ML17054B452

Rev 1 to Vol 1, Summary & Conclusions, to Final Rept of Independent Review Nine Mile 2 Related NRC Const Assessment Team Insps & SALP Rept & Niagara Mohawk Identified Deficiencies.

ML17054B452
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VOLUMEIFINALREPORTOFANINDEPENDENT REVIEWOFNINEMILE2RELATEDNRCCATINSPECTIONS ANDSALPREPORTANDNIAGARAMOHAWKIDENTIFIED DEFICIENCIES SUMMARYANDCONCLUSIONS REVISION1PreparedForNIAGARAMOHAWKPOWERCORPORATION 300ErieBoulevard WestSyracuse, NewYork13202March5,1985Management AnalysisCompanyProjectNumber:MAC-80-F138 NiagaraMohawkPowerCorporation PurchaseOrderNumber:180938503ii0433 85p3p7PDRADOCK050004ip' PDR 1~t5 10023h0'OREWORDVolumesI,IIandIIIofthisreportweredistributed simultaneously totheNuclearRegulatory Commission andtoNiagaraMohawkPowerCorporation onDecember26,1980.VolumeIcontained theExecutive SummaryandtheSummaryandConclusions fortheentirereport.Detailsofeachassessment werecontained inVolumeIIandidentification ofeachdocumentassessed, theresultoftheassessment andassignedresponsibility forcorrective actionareshowninmatricesinVolumeIII.TheExecutive SummaryandSummaryandConclusions reportedcertaindatainadifferent mannerthanhadbeenpresented orallytotheNRCandNMPC.Whilebothmethodswereconsistent withtheresultsshowninVolumesIIandIII,theSummaryexaggerated thepercentdeficient previously reportedforPhasesI,IIandIII.Inthesethreephases,thenumberofitemspreviously identified bytheNRCandNMPCexceedsthenumberofdocuments inwhichthedeficiencies wereidentified.

InPhaseIVthenumberofdeficient itemsandthenumberofdocuments areessentially onaone-for-one basis.TheoriginalversionofVolumeIevaluated allfourphasesonadocumentbasis.Ifonlyoneofseveralitemscoveredbyaspecificdocumentwerefounddeficient bytheAssessmerlt Team'nimplemented corrective action,theentiredocumentwasjudgedunsatisfactory.

Forexample,PhaseIconsisted of60documents containing 365items.Basedon13of60documents beingdeficient tosomedegree,thepercentunsatisfactory was22percent.Basedon38itemsof365beingdeficient thepercentunsatisfactory is10.1percent.Whentheinformation wasfurnished totheNRCinameetingNovemberIO,1980andintheinterimreports,thepercentunsatisfactory wasfurnished onthislatterbasis.Throughout theassessment, theteammaderecommendations intendedtoenhancetheeffectiveness ofcorrective actiononfutureoccurrences ofsimilarconditions.

Inallcaseswhererecommendations weremade,thecommitted corrective actionhadbeenimplemented andwassatisfactory forthespecificdeficiency identified.

Insomeinstances, reviewers ofVolumeIhadtheperception thatthecategorization "Satisfactory withRecommendations" equatedinsomemannerto"Unsatisfactory".

Thisperception isincorrect.

10023h0'ntheoriginalversionofthisvolume,theresponsibility forcorrective actionforPhasesI,IIandIIIwasassignedtoNiagaraMohawkeventhoughtheresponsibility fortakingcorrective actionwasthatofoneofthemajorcontractors.

ThisrevisionofVolumeIassignstheresponsibility forcorrective actiontotheorganization responsible forimplementing it.Whentheobservedcondition wasjudgedtobeunsatisfactory, aCorrective ActionRequest(CAR)wasoriginated bytheteam.Therewere77CARsand6ITTInspection Reportswritten,buttheseappliedtol32different deficiencies.

Itwasnotcleartosomereviewers thataCARcouldapplytomorethanonedeficiency andthusappearrepetitively inthereportagainstmorethanonedeficiency, morethanonecriterion ormorethanoneofthefourphases.Theassignment ofCARstoindividual qualityassurance criteriahasbeenreviewed.

Somehavebeendeletedwheretheassessment wasconcluded tobeinappropriate.

ThetotalnumbersofCARsandIRsremainunchanged.

ThereportincludedParetoanalysesrelatingtothedeficiencies intheoriginaldocumentandthoseidentified bytheAssessment Teamintheirinspection ofhardwareandreviewofdocuments.

Thepurposeoftheseanalyseswastoisolatetheprincipal causesofdefi-ciencybyresponsible organization andtoidentifythoseareaswherecorrective actioncouldbringaboutthegreatestimprovement.

Themannerofdisplaying thisinformation contributed toconfusion, becauseinordertoprovidealargerandtherefore moremean-ingfulsample,itemsthatweredispositioned "Satisfactory withRecommendations" and"Unsatisfactory" werecombinedtogethersolelyforthepurposeofanalysis.

Thiswasanalternative toanalyzing theentirepopulation foreachcontractor.

WordchangeshavebeenmadetomaketheanalysisofPhasesI,IIandIIIconsistent withotherrevisions inthereportandtoclarifytheintentofsuchcombination.

Inaddition, forfurtherclarif-ication,quantities havebeenrestatednumerically ratherthanasapercentage ofthetotalnumberofdeficiencies.

Thisprovidesamorereadilyunderstood viewoftheresults.Finally,theAssessment Teamevaluated certainbutnotalloftheoverallaspectsofthequalityassurance programastothedegreeofbeingsatisfactory.

Suchevaluation wasbeyondthescopeoftheassignedtask,butmoreimportantly itisnotconsidered that suchevaluations canbegenerically appliedtoNMPCandthefiveprincipal sitecontrac-tors.Suchevaluations occurredinonly12of18areasevaluated inSection0.0ofVolumeIandhavenowbeendeleted.Revisedareasthroughout areidentified byalineintherighthandmargin.Insummary,thepurposesoftherevisiontoVolumeIareasfollows:~Presentsummarized datainthesamemanneraspresented inchartsshowntheNRCinameetingNovember10,1980andconsistent withthemannershownininterimreports.~Assigntheresponsibility forcorrective actiontotheorganizations requiredtoimplement it.~Clarifytheacceptability ofcorrective actionsforwhichtheAssessment Teammaderecommendations.

~ClarifythatCorrective ActionRequestsmay,andoftendo,applytomorethanonedeficiency, qualityassurance criterion, orphaseoftheassessment.

~Provideanoverallstatement ontheadequacyofthecorrective actioneffort.~Eliminate confusion thatreviewers oftheoriginalversionofVolumeI,mayhaveexperienced.

10023h0'XECUTIVE SUMMARYTheNuclearRegulatory Commission (NRC)directedNiagaraMohawkPowerCorporation (NMPC)tohaveanindependent assessment ofcorrective actionimplementation andade-quacyperformed.

Management AnalysisCompany(MAC)wascommissioned byNMPCtoperformthisindependent assessment ofcorrective andpreventive actionsrelatedtodeficiencies identified bytheConstruction Appraisal Team(CAT)report,themostrecentSystematic Assessment ofLicenseePerformance (SALP)report,NMPCanditsfivemajorsitecontractors duringtheperiod3anuary1,1981toMarch31,1980.Theindependent assessment wasdividedintofourphases.Interimreportswereissuedforthefirstthreephases.Thisreportincludesthefinalresultsofthefirstthreephasesandtheresultsofthefourthphase.Manyoftherecommendations madeintheinterimreportshavesincebeenimplemented byNMPC.Thisreportdoesnotassesstheeffectiveness ofsuchimplementation orofchangesinorganization,

staffing, andprogrammadesinceMarch31,1980.Theresultsoftheassessment showthat96.1percentoftheitemsforwhichcorrective actioncommitments madebyNMPCanditscontractors overthisperiodwereadequately implemented.

In9.7percentofthesecases,theMACIndependent Assessment Team(Assessment Team)maderecommendations toenhancetheeffectiveness ofcorrective action.In3.9percentofthecases,thecommitted corrective actionwaseithernotimplemented ornotimplemented adequately.

ThePhaseIInterimReportcovered38of60NRC-identified CATitems,forwhichtheAssessment Teamissued6Corrective ActionRequests(CARs).Sixty-six CATitemswereoriginated, but6wereeithernon-safety-related orcombinedwithotherCATitemsreducingtheevaluated numberto60.Theremaining 22itemshavesincebeenassessed, andresultedintheissuanceof6additional CARs.ThePhaseIIInterimReportcovered33of36NRCviolations identified intheNRCSALPreport,and15of61Construction Deficiency Reports(CDRs).OneCARwasissued,38NRCSALPitemswereoriginated, but2wereforthedeficiencies alreadyaddressed inCATitems,thusreducingthenumberto36.TwoSALPitemsandthreeCDRitemshave 10023h0sincebeenevaluated bytheAssessment Team.Noadditional CARswereissued.ThreeSALPitemsand06CDRitemsarestillunresolved andrequireclosurebyNMPC,socorrective actioncouldnotbeconfirmed.

ThePhaseIIIInterimReportcovered169of196NMPCauditfindings, forwhichfourCARswereissued.TwohundredsixteenNMPCAuditItemswereoriginated, but19wereeithernon-safety-related, coveredinanotherphaseorwereNineMile1items.Oftheremaining 27items,7remainopenandrequireNMPCclosure,and20areevaluated here.Noadditional CARswereoriginated.

TherewasnointerimreportforPhaseIV.Itcovered2,600deficiency documents forthefivemajorsitecontractors.

Theevaluation showed2,550corrective actioncommitments tohavebeensatisfactorily resolved.

OnehundredfiftyofthesewerejudgedSatisfactory withadditional actionrecommended toenhancecorrective actioneffectiveness.

In90cases,thecorrective actionhadnotbeenimplemented adequately andCARswereorigi-nated.Whiletheoverallresultsoftheassessment showedacceptability in96.3percentofthecases,indicating ahighdegreeofreliability inimplementing committed corrective actions,somedeficiencies wereidentified bytheAssessment Team.Acceptable corrective actionhasbeencategorized as"Satisfactory" and"Satisfactory withRecommendations".

Inbothcases,thecorrective actionwasimplemented andwaseffective forthespecificdeficiency.

Analysisshowedthattheprimaryareasofdeficiency relatedto8ofthe18Criteriaof10CFR50,AppendixB,and5concernsrelatedtohardwaredeficiencies.

Theseareasarediscussed furtherinthefollowing paragraphs.

ProrammaticDeficiencies Programmatic deficiencies relatedto8ofthe18Criteriaof10CFR50,AppendixB,havebeenidentified asrequiring improvement.

Seventy-seven Corrective ActionRequests(CAR)wereoriginated toidentifyconditions judgedtobeunsatisfactory duringtheassessments.

ACARmayapplytomorethanonecriterion, deficiency orphaseoftheassessment.

10023h0DesignControlBothNiVlPCandStoneandWebsterEngineering Corporation (SWEC)havemadeimprove-mentsinthedesigncontrolsystem,including instituting acomputerized systemforpostingdesignchanges,reducingthenumberofdrawingstationsandproviding fasterdistribution ofchanges.However,theassessment pointedoutareasthatstillneedimprovement.

Somedrawingsarestillnotbeingreviewedaccording toprocedures, designchangesarenotalwayspostedagainsteachaffecteddrawingandthenumberofchangesindicateinadequate reviewofproposedchanges.TheAssessment Teaminitiated 3CARsforthisCriterion:

80.000280.006780.0072Instructions, Procedures andDrawingsLackofappropriate procedures andimproperprocedural implementation havebeenindicated astherootcauseofmanyofthedeficiencies.

Improvement shouldbemadebyincluding acceptance criteriaandinspection attributes ininspection plansandproce-dures.TheAssessment Teaminitiated 2CARsforthisCriterion:

80.011080.0116ControlofPurchased Materials Sourceinspection planningwhichwillrequirewitnesstestingandverification ofobjec-tiveevidencehasbeencommitted tobySWECQualityAssurance (QA),buthasnotyetbeenimplemented.

NMPChascommitted toparticipate (selectively) insourceinspection.

TheAssessment Teaminitiated 2CARsforthisCriterion:

80.013280.0160SpecialProcesses Someofthedeficiencies associated withtherequirements ofthisCriterion havebeencorrected.

TheAssessment TeamissuedaCARbecauseofimproperly maintained welderqualification records,anddatatransferred fromonequalification recordtoanotherwithoutcross-reference orcertification signature.

ReactorControls, Incorporated (RCI) 10023hOhasresolvedthisproblem.However,bothITTGrinnell(ITT)andRCIhavevisualinspection andpenetrant testingproblemsinvolving piping.Deviation Reports(DRs)havebeenclosedpriortocompletion ofradiography anddiscontinuities werelaterdisclosed requiring anotherDRtobeissued.TheAssessment Teaminitiated 0CARsforthisCriterion:

80.005080.011080.016180.0150Inspection Inspection problemswereidentified throughout everyaspectofthisassessment.

Race-wayinstallation inspections werenotbeingperformed inatimelymanner.Inspection plansandprocedures contained deficiencies intheacceptance criteria.

Noinspection attributes orcriteriahadbeenprovidedforKellemgrips,separation barriersorprotru-sionsintothecabletray.Mechanical inspection checklists forpipingdidnotreflectthelatestdesignchanges.Therewerealsoseveralinstances inwhichfieldQualityControl(QC)inspectors prepareddeficiency reportsbasedonreference dimensions ratherthanrequireddimensions.

TheAssessment Teaminitiated 7CARsforthisCriterion:

80.005580.006680.006980.007080.007780.010580.0138Nonconformance ControlNMPC'sandSWEC'ssystemsfornonconformance controlhavebeenimprovedsomewhatthroughtheestablishment ofanimprovedtrainingprogramwhichencompasses morethanjustQAandQCpersonnel.

Thiswillimprovethequalityawareness ofallsiteperson-neLHowever,Engineering andDesignCoordination Reports(ERDCRs)arestillusedtodocumentnonconforming conditions.

ThetrackingsystemforNonconformance andDisposition Reports(NRDs)isineffective andthereisnomechanism fortrackingdisposition orimplementation ofcorrective actionbyacontractor.

TheAssessment Teaminitiated 15CARsforthisCriterion:

I80.007080.009580.011080.015980.007580.010780.011580.016580.008980.010S80.010580.017280.010180.011180.0153 10023h0Corrective ActionBothNMPCandSWEChaveproblemswiththecorrective actionprocess,bothintermsofdelaysinimplementation andverification ofcorrective action.Responses tocorrec-tiveactionshavebeenslow.Verification toensurethatpreviously installed itemsmeetupdatedcriteriaislacking.TheuseofType"A"andType"C"Inspection Reports(IRs)hashamperedthecorrective actionprocessbecauseType"A"donotnormallyincludetheactiontakenorjustification toclose,andType"C"willprecludetrending.

Someimprovement hasbeenwitnessed intheformofrevisedprocedures andanupdatedtrendingprogram.TheAssessment Teaminitiated 19CARsforthisCriterion:

80.000980.006380.010280.011980.010180.005080.007180.010580.013680.015280.005280.008880.011780.0137S0.0150S0.005880.009180.011880.0100QualityAssurance RecordsNMPCandSWEChavebothaddressed theproblemofdocumentcontrolandQArecordsandhaveestablished ataskforcetoreviewthisarea.However,problemsstillpersistconcerning accessibility andretrievability ofalldocuments including QArecords.Relateddocuments arenotalwayscrossreferenced.

Thefacilities forhousingmanyoftheactiveQArecordsareinadequate.

One-hourfire-safe cabinetsarebeingusedforpermanent records.Onlyaminimumnumber'ofturnoverpackageshavebeentransmitted toNMPC.TheAssessment Teaminitiated 5CARsforthisCriterion:

80.000780.005680.012080.015180.0100HardwareDeQciencies Hardware-related deficiencies havebeenidentified infiveareasofconcern,asdiscussed inthefollowing sections.

WeldingSignificant progresshasbeenmadeincorrecting NRC-identified deficiencies intheareaofweldrepairing, weldmaterialcontrolandweldingqualifications.

However,theresultsofthisassessment haveemphasized thatweldingqualitywasamajorproblemthroughout theperiodassessed.

Theprojectneedstoreducethenumberofundersize weldsandimproveinitiation andmaintenance ofwelddatacardsandotherdocumentation.

vIII 10023hO'ipingMostofthepipingproblemsatNMP-2canbeattributed toITTandRCI.ITTisnotinspecting forattributes suchasconfiguration, locationandinterferences whichmakeitdifficult toevaluatetheoverallcondition ofthepipingprogram.Awalkdownprocedure hasbeendeveloped toassurethatpipingattributes areinspected, butinsomecaseschecklists forpipinginstallations donotcontainreference tothelatestdesigndocu-ments.Thenewprocedure requiresprovision forconfiguration inspection.

Thisareaneedsadditional improvement.

PipeHangersandSupportNMPCdidnotfullyaddresstheNRCconcernregarding ITTpipesupportandrestraint deficiencies notbeingidentified duringConstruction Acceptance Inspections.

ITTinspections ofpipesupportsandrestraints havealsonotbeeneffective inassuringthathardwareconformstodesignrequirements.

NMPCandSWEChaveinstituted actionstoimproveITToverallperformance inthisarea.Theeffectiveness oftheiractionsshouldbemonitored andrevisedasnecessary.

