g._., . . ~ . . _ _ _ . . . __ _ . _ _ _ _ . _ _ . ..--

.

O

a.(_'',

LL 4;

:\/: '.g;.

. . ..

eten.:b' "J P, .

- Rs2|| .; y +.y.J

y1B,

., $ n.asu' | k.,[

~ i, E.Ti...c<

'

e .s4

:A' V.sfJ3$4

|

|

1

o&>JQ-, , m

80021107h,b

. . - . - - . . .. .. .... .-- . . ~ . - . -

.

fD-B_

APPENDIX 1B

QUALITY ASSURANCE PROGRAM

TABLE OF CONTENTS

Section g1 DAVIS-BESSE NUCLEAR POWER STATION-QUALITY ASSURANCE IB-1

1.1 GENERAL 1B-1

1.2 DEFINITIONS 1B-2.

1.3 TOLEDO EDISON QUALITY ASSURANCE ORGANIZATION 1B-3

1.3.1 GENERAL 1B-3

1.3.2 QUALITY ASSURANCE ENGINEER - TOLEDO EDISON IB-3

1.3.3 ENGINEERING STAFF - TOLEDO EDISON 13-4

1.3.4 STATION OPERATING STAFF - TOLEDO EDISON 1B-4

2 BECHTEL 1B-6 '

2.1 GENERAL 1B-6I

2.2 ORGANIZATION 1B-6'

2.2.1 GENERAL 1B-6

2.2.1.1 Design Phase 1B-6

2.2.1.2 Procurement Phase 1B-6

2.2.1.3 Construction Phase IB-7

2.3 PROGRAM 1B-7

l2.3.1 GENERAL 1B-7|

.

2.3.2 ENGINEERING 1B-8

2.3.3 PROCUREMENT 1B-9

2.3.4 CONSTRUCTION 1B-10 3'

2.4 DESIGN CONTROL O'M9 18-1'

1B-1 Amendment No. 3- _ _ - . _ _ _ . _ _ __ _ , . _ .

-

D-B ']'

Section Page,1

2.5 PROCUREMENT DOCUMENT CONTROL 1B-12

3 2.6 INSTRUCTIONS, PROCEDURES AND DRAWINGS. 1B-13/

] 2.7 DOCUMENT CONTROL 1B-13

2.8 CONTROL OF PURCHASED MATERIAL, EQUIPMENT AND SERVICES 1B-13

2.9 IDENTIFICATION AND CONTROL OF MATERIALS, PARTS AND COMPONENTS 1B-14

3 2.10 CONTROL OF SPECIAL PROCESSES 1B-15

2.11 INSPECTION 1B-15,

3| 2.12 TEST CONTROL 1B-16

2.13 CALIBRATION OF MEASUREMENT AND "?ST EQUIPMENT 1B-16,

3 2.14 HANDLING, STORACE, SHIPPING AND PRESERVATION 1B-17

2.15 INSPECTION, TESTS AND OPERATING STATUS 1B-17

2.16 NON-CONFORMING MATERIAL, PARTS OR COMPONENTS 13-17 )

'

2.17 CORRECTIVE ACTION 1B-183

2.18 QUALITY ASSURANCE RECORDS 1B-18

2.19 AUDITS IB-18

3 BABCOCK & WILCOX 1B-20.

3.1 POLICY 1B-20

3.2 PROGRAM ELEMENTS 1B-20,

3.3 ORGANIZATION 1B-20,

| 3 3.4 QUALITY ASSURANCE PROGRAM 1B-201

3.4.1 OBJECTIVE - QA PROGRAM 1B-20

3.4.2 QUALITY LEVELS 1B-21

i 3.4.2.1 Quality Control 1B-21|'

3.4.2.2 Quality Assurance 1B-21i

|- 3.4.2.3 Planning 1B-21 v'

0220f . ,

|5 .

|| Amendment No. 3 1B-ii'

.. . - .

. _ _ . _ . . . . _ . .

!D-B

!,,

Section.P_ age,

3.4.2.4 Procurement 1B-21

3.4.2.4.1 Equipment Manufactured by Babcock & Wilcox 1B-21

3.4.2.4.2 Equipment Purchased by Babcock & Wilcox 1B-21

3.4.2.5 Erection 1B-22

3.4.2.6 Plant Test Program 1B-22

3.5 DESIGN CONTROL 1B-22

3.6 PROCUREMENT DOCUMENT CONTROL 1B-22

3.7 _ INSTRUCTIONS PROCEDURES & DRAWINGS 1B-22

3.8 DOCUMENT CONTROL 1B-23

3.9 CONTROL OF 1URCHASED MATERIAL, EQUIPMENT, AND SERVICES 1B-23 3

3.10 IDENTIFICATION AND CONTROL OF MATERIALS, PARTS AND COMPONENTS 1B-23

3.11 CONTROL OF SPECIAL PROCESSES 1B-23

3.12 INSPECTION 1B-23

3.13 TEST CONTROL 1B-24

3.14 CALIBRATION OF MEASUREMENT AND TEST EQUIPMENT 1B-24

3.15 HANDLING, STORAGE, SLIPPING, AND PRESERVATION 1B-24

3.16 INSPECTION, TEST, AND OPERATING STATUS 1B- 24

3.17 NON-CONFORMING MATERIAL, PARTS OR COMPONENTS 1B-24

3.18 CORRECTIVE ACTION 1B-25

3,19 QUALITY ASSURANCE RECORDS 1B-25

3.20 AUDITS 1B-25

.

.

0221-,

IB-iii Amendment No. 3

_ . . - - _ _._

,

.

o

D-B

LIST OF FIGURES

(AtRearofSection)

Figure No. Title

n-1 Quality Assurance Functional Organizational Chart

1B-2 Bechtel D-B Organization Chart

1B-3 Babcock & Wilcox - NPGD Organization Chart

.

:

.

O

l

.

0222~-

(

)/

'I

f

It hendment No. 2 1B~iv

. . _ _ _ _ _ . _ _ . ._ . _ . - - , _ _ _ _ _ __ __ _ .__. . . - - __

D-B

.si APPENDIX 1B

QUALITY ASSURANCE PROGRAM

' 1 DAVIS-BESSE NUCLEAR POWER STATION - QUALITY ASSURANCE

1.1 GENERAL

A Quality Assurance Program vill be in effect for the design, procurement,fabrication, construction, preoperational testing and start-up of certainidentified components and systems for the Davis-Besse Nuclear Power Station.The program entails quality assurance throughout those phases of the projectutilizing AEC Criteria and guidelines concerning the following:

;

_Organization

,

t Quality Assurance Program -

j Design controlProcurement document controlInstructions, procedures and drawingsDocument controlControl of purchased material, equipment and servicesIdentification and control of materials, parts and comperentsControl of special processesInspectionTest controlCalibration of measurement and test equipmentHandling, storage, shipping and preservationInspection, test and operating statusNonconforming material, parts, or componentsCorrective actionQuality assurance recordsAudits

,

Ultimate responsibility for the Quality Assurance Program rests with TheToledo Edison Company.

Implementation of the Quality Assurance Program vill be the day to dayresponsibility of : Bechtel, acting as agent for Toledo Edison; and theBabcock & Wilcox Ccmpany Nuclear Power Generation Department (NPGD) assupplier for the nuclear system. Quality control is the respo3sibility ofthe organization performing the actual work.

.

Specific Toledo Edison responsibility for auditing the Quality AssuranceProgram rests with their Quality Assurance Engineer, who reports directlyto the Toledo Edisen Power Group Vice President. *

The Quality Assurance Functional Organizational Chart, Fig.1B-1, . indicateshow the Quality Assurance Program relates to the Davis-Besse Project Organ-ization. Figure 13-2 depicts the organization of Bechtel, and Figure 13-3depicts the organization of B&W - NPGD, the seller of the nuclear steam -| 7,

,

L system.

