ML19254E661

Forwards Five Interim Repts Re Failure of Installed Hilti drop-in Anchors to Meet Tension Test Requirements,Component Qualification Test Documentation re-review & Pressurizer Heater Sys

ML19254E661
Person / Time
Site:	Midland
Issue date:	09/20/1979
From:	Gibbs M ISHAM, LINCOLN & BEALE
To:	Cowan F, Linenberger G, Smith I Atomic Safety and Licensing Board Panel
References
NUDOCS 7911020134
Download: ML19254E661 (8)

Text

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r- NRC PURUC DOCUMENT ROOM artu o conar.sPONDE.Nc3 ISHAM, LINCOLN & DEALd

. j eq COUNSELORS AT LAW

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m. W Ivan W. Sm2.th, Esq. Mr. Gustave A. Linenberger Atomic Safety and Licensing Board Atomic Safety and Licensing Bd. Panel U.S. Nuclear Regulatory Commission U.S. Nuclear Regulatory Commission Washingten, D.C. 20555 Washington, D.C. 20555 Dr. Frederick P. Cowan Apt. B-125 6152 North Verde Trail Boca Raton, Florida 33433 Re: Consumers Power Company (Midland Plant, Units 1 and 2)

Docket Nos. 50-329, 50-330 Gentlemen:

Enclosed are five interim reports submitted by Consumers Power Ccmpany to the Nuclear Regulatory Commission pursuant to 10 C.F.R. S50.55 (e) . The report relating to the diesel generator build-ing settlement references an enclosure, copies of which will be pro-vided to members of -he Atomic Safety and Licensing Board and any party upon request.

Very truly yours, w C.:> S Martha E. Gibbs i J

MEG bc cc: Service List w/ enclosures 7 91102 0 /3 Y 1248 276

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$1 eq N Nagg J Ste+evi H. Howelt

$tnior Vice President Generat offices: 1945 West Perne64 Road, Jackson, Michisan 49201 . (517) 7884 453

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Hove-2kT-79 o jj NT6*

5 gp <1MN Mr J G Keppler, Regional Director M' ,o Office of Inspection and Enforce =ent rfj;p'#v=" (

US Nuclear Regulatory Cc-~4ssion Region III to, 3" 799 Roosevelt Road *I" Glen Ellyn, IL 60137 MELM;D UUCLEAR PLANT -

UNIT NO 1, DOCKET NO 50-329 .

UNIT NO 2, DCCKEP NO 50-330 DROP-IU ANCECRS In accordence with the requirenents of 10 CFR 50 55(e), this letter constitutes an interi= report en the status of installed Hilti Drop-In Anchors which did not =eet the tencin testing requirc .ents.

The attach =ents to thic let er provide a descriptien of the discrepancy, potentici safety inplications, investi6ation and planned corrective actions.

Another report, eicher interis or final, vill be sent on or before October 12, 1979

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Enclosures:

1. Q,uslity Assurance Progica, Manegener:t Corrective Actics Report, MCAR-1, Repert 34, dated Ag::t 21, 1979

2. Letter, J A Rutgers to G S Keeley, MCAR-3k Interi: Report yl, dated Septenber 5, 1979 CC: Director of Office of Inspection &. Enforcenent Att: Mr Victer Stello, U3NRC (15)

Director, Office of Managenent Infornation E: Program Centrol, USURC (1)

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1248 277

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.' 2 Heve-2'47-79 4

BCC: JL3 acon, M-1085A RC3aunan, P14 hl2 i h"d31rd, JSC-2163 JLCorley, Midland LHCurtis, Eechtel AA ,

LADreisbach, Ee:htel-Midinni DZHorn, Midlard

' GSKeeley, Pik LOSB E'niferguglio, JSC-220A D33.111er, Miditnd -

KE!oring, Bechtel AA JARutgers, Bechtel AA PIGibbs, ILi3 Great Lakes QA Managers File: 0.4 9 33 O

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. QUALITY ASSURANCE PROGRAM Enclosure 1

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MANAGEMENT CORRECTIVE ACTION REPORT Ecve-247-79 MCAR 1 REPORT f40. 34 7220 0 NO. Various August 21, 1979 QOS NO. DATE i

• DESCRIPTION (including references):

Specification 7220-C-305, Section 6.2.2 requires tension testing of Drop-In Anchors to =eet the values indicated in table 3.2. Additional testing was required by

, Project Engineering in letter EEEC-2404, dated S-21-78 and EEBC-2965, dated 5-18-79, to verify past installation practices. A sa=ple and test of 60 rando=1y selected anchors were to be teste, with no failures. Contrar/ to this, 9 out of 32 drop-in anchors tested utilizing 4 sizes have failed. NCR-2461 has been generated to identify these failures. -

' RECOMMENDED ACTION (Optional)

1. Construction .

a) Provide Engineering with dat.a as to utilization, quantity, locatien and size of all "Q" Supports, utilizing drop-in anchors installed to date.

b) Deter =ine the cause (how and why) of the anchors failurcs.

