ML17054B167

Monthly Project Rept for Nine Mile Point Unit 2, Apr 1984

ML17054B167
Person / Time
Site:	Nine Mile Point
Issue date:	04/30/1984
From:	STONE & WEBSTER ENGINEERING CORP.
To:
Shared Package
ML17054B164	List: ML17054B163 ML17054B165 ML17054B166 ML17054B167 ML17054B168 ML17054B169 ML17054B170 ML18037A064 ML18037A065 ML18037A066 ML18037A067 ML18037A068 ML18037A069
References
NUDOCS 8411150121
Download: ML17054B167 (60)

Text

MONTHLY PROJECT REPORT NINE MILE POINT UN I T 2 AP R IL, 1984

~l

-. BOZ>09 50q2Z 050004i0 PDR ADQCK PDR l

0 EhfiE I. EXECUTIVE

SUMMARY

1-5 II. ENGINEERING 6-9 III. CONSTRUCTION 10 28 IV. QUALITY ASSURANCE 29 V. CONTRACT ADMINISTRATION 30 VI . START UP 8, TEST 31 40 VII. SCHEDULE Vrrr. COST 42 - 45 IX. RECORDS MANAGEMENT 46 - 50 X ~ LICENSING 51 54

EXECUTIVE SUMMARy The . 13 Milestone Schedules were 1ssued by Apr11 30th and they forecast a target fuel loading date oF October 1985. This is later than the d1rected target date of August 1985, but four months ahead of 'our oFficial 'fuel loading date. The ma)or cr1tical path identiF1ed involves resolving the complex1ties of installing whip restraints, small bore piping, conduit and electrical work in the restricted areas of the reactor, and conta1nment bu1ld1ngs. Thi s problem is rece1ving management prior1ty.

With the issue of the M1lestone Schedules, we can now say this Pro]ect is on schedule for an October 1986 commercial operat1on.

The Pro)ect 1s preliminarily assessed at 73.09'A complete. Unlike previously reported Construction percent complete, this Figure is representatSve of overall ~pro ect complet'lon Including test>ng, records and quality assurance.

Our Phase I Mork Force Reduction Plan is proceeding on schedule toward a May 15 reduction of the overall manual and non-manual work force by 1000, without signif1cant change to product1vity.

The overall performance of contractors is nearly acceptable.

However, ma)or shortcomings yet to be thoroughly addressed by this organization are as follows:

Housekeeping Housecleaning Improvement of superv1sion of work force Improved management oF work areas Adherence to schedule Intensive management efforts are being directed 1nto these areas.

Future reports will carry a section entitled "equality Performance Management Program" (OPMP). This w111 provide quality production and trending 1nformation for key 1nd1cators; together with related management actions.

The cleanup of the NRC - Cat Audit Action Plan continues essentially on schedule. No ma)or rework (other than PGCC) has been required. Independent OA verification of actions 1s underway. Our response to the NRC enforcement letter has caused some modifications to our action plans 1n the area of preventive act1on.

EXECUTIVE

SUMMARY

(Cont.)

Through April, $ 228. 5 mi 1 11on has been expended, whi ch s 1

$ 5.9 million under the Cash Forecast of $ 234.3 million'as defined in the $ 615 m1llion Cash Plan. During Apr11, $ 63.6 m1llion was expended, versus the $ 59.5 million planned.

Development of the cost control plan is not moving forward suf f iciently due to heavy commitments to the NMPC Cost staff .

This will l1ghten up in Nay and improvements are expected.

In Apr11 we welcomed, Nr. Jim Anderson, Start-up Nanager to the site. He is responsible for construction and pre-operational testing and start-up. Nr. Anderson 1 s f rom Nanagement Anal ys1s Company and brings with him extensive managerial experience in BMR Start-up.

NINE MILE POINT NUCLEAR STATION - UNIT 2 TOTAL PROSECT PERCENT COMPLETE PERCENT ITEM WEIONTEO PERCENT 1944 1945 1944 OF TOTAL PERCENT MPL I MILESTONES PROJECT OMPLETE CVII Inc n M I 0 v I I NOJIv v I

1. ENERQIZATION 41 40 V 2.40 48.1 2.39 .022

2. CONDENSATE DEMINERAUZER 2.98 4II.7 2.58 .043

3. SERVICE WATER e.oe dd.d $ .2$ .oe1

~ . STANDBY DIESEL .$ 3 $1 9 0.33 .017 Iinno S. INTEGRATED FLUSH 13.09 74.0 9.$ 9 .314 InIn

d. FLOW INDUCED VIBRATION 0.09 d4.4 0.0$ .002 ~ nrns

7. TURBINE QENEAATOA 2.70 7$ .2 2.03 ~ 051 ~ nIV

4. VENTILATION 4.4 5 47.S 3.00 ~ 093 Inno

9. INTEQAATED LEAK RATE 1.14 44A 0.53 ~ 039

~ IIlnl

10. RADWASTE SYSTEM 1.34 es.o 0.44 .Oii ~ nln 11 FUEL AECEIPT

~ .7$ 47.9 owe ~ 029 vnln

12. LOSS OF POWERIECCS .41 42.$ 0.34 ~ 024 ~ ~nn

13. FUEL LOAD .47 $ $ .5 0.2$ .011 3 lnnn

14. FUEL LOAD TO C.O. 1.10 0.0 0.0 .0 I I

SUBTOTAL 34.0>> 72.9 27.ee>> ~ 770>> I InnIInnl MRn 0 IVIES n5 II CONSTRUCTION I I

