ML18037A115

Project Rept for Oct 1984.

ML18037A115
Person / Time
Site:	Nine Mile Point
Issue date:	10/31/1984
From:	NIAGARA MOHAWK POWER CORP.
To:
Shared Package
ML18037A112	List: ML18037A111 ML18037A113 ML18037A114 ML18037A115
References
NUDOCS 8501250101
Download: ML18037A115 (48)

Text

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. STATUS AS'Of 30 SEP '84 . NMP2 CHOC PLAt)r((t)G DE(s(.

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K W M M W

As-Buil ts Stress Reconciliation As seen an attachment III, recei pt of AX as-buil t packages from Construction is behind-schedule. Of 190 packages to be submi tted, 65 had been received by the end of September, 1984. In accordance with the workaround plan, an additional 20 packages near completion are being processed to minimize impact to the Engineering reconciliation schedule.

A. detailed schedule consistent with the integrated flush s ch edul e is currently being developed by the pl arming organization to provide an as-buil t package "

submittal schedule. This schedule wil 1 be avail able by the end of October 1984, and development of Engineering's reconciliation schedule will be compl ete in mid-November 1984.

E ui ment (}uglification Although work continues to proceed on Equipment (}ualification, the effort remains behind schedule primarily due to delayed vendor document submittal s. A summary of actual components qualified ver sus scheduled is shown on attachment I V.

Vendors have been noti fied that all documentation must be complete by December 31, 1984, in order to meet the milestone o f 100 percent qual i fi ca tion by J une 1985. These vendor document submittal s continue to improve with the intensi fied review of the action items list and bimonthly schedule review meetings.

From/To Conduit Desi ns This effort is behind schedule as of September 30, 1984. The slippage was due to the priority of ACN incorporation by SEG personnel to meet the NRC commi tment and a shi ftin g o f manpower to the team supporting LKC's cable pulling effort.

Completion of the entire effort is presently scheduled for the end of January 1985.

Fire Detection Panels The work remaining includes fabrication and delivery of two local fire panels and the fire computer. Delivery of the last panel on this order is scheduled for November 15, 1984. The Star tup and Test group is presently developing a milestone schedule for testing the fire protection and detection systems.

Main Steam Isolation Valves The contractor mobil ized on site to begin the cutting operati on for the appl i cati on of the corrosion resistant overlay on October 8, 1984. Two valves have had the rough machining complete and the welding was begun on one valve.

Work is expected in be compl ete in support of testing requirements.

26

7. Pre- Test Procedures The issuance by NPC of Pre-op test procedure drafts for review is behind schedule; 36 have been received at CHOC versus 65 scheduled for the'end of September 1984. This has been mainly due to recent reor ganizati ons and shi fting of manpower. Thirty-four out of 36 drafts submitted to CHOC wet e reviewed and returned as of the end of September 1984.

The preamp test procedure draft due dates are being revised by NMPC and a new schedule will be included in the October status f

o the En gineering Work Plan.

S h d 1 As of September 30, 1984, 34 drawings were requir ed for construction. They consist of the following:

8 - El ectrical wiring and termination drawings. Expected issue had slipped from September to October due to lack of vendor detail s.

13 - Power drawings that contain holds due to lack of vendor detail on expansion joints and other miscellaneous equipment.

Expected issue is November 1984.

13 - Berm drawings rescheduled for October 1984 due to delay in PMP criteria.

D. ~Sta ffin The accelerated destaffing of the Engineering and Design staff has been completed. CEP's are currently being evaluated to assess future manpower requirements. See Section V for the Engineering staffing curves.

E. Other Activities Status of EBDCR's dispositioned by Engineering is illustrated on the fol lowing graph. Al though the backlog of ESDCR's has been reduced, this area will continue to be monitored closely.

27

STRUCTURAI FINAL LOAD VERlFICATION STATUS

$ 20 110

$ 00 SCHEDULED COMPLETE sa so O yp 60 50 Planned: 38 40 Actual: 36 30 20 10

~r ACTUALCOMPLETED 0

N A M J .J A 8 0 hl D J F N A IH J J A S 0 N

't984 1985

E8cDCR STATUS ATTACHMENT II 8000 7500 I

CONSTRUCTION 7000 WORK ITEMS 6500 ~ CAT I EdcDCR'S AWAITING OC VERIFICATION ~

6000 Ed>.DCR'S A WAITING ENGINEERING 5500 DIS POSIT ION lA

~~ 5000 Ci 4

LLI 4500 o-""

~~ 3500

~ 3000 2500 2000 g7I 87!

1500 1000 ~

Ob1 bS1 500 0

A S 0 N D J F M A M J J A S 0 N D J F M A M J J A S 0 1984 1985 1986 W W W W W W W W W W

STRESS RECONC ILIATION SCHEDULE 350 300 .I" .

250 N-5

~a

, SCHEDULE 200 LL RECEIPT OF "AX" O

~

AS-BUILTS FROM O ~50 CONSTRUCTION R

ENGINEERING COMPLETION 100 0yO Ol~

50 o+

ACTUAL SEP OCT NOV DEC JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV

<984 1985 NOTE: Planned is currently being revised and will be provided in next months report.

