ML20210L235

Forwards ALAB-106 Monthly Rept for Mar 1986,including Nonconformance Repts,Quality Action Requests,Mgt Corrective Action Repts & Quality Audit Findings

ML20210L235
Person / Time
Site:	Midland
Issue date:	04/25/1986
From:	Jackie Cook CONSUMERS ENERGY CO. (FORMERLY CONSUMERS POWER CO.)
To:	Taylor J NRC OFFICE OF INSPECTION & ENFORCEMENT (IE)
References
32645, ALAB-106, NUDOCS 8604290255
Download: ML20210L235 (13)

Text

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CGnsumers Power James W Cook Company m , ~ ,u ,. ,- ~ ~ , o . ,..,- . ,

and Constrution Generet officas: 1946 West Pernait Road, Jackean, MI 49201 * (617) 788 0453 April 25, 1986 -

Director of Office of Inspection * '

and Enforcement Att Mr James M Taylor US Nuclear Regulatory Commission Washington, DC 20555

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MIDLAND PROJECT - ALAB-106 MONTHLY REPORT FOR MARCH 1986 DOCKET NOS 50-329 AND 50-330 FILE 0.4.6 SERIAL 32645 In' accordance with Condition of Memorandum and Order ALAB-106, dated March 23, 1973, and Amendment No 1 of the Midland Plant Construction Permit, enclosed are five copies of the following documents written or closed during the month; Bechtel Nonconformance Reports, Quality Action Requests, Management Corrective Action Reports, Quality Audit Findings; Babcock & Wil,cox Reports of Noncon-formity; Consumers Power Company Nonconformance Reports, Audit Finding Re-ports, Quality Action Requests, Corrective Action Reports, and Management Correct'ive Action Request / Reports.

JWC/WRB/lr CC JGKeppler, USNRC Region III (w/ enc)

CBechhoefer, Esq ASLB (w/ enc)

ALAB-106 Service List (w/ene) 8604290255 860425 PDR R

ADOCK 05000329 PDR JO i

OC0486-0016A-MP02

7-i 4

ALAB-106 MONTHLY REPORT SERVICE LIST i Mr FrankiJ Kelley, Esq Mr Steve Cadler Attorney General of the- 2120 Carter Avenue State of Michigan St Paul, NN 55108

- Ms'Carole Steinberg, Esq ,

Assistant Attorney General . Mr William Clements (2) ,

- Environenntal Protection Div . Docketing & Services 720 Law Building US Nuclear Regulatory Commission

. Lansing, MI 48913 Office of the. Secretary Washington, DC 20555 Mr Myron M Cherry, Esq Cherry & Flynn Ms Mary Sinclair 3 First National Plaza 5711 Summerset Street Suite.3700 Midland, MI 48640 Chicago, IL 60602 Mr Joseph Rutberg Mr F C Williams, Esq Assistant Chief Hearing Council Isham, Lincoln & Beale US Nuclear Regulatory Commission 1120 Connecticut Ave, NW Office of the Executive Legal Director Suite'325 Washington, DC .20555 Washington, DC 20036 Ms Barbara Stamiris Mr P Robert Brown, Jr 5795 North River Road Clark, Klein & Beaumont Route 3 1600 First Federal Building Freeland, MI 48623 1001 Woodward Avenue Detroit, MI 48226  ;

Mr John Demeester, Esq Dow Chemical Building Ms Lynne Bernabei Michigan Division Government Accountability Midland, MI 48640' Project of the Institute for Policy Studies Mr Michael I Miller, Esq 1901 Q Street, NW Isham, Lincoln & Beale Washington, DC 20009 3 First National Plaza  ;

52nd Floor Mr James E Brunner, Esq Chicago, IL 60602 Consumers Power Company 212 West Michigan Avenue Jackson, MI 49201 OC0486-0016A-MP02

