ML17054B169
| ML17054B169 | |
| Person / Time | |
|---|---|
| Site: | Nine Mile Point  |
| Issue date: | 07/31/1984 |
| From: | STONE & WEBSTER ENGINEERING CORP. |
| To: | |
| Shared Package | |
| ML17054B164 | List: |
| References | |
| NUDOCS 8411150133 | |
| Download: ML17054B169 (86) | |
Text
project Report I
I I
Nine Mile Point Unit 2 84'~>>o~aS Beszoq PDR ADOCK 05000410 R
JULY 1984 PROJECT REPORT TABLE OF CONTENTS PAGE I EXECUTIVE
SUMMARY
1- 6 II MILESTONE STATUS 7- 8 II I CONSTRUCTION 9-31 IV ENGINEERING 32-38 V NGRKFORCE LEVELS 39-48 VI QUALITY ASSURANCE 49-51 V II CONTRACT ADMINISTRATION VIII STARTUP 5 TEST 56-66 IX COST 67-76 X RECORDS MANAGEMENT 77-80 XI LICENSING 81-83
I EXECUTIVE
SUMMARY
A. Project Director The Project was 76.70% complete at the end of this period. We should have been 79.21, Although the Project is still on schedule ror a February 1986 fuel load date, we continued the unacceptable trend of contingency erosion.
The 1.63% Project progress obtained for this period is considered by management as not satisfactory. The following 're reasons for this deviation from the-2.295 plan:
- 1. The unlevelized front end loading of Major'ilestones in support of systems completion work is creating a bow wave of work that is not being achieved.
- 2. The Startup production goals are inhibited by the lag in turnover of clean completed work.
W e reported previously that this gap of 2.0'5 delay should not be extrapolated to indicate a future trend. I am disapoointed in that although we. improved over the previous ",onth's performance nevertheless the shortfall in progress has widened this gap to 2. 5 .
The following immediate corrective actions are underway to bring a halt to this .decline:
- 1. Schedules are being levelized and refined
- 2. Commodity production plans are being finalized in accordance with the levelized and refined schedules.
- 3. Comprehensive and detailed work plans, as with the integrated system milestone rescheduling, are being developed to facilitate clear work plans to support required system completion turnovers in the most cost effective and work economizing fashion.
- 4. A specialist in the field of piping and related commodities is
~orking with SWEC and others to
. initiate improvements to uni t rates and better work techniques.
To meet our objectives and get this Project turned around NMPC met with SWEC Management and presented a stringent action plan reouiring significant immediate -corrective action. I sill be reviewi,ng SWEC's progress relative to this action plan with the SWEC. Project Director on a weekly basis and have targeted the end of August as a benchmark to me>sure SWEC's responsiveness to the Project needs.
As stated, the Project is completing a detailed assessment of the Integrated Flush Milestone Schedule. The preliminary indication is that by concentrating the .Project efforts on the work actually required for the Milestone, the March 4, 1985 scheduled Milestone date is achievable.
I. EXECUTIVE
SUMMARY
(Cont. )
A. Project Director (Cont.)
The Project is nearing completion of the revised cash flow forecast to the end of'he Project. Preliminary resul ts indicate that the 1984 cash flow wil 1 be in excess of the $ 675 x 106 previ ous ly projected. In addition, the efforts expended in the development of the forecast have added assurance, that the current $ 3.37 x 10 Project estima.e is adequate.
On July 27, 1984, NMPC provided the NRC with a status report relative to NMPC's commitments to the Construction Appraisal Team inspection report. Several items were not completed by the June 15, 1984, scheduled date; however, most were completed by July 27, 1984, with the balance to be completed by August 31, 1984.
The CHOC headquarters manhours continued to increase during this period. This management directed SWEC to immediately return to the planned manhour curve. During September SWEC is scheduled to be utilizing a system which provides weekly reporting of manhour expenditures. This will allow the Project to more closely detect manhour ove. runs and take prompt corrective action.
MAJOR PROBLEMS The following is an .update to the major problems define in last month's report.
- l. "Our ability to control work within schedule requires significant improvement." This item is addressed in several areas of the SWEC Action Plan.
- 2. "Despite strenuous planning efforts and excellent conduit production we have failed to ooen up adequate backlog for cable installation." The conduit production continues to be excellent; however, we still have not opened a significant cable installation backlog. Engineering will issue by 8/15/84 a System/38 computer report which will provide detailed information relative to the status of each raceway, and junction box. This report will allow construction to determine specific work which must be comp',eted for the raceway.
3.~ "Improved planning efforts and precise definition of components within test boundaries are required." This item is addressed in
~ ~
several areas of the SWEC Action Plan.
- 4. "RSIV modifications mtt".r bio "';ated very soon." 'etailed plan has been developed to resolve the problem which entails the application of a corrosion-resistive cladding to the affected area. It has also been identi ied that valve body test coupons were not heat treated as required by ASME. To meet code requirements, it may be necessary to cut -test coupons from ,he valve bodies.
I. EXECUTIVE
SUMMARY
! Cont. )
A.. Project Director (Cont.)
- 5. "The Records Identification and Management Program must be brought within total control at the earliest date." This item is addressed in several areas of the SMEC Action Plan.
The following items-are being added to the list of major problems:
- 6. In a number of significant areas we have not been satisfied with General Elect.ic Company attention to Project schedule requirements under the HSSS scope of work.
- 7. ITT Grinnell has not been able to meet the recovery plan for Large Bore Category I Pipe Supports. Additionally, the large bore hanger acceptance rate is unacceptable.
TOTAL PROJ ECT PERCENT COMPLETE
SUMMARY
TABLE
,NI NE MILE POINT NUCLEAR STATION - UNIT 2 PERCENT ITEM WEIGHTED PERCENT C MPI.ETE 1984 1985 1985 OF TOTAL PERCENT I MILESTONFo PROJECT OMPLET CUM lNC IS IMIAIMMMIAI SIOINIO I I I M IAIMIJ 4 lAIslra N l o A I AI M I AI MMIJI AI I Ic
'I. ENERGIZATION 4160 V 2.49 9L29 2.40 O.oooo
- 2. CONDENSATK OEMINERAIJZER 2.91 89.11 2.65 0.0513 ltltUM
- 3. SERVICE WATER 8.08 61A3 5.3d 0.1357
- 4. STANDBY DIESEL 0.53 85.08 0.34 0.0200 UIUM S. INTKQRATED FLUSH 13.09 7425 9.72 0.1728 UllM
- 6. FLOW INDUCED VIBRATION '.09 71.14 Rod 0.0044 UIUI~
I
- 7. TURBINE GENERATOR 2.70 77.68 2.10 0.0701 I IM
~ ~
- 8. VENTILATION l,45 70.09 3.12 0.1305 llull
- 9. INTEGRATED LEAK RATE 1.14 50.28 0.57 %0436
- 10. RAOWASTE SYSTKM 1.34 62.31 0.83 0.0244
- 11. FUEL RECFJPT 0.75 50.78 0.38 0.0273
- 12. LOSS OF POWER/ECCS 0.81 44.27 0.3d 0.0278
- 13. FUEL LOAD OAT 57.65 027 0.012'I
- 14. FUEL LOAD TO C.O. 1.10 I 0.00 0.00 0.0000 I SUBTOTAL 'MANACCMSNTCONIINOSNCT 38.00% 74.1 4 % 25. I 7% 0.7201'4 I
II CONSTRUCTION I I
COMMODITIES I I
- 1. PIPING 9AS 6544 844 OM15 L ELECTRICAL 5.53 TL04 4.84 04465
- 3. I 6 C 0.99 52.65 0.52 0.0474
- 4. HVAC 0.83 77.60 0.54 0.0214
- 5. CIVIL 13.10 100.00 13.10 SUBTOTAL. 3t.aafa 85.54fil 27AS fir 08489%
IIISTARTUP 8ITEST COMMOOITIES
'f. PRK OPERATIONAI. TESTING 0.80 0.00 0.000 0.0000 2.HYOROS OAO 19.33 0.155 0.0504 3.LOOP ~MIJBRATIONS OAO 3.02 0.024 0.0103
- 4. CONTROL CIRCUlT VERIFICATION OJIO LSS 0.031 L0158 S. INITIALEQUIPMENT OPERATION 0.50 I.d3 0.015 o,oat ~
- 6. FLUSHES 025 4.71 o.038 0.0233
- 7. PENETRATION LEAK RATE TESTS 045 0JI0 O.aao 0.0000 SUBTOTAL Loaft 541 % 0.250%
IV ENGINEERING 1 ~ DESIGN VERIFICAT1ON 0.54 28.do 0.154 0.0118
- 2. EOUIPMKNT OUAIJFICATION OAS 6%25 0.173 IL0029
- 3. IJCENSfNCL OBS 59.07 0457 Load d
- 4. SUPPORT OFSTARTUP L38 58.70 0451 O.of 27
- 5. BALANCEOF ENQINEERINQ 1IL27 91.95 I L801 IL0837 SUBTOTAT 2IL00% 88.88% 17.75 til 0.119916 V OUALliYASSURANCE L00% 5520% 2.7514 0.1 10%
Vl RECQROS TURNOVER t.00% 28.00% 0.25%
TQ PPP TOTAE. I OILO0% 75.70%
~
STATUS AS OF 7/15/14 I LKSTON FSCHEDULE CRITICAI. PATH .