NUMBER OF COMPONENTS E UIPMENT UALIF ICATION Attachment IV COMPLETION PROJECTION TARGET PLAN ACTUAL 3200 3100 w+ 100K COHPLETE (3085) 3000 TARGET PLAN 2900 2800 85K COMPLETE 2700 (2622) o 2600 2500 r r 2400 2300 2100 ACTI/AL~ (2150) 2000 (2092) 1900 (2000)

(1928) 1800 (1706) 1700 1600 lA lA lA EA lA lA lA lA lA lA CO CO CO CO CO CO CO CO CO CO CO CO CO CO OJ CU CO Ch O

V. WORKFOR CE LE VE LS The Site Staffing is shown on the following table and presented on a weekly basis on the following graphs. Additionally, a table has been added which displays the SWEC Non-Manual Staffing regardless of location.

SWEC Construction expended 184,447 manhours in October as compared to 191,340 manhours scheduled. CHOC expended 228,060 manhours in august (October payment) compared to 196,021 manhours scheduled.

32

OCTOBER SITE STAFFING (PAYROLL)

MANUAL NONAANUAL TOTAL COST REIMBURSNLE P A P A P A SWEC 1333 1396 1 063 1037 2396 2433 Wal sh 547 653 37 35 584 688 LKComs tock 731 736 100 100 831 836 ITT Grinnell 988 941 404 439 1392 1380 SMS 92 110 5 5 97 115 JCI 272 251 11 0 103 382 354 Schneider 150 147 19 20 169 167

'10 Painting 0 9 0 119 0 Sub total 4223 4234 1747 1739 5970 5973 Hard Money Al 1 210 , 44 254 GE /NSSS 72 72 NPC 565'2) 565'2)

TOTAL 4444 2420 6864 Note:

(1) Excludes CHOC paid site assigned personnel.

(2) NPC includes MAC, NYSEG, RGSE and Central Hudson.

33

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~!~

I October 84 TOTAL PR T Page I of 2 CHOC LOCATED SITE LOCATED TOTAL

~oe art.ment coen F I I I ed To ta 1 coen Filled Tota 1 coen F i 1 I ed To ta I MANAGEMENT 17 17 0 18 18 P I<0 J E CT CONTROLS 16 16 51 53 67 69 Planning 10 10 32 33 42 43 t1anagement Systems 4 4 4 4 Cost 15 16 21 22 SIIE ENGINEERING 7 443 45O 7 443 45O AOV I SORY OPERAT I ONS 39 39 9 133 142 9 I /2 181 PGCC 0 20 20 0 20 20 Startup C Test 39 39 9 113 122 0 152 161 PROJECT ENGINEERING 2 47O 472 2 47O 472 CONSTRUCTION 197 198 197 198 CCCP 0 7 7 0 7 7 Safety. 0 9 9 0 9 9 System Turnover 0 32 32 0 32 32 Construction Groups 1 149 150 I 149 150

SMEC NON-NORMAL TOTAI PROJECT Page 2 of 2 CHOC LOCATED SITE LOCATED TOTAL De artment ~0 en Filled Total ~0 en Filled Total Open Fi I led Total ADHINISTRATIVE SERVICES 51 52 25 237 262 26 288 Project Administration 0 0 I I Office Services 0 7 7 0 7 7 Project Records Admin. 2 18 20 2 18 20 Document Control 1 32 33 146 159 14 178 192 Systems Application 8 2 10 8 2 10 Data Prqcessing 1 13 14 1 13

~

Accounting 0 24 24 0 24 24 Time Office 1 12 13 1 12 13 First Aid 0 8 8 0 . 8 8 CIIOC System 38 0 18 18 0 i8 18 Training 0 7 7 CONTRACTS 6 NATERIALS 62 62 0- 68 68 Contracts 11 11 11 11 Haterials 23 23 23 23

. 16 Purchasing 0 4 12 12 16 Expediting 0 2 16 16 18 i8 QA/QC 16 284 300 16 288 304 QA 0 25 25 0 29 29 QC 16 259 275 16 259 275 LABOR RELATIONS/PERSONNEL GRAND TOTAL 3 587 590 61 1431 1492 64 2018 2082

SWEC ENGINEERING AND DESIGN PERSONNEL (SEG + CHOC)

PLANNED ACTUAL VARIANCE OCTOBER 539 764 225 1500 1400 1300

~1200

~ 1100

~1000 O

900

~ 800 CL o 700 4J 600 I

~~ 500

~ ~00 0 PL'AN DOES NOT INCLUDE

~~ 300 SCOPE INCREASES WHICH ARE BEING WORKED 200 100 JFMAM J JASOND J F MAM J JASOND J FMAM J JASO 1984 1985 1986 KEY 0-- ~ PLANNED ACTUAL 40 C.G. MODEL: NMBFGRPH06

SWEC ENGINEERING AND DESIGN 'MANHOURS.

