qam-3

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QAM-3

Quality Assurance Manual

FOR

FIELD REPAIR OF ASME AND NATIONAL BOARDSTAMPED PRESSURE RELIEF VALVES MANUFACTURED IN COMPLIANCE WITH

SECTION I, SECTION III AND/OR SECTION VIII OF THE ASME CODE

AND REPAIRED IN ACCORDANCE WITH NATIONAL BOARD INSPECTION CODE RA-2200

Revision 5

June 23, 2005

Location: CRANE NUCLEAR, Inc.2825 Cobb International Boulevard

Kennesaw, GA 30152

Approval: Steve FowlerQuality Assurance

Assigned to:

Controlled for revisions: Yes No

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TABLE OF CONTENTSSection Description Pg.

Manual Control 3Statement of Authority and Responsibility 5Control Sheet for Changes 6

Organizational Chart 71 Scope of Work 82 Drawings and Specification Control 93 Materials and Parts Control 104 Repair and Inspection Program 155 Special Processes (Excluded) 246 Calibration of Measurement & Test Equipment 257 Field Service Repairs 298 Records Retention 319 Procedures to Extend the "VR" Certificate of Authorization and

Stamp to ASME "NV" Stamped Pressure Relief Devices32

10 Nonconformities 33

Appx. A CRANE NUCLEAR, INC. QA Documents 34

3 Receipt Acknowledgement Letter 43 Purchase Requisition Form 123 Purchase Order Form 134 Material Requisition 144 Certificate of Qualification 204 Work Order Cover Sheet 214 Safety-Relief Valve Report Form 224 Safety-Relief Valve Report Form Continuation 23

4 Permanent Training Record 246 Surveillance Inspection Report 276 Receipt Inspection Report 286 Out of Tolerance Report 29

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Page 3 of 35MANUAL CONTROL

1.0 MANUAL REVISION CONTROL

1.1 Revisions to this manual are accomplished by revising and issuing the entire manual.Revisions to this manual are identified by revision/change bars in the left margin at eachsection that is revised, on each page. Revisions are prepared and approved by theQuality Assurance Manager. Revisions are prepared and approved by the National Board foracceptance prior to implementation.

1.2 Each revision is accompanied by an updated "Control Sheet for Changes" on Page 6 that itemizeseach new revised section as well as all prior revisions. A brief description of the subject of thechange is included with acceptance signoff blocks by CRANE NUCLEAR, INC. and the NationalBoard.

1.3 The title page is reissued each time the manual is revised and will specify Revision Date.

1.4 In summary, for each revision all changed sections, the affected "Control Sheet for Changes"page(s) and the title page are issued to holders of "Controlled for Revision" copies of this manualincluding the National Board. Manual holders should insert the revision sections and destroy thereplaced sections.

1.5 The Quality Assurance Manager is responsible for reviewing client contracts to assure that this"VR" Manual and referenced procedures meets the Code edition addenda specified.

1.6 After Code and NBIC revisions are approved, they shall be reviewed and the applicable changesincorporated into the "VR" Manual and referenced procedures within 6 months of the issuancedate shown on the addenda, except when Code work is contracted to CRANE NUCLEAR, INC.prior to the end of the six-month period, the addenda shall be reviewed and incorporated prior tothe start of any work.

2.0 DISTRIBUTION CONTROL

2.1 Any reproductions of this document shall be for "information only" and indicated as such bystamping the document "UNCONTROLLED". Otherwise, controlled copies are distributed toauthorized recipients who are charged with the responsibility of safeguarding it at all times.Recipients of "controlled for revision" copies of this document are to acknowledge receipt of thedocument and any subsequent changes by signing and returning a copy of the ReceiptAcknowledgement Letter (Manual Control Section, Page 4) to the Document Control Assistant.(see sample). If acknowledgement is not received within 15 days from the transmittal date, theDocument Control Assistant is responsible for follow-up on receipt of manuals and revisions andshall take all necessary action to resolve the status. Documents issued to potential clients willrevert to "Uncontrolled for Revisions" status if resolution is not obtained within sixty (60) days fromthe transmittal date.

2.2 The Document Control Assistant shall maintain a current listing of all Controlled manuals forissuing revisions and/or recall of these documents as applicable. A current copy of the QualityAssurance Manual shall be sent to the National Board.

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Page 4 of 35Receipt Acknowledgement Letter

DATE

CLIENTADDRESS

Dear :

As per your request, enclosed please find a controlled copy of .Please sign and return this letter within 15 days of receipt in order to certify control of your document(s).

Failure to acknowledge receipt of this document(s) or its revisions shall result in your copy of this document(s)being classified as "UNCONTROLLED". I hope you will find all in order.

Please call me if you have any questions.

Sincerely,

Document Control Assistant

Enclosurebcc: GRG

GGG

Signature Date

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Page 5 of 35POLICY STATEMENT - AUTHORITY AND RESPONSIBILITY

All ASME Code Stamped Section I "V", Section VIII, Division 1 "UV" and Section III "NV" valves thathave been capacity certified by the National Board, repaired by CRANE NUCLEAR, INC. Fieldservices that receive the VR Stamp will have been disassembled, inspected, and repaired asnecessary, such that the valves' condition and performance are equivalent to the standards for newvalves. All repairs to ASME Code Section III, "NV" stamped pressure relief devices will be performed inaccordance with the requirements of this "VR" Manual. In addition, the controls of the "NR" Manual,QAM-2, must be adhered to in order to apply both the "NR" and "VR" stamps to the CRANENUCLEAR, INC. nameplate. All repairs shall meet the National Board Inspection Code, and the

jurisdiction as applicable.

It is the responsibility of the Quality Control Representative to ensure that all activities anddocumentation of both "NR" and "VR" requirements as specified are satisfied. The requirementsspecified in this CRANE NUCLEAR, INC. Quality Assurance Manual for ASME stamped PressureRelief Valves will be followed. If there is a disagreement in the implementation of this manual, thematter is to be referred to me for resolution. Responsibilities defined in the Manual shall stay with theindividual assigned, but the function may be delegated.

Any employee who is concerned that requirements are not being met or that a significant defect ornonconformance exists, and does not receive a satisfactory response from their supervisor or chain ofmanagement when reporting it, can bring their concern to the attention of the Quality AssuranceManager without fear of repercussion. When major problems or differences of opinion on qualitycannot be resolved within the line organizations, they shall be brought to my attention for finalresolution.

