QUALITY ASSURANCE PLAN e* FOR SITE SUBSTATION LINE …/67531/metadc... · Institute of Electrical and Electronic Engineers, ANSI/IEEE 141, 1986, titled "Recommended Practice for Electric

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MLM-MU-91-65-0005 n . c.2,

RECEIVED 5.ui o 1 1996

O S T I n e*

QUALITY ASSURANCE PLAN n

n FOR e*

e* SITE ELECTRlCAL REPLACEMENTS AND

SUBSTATION LINE ITEM SU.BPROJECT: 69 KV SUBSTATION

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May 21, 1991 .

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EEnG MOUND APPLIED TECHNOLOGES e* P.O. BOX 3000 MIAMISBURG, OHIO 45343-3000 513-865-4020

DISTRIBUTION OF THIS DOCUMENT IS UNLIMITEDk T

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, recom- 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.

QUALITY ASSURANCE PLAN

for

S i t e Electrical Replacements and Subs ta t ion Line Item

Subproject: 69 KV Subs ta t ion

P r o j e c t AES No. M82742

Issue of May 21 , 1991

Prepared by: C. K. Ohler ..

EG&G Mound Applied Technologies

Miamisburg, Ohio

Approvals :

C . K e i t h 0 U r P r o j e c t Manager

- Date -!?,/zl/?!

Date

Date G ! / y J .

y$&i-, Pro jec t Engineer - Date Engineering Manager

Fredrick G. k a c h Date 5,k1/41 Loss Prevention and En p resen ta t ive

uav E. Frlag-h Date s7/?$/y/ '

Q u a l i t y Assurance E e

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&A P lan f o r S i t e Electrical Replacements and S u b s t a t i o n P r o j e c t

Table of Contents

1 . 2 . 3 . 4 . 5 .

Desc r ip t ion and Scope of P r o j e c t ...................... Purpose of QA Plan .................................... Applicable Documents .................................. Analysis of Consequence of F a i l u r e .................... Q u a l i t y Elements and Q u a l i t y Assurance E f f o r t s .........

Page

1

1

1

3

3

5.1 . 5 . 2 . 5 . 3 . 5 .4 . 5 .5 . 5 .6 . 5 . 7 . 5 .8 . 5 .9 . 5 . 1 0 .. 5: 11 . 5.12. 5.13. 5 . 14 . 5 . 15 . 5 .16 . 5 . 17 . 5.18. 5.19.

.. Organiza t ion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Q u a l i t y Assurance Program ........................ 5 Design.Contro1 .................................. 6 Procurement Document Cont ro l .................... 7 I n s t r u c t i o n s , Procedures, and Drawings . . . . . . . . . . 7 Document Control ................................. 8 Cont ro l of Purchased Items and Se rv ices . . . . . . . . . 9 I d e n t i f i c a t i o n and Cont ro l of Items . . . . . . . . . . . . . 9 Cont ro l of Processes ............................ 9 Inspec t ion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 T e s t Cont ro l .................................... 1 0 Cont ro l of Measuring and T e s t Equipment . . . . . . . . . 11 Handling, S to rage , and Shipping . . . . . . . . . . . . . . . . . 11 Inspec t ion , T e s t , and Operat ing S t a t u s . . . . . . . . . . . 12 . Contro l of Nonconforming I t e m s . . . . . . . . . . . . . . . . . . 12 C o r r e c t i v e Action ............................... 13 Q u a l i t y Assurance Records ....................... 13 Audits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Q u a l i t y Assurance Element Matrix

P r o j e c t Q u a l i t y Assurance Review

.

. - -. . . .. .. ._

QA P lan f o r 69 KV S u s b s t a t i o n P r o j e c t - Page 1

Scope of Pro . iec t

The 69 KV S u b s t a t i o n P r o j e c t is based on t h e recognized need t o provide a cont inuous , r e l i a b l e source of power and t o improve t h e f i r m capacity of t h e e lectr ical s e r v i c e t o a l l product ion f a c i l i t i e s a t Mound.

The p r o j e c t c o n s i s t s of t h e fo l lowing major element:

69 KV Subs ta t ion :

1. I n s t a l l a 69 KV S u b s t a t i o n and a s s o c i a t e d equipment wi th two paral le l 18 MVA t ransformers .

2. I n s t a l l d u c t bank as requ i r ed and provide 15 KV f e e d e r c a b l e from new s u b s t a t i o n t o e x i s t i n g S u b s t a t i o n 95 f o r connec t ion t o Mound's e x i s t i n g primary d i s t r i b u t i o n system.

3 . I n s t a l l duck bank f o r underground r o u t i n g of t h e 15 KV f e e d e r c a b l e from Manhole 5 C t o t h e e x i s t i n g power house c a b l e p i t .

4. Reconfigure e x i s t i n g Dayton Power and Light Co. 15 KV swi tchgear i n P' Building.

The purpose of t h i s Q u a l i t y Assurance P lan (&A P lan) is t o a s s u r e 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 EGStG Mound Applied Technologies , Miamisburg, Ohio (Mound) are m e t f o r t h i s hon-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 safety, p r o t e c t i o n of t h e environment, 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 documentation of q u a l i t y e f f o r t s . This &A P l an 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 des ign , 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 th is p r o j e c t i n o r d e r t o meet t h e s e o b j e c t i v e s .

3 . Applicable Doc-

The D . O . E . requirements f o r q u a l i t y assurance f o r p r o j e c t s such as t h i s one are s e t f o r t h i n AL Order 5700.6B, Revision 2 , da t ed 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 such as Mound t o develop non-weapons q u a l i t y a s su rance programs through a p p l i c a t i o n of a p p r o p r i a t e requirements of t h e consensus s t anda rd 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 f o r Nuclear F a c i l i t i e s " . That s t a n d a r d is des igna ted as ASME NQA-1-1989 E d i t i o n and is commonly ca lxed "NQA-1"-. A se t of 1989 addenda have been i s sued .

&A Plan f o r 69 KV S u b s t a t i o n P r o j e c t - Page 2

The Mound non-weapons q u a l i t y assurance program r e f l e c t i n g t h e D . O . E . guidance c i t e d above is presented i n Mound Technical Manual MD-10165. The implementation of t h a t program wi th in t h e Engineer ing Department is s e t f o r t h i n Mound Technical Manual MD-10241, t i t l e d "5700.6B Q u a l i t y Plans f o r Engineer ing Department" (Manual MD-10241).