: 022a1B-1 Amendment No.7

D-B

'The Toledo Edison quality assurance organization is described in Section1.3. Bechtel quality assurance implementation is outlined in Section 2 andthe BW NPGD quality assurance is discussed in Section 3.

1.2 DEFINITIONS

AEC Criteria: " Quality Assurance Criteria for Nuclear Power Plants"Appendix B (Proposed) 10 CFR 50, published on April 17, 1969

Construction Manacement is Bechtel, acting as Toledo Edison's agent.Bechtel's Construction Manager vill ad=inister all contracts for constructionand related work performed by Contractors. Bechtel vill conduct inspections

7 surveillance of Contractor's work and vill furnish assistance to ToledoEdison in verifying the fulfillment of all contracts.

Contractor is an organization which has a contract with Toledo Edison foron-site construction.

Critical Items are those structures, units and systems that require a degreeof formal docunentation and control over and above that applied in thecourse of nor=al engineering, procurement, construction, preoperationaltesting and start-up. As a minimu=, critical items include structures andsystems required to maintain the reactor primary system pressure boundary,provide containment and engineered safety features.

Desien Control is the process used to verify that the design drawings and ,

specifications, including fabrication and inspection procedures for both I

shop and field, meet the project requirements.

Desien Control Check List identifies the items requiring review by theBechtel Chief Engineers. This list vill generally include:

Project Design Criteria Manual for critical structuresa.and systems.

b. Q-List..

Piping and Instrumentation Diagrams for Q-List systems.c.

d .' Major drawings for Q-List structures and systems.

Procurement specifications and inspection procedures fore.Q-List items.

f. Field construction and inspection procedures for Q-List items.

Q-List is used to describe a master controlling document, and file index,prepared by Bechtel Engineering to identify all structures and systemsassociated with the reactor primary coolant boundary, en6-ineered safetyfeatures, emergency cooling systems, reactor containment and containmentcooling systems. Generally, the first Q-List issue identifies only the

As themajor critical structures, sub-structures, systems and sub-systems.design develops, individual units and components of each structure are added )-

)*

,

1B-2Amendment No. 7 s

0224

D-B

>

and appropriately indexed.

Quality Assurance (QA) is the formal program providing planned surveillanceand the documentation system necessary to provide Toledo Edison withassurance that steps associated with design, procurement , construction,preoperational testing and start-up of critical items or systems have beencarried out with the required level of quality control to meet the designintent and AEC Criteria.

Quality Centrol (QC) is the process used during design, procurement andconstruction, to assure that design control, fabrication and construction,comply with drawings and specificatiens.

Seller is the party or parties accepting a purchase order from the buyersfor the work specified. 7

1.3 TOLEDO EDISON QUALITY ASSURANCE ORGANIZATION

1.3.1 GEUERAL

Within The Toledo Edison Co=pany there has been established a qualityassurance organization to ensure that those systems and structures affectingthe public health and safety are specified, fabricated, shipped, stored, in-stalled, inspected, tested and started in accordance with sound engineeringprinciples incluaing applicable codes, specifications and procedures. TheToledo Edison Quality Assurance Program is implemented in accordance withthe Toledo Edison Nuclear Quality Assurance Manual, prepared by ToledoEdison Quality Assurance Engineer (QAE) and intended to comply with AECCriteria.

The QAE has t : necessary personnel reporting to him to implement theprogram. In addition, he can draw support as required, from any of Bechtel'sstaff of technical specialists. The Toledo Edison QA personnel do notrelieve Bechtel of the responsibility for day to day job progress andquality but vill advise the Eechtel Construction Manager of any non-con-formance.

1.3.2 QUALITY ASSURANCE ENGINEER - TOLEDO EDISON

The Toledo 291 son QAE vill monitor and audit all phases of the program. The

duties of the QAE are as follows:#

Review and acceptance of QC/QA programs for compliancea.vith the AEC Criteria,

b. Review, accept, monitor and audit QC/QA procedures.4

c. Monitor the QC/QA activities of Toledo Edison personnelcduring design, procurement, construction, pre-operationaltesting and start-up phases of the p-oject for conformanceto established procedures. |

_d. Provide monitoring and auditing of Bechtel Engineering f r

6compliance with QC/QA Procedures..-

02251B-3 Amendment No. T

11

D-B

e. Audit Babcock & Wilcox's and other Seller shops for7 |

compliance with QC/QA procedures, s

7 | f. Periodic observation of equipment testing at Seller'sshops.

2g. Provide monitoring and auditing of the Project Construction

Manager and Contractors for compliance with QC/QA pro-cedures and programs.

h. Provide monitoring and auditing of the permanent QC/QArecords.

1. Prepares Toledo Edison Nucid r Quality Assurance Manual.6

The Toledo Edison QAE has the authority to stop work in the event of non-conformance with drawings, specifications and/or procedures, establishedfor Q-List items.

1.3.3 ENGINEERING STAFF - TOLEDO EDISON

Toledo Edison Engineering consists of personnel from the Mechanical andElectrical Divisions. Their functions in relation to the Quality AssuranceProgram are as follows:

Establish, reviev ud approve Davis-Besse general designa.concepts, criteria and parameters, and document controlprocedures. i, '

b. Review and approve design for adequate materials, ease ofoperation, maintenance and reliability.

Review and approve specifications, bidders lists, bid eval-c.uations and purchase requisitions.

2 d. Review a .d approve all drawings issued for construction. I

1Review all correspondence and drawings exchanged betweene..

7| Bechtel and Toledo Edison Sellers.

f. Provide periodic technical assistance during inspection at |7| Seller's shops, site construction, pre-operational testing|and start-up.||

Engineering and general review meetings are held periodically between7 l Toledo Edison, Bechtel, Contractors and Sellers to review basic concepts, 1

design details, responsibilities, job progrecs, and effect any requiredaction.

1.3.k STATION OPERATING STAFF - TOLEDO EDISON |

|Folleving the signed release of equipment and cystems by Construction 1

Management personnel, the Toledo Edison station operating staff and engin-|eering personnel vill also verify and sign-off indicating that equipment Jl

0226 |

Amendment No. 7

.

D-B

and systems are ready for pre-operational testing and start-up. All opera-tions of equipment such as valves , motors, pu=ps , controls , etc. , will aehandled by Toledo Edison operators.

Test ' specifications for the nuclear and safety related station equipmentvill be prepared by Bechtel and the appropriate equipment Sellers. Toledo 7Edison opersting persennel, assisted by Bechtel, B&W and other equipmentSellers, as required, vill prepare the pre-operational test proceduresto comply with the test specifications. Toledo Edison vill conduct theprescribed tests, record the necessary data and prepare summaries of theresults. This test data and results will be reviewed and evaluated by

~

Toledo Edison, Bechte1, B&W, and other Sellers. |7

.

' 0227 !4L

,

l13-5 Amendment No. 7 |

i--

I

.

D-B

2 BECHTEL'

2.1 GENERAL

The Quality Assurance Program for the Davis'-Besse Nuclear Power Station isdesigned to provide Toledo Edison with QC/QA documentation, and the levelof integrity necessary to meet the engineering requirements and the AECCriteria. The program identifies the elements, organization, responsibleindividuals and QC/QA documentation requirements; coordinates Engineering,Procurement, Sellers, Construction Managerment and Contractors' partici-

7 pation in the program administration; and provides informatior, for Sellersand their Suppliers, Contractors and their Subcontractors. As Agents forToledo Edison, Bechtel has the responsibility to ensure that the QC/QArequirements are met.

2.2 ORGANIZATION

2.2.1 GENERAL

The Bechtel organization e= ployed to implement the Quality Assurance Pro-gra= on the Davis-Besse Nuclear Power Station is shown in Figure 1B-2.This organization's involvement is established in all phases of the projectincluding design, procurement and construction from initial engineeringdevelopment through acceptance by Toledo Edison.

