ML20084L354

Forwards Complete Response to Tracked Action Item 074 of Const Implementation Overview Nir 22,23,24,25,26 & 27 Re Document Control Program for Turbine Bldg Walkdown

ML20084L354
Person / Time
Site:	Midland
Issue date:	05/04/1984
From:	CONSUMERS ENERGY CO. (FORMERLY CONSUMERS POWER CO.)
To:	STONE & WEBSTER, INC.
References
CSC-7716, NUDOCS 8405140432
Download: ML20084L354 (19)

Text

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[ '3df hyh CONSUMERS POWER COMPANT y

fh33 MIDLAND ENERGY CENTER Transmittal Not CSC-7716 Date:

May 4, 1984 To:

Stone & Webster P O Box 1963 Midland, MI 48640 STAF PR\\HCIPbt ygp oE RA E4ASE Attached Isa Partial Response To b

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A g

X Complete Response To 1G SCS

^

For Your Information Other

==

Description:==

Tracked Action Item 074.

Signature: M x

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cc:

JGKeppler, NR egion III w/a?

JJHarrison','NRC Region III w/a' RJCook, NRC Site w/a RAWells, MPQAD w/a BHPeck, MEC w/a NIReichel, MEC w/a ok DDJohnson, MEC w/a h

8405140432 840504 9@

gDRADOCK 05000329

'N PM

P ITEM / HOLD POINT NOTIFICATION FORM Sheet 1 Of 2 ITEM NUMBER HOLD Polid huMBER STONE S WEESTER o '7V CONSTRUCTION IMPLEMENTATION

@TR ACKED ACTION ITEM OVERVIEW O TRACKED INFORMATION ITEM N/P/ ANP NuclEd# MANTJ.0. No. /4509 O TRACKED RECOMMENDATION ITEM, O UNTRACKEDITEM REF'E3ENCE(S)

NIR's 22,23,24,25,26 & 27 O HOLD POINT NOTIFICATION 1

CONDITION DETAILS During the period of March 19 to April 3, 1984, CIO conducted an in process evaluation of the site document control program which included'the corrective action related to CIO Item Number 043 and concerns expre.ssed to CIO by a CPCo employee.

Specific discrepancies noted are contained in the referenced NIR's.

Additionally, the following general concerns resulted from the evaluation:

1.

The document control program is very complex and problems currently being experienced are exaggerated by.

I a.

The number of design changes being generated.

b.

The number of different vehicles for making design changes and for updating design documents.

c.

The number of different document types that are being issued.

(P AGE E YES NO*S)

NO (Continued on Sheet 2)

ATTACHMENTS DATE RESPONSE REQ'D.

INITIATOR /DATE If INITIATION APPROVED /DATE l

+n W W h>A k k d %8 WL 1-n 89 RESPONSE (SEE NOTE)

//

I Response sent by our Letter CSC-77044 dated April 30, 1984.

(PAGE O YES NCPS>

0 NO t

ATTACHMENTS EST. CORRECTIVE ACTION RES D[

TITLE DATE COMPLE N DATE i/

/

g

[

gy RESPONSE ACCEPTED DATE RESPONSE VERIFIED / CLOSED DATE NOTE - FOR TR ACEED ACTION ITEMS ONLY. EXPLAIN CLE ARLY OR REFERENCE ATT ACHWENTS FOR:

1) CAUSE OF OBSERVED CONDITION 2) CORRECTIVE ACTION TAKEN 3) PREVENTlYE ACTION TAKEN 500-003(CN)

r m

Sheet 2 of 2 Condition Details (Cont.)

d.

The total volume of documents issued or available from previous issues.

2.

Training of personnel handling and using documents has not been extensive enough to prevent errors in document issues, control or use.

3.

Present implementation of the field drawing revision systems can lead to hardware deficiencies which would not be identified in the field.

4.

MPQAD must more aggressively monitor the document distribution and control process of discrepancies are to be identified and corrected.

5.

Complete implementation of system 38 and a reduction in the log time between document receipt and issue should be pursued expeditiously to decrease the discrepancies between document register listings of current documents and those available to users and to maintain consistency between Field Document Control Center and Document Control Stations.

6.

A walkdown of various plant buildings identified the attach-ed lists of discrepant documents. No determination could be made of whether the documents were in use or not since personnel were not available for comment.

However, having 3

these documents in work locations could easily lead to their use for plan work.

Although many of the discrepancies noted by CIO were in areas that are Non Q, the same documents and document control process are used for Q work.

Therefore it is impo" tant that corrective action be implemented prior to initiation of CCP Phase II work.

