IR 05000358/1982007

IE Mgt Meeting Rept 50-358/82-07 on 820504.No Noncompliance Noted.Major Areas Discussed:Status of Quality Confirmation program,820408 Immediate Action Ltr & Licensee Proposed Changes to Reinsp Program for Contractor

ML20062C679
Person / Time
Site:	Zimmer
Issue date:	07/15/1982
From:	Hunter D, Spessard R NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III)
To:
Shared Package
ML20062C655	List: IR 05000358/1982007 ML20062C653
References
50-358-82-07, 50-358-82-7, NUDOCS 8208050326
Download: ML20062C679 (6)

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r U.S. NUCLEAR REGULATORY CO,MMISSION .

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Report No. 50-358/82-07(DPRP)

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Docket No. 50-358 Nicerse N'o. CPPR-88

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Licenspe: Cincinnati Gas and Electric Company f',

< 139 East 4th Street ~ '

. Cincinnati, OH 45201

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Facility Name: ins. H. Zimmer Nuclear Poyce Station

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Meeting At: 11.' S. Nuclear Regulato: y Comnission

Region III Office ./,

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Glen Ellyn, IL 60137 -

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Meeting Conducted: May 4, I382,.. s .s u d

Report Prepared By: D.jk. Hunter, Chief

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Projects Section 2B , ,

Approved By:

kf c14 R. L. Spess rd, Director

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~7llIEIb Division of Project and !

Resident Programs i

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Meeting Summary

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Meeting on May 4, 1982 (Report No. 50-358/82-07(bPPP))

Meeting Subjects: A meeting was held at the Region III office on May 4,

< 1982, to discuss the status of the Quality Confirmation Program (QCP),

the status of the Immediate Ac:. ion Letter (IAL) issued on April 8, 1981, l

and the licensee's proposed cha6ges to the re-inspection progreat for con-l tractor inspector activities. A total of 36 NRC man-hours were involved j

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8208050326 820720 PDR ADOCK 05000358 G PDR

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DETAILS 1. Persons in Attendance Cincinnati Gas and Electric Company B. R. Sylvia, Vice President, Nuclear Operations H. R. Sager, Quality Assurance Manager M. J. Rulli, Independent Safety Review Group (Past Director, Quality Confirmation Program)

R. N. Taylor, Director, Quality Confirmation Program U. S. Nuclear Regulatory Commission Barrett, Project Inspector Schweibinz, Project Inspector Christianson, Senior Reactor Inspector Hunter, Chief, Reactor Projects Section 2B Streeter, Chief, Reactor Projects Branch 2 A. B. Davis, Deputy Regional Administrator 2. Management Meeting The licensee presented the revised submittal to the NRC, dated April 27, 1982, regarding the " Surveillance Program Per IAL to Reduce 100% Re-Inspections". The letter provided clarification of the previous letter dated March 24, 1982, concerning the sur-veillance program, as a result of discussions held onsite on April 21, 198 Initially the 100% re-inspection of contractor inspection activities would continue for 50% of the activities and surveillance would be performed by CG&E on 25% of the remaining inspection activities. Re-inspection of contractor activities in the area of pipe hangers will continue at 100%. The CG&E surveil-lance and re-inspections would be decreased within a controlled program, eventually decreasing over a period of months to approx-imately a 10% surveillance program of all activities. The program includes scheduling, tracking, review, and evaluation and increase, or decrease of re-inspection and surveillance activities based on the latest findings. The inspection and surveillance findings will be processed within the established nonconformance and corrective action program procedure The " Surveillance Program Per IAL to Reduce 100% Re-Inspection" de-scribed above is being evaluated by the NRC. Acceptance or rejection of the program will be documented in future correspondence with the licensee. This is considered an open ite (358/82-07-01) The licensee provided the status of the Quality Confirmation Pro-gram (QCP), including the scope of the program, the rework of the control room structural welds, the processing of of the Drywell 525 foot elevation structural steel welds, and the utilization of

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Certified Weld Inspectors (CWIs) in the structural steel are The overall QCP comple; ion was indicated at 55% and the individual task status was as follows:

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(1) Task I - Structural Steel: 4.5% complete with an estimated completion date of June 3,1982, except for the 525 foot elevation of the drywell. 6619 beam connections have been identified for inspectio This task was stopped on April 8, 1982, due to noted inspection inconsistencies found in the initial inspections. Certified

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Weld Inspectors (CWIs) were obtained to provide additional ex-pertise and training of all Task I inspectors, who lacked ade-quate inspection experienc The licensee has established a group to re-inspect the control room beams and to review the weld deficiencies as appropriat (2) Task II - Weld Quality: 34% complete with an estimated com-pletion date of October 31, 1982. 29,000 small bore pipe welds have been identified for revie Problems have been identified concerning welding procedures, welder qualifications, and heat number deficiencie (3) Heat Number Traceability: 55% complete with an estimated completion date of October 6, 1982. 2615 small bore piping drawings and 6792 purchase orders have been identified for review. Additionally, the large bore pipe drawings and 6792 purchase orders have been identified for revie Heat number traceability deficiencies have been noted on ap-proximately 20% of the documents reviewed. Both the essential systems and the systems important to safety will be reviewe The status of the traceability of the large bore piping has not been established due to problems with obtaining proper drawings and documentation. Additionally, numerous spool pieces have been modified in the field without the proper documentatio This problem is presently under evaluation by the license The review of 39.06 out of 6792 purchase orders has revealed deficiencies concerning Certified Material Test Reports (CMTRs)

and upgrade of non-essential material (4) Task IV - Socket Weld Fitup: 96% complete with an estimated completion date of August 13, 198 ,486 welds have been identified for revie The review of 28,277 welds to date (57,034 weld records) has revealed 457 welds which lacked evidence of disengagement