COMMODITIES I I

1. PIPINQ 9AS 77.0 7.3S 4$ 3

2. ELECTRICAL e.es sd.e 3.49 aie 3,le C 0.99 34.0 o.se .02d

4. HVAC 0.83 ed.o 0.54 .119 S. CIVIL 13.10 100.0 13.10 SUBTOTAL 31.0>> 41 44>> 25.26>> .744V III STARTUP & TEST COMMODITIES 1.HYOROS 1.0 8.4 .044 ~ 013

2. LOOP CAUBRATIONS 1.0 2.7 .027 .027

3. CONTAOL CIRCUIT VERIFICATION 1.0 1.1 .011 .011

4. INITIALEQUIPMENT OPERATION 1.0 1.$ .015 .01$

S.FLUSHES .75 0.9 .007 .007

d. PENETRATION LEAK RATE TESTS .2$ 0 0 SUBTOTAL 5.0>> 2A4>> .124>> .073>>

IV ENGINEERING

1. STRESS RECONCILIATION .$ 42 10.02 ~ 0543 .0257

2. EQUIPMENT QUALIFICATION .2$ 4 42.$ 4 ~ 1591 ~ 006$

3. UCENSINQ .seo 43.1e .3537 ~ 0090

i. SPARE PARTS .310 41.93 .1300 ~ 0100

5. BALANCE OF ENQINEEAIHQ 14.334 90.74 14.64 .0500 SUBTOTAL 20.0>> 46.70>> 1745>> ~ 101>>

V MISCELLANEOUS

1. QUALITYASSURANCE $ .0 50.0 2.50 .02$

2. AECOADS TUANOVEATO PPF 1.0 21.0 0.21 .030 SUBTOTAL 8.0>> ~ $ .2>> 2.71>> .055 TOTAL 100.0>> 73.09>> 1.76>>

IIIIVIII EÃ II II W NOTE: This table is preliminary and reflects project data available as of 5/I/84. Revised data from the Project Control Program will be included as it ls developed.

Revised Percent Com lete Ex lanation General The revised Nine Nile I I Pro) ect Percent Complete calculation basis is designed to provide a progress measurement tool which ts comprenhensive and broad based.

It 1ncludes input from milestone schedules. Construction coomodit1es, Startup and Test commodities, Engineering, equality Assurance and Records Nanagement. Th1s broad spectrum of inputs provides a balance between bulk pro)ect completion and schedule achievement, with a prioritization of work items.

The following is an overview for each category of the calculation basis.

Nilestones This category 1ncludes the l3 m1lestones recently established along w1th a milestone For Fuel load to commercial operation.

Progress will be based upon time earned on crit1cal paths.

Construction Coomodities This category 1ncludes the ma)or construction groupings of p1p1ng, electrical, instrumentat1on and control, heat1ng and ventilation and civil. Each ma)or grouping is progressed based on installation of various coomodities included w1thin the group.

Startu and Test Commodities This category includes key production based testing tasks (test commodities), piping hydros, loop calibrations, control circuit veri f ications, initial equipment operation, flushes and penetration leak rate tests. Progress w111 be based upon tasks completed.

En ineerin This category includes a miscellaneous item which reflects past Engineering tasks completed, along with essent1ally non-production related work to complete. In addition, s1gni f icant production related tasks for stress reconciliation, equipment qualification, licensing and spare parts are included. This category will earn progress based upon work completion as del1neated on the Engineering Summary Schedule Chart.

Niscellaneous This category is comprised of guality Assurance and Records Nanagement/Permanent Plant File related tasks. equality Assurance tasks will be measured by inspections completed on key commodities. Records Nanagement/Permanent Plant File tasks wi 11, be measured by documents entered into the Permanent Plant File.

Each month, the Total Pro)ect Percent Complete table will be updated, as well as an overall Percent Complete Curve showing the increment for that month and the cumulative amount through that period.

I I. ENGINEERING Overall Eng1neering and design efForts cont1nue on schedule. The 0

most notable areas include cable routing, cable t1cket1ng, set point development, responses to NRC FSAR questions, Appendix R efforts, Category II and III stress data packages, ALARA shielding, the main plant computer, emergency response fac111ty computer, and radiation mon1tor1ng computer ef forts.

