ML20092A732

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Forwards Const Implementation Overview,Weekly Rept 44 for 840409-13
ML20092A732
Person / Time
Site: Midland
Issue date: 04/19/1984
From: Karr J
STONE & WEBSTER, INC.
To: James Keppler
NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III)
Shared Package
ML20092A629 List:
References
SWM-089, SWM-89, NUDOCS 8406190328
Download: ML20092A732 (21)


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/ PRINCIPAL STAFF

'f. STONE & WEBSTER MICHIGAN, INC. 7A4 g {RP P. O. Box 1963, MIDLAND. MI 48641-1963 0

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Mr. J. G. Keppler, Administrator, Region III April 19, 1984 l Nuclear Regulatory Commission 799 Roosevelt Road J.0. No. 14509 Glen Ellyn, Illinois 60137 SWM-089 Docket No. 50-329/330 CIO Weekly Report No. 44 Construction Implementation Overview Midland Nuclear Power Plant The Construction Implementation Overview (CIO) Weekly Report Number 44, for the period April 9, 1984 through April 13, 1984, is enclosed.

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

/

J. E. Karr CIO Program Manager Enclosures DHA:NL cc:

DLQuame, CPCo Midland (site)

NIReichel, CPCo Midland (site)

RAWells, CPCo Midland (site)

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

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Stone & Webster Michigan, Inc.  :

CONSTRUCTION IMPLEMENTATION OVERVIEW

- CIC -

WEEKLY REPC'<T 2

-i NUMBER 44 t

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PERIOD - April 9,1984 through April: 13, 1984

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1; I . 0 ve rv i ew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  ;

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II. Act iv i ty Suma ry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 II1. Activity Detai1s................................ 1

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V. Attachments...........................'.......... 4 '

A. CIO Item Sumary -E t.

B. Hold Point Summary

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C. Nonconfomance Identification Report (NIR) Summary *

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D. Meeting Summary

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VI. Exhibits j

1. CCP Phase I Activity i 4

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N CIO REPORT NUMBER 44 I. OVERVIEW During this reporting period, Status Assessment (S/A), Quality Verification .'

Program- (QVP), Hanger Reinspection Program (HRP) and the Turbine Roll activities continued. Exhibit 1 indicates these Construction Completion e

Program (CCP) Phase I activities by discipline and module for S/A, QVP, and  ;- !

HRP for this reporting period.

The principal ' effort of CIO continues to be the ongoing assessment of CCP h Phase I activities, Turbine Roll preparations, and Auxiliary Flush h' et t

preparations.

Section II sumarizes CIO activities during this reporting period. Section III provides details of these activities.

II. ACTIVITY SUMARY b A. CCP Activity Monitoring B. Document Control Assessment i3, 2

C. Diesel Generator Program -

D. NRC Commitment List' s E. Zack Program Evaluation F. HRP. Evaluation Y G. CIO Action to Close Out NIR's and Items as Responses are Received H. Site Meetings Summary n

III. ACTIVITY DETAILS (Paragraphs Correspond to Items in Section II)

A. CIO continued our overview of CCP activity by attendance at team and subcontractor meetings, evaluating implementing PQCI's, witnessing work in progress in the plant, evaluating personnel qualifications and *

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Page 2 of 4 monitoring adherence to procedures.

Planning and preparation activities are underway to start S/A for the six new modules released by the NRC for Phase I activity.

CIO concerns in S/A include the lack of a single procedure for S/A and -

the ~ need to control the process of amplifying existing procedures. A good step-by-step procedure (FPG-9.910) exists for the perfomance of area S/A. However, no one procedure exists for system S/A. Interoffice memoranda (IOM's) and checklists with no administrative control are being used to augment procedures. This is addressed in CIO Item Number )

070. CIO is not confident that system S/A is being perfomed in an orderly, consistent fashion between system teams for system ccmmodities.

Ej CIO will continue'to monitor this activity. i Except for our concerns above, activities continue to be accomplished {i j satisfactorily and within the requirements of procedures. . . .