Materials StorageandControlSomeimprovement hasbeenmadeincorrecting NRC-identified deficiencies intheareaofmaterials traceability andhousekeeping, buttheprimaryconcernofplantandlaydownareastorageisstillaproblem.Repeatedinspections oftheseareasbytheAssessment Teamhaveindicated thattheproblemsofintermixing ofdissimilar items,intermixing ofacceptable andrejectedmaterials, storageofsafety-related materials atalevellowerthanrequired, lackofdunnageforpackaging sensitive itemsandprotection fromdamageanddeterioration tosafety-related equipment continue.

Personnel involvedshouldbeinformedofthenecessary requirements anddiscipline established andenforcedtoassurecompliance.

PowerGeneration ControlComplex(PGCC)Theseparation criteriaasitrelatestothePGCCcontinues tobeaproblem.NMPCQAhasnotprovidedassurance thatthiscriteriahasbeensatisfied.

ManyGEFieldDesignInstructions (FDls)andFieldDeviation DesignReports(FDDRs)remainopen.Separation 10023h0attributes arenotalwaysaccurately recordedonIRs.QCcontinues toidentifydisparities incableseparations assomething whichcanbedonelaterbyenteringan(L)ontheIRfortrackingpurposesandsubsequent reinspection.

Thisisbetterthantheformermethodofidentifying missedcriteriaas"later"withoutatrackingdevicetoaccomplish reinspection, butisstillinadequate.

TheAssessment Teamdetermined thatanumberofCARsrelatedtohardwareaswellastoqualitycriteria.

AnumberoftheCARsrelatedtohardwareonly.Hardware-related CARsarethosewhichidentified acondition thatmade,orcouldmake,thehardwarenonconforming orindeterminate toexistingspecified requirements ifthecondition hadnotbeenidentified.

Thefollowing listincludestheseCARsconsidered tobehardwarerelated.I80.000280.000380.000880.000980.0050.80.0052' 80.0050S0.005580.005680.005780.005880.006280.006380.006080.006680.006980.007080.007180.007280.007380.007080.007580.008980.009080.009280.009080.010580.010780.010880.010980.011080.0115S0.011680.011780.011880.011980.013580.013780.013880.013980.010080.010580.015180.015080.015680.015780.015980.016080.0167S0.016880.016980.017180.0173I 10023hO'OLUMEITABLEOFCONTENTSSection~PaeOREWORD~~~~~~~~~~~~~~~~~~e~~~~~~~~~~~~~~~~~~~~~~~~~~FEXECUTIVE SUMMARYiv1.0RODUCTION

~~~~~~~~~~~~~~~~~~~~e~~~~~~~~~~~~~~~~~~~~~INT1.1Scope~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~1.2ProspectApproach1~3Overview2.0IAOrganization ofReportSUMMARYOFASSESSMENT RESULTS1-72-12.1NRCOrderItems2.1.1QualityAssurance Program2.1.2SiteAuditingProgram2-12-12-22.1.3Cor'rective ActionSystem.....................

2-02.1AProcurement QualityAssurance 2.1.5DocumentandDesignChangeControl2.1e6Radiographic FilmQuality2.1.7ConcreteExpansion Anchors2.1.8PowerGeneration ControlComplex2-72-72-92-112-122.2Discipline Assessment Items2.2.1Civil/Structural

~~~~~~~~~~~~~~~~~~~~~~~~~~~2-132-132~2e2Electrical e~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~2-102.2.3Welding/NDE l2.2AMechanical 2.2.5Materials/Receiving 2.3Programmatic Items~~~~~~~~~~~~~~~~~~~~e~~~~~~2-152-182-202-212.3.1rainingT2-212.3.2Communication 2-222.3.3Inspection 2-23-x1-10023h0'OLUMEISection2.0TABLEOFCONTENTS(Continued)

PhaseIVSamplingAssessments 20.1SamplingPlan2.0.2PhaseIVHardwareSamplingAssessment Analysis2.0.3PhaseIVProgrammatic SamplingAssessment Analysis~Pae2-202-252-262-283.0ANALYSISOFDEFICIENCY DOCUMENTS 3-13.1Introduction

~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~3.2NMPCAnalysis3.3SWECProgrammatic 3.0SWECHardware3~5ITTProgrammatic 3.6ITTHardware3-13-53-73-83-93-110.03.7JCIProgrammatic 3.83CIHardware3.9RCIProgrammatic

.10RCIHardware3CONCLUSIONS ANDRECOMMENDATIONS 0.1NRCOrderItemAssessment 3-123-103-153-170-10.1.10.1.20.1.3QualityAssurance ProgramSiteAuditingProgramsCorrective ActionSystem0-10-20-20.10DocumentControl0-30.1.50.1.6DesignChangeControlProcurement QualityAssurance

~~~~~~~~~~~~~~~00-Xiit VOLUMEITABLEOFCONTENTS(Continued)

Section0.1.70.1.80.1.9Radiographic FilmConcreteExpansion AnchorBoltsPowerGeneration ControlComplex~~~~~~~~~~~,~~Pae0-50-60.2Discipline Assessments 0.2.1Civil/Structural

-Concrete0.2.2Civil/Structural

-ConcreteExpansion Anchors0.2.3Electrical/McC

-PGCC0.2e0Electrical/IRC

-SeismicCriteria0.2e5Welding/NDE

-WeldQualityandAssociated Documentation

