ML12150A036
| ML12150A036 | |
| Person / Time | |
|---|---|
| Site: | Watts Bar  |
| Issue date: | 05/24/2012 |
| From: | Haag R NRC/RGN-II/DCP/CPB2 |
| To: | Skaggs M Tennessee Valley Authority |
| Michelle Adams | |
| References | |
| Download: ML12150A036 (41) | |
Text
UNITED STATES NUCLEAR REGULATORY COMMISSION REGION II 245 PEACHTREE CENTER AVENUE NE, SUITE 1200 ATLANTA, GEORGIA 30303-1257 May 25, 2012 Mr. Michael D. Skaggs Senior Vice President Nuclear Generation Development and Construction Tennessee Valley Authority 6A Lookout Place 1101 Market Street Chattanooga, TN 37402-2801
SUBJECT:
MEETING
SUMMARY
PUBLIC MEETING WATTS BAR NUCLEAR UNIT 2
Dear Mr. Skaggs:
This refers to the meeting conducted at our request at the Spring City Municipal Building in Spring City, TN on May 22, 2012 at 1:00 p.m. The meetings purpose was to discuss the status of the Watts Bar Unit 2 Construction Project, including major milestones and potential challenges that may impact the project schedule with the public.
On May 22, 2012, the NRC held a Category 1 meeting in which TVA provided a presentation about the current progress and scheduling plans for the Waifs Bar Nuclear (WBN) Unit 2 construction project. The NRC staff presented information on the current status of the NRCs licensing and construction inspection programs for WBN Unit 2. Additional topics related to the WBN Unit 2 construction project were discussed between the NRC and TVA. Following these presentations and discussions, members of the public had an opportunity to provide comments and ask questions.
The agenda (Enclosure 1), the list of attendees (Enclosure 2), the TVA presentation material used for discussions (Enclosure 3), and the NRC presentation material used for discussions (Enclosure 4) are attached to this letter.
In accordance with 10 CFR 2.390 of the NRCs Rules of Practice, a copy of this letter will be available electronically for public inspection in the NRC PubHc Document Room (PDR) or from the Publicly Available Records (PARS) component of NRCs document system (ADAMS).
TVA 2
ADAMS is accessible from the NRC Web site at http://www.nrc.gov/reading-rm/adams.html (the Public Electronic Reading Room). Should you have any questions concerning this meeting, please contact James Baptist at 404-997-4506.
Sincerely, IRAI Robert Haag, Chief Construction Projects Branch 2 Division of Construction Projects Docket No. 50-391 Construction Permit No: CPPR-92
Enclosures:
- 1. Agenda
- 2. List of Attendees
- 3. Presentation
- TVA
- 4. Presentation
- NRC
TVA 3
cc w/encl:
Mr. G. P. Arent, General Manager, Nuclear Construction Licensing Tennessee Valley Authority 1101 Market Street Lookout Place 5A Chattanooga, Tennessee 37402-2801 Mr. 0. J. Zeringue General Manager Engineering and Construction WBN Unit Two Watts Bar Nuclear Plant Tennessee Valley Authority P.O. Box 2000 Spring City, Tennessee 37381 Mr. R. A. Hruby General Manger Technical Services WBN Unit 2 Watts Bar Nuclear Plant Tennessee Valley Authority P.O. Box 2000 Spring City, Tennessee 37381 Ms. D. K. Guinn Manager, Licensing and Industry Affairs Watts Bar Nuclear Plant Tennessee Valley Authority P.O. Box 2000 Spring City, Tennessee 37381 Mr. P. D. Swafford Chief Nuclear Officer and Executive Vice President Tennessee Valley Authority 1101 Market Place 3R Lookout Place Chattanooga, Tennessee 37402-2801 County Executive 375 Church Street Suite 215 Dayton, Tennessee 37321 County Mayor P.O. Box 156 Decatur, Tennessee 37322 Mr. D. H. Gronek Plant Manager, WBN Nuclear Plant Tennessee Valley Authority P.O. Box 2000 Spring City, Tennessee 37381 Mr. D. C. Romashko General Manager, Nuclear Construction Quality Assurance Tennessee Valley Authority 1101 Market Street Blue Ridge 3A Chattanooga, Tennessee 37402-2801 Mr. Joseph Shea, Manager Corporate Nuclear Licensing Tennessee Valley Authority 3R Lookout Place 1101 Market Street Chattanooga, TN 37402-2801 Mr. E.J. Vigluicci Assistant General Counsel Tennessee Valley Authority 400 West Summit Hill Drive West Tower 6A Knoxville, Tennessee 37902 Mr. Lawrence E. Nanney, Director Tennessee Department of Environmental Health and Conservation Division of Radiological Health 3rd Floor, L&C Annex 401 Church Street Nashville, TN 37243-1532 Mr. D. E. Grissette Site Vice President Watts Bar Nuclear Plant Tennessee Valley Authority P.O. Box 2000 Spring City, Tennessee 37381 Ms. Ann P. Harris Public 341 Swing Loop Rockwood, TN 37854
TVA 4
cc email distribution w/encl:
Greg Scott Tennessee Valley Authority Electronic Mail Distribution Watts Bar 2 Licensing Tennessee Valley Authority Electronic Mail Distribution Brenda Derrick Electronic Mail Distribution
ML12150A036 SUNSI REVIEW COMPLETE OFFICE RII:DCP RII:DCP RII:DCP RII:DCP RII:DCP RII:DCP RII:DCI SIGNATURE RCH CJE via E-Mail NAME RHaag CEven DATE 05/25/2012 05/24/2012 E-MAIL COPY?
