ML20054H131

Quality Plan for Underpinning Activities,Revision 2

ML20054H131
Person / Time
Site:	Midland
Issue date:	05/18/1982
From:	CONSUMERS ENERGY CO. (FORMERLY CONSUMERS POWER CO.)
To:
Shared Package
ML20054H130	List: ML20054H129 ML20054H131
References
MPQP-1, MPQP-1-R02, MPQP-1-R2, NUDOCS 8206220628
Download: ML20054H131 (16)

Text

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1 QUALITY PLAN FOR UNTERPIhWING ACTIVITIES t-I j-f v

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• MPQP-1 REVISION 2

.i May 18, 1982 Page 2 1

I QtALITY PLAN FOR UNDERPINNING ACTIVITIES GENERAL 1

All activities for the remedial soils work are. covered by the existing Consumers Power Company and Bechtel Power Corporation Topical Reports CPC-1-A and BQ-TOP-1, Revision IA, respectively. This Quality Plan provides a more detailed written description of the accomplishment of activities specific to certain soils remedial work. This Quality Plan was developed to describe how quality programmatic cov'erage is extended to encompass the underpinning contractors. g.

The senior management consisting of the Vice President of Projects,

[ Engineering and Construction (Consumers Power Company) and the Midland Project

,q Manager for Bechtel Power Corporation (CP Co's contractor for the Midland Nuclear Plant),

reviews and approves major decisions and design concepts regarding remedial soils work.

For CP Co, a Midland Project Office Executive Manager and an Assistant Project Manager, and for Bechtel, a Bechtel Assistant Project Manager, will manage the remedial soils work. The Bechtel Construction Remedial Soils Group Supervisor coordinates the Bechtel and 1

Subcontractor field activities.

The Manager of MPQ-1D and the Civil Section Head will manage the MPQAD support of remedial work with the overview of the Director of Environmental and Quality Assurance.

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MPQP-1 REVISION 2 M:y 18, 1982 Paga 3 c.

QUALITY PLAN FOR UNDERPINNING ACTIVITIES SCOPE This Quality Plan is applicable for all "Q" listed aspects of the auxiliary building and service water structure underpinning tasks. The "Q" list for this work covers activities, items and structures beyond the requirements provided by the FSAR. This extension to provide Quality Assurance Program coverage over and above safety related items will provide an additional assurance that the non-safety related activities will not have an adverse effect on safety related structures. The following major categories of the Y

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remedial soils work are deemed to be "Q" listed and covered by this Quality i

Plan.

1. Underpinning of Auxiliary Building, Specification 7220-C-195(Q) - as a minimum, any work associated with " Phase II" or beyond and specifically any work below the 609 foot level.

2. Underpinning of the Service Water Pump Structure, Specification 7220-C-194(Q).

i 3. Installation of Monitoring System and the monitoring of structural response to underpinning activities, Specification 7220-C-198tQ).

The remedial work associated with the BWST, DG Building and underground piping are covered solely by the Bechtel and Consumers Quality Aasurance Frograms and are not covered by the spec:al provisions of this Quality Plan. Likewise the "Q" listed activities associated -ith the freeze wall, permanent ar.d tempora ry dewatertag, soils borings. and observation wells remain as stated in the m 03S2-4025a-oo-27 e

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QUALITY PLAN FOR UNDERPINNING ACTIVITIES specifications, design documents and procedures covering those tasks.

Revisions to include additional specific activities for those task as "Q" listed (if any) will be done by revisions to the implementing work documents.

Any activity or structure associated with Tasks 1 through 3 described above, which will be excluded from Quality Assurance Program coverage will be done on an exception basis. ' These exceptions will be documented in appropriate design documents and implementing procedures.

Assurance of NRR Region I,II concurrence to any general exclusion from the Quality Assurance Program is 1

required prior to conducting any work activities in the excluded area.

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Specifications, applicable procurement documents, drawings and procedures 4

shall be specific as to the design attributen and activities which require quality verification.