~~~~~e~~~~~0.2.60.2.70.2.80.2.90.2.100.2.11Welding/NDE

-WeldRepairsWelding/NDE

-WeldMaterialControlWelding/NDE

-WeldQualifications Welding/NDE

-WeldInspection Mechanical

-PipingMechanical

-PipeSupportsandRestraints

~~~~~~~~~~0-90-90-100-100-110-11l0.2.12Mechanical

-RCIProgramWeaknesses 0.2.13Mechanical

-Bolting0.2.10Materials/Receiving

-BatteryRacks0.2.15Materials/Receiving

-StorageandHousekeeping 0.3Programmatic Items0.3.1Training0.3.2Communication 0.3.3Inspection

0.0 PhaseIVSamplingAssessment

-xni-~~~~~~~~e~~~~~~~~~~~0-120-120-130-130-150-I,6 10023h0'OLUMEITABLEOFCONTENTS(Continued)

LISTOFFIGURES~F1mreTitleDeficiency CodesBased18Criteria-10CFR50HardwareDeficiency Codes~Pae.3-33-0-XLV-10023h

01.0INTRODUCTION

SCOPEAspartofitsordermodifying theconstruction permitfortheNineMilePointUnit2(NMP-2)nuclearstation,theNuclearRegulatory Commission (NRC)directedNiagaraMohawkPowerCorporation (NMPC)tohaveanindependent assessment ofcorrective andpreventive actionsperformed.

Thisassessment wastoaddressdeficiencies identified byrecentNRCinspections andbyNMPCanditssitecontractors betweenJanuary1,1981,whenconstruction wasresumed,andMarch31,1980,whenarestructured qualityassurance (QA)organization wasinplace.Actualrestructuring beganinJanuary1980.TheNRCspecifically directedNMPCtoaddressthecorrective actioncommit-mentsmadeinresponsetotheConstruction Appraisal Team(CAT)reportofJanuary31,1980,themostrecentSystematic Assessment ofLicenseePerformance (SALP)report,deficiencies identified byNMPCasaresultofitsownsurveillance andauditactivities, anddeficiencies identified bythemajorsitecontractors:

StoneandWebsterEngineering Corporation (SWEC),ITTGrinnellIndustrial Piping,Incorporated (ITT),ReactorControls, Incorporated (RCI),GeneralElectric(GE),andJohnsonControls, Incorporated (JCI).Management AnalysisCompany(MAC)wascommissioned byNMPCtoperformanindependent reviewofcorrective actioncommitments andimplementations forprogramdeficiencies andnonconformances fortheperiodJanuary1,1981throughMarch31,1980.Thepurposeofthisreviewwastodetermine whethertheunderlying orfundamental causesforthedeficiencies hadbeencorrectly identified, andwhethercorrective andpreventive actionshaveadequately addressed theunderlying andfundamental causesandresolvedthedeficiencies.

12PROJECTAPPROACHAnalysisofthetaskdefinedbytheNRCmadeitevidentthattheworkcouldbedividedintofourphases:thefirsttwodirectedto.NRCfindingsandconcerns, thethirdtoNMPCsurveillance andaudits,andthefourthtodeficiencies identified bythemajorsitecontiactors.

Muchoftheworkofthevariousphaseswasactuallyperformed inparallel.

MACassembled a

10023h0teamofhighlyqualified personnel toperformtheassessment fromitsownstaffandfromotherconsulting andengineering organizations.

ThisIndependent Assessment Team(Assessment Team)wasmadeupofindividuals withnopreviousinvolvement atNMP-2.Eachteammemberhadtechnical expertise inoneormoreofthefollowing disciplines:

~Civil/Structural

~Electrical/Instrumentation andControls(IRC)~Welding/Nondestructive Examination (NDE)~Mechanical

~MaterialandReceiving

~SoftwareAsmanyas05professionals wereusedoveranapproximate 6-monthperiod,withanaverageof36personsthroughout theassessment.

TheAssessment Teamaveraged13yearsofnuclearexperience andhadatotalof1,007yearsofaccumulated professional experience.

Teammembersreviewedatotalof2,900documents andrelatedcorrective actioncommitments.

Ofthetotal,1,920documents relatedtocorrected physicalcomponents, systemsorstructures, whichwereassessedforconformance tospecified requirements aswellasforcorrection oftheidentified deficiencies.

Deficiencies weresegregated bydiscipline (e.g.,mechanical, electrical, civil/structural) andassignedthroughdiscipline leaderstoindividual teammembersforevaluation.

TheAssessment Teamevaluated thecorrective andpreventive actionsthatNMPCoritsappropriate contractor considered adequatetoresolvethedeficiency.

Deficiencies identified bytheNRCCATinspection, SALPassessment andbyNMPCauditandsurveillance activities were100percentevaluated.

Becauseoftherelatively largenumberofdeficiencies identified bythesitecontractors overtheperiodinquestion, astatistical samplingplanwasusedtoidentifythedeficiencies tobeevaluated.

Thedeficiencies wereidentified asprogram-maticorhardware-related andfurtherseparated bydiscipline.

10023hO1-3Thedeficiencies ineachspecificdiscipline identified byeachspecificcontractor constituted alot.Eachlotwassampledatnormalsamplinglevelsinaccordance withMIL-STD-105D, TablesI,IIAandVIIA,(withthemodifi-cationthatpopulations under100were100percentinspected) toachievea95percentconfidence levelthat95percentofthelotwasofadequatequality.Ifthesampleconfirmed thattherequiredlevelofqualityhadbeenmaintained, thelotwasconsidered acceptable andnofurtherreinspection wasrequired.

Ifthesampledisclosed thattherequiredlevelofqualityhadnot'eenmaintained, thesamplesizewasincreased totightened sampling.

Iftightened alsoshowedthatthedesiredqualitylevelhadnotbeenobtained, theAssessment Teammaderecommendations forimprovement whicharecontained inthisreport.TheAssessment Team'seffortconsisted ofathoroughreviewofthestatedcorrective andpreventive actionandstatedorimpliedrootcause;interviews withresponsible personnel; reviewofdesign,appropriate processes, acceptance criteriaandmethods;evaluation ofrelatedprocedures andotherdocumentation; andevaluation ofpersonnel skillrequirements andqualifications.

TheAssessment Teamperformed.

sufficient reinspection ofaffectedhardwaretodetermine whetherthecorrective actionhadbeenimplemented asstated,andwhetherithadbeenappropriately appliedonagenericbasissuchaswouldprecluderecurrence ofalikeproblemondifferent itemsofhardwareordocumentation.

Reinspection coincided withareviewofQAdocuments providing acceptance

criteria, e.g.,procedures, designdrawings, specifications, checklists, inspection instructions usedinperforming theoriginalqualityassessment, andthosedocuments pertaining tocorrective andpreventive measuresafterthedeficiency wasidentified.

Requiredphysicalinspections wereperformed bypersonnel qualified intheappropriate discipline.

Corrective actionrelatingtoanydeficiency wasevaluated as"Satisfactory",

"Satisfactory withRecommendation",

or"Unsatisfactory".

A"Satisfactory" ratingindicated thatthefundamental causeofthedeficiency hadbeencorrectly identified andthatthecorrective andpreventive actionhad 10023h4adequately addressed thecauseandresolvedthedeficiency.

Aratingof"Satisfactory withRecommendation" indicated thattheaction.hadadequately addressed thespecificdeficiency, buttheAssessment Teamfeltfurtheractionwouldassistinprecluding recurrence oftheproblem.Corrective actionsratedas"Unsatisfactory" werethoseforwhichthecommitted corrective andpreventive measureshadnotbeenimplemented,'r wasineffective inresolving thedeficiency.

Itemsrated"Unsatisfactory" wereidentified onanNMPCCorrective ActionRequest(CAR)bytheAssessment TeamandissuedtoNMPCfordisposition.

ThoseCARsoriginated bytheAssessment TeamwhichwereclosedbyNMPCwerealsoreviewedforadequacyofcorrective action.OVERVIEWTheAssessment Teamevaluated 2,900deficiency documents, totaling3,390items,anddetermined byreviewofdocuments andbyphysicalinspection ofaccessible hardwareitemswhethercorrective andpreventive actionhadbeentakenwhichproperlyaddressed thestateddeficiency andwasappropriately andeffectively appliedtoprecluderecurrence.

Asthefollowing figureshows,thisreviewdisclosed thatfor96.1percentoftheitemsevaluated, thecorrective actionwasappropriate andcorrected thespecificdeficiency.

Thisdisclosed ahighdegreeofreliability onthepartofNMPCanditscontractors inimplementing corrective actionascommitted.

Acceptable corrective actionshavebeencategorized as"Satisfactory" and"Satisfactory withRecommendations".

Inbothcases,thecommitted corrective actionwasimplemented andwaseffective forthespecificdeficiency.

In9.7percentoftheitemsevaluated, theAssessment Teammaderecommendations toimprovetheeffectiveness ofthecorrective action.Ig 10023h0'-5TOTALITEMASSESSMENTS SATISFACTORY (SAT),SATISFACTORY WITHRECOMMENDATION (S/R),ANDUNSATISFACTORY (UNSAT)ALLCONTRACTORS SAT(2,928)86.4%UNSAT(108)S/a(>>0)Theseassessments werefurthercategorized bythephaseoftheprojectinwhichtherecordswereevaluated.

Thiscategorization isshownonTable1below.TABLE1TOTALITEMASSESSMENTS BYPRO3ECTPHASEPHASEI11IHIVTOTALNumberofItemsSatisfactory Unsatisfactory TOTALASSESSMENTS 3281911852,5503,25837,10901323651921892>60037390PercentaeBreakdown Satisfactory Unsatisfactory 10.10.52.13A3989.999.597.996.696.1 10023hOTable2showsthedistribution oftheratedassessments amongtheresponsible organizations.

TABLE2!TOTALDOCUMENTASSESSMENTS BYORGANIZATION ORGANIZATION NMPCSW'ECITT3CIRCIGETOTALNumberofDocuments Satisfactory Unsatisfactory TOTALASSESSMENTS 511,200890012178572,832102369191108521,282930021197582,900PercentaeBreakdown Satisfactory Unsatisfactory 98.11.93.33.92.19.30.23.796.796.197.890.099.896.3Onthisbasis,96.3percentwereassessedasbeingSatisfactory orSatisfactory withRecommendation and3.7percentwereUnsatisfactory.

Therewassomevariation intheresultsoftheindividual phases.PhaseIitemswerefoundtobeSatisfactory orSatisfactory withRecommendation in328of365itemsinstances, for89.9percentofthetotal.PhaseIIcorrective actionwasfoundtobeSatisfactory orSatisfactory withRecommendation in99.5percentofthetotal.PhaseIIIitemswereSatisfactory orSatisfactory withRecommendation in97.9percentofthetotalassessments, andPhaseIVitemswereSatisfactory orSatisfactory withRecommendation in96.6percentofthetotal.Theneedforsignificant improvement inaddressing andimplementing effective corrective actionwasidentified onlyforPhaseLThoseitemsratedSatisfactory withRecommendation constituted 35.6percentofPhaseI,6.3percentofPhaseII,20.1percentofPhaseIII,and5.7percentofPhaseIV.Ingeneral,thisindicates thatwhilecorrective actionwas 10023hO'-7considered adequateforthespecificdeficiency, amorecomprehensive actionwouldhavebeenmoreeffective inprecluding recurrence ofthedeficiency onthesameorasimilaritem.Inotherwords,whiletheneedforsignificant improvements inaddressing andimplementing corrective actionappliedmainlytoPhaseI,theneedtosignificantly enhancecorrective actionstoimproveoveralleffectiveness isevidentforPhasesI,IIandIII.~ThoseitemsratedUnsatisfactory constituted 10.IpercentofPhaseI,0.5percentofPhaseII,2.lpercentofPhaseIIIand3.0percentofPhaseIV.Thisshowsthatcorrective actionimplementation exceeded95percentineachindividual phaseexceptPhaseI.Ingeneral,thisindicates thatwhilecorrective actionwasnottotallyadequateforthesespecificdeficiencies, onlyinPhaseIwastheinadequacy significant.

Whiletheoverallresultsweregenerally satisfactory, theAssessment Teamidentified specificareaswhichshouldbeimproved.

Theseareasandtheorganizations towhichtheyapplybecomemoreevidentwhenfurtheranalysesaremadetodetermine thecausesofthe3.9percentjudgedUnsatisfactory andthe9.7percentwherefurtheractionwasrecommended oftheitems.Combining dataforParetoanalysisofdeficiency documents wherecorrective actionwasjudged"Satisfactory withRecommendations" and"Unsatisfactory" providesasamplethatidentifies areaswhereactioninpreventing recurrence ofdeficiencies wouldbemostbeneficial.

Thisvolumeprovidescondensations ofrecommendations maderelativetoindividual deficiencies inVolumeII.Satisfying theindividual recommendations inVolumeIIwillsatisfytherecommendations madeinthisvolume.ORGANIZATION OFREPORTThisreportisdividedintothreevolumes.VolumeIpresentstheoverallresultsoftheassessment andanalyses, conclusions, andrecommendations forfurtheractionandpossibleimprovement.

10023hOVolumeIIcontainstheassessments ofthosecorrective andpreventive actionsrelatingtospecificdeficiencies whichwerejudgedbytheAssessment TeamtobeUnsatisfactory orSatisfactory withRecommendation.

OwingtothelargenumberofactionsratedSatisfactory, detailedassessments arenotincludedinthisreport.Objective evidencesupporting Satisfactory evaluations isavailable intheAssessment Team'sfiles.VolumeIIIcontainsthematricesoftheassesseditemsforPhasesI,II,IIIandIV.Eachmatrixlistsinnumerical orderthecompletion status,theMACdisposition ofeachitem,typeofdeficiency andinvestigative method.InterimReportswerepublished bytheAssessment Teamattheconclusion ofPhasesI,IIandIII.EachoftheInterimReportsrecordedtheresultsofassessments ofcorrective actionthatwerecompleteatthescheduled timeforthereport.ThisreportincludestheupdatedresultsoftheInterimReportsforPhasesI,IIandIII,andtheresultsofthePhaseIVassessment.

10023hO'-1

2.0 SUMMARYOFASSESSMENT

RESULTSThefollowing sectionssummarize theresultsoftheMACAssessment Team'sevaluation.

GeneralNRCconcernsstatedintheCATandSALPreportsaread-dressed,aswellasspecificdeficiencies forwhichtheteamfoundtheimple-mentation ofcorrective andpreventive actionstobelessthansatisfactory.

2.1NRCORDERITEMSTheNRC,initsCATandSALPreportsandOrder,identified significant pro-grammatic problemswithNMPC'sQAprogram,specifically insiteauditingprograms, thecorrective actionsystem,Procurement QualityAssurance (PQA),documentcontrol,designchangecontrolandtimeliness ofinspection andcor-rectionactivities.

TheNRC'sOrderalsoidentified areasofconcerninvolving

hardware, specifically radiographic film,concreteexpansion anchors,andcableinstallation inthePowerGeneration ControlComplex(PGCC).Theseareaswerespecifically addressed inNMPC'sresponseto.theOrderdatedMay10,1980.Theyareaddressed inthisreporttotheextentthattheAssessment Team'sevaluation substantiated orresolvedthem.2.1.1litAssurance ProamITheNRCSALPreportcitedaweaknesswithintheNMPC/SWEC/ITT QApro-gram.TheAssessment Teamreviewedandevaluated theQAprogramsofsitecontractors bymeansofinterviews andprogram/procedure overview.

TheNMPCsiteQAprogramhasbeenstrengthened.

QualityAssurance Proce-dure(QAP)19,00,"QualityAssurance Department atNineMilePointPP2",wasissuedMarch22,1980,todescribethesiteorganization anddefineresponsibil-ities.Thesiteorganization chartdescribes theresponsibilities ofeachofthefourunitswhichmakeupthesiteorganization.

Additional emphasishasbeenplacedontheauditandsurveillance programs.

SWECqualityprogramshavebeenupgraded, partlyinresponsetotheCATandSALPfindingsandpartlyasacontinuation ofongoingqualityimprovement programs.

Additional emphasishasbeenplacedonauditingandsurveillance ofconstruction activities.

Specialtaskgroupshavebeenestablished toinvestigate 2-210023h4problemareas.TheQualityControl(QC)staffhasbeenincreased byapproxi-mately20percent.Procedures havebeenrevisedtoprovidebettercontrolofqualityactivities.

ITThasincreased thesitequalitystafftoprovidebettercoverageofconstruc-tionactivities.

TheDirectorofQualityAssurance/Quality Control(QA/QC)wasassignedtheresponsibility fordeveloping trendreportstoidentifyproblemareasandprovideameasureofprogress.

Workisunderwaytoutilizeacompu-terizedsystemforpreparing trendreports.Thequalitydocumentation efforthasbeenupgradedandreorganized.

ItnowisdirectedbyaManagerwhoreportsdirectlytotheDirector, QA/QC.Approvalhasbeenrequested foradditional QAEngineers.

Procedures governing projectactivities havebeenreviewedand,whereindi-cated,upgradedtodirectmoreattention toqualityandtoassurethecompleted facilitywillconformtoestablished requirements.

Themeasuresnotedaboveshouldimprovequalityperformance intheareasofconcernnotedintheSALPreport.Someproblemareaspersist,andadditional improvements canbeexpectedasthelongerrangeprogramimprovements becomeeffective.Forexample,theresultsoftheindependent assessment confirmthatqualityprogramweaknesses existedintheareasidentified bytheNRC.Whileimple-mentation oftheactionsnotedabovewereconfirmed bytheAssessment Team,itistooearlytomeasuretheeffectiveness ofsuchchanges.Inaddition, theAssessment Teammadespecificrecommendations that,togetherwithcontinued emphasisonsurveillance andaudits,shouldenhanceprogrameffectiveness.

2.1.2SiteAuditinProramTheCATreportstatedthattheSWECauditingprogramwasnotsufficient anddidnoteffectively identifyandresolvemajorconstruction problems.

TheAssessment Team'sreviewoftheSWECauditingprogramprocedures revealedgeneraldirectives forcompliance withANSIN05.2.12andspecificinstructions regarding auditformatandformsutilization.

Theprocedures appearade-quateandshouldresultinaneffective auditsystem,ifproperlyimplemented.

10023hO'-3 ActionstakentoimprovetheSWECauditprogramincludedinitiation ofaprojectprocedure whichaddresses timelyclose-out ofauditobservations; increased auditfrequency perthe1980auditschedule; andsupplementing theauditstaffwithtechnical specialists fromoutsidethequalityorganization.

Thepreventive actionplannedisappropriate.

TheAssessment Team,initsreviewofSWEC'sAuditFindings, notedaconsid-erablelackofobjective evidencethattheactionstakentoresolvethefindingswerecompleted.

ExamplesincludePre-survey ASMEIIIAudit1983,C-0andSiteAudit20,1981.Additional SWECreporteddeficiencies, Nonconformance andDisposition Reports(NRDs),andInspection Reports(IRs),havealsobeenclosedwithoutsufficient evidencethatcorrective actionwasverified.Therewasnoenforcedtimelimitforreplyorconclusion.

FieldQualityControl(FQC)inspectors didnotidentifynonconformances adequately whichresultedinexcessive timespentresearching problemresolutions.

