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NUCLEAR QUALITY CONTROL MANUAL

1997 Edition

BECHTEL CONSTRUCTION OPERATIONS

INCORPORATED

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Copyright 1994-1997 Bechtel Corporation1997 Edition. All Rights Reserved.

Contains confidential information proprietary toBechtel and may not be disclosed to a thirdparty without Bechtels prior written permission

Printed in the United States of America.

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1997 Bechtel Corp. Nuclear Quality Control Manual TOC-1

NUCLEAR QUALITY CONTROL MANUAL

TABLE OF CONTENTS

INSTRUCTION

NUMBER TITLE REVISION

EFFECTIVE

DATE

N1.0 Introduction 1 18 December 1997

N2.0 Receiving Inspection 1 18 December 1997

N3.0 Field Procurement 1 18 December 1997

N4.0 Material Handling and Storage 1 18 December 1997

N5.0 Measuring and Test Equipment 1 18 December 1997

N6.0 Nonconformance Reporting 1 18 December 1997

N7.0 Quality Verification System 1 18 December 1997

N8.0 Housekeeping 1 18 December 1997N9.0 Construction Testing 1 18 December 1997

N10.0 Personnel Certification 1 18 December 1997

N11.0 (Sub)Contractor Control 1 18 December 1997

N12.0 Component/System Turnover 1 18 December 1997

N13.0 Quality Control Records 1 18 December 1997

N14.0 10 CFR 21 Reportability 1 18 December 1997

N15.0 Problem Investigation Requests 1 18 December 1997

N16.0 Safeguards Information Procedure 1 18 December 1997Glossary of Terms 1 18 December 1997

Manual Approvals:

Chief Construction Quality Control Engineer

Manager, Construction Resources & Technologies

Manager of Quality Assurance

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1997 Bechtel Corp. Nuclear Quality Control Manual N1.0-1

Instruc tion N1.0

Int roduct ion

1.0 PURPOSE

This manual describes the Quality Control system and the methods used to implement thesystem as required by the Bechtel Nuclear Quality Assurance Manual (NQAM).

2.0 SCOPE

2.1 The Quality Control system applies to the scope of work identified in the project specificQuality Assurance Program Plan (QAPP).

2.2 The applicability of individual functions, responsibilities, or requirements described in thismanual may be modified by agreement with the customer, and will be applied to theagreed-upon extent. Specific agreements that change or modify these instructions will bereflected in the project quality control procedures or project construction procedures.

2.3 When directed to use owner procedures to accomplish activities covered by this manual,Bechtel Quality Control interface requirements will be delineated in project quality controlprocedures or project construction procedures.

3.0 DEFINITIONS

3.1 For definition of common terms used throughout this manual, refer to the Glossary of

Terms at the end of the manual.

3.2 The term Bechtel, as used in this manual, applies to the following Bechtel entities as maybe required to accomplish Bechtel's scope of work on a nuclear project:

Bechtel Corporation (BCORP)

Bechtel Construction Operations Incorporated (BCOI)

Bechtel Power Corporation (BPC)

Bechtel Construction Company (BCC)

Bechtel Constructors Corporation (BECC)

Becon Construction Company, Inc. (Becon)

Bechtel affil iated companies

4.0 REFERENCES

The following documents have been used as guidelines for the development of thisinstruction:

a. ASME NQA-1

Quality Assurance Requirements for Nuclear Facil ities

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Instruction N1.0 Introduction

N1.0-2 Nuclear Quality Control Manual 1997:Rev.1

b. NQAM

Bechtel Nuclear Quality Assurance Manual

5.0 RESPONSIBILITIES

Quality Control personnel responsible for implementing the system defined by this manualare listed in the following sections:

5.1 Chief Construction Quality Control Engineer

The Chief Construction Quality Control Engineer (CCQCE) establishes the Quality Controlsystem in accordance with the NQAM policies and provides technical and administrativedirection to theProject Field Quality Control Engineer.

5.2 Project Field Quality Control Engineer (PFQCE)

The PFQCE manages the implementation of the Quality Control system at the jobsite byproviding technical and administrative direction to Quality Control Engineers (QCEs),

administrative staff, and subcontractors in accordance with this manual.5.3 Project Engineer

The term Project Engineer as used in this manual refers to the engineering organizationthat has the design responsibility. The owner designates the Project Engineer.

6.0 REQUIREMENTS

6.1 Nuclear Quality Control Manual

6.1.1 Coordination and Review

This manual does not assign responsibility to other organizations; however, instructionsand revisions to this manual that affect other organizations will be coordinated with theaffected organization. Approval signatures for changes to this manual must be obtainedprior to issuance of revisions.

6.1.2 Approvals

a. The Chief Construction Quality Control Engineer or designee approves the publicationof this manual and revisions by signing the Table of Contents.

b. The Manager, Construction Resources and Technologies or designee reviews thismanual and revisions for compliance with construction policies and signifies approvalby signing the Table of Contents.

c. The Manager of Quality Assurance, Bechtel Power Corporation or designee reviewsthis manual and revisions for compliance to the NQAM policies and signifies approvalby signing the Table of Contents.

6.1.3 Distribution and Control

a. This manual is controlled by the CCQCE. Each manual issued is identified by aunique number and assigned according to a master distribution list that is establishedand maintained under the direction of the CCQCE.

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Introduction Instruction N1.0

1997:Rev.1 Nuclear Quality Control Manual N1.0-3

b. The manual and revisions are transmitted by interoffice memorandum (IOM), whichestablishes the effective date of the instruction(s) and provides instructions forupdating the manual. The IOM may be used as a receipt acknowledgment form whichmanual holders must sign and return to the CCQCE.

c. The CCQCE shall verify the return of receipt acknowledgment forms subsequent to

issue of the manual or revisions. Appropriate measures shall be taken to obtainreceipts from any manual holders who are delinquent.

d. Receipt acknowledgment forms shall be kept on file until the next instruction revisiontransmittal is complete or the next configuration survey is complete.

e. Manuals to be consigned and distributed to the owner or regulatory agencies shall berequested by the Project Manager(s).

f. Manual recipients will be held responsible for retaining custody and for keeping themanual current.

g. When a controlled copy of the Nuclear Quality Control Manualis no longer needed it

may be returned or destroyed; however, the CCQCE shall be informed of the status ofthe manual.

6.1.4 Revisions

When revisions to this manual are necessary, they will be incorporated as follows:

a. The Table of Contents will be updated to reflect the current revisions and date of theindividual instructions.

b. The next consecutive revision number will be shown at the bottom of each page otherthan page 1 of the affected instruction(s).

c. When changes involve revising portions of a instruction, the revisions will be identifiedby a vertical line placed in the margin, adjacent to the applicable section number(s) orfigure(s).

d. When changes involve revising an instruction by adding or deleting a paragraph, therenumbering of subsequent paragraphs does not require a revision symbol.

6.1.5 Record Copy

The CCQCE shall be responsible for retaining two record copies of each instruction,including subsequent revisions, and the revision record page in separate and remotelocations. One copy may be an electronic file.

6.1.6 Forms Control

a. Forms shown as an integral part of the Nuclear Quality Control Manualare not

considered mandatory.

b. The field may develop and use forms in addition to or other than those shown in thismanual, provided they are reviewed and approved in accordance with instructions setforth in paragraphs 6.2.1 and/or 6.2.2 of this instruction.

c. A control system shall be established and used to control the forms required to

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Instruction N1.0 Introduction


implement the project quality system.

6.1.7 Configuration Survey/IOM

a. A configuration survey of controlled copies of the Nuclear Quality Control Manualwill

be conducted annually provided revisions to the manual have been issued within theyear.

b. Each manual holder listed on the master distribution list will receive the current statusof the manual contents from the CCQCE in order to conduct the survey of the Nuclear

Quality Control Manual.

c. Each manual holder upon receipt of the information will conduct a survey of themanual and return the information to the CCQCE attesting to the configuration of themanual.

d. The CCQCE will verify the return of the survey information approximately thirty daysafter transmittal.

e. A copy of the survey will be retained until the next survey.

f. Manual holders who indicate the need for current documents will be supplied anyrequested materials.

6.2 Project Quality Control Procedures and Project Construction Procedures

Project quality control procedures are published, distributed, and controlled by thePFQCE. These procedures provide detailed instructions to QC personnel for theimplementation of the requirements included in this manual. An identification system forthese procedures shall be established and the PFQCE shall determine when projectquality control procedures are needed.

6.2.1 Project quality control procedures convey provisions for the administration of Nuclear

Quality Control Manualrequirements. They delineate tasks and provide guidance for

accomplishing the responsibilities established by this manual.

