Text

Provides Initial Response to 820901 Confirmatory Action Ltr Re Course of Action in Progress to Assure That Facility Will Be Constructed in Accordance W/Fsar.Viewgraph of Facility Project Update Encl
	ML20027D049
Person / Time
Site:	Clinton
Issue date:	10/20/1982
From:	Hall D; ILLINOIS POWER CO.
To:	James Keppler; NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III)
References
	EA-82-093, EA-82-93, U-10003, NUDOCS 8210280213
	Download: ML20027D049 (43)
	v • d • e

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ILLINDIS POWER COMPANY y;;~; n-10003 dbj CLINTON POWER STATION. P.O. BOX 678. CLINTON. ILLINOIS 61727 October 20, 1982 Mr. Jenes G. Keppler U.S. Nuclear Regulatory Commission Region III 799 Roosevelt Road Glen Ellyn, Illinois 60137 Decket 50-461

Dear Mr. "eppler:

The purpose of this letter is to acknowledge receipt of and provide initial response to your September 1,1982 Confirnatory Action Letter (CAL) concerning our course of actions in progress to assure that the Clinton Nuclear Power Station will be constructed in accordance with the Final Safety Analysis Report.

Illinois Power Company's initial response to this CAL is as follows:

1.

The requirements imposed by the traveler control group will continue in effect until such time as mutually concurred on by IPC and the NRC..

2.

The trending program previously discussed with you by Mr.

Findley of Baldwin Associates will be extended to cover all ongoing safety related work.

Included in this trending program will be:

Large bore piping and hangers, small bore piping and hangers, instrumentation piping and hangers, electrical hangers, nechanical equipment, cable tray and attachments, cable pulling, cable terminations, and con-duit.

3.

IPC Ouality Assurance will continue to conduct and document surveillance of ongoing work related to the issues of this Confirmatory Action Letter.

4.

IPC agrees that Stop Work Action Numbers 010 and 014-020 will not be lifted until the NRC has concurred in the associated recovery plans.

5.

IP intends to develop and implement an Illinois Power Improvement Program Plan (Master Management Plan); the outline of this e rrort was presented to you on September 30, 1982.

The presentation is attached for reference and record purposes.

He understand that until NRC concurrence is received on this plan, no work activities associated with Ston Ucrk Action Numbers 010 and 014-0?0 uill be per#crme'd without advance opproval bv the NRC.

8210280213 821020 76 [ t /

PDR ADOCK 05000461 7

A PDR

f.G. Kropler October 20, 1982 NRC Page 2 of 2 6.

'7e are develoning a written nian #or the overinspection

( terned "re-in snection" in CA'd o# work which was completed nrior to Julv, 1982.

The overinsnection nlan will be subnitted to vou #or conment.

The overinspection work which uas in nrogress has been stonped until such tine as the written plan is anoroved by IPC.

7 t7e are developing a written plan for verification of all of the safety related, Augmented D, and Fire Protection dacumentation placed in the vault prior to July 26, 1982.

The plan will be subnitted to your staff for review and comment.

I trust this initial resnonse satisfactorily addresses vour concerns.

'7e will continue to keen vou advised as to our orogress in achie"ing our objective.

rel" dall Vice President cc:

US URC Resident Inspector Director-Ouality Assurance Director-office of T&E, Uashinnton, DC

'0555 Illinois Department of Nuclear Sa#et"

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INTRODUCTION i

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ILLIN0IS POWER COMPANY IMPROVEMENT PROGRAM C.

RECOVERY PROGRAM - UPDATE D.

