ML20087P844

Forwards Const Implementation Overview Weekly Rept 40 for 840312-16

ML20087P844
Person / Time
Site:	Midland
Issue date:	03/26/1984
From:	Karr J STONE & WEBSTER, INC.
To:	James Keppler NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III)
References
SWM-063, SWM-63, NUDOCS 8404090421
Download: ML20087P844 (22)

Text

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PRINCIPAL STAFP STONE & WEBSTER MICHIGAN, INC.v Wl u-?!*

D/RA Ot-P.O. box 2325. BOSTON M ASSACHUSETTS O2107 UHh NibF h

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F)f3 stiA ML yp-yito LA-o Mr. J. G. Keppler, Administrator, Region III March 26, 1984 Nuclear Regulatory Commission 799 Roosevelt Road J.O. No. 14509 Glen Ellyn, Illinois 60137 SWM-063 Docket No. 50-329/330 CIO Weekly Report No. 40 Construction Implementation Overview Midland Nuclear Power Plant The Construction Implementation Overview (CIO) Weekly Report Number 40, for the period March 12, 1984 through March 16, 1984, is enclosed.

This report includes a summary of CIO activities for the week and open Items, NIRs, and Hold Points.

hd VJ. E. Karr CIO Program Manager Enclosures JEK:NL cc:

DLQuamme, CPCo Midland (site)

NIReichel, CPCo Midland (site)

RAWells, CPCo Midland (site)

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

Public Document Room 8404090421 840326 PDR ADOCK 05000 gg 3 0 193,i S

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V, Stone & Webster Michigan, Inc.

CONSTRUCTION IMPLEMENTATION OVERVIEW

- CIO -

WEEKLY REPORT NUMBER 40 PERIOD - March 12, 1984 through March 16, 1984 Contents.

Page

.I.

0verview........................................

1 II. ' Activity Summary................................

2 III. _ Activity Details................................

2 IV.

General.........................................

7 V.

Attachments.....................................

7 A.

CIO Item Summary B.. Hold Point' Summary C.1 Nonconformance -Identification Report (NIR) Summary D.

Meeting Summary

.VI. Exhibits 1.

CCP Phase I Activity IE E 1 EIN EE 8

I m

7 CIO REPORT NtJMBER 40 I. OVERVIEW During this reporting period, Status Assessment (S/A) and Quality

)

Verification Program (QVP) activities continued. Additionally, activity in the area of the Hanger Reinspection Program (HRP) was initiated.

Overall activity levels were increased from previous reporting periods.

1 This was due to the assignment of additional personnel and tc the NRC l

release of additional modules for Phase I activity as identified in CIO Report Number 39.

It is noted that this additional release by the NRC covers only portions of each released module.

The release specifically identifies the systems which are necessary to support the turbine roll milestone of CPCo.

Exhibit 1 to this report identifies the modules currently released by the NRC and the S/A, QVP and HRP activity in each for this reporting period.

The principal CIO activity during this period was the ongoing assessment of Construction Completion Program (CCP) Phase I activities.

Overall, CCP activity continues to be performed in an acceptable manner.

Some deficiencies were observed, however, and these are described in Section III, following.

During this reporting period,.CI0'also completed, continued, or initiated assessments of additional CPCo activity and the activities of Zack and B&W.

These are described in the following sections of this report.

Page.2 of 7 II. ACTIVITY

SUMMARY

A.

.CCP Activity Monitoring B.

B&W ASME Program Activity Evaluation

-C.

Evaluation of BPCc Site Auditing Activities D.

Document Control Assessments E.

Training Program Evaluation j

F.

Review of Zack Welder Qualification Procedure G.

Attendance at Various Site Meetings i

l H.

CIO Action to Close Out Open Items and NIR's as Responses are Received III.- ACTIVITY DETAILS (Paragraphs Correspond to Items in Section II)

A.

CIO overviewed the CCP Phase I activities underway in each active module during this reporting period.

CIO reviewed personnel qualifications, checked documents in use, witnessed work in progress and reviewed resultant documentation.

CIO also overviewed the dispositioning of NCR's by BPCo Field Engineers in Module 800.

For the majority of work reviewed by CIO, all activities were performed satisfactorily and in accordance with procedures.

