IR 05000410/1986062
| ML20213G233 | |
| Person / Time | |
|---|---|
| Site: | Nine Mile Point  |
| Issue date: | 11/12/1986 |
| From: | NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION I) |
| To: | |
| Shared Package | |
| ML20213G221 | List: |
| References | |
| 50-410-86-62, NUDOCS 8611170395 | |
| Download: ML20213G233 (70) | |
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Report 50-410/86-62
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INITIAL OPERATING LICENSE
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REVIEW REPORT FOR
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NINE MILE POINT UNIT 2 DOCKET NUMBER 50-4I0 PREPARED BY UNITED STATES NUCLEAR REGULATORY COMMISSION
REGION I
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8611170395 861112 PDR ADOCK 05000410 G
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SUMMARY SALP No.
FUNCTIONAL AREA SF CONT PIP COMP SYS ELEC INST ENG QA LIC
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OP RAD SUR POT FP SEC CONST QA LIC
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SF = Soils and foundations CONT = Containment and other safety related structure PIP = Piping and supports COMP = Safety related components SYS = Support systems ELEC = Electrical power systems INST = Instrumentation and control ENG = Engineering QA = Quality Assurance LIC = Licensing OP = Readiness for Operations RAD = Radiological controls SUR = Surveillance POT = Preoperational testing FP = Fire protection SEC = Security CONST = Construction N = No basis for rating
- = Not assessed
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5.2 First SALP (February 1,1980 to January 31, 1981)
Inspection activity had covered the containment structure, reactor pres-sure vessel installation, reactor pressure vessel internals, biological shield wall, and quality assrance.
Only one notice of violation had been issued during the period for inadequate incorporation of design changes into the associated engineering drawings. NMPC had reported four 10 CFR 50.55(e) reports.
5.3 Second SALP (October 1, 1981 to September 30, 1982)
Two enforcement conferences (50-410/82-06 and 82-08) had been held to dis-cuss a violation involving ASME Class 1 weld procedures that had not been properly qualified for impact testing. The following root causes were identified: inexperience of the piping contractor (ITT) personnel, inef-fective Stone and Webster control of the piping contractor, and inadequate NMPC attention to subcontractor activities.
NMPC committed to strengthen ITT engineering and QA staffs, to increase SWEC audits of ITT programs, and to reorganize the NMPC corporate offices to create two new positions of Vice President-QA and Senior Vice President Nuclear to serve as respon-sible NMPC management for all project matters.
There were several concerns in the Electrical Power Supply area including failure to specify design separation criteria in the installation specifi-cation, cable trays did not conform to procurement specifications, incor-rect design of cable tray weldments, and inadequate weld deposit on cable tray cross braces.
There were significant weaknesses within NMPC and contractor QA programs including: inexperienced personnel on the QA staffs, failure of QA to identify programmatic weaknesses, NMPC overdependence upon SWEC QA to as-sure plant quality, inability of NMPC to resolve audit findings, lack of licensee control of SWEC activities, and inadequate NMPC management in-volvement in the project.
NMPC corrective actions to the QA shortcomings included: increased the site QA staff, created position of Vice President-QA, increased NMPC QA surveillances, increased SWEC surveillance of contractor activities, and increased overall NMPC management control of SWEC activities.
5.4 Third SALP (October 1, 1982 to September 30, 1983)
Region I identified two violations regarding the QC acceptance of noncon-forming concrete expansion anchor bolts and the inadequate QC inspection of structural steel bolted connections. The NMPC performed extensive re-inspections to assure the adequacy of other hardware.
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During the period, major deficiencies were identified by NMPC in the ITT I
radiography program.
Several instances of film enhancement were discov-ered by NMPC. The questionable welds were radiographed again and found acceptable. NMPC project management and oversight of ITT were weak as indicated by inadequate QA review of weld planner packages, inadequate
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control of the NDE process, and ITT QA management's prohibition of person-nel expressing quality concerns to the NRC.
An Enforcement Conference (82-13) was held on October 20, 1982 to discuss the inproper use of QC trainees and the falsification of QC inspection records. Region I stated that greater NMPC overview was required of pro-ject QA activities.
On May 23, 1983, a Management Meeting (83-09) was held to discuss the ne-cessity for increased NMPC control over ITT. Another Enforcement Confer-ence (83-14) was convened on August 30, 1983 to discuss the prohibition of personnel from bringing safety concerns to the NRC. Steps were instituted to increase the ITT QA staffing and to increase the level of NMPC surveil-lance of ITT activities.
5.5 Fourth SALP (October 1, 1983 to January 31, 1985)
There were further problems with the application of the AISC acceptance criteria for high strength bolting. NMPC reinspected and reworked the associated structural steel connections.
Vendor Procurement Quality Assurance (PQA) activities had not been effec-tively implemented. Nonconforming hardware had not been detected by PQA as evidenced by: undersized shop welds, inadequate mechanical component bolt thread engagement, and electrical equipment vendor wiring deficiencies.
The NMPC Quality Performance Management Program identified improved QC acceptance rates for piping and pipe support installations.
The SWEC small bore piping hardware was of high quality.
The control of Preventive Maintenance (PM) activities required greater levels of management attention to assure that plant equipment was properly maintained during the construction phase.
Electrical wiring deficiencies were identified throughout the PGCC panels.
The entire PGCC was reinspected by GE and SWEC personnel to identify all locations of electrical separation problems. Additional concerns regard-ing the PGCC wiring terminations, harness supports, and as-built verifica-tion were identified.
Extensive project management and quality assurance personnel changes re-sulted in improved NMPC control of site activities. The Quality Perfor-mance Management Program served as a management trending tool to identify those areas on which to focus management attention. Numerous program enhancements were instituted to upgrade site nondestructive examination efforts.
The rate of design change remained high.
Examples were detected in which the design change documents were inaccurate and not completely reviewed.
Several components were identified which engineering had not designed to
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appropriate seismic standards. Some instances were found where the design drawings had erroneously identified components as nonsafety-related.
An enforcement conference and several management meetings were held to discuss the CAT inspection findings and the implemented site corrective actions.
5.6 Fifth SALP (February 1,1985 to January 31, 1986)
This assessment concentrated mainly on readiness for operations and con-struction transition.
It found NMPC's performance satisfactory.
Improved craft attitudes regarding the necessity to build quality into the plant were apparent, while management maintained oversight of construction quality through a site trending effort that tracked key parameters.
In addition, the acceptability of previously installed components was assured through reinspection efforts. Notwithstanding, poor housekeeping condi-tions, the occasional lapses in the implementation of complete corrective actions, and control of Final Safety Analysis Report commitments were areau where improvement was noted as being needed.
The preoperational test activities have been executed by generally knowl-
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edgeable personnel, and the field testing was well controlled. Close mon-itoring of preoperational test activities was maintained by Quality Assurance personnel. Also, permanent plant staff were actively involved in the system turnover and preoperctional testing process to gain system familiarization and to exercise plant operating procedures.
Increased management attention was warranted in performing more timely reviews of preoperational test results to assure that satisfactory test completion was achieved.
For the transition from the construction phase, NMPC conducted a self evaluation to assure that all necessary preparations were performed to support plant operations.