CONSTRUCTION STATUS - PROGRESS AND EXPERIENCES 1

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VERIFICATION PROGRAM j

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IPC QA INVOLVEMENT IN S&L/GE OFF-SITE ACTIVITIES j

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ILLIN0IS POWER COMPANY IMPROVEMENT PROGRAM NUCLEAR PROGRAM MANAGEMENT PLAN OBJECTIVES IMPLEMENT A CENTRAL NUCLEAR PROGRAM MANAGEMENT FUNCTION COMPLETE TRANSITION TO TOTAL NUCLEAR PROGRAM MANAGEMENT IMPROVE AND INTEGRATE MANAGEMENT SYSTEMS INCLUDE ASPECTS NECESSARY FOR TRANSITION TO AND l

SUPPORT OF OPERATING PHASE l

VERIFY ADEQUACY OF COMPLETED WORK l

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ELEMENTS FUNCTIONAL CRITERIA - IDENTIFICATION OF REQUIREMENTS WHICH MUST BE MET TO PROPERLY MANAGE, CONSTRUCT, OPERATE AND MAINTAIN A NUCLEAR POWER PLANT, E.G.,

SOME SOURCE DOCUMENTS ARE FSAR, QAM, AND CORPORATE POLICY STATEMENTS ORGANIZATION - DEFINITION OF THE ORGANIZATION AND ITS FUNCTIONS, RESPONSIBILITIES, AUTHORITIES, AND ACCOUNTABILITIES TO SUPPORT CONSTRUCTION, STARTUP ACTIVITIES, AND PLANT OPERATION

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MANAGEMENT SYSTEMS - IMPROVEMENT AND INTEGRATION OF MANAGEMENT SYSTEMS AND PROCEDURES TO PROVIDE GREATER CONTROL OF NUCLEAR ENGINEERING, PROCUREMENT, CONSTRUCTION, l

TESTING, MAINTENANCE, STARTUP, AND OPERATIONS ACTIVITIES l

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o NUCLEAR PROGRAM MANAGEMENT PLAN TASKS EVALUATE RESULTS OF THE FOLLOWING:

NRC LuiTER SEPTEMBER 1, 1982 INPO EVALUATIONS LRS AUDIT REPORT JUMA REPORT VERIFICATION TEAM RE' PORT F8M REPORT NRC AND IP AUDIT REPORTS RECOVERY PROGRAM RECOMMENDATIONS f

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ESTABLISH MANAGEMENT SYSTEM REQUIREMENTS COMPARE EXISTING MANAGEMENT SYSTEMS TO REQUIREMENTS AND. IMPLEMENT CHANGES AS NECESSARY IDENTIFY ADDITIONAL MANAGEMENT SYSTEMS REQUIRED AND IMPLEMENT REVIEW DEPARTMENTAL AND CONTRACTOR PROCEDURES FOR CONFORMANCE TO MANAGEMENT SYSTEM PROCEDURES; IP.'LEMENT CHANGES AS REQUIRED DEVELOPMILESTONESCHEDULEFORTHISEFFORJ PREPARE AND IMPLEMENT APPROPRIATE IPC DOCUMENTS WHICH CODIFY SYSTEM 1

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OBJECTIVE 2 PHASE I DEVELOP A RESOURCE LOADED ACTIVITY SCHEDULE THAT INTEGRATES ON-GOING PROJECT MANAGEMENT, ENGINEERING, AND QUALITY ACTIVITIES WITH THE RECOVERY ACTIVITIES.

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e 4

y y

4 a

E d

2 2

2 5

E a

r.

E I' 5

=

u 2

C h

p.

i 0

9 N

- ~ - -

c

l TRAVELER STATUS SMALL BORE PIPING DISCIPLINE:

TRAV. CONTROL GROUP FINAL REVIEW INITIAL IN-CONST.

ENG.

INVEN-REVIEW PROCESS ENG.

