ML18037A068
| ML18037A068 | |
| Person / Time | |
|---|---|
| Site: | Nine Mile Point  |
| Issue date: | 06/30/1984 |
| From: | STONE & WEBSTER ENGINEERING CORP. |
| To: | |
| Shared Package | |
| ML17054B164 | List: |
| References | |
| NUDOCS 8411150129 | |
| Download: ML18037A068 (82) | |
Text
Project Report h
Nine Mile Point Unit 2 801 11 50129 841 109 PDR ADOCK 05000410 R PDR I
dl tI
JUNE 1984 PROJECT REPORT TABLE OF CONTENTS PAGE I EXECUTIVE
SUMMARY
1- 5 II MILESTONE STATUS 6- 7 III CONSTRUCTION 8-27 IV ENGINEERING 28-33 V MORKFORCE LEVELS 34-41 VI QUALITY ASSURANCE 42-43 VII CONTRACT ADMINISTRATION 44-47 VIII STARTUP & TEST 48-58 IX COST 59-67 X RECORDS MANAGEMENT 68-72 XI LICENSING 73-75
I. EXECUTIVE
SUMMARY
A. ~0i The Project was 74.95% complete at the end of this period. We should have been 77.03K complete. Although the Project is still on schedule for a February 1986 fuel load date, we suffered further erosion in our four months of schedule contingency for a net loss of four weeks.
The 1.3% Project progress obtained was disappointing and we failed to achieve 2.025 progress due to the following reasons:
- 1. Commodity production goals were not all achieved mainly because of diversion of labor to systems completion work, hanger clean-up work and inefficient use of our work -force.
- 2. Major Milestone Schedule delays caused by various difficul-ties experienced in completing systems.
- 3. Our schedules are not yet resource loaded and we have too many scheduled parallel activi ties to be worked on simul-taneously. This unfavorably skews the percentage calculations.
- 4. Oiscovered errors in ITT Grinnell actual weld count, down-graded the previous completion calculations.
We believe that the net 2X delay experienced over the past three months should not be extrapolated at this time to indicate a future trend as the following developments are occurring:
- 1. Schedules are being levelized and refined so that progress curve calculation adjustments (both plan and actual will be made in July.
- 2. Commodity production plans will be rescheduled in accordance with the new schedule plan and will no longer be measured against the '84 work plan.
- 3. Although system turnovers are behind schedule, a substantial number are almost 'through the gate'nd a heavy testing program should be carried out in July. Some schedule recov-eries may be expected.
- 4. Increased labor force diversion to the Integrated System Mile-stone work which is the key milestone of the 1984 work program.
- 5. Production rates of commodities are increasing in key areas together with improving numbers of hangers being brought to gC acceptance.
EXECUTIVE
SUMMARY
(Continued)
Although these developments should result in an improving schedule trend through the next few months, this management is concerned that we have not yet turned this Project around, nor have we demonstrated a fundamental ability to meet our program. The sit-uation is being closely watched and alternative'courses of action will be planned in July for those areas which are not clearly improving.
Significant attention to quality matters continue, with the NRC-CAT action program being brought to essential completion. The guality Performance Management Program was started and will focus senior management attention to ensure quality concerns are managed co-equally with those of cost and schedule.
Engineering activities continue in support of the schedule. A notable achievement was favorable resolution of the Appendix 'R'roblem, without significant cost or schedule impact. This was seen last month as a major schedule problem.
The cost of the Project continues just within the '84 cash flow plan. However, significant pressures are being felt due to excessive overtime and not yet satisfactory cost performance in L. B. Hanger leading to production. The new cost control program goes into effect in July, bringing to the Project new methods of cash flow control and productivity management.
Me welcome to the Project in this period Mr. Robert Gibson, the NMPC Project Control Manager. Mr. Gibson brings a wealth of experience and ability and will be the key driving force in the new schedule and cost programs.
MAJOR PROBLEMS I. Our ability to control work within schedule requires significant improvement.
- 2. Oespite strenuous planning efforts and excellent conduit production we have failed to open up adequate backlog for cable installation.
- 3. Improved planning efforts and precise definition of components within test boundaries are required.
- 4. MSIV valve modifications must be started very soon.
- 5. The Records Identification and Management Program must be brought within= total control at the earliest date.
EXECUTIVE
SUMMARY
(Continued)
B. Mana er ualit Assurance - Pro ects In general, construction activities continue to be performed in compliance, with guality Assurance requirements. Corrective actions have been developed and are initially being implemented to reduce the ITT Grinnell weld reject rate. Based on the reduction of NMPC guality Assurance identified deficiencies, it is apparent. more attention is being provided to procedural requirements.
The verification of the corrective and preventive actions required in the response to the NRC Notice of Violation has bea completed.
Identified deficiencies/discrepancies are presently being resolved.
The indendpendent service organization is presently performing the review of the CAT Inspection findings, the SALP Report and NMPC identified deficiencies.
The development of the guality Performance Management Program (gPMP) has been finalized and all'eviews are complete. Periodic meetings have been scheduled to implement the program.
TOTAL PROJECT PERCENT COIVIPLETE PERFORMANCE CU NINE MILE POINT NUCLEAR STATION - UNIT 2 100
~ t 5\
98 ~ ~~~ca%~~
96 r
rrr te 94 PLANNED ACTUAL 92 ZNC. 2.08>> 1. 30'A Ul 90 CU55. 14. 35>>
I O
88 rr 86 84 m 0
'r
%I W 82 80 rr o 78 PLANNED ~
76 MP ACTUAL 74 72.
AM MAT JVN JVL AVO 551 OCT NOV OCC JAN A55 MA1 A51 MAY JVN JVL AVO 551 OCT NOV OCC JAN 555 MA1 AAN~MAY JVN JVL AVO 5 1984 1985 1986 VOTE: This curve is preliminary & reflects project data available as of As revised Pro3ect Control Program data is finalired it IJill be included in the curve.
TOTAL PROJ ECT PERCENT COMPLETE
SUMMARY
TABLE Nl NE MILE POINT NUCLEAR STATION - UNIT 2 PERCENT ITEM WEIGHTEO PERCENT F TOTAL PERCENT COMPLETE 1965 1966
'ILESTONES PROJECT OMPLETE CIJM INC FMAMJ SOHO FMAMJ JASONO JIF M A MIJIJIAI
- 1. ENERGI2ATION 4160 V 2.49 9d.29 2AO 0.0058
- 2. CONDENSATE DEMINERALIZER 2.9d $ 7.39 2.80 0.0513
- 3. SERVICE WATER $ .08 dd.19 5.22 0.0452
- 4. STANDBY DIESEL 0.53 81.29 0.32 0.0100 37117 F 0
- 5. INTEGRATED FLUSH 13.09 72.93 9.55 0.0854 II~ I00
- 5. FLOW INDUCED VIBRATION 0.09 dd.23 O.08 0.0000 1I3
- 7. TURBINE GENERATOR 2.70 75.08 2.03 0.0280 010I I
- 8. VENTILATION 4.45 57.18 2.99 0.0783 II~ I ~ 0
- 9. INTEGRATED LEAK RATE 1.14 48Ad 0.53 0.043$ 7II ~ I ~ 8
- 10. RADWASTE SYSTEM 1.31 SO.48 0,$ 1 0.0183
- 1. FUEL RECEIPT 0.75 47.11 0.35 0.0273
- 2. LOSS OF POWER/ECCS 0.81 40.$ 4 0.33 0.0218 0
.3. FUEL LOAD OA7 55.08 0.28 0.0121 l 313 ~ 100
- 14. FUEL LOAD TO C.O. 1.10 0.00 0.00 0.0000 I I
UBTOTAL 30.0075 72.25% 27. ~ 5'l0 0.4321%
~ NANAGOIENT CONftNCKNCT I
.. CONSTRUCTION I I
COMMODITIES I I
I PIPING 9.45 $ 5.04 6.13 0.1898
~ ELECTRICAL 6.63 d9.51 4.51 0.2270 3,I$ 2C 0.99 47.dd OA7 0.0129 HVAC 0.$ 3 75.02 0.82 0.00'l9 CIVIL 13.10 100.00 13.10 BTOTAL 31.00'Yo $ 5.$ 9% 2$ .0010 0.401075
'I STARTUP & TEST
'0MMODITIES
- 0. PRE.OPERATIONAL TESTING 0.$ 0 0.00 0.000 0.0000 2.HYDROS 0.$ 0 7.07 0.057 0.0054 LOOP CALIBRATIONS 0.$ 0 1.77 0.014 0.0120 CONTROL CIRCUIT VERIFICATION 0.$ 0 1.78 0.014 0.0049
- z. INITIALEQUIPMENT OPERATION 0.$ 0 1.85 0.013 0.0009
- 8. FLUSHES 0.75 0.92 0.007 0.0009 PENETRATION LEAK RATE TESTS 0.25 0.00 a.oao 0.0000 JBTOTAL S.00% 2.10% 0.105% 0.0252%
IV ENGINEERING DESIGN VERIFICATION 0.54 18.97 0.092 0.0118
. EQUIPMENT QUALIFICATION 0.25 d8.11 0.170 0.0029
- 3. LICENSING O.SS 51.50 0.37$ 0.0053 SUPPORT OF STARTUP 0.38 d5.34 O.248 0.0270 BALANCE OF ENGINEERING 1$ .27 91.50 16.717 0.0837 SUBTOTAL 20.0015 SS.O3% 17.0170 0. 133717 QUALITYASSURANCE 5.00% 53.17'%.6S% 0.246%
Vl RECORDS TURNOVER 1.00% 19.00% 0.19% 0.000%
3 PPF
't OTAL 100.00% 74.95% 1.30%
6~4TUS AS OF 5/17/$ 4 NOTE: This tabl ~ is prellmlnary and reflects project data avallabl ~ as of d/17/$ 1.