YES NO YES NO YES NO YES NO YES NO YES NO YES NO
Letter to Michael D. Skaggs from Robert C. Haag dated May 25, 2012.
SUBJECT:
MEETING
SUMMARY
- PUBLIC MEETING WATTS BAR NUCLEAR PLANT UNIT 2 Distribution w/encl:
L. Raghavan, NRR S. Campbell, NRR P. Milano, NRR J. Poole, NRR F. Lyon, NRR M. Kotzalas, OEDO C. Evans, RIl L. Douglas, Rh EICS S. Shaeffer, Rll DRP R. Monk, RIl WBN Unit 1 SRI S. Dubose, RII Administrative Assistant Region II State Liaison Officer Region II Public Affairs Officer OE Mail (email address if applicable)
ConE Resource@nrc.gov PUBLIC
AGENDA FOR PUBLIC MEETING WITH NRC AND TVA May 22, 2012 1 :OOp Start of Meeting NRC Purpose of Meeting
Introductions
Status of Watts Bar Unit 2 Construction Project TVA Updates to the Unit 2 Construction Schedule TVA Update on Construction Inspection Activities NRC Licensing Status NRC Results of the Root Cause and Associated Corrective Actions TVA for the Recent Human Performance Event Assessment Results Regarding Work Order Quality Concerns TVA Corrective Actions to Address Commercial Grade Dedication TVA Violations Changes to Corrective Action Program TVA Preventative Maintenance and Equipment Layup Program Changes TVA Public Comments and Questions NRC 3:OOp Meeting Adjourned
SIGN-IN SHEET WATTS BAR UNIT 2 PUBLIC MEETING Date:
05/22/2012 Location: Spring City Municipal Building Name Company Betty Hamby Public Tom Trotter Public Bob Crane Public Woody Evans Public Tomy Finnell Public Gary Humphrey Public Pt.Irhne.rn Piihli Linda Ellis TVA Jim Hopson TVA Kay Whittenburg TVA Ann Harris Public Annette Gould Public Frederick Brown NRC Terrance Reis NRC Robert Haag NRC Mark Lesser NRC Kathleen ODonohue NRC Jaime Heisserer NRC William Burton NRC Gordon Arent TVA Tom Wallace TVA Ike Zeringue TVA Ray Hruby TVA Ric Wiggall TVA
(1)
Agenda Estimate to Complete Construction Schedule & Milestones Quality of Work Orders
- Asset Preservation Unit 1 / Unit 2 Interface Material Control Corrective Action Program Changes Conclusion Questions Ray Hruby Ike Zeringue Ike Zeringue Ike Zeringue Tom Wallace Ric Wiggall Ray Hruby 2
Watts Bar Unit 2 Estimate To Complete WA Board authorized completion of the Watts Bar 2 Project in accordance with the revised Estimate to Complete (ETC) on April 26, 2012.
- The project is scheduled to complete by December of 2015.
> Construction permit extension request was submitted on May 17, 2012.
- Project leadership has a high degree of confidence in the revised ETC.
- Though several project risks and opportunities remain, these are manageable.
- Completing the Watts Bar Unit 2 project helps WA balance its generating mix and achieve its vision to be a leader of low-cost cleaner energy.
