Text

Rev 1 to HVAC Recovery Plan. W/One Oversize Encl.Aperture Card Is Available in PDR
	ML20076D953
Person / Time
Site:	Clinton
Issue date:	05/03/1983
From:	; ILLINOIS POWER CO.
To:	;
Shared Package
ML20076D942	List: ML20076D944; ML20076D953;
References
	PROC-830503, NUDOCS 8305260253
	Download: ML20076D953 (58)
	v • d • e

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ILLINOIS POWER COMPANY RECOVERY PLAN HVAC Revision 1 May 3, 1983 REOCMENDED hh ' 2A 6.3 HVAC Recovery Plan Coordinator 4 -' k2 h /[eam Director ' kg3

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APP BY: ,

)/ / > JJ [)

ProjectManafer [

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'j IP Project Manager i

.f$%a b 5 1l9 3 BAManagerdandTS M Addnar deks 7IP -.

A0f dVice-President 0305260253 830519 -

IDR ADOCK 05000

HVAC RECOVERY PIAN Rev. 1 I Table of Contents II Introduction III Outline of Revisicms Page 1 Purpose - Scope Page 2 Plan Outline Pages 3-10 Plan Attachments:

1. HVAC Recovery Plan Matrix

2. IWAC Recovery Inval II Schedule SWA 14, 15 and 20

3. Detailed Verification Plan

4. HVAC Recovery Level III Schedule SWA 14, 15 and 20

5. Prerequisites for requesting lifting SNA 14,15 and 20 G

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Stop Work Action 14, covering all safety rela ^_ed INAC work was issued on June 23, 1982. '1he Stop Work Action was initiated l

because significant deficiencies were identified by the IP Verification Team and by Baldwin Associates Quality Assurance in the HVAC Quality Assurance Pqmu and in documentation of inspections.

4 Stop Work Action 15, for all attachments of non-safety hangers to seismic bs41 ding structures was issued on June 23, 1982.

'Ihis Stop Work Acticm was initiated because there were in-adequate quality assurance and quality ocntrol procedures for inspection and h=writation of this work.

Stop work 20, for all non-safety HVAC work in plant structures classified as seismic, Category I, was issued on Aug. 2, 1982.

Stop Work 20 was issued because there were inadequate controls for construction and inspection of non-safety, seismim1ly de-signed duct and hangers. '1he Stop Work was revised an October 25, 1982 to also include on-site fabrication and repair of non-safety, sei-ically designed duct work and wwsits.

II

CUIIJNE T REVISICNS 1

'IO DE HVAC RDCCNEEE PIAN Revision 1 of the HVAC Recovery Plan is issued to update the plan that was subnitted to the NaC on SepLieber 23, 1982. 'Ibe signi-ficant changes to that plan are identified below:

1. A purpose and scope section has been aN.

2. '1he implementation phase of the HVAC Recovery Plan (orginally Phase II) is now divided into three separate phases (II, III and IV) to provide a more logical sequence of operations.

3. Attachment 3, the Detailed Verificaticn Plan, has been rewritten to provide for changes in responsi-bilities for initial inspecticms, reinspections, and verifications of HVAC work. It also provides for the application of the IPC Overinspection Plan to HVAC work.

4. Logic diagrams defining the actions required for lifting the three respective stop Works (14,15 and 20) have been deleted. All actions for re-leasing the Stop Work Actions are now identified on the HVAC Rewvery Plan Schedules, Attachments 2 and 4 and on Attachment 5, Prerequisites for lift-ing SNA 14, 15 and 20.

! 5. An itemized list of specific actions required prior to lifting the Stop Work Actions has been developed and is included as Attachment 5.

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PURPOSE

'Ihe purpose of the INAC Recovery Plan is to investigate, evaluate and resolve identified problens which caused the Stop Work Actims 14, 15 and 20 to be issued and to establish methods and syst e s to assure that all previously installed INAC work conforms to all design requirenants.

'Ihe Plan provides a phased systen of investigaticn, definiticn of corrective actions, dew 1&t of schedules, and inplementation of plans in a sequenced order leading to a full release of the Stop Work Actions.

SCOPE

'Ihe scope of the INAC Recovery Plan includes the site receipt, in-stallaticm, inspection and turnover of all Safety Related and seis-mically designed INAC systans and ccznpanents. 'Ihe scope also in-cludes material procurenent, fabrication and shipnent of INAC material, prefabricated ccmponents, and sub-tier vendor supplied itens.