NOTE: This fable ls nredmfnsr7 and rerfects project Cata available ss of 7/15/84.
Revised data from Ihe Prolect Control Proaram will be Included as it ls developed.
TOTAL PROJECT PERCENT COMPLETE PERFORMANCE CURVE NINE MILE POINT NUCLEAR STATION - UNIT 2 100 sr
~ ~ yg H 98 96 r rrr
~
94 92 r r PLANNEO ACTUAI rr INC.
LLl 90 88 r CUM. 79.21 75.7D r
0 &6 rr 84 r 82 r 80
?8 PLANNED oammmmm 76 r ACTVAL 74 r r
Attt ISAT WN Wl, AIJ4 SSP OCl NOV OSC JJJS SKF MAC APL ISAY JWI JVI AQO SKP OCT NOV DCC JAN IlED IIAII A7ft ISAAC JQII JIJL AV4 SCP 4984 1986 $ 986 THLS CUAVE IS PAELIMUJAAYS AEFIXCZS PROJECT OAT% AVAILABLEAS OF 7/15/SS ASAEVISEO PROJECT CONTROL PAOCRAM CATA IS FtNAUZEO IT WILLBE INCLUOEO IN THE CURVE.
EXECUTIVE
SUMMARY
B. Mana er Ouality Assurance - Projects Corrective actions have been implemented to reduce the ITT Grinnell weld reject rate. Though the reject rate nas declined, it is still at an unacceptable level and corrective actions will continue.
Stone and Mebster is preparing to perform a detailed audit of the SWEC equality Assurance Program to determine its effectiveness in monitoring the on-site contractor's activities. Paral'lel to this action, NMPC Project guality Assurance is prepa'ring to perform a detailed assessment of the effectiveness and adequacy of the on-site contractor's programs.
The independent assessment team is continuing its review of complete CAT Action plans, NRC deficiencies identified in the SALP Report, and NMPC/Contractor identified deficiencies.
II. MILESTONE SCHEDULE STATUS A. Ener ization 4160V During July, a number of systems were turned over. However, the backl og of turnovers was not sufficiently reduced to recover schedule time. Further slippage was experienced on critical 416OV switchgear turnover and testing acti vi ti es. Overal 1 schedul e status through July is eight week behind schedule.
A study is underway to determine the impact of required modification to high pressure core spray 4160V switchgear modification upon the scope of tnis miles one. It has already been determined ,that these modifications will not impact the overall schedule.
B. Condensate Demineralizer The milestone schedule remains at four weeks behind schedule.
During July, the makeup water storage and transfer system was turned over and testing was initiated. No overall project delay is anticipated.
C. Service Water Overall status of this milestone remains at three weeks behind through July. Work concentration continued toward release and operation of three of the six service water pumps. The screenwell was flooded during July in preparation for pump operation.
Integrated Flush During July, the integrated flush status slipped to six weeks behind schedule. Although sfgnificant pragress. was made, the level of work completed was insufficient on a number of critical systems in the small bore piping area.
It has been recognized that a further subdivision of work is required to permit the integrated flush schedule to be maintained.
A study has been initiated to defer work not necessary to support the 'integrated flush and RPV Hydro to a point later in the schedule. This will optimize the application of resources to critical areas.
E. Turbine Generator During July, an improvement of one week was noted on work critical to supporting the lube oil flush. Overall status is now one week behind schedule.
0
II. HILESTONE SCHEDULE STATUS F. Diesel Generators Through July, the milestone status remained at two weeks behind schedule with no impact projec ed to the overall schedule.
G. Radwaste System An effort is underway to adjust the radwaste schedule and "";clop a revised work sequence. Status against the base milestone plan i s three weeks behind schedule.
For the balance of the milestones, work proceeded in suppor of the milestone dates with,no overall impacts noted.
- l. FLow Induced Vibration
- 2. Ventilation
- 4. Fuel Receipt
- 5. Fuel Load III. CONSTRUCTION A. General Overall, Construction cumulative performance relative to key indicator commoditi.es was positive in July. This is noteworthy, considering the high level's of absenteeism experienced during the week of July 4. The major construction commodities are depicted in t
the following graphs which have been updated to show year-to-date and current period performance.
SWEC S. B. PIPE r~ ~ ~ 65,967 Unit!
t~uantlt hanhnutt Rate[
Current Pl an 5,921 42,631 Month Actual 4,569 27,718 6.07 i I
, '1984 ear-co Plan 3 908 "."".6, 326 Date '"0 Actua I 31,?41 ~ 56a665 5 I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I l I I I JFWtAItl JJASONOJFMAMJJASONDJFMAMJJASO 1984 1985 1986 rIlnu lo.ov-ae SWEC small bore piping installation improved from the previous month.
A return to plan is expected in view of process improvements relative to shop fabrication previously identified. (See text for additional details.)
Planned Ac ual
SWEC S.B. HAIIGE'R 20,000 18,000 16,000 14,000 12,557 12,000 10.000 Un>t l.
8,000 ~v'nt!: .znhovrs Current Pl an 767 30,373 39.60 6,000 Honth Actual 634 27,066 42.69 4.000 1984 Year-to Plan 3,890 154,044 35.50 Oate Actual 4,481 171.076 38.18 2,000 I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I JFMAMJJASOHOJF14AltJJASONOJFMAQJJASO
%984 098S T986 THRu 10 Og<C SMEC small bore hangers continue to exceed cumulative plan requirements.
although production for this month f'ell slightly behind. ito negative impact projected.
Planned Actual
1TT PLAN VS ACTUAL S 8 PIPE 1)9,086 110000 108000
/
I 106000 I I
I 104000 I Un> t..
102000 ~0uaat( t tlallhours Rate Current Plan 999 3,486 Honth 3.49 c= 1GOOOO Actual 1,120 13.118 11.71 I
I 1984 Year-to Plan 20,299 70,843 Oate 98000 Actual 18,257 91,595 0 96000 94000 92000 I I I I I I I I I I I I I I I I I s I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I JFMAMJJASOHOJFMAMJJASON 0JFMAMJJAS0 CS84 1 885 f986 THnIJ fO OT a4 Good progress was reported relative to tTT Grfnnell small bore piping throughout the perfod, with the exception of the July 4th week and associated hfgh absenteeism. Ifowever, lTT Grfnnell achieved approximately 30" more than was required and continued progress is expected. Cumulative plan performance remains below plan.
The current period unit rate over run is a result of inefficiencies as a result of smal1 bore piping efforts in support ot system turnovers and rework levels !n excess of plan.
Ac ual
Pl armed ITT PLAN VS'CTUAL 5 8. HANGKQS 15,190 15000 14500 14000 13500 13000 Uni t 1
~ruantfu .'aanhnura Rate 12500 Current Plan I r 5,427 23.33
'!onth O n ran Ac ual 7 r Ig,
~
~
h a vaaaa ha V 1
~
1984 Year-to Plan 4,748 1!,0,581 23.29 1)500 Oate Actual 3,349 177,777 53.08 rf
'11000 10500 I I I I I I / I I I I I I I I I I I I I I I' I I I I I I I I I I I I JFMAMJJASONDJFMAMJJASON 0JFMAMJJASO I I 5984 1985 5986 THrrv 10 ~ Or ~4 ITT Grinnell small bore hangers also exceeded planned irstallatfon targets for this month, and recovery efforts are exoected to continue.
Significant reerk to the hangers for the service and instrument air :ystems required to support turnover priori ties nas contributed to the uni t rate overrun in this period.
