IR 05000330/1977002

Const Insp Rept 50-330/77-02 on 770228-0301.Noncompliance Noted:Failure to Rept Bulge Deficiency Per 10CFR50.55(e)(z). Related Info Encl

ML20140G896
Person / Time
Site:	Midland, 05000000
Issue date:	03/15/1977
From:	Hayes D, Yin I NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III)
To:
Shared Package
ML19255C661	List: IA-85-602, Forwards Revised Schedule for ACRS Subcommittee on Midland Plant 820429 Meeting in Washington,Dc to Discuss Util Remedial Action Re Soils & Structural Settlement Issues. Related Info Encl IR 05000330/1977002 ML20133D109 ML20140B741 ML20140B746 ML20140B751 ML20140B759 ML20140G820 ML20140G826 ML20140G835 ML20140G840 ML20140G846 ML20140G850 ML20140G856 ML20140G862 ML20140G868 ML20140G873 ML20140G878 ML20140G886 ML20140G891 ML20140G901 ML20140G906 ML20140G912 ML20140G916 ML20140G928 ML20140G933 ML20140G938 ML20140G942 ML20140G947 ML20140G951 ML20140G955 ML20140G961 ML20140G968 ML20140G973 ML20140G978 ML20140G985 ML20140G990 ML20140G996 ML20140H002 ML20140H008 ML20140H013 ML20140H020 ML20140H024 ML20140H028 ML20140H035 ML20140H040 ML20140H045 ML20140H052 ML20140H057 ML20140H064 ... further results
References
FOIA-85-602 50-330-77-02, 50-330-77-2, NUDOCS 8510080113
Download: ML20140G896 (18)

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. . . , UNITED STATES NUCLEAR REGULATORY COMMISSION ' OFFICE OF INSPECTION AND ENFORCEMENT

REGION III

. Report of Construction Inspection IE Inspection Report No. 050-330/77-02

I Licensee: Consumers Power Company 1945 West Parnall Road Jackson, MI 49201 Midland Nucicar Power Plant License No. CPPR-82 Unit 2 Category: A Midland, MI - Type of Licensee: PWR (B&W) 818 S'c Type of Inspection: Announced. Special Dates of Inspection: Feburary 28 - March 1, 1977 jl/"l77 . Principal Inspector.: I."T. Yin (Date) Accompanying Inspectors: None Ot.her Accompanyinc c sonne : None W ~ / 7) Reviewed By: D. W. Ilayes, Chief Projects Section (Date) s 'N '\\ 8510000113 050930 POR FOIA DRUNNERUS-bO2 PDR

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. .o . , ., SUMMARY OF FINDINGS Inspection Summary Inspection on February 28 and March 1,1977, (Unit 2, 77-02): Special inspection concerning extensive bulge in the Unit 2 containment liner One noncompliance item was identified relative to failure to plate.

report the bulge deficiency pursuant to the requirements of 10 CFR 50.55(e)(2).

Enforcement Items Deficiency (Unit 2 only)_ Contrary to the requirements of 10 CFR Part 50.55(e)(2), the licensee failed to notify the NRC RIII Of fice of Inspection a.id Enforcement of the Unit 2 containment liner plate bul-e deficiency within 24 hours.

- (Paragraph 1 Report Details) - Licensee Action on Previously Identified Enforcement Items Not inspected.

Other Significant Items A.

Systems and Components The Unit 2 containment liner plate bulge was examined by the inspector.

(Paragraph 2, Report Details) ' . , Facility Items (Plan' and Procedures) B.

The licensee's plans for determining the causes of the Unit 2 contain-ment liner plate bulge, and the procedures for examining, evaluating and repairing the damages had not been formulated at the conclusion . of the inspection.

- C.

Managerial Items . None.

. D.

Deviations . ' e None.

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Status of Previously Identified Unresolved Items Not inspected.

. . Management Interview A.

The following personnel attended the management interview at the conclusion of the inspection: Consumers Power Company (CP) D. R. Keating, Quality Assurance Engineer R. M. Wheeler, Field Engineer . Bechtel Power Corporation (Bechtel) . A. J. Boos, Project Field Engineer J. P. Connolly, Project Field Quality Control Engineer G. L. Richardson, Lead Quality Assurance Engineer - B.

