ML20080B481
| ML20080B481 | |
| Person / Time | |
|---|---|
| Site: | Midland |
| Issue date: | 12/05/1983 |
| From: | Baranow S STONE & WEBSTER, INC. |
| To: | James Keppler NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| Shared Package | |
| ML20080B405 | List: |
| References | |
| 14509, NUDOCS 8402070165 | |
| Download: ML20080B481 (18) | |
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Mr. J. G. Keppler, Administrator, Region III Dacember 5, 1983 Nuclear Regulatory Commission J.0. No. 14509 799 Roosevelt Road NRC File #83-12-5 Glen Ellyn, Illinois 60137 RE: DOCKET NO. 50-329/330 MIDLAND PLANT - UNITS 1 AND 2 OVERVIEW 0F THE CONSTRUCTION COMPLETION PROGRAM REPORT N0. 25 A copy of the Construction Implementation Overview Report No. 25 for the period November 28, 1983 through December 2, 1983 is enclosed.
This report includes evaluations of CCP activities, matrices of observations, NIRs, Hold Points and Affidivats and Resumes of newly assigned CIO Personnel.
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S. W. Baranow Program Manager SWB/fs Enclosures cc: JJHarrison, US NRC Glen Ellyn, IL RJCook, US NRC Midland (site)
DLQuamme, CPCo Midland (site)
RAWells, CPCo Midland (site)
RBXelly, S&W APAmoruso, S&W DEC 141983 8402070165 840203 PDR ADOCK 05000329 G
e Report No. 25 November 28, 1983 through December 2, 1983 Personnel on Site Stone & Webster Michigan, Inc.
A. Amoruso D. Cooke R. Scallan J. Karr S. Baranow R. Corson J. Seely D. Wells F. Bearham J. Langston W. Taylor L. Van Arsdale J. Barr C. Marrs J. Thompson E. Barcomb R. Carpeggiani D. MacBay R. Butler D. Beauchamp J. Chawla T. Parker N. Weatherall D. Brown A. Smith S. Narayandas T. Baumgartner W. Sienkiewicz i' B..Kasson Meetings Attended Date Attendees Purpose November 28, 1983 Consumers Power Company Daily Staff through Bechtel Power Company Managen,ent Meetings December 2, 1983 Stone & Webster CIO MPQAD November 28, 1983 Consumers Power Company Team Meetings through Bechtel Power Company December 2, 1933 Stone & Webster CIO November 29, 1983 Consumers Power Company QVP Status Bechtel Power Company Assessment MPQAD Stone & Webster CIO November 28, 29 MPQAD CI0 Sampling of and Stone & Webster CIO FCR/FCNs December 2, 1983 December 2, 1983 Consumers Power Company Weekly Sub-Contractors Bechtel Power Company Meeting Babcock & Wilcox Zack i
Owens-Coring Transco, Inc.
Penetration Seals Grinnell U.S. Testing Electrical Fire Proofing Stone & Webster CIO
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JOB NO. 14509 MIDLAND NUCLEAR POWER PLANT REPORT N0. 25 PAGE 2 Meetings November 28 through December 2, 1983 - During this period CIO attended daily meetings with staff management.
Subjects discussed at these meetings were:
A.
Stop Work Orders - Stop Work Orders addressing FRNs and FCNs were discussed daily. The total number of documents involved and their status was presented. End of week approximate figures were that only fifty (50) FCRs and FCN3 remain for first review, 5,000 are in document control for review and 400 have been returned from document control for re-review.
It is estimated that 500 of the 5,000 in document review will require re~ review.
The schedule of MPQAD and CIO audits and their impact on lifting Stop Work Orders was discussed.
Nonconformance Reports - The details of each NCR were discussed to B.
decide whether the nonconformance was representative of a generic problem. Also discussed were the preventative actions that could be undertaken.
~Two,onconforming conditions were the subject of extended discussion.
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n 1.
NCRs C00628, C00640 and C00650 referenced bypassing RC Hold Points on PQCI E-5.0 Rev. 13.
