IR 05000461/1982012
| ML20062J620 | |
| Person / Time | |
|---|---|
| Site: | Clinton  |
| Issue date: | 07/26/1982 |
| From: | James Keppler, Knop R, Spessard R, Walker R NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| To: | |
| Shared Package | |
| ML20062J588 | List: |
| References | |
| 50-461-82-12, NUDOCS 8208160419 | |
| Download: ML20062J620 (44) | |
Text
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. U.S. NUCLEAR REGULATORY COMMISSION
REGION III
Report-No. 50-461/82-12 (DPRP) Docket No. 50-461 License No. CPPR-137 Licensee: Illinois Power Company 500 South 27th Street Decatur, IL 62525 Facility Name: Clinton Power Station, Unit 1 Meeting At: U. S. Nuclear Regulatory Commission Region III Office 799 Roosevelt Road Glen Ellyn, IL 60137 Meeting Conducted: July 12
__ l } . W Meeting Attendees:/,/am s G. heppler, Regional 7/Jl'/[2 - / ' [/ Administrator -
Richard.
, Pr ects Branch I C $A h% &ger)D. Walker, Chief ), ~p g41 t o Projects Section 1C Approved By: R [rIc ' 7!2d!N-- Division of Project and Resident Programs Meeting Summary Meeting on July 12, 1982 (Report No. 50-461/82-12(DPRP)) Sub_iects Discussed: A meeting was held with corporate officers and staff of the Illinois Power Company at the NRC Region III office in Glen Ellyn, Illinois.
The purpose of the meeting was to discuss the existing stop work recovery plans and proposals with respect to continuing construction work activities at the Clinton Power Station.
i ! 8208160419 820727 PDR ADOCK 05000461 O PDR
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. 1.
Meeting Attendees Illinois Power Company W. G. Kelley, Chairman and President W. C. Cerstner, Executive Vice President L. J. Koch, Vice President, Engineering J. D. Geier, Manager, Engineering J. O. McHood, Vice President and Project Manager A. J. Budnick, Director of Quality Assurance Baldwin Associates J. E. Findley, Manager, Quality and Technical Services W. J. Harrington, Project Manager Sargent and Lundy Associates R. C. Heider, Project Manager Prairie Alliance J. Kodner, Attorney for Intervenor State of Illinois D. Willman, Assistant Attorney General U. S. Nuclear Regulatory Commission H. H. Livermore, Senior Resident Inspector J. G. Keppler, Regional Administrator R. L. Spessard, Director, Division of Project and Resident Programs R. C. Knop, Chief, Projects Branch 1 R. D. Walker, Chief, Projects Section IC C. C. Uilliams, Chief, Plant Systems Section R. S. Love, Reactor Inspector - J. H. Williams, NRR Program Manager R. J. Goddard, OELD Attorney
j 2.
Meeting Details A meeting was held in the NRC Region III office in Glen Ellyn, Illinois, on July 12, 1982, with the aforementioned attendees, to discuss Illinois Power f Company's plans of recovery from existing "stop works" as well as their - proposals to-justify continuation of contruction because of numerous and repetitive problems, i Mr. W. C. Gerstner of Illinois Power Company delivered a presentation defining action being taken by Illinois Power Company to identify and correct specific quality problems. The presentation is included as an attachment to this report.
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r . Mr. James G. Keppler, Regional Administrator, concluded that the presentation was too general in nature in some areas and that additional information should be provided at another meeting in the near future. The following matters are to be answered in detail in regard to the Recovery Plan: philosophy, schedules, NRC interaction, explicit description of re-inspection plans and extent, and how Quality Issues become integrated in each Recovery Plan.
Another area to be addressed in detail by Illinois Power Company is the ongoing construction work in the piping and pipe hanger area.
In light of the known deficiencies, Illinois Power Company was requested to justify and explain the basis for continuation of construction in the piping and pipe hanger areas.
A date of August 9, 1982, for the forthcoming meeting at the Clinton Power Station has been scheduled.