INDEX OF ATTACHME!nS ALAB-106 MONTHLY REPORT MARCH 1986 Bechtel Nonconformance Reports - None Bechtel Quality Action Requests - None Bechtel Management Corrective Action Reports - None Bechtel Quality Audit Findings - None Babcock & Wilcox Reports of Nonconformity - None Consumers Power Company Nonconformance Reports -

Q-00067, Opened 3/11/86, Closed 3/11/86 Q-00068, Opened 3/20/86 Q-00069, Opened 3/21/86 Q-00002, Closed 3/27/86 Consumers Power Company Audit Finding Reports - None Consumers Power Company Quality Action Requests - None Consumers Power Company Corrective Action Reports - None Consumers Power Company Management Corrective Action Request / Reports - None OC0486-0016A-MP02

To R J Erh rdt, P-14-113 J A Mooney, P-14-115A M

H P Lecnard , MEC'"iscar CONSUMERS From POWER November 21, 1985 COMPANY Date m.

Internal Subject MIDLAND ENERGY CENTER -

STATUS OF NCR Q-00002 Correspondence CC B H Peck, MEC J W Cook, P-26-336B EPL 48-85 R G Budrick, MEC D D Johnson, MEC J L Wood, MEC file: NCR Q-00002 The purpose of this meno is to document the corrective actions completed and in progress for NCR Q-00002, Revision 0, which was issued January 14, 1985.

The required process corrective action was to issue the procedures. This was accomplished as follows:

a. EN-002, Rev. O, issued 2/ 1/85, effective 2/ 5/85 ff.2

b. EN-003, Rev. O, issued 2/12/85, effective 2/15/85

c. EN-004, Rev. O, issued 2/12/85, effective 2/15/85 [(l['f '~

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d. CD-001, Rev. O, issued 2/ 1/85, effective 2/ 1/85

e. CD-002, Rev. O, issued 1/30/85, effective 2/ 1/85 Q

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f. PR-002, Rev. O, issued 1/28/85, ef fective 1/30/85 The required part corrective action was to review the work done from 1/1/85 to the effective dates of the procedures and establish whether or not this indeterminate condition is, in fact, an unacceptable condition. Since the closure of NCR Q-00002 is not needed to support S&M activities, the deferral of some of these activities is in accordance with our policies as stated in the QAPP, Sections 15 and 16. However, some actions have been cospleted at this. time and some are related to the " Pre-Post Shutdown QA Program Transition

• Review", dated .7/15/85, which was issued by W R Bird's memo Serial 32330, dated July 30, 1985. The current status is:

1. The risk to safety-related equipment has been assessed as insignificant (parair'aph 4.0 of the Transition Review).  ? .' ' -

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EN-002 deals with Corrosion Monitoring and the time frame in 2.

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question is addressed within the Transition Review (paragraph 3.4).

No further action.is required.

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3. EN-003 deals with Plant Modification Control, which has since been determined to be a non-Q activity. EN-003, Rev. 1, reflecting this was issued September 20, 1985 and made effective September 25, 1985.

No further action is required.

4. EN-004 deals with Design Control, basically the control of System Layup Requirements. The time period from 1/1/85 through 2/15/85 will be resolved by the completion of Task 2 in the Transition Review.

IC1085-0197-QLO1 11/21/85

2

5. CD-001 deals with Remedial Soils monitoring and the time frame in question is addressed within the Transition Review (paragraph 3.

• Task I of the Transition Review, while related to Remedial Soils Monitoring, is not related to NCR Q-00002. No further action is required with respect to dispositioning NCR Q-00002,

6. CD-002 covers Material, Receipt Storage Issue and Return. The indeterminacy caused by not having the procedure in place will be resolved by completion of Tasks 4, 5 and 6 of the Transition Review.

7. PR-002 deals with Procurement. Six (6) "Q" or "CQ" Procurements were subject to some processing from the time of shutdown until PR-002 became effective (Purchase Orders LP13-4725, 1006-1418, 2001-5057, 1906-0242, LP09-9388 and 2001-2443) . These activities were in accordance with the existing Station Orders, which invoke the same requirements as PR-002. No further action la required.

