ML20083J650
| ML20083J650 | |
| Person / Time | |
|---|---|
| Site: | Midland |
| Issue date: | 11/08/1983 |
| From: | Baranow S STONE & WEBSTER, INC. |
| To: | James Keppler NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| Shared Package | |
| ML20083J610 | List: |
| References | |
| 83-11-08, 83-11-8, NUDOCS 8401100234 | |
| Download: ML20083J650 (14) | |
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fRitCIPAL s7Agg ^I STONE & WEBSTER MICHIGAN, INC. WA A
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P.O. Box 2325. BOSTON. MASSACHUSETTS 02107
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Mr. J. G. Keppler, Administrator, Region III November 8, 1983 Nuclear Regulatory Commission J. O. No. 14509 799 Roosevelt Road NRC File #83-11-08 Glen Ellyn, IL 60137 RE: DOCKET NO. 50-329/330 MIDLAND PLANT - UNITS 1 AND 2 OVERVIEW 0F THE CONSTRUCTION ON COMPLETION PROGRAM REPORT NO. 21 A copy of the Construction Implementation Overview Report No. 21 for the period October 31, 1983 through November 4,1983 is enclosed with this report.
No Management Review Committee Meetings were held during this reporting period.
Evaluations of CCP activities including the final report of an allegation of l
improper welding, and matrices of Open Items, NIRs, and Hold Points, are attached.
Very truly yours, jf.- 4
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S. W. Baranow Program Manager SWB/ka cc: JJHarrison, US NRC Glen Ellyn, IL l
RCook, US NRC Midland (site) l DQuamme, CPCo Midland (site) l RBKelly, S&W APAmoruso, S&W RGBurns, S&W l
NOV 41983 1
8401100234 840106 PDR ADDCK 05000329 G
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Report No. 21 October 31, through November 4,1983 Personnel on Site Stone & Webster Michigan Inc.
A. Amoruso D. Cooke R. Scallan S. Baranow R. Corson.
J. Seely F. Bearham
,J. Langston W. Sienkiewicz J. Barr C. Marrs A. Smith R. Carpeggiari D. MacBay W. Taylor i
f J. Chawla T. Parker J. Thompson G. Foley (temporary)
Meetings Attended i
Date Attendees Purpose November 1,1983 Consumers Power Company Daily Staff.
through Bechtel Power Company Management Meetings
, November 4,1983 Stone & Webster CIO MPQAD
' November 3, 1983 Consumers Power Company Bi-Weekly Staff Bechtel Power Company and Meetings with Stone & Webster CIO Team Supervisors l
MPQAD November 1, 1983 Consumers Power Company QVP/ Status Stone & Webster CIO Assessment Bechtel Power Company MPQAD November 2, 1983 Consumers Power Company Area Team and and Bechtel Power Company System Team November 3, 1983 Zack Re' view Meeting MPQAD
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Stons and Webster CIO November 4,1983 Consumers Power Company Weekly Sub-Contractors l
Bechtel MTG Zack B&W Stone & Webster CIO
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l JOB NO. 14509 MIDLAND NUCLEAR POWER PLANT REPORT NO. 21 PAGE 2 November 1, through November 4,1983 - During this period, CIO attended daily staff managementmeetings and bi-weekly meetings with staff and team supervisors.
The main focus of attention during the week was the Stop Work Orders issued by MPQAD. At' the dailymeetings, details of current status and proposed actions are described as well as the logistics to resolve the problems in a timely manner.
Subjects discussed'at the daily staff management meetings were:
- Stop Work Orders
- NCR Dispositions
- Delays in Dispositioning/ Closing NCRs
- Audi,t Findings
- NRC Concerns l
- Document Control
' Training Progress
- Progress with Procedure issuance
- Major Meetings
- Status of System 38
- Other Administrative Activities
- Manpower Loading Subjects discussed at the bi-weekly meetings with staff, team supervisors and support personnel were:
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- Training
- Staffing to support Module 340 activities
- Punch List Coding
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JOB NO. 14509 MIDLAND NUCLEAR POWER PLANT R$ PORT NO. 21 PAGE 3
' Meetings November 1, 1983 - QVP/ Status Assessment. At this meeting, the main items discussed were assignments of key people to the teams that will assess Module 340 and preparations for this effort.