In the meantime, all existing "stop works" '. are to remain in place.
l I L ! l ! l l l l l-2-i h _
- - IP QUALITY RECOVERY PROGRAM
l 7/9/82
QUL 2 2 g y; - - _. -. . ... - - - - _ _ - _ _. . . . _ _ _ _ . . .
.- SCOPE: e DEFINE THE ACT10fl BEING TAKEN BY ILLit10lS POWER TO IDEilTIFY AllD CORRECT SPECIFIC QUALITY PROBLEt4S.
.
. J
" PURPOSE: G DEMONSTRATE THAT ASSEMBLED STRUCTURES, SYSTEMS, AND COMPONENTS MEET REGULATORY REQUIREMENTS.
O DESCRIBE HOW NEW WORK WILL MEET REGULATORY REQUIREMENTS.
O DEVELOP PLANS FOR RESOLVING IDENTIFIED QUALITY PROBLEMS.
G OUTLINE PERSONNEL RESOURCES REQUIRED TO SUPPORT THESE EFFORTS.
.
' IDENTIFIED PROBLEMS FALL INTO TWO (2) CATEGORIES CATEGORY I - ll0RK COrlTROLS 8 If4SPECT10f1 ' CATEGORY II - QUALITY RELATED ISSUES
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_ _ _ _ _ N _ . O _ _ _ _ I _ T _ _ C E _ P _ S _ _ N _ I & _ _ S _ L O . _ R _ _ T _ N . O _ . / _ C . K _ R _ _ O _ . W . _ _ - _ _ - _
- y _ ro ._ _ ge . _ t . a . C _ . _ _ . . _ . . - - - . . . .. . . .
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. - . . DEFINITION OF TERMS: _ _ _ _ - _ _ _ _ - -,, [ '?ik-nm1EEEE Tifi9El ~ ~ ~ (EXAMPLE) , I ,,.I
I
, , , , , i , , , , , , , 0% -----------------------------------------100% ACCEPTED WORK: FUL(YASSEMBLED INSPECTION ACCEPTED TRAVELERS FINAL REVIEWED & IN VAULT ' IN-PROCESS WORK: ASSEMBLED - PARTIALLY OR FULLY INSPECTION PARTIAL TRAVELERS NOT FINAL REVIEWED & fl0T IN VAULT ! NEW WORK: NOT ASSEMBLED NO INSPECTION PERFORMED TRAVELERS NOT RELEASED FOR WORK TO FIELD LEGEND: gg,ygggg7g ACCEPTED WORK ' - l{{l}ll IN-PROCESS WORK NEW WORK . w-y y y
g-g
- M M
N-'- '*' "' +=--s
l j ' - . SAFETY RELATED/AUG. D.
' WORK STATUS - SUMMARY lll lll LARGE BORE PIPE , lll'llllllllllllllllll LARGE BORE PIPE ilAllGERS - . ( gQ StiALL BORE PIPE i ! SMALL BORE PIPE ilAllGERS i I f1STRuf4EllTAT 10fl ! II. V. A. C.
. . .. g. . . . 'o% ' 7s%' ' ' ' 00% ' ' ' ' S
ACCEPTED
l llll Ifl-PROGRESS l.IllllIllIll! "
__ _ _ _.
_ _ . _ _ _ __ .
-
SAFETY RELATED/AUG. D.
