-. COOO-99- C6-fl W-VU1 VU/67531/metadc673393/m2/1/high_re… · QUALITY ASSURANCE PLAN Approvals : for ES&H Phase I1 Line Item Issue of May 21, 1991 ... or represents that its use

-. - COOO-99- C6-fl W-VU1 VU

Q U A L I T Y ASSURANCE PLAN

Approvals :

for

ES&H Phase I1 Line Item

Issue of May 2 1 , 1991

Prepared by: C. K. Ohler

EG&G Mound Applied Technologies

Miamisburg, ..Ohio

DISCLAIMER

This report was prepared as an account of work sponsored by an agency of the United States Government. Neither the United States Government nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsi- bility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Refer- ence herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, r a m - mendation, or favoring by the United States Government or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States Government or any agency thereof.

R . c. Herman Eng inee r ing S u p e r v i s o r

F r e d r i c k G. m c h Loss P r e v e n t i o n and

* Q u a l i t y Assurance /-

.

DISCLAIMER

Portions of this document may be illegible in electronic image products. Images are produced from the best available original document.

&A P l a n for ES&H P h a s e ' I I Line I t e m

Table of Contents

Page

. . . . . . . . . . . . . . . . . . . . . . 1. D e s c r i p t i o n and Scope of P r o j e c t 1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . Purpose of QA P l a n 2

3 . App l i cab le Documents 2

4 . Ana lys i s of Consequence of F a i l u r e . . . . . . . . . . . . . . . . . . . . . 4

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . 5 . Q u a l i t y Elements and Q u a l i t y Assurance E f f o r t s 4

5 . 1 . 5 . 2 . 5 . 3 . 5 . 4 . 5 . 5 . 5 . 6 . 5 . 7 . 5 . 8 . 5 . 9 . 5 . 1 0 . 5 . 1 1 . 5 . 1 2 . 5. 13. 5. 14. 5 . 15. 5 . 16. 5. 17. 5 . 18. 5 . 1 9 .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O r g a n i z a t i o n 4 Q u a l i t y Assurance h o g r a m 5

I n s t r u c t i o n s , P rocedures , and Drawings . . . . . . . . . . 7

C o n t r o l of Purchased I t e m s and S e r v i c e s 9 I d e n t i f i c a t i o n and C o n t r o l of Items 9 I n s p e c t i o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 T e s t C o n t r o l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0 C o n t r o l of Measuring and T e s t Equipment . . . . . . . . . 1 0

I n s p e c t i o n , Test, and Opera t ing S t a t u s . . . . . . . . . . 11 C o n t r o l of Nonconforming I t e m s . . . . . . . . . . . . . . . . . . 11

Q u a l i t y Assurance Records . . . . . . . . . . . . . . . . . . . . . . . 13 Audi ts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Design C o n t r o l 6 7 Procurement Document C o n t r o l

8 Document Con t ro l

. . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 C o n t r o l of P rocesses

Handl ing , S t o r a g e , and Sh ipp ing . . . . . . . . . . . . . . . . . 11

C o r r e c t i v e Act ion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Sof tware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

B r m e d i x A . Q u a l i t y Assurance Element Matr ix

A ~ u w d i x R P r o j e c t Q u a l i t y Assurance Review

ES&H Phase I1 Line I t e m - Page 1

The ES&H Phase I1 Line I t e m P r o j e c t c o n s i s t s of t h e f o l l o w i n g independent s u b p r o j e c t s : t h e N e w P o t a b l e Water System; t h e Exp los ives S a f e t y Upgrades and t h e F u e l O i l S t o r a g e System.

P a r t A 1 - w Potable Wat.er bvatem:

There are o v e r 100 b u i l d i n g s a t Mound. Most have p o t a b l e water s e r v i c e . The p o t a b l e water f lows t o e a c h b u i l d i n g t h r o u g h t h e domest ic water d i s t r i b u t i o n main from wells on p l a n t s i t e . Th i s domest ic water s e r v e s n o t o n l y as t h e p o t a b l e water b u t a l s o as t h e s u p p l y for p r o c e s s equipment and f i r e p r o t e c t i o n .

A s u r v e y o f a p o r t i o n of t h e s i t e has i d e n t i f i e d a number of cases were p r o c e s s equipment and f i r e l i n e s have been connec ted t o t h e domes t i c water system w i t h o u t backflow p r o t e c t i o n . I n t h e e v e n t of f a i l u r e of p r o c e s s equipment o r i n t h e e v e n t of a p l a n t f i r e , t h i s lack of p r o t e c t i o n c o u l d r e s u l t i n c o n t a m i n a t i o n o f t h e p o t a b l e w a t e r supp ly .

The scope of t h e s u b p r o j e c t i s t o e l i m i n a t e t h e haza rd c r e a t e d by t h e u n p r o t e c t e d c r o s s c o n n e c t i o n s . Th i s w i l l be accompl ished by m o d i f i c a t i o n s t o comple t e ly separate t h e c u r r e n t p o t a b l e water sys tem from a l l p r o c e s s e s n o t a s s o c i a t e d w i t h d r i n k i n g water.

P a r t R . - ~ l o s i v e s S a f e t v Unerades:

The scope o f t h i s s u b p r o j e c t is t o d e s i g n and c o n s t r u c t t h e f ol 1 wing :

I.) E i g h t (8 ) s i n g l e c e l l e a r t h cove red magazines e a c h des igned f o r s t o r a g e of 199 pounds of UNO Class 1 D i v i s i o n 1. 1 e x p l o s i v e s .

2 . ) A t h r e e (3) c e l l s e r v i c e magazine f o r B u i l d i n g 27 w i t h e a c h c e l l r a t e d for 13 pounds of TNT e q u i v a l e n t e x p l o s i v e s .

3. ) A f o u r ( 4 ) c e l l s e r v i c e . magazine p rov ided w i t h i n t e r i o r env i ronmen ta l c o n d i t i o n i n g for B u i l d i n g 48. Each c e l l s h a l l be r a t e d f o r 13 pounds of TNT e q u i v a l e n t e x p l o s i v e s .

4.) A s i n g l e c e l l s e r v i c e magazine t o house Pan tex non-propagat ing c a b i n e t s f o r I)S B u i l d i n g . The magazine s h a l l be des igned f o r 1 .3 pounds of TNT e q u i v a l e n t e x p l o s i v e .

5 . ) Exp los ive f ragment b a r r i c a d e s f o r magazines #7 and #ll and f o r B u i l d i n g s 27 and 49.


6 . ) M o d i f i c a t i o n s t o Magazine 2 0 f o r conve r s ion i n t o a n e x p l o s i v e i n s p e c t i o n and t r a n s f e r b u i l d i n g .

The scope of t h e s u b p r o j e c t is t o upgrade t h e f u e l o i l s t o r a g e and d e l i v e r y sys t em a t Mound by making improvements a t b o t h t h e day t a n k s i t e n e a r t h e Powerhouse and t h e main t a n k s i t e as f o l l o w s :

1. ) Four (4) 2 5 , 0 0 0 g a l l o n underground s t o r a g e t a n k s l o c a t e d eas t of t h e powerhouse w i l l be removed and r e p l a c e d w i t h one (1) 5 0 , 0 0 0 g a l l o n above ground o i l s t o r a g e t a n k . A s an i n t e g r a l par t of t h e t a n k i n s t a l l a t i o n w i l l be t h e c o n s t r u c t i o n o f a c o n c r e t e conta inment b a s i n and a n a u t o m a t i c foam f i r e s u p p r e s s i o n system. I n a d d i t i o n , a t r u c k l o a d i n g s t a t i o n and s p i l l containment sump w i l l be i n s t a l l e d i n t h e v i c i n i t y of t h e new t a n k .

