Discusses 850125 telcon re const sample reinsp activities ...

. . _ .

Commonwealth Edison: One First Natenst Plaza, Chr/go. IthnoisO' Addr:ss Reply to: Pcst Office Box Tf'

Chicago, Illinois 60690-

$

January 15, 1985

.'-

Mr. James G. Keppler-

Regional Administrator - Region IIIU. S. Nuclear Regulatory Commission799 Roosevelt RoadGlen Ellyn, IL 60137

Subject: Braidwood Station Units 1 & 2Braidwood Construction Assessment ProgramMonthly Meeting Minutes / Monthly ReportDocket No. 50-456 and 50-457

Dear Mr. Keppler:

The fifth open briefing on the status of the BCAP effort wasprovided to the NRC on January 3, 1985 at the Mazon EOF. Forwardedherewith is a meeting summary including a copy of the visual-aidmaterial used in the presentations. The next briefing meeting isscheduled for 9:00 a.m. on February 14, 1985 at the Mazon EOF.

Also forwarded herewith for your information is the BCAPDirector's Progress Report for the month of December,1984.

Please direct any questions relating to BCAP to MikeWallace, Assistant Manager of Projects and the Braidwood ProjectManager.

ytrulyyo}rs,

J /(dA'.

David H. Smith'

Nuclear Licensing Administrator

Attachments

cc: NRC Resident Inspector - BraidwoodNRC BCAP Inspector - BraidwoodJohn Hansel - ERC :

'

N. N. Kaushal - CECO

8503150301850hf)hg.

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* Meeting Summary

BCAP NRC/ CECO /ERC Monthly Meeting

January 3, 1985 9:00 a.m.

Mazon EOF

The meeting was opened with a brief statement by A. B. Davis of the NRCRegion III giving the purpose for the meeting, that is, to discuss BCAP, it'sprogress, and the Independent Expert Overview Group's (IEOG) review of the !BCAP. Mr. Davis also stated that upon completion of the presentation by CECO '

and the IEOG, the NRC would respond to questions from the public in attendance.

The following is the agenda utilized for the remainder of the meeting.

I. Introduction

Presented by the Braidwood Project Manager to provide the majortopics of the presentation (see Enclosure 1).

II. BCAP Task Force

Presented by the BCAP Director to provide the BCAP achievements

O for the month of December (see Enclosure 2).

III. Sargent & Lundy

Presented by the Sargent & Lundy Project Director to provideSargent & Lundy's status of work (see Enclosure 3).

IV. Quality Assurance

Presented by the General Supervisor of Quality Assurance todescribe the overview activities of the CECO BCAP QA group (seeEnclosure 4).

V. IEOG Progress Report

! Presented by the Assistant Project Manager of the IBOG to describe*

l the overview activities of the 1500 (see Enclosure 5)..

| Additional items discussed during the meeting are included inEnclosure 6. The attendance for the meeting is provided in Enclosure 7. The;

meeting adjourned at 10:30 a.m.

0760J

__

-.

Enclosure 1

!BRAIDWOOD CONSTRUCTION ASSESSMENT PROGRAti

(RCAE) ;

HONTHIY NRC STAFF BRIEFING

JANUARY 3, 1984

1. INTRODUCTION MIKE WALLACE

II. BCAP TASK FORCE NINU KAUSHAL

III. DISCREPANCY EVALUATION KEN K0STAL;

IV. QUALITY ASSURANCE NEIL SMITH

I V. INDEPENDENT EXPERT OVERVIEW GROUP BOB HAM

;

i

|

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. - - . - - .

_ . _ . . _ _ . . ___ . _ _ _. - - . _ - . _ _ . . _ - - _..

,

Enclosure 2.

'

Page 1 of 7,

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BRAIDWOOD CONSTRUCTION ASSESSMENT PROGRAM (BCAP)

! MONTHLY BRIEFING||

1

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i PRESENTED TO

I

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| REGIONAL 0FFICE -- REGION III

f U. S. NUCLEAR REGULATORY COMMISSION

.

.

