ML20071G861

Requests Concurrence in Lifting 820623 Stop Work Orders 017 Re Electrical Equipment Installation & 018 Re Electrical Instrumentation Installation.Recovery Plan,Correcting Deficiencies in Traveler Control Procedure,Encl

ML20071G861
Person / Time
Site:	Clinton
Issue date:	04/09/1983
From:	Hall D ILLINOIS POWER CO.
To:	James Keppler NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III)
Shared Package
ML20071G850	List: ML20071G861 ML20071G873
References
4250-L, 830408, U-10046, NUDOCS 8305240413
Download: ML20071G861 (34)

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ILLINDIS POWER 00MPANY IP CLINTON POWER STATION P.O. BOX 678. CLINTON, ILLINOIS 61727 Docket No. 50-461 April 8, 1983 FamCIPAL STAFF j RA isEE~

0/RA ISCS Mr. James G. Keppler A/PA l PA0_l

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Regional Administrator

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U. S. Nuclear Regulatory Commission Drg gWj I4CT Region III hwsa j

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Recovery Plan for Electrical Equipment and Instrumentation Installation

Dear Mr. Keppler:

On June 23, 1982 Stop Work Orders were initiated on Elec-trical Equipment Installation (SWO #017) and Electrical Instrumentation Installation (SWO #018).

These actions were taken because the procedures used to control travelers in these areas were considered to be inadequate.

A recovery plan was developed to correct those deficiencies and is attached for your review.

Illinois Power Company has completed the portions of the recovery plan which are necessary to lift these Stop Work Orders.

The appropriate procedures and instructions have been revised and training has been accomplished and documented.

Illinois Power Quality Assurance has verified that corrective action has been completed and is adequate.

It is requested that you review Illinois Power Company's actions and concur in lifting the Stop Work Orders on Electrical Equipment and Instrumentation Installation.

Sincerely yours, D. P. Hall Vice President REC /j f Attachment cc:

NRC Resident Inspector Manager - Quality Assurance Director - Office of I&E, USNRC, Washington, D.C.

20555 Illinois Department of Nuclear Safety pR13 $903 8305240413 830518 PDR ADOCK 05000461 A

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ILLINOIS POWER COMPANY IIk!

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RECOVERY PLAN 4,'

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ILL. POWER SLECTRICAL RECOVERY PLA

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ILL. POWER RECOVERY TEAM DIR.

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,6 ILL, POWER PROJECT MANAGER l

BA MANAGER OF QUALITY AND TEC AL SERVIC S j

ILL. POWER DIRECTOR-QUALITY ASSURANC dtCR_'

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OBJECTIVE I.

Resolve identifie'd Quality problems with electrical installation in order to obtaiti approval for Tifting Stop Work Orders 016, 017, 018.

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Resolve electrical,hapger con, trol and, inspection backlog.

.yj;i OBJECTIVE II.

Describe how new/in-progress / modification work meets regulatory

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req.nirements.'

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7S OBJECTIVE III.

Demonstrate that previously assembled electrical work meets regulatory requirements.

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.r ic'r OBJECTIVE IV.

Outline resources to support, recovery effort.

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Objective II & III Requirements i

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B.A. construction in all type of installations will perform a " walk down" of work to verify that installation and engineering requirements are completed before re-e:.

leasing work for quality inspection.

OBJECTIVE III:

1.

I.P. Quality Assurance will administer an over inspection of accepted work.

2.

At completion of audit / inspection, team will issue final report to Management.

Report will be reviewed to verify assembled structures meets regulatory require-i ments.

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• Proj. Engineering BA QA BA QC BA Tech. Servict.s' IP QA BA Electrical J. Ilarris D. Cordy R. Whitehead H. Daniell.

3. Shanbhag D. Hurphy B. Cre'ed C. Creathouse R. Dillman H. Hurray L

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Electrical Conduit

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PROBLEM; 1.

Present system of documenting completed work does not provide for timely inspections.

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Inadequate system of resolving construction / engineering / inspection conflicts caused failure to complete documentation in a timely manner.

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RECOVERY PLAN:

1.

