ML20214C348

Intervenor Exhibit I-ROREM-231,consisting of 830428 Memo Re Major Problems Affecting QC Insp Backlog Filing.Sample of Audits,Surveillances & Memos Received & Generated & Installation Repts Encl

ML20214C348
Person / Time
Site:	Braidwood
Issue date:	12/04/1986
From:	Corcoran T, Saklak R COMSTOCK ENGINEERING, INC.
To:	Marino R COMSTOCK ENGINEERING, INC.
References
OL-I-ROREM-231, NUDOCS 8705200669
Download: ML20214C348 (15)

Text

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L. K. Comstock Engineering Company, Inc.

Memorandum 'o7 fM 13 A8:40 yo: R. Marino ;h . Office: Braidwood

~~

R. M. Saklak/T. F. Corcoran

. Major Problem Af fecting

Subject:

Q.C. Inspection Backlog Filint Date.

April 28, ,198 y As requested during our conversation on Tuesday, April 26,1983, I have prepared, for your review, a short summary on a very large problem that has become a Quality concern.

~

I had stated that Insta11atien boorts being handed in by Comstock Construction were not being properly reviewed by construction as required in all of the installation procedures. Added to this problem was the acknowledgement by CECO Q.A. recently that their department inadvertantly accepted a revision to Procedure 4.3.12, REv. 6-10-81 (Hanger Installation) which removed the foreaans responsibility of verifying and signing instal-lation reports indicating that the journeymans work and the installation  ;

report were properly completed. This procedure existed for approximately '

eight (8) norths until a new revision came out reinstating the foremans responsibilities. The result from this has been an added workload in-volving reinspection of the files for the -ight (8) months worth of instal-lations in order to evaluate the scope of corrective action needed.

This lack of review and verification has allowed a multitude of problems (in these reports) pass through the paper flow system eventually dumping on to the Quality Control Department for Quality Control to resolve.

A fine example of how this has affected Q.C.'s inspections, backlog and u7 filing can be found in the area of hanger inspections. Since March 16,

.' 1982, when this problem was formally addressed to Comstock in a CECO audit ,

QA-20-82-31, Finding #2, (which by the way is still open) an on going crusade of memos, internal audits, surveillances and manhours have been generated to cleaning up this identified topic. Over one year later Quality Control is still receiving unacceptable installation reports, our backlog still exists and our inspection reports are reflecting the unsatisfactory conditions created by Construction. In hanger installations alone M. Kast I has recently sent back over 440 Installation Reports to Construction for their corrective actions in an effort to satisfy the subject Q. A. Audit.

l Through Ceco direction F. Rolan has asked Q.C. management what ascects of '

Quality Control would be desirable for incorporating changes in the .

Comstock Construction computer. Your office, via K. Craybill, had started i in identify the subjects that would be considered applicable in providing a closed loop system. R. Cosaro's response to this was that Craysi.s ideas were not necessary at that time, subsequently you were infern..

through T. F. Corcoran. T. F. Corcoran nov informs me that R. Cer r =ay possibly charter the system that Graybill proposed.

PDR

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Major Problem Affceting PC. 2 QC Inspection Backlog Filing 4-28-83 e

The lack of an effective scheduling department (and computer) which

. n normally acts as a focal point between Construction and Quality Control

/ has inhibited the requirement for maintaining, retrieving and tracking important documents.

s Attached you will find a small sample of audits, surveillances and memos received and generated along with reduced copies of installation reports (deficient and duplicates) which represent typical problems seen on installation reports. s s'

Prepared By: '

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Concurred By: ) ,-

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RMS/dar cc: W. A. Gardner QC Mars. File 1

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h L. K. COMSTOCK ENGINEERING COMPANY, INC. ,

i Memorandum for 4

og, Braidwood

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Frank Rolan

! T. F. Corcoran Installation Reports .

p. 3/3/82 i gg CONTROL NO: 83-03-03-01

• In order to reduce excessive ICR's the Foreman shesad state on the ,

installation reports " incomplete f abric'ation topics." They should l also initiate Field Trouble Reports for known problems, and not rely on QC reporting nonconformances that they should be reporting.

It is apparent to me that to really solve this on-going problem that the solution is for Area Supervisors to get directly involved with the Foramen to make it happen consistently. Tour support in this A area would be appreciated and benefit subsequent actions to reduce! '

really unnecessary ICR's. In-process activities are both of our ' .

objectives and time / cost reduction can thusly be achieved. ,

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Thank you.