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! QUALITY 15 NCR NO. 17 REV.

^

! ASSURANCE o-00067 o i91 VISION 16 DATE ISSUED

'IFORM QAD-1 3/11/86 NONCONFORMANCE REPORT 18 PAGE 1 0F 2 1 ITEM LOCATION Auxiliary bidg.

2 DRAWING OR PAJtT NO. AND REV. 3 PART NAME j4 SERIAL NO.

M416 Sh 1A & Sh IB NA NA 5 ITEM DESCRIPTION Dehumidification for Unit 1 CCW 6 ITEM STARTUP SYSTEM NO. 7 REFERENCE DOCUMENT 8 ASME A.? .. REQUIRED

' NA *10 22500649 step

.5,. NA' 9 INSPECTION PLAN REV. 10 ACTION ORGANIZATION WO-500649 0 O&M 11 ACTIVITY HOLD REQUIRED: ACTIVITY HOLD ORDER NO.

YES X NO NA ,

12 REQUIREMENT Establish the dehumidification flowpath by following the flow paths on the P& ids, All valves in the flowpath should be open and all other valves should be shut.

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13 NONCONFORMANCE

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Contrary to the requirement v.aly.es IVCCWO41B, 1VCCWO24A and IVCCWOO3B were found'to be

, shut. Valve IM01610B was found'to be open. ~'.

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l 14 NCR ORIGINATED BY l .,s

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-Y E F' Summers, fr. DATE

^ ^ ^

19 HOLD TAG APPLIED YES 1 NO ITEMS SECREGATED YES y NO NA /

' ^2 b UU 21 NEED TO REVIEW FOR i

REPORTABILITY YES 1 NO 1 DATE CE ERGINEERING' h

/ /

0 22 DETERMINED TO BE REPORTABL 25 SECTION HEAD ASSy

! N YES NO NAj i l'GNA ,

QA-006 Rev 3

g E CAUSE 34 PAGE 2 0F 2 Misinterpretation of the valve po:ition by the operator.

27 PROCESS CORRECTIVE ACTION REQUIRED J "- 2 YES NO Dua 4/'* /A 28 RECOMMENDED DISPOSITION.

@ REniORK l l SCRAP / REJECT l l REPAIR

• I IUSE AS IS*

<  ! cREQUIRES TECHNICAL JUSTIFICATION ATTACHED 29 ADDITIONAL INFORMATION 30 DISPOSITION CONCURRENCE

/ ( &L, . ,

l66 DATE 1A_)

QAD CONCURRENCE DATE ACTION ORGANIZATION

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ENGINEERING DATE A.N.I. (ASME) IF REQUIRED j' 31 DISPOSITION ACTION TAKEN ,

Valves repositioned as required.

i 33 NCR CLOSED BY 13 2 METHOD OF DISPOSITION ACTION VERIFICATION Visually witnessed valves repositioned.

RESULTS OF DISPOSITION ACTION VERIFICATION QAD DATE

+ X ;ACCFPTABLE i l UNACCEPTABLE l

!  ! IF UNACCEPTABLE, REFERENCE SUPERSEDING NCR ,

A.N.I. (ASME) DATE f - .IF REQUIRED

' QA-006 Rev 3 m

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. ~ ~ n ,r xq; c .-

.: s s . i' s

'OUALITY 15 NCR NO. 17 REV.

' ASSURANCE 0-00068 0 DIVISION 16 DATE ISSUED

j l ; FORM QAD-1 3/2 i /BL NONCONFORMANCE REPORT 18 PAGE 1 0F 2 i

1 ITEM LOCATION I Warehouse #2 l 2- DRAWING OR PART NO. AND REV. '3 PART NAME 4 SERIAL NO.

P.O. 5012-0837-QA 0 A//&

l 5 ITEM DESCRIPTION 1500# Sch-160 Bore Section III - Class I R. F. Weld Neck Orifice Flanges

! 6 ITEM STARTUP SYSTFM NO. 7 REFERENCE DOCUMENT 8 ASME A.N.1. REQUIRED NA QA-006, revision 3 NA 9 INSPECTION PLAN REV. 10 ACTION ORGANIZATION NA Engineering Technical Support 11 ACTIVITY HOLD REQUIRED: ACTIVITY HOLD ORDER NO.