Actual Planned
ITT PLAII VS ACTUAL L 8 PIPE 225;000 222,500 220,000
/
217,500 I
/
I I
215,000 Unit I 0~>>nti t Hanhours Pate I
I Current Plan 993 5,005 5.04 212,500 I Iionth .. Ac ual 1,242 17,932 14 44 210,000 f '.984 Year-to 23,6)6 119,025 5.04 Oate l nc us 1 >093 148,311 I
207,500 I
I 205,000 202,500 200,000 I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I FMAM J J*SOH J 0 J FMAM J JASON D J FMAM J JAS 0 1984 T985 1986 THnu 10 01 ~ ~0 Again. 1TT Grinnell's large bore pipe performance for the period exceeded the planned installation target. The period unit rate overrun is due to the closing out of punch list Ite11s for pipe that has previously earned full credit.
Actual Planned ITT PLAN VS ACTUAL L 8 NANGERS 18,181 18,000
)7,500 17,000 16,500 16,000
//
f1 1 t 15,500 j Current
~huanaia 450 nanhnura 64,013 Rate 142.25 I Nonth 15,000 4
I r -ta Ac'tua1 265 60,711 513,380 229.10 l42.25 le 1984 Year P! an 3,509 14,500 Oate
/
Actual 2,983 556,522 186.56 14,000 13,500 12,500 I 1 1 l 1 1 I r 1 I t 1 ) I I 11 I I I I t I I I I I I I I I I J FMAM J JA SON 0 J FMAM J JASOMO J FMAM J JAS O 1984 $ 985 4986 THRU '10 Ornate lTT Grinnell performance relative to large bore hangers exhibited a shortfall this period against the required target. Plans are currently
".eing developed to establish dedicated resources (craft, engineering, 0C, etc.) to drive this effort to successful completion (See tex. for additional details. )
The period unit rate is exceeding plan due to hanger ccmpTexity in the primary containment that requires excessive manhours. ln addition, hours in excess of plan are being expended to-advance hangers from the 4X to SX completion status.
Actual
--- --Pl armed
1TT L. 8. M<LOS(CAT 1) 4750 4 702 4500 I 4250 4000 I 3750 I 3500 3250 I 3000 I
I 2/ QO 2500 2250 2000 I I I 1 I I I r I't l I I 1 I r I r 1 I I I I I I I I I I I I I I I I I < I I J F M A M J J A S 0 H 0 J F M A M J J A S 0 N D J F M A M J J A S 0 r t9114 $ 985 I 1986 THnu 'l4 41 t4 Planned Actual iTT Grinnell large bore weld performance, although exhibiting a downturn in production, remains cumulatively above the plan. Also noted's a significant improvement in tne <<eld reject rate.
(See large bore weld curve.)
ITT PLAN VS ACTUAL L 8 'JELO (PROCESS) 17500 17000 r r
/
16500
/
/
I 16000 I I
I 15500 I
I 15000 I 14500 I I
I
>>000 a I
I 13500 13000 12500 I I I I I I I I I I I I I I I I I I I I I I I I,I I I I I I I I I I i I I I I I I I I I 4FMAMJJASOHDJFMAMJJAS7NOJFMAMJJASO I I 1984 19$ 5 I 7986 THAU 10 01 CC 1TT Grinnell large bore mid performance this month exceeded the plan.
Full recovery is, hcwever, contingent upon successful completion of the large bore piping effort.
Additionally. !TT Orinnell has suostant>ally Improved tneir '<<eld reject rate and is reporting 17.68 for 831.1 and 2.45 for ASHE 111.
Planned Actual 1TT PLAN VS ACTUAL L 8 '/ALVES 2200 2100 r' ~O 2>194 2000
/
/
1900
/
t
/ Uni t 1800 / ~2uanttt l4anhours Rate 1700 I Current Plan 70 2,292 32.74
/ Month
/ Actual 52 1.484 28.54
/
- 600 /
I il384 Year to Plan 920 30, '121 I 'gate 1500 / Actual 558 16,379 24.89
/
1400 1300 1200 I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I J FMAM J JA SOHO J FMAM J JASON 0 J FMAM J JA S 0 1984 1985 1986 THAV 10 Or ~a Expediting efforts are in progress to assure timely delivery of remaining valves. Large bore ra'Ive production is exhibiting positive trends which are exoected to continue.
Ac.ual Planned
'lC "PLAN 'IS AC v'AL CONQUEST 833000 835,673
/
800000 e
757000 a
733000
//
/
7COOOO UnIt t~uanttt uanhnurs Rate 667000 8 Curr ent Pl an 18,000 19,260 1. 07 Month Actual 23,807 26,976 1.13 633000 iL98'(ear-to Plan L53,000 '.53,7 Lo 1.07 IOate 600000 Actual 158,529 177,285 1.12 5670OO llllilllllrll 533000 I I I I I I I I I IIII ill I I I FMAI4JJASOHOJFllAMJJA.SOKOJFMAll JJAS0 1984 1985 1986 THRU 10 ~ Of CC LIJ: conduit continues ~e11 ahead of plan. (See text for additional am+eats. >
Actual Planned LKC PLAII VS ACTUAL CONOU[T SPTS.
32000 31,029 3050 a
r j/
29000 2750 I
/r 2500
/
/
2450 Unit
~Quantt. .".anl.uur: Rate Current 23CCO '"oo<<N Plan V 0 <<3
~
/
Ac uaa 5 QV 13, 00 21,50 1984 Year to Plan 9,400 127, 182 13.53 Oate Actual 10,453 165,941 15.!!7 2000 1850 I I I I I t f I I I I f f I I f I I I I I I t I I I I I I I I I I I I I I I I I I I I I I JFMAMJJASONOJFllAMJJASON DJFMAMJ JAGO 1984 1985 1986 THRU to ot ~ 66 Lf'C conauit supports installation continues cumulatfvely ahead of plan.
Actual Planned
LKC PLAII VS ACTUAL CABLE PULLIIIG 8,405.903 Cable Cumulative Ouantities as of 7/15/84 775000 Power 849,044 725000 / Control 3,017,469 Instrument 745,979 6750GG Jther 50,512
/
/
4,563,004 625000 /
'75000 /
/
t Uni r.
525000 O~uantft Hanhaurs Rate 475000 j ,Current
'!onth Pl an Actual 336,319 273,168 32,969 39,720 0.09 0 11
/
425000 1984 Year to Pl an 2,629,385 236,645 0.09 Gate Actual 2.074.178 241,112 0.12
. 5000 325000 I I I I I I I I I I I I I I I I I I I I I I i I I I I I I I I I I I I I I I I t I I I I I I I I J FaaAM J JA SOLD J FMALI J J A SON D J FNAM J JAS 0
$ 984 1985 1986 THAV 10 ~ 01 !s Although slight improvements are reported against LKC cable pulling performance, this area continues to receive Project Iianagement focus.
LKC/SWEC have apparently dissolved the log jam responsible for the negative trend wnich began in May. (See text ~or additional details . )
Actual Planned
~
LKC PLAN 'lS ACTUAL CABLE TERN 275000 276,663 250000 e
/
25000 r
20000 i
/
175000 Q 150000 Jhl t
~tu d fit f ' 'lanhours Race 100000 Currenr. Plan 21,123 18,377 Month Actual 8,857 12,543 1.42 75000 1984 Year to Plan 108,565 94,452 0.87 I Gate 50000 Actual 70,716 78,716 1.11 I I I I I I I I
I I I I
I I I I I I I I I!
I I I I r I I I I I I r I I I I I I I I I I I I I I I JFMAMJJASOKOJFMAMJJASOK0JFMAMJJAS0 1984 1985 1986 THRV ro Or ~ ~ 6 LKC's per formance relative to cable terminations continues to exnibit cumulative shortfall. Prospect is focusing efforts to increase the backlog of clean, available termination work.
Actual Planned JCI PLAt( VS ACTUAL SEISMIC SPTS.
55GO 5,3GO 5000 a/
r 4500
'000 I
/
/
3500 O~tuantt t nanhnurt nit 3000 Rate t Current Plan 282 Honth 11,793 41.82 2500 Actual 207 14,035 67.80 1984 Year to Plan 1,620 67 a 748 41.82 2000 ate
'ctual 1,254 71,727 57.20 1500 1000 500 I I I I I I I I I I I I I I I I I I I I t I I I I I I JF I I MAM I I JJASONDJFMAMJJASOH0JFMAMJJASO I I I 1984 1985 1986 YHRu ra ar ec JCI seismic supports continue to exhfbft a cumulative shartfall. However, this periad's performance Is a significant improvement fram the previous month. Efforts are being focused in the upper levels of the Reactor Bui1ding io support af the BIP TIO Program.
~ he unit ra'tes are over the alan as a result of seismic suooora oreviously reported as full credit .or <<hicil ~or'k is required to achieve gC acceptance.
