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{{#Wiki_filter:y' s-1                          UNITED STATES OF AMERICA 2                        NUCLEAR REGULATORY COMMISSION 3
4        BEFORE THE ATOMIC SAFETY AND LICENSING APPEAL BOARD 5
6 7
8                                          )
In the Matter of                        )    Docket No. 50-275 9                                          )
PACIFIC GAS AND ELECTRIC                )
10  COMPANY                                )    (Low Power Proceeding)
                                                        )
11  (Diablo Canyon Nuclear Power            )
Plant, Unit No. 1)                      )
12                                          )
13 14 15      AFFIDAVIT OF R. C. ANDERSON, J. B. HOCH,          G. H. MOORE, M. R. TRESLER, W. H. WHITE 16 17 18 STATE OF CALIFORNIA                    )
19                                          )    ss.
CITY AND COUNTY OF SAN                  )
20  FRANCISCO                              )
21 22 23  The above being duly sworn, depose and say:
24
(          25                    1. On September 28,      1981 PGandE noti fied the l
26  Regional Administrator of the NRC's Region V Office of l
l
!    C207070340 920702 PDR ADDCK 05000275 PDR O
 
O' 1 Inspection and Enforcement of a potential problem in the 2 analysis of piping systems contained in the annulus area of 3 the containment building. In response, the Staff issueu 4 Board Notification No. 81-27 and scheduled a series of 5 public meetings with PGandE to discuss the problem and 6 structure a program to resolve it.      PGandE meanwhile 7 implemented a design verification program to address 8 discrepancies it had found in the seismic design of the 9 annulus area of the containment.
10          2. PGandE's  program has  subsequently been 11 expanded  into  two  separate and comprehensive design 12 verification programs; one being performed by a group of 13 independent reviewers    and  the other being performed 14 internally by the PGandE/Bechtel Project (" Project"). These 15 programs will verify, on an extensive sampling basis, both 16 the seismic and non-seismic design of safety related 17 structures, systems and components for the Diablo Canyon 18 plant.
19          3. The verification program performed by the 20 group of independent reviewers is called the Independent 21 Design Verification Program ("IDVP").      This program is 22 managed and supported by Teledyne Engineering Services 23 Company with R. L. Cloud Associates, R. F. Reedy Inc. and 24 the Stone and Webster Engineering Company performing 25 independent design verification work in their respective 26 areas of responsibility:  R. L. Cloud Associates -- seismic,
                                                                                                      /
 
g.
1 1 structural and mechanical design;      R. F. Reedy -- quality 2 assurance;    Stone and Webster    --  systems design. The 3 Independent Design Verification Program includes performing 4 independent analyses and reviews, on a sampling basis, to 5 verify the adequacy of the design.        Some of the areas in 6 which  technical    verifications    are performed  include 7 structures, piping and supports, equipment qualification, 8 electrical raceways and ventilation duct supports,          and 9 system design.      The verification program, moreover,      is 10 designed to be self-expanding if deemed warranted by the 11 IDVP. The program establishes criteria for performance of 12 such additional verifications resulting from either the QA 13 reviews or the sample calculations.        Detailed descriptions 14 of the independent program are contained in "Diablo Canyon 15 Nuclear  Power    Plant  -  Unit 1,    Independent  Design 16 Verification Program, Program Management Plan, Phase I,"
17 approved by the NRC in a letter dated April 27, 1982, and 18 Phase II,  "Diablo Canyon Nuclear Power Plant - Unit 1, 19 Independent Design Verification Program, Program Management 20 Plan, Phase    II,"  submitted to the NRC on June 18, 1982.
21 These plans are attached to this affidavit.
22            4. The  Project internal    technical  program 23 includes verification work performed by a combined team of 24 PGandE and Bechtel personnel.        As a part of the Project 25 internal technical program, URS/Blume has conducted the 26 Blume Internal Review (BIR).      The Project work includes 1 reverification of additional samples as well as responding 2 to the findings of the IDVP. The Project internal technical 3 program also includes specialized analysis and qualification 4 work being performed by Westinghouse Electric Corp. and TERA 5 Corp. The technical verifications are being performed in 6 the  areas    of seismic and non-seismic safety-related 7 structures, systems and components.      This program was also 8 approved by the NRC Staff in its April 27, 1982 letter.
9            5. The two verification    programs have been 10 established in strict accordance with the November 19, 1981 11 Commission order, and the letter from Mr. Harold Denton, of 12 the same date. All verification efforts, both the Project's 13 and the independent reviewers',      are being performed in 14 accordance with the latest approved Quality Assurance 15 programs for the involved companies.
16            6. Over the past 9 months an extensive amount of 17 verification and review work has been performed under the 18 two verification programs.      The organizations involved in 19 the verification programs have expended approximately 2,500 20 man-months or in excess of 400,000 man-hours in reviewing 21 structures,    systems and components. In this effort, 22 thousands of calculations and analyses have been reviewed.
23            7. The IDVP to date has yielded 172 findings.
24 The vast majority of these findings are not errors, and very 25 few are errors of actual or potential significance.        Under 26 the classification system used in the IDVP, all findings are
 
1 first characterized as an "Open Item."      (See attached 2 Glossary.)  An Open Item is either a QA or Design Control    .
3 deficiency, a violation of the verification criteria, or an 4 apparent inconsistency identified in the performance of the 5 work. Each Open Item is ultimately recategorized as an 6 " Error," a " Deviation," or a " Closed Item."  Errors are 7 broken down into four categories, with Class A Errors being 8 the most significant and Class D Errors being the least 9 important. When the IDVP effort related to an Open Item is 10 complete, the IDVP issues a completion report. Of the 172 11 IDVP findings to date, completion reports have been issued 12 for eighty-nine (89) items, which have been categorized as 13 follows:  only one (1) Class A Error (may require physical 14 modifications or changes in operating procedures), no 15 Class B Errors (resolvable by more realistic calculations or 16 retesting); six (6) Class C Errors (no design criteria or 17 Operating  limits exceeded);  seventeen (17) Deviations 18 (departure from standard procedure which are not mistakes in 19 analysis, design,  or construction),  and fifty-two (52) 20 Closed Items (neither Errors nor Deviations, with no further 21 IDVP action required). Of the remaining eighty-three IDVP 22 findings for which no completion reports have been issued, 23 the IDVP has identified these findings as follows:  five (5) 24 Class A Errors; one (1) Class B Error; fifteen (15) Class C 25 Errors; no Class D Errors; seven (7) Deviations; fifty-four 26 (54) Open Items; and one (1) Closed Item.
1            8. The engineering design process, particularly 2  for seismic design, generally involves a complex combination 3 of engineering judgment,      expert opinions,  assumptions, 4 modeling    techniques,    computer  analyses  and  other 5 calculational methodology which is all directed toward 6 developing a reasonable understanding of the performance of 7 structures,    systems    and components  under postulated 8 Operating, accident and seismic conditions.        Final designs 9 are then developed based on this understanding.        The final 10 design considers inherent conservatisms as well as specific 11 margins  and  " safety"  factors applied throughout the 12 engineering process to cover certain changes, discrepancies 13 and unknowns.      It is not surprising,    then,  that an 14 independent verification program would discover differences, 15 discrepancies and even technical disagreements with the 16 original designs.      Furthermore,  although these kinds of 17 items have been surfacing throughout the verification 18 programs'  development thus far,      these differences are 19 exaggerated by the " low threshold" of the identification 20 criteria used for the IDVP.
21 ///
22 ///
23 ///
24 25 26 1                9. While the overall verification effort has 2    identified a number of Open Items, Deviations, and Errors, 3    in our judgment, the findings thus far in the review of the 4    seismic design for the Diablo Canyon plant would not have 5    caused any system, structure or component to fail to perform 6    its intended safety function.
7 8    Dated:    June 30, 1982 9
10                                                .
                                  ' ' ' = ~ -
11 Richard C. Anderson                  hichael R. Tre'sler i  '
William H. White 15            %
Gary    . Moore 16 17 18 Subscribed and sworn to before 19    me this 30th day of June, 1982 20
          ,-                    p 21 (Nancy J./ Lemasttrr, 22    Notary Public in and for the City and County of San Francisco, 23    State of California.
My commission expires April 14, 1986.
24 25 26 1                PROFESSIONAL QUALIFICATIONS OF 2                      RICHARD C. ANDERSON 3
4 5
6          My name is Richard C. Anderson. I am the 7 Engineering Manager in the Diablo Canyon integrated project 8 organization consisting of the Pacific Gas and Electric 9 Company and Bechtel Power Corporation employees. I am a 10 Registered Mechanical and Nuclear Engineer in the State of 11 California. I hold a BS degree in Mechanical Engineering 12 from the University of California at Berkeley.
13            I have been with Bechtel for more than 24 years 14 and for the past 5 years have been assigned as an engineer-15 ing manager in Bechtel's San Francisco Division, responsible 16 for all engineering work in the Pacific Northwest and Japan.
17 I have been assigned since March, 1982 specifically to the 18 Diablo Canyon Project to act as Project Engineering Manager.
19 Prior to these Engineering Manager assignments, I was the 20 chief nuclear / environmental engineer for Bechtel's San 21 Francisco Power Division, involved in nuclear power plant 22 design, safety, and operation.
23          Prior to that, I was assigned as an assistant 24 project engineer on a proposed nuclear power plant project 25 for PGandE and as mechanical supervisor and later project 26 engineer on another large nuclear power plant project in the i
1 United States. These assignments included supervision and 2 coordination of design, specification, procurement,    and 3 quality control activities.
4          I also served as senior mechanical engineer for 5 various other nuclear power facility projects in the U.S.
6 and abroad, which included work in systems, safety and 7 equipment engineering.
8          I have been an instructor in Bechtel's power plant 9 courses for over 10 years and have given numerous talks and 10 lectures in California on nuclear power and energy issues.
11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
 
1                PROFESSIONAL QUALIFICATIONS OF 2                          JOHN B. HOCH 3
4 5          My name is John B. Hoch. Since January 1982 I 6 have been employed as Project Manager of the Diablo Canyon 7 Project organization at PGandE. My responsibilities include 8 managerial and supervisory duties, and providing coordinate 9 and direction of the Diablo Canyon Project organization.
10          From 1980 to 1982 I was employed as Manager of the 11 Nuclear Projects Department at PGandE. My responsibilities 12 include managerial and supervisory duties, and providing 13 coordination and direction of the Nuclear Projects 14 Department in matters related to'PGandE's nuclear power 15 plants.
16          From 1959 to 1980 I was employed as an Engineer in    ,
17 various disciplines in PGandE's Engineering Department.      My 18 responsibilities included engineering,    design,  analysis 19 work, activities related to NRC licensing, and engineering 20 management for PGandE's Diablo Canyon Power Plant.
21          My educational background includes a BS degree in i  22 Mechanical Engineering from the Univeristy of Idaho, 1959, 23 and  graduate  studies  in Engineering,  University of 24 California, Berkeley, 1961 to 1962.
25          I  am  a  Registered  Professional  Engineer 26 (Mechanical and Nuclear) in the State of California.
 
1                  PROFESSIONAL QUALIFICATIONS OF 2                          GARY H. MOORE 3
4 5
6          My name is Gary H. Moore. I am the Unit 1 Project 7 Engineer of the Diablo Canyon Project consisting of the 8 integrated organization of Pacific Gas and Electric Company 9 and Bechtel Power Corporation.      I have held this position 10 since January, 1982.      I am responsible for the project 11 engineering work related to the design and analysis of 12 Diablo Canyon Power Plant Unit 1.        I am a Registered 13 Professional Engineer in Mechanical and Control Systems in 14 the State of California.
15          My educational background is as follows:
16 San Jose State University - BS in Mechanical Engineering, 17            1968 18 San Jose State University - MS in Mechanical Engineering, 19            1969 20            I joined PGandE in 1969 as a Mechanical Engineer 21 in the Mechanical and Nuclear Engineering Department, 22 designing instrumentation and control (I&C) systems for 23 conventional fossil plants.
24            In 1977, I was named a Senior Mechanical Engineer 25 supervising the I&C Group assigned to the Potrero Unit 7 26 Project.
L.
 
M 1                In 1979,  I was named Supervising Mechanical 2    Engineer, supervising the Mechanical and Nuclear Engineering.
3    Department's entire I&C Group, including responsibility for 4    the I&C design of the Diablo Canyon Power Plant.
5                I have completed the following formal training 6    courses:                                            - s 7    Simulator Training - Westinghouse Nuclear Training Center, 8                Zion, Illinois                                    ,
9    Westinghouse PWR Information Course 10 11 12 13 14
  .15 16 17 18 19 20 21 22 23 24 25 26
      ,            -      -                    ,      - - , -    - -  . ~  n. -n~.
 
1                  PROFESSIONAL QUALIFICATIONS OF 2                          MICHEL R. TRESLER 3
4 5            My name is Michel R. Tresler. From 1981 to the 6 present I have been employed as a Piping Design Coordinator 7 at PGandE.      My responsibilities    include supervision, 8 coordination, and direction of the piping and pipe support 9 analysis and design for Diablo Canyon Power Plant.
10            From 1980 to 1981 I was employed as a Supervising 11 Project Control Engineer in PGandE's Nuclear Projects 12 Department with responsibility to develop, implement and 13 maintain a project control system for Diablo Canyon Power 14 Plant.
15            From 1964 to 1980 I was employed in various 16 Positions as an engineer and superintendent in PGandE's 17 ensi neering Department and General Construction Department.
18 During that time, I held the positions of Engineer, Resident 19 Mechanical Engineer, Project Superintendent, and Assistant 20 Station Construction Superintendent.      My responsibilities 21 included engineering, analysis, design, field engineering 22 services, and supervision and management activities related 23 to large fossil-fired units and the Diablo Canyon Power 24 Plant. In particular from 1966 to 1970 I prepared startup 25 Procedures and supervised startup activities related to 26 fossil and nuclear power plants.
1          My educational background includes a BS degree in 2 Mechanical Engineering from the California Polytechnic State 3 University, 1964.
4          I have completed the following formal training 5 courses:
6 a. Westinghouse Reactor Operator Training School, 1969.
7 b. Westinghouse Design Lecture Series specific to Diablo a      Canyon, system and components design, 1971.
9 c. Stat-A-Matrix course covering the establishment of a QA 10      program and personnel training, 1973.
11 d. Westinghouse PWR Information Course, 1980.
12 e. Westinghouse simulator Training, 1980.
13 14 15 16 17 18 19 20 21 22 23 24 25 26 1                PROFESSIONAL QUALIFICATIONS OF 2                      DR. WILLIAM H. WHITE 3
4 5
6          My name is William H. White. I am an Assistant 7 Project Engineer in the Diablo Canyon integrated organiation 8 consisting of Pacific Gas and Electric Company and Bechtel 9 Power Corporation employees. My responsibilities include 10 supervision and direction of seismic related engineering 11 analyses for the Diablo Canyon Unit 1 Project Engineering 12 Organization. I am a Registered Professional Engineer    and 13 member of the American Society of Civil Engineers.
14          My educational background includes:
15 BS, Civil Engineering, University of Idaho; 16 MS , Civil Engineering, University of Colorado; 17 PhD, Civil Engineering, University of Colorado 18          For the past 5 years, I have been an engineering 19 specialist with Bechtel's San Francisco Power Division 20 working with the chief civil engineer's staff in the area of 21 seismic analysis for several Bechtel projects.
22          Earlier,  I was a structural engineer with the 23 Tennessee Valley Authority where I was responsible for 24 seismic analysis of all Category I      structures for a 25 twin-unit nuclear power plant, including the seismic input 26 for the design of the nuclear steam supply system.
1            I was an assistant professor at Oregon State 2 University where I taught undergraduate and graduate courses 3 in  structural  mechanics  and  analysis  and computer 4 applications. I performed a special study for Bechtel on 5 soil-structure  interaction for the proposed Mendocino 6 nuclear power plant while teaching at Oregon State 7 University.
8          While  employed  at  the Bettis Atomic Power 9 Laboratory,  I was a senior engineer working on shock 10 analysis of nuclear reactors aboard submarines and was 11 involved in programs to assess the shock resistance of 12 reactor internals subjected to long-term irradiation damage.
13 14 15 16 17 18 19 20 21 22 23 24 25 26
 
l l
i                                                                          ;
  '                                                                        \
1                              GLOSSARY 2
3 4
5 IDVP OPEN ITEM 6            This term is used by the independent reviewers to 7 describe any item of concern or potential concern identified 8 by the IDVP that has not been verified, fully understood, 9 and its significance assessed by the IDVP.
10            An Open Item report is issued by the IDVP for the 11 purpose of reporting an IDVP response to a QA and Design 12 control  deficiency,    a violation of the verification        -
13 criteria, such as differences in calculations or system 14 configuration, or an apparent inconsistency identified in 15 the performance of the work.
16 17 IDVP ERROR 18            The term as used by Joint Intervenors in their 19 Motion and by Mr.      Hubbard in his affidavit is a 20 characterization of any and al.'  items identified by the IDVP 21 and Project technical program.      All but a small number of 22 these Open Items have been verified by the IDVP as not being 23 " errors."
24            An Error is a form of program resolution of an 25 Open Item indicating an incorrect result that has been 26 verified as such. It may be due to mathematical mistake,
 
