ML20083J053

Forwards Bechtel Response to Observations 036 & 038 Re Control of Proposed Field Changes & Checklists Assuring Consistency During Status Assessment & Hanger Installation, Respectively

ML20083J053
Person / Time
Site:	Midland
Issue date:	01/05/1984
From:	Quamme D CONSUMERS ENERGY CO. (FORMERLY CONSUMERS POWER CO.)
To:	Baranow S STONE & WEBSTER, INC.
References
CSC-7134, NUDOCS 8401160145
Download: ML20083J053 (11)

Text

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Consumers

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Power o a ' o ---

I py y Site Manager a

wusse min Midland Project M r4

PO Sox 1963, Mdand. MI 48640 + (517) 631-8650

l. Sgyp 5Dd30 m l ~ f.E_

~~'L n January 5, 1984 n3-Mr S W Baranow Stone & Webster Michigan, Inc P O Box 1963 Midland, MI 48640 MIDLAND ENERGY CENTER GWO 7020 OBSERVATIONS NO 036 & NO 038 File:

Bl.l.7, 0655 UFI:

99*08, 53*50*04 Serial:

CSC-7134 Attached is Bechtel's complete response to your Observations No. 036 and No. 038.

Please advise if this response is adequate to close out these observations.

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DLQ/DDJ/ kip cc: JGKeppler, NRC Region III w/a

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JJHarrison, NRC Region III w/a RJCook, NRC Site w/a BHPeck, MEC w/s-RAWells, MPQAD w/a NIReichel, MEC w/a P

e 8401160145 840105 PDR ADOCP. 05000329 A

PDR UAN 1 1 I904

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Bechtel Power Corporation Post Office Box 2167 Midland Michigan 48640 December 30, 1983 Consumers Power Company P.O. Box 1963 Midland, MI 48640 Attention:

D.L. Quarme Midland Plant Units 1 & 2 Bechtel Job 7220

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REVIEW OF STONE & WEBSTER'S CCP OVERVIEW REPORT NO. 26 BCCC-8864

Dear Mr. Quamme:

Construction's review of Stone & Webster's Overview Report No. 26 id=4tified two (2) open (Construction) action items, specifically, Observations Nos.

36 and 38.

Detailed below is our complete response on the observations:

Observation No. 36s Ccatrol of field proposed changes are governed by FFD-2.000.

FPD-2.000 o

will continue'to allow use of FCNs for both "Q" and "Non-Q" items.

There has not been any deviation from this practice in the past, nor do we anticipate any change in the future. FCNs will still be utilized as a method for controlling field changes for both "Q" and "Non-Q" items.

Observation No. 38:

The checklists as shown in Attachment "N" of FPM-7.000 and Attachment "B"

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of FPM-9.200 or otherwise developed by the field, are intended to be used as guidelines / aids by the team field engineer (s) to assure consistency during status assessment and hanger installation.

The checklist is not intended to cover in detail every hanger in every situacion or to substitute for requirements called for in the technical documents.

Therefore, the checklist will not govern field engineering inspection / acceptance and will not be retained for record purposes. The design drawings, procedures and specifications contain the key requirements for hanger installation and inspection.

T'.

field engineer (s) and superintendent's acceptance of completed work is shown by the signoff of the Construction Work Package (CWP) (FPG-7.300) which accompanies each "Q" hanger.

In addition to the CWP, the field engineer is required to initial the P119/129 form (Stress Walkdown Form)

Bechtel Power Corporation D.r., Qu s e BCCC-8864 Page 2

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signifying that installation meets design requirements for all "Q" and critical non-Q hangers.

(See setached letter D.B. Miller to J.A. Rutgers, Section 7.d. Serial CSM-0655, dated 7/1/83: Management Review Meeting, May 18, 1983.)

If you have any questions concerning the above, please contact B.T. Foote at Ext. 7507.

Very truly yours, h 8 blFf G.A. Hierzer Site Manager n.ht GAH/ MAD / R/BTF/MRM/lec Written Response Requested: No Attachmentss (1)

D.B. Miller-ltr. to J.A. Rutgers, dated 7/1/83 Serial CSM-0655 (2) Copies of Observations Nos. 36 & 38 CC:

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MIDLAND INERGY CENTER 4 S_.,.... MANAGEMENT RrpIEW MEET'ING7 MAY 18 "1983 M O '

Reference:

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$W' STATUS REPbRT AND CIASURE10F ACTION ITEMS.k6..,

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STATUS ASSESSMENT MAWACEMENT REVIEW FOLLOW-UP The following items. identified during the Hanger Tesa Status Assessment Management

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Review have been resolved.

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1.