TES 1 NO NA 12 REQUIREMENT S2ction i+.2.2 of procedure QA-6, revision 3 states in part: "When a nonconformance is reported to or detected by QAD personnel, QAD is responsible for: ....d. Documenting l

nonconformance on a NCR (Appendix A").

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l 13 NONCONTORMANCE l A copy of a Part 21 Notice was received,by CPCo from Consolidated Pipe & Valve Supply, Inc.

. indicating a potential problem with Certified Material Test Reports for material furnished to the Midland Energy Center. This material was originally purchased by Consolidated Pipe l

& Valve.from Golden Gate Forge & Flange, Inc., located at Hunters Point, San Francisco, California. The president, vice president, and shipping foreman, all of Golden Gate Forge

&~. Flange, Inc., have been indicted and charged in Federal Court on conspiracy and making

- criminal false statements in connection with falsified test cert i ficat ions (Mill Test

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Raports). Reference Part 21 Notice from Consolidated 14 NCE ORIGINAT:3 BY .

L Pipe & Valve, dated March 4, 1986. /J f l W L/Li n h!Oksf,

'M C Butterfield l This NCR is not S&M related. DATE l / 20 LOCATION OF HOLD TAGS OR SEGREATED AREA l 19 HOLD TAG APPLIED C YES NO ITEMS SECREGATED / YES NO Warehouse #2 l~

- _ , , - n

, 21 NEED TO REVIEW FOR by gb- %b#

REPORTABILITY x YES NO NA DATE dN//</d 22 DETERMINED TO BE REPORTABLE 25 SECTION , RANCE ENGINEERING X YES NO o', 4 1t(, bj~f, "h g,4. .,

QA-006 Rev 3 l

26 CAUSE- 34 PACE 2 0F 2 f,. . , l ). I fl.y , . , / l.>,. v e . . < le r .

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!27 PROCESS CORRECTIVE ACTION REQUIRED l lYES I..)( l NO

28 RECOMMENDED DISPOSITION l l REWORK T SCRAP / REJECT l l REPAIR * ,

I lUSE AS IS*

CREQUIRES TECHNICAL JUSTIFICATION ATTACHED 29 ADDITIONAL INFORMATION .

l}') a h<r< *' n { may be re c{o s s o'Sa'* t%e , ye n cler crv- 9 c ra('('* d o

.30 DISPOSITION CONCURRENCE 22cuErA-ACTION ORGANIZATION 3/ukc DATE

1. A)& A QAD CONCURRENCE -

3AJ/ec DATE ,

tsaRsL ENGINEERING abriu DATE A.N.I. (ASME) IF REQUIRED 31 DISPOSITION ACTION TAKEN s

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33 NCR CLOSED BY 32 METHOD-OF DISPOSITION ACTION VERIFICATION RESULTS OF DISPOSITION ACTION VERIFICATION i I l UNACCEPTABLE QAD DATE i ACCEPTABLE IF UNACCEPTABLE, REFERENCE SUPERSEDING NCR A.N.I. (ASME) DATE l

.IF REQUIRED QA-006 Rev 3

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g'm u=l UI d'UI N N 15 NCR NO. 17 REV Q-00002 0 QUALITY ASSURANCE 16 DATE ISSUED January 14 1985 DIVISION NONCONFORMANCE REPORT 18 PAGE 1 0F 2 OAD FORM 1 1 ITD( LOCATION N/A 2 DRAWING OR PART NO. AND REV. 3 PART NAME 4 SERIAL NO.