Please advise CIO of the actions CPCo is taking or intends to take to address these issues identified above.

500-003(CN) w

item 074 Attachment I WALK-DOWN TV'RBINE BUILDING Page 1 of 4

~

DOCUMENT REV.

COMMENTS 1.

M0604 SH 8 12 FCN M03169 incorporated in Rev. 11 but still shown on register.

2.

M0603 SH 17 8

FCN M0 3267 incorporated in Rev. 6 but still shown on register.

3.

FSK 2-632-11-23 0

FCN M20247 not shown on FDCC outstanding amendment stamp but was in CWP.

4.

C-735 4

FCR C5004 listed in wrong block (in FCN block) on FDCC outstanding amendment stamp.

5.

C-733 29 FCN C5004 was attached, however the register shows no issue date.

6.

FSK-M-0GBD-3 DWG was stamped " Uncontrolled Not To Be Used 205-2-H24 for Construction".

Work being performed was hanger modification.

No attachment stamp on the drawing.

IDCN 12379 had CGS 0 work print stamp.

7.

FSK-M-0GBD-2 DWG was stamped " Uncontrolled Not To Be Used 205-2-H16 for Construction".

Work being performed was hanger modification.

No attachment stamp on the drawing.

IDCN 12378 had CGS 0 work print stamp.

8.

FSK-M-0GBD-3 DWG was. stamped " Uncontrolled Not To Be Used 205-2-H5 for Construction".

Work being performed was hanger modification.

No attachment stamp on the drawing.

IDCN 12376 had CGS 0 work print stamp.

9.

FSK-M-0GBD 3

DWG was stamped " Uncontrolled Not To Be Used 205-2-H6 for Construction".

Work being performed was hanger modification.

No attachment stamp on the drawing.

IDCN 12377 had CGS 0 work print stamp.

10.

FSK-M-0GBD 3

DWG was stamped " Uncontrolled Not To Be Used 205-3-H8 for Constructiori" Work being performed was ha'nger modification.

No attachment stamp on the drawing.

IDCN 11914 had CGS 0 work print

' stamp.

11.

J-203A-71-13 submitta]

Register shows IDCN 23995 but not listed and 13 attached to drawing.

12.

E-391 SH4 3

Marked voided and was found with the work-package.

?

Revision block illegible, register shows 13.

A-20 l

Rev. 22

%0-00H CN )

Item 074 WALK-DOWN TURBINE BUILDI'NG Attachment I Page 2 of 4 DOCUMENT REV.

COMMENTS 14.

C-732 22 Register shows DCN #16 but not attached to the drawing.

15.

C-404 SH 6

?

Revision block torn-off.

16.

C-733 29 Register shows FCN C-5002 but not attached to the drawing.

17.

C-735 4

Copy of a FCN attached to the drawing without the FCN number, dated 3-9-84. (Team #29) l i

I l

l l

500-003(CN)

f Item 074 a

l WALK-DOWN TURBINE BUILDING ge 3 4

~

DOCUMENT REV.

COMMENTS REV.

18 E675 SH 1 28 29 OUT OF REV.

19 A-17 18 19 OUT OF REV.

20 E682 SH1 24 25 0UT OF REV.

21 C-732 20 22 OUT OF REV.

22 E-685 SH1 15 16 0UT OF REV.

j 23 E-654 16 17 OUT OF REV.

24 E-679 SH1 34 35 0UT OF REV.

25 E-679 SH2 10 11 OUT OF REV.

26 C-3161 SH7 0

1 OUT OF REV.

27 E-681 SH1 26 27 OUT OF REV.

28 C-3161 SH4 0

1 OUT OF REV.

29 E-683 SH1 24 25 0UT OF REV.

30 C-878 16 17 OUT OF REV.

31 E-684 SH1 20 21 OUT OF REV.

32 FSK-J0-0072 SH1 6

5 0UT OF REV.

33 SK-2-632-4-4 503 1/fl 80 OUT OF REV.

34 FSK-JC2-0100 SH4 1

2 OUT OF REV.

l 35 E-680 SH1 27 Register shows FCN-E-301 but not attached to the drawing.

