ML20066B606
| ML20066B606 | |
| Person / Time | |
|---|---|
| Site: | Clinton, 05000000 |
| Issue date: | 08/09/1982 |
| From: | ILLINOIS POWER CO. |
| To: | |
| Shared Package | |
| ML20064L507 | List: |
| References | |
| FOIA-82-366 NUDOCS 8211090038 | |
| Download: ML20066B606 (47) | |
Text
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IP. QUAOTY PROGRAM-UPDATE i
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.8-9-82
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l PURPOSE:
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e Demonstrate that in-process work has been restricted
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and is under control.
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e Review the QC* backlog of in-process work and progress i
being made toward reducing the backlog.
l e Review progress of Stop Work. Orders and of the Recovery 1
t Team's P'lah for addressing identified quality concerns.
l e
2 l
x s
i TRAVELER CONTROL Estabilshed a central. Traveler Control-Group I
t
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e Placed under Quality Control jurisdiction l
e Established a computer tracking system for Traveler Control
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e Restrained in process work e
Forcing timely inspection of in-process work i
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IN-PROCESS TRAVELERS Allocation LB Pipe 50 LB Pipe Hangers 100
" SB Pipe 100 SB Pipe Hangers 100 Instrumentation 75 Elec. Hangers
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Senior PREPARE ORWARD REVIEW Discipline TRAVELER TRA EE up TRAVELER
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ERro Supenntendent REauEST TRAVEtE mAmER Quality Assurance u"8Ef&#c of u"!R To DRC AUDIT 6
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t l-BACKLOG -
SUMMARY
1 7-2-82 8-6-82 AVERAGE 9
FUNCTION' INSPECTED BACKLOG BACKLOG PER WEEK 1
LARGE' BORE PIPE 781 420 361 90
(
LARGE BORE PIPE HANGERS 1574 1402 -
172
'43 i
SMALL BORE PIPE 802
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I BACKLOG
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50%
75%
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G IN-PROCESS INSPECTION LAGGING CONSTRUCTION 1
O ELECTRICAL INSTRUMENTATION INSTALLATION -
TRAVELER REQUIREMENTS NOT.UNDERST0OD OR a
BEING FOLLOWED TRAVELER STATUS I
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23
/s 39 74 f3 v3 2rn 9 ISSUED STOP WORK ORDER #018 ON ELECTRICAL INSTRUMENTATION INSTALLATION
.4 RESTRAIN ISSUANCE OF ANY NEW PIPING TRAVELERS N ASSIG D - #
~d e CONCENTRATE ON COMPLETING IN-PROCESS WORK O CONCENTRATE ON REMEDIAL WORK 1
13
c BA-MAtlUAL DISTRIBUTION FORCE FORCE REDUC-SOPPORT S5FETY SAFETY r10N-TOTAL CRAFT AS OF AS OF TION (OLD)
(NEW)
. SAFETY 6/23/82 7/29/82 LABORERS 262 246
-16 173 73 246 l
CARPENTERS 121 107
-14 70' 2
27 107 OPERATORS 53 57
-1 57 57
(
TEAMSTERS' 50 11 6
-4 11 6 Il6 IRON WORKERS 66 55
-11 10 5
40 55 ELECTRICIANS 650 Il51
-199 91 137 52 171 451 PIPEFITTERS 620 till2
-178 86 2115 111 442 BOILERMAKERS 65 52
-13 12 31 2
7 52 CEMENT MASON 8
6
- 2' 1
5 6
TILERS MILLWRIGHTS 42 35
-7 7
15 13 35 SilEETMETAL 7
6
-1 1
4 1
6 BRICKLAYERS 5
4 1
0 4
4 SURVEYORS 15 13
-2 13 13 TOTALS 19f9 1520
-449 575 432 61 Il52 1520 14
(
~
l' ZACK-MANPOWER t
kbhR k?
I
' CRAFT 12 8
SUPERINTENDENTS /GF 95 DRAFTING /DETAll ING 33 FAB SHOP 10 7
LAYDOWN CREW -
10 7
N/S, NON SEISMIC HANGERS 55 0
N/S. DUCTWORK 50 40 N/S, SEISMIC HANGERS 38 24 CONSTRUCTION INSPEsTORS 10 7
TOOL CRIB /MAINT.
4 3
WELD SHOP 2
I' I
INJURED-2
.0 226 122 15 TOTAL
e Q&TS MANPOWER PROJECTION 325-300-e n.n.n n u n nin n a na"""""""'""""""
i
?
?
'275-
/
,c
~~
250-
/
l b
/
5
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(
175-
~
l MAYlJUN JUL AUG SEP
~
LEGEND JAN FEB MAR APR
.... -i-i-i-i '" FEB. FORECAST
....n......u n n u n n u REVISED FORECAST 16 ACTUAL a
(
BA-0VALITY RESOURCES GROUP ON-BOARD 0FFERS OFFERS A'CCEPTED PEllDING OllALITY ASSURAllCE
'. VENDOR SURVEILLANCE 14 1
PROCURENENT
'5 SYSTEMS 4
2.