N/A N/A N/A 5 ITEM DESCRIPTION Procedures for the Shutdown Phase of the Midland Energy Center:

EN-002 " Corrosion Monitoring" CD-001 " Requirements for Soils Remedial Work" EN-003 " Configuration Control" CD-002 - " Material Storage and Handling" EN-004 " Classification of Structures, PR-002 " Procurement" Systems and Components" 6 ITEM STARTUP SYSTEM NO. 7 REFERENCE DOCUhuG 8 ASME A.N.I. REQUIRED

• Y ^**"#*"

• 8##" No N/A Plan (QAPP) 9 INSPECTION PLAN REV 10 /CTION ORGANIZATION JAMooney, MEC Site:

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• Y ^**"#*"#*I N/A RJErhardt. Engineerina 11 ACTIVITY HOLD REQUIRED: ACTIVITY HOLD ORDER NO.

YES X NO N/A 12 REQUIREMENT QAPP, Policy 5, " Instructions, Procedures and Drawings" Sectioc 1.1 requires: " Activities effecting quality are accomplished in accordance with documented instructions."

QAPP, Introduction, Section 5.0 requires: "This QAPP is implemented on October 1, 1984 with full chapliance by January 1, 1985." -

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R 13 NONCONFORMANCE ' Contrary'to t'Ke above, the subject procedures were not approved as of, January 11, 1985'. These procedures address safety yelated activities that are ongoing -

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. - during the Shutdown Phase-of' the Midland Energy Center. _,

It is recognized that there have been extenuating circumstances such as: limited ~

, resources, slow response time during coussent cycle, and higher priority for S'hutdown ectivities that affect the Company's financial condition. It is also recognized that-these procedures will document, not change, the methods by'which these activities are performed. This condition is, however, in 14 R ORIGI TED BY noncompliance with the QAPP and action needs to j -

be taken to correct the condition on a priority fh / // b, basis. /DATE 19 HOLD TAGS APPLIED YES X NO 20 LOCATION OF HOLD TAGS OR SEGREGATED AREA ITEM SEGREGATED YES X NO N/A 21 NEED TO REVIEW FOR 23 TREND CODE 24 R REPORTABILITY [g,g,. j YES X NO O DATE: /M ) '

22 DETERVJNED TO BE REPORTABLE 25 SECTION READ, ASSURANCE'ENG EERING 0

N/A DATE .

/A g~

QA-6 Rev 0

NCR q.onony '

Pagn 2 of 2 '

f 6 CAUSE  !

l As recognized in block 13.

I l

27 PROCESS CORRECTIVE ACTION REQUIRED M YES l l NO 28 RECOMMENDED DISPOSITION GXlx REWORK I l SCRAP / REJECT l l REPAIR l l USE AS IS 29 CONDITIONAL RELEASE NEEDED l l YES l xxx l NO CR NO.

30 ADDITIONAL INFORMATION Process Corrective Action is to issue the procedures, which was completed 2/15/85. Part Carrective Action is to review the work done from 1/1/85 to the effective dates of the procedures and establish whether or not this indeterminate condition is, in fact, an unaccepcable condition and resolve. Refer to memo HPL 48-85 dated 11/21/85.

4 i .

31 DISTRIBUTION N RRitiCE

' B H Peck .

//- 2 7 - # I_ H P fennard- 4MM* # f '/_3 ACTION ORGANIZA ON DATE QAD CONCURRENCE / / DATE R C Budrie Nne Rentti ved ,

ENGINEERING DATE A.N.I. (ASME) IF' REQUIRED"

-32 DISPOSITION ACTION TAKEN R;maining actions: iden'tif,ied on c.emo HPL 48-85. dated 11/21/85 are detailed in para-graphs 4 & 6 of the memo. These paragraphs required completion of tasks 2,4,566 of'the

Transition Review Program.

Tasks 2,4,5&6.are now completed. Referench memo RLB 08-86,

. dated 3/27/86. .