Areas requiring attention relat1ve to schedule impact include:,

Of the 129 draw1ngs reported late last month, only llO rema1n to be issued. OF the 110 draw1ngs remaining, only 69 are required For construction and will be 1ssued as Follows:

Electrical - 32 drawings missing vendor 1nformation - June Structural 4 drawings scheduling requirements - May Neutron monitoring support - 4 drawings May Instrumentation - 4 drawings on hold - June Power Eng1neering 12 drawings on hold - July Berm Drawings - 13 drawings - September The As-Built stress effort remains behind schedule. A comprehensive integrated schedule is being developed to plan the completion of piping and hanger work and the engineering stress reconciliation effort, The complet1on of this work will support the Milestone Schedule target dates and includes the incorporation of the m1rror insulation installat1on and Inservice Inspection requirements. Th1s 1s expected to be available by June 1 0

The total Spare Parts Procurement Effort has been reassessed and a recovery plan schedule developed. The new schedule will have all spare parts procured by October 1984. At this stage, the procurement effort is approximately 50K complete. One Power spec1Fication, Penetration Seal Assemblies, has fallen behind schedule. A recovery plan is being developed to shorten specification preparation and bid evaluation time durations.

S1gnif icant actions have been taken 1n order to accomplish Headquarters'estaffing. In April, overtime levels were reduced to a 6X average and approximately 162 individuals have been removed from Headquarters'taf F. Approximately 25 of these indiv1duals were assigned to the Site Engineer1ng Group. The most significant area oF destaf f ing has occurred in the Engineering Mechanics Di v1s ion.

Fire detection panels will be delivered on s1te during the month of July as noted in last month's report.

In an 'effort to reduce Pro)ect Engineering and Design costs, SNEC 1s 1mplementing the following actions:

0

a. Eliminating the incorporation of ACNs, EE DCRs, N8Ds, and red line pipe support markups into Category II and III nonseismic draw1ngs'rid ",Category I'I and III seismic pipe support drawings and continuing the incorporation of ACNs and red line drawings 1nto Category II and III seismic pipe support calculations.

b. Sign1ficantly reduc1ng model maintenance to one equivalent man by July 1984 and relocat1ng the model to the s1te by mid-June to assist SEG and Construction in problem resolut1on.

c. Use of Record of Change 1n drawings will cease.

d. Revising the change Exception Restraint L1st update from weekly to monthly.

e. Reducing the level oF documentat1on of how NHP2 spec 1 f callyi complies with NRC Standard Review Plans. This effort is already partially complete and will be completed by January 1, 1985.

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III.CONSTRUCTION General Action programs have been 1nitiated by NMPC Construction to address housekeeping, housecleaning, material control, unit rate performance, and adherence to scheduled activities.

Construction completion for turnover schedules is be1ng reviewed to provide a plan for recovery of late BIP.'s.

submitted revised ,Construction organization charts for

'WEC has NMPC approval. NMPC's Construction staff will be structured to complement the SWEC 'organization. Rev1sed Contractor organization charts are due by May ll, 1984.

ITT-Grinnell Commodity performance cont1nued to improve slightly during April.

Grinnell continues to demonstrate 1mproved cooperat1on in support of the milestone schedules. They are making considerable progress in closure of NRC CAT audit findings. Rema1n1ng dev1ation reports are now priori t1zed by BIP' and will be completed at a rate supporting the turnover schedule. Ma)or act1on items are being assigned to rel1eve procedural problems and material constraints.

Commodity completion dates will be rescheduled to reflect production 1mprovements.

The loss of 21 gC personnel dur1ng this period forced the redeployment of ava1lable inspectors onto critical path act1v1t 1 es. E F f orts are underway to obtain replacement gC personnel. Nevertheless, a recovery plan has been agreed to by ITT-G, and Cat. I comnodi ties in the Conta1nment Bu1ld1ng are scheduled For essential completion over the next five months.

Plans are underway to transfer completion of Cat. II large bore hangers from 4x to 5x, to SWEC from ITT-Grinnell. This will permit .SWEC Engineering to evaluate hangers in the 4x condition, and should reduce rework.

A two-week freeze on taking pre-March '83 large bore Cat. I hangers from 4 x to 5x has been made while SEG conducted an engineering survey of hangers in this category. They will make recommendations as to the most efFicient method of cleaning up these hangers.

10

SMEC Force Account Small bore hanger installations were well ahead oF planned quant1t1es and Cat. 2 and 3 large bore hangers were slightly ahead of planned quantities..

SpeciFic act1ons have been assigned to recover what is envisioned as a temporary downturn in small bore piping performance. lt should be noted that the small departure is, in part, due to the 1984 work plan targets which spec1fied a more aggressive quantity installation target for th1s period. Performance requirements are currently being reconciled.

L. K. Comstock Cable pulling performance and condu1t installations improved during April while termination quantit1es were below planned quantities. The 1 inear Feet available for cable installation (clean work ava1lable) d1mini shed at the end of the month.

Terminations w1ll improve significantly as cable pull tickets are released. SNEC Engineering is currently expediting ticket releases.

Management action items addressed during the month included commitments to increase cable pulling backlog, improve comnodity performances through preplanning work activities, add1tion of planning engineers within LKC's stafF, and identified concerns requiring engineering resolution oF constraints by providing spec1f ication relief where possible, along w1th necessary c1 a ri f cat i 1 ons/1nterpretat 1 ons.