The permanent plant staff positions were filled with technically competent personnel. Due to a high Reactor Operator failure rate on the initial licensed operator examinations, increased man-agement attention was given to the operator training program to ensure that a sufficient number of licensed operators were available to support fuel load. As a result, significant improvement in candidate performance was noted on the second set of examinations.
Some recurring program and individual shortcomings were noted on the thrid set of examinations for
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6.0 ALLEGATIONS AND INVESTIGATIONS 6.1 Overview Allegations received by NRC Region I addressed both safety related and nonsafety-related areas.
Each allegation was reviewed by a board that included regional management, and appropriate followup was determined based on the potential safety significance of the allegation. Several of these allegations were investigated by members of the NRC Office of Investigations.
6.2 Unit 2 Allegations Region I records indicate that 37 Nine Mile Point Unit 2 allega*'ons have been received to date. Of those allegations which were substantiated, 5 resulted in enforcement action as discussed below:
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An allegation was received in September 1982 that uncertified quality control personnel.were performing inspections.
Subsequent Region I investigation verified that inspections of safety-related electrical equipment had been performed solely by uncertified trainees. The
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associated inspection records were falsified, as qualified Level II inspectors had signed the documents, which signified the inspections were performed by certified personnel.
The deficient inspections and the falsified inspection records demonstrated the need for NMPC to increase its management involvement with contractor activities to assure proper implementation of site QA/0C programs. A level III violation and civil penalty were assessed.
NMPC reinspected the work performed by the trainees and did not identify any substantive deficiencies.
An allegation was received in February 1983 that ITT welders were not
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provided weld procedures for ASME piping installation.
The concern was substantiated through interviews with craft supervision and weld rod room attendants, and a Level IV violation was issued. NMPC con-ducted extensive training programs to ensure that craft personnel were aware that weld procedures are maintained for reference at all ITT weld rod issue stations. NMPC verified that the weld procedures were indexed at the field stations.
An allegation was received in April 1983 that inconsistent diesel
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generator loading sequences were assumed by General Electric and Stone and Webster Engineering Corporation. The FSAR load sequencing was found to be inaccurate, and a Level V violation was issued for inadequate design review. NMPC amended the FSAR to portray the cor-rect load sequencing and instituted measures to enhance the review of FSAR submittals.
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"This Section Intentionally Blank" 6.4 Quality First Program In 1983 NMPC established an allegation clearinghouse program identified as the Quality First Program (Q1P). The Q1P program includes exit inter-views, a toll-free telephone line to receive concerns, and feedback to the concerned employee after the investigation is completed.
The adequacy of Q1P has been closely reviewed by Region I due to allega-tions that concerns were not properly handled when reported to the Q1P office. A Region I team inspection of the Q1P was performed on January 27, 1986.
The inspection scope included a review of identified concerns, interviews of Q1P personnel, review of concern resolutions, examination of related site procedures and hardware, and interviews of site personnel not affiliated with the Quality First Program. The resolution of safety re-lated concerns was found satisfactory.
Some program weaknesses were iden-tified in the area of handling of wrongdoing issues and the level of the
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Quality First documentation to substantiate concern closure. A subsequent followup inspection conducted in June 1986 indicated improvements in these weak areas.
6.5 Allegation and Investigation Summary and Conclusions The most significant allegations at Nine Mile Point Unit 2 have involved quality concerns and harassment of those raising such concerns.
In an attempt to identify and deal with these issues NMPC developed their Q1P program in late 1983. While this program appears to be working adequately based in Region I reviews, its integrity has been questioned several times by allegers. However, most of these concerns seem to be more indicative of poor employee relations and co;amunications rather than poor quality hardware.
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7.0 FUTURE REGION I ACTIONS Three resident inspectors are currently assigned to the Nine Mile Point site.
Region I resident and specialist inspections will continue through-
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out the startup test progran. Results evaluation will be closely monitored.
A Readiness Assessment Team inspection is currently planned during the low power portion of the power ascension test program.
A team inspection of the Post Accident Sampling System and related TMI Task Action Plan post-accident monitoring issues is planned during low power testing.
A plan is being developed to closely monitor the progress of the NMPC cor-rective action program resulting from recent reviews of the Unit 1 I&C technician's allegations and the QA program concerns brought to Q1P.
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8.0 SUMMARY AND CONCLUSIONS
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Region I has expended over 12,000 inspection hours at the Nine Mile Point Unit 2 facility and has determined that the project has been adequately managed while under close NRC scrutiny.
Early in the project few problems were identified.
Beginning in 1981 and continuing through the CAT inspec-tion in late 1983, significant weaknesses were identified in control over contractors and quality assurance, which resulted in both hardware and management deficiencies. As a result, two civil penalties and an order were issued. Consequently, experienced project construction and quality
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assurance management were brought in to correct deficiencies and complete i
construction. Under continued close Region I scrutiny in the form of an Augmented Inspection Program, which continued to identify and ensure cor-rection of deficiencies, the new management organization was verified as able to complete the construction of the facility with acceptable quality.
Although it developed and progressed very slowly, and early procedure re-views sometimes indicated an inadequate incorporation of licensing crite-ria, the preoperational, test program was ultimately well executed and results indicated few test exceptions.
In addition, surveillance test procedures have been completed after system turnover and prior to declar-
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ing systems operational in most cases.
At this time the remaining open issue that would prevent reactor opera-tion at Nine Mile Point Unit 2 is the resolution of problems with the
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Prior to initial criticality the deficien-cies associated with the MSIVs must be resolved, and the valves must be satisfactorily tested. On the basis that the license meets such a condi-tion, we believe it is acceptable to issue the low power operating license at this time.
t We therefore conclude that Nine Mile Point Unit 2 has been constructed substantially in accordance with Construction Permit CPPR-112, the FSAR, and NRC requirements. We further conclude that NMPC has taken all neces-sary actions to permit initial license issuance subject to conditions of the license.
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ENCLOSURE 1
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NINE MILE POINT UNIT 2 INSPECTION SUMMARY
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I INSPECTION NUMBER AREAS INSPECTED FINDINGS VIOLATIONS INSPECTION DATE NO. OF INSPECTORS j
72-01 Initial management meeting None None 4/10/72
7/28-8/24/72
73-01 QA Program None None 6/14/73
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9/26-9/27/74
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4/16-4/17/75
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75-02 Excavation progress, engi-2 UNR None
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7/9-7/10/75 neering review / approval
program, review of construc-
I tion procedures 75-03 Environmental protection None None
7/29-8/1/75 program
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Enclosure 1
.a INSPECTION NUMBER AREAS INSPECTED FINDINGS VIOLATIONS INSPECTION DATE NO. OF INSPECTORS 75-04 Site preparation activities 2 UNR None 10/21-10/22/75 and procedure review
76-01 Specification review, review 2 UNR Infraction:
2/24-2/26/75 of audits, material storage, Requisite QA
corrective action controls, requirements review of project manual not in spect-fication.
Infraction:
Specification review not performed in accordance with proce-dures.
Deficiency:
Audit
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findings not properly documented.
