ML20083J653

Forwards Const Implementation Overview Rept 22 for 831107- 11.Evaluations of Const Completion Program Activities & Matrices of Observations,Nonconformance Identification Repts & Hold Points Encl

ML20083J653
Person / Time
Site:	Midland
Issue date:	11/14/1983
From:	Baranow S STONE & WEBSTER, INC.
To:	James Keppler NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III)
Shared Package
ML20083J610	List: ML20083J631 ML20083J639 ML20083J650 ML20083J653 ML20083J682 ML20083J688
References
83-11-14, NUDOCS 8401100238
Download: ML20083J653 (15)

Text

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l STONE & WEBSTER MICHIGAN, INC.

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P.O. Box 2325. BOSTON. MASSACHUSETTS 02107 y,)

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ENF lFi le -fgb Mr. J. G. Keppler, Administrator, Region III November 14, 1983 Nuclear Regulatory Commission J. O. No.

14509 799 Roosevelt Road NRC File #83-11-14 Glen Ellyn, IL 60137 RE: DOCKET NO. 50-329/330 MIDLAND PLANT - UNITS 1 AND 2 OVERVIEW 0F THE CONSTRUCTION COMPLETION PROGRAM REPORT NO. 22 A copy of the Construction Implementation Overview Report No. 22 for the period November 7, 1983 through November 11, 1983 is enclosed with this report. No Management Review Committee Meetings were held during this reporting period.

Evaluations of CCP activities and matrices of Observations, NIRs and Hold Points are attached.

Very truly yours, S. W. Baranow Program Manager SWB/ka cc: JJHarrison, US NRC Glen Ellyn, IL RCook, US NRC Midland (site)

DQuamme, CPCo Midland (site)

RBKelly, S&W APAmoruso, S&W RGBurns, S&W 5

8401100239 840106 NOV 211983 PDR ADOCK 05000329 O

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Report No. 22 November 7, 1983 through November 11, 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

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R. Carpeggiani D. MacBay W. Taylor J. Chawla T.~ Parker J. Thompson G. Foley (temporary)

Meetings Attended Date Attendees Purpose ___

November 7, 1983 Consumers Power Company Daily Staff through Bechtel Power Company Management Meetings November 10, 1983 Stone & Webster CIO

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MPQAD J:..

November 7, 1983 Consumers Power Company Team Meetings l

through Bechtel Power Company,

November 10, 1983 Stone & Webster CIO November 8,1983 Consumers Power Company QVP Status Bechtel Power Company Assessment l

MPQAD Stone & Webster CIO I

i November 8,9,10, 1983 Consumers Power Company Area Team and l

Bechtel Power Company System Team MPQAD Review Meeting Zack Stone & Webster CIO November 10, 1983 US NRC Monthly Meeting Consumers Power Company Stone & Webster CIO/ Soils Public 4

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JOB NO.

14509 '

MIDLAND NUCLEAR POWER PLANT REPORT NO. 22 PAGE 2 Meetings November 7, through November 10, 1983 - during this period, CIO attended daily meetings with staff management and staff supervision.

The Stop Work Orders issued by MPQAD continue to be the prime topic of discussion. Also at these meetings, 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

• Status of NCR Dispositions

• Cause of delays in dispositioning/ closing NCRs

• Review of Audit Findings l

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• Discussions of NRC Concerns

• Document Contro.l Activities

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• Preheat vs L. P. Inspection

• Status of procedure approval and Issuance

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• Computer down time

• Administrative Activities

• Manpower requirements and loading

• MPQAD took exception to a root cause and preventative action assigned to them.

1 NCR # C 00708 addressed an arc strike observed on a fabrication produced at the Standish Fabrication Plant.

Thearcstrikewasapparentlyminutebutrequiredsomeworktoensbrethatno crack was present.

The disposition included a recommendation that MPQAD inspection personnel receive additional training in the evaluation of arc strikes.

l MPQAD took exception to this disposition on the basis that arcitrikes are caused by construction personnel and the prevention of arc strikes is a

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construction responsibility.

