.ist e.
f.
Certified Material certifications with traceability to location used g.
Hett treatment rc< ords h.
Fmal Hydrostatic and Pneumatic Test Results 1.
Final nondestructive examination reports including results of examination. Reports shall include required SNT TC 1 A information.
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Final radiographs as specified by the owner for Section XI applications.
k.
held procedures used 1.
Repair records Nonconformance reports affectinglifetime records m.
For Class 3, only records a, b, c, d, f, g, j, k, and m apply.
17.4.4 ne nonpermanent records shall include those records rc luired by the Code for Classes 1,2, MC and CS and shallbe classified as nonpermanent records and shall be maintained for the Project. The nonpermanent records required by the Code are:
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SectI!m U
Energy Applications, Div Page 4_oll. Rev. 1 p
QualliyAinuancthianual Date:
5/fd9L Reientionferiod QA Program Manual 3 years a.
b.
Design, Procurement, & QA Procedures 3 years c.
Installation & NDE Procedures 10 years d.
Personnel qualification records of the NDHPersonnel, Welders, Weld q t
Operators, Auditors,andinspect anand test personnel 3 years c.
Purchase Orders 10 years f.
Audit and Survey Reports 3 years g.
Fmal radiographs not covered by lifetime records 10 years R6 h.
Calibration records
- UntilRecalibrated i.
Process sheets, travelers, checklists 10 years J.
Joint welder identification remrd when used in lieu of stamping 10 years k.
Non-conformance reports affecting non-permanen... cords Same as Applicable Record For class 3 only records e, g and h apply 17.4.5 Nonconfonnance re sorts which affect these records listed !!!fetime and non permanent) sha 1 be retained with the applicable reccrds, 17.4.6 During the work, lifetime m.d non nanent records will be stored accessible to project personnu at th iome Office or Work location unless otherwise specified by the Quality Assurance Manager. 'Ihe QA Manager shall be responsible for accumulation of the required records.
17.5 Review of Records 173.1 Records shall be reviewed by Quality Assurance for legibility as they are made available during the course of the work. QA shall document the R6 revkw by initials and date on the record or on the front sheet of a group R6 (section) of records.
17.6 S.torage.
17.6.1 Prior to storage of records a wdtten storage precedure shall be prepared by QA Manager and responsibility assigned for enforcing the requirements of that procedure. This procedme shall include, as a minimum, ta) through (g)below:
(a) description of storage facility; (b) the filing system to be sued; (c) a method for verifying that the records received are in agreement with the transmittal document and that the records are legible; R6 ' Includes accumulated calibration data to substantiate and evaluate instrument / equipment O
assessment / adjustments, as necessary, made during calibration.
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foster.WheeletIncigvIorp.
Energy Applications, Div Page,Lgli, Rev. _L.
Dale!.5/fdL DuAlityEAMIAnCCMARRAI (d) a method of verifying that the records are those designated; (e) The rules governing access to and control of the files; (0
a method for rnaintaining control of and account ability for 1
secords remov(d from the storage facility; ion and disposing a method for filing supplementalinformat (g) of superseded records.
17.6.2 Lifetime and nonpermanent records shallbe stored in a manner that will protect them from deterioration orloss that would prevent their use. This may include duplicate copies stored separately.
17.6.3 Files of completed Code items records are stored in steel cabinets in a locked segregated area located in a fireproof building.
17.6.4 Access to these files shall be limited. The Quality Assurance Manager or designee shall be responsible for the integrity and access to the files.
Access shall be limited to a list of personnel established and maintained by Quality Assurance / Quality Control.
17.6.5 When dupilcate copies of Qulity Assurance Records are made for storage on microfilm, the accuracy of resolution shall be such that the copies O
information is complete and legible.
17.6.6 Reords shall be identified by subject, date originated and date recorded.
There shall be a system for retrieving records, including identification of storage location. A charge-out card system shall be used to identify persons removing records from file.
17.6.7 Records shall be corrected when required by single line through the erroneous entry entering correct information and the initials and date of the person authorized by the Manager of QA to make the Correction with the concurrence of the originating organization.
17.7 ValidAllon.
Records shall be validated by initiating, signing and dating. This validation shall be by the person responsible for the record or person authorized by the Quality Assurance Manager.
17.8 MaledalSupp]y.
For material supply, all records shall be maintained and certified by the Quality Assurance Manager.
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Sectitru _11L fositLWheeletEnergy_ Corp.
Energy Applications, Div.
Page 1 of 6 Fw._L.
Date: Jil6/92.