2 . ) The 3 0 0 , 0 0 0 g a l l o n above ground main f u e l oil s t o r a g e t a n k is t o be removed a i o n g H i t h t h e p i p i n g from t h e pumphouse t o t h e t a n k and t h e f u e l t r a n s f e r pump. The t a n k w i l i t h e n be r e p l a c e d w i t h t w o ( 2 ) 2 2 5 , 0 0 0 g a l l o n f u e l o i l s t o r a g e t a n k s . A s a n i n t e g r a l par t , t h e i n s t a l l a t i o n w i l l i n c l u d e a secondary conta inment b a s i n and a u t o m a t i c foam f i r e s u p p r e s s i o n systems w i t h n o z z l e s for e a c h t ank . I n a d d i t i o n , a f u e l o i l t r a n s f e r sump a l o n g w i t h a t r u c k un load ing s t a t i o n and conta inment sump w i l l be provided.

7 . PurDose of QA P l u

The purpose of t h i s Q u a l i t y Assurance P lan (&A P l a n ) is t o assure t h a t t h e o b j e c t i v e s of t h e United S t a t e s Department of Energy (D. 0. E. ) and EG&G Mound Applied Technologies , Miamisburg, Ohio (Mound) a r e m e t for t h i s non-weapons p r o j e c t r e l a t i v e t o h e a l t h and s a f e t y , p r o t e c t i o n of t h e envi ronment , r e l i a b i l i t y and c o n t i n u i t y of o p e r a t i o n s , and documentat ion of q u a l i t y e f f o r t s . This &A P l a n . i d e n t i f i e s t h e a c t i v i t i e s and r e s p o n s i b i l i t i e s which are necessary i n t h e d e s i g n , procurement , f a b r i c a t i o n , i n s t a l l a t i o n , and s ta r t up of t h i s p r o j e c t i n o r d e r t o m e e t t h e s e o b j e c t i v e s .

The D. 0. E . r equ i r emen t s f o r q u a l i t y a s s u r a n c e f o r p r o j e c t s s u c h a s t h i s one are se t f o r t h i n AL Order 5 7 0 0 . 6 B , Revis ion 2 , d a t e d J u l y 7 , 1989. That AL Order d i r e c t s c o n t r a c t o r s s u c h as Mobd

ES&H Phase I1 Line Item - Page 3

t o deve lop non-weapons q u a l i t y a s s u r a n c e programs th rough a p p l i c a t i o n of appropr i a t e r equ i r emen t s of t h e consensus s t a n d a r d of t h e American S o c i e t y of Mechanical Engineers (ASME) t i t l e d " Q u a l i t y Assurance Program Requirements for Nuclear F a c i l i t i e s " . That s t a n d a r d is d e s i g n a t e d as ASME NQA-1-1989 E d i t i o n and is commonly c a l l e d "NQA-1" . A set of 1989 addenda have been i s s u e d .

The Mound non-weapons q u a l i t y a s s u r a n c e program, r e f l e c t i n g t h e D. 0. E. gu idance c i t e d above, i s p r e s e n t e d i n Mound Techn ica l Manual MD- 10165. The implementat ion of t h a t program w i t h i n t h e Eng inee r ing Department i s se t f o r t h i n Mound Techn ica l Manual MD-10241, I s s u e 1 0 , t i t l e d "5700.6B Q u a l i t y P lans f o r Eng inee r ing Department" (Manual MD-10241).

Other Documents and Forms:

Mound Manual MD-10286 ~ t i t l e d " S a f e t y and Hygiene Manual".

Mound Manual MD-10129, t i t l e d "General S a f e t y Procedures f o r Handling Pyro techn ic Materials and Components".

Mound Systems Manual 804 , t i t l e d "Mound P r o j e c t Management Manual 804" , (Manual 804) p rov ides procedures f o r major o r c o n s t r u c t i o n cap i t a l p r o j e c t s .

Mound System Manual 808, t i t l e d " P l a n t Engineer ing Manual 808" , (Manual 808) p rov ides A/E d e s i g n guidance and g e n e r a l work requirements.

Mound Systems Manual No. 811 , t i t l e d "Mound Eng inee r ing Department AES System Manual", (AES Manual) p rov ides procedures for managing and documenting expense , c a p i t a l equipment , p r o d u c t i v i t y c a p i t a l , and r e imbursab le p r o j e c t s .

Mound SPA-891214, t i t l e d "Drawing Con t ro l P r o c e d u r e s " , d e s c r i b e s t h e Mound drawing c o n t r o l system.

Mound Form ML-8440, t i t l e d " P r o j e c t Q u a l i t y Assurance Review".

Mound Form ML-7588, t i t l e d "Engineer ing Review T r a n s m i t t a l S h e e t " .

Mound Form ML-8816, t i t l e d "Engineer ing Department Nonconformance Repor t" .

Mound Manual MLM-MU-91-63-0027, t i t l e d " Q u a l i t y Assurance P l a n for N e w P o t a b l e Water System".

Mound Manual MLM-MU-9 1-63-0001, t i t l e d " Q u a l i t y Assurance P l a n for Explos ive S a f e t y Upgrades".

Mound Manual MLM-MU-9 1-63-0002, t i t l e d " Q u a l i t y Assurance P l a n for t h e Fuel O i l S t o r a g e Sys-tem".


S u b p r o j e c t Q u a l i t y Assurance R e v i e w s were completed and approved on November 25, 1989 f o r t h e P o t a b l e Water System, December 6 , 1990 f o r t h e Exp los ive S a f e t y Upgrades and Februa ry 28 , 1991 f o r t h e F u e l O i l S t o r a g e System Upgrade. t o g e t h e r w i t h t h e S u b p r o j e c t Sponsor s , t h e E n g i n e e r i n g S u p e r v i s o r , t h e LP&EC R e p r e s e n t a t i v e , and t h e QA R e p r e s e n t a t i v e p a r t i c i p a t e d i n t h e a n a l y s i s of t h e p o t e n t i a l f a i l u r e modes and a s s o c i a t e d consequences. The most s e v e r e &A Leve l as d e f i n e d i n S e c t i o n 1 . 3 o f Manual MD-10241, w a s Leve l 1. Manual MD-10241 r e q u i r e s a w r i t t e n &A P l a n f o r any AES p r o j e c t a s s e s s e d as &A Level 1 o r 2 .

The P r o j e c t Manager,

The major c o n s i d e r a t i o n s i n d e t e r m i n i n g t h e &A Leve l are d e f i n e d i n t h e s u b p r o j e c t QA P l ans . Refer t o t h e QA p l a n f o r e a c h s u b p r o j e c t as i d e n t i f i e d i n S e c t i o n 3 . of t h i s document.

The q u a l i t y a s s u r a n c e e f f o r t s p lanned f o r t h i s p r o j e c t are summarized i n t h e f o l l o w i n g s e c t i o n s ( 5 . 1 t h r o u g h 5 . 1 9 ) and are d i s c u s s e d i n d e t a i l i n t h e a s s o c i a t e d MLM S u b p r o j e c t Documents. The f i r s t 18 s e c t i o n headings are t h e s a m e as t h o s e of t h e b a s i c r e q u i r e m e n t s , or e l e m e n t s , of b o t h ASME NQA-1-1989 E d i t i o n and D.0.E Order AL 5700.6B. , Rev i s ion 2 . The 1 9 t h s e c t i o n is f o r s o f t w a r e .

5 . 1 O r a n i z a t j o s

R e s p o n s i b i l i t y f o r t h e non-weapons q u a l i t y a s s u r a n c e program a t Mound is v e s t e d w i t h t h e D i r e c t o r of t h e Q u a l i t y Department. O v e r a l l a d m i n i s t r a t i o n o f t h e program i s d e l e g a t e d t o a s taff i n d i v i d u a l r e p o r t i n g t o t h e Manager o f Non-weapons Q u a l i t y Assurance. Implementat ion of t h e program is conducted by a " m a t r i x " o r g a n i z a t i o n i n v o l v i n g Department C o o r d i n a t o r s f rom t h e v a r i o u s depa r tmen t s .

