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/ .t< . , ATTACHMENT 2 _ 1 ' ILLINOIS POWER COMPANY QAI - 710.09 l ,. -QUALITY ASSURANCE INSTRUCTIONS Revision 3 (. TITLE: OVERINSPECTION EVALUATION PROGRAM Scope of Revision: Revision 3: lbjor Rewrite - Rewritten because the sample results, (accept / reject criteria) are evaluated in accordance with the new 95-5 and 95-15 limits depicted in attach- ments QAI 710.09F05 and QAI 710.09F06. QAI 710.09A01 superceded by 710.09F05 and 710.09F06. QAI 710.09F02 and 710.09F03 deleted. QAI 710.09F04 revised - removed switching requirements. QAI 710.09F05, 710.09F06 added. ' = ) i ' , nk = " F . i .. . ' ~, .. ,7 - , .. ' | ' ... E h .; .. a a . \ ''. ; g i * . . T .:; . 1 . ' . 1.| | .|. '~ s , , , , - .- . 4 - - .' . e, . - * w ., . ; . . .. . ( SIGNATURES ' Rev. 3 Rev. 4 Rev. 5 Prepared by: /[gM _ , supervisor of Welding, .ND6 Lu and Testing ' s Supervisor of Quality g j Engineering. /.)ff5__ 3 f 8407310324 840618 PDR ADOCK 05000461 g PDR L Manager - QA Approval: Approval Date: ' _ N100-183 (8/83)

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    .t< . , ATTACHMENT 2_ 1'

    ILLINOIS POWER COMPANY QAI - 710.09 l,.-QUALITY ASSURANCE INSTRUCTIONS Revision 3

    (.TITLE: OVERINSPECTION EVALUATION PROGRAM

    Scope of Revision:

    Revision 3: lbjor Rewrite - Rewritten because the sample results,(accept / reject criteria) are evaluated in accordancewith the new 95-5 and 95-15 limits depicted in attach-ments QAI 710.09F05 and QAI 710.09F06.

    QAI 710.09A01 superceded by 710.09F05 and 710.09F06.QAI 710.09F02 and 710.09F03 deleted.QAI 710.09F04 revised - removed switching requirements.QAI 710.09F05, 710.09F06 added.' =

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    SIGNATURES '

    Rev. 3 Rev. 4 Rev. 5Prepared by: /[gM _,supervisor of Welding, .ND6 Luand Testing ' sSupervisor of Quality g jEngineering. /.)ff5__ 3

    f

    8407310324 840618PDR ADOCK 05000461g PDR

    LManager - QA Approval:

    Approval Date: '

    _

    N100-183 (8/83)

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    '

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    *ILLINOIS POWER COMPANY QAI- 710.09

    g QUALITY ASSURANCE INSTRUCTION Revision 3

    1.0 PURPOSE / SCOPE

    1.1 Purpose

    This instruction establishes the methods used to evaluatethe results of the Illinois Pouer (IP) Company Overin-spection Program.

    1.2 Scope

    This instruction applies to all installed safety related,augmented Class D, fire protection, and scismic HVAC sys-tems, items, or components.

    2.0 DISCUSSION / DEFINITIONS

    2.1 Discussion

    2.1.1 The overinspection (OI) results will provide the data forthe evaluation of hardware acceptability and the BalduinAssociates (BA) quality decision process. The results of( these evaluations may also be used to reduce or modifychecklist attributes, as appropriate. Attributes may bereinstated based on input from the Corrective ActionProgram or as requested by the IP Manager of QualityAssurance.

    2.1.2 All nonconformances detected during the OI process shallbe documented on a Nonconformance Report (NCR) in accor-dance with Reference 6.1.

    2.1.3 Reports will be prepared and distributed to the followingpersonnel:

    .

