ML19329E282
| ML19329E282 | |
| Person / Time | |
|---|---|
| Site: | Midland |
| Issue date: | 12/31/1969 |
| From: | CONSUMERS ENERGY CO. (FORMERLY CONSUMERS POWER CO.) |
| To: | |
| References | |
| NUDOCS 8006120582 | |
| Download: ML19329E282 (36) | |
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oO '. i CONSUMEFS POWER COMPANY Midland Plant QA Program Plsh f INTRODUCTION The organization, administration and assignment of responsibility for Consumera Power Company's (CP Co) Quality Assurance Program is described in Appendix 1B of the Midland Plant PSAR. How this program will be implemented is stated be-lov and is referred to as CP Co's Midland Plant Quality Assurance Program Plan (QA Plan). Revisions to this plan are subject to review and approval by CP Co Management. The cbjectives, definitions and organization of CP Co's Quality Assurance Pro-gram are identified below: OBJECTIVES As part of the overall CP Co Quality Assurance Program, the Midland nuclear plant Quality Assurance objective is to yield maximum confidence that the plant is designed and constructed so that it can and will be operated without undue risk to the health and safety of the general public and plant operating personnel. Of equal importance as an objective of our Midland Quality Assurance procedure is the efficient and reliable perfor=ance of the plant. Close scrutiny of tL de-sign and procurement phases of a plant can, at times, identify problem areas before they interfere with the schedule, thus assisting in a timely plant avail-ability. The Quality Assurance Program vill start with the design phase and proceed throughout the construction and operating phases of the plant life. DEFINITIONS QUALITY CONTROL Quality Control is the detailed and systematic inspection, testing, and docu-mentation program to insure that the material, process, component, system, or facility is in accordance with predetemined quality requirements. Quality Control is further used to determine that the systems and components are built according to design. It is the first line of control and, as such, is the re-sponsibility of the organization perfoming the actual work, such as: the Engineer-Architect in the design; the Vendor in shop construction; the Con-structor in the installation and erection; and the Owner during operation. QUALITY ASSURANCE Quality Assurance is an independent audit to establish the effectiveness of the Quality Control programs throughout the design, construction and operating phases of plant life. Quality Assurance is the responsibility of vendors, sub-vendors, contractors and subcontractors, with the overall or finsi responsi-bility by the Owner. 1
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- ORGANIZATION All phases of design and constructicn prior to initial fuel loading are the responsibility of the Senior Vice President in charge of Generating Plant Engineering and Generating Plant Construction. Reporting to this Senior Vice President is a Manager of Generating Plant Engineering who has responsibility of the design, procurement, manufacturing and shipping phases of the Pru'?at.
The Manager assigns a me=ber of his technical staff to be Project Engineer for this particular project. The directicn and ccordination of the QA program from design through construc-tion is the responsibility of a Quality Assurance Engineer who reports to the Manager of Generating Plant Engineering. The Manager of Generating Plant Construction is responsible for plant con-struction and preoperational testing. Reporting to him is a Field Superin-tendent who is responsible for the overall construction of the plant. Bechtel vill be the Plant Constructor and will have responsibility for field QC. CP Co's Field QA Engineer, under the functional direction of the Generating Plant Department's QA Engineer, will perforu proper surveillance of Bechtel's QC-QA program to determine the program's effectiveness. The Field Quality Assurance Engineer will have the help of other engineers of the Engineering, Construction, and Operating Departments who are specialists in their fields. e 2
l [ f l l l CONSUMERS POWER CO. ORGANIZATION -DESIGN THROUGH CONSTRUCTION l l SENIOR VICE PRES l E N G. & CO N ST. I I I MANAGER MANAGER GEN. PLANT ENG'. GEN. PL ANT CONST. I I I I I I . I W MECH. CIVIL NUCLEAR PROJECT QA FIELD i ENG. ENG. ENG. ENG. ENG. SUPT I I I t___,____q l FIELD QA FIELD ENG. E N G*S.
- - - - DENOTES FUNCTIONAL RESPONSIBILITY
. SCOPE The CP Co's Quality Assurance Program encompasses all phases of the project including the design, procurement, shipping construction, preoperational testing, fuel leading, operation, refueling and maintenance. Overall re-sponsibility for the Quality Assurance Program rests with CP Co. The de-velopment, implementation, coordination and documentatien of the CA Program from design through construction are the responsibility of the CP Co QAE.
The responsibility for design, procurement of equipment other than the NSS and turbine generators and construction of the plant has been assigned to the Bechtel Corporation. Bechtel will perform the QA and QC for plant engineering, shop fabrication (including NSS, except for fuel), field fabrication and construction. Bechtel's program for fulfilling their Quality Assurance activities is described in the attached docu=ent, "Bechtel Corporation - Power and Indus-trial Division - Quality Assurance Plan for Midland - Units 1 and 2." Purther detail procedures and Bechtel policies are described in Bechtel's
" Nuclear Quality Assurance Manual - Power and Industrial Division."
Bechtel's program is implemented by the Bechtel Quality Assurance Engineer as described in these documents. The Babcock and Wilcox Ccmpany has a Quality Assurance Program fur the nuclear steam system. The scope of the B&W Progra= includes the design, ' i fabrication, shiIr.ent and shop testing of the components they furnisu. The program is administered by a separate Quality Assurance organization and its e implementation is described in Appendix 1B of the PSAR. I=plementation of CP Co's QA Program is described below. The first four sec-tions of the QA Plan cover design, procure =ent, construction and preoperational testing of items designated on the Q-List. A cajor subdivision's Q-List is included in the attached Bechtel QA Plan and is representative of those struc-tures, systems and components which will be subjected to the QA Program. Engineering and Quality Assurance functions are described under each project phase. Table 1 summarizes responsibilities for engineering, Quality Control and I Quality Assurance during the design, procurement, construction and preopera- l tional phases of the Midland project. Overall responsibility for the Quality ) Assurance Program rests with CP Co. l l l 1 l l l l 1 1 l l 1
Sheet 1 of 6 Table 1 Midland Plant Functional Responsibilities (Refer to last sheet for definitions and footnotes.) A
~ ~
B C D E F G Design Engg Desidi Engg - - Functional & Structure or Inter- Construc- Preoperational Structure,. System or Equip Criteria System Iayout face Procurement tion Tests Component Orig QC QA Orig QC QA Review Orig QC QC Orig QA QA QC QA Prestressed & Rein-forced Concrete. B B B B B B B V V, B B B CP CP CP CP i Liner Plate B B B B B B B V V, B B B i CP CP CP CP ; $ 4 Fuel Racks B B B B B .B B V V, B B- B m CP CP CP CP J Structural Steel B B B B B B B V V, B B B (V)2 (y)2 CP CP CP CP Emergency Reservoir B B B B B B B V V, B B B ] & Pipeline CP CP CP CP Ventilation Chimney B B B B B B B V V, B B B (V)2 (V)2 CP CP CP CP Reactor Coolant & B&W B&W B&W B&W B&W B&W B B&W V (V-B&W)3 B B CP CP CP h Pressure Control (B)1 B B CP (B-B&W) l