Other Documents and Forms: ..

Mound Manual MD- 10286, t i t l e d " 'Safety and Hygiene Manual".

Mound Systems Manual 804, t i t l e d "Mound P r o j e c t Management . Manual 804" , (Manual 804) provides procedures for major or ' 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 " General Requirements f o r A-E Work".

Mound System Manual 810 , t i t l e d "Master Cons t ruc t ion S p e c i f i c a t i o n s " .

Mound Systems Manual No. 8 i 1 , t i t l e d "Mound Engineer ing Department AES System Manual", (AES Manual) provides procedures f o r managing and documenting expense, cap i ta l equipment, p r o d u c t i v i t y cap i ta l , and reimbursable p r o j e c t s .

Mound SPA-89 12 14, t i t l e d "Drawing Cont ro l Procedures" , 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 Shee t" .

Mound Form ML-88 16, t i t l e d "Engineer ing Department Nonconformance Report".

Nat iona l F i r e P r o t e c t i o n Assoc ia t ion , NFPA 7 0 , 1990 t i t l e d "Nat iona l Electrical Code".

I n s t i t u t e of Electrical and E l e c t r o n i c Engineers , ANSI/IEEE 80 , 1986, t i t l e d "Guide f o r S a f e t y i n S u b s t a t i o n Grounding" -

I n s t i t u t e of Electrical and E l e c t r o n i c Engineers , ANSI/IEEE C2 , 1990, t i t l e d "Nat iona l Electrical. S a f e t y Code".

I n s t i t u t e of Electrical and E l e c t r o n i c Engineers , ANSI/IEEE C37, 1989, t i t l e d ' :Circui t Breakers , Switchgear , Relays , S u b s t a t i o n s & Fuses". .

&A P lan f o r 69 KV S u b s t a t i o n P r o j e c t - Page 3

* I n s t i t u t e of Electr ical and E l e c t r o n i c Engineers , ANSI/IEEE C57, 1990, t i t l e d " D i s t r i b u t i o n Power and Regula t ing Transformers I t .

I n s t i t u t e of Electrical and E l e c t r o n i c Engineers , ANSI/IEEE 141, 1986, t i t l e d "Recommended P r a c t i c e f o r Electric Power D i s t r i b u t i o n f o r I n d u s t r i a l P l a n t s " .

I n s t i t u t e of Electrical and E l e c t r o n i c Engineers , ANSI/IEEE 837, 1989, t i t l e d "Standards f o r Q u a l i f y i n g Permanent Connections used i n S u b s t a t i o n Grounding".

4 . Analvsis of Conseeuence of F a i l u r e .

A P r o j e c t Q u a l i t y Assurance Review w a s completed and approved on December 18, 1990. The P r o j e c t Manager, t o g e t h e r w i t h . t h e P r o j e c t Sponsor, t h e P r o j e c t Engineer , t h e LP&EC Represen ta t ive , and t h e QA Representa t ive 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 p r o j e c t s most s e v e r e QA Level a s de f ined i n S e c t i o n 1 . 3 of Manual MD-10241, was Q u a l i t y Level 1. Manual MD-10241 r e q u i r e s a w r i t t e n QA P lan f o r any AES p r o j e c t a s s e s s e d as QA Level 1.

The major c o n s i d e r a t i o n s i n determining t h e &A Level were t h e r i s k s of i n j u r y , Ioss 0.f l i fe , . and loss of equipment greater t h a n $ 5 0 0 , 0 0 0 t h a t may ensue i f proper des ign , i n s t a l l a t i o n . , and t e s t i n g techniques/procedures are n o t fol lowed f o r t h e 69 KV s u b s t a t i o n , and h igh vo l t age cable i n s t a l l a t i o n . The problem i n t h e s e areas would n o t be d iscovered u n t i l t h e sys t em is energized.

5 . Q u a l j t v E l e m e n t s and Q u a l i t v Assurance R f f o r t s

The q u a l i t y assurance e f f o r t s planned f o r t h i s p r o j e c t are e x p l i c i t l y d i scussed i n t h e fo l lowing s e c t i o n s ( 5 . 1 through 5 . 1 9 ) . The f i r s t 18 s e c t i o n headings are t h e same as t h o s e of t h e b a s i c requi rements , o r e lements , of bo th ASME NQA-1-1989 E d i t i o n and D.0.E Order AL 5700.6B, Revis ion 2. The 1 9 t h s e c t i o n is f o r sof tware .

5 . 1 Organ iza t ion

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 assurance program a t Mound is ves t ed wi th t h e D i r e c t o r of t h e Q u a l i t y Department. Overa l l a d m i n i s t r a t i o n of t h e program is delegated t o a s t a f f 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 of Non-weapons Q u a l i t y *

Assurance. Implementation of t h e program is conducted by a

QA P lan f o r 63 KV S u b s t a t i o n P r o j e c t - Page 4

"mat r ix" o r g a n i z a t i o n invo lv ing Department Coordinators from t h e va r ious departments .

Within t h e Engineer ing Department, t h e NWQA Program Manager manages t h e NWQA program. The NWQA Program Manager r e p o r t s t o t h e Manager of Engineer ing Systems and Design, 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 Engineer ing. A s t a f f of S e c t i o n NWQA S p e c i a l i s t s r e p o r t d i r e c t l y t o t h e NWQA Program Manager and implement t h e program i n t h e i r Sec t ion . Thus t h e NWQA s taff is a d m i n i s t r a t i v e l y independent of a l l o t h e r d i r e c t supe rv i s ion . Refer t o F igure 1 f o r t h e 69 KV S u b s t a t i o n P r o j e c t Matrix Organiza t ion Chart .

Those persons prominent ly a s s o c i a t e d wi th implementation of t h i s QA P ian for t h e S i t e Electrical Replacements and S u b s t a t i o n p r o j e c t are l i s t e d below t o g e t h e r w i th 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 .

Pro. iect Sponsor. Stephen E. Cradv - Responsible f o r p a r t i c i p a t i n g i n development of s t a t emen t of work and des ign c r i t e r i a ; i n t e r p r e t i n g p r o j e c t requi rements ; approving p r o j e c t des igns ; p a r t i c i p a t i n g i n des ign reviews; provid ing t e c h n i c a l suppor t for p r o j e c t des ign , c o n s t r u c t i o n , and t e s t i n g ; provid ing s t a r t - u p p l a n s ; and execu t ion of t h i s QA Plan.

