ML20136G769

Forwards Util Response to Matls Verification Program Problems Identified During 850530 Meeting W/State of Il. Resolutions Include Notification of Change Rept Processing W/Inspector Overview & multi-party Agreements

ML20136G769
Person / Time
Site:	Braidwood
Issue date:	06/14/1985
From:	Little W NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III)
To:	Norelius C NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III)
Shared Package
ML20136G602	List: ML20136G598 ML20136G611 ML20136G619 ML20136G627 ML20136G639 ML20136G738 ML20136G745 ML20136G752 ML20136G769
References
FOIA-85-452 NUDOCS 8508200011
Download: ML20136G769 (15)

Text

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N :' 1 4 Q35 MEMORANDUM FOR: Charles E. Norelius, Director, Division of Reactor Projects FRCH: William S. Little, Director, Braidwood Project

SUBJECT:

PATERIALS VERIFICATION (MTV) PROGRAM BRAIDWOOD Ever though we have not had any meetings with Ceco on the MTV progrim Mwe Wallace has kepime up-to-date on progress including meetings that they have had with the State of Illinois.

The National Board essentially ccmpleted the review of the MTV problem late in May, 1985. CECO met with the State of Illinois on May 30, 1985. Attendees at the meeting in addition to CECO were: Phillips Getschow Company (PGC)

Managerrent; Illinois Department of Nuclear Safety; Illinois Boiler Board; National Board of Boiler and Pressure Vessel Inspectors;'and Authorized Nuclear Inspectors. CECO's presentation included a history of the MTV problem and related circunstances, CECO's response to the problems, the results of.the MTV program and the proposed solution to the ancmalies identified. Each ancmaly has been addressed in an NCR and the resolution of the NCRs involve three steps:

1. flonnal PGCo processing of NCR's with ANI overview;

2. Ceco and S&L evaluation and disposition of nonconforming conditions; and

3. Use of a multiparty agreement for itens that cannot be disposed of using (1) ann (2)..

CECO plans to have completed (1) and (2) and identify those itens to be handled by a multiparty agreement by June 14, 1985 and will present their results to the State of Illinois on June 17, 1985 in a meeting at the Braidwood site.

They will then meet with us in a public meeting to present their conclusion and proposed resolution on June 25, 1985. -

William S. Little, Director Braidwood Project cc: James G..Keppler E. Greenman -

J. Harrisen D. Danielson L. McGregor R. Schulz W. Kropp M. Farber P. Pelke m RIII f B508200011 850719 PDR F01A PDR Littl /q(g GARDEBS-452 C6/14/85

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%r 32AR. Secticn ~, commits to the -.SME Soller ana . 'ressure /essel Ccde,

"1 Sammer 7 'cdenda, Th e ..EME 301ler and Pressure '/ e s s e l ~:od e . sectico :::. :oc:e:t1:n v COO ,

- aninaticns, "ests, and Insoection. states to par - ' ' n -, :c e : 8 sc J inal 2,: uni nsicna and tests sna11 ce estaaltanea .o ssur; c ;. 4 3. + n c ; :n

.;ccumented instructions, procedures and dr awi ng s. " . . . 'Chec k lists 2nall be preparea. including the document numbers and revisten to which tha e:' 3mi na t i cn

r t _ -I t .7 to be performed, with space proviced fcr raccrat g esuit of enaminations, tests, and inspections. The chect I t at sha;l include ; pace -or i itgnature, initials or stamp, and date of the Manufacturer's or Installer's reoresentative and for the Inspector's signature, initi als or stamo, and date or those activities which he wi tnes ses.

he -.5ME Boiler and Pressure '/ e s s e l Code, Section ::I. _ 'b:actten c-4440, lcntral of Purchased Materials, !tems, and Servicos. statas .a 3. r . that

,1:ar e s anall be designed to orevont ': h e ase at tnccrr3ct r 1:*sc+t -

i . t e.as

tam 3 ontch have not Oceived tne "eriutred examinat. cns. 1,21-

r n _ ._ _ : s o s .

• n C' 50. Appendi: 8. Criteria XVIII, Identification and Control cf

. Mtor i ai s,  :'ar ts , and Components states in part that identification and

_;nteci nea sures small be designed to provent the use of inccrrect nr jefective .na t er i a l , parts, and components.