One or more levels of monitoring, surveillance, verification and auditingIare provided, as required, within the organization.

2.2.1.1 Desien Phase

The Project Engineering Team has primary responsibilities for quality inthe design phase. Quality control begins with design and technical speci-fications prepared by Bechtel engineers, supported by Toledo Edison pur-danse orders and contracts, so written as to ensure co=pliance with the QAProgram. Personnel having QA-related functions in this phase are as

,

- follows:.

Project Engineering TeamChief Engineers and their Technical StaffCognizant Engineering ManagerQA Coordinator /QA EngineerMetallurgical and QC Services Department

2.2.1.2 Procurement Phase

The Toledo Edison Devis-Besse Purchasing Department is responsible for 3procurement. Toledo Edison, assisted by Bechtel, has the responsibilityfor establishing qualified acceptable sources of supply and shop inspec-

7 tion. Sellers and Contractors have the primary responsibility for thequality of their design, materials, equipment and services furnisned.

,

.Bechtel personnel having QA-related functions in this phase are as follows: ,

si

As

'

OR28_Amendment No. T 1B-6

_ _ _ _

D-B

,,

('

Shop InspectorsChief InspectorProject Engineering TeamChief Engineers and their Technical StaffCognizant Engineering ManagerQA Coordinator /QA EngineerMetallurgical and QC Services Department

2.2.1.3 Construction Phase

Acting as agent for Toledo Edison, the Bechtel Project Construction Manager | 7is responsible for site activities while administering contracts for theconstruction phase.

The Contractors have the primary responsibility for the quality of theirfabrications and ccnstruction, however, the ,Bechtel Project Field Engin-eering Group is responsible for providing adequate surveillance, monitoring

,

and auditing of all site QC related activities. Bechtel personnel havingQA-related functions in this phase are as follows:

Field EngineersQC EngineerProject Field EngineerMaterial SupervisorQA EngineerBechtel Project Construction Mana6er j7

! Project Engineering TeamChief Engineers and their Technical StaffCognizant Engineering ManagerQA CoordinatorMetallurgical and QC Services DepartmentIndependent Testing Laboratories

2.3 PROGRAM

2.3.1 GENERAL

The Quality Assurance Program is implemented in accordance with the Davis-Besse Nuclear Quality Assurance Manual prepared by Bechtel Project Engin-eering to meet the specific requirements of the Davis-Besse Project. Thismanual describes management and administrative procedures as well as indi-vidual responsibilities with regard to their participation in the QA oriented | 7phases of the project.

The Quality Assurance Program provides for at least ene level cf monitoringand verification by individuals organizationally independent of thosehaving primary responsibility for quality (e.g. , the Bechtel QCE monitors *

Contractors, Bechtel Shep Inspectors monitor Sellers, etc. ). Beyond this, the

Quality Assurance Program audits of engineering and field operations arecarried out under the direction of the Bechtel Quality Assurance Coordinator.

.

The Program as described in Sections 2.h through 2.19 is intended to ec= ply/

:( -0223

1B-T ndment No. 7

.

I

|; D-B

with the AEC Criteria.

General instructions, guidelines, procedures, check lists and appropriateforms are contained in the following documents:

a. Bechtel Procurement Denartment Inspection Manual - This

manual delineates Bechtel's policy of general and specifiedinspection instructions to be followed by Shop Inspectors,>

b. Bechtel Field Inspection Manual - This manual providesguidelines for the Quality Control / Inspection Surveil-lance Procedures for the Civil / Structural, Electrical, and

Mechanical construction disciplines.

c. Bechtel Field Procurement Procedures - This manual provides

guidelines for administrative policies and procedures forfield procurement.

d. Davis-Besse Field Procedures Index - This document providesan index cf all Field Quality Control procedures includingprocedures followed by Contractors and Sub-contractors,

e. Davis-Besse Engineerine Procedures Manual - This documentprovides instructions and guidance on administrative andprocedural matters for conducting the work. It outlines

organizational responsibilities and sets forth lines ofco==unication.

|

f. Davis-Besse Construction Manacement Procedure - This docu-ment is intended to provide instructions and guidance onadministrative and procedural matters with regard to siteConstruction Management.

2.3.2 ENGINEEING

The Project Engineering Team prepares the QA Program and has the primaryresponsibility for implementing this progra=. The Project Engineer, DesignEngineering Supervisors with their design groups, and the Quality Assurance

7 Engineer comprise the Project Engineering team. This team can draw technicalsupport of engineers, and technicians from any of Bechtel's technical staffs.The Engineering Team prepares drawings, specifications, bid ~ evaluations andall other tasks associated with the Bechtel engineering portion of theDavis-Besse Project.

Management assistance and surveillance of engineering is performed by theQA Coordinator, cognizant Engineering Managers with technical assistanceand independent review being provided by Chief Engineers and their technicalstaff. The QAE serves as the field representative of the Project Engineer.

The QAE provides surveillance of engineering and QC/QA activities in thefield. He normally does not perfor= inspection but makes spot checks of 'first level inspection during receipt, installation and final inspection

|I of critical items. His duties in the field are as follows: d

0230Amendment No. 7 1B-8 '

__

_ _ _ _ _ - _ _ _ - _ _ _ _ _ _ _ _ _ _ _

D-B.

r3i' Reviews and approves inspection reports for completenessa.

and monitors the permanent field QC/QA documentation files.

b. Monitors the procedures followed by Field Engineering forconformance with inspection procedures outlined in theField Inspection Manual, or other appropriate sources.

c. Monitora specifications and drawings used by first levelinspectors for adequacy.

d. Assures that timely reviews are conducted of pertinent QCrecords prior to key operations in fabrication or construction.

e. Monitors handling and storage control of Q-List items forcompliance with specification requirements.

f. Prepares and submits a bi-monthly Quality Assurance Reporton the status of quality control activities to the ToledoEdison QAE and the Bechtel Project Engineer for evaluation.Additional copies of the report are transmitted in accord-ance with project procedures.

g. Maintains s. concise log of his daily activities, f7The QAE has the authority to stop the work in the event of non-conformancewith drawings, specifications and procedures established for Q-List items.7

(2.3.3 PROCUREMENT

Bechtel's Procurement Department will assist Toledo Edison personnel per-forming quality related functions. These functions are as follows:

a. Establishing acceptability and qualifications of suitablesources of supply by pre-avard surveys of Sellers' Stality |7Assurance Programs to insure that systems, procedures andoperations are compatible with AEC Criteria.

b. Shop inspection shall be performed by Bechtel's shop in-spectors in accordance with the Bechtel Procurement Depart-ment Inspection Manual (PDIM). The extent of shop in-spection performed shall be determined by Toledo Edison

.and specified in their purchase orders. Toled< Edison'sSellers QC/QA requirements, prepared by Project Engin-eering, shall be an attachment to each applicable speci-fication and purchase order to advise the Seller and 7to ensure Toledo Edison that the Sellers will providea Quality Assurance Program consistent with AEC Criteria. -

c. Monitor the receiving, identificati n, and sterage ofmaterial at the jobsite.

.f

\ .

.0231 Yw..

%

13-9 Amendment No. 7

D-B

2.3 4 CONSTRUCTION

Implementation of the Quality Assurance Program at the site, by the Pro-ject Field Engineering Group, vill be in accordance with the Davis-BesseNuclear Quality Assurance Manual. Personnel performing the monitoring,surveillance and auditing functions during the construction phase, villbe provided with documents containing adequate instructions, guidelines

i and procedures to evaluate construction in accordance with the engineeringdesign, drawings, specifications and the intent of this PSAR Design Criteria.

The day to day surveillance, monitoring, and auditing of the Project FieldEngineering Group is provided by the Bechtel QAE.

Additional auditing of the QA Program implementation is performed by TheToledo Edison QAE and Bechtel's QA Coordinator. The QA Coordinator mayutilize the services of the Metallurgical and QC Services Department andother engineering staff personnel for these audits.