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JOB NO. 14509 i

MIDLAND NUCLEAR POWER PLANT REPORT NO. 22 PAGE 3 i

November 7, 1983 through November 10, 1983 - CIO personnel assigned to respective teams, attended team meetings for discussions of:

• mock status assessment to begin week of November 14, 1983

• review of status of open items

• s'tatus of Raceway / Cable packages, I

• mock status assessment of Small Bore Pipe Hanger Supports

• Installation / inspection of Diesel Generators

• Diesel Generators status and installation problems

• red line drawings

' preparation of Commodity lists

' Hanger Reinspection Program November 8, 1983 - QVP Status Assessment. At this meeting, the main item of discussion was the assignment of key personnel to the' teams that will assess

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Module 340 and the preparations for this' effort.

~ The ' major restraint affecting Module 340 continues to be the Stop Work Orders issued on the improper use of FCRs/FCNs. A schedule for release of the Stop Work Orders has not been established, however, indications are that portions of work may be able to resume before the end of November, 1983.

November 8, 9, 10, 1983 - Area and System Team Meetings. At these meetings, the subjects of importance addressed were:

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• status of resolution of restraints

• schedule of resolutions for removing restraints Restraints discussed at weekly meetings are relevant to on-going activities rather. than CCP. Typically they: fall into categories such as procurement delays, disposition to NCRs, and delays in obtaining design or construciton details. At each meeting a review of response status and target dates for removal of re-straints is discussed in detail and where necessary, an action is assigned.

• status of NCRs

I JOB NO.

14509 MIDLAND NUCLEAR POWER PLANT REPORT NO. 22 PAGE 4 ACTIVITIES 1.

Training Records CIO completed a sampling inspection of training procedures to determine the adequacy of the construction training matrix. Three discipline Field Engineers positions were selected for review of their reading assignments. A sample size of 50 procedures representing a lot size of 318 were reviewed by CIO. Considerations were given to those code 3

levels of reading Code O through Code 4. In this review, it was de-termined that five areas of discrepancies were evident.

Four of the five discrepancies had a Code level 0 against specific procedures. The CIO review of these procedures indicated that responsibilities were defined which automatically placed the pro-cedure into a Code level 2 or 3 requirement. The fifth discrepancy identified an area of inconsistency:

Discipline engineers, mech'anical and instrumentation require Code level 2 whereas discipline engineers, electrical and welding re-quire Code level 3 for Procedure FIG 1.400, " Preparation Review and Routing of Field Engineers Reports."

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NIR'008 is being issued to cover these discrepancies.

2.

System Interaction Walkdown of the Auxiliary Building continues in accordance with Mark Technologies Procedure WTP-3-Q " Procedure for l

Performing Walkdowns of SSIP/S Targets.

20 interactions were analyzed and' documented, 6' of which were witnessed l

l by CIO.

l The CIO evaluation was performed utilizing Attribute Checklist MP-MIS-MJ-022.

3.

FCR/FCNs Stop Work Orders Eighteen FCRs/FCNs selected by CIO for reviews of resolutions were properly addressed and completed. One FCR did not have the l

required Resident Engineer's signature. This was promptly corrected and all 18'FCRs/FCNs more considered satisfactory and acceptable.

l Resultsof the evaluation will be documented on Checklist MP-MIS-041,"FCR/

FCN Review and Resolution Program.".

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JOB NO. 14509 MIDLAND NUCLEAR POWER PLANT l

REPORT NO. 22 PAGE 5 t

OBSERVATIONS _

Durir.g a CIO Walkdown of Small Bore (Instrument Air) IRAC Systems, drawing

'SK-J-30-0220 Sheet 2 Rev. 7. it was observed that dielectric isolation spacers for galvanic protection of copper pipe to galvanized steel pipe supports were missing in some areas of this system. This inconsistency was pointed out to CPCo personnel who will perform the required research and take corrective action.