• I O x ;7 I.T- we ,)

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i T. F. Corcoran ,

QC Manager i

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cc: R. H. Saklak i M. Kast I 4 Ngrs file copy 1

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HR000034 l

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(* LQA-20-82-31 P ECo G. A AuD r. /"'"*"'

Findine #2 Contrary to 10CFR50, App. B, Criteria X, which states that

" ... inspection shall be performed by individuals other than those who perforia the activity being inspected...", L. K. Comstock craft personnel have been initialing various installation / verification reports indicating acceptance of the' installations.

Discussion:

L. K..Comstock's procedures 4.3.1 rev 8-20-81, 4.3.5 rev 5-27-81,

and 4.3.12 rev 6-10-82 for the installation of conduit, cable pan, and hangers, vere revised in nid-1981. These revisions shifted the responsibility for a 100% production installation verification from the foreman n the journeyman. The foreman now signs the installation verification report to sigMfy that the report is complete.

Corrective action required to close this item shall include procedure revisions and a documentation review to assure that all inspections were performed by individuals other than those who performed the activity. .

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L. K. COMSTOCK & COMPANY. nNC. . ..

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J 'ATTACIGENT 3 (4.14.1)

QUALITY ASSURANCE SURVIILLANCE REPORT No. s-014 PROJECT: BRAIDWOOD NUCIZAR PI. ANT UNITS 1 & 2

) COMPANY: Commonwealth Edison Company

, 10 CATION: -3raidwood, Illinois EURVIILLANCE DATE:11/23/82 AUDITOR (S): C. K. stiles [

PERSONS CONTACED, T. Corcoran, Frank Rolan, D. A. Brown-Ceco

REFERENCE:

In violation of Braidwood Procedure 4.8.12, paragraph 3.1, the

. construction departnant has not been using a valid hanger installation report (see Procedure 4.3.12) .

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MENGs It is abserved that there are great numbers of t:Ime card bacleaps entitled'" Banger Installation Report." These bogus EIt's are not approved by any present or past IKC Braidwood Procedures.

(1xhibit attached). , ,

CORRECTIVE ACTION & ACTION to PRECLUDE RIPETITION: To the attention of the Quality Control Manager.

)

L FOR REFEREEE ORY Response Date: Author:

E Reply Due Date: 12/15/82 Data Item Closed:

Disposition Acceptables

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• 'enssaasm anemovco msvisto 7 Ti.a onio. oats nav.oaTE FOR EA3 EPR RA3 46c.~

PRCCIDURE 7/1/'2 a

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L. K. Comstock Engineering Company, Inc.

Memorandum i

File Office. Ermidwooed To-From: M. Kast/1KCE QC Supervisor P

peze December 8.

Subject:

Inconolete Hanner Installation Reoorts A discussion was held on December 8,1982,' a.m. with D. A. Brown, CF.Co QA Supervisor, Braidwood Nuclear Power Plant, concerning incomplete hanger installation reports. Four (4) different deficiencias talked about were as follows:

1.) Ranger Installation Reports without procedure number.

2.)

• Foreman # signed but Installed By'# n ot signed.

.s .s 3.) # Installed By"but no Foreman's signature.

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4.) " Foreman"and* Installed By not signed.

(SAMPLES ATTACE':D) farra ztswed Mor awarmNin sx rxis MLnedagbom Q/ed./nn

$d Addd MrAunnsM 2tneers MMDED dsnoef YAAnlMd.1 DM4armt en His comments to se were that LKC QC would have to inspect all hangers listed on discrepant installation reports to verify that they were in fact installed and they show no deficiencies. No comments were addded as to what should be done or would be done if there were deficiencies noted.

All hangers listed on discrepant installation reports would be acceptable if in fact the inspection was performed.

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Mike Kast QC Sdpervisor ,

MK/tja cct T. Corcoran C. K. Stiles file s

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Fledtes Be. 2 (Aedit Fotet to. 5)

(Directed to the Freject sammager) U Concere me. t (medit reset No. 2) V U (Directed to the Freject Ismeeger) te vietetsee of Dr 4.3.12. pg. 3.4 regetrans v4 "The Forenes hoe toepected the heeger/seppost and g le stelselee of Br 4.3.12. pg. 3.1.4.2 two field welde were ende

. eigettsed the tempoetsen by his steentere/dete". ,g perpendicular to the web ed the opport tag eteet. *,

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.ae Thte uCa se esitt spam. .