WORK STATUS - SUMMARY ?E'"' s "$lN "; MHHMIHMMMI
ELECTRICAL C0flDUIT l I h llllllllllllllllllljlllllllll EQUIPf1EllT
' ! l l l l l l l l l l l l l l j l l l l l l l l lllllllllllllllllllh STRUCTURAL STEEL ! f I .. il iiiil l i i i i I L i i i i 0% 25% 50% 75% 100% t i i ACCEPTED i gggg g Ill-PROGRESS ! 'lilllllllllllllll "'"
' ' -- - - -
___.
_ _ _ . .. . l - . . LARGE BORE PIPING NMR ! . . . . i i PROBllU 0% 25% 50% 75% 100% G lfi-PROCESS QC IllSPECT10fl LAGGillG C0flSTRUCTIOfl ' (lfl-PROCESS WELD I flS PECT 10fl IS KEEPlflG PACE WITil C0flSTRUCTIOfi)
9 TRAVELERS lil Tile FIELD fl0T BElf1G COMPLETED Ifl A TIMELY FASil10fl SO QC CAtl DO TiiE FiflAL WALKDOWil l ' . ACTION TAKEi1 ! O RESTRAlfl RELEASE OF flew WORK TO Tile FIELD G C0flCEllTRATE Oil COMPLETIflG lfi-PROCESS WORK S C0flCEf1TRATE Ofl REMEDIAL WORK -
_ _.
. . -. - - - - . - -. - - - -. -. - -. - .. -. - - -.. - .. -..... .- -.
_ _ - _ _ _ _ _. . .. , ! LARGE BORE PIPE HANGERS I H E R I H H H I H H llH1 - ' ' ' PROBI Fil (jg f5% 50% 75% 100% , 9 Ill-PROCESS IllSPECTIOli LAGGillG C0flSTRUCT10fl G TRAVELERS Ifl Tile FIELD fl0T BEIf1G COMPLETED Ifl A TIMELY FAstiloft a . - . ACTION TAKEN G RESTRAlfl RELEASE OF f1EW WORK TO Tile FIELD e CollCEllTRATE Oil COMPLETillG lil-PROCESS WORK ,
' . - - .--. ..,- . - - - - - . - . _ __- . - - .. - - - _ _ _ _ . _ - _. . -
. . _ _ _ _ -.. _. _ .. .. SMALL BORE PIPING - ][]llll@ PROBl. Ell d% 25% 50% 75% [00% ' ' ' 9 Ill-PROCESS lilSPECTI0tl LAGGillG C0tlSTRUCTI0tl (Ill-PROCESS WELD lilSPECT10tl is KEEPillG PACE WITil C0flSTRUCT10ti) G TRAVELERS Ill Tile FIELD fl0T BEltlG COMPLETED Ill A TIMELY FASil10fl SO OC CAtl DO TiiE FlflAL WALKDOWil - . ACTION TAKEN O RESTRAlti RELEASE OF flew WORK TO Tile FIELD 4 C0tlCEllTRATE Oll COMPLETitlG lli-PROCESS WORK $ C0flCEllTRATE Oil REMEDIAL WORK
' - - - - . . .. -.. -.. - -. . . -. - . -.. - - -. . .. - -. .-
._. ___ _. -. ,. . I
i SilAlL BORE PIPE HANGERS MHRIHHHIMHHIHmill ' ' ' l PROBlEil d% '5% 50% 7S% 100% i G Ill-PROCESS IflSPECT10ft LAGGIf1G C0flSTRUCT10t1 (Itl-PROCESS WELD lilSPECT10tl IS KEEPlilG PACE WITil COTlSTRUCT10ti) S TRAVELERS lil Tile FIELD fl0T Bell 1G COMPLETED lil A TIMELY FAsillott ' , ACTION TAKEH G RESTRAlti RELEASE OF flew WORK TO Tile FIELD 9 C0flCEllTRATE Oil COMPLETillG lil-PROCESS WORK