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HVAC RECOVEIE PIAN outline Phase I: Investigaticm, evaluatim and Caractive Action Stop Work Actions 14,15, and 20.

A. Review Identified Problems.

B. Develop Cuu. active Action Plans and Schedules.

C. Develop plans to assure previously acw piimi work meets regulatory requirments.

Phase II: Inplementation of Plans to release Stop Work Actions 14, 15 and 20.

A. Develop schedules for inpleenting plans.

B. Review and approve responses to corrective action plans.

C. S & L to issue new hanger drawings.

Phase III: Partial release Stop Work Actions for inspection A. Release Stop Works for Zack inspection.

B. Release for BA Verification Inspections.

C. Perform BAQA and IPQA audits and surveillances.

Phase IV: Increnental release of Stop Work Actions l A. Release Stop Works for rework and/or new work.

! B. Perform BAQA and IPQA Audits and Surveillances Phase V: Overview of HVAC A. Identify and tabulate problems identified subsequent

to Stop Work Actions.

B. Review / develop corrective action plans.

C. Monitor and manage progress of resolutions.

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Phase I A. The problens and ocncerns which were identified in various special investigations, audits and reports were reviewed.

The information reviewed included:

- IPC Verification Taarn Audit Report

- BAQA W a1 Audit of Zack

- IPC Quality Assurance Survaillmx:e R=ru.i s

- IPC 10CFR 50.55(e) Reports

- Zack Co. Potential 10FCR Part 21 The respective problens and concerns were tabulated on the HVAC Recovery Matrix, included as Attactinent1.

B. The corrective action for each problen and area of con-cern was determined and is identified on the HVAC Matrix.

The status of the su.roctive actions was periodically up-dated on the Matrix and will be maintained until all items are fully closed.

A leve1II HVAC Recovery Sctwble has been prepared showing principle activities leading to a release of the Stop Work Actions for inspection and new work and is included as At-tachment 2.

C. Illinois Power, Baldwin Associates, and The Zack Co.

I have developed plans to assure that all work installed prior to the Stop Work will meet all specification and regulatory requirenents. This plan requires The Zack Co.

to review existing inspection h m tation, to review the qualifications of past inspectors and to identify work which will require reinspection. Additionally, following the reinspection of existing work by Zack, both doctanenta-ticri and work will be subject to verification by B.A.

Quality Assurance, and overinspection by I.P.C. The B.A.

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Phase I - C. (Cont.)

Verification and I.P.C. Overinspection will be perfUs=:d in accordance with the approved IPC Overinspecticn Plan and associated approved pWires and checklists.

'Ihe I.P.C. Overinspecticn Plan, phases II ard III will be nodified in their application to HVAC work by in-iHally expanding the amount of verificaticn by B.A.

Q.A. to 100% of ccmpleted work and to a mininum of 20% overinspection by IPQA. 'Ihese amounts of verifica-ticn and overinspection will continue until a sufficient lew.1 of confidence is gained in the acceptability of the work to allow a sanpling plan to be implemented for BA Verification and IPC Overinspection.

Attactnent 3 provides additional details for the HVAC verification and overinspection of h = ntation and ,

ccupleted work.

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I Phase II A. A conprehensive Imvel III Schedule and Iogic Diamun has been developed to show interactions, responsibi-lities, g =to pisites and restraints of activities leading to release of Stop Nbrk Actions 14, 15 and

20. Se latest issue of the Invel III HVAC Recovery ;

Schedule is provided as Attachment 4. mis schedule has been highlighted to show current progress for each activity.

Fran the typical logic diagrams shown in the boxed in areas of the Iavel III Sctwhile, detailed, Invel IV Schedules will be drawn for reinspecticm of respiive areas / elevations. %ese se' edules will be used to iden-tify reinspection scope, manpower requirenents, and actwhiled durations.

B. S e Zack Quality Assurance and Construction FrWaam was ccznpletely revised and resubnitted to Baldwin Associates and Sargent and Lundy for review and approval. A Clinton,

site unique Quality Assurance Manual has been developed.

I he Manual is tailored to the Clintcm HVAC project speci-l ficaticm and site Zack ocmstruction and quality practices.