. (cor.tinued en page 2)

REFEF.ndD TO G ENGINEERING CCONSTRUCTICN OOA MANAGEMENT E_Syslity Control O PROCUREMENT ,

ISSUED BY - NiC Pro,ect CA En; ne:r E' 2l di Oa e 11 REPORTAPLE DEFICIENCY I

potentially neportabic, to t' T@ED CLIENT _ M/2C/79 be deter =ined by Project em e c O NO l

O YES Engineerinr Pre;ect var:a;er

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!!! CAUSE CORRECTIVE ACTION TAKEN J- Mi u m At" AUTHORIZED BY ___

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TANDARD CfSTR'3UTION AC0!TICNAL C

STR!BUTION . AS APPROPR' ATE r.wo on uwacra sucnrga v uasacta FORMAL REPORT TO CUENT wacta es on . Ypo emosect tss v ra (Il Section 11 App! es) Date

• 3 - Q4 unsacta A40 Paocuniutsf SU*pt'Em Cyaviv uom J#3C4uaMaOER CONS 7RUC7CN MANaCE84 AO C4wawaCfe PR3J Surf Pn0J CO*dist uwacta C ECT uamaGE4 CstPCONSTACCE U.f*A

.4=> n oct ao ramecr ees=4rc~s uwacca c.w3.on emoevacus ,r uca CORRECTIVE ACTION IMPLEMENTED 43 PRNurg ue gi ua%aOn a paoj p.iccumeuggt uc#

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MCAR-34 A gust 21, 1979 Page 2 REC 05CtD*DED ACTIO" (Continued) -

c) Take necessary actions to preclude recurrance.

2. Quality Control

• a) Deter =ine why this high rate of failure for the Drop'In Anchors was not indicated by the nor=al in-process testing of anchors, referenced in section 6.0 of Spec. 7220-C-305.

3. Proj ect Encineering a) Evaluate this condition for reportability under 10 CFR 50.55(e) and issue interi= report to the FQAE by Septenber 4,1979, based on input fro =

engineering and construction and quality control.

b) Deternine adequacy of all "Q" Drop-In 1Echors.

c) Deter =ine cause of failure and take action to prevent recurrance.

1248 280 e

Enclosure 2 y , Hove-2' +7-7.~9 Bechtel Power Corporation s'

777 East Eisenhower Parkway Ann Arbor, Mich:gan .S 'i sinumress: P.O. Boa 1000. Ann ArMr. Michigan ASICS Septe=ber 5, 1979 BLC-8115 Mr. G. S. Keeley Project Mcnager Consucers Pcuer Co:pany 1945 West Parnall Road Jackson, Michigan 49201 Midland Units 1 & 2 Consu=ers Power Co=pany Bechtel Job 7220 MCAR 34 P;TERIM REPORT 1 Files: 2417/2801

Dear Mr. Keeley:

Attached for your information and use is Interi= Report 1 for MCAR 34, which addresses Drop-In Anchors. The report indicated a failure rate of 2S%. However, since writing the Interin Report,

' additional results have indicated that of 66 Drop-In Anchors tested, there were 13 failures, resulting in a failure rate of 20%.

The next report is scheduled to be issued on October 2, 1979.

Very tr . yours, 4 ,/ d N W ohn A. Rutgers #

Project Manage" JAR /SKC/kb Attachtest (3 pages) cc: Mr. 71. R. Bird Mr. B. W. Marguglio Mr. D. B. Miller

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Bechtel Associates ProfessionalCorporation Attach =ent to BLC-8115

SUBJECT:

MCAR 34 (issued 8/21/79) Drop-In Anchors INTERIM REPORT 1 DATE: Septe=ber 4, 1979 PROJECT: Consu=ers Power Co=pany Midland Plant Units 1 & 2 Bechtel Job 7220 Introduction As requested in MCAR 34, this report su=marizes project engineering's evaluation and action regarding the failure of the drop-in anchors to cect the tension testing criteria furnished by project engineering.