; g System - B&W Items CP CP CP ! ro Nu Reactor Coolant & B B B B B B B B V V, B B B CP CP CP 1 Ef Pressure control (B&W)6 CP (B&W)N CP CP CP (B-B&W) o 03 System - B Items 1
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Sheet 2 of 6 Table 1 (Contd) . A B C D E F G DesidiEngg Design Engg Functional & Structure or Inter- Construc- Preoperr.tional Structure, System or Equip Criterfa System Inyout face Procurement tion Tests Component Orig QC QA Orig QC QA Review Ori g QC QA QC QA Orig QC QA
*bhkeup & Purifica- B&W B&W BLW B B B B B&W V (V-P&W)3 e a cp cp cp tion System - (B)1 (MW)5 3&w 3 cp (3 35w)k B&W Items CP CP CP
*thkeup & Purifica- B B B B B B B B V V, B B B CP CP CP tion System - CP CP CP CP (B-B&W)b B Items Decay Heat Removal B&W B&W B&W B B B B B&W V (V-B&W)3 B B CP CP CP System - B&W Items (B)1 (B&W)5 B%W B CP (B-B&W) y CP CP CP Decay Heat Removal B B B B B B B B V V, B B B CP CP CP System - B Items CP CP CP CP (B-B&W)b Core Flooding Sys- B&W B&W B&W B B B B B&W V (V-B&W)3 B B CP CP CP tem - B&W Items (B)1 (MW)5 B&W B CP (B-B&W)b CP CP CP Core Flooding Sys- B B B B B B B B V V, B B B CP CP CP tem - B Items CP CP CP CP (B-B&W)h g Reactor Building B B B B B B B V V, B B B CP CP CP g Spray System CP CP CP CP (B)b p
- Component Cooling B B B B B B B V V, B B B CP CP CP g N System CP CP CP CP (B)4 N :a R
- Caseous Radvaste B B B B B B B V V, B B B CP CP CP dco System CP CP CP CP (B)b
Sheet 3 or 6 Table 1 (Contd) A B C E F G
~ ~ -D ~ ~ -
Design Engg Desigii Engg Functional & Structure or Inter- Construc- Preoperational Structure, System or Equip Criteria System Tayout face Procurement tion Tests Component Orig E QA Orig E E Eeview gg QA QC QA Orig gg Containment Isola- B B B B B B B V V, B B B CP CP CP tion System CP CP CP CP (B)b Main Steam System B&W B&W B&W B B B B B&W V (V-B&W)3 3 3 cp cp cp (Thru First Isola- (B)1 (MW)3 B&W B CP (B-B&W) tion Valve) - CP CP CP B&W Items thin Steam System B B B B B B B B V V, B B B CP CP CP (Thru First Isola- CP CP CP CP (B-B&W)b w tion Valve) - B Items s Feed-Water System B&W B&W B&W B B B B B&W V (B-B&W)3 B B CP CP CP (Thru First Isola- (B)1 (B&W)5 B&W B CP (B-B&W) tion Valve) - CP CP CP B&W Items Feed-Water System B B B B B B B B V V, B B B CP CP CP (Thru First Isola- CP CP CP CP (B-B&W)g tion Valve) - B Items
- Service Water B B B B B B B V V, B B B CP CP CP System CP CP h
G CP CP (B) S *Firefighting System B B B B B B B V V, B B B CP CP CP CP CP CP h.: N CP (B) dcn Diesel Oil System B B B B B B B V V, B B B CP CP CP CP CP CP CP (B)b
-. . - . . --. . . - . - . _ . . . . - - - . - . _ - - . . . . - . - . . .~ . - . . - - . ~ . - . - . . .- . _ ~ . . . - . . - --.
4
' SheetI t of 6
- Table 1 (Con *,d)
A B C -D - E -F. G Design Engg Desis Engg Functional & Structure or Inter- Construc- Preoperational Structure, System or Equip Criteria System Tayout face Procurement tion Tests
' Component Orig _ E QA Orig E QA Review Og QC QA QC QA Orig QC g ,
i
'* Reactor Building B B B B B B B V V, B B B CP CP CP
-Ventilation System CP CP CP (V)2-(y)2 (B)g CP i
t
- Auxiliary Building B B B B B B B V V, B B B CP CP CP Ventilation System _ CP CP CP (V)2 (V)2 (B)g ,
CP
- Radiation Monitoring B B B B B B B V V, B B B CP CP CP
- System CP CP CP CP (B)g Emergency Diesel B B B B B B B V V, B B B CP CP CP i Generators CP CP CP CP (B)b 'i
- Reactor Building B B B B B B B V V, B B B i Crane CP CP CP CP
- Auxiliary Building B B B B B B B V V, B B B i Crane CP CP CP CP
$
- Fuel Handling Equip- B&W B&W B&W B B B E B&W V (V-B&W)3 B B CP CP CP ment - B&W Items (B)1 (B&W)E B&W B CP (B-B&W)g i > CP CP CP i f$
, h*FuelHandlingEquip- B B B B B B B B V V, B B B CP CP CP a ment - B Items CP CP CP CP (B)b , i f+ i Em Switchgear Engi- B B B B B B B V V, B B B R neering Safeguards CP CP CP CP j dcn
- Station Pwr Tranaf B B B B B B B V V, B B B
- Engg Safeguards CP CP CP CP i
. l 1
- . , ~ . .-- - - - . . - , , . - - - -- .-, . . . _ - - - . . _ - . - _ . - - -
/
Sheet 5 of 6 Table 1 (Contd) A B C D F G
- ~ - -E - ~
Design Engg Desidi Engg Functional & Structure or Inter- Construc- Preoperational Structure, System or Equip Criteria System Tayout face Procurement tion Tests Component Ori g QC QA Orig QC QA Review Orig QC QA QC QA Orig gg Load Centers Engg B B B B B B B V V, B B B CP CP CP Safeguards CP CP CP CP (B-B&W)b Motor Control Center B B B B B B B V V, B B B CP CP CP Engg Safeguards CP CP CP CP (B-B&W) Switchboard & Elec- B B B B B B B B V V, B B B CP CP CP trical Panels CP CP CP CP (B)b Raceways Associated B B B B B B B V V, B B B w With Engineering CP CP CP CP A Safeguards Cable Associated B B B B B B B V V, B B B - With Engineering CP CP CP CP Safeguards Instrument Cable B B B B B B B V V, B B B (Assoc With CP CP CP CP Engg Safeguards) 600 V Control Cable B B B B B B B V V, B B B
> Switchboard Wire CP CP CP CP S (Assoc With Engg Safeguards) h a
?+ 125 V Station ' B B B B B B B V V, B B B CP CP CP h Batteries CP CP CP CP ( B-B&W) o> Battery Chargers B B B B B B B V V, B B B CP CP CP CP CP CP CP ( B-B&W)b L _ _. _
1, Sheet 6 of 6 Table 1 (Contd) A B C D F G
- - - -E -
< Design Engg Design Engg Functional & Structure or Inter- Construc- Preoperational Structure, System or Equip Criteria System Tayout face Procurement tion Tests Component' Orig QC QA Orig QC QA heview Og g QA QC QA Orig g QA A-c Inverters B B B B B B B V V, B B B CP CP CP CP CP CP CP (B-B&W)g , D-c Buses B B B B B B B V V, B B B
. CP CP CP CP 1
125 V D-c Distribu- B B B B- B B B V V, B B B CP CP CP , tion Panels- CP CP CP CP (B-B&W)b
; Containment Elec- B B B B B B B V V, B B B si e
trical Equipment C CP CP CP 4 N ' . a ! I - i fu a O 4 Na O 0) . 1 1
1 MIDIAND PIMP FUNCTIONAL RESPONSIBILITIES, DEFINITIONS AND FOOTNOTES DEFINITIONS ORIG = Originator QC = Quality Control QA = Quality Assurance B = Bechtel Corporation B&W = Babcock & Wilcox Co CP = Consumers Power Company V = Vendor Column A - Structure, System or Component Includes those structures, syste=s and components on the "Q" list as defined in Amendment No. 6. Where noted by an asterisk, only that portion falling under Class I Seismic Criteria is included. Column B - Design Engineering - Functional and Equiement Criteria Includes those criteria and requirements which form the basis for the detailed plant design, fabrication and construction. Design criteria may be defined in studies, reports, letters, memoranda or in the SAR. Column C - Design Engineering - Structure or System Layout Includes design drawings such as P&ID diagrams and general equipment or structural layouts. Column D - Interface Reviews Bechtel is responsible for conducting interface coordination and is necessary for the sstisfactory and orderly completion of the project. Column E - Procurement The manufacture or assembly and shipment of structures; sys-tems or components. Column F - Construction The constinction and/or erection of components, structures or systems at the plant site. 5f Amendment No. 8 2/9/70
MIDIAND PLANT FUNCTIONAL RFSPONSIBILITIES. DEFINITIONS AND FOOTNOTES (Contd) EEFINITIONS (Contd) Column G - Preoperational Tests Those tests conducted after construction and prior to fuel loading to assure integrity of the stracture, system or component. FOOTNOTES I General - The above table represents the broad scope of functional responsibilities and there may be exceptions in detail that may require revisions as the project progresses.