Q & TS i

HOLD HOLD TORY 9-3-82 215 6

75 610 100 76 153 2523 3658 9-14-82 177 6

82 674 99 70 97 2576 3781 i

9-17-82 216 8

103 678 100 76 67 2592 3840 9-24-82 210 9

111 638 100 65 84 2607 3824

REDEFINED INSTRUMENT AIR FROM INSTRUMENTATION To SMALL BORE (2" AND ABOVE) e

n Sf%LL BOPE PIPE

\\

4 Q

l 4

d 4

o' f

TOTAL WALKDOWNS 13 4

7 16 21 i

REJECTS 2

0 2

1 0

i

% EJEGED 152 0

282 61 0.

i TYPES OF REJECTS PROCEDURAL 0

0 0

0 TRACEABILITY 2

0 0

BENDS 0

0 1

0 0

~ !* -

CODE DATA PLATE O

O O

0 0

i i i CONFIGURATION O

O O

VALVE ORIENTATION n

n n

0 0

NCR/DR WORK 0

0 1

1 0

FLANCED CONNECTION n

n n

n 0

BILL OF MATERIAL 0

0 0

FAB. TRAV. OPEN l

o o

o O

O i

TRAVELER ATTACHMENT 0

0 0

G e

TRAVELER STATUS i

DISCIPLINE: SilALL BORE P!PE IIAllGERS TRAV. CONTROL GROUP FINAL REVIEW INITIAL IN-CONST.

ENG.

INVEN-REVIEW PROCESS ENG.

Q & TS HOLD HOLD TORY I

9-3-82 335 44 89 1506 100 23 13 383 2493 l

9-I4-82 406 60 126 "I316 88 24 63 385

2468 1

l 9-17-82 403 63 108

'I311 99 25 55 400 2464 l

9 -211-3 2 412 67 104 1299 100 35 40 413 2fi70

" REDUCTION OF TOTALS DUE To 9-3 COUNT BEING TAKEN FROM TRANSMITJALS & CARDS CAUS COUNTING.

WilEREAS Tile 9-Ill METil0D WAS IMPROVED TO A "llANDS UN IRAVELER COUNT.

,_-<a-i N

i l

&W 95

.r E,Vg'o O-G c

ym at e

o C

o o

e o

o C

C C

M E,

J 25 e

o o

o e

o o

C C

C E9 M '6 T

e o

o o

o C

q o

M M

E ~C~g 9

o e

N N

C d

c o

M M

M e

Een4~y e

e o

o o

e e

o e

c G

8 8

M E

b M

S S

=

E S

=

a 5

2 a

e e.

E g

=

~

or h

I

=

h H

M N

h g

E 5

3 5 *.

h 3

3 3

0 m

i O

n a

h Ca

=

t e

s s

a

=

g 3

s

=

=u i

1 5

g g

g e

a 25 a

o r

=

u u

e

~

g e

8

, - - = = -'

TRAVELER STATUS DISCIPLINE:

INSTRUMENTATION TRAV. CONTROL GROUP FINAL REVIEW INITIAL IN-VAULT TOTAL CONST.

ENG.

INVEN-REVIEW PROCESS ENG.

Q & TS I

^

HOLD HOLD TORY 9-3-82 195 62 10 1140 53 43 153 383 2039 9-111-82 199 71 29 1081 4fl 41 141 388 1994 9-17-82 198 78 38 1089 53 48 133 396 2033 9-24-82 201 83 97 1039 11 4 11 7 138 397 2040

REDEFINED IN9TRUMENTATION TO St1ALL BORE (2" O AND ABOVE) AND PURGED NON-SAFETY TRAVE SYSTEM COUNT

- lilCLUDES 30 TRAVELERS HISSED IN LAST WEEKS COUNT

I, INSTRlferi'ATION PIK N

s 4'

4 E

8 d

a 4

s a

a TOTAL WALKDOWNS 0

1 2

0 3

REJECTS 0

0 0

% REJECTED 0

0 0

TYPES OF REJECTS l

PROCEDURAL

'O' O

O O

O 1

TRACEABILITY 0

0 0

BENDS 0

0 0

i CODE DATA PLATE O

O O

0

,0,

SI.0PE o

0 0

'O O

1 CONFIGURATION 0

O O

VALVE ORIENTATION O

O O

o 0

NCR/DR WORK 0

0 0

0 C

FIANGED CONNECTION O

O O

O 0

SUPPORTS INSTALLED 0

0 0

Bil.I. OF HATERI AI.

