AUG 2 0 1992
Docket Nos. 50-390, 50-391License Nos. CPPR-91, CPPR-92
Tennessee Valley AuthorityATTN: Dr. Mark 0. Medford, Vice President
Nuclear Assurance, Licensing & Fuels3B Lookout Place1101 Market StreetChattanooga, TN 37402-2801
F
6{ff7
Gentlemen:
Subject: MEETING SUMMARY - WATTS BAR UNIT I
This letter refers to the meeting conducted at the Watts Bar site on July 30,1992. The purpose of the meeting was to discuss Unit 1 Completion Status,Quality Assurance Construction Records, and Plans for Training of LicensedOperators. A list of attendees and a copy of the TVA handout are enclosed.
It is our opinion that this meeting was beneficial and provided a betterunderstanding of TVA's activities. During the meeting TVA committed to providean informational submittal to the NRC to show how QA Records issues have beendispositioned by TVA. During a telephonic discussion on August 7, 1992, thesubmittal was further clarified to apply to Conduit Supports, Cable Tray Supportsand HVAC supports.
Should you have any questions concerning this letter, please contact me.
Sincerely,
(Original signed by J. Johnson)
Ellis W. Merschoff, DirectorDivision of Reactor Projects
Enclosures:1. List of Attendees2. Presentation Summary
cc w/encls: (See page 2)
,:;r 439209020268 920820PDR ADOCK 05000390A PDR -60° I Il
AUG 2 0 1920
Tennessee Valley Authority
cc w/encls:J. B. Waters, DirectorTennessee Valley AuthorityET 12A400 West Summit Hill DriveKnoxville, TN 37902
D. Nunn, Vice President,Tennessee Valley Authority3B Lookout Place1101 Market StreetChattanooga, TN 37402-2801
W. J. MuselerVice President, Watts Bar SiteTennessee Valley AuthorityP. 0. Box 800Spring City, TN 37381
M. J. Burzynski, ManagerNuclear Licensing andRegulatory Affairs
Tennessee Valley Authority3B Lookout Place1101 Market StreetChattanooga, TN 37402-2801
G. L. PannellSite Licensing ManagerWatts Bar Nuclear PlantTennessee Valley AuthorityP. 0. Box 800Spring City, TN 37381
TVA RepresentativeTennessee Valley Authority11921 Rockville PikeSuite 402Rockville, MD 20852
General CounselTennessee Valley Authority400 West Summit Hill DriveET liB 33HKnoxville, TN 37902
2
The Honorable Robert AikmanCounty ExecutiveRhea County CourthouseDayton, TN 37321
The Honorable Johnny PowellCounty ExecutiveMeigs County CourthouseDecatur, TN 37322
M. H. Mobley, DirectorDivision of Radiological HealthT.E.R.R.A. Building, 6th Floor150 9th Avenue NorthNashville, TN 37219-5404
State of Tennessee
bcc w/encls: (See page 3)
AUQ 2 0 1992
Tennessee Valley Authority
bcc w/encls:E. W. Merschoff, DRP/RIIJ. R. Johnson, DRP/RIIK. P. Barr, DRP/RIIB. M. Bordenick, OGCJ. B. Brady, DRP/RIIM. S. Callahan, GPA/CAR. D. Gibbs, DRP/RIIF. J. Hebdon, NRRG. C. Lainas, NRRH. H. Livermore, DRP/RIIP. S. Tam, NRRNRR Document Control DeskE.4 Wen c e/ evOg
NRC Resident InspectorU. S. Nuclear Regulatory CommissionRoute 2, Box 700Spring City, TN 37381e . ; ,X