The NCR is written egelset the weldteg of Ceedelt meegere W9 & g g CC.10. These hengere are leseted to the Amst18ery Datidig, *

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, 346' Elevot tee. et se-21. 2404 1 prewteg e-3302a to referenced en the BCE. .

• 3392 1 2373 1 2351 1 Sete of Corrective actses & 2349 1

&ctsee to Freclude Bayetitless

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• File folder labeled "Comitseretten 2m-4 3072sA* testattee see Ited tas us. 3 (And88 Petet me. 3) soport etteched to pero ff. sanger 52a. es foreman's eigemaare/

(strected to the trejset seemeser) ,

date. This se repeated to thse fonder.

i le viel'attee of er 4.3.12. pg. 3.1.4.2. the welder hoe met stamped Corrective Aettee 6 setten j his eyebel adjement to the weld. Se freelade Sepitataans The felleutsg mee ebeerved:

• Fledies No. 3 (andit potet Be. 7)

RANGE I (D& rested to the qlC 30amager)

M M 2405 4/s/e3 CC-Ile se esslettee of er 4.8.12 pg. 3.2. shich statoes C0-182 *ee a rendes beste se 12C toepeeter she11 perfere e CC-73 servet11emee se so-procese empporte/hengere Aeste11ettene CC-5 ~and h as pese 07.

CC-9 (F-9/14-15)

CC-6 se so-procese seepeettees were famed to the v alt that CC-19 ese W eden,eFore87.

CC-14 CC-12 Correettee settes & Aettee

• a 24e6 4/5/ 83 CC-9 (n-r/15) to Pres 3ede aspDettees *

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. ant 3/23/s3 smeer en IJssella

.l 2349 3/23/s3 ameer en IJs124ea l 23e3 3/1/83 62 f thee eene probles ese reported en Internet edit #1-018. Fledges f1. ,

t Corrective Aettes & Amt see to preclude tapetatSame = ,

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(Strected to the Freject gemeeger) (2 0 (essected to the Freject IImmager) d In etelettee of at 4.3.12, pg. 3.4 regassess d "The Foremos hoe tempected the henger/empport med v i in vietettee of SF 4.3.12, pg. 3.1.4.2 two field welde were enJe . eigattled the toepeettee by his eigentere/detaf*. g pespeediceter to the web of the espporties steel.

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• The welder's stamp one est eff tmed adjesent to the sold NCa #637 Reased S/10/02, one dispoettissed by Ceco em 12/16/82. a detested to asett potet so. 3, se fellemos

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The BCE to written agatest the weldtag of Omedelt Bengers CC-9 & ICS f jgggg CC.10. These hameere are leested to the Aust11ery Buildles, Sees 9 344' Elevettee, et so-21.

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presteg 9-3302A to referseced en the WCE. .

2404 1 2392 1 237S 1 ante of Corrective Aettee 6 2351 1 Act see to Free!.de tapetitsee: 2349 1 23e3 1 l

• gledtes me. 1 (assett retet me. 3) r!!e folder labeled "csettgeretten 25-4-Se73sa* Restellet ten (otracted to the reeject lemmeser) ,

saport etteched to pere $7, Seeger 524, se foremma's esgastere/

J date. This le repeated in this folder.

te vietettee of BF 4.3.12, pg. 3.1.4.2, the welder has est stemped Corrective Aettes & Aettee his eyehet adjesent to the weld. Le freclude Septattimes ,

The fellesleg wee ebeervedt

• Fledian No. 3 (andit potet me. 7)

EapISR S (Directed to the QC IImmager) l M 9$3 2405 4/4/03 CC-110

• In vietettee of er 4.8.12, pg. 3.3, uhteh states:

CC-te2 *ee e renden heele se SEC leapeeter shell perfere a CC-73 servettlesee se to-procese empporte/hsmesse teste11stamos CC-5 ~and h en pose ff.

CC-9 (F-q/14-15)

Cre6 Be te-process toepeettees were famed in the ven!t that CC-19 ere desgeseted se ,a peso f 7, CC-14 CC-12 correettve Aettes & Aetten .

24e4 4/5/s3 CC-9 (s r/15) to pr.a.a= aspettatant *

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