1 l

j 33 METHOD OF DISPOSITION ACTION VERIFICATION NCR CLOSED BY l

Ravicw of letter referenced above, RESULTS OF DISPOSITION ACTION VERIFICATION l X l ACCEPTABLE l l UNACCEPTABLE QAD / DATE IF UNACCEPTABLE, REFERENCE SUPERSEDING NCR NUMBER l A.N.I. (ASME) DATE l i IF REQUIRED QA-6 Rev 0 L _J

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' QUALITY 15 NCR NO. 17 REV.

ASSURANCE 4' - Gno c. '? O

DIVISION 16 DATE ISSUED

!FORMQAD-1 3/2/ M6 NONCONFORMANCE REPORT 18 PAGE l OF 2-L ITEM LOCATION Diesel Generators 1 & 2G - 011/012 2 DRAWING OR PART NO. AND REV. 3 PART NAME l4 SERIAL NO.

Lube oil NA sump tank foot valve NA ITEM DESCRIPTION Elastomer liner in the foot valve mounted in the Lube 011 Sump Tank 6 ITEM STARTUP SYSTEM NO. 7 REFERENCE DOCUMENT 8 ASME A.N.I. REQUIRED 1&2 PEA and 1&2 PED (6-6, revision 3' NA 9 INSPECTION PLAN REV. 10 ACTION ORGANIZATION NA Engineering Technical Support 11 ACTIVITY HOLD REQUIRED: ACTIVITY HOLD ORDER NO.

YES y NO NA 12 REQUIREMENT Section 4.2.2 of procedure QA-6, revision 3 states in part: "When a nonconformance is '

reported to or detected by QAD personnel, QAD is responsible for: ...d. Documenting nonconformance on a NCR (Appendix A)".

13 NONCONFORMANCE A copy of a Part 21 Hotice was received by CPCo from Transamerica Delaval Incorporated indicating a potential problem with an elastomer liner in the foot valve mounted in the Lube Oil Sump Tank. The foot valve is. manufactured by the Clear Flow Company located in Berkeley, California. The disintegration of,the ^ liner could cause a restriction in the valve preventing flow of oil to the on-engine lube oil pump, or the liner pieces could ,

flow upstream lodging in and damaging the on-engine lube oil pump. Reference Part 21 Notice from Transamerica Delaval Inc., dated March 10' 14 NCR 0 GINATED BY

<?

ggg DATE MCButterfielf 19 HOLD TAG APPLIED YES X NO ITEMS SEGREGATED YES 1 NO NA p p 21 NEED TO REVIEW FOR p,,

REPORTABILITY X YES NO NA DATE J @//84 ~

88 Nov4No 22 DETERMINED TO BE REPORTABLE 25 EAD, RANCE ENGINEERING X YES NO 0.4.9.115 g gggg QA-006 Rev 3

26 CAUSE 34 PAGE 2. OF L.

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!27' PROCESS CORRECTIVE ACTION REQUIRED l- IYES I l NO 12 8 RECOMMENDED DISPOSITION l l REWORK l l SCRAP / REJECT l l REPAIR

• l l USE AS IS*

cREQUIRES TECHNICAL JUSTIFICATION ATTACHED

29 ADDITIONAL INFORMATION l

5 t

'30 DISPOSITION CONCURRENCE ACTION ORGANIZATION DATE QAD CONCURRENCE DATE ENGINEERING DATE - A.N.I. (ASME) IF REQUIRED 31 DISPOSITION ACTION TAKEN .- . . . ,

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32 METHOD I)F DISPOSITION ACTION VERIFICATION 3J NCR CLOSED BY RESULTS OF DIbPOSITION ACTION VERIFICATION i  ; ACCEPTABLE i l UNACCEPTABLE QAD DATE IF UNACCEPTABLE, RE?ERENCE SUPERSEDING NCR y

A.N.I. (ASME) DATE

.IF REQUIRED QA-006 Rev 3

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