The major restraint affecting Module 340 is the Stop Work Order issued on the improper use of FCRs and FCNs. A schedule for releasing the Stop Work Order has not yet been established,but for planning purposes, it was decided to assume that the Stop Work Order will' be closed and work released on November 30, 1983.
November 2 and 3, 1983 - Area aad System Team Review Meetings. At these meetings, an item that is considered to be a restraint is discussed. Action person (s) are assigned to pursue the resolutions for removing restraints. Also discussed is the schedule for completing actions assigned to each restraint item and the pro-gress in meeting the schedule.
ACTIVITIES 1.
Training Records CIO completed a sampling inspection of Construction Training Records of 8 members of the Field Engineering Staff, 2 members of Area Teca Number 24, t
5 members of Field Procurement, 4 members of Sub-Contractors, 5 members of Management, and 4 members of the Construction General Serivces Organization.
Eight-hundred thirty-four (834) individual records were reviewed. The number of discrepancies that were noted resulted in a rejection of the training records for the 28 people sampled and issuance of NIR 007.
Principal categories of discrepancies were:
(a) course roster not completed properly,(b) training classes not documented, (c) reading assignments not documented, and (d) training records not canpleted consistently.
NIRs 006 and 007 has been issued as a result of these discrepancies.
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2.
Allegation On October 26, 1983 - CIO received an anonynous phone call alleging that welding was being performed, contrary to approved procedures.
(See CIO l
Report No. 20, dated October 31, 1983 for details of the initial investi-l gation).
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JOB No. 14509 NIDLAND NUCLEAR POWER PLANT REPORT NO. 21 PAGE 4 4
CIO met with Mr. L. Harrison (BPCo) to complete the investigation into the allegation. A weld was selected at random, joint HBC-4-2-1. C10 i
reviewed the welding records generated during the initial welding and subsequent repcir welding on the joint. The initial welding was performed utilizing approved procedure number P1-A-LH. The weld was completed using procedure PI-A-LH and accepted by BPCo and the Authorized Nuclepr Inspector on August 9,1981. This particular weld later became the suaject
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of NCR 2781 for being undersized. A repair was made using approved procedure PI-T-B. This mpair was inspected.and accepted by BPCo and the Authorized Nuclear Inspctor. A review of the code (QW-2.01.3 and QW-202.2) in-dicated that either PI-A-LH or P1-T-B could be used singly or in ccm-combination. In addition, BPCo Technical Specification G-27, Subsection Fom 84 Mechanical allows the use of either P1-A-LH (SMAW) or P1-T (TIG) for this weld.
In conclusion, CIO has detemined that the allegation was factual with' regard to the weld sequence. As the BPCo procedures utilized were approved and the intent of ASME code and the Technical Specification were complied with, CIO has determined.that no non--
compliance conditions exist. This closes the CIO iny'estigation of the allegation.
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PQCI Stop Work Order On November 3,19d3-MPQAD issued a Stop Work Order on the use of eight Electrical / Instrumentation PQCI's. The PQCI's specified inspection requirements for in-process and final inspections of welding, but these requirements were not. consistent.
The' potential for this problem was discussed in CIO Weekly Reports numbers 9, 11 an.d 18.
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FCP/FCN Stop Work Orders On October 22, 1983 - MPQAD issued Stop' Work Orders because of: concerns about processing design changes, CIO has been attending meetings of the Stop' Work Steering Committee and is developing checklists for use in evaluating steps taken to resolve FCR/FCN discrepancies. Attributes for these checklists are being extracted from.
(a) Flow Chart Plan (d) FID - 2.400 Rev. 4 (b) FPD - 1.000 Rev. 16 (e) PEP. - 4.62.1 Rev. 0 (c) FPD - 2.000 Rev. 10 (f) ADP.- 2.12 Rev. O e
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N0hNO.14509 MIDLAND NUCLEAR POWER PLANT REPORT NO. 21 PAGE 5 In addition, a sampling of FCR/FCNs will be reviewed to determine the adequacy of corrective actions.
