ML20066B604
| ML20066B604 | |
| Person / Time | |
|---|---|
| Site: | Clinton, 05000000 |
| Issue date: | 07/09/1982 |
| From: | ILLINOIS POWER CO. |
| To: | |
| Shared Package | |
| ML20064L507 | List: |
| References | |
| FOIA-82-366 NUDOCS 8211090036 | |
| Download: ML20066B604 (41) | |
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SCOPE:
e DEFINE THE ACTIOff BEING TAKEN BY ILLINDIS POWER TO IDENTIFY AND CORRECT SPECIFIC QUAL'TY PROBLEMS.
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8 PURPOSE:
4 DEMONSTRATE THAT ASSEMBLED STRUCTURES, c
SYSTEMS, AND COMPONENTS MEET REGULATORY REQUIREMENTS.
O DESCRIBE HOW NEW WORK'WILL MEET REGULATORY REQU,IREMENTS.
O DEVELOP' PLANS FOR RESOLVING IDENTIFIED QUALITY PROBLEMS.
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OUTLINE PERSONNEL RESOURCES REQUIRED TO SUPPORT THESE EFFORTS.
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IDENTIFIED PROBLEMS FALL INTO TWO (2) CATEGORIES CATEGORY I WORK CONTROLS 8 INSPECTION CATEGORY II QUALITY RELATED ISSUES 5
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ACCEPTED WORK:
FULLY ASSEMBLED INSPECTION ACCEPTED TRAVELERS FINAL REVIEWED & IN VAULT I,
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INSPECTION PARTIAL TRAVELERS NOT FINAL REVIEWED & NOT IN VAULT NEW WORK:
NOT ASSEMBLED NO INSPECTION PERFORMED TRAVELERS NOT RELEASED.FOR WORK TO' FIELD LEGEND:
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.m 9 IN-PROCESS QC INSPECTION LAGGING CONSTRUCTION (IN-PROCESS WELD INSPECTION IS KEEPING PACE WITH CONSTRUCTION)
O TRAVELERS IN THE FIELD NOT BEING COMPLETED IN A TIMELY FASHION SO'QC CAN DO THE FINAL WALKD,0WN e
ACTION TAKEN O RESTRAIN RELEASE OF NEW WORK.TO THE FIELD e CONCENTRATE ON COMPLETING IN-PROCESS WORK S CONCENTRATE ON REMEDIAL WORK 9*
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d Milllll SMALL BORE PIPING PROBLEll 0% 25% 50% 75% 100% a e e IN-PROCESS INSPECTION LAGGING CONSTRUCT 10tl (IN-PROCESS WELD INSPECTION IS KEEPING PACE WITH CONSTRUCTION) 4 S TRAVELERS IN THE FIELD NOT BEING COMPLETED IN A TIMELY FASHION SO OC CAN DO THE FINAL WALKDOWN t 6 0 - 0 ACTION TAKEN e RESTRAIN RELEASE OF NEW WORK TO THE FIELD e CONCENTRATE ON COMPLETING IN-PROCESS WORK e CONCENTRATE ON REMEDIAL WORK 9 e 11
e EM SMALL BORE PIPE liANGERS PROBLEf1 0% 25% 50% 75% 100% 9 IN-PROCESS INSPECTION LAGGING CONSTRUCTION (IN-PROCESS WELD INSPECTION IS KEEPING PACE WITH CONSTRUCTION) 0 4 TRAVELERS IN THE FIELD NOT BEING COMPLETED IN A TIMELY FASHION s ACTI0il TAKEN ~ > O RESTRAIN RELEASE 0'F NEW WORK TO THE FIELD O CONCENTRATE ON COMPLETING IN-PROCESS WORK O e I e 12
