ML20134A608

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Initial QA Audit Insp Rept 50-389/71-01 on 710929-1001.Major Areas Inspected:Qa Activities
ML20134A608
Person / Time
Site: 05000000, Saint Lucie
Issue date: 11/23/1971
From: Cochran B, Crossman W, Long F
US ATOMIC ENERGY COMMISSION (AEC)
To:
Shared Package
ML17198A269 List: ... further results
References
FOIA-84-293 50-389-71-01, 50-389-71-1, NUDOCS 8508150357
Download: ML20134A608 (7)
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U. S. ATOMIC ENERGY COMMISSION' DIVISION OF COMPLIANCE REGION II CONSTRUCTION INSPECTION REPORT C0 Inspection Report No.:

389/71-1 Florida Power and Light Company Hutchinson Island Unit No. 2 Fort Pierce Floride Docket No. 50-389 License No. Pending Category A1 Type of Licensees Combustion Engineering 800 Hwa PWR Type of Inspection:

Announced, Initial QA Audit Dates of Inspection:

September 29 - October 1, 1971 Dates of Previous Inspection: No Previous Inspection Principal Inspector

/2*I3"[/

r W. A. Crossman, Reactor Inspector Date (Construction)

Accompanying InspectorsY

'F A)L3/7/

B.J. Cochran, Reactor Inspector Date (Construction)

Other Accompanying Personnel None

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Revieund by k 3V1 F. J. Long, Senior R K tor Inspector

'Datd (Construction)

Proprietary Information:

None 0500t50357 OD0703 kgCH

-293 PDH

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FP&L 50-389/71-1 SECTION I Prepared By:

W A. Crossman and B h raq Enforcement Action:

None Licensee Action on Previously Identified Enforcement Matters:

None Unresolved Items A.

Ebasco's QA Manual (QAM) did not adequately describe design cont: 5 (Paragraph 4.b)

B.

Niecher CE nor Ebasco has an adequate system for acknowled tng tracs-4 mittal or receipt of new or revised design documents.

(Pa agraph 6 <l.

C.

The FP & L site staff appeared inadequate to implement the QA progrvm as construction activitios increase.

(Paragraph 4.a)

Status of Previously Reporte? Unresolved Items:

None Design Changes None Unusual Occurrences:

None Persons Contacted FP&L F. P. Green - Senior Nuclear Engineer C. S. Kent - Project Engineer

11. E. Mantz - Quality Assurance Engineer E.11. O'Neal - Project Manager W.11. Rogers, Jr. - Manager, Power Plant Engineering Ebasco N. J. Chiangi - Quality Compliance Supervisor W. C. liarman - Chief Quality Compliance Engineer E. P. O'Donnell - Nucinar Licensing Engineer E. E. Van Brunt, Jr. - Project Manager SE L. E. Anderson - Manager, Safety and Licensing T.11. Camon - Manager, Manufacturing Servi:.as, Quala y Control A. S. Jameson - Project Manag'er D

FP&L 50-389/71-1

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. Management Interview The inspectors were assured by FP&L that they had reviewed and approved CB&I, CE, Ebasco QAM's and have accepted them as the manuals and procedures for the Hutchinson Island Unit No. 2 project.

A. The FP&L attendees were advised that the site QC group was inadequately staffed with only one man to represent FP&L (Paragraph 4.a).

Also, the inspectors pointed out that although FP&L has an adequate auditing program commensurate with the work in progress, the present staff (one engineer) is inadequate to implement the program as coastruction activities incredse.

(Paragraph 4.f)

Rogers stated that he plans to increase the staff to provide audit capability commensurate with increase of construction activities.

(Paragraph 4.a)

I B. The inspectors apprised the Ebasco attendees that design review as addressed by Quality Compliance Procedure QC-18," Quality Control and Compliance Program for Design Control," was too limited to satisfy the requirements of Criterion III.

FP&L attendees explained that they were satisfied with Ebasco design review on the basis of Hutchinson Island Unit 1.

(Paragraph 4.b)

C. The inspectors pointed out that the requirements of criterion V were not satisfied based on the discrepancies contained in procedures and in-structions. written to satisfy Criteria III, VI, and XII.

FP&L attendees argued the adequacy of these procedures and instructions based on the success of Hutchinson Island Unit 1 construction.

(Paragraph 4.c)

D. The inspectors reported that neither CE nor Ebasco has a satisfactory procedure for acknowledging transmittal and receipt of design documents.

The CE and Ebasco attendees supported their position based on " trouble-free" conditions of the way they were transmitting and receiving design documents.

(Paragraph 4.d)

E. The inspectors reported that the Ebasco QA procedures for control of measuring and test equipment did not provide information on allowable tolerance for calibration of test equipment.

The Ebasco representative acknowledged the discrepancy and stated that the range of acceptabie settings, occ, would be posted on the chart with calibration frequencies.

(Paragraph 4.0) 6

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FP&L 50-389/71-1 i s-3, SECTION II - Prepared by W. A. Crossman and B. J. Ccch:an ADDITIONAL SUBJECTS INSPECTED, NOT IDENTIFIED IN SECTION I, WHERE NO DEFICIENCIES OR UNRESOLVED ITEMS WERE FOUND.

1.

General a.

