IR 05000329/1973007

Insp Repts 50-329/73-07 & 50-330/73-07 on 730905-07.No Noncompliance Noted.Major Areas Inspected:Batch Plant Restoration & Requalification.Qc Procedures Re Concrete Activities & Concrete Production & Placement

ML19338C118
Person / Time
Site:	Midland
Issue date:	10/15/1973
From:	Knop R, Rohrbacher R NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III)
To:
Shared Package
ML19338C116	List: IR 05000329/1973007 ML19338C115
References
50-329-73-07, 50-329-73-7, 50-330-73-07, 50-330-73-7, NUDOCS 8008050568
Download: ML19338C118 (16)

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DIRECTORATE OF REGULATORY.0PERATIONS-

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IU. S. ATOMIC ENERGY. COMMISSION

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REGION III:

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Report of Construction. Inspection

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RO-Inspection Report No. 050-329/73-07

' 'RO Inspection' Report No. ' 050-330/73-07 ~

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.-Licensee :

' Consumers Power Company

1945..Parnali Road

Jackson, Michigan 49201

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. Midland Plant, Units 1 and 2 Licenses No; CPPR-81 i'

Midland,' Michigan and No..CPPR-82 Category:

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Type of Licensee:

PWR~(B&W)fUnit 1 650 Mwe, Unit 2: 818 Mwe Type'ofLInspection:

' Routine, Unannounced'

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Dates of Mspection:

September 5 -- 7,1973 L Dates of Previous Inspection: -August 8 10,-1973

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. Principal'Inspec' tor:-JR. A. Rohrbacher

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a Accompanying Inspectors: None.

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Other,' Accompanying. Personnel: None:

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Reviewed-By

.R.^C. Knop,J Senior Reactor Ins'ector-

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' Reactor Construction Branch (Date)

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SUMMARY OF FINDINGS

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< Enforcement Action

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E-fA.- Violations 1.

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' No~. violations'of:AEC requirements'were identified.

B.-4 Safety Matters

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'Nd' safety matt m were identified.

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Licenisee Action 'on' Previously Identified Enforcement Matters.

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' Concrete-Placement' Activities-Not In Accordants With Applicable _ _

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Requirements-(RO Inspection Reports'No. 050-329/70-06, No.-050-330/70-06,

No. 050-329/71-01 and-No.-050-330/73-01)

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.During -the referenced inspection (September 1970),1 the inispector observed _

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.-impropertuse of~ vibrators during concrete placement, i.e.,Luse of vibrators

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l was not in'accordance'with'ACI Standard 301,? paragraph 803.d.. Subsequent ~

to'this inspection, Consumers PoweriCompany (CP) was~ informed that this..

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matter would remain on followup status until construction work was resumed.

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.and further inspection.could be made..

i During'this inspcetion',-activities as'sociated'with the:use of vibrators

during concrete placement were'._ observed. - Through discussions with ' site

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' ' personnel, review of records, and observation-of. concrete placement

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. activities-inl. progress,'it was, determined that the use of-vibrators

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during concrete _ placement met.' applicable requirements'(ACI-301). This

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1:l matter is' considered resolved..;Howeser, periodic inspection.of concrete C

. activities, including'use_'of'vibrstors,_are-to be:made during subsequent i

inspections.'=(Paragraph 21)

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Insufficient' Frequency of Aggregate Testing (R0' Inspection Reports No.-050-329/70-06,'No. 050-330/70-06, No.:050-329/71-01 and-

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-No. 050-330/71-01)

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~ During1the_ re$erence'd inspection -(September 1970), it was learned that

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- aggregateJgradation and t organicitests-of - sand :were not' being ^ conducted l

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?in accordance with applicable requirements,:1.e;, test' frequencies were j

(less: than required byf Section :5.1.1.3 of: the-Midland Project PSAR. ' CP

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(wa's'. informed :that ' this matter would ' remain ons a : followup ' status until.

