ML19269B795
| ML19269B795 | |
| Person / Time | |
|---|---|
| Site: | Midland |
| Issue date: | 01/05/1979 |
| From: | Howell S CONSUMERS ENERGY CO. (FORMERLY CONSUMERS POWER CO.) |
| To: | James Keppler NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| References | |
| HOWE-1-79, NUDOCS 7901100286 | |
| Download: ML19269B795 (22) | |
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M e % CODSUU10iS L. [N i POW 0r Q7 % Canigany 5J!,'"ff%1, General O f fices: 1945 West Parnall Hoad, Jackson, Michigan 43201 * (S17) 788-0453 January 5,1979 nove-1-79 Mr J G Keppler, Regional Director Office of Inspection and Enforcenent US Nuclear Regulatory Ccmmission Region III
'(99 Roosevelt Road Glen Ellyn, IL 60137 MIDLAND NUCLEAR PLANP -
UNIT UO 1, DOCKET LO 50-329 UNIT no 2, DOCKET NO 50-330 SETILEMENT OF DIESEL GENERATOR FOUNDATIONS AND BUILDING
Reference:
S H Howell letters to J G Keppler; Midland nuclear Plant; Unit No 1, Docket no 50-329; Unit No 2, Docket No 50-330; Settlement of Diesel Generator Foundations and Buildin6; c) Serial Hove-183-78; dated September 29, 1978 b) Serial Hove-230-78; dated november '(,1978 c) Serial Hove-267-78; dated December 21, 1978 This letter, as were the referenced letters, is an interim 50 55(c) report , on the settlement of the diesel generator foundations and building. Enclosure 1 provides the status of the actions being taken to resolve the problem. Enclosure 2 provides some typographical corrections and clarification to Enclosure 1. Another report, either interim'or final, vill be sent on or before February 23, 1979
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Enclosure 1: MCAR 24, Settlement of the Diesci Generator Foundations and Building, Interim Report #3, dated December 27, 1978 Enclosure 2: Errata and Clarification for MCAR 24, Interim Report #3 CC: ctor, Office of Inspection & Enforcement Att: Mr John G Davis, Acting Director, U3NRC (15) 790110D>$g Director, Office of Management Infonnation and Program Control, USHRC (1)
Enclosure 1
~. ' Howe-1-79 Bechtel Associates Professional. Corporation 777 East Eisenhower Parkway Ann Arbor, Michigan usd Ad@ess P.O. Box 1000 Ann Arbor, Michigan 48106 Page 1
SUBJECT:
MCAR #24 (Issued 9/7/78) Settlement of the dicsc1 generator foundations and building INTERIM REPORT #j[ DATE: December 27, 1978 PROJECT: Consumers Power Company Midland Plant Units 1 & 2 Bechtel Job 7220 Introduction This report is submitted to advisu of the interim status of the project's actions relating to the settlement of the diesel generator foundations and building as described in MCAR #24 and NCR 1482. Description of Deficiency The general foundation and building settlements (taken December 6,1978) are shown in Figures 1 through 4 (attached). Background Information The Category I structures on the plant site are shown in Figurc 5 (attached). Figure SA indicates the plant structures which are Category II. The plant fill was placed from 1975 to 1977. Scismic Category I structures placed on the plant fill include the diesel generator building, the underground diesel oil tanks, borated water storage tanks and basin, a portion of the service water pump structure, service water valve pits and the associated piping for cach of the above systems. The arrangement of the dicscl generator building is shown in Figurc 6 (attached). The settlement of Category I structures observed to date are as follows:
- 1) Reactor buildings - varies from 1/4 to 5/8 inch
- 2) Auxiliary building - approximately 3/8 inch Service water pump structure - varies from 0 to 1/4 inch
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3)
- 4) Service water valve pits - approximately 1/4 inch
- 5) Borated water storage tanks - approximately 1/4 inch
- 6) Diesel generator building 3/4 inches maximum
- 7) Diesel generator pedestal 1/4 inches maximum
Bechtel Associates Professional Corporation MCAR #24 INTERIM REPORT 3 Page 2 It is apparant that the structures on original soil show no settlement ' prob 1cm. These settlement values are consistent with the values in FSAR Figure 2.5-14A. Soil Exploration After the excessive setticment of the diesel generator building was observed, subsurface studies were conducted in the main plant area by Bechtel to provide information to be used for determining any required remedial measures. There are 29 borings, 14 dutch conc penetrations, and 1 test pit which were made in the dicscl generator building. Boring, dutch conc penetration, and the test pit locations in the plant area are chown in Figure 7. Figure 8 shows the locations of those in the .cscl generator building area. Split spoon, Shelby tube, and Osterberg tube sampics were taken from the borings and sent to the Goldberg-Zoino-Dunnicliff & Associates laboratory for testing. Bag samples were taken from the test pit. An undisturbed sampic was taken from the pit in the diesel generator building. In-place density test was made in the test pit by Goldborg-Zoino-Dunnicliff
& Associates.
