ML20093A241

Requests NRC Concurrence for Util to Initiate Pipe Hanger & Whip Restraint Installation & Rework,Release Up to First Sys Anchor & Destatus Hangers Requiring Rework

ML20093A241
Person / Time
Site:	Midland
Issue date:	06/21/1984
From:	Quamme D CONSUMERS ENERGY CO. (FORMERLY CONSUMERS POWER CO.)
To:	Harrison J NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III)
Shared Package
ML20093A238	List: ML20093A241
References
CSC-7929, NUDOCS 8407100243
Download: ML20093A241 (24)

Text

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s CORSumBIS POV!Br

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Sste Manager h0f Mndland Project

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M,dland Project Po, Box 1963. Midland. MI 48640. (517) 631 8650 n

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June 21, 1984 iC g

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ILE$b Mr John J Harrison, Chief RMA Midland Project Section U S Nuclear Regulatory Commission Region III 799 Roosevelt Road Glen Ellyn, IL 60137 MIDLAND ENERGY CENTER MIDLAND DOCKET NOS 50-329, 50-330 PIPE HANGERS AND WHIP RESTRAINTS FILE 0655.3 SERIAL CSC-7929 On May 10, 1984, and subsequently on May 29, 1984, Consumers Power Company discussed an initiative with the NRC relating to pipe hangers and whip restraints for the Midland Nuclear Plant. This letter is a formal request to consider this initiative, which we believe vill ta of substantial benefit to the efficient completion of the Midland Plant, contistent with the basic principles of the Construction Completion Program (CCP).

Specifically, Consumers Power Company requests:

1.

NRC concurrence to initiate pipe hanger and whip restraint installa-tion and rework. These proposed activities will be performed subsequent to reinspection status assessment of the hangers, but will proceed independent of the module sequence for other commodities and their Phase 1 status.

These activities are consistent with the specific provisions of Section 4.5.4 of the CCP.

2.

NRC concurrence to release, in conjunction with the hanger / restraint work, the associated piping system (s) (pipe and hangers), up to the first systems anchor, for adjustment, alignment and modification if necessary.

Installation of new piping will be limited to that necessary for hanger og work outlined in No. I above.

ok No 3.

NRC concurrence to destatus hangers requiring rework due to design Oo changes, and remove them from QVP, Inspection Status Assessment, and the by Hanger Reinspection Program (HRP). Full inspectien of the hanger / rest-M traint will be performed during and subsequent to performing the required E

modifications.

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The definitions, scope, quantities involved, and prerequisites to construction om of commodities associated with this initiative were defined in the May 29, vQ (Do.e gjN 26 N OC0684-0001A-CN01

2 1984 presentation to NRC. A copy of the presentation is attached to this letter.

We appreciated the opportunity to discuss the status of pipe hanger and whip restraint work with the NRC, and to present this initiative. We believe this initiative is reasonable and appropriate.

It will provide the advantage of balancing inspection and craft labor during the remainder of 1984, and will minimize the inspection of hangers that are currently scheduled for modification.

Should you require any further information, please do not hesitate to contact Consumers Power Company.

d41 g

r DLQ/EHP/k1w Attachment CC Regional Administrator, Region III DSHood, NRR Project Manager, Washington Midland Project Manager, Region III Midland Resident Inspector, Midland OC0684-0001A-CN01

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lNITIATIVES i

l PIPE HANGERS AND WHIP RESTRAINTS RELEASE

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AGENDA e SYNOPSIS j

• PURPOSE OF REVIEW 4

i e SCOPE AND STATUS e TO-GO QUANTITIES AND MANUAL MANHOURS l

• HANGER REINSPECTION PROGRAM (HRP) l

• PROCESS

• DEFINITIONS AND DESTATUSING

• PREREQUISITES TO CONSTRUCTION

• METHODS OF CONTROL

• PREREQUISITES TQ IMPLEMENTATION e

SUMMARY

l IDQ

i l

l SYNOPSIS l

l HANGER COMPLETION AND REWORK l

e INITIATION OF PIPE HANGER AND WHIP RESTRAINT AND ASSOCIATED l

PIPING INSTALLATION / REWORK FOLLOWING HANGER REINSPECTION l

INDEPENDENT OF COMPLETION OF PHASE I OF OTHER COMMODITIES i

IN THE SAME AREA.