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fconstruction'.worki was. resumed.softhat.further inspections ~could be made.

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. Discussions (with site personnel during,the current-inspection, review

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.of records, and: observations ~of: batch ~ plant: operation _-provided informa-

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stion to establish that the required frequ'ency of the subject testing -

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Ewas being maintained. 'However, this matter remains open pending further

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record review and' observations-during further' concrete production.

' Design Changes-

No design changec'we're identified.

Unusual Occurrences No~unusualLoccurrences were identified.

Other-Significant Findings l' A.~ ' ' Current 5 Findings

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. Facility Status

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-1 The licensee estimated current project status as follows:

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Activity Completion

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Engineering --

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' Construction 2%

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2.- Current Construction Activities

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. i a. ' Rest' oration and requalification of the concrete batch plant have

~been completed, and concrete is being produced as required.

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Two concrete pours for the Unit 2 tendon access gallery. walls have been made..

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Preparation for a construction lay-down area and other general

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site groundwork is in-progress.-

d. -Inspection'and evaluation of stored materials.and components

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is continuing'by the' licensee.

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l e.- Activities to provide; facilities _and develop procedures to

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restore and requalify containment liner plate are in progress.

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[3.': :. PersonnaliCnanges L.'R. Albert and M.JP. Hendrick have:been assigned to the Bechtel

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Corporation (Bechtel) Midland Project = Field'QC' staff as. Quality

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l-Control Engineers at the_ construction. site.

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Bn Unresolved Matters

1. -Be'chtel Q,ality Audit Pindings'

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- Bechtel-Project Audit.: Report No. C-1, dated July 19, 1973, was

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. reviewed during the previous inspection. This' audit report stated

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that:certain Bechtel activities'in the field were not in compliance with-established Bechtel procedures.- Corrective action is.in

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. progress. -This matter remains open pending review of corrective-I action.. (Appendix A)-

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. Site Sampling Program-I This program was reinitiated by CP during July 1973. Additional (;

samples were collected on July 24, 1973, and analyzed on August 4,

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p 1973.. This~ matter remains open pending evaluation of the~ data i'

'obtained.

(Paragraph 4)

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C.- Status of Prev'ously Reported Unresolved Matters i

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Consumers Power Company-Quality Assurance Manual (R0 Inspection Reports-No. 050-329/73-06 and No. 050-330/73-06)-

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'During the preYious inspection it was determined that the CP Quality.

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Assurance Manual ~(QAM).for'the Midland Project-lacked, or.was.incon-siste' nt with, certain requirements of 10 CFR 50, Appendix. B.

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revised-QAM,' dated-~ August'24, 1973, was' received by RO:III on

August 30, 1973. This matter remains'open pending completion of a

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detailed review of the manual.

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Babcock and Wilcox Company QA Program for the Midland Project

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~(RO Inspection Reports No.' 050-329/73-06:and-No. 050-330/73-06).

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CP and the? Babcock and Wilcox Company-(B&W) are continuing their, 1>

discussions relative"to'uPhrading quality assurance requirements common to componentisi arnished by1B&Wlfor the Midland; Project..

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Agreement.has been' reached.between CP and B&W on salient points.

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This matter remains open.pending RO:III review of the documentation

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Rest' oration and Requalification of.; Site Stored-Corponents

.(R0 Inspection Reports No. 050-329/73-05 and No. 050-330/73-05),

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"A representativeiof the licensee stated that work and quality controA

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Jprocedures are: continuing to be developed'for.use to verify that the-l

subject components meet : applicable requirements..This matter remains

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.open pending review'of completed procedures and an evaluation of l

procedure; implementation.