All Zack Field Construction Procedures (FCP) and Field Quality Control Procedures (EQCP) have been rewritten to address the concerns and problens raised prior to the Stop Work Actions. Additicmal sucodures and de-partmental instructions have also been written to better define activities affecting quality.

BA Quality Assurance has reviewed and has ccmditionally approved the revised Zack Quality Assurance Manual.

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Phase II - B. (Cont.)

Final approval will be granted upon approval of all inplementing edures referenced therein. IP Quality Assurance has also reviewed the Zack Quality Assurance Manual. B.A. Quality Assurance, and Sargent and Lundy, as applicable, have reviewed and will approve all Zack construction and quality pi d ares and have reviewed Zack Departmental Instructions.

C. Sargent and Lundy has been directed by Illinois Power to issue indivirb1 IWAC duct hanger drawings, in place of the previous hanger schedules and special details.

All inspections, reinspections and future work will utilize these new hanger drawings. Schedules have been prepared showing priorities for hanger drawing releases frun Sargent and Lundy.

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Phase III A. When the prerequisites listed in Attachment 5 are emplete, a request for an exception to the Stop Work will be issued for i W.en of specific areas / elevations. Zack QC will reinspect specific Safety Related work which has been iden-tified frtzn their review of hmtation. In addition, all Non-Safety Seismic Work will be inirgti:d. Invel IV Inspec-tien Schedules will be used to identify and monitor the in-spection/reinspecticn activities.

B. Following approval of the BA and IPC Verification /Over-inspection prMires and checklists, and acceptance of the work by Zack and BA Quality Assurance; the work will be subjected to BA Verification inspections and IPC Over-inspection.

C. During this phase of the Plan, BAQA and IPQA will audit and perform surveillances of the Zack Reinspection work.

7

Phase IV A. Following a review of the reinspecticn results by BAQA, the BA HVAC Manager and IP, and with NRC concurrence, a determination will be made to allow Zack to proceed with rework (if required) or initiation of new work, or both, cm an area / elevation. 'Ihe review will determine the scope of rework in a given area, the manpower required to resolve the deficiencies identified, and will evaluate the types of deficiencies as they would relate to the Zack program for new work. Zack has prepared procedures and established a work control function. 'Ihe purpose of the functicn is to assure timely inspection, by QC, of coupleted work and to limit issuance of rework or new work packages to a level ccnsistent with QC resources.

B. During the rework /new work phase of eaph area, BAQA and IPQA will perform audits and surveillances of the im-planentation of the revised Zack QA program and procedures.

BAQA has prepared Audit and Surveillance Plans for the re-inspection and rework phases of the HVAC Recovery Plan.

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Phase V A. During the inplanentation of Phases I and II of the HVAC Recovery Plan other sources of information be-came available for further review. Wese sources included:

1. A potential 10 T R 21 report on shop welder certification filed by me Zack Ccupany.

2. GAP allegations identified at Canonwealth Edison's LaSalle Station.

3. Zack Corrective Action Request No. 30 on Welding Procedures used for Clinton and Midland.

4. %e INPO Construction Audit of IPC and BA

.st Clinton.

5. Stone and Webster Engineering Evaluation of the Clinton Project.

6. NRC Region III and IV inspections performed at he Zack Ccm1pany. Reports 99900785/82-01, 50-373/82-51 (DETP) and 50-374/02-18 (DETP) .

7. Zack responses to NBC investigations and non-ccnformances in Report 99900785/82-01.

Each of these sources were reviewed to determine if ad-ditional corrective action plans were required.

Se ococerns not previously identified on the HVAC Matrix l

have been aMui along with the corrective actions being l

I taken or planned.

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Phase V - (Cont.)

B. To ccrnpletely resolve the technical concerns identified in the HVAC Matrix, Sargent and Lundy is developing a Technical Evaluation Pr%sma of Zack installed HVAC Systans. Areas to be addressed in the Technical Evalua-tien Prwimu include:

. Material certificaticn

. Disposition of Zack Non conformance Reports Shop and Field

. Weld Procedure qualification

. Welder Certification Shop and Field

. Installed location of Duct, Accessories, Equipment

'1his program is scheduled for full implementation ap-proximately June 1st and will conclude approximately Sw Lcuiser 1st.

C. During the course of all phases of the HVAC Recovery Plan, corrective acticn plans and schedules will be monitored and statused. Administrative and Managanent controls will

! be utilized to accomplish timely and adequate resolution of problans and concerns. Continual evaluations of man-power resources will be made and incorporated onto sched-ules to support all phases of the HVAC Recovery Plan.