The Quality Assurance Manager has the responsibility and authority to carry out the requirementsspecified in this manual, through the Quality Control Representative. This manual is a part of theCRANE NUCLEAR, INC. Quality Assurance System.

Revisions are prepared and approved by the Quality Assurance Manager. All revisions will be sent tothe National Board for acceptance prior to implementation.

Kirk Kelhofer DatePresident

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Page 6 of 35CONTROL SHEET FOR CHANGES

QAM-3

Section Rev/Date Reason for Change CRANENUCLEARApproval

Signature/Date

Nat'l BoardAcceptance

Signature/Date

TitlePg.,Pgs II &

IV

All.

All.

All.

All

0, 4/20/90

1, 2/22/91

2, 6/24/93

3, 7/19/99

4, 6/24/02

5, 6/23/05

Original issue of VR Manual

Name change to ITI MOVATS resultingfrom Westinghouse Corp. acquisition of

nuclear assets of NSSI HENZE-MOVATS.

Tri-annual VR Recertification

VR Certification and name change toCRANE MOVATS

Tri-annual VR Recertification and namechange to CRANE NUCLEAR, INC.

Tri-annual VR Recertification and NBIC andeditorial changes

J ack Cahoon02/28/90

Mark Milo02/22/91

Mark Milo6/24/93

Mark Milo7/21/99

Steve Fowler06/27/2002

Steve Fowler6/23/2005

J ack E. Cox02/28/90

T. R. Tarbay02/22/91

W. R. Hankins6/24/93

S. F. Harrison, J r.7/21/99

J im Hicks06/27/2002

J im Keenan6/23/2005

Original approval signatures for revisions 0, 1, 2, 3 & 4 are on file.

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Page 7 of 35CORPORATE ORGANIZATION CHARTAPPLICABLE FOR FIELD VRREPAIRS AND REPLACEMENTS

PRESIDENT

MANAGER

SUPPORTSERVICES

VICE PRESIDENT OF

OPERATIONS*

QA

MANAGER

PROJECT MANAGERQC

REPRESENTATIVE

J OB SUPERVISOR

REPAIR PERSONNEL

1

PARTS COORDINATOR

3

1 - Training2 - Machining3 - Material Control & Issuing4 - Receiving & Shipping

Typical FieOrganizatio

Communic

FunctionaResponsib

PURCHASINGRECEIVING/SHIPPING

4

DOCUMENT CONTROLASSISTANT

*The Vice President ofOperations is the Product LineManager for Valve Repair andReplacement Activities.

2

42

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Page 8 of 35SECTION 1 SCOPE OF WORK

1.0 SCOPE OF WORK

1.1 CRANE NUCLEAR, INC. is capable of performing all necessary repairs to ASME Code stampedSection I, Section III and Section VIII, Division 1 steam, Liquid, and air service pressure reliefvalves. This scope of work includes valve repairs during Field Service with or without mobileunits. The organizational and the quality control requirements of this manual apply to fieldrepairs controlled from the Kennesaw, Georgia Corporate Office. Repair capabilities consist of:disassembly and cleaning, replacement of manufacturer's parts, machining, lapping, assembly,and pressure testing. Additionally, conversions may be performed by upgrading/installingapplicable OEM parts (see Section 4.0, Repair and Inspection Program, sub-section 5.2) andreference NBIC RE-1061.g. Written standard procedures for the performance of the abovefunctions are a part of CRANE NUCLEAR, INC. Quality Assurance System and are listed inAppendix A.

1.2 Steam, liquid, and air testing of valves can be accomplished at field locations to the facility'smaximum capacity, or at Owner facilities with sufficient capacity and volume for codecompliance.

1.3 CRANE NUCLEAR, INC. also has the capability to apply an auxiliary lifting load on the spring ofa repaired valve to establish the set pressure, per RE-2030.

1.4 See Section 9 of this manual and the NR Quality Assurance Manual, QAM-2 for the applicationof the VR stamp to "NV" stamped valves.

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SECTION 2 DRAWINGS AND SPECIFICTION CONTROL

1.0 DRAWINGS AND SPECIFICATION CONTROL

1.1 CRANE NUCLEAR, INC. repairs valves to manufacturer's specifications, which are kept on filein the Operation's Department as they become available. The Vice President of Operations isresponsible to obtain current engineering drawings, specifications and/or changes directly fromthe valve manufacturer/assembler or from the Owner or CRANE NUCLEAR, INC. customers.He is responsible to immediately furnish these documents to the QC Representative for review.

1.2 The QC Representative will review these documents/changes for adequacy and for theimplementation process to achieve these specifications as necessary. Outdated drawings,instructions, specifications, etc., will be withdrawn from the QC files by the QC Representative.

The QC Representative will furnish updated specifications to the J ob Supervisor.

1.3 The Job Supervisor is responsible for the issuance of all drawings, specification, workinstructions and their revisions at the location where the prescribed activity is performed byqualified personnel for production purposes such as the repair, testing and inspection of safetyand safety relief valves.

1.4 The valve assemblers, valve manufacturers or their subcontractors supply replacement partsthat meet the ASME Code requirements for mechanical adequacy. The QC Representative isresponsible to insure that materials and replacement parts purchased meet the requirements ofASME Code Section II as stated in ASME Section VIII, Division I, Paragraph UG-136(b) (3),ASME Section I, Paragraph PG-73.2.3, the appropriate ASME specifications, and detaileddrawings and material specifications issued by the manufacturer of the valve, thus assuringcontrol of chemical and physical properties and quality at least to ASME Standards.

1.5 Repairs shall be conducted in accordance with manufacturer's drawings and/or

specifications, maintenance manuals, or catalogs as applicable, and augmented by writtenCRANE NUCLEAR, INC. Quality Assurance System Procedures, and/or owner/userprocedures.

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SECTION 3 MATERIALS AND PARTS CONTROL

1.0 RECEIVING AND INSPECTION, MATERIAL/PARTS ORDER PROCESSING

1.1 All purchased controlled items/materials are processed through a central receiving and

inspection station in the controlled storage area, by the Quality Control Representative.Items/materials are inspected and compared with procurement document requirements andmust pass the checkpoints delineated in Section 3.0 before they can be placed in controlledstorage.