4. ~ Evaluation of Rebar Tio Wire (R0 Inspection Reports

.No.>050-329/73-05 and No. 050-330/73-05)

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.As previously reported, significant deterioration'of some tie wire holding-exposed 1 reinforcing. steel in place was.such that the required support function during concrete placement was subject to question'.-

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.This tie wire has been inspected by the construction contractor.and,

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where necessary,Jadditional wire has been installed. The RO inspector observed the.new and existing tie wire on-the rebar-in the Unit.2 tendon access gallery' walls (where this deterioration was observed)

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and determined that the tie wire now in place was adequate. This,

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P matter is-considered to be resolved.

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. Management Interview

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.Two management intervlews:were held; one on. September 6, and the second on

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September 7, 1973..Tnis' report section includes matters discussed on both H

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dates.

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A. -The-following CP personnel attended one or both management interviews.

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IW E. Kessler, Project Manager *-

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'C. Q. Hills, Quality Assurance Administrator-T C.:Cooke, Project' Superintendent

R. E. Whitaker, Field Quality Assurance Egnineer

• Attended September 6, 1973, meeting only.

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EBA -Matters discussed-and comments on the part-of management personnel were.

as follows:

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-In' response to a question concerning the CP.QA staff to be assigned

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.to the construction' site,;the licensee stated that, in addition to the field'QA engineer 1 presently assigned to the site,'a QA engineer

will be assigned early in 1974 and anot!er' prior to'the end of 1974.

TheLinspector: stated that the.sizeLand capability of the CP.QA staff-would=be-reviewed ~ periodically to ascertain that' staffing would proceed-

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' in a -timely' manner,21.e., commensurate with project activities and Lrequirements.

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2. ; Upgrading of-the B&W QA program was discussed. The licensee stated

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.-that,'although discussiens are. con *inuing, essential agreement had been reached between CP and B&W.

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3.: Quality requirements and.QC procedures for receiving inspection and

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,related activities were discussed. The inspector-stated.that this j

matter would be reviewed during a subsequent insp'ection in connection-l

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REPORT DETAILS,

Persons Contacted Thelfollowing persons, in addition to individuals listed. under the Management Interview Section of this report, were conta-:ted during the inspection.

Consumers Power Company (CP)

B. H. Peck, Field-Supervisor - Mechanical Bechtel' Corporation (Bechtel)

C. E. Kinney, Project Field Quality Control Engineer F. W.' Joyce, Quality Control Supervisor G. L. Richardson, Project Field Quality Assurance Engineer F. A. Kapla, Quality Control Engineer Champion, Incorporated (Champion)

lr. E. Schmanski,~ Batch Plant Supervisor

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Results of Inspection 1.

Concrete - Class I Structures and Supports Two Class I pours have been made since restart of construction at the site. The. inner wall of-Unit 2 tendon access gallery was placed on

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August 28,.1973; the outer. wall was'placed on September 6,-1973.

About 400 yards'of concrete were placed during these two pours.

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~ Batch Plant Restoration and Requalification The concrete batch plant originally acquired for the Midland Project, which.was erected about July 1970, has been restored and'requalified.

. Champion is the concrete' contractor and batch plant operator.

A. review of,Champlot and Bechtel records indicate that all mechanical, electrical, and contro1Lequipment.has been checked and verified.to be in proper operating ccndition. The concrete

. transit trucks'have been restored.and checked also. Trial batches have been~made to check operation of the equipment and to test the concrete produced.

Champion-Weekly Progress Reports from June 23,

-1973, to August 28, 1973,. were reviewed.

These reports, and an

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inspection of-the. batch-plantiduring operation, indicated-that

' areas of. deficiency did not exist.-

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i These test reports were.in the Bechtel'QC file at'the site. The

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reports stated that applicable (specified) requirements were met and1were properly signed and dated. 1No deficiencies were identified.

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QC: Procedures Bechtel-QC procedures relative'to. concrete activities were reoieved.

The following'were included.