Within t h e Eng inee r ing Department , t h e Department C o o r d i n a t o r manages t h e NWQA program. The Department C o o r d i n a t o r r e p o r t s t o t h e Manager o f Eng inee r ing Systems and Des ign , who i n t u r n r e p o r t s t o t h e D i r e c t o r of Eng inee r ing . A s t a f f of S e c t i o n NWQA R e p r e s e n t a t i v e s r e p o r t d i r e c t l y t o t h e Department C o o r d i n a t o r and implement t h e program i n t h e i r S e c t i o n . Thus t h e NWQA s t a f f i s a d m i n i s t r a t i v e l y independent o f all o t h e r d i r e c t s u p e r v i s i o n .

Those pe r sons p rominen t ly a s s o c i a t e d w i t h implementa t ion of t h i s &A P l a n f o r t h e ES&H Phase I1 L i n e I t e m P r o j e c t are l i s t e d helow t o g e t h e r w i t h t h e i r f u n c t i o n a l t i t l e and g e n e r a l r e s p o n s i b i l i t i e s .


P r o .i e c: t S DO n s 0 7 .

i d e n t i f y i n g t h e need and j u s t i f i c a t i o n f o r t h e p r o j e c t and f o r rev iew of t h e p r o j e c t scope and d e s i g n t o e n s u r e t h a t t h e needs are m e t .

- Respons ib le for

. I I d e n t i f l e d i n SubDro.iect QA P l a n ) - * .

Respons ib le f o r p r o j e c t management, d e s i g n and s p e c i f i c a t i o n , c o n t r o l o f c o n s t r u c t i o n , a d m i n i s t r a t i o n of i n s p e c t i o n s , r e s o l u t i o n o f nonconformances, c o n t r o l of nonconforming i t e m s , and maintenance o f QA r e c o r d s . Respons ib le f o r e x e c u t i o n of t h i s &A P lan .

1Tfjchael R . H i j n t e r - Respons ib le f o r p r o j e c t management. Respons ib le for o v e r a l l a d m i n i s t r a t i o n of t h i s QA P l an .

SijbDro.iect Engj n e e r s . i n c l u d i n g o v e r s i g h t of d e s i g n and s p e c i f i c a t i o n , c o n t r o l of c o n s t r u c t i o n , a d m i n i s t r a t i o n of i n s p e c t i o n s , r e s o l u t i o n of nonconformances, c o n t r o l of nonconforming i t e m s , and maintenance of &A r e c o r d s f o r a s s i g n e d p o r t i o n s of t h e p r o j e c t . Refer t o s u b p r o j e c t & A P l ans for d e t a i l e d l i s€ o f e n g i n e e r i n g ass ignments .

Respons ib le f o r s u b p r o j e c t management

Desian Emineers. a s s i g n e d p o r t i o n s of t h e p r o j e c t . Refer t o s u b p r o j e c t QA P l a n s f o r d e t a i l e d l i s t of e n g i n e e r i n g ass ignments

Respons ib le f o r d e s i g n and s p e c i f i c a t i o n f o r

Design Reviewerg. Techn ica l peer rev iew of des ign . Detailed l i s t is d e f i n e d i n t h e s u b p r o j e c t QA P l ans .

&EC R e z e s e n t a t i v e . F r e d r i c k G . K r d - R e p r e s e n t a t i v e o f Loss P r e v e n t i o n and Environmental C o n t r o l (LP&EC) w i t h rev iew and a d v i s o r y r o l e .

01 S u p e r v i s w . u r K e l l s , r - Respons ib le for p o l i c y and a d m i n i s t r a t i o n o f drawing c o n t r o l .

b t e r i a 1 C o o r w . U - Respons ib le f o r c o n t r o l of i t e m s i n t h e material s t a g i n g area.

ReDresenta t ive . XKU&LL-EU!. - R e p r e s e n t a t i v e of Non-weapon Q u a l i t y Assurance. Respons ib le for review of t h i s QA P l a n and any i n t e r n a l Eng inee r ing a u d i t of t h i s p r o j e c t .

5 . 2 . Q u a l j t v Assurance P r o m

The non-weapons q u a l i t y program p l a n f o r t h e Engineer ing Department a t Mound is d e s c r i b e d i n Mound Techn ica l Manual MD-10241, I s s u e IO, t i t l e d " 5 7 0 0 . 6 B Q u a l i t y P lans f o r


Eng inee r ing Department". (Re fe r t o S e c t i o n 3 above f o r a d i s c u s s i o n of t h e r e l a t i o n of Manual MD-10241 t o Manual MD-10165, t o D . O . E . Order A 1 5700.6B, Rev i s ion 2 , and t o ASME NQA-1-1989 E d i t i o n . ) This QA P l a n f o r t h e ES&H Phase 11 Line I t e m P r o j e c t d e s c r i b e s t h e s p e c i f i c implementa t ion f o r t h i s p r o j e c t of t h e guidance i n Manual MD-10241, I s s u e 1 0 .

Th i s Q u a l i t y Assurance P lan is a n "umbre l l a " p l a n t o cove r t h e s u b p r o j e c t s i d e n t i f i e d i n S e c t i o n 1. The l i s t of s u b p r o j e c t QA P lans are as f o l l o w s :

* MLM-MU-91-63-0027 - N e w P o t a b l e Water System.

* MLM-MU-91-63-0001 - Explos ive S a f e t y Upgrades.

d MLM-MU-91-63-0002 - F u e l O i l S t o r a g e System Upgrades.

I n a d d i t i o n , e a c h s u b p r o j e c t QA P l a n w i l l be i n a fo rma t compatable w i t h t h e "Umbrella" P lan .

..

5 . 3 . D-n Control,

E x p l i c i t d e s i g n c r i t e r i a w i l l be developed. Design i n f o r m a t i o n w i l l be documented i n t h e form of s p e c i f i c a t i o n s and drawings . These documents w i l l be used a s communication t o o l s t o a s s u r e t h a t i t e m s can be c o n s t r u c t e d , f a b r i c a t e d , i n s p e c t e d and t e s t e d a c c o r d i n g t u d e f i n i t e d e s i g n i n t e n t .

A l l i s s u e s of drawings w i l l be checked by D r a f t i n g f o r a c c u r a c y and proper fo rma t . I n accordance w i t h S e c t i o n 1 8 0 0 , t i t l e d "

P r o j e c t Review", of Manual 804, s p e c i f i c a t i o n s and drawings w i l l be c i r c u l a t e d by t h e Design Engineer f o r rev iew and comment. Design documents w i l l be reviewed independen t ly by a peer Design Reviewer t o a s s u r e t h e t e c h n i c a l adequacy and safety of t h e d e s i g n . Design documents w i l l be reviewed by t h e Sponsor t o conf i rm t h a t t h e d e s i g n c r i t e r i a are s a t i s f i e d , and by t h e LP&EC R e p r e s e n t a t i v e t o a s s u r e t h e s a fe ty of t h e d e s i g n . Reviews and comments d e s i g n a t e d by t h e r ev iewer as r e q u i r i n g r e sponse w i l l . be documented by completed Eng inee r ing Review T r a n s m i t t a l S h e e t s . The Design Engineer is r e s p o n s i b l e f o r r e s o l v i n g any rev iew comments.

Eng inee r ing f low diagrams and w i r i n g schemat i c s w i l l be checked a g a i n s t f i n i s h e d sys tems and changed, i f n e c e s s a r y , s o t h a t t h e l a t e s t i s s u e shows t h e system as c o n s t r u c t e d . Any s u c h changes w i l l t a k e " f i e l d " changes i n t o accoun t .