N. N. KAUSilALBCAP DIRECTOR

JANUARY 3, 1985

| c

. _ . _ _ _ _ - _ _ _ . _ . . - . _ . . _ . . _ _ _ , - - . _ _ _ . . - - _ . - . _ , . - . . _ , _ - - . _ . . - _ . . - - . - . _ - . . -

. _ . . . . -. - _ __ _ ._ - _ _ _

Ehclosure 2*

,- Page 2 of 7

1)DEUE?!TATION STATUS

THE PROGRAM DOCUMENT HAS BEEN UPDATED TO INCLUDE:

MINOR EDITORIAL CHANGES AND CORRECTIONS* --

TRANSMITTED DECEMBER 13, 1984

REVISED CRITERIA ON INSPECTION ATTRIBUTES FOR*

: SAMPLE EXPANSIONS (PER LETTER O' CONN 0R TO KEPPLER,

AUGUST 30, 1984) TRANSMITTED DECEMBER 13, 1984--

O ELIMINATION OF COMMONWEALTH EDIS0N DESIGNATED*

REPRESENTATIVE POSITION TRANSMITTED DECEMBER--

20, 1984

.

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O (1134D)

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. _ _ _ _ _ . - _ _ _ . . - _ _ . - . . . _ . _ _ _ . . .. . . _ _ . . _ . _ _ ._.. __ _ . . __ _ _ _ _ . _ _ _ . . _ _ _ _ . . _ _ _ _ _ _ _ _ _ _ _ _ _ . . _ _ _ __

|

|. Enclosure 2*

| Page ? of 7

PRESENTATION DUTLINE

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: DOCUMENTATION STATUS.|

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Ihclosure 2-

Page h of 7.

U)/ CSR STATUS

COMPLETED TOTAL

IDENTIFICATION OF CONSTRUCTION CATEGORIES 34 34

DESCRIPTION OF POPULATIONS 30 34

IDENTIFICATION OF ITEMS IN POPULATIONS 20 34

RAND 0M PORTION SELECTION 13 34

ENGINEERING JUDGEMENT PORTION SELECTION 0/4" 34

REINSPECTION CHECKLISTS 19 31

VERIFICATION PACKAGES 783 2,860""

REINSPECTIONS 484 2,860**

,

DOCUMENTATION REVIEW CHECKLISTS 6 34

DOCUMENTATION REVIEW PACKAGES 181 3,180**

DOCUMENTATION REVIEWS 60 3,180*"

.

WORK STARTED ON FOUR (4) POPULATIONS, O COMPLETED*

| O"" APPR0XIMATE, CURRENT ESTIMATE

|

(1134D)

- .. .-

. _ _ . . . -.

Enclosure 2.

Page 5 of 7*

.

RPSR STATUS

,

IDENTIFICATION OF CONTRACTOR PROCEDURES IS*

COMPLETE, TOTAL OF 500 PROCEDURES IDENTIFIED.

IDENTIFICATION OF CONSTRUCTION REQUIREMENTS IN FSAR*

COMPLETED

IDENTIFICATION OF PERSONNEL QUALIFICATION AND*

CERTIFICATION REQUIREMENTS COMPLETED

IDENTIFICATION OF CONSTRUCTION REQUIREMENTS IN*

APPLICABLE SPECIFICATIONS IS 85% COMPLETE

DATA BASE IS BEING FINAL REVIEWED PREPARATORY TO*

INITIATING PROCEDURE REVIEW

.

O(1134D)

<_ _ . -

._ - - .- . - . . . . . - ._ - . . . - _ _ . . . . .

Enclosure 2*

Page 6 of 7,

|.

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RSCAP STATUS

:!

ALL SCAPS ARE UNDER REVIEW*j 1

!

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SIX (6) OBSERVATIONS IDENTIFIED DURING LAST MONTH'*

) (TOTAL TO DATE - 10)

QCSSR FINAL REPORT DRAFTED AND UNDERG0ING REVIEW*

SAFETY RELATED PIPE SUPPORTS REPORT IN DRAFT STAGE*

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OCSR REINSPECTION DISCREPANCIES BY CONTRACTOR4

RECEIVED. COMPLETED

CONTRACTOR POPULATION CURRENT CURRENT'

COMSTOCK CONDUIT 69 18

CONDUIT HANGERS 1 -

CABLES 1 -

CABLE PAN HANGERS 1 -

C EQUIP, INSTALL. -

DUCT HANGERS 38 21'

PHILLIPSGETODI SB PIPING 22 12

LB PIPING 5 3

!