Actual Plannea 23~
JCl PLAff 'IS ACTUAL lNST. TUB jffG 250,000 225,000
~ 230,115 200,000 r 175,000 y
150,000 e 125,000 c ~ Un> t
~OUaocit ffanhours Rate
!00,'300 ant ?lan '!0,803 ~
~ or ~
co 9
.":on:n Actual 10,555 17,042 1.50 75,000 1984 Year to Plan 61.414 91.507 1.49
.Oate 50,000 Actual 48,012 66,914 !.37 25,000 l I f I I I I I f f f I f l f l l l f f f l f I f f l I I l I I i I f I I I I I I I I I I JFMAMJJASOHOJFMAMJ I I I I I I I I I JASON OJFMAMJJAS0 f984 1985 1988
'rHRu 10 Ot I6 Johnson Conrrols installation progress is improving. This trend is positive and should provide recoverj.
Actual Planned III. CONSTRUCTION A. General (Continued)
Construction turnover nf systems to SWEC Advisory Operations Division for preliminary testing continues to exhibit shortfall. As discussed in various sections of this report, significant Project Management. actions are being provided in this area.
Meld reject rate performance has improved since the previous report. ITT Grinnell has implemented ' comprehensive program to complete activities within the proper levels of acceptabi'.ity and minimize repair work.
Construction Management thorough continues to emphasize housekeeping and cleanliness. General site conditions continue to improve as a result of proactive Materials Management within the power block, follow of contractor responsibilities, and virogous surveillance by Construction personnel.
Mr. J. Weaver commenced an assignment under the direction of the NMPC Sr. Manager of Construction relative to SMEC force account small bore piping production improvements. Mr. Weaver will also examine ITTG Cat. I Hangers.
III CONSTRUCTION (Continued)
B. Contractor Performance SWEC Force Account Overall, SWEC Force Account work scope performance continues to proceed in a posi ti ve di recti on both in tems of commodi ty installation targets and schedule compliance. However, there are areas, such as small bore piping, which require improvement. Specific production assessments and exceptions are addressed below.
Mechanical Equipment Erection Approximately 89% of the equipment scheduled to be installed has been released for external piping connections. The remaining equipment continues to be prioritized to support BIP turnovers. No schedule impacts are anticipated.
Cat II and III Han er Com letion Performance in this area remains above plan.
Small Bore Pi e and Sup orts The piping effort exhibited slight shortfalls during this period. SWEC has implemented pipe assembly walkdowns and a weld performance improvement plan designed to strengthen shop fabrication production. In addition, extensive modifications to the fabrication process, along with FgC hold point reductions, will improve small bore piping production.
Small bore hanger performance is tracking slightly ahead of plan.
Preventative Maintenance Planned maintenance requirements and inspections were performed during this period. Ho significant problems were identif ed.
~Pa< ntin (Temporary'I Schedule sequencing during July will prioritize requir d Milestone painting activity to avoid turnover impacts.
III. CONSTRUCTION (Continued)
- 2. ITT Grinnell Overall, ITT Grinnell's commodity installation performance through this period exhibited improvements. However, large bore hangers continue below planned quantities. Management actions will include improvement recommendations by Mr. J .
Weaver, review of potential positive actions which can be adapted from the SWEC Hanger Program, and a prioritization of those essential hangers required to support near term RIP turnovers.
SWEC is working with ITT to improve the turnaround to support the Stress Reconciliation Program.
Coordinated efforts are required on the part of ITT Grinnell to support Johnson Controls in the installation of .root valves and thermal wells.
- 3. L. K. Comstock t
L. Y. Corns.ock' production has generally ac el crated throughout thi s period in the areas of cabl e pull ing and condui t/raceway instal 1 ation. Emphasi s remains focused on these two elements so production 1 evel s can increase and cumulative deficits r ecover.
Although slight improvements were experienced relative to cable terminati.ons, LKC must substantially improve their performance in this area.
Assistance by Johnson Controls in identifying future instrument locations will permit L. K. Comstock to route conduit in advance of device installation.
Efforts continue toward release of raceway tickets on hold, improvement of the cable pulling backlog and cable termination output, and completion of the 4160v milestone. Internal management actions implemented by L. K. Comstock favorably accelerated production performance during the last half of the fiscal month.
Cable pulling backlog drawdown, electrical FgC inspector attrition affecting commodity releases, and BIP restraints continue to receive management scrutiny. The interim results thus far suggest favorable performance.
III. CONSTRUC ION (Continued)
B, Contractor Performance (Continued)
GE-PGCC July remains the goal for completion of subsequently separation problems and both divisional and identified'ubdivisional subdivisin~al outstanding open items. Progress is reported on schedule with total completion, including HSSS/BIP modifications, targeted for February 1985.
Johnson Controls Johnson Control s exceeded scheduled quanti ties for instrument tubing installation requirements, accelerating cumulative recovery. Process improvement plans have been devised and implemented in response to production deficits in seismic tube support installations. The instrumentation quantity develop-ment program has concluded, resulting in more accurate scope ti def ini on.
Johnson Controls is awaiting program manual changes unich will
- mprove gC inspection process for Ca.. ll and III insta11ations.
- 6. Schneider Power Corporation The HVAC effort is proceeding with improved commodi ty installation. The HVAC milestone schedule is undergoing logic and activity sequencing examination. Engineering clarific'ation and support of technical issues have improved considerably.
- 7. ~Yikin (Fine Protection - Radwaste)
Thi s contractor has performed on schedul e. However, 1 ate deli very of fire detection equi cment wi 1 1 have a short-term schedule impact. This contracto~ will demobilize on July 31, 1984 and remobilize on March 19, 1985.
- 9. Metal Cl addin Industries (Condensate Storage Tanks)
The tanks were successful ly hydrotested subsequent to minor rework. Additional rework has been punchlis ed on internals, but schedule impacts are not anticipated.
I I I. CONSTRUCTION (Continued)
B. Contractor Performance (Continued)
GE-PGCC July remains the goal for completion of subsequently identified subdi vi si onal separati on probl ems and both di vi si onal and subdivisional outstandin~ open items. Progress is reported on schedule wi th total comp 1 eti on, incl uding NSSS/8 IP modifications, targeted for February 1985.
5, Johnson Controls Johnson'ontrols exceeded scheduled quantities for instrument tubing installation requirements, accelerating cumulative .
recovery. Process improvement plans have been devised and implemented in response to production deficits in seismic tube support installations. The instrumentation quantity develop-ment program has concluded, resulting in more accurate scope definition.
Johnson Controls is awaiting program manual changes which will improve QC inspection process ,or Cat. I.' and III installations.
6.
T ne HVAC effort is proceeding with improved commodity installation. The HVAC milestone schedule is undergoing logic and activity sequencing examination. Engineering. clarification and support of technical issues have improved considerably.
- 7. ~Vikin (Fire Protection - Radwaste)
Thi s contractor has performed on schedul e. However, 1 ate del i very of fire detection equi pment wi1 1 have a short-term schedule impact. This contractor will demobilize on July 31, 1984 and remobilize on March 19, 1985.
- 8. Metal Claddin Industries (Condensate Storage Tanks)
The tanks were successfully hydrotested subsequent to minor rework. Additional rework has been punchlisted on internal s, but schedule impacts are not anticipated.
III. CONSTRUCTION (Continued)
B. Contractor Performance (Continued)
- 9. Insulation Contracts (Various)
Schedule slippages in hydro testing mechanical piping systems are restraining insulation'pplications. This is not significant in terms of maj or impact, but does req" i re management attention. The contractor i s restricting manpower levels until a sufficient backlog is generated.
- 10. Randall Electric Progress is being affected by the late release of cooling tower electrical design information. Engineering is expediting required design information. Schedule exposure is not serious at this time.
- 11. Synder, Mackin and Shaffer Major efforts are underway to consolidate and streamline the construction site power syst ms.
- 12. Tuscarora Construction (Revetment Oitch)
Progress is currently three weeks behind schedule and completion is anticipated in October 1984, w.'th no schedule impacts.
Pullman (Main Gas Stack)
Pullman has fallen behind the schedule and has been advised that backcharges will be employed to recover costs generated in maintaining the on-site concrete batch plant beyond the scheduled dismantling. Pullman is reassessing their manpower and the potential for shift work to avoid this action.
- 14. Reactor Controls Inc. (.'ISSS)
In general,. the Recirculation System and control rod drive installations are ,proceeding on schedule. 'nternal activi".y on the RPV remains about eight weeks behind schedule. This portion of work is being assessed.
C. Construction Com letion The status of the Boundary ~>>'tification Package (BIP) Construction Completion Program as of July 17, 1984 is shown in the following table.