CIO did, however, identify one deficiency.

In one case, S/A was being performed using documents that were not marked " Status Assessment Print" or with an expiration ~ date.

These documents were being used as reference drawings and were stamped " Uncontrolled not to be used

.for Construction". This was identified as CIO Item Number 063.

On March 13,

1984, CIO met with CPCo, MPQAD and BPCo personnel -

relative to.CCP progress and status.

CPCo presented the current

I Page 3 of 7 status of CCP Phase I activity and reviewed with CIO their intent to request NRC release of additional modules fo'r CCP Phase I activity in the near future.

The CPCo presentation was essentially the same as that intended for use in a meeting with the NRC.

During the discussion which followed, CIO identified the following relative to CCP Phase I activity and the eventual transition to CCP Phase II.

Insofar as field activities are concerned, CCP activity (S/A and QVP) is proceeding very well.

With the exception of minor deviations (as identified in this and previous CIO reports), the program is considered satisfactory in all respects.

CIO is concerned that the program integration necessary to identify the full scope of work required, status progress and report on completion, does not appear to be functioning well at this time. Although the coint of transition to Phase II has not

-yet been reached, CI0's assessment is that integration should_be an ongoing effort if problems are to be avoided in the future.

CIC foresees difficulty in maintaining the administrative work load imposed by the current training program.

_CIO is still identifying inconsistencies in the site document control program implementation.

These have been minor and isolated instances but, with increased work loads, more attention will have to be directed to this area if satisfactory performance

Page 4 of 7

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is to be maintained.

A further meeting was held between CIO and CPCo, MPQAD and BPCo on the above issues on March 15, 1984.

Additional information was provided and_ discussed by each organization.

CIO concerns remained the same.

CPCo indicated that they will continue to work,to resolve issues raised by CIO.

B.

During this period, CIO initiated an evaluation of the B&W Quality Assurance Program with particular emphasis on contemplated work under the jurisdiction of the ASME Boiler and Pressure Vessel Code,Section III.

~The initial assessment work included a review of the Final Safety Analysis Report, B&W Program manuals and procedures and implementation documentation.

The below listed issues have been identified to date which require further information to resolve or identify as CIO Items /NIR's.

CIO will pursue these in the next reporting period.

Procedures in the QC Manual were missing pages (four procedures of eleven reviewed).

One NDE procedure appears to be unapproved by the Authorized Nuclear Inspector (ANI).

BPCo is not on B&W's approved ASME supplier's list but is 1providing material.

BPCo' Certificates of Compliance provided to B&W appear deficient l

Page 5 of 7 in at least five instances.

Current welding undercut requirements appear to conflict with specified codes and the FSAR.

Uncertified torque paint may have been used on "Q" bolts.

BPCo material withdrawal requests provided to B&W appear to be corrected improperly.

C.

CIO. conducted an evaluation of BPCo site auditing activities during this reporting period.

Within the assigned scope of work for BPCo site personnel, the audit program is functioning adequately and in accordance with procedures (Re: Checklist MP-MIS-088-0001).

Some attributes listed in CI0's evaluation checklist were not verifiable

-during this evaluation _ since they were the responsibility of BPCo's Ann Arbor or San ~ Francisco office.

These will be considered for inclusion in future CIO assessments.

D.

During CIO overview of QVP activities in Module 340, two drawings were found on a pipe-whip restraint.

These were not controlled or stamped as Status Assessment Prints or Work Prints.

Field Document Control

was notified and'the prints were removed.

CIO has not identified the user of the documents to date or the reason they were in the field.

This issue will be followed up by CIO next week.

-CIO conducted an assessment of Zack document control ~ procedures and

-practices.

CIO found the procedures-and practices to be acceptable a

Page 6 of 7 with one exception which was identified as CIO Item Number 065.

This item identifies a-discrepancy in Zack Procedure MB-FP-7C.

The procedure references the SCN (Specification Change Notice) as the document used to notify Zack of addenda retirement information.

The correct document is a SCCN (Subcontractor Change Notice).

CIO continued the review of document control concerns presented to CIO by a CPCo employee.

This activity should be completed prior to March 30, 1984.