Descriction of Deficienev Specification 7220-C-305, Section 6.2.2 requires tension testing of drop-in anchors to caet the values indicated in Table 3.2 of that specification. Inprocess inspection of drop-in anchors is required in However, when it was learned that this Specification 7220-C-305.the time of installation was not being done at all ti=es, inspection at 21, 1978, and testing was requested by project engineering on August again on May 18, 1979, to verify the adequacy of past installation.

For the testing results to be acceptable, it was necessary thatAccordinga sample of 60 randc=1y selected anchors be tested with no failures.

to Specification 7220-C-305, the anchor is considered acceptable if a test load equal to twice the design allowable the anchor tensile does lead not is applied break, distort, and the concrete does not break out; or defer =; and the anchor does not slip excessively or beccee loose.

Excessive slippage is evident when the washer between the bolt and the concrete can be rctated by hand. However, upon completing tension cests on 32 drop-in anchors involving four dif ferent bolt diameters, nine '

A nonconformance Report (NCR) has been generated failures had occurred. Approxicately 900 drep-in anchors had been to identify these failures. engineering requested that installed as of August 17, 1979, when project drop-in anchor installation be suspended until further notice.

1248 282

C Bechtel Associates ProfessionalCorporation

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Attachment to BLC-8115 MCAR 34

, Interim Report 1, Septenber 4,1979 -

! Page 2 Investination i The loads listed for drop-in anchors in Specification 7220-C-305, Tab'e 3.2 were established by Hilti, the manufacturer, through their own testing program. Project engineering net recently with a representative of Hilti at the Midland site to witness testing and installation practices used for the drop-in anchors. Only ti crectrical group used the drop-in anchor bolts for substantial loads; the other mups have ILnited their usage to loads of less than approxi=ately 200 pounds.

The Hilti representative verified that the testing procedure used is consistent with Hilti's own test procedure. He maphasized that, if tha plug which expands the anchor is not driven in ,:o=pletely with the Hilti tool, the full capacity will not be attained. fhe design of the Hilti drop-in anchors and .se method of setting are illustrated in Figure 1.

Based on a preliminary investig scion on August 23, 1979, some of the installed plugs vers found to be not fully driven into the anchor; however, the extent to which this contributed to the cause of the anchor failures was not established. It was deterair.ed.that further testing would be needed to establish the specific cause(s) and extent of the anchors' failure ts pass the test.

Safety I olications Project engineering's investigation of the deficiency shows an implication of an adverse effect on plant safety, and therefore is reportable under 10 CFR 50.55(e). Preliminary indication of a 28% failure rate demonstrates an inability to ensure the adequacy of anchor bolt capacities.

Corrective Action Project engineering has requested that additional testing be performed on a randon sampling of 100 drop-in anchors to establish what portion were not correctly set and the effect of this deficiency on the bolt capacity. Results are expected by September 7, 1979; the evaluation will be presented in the next report scheduled for October 2, 1979.

Submitted by:'

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Approved by: 70 ,7- . // f sca i . C ' ',- . ..

Concurrence by: ' h ~~. - / , [ .~

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1)hu; . nGCliOR Attachcent to P.LC-8115

): CAR 34 I!.TERIM REPORT 1 '

September 4,1979 -

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TYPICAL HILTI DROP-IN ANCHOR

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(PER IIILTI ANCIIOR AND FASTENER DESIGN MANUAL)

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. Senior Vice President General O ffices: 1945 West Parnell Road, Jackson, Michigan 49201 e (517) 7884453 Septe ber 10, 1979 '

Hove-246-79

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Mr J G eppler, Regional Director ,; ' /,,

%;f .d.,g Office of Inspection and Enforcement y\

Region T.~1 y ' ' '

fl US Nuclear Regulatory Cc==1ssion  !!.. < L(g;f,' Q'- s- l 799 Roosevelt Road Glen Ellyn, IL 60137

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MIDLA:iD 1;UOLEAR PLA!;T 2- '3 c.

U:lTT 1:01, DCC:M 1:0 50-l39 .

gj-t .:: t i V UIIIT NO 2, DOC C ,UO 50-330 CCMPC :II.T QUALIFICATION TIST DCCD21;TATION RE-RITIEW

Reference:

S H Howell letters to J G eppler; Midland Nuclear Plant; Unit Ito 1, Docket No 50-329; Unit No 2, Decket No 50-330; Cc=penent Qualification Test Docu entation Re-Review;

1) Serial Heve-252-78, dated Ecve ber 28, 1978

2) Serial Hove-17-79, dated January 17, 1979 3 Serial Hove-79-79, dated March 9,1979 4 Serial Hove-133-79, isted Mey 4,1979

5) Serial Hove-193-79, dated July 6,1979 The referenced letters were interi= 50 55(e) reports as is this letter.