Matters discussed were as follows: 1.

The inspector stated that it did not appear the licensee had met the requirements of 10 CFR 50.55(e)(2) relative to prompt reporting of the liner bulge deficiency and that this matter would be discussed with RIII management.

Subsequent to the inspection the licensee wcs notified that failure to report the bulge deficiency within 24 hours was ' considered contrary to the requirements of 10 CFR 50.55(e)(2).

2.

The inspector discussed the possible cause of the Unit 2* containment liner plate bulge, the repair procedures, and the QA/QC requirements for the future testing and repair work.

The licensee indicated that they will caintain close communication with RIII relative to the examination and repair work status.

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/,s , REPORT DETAILS , , Persons contacted In addition to the individuals listed under the Management Interview section of this report, the following persons were contacted: ' ' Consumers Power Company (CP) l J. L. Corley, Quality Assurance Superintendent ,Bechtel Power Corporation (Bechtel) H. Wahl, Manager of Engineering T. Johnson, Supervisor of Special Structures Group R. Castleberry, Project Engineer , T. Thirugavadam, Civil Design Engineer . Results of Inspection , 1.

Failure to Promptly Report Liner Bulge Deficiency 10 CFR Part 50.55(e)(1) and (2) states, in part, "If the permit is for construction of a nuclear power plant, the holder of the permit , shall notify the Commission of each deficiency found in design and construction, which, were it to have remained uncorrected, could have affected adversely the safety of operations of the nuclear power plant at any time throughout the expected lifetime of'the . (2) The holder of the construction permit shall within plant, .. 24 hours notify the appropriate Nuclear Regulatory Commission Inspection and Enforcement Regional Office of each reportable , deficiency."

Contrary to the above requirements, the Unit 2 containment liner plate bulge was identified at approximately 11:00 p.m., EST, February 26, 1977, and was not reported to the NRC RIII Office of Inspection and Enforcement until about 2:15 p.m., EST, , , February 28, 1977.

2.

Examination of the Bulge , The RIII inspector was dispatched to the Midland construction site following notification of the Unit 2 liner place bulge. The purpose t-4

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. ~ 1: ( - . j/, ( . . . of the site visit was to determine the extent of the damage, and to assess the stability of the liner plate bulge area.

The bulge was first identified during a routine walk through in the Unit 2 containment by the night watchman at about 11:00 p.m., on February 26, 1977. The bulge on the liner plate occurred between columns 250 degrees and 270 degrees, a span of 20 feet and between elevations 593 feet (base mat) and about 700 feet. The liner was anchored to 14-inch wide flange I-beam columns at 250 degrees and 270 degrees by full penetration welds and into the concrete structure by 3-inch x 2-inch x 1/4-inch angle iron welded to the plate and run vertically on 14-inch centers and by 5-inch channel iron welded on - As edge to the angle iron and run horizontally on 4 foot centers.

a result of the bulge the angic iron, which extended into the con- . crete 3-inches, broke at the welds to the 5-inch channel tearing the concrete away.,The 5-inch channel iron remained firmly embedded in all areas observed through the three 12-inch by 24-inch inspec-tion holes cut into the liner plate following the incident.

- Water was pouring from tear holes in the liner plate around the penetrations located approximately 10 to 15 feet about the base mat when the bulge was first discovered. Additional holes (4) were cut into the liner plate to facilitate draining, however, water continued to flow. The source of water, which was valved off to stop the draining, was a 2-inch construction water line embedded in the containment concrete structure about 12-18 inches behind the , liner plate. This water is used primarily to wet down the concrete ~ during the curing process. Within a few inches from the water line, there are also a 2-inch compressed air line and a 2-inch grease line.

These lines are located at Azimuth 259 at elevation 602'-7" and 261 at elevation 700'-0".

For Unit I containment,

these lines are located at Azimuth 101 at elevation 602'-7" and 99 at elevation 700'-0".

The licensee construction contractor, Bechtel Power Cornoration, indicated that they will abandon the use of the 2-inch war.or lines in both Units 1 and 2 containment, however, whether'or not to use the air and grease lines during future construction has not yet been determined.