, to GR 50. Appendi:- 8 Criteria (. Inspection states to part. A program for insoection of activities affecting quality shall be established and e:<ecuted OL r

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-1 10-bvior f a, the organa ation. performing the' activity to verify conformances with the-documented instructions, precedures,.ano drawings ice accumplishing the activity."'

-10 CFR-30, Appendin 9. Criterion (VII. Quality Assurance Recorcs, states in

. p ar t' . ." Sufficient recorcs snail be maintained to Jurnish evidence of

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cactivitiesfaffecting quality. "he records shall include at least the following: Operating logs and the results of reviews, inspections, tests.

audits,: monitoring of work performance, and materials analysis.'

.The' CECO CA manual states in part in Section--Q.R. 10.0, Inspection. " Written-

-procedures of checklist will be used to specify and verify final inspections and tests..." " Inspection and test records will provide ocjective evidence that inspections and tests were performed in compliance'with instructions and procaduras to verify design .ino code requirements."

The' CECO QA manual cefines Quality Assurance recor,ds in G.P. i '/ . 1. Quality Assurance Records,.as documentary avidencw that design, use of correct materials, work by qualified personnel, or accomplishment of a required operation or test rcaforms to the. requirements.

The drawings for.ASME S&PV Code andLother safety related piping' required'the installation' of cpecified materials that metfthe' applicable ANSI and ASME Boiler and Pressura Vessel--Codes, and the Sargent and=Lundy design specification.. 'In addition, safetyfrelated materia 1Linstalled-must be from an approved,' qualified s..pplier,Las stipulated in/the CECO-QualityLAssurance 11anua l , Sect' ion O. R. No. 4 Procurement Document'Contrel.

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Contr3ry to'the aoova,. an adequate material control and cocumented insoection

' program'was not establisned bv the licensee to assure correct naterial

' installation. Inscection records did not exist assuring correct material installation and numerous items do not contain identification markings.

As 2. result. Items had been installed with either the quality of the item being indeterminate or items had oeen installed.that were in noncompliance with-the ASME Soiler and Pressure '/essel Code._Sargent and Lundy design-specification, crawing requirements, or CECO QA manual.

Installed material violations included:

a. Minimum wall violations.

o. Components that cannot be identified and therefore were not traceable to certificates of compliance or certified mater i al test reports and approved vendors. p l

c. :ncorrect schedules of pipe installed. g

d. Material where it.could_not be determined'if the required NDE was performed.

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e. Removals of ASME namep1ates, wF.ich ide:nti fied the: spools, without adequate-control's. .

Minimum wall violations ~is contrary co the ASME_ Code.

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Matcr,i al that is not traceable to ' the reoutr ac e::aminations or tests is contrsrv_to the CECO :2A r,a n u a i and V5ME Ccde.

Incorrect scnedules is ccntrary to drawing and design scacification eecuirements.

Indeterminate NDE is contrary to design specifications and the ASME Ccde.

Removal of ASME nameplates without adequate :antroin 1. centrary to ASME Code.

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4 BRAIDWOOD NRC CONSTRUCTION INSPECTION EXPERIENCE l

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~s BRAIDW00D SITE WORK BEGAN AUGUST'1975 .

26000 MAN-DAYS ' INSPECTION THRU 1983 CONSTRUCTION INSPECTION 91 70% UNIT.1 50% UNIT 2 PRE 0PERATIONAL TEST' PROGRAM INSPECTION < 10%

STARTUP TEST PROGRAM INSPECTION # '0%

L CONSTRUCTION SRI ASSIGNED JANUARY 1982.

OPERATIONS SRI ASSIGNED DECEMBER 1983 1

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'.5 1 SALP 1 COVERED PERIOD - - ' JULY 1979 THRU JUNE 1980 c BRAIDWOOD RATED AS AVERAGE NONCOMPLIANCE RECORD WAS DEEMED TO BE. AVERAGE

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i BRAIDWOOD WAS RATED CATEGORY 2 IN ALL AREAS EXCEPT FOR.TWO, WHICH WERE.N0T RATED' .l

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i CONCLUSION t 1 OVERALL REGULATORY PERFORMANCE WAS SATISFACTORY, HOWEVER, y

NEEDS-ATTENTION ON ASSESSING SIGNIFICANCE OF NONCONFORMANCES s

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'TWO AREAS RATED CATEGORY 3 CONCLUSION LEVEL 0F OVERSEEING QUALITY ACTIVITIES WERE GENERALLY ACCEPTABLE. WEAKNESSES IN THE AREAS OF SAFETY RELATED COMPONENTS AND QUALITY ASSURANCE WERE NOTED.

