ML19291B161

Forwards QA Program Mgt Corrective Action Rept 33 Re Discrepancies Found in Containment Bldg Tendons Supplied by Inryco.Next Rept Will Be Sent by 790928

ML19291B161
Person / Time
Site:	Midland
Issue date:	08/23/1979
From:	Howell S CONSUMERS ENERGY CO. (FORMERLY CONSUMERS POWER CO.)
To:	James Keppler NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III)
Shared Package
ML19291B162	List: ML19291B161 ML20062H303
References
HOWE-226-79, NUDOCS 7908290560
Download: ML19291B161 (2)

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83 L5 PGW8r Stephen H. Howell Senior Vice Eyeslient

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General Of fices: 1945 West Parnall Road, Jackson, Michigan 49201 . (517) 7884453 August 23, 1979 Howe-226-79 Mr J G Keppler, Regional Director Office of Inspection and Enforcement US Hu: lear Regulatory Cczmission Region III 799 Roosevelt Rocd Glen Ellyn, IL 60137 MIDLAUD UUCLEAR PI/.NT -

UNIT E0 1, DocKDr no 50-329 tmIT no 2, Ir0ELT r0 50-330 C0!TfAIEMEI.T EUILDIE3 PRESTRESSInG TEHDONS In accordance with the requirements of 10 CFR 50 55(o), this letter constitutes an interim report on the status of the ccat,uintuent, buildlut,s tendonc being supplied by Inryco. The tendon wires fabricated at the Florida facility were found to have indeterminate lengths. In the July 26 oral report on this subject, it was stated that there vere a total of 31 tendons involved. Later investigation revealed that, in fact, there were 38 tendons as follows:

Shipped to site:

7 verticels installed in Unit 2 10 horizontals on hold at site On hold at Inryco's Wiremil Facility:

7 verticals 14 horizontals The attachments to thin letter provide a description of the diserapancy, potential safety implications invcatigation and planned corrective acticas.

Another report, cither interim or fincl, vill be sent on or before September 28, 1979 WRB/lb Attachments: 1. Quality Assurance Program, Manage =ent Corrective Action Report, MCAR-1, Report 33, dated July 27, 1979

2. McAR-33, Interim Report #1, eated August 10, 1979 7 9082 90ST>o 2012 J54

2 Eove-226-79 CC: Director of Office of Inspection & Enforce =ent Att: Mr Victor Stello, U3IaC (15)

Director, Office of Managemnt Infomation and Progrca Control, USImc (1)

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QUAll1Y ASSUllANCE l'ROGHAM Attachment 1 MANAGEMENT CORRECTIVE ACTION REPORT Howe-226-79

,/ MCAR 1 REPORT NO. 33 1 In7- DATE July 27, 1979 JOB NO. 7220 O NO. ,

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• DESCRIPTION (including references):

Section 3.8.1.6.3.2 of the Midland Inits 1 and 2 FSAR states in part "The diff.v.cntial length cf any tuo wires in the same tendon uo to 100 feet vire length is i 1/*,6 inch  ;

and 1/8 inch for wires longer than 100 feet. Cutting tolerances for overall tendon length is i 1/2 inch up to 100 feet and i 1 inch over 100 feet." These requirements are reflected in Inryco Post Tensioning Procedure PT 5,1 (Fabrication Tendons).

Contraryto this requirement tendons were produced with varying unknown vire '.c nc t h s .

Some tendons vere accepted by Iaryco QC and 17 tendons vere shipped to the Jcbsite (Continued on page 2)

• RECO$ MENDED ACTION (Optional)

Actions to be acce=plished by supplier. Availabic data to be provided to Bechtel Project Engineer on or before August 8,1979. At that tiue a schedule for cnswering other questions vill be provided.