I I I. CONSTRUCTION (Continued)
BIP CONSTRUCTION TURNOVERS to AOD As of July 17, '1984 Schedule Cum. Actual Cum 4160 Volt Energi zation 31 24 Service Water 20 16 Condensate Demin. 13 10 0;esel Generator 0 0 Turbine/Generator 1 1 Radwaste 2 1 Integrated Leak Rate Test 0 0 Ventilation 9 3 Integrated Flush. 0 0 Fuel Receipt 0 0 Fuel Load 1 1 Loss of Power/ECCS 2 2 58 Since last month's report, a total of 17 BIPs have been accepted by SWEC A.O.D. for Preliminary Testing. Those BIPs accepted included:
4.001 and 44.002 (Condensate Storage and Transfer) 810.A01 (Circ. Water Supply to Service Water)
$ 10.BOl (Acid Treatment) 916.001 (Demin. Mater Storage and Transfer) 8'22.C01 (Waste Oil Collection) 858.001 (Diesel Fire Pump Room Vent.)
A/66.001 (Aux. Boiler Drains)
$ 66.003 (Condensate Storage Drains) 871.A10 (600v Load Centers) 871.A11 (Motor Control Centers) 471.B03 (Power Distribution Panels)
'-,".71'.e05 and 971.805 (Reactor Protection i/G Sets) 472.001 (4160v Switchgear)
AE72.003 (4160v Switchgear) f74.002 (Emergency DC Distribution).
IV. ENGINEERING A, General Overall Engineering and Design efforts continue on schedule. The most notable areas include cable routing and ticket;ng, setpoint development, responses to CESAR questions, Appendix R efforts, Cat.
II and III stress data packages, ALARA shielding and P&IDs. The Bar Chart Summary of the 1984 Engineering Work plan, as amended, is proviu~d on the following two pages.
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IY. ENGINEERING (Continued)
B. Problem Areas Spare Parts The spare parts effort remains behind schedule, primarily due to discrepancies. between GE and SWEC gA categorizations.
Additional manpower has reduced the backlog of purchase orders. The total procurement effort is scheduled to be complete by October 1984.
- 2. As-Builts The revised as-built stress schedule, based on the Project Milestone schedule, has been incorporated into the Engineering Work Plan. Additional revision may be required, however, once construction manpower levelization scheduled for early August 1984 is completed.
- 3. Ap endix R DIscussions were held with GE and the NRC to ensure that SWEC's approach of addressing a control room fire and rela.ed spuri ous operati on was ace eptabl e to the NRC. Desi gn changes for r erouting of cables required for safe shutdown were started in accordance wi th schedul es recently developed to monitor work related to this effort. The Engineering Work Plan will be revised to reflect these schedules. Evaluation of the fixes necessary to have a safe shutdown capability in case of fire in the control room or relay room is in progress. Because of spurious operation r defined rules, SWEC is generating a list of the minimum required number of signals. A meeting is scheduled with NMPC for July 26, 1984, to review this final list.
E ui ment gualification Equipment gualification remains behind schedule. However,
~
specifications are being amended to include the revisea environmental requirements. Resolution of comments relating to qualification documents continues to improve. An additional 61 documents have been approved since last month.
~ '
Iy. ENGINEERING (Continued)
B. Problem Areas
- 5. Main Steam .solation '/gives Similar type'alves furnished on other plants have experienced corrosion problems during extended periods of storage and layup, affecting seating capaoility. A detailed plan has been developed to resolve the problem which entails the applica+ion of a corrosion-resistive cladding to the affected area. A request for proposals has been issued and an award is expected on July 24, 1984.
It has also been identified that valve body test coupons were not heat treated as required by ASME. To meet code requirements, it may be necessary to cut test coupons from the has been developed to address all valve bodies. A plan possible solutions.
C. O~iS h d1 As of July 0, 91 drawings are requi red for construe".ion.
~ They consist of the following:
New drawings added this month:
20 - Power drawings which show additional details for sealing electrical and piping wall and floor sleeves. These drawings are scheduled for issue in December and will have no impact on construction.
2 - Vessel drawings that are requi red for additional details for the reactor head. cavity pit and canal were added to the schedule and will be issued in August.
Drawings issued at 80% and needing finalizat on:
31 - Electrical wiring and termination drawings. Expected issue is the end of July.
21 - Power drawings that contain holds due to lack of vendor detail on expansion joints and otl er miscellaneous equ'.pment.
Expected issue is September.
13 - Berm drawings scheduled for September.
4 - Ir.:.+rumentation drawings - <<i ~duled fo~ August.
IY. ENGINEERING {Continued)
~Staf fin An accelerated Headquarters and SEG destaffing effort is underway in order to meet the 1984 cash flow requirements. Some of the activities discussed in Section IV.B may have revised schedule dates as a result of the plan. Details of the evaluation and revised manpower plans will be provided this month. See Section Y for the present Engineering staffing curves.
E. Other Activities Status of ESDCRs disposit;oned by Engineering is illustrated on the following graph.
EXOCR STATUS OOOO g00 800 700 h ~ 555 600 'v' I
500 I U
C7 Oays Open 400 300 I:.: -:0,'OO 100 I I I I I I I I I I I I I I I' I I I I I I I I I I I I I I I I l I I I I I I I I I I I I I I l l s I I I I I I I I I l JFMAMJJ*SOHOJFMAMJJASOK0JFMAMJJASO 1984 1965 1966 anu ca-ot-Ic Open with Engineering at IIanth End
Ans'~ered by Engineering during .".anth MORKFORCE LEYELS The site staffing is displayed on the following table. The planned number corresponds to the $ 630 million cash flow (See Cost Section for explanation). Also attached is a gr'aph depicting the site equivalent headcount. Graphs depicting the site manual and non-manual payroll headcount and percent overtime have been added. The site equi valent staffing for July was 143 less than the June count.
The CHOC staffing is displayed on the Headquarters Services Manpower Graph. The actual increased by 36 during July. However, NMPC has aggressively addressed the CHOC staffing. and a large reduction can be expected during the next period.
JULY SITE STAFFING (EgUIYALENT)
MANUAL NON-MANUAL TOTAL COST REIMBURSABLE P(1) A P(1) A A S'AEC 777 1343 1129 1109 1906 245'2 Malsh 717 26 35 620 752 594'47 t KConstock 779 100 108 647 887 ITT Grinnell
'052 752 898 300 380 1278 SMS 75 89 3 5 78 94 JCI 181 203 80 80 261 283 Schneider 139 136 16 7 155 143 Nil tsie 139 0 10 0 149 0 Subtotal 3204 4165 1664 1724 4868 5889 Hard Money All 193 37 230 GE/NSSS NMPC 441(2) 441 (2 )
TOTAL 4358 2287 6645 Note:
(1) 630 Plan
~'2) NMPC includes MAC, NYSEG, RGhE and Central Hudson.
'I 984 TOTAL SITE STAFFING 'I
{exciuding choc paid 8c nape) 7.0
-ACT EQUIVALENT 6.0 5.0 Z
630 PLANNED EQUIVALENT-Z Ol 40 3.0 Z
2.0 1.0 0,0 J F M A M J J A S 0 N D 1984
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SWEC HEAOQUARTERS SERVICES EQUIVALENT HANPOWER (E'C Including SEG, Project Services Ad Ops, QA/QC) 1500 Planned . Actual VarIance I
June t,253 [ l,410 ! 157 1350 I
/i 1200 I g 1050 0JFMAMJJA 900 750 600
'; ~Represents the April Revised Estimate 450 JASON 300 150 Qr ~
~ ~
I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I l I I I I I I I I I I I I I JFMAMJJASONOJFMAMJ SO 1984 1985 1986 TKRU 10 yt L6 SWEC <<EAOCOAI'.T:-SS Cumulative Iianhours (CHOC, and Site including Advisory Operations, SEG, OA/gC ana ?roject Servicesj 17
~ ~ ~ ~
~
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,~
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/r' June Pesults or innod Ac ua 1 'far<<ance',
CHOC 164,086 174,341 10,255 SEG 30,)55 44,268 14,113 TOTAL 194,241 218,609 24,368 13 I I I I I I I I I I I I I I I I I I I I I I I I I I I I 'I I I I I I I I JFMAMJJA I
SOHO JFMAMJJA SON 0JFMAMJJASO I I I I I I I I I I I 1984 1985 1986 THnv r0 ~ 01 cc The continuing trend of SWEC headquarters overruns in equivalent manpower=
has been directed by I<<HPC to be brought under mroediate control and com-pliance with the plan. Oeviations from the alan will be accepted only
<<ith;IHPC prior aporoval.