. The need for verification shall be dictated by the following principal:

The Quality Assurance Program shall provide control over activities i

, affecting the quality of the identified structures, systems and components i

to an extent consistent with their importance to (a) safety; (b) their possible detrimental interaction or effect on safety related structures t and items; or (c) assuring obtainment of the overs 11 Project Objectives.

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. The term quality verification includes all Quality Control and Quality Assurance Organt ation activities and responsibilities as well as tr.e aquisition of documentation attesting to quality of procured items, i

calibration, testing, process qualifications, etc.

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MPQT-1 REVISION 2 M:y 18, 1982

Page 5 QUALITY PLAN FOR UNDERPINNING ACTIVITIES

, REMEDIAL SOILS WORK ORGANIZATIONS 4

Organizations involved with the underpinning are defined in the Functional Matrix, Attachment I and as follows:

CP Co Project Management - Sets policy, coordinates licensing review, and submittals to the NRC.

j CP Co Safety and Licensing - Performs licensing reviews and coord,inates FSAR v revisions.

i CP Co Design Production - Provides client design input and performs reviews of' and comments on Bechtel Design Documents.

1 CP Co Site Management - Monitors remedial activities with respect to commercial type items, construction activities such as i

. equipment care, labor and production.

Bechtel Project Management - Coordinates with client and sets policy for Bechtel organizations.

Bechtel Project Engineering - Establishes design criteria and reviews input j from non-Bechte) sources. Originates and issues i

design documents for construction.

Sechtel Project Geotechnical Engineer - Functions as Project Engineering's Geotechnical representative on project. Performs geotechnical d mt03S -4025a-66-2' l2

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,, REVISION 2 May 18, 1982

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QUALITY PLAN FOR UNDERPINNING ACTIVITIES reviews related to design criteria and procedures. . Interfaces with Geotech

, Services and Resident Geotechnical Engineer.

Bechtel Construction Remedial Soils Group - Performs the overall on-site management of all remedial underpinning activities including Y

construction coordination between

, Bechtel, CP Co and Subcontractor, Provides direction over Subcontractor activities, and I

shall be the single point of contact between the Subcontractor and Bechtel, and CP Co, the NRC

' and other agencies.

Geotech Services - Provides design and field geotechnical services as j requested by Project Engineering.

i Resident Geotechnical Engineer - Perfc tms foundation inspection and geotechnical on-site monitoring cf related construction activities. Interraces with the

! Project Geotechnical Engineer.

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i MPQP-1

REVISION 2 May 18, 1982

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j QUALITY PLAN FOR UNDERPINNING ACTIVITIES Bechtel Quality Control (QC) - Performs first-line inspection verification.of h

1 site Q-list activities. Reviews Q-listed i-construction procedures, drawings and specifications.

Midland Project Quality Assurance (MPQAD) - Provides the quality assurance for all remedial work including work done by Bechtel and Bechtel Y

Subcont ra c to rs . Develops quality.

plans, reviews design documents .

and construction procedures.

Performs overinspections and pre- '

planned audits.

Subcontractor - Perform construction activities as contracted for, within the j framework of the Midland Project Quality Program.

i Consultant - Provides advice to Bechtel Project Engineering or Bechtel j

j Construction (Remedial Soils Group) on construction methods, design, instrumentation or geotechnical items.

DESIGN CONTROL Desian Control for the enderpinning of the Auxiliary Building (Electrical Penetrations and Control Structure), Feedwater Isolation Valve Pit fill a

material replacement and Service Water Pump Structure underpinning ill be i provided by Project Engineering. Engineering Depa rtment Procedures (EDPs) and miO3S2-e025a-co-27

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MPQP-1 REVISION 2 May 18, 1982 Page 8

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QUALITY PLAN FOR UNDERPINNING ACTIVITIES Engineering Department Project Instructions (EDPIs) will provide the controls for Engineering activities which are responsive to the Quality Program requirements.

Design criteria will be developed from input from consultants, the Midland Plant Safety Analysis Report, 50.54(f) responses submitted to the NRC staff, meetings with and submittals to the NRC staff, and testimony during the ASLB Soils hearing. .