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Vr-62 Vr-63 C Revise prembres. C in prucess. Procabres wete \ ll/2/Hk Vr-96 sadnitted.

Vr-97 D Train personnel to new pro- Heing reviewixl and cumamttd un Vr-103 cedures. by DA, IP and S&l.. Netings to A2/14/81 VF-104 discuss these cximants are sctad-VF-105 uled for week of 2/14.

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IM FD ' STA.'nlS OllE!!S FD0llE DESCRllTlai DERECTIVE ACrial g g e,,,,,

g g,1 g.gy, lal isA 6 IP UA to ineiease la) Ilm lasjan increasal surwill.mee g 11/82 10 vr-52 1) 'there is not suf ficient of Zack in tkw., 1982.

VF-100 surveillance of Zack's surveillance of lutthare larthare installation. installation.

Ib) MDA to develop surveillance, Ib) BA sulznittal: 410/21/U. Sugersuksi ty 1/z's atdit and insgoction goint BA0A Audit Plan-Reinsp.

11AQA Surveillance Plan-Huinsp. N10/21/8; Sadmittal schedules.

BAQA Instoction Point ducklist Al/4/83 for shop-shi@ing releases.

BAQA Site Surveillance Audit schatulo ard surveillance check A3/25/83

2) 'Ihere is not enough plan sutmitted BAQA nanpmer to devote 11A increased to 3 full time frtzn A10/1/82 BA OA to increase maniower 21 j to Zack surveillance. 2)

I full tine Vendor Surveillance I

for vendor surveillance .

Dujineers.

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FD0 llc DESOtIPfl01 00RRFLTIVE ALTIG3 c3g, 1

MTE 14 81-04 Possible inconsistercies Investigation arul reporting Interim Retorts 50.55te' in material certificati<ms assigrux! to IP P.M. - orpliarce Ll4-81 (11-041-L, U-0325 % 11/4/81 for Zack supplial dict and (R. Folck) Ll4-82 (02-03)-L, U-0413 N 2/3/82 hangers. 1.14-82 105-031-L, U-0474 4 5/3/82 U-0524 \ 8/3/82 Notification: U-10007 \ 11/3/82 Irl4 (10-02) U-10026 % 2/3/83 53-identifial discrepancies Zack PCR's sulsnittul 32 use as is NCR's have been txrituj evaluated by accepted by S&L IP/tiA arul Shl.

BA pretared NCR's to cover the Zack 4 9/10/8; tCR's 8231 8232 8212 8444 8548 8668 119 las pen fosiitd surveillances on A 8/82 akspiacies of actions taken by Zack.

tieirvj trackal by lit Some deficiencies were found and re-ported. Zack to respnl by 9/15/82. Corrective Action (see R. l'olck - Resort Y-12169 t*rogram Refer to 10tTR 50.55tel 81-04 tCR status tbtrix VT - VERIFICATla; M - UE 1iZi EQ - EA (B /IDIT gJpr. . gyg= 177)g im - 19 M carwryit aryv

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16 NIC 1) 38 safety relatal turqers itun on IFulHS 30-16-05 on 800 control were in- IIVAC turners with similar stalled in disagrounent attaclununt details was con- 017-80 (09-19) with NCR 3030 disposition ducted 037-80 (08-281-0, Ib) CAR 356 was written and a lb) Im exteriul audit E-265A NIC letter dated 8/28/80 document control procalure Doctments and tracks follow-up Resident NIC in-was changed and implanented sprtor iruficatul he will tot close this itun until resolution of Zack O ulity o ncer ns (SW) 3014 6 1015) 80-16-06 2) Zack inc.orrectly verifiec 2a) Ikxioctrination of all Zack 2) Corrective action has been cun- 2) lesident NIC in-l OC Personnel on inspection pleted. surtor irmlicates the faulty inspection of S.R. IfvAC hangers on 800 criteria le will tot close Control this itun until 2b) Design claryes are formully resolution of Z.m.i Insprtion records of transnitted to the ZAck OC Otulity concerns to te placed on readisq board ISHL) 3014 6 1015) no I pletal work installations

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STA M gy y , UIIEE FDeltG DESCRIIT10H CORRECTIVE N.TICH 17 Ll6-81 Inorger fan casings on g Investsgation anil resgawise ly a,litort I.14-81, 10-22 Y7146 il0/22/81 10CFR21 Duf falo Forge Fans. Mastd N3ED - J. D. Ccier arul l'. E. Su[plemsit Ll4-81-12-08 Y-7308 not athspately omtain Wallerg and thif falo Ibrge. Final Iq ort 1606-i., U-0479 missiles.