The direction of Field Engineers perfoming QC inspection surveillancefunctions is the responsibility of the QC Engineer who reports to the Pro-ject Field Engineer. The Project Field Engineer has the overall responsi-

'bility of direction, guidance and coordination of the site QC relatedactivities,

a. Project Field Engineer

The Project Field Engineer in conjunction with the QC Engineerand the Senior Field Engineers (of the appropriate discipline)assigns qualified Field Engineers to perform their QC relatedfunctions. He coordinates the availability of Field Engineerswith ths QC Engineer and Senior Field Engineers in regard toprogressive surveillance, monitoring and auditing of the con-

T| struction effort. He coordinates the Contractors and Sellerswith regard to resolution of non-conformance items.

b. QC Engineer.

The QC Engineer, in conjunction with the Senior Field Engineers,is responsible for the direction of the QC inspection surveil-lance functions of Field Engineers. He has the responsibilityfor review of QC reports and maintenance of the permanent filesfor all QC/QA records at the jobsite. He is responsible for thecoordination of testing laboratories with regard to QC surveil-lance efforts. The QC Engineer has the authority to initiateaction to stop work where necessary,

c. Field Engineers

The Field Engineers perform the QC assignments and are responsible7 for filling out the appropriate inspection surveillance forms.

Field Engineers' function on a disciplinary basis, '.g., mechani-cal equipment, civil / structural, electrical /pover, instrumentation /

)

Amendment No. 7 1B-10 -

_

_ _ _ -

D-B

s

control, welding / metallurgy.'

The number of Field Engineers assigned depends upon the require-ments of the variable quality control surveillance workload,Field Engineers have access to all design drawings, procurementdocuments, applicable codes, and the Contractor's sa=pling andtesting, and are thoroughly familiar with the QC requirementsfor their assignments.

2.h DESIGN CONTROL

Several levels of design review and approval are applied to significantdesign aspects of Bechtel work. These standard practices include:

a. Checking and review of design, by engineering personnelwithin the Project Engineering Team having technical quali-fications comparable to those of the engineer or designerwho originated the work.

b. Review and approval by the originating engineer's DesignGroup Supervisor.

c. Review and approval by the Bechtel Project Engineer.

d. Review and/or approval by the appropriate Chief Engineerof certain key designs and calculations.

,

A Design Control Check List is prepared for the Q-List items under directBechtel design control, which is reviewed and approved by the ProjectEngineer and the cognizant Chief Engineers.

.

In implementing Design Control, Quality Assurance functions performed bythe Chief Engineers and the cognizant Engineering Manager are as follows:

a. Chief Engineers

The Chief Engineers provide an independent review for all itemson the Design Control Check List. They coordinate and assurenecessary technical review by specialists and consultants.Chief Engineers may delegate their review responsibilities toqualified specialists on their staffs.

b. Engineering Manager_

The Engineering Manager provides management guidance and sur-veillance of the Project Engineering activities. His QA-relatedfunctions involve verification through project reviews thatProject Engineering is fulfilling its QA responsibilities.

Bechtel drawings, specifications and procurement packages are routinelysubmitted to Toledo Edison for appropriate review. Drawings and specifi-.-

t cations which have a bearing on the B&W Nuclear Steam Supply System or re-t

.02aa gr-

1B-11 Amendment No. 2

D-B

sult from criteria supplied by them are routinely submitted to B&V for re-view and comment. In a similar manner, information developed by B&W affect- '

ing the Bechtel-B&W interface is submitted by B&W to Toledo Edison andBechtel for review and comment.

The Project Engineering Team employs several documents to establish design !requirements for the project. These documents include AEC criteria anddesign bases as proposed by the license application and accepted by the AEC;basic Toledo Edison-furnished data defining plant requirements; B&W-furnishedcriteria and data; Project Design Criteria Manual prepared by all disciplines;and Bechtel design guides, standard specifications and data sheets.

.

Bechtel QA verification steps include appropriate documentation to assurethat:

Review of project scope and procedures has been acco=plisheda.by appropriate Chief Engineers, their staffs and technicalspecialists ,

b. Design is in accordance with appropriate codes and standards.

c. Key drawings and specifications are checked by the ProjectEngineering Team and are reviewed by appropriate ChiefEngineers, their staffs and/or specialists,

d. Shop / Field inspection and test requirements have beenspecified. ,

7| e. Seller's shop drawings have been checked by the ProjectEngineering Team,

f. Field Engineering, including changes, for units and systemson the Q-List vill be reviewed by the Project Engineering

team. Applicable field drawings and procedures and fieldchange notices vill be forwarded by the Project Field Engineerto the Project Engineer for review and approval.

,

2.5 PROCUREMENT DOCUMENT CONTROL

The technical specifications of the procurement documer.ts are prepared bythe Project Engineering Team. QC/QA requirements are included in the spec-ifications relative to code certification, fabrication, testing and in-

spection, including drawing and data requirements.

7 | Toledo Edison purchase orders vill require Contractors and Sellers toprovide a Quality Assurance Program consistent with the QA requirementsof the AEC Criteria. It is the responsibility of Project Engineering toconsider the adequacy of the program offered by bidders in bid analysis.

Provisions are made in the ptocurement documents for periodic audits and7 | final inspection in Seller shops, as appropriate.

.

0234Amendment No. T 1B-12

.

_ _

D-B

- 2.6 INSTRUCTIONS, PROCEDURES AND DRAWINGS(

Guidelines for accepting Sellers and/or Contractors' required documented |7instructions, procedures and drawings are contained in one or more of thefollowing:

a. Davis-Besse Nuclear Quality Assurance Manual.

b. Be'chtel civil, electrical, mechanical and welding engineer-ing standards including Nuclear Pcver Station DesignStandards.

2

c. Procurement Department Inspection Manual.

d. Field Inspection Manual describing general guidelines andprocedures for Field Inspection.

e. QC Requirements for Contractors..

6f. QC/QA Requirements for Suppliers and Equipment Manufacturers.

2.7 DOCUMENT CONTROL

Measures shall be taken to ensure Toledo Edison that Docunent Control villbe maintained for drawings, specifications and procedures by Engineering,Sellers and Contractors, through all phases of the project, including |7start-up, to assure that the fabrication, construction and inspection iscompleted in accordance with the latest approved copy of the appropriatedocument.

The review and approval of design documents is discussed in " Design Centrol",Section 2.h. Approved drawings and specification are promptly issued toorganizations and individuals performing the verk and to those responsiblefor inspection. Changes made by the Project Engineering Team or propcsedby Field Engineering to approved drawings are reviewed and approved by theProject Engineering Team in accordance with procedures for review of theinitial issue. Where significant changes are involved, review by cognizantChief Engineers and/or technical specialists is performed. 2

The Construction Management organization is responsible for implementationof procedures that vill control the distribution of approved drawings andassure that obsolete drawings are voided or destroyed.

The QAE will monitor field engineering activities to verify that fieldengineering changes are reviewed and approved by the Project EngineeringTeam. He vill also make spot checks to assure that a drawing control log isbeing maintained and that only current design documents are in use.

_

2.8 CONTROL OF PURCHASED MATERIAL, E;UIPMENT AND SERVICES'

The Toledo Edison Davis-Besse Purchasing Department is responsible for pro-curement. Toledo Edison, assisted by Bechtel, has the responsibility forestablishing qualifie.d acceptable sources of supply and shop inspection.

C When Sellers are required to procure critical items of equipment or 9 1

materials, their procurement procedures will follev the requirements of 7this section. Bechtel vill monitor the Sellers procurement activities

02351B-13 Amendment No. T

.

l

i

D-B'

to assure compliance with the requirements contained therein. |

The Quality Assurance Program includes a comprehensive system to assure thatall purchased material, equipment and services conform to the Toledo Edisonpurchase orders. These documents incorporate QA requirements which providefor the evaluation of the Sellers quality assurance program. The QA require-ments also specify b yer inspection surveillance as required, Sellers prepar-ation and maintenan..e of appropriate test and inspection records, certificates ;

and other QC documestation, and Seller submittal of QC records considered )necessary for buyer retention to verify quality of completed work.