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i EN $[III}} INSTRUf1ENTATION c PROBLEf1 0% 25% 50% 75% 100% s e IN-PROCESS INSPECTION LAGGING CONSTRUCTION 'O ELECTRICAL INSTRUMENTATION ItiSTALLATION - TRAVELER REQUIREMENTS NOT UNDERSTOOD OR BEING FOLLOWED ACTION TAKEN 9 ISSUED STOP WORK ORDER #018 ON ELECTRICAL INSTRUMENTATION INSTALLATION G RESTRAIN ISSUANCE OF ANY NEW PIPING TRAVELERS f G CONCENTRATE ON COMPL'ETING IN-PROCESS WORK e CONCENTRATE.ON REMEDIAL WORK ^ 13
H,V A.C. 'o%wer. - 4 :9 l l-l l l l l.l-lqllllllllll[l i PROBLEfl. o 3 g 73 g i 4 DOCUMENTATION DOES NOT REFLECT lilSTALLED HARDWARE CONFIGURATION .p. ( ACTIO?! TAKEN O ISSUED STOP WORK ORDERS FOR ALL SAFETY RELATED (SWO #0111) AND NON-SAFETY SEISMIC (1ST ATTACHMENT WELDS) INSTALLATION (SWO #015) 4 DEVELOPING A PLAN OF ACTION FOR LIFTING.THE STOP' WORK IN CONJUNCTION WITH THE SUBCONTRACTOR (ZACK) 9 I l l i l 14 l -- - -- J
c ELECTRICAL HANGERS C
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PROBLEll 6% 25% 50% 75% 100% \\ i,a O IN-PROCESS INSPECTION LAGGING CONSTRUCTION O TRAVELER CONTROL IN-EFFECTIVE r a ACTI0tl TAKEN C. 3 O ISSUED CAR-100 TO CORRECT TRAVELER CONTROL SYSTEM O ESTABLISHED CONTROL OF TRAVELERS.IN THE FIELD 4 IMPOUNDED PROBLEM TRAVELERS t 3 G CONCENTRATE ON' COMPLETING IN-PROCESSWORk i S RESTRAIN ISSUANCE OF ANY NEW WORK TO THE. FIELD 15 s
J ELECTRICAL-CONDUfT NUTHUTHillHHillHHUTHHITlTTlHHlli PROBLEri d% 25% 50% .75% 100% 4 IN-PROCESS INSPECTION LAGGING CONSTRUCTION ON CONDUIT (EXCEPf CONTAINMENT) ACTION TAKEN ,e 9 STOP WORK ORDER #016 ISSUED ON CONDUlT EXCEPT FOR CONTAINMENT 4 CONCENTRATE ON COMPLETING IN-PROCESS WORK 4 CONCENTRATE ON REMEDIAL WORK, 16 O
EQUIPMENT (MECH - ELECT) it. - 6,- l l l l l l l l l l,g.l,l.l l,l llllllll. PROBLEf1 s c 4 NO TRAVELER LOG BEING MAINTAINED BY ENGINEERING (ELECTRICAL) O PROCEDURE NOT BEING FOLLOWED -(ELECTRICAL) e t ACTI0il TAKEN I 9 STOP WORK ORDER #017 ISSUED ON ELECTRICAL EQUIPMENT 4 ESTABLISHED A LOG FOR CONTROL OF TRAVELERS S VERIFICATION THAT ALL EQUIPMENT INSTALLED HAS A TRAVELER IS PRESENTLY IN-PROGRESS 9 17 5
't s ~ C s STRUCTURAL STEEL -[ l l l:ld [l l-l l l-l l l-l:l:l lllllllllllllllll i i PROBLEf1 0% 25% 50% 75% 100% G INSPhCTION LAGGING CONSTRUCTION e INSPECTION RECORDS MISPLACED OR LOST ON ELEV. 737 4 ENGINEERING MODIFICATIONS ISSUED .r ACTI0tl TAKEN 4 ISSUED STOP WORK ORDER #019 t
- 4. DEVELOPED A RE-INSPECTION SEQUENCE.AND FORTHCOMING MODIFICATiuN SCHEDULE