Revise documentation system (BAP 3.3.1) to utilize a traveler to perform and docu-ment the work.

2.

Restrain new work until the backlog of work in progress is reduced to an acceptable level.

This will be accomplished by the in-process Traveler Control Group (BAP 2.32).

3.

Total of 124,727 feet issued for work.

(as of 6/30/82) a.

28,355 feet with documentation in the vault.

b.

86,884 feet in-progress work.

c.

9,488 feet ready for inspection, to be issued under new traveler system.

1 4.

Complete and inspect 3,000 feet per week, i

a.

Inspection at a rate of 2 minutes per foot requires 100 manhours per week.

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Assign two inspectors to perform the work., (2 inspectors presently avail-able).

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PRELIMINARY REPORT

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STOP WORK 016

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Stop Work Definition:

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llI TITLE WORK AREAS C ' ic-i RESOLITft0N WORK NOT u,$

PROBLEM AFFECTED AFFECTED RESPONSIBILITY AFFECTED

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All new Conduit All "new" (No All areas south Work off All non-safety (not IE, Installation hours charged of "S" line, Inspection Aug D, Fire Protection)

.i !g prior to June pum** rooms in Backlog.

and all conduit hangers Inspection

,,28, 1982) con-Screenhouse ind may be worked. All con-

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Backlog duit containing some areas of duit in Containment. All Class IE, Aug D.

Main Steam

' 2I "old" (hours charged C

and Fire Pro-Tunnel and prior to June 28, 1982) tection cables, Turbine Building, conduit work started before EXCEPT in.

NOT Containment.

June 28, 1982 may be worked.

Containment.

CENERAL NOTE:

Issuance of 3

Conduit Cards Change documents and for above may drawing revisions requiring NOT proceed, traveler revision may be worked E

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allowed to be worked under these guidelines. This is to ensure work in progress is

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I Revision 1 Containment is All areas asi'

'Same as mbove.

No changes except "new" No change now included in described conduit in Containment cannot the Stop Work.

above INCLUDING Containment.'

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be worked.

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i Revision 2 All conduit Same as Re-Same as above.

All non-scheduled con-All Conduit installation, vision 1.

duit including lighting and j

old or new.

All and communications.

scheduled con-duit installed per BAP 3.3.1.

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Rel'ated Action:

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Potential 10CRF50.55(e) Deficiency 82-07. Untimely Inspection 1-E Item 80-27-01, Untimely Inspection i

Stop Work 007, Inadequate Construction Controls

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Analysis

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An estimated 9,488 feet of conduit is in the inspection backlog.

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4 and verification controls regulating the conduit installation.

These controls have been rewritten to 4

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correct the problems and are now in the review approval cycle.

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i I Recovery Program and Recommendations:

i Recovery Activities-1.

Finalize the revision of constructicn and verification controls, i.e., BAP 3.3.1/E-012/QCI-405.

The completion of this activity is now scheduled for July 21, 1982.

2.

Conduct training in the implementation of the revised construction controls. The completion of this activity is now scheduled for August 18, 1982.

3.

Submit to NRC for review and approval for partial lifting of Stop Work.

4.

Partially lift the Stop Work, pending approval of NRC.

5.

Work off the inspection backlog.

This activity is expected to require 4 weeks for completion from the time it commences.

Projected completion date is September 2!., 3982.

.n 6.

Submit to NRC for review and approval for complete lifting of Stop Work.

9 7.

Fully lift the Stop Work, pending the elimination of the inspection backlog and commence new conduit work.

n Recommendation:

Reaudit/ surveillance the Electrical Conduit Installation program to identify any deficiencies in the controls instituted in the new procedures and to determine the timeliness of inspection activities.