Revised data horn the Project Control Program will be InclIJded aa lt Ia developed.
NOTE 2: An adjustII7ent 75as made ln the cumutatIve percent co577otete earned as of 5/20/Sa, due to cu100Jlitlve quantity reductions oor IT ur0nneI ~ I
.55 l. s. vetds, co77Ioleted Start 'Jp and '.est cor577ocit es and oa'Oc na IIII aa ~ ~ ~ 0 saeOI07 0 '3A(oI0 Innn,nn nrur
~
~
II. MILESTONE SCHEDULE STATUS A. Ener ization 4160V During June, the 4160V Milestone slipped to four weeks behind schedule because of, late completion of 4160V Switchgear and Unit Substations primarily due to difficulties experienced in co'mpleting system turnovers. Intensive efforts to complete this work are underway and testing of this system will be fully in progress by July. No delay to the overall schedule is expected.
B. Condensate Demineralizer The schedule 'slipped to four weeks behind due to late completion of Make-Up Water Storage and Transfer and repair of Condensate Storage Tanks. Production of Demineralized Water will be on schedule, but our ability to store large quantities of water is hampered by the late completion of the Make-up Water Storage and Transfer System.
No Project schedule delay is anticipated.
C. Service Water Overall status of this work is three weeks behind because electrical activities in the Service Water Pump Bays not projected to be completed. Work arounds have ,been developed but the and a change of requirements by Startup has stalled delayed'mplementation their implementation. 'his negativity may not be fully recovered.
D. Turbine Generator Current status is two weeks behind due to late completion of electrical activities in the Lube Oil/Seal Oil System. It is anticipated that the time will be recovered to ensure overall Milestone completion wi11 not be affected.
E. Inte rated Plush Overall status through June is four weeks behind schedule. Work involved in this milestone includes the most complex and labor intensive efforts on the Project. This milestone is the Project critical path.
During June, significant work was completed on a number of systems required to support integrated flush, but the overall progress was insufficient to maintain schedule. Considerable effort was applied to address this production, shortfall. Programs have been established to enhance large bore hanger and small bore piping production.
II. MILESTONE SCHEDULE STATUS (Continued)
F. Diesel Generators Schedule slipped two weeks due to low overall performance in all areas. A detailed schedule was developed to ensure GE modifications do not impact the overall Milestone. There is no impact to the overall Project Schedule.
Scheduled slipped three weeks due to insta11ation of electrical for Liquid Radwaste Systems and late design of Solid Radwaste System.
Information 'or the development of a detailed Solid Radwaste Schedule was received from CHOC and Toronto. Testing logic has been revised to reflect this. There is no impact to the overall Project Schedule.
H. Inte rated Leak Rate To maintain the schedule, local leak rate testing should be started at this time but has not due to delays in systems required to release this work. Work, will be expedited in this area to support this testing in the near future.
For the following, work proceeded in support of the Milestone dates with no overall impacts noted..
- 1. Ventilation
- 2. Loss of Power/ECCS
- 3. Fuel Receipt
- 5. Fuel Load
III. CONSTRUCTION A. General The'ajor construction commodities are depicted in the following graphs which have been updated to show year-toMate and current period performance. Construction has developed detailed action
. plans to provide the basis for unit rate improvements. Interim results reflect unit . rate reductions for several key indicator commodities.
Construction turnover of systems to SWEC Advisory Operations Division for preliminary testing continues to exhibit shortfall. As discussed in various sections of this report, significant Project Management attention is being provided in this area.
Significant actions are currently underway 'to improve weld reject rate performance. The Piping-Mechanical Contractor (ITT Grinnell) has submitted a comprehensive program to complete such activity..
within the proper levels of acceptability and thus minimize repair work.
Construction Management continues to emphasize housekeeping and cleanliness. General site conditions continue to improve as a result of proactive Materials Management within the power block, follow through of contractor responsibilities, and virogous surveillance by Construction personnel.
NMPC Corporate Risk Management has recognized Construction Management for noteworthy ef for ts relative to safety and loss prevention/control. Approximately 540 million has been realized under the wrap-up program - resulting from insurance premium returns and lower liability premiums. The Project is to be commended'n this regard.
SPEC 5 8 PIPE r~ ~ o 65,967 UNIT UAHTITY MAHNOURS RATE CURRENT PLAN 5,831 41.983 7.20 ANTH ACTUAL 3,885 19.853 S.ll 1984 YEAR-TO PLAN 31,077 223.754 7.20 DATE ACTUAL 26,785 128,947 4.81 J F as A Q J J A i0 N 0 J F Il A II J J A 0 0 N 0 J F N A as J J A t 0 1084 1985 1986 YHnv 10 01 ~ ~ a SPEC Small Bore piping effort exhibited a deficit against planned quantities this report period. Process Improvements to strengthen shop fabr ication and weld performance along with schedule refinements should reverse this trend. It should be noted that the unit rates are below plan.
Actual
Planned
5'HAEC S.S. HANGc,R c< ~ 4 'J 15,300 14.""0 12,55 12.300 10,000 8,300 iP"-
OUAHTTTY MAHHOURR RATC I
CURRENT PLAN 736 29,146 39.60 6,000 ! .I0NTH AC.DAL 536 21.540 40.37 4,33v 1984 vSAR-;0 PL>>ti 3.:23 !23,571 39.5C OATc ACTUAL 3 H847 144,010 37.4g 2 ~ u00 I I I I I I I I I I I I JFMAMJJASOIIDJFMAMJJASOHDJFMAMJJASO 1984 1985 1996~
rRRAQ To 49 ~ ~s Although a s lght downturn 'in oroduct inn was exprr ience1i 1
this ocr lod, the SSIEC Small Sore Hanger ef fur t cumulatively well anead of the plan.
Actual
--.-------Planned
ITT PLAN VS ACTUAL 5 6 PIPE 1'.. 'c
~ sac ~ ~
~ g I s>> vv
+01 ~ ~
,'IANIIOURS RAT "RR0 "IT PL4N 1.700 5.333 3 49
."ONTP
(- 100000 C
ACTUAL 644 12,495 14.60 1964 YEAR- PLAN 19,300 6/ 357
~ 3.49 TO-GATE ACTUAL 17,147 76.477 4. 56 96300
'6000 34000 9ZOOO I
JFMAMJJASONOJFMAMJJASOHDJF MAM JJASO 1984 1985 1986~
Twnu 10 OI It Sma'll bore oipe oroduction be9an tnis oerioo ai.ead af Plan, but decelerated..his is attriouteo to ~cess;onment of crews in resoonse to ur9ent trIm out reuuirements in suooort of immInent 31P turnovers. NanOOwer reCO0nIendat!ons are ~ortn-comIng and will be assessed oy manaaenent. 'Jorkino on the OunCnliSt 'Or the SIP SySten turnOVer iS the PrImary reaSOn
'or the June E. Rate Ratio abnormality.
Ac'cua 1
Planned
<<Trim out is defined as ounch list actIvity.