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4 i 4 7 1 e l TR AINING : 4 INCREASED TRAINING IS NECESSARY FOR PROJECT PERSONNEL. l 9 INCREASED TRAINING IS NECESSARY AT THE CRAFT AND FOREMAN LEVEL. e' b I i f 20 ) e
\\ t CORRECTIVE ACTION : .4 PROJECT EFFORTS NEED TO BE MORE TIMELY IN ADDRESSINd' FINDINGS OF AUDITS, SURVEILLANCES, AND CORRECTIVE ACTION REQUESTS. i e RESPONSIVENESS TO NRC NONCOMPLIANCES, UNRESOLVED ITEMS, AND OPEN ITEMS NEEDS IMPROVEMENT. ) e. . i 4 21 ^
] NONCONFORMANCES: l l THE NUMBER OF NCR'S WHICH HAVE NOT BEEN CLOSED IS, CONSIDERED EXCESSIVE. THE NUMBER OF OPEN DR'S IS INCREASING. .r NCR/DR PROCEDURES ARE BEING REFINED IN a ORDER TO ENHANCE THEIR EFFECTIVENESS. + t e e O 6 22 9
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,s i s VERIFIC ATION TEAM REPORT: j SPECIFIC HARDWARE PROBLEMS AND PROCEDURAL ~ . CONCERNS WERE IDENTIFIED AND ARE BEING . ADDRESSED. r RECOMMENDATIONS OF THE-VERIFICATION TEAM WILL BE ADDRESSED FOR PROGRAM IMPROVEMENTS. .-,-v e = I 9 C g f s M.ge,, .a N t
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3 l h i PROJECT APPRO ACH: i O REALIGNMENT OF PROJECT PPIORITIES AND PERSONNEL ASSETS TO ADDRESS IDENTIFIED , PROBLEMS. t r 9 0. e i 1 1 4 l 25 i
- 0 l g t ASSIGNMENT OF IP SUPERVISORY PERSONNEL TO MANAGE THE RECOVERY PLAN. THEIR RESPONSIBILITIES *lNCLUDE: 4 A. DEVELOPMENT OF RECOVERY PLAN (S).- 3. OBTAINING MANAGEMENT APPROVAL OF RECOVERY PLAN (S) FROM BA &'IP PROJECT M'N4GEMENT (CONCURRENCE OF A BA/IP-QA REQUIRED). C. COORDINATING COMMITMENTS OF RECOVERY RLAN(S). D. MONITORING PERFORMANCE AND STATUS OF RECOVERY PLAN (S). O e 9 ] ' 26 e Q-
I \\ VERIFICATION THAT ACCEPTED WORK IS IN ACCORDANCE WITH DRAWINGS, SPECIFICATIONS, AND DOCUMENTATION REPRESENTING I THE AS BUILT CONFIG'JRATION. A. PERFORM BA QA AUDIT ACTIVITIES. B. PERFORM IP QA SURVEILLANCE ACTIVITIES. 4 C. REINSPECTION OF SPECIFIC AREAS IN ACCORDANCE WITH RECOVERY PLANS. f i I 1 l' 9 [ ' 27 I -
t p C I g e VERIFICATION THAT IN-PROCESS WORK IS IN ACCORDANCE WITH DRAWINGS AND SPECIFICATIONS. A. INCREASED SCOPE AND FREQUENCY OF BA QA. AUDIT ACTIVITIES. B. INCREASED SCOPE AND FREQUENCY OF IP QA SURVEILLANCE ACTIVITIES. C. INCREASED BA QC/TS CONTROLS. i e e a l ' 28 k
7 e ) VERIFICATIONTHATNEWWORKISINACCORDANCEWkTH DRAWINGS AND SPECIFICATIONS. A. INCREASED SCOPE AND FREQUENCY OF BA QA AUDIT ACTIVITIES. B. INCRE'ASED SCOPE AND FREQUENCY OF IP QA SURVEILLANCE l ACTIVITIES. C. INCREASED BA QC/TS CONTROLS. i D. ADDITIONAL REVIEW BY BA QA/QC,0F TRAVELERS ASSOCIATED WITH STRUCTURES, SYSTEMS, AND COMPONENTS. 4 1 4 i e 29 4 0