2.
MCR C00708 referenced arc strikes on structural members fab-ricated at the Standish shop.
C.
Training - Sessions are being scheduled after a recent delay due to Stop Work Order commitments.
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CIO NIRs 006( 007 and 008 were discussed in detail. Re-audits, schedule for attaining compliance and the impact of NIRs on status assessment were topics at several meetings.
D.
Procedure Approval and Issuance - All Procedures required for status assessment have been issued-However revisions to Procedures present a potential problem due to the high number of revisions and time taken to process revisions.
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JOB NO. 14509 MIDLAND NUCLEAR POWER PLANT REPORT NO. 25 PAGE 3 November 28 through December 2, 1983 - CIO personnel assigned to respective teams attended meetings for discussions of:
A.
Teams 8 and 18 Discussions centereh an the up-dating of the team members (a) required training tjybe in compliance.with the Training Matrix. Up-dating is anticipated to be complete within two weeks. -
Method of communication Teams 27.and 28 - Discussion items were:
B.
with project during the Stop Work Order period.
(a)
Verbal communication should be limited.
Written comunication will be generated by the Recident (b)
Engineer by issuing a Resident Engineer Memorandum (REM) to Ann Arbor for problem resolutions. Responses from project will be in the form of Design Change Notice (DCN) or a Specification Change Notice (SCN).
(c)
Composite drawings for all penetra'tions should be issued for use in status assessment.
(d)
Team quality representatives are responsible for marking-up punchlists to define QC commitments.
C.
Team 5 - For discussions of:
(a)
Team restructuring by cddition of hanger personnel.
Status assessment training. This training is on-the-job (b) training where Mechanical Field Engineers and Instrumentation Field Engineers perform a mock status assessment of pre-This mock assessment is then graded designated components.
by the Lead Field Engineer of the specific disciplines.
This concept and pre-development of checklists has been cdopted by other Groups and it appears there will be common-ality in the use of techniques and checklists.
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JOB NO. 14509 MIDLAND NUCLEAR POWER PLANT REPORT NO. 25 PAGE 4 D.
BHO Hanger Team - For discussion of:
(a)
Mock assessment of "in-house" hanger training in pre-operation for status assessment. CIO witnessed mock assessments of hardware and determined that the mock assessment performed was effective and in compliance with CCP requirements.
In-house training on' executing software (i.e., NCRs, CWPs, FCRs and FCNs) is scheduled for week of December 12, 1983.
E.
Team 14 - For discussion of:
(a)
Up-dating of Punchlist is progressing in a satisfactory manner.
(b)
Required reading and training for this team is coristdered to be 83% completed.
November 29, 1983 - QVP Status Assessment Meeting:
The restraints affecting commencement continue to be the principal item on the agenda. The restraints are the FRN/FCN Stop Work Orders, preparation of 'a schedule, establishment of priority modules and CIO NIRs.
FCR/FCN Meetings - Discussions of:
(a)
Status of Phase I and II completion.
Readiness of the Master Log to concide with the antici-(b) pated review by CIO of the FCRs/FCNs considered acceptable by both BPCo and CPCo.
(c)
Status and population of FCR/FCNs in tne resolution phase.
December 2, 1983 - Subcontractors' Meeting - 9:00 a.m. - Spokesman - BPCo Superintendent..
B & W Construction Company - FCA (field change authorization) work being done. Containment (Unit I) area is being converted into a " controlled access area". Also, B & W are es-tablishing a cleanliness criteria "no eating in these established areas". The "D" rings are a cleanliness con-Formal training is being discussed with MPQAD.
cern.
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JOB NO. 14509 MIDLAND NUCLEAR POWER PLANT REPORT NO. 25 PAGE 5 Zack Company - Perform "8 foot criteria" walkdown will be complete by December 30, 1983. The System Team Supervisor has three men from Zack Company working on this hanger walkdown.