*FOR PREVIOUS CONCURRENCERII:DRP RII:DRP
*RGibbs:vyg08/ /92
*KBarr08/ /92
- SEE ATTACHED COPYki RP
Wilson2 08/;0/92
3
I. P
J nson0 26/92
Tennessee Valley Authority
bcc w/encls:E. W. Merschoff, DRP/RIIJ. R. Johnson, DRP/RIIK. P. Barr, DRP/RIIB. M. Bordenick, OGCJ. B. Brady, DRP/RIIM. S. Callahan, GPA/CAR. D. Gibbs, DRP/RIIF. J. Hebdon, NRRG. C. Lainas, NRRH. H. Livermore, DRP/RIIP. S. Tam, NRRNRR Document Control Desk
NRC Resident InspectorU. S. Nuclear Regulatory CommissionRoute 2, Box 700Spring City, TN 37381
R: IDRP
b s: vygj 08/\/92
F.Barr08/ly/92
3
AUG 2 0 1992
ENCLOSURE 1
LIST OF ATTENDEES
Title
Regional Administrator, RIIDeputy Director, Division of Reactor Projects, RIIBranch Chief, Division of Reactor Projects, RIISection Chief, Division of Reactor Projects, Watts Bar, RIIResident Inspector, Watts BarEngineering Branch Chief, Division of Reactor Safety, RIIAssistant Director for Region II Reactors, NRRResident Inspector, Watts BarSenior Project Manager, NRRDirector, Division of Reactor Projects I/II, NRRSenior Resident Inspector, Watts Bar
Manager of Compliance and LicensingEngineering Manager, Watts BarVice President, Completion AssurancePresident, Generating GroupProject Manager, QA Records, Watts BarOperations Training Manager, Watts BarVice President, Nuclear Assurance, Licensing and FuelsPlant Manager, Watts BarVice President, Watts Bar SiteVice President, Nuclear ProductionSite Licensing Manager, Watts BarLicensing Manager, Browns FerryEngineering and Modifications Manager, Watts Bar
Name
NRC Staff
S .J.B.K.K.C.G.J.P.S.G.
EbneterJohnsonWilsonBarrIveyJulianLainasLaraTamVargaWalton
TVA Staff
M.W.N.0.R.S.M.D.B.D.G.B.H.
BurzynskiElliottKazanasKingsleyLewisMcNairMedfordMoodyMuselerNunnPannellSchofieldWeber
.
NR CITVA MANAGEMENT MEETING
JULY30, 1992
WA TTS BAR NUCLEAR PLANT
I -. 4
0 0
NRC/TVA MANAGEMENT MEETING
AGENDA
I. OPENING REMARKS
II. OVERVIEW
* Schedule Status
m. PLANT COMPLETION ACTIVITIES
* Ongoing Engineering/Modifications/StartupWork
* Progress in Material Area
* Status of Hold on Cable Work
IV. COMPLETION ASSURANCE
* Quality of Construction
* Quality Assurance Records
* Implementation Details for Civil CommoditySupport Records
V. TVA PLANS FOR TRAINING OF LICENSEDOPERATORS
VI. CLOSING REMARKS
VII. PLANT TOUR (1-2 HRS)
TVA/NRC - NUNN/EBNETER
TVA - MUSELER
TVA - WEBER
TVA - KAZANAS/LEWIS
TVA - MOODY
NRC/TVA
(AS REQUESTED)
WllN-
HI. OVERVIEW
WDN2
OVERVIEW
* COMPLETION SCHEDULE ISSUED (6/92)
* PROGRESS TO DATE POSITIVE(6 WEEKS)
* QUALITY INDICATORS REMAIN POSITIVE
* SOME ISSUES ARISING AS WORK INTENSIFIES
* WORKFORCE PLANNING
- Engineering Declining
- Construction Ramp-up
RWN3
JULY 27, 1992
WAITS BAR NUCLEAR PLANTCRITICAL PATH ANALYSIS
1992 1993 1994
1 | Jun Jul Aug SeD OCt NOv Dec Jan Feb Mar Apr kLy Jun Jul Aug Sep OCt NOv DeC Jan Feb
I I-
STINT Wa Ws LA
Dem '1506
V 1 0 '' baL
waa -in., n.IY
r.AU MOLL PINS
es tti asa am
LgSSO ISIA ezSS.
