ML20082M246

Suppls 831121 Response to NRC Re Util Course of Action.Responses to Questions 16,17 & 2 Encl.Responses Do Not Reflect Replacement of Hj Kaiser W/Bechtel as Constructor

ML20082M246
Person / Time
Site:	Zimmer
Issue date:	11/29/1983
From:	Williams J CINCINNATI GAS & ELECTRIC CO.
To:	James Keppler NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III)
References
LOZ-83-0238, LOZ-83-238, NUDOCS 8312060066
Download: ML20082M246 (36)

Text

_

t TIIE CINCINNATI GAS & ELECTRIC COMIbNY dE" "

CINCINN ATI,OH10 45208 November 29, 1983 LOZ-83-0238 J. WILLI AM S, JR SENSOR VICE PRESIDENT NUCLEAR OPERATIONS PRIN91 PAL STAFF Docket No. 50-358

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U.S. Nuclear Regulatory Commission f/iu

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Region III E

799 Roosevelt Road y) gg _hJ V Glen Ellyn, Illinois 60137 za L

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" i R) f(2[3 Attention:

Mr. J.G. Keppler Regional Administrator Gentlemen:

RE:

WM. H. ZIMMER NUCLEAR POWER STATION - UNIT 1 CG&E COURSE OF ACTION W.O.

57300, JOB E-5590, FILE NO. 956C, This supplements my letter of November 21, 1983 and provides further responses to cuestions contained in your letter dated November 15, 1983.

Attached are responses to NRC Questions 16 and 17, and u aupplemental response to NRC Question 2.

Please note that these responses do not reflect the replacement of H.J.

Kaiser with the Bechtel Power Corporation as Constructor.

This change will significantly reduce the Kaiser supervision from that shown in these responses.

In addition, some copies of the previous response did not contain our responses to NRC auestions 23 and 24.

Additional copies of these responses are also attached.

Very truly yours, y

THE CINCINNATI GAS & ELECTRIC COMPANY 1 m By

~ JR./

IAM3 SENIOR VICE PRESI ENT GCF/cse 8312060066 831129 PDR ADOCK 05000385 PDR A

NOV 3 01983

, /

Mr. J.G. Keppler Regional Administrator November 29, 1983 LOZ-83-0238 Page 2 cc:

NRC Office of Inspection & Enforcement Washington, D.C.

20555 NRC Resident Site Supervisor ATTN:

W.M. Hill, Jr.

NRC Zimmer Project Inspector, Region III ATTN:

E. R. Schweibinz NRC Office of Nuclear Reactor Regulation ATTN:

D.G. Eisenhut L.L. Kintner NRC Office of the Executive Legal Director ATTN:

Jim Lieberman I

I-l

RESPONSES TO NRC-COA QUESTIONS - ROUND 2 ENCLOSURE 1 Question 2:

There is a need for CG&E to have a formalized methodology to determine validity of documents which may be used to justif y adequacy of SSCs. Describe the key elements of your methodology.

Response

The details of a formalized methodology to determine validity of purchase order, installation and other quality documents which may be used to justify adequacy of SSCs are described in implementing procedures and instructions (e.g. PVQC Procedures and Quality Verification Instructions and checklists.) In summary this methodology consists of first identifying the quality documents required, reviewing their function or purpose, and determining the specific requirements of the applicable design specifications, regulatory codes, and project commitments. These requirements are documented on detailed checklists prepared in accordance with project procedures.

Then the project quality documents are reviewed to determine if these requirements are included and if the inf ormation provided on the document is valid. This process is accomplished by:

1) Determining if the procedures for preparirg the document were followed.

2) Determining if the individuals performing the work and the individuals inspecting the work were properly qualified and/or certified.

3) Determining if the required information is provided and is correct and properly supported.

4)

Comparing the document to the as-constructed condition through visual and physical inspection to verify its ac cu racy.

The following is a typical example of document reviews that may take place to check the adequacy of a valve or an ins trument.

The document reviews would typically censist of three major steps as follows:

1.

Pre-Purchased Document Review The document reviewers would check the purchase order to assure that the design specifications and regulatory and code requirements were detailed in the purchase order to the vendor.

A review is made to assure that QA requirements are provided for in the purchase order.

These QA requirements typically include provisions for the vendor to 1) qualify their sub-suppliers, 2) specify the records required of the vendor (such as data sheets, performance curves, CMTRs, code data sheet s,

Page 2 shipping and storage requirements, etc.) and 3) properly document nonconformances and/or purchase order j

exceptions. Any special shipping requirements, record l_

retention requirements, and document review approval by the vendor will be reviewed for inclusion in the purchase order if required by specification or code.