* - Only that portion of system falling under Class I Seismic Criteria.
1 - (B) denotes CP Co may request Bechtel's assistance in performing surveillance of B&W. 2 - (V) denotes vendor or subcontractor. 3 - (V-B&W)3 denotes vendor or B&W. k - (B-B&W) or (B) denotes with assistance from Bechtel and B&W or Bechtel. 5 - (B&W)5 denotes B&W furnishes to Bechtel equipment draw-ings required for system. 6 - (B&W)6 denotes B&W furnishes to Bechtel infor=ation such as support requirements. DESIGN PHASE EESIGN - CP CO - GENERAL The applicant, CP Co, is responsible for the overall preparation, editing and presentation of the SAR and, as such, is directly responsible for design cri-teria reflected by the SAR. Bechtel and B&W assist in preparing draft caterial for their responsible areas. CP Co's mechanical, electrical, civil and nuclear engineers and specialists will review design criteria, specifications and plant general arrange =ent, P&ID, single line and schematic drawinga prepared by Bechtel or B&W. Distribution of documents for review vill be according to established procedures which vill furnish the QAE with assurance of review by appropriate engineers. The QAE vill review documents for QO and/or QA requirements. 5g Amendment No. 8 2/9/70
DESIGN - Q-LIST The Q-List consists of ci'cical structures, systems and components which re-quire additional design control measures. This list is updated from time to time and is reviewed and approved by CP Co engineering personnel and QAE in the same manner as other documents. DESIGN . BECHTEL Bechtel is responsible for the development of plant design criteria necessary for the preparation of component, system and structural specifications and drawings required to construct the Midland Plant. Bechtel is responsible for preparing specificstions and drawings for components they are purchasing and all structures. They are responsible for resolving interface engineering problems with B&W or other vendors. Bechtel-prepared purchase specifications shall provide technical infor=ation required for defining caterial selection, handling and identification, size, operating characteristics, functional requirements, code, inspection and docu-mentation requirements. Drawings shall provide infor=ation necessary for the construction, placement er assembly of structures, syste=s and components. Bechtel shall provide Quality Control and Quality Assurance of their engineering during the Design Phase and shall provide CP Co QAE with documentation verifying compliance with codes, SAR, and other governing regulations. DESIGN - B&W B&W is responsible for the design and engineering of the NSS equiment they are furnishing. B&W shall prepare specifications, drawings and other criteria necessary for the manufacture and operation of their equigent. B&W purchase specifications shall provide technical information required for defining ca-terial selection, handling and identification, size, operating characteristics, functional requirements, code, inspection and documentation require = ente. B&W shall provide Quality Qatrol and Quality Assurance of their engineering during the Design Phase of this project and will provide CP Co with sufficient documentation to assure compliance with applicable codes and procurement documents. DESIGN - CHANGES Design changes may be accomplished through addenda to specifications or re-visions to drawings and will require review equivalent to that provided for the original design. Design changec which represent significant deviations from plant features involving reviewing nuclear safety aspeets presented in the SAR must be approved by CP Co Senior Vice President in charge of Generating Plant Engineering and Generating Plant Construction or his designated representative. 6
9 DESIGN - CP CO QAE ! The CP Co QAE will perform audits or reviews to assure that specifications, design criteria and drawings have been prepared, reviewed and approved by qualified Bechtel or MW personnel. The CP Co QAE will assure that specifi-cations, desi n 6 criteria and drawings have been reviewad by appropriate CP Co engineers and/or specialists and will review same for QA and QC requirements. The CP Co QAE will maintain a separate file of the SAR, general project speci-fications and design criteria but may use the project detailed specifications, purchase orders and drawing files for reference. Docu=entation for reviews by i C8 Co personnel will be maintained by the CP Co QAE. The CP Co QAE will randomly audit Q-List component records at B&W and Bechtel to insure independent engineering review of calculations and analysis of critical design data. DESIGN - CP CO QA FILE DOCUMENTS Documents to be retained in the CP Co QA file or are otherwise available after the Design Phase include: A. Final specifications. B. Verification that Q-List component specifications have been prepared, reviewed and approved by competent personnel. C. Verification that the design of Q-List structures systems and components is in conformance with applicable codes, SAR and procurement documents. D. Verification that Q-List component specifications have had CP Co reviews. E. A copy of the SAR with amendments. F. A copy of the B&W and Bechtel QA Program Plans. G. CP Co audit reports. H. Final drawings. 1 I. Verification that the Q-List has been reviewed by CP Co engineering personnel. J. Procedures used by CP Co for distribution and approval of design documents. PROCURDETP PHASE PROCURDEC - GENERAL Components for the NSS are either manufactured by B&W or are purchased 'by them. All other Q-List components will be purchased by Bechtel. PROCURDIENT - B&W B&W may confer with CP Co regarding their purchase of NSS components but B&W retains the prerogative to select vendors. 7
PROCURD4ENT - BECHTEL HOME OFFICE Bechtel purchases are subject to review and approval by CP Co. Vendors of Q-List items are required to provide a description of their QC/QA programs. Established procedures will be fonowed to distribute bid evalations and purchase recommendations for review by management and engneers. PROCURD4ENT - BECHTEL CONSTRUCTION The scope of procurement made by Bechtel Construction from the jobsite is jointly established by the Project Engineering and Construction groups and subject to Consumers approval. Critical phases of field procurement activities that may affect job quality are identified and are reviewed by engineering. Procurement of materials by Bechtel Construction at the plant site will be allowed only after approval by Bechtel Engineering. PROCURD4ENT - INSPECTION (BECHTEL PURCHASES) Bechtel will make inspection assignments using qualified inspectors. These inspectors will perfom shop inspections in accordance with Bechtel's Shop
' Inspection Manual. They will audit vendors' records and obtain all necessary documentation as prescribed in the governing specification and codes. Hold points or witness points muy be established in the vendors' QC plan. When this is done, the inspector shall confirm that he has witnessed the designated operations or tests.
When equipment is ready to ship, the inspector shall prepare a " Certified Shcr !aspection Report" which shall list documerits required and all documents forwarded with earlier reports or his filal report and which shall attest that requirements of the specification and other governing codes have been met. A copy of Bechtel Inspection Reports shall be sent directly to CP Co QAE. Additional copies of inspection reports will be transmitted to CP Co's Project Engineer for distribution and review by project personnel. The Bechtel shop inspectors will contact CP Co QAE or designated alternates whenever specified hold or witness points are pending or a significant QA problem occurs and nomal procedural channels would require excessive time. PROCURD4ENT - INSPECTION (B&W NSS) B&W Quality Assurance personnel vill inspect equipnent during manufacture and audit records to detemine ecmpliance with procure =ent documents. Bechtel inspection of B&W-supplied components.will be conducted as described below. Bechtel vill make inspection assignments using Wii led inspectors. Tnese inspectors will perfom shop inspections in 9 c h a with Bechtel's Shop Inspection Manual. They will audit approp- Je
- N . = cturer's records and obtain all necessary documentation as p:. .scris : .'n the governing 8
specification and codes. Witness points may be established by B&W in the manu-facturer's QC plan. If these points are witnessed, the inspector shall confirm . that he has witnessed the designated operations or tests. A copy of Bechtel Inspection Reports shall be sent directly to CP Co QAE and B&W Project Manager. Additional copies of inspection reports will be transmitted to CP Co's Project Engineer for distribution and review by project personnel. The Bechtel shop inspectors will be instructed to contact CP Co's QAE or desig-nated alternates whenever specified witness points are pending or whenever a significant QA problem occurs. PROCUREMENT - CP CO QAE The procurement phase of this project will involve active participation of CP Co personnel into inspections, auditing and witnessing tests at manufacturer's
-shops. The services of mechanical, electrical, civil and nuclear engineers, as well as specialists, such as velders, radiographers, chemists and metallur-gists, may be used in making these shop inspections and audits.
