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Category:QUALITY ASSURANCE PROGRAM
MONTHYEARML20093C3211984-10-0101 October 1984 Rev 0 to QA Program Plan for Shutdown Phase ML20092H5511984-06-15015 June 1984 Rev 5 to Project QA Plan, CPC Midland Idcvp ML20084L4011984-05-0404 May 1984 Rev 16 to QA Program Manual for Midland Nuclear Plant ML20082D4401983-11-15015 November 1983 Rev 15 to Vol 1 of QA Program Manual ML20082N0661983-10-25025 October 1983 Rev 2 to QA plan.Third-party Const Implementation Overview Encl ML20085D9321983-06-29029 June 1983 Rev 14 to Vol I of QA Program Manual,Policy 1, Organization ML20072A8601983-05-24024 May 1983 Rev 1 to Quality Verification Program Midland Nuclear Co Generation Plant Units 1 & 2 ML20023D1441983-05-0303 May 1983 Draft Quality Plan for Underpinning Activities ML20023D5281983-05-0202 May 1983 Rev 3 to Project QA Plan for Midland Independent Design Const & Verification Program. ML20071A6131983-02-17017 February 1983 QA Program Manual for Midland Nuclear Plant, Vol 1,Rev 13 ML20072M6251983-02-17017 February 1983 Vol I,Rev 13 to QA Program Manual for Midland Nuclear Plant ML20071C6861983-02-15015 February 1983 Rev 2 to Project QA Plan for Independent Design Const & Verification Program ML20072B2121983-01-17017 January 1983 QA Program for Midland Independent Design & Const Verification Program,Rev 1 ML20076G0451983-01-12012 January 1983 Rev 2 to QA Manual ML20062G0071982-07-26026 July 1982 Quality Plan for Remedial Soils Activities & Soils-Related Work in Quality Areas, Revision 0 ML20062G0061982-07-26026 July 1982 Quality Plan for Underpinning Activities, Revision 3 ML20054H1311982-05-18018 May 1982 Quality Plan for Underpinning Activities,Revision 2 ML20054H0811982-04-0202 April 1982 2 to QA Program Manual for Midland Nuclear Plant, Vol I ML20052F2791982-04-0202 April 1982 QA Program Manual for Midland Nuclear Plant,Vol 1. ML20052A7471982-03-0202 March 1982 Quality Plan for Underpinning Activities, Revision O ML20052A7511981-11-18018 November 1981 QA Program Policy-List of Definitions, Revision 11 ML18046A3741980-09-26026 September 1980 Vol 1,Revision 10,to QA Program ML20062H3031979-07-27027 July 1979 QA Program Mgt Corrective Action Rept 33:tendons in Containment Bldg Found to Have Unknown Wire Lengths.Caused by Manufacturer & QA Program Errors.Production Equipment & QA Procedures Being Corrected ML19329F1931976-11-0909 November 1976 QA Program for Bechtel Corp Topical Rept Implementation ML19329E2821969-12-31031 December 1969 QA Program for Facility 1984-06-15
[Table view] Category:TEXT-SAFETY REPORT
MONTHYEARML20058L8721992-12-31031 December 1992 1992 Annual Rept,Cpc ML20126D7211992-12-16016 December 1992 Potential Part 21 Rept Re Actual Performance of Rosemount Supplied Bailey Bq Differential Pressure Transmitters Differing from Rosemount Original Spec.Bailey Controls Encl.Evaluation Not Yet Performed ML20246N1221988-12-31031 December 1988 CMS Energy 1988 Annual Rept ML20154J4101988-05-12012 May 1988 Addendum 1 to Supplemental Part 21 Rept 145 Re Potential Problem w/F-573-156 Pressure Sensor/Lube Oil Trip.Initially Reported on 880429.Addl 1-1/8-inch Diameter W/Deep Counterbone in Pressure Head Added to Activate Valve ML20153B6191988-04-29029 April 1988 Part 21 Rept Re Potential Defect in Component of Dsr or Dsrv Standby Diesel Generators Supplied to Utils.Recommends Return of Subj Components in Onsite Warehouse Storage & Suggests Surveillance of Devices Already Installed ML20196J3801987-12-31031 December 1987 CMS Energy Corp 1987 Annual Rept ML20215G2441987-06-16016 June 1987 Part 21 Rept Re Failure of Load Sequencing Equipment Supplied in Aug 1977 During Scheduled Testing.Caused by Open Electrical Connection on One Crimp Lug.Since 1978,insulated Lugs Used on All Equipment ML20216E4721987-05-28028 May 1987 Part 21 Rept 140 Re Potential Defect in Air Pressure Regulators Mfg by Bellofram.Dripwell Gasket May Fail Due to Mismachining of Gasket Seating Surface Causing Loss of Control Air & Starting Air Pressure ML20207R9041986-12-31031 December 1986 CPC 1986 Annual Rept ML20214A0951986-11-14014 November 1986 Insp & Evaluation Re Adequacy of Stabilization Plan,In Response to Util 860701 Request for Withdrawal of Applications to Extend CP & Util Motions Seeking Withdrawal of OL Application