Zack training will tue complete by December 25, 1983. MPQAD has Zacks Procedure for review, scheduled to be returned to Zack on December 15, 1983. Forty-seven Linear Feet of duct l
require re-inspection due to the ',' weld samples" which has a direct effect on the installation: quantity curve, Punchlist Summary needs to be re-computed, Bechtel seems to think Quantity / Manhours correlations are incorrect.
Owens-Coring Fiberglas - BPCo requires that method of providing hydro
' status and insulation be cleaned up to eliminate confusion.
Owens-Corning reported that the working hours were changed to 32 hours3.703704e-4 days <br />0.00889 hours <br />5.291005e-5 weeks <br />1.2176e-5 months <br /> a week. BPCo advised that this practice may be contrary to the_ subcontractors working agreement.
Transco, Inc. - No activities.
P.enetration Seals - BPCo had a problem with Contract Clarifications and Additions, and asked for more detailed reports on:
- 1) Cancellation Clause, 2) Additional Scope - Conduit.
Penetration Seals Company will report before next weeks meeting.
Grinnell-Fire Protection System - Grinnell will have by next meeting, Engineering reviews of any additional requirements for Sprinkler, systems. Grinnell has to re-submit as-built drawings, incorporating the remaining Bechtel comments by December 7, 1983.
.U.S. Testing Company, Inc. - U.S. Testing home office management personnel has supported site activities with the assignment of a Site Manager. NCR #562 will be cleared up by December 1, 1983, six QARs remain open, Numbers 57, 58, 59, 62, 64 and 72.
Electrical Fire. Proofing - BPCo requested a break down of the four types of seals to add to the action list.
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-JOB NO. 14509 MIDLAND NUCLEAR POWER PLANT REPORT NO. 25 PAGE-6 ACTIVITIES 1.
' Training Classes CIO attended and evaluated construction training classes on:
(a)
Construction Punchlist FPG-9.900.Rev. 2.
(b)
Construction Completion Program. "
This presentation was not evaluated by TET. CIO evaluations of the effectiveness of the presentation were considered to be satisfactory. Presentations were in compliance with FPG-2.000 " Training of Constructions Personne!".
Results of the evaluation have been documented on checklist MP-MIS-001E and,are available for review.
- 2., Training Records In response to CIO NIRs 006 and 007, CIO was advised by memorandum on November 30, 1983, that corrective actions were underway to resolve the
-discrepancies noted on the~NIRs. CIO performed a review of the~origiWII ---
P descrepant records on December 3.and December 4, 1983, and determined that numerous records still required corrections.
CIO, when notified that all corrections have been completed, will per-form a review of the training records, and if satisfactory, will then.
. perform a sample inspection of the balance of the established lot size.
Sampling will be done of individual. team training records.
3.
CIO performed a verification of the identifications and tagging of LAQTS bolts of flange connections in the Diesel Generator Building.
~ IO OBSERVATIONS C
- 031-CIO reviewed the training records of 6 of 45 MPQAD personnel as noted on NIRs 002, 003 and 004. The records reviewed were con-sidered satisfactory and acceptable by CIO. A sample inspection of the training records of the balance of MPQAD personnel (39) is scheduled for completion during the week of December 5, 1983.
If this sampling review produces satisfactory results, NIRs 002, 003 and 004 will be closed out.
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JOB NO. 14509 MIDLAND NUCLEAR POWER PLANT REPORT N0. 25 PAGE 7
- 035 Concerning ti.is observation, CIO found no evidence that the require-ment for the galvanic protection of copper pipe was defined in either specifications or drawings..The governing document for in-stallation of the support' components is described on an Interoffice Memorandum dated May 4, 1979, from A. J. Boos to Field Engineers and Mechanical Superintendents.
The portion of the instrument air system in consideration is Non-Q and the noted condition was referred to CPCo by CIO for resolution.
The method of promulgating job requirements used (e.g., by Memo-randum) should be reviewed by CPCo to ascertain that requirements for Systems are only issued through authorized controlled documents such as specifications and drawings.