GE PGCC Corrective resolutions for sub-di vi s 1 onal separation def ic 1 enc 1 es are proceeding favorably. A scheduled completion forecast has been established as May 16. Of significant note is the fact that out oF 42 panels, only 4 rema1n on hold as of this writing. These are scheduled for May 29. Two additional panels were added (in terms of scope growth) to original subdivi s ional 1nvol vement.

Estimated completion is slated for June 10. These were added the first week in May.

The criteria provided for divisional separation are being implemented, and approximately 75M are resolved which will allow activities to conclude on May 16. The 1ntegrated (NMPC/SPEC/GE) team continues to drive toward resolution: grounding concerns, separation issues, timely disposition of NLD's, and clean work ava1lab111ty.

11

Johnson Controls Inc.

Instrument tubing and seismic tube support installat1ons continued to fall short of planned quantities. However, management actions taken yielded improvements at the end of Apr1l. Management action items under consideration during the month 1ncluded instrumentation scope defin1tion, material requ1rements, equality Control inspection procedures and 1nterface with related construction act1vit1es performed by others.

Particular effort has been made to establish a clear defin1tion of JCI's scope of work for planning and scheduling activities. JCI has established more aggressive supervis1on against a tight weekly commodity performance program. These efforts have formed the basis for a )oint SNEC/JCI/NMPC recovery plan which will 1mprove the installation rates to a satisfactory level in the near term.

Schneider Power Cor . HVAC During April, fire damper concerns were resolved and orders were placed to supply necessary replacements. Discussions continue on leak test requirements.

(

Construction Com letion and Release For Prelim1nar Tests The status of the Boundary Identl flcat'lon Package (BIP)

Construct1on Completion Program as of April 19, 1984 is:

ITEM SCHEDULED ACTUAL Sub BIP's Issued 329 329 Equipment Release Reports (ERR'S) Issued by Construction 92 36 Sub BIP's Accepted by SNEC AOD 92 28 During April, one (l) BIP (91.001 PROCESS COMPUTER) was accepted by SNEC AOD for preliminary test.

It should be noted that changes in SNEC's allocation oF personnel to . the Construction Completion Program, institution of revised schedules, and ad)ustments to manual staffing w111 support future construction completion goals and s igni f icant improvement is anticipated by June 198h.

Future status will be reported against the new m1lestone plan.

12

Other Contractors To Be Noted:

Contractor Remarks Zurn Industries (Cooling Tower) Remobilized for punchlist and general cleanups Tuscarora Const. (Revetment Mobil1zed this month and began Ditch) excavation act1vit1es.

John P. Bell 8 Sons, Inc. Mobilized for construction of (Sewage Plant) Sewage Treatment Plant.

Pullman Power Products Corp. Mobilized and had the1r 1st (Main Stack) concrete placement the week of April 24.

Unit Rate Im rovement Pro ram A procedure for improving construction unit rates has been drafted and implementation 1s currently in progress. Thirteen basic key commodities (i.e. SB pipe, LB pipe, etc.) and eight non-un1t rate activ1ties (i.e. scaf Folding, general clean-up, etc.) have been selected for routine monthly rev1ew. Target un1t rates and manhours are be1ng set up and progress w111 be mon1tored aga1nst these targets. The targets w111 be establ1shed as a ]oint effort by SNEC, Contractors, and NMPC. Corrective action requirements will be period1cally assigned in an efFort to bring actual un1t rates down to the target levels. Future monthly reports will address (at a summary level) the progress being made 1n this area.

13

SITE STAFFING (As of April 27, 1984)

NANUAL NON-MANUAL TOTAL Stone h Webster 1286 1392 2650 Wal sh 835 41 876 L.K. Comstock 840 99 939 ITT Grinnell 1151 437 1588 Pullman Power ll 14 S/M/S 125 130 Zurn 23 26 Gives 15 18 Grinnell Fire Prot. 16 18 Reactor Controls 63 12 75 Castaldo 9 1 10 Schneider 154 15 169 G.E. Multicraft 69 10 79 Plimouth'gmt. 12 1 13 Johnson Controls 183 85 268 Central City Roofing 4 4 R.A. Keasby 5 5 Viking Fire Prot. 4.

Randall Electric 5 0 5 H.H. Robertson 5 5 Metal Cladding 3 1 NMPC Staff 0 382 382" TOTAL MANUAL 4831 TOTAL NON-MANUAL 2579 TOTAL SITE STAFFING 7410 "Includes MAC, NYSEG 8 RGIIE

lg84 ITT PLAN VS ACT S B PIPE 120 115 110 105 0

g~ 100 I- n OD

/~a 95 80 75 0 26 52 WEEKS

+ ACT o BCKLG Production has been trending well.

No major actions requi red. Commodity essentially on track.

't 984 ITT PLAN VS ACT S B HANGERS 13 26 52 WEEKS

+ ACT a BCKLG The installation rate is below plan.

Actions have been assigned to SWEC Engineering, Construction and ITT Grinnell to generate recovery dates.

Planned targets reflect the 1984 work plan and require adjustments consistent with Milestone Schedule quantity requirements.