Inspections are not scheduled but the following guides will be used:
- 1. Any component will be subject for inspection.
- 2. The decision to inspect or audit a manufacturer vill be influenced by past perfor=ance, the component and inspection reports.
3 Each Bechtel inspector assigned to the Midland project will be subject to review.
- h. Requests to inspect or audit may be made by Engineering, Canstruction or Operations.
5 Industry reports regarding components, manufacturers or procedures where
*"ch affect our QA program vill be given appropriate review and action.
Inspection or audit of manufacturers will be performed by CP Co QAE or others. Prior to visiting a vendor, the QAE inspector or auditor will review the QA file and establish any special inspection or audit requirements to supplement regular procedures . Reports will be prepared subsequent to an inspection or audit for distribution in accordance with prc slures for reviews by such CP Co personnel as the Senior Vice President in charge of Generating Plant Design and Generating Plant Con-
~s truction, the Manager of Generating Plant Engineering, the Manager of Generating Plant Construction, the Project Engineer, the Operations Superintendent -
Nuclear, the Plant Superintendent and the CP Co Field QAE. The comments re-sulting from these reviews will be forwarded to the CP Co QAE for appropriate action. 9
PROCURDIENT - CP CO QA FILE DOCUMENTS The QA file will contain or otherwise have available the following procurement documents at the conclusion of the QA program:
- 1. Verification by a responsible Bechtel engineer that a structure, system or component has been designed and procured in accordance with governing documents.
- 2. Bechtel inspection reports.
3 CP Co inspection and audit reports. 14 . Purchase orders (technical infor=ation cnly). 5 Exc'ept for radiographs, documentation as defined in B&W and Bechtel specifications such as:
- a. Material certifications, physical and chemical reports.
- b. Nondestructive testing certifications.
- c. !bjor repair details and approvals for such repairs.
- d. Variance reports.
CONSTRUCTION . CONSTRUCTION - GENERAL Construction QC and QA responsibilities rest with Bechtel but CP Co will actively participate in field Quality Assurance. Bechtel engineering will have a field representative, ie, their QAE. CP Co personnel at the site will include a Con-struction Field Superintendent with Field Engineers and a Field QA Engineer. CONSTRUCTION - BECHTEL QC Construction responsibility commences with the site acceptance of systems, com-ponents or materials as delivered and will terminate when the systems, component or materials are completely installed and erected, cleaned and designated ready for preoperational testing by Bechtel. Details of Bechtel's field inspection program and procedures are described in Bechtel's Field Inspection Manual. CONSTRUCTION - BECHTEL QA The Bechtel QAE is stationed.at the jobsite after field work starts. He is a field representative of t,he Project Engineering Team and is responsible for e veillance of engineering and Bechtel QC activities in the field. He has aut) ity to stop work and assure correction of any deviation in quality of constr,t, tion E.?.terials and workmanship. The Bechtel QAE shall verify that each comI system or structure has been installed or erected in accordance with govern-document s. 10
CONSTRUCTION - CP CO FIELD QAE The CP Co Field QAE functionally reports to the Generating Plant Engineering DeIsrtment's QAE. The Field QAE is responsible for:
- 1. Deterining that Bechtel's Field QC and QA Programs are properly imple-ment- and are effective.
- 2. Reporting conformance to or deviations from the Bechtel's QC or QA Programs.
3 Detemining that proper corrective actions have been applied to deviations. 4 4. Ascertaining that proper QC and QA documentation of Bechtel field con-struction is accomplished. The CP Co Field QAE will perfom his duties through persistent surveillance at the site. Specific guidelines for accomplishment of CP Co Field QA are provided in written procedures. Audits will be performed independent from the nomal surveillance, inspection, and test programs. Schedules and checklists will be utilized in assuring adequate planning for proper audit, visibility of fabrication, erectica and quality detemining tasks. Audits will be =ade at regular or irregular intervals, or by request. They will be initiated by the CP Co Field QA Engineer and may be performed by himself, CP Co constructica field engineers, specialists, inspection labs or consultants. Inspection laboratories or consultants may be called upon by the CP Co Field QAE to make detailed examinations at intervals or when a particular circumstance may make their services desirable. They will work closely with the CP Co Field QA Engineer or CP Co construction field engineers. A report documenting all as-pects of each visit will be made. The CP Co Field QAE will assure that equipment at the site is properly protected whether it is in storage or in place. CP Co field personnel are instructed to report to CP Co Field QAE unsatisfactory equi; cent protection when observed dur-ing routine surveillance of the site. , The CP Co Field QAE will have access to a file of Bechtel Shop Inspection Reports. He vill review these reports and observe potential problem areas. Problem areas noted on Bechtel field inspection reports are filed for follow-up and later check and verification that proper corrective measures have been per-formed. When discrepancies or deviations are found during audits or site surveillance, the CP Co Field QAE will inform the Bechtel QC and QA Engineers and the CP Co QAE. He vill also file the deviation or discrepancy for follow-up. At the appropriate follow-up time, the CP Co Field QAE will recheck deviations or discrepancies. If corrective action was perfomed, records are so noted and closed. If corrective action was not performed, the CP Co Field QAE will notify , the CP Co's Field Superintendent, Manager of Construction and QAE for further resolution. 11
~, The CP Co Field QAE will audit Bechtel QC forms and records. He vill witness a portion of nondestructive tests (NM) and may occasionally request additional NI7f be performed himself. He or his assistants vill review field radiographs (RT) 100 percent. He may call upon specialists to review some of the RT and audit field radiographs. The CP Co Field QAE cay call upon CP Co's General Laboratory personnel to review field radiographers' qualifications and conduct of operations.
The Field QAE will perform or supervise audits including the following: quality checks on concrete, tendons, piping, equipment, site storage, radiographic tech-niques, electrical, veld rod control and other items on the Q-List. These au-dits will be performed in accordance with written procedures. CONSTRUCTION - B&W B&W vill provide erection criteria for equipment it supplies and one or more erection consultants to assist CP Co and Bechtel in the interpretation of B&W requirements during the construction period. The B&W site representative shall advise Bechtel and CP Co of any field condi-tions or actions observed which do not meet B&W requirements. CONSTRUCTION - CP CO QAE The CP Co QAE or his representative vill on an unscheduled and announced or unannounced basis perfom surveillance inspections and audits at the site. Audits will cover both Bechtel and CP Co QA records and will be conducted in the same manner as shop audits. CONSTRUCTION - CP CO FIELD QA FILE DOCUMENTS At the conclusion of the construction phase of this project, the CP Co Field QA files vill contain or have access to the following documents:
- 1. Final approved specifications and drawings.
- 2. A copy of the SAR.
3 A copy of Bechtel's QA Manual and Bechtel's Field Inspection Manual.
- 4. Q-List.
5 Bechtel Shop Inspection Reports.
- 6. Bechtel certification attesting that systems, components or materials have been installed, cleaned, erected and are ready for preoperational testing.