Resolve Us's of After-The-Fact FCRs

--Pro, ject Management Response - The project has. committed to use a nonconformance report to document any nonconforming condition on the~ finished portion of partially complete work items observed during the status assessment acc0vity.. This was committed to in our June 10, 1983 letter to the NRC.-

2.

Obtain Release of Training from NRC asd Train the Team. --Project Managemen'c RespoSee - The project has submitted a letter to the NRC (June 3) explaining the CCP. 13ut NRC had comments on that submittal and the project submitted

' Revision 1 to the CCP on June' 10, 1983.

Release of training was given by the NRC on June 20, 1983.

3.

Rediins Incorooration Status (Informal Response made to D B Miller.

D B Miller to discuss with MPQAD. Bechtel to respond to D 3 Miller input)

Response - Redlines for small' bore pipe hangers have been incorporated in the drawings and the drawings have been re-issued.

(An exception list is available)

Redli ea against large bore pipe hangers will be incorporated as part of the n

seismic' reanalysis being performed by Project Engineering.

The forecast comple-tion date for this activity is 9/15/83.

Th'e use of redlines was discontinued on March 8,1983.

FCRs/FCNs vill be used

?

in the future for change initiation and approval.

4.

LAOTS o t Impact

--TJValenzano to Provide Input

' Response - The commitment to the NRC to locate indeterminant LAQTS bolt'ing material will be incorporated into the CCP.

The planned program is outlined in letter dated June 16,1983 (Serial 23277) from J A Pastor, "LAQTS Bolt Study Integration into the CCP".

5.

System' Interaction Requirements for Status Assessment.

..f l.

--DBMiller to write up results o,f FWB/DBM Meeting Response - F W Buckman met with D B Miller to discuss the requirements of. system interaction (SI) valkdowns on status assessment, FWB and DBM both agree that the two programs are not prerequisites for each other, but should be coordinated J

-for efficient use of resources.

This was' discussed with NRR and NRR had no restraints to starting the SI walkdowns.

6.

Verify J A Rutgers Memo Satisfies "Q" Desienation Problems

--D B Miller Response - Based' on BLC-16893 and the closure of the two items listed in that letter, CPCo is satisfied with dechtel's response.

Page 2 Status Assessment Managewent Review - Follow-up m

7.

Management R'eview' Team Comments There are not adequate management controls written into the program.

a.

procedures to establish responsibility for assuring qualified personnel are assigned to perform hanger statusiag activities.

--Bechtel The following is a stat'e=ent of Bechtel policy and phil.osophy regarding the qualification requirements to fill project positions.

Peo~le.

Key to the selection process is " knowledge requirements".

p are assigned to positions based on their ability to fulfill the 8

required duties and responsibilities. A judgement regarding this ability is made.

The selection process is not restricted to applicants / employees who have fromal education.

There are a wide variety of ways to obtain job-related skills, and the objective is that people' filling positions have these skills.

If' candidates for" employment from outside Bechtel do claim educationIa1 degrees or applicable work experience, Bachtel has a standard procedure

=

for verifying such claims.

Briefly, at least the highest degree claimed and all employment during the past year is verified.

The information supplied by the candidate on the employment application is verified verbally or in writing.

The form documenting verifica-tion is filed in the employee's master personnel file.

Judt ment regarding the abilities of candidates from within ?echtel is made using a resume of Bechtel and outside experience and formal a. val-uations of performance in previous Bechtel positions.

In summary, the suitability of candidates for project positions is judged based on past performance.

Adequate performance on the q

i project is confirmed by evaluation of work in the current pcsitions.

The Construction Training Program addresses the application of profes-sional skills and knowledge to the unique procedures, specifications and requirements of the Midland Project.

TPG-2.000 (Training of Construction Personnel) requires that an individual's supervisor ensure that personnel know and understand the training requirements

~

and verify that all required training is complete.

The Team charters FPG 9.800 3'ulk Hanger Organization FPG 9.700 System Team Charter.

FPG 7.400 -" Area Team Charter vill require that an individual's training is received prior to performing work.

The Team Supervisor is responsible for ensuring that this is accomplished.

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' Pcg3 3 Status,Assassnest Mantgscent Ravicw b Follow-up This will be Laplemented with the above procedures by the dates

. indicated Training Supervisory.

Raouirements_

Responsbility

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FPG 9.800 Complete 7/8/83 FPG 9.700 7/8/83 7/8/83 FPG 7.400 7/8/83 7/8/83 7.

b.

The formal training programs for' construction' personnel phould include examinations at th~e completion of training to assure the training objectives have been met.

--Bechtel A-Training Evaluation Team (TET) has been established to evaluate

' effectiveness of training and to make recommendations for changes to the program.'. The TET function is covered in Bechtel Guideline G-4.00.