2.0 PURCHASE OF PARTS AND MATERIALS

2.1 The purchase of replacement parts and materials from valve assemblers, original valvemanufacturers or their distributors is by CRANE NUCLEAR, INC. Purchase Order. The QualityControl Representative is responsible to assure that purchase documents for the procurementsof controlled parts and materials include requirements to the extent necessary to assure theircompliance with the Owner's specifications and ASME/ANSI requirements. Replacement

critical parts shall meet the manufacturers specifications. Purchase Requisitions and PurchaseOrders (Section 3, Pages 12 &13) shall be controlled, prepared and issued in accordance withCRANE NUCLEAR, INC. Procedure, QAP-4.0. Copies of all applicable purchase requisitionsand purchase orders are retained in the job file. Procurement documents including changes arereviewed for adequacy and approved for release by the Vice President of Operations and/or QCRepresentative and are distributed for use to the location where the activity is performed. Thevendor requirements will be shown on the sample purchase requisition and purchase order.

3.0 RECEIVING AND INSPECTION OF PARTS AND MATERIALS

3.1 When controlled parts and/or material are received, they are processed through the followingcheckpoints by the Quality Control Representative before being used in repairs:

3.1.1 Check that the proper Purchase Order and Item Number are identified on the vendorpacking slip.

3.1.2 Check that the items/materials received are properly identified and that theitems/materials received agree with the items/materials ordered.

3.1.3 Check that the Certification requirements of the purchase documents are received.

3.1.4 Check that replacement critical parts shall meet the manufacturers specifications.

Failure to meet any of the above checkpoints redirects items/materials into dead storage,

requiring disposition by the QC Representative.

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4.0 STORAGE OF PARTS, MATERIAL AND CERTIFICATION RECORDS

4.1 The parts and/or material that have been received for inventory stock that meet the receivingcheckpoints are labeled (tag or identified paint) by the Quality Control Representative as toPurchase Order number and a description of the item received. The Certification Reports are

placed in a special Certification File which is maintained by the Document Control Assistant.

5.0 ISSUANCE OF PARTS AND MATERIALS (ACTIVE STORAGE ONLY)

5.1 As items/materials (parts) are needed, they are issued under the control of the Quality ControlRepresentative to the Repair Personnel, using a Material Requisition Form (Page 14).

5.2 Repair Personnel are responsible for entering a description of the item(s) replaced and thecorresponding Purchase Order numbering on the Safety Relief Valve Report (SRVR- Discussedin Section 4) for traceability of controlled parts/material.

6.0 DEAD STORAGE (NON-CONFORMING PARTS AND MATERIALS)

6.1 Items/material (parts) that do not meet the receiving checkpoints are segregated and placed in adead storage by the Quality Control Representative. The items/material will be labeled "DONOT ISSUE MATERIAL". Items/material will be "cleared" for use by QA/QC personnel only.

7.0 DISPOSITION OF DEAD STORAGE ITEMS (NON-CONFORMING PARTS AND MATERIALS)

7.1 The Quality Control Representative must resolve discrepancies in the following manner:

7.1.1 Checkpoint failures are corrected by coordination with the vendor/manufacturer,resulting in corrected vendor certified documentation to assure that material/partscomply with appropriate specifications identified on our procurement document; or

7.1.2 Inability to satisfactorily resolve any checkpoint discrepancy results in the terms beingreturned to the vendor.

8.0 CONTROLLED STOCK

8.1 All controlled items/material are clearly identified and stored separately from similar uncontrolleditems/material. Controlled items/material shall be identified and controlled in accordance withQAP-8.0.

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PURCHASE REQUISITION FORM

CRANE NUCLEAR Page of2825 Cobb International Boulevard

Kennesaw, GA 30152-4352(770) 424-6343FAX 429-4750

Vendor: Terms: PO#Address 1: Cust/Int WO# DateAddress 2: AR WO# Req. DateCity/State/Zip: F.O.B. Storage LevelPhone: Major Acct. Safety Grade Yes NoFax: Dept./Product Line 10CFR21 Yes NoContact: Primary

CRANE VendorQTY Stock# Part# Description Unit Cost Total

RequisitionerApproval Budget OwnerApproval ControllerApproval QAApproval Vice President

Requisitions submitted for purchase musthave proper approval prior to processing

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PURCHASE ORDER FORM

CRANE NUCLEAR

P. O. Number

145032825 Cobb International BoulevardKennesaw, GA 30152-4352

(770) 424-6343

Vendor: Ship to: CRANE NUCLEAR, INC.Industrial Valve Attn: Receiving Dock510 Industrial Drive SW 2825 Cobb International Blvd.Cleveland, TN 37311 Kennesaw, GA 30152-4352

P.O. Date

5/23/02

Ship Via

FEDEX

F.O.B

Origin

Terms

N30

Buyer

Ann HewetFreight Confirming Copy Sent Contact

Don Miller800-982-5837

Remarks

Normal

QTYRequired

1 ea.

1 ea.

Item Number/Date Required

NS5/28/0

NS5/28/02

Description

4318301

Disc (Thermo)

P523CRSpring (280 PSI Set)

Above parts for 1 X G X 1 consolidated type 1811GB Safety Valve,S/N BV 9847, NB V stamped steamservice.

Parts shipment shall include a Certificateof Conformance referencing this purchaseorder that parts supplied are O. E. M. partsand are furnished in accordance withAttachment 1, Sections 5, 6, 7, 8, 9, and

12.

Unit Cost

$366.40

$12.80

Amount

$366.40

$12.80

This Order is subject to the terms and condi tions as set forth on the reverse side

Quality Assurance Signature Authorized Signature

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Page 14 of 35MATERIAL REQUISITION FORM

CRANE NUCLEAR, INC. N 1000Material Requisition

Issue To _______________________________________________Name I.D.

J .O. or W.O. ___________________ Equip. No. _______________

Description _____________________________________________

Manufacturer ____________________________________________

P.O. No./Item No. ________________________________________

Heat/Lot No. ____________________________________________

Specification ____________________________________________

Type & Size ____________________________________________

Amount Issued __________________________________________

Date __________________________________________________Q4/91

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Page 15 of 35SECTION 4 REPAIR AND INSPECTION PROGRAM

1.0 REPAIR PROCEDURES

1.1 All ASME Code stamped pressure relief valves, Section I, Section III or Section VIII, Division 1are repaired by a qualified Repair Personnel utilizing CRANE NUCLEAR, INC. Valve Repair

Procedures, VRP's (Ref. Appendix A).