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TRAINING BAP 331/E-Ol2/0Cl-405 STAR 9 UCOMPLE T E

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U INSPECTION ACTIVITY INSPECTION DACK LOG PROJECTED COMPL ETION 4 WE EKS FwRTIAL LIFT i

LIFTING STOPWORK-016 U LIFT U Uswo.O 16 NRC NRC/

APFROVAL APPROVAL

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pLgt p STOP N/A In the conduct of the Stop See Revision 2 See Revision 2 See Revision WORK HOT AFFECTED ci KORK Work 007 resolution, pcten-2 All nonsafety (not 016 tial deficiencies were iden-tified in the construction IE, Aug D. Fire and verification controls Protection) and all regulating conduit installa-conduit hangers may.

be worked. All con-tion. Above control defi-ciencies, realized as untimel)

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inspections, resulted in an

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All "old" (hours inspection backlog.

charged prior to Affected work includes all June 28, 1982) con-duit work started "new" (no hours charged prior before June 28, 1982 to June 28, 1982) conduit containing class IE, Aug D.

may be worked.

and Fire Protection cables, EXCEPT in Containment.

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N/A Containment included in the See Revision 2

See Revision 2 See Revision No changes except' 1

Stop Work.

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• new" conduit in Coa-tainment cannot be worked.

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N/A All conduit installation, old 1.

Revise construction and 1.

Finalize the revision of 7/21/82 All nonscheduled 2

or new. All acheduled con-verification controls.

BAP 3.3.1/E-012/QCI-405' conduit including duit installed per BAP 3.3.1.

Conduct training in the 8/18/82 lighting and impicmentation of the e mmunicati ns.

revised construction con-trols.

NRC Review / Approval 8/20/82 Partially lift the Stop 8/23/82 Work, pending the comple-i;1on of training and NRC opproval.

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Resolve inspection back-2.

Work off the inspection 9/17/82 WORK Description.)

log of,an estimated backlog. This activity 016 9,488 feet of conduit.

is expected to require Rev.

four (4) weeks for com-pletion from the time it Commences.

NRC Review / Approval 9/20/82 Fully lift Stop Work 9/23/82.

pending the elimination of the inspection back-log and NRC approval.

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PROBLEM:

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Inadequate traveler logging system for tracking Electrical Equipment Installation e

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Travelers which failed to promote prompt completion of work and timely inspections.

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Inadequate system of resolving constructi'on/ engineering /. inspection conflicts caused l

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RECOVERY PLAN:

1 1.

Revise traveler' logging 'ystem to provide a better flow of documentatio.n and promote s

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1 2.

Restrain new work until the backlog of work in progress is reduced to an acceptable t

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This will be accomplished by the in-process Traveler Control Group.

l 3.

4 Total of,286 travelers iss_ued.

(as of 6/28/82) a.

36 in the vault I

b.

150 in progress work ic.

100*in final review process 8

4.

Complete and inspect 5 travelers per week.

3 1

Inspection race of 4 hours4.62963e-5 days <br />0.00111 hours <br />6.613757e-6 weeks <br />1.522e-6 months <br /> per traveler requires 20 manhours per' week.

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Assign one inspector to perform the work.

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PRELIMINARY REPORT STOP WORK 017 '

Stop Work Definition:

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TITLE WORK AREAS RESOLUTION WORK NOT PROBLEH AFFECTED AFFECTED

. RESPONSIBILITY AFFECTED s

Electrical All IE, Aug D, All Train personnel in Non-safety work with no Equipment Fire Protection electricians, need for quality Quality / Technical Services Installation Electrical Quality Control approach to traveler involvement.

/juipment.

E and Technical details and require-Traveler Services ments of BAP 2.10.

requirements NO work to be Inspectors and procedures 1

perfo rmed ! I l not understood nc-being No traveler.

fo ' owed.

work to be j

performed.

i Relate Action:

Internal Audit I-195. Electrical Equipment Installation Corrective Action CAR 90, Bypassed DR 11o'14 Tag Corrective Action CAR 100 Inadequate Traveler Control 4'

Analysis:

Internal Audit I-195 findings identified numerous procedural violations and'are indicative of poorly trained personnel.

In addition, unsubstantiated concerns have arisen regarding the adequacy of traveler instructions to construct and verify equipment installation and modifications, and the adequacy of the,

t raveler log.

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R'ccevery Program cnd Rsecamendationst Recovery Activities 1.

Finalize approval of the latest rev' sed procedure (QCI 404).

2.

Expedite c'losure of DR's 1588, 1589 and 1590.

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Finalize the I-195 corrective actions and close Baldwin Associates Internal Audit I-195.