Y Design documents, including specifications, drawings and procurement documents, shall be specific as to what is required to ascertain that processes, activitie's and final products meet their design requirements.

Design documents, including specifications and drawings (as well se changes and revisions to these documents), will be reviewed and checked for compliance 4 to design requirements by Bechtel Project Engineering. Design documents will

) be reviewed by Quality Control and MPQAD.

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)i1 The MPQAD review applies to design documents designated as either Q-listed or

] non Q-listed.

For documents which are not Q-listed, the MPQAD review is 1

limited to assuring the document in fact does not require Q-listed activities l3 to protect Q-listed items, systems, or structures. Subsequent revisions to documents concurred to be non Q-listed need not be submitted to MPQAD for review unless such a revision specifically adds an activity which sr.ould be subject l

to the Quality Assurance Program.

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MPQP-1 i REVISION 2 May 18, 1982 4 Page 9 J

QUALITYPLANFORUNDERPINNINGACTIV5 TIES a

MPQAD will act as the focal point for the assurance of the resolution of quality related comments.

Technical specifications and revisions thereof will be generated, reviewed, approved, and controlled by Bechtel Project Engineering in accordance with EDP 4.49. Initial specifications will also be reviewed by CP Co Design Production and comments submitted to Bechtel Project Engineering.

Specification Change Notices (SCNs), used as interim change docum,ents between revisionsofthespMEification,willreceivethesamelevelofreviewand approval by Bechtel Project Engineering as the basic specifications.

Specification Change Notices shall be administered and controlled in accordance with EDPI 4.49.1.

Project Engineering will prepare, review, approve, issue and control design H~

drawings in accordance with EDP 4.46. Changes to engineering drawings will receive the same level of review and approval as the basic drawing and are administered in accordance with EDP 4.47 and EDPI 4.47.1.

Bechtel design calculations shall be originated, checked, approved, controlled and documented by Project Engineering in accordance with EDP 4.37. All design t

l calculations' submitted by the consultant will be checked, reviewed and approved by Bechtel Project Engineering.

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Bechtel Construction Remedial Soils Group shall request from or notify Project 1

.l Engineering of changes to design documents by Field Change Requests (FCRs) and Field Change Notices (FCNs), respectively. The FCRs will be reviewed, i-miO3S2-4025a-66-27

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QUALITY PLAN FOR UNDERPINNING ACTIVITIES evaluated, dispositioned, controlled and administered in accordance with EDP 4.62.

FCNs will allow Field Construction to initiate field changes in design documents within the allowable guidelines of Field Procedure FPD-2.000 and Specification G-34 (Q) as provided by Project Engineering. FCNs will be reviewed, evaluated, dispositioned, controlled and administered according to EDPI'4.62.1.

t The design interfaceg-for the underpinning activities between Project Engineering, project groups, technical support groups and consultants shall be r administered as illustrated in Attachment 2, Design Document Interface i

Flowchart. Geotech Services, design and calculation reviews will be accomplished per EDPI 4.25.2.

The Subcontractor received design documents from the Bechtel Construction Remedial Soils Group to be utilized for

, Construction. .

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j Inspections are performed by Bechtel QC to verify that construction is being I,

j performed to the latest revisions of the design documents; audits and/or l

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.t overinspections will be conducted by MPQAD. Field geotechnical activities, a

including subgrade acceptance, are accomplished in accordance with 3

'I EDPI 2.14.8.

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'l PROCL'REMENT AND RECEIVING i

l' All procurement of Q-list items and services for the remedial underpinning work will be performed by Bechtel employing the technical and quality l requirements established in the specifications and drawings. Q-material l

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] QUALITY PLAN FOR UNDERPINNING ACTIVITIES I

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requisitions will be originated by Bechtel Coastruction Remedial Soils Group

in accordance with FPG-8.000. Bechtel Construction Remedial Soils Group is responsible for assuring that applicable Quality Program Requirements, design

, bases, specifications, procedures and drawings are included and referenced in the procurement documents.