Procedures for submittal and review of Seller shop drawings and data on Q-Listitems are the same as employed for normal procurement. These are submittedto Project Engineering for review and approval. Shop Inspectors receivecopies of approved drawings and assure that any changes proposed by the Seller,following drawing approval, are submitted to Project Engineering for evaluation.

7 Bechtel Shop Inspectors review and verify Seller QA records and prepare re-ports documenting Seller data not submitted to Toledo Edison. Where Bechtelshop inspection is performed, final inspection is nomally performed upon thecompleted item just prior to preparation for shipment. At that time, the ShopInspector, if satisfied that the fabrication and necessary documentation arein order, vill release for shipment. Packaging, protection and loading mayor may not be witnessed, but where not witnessed, Sellers' procedures arecarefully reviewed. Release for shipment is not " acceptance". Final accept-ance is always in the field.

For Q-List items, Shop Inspectors verify that all required-documentation and iinformation is available and vill be transmitted promptly to the ProjectEngineering Team. Upon release for shipment, the Shop Inspector promptlynotifies the Project Construction Manager and the Project Engineer. In thefield, this notification is passed on to the Material Supervisor and ProjectField Engineer so that preparation for receipt inspection can proceed.

29 IDENTIFICATION AND CONTROL OF MATERIALS, PARTS AND COMPONENTS

Appropriate requirements for identification and control of materials, parts.

and components vill be established through review of specifications anddrawings along with Seller's Quality Assurance Program and procedures.Traceablility will be accomplished where required by code, standard or spec-

| ification.1

Fabrication and construction practices vill incorporate measures for con-tinuous material control, and identification as practical. Positive controlof non-conforming items vill be maintained by suitable markings and/orsegregation.

#\-

0236I

| -

Amendment No. 7 1B-lhr

.. .. . - - . . . . .

.

D-B

,2.10 CONTROL OF SPECIAL PROCESSES

Use of qualified procedures and applicat' ion thereof as required by estab-linhed codes and standards will be rigidly enforced for all Sellers andContractors. Procedures for other special processes, as required, vill be 7prepared by Sellers, Contractors, or Project Engineering, and approved bythe Project Engineer. .

The Metallurgy and Quality Centrol Services Section is responsible for pro-viding Engineering, Shop Inspection and Construction Management with thespecialized services of engineers and technicians experienced in metallurgy,corrosion control, metal fabrication techniques , velding and non-destructivetesting. The following services are available upon request to the ChiefMetallurgical Engineer or Chief Welding Engineer.

a. Providing assistance to Construction Management in thequalification of all field velding engineers.

b. Providing assistance to Project Engineering and ConstructionManagement on technical problems in the field involvingmaterials, fabrication, velding, non-destructive testingand code requirements.

2.11 INSPECTION

For field operation the Contractor is responsible for the quality of hisfabrication / construction. The first level of inspection is under the,,,

direct supervision of the Contracter's responsible representative. Thisfield inspection is carried out in ~0erdance with procedures furnished bythe Contractors and approved by Project Engineering. In-process inspectionsurveillance of activities affecting quality is carried out by BechtelField Engineers in accordance with the Davis-Besse Nuclear Quality AssuranceManual and the above inspection procedures. Inspection surveillance per-formed by Bechtel Field Engineers is supervised by the QC engineer andmonitored by the QAE. All critical components and materials will havefield inspection documentation prepared at three stages: (1) upon receipt,(2) after installation or physical completion of fabrication work, and(3) at the end of the construction period when all necessary cleaning,lubrication and static tests have been ecmpleted.

Bechtel's Shop Inspectors are responsible for carrying out, or participat-ing in shop qualification inspections, inspection of work in process atSeller's and Supplier's shops, witnassing of significant tests and |7for final inspection and release of equipment for shipment. Mandat ,ryhold points vill be specified when, in the opinien of Engineering or theBechtel Inspector, work should not proceed without prior examination by .

the Bechtel Inspector. In special cases, Engineering personnel may parti-cipate in such inspections.

Under the . rules of ASME and ANSI codes , certain work requires inspectionby a " Qualified Inspector". The " Qualified Inspector" must be a NationalBoard Commission Inspector employed by an insurance company or State, pro-| 7~..

s/ - ',

,

023>7,

13-15 Amendment No. T

_ _ _ _ _ _

D-B

N 'vince or Municipal Government. The Quality Assurance Program vill providethat the work is performed'in accordance with the applicable code QA re- -

quirements by Contractors with appropriate authorizations, and inspectedby " Qualified Inspectors".

2.12 TEST CONTROL

7 | Seller and Contractor test operations procedures are reviewed by Bechtelin accordance with procurement procedures previously described.

In the field, certain test operations are carried out by the Contractorunder the survrillanca of the Bechtel QC Engineer in the course of plantconstruction. The Bechtel QC Engineer may carry out additional test oper-ations to assure the quality of the field construction utilizing qualifiedindependent testing laboratories.

Subsequent to completion of construction, startup organizr ': ;ns vill be in-volved in system checkout and startup operation.

Test specification for the nuclear and safety related station equipmenttill be prepared by Bechtel and the appropriate equipment Sellers. ToledoEdison operating personnel, assisted by Bechtel, B&W and other equipment

7 Sellers, as required, vill prepare the pre-operational test proceduresto comply with the test specifications. Toledo Edison vill also performthe prescribed tests, record the necessan data and prepare series ofthe results. This test data and results vill be eviewed and evaluatedby Bechtel, B&W, Toledo Edison, and other Sellers as appropriate. ),

2.13 CALIBRATION OF MEASUREMENT AND TEST EQUIPMENT

Certain tools, measuring instruments, test and calibration equipment requirea control program for maintenance and calibration to ensure a high degreeof accuracy and repeatability. The system applies to the Contractors ,

7| Sellers,ConstructionManagementandstart-uporganizationsandshallprovide for:

.

Identification of the tools, devices, test and calibrationa.equipment requiring special controls.

b. Establish the calibration intervals on the basis of equip-ment stab'lity, purpose and degree of usage.

The necessary calibration procedures to be utilized. Thesec.procedures may be a ec=pilation of published standard prac-tices or manufacturer's written instructions. Instruments

and equipment vill be calibrated and utilized in similarenvironments when necessary.

d. The calibration of instruments , tools and equipment may beperformed by a co=mercial facility utilizing reference stand-

7 ards. Such calibrations vill be certified as traceable tovalid national standards or derived from accepted values of s

'

, ~ /'

0238.-Amendment No. I

; 13-16

,_ --- - . - - - - . . - - . . - - - . - .

.

~

D-B

f

natural physical constants. All reference standards usedin the calibration system shall be supported by certificates,reports or data sheets attesting to the date, accuracy andconditions under which the results furnished were obtained.

2.14 HANDLING, STORAGE, SHIPPING AND PRESERVATION

Special handling, storage, shipping and preservation requirements areidentified in procurement specifications for Sellers ' work.

[ 7

The Contractor is responsible for the field storage control of Toledo Edisonand/or Contractor procured equipment and materials. The QC Engineer villmaintain surveillance of the control, identification and protection ofequipment and materials. The Contractor is responsible for storage controlidentification and protection of Contractor-furnished material.

Material control and identification procedures vill be submitted by the *

Seller and Contractor and approved by the QC Engineer and the Project | 7Engineering Team. These procedures will be in effect from the time the.

materie.1 is shipped until it is released for pre-operational testing andstartup.

T1'e procedures vill specify the requirements and verification methods forspecial environments necessary for the preservation of the equipment ormaterials.