11
ITT PLAN VS ACTUAL 5 " HANGtRS
~ ~
I ~ ~f
~ ~I
~
~ as,r,ig CUPPCNT P'N 397 9,246 Q3
~ y II0IITH C, ",AL 265 21,105 T9.64 1984 '<EAR- PLAN jc 105,154 23.29 n
'vv TO-0ATK 'C.U L 3,049 '55.303 50.84 12 .'Gv V4 3530 I I I I I I I I I I I I I I JFMAMJJASONDJFMAMJJASONDJFMAMJJASO 1984 1985 1986 Produc t ion imorovement actions are oeino Imt lenented THAI,'e ~ QI ~ ag aS a reSult Of jdint aCtidn Oy 5'SEC, IT G. 'NPC. (See test:or additional coInIentS. )
Actual Planned 12
ITT PLAN VS ACTUAL L 8 PKPE w ~ I C
1 0 I%
xa,v ~ avv
". 7,530 UNlT ~
GUA'IT 1 TY,'QNHQVR5 RATE 5 GGG
~ ~
CURRENT PLAN 1.635 8.240 5.04 ANTH 212,500 ACTUAL 1,270 13.683 '0.77 1984 YEAR- 22.623 11',320 5.04 210,000 70-GATE ACTUAL 20,451 130.379 6.38 2C7,5GG 205, 00 202 500 l I l I I J F M A M J 1984 J A S Cumulative 0 sa D J F M A M J J A S 0 H 19$ 5 D J F M A M J 1IBg THnu lo
~~
J p 4$ ~ Q S O monthly production is s lightly below plan.
Manpower requirements are being assessed as a greater percentage of trim effort ls required than that originally anticipated in response to SIP turnoverS. Recovery ls expected.
Actual Planned 13
1TT PLAN VS ACTUAL L 8 HANGERS
~}8.181 1 0 /INN
~ I/
~ J
'c 8 5'N I ~ i NU'I 1, I 5IANi/1 t IP 5 RA E 14,50'URRENT 15,000 9'tONTH PLAN AC O'L 460 276 65 43c 56,?66 142 2c 205.57 5984 YEAR- 3,159 449,368 142. 5 I TO-GATE 54,000 ACTUAL 2,718 495.791 182.41
~ ~
13,000/
I I I I I I I I I
1984 I
JFMAMJJASDNDJFMAMJJASDNDJFMAMJJASD I
1 I
9 85 I
1 988 T881u,5Q 45
~1 ~4 ttdnthiy OuantitieS remain below plan. IIanagement actions have been established to drive the large bore hanger completion effort. Oedicated hanger cre~s are assigned and preSCribed in a manner Similar cO that whiCh reSul ted in successful completion of the Five-Meek Accelerated Pipe Mhip Restraint effort. Actual Planned
'14
PLAN V5 AC,URA9
- l. 8 'N:LO RU r R
~ r ~vO
~ rT I 6
UNTRT i TU'N 1TT NRNNUURT I A~E I I 6 ~ o 'J v ('URRENT oLAN 400 9.244 C4 F 66 RIONTH ACTUAL 1 11,230 21.98 1984 YEA)- PI.AN 3,750 86,663 23 1 6-COO ~
TO-OATE ACTUAL 4,334 123,603 28.52 '
Trrr rl
~ ~
I I 1 I I I I I I I I I I J F M A M J J A S 0 fa 0 J F M A M J J A 5 0 fl 0 J F M A M J J A S 0 1984 1985 1996~
TI669V 10 09 ~ ~ 4 Performance this month exteeded the plan. Thl t t rend IS posltlve and should lead to full recovery.
Actual Planned 15
,'TT PLAN VS ACTUAL L YAL'l85 4
e o,lC 1 30 UN1.
QUANT1TY ~ANHOURS RA c 1700 URRBNT O'ft 100 3.274 32.,4
'.!ON TH 1500 ACTUAL 75 1.907 25.43 i 1984 YKAR- 850 27.829 32.74 1500 TO OATK I AC. UAl. 506 14,895 24.58 1egO I I I l l I l I
J F M A M J J A 5 0 la 0 J F M A M J J A 5 0 Fa 0 J F M A M J J A 5 0 1984 1985 teee~
7eenu eo Oe ~ II, valve production 'is paced by LB pipe inStallatlons.
txpedlting efforts are in progreSS to asSure enater la I avia lability vnen needed.
Ao~u>>l Planned 16
LKC PLAN VS ACTUAl.
CONDUIT 6355,67:.
p
" 3) 733000 700000 IJI' gyle l T .".AlIHOURS 667000
, CURP5'IT PLAN 22.000 23,540 ,7I
',".0NTN ACTUAL 22,764 21,596 0 633000 45'.37m
~ l984 YEAR- PLAN 135.000 i44,450
'O-OATK ACTUAL 134,722 150,309 600000 567000 533000 I I I I I I I I I I J F M A M J J A S 0 N 0 J F M A M J J A S 0 k 0 J F M A M J J A S 0 1984 1985 1986~
THAu so '/ ~(
LKC had an outstanding performance ln th'ls area for the last two ~eeks ln the period. Attention ls focused on sustaining thiS trend . Increased conduit race~ay ~I I I Improve capie pulling performance.
Actva I Planned
LKC PI.AN VS ACTUAI.
CONOU1T SPTS.
3h 3R,. ".
29000 27 v 2600 UN1T UU ~ RT!,T RARHUURE ROTE 2450 CURRENT PLAN 1,200 16,236 13.53 NO.'I TH ACTUAL 1,318 23,296 17.68 2300 1984 YEAR- PLAN 8,200 110.946 13. 53 E TO-DATE ACTUAL 9,060 1!6.614 17.29 I 21c0 2000 1850 I I I I I J F M A M J J A 8 0 M D J F M A M J J A 5 0 H D J F M A M J J A $ 0 1984 1985 1986 THnu 10 01 ~
IC Performance continues above the plan. The unit rate 'or the month aopears high; however, the planned rate is a composite of suoportS with 3 m-hr./so!. to 19 m-hr.(SOt.
and ',Or the mdnth apprpximately 90'f the inStal'.ed supports were lg m-hr./spt.
An'UAT
-.-- --- Plan nn 18
LKC PLAN VS ACTUAL CAo' PEJLLrttu 8 405 or3 I' Q TA 3
q0 575000 52 GGQr
~ /
575000
/
/
525000 d r
/
/r 475000
/ OUAHTITY IHIHHOURS UNIT:
RATE E
l CURRENT PLAN 362.935 32.664 0.09 425000 'GNTII AC UAL 272.155 37.351 0.!4 I
I I~ I 1984 Y6AR- PLAN 2,253,066 203 '96 0 '9 !
375000 TO-GATE AC UAL 1,801,010 210,392 0.12 !
~ ~
3250000 I I I ~ I I I I I i I I J F M A M J J A S 0 II 0 J F M A M J J A 5 0 Il 0 J F II A M J J A S 0 1984 1965 TORO~'ronu EO '1 ~0 An lncreaslng!y positive trend @as observed during the last thoro weeks ln the fiscal Exonth. and LKC exceeded the planned rate during that period. Aga'in, efforts are being applied tO 1nCrease the cable pulling backlog of c lean ava liable bulk pullS. IndlCatlOnS are pOSltlve.
Actual planned I,t c~
r dp 1 /tR1 1.9
LKC Pl.AS VS ACTUAL CASLE TERM
'<<<<I
~ I I <<<<( ~
"4'(H0005 9<< ~
t CI<<00!<<T PLAS ',7,774 15,463 ~
).87 50000 <<IQE 'TI(
ACTUAL 8 OI2 9839 1 1 1984 104R- PLAN 87,442 76.075 0.87 TO-OATS 100000 ACTUAI. 61,859 66.273 1.07 I) '1<<<<<<
50000 I I I I I (
JFMAMJJA SOHO JFMAMJJASON 0J F MAM JJA SO 1984 1985 1986 T441V 10 01 ~
~ IL Te~>nac(cns are oeh(no ac ch1s sime. Cable serninacinns T
are ccs: eI.'eCC:vely aool leo in bull . racner shan 'n(eCe "..ea."",
,hiS acc>v(sy iS Pace". bv ecuipaient reac(neSS anh cable bulling.
Acsua 1 Planned 20 4
JC6 PLAN VS ACTUAL SE!SH1C SPTS.
5,300 4
/
3500 3000 'N62 t ~ ~9'V, ~n) ( 8a I I 2500 1CURPEIIT 1
P'N 281 !1,751 <<1
~ 'I
~ v'
)
NONTH ACTUAL 160 9.580 60.50 2000 1984 YEAR- PLAN 1,320 55,202 41.32 TO-OATE 1500 ACTUAL 1,047 57 '92 55.10'000 500 I
1984 I
JFMAMJJA SOHO JFMAMJJASOff 0JFMAMJJ*S0 1985 1
Quantity develOOment effOrt IS COmOlete and the number Of identified supports will be amended to 4900. Ho~ever. JCI I
1966 Y96AU 10=
~
49' I I I is providing for a contingency allowance that will drive Internal targets In a manner essential ly cons'istent with the 5300 (Igure. JCI has orooosed and lmolemented specific action program to improve performance 'in this area.
