ML20080D514

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Trip Rept of Caseload Forecast Panel 810929-1001 Site Visits Re Const Status Observation & Scheduled Completion Date. Related Info Encl
ML20080D514
Person / Time
Site: 05000000, Fermi
Issue date: 11/24/1981
From: Kintner L
Office of Nuclear Reactor Regulation
To:
Office of Nuclear Reactor Regulation
Shared Package
ML082380886 List: ... further results
References
FOIA-83-498 NUDOCS 8402090147
Download: ML20080D514 (8)
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Text

F-a fu%q[g UNITED STATES s

NUCLEAR REGULATORY COMMISSION o

W ASHINGTON. D. C. 20555 ep,

s...../

Docket No.:

50-341 NOV 2 41981 APPLICANT: Detroit Edison Company FACILITY:

Fermi 2

SUBJECT:

SUMMARY

OF CASELOAD FORECAST PANEL SITE VISIT ON SEPTEMBER 29, SEPTEMBER 30 AND OCTOBER 1, 1981 Introduction Representatives of the NRC (Mr. W. Lovelace, Office of Management and Program Analysis, Mr. Bruce Little, Fermi 2 Resident Inspector, and Mr. L. Kintner Fermi 2 Licensing Project Manager) met with representatives of Detroit Edison Company to observe the status of construction of Fermi 2 and hear applicant's basis for its scheduled completion date.

Principal participants for the applicant were: Mr. W. Fahrner, Manager, Enrico Fermi 2 Project; Mr. R. Vance, Assistant Project Manager for Engineering, and; Mr. S. Noetzel, Assistant to the Manager. Mr. H. Tauber, Vice President, Engineering and Construction, participated in the summary meeting on October 1.

All participants in the meetings are listed in Enclosure 1.

Summary The applicant presented information in accordance with the agenda attached to the meeting notice. On September 30, applicant conducted a tour of major buildings, equipment, and systems.

In an overview of project construction, applicant said. that construction is 87%

completed. One area, the control room, has been turned over to the operations organization. Mechanical erection of the main turbine generator is essentially complete. The initial core loading has been fabricated. Division I equipment in the residual heat removal building is nearly completed.

Power systems have been energiz ]ea. Construction and engineering activities that may impact scheduled completion date (November 29, 1982) include; plant security system design and procurement, modification of liquid and solid radwaste systems, and hydrostatic testing of the reactor pressure vessel. gives a sumary schedule for plant completion, showing impact of certain activities on the scheduled plant completion date.

The applicant said that it planned to recover some schedule slippage by using 2 shifts; for example, for the reactor pressure vessel hydrostatic testing and completion of the reactor internals. This depends partly on obtaining State approval to issue more bonds to support this increased level of construction.

In addition, applicant plans to complete some tasks in parallel, rather than in sequence. For example, checkout and initial operation will be done in parallel with paper work for system hydrostatic testing and completion of installation of hangars.

I I

B402090147 831031

$E 83-498 PDR

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9 Fermi Engineering activities for the orginal scope of work is 93% complete and for new scope of work, including TMI-related work, it is 42% complete; however, all new work has not been completely identified. New engineering work is about 10% of the orginial scope of engineering work.

Presently over 700 engineers and technicians are working on new work such as modifications required for fire protection (Appendix R to 10 CFR 50) and modifications to safety relief valve controls and postion indication (TMI requirements in NUREG-0737).

The purchasing activities are directed and conducted from the site by about 50 employees, including purchasing, inspection of equipment, material control, and warehousing. Except for delivery of the uninterruptible power supply for the plant security system, essentially all materials are expected to be delivered by the first quarter of 1982. The Fermi 2 sumulator, which is not required prior to fuel loading, is scheduled for delivery in the first quarter of 1983. Material purchases are assured of minimum delays by a dedicated expeditor; for example, radwaste system equipment, cables, and pipe hangars.

Craft workers are projected to increase from about 1400 persons now to about 2280 persons in the first quarter of 1982 and then decrease to about 730 in thg._let q"atr of 1982.gipefitters and welders have the largest projected increase, almost double the current number. Availability of craft personnel in the area is good except that availability of construction equipment operators is excellent and the availability of pipefitters is only fair. All craft union contracts expire in mid-1982 except the electriciains contract which expires May 1, 1984. Applicant expects all contracts will be renewed without major work stoppage. Productivity, as measured by work sampling, is slightly above national averages.