CRANE NUCLEAR, INC. procedure may be augmented by owner/user approved procedures,when they do not conflict with manufacturers procedures.

1.2 Repair and assembly procedures are in compliance with valve manufacturers'specifications/drawings and manuals. Replacement parts shall be in compliance withmanufacturers' specification/drawings.

2.0 CONTROL FORMS

2.1 Each valve is controlled throughout the repair process through the use of three forms which are

(a) a Work Order Cover Sheet (Section 4, Page 20), (b) a Safety Relief Valve Report (Section 4,Page 22) and (c) a Work Traveler, an additional form required for "NV" valves only, asdiscussed in the NR Manual, QAM-2, Section 9.

2.1.1 A CRANE NUCLEAR, INC. Work Order Cover Sheet specifies what repairs oradjustments and testing are to be performed, the identity of each valve, pressure settingand other date useful for the complete processing of the job. The work orders areinitiated by the Project Manager. The QC Personnel review Work Orders for compliancewith customer written requirements. Customer requirements not in compliance with"VR" requirements are resolved by the Vice President of Operations.

2.1.2 A Safety-Relief Valve Report Forms (SRVR), in addition to containing a complete

description of the valve, describes the status of all components, work performed, and theidentity of the workers and inspectors. It also identifies the Work Order number, theWork Order Item number, and parts and/or material used and theircontrol number, as tested set pressure and blowdown, and final inspection sign-offs. TheSafety-Relief Valve Report Continuation Form is used to document M&TE and priorrepair information on the valve.

2.1.3 Each spring is checked for proper spring range, and the spring marking is recorded onSRVR form by the repairer. The QC Representative must obtain and verify the springrange when there is a set pressure change and perform the new capacity calculationbased on that for which the valve was originally certified.

2.1.4 The performance testing process will be verified by the QC Representative by hissignature on the SRVR form.

2.1.5 The Work Order and Safety Relief Valve Report(s) are placed in the J ob File uponcompletion.

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3.0 IDENTIFYING PARTS

3.1 Valve components are identified by means of Work Order and Item number tags either affixed tothe parts or to parts pan used to store parts/components for each valve processed for repair.

Springs purchased to manufacturers' specifications are tagged upon receipt for storage with thespring number, set pressure range, Purchase Order, Work Order Item number as appropriate.

4.0 SPECIAL PROCESSES

4.1 Special Process regarding welding, NDE and Post Weld Heat Treat are currently excluded fromthe CRANE NUCLEAR, INC. QA Program. In the event CRANE NUCLEAR, INC. determinesthe need for such Special Process; they will be reinstated under the guidance of the ANIS.

5.0 NAMEPLATE (CRANE NUCLEAR, INC.)

5.1 Each ASME Code Stamped Section I, III and Section VIII Safety and Safety Relief Valve

repaired that meets the applicable requirements of the ASME Code is furnished with a metalCRANE NUCLEAR, INC. repair nameplate permanently attached to the valve adjacent to theoriginal stamping. On small valves, the nameplate may be securely attached to the valve bymeans of safety wire. The CRANE NUCLEAR, INC. nameplate, as a minimum, will contain thefollowing formation:

1. Repaired by CRANE NUCLEAR, INC.2. Date of Repair3. Work Order and Item Number (unique identifier)4. Set Pressure5. Capacity (if set pressure is changed)6. VR Stamp and VR Serial Number

7. Type/Model#(if changed from original) by conversion

5.2 The Valve Repair Technician is responsible for stamping the proper data on the nameplate. Therepairer is responsible to mark out, but leave legible the set pressure and capacity for "V" and"UV" valves and blowdown for "V" stamped valves on the manufacturers' nameplate, whenchanged. When there is a change to service conditions to set pressure, temperature (TC), backpressure, and Cold Differential Test Pressure (CDTP) the nameplate data shall be indicated onthe repair tag. The Standard CRANE NUCLEAR, INC. Safety and Safety Relief Valve repairnameplate is shown below.

NAMEPLATE

REPAIRED BY

CRANE NUCLEAR, INC.

TYPE/MOD.

CAPACITY TC

SET PRESS. CDTP

WORK ORDER NO. Date

NO. Symbol

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6.0 NATIONAL BOARD REQUIREMENT FOR VR STAMP USE

6.1 Listed below are mandatory conditions, all of which must be met, for stamping the VR symbol onthe CRANE NUCLEAR, INC. nameplate of a repaired valve:

6.1.1 Manufacturer's nameplate must contain ASME Code "V" or "UV" Code symbol stamp and NBsymbol (certification of capacity).

6.1.2 Valve must have been set and all external adjustments safety wired and sealed only bypersonnel authorized to seal valves. See Paragraph 9 in this section pertaining to authorizedpersonnel.

6.1.3 The VR Stamp cannot be applied until final settings comply with ASME Code "V", "NV" and"UV" performance requirements as applicable.

6.1.4 NV stamped valves must also meet "NR" requirements, as identified in Section 9.

6.1.5 ASME Sections I, III and VIII valves set at 15 psi or above may be stamped with the VRsymbol.

7.0 NAMEPLATE DATA

The Vice President of Operations will maintain custody and control of the "VR" stamp and issue it to theQuality Control Representative when required for use. The QC Representative shall verify thatnameplate data is correct and that the requirements of Section 6.0 are met prior to application of "VR"symbol stamp.

8.0 MANUFACTURER'S NAMEPLATE (Section I and VIII Valves Only)

8.1 When the information on the original manufacturer's or assembler's nameplate or stamping isillegible, the nameplate or stamping will be augmented or replaced by a nameplate furnished bythe "VR" stamp holder, stamped "duplicate" which contains all information which originallyappeared on the nameplate or valve as required by the applicable section of the ASME Code,except the "V" or "UV" symbol and the National Board mark. The CRANE NUCLEAR, INC.nameplate with the serialized "VR" stamp and other required data specified in Paragraph 6above will make CRANE NUCLEAR, INC. responsible to the Owner and the J urisdiction that theinformation on the duplicate nameplate is correct.

8.2 When the original valve nameplate is missing, CRANE NUCLEAR, INC. is not authorized toperform repairs to the valve under the "VR" program, unless positive identification can be madeto that specific valve and verification that the valve was originally stamped with a "V" or "UV"

stamp. Valves that can be positively identified will be equipped with a duplicate nameplate inaddition to the CRANE NUCLEAR, INC. "VR" stamped nameplate. CRANE NUCLEAR, INC.responsibilities for accurate data, as described in Paragraph 8.1 above, shall apply.