Significant deficiencies intheNMPCauditprogramwereaddressed intheCATreport.TheAssessment TeamverifiedthattheNMPCapproachtositeauditshassincebeenevaluated andpositiveactionhasbeentakentoemphasize hard-wareinsubsequent audits.Thisactionhasbeeninitiated throughdevelopment andimplementation ofnewQAprocedures.

The150"openaudititems"identi-fiedbytheNRChavesincebeenclosedandreportedthroughthenewNMPCcomputerized trackingandtrendingsystem,andNMPChasdiscontinued theuseof"openaudititems".AnumberofNMPC'saudititemswereclosedwithoutverification thatrequiredactionswereaccomplished anddocumented.

EightNMPCaudititemsfailedtoidentifyobjective evidencetosupportauditclosure.ManyNMPCaudititemsfailedtoidentifyadequatecorrective actionandactionstopreventrecurrence ofauditdeficiencies.

TheNRCalsoexpressed aconcernthatinthecaseofNMPCandITTsomeauditobservations shouldhavebeenwrittenasnonconformances, andthatthereisnotamechanism inplacetoreviewauditobservations forsignificance andrep'orta-bility.NMPCrevisedtheirprogramtoincludeprovisions forreviewing auditdeficiencies forsignificance.

Thisconcernwasaddressed inCATItem 2-010023h403D-83.TheAssessment Team'sreviewrevealedthatthelicensing procedures associated withreporting andcorrection ofdeficiencies under10CFR50.55(e) andlOCFR,Part21,havenowbeenimplemented.

ITTissuedaletterindicating thattheManagement AuditReportwouldincludeastatement thatthe10CFR50.55(e) reviewhasbeenaccomplished.

InthecaseofITT,theAssess-mentTeamrecommends thattimelyreviewforreportability andcommitments foractionstopreventrecurrence beaddressed byITTinprocedures toassurecontinued compliance.

Auditortrainingonreportable deficiencies shouldbereevaluated, andanyitemslackingobjective evidenceoflOCFR50.55(e) reviewshouldberereviewed anddocumented.

Responsetimehasbeeninordinately longforvendorandcontractor AuditFindingswhichresultedinAuditReportsnotbeingclosedinatimelymanner.Inoneinstance, thisresultedininadvertent useofanunapproved supplier.

Additionally, NMPChasacceptedcontractors'esponses toauditfindingswith-outalwayshavingmadeacomprehensive reviewofsupporting documentation.

TheAssessment Teamidentified atleasttenNMPCaudititemsthatwerenotclosedinatimelymannerinaccordance withprocedural requirements.

ForSWEC'sNRDs,therewereseveralinstances ofdelaysofupto70daysfromthetimethenonconformances werefirstdiscovered untilthenonconformance documentwasprepared.

SomeexamplesareSWEC'sNRDs5332,5026,5145,6903,and0801.Anexcessive amountofdelaywasalsonotedintherevisingofConstruction Management Procedures (CMPs).Inassessing SWECSiteAudit23,oneCMPrevisionrequiredsevenmonths,anothertenmonths.Theprogramshouldbereviewedforefficiency andtimeliness.

2.1.3Corrective ActionSstemTheNRCstatedinitsCATreportthat"corrective actionsystemswerede-ficientwithregardtothecorrection ofnonconformances identified andtheassociated documentation".

TheNRC'sconcernsregarding theadequacyofNMPC'sverification ofcorrective actionfocusedondocumentation, timeliness, andtheeffectiveness ofsurveillance andverification activities.

I0023hO'-5 Documentation SomeEngineering andDesignCoordination Reports(ERDCRs)wereusedtodocumentnonconforming conditions, asnotedinCATItem9-83.TheAssess-mentTeamfoundbyreviewoftrainingrecordsthattrainingofsiteofficepersonnel, CherryHillPQApersonnel andselectedkeypersonnel intheproperuseofthesehasbeenaccomplished.

Engineering changesof,acceptance criteriaarenowresolvedforCATitemdeficiencies, butFQCverifications havenotbeenperformed toensurethatpreviously installed itemswouldmeettherevisedcriteria.

FQCverification ofpreviously installed itemsisplannedbutnotasyetimplemented.

SWECissuedProjectProcedure (PP)20,Supplement Number820-67onMarch30,l980toprovideadditional construction guidancerelativetosituations inwhichadesignchangeisissuedafteraninstallation hasbeencompleted andinspected.

TheAssessment Teamrecommends thatallpre-viouslyissueddesigndocuments, HcDCRsandEngineering ChangeNotices(ECNs),thatidentified nonconforming conditions bereviewedforpotential reportability underlOCFR50.55(e) andlOCFR,Part21.TheSALPreportalsonotedproblemsinthedocumentation ofcorrective action.TheNRCnotedthatthedocumentation packetshouldcontainacopyoftheinitialsurveyreportwiththeassignedconcernnumber;actionthatwasinitiated tocorrect;lOCFR50.55(e) interimreport,ifapplicable; verifiedcor-rectiveactiontaken;finallOCFR50.55(e) report,ifapplicable, togetherwiththeNRCfinalIRwiththelineitemnoticeofclosure;andthatsuchdocumenta-tionshouldbemandatory.

TheAssessment Teamdetermined thatalldocumen-tationpackagesprocessed oflatehavebeenverycomplete, andtheappropriate degreeofdocumentation isnowrequired.

Therefore, thisisnolongerconsid-eredaconcern.TheNRCalsoexpressed concernthattheuseofType"C"IRsprecludetrending, andallowtraining, meetingsandmemostobeusedtocorrect'thedeficiency ratherthanpreparing anNhD.TheAssessment Teamsubstantiated theiVRCconcern,andrecommends thatType"C"IRsbeutilizedasaprogrammatic surveillance documentonly.Anycorrective actionforhardwaredeficiencies requiredbyaType"C"IRshouldbedispositioned usingaNRD.Itisrecom-mendedthatfurtherfollow-up onthisconcernbeinitiated byNMPC.CAR 2-610023hO80.0166wasissuedby'heAssessment TeamonthetimelyclosureofSWEC'sType"C~!ftRsSWECType"A"IRsdonotnormallyindicatetheactiontakenand/orthejustifi-cationtoclosethedeficiency.

Thisresultsinlittlesupporting documentation toverifywhatactionsweretakentoresolvetheproblem.Thisdeficiency contributed toCAR80.0116regarding reworkedanchorbolts.Timeliness Excessive contractor delaysinimplementing committed corrective/preventive actionwerenotedintheCATAssessment.

AnexampleofthisisCATItem31-83.TheSALPreportalsonoteddelaysofuptoeightmonthsininitiating, resolving anddispositioning deficiencies.

ExamplesincludeNRCItem81-13-01EandCDR81-02.TheAssessment Teamnotedsomeinadequacies inthetrackingsystemforNRDsrelatedtoexpeditious closureofopenNdcDs.Thepresentsystemforwardsacopyofthedispositioned NODtothecontractor forhisaction.Thereisnomechanism for.trackingwhatthecontractor isdoingtoimplement thedisposi-tionandclosetheNRD.NRD-0952, forexample,hasremainedopenformorethanayearwiththecontractor takingnoactiontomakethenecessary repairs.TheNADlogshouldbemonitored periodically andstatusupdatesprovidedsothatNdcDscanbeclosedoutmoreexpeditiously.

NRD-2928isanexampleofanNRDthathasbeensuperseded numeroustimesbecauseofchangesincondition details.AneffortshouldbemadebySWEC'sFQCtoprovidecompleteinforma-tionsuchaswithsketchesidentifying theas-builtsituation.

Theengineershouldthenconfirmthesituation sothatacompletedisposition canbeprovidedtoresolvetheentirediscrepancy.

Verification ofCorrective ActionTheNRCnotedthatreinspection activities bycontractors andverifications byNMPC'sQAhavenotbeentotallyeffective.

Examplesofthiscondition werefoundbytheAssessment TeaminCATItem25-83,"RCIUndersized Welds";

10023hO'-7 CATItem01-83,"WeldFillerControl";

andCATItem21-83,"CivesUndersized Welds",whichresultedintheissuanceofCARs80.0003,80.0105and80.0057.2.1.0Procurement alitAssurance TheiVRC'sconcernthatmaterialinspected atthesourcepriortoreleasebySWEC-PQChasoftenbeeninnoncompliance w'ithprocurement documents wasassessedbyCATItem7-83.TheAssessment Teamverifiedthatcorrective actionaddressed thecommitment torevisesourceinspection planningtorequirewitnesstestingandverification ofobjective evidence.

Thepreventive actionplansrequireforNMPCtoparticipate insourceinspection (selectively).

Theactiontaken,inadditiontoimplementation oftherecommendations inSection0.0,shouldresolvethisconcern.TheNRCalsonotedthatalthoughtheinspection planforCivesSteelrequired100percentvisualexamination inaccordance withAWSD.l.l,beamswerefoundwithinsufficient weldmaterial.

Thishasbeenaddressed inCATItem21-83.TheAssessment Teamootedllunsatisfactory weldsthatwereidentified andreportedonNdcDs,butwerethendispositioned "acceptasis".TpeAssessment Teamhasrecommended that.theentirelot(notjustthosethatwereconsidered unsatisfactory) bereinspected anddispositions madebyEngi-neeringtoensurethatbeamswithunsatisfactory weldsarenotbeingusedelsewhere intheproject.2.1.5DocumentandDesinChaneControlDocumentControlThemajorNRCconcernspertaining todocumentcontrolwere:(1)drawingswerenotbeingreviewedaccording toprocedures, and(2)iVMPCandSWECdidnothaveadequatecontroloverthedesignchangesystem.TheAssessment TeamverifiedthatiVMPChasinstituted anumberofchangesinitsdocumentcontrolsystem.Ithasestablished acomputerized systemforpostingdesignchangesandreducedthenumberofdrawingstationstoaidinmorepromptdistribution ofchanges.Inaddition, iVMPCestablished ataskforcetoreviewtheproblemandareviewprocessfornewdrawings.

TheAssessment Teamrecommends thatallNMPCpermanent plantrecordsbe 2-810023hOindexed,protected, consolidated andretrievable inaccordance withANSIN05.2.9.Atpresent,recordsaredifficult toaccess,astheyarekeptinseveraldifferent locations andindexingforretrievability isnotuniform.Despiteimprovements andcontinued attention byNMPCandSWEC,documentcontrolcontinues topresentproblems.

Improvements havebeenandarebeingmadebutproblemareasstillpersist.Relateddocuments donotcross-reference eachotherforeaseoftracking.

TheITTprogram(s) foridentifying, voiding,superseding, invalidating andclosingdeficiency documents shouldbereevalu-ated.Inonecase,fourdifferent DRs,oneNRDandoneIRweregenerated toidentifyandprocessthesameproblemwhich,inthefinalanalysis, wasnotanonconformance.

Averification ofdeficiency shouldbeinitiated oneachnonconforming condition identified inordertopreventthistypeofsituation.

Thebasisforclosureofvoidedorsuperseded nonconformance documents shouldalsobelistedonapplicable forms.Frequently insufficient orincorrect reference information anddisposition directions areprovidedoncorrective actiondocuments, Forexample,ITTNRP-077wassubmitted toSWECfordisposition; however,SWECreturnedsametoITTunanswered becauseofinsufficient information.

SWECrequested ITTtoreevaluate andprovidesupporting dataandresubmit.

Thisactionneveroccurred, andtheNRDwassubsequently closedbyoriginating otherNRDs.Thereappearstobeaprogrammatic deficiency inITT'sNODprogram.InthespecificcaseofITT'sNRDIG-1750,theNRDwassubsequently revisedfromCATIItoCATIwhentheclose-out signature wasappliedwithoutobtaining newsignatures fromthosewhopreviously approvedthedisposition.

Theprocedures shouldberevisedtocorrectthisproblem.ITTprocedure FQCIO.I-O,Revision15,doesnotrequiretheNODformtobefullycompleted whenanewYidcDisissuedunlesstheNODhasbeenprocessed byDocumentControl.Thisdeficiency allowsNRDstobesuperseded orrevisedbysubsequent NRDswithoutproviding apapertrailtofollowtheproblem.Theprocedure shouldbeamended.

100231K'-9 DesignChangeControlTheNRC'sCATreportidentified problemsinthedocumentchangecontrolprogramindicating that"craftsandinspectors maynotbeusingthelatestdesigndocuments intheperformance oftheirwork".Italsocitedthe"highrateofdesignchangeinitiation andtheinability tomaintainandreviseconstruction drawingsinatimelymannertoreflectsuchchanges".

DuringtheAssessment Team'sreviewofdrawings, itwasnotedthatrecentchangestosomedrawingsusegenericandnon-specific terminology inthedrawingrevisionblock.Anexampleis"(F-8,G-8)asperlatestdesigndocu-ments".Severalexamplesofthiswerenoted.Thispracticemakesitvirtually impossible toidentifywhetherallappropriate changeshavebeenincorporated.

SWECshouldberequiredtobemoreexplicitinidentification ofchangestodrawings.

TheNRC'sconcernthatQCinspection hadnotbeengiveninspection attributes toassurethatequipment (batteryrack)installations areconsistent withseismicqualification requirements wasaddressed inCATItem2-83.Thiswasnotsubstantiated bytheAssessment Team.Theinspector properlyinspected tothedrawing,whichspecified "steel"bolts.Thisspecification isconsistent withseismicqualifications.

TheAssessment TeamconcurswithNMPC'sconclusion.

TheNRC'sconcernthatinadequate procedural controlexistsfortrackingallaspectsofequipment andtheirdesignchangeswithseismicqualification requirements wasaddressed inCATItem2-83.NMPC'sactionsweretoidentifyandreviewexistingassemblies andconnections forconsistency withseismicqualifications, andtoestablish trackingcontrolsfordesignchangeswithseismicqualification requirements inSWEC'sPP90.TheAssessment Teamverifiedthattheseactionswereappropriate andthattheyhadbeenimplemented.

2.1.6RadioahicFilmaliInitsCATreport,theNRCfoundiVMPC'sprogramforreviewandacceptance ofradiographs wasdeficient.

TheAssessment Teamsubstantiated thiscon-cern.Itfoundthattheoverallqualityoftheradiographic filmanditshandlingwaspoor.Originalfilmwasnotavailable forthoseweldments thatwere L0023h0repaired, makingitimpossible todetermine whatareawasactuallyrepaired, oriffullcoverageoftherepairareawasobtained:

Inthemajorityofcases,no"readersheet"fortheoriginalweldwasavailable whenrepairswererequired.

Thecondition ofthefilmwassuchthattherewasconcernwhetherthefilmwouldremainlegibleforthedurationoftherequiredretention.

Finally,therewerediscontinuities onsomeradiographic filrqthatwerenotnotedontheRadiographic Examination (RT)readersheet.TheNRCnotedthatSWECIRsidentifying radiographic problemswerenotbeingdispositioned inatimelymanner,corrective actionappearedinadequate, andSWEChadfailedtocontrolandmonitorthesiteradiographic activities ofITT.TheAssessment Teamreviewedtheproblemandthecorrective actionthathadibeentaken.NMPCconducted a100percentreviewofITT'sradiographs whichhadbeenacceptedandfiledinthevaultasof3anuary1980.Deficiencies discovered byNMPCduringthereviewwerenotedonNMPC'sSurveillance Reports(SRs).AsaresultofNMPCSRs,SWECgenerated severalType"C"IRstotrackNMPC-identified deficiencies andinitiatecorrective.

action.The.majorityoftheseType"C"IRs.werestillopenasofNovember1980.SWECisnowintheprocessofconducting a100percentreviewofallITTradiographs.

Problemswithradiography processing andcontrolhavealsobeenidentified bySWEC,ITTandRCI.Surveillance activities byNMPCandSWECarecontinuing andprogressisbeingachieved.

Themajorconcernisthatnonconformance reportsarecontinually beinggenerated andtheactionplanisbecomingfrag-mentedandunwieldy.

Itisrecommended thatamatrixbegenerated forthisCATItemtoidentifytheconcernandprogresstakentoaddress/resolve theproblem.Afilmreviewwasperformed byNMPCinresponsetoNRCBulletin82-01and82-01,Revision1,Supplement 1,whichrequired100percentreviewofshopradiographs forqualityclass1and2pipingwithwallthickness lessthan1/2-inch.DuringNMPC'sfilmreview,enhancement problemswerediscovered withregardtotwospecificradiographers.

Thereviewwasconducted atboththeishopandatNMP-2.Theoriginalscopewasexpandedtoincludeallfieldradio-graphstakenwithinthetimeframethattheradiographers inquestionper-i 10023hO2-11formedworkatNMP-2.Whereverpossible, allradiographs suspected ofenhancement werere-radiographed.

Insomecasesweldswerecutoutand,inothercases,weldshadbeendeletedduetodesignchanges.However,corrective actionwasperformed inallcases.TheAssessment Teamreviewedallrelateddocumentation pertaining totheenhancement problemandalsoperformed areviewofradiographs (approx-imately150).Thisreviewconcurred thattheenhancement problemwasinfactisolatedtothetworadiographers inquestion.

Theenhancement condition isnolongeraproblem,andtheotherradiographic problemsalsoappeartobeintheprocessofresolution.

Basedontheactiontakentodateandtheactionsinprogress, theAssessment Teambelievesthatradiography performed on-sitewillmeetthequalityrequirements.

\2.1.7ConcreteExsionAnchorsInitsCATreportandintheOrder,theNRCstatedthatconcreteexpansion

~anchorswerenot.adequately set.Thiswasbasedonanobservedlossoftensionpreload,ofanERDCR'srequestfor"slippage"

criteria, andstrengthdifferences betweentheconcreteusedinthepre-qualification testandthatusedinthefield.Basedonthetensiontestsperformed, SWEChasconcluded thattheboltshavebeenproperlyset.TheAssessment Teamreviewedtherelevantdocumen-tationandconcursinthisdetermination.

TheNRCalsonotedthattherewasnoinspection attribute toassurenutsarenot"bottoming out"onthethreadsoftheconcreteexpansion anchorbolts.TheAssessment Teamverifiedthatrevision0toSpecification S203Cincludedanattribute for'bottoming out".Installation procedures for"drilled-in concretetypeexpansion anchors"havebeenrevisedtoincludethisinspection attribute.

10023h4PowerGeneration ControlComlexTheNRC'sOrderobservedcableseparation violations incablesinPGCCduct-waysandcableswhichenterPGCCcontrolboards.TheAssessment Teamfoundthatconcernsareactivelybeingaddressed byNMPC,SWECandGEbydeveloping andimplementing subdivisional separation instructions formodifying theclasslEdivisionpanelsandtermination cabinetsinvolvedinpreviously acceptedshoporvendorwiring.Thestatusofthisworkaccomplished todatewasstilluncleartotheAssess-mentTeam.ManyFieldDesignInstructions (FDls)andFieldDeviation DesignReports(FDDRs)remaintobeclosedout.Work,rcworkandrepairstillmustbeperformed throughout thePGCCcomplexforthereduction orelimination ofallseparation criteriaconcerns.

ItappearsthatNMPCisnotproceeding forcefully togetGEandSWECtoresolvetheseparation criteriaproblem.Therearenumerouschangedocuments toresolvetheproblemsrelatedtoGEequipment, toauthorize thework,andtoverifythecompletion ofwork.Aconcerted effortmustbemadetoclose-out thedocumentation bycompleting theprescribed work.Specificexamplesofthisconcernarediscussed below.Theunderfloor racewaycovershavenotbeeninstalled forproperseparation.