6.2.2 Project construction procedures provide construction personnel with the requirements andresponsibilities established by the project and the customer. When project quality controlprocedures are not used, project construction procedures will also provide quality controlwith the requirements of 6.2.1, 6.2.3, and 6.2.4 of this instruction.

6.2.3 Project quality control procedures also provide detailed direction for the quality verificationand monitoring activities performed by QCEs. Project quality control procedures are thecontrolling documents that specify what quality verification and monitoring activities arerequired; the applicable criteria by explicit statement or by reference to the governing

design document; how, by whom, and at what frequency activities are to be performed;and sequencing of activities when required. Normally, quality control verification activitiesare documented on the work plans and inspection records; however, the project qualitycontrol procedures may contain additional data sheets, monitoring checklists, and otherinspection examination and test records that may be required to supplement the workplans and inspection records. General requirements for content of project quality controlprocedures shall be in accordance with Instruction N7.0 of this manual. Project qualitycontrol procedures require the approval of the PFQCE and the Project Quality AssuranceManager/Project Quality Assurance Engineer (PQAM/PQAE).

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Introduction Instruction N1.0


6.2.4 Control

Control of project quality control procedures, including coordination and review, approval,distribution, revision, form control, and the configuration survey, shall be the same asthose established for this manual except for the following:

a. The PFQCE shall accomplish the activities described for the CCQCE.

b. Approval shall be as defined in paragraphs 6.2.1, 6.2.2, and 6.2.3 of this instruction.

c. The PFQCE shall be responsible for retaining two record copies of each instruction,including subsequent revisions, in separate and remote locations. One copy may bean electronic file.

d. A single record copy of each project quality procedure, including the subsequentrevision, may be retained in an established quality control records vault in lieu ofretaining two record copies in separate and remote locations.

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Instruc tion N2.0

Receiving Inspect ion

1.0 PURPOSE

This instruction defines Quality Control activities for the review and approval of a MaterialReceiving Instruction (MRI); the performance of required receipt inspections for bothhardware and documentation received from Suppliers; and the documentation of thereceipt inspection.

2.0 SCOPE

This instruction applies to all safety-related and ASME items applicable to the project. Inaddition, receipt inspections shall be conducted on Reliability Related Itemsand Balance

of Plant Itemsas designated by the Customer. The instruction does not apply to

(sub)contractors' receiving inspection functions.

3.0 DEFINITIONS

3.1 See Glossary of Terms at the end of this manual.

4.0 REFERENCES

4.1 Nuclear Quality Assurance Manual (NQAM)



The PFQCE reviews work load requirements and assigns properly certif ied QCEs to

perform the duties specified in this instruction. In addition, the PFQCE shall verify theproper implementation of the quality system described in this instruction.

5.2 Quality Control Engineers (QCE)

QCEs review and approve MRIs for f ield purchased items and MRIs for ProjectEngineering purchased material requisitions, identify receiving inspections to beperformed, perform receipt inspections of material and documentation in accordancewith the approved MRI, and provide technical assistance to the receiving inspectiongroup as required.

6.0 REQUIREMENTS

6.1 General

6.1.1 The extent of the receiving inspection depends upon whether the item is a standardcatalog item or is specifically designed for a particular or unique application, and whetherit was subjected to Procurement Supplier Quality Department (PSQD) surveillanceinspection.

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Instruction N2.0 Receiving Inspection


6.1.2 Items or materials for which PSQD assignments have been made and are released bytheir representative at the supplier's facility are normally inspected for identification,shipping damage, and documentation at receipt.

6.1.3 Suppliers for whom PSQD assignments have been made may sublet portions of theoriginal order to sub-suppliers. PSQD is responsible for determining if a surveillance

inspection assignment should be made for the sub-supplier.6.1.4 Receiving inspection on items shipped directly to the jobsite from a sub-supplier shall be

made in accordance with a MRI after determining if a PSQD assignment has been made.

6.2 Documentation Requirements

6.2.1 Material Receiving Instruction (MRI)

6.2.1.1 The MRI, shown in Exhibit N2.0-1, is routed to Quality Control (QC) for review, inclusionof required receipt inspections, and approval.

6.2.1.2 The review of the MRI verifies that the proper design document reference has beenmade and that special handling and storage requirements have been identified.

6.2.1.3 Using the appropriate procurement and/or installation specifications or drawings, theQCE shall determine the required receipt inspections and so indicate on the MRI.

6.2.1.4 After review of the MRI for the inclusion of the proper receipt inspection activities, theQCE shall signify approval by signing and dating the appropriate blocks on the MRI form.

6.2.1.5 The QCE performing receipt inspection may revise the MRI to be compatible with theactual shipment being received. For example, the MRI may have been developed for acomplete, factory-assembled component such as a pump, but a partial shipment fromthe manufacturer may consist of only replacement gaskets. In this case, the MRI wouldbe revised to accommodate these items only. Revisions of this type shall not increase

the scope of the MRI or lessen the inspection requirements for the item(s) in question.6.2.2 Material Receiving Report (MRR)

The MRR, shown in Exhibit N2.0-2, is a form that documents the receipt of items, anddescribes the items, quantities, purchase documents, etc. When signed by the receivingQCE in the appropriate block, it documents the receiving inspection process andreferences the MRI used.

6.3 Receiving Inspection

6.3.1 Items Covered by Procurement Supplier Quality Department Surveillance Program

Items and documentation for which a Procurement Supplier Quality SurveillanceInspection assignment has been made are subject to shipping damage inspection anditem inspection upon receipt.

6.3.1.1 Shipping Damage Inspection

Preliminary visual inspections or examinations shall be performed as identified on theMRI.

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Receiving Inspection Instruction N2.0


6.3.1.2 Item Inspections

Item inspections shall be performed in an area equivalent to the level of storage requiredfor the item. The item inspections, as identified on the MRI, shall include the following:

a. Packaging

Verification that the level of packaging has been maintained on items for protectionagainst corrosion, contamination, physical damage, or any effect which would lowerthe quality or quantity, thereby causing the item to deteriorate during the time ofshipment.

b. Supplier Documentation

Verification that the documentation received indicates the item received wasfabricated, tested, and inspected prior to shipment in accordance with therequirements of the procurement documents and is traceable to the hardware.

c. Protective Covers and Seals

Verification that required covers and seals are in place.

d. Coatings and Preservatives

Verification that coatings and preservatives are in accordance with specifications,purchase orders, or manufacturers' instructions.

e. Inert Gas Blanket

Verification that the inert gas blanket pressure is within the acceptable limits.

f. Desiccant

Verification that desiccant is not saturated as indicated through visual inspection ofhumidity indicators.

g. Physical Damage

Verification that parts of items are not broken, cracked, missing, deformed, androtating parts turn without binding.

h. Cleanliness

Verification that accessible internal and external areas are within the specificationrequirements for dirt, soil, mill scale, weld splatter, oil, grease, or stains.

i. Identification and Marking

Verification that identification and markings on the outside of all packages, skids, orprotective covering shall be maintained.

Note: With the exception of supplier documentation, acceptance sampling may beused in lieu of 100 percent item inspection for groups of like items.Sampling inspection will be performed in accordance with Exhibit N2.0-3.

Acceptance sampling shall not be used for supplier documentation.

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6.3.1.3 Nonconforming Items

Items received at the jobsite without Procurement Supplier Quality Release whenrequired shall be placed on "Hold" or considered nonconforming and processed inaccordance with Instruction N6.0 of this manual. The exception to this occurs when awritten Waiver of Procurement Supplier Quality Release, signed by the Project Engineer

for home office purchases or by the Field Engineer for field purchases, is received priorto or at the time of receipt. Refer to Section 6.3.2 of this instruction for additionalinspection requirements.

6.3.2 Items Not Covered by Procurement Supplier Quality Department Surveillance Program

6.3.2.1 Unless the complete item was inspected or examined at the source, as evidenced by theProcurement Supplier Quality Representative's signature on the document list, it shall beinspected or examined at the point of receiving to verify conformance to specifiedprocurement document requirements. Measuring and Test Equipment (M&TE) shall beused as required to perform the required verif ications. Calibration of any M&TE usedshall be verified prior to use and the identification number and calibration due date shallbe entered on the MRI. In addition to the requirements of Section 6.3.1 of this

instruction, item inspections described on the MRI shall include but shall not be l imited tothe following as appropriate:

a. Physical Properties

Verification that physical and chemical properties conform to the specifiedrequirements by reviewing chemical and physical test reports.

b. Dimensions

Verification that critical construction dimensions conform to drawing and specificationrequirements. Examples are baseplate mounting holes, overall external size,configuration, and orientation of parts.

c. Weld Preparations

Verification that weld preparations are in accordance with applicable drawings andspecifications.

d. Workmanship

Verification that the workmanship characteristics conform to specified requirements(accessible areas only).

e. Lubricants and Oils

Verification of the presence of required lubricants and oils as required by eitherprocurement documents or manufacturer instructions.

f. Electrical Insulation

Verification of electrical insulation by insulation resistance tests for motors,generators, control and power cable to ascertain conformance to specifiedrequirements.