1 use of wrong analytical method, omission of data, or use of 2 inapplicable data. An Error is classified as one of the 3 following:
4            Class A Error - An Error is considered Class A if 5 design criteria or operating limits of safety related 6 equipment  are  exceeded  as  a  result,  and physical 7 modifications or changes in operating procedures are 8 required.
9            Class B Error - An Error is considered Class B if 10 design criteria or operating limits of safety related 11 equipment are exceeded, but are resolvable by means of more 12 realistic calculations or retesting.
13            Class C Error - An Error is considered Class C if 14 no design criteria or operating limits are exceeded.      No 15 physical modifications are required.
16            Class D Error - An Error is considered Class D if 17 safety related equipment is not affected.      No physical 18 modifications are required.
19            From the definitions above, only Class A or B 20 Errors result in exceeding a design criterion or operating 21 limit. Consequently, only Class A or B Errors could be of 22 safety significance, but are not necessarily so.
23 24 DEVIATION 25            This is a term used by the IDVP to identify a form 26 of program resolution of an Open Item indicating a departure
\
1 from standard procedure which is not a mistake in analysis, 2 design or construction. No physical modifications are 3 required, but if any are applied they are subject to 4 verification by the IDVP.
5 6 DISCREPANCY AND DEFICIENCY 7          These terms have been used interchangeably in the 8 Hubbard affidavit and Joint Intervenors' Motion with the 9 terms " error" or " serious design error."
10 11 IDVP CLOSED ITEMS 12          This is a term used by the IDVP. It is a form of 13 IDVP program resolution of an Open Item which indicates that 14 the reported item is neither an Error nor a Deviation. No 15 further IDVP action is required.
16 17 IDVP COMPLETION REPORT 18            This report is used by the independent reviewers 19 to indicate that the IDVP effort related to an IDVP Open 20 Item is complete.
21 22 23 24 25 26 i
  )*
1                    UNITED STATES OF AMERICA      -
2                  NUCLEAR REGULATORY COMMISSION    -
3 4      BEFORE THE ATOMIC SAFETY AND LICENSING APPEAL BOARD 5
6 7
                                        )
8 In the Matter of              )    Docket No. 50-275
                                        )
9 PACIFIC GAS AND ELECTRIC      )
COMPANY                        )    (Low Power Proceeding) 10                                )
(Diablo Canyon Nuclear Power  )
11 Plant, Unit No. 1              )
                                        )
12 13 14                  AFFIDAVIT OF RICHARD S. BAIN 15 16 STATE OF CALIFORNIA            )
                                        )    ss.
17 CITY AND COUNTY OF SAN          )
FRANCISCO                      )
18 19 20 21 The above being duly sworn, deposes and says:
22 23            1. My name is Richard S. Bain. I have been 24 Manager of Station Construction and have had responsibility i
25 for the construction of Diablo Canyon Nuclear Power Plant 26 since 1975. Prior to my appointment as Manager, Station
 
  ).
o 1 Construction, I was the Station Construction Superintendent 2 at PGandE's San Francisco General Offices, and was assigned 3 direct supervision of all construction activities, including 4 supervision of construction contracts for Diablo Canyon from 5 its inception. A summary of my experience and responsibili-6 ties is contained in Attachment A.
7            2. I have carefully read the affidavit of Mr.
8 Richard B. Hubbard dated May 24,    1982 filed with Joint 9 Intervenors' Motion dated June 8, 1982.            I will address my 10 comments specifically to Mr. Hubbard's allegations of an 11 inferred " breakdown" of quality assurance and quality 12 control in the constructi6n and installation of equipment 13 and apparatus at Diablo Canyon.        As      I will comment 14 hereinafter,  PGandE had in place a comprehensive and 15 vigorous on-site construction quality assurance / quality 16 control program. This program was subjected to numerous 17 internal and NRC (AEC) audits during construction activity 18 at Diablo Canyon. No such " breakdown" occurred.
19            3. There were three types of on-site procedures 20 and instructions that were developed and applied at Diablo 21 Canyon to provide the requisite direction for these actions 22 and activities necessary to assure design and quality
;    23 requirements being in conformity with the Quality Assurance 24 Program. They consist of:
25      a. Quality control procedures to establish the 26            control, direction and methods for acceptance of
 
h.
1        physical work performed by PGandE personnel and'as 2        required by the Senior Site Representative to 3        control project activities affecting quality.
4    b. Preoperational and startup test procedures to 5        assure that systems and components meet design 6        requirements. To the extent feasible,                test 7        procedures incorporate approved plant operating 8        procedures and provide for testing of items under 9        simulated operating conditions.
10    c. Field instructions developed by the Resident 11        Engineers  (Civil,  Electrical,  Mechanical,            and 12        Start-up) to provide the Project Superintendent 13        with  supervisory  support  for  the  on-site 14        activities  through Resident Engineers,          Field 15        Engineers and Field Inspectors.      With respect to 16        quality control,    the responsibilities of the 17        Resident Engineers include:      (1) preparation of 18        quality control plans for site-related activities, 19        (2) direction of quality control activities, (3) 20        review  and  approval  of  field contractors' 21        individual  quality  assurance procedures,              (4) 22        supervision of Field Engineers and Inspectors, (5) 23        review  of  site-related  quality    assurance 24        procedures, and (6) preoperational testing and 25        startup.
26 ///
 
1            4. PGandE has always recognized the.importance 2 of supervisory surveillance and inspection during construc-3 tion activity. Even prior to the promulgation of 10 C.F.R.
4 Part 50,    Appendix B and the formalization of quality 5 assurance requirements, PGandE had procedures for cleaning 6 and flushing; shipping, receiving, storage and handling; 7 housekeeping; dimensional checking and quality testing in 8 P l ace at Diablo Canyon.
9            5. The first on-site Quality Control Engineer 10 was appointed in June 1969.          This position has been 11 continuottsly maintained by a succession of engineers since 12 that first appointment.      The purpose of the on-site Quality 13 Control Engineer was to assist the Project Superintendent 14 and resident engineers in implementing the quality program, 15 Provide guidance to the contractors quality groups, and 16 inspect and audit for compliance to PGandE quality program.
17 This inspection / audit was conducted in addition to and 18 supplemental to the quality control inspections and audits.
19 The cn-site quality engineer has remained independent of 20 direct responsibility      for  the  scheduling, cost,  or 21 Performance of construction.
22            6. Quality Control Provedures and Departmental 23 Instructions were developed at Diablo Canyon as early as 24 October 1969 to implement the requirements of the PSAR and 25 Proposed 10 C.F.R. Part 50, Appendix B and PGandE's PSAR.
26 ///
4 d'
1            7. For the construction and installation of the 2 building, equipment, and apparatus at Diablo Canyon, PGandE 3 required that each contractor performing work at Diablo 4 Canyon have a quality assurance program qualified to PGandE, 5 industry, and Nuclear Regulatory Commission (Atomic Energy 6 Commission) quality assurance requirements.      The contractor 7 and any sub-tier contractor or supplier providing a service 8 or material to be installed at Diablo Canyon adhered to 9 these procedures in the performance of work at the site or 10 any other    location affecting materials      or products 11 ultimately destined for Diablo Canyon.      These programs were 12 reviewed,  approved,    and  audited  by  PGandE.  (See 13 Attachments 1,  2, 3 and 4 for illustr:'uve examples. )
14            8. Quality procedures, work practices, personnel 15 quali fications , forms,  etc.,  prepared by contractors were 16 submitted to PGandE General Construction, Quality Assurance, 17 and other departments for review and approval.        The same 18 rigid experience requirements established for Company field 19 engineers and inspectors were also required of contractors.
20            9. Quality control at the Diablo Canyon site was 21 a multi-tiered operation.        As a requirement of all bid 22 specifications, each contractor was required to prepare and 23 staff a site quality assurance / quality control organization 24 adequate to inspect the quality of work performed.        PGandE 25 field engineers and inspectors reinspected this work for 26 compliance with the applicable design documents and Q
1 specifications. The General Construction quality control 2 on-site group was then directly involved in the -verification 3 of the adequacy and effectiveness of the contractors' 4 quality assurance program and the Company's following 5 inspections. Finally, Corporate on-site quality assurance 6 engineers verified the adequacy and effectiveness of the 7 entire process.
8            10. The complementing ratio of Company field 9 engineers and inspectors overseeing the contractors' work 10 varied from a maximum of 18 workers to 1 inspector to a 11 minimum of 8 workers to 1 inspector, and averaged 13.5 12 workers to 1 inspector.
13            11. The first construction QC audit was conducted 14 on February 11, 1970, and from that date there have been 707 15 such audits. In every instance any discrepant condition was 16 corrected.      In every instance of a contractor QA/QC 17 identified discrepancy a Company discrepancy report was also 18 filed to be certain that the condition was properly 19 processed. This duality of documentation established a 20 double-check for satisfactory resolution of the discrepancy 21 ///
22 ///
23 ///
24 i
25 26 1
1 in accordance with quality      assurance / quality control 2 procedure, engineering design and specification.,
3 4 Dated:  July 1, 1982 5
6
                                                  \                  t 7                                                N        .  $d4A Richard S. Bain 8
9 10 subscribed and sworn to before 11 me this 1st day of July, 1982 12    ,                              --_
13 NKncy J. L6 master, 14 Notary Public in and for the City and County of San Francisco, 15 State of California.
My commission expires April 14, 1986.
16 17 18 19 20 21 22 23 24 25 26
 
1                  PROFESSIONAL QUALIFICATIONS OF 2                            RICHARD S. BAIN                  _
3 4
5            My name is Richard S. Bain.              I am Manager of 6 Station Construction in the General Construction Department 7 in the Pacific Gas and Electric Company.              I have held this 8 position  since  1975. I  am  responsible        for  the 9 administrative, technical, and physical services necessary 10 to assemble, install, test, and make operable (1) plant and 11 auxiliaries  of    electric  generating  stations;          (2) 12 transmission and distribution electrical stations;                (3) 13 communication systems;      (4) gas pipeline compressor and 14 metering stations as assigned by Gas Construction; and (5) 15 water treatment facilities as assigned by Civil-Hydro 16 Construction. I am responsible for assuring the established 17 conditions and specifications are met within acceptable 18 schedules,  and providing manpower and equipment for 19 maintenance and repair of facilities.
20            Prior to my duties as Manager, I was Station 21 Construction Superintendent with the General Construction 22 Department in the Pacific Gas and Electric Company beginning 23 in 1953. I was responsible for providing prompt, effective, 24 and safe construction services for power plant facilities in 25 accordance with engineering specifications.              During that 26 time I was assigned the responsibility for the construction
 
1          of Diablo Canyon Power Plant with its inception in 1966. My 2          responsibilities    included  also the the planning and 3          supervision of construction work related to the Humboldt Bay 4          Power Plant and other planned nuclear power stations.
5                        I am a member of the American Society of 6          Mechanical Engineers Committee on Nuclear Quality Assurance 7          and have been involved in the preparation of ANSI N45 8          industry nuclear codes    ad standards.
9                        My educational background includes a BS in 10          Industrial Engineering from Stanford University in 1947.
11 12 13 14 15 16 17 18 19 20 i  21 22 23 24 25 26
 
PACIFIC CAS AND ELECTRIC COMPANY SUPPLEMENTARY SPECIFICATION FOR MANUFACTURER'S QUALITY CONTROL SYSTEMS REQUIREMENTS s 1.0 SCOPE This Supplementary Specification establishes requirements for the manuf acturer's systems for control of quality during manufacture, including inspection plans. Should this Supplementary Specification conflict with the Specific Conditions, the latter shall govern. Items required to comply with certain codes or standards by the Specific Conditions may have additional requirements such as found in Paragraph N-832 of Section III, Nuclear Vessels, ASNI Boiler and Pressure Vessel Code.
* 2.0 SYSTEM REQUIREMENTS The manuf acturer shall establish and maintain a system for the control of quality during the order that shall assure that all supplies and services, including subcontracted items, meet all drawing and order requirements.
2.1  Drawings and Changes:      The manuf acturer's system shall provide procedures which will assure that the latest applicable drawings, specifica-tions, and instructions required by the contract or purchase order as well as authorized changes thereto are used for manufacture, inspection, and testing.
2.2  Description of Procedures:        The manufacturer shall maintain a written description of procedures for control of quality and inspection show-ing in detail the implementation of the quality requirements of the contract or purchase order and the requirements of this Supplementary Specification.
In addition, the procedures shall include (but not be limited to) quality control measures governing:
2.21 Qualification of processes, equipment, personnel, and laboratories.
2.22 Receiving inspection.
,sq 2.23 Certification of material used and final product.
U 2.24 Quality audits.
April 1968 BAIN Attachment 1
 
Suppl. Spac.
Quality Control      j Systems              )
l l
2.3 Management Review: The manufacturer's quality system shall provide for the identification and evaluation of significant or recurring discrep-
    '          ancies and for alerting the manuf acturer's cognizant management to the need for corrective action. Corrective action shall be reviewed by the manufac-turer for effectiveness and the need for further action.
    \
3.0 PROCESS PROCEDURES The manuf acturer shall operate under a controlled manufacturing system such as process sheets, shop procedures, travelers, etc. Special controlled processes such as welding, heat treating, nondestructive testing, and inspec-tion techniques shall be a part of and included in the system.
3.1 Procedure Revisions: There may be a need to revise or eliminate a previously approved inspection procedure. When this occurs, the change to (or elimination of) inspection procedures shall require Purchaser's approval.
3.2    Inspection Plans:  Inspection planning for~this order shall be completed in writing by the manufacturer, covering subcontracted work as well as his own, to the following minimum requirements:
3.21 All inspection operations through shipment shall Le listed and referenced to the manuf acturer's/ subcontractor's manufacturing procedures. This Inspection Check List shall be submitted to Purchaser for approval in advance of fabrication.
3.22 Characteristics specified by the order and its referenced drawings and specifications shall appear on the check lists under the appropriate inspection operation. Space shall be provided for a nota-tion of the document number and revision to which the inspection was made and for the inspector's signature or stamp. Each characteristic so listed shall be inspected (using approved procedures wherever these are required) and the result recorded.
3.23 When a combined manuf acturing and inspection plan meets the requirements above, a separate check list of special format is not requi, red.
I    4.0  NONCONFORMING COMPONENTS OR MATERIAL
      )              All nonconforming material and components shall be kept identified and recorded to prevent intermingling with conforming material. Material or components that fail to meet acceptance standards shall be disposed of as l      follows:
April 1968
 
Suppl. Spac.
Quality Control Systema 4.1 Components or material that do not meet specifications may be sub-mitted for possible acceptance in accordance with the purchase order.
4.2 The manuf acturer shall be responsible for establishing and control-ling repair procedures. He shall obtain written approval from Purchaser of any repair procedure which utilizes operations not performed in the normal manufacturing process. Each repair shall be recorded.
4.3 When the manufacturer elects to scrap the defective material or component, adequate records shall be maintained to verify that the rejected material or component has not been used.
5.0 QUALITY CONTROL RECORDS 5.1    The manufacturer shall maintain a complete file of all records for material and items manuf actured. This shall include chemical and physical properties of materials, inspection, test, and analysis data taken before, during, and after manufacture as required, the manufacturing and inspection procedures, specifications, and drawings used. The records shall include all closely related data such as qualifications of personnel, procedures, and e q uipmen t , and data on nonconforming material.
5.2    Purchaser shall be provided access to records on special request as needed for engineering studies. However, copies of all data specifically requested in Purchaser's specification or purchase order shall be submitted to Purchaser as required. The manuf acturer shall maintain a record file for a minimum of 5 years after order completion, after which time he shall either request disposition instructions from Purchaser or continue to maintain the records.
6.0  CONTROL AND IDENTIFICATION OF MATERIAL l
l i
The manufacturer shall maintain a system of material control adequate to assure identity of all material used and that it meets the applicable specifications, prior to start of manufacturing operation. Identification of all material shall be maintained throughout all operations by heat number (or l7          any other suitable means traceable to the heat number) and recorded on inspec-tion data records for each component.
  )
I April 1968
 
Suppl. Spac.
Quality Control Systema N
8.2 Where applicable, the manuf acturer's control charts and other sta-
,          tistical data shall be made available for inspection to Purchaser and shall be maintained as a record substantiating the acceptability of the components or material.
9.0 HANDLING AND STORACE 9.1 The quality program shall require the use of handling procedures and equipment inspection with a monitoring program established to prevent handling damage to the product. The equipment inspections shall include any load bearing devices (hooks, shaf ts, slings, etc.) the f ailure of which could result in product damage.
9.2  The manufacturer shall provide adequate work and inspection instructions for storage, preservation, packaging, and shipping to protect the products and/or supplies f rom damage, loss deterioration, degradation, or substitution of product or supplies. Any special handling instructions during shipping and storage shall be prominently displayed on the shipping package.
7 1
i April 1968 '
 
l 5722t S " ' ' ' ' ' ' ^' ' " " 7 * * ' -*
D                                                          G.M. NO.        167027
: c.                                        SPECIFICATION                                              1 FOR v
FURNISH AND ERECT CONTAINMENT STRUCTURE LINER FOR UNIT 1 DIABLO CANYON SITE FOR THE PACIFIC GAS AND ELECTRIC COMPANY SAN FRANCISCO, CALIFORNIA Department of Engineering Comprising Specific Conditions Appendix h                                  Form of Proposal Insurance Questionnaire
                                                                          .1 APPROVED BY J. J. McCann/ATL(NLT/DBN)            BIDDER - SIGN HERE TO INDICATE THIS B.,W. Shackelford/RVB(EPW/SP)      HAS BEEN USE    IN PREPARING PROPOSAL l          D. V. Kelly /JOS(WJL)                              <    TN9M4Ah .187/$
    '                                          FIRM d [$ dd8 /
BY      d; DATE    b/ 7 hd  '
O  DATE February 25, 1969 BAIN Attachment 2 s
 