15 '

1984 ITT PLAN VS ACT L 8 WELDS 23.5 23 22.5 22 21.b gC On 21 20.5 20 19.5 19 18.5 13 26 52 WEEKS

+ ACT o BCKLG Installation ahead of plan. An action plan is in place for Cat. I welds on the critical path.

16

1984 ITT PLAN VS ACT L B VALVES 2.2 2.1 2.0

~cD 1.7 o

1.6 1.5 1.h 1.3 1.2 0 13

+

26 WEEKS ACT o BCKLG 52 I

., Production will improve as a result of valve releases from the warehouse which required clearing of .UNSATS.

Action in progress.

17

1984 ITT PLAN VS ACT

'L B HANGERS 19 17 4 16 i5, 15 14 12 26 39 WEEKS

+ ACT 0 BCKLG Construction commodity installation essentially on target.

Cat. I hanger recovery plan is in effect for critical path hangers.

18

1984 ITT PLAN VS ACT L B PIPE 228 226 224 222 220 218 ta4 Qc 216 I- e 214 Pj 212 210 208 206 204 202 200 13 26 39 52 WEEKS

+ ACT a BCKLG Production reflects Easter week's high absenteeism.

No major actions indentified or required except for Cat. I pipe - Action plan in place.

19

SWEC PLAN VS ACT S 8 PIPE 70 60 50

~4 Vc h0

<o Rj BD 20 10 39 52 1984

+ ACT o BCKLG Slight downturn in production.

Plan based on 1984 work plan shows aggressive installation targets for this period and may be more than milestone schedule requires. Curves to be reconciled by SMEC.

SWEC obtaining additional field engineering support.

20

SWEC PLAN VS ACT S B HANGERS 26 52 1984 PLAN + ACT o BCKLG Tracking well above plan.

21

SWEC CAT 2 Bc 3 L 8 HGRS 5

Xc 0

26 39 52 ACT x BL LB Hangers (Cat. 2 and 3) on target.

22

LKC PLAN VS ACT CONDUIT SPYS 32 31 30 28 26 25 x'U C n 24 21 20 18 17 16 0 13 26 39 52 1984

+ ACT o BCKLG Tracking above plan.

Work underway to open up clean work available (CWA).

23

LKC PLAN VS ACT CONDUIT 760 740 720 700 N

660 Idm

<0a 640 I-og 620

< 6OO 580 560 540 520 500 0 13 26 39 52 1984 PLAN + ACT a BC KLG Conduit insta11ation essentia11y on track.

No significant management action required.

LKC PLAN VS ACT CABLE TERM 280 260 240 220 200 180 4 160 XC o~

n 140 120 100 80 60 20 0

13 26 39 52 1984 PLAN + ACT O BCKLG Cable terminations are under management review.

Problems with backlog (CWA) - JCI interface problem yet to be solved and implemented.

25

LKC PLAN VS ACT CABLE PULLING

~e

<c

~+o 0=

Og ta.~ 5 13 26 52 1984 PL o ACT h BKLG Essentially on plan, but available work is very low.

Thirteen Point Action Plan in progress to strengthen clean work available (CWA).

Relief has been provided by SWEC Engineering in permitting "pulling thru" junction boxes.

26

JCI PLAN VS ACT INST. TUBING 220 210 200 190 180 170 160 Li R 150 o+

OO 130 120 110 100 90 80 70 60 50 0 13 26 39 52 1984

+ ACT o BCKLG Tubing performance is paced by tube support installation.

As this improves, tubing will improve.

See text for management actions.

Layout team will facilitate instrument locations.

0 27

JCI PLAN VS ACT SE:ISMIC SPTS.

4.6 44 4.2 3.8 3.6 3.4 n

gC 3.2 2.8 24 2.2 1.8 14 0 13 26 52 1984

+ ACT 0 BCKLG Major management action to reconcile SWEC/JCI recovery forecast (see text).

Action assigned to expedite material constraints, engineering restrictions, improve planning efforts, Layout team (interdiscipline) for instrument location will improve production.

28

IV. UALITY ASSURANCE NMPC responded to the Notice of Violation, Enclosure 2, of NRC letter dated March 20, 1984, (Enclosure 2 cited NMPC for eight

[8] alleged violations of 10 CFR 50 Appendix B). The response was submitted to the NRC on May 4, 1984. Presently, a response is being drafted for the requirements outlined in Sect1on IV ASB of the NRC order, Enclosure 4 (March 20, 1984).

\

Briefly, Section IV A requires NMPC to submit a plan For the review of (l) the CAT inspection f1ndings,- (2) the recent SALP report and (3) licensee identified deficiencies. The review is to include a thorough re-1nspection of identified defic1encies. Section IV 8 requires submittal oF a list of performance indicators to be used for measuring and monitoring construction performance of future work.

The Final Section, IV C, requires a plan to be developed for an independent third party appraisal of organ1zational responsib111ties, management" control, staffing levels, communication and operating practices. The response to this item is still under evaluation, but will be 1ssued in the near futures

2) Implementation of the new on-site audit program (gAP 19.05) began Apr11 16, 1984, w1th an aud1t of ITT Grinnell. As a result, 16 aud1t findings were issued, sumnarizing that there are program implementation and application problems w1thin ITT Grinnell. Further audits w111 cogence as scheduled.