. .. insrauneran1mn HIHHHHIIElElllEEEMBHME b% 25% 50% 7d% 100% PROBIEil G lil-PROCESS IllSPECTIOil LAGGillG C0flSTRUCT10fl 4 ELECTRICAL IflSTRUMEilTAT10fl IrlSTALLAT10fl - TRAVELER REQUIREMEflTS fl0T UllDERSTOOD OR BEIflG FOLLOWED . . ACTI0il TAKEli G ISSUED STOP WORK ORDER #018 Of1 ELECTRICAL IllSTRUMEllTATI0li lilSTALLAT10fl G RESTRAlfl ISSUAllCE OF AtlY flew PIPiflG TRAVELERS ' . O C0flCEflTRATE Oil COMPLETitlG Ifi-PROCESS WORK G C0flCEllTRATE Oil REMEDIAL WORK
-. - - - - - -
______ _ _ - _ __ _ _ .. ,. . . II,V, A.C. } . . , , i PROBl. Ell O DOCUMEllTATIOfl DOES fl0T REFLECT lilSTALLED HARDWARE C0tlFIGURAT10fl ... . I'
, ' I ACTIO?l TAKEH , l e ISSUED STOP WORK ORDERS FOR ALL SAFETY RELATEu (SWO #0111) AllD fl0ft-SAFETY SEISMIC (}ST ATTACliMEilT WELDS) IflSTALLATIOri (SWO #015) 4 DEVELOPlilG A PLAtl 0F ACT10tl FOR LIFT 1flG TiiE STOP WORK 1il C0tlJutlCT10fl WlTH THE SUBC0f1 TRACTOR (ZACK) -l
, .,,,, - - - _,,, _, -. _. -. ,.. _ _.,, _. - _,,,. _____,,____-_.____.--.-.r,., .. _..... _.,, _ _.. ,, .... m,. __.__ _,, _. _. _., ..-, _. _ __. -..___-..., _ _. _. _,,. _ _ _ _ _.. _ _ _., _, _ _. _.
- _ _ _ _ _ ___ __ _ _ _ . . _ .. . El ECTRICAl HANGFRS H H H I H H H HR!iifi
, , , , e PROBLEll 6% 25% 50% 75% 100% 9 Ift-PROCESS IllSPECT10fl LAGGillG C0flSTRUCT10ft e TRAVELER C0flTROL Ill-EFFECTIVE s O i . . ACTION TAKEi1 C
9 ISSUED CAR-100 TO CORRECT TRAVELER C0flTROL SYSTEri O ESTABLIStiED C0flTROL OF TRAVELERS.IN Tile FIELD ' . S If1P0utlDED PROBLEf4 TRAVELERS 9 C0flCENTRATE Oil COMPLETillG Ill-PROCESS WORid S RESTRAlfi ISSUAflCE OF Ally flew WORK TO TiiE FIELD
- __ . -._- _ _ -.. __-.- . .- - -... . - - - - - - - - - - - - -
. . El.ECTRICAL - CONDllIT E H H M lllllllll @ lllll $ l M }ll[] Q PROBlEll d% 25% 50% 75% 100% . G lil-PROCESS lilSPECTI0tt LAGGil1G CollSTRUCTI0ri Oil C0tlDUIT (EXCEPT C0t11Alf1MEllT) ' , ACTION TAKEN 4 STOP WORK ORDER #016 ISSUED Oil C0ilDUIT EXCEPT FOR C0flTAltlMEllT 4 CollCEllTRATE Oil COMPLETitlG Irl-PROCESS WORK 9 C0flCEllTRATE Oil REMEDIAL WORK j
t -. . _ . - _ .- -
.. - .. , E0lllPIiENT (f4ECH - ELECT) HMHMM ' ' ' ' ' PROBl. Ell O l10 TRAVELER LOG BEIflG fiAIflTAIflED BY EllGIflEERIflG (ELECTRICAL) G PROCEDURE fl0T BElflG FOLLOWED (ELECTRICAL) ' , . ACTION TAKEN O STOP WORK ORDER #017 ISSUED Oil ELECTRICAL EQUIPMEllT S ESTABLISHED A LOG FOR C0flTROL OF TRAVELERS S VERIFICAT10fl TilAT ALL EQUIPMEllT IflSTALLED llAS A TRAVELER IS PRESEllTLY lil-PROGRESS '
. -. . - -. . . . .. - . .. - -. -- -_ . - - - . -. . - - -. . - - -.