l

__ASSOCIATED PIPING l

l e REVIEW AND REWORK OF PIPING INC.LUDES, PIPE LOCATION, i

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SLOPE AND ALIGNMENT AND RELATED ACTIVITIES TO CORRECT

[

l ANY NON-CONFORMANCES, i

DESTATUSING

• DESTATUS HANGERS WITH ANTICIPATED DESIGN CHANGES IN THE HANGER REINSPECTION PROGRAM SCOPE

• DESTATUS HANGERS WITH PARTIAL INSPECTIONS OR NO INSPECTIONS ypq

f PURPOSE OF REVIEW i

f e THE CCP SECTION ON SPECIAL PROCEDURES ALLOWS "Q* PIPE HANGERS TO BE i

INSTALLED BY A SPECIALIZED TEAM OUTSID.E THE DEFINED MODULE SEQUENCE.

j l

e REQUIREMENTS OF CHECKING, REVIEW, APPROVAL AND VERIFICATION THAT l

INACCESSIBLE ITEMS WILL NOT BE COVERED-UP; WILL BE IMPLEMENTED.

I e HANGERS ARE BEING REINSPECTED / VERIFIED UNDER THE HANGER REINSPECTION j

PROGRAM (HRP) l l

l e HANGERS WITH CLOSED QCIR's WILL FOLLOW HRP PROCEDURES AND CONTROLS.

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e CCP PROCEDURES AND Gun

^* S ARE BEING FOLLOWED FOR PIPE HANGERS WITH OPEN INSPECTION RECORDS.

. OTHER CLOSED INSPECTION RECORDS.

o CONCURRENCE IS REQUESTED FOR INITIATION OF INSTALLATION OF ALL 'Q* PIPE HANGERS & WHIP RESTRAINTS SUBSEQUENT TO REINSPECTION.

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e CONCURRENCE FOR RELEASE OF ASSOCIATED PlPING SYSTEM FOR REWORK /

INSTALLATION.

I e CONCURRENCE IS ALSO REQUESTED TO TREAT WHIP RESTRAINTS THE SAME AS PIPE HANGERS

• CONCURRENCE TO DESTATUS HANGERS g

l SCOPE AND STATUS l

j HANGERS 1

TOTAL HANGERS (Q) 14,900 l

- L P.

=

4,800 4

I S.P.

10,100 P-2..t O H ANG=E R 1WS 4

j COMPLETED

.PART:AL NO NEW INST.

INSPECTIONS INSPECTIONS INQPECTIONS TO GO SCOPE 5700 EA.

11C?

4393 EA.

3707

' VERIFkCATION COMPLETE (4/20/84) 1500 2750NST.S/A) '

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NCR'S - TOTAL 140s 90 CONFIGURATION 352 89 MATERIAL 74 6

DAMAGE 211 7

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WELDING 562 8

OTHER 210 l

ESTIMATED MANHOURS 53,000 (MPOAD/QC) i

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47V

SCOPE AND STATUS (Continued)

J WHIP RESTRAINTS TOTAL NO. OF RESTRAINTS :

2'86 (UNIT 11 & COMMON) l ON DESIGN HOLD 129 i

i INST.S/A INSP. S/A OVP SCOPE 81 81 76 1

COMPLETE 81

• 27

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l NCR'S 85 NA NA l

CONFIGURATION 6C l

MATERIAL 0

)

DAMAGE O

WELDING 25 ESTIMATED MANHOURS 5800 4000 4000 l

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j PARTIALS FOR TURBINE ROLL l

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T_O-GO QUANTITIES AND MANUAL MANHOURS 1

TO-GO

OTY,

}1 HRS-(EST)

LARGE PIPE HANGERS (Q)

TOTALTO GO 4,378 323,000 NEW 1,007 213,000

}

MODIFICATIONS 3,371 110,000 SMALL PIPE HA GERS (O) i TOTAL TO GO 6,917 302,000 NEW 2,398 202,000 1

MODIFICATIONS 4,219 100,000 e

WH!P RESTRAINTS i

l TOTAL TO GO 286 109,400 1

i NEW 76 60,800 iL.