3) The Surve 1 1 lance Program indicates that 'he overall construction activit1es at the site are being performed 1n compliance with the equality Assurance requ1rements and comm1 tments. Identi f i ed def1c1encies are being correctly documented and di sposit1oned.

4) The Construction gA Oepartment 1s presently at an effective level (45 personnel), with the poss1ble need of an additional three to six people.

5) Future reports w111 include information on the "equality Performance Management Program". It will provide quality production and trending information For key 1ndicators.

1 29

COMTRACT AONINISTRATION

l. ITT Gr1nnell ~ Lar e Bore Pi e P30lB ITT Grinnell shipped fourteen pr1or1ty spool s that construction needed by April 30. There currently are th1rty spools outstanding with anticipated site delivery oF Nay 30.

Grinnell threatened to stop shipments because of a SWEC 1nventory audit and recomnendation to deduct Funds. Grinnell is rev1ewing all backcharge claims and will consult NNPC/SWEC Nanagement regarding the cla1ms.

2. Atwood and Norrill P304K Ongo1ng and engineering problems, relating to unacceptable seismic performance oF F1fteen priority service water valves, has restrained their pro)ected mid-Apr1l del1very. Some of the seismic problems have been resolved and SNEC eng1neering has scheduled another meeting w1th AM for Nay 4 to resolve the balance of the seismic problems.

3. S are Parts - CHOC Orders Approximately 200 CHOC-issued spare parts purchase orders remain to be 1ssued. SWEC is behind schedule and a recovery plan to support system turnover has been developed. SWEC's current schedule indicates completion by the end of October 1984. Nonthly meetings have been scheduled to ensure support of f1eld activit1es.

4. ITT Grinnell P1 e Han ers P301N Grinnell stopped shipment oF pipe hangers from Apr11 2l through Nay 2 because funds were being withheld under the engineering rate claim. Gr1nnell agreed to release the material that was ready for shipment prov1ding that SWEC would work toward exped1ting resolution of the claim. SWEC plans resolution by Nay 25, pending timely response from Gr1nnell of

~

)ustif ication of charges.

30

YI. STARTUP 5 TEST The N1lestone Schedules were 1 ssued by April 30 as scheduled.

They are under detailed rev1ew, but are now being used as the prel1mina ry Pro) ect Schedule. To a id in accomp1 1shing construction turn-over comoi tments f or these schedules, a new =

Construction Completion . Turnover Group has been formed to dynamically co-ordinate and push construction to on-time systems turn-over.

Prel1minar Test Status Initial energization of the 115KV yard was completed April 29th.

Na)or emphasis continues on electrical systems.

Nechanical system testing is in progress on the Mater Treatment System. Approximately 99K of the flushing has been completed.

In1tial operation of equ1pment 1s in progress. Field I8C work 1s approximately 75K complete. Safe Fluid operat1ons, loading of resins, and acid and caustic 1s expected to take place in Nay.

The system is expected to be operable by the 'end of Nay.

The following systems are expected to be released to NNPC in early Nay:

ll5KV yard drains 115KV yard (SIP 70.001) ll5KV yard ground grid No ma)or items are expected to be open against the turnover.

l. Re lacement arts: Lack of replacement parts continues to affect the test effort. Lead times of up to 24 weeks have been quoted by some electrical vendors.

Prelim1nary meetings were held in CHOC w1th Plant Service Division personnel responsible for the effort. A tentative plan has been developed to get back on schedule.

2. Late release oF s stems From construction: Efforts continue on the development of m11 estone plans and work around in various areas to support the overall Pro)ect Schedule.

31

3. Desi n chan es: Late des1gn changes and modifications continue to impact the overall schedule and test program.

Late mod1fications to the 115KV yard precipitated a ma)or retest effort. Electrical modi Fications are expected to affect 13.8, 4160, 600 volt sw1tchgear and load centers and 125VDC Systems. Mork around plans w1ll be developed as the engineering for the modifications are developed and the test schedule modified to integrate this work into the program.

4. GE Data Base: The review of the overall GE data base associated with NSSS equipment is scheduled to start 1n Nay.

This review should alleviate problems be1ng encountered during preparat1on of the Loop Calibration Reports and Field testing of electrical and control equipment. This efFort is scheduled for completion by October.

32

5Th'F;Tup L TEST LOOP CALIBRATION APR JUL OCT SCHEDULED dAN 85 MONTH APR ACTUAL VUL OCT 0

33

CHOC llOD LCR PRODUCTION (CUN) r

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<.OIITROL CIRCUIT VERIFICATION APR JUL OCT dAN 85 APR JUL OCT tv1ONTH SCHECiULED ACTUAL 36

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APR JUL OCT dAN 85 APR JUL MONTH SCHEDULED ACTUAL 37

CoNPLETED (Cia%).