3 Encbsure 3
Independent Assessments Several root and contributing causes of project performance have been identified Leadership: Organization and management capabilities misaligned with unique project characteristics Estimate: Inadequate understanding of the work to be done led to low initial estimates and impeded planning Execution: Management did not execute a robust execution plan or fully utilize available capabilities Oversight: Inadequate Nuclear Generation Development and Construction/WA oversight and project assurance Independent assessments aligned with TVA Root Cause Analysis (RCA)
McKinsey and Associates Insights are incorporated directly into the body of the RCA High Bridge Associates Aligned with ETC methodology and provided suggested corrective actions consistent with RCA TVA Inspector General Aligned with RCA and provided insight into additional programmatic improvements 4
Corrective Actions Comprehensive revision of ETC Ensured buy-in of revised cost/schedule Restructured project organization
- Established independent, integrated schedule and cost monitoring tools to track progress Improve quality and timing of Planning documents Improve effectiveness of field engineering Utilize independent, integrated schedule and cost monitoring tools to track progress Establish process and oversight improvements Increase transparency, build trust Initiate regular executive sponsor meetings Streamline work package rebuilds
- Surface productivity measures Establish a process to control project scope
- Provide regular project updates Empower employees
- Improve craft morale 5
Completed Project Execution Improvements Ongoing Planned
Organization Chart rcA TA MechanronlMgr SeeFieIdongineoring
Bob JohnsOn (0)
Ode Morgan (0)
WA WA FAC/Supporl Eloctnical Mgr J. Loog (0)
R. W. Harrirrqton Super.rsOr Suparv.nor Construction Conernicoon Oeosooren Woorringroo Richard Bailey r
Senior Manager Senior Manager Senior Manager WBN U2 System Engineenog WBN U2 Operations Completion Richter E. Wiggall Tom Wallace Robert Beeckee (0)
I
[::
NcIcror]
Broon Connorghonn Ron Sen Suppoir Project Maragon Bean Copp SCn
[eeeZenr Rotubunal Managenrerni Devolopmerni Brian Bnody r Senor Manager MecrranicaOrgucjear I
Willrer Crutch Senior Specalni Nucleon Engineer Dougino Helero Technical Sersices Senior Manager Engineering & Construction I
GeneralManager WBN2QuolityAnsurance GeneratManager rvASatery TVACol TVAProcureml RayA. Hrnrky Rant R. Baron O.J.Zenngrse Greg Poe)c(
Chad May DarsOliver)c)
M onagCornplraccej Man Schedule Project Manager Rotational Cosi Management Management Alison Wigietne Nick_Welch Senior Manager Licensing Gordon Areet Project Manager Edward 0. Hicks Secunty Manager Roger Reynolds Project Managor Danid Braeham Senior Program Manager Keoin Casey Senior Manager Rotaticral Management Site Coootnucticn Decelnpment Howard Lawrence Ed Freeman Bechtel Project Director Mike McLemore Bechtel Bechtel Bechtel Bechtel Bechtel Bechtel Bechtel Bnctrtet Project Controls Go/DC ES&H Constructino Procurement Serinces Project Engineer Project Engineer Mgr IIaI SobContracts Enghreehng III caere II B
htl lii
- 0er I I ASME Startup I
tun.Seonnrsniroo I I 5
aPP I_I0 Mecharhcat Hydro Test Group
_________________ I Bechtet N-5 Groap
_________________ I Bechtel WeioicgtRT
-I Bechtel Project Field Eog I
Bechtel Fietd Engineering 6
Construction Phase Map 7
m C) 0 C)
CD LI,n CD CD Q)
(b)
CD (ri 0
CD(n
0.7 0.65 0.6 0.55 0.5 0.45 0.4 0.35 0.3 0.25 0.2 Safety Performance Mar-12 Oct-li Nov-li Dec-il Jan-12 Feb-12
- Target 9
Project Quality Quality Control Acceptance Rate April 2011 through March 2012 April May June July Aug Sept Oct Nov Dec
-r-I 97.9%
1 100.0%
95.0%
90.0%
85.0%
80.0%
75.0%
70.0%
65.0%
60.0%
55.0%
50.0%
Jan Feb Mar Encosure 3
Schedule Performance Measures of Success Calendar Year 2012
- Schedule Performance Index Consistently >1
- Earned Hours vs. Schedule
-- Consistently >1
- Commodity Work Off Meeting Schedule
- Piping
- Electrical
- Instrumentation
- Ventilation
- Hangers and Supports Encosure 3 11
Work Order Quality Quality Assurance Identified Defidencies in Work Order Packages Related to Document Completeness.