Attention shouldbegiventoinstalling thecoversassoonaspossibleinthesequenceofevents.Installation ofthecoversatalaterdatemaybeasignifi-cantproblem.Separation attributes arenotalwaysaccurately recordedonIRs,astheAssess-mentTeamverifiedforCATItems3-83and8-83.TheIRsweremarkedas"later"or"NR"whendivisional separation criteriawerenotmet,ratherthanbeingdocumented asnonconformances.

Theuseof"NR",whichisimproper, occurredonceandisconsidered anisolatedcase.Inspection plansnolongerallowdivisional separation tobeinspected later,buthavebeenmodifiedtoallowtheuseofan"L"(later)attribute forseparation barrierswhichwillbetrackedbycomputerforsubsequent inspection.

Powercableseparation criteriawerenotbeingmetandwerenotbeingidenti-fiedonQAinspection recordsaccording toCATItem8-83.Theconcernwasinreference totheinspections madeofpartialcablepulls.iVMPC'scorrective 10023h02-l3actionwastoreviseInspection PlanN20E061AFI025 torequirethatpartialcablepullsbeinspected backthroughthelastracewaysectionortotheextentnecessary toassurethatthecablemetspecification requirements.

TheAssessment Teamverifiedandconcurred withtheappropriateness ofthisaction.2.2DISCIPLINE ASSESSMENT ITEMS2.2.lCivil/Structural Generally, concreting activities werefoundbytheNRCtobeinaccordance withthespecifications andapplicable requirements, exceptforreinforcing steelspacingviolations inoneplacement, inadequacies intheinspection planforconcretesurfacedefects,andacceptance criteriaforunitweighttests.TheNRC'sconcernthatreinforcing steelviolations werenotidentified bySWEC'sQCInspection, andthattheretraining sessiontopreventrecurrence wasconducted improperly wasconfinedspecifically tooneconcreteplace-ment.Toalleviate theconcerns, thepreplacement IRwasmarked"Unsat"andthereinforcing steelviolations werecorrected priortoconcreteplacement.

Impropertrainingwas'corrected byconducting asecondtrainingsessionrelativetoreinforcing steelplacement.

Thistrainingwasconducted bytheSWECDiscipline Inspection Supervisor.

TheAssessment Teamverifiedtheresolution oftheconcerns.

TheNRC'sconcernregarding inadequate inspection criteriaforconcretesur-faceinspections whichledtotheinstallation ofplatesandequipment oncon-cretesurfacesthathavenotbeeninspected hasbeenresolved.

AreviewofselectedSurveillance Inspection Reports(SIRs)bytheAssessment Teamdis-closedthattherewerenosurface-mounted plateswhichcoveredvoidsorhoneycomb areas.Documentation identifying theresolution oftheconcretesurfaceinspection concernandtheAssessment Team'sconcurrence hasbeenprovidedunderCATItem.38-83.

TheNRC'sconcernrelativetoadequateacceptance criteriausedforconcreteunitweighttestshasbeenresolved.

SWECEngineering reviewedallconcreteunitweightreportsforconcreteplacements toverifythatshielding 2-IOi0023h4requirements wereadequate, whichtheAssessment Teamdetermined wasanacceptable resolution.

Inaddition, anewattribute hasbeenaddedtotheInspection PlanforSpecification S203Hrequiring thatSWECEngineering willbenotifiediftheunitweightofconcretefallsbelow138poundspercubicfoot.Resolution ofthisconcernandtheAssessment Team'sconcurrence hasbeendocumented forCATItem36-83.TheNRCcitedthelackofevidenceofrepairorretesting foroneconcretetruckmixer(truck/125)whichhadfailedmixeruniformity testing.TheAssess-mentTeam'sreviewofconcretecompressive strengthtestreportsforaone-monthperiodafterthefailedmixeruniformity testsubstantiated theacceptability oftheconcretethatwasusedoutofmixertruck825.Anewattribute hasbeenaddedtotheSWECQAInspection PlanforSpecification S203Arequiring thataletterbesenttothecontractor informing himthatatruckwithadeficient mixercannotbeuseduntiltheunsatisfactory condition iscorrected.

TheAssessment Teamverifiedandconcurred withthisresolution.

2.2.2Electrical Deficiencies inelectrical andinstrumentation construction identified byCATincluded(l)useofindeterminate materials inseismicboltingapplications, (2)lackofdocumentation forinspection attributes, and(3)inadequate useofprocedures containing appropriate acceptance criteria.

0SeismicBoltingTheNRC'sconcernthattheMotorControlCenter(MCC)seismicqualification isnotapprovedbythevendorandthatmaterialsubstitutions arebeingmadeon-sitewithoutthevendor'sknowledge wasaddressed inCATItem2-83.TheAssessment TeamreviewedSWEC'sevaluation oftheNRCconcernandagreeswithitsdetermination.

SWECreviewsandacceptsvendordesignsandseismicqualification reports.SWEC,notthevendor,isresponsible forassuringthaton-siteitemsdonotviolateseismicqualifications.

Inthiscase,therewasnomaterialsubstitution andnoviolation ofseismicqualifications.

CATItem2-83addressed theNRC'sconcernthatthereisnoassurance thatthesiteas-builtMCC(material substitution) isconsidered fortheseismicreport.

10023hV2-15NMPC'sactionwastoobtainarevisedvendordrawing(to,beapprovedbySWEC),andtoperformaninspection toverifythatcorrectboltinghadbeenused.Theseactionsweresubsequently foundunnecessary, sincetheseismicanalysisshowedthattheboltsthatwerespecified andusedwereacceptable.

Thefactthatthevendorhadusedaspecificgradeofboltinhisseismictestingwasirrelevant.

TheAssessment Teamreviewedandconcurred inthisdetermi-nation.Acceptance CriteriaTheNRC'sconcernwithcableinstallation whichisnotinconformance withtheFinalSafetyAnalysisReport(FSAR)orInstitute ofElectrical andElectronic Engineers (IEEE)380hasbeenaddressed inCATItem3-83.GEhastakenexception totheFSARcommitment toRegulatory Guide1.75,"Physical Inde-pendenceofElectrical Systems",

whichendorsesIEEEStandard384,"Trial-Use StandardCriteriaforSeparation ofClasslEEquipment andCircuits",

and,insodoing,hassubmitted totheNRCacomparison oftheGENMP-2designtothecriteriacontained inRegulatory Guide1.75andIEEE380.Asofthisdate,noresponsehasbeenforthcoming fromtheNRC.TheAssessment Teamdeter-minedthat'subjecttoNRC'sacceptance ofGE'sposition',

thestatedconcernisresolved.

..3~/ProblemsintheWelding/NDE areaidentified bytheNRCinvolved1)thequalityofradiographic film,and2)thequalityofweldsandassociated documentation.

Thefirstconcernwasaddressed aboveinSection2.1.7,Radiographic FilmQuality.Thesecondconcern,addressed inthissection,coversweldquality,weldingrepairs,weldmaterialcontrol,welderqualifications, andweldinspec-tion.TheNRCidentified alargenumberofundersized shopweldsforsupportsbyCivesSteelinCATItem21-83.Basedonvisualinspection, 15to20percentwererejectable.

TheMDusedtocloseoutthedeficiency sampledonlyasmallnumberofwelds.TheAssessment Teamrecommends thatallsupportweldsbyCivesSteelbedispositioned byEngineering whichshouldalleviate thisconcernupon'implementation.

10023h0Anumberofproblemshasbeennotedregarding welddocumentation, including illegible welder'sstencils, bypassedholdpoints onwelddatasheets,incomplete WeldMaterialRequisitions (WMRs),andConstruction Completeness Check-lists.Whilesomecorrective actionhasbeentaken,moreisnecessary.

Forexample,FQCpeopleverifywelder'sstencilsandtrainingofFQCpersonnel wasinitiated, butstencilsareappliedbyweldersandtheyshouldbetrainedintheproperapplication ofthestencil.Thiswouldeliminate theproblematitssource.Trainingisalsorequiredtoeliminate thebypassing ofidentified holdpoints, accelerate theorganization ofnonconformance whenholdpoints arebypassedandinproperlyandfullycompleting WMRs,Construction Completeness Check-listsandlikedocuments.

WeldRepairsTheAssessment Teamfoundanumberofproblemswithweldrepairs,asdis-cussedinthefollowing paragraphs.

Over-grinding isacommonoccurrence whenattempting toremoveminordefects.Craftsshouldbeinstructed nottochase(grind)defectstotheextentthatminimummaterialthickness isvio-lated.DefectswhichcannotberemovedwithaminimumofgrindingshouldbedirectedtoEngineeing fordisposition.

Allcontractors exceedengineering welddesignsizewhenperforming weldrepairs.Duringreinspection thiscondition existedinapproximately 75percentofreworkedwelds.Althoughnodistortion wasobserved, depositing moremetalthanrequiredbydesigniscostlyintimeandmaterial.

Craftsshouldbeinstructed/trained tolimitweldsizetoEngineering requirements.

instruction shouldbeapplicable toinitialweld,repairandrework.ITTconsistently failedtoidentifyweldrepairsaccording toSpecification P30ICwhichstatesthat"eachattemptatrepairofasubjectweldwillbeidentified withanRl,R2,etc.,asrequired".

Onpiperestraint weldrepairs,theinterpretation ofSpecification P30lC,i.e.,replacement ofweldnumbersonmajorrepairsanddetermining whenaweldshouldorshouldnotshowa"deleted" indicator, isinconsistent.

At0 10023hO2-17SWEC'sQAprocedure, QS-9.3,specifies thatWeldDataSheets/Weld RepairDataSheetsarenotrequiredforweldswhichdonotrequireNondestructive Examination (NDE).Thiscondition createddifficulty inverifying theadequateclose-out ofthesetypeIRs.Duetoalackofdocumentation, theAssessment Teamhadnochoicebuttoacceptreworkofweldsbasedonvisualinspection ofcondition (ifaccessible) andinspector's signature.

Thispracticeisalsoper-formedbyothercontractors on-site.TheAssessment Teamdetermined thistobeunsatisfactor yandCAR80.0110wasissued.WeldMaterialControlTheAssessment Teamalsofoundanumberofproblemswithweldmaterialcontrol.3CIweldfillermaterialcontrolprocedures requiretheforemanorweldertoplacetheweldnumberofthejointbeingweldedonthecarboncopyoftheWMR(QualityCategoryIonly).Whenreviewing WMRs,itisdifficult todetermine whereweldingwasactuallyperformed fromthesedocuments.

ThecurrentRevision12ofQualityAssurance Standard9.00hasdeletedtheabovesentencebutdidnotreplacetherequirement; therefore, theweldnumberplacement sectionisnotcoveredclearly.Thesurveillance performed bySWEConcontrolofweldfillermaterialisper-formedonceaweek,butthesurveillance doesnotdistinguish betweenCATIorCATIIwork.Therefore, manyoftheWMRsinspected areforCATIIworkorweldertesting,etc.TheNRC'sconcernsrelativetoweldrodcontrolhavebeenaddressed inCATItemOl-83.Committed corrective actionhasbeenconsid-eredinadequate andCAR80.0105hasbeeninitiated.

Inaddition, minorerrorsarefrequently madewhencompleting WMRs.TheAssessment Teamrecommends aprogrammodification toprovidecleardefinition ofrespon-sibilities forqualityverification, increased QCin-process inspection andmoni-toring,andadditional trainingforcrafts.WelderQualifications TheNRC'sconcernthat,welderqualifications donotmeetAmericanSocietyofMechanical Engineers (ASME)CodeSectionIXineffectattimeofqualification 2-ISI0023h4wasaddressed inCATItem26-83.Thecondition ofsomewelderqualification recordswasobservedbytheAssessment Teamtobeunsatisfactory andCAR80.0002wasgenerated.

%'eldInspection TheNRCcitedproblemsinvolving ITTinthevisualandpenetrant inspection ofpipingweldsinstainless steelsystems,andthevisualinspection ofweldsonpipesupports/restraints.

Also,problemswiththevisualinspection ofpipingsupportweldsandthedocumentation forsomewelderqualifications wereidentified inactivities involving RCI.TheAssessment TeamfoundthatITThasonmanyoccasions closedDeviation Reports(DRs)priortocompletion ofradiography.

Atalaterdate,radiography isperformed andrejected, andanotherDRisgenerated.

Thissequenceofeventsisduplicated numeroustimes,untilanacceptable radiograph isavailable.

MostoftheDRsgenerated donotreference thepreviousDR.Insomecases,fiveorsixrepairshavebeenmadetoaweldmentforthesametypeofdiscontinuity.

Inadditiontodifficulty createdintrackingadefective weld,DRsdonotreceive.Engineering disposition.

Excessive repairstoweldjointscouldbedetrimental totheintegrity oftheweld.Inaddition, evaluation oftherootcauseofconditions causingunacceptable radiographs isnotevident.TheAssessment Teamrecommends establishing ameansofidentifying thecut-outorrepairstatusofaweld.Aspacefornotingtherootcauseshouldbeaddedtoformsusedtoreportweldingnonconformances.

2.2.0Mechanical PipingTheNRCfoundinitsCATreportthatHeating,Ventilating andAirConditioning equipment (HVAC)andpipingrunsweregenerally constructed inaccordance withapplicable requirements exceptintwoareas:ITTpipesupport/restraint deficiencies notidentified duringconstruction acceptance inspections, anddeficiencies inRCI'spipingQA/QCprogram.TheNRCindicated thatITT'sQCinspection isnotinspecting forpipingattributes suchasconfiguration, locationLandinterferences.

Thecorrective actionincludedafinalwalkdownprocedure thatisintendedtofurtherassuresuchpipingattributes areinspected.

I0023h02-l9However,noCATitemsassessedprovidedane'valuation oftheconfiguration inspections andresultant rework/repair versusconstruction progress.

CATItemI5-83evaluated inspection planningandconstruction statusbutdidnotincludeactivities specifictoITT'sQCinspection attributes oranevaluation.

TheAssessment Team'sconclusion isthatiVMPCdidnotaddresstheissue.Theconcernsoftheissueremainunevaluated.

PipingSupportsandRestraints ITT'sQCinspections ofpipesupports/restraints havenotbeentotallyeffective inassuringthathardwareconformtodesignrequirements.

CATIteml0-83didpartially addresstheconcernbutlimiteditselftosupport/restraint inspections foradequateclearance.

Planningandstatusing activities affecting allcon-struction activities wereinitiated, butnothingspecifically addressed theNRCconcern.CATItem53-83limiteditselftofilletweldsonsupports/restraints andaddressed theeffectiveness oftheseinspections only.Theconcernoftheadequacyofpipesupport/restraint inspections toassurethathardwareconformtodesignrequirements remainsunaddressed byNMPC.RCIProgramWeaknesses TheCATreportalsoidentified RCIQA/QCprogramweaknesses indocumenta-tion,drawingdocumentcontrol,documentation ofnonconforming conditions andprocedural timingofinspections.

CATIteml7-83addressed severalspecificnonconformances identified bytheNRCwhichhadalsobeenidentified'on RCINonconformance Reports(NCRs)priortotheNRCCATinspection.

CATIteml8-83addressed RCIprogramweaknesses regarding timeofinspection, establishment ofholdpoints andacceptance criteria.

CATIteml9-83addressed RCIQA/QCprogramweaknesses regarding (a)bypassing QAreviewandsubsequent actionthroughidentification ofnonconforming conditions ondocuments otherthanthoseintendedtobeusedtoreportnonconforming conditions, and(b)failuretoaddressthecompleteproblemonreportednonconformities.

CAR80.0050wasissuedtoreportRCI'sfailuretoissueNCRsandtofollowprocedures.

CATItem20A-83addressed RCIQA/QCprogramweaknesses regarding lackofrequirements toidentifyonSRs,datasheets,andinspection checklists those 2-20I0023h4changedocuments (ECNsorNCRs)ineffectatthetimeofinspection; CAR80.0I6Iresulted.

Whileprocedures havebeenrevisedtonowrequireidentifi-cationofECNsandNCRsineffectattimeofinspection, implementation ofthisrequirement wasassessedasinadequate.

CATItem20B-83addressed theproblemofexcessive quantities ofchangedocuments outstanding againstdraw-ings.Althoughitwaslaterdetermined thatadeficiency didnotexist,theAssessment Team'sreviewofRCI'sdocumentcontrolrevealedcontinuing concernswhichwarrantimprovement.

iVMPCandSWECshouldmonitorRCI'simplementation ofthedrawingcontrolsinitsprocedures toensurethattheEngineering ChangeControlLogisusedeffectively.

Mechanical BoltingTheiVRCciteddeficiencies inmechanical equipment boltingthatpertained toinadequate QCverification ofbolttorquingandinadequate QCinspection relativetomissingboltwashers.Thecorrective actionrequiredwasherstobeaddedtoanchorboltsandtheboltsretorqued.

Requiredtorquevalueswereappliedtotheanchorboltsanddocumented bySWECFQCduringinstallation.

NMPCinstructed SWECt'odevelopasamplingplanforinspection ofallsafety-relatedinstalled equipment toverifythatanchorboltfasteners asinstalled areinconformance withdesignrequirements.

TheAssessment Teamconcluded thatSWECfailedtoprovideeffective evidencethattheattributes listforthesamplingplanwasapprovedbyNMPCpriortoimplementation oftheplan.AsaresultCAR80.0055wasissuedbytheAssessment Team.2.2.5'Materials/Receivin TheCATreportfoundprojectstorageandmaintenance programstobeaccep-table,butsomespecificdeficiencies werenotedinmaterialtraceability, mate-rialcontrolandstorage,housekeeping, andsourceinspections.

MaterialTraceability NRCconcernsregarding materialtraceability inthestructural assemblyofelectrical equipment wereaddressed byCATItem2-83.Batteryrackswereassembled usingunmarkedmaterial; inadequacies indrawingsandspecifications twerenoted;andinspection plansdidnotincludeinspection boltingattributesfor 10023h02-21materialrequirements.

TheAssessment Teamdetermined byverification ofdocumentation andfieldinspection thatallrelativeandrequiredcorrective actionhadbeentaken.Actionstopreventrecurrence areadequateandareinplace.StorageandHousekeeping Severalinstances ofinadequate housekeeping andimproperstorageofmaterials andequipment havebeenaddressed inCATItem06-83.Severalexamplesofimproperstorageandlackofprotection fromdamageanddeterioration tosafety-related equipment intheplantandinlaydownareaswerenotedbytheAssessment Team.Actiontakentocorrecthousekeeping/storage conditions wasevaluated anddetermined tobeinadequate orineffective.

Someimprove-menthasbeenevidenced inspecificareas;however,theoverallcondition hasnotsignificantly improvedandCAR80.0100hasbeenissuedbytheAssessment Team.Anoverallprogrammatic evaluation ofthematerials andreceiving operations resultedinobservations ofthefollowing unresolved deficiencies inthehouse-keepingandmaterialstoragearea.~Dissimilar materials stored/stacked together~Lackofdunnage~Storageatlowerlevelthanspecified, suchasDforB~Materialstoredinunassigned areas~Contractor materialintermixed