1. Deternine the extent of the hardware probica.

a) Hov vas probics detected.

b) Deternine which tendons are acceptabic for use ard provide data and rationcle to substantiate. (Continued on page 2) i REFERRED TO O ENGINEERING O CONSTRUCTION OOA MANAGEMENT O _

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DE PROCUREMENT i ISSUED BY - M Pro;cct G A Enyncer Date I '

il REPORTABLE DEFICIENCY Potentially reportabic N TIFIED CLIENT O NO D YES Pro;ect Manager Date / ,

Ill CAUSE -

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CORRECTIVE ACTION TAKEN l

7908290 % 7. 3 AUTHORIZED BY Dato ST ANDARD DiSmBUDON ADO' TONAL D:STR'00 TION - AS A"PROPRIATE FORMAL REPORT TO CLIENT E

c.,NCu c'[S'i"> (if Section li Applics) Date v . aa u aw.o.

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aaO Ca pasa,J H ptOJ grt S-9c3 cte.,f u uwace R IS4L186 C B eWa*J R CW D COrdf M OC (Nleht(F4 a u to CORRECTIVE ACTION IMPLEMENTED ano ter er cia 'n w can. . oms cas.c4scw, ano n.uu et . casau a aw n,tu, x,. mx,u uoo %, uc.a usi ,n ,

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• L se ter serrt e a waun et.n U .I q fa0 VERIPED BY .

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,. ' MAllAGIMENT ColmECTIVE ACTION RITORT REPORT No. 33 Page 2 DESCRIPTION rontinued (7 verticals and 10 horizontals). Of the tendons shipped to the Site the 7 verticals were inserted into the Contain=cnt (#2). NCR 2373 was issued placing the tendons at the Site on hold. Shipment from the Florida facility have been placed on hold.

RECO}24 ENDED ACTIQU Continued c) Is the problen limited to those tendons produced at the Wire Mill facility in Florida or are the tendons produced at Inryco, Melrose Park, Ill also questionabic.

d) If the Melrose Park tendons are considered satisfactory what is the basis for this conclusion.

2. Provide disposition instructions for tendonc determined to be bad or questionable.

3. Remedial action to the manufacturing process to prevent similar problems in the future.

a) Include complete evaluation of manufacturing process.

b) Correction of any deficiencies.

c) Proof of effectiveness of corrective actions.

4. Remedial action regarding the quality progran to prevent similar problems in the future, a) Evaluation of Quality Program.

b) Correc fon of deficiencies.

c) Proof of effectiveness of corrective action.

PROJECT ENGINEERING 2%J

1. To evaluate responses frou vendor and issue Interin Report on August 10, 1979 to Quality Assurance. ,

2. Also, determine reportability under 10 CFR 50.55(c) and identify in the Interin Report.

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Attachment 2

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Bechtel Associates ProfessionalCorporation

SUBJECT:

MCAR 33 (Issued 7/27/79)

Differential Wire Length of Contdinment Building Prestressing Tendons INTERIM RLf3RT 1 DATE: Auguet 10, 1979 PROJECT: Consumers Power Company Midland Plant Units 1 and 2 ,

Bechtel Job 7220 Introduction This report summarizes proj ect engineering's actions and evaluation to date regarding the -differential length of prestressing tendons.

Description of Deficiency On July 20, 1979, Inryco, the post-tensioning vendor, informed Bechtel construction that it was placing all tendons manufactured at the Wiremil facility in Florida on hold, due to tendons being manufactured to unknown wire Ict.gths. This is in violation of the Inryco Post Tensioning Procedure PT 5.1, Fabrication-Tendons, and the Midland Plant Units 1 and 2 FSAR Subsection 3.8.1.6.3.2. The commitment stated that the differential wire length for any two wires in a tendon is + 1/8 inch for tendons over 100 feet. And the cutting tolerances for overall tendon length is t 1 inch for tendons over 100 feet. There were 17 tendons shipped to the site that were manufactured in Uiremil. Out of the 17 tendons, 7 are verticals and they have been installed into the sheaths. The remainder are horizontals and they have not been installed, NCR 2373 was issued placing the tendons at the site on hold.

Investication -

An investigatien was initi: ted, with both the Uiremil and Melrose Park facilities being examined by Bechtel and CFCo personnel. The finding is that only the tendons produced at the Wiremil facility are of differential wire lengths (38 tendons total). The review of the manufacture / inspection

• processes at Melrose Park revealed no indications that the tendons delivered from the Melrose Park facility are not in compliance with the FSAR. 'lhe disposition of the 38 tendons in question has not been finalized.