- E.

CIO attended and evaluated the following training class:

Issuing, Verifying and Documenting Terminations and Termination Reworks (FPE-9.200)

The training was conducted in an effective manner and in accordance with Procedure FPG-2.000 (Re: Checklist Number MP-MIS-035E-0019)

I F.

CIO reviewed Zack Welder Qua'lification Procedure MB-FP-18 during an ongoing assessment of Zack welding. The procedure was acceptable with the exception that the method for updating welder qualifications was not specified.

This was issued as CIO Item Nu'mber 066.

G.

Meetings attended by CIO are summarized in Attachment D.

H.

Activity relative to CIO Items, Hold Points and NIR's is summarized in Attachments A, B and C respectively.

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- I V.' GENERAL A.

CIO staffing remained at 33 during this reporting period.

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V.

ATTACHMENTS l

1 A. - CIO-Item Summary l

'B. - CIO Hold Point Summary-C. - CIO NIR Summary i

D. - Meeting Summary' t

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NOTES:

1.

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identifies changes from previous report CONSTRUCTION IMPLEMENTATION OVERVIEW 2.

Closed items will be identified in the report for the MIDLAND NUCLEAR C0 GENERATION PLANT

~ week of closure and dropped from further reporting CIO ITEM

SUMMARY

Classifi-Open CPCo Response Closed Remarks

. No.

Description Document /Date Document /Date Document /Date cation-030 Tracked Need to review Vendor Equipment Report No. 5 Action Verification Program - MPQAD/SMO 7/18/83 034 Tracked NIR 008 issued on November 10, 1983 Report No. 22 N/A Item Notiff-Item closed 7

Action to address upgrading five training 11/14/83 cation Report subsequent to y

level codes in the System Team 3/12/84 NIR closure.

Training Matrix.

037 Tracked CIO observed that two boards with Report No. 24 Partial respons<

Action protruding nails lying in Cable Tray 11/29/83 (CSC 7244 dated 1AKA019 (Q Tray) had punctured the 1/27/84) accepted cable jacket of a "Q" cable.

The via CIO letter cable is Q-Channel A. 480V, MCC.

SWMCP-024 dated NCR 000925 was issued by MPQAD on 2/3/84. Closurc j

November 22, 1983. CIO will track pending cable this item to assure that corrective repair during action (repair) has been performed CCP Phase II.

gg to approved procedures.

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CIO ITEM

SUMMARY

- CONTINUATION SilEET Classifi-Open CPCo Response Closed i

No.

cation Description Document /Date Document /Date Docunent/Date Remarks 043 Tracked CIO Phase III evaluation of arent-Item Notifi-Item Notifi-Ref. CPCo Action.

tectural/ civil document control cation Report cation Report letter measures resulted in findings listed 1/6/84 1/17/84 CSM-0719, in the Item Notification (similar 1/16/84 conditions are identified in MPQAD MQAR-DAT-1). CIO requests CPCo's l

plan for addressing the problems i

noted and for implementing and

(

verifying corrective action on both i

l MQAR-DAT-1 and this item.

l 046 Tracked CIO requests placement on distribu-Item Notifi-Item Notifi-Partial CPCo Infor-tion for documentation and proce-cation Report cation Report response -

mation dures pertinent to the NRC Project 1/18/84 2/8/84 Implementation Commitment Tracking Program, advance to take 8 to notice of related meeting and a 12 months.

schedule which addresses completion of these events.

/N RAF c+ n 049 Tracked A CIO review of document control Item Notifi-Item Notifi-CIO awaiting 8 [E Infor-methods resulted in the following cation Report cation Report completion of

["c mation observations:

(1) Some uncontrolled 1/26/84 2/3/84 CPCo correc-

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specs contained controlled copies of Live action.

c' jj FCRs, FCNs and SCNs; (2) Controlled 2= ;t documents are being " decontrolled"

_e via a line-out method which is not P

proceduralized ; and C)

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CIO. ITEM

SUMMARY

- CONTINUATION SilEET Classifi-Open CPCo Response Closed No.

cation Description Doctment/Date Document /Date Docinent/Date Remarks

-049 (Con't)

(3) CPCo DCC personnel are unaware of the Bechtel Ann Ar'oor method of Identifying document transmittals as either controlled or uncontrolled.

