IR 05000330/1977002

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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: ... 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

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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 

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Type of Licensee: PWR (B&W) 818 S'c Type of Inspection: Announced. Special Dates of Inspection: Feburary 28 - March 1, 1977 I."T. Yin jl/"l77 . Principal Inspector.: 

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Accompanying Inspectors: None Ot.her Accompanyinc c sonne : None ~ W D. W. Ilayes, Chief / 7) Reviewed By: Projects Section (Date) s 

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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 plate. One noncompliance item was identified relative to failure to 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 

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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 hour (Paragraph 1 Report Details) 

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Licensee Action on Previously Identified Enforcement Items Not inspecte Other Significant Items Systems and Components The Unit 2 containment liner plate bulge was examined by the' inspecto (Paragraph 2, Report Details) 

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     . Facility Items (Plan' and Procedures)

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 inspectio . C. Managerial Items Non . Deviations   .
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Management Interview 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) 

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A. J. Boos, Project Field Engineer J. P. Connolly, Project Field Quality Control Engineer 

- G. L. Richardson, Lead Quality Assurance Engineer Matters discussed were as follows: 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). 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 wor The licensee indicated that they will caintain close communication with RIII relative to the examination and repair work statu .

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REPORT DETAILS , Persons contacted In addition to the individuals listed under the Management Interview section of this report, the following persons were contacted: 

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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 

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R. Castleberry, Project Engineer T. Thirugavadam, Civil Design Engineer 

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Results of Inspection Failure to Promptly Report Liner Bulge Deficiency 10 CFR Part 50.55(e)(1) and (2) states, in part, "If the permit is 

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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 plant, . . . (2) The holder of the construction permit shall within 

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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 

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 , of Inspection and Enforcement until about 2:15 p.m., EST, February 28, 197 , 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
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of the site visit was to determine the extent of the damage, and to assess the stability of the liner plate bulge are 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 edge to the angle iron and run horizontally on 4 foot centers. As a result of the bulge the angic iron, which extended into the con-
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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- 

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tion holes cut into the liner plate following the inciden 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 

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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 

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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 

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future construction has not yet been determine 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 

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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 galler * 

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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 procedure 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 week .

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C. Midland 2: Liner Plate Repair R. Shewmaker, NRC Staff, discursed propcsed repairs to the 

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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 concret + 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 reevaluate 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 plan Two tendons were misplaced and others had to be relocated to correct the deficiency. The NRC Staff agrees with the fix that was mad All of the modifications nave been documente ' R. Shewmaker noted that this was a quality control break- 

. down which occurred .ihen.the chief surveyor was on vacatio 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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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 ibefore the U.S. Supreme Court. Involved in this decision, is the 

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      'l EXCERPT FROM   l MINUTES OF 215TH ACRS MEETING MARCH 9-10, 1978
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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 Compan This program was proposed in Amendment 8, to the PSAR for Midland dated February 9,197 In the original design of Midland, secondary steam was to be sold to Dow for process purpose 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 

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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 deliverie 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 decisio 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 exchanger (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 criteri T. Sullivan, Consumers Power Company, said that with the original design of the process steam supply system, there was 

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concern that the limits set by 10 CFR 20 would have to be met with regard to the steam supplie However, with tertiary 

, heat exchangers, the steam supply system mild not be a signifi-cant release path for radioactive material 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 material Fo/A-35-A oL E ['ti

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D oe N/ou"D Jh/76' /??L e968 \ RLCElVLD ADVISORY COMMITTEE ON { REACTOR SMECUARDS U.S. N. CHRONOLOGY MAR 1 i 1978 PROCESSSTEAMRADIATIONMONITORIN$si 910ngil:2,343$ i 

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MEASUREMENT CONCEP JUNE-18,1970 ACRS REPORT ISSUED BASED ON DIRECT EXPORT OF SECONDARY STEAM AND DESCRIBING DEVELOPMENT PROGRA AuG. 14, 1970 PSAR AMEND. 15 INTRODUCES TERTIARY HEAT EXCHANGER SEPT. 1, 97 

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