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(1) Inspection P1'an for Concrete Preproduction

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(2)~ Mast'er Inspection Plan (for concrete)

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(3) Material Certification Requirements (4)' Inspection Plan for Receiving Reinforcing Steel-(5) Testing Requirements (including rebar)

j (6) Batch Plant-Operations (including material sampling)

'(7) Preplacement Inspection (8) Delivery-(including time and temperature limits)

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(9) Placement-(including specified mix, adequate crew, and equipment)

i (10) Testing -(including'-types, sampling location and frequency)

Standard forms,;such as checklists and field inspection report sheets,

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.Ere used-with most'of the above procedures so that.the required-information can be recorded conveniently.

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QC Records-

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Records were reviewed pertaining to the first Class I concrete. pour.

made after the restart of construction at the site.... the inner

- l wall of:the-Unit 2 tendon' access gallery. Through this record review,-

it was' determined that concrete activities relative to this pour met applicable raquirements.

The necessary records required for' review

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.were readily available from:the.Bechtel QC. file and included the

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required ~ data..~The'se records-include' verification of proper mix-

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xauthorized.and used, proper: location documented, and. adequate transit

. tickets.- Data relative tozslump,. air.entrainment,-temperature, and

timelof placement _-(takeniat the placement' location)'were reviewed.

. 1 About. half the' trip tickets and related concrete' production records

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for this pour were_ reviewed. No discrepancies were identified, tThe inspector observed that similar records were being generated'

during placement of.the Unit 2 outer wall on September 6, 1973.

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Quality records relative to incoming materials were reviewed. These records. indicated that the following materials met applicable require-

ments: _ cement, fly ash, water, sand, -aggregate, and rebar. = Mill

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certifications,' users test results,_and inspection records were included inlthe above quality records.

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l e,--Obsereution'of Work - Concrete Production and Placement i

The Unit l2 tendon gallery outer wall-placement area was inspected

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prior to concrete placement.

It was observed that the formwork was

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solid, clean, tight, and adequately-braced.

The rebar was free from loose rust, properly spaced, and adequately held in place.

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Adequate transporting and handling equipment, vibrators, and crew were on hand prior to placement.. Adequate perscnnel, as'well as sampling:and test equipment, were available at the' placement site, and Bechtel QA, QC,-and field engineers were present to observe and

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i inspect operations in progress.

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Through observation of QA and QC activities at the tire of concrete placement and from discussion with the QA and QC engineers present,

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it was determined that these engineers were qualified to monitor and As/

audit concrete activities. A representative of CP. stated that CP had reemphasized the.need for adequata engineering surveillance and-QC coverage by Bechtel during placement of all Class I pours.

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It was observed that cone ete handling and vibrator usage were in accordance with applicable requirements. Two vibrator crews were-observed at four areas of the pour during placement. Through discussions.with cite personnel and review of' records, it was-g verified that instruction in the use of vibrators took place on

August 27,'1973.- Demonstration and. practice included use of

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vibrators in fresh concrcte. About 27 attended-this Bechtel

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training session,~1ncluding ten' laborers, three foremen, and fourteen' engineers-(field, QA, and QC).

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During placement, it was observed that truck transit tickets were

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received and. reviewed upon truck arrival and.that samplieg and testing was done properly and the results recorded. The inspector observed-that the first load:of concrete received for this pour

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was rejected.at the' placement location, due to improper slump.

Methods'used.to take slump and air entrainment measurements met applicable requirements.: It was observed that sampling and testing

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frequency was more frequent than required at the placement location

!and.that samples were taken in a manner.co obtain representative samples. A'Bechtel QA engineer, among other engineers, was at the pour-location verifying that sampling.and testing requirements were l

Emet. - The inspector did not identify any deviations from applicable

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requirements during observation of concrete placement activities.

During observation of batch plant operations, it was noted that the-required mix was being batched and that sampling and testing met applicable requirements.

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. 2'.

Existing Concrete Structures

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Subsequent to the' previous inspection, formwork and soil were removed.