Any source inspection or audit requirements will be reviewed for inclusion in the purchase order. Pa st Zimmer problems from audit reports, NCR inspection reports, etc., are also reviewed to identify any additional requirements.

Once the requirements are identified, they are incorporated into the QV checklf sts, which will be utilized for the detailed review and verification of the receiving and installation documentation.

Provisions in the purchase order for documents, such as 4

specifications, that are to be sent to the vendor, will l

be reviewed.

The approved vendors list ( AVL) will be checked to assure the vendor was qualified to supply material during that time period.

II.

Receiving Documentation The receiving documentation review includes jobsite receiving reports, documentation f rom vendors, and source inspection reports (when required).

Receiving reports (MRRs) will be reviewed according to the checklist to assure the quality-related aspects of the document are properly completed for such things as quantity and description of material received. In addition, receipt inspection reports are reviewed to assure that the form 1) is adequate for the purpose intended, 2) is properly completed (noting exceptions

, as required), 3) properly identifies the material, 4) identifies the required documents, and 5) is traceable to the material.

In addition these receipt inspection

[

j reports will be reviewed to assure that configuration checks, which are required to be performed upon receipt, were actually made, proper storage was i

provided, and nonconformance or discrepancies were identified.

]

[

Documentation f'om the vendor is reviewed according to the checklist to assure that it meets the purchase

-order requirements. A review of the documents will be made to assure that the required technical or purchase order forms are included.

Also, source inspection releases, if required by the P.O., will be reviewed.

Where concern exists that documentation may have been falsified, additional checks against vendor retained data and the results of visual and physical tests, will i

be made.

m

-. -. ~

Page 3 l

Finally, the source inspection reports, and audit and shop releases will be technically reviewed for adequacy.

III. Storage, Maintenance, and Installation Documents As part of a separate review, storage and maintenance documents for safety-related SSCs will be reviewed against pre-defined checklists to assure that thes e SSCs meet vendor and design specifications.

Installation documents will also be reviewed against pre-defined checklists.

The inspection documents will be reviewed to assure the forms are adequate for the purpose intended.

The data on the document will be reviewed to assure that required inspections have been made, hold points have been verified, cleanliness requirements have been met, special processes have been performed (such as non-destructive examinations),

inspectors have been certified and craf tmen have been qualified (when required), and nonconforming items have been documented. Where concern exists that documentation may have been falsified, additional checks against vendor retained data and the results of visual and physical tests, will be made.

Questions & Comments on the Course of Action (COA)

Page 19

16. Mr. Dickhoner's COA transmittal letter. states approval of a substantial increase, approximately doubling the staffing, in the number of CG&E people assigned to the accomplishment of the work which lies ahead.

Provide an organization chart which indicates where the old and new CG&E personnel are.or will be assigned.

Organization charts providing the response to this question are attached.

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Q U A LIT Y ASSURA'NCE DEPARTMENT 4

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APPENDIX A i

i

Questions & Comments on the Course of Action (COA)

Enclosure'l Page 20

17. Provide information indicating which present and former managers and supervisors of CG&E, HJK, S&L and GE in place at the time of the Show Cause Order will still be in responsible positions under the organization described in the COA.

If such managers or supervisors will be in positions different from positions occupied prior to the Show Cause Order (SCO),

identify both the old and new positions.

How and to what extent has CG&E assured itself that these individuals can be relied upon to identify and correct problems at the site?

Present CG&E managers and supervisors are indicated on the organization charts provided with our response to Question 16, and those who held different positions at the time of the Show Cause Order are listed on Attachment 1 to this response along with their former and current positions.

Listed on are all present and former HJK, S&L, and GE managers and supervisors located at the jobsite along with their present and former positions / status on the Zimmer project.

As stated in the response to the initial set of NRC questions on the COA (Figure 2, No. 4), CG&E has reviewed the resumes of management personnel on Figure 2 and Mr. Williams has personally interviewed each of the CG&E persons who were reassigned from previous Zimmer assignments.

CG&E and Bechtel will also be interviewing key H.J. Kaiser personnel.

Questions & Comments on the Course of Action (COA)

Page 21 In addition, the reorganization and restructuring of the various organizations, along with CG&E bringing in an experienced Project Director (Bechtel) to direct and oversee these organizations, will help ensure that individuals are kept accountable for their responsibilities and can be relied upon to identify and correct problems at the site.