051 Track'ed CIO requests to be informed of meet-Item Notiff-Partial response Action Ings regarding the proposed plan cation Report provided via of action to address deficiencies 2/3/84 CSC-7423 dated identified in MPQAD Audit Report No.

3/6/84. CIO MSA-83-7 as well as a copy of the awaiting further proposed plan one week prior to its CPCo action.

implementation.

052 Tracked CIO requests copies of audit Item Notifi-Item Notifi-A total of 40 t

l Infor-reports for audits performed cation Report cation Report audit reports mation by the NRC, CPCo and BPCo of 2/3/84 3/12/84 have been pro-site activities / organizations which vided by CPCo l

addressed Criteria XVIII of 10CFR50 between 3/12/84 Appendix B.

and 3/15/84.

l 053 Tracked As described in Section 4.2 of the Item Notifi-Item Notifi-Action CCP, CIO requests that CPCo provide cation Report cation Report a listing of all status assessment 2/16/84 2/23/84 teams, the respective team's scope and their working schedule.

,em 055 Tracked Clarification is required regarding Item Notifi-Item Notiff-O R-(

97 Infor-training requirements for area team cation Report cation Report

%:o mation

1. 23/24 personnel performing status 2/17/84 3/15/84 assessment of raceway completion.

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CIO ITEM StM1ARY - CONTINUATION S LEET Classifi-Open CPCo Response

' Closed No..

cation Description Document /Date Document /Date Document /Date Remarks j

056 Tracked During a training ev'aluation for' Item Notifi-Item Notifi-1 Infor-PQCI C-1.50, CIO observed discrep-cation Report cation Report mation ancies in the lesson plan. 'CIO.

2/17/84 2/29/84 requests a review to determine what impact these items have on the training provided. CIO further requests information on how MPQAD assures that document changes are referenced on the lesson plan.

058 Tracked CPCo should review past audits to Item Notifi-Item Notifi-Infor-assure that applicable 10CFR50, cation Report cation Report i

mation' Appendix B criteria were adequately 2/18/84 3/13/84 l

addressed.

059 Tracked CPCo should review audits performed Item Notifi-Item Notifi-Infor-prior to June 1983 to assure adequacy cation Report cation Report

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mation of auditing, proper closeout,'10CFR50 2/18/84 3/13/84 Appendix B compliance, and objective -

evidence as to adequacy of the audits 060 Tracked CIO provides a series of recommen-Item Notifi-Item Notifi-Recommen-dations in the following categories:

cation Report cation Report dation

1) Management Involvement; 2) Track-2/17/84 3/13/84 RF 1

-ing Audits / Audit Findings; and 3)

Audit Personnel Training and-Certif-

{g icate Records.

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CIO ITEM

SUMMARY

- CONTINUATION SHEET Classifi-Open CPCo Response Closed

'No..

cation Description Document /Date Document /Date Document /Date Remarks e

061 Tracked CIO recommends that the receipt Item Notifi-Recommen-acknowledgement copy of the Bechtel cation Report dation transmittal form be revised to pro-3/2/84 vide for a signature /date by the 4

recipient.

062 Tracked CIO has determined that status Item Notifi-CPCo has re-Action assessment is being performed on cation Report quested BPCo pipe supports by personnel-who have 3/6/84 (Ref. CSC-7424 not completed required training. All dated 3/7/84) personnel performing hanger support to perform status assessment should be checked corrective action and to assure they are properly qualified respond by Any previous. supports that were j

assessed by unqualified personnel 3/12/84.

should be reassessed.

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063 Tracked During a review of referenced draw-Item Notifi-1 Action ings'being used for status assess-cation Report ment, CIO identified a number of 3/15/84

's drawing identification and revision control discrepancies.

i 064 Tracked CIO recommends implementation of-Item Notifi-f[!f Recommen-MPQAD plan to consolidate welding cation Report g [5 '

dation inspection requirements for electri-3/16/84 j['c 4

cal / instrumentation equipment and gg' supports into PQCI's CW-1.00 and "I;

EW-1.00.

