ML19344A089
| ML19344A089 | |
| Person / Time | |
|---|---|
| Site: | Midland |
| Issue date: | 08/23/1979 |
| From: | Howell S CONSUMERS ENERGY CO. (FORMERLY CONSUMERS POWER CO.) |
| To: | |
| References | |
| HOWE-226-79, NUDOCS 8007290969 | |
| Download: ML19344A089 (7) | |
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7,M August 23, 1979 Ecwe-226-79 Mr J G Keppler, Regional Director Office of Inspection and Enforce =ent US Nuclear Regulatory Co==ission Regien III 799 Roosevelt Ro,d Glen Ellyn, IL 60137 MIDLAND NUCLEAR PIAUT -
UNIT NO 1, DOCKrI' no 50-329 UNIT 50 2, DOCKET NO 50-330 C0!TIAH2C.':' FUILDIIU PRESTRESSING TEIDOIG In accordance with the requirements of 10 CFR 50 55(e), this letter constitutes en interi= report on the status of the centainnent building tendons being supplied by Inryco. The tendon vires fabricated at the Florida facility vere found to have indeter=inate icngths. In the July 26 oral report on this subject, it was stated that there vere a total of 31 tendcns involved. Later investigation revealed that, in fact, there vere 38 tendons as felicus:
Shipped to site:
7 verticals installed in Unit 2 l
10 hori ortals en hold at site On hold at Inryco's Wire =11 Facility:
7 verticals
-i 14 horizontals The attachments to this letter provide a descriptics of the discrepancy, potential safety inplications, investigatien and planned corrective actions.
Another report, either interin or final, vi1~ be sent on or before Septe=ber 28, 1979 L
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was/lb Attach:.:nts:
1.
Quality Assurance P cgrc=, Manage =ent Corrective Actica Report, MCAR-1, Report 33, dated July 27, 1979 2.
MCAR-33, Interin Report yl, dater' August 10, 1979 072 nn 94 9 O
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2 Hove-226-79 CC: Director of Office of Inspection & Enforce =ent Att: Mr Victor Stello, USIGC (15) 3 Director, Office of Manage =ent Infotustion and Program Control, USIT.C (1)
BCC: JL3 acon, M-lC85A RC3au=an, Pik 412 WR31 d, JSC-2163 RLCastleberry, Bechtel AA -
JLCorley, Midlcnd Bechtel-Midland LADreisbach,4 LOS3 GS*<eeley, P1 ITAMarguglio, JSC-220A PAMartinez, Bechtel AA
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D3:1111er, Midisnd WGMoring, Bechtel AA CAHunt, P14-2093 GT31ach, Midland-MEGibbs, II2:3 Great Lakes QA Managers File: 0.4 9 30 e
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OUALITY A0GURANCE PROGRAM -
AttS:h:ent 1 MAtu'IMENT CORRECTIVE ACTION RT ~
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MCAR1 REPORT NO.
33 s
JOS NO.
7?M Q NO.
1 107 DATE July 27. 1979 1
' DESCRIPTION (including references):
Secticn 3.8.1.6.3.2 of the Midland Units 1 and 2 FSAR states in part "The differential 3
le 5th of any two wires in the sane tendon up to 100 feet wire length is i 1/16 inch and i 1/8 inch for wires longer than 100 feet.
Cutting tolerances for overall tendon length in i 1/2 inch up to 100 feet and i 1 inch over 100 feet."
These require =ents are ref*.ect:ed in Inr/co Post Tensioning Procedure PT 5.1 (Fabrication Tendons).
Contreyto this requirement tendons were produced with varying unknown wire lengths.
Some tendons were accepted by Inryeo QC and 17 tendons were shipped to the Jobsite (Continued on page 2)
- RECOMMENDED ACTION (Optional) i Actions to be accc=plished by supplier. Available data to be provided to 3echtel Project Engineer on or before August 8,1979. At that time a schedule for answering other questions will be provided.
l 1.
Determine the extent of the hardware problem.
a) Ecw was problem detected.
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b) Deter ine which tendons are acceptable for use and provide data and rationale to substantiate.
(Continued on page 2)
REFERRED TO O ENG!NEERING O CONSTRUCTION OOA MANAGEMENT O
CP.NOLUREMENT 1
ISSUED BY
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Prc.iect CA Eri;.neer Oate REPOCTABLE DEFICIENCY Potentially reportable IFIED CUENT C NO O YES
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DESCP.IPTIO;I Continued (7 verticals and 10 horizontals). Of the tendons shipped to the Site the 7 verticals were inserted into the Contain=ent (#2). NCR 2373 was issued placing the tendons at the Site on hold.