8.3 When a duplicate nameplate is affixed to a valve, it shall be marked "Sec I" or "Sec VIII" asapplicable to indicate the original ASME Code stamping.

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9.0 VALVE TESTING, SETTING, SEALING, AND SHIPPING PREPARATION

9.1 CRANE NUCLEAR, INC. performs safety valve set pressure adjustments and performancetesting of all refurbished valves utilizing the applicable service medium. Valves marked for air,gas or vapor shall be tested on air or gas. Valves marked for liquid shall be tested on water or

other suitable liquid. Valves for steam services shall be tested with steam. API Standard 527,Commercial Seat Tightness of Safety Relief Valves is the criteria for seat leakage. MSS-SP-6,Standard for Contact Faces of Pipe Flanges and Connecting-End Flanges of Valves & Fittings iscriteria for contact face finishes. A back pressure test will be performed on bellows or closedbonnet valves to a minimum 30 PSI. Access to all external adjustments such as adjusting ringlocking pins, overlap collar, cap and release lever are secured with safety wire and a lead sealis applied on each safety wire. Lead seals are crimp-sealed, embossed with "CRANE NUC" onone side and "XX" on the other side. The other side, denoted as "XX" may be blank, contain theindividual's initials, or an assigned traceable number. The Vice President of Operations controlsthe crimper and only Operations personnel authorized by the Vice President of Operations shallseal safety and safety relief valves.

9.2 LIFT ASSIST TESTING

9.2.1 A device may be used to apply an auxiliary lifting load on the spring of a repaired valveto establish the set pressure in lieu of the tests required in paragraph RE-2030(a)(1)when such testing at full pressure:

.1 may cause damage to the valve being tested; or

.2 is impractical when system design considerations preclude testing at fullpressure.

9.2.2 While actual valve blowdown and valve performance characteristics cannot be verified,valve set pressure may be determined to an acceptable degree of accuracy using this

testing technique, provided, as a minimum, that:

.1 equipment utilized is calibrated as required in paragraph RA-2255(m);

.2 the device and test procedures which have proved to give accurate results areused and followed;

.3 a static inlet pressure is applied with the test medium specified in paragraph RA-2010; and

.4 adjustments are made in accordance with the valve manufacturersrecommendations as to ensure proper lift and blowdown.

9.4 CRANE NUCLEAR, INC. die imprints are as shown below.

9.5 Protectors are installed on inlet and outlet flanges, and if required, each valve may be painted.

CRANENUC

XX

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Page 19 of 3510.0 TRAINING PROGRAM

10.1 Persons conducting repairs shall undergo an "in-house" training program sponsored by CRANENUCLEAR, INC. Refresher and/or upgrading training shall be conducted based on needs suchas changing requirements or performance. Repair Personnel shall also receive trainingpertaining to any quality manual change that impacts their responsibility within the quality

control system. Training shall include, but not be limited to, company generated slidepresentations, hands-on training, video tapes and training schools. Repair Personnel will not beallowed to conduct VR repairs unless it is documented by the Vice President of Operations thatthey have been accepted as qualified to perform the assigned repair function(s). Written or oraltesting and observation of on-the-job performance are means of evaluating Repair Personnel.

The evaluations are documented on the Certificate of Qualification on Page 20 and maintainedin the training files.

10.2 The training activities shall be documented and records of training shall be retained by theOperations Department. See sample of Permanent Training Record on Page 24.

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Page 20 of 35CERTIFICATE OF QUALIFICATION

We hereby certify that employee is qualified to perform the duties and assumethe responsibilities of .

This certification is based upon the following, as checked:

Record of Experience and Education

Written/Oral Examination and/or Practical Examination

Proficiency Demonstration

The following Codes and Standards are applicable to the qualifications noted above:

ANSI/ANS 3.1 1978 Edition

ANSI/ASME N45.2.6 - 1978, Level II

CRANE Nuclear Quality Assurance Program

Initial Certification Recertification/Renewal

The above individual has satisfactorily completed the training and certification requirements ofCRANE Nuclear Procedure QAP-2.0.

Signed: Date:Quality Assurance Manager

Annual Evaluation(Initial Date)Annual Evaluation(Initial Date)Annual Evaluation(Initial Date)Annual Evaluation

(Initial Date)

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WORK ORDER COVER SHEET

LOG NUM: 24141 C/N: N/A AWO: N/A

BOOK DATE: 6/3/2002 PO NUM / RLS#: DEMO FOR NR/VR SURVEY

UTILITY NAME: ABC Nuclear BLANKET WO NO: N/A

PLANT NAME: ABC Nuclear Plant TYPE: N/A

REQD AT SITE DATE: 6/3/2002

EQUIPMENT RETURN DATE: N/AATTACHMENTS: WORK END: 9/3/2002

Acknowledgment LetterPO Review Cover Sheet 10CFR50/21: Y N

Purchase OrderOffer CLIENT CONTACT:Equipment Checklist Client Title:Other Telephone Number:

DESCRIPTION: Demo Repair Service at field location at 1709 Imperial Hwy., Thorofare, NJ. Perform repair IAW QAM-2 and

QAM-3, as applicable.

SPECIAL INSTRUCTIONS:.Repair notification of the National Board and Authorized Nuclear Inspection Supervisor. All M&TEto be used must be provided and calibrated IAW QAM-2 and QAM-3.

PURCHASE ORDER SEGMENTATION:

ORDER VALUE: NTE:

WO SuffixCode Product Line $ Value

WOS1 SEG1:

WOS2 SEG2:

WOS3 SEG3:

WOS4 SEG4:

WOS5 SEG5:

WORK ORDER DISTRIBUTION:

DELIVERY OWNER: CC: Account Manager:Project Manager: PCC Coordinator:

Product Line: Document Control:Product Line: Shipping:Other(s): Accounting:

Other(s):

S & M File

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SAFETY RELIEF VALVE REPORT FORM

CRANE NUCLEAR, Inc.Safety Relief Valve Report WO# DateCustomer: .Site: P .V.#Description: Size Mfg. Type/Style Set Pressure PSIGShop No. S/N Service Medium Back Pressure PSIGV UV NV Other None VR Repair Requested: CDTP: PSIG TC: PSIG Capacity:

Service Required:

Pretest

Test Only

Test & Reset

Complete Overhaul

Pretest Report N/A

Set Pressure PSIG

Simmers (Leaks) at PS IG

POPS at PSIG

After Reseating:

Tight Leaks To PSIG

Test Medium:

Steam

Nitrogen

LiquidOther:

Change Set Pressure To

N/APSIG

#/HR Steam

SCFM Air

GPM Liquid

Spring Data:

Replace:

Yes No

Existing No.