Changes i n t h e d e s i g n documents w i l l be c o n t r o l l e d as d e s c r i b e d i n S e c t i o n 5 . 6 below.

ESStH Phase I1 Line Item - Page 7

P r i o r t o t r a n s f e r of t h e s y s t e m t o t h e Envi ronmenta l , S a f e t y and H e a l t h Department, a l i s t of t h e d e s i g n drawings and o t h e r documenta t ion w i l l be compiled. Th i s l i s t w i l l show t h e l a t e s t i s s u e of e a c h drawing.

Procurement documents w i l l be c o n t r o l l e d i n acco rdance w i t h t h e C o n t r a c t i n g and Procurement Systems Manual 701. Purchase r e q u i s i t i o n s f o r Procurement Leve l 1 items w i l l be c o n t r o l l e d i n accordance w i t h S e c t i o n 1 . 5 . 4 of Manual MD-10241. I n o r d e r t o v e r i f y conformance of c r i t i c a l purchased material as d e f i n e d i n t h e s u b p r o j e c t &A p l a n s , w i t h s p e c i f i c a t i o n s , e x p l i c i t r equ i r emen t s f o r t e s t i n g and e v a l u a t i o n w i l l be i n c l u d e d i n t h e pu rchase c o n t r a c t { s } . Purchase c o n t r a c t { s ] f o r c r i t i c a l material or s e r v i c e s w i l l e x p l i c i t l y r e q u i r e d e l i v e r y of w r i t t e n c e r t i f i c a t i o n s from t h e s u p p l i e r s . Purchase c o n t r a c t s f o r c r i t i c a l material o r s e r v i c e s w i l l c o n t a i n e x p l i c i t r equ i r emen t s f o r t h e s u p p l i e r t o have a q u a l i t y a s s u r a n c e program c o n s i s t e n t w i t h specif ic r equ i r emen t s of NQA-1. ' A s d e f i n e d i n t h e pu rchase c o n t r a c t s , Mound r e p r e s e n t a t i v e s w i l l have t h e r i g h t of access t o vendor ' s shops f o r w i t n e s s , i n s p e c t i o n , o r t e s t i n g of c r i t i ca l material o r s e r v i c e s .

Level 1 procurement items and material are i d e n t i f i e d i n t h e s u b p r o j e c t Q u a l i t y Assurance P l a n s as l i s t e d i n S e c t i o n 3 of t h i s document.

5 . 5 . I n s t r u c t i o n s , Procedures I & Dr-

Work packages w i l l be p repa red as per Procedure N o . 500, t i t l e d "Guide l ines f o r P r e p a r a t i o n and T r a n s m i t t a l of AES Work Packges" , of t h e Mound Eng inee r ing Department AES System Manual i n o r d e r t o a u t h o r i z e in-house f a b r i c a t i o n and i n s t a l l a t i o n . I n accordance w i t h t h i s p rocedure , work packages w i l l be s u f f i c i e n t l y comple te (approved d rawings , s p e c i f i c a t i o n s , j o b d e s c r i p t i o n , M S R , material l i s t , l i s t of r e q u i r e d p e r m i t s , H e a i t h Phys ic s r e q u i r e m e n t s , s p e c i f i c known haza rds o r c o n d i t i o n s , r equ i r emen t s f o r c o o r d i n a t i o n , e t c . ) t o p r o v i d e t h e i n f o r m a t i o n needed f o r do ing t h e work p r o p e r l y . P r i o r t o submiss ion , t h e s u i t a b i l i t y of work packages w i l l be reviewed by t h e Design Eng inee r ' s s u p e r v i s o r . Approval w i l l be i n d i c a t e d by t h e s u p e r v i s o r ' s s i g n a t u r e on t h e bottom o f t h e completed AES Work Package Check L i s t . t i m e l y manner t o a l l o w t h e work d e s c r i b e d t h e r e i n t o be schedu led .

Work packages w i l l be s u b m i t t e d i n a


Design documenta t ion w i l l be p repa red i n accordance w i t h t h e r equ i r emen t s d e f i n e d i n P l a n t Engineer ing ,Manual 808 , "Genera l Requirements f o r A-E Work", Volumes I & 11, and t h e s u b p r o j e c t Design Cr i te r ia . t h a t t h e s c o p e of work is a d e q u a t e l y communicated. The A-E P r o j e c t Manager w i l l recommend t h e documentat ion f o r a p p r o v a l a t t h e comple t ion of T i t l e I1 review. The drawings are approved by t h e C o n s t r u c t i o n Manager and the P r o j e c t Manager and each drawing is s i g n e d .

The documenta t ion w i l l be reviewed t o e n s u r e

P r e l i m i n a r y drawings w i l l n o t be used for c o n s t r u c t i o n .

" F i e l d " changes d u r i n g c o n s t r u c t i o n w i l l be c o n t r o l l e d i n accordance w i t h S e c t i o n 1500, t i t l e d " P r o j e c t Change c o n t r o l and c o n f i g u r a t i o n Review", o f t h e Mound P r o j e c t Management Manual 804.

An up-to-date se t of r e d l i n e drawings w i l l be ma in ta ined by t h e c o n t r a c t o r as r e q u i r e d i n t h e procurement documentat ion. A l l changes w i l l be i n c o r p o r a t e d i n t o t h e " a s - b u i l t " drawings .

With t e c h n i c a l i n p u t t o be p rov ided as n e c e s s a r y by t h e - p r o j e c t team, comple te w r i t t e n o p e r a t i n g and maintenance i n s t r u c t i o n s . for t h e P o t a b l e Water System and f o r t h e Fue l O i l S t o r a g e System w i l l be p rov ided . These i n s t r u c t i o n s w i l l i n c l u d e o p e r a t i o n . o f t h e sys t em, alarm sys tems and emergency p r o c e d u r e s , material t r a n s f e r p r o c e d u r e s , material a c c o u n t a b i l i t y , spare parts l i s t , and any special r e q u i r e m e n t s for i n s p e c t i o n or test of rep lacement p a r t s .

I n o r d e r t o a l l o w unambiguous i d e n t i f i c a t i o n , t h e d a t e o f i s s u e w i l l appear on s p e c i f i c a t i o n s and drawings. c a t a l o g e d , hand led , and f i l e d i n accordance w i t h Mound s p e c i f i c a t i o n SPA-89 1214, t i t l e d "Drawing C o n t r o l P rocedures" .

Drawings w i l l be

Drawing i s s u e s w i l l be o f two types , p r e l i m i n a r y and approved. P r e l i m i n a r y i s s u e s w i l l be i n d i c a t e d by 0 , 1, 2 , e tc . and approved i s s u e s w i l l be i n d i c a t e d by A , B , C , e tc . P r e l i m i n a r y i s s u e s w i l l be c o n t r o l l e d , b u t w i l l n o t r e q u i r e a p p r o v a l s o t h e r t h a n t h e i n i t i a l s of t h e Design Draftsman or Design Engineer . P r e l i m i n a r y i s s u e s w i l l be p rominen t ly marked as such . of " o r i g i n a l " i s s u e A of drawings w i l l be s i g n i f i e d by d a t e d s i g n a t u r e s or i n i t i a l s of the A-E P r o j e c t Manager, A-E Design Eng inee r , A-E Des igne r , t h e EG&G C o n s t r u c t i o n Managers, EG&G P r o j e c t Manager and o t h e r s as a p p r o p r i a t e i n t h e T i t l e b l o c k s . Approval o f changes t o p r e v i o u s l y approved drawings (ie. i s s u e B or above) w i l l be s i g n i f i e d by d a t e s i g n a t u r e s or i n i t i a l s 6 f t h e same f u n c t i o n a l r e p r e s e n t a t i v e s i n r e v i s i o n b locks .