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CIO ITEM SIM4ARY

. CONTINUATION SH.EET

.Classifi-Open CPCo Response Closed No..

cation Description Document /Date Document /Date Document /Date Remarks 065' Tracked CIO recommends that Zack Procedure Item Notiff-Infor-MB-FP-7C be revised to reflect the cation Report mation BPCo requirement that notification 3/16/84 of addenda retirement information for BPCo documents is provided via

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a Subcontractor Change Notice (SCCN).

066 Tracked CIO recommends that Zack revise.

Item Notifi-Infor-either Procedure MP-FP-18 or Pro-cation Report mation cedure MP-FP-23 In order that the 3/16/84 method used to update the welder qualification matrix be properly addressed.

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NOTES:

1. d identifies changes from previous report

' CONSTRUCTION IMPLEMENTATION OVERVIEW

2. Closed lloid Points will be identified in the Report for MIDLAND N" CLEAR C0 GENERATION PLANT the week of closure and dropped from further reporting

CIO HOLD POINT

SUMMARY

Established CPCo Response Lifted RMs No.

Description Document /Date Document /Date Document /Date 005 CPCo has committed 10 develop a Vendor Report No. 18 Equipment Verification Program. Program 10/17/83 is required before implementation of Phase II.

i 007 Evaluation'of Management Review of Report No. 19 results of Phase I activities.

Evalua-10/26/83 tion is required before implementation of Phase II.

l 010 NIR 008 has been issued on November Report No. 22 N/A Hold Point Hold Point closed i

(

10, 1983 to address upgrading five-11/14/83 Notification subsequent to l

Items in the System Team Training-Report 3/12/84 NIR closure.

Matrix of the Construction Training Program.

1 Corrective ~ action must be completed l

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

I

.015 CIO has requested that the requirements Hold Point Hold Point 7r,

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4 5 l' for the exclusive use of chromel-alumel Notification Notification thermocouples and extension wires for Report 2/1/84 Report 2/10/84 I

PWHT and certification of.the accuracy

$ 5?

of the thermocouples via a C of C be "E

reinstated in PQCI PW-1.00.

Release is U'

contingent upon CIO review and acceptance of the calibration certification.

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C STONE & WEBSTER MICillGAN, INC.

NOTES:

1.

(Identifieschangesfrompreviousreport

' CONSTRUCTION IMPLEMENTATION OVERVIEW 2.

Closed illRs will be identified in the report for the MIDLAND NUCLEAR C0 GENERATION PLANT week of closure and dropped from further reporting i

110tlCONFORMANCE IDENTIFICATION REPORT StM4ARY No.'

Description

. Issue Date Response Date Closure Date Remarks 008 Need to upgrade five training level codes 11/10/83 02/29/84 03/12/84 Reference completed'(

in the System Team Training Matrix.

checkIlst MP-MIS-045E-0002 and NIR 014 As documented on CIO Evaluation No. MP-MIS-01/27/84 021.

074-0001, FPD 1.000 requirement that a copy I

of all transmittals for "Q" listed items be i

transmitted to MPQA0 and the Project Supplier Quality Representative was not being satisfied 015 In violation of PSPG-7.1, correction fluid 02/17/84 was used on MPQAD Audit Report No. M01-346-02.

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016 Contrary to their MPQAD Procedure F-1M deft-02/17/84 nitions. "nonconformances" were documented as " observations" in Audit No. M01-346-02.

017 The recommended corrective action for Audit 02/17/84

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finding 01F, Audit No. M01-346-02 was not l

Implemented, yet the audit was closed out.

019 As documented on CIO Evaluation No. MP-MIS-02/29/84 082-0001, several discrepancies were identi-3x fled on the FDDL.

gg R5 020 As documented on t,.

Evaluation No. MP-MIS-03/02/84 gx 082-0001, 4 out of 25 Distribution change gg Request Forms were not properly signed in q

vi01ation of FPZ-1.000.

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CIO NONCONFORMANCE IDENTIFICATION REPORT

SUMMARY

- CONTINUATION SHEET No.