(SEG + CHOC)

PLANNED ACTUAL VARIANCE OCTOBER 88,000 141,090 53,090 (x1,000,000)

CUMULATIVE 12,047,000 12,204,739 157,739 13.0 12,8 12.6 12.4

11. 6

11. 4 11.2

11. 0

10. 8 PLAN DOES NOT INCLUDE SCOPE INCREASES WHICH ARE BEING WORKED 10.4 J F MAM J JASOND J F'MAM J JASOND J F'MAM J JASO KEY NOTE:

OCTOBER ACTUALS PROJECTED. 41 o- -o PLANNED AC TllAL C.G. MODEL: NMBFGRPH12

VI. QJALITY ASSURANCE A. OA-Projects Activities Detail Assessments ~

The Assessment of Johnson Controls I nc. ( JCI ), Reactor Controls Inc. (RCI), ITT Grinnell, and Stone 5 Webster (SWEC) has been completed and the final reports issued summarizing the resul ts.

One Corrective Action Request (CAR) and four recommendations have been i'dentified for JCI, ten CARs and fourteen recommendations for RCI, six CARs and ei ghteen recommendations for I TT Grinnell, and one CAR and fifteen recommendations identified for SWEC, with no CARs bein g ini ti ated.

Surveillance As of September 21, 1984, a total of 58 Surveillance Reports had been generated for reviewing completed and accepted safety related permanent plant items. The data obtained from those reports has been -

summarized, in regards to activity, contractor, and deficiency. To date, a problem has been identified in the area of ITT Grinnell installed pi pe supports and SWEC/Comstock installed cabl e trays, in that i tems have been gC accepted that do not conform to all of the specifications/drawing requirements.

Some posi tive resul ts of this activity is in regards to Fi el d Raceway Supports and Nuclear Coating. A total of 228 supports were reviewed wi th one minor discrepancy being identified, which was later resolved by SWEc, and approx. 2000 ft 2 of coatings was reviewed and found to be free of defects and discrepancies. As a result, NPC gA does not plan to continue this effort for Field Raceway Supports and Nuclear Coatings, but will continue the effort in other areas.

Surveillance Another 88 surveillances were performed during September 19, to October 19, 1984, involving approximately 1,062 attributes from approval checklists. From these surveillance activities the following nuober of deficiencies/discrepancies were identified:

HARDWARE SWEC ITT Grinnell JCI RCI All of the above defi ci enci es/discrepancies have been properly identified and are being resolved. In addition to the above, Seven Corrective Action Requests (CARs) were issued as follows:

HARDWNE SOFTWARE SWEC ITT Gr innel 1 JCI RCI CAR ¹84.0112 imposed a "Stop Further Processing Order" on RCI 's activities involving General El ectric's (GE) FDI-14-31263.

Contrary to stated requirements, RCI failed to comply with their program requirements when performing work to GE FDI-14-31263 which requires the removal of insulation brackets and base pads from the reactor pressure vessels. RCI's program does not adequately describe the equal ity Control activities being performed or required to assut e adherence to the design instructions pr ovided by GE FDI-14-31263 nor the corresponding SWEC ESDCR C18108.

CAR ¹84.0126 imposed a "Stop Further Processing Order" on I TT Grinnell s activities for threading rod.,I TT Grinnell was threading rod in the Pipe Support Fabrication Shop at Nine Mile Point ¹2. The threaded rod was marked for pipe support BZ 72 AJ-l, ASME III,, gA Cat. 1, Class 3. Currently, ITT Grinnell does not have a procedure for machining threads on bar stock or machining other items at the Nine Mile Point ¹2 Site, nor do they have an adequate inspection program to inspect or verify the threading of rod, to assure the requirements of ASME III Subsection NF are being met.

As of October 24, 1984, acceptable corrective actions have not been provided to allow resumption of the related activities. Therefore, both "Stop Further Processing Orders" remain in place.

Audits An audit was performed of SWEC's procurement activities. -

Twelve Audit Finding Reports (AFRs) were issued 'esul ting in the initiation of a Significant Deficiency Report.

The condition described on the Significant Deficiency Report was as follows:

RG-VR-N2-84007

'Pudit identified significant problems wi th SWEC's Fiel d Purchasing Functi ons. Anong the more si gni ficant are:

l. Uncontroll ed changes to procurement documents

2. Improperly attested certificates of conformance

3. Use of unapproved vendor for calibration of MSTE

4. Bypassing F()C review of requisition and purchase order

5. Grossly i nadequate training A Stop Work Order was recommended, but was not required due to the iomediate corrective action taken by SWEC, as follows:

43

"The following SWEC action will be effected immediately to assure that subsequent procurement activities are adequately controlled:

1. 'ssign a QAE to review and appr ove all PR's/PO's prior to issuance

2. Provide immediate interm training (wi th special emphasis on use of Qualified Vendors, Classification of Safety Category, and Control of Changes) for procurement per sonnel. Develop and implement a training program. (reflective of all phases of Site Procurement Process and activities) for the personnel ihvo1 ved, eg; Procurement, SEG and QA/QC. Provide NPC-QA Proj ects a training schedule, refl ective of the developed training program with start and completion training dates and a matrix of personnel by organization and required Training Course Procedures."

Quality Trending The Quality Trend Reports for the first 3 quarters of 1984, have been i s sued, re fleeting the r esul ts ob tained from Surveil lance Reports, Corrective Ac tion Requests, and Audi t Finding Re por ts .