7 Field audit reports.
- 8. Record of nondestructive tests.
s
PREOPERATIONAL TESTING PPIOP - GENERAL The preoperational test program is defined as the preparation of test proce-dures, the running of the tests, and the review of test results en equipment and systems after they have been inctalled in the plant. The test program assures that systems are installed as designed and that all systems will function prior to initial fuel loading. PREPARATION CF PREOPERATIONAL TESTS The responsibility for assuring that the preoperational test procedures are prepared and that they are adequate with respect to thoroughness of testing is by the CP Co Engineering Department. The procedures will be prepared by CP Co, Bechtel, and B&W with CP Co assuring that adequate review is given by the two parties to the procedures prepared by the third party. RUNNING OF PREOPERATIONAL TESTS The responsibility for running the preoperational tests vill be with the CP Co Construction Department. They will be responsible for seeing that, in addition to the Construction Dept, Bechtel, B&W, and CP Co Engineering and Operations review all test results for adequacy. PREOP - CORPICTIVE ACTION The corrective actions that are required as a result of deficiencies found during preoperational testing aball be conducted in accordance with governing procedures and shall be fully documented. OTHER PHASES OF QA PIAN As the implementation plans for the re=aining phases of the CP Co's Quality Assurance Plan are completed, they will be appended hereto. I 9 13 I
SUMMARY
OF PROCEDURFi AND RESPCNSIBILITIES INTP.0 DUCTION The organizatier., admuistration and assignment of responsibility for Consumers Power Company's (CP Co) Quality Assurance Program is described in Appendix 1B of the Midla.1d Plant PSAR. How the program vill be imple-
- mented is stated in Amendment 6 of the Midland Plant PSAR and is re-ferred to as CP Co's Midland Plant Quality Assurance Program Plan (QA
, Plan).
Table 1 of the QA Plan su=marizes responsibilities for engineering, Quality Control and Quality Assurance during the design, procureme .t, contruction and preoperational phases of the Midland project. One of the objectives of this supplement is to clarify the functional respon-sibilities shown in Table 1 of the QA Plan. The attached copy of Table 1 (Revised 2/2/70) accomplishes this objective. T'2e QA Plan also refers to procedures which will be followed in implementing the QA Pro-gram. The other objective of this supplement is to provide in abstract form a description of the procedures which are being assembled for Consumers Power Company's Midland Plant Quality Assurance Manual (QA Manual). QA MANUAL Consumers Power Company is in the process of assembling and formalizing a QA Manual for use by personnel concerned with the Midland Plant QA Program. The Manual vill document the policies, procedures and instruc-tions necessary for fulfilling the QA Program objectives. The title, purpose, scope and headings given in the following abstracts are those tentatively being used in the QA Manual. The procedure number listed for reference vill be replaced by another numbering system. PROCEDURE NO. 1 - QUALITY ASSURANCE MANUAL
Purpose:
This document establishes criteria for preparing and imple-menting QA Program Procedures. Scope: This procedure shall apply to the design, procurement, construc-tion and preoperational phase of the QA Program. Major Headings: Ad=inistration of manual and procedures, manual assign-ment, preparation and review, revisions and review, procedure designations, implementation, definitions and abbreviations. Note: The following definition for quality assurance shall apply: Quality Assurance is a planned syste=atic audit and control of the Quality Program to insure that adequate quality program elements are being imple-mented. Quality Assurance activities are performed by personnel who are independent of the Quality Control and work function. L. 14 Amendment No. 8 2/9/70
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PROCEDURE NO. 2 - ORGANIZATION (Design to Preop)
Purpose:
This procedure establishes the organization and defines the responsibilities of personnel assigned to the project. Scope: This procedure shall apply to the design, yrecurement, construc-tion a f preoperational phases. Major Headings: C ganization and Administration (with block diagrams), responsibility assignments, document distributing and reviewing responsi-bilities, QA Program evaluation. PROCEDURE NO. 3 - DOCUMENT CONTROL (Design to Preop)
Purpose:
This procedure establishes criteria for obtaining, distributing, reviewing and filing documents prepared by CP Co., the Engineer-Architect, the NSS supplier and other vendors. Scope: This procedure shall apply to design, procurement, construction and preoperational phase documents such as: specifications, requisitions, purchase orders, drawings, inspection and audit reports, vendor test re-ports, preoperational and hot functional tests reports, radiographs, mill test reports and other NDT reports and data. I Major Headings: General, file numbering system, documentation require-ments, what CP Co will obtain from vendors, records retaine.1 by manufac-( turers, microfilming, original documents, retention, project file, QA file, Field QA file, procurement, distribution, review responsibilities and document subheadings. PROCEDURE NO. 4 - QAE AUDITS AND/CR INSPECTIONS - GEIERAL
Purpose:
This procedure establishes methods for perfoming audits and/or inspections to assure compliance with the SAR, codes, specifications and the 10 CFR 50 Quality Assurance criteria. Scop;? This procedure shall apply (a) to QAE audits of the Engineer-Architect, the NSS supplier, vendors, CP Co project engineering, and the site; and (b) to QAE inspections of equipment during procure =ent and at the site. Major Headings: General: This document is intended to be a basic audit and inspection procedure all) wing for develop =ent of special purpose procedures. Audits: Tentative subheadings are: Types, Basic Criteria, Preaudit Preparation, document requirements, Frequency of Audits and, Bechtel, B W , Vendor, Project Engineering (CP Co), and site audits. Equipment Inspections: Tentative subheadings are: Basic Criteria, Preinspection Preparation, Frequency and BW, Vendor and site inspections. 4 E Amendment No. 8 2/9/70
i I l 1 Perfomance Tests: Covers witnessing perfomance tests in vendors shops. Reports: References procedure for preparing and distributing reports. Deviations and Corrective Actions: References procedures for issuing deviation notices and submitting corrective actions. PROCEDURE NO. 5 - FIEID QAE AUDITS AND/OR INSPECTIONS - GENERAL
Purpose:
This procedure establishes methods for performing site audits and/or inspections to insure compliance with the SAR, codes, specifications and the 10 CFR Quality Assurance criteria. Scope: This procedure shall apply to audits and inspections by the Field QAE at the plant site during the construction and preoperational phases of the project. Major Headings: General: This document is intended to be a basic audit and inspection procedure allowing for development of special purpose procedures for items such as concrete, tendons, radicgraphy and welding. Audits: Tentative subheadings are: Basic Criteria, Types, Document Requirements, Frequency of Audits, and Preaudit Preparation. Inspections : Tentative subheadings are: Types (Covers Receiving, Storage, and In Place), Basic Inspection Criteria, Preparation and Frequency. Tests: Test are to be covered by a separate procedure. Reports: References procedure for preparing and distributing reports. Deviations and Corrective Action: References procedures for issuing deviation notices and submitting corrective actions. PROCEDURE NO. 6 - DEVIATIONS AND CORRECTIVE ACTION (Design to Preop)
Purpose:
This procedure establishes methods for reporting deviations and , corrective actions. Scope: This procedure shall apply to the design, procurement, construc-
. tion and preoperational phases of the project.