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4.

Quality Assurance complete the review of CAR-90 responses and expedite closure.

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m PEoject Engineering initiate response to C.AR-100, transmit to Quality Assurance for review.and closure.

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6.

Conduct training to implement BAP 2.10 and ; revised' QCI 404.

7.

SMmit to'NRC for review and approval to lift Stop Work 017.

8.

Fully lift'the Stop Work pending NRC approval.

.i, Recommendation Reaudit/ surveillance the Electrical Equipment Installation Program to identify any deficiencies regarding the adequacy of traveler instructions to construct ar.d verify equipment installation and modifications, and the adequacy of the traveler log.

Include corrective action an this recovery program as required.

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1. Answer findings identified 1.

Finalize approval of the 8/13/82 nal.'

identified numerous procedural on Internal Audit I-195.

latest revised Quality Audit violations and are indicative Control Instruction (QCI) 1-195 of poorly trained personnel.

404.

Revise BAP 2.10 per 5/25/82 Project Procedure Change Request PCR-28A-82.

Conduct training, given 9/10/82 to all Supervisory, Quality, and Engineering Personnel as appropriate, to implement DAP 2.10 Equipment Installation, and the revised QCI 404.

Expedite closure of Dev-(TBD) istion Reports (DR's) 1588, 1589, 1590.

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$8 FIN 0ltsG DESCRIPilCN Rt0VintD QR C,TI E OURSE OF ACil0N It g,

ACTION TAKEN TO SATISFY SWO COMMiiMENT fC T C w

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CAR-N/A An adequate logging system ha< Project Engineering initiate 1.

To be determined by 8/2/82 On July 28, 1982 100 not been established for response, transmit to Quality August 2, 1982.

Project Engineering Electrical Travelers.

Assurance 'for review and requested an extensior closure.

2.

Project Engineering 8/13/82 (IIRS-200-82) to to forward response August 2, 1982.to to Quality Assurance allow time to for reviev, assemble final respont 1.

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8/9/82 4'

'3 IP RECOVERY PROGRAM Electrical Instrumentation

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,p' PROBLEH:

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1.;'Present system of documenting travele'r logging' locations'was not'being followed.

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Traveler preparation did not have required detail for proper installation.

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't RECOVERY PLAN:

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1.

Review of proce' dure and installation requirements revealed personnel. training

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j deficiencies, require perscanel be traine'd to project requirements.

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2.

There have only been 16 Electrical Instrumentation Travelers issued.

Review all Instrumentation Travelers for procedural and installation requirements.

Issue to j

Quality Department for their review and approval.

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Issue Instrumentation Travelers to field for verification and work.

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O/Y/04 PREI,IMINARY REPORT STOP WORK 018

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I Stop Work Definition:

TITLE WORK AREAS RESOLUTION WORK NOT PROBLEM AFFECTED AFFECTED RESPONSIBILITY AFFECTED i

Electrical All IE, Aug D, All Extensively train Non-safety work with no Instrumentation Fire Protection electricians, affected personnel Quality involvement.

x Installation instrumentation inspectors, in requirements of 2

installations Technical BAP 2.6 and BAP 2.10.

Traveler and traveler Services

. requirements work.

not understood

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or being

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followed Related Action:

q Internal Audit I-214, Instrumentation Installation Corrective Action CAR 100, Inadequate Traveler Control (Tracked on Stop Work 017 Bar Chart) i Analysis:

Internal Audit I-214 findings identified numerous procedural violations and are indicstive of poorly trained personnel. A response has been made to I-214; considerable personnel training and indoctrination will be required. The number of electrical instrument travelers to date is small.

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. t, 4-i R:covery Program and Recommendations:

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'F Recovery Activities l.

Finalize approval of the latest revised procedure (QCI 404).

2.

Conduct training and indoctrinate personnel in BAP 2.6.

Training to be conducted concurrently with BAP 2.10 and QCI 404.

n 3.

Develop, implement and finalize corrective action for Baldwin Associates Internal Audit 1-214 and expedite closure of san.c.

4.

Revise and rework all existing electrical instrumentation travelers and submit to QA for review.