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B. As reported in Weekly Reports 42 and 43, CIO found discrepancies at Work [4 F

Print Stations 209, 219, 309 and Document Control Stations 59 and 501. F NIR's 022, 023, 024, 025, 026 and 027 and Tracked Action Item 074 have

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been issued to document these discrepancies. CIO attended a '

presentation by CPCo and BPCo on the corrective action for the identified discrepancies in the Document Control Program. The program, as presented, should be effective in eliminating future problems and correcting presently identified deficiencies. l C. Work has begun on Diesel Generator (2 PEA) in Bay 3 on the removal of piping assemblies between the diesel generator skid and adjacent equipment. As reported in Weekly Report 43, CIO reported that purchase l

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Page 3 of 4 orders for ASME III- material were procured from non-ASME III manufacturers and that memoranda requesting revisions to seven purchase orders which documented nonconforming conditions on received items in

. lieu of NCR's were sent to the Purchasing Department. NIR's 030 and 029 f were issued respectively to document these discrepancies. -

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D. One hundred and sixty eight items that were commitments made to the NRC l

'in the CCP have been entered into the Correspondence and Commitment Management System (CCMS). This CCP commitment list was entered on s'

schedule and is the first milestone on the completion of the CCMS. $

5 E. CIO started an evaluation of Zack welder qualifications. No unsatisfactory conditions were encountered during this initial 5 k

verification. Certification paperwort needs to be completed by WQAD to K complete this. verification. i F. In the HRP, 45 inspectors are certified and 122 hangers have been f 1 reinspected to date in modules 101, 102, 110, 120, 130, 140, and 150.

6 CIO is formulating a sample plan to overview the HRP in module 102. Ten

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hangers will be checked for documentation and monitoring of WQAD '

inspection.

I' G. Activities related to CIO Items, Hold Points and NIR's are summarized in f i

54 Attachments A, B and C respectively. .

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i H. The summary of meetings attended by CIO 15 in Attachment D.

IV. GENERAL A. CIO staffing remained at 34 during this period.

B. Messrs. R. B. Kelly, SWEC QA Director, and R. G. Burns, SWEC QA Manager, I

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- Page 4 of 4 were onsite April 11 and 12, 1984. They attended the monthly NRC-CIO public meeting held at the CPCo office in Midland. Mr. Kelly participated in a site tour to familiarize himself with the plant and typical hardware deficiencies identified through CCP activities.

C. The monthly NRC public meeting was held at the CPCo Midland office on April 12, 1984. The meeting participants were the NRC, CPCo and the CIO and soils investigation groups. '

1 V. ATTACHMENTS A. CIO Item Sumary $1 B. CIO Hold Point Summary $

C. CIO NIR Summary D. Meeting Sunmary _

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STONE & WEBSTER MICHIGAN, INC. NOTES: .1. ( 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'droppe<1 from further reporting CIO ITEM SlM4ARY Classifi- Open CPCo Response Closed Remads No. cation scription Document /Date Document /Date Document /Date 030 Tracked Need to review Vendor Equipment Report No. 5 CPCo Transmit- Response con-Action Verification Program - MPQAD/SMO 7/18/83 tal CSC-7573 sists of the-dated 4/2/84 synopsis of

- the Vendor Workmanship Verification Program.

037 Tracked CIO observed that two boards with Report No. 24 Partial responso Action protruding nails lying in Cable Tray 11/29/83 (CSC 7244 dated 1AKA019 (Q Tray) had punctured the 1/27/84) accept.

cable jacket of a "Q" table. The ed via CIO let-cable is Q-Channel A. 480V, MCC. ter SWMCP-024 NCR 000925 was issued by MPQAD on dated 2/3/84.

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

043 Tracked CIO Phase III' evaluation of archi- Item Notiff- Item Notifi- Further CPCo Action techtural/ civil document control cation Report cation Report response (CSC-measures resulted in findings listed 1/6/84 1/17/84 7415 dated 3/5/

in the Item Notification (similar 84) details conditions are identified in MPQAD BPCo corrective MQAR-DAT-1). CIO requests CPCo's action plan for y3, plan for addressing the problems document contro .g g g noted and for implementing and ag5 verifying corrective action.on both g '<

MQAR-DAT-1 and.this item.