- 036 Report #24 dated november 29, 1983, states in part "FCNs would no longer be issued for Non-Q items". The observation should be revised to read "FCNs will no longer be issued for Q items and will in the future apply to only Non-Q items.
GENERAL An audit was performed by Stone & Webster, Boston, of the CIO program and I
activities, November 28, 1982 through December 2,1983. The audit was conducted by Mr. J. Cunningham, Lead Auditor, assisted by Mr. R. Laskey.
The -audit f-indings-will be issued within 30 days.and will be available for on site reviews.
Signed affidavits and resumes of Stone & Webster personnel assigned to the CIO staff have been transmitted to Mr. J. J. Harrison, US NRC, Glen Ellyn, Illinois.
E. G. Barcomb, Jr., QC Inspection Supervisor
'T. L. Baumgartner, QA Engineer D. W. Beauchamp, Senior QC Inspector D. W. Brown, QA Engineer.
B. Z. Kasson, QA Engineer L. M. Van Arsdale, QC Engineer C. L. Wells, Chief QC Inspection Supervisor
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STolil & WEll!iTEli HICllItiAli, _ INC.
C0f4SlHUCllDil IHl'I EHElll AIIIHi UVEllVIEW NIR LUG
SUMMARY
DATE DATE DATE J
NIH HPQAD No.
NCR NO.
SUBJECT OF DISP. BY CLOSED
' REMARKS ISSUE MPQAD OAR NO.
NIR issued us closed-no cor-001 N/A Training Records-8/15/83 8/15/83 8/17/83 rective action required 002 QAR Forms from both procedures B-3M and RT 00005 B-3M-1 are intermixed in training 10/4/83 10/12/83 records 003 QAR
. Yearly vision examination was exceeded 10/4/83 10/12/83 f
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OJT training records not available in RT 00007 training records. Revision number not 10/4/83 10/12/83 004 listed on DJT Record Memo to CPCo ad-l vising that NIR-005 1
QAR Personnel Certification Form Q;.-116-1, RT 00011 Attachment D is unavailable in record 10/4/83 10/12/83 10/20/83 can be closed out.
Records for Level 11 l
005 files certifications have been verified by CIO Discrepancies in three areas of 10/27/83 Construction Training Records 006 t
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MIDLAND NUCLEAR COGENERATION PLANT CIO OBSERVATIONS
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Originating CPCo Response
. Status Close-Out tion Observations Document /Date Document /Date Open/ Closed Document /Date N
er 006 MRC Meeting
- Report No. 1 Letter Closed Report No. 5 Program (Training) requires revision to 6/3/83 7/1/83 7/18/83 address how " Trainers" are trained 007 Method of communication / notification with Report No.1 Letter Closed Report No. 4 MPQAD when PQCI's are found to be ambiguous 6/3/83 7/1/83 7/12/83 or do not meet code requirements
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008 MRC Meeting 6/1/83 Report No. 2 Letters Closed Report No. 9 idequacy of drawings (A8) - large bore 6/14/83 7/1/83 8/15/83 pipe hangers 8/9/83 Hold Point Released 8/15/83 009 MRC Meeting 6/1/83 Report No. 2 Letters Closed Report No. 9 Additional verification of equipment 6/14/83 7/1/83 8/15/83 received and installed 8/9/83 (E-2) 010 MRC Meeting 6/1/83 Report No. 2 Letters Closed Report No. 9 Material traceability of installed 6/14/83 7/1/83 8/15/83 l
hangers (E3) 8/9/83 l
Hold Point Released 8/15/83 011 MRC Meeting 6/1/83 Report No. 2 Open pending 6/14/83 receipt of (a) discussion of nonconforming items Nutech Pro-l with Project Engineering gram l
(b) has a program beert developed and responsibilities established of personnel assigned to process nonconformances?