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from the south wall of the Auxiliary Building exposing concrete surfaces and the waterproof membrane not previously visible for inspection.

During inspection of ' this concrete, no cracks (except hairline cracks)

or'other evidence of structural defects were observed.

In addition, no l

soil erosion, orlother deleterious effects, were identified at or near the bottom southwest corner of the Auxiliary Building due to previous

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heavy rains.

L The Auxiliary Building waterproof membrane and the membrane adjacent to the Unit 2. floor base slab were being secured-and sealed during the

[,,q current inspection. No deficiencies were identified during observation

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's-of this activity.

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QA/QC Staff at Site

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During the current inspection, it was determined that the following

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personnel were 'directly involved in QA/QC activities at the site.

' Consumers Power-Company (CP)

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l C. Q. Hills, Quality Assurance Administrator (part time)

i R. E. Whitaker, Field Quality Assurance Engineer

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Bechtel Corporation (Bechtcl)

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Direct Quality Assurance Functions L

J..I. Dotson, Project Quality Assurance Engineer (part time)

.G.>L. Richardson, Project Field Quality Assurance Engineer

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Direct Quality Control-Functions

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C. E. Kinney, Project Field Quality Control ~ Engineer F. A. Kapla, Quality Control Engineer

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L. R. Albert, Quality Control Engineer (Civil)

M.' P. Hendrick, Quality. Control Engineer (Welding)

N. V. Plante,-Quality Control Engineer (Civil)

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L. (NMI) Shively, Quality Contrcl Engineer (Civil)

J. C. Fitzgerald, Quality Control Engineer

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4.

Site Sampling ~ Program

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This program.was reinitiated by CP during July 1973.

Site samples taken on' July 24, 1973, were from the approximate locations of samples taken on July 2, 1971, and by the same person.

Nine wipe samples were taken from existing concrete structures and from carbon steel components stored at the site and at an adjacent storage area.

Four samples of rust from stored steel components and one sample of wa'er from a surface

- depression at the site were taken also. Analysis of these samples were made at the CP Chemical Laboratory at Palisades. The procedures used

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and the data obtained were reviewed. The types of analyses performed and the sampling locations selected appeared to be adequate.

Data from these and. previous sam? e analyses were given to Bechtel for evaluation.

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The results of this e"aluation will be reviewed for adequacy, during a

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/~'N subsequent inspectior, when a' copy is made available by CP.

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5.

Liner Plate Restorr.cir.. and Requalification

A concrete slab has been poured for a structure that will house liner plate restoration and inspection activities. Actual work on the containment liner plates will not start for a month or two, but work and QC procedures are continuing to be developed for use to verify that the liner plates will meet applicable' requirements prior to use.

t 6.

Site'Requalification Activities Work is continuing at the site to determine.the affect of the environment on stored' materials, components, structures, and earthwork.

Personnel of_Bechtel'and of Soils and Materials Engineers,' Incorporated, examined and tested in-place plant soils during the first he.lf of June 1973 to determine possible changes that may have o' curred during the c

last two-and-one-half years.

The data and other results of.this work

- are-included in "Intertm Report.on the Examination and Testing of In-Place Soil Conditions, Midland Plant, Units 1 and 2," dated

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July 16, 1973. The work included vis'ual examination, soil test Q.

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borings,-undisturbed sampling, was well as compression, plasticity, and compaction tests.

The report concluded that examination and testing indicated that subsurface soils in the plant area had not been cffected

' adversely by work termination of about two-and-one-half years.

.'

On June 28;- 29, 1973, Bechtel personnel.made a corrosion inspection

'

to establish eumulative corrosion effects on stored and constructed

materials, especially on reinforcing. steel, sump liners, and penetration

'

fittings..'A Bechtel memo, dated July 24,'1973, contained the results

'

of this inspection.