6/26/81 il RLvork of fans to le dme at in DA to g=>rfona wrk. II W lus a notifi I2/1/82 Clinton site per Duf falo Dyi- cation goint plan in ef fect for sur-neering drawirns veillarre 8/25/82 Pending BA Construction re-work Kiterial Receipt die 12/1/82 il2/1/82 Waiting work assigtiment Ilm Ntitificalitsi Estimsted cmpletion Kiy,1983 luint (Y-120901 I

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R ECOVERY PL AN(S)- H V A C IG.V O 4 2D- 83

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FD0ItC DESOlllTim 00RRFLTIVE ACrim N F 1..

I DNIE 18 M1A-t-83 1. Zack Organization I al Fill Project Munjer Va- I al Vacarxy. Filled A2/l/85 Deficiencies cancy.

I b) Fill W nuwjer Vacancy I b) Vacancy Filled 84/11/83 1 c) llire new Assistant Project nuwjer I cl Vacarxy. Filled \3/24/83 (Weldiry & Sprial Projects)

2. Crumunication lines be- 2. Establish Mainistrative 2. letter 16-l!-4-83 11/25/83 twen BA and Zack inade- Directives to use llA IfVAC Ictter DEK-il-90-83 43/24/83 quately defined. as contract cxmmu11 cation interface.

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g, g, IM1E 19 M M-1-83 1. Im organization 1. Fill tw IIVN' nirajer vacancy 1. Vacancy fillet by D. E. Konxman Al/17/U) vacancies

2. Inadequate contract 2. Develop Sulxxmtract Project 2. Im narajosnent and tacturtantal Atkninistraticn Pro- Managtmmt Gaides arul Pro- Guides pregural codures cubires - Subcontract Change Control Sub-402 A4/20/83

- Subcontract Close-out Sub-401 A4/22/83

- Reintmarsable Criteria A4/19/83

- Stixontract Ackninistration E6/17/83 i

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g IKIE 23 IIC-C 1. Inproperly certifial 1 a) Zack review fabrication I a) Zack prepared NPR 421 ./10/22/ 1 al la to p>rt1 mire tam docunentation and note 82 82-069 Helders in Cicero sliop discretencies Irc-c 1 b) BAQA performxi evaluation docu-rnented on restonse to ARR 7CO, C5/1/83 82-070 781 1 c) S&L will include in t&linical E8/83 '

evaluation plan Zack Nuclear Safety Related 2 al Zack sugplia! Clinton Corrective A4/1/83 CAR-30 2. Incorrect welding pro- 2 a) Work in shop nalted cedure specificatim Action plan via letter fMEIA-Il88 qualification 2 b) Zack te validate old pro- 2 b) Program plan sutrnitted A4/20/8:

cedures and provide plan for resolving to la 2 c) S6L to perfonn technical evaluation

3. Zack to use only qualifial 3 a) liioton removed frun AVI. Al2/14/8 i

3. Unqualified testuvj laboratory suppliers for testiivj ser- Pittsburgh testing to be usal itm) vices. tensile testing i

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R ECOVERY PL AN(S)- H V A C REV o 4-20-83 I" FDOING DESLRIPTIQ1 CORRECTIVE ACTIGI STA M UMNIS 24 tHC 1. Inadequate corrective 1 a) ihmelop arul impImust I a) DA revisal 110A 162 %3/22/83 50-373/ action syston at Ceco, improvtxl corrective -

82-51 tasalle action program 4 1 b) Zack OAM and procedures t w ?-8 8 8 1 b) Zack to inclisle corrective 11/10/83 action trending into site noneformance arxl OAI-10 procedure OA surveillance irxlicate trending to be done on a l

nonthly tasis by Zack in Cicero l

I c) Cicero OAM to be revised arul ;5/20/83 resutmitted IFC-C 2. Zack non-confornmces 2 al Review all Cicero Shop 2 al See 50.55(e) 81-04 064 inporperly closed closed non-conformances relating to Futerial '