NOTE:
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MIDLAND HUCLEAR C0 GENERATION PLANT-CIO OBSERVATIONS Originating CPCo Response
. Status Closa-Out tton Observatlons Document /Date Document /Date Open/ Closed Document /Date r
030 Need to revier Vendor Equipment
. Report-No. 5 Open Verification. Program - MPQAD/SMO 7/18/83
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l 031 NIRs 002, 003, 004 and 005 were issued on Report No. 16 Open-October 3,1983 for discrepancies observed 10/3/83 in the. review of Training Records of 6 of 45 MPQAD personnel.
032' NIR 006 issued on October 27, 1983 to ad-Report No. 20
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Open dress discrepancies observed during sample 10/31/83 f
inspection of Construction Training
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Records of Teams 5, 6, 8, 9, 12, 13.-16, 17, 19, 20, 25, 26 (27/28) 29, 30, 31, 32/
33 and BHO staff.
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033 NIR 007 issued on November 7, 1983 to Report No. 21 Open address discrepancies observed in two 11/08/83 areas during inspection of Construction Training Records for Teams No. 24, Field Procurement, Sub-Contractors Management, Field Engineering Staff, and Construction General Services Organization.
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STONE A WEDSTER MICllIGAN, INC.
MIDLAND NUCLEAR C0 GENERATION PLANT CIO OBSERVATIONS Originating CPCo Response
. Status Close-Out
'[,ation Observations Document /Date Document /Date Open/ Closed Document /Date p
034 NIR 008 issued on November 14, 1983 to Report No. 22 Open address five unsatisfactory conditions 11/14/83 observed during the review of 50 training,
l levels assignments in the System Team Training Matrix of the Construction Training Program.
'035 CIO observed that dielectric isolation Report No. 22 Open I
spacers for galvanic protection of copper 11/14/83 l
pipe to galvanized steel pipe supports were missing in some areas on this system, Small Bore (Instrument Air) KAC Systems, J
H drawing FSK-J-30-0220 Sheet 2 Rev. 7.
036 At team meeting of teams 26 and 27 held on Report No. 24 Open November 22, 1983, a decision that FCHs 11/29/83 5:ould no longer be issued for "non-Q" items was discussed. The method for con-trolling changes has not been finalized.
037 CIO observed that two boards with pro-Report No. 24 Open truding nails lying in Cable Tray 1AKA019 11/29/83 (Q Tray) had punctured the cable jacket
'of a "Q" table. The cable is Q-channel A.
'480V. MCC. NCR C00925 was issued by MPQAD on November 22, 1983. CIO will track this item to assure that corrective action (repair) has been performed to approved procedures.
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$ TONE & WEBSTER MICHIGAN, INC.
CONSTRUCTION IMPLEMENTATION OVERVIEW Il0LD POINT LOG SIREARY ORIGINATING CPCo RESPONSE STATUS
.CLOSE-0UT NO.
SUBJECT DOC /DATE DOC /DATE OPEN/ CLOSED DOC /DA7E l
001 Adequacy of drawings A8 - large bore pipe Report No. 6 Letter Closed Report No. 9 hangers. CIO established Hold Point when MPQAD 7/25/83 8/9/83 8/15/83 issued 2 NCRs against the use of red-lined drawings which were volded.,by Project Engineering..
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l 002 Material traceability of installed hangers (E3).
Report No. 6 Letter Closed Report No. 9 l
CPCo response dated 7/1/8.3 indicated report on 7/25/83 8/9/83 8/15/83 material traceability was to be issued in a timely manner. Due to uncertainty of when the report would be issued, a Hold Point was
-established by CIO.
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003 Has a program been developed and responsibilitie!
Report No. 6 Letter Closed Report No. 9 established for personnel assigned to processl 7725/83 8/9/83 8/15/83 nonconformances?
l lias a meeting been held with Project Engineerin'g to discuss methodology of processing non-confomances?
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HOLD POINT LOG
SUMMARY
ORIGINATING CPCo RESPONSE STATUS CLOSE-0UT N0.
SUBJECT DOC /DATE DOC /DATE OPEN/ CLOSED DOC /DATE 004 Evaluation of Phase I Management Review Report No. 1 Letters Closed CIO Letter to Committee meetings.