~-Useofrejectedhandlingslings~Scrap,surplus,rejectedandacceptedmaterialintermixed 2.3PROGRAMMATIC ITEMS2.3.1~TraininAccording toboththeCATandSALPreports,SWEC'sandITT'strainingrecordsweredifficult touse.Subsequent reviewsbytheAssessment Teamnotedsimi-larproblemsfor3CIandComstock.

Theprograms, ingeneral,includednolessonplans,littledetailastosubjectmatterandnopre-determined listof 2~22l0023hOrequiredattendees.

Nowrittenexamination notesandnosignedattendance sheetswereavailable.

Theprocedure title,numberorrevisionoftheprocedure trainedtoareoftennotnotedonthetrainingrecords.Because3CI'strainingrequirements werenotproceduralized adequately, andnumerousinformaltrainingsessionsofrequirements, suchasrequiredreading,werenotrecordedandfiledwiththeindividuaVs Qualification/Certification Record,itwasextremely difficult todetermine evenminimumcapability.

Thequestionofadequateexperience forcertification couldnotbeanswered.

JCIshoulddocumentthebasisforcertification byincluding detailsofexperience andeducational background.

Thereisatendencytonotrequireadditional trainingorretraining forisolatedcasedeficiencies whentrainingwouldbeappropriate preventive action.ExamplesincludeNRCitems82-l2-02and83-02-06.

TheAssessment TeamfoundevidencethatSWEC'strainingprogramhasimproved.

Anewtrainingcoordinator hasbeenemployed.

TherehasbeensomeattempttohaveITTandComstockpersonnel trainundertheSWECprogrambutthereisnoevidencethatthishashappenedorthattheprogramsofITTandComstockareimproved.

Inaddition, noattempthasbeenmadetoretraininisolatedcaseproblemsasapreventive actionmeasure.0Ingeneral,theadequacyandqualityofthetrainingrecordsremainaconcern,butimprovements plannedintheoveralltrainingprogramshouldresultinbetterrecords.2.3.2Communication TheAssessment Teamnotedwhatappearstohavebeenacommunication prob-lembetweenNMPCandGE.Thisresultedinaninterface problemthataffectedGEdrawings, testinstructions, shipshortauthorizations, andworkorderpackages, andcauseddelaysinimplementing therequiredcorrective action.Procedural modifications havebeenmade,butthesewilltaketimetoshowpositiveresults.Atthemoment,thisremainsanareaofconcern.

l0023h02-232.3.3~lnsectionCATIteml-83addressed theNRC'sconcernthatracewayinstallation inspec-tionsarenotbeingperformed inatimelymanner.Asamplingof08recentracewayticketsshowedanaverageof70daysbetweencompletion andinspection.

iVevertheless, theresolution isconsidered satisfactory sincetheAssessment Teamhasalsoverifiedthatcablepullingisnottobeperformed untiltheracewayhasbeenaccepted.

TheNRC'sconcernthatinspection plansandprocedures containdeficiencies relativetoinspection criteriawasaddressed inCATItem6-83.Noinspection attributes orcriteriahadbeenprovidedforKellemgrips,temporary identifica-tion,separation barriersorprotrusions intothe'cabletray,althoughtheseattributes hadbeenspecified.

TheAssessment TeamfoundthatiVMPCappro-priatelyrevisedtheinspection plansandprocedures toprovideforinspection oftheseattributes, butdidnotmakeprovision forverifying theinstallation ofpermanent Kellemgripspermitted tobeinstalled aftercablepulling.Arec-ommendation forcorrecting thishasbeenmadeunderCATItem6-83.CATIteml1-83identified.a programmatic deficiency regarding FQCpersonnel beingunawareofprocedural requirements forPreliminary Inspection Verifi-cation(PIV)inspection orcompleting IRswithoutactuallyinspecting theequip-ment.TheAssessment Teamrecommends thattraininginthisareabeexpandedtodisciplines otherthancraftandelectrical, andshouldhaveamoreextensive curriculum.

TheCATreportalsonotedthatITTinspection checklists forpipingdonotreflectthelatestdesigndocument.

Corrective andpreventive actionswereinitiated toassurethatITTinspection checklists willreflectthelatestdesignand/ordesignchangedocument.

TheAssessment Teamconcluded thatcorrec-tiveactionhadnotbeencompletely addressed, andtherefore, CAR80-0058wasissued.Itssatisfactory completion willresolvetheconcern.h 10023h0Inspection Attributes Thelackofdocumentation onIRs(notidentifying drawingrevisionandtheERDCRtowhichtheitemwasinspected) wasaddressed inCATItem0-83.TheAssessment TeamverifiedthatNMPChadrevisedappropriate procedures torequirerecording ofthespecificdocuments used,andtoreviewpriorinspections toverifythatthelatestdocuments atthetimeof'inspection hadbeenused.Theprocedures havebeenrevised,butthatthereviewsofpr'.orinspections hadnotbeenperformed.

CAR80.0058wasissuedbytheAssessment Team.Therewereseveralinstances whenfieldQCinspectors preparedDRsbasedonreference dimensions ondrawingsratherthanrequireddimensions.

Reference dimensions wereconsidered "absolute",

resulting innonconformance documents beingprocessed whichwereinvalid.PHASEIVSAMPLINGASSESSMENTS The.Assessment forPhaseIYwasbasedonasamplingofdeficiencies andnonconformances reportedbythefivemajorcontractors duringtheperiodbetween3anuaryI,l98landMarch31,l980.TheitemsweredividedamongtheAssessment Teambyapplicable discipline and,withineachdiscipline, classified aseitherhardwareorprogrammatic-related.

Thestatistical methodsforsampleselection weredesignedtoprovide95percentconfidence thattheevaluated elementsoftheentirepopulation havelessthan5percentnoncompliance.

Thisisconsistent withpastNRCrecommendations relatedtoreinspections ofsafety-related itemsandwillproduceresultsatleastequivalent tothoseexpectedfroml00percentinspection.

Thestatistical samplingmethodsusedduringthesampleselection areinaccordance withMIL-STD-105D TablesI,IIAandVIIA,probablythemostwidelyusedsamplingstandardappliedtoassesscompliance withrequirements.

Twelvecategories ofdeficiencies inPhaseIYhadpopulations whichallowedtherapplication ofthestatistical'sampling plan.

10023h42-25~Whenthesamplevalidated thattherequiredlevelofqualityhadbeenmaintained, thelotwasconsidered acceptable andnofurthersamplingwasrequired.

~Whenthesampledisclosed thattherequiredlevelofqualityhadnotbeenmaintained, theAssessment Teamincreased thesamplesizeandtightened samplingperestablished tables.~Whentightened samplingdisclosed thatthedesiredqualitylevelhadbeenobtained, nofurthersamplingwasrequiredofthatlot.2.0.1SamlinPlanResultsThefollowing tablerepresents thosecategories ofdeficiencies whosepopula-tionsweresuchthatthestatistically validsamplingplanwasapplicable.

Thecategories shownbelowas"other"arethosepopulations ofdeficiencies classified bytherespective contractor asnotpertaining toaspecificdiscipline.

Hardware:

O~tt/DiscPopula-tionSWECNDE265SWECOther2,009SWECCivil1,166SWECMech505SWECElec1,098TotalQuantity5~amled128128133386NormalAcceptNumberResultsPassedNormalN/A3FailedTightened Passedi4ormal5FailedTightened 12FailedTightened MACTightened MACDefi-AcceptDefi-cienciesNumbercienciesN/AITTMechITTNDEITTOther3CIMech1,2061,387190127'81163102N/AN/APassedNormal8FailedTightened 2FailedTightened PassedNormal 2-26=10023h0Prorammatic:

fTTMechITTOther3CIOther2130151001451075FailedTightene9FailedTightened 1FailedTightened

2.0. 2PhaseIVHardwareSamlinAssessment

AnalsisSPECConclusion Theresultsoftheapplication ofthestatistically validsamplingplanstotheCivil/Structural andElectrical populations ofdeficiencies providesjustification foracceptance ofthelots.Theresultsoftheapplication ofthestatistically validsamplingplansforthedefinedpopulations ofdeficiencies fortheMechariical andWelding/iNDE disci-plinesandSWEChardware"other"providesjustification forreinspection oftheselots.Allthreelotsfailedtightened sampling.

Recommendation TheMechanical andWelding/NDE itemsfailingtheoriginalnormalandtight-enedsampling'planshouldbeverifiedbyreviewofthestateddeficiency, theoriginalacceptance, criteria,.and thecommitted corrective action,andverifi-cationthroughrecordsorhardwarereinspection asappropriate forcorrective actionimplementation.

Forthehardware"other"category, theAssessment TeamhasreviewedtheCARsleadingtothefailureofthesamplingplanandhasmadeajudgmentthatnoneofthedeficiencies reflectonthein-placequalityofhardware.

Theyarethekindsofdeficiencies thatcanandshouldberesolvedduringdocumentreviewp'riortorecordsturnover.

Onthisbasis,theAssessment Teamrecom-mendsthatSWECandNMPCperformatechnical reviewoftheidentified deficiencies andassessthepossibleimpactontheprojectifsuchweretorecurintheremainder ofthepopulation.

10023h0'-27 Mechanical hardware"other"itemsrepresent approximately 50percentofthepopulation anditisestimated onaworst-case basis,approximately l,002itemswouldberequiredtobereinspected ona100percentbasis.TheAssessment Teamrecommends anormalsampleoftheremaining mechanical hardware"other"itemsbetakenandifnohardware-affecting deficiencies aredisclosed, theremainder oft'hispopulation beaccepted.

Conclusion Theresultsoftheapplication ofthestatistically validsamplingplanforthedefinedpopulation ofdeficiencies fortheMechanical discipline providesjustifi-cationforacceptance ofthelots.Theresultoftheapplication ofthestatistically validsamplingplantotheWelding/NDE andhardware"other"population ofdeficiencies providesjustifi-cationforreinspection ofthislot.Thesetwolotsfailedtightened sampling.

Recommendation Thepopulation ofITTHardwareWelding/NDE deficiencies was1,387.Atotalof281itemswasreviewed.

Tenofthesewerefoundtobeunsatisfactory caus-ingthesamplecategorytofailthetightened sampleplan.TheAssessment Teamhasreviewedthetenfailures, andhasfoundthattheyrepresent theentiretimeperiodoftheassessment.

Sevenofthetenfailuresrelatetohard-waredeficiencies thatinvolvethein-placequalityoftheitem.TheAssessment Teamrecommend thatthecontractor begiventheresponsibility forreinspect-ingtheremaining l,l06documented items.Vponcompletion ofthecontractor reinspections ofthesepreviously documented deficiencies, iVMPCshouldper-formastatistical samplingtoverifythecontractor's actions.ITThardware"other"itemsfailingtheoriginalnormalandtightened samplingplanshouldbeverifiedbyreviewofthestateddeficiency, theoriginalaccep-tancecriteria, andthecommitted corrective action,andverification throughrecordsorhardwarereinspection asappropriate forcorrective actionimple-mentation.

2-28l0023h43CIConclusion Theresultoftheapplication ofthestatistically validsamplingplantotheMechanical population ofdeficiencies providesjustification foracceptance ofthelot.2.0.3PhaseIVProammaticSamlinAssessment AnalsisConclusion Theresultoftheapplication ofthestatistically validsamplingplantotheMechanical andprogrammatic "other"population ofdeficiencies providesjustification forreinspection oftheselots.Thetwolotsfailedthetightened samplingplan.Recommendation Itemsintheselotsfailingtheoriginalnormalandtightened samplingp1ansshouldbereverified byreviewofthestateddeficiency, theoriginalacceptance

criteria, andthecommitted corrective action,andver'ification through'records orhardwarereinspection asappropriate forcorrective actionimplementation.

Onehundredthirteenreinspections shouldbeperformed fortheremaining Mechanical population and270reinspections shouldbeperformed fortheremaining "other"population.

3CIConclusion Theresultoftheapplication ofthestatistically validsamplingplantotheprogrammatic "other"population ofdeficiencies providesjustification forreinspection ofthelot.Thelotfailedthetightened samplingplan.

l0023hl'-29 Recommendation itemsinthelotfailingtheoriginalnormalandtightened samplingplanshouldbereverified byreviewofthestateddeficiency, theoriginalacceptance cri-teria,andthecommitted corrective action,andverification throughrecordsorhardwarereinspections asappropriate forcorrective actionimplementation.

Threehundredtwenty-one reinspections shouldbeperformed fortheremaining population.

IlIIIII 10023h03-13.0ANALYSISOFDEFICIENCY DOCUMENTS

3.1INTRODUCTION

Thissectionpresentsaquantitative analysisoftheresultsoftheevaluation ofdeficiency documents, fortheprojectasawhole,andforeachresponsible organization (NMPC,SPEC,ITT,etc.)TheAssessment Teamdeveloped aseriesofcodesforclassifying hardwareandprogrammatic deficiencies andtheircausesinordertoanalyzewhichofthosecausesoccurredmostfrequently.

Programmatic deficiencies wereidentified inaccordance withthe18Criteriaof10CFR50,AppendixB.Hardwaredeficiencies werecategorized according to51codesrelatingtoconstruction materials, components andprocesses.

Twothousandninehundredfortyrecordswereassessed, resulting in0,300codeddeficiencies, including thoseontheoriginaldeficiency documentandthoseresulting fromevaluation bytheAssessment Teamastocorrective actionimplementation.

These0,300codeddeficiencies included1,701programmatic deficiencies and2,059hardwaredeficiencies.

Onehundredfortywereidentified as"nodeficiency".

Paretochartsweredeveloped andanalyzedinordertopinpointthoseareasinwhicheffortsatimprovement couldbemademosteffectively.

TheParetoprinciple holdsthatamajorityofthesignificant problemshaverelatively fewcauses.This-methodofanalysisgraphically identifies thesignificant areasrequiring correction andalsodisplaysthosewheretheefforttobringaboutcorrection maybemorecostlythanthebenefitstobederived.TheParetoanalysiswasconducted foralldeficiencies evaluated bytheAssessment Team,andforthose.deficiencies evaluated bytheAssessment TeamasSatisfactory withRecommendation (S/R)orUnsatisfactory (UNSAT).Thepurposeincombining thesetwosetsofdataissolelytoprovidealargeenoughsampleofthetotalpopulation toprovidemoremeaningful dataastotheunderlying causesofproblemsthanwouldhaveresultedfromanalyzing onlythosecategorized asUnsatisfactory.

Thiswasanalternative toanalyzing theentirepopulation.

TheParetoanalysisprogramidentified thecause,whetherthedeficiency wasprogrammatic orhardware-related, theresponsible organization andthephase 3-210023h0oftheprograminwhichthedeficiency wasevaluated.

Oneormoredeficiency codeswereassignedtoeachdeficiency toreflectthecitedproblem,aswellasanydiscrepancy intheresolution oftheidentified problem.Thesedatawerethenenteredintoacomputerandsortedbyvariousmethodstoidentifysignifi-cantpopulations ofdeficiency codesrelatedtoeachspecificorganization.

Thefollowing contractors andvendorswerecodedasSWECresponsibilities:

L.K.ComstockCivesSteelWalshConstruction CompanyNorthernReadyMixDamesandMooreMiscellaneous suppliers Electrical Structural/Steel ErectorCivilConcreteSupplierGeotechnical ServicesForallcontractors, deficiencies maybecategorized aseitherhardwareorprogrammatic oracombination ofbothandaresodisplayed intheParetocharts.Thesamerecordmayprovidebothhardwareandprogrammatic deficiencies.

Thetotal'coded deficiencies willbegenerally greaterthanthenumberofdocuments judgedSatisfactory withRecommendation orUnsatisfactory.

Theprogrammatic codeddeficiencies andthehardwarecodeddeficiencies forallorganizations asidentified bytheoriginaldeficiency documents areshownonFiguresAandB,respectively.

FigureAindicates thatdeficiencies againstthefollowing Criteriaof10CFR50,AppendixB,accounted formorethan5percentofthetotaldeficiencies:

Criteria17(QualityAssurance Records);

5(Instructions, Procedures andDrawings);

10(Inspections);

15(Nonconforming Materials, PartsorComponents);

2(QualityAssurance Program);

9(ControlofSpecialProcesses);

16(Corrective Action);8(Identification andControlofMaterials, PartsandComponents);

and3(DesignControl).

Thesearethesignificant areasofprogrammatic deficiencies fortheperiodcoveredbythisassessment.

FigureBindicates thatdeficiencies inexcessof5percentofthetotalexistagainstonly0of51hardwaredeficiency codes:38(Welding);

Ol(PipeandHanger/Supports);

63(Material);

and00(Piping/Pipe Spools).

225ParetoAnalysisDistribution ofProgrammatic Deficiency Codes-AllContractors Pio080600O00I-0200l75.>OCOl150oQCl125~000->00<7550~~~~~0~~~~~~~~CRITKRfALOrganhationLOAPtogramOwlgnConttoti.Pcocuremsnt Oocunt~Conttol5.Instcuctlons, Ptooockew andOrawingsLOooLsnsnt Ccnttol1.ContrololpurctawdMstetlatr EydpmentendSarrtcesLldsntlllcatlon an4ControlotMatsltalar PatteendCocnponsnts ContcolotSpectstPtocesswlLlnspectlon lLTwtConttolControlotMesswingan4TwtEydpmsntlLHandling, StorageandShlpplngli.lnspsctlon, Testen40perattng Statusl5.Nonconlorcnlng Mstetlats, PartsocComponents l4.Correcttw ActtonlT.QARecordslLAudtts5%-25rr~~0175101529168361871131241114Deficiency CodesBased18Criteria-10CFR50FigureA 24ParetoAnalysisDistribution ofHardwareDeficiency CodesAllContractors 20<1SIS~~0400(34=zoo4O0I200~E00f4oOaftclency11ConcretePlacement 12RoberPlacement 13CadweldPlacement 14S/S8oltlng15S/SWelding16EmbedPlacement 17Coatings18Waterproofing 19ConcreteMaterialTesting20Expansion Anchors21Inspection 22Soils23CableTray/Conduit Installation 24Conduit/Tray Supports25CablePulling/Routing 26CableTermlnatlon 21Contlnulty sndMeggerTesting28Instrumentatlon Installation 29Instrument Cable31CabloSeparation 32.FireProtection 33Housekeeping 34TrayLoadingandIdentlflcstlon 3SPenetration Inatallatfon andTestingEquipment Setting/Installation 31Equfpment (ExceptPumps,ValvesandHeatExchanges) 38Welding(Performsnce) 39Qusllflcatlon sndSettingofExpansion Anchors40Plplng/Pipe Spools41PlplngHangars/Supports 42Hydrostatic Testfng43HolstlngsndRlgglng44HVAC45Penetrstlons 46Radlographlc Testing(RT)47Ultrasonic Testing(UT)48LlquldPenetrant Testing0P)49VisualInspection (VT)50MagneticPartfcfeTesting(MT)51Welding(Procedure) 52WewerQuallflcstlon 53WeldMaterial54f4otAssignedSSValves56MTBZSlPreventive Maintenance 585/SFabrlcatlon/Erection 59Pumps60HeatExchsngers 61Handling/Storage 62WeldDesign6'3Materials 5%034414340372011151453214455541249302431434144IQ242534541413441751235742HardwareDeficiency CodesFiureB l0023hO3-53.2PHASEI,IIANDIIIANALYSISPhaseI,IIandIIIprogrammatic/hardware deficiencies consisted ofmechanical, electrical/I@C, civil/structural, welding/NDE, material/receiving andsoftwaredeficiencies notedbyNMPConcorrective actiondocuments asprogrammatic orhardwarerelated.All296oftheNMPCprogrammatic/hard-waredocuments wereevaluated bytheAssessment Team.Ofthese296deficiency documents, 93.9percentwereratedbytheAssessment TeamasSatisfactory orSatisfactory withRecommendations.