Pro .i e & Engineer. l iam A . Saul - Responsible f o r p r o j e c t des ign and t e c h n i c a l guidance; developing material and equipment s p e c i f i c a t i o n s ; p a r t i c i p a t i n g i n des ign reviews; approving . p r o j e c t des igns ; reviewing i n s p e c t i o n and t e s t i n g documentation; r e s o l v i n g nonconformance i s s u e s ; c o n t r o i l i n g nonconforming, i t e m s ; and main ta in ing QA r eco rds . Responsible f o r execu t ion of t h i s QA Plan.

Pr0.iec-t Manager. C. Keith Ohler - Responsible f o r o v e r a l l . planning , eng inee r ing , and c o n s t r u c t i o n ; i n concurrence wi th t h e

P r o j e c t Sponsor and P r o j e c t Engineer main ta in ing bo th t e c h n i c a l and a d m i n i s t r a t i v e c o n t r o l of t h e p r o j e c t ; e s t a b l i s h i n g p r o j e c t o b j e c t i v e s ; approving p r o j e c t des igns ; p a r t i c i p a t i n g i n des ign reviews; e s t a b l i s h i n g and main ta in ing a p r o j e c t i n fo rma t ion , p lanning , and c o n t r o l system; c o o r d i n a t i n g a l l budget, f i n a n c e , c o s t s , s chedu les , and t e c h n i c a l r e p o r t i n g ; and deve lop ing /con t ro l l i ng Q u a l i t y Assurance Program.

Cons t ruc t ion M a n a s . . Robert TI. S t a n l e v - Responsible f o r 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 nonconformance, c o n t r o l of nonconforming i t e m s , and maintenance of QA r eco rds . Responsible f o r execu t ion of t h i s QA Plan.

Cons t ruc t ion Ins Dectoy. David C . Weimer - Responsible for c o n s t r u c t i o n i n s p e c t i o n , v e r i f i c a t i o n , and v a l i d a t i o n t o a sgure compliance wi th des ign documentation.

. . FIGURE 1 PRUJECT MATRIX CIRGANIZATIUN CHART

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PROJECT MANAGER -

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PLANT ENGR MANAGER 4

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1 --- t ENGR SERVICES a MANAGER

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PRUJ MANAGEMENT & PLANNING MANAGER .

L POWER SPECIALIST (PRUJ ENGR)

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NWQA PROGRAM MANAGER €23 NWQA SPECIALIST

FCT SI IPPnRT GRfll IPS

CONTRACT & PROCUREMENT SAFETY CIVIL SCHEDULING

MECHANICAL SITE PLANNING APCHITECTURAL CONSTRUCTION INSPECTION

.. . ..

&A Plan for 69 KV Substation Project - Page 5 Bes im/Bui ld Eng i n e e r i n p F i r m . - Responsible f o r des ign; t e s t i n g ; s p e c i f i c a t i o n s ; t r a i n i n g ; drawings; des ign reviews; equipment procurement; subcon t rac to r n e g o t i a t i o n s and c o n t r o l ; schedul ing; conformance t o s p e c i f i c a t i o n s and t e s t i n g ; conformance t o safety; development, implementation and c o n t r o l of EG&G Mound approved Q u a l i t y Assurance Program; c o n s t r u c t i o n ; and c o n s t r u c t i o n in spec t ion .

Des- Rev1 'ewers. Technical peer review of design.

W i l l i a m J. Lvons - Electrical .

e KaDka (or des ignee) - HVAC.

David Hei tz (or d es l anee ) * - F i r e A l a r m Systems.

Technical Consul tant . Bober t H. Brvan - Technical advisory r o l e f o r des ign , maintenance and t r a i n i n g requirements of t h e p r o j e c t .

&RC R epres ent ,qt 1 ve . Fredr i ck G. Krach - Representa t ive of Loss Prevent ion and Environmental Cont ro l (LPSrEC) wi th reviaw and adv i so ry r o l e .

DrawbP Cont ro l Super v i s o r . Arthur K e l l e r - Responsible f o r p o l i c y and, a d m i n i s t r a t i o n of drawing c o n t r o l .

t e r i a l Coordinator . DesignLBuild F i r m - Responsible f o r c o n t r o l of i t e m s i n t h e ' m a t e r i a l s t a g i n g area.

BA R e D r e s e n t a t i VF! . Trudv E. Pru& - Represen ta t ive of Nonweapon Q u a l i t y Assurance: Responsible f o r review of t h i s QA P lan and any i n t e r n a l Engineering a u d i t of t h i s p r o j e c t .

ce P r o m a n

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 descr ibed i n Mound Technica l Manual MD-10241, t i t l e d "5700.6B Q u a l i t y Plans f o r Engineer ing Department". (Refer t o Sec t ion 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 'AL 5700.6B, Revis 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 69 KV Subs ta t ion P r o j e c t d e s c r i b e s t h e specific implementation f o r t h i s p r o j e c t of t h e guidance i n Manual MD-10241.

This Q u a l i t y Assurance Plan is t h e minimum guidance document t o address a l l q u a l i t y elements as i d e n t i f i e d i n MD-10241. A separate Q u a l i t y Assurance P lan , as o u t l i n e d i n t h e Design - Criteria Document, w i l l be w r i t t e n by t h e Design/Build F i r m d e t a i l i n g specif ic q u a l i t y assurance requirements . The D/B p l a n w i l l be submi t ted f o r approval t o EG&G-Mound Personnel as a par t of t h e T i t l e I Design Package.

&A Plan f o r 69 KV S u b s t a t i o n P r o j e c t - Page 6

5 .3 . Des ign C o n t r o l

E x p l i c i t des ign c r i t e r i a w i l l be developed. Design in fo rma t ion 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 as communication t o o l s t o a s s u r e t h a t i t e m s c an 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 accord ing t o d e f i n i t e d e s i g n i n t e n t .

All electr ical d e s i g n c o n s i d e r a t i o n s f o r t h i s p r o j e c t w i l l be i n compliance w i t h t h e a p p r o p r i a t e DOE, Mound, ANSI/IEEE and NFPA s t a n d a r d s as d e f i n e d i n S e c t i o n 3..