014l"7^ tooko
PATH C Du tssl 1011u
feA21 -L "
~I I01M I-ORIs wIma
01 ,TAIl 1 e1101CTIC
I I tTl~ -. ~ te :ISu
ai... mv..ma
tTM
-. m OV, Mw I SeVT P @ .
.l . . a .
-C._. ... .u. .
.M .. E
. . .
"ss. L"'o PdIts cILEt
r
pau~
pomp
- 0u
: :
PATH A: PRIMARY PATH TO FUEL LOADSYS 212 - (4W0V SHUTDOWN POWER) MODS RELEASE TO SU
ENG ISSUE DCN M-16440 (DIESEL GENERATOR UNDER VOLTAGETRIP)
SYS 067 - (RELEASE FOR FLUSHEMERGENCY RAW COOLING WATER)ENG ISSUE DCN 1241S (DOCUMENT REVISION FORMATERIAL PROCUREMENT)ENG ISSUE DCN M-17641 (REPLACE ROLL PINS)
PATH B: CVCS PATH TO PRIMARY HYDRO, HFT, AND FUEL LOAD* SYS 062 - (CHEMICAL & VOLUME CONTROL) MODS RELEASE TO SU
PATH C: EAGLE 21- REACTOR PROTECTION TO PRIMARY HYDRO* SYS 099 - (EAGLE 21 - REACTOR SAFEGUARD SYS
PROTECTION SYS) OPERATIONALENG ISSUE DCN 16617 (TVA INSTALLATION DOC)MODS WRITE WORKPLAN DCN M-16617-A (EAGLE 21 INSTALLATION)
O DAY FLOATPLAN: 10 NOV 92PLAN: 29 JUL92
PLAN: 04 NOV 92
PLAN: COMPLETE
PLAN: COMPLETE
O DAY FLOATPLAN: 02 DEC 92
0 DAY FLOATPLAN: 10 JAN 93
PLAN: COMPLETEPLAN: 29 JUL 92
WEN4
S., Ct SeCc.eU)
PATH A
SYS 2124906 m.Jrm
-I
MT OR7
ire2SYS 030WA
-L,
WATTS BAR UNIT ISYSTEM COMPLETION AND TURNOVER SCHEDULE
Wele Fndinu (7J76/97 STATUS =
TURNOVERMILESTONEEngineeringComplete
ModsRelease toStartup
199206/14 4
Week Endin2 107/119 10 08/02 08/09 08116 08/23 I 08/30 09/06
199209/13
- I -4. -4.- -? -? -
210261 (4)
018213240249
214216212
024025047218
059099
012032045208237
A. A- -� -4 I I I
235 (4) 044203209248
261 (4)959
210236 (5)
240
225226249
218 024217
014035
216
Start Preop 201 (1) 211 (2) 239 200 PTI(3 241 205
Testing .IjIi248SU Turnover 201(1) 202 2 244 200
to Ops038
NOTES:(1) Start Preop - SYS 201 - FCST: 08/05 -
SU Turnover - SYS 201 - FCST: 081 -
(2) Start Preop - SYS 211 - FCST: 08/07 -
(3) Start Preop - SYS 200 (PTI) - FCST: 0828 -
(4) Eng Compl - SYS 261 - FCST: 08/14 -
Mods Rel To SU-SYS 261 -FCST; 09/27-
Mods Rel To SU - SYS 235 - FCST: 08/16 -
(5) Mods Rel to SU-SYS 236-
' Turnover to Plant - SYS 959 -
MISCSLWK3
ATI 201-01 performance will not be able to re over to support turnover to OPS. Procedure redraft and approval delay start.
Turnover to OPS Sys 201 is reforecast to T/O to Plant week ending 0W30/92.
PTI 21 1-01 performance delayed by late procedure development and approval.