2 AUDITS 13 3
2
. DOCUMENT RECORDS 20
. STAFF 5
TOTAL 61 5.-
5 OllALITY C0flTROL DOCUMENTATION
'7 itATERIAL CONTROL 22 1
P! PING / MECHANICAL 35 8
ELECTRICAL - C/S 38 4
STAFF 6
TOTAL 108 0
13 D
TECHNICAL SERVICES NDE & MEAT TREAT.
3 WELDING 69 1
STAFF 3
TOTAL 75 1
0 TRAINING X9 0
'0 ADiilNISTRATION 5
'O O
g TOTAL 256 6
18
-STOP WORK ORDER -
SUMMARY
SWO #
FUNCTION STATUS
SUMMARY
(
ELECTRICAL CABLE TRAY READY TO RESUME WORK ON A LIMITED BASIS -
2 007 AND ATTACHMENTS WEEK OF 8-23-82 010 REFUELING BELLOWS AT S a L FOR ENGINEERING DISPOSITION Olli ZACK - SAFETY P. ELATED WORK HELD FOR QAM, PROCEDURE P.EVISIONS 015 ZACK - IST ATTACHMENT WELDS HELD FOR PROCEDURAL APPROVAL l
016 ELECTRICAL CONDUIT INSTALLATION P.ECOVERY PLAN BEING DEVELOPED ELECTRICAL EQUIPMENT RECOVERY PLAN BEING DEVELOPED 017 INSTALLATION ELECTRICAL INSTRUMENT P.ECOVERY PLAN BEING DEVELOPED 018 INSTALLATION 019 SfRUCTURALSTEEL RECOVERY PLAN COMPLETE-READY FOR NRC REVIEW 020 ZACK - Non-SAFETY WORK HELD FOR PROCEDURAL CHANGES AND APPROVAL E
SPARE /
RECOVERY PLAN BEING DEVELOPED p
p 18
PROBLEM:
s C INSTALU. TION, CONTROLS FOR CABLE TRAY, AND CABLE TRAY ATTACFfENTS WERE INADEQUATE 2
AFFECTED WORK:
[
O
- ALL SAF$1Y-RELATEDj SEISMIC CATEGORY i-E CABLE TRAY AND CABLE TRAY ATTACHfENTS g
a
'
- CABLE PULLING
- CABLE TERMINATIONS N
4 WORK 'NOT AFFECTED:
5 i
- NON-SAFETY CABLE TRAY AND ATTACHfENTS r
)
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ELECTRICAL STbPWORK - 007 PROGRESS V
SCHEoutEn V
i Y
ACTUAL Y
JULY AUGUST SEPT TRAY ATTACHMENT HANGERS I
10 20 i
10 20 1
10 20 l
l i
t 1
I NRC 2
HOLD NRC HOLD 7
t 2
4 5
6 NOTE: 30 TRAVELERS QC ACCEPTED Q ' Q G
G FIRST,147 TRAVELERS
- 1. REWORK TRAVELER
- 2. INITIAL REVIEW
- 3. FIELD WORK
- 4. QC INSPECTION
- 5. FINAL REVIEW
- 6. COMPLETE I
b I
2 3
4 5
6 9 9 9
9 SECOND,150 TRAVELERS 9
9 9
0 e
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4 ELECTRICAL STOPWORK - 007 PROGRESS 9
SCIIEDULED 9
v ACruAt Y
N JULY AUGUST SEPT I
10 20 1
10 20 1
10 20 t
t i
I l
TENTATIVE WORK NRC SCHEDULE A
6 STOPWORx l
connENCE TRAY ATTACHMENTS WORK NRC APPROVAL
.y g PARTIAL LIFT 2n d.
CROUP y Q LIFTEC NRC APPROVAL.h PREPARE.Y hTRAVELERS dNITIAL STOPWORK TRAY HANGERS WORK h ST0i' WORK PREPARE NITIAL CABLE TRAY WORK NRC APPROVAL hTRAVELERS EVIEW NRC APPROVALy QIFTED A
b CONDUIT FIRST STOPWORK NRC APPROVAL Y 9 0NLY-9 TRAY ROUTE y 9 LIFTED CABLE PULL CABLE TERMINATIONS NRC APPROVAL STOPWORK LIFTED IP MGMT.
CORRECTIVE ACTION PENnINc IPQA EVALUATION U
ELECTRICAL MCAR - 003-READYTOCLOSEp QTRAININC 1
2 3
4 5
+
STOPWORKS LIFTED
- 1. PARTIAL ATTACllHENT
-Q Q
Q' Q
g'
- 2. PARTIAL CABLE IN' CONDUIT
- 3. SWA LIFTED TERMINATIONS
- 4. PARTIAL CABLE IN FIRST TRAY ROUTE
- 5. STOPWORK-007 LIFTED 21
SWO +010 - REFUELING BELLOWS PROBLEMi
~* WELD ROD AND INSPECTORS QUALIFICATIONS QUESTIONABLE t
'AFFECTED WORK:
- DRYWELL REFUELING BELLOWS WORK 'NOT AFFECTED:
- NOT APPLICABLE
)
6 e
'2 2
~
e.
SWO +014 - ZACK H. V. A. C.