Actual Planned HEAOOUARTERS SEG EQUfVAI.EIIT MANPOWER
'ctual 250
/
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! Planned 230 t 286 '6 l
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OkOJFMAMJJASOk0JFMAMJJA SO 1984 1985 1986 THRIJ 10 01 ~ 46 Note: The Actual manpower reflects scope increases not included in the Planned manpower Actual Planned V I. QUALITY'SSURANCE A. NRC Construction Assessment Team (CAT) and Enforcement Letter As a result of the verification of corrective/preventive act'ons for the eight violations identified in the Enforcement Letter, 19 discrepant/deficient items had been identified. As of July 23, 12 items have been resolved and actions continue to resolve the remaining seven.
NRC personnel arrived on site 7/16/84 to resolve questions that developed during their review of NMPC's response to the Enforcement Letter. As a result, NMPC will provide further clarification in a letter to the NRC.
NMPC Quality Assurance Engineering has developed all checklists required for verifying the implementation of the action plans developed to correct the deficiencies identified in the CAT Report. As of July 20, 59 checklists have been completed for verifying 59 CAT action plans, previously reported as 60. Of the remaining seven CAT Action Plans, four have been combi ned with other checklists and three do not requi re any verification as a result of the responses. It is anticipated that the completion date for initial verification of the 59 action plans will be 7/27/84. To date, 58 of the CAT Action Plans have beyn verified.
As a result, 57 open items remain unresolved. The scheduled completion date for resolution and reverification of the open items is 8/30/84.
B. Other NRC Activities On July 16, NMPC QA identified a potentially reportable deficiency per 10CFR50.55e. The deficiency was delineated on an HMPC Corrective Action Request which identified a failure in RCI' QA Program to identify and correct deficient welds in the en~erprise system. NMPC Nuclear Licensing was notified of the condition and is evaluating the deficiency to determine if it should be reported to the NRC.
NRC open items, unresolved items and Notices of 'liolations, that remained open as of July 20, are statused below.
VI. QUALITY ASSURANCE (Continued)
Additional Action Final On NRC Item Reauired Rev'.'ew Hold ~Reviewio Total Open: 3 1 21 Unresolved: 17 5 11 58 Violations: 23 TOTAL 102 1- NRC Open Item, Unresolved Item, or Notice of Violation 2- Additional action required within NNPC or contractor prior to final review and verification by QA (i.e. more documentation required, additional calculations to be performed, etc.)
The package for the item is completed and is being revi wed
.or adequacy and completeness prior to subm..'ttal to the NRC.
Items which parallel or are identical to items presently identified in the CAT inspection and require further resolution prior to submit.al.
Items which have been completed and have been forwarded to the NRC for review and approval for closure of the item.
VI. QUALITY ASSURARCE I Continued)
C. ~Staffin The present Qual i ty Assurance/Qual i ty Control S ta ff ( inc uding 1
contractors) at the Project Site i s 594. NMPC QA-Projects i s presently below the author ized staffing level due to recent transfers and resignations.
The first QA Team Building Session commenced the week of June 25 as scheduled. Subsequent sessions have been held periodically with further sessions scheduled for the near future.
D. Inde endent Review The independent assessment team has performed their review of completed CAT Action Plans (Phase 1). The remaining CAT Action Plans will be reviewed as they are completed. As a result of the review performed to date, two Corrective Action Requests have been issued identifying deficiencies that had rema'ined uncorrected.
The review of the NRC deficiencies-identified in the SALP Report (Phase II) and the review of NMPC deficiencies identified during 1/1/81 through 3/31/84 (Phase III) is still in progress. The review of Contractor's deficiencies identified during 1/1/81 through 3/31/84 (Phase IV', has just commenced.
V II . CONTRACT ADMINISTRATION A. Major Contracts/Purchase Orders to Go Two CHOC originated Purchase Orders were awarded during the last reporting period with one Purchase Order remaining.'he table below summarizes these orders.
CHOC ORIGINATED PURCHASE ORDERS TO GO OUT TO BID DATE OF AWARD FRD Present Present Descri tion OATE ~Ai i d ~Ai i 1 Dripproofing Mod. HPCS Diesel Generator (Engr. 4 Design) 9/14/84 6/11/84 7/30/84
- 2. P233N Alara Shielding Steel 2/25/85 4/02/84 6/27/84 N 3 W014B Resin Sampling Sys. 8/17/84 3/23/84 7/06/84**
- P.O. No. not assigned.
~ Actual Date of Award VII. CONTRACT ADMINISTRATION (Continued)
B. Major Contract Issues-
- 1. P301C - ITT Grinnell Negotiations are underway with ITT Grinnell to incorporate a revised incentive program. The program clearly defines performance goals consistent with schedule objectives.
- 2. P800A - G.E. NSSS Contract - Cost Allocation During July, NMPC, SWEC and G.E. met to review contractual guidelines and implement a technical review program designed to establish cost allocation for corrective actions previously taken in the field. This program will initially emphasize PGCC (including electrical separation) rework. To date, approximately $ 2.6M has been deducted from recent PGCC invoices.
During this reporting period, eighteen NSSS quotations have been dispositioned, including acceotances of major quotations regarding Mechanical Equipment gualification and HPCS Diesel Generator Requalificazion and Modifications.
- 3. P282K - Rockwell International Hydro en Recombiners A site meeting was held July 13, 1984, between SWEC, NMPC and Rockwell to discuss Rockwell's requalification proposal
($ 250,000). SWEC and NMPC have taken the position that qualification is an existing part of the PO (M/C 4 for
$ 37,000).
Rockwell 's original qualification program failed and has requested a new qualification program for $ 250,000. It was discovered that lack of traceability was the reason for Rockwell's original qualifications failure. As a result of the meeting, SWEC CHOC Engineering is evaluating whether there .is an Appendix "B" violation, and will file an appropriate 10CFR50.55(e), if appropriate. This evaluation will be completed the week of July 27, 1984. Rockwell feels there is no Appendix "B" violation and will present their formal position on this and the qualification issue on August 1.
YI I. CONTRACT AOMINISTRATION (Continued)
- 4. ~Sare Parts CHOC is continuing to fall behind schedule in procuring spare parts to support construction and system turnovers. NMPC Contract Administration and SPEC Purchasing are pursuing a recovery plan,to the schedule by *the end of July. Listed below is the current status of May, June and July.'s Scheduled vs. Actual.
S are Parts Pro ram hon'ay Scheduled Com leted Phase I 33 Phase II 9 7 June Phase II 16 10 July Phase II 23 12 C. Material Mana ement
- 1. Su lus 5 Sera Materials Efforts are ongoing to identify surplus and scrap materials.
Shipments of embed plate received in 1977-1979 are with SEG or disposition.
- 2. ~5P 4 Provisions for spare parts storage on site are progressing on schedule.
- 3. Valve Inventory Small and large bore generic valve inventories were completed during July. Accurate on hand quantities have been provided to cognizant areas for planning, installation and ordering purposes. guantities are presently being loaded into an automat!ed system to more readily trace these commodities.
D. Ex editin
- 1. P301N - ITT Grinnell Lar e Bore Hanger Materials ITT's performance to support material 'needs for the Primary Containment has been excellent to date.
VII. CONTRACT ADMINISTRATION (Continued)
- 2. P800A - G.E. HPCS Switch ear 102 The five HPCS Switchgear Breakers critical to testing within the 4160V Milestone were returned to G.E.- Philadelphia for re-work on 7/7/84 and returned to the site on 7/11/84, minimizing further delays.
- 3. Cate ory I ASME Boltin Hardware Shortages of ASME Bolting Hardware is impacting construction activities of JCI, ITT Grinnell and SMEC. Hardware Specialty and Hub, Inc., the two main stocking distributors are experiencing eight to 12 week lead times from. bolting manufacturers. Reject rates of 50% and gr ater have caused further delays. Expediting has extended shop coverage of suppliers and manufacturers to improve delivery. SMEC Purchasing and NMPC Contract Administration have pursued alternative nucIear suppliers and established additional blanket orders to support the warehouse minimum/maximum bolting program.
VIII. STARTUP AND TEST A. General Startup Administrative Procedures (SAP) guidelines for the Star tup and Test Program organization and the Joint Test Group (JTG) have been approved by the Site Operations Review Committee (SORC ).
Thirty-one of the known 144'reoperational Test procedures are in the review and approval stage.
Preliminary testing continues with the major emphasis on electrical systems. Mechanical system testing is essentially complete on the Mater Treatment System, with water production commencing in June.