,

The Material Supervisor vill issue a ; riodic report documenting the statusof storage and preservation activities for Q-List items.

2.15 INSPECTION, TESTS AND OPERATING STATUS

Records of inspections and tests are provided in the form of written reportsor other appropriate records for all Q-Listed items showing inspection per-formed, results, and clear identification of the item. Specific detailsfor marking, tagging or otherwise indicating inspection and acceptancestatus of equipment vill be required.

When Inspectors identify a non-conforming item that cannot be promptly re-paired the item is marked, identified or tagged to indicate its non-con-formance and status.

Subsequent to completion of construction, pre-operational and startup teststatus of equipment and systems is identified by means of tagging proceduresto prevent inadvertant operation.

2.16 NON-CONFORMING MATERIAL, PARTS OR CCMPONENTS g -

The Quality Assurance Program requires procedures controlling materials, ;

parts or components not conforming to approved requirements to prevent,

s ,their inadvertent use or installation.*

|

(~ No'n-confoming items are identified and documented with notifications and |disposition information to affected organizations.

0239,

1B-17 Amendment No. 7,.

$t

D-B

mFor non-conforming ite=s which may be made usable through rework, repair ormodification of requirements, reports are prepared and submitted to theProject Engineering Team for appropriate guidance. Documented proceduresvill be followed in determining ultimate disposition of the non-conformanceitem. Records of resolution for these cases vill be prepared and incorpo-rated in the QC/QA files.

2.17 CORRECTIVE ACTION

2The Davis-Besse Nuclear Quality Assurance Manual incorporates proceduresfor identification and reporting of all conditions adversely affectingquality, such as failures, malfunctions, deficiencies and deviations ,causing defective material and equipment. The prime responsibility foridentifying, reporting and implementing the necessary corrective action ft"

7 such conditions lies with the Contractors or Seller performing the work.The Contractor / Sellers' approved Quality Assurance Plan vill incorporatemeasures to ensure that the above responsibilities are performed. In orderto prevent recurrence of any of the above conditions, it vill be the re-sponsibility of the Contractor / Seller to document the condition, causeof the condition, and the approved corrective action take .

2.18 QUALITY ASSURANCE RECORDS

The Project Engineer maintains the permanent files for collection of allBechtel design control documents. The QC Engineer maintains the permanentfiles fer collection of QA related documentation required throughout theprocurement, construction, and start-up phases of the project describedin preceding sections.

The QC/CA files are available for audit by Toledo Edison during the designand construction period and are turned over to Toledo Edison at the com-pletion of the project. Toledo Edison vill provide permanent QA recordstorage facilities at the Davis-Besse Station under the responsibility ofToledo Edison's QAE. Detailed Bechtel QA audit reports are not includedin the QA files however, su= mary records of date, scope and identity of

3auditors and conclusions vill be made available. Summaries of "Significant

6 | Deviation Reports" are included in the QA files.

2.19 AUDITS

The Quality Assurance Program includes specific audit activities:

a. Periodic audits of Project Engineering activities and re-cords are carried out by, or under the direction of, the

2 QA Coordinator.

7| b. Bechtel Shop Inspectors perform periodic audits of Seller'sQuality As3urance Program conformance and records.

c. The QAE provides frequent audits of field QA related in-spection and surveillance activities and reporting.

0240

Amendment No. 7 1B-18

.

_. .. . .

D-B_

d. Tha QA Coordinator audits the site QA related activitiesfor conformance.

All of the above are carried out periodically during the design and con-struction period. Follow-up action, including re-audit of any type ofnon-con for:nnce, shall be taken to insure proper corrective action. Atthe completion of construction, a final audit is performed on the asso-ciated QA records to assure necessary inspections and rec'rds have been pre-pared and are on file. A final report is prepared confirming this finalexamination and audit.

All phases of the Davis-Besse Project are also subject to audits by theToledo Edison QAE.

1

J

-

.

'

0241i

1B-19 Amendment No. 2,

_ +"4

D-B

3 BABCOCK & WILCOXi

3.1 POLICY

The Babcoch & Wilcox Company has a progra= of quality assurance for itsgnuclearsteamsystems. The following is an extraction from the Authorized

7 | Quality Assurance Program dated 8-1-60 The Quality Assurance Programincludes in its scope the design, fabrication, shipment, erection, and testing,

of B&W nuclear steam systems and fuel. The program is administered by aseparate B&W quality assurance organization whose responsibility is to assurethe implementation of the program.

3.2 i P30 GRAM ELEMENTS

The B! W QA Program includes the following: o*ganization; planning; designcontrol; procurement document control; instructions, procedures, anddrawings; identification and control of materials, parts, and components;control of special processes; inspection; test control; calibration ofmeasurement and test equipment; handling, storage, shipping, and preserva-tion; inspection, test, and operating status; non-conforming material, parts,or components; corrective action; quality assurance records; and audits.

B&W has established a basis for classifying equipment in accordance with theimportance of its nuclear-safety related function. The elements of the B&WQA Program are selectively applied in accordance with the equipment classi-fi cation.

3.3 ORGANIZATION ,

The Company executes its utility Nuclear Steam System contracts through thePower Generation Division which designs, manufactures, procures, erects, andservices nuclear equipment including reactor cores. Within this Division,the Nuclear Power Generation Devartment has the overall responsibility forcccmercial nuclear utility systems and fuel contracts. The B&W-NPGDQuality Assurance organization administers the B&W Quality Assurance Programwithin the Power Generation Division with direct administrative responsib-ility to the Vice President in charge of the Nuclear Power Generation De--

partment. Fig. 1B-3 depicts the B&W-NPGD Quality Assurance organization.

3.h QUALITY ASSURANCE PROGRAM,

,

3.h.1 OBJECTIVE - QA PROGRAM

The objective of the B&W Quality Assurance Program is to (1) establishquality requirements; (2) document and communicate the established qualitylevel; (3) provide or select manufacturing facilities that assure achieve-ment of the quality requirements level; (h) monitor the manufacturing asappropriate to assure that quality processes are being used; and (5) pro-vide - documentation to demonstrate that the quality level set has beenachieved.

:y

0242 s

Amendment No. T 1B-20

_

.

D-B

f~t 3.k.2 QUALITY LEVELS

B&W's quality progrem functions on two levels: quality control and qualityassurance. We define these terms as follows:

3.h.2.1 Quality control is the first level and the most detailed functionof a quality program. The activities are directed toward measuring quantita-tively the quality of the work product of any operation. Activities duringthe various design phases of a project include a check of design calcula-tions, drawings, or specification content. Quality control in manufacturingincludes systematic inspection, testing, and documentation to establishproduct conformance to specification requirements. Quality control can beperformed by personnel in the same organization responsible for the workfunction.

3.h.2.2 Quality Assurance is a planned, systematic audit and evaluationof the quality control function to determine that adequate quality programelements are being implemented. Quality assurance activities are performedby personnel who are independent of the quality centrol end work function.

3.k.2.3 Planning

BiW implements its QA Program by t2e of standards and written procedures.Emphasis is placed upon establishment of an audit program and documentationrequirements consistent with the nuclear safety-related functions by es-tablishing essentiality levels for equipment.

3.h.2.h Procurement

Equipment supplied by B&W for a nuclear contract is procured in conformancewith a nuclear quality program requirements specification and a system ofclassification of equipment according to its nuclear safety function. Thisspecification includes Code requirements and, as appropriate, special pro-vis,iens such as material specifications and material centrol, velding re-quirements, cleanliness requirements , non-destructive testing, acceptancecriteria, maintenance of records, packaging, and shipping requirements.B&W-NPGD QA audits and evaluates suppliers per the quality control programrequirements as appropriate to equipment classification.

3.4.2.4.1 For eculement manufactured by B&W, B&W prepares both functionaland equipment specifications. 7&W performs functional and mechanical designand establishes the material requirements, manufacturing processes, andinspection and test requirements. B&W Quality Assurance audits the workto assure that standards, design reviews, and quality control proceduresare implemented.