Actual Planned 21
JC! PLAN VS ACTUAL INST. TUB ING 0 ~
~
0 ~ ~
r ggp 2v\
'- ~
~ ~ ~
~ f ~
0 0/I vv'5Q,QCQ 125,000
'JN I ~
~
P.'AllT: Y .".ANHOUAS P
!QC,QOC I
CURRENT PLAN ! 0, 766 16.041 1.49 ANTH 75,000 ACTUAL 11,374 16,569 1.46 1984 YEAR- P'N 50.611 75.4'.0 0-CATE AC,UAL 37,357 79.687 2. 13 I
,5 0QQ I I I I I I I I I
JFMAMJJASOH'DJFMAMJJASOHDJFMAMJJABO 1984 1985 1988 YHnv 10 OI 00 HonthlY ouantitles exceeu the olanneO target. JCI IS managing, the work effort to sustain this improved treno.
ACsud1 P!anneh 22
III CONSTRUCTION (Continued)
B. Contractor Performance SWEC Force Account
. t Overall, SWEC Force Account work scope performance continues to proceed in a positive direction both in terms of commodity installation targets and schedule compliance. However, there are areas, such as small bore piping which require improvement. Specific production assessment and exceptions are, addressed below.
Mechanical E ui ment Erection Approximately 87K 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 I and III Han er Com letion Performance in this area remains above plan.
Small Bore Pi e and Su orts The piping effort exhibited slight shortfalls during this period. SWEC has implemented pipe assembly walkdowns and a weld performance improvement plan submittal designed to strengthen shop fabrication production.
Small bore hanger performance is tracking ahead of plan.
Condenser Erection This effort has been concluded.
Preventative Maintenance All planned maintenance requirements and inspections were performed during this period. No significant problems were identified.
- 2. ITT Grinnell Overall, ITT Grinnell's commodity installation performance through this period exhibited shortfall with the exception of large bore welds. ITT Grinnell expended major effort in the area of trim out for BIP subsystems ready for turnover and preliminary, testing. This is the primary contributor to bulk commodity installation deficits. Additionally, materials restraints are creating completion problems with the Condensate Storage and Service Water systems. Engineering design information is also required to finalize efforts in the Closed Loop Cooling system.
23
III. CONSTRUCTION (Continued)
B. Contractor Performance (Continued) 3~ L. K. Comstock L. K. Comstock's production has increased in the last two weeks in the areas of cable pulling and conduit raceway installation. It is essential that efforts remain focused on these,two elements so production levels increase and cumulative deficits recover.
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 completion of the 4160v milestone.
Internal management actions implemented by L. K. Comstock.
favorably accelerated production performance dux'ing the last half of the fiscal month.
Cable pulling backlog drawdown, electx'ical FQC inspector attrition affecting commodity releases, and BIP restraints continue to receive management scrutiny.
4~ GE-PGCC The middle of July is now the target date for completion of subsequently identified subdivisional separation problems and both divisional and subdivisional open items. 'rogress is reported on schedule with total completion, including NSSS/BIP modifications, slated for February 1985.
5 ~ Johnson Controls Johnson Controls exceeded scheduled quantities for instrument tubing installation requirements, thus accelerating cumulative recovery. Process improvement plans have been devised and implemented in x'espouse to production deficits reflected in seismic tube support installations. The, instrumentation quantity development program has been concluded, resulting in more accurate scope definition. This .will allow JCI to properly manload their work effort.
Johnson Controls continues to puxsue BIP turnovers, but must be fully supported by Contractors whose work precedes I6C work activity. Improved communications between ITT Grinnell and Johnson Controls has been established.
24
III. CONSTRUCTION (Continued)
B. Contractor Performance (Continued)
- 6. Schneider Power Cor oration The HVAC effort is proceeding with commodity installation improvements noted. The HVAC milestone schedule is currently undergoing logic and activity sequencing examination.
Engineering clarification and support of technical issues has improved considerably.
- 7. ~Vikin (Fdre Protection - Redeeete)
This contractor has performed on schedule. However, late delivery of fire detection equipment will have' short-term schedule impact.
- 8. ITT Grinnell Fire Protection On schedule, and efforts continue in preparation for testing activity.
- 9. Metal Claddin Industries (Condensate Storage Tanks)
Rework is essentially completed. However, results of the pending hydro test may result in some additional activity.
Kinor schedule problems are anticipated required. No serious impact projected.
if tank stiffeners are
- 10. Insulation Contracts (Various)
Schedule slippages in hydro testing mechanical piping systems are currently restraining insulation applications. This is not currently significant in terms of major impact, but does require careful management attention.
ll. Randall Electric Limited progress is still affected by the late release of cooling tower electrical design information. SWEC is currently evaluating change authorizations requested by Randall.
Engineering is expediting design information. Schedule exposure is not serious at this time.
- 12. S der Mackin and Shaffer ttajor efforts are underway to consolidate and streamline the construction site power systems.
25
III. CONSTRUCTION (Continued)
B. Contractor Performance (Continued)
- 13. Zurn Industries (Cooling Tower)
Engineering and Zurn are currently evaluating, minor cracks occurring in concrete strip footings which support portions cooling tower internals. The situation is not deemed ro be of'he serious and may not warrant extensive repairs. This condition may be left as is, or undergo minor rework.
C. Construction Com letion The status of the Boundary Identification Package (BIP) Construction Completion Program as of June 11, 1984 is shown in the following table. Note: This status reflects revision to previously reported data and will be the basis for future comparisons.
e 26
III. CONSTRUCTION (Continued)
BIP CONSTRUCTION TURNOVERS to AOD As of May 28, 1984 Schedule Cum. Actual Cum.
4160 Volt Energization 34 20 Service Water 19 11 Condensate Demin. 9 5 Diesel Generator 0 0 Turbine/Generator 1 0 Radwaste 1 0 Integrated Leak Rate Test 0 0 Ventilation 3 1 Integrated Flush 0 0 Fuel Receipt 0 0 Fuel Load 1 1 Loss of Power/ECCS 2 0 70 38 Only one BIP has been accepted by SWEC A.O.D. since the last report; SIP 874.003 Emergency DC Distribution. Although the number of BIP's accepted is currently 32 behind schedule, SWEC Construction has issued Equipment Release Reports for 11 of those BIPs and they are undergoing inspection by SWEC FgC.
It is expected that SWEC A.O.D. acceptance will occur by the end of June.
In addition, a major effort has been made to prioritize construction work on critical BIPs to recover Hilestone Schedule slippage.
27
IV. ENGIiaEERING A. General Overall Engineering and Design efforts continue on schedule. The most notable areas include conduit, cable ticketing, set point development, responses to FSAR questions, Appendix R efforts, Cat II and III stress data packages, A1ARA shielding and P&IDs. The Bar Chart Summary of the 1984 Engineering Work plan, as amended, is provided on the following two pages.
28
~ ~ I ~ ' ' ' ~ ~
RQGQiXI
~ CRBRR~HK~S~MKK~W~~RK~~~~~~~W~EH~KRM~~
5558%
5%8%
i~SR
~88
~ ~ 4 4 I
~ ~
I~SR
~58 .
gg i~WE
'R
'. WS I~WC L~RR j'\
j
d if
IV. ENGINEERING (Continued)
B. Problem Areas The spare parts effort remains behind schedule. However, 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 as-built stress schedule has been integrated into the Project Hilestone schedule. The revised schedule is expected to be levelized by mid July. The Engineering Work Plan will be revised to reflect this schedule.
- 3. A cadiz R A plan has been developed to address compliance with Appendix R. Remote shutdown capability and fire induced spurious operation, considering a postulated fire in the Control Room were evaluated. A maximum cost of approximately 43 million has been estimated for needed changes. Additional meetings with GE will be held in June in an attempt to reduce costs.
No serious schedule impacts are anticipated.
- 4. E ui ment uglification Vendors identified for lack of responsiveness have been contacted. A11 have provided dates for submittal of revised documents to SWEC for approval. Expediting continues to monitor vendor performance to maintain these dates.
- 5. Hain Steam Isolation Valves A technical problem is currently being addressed on the MSIV's. Similar type valves furnished on other plants have experienced corrosion problems during extended periods -of storage and layup, affecting seating capability. A detailed plan to address this problem will be developed by early July.