The analysis, design'and installation of pipe hangars, restraints, and snubbers for the as-built piping system is being done now.

Reanalysis of stresses has been completed for 8 of 19 total as-built systems in accordance with IE Bulletins 79-02 and 79-14. Temporary supports are adequate for initial tests, so that testing can be done. concurrently with the installation of permanent supports.

Of 13,000 large bor'e pipe hangars and other type supports, about 9,760 have been accepted.

Of 9,630 small bore pipe hangars about 6,600 have been accepted.

The remainder of reanalysis and installation is expected to be completed within i

joutoneyear.

The percentage completion of bulk quantities is:

large bore pipe, 99%; small bore pipe, 85%; concrete 99%; electrical cable, 97%; electrical termination, 85%, and; instrumentation, 85%.

There are a total of 144 preoperational and acceptance tests to be performed after systems are turned over to the operations organization and system checkout and initial operation is completed.

Ninety six percent of the. procedures for these tests have been written and 89% have been approved for use. Thirty-four of the 144 systems have been turned over to operations and are undergoing checkout and initial operation. One peroperational test is underway, but none have been kompleted.

L o

Fermi

. The applicant identified potential schedular problems associated'with the following TMI (NURG-0737) requirements:

II.B.3 - Post Accident Sampling; II.F.2 - Inadequate Core cooling and; III.A.l.2 - Emergency Response Facilities.

Most potential design deficiencies reported in accordance with 10 CFR 50.55(e) have been completed or are pending NRC review. There appear to be no schedular problems with the remainder.

Conclusion The NRC staff obtained sufficient information from the meeting and plant tour to estimate fuel load date. Construction management and control appear to be good; however, it appears to the staff that it is unlikely that the applicant's scheduled fuel load date (November 1982) will be met.

e NRC staff estimates plant construction will be completed sufficiently for fuel loading in February 1984, based on its estimated completion of hydrostatic testing of the reactor pressure vessel in April 1982 and completion of system checkout, initial operation, and preoperational testing within 22 months after hydrostatic testing. This estimate assumes applicant will make up 2 months of the 9 months slippage in the schedule for hydrostatic tests of the reactor pressure vessel and will complete properational testing at a rate near the upper Qnd of the range experienced at other plants.

Mr. H. Tauber strongly disagreed with the staff's estimated plant completion date and stated the plant target date for fuel loading would remain as November 1982. Applicant said that their testing program ::annot be directly compared to that of other utilities because much of the Fermi 2 system testing will be done during checkout and initial operation and hydrostatic testing. Therefore they consider 13 months to be ample time to complete preoperational testing af ter the hydrostatic tests of the reactor pressure vessel are completed.

They expect to complete the hydrostatic testing in December 1981.

The staff said it will monitor progress of construction and testing activities closely.

If major milestones are achieved sooner than we now estimate, the NRC Caseload Forecast Panel will reassess its estimated fuel load dcte, so that routine administrative aspects of licensing activities will not impact fuel loading.

h L.

. Kintner, Project Manager Licensing Branch No.1 Division of Licensing

Enclosure:

As stated cc:

See next page

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Plant Name:

Fermi 2

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i-Applicant Estimated Date:

November 1982

$5.-

NRC Estimated Date:

February 1984 I ry%

i Date NRC Estimate Was Established:

September 29, 1981 - October 1,19gg

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Detailed Discussion of How the NRC Established Independent Estimate:

Caseload Forecast Panel visited the Fermi 2 site to obser Th' bM progress, discuss current status of construction and schedule for project completion during the period of September 29, 1981 through October 1, 193) d M S '-

c D:yp, The Caseload Forecast Panel arrived at the following conclusion:

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1.

The Panel estimates plant construction will be completed sufficiently -

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for fuel loading in February 1984.

This estimate assumes applicant will make up 2 months of the 9 months negative float in the current schedule for hydrostatic tests of the reactor pressure vessel and will complete all preoperational testing at a rate near the upper end of the range experienced at other plants.

The conclusion is based on the following observations by the Panel:

(a)

Current completion status of systems necessary for reactor pressure vessel hydro and associated stress reports.

l

.d (b) Curent completion status of control rod drive systems and reactor internals.

(c)

Current design, procurement, and construction status of plant security system.

(d)

Current completion status of balance of plant systems.

(e) Completion of modification to the liquid and solid radwaste systems.

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(f) Current status of and work remaining to be completed in the reactor 1 '..

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building and RHR complex.