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' ATTACHMENT 1 TO QUESTION 17 RESPONSE PERSON POSITION AT TIME OF SCO CURRENT POSITION Nuclear Engineering Department (NED)

R.L. Thoney Engineer Ar: ting Director - Planning Start-up Testing Department (STD)

J. Aufdekamp Test Coordinator-Leak Rate Test Coordinator-NSSS Nuclear Project Controls Department (NPC)

B.K. Culver Manager, Generation Construction Manager - NPC Department (GCD)

G.E. Bennett Director-Systems Support Director-Project Records Group, GCD Management W.D. Corbin Startup Scheduler, NPD Director-Planning &

Scheduling S.E. Martin Procedure Writer, GCD Director-Management Information W.B. Murray Director-Project Controls Director-Cost Control, Group, GCD Cost Estimating Nuclear Construction Department (NCD)

W.N. Tobler Senior Shift Engineer Assistant to the Manager D.J. Schulte Q.A. Engineer Director-Codes and Stand-ards Compliance B.A. Gott Structural Engineer Lead Structural Engineer PVOC & Nuclear Project Support Services Department G. Orlov Assistant Director, Director, PVQC Quality Confirmation Program (OCP)

N. Bannerjee Quality Engineer,QAD Supervisor - Document Review & Inspections

--g

. to Question 17 Response (cont'd.)

R. Kare Administrative Asst.,0CP Supervisor - Program Assessment Nuclear Production Department (NPD)

G.A. Appel Station Chemist Superintendent-Chemistry T.W. Cummins Shift Supervisor Superintendent-Radwaste J.A. Jaap Engineering Assistant Assistant Superintendent-Operations D. Outcult Associate Engineer -

Plant Shift Director Startup P.A. Russ Associate Engineer -

Plant Shift Director Startup Radiological & Environmental Controls Department (REC)

D.L. Erickson Rad-Chem Supervisor, NPD Director, REC Nuclear Licensing Department (NLD)

G.C. Ficke Director-Nuclear Licensing, Manager - NLD Licensing & Environmental Affairs Department (LEAD)

Quality Assurance Department (OAD)

I J.F. Shaffer Director, QCP Manager - QAD R.E. Spence Director - Startup QA/QC Director - Quality l

Engineering J.M. Smith Procedure Writer - Program Director - Inspections l

Development and Surveillances i

. ATTACHMENT 2 TO QUESTION 17 RESPONSE GENERAL ELECTRIC - JOBSITE MANAGERIAI/ SUPERVISORY PERSONNEL PERSON POSITION AT TIME OF SCO CURRENT POSITION 4

T. Bloom

. Site Resident Manager Same W. Heaton Site Electrical Manager Same S.C. Quijano Not assigned to project Site QA Engineer J.A. Steininger Not assigned to project Operations Manager l

M. Dick Site QA Engineer Not assigned to project I

l A.I.. - Jenkins Operation Manager Not assigned to project 1

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L Page 1 of 11 l,

i SARGENT & LUNDY - JOBSITE MANAGERIAL / SUPERVISORY PERSONNEL PERSON 90SITION AT TIME OF SCO CURRENT POSITION T. Daley Field Project Manager Same B.F. Murphy Nuclear Power Services Same Project Engineer H.N. Jamison/J. Eng.

Electrical Coordinator Same B.H. Larson Structural Coordinator Same R.J. Suslick Not assigned to project Asst. Field Project Phnager T.J. Muzalski Not assigned to project Mechanical Design Coordinator D.D. Felkins Not assigned to project Skid Walkdown Task leader A.L. Kapil Non-supervisory project Seismic Separation Survey Task position lead er A. Sengupta Non-supervisory project Seismic Separation Study Task position leader J.E. Rodriguez Not assigned to project Quality Control Field Co ordina t or D.B. Walker Not assigned to project Joint Test Group Nbmber B.L. Weinhold Not assigned to project Piping Support Field Co ordina t or J.L. Vagt Non-supervisory project Support Design Section leader position G.Z. Girgis Not assigned to project Piping Analysis Field Lead Engineer J.E. Grundman Piping Support Field Engineer Not assigned to project M.A. Milad Support Design Section Leader Not assigned to project L. Fergusson Piping Analysis Field Lead Not assigned to project i

Engineer l

Page 2 of 11 i

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H.J. KAISER - JOBSITE MANAGERIAL / SUPERVISORY PERSONNEL PERSON POSITION AT TIME OF SCO CURRENT POSITLDN ADMINISTRATION & SERVICE DEPT.