IV. ENGINEERING (Continued)
C. Drawin Schedule Of the 9665 drawings, 92 remain to be issued. Of the 92, 71 are required for construction and will be issued as follows:
Electrical - 29 - July Instrumentation - 4 June Power Engineering 25 on hold September Berm Drawings 13 - September The increased number of Power Engineering drawings on hold is primarily due to ECN changes where vendor information is not available. Examples of ECN changes include added expansion joints, a small localized air conditioning unit in turbine building and other minor heating and ventilating duct changes.
D. ~Saaff1a Headquarters E&D destaffing continues and action is currently being taken which will reduce the staffing level to approximatley 617 equivalent Engineering and Design personnel in July. See Section V for Engineering Staffing curves.
The total scope of the SEG is still under review and will be finalized by July 1, 1984.
E. Other Activities Status of E&DCRs dispositioned by Engineering is illustrated on the following graph. This area will be monitored closely and continued emphasis will be placed on reducing the number of E&DCRs open for over 60 days with Engineering.
32
E&OCR STATUS
+h IVV s du 34 "5 Ogden I
cc8 54 i4i 600 I I
I 500
~'00 CO 300 200 I ".0
~
I I I I I
JFMAMJJASONOJFMAMJJASONOJFMAMJJAQO 1984 1985 'I 9 8 6 THllu 10 eI ~ ~(
Oven >th E gi eer> q zc !lo
4nswerod by Engineering during Icnpb 33
V.
The site staffing for all contractors is displayed on the following table. The planned number corresponds to the approved 5630 million cash flow (See Cost Section for explanation). Also attached is a graph depicting the site equivalent and site payroll headcount. The graph indicates that approximately 200 equivalent people have been added since, the last report. Of these, approximately 100 SWEC manual and 70 non-manual additions were the largest contributor. (See Cost Section for explanation.). It should be noted that the headcount table was changed to "equivalent personnel" for this report because the budget was based on equivalent personnel.
The CHOC staffing is displayed on the Headquarters Services Manpower Graph. The total headcount continues to decrease. Also attached is the Site Engineering Group workforce levels.
6/15/84 SITE STAFFING (EQUIVALENT)
MANUAL NON-MANUAL TOTAL COST REIMBURSABLE P A SWEC 1120 1256 1112 1166 2232 2422 Walsh 718 698 38 40 756 738 LKComstock 646 829 100 103 746 932 ITT Grinnell 819 937 350 449 1169 1386 SMS 114 -
100 4 5 118 105 JCI 169 193 80 94 249 287 Schnei der 131 144 16 18 147 162 Wiltsie 150 0 10 0 160 0 Subtotal 3867 4157 1710 1875 5577 6032
~d Oavis Fetch 1
'1 2 RAKeasbey 5 0 5 Central City 2 0 2 Gives 13 3 16 ITT FPS 9 1 10 RCI 80 12 92 Castal do 14 1 15 GE 70 10 80 PMI 3 0 3 HHRobertson 1 1 2 Zurn 18 0 18 Pullman 14 3 17 Viking 3 1 4 Randall 9 0 9 Metal Cladding 1 1 2 Tuscarora, 9 4 13 Subtotal Hard Money 252 38 290 GE/NSSS 76 76 NMPC 408 408 TOTAL 4409 2397 6806 Notes: A. SEG CHOC paid are not included on this report, see the
. following three curves.
B. NMPC includes MAC, NYSEG, RGhE and Central Hudson.
35
f984 TOTAI. SITE CONSTRUCTION KENUAL k NONXhNUhL
-ACTUAL PAYROU. RARTORER
-ACTUAL EQLOVALDiT IIAIIPOWER 5 ~ -630 PLANNED EQUlVALENT Zg EMPOWER
~c he g OO 3
16-Dec 16-impar 15-Jun 14-Sep 14-Dec IQ64 36
SIIEC WEAOQ".ARTERS SERI'!CES EQL'IVALEIIT MANPOwER (ELO Including SEG, Project Services Ad Ops. OA/OCI
~ V ~ I nneu NC tun:
- r at ..s'
~ ~
I 350 l 2'30 /
I 'I
>I I
t ~ I 05n l
0 750 l
600
',e Represents Estimate the April Revised 1
<<50 <<
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~ l 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 a i I I I I I J F M A M J J A SO1ID J F M A M J J A 8 0 aa D J F M A M J J A S 1984 1985 1986
'tHnu IO ~ 0t 00 ~
Actual Planned 37
SIIEC ENGINEERIIIG AGIO GESIGN (CHOC, and Site including Advisory Operaticns, SEG, 0'.'3C and Pr.;Sec: Se. vices,
~ ~
~~
- 6 ~
Z X '5 I~le Re: 1:e Planned Actual Variance
, CHOC 167,317 205,078 37,761 1 eS l
SEG 41,600 45, 105 3,505 l'OTAL 208,917 250..'93 41.266 13 I I I I I I I I I J p aa A ea J J A S O ia 13 J S as A M J J A S 0 li II J F N A N J J A S 0 1984 1985 1986 TNllu l0'l '00 Ac'tua I Planned 38
S)tcC:ltG)NE:RittG APIQ DES)GIP, E?S0ttttKL tCherry fti))',
i00 Plan nn Pfc ual !ariance 90 554 559 n
ao C
4l I
'4I 70 C
60 au CL \
a 50 IC Reoresents the Aor 1) Revised (stfmate 0 I
\
C \
40
'0 30 loo a~>>
I I I I I f I I f I I I f I I I I I I I I I I I t I I I I I I I I I I I I I I I l ~ I I I I I I I JJA P a ~
J F M A M J J A $ 0 k 0 J F M A M J J A 9 0 k 0 J F MAM SO 1984 )985 1988 fHnu fe gf~
?rojected ac'nal F)armed 39
SEC EQUIVALENT .'IANFQ"C-."
'I 'I 1" -"
~
~
\
I 6
c I
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~
',e- IleoresentS the Aoril revised estimate.
l00 r, 6
\
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6
~ ~
I I I I I I I I I I I 1984'98$
I JFIIAssJJASONOJFseAMJJASOlIOJFNAesJJASO 6'6 THAI/ 64 66
~
46 ~
Qg
~I cc: cl Planned 40
SFrEC ENGINEERlNG ANO OESIGN NANNPgRS ICNerry VII))
a
>r Planned actual '(ar'.ance
/ . June IP9,OOO 'PC,Pnp I,7,3OPI
', Cumulative,?1,177,41S I 11,2'16,".78 '9,463 I I I i I I I J
I I I I
I I
I F M A M J I
I I
I I J A I
I S
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ia D J I
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I I I M A M J I I J A 8 I I 0
1984 1985 19 86 IHnu 10'at ~
~$
aa:ual Planned
B A. alit Performance Mana ement Pro ram The Quality Performance Management Program (QPMP), including the Quality Performance Indicator Program (QPIP) has been developed and initial implemlentation of the program began on June 8. The first QPMP Report was issued to the Co-tenants on June 21 and included details regarding the installation of Cat. I commodities.
Therefore, this information will not be duplicated in this report.
B. NRC Construction Assessment Team (CAT) and Enforcement Letter As a result of the verification of corrective/preventive actions for the eight alleged violations, 19 discrepant/deficient items had been identified. Of the 19 items, 10 have been resolved and actions continue to resolve the remaining nine.
The review by an independent group of the CAT inspection findings,-
the SALP, and NMPC identified deficiencies began on June 4. Status of the results will be provided as the review proceeds.
NMPC Quality Assurance Engineering continues to develop checklists for verifying the implementation of the plans developed to correct the deficiencies identified in the CAT Report. As of June 20, 58 checklists have been completed for verifying 60 CAT action plans.
It has been determined that three of the remaining six CAT Action Plans do not require any verification as a result of the reponses.
The remaining three action plans are expected to be finalized and forwarded to NMPC Quality Assurance Engineering no later than June 29, 1984. It is anticipated that the checklists and verification will be completed by July 6.
C. Other NRC Activities During the exit meeting for NRC Inspection 84-09, the Resident Inspector commented that he was pleased with the number of items presented for closure during this inspection period and hopes the trend will continue.
NRC open items, unresolved items and Notices of Violations, that remained open as of June 20 are statused below. This includes 10 new items received in June as a result of NRC Inspection Report 84-09.
Additional Action Final On NRC Item Re uired Revfev Hold ~Revieeio Total Open: 21 Unresolved: 28 22 59 Violations: 22 TOTAL 102 1- NRC Open Item, Unresolved Item, or Notice of Violation 2- Additional action required within NMPC or contractor prior to final review and verification by QA (i.e. more documentation required, additional calculations to be performed, etc.)