NEWBERG CONCRETE PLACEMENT 58 18

237 90

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__ _ _ _ . - _ _ . _ . . - _. _ . . ._ -

1-03-85Enclosure 3

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*

Page 2 of 12,2.

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CSR DISCREPANCIES BY CLASSIFICATION

CAIEGORY RECEIVED COMPLEIED1

WELDJNG - UNDERCUT, UNDERSIZE, POROSITY 40 22

DIllENSIONAL - LOCATION, LENGTH 32 23

BOLTING - LOOSE, MISSING, PATTERN 11 5

CONCRETE SURFACE DEFECT 24 6

DAMAGE - DENTS, HOLES 17 2

WRONG iMTERIAL - GAUGE, SIZE 3 2

INCOMPLETE HVAC - SEALANT, CONNECTION 3 -

Ef1BEDMENTS 21 2

HVAC FIT-UP - DUCT, HANGERS, DAMPER 1 1

- CABLE PAN HANGER FIELD FAB 1 -

INVALID - NOT DISCREPANT, NOT SAFETY RELATED 20 20

VALVE STEM ORIENTATION 10 -

SEGREGATION CODE LABELS - MISSING, ETC. 22 4

ELECTRICAL T1ECHANICAL CONNECTIONS - LOOSE 16 -

ELECTRICAL SEPARATION 7 -

MISCELLANE0US - I.D. TAGS, ETC. 9 3

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MISSI NGi WELD ON * 1=ure 3.

Page 3 of 12*

AN MVAC SUPPORT-

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BRAIDWOOD CONSTRUCTION ASSESSMENT PROGRAMOt CSR WELD M'J,

V Weld Map Cdntinuation. Braidwood Station Units 1&2( Identification No: / 5 R-T- H -O3 Project 4683/4684

Comnonwealth Edison CompanyObservation Record No: C 5 p.T- N -CD @t?-/ Safety RelatedPackage No: E S R T R -03 -043 Calculat. ion No:Component No: O 169 Revision No:Drawing No: n1. /3 2 3 . 7 Page ofInspectorSignature: 7M

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CONCRETE REIN FORCEMENT EXPOSED DUE R~

TO SURFACE DE F EC I 5 IN SLAB *c $= 3Page 5 of 12

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JAM. 3.,1985

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EME,EDMENT PLATE -

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Page 7 of 12*

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O EECTRICAL DISCREPA'1CY DISCUSSION 1y

DISCREPN4CY

FLEX C0iOUIT FITTIlES LOOSE ;

A. CABES t0T INSTALLED-

B. CABES IfSTALLED #iD Q.C. ACCEPTED

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Enclosure 3Page 8 of_12-

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OELECTRICAL DISCREPAi1CY DISCUSS 101

SEG [GATION C01 LABELS

DISCEPANCY

A. GLDulT filSSING SEGEGATIG1 COI LABEL AT EQUIRM END

B. ONLY DE HALF 0F SEGEGATION COI ON CONDUIT IC 0F ICIE

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Enclosure 3Page 11 of 12

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FIT- UP GAP AND UNDERSIZE FILLET

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Enclosure kPage 1 of 1h

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BCAP 0.A.

MONTHLf BRIEFING

N. P. SMITH

JANilARY 3. 1985

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i jj BCAP STATUS.

MEETING

for

December, 1984

INDEPEND'ENT EXPERT OVERVIEW GROUP

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January 3, 1985.

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Enclosure 5 **

Page 2 of 6|, .

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~~0 3 :: CS

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o Executive Summaryi

.

o Overview Activities.

!O o c'osec: ::ssues anc Concerns'

| o 0]en ::ssues anc; Concerns!

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Enclosure 5j Page 3 of 6' *

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EXECUTIVE SUMMARY

o BCAP OVERVIEW,

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Functioning xas designed with checks and. bal ances in pl ace.

o CSR ELEMENT ,' .