Certifications armi std)- ,

mit to S&b via BA PCR's 2 b) Review all Cicero SIrp PCR's 2 b) S&I. to include in Teclinical '8/15/83 relating to fabrication arul Cvaluation Vesslor suppliol ituns 2 c) Review all Zack site 2 c) S&L to include in 1tdinical 2/83 generated ICR's for INaluation wloch no BA ICR was written 2 d) Zak revised twt-8 rum- 2 d) EE T-8 accepted (3/30/81 conformmces 2 el Zack to train Cicero ger- 2 el Zack Ast. 041 sonnel on IAN Proculure Ictter Cm mitment to training A3/9/83 (R. J. Basiaga to C. Roshy)

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g gggg ID.1 25 NIC Inadequate Weld 1. Revise arul resdsnit 1. Sulsnitted to DA arul S&I, All-5-62 Aggsrtwal lasations layjian IV Filler Metal Control Shop Prootxhnre int-6 Slug, OA Munkal Itegurt it view azul ogg,reeval 89900785/ lb Shop work halted Ier Zack CAlt-30 Al2-6-82 32-01 Ic Shop OA Hanual returrux! A4-It-83 Cassiitional Accept

2. s&L to incitale a review for 2. S&1. Technical Evaluation A4-19-83 technical adequacy of welds Program description sutsnitted to perforined under conditions Irc n>ted.