Whentranslated intodeficient itemsratherthandocuments, theresultsare90ApercentSatisfactory andSatisfactory withRecommendations and5.6percentUnsatisfactory.

tDLA10ClDOOVDCiesHO0R20o15DCI'0~100e5X0NMPCPARETOANALYSlSOFPROGRAMMATlC DERClENClES

.FORS/R8cUNSAT1$1$$J10$11$4'I74121$1~1$2171$$1411Programmatic Oeficiency Codes 3-610023hOOutofthe33NMPCdocuments evaluated asSatisfactory withRecommenda-tionorUnsatisfactory, therewere156coded,deficiencies.

Thesewerecombinedforanalysis.

Thedistribution ofthemostsignificant codeddeficiencies amongthevariouscriteriaareasfollows:CodedDeficiencies

~Criterion 16~Criterion 15~Criterion 2~Criterion 5~Criterion 3~Criterion 18~Criterion 17Corrective ActionNonconforming

Material, PartsorComponents QualityAssurance ProgramInstructions, Procedures andDrawingsDesignControlAuditsQualityAssurance Records3915Theprincipal rootcausesofthesedeficiencies, indescending orderofimportance, are:~Notimplemented inapprovedprogram/procedures

~'eficiency intheapprovedprogram/procedures

~Lackoftimeliness Inaddition, thefollowing rootcausesforapplicable:

~Inadequate workmanship

~Inadequate materialtraceability

~'nadequate handling/storage/protection

~Inadequate reinspection ofdispositions

~Inadequate designdetail~Inadequate acceptance criteriahardwaredeficiencies arealso 10023h03-73.3SPECPROGRAMMATIC Onehundredforty-one documents detailing civil/structural, electrical/IdcC, welding/NDE, mechanical andotherdeficiencies notedbyS'SEConcorrective actiondocuments asprogrammatic-related wereassessedbytheAssessment Team.Duetotherelatively smallsizeofthepopulations ofthesepreviously identified deficiencies, thesedisciplines wereassessedasagroup.SWECPARETOANALYSISOFPROGRAMMATIC OEFICIENCIES COOESFORS/R8cUNSATI5DVCCl0a~'00I%a040~300O~200F10Sattef44toty

~ReCam~datfOta CZUneathfaCbXy 171551457151525451'I12ISI~17147541555515I5rogrcI7II71ctlc Oaftciency CodesTherewereatotalof120programmatic codeddeficiencies against10S'IttECprogrammatic and90hardwaredocuments assessedasSatisfactory withRecommendation orUnsatisfactory.

Thesedatahavebeencombinedforthepurposeofanalysis.

Thequantities shownreflectthedistribution ofthecodeddeficiencies amongthevariouscriteria.

Thefollowing arethemostsignificant problemareas:CodedDeficiencies

~Criterion 17~Criterion 15~Criterion 10~Criterion 7QualityAssurance RecordsNonconforming Materials, PartsorComponents Inspection ControlofPurchased

Material, Equipment andServices3320 3-810023h0~Criterion 8~Criterion 3Identification andControlofMaterials, PartsandComponents DesignControlCodedDeficiencies Theprincipal rootcausesoftheseCriteriadeficiencies, indescending orderofimportance, are:~Deficiency intheapprovedprogram/procedures

~Notimplemented inapprovedprograms/procedures

3.0 SWECHARDWARESWEChardwareconsisted

ofmechanical, electrical/IRC, civil/structural, welding/NDE andotherdeficiencies notedbySWEConcorrective actiondocuments ashardware-related.

Atotalof960SWEChardwaredocuments wereassessedbytheAssessment Team.Duetothelargesizeofthepopulation ofthesepreviously identified deficiencies, theywereassessedbytheapplication ofastatistically validsamplingplan.SWECPARErOANALYSlSOFHAROWAREOEFlClENClES FORS/R8cUNSATCltsClVClVCLi20o16Cl~12ClOSODgZSathtcctortj'ith Kgitecomalwocctioes Unoctiahlctoty SSCSSS4441SSSIS7SS40XlSI404$1110J50177SCCSSSS71S1~7017HcrdwareDeficiency Codes4$SSSSWLeXC40SoSS4071LaxW 10023hO'-9Therewereatotalof110hardwaredeficiencies codedagainst90SWEChardwareand10programmatic documents assessedasSatisfactory withRecommendation orUnsatisfactory.

Thesedatahavebeencombinedforthepurposeofanalysis.

Thefollowing arethemostsignificant problemareas.Thequantities shownrepresent thedistribution ofthesecodeddeficiencies amongthevariouscodes;noneofthesecategories accounted forasmuchas5percentofthetotalpopulation ofassesseddocuments.

CodedDeficiencies

~Code63~Code53~Code38~Code25~Code00~Code55MaterialControlControlofVeldMaterialWeldingCablePullingHVACValves22161313Theprincipal rootcausesofthesedeficiency codes,indescending orderofimportance, are:~Inadequate/incomplete documentation Inadequate workmanship Failuretofollowprocedures VendorerrorInadequate configuration controlInadequate disposition onnonconforming documents Inadequate reinspection ofdispositioned nonconforming documents ITTPROGRAMMATIC ITTprogrammatic deficiencies consisted ofcivil/structural, welding/NDE, mechanical andotherdeficiencies notedbyITToncorrective actiondocuments asprogrammatic-related.

Atotalof331ITTprogrammatic documents wereassessedbytheAssessment Team.

10023hODuetothelargesizeofthepopulations ofthemechanical andotherclassified deficiencies, thesewereassessedbytheapplication ofthestatistically validsamplingplan.Civil/structural andwelding/NDE wereassessedintheirentirety.

m'ARETOANALYSISOFPROGRAMMATIC OERCIENCIES FORS/R8cUNSATCI10VCClOClClO~OOIJOC-12Ict8OOe>4C)E0Satiefactonl withEgRecontntendatione CZUneathfactofy 1014142$1792441714141414249$7121711114Pragrantrnatic Oeficiencv CodesTherewereatotalof109programmatic codeddeficiencies againstff1ITTprogrammatic and57hardwaredocuments assessedasSatisfactory withRecommendation orUnsatisfactory.

Thesedatawerecombinedforthepurposeofanalysis.

Thefollowing arethemostsignificant problemareas.Quantities shownreflectthedistribution ofcodeddeficiencies amongthevariouscriteria.

CodedDeficiencies

~Criterion 15~Criterion 16~Criterion 10Nonconforming Materials, PartsorComponents Corrective ActionInspection 1916Thefollowing accounted forlessthan5percentofallassesseddocuments butwerecontributory:

,CodedDeficiencies

~Criterion 5Instructions, Procedures andDrawings 10023hO3-11~,Criterion 17~Criterion 2~Criterion 3~Criterion 9QualityAssurance RecordsQualityAssurance ProgramDesignControlSpecialProcesses CodedDeficiencies 7Theprincipal rootcausesoftheCriteriadeficiencies, indescending orderofimportance, are:~Notimplemented inapprovedprogram/procedures

~Lackoftimeliness

~Deficiency inapprovedprogram/procedures 346ITTHARDWAREITThardwareconsisted ofwelding/NDE, mechanical andotherdeficiencies notedbyITToncorrective actiondocuments ashardware-related:

Atotalof571ITThardwaredocuments wereassessedbytheAssessment Team.CVOOtIOO4)CI-20OQ0la50Oe40a~300CJ200IIlozm'ARETOANALYSlSOFHARDWAREDEFlCIENClES FORS/RdcUNSATScthfcctoty withKQRecommendotionc Vnccticfccto1y 544041445545152142405554C5054HardwareDeficieftcy Codes5440401142552055544555 3-1210023hODuetothelargesizeofthepopulations ofthesepreviously identified deficiencies, thesewereassessedbytheapplication ofthestatistically validsamplingplantoeachoftheITT-defined population breakdowns.

Therewereatotalof102hardwarecodeddeficiencies against57ITThardwareand01programmatic documents assessedasSatisfactory withRecommend-ationandUnsatisfactory.

Thisdatahasbeencombinedforthepurposeofanalysis.

Thefollowing arethemostsignificant problemareas.Thedistribution ofcodeddeficiencies amongthevariouscodesisasfollows:CodedDeficiencies

~Code38~Code00~Code01~Code55WeldingPipingandPipeSpoolsPipingHangersandSupportsValves381710Theprincipal rootcausesofthesedeficiency codesindescending orderofimportance, are:~Inadequate workmanship

~Inadequate handling/storage/protection

~Failuretofollowprocedures

~Inadequate configuration control~Inadequate timeliness

~Inadequate designdetail3.7JCIPROGRAMMATIC 3CIprogrammatic consisted ofcivil/structural, welding/NDE, electrical/INC, mechanical andotherdeficiencies notedbyJCIoncorrective actiondocu-mentsasprogrammatic-related.

Atotalof1973CIprogrammatic documents wereassessedbytheAssessment Team.L 10023h43-13Duetothesizeofthepopulation ofthesepreviously identified deficiencies, theywereassessedbytheapplication ofthestatistically validsamplingplantoeachofthe3CI-defined population breakdowns.

JCIPARTETOANALYSISOFPROGRAMMAilC DEFICIENCIES FORS/RdcUNSATClClOc~20o4O10OO0VC~3a'O>20Q~t04t114SotJotoctcuy

~KgRocommoneatton4 CZVnoottcfocbxy 4t4410ProgrcmmatIc Deficiency CadesAtotalofll3CIprogammatic codeddeQaiencies wereidentified.

against8,programmatic and5hardwaredocuments assessedasSatisfactory withRecommendation orUnsatisfactory.

Thesecombineddatawereanalyzedtodetermine themostsignificant problemareas.However,apopulation ofl2istoosmallforaccurateanalysis, andfurthermore, noneoftheareasrepresents asmuchas2percentofthetotalpopulation ofassesseddocuments.

Thequantities shownrepresent thedistribution ofthecodeddeficiencies againstthevariouscriteria.

I'odedDeficiencies

~Criterion 5~Criterion 3~Criterion l5~Criterion l7Instruction Procedures andDrawingsIdentification andControlofMaterial, PartsorComponents Nonconforming

Material, PartsorComponents QualityAssurance Records 10023hOTheprincipal rootcauseofthesecodeddeficiencies is:~Notimplemented inapprovedprogram/procedures 3CIHARDWAREJCIhardwareconsisted ofcivil/structural, welding/NDE, mechanical andotherdeficiencies notedbySWEConcorrective actiondocuments ashardware-related.Atotalof2223CIhardwaredocuments werea=sessedbytheAssessment Team.Duetothesizeofthepopulations inthemechanical discipline, thepreviously identified deficiencies wereassessedbytheapplication ofastatistically validsamplingplan.Inallotherdisciplines, 100percentofthepopulation wasassessed.

JCIPAREl'O'ANALYSIS QFHARDWAREOERCIENCIES FORSR8cUNSAT0)ClVC'oZOVIC1~laOO00NjgVCI~30201ClEIto%41HardwareOeficiency CodesSatiafoctory withKgRacommanaationo Vnootfafactmy Atotalofllhardware-coded deficiencies representing five3CIhardwareandeightprogrammatic documents assessedasSatisfactory withRecommendation orUnsatisfactory wereidentified.

Thesedatahavebeencombinedforthepurposeofanalysis.

Noneofthesecodesrepresent asmuchas5percentofthe 10023h03-15totalpopulation.

Thefollowing listingrepresents thedistribution ofcodeddeficiencies withinthevariouscodes:~Code38~Code28~Code15~Code53WeldingInstrumentation Installation Structural SteelWeldingWeldMaterialCodedDeficiencies Theestablished rootcausesofthesedeficiency codes,indescending orderofimportance, are:Inadequate workmanship Failuretofollowprocedures Inadequate materialtraceability Incomplete documentation Inadequate configuration controlInadequate identification 3.9RCIPROGRAMMATIC RCIprogrammatic consisted ofwelding/NDE, mechanical andotherdeficien-ciesnotedbyRCIoncorrective actiondocuments asprogrammatic-related.

Atotalof100RCIdocuments wereidentified asprogrammatic andwereevaluated bytheAssessment Team.Onehundredpercentofthepopulation wasassessed.

Therewere10RCIprogrammatic and17.hardware documents assessedasSatisfactory withlRecommendation orUnsatisfactory, whichresultedin30programmatic codeddeficiencies.

Thesedatawerecombinedforthepurposeofanalysis.

10023hO2310RCIPARETOANALYSISOFPROGRAMMATIC OEFICIENCIES FORS/RdcUNSATOScr~10VO000I0Rp~6O44,0Clls0o20Scthtcctory withKgRocornrnon4ceono Unset&cctory14,410141711144141101$21214Programmatic Oeficiertcy CodeeAllofthesecodeddeficiencies couldbeclassified under10CFR50,Appendix8,Criterion XVICorrective Action;however,forfurtheranalysisthesehavebeenclassified toidentifythespecificareawherecorrective actionwasnotfullyaccomplished inthefollowing tabulations.

Noneoftheseareasaccountsformorethan3percentofthetotalpopulation.

Thefollowing arethemostsignificant problemareaswithinthetotalofcodeddeficiencies.

CodedDeficiencies

~Criterion 9~Criterion 15~Criterion 16~Criterion 10~Criterion 1~Criterion 18SpecialProcesses Nonconforming

Material, PartsorComponents Corrective ActionInspection Organization Audits10I5 10023h03-17Theprincipal rootcausesofthesedeficiencies, indescending orderofimportance, are:~Notimplemented inapprovedprogram/procedures

~Deficiency intheapprovedprogram/procedures 3.10RCIHARDWARERCIhardwareconsisted ofwelding/NDE, mechanical andotherdeficiencies notedbyRCIoncorrective actiondocuments ashardware-related.

Atotalof78RCIhardwaredocuments wereassessedbytheAssessment Team.Onehundredpercentofthepopulation wasassessed.

RCIPARETQANALYSISQfHAROWAREDEFICIENCIES FQRS/R8cUNSATCOC40OO4OO9)00lC0108Cl6OII2:sooo444I5414satfsfacbxy wfthEZlRoaommonaatIono Unoatfafocbxy JS44o34011HardwareDeficiency CodesTherewereatotalof26hardwarecodeddeficiencies identified for17RCIhardwareand10programmatic documents assessedasSatisfactory withRecommendation orUnsatisfactory.

Thesedatawerecombinedforthepurposeofanalysis.

Thefollowing arethemostsignificant problemareasidentified.

Thequantities shownrepresent thedistribution ofcodeddeficiencies withinthevariouscodes.~-Code38~Code06WeldingRadiographic TestingCodedDeficiencies 10 10023h0Otherareascontributing tothetotalare:CodedDeficiencies

~Code00~Code53~Code55Piping/Pipe SpoolsWeldMaterialValvesTheprincipal rootcausesofthesedeficiencies, indescending orderofimportance, are:~Inadequate workmanship

~Inadequate materialtraceability

~Inadequate handling/storage/protection

~Incomplete documentation

~Inadequate cleanliness control 10023M'.0CONCLUSIONS ANDRECOMMENDATIONS NRCORDERITEMASSESSMENT 01.1Assurance ProramConclusion NMPCandallfivemajorcontractors atNMP-2haveimprovedtheirQAPrograms.

Organization andfunctional delineation hasbeenaccomplished.

ACARwasissuedforadeficiency inthisareabuthassincebeenresolved.

Thes'taffsofeachorganization havebeenincreased intheappropriate areas.Procedures definingresponsibilities andinterfaces havebeenaccomplished inmostcases.Procedures governing projectactivities havebeenupgraded.

Theauditingfunctionhasimprovedthescopeofauditschedules toincludemorehardwareactivities.

Problems, however,stillpersist.ForCriterion 7ofthe18CriteriatolOCFR50,AppendixB,thereisstillroomforimprovement.

ItistheopinionoftheAssessment TeamthatNMPChaseithercorrected orhasanacceptable planforcorrecting thedeficiencies noted.Recommendations

~Continuetoemphasize auditsandsurveillance asameansofidentifying areasofnoncompliance, statusing QAprogramprogressandassuringprogrameffectiveness

~Emphasize theimportance ofdetermining rootcauseasameansofavoidingrepetition ofpastproblems~Refinethecomputerized trendingprogrambyimproving thedatabaseanddeficiency codes;restrictinterpretation ofproblemandcausecodestoasfewpeopleaspossibletoavoidadilutionofrepetitiveness throughdifferences ininterpretation; considerassigning aCorrective ActionCoordinator toperformthesetasks~Continueuppermanagement's involvement intheQAprogram;requiremonthlyreportson:Theperformance andclosingofauditsandsurveillance Thestatusofthecorrective actionprogram(deficiency reporting documents openedandclosed,chartsandgraphs) 0-210023h0Trendingresults~Continuetoupgradeprocedures andtrainingprogramstokeepupwiththestateoftheartandavoidrepetition ofadverseconditions 0.1.2SiteAuditinProramsConclusion BothNMPCandSWEChaveevaluated theirauditprogramsandhavetakenpositiveactiontoimprovethem.Newandrevisedprocedures havebeendeveloped whichareincompliance withANSIN05.2.12.

Auditorsarebeingtrainedandcertified toANSIN05.2.23.

Auditprogramsareconcentrating onconstruction andhardwareproblemsandtheuseoftechnically qualified auditorsoutsidetheQAorganization.

TheAssessment Teamconcluded thattheauditprogramsofbothNMPCandSWECarevastlyimproved, andthereisstrongevidencethattheproperstepsarebeingtakentopreventrecurrence ofthosekindsofproblemscitedbytheNRC.Recommendations

~Enforcethenewauditreportsrequirements fortimelyclosureofauditfindingsandAssurethatallauditfindingsincorporate thedeterminations ofroot'causeandactiontopreventrecurrence Continuetrainingofnewauditorsandretraining ofcertified auditorsinthelatest'auditing techniques andgoals~Betterdistinguish betweenthesurveillance programandtheauditprogram0.1.3Corrective ActionSstemConclusion Therecontinuetobeproblemswiththecorrective actionsystemsofbothNMPCandSWEC,bothintermsofdelaysinimplementing corrective actionandverification ofcorrective action.ERDCRsareusedtorecordnonconfor-mances;thetrainingsystemforNdcDsisineffective; andthereisnomech-anismfortrackingcontractor implementation ofdispositions.

Responses to 10023h0'-3corrective actioncontinuetobeslow.Verification toensurethatpreviously installed itemsmeetupdatedcriteriaislacking.TheuseofType"A"andType"C"IRshashamperedthecorrective actionverification process.TheAssessment Teamconcluded thatalthoughsomeimprovement hasbeenachievedintheformofrevisedprocedures andanupdatedtrendingprogram,!muchremainstobedone.Recommendations

~Establish aCorrective ActionCoordinator toinitiatetracking, trendingandreporting ofcorrective actionprogress~Establish alogfordeficiency reporting documents asabasisforstatusing corrective action~Developasystemthatrequirespromptreplyandaction~Discontinue theuseofSWECType"C"IRsasanonconformance document0.1.0DocumentControlConclusion NMPCandSWEChavegonetogreatlengthstoaddresstheproblemsofdocu-mentcontrol,andhaveestablished ataskforcetoreviewtheexistingandupcomingproblemsofdocumentcontrol.However,theAssessment Teamnotedcontinued problemswithaccessandretrievability.