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76-02 Blasting records, QA proce-4 UNR None 4/12-4/14/76 dures for concrete and foun-
dations, site preparation, groundwater control 76-03 Site preparation excavation 3 UNR None 5/25-5/27/76 mapping, design review
meetings, porous concrete foundation drainage system, batch plant qualification, concrete mixes l
76-04 Concrete activities, batch None Infraction:
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7/19-7/21/76 plant operation Inadequate
cadweld in-spections 76-05 Environmental protection 1 UNR None
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8/16-8/20/76 activities
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Enclosure 1
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INSPECTION NUMBER AREAS INSPECTED FINDINGS VIOLATIONS INSPECTION DATE NO. OF INSPECTORS 76-06 Foundation backfill opera-3 UNR Infraction:
9/28-9/30/76 tions, site preparation Concrete curing
inspections not performed 76-07 Site preparation and founda-1 UNR Infraction:
11/16-11/18/76 tion records, QC personnel
qualification, batch plant operation 77-01
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Containment base mat concrete, None None
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3/22-3/24/77 geologic investigation on
rock stress 77-02 Containment reinforcing steel 2 UNR None 4/5-4/7/77 cadwelding, QA Manual review
for containment liner contractor 77-03 Containment steel liner in-None None 4/14/77 stallation, geologic investi-
gation review 77-04 Containment structural steel, 2 UNR None 5/2-5/5/77 containment concrete proce-
dures, containment base mat concrete activities, noncon-formance program review 77-05 Containment base mat concrete, 1 IFI None 5/17-5/19/77 containment liner welding
77-06 Containment base mat concrete, 3 UNR None 6/8-6/10/77 containment structural steel I
welding, component storage, reinforcing steel erection 77-07 Containment base mat concrete None None 6/15/77
77-08 Primary containment steel None None 7/18-7/20/77 liner welding, control of weld
material, weld inspection I
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Enclosure 1
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INSPECTION NUMBER AREAS INSPECTED FINDINGS VIOLATIONS INSPECTION DATE NO. OF INSPECTORS 77-09 Environmental protection None Infraction:
8/3-8/5/77 program Settling pond
operation procedures not followed.
77-10 Component storage and main-1 UNR Deficiency:
8/23-8/25/77 tenance, containment basemat Failure to
concrete records perform proper preventive maintenance on recirculation pump motors.
77-11 QA record review for concrete 1 IFI Infraction:
10/11-10/13/77 basemat concrete Failure to
follow procedures for batch plan uniformity tests.
Infraction:
Failure to document and report corrective actions to management relative to I&E Bulletins &
Circulars.
77-12 Installation and welding of 1 UNR None 11/15-11/17/77 containment liner
78-01 Measuring and test equip-None None 1/31-2/2/78 ment nondestructive weld I
examination
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78-02 Reinforcing bar installa-None None 3/28-3/31/78 tion, I&E Bulletins and
Circulars
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Enclosure 1
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INSPECTION NUMBER AREAS INSPECTED FINDINGS VIOLATIONS INSPECTION DATE NO. OF INSPECTORS i
78-03 Piping and supports in-None None j
4/24-4/26/78 sta11ation, penetrations,
geotechnical review 78-04 Equipment storage, sur-None None 5/15-5/18/78 veillances, concrete activities
78-05 Cable tray support records None None 6/14/78
78-06 Mechanical equipment in-1 UNR None 7/25-7/27/78 sta11ation, equipment main-
tenance, I&E Bulletins and Circulars 78-07 Risk release program equip-1 UNR None 9/26-9/28/70 ment installation documentation
78-08 Management controls 2 UNR None 9/25-9/29/78
78-09 Concrete activities, equip-1 UNR None 10/30-11/2/78 ment installation
79-01 Structural steel erection, 2 UNR None 1/8-1/11/79 cadweld operations
i 79-02 Containment liner welding, None Infraction:
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3/20-3/23/79 structural steel erection, Required
stud welding, equipment storage radio-
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graphy exami-
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nation not j
performed.
79-03 Reinforcing bar, concrete 1 UNR None
4/24-4/26/79 activities, backfill operation
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Enclosure 1
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INSPECTION NUMBER AREAS INSPECTED FINDINGS VIOLATIONS INSPECTION DATE NO. OF INSPECTORS 79-04 Containment liner installation, None None 4'
7/10-7/12/79 piping, structural steel erection
l 79-05 Structural steel erection, None Infraction: No 5/14-5/17/79 containment liner installa-procedure for
tion ultrasonic examination.
79-06 Concrete activities, rein-1 UNR None 8/27-8/31/79 forcing bar storage, elec-1 IFI
trical installation i
79-07 Suppression pool downcomers, 4 UNR None 10/9-10/12/79 electrical activities 1 IFI
79-08 Reactor pressure vessel None None 11/6-11/8/79 transport / rigging / lifting
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79-09 Containment liner welding, 1 UNR None 11/28-11/30/79 equipment rigging, valve
installation
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80-01 Equipment maintenance and 1 UNR Infraction:
1/9-11/11/80 storage Invalid j
preventive
maintenance records.
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80-02 Reactor pressure vessel None None 3/19-3/21/80 storage, biological shield i
& 4/10-4/11/80 wall installation
80-03 Plant tours None None 4/24/80
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80-04 Repair of biological shield 2 UNR None
5/12-5/15/80 wall welds
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INSPECTION NUMBER AREAS INSPECTED FINDINGS VIOLATIONS INSPECTION DATE NO. OF INSPECTORS 80-05 Containment reinforcing bar 2 UNR None
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6/17-6/19/80 cadweld operations l
80-06 Reactor pressure vessel None None 7/14-7/18/80 storage'and placement
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80-07 QA procedure review, review 1 UNR None
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7/15-7/18/80 of engineering design changes,
2 nonconformance report disposition, trend analysis, audit program 80-08 Reactor pressure vessel placement None None 8/4-8/8/80
80-09 QC record review, reactor 1 UNR None 9/9-9/11/80 pressure vessel storage,
CRD hydraulic control unit
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storage i
80-10 QA program review None None 9/23-9/26/80
80-11 Concrete record documenta-None Infraction:
j 10/21-10/23/80 tion review Inadequate
& 11/4-11/6/80 document i
i control of engineering
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changes, i
j 81-01 Concrete placement, rein-1 UNR None i
1/20-1/23/81 forcing bar cadwelds, engi-I neering change document review
i 81-02 Environmental protection None None 2/18-2/25/81 program
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81-03 Plant tour, cadweld None None 4/21-4/23/81 operations
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Enclosure 1
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INSPECTION NUMBER AREAS INSPECTED FINDINGS VIOLATIONS INSPECTION DATE
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NO. OF INSPECTORS 81-04 SALP management meeting None None 4/22/81
81-05 Primary containment liner, 3 UNR None 6/23-6/25/81 equipment storage, house-I keeping 81-06 I&E Bulletin and Circular None None 7/14-7/16/81 review
81-07 Electrical procedure review, 1 UNR Violation:
7/27-7/31/81 installed raceway, geologic Pump motor
fault study review, primary electrical containment concrete test data not submitted to engineer-
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ing.