PROBLEM:
i t
- WORKING WITH0lfT. APPROVED PROCEDURES
.\\
- DOCUENTATION DOES NOT REFLECT INSTALLED HARDWARE CONFIGUPATION
'1 e
AFFECTED WORK:
'l
- ALL SAFETY PELA1ED WORK ASSOCIATION WITH HANGERS, DUCT AND EQUIPENT WORK 'NOT AFFECTED:
- NON-SAFETY DUCT, HANGERS AND EQUIPENT N
e e
O e
4 9
23 1
s,.
PHOBLEM:
C NO PROCEDURAL COVERAGE
.c-AFFECTED WORK:
l
/
e WORK 'NOT AFFECTED:
- NON-SAFETY DUCT, N/S NON-SEISMIC HANGERS AND EQUIPK NT
- BA SHEET ETAL WORK 24 s
e
'[
f a
/
[-
SWO #016 - CO'NDUIT INSTALLATION PROBLEM:
{
- IN-PROCESS INSPECTION LAGGING CONSTRUCTION
- WORK BEING ACCOWLISHED PRIOR TO ISSUANCE OF A TRAVELER AFFECTED WORK:
- ALL CONDUIT INSTALLATION WORK 'NOT AFFECTED:
- NON-SAFETY CONDUIT INSTALLATIONS
- CONDUIT HANGERS
- NON-SCHEDULED CONDUIT FOR LIGHTING AND C0muNICATION e
e 9
h.
25 m
- 4 0,
' P 1
- ,,P,,
g
. L ',
a
., f,'
SWO +017 - ELECTRICAL EQUIPMENT PROBLEM:
(
- TRAVELER REQUIREENTS NOT UNDERST0OD
- PROCEDURES NOT BElf#1 FOLLQED i
AFFECTED WORK:
- ALL CLASS I-E, AUG-D AND FINE PROTEdTION e
WORK 'NOT. AFFECTED:
- NON-SAFETY WORK I.
l
'26 w
^
SWO +018 - ELECTRICAL INSTRUMENTATION r
PROBLEM:
- TRAVELER REQUIREENTS NOT LNDERSTOOD
'
- PROCEDURES NOT BEING FOLL&ED I
AFFECTED WORK:
- ALL CLASS I-E, AUG-D, FIRE PROTECTION ELECTRICAL INSTRtfENTKf!ON INSTALLATIONS
~
WORK 'NOT AFFECTED:
- NON-SAFETY WORK J
e e
d 1
t 17
SWO +019 - STRUCTURAL STEEL PROBLEM:
- INSPECTION LAGGING CONSTRUCTION 9
- INSPECTION RECORDS MISPLACED OR LOST ON ELEVATIONS 737-CONTAINKNT o
AFFECTED WORK:
- ALL SAFETY RELATED (SEISMIC) WORK IN THE CONTAlbfENT INCLUDING FABRICATION IN THE POWER BLOC MONORAILS, COVER PLATING, STEEL BEAMS AND MODIFICATIONS O
i WORK 'NOT AFFECTED:
t'
- NON-SAFETY GALLERY STEEL, HANDRAILS
- GAS BOUNDARY STEEL (5XTERNAL TO CONTAlt#ENT)
- TENORARY ATTACHENTS s
- PIPING AND ELECTRICAL HANGER INSTALLATION
- FABRICATION WORK' IN FAB. SH0' PS (EX' ERNAL.T0 POWEP BLOCK)
T
'2 8
t.
1 l
1 i
SWO #020 - ZACK H. V.' A. C.
PROBLEM:
l
- LACK 0F CONTROL ON NON-SAFETY WORK O
(
AFFECTED WORK:
- ALL NON-SAFETY WORK IN ALL STRUCWPES CLASSIFIED AS SEISMIC CATEGORY I WORK 'NOT AFFECTED:
- ALL NON-SAFETY WORK IN NON-SEISMIC STRUCTURES
'e e
e e
5 9
29 N
~
l JP PROCUREMENT STOP WORK 1,
PROBLEM:
?
- ADEQUATE PROCEDURES FOR CLASSIFYING, REQUISITIONING, PURCIMSIfG AND RECEIVING a
l C0f00DITIES AND SERVICES ARE NOT WRITTEN AND IMPLEMENTED.
- PERSONNEL TRAINING IN MEETING Tile PROCUREMENT REQUIREMENTS FOR MISI N45.2.13 AND NGI N18.7 IS LACKING.
1 AFFECTED WORK:
- SPARE AND REPl.ACEENT PARTS PURbHASED BY ILLIN0IS POWER COMPANY, PURCHASING DEPARDENT OR CLINTON SITE PURCHASING.
. WORK 'NOT AFFECTED:
- PROCUREMENT OF C0fNODITIES AND SERVICES BY BALD 11N ASSOCIATES.