I 8831-X Quality Assurance 18-1
  ) .                                                          SECTION 18 QUALITY ASSURANCE 1.0 DEFINITIONS 1.1 Quality assurance comprises all those planned and systematic pro-grams necessary to establish confidence that will perform satisfactorily in service.            a material, component, or system 1.2 Quality control comprises those quality assurance actions which provide    a means    to control the quality of the material, component, or system to predetermined requirements.
1.3 Product includes material, components, devices, equipment, systems, structures, tions of thisservices,    and other items furnished by Contractor under other sec-Specification.
Product may consist of individual itecs, assemblies of items, or items in any state of fabrication.
l 2.0 SCOPE 2.1 Quality affecting the quality of products thatassurance requirements shall apply to all activities are important to nuclear safety and I            to the prevention of accidents or to the mitigation of their consequences          .
All products provided under this Specification shall be considered as within the above category unless specifically exempted in writing.
I 2.2 Activities subject to quality assurance requirements include designing, purchasing, fabricating, handling, shipping, storing, maintain-ing, constructing, inspecting, testing, repairing, modifying, and documenting            .
2.3 Contractor is responsible for performanc. of all quality assur-ance activities necessary to assure that products furnished by him are l
complete
* and in accordance with design and specification.
2.4 Contractor shall submit with his proposal a description of his proposed quality assurance program (bid Item 500).
        '            1969, Contractor shall prepare in detail and submit Not          later than May to Specification  No.20, 8831        i Contractor for submittal to Constructor for approval eighteen copies of his quality assurance program which shall define the program and designate the qualifications, pliance            functions, with the          and number of personnel necessary to assure com-Specification.                                                            -
The program and methods used to implement these requirements shall be developed by Contractor based on the outline                      "
{
provided in Paragraph 3.0 of this Section. Contractor shall revise all or any it doesportion not of  the quality satisfy        assurance program where, in Company's judgment, requirements.
start of work.                            Such corrections shall be made prior to
      -                                                                                                            1
 
l 8831-X Quality Assurance
(    )                                                                    18-2 2.5 Contractor shall be fully accountable for scheduling his work so as to permit adequate time for compliance with the quality assurance require-ments of this Specification.
l 3.0 QUALITY ASSURANCE REQUIREMENTS
 
===3.1 Organization===
Contractor's quality assurance organization shall have clearly defined responsibility and authority for implementation of a comprehensive quality assurance program, Contractor shall require his sup-pliers and subcontractors to establish adequate quality assurance organizations.
Quality assurance personnel shall be independent of manufacturing, fabrication, and construction forces and shall not perform functions other than those of quality assurance. Quality assurance personnel shall have sufficient and well defined responsibility, authority, and organizational freedom to identify and evaluate quality problems and to require implementation of approved solutions.
Contractor shall provide with his detailed quality assurance program as required in Paragraph 2.4 a description of his suppliers' and subcontractors' quality assurance organizations. The descriptions shall include the duties, responsibilities, numbers, and basic qualifications of key personnel to be assigned to these activities. The chove shall include a chart indicating responsibility and lines of authority between Contractor, Contractor's con-struction supervision, suppliers and subcontractors, and quality assurance personnel.
3.2  Procedures and Plans: Contractor shall review the requirements of the Specification and prepare written procedures and plans for the following:
3,21 Proposed sequence of shop and field fabrication and construc-tion activities in detail and including and identifying those operations specifically related to quality.
3.22 Monitoring, inspecting, testing, and control of shop and field fabrication processes, test equipment, fixtures, tooling, and per-sonnel skills required to assure the product quality.
3.23 All nonfabrication work affecting quality, including but not limited to designing, detailing, purchasing, handling, inspecting, test-ing, and shipping.
3.3 Approval of Procedures:      Procedures shall be submitted to Construc-tor for approval prior to initiation of the work. Work shall not proceed until written approval of the corresponding procedure has been obtained.
3.4    Hold Points:  Company may indicate mandatory inspection hold points k        which shall require witnessing or inspecting by Company. Work shall not pro-ceed beyond these hold points prior to such witnessing or inspection.
 
l 8831-X            l Quality Assurance  i 18-3              l l    l                                                                                    l
 
===3.5 Records===
Contractor shall prepare, use, and maintain adequate
.            records to attest to and document the quality of the product. Such a set of records shall include, as a minimum, material analyses, design checks, inspec-tions, tests, workmanship, and procedures; qualifications of equipment,        l procedures, and shop, field, and technical personnel; and nonconformances and  ;
subsequent corrective actions. Inspection and test records shall indicate the nature of observations and type of nonconformances found. Records of work p2rformance shall indicate acceptability of the work and/or material or necessary corrective action in cases of nonconformances. All records and documents must be preserved for ultimate use by Company for a minimum of ten years. Until such time as they may be transferred to Company, the records and documents shall be available for inspection and review by Company and regulatory agencies at any time. Contractor shall submit his record proce-dure to Constructur for review and approval prior to beginning fabrication or installation activity. Contractor's procedure shall include a system for identifying the inspection status of products. This may be accomplished by stamps, tickets, or tags.
3.6 Corrective Action: The quality assurance program shall provide a system for prompt detection, identification, and correction of conditions having an adverse affect on quality. Any factor of Contractor's operations which has had or could reasonably be expected to have an adverse effect on product quality shall be identified and corrected. The program shall require I
effective use of all data regarding defects which will not be limited to product items, but shall include methods, processes, and facilities. All conditions adverse to quality shall be documented and brought to the atten-tion of Constructor and Contractor's supervision and management for analysis, evaluation, and prompt corrective action.
3.7  Specification. Drawing, Documentation, and Change Control:    Con-tractor shall prepare, naintain, and use a procedure for assuring that specifications, drawings, procedures, instructions, authorized changes, and other documentation, which deal with activities affecting quality, are cur-rent, adequate, and available for use in fabrication, construction, inspection, and testing. The procedure shall stipulate that obsolete documentation be removed from point of use.
3.8 Measuring and Testing Equipment: Contractor shall prepare, maintain, and use a procedure for the maintenance and periodic calibration of measuring and testing equipment used to determine product conformance.
All measuring and testing equipment shall be calibrated against certified measurement standards which have known valid relationships to national standards, t
          ,      3.9 In Process and Pinal Inspection: Contractor's quality assurance l  program shall assure that work is accomplished under controlled conditions which include documented work instructions and test procedures, adequate equipment, and any special environments that may be required. Inspection
{      personnel shall be qualified in their specific area of responsibility and knowledge. Documented work instructions shall include criteria for accept-able and unacceptable conditions including workmanship. Physical examination, 9
 
8831-X Quality Assurance 18-4 l l measurements, and/or tests shall be performed as required during product
  .            processing at appropriate points so as to assure quality of the end product.
Contractor shall maintain close coordination with Company to facilitate inspection or witnessing of tests by Company.
3.10 Product Control: All products subject to quality control require-ments which have been approved for use shall be identified and segregated to assure that only these products are used in the work.
3.11 Nonconforming Products: Contractor's quality assurance program shall require that products which fail to meet requirements are identified and segregated and removed from work site or from areas designated for approved material.
3.12 Handling and Storage: Contractor's quality assurance program shall provide and use adequate procedures to assure that all necessary meas-ures are taken to prevent damage or deterioration of products during handling or storage.
3.13 Special Protection, Packing, and Packaging: Contractor's quality assurance program shall provide and use adequate procedures to assure that products requiring special protection, packing, or packaging shall be given appropriate consideration and treatment.
l 3.l'4 Cleanliness: Contractor's quality assurance program shall provide adequate procedures to assure that products are provided and maintained in an appropriate state of cleanliness.
3.15 Audit: A procedure for a system of audits shall be established and used to assure compliatice with all aspects of the quality assurance pro-gram and to determine its ef f ectiveness. Audits shall be made on a planned periodic basis. Contractor shall include as a requirement of his purchase 3
orders and subcontracts a statement essentially as follows: " Contractor      j l              and/or Company shall have the right to conduct quality assurance audits and inspections at any time during production and testing as may be deemed        '
necessary."
i 4.0 CONTROL OF WORK l                4.1    Company will perform a continuing audit of Contractor's quality assurance program. This is in addition to the audit by Contractor described in Paragraph 3.13.
1 t
 
t 8831-X Quality Assurance 18-5 4.2 Company will stop or reject work which, in his opinion, ir, below specified quality standards. Work shall not be resumed until acceptable
. corrective measures are adopted by Contractor. Exercise of this authority shall be by written directive describing the work in question and reason for its suspension.
                                                                                -    . CIVIL.
sANTON W.
                                                                          =        SHACAnf0A0
                                                                          .        he,7305  =
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se,r                  PACIFIC G AS AND ELECTRIC COMPANY S AN FRANCISCO, CALIFORNI A i    .
DEPARTMENT OF ENGINEERING
>'                        ACCOUNTING      DATA
              . ~""::        ... =-  c~~    ~m=q+y 167027          18 Various Various      40                          8752
  '        GM 169972 SPECIFICATION NO.
Project File Number 30.70 SPECIFICATION
                ~
FOR e
INSTALLATION OF THE NUCLEAR STEAM SUPPLY SYSTEMS FOR UNITS 1 AND 2 - DIABLO CANYON SITE COMPRISING Spacific Conditions General Conditions Proposal Form Insurance Questionnaire Appendix I
s.
APPROVED BY 6            J. J. McCann (ATL)(EDC/ MPH)                                          ^
D. V. Kelly (HJG/RML/AGW/NLZ)                                    ^      ^
                                                            "^
T. A. Bettersworth (JWC/DN)
FIRM R. V. Bettinger (EPW/VJG)                            ,
W. J. Lindblad                            DATE C. V. Richards DATE May 3, 1972                                    BAIN Attachment 3 I
 
8752 General 1-1
>.                                  SPECIFIC CONDITIONS SECTION 1                                      I GENERAL l
1.0 SCOPE OF WORK 1
 
===1.1 General===
This Specification covers the installation of the            I nuclear steam supply systems at Company's Units 1 and 2 - Diablo Canyon Site. The nuclear steam supply systems are Westinghouse Electric Corpo-ration four-loop pressurized water reactors. The material, equipment, and components to be installed are Company furnished and comprise a major portion of the primary or reactor coolant system. The items to be installed for Unit I are itemized and described in Secticn 2 of this Specification, and the accompanying drawings show and locate the Unit 1 system and equipment. Unit 2 will be similar, except opposite hand.
Contractor shall provide all labor, supervision, inspection, material, supplies, equipment, tools, and facilities required to complete the installation of the items furnished. All work performed under this Specification shall be to the satisfaction of the Constructor, but this shall not be construed as to relieve Contractor of the responsibility to      l complete and guarantee the work as specified.
1.2  Heavy Equipment Handling: Company has contracted with others for receiving, transporting, storing, and lif ting the heavy equipment and components to be installed under this Specification. Refer to Sec-tion 2 for the heavy items which will be handled by others. Contractor will not have to handle these items, except as noted in Section 2.
I 1.3  Installation Procedures :  Contractor shall prepare detailed writ ten installation and erection procedures and instructions for all        ,
work to be performed under this Specification.      Company and the nuclear steam supply system supplier, Westinghouse, will provide the technical data and information necessary to develop these instructions.      Refer to Section 3 for installation procedure requirements.
1.4  Quality Assurance: Work activities affecting structures, systems, equipment and components, that are essential to the nuclear          !
safety of the plant and to the prevention of accidents or to the miti-gation of their consequences shall be performed and documented by a quality assurance program. All the structures, systems, equipment and components for the Diablo Canyon Site that require quality assurance measures are categorized as " Design Class I." With a few exceptions, 4        the material, equipment, and components installed under this Specifica-      l tion are Design Class 1, and are specifically noted as such in the descriptions of Section 2. Contractor shall implement a quality assur-anee program f or all work performed and material supplied for Design Class I items. Ref er to Section 4 for Contractor's Quality Assurance Program requirements, i
 
8752 Quality Assurance 4-1 SECTION 4 CONTRACTOR'S QUALITY ASSURANCE PROGRAM
  ,      1.0  GENE GI.
i            1.1  This Section establishes the requirements for Contractor's quality assurance program for the control of quality of material supplied and work performed under this Specification.
1.2 Cont ractor's quality assurance program shall apply to all material supplied for and work performed on Design Class 1 structures, systems, and components, including equipment and accessories. Design Class 1 items are identified in other sections of this Specification.
1.3 Contractor's quality assurance program shall include the          i following activities : preparing drawings, purchasing, fabricating, receiving, handling, shipping, storing, maintaining, installing, erect-ing, assembling, constructing, inspecting, testing, repairing, modifying, recording, docuraenting, and auditing.
1.4  Contractor shall schedule his work to permit adequate time for implementation of the quality assurance program.
1.5 Contractor shall assure that his suppliers and subcontractors conform to all requirements of the quality assurance program.
2.0  DEFINITIONS 2.1  Quality assurance comprises all those planned and systematic I
actions necessary to establish confidence that the equipment and systems l            will perform satisfactorily in service.
2.2 Quality control comprises those quality assurance activities related to the physical characteristics of a material or work which l            providys a means to determine and control the quality of the material supplied and work performed to predetermined requirements.
  ,                2.3 Material includes components, devices, equipment, systems, i            structures, and other items. furnished by Cont ractor to complete the requirements of this Specification. Material may consist of individual items , assemblies of items, or items in any state of fabrication.
2.4 Work includes all activities by Contractor to complete the j            requirements of this Specification, l
l i
 
8752 j
i Quality Assurance 4-2 la 3
3.0 SUBMITTALS 3.1 Bidder shall submit with his his proposed quality assurance program, proposal a brief description of his:                                          including details or samples of (1) quality assurance organization, (2) quality assurance proce-dures manual, and (3) quality assurance inspection and test plane 3.2 Within 30 days following the award ot contract, Contractor shall submit to Constructor for approval six copies of (1) his quality assurance organization description, designating qualifications, respon-sibilities, and numbers of personnel, in accordance with Paragraph 4 2 of this Section; and (2) his quality assurance procedures manual, includ-ing all the procedures necessary to assure compliance with the require-ments of Paragraph 4.3 of this Section.
Contractor shall revise all or any portion of his quality assurance organization and quality assurance manual where, in Company's judgment , they are not satisfactory. When Company approves of Contractor's quality assurance organization and quality assurance procedure manual, nineteen copies of the approved organization and manual shall be submitted to Constructor. Contractor's quality assurance organization and quality assurance procedures manual shall be approved prior to the start of any work.
: 3. 3 At least 21 calendar days prior to the start of work on any Design Class I structure, system, or component, including equipment and accessories, Contractor shall prepare and submit to Constroctor for approval six copies of a specific inspection and test plan for that work.
This of thisplan  shall be in accordance with the requirements of Paragraph 4.4 Section.
where, in Company's judgment, Contractor shall revise all or any part of the pla it is not satisfactory. When Company approves the inspection and test plan, nineteen copies of the approved inspection and test plan shall be submitted to the Constructor, and it shall be used for documenting and recording all inspections and tests performed on that Design Class I item. Inspection and test plans shall be approved prior to the start of any work on Design Class I items.
Upon completion of the installation and upon Company acceptance of the equipment, nineteen copies of the completed inspectioi and test plan shall be forwarded to Constructor.
4.0 QUALITY ASSURANCE PROGRAM REQUIREMENTS 4.1 Quality Assurance Program:
* 4.11  Contractor's quality assurance program shall consist of a quality assurance organization, a quality assurance procedures manual, and quality assurance inspection and test plans in accordance with the following paragraphs, y ._
 
8752 Quality Assurance 4-3
    \
4.2 organization:
4.21 Cont ractor's quality assurance organization enall have clearly defined responsibility and authority for implementation of a comprehensive quality assurance program. The organization shall require quality control personnel:      (1) to have sufficient and well de fined responsibility, authori ty, qualifications , and organiza-tional f r eedom to identify and evaluate quality problems and, when necessary, to require implementation of approved corrective actions, and (2) to be generally independent of procurement, manufacturing, f ab ri cat ion , scheduling, and construction forces.
4.22 Cont ractor shall require his suppliers and subcontractors to establish adequate quality assurance organizations. Contractor shall provide with his detailed quality assurance program submittal (as required in Paragraph 3.2 of this Section) a description of his suppliers' and subcontractors' quality assurance organizations, including qualificat ions , responsibilities , and numbers of personnel, and a chart indicating responsibilities and lines of authority between Cont ractor, Cont ractor's const ruction supervision, suppliers and subcont ractors, and quality control personnel.
4.3    Procedures Manual: Cont ractor's quality assurance procedures manual shall detail the methods used by Contractor to control the quality of material supplied and work performed under this Specification. Con-tractor shall conduct his work in accordance with the procedures therein.
The manual shall include the following procedures as a minimum:
4.31    Design Control: Contractor developed designs for structures , systems , and components shall be reviewed for complete-ness , design adequacy, material compatibility, code conformance, currentness, and other similar items.        Reviews of design adequacy shall consist of checking the design with alternate or simplified calculation methods, by performance of a testing program which is approved by Company, or by conducting a complete design review.
Control measures for design changes shall be commensurate with those applied to the original design.
4.32 Document Con t ro l,: Contractor shall assure that specifications, drawings, procedures, instructions, inspection and test plans, and any other quality related documents , as well as authorized changes, used in work performed under this Specification are current, properly completed, approved by authorized personnel, and distributed for use. The procedure shall assure that obsolete documentation be removed f rom use.
  \
f
 
f 8752 Quality Assurance 4-4 4.33 Material and Work Procurement Control: Cont ract or shall
* assure that all material and work furnished by suppliers or sub-contractors under this Specification conform to the applicable requirements of the procurement documents such as drawings, spec t-s fications, and codes. Contractor procurement control includes evaluation and selection of qualified suppliers and subcont ractors, the transreission of applicable design and quality requirements to suppliers and subcontractors, the assurance that supplier and sub-contractor quality assurance programs are consistent.with this Specification, and source inspection by Contractor at the supplier or subcontractor. This procedure shall not include Company fur-nished material until delivered to Cont ractor.
4.34 Receipt Inspection of Material: Contractor shall inspect to the extent necessary all material delivered into his custody to assure conformance to rpecifications, drawings, purchase orders, and other technical requirements. Receipt inspection may vary as to amount and type depending on the item and supplier.
Company furnished material need only be inspected for completeness and damage during handling if Company specifically identifies and exempts the equipment in writing.
4.35 Identification, control, and Status of Material:
Contractor shall develop measures to maintain identity and trace-ability of material to assure that prescribed inspections and tests have been performed, to identify nonconforming matei-ial, and to pre-vent the use of incorrect or defective material. Suitable means of marking or recording material, such as stamps, tags, labels, or routing cards shall be employed. Cont rac tor shall submit his proposed method of identification marking for approval.
4.36 Handling, Storage, Packaging, Shipping, and Preservat ion of Material: Contractor shall assure that all necessary measures are taken to prevent damage, loss, or deterioration of material during handling, storage, packaging, shipping, receiving, preserving, installing, erecting, and maintaining until acceptance by Constr uc-tor.      Material requiring special protec t ion, preserving, or packaging i
shall be given appropriate consideration and t reatment . This will j        include, when necessary , the es cablishment and periodit verification of protective environments, such as inert gas, moisture content, and i        temperature levels.
i 4.37 Nonconforming Material Cont rol:    Cont ractor shall assure l*        that material which f ails to meet requirements of this Specificat ten j        are identified, segregated, and then remaved from areas designated for approval material. Nonconforming items shall be rev2ewed, t
accepted, rejected, repaired, or reworked in accordance with proce-dures requiring designer review.        If Company furnished material is nonconforming, Cont ractor shall noti fy Const ruc tor      if Contractor    ,
proposes to use any material which does not meet the requirements of this Specification, a written report shall be prepared for Engi-neer's approval. Company will furnish Contrattot        with inst ructions for submitting nonconforming material repor ts -
 