+ PRESSURE TESTS (PTs)

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PROCEDURES ISSUED

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,-'.FPF:.', ED EXC:EE=TICN ITEMS TVPI IED OVEP, BIPs E>>;CEPT 103.001 600 500 "00 200 100 0

4,1202x 5~~4 5/'1 15/1 M~~~25 6/1, 6/8 6/1 M/2M/29 7/6 7/1 37/207/27 1934 I.! EV.~ E;~C EPTIOI J lTEhA OLD E><CEPTION ITEMS 40 '

VII. SCHEDULE PROGRAN DEVELOPNENT Mork proceeded Schedules'he on development and 13 schedules were completed initial issue of the Nilestone as planned on April 30, and I

are now under detailed review by Contractors and Pro)ect Nanagement.

The balance oF the schedule program development on the area system, thirteen-week system completion and weekly work schedules proceeded as planned. An integrated staff of approximately 60 NNPC, SMEC and contractor planning engineers have supported this intensive effort over the past four weeks.

SCHEDULE CONPLIANCE Through April, work proceeded essentially in accordance with the first five milestone schedules issued For use. The Service Mater milestone fell one week behind schedule due to delays on water hammer modifications. This problem has been addressed and work around planning has been inltlated by the system completion and thirteen-week look ahead planning group.

Intensive detailed workshops have been established to assure that Nllestone 1, 4160 V Energlzation, is met. Detailed planning has been initiated For the Primary Containment and Secondary Containment to provide clearer focus on congestion problems identified during the development of the Integrated Flush Nilestone Schedule.

41

VIII. COST Variance Anal sis Approximately $ 2,210 million

• has been charged on the Total Pro)ect to date. Through April 1984, $ 228.5 million has been expended, which is

$ 5.9 million under the cash forecast of $ 234.3 million as defined in the

$ 615 million Cash Plan. During April, $ 63.6 million was expended, versus the $ 59.5 million planned.

The $ 4.1 million overrun for April is broken down as follows:

VARIANCE RENARKS SWEC Non-Manual $ 5.8 million over Due to the SWEC contract renegotiation, the elimination of the two month billing lag resulted in $ 2 7 million of this overrun. The manpower was 12 men over plan. Overtime was excessive (245, actual vs. 10.54 planned).

Cives $ 1.0 million over Due to payment of $ 1.4 million as a result of negotiated settlement oF Gives contracts.

L. K. Comstock $ .8 million over Manual headcount was 45 men over plan, plus extensive overtime (19K planned vs. 32 actual) .

ITT Grinnell $ .2 million over Que to lack of April invoice payments, the 316 manual headcount overrun, and 93 non-manual headcount overrun is not represented in this month's expenditures.

Total Construction $ 6.4 million over 42

VARIANCE REMARKS Headqrts. Labor $ 9.9 million over Due to the SPEC contract renegotiation, the elimi-nation of the 60 day b1lling lag to 30 days resulted in the 'ayment of two bills (Jan. and Feb.) scheduled to be paid in April and May.

Headqtrs. Material $ 11.5 m1111on under Lag in invoicing and delivery.

Total Headqtrs. $ 1.6 mill1on under Client Cost $ .7 million under Total Pro)ect $ 4.1 million over This figure excludes $ 2.6 million in Administrat'ion Building Expenditures chargeable to NMPl and $ 5.2 m1llion in AFUDC payments made in 1972, 1973 and 1975.

43

TOTAL RKVECT TO OATS (mammlcss Ale <<sADctpfmcs)

CASH PL(Sf 3400 370 3200

,.3 3100 vv 3000 two

)g 2 rJ g 2700 J

APRIL 26M 2 Plan AS)us I 'arsance Current 59,554 63,646 4,092 over Period 2400 Pro)ect 2,215,691 2e209eSIT 5,880 under To Date 2300 (Dollars ln Thousands) 2200 2100 1984 aporoved 561S nllllon cash forecast 1984 560 ellllon contln9ency (Thua $ 61$ os)lion 1984 cash forecast) 1985 $ 54) nilllon cash forecast 1986 5161 allison cash forecatt

Bud et Status and Ex enditure The current ROD 1 cost file is not yet loaded to reflect the April 1, 1984 reestimate. The MOO 1 file is due to be loaded by July 1, 198'.

Hence, the NOD 1 drawdown exposure of the reestimate will not be available until July.

NOTE: The Progress Ad)usted Cash Flow was not included due to the development of the new Pro)ect Nilestone Schedule, Percent Complete Tracking System, and the ongoing revisions to the Cost Control Program.

45

IX. RECORDS MANAGEMENT S1 ni f1cant Activities The revised NNP2 Records Management plan was completed and approved by the Pro)ect.

As a result of this eFfort, Records Nanagement has developed the NMP2 Records Management Concern Status Report to ident1fy and track all open Records Nanagement concerns for timely closure.

Also, a record traceability matrix 1s in the hands of all Pro)ect participants that generate records. This matrix, when completed, will 1dentify the level of traceab111ty of required records to component, system, etc. Pro)ected completion will be established shortly.

in the near term are planned I'ctions as follows:

l. Develop and issue a Pro)ect position on record rev1ew, including a policy on CAT II and III records.

r

2. Issue the revised Records Management plan and conduct training sess1ons For Pro)ect participants.

3. Review Pro)ect participants'ecords procedures to ensure compliance to revised Records Management plan.

4. Complete the record 1denti f ication Pro)ect and modi fy NMP2 required records list as requ1red.

5. Develop and issue a pro)ect Guideline for the control of the required records list.

46

Permanent Plant File Effort The following table summarizes the production levels of records receipt, preparation, filming and index'ing into the Permanent Plant File.