36 E-583 SH1 13 Register shows IDCN 21820 but not attached to the drawing.

37 J-203A-82-13 submittal Register shows IDCN 24056 but not 13 attached to the drawing.

38 J-203A-85-11 submittal Register shows IDCN 24058 but not 11 attached to the drawing.

39 submittal Register shows IDCN's 21956 J-203A-70-11 11 23994 but not attached to the drawing.

l 40 J-203A-69-13 submittal Register shows IDCN 23993 but not 13 attached to the drawing.

j WALK-DOWN INSIDE CONTAINMEN T 1

41 FSK-JC2-0084 SH2 1

3 Drawing stamped controlled in red, and there was an old work print stamp on the drawing.

42 FSK-JC2-0090 0

-2 Drawing stamped controlled in red.

l 43 FSK-JC2-0085 SH 2 1

2 Drawing stamped "Workprint" as well as " Void" in red.

500-003(CN)

Item 074 I

WALK-DOWN TURBINE BUILDING g

4 DOCUMENT REY.

COMMENTS REV.

44 FSK-JC2-0091 0

2 Drawing stamped "Workprint" as well as " Void" in red.

45 C-1043 7

7 DCN #5 & 6 not attached however, DCN #5 & 6 were listed in front of drawing.

46 E-750 SH1 No status stamp on the drawing.

WALK-DOWN DOCUMENT CONTROL CENTER STATION #503 47 M 0410 18 18 Register dated 3/1/84 shows five change documents as currently outstanding, however, rev. 18 has them as being incorporated (July 83) 48 M-483-3A 11 FCN-M-5749 was stamped uncontrolled as attached to the j

controlled DWG (M-483-3A) f WALK-DOWN SERVICE WATER PUMP-HOUSE 49 C-805 16 16 Register indicates that DCN #11 should be attached to drawing.

DCN #11 not attached to drawing.

a Drawing was partially illegible.

STATION N0 503 j

50 M-438-3A 11 11 Drawing stamped " Controlled" with FCN M-5749 attached and stamped Y

1 I

l I

500-003(CN)

E X8em 074 Attachment II Page 1 of 7

. Drawing M-480 Rev 18 was evaluated at Stations 59,309,501,

& 503.

The Drawing differed at each Station as follows:

ATTACHMENTS STATION #

ATTACHED /SHOULD NOT BE NOT ATTACHED /SHOULD BE 309 IDCN's 23061 & 23063 FCR M-10283 503 FCR M-7044 FCR's M-10157, M-10196, M-10796, M-10283 IDCN's 23061 & 23063 IDCN 24776 501 FCR's M-10157, M-10196 M-10796, M-10283 59.

All Attachments are OK however, the copy they use for control is not stamped " Controlled".

-The attachments shown in the 3-26-84 register are all

current, however, the extreme right hand column " Process Distr" does not have the date of distribution of all these documents.

Also the date column to the left of this column is supposed to reflect the date the attachments were received

.at DCC-All.these dates do not appear either.

t e

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\\ d Company File Bl.1.7, 0655 usoi.no proi.ct: po son issa, u ai.no, ui 4as4o. (sivi sas.asso UFI: 99*08 Serial: CSC-77'04 April 30, 1984 Mr. J. E. Karr Stone and Webster Michigan, Inc.

P.O. Box 1963 Midland, MI 48640 MIDLAND ENERGY CENTER GWO7020 STONE AND WEBSTER CONSTRUCTION IMPLEMENTATION OVERVIEW ITEM NO. 074 DATED 4-13-84 In pursuance of your Open Item Number 074, a response is attached to address your concerns delineated in your item notification form.

This also provides an updated response to tracked Open Item hbmber 043 in reference to Document. Control Distribution Back Log.

Should you or your staff have any questions on the content, contact Lonnie Worley at extension 7707.

DLQ/LWW/jld cc:

DDJohnson BHPeck h7 Reichel TASpelman JBKeppler, Regional Administrator, Region III JJHarrison, Chief, Midland Section, Region III BBurgess, NRC Resident Inspector RAWells, MPQAD

Rasponse to Itsm Numbar 074 Dated April 13, 1984:

?

Many of the concerns expressed in this " Item / Hold Point Notification" were previously identified as part of the document control corrective action plan, the Bechtel self appraisal team (SAT) analysis, and various engineering initiatives underway in both the " SAT" review and in previous management presentations.

Implementation of several items are currently in process with the remaining in review and/or forthcoming.

The following items address each of the concerns identified:

1.

Corrective action in identified areas will reduce the complexity of the document control program.

Items identified below will enhance document control program understanding by all organizations.

During the week of March 14, a constructibility/instructibility review a.

was performed consisting of representatives from Resident Engineering, Field Engineering, and MPQAD. This-review consisted of an in-depth look at the present design documents and Project Quality control Instructions (PQCIs). The review determined that present design are constructible and that the PQCIs are verifiable for the completion of constructions activities.

Based on the above review, we have confidence that future design changes will be minimized.

b.

The number of the different vehicles being utilized for making design changes and for updating design documents is currently being reviewed and evaluated.