A l . 1 s t r u c t u r a l d e s i g n c o n s i d e r a t i o n s w i l l be i n compliance wi th recognized eng inee r ing s t a n d a r d s .

e e r i n a F i r m .

The D/B Con t rac to r w i l l be r e s p o n s i b l e f o r des ign ing t h e p r o j e c t t o . e x p l i c i t cr i ter ia . Design in fo rma t ion , s p e c i f i c a t i o n s , drawings, and c a l c u l a t i o n s w i l l be p r e s e n t e d , reviewed, and v e r i f i e d f o r d e s i g n i n t e n t on a r e g u l a r _. basis.

All des ign in fo rma t ion , s p e c i f i c a t i o n s , drawings, and c a l c u l a t i o n s w i l l be f o r m a l l y reviewed wi th a p p r o p r i a t e EG&G Personnel d u r i n g s p e c i f i e d d e s i g n review meetings. The number . . and t iming of t h e reviews w i l l be c o n t r o l l e d and are a t t h e d i s c r e t i o n of t h e D/B F i r m . However, minimum fo rma l d e s i g n reviews w i l l be conducted p r i o r t o submission of T i t l e I and 11. The r e s u l t s of all reviews and c o r r e c t i v e a c t i o n w i l l be documented and maintained as permanent p r o j e c t r eco rds .

All i s s u e s of drawings w i l l be checked b y . d r a f t i n g f o r accu racy and proper format . I n accordance wi th S e c t i o n 1 8 O O j t i t l e d "

P r o j e c t Review" , of Manual 8 0 4 , d e s i g n in fo rma t ion , s p e c i f i c a t i o n s , drawings, and c a l c u l a t i o n s w i l l be . c i r c u l a t e d by t h e P r o j e c t Engineer f o r review and comment. Design documents w i l l he reviewed independent ly by a pee r Design Reviewer t o assure t h e t e c h n i c a l adequacy and s a f e t y of t h e des ign . Design documents w i l l be reviewed by t h e Sponsor t o confirm t h a t t h e d e s i g n c r i te r ia are s a t i s f i e d , and by t h e LF&EC Represen ta t ive t o a s s u r e t h e sa fe ty of t h e des ign . Reviews and comments des igna ted by t h e rev iewer as r e q u i r i n g response w i l l be documented by completed Engineer ing Review T r a n s m i t t a l Shee t s . The P r o j e c t Engineer is r e s p o n s i b l e for r e s o l v i n g any review comments.

Engineer ing f low diagrams and w i r i n g schemat ics 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 necessa ry , so 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 such changes w i l l t a k e " f i e l d " changes i n t o account . . 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 desc r ibed i n S e c t i o n 5 . 6 below.


P r i o r t o t r a n s f e r of t h e system t o Electrical Maintenance, a l i s t of t h e d e s i g n drawings and other .documentat ion w i l l be

' compiled. This l i s t w i l l show t h e l a t e s t i s s u e of each drawing.

ent Control,

Procurement documents w i l l be contro ' l led i n accordance wi th t h e Con t rac t ing and Procurement Systems Manual 701. Purchase r e q u i s i t i o n s f o r Procurement Level 1 i t e m s as s p e c i f i e d i n T i t l e I Design w i l l be contro. l led i n accordance wi th S e c t i o n 1 . 5 . 4 of Manual MD-10241. A l l Level 1 procurement i t e m s w i l l be i d e n t i f i e d and l i s t e d i n t h e Design/Build Q u a l i t y Assurance Plan.

. .

Procurement w i l l be executed by t h e Design/Build (D/B) F i r m wi th d e t a i l e d reviews by Mound personnel . A l l s p e c i f i c a t i o n s f o r equipment t o be purchased w i l l be reviewed f o r i n c l u s i o n of Mound and DOE requi rements , codes, and s t anda rds . S p e c i f i c a l l y , t h e P r o j e c t Engineer , and o t h e r s t h a t he s o d e s i g n a t e s , w i l l review t h e procurement documents f or' . ' inclusion of t h e requirements of The Mound Master S p e c i f i c a t i o n s , A N S I C57 ( t rans?ormers) , A N S I C 3 7 ( swi t chgea r ) , N F P A 70 (Nat iona l Electric Code), and o t h e r a p p l i c a b l e documents as s p e c i f i e d i n t h e Design Cr i te r ia and o r Sec t ion 3 of t h i s document.

In spec t ion of equipment before shipment w i l l be done by Mound and D/B personnel . A s a p p r o p r i a t e , t h e procurement documents w i l l i nc lude requirements f o r - r i g h t of access by Mound and D/B personnel t o vendor 's shop du r ing s e l e c t e d f a b r i c a t i o n , i n s p e c t i o n , and t e s t i n g stages.

'Procurement w i l l be complete upon s u b m i t t a l of s a t i s f a c t o r y f i n a l acceptance t e s t i n g and or performance d a t a as de f ined i n t h e procurement document, and f i n a l w r i t t e n approval by Mound and D/B personnel .

.Note: A l l s u b c o n t r a c t i n g procurement s h a l l m e e t t h e same requirements as s p e c i f i e d above.

5 . 5 . I n s t r u c t i ons , Procedures . and Draw-

All i n s t r u c t i o n s , procedures , . and drawings w i l l be prepared and maintained th rough c o n s t r u c t i o n by t h e Design/Build (D/B) f i r m .

Mound personnel w i l l review a l l i n s t r u c t i o n s , p rocedures , and drawings f o r compliance wi th requirements de f ined i n P l a n t Engineer ing Manual 808 "General Requirements f o r A-E Work" - t h e p r o j e c t Design Cr i te r ia , t h e P r o j e c t Management P lan , MLM-MU-69-0006, Drawing Cont ro l Procedures , SPA891214, and Mound MD-10286 " S a f e t y and Hygiene Manual. -

QA Plan for 63 KV Substation Project = Page 8

A l l i n s t r u c t i o n s , procedures , and drawings w i l l r e q u i r e s igned a p p r o v a l ' b y a p p r o p r i a t e Mound personnel p r i o r t o release and use.

F i n a l drawings w i t h a p p r o p r i a t e s igned approvals w i l l be r e q u i r e d f o r c o n s t r u c t i o n .

. " F i e l d " changes du r ing 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 wi th S e c t i o n 1500 , t i t 1 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", of t h e Mound P r o j e c t Management Manual 804.