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Recovery _
[ Plan Organization DATED. 7/H/82 Recovery Plan Director PE HENRY SWIFT-2305 LARRY BR00$KY-78-202 4
I Cl 1/88 tural Electrical Coordinator Training Coordinator C or n o 9,d tnat9, DANA KORNEMAN-2514 BILL CALHOUN-2519 FRANK SCHWARZ-2515 ED CONHON-2532 I
I I
I PE.-MANOUCHY CAEENI-23tg RE.-JACK HAT RIS
- 2721 PE,-PAT.McH000-2403 P4-BILL PAWLECMI-2303 RE.-BRIAN CREED 2721 p.pfM. JIM MACKEY-2821 ASST. P.M.-NEAL DILLON-2192 QA.-LARRY GEL 8ERT-2355 Q.A.-FRED BURNETT-2757 8AC/S-STEVE [CLARY-2470
' 4A-808 8ALOWIN-2880 8AOC-JIM CONNELLY-2458 IS.-MIME DANCLL QA-LINN LONGETEG-2103 ipog.GLENN BELL-2771 BAQC-DENNIS THREAT-2245 l
lPOA-ROBIN DILLMAN-2164 ipgg.gggy gggg.2379 HVAC-QA.-MAR $HA $UhNER-220 8AE-DALE MURPHY-2522 4A.-JM MOFFAT-2757 Nonconformance Corrective Action Verification Team Coordinator Coordinator Report Coordinator GEORGE MOT 5EG000-2650 ED CONtJON-2532 GENE STINNETT-2593 I
I I
PE.-RON FUNK-2402 P.E. LARRY WHITTET-2348 PE.* DICK SCHMIOT-2403-(
l Q.A. WARREN $080LEW5NI-229I QA.-GUNARS 80Rvis-230F Q.A.-DEREK SELVA-2214 Q A.-8ILL ATKINS 2228 QA-JAMES BRAUN 2104 Q A.5 R00 HICKS-2219
- PQA=.*llCN SEYFERTH = 2783 PQA*808 DERBORT-2779 31 b
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E 8/5/82 RECOVERY PLAN - STRUCTURAL STEEL-l
(
OBJECT 3VE I.
RESOLVE IDENTIFIED QUALITY PROBLEMS WITH STRUCTURAL STEEL IN. ORDER TO OBTAIN APPROVAL FOR LIFTING STOP WORK ORDER #19 AFFECTING THE CONTAINMENT BUILDING.
OBJECTIVE II. DESCRIBE HOW.NEW / IN-PROCESS / MODIFICATION WORK MEETS. REQUIREMENTS.
OBJECTIVE III.
DEMONSTRATE THAT PREVIOUSLY ASSEMBLED STRUCTURAL STEEL MEETS REQUIREMENTS.
OBJECTIVE IV.
OUTLINE RESOURCES TO SUPPORT RECOVERY EFFORT..
32
l 8/5/82 i
STRUCTURAL STEEL i
~
PROPOSED TRAINING REQUIREMENTS
?
r TOPIC CLASS ATTENDANCE s
Rev.6 BAP 3.1.3 Engineers, Sup'r., QC, TS
[
Structural Steel Acceptance Crlieria Eng., Sup'r, QC, TS, and i
7 Craf tsmen ( IW, BM, PF)
C243 No Vetbal Changes QC (Civil)
Intradepartmental QC Jam - nuts-Training
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INDEPENDENT OVERINSPECTION -
OVEfWIEW OVERINSPECTION TO BE.PERFORE D BY QUALIFIED UNITED STATES TESTING COMPANY INSPECTORS WITH PROCEDUR$S/ INSTRUCTIONS APPROVED BY IP SAMPLE SIZE WILL NOT BE STATISTICALJ, RATHER IT WILL BE A GENEROUS AND REPRESENTATIVE SAMPLE OF ALL WORK THAT HAS BEEN ACCEPTED OVERINSPECTIONS EAT ARE CONDUCTED WILL BE DoctfENTED ON APPROVED CHECKLISTS OVERINSPECTION WILL VERIFY THAT ACCEPTED WORK I,S IN ACCORDANCE
~
WITH DRAWINGS, SPECIFICATIONS, AND DOClFENTATION REPRESENTING
, E E AS-BUILT CONFIGURATION
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$o SCOPE AND SIZE OF OVERINSPELTION SAPI_ES PRIORITY I WORK STRUCTURAL STEEL
- ALL ACCESSIBLE STRUCTURA' STEEL AT 825 FT LEVEL CONTROL BUILDING
- ONE ELEVATIOA 0F FUEL AND AUXILIARY BUILDING
- ONE ELEVATION AND QUADRANT OF*
CONTAINENT
~,
uRE AND SMU_ BORE
- 20% OF ACCEPTED TRAVELERS B,Y SYSTEM PIPING WE BORE - APPROX. 9) TRAMRS SmLLBORE-APPROX.450 TRAVELERS E M N BOE
- 20% OF ACCEPTED TRAVELERS BY SYSTEM SUPPORTS LARGE BORE - APPROX. 200 TRAVELERS SMALL BORE - APPROX. 35 TRAVELERS MECHANICAL EQUIPMENT
- 20% OF ACCEPTED EQUIPMENT TRAVELERS (APPROX.35 TRAVELERS)
ELECTRICAL HANGERS
- 20% OF ACCEPTED HANGERS (APPROX. 3950 TRAVELERS)
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9 PAGE2 PRIORT1Y II WORK
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ELECTRICAL CABLE ROUTING (TOBEDETERMINED)
INSTRlNENTATION (TOBEDETERMINED)
ELECTRICAL CONDUIT (TO BE DETERMINED) i e
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SCEDULE AND MANPOWER MIESTONES WEEK OF AUGUST 9 BEGIN TRAINING INSPECTORS WEEKOFAUGUST16
.BEGIN OVERINSPECTION SEPTEMBER DEVELOP PLANS FOR PHASE II OVERINSPECTION OCTOBER 1/50FPHASEIOVERINSPECTIONCOMPLETE JANUARY 196 '
3/5 0F PHASE I OVERINSPECTION COMPLETE MARCH 19 8 PHASE I OVERINSPECTION COMPLETE BASED ON PROJECTED PROGRAM f%NPOWER AUGUST 9 9 UST INSPECTORS NOVEMBER 1 18-20 UST INSPECTORS e
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OVERINSECTION ESULTS
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s IP WILL DOCtMNT, EVALUATE AND TREND PROBLEMS USING NCR/DP/CR EVALUATIONS OF THE OVERINSPECTION RESULTS WILL BE ONGOING.