.. . m. STRUCTURAL STEEL lllllll M {llll [{lH}@HHHQQ a a i I i PROBl.Eil 0% 25% 50% 75% 100% 9 tilSPECTIOff LAGGillG CollSTRUCTI0ll G lilSPECTI0tt RECORDS filSPLACED OR LOST Oil ELEV. 737
O EllGillEERIflG MODIFICAT10tlS ISSUED . ' . ACTI0il TAKEN 4 ISSUED STOP WORK ORDER #019 4 DEVELOPED A RE-IflSPECT10ft SEQUEtlCE.AtlD FORTilCOMIflG MODIFICAT10ft SCilEDULE
.. .-- - - - .._ -.. - - _ - -. ..- ._.
- - .. . . - -. _ - _ - - .
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- R - - - w - w Y - - - w T , - - - - I - w L . _ A . - - w U - w w - - - - Q - s e - - w w - ~ - - w - - - w I w I y w w - e r - - - - o s - - - w g - - e - w - . t . - - - a e - - - ., - C - . - - - - - w - v - . - - - -- - - . +
. .. TR AINING : G IllCREASED TRAlfiltlG IS flECESSARY FOR PROJECT PERS0fillEL.
. 9 I llc R E A S E D T R A lil lfl G IS tlECESSARY AT THE CRAFT AtJD FOREMAtl LEVEL.
. . _... _ _ _____ ! . . ,, i I J
)
- l l
!
. I ! CORRECTIVE ACTION :
G PROJECT EFFORTS NEED TO BE MORE TIMELY IN ADDRESSlHd FINDINGS OF AUDITS, SURVEILLANCES, AND CORRECTIVE ACTION REQUESTS.
I G RESPO!1SIVENESS TO N9C N0f1 COMPLIANCES, UNRESOLVED ITEMS, AND OPEN ITEMS NEEDS j IMPROVEMENT.
!
l h ' -
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._ -. - - -. .. -.. - . , , . .. i !
i s
s . - NONCONFORMANCES: , i
TiiE llUMBER OF NCR'S WHICilllAVE NOT BEEN i CLOSED I S ',CONSI DERED EXCESSIVE.- , t l TiiE NUMBER OF OPEN DR'S IS INCREASING.
! ilCR/DR PROCEDURES ARE BEING REFINED IN ORDER TO ENilANCE TiiEIR EFFECTIVENESS.
, ! , , I I e > ' -
! . -
- - . - -. _.,__=_,-,--,._...._,-,_,.._,,--~,...__,_,._--.....,._.,-,,_~,,.,.__,-_._..,._.._.._,_..-.-_-_,_.;-. - - - - - - .,,,_m._.,. . -. . -
. - - - . _ _ _ -.. -. ....-.... _.. - -. _. -. . - - -.. - - -. -...,.. -.._... - - -.. -. - - - -.
. i - .. . j 4j.
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+
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VERIFIC ATION TE AM REPORT: I , ! t , , l SPECIFIC HARDWARE PROBLEMS AND PROCEDURAL CONCERNS WERE IDENTIFIED AND ARE BEING ADDRESSED.
i i , . ! RECOMMENDATIONS OF THE VERIFICATION TEAM i ' WILL BE ADDRESSED FOR PROGRAM IMPROVEMENTS.
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2 . _ _ . - . . . . . . Y . RE . V O . . - C _ . . E .. R F . - . O . SD . O . H _ T . _ E . . M . _ . . . . - . . . . _ . . _ . . . . _ . . ._ O
l
, . .. PROJECT APPRO ACH: , e REALIGilMEllT OF PROJECT PRIORITIES AtJD PERS0titlEL ASSETS TO ADDRESS IDENTIFIED PROBLEMS.
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.. _ - -.. . -. _ . . - - _ - - -... . .- ... - - - . -...- . . .
., . .
. ASSIGNMENT OF IP SUPERVISORY PERSONNEL TO MANAGE THE RECOVERY PLAtl.
THEIR RESPONSIBILITIES INCLUDE:
A.