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ATIACHMENT 3 Page 1 DEIAILED VERIFICATICN PIAN SITE INSIALIATICE NORK 1.0 SAFEIY RELATED INSPECTICN DOCUMENIATION 1.1 Zack Quality has assa bled and reviewed inspection h=ntation for all cxanpleted and in-process work.
Inspection h=mtation found to be questionable or inccanplete has been identified and assigned to the reinspection work scope.
1.2 '1he hwntation for the VC systen previously sub-mitted to BA has been returned to Zack Quality As-surance for review. Questionable or inconplete h m ntation will be identified and reinspections performed as necessary.
1.3 Upon completicn of all work, rework, and inspections for an HVAC systen or (subsystan),h=mtaticn pack-ages for that scope of work will be assembled and the h _w ntation transferred to Baldwin Associates.
Zack is developing procedures which will provide specific instructicos for the assenbly and contents of documentation turnover packages.
1.4 Baldwin Associates Quality Assurance will review and transmit to the B.A. Records Vault all acceptable HVAC hwntation packages in accordance with BACE Instruc-tions and Procedures.
1.5 All HVAC Quality documentation which has been placed in the BA Records Center Vault will be reviewed in accord-ance with the IPC Records Verification Pr@ m u.
ATI%CHMENT 3 Page 2 DETIAILED VERIFICATIN PIAN SITE INSIALIATIN WORK 2.0 VERIFICATIN OF INSTAILED AND ACCEPTED SAFETY REIATED NORK 2.1 Following transfer of systans (sub-systems, wurni:iilts) to BA; all Safety related, accessible HVAC work will be verified by the BAQA Verification Department, in ac-cordance with their approved g --dwes and checklists.
l All non-conforming conditions will be evaluated for im-pact on inaccessible areas,in accordance with the Over-inspection /Verificaticn pw=u. (see par. 5.0).
2.2 IPC Quality Assurance will perform surveillance of the BA field verification work.
! 2.3 Following acceptance of the work by the BA Verification Department, the IPC OvannanatM.icn Department will select a mininum of a 20% sample of accepted work for additional overinspection and acceptance. (see par. 5.0).
, 3.0 Cm PLETED NON-SAFETY SEISMIC NORK 3.1 Zack will assemble new inspection packages for all con-pleted non-safety seismic work. '1hese packages will con-tain the new hanger drawings, inspection checklists, forms, etc.
3.2 Zack QC inspectors will inspect all accessible cm pleted seismic work using new, approved inspection checklists, and procedures. All deviations will be identified and -
subnitted for review by BA and IPC. All non-conforming conditions will be evaluated for impact on inaccessible areas.
3.3 BAQA will perform audits and surveillance of Zack's in-spection effort.
3.4 IPQA will perform surveillances of Zack's inspection work.
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- ATIACHMENT 3 Page 3 DEDLILED Eu.nCATIN PLAN SI'IE INSTALIATICN WORK 3.0 CIEPLETED NON SAFETY SEISMIC WORK (Cont.)
3.5 After Zack QC ac=vi.zure of the ocmpleted ncm-safety seismic work, cmpleted h==ntation packages will be forwarded to BAQA. (See par. 1.3, 1.4, 1.5) .
3.6 Fbilowing a review and acceptance by BAQA, all work will be subjected to BA Field Verification. All ac-cessible Non-Safety Seismic work will be subjected to 100% inspection by the BAQA Verification Depart-ment. (see par. 5.0).
4.0 IN-PROCESS SAFEIY AND SEISMIC WORK r
4.1 Zack will assenble new work control packages for all '
l in-process work. 'Ibese packages will contain the new hanger drawings, and new inspection checklists, fonns, etc.
4.2 Zack QC inspectors will verify, by inspection, that partially cm pleted work conforms to all specification and drawing requirements. All deviations will be identi-fled and subnitted for review by BA and IPC.
4.3 After disposition of the deviations, the Stop Work Action (s) will be released for rework or repair.
4.4 After all deviations have been dispositioned and with NBC ccocurrence, the Stop Work Action (s) will be re-leased for otmpletion of in-process work and initia-tien of new work.
5.0 OVERINSPTTICN - VERIFICATION 5.1 'Ihe IPC Overinspection Plan, Revisicn 1, phases II and III are being modified in their applicaticm to HVAC work j by initially expanding the anount of verification by BAQA to 100% of empleted work and to a mininum of 20%
overinspecticm by IPQA.
ATIACHMarr 3 Page 4 DEIAILED VERIFICATICN PIAN SITE INSTALIATICN NORK 5.0 OVERINSPECTICN - VERIFICATION 5.1 (Ccmt.)
'Ihese amounts of verificaticm and overinspection will continue until a sufficient level of confidence is gained in the acceptability of the Zack program to allow a sampling plan to be implemented.
l l
1
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s ATDCHMENr 3 Page 5 DE%ILED VERIFICATICN PIAN CICERO SHOP FABRICATED WORK 6.0 SAFETY REIATED AND SEISMIC WORK 6.1 All Safety Related and Seismic work, delivered but not installe.1, will be reinspected by Zack Quality control prior to installation.
6.2 Previously installed Safety Related and Seismic work will be reinspected by Zack Quality control in ac-cordance with an approved sanpling plan, concurrent with the inspection / reinspection effort identified in paragraphs 3.0 and 4.0.
6.3 Shop Fabrication, and inspection documentation will be reviewed by Zack Quality Assurance prior to in-corporation into Turnover Packages. Any discrepancies will be identified in accordance with the Zack Docu-mentation Turnover Fn:cedure.
6.4 BAQA has initiated a 100% shipping release hold point at the Cicero Fabrication Facility. All hmmmtation is being reviewed and accepts:d prior to use at the Clintan Site. All documentaticm for material previously shipped is being reviewed.
6.5 The BA Verification of installed work in paragraphs 2.0 and 3.6 will irclude shop fabricated work.
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- ATDCINENT 5 i
i Em.rw.QiJISITES FOR LIFFING ShR 14,15, and 20 A. For Inspections
~~1. Approved Zack Qaulity Assurance Manual.~~
~~! 2. Approved Zack Quality PrMires (FUP's) .~~
~~3. Approved Zack Construction PrMires (FCP's)~~
~~! 4. Approved Zack Trainirq Faws-u & All Training Cmpleted.~~
~~5. Definition of scope of empleted work.~~
~~6. Released "For Construction" Sargent & Lundy indivi-dual hanger drawings.~~
~~7. Baldwin Associates QA Inspection Point Faws-u and Audit /Suruillance Schmails.~~
~~8. Disposition of all material certification NCR's on IPC 50.55(e) 81-04.~~
~~9. Identification of all actions required to address Zack CAR's and closure of those which can be closed j~~
without 42uspection.
B. For Rework /New Work In addition to 1 through 9 above:
~~1. Identification and disposition of all non-conforming conditions identified during the reinspection phase.~~
~~2. Evaluation of types of conditions identified and in-corporation of manns to prevent reoccurrence into the Zack program.~~
~~3. Approved Zack welding and Welding Procedure Qualifi-catica Plan and Procedures.~~
~~4. Walder Certification and Training.~~
~~5. NBC Concurrence.~~
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