PERIODIC REPORTS WILL BE ISSUED THAT ADDRESS SPECIFIC PROBLEM AREAS ANDOUR PLAN FOR RESOLVING THE. ISSUES
~
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SAffLING OF SPECIFIC INSPECTION ACTIVITIES t%Y BE INCREASED /
DECREASED BASED UPS OUR EVALUATION OF TE RESULTS 9
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STRUCTURAL STEEL
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RECOVERY PLAN V
ESTIMATE'V Y
COMPLETE Y n
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% NRC APPROVAL JULY, AUG, SEPT, OCT, NOV, DEC IDENTIFY QUALITY PROBLEMS l
l PR0e0sE CORRECTIVE ACTI0rts, DEVELOP PLAN i
DEVELOP A PROGRAM FOR OVERINSPECTION s
OBTAIN INTERNAL APPROVAL'0F PLAN 1
OBTAIN NRC C6flCURRENCE 0F PLAN l!FT STOP WORK 090ER 19 EV PERFORM REINste.; IONS V
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e PIPl'NG MECHA'NICAL RECOVERY PLAN V
ESTIMATE 7
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_Y JULY, AUG, SEPT, OCT, NOV DEC y
TABULATE QUALITY PROBLEMS IM LEMENT A PROGRAM TO REDUCE BACKLOG OF Y
NSTALLED BUT NOT INSPECTED WORK l.
DEVELOP A PROGRAM FOR NEW AND IN-PROC.ESS WORK DEVELOP A PROGRAM FOR OVERINSPECTION RESOLVE AND TRACK QUALITY PROBLEMS
)
OBTAIN INTERNAL APPROVAL OF PLAN b
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OBTAlta NRC CONCURRENCE OF PLAN m
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t INPROCESS WORK IMPROVEMENTS IMPROVE TRAVELERS IWROVED ISO EVISION PROCESS
~
IWROVED ESIGN DRAWING REVIEW / INCORPORATION ENGINEERING REVIEW INPROCESS TPAVELERS IMPROVE INSPECTION PROCEDURES PROVIE tDE SRCIFIC CRITERIA & CECKLISTS PROVIDE ADDITIONAL, S CIFIC APPLICATIONS
~ CONSTRUCTION VERIFICATION OF WORK SRCIFIC DiECKLISTS PIPING DEPT, MANAGEENT ANALYSIS / TRENDS IP CONSTRUCTION EVIEW INCREASED SCOPE & FREQUENCY OF BA QA AUDITS INCREASED SCOPE & FREQUENCY l
OF IP SURVEILLANCE I.
l 41 l
V COMPLETE Y
~
@NRC, APPROVAL JULY, AUG, SEPT, OCT, NOV, DEC IDENTIFY'0UALITY PROBLEMS
(
PROPOSE CORRECTIVE' ACTIONS, DEVELOP PLAN 2
DEVELOP A PROGRAli FOR OVERINSPECTION I
IMPLEMENT A PROGRAM FOR IN-PROCESS CONTROLS Y
OBTAIN INTERNAL APPROVAL OF PLAN E
OBTAIN NRC CONCURRENCE OF PLAN LIFT STOP WORK ORDER 16
- U LIFT STOP WORK ORDER 17
- h 3
LIFT STOP WORK ORDER 18 k
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JULY ' AUG SEPT OCT NOV DEC }JAN FEB I
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IDENTIFY 00ALITY PROBLEMS U
REVIEW CORRECTIVE ACTION PLANS AND SCHEDULES DEVELOP'OVERINSPECTION PLANS OBTAIN INTERNAL APPROVAL OF PLAN OBTAIN NRC CONCURRENCE OF PLAN MONITOR CORRECTIVE ACTION PERFORM REINSPECTIONS SEQUENTIALLY LIFT STOP WORK ORDER lli SEQUENTIALLY LIFT STOP WORK ORDER 15 U
LIFT STOP WORK ORDER 20 N7 e
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TRAINING
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EVALUATE TRAINING PROGRAMS D
PROVIDE RECOMMENDATIONS U
i, REVIEW CORRECTIVE ACTION PLANS AND SCHEDULES D
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OBTAIN INTERNAL APPROVAL OF PLAN
,D OBTAIN URC CONCURRENCE OF PLAN k
9 MONITOR CORRECTIVE ACTION e
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.VERIFICATIO'N TEAM REPORT ~
l RECOVERY PLAN U
ESTIMATE 9
l
( V COMPLETE Y
I I
I I
i DEVELOP MATRIX OF QUALITY ITEMS CATEGORIZE AND ASSIGN MATRIX ITEMS U
OBTAIN INTERNAL APPROVAL OF PLAN OBTAIN NRC CONCURRENCE OF PLAN k
I REVIEW AND ASSESS RESPONSES MONITOR AND APPROVE CORRECTIVE ACTION 9
9 MONITOR RESULTS OF OVERINSPECTION EFFORT 9
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9 PREPARE REPORT 45 e
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l' RECOVERY PLAN 3
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C0l1P'LETE Y
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SORT AND CLASSIFY NCR/DR'S g
REVISE NCR/DR PROCEDURES Y
U IMPLEMENT COMPUTER TRACKING AND REPORTING Y
9 WORKING OFF BACKLOG Y
Q IMPLEMENT A PROGRAM FOR EMPHASIZING QUALITY Y
9 PR VIDE CONTINUING RECOMMENDATIONS AND
)
.TTENTION
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0BTAIN NRC CONCURRENCE OF PLAN 46
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CORRECTIVE ACTIO'N
~
RECOVERY PLAN
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JULY ' AUG ' SEPT' OCT ' NOV ' DEC i
TABULATE'AND STATUS OPEN ITEMS, EVALUATE YY EVALUATE SEQUENCING OF CORRECTIVE ACTION ACTIVITIES.