}
8752 Quality Assurance 4-5 4.38 Qualification of Processes and Personnel: Contractor shall assure that special processes, such as welding, heat treating, and nondestructive testing, are controlled in accordance with appli-icable codes, standards, specifications, etc. Special processes shall be accomplished by qualified personnel using qualified
  ,  procedures.
4.39 Calibration of Measurement and Test Equipment:      Contractor shall assure the maintenance and periodic calibration of measuring and testing equipment used. All measuring and testing equipment shall be calibrated against certified measurement star.C rds which have known valid correlation to national standards.
: 4. 310 Corrective Action: Contractor shall assure that all conditions which adversely affect quality and tend to cause failures, malfunctions, deficiencies , deviations , defective items , and noncon-formances are promptly identified, reported, and corrected to pre-clude repetition. Contractor shall maintain records on all conditions which adversely affect quality. These records shall indicate each condition, the cause of the condition, and the corrective action taken. A copy of these records shall be forwarded to both the Con-structor and the Contractor's supervision and management for analysis, evaluation, and review.
4.311 Records:  Contractor shall use, collect, and maintain records and data essential to document the quality of material supplied and work performed under this Specification. Records are considered one of the principal forms of objective evidence of qual-ity, and procedures shall assure thit records are complete and reli-able. Records collected shall include, as a minimum, the following:
drawings, specifications, purchase orders, work orders, inspection reports, test reports, work performance records, work procedures, qualification records for procedures, equipment and personnel, non-conformance reports, corrective action records, and audit records.
Inspection and test reports shall indicate the nature of observa-tions or test, the acceptable limits of observations or tests, the results, the type of nonconformances observed, and the identity and signature of the observing personnel. Work performance records shall indicate acceptability of the work and/or material or necessary corrective action in cases of nonconformances. All records shall be collected and filed in one hour rated fireproof cabinets at one loca-tion at suppliers' and subcontractors' shops or at the work site.
All records shall be preserved by Contractor for use by Company for ten years. If Company has not requested custody of the records and documents before the end of the ten-year period, Contractor shall request disposition instructions from Company. Until such time as they may be transferred to Company, the records and documents shall s
be available for inspection and review by Company and regulatory agencies. Upon request, duplicate copies of records and documents for specific items shall be provided promptly by Contractor to Constructor.                                                                ,
I i
 
8752 Quality Assurent<
4-6 4.312 Audits:
Contractor shall establish a system of audits to assure compliance with all aspects of the quality assurance program and to determine its ef fectiveness.
on a planned periodic basis.                    Audits shall be made Follow-up shall be taken where necessary. Audit        action, including reaudi ts, and forwarded to Constructor for review.results shall be document 4.4 _ Inspection and Test Plans:
Contractor's quality assurance inspection test          and test plans shall identify the specific inspection and requirements for the construction, erection, and installation of Contractor shall review the drawings , specifications, p                        ,
codes,    manufacturers' to structures,                instruction manuals, and other documents perta systems, equipment, tion and prepare written inspection and test plans.and            components The inspection  and under test plans will establish the initial, in-process, and final inspections and tests that are performed to assure quality. Inspection and test plans shall include receipt inspection, storage inspection,        dimension inspections, visual inspection, cleanliness inspections, tions , weld inspections , nondestructive tes ts, materials testsfit-up, inspec-electri-cal circuit other inspections and tests required by this Specification.            The plans contin shall be in accordance with the following:
4.41 Plans shall be specific for structures, systems, equipment, Specification.
and components, as specified in other sections of this 4.42  Plans shall follow the sequence of construction activities, from the to the completion      receipt of material, components, or equipment of work.
4.43 Plans shall itemize inspection and test points, indicating in the sequence of construction activities when the inspection or test point occurs.
4.44 Plans shall itemize characteristics to be inspected or tested at each inspection and test point.
4.45  Plans shall describe or reference accept ance criteria for each inspection and test point.
t 4.46    Plans shall designate inspection and test results to be recorded,    data  to be collected, and the identity an1 signature of the observing personnel. Plans shall be filled out and completed as work is performed and progresses .
s
 
os                                                                      8752 Quality Assurance 4-7 4.47 Plans shall indicate inspection hold points for Company's witnessing and review of the inspection or test, as required by
      ,,                other sections of this Specification. Work shall not proceed beyond g                these points without Company approval.
4.48 Plans shall list the records, forms , or documentation used and collected at each point. Sample forms shall accompany the plans. In approving the plan, Company will designate the specific fo rms to be retained by Cont ractor and those to be submitted to 3,                Company.
    ;ad                      4.49 Plan changes shall be approved by Company.
4.410 Upon Company acceptance of structures, equipment, a                systems, or components, nineteen copies of the completed inspection and test plan shall be forwarded to Constructor. The original shall be retained by Contractor in accordance with Paragraph 4.311 of this
      .                  Section.
    '=
11 5.0 COMPANY INSPECTION AND AUDITS 5.1  Company will perform a continuing audit of Contractor's quality assurance program. This is in addition to the audits performed by Contractor.
5.2  Company will reject material and/or stop work which in its opinion is below specified quality levels or not in accordance with Con-tractor's quality assurance program as approved. Work shall not be resumed until acceptable corrective measures are adopted by Contractor.
Contractor will be notified by written directive describing the work in question and reason for its suspension.
5.3 Company will perform of f-site shop inspection on Contractor and his subcontractors and suppliers. Subcontracts and purchase orders shall include the following statement:
                              "All work on this cont ract/ order is subject to inspection
    ,                and test by PG6E at all times (including the period of perform-
* ance) and places; and as a minimum final inspections and tests will be observed prior to shipment. The PG&E representative who normally services your plant shall be notified forty-eight
  '                    (48) hours in advance of the time material or work is ready for inspection or test."
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1 PACIFIC CAS AND ELECTRIC COMPANY                                  l SAN FRANCISCO, CALIFORNIA Department of Engineering 20 ACCOUNTING DATA                                              SPECIFICATION NO. 8828
'e CM 167027 & 169972                                          Rev. No. 4 Loc. Div. 18                                                Project File No. 131.10 Account 61                                                  Plant Strutture Activity Item 30                                            Safety Related: No Location and/or Item 40 SPECIFICATION FOR ARCHITECTURAL FINISH k'ORK UNITS 1 AND 2 DIABLO CANYON SITE l
APPROVED BY                    4 CONTRACTOR GIGN HERE TO INDICATE TIIAT THIS REVISION IS ACCEPTABLE J. J. McCann/
f )[h    6/(_. -
(NL APP) (EDC)
F1cm R. V.
g/      Q Be ttinger/IR
                                                                                \cpmf;-jf}'_()'
3/ rig /GPB)
By
                                                        '3l>n(
D. V. Kel y b  Date                                                        g/
C. V. Richard /CER Q 4'
ACCEPTED BY JBf/M B. Hoch J.
DATE June 1, 1978                                  BAIN Attachment 4 Sff/
g.lQ b
 
8828 Ravision 4 Page 1 SPECIFICATION FOR FIELD CONTRACTOR'S QUALITY ASSURANCE PROGRAM (FOR SPECIFICATION 8828) w ,
1      GENERAL 1.1 This Specification establishes the requirements for Contractor's Quality Assurance Program to assure quality during the procurement and installation of components or equipment and the performance of work for those components identified in the attached Supplement, which ar'e to be constructed after the issuance of this Specification change.
        )*1.2 Contractor's Quality Assurance Program shall apply to all activities affecting the quality of material supplied and work performed including:
Purchasing, Receiving, Handling, Constructing, Erecting, Maintaining Storing, Documenting, Inspecting and Testing.
1.3 Contractor shall also assure compliance with all quality requirements contained in the contract that are not described in this Specification.
1.4 This Specification shall be used in conjunction with the specified codes or standards (N.F.P. A. , U.L. , A.S.T.M. , A.W.S. , etc. ) in order that activities not included in the codes or standards will be provided for.
2    DOCUMENTS FOR SUBMISSION 2.1    Contractor shall submit, to Company for approval, information which fully describes the Quality Assurance Program demonstrating that work will be performed under a controlled program conforming to the requirements of Paragraph 3 below.
2.2      Eight (8) controlles copies of final, approved Quality Assurance Programs shall be submitt i to the Company by Contractor for approval, l
QUALITY ASSURANCE PROGRAM 3.1      Contractor's Quality Assurance Program shall describe in detail the procedures and methods used by Contractor to assure that all supplies 4        purchased and work performed satisfy all untract requirements. The Program shall describe the methods of implementation of the following requirements:
 
8828 Revision 4 Page 2
 
====3.1.1 Organization====
The Contractor shall assign and identify personnel who will be responsible for implementing the Quality Assurance Program and such assigned personnel shall have direct access to such levels of management as necessary to achieve
* ef fective implementation of the Contractor's QA program.
3.1.2 Procurement Document Control: Contractor shall assure that applicable requirements and specifications necessary to assure adequate quality are included or referenced in C,ontractor's, pro-curement documents. Changes shall be subject to the same degree of control utilized in the prcparation of original procurement s
documents.
3.1.3    Instructions, Procedures, and Drawings:    Contractor shall assure that all activities af fecting quality are prescribed by documented instructions, procedures, or drawings.      Such instructions, procedures, or drawings shall include quantitative or qualitative criteria for determining that activities affecting quality have been accomplished satisfactorily. Quantitative criteria, such as dimensions, tolerances, and test limits, and qualitative criteria, such as comparative workmanship samples, shall be specified, when appropriate, for determining acceptable work performance and quality compliance.
3.1.4    Procurement Control: Contractor shall perform receipt inspection on all material and equipment delivered into his custody to assure conformance to the procurement requirements. Company-furnished materials and equipment need only be inspected for completeness and damage during handling if Company specifically identifies and exempts the equipment in writing.
Contractor shall assure that documentary evidence that items conform to the procurement requirements is available to the Company prior to the installation or use of such items. Documentary evidence shall I        be sufficient to identify the specific procurement requirements that have been met. Where not precluded by other procurement requirements, written certifications of conformance which identify the procurement requirements that have been met may be used as documentary evidence, providing means are available to verify the validity of such certifications.
3.1.5  Document Control: Measures shall be established and documented to assure that all quality-related documents are reviewed for adequacy, approved for release by authorized personnel, and properly distributed.
Changes to documents shall receive the same degree of review and I      approval as the original documents.
Written procedures governing document control shall provide for the identification of individuals or organizations responsible for pre-paring, reviewing, approving, and issuing documents and changes thereto. These procedures shall preclude the possibility of use of superseded, obsolete, or void documents.
 
8828 Revision 4 Page 3 3.1.6 Identification and Control of Material and Equipment:
Contractor shall establish and document measures to identify and control material and equipment. These measures shall prevent the use of incorrect or defective material.
Traceability when required by Specification for material and equip-
;  ment shall be maintained with records and markings. When identi-fication marking is used, the marking shall be clear, unambiguous, and indelible, and the method of marking shall not af fect the function of the material or equipment.
  *3.1.7 Control of Measuring and Test -Equipment: Contractor shall assure that all tools, gages, inst rument e, and other measuring and test equipment used in activities affecting quality are of the proper range, type, and accuracy to verify conformance to established requi rement s.
  *3.1.8 Inspection: Contractor shall assure that activities affect-ing quality are inspected for conformance to the documented instruc-tions, procedures, and drawings used in the accomplishment of the activity.
Written procedures shall require that inspections are performed according to written instructions or checklists which are based on the ins truct ions , procedures , and drawings used in accomplishment of the activity being inspected.      Inspection procedures shall also require the documentation of the qualitative or quantitative results of the specific parameters being inspected.
  *3.1.9    Test Control:    Contractor shall assure that a test program will be established which identifies and documents all testing required to demonstrate that an item will perform satisfactorily in service. Written procedures shall require that all testing be performed in accordance with written test procedures which incor-porate all requirements and test limits specified in the design docume nt s. Test procedures shall assure that prerequisites, such as calibrated instrumentation, appropriate equipment and environ-mental conditions, and trained personnel, are met. Test require-ments, results, and acceptance criteria shall be documented and evaluated by authorized personnel to assure that all requirements have been satisfied.
  *3.1.10 Inspection Plan or Procedures: Contractor shall perform required inspections in accordance with a written inspection plan or e  procedure. The Contractor shall assure that all inspections required by the attached Supplement are identified in the inspection plan or procedure. The plan or procedure shall be developed in
,  accordance with the following:
The plan or procedures shall identify the characteristics to be inspected.
 
8828 Revision 4 Page 4 The plan or procedures shall describe the inspection instructions or procedures to be used.
~
The plan shall list the records, forms, or other documentation used.
              *The plan or procedure shall indicate all inspection hold points for Company witnessing and review of the inspection or test, as required by the attached Supplement. The plan shall provide for adequate advance notice to Company's inspector. Work shall not proceed beyond inspection hold points until such points have been witnessed or inspected by the Inspector. Records shall be kept of all tests and inspections including nonconformances observed and the identity and signature of the inspection and test personnel.
        *3.1.11 Inspection and Operating Status: Contractor shall establish and document measures to identify inspection status of items and work.
Such measures shall provide means for assuring that required inspec-tions are performed and that the acceptability of items or work with regard to inspections is known at all times. Written procedisres shall provide for the status of inspections through the use of indicators such as tags, markings, stamps, or records. The procedures shall assure that only items, or portions of work, that have passed required inspections are accepted and that nonconforming items are clearly identified.
        *3.1.12    Nonconforming Material Control:    Contractor shall assure that material, equipment, services, or activities which do not conform to requirements are identified, documented, segregated, evaluated, and accepted, rejected, reworked, or repaired in accordance with documented procedures. If Company-furnished material is found to be nonconforming, Contractor shall notify Constructor.
Written procedures controlling nonconformances shall define the responsibility and authority for the disposition of nonconformances.      I Such procedures shall provide for the reinspection of all repairs or rework in accordance with applicable procedures.
If Contractor proposes to use any special procedures or materials for repair or rework, a written description of Contractor's proposal shall be submitted for Constructor's approval. When Contractor elects to accept a nonconformance as is records shall document the basis for acceptability. When Contractor elects to scrap a nonconformance, adequate records shall be maintained to verify that the nonconformance has not been used.
3 3.1.13 Handling, Storage, and Shipping: Contractor shall establish and document measures to control handling, storage, and shipping, including cleaning, packaging, and preservation of material and equipment in accordance with instructions, procedures, or drawings, to prevent damage, deterioration, and loss.
 
8828      !
Revision 4 I Page 5 9        *3.1.14    Corrective Action: Contractor shall assure that all condi-tions which are adverse to quality, such as failures, malfunctions, deficiencies, deviations. defective material, and nonconformances are promptly identified ci corrected as soon as practical. Correc-
* tive action shall be sui < sciently comprehensive to intercept and correct all items af fectt i by the adverse conditions. In the case of significant conditions adverse to quality, written procedures shall require that the cause of the conditions be determined and appropriate corrective action taken to minimize the possibility of repetition.
* Contractor shall maintain records on all conditions which adversely
  }        affect quality. These records shall identify each condition, the cause of the condition, and the corrective action taken, and shall be forwarded to both Constructor and Contractor management levels for review.
          *3.1.15 Records: Contractor shall use, collect, and maintain records and documents suf ficient to furnish documentary evidence of the quality of material supplied and work performed. Written procedures shall identify all records which are to be retained, and shall prescribe the retention period, storage location, and assignment of responsibility. Records collected shall include, as a minimum, the following: drawings, specifications, purchase orders, work orders, material certifications, work procedures, personnel and equipment qualification records, nonconformance reports, corrective action records. Work performance records shall indicate acceptability of the work and/or material or necessary corrective action in cases of nonConformances.
Requirements and responsibilities for record transmittal, retention, and maintenance subsequent to completion of work shall be established and documented consistent with procurement documents.
In general, records which identify the as-built condition of materials or equipment shall be maintained for a minimum of ten years. At the end of the ten-year period, Contractor shall request disposition l
'          instructions from the Company for all documents which Company has not requested custody of. These records shall be indexed, filed, and i
'          maintained in facilities that provide suitable environment to minimize deterioration or damage and to prevent loss. Until such time as they may be transferred to Company, all records shall be available for
  )  ,      inspection and review by Company and regulatory agencies.
3.1.16 Audits: Contractor shall establish a system of audits to I      assure compliance with all aspects of the quality assurance program and to determine its effectiveness. Personnel performing audits shall not have direct responsibilities in the areas being audited.
Follow-up action, including reaudit, shall be taken when necessary.
Audit results shall be documented and forwarded to Contractor's management for review.
 