The E&W detailed re-review of qualification docu entction, consisting of ec=parison of the cc::ditions the equipment was qualified to versus the postulcted design besi: cecident conditions as defjned in the Istut, is now scheduled for cc pletica in November,1979 .

As of August 15, 1979, qualification has been ec=pleted en 15 of the 3echtel Furchase Orders for safety grade equip =ent. For the qualification to be censidered cc:plete, any quastiens resulting frc: the re-reviev =ust be resolved and all required qualification documentation sust have been received and approved by Eechtel. The enclocure provides the latest status of the 3echtel qualificatica re-review effort.

Beyond the previously identified Foxboro Model E10 transmitters, no other equiptent has been dete=:ined not to be capable of meeting its qualificatien requirenent s.

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1243 2 8 5._.

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, Hove-246-79 ,

Another 50.55(e) report, either interi= or final, vill be sent on or before March 1, 1980.

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Enclosure:

'ualification Test Status Report, Revision 9, cated August 15, 1979 CC: Director, Office of Inspectics & Enforce =ent Att: MrVictorStello,US!EC(15)

Director, Office of 2:anagement Infor=ation & Progres Control, USliRC (1) v/o

Enclosure:

3CO: JL3 acon,if-1065A ,

WR31rd, JSC-2163 JL0erley, !!idland L3Curtis, 3echtel AA LADreisbach, Bechtel-Midlan:1 GSi:eeley, Plk h083 CD:ahaney, 307 B'.C:arguslio, J00-220A D3 Miller, Mid..and JF::e gen, Beehtel-Midland JAPastor, Pik h03 JIRutgers, 3echtel AA '

IIJSchaeffer, Midland -

MEGibbs, IL&B File: 0.h.9.22

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/a,c .) ) l. ,..w-ri g e s= +t *- y Stephen H. Howell ll U S E h *' Senior bice Pressdent i

General offices: 1945 West Pernali nood, Jackson, Mich; gen 49201 * (517) 788 4453 l Septe=ber 7. 1979 Hove-241-79

• Mr J G Keppler, Regional Director Office of Insp2ction and Enforcement Region III US Nuclear Regulator /- Cc=rission 799 Roccevelt Road Glen Ellyn, IL 00137 HIDLAITD NUCLEAR PLAI:T U m IiO'1, D00 2 EO 50-329 .

UH1T UO 2, DOC:CT 1:0 50-330 PRESSURIZER IEl.TER SYEI

References:

(a) Letter, S H Ho, ell to J G Keppler; Midland Nuclear Plant; Unit I;o 1, Locket Iio 50-329; Unit No 2, Docket No 50-330; Pressuricer Hecter System; Hove h-79; dated January 5, 1979 (b) Letter, S H Hcvell to J C Keppler; Midland Nuclear Plcnt; Unit No 1, Docket No 50-329; Unit no 2, Docket no 50-330; Pressuricer Her.ter System; Ecue-91-79; dated March 16, 1979 (c) Letter, S E EcVell to J G Keppler; Midlend liuclear Plant; Unit Ho 1, Dochet No 50-329; Unit Ho 2, Docket Uo 50-330; Pressuricer Hecter Systes; dated June 8, 1979 The referenced letters vere interim 50 55(e) reports as is this letter.

No s16 nificant problees have been encountered since the last interl= report, and the schedule for the final delive:/ and conpletion of the qualification of all involved cenpenents is still June of 1980. -

Another 50 55(e) report, either interim or final, vill be provided on or before February 1, 19EO.

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CC: Director of Office of Inspection & Enforcement Att: Mr Victor Stello GIRC(15)

Director, Office of Monegec.ect ,

Infor= tien & Program Control, U31TRO (1) 4g }g7 (

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2 Hode-241-79 BCC: JL3acen, M-1085A RCEauman, Plk-412 UR31rd, JSC-2163 LHCurtis, Bechtel AA JLCorley, Midland LADreisbach, Eachtel-Midland GS:-:eeley, Plk kOS3 .

CE'eheney, Ba'.1 Lynchburg E'<.):srgglio, JSC-22CA DE!1ller, Midland LE:oring, Bachtel AA J1!c'egen, Ecchtel-Midle.nd EGibbs, IL&3 File: 0.4 9 23 1243 288 e

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