ML20215G6801986-10-10010 October 1986 Part 21 Rept Re Vendor Tests of air-operated Diaphragm Valves Revealing Natural Frequencies Less than Required Values of 33 Hz.Initially Reported on 841227.No Adverse Effects Noted During Testing ML20215G5351986-10-10010 October 1986 Part 21 Rept Re Vendor Tests of air-operated Diaphragm Valves Revealing Natural Frequencies Less than Required Values of 33 Hz.Initially Reported on 841227.No Adverse Effects Noted During Testing ML20205F6141986-08-13013 August 1986 Part 21 Rept Re Connecting Rod Bolts for Dsrv Engines.Listed Procedures Recommended for Next Connecting Rod Insp, Including Replacement of Bolts Due to Cracked Threads & Large Grooves & Galls in Threads ML20206U0591986-07-0202 July 1986 Part 21 Rept Re Potential Defect in Component of Dsrv Standby Diesel Generators,Involving Problem W/Fastening of Engine Connecting Rod Assembly Which Could Result in Engine Nonavailability.Procedure Will Be Issued by 860718 ML20197H2581986-05-0808 May 1986 Part 21 Rept 135 Re Defect W/Lube Oil Sump Tank Foot Valve of Standby Diesel Generator.Caused by Extrusion of Liner Matl Due to Overpressurization.Corrective Actions Being Developed.List of Affected Sites Modified ML20203N4171986-04-30030 April 1986 Rev 2 to Tdi Owners Group App Ii:Generic Maint Matrix & Justifications ML20205N6811986-04-14014 April 1986 Final Part 21 & Deficiency Rept 86-03 Re Consolidated Pipe & Valve Supply,Inc Certified Matl Test Repts.Initially Reported on 860321.Six raised-face Orifice Flanges Statused & Segregated Per QA Procedures ML20205N7381986-04-14014 April 1986 Interim Deficiency & Part 21 Rept 86-02 1 Re Elastomer Liner in Clear Flow Co Foot Valves Used in Lube Oil Sump Tanks of Tdi Diesel Generators.Initially Reported on 860321. Action Will Not Be Pursued Unless Facility Reactivated ML20140H5991986-03-24024 March 1986 Second Interim Deficiency Rept 86-01 Re Error in Bechtel Computer Analysis Program.Initially Reported on 860121.No Corrective Actions Will Be Pursued & No Further Repts Will Be Submitted Unless Project Reactivated ML20154N3431986-03-10010 March 1986 Initial Part 21 Rept 135 Re Potential Problem W/Lube Oil Sump Tank Foot Valve of Dsrv Standby Diesel Generator for Facilities.Cause Not Determined.Recommends Utils Inspect Condition of Foot Valve Liners & Notify Tdi of Findings ML20153F5391986-02-14014 February 1986 Interim Part 21 & Deficiency Rept Re Error in Bechtel Computer Analysis Program ME101.Initially Reported on 860121.No Corrective Actions or Further Repts Will Be Submitted Until Project Reactivated ML20137N6101986-01-10010 January 1986 Interim Part 21 & Deficiency Rept 85-08 Re Isolated Failures of Betts Spring Co Intake & Exhaust Valve Springs Reported by Tdi.Initially Reported on 851218.Corrective Actions Will Be Pursued If Units Reactivated ML20141N8361985-12-31031 December 1985 CPC 1985 Annual Rept ML20138M3891985-12-12012 December 1985 Topical Rept Evaluation of Rev 1 to BAW-1847, Leak Before Break Evaluation of Margins Against Full Break for Rcs.... Rept Presents Acceptable Justification to Eliminate Dynamic Effects of Large Ruptures in Piping ML20198C4981985-11-0606 November 1985 Part 21 Rept Re Potential Defect in Dsr or Dsrv Standby Diesel Generator Intake & Exhaust Valve Springs Mfg by Betts Spring Co.Users Recommended to Inspect Engines for Broken Springs & Identify Original Mfg ML20138B9531985-10-0909 October 1985 Interim Deficiency Rept Re Larger than Anticipated Util Movement Where Freezewall Crossed safety-related Utils at Monitoring Pits 1,2,3 & 4.Initially Reported on 850917.No Action Will Be Taken ML20138C3111985-10-0808 October 1985 Interim Deficiency Rept Re Limitorque motor-operated Butterfly Valves Not Opening Electrically After Closed Manually.Initially Reported on 850912.No Corrective Actions Will Be Taken Unless Facility Reactivated ML20138C3251985-10-0808 October 1985 Interim Deficiency Rept Re Loose Set Screws on Anchor Darling Swing Check Valves & Disc Nut Pin Problems Causing Inoperability.Initially Reported on 850912.No Further Corrective Action Will Be Taken Unless Facility Reactivated ML20132B0261985-09-0303 September 1985 Part 21 Rept Re Possibility of Engine Ingestion of Unwelded Part in American Air Filter Standby Diesel Generator Intake Silencer.Immediate Hold Should Be Placed