8828 Revision 4 Page 6 Written procedures which govern the audit program shall assign responsibilities for the audit program; establish the frequency of audits, prescribe the minimum qualifications for auditors and their independence from the area being audited; and prescribe the format
  ,              for documenting audit results. The procedure shall prescribe the
* mechanism for submitting audit results to appropriate levels of management and also the criteria for determining when follow-up action is required.
4    COMPANY INSPECTION AND AUDITS 4.1  The Company will perform periodic audits as well as continuous inspection of Contractor's activities throughout all work performed.
a4.2 The Company will reject material and/or stop work which, in its opinion, is not in accordance with the quality assurance requirements herein. Work shall not be resumed until corrective measures, which are approved by the Company, have been adopted by Contractor.
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Revision as of 05:56, 15 March 2020

Affidavit of Rc Anderson,Jb Hoch,Gh Moore,Mr Tresler & Wh White.Design Verification Program Findings Prove No Sys, Structure or Component Would Fail to Perform Intended Safety Function.Prof Qualifications Encl
ML20054L282
Person / Time
Site: Diablo Canyon Pacific Gas & Electric icon.png
Issue date: 06/30/1982
From: Richard Anderson, Hoch J, Moore G, Tresler M, William White
PACIFIC GAS & ELECTRIC CO.
To:
Shared Package
ML20054L277 List:
References
NUDOCS 8207070340
Download: ML20054L282 (55)
v • d • e


Text

y' s-1 UNITED STATES OF AMERICA 2 NUCLEAR REGULATORY COMMISSION 3

4 BEFORE THE ATOMIC SAFETY AND LICENSING APPEAL BOARD 5

6 7

8 )

In the Matter of ) Docket No. 50-275 9 )

PACIFIC GAS AND ELECTRIC )

10 COMPANY ) (Low Power Proceeding)

)

11 (Diablo Canyon Nuclear Power )

Plant, Unit No. 1) )

12 )

13 14 15 AFFIDAVIT OF R. C. ANDERSON, J. B. HOCH, G. H. MOORE, M. R. TRESLER, W. H. WHITE 16 17 18 STATE OF CALIFORNIA )

19 ) ss.

CITY AND COUNTY OF SAN )

20 FRANCISCO )

21 22 23 The above being duly sworn, depose and say:

24

( 25 1. On September 28, 1981 PGandE noti fied the l

26 Regional Administrator of the NRC's Region V Office of l

l

! C207070340 920702 PDR ADDCK 05000275 PDR O

O' 1 Inspection and Enforcement of a potential problem in the 2 analysis of piping systems contained in the annulus area of 3 the containment building. In response, the Staff issueu 4 Board Notification No. 81-27 and scheduled a series of 5 public meetings with PGandE to discuss the problem and 6 structure a program to resolve it. PGandE meanwhile 7 implemented a design verification program to address 8 discrepancies it had found in the seismic design of the 9 annulus area of the containment.

10 2. PGandE's program has subsequently been 11 expanded into two separate and comprehensive design 12 verification programs; one being performed by a group of 13 independent reviewers and the other being performed 14 internally by the PGandE/Bechtel Project (" Project"). These 15 programs will verify, on an extensive sampling basis, both 16 the seismic and non-seismic design of safety related 17 structures, systems and components for the Diablo Canyon 18 plant.

19 3. The verification program performed by the 20 group of independent reviewers is called the Independent 21 Design Verification Program ("IDVP"). This program is 22 managed and supported by Teledyne Engineering Services 23 Company with R. L. Cloud Associates, R. F. Reedy Inc. and 24 the Stone and Webster Engineering Company performing 25 independent design verification work in their respective 26 areas of responsibility: R. L. Cloud Associates -- seismic,

/

g.

1 1 structural and mechanical design; R. F. Reedy -- quality 2 assurance; Stone and Webster -- systems design. The 3 Independent Design Verification Program includes performing 4 independent analyses and reviews, on a sampling basis, to 5 verify the adequacy of the design. Some of the areas in 6 which technical verifications are performed include 7 structures, piping and supports, equipment qualification, 8 electrical raceways and ventilation duct supports, and 9 system design. The verification program, moreover, is 10 designed to be self-expanding if deemed warranted by the 11 IDVP. The program establishes criteria for performance of 12 such additional verifications resulting from either the QA 13 reviews or the sample calculations. Detailed descriptions 14 of the independent program are contained in "Diablo Canyon 15 Nuclear Power Plant - Unit 1, Independent Design 16 Verification Program, Program Management Plan, Phase I,"

17 approved by the NRC in a letter dated April 27, 1982, and 18 Phase II, "Diablo Canyon Nuclear Power Plant - Unit 1, 19 Independent Design Verification Program, Program Management 20 Plan, Phase II," submitted to the NRC on June 18, 1982.

21 These plans are attached to this affidavit.

22 4. The Project internal technical program 23 includes verification work performed by a combined team of 24 PGandE and Bechtel personnel. As a part of the Project 25 internal technical program, URS/Blume has conducted the 26 Blume Internal Review (BIR). The Project work includes 1 reverification of additional samples as well as responding 2 to the findings of the IDVP. The Project internal technical 3 program also includes specialized analysis and qualification 4 work being performed by Westinghouse Electric Corp. and TERA 5 Corp. The technical verifications are being performed in 6 the areas of seismic and non-seismic safety-related 7 structures, systems and components. This program was also 8 approved by the NRC Staff in its April 27, 1982 letter.

9 5. The two verification programs have been 10 established in strict accordance with the November 19, 1981 11 Commission order, and the letter from Mr. Harold Denton, of 12 the same date. All verification efforts, both the Project's 13 and the independent reviewers', are being performed in 14 accordance with the latest approved Quality Assurance 15 programs for the involved companies.

16 6. Over the past 9 months an extensive amount of 17 verification and review work has been performed under the 18 two verification programs. The organizations involved in 19 the verification programs have expended approximately 2,500 20 man-months or in excess of 400,000 man-hours in reviewing 21 structures, systems and components. In this effort, 22 thousands of calculations and analyses have been reviewed.

23 7. The IDVP to date has yielded 172 findings.

24 The vast majority of these findings are not errors, and very 25 few are errors of actual or potential significance. Under 26 the classification system used in the IDVP, all findings are

1 first characterized as an "Open Item." (See attached 2 Glossary.) An Open Item is either a QA or Design Control .

3 deficiency, a violation of the verification criteria, or an 4 apparent inconsistency identified in the performance of the 5 work. Each Open Item is ultimately recategorized as an 6 " Error," a " Deviation," or a " Closed Item." Errors are 7 broken down into four categories, with Class A Errors being 8 the most significant and Class D Errors being the least 9 important. When the IDVP effort related to an Open Item is 10 complete, the IDVP issues a completion report. Of the 172 11 IDVP findings to date, completion reports have been issued 12 for eighty-nine (89) items, which have been categorized as 13 follows: only one (1) Class A Error (may require physical 14 modifications or changes in operating procedures), no 15 Class B Errors (resolvable by more realistic calculations or 16 retesting); six (6) Class C Errors (no design criteria or 17 Operating limits exceeded); seventeen (17) Deviations 18 (departure from standard procedure which are not mistakes in 19 analysis, design, or construction), and fifty-two (52) 20 Closed Items (neither Errors nor Deviations, with no further 21 IDVP action required). Of the remaining eighty-three IDVP 22 findings for which no completion reports have been issued, 23 the IDVP has identified these findings as follows: five (5) 24 Class A Errors; one (1) Class B Error; fifteen (15) Class C 25 Errors; no Class D Errors; seven (7) Deviations; fifty-four 26 (54) Open Items; and one (1) Closed Item.

1 8. The engineering design process, particularly 2 for seismic design, generally involves a complex combination 3 of engineering judgment, expert opinions, assumptions, 4 modeling techniques, computer analyses and other 5 calculational methodology which is all directed toward 6 developing a reasonable understanding of the performance of 7 structures, systems and components under postulated 8 Operating, accident and seismic conditions. Final designs 9 are then developed based on this understanding. The final 10 design considers inherent conservatisms as well as specific 11 margins and " safety" factors applied throughout the 12 engineering process to cover certain changes, discrepancies 13 and unknowns. It is not surprising, then, that an 14 independent verification program would discover differences, 15 discrepancies and even technical disagreements with the 16 original designs. Furthermore, although these kinds of 17 items have been surfacing throughout the verification 18 programs' development thus far, these differences are 19 exaggerated by the " low threshold" of the identification 20 criteria used for the IDVP.

21 ///

22 ///

23 ///

24 25 26 1 9. While the overall verification effort has 2 identified a number of Open Items, Deviations, and Errors, 3 in our judgment, the findings thus far in the review of the 4 seismic design for the Diablo Canyon plant would not have 5 caused any system, structure or component to fail to perform 6 its intended safety function.

7 8 Dated: June 30, 1982 9

10 .

' ' ' = ~ -

11 Richard C. Anderson hichael R. Tre'sler i '

William H. White 15  %

Gary . Moore 16 17 18 Subscribed and sworn to before 19 me this 30th day of June, 1982 20

,- p 21 (Nancy J./ Lemasttrr, 22 Notary Public in and for the City and County of San Francisco, 23 State of California.

My commission expires April 14, 1986.

24 25 26 1 PROFESSIONAL QUALIFICATIONS OF 2 RICHARD C. ANDERSON 3

4 5

6 My name is Richard C. Anderson. I am the 7 Engineering Manager in the Diablo Canyon integrated project 8 organization consisting of the Pacific Gas and Electric 9 Company and Bechtel Power Corporation employees. I am a 10 Registered Mechanical and Nuclear Engineer in the State of 11 California. I hold a BS degree in Mechanical Engineering 12 from the University of California at Berkeley.

13 I have been with Bechtel for more than 24 years 14 and for the past 5 years have been assigned as an engineer-15 ing manager in Bechtel's San Francisco Division, responsible 16 for all engineering work in the Pacific Northwest and Japan.

17 I have been assigned since March, 1982 specifically to the 18 Diablo Canyon Project to act as Project Engineering Manager.

19 Prior to these Engineering Manager assignments, I was the 20 chief nuclear / environmental engineer for Bechtel's San 21 Francisco Power Division, involved in nuclear power plant 22 design, safety, and operation.

23 Prior to that, I was assigned as an assistant 24 project engineer on a proposed nuclear power plant project 25 for PGandE and as mechanical supervisor and later project 26 engineer on another large nuclear power plant project in the i

1 United States. These assignments included supervision and 2 coordination of design, specification, procurement, and 3 quality control activities.

4 I also served as senior mechanical engineer for 5 various other nuclear power facility projects in the U.S.

6 and abroad, which included work in systems, safety and 7 equipment engineering.

8 I have been an instructor in Bechtel's power plant 9 courses for over 10 years and have given numerous talks and 10 lectures in California on nuclear power and energy issues.

11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

1 PROFESSIONAL QUALIFICATIONS OF 2 JOHN B. HOCH 3

4 5 My name is John B. Hoch. Since January 1982 I 6 have been employed as Project Manager of the Diablo Canyon 7 Project organization at PGandE. My responsibilities include 8 managerial and supervisory duties, and providing coordinate 9 and direction of the Diablo Canyon Project organization.

10 From 1980 to 1982 I was employed as Manager of the 11 Nuclear Projects Department at PGandE. My responsibilities 12 include managerial and supervisory duties, and providing 13 coordination and direction of the Nuclear Projects 14 Department in matters related to'PGandE's nuclear power 15 plants.

16 From 1959 to 1980 I was employed as an Engineer in ,

17 various disciplines in PGandE's Engineering Department. My 18 responsibilities included engineering, design, analysis 19 work, activities related to NRC licensing, and engineering 20 management for PGandE's Diablo Canyon Power Plant.

21 My educational background includes a BS degree in i 22 Mechanical Engineering from the Univeristy of Idaho, 1959, 23 and graduate studies in Engineering, University of 24 California, Berkeley, 1961 to 1962.

25 I am a Registered Professional Engineer 26 (Mechanical and Nuclear) in the State of California.

1 PROFESSIONAL QUALIFICATIONS OF 2 GARY H. MOORE 3

4 5

6 My name is Gary H. Moore. I am the Unit 1 Project 7 Engineer of the Diablo Canyon Project consisting of the 8 integrated organization of Pacific Gas and Electric Company 9 and Bechtel Power Corporation. I have held this position 10 since January, 1982. I am responsible for the project 11 engineering work related to the design and analysis of 12 Diablo Canyon Power Plant Unit 1. I am a Registered 13 Professional Engineer in Mechanical and Control Systems in 14 the State of California.

15 My educational background is as follows:

16 San Jose State University - BS in Mechanical Engineering, 17 1968 18 San Jose State University - MS in Mechanical Engineering, 19 1969 20 I joined PGandE in 1969 as a Mechanical Engineer 21 in the Mechanical and Nuclear Engineering Department, 22 designing instrumentation and control (I&C) systems for 23 conventional fossil plants.

24 In 1977, I was named a Senior Mechanical Engineer 25 supervising the I&C Group assigned to the Potrero Unit 7 26 Project.

L.

M 1 In 1979, I was named Supervising Mechanical 2 Engineer, supervising the Mechanical and Nuclear Engineering.

3 Department's entire I&C Group, including responsibility for 4 the I&C design of the Diablo Canyon Power Plant.

5 I have completed the following formal training 6 courses: - s 7 Simulator Training - Westinghouse Nuclear Training Center, 8 Zion, Illinois ,

9 Westinghouse PWR Information Course 10 11 12 13 14

.15 16 17 18 19 20 21 22 23 24 25 26

, - - , - - , - - - . ~ n. -n~.

1 PROFESSIONAL QUALIFICATIONS OF 2 MICHEL R. TRESLER 3

4 5 My name is Michel R. Tresler. From 1981 to the 6 present I have been employed as a Piping Design Coordinator 7 at PGandE. My responsibilities include supervision, 8 coordination, and direction of the piping and pipe support 9 analysis and design for Diablo Canyon Power Plant.

10 From 1980 to 1981 I was employed as a Supervising 11 Project Control Engineer in PGandE's Nuclear Projects 12 Department with responsibility to develop, implement and 13 maintain a project control system for Diablo Canyon Power 14 Plant.

15 From 1964 to 1980 I was employed in various 16 Positions as an engineer and superintendent in PGandE's 17 ensi neering Department and General Construction Department.

18 During that time, I held the positions of Engineer, Resident 19 Mechanical Engineer, Project Superintendent, and Assistant 20 Station Construction Superintendent. My responsibilities 21 included engineering, analysis, design, field engineering 22 services, and supervision and management activities related 23 to large fossil-fired units and the Diablo Canyon Power 24 Plant. In particular from 1966 to 1970 I prepared startup 25 Procedures and supervised startup activities related to 26 fossil and nuclear power plants.

1 My educational background includes a BS degree in 2 Mechanical Engineering from the California Polytechnic State 3 University, 1964.

4 I have completed the following formal training 5 courses:

6 a. Westinghouse Reactor Operator Training School, 1969.

7 b. Westinghouse Design Lecture Series specific to Diablo a Canyon, system and components design, 1971.

9 c. Stat-A-Matrix course covering the establishment of a QA 10 program and personnel training, 1973.

11 d. Westinghouse PWR Information Course, 1980.

12 e. Westinghouse simulator Training, 1980.

13 14 15 16 17 18 19 20 21 22 23 24 25 26 1 PROFESSIONAL QUALIFICATIONS OF 2 DR. WILLIAM H. WHITE 3

4 5

6 My name is William H. White. I am an Assistant 7 Project Engineer in the Diablo Canyon integrated organiation 8 consisting of Pacific Gas and Electric Company and Bechtel 9 Power Corporation employees. My responsibilities include 10 supervision and direction of seismic related engineering 11 analyses for the Diablo Canyon Unit 1 Project Engineering 12 Organization. I am a Registered Professional Engineer and 13 member of the American Society of Civil Engineers.

14 My educational background includes:

15 BS, Civil Engineering, University of Idaho; 16 MS , Civil Engineering, University of Colorado; 17 PhD, Civil Engineering, University of Colorado 18 For the past 5 years, I have been an engineering 19 specialist with Bechtel's San Francisco Power Division 20 working with the chief civil engineer's staff in the area of 21 seismic analysis for several Bechtel projects.

22 Earlier, I was a structural engineer with the 23 Tennessee Valley Authority where I was responsible for 24 seismic analysis of all Category I structures for a 25 twin-unit nuclear power plant, including the seismic input 26 for the design of the nuclear steam supply system.

1 I was an assistant professor at Oregon State 2 University where I taught undergraduate and graduate courses 3 in structural mechanics and analysis and computer 4 applications. I performed a special study for Bechtel on 5 soil-structure interaction for the proposed Mendocino 6 nuclear power plant while teaching at Oregon State 7 University.

8 While employed at the Bettis Atomic Power 9 Laboratory, I was a senior engineer working on shock 10 analysis of nuclear reactors aboard submarines and was 11 involved in programs to assess the shock resistance of 12 reactor internals subjected to long-term irradiation damage.

13 14 15 16 17 18 19 20 21 22 23 24 25 26

l l

i  ;

' \

1 GLOSSARY 2

3 4

5 IDVP OPEN ITEM 6 This term is used by the independent reviewers to 7 describe any item of concern or potential concern identified 8 by the IDVP that has not been verified, fully understood, 9 and its significance assessed by the IDVP.

10 An Open Item report is issued by the IDVP for the 11 purpose of reporting an IDVP response to a QA and Design 12 control deficiency, a violation of the verification -

13 criteria, such as differences in calculations or system 14 configuration, or an apparent inconsistency identified in 15 the performance of the work.

16 17 IDVP ERROR 18 The term as used by Joint Intervenors in their 19 Motion and by Mr. Hubbard in his affidavit is a 20 characterization of any and al.' items identified by the IDVP 21 and Project technical program. All but a small number of 22 these Open Items have been verified by the IDVP as not being 23 " errors."