1 o s REALLOCATION OF PROJECT PERSONNEL RESOURCES TO RESOLVE AND DISPOSITION PROBLEMS. A. REASSIGNMENT OF OPERATIONS, ENGINEERING AND CONSTRUCTION PERSONNEL TO ACTIVELY PURSUE IDENTIFIED PROBLEMS. B. ' ADDITIONAL STAFFING O'F QUALITY PERSONNEL TO INDEPENDENTLY REVIEW STATUS OF RECOVERY PLANS, EVALUATE CORRECTIVE ACTION, AND VERIFY COMPLETED ACTIONS.' C. RESTRAIN CONSTRUCTION CRAFT EFFORTS ON NEW WORK IN DESIGNATED DISCIPLINES; EMPHASIZE UTILIZATION OF CRAFT IN COMPLETING WORK FOR ACCEPTANCE. e 4 8 7. e e b 30 A ~
MANAGEMENT CONTROLS EXECUTIVE VICE PRESIDE'T N BA MANAGER
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PR0 JECT MANAGER - ~~- 1P DIRECTOR ) QUALITY a TECHNICAL QUALITY ASSURANCE d SERVICE i i i i..................................................'.........REE DY.EU...EJ. A n.. f.l..t..E9D M.Y)..................,.............. ! Ul F'ECTOR I 1 IlF. SCHWARZ) MECHANICAL ELECTRICAL CIVIL / STRUCTURAL COORDINATOR (D. KORNEMAN) COORDINATOR (W. CALHOUN) COORDINATOR -SMALL/LARGE BORE PIPING -ELECTRICAL EQUIPMENT STRUCTURAL STEEL (STOP WORK 17) (STOP WORK 19) -PIPING HANGERS & SUPPORTS -ELECTRICAL INSTRUMENTS -MECHANICAL EQUIPMENT (STOP WORK 18) -HVAC (STOP WORK 114 a 15) -CONDUIT (STOP WORK 16) -MECH. INSTRUMENTATION -HANGERS l l(G.STINNETT) 4 l TRAINING NONCONFORMANCES CORRECTIVE ACTION VERIF1 CATION lEAM i COORDINATOR (E. CONNON) COORDINATOR (G. MOTSEGOOD) COORDINATOR (E. CONNON) REPORT COORDINATOR r l -0UALITY -NCR -CAR -HARDWARE CONCERNS -- PROJ ECT -DR -AUDIT / SURVEILLANCE -PROCEDURE CONCERNS \\ MANAGEMENT FINDINGS -ENG INEERING -PROCEDURES -NONCOMPLIANCES -RECOMMENDATIONS -CONSTRUCTION ~ A
~ -c O N CO 8 O Z O H D-CD I- .CO O U.i O CC D O g T g. O e e c i e O .s a e 4 o d 4
BA-MANUtd. DISTRIBUTION CRAFT FORCE AS OF FORCE AS OF DELTA SUPPORT SAFETY (OLD) SAFETY (NEW) NON-SAFET'Y TOTAL 6/23/82 7/6/82-LABORE8S' 262 237 25 165 73 238 CARPENTERS 121 108 13 75 5 '27 107 ) OPERATORS 58 55 3 56 56 TEAMSTERS 50 47 4 46 ' 46 IRON WORKERS 66 56 10 10 5 41 56 ELECTRICANS 650 497 153 91 207 72 127 497-PIP 5 FITTERS 620' 444 176 '9'S 227 '122 '444 BOILERMAKERS 65 52 13 12 23 2 15 52 CEMENT MASON '8 6 2 1 5 6 . TILERS MILLWRIGHTS 11 2 35 7 7 8 20 35 SHEETMETAL 7. 6 1 1 5 6 BRICKLAYERS' '5 5 0 5 5 SURVEYORS 15 13 2 13 13 TOTALS 1969 1561 408 572-470 84 435. 1561-33
ZACK CRAFT 6/23/82,0F FORCE AS FORCE AS OF 6/29/82 SUPERINTENDENTS /GF 12 DRAFTING / DETAILING 33 FAB SHOP 10 LAYDOWN CREW --- 10 N/S, NON SEISMIC HANGERS 55 s N/S, DUCTWORK 50 N/S,'SslSMIC HANGERS 38 CONSTRUCTION INSPECTORS 10 TOOL CRIB /MAINT. 4 WELD SHOP 2 INJURED 2 ' 34 TOTAL 246 226 ~ n