DEVELOPMENT OF RECOVERY PLAN (S).
B.
OBTAINING MANAGEMENT APPROVAL OF RECOVERY PLAN (S) FROM BA & IP PROJECT M'NAGEMENT (CONCURRENCE OF A BA/IP-0A REQUIRED).
C.
COORDINATING COMMITMENTS OF RECOVERY PLAN (S).
D.
MONITORING PERFORMANCE AND STATUS OF RECOVERY PLAN (S).
I
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_ _. - - -. -_ _.._ __..._... _ _.. _ ... _. _-_ __ _ _. - -_. __ _ _. _ _.._ _. _.. -, _ _._.
_.. _.. _.__ __. _ _.. _ _. _... _ i
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i A ! , VERIFICATION THAT ACCEPTED WORK IS IN ACCORDANCE WITH
l DRAWINGS, SPECIFICATIONS, AND DOCUMENTATION REPRESENTING i ' THE AS BUILT CONFIGURATION.
t - . A.
PERFORM BA OA AUDIT ACTIVITIES.
' l i ! B.
PERFORM IP QA SURVEILLANCE ACTIVITIES.
i - -
1 .. ! C.
REINSPECTIOH OF SPECIFIC AREAS IN ACCORDANCE WITH
> RECOVERY PLANS.
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_ _ _ _ _ _ _ _ _ _ _ _. _ _ _ _ _ _.. _. _
.. . ! i s VERIFICATION TilAT IN-PROCESS WORK IS IN ACCORDANCE WITH DRAWINGS AND SPECIFICATIONS.
,
A.
INCREASED SCOPE AND FREQUENCY OF BA QA AUDIT ACTIVITIES.
. , B.
INCREASED SCOPE AND FREQUENCY OF IP QA SURVEILLANCE ACTIVITIES.
! C.
INCREASED BA QC/TS CONTROLS.
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i i ! . - .-. - _ . . .... . . ...
_. _ _ _ _ _. _ _ _ _. - .__ . _. _ . . . I i 1-
, k ' ) VERIFICATION THAT NEW WORK IS IN ACCORDANCE WITH DRAWINGS AND SPECIFICATIONS.
A.
INCREASED SCOPE AND FREQUENCY OF BA QA AUDIT ACTIVITIES.
, i B.
INCREASED SCOPE AND FREQUENCY OF IP OA SURVEILLANCE ! ACTIVITIES.
! . C.
INCREASED BA QC/TS CONTROLS.
i D.
ADDITIONAL REVIEW BY BA QA/QC OF TRA,VELERS , ASSOCIATED WITH STRUCTURES, SYSTEMS, AND COMPONENTS.
.
. , REALLOCATIOil 0F PROJECT PERSONNEL RESOURCES TO RESOLVE AND DISPOSITION PROBLEMS.
A.
REASSIGNMEt4T OF OPERATIOlis, ENGINEERING AND C0riSTRUCTION PERS0!1tlEL TO ACTIVELY PURSUE IDENTIFIED PROBLEMS.
B.
ADDITIONAL STAFFING OY QUALITY PERSONNEL TO INDEPENDENTLY REVIEW STATUS OF RECOVERY PLANS, EVALUATE CORRECTIVE ACT10tl, AtlD VERIFY COMPLETED ACT10tlS.
C.
RESTRAIN C0tl5TRUCT10tl CRAFT EFFORTS ON NEW WORK IN DESIGilATED DISCIPLINES; EMPHASIZE UTILIZAT10tl 0F CRAFT Ill COMPLETING WORK FOR ACCEPTAtlCE.