QualityAssurance. Manual O
18.0 AUnlTS 1ND1%
PAGE 1
INDEX 2
18,1 PURPOSE 2
18.2 SCOPE 2
R4 18.3 RESPONSIBILITIES 18.4 EVALUATION OF QUALITY ASSURANCE PROGRAM -
3 18.5 SUBCONTRACTEDMANUFACTURE ANDINSTAllATION 4
4 R4 18.6 QUALIFICATION OF AUDTIOR PERSONNEL R4 18.7 hW4AGEMENTREVIEW 5
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Secti:ru 18 Energy Applications, Div.
Page 2 of 6 Rev._1_
QualityAssurancc11anual Date: Jil6/fl 18.0 AUDIIS 18.1 Purpose.
To establish requirements for planned and periodic auditing of the Quality Assurance Program to deterr Me its effectiveness in meeting Code, Regulatory, and contract requirements.
18.2 Scope.
This section describes the audit program for assuring compliance with the FWEA Quality Assurance Program.
183 Itcspmulbilitics.
183.1 The Quality Assurance Manager is responsible for establishing and implementing an audit program to assure compliance with Code, Regulatory, and contract requirements.
183.2
'Ihe Quality Assurance Manager is responsible for assuring that the entire q
program is audited annually!n accordance with a schedule prepared and Q
maintained by the Quality Assurance Manager.
1833 Quality Assurance is responsible for re-audit of any deficient areas found and for making audit reports available to the Authorized Inspector.
183.4 T1.e Manager of Quality Assurance and/or QA/QC Supervisor (as applicable for Home Office or Work Location) is responsible for the selection and assignment of qualified Lead Audhors.
R4 183.5 The FWEA Director is responsible for assigning Management Personnel (lead Auditor indeper. dent of Qvslity Assurance) to periodically (minimum, annually) audit the Quality Assusance Activities Program.
Deficient areas will be re-audited.
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Page3offt Rev.._(_
QuAlliy_ Assurance.AianuAl Date:.326/9L
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I 18.4 Exaluatiqn.0LQualitylliuIanscAogtata.
18.4.1 The Quality Assurance Manager or his designec audits on an annualbasis, quality assurance methods, procedures, instructions, manual and other acthities affecting quality of the product in order that all aspects of the program are audited.
18.4.2 The FWEA QA Manager shall arrange for internal home office and work location audits in accordance with a schedule. The FWEA Quality Assurance Manager shall assign a lead Auditor to perform the audits.
The lead Auditor shall designate his audit team and prepare an audit plan which shall identify: audit scope, requirements, audit personnel, activities to be audited, organizations to be notified, applicable documents, schedule, and shall provide the audit checklist.The audit plan shall include the Lead Auditor's concurrence that the designated sudit team is adequate for performance of the audit. The audit plan shall be approved by the QA Manager.
The audit team performs the audits in accordance with the audit plan. The O
Lead Auditor prepares, signs and dates the audit report which will include the following information as appropriate:
(a) Description of the audit scope (b) Identificationof theauditors (c) Identification of persons contacted during audit retivities (d) Summary of audit results, including a statement on the effectiveness of the quality assurance program elements which were audited (e) Description of each reported adverse audit finding in sufficient detail to enable corrective action to be taken by the audited organization The QA Manager approves the audit report and distributes it to the Manager (s) of the audited areas to report the audit findings and establish corrective action in accordance with Section 16. The audit area manager investigates the audit findings to prevent recurrence and notifies quality assurance of the action to be taken. Quality Assurance Manager concurs with the action to be taken. Reaudits of corrective action with objective evidence is required to close out the audit, b,A
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Section: _1B_
[oster WhccletEncigylorp, Page 4 of 6_ Rev. 4 Energy Applications, Div.
Date: _5/6/9L C')s Quality _ Assurance. Manual
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18.5 Suhtentractedldanufacture andlnstallation.
The Quality Assurance Manager shall provide for surveys and Audits of vendors by a Lead Auditor for compliance with the vendor's Quality Assurance Program and the requirements of the INVEA Purchase Order using a written check!kt.
Surveys and Audits will be conducted as described in Section 7.
18.6 Qualificallon.oLAudit Personnet The Quality Assurance Manager shall prepare and approve a procedure for the qualification and certification of auditors and Lead Auditors; the procedure shall include the following:
Auditors and prospective Ixad Audite ' shallhave the ability to communicate a.
effectively both orally and in writing. The Quality Assurance Manager or Corporate Director of Quality Assurance shall attest to this in writing.
b.
Auditors and prospective Lead /,"litors shall have training as deemed necessary by the QA Manager to assure their competence in auditing skills.