I BA MANAGER OF. QUALITY, TECH. SERVICES ZACK-QA/QC . AND TRAINING SITE unummununumm-QUALITY QUALITY-TECHNICAL 9 TRAINING M CONTROL SER\\/ ICES ,0 ASSURANCE h .l 35 C l ) 0 g ' t 1 l s l
7 Q&TS MANPOWER PROJECTION 325 - 3OO- ? y 275-s 4 250 - / / r 225-p' 200 - ) l e I' h 17'5-e 3, \\ c a JAN l FEB I I I I I I I I I I MAR APR MAY JUN JUL AUG SEP OCT NOV DEC s CURRENT ........................ R E VI S E D g
u .e IP/QA ORGANIZATION I i PRESIDENT ..........e i i i i EXECUTIVE i VICE i PRESIDENT i i 1 i DIRECTOR ASSURANCE ~ l I I I I I' SUPERVISOR SUPERVISOR SUPERVISOR SUPERVISOR ADMINISTRATIVE 6M ,Adt QUALITY OUALITY PROGRAMS & AUDITS & SUPERVISOR ENGINEERING CONTROL PROCEDURES SURVEILLANCE SECTION SECTION SECTION SECTION SECTION l 37 0
' ILLINOIS POWER QUALITY ASSURANCE FORECAST 120 - 118 110 - IP AND
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100-CONSULTANTS 90 - d z 80-y 70 m 70 - 71 l 60 - f 50-o- IP 6 40-l 43 30-26 5 t 20- .21 10 - e [ 38 1 Jan 82 1 Apr 82 1 July 82 1 Sept 82
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- ,j RESOURCES
i s e 4 DUE TO THE COMPLEX NATURE OF THE PROBLEMS WE IDENTIFIED THE FOLLOWING DECISIONS WERE MADE:
- RESTRAIN NEW WORK UNTIL h5 HAVE COMPLETED DEVELOPMENT OF OUR RECOVERY PLANS.
e AS THE RECOVERY PLANS ARE DEVELOPED WE WILL ALLOCATE MANPOWER TO SUPPORT EACH PLAN. PR'EL.IMI' NARY FORECASTS OF THE REQUIRED MANPOWER RESOURCES HAVE BEEN PREPARED. O CONTINUE TO ADVERTIZE, INTERVIEW AND HIRE EXPERIENCED I QUALITY PERSONNEL.. 6 SUPPLEMENT EXISTING STAFF WITH CONSULTANTS AS REQUIRED j TO SUPPORT THE RECOVERY PLAN. 9 e 4 C 39 5
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SUMMARY
O EVEN THOUGH INSPECTION IS LAGGING CONSTRUCTION WE HAVE DEMONSTRATED THAT WE HAVE CONTROL AND A METHOD OF STATUSING THE INSPECTION EFFORT. O W'E HAVE CHANGED THE PROJECT PHILOSOPHY TO FORCE TIMELY COMPLETION AND INSPECTION OF IN-PROCESS AND NEW WORK. e ASSIGNMENT OF DEDICATED MANAGEMENT STAFF TO AGGRESSIVELY PURSUE RESOLUTION OF QUALITY ISSUES. j t t ) g t i 40 I e
LEGEND: PREPARE Y REYlEW 0-NRC CONCURRANCE O e SCHEDULE: IP APPROVAL O s S STOP WORKS e STRUCTURAL STEEL v 0 0 e ZACK RECOVERY PLAN y 0 0 e ELECTRICAL EQUIP. INST'L. Y O G e CONDUIT INSTALLATION y 0 O e ELECTRICAL INSTRUMENTATION y 0 0 C 4 QUALITY ISSUES ( e VERIFICATION TEAM Y O O e NON CONFORMANCES Y D D e CORRECTIVE ACTION Y D G e TRAINING V D O g
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