ML20024D036

Forwards Fifteenth Progress Rept Re Actions Taken to Correct Violations Noted in 800717 Notice of Violation & Addl Info.Rept Covers Activities of Quarterly Verification Program During Apr-June 1983

ML20024D036
Person / Time
Site:	Columbia
Issue date:	07/18/1983
From:	Carlisle C WASHINGTON PUBLIC POWER SUPPLY SYSTEM
To:	Martin J NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION V)
References
G-O2-83-618, NUDOCS 8308030021
Download: ML20024D036 (17)

Text

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TEC5ygg t;~w Washington Public Power Supply System P.O. Box 968. 3000GeorgeWashingtonWay Richland,Washingto 3

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- ou L~aa::;n7 July 18, 1983 Docket Number 50-397 G-02-83-618 Responds to: N/A Response required by: N/A Mr. J. B. Martin, Regional Administrator Nuclear Regulatory Commission Region V 1450 Maria Lane Suite 210 Walnut Creek, California 94596

Subject:

SUPPLY SYSTEM NUCLEAR PROJECT NO. 2 FIFTEENTH PROGRESS REPORT - 10CFR50.54(f)

Reference:

a)

G02-80-153, N.O. Strand to USNRC, "WPPSS Nuclear Project No. 2 Docket No. 50-397, EA-80-20, Notice of Violation and Additional Information -

10CFR50.54(f)," dated July 17, 1980 This is the fifteenth Progress Report on the actions we have taken in regard to our commitments in Reference a). This quarterly report covers activities of our Quality Verification Program during the period of April through June 1983.

During the month of June, two important interface meetings occurred between the Supply System and the Region V.

As a result of these meetings, the Supply System committed to perform additional veri-fication tasks.

These are discussed along with our general progress in the attachments.

9308030021 830719 PDR ADOCK 05000397 o

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O J.B. Martin Page 2 Please contact me if you have any questions on this matter.

C.S. Carlisle Program Director, WNP-2 CSC:RLK:eek Attachments:' l.

WNP-2 Project Review of Completed Safety-Related Work -

Progress Report lA. Prepurchase and Inactive Contracts -

Status Repor'c 1B. Deficiency Document Review -

Status Report cc: WS Chin, BPA - Richland, WA JA Forrest, B&R - Richland, WA PE Grady, BPA - WNP-2 JB Knotts, Jr.,.Debevoise & Liberman, Washington, DC to Lewis, EFSEC,. Olympia, WA TA Mangelsdorf, Bechtel - WNP-2 A Toth, NRC, Resident Inspector, WNP-2 JJ Verderber, B&R, Woodbury, NY t

4 ATTACHMENT 1 Page 1 of 6 FIFTEENTH PROGRESS REPORT WNP-2 PROJECT REVIEW OF COMPLETED SAFETY-RELATED WORK A.

INTRODUCTION This report covers activities of the Supply System's Quality Verification Program (QVP) during the months of April, May, and June,1983.

Reinspec-tion of welded structural steel installed by an inactive contractor, in-itiated in the previous report period, has been completed. Our special review of prepurchase and inactive (PP&IA) contracts, designed to strengthen confidence in the adequacy of work produced by those con-tractors, was initiated during this report period. However, the depth of this review was questioned by the NRC prior to completion, and additional work was initiated. The analysis of results of previously-completed re-inspections of active contractors' work continues along with preparation of reports. Our review and reporting of Engineering and QC documents for Special Tasks continues.

B.

GENERAL INFORMATION 1.

In our last progress report, an additional action of revising our commitment summary to record general information and identify changes was discussed. During this report period Letter No.

G02-83-339, dated April 18, 1983, was sent with a revised summary of commitments for your information and use.

2.

A presentation of QVP results and status was made to NRC-Region V representatives at Walnut Creek on June 7,1983, as part of a general WNP-2 Project status presentation. During the meeting several questions / issues were discussed and eight specific issues arose which were further addressed by the Supply System at a meeting with Region V representatives at the Project Site on June 21, 1983.

These are enumerated below:

(1) Hardware supplied under prepurchase contracts and work per-formed by inactive contractors may not have been sampled for reinspection.

(2) Define the logic for sample selection and distribution of the sample size for active contracts.

Include consideration of the time period when work was accomplished.