EVALUATE TRAINING EVALUATE MANAGEMENT ROLE YY PROVIDE RECOMMENDATIONS D
k OBTAIN INTERNAL APPROVAL OF PLAN D
l' OBTAIN NRC CONCURRENCE E
MONITOR STATUS OF CORRECTIVE. ACTION ITEMS 9-9 e
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CUSTOM METAL FABRICATION June 9, 1982 U.S.N.R.C.
Regional III Office 799 Roosevelt Road Glen Ellyn, Illinois 60137 Attn:
Mr. J.G.
Keppler Re:
Possible Deffective Curtain Type Fire Dampers as furnished to Zack Company by American Warming and Ventilating Inc.
Subject:
Reportable 10 CFR Part 21 Gentlemen:
Zack Company received the attached letter dated June 2, 1982 from American Warming and VE tilating Inc. on June 8,
- 1982, in regards to a possible discrepancy in Curtain Type Fire Dampers 18" wide and narrower.
Zack Company has commenced inspections of listed fire dampers.
We will issue a formal report as to the findings / discrepancies found at completion of the investigation.
Yours very truly,
\\M nc k S _
b.
Martin L.
Skates MI.S /1 f encl.
CC:
T. Quaka - CECO QA C.Z.
DeZutel J.C.
DeZutel D.
Malzahn
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Haumgardner C.
1:1chstaedt C.A.
V.C.
Site File / Chicago / Site k'fADOCHi MOS C2G6(Nit
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- F OUNULD TO SOLVE THE UNIQUE METAL F ADRICATeON NEF DS Or INDUSTRv -
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- -::. Jo:iph Dierbech Curt.:en Type Fire Dampers an furninhed to ::ack Company by American hrming 1.
n 4.t i 1.:! i ng Comp.sny
.: 19 port able 10 CI'it Part 21
...:
- i c e. n :
- . t o confarm our telephone convernation of 12:40
- cDT, thin dat.e in regards to a possible discrepancy it.- s'.ampe r c l onu re. 7.ach Company received the a t t ached
- .. d..ted June 2, 1982 from American W rming and Venti-inc. on Junn 8, 1982.
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- .. ny wi l l < onm. nce - inspection of linted fire
- . r :. W hi : Jay June 9..1982. We will issue a f o rrnal
.u. to t h. - fi$idingn/dinerepancien found on innpection.
- truly,
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sa s sa anc ventilating inc June 2, 1982 The 7.a ch Ce..:.priny 4 600 E'e:st 121h. Place Ch ; c.::m, I I, 60650 A:tn:
Carl Eichstaedt Ref 7.ack P.O. No. 9505 Coraonwealth Edison /LaSalle Nuc1 car Station AW Job No. 90116 Subj ect :
Curt ain Type Fire Damper Discrepancies
Dear Mr. Eic hstaedt :
it 7
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There is a possibility that certain Curtain Type j
Fire Da::.pers shipped before March 24, 1981 may not close I
/
when the fusible link separates.
L.)
These fire dampers are units 18" wide and nstrower which have small fu::ible links.
A list of the applicable tag numbers i t, attached.
Attached is a set of instructions for inspection and, i f dampers are found to be per sketch "A",
instruc-tions for replacement of clover hooks.
If you find any danpers needing to have the clover chant.ed, we will be '-
happy to send you the necessary parts.
Yours truly, h
Donald E. Sloan Q.A. Manager cc File, chron, Q.A.