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Rather than use examina'tions.to test student comprehension of presented material, the training effectiveness will be checked initially and then

' monitored periodically by sampling the class attendees using an appropriate combination of oral questions, written questions and observation of app 1'i-cations of the process covered in the training.

Reports will be made to the training coordinator and project management for action.

Several questions of the review team remain unresolved pending approval

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7.

c.

of a revision to FPM-9.200.

--Bechtel The revision to FPM-9.200 has been issued.

Unresolved questions have been addressed to the satisfaction of the review team.

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7.

d.

1Due use of a checklist for conduct of hanger statusing was reco:snended l

by the review team.

The BRO disagrees with the team's position.

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The design drawings, procedures and specifications contain the key require- !

ments for hanger installation and inspection.

the checklist as show.: in k

Attachment "B" in FPM-9.200, Rev. O is to be used as a guideline / memory key indicator to the team field engineer to assure consistency during status g

assessment and hanger installation. The checklist is not intended to I,

cover in detail every hanger in every situation or to substitute for re-i quirements called for in the, technical documents.

Therefore, the checklist f

I will not govern field engineering inspection / acceptance and will not be

.k retained for record purposes.

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The field engineer and superintendent's acceptance of completed work is i

shown by the signoff of the Construction Work Package (CWP) (FPG-7.300)

'i which accompanies each "Q" hanger.

In addition to the CWP, the field I. -

engineer is required to initial the P119/129 form (Stress Walkdown Form) 3 signifying that installation meets design requirements for all "Q".and '

critical non-Q hangers.

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Page 4 Status' Assessment Management Review ' Follow-up There is still no 'overall CCP procedure which identifies external 7.

e.

restraintstoprogram1mpisakutal' ions.suchasthird.partyover-inspections,or management review team " hold points".

--D B Miller

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CPCo letter to Bechtel dated.6-7-83 (Serial 23091) descr.ibes the CCP Management Review process including NRC release points.

Also all Project II networks have,been_chapged.to reflect-NRC hold points and CCP logic.

Stone & Webster hold points have not been determined as of this time.

.Ston.e & Webster hold points will~be determined af ter NRC acceptance of S&W.

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7.

f.

Coordination of MPQAD, Teams, etc., to ensure optimizing work.

--D B Miller

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Response - CPCo letters'have been written to address work priorities for MPQAD hanger teams. The scheduling process is nearing completion for providing priorities to-the various. groups.

These actions allow start of the status assessment..

7.

g.

Establish references and a reference tracking system.

--D 3 Miller The review process for field procedures includes a technical review by the Project Field Engineer or designee.

This review includes a considera-tion of potential impact on o*.her procedures and initiates changes to these procedures if required.

The list of references in each procedure provides a guide for this part of the PFE review.

Each procedure change vill also be~ reviewed by the appropriate Assistant Project Field Engineer and Lead Discipline Supervisor to determine additional training needs and they *will inform the Training coordinator who will ensure updating of lesson plans, training matrices and scheduling of training for affected personnel.

(paragraph 5.6,FPG 2.000) 7.

h.

Resolve relationship between hanger & system teams

--Bechtel Response - FPM-9.200 (Bulk Ranger Organization Hanger Walkdowns)

Sections 3.2, 5.3, 5.5, 5.6, 5.8.2 and 5.9 and FPM-9.800 (Bulk Hanger

~

organization Charter) Section 5.4 define the syste,m/ Hanger Team relationship.

7.

i.

Hangers on turned-over systems must be inputted into the master punchlist.

--R E McCu'e Response - NORs written on turned-over equipment are processed through the test group as an actio.. addressee. A process has been establiched to ensure that identified work is added to the master punchlist.

7.

j.

Review the MPQAD training program instructions for possible selected use.

--Bechtel Resconse, Some of the MPQAD modules will be used.

The MPQAD Train'-the-Trainer format was used.

Also, MPQAD is part of a training evaluation team that will monitor the implementation of construction training.

.i..

Pagn 5 Status Assessment Mantscment Revity - Pollow-up 1

7.

k.

Add to training program procedure the present practice of revision review currently being used.,

Response - T,he process for review of construction procedures revisions for any new training requirements has been incorporated into Rev. 3 of FPG-2.000, paragraphs 5.5 and 5.6.

Stone & Webster Report Received on Management Review.

--D B Miller 8.

Response - The report was received and the action items have been closed.

(D B Miller letter to Stone & Webster dated July l',1983, Filer. 0655. B1.1.4) 9.

Need to Have Milandin Flowchart for Future Management Reviews.

--D B Miller Response - The flowchart has been received and will ba used at future meetings.

10.

Need Procedure to Handle hanger Lists.

--Bechtel Response - The procedure

• to handle hanger lists is covered in FPG-7.500, Section 7.