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CIO ITEM SLMtARY - CONTINUATION SHEET-Classifi- .

Open CPCo Response Closed cation Description Document /Date Document /Date Document /Date Remarks No. .

046 Tracked CIO requests placement on-d.ist'ribu- Item Notiff- Item Notifi- Partial CPCo tion for documentation and proce- cation Report cation Report response ---

Infor- Implementation mation dures pertinent to the NRC Project 1/18/84 2/8/84 -

Commitment Tracking Program, advarce to take 8 to notice of related meeting and a ,

12 months.

schedule which addresses completion of these events.-

049 Tracked A CIO review of document control Item Notiff- Item Notifi- Item Notifi-Infor- methods resulted in the following cation Report cation Report cation Report mation observations: (1) Some uncontrolled 1/26/84 2/3/84 4/11/84 specs contained controlled copies of FCRs, FCNs and SCNs; (2) Controlled documents are being " decontrolled" via a line-out method which is not proceduralized; and (3) CPCo DCC personnel are unaware of the Bechtel Ann Arbor method of identifying document transmittals as either controlled or uncontrolled.

051 Tracked CIO requests to be informed of meet- Item Notifi- As stated in Action ings regarding the proposed plan cation Report CPCo Transmit-of action to address deficiencies 2/3/84 tal CSC-7583 identified in MPQAD Audit Report No. dated 4/4/84, MSA-83-7 as well as a copy of the the proposed proposed plan one week prior to its plan should implementation. be available ,

by 4/20/84 .

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053 Tracked As described in Section 4.2 of the Item Notifi- Item Notifi- *g5 Action CCP, CIO requests that CPCo provide cation Report cation Report N T<

a listing of all status assessment 2/16/84 2/23/84 o,, g g teams, the respective team's scope M-and their working schedule. , >g 5

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CIO ITEM SUP9(ARY - CONTINUATION SHEET Classifi- Open CPCo Response Closed No. cation Description Document /Date Document /Date Document /Date Remarks 055 Tracked Clarification is required regarding Item Notifi- Item Notifi- Supplementary Infor- training requirements for area team cation Report cation Report information re- -

, mation #23/24 personnel performing status 2/17/84 3/15/84 -

quested by CIO assessment of raceway completion'. 1 (i.e., SA training matri-ces) provided by CPCo via CSC-7558 on 3/28/84.

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

mation Appendix B criteria were adequately 2/18/84 3/13/84 4/10/84 l addressed.

1 059 Tracked CPCo should review audits performed Item Notifi- Item Notifi-Infor- prior to June 1983 to assure adequacy cation Report cation Report mation of auditing, proper closecut,10CFR50 2/18/84 3/13/84 Appendix B compliance, and objective evidence as to adequacy of the audits.

t 060 Tracked CIO provides a series of recommen- Item Notifi- Item Notifi-Recommen- dations in the following categories: cation Report cation Report I

dation 1) Management Involvement; 2) Track- 2/17/84 3/13/84 ing Audits / Audit Findings; and 3)

Audit Personnel Training and Certif-
ication Records.

j 061 Tracked CIO recommends that the receipt Item Notifi- Item Notifi- BPCo to include m > :c 1 Recommen- acknowledgement copy of the Bechtel cation Report cation Report a signature / $N%

i dation transmittal form be revised to pro- 3/2/84 4/10/84 date line on *85 I vide for a signature /date by the their transmit- "P l recipient. tal.

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CIO ITEM SMARY - CONTINUATION SHEET Classiff- Open CPCo Response Closed Document /Date Document /Date Document /Date Remarks No. cation Description 062 Tracked CIO has determined that status Item Notifi- Transmittal BPCo response Action assessment is being performed on cation-Report CSC-7580 evaluated by pipe supports by personnel who have 3/6/84 4/4/84 . CPCo and trans -

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not completed required training. All personnel performing hanger support for acceptance .

status assessment should be checked to assure they are properly qualified.

Any previous supports that were assessed by unqualified personnel should be reassessed.

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

control discrepancies.