24 An Error is a form of program resolution of an 25 Open Item indicating an incorrect result that has been 26 verified as such. It may be due to mathematical mistake,

1 use of wrong analytical method, omission of data, or use of 2 inapplicable data. An Error is classified as one of the 3 following:

4 Class A Error - An Error is considered Class A if 5 design criteria or operating limits of safety related 6 equipment are exceeded as a result, and physical 7 modifications or changes in operating procedures are 8 required.

9 Class B Error - An Error is considered Class B if 10 design criteria or operating limits of safety related 11 equipment are exceeded, but are resolvable by means of more 12 realistic calculations or retesting.

13 Class C Error - An Error is considered Class C if 14 no design criteria or operating limits are exceeded. No 15 physical modifications are required.

16 Class D Error - An Error is considered Class D if 17 safety related equipment is not affected. No physical 18 modifications are required.

19 From the definitions above, only Class A or B 20 Errors result in exceeding a design criterion or operating 21 limit. Consequently, only Class A or B Errors could be of 22 safety significance, but are not necessarily so.

23 24 DEVIATION 25 This is a term used by the IDVP to identify a form 26 of program resolution of an Open Item indicating a departure

\

1 from standard procedure which is not a mistake in analysis, 2 design or construction. No physical modifications are 3 required, but if any are applied they are subject to 4 verification by the IDVP.

5 6 DISCREPANCY AND DEFICIENCY 7 These terms have been used interchangeably in the 8 Hubbard affidavit and Joint Intervenors' Motion with the 9 terms " error" or " serious design error."

10 11 IDVP CLOSED ITEMS 12 This is a term used by the IDVP. It is a form of 13 IDVP program resolution of an Open Item which indicates that 14 the reported item is neither an Error nor a Deviation. No 15 further IDVP action is required.

16 17 IDVP COMPLETION REPORT 18 This report is used by the independent reviewers 19 to indicate that the IDVP effort related to an IDVP Open 20 Item is complete.

21 22 23 24 25 26 i

)*

1 UNITED STATES OF AMERICA -

2 NUCLEAR REGULATORY COMMISSION -

3 4 BEFORE THE ATOMIC SAFETY AND LICENSING APPEAL BOARD 5

6 7

)

8 In the Matter of ) Docket No. 50-275

)

9 PACIFIC GAS AND ELECTRIC )

COMPANY ) (Low Power Proceeding) 10 )

(Diablo Canyon Nuclear Power )

11 Plant, Unit No. 1 )

)

12 13 14 AFFIDAVIT OF RICHARD S. BAIN 15 16 STATE OF CALIFORNIA )

) ss.

17 CITY AND COUNTY OF SAN )

FRANCISCO )

18 19 20 21 The above being duly sworn, deposes and says:

22 23 1. My name is Richard S. Bain. I have been 24 Manager of Station Construction and have had responsibility i

25 for the construction of Diablo Canyon Nuclear Power Plant 26 since 1975. Prior to my appointment as Manager, Station

).

o 1 Construction, I was the Station Construction Superintendent 2 at PGandE's San Francisco General Offices, and was assigned 3 direct supervision of all construction activities, including 4 supervision of construction contracts for Diablo Canyon from 5 its inception. A summary of my experience and responsibili-6 ties is contained in Attachment A.

7 2. I have carefully read the affidavit of Mr.

8 Richard B. Hubbard dated May 24, 1982 filed with Joint 9 Intervenors' Motion dated June 8, 1982. I will address my 10 comments specifically to Mr. Hubbard's allegations of an 11 inferred " breakdown" of quality assurance and quality 12 control in the constructi6n and installation of equipment 13 and apparatus at Diablo Canyon. As I will comment 14 hereinafter, PGandE had in place a comprehensive and 15 vigorous on-site construction quality assurance / quality 16 control program. This program was subjected to numerous 17 internal and NRC (AEC) audits during construction activity 18 at Diablo Canyon. No such " breakdown" occurred.

19 3. There were three types of on-site procedures 20 and instructions that were developed and applied at Diablo 21 Canyon to provide the requisite direction for these actions 22 and activities necessary to assure design and quality

23 requirements being in conformity with the Quality Assurance 24 Program. They consist of

25 a. Quality control procedures to establish the 26 control, direction and methods for acceptance of

h.

1 physical work performed by PGandE personnel and'as 2 required by the Senior Site Representative to 3 control project activities affecting quality.

4 b. Preoperational and startup test procedures to 5 assure that systems and components meet design 6 requirements. To the extent feasible, test 7 procedures incorporate approved plant operating 8 procedures and provide for testing of items under 9 simulated operating conditions.

10 c. Field instructions developed by the Resident 11 Engineers (Civil, Electrical, Mechanical, and 12 Start-up) to provide the Project Superintendent 13 with supervisory support for the on-site 14 activities through Resident Engineers, Field 15 Engineers and Field Inspectors. With respect to 16 quality control, the responsibilities of the 17 Resident Engineers include: (1) preparation of 18 quality control plans for site-related activities, 19 (2) direction of quality control activities, (3) 20 review and approval of field contractors' 21 individual quality assurance procedures, (4) 22 supervision of Field Engineers and Inspectors, (5) 23 review of site-related quality assurance 24 procedures, and (6) preoperational testing and 25 startup.

26 ///

1 4. PGandE has always recognized the.importance 2 of supervisory surveillance and inspection during construc-3 tion activity. Even prior to the promulgation of 10 C.F.R. 4 Part 50, Appendix B and the formalization of quality 5 assurance requirements, PGandE had procedures for cleaning 6 and flushing; shipping, receiving, storage and handling; 7 housekeeping; dimensional checking and quality testing in 8 P l ace at Diablo Canyon.

9 5. The first on-site Quality Control Engineer 10 was appointed in June 1969. This position has been 11 continuottsly maintained by a succession of engineers since 12 that first appointment. The purpose of the on-site Quality 13 Control Engineer was to assist the Project Superintendent 14 and resident engineers in implementing the quality program, 15 Provide guidance to the contractors quality groups, and 16 inspect and audit for compliance to PGandE quality program.

17 This inspection / audit was conducted in addition to and 18 supplemental to the quality control inspections and audits.

19 The cn-site quality engineer has remained independent of 20 direct responsibility for the scheduling, cost, or 21 Performance of construction.

22 6. Quality Control Provedures and Departmental 23 Instructions were developed at Diablo Canyon as early as 24 October 1969 to implement the requirements of the PSAR and 25 Proposed 10 C.F.R. Part 50, Appendix B and PGandE's PSAR.

26 ///

4 d'

1 7. For the construction and installation of the 2 building, equipment, and apparatus at Diablo Canyon, PGandE 3 required that each contractor performing work at Diablo 4 Canyon have a quality assurance program qualified to PGandE, 5 industry, and Nuclear Regulatory Commission (Atomic Energy 6 Commission) quality assurance requirements. The contractor 7 and any sub-tier contractor or supplier providing a service 8 or material to be installed at Diablo Canyon adhered to 9 these procedures in the performance of work at the site or 10 any other location affecting materials or products 11 ultimately destined for Diablo Canyon. These programs were 12 reviewed, approved, and audited by PGandE. (See 13 Attachments 1, 2, 3 and 4 for illustr:'uve examples. )

14 8. Quality procedures, work practices, personnel 15 quali fications , forms, etc., prepared by contractors were 16 submitted to PGandE General Construction, Quality Assurance, 17 and other departments for review and approval. The same 18 rigid experience requirements established for Company field 19 engineers and inspectors were also required of contractors.

20 9. Quality control at the Diablo Canyon site was 21 a multi-tiered operation. As a requirement of all bid 22 specifications, each contractor was required to prepare and 23 staff a site quality assurance / quality control organization 24 adequate to inspect the quality of work performed. PGandE 25 field engineers and inspectors reinspected this work for 26 compliance with the applicable design documents and Q

1 specifications. The General Construction quality control 2 on-site group was then directly involved in the -verification 3 of the adequacy and effectiveness of the contractors' 4 quality assurance program and the Company's following 5 inspections. Finally, Corporate on-site quality assurance 6 engineers verified the adequacy and effectiveness of the 7 entire process.

8 10. The complementing ratio of Company field 9 engineers and inspectors overseeing the contractors' work 10 varied from a maximum of 18 workers to 1 inspector to a 11 minimum of 8 workers to 1 inspector, and averaged 13.5 12 workers to 1 inspector.

13 11. The first construction QC audit was conducted 14 on February 11, 1970, and from that date there have been 707 15 such audits. In every instance any discrepant condition was 16 corrected. In every instance of a contractor QA/QC 17 identified discrepancy a Company discrepancy report was also 18 filed to be certain that the condition was properly 19 processed. This duality of documentation established a 20 double-check for satisfactory resolution of the discrepancy 21 ///

22 ///

23 ///

24 i

25 26 1

1 in accordance with quality assurance / quality control 2 procedure, engineering design and specification.,

3 4 Dated: July 1, 1982 5

6

\ t 7 N . $d4A Richard S. Bain 8

9 10 subscribed and sworn to before 11 me this 1st day of July, 1982 12 , --_

13 NKncy J. L6 master, 14 Notary Public in and for the City and County of San Francisco, 15 State of California.

My commission expires April 14, 1986.

16 17 18 19 20 21 22 23 24 25 26

1 PROFESSIONAL QUALIFICATIONS OF 2 RICHARD S. BAIN _

3 4

5 My name is Richard S. Bain. I am Manager of 6 Station Construction in the General Construction Department 7 in the Pacific Gas and Electric Company. I have held this 8 position since 1975. I am responsible for the 9 administrative, technical, and physical services necessary 10 to assemble, install, test, and make operable (1) plant and 11 auxiliaries of electric generating stations; (2) 12 transmission and distribution electrical stations; (3) 13 communication systems; (4) gas pipeline compressor and 14 metering stations as assigned by Gas Construction; and (5) 15 water treatment facilities as assigned by Civil-Hydro 16 Construction. I am responsible for assuring the established 17 conditions and specifications are met within acceptable 18 schedules, and providing manpower and equipment for 19 maintenance and repair of facilities.

20 Prior to my duties as Manager, I was Station 21 Construction Superintendent with the General Construction 22 Department in the Pacific Gas and Electric Company beginning 23 in 1953. I was responsible for providing prompt, effective, 24 and safe construction services for power plant facilities in 25 accordance with engineering specifications. During that 26 time I was assigned the responsibility for the construction

1 of Diablo Canyon Power Plant with its inception in 1966. My 2 responsibilities included also the the planning and 3 supervision of construction work related to the Humboldt Bay 4 Power Plant and other planned nuclear power stations.

5 I am a member of the American Society of 6 Mechanical Engineers Committee on Nuclear Quality Assurance 7 and have been involved in the preparation of ANSI N45 8 industry nuclear codes ad standards.

9 My educational background includes a BS in 10 Industrial Engineering from Stanford University in 1947.

11 12 13 14 15 16 17 18 19 20 i 21 22 23 24 25 26

PACIFIC CAS AND ELECTRIC COMPANY SUPPLEMENTARY SPECIFICATION FOR MANUFACTURER'S QUALITY CONTROL SYSTEMS REQUIREMENTS s 1.0 SCOPE This Supplementary Specification establishes requirements for the manuf acturer's systems for control of quality during manufacture, including inspection plans. Should this Supplementary Specification conflict with the Specific Conditions, the latter shall govern. Items required to comply with certain codes or standards by the Specific Conditions may have additional requirements such as found in Paragraph N-832 of Section III, Nuclear Vessels, ASNI Boiler and Pressure Vessel Code.

  • 2.0 SYSTEM REQUIREMENTS The manuf acturer shall establish and maintain a system for the control of quality during the order that shall assure that all supplies and services, including subcontracted items, meet all drawing and order requirements.

2.1 Drawings and Changes: The manuf acturer's system shall provide procedures which will assure that the latest applicable drawings, specifica-tions, and instructions required by the contract or purchase order as well as authorized changes thereto are used for manufacture, inspection, and testing.

2.2 Description of Procedures: The manufacturer shall maintain a written description of procedures for control of quality and inspection show-ing in detail the implementation of the quality requirements of the contract or purchase order and the requirements of this Supplementary Specification.

In addition, the procedures shall include (but not be limited to) quality control measures governing:

2.21 Qualification of processes, equipment, personnel, and laboratories.

2.22 Receiving inspection.

,sq 2.23 Certification of material used and final product.

U 2.24 Quality audits.

April 1968 BAIN Attachment 1

Suppl. Spac.

Quality Control j Systems )

l l

2.3 Management Review: The manufacturer's quality system shall provide for the identification and evaluation of significant or recurring discrep-

' ancies and for alerting the manuf acturer's cognizant management to the need for corrective action. Corrective action shall be reviewed by the manufac-turer for effectiveness and the need for further action.

\

3.0 PROCESS PROCEDURES The manuf acturer shall operate under a controlled manufacturing system such as process sheets, shop procedures, travelers, etc. Special controlled processes such as welding, heat treating, nondestructive testing, and inspec-tion techniques shall be a part of and included in the system.

3.1 Procedure Revisions: There may be a need to revise or eliminate a previously approved inspection procedure. When this occurs, the change to (or elimination of) inspection procedures shall require Purchaser's approval.

3.2 Inspection Plans: Inspection planning for~this order shall be completed in writing by the manufacturer, covering subcontracted work as well as his own, to the following minimum requirements:

3.21 All inspection operations through shipment shall Le listed and referenced to the manuf acturer's/ subcontractor's manufacturing procedures. This Inspection Check List shall be submitted to Purchaser for approval in advance of fabrication.

3.22 Characteristics specified by the order and its referenced drawings and specifications shall appear on the check lists under the appropriate inspection operation. Space shall be provided for a nota-tion of the document number and revision to which the inspection was made and for the inspector's signature or stamp. Each characteristic so listed shall be inspected (using approved procedures wherever these are required) and the result recorded.

3.23 When a combined manuf acturing and inspection plan meets the requirements above, a separate check list of special format is not requi, red.

I 4.0 NONCONFORMING COMPONENTS OR MATERIAL

) All nonconforming material and components shall be kept identified and recorded to prevent intermingling with conforming material. Material or components that fail to meet acceptance standards shall be disposed of as l follows:

April 1968

Suppl. Spac.

Quality Control Systema 4.1 Components or material that do not meet specifications may be sub-mitted for possible acceptance in accordance with the purchase order.

4.2 The manuf acturer shall be responsible for establishing and control-ling repair procedures. He shall obtain written approval from Purchaser of any repair procedure which utilizes operations not performed in the normal manufacturing process. Each repair shall be recorded.

4.3 When the manufacturer elects to scrap the defective material or component, adequate records shall be maintained to verify that the rejected material or component has not been used.

5.0 QUALITY CONTROL RECORDS 5.1 The manufacturer shall maintain a complete file of all records for material and items manuf actured. This shall include chemical and physical properties of materials, inspection, test, and analysis data taken before, during, and after manufacture as required, the manufacturing and inspection procedures, specifications, and drawings used. The records shall include all closely related data such as qualifications of personnel, procedures, and e q uipmen t , and data on nonconforming material.

5.2 Purchaser shall be provided access to records on special request as needed for engineering studies. However, copies of all data specifically requested in Purchaser's specification or purchase order shall be submitted to Purchaser as required. The manuf acturer shall maintain a record file for a minimum of 5 years after order completion, after which time he shall either request disposition instructions from Purchaser or continue to maintain the records.

6.0 CONTROL AND IDENTIFICATION OF MATERIAL l

l i

The manufacturer shall maintain a system of material control adequate to assure identity of all material used and that it meets the applicable specifications, prior to start of manufacturing operation. Identification of all material shall be maintained throughout all operations by heat number (or l7 any other suitable means traceable to the heat number) and recorded on inspec-tion data records for each component.

)

I April 1968

Suppl. Spac.

Quality Control Systema N

8.2 Where applicable, the manuf acturer's control charts and other sta-

, tistical data shall be made available for inspection to Purchaser and shall be maintained as a record substantiating the acceptability of the components or material.

9.0 HANDLING AND STORACE 9.1 The quality program shall require the use of handling procedures and equipment inspection with a monitoring program established to prevent handling damage to the product. The equipment inspections shall include any load bearing devices (hooks, shaf ts, slings, etc.) the f ailure of which could result in product damage.

9.2 The manufacturer shall provide adequate work and inspection instructions for storage, preservation, packaging, and shipping to protect the products and/or supplies f rom damage, loss deterioration, degradation, or substitution of product or supplies. Any special handling instructions during shipping and storage shall be prominently displayed on the shipping package.

7 1

i April 1968 '

l 5722t S " ' ' ' ' ' ' ^' ' " " 7 * * ' -*

D G.M. NO. 167027

c. SPECIFICATION 1 FOR v

FURNISH AND ERECT CONTAINMENT STRUCTURE LINER FOR UNIT 1 DIABLO CANYON SITE FOR THE PACIFIC GAS AND ELECTRIC COMPANY SAN FRANCISCO, CALIFORNIA Department of Engineering Comprising Specific Conditions Appendix h Form of Proposal Insurance Questionnaire

.1 APPROVED BY J. J. McCann/ATL(NLT/DBN) BIDDER - SIGN HERE TO INDICATE THIS B.,W. Shackelford/RVB(EPW/SP) HAS BEEN USE IN PREPARING PROPOSAL l D. V. Kelly /JOS(WJL) < TN9M4Ah .187/$

' FIRM d [$ dd8 /

BY d; DATE b/ 7 hd '

O DATE February 25, 1969 BAIN Attachment 2 s

I 8831-X Quality Assurance 18-1

) . SECTION 18 QUALITY ASSURANCE 1.0 DEFINITIONS 1.1 Quality assurance comprises all those planned and systematic pro-grams necessary to establish confidence that will perform satisfactorily in service. a material, component, or system 1.2 Quality control comprises those quality assurance actions which provide a means to control the quality of the material, component, or system to predetermined requirements.

1.3 Product includes material, components, devices, equipment, systems, structures, tions of thisservices, and other items furnished by Contractor under other sec-Specification.