5.

Submit to NRC for review and approval to lift Stop Work 018.

6.

Fully lift the Stop Work pending NRC approval.

Recommendation Reaudit/ surveillance the Electrical Instrumentation Program to identify any deficiencies regarding the adequacy a

of traveler instructions to construct and verify instrument installation and modifications, and the adequacy of 'the traveler log.

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JULY AUGUST SEPTEMDER OCTOBER NOVEMBER

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j REWRITE PROCEDURES arv APP ISSUED ST84UCTION I

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BA INTERNAL AUDIT l-214 INSTRUMENTATION VIr" trusion Y

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RESPONSE

8/6/82 TRAINING START FitaSit BAP 2.6 (BAP 2 80/0C1-404)

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a APPROVAL 3.swo-on og3go INSTRUMENTATION OUUO TRAVELERS 1

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I.P.1'Kanagement Controls itecoverM Plan _(s..),

Instrumentation Install.

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FINOING OCSCRIPTION ItEOUIRED fitCitvE OuR';E Cr ACTON It 1CTON TixEN TO SATISFY SWO COMMITMENT SC C

ET COMMEgTS I

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Inter-N/A Internal Audit 1-214 findings 1.

Senior Discipline Engin-

1. Project Engineering to 8/6/82 Project Engineering nal identified numerous proced-eers to respond to Audit develop, implement and forwarded Audit ural violation and are indic-finding as they apply.

finalize corrective action response on 1-214 ative of poorly trained and close Baldwin Assoc-electrical personnel.

lates Internal Audit I-214.

instrumentation to Quality

2. Rewrite QCI 404 review and 8/13/82 Assurance on approve.

8/6/82.

3.

Train affected personnel 9/10/82 in requirements of BAP 2.6, 2.10 and QCI 404.

4.

Rework travelers and 9/13/82 submit to BA QA for review.

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8/9/82 j

RECOVERY PLAN Inprocess Control of Travelers 2,

1 1.

Objective:

Limit the number of hanger travelers available to the Electrical Construction Department for work in order that the backlo~g of uninspected work be reduced.

2.

Analysis:

Installation of hangers did not take into account available QC Staffing, there-by creating a backlog of uninspected work.

3.

Solution:

An "Inprocess Traveler Control Group" has been created to act as the limiter of traveler issuance to the field.

A limit has been established which reduces the level o'f construction activity, bringing it into agreement with QC Staffing.

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RECOVERY PLAN 4

BACKLOG OF HANbER" TRAVELERS FOR FINAL REVIEW 1.

Objective:

Reduce tbn backlog of Electrical Hanger Travelers held in the Electrical p

i Engineering Department pending Final Review.

2.

Analysis:

A large number, approxim'ately 4500, Electrical Hanger Travelers are

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. currently being held in Engineering:pending Final Review.

The largest contributing i

factor to this backlog is the necessity 'to prepare revisions to Electrical Hanger j

Drawings (EHD) to incorporate " Redline changes.

Drafting resources had been m.

j a,llocated to the development of new EHD's rather than the revision of existing ones.

3.. Solution:

The backlog will be eliminated by 1 October 1982.

In order to accomplish this, five draftsmen have been hired.

The Electrical Drafting Department has been placed on a six-ten hour day basis with all time beyond 40 hours4.62963e-4 days <br />0.0111 hours <br />6.613757e-5 weeks <br />1.522e-5 months <br /> devoted to reducing the backlog.

The regular 40 hour4.62963e-4 days <br />0.0111 hours <br />6.613757e-5 weeks <br />1.522e-5 months <br /> week is devoted to normal work functions which includes processing revisions to EHD's which are a part of each weeks work.

depicts the estimated completion schedule.

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8/9/82 IP RECOVERY PLAN t'

Electrical llangers I

l PRO,BLEH:

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Inadequate logging system for tracking travelers in order to complete work and perform timely inspections.

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Inadequate system of resolving construction / engineering / inspection conflicts caused failure to I-complete documentation in a timely manner.

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Travelers were issued to the field for construction in an uncontrolled manner which failed to promote prompt completion of the work and resolution of problems.