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i 1982 CONSTRUCTION ASSESSMENT TEAM FINDING i

I SIX INSPECTORS 467 MAN-HOURS AREAS REVIEWED:

QA PROGRAM INTERFACE & OVERVIEW CORRECTIVE ACTION SYSTEM DESIGN CHANGE CONTROL MATERIAL TRACEABILITY' ELECTRICAL CABLE INSTALLATION ELECTRICAL CABLE PROCUREMENT RECORDS OF CABLE INSTALLATION I

IN PROCESS INSPECTIONS QC' INSPECTOR QUALIFICATION RESULTS:

TWO ITEMS OF NONCOMPLIANCE NEITHER WAS DEEMED HIGHLY SIGNIFICANT CONCLUSION WITHIN THE AREAS INSPECTED, QA PROGRAM FOR THE BRAIDWOOD STATION APPEARED GOOD

4 1982 - 1983' INSPECTION OF MECHANICAL ERECTION EQUIPMENT TWO INSPECTORS - 328 HOURS AREAS INSPECTED:

INSPECTION AND REVIEW 0F LICENSEE'S ACTIVITIES RELATIVE TO THE INSTALLATION AND INSPECTION OF NUCLEAR STEAM SUPPLY SYSTEM AND OTHER MECHANICAL SAFETY RELATED EQUIPMENT RESULTS:

. COMMONWEALTH EDISON DID NOT ADEQUATELY DOCUMENT AND IMPLEMENT AN ACCEPTABLE PROGRAM IN ACCORDANCE WITH

, ENDIX B FOR MECHANICAL' SAFETY RELATED COMPONENTS

- 7 EXAMPLES

. COMMONWEALTH EDIS0i< d NOT REPORT PROBLEMS WITH THE MECHANICAL SAFETY RELATED COMPONENTS TO THE NRC ACCORDING TO 10 CFR 50.5S(e) 0RDER IMPOSING $100,000. FINE ISSUED JUNE 1983-STATUS:

. RETR 0 INSPECTIONS OF WORK HAVE BEEN COMPLETED

. SOME-CORRECTIVE ACTIONS STILL IN PROGRESS 9

7 CURRENT INSPECTION ISSUES i i

o INSPECTION BEGAN IN 1983-FINAL REPORT NOT YET ISSUED FOUR INSPECTORS & 300 MAN-HOURS AREAS EXAMINED:

HEATINGVENTILATIONANDAIRCONDITION.(HVAC)

SMALL BORE PIPING (SBP)

LARGEBOREPIPING(LBP)

ELECTRICAL RESULTS:

SOME PROGRAMMATIC QA WEAKNESSES WERE FOUND FOR EXAMPLE: . FIELD ROUTING SBP WITHOUT ADEQUATE IN PROCESS QUALITY CONTROL AND ENGINEERING ONE SIGNIFICANT MATTER STILL~UNDER REVIEW ADEQUACY OF DOCUMENTS RELATING TO HEAT NUMBERS TRACEABLE TO SPECIFIC SB AND LB PIPING STATUS:  ;

LICENSEE HAS MADE COMMITMENTS TO D0 REINSPECTION IN AFFECTED l

AREAS: HVAC WELD AND CONFIGURATION; HVAC DUCTS; SBP INSTALLATION l AND CONFIGURATION; DOCUMENTATION RELATIVE TO HEAT NO TRACEABILITY.(SBP&.LBP)ANDELECTRICALWORKPACKAGES

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.e-3 COMMONWEALTH EDISON COMPANY-HAS' RETAINED CONSULTANTS TO DO SPECIAL REVIEW

- CONSULTANTS REPORT DIRECTLY TO THE PRESIDENT OF COPf10NWEALTH EDIS0N COMPANY REGION III~ VIEWS THIS STEP AND OTHER' ACTIONS AS BEING POSITIVE INDICATORS f

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.Date REF: Facility A/ dah Inspection Report No(s). 6b NI a b d 6T- J~7, b -d f OR License No(s).

Thank you for your letter dated [MN .

informing us of the steps you have taken to correct the non-compliance which we brought to your attention in our letter dated I- I-N . We will examine these saatters during

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