6.3.2.2 Acceptance sampling may be used in lieu of 100 percent item inspection for groups of

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like items. Sampling inspection will be performed in accordance with Exhibit N2.0-3.

Note:In Exhibit N2.0-1, under the column titled METHOD, the letter designationsshown (W,R,I,S,T) refer to the applicable verification methods which are definedin Instruction N7.0, Section 3.0 of this manual.

6.3.3 Special Receiving Inspection Requirements

When items require inspections or examinations other than those described inSections 6.3.1 and 6.3.2 of this instruction because of their uniqueness or complexity,the additional requirements shall be identified on the MRI. Verification of theseadditional requirements shall be documented by signoff of the MRR.

6.4 Sampling Inspection for Bulk Items

6.4.1 Acceptance sampling inspections may be implemented on a project at the discretion ofthe PFQCE. The sampling table used to determine acceptance or rejection of lots of likeitems is shown as Exhibit N2.0-3.

6.4.2 The inspection requirements of the MRI shall apply to the sample.

6.4.3 When specification, code, standard, customer, or project requirements have previouslyestablished a sampling program, Exhibit N2.0-3 is not applicable.

6.4.4 Sampling shall not apply to the review of documentation.

6.5 Disposition of Received Items

6.5.1 Acceptable

Containers and items that are verified to be in accordance with the MRI requirementsand that are in conformance with specified requirements shall be placed in a designatedstorage area for acceptable items or moved to the final location for installation or use.

Verification results shall be documented by signoff on the MRR.

6.5.2 Nonconforming

Items inspected that do not conform to the specified requirements shall be identified asnonconforming and shall be processed in accordance with Instruction N6.0 of thismanual.

6.6 Marking

6.6.1 Changing, correcting, or otherwise marking ASME Code nameplates is strictly prohibitedunless approved in writing by the item manufacturer's Authorized Nuclear Inspector(ANI).

6.6.2 Safety related bulk items shall be identified if similarities in physical characteristics could

cause intermingling with non-safety relateditems of the same type.

6.7 Documentation

Supplier documentation, MRIs, and MRRs shall be forwarded to the Quality Controlrecords area for processing and retention in accordance with Instruction N13.0 of thismanual.

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MATERIAL RECEIVING INSTRUCTION (MRI)EXHIBIT N2.0-1

MATERIAL RECEIVING INSTRUCTION

1. Specification No., Rev.

,

2. P.O./FMR No.

3. ASME/ANSI

Yes No

4. Q/BOP

Q BOP

5. MRI No., Rev.

6. Item/Description

7. Supplier

8. Quality Surveillance

Assignment Made?

Yes No

9. Storage Level Requirements

A B C D Outdoor Outdoor Weatherproof

10. Special Storage Instructions

11. Special Handling Instructions:

12. Initiated By: Date: 13. Reviewed/Approved By: Date:

14. Receiving Inspection Requirements For BOP and Q Items 17. Method 18. N/A QCE Date

A. Verify Items Are Free of Damage Caused By Shipping I

B. Verify The Level Of Packaging Has Been Maintained I

C. Verify Identification And Markings Are As Specified I

D. Verify Coatings And Preservatives Are As Specified I

E. Verify Protection Covers & Seals Meet Their Intended Function I

F. Verify Inert Gas Blanket Pressure Is Within Specified Limits I

G. Verify Desiccant Is Not Saturated I

H. Verify Items Meet Specified Cleanness I

I. Verify Items Are Free Of Physical Damage I

J. Verify Documents (Reference Form G-321-C) R

15. Receiving Inspection Requirements For Q Items Not Released By

Procurement Quality

A. Verify Physical Properties (See Documentation) R

B. Verify Dimensions/Configuration I

C. Verify Weld Preparations I D. Verify Workmanship I

E. Verify Lubricant/Soils I

F. Verify Electrical Insulation W

16. Unique Inspection Requirement For Items

A. Verify

B. Verify

C. Verify

D. Verify

E. Verify

19. Sampling Used? Yes No

Item Description

Trace Number Quantity Sampling

Table

20. Remarks/Comments

Use Additional Space if Needed

A.

B.

C.

D.

E.

F.

G.

H.

FORM T_MRI.DOC 1997:REV.0

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INSTRUCTIONS FOR PREPARING THE MATERIAL RECEIVING

INSTRUCTION (MRI)EXHIBIT N2.0-1a

ENTRY NO. ENTRY ENTERED BY DESCRIPTION

1 Specification Originator Enter the specification number under which the item wasprocured

2 Purchase Order/FMR Number Originator/QC Enter the Purchase/FMRNumber Order/Field MaterialRequisition number andrevision

3 ASME III Code Item Originator/QC Check the appropriate block

4 Safety Class Originator/QC Check the appropriate blockindicating the item/material issafety, regulatory, reliability or

non-safety related5 MRI Number Originator Enter the MRI number assigned

by Field Engineering andrevision

6 Item and Description Originator Enter the description of the itemto which the MRI applies

7 Supplier/Vendor Originator/QC Enter the name of thesupplier/vendor. (Name may beentered after receipt of materialif the supplier/ vendor cannot beidentified prior to requisitioning)

8 Quality Surveillance

Assignment Made

Originator Check the appropriate block

9 Storage Level Requirements Originator Check the appropriate StorageLevel as required by thespecification

10 Special Storage Originator Enter any Special StorageInstructions as defined by thespecification

11 Special Handling Instructions Originator Enter any Special HandlingInstructions and/or WP numberfor Special Handling/Rigging

12 Initiated By Originator Signature and date of theengineer who originated the

MRI (QCE for M&TE)

13 Reviewed/Approved QC, Discipline Signature of the Quality ControlEngineer who reviewed theMRI, entered inspectionrequirements, and approved theMRI

14, 15 Receiv ing InspectionRequirements

Preprinted

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INSTRUCTIONS FOR PREPARING THE MATERIAL RECEIVING

INSTRUCTION (MRI)EXHIBIT N2.0-1a

ENTRY NO. ENTRY ENTERED BY DESCRIPTION

16 Unique InspectionRequirements for Items

Quality Control Enter inspection requirementsunique to the item to bereceived, which are notaddressed in entries 14 and 15(e.g., verify reliability of loadindicating washers)

Note: Verification methodsshall be added forunique inspectionrequirements identifiedin Entry No. 16.

17 Verify Method Quality Control Discipline Preprinted verification method

to be used

18 N/A Quality Control Engineer Initials and date of the QualityControl Engineer checking theN/A column indicating theinspection requirements are notappropriate for the item beingreceived

19 Sampling Used: Yes/No QC, Receiving Check the NO block if samplingwas not used to perform theitem inspection

Check the YES block ifsampling was used to performthe item(s) inspections, andmake the following entries:

Enter a brief description of thetype or types of item(s) coveredby the sampling. Enter thetrace number of the materialsbeing inspected (e.g., heatnumber, lot number, etc.).Enter actual count of material.Enter the appropriate letter fromthe sampling inspection table.

20 Remarks/Comments Originator/QC Enter appropriate remarks or comments. Also enter type,serial number, last calibration

date and next calibration date ofany M&TE used

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MATERIAL RECEIVING REPORTEXHIBIT N2.0-2

MATERIAL RECEIVING REPORT

DISTRIBUTION P.O. NO.: JOB NO.: SPECIFICATION NUMBER

MRR NO.: DATE:

VENDOR: REFERENCE DRAWING

SHIPPED BY:

SHIPPING POINT: SERVICE

P.O. ITEM NO./

Q NO.

QUANTITY

RECEIVED COMPLETE DESCRIPTION

/

/

/

/

/

/

/

/

/

/

/

/

/

/

/

/

SHOP INSPECTION RELEASE RECEIVED

YES NO N.R.

QC RECORDS RECEIVED

YES NO N.R.