Approval

ES&H Phase I1 Line item - Page 9

Changes i n t h e d e s i g n documents w i l l be c o n t r o l l e d , documented, and i n c o r p o r a t e d a t t h e ear l ies t pract ical t i m e i n t o a new and d i s t i n c t l y l a b e l e d i s s u e of t h e document. The l a b e l w i l l f a c i l i t a t e easy r e c o g n i t i o n of t h e l a t e s t i s s u e of t h e document. Drawings w i l l be changed i n acco rdance w i t h SPA-89 1214.

The Design Engineer w i l l i n i t i a t e any s u c h changes.

P o t e n t i a l s u p p l i e r s o f c r i t i c a l purchased materials o r s e r v i c e s as o u t l i n e d i n t h e s u b p r o j e c t QA P l ans w i l l be e v a l u a t e d t o a c e r t a i n t h e i r c a p a b i l i t y t o p r o v i d e adequa te q u a l i t y . Th i s e v a l u a t i o n w i l l be done by e i t h e r examina t ion o f w r i t t e n documenta t ion o r by s i t e v i s i t s and w i l l be documented by w r i t t e n communication t o Procurement and C o n t r a c t i n g .

I f w r i t t e n c e r t i f i c a t i o n s of methods, compos i t ion of materials, i n s p e c t i o n , o r t e s t r e s u l t s for purchased material or s e r v i c e s , as o u t l i n e d i n , t h e s u b p r o j e c t Q u a l i t y Assurance P l a n , are r e q u i r e d by t h e pu rchase c o n t r a c t , t n e n a check w i l l be made t o v e r i f y t h a t s u c h documents have been r e c e i v e d . Any s u c h documents w i l l be reviewed for comple teness and adequacy.

Refer t o s u b p r o j e c t Q u a l i t y Assurance P l a n s f o r d e t a i l e d r e q u i r e m e n t s .

5 . 8 . I d e n t i f i c a t i o n and Control of I t e m s * .

Purchased i t e m s w i l l be i d e n t i f i e d by pu rchase o r d e r number and r e c e i v i n g i t e m number.

I n o r d e r t o m a i n t a i n i n d i v i d u a l i d e n t i t y of i t e m s , i d e n t i f i c a t i o n markings w i l l be used as r e q u i r e d by t h e s u b p r o j e c t QA P l a n s .

5 . 9 . C o n t r o l of Processes

Refer t o t h e a p p l i c a b l e Q u a l i t y Assurance P l a n , as i d e n t i f i e d i n S e c t i o n 3 of t h i s manual, f o r a d e t a i l e d d e s c r i p t i o n of t h e s u b p r o j e c t p r o c e s s c o n t r o l r e q u i r e m e n t s .

Note: A s a minimum, p r o c e s s c o n t r o l w i l l be r e q u i r e d f o r weld ing of a l l b l a s t door s and s t o r a g e t a n k s .

.

ES&H Phase I1 Line I t e m - Page 1 0

In o r d e r t o a s s u r e good workmanship and conformance t o t h e d e s i g n s p e c i f i c a t i o n s and drawings , f i e l d c o n s t r u c t i o n i n p r o g r e s s w i l l be r e g u l a r l y i n s p e c t e d by t h e P r o j e c t Engineer r e s p o n s i b l e for the work package i n s t a l l a t i o n o r by a d e s i g n a t e d i n s p e c t o r . A d a i l y c o n s t r u c t i o n logbook w i l l be ma in ta ined as a d i a r y o f t h i s i n s p e c t i o n e f f o r t . The logbook w i l l be used f o r n o t e s on the p r o g r e s s of i n s t a l l a t i o n , n o t e s on special i n s p e c t i o n s and t es t s , and documenta t ion of conce rns o r i t e m s t o be r e s o l v e d .

The r e s u l t s o f t h e s e and any o t h e r i n s p e c t i o n s w i l l be documented. Depa r tu re s from s p e c i f i e d r equ i r emen t s w i l l be c o n t r o l l e d i n acco rdance w i t h S e c t i o n 5 . 15 of t h i s &A P lan .

Requirements f o r d e t a i l e d i n s p e c t i o n s are i n c l u d e d i n t ,he a p p l i c a b l e Q u a l i t y Assurance P l a n s as i d e n t i f i e d i n S e c t i o n 3 of t h i s manual.

Tests w i l l comply w i t h t h e s u b p r o j e c t QA P l a n s i n o r d e r t o demons t r a t e s a t i s f a c t o r y performance f o r s e r v i c e . Refer t o t h e a p p r o p r i a t e s u b p r o j e c t &A P l a n f o r d e t a i l e d d e f i n i t i o n of t e s t i n g r e q u i r e m e n t s .

The t e s t r e s u l t s w i l l be documented. Such documenta t ion w i l l i n c l u d e e x p l i c i t i d e n t i f i c a t i o n of t h e i t e m ( s ) t e s t e d . , t h e d a t e of t h e t e s t , t h e t e s t s e t up o r c o n d i t i o n s , t h e t e s t r e s u l t ( q u a n t i t a t i v e i f a p p l i c a b l e ) , t h e s i g n a t u r e of t h e p e r s o n ( s ) per forming t h e t es t , r e f e r e n c e t o t h e a c c e p t a n c e c r i t e r i a , a s t a t e m e n t of a c c e p t a n c e o r r e j e c t i o n , and t h e s i g n a t u r e o f t h e pe r son r e s p o n s i b l e f o r e v a l u a t i n g t h e t e s t r e s u l t .

Note: A s a minimum, t e s t i n g w i l l be r e q u i r e d f o r f i r e p r o t e c t i o n sys t ems , l i g h t n i n g p r o t e c t i o n systems and c o n c r e t e .

The a c c u r a c y and s u i t a b i l i t y of measuring and t e s t equipment used a t Mound w i l l be a s s u r e d t h r o u g h u s e of the s e r v i c e s of the Mound S t a n d a r d s group i n acco rdance w i t h t h e p rocedures i n Manual MD-10096, t i t l e d "Mound Metrology Systems". Vendor c e r t i f i c a t i o n s w i l l be o b t a i n e d t o a s s u r e t h e a c c u r a c y and s u i t a b i l i t y of measuring and t e s t i n g equipment used by s u p p l i e r s of c r i t i c a l materials and s e r v i c e s .


Mound - s C o n s t r u c t i o n Managers w i l l v e r i f y t h a t measuring and t e s t i n g equipment is p r o p e r l y u t i l i z e d and is adequa te t o meet a l l t e s t i n g r e q u i r e m e n t s .

Mound's S t a n d a r d s g roup w i l l a c t as a c o n s u l t a n t i f c e r t i f i c a t i o n , c o n t r o l , or u t i l i z a t i o n of measuring and tes t equipment is i n q u e s t i o n .

Rece iv ing and d e l i v e r y of incoming materials w i l l be handled t h r o u g h Mound's Material C o n t r o l System o r by t h e Prime C o n t r a c t o r . D e l i v e r y w i l l be made t o t h e l o c a t i o n i n d i c a t e d on t h e material l i s t and pu rchase o r d e r form.

G Materi a1 Coord ina to r :

The material c o o r d i n a t o r w i l l pe r form a r e c e i v i n g i n s p e c t i o n t o conf i rm t h e i d e n t i t y of materials, conf i rm t h e p r e s e n c e of

m a i n t a i n a log of materials i n and o u t of t h e s t a g i n g area. foreman or p l a n n e r w i l l c o n t r o l materials be ing i n s t a l l e d .