A s a minimum, w r i t t e n i n s t r u c t i o n s and procedures w i l l be r e q u i r e d f o r t h e fo l lowing:

F9 KV Subs ta t ion . .- The i n s t r u c t i o n s / p r o c e d u r e s w i l l i n c l u d e a n overview of des ign i n t e n t , o p e r a t i o n of t h e sys tem, d e s c r i p t i o n of alarm systems, emergency procedures , a spare parts l i s t , drawing l i s t , requirements f o r i n s p e c t i o n o r t es t of replacement par ts , special personnel s a f e t y c o n s i d e r a t i o n s , p o t e n t i a l safety haza rds , and personnel t r a i n i n g requirements/qua, l i f icat ions as r e l a t e d t o 69 KV/12,470 V system maintenance.

5 . 6 . D o c u m t C o n t r o l

I n o r d e r t o a l low unambiguous i d e n t i f i c a t i o n , t h e d a t e of 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. Drawings w i l l be c a t a l o g e d , handled, 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 12 14 , t i t l e d "Drawing Cont ro l Procedures" .

Drawing issues w i l l be of two types , p r e l i m i n a r y and approved. P re l imina ry i s s u e s w i l l be . i nd ica t ed by 0 , 1, 2 , etc. and approved i s s u e s w i l l be i n d i c a t e d by A , Bj C , etc. P re l imina ry i s s u e s w i l l be c o n t r o l l e d by t h e Design/Build (D/B) f i r m and w i l l n o t r e q u i r e approvals o t h e r t h a n t h e i n i t i a l s of t h e a p p r o p r i a t e Mound personnel . P re l imina ry i s s u e s w i l l be prominent ly marked as such. Approval 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 o r i n i t i a l s of t h e Design Draftsman, Checker, P r o j e c t . E n g i n e e r , peer Design Reviewer, Sponsor, LP&EC R e p r e s e n t a t i v e , Fac i l i t i e s Design D r a f t i n g 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 locks . Approval of changes t o p rev ious ly approved drawings (ie. i s s u e B o r 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 o r i n i t i a l s of 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 blocks.

Changes i n t h e des ign documents w i l l be c o n t r o l l e d , documented, and inco rpora t ed a t t h e ear l ies t practical 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 tes t i s s u e of t h e document. The P r o j e c t Engineer w i l l i n i t i a t e any such changes. Drawings w i l l be changed i n accordance w i t h Manual 8 0 4 , S e c t i o n 1500.

.

QA Plan for 69 KV Substation Project - Page 9 d Se rv ices ..

P o t e n t i a l manufacturers f o r a l l electrical equipment i d e n t i f i e d as Level 1 items i n t h e Design/Build s u b p r o j e c t Q u a l i t y Assurance P lan w i l l be eva lua ted t o a s c e r t a i n t h e i r c a p a b i l i t y t o provide adequate q u a l i t y . This e v a l u a t i o n w i l l be based on u t i l i z i n g manufacturers wi th a proven performance r eco rd ; vendor s i t e v i s i t s and e v a l u a t i o n s ; and w r i t t e n f a b r i c a t i o n , i n s p e c t i o n , and t e s t documentation.

Wri t ten c e r t i f i c a t i o n s of methods, composition of materials, i n s p e c t i o n , or t e s t r e s u l t s f o r purchased material or s e r v i c e s i d e n t i f i e d and l i s t e d i n t h e Design/Build s u b p r o j e c t Q u a l i t y Assurance P lan as Level 1 i t e m s du r ing T i t l e I , w i l l be s u p p l i e d by t h e Design/Build (D/E) f i r m . Any such documents w i l l b e . reviewed for completeness and adequacy by a p p r o p r i a t e Mound personnel . All such documents w i l l be maintained as permanent p r o j e c t r eco rds .

Purchased i t e m s w i l l be i d e n t i f i e d by purchase 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 main ta in i n d i v i d u a l i d e n t i t y of i t e m s , manufacturer s e r i a l numbers o r unique i d e n t i f i c a t i o n markings w i l l be used t o c o n t r o l a l l Level 1 i t e m s r e q u i r i n g w r i t t e n c e r t i f i c a t i o n s .

Purchased items n o t r e q u i r i n g w r i t t e n c e r t i f i c a t i o n s w i l l be i d e n t i f i e d and c o n t r o l l e d by e s t a b l i s h e d , e n g i n e e r i n g practices.

The Design/Build F i r m w i l l be r e s p o n s i b l e t o main ta in and c o n t r o l a l l documentation and c e r t i f i c a t i o n s r e l a t i n g ' t o purchased i t e m s . The documentation w i l l be submi t ted i n an organized format t o Mound upon f i n a l acceptance of t h e p r o j e c t .

5 . 9 . Control of Processes

' Q u a l i f i e d e l e c t r i c i a n s wi th previous r e l a t e d exper ience must be used f o r a l l splices and t e rmina t ions on c a b l e s and equipment t h a t w i l l o p e r a t e a t o r above 1 2 , 4 7 0 VAC.

Wri t ten q u a l i f i c a t i o n s of key c o n t r a c t e l e c t r i c i a n s used f o r t h e splices and t e r m i n a t i o n s de f ined above w i l l be provided by t h e Design/Build (D/B) f i r m and maintained as par t of t h e permanent p r o j e c t r eco rds by Mound's P r o j e c t Manager.

Note: I t w i l l be t h e r e s p o n s i b i l i t y of t h e Design/Build FirG t o v e r i f y and document a l l q u a l i f i c a t i o n s of key subcon t rac t e l e c t r i c i a n s .

&A Plan for 69 KV Substation Projsot - Prig9 10

5.10. InsDect jon

I n o r d e r t o a s s u r e good workmanship and conformance t o t h e des ign 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 progress w i l l be r e g u l a r l y in spec ted by t h e Pro ' ject Engineer or by t h e P r o j e c t I n s p e c t o r r e s p o n s i b l e f o r c o n s t r u c t i o n . A d a i l y c o n s t r u c t i o n logbook w i l l be maintained as a d i a r y of 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 t h e . progress of i n s t a l l a t i o n , no te s on s p e c i a l i n s p e c t i o n s and tests, and documentation of concerns o r i t e m s t o be r e so lved .