. The bulge plate appeared to be in stable condition held by the full penetration velds to the 14-inch wide flange 1-beam columns, by the base mat floor plate and by heavier penetration sectior.s near the floor and upper end of the bulge.

Tear holes were observed near the columns., adjacent to the penetrations and near a stif fener plate installed at elevation 510 feet to resist wind loads during construction.

The lower penetration section was bent and may have to be replaced. The outside of the containment struture was examined and no cracks or other - damange was in evidence. Also there was no apparent damage to the tendon shcaths and no unaccounted for water was in the tendon gallery.

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/ At the time of RIII inspec. tion on February 28, 1977, the licensee AE/ Constructor had not completed formulating plans to assess the cause and extent of the damage and to develop repair procedures.

Subsequent to the inspection on March 4,1977. RIII was informed by the licensee by telephone that a section of the liner plate near the bottom of the bulge was cut to remove the concrete debris, and seven additional 12-inch x 24-inch inspection holes have been cut into the liner. After the debris has been removed, the licensee plans to cut out small sections of the liner plant starting at the top of the bulge area and working down to where localized damage, and thus evidence of the cause should be uncovered.

This operation is expected to take two to three weeks.

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D .- .. ( l dl Excerpt from Hinutes of 205th ACllS Peetin't May 5-6, 1977 .- C. Midland 2: Liner Plate Repair R. Shewmaker, NRC Staff, discursed propcsed repairs to the ' 1.iner plate of the containment building from the bulge reported at the 204th ACRS Meeting (see Appendix XXII). !!e noted that pipe penetrations and stiffening coltrnns had arrested the extent of the bulge and there was no tearing of the metal.

It is believed that free::ing was the cause of the failure of a pipe used to supply concrete curing water. The section of the failed pipe was removed, as well as the bulged section of the liner.

It is proposed to re-crect tbc liner plate with two-inch steel angles similar to the original construction. The concrete that was damajed will be removed and replaced with dry-pack concrete. Nelson studs will be placed between the angles. The three-inch void between the liner plate and the concrete wall will be filled with grout. W e liner plate , will be retested to develop the liner design criteria. NRC Staff believen that the proposed repairs are reasonable, but may require see additional rock anchors where the five-inch channels are not adequately e-bedded in concrete.

Mr. Okrent, noting the number of problems that have occurred + relating to centainment liners during construction, and the fact that these. liners ate not tested under accident conditions, suggested that the reliability of containmcat liners might be reevaluated.

Diote: h is matter, along with the reliability of other engineered safety features, aill be considered at a joint meeting of the Siting Evaluation Subcomittee and the Reactor Safety Study Working Group.)

• D. Midland 1: Misplaced Tendons R. Shewmaker said that a problem'had developed during the construction of the c'ntainment structure at the Midland 1 plant.

Two tendons were misplaced and others had to be relocated to correct the deficiency. The NRC Staff agrees with the fix that was made.

All of the modifications nave been documented.

- ' R. Shewmaker noted that this was a quality control break-down which occurred.ihen.the chief surveyor was on vacation.

. We error was found before the next higher pour was made.

(For diagrams of the error and the fix see Appendix XXIII.)

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i EXCERPT FROM MINUTES OF 212TH ACRS f1EETING DECEMBER 8-10, 1977 D. Aeschliman v. NRC The Chairman informed the Committee that the appeal of the verdict of the Aeschliman v. NRC case, regarding the licensing of the Midland Nuclear Power Plant, Units 1 and 2, has been argued Involved in this decision, is the ibefore the U.S. Supreme Court.

requirement for the ACRS to be informing the public as well as A decision is expected from the Supreme Court in - the Canmission.

three to four months.

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-- ' (' 118 . -1 'l EXCERPT FROM MINUTES OF 215TH ACRS MEETING MARCH 9-10, 1978

D. Midland, Units 1 and 2: Radiation Monitoring of ' Process Steam (Note: Mr. Kerr did not participate in this discussion.] , D. Hood, NRC Staff, noted that the Consumers Power Company, applicant for Midland Nuclear Power Plant, Units 1 and 2, has requested elimination of a research and development program to assure the adequacy and feasibility of the radiation moni-toring system for the process steam to be supplied to the Dow Chemical Company.