Major Headings: General, Field QAE action, QAE action, follow-up, corrective action, and QA program evaluatien. ' PROCEDURE NO. 7 - REPORTS a
Purpose:
Ihis procedure establishes the basic requirements for reporting ( audits and inspections. Major Headings: For=at, distribution. 16 Amendment No. 8 2/9/70
, , . .,c..m , . _ ,
CONSUMERS PCWER CGCJANY MIDLAND PLANT UNITS 1 & 2 NUCLEAR QUALITY ASSURANCE Q-List The purpose of this list is to specify those items within the scope of the Nuclet.r Quality Assurance Program. Items listed require special consideration during design, manufacture, and construction as outlined in the Nuclear Quality Assurance Manual. This is a list of all seismic Class I structures, systems, and equip::ent as defined in Appendix 5-A of the PSAR. (The attached issue of the Q-List defines cajor subdivisions. A detail list with further subdivisions is issued to all parties carrying out the QA Program and kept up to date as the project progresses.) The Q-List is divided into three major sections:
- 1. Civil Structural
- 2. Mechanical 3 Electrical CIVIL STRUCTURAL SECTION Civil structural items within the scope of the Nuclear Quality Assurance Program are as follows: '
Reactor building. Portions of the auxiliary building housing the engineered safeguards systems, control room and radioactive materials. Enclosures for service water pumps. Diesel generator foundation, building, and fuel storage tanks. Supports for Class I system co=ponents. Emergency reservoir and pipeline. Q-Number Description Stec No Re= arks 1.1 Prestressed & Reinforced Concrete , 1.2 Liner Plate 13 Fuel Racks )
- 1. l+ Structural Steel- j 15 Emergency Reservoir & Pipeline 1.6 Ventilation Chimney A-1
MECHANICAL SECTION Q-Number Dest ription Spec No Remarks 2.1 Nuclear Plant Systems 2.11 Reactor Coolant and Pressure Control System 2.12 Makeup and Purification System
- 2.13 Decay Heat Removal System 2.14 Core Flooding System 2.15 Reactor Building Spray System 2.16' Component Cooling System
- 2.17 Gaseous Radvaste System
- 2.18 Containment Isolation System 2.2 Steam Plant Systems 2.21 Main Steam System (Thru First Isolation Valve) 2.22 Feed-Water System (Thru First Isolation Valve) 23 Miscellaneous Systems 2 31 Service Water System
- 2 32 Firefighting Syste=*
2 33 Diesel 011 System 2 34 Reactor Building Ventilation System
- 2 35 Auxiliary Building Ventilation Syste=*
' 36
.. Radiation Monitoring Syste=*
2.4 Isolated Equipnent 2.41 Emergency Diesel Generators 2.4. Reactor Building Crane
- 2.43 Auxiliary Building Crane
- 2.44 Fuel Handling Equipment *
- Class I Portions ,
A-2
ELECTRICAL SECTION Q-Number Description Equip No Spec No Rer:: arks 31 Switchgear Engineering Safeguards 3 11 Station Power Trans Engineering Safeguards 3 12 Load Centers Engineering Safeguards 3 13 Motor control center Engineering Safeguards 32 Switchboards & Panels 33 Raceways Associated With Engineering Safeguards 34 cable Associated With Engineering Safeguards 3 41 Instrument cable 3 42 600 V control cable Switchboard Wire 35 D-c Equipment 3 51 125 V station Batteries 3 52 Battery Chargers 3 53 A-C Inverters 3 54 D-C Buses 3 55 125 V D-C Distribution Panels 3.6 Miscellaneous Electrical Equipnent 3 61 Containment Electrical Penetrations 1 i 4 A-3
BECHTEL CORPORATION POWER AND INDUSTRIAL DIVISION QUALITY ASSURANCE PLAN 4 FOR MIDLAND PLANT - UNITS 1 & 2 INTRODUCTION Consumers Power Company has assigned the responsibility for the design, pro-curement of equipment (other than the NSS), and construction of the plant to Bechtel. Bechtel will perform the quality assurance effort for all phases of plant engineering, shop fabrication (including the USS), field fabrication, and construction. This effort will be applied to~all critical items and sys-tems so designated on the "Q-List." The Bechtel Nuclear Quality Assurance Manual, Revision 4 (hereafter referred to as NQAM), is the basis for the quality assurance programs on Bechtel Power and Industrial Division nuclear projects. The guidelines for implementing and maintaining the Bechtel Quality Assurance program for the Midland Plant will be contained in this document, referred to herein as the Quality Assumnce Plan. FURPOSE The general purpose of this quality assurance plan is to assure that materials, equipment, and vo'r.manship employed in the construction of the Midland Plant conform to high . standards of quality consistent with public safety and plant reliability. Tocumentation will be provided by the quality assurance program to demonstrate that the requirements are met. SCOPE This plan will describe the policies, practices, and procedures to be followed in implementing and maintaining an effective, documented quality assurance pro-gram during the design, procurement, and construction stages of the Midland Plant. Responsibilities and authorities of the organizations and individuals involved in the Bechtel quality assurance program will be defined and the major struc-tures, systems, and components covered by this program will be identified. QUALITY ASSURANCE PLAN . ORGANIZATION
- The organization employed for implementation of the Bechtel Quality Assurance Program on the Midland project is shown in Figure 1. The program covers three i main phases of the project, namely: Design, Procurement, and Construction. The personnel having quality assurance related functions are listed for each phase. ,
B-1 l l
/ A. Design Phase Project Engineering Team Quality Assurance Engineer
. Chief Engineers and their Technical Staffs Engineering Manager Manager - Quality Assurance
-Quality Assurance Coordinator .
Metallurgical and Quality Control B. Procurement Phase Project Engineering Team Quality Assurance Engineer Chief Engineers and their Technical Staffs Engineering Manager Manager - Quality Assurance Quality Assurance Coordinator Metallurgical and Quality Control Shop Inspectors C. Construction Phase
~ Project Engineering Team Quality Assurance Engineer Chief Engineers and their Technical Staffs Engineering Manager Manager - Quality Assurance Quality Assurance Coordinator Metallurgical and Quality Control Project Field Engineer Quality Control Engineer Field Engineers The authority and duties of the personnel involved in the various phases of the quality assurance program are as follows:
A. Project Engineering Team The project engineering team has primary responsibility for implementing the quality assurance program. They prepare drawings, specifications, pur-chase requisitions, and bid evaluations in accordance with the quality re-guirements. They also prepare and implement the Q-List and design control check list, review fabrication and inspection procedures, and shop inspection reports. Through the quality assurance engineer they provide surveillance j of field engineering, quality control, and construction activities. B. Quality Assurance Engineer
- The quality assurance engineer'(QAE) is the field representative of the pro-ject engineering team, and receives supervision and technical support from B-2
the project engineer. However, the QAE is assigned by, and administra-tively reports to, the manager-quality assurance. Prior to commencement of construction he is stationed in the home office to assist the project engineer and design supervisors in the implementation of the quality assurance program. At the jobaite the QAE performs quality assurance surveillance of field activities including engineering, quality control, and construction acti-vities. He reviews and accepts inspection reports, performs audit of the field QA/QC documentation files, and monitors the overall quality control program. The quality assurance engineer has the authority to stop field work in the event of nonconformance with drawings, specifications, and procedures es-tablished for structures, systems, and units on the Q-List. He also serves as field contact for the applicant's quality assurance organization and others concerned with quality assurance in the field. C. Chief Engineers The Bechtel organization provides for a chief engineer for each discipline (eg, civil, mechanical, etc) to provide technic 1 support and coordination of the engineering design supervisors. Since the engineering effort for ce project is under the sole direction of the project engineer, the chief engineers qualify for the necessary independent review of engineering. The chief engineers provide independent documented review for all items on the design control check lists. In so doing, they coordinate and assure necessary technical review by specialists and consultants. Chief engineers may delegate review to qualified specialists on their staffs. D. Engineering Manager The engineering manager provides management guidance and surveillance of the Midland Plant and other nuclear project engineering activities. His QA-related functions involve verification through project reviews that project engineering is carrying out its QA responsibilities as well as other design responsibilities. E. Manager - Quality Assurance The manager-quality assurance is responsible for overall direction of the quality assurance program including formulating and implementing policy, ad-ministration, and coordination of the program and administrative and techni-cal supervision of the quality assurance engineers and coordinators. He is responsible for providing overall coordination of engineering, procurement and construction departments in quality assurance activities to effectively implement the program. F. Quality Assurance Coordinator
- The quality assurance coordinator reports to and assists the manager-quality assurance in carrying out and' implementing all activities related to the quality assurance program. His recponsibilities include coordinating and B-3 O
. i
, assigning QAE, reviewing and evaluating project quality assurance programs, and auditing the perfomance of the various programs. He provides an inde-pendent channel for QAE communication to canagement.
G. Metallurgical Quality Control The quality assurance aspects of metallurgy and velding activities are coor-dinated by metallurgy and QC services. Their function includes preparation of specificatiens and procedures for materials, fabrication, and nondestruc-tive testing plus providing technical consultation and guidance for engi-neering, procurement, and construction. In addition, they provide velding and inspection training services at the jobsite. I H. Shop Inspectors The shop inspectors are responsible for shop qualification inspections,
' in-process inspection of work in suppliers ' shops, checking of documentation and final inspection and release of equipment, for shipment. Their activ- , ities are carried out in accordance with the Procurement Department Inspec-tion Manual and as supplemented by the drawings, specifications, and additional instructions provided by engineering.