When a negative trend is suspected a "Suspected Trend Investigation Report" (STIR) i s issued to the Qual i ty Engineering group, identi fying the problem area. Qual ity Engineering then investi gates the problem to determine i f a negative trend does exist. To date, eighteen STIRs have been issued, twelve have been investi ga ted resul ting in the identi fication of two nega tive trends, for which Corrective Action Request have been issued. The remaining six STIRs are presently undergoing an investigation.

The NRC Resident Inspector held an informal exit meeting October 19, 1984. To date there were no violations identified but he did i denti fy seven potenti all y unr esol ved/o pen items. These seven items are presently being investigated and addressed by NPC and SWE C.

Further investigation into the "dupl ication of radiographs" is continuing by SWEC and I TT Grinnell . Since the initial i denti fi cation of, the problem, SW EC and ITT Grinnel1 have identified a second instance of duplication, bringing the total to iMo.

NRC Open Items, Unresolved Items and Notices of Violations, that remained open as of September 20, are statused below:

3 4 Additional Action Final On NRC Item ~Re uired Review Hold ~Reviewin Total Open: , 10 2 2 Unresolved: 18 22 7 6 53 Violations: 7 7 2 10 26 TOTAL 96 The actual No. of Violations awaiting a response to be forwarded to the NRC is 8 (Blocks 3 8 4).

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 ()A (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 par all el or are identi ca 1 to i tems presently identi fied 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.

B. Inde endent Review The Independent Assessment team has per formed their review of completed CAT Action Plans (Phase I). The remaining 9 CAT Action Plans will be reviewed. As a result of the review performed as of September 17, nine Corrective Acti on Requests have been issued identifying deficiencies that had remained uncorrected. Seven of the Corrective Action Requests presently identify software defi ci enci es and two identi fy a hardware defi ciency. One identified hardware deficiency will require a reinspection of all we 1 ds on the En ter prize Sys tern by RCI and may requi r e a reinspection of all previous RCI l}uality Control accept welds. The second hardware deficiency relates to the storage, protection, and control of material.

45

The, review of NRC identified deficiencies (Phase II) is in progress. As a resul t of the review performed to date, four Corrective Action Requests have been issued identifying deficiencies/discrepancies. The four Corrective Actions presently identify software deficiencies.

The review of NPC identified deficiencies during January 1, 1981 through March 31, 1984 (Phase II I) is in progress. The review consists of 216 items, 180 of which have been reviewed and are closed, eight are out of the scope of the review (CAT-II and Unit I), an'd the remaining are awaiting closure by NMPC.,As a result of this review to date, three Corrective Action Requests have been issued. Two of the Corrective Action Requests identify software deficiencies and one identifies a hardware deficiency.

4 The review of Contractor's deficiencies identified during January 1, 1981 through March 31, 1984, (Phase IV) is in progr ess. A smaple of approximately 2,500 items has been selected for review, of which 2131 items have been reviewed and are closed, 200 items are presently being reviewed, and the remaining items have been assigned to individual s to commence the review. As a resul t of these actions 43 Corrective Action Requests have been issued. Of the 43 Corrective Action Requests, 17 identi fy software defi ci enci es and 26 identi fy hardware de fici enci es. The final report for all four phases is scheduled for issue on December 18, 1984.

VI I. CONTRACT ADMINIS'1RATION a or ontract ssues

1. Lar e Steam Turbine Generator S are 5 Renewal Parts Contract-I A revised draft contract document, incorporating comments from NPC Contract Admi nistration and NPC System Law Department was submitted to General Electric on October 2, 1984. A response was requested from GE by October 24, 1984. A negotiation meeting, if necessary, should occur during the month of November.

2. GE S are Parts Excess Inventor Sale - NSSS A proposal was received from General Electric on October 11, 1984, offering an inventory of NSSS startup, test and operational spare parts at a substantial discount (35-50%). Effort is underway by all involved project groups to ensure that maximum advantage is taken of this offering by GE.

3. P800A - GE NSSS Contract Amendment No. 18 Amendment No. 18, incorporating the prov i si ons o f the ne goti a ted s ettl ement rel a ting to contract extens ion and other matters, is currently being developed and formalized between %PC and 46

GE. It is anticipated that the final agreement will be signed by November 15, 1984. In the interim, both parties are operating in accordance with the basic agreements.

4. P800A - GE NSSS Contract - Cost Allocation The cost allocation program remains a priority matter for Contract Administrati on resolution. Ef forts continue to bring General Electric to the table in a joint team approach to mutually determine FDDR cost responsibility. NPC continues to make invoice deductions representative of estimated "separation" costs wi th total deduction to date of 55,600,838.00.

5. Startup and Test Services - RF(}

Three vendors were added to the list of b'idders for this RF(}. As a result, the bid due date is being extended by two weeks beyond the or i gi nal due da te of Oc tober 23, 1984. This extens ion wi 1 1 not impact schedule.

6. P301N - ITT Grinnell En ineerin Bill in Issue I TT Grinnell has noti fied SWEC/NMPC that their position on the resolution of the Engineering Billing Issue is not negotiable and they have, suggested that the services of an independent arbitrator be solicited in resolving this dispute. The terms of the subject Purchase Order do not allow for arbitration. Currently NPC Contract Administration and the law department are reviewing the issue of third party involvement.