    IP Vice President

    " IP Manager of Quality Assurance

    IP Director of Quality Systems and Audits

    IP Director of Quality Engineering and Verification* IP Director, Design Engineering

    IP Central Records File

    N100-184 (12-79)- Page 1 of 5 |

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    ''ILLINOIS POWER COMPANY QAI- 710.-09

    '

    QUALITY ASSURANCE INSTRUCTION Revision 3

    BA Manager - Quality & Technical Services

    2.2 Definitions

    None

    3.0 RESPONSIBILITIES

    3.1 The Supervisor-Uelding, NDE and Testing is responsible forthe implementation of the Overinspection Programs and forissuance of report (s) in accordance with para. 4.3.

    3.2 The OI QA Analyst is responsible for:

    a) Collecting and foruarding Evaluation Analysis Data tothe Programs and Procedures Group for computer input.

    b) Coordinating and preparing reports.3.3 The Supervisor-Quality Systems is responsible for:

    ( a) Computer support of the Overinspection Program includingsinput of overinspection data and providing computerprint-outs to the IPOI QA Analyst on request.

    b) A root cause investigation being performed when anadverse trend is identified by the Corrective ActionProgran per reference 6.3. *

    3.4 The Discipline Overinspection Supervisor (DOIS) is responsi-ble for reviewing all overinspection reports and completedchecklists for accuracy prior to data input.

    4.0 INSTRUCTIONS

    4.1 Data Input

    4.1.1 On completian of each OI Report, the information containedon the 01 Report and checklist (s) as applicable is pre-pared by the QA Analyst and entered into the computer byQuality Systems.

    4.1.2 Upon completion of data entry for all 01 reports of a lot,a computer printout will be issued to IPOI which will be

    N100-184 (12-79). page 9 of s

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    '' ILLINOIS POWER COMPANY QAI- 710. 09

    QUALITY ASSURANCE INSTRUCTION Revision 3-

    used to develop a report documenting the results ofoverinspection activities.

    4.2 Evaluation

    The assembled data shall be reviewed by the QA Analyst asfollows:

    4.2.1 One hundred percent Inspection - Determine the totalnumber of critical and non-critical attributes inspected,calculate the percent accepted, and provide other inforna-tion required per paragraph 4.3.3. No fu.ther evaluationis required, except comments or conclusions asappropriate.

    4.2.2 Sample Inspection - In addition to the above, aconfidence statement shall be included in accordance withpara. 4.3.4.

    4.3 Renorts

    4.3.1 A prelinincry report for each lot shc11 be dr.veloped andissued uhen the lot has been overinspected completed butcontains NCRs. If none are written, proceed to para.4.3.2.

    4.3.2 A final report for each lot overinspected shall bedeveloped and issued when all NCRs' pcrtaining to the lothave been dispositioned and/or the lot does not containNCRs.

    4.3.3 The report (s) shall identify the following:Master Lot Number

    Discipline (mechanical, electrical, HVAC, etc.)

    Humber of critical and non-critical attributes inspected* Dunber of critical and non-critical attributes acceptedCalculated percent for accepted critical and non-critical attributes

    N100-184 (12-79). page 5 of 5.

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    ILLINOIS POWER COMPANY 'QAI- 710.09''

    {' QUALITY ASSURANCE INSTRUCTION Revision 3

    * Comparison of calculated percents against 95% (critical)and 85% (non-critical) guidelines

    Conclusions and/or recommendations as appropriate

    4.3.4 If sampling has been utilized, the report shall includeconfirmation of 95% confidence having been reached that 5%or less of the critical and 15% or less of the non-critical attributes in the uninspected portion are unsat-isfactory. This is accomplished by comparison of thetotal attributes inspected and the total unsatisfactoryattributes found against the 95-5 and 95-15 limits depict-ed in Appendices 7.2 and 7.3. If these limits are notexceeded, the lot is accepted. If these limits areexceeded, proceed to paragraph 4.3.5.

    4.3.5 If campling has been utilized but does not meet acceptancecriteria, the Supervisor-Uelding, NDE and Testing shallreturn the subject lot to BA for reverification anddevelopment of a corrective action plan.