Relateddocuments werenotcross-referenced foreaseoftracking.

Thefacilities forhousingthemanydocuments areinadequate, andonlyone-hourfiresafecabinetsarebeingusedforpermanent records.TheAssessment Teamconcluded thatbothNMPCandSWEChaveasignificant documentcontrolproblemthatmustbeaddressed beforethemonumental taskofsystemturnover.

Recommendations

~Preparenowfortheeventuality ofdocumentturnoverbyprioritizing theworkeffortandsimplifying theworkflow~Makesurethatallpermanent plantrecordsareindexed,protected, consolidated andretrievable ioaccordance withANSIN05.2.9 10023h0~Providemorespaceandbetterequipment forhousingtheworkingdocuments andpermanent records~Hireandtrainadditional personnel forthedocumentcontroleffortDesiChaneControlConclusion NMPCandSWEChavetakenstepstoimprovethedesigncontrolsystem,suchasinstituting acomputerized systemforpostingdesignchanges,reducingthenumberofdrawingstationsandattempting tomakepromptdistribution ofchanges.However,theAssessment Teamidentified situations inwhichdrawingswerenotbeingreviewedaccording toprocedure, designchangeswerenotbeingpostedagainsteachaffecteddrawingandthenumberofchangesindicateinadequate designchangereview.IntheopinionoftheAssessment Team,bothNMPCandSWECaretobecommended fortheirdedication toresolving thedesignchangeproblem,andtheyhaveappropriately identified stepsrequiredtoensuretheintegrity ofthedesigndocuments.

Recommendations

~Improvethereviewcyclefordrawingchangesandtherebyreducethevolumeofchanges~Improveandincreasetrainingintheareaofchangecontroltoprecludeworkingtoinaccurate ormissingprocedures

~Continuetoreducethenumberofdrawingstations~Reducethetimeittakestoincorporate adesignchangeinordertoassurethatallpersonnel areworkingtothelatestrevision~Standardize theterminology usedinthedrawingrevisionblocktoavoidambiguity, andensurethatappropriate designchangeshavebeenincorporated IProcurement liAssurance TheNRC'sconcernsrelativetoCriterion 7requirements arewellfounded.Lackofattention tospecification requirements intheinspection processwas 10023h0'videntandthecommitment toperform100percentreinspection wasnotcar-riedthroughtotheInspection PlanChecklist.

SWEChasinstituted atrainingprogramforPQAinspectors whichseemstobeworking.TheAssessment Teamcouldnotfindanyfurtherevidenceofmaterialbeingacceptedthatdidnotconformtoacceptance standards.

Additionally, sourceinspection isnowrequiredforselectedCategoryIitems.TheAssessment Teamconcluded thattheprogramandsystemforcontrolling procurement atNMP-2asrequiredbyCriterion 7isinplaceandworking.Theimplementation ofcommitments shouldpreventrecurrence.

Recommendations

~Reinspect allCivessteelbeamstoensureunsatisfactory weldsarenotbeingusedelsewhere ontheproject~ContinuetoimprovethetrainingofPQA/QCpersonnel inCriterion 7principles andindustryrequirements

~Avoidbypassing sourceinspection inlieuofinspection uponreceipt~Assurethatspecification anddrawingrequirements areincludedintheReceiptInspection Checklist 0.1.7RadiorhicFilmI'heAssessment Teamperformed anextensive reviewofradiographic filmpro-cessingandcontrolbySWEC,ITTandRCI.Thecondition ofthefilmandhandlingpractices werepoor.Theoriginalfilmwasnotavailable forweldsrequiring repair.NMPCconducted a100percentreviewofITTradiographs thatwereacceptedandfiledinthevault.Deficiencies wererecordedonSRsandconditions corrected.TheAssessment Teamconcluded thatradiographic filmproblemsidentified bytheCATTeamanddocumented ontheorderhavebeencorrected, butthisoperation shouldbemonitored throughfrequentauditsandsurveillances toensurethecontinued integrity oftheradiographic process.)

10023h0Recommendations

~Providethecontrolsandequipment necessary toprocessandstorenewandprocessed filminanappropriate manner~Continuetrainingradiographers andfilmhandlingpersonnel inproperhandlingpractices forprocessed film~Performregularly scheduled surveillance andinspection offilmprocessing andhandling, asanadjuncttotheauditingeffortsConcreteEonAnchorBoltsConclusion AreviewoftheactiontakenbySWECtosubstantiate theadequacyofinstal-ledconcreteexpansion anchorboltswasconducted bytheAssessment Team.TheNRCexpressed concernthatsomeconcreteanchorswerenotadequately set.SWECconcluded thattheboltsweresetproperly.

TheAssessment Teamagreeswiththisconclusion.

Recommendations Continuetoadheretothestrictrequirements oftheconcreteexpansion anchorboltinstallation procedures

~Continuesurveillance oftheinstallation activities toprovideassurance oftadherence todesignrequirements PowerGeneration ControlComlexConclusion TheAssessment TeamhasreviewedtheNRCorderwhichnotesthePGCCdeficiencies relatedtoseparation criteriaandtheconcernthatNMPChasnotprovidedassurance thatthiscriteriahasbeensatisfied.

Theyhavealsoevaluated whathasbeendonetocorrecttheadverseconditions.

Atthispoint,itisstillunclearhowmuchcorrective actionhasbeenaccomplished.

ManyFDIsandFDDRshavenotyetbeenclosedout,andprogressisslow.Aconsiderable amountofworkinvolvesGEequipment andthereseemstobeareluctance topushGE.

10023hO0-7Recommendations

~Makeaconcerted efforttocompletetheprescribed worksothatrelateddocumentation canbeclosedout~Installseparation coversforinstalled underfloor racewaysasclosetoracewayinstallation aspossible~ReviseInspection PlanN20E061AF1025 torequirethatpartialcablepullsbeinspected totheextentnecessary toassurethatinstalled cablemeetsspecification requirements 0.2DISCIPLINE ASSESSMENTS L2.1Civil/Structural

-ConcreteConclusion Withtheexception ofonereinforcing steelspacingviolation, whichwasnotidentified byQC,theconcreting activities werefoundtobeSatisfactory bytheNRC.TheNRC'sconcernsregarding adequateinspection criteriaforconcretesurfacesandcriteriaforconcreteunitweighttestshavebeenresolved.

Concretethathadbeenmixedwithatruckthatfailedmixeruninformity testingwascertified asacceptable throughreviewing compressive strengthtestreports.Recommendations None.4.2.2Civil/Structural

-ConcreteExansionAnchorsThisNRCconcernisaddressed inSection0.1.8.4D.3Electrical/IRC

-PGCCThisNRCconcernisaddressed inSection0.1.9.

0-8l0023hO0.2.0Electrical/IbrC

-SeismicCriteriaConclusion TheNRC'sconcernregarding seismicboltingcriteriaasitappliestotheMotorControlCenter(MCC)wasgiventoSWECforcorrective action.SWEC'sevaluation ofthematerialsubstitution practices wasreviewedbytheAssessment TeamduringaCATItemevaluation.

SWECdetermined thattheyareresponsible forassuringthatthesubstituted itemsdonotviolateseismicqualification.

Inspection byNMPCsubstantiated thefactthattheboltsasspecified andasusedwereacceptable.

TheAssessment Teamdetermined throughareviewthattheboltswereacceptable andconcurred withactionandconclusions ofthedeficiency itemdisposition.

Recommendations None.L2QVeldinNDE-VeldliandAssociated Documentation Weldqualityproblemshavebeendocumented bytheNRCandbyinternalauditsofITT,CivesandRCIweldingoperations.

Undersized, oversized andnot-to-specification weldswerenotedinseveralareas.TheNRCnotedthata'IlargenumberofCivesshopweldsforsupportswereundersized and15to20percentwererejectable.

RejectedweldswererecordedonNRDsanddispositioned "acceptasis"butonlyasamplingoftherejectedweldswereontheNRDs.TheAssessment Teamconcludes thatweldingpractices atNMP-2requireconsiderable attention fromQAtoimproveweldqualityandimproveassociated documentation.

Recommendations

~Examinetherecurrence ofundersized andoversized weldsandtakepositivestepstoimprovetheintegrity ofthisoperation

~Performsourceexamination toprecludeoff-siteweldingarrivinginanonconforming condition 10023hO0-9~Developimprovedprocedures foron-sitewelding;reviewandapproveprocedures usedforoff-sitewelding~Improvewelddocumentation andoriginate andmaintainwelddatasheetsaspermanent recordsL2.6VeldinNDE-VeldReirsAllcontractors'eficiency reporting documents haveindicated excessweldre-pairsforbothbuttandfilletwelds.Allcontractors exceedengineering welddesignsize(approximately 75percentofthetime).ITTfailedtoidentifyweldrepairsnotinaccordance withtheapplicable specifications.

Over-grinding hasbeenacommonpracticeforremovingminordefects.Theseareallratherminorprogramdiscrepancies whichcanbecorrected withadditional trainingandweldingprocedures.

Recommendations C~'ddressweldingperformance datatodetermine andmonitorwelder'capability

~DirectdefectsthatcannotberemovedwithminimumgrindingtoEngineering fordisposition

~Instructcrafttolimitweldsizeforrepairstospecified Engineering requirements L2.7VeldinNDE-VeldMaterialControlConclusion Themostsignificant weldmaterialcontrolproblemwasthatofweldrodcontrol,whichresultedintheinitiation ofaCARbytheAssessment Team.TheCARhasbeensatisfactorily resolved.

tt)Recommendations

~Increasethefrequency ofQCin-process inspection andmonitoring

~ReviewWMRsforcompleteness sothatminorerrorsarenotrepeated 0-1010023h00.2.8VeldinNDE-Veldinlifications Conclusion TheNRChadidentified acaseofwelderqualifications notmeetingASiMECodeSectionIXineffectatthetimeofqualification.

TheAssessment Teamdetermined thatwelderqualification recordswereinadequate andissuedaCARforthecondition.

TheCARhassubsequently beenresolvedsatisfactorily andclosed.Recommendation None.0.2.9VeldinNDE-VeldInstionTheradiographic filmproblemshavebeendiscussed inSection0.1.7ofthisreport.TheNRChasindicated thatITTandRCIhaveproblemsintheNDEarea.Theynotedthatbothofthese.contractars hadvisualandpenetrant in-spectionproblemsinvolving pipingandpipesupports/restraints.

Additionally, ITT,onmanyoccasions, hasclosedDRspriortocompletion ofradiography.

Insomecases,radiography performed laterdisclosed unacceptable disconti-nuities,necessitating anotherDR.TheAssessment Teamhasdetermined thatmostoftheproblemsinvolving NDEoperations havebeenresolved.

Recommendations

~Reference apreceding DRwhengenerating afollow-on DRforthesameweldingproblem,topreventrepeating repairsforthesamediscontinuity

~AssignEngineering todisposition DRswhentheintegrity oftheweldisinquestion~Establish thenumberoftimesagivenweldcanbereworkedpriortoremovingtheentireweld~Establish ameansbywhichthecutoutorrepairedsectionoftheweldcanreadilybeidentified forNDEpurposeslLi 10023h1.0.2.10Mechanical

-PiinConclusion TheNRCidentified problemswiththepipingQCprogramsofITTandRCI.ITTisnotinspecting forpipingattributes suchasconfiguration, locationandinterferences.

Anotherproblemindicated wasthatchecklists forpipingdidnotreflectthelatestdesigndocuments.

Corrective actionincludedafinalwalkdownprocedure intendedtoassurethatpipingattributes areinspected, andinspection checklists werechangedtoassurethatlatestdesignrevisions havebeenincorporated.

However,noattention wasgiventoconfiguration inspection orresultant reworkversusconstruction progress.

TheAssessment TeamissuedaCARforunsatisfactory conditions inthisarea.Recommendations

~Assurethatinspection plansandprocedures containtheattributes ofconfiguration, locationandinterferences tobeinspected

~Assurethattheinspection plansandprocedures determine acceptance criteria~ReviseITTinspection checklists toreflectthelaterdesignchangereferences L2.11Mechanical

-PiSurtsandRestraints

'Conclusion NRC'smainareaofconcerninthepipingareawasthatITTpipesupport/restraint deficiencies arenotbeingidentified duringconstruction acceptance inspection.

ITTinspections ofpipesupports/restraints havenotbeentotallyeffective inassuringthathardwareconformstodesignrequirements.

NMPCdidnotspecifically addresstheNRCconcerninproposedcorrective action;therefore, theresponseremainsincomplete.

TheAssessment Teamconcluded thatthequestionofadequacyofpipesupport/restraint inspections toassurehardwareconformity todesignrequirement remainsunanswered.

0-1210023h0Recommendation

~RevisetheactionplanforCATItems10-83and/orCATItem53-83toincludeanevaluation andimprovements totheinspection processforpipesupports/restraints, toassureconformity betweendesignandhardware0.2.12Mechanical

-RCIProramWeaknesses Conclusion TheNRChasidentified QA/QCprogramweaknesses forRCIwithregardtodocumentanddesigncontrol,documentation ofnonconforming conditions andprocedural timingofinspections.

Specialcriticism wasleviedbecauseoffailuretoidentifysurveillance reports,datasheets,andinspection checklists, thosechangedocuments ineffectatthetimeofinspection.

TheAssessment Teamhasreviewedthecitedconditions, observedtheRCIQCprogressinovercoming thesedifficulties, andhasconcluded thatRCIisstronglyattempting toputtogetheraviableQCprogram,butmuchworkandtrainingmuststillbeaccomplished.

\Recommendations

~Monitor,inspectandauditRCI'simplementation ofdrawingcontrolstoassurethatanengineering changelogisbeingmaintained andusedeffectively

~Establish holdpoints forinspection, establish acceptance criteriaandperforminspections inatimelymanner~Documentnonconformances ondeficiency reporting documents ratherthanthedocumentusedforinspection 0.2.13Mechanical

-BoltinConclusion NRCciteddeficiencies inmechanical equipment boltingpertaining toinade-quateverification ofbolttorquingandmissingboltwashers,indicating inadequate inspection.

Requiredtorquevalueswereappliedtoanchorboltsinsubsequent testsbySWECFQC.Asamplingplanwasdeveloped perNMPCinstruction.

However,thesamplingplaninspected boltsforjoining components ratherthananchorbolts.Consequently, theAssessment TeamhasissuedaCARwhichhasnotasyetbeenresolved.

Recommendation

~Reestablish asamplingplanforanchorboltsandclosetheAssessment Team-issued CAR0.2.10Materials/Receivin

-BatterRacksNRCwasconcerned aboutbatteryracksbeingassembled usingunmarkedmaterial, andwithinadequate drawingsandspecifications.

TheAssessment Teamhasdetermined thatthosedeficiencies havebeencorrected.

Recommendations None.L2.15Materials/Receivin

-StoraeandHousekeeinSeveralexamplesofimproperstorageandlackofprotection fromdamageanddeterioration ofsafety-related equipment intheplantandlaydownareashavebeennotedbytheNRC.TheAssessment Teamhasmadethreemonthlyreviewsoftheseconditions forverification purposesandhasconcluded thattheconditions havesomewhatimproved, butitwasnecessary toissueaCARforprograminadequacies.

Theconclusion isthatSV/ECneedstomakesignifi-cantimprovements inthesystemandfacilities.

Recommendations

~Avoidstorageinlevelslowerthanspecified

~Donotstorematerials inunassigned areas~Donotmixdissimilar materials

~Donotintermingle contractors'aterials 10023hV~Donotintermingle scrap,surplus,rejectedandacceptable materials

~Maintainanadequatesupplyofdunnage03PROGRAMMATIC ITEMS0&.1~TfRillhlEachofthefivemajorcontractors toNMP-2hasbeencitedforinadequate trainingprograms.

Thereisatendencytonotrequireadditional trainingwhenisolatedcasedeficiencies areidentified.

TheAssessment Teamhasreviewedthetrainingprogramofallfivecontractors.

Evidenceindicates thatprogresshasbeenmadeintheformofSWEC'sassignment ofanewtrainingcoordinator alongwithavastlyimprovedscheduleandcurriculum definition.

Recordsarestillsomewhatofaconcern,butitisthoughtthatprogressisbeingmadeincorrecting thisproblem.Recommendations

~Improvethebring-upfileforrecertification ofcraftsmen andphysical/

eyetestrequirements

~Continuetoimprovethetrainingprogramforquality-affected operators

~Involvemorethanjustlinepersonnel inthetrainingstructure

~Addproblemsolvingpracticetothetrainingsessionstoincreaseinterestandeffectiveness 0.3.2Communication Conclusion TheAssessment Teamdetermined thattherewasadecidedcommuncationproblembetweenNMPCandGE,whichresultedinaninterface problemaffecting GEdrawings, testinstructions, ship.shortauthorizations andworkorderpackages.

Theresultsweredelaysinimplementing requiredcorrective action.Theassignment ofawestcoastNMPCliaisonhashelpedconsiderably, alongwithprocedural modifications.

TheAssessment Teamfeelsthisproblemhasbeenovercomeandconcludes thatitisasatisfactory resolution.

10023hO.0-15Recommendations None.OD.3~InsectionConclusion AmajorportionoftheNRCconcernsaboutNMP-2operations aretheresultofinadequate inspection practices anddocumentation.

TheNRCidentified problemswithinspection scheduling thatresultedinconstruction delays.Insomecases,inspection plansandprocedures donotcontaininspection attri-butesoracceptance criteria.

SomeFQCpersonnel areunawareofprocedural requirements.

Mechanical equipment checklists lackadequateQCverification ofconfiguration, locationandattachment details.Somedonothavethelatestdesigndocumentation references.

Holdpoints onwelddatasheetshavebeenbypassednumeroustimesbyallcontractors.

Thereareseveralinstances whenfieldQCinspectors prepareddeficiency.

reportsbasedonreferenced dimen-sionsonthedrawing,ratherthantherequireddimensions.

Alloftheseinspection programdeficiencies havebeenobserved, witnessed andreviewedbytheAssessment Team.Someprogresshasbeenmadeintheformofimprovedprocedures andapplicable

training, butmuchmoreshouldbeaccomplished.

lr)Recommendations

~Ensurethatinspection checklists reflectthelatestdesigndocuments

~Assurethatinspections arescheduled andperformed inatimelymanner~Assurethatacceptance criteriaandattributes tobeinspected areincludedininspection plansandprocedures

~Assurethatmechanical equipment checklists containaplaceforverifica-tionofconfiguration, locationandattachment details~Donotbypassholdpoints forweldingoperations

~Assigninspectors inthefield 10023hOPHASEIVSAMPLINGASSESSMENT Conclusions andRecommendations relativetothePhaseIYsamplingassessment areincludedinSection2Aofthereport.