GENERAL
- 1. Signed affidavit and resume of W. C. Taylor, Assistant Superintendent of Field Quality Control, has been transmitted to Mr. J. J. Harrison, US NRC, Glen Ellyn, IL.
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- 2. In accordance with the latest PQCI Control Log dated October 26, 1983, 65' PQCIs are listed as active. The status of CIO checklists for these PQCIs follows:
(a) approved 37 (b) under revision and draft review -28 Zack Training
- 3. In accordance with a pre-established CIO monitoring schedule of Zack activities, CIO performed a' review of 36 training records of 2 Field Engineers. Results were determined to be satisfactory and were documented on Checklist MP-MIS-Z-025 which was developed to meet the requirements of Zack MB-FP-16 "On-going Training" Rev. 1.
This procedure is being revised to include matrices, required reading lists and formalizing training packages.
l This revision is currently in review by MPQAD. Upon receipt of the approved l
version, CIO will d#velop a new Checklist and repeat the evaluation.
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' STONE & WEBSTER MICllIGAN, INC.
MIDLAND NUCLEAR C0 GENERATION PLANT CIO ODSERVATIONS Obs F tion
- Originating -
CPCo Response
. Status Close-Out Observations gDocument/Date Document /vate Open/ Closed Document /Date m r 030 Need to review Vendor Equipment iReport No. 5 Open Verification Program - MPQAD/SMO I
7/18/83 1
031 NIRs 002, 003, 004 and 005 were issued on IReport No. 16 Open October 3, 1983 for discrepancies observed' l
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 Open dress discrepancies observed during sample 10/31/83 inspection of Construction Training Records of Teams 5, 6, 8, 9, 12, 13, 16, 17, 19, 20, 25, 26 (27/28) 29, 30, 31, 32/
33 and BH0 staff.-
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STONE & WEllSTEll HICllIGAN, INC.
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CONSIRUCrioH IMI'l.EMtNI ArlHN UVERVIEW NIH LUG SUH4ARY NIR
~HPQAD DATE DATE uATE NO.
NCR NO.
SUBJECT OF DISP. BY CLOSED.
REMARKS DAR NO.
ISSUE MPQAD 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 Foms 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 RT 00006
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l OJT training records not available in l 004 RT- 00007 training records. Revision number not 10/4/83 10/12/83 listed on OJT Record
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i Memo to CPCo ad-I QAR Personnel Certification Form QA-116-1, vising that NIR-005 RT 00011 Attachment D is unavailable in record 10/4/83 10/12/83 10/20/83 can be closed out.
005 files Records for Level II 8
certifications have been verified by CIO l
Discrepancies in three areas of 006 Construction Training Records 10/27/83 t
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STONE AND WEBSTER ENGINEERING CORPORATION QCI 15.01 n 4.1 j
fttac h0NCONFORMANCE IDENTIFICATION REPORT Page 1 of 2 DATE OF NONCONFORMANCE:
November 7, 1983 NIR NUMBER 007 IDENTIFICATION / LOCATION Or ITEMS:
.9 DESCRIPTION OF NONCONFORMANCE:
During the review of 834 non-manual Construction Training Records, two areas 6
of discrepancies were observed which werb not in compliance with'the requirements of FPG-2.000 Rev. 5 " Training of Construction Personnel."
(The following Teams were evaluated #24, Field Procurement, Sub Contractors, Managements, F.E. Staff, and CGSO.
(See attached for descriptions fo Discrepancies) 7fh/$ M[
PROGRAM MGR M
INIIIATOR cf DATE WoMmben ' 7; 1983 DATE 5 N Z / $
CORRECTIVE ACTION BY:
IDENTIFY ORGANIZATION TAKING CORRECTIVE ACTION l
9 VERIFICATION SAT UNSAT NEW NIR#
CONCURRENCE i
INITIATOR PROGRAM M'GR DATE DATE DATE REMARKS 4
NIR 007 1)' Course Rosters Attachment D to FPG-2000 exhibited one or more of the following discrepancies.