Laboratory tests made to date have been concentrated on sampics taken from the diesel generator building area with some tests made in other areas of the plant. Laboratory tests performed include:
- a. Soil classification tests (e.g., Atterberg limits and gradation analyscs)
- b. Shear strength property tcsts consisting of torvanc strength, unconfined compression strength, and unconsolidated undrained triaxial strength tests, along with unit weight and moisture content
- c. Tests made to evaluate consolidation properties of the fill by conducting one-dimensional consolidation tests, specific gravity tests, and tests to evaluate the effects of saturation
- d. Mineralogy tests made to evaluate the swelling potential of the fill material including cation exchange capacity and x-ray diffraction tests
- e. Compaction tests to evaluate the percent compaction of fill materials Results from these tests are being evaluated.
~.
MCAR #24 INTERIM REPORT 3 Page 3 Corrective Action The following alternative plans have bcon considered by project engineer-ing:
- 1) No corrective action required
- 2) Modify the present strip foundations for the walls to a continuous mat foundation for the entire building.
- 3) Preload and consolidato the soil under the building.
- 4) Combine Items 2 and 3 above.
- 5) Underpin the building to transmit loads directly to the original soil layer.
- 6) Remove and replace the building and fill material.
Dr. R. Peck of Albuquerque, New Mexico, and Dr. A. Hendron, Jr. of the University of Illinois have been retained by Ecchtel as soil consultants. Mr. John Dunnicliff of Goldberg-Zoino-Dunnicliff & Associates has been retained as our instrumentation consultant. Dr. Woods of the University of Michigan has been retained to interpret the results of the dutch cono ponctration data. These evaluations are under way and will be addressed in subsequent reports. Our soil consultants have indicated the fill is settling under its own weight. They advise us that there are only two suitable options at this time:
- 1) Remove and replace the building and fill material
- 2) Proload and consolidate the soil under the building Of these corrective action plans, Dr. Peck and Dr. Hendron have recommended preload'ing and consolidating the soil under the building. This will allow the settlement of the building and underground utilitics to take place before plant operation.
Modification of the foundation and underpinning the building were dismissed as possible solutions because the residual setticment of the utilitics during the operation of the plant would not.be minimized.
~ r.. MCAR #24 INTERIM REPORT 3 Page 4 The preload option was selected because of the soil consultants' (Dr. Peck and Dr. Hendron) recommendations for corrective action. In order to maximize the preload and minimize the schedule impact, construction of the dicsc1 generator building is being continued. The exact amount of preload and the consolidation duration are difficult to determine. To assist in the determination of the necessary amount and duration of the preload, a system of instrumentation is being placed to record the soil movement and the pore water pressure during proload. The instrumentation consists of piezomoters, settlement platforms, and Borros anchors at selected locations and' elevations within and around the diesel generator building. Control instrumentation was installed in the area not affected by the preload. The additional settic=ent cannot be accurately predicted at this time. fetivities Completed Since Previous Report The following activitics were completed since the last interim report dated November 3, 1978:
- 1) Isolating Duct banks The extent of the contact between the structure and the duct banks was explored. It was determined that the duct banks were restraining the diesel generator building from settling independently. Hence, it was decided to free the building from the duct bank restraint.
The structure and utilitics were closely monitored during the release of this restraint. No distress to date has been noted in the utilitics due to the settlement. There were gaps in the order of 1-1/2 inch between the mud mat and the footings in the northeast area of the building. These gaps were reduced to 3/4 inch or less when the duct banks were isolated from the building. Therefore, there will be no grout placed between the underside of the footing and the mud eat prior to preload. To ensure the free movement, a minimum of 2 inches of Ethafoam will be placed around the duct bank and the excavated area filled with lean concrete prior to preloading.
?.
Bechtel Associates ProfessionalCorporation HCAR #24 INTERIM REPORT 3 Page 5
- 2) Meeting at Midland Jobsite A meeting was hcid on December 4,1978, with the NRC, Consumers Power Company, and Bechtel representatives. The purpose of the meeting was to inform the NRC of the current status of the dicscl generator building sett1cment.
- 3) Soil Instrumentation The installation of the instrumentation described under "Correctivo Action" has been completed.
Activities in Progress The activitics in progress include the following:
- 1) The foundation data survey program is outlined in FSAR Subsection 2.5.4.13.2. This program provides for survey data to be gathered at 60-day intervals until the end of construction. The survey data is gathered at 90-day intervals for the first year of operation.