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(g)

Engineering effort for new issues, including TMI-related work is tpg J

42% complete and all new work has not been completely identified.

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, nWWE (h) The pipefitters and welders craft personnel have to almost double

g?M}%p;gga the current force, and availability of these crafts is only fair.g'iigg y

(i) Only 34 of 144 systems have been turned over to operation and are - s;&i g

Only one preoperationa1gg; undergoing checkout and initial operation.

test is underway.

None have been completed.

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UNITED STATES V.

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NUCLEAR REGULATORY COMMISSION o

WASHINGTON. D. C. 20555

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DEC 161982 Docket No.:

50-341 APPLICANT: Detroit Edison Company FACILITY:

Fermi 2

SUBJECT:

SUMMARY

OF CASELOAD FORECAST PANEL SITE VISIT ON AUGUST 24-26, 1982 Introduction The NRC Caseload Forecast Panel for Fermi 2 met with Detroit Edison Company representatives at the Fermi 2 Plant to hear r.pplicant's basis for Fermi 2 currently scheduled completion date'and to observe the status of construction, Participants in the meeting are listed in Enclosure 1.

Selected Detroit Edison Company summary sheets showing Fermi 2 construction status and projected completion are provided in Enclosure 2.

Summary The applicant presented)information in accordance with the agenda attached to the July 27, 1982 me,eting notice. On August 25, 1982, applicant conducted a tour of major buildings, equipment, and systems.

In an overview of project construction, applicant said that it recognizes the official Fermi 2 target. fuel load date of November 1982 cannot be met, and that it plans to officially revise this target date by letter to the NRC. Based on March 1982 projections, the target fuel load date is June 13, 1983. Currently

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there are 5200 people on site of which 2500 are craft personnel,1100 are nuclear operations personnel and 180 are engineering personnel.

In April 1982, the t

main turbine was put on turning gear and Division I diesei generato'rs were I

i., test operated.

In July 1982 the reactor pressure vessel hydrostatic test was

., completed. Division II diesel generator sets will be tested by the end of t.he year. The major construction effort is completion of the radwaste building addition and radwaste system modifications; therefore, 3 shifts are being used for this work. Preoperational tests are being run with 2 shifts. The critical path preoperational test is the Flow - Induced Vibration Test (See Enclosure i

2, sheet 9.)

Installation of reactor internals must be completed by October 9 to meet the target fuel load date; therefore, reactor internals work is being expedited.

The overall project is 90.8% completed (Enclosure 2, sheets 1-5).

Engineering activities peaked in mid-1982. Of a total of 17,575 project engineering documents that have been identified (drawings, specifications, reports), 17,385 have been completed. During the past 12 months, the engineering work required by the new issues resulting from the TMI accident, NRC operating

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license review, and DECO safety reviews has been 70% completed. Original engineering work is 87% completed. Critical path engineering tasks needed to support fuel loading are; modifications required for autor,iatic isolatio.n of RCIC and HPCI (January 2,1983), and as-built pipe stress analyses (April 6, 1983.)

OO A n n >is 2 I m ' %1 I V v v i

y i

. DEC 161982 Procurement activities are performed and managed by about 85 on-site personnel.

These activities include purchasing, receipt inspection, expediting, material control, and warehouse operations. Most activities are related to startup, replacement parts, and building an inventory of stock items to support operation.

All material for radwaste systems has been ordered and all but a few items l

have been delivered. Procurement of spare parts is well underway with more than 59*. of the total on order.

In response to the staff's question, applicant

~

said there are no procurement problems to meet the estimated June 1983 fuel load date.

Craft worker availability is good except for welders who have a high rate of failure to pass qualification tests. Currently there are about 2500 craft workers employed.

In June of this year, several contracts expired', resulting in withholding of services for about two weeks. Most contracts have now been reviewed with a new expiration date of June 1984, except for electricians who have a contract expiration date of June 1983. Boilermakers, glaziers ironworkers and painters are working while negotiating contracts.

Most of the pipe stress analysis of as-build pipe hangers and snubbers has been completed and installation changes made. This program has been extensive over the last two years. Remaining effort includes work on small bore pipe systems and reassessnient of the requirement for snubbers in accordance with i

Fermi 2 Inspection Report No. 50-341/82-08.

No major problems are seen in completing this effort prior to the target fuel load date.

t The percentage completion of bulk qualities is shown on sheet 6 of Enclosure 2.

Remaining work is principally in the electrical area; cable, terminations, and conduit.