. . )
. .. MANAGEMENT CONTROLS ' EXECUTIVE VICE PRESIDENT Bh MAtJ AG E R """""** **-~~~~~~~~~~~~~~~~~~~~ ********* - PROJ E C T mat 1 AG E R - - - -- - ........ 1 P D 1 R ECTOR QUALITY 8 TEClittlCAL QUALITY ASSURANCE SERVICE i i i ...........................................................b6 Y.Ol37...b.bd...l.t..h.O.N.h.b.T.................................. s IgECTOR I I I(F. SCllWARZ) MECHAlllCAL ELECTRICAL CIVIL / STRUCTURAL C00RDIf1ATOR (D. KORflEMAN) COORDINATOR (W. C All10Uf1) C00RDitlATOR-SMALL/LARGE BORE PIPIllG-ELECTRICAL EQUIPMEllT STRUCTURAL STEEL (STOP WORK 17) (STOP WORK 19) -PIPIf1G liAllGERS 8 SUPPORTS-ELECTRICAL lilSTRUMENTS-MECilAlllCAL EQUIPMEllT (STOP WORK 18) -HVAC (STOP WORK lli 815) -C0rloulT (STOP WORK 16) - MECil. IflSTRUMEllTAT10fl-liAtlGERS . ! l l l(G. S l fit 1 E T T ) TRAlillflG NONC0tlFORMAllCES CORRECTIVE ACT10rl VERIF1 CATION l[EAM C00RDIllATOR (E. C0f1N0ft)C00RDillATOR (G. MOTSEGOOD) COORDINATOR (E. C0tir10N) REPORT C00RDitlATOR-0UALITY-NCR-CAR-liARDWARE CONCERNS-PROJECT-DR-AUDI T/SURVE I LLAtlCE-PROCEDURE CONCERNS MAllAGEMEllT FINDitlGS - -ENG I NEER i f1G-PROCEDURES-t10t1COMPLI ANCES-RECOMMENDATIONS ' -C0rlSTRUCT I ON
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r D - - - . . - -
. -. ... - -. _. -. __ . .-. - . _.. - - . . - . ._ - . . BA-MANUAL DISTRIBUT10tl
CRAFT FORCE AS OF FORCE AS OF DELTA SUPPORT SAFETY (OLD) SAFETY (f1EW) NON-SAFETY TOTAL 6/23/82 7/6/82 LABORERS 262 237
165 .73 238' r CARPEllTERS 121 108
75
27 107 OPERATORS
55
56
i TEAMSTERS
11 7
11 6 fl6 . IR0tl WORKERS
56
10
til
ELECTRICAfJS 650 1197 153
207
127 1197 PIPEFITTERS 620 111111 176
227 122 111111 BOILERMAKERS
52
12
2
52 CEMEtJT MAS 0ta
6
1
6 TILERS ! MILLWRIGHTS 11 2
7
8
35 f SHEETMETAL
6
1
6
5 BRICKLAYERS
5
' - SURVEYORS
.13
13
TOTALS 1969 1561 1108 572 117 0 8 11 113 5 1561 l -. - -- - .- - ..-. .. . . -... . - .
' .. . ZACK CRAFT FORCE AS OF FORCE AS OF 6/23/82 6/29/82 SUPERiflTEllDEilTS/GF
DRAFT IllG/DETAI LIllG
FAB SHOP
LAYDOWil CREW
N/S, N0il SEISMIC HAllGERS
N/S, DuCTWORK
N/S, SEISMIC HAtlGERS
C0ilSTRUCTlott i llSPECTORS
TOOL CRIB /MAltlT.
It WELD SHOP
IllJURED
34 TOTAL.
2116 226 .
... -...- .--
.
.- - - - - - - - -, -
m
- .
O BA MANAGER OF l QUALITY, TECH. SERVICES ZACK-QA/QC AND TRAINING SITE QUALITY QUALITY TECHNICAL TRAINING ASSURANCE CONTROL SERVICES )
_ . . - ..
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. I \\ gn;y Q&TS MANPOWER PROJECTION o 4hs9 325 - 300 -
- ..n.n..............na"'""""'""'"""'""
?
? ? 275- ?