' s p e c i f i e d c e r t i f i c a t i o n s , s t o r e and c o n t r o l t h e materials, and The

The C o n t r a c t o r S u p e r i n t e n d e n t w i l l pe r form a r e c e i v i n g i n s p e c t i o n t o c o n f i r m t h e i d e n t i t y of material, conf i rm t h e p r e s e n c e of s p e c i f i e d c e r t i f i c a t i o n s , s t o r e and c o n t r o l t h e material.

A l l c r i t i c a l equipment as i d e n t i f i e d i n t h e s u b p r o j e c t &A P l a n s w i l l be v i s u a l l y i n s p e c t e d p r i o r t o i n s t a l l a t i o n . observed w i l l be r e c o r d e d by Mound's P r o j e c t I n s p e c t o r i n t h e d a i l y log. I n s t a l l a t i o n of t h e equipment w i l l be h a l t e d u n t i l a n a s ses smen t of t h e damage by t h e manufac turer o r a d e s i g n a t e d r e p r e s e n t a t i v e c a n be made. W r i t t e n documentat ion of t h i s a s ses smen t w i l l be ma in ta ined by t h e c o n s t r u c t i o n manager.

Any damage

A l l i n s p e c t i o n and t e s t i n g c e r t i f i c a t i o n s for c r i t i c a l equipment w i l l be reviewed and v e r i f i e d by t h e p r o j e c t i n s p e c t o r p r i o r t o i n s t a l l a t i o n .

I n acco rdance w i t h S e c t i o n 1 . 5 . 15 of Manual MD-10241, i n s t a n c e s

ESSEH Phase I1 - Page 12

of i t e m s or a c t i v i t i e s t h a t are judged by t h e P r o j e c t Engineer as d e p a r t u r e s from s p e c i f i e d r equ i r emen t s (eg. drawings o r s p e c i f i c a t i o n s ) w i l l be d e s i g n a t e d by t h e P r o j e c t Engineer as " d e v i a t i o n s " . The P r o j e c t Engineer w i l l immedia te ly mark or p h y s i c a l l y s e g r e g a t e any d e v i a t i n g i t e m s s o as t o p r e v e n t i n a d v e r t a n t u s e p r i o r t o d i s p o s i t i o n . Using a n Eng inee r ing Department Nonconformance Report form, t h e P r o j e c t Engineer w i l l p r o v i s i o n a l l y c l a s s i f y s u c h d e v i a t i o n s as "major" or "minor" . A major d e v i a t i o n w i l l be d e f i n e d as a d e v i a t i o n which is l i k e l y t o r e s u l t i n a n u n s a f e c o n d i t i o n or p r e v e n t i n t e n d e d u s e o r r e s u l t . A minor d e v i a t i o n w i l l be d e f i n e d as a d e v i a t i o n which is n o t l i k e l y t o r e s u l t i n an u n s a f e c o n d i t i o n or t o p r e v e n t i n t e n d e d u s e or r e s u l t . On t h e Repor t form, t h e P r o j e c t Engineer w i l l a l s o d e s c r i b e t h e d e v i a t i o n , s t a t e t h e a p p a r e n t c a u s e , and s t a t e and j u s t i f y a recommended d i s p o s i t i o n . D i s p o s i t i o n may i n c l u d e "scrap" "repair" or " rework" , or " u s e as i s" .

The P r o j e c t Engineer w i l l t h e n convene a Review Committee t o e v a l u a t e t h e s i t u a t i o n . If a major d e v i a t i o n is i n v o l v e d , t h e n t h e Review Committee w i l l c o n s i s t of ' . 'at least t h e Sponsor , the P r o j e c t Eng inee r , t h e Design Engineer ( i f d i f f e r e n t t h a n t h e P r o j e c t E n g i n e e r ) , t h e LP&EC R e p r e s e n t a t i v e , and t h e QA R e p r e s e n t a t i v e . If a minor d e v i a t i o n i s i n v o l v e d , t h e n t h e Review Committee w i l l c o n s i s t of a t l ea s t t h e P r o j e c t Engineer and t h e &A R e p r e s e n t a t i v e . In e i t h e r case, o t h e r s p e c i a l i s t s may be added t o t h e Review Committee as r e q u i r e d . The P r o j e c t Engineer will be the c h a i r p e r s o n of t h e Review Committee.

The Committee w i l l review t h e p r o v i s i o n a l r e p o r t ' a n d d i s p o s i t i o n recomended by t h e P r o j e c t Eng inee r , making any a g r e e d changes . For major d e v i a t i o n s , t h e Committee w i l l a l s o de t e rmine and s t a t e on t h e Repor t form t h e r o o t c a u s e and any c o r r e c t i v e a c t i o n t o be t a k e n . F o r minor- d e v i a t i o n s , s t a t e m e n t of r o o t cause and c o r r e c t i v e a c t i o n w i l l be o p t i o n a l . The Committee w i l l r e a c h a consensus , and each member w i l l s i g n t h e Repor t form.

The P r o j e c t Engineer w i l l implement t h e c o r r e c t i v e a c t i o n i n d i c a t e d by t h e Committee, d e s c r i b e t h e a c t i o n on t h e Repor t form, and c e r t i f y on t h e Report f o r m ' t h a t t h e a c t i o n was t a k e n . The QA R e p r e s e n t a t i v e w i l l t h e n r ev iew t h e Repor t form and , when s a t i s f i e d , w i l l a l s o s i g n t h e form t o " c l o s e o u t " t h e d e v i a t i o n . A s a minimum, c o p i e s of t h e Repor t w i l l be d i s t r i b u t e d t o t h e p r o j e c t f i l e and t o t h e &A R e p r e s e n t a t i v e . A l l d e v i a t i o n s w i l l be s o r e s o l v e d p r i o r t o c l o s e o u t of t h e p r o j e c t .

5 . 16. C o r r e c t ; ve Ac t ion

The P r o j e c t Engineer w i l l moni tor t h e p r o j e c t f o r c o n d i t i o n s


a d v e r s e t o q u a l i t y . d i s c u s s i o n s a t p r o j e c t mee t ings , p e r i o d i c rev iew of t h e p r o j e c t logbook, and r ev iew o f Nonconformance Repor t s . I f a d v e r s e t r e n d s are i d e n t i f i e d or a p o t e n t i a l e x i s t s f o r r e p e t i t i o n of a major d e v i a t i o n , t h e P r o j e c t Engineer w i l l i n i t i a t e c o r r e c t i v e a c t i o n . t h e a c t i o n i s e f f e c t i v e , and document any s u c h a c t i o n s and t h e r e s u l t s by use o f t h e Eng inee r ing Department Nonconformance Repor t form and t h e p rocedure d e s c r i b e d i n S e c t i o n 5 .15 . The c o r r e c t i v e a c t i o n Review Committee w i l l c o n s i s t of a t l eas t the Sponsor , t h e P r o j e c t Engineer , t h e Design Engineer (if d i f f e r e n t t h a n t h e P r o j e c t E n g i n e e r ) , t h e LP&EC R e p r e s e n t a t i v e , 'and t h e QA R e p r e s e n t a t i v e . Other spec ia l i s t s may be added t o t h i s Committee as r e q u i r e d .

Th i s w i l l be performed by n o t i n g

The P r o j e c t Engineer w i l l f o l l o w t h r o u g h t o v e r i f y t h a t

c

P r o j e c t r e c o r d s w i l l be ma in ta ined d u r i n g t h e p r o j e c t e x e c u t i o n . After d r a f t i n g or e d i t i n g work is comple ted , d e s i g n drawings and c o n t r o l l e d s p e c i f i c a t i o n s w i l l be s t o r e d i n Drawing C o n t r o l i n acco rdance w i t h SPA-891214, t i t l e d "Drawing C o n t r o l P rocedures" . These p rocedures i n c l u d e s t o r a g e o f mic ro f i lm c o p i e s of a l l i s s u e s of drawings . i s s u e s and any o p e r a t i n g and maintenance manuals f o r equipment and components w i l l be t r a n s f e r r e d . t o t h e Sponsor af ter comple t ion o f . t h e p r o j e c t . T h e f o l l o w i n g l i s t shows o t h e r p r o j e c t r e c o r d s which w i l l be t r a n s f e r r e d t o t h e Eng inee r ing Systems and Design s e c t i o n f o r s t o r a g e a f t e r comple t ion of t h e p r o j e c t .