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-'90116 O'.*C 3 7 Y IVX42Y OVC38Y IVX45Y OVC358Y IVX46Y OVC46Y 2VD04Y OVC4/Y 2VD07Y OVC48Y 2VD12Y OVC59Y 2VD15Y OVD07Y 2VD21Y IVD04Y 2VD25Y IVD07Y 2VX30Y IVD15Y 2VX31Y IVD25Y 2VX32Y IVX30Y 2VX33Y IVX31Y 2VX34Y IVX32Y 2VX35Y IVX33Y 2VX36Y IVX34Y 2VX37Y IVX35Y 2VX38Y IVX36Y 2VX39Y IVX37Y 2VX40Y IVX38Y IVX39Y e
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any r.upport s and luspect to make certain that, the fuse link a..~mbly it. eentered on the blade stack.
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- 312/242 3434 44o1 WESTERN. FUNT MICHIGAN 48506
- 313/736 204o the co.
CUSTOM METAL FABRICATION August 2, 1982 l
l U.S.N.R.C.
Region III Office l
799 Roosevelt Road Glen Ellyn, Illinois 60137 Attn:
Mr. J. G. Keppler Re:
Telecon of July 29, 1982 to Mr. Robert Walker at 4:20 P.M.
Subject:
Potential 10CFR21 - Weld Records Gentlemen:
This letter is to confirm the verbal telephone report given by Mr. D. E. Calkins, Manager of Engineering for the Zack Company on Thursday, July 29, 1982 at 4:20 P.M. to Mr. Robert Walker at the Region III, Glen Ellyn officos of the Nuclear Regulatory Commission.
The attached report and corrective action plan has been pre-pared by Mr. Martin Skates, Quality Assurance Manager, as my designee for all Eack Company quality related matters.
During the course of an existing internal Zack Company investi-gation, initiated by the Eack Company officers, a box of paper-work was observed being taken to the trash by a plant employee.
The company maintenance man brought the documents to the atten-tion of Zack management.
A preliminary review of the documents (see attached report for details) indicates a possible discrepancy between the welder of record and the welder who may have actually performed the welds.
This potential discrepancy is still in the process of being fully investigated, but the initial indications are that it could have occurred during the 1977 to 1981 time frame.
[
990Q1A0349 H2fua ns 4 982t PDR ADOCK 0S0005 PDRg/ j)1 -
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- FOUNDED TO SOLVE THE UN8QUE METAL FABRICATON NEEDS OF INDUSTRY
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Region III Office August 2, 1982 Page 2 The Zack Company has initiated and is still in the process of conducting a full scale investigation of this potential discrepancy.
However, in an attempt to keep all relevant information open and available to the appropriate parties, the Zack Company is initiating this potential 10CFR21 be-fore it has been determined tr at a deficiency does exist.
By copy of this letter and the attached report the Zack Company is also confirming the verbal notifications given to the effected utilities.
The Zack Company will cooperate with the Nuclear Regulatory Commision and the respective utilities to the fullest de-gree possible in the performance of this investigation and its closure.
Should you have any questions or problems concerning this matter, please do not hesitate to contact me or Mr. Martin Skates at (312) 242-3434.
Very truly yours, THE ZACK COMPANY l
l c
CHRISTINE ZACK DE ZUTEL, PRESIDENT l
CZDZ/ art Encl.
1 cc:
Mr. William Harrington Baldwin Associates Mr.
L.
E.
Davis Bechtel Power Company Mr. Dan L.
Shamblin Commonwealth Edison Company
THE ZACK C(MPANY POTENTIAL 10 CFR21 REPORTABLE DEFICIENCY EVALUATION FOR ACCURACY OF WELDER RECORDS PREPARED BY:' David E. Calkins, Nnager Engineering REVIEWED BY: %. k.
I!I[8E I
M. L. Skates. Manager Quality Assurance m,Ao 3 7
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APPROVED BY:
_u CFFri stine Zack DeZp, Preslc enQ l
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1.0 Notification
1.1 The Zack Company in accordance with the intent of the reportability requirements within the Code of Federal Regulations, is reporting a Potential 10CFR21 condition relating to a possible discrepancy in the documentation that reflects the welder of record and the welder who may have actually perfonned the elds.
1.2 This report constitutes the Zack Company's official written notificaiton of a Potential 10CFR21 condition and c)nfirms our verbal notification on Thursday, July 27,1982 at 4:20 PM'-
to Mr. Roger Walker at the Region III Glen Ellyn Offices of the Nuclear Regulatory Comission.
The infonnation relative to this report was obtained Tuesday, July 27, 1982.
The saaintenance rsr. observed a box of paperwork being taken to the trash by a plant employee. The r.aintenance man checked with manage-ment to see if the documents should be kept. A review of some of the documents raised questions about welding documentation.
2.0 Identification
The possible deficiency being investigated is that certain working copies of the shop travelers were obtain;.d and that these ccpies were compared against the official quality record copies. A possible discrepancy exists between certain infor-mation contained on the working copy versus the Q.A. record copy.
The components involved are ductwork (geometrically shaped sheet metal) an d hangers (structural steel support members) shipped to the followii.g nuclear facilities:
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Page 2
- 1. LaSalle Nuclear Power Station Marseilles, Illinois
- 2. Clinton Power Station
. Clinton, Illinois
- 3. Midland Power Station Midland, Michigan 2.2 The work being reviewed for a potential discrepancy by the Zack Company is limited to work performed at its Cicero, Illinois and Chicago, Illinois facilities.