The Field Procurement Department initiates formal purchase orders and'will be responsible for ensuring that the procurement package is complete and includes all of the information required by the supplier.

MPQAD revjews and approves procurement documents in ac'cordance with MPQAD Procedure M-5 to assure that necessary Quality Assurance Program requirements are included.

Upon receipt of Q-material, inspections are performed by Quality Control in accordance with PSP G-5.1 to verify items comply with the procurement package requirements and quality verifications packages are complete. Quality i

verification packages are reviewed for availability, traceability and legibility by Bechtel QC and audited by MPQAD (MPQAD Procedure F-lM). In addition, a technical review will be performed by Bechtel QC for non-shop inspected items.

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PREPARATION AND IMPI.EMENTATION OF PROCEDURES / INSTRUCTIONS s

i Written instructions to the Subcontractor are in the form of engineering specifications, drawings, and approved changes thereto.

! The G-321D form (controlled by EDP 4.58) attached to the specifications l

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identify the procedures, which as a minimum, are to be submitted by the i

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' MPQP-1 l REVISION 2 l May 18, 1982

, Page 12 QUALITY PLAN FOR U.iDERPINNING ACTIVITIES Subcontractor prior to the start of fabrication and construction. These procedures are logged, controlled, and distributed by the Field Document Control Center and are reviewed by Project Engineering, Bechtel QC, MPQAD and as defined in the Quality Plan and Q-Listed Activities for each technical specification. Project Engineering defines the specific quality attributes of each procedure. The MPQAD review applies to procedures / instructions designated as either Q-listed or non Q-listed. For documents which are not Q-listed, the MPQAD rpview is limited to assuring the document in fact does not require Q-listed activities to protect Q-listed items, systems, or structures.

Subsequent revisions to documents concurred to be non Q-listed need not be submitted to MPQAD for review unless such a revision specifically adds an activity which sould be subject to the Quality Assurance Program.

These p,rocedures, when approved by Bechtel Project Engineering, Bechtel QC and MPQAD, provided authorization for fabrication / construction to proceed.

INSPECTION, EXAMINATION, TEST AND CALIBRATION Quality verification, inspection and testing of Bechtel and Subcontractor Q-list activities is performed by Bechtel Quality Control, independent of the Subcontractor and the Bechtel Construction Remedial Soils Group. Bechtel QC will prepare inspection p1'.ns (in accordance with PSP G-o.1 and G-1.1) utillaine inputs frem techt.ical specifications, design drawings and a l Subcontractor procedures. Project Quality Control Instructions tPQCIs) are prepared to cover all Becht.el and Subcontractor Q-list activities. Existing POCis are adapted for standard construction activities such as concrete mt0382-4025a-oo-27

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. 1 i MPQP-1 REVISION 2 May 18, 1982 Page 13 QUALITY PLAN FOR UNDERPINNING ACTIVITIES batching, placement and testing, and reinforcing steel installation.

Additional PQCIs are developed as necessary to verify new underpinning activities such as temporary support installation, load transfer and threaded reinforcing connectors.

All PQCIs are subject to MPQAD review according to MPQAD Procedure E-2M. In addition, inspection and test activities are monitored by MPQAD,through the use of overinspection plans based on an a

, independent evaluation of design and procurement documents (MPQAD Procedure E-1M).

The 1r Subcontractor is indoctrinated to Bechtel Q'C and MPQAD procedures and inspection planning to assure that hold and witness inspection points included as an integral part of the Subcontractor's procedures, are adhered to.

For site construction activities, the detailed implementing procedures shall utilize integrated construction planning as follows:

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Hold points shall be clearly identified in the procedures.

b) i The procedures shall provide for QC/QA signoff to record the completion of a the inspection holdpoints prior to proceeding with the further' execution of subsequent procedural steps.

Tests are performed to qualify, demonstrate or assure that the quality of procured items or completed construction is as defined in applicable engineering drawings and procurement documents.