064 Tracked CIO recommends implementation of Item Notifi- Item Notifi- See Attachment Recommen- MPQAD plan to consolidate welding cation Report cation Report A, Sheet 5 of 7 dation inspection requirements for electri- 3/16/84 3/30/84 cal / instrumentation equipmcnt and supports into PQCI's CW-1.00 and EW-1.00.

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CIO ITEM StMtARY - CONTINUATION SHEET No. Remarks 064 CIO has received a response to Item 064 and has determined that the response is acceptable. The response describes actions different from those actions

.previously proposed by MPQAD and described in CIO Weekly Report Number 36.

Weekly Report Number 36 stated that MPQAD planned to have the requirements for inspection of welds on electrical equipment and supports in both CW-1.00 and EW-1.00.. MPQAD has now stated that the requirements for the inspection of welds on electrical equipment and supports has been deleted from CW-1.00.

This item currently remains open until verification by CIO that actions described in the MPQAD response have been completed.

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Cl0 ITEM SlMtARY - CONTINUATION SHEET Classifi- Open CPCo Response Closed No. cation Description Document /Date Document /Date Document /Date Remarks 065 Tracked CIO recommends that Zack Procedure Item Notifi- Partial re-Infor- MB-FP-7C be revised to reflect the cation Report sponse to Items mation BPCo requirement that notification 3/16/84 065, 066 8 067 of addenda retirement information provided in for BPCo documents is provided via BPCo letter a Subcontractor Change Notice (SCCN). BCCC-9193 transmitted to 066 Tracked CIO recommends that Zack revise Item Notifi- CIO on 3/30/84.

Infor- either Procedure MP-FP-18 or Pro- cation Report Revisions to mation cedure MP-FP-23 in order that the 3/16/84 MB-FP-5 and MB-method used to update the welder FP-7C should be qualification matrix be properly approved by addressed. 4/6/84.

Revision to MB-067 Tracked CIO recommends that Zack Procedure Item Notifi- FP-23 should be Infor- MB-FP-5 be revised to address cation Report approved by mation required actions for incomplete 3/20/84 4/20/84.

and damaged items.

068 Tracked The Midland Plant FSAR (Table 3.2-4) Item Notifi-Action specifies use of the 1974 Edition cation Report (no addenda) of the ASME III, 3/23/84 Division 1 Code, Subsection NF (i.e.,

installation of hangers and supports for nuclear piping). A BPCo specifi-cation, as well as the B&W QA Program Manual, reference an earlier code edition in violation of ASME III, Division I, Article NA-1000 (1974  ? ?;ji Edition). CIO requests the cause, @ g 94 resolution, and corrective / preven- a,[};7 tative action for this condition, o@,

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CIO ITEM SISMARY - CONTINUATION SHEET Classifi- Open CPCo Response Closed Document /Date Document /Date Document /Date Remarks Noo cation Description l 070 Tracked 10Ms have been issued by various Item Notifi- '

Action BPCo personnel to clarify the cation Report '

i status assessment process. These, 4/10/84 10M's are not being processed

! through any single point of ad-ministrative control.

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071 Tracked CIO requests information regarding Item Notifi-  !

Infor- CPCo action resulting from NCR cation Report mation M01-9-9-075 which documented 4/11/84 "

seven ine.onsistencies between i the FSAR, a specification and AWS D1.1. ,

072 Tracked CIO should be informed of action Item Notifi-1 Infor- being taken to resolve administra- cation Report j mation tive inconsistencies in B&W NDE 4/11/84 procedures (i.e., NDE-PQ-RT-200, .

NDE-PQ-RT-201, and NDE-PQ-RT-202). .

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I 073 Tracked CIO requests B&W's documentation Item Notifi-  ;

4 Infor- supporting required demonstration cation Report  ;

i mation of Procedure NDE-PQ-MT-201, Rev. 0 4/11/84

! to the ANI.

During an evaluation of the site Item Notifi- I' j 074 Tracked a Action document control program, CIO cation Report I has addressed a number of general 4/13/84 concerns which must be addressed o w s-I by CPCo.