HMPC Records Management has been advised of the system turnovers to support development of a required records list and deficiency list of outstanding documentation to support the turnover process.
Startup Turnover Reports (STR's) were issued on the following:
115KV yard drains (BIP 66.004) 7/5 125 VOC control power (BIP 73.001, .002, .003) 7/6 B. Preliminary 'est Status Initial energization of the reserve station transformer and two 13.8KV bu es occurred this month. Make-up aemineralizer system was operable in June. Meehan cal system test ng is in progress on the Mater Treatment System with flushing completed. Field IBC work is approximately-98~ complete for the Water Treatment System.
C. Major Problems
- 1. Replacement Parts: Lack of replacement parts continues to a ect tne test)ng effort. Preliminary meetings have been held in CHOC with Plant Service division personnel. CHOC Engineering has developed a schedule to bring this effort back on track.
- 2. Release of Syst ms From Construction: Startup and Test is wor ~ ng wit const. uction to aetenn~ ne which turnovers are critical to testing. Currently, 21 BIP'urnovers are behind schedule. Their status as of July 17 is provided in the Construction Section of this report.
YIII. STARTUP ANO TEST (Continued)
- 3. Systemic Sof tware: Current Permanent Plant Fil e contents in icate a nee to increase the emphasis and activities for software processing to be completed to support system turnover. A major effort remains underway by Records Management to define the records required for turnover.
- 4. Project Milestone Inta ration: Startup and Test comp1eted the snstva review o tata ms estone integration on June 15. The
,input used is based on the original milestone schedules. The milestone. schedules are under review, and have been updated to show current project standing.
STARTUP h TEST PLJSHES 2.0 1.8 1.6 e ~ ~ ~ ~
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.2 I I I I I I I I I I I I I I I I i I I I I I I I JFhiAMJJASOHDJFlIAlAJJASOIIDJFNALI JJASO 1984 t9 85 1988 THRIl tO Og Actual Scheda1 ef STARTur A TEST CONTROL CIRCUIT VERFICATION 10 C
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I I I I I I I I I I I I I I l I I I I I I I I I l I I i I I I I I l I I I I I l l I i I I I I i i I I J FMAMJ JA SOKO J F MAM J JASOK 0 J FIOAT J JAS 0 1988 'f $ 86 THIW fO 0'l tC Actual Sc~edu1ed IX. COST A. Cash Flow Summary Approximately $ 2,391 million* has been charged on the total Project to date.
As of July 15, approximately $ 409.3 million has been expended in 1984. This is $ 2.4 million under the $ 630 million 1984 forecast plan. The original $ 615 million 1984 forecast has been revised to
$ 630 million to reflect the recent contract re-negotiations between SWEC and NMPC for non-manual and Headquarters services.
Approximately $ 53.0 million was expended in July versus the $ 46.2 million planned.
B. July Cash Flow Variance Analysis Variance Remarks SWEC Manual and mimlion over Tlie manua1 staffing was approxi-Non-Manual mately 675~ manuals over the plan of 797.
The non-manual manoower was 83++
men over plan and non-manual overtime'as over plan at 21 L. K. Comstock $ 1.5 million over The manual staffing was approximately 321** manuals over the plan of 577. The manual overtime was 27 versus 22 planned. The non-manual staffing was approximately 6** men over the plan of 100. The non-manual overtime was 21% versus 18 plan.
ITT Grinnel1 $ 1.2 million over The manual staffing was approximately 321** manuals over the plan of 577. The nonmanual staffing was approximately 140 over the plan of 300. The-nonmanual overtime was 28% versus 25 plan.
Cont:nued-Note* This figure excludes $ 2.6 million in Administration Building Expenditures.
~ All manpower figures are approximate since actual payroll headcount figures for week ending date 7/13/84 were not available.
IX. COST (Continued)
Variance Remarks FPO's $ .3 million over The 1984 cumulative $ 6.3 million overrun is attributed to higher than anticipated staffing levels through 1984 and to an initial under e~+'.mate of the 1984 FPO cash requireme'nts.
+Other Misc. $ 2.4 million undet Total Construction $ 3.3 million over Headqrtrs. Services $ 1.4 million over July payment for May ser vices.
Manhours o verr an app roximate 1 y
-41,000 from plan mainly in CHOC Engineering and Design. Major reasons for overrun were new or increased work scope not in the budget.
Hdqtrs. Material 5 1.4 million over Total Headqrtrs. $ 2.8 million over Client Cost .8 million over TOTAL PROJECT $ 6.8 million over
'I
1984 PROJECT CASH PLANS 7CO 630 600
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Period ar 411,746 409,316 2,430 und r Gate l00 I I
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, I984
-:----- PRELIMINARY'EVISED
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AOJUSTEO APPROVEO PLAN ESTIMATE PLAN ACaUAL
',(Continued)
Pr ct Forecast evised Project Forecast is currently in process. Essentially, all input has been completed on a preliminary basis. he commodity curves are under joint iVMPC/SWEC review. Any adjustments resulting from this review will be incorporated and a final package will be prepared for the target due date of 8/1/84.
Project Estimate SMEC is presently loading the Total Project Estimate file which combines the expenditures through Oecember 1983 with the "To Go" Project Estimate of 4/1/84. This effort is targeted for completion by 8/15/84. Once the Total Project Estimate is available, a Monthly Estimate Status Statement showing actual expenses compared to the 4/1/84 Budget Estimate will be presented in this report.
Contin enc Mana ement Pro ram The Contingency Management Program was instituted to keep track of all it ...s .hat uere not included in the April 1, 1984 Baseline Estima~ and therefore, must be taken . from Contingency. The Contingency balance has been adjusted, based on NMPC's estimate review, to $ 205,000,000. The following is a summary of the items af ecting Contingency up through July 20 and are broken into two ories: VMPC Approved Changes and Potential Changes. The HHPC ved Changes are actual items that have already affected the estimate and have been approved by the Project Oirector. The Potential Changes are items which management believes may have some exposure that could affect the estimate at a later time.
To date, the Contingency balance has been increased by $ 4,495,000 in approved additions. Also, $ 38,845,766 in potential changes have been identified and are under review.
CONTINGENCY MANAGEMENT PROGRAM APPROVED CHANGES APRIL 1, 1984 TO JULY 20, 1984 CONTINGENCY DRAWDOWN ADDITION BALANCE Balance 4/1/84 $ 205,000,000 Rejection of NSSS PGCC quote 256 by NMPC.
This quote dealt with the Compensated Water Level Instrumentation.
System. $ 695,000 Budget value in excess of vendor quote for Soecification P233N for the procurement of materials and fabrication of Reactor Building radiation shields. 800,000 NSSS'mendment ;-20 quote under budgeted amount.
Amendment 820 is for technical technical for preliminary test and startup. 3,000,000 Totals 4,495,000
$ 209,495,000 POTENTI "i-'HANGES (DOLLAR ESTIMATE ARE ORDER OF MAGNITUDE)
APRIL 1, 1984 TO JULY 20, 1984 ITEN DRAWDOWN ADDITION Relocation of Technical Support Center Based on Recently Completed Radiation Dose Calculations and Finding that Original Site would be Uninhabitable Following a Loss of Coolant Accident ($ 800,000 Construction and $ 200,000 Engineering). $ 1,000,000 Headquarter Manhour increase for computer processing to create a report to compare Test Loop Diagrams and Electrical Cable Schedule Information System 70,000 NRC Initiated 3rd Party Review 5,COO,OCO Future Client Manpower Additions over and above NRC Initiated 3rd Party Review 1,000,000 Paid Overtime For NMPC Personnel per Corporate Policy Concerning Extended Overtime. Being Paid to NMPC Construction Personnel Working with SWEC 100,000 Implementation of "Fixes"'ue to Appendix R Evaluation Including Recent Guidance by NRC Pertaining to Potential Fire in Control Room 3,000,000 POTENTIAL CHANGES (DOLLAR ESTIMATE ARE ORDER OF MAGNITUDE)
APRIL 1, 1984 TO JUNE 20, 1984 (Continued)
ITEM DRAWDOWN ADDITION H/() Manhour Overrun. Scope additions for Humphrey concerns, equipment qualifications, security system, etc. 3,000,000 Delay of Remaining Railroad Work, currently scheduled for 1985 until 1987 70,000 Headquarter manhour increases over and above the 4/1/84 estimate ( see attached schedule) 25,095,766 Increase to the Site Document Control Department Staff 750,000 Addition of new photocopy machines a the site. 400,000 TOTALS $ 38,915;766 $ 70,000 NET POTENTIAL CHANGES $ 38,845,766 POTENTIAL CHANGES HEADQUARTER MANHOUR INCREASES OVER AND ABOVE THE APRIL 1, 1984 ESTIMATE Description Dollar f CI Amount
~!lt Change Evaluation b
Planning and Scheduling: Temporary Site assistance for revised project planning program. 5 746,295 01164 Reevaluation of Records Management Budget in support of the July I, 1984 forecast effort. 2,651,387 01161 Revised budget for Project Cost including System 38 and mainframe applications computer support. 167,500 01165 Telecomaunciations support for the project 101,800 01157 Department 53 budget from May 1984 through September 1986 309,!00 01166 Computer Department services support for the Project. 1,157,791 01158 Preliminary Test Program
~ ~
Field Testing
~
10,712,000 01131 AOD CHOC Review of NMPC preoperational and acceptance test procedures 259,700 01130 Extracting cable numbers from test loop diagrams 53,200 01149 PGCC/HSSS support 1,910,192 01153 Spare Parts procurement/
evaluation 801,598 00159 Project Management budget revision 424,299 01168
~
Management Systems Division revised budget 72,800 01169 Division 78 (8oston Forecasting) revised budget 2,130 01170 Revised budget for QA/QC, Engineering Assurance and FQA 4,243,480 0117l Syst m 38 Activity control'ystem 266,800 01172 Division 06 (Purchasing and Travel) revised budget 704,498 01173 Project Cost environmental support 208,298 01174 Problem reporting system (AOD Headquarters Loop Cal'bration Reports) 302,598 01175 TOTAL INCREASES $ 25,095,766*
- This amount may decrease based on reevaluations of SWEC Headquarters manpower levels presently being performed by NMPC. Amount of decrease is unknown at this time.