Total To Percent Narch A~ri 1 Date C~om 1 etc A~ct'I v I t Record Receipt and 68,907 80.178 1,909,461 24'A Preparation ( Includes Pages Pages Pages Aperture Cards)

Record Nicrof i lming 42,438 104,573 1,524,012 And Verification Pages Pages Pages

( Includes Aperture Cards)

Computer Indexed 20,304 22,554 246,858 38K Entries . Entries Entries Entries Records Indexing And 25,152 24,881 393,909 16'A" Computer Entry Documents Documents Documents Percent complete is based on an estimated 2,400,000 documents comprising 8,000,000 pages and 650,000 computer index entries required for permanent plant file entry by fuel load.

The following three pages are planning curves for record production (documents, pages and index entries).

Record Turnover The following are estimated percent completes of SMEC turnover of documentation to the NNPC Permanent Plant File.

Total Turnover of CHOC Documents 87k Complete Total Turnover of SMEC Site Documents 6X Complete Total Turnover of All SMEC Documents 17 Complete The following are estimated percent completes of NNPC Syracuse turnover of documentation to the Permanent Plant File.

Total Turnover of NNPC Syracuse Documents 70K Complete The total estimated percent complete of turnover documentation to the PPF ~19 Complete.

NMP2 PERMANENT PLANT FILE COMPUTER INDEXED ENTRIES PLANNED VS. ACTUAL CIU CCCOUOOOOOC OCVUCL 0

~ 40 C

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o 1984 1985 1986 Note 1 - Fuel Inad Note 2 - Proposed Proposed Cccmercial Operation 48

NMP2 PERMANENT PLANT FILE DOCUMENTS INDEXED PLANNED VS. ACTUAL Im 4NONoceeel *CONCL 4044

~ 400 4 F 40 4 F 00 D

4400 C

V 4400 I ~ 00 N

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I ~ 00 1440 I

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NMP2 PERMANENT PLANT FILE PAGES ENTERED PLANNED VS. ACTUAL eo eeooeceeel eccveL 0

~ 004

~ 040 oooo A

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4440 oooo N

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1983 1984 1985 1986 Note 1 - Proposed Rml Inad Note 2 - Proposed Camercial Operation 50

X. LICENSING FSAR Status A total of 787 questions relative to the FSAR and ER-OLS have been received from the NRC.* As of this period, 639 responses are completed.

Of the responses yet to be completed, 16 involved'nstrument/Control questions. Reference the table on the following page for additional information. Amendment 10 to the FSAR was sent to the NRC on April 31.

Safet Evaluation-Re ort NMPC received the partial draft NRC Safety Evaluation Report. It contains 172 open items out of an expected 450. Twenty-seven of these items were closed during April.

50.55 e REPORTS Three 50.55(e) Reports were sent to the NRC.

1) Foxboro Panel Filler Assemblies 55(e) 84-12, Interim 30-day Report

2) Single Girdei Cranes 55(e) 84-13, Interim 30-day Report

3) PGCC Separation Criteria 55(e) 84-14, Interim 30-day Report 0 Ins ection Re orts

1) I.E. Inspection Report Response 84-02 was sent to the NRC One item was reported to the NRC as a potential deficiency under 10CFR 50.55(e).

1) RCIC Turbine Exhaust Check Valve - 55(e) 84-15 51

STATUS OF RESPONSES TO BRANCH TECHNICAL ESTIONS NUHBER OF RESPONSES SCHEOULE FOR RESPONSE, CNPLETION Technical Question Questions 1984 1985 Areas Received Coryleted o~utstanutn l~h tune s~etunber ttee ER-OLS 51 49 2 2 INSTRUHENT AN0 CONTROL%'21 46 16 RADIOLOHC 470, 471 52 40 12 2 6 1 1 EFFLUENT 460 PIPINC 210 STRUCTURE/220 SEISMIC-230 92 53 52 CEOLOGY-231 EQUIPMENT HYDROLOGY-240 6EOTECH-241 QUAL. 14 10 270 271 QA 260 51 51 FIRE PROTECTION 280 PONER SYSTEM 118 8 2 430 CONT AIQlENT REACTOR PHYSICS CORF. PERFORtl 57 3 6 480, 491, 492 REACTOR SYSTBl 49 43 1 1 440 AUXILIARY SYSTN 51 1 6 410 52

MUNBER OF RESPONSES SCHEDULE FOR RESPONSE COMPLETION Technical question guestions 1984 1985 Areas Received Gag>1eted d~utstandln h~a dune S~etenner dec Other 21 5 6 100, 250, 2Sl 252, 281, 311 450, 451, 620 630, 640, 730, TOTALS 787 148 20 91 23 2 6

~ Five questions have been schedule for closure, the remaining 36 are being discussed in scheule meetings with the comnission.

53

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