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RECOVERY PLAN:

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Revise the procedure (BAP 3.3.6) to provide a better floc of documentation and completion of work.

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f. 2 Restrain new. work until the backlog of work in progress is reduced to an acceptable level. This

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Q will be accomplished by the in-process Traveler Control Group (BAP 2..E).

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.P li!3. Total of 32,289 travelers issued. (as of 7/26/82)

(5,918 have been deleted)

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10,022 In the vault l b.

10,956 in-progress work l!

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1,441 ready for inspection i

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9,870 in final review process l

564. Complete and inspect 350 per week.

Inspection at a rate of 1.5 hours5.787037e-5 days <br />0.00139 hours <br />8.267196e-6 weeks <br />1.9025e-6 months <br /> per hanger' requires $25 manhours per week.

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Requires 13 inspectors to perform the work (10 inspectors presently available).

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Personnel requisitions have been issued to hire additional inspectors.

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Present personnel will work additional hours during peak loading to meet present b

j schedule until additional staffing is accomplished.

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3..

IP RECOVERY PROGRAM Electrical Cable Tray Attachments PROBLEM:

1.'

Previous documentation system did not allow for incorporation of design changes, therefore, inspection documentation in the vault does not reflect actual installed configuratior..

2.

Previous documentation systen,did not provide adequate tracking of completed work.and did not produce timely inspections.

3.

Present documentation system does not provide for construction verification of completed work

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and incorporation of unique design changes for individual cable tray attachments.

RECOVERY PLAN:

1.

Previousdocumentationsystem(BAP3.3.11)wasrevisedtoprovideaegbletrayattachment traveler in order to provide unique inspection documentation for each cable tray attachment.

2.

Restrain the release of new work until the backlog of in-process work can be issued under the new traveler system, completed, and inspected. This will be accomplished with the in-process Traveler Control Group (BAP 2.32).

3.

Revise present documentation system (BAP 3.3.11) to allow for construction verification of completed work.

Incorporate Electrical Hanger Drawings (EHD) to reflect unique design changes of individual cable tray attachments.

4.

Initiate 3,378 cable tray attachment trayelers.

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Complete and inspect 50 attachment travelers per week.

a.

Inspection rate of 2 hours2.314815e-5 days <br />5.555556e-4 hours <br />3.306878e-6 weeks <br />7.61e-7 months <br /> per traveler requires 100 manhours per week.

b.

Assign two inspectors to perform the work. (2 inspectors presently available) e

i 8/9/82 IP' RECOVERY PROGRAM Electrical Cable Tray

.. t; PROBLEH:

1 1.

Present system of documenting completed work does not allow for timely inspections.

2.a' inadequate system of resolving construction / engineering / inspection conflicts caused failure to complete documentation in a timely manner.

3 RECOVERY Pl.AN:

1.* Revise documentation system (BAP 3.3.10) to utilize a traveler to perform and document

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the work.

t" 2., Restrain new work until in-process work is issued under the new traveler system, complet,ed,

and inspected. This will be accomplished with the in-process traveler control group (BAP 1.32)r 3.'; cable tray installation travelers to be,,1,ss,ued for 45,000' feet of $ble tray.

1 4.

Complete and inspect 1,000 feet per weck a.

Inspection rate of 2 minutes per foot. requires 34 manhours per week.

b.

Aasign one inspector to perform the work.

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MANPOWER PROJECTION

' CLASS 1E/ SEISMIC CATEGORY I WORK BAP COMMODITY Q.C. STAFFING WEEKLY QUANTITY ELECTRICIANS 1

3.3.1 Conduit 2

3,e000 (ft) 83

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3.3.2 Cabl'e 6

18,000 (ft) 43 3.3.6 Cable Tray and Conduit llanger 13 350 (ea) 338 3.3.10 Cable Tray 1

1,000 (ft) 23 3.3.11 Cable Tray Attachments

_2 50 (ea) 55 TOTAL 24 542 1.

Quantity shown is based upon manning level of Q.C. inspectors.

2.

Electrical manning includes supervision (e.g. Foremen and General Foremen).

3.

Electrical manning does not include non-safety or support functions.

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