3.h.2.h.2 For eauitment uurchased by B&W, B&W prepares functional or equip-asnt specifications. Suppliers prepare detailed designs and requirements.For selected equipment, a supplier certification audit is performed inaccordance with written procedures prior to placement of a purchase order,or prior to release to manufacture.

L 0243

W1B-21 ' Amendment No. 2

.__

D-B

3.h.2.5 Erection

In those contracts where B&W has an erection responsibility, B&W establishesan erection plan for its scope of supply which encompasses quality assuranceprovisions. In executing the work of the plan, B&W procedures and standards. are used which have been previously developed for erection work. These in-clude document control, material control, control of special processes,inspection, gage control, status of inspections and tests, non-conformingmaterial, corrective actions, and documentation.

In those contracts where B&W furnishes advice and consultation for theerection of equipment supplied by it, B&W' supplies erection criteria.

3.h.2.6 Plant Test Program

B&W prepares test specifications for the plant test programs for equipment;

and systems within the B&W scope of supply.. B&W supplies advice and con-sultation during the test program and reviews the test results. B&W pro-cedures and standards are used in the preparation, approval, and modifica-tion of test specifications.

3.5 DESIGE CONTROL

The B&W QA Program incorporates provisions to ensure that limits imposedby the " design bases" and applicable regulatory requirements are correctlytranslated into specifications, drawings, procedures, and instructions.

!Designs and drawings prepared for equipment manufactured by B&W and itssuppliers are reviewed by B&W-NPGD for conformance to specifications and bythe Utility (or its agents) for compatibility with interface requirements.

Design reviews are conducted by personnel who did not perform the originaldesign work.

The B&W-NPGD QA organization provides an independent audit and evaluationof engineering documents, including spec $ fications, instructions, proced-'

ures, and drawings. '

3.6 PROCURDENT DOCUMENT CONTROL

Purchase order requisitions and internal B&W manufacturing instructions pro-vide the controls required to assure that procurement documents and changesthereto include all quality control requirements as described in paragraph3.h.

3.7 INSTRUCTIONS, PROCEDURES, AND DRAWINGS

B&W manufacturing operations and inspections are performed in accordancewith written procedures and instructions.

B&W suppliers are required to have appropriate drawings and written pro-cedures covering vork processes and quality control requirements. T

.F. \

k

t 1B-22 N'NAmendment No. 2,

D-B.

<-

3.8 DOCUMENT CONTROL

Procedures are established within B&W to control the preparation, approvaland distribution of specifications , drawings , instructions , and changesthereto.

B&W suppliers are required to have document controls which include pro-visions for B&W approval of supplier-proposed variations from Blv-NPGDspecifications.

3.9 CONTPOI 0F PURCHASED MATERIAL, EQUIPMENT, AND SERVICES

B&W has procedures to assure that purchased material conforms to speci-fications for B&W manufactured equipment. Incoming material is subject toa receipt inspection and identification. Rejected material is properlyidentified for disposition. Accepted material is entered under materialscontrol for proper process use.

Consistent with classification of purchased equipment, conformance topurchase specifications is assured by B&W requirements of supplier materialcontrol and fabrication procedures, and quality control provisions. As re-quired by the procurement documents, quality control documentation issupplied to, and reviewed by, B&W for completeness.

3.10 IDENTIFICATION AND CONTROL OF MATERIALS, PARTS, AND COMPONENTS,

For equipment manufactured in B&W shops, detailed quality control proceduresare used to identify and control materials and parts throughout the manu-facturing process. These procedures include marking and identification ofmaterials , storage, material inventory, material release, material certifi-cation records, and disposition of defective material.

Suppliers of equipment purchased by B&W are required to have adequate=aterial control procedures.

3.11 CONTROL OF SPECIAL PROCESSES

Detailed procedures are used to control special processes for equipment i

manufactured in B&W shops. These procedures include veld procedure qualifi- !

!cation, velder qualification, veld process control, heat treatment, non-destructive inspection, NDT perconnel qualification and certification, andcle aning.

B&W suppliers have similar procedures when required by B&W procurement docu-ments.

<

3.12 INSPECTION

B&W fabricates components under a controlled manufacturing system. This

system combines the manufacturing and inspection plans which include process(fabrication) sheets , inspection requirements, inspection status, variationnotices including corrective action, identification, and documentation.\_ s

Shipping releases are given after a review is made of upgrading points to

0245 M1B-23 Amendment No. 2

IHB

| confirm that fabrication sequences, inspection points, material certifica- *

i tions, and tests have been completed.

B&W invokes similar requirements to those stated above on its suppliers.

3.13 TEST CONTROL

| B&W-NPGD procurement documents establish equipment testing requirements.j B&W shop tests are performed in accordance with written test procedures.

B&W suppliers utilize standard or special test procedures. These test re-!

sults are documented and evaluated on the basis of specified acceptance /rejection criteria and become a part of the Quality Assurance records.

3.1h CALIBRATION OF MEASUREMENT AND TEST EQUIPMENT

The B&W manufacturing program includes procedures for calibration ofmeasuring and testing equipment used in activities affecting quality atperiodic intervals.

Where required by B&W procurement documents, similar procedures are usedby B&W suppliers.

3.15 HANDLING, STORAGE, SHIPPING, AND PRESERVATION|

B&W establishes requirements for shipping, handling, and pre-installation| storage for B&W supplied equipment.

!

| These requirements include instructions for special protective environments'

when necessary.

3.16 INSPECTION, TEST, AND OPERATING STATUS

The B&W manufacturing process includes quality control procedures coveringthe status of shop inspections and tests. This includes inspection ticketsand other special status markings applicable to the equipment involved.

B&W suppliers are require.d to have similar procedures consistent with theirmanufacturing processes.

i

!

3.17 NON-CONFORMING MATERIAL, PARTS, OR COMPONENTS'

The B&W manufacturing process includes quality control procedures for theidentification and disposition of rejected material, parts, and/or compo-nents.

B&W suppliers are required to have similar procedures consistent with theirmanufacturing processes.

1

i

0.?s16 [Amendment No. 2 1B-24

,

.

D-B

r.$ 3.18 CORRECTIVE ACTION

The B&W manufacturing process includes quality control procedures encom-passing corrective action for items not passing inspection. Variationsfrom specifications are reported and resolved consistent with the nature ofthe variation. The possible causes of the deficiency are investigated, andcorrective action is instituted and documented by necessary changes inspecifications and manufacturing process.

B&W suppliers are required to have similar procedures consistent with theirmanufacturing processes.

3.19 QUALITY ASSURANCE RECORDS

Records including, or certifying, the results of inspections, tests , audits,and material analysis are included in the B&W Quality Assurance Records, asapplicable, and transmitted to the Utility. -

Records, including data such as qualifications of personnel, quality controland manufacturing procedures, and radiographs, are retained by the equipmentmanufacturer in accordance with the requirements specified in the procure-ment documents and codes.

3.20 AUDITS

'

Audits are performed by B&W-NPGD Quality Assurance on shop and field act-ivities; to determine compliance witn this QA Program. These audits aremade on B&W manufacturing operations, B&W suppliers, and erection of B&Wequipment. Audit resulcs are documented, and corrective action, if necess-ary, is taken.

B&W shops and B&W suppliers are required to have quality control procedurescovering internal audits with provisions for documentation and necessarycorrective action.

I

|.

&

"i~.

I

U?A? j|

|

13-25 Amendment No. 2

w1

TECO PR

' lEXEC.

VICE PRES.

I

i 1oELEC. GP. FIR GP-

VICE PRES . VICE PREE

I

I I I

NECH. ENG. QUALITT NE L E C. [N G. OlV OlV. ASSUR ANCE FCHF.ELEC.ENG :HF. MECH.ENG ENG.