NONCONFORMANCE ISSUED

YES NO TAG NO.:

INSPECTION PROCESS USED:

COMMENTS/INSTRUCTIONS:

INSPECTED BY: DATE:

APPROVED BY: DATE:

DELIVERING CARRIER: P.O. NO.: CAR NO.:

DATE RECEIVED: WEIGHT: CHARGES: PREPAID COLLECT

PACKING SLIP NO.: PARTIAL COMPLETE OSD NO.:

DELIVER TO/LOCATION:

CHECKED & COUNTED BY: REPORT PREPARED BY:

FORM T_MRR.DOC 1997:REV.0

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ACCEPTANCE SAMPLING INSPECTION TABLEEXHIBIT N2.0-3

A. LOT OR BATCH SIZE 2 TO 15

QTY USED IN EACH SAMPLE SET 2

SAMPLE SET NO. 1 2 3 4 5 6 7Cumulative Specimens Taken 2 Single

Number of rejects allowed in thissample set to ACCEPT THE LOT

0 Single

Number of rejects found in this setwhich requires the LOT TO BEREJECTED

1 Plan

B. LOT OR BATCH SIZE 16 TO 50


SAMPLE SET NO. 1 2 3 4 5 6 7

Cumulative Specimens Taken 2 4 6 8 10 12 14

No. of rejects allowed in this sampleset to ACCEPT THE LOT

* * 0 0 1 1 2

Min. of cumulative rejects whichdesignate next set to be drawn andinspected

N/A N/A 1 1 2 2 N/A

No. of cumulative rejects foundwhich require the LOT TO BEREJECTED

2 2 2 3 3 3 3

* Acceptance not permitted of this sample size

C. LOT OR BATCH SIZE 51 TO 90


SAMPLE SET NO. 1 2 3 4 5 6 7



* 0 0 1 2 3 4


1 1 1 2 3 4 N/A


2 3 3 4 4 5 5


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D. LOT OR BATCH SIZE 91 TO 150


SAMPLE SET NO. 1 2 3 4 5 6 7Cumulative Specimens Taken 5 10 15 20 25 30 35


* 0 1 2 3 4 6


1 1 2 3 4 5 N/A


3 3 4 5 6 6 7


E. LOT OR BATCH SIZE 151 to 280QTY USED IN EACH SAMPLE SET 8

SAMPLE SET NO. 1 2 3 4 5 6 7



* 1 2 3 5 7 9


1 2 3 4 6 8 N/A


4 5 6 7 8 9 10


F. LOT OR BATCH SIZE 281 to 500


SAMPLE SET NO. 1 2 3 4 5 6 7



0 1 3 5 7 10 13


1 2 4 6 8 11 N/A

No. of cumulative rejects found

which require the LOT TO BEREJECTED

4 6 8 10 11 12 14


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G. LOT OR BATCH SIZE 501 to 1200


SAMPLE SET NO. 1 2 3 4 5 6 7Cumulative Specimens Taken 20 40 60 80 100 120 140


0 3 5 7 11 14 18


1 4 6 8 12 15 N/A


5 8 10 13 15 17 19

H. LOT OR BATCH SIZE 1201 to 3200

QTY USED IN EACH SAMPLE SET 32SAMPLE SET NO. 1 2 3 4 5 6 7



1 4 8 12 17 21 25


2 5 9 13 18 22 N/A


7 10 13 17 20 23 26


I. LOT OR BATCH SIZE 3201 to 10,000


SAMPLE SET NO. 1 2 3 4 5 6 7



2 7 13 19 25 31 37


3 8 14 20 26 32 N/A


9 14 19 25 29 33 38

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Instruc tion N3.0

Field Procurement

1.0 PURPOSE

This instruction defines Quality Control responsibilities for review of Field MaterialRequisitions (FMRs).

2.0 SCOPE

This instruction applies to FMRs for Safety Related and ASME items. In addition, FMR

review shall be conducted on Reliability Related Itemsand Balance of Plant Itemsas

designated by the Customer. This instruction does not apply to (sub)contractors' FMRfunctions.

3.0 DEFINITIONS


4.0 REFERENCES




The PFQCE reviews work load requirements and assigns properly certif ied QCEs toperform the duties specified in this instruction. In addition, the PFQCE shall verify theproper implementation of the quality system described in this instruction.

5.2 Quality Control Engineer (QCE)

QCEs review FMRs for inclusion of quality requirements prior to approval for purchase.

6.0 REQUIREMENTS

6.1 Review of FMRs

6.1.1 All permanent plant FMRs shall be reviewed to verify that the item's quality level hasbeen properly classified.

6.1.2 If all the items on the FMR are of a level not requiring Quality Control, the FMR shall bestamped and signed QCApproval Not Required, and returned to the originator.

6.1.3 If an item on the FMR is of a quality level requiring Quality Control review, the assignedQCE shall review the purchase specification to ensure the following attributes areaddressed as applicable:

a. Quality verification document requirements are included in the procurementdocuments.

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Instruction N3.0 Field Procurement


b. Supplier Quality Surveillance Inspection requirements are identified.

c. Vendor Quality Assurance Program requirements are imposed.

d. References to Project Engineering specifications are to the current revision, andreferences to standards (ASTM, ASME, etc.) are to the revision specified by ProjectEngineering.

6.2 Approval and Documentation

The signature and date of the QCE performing the review shall indicate approval of theFMR. Revisions to an FMR shall be returned to the QCE for review and approval.

6.3 FMRs for Measuring and Test Equipment Items and Calibration Services

FMRs for measuring and test equipment items and offsite calibration services shall bereviewed for conformance to the procurement requirements of Instruction N5.0 of thismanual.

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Instruc tion N4.0

Material Handlin g and Storage

1.0 PURPOSE

This instruction defines the Quality Control requirements relative to storage and handlingof items and equipment to preclude damage or degradation.

2.0 SCOPE

This instruction applies to items and equipment from the time of receipt inspection untilthe customer assumes the responsibility. In addition, this instruction applies to"Reliability Related Items" and "Balance of Plant Items" as designated by the Customer.This instruction does not apply to (sub)contractor storage and handling functions.

3.0 DEFINITIONS


4.0 REFERENCES




The PFQCE reviews work load requirements and assigns properly certif ied QCEs toperform the duties specified in this instruction. In addition, the PFQCE shall verify theproper implementation of the quality system in this instruction.


Quality Control Engineers shall:

a. Monitor and verify that storage and control are in accordance with project proceduresand project quality control procedures.

b. Monitor handling operations for the use of appropriate equipment and techniques.

c. Verify that specially selected equipment has been inspected and documented inaccordance with the applicable procedures.

6.0 REQUIREMENTS

6.1 General

6.1.1 For purposes of this instruction, the term monthly observations means observationsconducted approximately every 30 days.

6.1.2 Storage and handling conditions that are in noncompliance with procedural requirementsshall be reported to the responsible organization for correction. Deficiencies not

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Instruction N4.0 Material Handling and Storage


corrected within the surveillance period shall be documented in accordance withInstruction N6.0 of this manual.

6.1.3 Items released from storage and placed in their final locations shall be observed inaccordance with the requirements of this instruction.

6.2 Storage

6.2.1 Quality Control personnel shall perform and document monthly observations of QC holdareas, storage areas, and methods and control of items in storage, including in-placestorage, to ascertain compliance with specified requirements.

6.2.2 The following general characteristics shall be observed as a minimum for the appropriatelevel of storage.

6.2.2.1 Storage Areas

a. Access is controlled.

b. Environmental requirements are applied.

c. Cleanliness requirements are enforced.

6.2.2.2 Storage Methods

a. Items are properly stacked or cribbed.

b. Hazardous chemicals, paints, solvents, and other like materials are properlyprotected and hazardous storage areas are identified.

6.2.2.3 Control of Items in Storage

a. Items in storage are identified and marked, as required.

b. Items in storage are checked for physical damage.

c. Cleanliness is maintained.

d. Covers, caps, plugs, or other required closures are intact.

e. Temporary preservatives are left intact during storage.

f. Items pressurized with inert gas are monitored to ensure that the gas pressure ismaintained within specified limits during storage. Desiccant humidity indicators shallalso be monitored.

g. Items in storage are protected from work activities being performed in or near the

area.

h. Limited shelf life items are dated.

6.3 Handling

6.3.1 Quality Control shall monitor handling operations for the use of appropriate equipmentand techniques.

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Material Handling and Storage Instruction N4.0


6.3.2 Where handling operations require the use of specially selected equipment (i.e., where aspecific procedure is required), Quality Control shall verify that the equipment and riggingused for handling has been inspected, and documented in accordance with theapplicable procedure.

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Instruc tion N5.0

Measurin g and Test Equipment

1.0 PURPOSE

This instruction describes the Quality Control Program associated with calibration andcontrol of measuring and test equipment (M&TE) and reference standards used forverification of construction.