There are a total of 143 preoperational and acceptance tests. Of these, two have been completed by the Systems Completion Organization and are ready for turnover to Nuclear Operations as soon as adminstrative procedures are completed.

Four other tests are expected to be completed shortly. A network of tasks needed to complete the tests has been computerized. Sheets 7 and 8 of Enclosure 2 show 16 tasks that are near the critical path to fuel load date. The most

" limiting task is called Control Rod Drive Drive Hydraulic System and Reactor Internals, and it includes the Flow Induced Vibration Test, as discussed above.

The projected fuel load date through this path is 5 weeks later than the June 13, 1983 target date.

Projected fuel load dates for the other-15 tasks near the critical path extended from 9 weeks earlier to 7 weeks later than the target date.

Completion of NRC-required modifications was also described. Of the new issues (TMI or other recent NRC requirements), the fire protection modifications are still under development, safety relief valve in-plant test instrumentation has, not been purchased, and the contract for installation of supports for M

piping attached to the torus has not been made. The completion of corrective actions for design deficiencies (as defined in 10 CFR 50. 55(e)) is planned l

e 9

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3 DEC 161982 to support a June 13, 1983 fuel load date. Some items that may impact that date are; procurer.'ent of Fisher control valves, procurement of new actuator

~

parts for Powell Valves if analysis indicates they are needed, and repair or replacement of torque switches on Limitorque motor operators for valves, if analysis concludes they are needed.

During the meting, the applicant said that some of the welds on jet pumps (inside the reactor) will have to be reworked and'this may impact the target fuel load date by 6 to 8 weeks.

Conclusion The Detroit Edison Company has provided the necessary information for the NRC Caseload Forecast Panel to estimate the Fermi 2 fuel load date.

Data provided in the previous panel visit of September 29, 30 and October 1,1981 was also considered in the panel's current estimate.

The panel believes that the change in the organization to include the Systems Completion Organization for preoperational testing is an improvement over the previous organization and may improve the rate of completion of tests. However there are only a few tests completed to date, so efficiency of the new organization has not been demonstrated.

The panel notes that h major milestone,. reactor pressure vessel hydrostatic test, was completed under the new organization at the end of July 1982.

In its previous visit, the panel estimated this would be completed in April 1982. Five other i

tests have been completed or nearly completed out of 143 total preoperational tests. The appifcant is using a critical path network method to control priorities for construction completion and preoperational testing and to point out problem areas and take corrective action.

l The NRC Caseload Forecast Panel concludes that February 1984 is the earliest date the plant will be completed sufficiently for fuel loading. This is the same date estimated by the panel last year, which indicates the applicant is

. providing manpower and funds at a rate anticipated last year.

The following observations result from information and data provided during the panel's current visit.

l The electrical work appears to require a major effort if it is to be I

consistent with completion of other craftwork. This is based on the large amount of electrical and instrument cable to be installed, terminations to be completed, conduit and hangers to be installed, and i

the rate at which electrical work is currently being done.

New work also appears to require a major effort. The radwaste building l

modifications and security system modifications arose as new work not y,.'

considered in last years estimate. During this review, rework of drywell structural steel was identified as potential new work. The panel expects other new work may arise before completion of the plant for fuel loading.

9 e

f 8

4-DEC 161982 The numbers of preoperational tests completed to date results in a rate of completion less than that required to meet a June 1983 fuel load date.

Another factor that makes a June 1983 fuel load date appear overly optimistic is the large number of punch list items that must be completed af ter test completion.

Mr. Harry Tauber, DECO Vice President of Engineering and Construction, stated that he disagrees with the panel's estimate. He stated that personnel in the While only a few tests preoperational testing organization will increase.He also said that most of the engineering are completed, many are near completion.

analyses are completed so that he believes major construction modifications due to NRC new requirements have been identified and included in their projected fuel load date. Further, punch list items, such as reanalysis of drywell structural steel, may result in no further work, instead of the modifications as assumed in the panel's estimate.

By letter dated October 1,1982, Detroit Edison said the current projected fuel load date for Fermi 2 is seven weeks later than the target date of June 13, 1982, resulting in a current fuel load date projection of August 1,1983.