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and the welds have been radiographed. The radiographs re-vealed 73 sockets which appear to lack disengagemen (5) Task V - Radiographs: 95% complete with an estimated comple-tion date of October 4, 1982. 4134 welds (18,079 pieces of film) have been identified for review. All 4134 welds have been reviewed and inadeqaute shimming of the penetrameters was revealed in about half of the radiograph The licensee is preparing a code inquiry conentning the shimming issue.

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61 radiograph configurations have been identified for the performance of a special test to qualify the original radio-graphs. Twelve of the welds identified are inaccessible, requiring further evaluation. This is an open ite (358/82-07-02)

(6) Task VI - Cable Separation: 49% complete with an estimated completion date of July 30, 1982. The scope of this task has been expanded to include Class 1E panels, high energy pipe /

missile areas, and Appendix R (Shutdown) cable (7) Task VII - Nonconformances (NRs): 66% complete with an esti-mated completion date of August 20, 1982. 3365 surveillance reports, 185 NRs with control numbers only, 1067 voided NRs, and 470 NRs stamped inspection reports have been identifie The procedure controlling the punch lists (19-QA-20) and the procedure for performing a sampling of 300 properly closed NRs are being provide Approximately 32% of the voided NRs require additional evalu-ation by HJK/QA. The impound area for material removed during rework has been established. Additionally, 5% of the surveil-lance reports may have to be transferred to NR The licensee sent approximately 200 certified letters to former QC inspectors soliciting knowledge of voided NRs. The response from the former employees has been minima (8) Task VIII - Design Control and Verification: 90% complete with an estimated completion date of June 1, 198 (9) Task IX - Design Document Changes: 28% complete with an esti-mated completion date of January, 1983. The scope of the task has been expanded to include other site contractor Pipe supports are being removed from this task and being handled in a separate re-inspection and rework program due to the ex-tensive modification of the pipe hanger (10) Task X - Subcontractor QA Programs: 45% complete with an esti-mated completion date of July 16, 198 audits have been identified for revie i

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. The licensee provided the status of the Immediate Action Letter (IAL) items as follows:

(1) Item 1 - Quality Assurance Staffing CG&E has maintained the QA Department staffing level at about 220 person Temporary and permanent QAD personnel have been re-evaluated and certified according to the requirements of job functions and ANSI N45.2.6 - 1978 as appropriate. Functional job

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descriptions and certification were completed for Level III QAD personnel by March 5, 1982, and for Level I and II QAD personnel by March 26, 198 (2) Item 2 - Independence and Separation Between Kaiser Construction and Kaiser QA/Q Completed in 1981 with no significant chang (3) ltem 3 - QC Inspections The reduction of the 100% re-inspection of QC inspection activities conducted by contractors was discusse (See paragraph 2a)

(4) Item 4 - QC Inspection Procedures A re-review of all QC inspection procedures (38) was com-menced after completion of Level III personnel certifications (March 5, 1982). The procedure reviews were completed on April 2, 1982. The review of inspection procedures resulted in a total of 6 procedures (3 welding and 3 electrical) re-quiring procedure revisions to assure compliance with project requirements. These changes are being evaluated for impact of quality activitie The re-review of the Quality Confirmation Program (QCP) pro-cedures (16) was completed on April 20, 1982, and resulted in one procedure requiring revision. The change is being evalu-ated for impact or quality activitie The re-review of the superceded inspection procedures (69)

was begun on April 20, 1982, and is scheduled for completion in May, 1982, and the re-review of all other QA inspection procedures is scheduled for completion by June 30, 198 (5) Item 5 - Training Training and refresher training is continuing as necessar J

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(6) Item 6 - Deviations from Codes and FSAR Statements Management directives and instructions are complet FSAR changes will be made semi-annuall The FSAR has been reviewed and corrections submitte (7) Voiding of Nonconformance Reports The review of voided nonconformance reports is incorporated in QCP Task 6. This activity is being monitored by the NRC.

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(8) Item 8 - QA/QC Records Control of records has been established by the license (9) Item 9 - Conditions Adverse to Quality Review of all surveillance and nonconformance reports is being provided by QAD quality engineer (10) Item 10- Audit Program The on-site audit schedule, vendor audit schedule, and tracking systems are developed and implemente d. The need for guidance to be issued by CG&E regarding the consider-ation of identified items to be included within the QCP was discusse The licensee stated that guidance could be provided. This item is considered open and will be reviewed at a future inspectio (358/82-07-03)

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