PTI 200-01 approval and performance will not be able to recover to support turnover to Op.. Procedure drafting and comment Incorporation delays
approval. Turnover to Ops for Sys 200 is reforecast to T/O to Plant weekending 09127/92.
DCN 18589-A is being prepared by outside vender, The Human Factor, who slipped design schedule from 07131192 to 08/14,92.
Mods reforecast due to Engineering (DCN 18589) and material delivery due 09/21/92.
Due to late identified scope (DCN 18132) on hot MCCs.
ECN 2919/DCN 19274 rollover from Sys 082. Subscope (236A) for "5th Vital Battery' to be Mods released 12/22.
Startup testing and Plant turnover scope combined with system 059 week ending0317,93.
I
w v~~~ --t - ff~w- ------------ r.x. .MMI-111111
0 9
III. PLANT COMPLETION ACTIVITIES
WDN4
ONGOING ENGINEERING/IMODIIICATIONS/STARTUP WORK
ENGINEERING
* Started destaffing of contractor
* Established- and- working- to -completion plans for Civil, Mechanical, Electrical anddeveloping. plan for closure
* Put in-place and refined SPAE process
* Engineering moving from production to closeout
* Civil IDI inspection by NRC in-process
* Hanger and Analysis Update Program (IEB 79-02/14)
- Purpose: Ensure pipe supports comply with licensing requirements
- ENG: Complete except for Integrated Interaction Program/document closure
- MODS: 45% complete
MODS
* Quality is remaining high
* Productivity is coming up from restart, both by time study and unit rate
* Unit rates are coming into planned band
* Mods management is working with craft force to remove remaining barriers to productivity
* Some isolated cases of problems
STARTUP
* Program is producing results
* Region has been conducting site reviews
* Working on resolution of Chapter 14 FSAR RFI from NRR
* Working at measured pace on acceptance tests and incorporating feedback into programs
WN-7
RIP - REPLACEMENT ITEMS PROGRAM
* DESCRIPTION:
Provide assurance that spare and replacement parts procured as commercial grade items(CGI) have not degraded the host equipments capability to perform its safety-relatedfunctions, non-negated environmental and/or seismic qualifications.
* STATUS
* Completed 50.49 Review -* Completed ASME III piece parts -* Completed construction ledgers cards -* Completed SSEA review -
* Completed procedures, training,CAP Revision
* Completed construction installed items
No failuresNo failuresNo failuresNo failures (some items replacement
for economic reasons)Procedure and training implemented,
awaiting SER on CAP revisionNo failures
* WORKING
Maintenance installed items -Program support and closure work -QA Level III material -
73% (no failures to date)60%50% (no failures to date)
* SUMMAlRY:
* RIP project 85% complete scheduled finish 12/28/92* No impact to system testing anticipated
RN4
MWP - MATERIALS EMPROVEMENT PROJECT
* GOAL:
* Resolve material concerns
* Evaluation of QA materials
* Facility upgrades
* Control and reduction of backlogs
* STATUS:
* Communication issues - 100%* Management issues -
95%* Techncal/PrOgrammatic
issues - 80%* Material segregation - 78%* Sanitization of material
56%
* SUMMARY:
MW4 project 79% complete, scheduled finish 12/92
* 0
STATUS OF HOLD ON CABLE WORK
02/05/92 - 04/15/92
06/02/92-06/10/92
06/23/92-06/25/92
07/07/92
07/20/92
07/23/92
CBLPUL computer program problems PER 92-0031111-W-92-001
Max Pull Tension problems with additional manual calculation errors. PER 92-0137reviewed 105 calcs with two errors. PER 92-0137 was upgraded to SCAR 92-0137
.-because of repetitive problem.
QA issued FIR 92-0047 on QC problems with Min Training Radius (MTR) and Max Pull
Radius (MPR). Management issued temporary hold till lessons learned and QE review
added to field calc.