D. Richardson Non-supervisory project Department Manager position B. Ferree Warehouse Supervisor Same D. O'Keefe Purchasing Manager Same i

J. Hill Non-supervisory project Accounting Supervisor position R. Wieskamp Not assigned to project Of fice Services Manager E. Mendez Not assigned to project Training Supervisor D. Taylor Not assigned to project Document Control Supervisor B. Rokey Accounting Supervisor Not assigned to project B. Wilson Of fice Services Supervisor Not assigned to project G.G. White Training Supervisor Not assigned to project J. Bradford Document Control Supervisor Not assigned to project C. Yohe Construction Services Manager Not assigned to project Page 3 of 11

H.J. KAISER - JOBSITE MANAGERI AL/ SUPERVISORY PERSONNEL PERSON POSITION AT TIME OF SCO CURRENT POSITION CONTROLS DEPT.

B. Scott Department Manager Same R. Faria Not assigned to project Lead Schedulirg Supervisor 1

See Note (1)

See note (2)

Lead Estimator See Note (1)

See note (2)

Lead Cost & Engineer (1) Position is currently open.

(2) Position did not exist at this time.

ENGINEERING DEPT.

B. Evans Electrical Dept. Manager (1)

Department Manager M. Goedecke Welding Manager Technical Engineer Supervi sor W. Cureton Not assigned to project Equipment Sup ervis or Turnover Supervisor M. Butterworth Non-supervisory project Welding Manager position (1) See Electrical Dept, b

1 i

Page 4 of 11

H.J. KAISER - JOBSITE MANAGERIAI/ SUPERVISORY PERSONNEL PERSON POSITION AT TIME OF SCO CURRENT POSITEDN INDUSTRIAL RELATIONS DEPT.

S. Armkneckt Not assigned to project Department Manager C. Lowe Safety Supervisor-Same J. Heffner Not assigned to project Personnel Manager D. Biller Personnel Manager N t assigned to project o

PROJECT MANAGEMENT M. Noffsinger Not assigned to project Project Director K. Dempsey Construction Mgr. - 1st shif t Project Nhnager J. Connor Construction Mgr. - 2nd shif t Construction Mgr. - 1st shif t M. Albertin Project Manager Not assigned to project PIPING DEPT.

R. Cranston Department Manager Same J. Crossman General Superintendent Same J. Taylor Not assigned to project Piping Engineer Supervisor R. Maroske Design Supervisor Same T.R. Bietsch Piping Engineer. Supervisor Non-supervisory project position Page 5 of 11

H.J. KAISER - JOBSITE MANAGERIAL / SUPERVISORY PERSONNEL PERSON POSITION AT TIME OF SCO CURRENT POSITION ELECTRICAL DEPT.

J. Mullen Construction Engineer Department Manager D. Schwartz Not assigned to project Project Electrical Engineer B. Evans Department Manager Engineering Dept. Manager (1)

E. Kwalick Project Electrical Engineer Not assigned to project (1) See Engineering Dept.

CIVIL DEPT.

C. Clifton Department Manager Same G. Adams General Superintendent Same M. Soyoguz Project Civil Engineer Same Page 6 of 11

.~ _ _.

H.J. KAISER - JOBSITE MANAGERIAL / SUPERVISORY PERSONNEL 1

J PERSON POSITION AT TIME OF SCO CURRENT POSITION QA MANAGEMENT R.A. Davis Quality Control Manager Site QA Manager W.A. Hedzik Site QA Manager Not assigned to project QA ADMINISTRATION B.D. Varchol QA Adr.inistration Manager Same E TRAINING J. Danner Training Supervisor Same i

QA PROCEDURE COMMITMENT R.F. Becraft Supervisor Same NR/ CAR COORDINATION t

1 J. Killinger Non-supervisory project Coordinator position B. Eckman Coordinator Non-supervi sory project, s

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H.J. KAISER - JOBSITE MANAGERIAL / SUPERVISORY PERSONNEL i

l PERSON POSITION AT TIME OF SCO CURRENT POSITION QUALITY ENGINEERING K. Graybill Not assigned to project Quality Engineering Manager D. McCulley Supervisor Electrical Same K. Bishop Non-supervisory project Senior Supervisor position J. Moskawa Not assigned to project Supervisor Mechanical M. Boorady Non-supervisory project Supervisor Civil position R. A. Ausherman Quality Engineering Manager Not assigned to project R. Staymates Supervisor Mechanical Not assigned to project E. Wagner Supervisor Welding Non-supervisory project position F. Householder Supervisor Civil Non-supervisory project position R. Lawton Supervisor Calibration and Not assigned to project Receiving Inspection Page 8 of 11 1