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3 STONE & WEBSTER MICHIGAN, INC. NOTES: 1. % identifies changes from previous report ColeSTRUCTION IWLEDENTATION OVERVIEW 2.' Closed Hold Points will be identified in'the Report for MIOLAND NUCLEAR C0 GENERATION PLANT the week of closure and dropped from further reporting CIO HOLD POINT SiSOERY No kscription Established CPCo Response Lifted ds Document /Date Document /Date Document /Date 005 CPCo has committed to develop a Vendor Report No. 18 CPCo Transmittal CPCo response Equipment Verification Program. Program 10/17/83 CSC-7573 dated consists of the  !

is required before implementation of

  • 4/2/84 synopsis of the Phase II. Vendor Workman-ship Verification Program.

007 Evaluation of Management Review of Report No. I'9 results of Phase I activities. Evalua- 10/26/83 tion is required before implementation of Phase II.

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STONE & WEBSTER MICHIGAN, INC. NOTES: 1. (identifieschangesfrompreviousreport  ;

CONSTRUCTION IfFLEPENTATION OVERVIEW 2. Closed NIRs will be identified in the report for the MIDLAlm NUCLEAR COGENERATION PLANT week of closure and dropped from further reporting NONCONFORMANCE IDENTIFICATION REPORT SupMARY No a Description Issue Date Response Date Closure Date Remarks 014 As documented on CIO Evaluation No. MP-MIS- 01/27/84 074-0001, FPD 1.000 requirement that a. copy of all transmittals for "Q* listed items be transmitted to MPQAD and the Project Supplier -

Quality Representative was not being satisfied.

015 In violation of PSP G-7.1, correction fluid 02/17/84- 04/10/84 04/10/84 MPQAD response (i.e.

was used on MPQAD Audit Report No. M01-346-02. QAR RB-00001) un-satisfa'ctory. Ref-erence new NIR 028.

016 Contrary to their MPQAD Procedure F-1M deft- 02/17/84 04/10/84 04/13/84 Corrective action nitions, "nonconformances" were documented performed via QAR as " observations" in Audit No. M01-346-02. RB-00002.

017 The recommended corrective action for Audit 02/17/84 finding 01F, Audit No. M01-346-02 was not implemented, yet the audit was closed out.

019 As documented on CIO Evaluation No. MP-MIS- 02/29/84 03/14/84 QAR RA-00134 issued C82-0001, several discrepancies were identi- to track corrective fied on the FDDL'. action.

020 As documented on CIO Evaluation No. MP-MIS- 03/02/84 QAR RA-00135 issued 082-0001, 4 out of 25 Distribution Change to track corrective m>r Request Foms were not properly signed in violn*, ion of FPZ-1.000.

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s CIO NONCONFORMANCE IDENTIFICATION REPORT SUMARY - CONTINUATION SHEET No. Description -

Issue Date Response Date Closure Date Remarks 022 At work Print Station 219, CIO reviewed 80 03/23/84 out of 1116 documents. 20 documents were found discrepant, as described in the NIR. -

023 At Work Print Station 209, CIO reviewed 03/23/84 80 o'ut of 1116 documents. 23 documents contained discrepancies, as decribed in the NIR. '

024 At Document Control Station 501, CIO 03/23/84 reviewed 200 out of 5533 drawings. A total of 13 discrepancies were identified, as described in the NIR.

025 At Work Print Station 219, CIO found four 04/03/84 additional discrepant areas at completion of evaluations.

026 At Work Print Station 309, four documents 04/03/84 were found by CIO to be discrepant.

027 At Document Control Stations 59 and 501, 04/04/84 discrepancy found to exist between control drawings used by BPCo field engineers and those in BPCo Document Control Center.

028 Response to NIR 015 was not accepted by 04/09/84 CIO. Requirements for making corrections to QA records should be proceduralized.  ;? ?;af

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5 CIO NONCONFORMANCE IDENTIFICATION REPORT St# MARY - CONTINUATION' SHEET No. Description - Issue Date Response Date Closure Date Remarks 029 In violation of the BPCo ASME III Manual, a 04/11/84 BPCo. memorandum requests revisions to_seven Purchase Orders due to material / documentation discrepancies for received material.