A s a minimum.al1 splices and t e r m i n a t i o n s made on c a b l e and equipment t h a t w i l l o p e r a t e a t 12,470 VAC o r h i g h e r w i l l be in spec ted and t e s t e d by a p r o j e c t i n s p e c t o r t h a t meets the . w r i t t e n approval of t h e Mound P r o j e c t Engineer. C a r e f u l a t t e n t i o n w i l l be g iven t o t h e q u a l i t y of t h e spl ice and o r t e rmina t ion . The i n s p e c t o r w i l l v e r i f y t h a t t h e splice and t e r m i n a t i o n conforms t o t h e requirements f o r medium and h igh v o l t a g e i n s t a l l a t i o n s . Documentation of t h e i n s p e c t i o n and t e s t r e s u l t s w i l l be maintained as permanent p r o j e c t r e c o r d s . Departures from s p e c i f i e d requirements 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 5.15 of t h i s 'QA Plan.

Tests w i l l be performed on t h e 69 KV S u b s t a t i o n Systems i n o r d e r t o demonstrate s a t i s f a c t o r y performance f o r s e r v i c e . These tests w i l l i n c l u d e t h e fo l lowing:

Transformers: Before d e l i v e r y t o Mound t h e t r ans fo rmers s h a l l be t e s t e d t o ANSI C57 s t a n d a r d s . T e s t s s h a l l i n c l u d e r e s i s t a n c e of a l l windings a t a l l t ap p o s i t i o n s , no-load l o s s , t o t a l loss, impedence, exc iEing c u r r e n t , d i e l e c t r i c t e s t . o f windings, d i e l e c t r i c of l i q u i d , water c o n t e n t of l i q u i d , p r e s s u r e tes ts , r a t i o t e s t s , and leakage tests. After d e l i v e r y b u t b e f o r e e n e r g i z a t i o n , t h e r e s i s t a n c e t o ground s h a l l be t e s t e d us ing 1000 v o l t megger, d i e l e c t r i c tes ts s h a l l be made, and r e s i s t a n c e tests s h a l l be made of a l l windings a t a l l t a p p o s i t o n s .

Switchgear: 1 5 K V r a t ed : T e s t s s h a l l be made i n compliance w i t h ANSI C37 s t a n d a r d s . Tests s h a l l i n c l u d e r e s i s t a n c e of a l l connec t ions , o p e r a t i o n a l t es t of a l l mechanical parts i n c l u d i n g s p r i n g s , h i p o t t e s t of a l l i n t e r c o n n e c t i n g cab le s .

Cables: 15KV: Con t inu i ty tes ts , h i p o t tests t o ground as per Mound cr i ter ia , phasing t e s t t o conform t o Mound phase r o t a t i o n s t a n d a r d s h a l l be performed.

Cables: 480V: Con t inu i ty t e s t s , megger tests t o ground w i t h 1 0 0 0 v o l t tes ter , phase r o t a t i o n t e s t t o ensu re proper ope ra t ion 'o f r o t a t i o n equipment s h a l l be performed.


A l l t e s t r e s u l t s s h a l l be documented and submi t ted t o t h e Mound P r o j e c t Engineer f o r approval p r i o r t o ene rg iz ing any equipment.

All tests s h a l l be performed by q u a l i f i e d workmen t h a t meet t h e w r i t t e n approval of t h e Mound P r o j e c t Engineer. The Design/Build F i r m ( i n s t a l l a t i o n a c t i v i t i e s ) s h a l l submit i n w r i t i n g , t h e q u a l i f i c a t i o n s of a l l personnel t h a t w i l l perform t h e tes ts .

Tes t ing of l i v e c i r c u i t s s h a l l comply wi th t h e p rov i s ions of 29 CFR 1910.300 through 29 CFR 1910.399, t i t l e d "Electrical Rela ted Work P r a c t i c e s " . The r e g u l a t i o n t o check t e s t equipment be fo re and a f te r t e s t i n g of l i v e c i r c u i t s s h a l l be fol lowed e x p l i c i t l y .

The r e s u l t s of t h e s e tests w i l l be documented. Such documentation w i l l i nc lude 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 items 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 ) performing t h e t e s t , r e f e r e n c e t o t h e acceptance c r i t e r i a , a s t a t emen t of acceptance o r r e j e c t i o n , and t h e s i g n a t u r e of t h e person 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 . ..

A d e t a i l e d t e s t p l a n w i l l be developed by t h e Design/Build F i r m du r ing T i t l e I.

The c e r t i f i c a t i o n c o n t r o l , and u t i l i z a t i o n of measuring and t es t equipment w i l l be t h e r e s p o n s i b i l i t y of t h e Design/Build (D/B) f i rm.

Mound's P r o j e c t Engineer and P r o j e c t In spec to r w i l l v e r i f y t h a t .measuring and t e s t equipment is p rope r ly u t i l i z e d and is adequate t o m e e t a l l t e s t i n g requirements .

Mound's Standards group w i l l act 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 , o r u t i l i z a t i o n of measuring and t e s t equipment is i n ques t ion .

. . a . S to rage . and Shim-

Receiving and d e l i v e r y of incoming materials w i l l be t h e r e s p o n s i b i l i t y of t h e Design/Build (D/B) f i r m . Del ivery of equipment and material w i l l be made t o t h e l o c a t i o n des igna ted on t h e c o n t r a c t drawings.

The D/B Cons t ruc t ion Manager o r a des igna ted r e p r e s e n t a t i v e w i l l perform r e c e i v i n g and i n s p e c t i o n t o confirm t h e i d e n t i f i c a t i o n of m a t e r i a l , t h e presence of material c e r t i f i c a t i o n s , s t o r e material, and c o n t r o l material.


5. 14. InsDect ion. T e s t . and O w r a t i n g S t a t u i

A l l items and equipment w i l l be v i s u a l l y i n s p e c t e d by t h e Design/Build Cons t ruc t ion Manager p r i o r t o i n s t a l l a t i o n . Any damage observed w i l l be tagged i n a v i s i b l e l o c a t i o n w i t h a n a p p r o p r i a t e l a b e l ( i . e . "DAMAGED MATERIAL DO NOT USE"). Any damage observed w i l l be recorded 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 assessment of t h e damage by t h e manufacturer o r o t h e r q u a l i f i e d pe r sonne l can be made. Wri t ten documentation of t h i s assessment w i l l be maintained by t h e P r o j e c t Engineer. No t a g w i l l be removed wi thout fo l lowing t h e procedures as o u t l i n e d i n S e c t i o n 5 .15 of t h i s manual.