At the end of this period, the survey data will be reviewed and an appropriate survey interval program developed, based on building performance. This foundation data survey program has been expanded to provido additional settlement points and some shortened survey intervals. The settlement points have been increased from 69 to 180. These additional points are for structures located on the plant fill. The data survey is presently being conducted on the structures at the following intervals: a) Diesel generator building at 7 days b) Remaining structurcs on plant fill at 14 days c) Main structures at 60 days - no change from previous interval
- 2) Utility Monitoring There are utilitics passing near and under the diesel generator building as shown in Figures 9 and 10, some of which are Seismic Category I. These utilities are being evaluated based upon their
MCAR #24 II;TERIM REPORT 3 Page 6 relationship to plant safety, plant operation, and geometric sensi-tivity to settlement. The integrity of these utilitics will be verified by monitoring representative lines. The monitoring will include visual examination for damage and movement, pressure tests, and continuity tests as indicated in Figure 11. The utilitics which have been selected for profile monitoring are a condensato line and a service water line. Sec Figure 11 for the location of the lines.
- 3) Monitoring Cracks in the Diosc1 Gr.ncrator Building Wall The existing cracks in the dier,c1 generator building are being mapped to assist in the evaluation of the structura after preloading.
Some of the cracks have closed after the four duct banks were released. Strain gages will be placed at selected crack locations for monitoring during preload.
- 4) NRC Inspection Report The following items addressed in NRC Inspection Reports 50-339/78-12 and 50-330/78-12 dated November 14, 1978, are being investigated by project engineering:
- a. FSAR Tabics 2.5-14, and 2.5-9 and 2.5-10 conflict with the fill material description in Drawings C-109, Rev 2 and C-117, Rev 6.
- b. FSAR Table 2.5-21 and Subsection 2.5.4.5.3 conflict with Specification C-210 and Quality Control Instructions C-102 regarding required number of passes for compaction.
- c. FSAR Subsection 3.8.5.5 - Expected setticment
- d. Conflict between FSAR Figure 2.5-47 and project Drawing C-1001, Rev 5 regarding foundation cicvation.
- c. Conflict in Specification C210 regarding compactive effort and test method e
Bechtel Associates Professional Corporation MCAR #24 INTERIM PIPORT 3 Page 7
- f. Conflict between consultants' recommendation and Specification C-210 regarding lif t thickness and compaction requirements
- g. 12% tolerance in moisture content permitted in Specification C-210 and whether the material that was placed related to the selected proctor
- h. Cracks in the dicscl generator building structure
- i. NRC Question 362.2, Subsection 2.5.4.5.1
- 5) Direct Effect of Surcharge The direct effect of the surcharge is being investigated as informa-tion becomes available. This will be addressed in detail in subsc-qucnt reports.
Future Activitics The activitics planned for the future include the following:
- 1) Surcharge Operation The consultants, Dr. R.B. Peck and Dr. A.J. Hendron. have recommended the proloading of the dicsc1 generator building area to consolidate the underlying material. It is estimated that between 15 and 20 feet will be utilized. The preload berm will extend 20 feet minimum irom the exterior of the building as shown in the referenced Figure 11 (attached). The preload berm betwcon the dicscl generator and turbine buildings will be detailed in future reports.
- 2) The following preparations are being made to prepare for the proload:
a) Freczo protection in the form of about 2 to 3 feet of sand is being placed on the present grade in the areas to be surcharged. b) Because of the close proximity of the diesel generator and the turbine buildings, additional details are being developed to strengthen the turbine building wall for the surcharge load in this area.
r MCAR #24 INTERIM REPORT 3 Page 8 c) The cicvation of the water tabic is important in ensuring optimum use of the proload. The water tabic in the area of the dicsc1 generator building is influenced by the water cicvation of the cooling pond. The cooling pond will be filled concurrently with the placing of the surchargo. The soil consultants have concurred to start filling the cooling pond as soon as possibic.
- 3) Analysis of Structures Analyses will be performed as required to evaluate the effects on the structures.
Schedule Impact The impact of the dicsc1 generator building settlement prob 1cm on the schedule will be discussed in subsequent reports. Submitted by: ffA /
,cvi-db,no:L w ' ,
Approved by:,WYbMW Concurrence by:
/
RB/js BECHTELASSOCIATESPROFySSIONALCORPORATION 12/11/13 O
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. Enclosure 2 Howe-1-79 ERRATA AND CLARIFICATION 10R MCAR 24, IIEERIM REPOTE #3
- PaBe 2, Line 3:
FSAR Figure 2 5-lhA should read FSAR Table 2 5-lhA
- Page 6, Paragraph h) b.:
0-102 should read C-1.02
- Figure 8:
Boring labeled D chould not be on this Figure.
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