11.

Lesson Plans in Place with the New Format.

--Bechtel J

Response - A guideline (GS.00) for Less.on Plan Dev'elopme6t has been i~ssued.

Lesson plans required for Hanger Team Training are being prepared and approved prior to scheduled training; 12.

Complete QA Procedures Necessary to Support Team Status Assessment Activities.

--MPQAD The procedure'for processing commodity lists within MPQAD (tentatively assigned Number T-4) is dependent upon the field procedures describing preparation and control of the lists'.

This procedure is presently scheduled for issuance by July 8, 1983.

All other required procedures are completed.

13.

Establish Scope of PQCI P.230 Vs Normal Insnection PQCIs.

--MPQAD All hangers which' have a closed P-2.10 inspection report vill be reinspected in accordance with PQCI P-2.30.

All other hangers which may have closed irs (P2.00, C1.50, etc) on parts of the hangers vill be inspected under the Construction Completicu Program.

4 O

S10!1E & HElfSTER MICillGAN,,INC..

MIDLAllD NddLCAR C0GENERATI0tl'PLMIT

'CIO ITEMS ORIGlHATING CPCo RESPONSE' STATUS CLOSE-0UT 8 1I 11 CLASSIFI-DOCUMEHF/DATE DOCU! DENT /DATE OPEN/ CLOSED DOCUMENT /DATE OBSERVATIOliS i

Ho. _ _

CAI 10tl

/

14,19'03!

Report No. 22 Uh'en j

l 034 1 racked filR 000 issued on tiovember 1

to address five unsatisfactory con-;

i I

l Action

~

diLions observed during the review '

j of 50 training levels assignments ~

l l

in the System Team Training Matrix g

of the Construction Training Program.

i Report No. 22 Open 035 Tracked CIO observed that dielectric iso-1 i

11/14/03 Action lation spacers for galvanic pro-tectionofcopperpipetogalvanizedj steel pipe supports were missing in some areas on tiils system, Small j

i Bore (Instrument Air) KAC Systems,

,i drawing FSK-J-30-0220 Sheet 2 Rev.7.;

)

OM Tracked At team meeting of teams 26 and 27 Report flo. 24 Open 8

held on November 22, 1983, a decision 11/29/03

,t

.i Infor-that FCNs would no longer be issued mation for "Q" items was discussed.

The nethod for controlling changes has l,

i.

iot been finalized.

Open 017 Tracked CIO observed that two boards with pro-Report No. 24 11/29/03 Lruding nails lying in Cable Tray Action 1AKA019 (Q Tray) had punctured the The cable Jacket of a "Q" cable.

cable is Q-channel A, 400V. MCC.

PlCR C0092S was issued by MPQAD on

'lovember 22, 1983.

CIO will track this item to assure that corrective iction (repair) has been performed Lo approved procedures.

~

R JOB NO. 14509 MIDLAND NUCLEAR. POWER PLANT REPORT NO. 26 PAGE 3 CIO performed a 100% re-inspection of the corrective actions of i

j the Construction Training Records that were determined to be dis-4)

Records were in compliance i

crepant as noted on NIRs.006 and 007.with the reouirements of P to.be satisfactory.

[.In._a.dd.ition,. CIO performed 100% ' inspection of the records of two

~

RecoFds sETe'cted were~ examined and were members of Team 27/28'.

The results of found to be in compliance with FPG-2.000 Rev. 6..

the CIO evaluation of the records sampled were considered to be satisfactory.

The acceptance of the training records by CIO of the two members, qualifies them to perform Status Assessment for Phase I activities.

Training records of other members of Team 27/28 will require sampling for CIO review before they will be permitted to perform Status. Assessment and before NIRs 006 and 007 ca1 be closed.

Meetinks attended are summarized in ' Attachment A..

5)

NEW CIO OBSERVATION Tracked Information Item - #38 In reviewing a checklist developed by Bechtel Lead Field Engineers as and aid'in conducting Status Assessments :to Procedure 'PM-7.000 Rev.1 (Mechanical System Status and Completion), the CIO noted that the check-list does not include all of the attributes required by the procedure.

If special checklists are to be used in statusing, these lists should be addressed by an administrative procedure that provides details on how

~_

the lists are to be prepared and used.

Consumers Power Company is being requeste:' to provide background on this item.

OPEN ITEMS, NONCONFORMANCES, AND HOLO POINTS Item 031 was closed during Open C10 items are summarized in Attachment 5.

the reporting period.

Open C10 Nonconformance Identification Rescrcs (NIRs) are Attachment C.

Hold Paint 006 was closed Open C10 Hold Points are summarized in Atti:n en-D.

during tne reporting period.

1

_.