H.J. KAISER - JOBSITE MANAGERI AL/ SUPERVISORY PERSONNEL PERSQ4 POSITION AT TIME OF SCO CURRENT POSITION QUALITY CONTROL C.W. Smith Supervisor Civil Quality Control Manager P. Norman Supervisor Mechanical Same C. Melton Supervisor Hangers Same D. Donovan Non-supervisory project Supervisor Civil position C. Cherry Supervisor Calibration and Same Receiving Inspection J. Collins Not assigned to project Supervisor Electrical R.A. Davis Quality Control Manager Site QA Manager R. Prewitt Supervisor Night Shift Non-supervisory project position Page 9 of 11

H.J. KAISER - JOBSITE MANAGERIAL / SUPERVISORY PERSONNEL PERSON POSITION AT TIME OF SCO CURKENT POSITION QA RECORDS J. Murray Cupervisor Senior Records Manager M. Bussell Non-supervisory project Supervisor Senior position R. Nonell Non-supervisory project Supervisor Senior position M. Edmonds Not assigned to project Supervisor Senior J. Cochran Supervisor Hangers Same W. Biehle Supervisor Electrical Same D. Damewood Non-supervisory project Supervisor Pre-Purchase position T. Zeak Non-supervisory project Supervisor Piping position F. McCrystal Non-supervisory project Supervisor Civil (Structural) position S. Connor Supervisor Records Control Supervisor Civil (Containment)

G. Fones Records Manager Not assigned to project M. Peel Supervisor Pre-Purchase Non-Supervisory project position B. Swift Supervisor Piping Not assigned to project T. Royster Supervisor Civil Not assigned to project AUDIT W. Fritz Non-supervisory project Supervisor - Audits position Page 10 of 11

- - =- _ _ _.., = _ _ -

i l

WM. H. ZIMMER NUCLEAR POWER STATION

SUMMARY

OF MANAGERIAL / SUPERVISORY PERSONNEL POSITION STATUS I

BY ORGANIZATION I

NUMBER OF PERSONS / CATEGORY POSITION STATUS CATEGORY Gd S&L HJK j

1) Assigned as manager /

2 5

21 supervisor at SCO and currently assigned to same position at jobsite i

2) Assigned as manager /

0 0

8 supervisor at SCO and currently assigned to new managerial /

supervisory position at

}

jobsite i

3) Assigned to non-0 3

12 supervisory position at SCO and currently assigned managerial /

supervisory jobsite position

4) Not assigned to project 2

7 14 at SCO and currently assigned managerial /

supervisory jobst,te position 1

. Total number of managers 4

15 55 and supervisors currently i

assigned to jobsite (total of categorien 1-4)

5) Assigned as manager /

2 3

15 supervisor at SCO and currently not on project

6) Assigned as manager /

0 0

6 supervisor at CCU and currently a. signed to non-supervisory position at jobsite 1

Page 11 of 11

V.

Questions & Comments on the course of Action (COA)

Page 30

23. Has the Master Training Plan been developed?

If it has not, when do you expect it to be completed?

The Master Training Plan is being developed.

It is expected to be comoleted in December.

V.

Questions & Comments on the Course of Action (COA)

Page 31

24. Define the terms " project direction", " administrative direction", and " access", as used in Figures 1 and 2, Volume 1 of the COA.

The Project Manager provides " project direction" through the establishment of policies, procedures, project objectives and daily communication with key staff members and contractor management.

Project direction indicates the individuals or functions with direct line responsibility for implementation of organizational and departmental activities consistent with the direction of the Project Manager.

" Administrative direction" indicates the individuals with key communication interfaces required on a day-to-day basis to ensure that the Project Manager's directions are carried out and activities are coordinated and consistent with project obj ectives.

Where it was considered advantageous for individual positions or functions to advise, review, recommend or otherwise communicate outside the conventional direct line authority on matters important to the construction and operation of the Zimmer Project, a formal direct " access" path was identified for such communications.

Changes in policy or direction as a result of such communication will be directed in accordance with established policies and procedures by the individuals

Questions & Comments on the Course of " Ouion (COA)

Page 32 l

with direct line responsibility for construction or operation of the project.

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