2.0 SCOPE

2.1 This instruction applies to all safety-related and ASME items applicable to the project. Inaddition, this instruction shall be applied to Reliability Related Itemsand Balance of Plant

Itemsas designated by the Customer. This instruction does not apply to the control of

(sub)contractor M&TE.

2.2 Calibration controls are not required for standard off-the-shelf measuring equipment(e.g., rulers, tape measures, levels) that is not liable to change or drift during use. Suchdevices shall be visually inspected to ensure that damage or deterioration has notimpaired accuracy. When required by additional project requirements, a project qualitydocument may define the project-unique methods and controls.

3.0 DEFINITIONS


4.0 REFERENCES






Quality Control personnel shall maintain control and calibration over M&TE inaccordance with this instruction or submit M&TE to an approved calibration laboratory for

calibration. In either case, Quality Control shall maintain the calibration records and shallimplement the program for recall of equipment for calibration.

QCEs perform product acceptance measurements and tests using certified M&TE andrecord the acceptance M&TE identification numbers used on the appropriate verificationrecords.

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Instruction N5.0 Measuring and Test Equipment


6.0 REQUIREMENTS

6.1 General

6.1.1 QCEs calibrating M&TE shall be trained in the proper methods and procedures asdescribed in Instruction N10.0 of this manual.

6.1.2 Upon receipt of an M&TE item calibrated by a calibration laboratory, the responsibleQCE shall inspect the item for damage and identification. The responsible QCE shallreview the laboratory's calibration certificate for out-of-tolerance as-found conditions,after-adjustment tolerances, and traceability to nationally recognized standards.

6.1.3 M&TE shall be calibrated in accordance with the manufacturer's recommendedstandards or standards that have uncertainty (error) requirements of no more than one-fourth of the intended use of the equipment being calibrated. Deviations from thisrequirement shall be justified and documented.

6.1.4 Reference standards shall be traceable to a nationally recognized standard. If nostandard exists, the basis for calibration may be an approved engineering specification,

Quality Control calibration procedure, or manufacturer calibration procedure, providedthat the basis used is documented.

6.1.5 The tolerance and frequency of calibration for M&TE shall be listed on Exhibit N5.0-1.The M&TE calibration tolerance and frequency list is a list of equipment showing thecalibration intervals and tolerances. The intervals begin at the time of first issue or use,except in the cases of pressure and vacuum gauges, oxygen analyzers, and other M&TEthat has a shelf li fe after calibration/recharging. In these cases, the calibration intervalwill begin at the time of calibration/recharge.

6.1.6 A system of labels shall be used to indicate the calibration status and usage control ofM&TE items and reference standards. An acceptable label is shown in Exhibit N5.0-2.

6.2 Procurement of Calibration Services

6.2.1 Suppliers of M&TE calibration services shall be listed on the Bechtel Evaluated SupplierList (ESL) or on the customer's approved vendor list.

6.2.2 When a calibration supplier is reviewed and approved by Bechtel Quality Control, thesupplier shall transmit a controlled copy of its Quality Assurance Program for review andapproval.

6.2.3 The supplier's Quality Assurance Program shall be reviewed for compliance with:

a. ANSI N45.2 and applicable ANSI N45.2 daughter standards, or

b. ANSI/ASME NQA-1, or

c. As specified by the customer

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Measuring and Test Equipment Instruction N5.0


6.2.4 The supplier's Quality Assurance Program shall address the following 10 CFR 50Appendix B criteria as applicable:

I. Organization

II. Program

IV. Procurement Document Control

V. Instructions, Procedures, and Drawings

VI. Document Control

VII. Control of Purchased Materials, Services, and Equipment

VIII. Identification and Control of Material, Parts, and Components

X. Inspection

XI. Test Control

XII. Control of Measuring and Test Equipment

XIII. Handling, Storage, and Shipping

XV. Nonconforming Material, Parts, or Components

XVI. Corrective Action

XVII. Records

XVIII.Audits

6.2.5 The supplier's Quality Assurance Program or implementing procedures shall include the

following elements of control:

Calibration intervals of reference standards

Environmental conditions

Control and segregation of obstacle, damaged, or otherwise nonconformingequipment

Corrective action

Records

Unique identification of reference standards

Traceability to a nationally recognized standard

Calibration procedures

Requirements for calibration of M&TE with a reference standard having anuncertainty (error) of no more than one-fourth of the item being calibrated

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Sources of calibration

Reference standard recall system

Personnel qualification and training

6.2.6 A pre-award survey shall be performed by the Procurement Supplier Quality Departmentor Quality Control, and the supplier shall be placed on the ESL or restricted to thequalifying project.

6.2.7 The supplier shall be audited by the Procurement Supplier Quality Department asrequired by its procedures to maintain an acceptable status on the ESL.

6.2.8 The customers calibrated laboratory or a calibration laboratory(s) qualified by thecustomers may be used without further evaluation, provided the laboratory(s) is qualifiedfor the intended service. When using a customer qualified laboratory, the qualificationdocumentation or statement of qualification shall be obtained from the customer andretained in the Quality Control files.

6.3 Procurement of Measuring and Test Equipment

6.3.1 M&TE item purchases shall have a certificate of calibration traceable to a nationallyrecognized standard or a certificate stating that the manufacturer is using standards thatare traceable to a nationally recognized standard, or shall be calibrated by the M&TElaboratory or an approved calibration laboratory before use.

6.3.2 When the manufacturer's documents are used, the M&TE item identification code shallbe annotated on the documents and filed as a quality record.

6.3.3 M&TE items may be repaired or recalibrated by the manufacturer and records providedas described in Section 6.3.1 of this instruction.

6.4 M&TE Identification

6.4.1 Each M&TE item and reference standard shall be assigned a unique code. The codeshall be affixed to the device by an approved method.

6.4.2 A master list of identification codes shall be maintained showing pertinent informationsuch as type, range, calibration intervals, and status (i.e., active or withdrawn fromservice). An example master list form is shown in Exhibit N5.0-3.

6.4.3 When neither labeling nor other form of coding is practical due to size or functionalcharacteristics of the item, a recall system shall be used to ensure proper control.

6.5 Storage

M&TE items used for quality verification shall be stored in a location approved by thePFQCE until their use to perform a test, measurement, or other function is required.

6.6 Calibration Procedures and Calibration Intervals

6.6.1 Calibration procedures for calibrating M&TE items shall be used if a jobsite calibrationlaboratory is established. Procedures may be the manufacturer instructions or may bedeveloped from sources such as manufacturer handbooks, published standard practices,mili tary calibration programs, or engineering specifications.

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6.6.2 Suppliers of calibration services shall calibrate the M&TE items using their calibrationprocedures developed in accordance with their approved Quality Assurance Program.

6.6.3 Calibration intervals for M&TE items shall be as listed in Exhibit N5.0-1 or by thecustomer procedures when using the customer calibration laboratory. These intervalsshall be based on the manufacturer's recommendations or intended use of the item.

6.7 Maintenance and Repair of M&TE and Reference Standards

6.7.1 M&TE items shall be maintained and repaired by M&TE laboratory personnel or by anapproved offsite calibration laboratory or by the manufacturer.

Note: Deadweight testers are field repairable M&TE standards.

6.7.2 Reference standards shall be calibrated and repaired by an approved offsite calibrationlaboratory or manufacturer.

6.7.3 Calibration records shall be annotated to indicate the history of maintenance, repair, andcalibration.

6.8 M&TE Withdrawal and Control

6.8.1 M&TE shall be issued from a controlled area by a QCE or a person designated by thePFQCE.

6.8.2 An M&TE Issue Record as shown in Exhibit N5.0-4 shall be initiated for each item ofM&TE. This record provides a current status of the item, history of usage, uniqueidentification, and restrictions, if any.

6.8.3 Upon withdrawal of M&TE, the responsible QCE shall:

6.8.3.1 Ensure that calibration is current and that the calibration sticker is legible.

Note: In the event that the calibration label becomes illegible, is destroyed, or has beenremoved, calibration status shall be verified by the M&TE Issued Record and areplacement label shall be attached bearing the appropriate recalibration data.

6.8.3.2 Complete the M&TE Issue Record with the following information:

a. The name of the person the M&TE item was issued to.

b. Work Plan and Inspection Record Number (if applicable) and/or item description(hanger number, weld number, etc.).

6.8.4 Whenever possible, torque wrenches will have a functional check performed uponreturn. This check consists of testing the wrench on a calibrated torque tester at the

setting(s) for which it was used. This information shall be entered on the M&TE IssueRecord, including the initials of the person performing the check.

6.8.5 When a torque wrench is to be used for several days, the responsible QCE may performa daily functional check at 20, 50, and 80 percent of the scale to ensure the performanceof the tool. When a functional check is performed, the results will be recorded on theM&TE Issue Record.