I. Project Field Engineer The project field engineer's duties include the surervision of quality control inspection at the jobsite. In carrying out this ' Assignment, he assigns quali-fled field engineers to perform quality control inspections. He supervises the preparation of inspection check lists, verifies accuracy and completeness of inspection reports, and ascertains that defects are removed and that re-pairs are carried out in accordance with applicable specifications, instruc-tiens, and procedures. The field quality control program is carried out in accordance with the Bechtel Nuclear Quality Assurance Manual, the Bechtel Field . Inspection Manual and as supplemented by the drawings, specifications and addi-tional instructions. J. Quality Control Engineer The quality control engineer reports to and assists the project field engi-neer in carrying out quality control inspection responsibilities. He nor= ally is assigned responsibility for review of inspection reports, coordination, training and advising field engineers in tne performance of quality control inspection assignments, coordination of testing laboratories, and overall detailed execution of field inspection and caintenance of the field QC/QA files. K. Field Engineers /Insrectors Field engineers / inspectors carry out the inspection assignments and are respon-sible for completing the appropriate inspection forms. Field engineers / inspectors function on a disciplinary basis, eg mechanical equipment, civil / structural, electrical / power, instrumentation / con, trol, and welding /setellurgy. The number of inspectors assigned varies depending upon the requirer.sts of the quality con-trol inspection workload and construction schedule. They c.sve access to all the design drawings, applicable codes, and sampling and testing procedures pertaining to their inspection assignments. B-4 w
- ._ , . , . _ . m, _ _ _ _ _
e L. Material Supervisor The material supervisor is responsible for normal receiving inspection and storage of material and equipment prior to installation. He performs his duties in accordance with the HQAM, field procurement procedures, and additional instructions provided by engineering. QUALITY ASSURANCE PROGRAM The quality assurance program covers all phases of the project including engi-neering, procurement and construction from initial design development through acceptance by the client. The scope of the quality assurance program is defined by the Q-List which is a list of critical items requi*ing quality assurance coverage. This list includes all structures, equipment, and systems associated with the reactor primary coolant boundary, engineered safeguards, emergency cooling systems, reactor containment, and containment cooling systems. Other systems may be added at the discretion of the client, nuclear steam supply system seller (for items in his scope of supply), chief engineers or the project engineer. Since the Q-List is a working document and therefore vill be updated periodically to give more detail, a basic Q-List in sufficient detail to show the general scope of the Bechtel QA program for the Midland Project is included (Figure 2). The Q-List is prepared by the project engineering team, then reviewed and approved by chief engineers. The degree of inspection and control afforded items on the Q-List is determined on a case-by-case basis by the project engineering team through consultation with the chief engineers and Bechtel's technical special-ists. Te ctors considered in establishing the degree of contral include: nature of the item, importance of the ites to plant safety and reliability, previous experience with this cr comparable items, capabilities of potential vendors or subcontractors, and requirements of applicable codes or standards. Where deemed necessary, Bechtel engineering documents include specific procedures or requi-sites for the production and quality assurance of the item or request their prep-aration by the organization responsible for manufacturing or erection. The following basic principles are applied in the accomplishment of the quality assurance program: A. The project engineering team has primary responsibilities for quality in the design phase. B. Vendors and subcontractors have primary responsibilities for quality of materials, equipnent, and services furnished by them. C. The Bechtel project field organization supervised by the project superinten-dent has primary responsibility for quality of construction perfomed directly by Bechtel. D. One or more levels of inspection or checks are provided as required within the organization having primary quality responsibilities. B-5
The quality assurance program provides for at least one level of monitoring and verification by individuals not under the direct control of the group having primary responsibility for quality (eg, the quality assurance engineer suneys ccnstruction, Bechtel shop inspectors survey vendors, etc). Beyond this, quality assurance audits of engineering and field operations are carried out under the direction of the quality assurance coordinator. DESIGH COYfROL Several levels of design review an pproval are applied to significant design aspects of Bechtel verk. These standard practices include: A. Checking and review by design and engineering level personnel within the project engineering team having technical qualifications comparable to those of the engineer or designer who originated the work. 3 Review and approval by the originating engineer's design supervisor. C. Review and approval by the project engineer. D. Review and approval by the appropriate chief engineer of key design drawings specifications and documents such as electrical single-line drawings. For structures, syste=s and components en the Q-List, additional design control measures are i=plemented. A Design Control Check List is prepared which iden-tifies drawings, specifications, and other data (including the Q-List) which shall be reviewed by chief engineers or technical specialists under the chief engineer's direction. The Design Control Check List is agreed on by the project engineer and the cognizant chief engineer soon after initiation of the project. When periodic design reviews are dee=ed necessary, chief engineers and the project engineer agree on appropriate schedules and procedures. When an item identified in the Design Centrol Check List has been completed, the cognizant chief engineer will have a final review performed and execute a design control approval signifying that the necessary initial, periodic, and final review and monitoring work has
. been ecmpleted and the ites is satisfactory from the standpoint of quality assur-ance requirements. Specifications, design and interface infor=ation-and systems criteria developed by the nuclear steam syste= supplier are submitted by the sup-plier to Bechtel for review. Drawings, specifications, and procurement packages are also routinely sub=itted to the client for appropriate review.
The project engireering team e= ploys several documents to establish design require-ments for the project. These documents include or incorporate applicable AEC regu-latory requirements and design bases as proposed by the license application and accepted by the AEC, basic client-furnished data defining plant requirements, basic engineering data amplifying the basic client-directed project data, NSS supplier furnished criteria and data, project criteria and Bechtel design guides, standard specifications and data sheets. FROCUREMENT DOCUMENT CONTROL Technical aspects of procurement docu=ents are prepared by the project engineering team in accordance with the procedures described in the preceding section. Appro-priate vendor quality assurance program requirements are incorporated in the B-6
procurecent documents. Provisions are =ade for periodic and final inspection in vendor shops as appropriate. All procure =ent, whether carred out by hc=e office procurement department, or the field procurement organization, employs specifications and quality assurance requirements established by the project engineering team. INSTRUCTIONS, FROCEEURES AND LRAWINGS General procedures for carrying cut engineering, precurement and construction are contained in the following nanuals and documents: A. Project Engineer's Manual centaining requirements for carrying out engi-neering activities. B. Nuclear Quality Assurance ?tanual defining responsibilities and outlining quality assurance activities and procedures. C. Field Inspection Manual describing general guidelines and procedures for field inspection. D. Procurement Department Inspection Manual containing shop inspection instruc-tions, guidelines and procedures. E. Field Procurement Procedures specifying field purchase instructions for field jurchases and caterial receiving inspection. F. Bechtel general and technical engineering standards including nuclear power station design standards which establish selective criteria, guidelines and standards for staticn design. These are supplemented by specific inctructicns and procedures which may te prepared by engineering, obtained from vendors, or prepared by vendor, subcon-tractor, er Bechtel construction personnel as required. When appropriate, such instructions and procedures are reviewed and approved by the project engineering team and Bechtel specialists. DOCUMENT COICROL The review and approval of design documents is covered in the " resign Control" section. Approved drawings and specifications are promptly issued to individual organizatiens and individuals performing the work and to those responsible for inspection. Changes made by the project engineering team cr proposed by field engineering to approved drawings are reviewed and approved by the project engi-neering team in accordance with procedures for review of the initial issue. Where significant changes are involved, review by cognizant chief engineers and/or tech-nical specialists is performed. The project field organization is responsible for implementation of a f'ield pro-cedure that will control the distribution of approved drawings and assure that obsolete drawings are voided or destroyed. The quality assurance engineer vill monitor field engineering activities to verify that field engineering changes are reviewed and approved by the project engineering team. He vill also take spot checks to assure that a dravir4 control log is being taintained and that only current design documents are in use. B-T