Calibration, maintenance and control of measuring and test equipment ts provided by an approved agency which will be pre qualified by MPQAL. This agency provides for the traceability to National Standards, the unique mt03S2-4025a-o6-27

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• L l QUALITY PLAN FOR UNDERPINNING ACTIVITIES identification of each instrument or equipment requiring calibration, the t

establishment of calibration frequencies, and the identification of calibration status. Calibration records are maintained by the agency and transmitted to Bechtel Construction Remedial Soils Group for review. 'At the completion of the subcontract, these records will be turned over to Bechtel Quality Control. Performance and effectiveness of the agency is verified by MPQAD audits and/or overinspections in accordance with MPQAD Procedures F-1M and E-1M.

HANDLING AND STORAGE All Q-list material is stored and handled in accordance with general Field.

Procedures FPG 4.000 and 5.000 and supplemented by the Subcontractor's procedure. Storage and handling of material and equipment is subject to Bechtel QC inspection and verification according to PSP G-5.1 and MPQAD l

overinspections and/or audits. (MPQAD Procedures E-1M and F-1M).

l DOCRiENT CONTROL AND QUALITY RECORDS I

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Subcontractor documents which are to be submitted for review and comment by t

Bechtel Project Engineering, Bechtel ~ and MPQAD are controlled by the Field 4

Document Control Center (FDCC) -c ; cm- 2nce with FPD 1.000. Prior to the i

start of work, the Subcontractc- s u cra . . ... construction procedures as required i by the specifications, purchase orders and/or drawings to Bechtel Construction Remedial Soils Group. Bechtel Construction Remedial Soils Group and the FLCC distributed the procedures for review and approval as defined in tne Quality mt03S2-4025a-66-27

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,. QUALITY Pl.AN FOR UNDERPINNING ACTIVITIES

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2 Plans for the underpinning activities. Bechtel Project Engineering is responsible for resolving review comments.

i All quality records are controlled by EDPs 5.16 and 5.24, Bechtel QC Procedure PSP G-7.1 and MPQAD Procedures F-11M and F-12M. These procedures will ,

prescribe the requirement for preparation, control, distribution and transmittal of all Q-related procedures, specifications, drawings and inspection records. ,

Y NC:4 CONFORMING ITEMS AND CORRECTIVE ACTION Nonconformances discovered during construction inspection activities are documented and controlled by Bechtel QC in accordance with PSP G-3.2 and MPQAD i

in accordance with MPQAD Procedurc F-2M. These procedures provide for the identification and documentation of the nonconforming item, identify the authority for and disposition of the nonconform3 ng condition, and provide for documenting the reinspection and closeout of the nonconformance.

4 j Within the Midland Project Quality Program, the identification of significant i

2 and reportable items is accomplished by Bechtel QC and MPQAD through the review of nonconformance reports, supplier surveillances and qualit i assurance 4

l audits. Corrective action for significant quality problems will ce controlled i

l by Bechtel PSP G-3.2 and MPQAD Procedure F-3M.

,' In the design phase. investigation or cause and action taken to reclude recurrance of desten deficiencies will be accomplished through E2P 4.65.

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.r QUALITY PI.AN FOR UNDERPINNING ACTIVITIES h?

- Design deficiencies include those items which are not identified in the course

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of design development and which ultimately require changes.

AUDITS Audits are performed by MPQAD to verify conformance of Q-list activities.

MPQAD Procedure F-1M includes provisions for the identification of deficiencies, the determination of corrective action, and the necessary follow up to verify that timely and effective action is taken.

t' TRAINING AND CERTIFICATION i

l All inspectors and quality auditors are trained and certified in accordance i

wich PSP G-8.1 or MPQAD Procedures B-2M and/or B-3M. Subcontractor field supervisory and engineering personnel are indoctrinated to the Midland Project i Quality Program. This included an introduction to the quality system, inspection techniques, nonconformance control, VRC activities, field and

, engineering design changes and site organizations and interfaces. The

-i indoctrination is completed prior to any Q-listed work proceeding. The

,( Subcontractor is required to implement training for the procedures covering i

.i li the Subcontractors Q-listed activities.

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