,
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250 - ,/ I i / / 225 - / , _- l l 200 - 175-JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC LEGEND
CURRENT ........................ R E VIS E D --- .. .. - . - - . _ -. .. - - - . -... - . - .. .. _
- - .. ! I IP/QA ORGANIZATION i
PRESIDENT ...- -- 3 ! ! ! !
i .
EXECUTIVE VICE i ) ! ) PRESIDENT ! !
I i
DIRECTOR ! ..........i OUALITY ~ ASSURANCE _ I I I I I I SUPERVISOR SUPERVISOR SUPERVISOR SUPERVISOR ADMINISTRATIVE QUALITY OUALITY PROGRAMS & AUDITS & SUPERVISOR ' ENGINEERING CONTROL PROCEDURES SURVEILLANCE SECTION SECTION SECTION SECTION SECTION
. , -,,.,. _, _ _ - -,. - _ _, ._-,_--__,-___ _ _,.-__,-_.._.,--.-_---__, - -..___,om.
=, - -,,,-,.,.--,-,_,--._ .,,_--,_.-,,.--e_-.m e__, _,,,. -, _,, -, -,-- - _ _ -, _, - - -
_ _. -_ -___ - .. l lLLINOIS POWER QUALITY ASSURANCE FORECAST l 120 - 118 110 - IP AND 100 - CONSULTANTS 90 - ! ' z 80-l h
y 70 - m -
60-
f 50-O IP 40-
30-
- 20 -
10 - !
1 Jan 82 1 Apr 82 1 July 82 1 Sept 82 .. . - - . _ - _ _ . - . - . ...... .. . - - - . - - - . - - -.. - - . . , _ -. -. .
. - -. . -- -. - .. .- .. - - - - - '. .. . RESOURCES: G DUE TO THE COMPLEX NATURE OF THE PROBLEMS WE IDENTIFIED THE FOLLOWING DECISIONS WERE MADE:
- RESTRAIN NEW WORK UNTIL WE HAVE COMPLETED DEVELOPMENT-0F OUR RECOVERY PLANS.
, e AS THE RECOVERY PLANS ARE DEVELOPED WE WILL ALLOCATE MAf1 POWER TO SUPPORT EACH PLAN.
PRELIMINARY FORECASTS OF THE REQUIRED MANPOWER RESOURCES HAVE BEEN PREPARED.
O CONTIlluE TO ADVERTIZE, lilTERVIEW AND HIRE EXPER!ENCED QUALITY PERSONilEL.
, 4 SUPPLEMEllT EXISTif4G STAFF WITH C0tlSULTANTS AS REQUIRED TO SUPPORT THE RECOVERY PLAtl.
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-. - ', . J SUMMARY: ,
1 e EVEN THOUGH INSPECTIOil IS LAGGING CONSTRUCTION WE HAVE DEMONSTRATED TilAT WE HAVE CONTROL AND A METil0D OF STATUSING TiiE INSPECTION EFFORT.
i G WE HAVE CHANGED THE PROJECT PiilLOSOPHY TO FORCE ' TIMELY COMPLETION AND INSPECTION OF lll-PROCESS AtJD NEW WORK.
. l . l G ASSIGNMENT OF DEDICATED MANAGEMENT STAFF TO AGGRESSIVELY PURSUE RESOLUTION OF QUALITY ISSUES.
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s. . LEGEt1D: PREPARE Y REVIEW O f1 R C C 0 flC U R R A t1C E O SCHEDULE: IP APPROVAL
0 STOP WORKS e STRUCTURAL STEEL y O O e ZACK RECOVERY PLAtt Y O O e ELECTRICAL E0uid. lilST'L.
Y O O e C0tlDUlT If1STALLATI0fl y
0 e ELECTRICAL lilSTRUMEllTATI0tl y
0 4 OUALITY ISSUES l e VERIFICATIO!l TEAM V O O l e fl 0tl C 0 t1 F O R M A tl C E S Y O D e CORRECTIVE ACT10t1 Y O O e TRAltlitlG Y O O e OTilERS Y O p 4g t }}