7. Reactor Controls, Inc.

Reactor Controls has proposed conversion of their lump sum contract to cost reirrbursable to accommodate impacts resulting from (}A program enhancements imposed by NPC/SWEC (}A. RCI has agreed to implement the l}A enhancements. NPC/SWEC have committed to expeditiously pursue commercial resolution and to reimburse RCI for construction cost impacts in the interim.

B. ~Edi

l. BALANCE OF PLANT (BOP):

The f to ta 1 number o .SOC purchase orders for permanent pl ant equipment is 339, of which 257 are completed. This represents 76% of the total purchase orders placed which are now complete as presently defined, excluding spare parts orders.

There is a total of eighty-two (82) open CHOC orders with deliveries projected through June 15, 1985. These orders are broken down into two (2) commercial categories:

On or ahead of purchase order commitment 20 Behind purchase order commi tment 62 47,

Of the sixty-two (62) negative deliveries, forty-four (44) are considered to be impacting the P roj ect schedul e to various degrees. The construction completion and startup and test groups are in the pr ocess of defi ning the cri ti ca 1 i ty of these deliveries to the project schedule. There are items on sixteen (16) purchase orders whi ch have been i den ti fi ed as having del iveri es whi ch will create an impact to turnover for AOD testi ng.

3. Ex editin Corrective Actions Of the sixteen (16) most critical orders impacting turnover and test, expediters have taken steps to improve all phases of vendor schedul es during engi neering, procurement, production and shi pment. Regul ar shop visits are conducted by expediters and NPC Contract Administration to minimize the impact of these late deliveries to construction schedules.

4. Hanger Material Status:

Special expediting measures are being directed toward this effort since 259 BZ's have been identified by construction as short material required to complete the balance of plant. Expediters have been assured that all required materials are on order at this time with either ITT Grinnell or NPS Industries.

a. P301N - ITT Grinnell: There is a total of seventy (70) shop or ers open o w ich twenty-six (26) are designated as priority to complete hangers in the Primary Containment. The priori ty orders are projected for delivery through November 15, 1984. The estimated compl eti on for the balance o f non-priority orders is January 31, 1985.

b. P301 R and Various FPO's - NPS Industries: A total o f 958 pi eces o arge ore materia .. ave een ordered from this vendor through Bulk Order k2N issued October 1, 1984. As of October 17, 1984, 649 pieces have been shipped. The balance of 240 pieces on Bulk Order 81N are scheduled through October 31, 1984. The sixty-nine (69) new pieces on the second bulk order'ave a quoted lead time of four (4) to eight (8) weeks after release to shop for shipment, anticipated by year's end.

A total of 2,209 items of small bore materials and 252 special pi pe cl amps remai n on or der wi th shi ppi ng commi tments now s ch edul ed through December 15, 1984. NPS di d complete and ship 1,894 small bore supports during the month of September, 1984.

48

One expeditor has been assigned full time to provide shop coverage on a weekly basis due to certain vendor. commitments not being met.

5. Lar e and Small Bore Valves:

SWEC Engi neering has requested quotations from various vendors total 1 ing approximately 2,500 addi tional new valves. Of this total, 149 were identified as required for permanent plant and the remai nder as Spare/Repl acement val ves. Thir ty-five (35) o f these 149 unique items have been lWX awarded by CHOC on seven (7) purchase orders. These addi tional val ves bri ng the to ta1 on order for the Project to approximately 15,600 of which only about 5% are left to ship, the majority of which are small bore valves.

VIII. STARTUP AND TEST A. General Startup Administrative Procedures (SAP) have been drafted and Joint Test 'roup ( JTG) review and approval is scheduled to begin on 10/29/84. These procedures will streaml ine and set policy for the Startup and Test Program.

B. Release for Testing Status Of the 94 subBIP eleases scheduled as of October 22, 1984, 80 have, been accepted for Preliminary Testing. There are 2 additional subBIP eleases which have been accepted as early releases.

There are 14 subBIP eleases overdue per the Project Schedule issued October 15, 1984. (See Attachment 1)

C. Prel iminar Test Status Preliminary testing continued with emphasis on supporting testing in progress on Service Water, Condensate System, Instrument Air System, Turbine Building Closed Loop Cooling, Makeup'Water, Control Rod Drive Hy draul i cs, and Turb ine Generator, Lube Oil System. Elec tri cal testing is being prioritized to support the startup schedule.

D. Turnover Status Project Records Management has the schedule of system turnovers to support development of a required recor ds 1 is t and in clus i on o f outstanding documentation on the Installation Completion Report (ICR) to support the turnover process.

49

VIII. STARTUP AND TEST (Cont'd)

F. Prep /Acce tance Testin Status Startup and Test is preparing to begin an Acceptance Test for System 15 - Makeup Water Treating in mid-November, 1984.

E. Major Problems

1. Material s and S are Parts: An evaluation of the present terra s an pare arts rogram is in process. The initial problems identified are being addressed and resolutions are in progress (i .e. compl eting an inventory o f the warehouse an d feedback is being provided to user organizations). The Controlling Procedure ( PG-35) is being -revised to streamline the efforts.