New No.

APPLICABLE PARTS CONDITION RECEIVED WORK PERFORMED *PARTS/MATERIAL USED

ITEM

Typical Parts

(Write in Parts not

listed, line out parts

not used)

Serviceable

Dirty

Plugged

Pitted

Cut

Corroded

GalledBroken

Missing

Bent

*Replaced

Machined

Lapped

Cleaned

Polished

QTY

Write in ControlNumbers

(i.e. RIR, P.O., Etc.)Work Performed By

1 Bonnet

2 Spring

3 Spring Washers

4 Body

5 Inlet

6 Outlet

7 Guide/Eductor

8 Guide Ring

9 Guide Ring Pin

10 Disc

11 Disc Holder

12 Nozzle

13 Nozzle Ring

14 Nozzle Ring Pin

15 Spindle Assembly

16 Spindle (Lift) Nut

17 Cap

18 Release Gear Assy.

19 Fasteners

20 Bellows

21 Gasket

22 Manf. Name Plate

23 Vent/Drains24

25External Adjustments: AS Found Measurements: AS Left Measurements:

Compression ScrewTOP or Upper Guide RingLower Guide RingNozzle Ring

Set Pressure: PSIG CDTP PSIG TC: Blowdown: PSIGBack Pressure Test PSIG Capacity: Seat Tightness Test: PSIG

VR Stamped: Yes No VR Stamp No. NRVR Stamped: Yes No NRVR Stamp No.

CNI QC Inspector Date CNI Certifying Tester Date Customer Inspector Date

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Safety Relief Valve Report Form Continuation

WO# Customer P.O. #

Shop No. or S/N: P.V.#

M&TE Used:

ID No. Cal. Date Cal Due




Prior Repair Information:

Remarks:

Prior Repair Performed By(Record Name, Location)

Shop Order No. Date

Capacity of Prior Repair:

Set Pressure from Prior Repair:

VR Stamping Yes No

VR No.

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Page 24 of 35PERMANENT TRAINING RECORD

LOCATION DATE(S)

SUBJECT INSTRUCTOR

DURATION.

WRITTEN TEST YES NO TEST TITLE

ATTENDEES: TEST SCORE: ATTENDEES: TEST SCORE:

. 7.

2. 8.

. 9.

4. 10.

. 11.

6. 12.

DESCRIPTION OF TRAINING (INCLUDE COMPANY POLICIES/PROCEDURE(S): COMPONENTTYPE(S), SPECIFICATIONS(S), STANDARDS, CODES, REGULATIONS, ETC. AS APPROPRIATE):

Copies Distributed to: Employee Training File

NSTRUCTOR SIGNATURE DATE

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Page 25 of 35SECTION 5 WELDING, HEAT TREATMENT, AND NONDESTRUCTIVE EXAMINATION

1.0 WELDING, HEAT TREATMENT AND NONDESTRUCTIVE EXAMINATION

1.1 Special Process regarding welding, NDE and Post Weld Heat Treat are currently excluded fromthe CRANE NUCLEAR, INC. QA Program. In the event CRANE NUCLEAR, INC. determinesthe need for such Special Process; they will be sub-contracted utilizing an approved NR or RCertificate holder, as applicable.

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SECTION 6 CALIBRATION OF MEASUREMENT AND TEST EQUIPMENT

1.0 CALIBRATION OF MEASUREMENT AND TEST EQUIPMENT

1.1 The Quality Control Representative is responsible to assure that all measuring and test

equipment is calibrated in accordance with the requirements of CRANE NUCLEAR, INC.Procedure, QAP-12.0. This procedure defines the requirements for a written schedule ofaccuracies and frequencies for calibrating gauges, measuring and test equipment owned byCRANE NUCLEAR, INC., and the documentation requirements on the calibration record.

1.2 All Repair Personnel are responsible for ensuring instruments used are of the proper range, typeand accuracy to verify conformance to established requirements. These instruments will bemarked with a unique identifier and their use will be documented on the procedure or traveler asapplicable.

1.3 Any measuring or test instrument supplied by the Owner or Subcontractor will not be used untilthe Quality Control Representative has verified that the instrument is calibrated at least to the

requirements of the CRANE NUCLEAR, INC. procedure and has been documented on anReceipt Inspection Report (RIR).

1.4 Pressure gauges, and other measuring and test equipment used to verify product conformanceand found to be outside the allowable tolerance as required in QAP-12.0 will require the QualityControl Representative to initiate an Out of Tolerance Report (OTR) and such findings as itemsmeasured, tested, etc., shall be listed and included in the report.

1.5 Samples of SIR, RIR and OTR are included on Pages 27 through 29.

1.6 Measuring and Test Equipment shall be calibrated at frequencies shown below:

Pressure Gauges - Every Twelve Months Length Measurement Gauges - Every Twelve Months Torque Wrenches - Every Twelve Months

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SURVEILLANCE INSPECTION REPORTPage of

Description Location SIR No.

System Component Part No.

Insp. Date: J .O./W.O. No. P.O. No.

Spec. No. Rev. No. Procedure No.Rev. No.

Drawing No. Rev. No. QTY. Insp. QTY. Rej.

Inspection Type: In-process Hold Point Final

M&TE USED

M&TE Type: S/N: Cal. Date Cal Due Date



Observations:

Disposition: Sat. Unsat. Date: DR/NCR No.

Reinspection: Sat. Unsat. N/A

Performed By: Date:

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Page 28 of 35CRANE NUCLEAR, INC.