Ih addition to observing dense brown. rust on exposed steel surfaces, the memo states that some random -pitting (up to approxi-mately ten mila' deep) was observed beneath the rust on some sump liners and rebar. - The memo recommends that sump liner thickness measurements

be made after rust removal'and that the data be submitted to Bechtel Project Engineering for review. -In addition, the memo recommends that

j rebar, subject to long-term water and/or mud immersion be discarded.

'

The RO inspector observed that certain other recommendations relative to stored material restoration was in progress, i.e., remcval of loose

'

rust from partially embedded rebar and trumpet plates, i

CP personnel made an inspection of materic1s stored at the site on

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i July 5, 1973. A memo of this inspection, dated July 9, 1973, indicated that the following components, among others, were inspected: containment liner-plate, penetrations, steel C-36 girders, sump liners, polar crane ()s support brackets, in-place rebar, cadwelds, concrete structures, and (,,.

water stops.

The memo recommends that stainless steel stored at the

,.

site be inspected by PT for evidence of stress corrosion craciing.

Based on personal observations by the RO inspector during the last several months, it was determined that the results of the above two inspections, by CP and Bechtel personnel, fairly represent the condi-tion of l stored material, components, and structures at or near ' the

,

construction site. Moreover, the recommendations made as a result of these inspections appear to be adequate.

Surveillance in this area will continue in the future to determine that the licensee is meeting

'

ihe. applicable commitments.

Attachment:

t Appendix A l

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APPENDIX A-

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'Bechtel Quality Audit Finding' Reports During the; period' July 16'through' July 19, 1973, Bechtel QA engineers

.i

l conducted a'QC systems audit.of the Bechtel field organization at.the Midland construction site. The deficiencies found are detailed in 15 Quality Audit' Finding Reports.-- (See RO Inspection Reports No. 050-329/73-06

,

.and'No.'050-330/73-06 for a summary of findings and-proposed recommended

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.

Daction.)

b i

The corrective-action taken and the extent of. implementation relative to j

i these'. findings are summarized.below.

.

~1.

QA Finding No.-l'

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F j

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_

A containment liner plate QC itispection plan is being developed. The-l

inspection-is'to_be completed prior to liner plate installation. This

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P

' finding will be closed out by Bechtel after verification that the'QC

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~

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plan is adequate and properly implemented.

.2.

QA Finding'No. 2

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On July 16, 1973,' Project Engineering wrote a memo rel'acive to the

ac'ceptance of review of the modification to Specification No. C-208.

,j'

The memo-was. deemed a

REGION lit,

$, Ogg 799 ROOSEVELT ROAD GLEN ELLYN. ILLINOIS 60137'

Was ass.asso

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v 050-329/73-07-i A.'

.'R0 Inspection Report No. ' 050-330/73-07'

Transmittal Date

October 16, 1973

~ Distribution:

' Distribution:

RO Chie f.... FS&EB

.RO Chief, FS&EB l

RO:HQ. (5)

RO:HQ (4)

~

c

DR Central' Files.

L:D/D for Fuel & Materials l

Regulatory Standards (3)

DR Central Files L-Licensing-(13)

RO Files RO Files l

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B.'

RO Inquiry-Report No.

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LTransmittal Date

Distribution:

'

Distribution:

~

ROl Chief, FS&EB RO. Chie f, FS&EB

_

RO

HQ'(5)

RO:HQ.

DR' Central. Files DR Central Files

,

- Regdletory. Standards ' (3)

RO Files U

Licensing ;'(13).

RO Files.

.l

.

.

,

,

l C... Incident Notification Frc n

.(Licensee & Docket No. -(or License No.)

Transmit tal ~ Da te :

.

,

.

i Distribution:

Distribution:

-

RO Chie f, jFS&EB RO chief, FS&EB iRO:HQ:l(4)..

. RO:HQ,(4)

Licensing _(4).

L:D/D for' Fuel 6' Materials

,

DR Central Files

.DR Central. Files RO Files

.

RO Files.

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