Improvement. in production of reinspection '

packages and performance of reinspections.No ' major problems are evident.

! o RPSR ELEMENT '

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Checklists nearing completion. Ac tual"

review of procedures near commencement.,

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o RSCAP ELEMENT * ' ., ,

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Determination of relevant commitments stillin-progress.

e s,

'o BCAP QA/'. . ,

Large effort on recertification of PTLt' }-inspectors.

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OVERVIEW ACTIVITIES'

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REINSPECTIONS:

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o Surfaced / closed concern on quality of

comple' a reinspection packages.!

AUDITS'

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o Monitored BCAP QA audits

DOCUMENTATION REVIEW

o Maintained reviews of BCAP observa-tions and S&L Design Significant

Eval uati ons

o Maintained reviews of chec(lists,

procedures and pl ans

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CLOSED ISSUES

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ISSUES.

1) Revision to BCAP Program Document.

' O 23 Resolution on " sold Tags" for areas; to be reinspected by BCAP inspectors

- Issued PCD-15.

3) Evaluation of CSR discrepancies to

the most adverse location within t1epopul ati on .

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OPEN ISSUES

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ISSUES_

1) Control points for reinspections.,

2) Resolution of inspector reinspection; element of RSCAP. |

|3) Resolution of documentation problems

found during small bore piping con-figurati on review.

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Enclosure 6

Items Discussed at the NRC/ CECO /ERC Meeting

January 3, 1985 9:00 a.m. ,

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During Mr. Kaushal's presentation, it was stated that under CSR )element of BCAP, three populations will require document review only. |These three populations have been identified as Post Tensioning, Cored '

Holes and Cadwelds.

Mr Kostal stated, during the Sargent & Lundy presentation, that thetesting of the silicon bronze welding process has been established and thathe would keep the NRC informed of the test results in future meetings.

A discussion of the engineering evaluation of loose flex connectionson conduit centered around the approach that Sargent & Lundy will take toanalyze these discrepancies.

Mr. Smith presented the BCAP-QA activities for the month of Decemberduring which discussion centered around the recertification of BCAP- QAinspectors and the validation method used to evaluate BCAP Task Forceinspections.

Mr. Ham stated that the 1500 had found an inspection observation withan incorrect elevation stated on it which had been reviewed by the BCAPEngineering group without finding the error. The point was made that theTask Force should not count on catching problems of this type in the

,

Engineering review process. Mr. Ham stated that he had the understanding ,that BCAP would include the highly stressed items in the Engineering

; Judgement portion of the reinspection samples under CSR. Mr. Wallace ;'stated that CECO had planned to prepare a comprehensive presentation on the

subject of adverse locations and highly stressed samples which would bepresented at the February meeting.

This concluded the presentation from CECO and IEOG to the NRC. Atthis time the NRC opened the meeting for questions to the NRC from thepublic in attendance.

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Mr. D. Cassel expressed a concern that the IBOG did not have acomplete understanding of how the highly stressed items were being included,

! in the reinspection sample under CSR.||

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The NRC stated that the lack of a response to highly-stressed-items

question during this meeting did not hurt the BCAP Program. They furtherstated that they would wait until the February meeting to address thisafter the presentation on this topic is made by Ceco.

Mr. Cassel expressed a second concern which applied to the NRC Policyallowing third party independent groups to be hired by the utility ratherthan being hired by the NRC. Mr. Cassel said he was not suggesting that

BCAP was not operating properly nor was he questioning the integrity orqualifications of the IBOG or BCAP personnel, but rather wanted to expresshis concerns.

Mr. Forney of the NRC responded to Mr. Cassel's concern and statedthat in the past when the NRC was requested to pick the independent revieworganization, they (NRC) declined to do so. He further explained that inthe case of the BCAP IEOG, Region III did review the selection.

Mr. Davis of the NRC stated that the CECO selection of the independent

review organization (IEOG) for BCAP followed specifically the policyestablished by the commissioners of the NRC.

There being no further questions the next meeting was scheduled forFebruary 14, at 9:00 a.m. The meeting was adjourned at 10:30 a.m.