2. Release of S stems From Construction: Startup and .Test is wo sng w> t urnover to etermsne s ch releases are pri ority for testing. The releases are not being accomplished in a timely manner due to procedural and programmatic problems. A maj or ity of these problems are being addressed by the new SAP's.

3. S stemic So ftware: Current Permanent Plant File contents s n i cate a nee to incr ease 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. (See Section X).

4. Proj ect Schedul e Inte rati on: Ef fective October 4, 1984 the We nes ay tartup meeting was cancelled and replaced with the Plan of the Day (POD) meeting. The purpose of this meeting is to direct and coordinate activities required to support the Startup Test ScHedule. Probl ems and restraints that hamper testing will be the focus and- action items assigned. The organizations invol ved i n th e POD are En gi neer ing, Cons truction, Sys tern Turnover, QA, FQC, and Nuclear, Operations, and Materials.

E. Fuel Status

l. Enriched uranium has been delivered to G. E.

2. G. E. currently fabricating the bundles; scheduled to complete by May, 1985.

3. %PC currently evaluating storage requirements pr ior to shipment to Site.

50

Attachment 81 SubBIP 'A" Releases Released Early Total Scheduled IAW Schedule Release Releases Accepted 80 82 Late Per Scheduel: 14

'B'omponent Releases Early Releases  % Completed Schedule Accepted Testing N/A 150 65%

51

ELECT PROC ISSUED (CUMULATIVE) 10/1S/84 30 29 28'6 2S 24 23 21 APR MAY JUN JUL AUG SEP OCT NOV DEC JAN FE8 MAR APR MAY JUN SCHEDULED 28 ACTUAL 28 52 '

MECH PROC ISSUED (CUMULATlvE) <ops sga4 38 32 30 j 2B 24 22 20 la 1B 14 APR MAY JUN JUL AUG SEP OCT NOV CEC JAN FEB MAR APR MAY JUN 7 proowdurs= ln JTG rmvlaw oyola SCHECULEC 23 ACTUAL 23 53

I8'C PROC ISSUED (CU.'A ULATIVE) 10/1584 36 31 29 27 snag APR MAY JUN JUL AUG SEP CCT NCV OEC JAN FEB hIAR APR h(AY JUN 6 PRGCEOURES IN JTQ REVI V/ CYCLE SCVEOULEO '3n ACTUAl 32 54

I X. COST A. Cash Flow Summar Approximately $ 2,550 million* has been charged on- the total Project to date.

As of October 14, approximately 568.4 million had been expended in 1984 versus 572.8 million forecasted or an underrun of 4.4 million.

Approximately 49.0 mill ion was expended in October versus 53.0 million planned.

B. October Cash Flow Variance Analysis Variance Remarks FPO's 8 .4 million over Other Misc. S .1 million over Total Construction S .5 million over He adqrtr s. Ser vi ces $ 1.5 million over October payment for August services. Manhours overran foreca st.

HQ NSSS/PGCC 92.1 million under No payments were made to G.E.

Hdqtrs. Material Sl .1 million under Total Headqrtrs. $1 .7 million under Client Cost S .6 million over Contingency $ 3.5 million under TOTAL PROJECT S 4.0 million under

• This figure excludes 82.6 million in Administration Building Expenditures and 5.3 million in previously paid AFUDC payments.

PROJECT FORECAST 3.5 3.4 3.2 R PlAN 3.1 (NC CONT-3.0 -R PLAN LESS CONT z 2,9 Jo 2.7 go 26

-ACT 2.5 2A 0

2,3 2,2 2.1 2.0 1.9 1.8 DEC JUN DEC JUN DEC JUN DEC 1984 1985 1986 56

I X. COST (Continued)

C. Common Facil ities A proposed pl an for all oca ting the costs o between Units 1 and 2 has been developed.

Niagara Mohawk Management for review by mid-November, 1984.

't f common facil i ties will be submitted to The plan is presently being reviewed by the Accounting Department. Once this plan has been finalized, it will be presented to the Cotenants for their approval.

Contin enc Management Pro ram The Contingency Management Program was instituted to identify all items that were not included in the April 1, 1984 Revised Estimate Baseline* and therefore, must be funded from Contingency. The Contin gency balance appropri a ted for the 4/1/84 estimate was

$ 205,000,000. To date, the Contingency balance has i ncreased by

$ 4,357,626 for approved changes. However, as of October 23, 1984, there are pending CEP s which total appr oximately $ 1 3.5 mill ion.

These pending CEP's are ei ther approved prel iminary packages or compl eted packages bei ng revi ewed by NPC. Al so, we have a potential contingency exposure for approximately $ 13.1 million for CEP's not yet transmitted to NPC.

The Project is currently reviewing the CHOC 1985 manpower forecast as well as other potential contingency drawdowns. The resul ts of this review will be reported in next Month's Report.

NOTE: Three pending additions previously reported to Project Contingency are being removed due to. the following reasons:

o Rejection of NSS/PGCC (}uote 256: Funds were placed in the en en ontingency count wi in the NSSS/PGCC budget.

o Bud et value in excess of vendor uote for S ecification P233N:

ditiona e ort may e require or is scope o wor .

o NSS Anendment 0'20 uote under bud eted amount: The total doll ar impact as not yet een con irme; quo es are still out to various vendors.

