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