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6.9 Recall of M&TE

6.9.1 The recall system is used to ensure that M&TE is calibrated within the established timeinterval.

6.9.2 The M&TE Issue Record files will be reviewed each month and calibration due notices asshown in Exhibit N5.0-5 will be initiated and issued before the calibration due date.

6.10 Customer M&TE

6.10.1 If necessary, the Customer's calibrated M&TE may be used by Bechtel personnel.

6.10.2 Upon withdrawing M&TE from the Customer's M&TE facility, the responsible QCE willensure that the M&TE is calibrated and ready for use.

6.10.3 After use, the M&TE will be returned to the Customer's M&TE facility.

6.10.4 When notified by the Customer that the returned M&TE was out of tolerance, anevaluation will be performed in accordance with Section 6.13 of this instruction.

6.11 Damaged or Lost M&TE

6.11.1 M&TE that has been damaged or has obvious or suspected discrepancies shall bewithdrawn from service and appropriately controlled by tagging. The M&TE IssueRecord will be so noted, and the item will be repaired and/or calibrated or will bediscarded.

6.11.2 When M&TE is damaged, has discrepancies, or is lost, an evaluation will be performed inaccordance with Section 6.13 of this instruction.

6.12 Contaminated M&TE

6.12.1 A supply of contaminated M&TE is usually maintained by the Customer of operating

facili ties. When work is to be performed in an area where equipment is likely to becomecontaminated, this equipment should be used if possible.

6.12.2 Care shall be taken to protect clean M&TE from contamination by bagging, taping, etc.

6.12.3 Should M&TE become contaminated, the following applies:

a. Attempt to remove contamination by light cleaning (wiping, lifting with tape, etc.)

b. If light cleaning does not achieve satisfactory results, submit the M&TE fordecontamination.

c. At the Customers facility for contaminated M&TE, attempt to perform a functionalcheck of contaminated M&TE.

d. Note on the M&TE Issue Record that the item is out for decontamination and enterthe effective date.

e. M&TE that cannot be successfully decontaminated shall be turned over to theCustomers program or become inactive, and the Issue Record shall be so noted.

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6.13 Nonconformances

Hardware previously accepted with an item of M&TE that is overdue for calibration,returned in an out-of-tolerance condition, damaged, or declared lost or stolen shall beevaluated for a nonconforming condition and documented on a Nonconformance Reportin accordance with Instruction N6.0 of this manual. A Nonconformance Report is not

required for the following conditions:a. When M&TE has not been used since its last calibration.

b. When M&TE was not used for final verification.

c. When M&TE usage was limited to non-quality-related installations. In this case amemo shall be sent to the users identifying the condition.

d. When damage did not affect the calibration tolerance of the M&TE item.

e. When a satisfactory functional check has been performed for the last usage of theitem.

f. When the acceptance of the hardware can be reverified for a one-time use of theM&TE item or when a reverification can be performed on the last three itemsaccepted for multiple uses of the M&TE items.

6.14 Records

The following M&TE records shall be maintained in accordance with Instruction N13.0 ofthis manual:

a. Calibration Supplier Quality Assurance Program and/or customer approvaldocumentation

b. Jobsite calibration procedures

c. Certificates of Calibration

d. Tolerance and Calibration Frequency List (Exhibit N5.0-1)

e. Master List of Identification Codes (Exhibit N5.0-3)

f. M&TE Issue Record (Exhibit N5.0-4)

g. Calibration Due Notice (Exhibit N5.0-5)

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MEASURING & TEST EQUIPMENT LABELEXHIBIT N5.0-2

M&TE Number:

Calibration Due Date:

Use Restrictions:

8 0 2 4 5 0

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MEASURING & TEST EQUIPMENTEXHIBIT N5.0-3

M&TE IDENTIFICATION LIST

NUMBER: DATE:

PROJECT NUMBER: PROJECT NAME:

ITEM NO. TYPE RANGECALIBRATION

FREQUENCY REMARKS

INITIATOR: DATE:

FORM: T_MTE_ID.DOC 1997:REV.0

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M&TE ISSUE RECORDEXHIBIT N5.0-4

M&TE ISSUE RECORD

NUMBER: DATE:


ITEM: M&TE NO.:

CALIBRATION NO.: CALIBRATION DUE DATE:

MFG.: MFG. MOD. NO.: RANGE:

ISSUE ISSUE WP&IR NO./ FUNCTIONAL CHECK DATE

DATE TO ITEM DESCRIPTION VALUE QCE DATE RECEIVED REMARKS

FORM: T_ISSUE.DOC 1997:REV.0

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CALIBRATION DUE NOTICEEXHIBIT N5.0-5

CALIBRATION DUE NOTICE

NUMBER: DATE:


TO: DEPARTMENT:

THIS IS TO ADVISE YOU THAT THE FOLLOWING CALIBRATIONS ARE DUE IN

ITEM NO. TYPECALIBRATION

DUE

CALIBRATION

FREQUENCY REMARKS

COMMENTS:

INITIATOR: DATE:

FORM: T_CALDUE.DOC 1997:REV.0

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Instruc tion N6.0

Nonconform ance Report ing

1.0 PURPOSE

This instruction describes the system to be used for identifying, resolving, correcting,controlling, and documenting nonconformances.

2.0 SCOPE

This instruction applies to nonconformances that occur within Construction's scope ofwork on all safety related and ASME items. In addition, this instruction may be applied toReliability Related Itemsand Balance of Plant Itemsas designated by the Customer. It

does not apply to design changes to completed work or to nonconformances detected by(sub)contractor quality programs.

3.0 DEFINITIONS


4.0 REFERENCES

4.1 Nuclear Quality Assurance Manual


5.1 Employees

Any employee who discovers a nonconformance as defined herein is responsible forinitiating a Nonconformance Report (NCR).

5.2 Quality Control Engineer (QCE)

Quality Control Engineers are responsible for the NCR process, including the control ofnonconforming material.

The Quality Control Engineer shall notify the PFQCE of any activity that is suspected ofbeing improperly controlled.


The PFQCE or designee shall stop work on an activity when it is determined that theactivity is improperly controlled.

5.4 The PFQCE or designee is responsible for validating, numbering, logging, distributing,and tracking safety related items. Additionally, the PFQCE or designee shall advise thePQAM/PQAE if potentially significant conditions adverse to quality are identified. ThePFQCE is responsible for the proper implementation of this instruction.

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Instruction N6.0 Nonconformance Reporting


6.0 REQUIREMENTS

6.1 General

6.1.1 Conditions

6.1.1.1 Incomplete work or items not yet in conformance because the work has not proceeded to

a completed stage, shall not be considered nonconforming.

6.1.1.2 NCRs are not required to cover situations and resolutions covered by specification if averif ication procedure covering the work is open (i.e., concrete repairs, base repairs,base metal gouge repairs, etc.).

6.1.1.3 Noncompliance with process requirements discovered during monitoring that render thequality of the item indeterminate or unacceptable shall be considered hardwarenonconformances and shall be reported on NCRs.

6.1.2 Voiding

A NCR(s) may not be voided after it has been validated. If it becomes necessary to

discontinue processing after validation (i.e., reported nonconformance is erroneous,nonconformances reported in duplicate, etc.), Quality Control shall explain the reasonsfor the action on the NCR and complete the NCR by signing the appropriate blocks.

6.1.3 Superseding

6.1.3.1 Subsequent to validation, an NCR may be superseded for clarification. An appropriatestatement noting this fact shall be entered on both the superseded (old) and thesuperseding (new) NCRs along with necessary cross-references. The superseded NCRshall be closed out by signing the appropriate blocks.

6.1.3.2 If an NCR is lost or destroyed, it may be superseded or a copy may be stampedDuplicate Original by Quality Control. Further processing shall continue on the copy.

6.1.4 Erroneous NCR Entries

Correction of erroneous entries shall be by lining out the original entry and entering thecorrect entry. The date and initials of the person making the change shall be indicated.

6.1.5 Status of Open NCRs

The PFQCE shall publish a list of open NCR(s) showing the report number and date.The list shall be distributed to the appropriate department heads. The frequency forpublication of this list shall be at the discretion of the PFQCE. NCR distribution shall bein accordance with project requirements.

6.2 Nonconformance Reports

6.2.1 Any person who observes or becomes aware of a nonconforming condition shall initiatean NCR. A sample Nonconformance Report and Supplement Sheet is shown in ExhibitsN6.0-1 and N6.0-2.

6.2.2 Following validation of the NCR, it shall be processed and the disposition obtained inaccordance with Section 6.3 of this instruction.