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a . AES, s t a t e m e n t of s cope of p r o j e c t , AES Cos t E s t i m a t e

b. M S R s . c. Work package i n f o r m a t i o n i n c l u d i n g scope of package ,

Summary, and AES Cost E s t i m a t e Detail.

special i n s t r u c t i o n s , and material l i s t . As s t a t e d above, drawings w i l l be s t o r e d separately i n Drawing C o n t r o l .

d. P r o j e c t s c h e d u l e , i n c l u d i n g t a r g e t s c h e d u l e and r e v i s i o n s .

e. Completed P r o j e c t Q u a l i t y Assurance Review and &A Plan . Audi t r e p o r t i f p r o j e c t a u d i t e d .

f . Monthly p r o g r e s s r e p o r t s and o t h e r major r e p o r t s . g . Meeting minu tes , i m p o r t a n t co r re spondence and t e l e c o n

h. P r o j e c t c l o s i n g i n f o r m a t i o n , i n c l u d i n g c o s t summary,

i . Any PSAR o r FSAR. j . Any Eng inee r ing B u l l e t i n s o r r e c o r d s o f ConfiguraOion

n o t e s .

and r e p o r t s of any p r e o p e r a t i o n a l r e a d i n e s s r ev iew, e tc .

Board a c t i o n s .

ES&H Phase I1 Line Itern - Page 14 11.

111.

a. Design Cr i te r ia . b. Design C a l c u l a t i o n s . c. S p e c i f i c a t i o n s . d. Completed Engineer ing Review T r a n s m i t t a l S h e e t s . e. L i s t of drawings and c o n t r o l l e d s p e c i f i c a t i o n s .

a . Any s u p p l i e r e v a l u a t i o n r e p o r t s . b. Purchase Orde r s , any a s s o c i a t e d s p e c i f i c a t i o n s , c. S u p p l i e r shop drawings i f n o t t o be s t o r e d i n Drawing

d. Any s u p p l i e r material c e r t i f i c a t i o n s and i n s p e c t i o n or

i m p o r t a n t cor respondence , and any b i d e v a l u a t i o n r e p o r t s .

C o n t r o l .

tes t r e p o r t s .

V I . F a b r i c a t j o n and i n s t a l l a t i on r e c o r d s

a. P r o j e c t logbook. b. I n s p e c t i o n r e p o r t s , t e s t r e s u l t s , and c a l i b r a t i o n

c. Any nonconformance r e p o r t s . r e c o r d s .

5 . 18. Audi t s

Th i s p r o j e c t is s u b j e c t t o independen t a u d i t a t any t i m e by t h e S e c t i o n &A R e p r e s e n t a t i v e . The purpose of s u c h a u d i t would be t o d e t e r m i n e t h e deg ree of compliance w i t h t h e p r o v i s i o n s of t h i s &A P l a n and t h e adequacy of documenta t ion of q u a l i t y a s s u r a n c e e f f o r t s . I n p a r t i c u l a r , t h e p r o j e c t hardware and f i l e s may be a u d i t e d p r i o r t o t r a n s f e r of t h e p r o j e c t t o t h e Sponsor * s o r g a n i z a t i o n .

In a d d i t i o n , t h i s p r o j e c t is s u b j e c t t o independent a u d i t by a u d i t o r s from t h e Performance Assurance Group a t Mound. Such a u d i t would be i n accordance w i t h Manual MD-10181, t i t l e d "Mound Q u a l i t y Audit Program". The p rocedures r e q u i r e d by t h i s Manual i n c l u d e a u d i t r e p o r t s t o r e s p o n s i b l e management and p r o v i s i o n for any n e c e s s a r y fol low-up a c t i o n . The purpose of s u c h a u d i t would be t o de t e rmine b o t h t h e d e g r e e o f compliance w i t h t h i s QA P l a n , and t h e adequacy and e f f e c t i v e n e s s o f t h e QA P l a n i t s e l f .

A l l s o f t w a r e used f o r t h i s p r o j e c t w i l l be proven , commerc ia l ly a v a i l a b l e packages. T h e r e f o r e , s o f t w a r e q u a l i t y a s s u r a n c e w l l l n o t be r e q u i r e d f o r t h i s p r o j e c t .

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-7- - m NEW POTABLE WATER SYSTEMS, ESEH PKASE I1 - .. AES: 5 0 1 0 7 1 m m o N :

S O N S O R : John Hussmann C/C: 8 8 1

ENGINEER: G a r y L. Coons HP NO.: 3945

QA MEmNC UTE November 2 8 , 1 9 8 9

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--.-.QUALITY ASSURANCE REVIEW

.. TASK RISK RMW, MAJOR CONCERNS, k JUSTiRCATION FOR LEVEL ASSICNMPCT: - 1) Backf low prevention procurea~l 0 t and installation is critiw and must be

c&tmlled. This involves selecting and specifying the c m type and mbnitoring the i n s c u t i o n &testing.

2) Pipeing system mterial, installa tion, and testing is a concern and m s t be m n i t d .

3) Desigdconstruction change corrtml, as-builts , and code requirments m u s t be documated.

If these system features fail, it could resul t with serious health concerns.

DMER CUNSIOERATIONS/SPECUt. PUNS:

During ConstructiQn, asbestos will be encwntered associated with pipe insulation. dcamented.

Pmc@res t o deal with asbestos must be addressed and - A plan mst be prepared during T i t l e I design.

. . I AMlClPATm OA REQUlREfilENT

I LEVEL1 t ..-... [ e l A1

.. -1 .

.. PROJECT QUALITY ASSURANCE REVIEW

-. .--.

T i t l e : ES&H I I b : E x p l o s i v e s Safety U p q r a d e s

AES : J(:)1(:)72 L o c a t i o n : S i t e

S p o n s o r : Georqe B a l l 111 cc: LOO

E n g i n e e r : R o b e r t 6. W i s e HP NO.: 5362

QA M e e t i n g D a t e : December 6, i990

P r o j e c t D e s c r i p t i o n Y S c o p e :

The - I.

2.

- .3 .

4.

5.

6 .

s c o p e o f t h e p r o j e c t i s ' t o d e s i g n a n d c o n s t r u c t t h e f o l l o w i n g : 8 s i n g l e cell e a r t h c o v e r e d s t o r a g e m a g a z i n e s s i t e d f o r s t o r a g e o f i99 p o u n d s of UNO C l a s s / D i v i s i o n i.1 e x p l o s i v e s .

A 3 cell service m a g a z i n e f o r b u i - l d i n g 27 e a c h cell r a t e d f .or.13 p o u n d s TNT e q u i v a l e n t e x p l o s i v e s and s i t e d . a c c o r d i n g l y .

A 4 cel l m a g a z i n e fo r b u i l d i n g 48 e a c h ce l l r a t e d f o r 13 po&ds of TNT e q u i v a l e n t e x p l o s i v e s and s i t e d a c c o r d i n g l y . m a g a z i n e w i l l a l so be p r o v i d e d w i t h e n v i r o n m e n t a l c o 6 . d i t i o n i n q of it 's i n t e r i o r .