l MODIFICATIONS 81 48,600 l

i DESIGN HOLD 129 67Y

.. _. _...... _ _.. _ _ __ESN]ED OCyANHgRSfOR lN-PROCESS INSPECTON ARE 110,000

l HANGER REINSPECTION PROGRAM (HRP) i I

I ALL SAFETY RELATED PIPE HANGERS FABRICATED AND INSTALLED 1

BY BECHTEL CONSTRUCTION AND INSPECTED AND ACCEPTED BY

, BECHTEL QC IN ACCORDANCE WITH. PQCl P-2.10 ON OR BEFORE

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HRP ' HANGERS i

j CHARACTERIZATION OF FINDINGS i

4 e NCRs TO DATE HAVE NOT REVEALED ANY SAFETY CONCERNS I

THAT ARE REPORTABLE 8'NCRs AND FINDINGS TO DATE INDICATE MAJORITY OF REJECTIONS RELATED TO WORKMANSHIP ATTRIBUTES, SPECIFICALLY ON WELDS l

E.G. UNDERSIZE, POROSITY, ARC STRIKES, UNDERCUT ETC.

i e TRENDING AND FEEDBACK FROM THE REINSPECTION PROGRAM HAS ENABLED CHANGES TO TECHNICAL SPECIFICATIONS TO MAKE THE i

CRITERIA CLEAR AND CONCISE.

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l 8RW 4

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QUALITY FEEDBACK TRAINING

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(APPROXIMATELY 20% TO 25% RELATED TO HANGER

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REINSPECTION / STATUS MANAGEMENT PROGRAM)

TRAINING BULLETINS 371SSUED TO DATE l

190 TRAINING SUBJECTS

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OIP BULLETINS 9 ISSUED TO DATE I

36 SUBJECTS COVERED l

NCR MANAGEMENT REVIEWS l

74 REVIEWS COMPLETED l

125 NCR'S REPORTED ROOT CAUSE

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' 62 REVIEWS RESULTED IN PERSONNEL ACTION / PROCEDURE CHANGE / TRAINING l

WEEKLY OUALITY ENHANCEMENT MEETINGS l

44 MEETINGS HELD i

42 ISSUES TAKEN ACTION ON l

36 ACTION ITEMS CLOSED BY PROCEDURE CHANGES / TRAINING WEEKLY CONSTRUCT 80N NCR'S TREND REPORTS 1

IDENTIFIED SIGNIFICANT COMMODITY DISCREPANCIES PREPARING TO PRESENT MAJOR CATEGORIES IN TEAM MEETINGS AS l

LESSONS LEARNED TO PREVENT RECURRANCE l

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BECHTEL SELF-APPRAISAL TEAM MONITOR STATUS ASSESSMENT TEAMS PROGRESS l

PROVIDE FEEDBACK TO MANAGEMENT ON PERFORMANCE

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I DEFINITIONS j

DESTATUS l

e TRANSFER OF HANGERS FROM QVP AND INSPECTION STATUS i

ASSESSMENT OF PARTIALLY INSTALLED HANGERS.

l e REMOVAL OF HANGERS FROM HANGER REINSPECTION PROGRAM l

DUE TO DESIGN CHANGES 1

e INSTALLATION STATUS ASSESSMENT BY FIELD ENGINEERING ON 1

DESTATUSED HANGERS.

• 100% INSPECTION OF COMPLETED HANGERS BY MPQAD/QC i

THIS INCLUDES:

j e IMPLEMENTATION OF ALL IN-PROCESS INSPECTION ACTIVITIES DURING HANGER COMPLETION e COMPLETE FINAL INSPECTION OF" ENTIRE HANGER DJSIGN CHANGES _

o ANY DESIGN CHANGE (DRAWINGS OR SPECIFICATIONS) WHICH I

RESULT IN HARDWARE MODIFICATIONS i

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l HANGER DESTATUSING i

l EXISTING PROGRAM PROPOSED PROGRAM s

. WITHOUT DESTATUSING g

WITH DESTATUSING l

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50% OF SCOPE (APP.)