81-08 QA program personnel None None 8/4-8/6/81 certifications, licensee
audits 81-09 Primary containment record 1 UNR None 8/18-8/21/81 review, biological shield
wall welding, weld filler metal control, pipe welding 81-10 Plant tour, concrete aggre-1 UNR None l
9/1-9/3/81 gates, corrective action
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programs
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81-11 Plant tour, review of QA None None 9/29-9/30/81 organization
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81-12 Containment penetrations, 1 UNR Violation:
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10/13-11/13/81 piping and structural steel 1 IFI Incorrect
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erection date sheet.
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Violation:
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Inadequate
corrective actions.
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Enclosure 1 l
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INSPECTION NUMBER AREAS INSPECTED FINDINGS VIOLATIONS INSPECTION DATE
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NO. OF INSPECTORS j
81-13 Region I CAT inspection, 1 UNR Violation:
11/30-12/18/81 welding, nondestructive Ineffective QA
examination, electrical, program.
structural, procurement Violation:
l Lack of design control.
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Violation:
Inadequate equipment
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qualifica-tion.
81-14 Structural steel erection, 1 UNR Violation:
12/21/81-1/15/82 piping activities, welder 1 IFI failure to qualification implement
checklists.
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82-01 Pipe whip restraints, 3 UNR Violation:
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1/18-2/26/82 structural steel, welder Inadequate QC
qualification, nondestruc-personnel tive examination, piping, training, procurement Violation:
Failure to follow l
instruc-tions.
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82-02 Pipe supports, RPV nozzle 3 UNR Violation:
3/1-3/26/82 modifications, structural failure to
steel, receipt inspection, record data
nondestructive examinations, properly.
piping
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82-03 Structural steel, cadwelding, 4 UNR Violation:
'l 3/29-4/30/82 expansion anchors, piping, 4 IFI Failure to
equipment, design control correctly translate design informa-
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tion.
Violation:
Failure to impose QA requirement
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on purchase
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orders.
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Enclosure 1 6 -
INSPECTION NUMBER AREAS INSPECTED FINDINGS VIOLATIONS j
INSPECTION DATE
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NO. OF INSPECTORS i
82-04 Electrical components 3 UNR None 5/11-5/13/82
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82-05 Piping, HVAC installation, 1 IFI None
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5/10-6/3/82 structural steel
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82-06 Enforcement conference on None None 6/1/82 ITT Class I weld procedure
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82-07 Piping, rigging, mechanical 1 UNR Violation:
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6/21-7/23/82 equipment storage, structural 4 IFI Inadequate
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I steel control of j
rigging
operations.
l Violation:
l Failure to
identify a
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nonconforming
condition
l 82-08 Meeting on ITT welding None Violation:
7/16/82 procedures Failure to
control weld-
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ing processes.
82-09 Management controls 1 UNR None l
7/13-7/16/82 &
7/20/82
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82-10 Concrete testing, concrete 2 UNR Violation:
7/26-8/27/82 expansion anchors, piping, Underlength i
reactor head cavity, pit, welds on
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review of engineering design cable tray changes braces.
i Violation:
j Aggregate i
material not
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properly tested.
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_
. _ _ _ _
-.
.
.
.
...
..
.
__
. _ _
__.-
__
__
_
--
.. _ _
. _ _ _
_.
_
__
.-
_
1
,.
Enclosure 1
..
.
!
INSPECTION NUMBER AREAS INSPECTED FINDINGS VIOLATIONS INSPECTION DATE NO. OF INSPECTORS
'
82-10(Cont)
Violation:
'
Inadeqate inspection of concrete
,
expansion j
anchors.
j 82-11 Mechanical equipment erection, 4 UNR Violation:
8/30-9/30/82 piping diesel generator build-2 IFI work per-
2 ing, weld rod control, welder formed with-qualification, pipe supports, out planner
'
raceway package.
Violation:
Weld filler material
!
not properly
'
stored.
i 82-12 Small bore piping, instrumen-2 UNR Violation:
j 10/12-11/12/82 tation, structural steel, re-2 IFI ASME piping I
circulation pipe welds, non-planner
'
conformance reports package not properly j
reviewed.
!
82-13 Enforcement conference re-None None i
10/20/82 garding use of trainees to j
conduct inspection
!
82-14 High strength bolting, elec-1 UNR Violation:
'
11/15-12/22/82 trical support welds, struc-2 IFI high
!
tural steel welding qualift-strength j
cations, measuring and test bolts not
equipment inspected
.
per AISC.
l Violation:
l Weld
!
material requisition
!
improperly i
filled out.
Violation:
Improper concrete i
anchor bolt i
installa-tions.
i l
i
-
- - -.
.. - - -
- -.-
.-- --,-_---_- -,,.
.-
..
Enclosure 1 INSPECTION NUMBER AREAS INSPECTED FINDINGS VIOLATIONS INSPECTION DATE NO. OF INSPECTORS 82-15 Bioshield wall fill material None None 12/13-12/17/82 placement, reactor building I
concrete activities 82-16 Equipment storage, raceway 2 UNR None 12/14-12/16/82 installation
83-01 Instrumentation, pipe whip 4 UNR Violation:
1/3-2/4/83 restraints, engineering 7 IFI procedures
change documents, pipe not available supports, piping, cables to welders.
83-02 Safety related equipment, 3 UNR Violation:
2/7-3/11/83 concrete installation, cables, 2 IFI Planner
structural welding, piping package adhered to
'
for pipe
-
installation activities.
83-03 Electrical equipment storage 5 UNR None 3/1-3/3/83 raceway installation
83-04 Piping, licensee surveillances 2 UNR None 3/14-4/15/83 and audits, instrumentation 1 IFI
supports, structural steel, HVAC duct 83-05 Recirculation piping, con-1 UNR Violation:
4/25-5/27/83 tainment liner, procurement, 4 IFI Inadequate
corrective action, instru-trend mentation supports, piping analysis, and pipe supports Violation:
Underlength fillet welds.
83-06 OA record review, design veri-2 UNR Violation:
5/16-6/1/83 fication procedures, as-Inconsistent
built plant verification FSAR diesel generator load sequen-cin..
..
Enclosure 1
.
INSPECTION NUMBER AREAS INSPECTED FINDINGS VIOLATIONS INSPECTION DATE NO. OF INSPECTORS 83-07 Pipe supports, piping, struc-3 UNR None 6/13-6/17/83 &
tural steel, weld filler 3 IFI 7/13-8/5/83 material control, cable and I
equipment installation 83-08 Switchgear installation and 3 UNR Violation:
6/7-6/9/83 instrumentation Deficient I
vendor wiring on electrical equipment.
83-09 Management meeting regarding None None 5/23/83 licensee overview of contrac-
tor performance 83-10 Corrective action programs, 2 UNR None 7/25-7/29/83 piping and plant housekeeping 1 IFI
83-11 Cables, raceway, motor con-1 UNR None 8/2-8/4/83 trol centers, electrical QA 1 IFI
records 83-12 Preventive maintenance, pipe 5 UNR Violation:
8/8-9/21/83 supports, cables, concrete 5 IFI Installed
placement, recirculation cable not piping nozzle modification properly inspected.
Deviation:
Inspection holdpoints not specified in QC inspec-tion plans.