Shipnent frcn the Florida f acility have been placed on hold.
RECCl27.K::ED ACTION Continued c) Is the proble: limited to those tendons produced at the Wire Mill facility in Florida or are the tendons produced at Inryco, Melrose Park, Ill. also questionable.
d) If the Melrose Park tendons are considered satisfactorf what is the basis for this conclusion.
2.
Provide disposition instructions for tendons deter =ined to be bad or questionable.
3.
Re=edial action to the =anufacturing process to prevent similar problems in the future.
a) Include co=plete evaluation of =anufacturing process, b) Correction of any deficiencies.
c) Proof of effectiveness of corrective actions.
4.
Renedial action regarding the quality progrs= to prevent si=ilar problems in
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the future.
a) Evaluation of Quality Progra=.
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b) Correction of deficiencies.
c) Proof of effectiveness of corrective action.
PROJECT ENGINT.ERING 1.
To evaluate responses fro: vendor and issue Interi: Report on August 10, 1979 to Quality A.ssurance.
2.
Also, determine reportability under 10 CFR 50.55(e) and identify in the Interin Report.
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. Bechtel Asst
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SUiUECT:
MCAR 33 (Issued 7/27/79)
Dif ferential W re Length of Contain=cn Building Prestressing Tendons 5
INTERIM REPORT 1 DATE:
August 10, 1979 PROJECT:
Consumers Pouer Company Midland Plant Units 1 and 2 Bechtel Job 7220 Introduction This report su==arizes proj ect engineering's actions and evaluation to date regarding the differential length of prestressing tendons.
Descriotion of " "- i.ancv On July 20, 1979, Inryco, the post-censioning vendor, iltformed Bechtel construction that it was placing all tendons manufactured at the Iliremil facility in Florida on hold, due to tendons being manufactured to unknown wire lengths. 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 co==it=ent stated that the differential wire length for any two wires in a tendon is i 1/8 inch for tendons over 100 feet. And the cutting tolerances for overall tendon length is i 1 inch for tendons over 100 feet. There were 17 tendons shipped to the site that were manufactured in t? ire =il.
Out of the 17 tendoits, 7 are
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verticals and they have been installed into the sheaths. The rc=sinder are hori:entals and they have not been installed. NCR 2373 was issued placing the tendons at the site on hold.
Investication An investigation was initiated, uith both the t? ire =11 and Melrose Park
-l facilitics being e>:anined by Bechtel and CPCo personnel. The finding is that only the tendons produced at the Iliremil facility are of differential uire lengths (38 tendens total).
The review of the man'ufacture/ inspection processes at Melrose Park revealed no indications that the tendons delivered frc= the Mc2 rose Park facility are not in corpliance with the FSAR. The disposition of the 38 tendons in question has not been finalized.
A meeting uns hc2d on August 9, 1979, at Melrose Park to discuss the
-i questions presented in MCAR 33 and the draft rc=cdial procedures to correct the deficiencies. The information gathered is being evaluated and will be included fit the ne::t' report scheduled to be issued on September 10, 1979.
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Bechtel Associates ProfessionalCorporation MCAR 33 Interim Report 1 August 10, 1979 Page 2 3
Safety Innlications Project engineering's investigation indicates that the quality assurance the Uiremil facility broke down. The differcatial wire program used at lengths in a tendon will cause wire stresses in excess of the design The safety margin of the containment structure is thus reduced values.
from the design conditions as stated in the FSAR. Therefore, the deficiency is considered reportable under 10 CFR 50.55(e). However, the situation proba'cly 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 vill not fail during any design condition.
Since a tendon e>:periences the highest stress level during the 2) initial prestressing operation, wires that are overstressed may break.
The condition would have been detected as a part of speci-fication requirements for broken wire.
9 During the prestressing operation, the jacking force is nonitored with calibrated gages and the tendon elongations are checked against calculated values. Any abnormality would be detected and l
corrective measures will be made.
9 Corrective Action the ten horizontal tendons not installed are being shipped At pre 34r.t, back to the Wiremil facility. The disposition of the seven installed Wiremil has vertical tendons, as propos<td by Inryco, is being revicued.
initiated corrections to P te production equipment to eliminate the source of t.h'c length variation probicm. A vire length verification procedure is being formulated by Inryco.
If the procedure is approved by 3cchtel and CPCo. tha snipment of tendons to the site vill commence.
Submitted by:
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