Cause
> Complex work packages and inconsistent adherence to procedural guidance Corrective Actions
> Re-write complex work order packages to reduce and eliminate potential human error traps
> Established a Work Closure Group to review work orders for completeness prior to closure Trained work closure group on expectations and procedural guidance
> Revised governing procedure to add clarification to the closure review process
> Construction superintendent briefed construction discipline superintendents regarding expectations for work order completion by the craft 12
Work Order Quality Work Implementation Quality Control inspections
> Quality Assurance audits
> Work order closure review
> As-built verifications of engineering documents
- Testing
> Component testing
> System tests, pre-op and acceptance tests
> Integrated plant testing
- Validation
> Operational Readiness Turnover Process, including system walkdowns, re verifications of processes and commitments as was completed by the System Pre-operability Checklists for Unit 1 licensing System Plant Acceptance Evaluation, a final engineering review in support of system readiness for turnover and licensing 13
Asset Preservation
- Process
> Strengthening the process that manages and provides oversight of activities that ensure plant equipment and system are maintained and properly layed-up
> Reviewing plant equipment ensuring lay-up and preservation requirements are in the program
- Oversight Establishing performance indicators to facilitate monitoring of the effectiveness of the asset preservation program for each system Perform periodic assessments of program effectiveness
Unit 1/Unit 2 Interface Unit 1 Presence on Unit 2 Prior to planning evaluation performed to determine impact on operating Unit requires SRO input Interface Common system component Auxiliary Building Secondary Containment Enclosure Proximity to trip or risk sensitive equipment Activities affecting Unit 1 are in operating plant schedule and receive risk review
> Construction activities in common plant areas are monitored and controlled
> All work planned on operating plant side of the interface is performed in accordance with operating plant processes and requirements Unit 2 Presence on Unit 1
> A Unit 2 WA manager participates in Unit 1 Plan of the Day meeting Work in operating spaces is reviewed daily with the plant management
> Unit 2 atlends daily schedule meetings and provides input
> Unit 2 unrestricted access is controlled by procedure and by approved access list 15
Unit 1/Unit 2 Interface Unit 1 Pressurizer Heater Transformer De-energized Cause
> Direct cause was improper use of human performance tools
- specifically, individuals failed to verify correct component to work on
> Root cause identified that process to restart work that had been started and delayed should be strengthened to protect plant and workers Corrective actions
> Stopped project work and sent craft home to ensure we understood what occurred and that we had proper controls in place to protect plant and workers
> Senior managers met with supervisors and craft to discuss event and what must happen to move forward
> Verification practices are now observed in the field by supervisors Involved plant operators to actively challenge workers in operating spaces Injected additional levels of approval to work in common areas Involved the trade unions in root cause and developing measures to prevent reoccurrence 16 Encosure 3
Unit 1/Unit 2 Interface Corrective Actions (continued)
> Placed additional controls on individuals granted unrestricted access to operating spaces Formalized process for continuing work in the event the work package activity has been delayed
> Formalized requirements for Pre-Job Brief and STARRT card Briefings
> Required technical data fields on data sheets to be populated prior to going to the field.
> Supervisor or Operations approval required prior to work in common areas
> Union representatives reviewed event and importance of using human performance tools during meetings with the craft
> Access to individuals in Unit 1 areas limited, with upper management approval required for access authorization 17
Unit 1/Unit 2 Interface Corrective Actions (continued)
> Event Scenario incorporated into Dynamic Learning Center training
> Strengthened requirements
- Pre-job and STARRT Card Briefings
> Developed process for continuing work after work package has been delayed Required unit identifications on data sheets for field work Conclusions
> Controls are in place to protect personnel and equipment and assure the safe operation of Unit 1.
> We took aggressive action and fixed this problem.
> If challenges are encountered, the team responds quickly and actions are put into place to address the problem and to preclude it from happening again.
18
Material Control Program Issues Program implementation weaknesses were identified in specifying failure modes, safety functions and critical characteristics when performing commercial grade dedications.
Commercial grade dedication is the process where Engineering evaluates a commercially available component to ensure it can perform a design safety function prior to approving the component for use.
Cause
> Methods used by Unit 2 to perform commercial grade dedications were not in accordance with current industry guidance and standards.
Corrective Actions Independent industry experts performed 100
% review of commercial grade dedication packages utilized by Unit 2 Completion Project.
No technical issues identified that would challenge the components ability to perform its safety function 19
MaterEal Control Corrective Actions (continued)
> Revise program procedures to incorporate latest regulatory and industry standards Provided EPRI training on commercial grade dedication to unit 2, procurement engineering group personnel
> Unit 2s commercial grade dedications identified with weaknesses will be revised/updated
> Re-review the Unit 2, Replacement Items Project (RIP) Corrective Action Program for any potential impact Conclusions
> Actions have been taken to address the weaknesses identified in the Commercial Grade Dedication program.
> Commercial Grade Dedication packages used in support of Unit 2 have been evaluated.