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50% OF SCOPE (APP.)

100% OF SCOPE i

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50% OF SCOPE (APP.)

I 100% (INCL. IN PROCESS)

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ACTIVITIES RELATED TO PIPING SYSTEM REVIEW ASSOCIATED WITH HANGER AND WHIP RESTRAINT i

REWORK / INSTALLATION I

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e PIPE LOCATION WITHIN INSTALLATION TOLERANCES e PIPE SLOPE i

PER DESIGN DOCUMENTS e ALIGNMENT VERIFICATION AND MAINTENANCE OF k

ALIGNMENT AT FLANGED CONNECTIONS AND EQUIPMENT PER APPLICABLE DESIGN AND VENDOR DOCUMENTS.

WORK ACTIVITIES INVOLVED e ACTIVITIES TO CONFORM TO ITEMS NOTED ABOVE INCLUDING CUTTING, WELDING,- GRINDING, ETC.

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• PREREQUISITES FOR PHASE ll CONSTRUCTION I

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PRIOR TO RELEASE OF HANGER OR WHIP RESTRAINTS FOR l

REWORK / INSTALLATION.

e FIELD ENGINEERING STATUS ASSESSMENT COMPLETION 1

i e FIELD ENGINEERING REV!EW OF PIPING ASSOCIATED WITH HANGER I

OR WHIP RESTRAINT ON EITHER SIDE UPTO THE FIRST ANCHOR

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POINT (FLUED HEAD, IN-LINE ANCHOR, PUMP, EQUIP. ETC).

)

e QVP OR INSPECTION STATUS ASSESSMENT OF ASSOCIATED PIPING e MPQAD/QC REINSPECTION COMPLETION TO SUPPORT START OF CONSTRUCTION i

t e PHASE 11 RELEASE BY SITE MANAGEMENT AS DESCRIBED IN CCP.

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19DQ

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METHODS 'FOR CONTROL i

i e MPOAD AND FIELD ENGINEERING PROCEDURES I

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• PQCl AND VIR'S e NCR'S j

e COMMODITY LISTS 4

I e CWP/CWR l

oQWP I

j e PUNCHLIST I

e DESIGN DOCUMENT RECISTER (DRAWINGS AND SPECIFICATIONS) 4 I

)

l THE ABOVE NOTED CONTROLS ARE COVERED IN EXISTING PROCEDURES I

i 20DQ

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PREREQUISITES TO IMPLEMENT TION

• STAFFING l

PRESENT NON-MANUAL & MANUAL STAFFING REQUIREMENTS ADEQUATE.

i e PROCEDURE CHANGES REVISION TO FPM-7.000 AND FPG-9.910 TO ADDRESS ASSOCIATED PIPING SYSTEM REVIEW.

e TRAINING NECESSARY TRAINING FOR THE PROCEDURES NOTED ABOVE f

e CRAFT TRAINING j

NO ADDITIONAL TRAINING NEEDED l

e QC CERTIFICATION i

NO ADDITIONAL TRAINING OR CERTIFICATION NEEDED l

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I 2iDQ

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SUMMARY

l e CONCURRENCE TO RELEASE FOR REWORK / INSTALLATION OF

'Q* PIPE HANGERS; WHIP RESTRAINTS SUBSEQUENT TO REINSPECTION / ASSESSMENT.

1 i

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e CONCURRENCE FOR RELEASF OF ASSOCIATED PIPING SYSTEM (PIPE a HANGERS)

UPTO FIRST ANCHOR FOR ADJUSTMENT, AllGNMENT AND MODIFICATION IF NECESSARY.

• CONCURRENCE TO DESTATUS HANGERS e APPROACH IDENTIFIED CONFORMS TO THE BASIC PRINCIPLES OF THE CCP AND j

HRP.

l l

e DESIREABLE TO:

l

• MORE MANUAL WORKLOAD IN 1984 I

• SUPPORT SYSTEM COMPLETION

• PRIORITIZE MPQAD WORKLOAD 22DQ

.