This observation will be classified as an Open Item and will be tracied until all corrective action has been satisfactorily completed.

GENERAL i

1.

Checklists have been developedto establish the readiness of System, Area and$

BHO teams to perform preliminary walkdowns by System, Discipline and Areas.

2.

Mr. R. B. Kelly, QA VP and Manager, Mr. R.G. Burns Assistant QA Manager and Mr. J. Karr, Project QA Manager were on site November 9,1983.-

3.

In accordance with the latest PQCI Control og dated November 4,1983; 65 PQCIs are listed as active. The status of CIO Checkl.ists for these PQCIs follows:

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(a) approved - 37

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28-(b) under revision and draft review l

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S[0NEANDWEBSTERENGINEERINGCORPORATION QCI 15.01 NONCONFORMANCE' IDENTIFICATION REPORT fttac n 4.1 PAGE 1 0F 2 DATE OF NONCONFORMANCE:

NIR NUMBER oog IDENTIFICATION / LOCATION OF ITEMS:

SYSTEM TEAM TRAINING MATRIX, REY.1, DATED JULY 20, 1983

, DESCRIPTION OF NONCONFORMANCE:

During the review of the adequacy of the construction training matrices,a sample size of 50 training level assignments, representing a lot size of 318 assignments, five unsatisfactory conditions \\were observed'in the training level assignments.

The System Team Training Matrix of the Construction Training Program was utilized to perform the review.

See the attached for unsatisfactory conditions observed.

The five unsatisfactory conditions reported represents a reject condition for this lot size of 318.

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PROGRAM MGR c-INITIATOR

/[1 83 8 d A6p DATE DATE CORRECTIVE ACTION BY:

'N IDENTIFY ORGANIZATION TAKING CORRECTIVE ACTION l

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VERIFICATION SAT UNSAT NEW NIR#

CONCURRENCE INITIATOR PROGRAM RGR DATE DATE DATE REMARKS i

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i NIR #008 PAGE 2 0F 2

11. *F'PG 9.700 " System Team Charter" f

FPG 9.700 appears on the " System Team Training Matrix" as a Level "0" (no training required) for the system team field engineer, mechanical.

Paragraph 5.2.7 of this procedure identifies the job responsibilities and reporting relationships for the system team field engineers. As such, a level of training of "0" (no training) is not satisfactory.

2.

FP0 1.201, "Bcchtel Assigned Post Turnover (PTO) Work".

FP01.201 appears on the " System Team Training Matrix" as a Level "0" (no training required) forthe system team field engineer, mechanical.

In discussion with the Team #5 supervisor, itwas noted that the Team members do get involved in Post Turnover Work. Because of this involvement by the Team members, a level of training of "0" (no training) is not satisfactory.

1 3.

FIG 1.400 " Preparation, Review and Routing of Field Engineer's Reports."

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FIG 1.400 includes responsibilities for several disciplines,.ie; mechanical, civil, welding, and instrumentation as well as including responsibilities for the electrical discipline. The following conditions were noted as being unsatisfactory; (a) The " System Team Training Matrix" under the column entitled " Responsible Discipline" shows this procedure to be an el.ectrical discipline

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procedure.

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~ ^{b) The~ " System. Team. Training Matrix" requires the field engineers of the mechanical and the instrumentation disciplines to receive a level "2" training whereas the field engineersof the electrical and _ welding disciplines receive a level "3" training. There is an inconsistancy of training levels being assigned.

4.

Specification M-214, " Piping System Erection Fit-up Control Requirements."

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M-214 appears on the "Sys1.em Team Training Matrix" as a level "0",.(no training required) for the system team field engineer, welding.

Specification pages 3, 5, 7B and 8 address welding. Also, weld fit-ups are addressed throughout this specification. As such, a level of training of "0" (no training) is not satisfactory.

5.