This program was proposed in Amendment 8, to the PSAR for Midland dated February 9,1970.

In the original design of Midland, secondary steam was to be sold to Dow for process purposes.

Since that time, and following Congressional passage of the Dulaney Amendment, which prohibits delivery of potential carcinogens, the steam delivery system was modified to provide for a set of reboilers, and delivery to Dow of ter-tiary steam instead of secondary steam. 'Ihis tertiary steam will be essentially nonradioactive, and the Applicant believes that - this modification obviates the need' for the R&D program in question. Radiation monitors will be installed on each of the steam lines, both high pressure and low pressure.

In addition, blowdown from each evaporator will be monitored.

He also noted that in its 1968 report, the Comittee requested that it be keph ! informed of matters regarding monitoring of the process steam deliveries.

C. Burke, NRC Staff, noted that this report is a status report, that the NRC Staff is reviewing the nutter, and as of this time has made no decision.

Mr. Siess noted that, unless open steam is used in some of the Dow products, there is a fourth barrier to the transmission of radioactive material, in the form of Dow's heat exchangers.

(For the chronological history of this research project, and for the original and modified designs of the process steam systems, see Appendix XIX.)

Mr. Ebersole requested that the NRC Staff inform the Ccmnit-tee whether the safety analyses for the main steam line isolation valves in the Midland Nuclear Power Plant, Units 1 and 2, have been updated to conform with the current NRC rules and criteria.

T.

Sullivan, Consumers Power Company, said that with the ' original design of the process steam supply system, there was concern that the limits set by 10 CFR 20 would have to be met with regard to the steam supplied.

However, with tertiary heat exchangers, the steam supply system mild not be a signifi- , cant release path for radioactive materials.

The existence of three barriers to the passage of radioactive materials, and the hugh mass of water involved in the evaporation in the tertiary pI h /h system, will prevent the transfer of significant concentrations of radioactive materials.

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pfft $7pff 8' n=Aw/7 ^' ' D N/ou"D Jh/76' /??L e968 - ., oe ' \\ . , RLCElVLD ADVISORY COMMITTEE ON REACTOR SMECUARDS U.S. N.g.c { CHRONOLOGY MAR 1 i 1978 PROCESSSTEAMRADIATIONMONITORIN$si 910ngil:2,343$ ~ i Y OCT. 30, 1968.

PSAR SUBMITTED.

PROCESS STEAM SYSTEM DESIGN BASED UPON DIRECT EXPORT OF SECONDARY STEAM TO UOW.

FEB. 9, 1970 PSAR AMEND. 8 PROPOSES R&D TO RESOLVE FEASIBILITY AND ADEQUACY OF RADIOACTIVITY MEASUREMENT CONCEPT.

, JUNE-18,1970 ACRS REPORT ISSUED BASED ON DIRECT EXPORT OF SECONDARY STEAM AND DESCRIBING DEVELOPMENT PROGRAM.

AuG. 14, 1970 PSAR AMEND. 15 INTRODUCES TERTIARY HEAT EXCHANGERS.

SEPT. 1,

ACTS SUBCOMMITTEE MEETING , SEPT. 2,1 $7 ACRS SUPPLEMENTAL REPORT ISSUED.

DETAILED 970 ACTS MEETING ON REBOILERS DEPT.

- PROCEDURES FOR MONITORING AND CONTROL TO BE DEVELOPED DURING CONSTRUCTION.

ACRS TO BE KEPT INFORMED.

N0v. 12, 1970 SER ISSUED.

REFERS TO R&D PROGRAM TO VERIFY SENSITIVITY OF GROSS GAMMA MONITOR.

MAY 3, 1977 STAFF M(8U NOT NEEDED, EIING WITH APPLICANT.

APPLICANT STATES

AuG. 29, 1977 FSAR TENDERED.

' SEPT. 1, 1977 APP I[ ANT LETTER REQUESTS ELEMINATION ' 0F $8U COMMITMENT.

MARCH 1, 1978 FSAR SECTION 11.6 SUBMITTED DESCRIBING PROCESS STEAM RADIATION MONITORING PROGRAM.

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