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 :€or Level 1 i t e m s 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 In spec to r p r i o r t o i n s . t a l l a t i o n .

5 .15 . Cont ro l of Nmc- ..

I n accordance 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 of i t e m s o r 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 requirements ( i . e . equipment, drawings o r s p e c i f i c a t i o n s ) w i l l be des igna ted by t h e P r o j e c t . .

- Engineer as " d e v i a t i o n s " . The nonconforming i t e m s or a c t i v i t i e s I

w i l i be . immedia te ly marked o r p h y s i c a l l y s s g r e g a t e d t o p reven t i n a d v e r t e n t use p r i o r t o d i s p o s i t i o n . Using an Engineer 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 lass i fy such 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 de f ined 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 unsafe c o n d i t i o n or preven t in tended use or r e s u l t . A minor d e v i a t i o n w i l l be de f ined 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 unsafe c o n d i t i o n or t o p reven t in tended use or r e s u l t . On t h e Report 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 appa ren t cause , and s ta te 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 m a y i n c l u d e "scrap", "repair" or "rework", o r "use as is".

The. P r o j e c t Engineer w i l l then .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 involved , t h e n t h e Review Committee w i l l c o n s i s t of a t least t h e Sponsor, t h e P r o j e c t Engineer , 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 Eng inee r ) , t h e P r o j e c t Manager, t h e LP&EC R e p r e s e n t a t i v e , and t h e &A Represen ta t ive . If a minor d e v i a t i o n is invo lved , t h e n t h e Review Committee w i l l c o n s i s t of a t l eas t t h e P r o j e c t Engineer and t h e QA Representa t ive . I n e i t h e r case, o t h e r specialists 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 w i l l be t h e 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 and d i s p o s i t i o n recommended by t h e P r o j e c t Engineer, making any agreed 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 determine and s t a t e on t h e Report form t h e r o o t cause and any c o r r e c t i v e a c t i o n t o be taken. ' Fo r minor d e v i a t i o n s , s t a t emen 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 ach a consensus, and each member w i l l s i g n t h e Report 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 Report form, and c e r t i f y on t h e Report form t h a t t h e a c t i o n w a s taken. The &A Representa t ive w i l l t h e n review t h e Report 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 ou t " t h e dev ia t ion . A s a minimum, copies of t h e Report 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 , t o t h e QA Representa t ive and t o t h e a p p r o p r i a t e Design/Build Representa t ive . w i l l be s o r e so lved 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 .

A l l d e v i a t i o n s

5 . 16. Corrective Act ion

The P r o j e c t Engineer w i l l monitor t h e p r o j e c t f o r cond i t ions adverse t o q u a l i t y . This w i l l be done by n o t i n g d i scuss ions a t p r o j e c t meetings, p e r i o d i c review of t h e p r o j e c t logbook, and review of Nonconformance Reports. If adverse 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 . The P r o j e c t Engineer w i l l f o l low through t o ' v e r i f y t h a t t h e a c t i o n is e f f e c t i v e , and document any such a c t i o n s and t h e r e s u l t s by use of t h e Engineering Department Nonconformance Report form and t h e procedure desc r ibed 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 least t h e Sponsor, t h e P r o j e c t Engineer , t h e Design Engineer ( i f d i f f e r e n t t han t h e P r o j e c t E n g i n e e r ) , t h e P r o j e c t Manager, t h e LP&EC Represen ta t ive , and t h e QA Representa t ive . Other special is ts may be added t o t h i s Committee as r equ i r ed .

P r o j e c t records w i l l be maintained du r ing t h e p r o j e c t execut ion. After d r a f t i n g o r e d i t i n g work is completed, des ign 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 Cont ro l i n accordance wi th SPA-8912 14 , t i t l e d "Drawing Cont ro l Procedures" . These procedures inc lude s t o r a g e of microf i lm copies of a l l i s s u e s of drawings. A drawing l i s t showing la tes t 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 completion of t h e p r o j e c t . The fo l lowing l i s t shows o t h e r p r o j e c t r eco rds whi'ch w i l l be t r a n s f e r r e d t o t h e Engineer 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 completion of t h e p r o j e c t .

-I_


I. P r o j e c t management in fo rma t ion

a. AES, s t a t emen t of scope of p r o j e c t , AES Cost E s t i m a t e

b. MSRs. c. Work package informat ion inc lud ing scope of package,

special i n s t r u c t i o n s , and material l i s t . A s s t a t e d above, drawings w i l l be s toked separately i n Drawing Cont ro l .

r e v i s i o n s .

Plan. Audit r e p o r t i f p r o j e c t aud i t ed .

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

d. P r o j e c t schedule , i n c l u d i n g ta rge t schedule and

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

f . Monthly progress r e p o r t s and o t h e r major r e p o r t s . g. Meeting minutes , impor tan t correspondence and t e l e c o n

h. P r o j e c t c l o s i n g informat ion , i nc lud ing c o s t summary,

i. Any Engineer ing B u l l e t i n s or r eco rds of Conf igura t ion

no te 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 review, e tc .

Board a c t i o n s .

iI. Des ian information.

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 Shee ts . 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 .

IiI. Procurement record.- P

a. Any suppl . ie r e v a l u a t i o n r e p o r t s . b. Purchase Orders , 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 o r

impor tan t correspondence, and any b id e v a l u a t i o n r e p o r t s .

Control .

t e s t r e p o r t s .

VI.

a. P r o j e c t logbook. b. In spec t ion r e p o r t s , equipment c e r t i f i c a t i o n s , t e s t

r e s u l t s , and c a l i b r a t i o n r eco rds . c. Any nonconformance r e p o r t s .

5 . 18. Au&i&-

This p r o j e c t is s u b j e c t t o independent a u d i t a t . a n y t i m e by ' the . S e c t i o n QA Represen ta t ive . The purpose of such a u d i t would be


t o determine the degree of compliance wi th t h e p rov i s ions of t h i s QA P lan and t h e adequacy of documentation of q u a l i t y assurance 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 har'dware 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 rgan iza t ion .

I n 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 wi th Manual MD-10181, t i t l e d "Mound Q u a l i t y Audit Program". The procedures r e q u i r e d by t h i s Manual i nc lude a u d i t r e p o r t s t o r e spons ib l e management and p r o v i s i o n f o r any necessary follow-up a c t i o n . The purpose of such a u d i t would be t o determine both t h e degree of compliance wi th t h i s QA P lan , and t h e adequacy and e f f e c t i v e n e s s of t h e QA P lan i t s e l f .