83-13 Environmental protection None None 9/14/83 program
83-14 Enforcement conference on None None 8/30/83 licensee overview and
investigations of the piping contractor
. _ - -.
._
_
_ _ _ -. _
__
._
.
___
_
._
_. _ _
_
.
.
.-
i
Enclosure 1
..
,
INSPECTION NUMBER AREAS INSPECTED FINDINGS VIOLATIONS
- - -
l INSPECTION DATE NO. OF INSPECTORS l
83-15 Electrical cables, motor 1 UNR None
10/18-10/20/83 control centers and QA
records 83-16 Equipment turnover, piping, 6 UNR Violation:
10/1-12/2/83/84 pipe supports, reactor build-2 IFI Nonconforming
ing enclosure, CRD piping, welds accepted fire protection, instrumenta-by quality tion QA program control.
83-17 RPV storage, hydraulic con-4 UNR None 12/5/83-1/20/84 trol unit installation, 5 IFI
piping, pipe supports, welder qualification, HVAC systems l
83-18 I&E CAT Inspection 91 IFI Violation:
11/7-11/19/83 Inadequate
-
& 11/28-12/9/83 review of
design change documents, inadequate review of radiography film, defic-
,
l ient inspection l
procedures, I
nonconforming i
pipe supports, electrical separation violations, inadequate inspection documentation, inadequate weld filler metal control, Deficient NDE weld ' surface exams, non-conforming conditions not identified on NCRs.
,_.. - - -.--
.. _ -. - -,.. - - -.... _ -..
. _ _, -
- - -. -. _, -
- _ - - _ -, - _ -,
.
- - _
=_
-_
,. -
-
-_
..
..-
15 Enclosure 1
.
INSPECTION NUMBER AREAS INSPECTED FINDINGS VIOLATIONS I
INSPECTION DATE NO. OF INSPECTORS i
84-01 Pipe supports, diesel gen-4 UNR Violation:
i 1/23-3/2/84 erator cranes, reactor 1 IFI Nonconforming
vessel internals, QA program pipe supports.
Violation:
Failure
.i to follow
'
procedure for handling of significant deficiency.
84-02 Cables, switchgear and QA 5 UNR Violation:
2/7-2/9/84 records Wrong non-I conformance
form in use.
84-03 Management meeting on None None 2/22/84 licensee corrective actions I
for CAT findings 84-04 Concrete anchor bolts and None None 3/12-3/16/84 and structural steel
welding l
84-05 Electrical terminations, 3 UNR Violation:
3/5-4/7/84 piping, pipe supports, QA 1 IFI Inadequate i
surveillances, contractor design control j
audits, design control for Seismic
II/I items.
,
84-06 Structural steel, weld 2 UNR Violation:
l 4/9-5/11/84 material control, pipe 2 IFI Weld filler i
supports, housekeeping, not control-post inspection rework led.
control Violation:
-
Rework to
structural
beams not
controlled.
Violation:
i Inadequate l
inspection of bolting
,
'
and pipe
supports.
.
l
,
t
,
!
--,_-[..______..
._.
. _ _..
..,
. _ _.... _. _ _,. _ _. _ _ _ _. _.. _. _.. ~ _ _ _ _ _ _. _ _.. _. _. _., -..... _,
..
l
..
Enclosure 1 INSPECTION NUMBER AREAS INSPECTED FINDINGS VIOLATIONS INSPECTION DATE NO. OF INSPECTORS 84-06 (Cont.)
Violation:
Lack of inspection status for structural steel.
'
Violation:
Inadequate plant house-keeping.
84-07 Large and Small bore pipe None None 5/14-5/18/84 supports
84-08 NDE van inspection of ASME 3 UNR Violation:
4/30-5/25/83 and structural weldments by film indica-
independent examination tion evaluated /
documented.
Violation:
,
Inadequate review of t
RT film.
Violation:
Minimum wall violation.
,
84-09 Corrective action programs, 1 UNR Violation:
5/14-6/15/84 electrical penetrations, pipe 4 IFI trends not
whip restraints, component detected by
,
supports analysis.
Violation:
Penetration NDE not per-formed.
i 84-10 Pre-operational security 25 IFI None 5/21-5/24/84 inspection
,
F am ~ 's-m
- ~s - rs w w w wg m -e-m-w e
,-www-wn-,------wwo-,--ws-o n--w-~---*
.. - _.
-
.-- =.
.
-. -
.
'
..
.-
Enclosure 1 i
.
INSPECTION NUMBER AREAS INSPECTED FINDINGS VIOLATIONS
!
INSPECTION DATE NO. OF INSPECTORS 84-11 Document control, contain-5 UNR Violation:
6/18-7/27/74 ment supports, design change 2 IFI Hold points
control, plant stack, battery violated i
instsllation, equipment pre-during pipe
ventive maintenance whip restraint
-
installation.
Violation:
<
q Inadequate review of design change documents.
I 84-12 Cancelled 84-13 Design change control, re-4 UNR Violation:
.
'
7/30-9/6/84 vetment ditch, pre-op per-Inadequate
sonnel qualifications, hydro-thread
tests, preventive maintenance, engagement
,
standy liquid control system, of strainer weld filler metal control top bolts.
Violation:
Field issued weld filler
metal not controlled.
,
84-14 Welder qualifications, weld-4 UNR None 8/20-8/24/84 ing, welding records
1 l
84-15 Electrical cable separation, 6 UNR None
'
9/10-11/2/84 containment penetrations, 3 IFI
diesel generator modifica-tion:
!
84-16 Radiological control None None 10/29-11/2/84 staffing
i
'
84-17 Safety related equipment in-1 UNR None l
10/29-11/2/84 stallation, inspection of
1 equipment, preventive j
maintenance
8 i
s
.-
-, - _ _.. _ _ _ - - - _ _.
__ _ --
_. - _..... -. - _
-
-
-
- - -
. - -.-
_
__
_ - _ _
_. _ _ _ _ - _ _ _ _
_.. _ _ _
_ _. -. _
_ _ _ _ _ _ _. - _ - _ - _ _. _.
.-
..
Enclosure 1
<
..
!
l i
INSPECTION NUMBER AREAS INSPECTED FINDINGS VIOLATIONS
!
INSPECTION DATE
!
NO. OF INSPECTORS f
!
84-18 Region I CTI, QA, project 2 UNR Violation:
12/3-12/14/84 mar..gement, mechanical, elec-5 IFI Failure to
!
trical, instrumentation, execute design control & welding adequate PM
,
program.
.
Violation:
Undersized weldments on instrument support stand.
84-19 MSIV cladding, instrument 2 IFI Violation:
,
'
11/5-12/21/84 tubing, small bore supports, to perform
',
i
concrete expansion anchors adequate QC inspections on supports.
Violation:
Lack of l
effective
corrective action j
implementa-
!
tion.
!
84-20 Management meeting to None None 11/14/84 discuss CAT corrective
'
j actions
a 84-21 Concrete expansion anchors, 3 UNR Violation:
12/24/84-1/1/85 design control, HVAC supports 3 IFI Inadequate
!
PSI, QA corrective action HVAC support l
systems inspection.
j Violation:
}
Failure j
commitments
to site design docu-
ments, i
.