    (s 4.4 Reduction of Checklist Attributes

    4.4.1 The 01 Checklist may be revised based upon evaluation of-the overall results. Specific inspection attributes maybe deleted provided the following criteria are met:

    * The specific attribute has been' inspected in at leastten consecutive overinspection lots

    AUD

    * Found acceptable in a ninimum of 300 consecutive in-spections

    AMD

    Found acceptable in four different areas or buildings4.4.2 Provided the criteria for reduction of attributes spec-

    ified in 4.4.1 has been satisfied, the justification forreduction shall be documented on Appendix 7.1 and submit-ted to the Manager-IPQA for approval.

    N100-184 (12-79) Page 4 of 5

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    '' ILLINOIS POWER COMPANY QAI- 710c09 |

    /' QUALITY ASSURANCE INSTRUCTION Revision 3(

    4.4.3-

    Upon approval by the Manager-IPQA, a revision to thechecklist shall be initiated in accordance with Reference6.2 to delete the attribute. Until the revised checklistis issued, the attribute (s) will not be overinspected.The ti/A column for the attribute (s) shall be checked andthe approved termination form request number shall beentered in the objective evidence block.

    5.0 RECORDS

    5.1 Records as defined in Reference 6.5 shall be processed inaccordance with Reference 6.4.

    5.1.1 Overinspection documents are designated Record Type4126.6-L.

    6.0 REFERENCES

    6.1 QAI-710.06, OVERINSPECTION IIONC0!!FORMAIICE INSTRUCTIONS

    e 6.2 QAP-105.01, PREPARATION, REVIEW, APPROVAL, LEVISION, AND( CAI!CELLATI0li 0F QUALITY ASSURANCE PROCEDURES / INSTRUCTIONS6.3 QAP-116.06, QUALITY ASSURA11CE COI!PUTERIZED TREND PROGRAll

    6.4 QA'P-117.01, RECORDS CONTROL

    6.5 QAl-710.02, DOCUI!EI1TATION IDENTIFICATI0!1, ISSUING ANDTRACKIl1G

    7.G APPENDICES /DOCUllEIITS

    7.1 QAI-710.09F04 OVERINSPECTION PROGRAll NOTIFICATIOi; 0F TER-111 NATION OF CllECKLIST ATTRIBUTES

    7.2 QAI-710.09F05, 95-5 Criterion

    7.3 QAI-710.09F06, 95-15 Criterion

    N100-184 (12-79) page s of 5

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

    -g.

    CVERIIISPECTION PROGRAlf QM- H 0. 06'~ NOTIFICATIGN OF TERIIII4ATICN OF Revision 1

    CHECKLIST ATTRIBUTES,

    'Date1

    _

    L Termination of Checklist Attribute (s)

    Date.--

    Request y_ _ , _

    Termination of Attribute (s) as identified herein is"requested.

    Discipline__,,,, _ _ , . . . _

    IP 01 Checklist QAI-710. __ RevChecklist Titic

    -_

    -

    Attribute,,,,________, _ _,,,

    Chechlist attribute nutber(s) to be deleted

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

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

    Justification

    The above attribute (s) hae/hcve been overinspected

    sequentially in the follouing ten lots _ ,,,---- ... -- .. . . . --_ -

    in areas ,,___ _ _ _,_ __ ,,

    '

    a total of times uith no rej ections.

    1

    Initiated by. . 'I7Ql AMlyat Date'

    ~~'"~~~~--~~~0 ~ ~ ~

    Reviewed by Date___,.,,,,Supervisor-Welding !!DE & Testing

    Approval_ _ __ _Datellanager-LPQA

    N100-185 (12-79) Page o f_.

    - --

    -- --

    . _ _ . . ___ __

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    QAI- 710.09F05#

    95 - 5 CRITERIA Rev3.sion 0

    Date

    N.

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    . QAI- 710.09F06'

    95 - 15 CRITERIARevision 0

    Date

    .

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