0 0

0 TRAVEI.ER ATTACilHENT 0

0 0

Fall. TitAV. OPEN O

O O

i TRAVELER STATUS i

DISCIPLINE: ELECTRICAL HANGEPS-TRAV. CONTROL GROUP FINAL REVIEW INITIAL IN-CONST.

ENG.

INVEN-VAULT TOTAL REVIEW HOLD HOLD TORY

~

9-3-82 7088 50 1783 7700 500 14823 1061 11,360 3tl,365 i

9-111-82 71148 51 1621 7406 489 11291 1211 11,582 311,099 9-17-82 7387 51 1799 7252 197 11061 1135 11,732 33,9111 8

j 9-211-82 7586 49 1791 71115 498 3661 1512 11,F56 311,222

INCLUDES 6011 DELETED

- DECREASE DUE TO LOWER COUNT OF 95 TRAVELERS ON 9-14-82

- - A DISCREPANCY llAS BEEN DISCOVERED IN AC BETWEEN THOSE TRAVELERS BEING COUNTED FOR INITIAL AND Til0SE ON ENGINEERING HOLD.

A " HANDS ON" REC 00tlT IS IN PROGRESS AND Tills FIGURE WILL BE ADJUSTED ON THE NEXT ISSUE OF THIS REPORT.

l

~

a.-

I ELECTRICAL IWKER P

e e

e

{

,N d

g W

M

[

A TOTAL INSPECTIONS 131 57 67 93 130 REJECTS 16 5

8 9

19 I REJECTED 12.21 8.77 11.08 9.67 14.61 TYPES OF REJECTS LOCATION 6

2 0

1 0

CONFICURATION 4

2 8

4 15 ORIENTATION 0

0 0

ELEVATION 1

0 0

0

,,0 "Z" DIHENSION O

O O

TRACEABILITY 2

1 0

1 1

DEFECTS 2'

O 1

0 0

TOROUE O

O 1

0 0

SilARP EDCES 1

0 0

1 1

TOUCll-UP 3.

I 1

1 2

DOCUMENTATION 3

0 1

2 1

.O

l TRAVELER STATUS DISCIPLINE:

ELECTRICAL TPAY ATTACHMENT TRAV. CONTROL GROUP FINAL REVIEW INITIAL IN-CONST.

ENG.

INVEN-REVIEW PROCESS ENG.

Q&TS HOLD HOLD TORY 9-211-82 31 1

96 128 i

f e

M g

9

I i

TRKVELER STATUS DISCIPLINE:

FIFCTRICAI CARIF TRAY I

TRAV. CONTRO!. GROUP FINAL REVIEW INITIAL IN-VAULT TOTAL CONST.

ENG.

INVEN-l REVIEW PROCESS ENG*

Q & TS HOLD HOLD TORY l

l l

l 9-2LI-82 8

g l

l i

I

\\

l I

l 1

4

\\

l l

TRAVELER STATUS DISCIPLINE: MECHANICAL EQUIPMENT l

l TRAV. CONTROL GROUP FINAL REVIEW' l

INITIAL IN-CONST.

ENG.*

INVEN-REVIEW PROCESS ENG.

Q & TS HOLD HOLD TORY 9-17-82 3

2 6

114 10 22 28 262 447 9-24-82 12 4

9 69

.10 43 77 262 486 L

1

=

1 TRAVELER' STATUS DISCIPLINE: PIPING EQUIPMENT i

TRAV. CONTROL GROUP FINAL REVIEW INITIAL IN-CONST.

ENG.

INVEN-REVIEW PROCESS ENG.