57

CONTINGENCY MANAGEMENT PROGRAM APPROVED CHANGES April 1, 1984 to October 23, 1984 Contingency Item Drawdown Addition Balance Balance 4/1/84 S205,000,000 Incr ease to contingency based on the latest Project forecast (CEP in process) 13,991,441 APPROVED CEP's

• f01130 Approx. $ 186,000

%1149 53, 200 801153 Approx. 1,735, 292

%1160 Rev. 1 Approx. 683,500 801163 1,254,494 Kl 164 Rev. 1 Approx. 500,000 801167 83,998 Rl 171 4, 243,480 801172 266,800

%1178 91,900 801225 535 151

$ 9,633,815 $ 13,991,441 NET CHANGE $ 4,357,626 $ 209,357,626

• CEP5 Descri tion 01130 AOD CHOC Revi ew of NMPC Preoperational and Acceptance Test Procedures.

01149 Extraction of Cable Numbers from Test Loop Diagrams.

01153 PGCC/NSS Support-Revised Budget.

01160 Rev. 1 Technical Support Center.

01163 PGCC Separation 01164 Rev. 1 Temp. Site Assistance for Planning 8 Scheduling 01167 System 38 and Peripheral Equipment 01 225 Additional Personnel for SWEC gA/gC Or ganization 01171 gA/gC, EA PgA - Budget Revision 01172 Data Base Accuracy for System 38 Activity Control System.

01 178 Ductwork (}uali fication.

58

RECORDS/INFORMATION MANAGEMENT A. Progress made during the past month:

L. K. Comstock and Walsh Construction assessment for compl iance to Records Management Plan has been completed. Supporting documentation is being completed. Procedural changes are not required since their completed records are controlled by FOC's procedures.

2. The assessment of JCI's program is complete and all procedures are in final draft form. Approval is expected within 2 weeks.

3. The i niti al assessment of ITT Gri nnell 's program has been completed. The detailed review of Grinnell s procedures has commenced and initial revisions are due for review by 10/26/84.

plan to initiate the turnover

4. A of CHOC E8D CR' has been developed and the review and filmi ng will be i ni tiated by 10/25/84. These documents will support the Records Management Production Recovery Program.

Review of the Record Identifi cation/Traceabil ity Matrix is approximately 40% complete. The balance will be sent for review by 10/26/84. The compi 1 ing of the dr a ft Required Records List has been initiated and completed for JCI.

B. Ma jor Activities in Progr ess:

A review of the Start-up Administrative Procedures is currently being per formed for compliance to the Records Management Plan. Areas of revision are being negotiated with start-up for incorporation into the first issue of the SAP's.

2. A Records Management i ndiv i dual has been pl aced in Reactor Control 's house to develop procedural revisions with RCI personnel. This action will expedite the compliance of RCI to the Records Management Plan.

3. The balance of the draft SWEC Project Procedures have been reviewed internally and will be submitted for project review by 10/26/84.

4, Construction of the Record Acceptance Center has been expedited. The high density storage units have been ordered and construction of the vault has been initiated.

59

C. Record Turnover The -following are estimated percents complete. of SWEC turnover of documentation to the NMPC Permanent Plant File.

Total Turnover of CHOC Documents 97% Compl etc Total Turnover of SWEC Si te Documents 13% Compl ete Total Turnover of all SWEC Documents 25% Compl etc The following are estimated percents complete of %PC Syracuse turnover of documentation to the Permanent Plant File.

Total Turnover of NPC Syracuse Documents 87% Compl ete The total estimated percent compl ete of turnover documentation to the PPF 32% Compl ete.

60

NMP2 PERMANENT PLANT FILE

-Note l - Fuel Load Note 2 Camercial Operation COMPUTER INDEXED ENTRIES PLANNED VS. ACTUAL AOTISAL 0 CIN 2oovoANOSI

~ 00 Note 2 200 Note l I

200 D

~

s x eoo E

D opo 0

E 7

200 anticipated R X-Recoy~

e IOO Program s

c Co Z c g c CO Z c c cr CO Z o

o C Z 22 r

c: m

'sS o

D <

m

'ts (

'I 984 1985 1986 The following. tables summarize the production levels of record receipt, pr eparat'ion, f ilming and indexing into the Per manent Plant File.

Total. to Percent October September Date ~Cpm late Activity Record Receipt and 148,208 126, 300 22 4442 123 Preparation (Includes Pages Pages Pages Apertur e Cards Records Picrofilming 1342642 108, 164 2 074 826 Pts<

And Verifi-cation Pages Pages Pages (Includes Aperture Cards)

Computer Indexed 9,937 15,439 375,710 Entries Entries Entries Entries Records Indexing And 32;696 55,753 585,286 Documents Documents Documents Pere'ent 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 ent'ry by fuel load.