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Enclosure ~1I* List of Attcndres

6

}|ME POSITION ORGANIZATION

R. A. Gardner Reactor Inspector Region III, NRC4

A. B. Davis Deputy Regional Admin. Region III, NRC

W. L. Forney Chief, Projects Section 1 A Region III, NRC

I E. Greenman Asst. Director Branch Region III, NRC

R. J. Lauer Attorney Isham, Lincoln & Beal

L. O. Del George Asst. Vice President CECO' D. Cassel Attorney PBI

C. W. Schroeder Proj. Lic. & Compliance Supt. CECO

P. A. Lau BCAP Q.A. CECO,

D. H. Smith Nuclear Licensing Adm. CECO

J. D. Deress Proj. Eng. Mgr, BY/BR CECO

V. A. Hoffman Site Manager of SWBC SWBC

W. Willoughby BCAP Technical Asst. SWEC,

' A. Scaccia Off Site Emer. Planner CECO

| D. L. Leone Projects Eng. Mgr. - BY & BR S&L

G. M. Orlov Asst. Director BCAP CECO

R. L. Byers Asst. Director BCAP CECO

K. T. Kostal Project Director Braidwood S&L

J. L. Hansel IEOG, Project Manager ERC

R. E. Ham IBOG, Asst. Project Manager ERC

B. R. Shelton Projects Eng. MGR CECO,

N. P. Smith General Supervisor - QA Ceco'

D. L. Uhamblin Proj. Const. Superintendent CECO

E. E. Vitzpatrick Asst. Manager QA CECO

T. J. Maiman Manager of Projects CECO

N. N. Kaushal BCAP Director CECO

D. L. Farrar Nuclear Licensing CECO

W. L. Chase Consultant ERC

.I. M. Johnson Nuclear Communications Ceco

M. J. Wallace Project Mgr. CECO .

R. R. Minue Nuclear Engineer State of Ill Dept.

Of Nuclear Safety

L. Ferguson Utility Engineer I.C.C.

J. Mcdonald Utility Engineer I.C.C.

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BRAIDWOOD STA? ION ;

6 BRAIDWOOD CONSTRUCTION ASSESSMENT PROGRAMREPORT PERIOD DECEMBER 1, - DECEMBER 31, 1984

1. SUlWIARY/ STATUS ;

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This is the sixth monthly Progress Report cn the Braidwood Construction ~jAssessment Program (BCAP), covering the period from December 1, through

December 31, 1984.

During this period, CSR inspections have progressed on an additional fivepopulations, bringing the total to eleven. Preparation of additionalinspection packages has continued. Document Review was also initiatedduring this period.. In the RPSR effort, accumulation of constructionrequirements from the FSAR for checklist preparation was completed. Useof Sargent & Lundy specifications for this purpose is nearingcompletion. Progress continues on all active programs in the RSCAPelement.

|As of December 31, the number of personnel assigned to the BCAP effort

1 has risen to 104. Satisfactory office and clerical support continues tobe available to the BCAP workforce.

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II. SCHEDULE ANALYSIS

The rescheduling effort was completed during this period. Resourcesrequired to support this schedule have been established and authorizedfor joining the BCAP workforce in January. Personnel additions inJanuary will include five engineers and 16 inspectors.

III. PERSONNEL AND BOUIPMENT STATUS

BCAP manpower totaled 104 as of December 31, 1984. No additionalInspectors were certified during December. Inspection personnelactivities included training, accessibility walkdowns, reinspections,document reviews and weld mapping.

The Mapper Data Base, for tracking observations and verificationpackages, is being updated regularly. Reports are issued monthly, and

i interim reports are available on an as-required basis.!

IV. BCAP BLEMENT STATUS

A. CSR STATUS

During this period, preparation of visual inspection packages andperformance of inspections continued. At this time, 11 populations

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are being inspected: HVAC Ducts, Duct Hangers, HVAC Equipment,concrete Placements, Small Bore Pipe Configurations, Large Bore PipeConfigurations, Large Bore Pipe Rigid Pipe Supports, Large Bore

,

| Mon-Rigid Pipe Supports, Small Bore Pipe Supports, Conduit andConduit Hangers.

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Large bore pipe bolted joints and small bore pipe bolted joints werecombined into a single population thus reducing the totalpopulations to 34.