BL'OCK NO.
ENTRY REQUIRED ENTRY RECORDED
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1 CCP DWG. No. Fig.
No. Course No.
2 (a) Name of lesson Either a, b, or (b) Procedures c missing (c) Revision 6
Location of Session Bechtel In addition some entries were left blank 2)
In addition to these violations, inconsistencies were noted in 6 areas:
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(1) Modification to records, some lined through, signed and dated and others simply lined through.
(2) Some entries on course register are completed using pencil while most are in ink.
(3) Difficulty is experienced in determining the accuracy of records where attendance at a course carries credit for several others.,(4) Some entries carried the revision number to procedures and some omitted the revision.
(5)
Proper " Course. Roster Form" as listed in Procedure FPG-2.000 were not utilized.
(6)
Some courses on Rosters contain information not identi-cal to matrix listing.
It is recommended that The disposition to this NJR include a comitt-
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ment to verify training records of each individual prior to status assessment assignment.
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$ TONE 8 WEBSTER MICHIGAN. INC.
CONSTRUCTION IMPLEMENTATION OVERVIEW It0LD POINT LOG SUPMARY ORIGINATING CPCo RESPONSE STATUS CLOSE-0UT No*
SU3 JECT DOC /DATE DOC /DATE OPEN/ CLOSED DOC /DATE 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 voided.,by Project T
Engineering.
I 002 Material traceability of installed hangers (E3).
Report No. 6 Letter Closed Report No. 9 CPCo response dated 7/1/83 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.
1 003 Has a program been developed and responsibilities Report No. 6 Letter Closed Report No. 9 established for personnel assigned to process 7/25/83 8/9/03 8/15/83 nonconfbrmances?
Has a meeting been held with Project Engineering l
to discuss methodology of processing non-i confomances?
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$ TONE & WEBSTER MICHIGAN, INC.
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CONSTRUCTION IMPLEMENTATION OVERVIEW
~ HOLD POINT LOG SIM4ARY I
ORIGINATING CPCo RESPONSE STATUS CLOSE-0UT NO.
. SUBJECT DOC /DATE DOC /DATE OPEN/ CLOSED DOC /DATE 004 Evaluation of Phase I Management Review Report No. 1 Letters Closed CIO Letter to l
Committee meetings.
6/3/83 7/1/83 J.G. Keppler through 8/9/83 dated 10/12/82 Letter of l
G/30/83 l
005 CPCo has committed to develop a Vendor Report No. 18 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. 1E 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 Revieg of results of' Report No. 19 Open Phase I activities. Evaluation of Management 10/24/83 Review Committee plans and procedures for Phase II implementation.
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Re-worded
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STONE & WEBSTER MICHIGAN, INC.
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CONSTRUCTION IMPLEMENTATION OVERVIEW
HOLD POINT LOG SIM4ARY ORIGINATING CPCo RESPONSE STATUS CLOSE-0UT NO.
,.uBJECT o
DOC /DATE DOC /DATE OPEN/ CLOSED DOC /DATE i
l 008 NIR 006 has been issued on October 27, 1983 to Report No. 20 Open i
address discrepancies observed during the sample 10/31/83 inspection of 2,054 Construction Trainingl 4
i records of 31 members of Teams 5, 6, 8, 9, 12 j
13,16,17,19,20,25,26,(27/28),29,30;'31, (32/33) and BHO staff.
1 Corrective action must be. completed before any
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walkdown, assessments can be performed by the
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personnel in question.
009 NIR 007 has been issued on November 7, 1983 to Report No. 21
' Open J
address discrepancies observed during sample 11/7/83 i
inspection of 834 Construction Training records of 18 members of Team 24, Field Procurement, Sub-Contractors, Management, F.E. staff and i
Construction General Serivces Organization.
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Corrective action must be completed before any i
walkdown, assessments can be performed by the l
personnel in question.
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