B:L2 61

Note 1 Fuel Loag NMP2 PERMANENT PLANT FILE Note 2 Canaercial tion DOCUMENTS INDEXED ~ LAIIIICO PLANNED VS. ACTUAL 0 (I 0 I II0 V 5 A II0 51 AC TV*L 1000 1 ~ 00 Notel2 1000 1 ~ 00 Note 1 0

1100 C

M 1500 N

~ aoo S

F 500 1100 I

1000 0

6 ~ 00 X

6 F 00 0 oooQ A 5 cAPk<W F 00 X-Recovery 100

• IO c r r r c 01 z c c'm 0

r D os z 5 r c o r Ch Z ss ~

m D ( Z ( z m D D 1983 1984 1985 1986 NMP2'ERMANENT PLANT FILE PAGES ENTERED PLANNED VS. ACTUAL IIV TIIOVOAII05) AC1VAL 8

~ 000 Note 2 0000 rooo A

G S 0000 S

~ aoo X

N ' X soao X A

E 10OO @X

. eoee Antici

.Qoo X-Recov 1000 Pzogr r r ~ 50 z ~ x r ~ 0 z ~ x r ~C z c r r ~ z z ss g rC m D

()

SA Z SA ss

)I

~ r C m D < Z )Iss <

CS SA g r L

m Q  % SI S, C Lo m g C

1983 1984 62 1985 1986

XI. LI CENSING A. FSAR Status A total of 850 questions relative to the FSAR and ER-OLS have been received from the NRC. For this period, 832 responses are complete. Anendment 14 was sent to the NRC October 5, 1984.

B. Safe Evaluation Re ort (SER) Status There are 233 SER open items and an additional 80 Power Systems SER items for a total of 313. We believe that 294 SER items are NPC action complete.

Fourteen 50.55(e) Reports were sent to the NRC.

1. Materials supplied by Tube-Line (1983), Final Report.

2. PWHT for SFC Heat Exchangers (55(e)-84-35), Interim Report.

3. PWHT for FWS Valves (55(e)-84-37), Interim Report.

4. Impact Test on Check Valves (55(e)-84-38), Interim Report.

5. Curtain Type Fire Dampers (55(e)-84-36), Interim Report.

6. PWHT Coupons for MSIV (55(e)-84-23), Final Repor t.

7. HEA Relays (1983), Final Report.

8. Dupl icate Radiographs (55(e)-84-39), Interim Report.

9. Single Girder Crane in Diesel Gen. Rm. (55(e)-84-13), Final Report.

10. PT Exam of ITT Welds (55(e)-84-06), Final Report.

11. CPS Valve Seismic gualification (55(e)-84-40), Interim Report.

12. Magnetrol Level Switches (55(e)-84-41), Interim Report.

13. 'PS Valve LOCA Closure (55(e)-84-42), Interim Report.

14. Sockolets by Bonney Forge (55(e)-84-43), Interim Report.

63

XI LICENSING (Cont'd)

D. 50.55(e) 's Identi fied Five items were reported to the NRC as potential deficiencies under 10CFR50. 55e.

l. Sockolets by Bonney Forge (55(e)-84-43)

2. Rosemont Transmitter Leakage (55(e)-84-44)

3. g. A. on Cable Terminations (55(e)-84-45)

Glow Valve Motor Operator Wiring (55(e)-84-46)

5. Seismic qualification of HPCS Batteries (55(e)-84-47)

E. Ins ection Re orts Response was submi tted to violations identified in Inspection Report 84-11 (2 violations).

F. Advisor Committee on Reactor Safet (ACRS)

A first draft of the NMP2 positions for each topic has been received by NP2 Licensing. The drafts are on review. The first preparatory meeting will be held on November 5 and 6.

64

STATUS OF RESPONSES TO BRANCH TECHNICAL QUESTIONS NUMBER OF RESPONSES SCHEDULE FOR RESPONSE COMPLETION Technical Question Areas INSTRUMENT AND Questi ons d ~cd 1d dodd d d 1984 Oct.

1985 CONTROLS* 85 85 421 DISCREPANCI ES RAD IOLOGI C 470, 471 62 59 EFFLUENT 460, 451, 810 PIPING 210 168 166 S TRU CTURE/220 SEISMI C-230 GEOLOGY-231 HYDROLO GY- 240 6EOTE N-241 STRUCTURAL AUDIT EQUI FM EN T 13 10 QUAL.

270 271 QA 260 51 51 FIRE 33 30 I

PRO TE CT ON 280 POWER 118 117 S YS TEN 430 CONTAINMENT 67 67 REACTOR PHYSI CS CORE PERFORM 480, 491, 492 REACTOR 49 S YSTEM 440 65 I

SlA1US OF RESPONSES TO BRANm TECHNICAL QUESTIONS NUMBER OF RESPONSES SSEDULE FOR RESPONSE COMPLETION Technical Question Ques ti ons 1984 1 985 Areas R i d ~C1 d ~at t di Oct.

AUXI LI ARY 51 51 S YS TEN 410 STARTUP 5 41 39 TEST 640 O'WER 61 59 100, 250, 251 252, 281, 311 450, 620, 630 730 TOTALS 850 832 18 10 NOTE:

(1) Excludes CHOC paid site assigned personnel.

(2) NPC includes MAC, NYSEG, RGSE and Central Hudson.

66

. I