6/3/83 7/1/83 J.G. Keppler through 8/9/83, dated 10/12/8:
Letter of 6/30/83
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005 CPCo has committed to develop a Vendor Report No. IE-Open Equipment Verification Program. Program is 10/17/83 required before implementation of Phase II.
006 NIRs 002, 003, 004 and 005 issued October 3 Report No. 10 Open 1983 to address discrepancies observed during a sample inspection of Training Records of 6 of 45 MPQAD personnel. Corrective action must be completed before any inspections can be performed by the 45 personnel in question.
007 Evaluation of Management Review of results of Report No. 19 Open Phase I activities.
Evaluation of Management 10/24/83 Review Committee plans and procedures for Phase 11 implementation.
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STONE & WEBSTER MICllIGAN, INC.
CONSTRUCTION IMPLEMENIATION OVERVIEW 110LD POINT LOG
SUMMARY
i ORIGINATING CPCo RESPONSE STATUS CLOSE-00T NO.
SUBJECT DOC /DATE DOC /DATE OPEN/ CLOSED DOC /DATE 008 NIR 006 has been issued on October 27, 1983 to Report tio. 20 Open address discrepancies observed during the sample 10/31/83 inspection of 2,054 Construction Traininq records of 31 members of Teams 5, 6, 8, 9, 12, 13, 10, 17, 19,\\20, 25, 26, (27/28), 29, 30, 31, (32/33) and BH0~ staff.
Corrective action must bexcompleted before any walkdown, assessments can be performed by the personnel in question.
009 NIR 007 has been issued on November 7, 198; to Report No. 21 Open address discrepancies observed during sample 11/7/83 inspection of 834 Construction Training records of 18 members of Team 24, Field Procurement, Sub-Contractors, Management, F.E. staff and Construction General Serivces Organization.
1 g Corrective action must be completed befor'e any walkdown, assessments can be performed by the personnel in question.
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CONSTRUCTION IMPLEMENTATION OVERVIEW HOLD POINT LOG St# NARY i
ORIGINATING CPCo RESPONSE STATUS CLOSE-00T i
NO.
SUBJECT DOC /DATE DOC /DATE OPEN/ CLOSED DOC /DATE 4
j 010 NIR 008 was issued November 14, 1983 to address Report No. 22 Open i
5 unsatisfactory conditions observed during the
' 11/14/83 review of 50 training level assignments re-l presenting a lot size of 318 assignments on the System Team Training matrix of the Con-struction Training Program.
4 Corrective action must be completed before any walkdown, assessments can be performed by the
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personnel in question.
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Ist 011 Prior to lifting of Stop Work Orders relating to Report No.23 Open the FCR/FCN Review and Resolution Program, CIO 11/21/83 i
a has established a Hold Point at the conclusion s
i 3's of Phase II activities to evaluate the adequacy of MPQAD performance during Phase I and Phase II activities. The Hold Point encompasses all the Stop Work Orders with the exception of Stop Work i
Order No. FSW-36 which has been lifted by MP0AD.
l This Hold Point does not apply to Phase III.
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CONSTRUCTION IMPLEMENTATION OVERVIEW ll0LD POINT LOG SUPNARY ORIGINATING CPCo RESPONSE STATUS CLOSE-0UT NO*
SUBJECT DOC /DATE DOC /DATE OPEN/ CLOSED DOC /DATE t
010 NIR 008 has been issued on November 14, 1983 to.
Report No. 22 Open address five unsatisfactory conditions observed 11/14/83 during the review of 50 training level assign-ments representing a lot size 318 assignments in the System Team Tral'ning Matrix of the Construction Training Program.
Correctives action must be completed before any walkdown, assessments can be perfonned by the personnel involved in these training activities.
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i 011 Prior to start of Phase III activities of Report No. 22 Open i
FCR/FCN Resolution Program, CIO has established 11/14/83 1
a Hold Point at the conclusion of Phase II activities to evaluate MPQAD performance.
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