(3) Provide the basis for judging the acceptability of contractors' past work based on QVP results.

ATTACHMENT 1 Page 2 of 6 (4) Define the methodology for evaluating the results of review and reinspection in determining the need, if any, for expansion of sanple size.

(5) Describe the program for evaluation of NDE contractors' work, including the consideration of sampling vendor radiographs.

(6) Prepurchase and inactive contractors' procedures may not have been examined for technical adequacy.

(7) It would be desirable for the NRC to review the planned content of the final QVP Summary Report.

(8) The impact of the NRC Construction Assessment Team's findings should be considered in the conclusions reached by the QVP.

At the June 21 meeting, information was provided in order to satisfy issues, 2, 3, 4, and 7.

Information was also provided to describe three commitments made at the meeting to address issues 1, 5, 6, and 8.

These commitments are:

e The special PP&IA review program, originally designed to assure our document-review-oriented program was satisfactory, is being extended to address issues 1 and 6.

e An NDE reverification program is being initiated to address issue 5.

e A comparison of the Construction Assessment Team's findings with QVP results will be made and analyzed to address issue 8.

Information pertaining to all eight issues will be included in the QVP Overview Report.

3.

The schedule for completion of the QVP was also discussed in the June 21 meeting. As a result of the new commitments, our reports will be delayed beyond original plans.

Our original intent was to complete the lower-level detailed reports first, then the intermediate-level task reports, and finally the Overview Report.

Because the task reports will include summary and general information, somewhat similar to the Overview Report, we now intend to prepare the Overview Report as soon as the detailed reports are complete. This will afford the opportunity for NRC Region V review of QVP results while the specific task reports are being completed by the Supply System.

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ATTACHMENT 1 Page 3 of 6 We are developing a new schedule for completing QVP activities in a manner which provides the Overview Report, an outline of which was furnished at the June 21 meeting, to you approximately September 1.

Completion of the intermediate-level task reports will follow.

4.

Technical Audit Associates (TAA) performed an audit of the QVP on April 29,1983, and listed two " findings" in an audit report dated May 16, 1983. These findings were both related to contract 215 equipment installation reinspection, which was not part of the scope of QVP. A response explaining how equipment reinspection is covered by the Project was sent to TAA on May 26, 1983.

C.

SYSTEMS COMPLETION 1.

The following is a brief report for each of the active site contract reverification activities:

o Contract 210A, Peter Kiewit Sons - Complete, reported earlier.

o Contract 213A, Pittsburgh-Des'loines Steel - Complete, reported earlier. The R9 verification Report for this contract was reviewed by an NRC Region V representative during the report

period, o

Contract 215/250, WBG/Bechtel - The following is a summary of work during this report period:

Startup Systems - The remaining two (of thirty-seven) sys-tem reports were completed by the Bechtel Reverification Group (BRG) and approved by Bechtel QA. These documents complete the reporting of detailed hardware reinspection results for contract 215.

Previously-comtleted system reports are being updated and clarified to accommodate new information. Twenty-nine such revisions are being made and will be issued with the contract 215 Reverification Report.

Structural Steel - A report, similar to the system re-ports, for the reinspection of contract 215 structural steel construction was completed by the BRG and approved by BQA. The report records that a " low incidence of un-acceptable findings and the minor nature of the individual defects when evaluated with respect to the magnitude of welding and weld patterns specified in the design" provide a high level of confidence in the safety and quality of the contract 215 structural steel.

~

ATTACENENT 1 Page 4 of 6 Results Analysis - Analysis of all of the contract 215 reinspection results by BRG and the A N began during the report period. Based on comments received from the Re-sident Inspector, this work is being extended in detail to determine the possibility of component failure which could result from deficiencies identified in our reinspections.

Contract 215 Reverification Report - A draft of this re-port is being prepared by BRG to cover the reinspections, the system reports, related program evaluations, the structural steel report, analysis of results, and overall conclusions drawn from these activities. The majority of sections for this report are currently under review by BQA and the QVP office.

The remaining sections will be pre-pared upon completion of the results analysis.

o Contract 216, The Waldinger Corporation - Complete, reported earlier. An addendum to the reverification report has been completed, reviewed, approved, and distributed in late April.

o Contract 217, Sentry - Complete, reported earlier.

e Contract 218, Fischbach/ Lord (F/L) - The draft of the final reverification report has been reviewed by BQA and the QVP office during this report period.