This training mayinclude:
O Knowledge and understanding of applicable codes, standards,
(_/
(1) regulations and regulatory guides as applicable.
(2)
General structure of Quality Assurance programs.
(3)
Auditing techniques.
(4)
Audit planning (Lead Auditors only).
(5)
On-the-job training in the applicable elements of the audit program.
Training may be waived based upon satisfactory education, experience and previous on the job performance. Justification of waiver shall be documented.
Prospective Lead Auditors shall have participated in five (5) Quality c.
Assurance audits in a period of time not to exceed three (3) years prior to qualification, one of which shall be a Nuclear Quality Assurance audit within the year prior to qualification.
The prospective Lead Auditors shall pass an oral examination. A record of the d.
questions shall be maintained by the Quality Assurance Manager arid the results shallbe documented.
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EoitetWheeletEncigy_ Corp, S:cti:n:
11L Energy Applications, Div.
Page 5 of 6 Rev.._L.
Quality _AssuIance Manual Date: Jil4/9L
(,3 q.J' Auditors and prospective lead auditors shall maintain their proficiency of R4 e.
R4 audit skills by regular active and continued participation in the audit process R4 1.e. internal audits, vendor surveys and audits; review and study of codes, R4 standards, procedures, etc. related to the Quality Assurance Program and R4 participation in training programs. Lead Auditors shall have their R4 qualification extended based on annual assessment by the Quality Assurance R4 Manager. This evaluation shall be documented.
f.
Lead auditors who fall to maintain their proficiency for a period of two years or moie shall reluire requalification. This shall include examination in accordance with (d) and participation as an auditor in at least one nuclear quality assurance audit.
g.
Prior to commencing an audit, the Lead Auditor shall concur that assigned per sonnel collectively have the experience or training conunensurate with the scope, complexity or special nature of the activities to be audited.
h.
Records of personnel qualifications for auditors and Lead Auditors shall be established and maintained by the Quality Assurance Manager.
i.
The Quality Assurance Manager shall certify auditors and Lead Auditors.'Ihis certification shallinclude:
n (VI (1)
Company name (2)
Auditor or Lead Auditor's name (3)
Date of Certification or recertification (4)
Basis o, qualification (i.e. education, experience, communication)
(5)
Certifier signature with date.
J.
Records of auditor and Lead Auditor shall be maintained and updated annually by the Quality Assurance Manager.
18.7 hianagementRcriew_
18.7.1 On an armual basis, the Quality Assurance Manager shall report to the R4 FWEA Director advising on compliance with the Code, Regulatory Requirements and this manual and the effectiveness of the QA program.
R4 The assessment report shall be reviewed by the FWEA Director who shall indicate his acceptance or comment.
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Section: __18 Essier Wheeler EncigyDap.
Energy Applications, Div.
Page 6 of 6_ Rev. 4 Date: ;_5/6/92-O ualliyJusutanceManual Q
18.7.2 The General Mgr. reviews the Quality Assurance Program by:
(a) Reviewing management reports, (b) Reviewing the results of internal and external audits, (c) Any other pertinent informa tion. such a s trends of nonconformances and corrective actions.
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- _1!L Energy Applications, Div.
Pagelpli Rev._2_
Quallly331RTAnCC.hianUAl Date: 12/14/90 19.0 AUIllORIZEDNUCLEAILINSEECHON INDEX 1%GE R2 INDEX 1
19.1 PURPOSE 2
19.2 SCOPE 2
19.3 RESPONSIBILITIES 2
19.4 INTEGRATION OF AUTHORIZED INSPECTION PROGRAM IN THE FWEA QUALITY ASSURANCE PROGRAM 2
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0151a 19
Eosicr_ Wheeler. Energy Corp.
S:ctiom
_19._
Energy Applications, Div.
Page 2 of 5 Rev._2_.
Quality _ Assurance 11anual Date: 12/2 0 0 19.0 AUEllORIZED NUCLEAILINSEECHON 19.1 Entpsss This sect!on establishes the : esponsibilities of IMEA in assisting the Authorized inspector in the discharge of his duties.
19.2 Scoge This section establishes provisions in the FWEA Quality Assurance Program for the Authorized Inspector to fulfill his duties in meeting Code requirements.
19.3 Responalhlllites.
19.3.1 The Quality Assurance Manager or QA/QC Supervisor is responsible for:
(a) Making copies of the Certified Design Specifications, the Quality Assurance Manual and project, design, process and certification documentation available to the Authorized Inspector.
(b) Providing acctss to the Authorized Inspection Agency g
Representative.