3- The package for the item is completed and is being reviewed for adequacy and completeness prior to submittal to the NRC.
4- Items which parallel or are identical to items presently identified in the CAT inspection and require further resolution prior to submittal.
5- Items which have been completed and have been forwarded to the NRC for review and approval for closure of the item.
D.t ~Staf fit The present Quality Assurance/Quality Control Staff (including contractors) at the Project Site is 540. This is an acceptable staffing level to support the construction activities that are presently being conducted.
The coordinator for the QA Team Building Program arrived on site June 11. Plans have been initiated for the development of the Program, with the first Team Building Session tentatively scheduled for the week of June 25.
E. Inde cadent Review The independent review required by the NRC has commenced with an initial assessment of the actions presently performed for the CAT Inspection findings. The review is still scheduled for completion within six months.
VII. CONTRACT ADMINISTRATION A. Ma or Contracts/Purchase Orders to Go Three CHOC-originated purchase orders remain to be awarded. The table below lists the purchase orders and their estimated value.
Eighteen site originated contracts remain to be awarded. Most are miscellaneous contracts such as doors, floor, tile and fencing.
CHOC ORIGINATED PURCHASE ORDERS OUT TO BID DATE OP AWARD FRD PRESENT PRESENT DATE ANTICIPATED ANTICIPATED Dripproofing Mod. HPCS 9/14/84 (A) 6/11/84 (A) 7/2O/84 Diesel Generator (Engr.
and Design)
- 2. P233N Alara Shielding Steel 2/25/85 4/02/84 (A) 6/28/84
- 3. W014B Resin Sampling Sys. 8/17/84 3/23/84 (A) 6/22/84 A ~ Anticipated
~ ~ P.O. Number Date, otherwise all dates are to be considered actual.
not assigned.
VII, CONTRACT ADMINISTRATION (Continued)
B. Ma or Contract Issues
- 1. P301C ITT Grinnell Negotiations are planned with ITT Grinnell during late June, to incorporate a revised incentive program. The program clearly defines performance goals consistent with schedule objectives.
- 2. E061A - L. K. Comstock Negotiations regarding fee adjustment associated with 1.6 million manhours of contract growth are planned with LXC during the July. A revised incentive program format will also be discussed.
- 3. P800A - G.E. NSSS Contract - Cost Allocation G.E., NMPC and SWEC are developing a program to review past charges for design revisions and hardware changes. The result is expected to be agreement on cost responsibility and requisite credit refunds to NMPC.
Major deductions have been made from G.E.'s March and April PGCC invoices for electrical separation correction costs.
Cost responsibility for electrical separation correction will be included in the joint program.
- 4. P282K Rockwell International H dro en Recombiners Rockwell's qualification proposal to allow NMPC particiation in their generic program for approximately 4250,000 plus an additional 4250,000 for two replacement power cabinets, has been recommended by SWEC.
This proposal is currently being reviewed by NMPC and will be responded to by the end of June.
5; S re Parts CHOC is currently six weeks behind schedule in procuring spare parts to support construction and system turnovers. CHOC Purchasing is aggressively expediting vendor responses and SWEC Engineering to recover the proposed schedule by the end of July. Listed below is the current status of May and June's Scheduled vs. Actual.
VII. CONTRACT ADMINISTRATION (Continued)
B. Ha or Contract Issues S are Parts Pro ram (Does not include NSSS)
Month Scheduled ~Con leted May Phase I 35 5 Phase II 9 5 June Phase II 16 4
- 6. ITT Grinnell - P301B - Sho Fabricated Pi e Backcharges (4300,000) ITT's Management met with SWEC/NMPC to discuss the disputed issues related to SWEC's Accounting verification audit. Agreement was reached in several areas of dispute. ITT is responsible for responding to the remaining issues. The next meeting is planned for July 11.
ITT also requested a delay in discussion related to the backcharge issue (4500,000) respond to each backcharge.
C. SWEC Materials Control
- 1. Inventor Control As a result of the late April inventory, the Warehouse has been able to start a consolidation effort by applicable purchase order and purchase order specification number.
Additionally Materials Management has been able to readily identify potential surplus, and advise cognizant contractors and engineers accordingly.
During this reporting period the Materials Group has been pursuing the completion of the automated s pare par ts program and system. Data. is now being entered where possible.
However, a massive backfit effort will be required.
- 2. Material Review Board The weekly Materials Hanagement meetings have produced positive results in clearly identifying priority materials required to meet schedules. The majority of the problems identified have been long lead time items and are the responsibiltiy of the expediting group.
VII. CONTRACT ADMINISTRATION (Continued)
C. SWEC Materials Control (Continued)
D. E~)edit~in
- 1. P800A G.E. HPCS Switch ear 102 The shortage of five main breakers and'hree Buss Bars that were impacting test of the 4160 Milestone has been resolved. G.E. in Philadelphia fabricated and shipped all five breakers before the June 25 promise date. San Jose has also placed an order for the missing Buss with Philadelphia for a June 27 delivery date.
- 2. P301N - ITT Grinnell Lar e Bore Han ers Expediting has identified 45 of 120 priority orders of bulk material currently outstanding. ITT has commmitted to ship 80K of priority materials prior to the July 12 plant vacation shutdown. Late ordering of materials and, long lead time specialty items requiring 10-16 weeks will delay the balance of priority materials to ship prior to shutdown. Currently, 345 points of support are required to complete the, Primary Containment by October 15.
Engineering is reviewing all BZ drawings to identify what materials must be ordered.
47
VIII. STARTUP ANO TEST A. General Startup Administrative Procedures (SAP) generation and revision is in progress and will provide improved overall direction for the Startup and Test Program. Twenty-five (25) of the known one-hundred and forty-two (142) Preoperational Test procedures are in the review and approval stage.
Preliminary testing continues with the major emphasis on electrical systems. Mechanical system testing is in progress on the Water Treatment System, and it is expected to be operable this month.
NMPC Records Management has been advised of the below listed system turnovers and are currently developing 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:
115 KV yard (BIP 70.01) 5/23 115 KV yard ground grid (BIP 77.001) 5/23 and,are expected on the following in June:
115 KV yard drains (BIP 66.004) 125 VOC control power (BIP 73.002, .003)
B. Preliminar Test Status Initial energization of the reserve station transformer and two 13.8KV buses occurred this month. Make-up demineralizer system should be operable in June. Mechanical system testing is in progress on the Water Treatment System with 99% of the flushing completed and initial operation of equ'ipment in progress. Field I&C work is approximately 90% complete for the Water Treatment System.
- 1. Re lacement Parts: Lack of replacement parts continues to affect the testing effort. Preliminary meetings have been held in CHOC with Plant Service Oivision personnel. CHOC Engineering has developed a schedule to bring this effort back on track.
- 2. Release of s stems from construction: Startup and Test is working with construction to determine which turnovers are critical to testing. Currently, thirty-three (33) BIP turnovers are behind schedule. Their status as of June 25 is as follows:
48
VIII. STARTUP ANO TEST (Continued)
C. ~b1 (C Schedul e Turnovers Actua 1 Turnovers Initial Energization 4160 V Milestone 34 20 Condensate Demineralizer Milestone 9 5 Service Water System Milestone 20 11 Integrated Systems Flush Milestone 0 0 Flow Induced Vibration Test Milestone 0 0 Turbine on Turning Gear Milestone 1 0 Ventilation Systems Milestone 5 1 Integrated Leak Rate Test Milestone 0 0 Standby Diesel Generator Milestone 0 0 Radwaste Systems Milestone 1 0 Fuel Receipt Milestone 0 0 Loss of Power/ECCS Tests 2 2 Fuel Load Milestone 1 1
- 3. Desi. n Chan es: A change control procedure has been developed to effective y manage future changes. Previous design changes had impacted the test program.
- 4. S stemic Software: Current Permanent Plant File contents indicate a need to increase the emphasis and activities for software processing to be completed to support system turnover. A major effort remains underway to define the records required for turnover and provide the required records to support turnover.
5 ~ Pro 'ect Milestone Inte ration: Startup and Test completed the initial review of total milestone 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.
49
STARTUP 4 TES6 FLUSHES
~ ~ ~
P
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JFNAIIJJASONDJFNALIJJASDNDJFAIAAI JJAQQ 1984 1986 1 986 T96nu 60'8 ~
~6 behind schedule due to late turnovers !rom
'.onstruction to AOO'.
ala a'1 Scheduled 50
STAR.llP S .ST LOOP C'L -RATION 6 I/
/I
/r C
p
~ g APT 5
= ia Q I I
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~ r JFMAMJJASOMDJFMAMJJASONDJFMAMJJAgO 1984 1985 1086 vppnv so es. ~ (
'ate due to turnover proolems and paper process. >he procedures are being corrected to Snake tee process ".,ore efficient.