Detroit Edison is taking steps to try to reduce the current negativity in the schedule.

g' e

L. L. Kintner, Project Manager Licensing Branch No.1 Division of Licensing

Enclosures:

As stated t-cc:

See next page t

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,.Ssteg UNITED STATES

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NUCLEAR REGULATORY COMMISSION

/s.[.f,

. :, C WASHINGTON, D. C. 20555

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^

AUG 2 1,033 Docket No.:

50-341 APPLICANT:

Detroit Edison Company FACILITY:

Fenni-2

SUBJECT:

SUMMARY

OF CASELOAD FORECAST SITE VISI'T ON JUNE 7-9, 1983 Introduction Members of the Nr(C staff comprising a Caseload Forecast Panel for Fermi-2 met with Detroit Edison Company (DECO). representatives at the Fermi-2 facility on June 7, 8 and 9,1983, to hear DECO's basis for its revised scheduled com-pletion date of December 30, 1983, and to observe the status of construction.

Participants in the meeting are listed in Enclosure le Selected summary sheets showing the construction status and the projected completion date for Fenni-2 are contained in Enclosure 2.

Summary The applicant presented infonnation in accordance with the agenda attached to the May 27, 1983, meeting notice with a slightly different order of presentation. On June 8,1983, DECO conducted a tour of major buildings, equipment, and systems. Based on May 1985 projections, DECO stated that its target fuel load date is December 30, 1983.

DECO indicated in its introduction ( Agenda Item 1) to its presentation that it had a number of small problems which were causing its construction schedule to slip from August 1983 to December 30, 1983. An example of this was the vibration problem in the RHR pumps which had delayed the preoperational test

.of this system. With respect to its design and engineering ef fort ( Agenda Item 2), DECO stated that it was now in a " punch list" mode; i.e., it was working to clean out the small unresolved details of the design and/or construction. Whereas the Fermi-2 facility had about 23,000 items on its punch list in August 1982, the list was now down to about one-fifth that number. The applicant also stated that it had completed its piping stress analysis and would be submitting its environmental qualification rep;rt to the NRC staff in early to mid-July. The significant engineering effort not completed was discussed and included satisfying the Appendix R requirements, reconciling the 'as-built" piping stress analysis with the original design and completing the equipment environmental qualifications.

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2 983 AUG 1

With respect to procurement activities (Agenda Item 3), DECO's presentation indicated that its present mode was oriented towards expediting critical parts and materials and transferring the procurement function to the Nuclear Operations group. DECO indicated that some replacement valves were expected to be delivered late and that it planned to install replacements at the.first fuel outage if the affected systems develop any problems. The craft work force availability (Agenda Item 4) was characterized by DECO as good to excellent with no significant problems in this area. As of May 31, 1983, there were about 1890 crafts people on the site, down from the March peak of abou* 2100; about 700 will be on-site by December 1983. A number of contractors htye been demobilized after completing their portion of the facility. There are no labor contracts to be negotiated for the remainder of 1983. Daniel Construction and DECO estimated that the craft work force was working productively about 50 percent of the time.

DECO stated that it had effectively installed all but 480 of the raquired 14,360 large bore pipe hangers and all but 600 of the required 13,200 small bore pipe hangers (Agenda Item 5). The major work effort that remains is a possible reworking of the pipe hangers and restraints resulting from completion of the stress report reconciliations presently being completed. This recon-ciliation was necessitated by the addition of steel supports in the drywell which in turn caused some of the pipe hangers and pipe whip restraints to be moved. The additional steel had been added to accommodate the pool dynamic loads in the torus. This reconciliation process of the "as-built" (i.e.,

relocated) pipe support locations for ASME Class 1 piping will be furnished late in the year, close to the applicant's estimated fuel load date. The staff's position on this matter is that all stress levels of safety-related piping must be demonstrated to be conservatively bounded prior to licensing of the Fermi-2 facility.

The remaining work items on the critical paths and the project schedule (Agenda Items 6 and 13) were discussed by Deco. There was indication of some slips past December 30, 1983, but DECO believes that these limited number of critical paths can be brought into line. With respect to the installation of bulk quantities (Agenda Item 7), DECO stated it has reached about 95 percent completion of the facility. Some of the work not complete is plant painting (65 percent complete by May 1983) and penetration seals (83 percent complete).

The relatively slow closure of those items reported in accordance with Sectior:

i 50.55(e) of 10 CFR Part 50 (Agenda Item 10) was spotlighted by Region III representatives with emphasis on the lack of readily available documentation l

to close out these items. DECO was requested by Region III to expedite the resolution of the outstanding 50.55(e) items so that these items would not delay issuance of the OL at the time of plant completion. DECO agreed to improve its performance in this area.