Drawing E-039

" Seismic Wireway Supports.":

E-039 appears on the " System Team Training Matrix,"'as a level "0" (no training required) for the system team field engineer, welding.

This drawing contains weld sizes and weld symbols for typical wireway supports. As such, a level of training of "0" (no training) is not 1

satisfactory.

It is recommended that the disposition to this NIR include a committment to verify the adequacy of all training matrices.

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Cul4SiltUCTinli IMPl.EMEHIATifN4 UVERVIEW NIR l.UG SUl44ARY HIH HPQAD DATE DATE DATE No.

NCR NO.

SUBJECT OF

' DISP. BY ct,0 SED Rc_ MARKS OAR 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 i

required 002 QAR Forms from both procedures 8-3M'and RT 00005 B-3M-1 are intermixed in training 10/4/93 10/12/63 records 003 QAR Yearly vision examination was exceeded 10/4/83 10/12/83 RT 00006

.l OJT training records not available in'

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RT 00007 training records. Revision number not 10/4/83 10/12/83

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004 listed on DJT Record

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s Memo to CPCo ad-QAR Personnel Certification Fora QA-116-1, vising that NIP.-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 Il certifications have been verified by CIO Discrepancies in three areas of 006 Construction Training Records 10/27/83

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STONE & WEDSTElt CllIGAN, INC.

CONSTRUCTION IMPLEMENTATION OVERVIEW s

- NIR LOG

SUMMARY

NIR HPQAD DATE DATE DATE NO.

NCR NO.

'9 SUBJECT OF DISP.

CLOSED REMARKS ISSUE Discrepancies in two areas of Construc-007 tion Training Records for the following.

11/7/83 teams No. 24, Field Procurement, Sub-8 Contractors, Management, Field Engi-neering Staff and Construction General

. Services Organi7ation Five unsatisfactory conditions were 008 observed in training level assignments 11/14/83 during the review of the adequacy,0f the construction training matrices.

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SIDHE & HEUSTER HICHIGAN, INC.

MIDLAND Nt' CLEAR C0 GENERATION PLANT CIO OBSERVATIONS' Observation Originating CPCo Response

. Status Close-Out Number Observations Document /Date Document /Date Open/ Closed Document /Date 030 Need to review Vendor Equipment Report No. 5 Open Verification Program - MPQAD/SMO 7/18/83 031 NTRs 002, 003, 004 and 005 were issued on Report No. 16 Open Oct.ober 3, 1983 for discrepancies observed 10/3/83 in the review of Training Records of 6 of 45 MPQAD personnel.

032 NIR 006 issued on October 27, 1983 to ad-Report No. 20 Open dress discrepancies observed during sample i10/31/83 inspection of Construction Training l'

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..

033 NIR 007 issued on November 7, 1983 to Report No. 21 Open

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addres; discrepancies observed in two areas 11/08/83 during inspection of Construction Training Records for Teams No. 24 Field Procurement i

Sub-Contractors, Management, Field Eng-ingering Staff, and Construction General Services Organization.

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CONSTRUCTION IMPLEMENTATION OVERVIEW HOLD POINT LOG

SUMMARY

NO*

SUBJECT ORIGINATING CPCo RESPONSE STATUS CLOSE-0UT DOC /DATE DOC /DATE OPEN/ CLOSED DOC /DATE 001 Adequacy of drawings AB - large bore pipe Report No. 6 Letter Closed Report No. 9 l

1 hangers. CIO established Hold Point when MPQAD 7/25/83 8/9/83 8/15/03 i

issued 2 NCRs against the use of red-lined drawings which were volded.by Project Engineering.

l 002 Material traceability of installed hangers (E3).

Report No. 6 Letter Closed Report No. 9 l

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 11old Point was established by C10.

i 003 lias a program been developed and responsibilities Report No. 6 Letter Closed Report No. 9

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estabilphed for personnel assigned to process 7/25/83 8/9/83 8/15/83 nonconformances?

lias a meeting been held with Project Engineering to discuss methodology of processing non-conformances?