Four additional calc problems identified, administrative hold placed on calc activities until
II-W-92-011 is complete.
II-W-92-011 completed, reviewed, approved.
* All calcs reviewed in all Mods disciplines* Extent of condition for SCAR 92-0041, PER 92-0137 and FIR 92-0047 reviewed all
workplans worked since 11/22/91 (589).
Electncal Workylans* Max pull tension* Min bend radius and pulling radius* Min acceptable megger reading* Raychem sizing
Mechanical Workylans* Pressure tests* Welding data sheets* Torque calc using a crow foot* Commodity clearance* Anchors* Cold bending min design thickness calc
Results* Found some math errors* No hardware deficiencies have been identified to date
Management released administrative hold based on:
* Personnel required to perform calcs have been formally trained by corporate
engineering.
* Integrated format for performing manual cable pull calc has been developed.
* Quality indicator developed and in place.* Small dedicated group will prepare/review all cable pull caics - will be put under
Design Engineering by 08/14/92.* And other II-W-92-011 issues worked.
WEN-10
IV. COMPLETION ASSURANCE
WBN11
CONSTRUCTION QUALITY STATUS
* QUALITY OF WORK IN FIELD REMAINS -IIIGH - GOOD INSPECTIONRESULTS
* ACCEPTANCE RATE CONSISTENTLY ABOVE 98 PERCENT
QC INSPECTIONS
*00
901-
,0
$ 70
so t-
s'I.oo. asn i a osn un O M oW OM OM o 1713 07110 MyOT
REV. .1701.461.7 I1.300 716 1950 11.8 1229f1. 091.45Y.05 27 .15ACC. 2.14Cl1 .44i1 .7031 288 700 939 I1.8291 1941 .6511 .43212.02s 225112.138
ACC. |98 99 98 99 98 99 99 97 96 98 | 99 99 99A I 97 97 1 97 97 97 97 97 97 97 97 1 97 97 97
0A ACC.
--AOL
OPPORTUNITIES FOR 1IMPROVEMENT
- Field Engineering Calculations
- Training Program Problems
TARGETS FOR RECENT COMPLETION ASSURANCE EVALUATIONS
- Systems Plant Acceptance Evaluation
- Replacement Items Program
- Corrective Action
- Turnover Process Construction Startup and Test Underway
W3N-2
QA RECORDS CAPRESOLUTION OF RECORDS DEFICIENCIES
OPTIONS FOR RESOLUTION
- Alternative or redundant source documents
- Information generated by CAPs and SPs
- Testing and other performance data
- Reinspecting, retesting, reanalysis, rework, or replacement of
the plant features
* GUIDELINES FOR APPLYING RESOLUTION OPTIONS
DEPENDING UPON TIHE SIGNIFICANCE OF THIE RECORDS
- Records required by NRC Regulations
o Replace records, or
o Modify records to bring into conformance, or
o Justify an exemption
WBN-13
QA RECORDS CAP
RESOLUTION OF RECORDS DEFICIENCIES(continued)
- Records required to demonstrate qualification of
safety-related features, attributes, and functions of the plant
or activities
o Any of the above options, or
o Creation of alternative records, or
o Development of alternative technical bases demonstrating
qualification
RECORDS PLANS (ELEMENT MATRICES)
- Identify essential records required to demonstratequalification
- Identify original records for which supplemental/alternaterecords are to be used
- Perform technical content review of essential set of records
- Assure the timely retrieval of all required records
WBN-14
QA RECORDS CAP
RESOLUTION OF RECORDS DEFICIENCIES(continued)
RESULTS TO DATE
- Record quality reviews of all ANSI record types complete
- All resolutions of record quality problems accomplished in
accordance with established guidelines
- Considerable corrective actions underway to improve records
indexing
* SUMMARY
- Records CAP provides options for resolution of problems
- Implementation is defined in records plans
- Four records plans completed to date
- Technical content reviews in progress to ensure record
adequacy
- Current schedule to complete - March 1993
WBN-lS
IPLEMETA7ION DETAILS FOR
CPVL COMMODITY SUPPORT RECORDS(HVAC, CABLE TRAY AND CONDUIT
SUPPORTS)
W&N-l6
RECORDS PROBLEMSRESOLVED BY WBN PROGRAMS
* COMMODITY CAPS ISSUED IN 1988 BASED ON
CONFIGURATION ISSUES
* WELDING CAP PROJECT RESOLVED WELD QUALITY
DISCREPANCIES
* ANCHOR BOLT INSTALLATION AND TESTING PROBLEMS
WERE RESOLVED THROUGH EMPLOYEE CONCERNS
SPECIAL PROGRAM
* SUPPORT MATERIAL TRACEABILITY ISSUES RESOLVED
BY EMPLOYEE CONCERNS SPECIAL PROGRAM
WBN-17
CORRECTIVE ACTION?