In response to Region V's issue (2), discussed in General Item 2., the BRG has compiled information on the time distribution of the reinspection sample. This information is being incorporated into the report.

e Contracts 219/234, O. B. Camon - Complete, reported earlier.

In response to the Technical Audit Associates' (TAA) request to clarify coating reinspection which resulted in rework, Revision

1. 1 to these contract reports have been issued.

e Contract 220, Johnson Controls, Inc. - The final reverification report has been reviewed, approved, and issued in early May.

D.

PREPURCHASE AND INACTIVE CONTRACTS 1.

With the completion of the documentation review for contract 7426, Northwest Copper, all originally-planned documentation reviews for the prepurchase and inactive contracts are complete. Contract 7426 is being evaluated by the QVP office. The status report (Attachment IA to this report) has been updated to reflect the current prepur-chase and inactive contract review status. The overall task report is currently in progress and nearing completion.

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ATTACHMENT 1 Page 5 of 6 2.

During this report period, the contract-206 welded-structural-steel reinspection was completed and the final report of those activities is u1derway.

The review and evaluation of the follow-up contracts, contracts 206A (Peter Kiewit), 210 (Peter Kiewit) and 6426 (Wright-Schuchart-Harbor, interim contract), completed the contract 206 (Bovee-Crail) work. Reports of those activities have been prepared and are under review at the QVP office.

3.

A special review of the critical components for WNP-2 provided by prepurchase and inactive (PP&IA) contracts was initiated in this report period. A list of these critical components was developed by Project Engineering, from which a sample was selected for review.

This resulted in a sample of quality records, vendor qualifications and technical adequacy of procedures for components in 20 of the 62 PP&IA contracts being reviewed. A field verification walkdown of this hardware was performed to confirm that components were accur-ately represented by the records. Reinspection of components has not yet been accomplished.

Procedures for this program and the review results were examined by an NRC Region Y representative, and the program was discussed at the June 7 Region V meeting. As a result of our discussions, it was decided to reconsider the list of 62 PP&IA contracts for possible additional review. This additional review is being conducted in four parts, any or all of which may be applied to a particular contract or component.

The review strengthens previous assessments of work adequacy and assures attention to our commitment to address the need for reinspection even though the records indicate the hard-ware is adequate, as discussed in item B.2. of this report. The four parts of our additional verification review are:

Review of Vendor Qualifications l

Review of Technical Adequacy of Vendor Procedures Review of Quality Documentation Sample Reinspection of Installed Components (including com-ponents from the 20 contracts discussed above)

E.

SPECIAL TASKS l

1.

Deficiency Document Review - All procedure and document reviews for i

site documents identified under this task have been completed. Pro-gress continues on the preparation of reports verifying the tech-l nical adequacy of those documents which disseminated design change l

i

ATTACHMENT 1 Page 6 of 6 information to contractors. Of eight types of documents examined, the reports on two have been reviewed and approved, one report is in

- final draft following review, and drafts of the remaining five are underway. No trends of technically inadequate document dispositions have been demonstrated.

The review of contractors' internal documentation and procedures has been completed on eighteen of twenty-three contracts identified.

The review of the remaining five contracts is approximately 75%

complete and is expected to be completed early in the next report period.

- The status of our reviews is summarized in the charts comprising B to this report.

2.

Personnel Qualifications - The examination of personnel qualifica-tions reviews conducted under the Restart Program continued during this period. The results of this examination, combined with similar information from reviews performed in the QVP, will be assessed'to determine if further investigation is warranted. An analysis of the Deficiency Document Review results for engineering personnel employed by both the A/E and the construction contractors was.

completed during this period, and preparation of the report began.

3.

Receiving Inspections - No progress during this report period.

4.

Grout Evaluation Program - Complete, reported earlier.

5.

Evaluation of Concrete Quality Records - Early in the report period, it was decided that, since visual nondestructive inspection of con-crete would generally not provide enough information to determine the quality or adequacy of concrete, a special technical review of concrete quality records was initiated. Such a review was con-sidered to be useful in assessing the adequacy of concrete installed prior to the stop wJrk order of July, 1980. This review will be i

reported as a fifth special task.