IX. COST (Continued)
G. Covnon Facilities The costs of facilities common to iltlP 81 and NMP82 must be split in an equitable and justifiable manner. A review. is now in process to arrive at this allocation approach. The review will be performed in two phases. Phase I is the review of facilities that are common at this time. Phase II is the review of facilities that will become common at a later date. Phase I is scheduled to be completed this fall. Phase lI will be done when it is considered necessary.
RECORDS/INFORMATION MANAGEMENT A. Si nificant Activities The following policies were finalized and distributed to project participants for incorporation as Project Guidelines by August 1, 1984.
- 1. Record Review and Transfer Policy of Category I Records.
- 2. Record Review and Transfer Policy of Category II and III Records.
- 3. Owner Verification and Acceptance of Category I Records.
- 4. Owner Verification and Acceptance of Category II and III Recor ds.
The . activity involved with compiling the NMP2 Records/
Traceability Matrix was initiated with SWEC and NMPC.
Associated with this activi .y is the initiation of the procedural review for compliance to the Records Management Plan.
Comments on Project Guidelines 80 and 81 on the Records .
Traceability Matrix and Required Records List respectively were resolved and .have been submitted for final approval.
The initial logic for the scheduling of all Project Record-Related Activities 'as finalized. Project Control committed to a. 7/20/84 issue date.
Key Actions in the Near Term are planned as follows:
- 1. Issue of first five System Records Lists, transmittal of remaining system records relating to first five systems, and accountability of those records.
- 2. 'eview and track progress of init al schedule logic with Project Control for the scheduling o, Project record-related
'activities.
3, Preparation of gene. ic records list for non-systems related records by 8/1/84'.
RECORDS/INFORMATION MANAGEMENT A. Si nificant Active t ies (Continued)
- 4. Final completion of Records/Traceability Matrix and initial review for revision to Required Record List by 8/30/84.
- 5. Focused attention to be placed on record storage concerns in field. Joint Reco~~s Management/gA assessment will be conducted and corrective actions taken.. Commence on or about 8/6/84.
B. Record Turnover The following are estimated percents complete of SWEC turnover of documentation to the NMPC Permanent Plant File.
Total, Turnover of CHOC Documents 89". Complete Total Turnover of SWEC Site Documents 10% Complete Total Turnover of all SWEC Oocuments 21% Complete The ,ollowing are . estimated percents complete o= .'IYPC Syracuse turnover of doc"men ation to the Permanent Plant File.
Total Turnover of NMPC Syracuse Documents 73% Complete The total estimat d percent comp'lete of turnover documentation to the PPP 2S": Complete.
- Cumulative Total up to 6/20/84 recalculated to 26%.
NMP2 PERMANENT PLANT FILE INDEXED ENTRIES 'OMPUTER
~ LANNOO PLANNED VS. ACTUAL Ac'1VAI 0 lIN TNOIIOAN001
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.The following tables summarize the produiction levels of record rece't preparation, filming and indexing into the Permanent Plant File.
July June Date'ercent Total To Ccmclete
~Act tvtt Record Receipt and 461590 109,506 2,078,781 26, Preparatior. (Includes Pages Pages Pages Aperture Cards)
Recor ds Hicrofilming 46,040 1281327 1,753,511 22Ne And V.erif icat'ion Pages Pages Pages (Includes Aperture e Cards)
Computer Indexed 7,045 41, 038 3401298 52$
Entries Entries Entries intr ies Records Indexing And 71045 41,038 487,349 20~>
Computer Entry Documents Document s Documents Percent complete is based on an estimated 2,400,000 documents comprisin 8,000,000 pages and 650,000 computer index entries required for Permanen Plant File entry .by fuel load.
NMP2 PERMANENT PLANT FILE Note 1 - Fuel Load DOCUMENTS INDEXED Nate 2 - O5IIIercial Qgereticn kl,k OIIC 0 PLANNED VS, ACTUAL lle I((405leOSI kC ( el L 0
$ 000 t ~ 00 I ~ 00 Mite 2 0
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XI. LICENSING A. FSAR Status A total of 850 questions relative to the FSAR and ER-OLS have been received from 'he HRC. For thi s period, 780 responses are complete. Amendment 12 of the FSAR was sent to the NRC on July 5.
Amendment 13 will be sent to the NRC the first week in August.
B. SER Status There are 233 SER open items and an additional 80 Power Systems SER items for a total of 313. Based upon meetings with tne NRC, we believe that 204 SER items are closed.
~S.55(
Seven 50.55(e) Reports were sent to the NRC.
- 1. Anchor Darling Valves, final report
- 2. MSIV Test
- 3. Rosemount 510 OU Racks', final report
- 4. Velan Valves, final report
- 5. RCIC Turbine Exhaust, final report
- 6. SRC Controllers, interim 30-day report
- 7. Rockbestos Control Cable, interim 30-day report Ins ection Re orts I.E. Inspection 84-06 was received and contained five violations.
Six items were reported to the NRC as a potential deficiencies under 10CFR50.55(e).
- l. RHR Safety Valves (55(e)-84-23)
- 2. Cat. I MCC (55(e)-84-24)
- 3. MSIV Corrosion'(55(e)-84-25)
- 4. SAM Relays (55(e)-84-26)
- 5. gC for Cat. I Bolted Joints (55(e)-84-27)
- 6. RCI Undersi.zed Melds (55(e)-84-28)
STATUS OF RESPONSES TO BRANCH TECHNICAL QUESTIONS NUMBER OF RESPONSES SCHEDULE FOR RESPONSE COMPLETION Technical Question Questions 1984 1985 Areas R i d C %1 d ~OI t Ch ~A ~Se D ER-OLS 51 50 1 1 INSTRUMENT AND CONTROLS* 85 68 17 17 421 DISCREPANCIES RADIOLOGIC 470, 471 62 3 2 EFFLUENT 460, 451, 810 PIPING 210 168 160 STRUCTURE/220 SEISMIC-230 GEOLOGY-231 HYDROLOGY-240 GEOTECH-241 STRUCTURAL AUDIT EQUIPMENT 13 QUAL.
270 271 QA 260 51 51
'IRE 33 29 3 1 PROTECTION 280 POWER 118 107 SYSTEM 430 CONTAINMENT 67 8 REACTOR PHYSICS COPE PERFOPM 480, 491, 492 REACTOR 49 44 SYSTEM 440 STATUS OF RESPONSES TO BRANCH TECHNICAL (}UESTIONS NUMBER OF RESPONSES SCHEDULE fOR RESPONSE COMPLETION Technical question (}uestions 1984 1985 Areas R \ 4 ~C1 d ~OCh J 1 S AUX ILIARY 51 45 6 5 1 SYSTEM 410 STARTUP & 37 TEST 640 OTHER 61 55 100, 250, 251 252, 281, 311 450, 451, 620 630, 640, 730 TOTALS 850 780 70 55