Product may consist of individual itecs, assemblies of items, or items in any state of fabrication.

l 2.0 SCOPE 2.1 Quality affecting the quality of products thatassurance requirements shall apply to all activities are important to nuclear safety and I to the prevention of accidents or to the mitigation of their consequences .

All products provided under this Specification shall be considered as within the above category unless specifically exempted in writing.

I 2.2 Activities subject to quality assurance requirements include designing, purchasing, fabricating, handling, shipping, storing, maintain-ing, constructing, inspecting, testing, repairing, modifying, and documenting .

2.3 Contractor is responsible for performanc. of all quality assur-ance activities necessary to assure that products furnished by him are l

complete

  • and in accordance with design and specification.

2.4 Contractor shall submit with his proposal a description of his proposed quality assurance program (bid Item 500).

' 1969, Contractor shall prepare in detail and submit Not later than May to Specification No.20, 8831 i Contractor for submittal to Constructor for approval eighteen copies of his quality assurance program which shall define the program and designate the qualifications, pliance functions, with the and number of personnel necessary to assure com-Specification. -

The program and methods used to implement these requirements shall be developed by Contractor based on the outline "

{

provided in Paragraph 3.0 of this Section. Contractor shall revise all or any it doesportion not of the quality satisfy assurance program where, in Company's judgment, requirements.

start of work. Such corrections shall be made prior to

- 1

l 8831-X Quality Assurance

( ) 18-2 2.5 Contractor shall be fully accountable for scheduling his work so as to permit adequate time for compliance with the quality assurance require-ments of this Specification.

l 3.0 QUALITY ASSURANCE REQUIREMENTS

3.1 Organization

Contractor's quality assurance organization shall have clearly defined responsibility and authority for implementation of a comprehensive quality assurance program, Contractor shall require his sup-pliers and subcontractors to establish adequate quality assurance organizations.

Quality assurance personnel shall be independent of manufacturing, fabrication, and construction forces and shall not perform functions other than those of quality assurance. Quality assurance personnel shall have sufficient and well defined responsibility, authority, and organizational freedom to identify and evaluate quality problems and to require implementation of approved solutions.

Contractor shall provide with his detailed quality assurance program as required in Paragraph 2.4 a description of his suppliers' and subcontractors' quality assurance organizations. The descriptions shall include the duties, responsibilities, numbers, and basic qualifications of key personnel to be assigned to these activities. The chove shall include a chart indicating responsibility and lines of authority between Contractor, Contractor's con-struction supervision, suppliers and subcontractors, and quality assurance personnel.

3.2 Procedures and Plans: Contractor shall review the requirements of the Specification and prepare written procedures and plans for the following:

3,21 Proposed sequence of shop and field fabrication and construc-tion activities in detail and including and identifying those operations specifically related to quality.

3.22 Monitoring, inspecting, testing, and control of shop and field fabrication processes, test equipment, fixtures, tooling, and per-sonnel skills required to assure the product quality.

3.23 All nonfabrication work affecting quality, including but not limited to designing, detailing, purchasing, handling, inspecting, test-ing, and shipping.

3.3 Approval of Procedures: Procedures shall be submitted to Construc-tor for approval prior to initiation of the work. Work shall not proceed until written approval of the corresponding procedure has been obtained.

3.4 Hold Points: Company may indicate mandatory inspection hold points k which shall require witnessing or inspecting by Company. Work shall not pro-ceed beyond these hold points prior to such witnessing or inspection.

l 8831-X l Quality Assurance i 18-3 l l l l

3.5 Records

Contractor shall prepare, use, and maintain adequate

. records to attest to and document the quality of the product. Such a set of records shall include, as a minimum, material analyses, design checks, inspec-tions, tests, workmanship, and procedures; qualifications of equipment, l procedures, and shop, field, and technical personnel; and nonconformances and  ;

subsequent corrective actions. Inspection and test records shall indicate the nature of observations and type of nonconformances found. Records of work p2rformance shall indicate acceptability of the work and/or material or necessary corrective action in cases of nonconformances. All records and documents must be preserved for ultimate use by Company for a minimum of ten years. Until such time as they may be transferred to Company, the records and documents shall be available for inspection and review by Company and regulatory agencies at any time. Contractor shall submit his record proce-dure to Constructur for review and approval prior to beginning fabrication or installation activity. Contractor's procedure shall include a system for identifying the inspection status of products. This may be accomplished by stamps, tickets, or tags.

3.6 Corrective Action: The quality assurance program shall provide a system for prompt detection, identification, and correction of conditions having an adverse affect on quality. Any factor of Contractor's operations which has had or could reasonably be expected to have an adverse effect on product quality shall be identified and corrected. The program shall require I

effective use of all data regarding defects which will not be limited to product items, but shall include methods, processes, and facilities. All conditions adverse to quality shall be documented and brought to the atten-tion of Constructor and Contractor's supervision and management for analysis, evaluation, and prompt corrective action.

3.7 Specification. Drawing, Documentation, and Change Control: Con-tractor shall prepare, naintain, and use a procedure for assuring that specifications, drawings, procedures, instructions, authorized changes, and other documentation, which deal with activities affecting quality, are cur-rent, adequate, and available for use in fabrication, construction, inspection, and testing. The procedure shall stipulate that obsolete documentation be removed from point of use.

3.8 Measuring and Testing Equipment: Contractor shall prepare, maintain, and use a procedure for the maintenance and periodic calibration of measuring and testing equipment used to determine product conformance.

All measuring and testing equipment shall be calibrated against certified measurement standards which have known valid relationships to national standards, t

, 3.9 In Process and Pinal Inspection: Contractor's quality assurance l program shall assure that work is accomplished under controlled conditions which include documented work instructions and test procedures, adequate equipment, and any special environments that may be required. Inspection

{ personnel shall be qualified in their specific area of responsibility and knowledge. Documented work instructions shall include criteria for accept-able and unacceptable conditions including workmanship. Physical examination, 9

8831-X Quality Assurance 18-4 l l measurements, and/or tests shall be performed as required during product

. processing at appropriate points so as to assure quality of the end product.

Contractor shall maintain close coordination with Company to facilitate inspection or witnessing of tests by Company.

3.10 Product Control: All products subject to quality control require-ments which have been approved for use shall be identified and segregated to assure that only these products are used in the work.

3.11 Nonconforming Products: Contractor's quality assurance program shall require that products which fail to meet requirements are identified and segregated and removed from work site or from areas designated for approved material.

3.12 Handling and Storage: Contractor's quality assurance program shall provide and use adequate procedures to assure that all necessary meas-ures are taken to prevent damage or deterioration of products during handling or storage.

3.13 Special Protection, Packing, and Packaging: Contractor's quality assurance program shall provide and use adequate procedures to assure that products requiring special protection, packing, or packaging shall be given appropriate consideration and treatment.

l 3.l'4 Cleanliness: Contractor's quality assurance program shall provide adequate procedures to assure that products are provided and maintained in an appropriate state of cleanliness.

3.15 Audit: A procedure for a system of audits shall be established and used to assure compliatice with all aspects of the quality assurance pro-gram and to determine its ef f ectiveness. Audits shall be made on a planned periodic basis. Contractor shall include as a requirement of his purchase 3

orders and subcontracts a statement essentially as follows: " Contractor j l and/or Company shall have the right to conduct quality assurance audits and inspections at any time during production and testing as may be deemed '

necessary."

i 4.0 CONTROL OF WORK l 4.1 Company will perform a continuing audit of Contractor's quality assurance program. This is in addition to the audit by Contractor described in Paragraph 3.13.

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t 8831-X Quality Assurance 18-5 4.2 Company will stop or reject work which, in his opinion, ir, below specified quality standards. Work shall not be resumed until acceptable

. corrective measures are adopted by Contractor. Exercise of this authority shall be by written directive describing the work in question and reason for its suspension.

- . CIVIL.

sANTON W.

= SHACAnf0A0

. he,7305 =

Of cad wn

se,r PACIFIC G AS AND ELECTRIC COMPANY S AN FRANCISCO, CALIFORNI A i .

DEPARTMENT OF ENGINEERING

>' ACCOUNTING DATA

. ~"":: ... =- c~~ ~m=q+y 167027 18 Various Various 40 8752

' GM 169972 SPECIFICATION NO.

Project File Number 30.70 SPECIFICATION

~

FOR e

INSTALLATION OF THE NUCLEAR STEAM SUPPLY SYSTEMS FOR UNITS 1 AND 2 - DIABLO CANYON SITE COMPRISING Spacific Conditions General Conditions Proposal Form Insurance Questionnaire Appendix I

s.

APPROVED BY 6 J. J. McCann (ATL)(EDC/ MPH) ^

D. V. Kelly (HJG/RML/AGW/NLZ) ^ ^

"^

T. A. Bettersworth (JWC/DN)

FIRM R. V. Bettinger (EPW/VJG) ,

W. J. Lindblad DATE C. V. Richards DATE May 3, 1972 BAIN Attachment 3 I

8752 General 1-1

>. SPECIFIC CONDITIONS SECTION 1 I GENERAL l

1.0 SCOPE OF WORK 1

1.1 General

This Specification covers the installation of the I nuclear steam supply systems at Company's Units 1 and 2 - Diablo Canyon Site. The nuclear steam supply systems are Westinghouse Electric Corpo-ration four-loop pressurized water reactors. The material, equipment, and components to be installed are Company furnished and comprise a major portion of the primary or reactor coolant system. The items to be installed for Unit I are itemized and described in Secticn 2 of this Specification, and the accompanying drawings show and locate the Unit 1 system and equipment. Unit 2 will be similar, except opposite hand.

Contractor shall provide all labor, supervision, inspection, material, supplies, equipment, tools, and facilities required to complete the installation of the items furnished. All work performed under this Specification shall be to the satisfaction of the Constructor, but this shall not be construed as to relieve Contractor of the responsibility to l complete and guarantee the work as specified.

1.2 Heavy Equipment Handling: Company has contracted with others for receiving, transporting, storing, and lif ting the heavy equipment and components to be installed under this Specification. Refer to Sec-tion 2 for the heavy items which will be handled by others. Contractor will not have to handle these items, except as noted in Section 2.

I 1.3 Installation Procedures : Contractor shall prepare detailed writ ten installation and erection procedures and instructions for all ,

work to be performed under this Specification. Company and the nuclear steam supply system supplier, Westinghouse, will provide the technical data and information necessary to develop these instructions. Refer to Section 3 for installation procedure requirements.

1.4 Quality Assurance: Work activities affecting structures, systems, equipment and components, that are essential to the nuclear  !

safety of the plant and to the prevention of accidents or to the miti-gation of their consequences shall be performed and documented by a quality assurance program. All the structures, systems, equipment and components for the Diablo Canyon Site that require quality assurance measures are categorized as " Design Class I." With a few exceptions, 4 the material, equipment, and components installed under this Specifica- l tion are Design Class 1, and are specifically noted as such in the descriptions of Section 2. Contractor shall implement a quality assur-anee program f or all work performed and material supplied for Design Class I items. Ref er to Section 4 for Contractor's Quality Assurance Program requirements, i

8752 Quality Assurance 4-1 SECTION 4 CONTRACTOR'S QUALITY ASSURANCE PROGRAM

, 1.0 GENE GI.

i 1.1 This Section establishes the requirements for Contractor's quality assurance program for the control of quality of material supplied and work performed under this Specification.

1.2 Cont ractor's quality assurance program shall apply to all material supplied for and work performed on Design Class 1 structures, systems, and components, including equipment and accessories. Design Class 1 items are identified in other sections of this Specification.

1.3 Contractor's quality assurance program shall include the i following activities : preparing drawings, purchasing, fabricating, receiving, handling, shipping, storing, maintaining, installing, erect-ing, assembling, constructing, inspecting, testing, repairing, modifying, recording, docuraenting, and auditing.

1.4 Contractor shall schedule his work to permit adequate time for implementation of the quality assurance program.

1.5 Contractor shall assure that his suppliers and subcontractors conform to all requirements of the quality assurance program.

2.0 DEFINITIONS 2.1 Quality assurance comprises all those planned and systematic I

actions necessary to establish confidence that the equipment and systems l will perform satisfactorily in service.

2.2 Quality control comprises those quality assurance activities related to the physical characteristics of a material or work which l providys a means to determine and control the quality of the material supplied and work performed to predetermined requirements.

, 2.3 Material includes components, devices, equipment, systems, i structures, and other items. furnished by Cont ractor to complete the requirements of this Specification. Material may consist of individual items , assemblies of items, or items in any state of fabrication.

2.4 Work includes all activities by Contractor to complete the j requirements of this Specification, l

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8752 j

i Quality Assurance 4-2 la 3

3.0 SUBMITTALS 3.1 Bidder shall submit with his his proposed quality assurance program, proposal a brief description of his: including details or samples of (1) quality assurance organization, (2) quality assurance proce-dures manual, and (3) quality assurance inspection and test plane 3.2 Within 30 days following the award ot contract, Contractor shall submit to Constructor for approval six copies of (1) his quality assurance organization description, designating qualifications, respon-sibilities, and numbers of personnel, in accordance with Paragraph 4 2 of this Section; and (2) his quality assurance procedures manual, includ-ing all the procedures necessary to assure compliance with the require-ments of Paragraph 4.3 of this Section.

Contractor shall revise all or any portion of his quality assurance organization and quality assurance manual where, in Company's judgment , they are not satisfactory. When Company approves of Contractor's quality assurance organization and quality assurance procedure manual, nineteen copies of the approved organization and manual shall be submitted to Constructor. Contractor's quality assurance organization and quality assurance procedures manual shall be approved prior to the start of any work.

3. 3 At least 21 calendar days prior to the start of work on any Design Class I structure, system, or component, including equipment and accessories, Contractor shall prepare and submit to Constroctor for approval six copies of a specific inspection and test plan for that work.

This of thisplan shall be in accordance with the requirements of Paragraph 4.4 Section.

where, in Company's judgment, Contractor shall revise all or any part of the pla it is not satisfactory. When Company approves the inspection and test plan, nineteen copies of the approved inspection and test plan shall be submitted to the Constructor, and it shall be used for documenting and recording all inspections and tests performed on that Design Class I item. Inspection and test plans shall be approved prior to the start of any work on Design Class I items.

Upon completion of the installation and upon Company acceptance of the equipment, nineteen copies of the completed inspectioi and test plan shall be forwarded to Constructor.

4.0 QUALITY ASSURANCE PROGRAM REQUIREMENTS 4.1 Quality Assurance Program:

  • 4.11 Contractor's quality assurance program shall consist of a quality assurance organization, a quality assurance procedures manual, and quality assurance inspection and test plans in accordance with the following paragraphs, y ._

8752 Quality Assurance 4-3

\

4.2 organization:

4.21 Cont ractor's quality assurance organization enall have clearly defined responsibility and authority for implementation of a comprehensive quality assurance program. The organization shall require quality control personnel: (1) to have sufficient and well de fined responsibility, authori ty, qualifications , and organiza-tional f r eedom to identify and evaluate quality problems and, when necessary, to require implementation of approved corrective actions, and (2) to be generally independent of procurement, manufacturing, f ab ri cat ion , scheduling, and construction forces.

4.22 Cont ractor shall require his suppliers and subcontractors to establish adequate quality assurance organizations. Contractor shall provide with his detailed quality assurance program submittal (as required in Paragraph 3.2 of this Section) a description of his suppliers' and subcontractors' quality assurance organizations, including qualificat ions , responsibilities , and numbers of personnel, and a chart indicating responsibilities and lines of authority between Cont ractor, Cont ractor's const ruction supervision, suppliers and subcont ractors, and quality control personnel.

4.3 Procedures Manual: Cont ractor's quality assurance procedures manual shall detail the methods used by Contractor to control the quality of material supplied and work performed under this Specification. Con-tractor shall conduct his work in accordance with the procedures therein.

The manual shall include the following procedures as a minimum:

4.31 Design Control: Contractor developed designs for structures , systems , and components shall be reviewed for complete-ness , design adequacy, material compatibility, code conformance, currentness, and other similar items. Reviews of design adequacy shall consist of checking the design with alternate or simplified calculation methods, by performance of a testing program which is approved by Company, or by conducting a complete design review.

Control measures for design changes shall be commensurate with those applied to the original design.

4.32 Document Con t ro l,: Contractor shall assure that specifications, drawings, procedures, instructions, inspection and test plans, and any other quality related documents , as well as authorized changes, used in work performed under this Specification are current, properly completed, approved by authorized personnel, and distributed for use. The procedure shall assure that obsolete documentation be removed f rom use.

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f 8752 Quality Assurance 4-4 4.33 Material and Work Procurement Control: Cont ract or shall

  • assure that all material and work furnished by suppliers or sub-contractors under this Specification conform to the applicable requirements of the procurement documents such as drawings, spec t-s fications, and codes. Contractor procurement control includes evaluation and selection of qualified suppliers and subcont ractors, the transreission of applicable design and quality requirements to suppliers and subcontractors, the assurance that supplier and sub-contractor quality assurance programs are consistent.with this Specification, and source inspection by Contractor at the supplier or subcontractor. This procedure shall not include Company fur-nished material until delivered to Cont ractor.

4.34 Receipt Inspection of Material: Contractor shall inspect to the extent necessary all material delivered into his custody to assure conformance to rpecifications, drawings, purchase orders, and other technical requirements. Receipt inspection may vary as to amount and type depending on the item and supplier.

Company furnished material need only be inspected for completeness and damage during handling if Company specifically identifies and exempts the equipment in writing.

4.35 Identification, control, and Status of Material:

Contractor shall develop measures to maintain identity and trace-ability of material to assure that prescribed inspections and tests have been performed, to identify nonconforming matei-ial, and to pre-vent the use of incorrect or defective material. Suitable means of marking or recording material, such as stamps, tags, labels, or routing cards shall be employed. Cont rac tor shall submit his proposed method of identification marking for approval.