The task includes:

1) A review of procedures for formwork, rein-forcing steel, and concrete placement; deficiencies identified on

. nonconformance reports and corrective action documents during the construction; and QC inspection records; 2) analysis of the review results to determine if significant problems exist; and 3) prepara-tion of a report.

The technical reviews have been completed and the analysis and re-port preparation are well underway, with completion estimated at 90%.

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. FIFTEENTH FROGtESS REPORT SUPPLY SYSTEM REVIEW OF PREPURCHASE APO INACTIVE CONTRACTS STATUS REPORT l

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t FIFTEENTH PROGtESS REPORT Attachment IB Page 1 of 4 DEFICIENCY 00CtA4ENT REVIEW StAe4ARY QC - I C(NTRACTS f, GML7i) CLASS-1 SEISMAC-1 SITE DOCLMENTATION SUBICT l-i

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-i 206* 18evee-Cra11 I Yes !

-7 l E l 7 l Yes l 7-l Yes. l 7 l Yes I 7 l Yes I 7 I Yes I 11 l E l 7 l l 206A* IPeter Kienit Sons' l Yes I 7 l Yes l 7 l E l 7 l Yes l 7 l Yes l 7 l Yes l 7 l Yes l 11 I Yes l 7 l l 207* iPittsburgh-Des Moines ! Yes l 7 I Yes l 7 I Yes I 7 l Yes l 7 l Yes ] 7 l Yes l 7 l Yes l 11 l Yes l 7 l 8 209' lLampson Inc l Yes l 7 1 D l 7 l E l 7 l Yes.l

-7 l Yes l 7 l Yes l 7 l 0 l 7 I D l 7 I I 210* lPcter Kiewit Sons' l Yes' l 7 l Yes l 7 l E l 7 l Yes l 7 l Yes j 7 l Yes I 7 l Yes i 11 l Yes l 7 l l 210A l Peter Kiewit Sons' l Yes ! 7 i B l 7 l B l 7 l Yes l 7 l E l 7 l Yes j 7 l B l 7 l B l 7 l l 6426* !Wr17t Schuchart Harbor l Yes ] 7 l E l 7 l Yes l 7 l Yes l 7 l Yes I 7 l Yes l 7 l Yes l 11 l Ves I 7 l l 213* lPJ*.tsburgh-Des t*aines ! Yes l 7 1'Yes l 7-1 E l

'7 l Yes I 7 l Yes l 7 l Yes l 7 l Yes l 11 l Yes ] 7 l

.I 2DA* !?lttstntrgh-Des Moines I Yes [ 7 l Yes l 7 I E l 7 l Yes I 7 l F l 7 l Yes l 7 l Yes l 11 l Yes l 7 l 1 215 lK:i/Roccon/CERI l Yes I 7 l Yes ]

7.

l F l 7 l Yes l 7 l F l 7 l Yes - l 7 l Ves.l 11 l Yes I 11 l l 216 lWalcinger l Yes l 7 l Yes l 7 l F l 7 I Yes. l 7 l F l 7 l Yes ! 7 I Yes l

11. l Yes j 7 l 4 217 l Sentry l Yes ! 7 l Yes l 7 ] F l 7 l Yes l 7 l F l 7 l Yes-l 7 l Yes I 11 l Yes l 7 l l 218 lFischbech/ Lord 1 Yes ! 7 l Yes l 7 l F l 7 l Yes l 7 l F.

l 7 l Yes l 7 l Yes l 11 l Yes l 7 l

! 219 l0.B. Cannon 1 Yes l 7 j Yes l 7 l F l 7 l Yes l 7 l F l 7 l Yes l 7 l Yes l 11 l Yes l 7 i

! 720 l Johnson Controls

! Yes ! 7 l Yes l 7 l F l 7 l Yes l 7 l F l 7 l Yes l 7 l Yes l 11 l Yes l 7 l l 221* l Pacific Testing Labs j Yes l 7 l E l 7 l Yes j 7 l Yes ] 7 l Yes ] 7 l Yes l 7 l Yes j 11 l Yes l 7 l l 22iA l Pacific Testing Labs l Yes l 7 l D l 7 l E l 7 l Yes l 7 l E l 7 l Yes ! 7 l D l 7 l D l 7 l l 225* IMcMillan Brothers l Yes l 7 l D l 7 l E l 7 l Yes ] 7 l Yes l 7 i Yes l 7 l Yes l 11 l Ves l'

7 l l 126 l$1ae f'ontruction Co.