RECEIPT INSPECTION REPORT

ReceivingMaterial/Equipment/Service Description: Purchase Order No.:

Supplier/Location Item No.:

__ No Shipping Damage __ Properly Packaged __ Cleanliness Satisfactory __Properly Identified

Requisition No.:

Remarks:

FORWARD TO QA/QC Material Control Signature: Date:

QA/QC ReceiptDocumentation:

Required by P.O. Available:Yes __ No __ Yes __ No __ Certificate of ConformanceYes __ No __ Yes __ No __ Other (Specify) ______________________________________

Material Inspection:__ P.O. Requirements Met __ P.O. Requirements Not Met

Disposition:__ Accepted - QA/QC Inspection Tag (Attached) _____________________ Date: _________________

__ Rejected - Hold Tag (Attached) _________________________________ Date: _________________

Method of Acceptance:

__ Receipt Inspection __ Certificate of Conformance__ Source Verification __ Conform to P.O. (Cert, Quals)__ Testing __ Preinstallation __ Post Installation (supportive Documents Attached)

Remarks:

QA/QC Signature: Date:

Clearance

Release of HOLD Items or Services: __ Hold Tag Cleared Date:

Action Taken:

QA/QC Signature: Date:

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Page 29 of 35OUT OF TOLERANCE REPORT

P.O. / J.O.:Issue Date:

LocationUsed:

M&TEDescription Serial Number

LastCal. Date

Cal.Due Date Mode

Based on a review of the out-of-tolerance condition, the checked action is required.

--- No Action Required:--- M&TE was not used during period--- Affected range(s) was not used--- Instrument would not function upon receipt, therefore no as found data was obtainable.

It is assumed that failure time and cause were known, providing reasonable assurancethat the instrument was in calibration prior to failure.

--- Based on Evaluation:

--- The error did not cause any test result/calibration to exceed equipment allowabletolerances.

--- The error introduced when using this M&TE could cause an error which may exceed thallowable tolerances of the equipment tested/calibrated.

--- The equipment listed on the attached list was retested/reworked, and no further action

is required.

--- Ranges Affected / % Error*:

PreparedBy:

Date:

Evaluation PerformedBy:

Date:

*The indicated effect on data is a suggested disposition based upon the intimate knowledge of themanufacturer. In most cases, this disposition is general and conservative in nature. Final dispositioof data shall be the responsibility of the user.

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Page 30 of 35SECTION 7 FIELD SERVICE REPAIRS

1.0 GENERAL

1.1 The field repair functions will be under controls which are managed by the Vice President ofOperations.

2.0 SCOPE OF FIELD SERVICE REPAIRS

2.1 CRANE NUCLEAR, INC. is capable of performing all necessary repairs to ASME Code stampedSection I, and Section III and Section VIII, Division 1, steam, liquid and air service only pressurerelief valves. The scope of work includes valve repairs at field locations with or without mobileunits. The organizational and quality control requirements of this manual apply both to theKennesaw, Georgia facility and to field repairs controlled from this location. This controlconsists of utilizing only qualified Repair Personnel as indicated in the Organization Section ofthis manual. These individuals are assigned by the Director of Operations and the QualityAssurance Manager prior to mobilization to the field. Repair capabilities consist of: disassemblyand cleaning replacement of manufacturer's parts, machining, lapping, assembly, and pressure

testing. Additionally, conversions may be performed by upgrading/installing applicable OEMparts (see Section 4.0, Repair and Inspection Program, sub-section 5.2) and reference NBICRE-1061.g. These activities are performed at field locations only. Written standard proceduresfor the performance of the above functions are a part of CRANE NUCLEAR, INC. QualityAssurance System and are listed in Appendix A.

2.2 Steam, liquid, and air testing of valves can be accomplished at field locations to the facility'smaximum capacity, or at Owner facilities with sufficient capacity and volume for codecompliance. Valves up to including ZZ orifice sizes or 20" inlet flanges can be tested by thefabrication of special adapter plates as required to attach valves to the air or steam test systemsas applicable. The VR stamp will not be applied until final settings are completed.

2.3 Field activities that are performed using the Owner/User facility and performance testingequipment shall be qualified to ensure that the equipment and testing procedures will provideaccurate ranges established for that equipment. This qualification may be accomplished bybench mark testing, comparisons to equipment used for verification testing or comparisons tofield performance. This qualification shall be documented and provisions made to retaindocumentation for a period of at least five years after the testing equipment is retired.Documentation of this qualification shall include but not be limited to: schematic/drawing of theperformance equipment; size and pressure ranges of valves to be tested; dimensions of testvessels; accuracy of pressure measuring equipment (M&TE); size and design type of valvesused to control flow; and, method of qualification. Alternately, the use of test equipmentpreviously qualified can be subsequently qualified by audit of the qualification documentation andaccepted by letter to file approved by the VP of Operations and QA Manager.

2.3 CRANE NUCLEAR, INC. also has the capability to apply an auxiliary lifting load on the spring ofa repaired valve to establish the set pressure, per RE-2030 of the NBIC.

3.0 CONTROL OF VR STAMP FOR FIELD REPAIRS

3.1 The QC Representative issues a controlled number of "Pre-VR Stamped" (For Section III "NV"valve repairs the tags are "NRVR" stamped) blank nameplates for each field repair job that hasVR requested repairs. All pre-stamped nameplates must be accounted for by the QualityControl Representative, either by return of unused nameplates or by valve report forms for VRrepairs for which the nameplates were used.

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Page 31 of 354.0 AUDITS

4.1 The Quality Control Representative shall conduct annual written audits of field service VR repairwork using the approved audit checklist. The audits shall consist of evaluation of all applicableessential Quality Control elements and are identified in this manual and in CRANE NUCLEAR,INC. QAP-18.0 for field repairs. Documented evidence of the audits shall be maintained in the

QC files at least five years.

5.0 CUSTOMER FURNISHED PRESSURE GAUGES

5.1 When customer-furnished pressure gauges are used to verify pressure, Quality ControlRepresentative must verify that gauges with up-to-date certified calibration stickers are used.Customer gauges used must be recorded on the Safety-Relief Valve Report by the repairer.

6.0 CUSTOMER SUPPLIED PARTS

6.1 When customer supplied parts are used, the Quality Control Representative must identify andverify traceability of the item to the valve manufacturer (e.g.). Customer Purchase Order on an

assembler, Manufacturer or Manufacturer subcontractor Packing Slip or their Identification tagon the replacement item on the Safety-Relief Valve Report and record the transaction as"Customer Furnished".

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Page 32 of 35SECTION 8 RECORDS RETENTION

1.0 RECORDS RETENTION

1.1 The retention of records pertaining to the quality control system as outlined in this manual shall becarried out as described below:

Records in this section shall be retained for minimum of five (5) years.