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s AUG 2 1983 DECO briefly discussed the radwaste systems modifications required to satisfy the pertinent portions of NUREG-0737 ( Agenda Item 14).

No significant problems were identified by DECO.

On June 8,1983, the meeting was continued starting with a discussion of the status of operator training. DECO indicated that it should have 10 SR0's and 15 RO's by December 30, 1983, which would be sufficient to support five shif ts by its estimated fuel load date.

DECO plans to have sufficient qualified operating personnel by the end of 1984 to support six shifts (i.e.,12 SR0's and 12 RO's).

The area that appears to the NRC staff to be the presi;ing (Agenda Item 8).

1t critical path prior to the fuel load is preoperational and acceptance test The large number of " punch list" items plus difficulties in starting up various systems has caused the testing schedule to lag. To support its December 30, 1933, estimated fuel load date, DECO will have to cor.plete and accept about 20 tests per month corresponding to a completion rate of about 15 percent per month.

The staff expressed doubt that this rate could be achieved or sustained based on the experience of other units at a comparable stage of completion.

It was also pointed out that other facilities have many more test engineers at this stage.

[

The security systems modifications (Agenda Item 15) w.e then discussed; no significant problems were identified. The installation of an additional 24 tons steel in the drywell to accommodate the pool dynamic loads ( Agenda Item

16) has been accomplished. The last agenda item (No. 18) discussed was the installation of fire protection for the facility. The staff noted that some items were scheduled for the end of November 1983 which leaves a minimum amount of time for Region III to inspect and accept these items prior to DECO's esti-mated fuel load date of December 30, 1983.

Conclusion Based on the information provided by Detroit Edison and on the observations made during its tour through the Fermi-2 facility, the staff agrees with DECO that construction of the facility is effectively completed.

However, the staff believes that there are numerous small items yet to be corrected (i.e., the " punch list") and these, in turn, have significantly slowed the preoperational and acceptance testing.

Both of these matters were identi-fied in the previous visit of the staff in August 1982 as potential factors which ciuld delay the fuel load date. While the " punch list" items have been greatly reduced since the previous site visit, the staff continues to believe that additional effort must be concentrated on this area to permit the testing program to be accelerated.

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, AUG 2 1983 The staff noted at the conclusion of its visit that there are two additional factors which could potentially delay the fuel load date. The first of these is a possible reworking of the Class 1 piping supports inside the drywell as a result of the reconciliation of the "as-built" piping stress analysis. The second is a potential delay that may result from the limited access in the drywell which could lengthen the estimated two week period presently scheduled to accomplish the induction heating stress improvement (IHSI) program. While it recognizes these factors, the staff does not assign any weight to the:n in arriving at its estimated fuel load date since their impact is speculative at this time.

Based on the foregoing discussion, the NRC staff concludes that the applicant's December 1983 fuel load date is very optimistic. The staff believes that if the preoperational and acceptance testing programs can be accelerated and that accelerated rate maintained, the earliest fuel load date achievable is July 1984.

The staff indicated that they would remain cognizant of the pre-operational and acceptance testing program accomplishments such that a more definitive projection of the fuel load date may be made toward the end of 1983.

Mr. Harry Tauber, DECO Group Vice-President, speaking for DECO stated that he disagrees with the staff's estimate.

It is his belief that DECO's estimated fuel load date of December 30, 1983, is reasonably achievable based on the present organizational structure and the resources available to accomplish this goal.

The staff stated that they would continue its licensing review effort to support the applicant's estimated fuel load date.

M. D. Lynch, Project Manager Licensing Branch No. 1 Division of Licensing

Enclosures:

As stated cc w/encls.:

See next page t

9 pwon o,

UNITED STATES y

).g'( (,g NUCLEAR REGULATORY COMMISSION E

WASHINGTON, D. C. 20555

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ste 12 ten DOCKET N05. 50-416 AND 50-417 APPLICANTS: MISSISSIPPI POWER AND LIGHT COMPANY; MIDDLE SOUTH ENERGY, INC.

FACILITY:

GRAND GULF NUCLEAR STATION, UNITS 1 AND 2

SUBJECT:

SUMMARY

OF AUGUST 21-22, 1979 CASE LOAD FORECAST PANEL MEETING AND SITE VISIT On August 21 and 22,1979, the pariel met with representatives of the applicant (Mississippi Power and Light Company), their architect-engineer, Bechtel Power Corporation, and their NSSS supplier, General Electric Company, to review the construction and preoperational testing progress at the Grand Gulf Nuclear Station (GGNS) Unit 1 and to estimate the most likely fuel load date.