Q&TS HOLD HOLD TORY 9-24-82 3

6 44 86 10 13 385 l

i I

i 1

O

l.......

l VERIFICATION PROGRAM OBJECTIVE VERIFY ADEQUACY OF INSTALLED HARDWARE AND COMPLETED DOCUMENTATION.

ELEMENTS OVERINSPECTION PROGRAM (SEPARATE FROM THE RECOVERY PROGRAM)

VAULT DOCUMENTATION VERIFICATION NOTE:

PROBLEMS IDENTIFIED IN THIS PROGRAM WILL BE ADDRESSED BY EXISTING PROJ'ECT PROCEDURES AND INSTRUCTIONS.

OVERINSPECTION PROGRAM

SUMMARY

OBJECTIVES REINSPECT A PERCENTAGE OF ACCEPTED WORK WHICH WAS PLACED IN DOCUMENT VAULT PRIOR TO JULY 26, 1982 REINSPECT A PERCENTAGE OF ON-GOING WORK.

SAMPLE SIZE THE 20% COMMITMENT REPRESENTS A GENEROUS, BUT NOT STATISTICAL, SAMPLE OF COMPLETED WORK.

TABLE I COMPARES THE NUMBER OF TRAVELERS BEING OVER-INSPECTED TO THE MIL STD 105D NUMBER.

IN ALL CASES THE 20% SAMPLE IS LARGER.

l THE 20% SELECTED ARE A RANDOM SELECTION OF THE TRAVELERS IN THE VAULT.

THE TRAVELER SELECTION IS PERFORMED BY UST.

l i

l

.s

TABLE I COMPARISON OF SAMPLE SIZE OVERINSPECTION MIL STD 105D LARGE BORE 47I 94 50 SMALL BORE 2364 472 3I5 LARGE SUPPORTS 1007 201 80 SMALL SUPPORTS 170 34 32 ELEC. HANGERS 9793 1959 200 MECHANICAL EQUIP. 175 35 32 BEAMS 825 LEVEL I44

~

~' 29 20 l

l

OVERINSPECTION s

CONDUCT OF REINSPECTION INSPECTION CHECKLISTS ORIGINALLY DEVELOPED BY U.S. TESTING CO,.

USING BA QC/TS CHECKLISTS AND VERIFICATION TEAM CHECKLISTS.

INITIAL DATA AND FINDINGS INDICATE THAT REFINEMENTS TO ADMINI-

~

STRATIVE CONTROLS ARE NECESSARY.

PROGRAM QUALITY ASSURANCE PROCEDURES ARE BEING REVISED TO INCORPORATE PROGRAM IMPROVEMENTS:

A.

PRESCRIPTIVE DETAILS OF INSPECTION CRITERIA B.

MECHANICS FOR INCREASING / DECREASING SAMPLING SIZE C.

ADMINISTRATIVE FLOW PATHS FOR DOCUMENTATION D.

DESCRIPTIONS OF SAMPLE CATEGORIES E.

CONTROLS FOR TRENDING OF RESULTS INITIAL NONCONFORMANCES HAVE BEEN DOCUMENTED ON NCR'S AND DR'S AND ARE IN PROCESS OF BEING EVALUATED BY ENGINEERING FOR SAFETY SIGNIFICANCE AND DISPOSITION.

1 i

RESULTS TO DATE FIRST STATUS REPORT DUE OCTOBER 8.

EXAMPLES OF PRELIMINARY FINDINGS 2

STRUCTURAL STEEL BLDG. - CONTROL ELEVATION 847 3

SAMPLE SIZE 20 BEAMS NUMBER OF CHECKLISTS UTILIZED (2)

UST (CL) QII.IIC22 WELDING UST (CL) OII.06CI6 BOLTED, STRUCTURAL STEEL TOTAL NUMBER OF CHARACTERISTICS EXAMINED I,355 PROBLEMS l)

COPE DIMENSIONS (TOLERANCE) 30 A) DRAWING FAILED TO CONTAIN COPE TOLERANCES 2)

WELD SIZE & PROFILE OR CONFIGURATION 105 A) DRAWINGS ONLY REQUIRED VERTICAL FILLET WELDS ON TIE TO EMBEDJ NO HORIZONTAL FILLET WELDS WERE REQUIRED.