030 BPCo ASME III Manual states that the'PQAE 04/11/84 shall assure that items are procedured only from acceptable manufacturers. P0s 7220-F-64832(A), Rev. 2 and 7220-F-64487(A), Rev. I reference manufacturers which are no't listed on the ASME Evaluation Supplier Listing.

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CONSTRUCTION IMPLEMENTATION OVERVIEW MIDLAND NUCLEAR C0 GENERATION PLANT ,

I WEEKLY MEETING StM4ARY .

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Date Attendees Discussion Topic CIO Comments

! April 9, NIR Meeting MPQAD 1) Initial response to NIR's 022, 023, and 024 No CIO concerns identified.

1984 CIO j .

! April 10, Area Team CPCo 1) Forecast distribution of structural steel No CIO concerns identified.

! 1984 Staff Meeting MPQAD and penetration drawings

'2) Disposition of NCR applied to special doors f

j 3) Revision to issuance of drill permits

) 4) Clarification of FPC-2.000 to be issued j for CWP sign off for subcontracts April 10, Team Meetings CPCo 1) Problems with NCR's generated by field No CIO concerns identified.

4 April II, MPQAD engineers 1984 o

2) Generating of CWP's to maintain backlog of work -
3) New modules released for Phase I activities

! 4) Notification to lead field engineer for difficulties in obtaining S/A prints

, 5) New revisions to Spec. C-305 for S/A of j structural steel y l l6) S/A raceway in modules 340, 800 and 820 $h4 aG April 11, R,! a?

CPCo Document CPCo 1) Presentation on document control

1984 Control BPCo corrective action No'CIO concerns identified. /E 4

CIO -

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WEEKLY MEETING SUMtARY - CONTINUATION SHEET Date ,"9 Attendees Discussion Topic CIO Comments April 12 Subcontract Zack 1) Discussion on proposed solution to three No CIO concerns identified.

1984 Meeting CIO Zack tracked items -

April 12, NRC Public NRC 1) Monthly public meeting in Midland No CIO concerns identified.

l 1984 Meeting CPCo 4

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April 13, Subcontract BPCo 1) Better method of reporting installed No CIO concerns identified.

j 1984 Meeting Zack ,quantitles of HVAC duct work i -

2) 2BPCo to resolve with MPQAD the number of

! remaining Zack NCR's i 3) B&W to review schedule and manpower to j reflect program and funding for work in j 1984

li j April 13, QVP Assess- MPQAD 1) DIIA's and their transition to NCR or QAR No CIO concerns identified.

1%4 ment CIO

2) New draft of Procedure N-12

! 3) Microfilming to continue for the pres- .

ervation of documentation April 13 Turbine Roll MPQAD 1) Discussion of status of sluice gates in No CIO concerns identified.

j 1984 Meeting CIO Service Water Pump House. ,,,

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CCP PHASE I ACTIVITY- Weekly Report No. 44

~.. Exhibit 1 April 9 - April 13, 1984 Page 1 of 2 MODULE S/A QVP HRP 102 East Auxiliary Bldg Electrical Hangers Pipeway to Eleva-tion 630 -

120 Auxiliary Building Electrical Hangers '

Elevation 584 ,

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  • 180 Auxiliary Building Roof Elevation 704
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  • 200 l Control Tower &  %

Electrical P4_netrations 340 fh RCB except inside D Hangers Electrical j rings, reactor cavi Electrical )

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ty & fuel handling Instruments Piping  !;

410 TGB #2 Elevation 614 9 o

  • 420 f TGB #2 i Elevation 634 .

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Elevation 634 630 TGB #1 Elevation 659

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,; (continued) Page 2 of 2 MODULE S/A' QVP HRP 101 North Auxiliary Hangers Building Pipeway to Elevation 650 .

110 Auxiliary Building Hangers Elevation 568 ,

130 Auxiliary Building Hangers Elevation 599 u 140 Auxiliary Building Hangers Elevation 614 i

150 Auxiliary Building l Hangers J Elevation 634 ,

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Control Room Electrical Elevation 659 -

820 Piping Diesel Generator Hanger Building Electrical .

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