3.0 Potential Deficiency Discription:
3.1 The Zack Company utilizes a traveler system to fabricate the components and to record as built, as welded conditions and as inspected verifications. Certain " working" copies (photo-copies) of the official travelers utilized by the production tradesmen contain the initials of various tradesmen who apparently performed some fuirtion on that component. Relevant information (i.e. welders nuncers, material identification, etc.) was then transfered to the official copy (original traveler). The initial review of the working copies of certain travelers indicates that they contain inconsistencies.
The Zack Company is in the process of trying to determine if the initials of a welder on the working copy indicate that the individual actually welded on the component, or whether they represent some other function he performed.
4.0 Action Taken To Date:
The Zack Company has initiated the following actions in an effort to determine the ramifications of, the validity of the inconsistencies and the possible safety implications, if any.
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Page 3 4.1 The Zack Company has initiated an investigation into the authenticity and validity of thE information, the basis for theaccumulati$nfortheinformation,andthereasonthein-formation was being discarded.
4.2 The individual discarding,the box.of paperwork (working copies of certain travelers) has been suspended for thirty days pending"the results of the'Zack investigation.
32.'
2,..v?..:f M,,
4.3 Pinkerton Security se,rvice was obtai.n.ed to provide 24 hour2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br />
- c. ~
.g er
- ,~.s surveillance of all Zack; records. to provide assurance that no y2 relevant documents would leave the promises.
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u 4.4 The Zack Compay has also initiated the gathering of the following types of information, to ' substantiate the quality records and
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provide the information necessary to determine whether a safety problem exists or not payroll records will be 'used to validate time frames welders worked.
Validation that all welders available were qualified and certified to perform work.
Validating the other inspections performed (i.e. shop, site, client).
Obtaining additional clarification relevant to the meaning ofinformationonworkingcopies(photocopies)fromavail-able personnel. This infomation could be ot*tained in form of telephone conversations, statements, etc.
4.5 A management directive has been issued to all Zack Cagany enployees regarding the disposal of documents.
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tecr~k&mm=:n 3 Page 4 5.0 Corrective Action Plan.
5.1 To do a full scale investigation of Safety Related Travelers, Weld Wire Issue Slips, Welder Qualifications and Shipment Packages corresponding to the working copies of travelers obtained for the time frame of 1977 through 1981 on the LaSalle Power Station, Midland Power Station and the Clinton Power Station.
5.2 As additional temporary surveillance program to verify the identification of the record of welders will be established to substantiate that correct welder identifications are transposed to the record documents; 5.3 To bring in-house, additional qualified personnel to assist in the investigation.
5.4 To submit a final report to the N.R.C. by August 31. 1982, i
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' Attactnent 1 LaSalle Project - 3300 Traveler Information:
1.
The yellow traveler is the Quality Control Document that is maintained as a part of Zack's permanent records systen for final turnover, also for the Quality Control Inspector verification.
2.
The white traveler was a copy of the yellow traveler used by the shop fabrication foremen to record as-built or as-welded conditions during actual fabrication.
A review of one hundred and seventy yellow and white safety-related shop travelers has revealed the following conditions; A.
Category-1 Seventeen (17) travelers shows the yellow travelers and the white travelers reveals the same welder information.
B.
Category-II.
Thirty-eight (38) travelers shows the white traveler contains more welder identification than the yallow traveler.
C.
Ca tegory-III. Fifty-eight (58) white travelers shows different welder identification than the yellow traveler.
D.
Category-IV, Fif ty-seven (57) yellow travelers shows more welder identifications than white traveler, l
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$'i bh$iY $b$ll h YbY Attactrent 2 Midland Project - 2400 Traveler Information; 1.
The yellow traveler is the Quality Control Document that is maintained as a part of Zack's permanent system for final turnover, also used for the Quality Control Inspectors verifications.
2.
The white traveler was a copy of the yellow traveler used by the shop fabrication foreman to record as-built or as-welded conditions, during actual fabrication.
A review of nine hundred and fifty-one safety-related shop travelers has revealed the following conditions at this time; A.
Six hundred and eighty-one (681) travelers-shows the yellow travelers and the white travelers reveals the same welder infonnation.
B.
One hundred and thirty (130) travelers shows the white travelers contains more welder identifications than the yellow traveler.
C.
One hundred and forty (140) travelers show unverified welder qualification at the time of issue on the travelers.
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Clinton Project - 2900 Traseler Information:
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1.
The yellow traveler is the Quality Control Document that is maintained i
as a part of Zack's permanent system for final turnover, also used for the Quality Control Inspectors verifications.
q, 2.
The white traveler was a copy of the yellow traveler used by the shop fabrication foreman to record as-built or as-weldtd conditions, during actual fabrication.
I A review of eleven hundred and sixty-six (1166) safety-related shop travelers has revealed the following conditions at this time:
A.
Seven Hundred and twenty (320) travelers shows the yellow travelers
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and the white travelers reveals the same welder information.
B.
One Hundred and sixty-two (162) travelers show the white traveler contains more welder identifications than the yellow traveler.
C.
Two Hundred and eighty-four (284) travelars show unverified welder qualification at the time of issue dates on the travelers, i
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