ACTION I)

NCR WAS INITIATEDj BRISTOL STEEL AND SARGENT & LUNDY l

ARE IN PROCESS OF EVALUATING AND DISPOSITION!NG.

l 2)

NCR WAS INITIATEDJ BRISTOL STEEL AND SARGENT & LUNDY ARE IN PROCESS OF EVALUATING AND DISPOSITIONING.

I l

r-

<-r--

--4.

m----

LARGE BORE PIPING SUPPORTS BLDG, - CONTAINMENT ELEVATION 739 THRU 764 FUEL ELEVATION 745 SAMPLE SIZE 13 EACH NUMBER OF CHECKLISTS UTILIZED (2)

UST(CL) QII 02C09 OVERINSPECTION OF PIPING RUNS UST(CL) QII.IIC22 WELDING OVERINSPECTION TOTAL NUMBER OF CHARACTERISTICS EXAMINED 244 PROBLEMS I)

TRACEABILITY - WELDER ID OR RIR NUMBER 6

A)

WELDER ID AND RIR NUMBER IS INCLUDED

- IN TRAVELERJ HOWEVER WAS NOT AFFIXED TO HARDWARE.

I 2)

HARDWARE INSTALLATION-INCOMPLETE 6

A)

MISSING NUTS, BOLTS, AND PINS.

ACTION I)

DR WAS INITIATEDj IN PROCESS OF EVALUATION BY BA AND IP FOR DISPOSITION l

2)

DR WAS INITIATEDj IN PROCESS OF EVALUATION OF BA AND IP FOR DISPOSITION l

_ ~ _ _

QA INVOLVEMENT WITH A/E AND NSSS SUPPLIER IP QA AUDIT TEAMS

. PERSONNEL WILL BE SUPPLEMENTED FROM NSED OR CONSULTANTS-

. ENGINEERING DRAWINGS, CALCULATIONS, ANALYSES, EVALUATIONS, WILL BE REVIEWED IN DEPTH ON A SAMPLING. BASIS BY EXPERIENCED TECHNICAL / ENGINEERING PERSONNEL.

IP QA WILL REVIEW AND APPROVE SARGENT & LUNDY PROJECT INSTRUCTIONS PRIOR TO IMPLEMENTATION OF CLINTON-RELATED WORK.

IP - S8L REPORTING CHAINS ARE BEING MODIFIED TO ESTABLISH IP QA AS THE LEAD QA ORGANIZATI,0N.

. S&L QA WILL F.EPORT TO S&L MANAGEMENT AND IP QA.

. S&L QA ACTIVITIES WILL MORE CLOSELY BE MONITORED AND DIRECTION WILL BE GIVEN BY IP QA AS NECESSARY.

. S&L QA WILL ESTABLISH A RESIDENT QA AUDITOR AT CLINTON WHO WILL REPORT TO IP QA AND S&L QA.

IP - GE REPORTING CHAINS ARE BEING MODIFIED TO ESTABLISH IP QA AS THE LEAD SITE QUALITY ORGANIZATION.

. GE SITE QUALITY, CONTROL WILL REPORT TO GE MANAGEMENT AND IP QA.

. GE QA ACTIVITIES WILL MORE CLOSELY BE MONITORED AND DIRECTION WILL BE GIVEN BY IP QA AS NECESSARY.

4 4 e i

ILLINOIS POWER COMPANY RECOVERY 8 INTEGRATION PLAN CLINTON POWER STATION PROJECT RESOURCE EVALUATION FLOW CHART E

o OBJECTIVE !

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Dear Mr. "eppler:

SUMMARY

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