> No technical issues have been identified that would challenge the components ability to perform its safety function.
20
Corrective Action Program Changes Effective use of CAP and work processes to drive timely correction of identified problems or issues
- Cause
> Insufficient line management involvement and focus combined with large influx of low threshold items into the CAP insufficient project integration
- Corrective Actions
> Increase line management involvement (vs. support staff) at key process points initiation, screening reviews, corrective action plan approval
> Clarify through communication, training and process changes the most appropriate correction processes to expedite handling and completion
> Re-review backlog for impact potential, priority, schedule integration
eliminate duplicative tracking and heighten monitoring of work-off plans
> Restructure CAP alignment, monitoring, and oversight to improve effectiveness 21
ConcIusons
- Complete Watts Bar Unit 2 in a safe and quality manner Focus on safe and uninterrupted operation of Unit 1
- Completing the project continues to be a cost-competitive investment in power generation capacity
- Independent, integrated schedule and cost performance indicators and tools in place to monitor progress and verify results.
- High degree of confidence in the revised schedule
- Several project risks and opportunities remain, yet these are manageable
- The project is scheduled to complete by December of 2015
> Construction permit extension request submitted on May 17, 2012 22
QUESTIONS?
?U.S.NRC United Statm Nudar Regulatory Cornntision Protecting People and the Environment
U.S.NRC Category I P LIbIiC IVIeetIiig United States Nuclear Regulatory Commission Protecting People and the Environment
- Please sign in
- Feedback forms
- Public invited to observe initial portion of meeting
- NRC available for questionslcomments
- Agenda, slides, meeting summary, and list of attendees in Agency wide Documents Access and Management System (ADAMS)
cU.S.NRC Age 1 d
1da United States Nuclear Regulatory Commission Protecting People and theEnvironment I :OOp - Introductions Status of Watts Bar 2 Construction Project (TVA)
Update on Construction Schedule (TVA)
Update on Construction Inspection Activities (NRC)
Licensing Status (NRC)
Discussion of Recent Issues (TVAINRC)
Public Comments and Questions (NRC) 3:OOp - Meeting Adjourned
2 U.S.NRC I iiSpectioii Progra 111 Updates United States Nuclear Regulatory Commission Protecting People anti the Environment
- Results of the End-of-cycle assessment review issued in a March 5, 2012 letter to TVA
- Overall acceptable performance
- Three items highlighted:
- Inadequate corrective action for new and historical items
- Commercial Grade Dedication program violations No substantive cross-cutting issues
ø L
- U.S.NRC I iispectioii Progra 111 Update5 United States Nuclear Regulatory Commission Protecting People and the Environment
- Next periodic assessment in August for the Mid-Cycle review
- Expended approximately 4,285 inspection related hours in 1 st Quarter of 2012 I
tU.S.NRC i iiipaCt Of SClied U Ie Chaflg United States Nuclear Regulatory Commission Protecting People anti theEnvironment on Inspection Program
- Reviewing TVAs Primavera construction schedule
- Adjusting NRC schedule for remaining inspection items
- Pace of regional inspections has slowed
- Number of resident inspectors reduced to three for the next six months
- Assigning a permanent 3rd resident inspector Use rotations for resident position
US.NRC StatLiS Of IuspeCt1011 Iteills United States Nuclear Regulatory Commission Protecting People and the Environment
- Approximately 537 construction inspection items in the Inspection Planning and Scheduling (IP&S) database
- Closed 206 items
- Many remaining lP&S items have been inspected, but require additional effort to close
- Closed eight (8) Corrective Action Programs and Special Programs, many sub-issues also closed I
I
Problem Identification &
Resolution Inspection
- Documented in Inspection Report 05000391/2012612 (ML12131A231)
- Identified two (2) Severity Level IV violations for incomplete problem identification and lack of timely corrective actions
- Concluded that a decline in performance in the Corrective Action Program had occurred since 2011
- Follow-up inspection being planned U.S.NRC United States Nuclear Regulatory Commission Protecting People and the Environment 4!
U.S.NRC I.. ICe11S I 11g SttLI5 United Stares Nuclear Regulatory Commission Protecting People a the Environment Safety Reviews - 96% complete Results documented in SSERs 21 through 25 SSER 26 scheduled for September 2012 Fire Protection and closure of open items
- Security Program Reviews - 100%
complete
- Emergency Preparedness Program - 100%
complete
- Environmental Reviews Draft published for comment in November2011 Staff currently addressing comments Final scheduled to be published in Au
JUS.NRC United Stitis Nuclear Regulatory Coniniion 10 Protecting People and the Environment