6.2.3 When Project Engineering disposition is required, the NCR will be forwarded to the

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Nonconformance Reporting Instruction N6.0


Project Engineer for disposition.

6.2.4 NCR(s) shall be accurately and concisely written to ensure that the nonconformance iscorrectly described, the appropriate criteria are referenced, and sufficient data areprovided to facilitate a proper and complete disposition for resolving thenonconformance. Sketches or photographs may be included to aid the dispositioner.

6.2.5 The PFQCE or designee shall be responsible for reviewing NCR(s) to determine ifnonconformances appear to be potential significant conditions adverse to quality. If sucha condition appears to exist, the PFQCE will advise the Project Quality AssuranceManager/Project Quality Assurance Engineer (PQAM/PQAE).

6.2.6 Subsequent to validation, NCR(s) shall be serialized, logged, and routed to theappropriate organization for disposition. A sample Nonconformance Log is shown inExhibit N6.0-3.

6.3 Dispositions

6.3.1 Field Engineering is responsible for providing and approving dispositions to correct

nonconforming conditions by Rework, Reject, or Otherdispositions not requiring ProjectEngineering input.

6.3.2 For field design, the Field Engineer shall approve Repairand UseAs Isdispositions.

6.3.3 If Project Engineering disposition is required, the Field Engineer or designee mayrecommend Repair, Use As Is, and Otherdispositions to Project Engineering as

appropriate.

6.3.4 Quality Control may disposition NCR(s) for missing or inappropriate documentation fromSuppliers/(sub)contractors and for correction of housekeeping deficiencies that do notinvolve hardware nonconformances. These dispositions are limited to directing theresponsible organization to obtain the proper documentation and to correcting the

housekeeping deficiencies. They do not require disposition concurrence of the PFE.

6.3.5 The Project Engineer is responsible for providing and/or approving Repairand Use As Is

dispositions.

6.3.6 The PFQCE or designee shall review and provide concurrence for dispositions.

6.3.7 Interim dispositions shall be provided and approved by Field or Project Engineering whennecessary to investigate or to further process in order to determine the extent of thenonconformance. The interim disposition shall include any limitations of the workpermitted. These actions must be specifically detailed on the report and requireconcurrence by PFQCE or designee prior to proceeding with the interim disposition.

6.4 Correction of Nonconformances

6.4.1 If the disposition is Reworkor Repair, instructions shall provide a level of detail sufficient

to identify operations, inspections, and tests required to accomplish the rework or repairof the item. Instructions shall specify the extent of reinspection or retest required andshall be the same or equivalent to those applied to the original work.

6.4.2 When dispositioning nonconformances Use As Is, the engineering rationale shall be

provided and design calculations referenced where such evaluations are required.

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6.4.3 If the final disposition is Reject, Quality Control personnel shall sign and date the NCR

final acceptance block only after ensuring that measures have been taken to preventinadvertent use of the item.

6.4.4 The use of the disposition Otheris limited to those situations or actions required that do

not fall into the category of Rework, Repair, Reject, or Use As Is, and will require

appropriate explanation.

6.5 Control of Nonconforming Items

6.5.1 When practical or necessary for proper control, nonconforming items or materials shallbe controlled from inadvertent use or continued processing by tagging with a QC HoldTag or by segregating the item by impounding it and placing it in a controlled QC Hold

Area. A sample QC Hold Tag is shown in Exhibit N6.0-4.

6.5.2 Nonconforming items may be conditionally released for installation prior to disposition ofthe nonconformance when requested by Field Engineering and approved by the PFQCEor designee and the PQAM/PQAE, if each of the following conditions is met:

a. Traceability and identification of the nonconforming item are maintained.

b. The nonconforming item can be removed or corrected at a later date.

c. Concurrence of the Authorized Inspector is obtained for ASME code items anddocumented on the NCR.

d. Items that are nonconforming due to missing, incorrect, or incomplete supplierdocumentation shall have the following information on site prior to conditional release:

1. Bechtel Shop-Inspected Item

A signed document list, fax, or telecon from the Bechtel Supplier that the itemand prescribed documentation are in full conformance with the requirements ofthe procurement documents and that this documentation follows by mail.

2. Non-Bechtel Shop-Inspected Items

A signed document list, fax, or telecon from the supplier that the item andprescribed documentation are in full conformance with the requirements of theprocurement documents and that this documentation follows by mail.

Items that are nonconforming due to incorrect documentation may be conditionallyreleased if, in the judgment of the PFQCE, sufficient information to identify andretrieve the item is available at the jobsite.

6.5.3 The PFQCE or designee shall define on the NCR the limitations of further work orprocessing of the released item. Work or processing that exceeds the stated limitationshall be considered nonconforming.

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6.6 Procedural/Program Violations

Procedural violations or program violations, including those by other contractors that donot result in a hardware nonconformance, may be documented on an NCR. If used forthis purpose, the NCR shall be clearly labeled Procedural Violation, and does not require

a disposition. Such NCR(s) shall be sent to the appropriate department head or

designee for a statement of action to prevent recurrence and completed by signing theappropriate blocks.

6.7 Stop Work Authority

6.7.1 Quality Control personnel have the authority to stop work operations for constructionactivities that are determined to be improperly controlled. The work stoppage shall bedocumented as soon as possible after being placed in effect. The PFQCE shallcoordinate work stoppages with appropriate personnel.

6.7.2 Stop work actions shall be documented and authorized by the PFQCE by use of theStop Work Notice. A sample Stop Work Notice and instructions is shown inExhibit N6.0-5.

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NONCONFORMANCE REPORTEXHIBIT N6.0-1

NONCONFORMANCE REPORTREPORT NUMBER: DATE:


WP&IR NUMBER REV SAFETY RELATED ASME ITEM

Yes No Yes No

DRAWING/SPECIFICATION/ITEM NUMBER REV ITEM DESCRIPTION

ITEM LOCATION PO NO. SUPPLIER/SUBCONTRACTOR

NONCONFORMING CONDITION DESCRIPTION: CHECK IF DIGITAL PHOTO ATTACHED

REPORTED BY: DATE:

REVIEWED BY: DATE:

VALIDATED BY: DATE:

RECOMMENDED DISPOSITION: Rework Repair Use As Is Reject Other

DISPOSITION BY: DATE:

PFE CONCURRENCE: DATE:

PROJECT ENGINEER APPROVAL REQUIRED: YES NO

FINAL DISPOSITION: Rework Repair Use As Is Reject Other

PE CONCURRENCE: DATE: DESIGN CHANGE REQUIRED YES NO

DRAWING/SPECIFICATION NUMBER: REV.: DCN NUMBER:

DISPOSITION IMPLEMENTATION DATE: REINSPECTION REQUIRED YES NO

PFE CONCURRENCE: DATE:

PFQCE CONCURRENCE: DATE:

AI CONCURRENCE (ASME ITEMS ONLY): DATE:

RESULTS:

REINSPECTED BY: DATE:

PFQCE REVIEW: DATE:

AI REVIEW (ASME ITEMS ONLY): DATE:

REMARKS:

FORM T_NCR.DOC 1997:REV.1

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NONCONFORMANCE REPORT SUPPLEMENT SHEETEXHIBIT N6.0-2

NONCONFORMANCE REPORT SUPPLEMENT SHEET

NCR NUMBER: DATE:

PROJECT NO.: PROJECT NAME:

NONCONFORMANCE DESCRIPTION (CONTINUED):

FIELD ENGINEERING RECOMMENDED DISPOSITION (CONTINUED):

PROJECT ENGINEERING DISPOSITION (CONTINUED):

REMARKS/OTHER (CONTINUED):

FORM T_NCRSUP.DOC 1997:REV.0

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NONCONFORMANCE REPORT LOGEXHIBIT N6.0-3

NONCONFORMANCE REPORT LOG

PROJECT NO.: PROJECT NAME:

NCR NUMBER DATE DESCRIPTION/ REMARKSDISPOSITION

DATE DATE CLOSED

FORM T_NCRLOG.DOC 1997:REV.0

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QC HOLD TAGEXHIBIT N6.0-4

INSTRUCTIONS FOR PREPARING THE

"HOLD FOR Q. C. CLEARANCE TAG"Note all entries to be made using weatherproof marker

ENTRY INSTRUCTIONS

BLOCK NO. ENTRY INFORMATION

(1) Enter the NCR number, as shown on the NCR

(2) Signature, date of signature, and site telephone number of the Engineer who applied the tag.

(3) Indicate in the appropriate block, the primary reason for affixing the hold tag.

(4) Enter pertinent information to expand upon status Block 3. Indicate whether item can be released forfurther processing and what the limitations are, or if the item(s) are to be held pending final dispositioninstructions.