In addition to the 11 populations now t*ing inspected, documentreview was started for Small Bore Pipe Configuration. Packages forthe random portion of the sample are being assembled for twoadditional reinspection populations and two additional documentreview populations. Technical review has been completed for 31 of76 checklists and instructions, of which 14 have been released forreinspection / review. Initial engineering judgment samples have beenidentified. Packages were issued and reinspection initiated forfour populations. Checklists and instructions for the remainingpopulations in each discipline are being developed.

During December, the number of certified inspectors remained at atotal of 22. This total reflects three Level III and nineteen LevelII inspectors. To date 544 inspections have been completed with 765observations recorded.

B. RPSR STATUS

During December, the RPSR group was primarily involved in developingchecklists with construction and personnel qualification /certification requirements from the FSAR and applicable Sargent &Lundy specifications. This effort consisted of breaking downreferenced codes and standards into construction requirements,preparing ten checklists to complete the total number of 29, andresolving open items. Finalization of the lists requires resolving

' two remaining open items and then conducting final reviews andsignoffs.

Contractor procedures have been assembled for review. Engineers whowill be involved are becoming familiar with the general content ofthese documents. The actual comparison of requirements inchecklists to articles in procedures is expected to commence uponfinalization of the checklists.

C. RSCAP STATUS

The nine RSCAP programs have progressed as follows:

a. Quality Control structural Steel Review - 95%.

b. Safety Related Pipe Supports - 90%.

% c. NSSS Component Supports - 70%.

(0631J)

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d. Electrical Installation Documentation Review - 55%.

e. Quality control Inspector Reinspection Program has been- placed on hold,

f. Reinspection of Safety Related Mechanical Equipment - 50%

g. HVAC Welding, configuration, stiffeners, fittings - 50%.,

h. Piping Heat Number Traceability - 50%.

i. Instrumentation Installation Verification - 30%

V. PROBLEMS /DISCREPENCY FINDINGS

A. Implementation Problems

No specific implementation problems were experienced during thisperiod.

B. Discrepancy Findings

N As reported in Section IV a total of ~165 observation reports havebeen written as of December 31, 1984. Of these the review forvalidity has been completed on 365. of these, 332 have beendetermined to be valid discrepancies and have been forwarded to

| Sargent & Lundy for review for design significance.

-ro date S&L has not identified any discrepancy as design significant. -

VI. RECOPEENDATIONS

; No specific recommendations are offered at this time.

N.M. MN. N. KaushalBCAP Director

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,.[e"""O UNITED STATES

NUCLEAR REGULATORY COMMISSION4S REGION lli

,y E 799 ROOSEVELT ROAD

h GLEN ELLYN, ILLINOIS 60137

' ' ' . . . . .February 7, 1985

MEMORANDUM FOR: Region III Files (Braidwood)

FROM: P. R. Pelke, Project Inspector, Section 1A

SUBJECT: BCAP CONFERENCE CALL ON JANUARY 25, 1985

On January 25, 1985, Messrs. Greenman, Forney, Gardner and Pelke discussedthe status of BCAP with Messrs. Wallace and Fitzpatrick during a teleconheld at the licensee's request.

Over the last few days, the licensee had received input from several sourceswhich caused them to take a midpoint look at the BCAP Construction SampleReinspection (CSR) activities. The sources included findings by ERC,the CAT team, R. Gardner and the licensee's QA organization. The midpointlook amounted to a stoppage of certain CSR inspections until the licenseecould ascertain the significance of the findings.

CSR activities were stopped in the areas of mechanical pipe supports,electrical hangers, and civil / concrete placements. Other areas of CSRwere allowed to continue. The licensee is implementing a program toaddress the problem areas including a repeat inspection of 160 mechanicalpipe supports, an assessment of the need to reinspect other BCAP populations,an assessment of the need for additional training of BCAP inspectors, andan assessment of the need to revise CSR checklists and instructions.

Q~s

P. R. PelkeProject Inspector

cc: J. G. KepplerA. B. DavisC. E. Nore11usE. G. GreenmanR. F. WarnickW. L. ForneyR. N. GardnerR. Schulz

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