!
!
i
!
'
I
i
-...- - - - -,._..
.
. - - -. - _ - - - - -, _. -, -
- - -, -, - _ - - -. - -. - _.
_ _._ _
_..
_
_
_
_ _ _..
_ _..
- _ _ - - _.
___ _.-__ -_
J t
.*
..
Enclosure 1 l
INSPECTION NUMBER AREAS INSPECTED FINDINGS VIOLATIONS
,
INSPECTION DATE
'
NO. OF INSPECTORS
,
.
j 85-01 Preoperational test program None None 1/15-1/18/85 and procedure review
85-02 Review of Johnson Controls None None 1/28-2/1/85 and Reactor Controls welder
qualification and welding operations.
85-03 Instrumentation, electrical, 2 UNR Violation:
i 2/11-2/15/85 HVAC, and preventive main-Inadequate
,
3 tenance HVAC baseplate installation.
Violation:
.
Inadequate
]
PM for
inplant elec-trical items.
.
85-04 FSAR verification, electrical None None 2/4-3/18/85 equipment wiring, ACRS
,
hearing participation
'
85-05 Management meeting to None None 2/6/85 discuss CAT enforcement corrective actions,
i
85-06 QA/QC for system turnover 4 UNR None i
3/4-3/8/85 control, pipe supports, CR0
!
piping
!
j 85-07 Cancelled I
85-08 Electrical equipment install-None None i
3/18-3/22/85 ation, electrical QC records, j
instrumentation components i
i 85-09 Management meeting to discuss None None
2/27 & 3/16/85 conduct of Engineering Assur-
!
ance audit and as-built veri-fication of RCIC system
,
!
l i
i l
i a
-
-
-. _ _ _ _. _.
. -. -. -. --
-.
... - - -
- _
_. -.
-.
_
- - -...
-- -.
.
\\
.-
'
.
Enclosure 1 j
.
INSPECTION NUMBER AREAS INSPECTED FINDINGS VIOLATIONS
'
INSPECTION DATE NO. OF INSPECTORS
,
85-10 Reactor coolant system hydro 2 UNR Violation:
3/19-4/26/85 test, spent fuel racks, nitro-Improper
gen inerting system, allega-concrete l
tions, QPMP expansion bolt instal-lation, i
85-11 Reactor coolant system hydro 1 UNR None 4/2-4/4/85 &
test
4/9-4/12/85
85-12 Cable pull tension calcula-None None
]
5/6-5/10/85 tions and open items t
!
I
'
85-13 EA audit, QPMP, diesel ex-4 UNR None
>
)
4/29-6/7/85 haust system, CR0 hydrotest, 2 IFI
3 instrument tubing and supports,
'
,
i MSIV testing, pipe supports, allegations, SU-QA records,
,
battery preoperational test s
l procedure, CRD installation 85-14 Review of EA audit plan numerous None 4/22-4/23/85 comments
85-15 Operator licensing exams None None 6/11-6/19/85
,
l
'
t'
85-16 Preservice inspection None None 5/28-5/31/85 activities
85-17 Open Items review None None i
6/10-6/14/85 j
i
!
85-18 Review of EA program plan
None j
5/21-5/24/85 implementation items
!
\\
j 85-19 RPV internals, flood control 2 UNR None j
6/10-7/19/85 berm, QA activities, 3 IFI
!
QPMP, preliminary testing I
!
'
,.,-~--.n__nn-n-
_
. - -.
- ~ ~<---- - ~ ~ -~~- - - - - --
~~'
.-
..
Enclosure 1 INSPECTION NUMBER AREAS INSPECTED FINDINGS VIOLATIONS INSPECTION DATE NO. OF INSPECTORS
'
85-20 Preoperational radiological 1 UNR None 6/24-6/28/85 controls, preop testing rad-8 IFI
waste systems, HVAC material control 85-21 Management meeting to discuss None None 6/17/85 licensee reinspection of
large bore pipe supports 85-22 Cancelled 85-23 Preservice inspection program 1 IFI None 7/16-7/19/85 and examination data
85-24 HVAC duct supports and open None None 7/22-7/26/85 item review
-
85-25 Piping and supports, hydro-2 UNR None 7/22-8/30/85 static testing, diesel gen-2 IFI
erator testing, RPV internals QPMP 85-26 Management meeting to discuss None None 7/23/85 licensee hardware verifica-tion, FSAR verification, and electrical separation 85-27 QPMP, local leak rate testing 1 UNR None 9/9-10/18/85 ing, pipe welds, HPCS walk-down, 2 IFI
PM program, preoperational procedures, QA Audits.
85-28 Review of EA audit results 23 OI's None 8/12-8/16/85 and corrective actions 85-29 ASME C1.1 weld impact test 1 UNR None 9/30-10/4/85 data, bioshield wall weld-
ments, pre-and postweld heat treatment, welder quali-fication, QC records
.-
Enclosure 1
.
INSPECTION NUMBER AREAS INSPECTED FINDINGS VIOLATIONS INSPECTION DATE NO. OF INSPECTORS 85-30 Preoperational test program 1 UNR None 9/9-9/13/85 implementation, QA/QC inter-
face with test program 85-31 Review of licensee large 1 UNR None 10/7-10/11/85 bore pipe support verification,
as-built pipe stress reconciliation program 85-32 Rad Controls program, fuel 9 IFI None 10/14-10/18/85 receipt planning, preopera-
tional testing of radwaste systems, HVAC, shield survey program
!
85-33 Review of RPV hydrotest None None 10/21-10/25/85 results and open item review
-
85-34 Fire protection review, safe 7 UNR None 10/21-10/25/85 shutdown capability, emergency
lighting system
,
85-35 Electrical equipment install-None None 10/28-11/1/85 ation
85-36 Allegation, QPMP, preopera-None Violation:
10/21-11/26/85 tional testing, preliminary Undersized
testing, electrical equipment, bolting walkdown hardware in
preoperational preparedness, i
RCIC mote shutdown panel 85-37 Training program review for 1 IFI None 10/28-11/1/85 licensed operators and tech-
nical training for mechanics, electricians, and I&C technicians.
l
- - - - -... - - - -, _ -. _...
.__.,,
,. -.
, _ _..,. -
_ _ _
_ _ _ -.. _ - - - -. _ _ _ -
, - - _ _ - _ _ - - -
._
_
_
-.
.-
,,
Enclosure 1
..
INSPECTION NUMBER AREAS INSPECTED FINDINGS VIOLATIONS INSPECTION DATE NO. OF INSPECTORS 85-38 Security plan implementation None None 10/28-11/1/85 for fuel receipt, preopera-
tional security program 85-39 Cancelled 85-40 Nuclear material control None None
11/25-11/27/85 and accounting, shipping i
receiving, materials control
'
system 85-42 Neutron monitoring system 1 UNR Violation:
11/12-11/15/85 installation Coaxial cable
installed w/o procedure.
Violation:
Minimum cable bend radius violated.
,
,
85-43 NDE van inspection of ASME None None 12/9-12/19/85 piping weldments
l 85-44 Allegation followup, fuel 1 IFI None 12/2/85-1/10/86 receipt, preoperational
testing, information notices.