I Yes l 7 l E l 7 l E l 7 l Yes l 7 i E l 7 I Yes I 7; I Yes I 7 l E l 7 l 1 233* lDF 31aw I Yes l 7 l Yes l 7 l Yes l 7 I Yes l 7 l Yes l 7 l Yes l 7,

l Yes l 11 l Yes l 7 l l 234 10.B. Cennon i Yes I 7 l Yes i 7 l E l 7 l Yes I 7 l E l 7 l Yes l 7 l Yes _ l 11 l Yes l 7 l 4 235 (CE IS4E l Yes I 7 1 0 1 7 l E I 7 I Yes l 7

I E l 7 I Ves I 7 l D l 7 1 D I 7 l I

NOTES:

LETM):

A 7 Review nat commenced PO4 - Project Change Notice i

B - No QC-I Work performed prior to 7/f6 PED - Project Engineering Directive C - Special Review NCR - Nanconformance Report 0 - tb QC-1 or UC-II/SC-1 Docunentation closed prior to 7/80 RFI - Request For In'ormation E - Document not used for this contr. set ECN - Engineering Change Notice F - Document reviewed under CAR 1475 CNR - Contractor Walver Request

• - Denotes Inactive Contract RCC - Request for Contract Change

- Pkmbers indicate action in Flow Cheat, Page 4 C.O. - Change Order

+

s

rIFTEENTH PR0 MESS REPORT Attachmen.t IB Page 2 of 4 DEFICIENCY DOCLMENT REVIEW TASK NONCONFGWANCE REPORT (NCR)

REVIEW SIM44tY 7

l l

l l 00CLMENTS l

l l

l l 10. OF Nm'S l l IDENTIFIED l CLARIFICATION l l

l (DNTRACT l CLOSED PRIM l l REQUIRING l PROVIDED -

l (DN E ACT l CONTRACTOR I

ACTIVITY l

TO 7/80 l S44R.E l CLARIFICATION l Nm CLEARED l

REMARMS 205*

l Stew-Erikson i Rx Bldg. Substructure i

31 1

4 1

0 l

~

206*

I Bovee-Crall l General Construction 1

417 l

42 1

0 l

l 206A* l Peter Kiewit Sons' l Arch. Construction 1

387 l

39 I

4 1

4 l

l l

1 1

I I

l 207' l Pittsburgh-Des l

l l

l l

l l Molnes Steel Co.

I Structural Steel l

32 l

3 1

1 l

1 1

209' I Lampson Inc.

l Rigging of Reactor Pressure l l

l l

l l

1 Vessel 1

2 1

0 1

I l

21 0*

l Peter Kiewit Sons' l Arch. Construction Al l

5 l

0 l

l 210A I Peter Kiewit Sons' l Arch. Construction' l

A I

A l

l l

6426*

I wright Schuchart i

l l

l l

l l Harbor i Interim General Construction l 113 l

11 1

0 l

l 213' l Pittsburgh-Des l

l l

l l

l l Moines Steel Co.

1 Primary Cont Vessel l

104 I

10 1

1 l

1 l

J 213A' l Pittsburgh-Des l

l l

l l

l l Moines Steel Co.

I Primary Cont Vessel Retrofit l 75 l

10 l

1 1

1 1

215 l WSH/Boecon/GERI l Mechanical Construction l

1016 l 126 l

11 l

11 I

216 l Waldinger l HVAC, Plunbing l

422 1

49 l

15 l

15 1

g 217 l Sentry l Fire Protection 1

3 l

1 1

0 l

l 218 i Fischbach/ Lord l Electrical Construction l

375 l

37 l

6 l

6 l

219 1 0.B. Camon l Special Coatings l

13 1

2 1

0 1

l 270 l M oson Controls l Instrumentation l

27 1

3 1

0 l

l 221' l Pacific Testing Labl Testing l

6 l

1 1

0 l

l 221A l Pacific Testing Labi Testing l

A l

A l

l l

225*

I McMillan Brothers l Makeup Water Pump House 1

24 l

2 l

1 l

1 l

233*

l BF Shaw l Spray Pond Alterations l

4 1

1 1

0 l

1 J

234 1 0.B. Camon I Wetwell Coating l

4 l

1 1

0 l

l 235 l CE IS&E l I&C Board Modification I

B l

B l

1 1

I I

l l

l 1

l l

l l

3096 1 347 I

40 l

40 l

• Inactive Site Contract A: No QC-1 NCR's closed prior to 7/80

.r O

^

r1FTEENTH FR0 MESS RER)RT Attachment IB Page 3 of 4 DEFICIENCY 00CtMENT REV!cW SlM4ARY QC - 1 CDNTRACTS