Description -

Issue Date Response Date Closure Date Remarks 021 During.a resampling/ evaluation of the 03/12/84 Corrective action Construction Training Matrix in conjunction was initiated at the with the closure of NIR 008, two nonconfor-time of the evalua- -(

mances were identified regarding requirements tion in the form of for training to BPCo field procedures.-

changes to the appro-priate matrices.

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CONSTRUCTION IMPLEMENTATION OVERVIEW MIDLAND NUCLEAR C0 GENERATION PLANT WEEKLY MEETING SUPMARY Date "9

Attendees Discussion Topic CIO Comments March 12, NRC Meeting NRC

1) NRC was concerned that different revisions Documents are attachments to 1984 with CIO CIO of documents in a package had the same SAP prints and can properly SAP date.

have different revisions.

No problem identified.

March 13, Construction CPCo

1) Discussed general status of construction No CIO concerns identifieo.

1984 Status BPCo Meeting B&W CIO March 13, Area Team CPCo

1) Status Assessment scheduled to be complete No CIO concerns identified.

1984 Staff Meeting MPQAD by 3/23/84 to support turbine roll

2) Discussed diesel generator work

3) Emphasized need to update MLCS

4) Discussed work required to support sub-contractor in Control Room March 13, CCP General CPCo

1) Discussed CPCo plans for near term presen-CIO identified concerns gg 1984 Coordination MPQAD tation to NRC on CCP status relative to integration of gg Meeting BPCo CCP Phase I results into a ga;;-

2) Reviewed presentation to be made to the CIO NRC in the near future on CPCo proposal master list of plant status g,

for release of additional modules for and work to go.

Eg CCP Phase I.

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WEEKLY MEETING SUPMARY - CONTINUATION SHEET Date

Attendees Discussion Topic CIO Comments t

l March 13, Group Staff CPCo

1) Discussed CIO NIR 021 (Training Matrix)

No CIO concerns identified.

March 14, Meetings MPQAD

2) Status Assessment can begin in Control Room in two weeks if Module 240 is released ch 16, 1984

3) Emphasized training requirements

4) MLCS must be kept up to date

5) May get more modules released soon March 13, HRP Action CPCo

1) Discussed HRP status in Modules 102 and 120 No CIO concerns identified.

1984 Items Meeting o

2) Working to finalize baseline number of hangers j

l

3) Thirty nine people are qualified for i

hanger reinspection March 14, Team Meetings CPCo

1) Need to support non-Q work with team No CIO concerns identified.

and MPQAD personnel Ma h 15,

2) Ensure files contain no unstamped "infor-mation only" drawings

3) Status of teams' activities for S/A and turbine roll support

4) Stressed update of MLCS g

5) Reviewed results of self appraisal teams

6) Reviewed proper reporting of S/A results b

via NCR's, FCR's, FCN's, etc.

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7) MPQAD inspections are to be requested "r+

using CWP's 8

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WEEKLY MEETING SUP9tARY - CONTINUATION SHEET Date 9

Attendees Discussion Topic CIO Comments March 16, QVP Status MPQAD

1) QVP progress No CIO concerns identified.

1984 Meeting CIO

2) Document Control is now publishing two register updates each day

3) Deviation Request processing is taking too long March 16, Subcontracts CPCo B&WI - Will have four inspectors; two are No CIO concerns identified.

1984 Meeting BPCo presently qualified k

Zack Scheduled completion of Control Room is 5/1/84 CIO l

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CCP PHASE I ACTIVITY Exhibit 1 March 12 - March 16,1984 l

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j MODULE S/A QVP HRP Hangers 102 Mechanical Instrumentation Mechanical East Pipeway to I&C Mechanical Hangers Elevation 630 Electrical 120 Mechanical Auxiliary Building Elec rical Elevation 584 180 Mechanical Mechanical Auxiliary Building Elevation 704 & above 200 Control Tower &

Architectural Electrical Penetrations Arcnitectural Whip Restraints Electrical 340 Mechanical Civil Reactor Building I&C Mechanical Electrical Instrumentation 410 Turbine Building Elevation 614 420 Turbine Building Elevation 634 430 Turbine Building Elevation 659 620 Turbine Building Elevation 634 630 Turbine Building Elevation 659 800 Service Water Electrical Mechanical Pump House Whip Restraints Instrumentation

• Released for partial systems only

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