85-45 Fire protection program 1 UNR None 12/9-12/10/85 for fuel receipt
85-46 Preservice inspection 1 UNR None 12/9-12/12/85 activities
85-47 Radiological controls 3 IFI None 12/16-12/20/85 program, fuel receipt, pre-
operational testing 86-01 IEB's, allegations, refuel-2 UNR Violation:
1/13-2/21/86 ing floor contamination, pre-Inadequate
operational testing, pre-preopera-operational service inspection tional test i
CRD removal rework control, procedure acceptance criteria.
. - - - -. -,
.
..
,. _, -. -.. _ - - -
_.. - - _ _ _. - -. _, -. - - _, -. -,.
.
e=
j,
Enclosure 1 INSPECTION NUMBER AREAS INSPECTED FINDINGS VIOLATIONS IASPECTION DATE N0. OF INSPECTORS 86-02 Tech Spec review 4 IFI None 1/6-1/17/86
86-03 Preop test procedures &
1 UNR None 1/21-1/24/86 test conduct
86-04 Impl= mentation of Q1P None None
1/27-1/31/86
86-05 Preop test, interim surveillance None None 3/3-3/7/86 preliminary test procedure review
86-06 Management meeting:
None None 1/22/86 Construction completion, preoperational test status
'
and operational readiness.
86-07 Inspection of Engineering None None 1/3 and 1/7/86 Assurance audit results and corrective actions 86-08 Instrumentation components 1 UNR Violation:
3/3-3/7/86 and cables Unaccept-able Cable separation.
Violation:
Use of uncontrolled drawing.
Violation:
Damage to instrument tubing.
Violation:
EQ cable connector integrity lacking.
.
. _ - _ _
e=
Enclosure 1
..
INSPECTION NUMBER AREAS INSPECTED FINDINGS VIOLATIONS INSPECTION DATE NO. OF INSPECTORS 86-09 Structural integrity test, 45 IFI Violation:
2/22-4/18/86 raceway installation, pre-1 UNR Improper
operational test procedure, design preoperational test witness control for and TMI action plan items.
class IE cable routing.
86-11 Readiness implementation of 2 UNR None 3/31-4/4/86 operational QA program,
Audits, QA/QC surveillances, M&TE, nonlicensed training, safety review committee.
86-12 Radiological controls, 1 IFI None 3/24-3/28/86 training, exposure control,
ALARA, control of contaminated material.
l l
86-14 Preoperational test program None None 3/31-4/4/86 procedure review and test I
witnessing.
86-15 Preoperational testing, None None 4/7-4/11 and operational readiness, 4/21-4/25/86 administrative procedures,
operations procedures, design changes, and modifications.
86-16 Integrated Leak Rate Test 1 UNR None 4/7-4/15/86 (ILRT) and Structural
Integrity Test (SIT).
86-17 Radiochemistry, liquid and 3 IFI None 4/28-5/1/86 gaseous radwaste, effluent
radiation monitors, procedures, training and qualification.
86-18 TMI action plan items, 4 IFI None i
4/19-5/31/86 generic letters, preopera-
tional test procedures, pre-operational test witness, and preoperational test results.
.
__
_ _ _ _. _ _ _ _ _. _ _ _ _ _ _ _ _ _
_. _
-
.
+
,.
Enclosure 1
..
INSPECTION NUMBER AREAS INSPECTED FINDINGS VIOLATIONS
INSPECTION DATE
.
NO. OF INSPECTORS a
86-19 Radiological controls inspec-None None 5/19-23/86 tion covering the Preop Test
program and licensee action on previous findings.
86-20 Preoperational test proce-1 UNR None 5/5-5/9/86 dures, test witnessing, test
results review, power ascension test program and QA/
QC interfaces.
86-21 Fire protection / prevention None None 5/12-5/15/86 program readiness, admini-
strative controls, training, QA audits.
86-22 Procurement, receipt, storage 1 UNR None 4/30-5/9/86
& handling document, records
management programs, and licensee actions on previous
,
inspection findings.
86-23 Emergency preparedness 13 IFI None 5/19-22/86 implementation appraisal,
including organization, admini-stration procedures, training,
'
s.
facilities, and equipment.
86-24 Status of security program None None a
t
'
5/12-16/86w testing and maintenance,
physical barriers, security system power supply, lighting, licensee action on NRC in
'
circulars, bulletins and inspection follow-ups.
86-26 TMI action plan items, main-None None 5/20-23/86 tenance organization, main-
tenance staffing, proper QA/
QC interfaces, and emergency
'
operating procedures.
-
.
2
>
86-27 Preoperational test program, 1 UNR None
>
5/19-5/23/86 test witnessing, test
I results evaluation.
,
y- - -
e,
.r
- - -
---.m.4
,
,
-.
-
-
. -,
. - -
,~..., -.. - -
-,-
.-
_.
.
_
_
-.
-r
!
Enclosure 1 INSPECTION NUMBER AREAS INSPECTED FINDINGS VIOLATIONS INSPECTION DATE NO. OF INSPECTORS 86-28 Inspection of licensee None None 5/27-6/13/86 action or construction
deficiencies, IE Bulletins and Outstanding Items
'
86-29 TMI action plan items, IE 5 IFI None 6/1-7/6/86 Bulletins u irculars, NRR
open items, QIP follow-up, preop test procedure review, test witnessing, and test result review.
86-30 Preop testing None None 6/2-6/6/86
86-31 Preop test program, prelim.
None None 6/16-6/27/86 test witnessing,-test review,
QA/QC interface with preop test program.
86-32 Preservice inspection None None 6/23-25/86 program, review of
installation procedure, and QC inspection of
,
l bolted piping joints 86-33 Preop testing None None 6/30-7/11/86
,
'
86-34 Operator licensing None None 7/21-9/21/86 l
l 86-35 Radiochemistry, liquid 1 IFI None
,
7/7-11/86 radwaste, and gaseous
!
radwaste l
86-36 Operational readiness of 1 UNR None 7/7-11/86 of instrumentation and I
control maintenance program 86-37 Previous findings, instru-None None 7/14-8/15/86 mentation, electrical,
equipment qualification I
!
l
.
r
Enclosure 1 g.
.,
INSPECTION NUMBER AREAS INSPECTED FINDINGS VIOLATIONS INSPECTION DATE NO. OF INSPECTORS 86-38 Preop testing results &
2 IFI None 7/14-24/86 startup program
86-39 Resident Inspector None None 7/7-8/31/86
86-40 Physical security &
None None 7/28-8/2/86 safeguards
86-41 Startup program; surveillance None None 7/29-8/1/86 testing, ILRT
l 86-42 Resident Inspector None None t
9/1-9/30/86
86-43 IE Bulletins & previous None None 7/28-8/1/86 findings
86-44 EP appraisal followup None None 8/4-6/86
86-45 Environmental monitoring None None 7/21-25/86 program
86-47 Tech. Spec. surveillance 8/4-8/8/86 program
i i
,
-
-
,
-..
.. -
.
... -.,
.
._-
--
.
-
o'
..
ENCLOSURE 2 QUALITY ASSURANCE /0UALITY CONTROL SUMMARY A.