,GOi ie <

PROJECT _I I

ENG. l ..

.-

BECHTEL '"#E"! ~!F "

- -.

| 7.___... .._ __) ; p -_- -- - .--q

CNIEF CNIEF ENG. [.. PEECT ..j u;R 0. A . 'I_START UP EN SPECIAllST ENGR. _.-. Q. A. C00RO.,

_________________..I | !t ., _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ -'

O.A. - --f -~

ENGR.CEslCN

ENG. SUPV. * !

; - - - -|

'| i

0.C. i

! ENGR.

I iI TEST

~

,

LA8S

: I'' B BW d

e PCIER GENERATION| ||

| |

| I I I'

| BAABERTON FEEDER NUCLEAR PoiNUCLEAR EQUIP PLANTS GENERAT10h Di

! I'

I I I,-

! - QUALITY ENGINEERING gggygggy- - - *

ASSURANCE DEVELOPMENT, ,'

| 1

| | I I

| NUCLEAR !YSTEMS COMPONENT NS$ CONTRACTS

| ENGINEERING ENGINEERING (PROJECT BET..)

: :L. .. ...................-..___.............a. . . . -

-

Q/A REPRESENTATIVE Q/A REPRESENTATIVE

B & 5 N ANUF ACTl! RED EQUIPuENT -]- 8&SPR UIPMEhi _

__---- -

1 I

Q/A REPAESENTATIVE 0/A REPRESENTATIVE

Q5)#}.C7' O B & 5 PURCHASED EQUIPMENT

- -

FUEL & CORE COUPONENTS~

N ECMANI C AL

l'

--

_

v41

||1

-|}

51 DENT ,

I

|I

SR.VICE PRES. |

,

_ lADMIN. GP.

_VICE PRES.

I I !

t. PLANT PWR. PROD- PURCl;. t STORES |iST.DIV. OlV. OlV. DIPECTORd. SUPT IEN SUPT.

li

l | |

-

.

CONSTRUCTION PROCUREutNTMANAGEulNT

I. __.T- T- ~~~ ! -- -~~!--~~~~~--------- - -----

T-~~ I ---- ~~~l |'

NETALLURST [,,. PROJ. CONST. ,ggp, gypy,, ggpg gypy.Il 3

_. . . .. . . . . .__J_.

p. ....,... .-......__.3! ! !

PRC). FLD. SCHED. COST FIELO WATL. SHOP INSP.. .. EXPD.'ECC. ENG. ENG. SUPTS. SU P V.'

i i ; i

| !FLD. ENG.--

TECO-

A S S T..

-.] gfERSE '--~--JCONTRACTORS - TJpis -

g,.LO. ENS __. $yppt|ggs

_ _

l|

-

DIV1810N,

y _ __ _ __ _ a, ,

ER ERECil0N 'PURCH A $ LNG --

LEGEND*

iPT. CouPANY DEPT.

IRESPONSIBILITY

| | | | -- 0.A. SURVEILLANCE & AUDIT

Comuf RCI AL NOUNT VERNON ! - - - - INSPECTION SURVElLLANCEPURCHA$ LNG I C00R0lNAT10N#UCLEAR FUEL WORKS

I I

FUEL C0hiRACTS Fl[LO SERVICESMANAGEutNT AND TRAINfNC |

___Jl ,

I !

- 04 Fl[LO REPRESENTAfiVES --

1

I QUAlliY ASSURANCE FUNCTIONAL ORGANIZATION CHART- - - - - - _ - ___.I DAVIS-BESSE NUCLEAR POWER STATION i

PRINCIPAL FLOW PATHS |FIGURE IB-1

AWENOWENT NO. 84

0249 f

._

-.

THE TOLEDOEDeSON CO.

ENGINE E RING$ CONSTRUCTIONMANAGEMENT

- MANAGEMENT PROCUREMENT

n I. . . . . . . . . . . . . . . . . . . . . .

...3 7.................................)........7..........-...............-...............p. ..........e 1 -

CH6EF STCL.iT UP CHIEF ENGINEERS | PROJECT'

s MGR_QA METALLURGY PROJECT CONSTRUCTION $NSP. EMM3ENGINE E fl ... ... '

-SPE Q ALISTS ENGINE E R O A COORDINATOR | QUALITY CONTROL MANAGER SUPV. SUPV.1 i I 3

I e ,

i I :

_..i . .- .i o^ST ART UP "

g DES 8GN | IE NGINEE RS

ENG. SUPV. ! | f""T """" 13 .-g----- I

-

ARCHITECTURAL PROJECT COST SCHED. FLD. MATL SHOP| FIELD ENGINE E R ENGR. ENGR. SUPTS. SUPV. Ignf, EMPD.

e

. -*

i-~ ~ - - - @ g g g

cIViimenuCTunAL 8, 1 I1 I **I |'I----- IE LECTRICAL ENG NEER e FIELD E NEERS !l : 'II || MECHANICAL | [ e

| g*

iFIE LD E NGINEE RS TFCO |*g---

-a ' - - - -

ASST [S I SUPPLIERS.TECONUCLEAR b., ^ ' " " ~

I SUP

FIE LD E NGINE E RS II LAYOUT SUPPLIEAS ----------.l

I

DRW3,SPE CS, TEST LASSO L IST. ETC

LEGEND

RESPONSIBILITY=- O A SURVEILLANCE & AUDIT- - -- INSPECTION SURVEILLANCEQ ---------- COORDINMIONN

(j{ DAVIS-8 ESSE NUCLEAR POWER STATION

Q BECHTEL QUALITY ASSURANCEORGANIZATION CHART

FIGURE 18-2AMENDMENT NO. 5

.

i

_ _ _ _ _ _ _ _ _ e _ __ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

%

B&W *

POWE R GENERATION DIVISION

B ARBE RTON FEEDER N UC LE AR EHECTIONPURCHASINGNUCLE AR EQUIP. PLANTS POWER GENER ATION COMPANY

|

. ENGINEERING QUALITYCOMME RCI AL MT. VER NONDEVELOPMENT ASSURANCE NUCLEAR FUEL WORKS

PURCHASING

I

O/A REPRESENTATIVE NUCLEAR COMPONE NT NSS FUEL FIE LD SERVICE-

B&W MANUF ACTURED EQUIP. SYSTEMS ENG. ENGINEERING CON TR ACTS CONTRACTS MGMT. AND TRAINING

Q/A REPRESENTATIVES&W PURCHASED EQUIPMENT -

h4ESHANICAL

O/A REPRESENTATIVEB&W PURCHASE EQUIPMENT -

ELECT RICAL

O/A REPHESENTATIVEFUEL & CORE COMPONENTS - |

Q/A FIELD REPRESENTATIVES_

I

CN 0 AVIS-BESSE NUCLEAR POWER STATIONC/l 8 & W QUAL;lTY ASSURANCE

P ORGANIZATION CHARTFIGURE 18-3

AMEN 0 MENT NO. 2

i

*

(-

D-B

Table No. 1B

PROJEUP FUNCPIONAL RESPONSIBILITY SUletARY

DAVIS-BESSE NUCLEAR POWER STATION

Construction SystemsManagement Checkout

andQuality Quality Engineering Construction AcceptancePROJECP PART Control Assurance Design Procurement Inspection Contractor Testing

I Nuclear Power B

Station * B B , TE B TE B TE, B

II Nuclear Steam B&W, B&W, B, B TE, B,Supply System B&W B , TE B&W B&W TE UEN

III Turbine Generator GE, B B TE , B ,Equipment GE B , TE GE GE TE GEB&W B&W, B

IV Nuclear Fuel B&W B, TE B&W B&W TE B&W TE, B&W

V ElectricalB

Suitchyard B B, TE B TE B TE , B

TE = Toledo Edisond)RC B&W = Babcock & WilcoxUI B = Bechtel

EO GE = General Electric

#Except Parts II, III, IV and V