CONTROL OF PURCHASED MATERIAL, EQUIPMEIC AND SERVICE 3 The Bechtel quality assurance program includes a ecmprehensive system to assure that all purchased =aterial, equipment and services conform to the procurement documents. It provides for evaluation of vendor's quality assurance program and preparation of procurement specifications incorporating quality assurance ~ requirements. The quality assurance requirements include an appropriate vendor quality assurance program, purchaser surveillance as required, vendor preparation and maintenance of appropriate test and inspection records, certificates and other quality assurance documentatica and vendor submittal of quality control records considered necessary for purchaser retention to verify quality of completed work. Bechtel shop inspectors review and verify vendor quality assurance records and prepare reports documenting vendor data not submitted to purchaser. Where Bechtel shop inspection is performed, a final inspection of the finished item is carried out in the vendor's shop prior to release for shipment; Bechtel field procurement procedures provide for receipt inspection by the caterial supervisor en all mate-rials and equipment delivered to the jobsite. For significant items or critical materials which form parts of Q-List systems, Bechtel field engineers carry out an independent receipt inspection and prepare receiving reports which supplement receiving reports required by standard field procurement procedures. Bechtel pro-curement procedures also provide for periodic audits of vendor quality assurance activities as appropriate. IDENTIFICATION AND CONTROL OF MATERIAIS, PARTS AND COMPONENTS As applies to vendors, appropriate requirements for identification and control of taterials, parts and cc=ponents will be established through review of the vendcr's quality assurance program and procedures agreed to prior to bid award. Bechtel field procedures and practices incorporate measures for material control, in-cluding segregation of nonconforming items, and for marking and identification as required. Traceability will be accomplished where required by code, standard, or specification. In other cases, measures such as physical separation or appropri-ate =arking procedures are used to identify and control materials or components of specific type, specification, class, etc. Positive control of nonconforming items will be maintained by suitable earkings and/or segregation (see "Noncon-forming Material, Parts or Components"). CONTROL OF SPECIAL PROCESSES Use of qualified procedures and application thereof as required by establisbed codes and standards will be rigidly enforced on all Bechtel vendors, subcontrac-tors and Bechtel personnel. For other special processes identified by equipment suppliers or project engineering, procedures will be prepared by equipment sup-pliers, project engineering, or field engineering and approved by appropriate personnel in the organization which identified the process. Perscnnel performing such operations will be trained and carefally supervised by personnel familiar with the specific prccess. INSPECTION Bechtel performs periodic and final inspection of vendor work as described pre-viously. This is normally performed by shop inspectors; however, in special B-8
, cases engineering personnel participate in such inspections. Inspection prac-tices nor= ally include witnessing of significant tests, as appropriate, and requirements for vendors to accept mandatory hold-points where, in the opinion of Bechtel inspectors, work should not proceed without prior ern*ation by the Bechtel inspector.
For field operations, in-process, and final inspection of activities affecting quality are carried out by Bechtel field engineers with knowledge of the dis-cipline involved, project requirements and the inspection processa. Field inspection is carried out in accordance with guidelines and procedures contained in the Bechtel Field Inspection Manual supplemented by approved procedures for special processes and specific project requirements. Field inspection operations are supervised by the quality control engineer and monitored by the quality assur-ance engineer. Reports or records of inspection operations are prepared by the field engineers / inspectors, approved by the quality control engineer, accepted and distributed by the quality assurance engineer. TEST CONIROL Supplier and subcontractor test operations, including procedures as appropriate, ' are reviewed in accordance with procurement procedures previously described. In the field, certain test operations are carried out by the construction organi-zation in the course of plant construction. Subsequent to completion of construc-tien, the Bechtel startup organization may be involved in ystem checkout and
, startup operations. Construction tests are normally perfomed in accordance with , standard construction practice or via specific test procedures as specified by the project engineering team. Results of required test's are documented.
, CALIERATION OF MEASUREMEDT AND TEST EQUIRST Vendor procedures for control of measurement and test equipment are reviewed as appropriate in evaluating the vendor quality assurance program. In the field, a standard written procedure is followed to provide centrol and periodic calibra-tion of special tools, measuring and test equipment. HANDLING, STORAGE, SHIPPING AND PRESERVATION Special handling, storage, shipping and preservation requirements are identified in procurement specifications for vendor's work. In the field, caterials and equipment are stored in accordance with standard procedures as well as specific requirements and any special procedures issued by the project engineering team. These are prepared by the field organization, approved by the project superinten- ' dent and reviewed by the project engineering team. When special environmental preservation is required, documentation of the conditions is provided. INSPECTION, TESTS AND OPERATING STATUS Documentation of inspections and tests is provided by inspection reports or other records. This documentation identifies the ite=s that conform to inspection and test require =ents. Nonconforming items are reported and tagged (see "Noncon-forming Material, Parts or Co=ponents"). Current practices provide for the pro-ject field organization to develop specific procedures for the marking, tagging, or otherwise indicating inspection and acceptance status of items and/or systems. I B-9 i l l
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;" NONCONFORMING MATERIAL, PARTS OR COMPONENTS The Bechtel Quality Assurance Program provides measures which control =aterials, parts or components not conforming to prescribed requirementa to prevent their inadvertent use or installation. Materials are physically cuatrolled in accord-ance with procedures described under " Identification and Control of Materials, Parts and Components." For nonconforming items which may te made usable through rework, repair or modification of requirements, reports are prepared and sub-mitted to the project engineering team for appropriate guidance. Records of resolution for these cases are prepared and incorporated in quality assurance files. Where rework, repair or approval for use is not feasible, nonconformira materials are either removed from the construction site or utilized in systems or structures where their characteristics satisfy requirements for such systems.
CORRECTIVE ACTION The Bechtel quality assurance program incorporates procedures for identification and reporting of situations which are deemed adverse to quality through prepara-tion of "Significant Deficiency Reports." These include reports of significant failures, talfunctions, deficiencies, deviations, defective material, etc, that cannot be resolved at the site and/or require management attention. Routine occur-rences of rework generally anticipated for the activity involved are not normally ' + included in the corrective action program. The report is initiated by the quality assurance engineer and reviewed by the project engineering team, chief engineers, and/or engineering specialists. Copies are sent to the QA coordinator and manager-quality assurance. Upon resolution of the problem the project engineer completes the "Significant Deficiency Follow-up Report" and transmits the report to the quality assurance engineer with the sa=e distribution of copies as the initial report. The "Significant Deficiency Follow-up Report" is classified as Bechtel confiden-tial information and vill not be incorporated in project quality assurance files. This policy is followed in order to permit free, factual reporting of all situa-tions,~ some of which may involve personnel evaluations, etc. A sn-ry of these reports will be incorporated in the project quality assurance records. QUALITY ASSURAUCE RECORDS Copies of all documentation pertaining to the quality assurance program, preIared by Bechtel or obtained from vendors and subcontractors, are collected in project quality assurance files. However, as noted in the preceding section, only the su= mary logs of "Significant Deficiency Paperts" are included. These files are available for audit by management and the client during the design and construction period and are turned over to the client at the completion of the Bechtel contract. ' Detailed Bechtel quality assurance audit reports are not included in such files,
- but, su= mary records and conclusions will be cade available. ,
l l AUDITS ' The quality assurance program includes-four specific audit activities: A. Periodic audits of project engineerir4 activities and records are carried out by, or under the direction of, the quality assurance coordinator. B-lO W
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rw B. Bechtel shop inspectors carry out periodic audits of vendor's quality assurance progran and records. C. Quality assurance engineer carries out frequent audits of field inspection activities and reporting. D. Periodic audits of field quality assurance and inspecticn activities are carried out under the direction of the quality assurance coordinator. All of the above are carried out, on a sampling basis, periodically during the design and construction period. At the completion of construction for systens and structures subject to the quality assurance program, a final inspection is performed on the work and associated quality assurance records to assure neces-sary inspections and records have been prepared and are on file. A final inspec-tion report is prepared confirming this final excaination and audit. B-11}}