Actual SCheduied
CHOC LOOP 'ALIB."-'O' P-'P'--T (Cu~u'e8!vei I
/I C
6 /
I
/
5 I
/ 8 CC /
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I I J F ee A ee I
J 19B4 J A S I
0 N 0 J F LI A M J 1985 5986~
J A S 0 N 0 J F N A N J 189A V 10 48 ~
J A S Il I
0 Accubl Screduiee 52
PREOP66'rC "0TAlICE PROCKOUR S )SSUE0 (Cureu)aeiVe)
'6 5
)4 l00 80 50 CO
/
I ( I I I I'1 I I I I 1 I I ) I I ) I I I I I I I I I I 1 I I I I I I I I r 1 I I I I I JF MAM JJASONOJFMAMJJASOHDJ FMAMJJASO 6 6 6 6 1984 1985 1666~
T66llu 10 01 II Scnedu)ed Aceue 1 53
ELEC PROCEQURES ISSUED (Cumulative) 1C 27 f t I ~ 0 I
I I
2c v1 2c CD CC'4 22 I
JFMAMJJASONDJFMAMJJASONOJFMAMJJASO 1984 1985 1986
'THAu 1Q Actual Scheduled 54
roc FRoceouRes rssveo (Cunulative) 2
<<0 38 I I
I P
u 36 I
I I
34 I 32 I
I
/
30
/
I I t J F M A M J J A S 0 N 0 J F M A M J J A S 1984 1985 0 N 0 J F M A M THnu 1986 10 J J A 01 ~ ~ C S 0 Ac all SChedured he needed orocedures are in :he revue~ c ICle. Jhon coeiolese,
~e <<ill oe back on schedule.
55
IIKCII PROCEOURKS ISSUED (Cumulacive) 6 5
CL 4
/
/
j 38 /
/
I I I I J FMAM J JASONO J FMAM J JASON0 J FNAM J JAg O 1984 1985 1986~
THAu tg pg g(
4c V4 I Scheduled
.TASTIIP 5 T:ST
'ni:ill Kquicren'. Operation I
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I I I I I I I I I I I I I J F M A M J J A S 0 Ii 0 J F M A M J J A S 0 N 0 J F M A M J J A S 0 1984 1985 1986 THOU 10 01 ~ OL AC Ue I Scheduled 57
STARTUP 6 TEST CQtlTROL C IRC'J IT VERF I CAT ION
/
6
/
I 9
I
/
5 J
r
/
I I
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/
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/
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I I I l I J F M A M J J A S 0 N 0 J F M A M J J A S 0 St 0 J f M A M J J A 9 0 1994 1985 199 9 Twnu Io pica' AC Lua 1 Scneduled Falling benind due to lace turnovers. Host of che proale~
is software.
58
IX. COST A, Cash Flow Summar Approximately 52,338 million* has been charged on the total Project to date.
As of June 17, approximately 5356.3 million has been expended in 1984. This is 59.4 million under the $ 630 million 1984 forecast.
The original 4615 million 1984 forecast has been revised to 4630 million to reflect the recent contract re-negotiations between SWEC and NMPC for non-manual and Headquarters services.
Approximately 456.0 million was expended in June versus the 852.9 million pLanned.
B, June Cash Flow Variance Anal sis Variance Remarks SWEC Manual and ~4 elllloe over The non-manual manpower was Non-Manual 31 men over plan. Non-manual overtime was 21X versus 10. 5X planned. It should be noted that the substantial planning and CAT efforts have required non~nuaL personnel. The f manual staf ing was 150 over plan as more craft was required for the painting and small bore efforts.
L. K. Comstock .7 million over Non~nual overtime was 21X versus 18X planned. Manual headcount was 151 men over plan.
Manual overtime was 31% actual vs. 22X planned. Higher than forecasted manpower and overtime were used to meet "new" milestone schedules that differ from the 5630 million plan.
ITT Grinnell 41.1 million over Non-manual headcount was 81 men over plan. Manual headcount was Continued Note~ This figure excludes 42.6 million in Administration Building Expenditures.
59
IX. COST (Continued)
Variance Remarks 24 men over plan Non-manual manpower overruns are basically due to support of the CAT action items and document reviews.
Manual manpower overrun reflects unit rates in excess of original 5630 million plan.
FPO's 42.3 million over The overrun is attributed to higher than anticipated staffing levels through 1984 and to an initial under estimate of the 1984 FPO cash requirements.
Other Misc. $ 2.6 million under Total Construction 41.9 million over Headqrtrs. Services 41.4 million over June payment for April services.
Hanhours overran approximately 34,000 from plan mainly in CHOC Engineering and Design. Major reasons for overrun were new or increased work scopes in the following areas: spare parts; PGCC separation; PGCC/NSSS FDI/FDDR review; Humphrey '
concerns; seismic conduit. Also contributing to the overrun was the monthly paid employee overtime worked in Aarch and billed in April (normal one month lag).
Hdqtrs. Miterial 4 .4 million over Total Headqrtrs. 4 1.8 million over Client Cost .6 million under TOTAL PROJECT 3.1 million over 60
1984 PROJECT CASH PLANS 700 675 600 / /
/
/I/
/ /
/'~/
500 ./
400
/ /
0 /
O O / /
p\
X /
v)
/,/
3QQ O
O 200) / Plan Actual Variance Current Period 52,925 56,028 3103 over Project to '00]
Oate 2,347,072 2,337,675 9397 under.,'
J F M A M J J A S 0 N 0 1984 PRELIMINARY RE'ilSEO ESTIMATE . LAN AOJUSTED APPROVED PLAII ACTUAL NOTE: The $ 675 Million projection is preliminary based on the revised estimate. SWEC's official revised forecast will be submitted in July, 1984.
61
EX. COST (Continued)
A joint (SWEC and NMpC) evaluation of the April 1984 Revised Estimate was completed by mid-June. As a result of this evaluation, specific areas were re-estimated resulting in a 549 million shift of funds from contingency into the baseline estimate:
(4 x mil)
Original April 1984 Revised Breakdown Breakdown Baseline Estimate 3,116 3,165 Contingency 254 205 Total 3,370 3,370 Major changes were in the following areas:
A rox.
- l. Lump Sum/Unit Price Contract 10 million
- 2. Painting 8 million 3~ HVAC 4 million 4~ Grinnell (Weld qty, productivity 12 million and 1985 non~nual)
- 5. CHOC P.O.'s 8 million
- 8. Contingency (49 million)
Net change to Total Estimate 0 These changes were discussed at the June 14, 1984 Co-tenant Neeting.
The above changes are currently being inputed into the "To Go" estimate file. Once this input is complete, an Estimate Status Breakdown showing actual expenses compared to the April 1, 1984 Budget Estimate will be prepared.
D. Cost Centers and Pro-Active Cash Flow An overview of the Cost Control Plan was presented to the functional managers on June 21, 1984. The Cost Center Program will be totally defined by the end of June and implemented in July.
The pro-active cash flow for July has been drafted. Projected values for July are in the process of review with the functional managers.
62
IX. COST (Continued)
E. Contin enc Mana ement Pro ram The Contingency Management Program was instituted to keep track of all items that were not included in the April 1, 1984 Baseline Estimate and therefore must be taken from Contingency. The Contingency balance has been ad)usted, based on NMPC's estimate review, to 5205,000,00. The approved changes reported last month have been accounted for in the review ~and re~valuation of Contingency. The following is a summary of the items affecting Contingency up through June 17 and are broken into two categories:
NMPC Approved Changes and Potential Changes. The NMPC Approved Changes are actual items that have already affected the estimate and have been approved by the Pro)ect Director. 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 5I.,495,000 in approved additions. Also, 513,600,000 in potential changes have been identified and are under review.
63
CONTINGENCY ifNNAGEMENT PROGRAM APPROVED CHANGES APRIL 1, 1984 TO JUNE 17, 1984 CONTINGENCY ZTZM DRAWDOWN ADDITION BALANCE Balance 4/1/84 4205,000,000 Refection of NSSS PGCC Quote 256 by NMPC.