The previous caseload forecast panel visit in May 1978 (report dated June 7, 1978) had predicted a fuel load date of March 1981, compared to the applicant? s estimate of October 1980. The forecast panel.'s estimate was influenced by con-cerns about:

(1) the lack of qualified electricians and (2) the potential pro-blem of conflicts between the actual construction schedule and the startup test program schedule needed to support the fuel load date. The applicant met with NRC staff on January 9,1979 (report dated January 23, 1979) to state their belief that they had overcome these problems, had identified and solved otner potential problems, and were still predicting a fuel load date of October 1980.

It was agreed to conduct another caseload forecast panel visit in August 1979.

The panel met at the construction site on August 21; 1979 and was briefed on the plant! s status during the morning.

In the afternoon the panel toured the plant and inspected the status of construction. An exit meeting was held on August 22, 1970 at the applicant? s offices in Jackson, Mississippi.

The i

meeting agenda and attendees are listed in Enclosures 1 and 2 respectively.

The handouts provided at the meetings are available from Dr. Cecil Thomas, the LPM.

By way of introduction, the applicant reiterated the company's financial and resource conmitment to their predicted fuel load date of October 1980. Their need for powr from Grand Gulf Unit 1 is based upon a reserve capacity goal of 16% of annual peak load, and a projected crowth rate of 6.7% per annun.

(Their actual 1978 growth rate was 8.9%). With the station 17 operation in 1981, their reserve would be 22%; without it, only 12.4%. They hoped to show the panel that they would be able to meet tho October 1980 date although their latest startup testing milestone chart showed November 21, 1980 for fuel load.

The status of plant design,. procurement, manpower, construction, and the startup preoperational test program is discussed below.

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SEP 121979 Plant Design Plant design is being handled by Bechtel Power Corporation both at Gaithersburg, Maryland and at the plant site. Bechtel estimates the design effort is 90% com-plete on Unit I and comon facilities required for Unit 1 operation. They have shifted their emphasis to three items:

(1) an acceptability analysis of installed equipment that vary from design parameters; (2) Mark III containmer:t questions; and (3) the testing program. The applicant anticipated little diffi-culty in complying with the applicable requirements of NUREG-0578, "TMI-2 Lessons Learned Task Force:

Status Report and Short-Tenn Recommendaticns,"

but expressed concern and a strong desire that long-term requirements for boiling water reactors, especially BWR6/ Mark III systems, be identified as soon as pos-sible to permit them to meet their fuel load date.

P rocurement Procurement of bulk quantities aopears to be in good shape and is estimated now at 90% overall. This represents a reduction in the applicant'.s estimate made during the last panel visit due to a significant increase in required wire and cable, conduit, and cable tray.

The applicant stated that the lead time for cable has doubled and is beginning to restrain them. To minimize the impact, they have scoured the country and all dealing with other companies to reduce lead times. They currently have enough cable on hand to meet the condensate and feedwater flush milestone of Septemoer 1979 and feel that the problem is well in hand. HVAC equipment is a concern of the applicant. They have replaced their previous subcontractor in this area and have found that not only was procurement behind, but also the subcontractor had not even designed some fire dampners and registers. This will impinge on instrument installation but again they feel confident they can overcome the problem. Some equipment shortages are being met by substituting Unit 2 itens. The Unit 2 Power Genera-tion Control Complex is expected in September from General Electric and must be in place before the ccmmon control building can be closed and HVAC installed.

The applicant is now sending their own representatives to any supplier which they feel could impact on the plant schedule.

Ma power Manpower problems appear to be solved. Three actions have been + en by the applicant which have improved the quality and quantity of manual..ibor:

(1) the wage rate was raised from the Jackson, Mississippi rate to an "eight city average" wage rate; (2) this rate will be adjusted annually each January, thereby satisfying local unions; and (3) the work week was increased to 48 hours5.555556e-4 days <br />0.0133 hours <br />7.936508e-5 weeks <br />1.8264e-5 months <br />, consirting of four ten-hour days and one eight-hour day with additional overtime up to a total of 55 hours6.365741e-4 days <br />0.0153 hours <br />9.093915e-5 weeks <br />2.09275e-5 months <br /> permitted. This third action attracts the more skilled labor which seeks overtime work, and also allows the company to get a forty-hour work week prior to Friday when severe absenteeism cuts the work force by 15 to 25%. The current job site population now totals 4400 (Bechtel 2945) with several hundred additional manual workers.