4.36 Handling, Storage, Packaging, Shipping, and Preservat ion of Material: Contractor shall assure that all necessary measures are taken to prevent damage, loss, or deterioration of material during handling, storage, packaging, shipping, receiving, preserving, installing, erecting, and maintaining until acceptance by Constr uc-tor. Material requiring special protec t ion, preserving, or packaging i

shall be given appropriate consideration and t reatment . This will j include, when necessary , the es cablishment and periodit verification of protective environments, such as inert gas, moisture content, and i temperature levels.

i 4.37 Nonconforming Material Cont rol: Cont ractor shall assure l* that material which f ails to meet requirements of this Specificat ten j are identified, segregated, and then remaved from areas designated for approval material. Nonconforming items shall be rev2ewed, t

accepted, rejected, repaired, or reworked in accordance with proce-dures requiring designer review. If Company furnished material is nonconforming, Cont ractor shall noti fy Const ruc tor if Contractor ,

proposes to use any material which does not meet the requirements of this Specification, a written report shall be prepared for Engi-neer's approval. Company will furnish Contrattot with inst ructions for submitting nonconforming material repor ts -

}

8752 Quality Assurance 4-5 4.38 Qualification of Processes and Personnel: Contractor shall assure that special processes, such as welding, heat treating, and nondestructive testing, are controlled in accordance with appli-icable codes, standards, specifications, etc. Special processes shall be accomplished by qualified personnel using qualified

, procedures.

4.39 Calibration of Measurement and Test Equipment: Contractor shall assure the maintenance and periodic calibration of measuring and testing equipment used. All measuring and testing equipment shall be calibrated against certified measurement star.C rds which have known valid correlation to national standards.

4. 310 Corrective Action: Contractor shall assure that all conditions which adversely affect quality and tend to cause failures, malfunctions, deficiencies , deviations , defective items , and noncon-formances are promptly identified, reported, and corrected to pre-clude repetition. Contractor shall maintain records on all conditions which adversely affect quality. These records shall indicate each condition, the cause of the condition, and the corrective action taken. A copy of these records shall be forwarded to both the Con-structor and the Contractor's supervision and management for analysis, evaluation, and review.

4.311 Records: Contractor shall use, collect, and maintain records and data essential to document the quality of material supplied and work performed under this Specification. Records are considered one of the principal forms of objective evidence of qual-ity, and procedures shall assure thit records are complete and reli-able. Records collected shall include, as a minimum, the following:

drawings, specifications, purchase orders, work orders, inspection reports, test reports, work performance records, work procedures, qualification records for procedures, equipment and personnel, non-conformance reports, corrective action records, and audit records.

Inspection and test reports shall indicate the nature of observa-tions or test, the acceptable limits of observations or tests, the results, the type of nonconformances observed, and the identity and signature of the observing personnel. Work performance records shall indicate acceptability of the work and/or material or necessary corrective action in cases of nonconformances. All records shall be collected and filed in one hour rated fireproof cabinets at one loca-tion at suppliers' and subcontractors' shops or at the work site.

All records shall be preserved by Contractor for use by Company for ten years. If Company has not requested custody of the records and documents before the end of the ten-year period, Contractor shall request disposition instructions from Company. Until such time as they may be transferred to Company, the records and documents shall s

be available for inspection and review by Company and regulatory agencies. Upon request, duplicate copies of records and documents for specific items shall be provided promptly by Contractor to Constructor. ,

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8752 Quality Assurent<

4-6 4.312 Audits:

Contractor shall establish a system of audits to assure compliance with all aspects of the quality assurance program and to determine its ef fectiveness.

on a planned periodic basis. Audits shall be made Follow-up shall be taken where necessary. Audit action, including reaudi ts, and forwarded to Constructor for review.results shall be document 4.4 _ Inspection and Test Plans:

Contractor's quality assurance inspection test and test plans shall identify the specific inspection and requirements for the construction, erection, and installation of Contractor shall review the drawings , specifications, p ,

codes, manufacturers' to structures, instruction manuals, and other documents perta systems, equipment, tion and prepare written inspection and test plans.and components The inspection and under test plans will establish the initial, in-process, and final inspections and tests that are performed to assure quality. Inspection and test plans shall include receipt inspection, storage inspection, dimension inspections, visual inspection, cleanliness inspections, tions , weld inspections , nondestructive tes ts, materials testsfit-up, inspec-electri-cal circuit other inspections and tests required by this Specification. The plans contin shall be in accordance with the following:

4.41 Plans shall be specific for structures, systems, equipment, Specification.

and components, as specified in other sections of this 4.42 Plans shall follow the sequence of construction activities, from the to the completion receipt of material, components, or equipment of work.

4.43 Plans shall itemize inspection and test points, indicating in the sequence of construction activities when the inspection or test point occurs.

4.44 Plans shall itemize characteristics to be inspected or tested at each inspection and test point.

4.45 Plans shall describe or reference accept ance criteria for each inspection and test point.

t 4.46 Plans shall designate inspection and test results to be recorded, data to be collected, and the identity an1 signature of the observing personnel. Plans shall be filled out and completed as work is performed and progresses .

s

os 8752 Quality Assurance 4-7 4.47 Plans shall indicate inspection hold points for Company's witnessing and review of the inspection or test, as required by

,, other sections of this Specification. Work shall not proceed beyond g these points without Company approval.

4.48 Plans shall list the records, forms , or documentation used and collected at each point. Sample forms shall accompany the plans. In approving the plan, Company will designate the specific fo rms to be retained by Cont ractor and those to be submitted to 3, Company.

ad 4.49 Plan changes shall be approved by Company.

4.410 Upon Company acceptance of structures, equipment, a systems, or components, nineteen copies of the completed inspection and test plan shall be forwarded to Constructor. The original shall be retained by Contractor in accordance with Paragraph 4.311 of this

. Section.

'=

11 5.0 COMPANY INSPECTION AND AUDITS 5.1 Company will perform a continuing audit of Contractor's quality assurance program. This is in addition to the audits performed by Contractor.

5.2 Company will reject material and/or stop work which in its opinion is below specified quality levels or not in accordance with Con-tractor's quality assurance program as approved. Work shall not be resumed until acceptable corrective measures are adopted by Contractor.

Contractor will be notified by written directive describing the work in question and reason for its suspension.

5.3 Company will perform of f-site shop inspection on Contractor and his subcontractors and suppliers. Subcontracts and purchase orders shall include the following statement:

"All work on this cont ract/ order is subject to inspection

, and test by PG6E at all times (including the period of perform-

  • ance) and places; and as a minimum final inspections and tests will be observed prior to shipment. The PG&E representative who normally services your plant shall be notified forty-eight

' (48) hours in advance of the time material or work is ready for inspection or test."

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1 PACIFIC CAS AND ELECTRIC COMPANY l SAN FRANCISCO, CALIFORNIA Department of Engineering 20 ACCOUNTING DATA SPECIFICATION NO. 8828

'e CM 167027 & 169972 Rev. No. 4 Loc. Div. 18 Project File No. 131.10 Account 61 Plant Strutture Activity Item 30 Safety Related: No Location and/or Item 40 SPECIFICATION FOR ARCHITECTURAL FINISH k'ORK UNITS 1 AND 2 DIABLO CANYON SITE l

APPROVED BY 4 CONTRACTOR GIGN HERE TO INDICATE TIIAT THIS REVISION IS ACCEPTABLE J. J. McCann/

f )[h 6/(_. -

(NL APP) (EDC)

F1cm R. V.

g/ Q Be ttinger/IR

\cpmf;-jf}'_()'

3/ rig /GPB)

By

'3l>n(

D. V. Kel y b Date g/

C. V. Richard /CER Q 4'

ACCEPTED BY JBf/M B. Hoch J.

DATE June 1, 1978 BAIN Attachment 4 Sff/

g.lQ b

8828 Ravision 4 Page 1 SPECIFICATION FOR FIELD CONTRACTOR'S QUALITY ASSURANCE PROGRAM (FOR SPECIFICATION 8828) w ,

1 GENERAL 1.1 This Specification establishes the requirements for Contractor's Quality Assurance Program to assure quality during the procurement and installation of components or equipment and the performance of work for those components identified in the attached Supplement, which ar'e to be constructed after the issuance of this Specification change.

)*1.2 Contractor's Quality Assurance Program shall apply to all activities affecting the quality of material supplied and work performed including:

Purchasing, Receiving, Handling, Constructing, Erecting, Maintaining Storing, Documenting, Inspecting and Testing.

1.3 Contractor shall also assure compliance with all quality requirements contained in the contract that are not described in this Specification.

1.4 This Specification shall be used in conjunction with the specified codes or standards (N.F.P. A. , U.L. , A.S.T.M. , A.W.S. , etc. ) in order that activities not included in the codes or standards will be provided for.

2 DOCUMENTS FOR SUBMISSION 2.1 Contractor shall submit, to Company for approval, information which fully describes the Quality Assurance Program demonstrating that work will be performed under a controlled program conforming to the requirements of Paragraph 3 below.

2.2 Eight (8) controlles copies of final, approved Quality Assurance Programs shall be submitt i to the Company by Contractor for approval, l

QUALITY ASSURANCE PROGRAM 3.1 Contractor's Quality Assurance Program shall describe in detail the procedures and methods used by Contractor to assure that all supplies 4 purchased and work performed satisfy all untract requirements. The Program shall describe the methods of implementation of the following requirements:

8828 Revision 4 Page 2

3.1.1 Organization

The Contractor shall assign and identify personnel who will be responsible for implementing the Quality Assurance Program and such assigned personnel shall have direct access to such levels of management as necessary to achieve

  • ef fective implementation of the Contractor's QA program.

3.1.2 Procurement Document Control: Contractor shall assure that applicable requirements and specifications necessary to assure adequate quality are included or referenced in C,ontractor's, pro-curement documents. Changes shall be subject to the same degree of control utilized in the prcparation of original procurement s

documents.

3.1.3 Instructions, Procedures, and Drawings: Contractor shall assure that all activities af fecting quality are prescribed by documented instructions, procedures, or drawings. Such instructions, procedures, or drawings shall include quantitative or qualitative criteria for determining that activities affecting quality have been accomplished satisfactorily. Quantitative criteria, such as dimensions, tolerances, and test limits, and qualitative criteria, such as comparative workmanship samples, shall be specified, when appropriate, for determining acceptable work performance and quality compliance.

3.1.4 Procurement Control: Contractor shall perform receipt inspection on all material and equipment delivered into his custody to assure conformance to the procurement requirements. Company-furnished materials and equipment need only be inspected for completeness and damage during handling if Company specifically identifies and exempts the equipment in writing.

Contractor shall assure that documentary evidence that items conform to the procurement requirements is available to the Company prior to the installation or use of such items. Documentary evidence shall I be sufficient to identify the specific procurement requirements that have been met. Where not precluded by other procurement requirements, written certifications of conformance which identify the procurement requirements that have been met may be used as documentary evidence, providing means are available to verify the validity of such certifications.

3.1.5 Document Control: Measures shall be established and documented to assure that all quality-related documents are reviewed for adequacy, approved for release by authorized personnel, and properly distributed.

Changes to documents shall receive the same degree of review and I approval as the original documents.

Written procedures governing document control shall provide for the identification of individuals or organizations responsible for pre-paring, reviewing, approving, and issuing documents and changes thereto. These procedures shall preclude the possibility of use of superseded, obsolete, or void documents.

8828 Revision 4 Page 3 3.1.6 Identification and Control of Material and Equipment:

Contractor shall establish and document measures to identify and control material and equipment. These measures shall prevent the use of incorrect or defective material.

Traceability when required by Specification for material and equip-

ment shall be maintained with records and markings. When identi-fication marking is used, the marking shall be clear, unambiguous, and indelible, and the method of marking shall not af fect the function of the material or equipment.
  • 3.1.7 Control of Measuring and Test -Equipment: Contractor shall assure that all tools, gages, inst rument e, and other measuring and test equipment used in activities affecting quality are of the proper range, type, and accuracy to verify conformance to established requi rement s.
  • 3.1.8 Inspection: Contractor shall assure that activities affect-ing quality are inspected for conformance to the documented instruc-tions, procedures, and drawings used in the accomplishment of the activity.

Written procedures shall require that inspections are performed according to written instructions or checklists which are based on the ins truct ions , procedures , and drawings used in accomplishment of the activity being inspected. Inspection procedures shall also require the documentation of the qualitative or quantitative results of the specific parameters being inspected.

  • 3.1.9 Test Control: Contractor shall assure that a test program will be established which identifies and documents all testing required to demonstrate that an item will perform satisfactorily in service. Written procedures shall require that all testing be performed in accordance with written test procedures which incor-porate all requirements and test limits specified in the design docume nt s. Test procedures shall assure that prerequisites, such as calibrated instrumentation, appropriate equipment and environ-mental conditions, and trained personnel, are met. Test require-ments, results, and acceptance criteria shall be documented and evaluated by authorized personnel to assure that all requirements have been satisfied.
  • 3.1.10 Inspection Plan or Procedures: Contractor shall perform required inspections in accordance with a written inspection plan or e procedure. The Contractor shall assure that all inspections required by the attached Supplement are identified in the inspection plan or procedure. The plan or procedure shall be developed in

, accordance with the following:

The plan or procedures shall identify the characteristics to be inspected.

8828 Revision 4 Page 4 The plan or procedures shall describe the inspection instructions or procedures to be used.

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The plan shall list the records, forms, or other documentation used.

  • The plan or procedure shall indicate all inspection hold points for Company witnessing and review of the inspection or test, as required by the attached Supplement. The plan shall provide for adequate advance notice to Company's inspector. Work shall not proceed beyond inspection hold points until such points have been witnessed or inspected by the Inspector. Records shall be kept of all tests and inspections including nonconformances observed and the identity and signature of the inspection and test personnel.
  • 3.1.11 Inspection and Operating Status: Contractor shall establish and document measures to identify inspection status of items and work.

Such measures shall provide means for assuring that required inspec-tions are performed and that the acceptability of items or work with regard to inspections is known at all times. Written procedisres shall provide for the status of inspections through the use of indicators such as tags, markings, stamps, or records. The procedures shall assure that only items, or portions of work, that have passed required inspections are accepted and that nonconforming items are clearly identified.

  • 3.1.12 Nonconforming Material Control: Contractor shall assure that material, equipment, services, or activities which do not conform to requirements are identified, documented, segregated, evaluated, and accepted, rejected, reworked, or repaired in accordance with documented procedures. If Company-furnished material is found to be nonconforming, Contractor shall notify Constructor.

Written procedures controlling nonconformances shall define the responsibility and authority for the disposition of nonconformances. I Such procedures shall provide for the reinspection of all repairs or rework in accordance with applicable procedures.

If Contractor proposes to use any special procedures or materials for repair or rework, a written description of Contractor's proposal shall be submitted for Constructor's approval. When Contractor elects to accept a nonconformance as is records shall document the basis for acceptability. When Contractor elects to scrap a nonconformance, adequate records shall be maintained to verify that the nonconformance has not been used.

3 3.1.13 Handling, Storage, and Shipping: Contractor shall establish and document measures to control handling, storage, and shipping, including cleaning, packaging, and preservation of material and equipment in accordance with instructions, procedures, or drawings, to prevent damage, deterioration, and loss.

8828  !

Revision 4 I Page 5 9 *3.1.14 Corrective Action: Contractor shall assure that all condi-tions which are adverse to quality, such as failures, malfunctions, deficiencies, deviations. defective material, and nonconformances are promptly identified ci corrected as soon as practical. Correc-

  • tive action shall be sui < sciently comprehensive to intercept and correct all items af fectt i by the adverse conditions. In the case of significant conditions adverse to quality, written procedures shall require that the cause of the conditions be determined and appropriate corrective action taken to minimize the possibility of repetition.
  • Contractor shall maintain records on all conditions which adversely

} affect quality. These records shall identify each condition, the cause of the condition, and the corrective action taken, and shall be forwarded to both Constructor and Contractor management levels for review.

  • 3.1.15 Records: Contractor shall use, collect, and maintain records and documents suf ficient to furnish documentary evidence of the quality of material supplied and work performed. Written procedures shall identify all records which are to be retained, and shall prescribe the retention period, storage location, and assignment of responsibility. Records collected shall include, as a minimum, the following: drawings, specifications, purchase orders, work orders, material certifications, work procedures, personnel and equipment qualification records, nonconformance reports, corrective action records. Work performance records shall indicate acceptability of the work and/or material or necessary corrective action in cases of nonConformances.

Requirements and responsibilities for record transmittal, retention, and maintenance subsequent to completion of work shall be established and documented consistent with procurement documents.

In general, records which identify the as-built condition of materials or equipment shall be maintained for a minimum of ten years. At the end of the ten-year period, Contractor shall request disposition l

' instructions from the Company for all documents which Company has not requested custody of. These records shall be indexed, filed, and i

' maintained in facilities that provide suitable environment to minimize deterioration or damage and to prevent loss. Until such time as they may be transferred to Company, all records shall be available for

) , inspection and review by Company and regulatory agencies.

3.1.16 Audits: Contractor shall establish a system of audits to I assure compliance with all aspects of the quality assurance program and to determine its effectiveness. Personnel performing audits shall not have direct responsibilities in the areas being audited.

Follow-up action, including reaudit, shall be taken when necessary.

Audit results shall be documented and forwarded to Contractor's management for review.

8828 Revision 4 Page 6 Written procedures which govern the audit program shall assign responsibilities for the audit program; establish the frequency of audits, prescribe the minimum qualifications for auditors and their independence from the area being audited; and prescribe the format

, for documenting audit results. The procedure shall prescribe the

  • mechanism for submitting audit results to appropriate levels of management and also the criteria for determining when follow-up action is required.

4 COMPANY INSPECTION AND AUDITS 4.1 The Company will perform periodic audits as well as continuous inspection of Contractor's activities throughout all work performed.

a4.2 The Company will reject material and/or stop work which, in its opinion, is not in accordance with the quality assurance requirements herein. Work shall not be resumed until corrective measures, which are approved by the Company, have been adopted by Contractor.

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