* RECORD PLANS (ELEMENT MATRICES)
- Critical Attributes
- Essential Records
- Matrix is a record indexed to each unique commodity IDnumber
* MISSING CONDUIT SUPPORT RECORDS
- The Conduit Support Matrix shows the alternate recordsfrom CAPS, corrective action documents, etc.
- In the event of areas with large number of missing records,sample inspections will be performed
* DOCUMENTATION ENHANCEMENTS
- General notes posted against applicable drawings
- Support variances cross-referenced to unique support number
- CAP supplemental record and a matrix, or "road map" of allsupplemental records, directly cross-referenced to eachsupport
WMLIF
CONDUIT SUPPORT ATTRIBUTE COVERAGE MATRIX
original Subsequent Reference
Inspection CAP Program, or CAP, or Corrective Action
Attribute Process Other Review Document Remarks
Clamps (2-Hole) QCP 3.3 Cpnduit CAP NE Walkthrough Procedures
WP-51, TI-2006, TI-2011/NC
Workplan Nos. M569501 through
M569516
I
SUMMARY
* ORIGINAL QC RECORDS FOR THESE 3 COMMODITIESARE EVIDENCE OF A CONTROLLED CONSTRUCTIONPROCESS; FINAL VERIFICATION THAT COMMODITIESWILL ADEQUATELY SERVE THEIR DESIGN FUNCTION IS
PROVIDED BY SUBSEQUENT RECORDS
* ADEQUATE ALTERNATE RECORDS FOR CRITICALATTRIBUTES ARE DEFINED AND TRACEABLE TO
INDIVIDUAL ITEMS
WBN-20
CONCLUSION
* THE QA.RECORDS CAP PROVIDES ALTERNATIVEMETHODS FOR RESOLUTION OF QA RECORDSPROBLEMS
* THE RECORDS PROJECT, THROUGH AN INTERFACEWITH OTHER CAPS AND SPECIAL PROGRAMS, IS
COORDINATING THE DOCUMENTATION OF TILESERESOLUTIONS
* THE TOTAL PACKAGE OF DOCUMENTATION THAT
SUBSTANTIATES THE QUALIFICATION OF HARDWAREITEMS WILL BE IDENTIFIED AND MADE RETRIEVABLETHROUGH THE WBN RECORDS MANAGEMENT SYSTEM
WBN-21
V. TVA PLANS FOR TRAININGOF LICENSED OPERATORS
WBN-22
PROPOSED WBN OPERATOR LICENSING PLAN
1. REQUEST ONE TYPE EXAM
* Examine all current license holders and candidatesusing Initial exam format
* Exam counts toward license renewal requirements
2. 75 COLD LICENCES NEEDED
* 60 prior to fuel load
* 15 prior to commercial operation
3. PROPOSED NRC EXAM SCHEDULE
GROUP CANDIDATES DATE
1 20 4/1/93
2 20. 7/1/93
3 20i 10/1/93
FUEL LOAD 1/94
1 15 4/1/94
WDN-23