HOLD

FOR

QC

CLEARANCE

MAY NOT BE REMOVED

WITHOUT AUTHORIZATION

HOLD

FORQ

.C.

CLEARANCETAG

(1)Devia

tion

Con

tro

l:______________

_____________

(2)Resp

ons

ibleEngr:

_____________

Ex

t:______

(3)Ho

ld

For:

Rework

Re

jec

t

Dispos

ition

Documen

tation

Other

(Exp

lain)

(4)Remarks:

______________________

____________

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Instruc tion N7.0

Qual i ty Veri f icat ion System

1.0 PURPOSE

This instruction describes the quality verification system used by Quality Control toplan and perform inspections, tests, and reviews in order to determine compliance toengineering and quality requirements. It provides for planning the activities,establishing verification points, documenting the performance and results of theverif ication, controlling special processes, and providing status. This instruction alsoprovides for monitoring certain construction processes and for documenting themonitoring activities.

2.0 SCOPE

This instruction applies to quality control inspection of safety-related or ASME activitiesand items. In addition, this instruction may be applied to Reliability Related Items and

Balance of Plant Itemsas designated by the Customer. This instruction does notapply to (sub)contractor quality verification activities.

3.0 DEFINITIONS

3.1 Quality verification activities shall be performed by one of the following definedmethods.

a. Witness (W): To watch over, observe, or visually examine a specific work

operation or test which is performed by others under construction supervision.

b. Review (R): To examine any form of documentation for the purpose of

establishing acceptability to specific requirements.

c. Inspect (I): Visual examination or measurement to verify the conformance of an

item to predetermined quality requirements.

d. Surveillance (S): In-process monitoring of activities to the degree necessary for

assurance that the process/method is in compliance with established criteria.

e. Test (T): Activities performed to determine or verify the capability of a component,

structure, or system to meet specified requirements by subjecting the item to acontrolled set of physical, chemical, environmental, or operational conditions.

4.0 REFERENCES

4.1 Nuclear Quality Assurance Manual

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Instruction N7.0 Quality Verification System




The PFQCE is responsible to ensure appropriate project quality control procedures areissued which implements the verif ication system. These project quality controlprocedures shall be reviewed to ensure the requirements of this instruction areincorporated.

In lieu of separate project quality control procedures, the PFQCE is responsible toensure appropriate quality control instructions, which implement the verificationsystem, are incorporated into the project construction procedures. These projectconstruction procedures shall be reviewed to ensure the requirements of thisinstruction are incorporated.


6.0 REQUIREMENTS

6.1 General

The Quality Verification System consists of both quality verification and monitoringactivities that provide documented results of verification activities.

6.1.1 Quality Verification Activities

Quality verification activities are identified as methods used to verify the acceptabilityof items. Sign-off responsibility for quality verification activities is required.

6.1.2 Hold Points

Hold points are applied to verification activities beyond which work shall not proceeduntil the appropriate verification is performed and the hold point is released by QualityControl. Hold points are identified on the Work Plan and Inspection Record (WP&IR).

6.2 Planning

Planning is performed by using project quality control procedures, or projectconstruction procedures, and WP&IRs to ensure that minimum quality verificationactivities will occur at predetermined points during construction. Activities will becarried out in sequence, if required, and adequate control of work operations will bemaintained and documented.

6.2.1 Project Quality Control Procedures and Project Construction Procedures

Project quality control procedures, or project construction procedures, describe theminimum monitoring and verification activities performed by Quality Control Engineers(QCEs) to verify that work performed by construction conforms to the programrequirements.

6.2.1.1 Preparation

The primary documents used by Quality Control Engineers as a basis for preparing

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Quality Verification System Instruction N7.0


project quality control procedures, or project construction procedures, are:

a. Engineering drawings and specifications

b. The Nuclear Quality Control Manual

c. Construction Procedures

d. National codes and standards made applicable by the engineering specificationsand drawings

6.2.1.2 Identification

6.2.1.2.1 Witness, review, inspect, surveillance, and test activities shall be identified in theproject quality control procedures, or the project construction procedures, by theapplicable code letter (i.e., W, R, I, S, T).

6.2.1.2.2 When witness, review, inspect, or test activities are to be implemented by use of asampling plan, the sample size and frequency shall be identified in the project qualitycontrol procedures, or the project construction procedures. The sampling plan shall be

as specified by the engineering technical specifications or other applicable programcriteria.

6.2.1.2.3 The WP&IRs identify, by description or reference to the applicable engineering andconstruction documents, the acceptance criteria to be used for verification.

6.2.1.2.4 Additional data sheets and other inspection, examination, and test reports which mustbe prepared to supplement the WP&IRs to provide the required quality verificationdocumentation shall be identified in the project quality control procedures, or theproject construction procedures, and shall provide for the following:

a. The type of quality verification activities

b. The identification of the QCE performing the activity, the QCE's initials, and thedate on which the activity was accepted

c. The results of the verification activity, including the identification ofnonconformances

6.2.1.3 Process Controls

6.2.1.3.1 Project quality control procedures, or project construction procedures, shall include thefollowing process controls as applicable:

a. Preprocess controls to ensure any applicable prerequisites are conducted prior tobeginning monitoring or verification activities

b. In-process controls to ensure that methods and techniques used during theperformance of the activity are correctly applied

c. Post-process controls to assure that, upon completion of the activity, satisfactoryresults have been obtained

6.2.1.3.2 Pre-process controls. Project quality control procedures, or project constructionprocedures, shall contain requirements for ensuring that monitoring and verificationactivities are conducted using the latest approved drawings, specifications, and

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Quality Verification System Instruction N7.0


6.2.2 Work Plan and Inspection Records (WP&IRs)

6.2.2.1 Initial Review and Approval

6.2.2.1.1 WP&IRs shall be reviewed and approved by a certified Level II or III QCE to assurethat the records include (as applicable):

a. Engineering drawings and specification

b. Provisions specifying the engineering drawings and/or specification revision leveland applicable Design Change Notice (DCN) or Change Request/ Notice (CR/N)

c. An orderly sequence of quality verif ication activities

d. Hold points identified as required by project quality control procedures

e. Provisions for recording performance or other data, as required

f. Provisions for entry of sufficient information to allow for part traceability

g. Any special requirements not contained in the project quality control proceduresbut required by the vendor/manufacturer

h. Identification of the items to which the inspection record applies

i. Provisions for sign-off by the QCE(s) who performed the verif ication activities andreviewed and approved the results, including the date

j. Provisions for the results of the verification activities, including the identification ofany nonconformances

k. Provisions for identification of calibrated measuring and test equipment (M&TE)used for verification activities

l. Provisions for partial acceptance of item installations

6.2.2.1.2 WP&IRs, which are repetitive computerized forms, shall be reviewed and approved inaccordance with their governing project quality control procedures, or projectconstruction procedures.

6.2.2.2 Revisions to WP&IRs

6.2.2.2.1 Revisions to WP&IRs that require Quality Controls approval prior to start of the revisedwork operations are:

a. Rework of previously verified and accepted work

b. The addition to or deletion of listed work operations and/or verif ication activities,witness points, and hold points. This does not apply to the addition of an entirecomponent to a fabrication or erection work plan where the individual work stepsremain the same and verification provisions are by matrix.

6.2.2.2.2 The QCE approving the revisions shall be certified Level II or III.

6.2.2.3 Final Review

Completed WP&IRs shall be reviewed by Quality Control personnel to ensure that:

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Instruction N7.0 Quality Verification System


a. Objective evidence of inspections, data recordings, certification of material,processes, and test equipment are recorded and are legible.

b. Conditions of nonconformance are documented and authorized in accordance withthe requirements of Instruction N6.0 of this manual.

c. Supplementary quality verif ication records prepared in support of the WP&IRs areavailable, legible, traceable, and contain the required sign-offs.

6.2.2.4 Replacement of Lost or Mutilated WP&IRs

WP&IRs that become lost or mutilated after QC signs off any item shall be replaced asfollows:

a. If mutilated, a new WP&IR shall be signed in the appropriate places and themutilated WP&IR attached to it as justification for signing the new one.

b. If mutilated beyond legibility or lost, a replacement WP&IR issued by FieldEngineering shall be signed off by the original QCE or his supervisor afteraccomplishing whatever re-verification is practical to establish acceptability of theitem. If re-verif ication is not possible, an NCR shall be initiated and directed toProject Engineering for their disposition.

6.2.2.5 Corrections

Corrections or supplements to entries in WP&IRs made by Quality Control personnelshall be accomplished by lining out the original entry and entering the correction orsuppl

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