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CONSTRUCTION IMPLEMENTATION OVERVIEW l

h HOLD POINT LOG St# NARY 4

'I ORIGINATING CPCo RESPONSE STATUS CLOSE-0UT NG SUBJECT f

. DOC /DATE DOC /DATE OPEN/ CLOSED DOC /DATE 004 Evaluation of Phase I Management Review Report No.'I Letters' Closed CIO Letter to Committee meetings.

6/3/83 7/1/83 J.G. Keppler through 8/9/83 dated f0/12/8: -

Letter of 6/30/83

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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

.'l Report No. IE

'.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.

i 007 Evaluation of Management Review of results of Report No. 19 Open Phase 1 activities.

Evaluation of Management 10/24/83 Review Committee plans and procedures for PhaserII implementation.

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STONE & WEBSTER MICHIGAN, INC.

CONSTRUCTION IMPLEMENTATION OVERVIEW HOLD POINT LOG

SUMMARY

a ORIGINATING CPCo RESPONSE STATUS CLOSE-0UT NO..

SUBJECT

• DOC /DATE DOC /DATE OPEN/ CLOSED DOC /DATE NIR006hasbeenissuedonOctober27,19h3to

. Report No. 20 Open 008 address discrepancies observed during the sample 10/31/83 inspection of 2,054 Construction Training records of 31 members of Teams 5, 6, 8, 9, 12 13,16,17,19,20,25,26,(27/28),'29,30,31, (32/33) and BHO staff.

Corrective action must be~ completed before any walkdown, assessments can be performed by the personnel in question.

009 NIR 007 has been issued on November 7, 1983 to Report No. 21 Open address discrepancies observed during sample.

11/7/83 j

inspection of 834 Construction Training records

.of 18 members of Team 24, Field Procurement, Sub-Contractors, Management, F.E. staff and g

Construction General Serivces Organization.

Corrective action must be'complbted before any

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walkdown, assessments can be performed by the personnel in question.

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CONSTRUCTION IMPLEMENTATION OVERVIEW HOLD POINT LOG St# NARY ORIGINATING CPCo RESPONSE STATUS CLOSE-00T NO*

SUBJECT DOC /DATE DOC /DATE OPEN/Cl.0 SED DOC /DATE 010 NIR 008 has been issued on November 14,~1983 to Report No. 22 Open address five unsatisfactory conditions observed 11/14/83 during the review of 50 training level assign-ments representing a lot size 318 assignments

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in the System Team Tral'ning Matrix of the Construction Training Program.

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Correctives action must be completed before any l

walkdown, assessments can be performed by the personnel involved in these training activities.

011 Prior to start of Phase III activities of

, Report No. 22 Open FCR/FCN Resolution Program, CIO has established 11/14/83

-a Hold Point at the, conclusion of Phase II activities to evaluate MPQAD performance.

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O IN~l7Fiis gM Mr. J. G. Keppler, Administrator, Region III November 22, 1983 Nuclear Regulatory Comission J.O. No.

14509 799 Roosevelt Road NRC File #83-11-22 Glen Ellyn, IL 60137 RE: DOCKET NO. 50-329/330 MIDLAND PLANT - UNITS 1 AND 2 OVERVIEW 0F THE CONSTRUCTION COMPLETION PROGRAM l

REPORT N0. 23 A copy of the Construction Implementation Overview Report No. 23 for the period November 14, 1983 through November 18, 1983 is enclosed.

The report includes evaluations of CCP activities and matrices of Observations, NIRs and Hold Points.

Very truly yours, b MNaf y

S. W. Baranow Program Manager SWB/ka 9

Enclosure cc: JJHarrison, US NRC Glen Ellyn, IL RJCook, US NRC Midland (site)

DLQuame, CPCo Midland (site)

RAWells, CPCo Midland (site)

RBKelly, S&W APAmoruso, S&W e

4 NOV281983

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