A meeting was held on August 9, 1979, at Melrose Park to discuss the quastions presented in MCAR 33 and the draft remedial procedures to correct the deficiencies. The information gathered is being evaluated and vill be included in the next' report scheduled to be issued on September 10, 1979. ,

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Bechtel Associatos Professional Corporation

}! CAR 33 Interim Report 1 August 10, 1979 Page 2 Safety Implications Project engineering's investigation indicates that the quality assurance program used at the Wiremil facility broke down. The differential wire lengths in a tendon will cause wire stresses in excess of the design values. The safety margin of the containment structure is thus reduced from the design conditions as stated in the FSAR. Therefore, the deficiency is considered reportable under 10 CFR 50.55(e). Iloweve r , the situation probably would not have adverse effect on plant safety for the following reasons:

1) A tendon is subjected to the maximum stress during the initial prestressing operation, when they are stressed to 80% of the ultimate strength. Therefore, if a tendon can withstand the initial prestressing force, it will not fail during any design condition.s .

2) Since a tendon experiences the highest stress level during the initial prestretsing operation, wires that are overstressed may break. The condition would have been detected as a part of speci-fication requirements for broken wire.

3) During the prestressing operation, the jacking force is monitored with calibrated gages and the tendon elongations are checked against calculated values. Any abnormality would be detected and corrective measures will be made.

Corrective Actig At present, the ten horizontal tendons not installed are being shipped back to the Wiremil facility. The disposition of the seven installed vertical tendons, as proposed by Inryco, is being reviewed. Wiremil has initiated corrections to the production equipment to clininate the source of the length variation problem. A vire length verification procedure is being formulated by Inryco. If the procedure is approved by Bechtel and CpCo, the shipment of tendons td the site will commence.

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< ..blW ORA MIM FOR:

L'l A. Schwencer. Chief. Operating Reactors Branch No.1. DOR 1

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, R. W. Reid. Chief. DiMtrattog Reactors Branch No. 4, DDR Nt0H: ,[ Id. O. iiiller, Chief, License Fee l'anagement Branch, AD.9 .

f, y SusJECT:

CLARIFICATI0ii 0F FEE CLASSIFICATION FOR RADIATIOt PROTEC j .

MANAGER QUALIFICATIONS TECHNICAL SPECIFICATI0'i CHMGES

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.Me have moeived your fee classification forms on the fellowing applications thich reveal what. appears to be inconsistent fee treatment on applications

' that are for the same subject'iten: '

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_L , l July 10,1979 application for Potat Beach I and 2 - no fees paid;

"?se fons dated August I stated that action is Classes I and II; that' app 11 cation is exempt from fees because Commission requested

_ ._.'1% 3/24/77 to simplify or clarify license or TS for convenience of Commission, with only minor safety significance.

" A Herch 21 '1979 applicatten for Oconee 1, 2 and 3 - no fees paid

. initially. However, fee form dated June 25 stated that one

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C1sas'Ill and two duplicate Class I fees were due because single

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4safett issue to meet RG 1.8 Fees requested by latter dated l -: June 3; paid vith letter from Duke dated July 13.

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e" -To avoid 'a possible inequity la fee treatment, it is requested that you recon-

- J sider your previous fee determinattee for the above items and provide this

. ;office trtth clarifying data as to ulty the two different positions are correct and Mffled'.'

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1f your reconsideration reveals that both appitcations should

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< yantesLyes does appropriate the sam,e fee determinaties, for clarfficatten.sisply provide amended fee fora (s) with any J .

y- Care espies of aesh of your previous fee classiftFor your convenience, attached <

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C Betelthetbecauseanapplicationisasaresult's N^@_ J 9t W,est) y ; %11y a emespt from fees ~unless it is to simp 1tfy 1ssion request.

or clarify the 11esase er M.7.v,4: ^. .e.for the c conventence'of

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Enclosures:

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1. Copy'gf Point Beach Fee Form dtd. 8/1/79 --

2. ' Copy of Oconee Fee Form dtd. 6/25/79 e

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N C.' Trammell, ORB-1 f _M. Fairtile, ORB-4 1 - C. Pa:Tinh, ORB-1 1,. _R. Ingram, 0Fli-4 h -

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Regulatory Docket Files (5) -

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