This quote dealt with the Compensated Water Level Instrumenation System. 4695,000 Budget value in excess of vendor quote for Specification P233N for the procurement of materials and fabrication of Reactor Building radiation shields. 800,000 Totals 1,495,000 II June 17 Balance 4206,495,000 4
POTENTIAL CHANGES
'DOLLAR ESTIHATE ARE ORDER OF HAGNITUDE)
APRIL 1, 1984 TO'JUNE 17, 1984 ITEN DRAMDOWN 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 (4400,000 Construction and 4100,000'ngineering).
soo,ooo Headquarter Hanhour 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 6,000,000 Future Client Hanpower Additions over and above NRC Initiated 3rd Party Review 1,000,000 Paid Overtime For NHPC Personnel per Corporate Policy Concerning Extended Overtime. Being Paid to NHPC Construction Personnel Working with SPEC 100,000 65
POTENTIAL CHANGES (DOLLAR ESTIHATE ARE ORDER OF MAGiVITUDE)
APRIL 1, 1984 TO JUNE 17, 1984 (Continued) 110M DRAWDOWN ADDITION Implementation of "Fixes" due to Appendix R Evaluation:
Including Recent Guidance by NRC Pertaining to Potential Fire to Control Room 3,000,000 H/Q Hanhour Overrun. Scope additions for spare parts, Humphrey concerris, PGCC separation, equipment qualifications, etc. 3,000,000 Delay of Remaining Railroad Work, currently scheduled for 1985 until 1987 70 000 TOTALS 513,670,000 470,000 VET POTENTIAL CHANGES 413,600,000 66
IX. COST (Continued)
F. Common Facilities The costs of facilities common 'to NMP 41 and NMP42 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 II will be done when it is considered necessary.
67
RECORDS/INFORifATION MANAGEMENT A. Si ficant Activities A significant effort has taken place this month to identify Category I and Category II and III record review and the optimum flow of records from originators to the permanent plant file. The goal is to minimize redundant reviews and eliminate the transfer of records to intermediate file areas where possible. Efforts continue to identify and plan all record activities on Pro)ect as part of 15th milestone schedule.
The Turnover Specifications for the initial systems to be turned over were issued. They include a "Required Records List for Initial System Turnover".
The Project Guidelines governing the creation of the MG'2 Records/Traceability Matrix, the control and issue of the NMP2" Required Records List and .the issue of Turnover Specifications were completed and are in draft review cycle.
Assigned Planner from Pro5ect Control initiated efforts to incorpoxate Records Management Schedule input into Milestone Schedule.
Key Actions in the Near Term are planned as follows:
Develop procedure for control and issue of System Records List.
2~ Coordination and training of asks gned "Records Custodians" on the NMP2 Records Management Program.
- 3. Issuance of System Records List for BIP's 66.004, 70.001 and 77.001.
- 4. Draft of detailed Project position in the following areas to be completed by July 15, 1984:
Review and transfer of Category I Required Records.
Review and tx'ansfer of Category II and III Required Recox'ds.
Owner verification and acceptance of Required Records.
68
X. RECORDS/LVFORMATXON MANAGEMENT (Continued)
B. Record Turnover The following are estimated percents complete of SWEC turnover of documentation to the ilPC Permanent Plant File.
Total Turnover of CHOC Documents 87K Complete Total Turnover of SWEC Site Documents 6X Complete Total Turnover of all SWC Documents 17K Complete The following are estimated percents complete of NMPC Syracuse turnover of documentation to the Permanent Plant File.
Total Turnover of NMPC Syracuse Documents 716 Complete The total estimated percent complete of turnover documentation to the PPF 19K Complete.
C. Permanent Plant File Effort The following three pages identify planning curves and production figures for record receipt filming and indexing into the Permanent Plant File.
69
NMP2 PERMANENT PLANT FILE DOCUMENTS INDEXED PLANNED VS. ACTUAL Ilo I000$ 100$ 1 aC foal Note 2 I ~ 40 0
IIOO C
0IOO M
IOOO N
I004 S
I ~ 04 I $ 04 I
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~ oo X
~ 00 0
oo c g g c OI z c- g g c- 4I z co < I r c 4I z rc 3
z III C D Ia Ia III
'a$
c z p g r C III o g
( Ia z Ie Ie C nl C 1983 1984 1985 1986 Note 1 - Fuel Load Note 2 - Ccaaaroial Operation The following table summarizes the production levels of record receipt, preparation, filming and indexing into the Permanent Plant File.
To ta 1 To Percent June Hay Date ~Com late Activity
~ecord eccl pt aod 109, 506 13,224 2 $ 032, 191 25$
Preparation ( Includes Pages pages, Pages Aperture Cards)
Records Micro f i liming 128,,327 55 I 132 1,707, 471 21%
And Verification Pages pages Pages
( Includes Apertures Cards)
Computer Indexed 41 $ 038 45,357 333 I 253 51%
Entr ies Entries Entr ies Entries Records Indexing And 41,038 45,357 480,304 Computer Entry Documents Documents Documents Percent complete is based on an estimated 2,400,000 documents comprising 8,000,000 pages and 650,000 computer index entries required for Permanent Plant File entry by fuel load.
NMP2 PERMANENT PLANT FILE PAGES ENTEREO 0 C ~ II 4 ~ 0 PLANNEO VS. ACTUAL (IW 'f((04$ 044$ ( Ia(00$ 0
~ 004 Note 2
~ 040 Note 1 (s
rooo A
G oooo S
$ 004 oooo N
T saaa R
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~ (
1983 1984 1985 1986 Note 1 - Fuel Zoad Note 2 - Coaxrercial Operation 71
NMP2 PERMANENT PLANT FILE COMPUTER INDEXED ENTRIES PLANNED VS. ACTUAL II4 ~ ee 0 V 0 4 a 0 01 4C1V4L 0
~4 ~
C 0
LI ~4 ~
P V
T F 10 Note 2 R
I H
0
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1984 1985 1986 Note 1 - Fuel Zaad Note 2 - Cmmercia1 Operation 72
XI. LICENSING A. FSAR Status A total of 850 questions relative to the FSAR and ER-OLS have been received from the NRC. As of this period, 733 responses are complete. Of the responses yet to be completed, 54 involve Instrument/Control questions and discrepancies. The following, table provides a detailed breakdown of the responses.
to the FSAR was sent to the NRC on June 5. Amendment 12 will be Amendment ll sent to the NRC the first week in July.
Bo 50.55(e) Re orts Three 50.55(e) Reports were sent to the NRC.
- l. E1ectrical penetrators by Conax Corporation (55(e)-84-17),
interim 30 day report
- 2. Pacific Scientific snubbers, final report I
- 3. Feedwater piping spools (55(e)-84-05), final report Ins ection Re orts
- l. I.E. Inspection 84&5 response was sent to the NRC. One violation was.identified. Five items were reported to the NRC as a potential deficiency under 10CFR50.55(e).
a~ HPCS diesel generator control panel wiring (55(e)-84-19)
- b. Rockbestos cable (55(e)-84-19)
C~ Silicone controlled rectifiers used in the ITE Brown Boveri trip devices (55(e)-,84-20) d~ Service life of relay in safety-related system (55(e)-84-21)
- e. Valves supplied by Velan (55(e)-84-22) 73
STATUS OF RESPONSES TO SRANCH TECHNlCAL UESTlONS NUHSER OF RESPONSES SCHEOULE . OR RESPONSE COHP'TlON Tesnnica 1 bastien Qestions 1984 1925 seas s ~c~ I cc c gygga C~utaflCtn ~'~lv Sent. Oe .
ERWLS 51 50 lNS U" N ANQ C3N,RGLS
'I 4 f 0;SCREPANC.'ES 05 31 54 54 RAC lOLOGlC 47Q, 471 EFFL'JENT 460, 451, 810 62 55 P lP lNG 210 STRUCTURE/220 SE lSH lC-230 GEOLOGY-231 HYOROLOGY-ZAO GEOTECH-241 STRUCTURAL'UO 1 T 168 160 EOUlPHENT OVAL.
210 211 13 OA 260 51 51 F lRE PROTECTlON 280 33 3 1 POMER SYSTEH 430 118 101 1 3 CONTA[NHENT REACTOR PHYS lCS CORE PERFORH 480, 49I, 492 67 58 REACTOR SYSTEH 440 49 44 AUXIL,'ARY SYSTEH 410 51 45 74
STATUS OF RESPOHSES u 3RAnCH TECHNICA'UES .'ONS NLNSER QF RESPONSES SCHEOU<E <OR RESPOHSE COMPLET:ON Tecnnsca I Ques:Son Ouescions 1984 1985 snnss lndss nd Qttd t ~ Sd ~dts:antis STARTUP 6 TEST 640 32 2 I OTHER 100, 250, 251, 252, 281, 311, 450d 620d 630d 730 61 55 TOTAL.S 850 133 98 8 4 75
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