1.1.1 Quality Control records maintained in each numbered J ob File as applicable:

(a) Safety-Relief Valve Report

(b) Non-destructive test records.

(c) Records of heat treatment or stress relief.

(d) Work Order.

(e) Purchase Order for parts or material purchased specifically for a given WorkOrder.

(f) A copy of the certification papers of all certified parts and materials used in repairof a valve or valves for a specific Work Order.

1.1.2 Other quality control files shall contain the following records:

(a) Master copies of certification papers, verifying the specifications for quality ofcontrolled parts or materials; and all of which are not procured for a single WorkOrder will be maintained in a certification file to allow placing a copy in theappropriate J ob File, as the controlled items/materials are issued for subsequent

jobs, until all items/materials covered by the certification papers are consumed.

(b) Purchase Orders for replenishment of storeroom stock.

1.2 Quality Control records in this section have varying retention times as specified.

1.2.1 Calibration Records are maintained for recalibration and trend analysis documentationpurposes. Maintain the three most recent calibrations and five years (5) after gauge ormicrometer is no longer used for repairs.

1.2.2 The QC Representative is responsible to ensure that the records are complete,identifiable, and retrievable. Necessary precautions shall be taken by the Vice President

of Operations to protect these records from theft, loss, damage, or deterioration forspecified duration. Copies shall be provided to the Owner upon request. Retention timeof the NVR-1 forms is as specified in the NR Manual.

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SECTION 9 PROCEDURES TO EXTEND THE "VR'" CERTIFICATE OF AUTHORIZATION AND STAMP TOASME " NV" STAMPED PRESSURE RELIEF DEVICES

1.0 PROCEDURES TO EXTEND THE "VR" CERTIFICATE OF AUTHORIZATION AND STAMP TO ASME"NV" STAMPED PRESSURE RELIEF DEVICES.

1.1 Approval to use the National Board "VR" stamp on ASME Code "NV" class 1, 2, and 3 stampedpressure relief devices which have been capacity certified by the National Board may be givensubject to the following provisions:

1.1.1 Administrative Procedures

a. Repair activity shall be performed in accordance with the requirements of thismanual. In addition, the referenced procedures, process controls, anddocumentation requirements as specified by the "NR" Quality Assurance Manual(QAM-2) are applicable in their entirety.

b. The interfacing of the activities and documentation requirements, responsibilitiesand duties between the Owner and CRANE NUCLEAR, INC. shall be clearlydefined prior to implementation and shall be subject to acceptance of the Owner,the Authorized Nuclear Inspector (ANI), and the jurisdiction as applicable.

c. It is the responsibility of the Quality Control Representative to ensure that allactivities and documentation requirements of the "NR" and "VR" QualityAssurance Programs are satisfied for the activities they are implementing.

1.2 General Rules

1.2.1 ASME Code Section III "NV" stamped pressure relief devices which have been repaired

in accordance with these rules shall be stamped with both the "VR" and "NR" stamps,when authorized by the ANI.

1.2.2 The "VR" and "NR" stamps shall be applied only to "NV" stamped (Class 1, 2, or 3)National Board capacity certified pressure relief devices which have been disassembledinspected and repaired as necessary, such that the valves ' condition and performanceare equivalent to the standards for new valves. Stamping shall be as specified in RE-1060 and RA-2370(e).

1.2.3 Documentation of the repair of "NV" stamped pressure relief devices shall be recordedon the National Board Form NVR-1, Report and Repair, Modification or Replacement ofNuclear Pressure Relief Devices. The Quality Control Representative shall file the

original form with the National Board, and provide a signed copy to the Owner, theJ urisdiction and the Authorized Inspection Agency.

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Page 34 of 35SECTION 10 NONCONFORMITIES

1.0 NONCONFORMITIES

1.1 Any suspected nonconformity shall be reported to the Quality Assurance Manager by anyCRANE NUCLEAR, INC. employee. It is the responsibility of the cognizant individuals whom

are assigned with this task by the responsible line manager in accordance with QAP 15.0 fordispositioning all nonconformities.

1.2 Nonconforming materials, parts or items/components, hereafter referred to as items discoveredduring receiving inspection or at any later time during the work cycle will be clearly identified andshall be segregated whenever practical in areas clearly identified as containing nonconformingitems.

1.2.1 Material and parts received for Section I and VIII valves will be processed fornonconformities as described in Section 3 of this manual.

1.2.2 Nonconformities of measuring instruments and corrective actions are detailed in QAP-

12.0, Control of Measuring and Test Equipment, and QAP-12.1, Control of Measuringand Test Equipment at Field Locations.

1.2.3 Nonconformities of a complex nature that, for example, require equipment alteration,procedure or process revision will be documented on a Corrective Action Report asdetailed in QAP-16.

1.2.4 All nonconformities for the repair or replacement of Section III valves will be processedas in Sections 15 and 16 of the CRANE NUCLEAR, INC. "NR" Manual QAM-2.

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APPENDIX AQUALITY ASSURANCE DOCUMENTS

Procedure # Title

QAM-2 Quality Assurance Manual for Field Repair or Replacement of Class 1, 2, and 3 LineValves

QAP-2.0 Personnel Qualification ProcedureQAP-4.0 Procurement Document ControlQAP-5.1 Control of Travelers and Work PackagesQAP-7.0 Control of Purchased Material, Equipment, and ServicesQAP-8.0 Identification & Control of Material & EquipmentQAP-12.0 Control of Measuring and Testing EquipmentQAP-12.1 Control of Measuring and Test Equipment at Field LocationsQAP-13.0 Handling, Storage and ShippingQAP-15.0 Control of Nonconforming Materials, Parts or ComponentsQAP-15.1 Discrepancy ReportingQAP-16.0 Corrective Action ReportQAP-17.0 Review, Collection, Storage and Maintenance of Quality Assurance RecordsQAP-18.0 Internal and External AuditingQAP-19.0 Reporting of Defects and NoncomplianceDCP-1.0 Document Control Distribution ProcedureDCP-2.0 Preparation, Review and Approval of Engineering, Quality DocumentationVRP-4 Safety & Safety Valve General Repair ProcedureVRP-5 Disassembly, Inspection, Rework, Reassembly, and Testing of Crosby Pressurizer

Safety Valves