T h i s

A s i n g l e cell service m a g a z i n e for D S b u i l d i n g . T h i s m a g a z i n e will h o u s e F'antex n o n - p r o p a g a t i n g c a b i n e t s . T h e m a g a z i n e w i l l b e d e s i g n e d a n d s i t e d f o r 1.3 pounds TNT e q u i v a l e n t e x p l o s i v e s .

E x p l o s i v e f r a g m e n t b a r r i c a d e s f o r m a g a z i n e s 7 a n d 11 a n d for b u i l d i n g s 27 and 49.

M o d i f i c a t i o n s of Magaz ine 20 t o c o n v e r t it i n t o a n e x p l o s i v e s i n s p e c t i o n a n d t r a n s f e r b u i l d i n g .

A l l i t e m s on t h e p r o j e c t w i l l h a v e i n t e r i o r a n d e x t e r i o r electrical systems a n d l i g h t i n g as r e q u i r e d . I n a d d i t i o n t h e y w i l l a l so h a v e l i g h t n i n g p r o t e c t i o n as r e q u i r e d .

. ..-. .

...

. T i t l e : ESbH I I b : E x p l o s i v e s Safety Upqrades

AES : JOlLo72 .-.-. L o c a t i o n : S i t e

S p o n s o r : Georqe B a l l I11 CC: LO(3

E n g i n e e r : R o b e r t K. Wise H F NO. : 5362

QA M e e t i n g Date: December 6 , 199C)

TASK R I S K REVIEW. MAJOR CONCERNS,& JUSTIFICATION FOR LEVEL , ASSIGNMENT

Most of t h e c o n c e r n s f o r t h e p r o j e c t are w i t h t h e d e s i g n a n d c o n s t r u c t i o n of t h e e a r t h c o v e r e d m a g a z i n e s a n d service m a g a z i n e s . S t a n d a r d m a g a z i n e d e s i g n p r a c t i c e s i n c l u d e c e r t a i n s a f e t y systems i n t e n d e d t o m i t i g a t e r i s k . The l i g h t n i n g p r o t e c t i o n sys tem is i n t e n d e d t o reduce t h e risk of a n a c c i d e n t a l d e t o n a t i o n o f m a g a z i n e c o n t e n t s by a l i g h t n i n g s t r i k e . The e x p l o s i o n p r o o f electrical ' fixtures i n t h e i n t e r i o r of a m a g a z i n e reduce t h e r i s k of a n a c c i d e n t a l d e t o n a t i o n f r s m s p a r k s . The b l a s t d o o r s , s tructural d e s i g n a n d s i t i n g are i n t e n d e d t o i r e v e n t p r o p a g a t i o n ' o f E x p l o s i o n s be tween m a g a z i n e s s h o u l d a n a c c i d e n t a l d e t o n a t i o n occur. T h e s i t i n g of t h e .magaz ine r e l a t ive t o s u r r o u n d i n g b u i l d i n g s arid o t h e r m a g a z i n e s

' i s a l so i n t e n d e d t o m i n i m i z e t h e r i s k of *severe damage t o s u r r o u n d i n g b u i l d i n g s and i n j u r y o r d e a t h t o p e o p l e o u t s i d e t h e m a g a z i n e area.

The c o n c e r n s are t h a t t h e b l a s t d o o r s , s t ruc tura l , s i t i n g , electrical systems and l i g h t n i n g p r o t e c t i o n systems are a l l p r o p e r l y d e s i g n e d and t h a t t h e s e d e s i g n s ' a r e c o n s t r u c t e d a c c o r d i n g t o t h e d r a w i n g s a n d s p e c i f i c a t i o n s i n c l u d i n g t h e materials of c o n s t r u c t i o n .

The p r o j e c t is c o n s i d e r e d a L e v e l 1 b e c a u s e t h e s e s a f e t y systems m u s t f u n c t i o n p r o p e r l y i n order to m i n i m i z e t h e risk of severe i n j u r y o r d e a t h a n d / o r t h e loss of r a w material w h i c h c o u l d a d v e r s l e y affect o u r m i s s i o n .

OTHER CONSIDERATIONS/SPECIAL PLANS: None r e q u i r e d QA L e v e l 1

A s s i g n m e n t of C o n s e q u e n c e of F a i l u r e :

L e v e l 1 X

L e v e l 2

L e v e l 3

---

S p o n s o r :

S u p e r v i s o r :

. .. -.. .

. - \,.-

PROJECT QUALITY ASSURANCE REVIEW

T i t l e : G&H IIc: Fu e l 011 Storaa e Svstem

AES: J.&, .Location: S i t e

Sponsor: -le5 Friedman CC: TI00

HP NO.: 5362 . .

Engineer: 8. K . Wise

' The p r o j e c t is intended t o upgradk t h e fuel- o i l s to rage and de l ive ry system a t Mound by making improvements a t both t h e Day tank s i te near t h e power house and t h e main tank s i te .

.. Demo lit ion

The fou r 25,000 ga l lon Underground Storage. Tanks loca ted east of t h e powerhouse w i l l be decommissioned*and removed.

I n s t a l l a t i o n A 50,000 g a l l o n above ground o i l s to rage tank w i l l be

e i n s t a l l e d a s a replacement.' I n t e g r a l t o t h e tank i n s t a l l a t i o n w i l l be t h e cons t ruc t ion of a concre te containment bas in and an automatic foam f i r e suppression system. I n add i t ion , a t ruck unloading s t a t i o n and i t ' s containment sump w i l l be i n s t a l l e d with t h e new tank .

* -

Demolit ion The 3 0 0 , 0 0 0 g a l l o n above ground f u e l o i l s to rage tank is t o be removed including t h e p ip ing from t h e pump house t o t h e tank . The f u e l t r a n s f e q pump w i l l also be'.removed.

I n s t , a l l a t i o n The 300,000 g a l l o n tank w i l l be replaced by two 225,000 gallon f u e l o i l s to rage tanks . secondary containment through t h e i n s t a l l a t i o n of a concrete '

containment bas in . automatic foam f i re suppression system with nozzles f o r each tank . w i l l be i n s t a l l e d with t h e new tanks . pump and containment sump w i l l a l s o be i n s t a l l e d with t h e new main s to rage tanks .

The f u e l tanks w i l l be provided

I n t e g r a l t o t h e i n s t a l l a t i o n i s an

A t r u c k unloading s t a t i o n and i t ' s containment sump A f u e l o i l transfer

The 225,000 g a l l o n tanks are planned f o r i n s t a l l a t i o n i n t h e area east of t h e bui ld ing 19 s to rage b ins and south of WD bui ld ing . , Consequently, t h e f u e l t r a n s f e r p ip ing w i l l be extended. i n s t a l l a t i o n of a number of pipe s tanchions.

The p ip ing w i l l be overhead and w i l l r e q u i r e t h e

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Title:

Location : Site

cc : TI00 Sponsor: w l e s F r i e r l m a

Engineer:&& ert K. W w HP NO. : 5362

TASK RISK RE VIEW. B J O R CONCRRNS. i?z JI J S T ~ O N FOR L R v m

The main concerns for this project are the consequences of an oil spill resulting from a leaking-oil tank and the risk and consequences of an oil tank fire. There fore, the main concern for this groject is the design and installation of the above ground storage tanks. 'Because the tank itself is the primary containment for the fuel oil it 'will receive greater emphasis than the.containment basin. If the tank does not fail, the secondary containment basin is not needed. In addition the appurtenances associated with the tanks must be properly designed and installed in order to minimize the risk and consequences of a tank fire.

The close proximity of buildings at the day tank site places . emphasis on the foam fire suppression system for this tank.

The removal of the Underground Storage Tanks at the power house and the remediation of this site are also emphasis areas.

O t h e r c o o - :

None required &A Level42

Assignment of Consequence of Failure:

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Level 1 - Level 2 L Lev-1 3 -

Approvals Dates

Construction Manag

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