Much of the information presented within this enclosure was compiled by the applicant's Quality Assurance (QA) organization.
The data were extracted from NMPC QA report " Quality of Construction Report" dated March 10, 1986.
The information has not been verified for accuracy by Region I.
B.
A multi-tier quality program has been implemented during the construction phase at Nine Mile Unit 2.
First line Quality Control (QC) inspection responsibilities have been performed by Stone and Webster Engineering Corporation (SWEC), ITT-Grinnell Inc. (ITT), Johnson Controls, Inc. (JCI)
and Reactor Controls, Inc. (RCI).
Each of those contractors also had an affiliated QA organization that performed audit, surveillance, and other QA functions.
SWEC site QA has performed surveillance of the sub-contractor efforts.
SWEC QA audits have been performed by the Boston QA Auditing Department. The applicant has maintained a site QA organization that has performed both surveillances and audits of all contractors.
NMPC Audits and Surveillances NMPC has conducted over 180 audits and 8,800 surveillances of SWEC, GE, and the other site sub-contractors. A summary of the NMPC audits and surveillances is shown in the following tabulation:
AUDITS TOTAL YEAR OFF-SITE ON-SITE SURVEILLANCES FINDINGS 1972
0
20 1973
0
39 1974
0
20 1975
1
25 1976
3 302
1977
4 800
1978
4 673
1979
2 569
1980
5 359
1981
4 742
1982
9 822
1983
4 1959
1984
9 1570 263 1985
37 981 124 Totals 101
8851 939 As a result of the findings identified during the conduct of audits and surveillances, NMPC QA has exercised the authority to issue Stop Work Orders on nine occasions to cease work activities to prevent degradation of the conduct of safety-related activitie __
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. _ _ _ _.
.e
Enclosure 2 SWEC Audits
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l l
SWEC has conducted audits of component suppliers, engineering activities,
)
QA programs, construction activities and subcontractor activities.
SWEC Quality Assurance Auditing Division (QAAD) has performed site, subcontractor, ASME and supplemental audits as summarized by the following:
No. of Audits Total Year Program Site Contractor ASME Supplement Findings
1975
1
1976
4 112 1977
4
112 1978
4
1 111 1979
4
1 120 1980
4
49 1981
4
66 1982
4
112 1983
4
4
1984
4
6
1985
4
-
77 Totals 11
53
10 983 Ten Stop Work Orders have been issued as a result of the deficiencies identified by the QAAD audits.
SWEC Procurement Quality Assurance Division (PQAD) has performed supplier audits as summarized below:
SUPPLIER TOTAL YEAR AUDITS FINDINGS 1974
3 1975
0 1976
19 1977
106 1978
289 1979
241
,
1980
195 g
1981
229 g
,
1982
392
-
,
1983
280 1984
190 1985
101 Total 337 2045
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s f
Enclosure 2 SWEC Engineering Assurance (EA) has performed audits and surveillances to ensure
!
that the design control process has been adequately implemented.
The EA activities are summarized below:
NUMBER NUMBER YEAR OF AUDITS OF SURVEILLANCES
,
1972
1973
1974
!
1975
1976
1977
1978
1979
1980
1981
2 1982
1 1983
11 1984
19 1985
8 Total
41 ITT Audits ITT was the major piping subcontractor responsible for fabrication and installation of large bore and small bore piping and supports.
ITT performed audits of site and vendor activities as summarized:
SITE VENDOR AUDIT YEAR AUDITS AUDITS FINDINGS 1977
0 1978
2 1979
18 1980
0 1981
1 1982
2
1983
2
1984
2
1985
4
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Total
10
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Enclosure 2
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ITT issued eight Stop Work Orders as a result of deficiencies identified regarding the piping activities.
JCI Audits JCI was the subcontractor responsible for the installation of instrument tubing, supports and instruments. JCI performed the following audits:
SITE CORP.
AUDIT YEAR AUDITS AUDITS FINDINGS 1983
2
1984
6
1985
3
TOTAL
11
JCI issued six Stop Work Orders to halt specific activities until necessary corrective actions were implemented.
RCI Audits RCI was the subcontractor responsible for the design and installation of the CRD system and installation of reactor internals and recirculating water system piping.
RCI performed the following audits:
SITE ENGR.
AUDIT YEAR AUDITS AUDITS FINDINGS 1981
1
1982
1
1983
1
1984
1
1985
1
TOTAL
5
Seven Stop Work Orders have been issued by RCI.
QC Inspections QC inspections have been performed by SWEC, ITT, JCI and RCI.
The inspections were performed to inspection plans or checklists to verify conformance of hardware or acceptability of software.
The SWEC inspections are summarized below:
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_
_-
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__ -_
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se
g.
Enclosure 2 RACEWAY ASME PROCUREMENT YEAR STRUCT REC ELEC MECH PGCC HANGERS S/B INSTR QA 1975 321
0
1976 3391 912
120 151 1977 2937 2739 860 862 754 1978 5728 2535 985 1191 1379 1979 8213 2770 1840 -1618 1589 1980 2500 1052 194 786 965 1981 6188 1864 2324 903 1102 1982 11041 2801 5984 1471 1691 1983 10581 4067 3883 2602 2635 7584 180 2000 1984 5694 4462 7123 4495 3792 9904 3038 1906 1985 3293 4017 14577 3636 4180 8760 5097 315 1005 TOTAL 59887 27219 37857 17684 10607 26248 8315 315 12542 Total Procurement QA Inspection Reports thru 1985 = 12,542 Total Field QC Inspection Reports thru 1985
= 188,167 The subcontractor QC organizations have generated the following Inspection Reports (irs) through 1985:
-
ITT - 74,106 irs JCI - 17,938 irs RCI 2,985 irs
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NONDESTRUCTIVE EXAMINATIONS (NDE)
Nondestructive examinations have been performed to verify through surface and volumetric examination that components and welds are in compliance with design requirements. SWEC has generated the following NDE reports:
RADIO-ULTRA-MAG LIQUID BUBBLE WELDER YEAR GRAPHY SONIC PARTICLE PENETRANT TEST QUALS.
1976
1977
1978
1979 197 127 191 1980
1981 x
161
,
!
1982 2925 317
231 1983
39 1137 860
734 1984
1161 3698 126 1529
1985 132
1372 4876 196 524 TOTAL 344 289 6756 9823 396 3309
- 6301 inches x 1676 inches
_ _.
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_
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F o
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Enclosure 2 Initial Acceptance Rate, Volumetric Examination 83%
Initial Acceptance Rate, Surface Examination 97.5%
ITT has generated the following inspection reports:
YEAR LIQUID PENETRANT / MAG. PARTICLE RADIOGRAPHY 1982 1729(1)
774 1983 2867 633 1984 7590 1163 1985 11819 1832 TOTAL 24005 4402 Initial Acceptance Rate, Volumetric Examination 72%
Initial Acceptance Rate, Surface Examination 95%
NOTE 1: LP/MT exam totals for 1982 for first nine months only.
NOTE 2: SWEC QA/NDT, Boston conducted a complete review of 4,189 ITT Grinnell radiograph packages prior to 11/25/84. A total of 775 weld radiograph packages required some form of corrective action, which has been accomplished.
,