(c) Acting as official contact with the Authorized Inspector at his location.
19.4 Integrallon.nfaniho11redlnspection Funclinain the FWEA Oualitylslutante Program 19.4.1 Access for Authorized Inspector The Authorized Inspector shall:
t (a) Have free access at all times to thoselocations where Code activities are being performed; (b) Be kept informed of the progress of the work; and (c) Be notified, a reasonable time in advance, when his presence is required for designated Hold Points.
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foster.WheeletEncigyf.orp.
Sectioru 19 Energy Appilcations, Div.
Page 3 of 5 Rev..l Qualliy.Assmancc11anual Date: 12dil911 19.4.2 The Quality Assura;.cc Manager or QA/QC Supervisor shall review the wor k package, process informa tion, hea t trea tment operations; applicable Inspection points, drawings, changes in procedures or instruction, and nonconformance dispositions with the Authorized Inspector for his designation of Hold Points. Work shall not be performed beyond designated IIold Points until the Authorized Inspector has indicated his acceptance by sign-off.
19./. 3 Interface with theAuthorized inspfvtor The Quality Assurance Manager or QA/QC Supervisor shalt be the offidal contact with the Authorized Inspector. Documentation such as design specification; design drawings; design reports; NDE proctdures; weld material and heat treat records; and examination and test reports shall be available for his review, when requested.
19.4.4 Nandestructivelixamination (a) He Authorized Inspector will be given the opportunity to verify the certification of NDE operators to the requirements of SNT 'IC 1 A and the Code and to audit the training programs.
(b) All procedure and operator qualifications shall be submitted for review by the Authorized Inspector. The Authorized Inspector shall be given the opportunity to witness nondestructive examinations and assess procedure capability.
(c) ne Authorized Inspector may require requalification of a procedure or operator when he has reason to question the NDE procedure or operator's performance.
19.4.5 IVelding Control ne authorized Inspector will be afforded the opportunity to witness an i /or review the following areas of welding, as a minimum:
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_19_.
Fnergy Applications, Div.
Page 4 of_5 Rev. 1,.
o Q.uall.ty_Assuranse Manual Date: 12/1 0 0
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(a) Weld Procedure Qualification and Certification. (Weld Procedure Specification and Procedure Qualification Record shall be submitted to the ANI)
(b) Weld Proc
- Jure Application (c) Weld Inspection (d) Weld Records (e) Welder Qualification Records (f) Tlu. Authorized Inspector may require requalification of the procedure or personnel when he has reason to question the weld procedure or welder's performance.
19.4.6 Final Tests. Data ReoortCertification and Stamping (a) The Quality Assurance Manager or QA/QC Supervisor shall arrange for the Authorized Inspector to witness final hydrostatic or h
pneumatic tests and other examinations required by the Code.
J (b,
o completion of work at the work loc 210 the QA/QC Supervisor shall prepare the appropriate Data Twpurt. The Quality Assurance Manager shall review the data package and the Data Report and when satisfied, he shall certify the Data Report.
(c) The Quality Assurance Manager shall submit the Data Report and all required documentation to the ANI for his review and certification.
(d) After the Data Report has been certified by the ANI, the nameplate shall be stamped in the presence of the ANI. (In the case of core support structures, the marking and stamping shall be applied dir etly to the support.)The nameplate shall then be attached by a method that will not affect the structural integrity of the item. The i
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foster wheder Enerev corn.
Section: 1 Energy Applications, Div.
Page 5 of 5 ReW 1_
Quality Asautance Manual-Date: 12/1U90 Quality Assurance Manager shall assure that the nameplate has been attached to the correct item and the 'ANI shall verify that this has been done and he shall sign the process she
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(e) In case the nameplate cannot De attached dir 4
.t heitem(due to size or other considerations), the nameplate, y be ittached in a:
manner acceptable to the ANIc This alternate method shall be.-
documented by the Quality Assurance Manager and the ANI shall be requested to sign and date the document to show his concurrence.
19.4 I Audit The Quality Assurance Manager and Authorized Inspector shall accoupany the ANIS during his audits.
19.4.8 FWEA shall submit to the Authorized Inspector the certified reports of the results of tests performed to the requirements of:
(a) The materialspecifications O
(b) Applicable material requirements specified by the Code including certified report of the required test and examination results.
19.4.9 All quality documentation, including CMTR's, COC's, Procedures, Drawings, personnel training and qualification records, Inspections, Examinations and test records Weld Material records, heat treat, calibration records,nonconformance reports, and Design Reports shall be.
made available to the Authorized Inspector.
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