A l l s o f tware used i n t h i s p r o j e c t w i l l be proven, commercially a v a i l a b l e packages. Therefore , so f tware q u a l i t y assurance w i l l no t be r e q u i r e d f o r t h i s p ro j ec t .

When p o s s i b l e , a l l des ign c a l c u l a t i o n s de r ived by a so f tware package w i l l be reviewed and v e r i f i e d .

.

.

X X 1 X

X X X X X

-

X

X X X X X

X

X X X X X.

X

X X X X X

-

X

X X X X X

X X X X

X X X X X

-

X X

X X X X X

-

K

X K ' K X X

-

X

X X X X X

X

x . X X X

X X X X

/

-. .

PROJECT QUALITY ASSURANCE REVIEW

TITLE: S i t e Electrical Replacements & Subs ta t ions

nn * ' LOCATION: p,q?ypd

C C SPONSOR: A . Saul 87 0 &&& . . William E. Huf fman HPNO.: 4001

LOJECT DESCRIPTlON/SCOPE:

lESCRIPTION/SCOPE:

This p r o j e c t c o n s i s t s of two (2) p a r t s ( suhpro jec t s ) ' t ha t w i l l b e designed t o r e p l a c e . key, electrical systems a t Mound t o ensure continuous, r e l i a b l e power

. t o Droduction f a c i l i t i e s . P a r t A, S i t e Electrical Replacements: . c o n s i s t of t h e .. replacement six (6) ' embrgency generators ; 35% of the primary d i s t r i b u t i o n cab le ; seven (7) PCB subs ta t ions and one (I) space. t ransformer; and t h e i n s t a l l a t i o n of two (2) t i e c i r c u i t breakers . P a r t B: and cons t ruc t ion of. a new s u b s t a t i o n (69kV) and t h e ,feeders (two,2).

,

' provides for. t h e des ign , procurement

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

'ASK RISK REVIEW, MAJOR CONCERNS, ti JUSTIFICATION FOR LEVEL ASSIGNMENT:

This p ro jec t i s considered t o be normal cons t ruc t ion and thGs no t s u b j e c t t o s p e c i a l concerns. have t o have p a r t i c u l a r care w i t h t h e removal of PCB conta in ing equipment. l e v e l of e x p e r t i s e ( c e r t i f i e d ) requi red t o accomplish t h i s i s n o t p a r t i c u l a r l y d i f f i c u l t t o ob ta in and most major electrical i n s t a l l a t i o n ope ra t ions can accomplish t h i s a c t i v i t y . a QA review and poss ib l e p l an generat ion w i l l occur. . A l s o , should t h e work e f f o r t on t h e emergency genera tors r e q u i r e a c t i v i t y involv ing the e x i s t i n g underground tanks , QA w i l l be invo lved .a t t h a t t i m e .

However, , there are seven s u b s t a t i o n s t o be rep laced t h a t w i l l The

Should a p a r t i c u l a r l y d i f f i c u l t removal be encountered,

Emergency power c a p a b i l i t y t o c r i t i ca l f a c i l i t i e s w i l l be maintained.

ZITHER CONSIDERATIONWSPECIAL PLANS:

Action Descr ip t ion Memorandum are on f i l e f o r Part A: 11/22/88. le t ter 2/22/90 - Willard Taylor t o W i l l i a m E. Huffman.

2/17/&8 and Part B:, Environmental Review of DP&L Feeders n o t -required:- referenceDP&L

I ANTICIPATED QA PROGRAM REQUIREMENT I

Level 2 ]I ML-8440 (1 1-89)

.- . - . - -. .

APPROVALS DATES

Rev. t o QA Review February 26, 1990

PROJECT QUALITY ASSURANCE REVIEW

TITLE: SITE ELECTRICAL REPLACEMENTS AND SUBSTATION I LOCATION: M d

SPONSOR: . . A -/ST f PHGh) E. cw%Y 870 I

ENGINEER: C. Keith Ohler HPNO.: 4337 QA MEETING DATE: ~d~~ 18 1 990

PROJECT DESCRIPTIONISCOPE: .

ANTICIPATED QA PROGRAM REQUIREMENT

Level 2

4 DESCRIPTIONISCOPF:

The S i t e Electrical Replacements and Subs ta t ion p r o j e c t c o n s i s t s of two (2) subpro jec t s designed t o r e p l a c e key electrical power d i s t r i b u t i o n systems a t Mound. Part A, S i t e Electrical Replacements: c o n s i s t of t h e replacement of s ix (6) emergency gene ra to r s ; 35% of t h e primary d i s t r i b u t i o n cab le ; seven (7) PCB s u b s t a t i o n s and one (1) s p a r e t ransformer; and t h e i n s t a l l a t i o n of two (2) t i e c i r c u i t breakers. P a r t B: provides f o r t h e des ign , procurement, and c o n s t r u c t i o n of a new 69 Ki lovo l t s u b s t a t i o n and two (2) new primary f eede r s .

CASK RISK RFVIFW. MAJOR CONCFRNS. & JUSTIFICATION FOR LFVFl ASSIGNMFNT:

T h i s p r o j e c t i s considered o v e r a l l t o . b e Q u a l i t y Level 1. The assessment is based on t h e r i s k of i n j u r y , l o s s of l i f e , and l o s s of equipment g r e a t e r than $500,000 t h a t may ensue i f proper t e rmina t ion techniques and t e s t i n g procedures are n o t followed f o r t h e h igh v o l t a g e i n s t a l l a t i o n . The problems i n t h i s area would no t occur u n t i l a f t e r t h e system i s energized. formers con ta in ing PCB's. i n t h e removal, t r a n s p o r t a t i o n , and d i s p o s a l of t h e t ransformers .

Also, an environmental r i s k exists by t h e removal o'f t r ans - Appropriate EPA r e g u l a t i o n s must' be followed

Action Descr ipt ion Memorandums are on f i l e f o r P a r t A: P a r t k: 11/22/88. Environmental R e v i e w of DP&L Feeders are no t required: Huffman.

2/17/88 and

r e f e r e n c e DP&L letter 2/22/90 - Willard Taylor t o W i l l i a m E.

I Level3 Cl 1 ML-8440