Installation 4

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, SEP 1 2 197J rates have increased significantly (wire and cable 59%, conduit 132%) with the Productivity, as measured by Bechtel and the applicant, appears 48 hour5.555556e-4 days <br />0.0133 hours <br />7.936508e-5 weeks <br />1.8264e-5 months <br /> week.

to have improved and remains within their manhour budget as adjusted for the increased bulk quantities.

In this panelf.s opinion, the concern over the craft workforce, expressed during the last caseload panel visit has bean resolved.

Construction Construction progress was reported as 82% overall with an average rate of 1.75%

per month fran December 1978 to June 1979 and 2.25% from June 1979 to August 1979.

At these rates, the applicant and Bechtel stated that they expacted to be completed with construction in June 1980 or April 1980 respectively.

How-ever, they agreed with the panel that these rates will slow as construction nears completion because of interferences, nearly filled trays and conduits, and testing requirements. A more realistic projectf un, they stated, was that the plant would be 94% to 98% complete in October 1980, at which point fuel The panel considers this optimistic, particularly considering could be loaded.

the conflicts which will arise with respect to preoperational testing while completing systems.

Concrete work is 98% complete with the steam tunnel being the major job left.

Pipe hangers are 72% ccmplete, not including any modifications, or additions Wire and cable is only required by reanalysis of the Mark 111 containmsnt.

63% complete, with conduit at 73% and connections at 52%. The applicant is vigorously attacking this difficult area. The unit one cooling tower repairs were just commencing during the panel!,s visit. Other construction prnblems were identified by the applicant, including placement of the main turbine and the hydrostatic test of the service water system; however, they felt neither would impact on the fuel load date. The HVAC subcontractor problem discussed previously is causing scheduling problems which the applicant again feels they have under control.

Startup Preoperational Test Program The startup preoperational test' program and milestones were outlined by the They consider a perind of eighteen months, from plant energization appl icant.

in May 1979 until November 1980, sufficient to accomplish this, despite their original estimate of two years. The actions taken by the applicant to achieve this are:

(1) more careful planning of preoperational tests to dovetail together in a shorter schedule; (2) a shift from bulk installation of commo-dities to a systems completion approach, (3) the establishment of task forces called " Systems Completion Groups" to oversee systems and critical path mile-stones; (4) the addition of ten more rtartup engineers from consulting firms; and (5) hiring a new assistant plant manager with ten years of BWR experience.

The panel considers the preoperational test schedule as the major delaying item for plant fuel load. Our reasons are as follows:

j

i-j' SEP 121gp3 Recent experience with other new generation plants indicates that a two-year 1.

test schedule (beginning at plant energization) is average.

In addition, the period from reactor pressure vessel hydro to fuel load for recent BWR's has taken. on average, ten months, whereas Grand Gulf is planning on only seven.

These time spans would place the applicant.',s fuel load between February and May 1981.

Because construction is not further along, the applicant has made a late 2.

start considering their November 1980 target date.

For example, they do not plan to meet with the Region II inspectors to discuss test procedures until early October and the bulk of testing does not commence until early 1980.

The Susquehanna 1 plant, also a BWR with Bechtel as the architect-engineer, 3.

is ahead of Grand Gulf 1 in both construction and test schedule, and yet it is now listing March 1981 as its fuel load date.

The completion of electrical work will almost certainly interfere with and 4.

delay preoperational testing.

Conclusion The applicant has made dramatic progress in actual construction since the last caseload forecast panel meeting and has used aggressive managerial techniques to overcome labor and material problems. The applicant now predicts a November 1980 fuel load date and is pressing for October 1980. However, the panel feels this prediction is overly optimistic. Ignoring the possible delays which could be caused by TMI-2 related requirements, Mark III containment questions, and HVAC or PGCC problens, we estimate a fuel load date of April 1981 based on the length of time required for preoperational testing, the probable adverse impact on the test schedule resulting from final electrical work, and ur. foreseen delays, which may develop in the construction work that still must be completed. At the exit interview the panel discussed these conclusions with the applicant.

In addition, the panel stressed the conmit-ment of the NRC Staff to complete its licensing review in a timely but thorough manner so as not to delay plant operation unnecessarily.

//A, c. NSF Thomas C. Houghton h Light Water Reactors Branch No. 2 Division of Project Management l

Enclosures :

1.

Site Visit Agenda Att ndance List 2.

e ccs w/ enclosures:

1 See next page l

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