Documents Reviewed FP&L

- QA Manuai

- QA Audit Procedures and Forma C_f

- Nuclear Power Department Methods and Procedures Instra-ti:n Manual (MPI)

- Manufacturing Services Quality Assurance Manuai (WQC)

- Nuclear Power Department QA Manual

- Chattanoogoa Operations QA Manual

- Manufacturing Services Quality Control Man.a; tot N2 tv.s ?.apu,.c -

- Safety and Licensing Procedures Manual Nuclear Products Manufacturing QC Manual Ebasco

- Quality Compliance Manual Quality Compliance Work Performance Forms CD&I

- Quality Control Manual (2 Vols.)

b.

FP&L QA Program FP&L has prepared 4 QAM that briefly addresses each ;f the 18 criteria but if considered by itself, it would be inajequate to meet the requirements of 10 CFR 50, Appendix B.

9

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FP&L 50-389/71-1 i s.

_a.

The FP&L QAM is suppleme'nted with manuals from CE.wir tajer c:n-tractors to make up.the overall Hutchinson Island QA petg: 4m, Each contractor (CB&L, CE, and Ebasco) is ccntra: cad to Laplemen-their own QA program with Ebasco c:mmissi:nad t. estaolish and 1

maintain the QA records and files until they are t.cred.ser c:

i FP&L.

Ebasco is also contracted to pet 1stm Level L: and Level ~1!

surveillance over CB&I site activities ~and CE's vendct shops.

4 2.

Project Status,

i Engineering - As of October 1, 1971, 80% of the engineering.le+1gn was completed.

Procurement - (1.) 80% of the orders have been ple. e t e rare Secrerb-r (2.) Containment erectivn is scheduled 1, 1972.

(3.) Reactor delivet y is si heduled Apr-19 7.).

(

.tv 19, 19'8 (4.) Steam Generat.r delisdry is sc.he1 1

Site Preparation - Soil compacci..n to the fnundattiin el tw 100%

complete.

Statiin3 - Starfing is 70 to 801 ermptere in the 4...

tv ener;l and quality compliane.e gr.mps.

Ccur r t.. r ing - All contracts have been let Fuel Loading - Scheduled for February 1, 19th Operation - Scheduled car April 1, 19/6.

]

J.

Criteria Adequately Addressed The FP&L quality assurance-program, supplemented by he J :omentej tsi..iticient programa of,the A-E (Ebasco) and the NSSS (CEi pt, documentation to adequately address the t.)llawlaf Qn

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Critarion II - Quality Assurance Pragram Criterion IV - Procurement Document C3ntr.,1 Criterion VII - Control of Purahaset Mstettit, d4.:

a ac t Servi'.es Celterion VIII - Identification and Cc,uct.11 ct M4'+ctiss, Parts, and Cgsponents Celterion IX - Control of Special Pr.x -ssed 6

_. _,,,. _, _. _. _. _, -,.. ~ _ -. - - = - _ - - _, - _ _. -. _, -... - -, _ _

E

. i EPst 50-389/71-1 t'

Criterion X - Inspection Criterion XI - Test Control Criterion XIII - Handling.,.Storaga, and Shipping Criterion XIV - Inspection, Test and Operating Status Criterion XV - Nonconforming Materiais, Parts, or Camponents Criterion XVI - Corrective Action Criterion XVII - Quality Assurance Records DETAILS OF SUBJECTS DISCUSSED IN SECTION I 4.

Criteria Requiring Further Inspection The following criteria were revealed by the QA audit to reqaire adc;;::ne, action:

a.

Criterion 1 - Organization When advised of the AEC's position that FP&L's site QC Group is inadequately staffed with only one man onsite, Rogers stated char.

he plans to increase the onsite force.

He outlined FP&L's' plan to establish an organization which will be increased to fc9e QC engineers (including Mantz).

Plans are to add one ele:trical, one mechanical and a third mechanical / electrical engineer during the first half of 1972.

b.

Criterion III - Design Control Ebaecc addressee Criterion 111, "Deingn Contrel," in PWR QC-LA,"

Qaality Control and Campliance Program tor Design Control,"

Revil, January 29, 1971 The procedure bretly addresses design review but the scope and depth appear to be too limited to adequately satisfy the requirements at Criterion III " Design Control." FP&L was advised that the inspectors planned an audit of Ebasco's corporate offices and design control would be reexamined at that time, c.

Critet ton V -Instructions, Procedures and Drawings Instructions, procedures and drawings generated by Ebasco for design and c:nstruction of liucchinson Island No. 2 Plant are not spe:111e and detailed enough in many areas of their QA pecgram.

Ebas<c attandees were informed that the inspecter6 would arrange a torperate audit of Ebasco.

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FP&L 50-389/71-1 ' '.

d.

Criterion VI - Document Control A review of CE and Ebasco procedures indicates they are responsive to the requirements of this criterion;however, neither organizatt:n has an adequate system for acknowledging. transmittal or receipt of new or revised. design documents.

Ebasco issues.a summary list of all design documents identifying the latest issue every four to six weeks. They do not have any way of verifying that all persons on the document list have received the latest revision until the listing is released and then they depend on every:ne s,

on the list" to inventory their documents to confirm that they have the latest issue.

Criterion XII - Control of Measuring and Test Equipment a.

CE and Ebasco have provided for the requirements of this criterion in adequate manner.

However, since Ebasco is responsible far the construction test and measurement equipment, the inspectar pointed out that they have not established calibration tolerances for acceptance criteria.

f.

Criterion XVIII - Audits FP&L has :n adequate program for auditing construction activities commensurate with the work in progress; however, the present staff (one engineer) is inadequate to implement the program as construction activities increase.

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