'l GJALITY CLASS-1 SE1941C-I l

CONTRACTm 00CtDENTAIION l

l SITE WORK ERFORIED l

StBJECT TO QVP REVIEW l

l l

INTERNAL DOCl#ENTS l

l Contract l Contractor 1 DD e Review Status +

D(D Review Status +1 1

205*

l Stewart-Erickson l Nm l Yes

, Complete None

'Completel l

206*

I Bovee-Crall l IR l Yes ICompletel Nm l Yes lCongletel 1

206e l Peter V!ewit Sons' l IR l Yes 1

6 i None 1 I

l l

207*

l Pittsburgh-Des Nolnes l

l Yes ICompletel I Yes (Congletel i

209*

l Lampson Inc l

l D lCompletel I

D ICompletel l

210' I Peter Kiewit Sons' l IR l Yes lCompletel None 1 lCompletel l 21DA l Peter Klewit Sons' l N/A l B lCompletel N/A l B lCompletel

! 6426' l Wright Schuchart Harbor l IR l Yes lCompletel IR l Yes lCongletel i

213*

I Pittsburgh-Des Nolnes l CMt I Yes lCompletel ECAR l Yes l'ongletel l

213A* 1 Pittsburgh-Des Nolnes l CAR l Yes ICompletel ECAR l Yes IOompletel l

215 i WSH/Boecon/GERI l IR l Yes lCompletel Fm l

.C ICompletel i

216 l Waldinger l DR I Yes ICongletel DR I Yes lCompletel -

l 217 1 Sently l IR l D lCompletel IR l D 10ampletel l

218 l Fischbach/ Lord l IR l Yes lCompletel IR l Yes lCompletai l

219 i O.0. Camon l IR l Yes ICompletel None l lCompletel l

2'20 l Johnson Controls 1

221*

l Pacific Testing Labs l ISR l Yes (Congletel JRN l. Yes ICompletel l

l Yes ICompletel l Yes ICompletel 1

221A 1 Pacific Testing Labs l

l D

lCompletel l D lCongletel l

225*

) NcNillan Brothers l ICL l Yes l

6 l

C#t I Yes 1

5 l

226 l Slee Construction Company l

l Yes 1

6 l

l Yes l

3 l

l 233*

l BF Shaw l

l Yes l

5 l None 1 l Complete l l

234 1 0.B. Cannon l IR l Yes ICongletel None l lCompletel i

235 l T IS&E I ml Yes 1

6 l None !

ICompletel NOTES:

LEEPO:

A - Review not courenced IR - Inspection Report 6 - No QC-1 Work performed prior to 7/80 CAR - Corrective Action Report C - Special Review DR - Deficiency Report 0 - No QC-I or QC-II/SC-1 Documentation closed prior to 7/80 ISR - Inspection Surveillance Report DD - Deficiency Document m - Quality Report O(D - DPsigi Change Document

- Denotes insetive Contract ECAR - Engineering Corrective Action Report-F m - Field Change Request

- Nunbers indicate action in Flow Chart, Page 4 JFRN - Johnson Controls Field Request Notice

+

ATTACHMENT 1B '.'

Paga 4 of 4 FIFTEENTH PROGRESS REPORT FLOW CHART FOR REVIEW 0F CONTRACTOR INTERNAL DOCUMENTATION 7

Write Report s-d b

1 2

3 4

5 6

11 1

Coordinator A Checklist --) Procedural A Logbook A Sample Decision Wri te Interface Interview Review Review Review To Report Sample r

g V

l f

Yes.

No s

A

\\

i 10 i

8 9

Decision l

Docurent Y

Review To

[

Selection Increase

_ s Sample jg

~

Iw Yes

=;-

\\

l i

l

.-