Bechtel and CPCo are reviewing the different document types being used c.

on the project with a goal of reducing the number to a minimum number and clearly defining the use of each.

This review is part of the corrective action plan.

It is important to remember that the number of different document types being issued will be reduced as different scopes of work permit. The'need for SAPS will be eliminated after l

Phase I of the CCP is complete.

At the commencement of Phase II, work prints will be the primary document utilized for field installations.

i d.

In order to reduce the volume of documents issued or available from previous issues, the field has been purged for the following types of drawings / documents:

1)

Old work prints 2)

Drawings / documents no longer being utilized 3)

Drawings / documents not required 2.

Training of field personnel on document control issues, control or use will consist of the following:

Training of Field. Engineers /Other Users Document control orientation sessions will be conducted during May to familiarize jobsite personnel with the document control process, controls, and tools (registers, forms, etc).

0084m1

Training of psrsonnel on the use of the System 38 terminals for DDR ncessa will be conducted during May.

Training of Document Control Personnel The applicable processing personnel in document control have been trained on System 38.

These training sessions began in August 1983 and is an ongoing activity as new hires are indoctrinated.

i Several changes have been implemented within the document control organization to increase the overall training within the group:

l a.

Five experienced document control supervisors have been added to the j

staff within the past 2 months.

Additional supervisors were added earlier beginning in September 1983.

b.

The number of coordinators have been increased in all areas, Training programs for specific areas are being prepared as part of the c.

t corrective action plan, With the increase in supervisors and coordinators, more on-the-job training will be accomplished.

The Internal Audit Group will be monitoring the processing activities performed by the document control personnel for compliance to proce3ures.

This will be another resource which can be utilized to identify any training problems.

3.

A system of checks and balances are provided in the requirements of the

.CCP to assure that all installations are completed to the latest engineering criteria.

Prior to commencement of physical work in Phase II of the CCP, the j

a.

i latest criteria is again verified against the status assessment prints to determine if additional design changes have been made.

i l

t b.

Additionally, during Phase II of CCP, the final installed system will be inspected by MPQAD-QC for acceptability to the latest design j

criteria.

t As a final check, prior to system turnover, the system is walked down c.

to verify that the system is complete and in accordance to the latest design criteria.

l Document control and engineering has assurance through the checks and i

balances identified above that any deficiencies.will be identified.

4.

MPQAD is monitoring the document distribution and control process more t

aggressively.

MPQAD has increased its role in the document control areas as follows:

l 0084m2

Increase concantration on process through:

a.

Implementing the Document Control Assurance Group b.

Increasing in-process audits c.

Formal releases of satellite stations d.

Augmented corrective action plan I

The. Document Control Assurance Group will:

i a.

Maximize MPQAD involvement in FDCC process and corrective' action plans j

b.

Provide on-going checks and feedback on system c.

Maximize checks on correct document use Formal release of satellite stations:

I a.

MPQAD will approve and release satellite station for Q-related activities by written notice.

The augmented corrective action plan was a result of the Document Control i

Task Force represented by SMO and MPQAD. The augmented corrective action l

plan reprioritized document control priorities and accelerated various activities within the short-and long-term corrective action plan.

Tta augmented corrective action plan is as follows r

a.

Eliminate "old" work prints by April 13, 1984. (Completed) b.

Evaluate the number and types of drawings and define their purpose by April 20, 1984.

(Evaluation in approval cycle) c.

Clarify instructions for drawing use by external jobsite groups by

-April 27, 1984.

d.

Review all document control procedures for completeness, consistency, and consolidate to a practical degree by June 1, 1984.

l e.

Eliminate backlog by May 1, 1984. (Completed) f.

Develop a plan for incorporating construction assistants into document control and review management and supervision of the work print group by April 16, 1984.

(Plan in approval cycle) l g.

Naw schedule and scope for satellite stations including collapse of l

all current work print stations into same by May 1, 1984.

(Plan is I

ready for issue) l 5.

The complete impicmentation of the System 38 is tentatively scheduled for July 1984.

The existing backlog within the Document Control Center is scheduled to be worked off by May 1, 1984.

I I

0084m3

6.

Five main satellite stations containing controlled decwings and w3rk prints are currently being established by the Document Control Center.

The forecasted completion for controlled drawings is mid-May. Work prints are scheduled for incorporation by mid-June.

Trained document control personnel will be located at each station for the purpose of maintaining the station and in providing assistance to those individuals utilizing the station.

Therefore, construction personnel will be able to utilize the controlled documentation in those areas to verify they are working with the latest design criteria.

b b

e e

-0084m4

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