on Diesel Engines/Intake Silencers Not Yet in Svc ML20132D3191985-07-10010 July 1985 Interim Part 21 & Deficiency Rept Re Rupture During Testing by Wj Woolley Co of Inflatable Seal,Mfg by Presray Corp,Used in Personnel Air Locks in Reactor Containment Sys.Initially Reported on 850614 ML20129G0601985-04-26026 April 1985 Interim Deficiency Rept Re Potential for Cracking of Check Valves in on-engine Mounted Starting Air Piping of Tdi Diesel Generators.Initially Reported on 850401.Cause Not Determined.No Corrective Actions.Related Correspondence ML20112J3951985-03-22022 March 1985 Interim Part 21 & Deficiency Rept Re Failure of Gulf & Western MSIV Actuator Latch Roller Bearing.Matter Will Not Be Pursued Unless Plants Reactivated ML20100B6361985-01-21021 January 1985 Rept on Welding Allegations ML20114D3571984-12-21021 December 1984 Interim Deficiency Rept Re Diesel Fuel Oil Tank Soils Borings.Initially Reported on 841121.No Corrective Actions Necessary Due to Present Project Shutdown ML20100K9791984-11-27027 November 1984 Part 21 & Interim Deficiency Rept Re Ruskin Mfg Co Interlocking Blade Fire Dampers.Initially Reported on 841121.Corrective Action Will Not Be Pursued & No Further Repts Will Be Made Unless Plant Reactivated ML20100D9841984-11-21021 November 1984 Deficiency Rept Re Diesel Fuel Oil Tank Boring Logs.Util Response to Dow Chemical Co 841113 Request for Admissions Encl ML20100E4451984-11-15015 November 1984 Interim Deficiency Rept Re Cardinal Industrial Products Corp Spare Studs Received W/O Ultrasonic Exam.Initially Reported on 841010.Corrective Actions Will Not Be Pursued Unless Midland Reactivated ML20100E2621984-11-15015 November 1984 Interim Part 21 & Deficiency Rept Re Rosemount 1153 Series B Transmitters Potentially Leaking.Initially Reported on 841010.Four Units Shipped to Facilities.Corrective Actions Will Not Be Pursued ML20100E2371984-11-15015 November 1984 Interim Part 21 & Deficiency Rept Re Tdi Fuel Control Level Cap Screws.Initially Reported on 841010.No Corrective Actions Will Be Pursued & No Further Repts on Subj Made Unless Midland Reactivated ML20099E3531984-11-0909 November 1984 Interim Deficiency Rept Re Small Bore Piping Anchor Design. Initially Reported on 840816.Listed Corrective Actions Will Not Be Pursued & No Further Repts Will Be Made Unless Facilities Reactivated ML20093C3211984-10-0101 October 1984 Rev 0 to QA Program Plan for Shutdown Phase ML20093H3961984-08-0202 August 1984 Interim Deficiency Rept Re Seismic Qualification of Power Supplies for Eccas & Ni/Rps Equipment.Initially Reported on 840705.No Activity Being Currently Pursued.No Further Repts Will Be Made Unless Facilities Reactivated ML20093H8521984-08-0202 August 1984 Interim Deficiency Rept Re Field Installation of Itt Grinnell Struts & Extension Pieces.Initially Reported on 840705.No Activity Being Currently Pursued.No Further Repts Will Be Made Unless Facilities Reactivated ML20096A7781984-07-27027 July 1984 Final Deficiency Rept Re Defective Capstan Springs in Pacific Scientific Mechanical Shock Arrestors.Initially Reported on 840106.W/o Description of Investigation & Corrective Actions.Related Correspondence ML20093H8111984-07-27027 July 1984 Final Part 21 & Deficiency Rept Re Capstan Springs in Mechanical Shock Arrestors Supplied by Pacific Scientific. All Suspect Shock Arrestor Capstan Springs Will Be Inspected for Cracks & Defective Springs Replaced ML20093H8871984-07-20020 July 1984 Interim Deficiency Rept Re Reactor Coolant Pump Seals & Seal Covers.Initially Reported on 840622.No Activity Currently Being Pursued.No Further Repts Will Be Made Unless Facilities Reactivated ML20090G2141984-07-18018 July 1984 Idcvp:Control Room HVAC Sys Performance Requirements, Draft Topical Rept ML20093H4751984-07-17017 July 1984 Interim Deficiency Rept Re Core Flood Line Piping Supports in Reactor Pressure Vessel Connection Supplied by Bechtel. Overstressing Could Occur in Pipe Supports.No Commitment Made for Further Repts ML20096A2951984-07-11011 July 1984 Final Deficiency Rept Re Concrete Embedment Design Using Shear Lugs Located Outside Compression Zone.Initially Reported on 821203.Use of Shear Lugs Outside Compression Zone Is Proper Design Technique.Related Correspondence ML20093G7891984-07-11011 July 1984 Final Deficiency Rept Re Concrete Embedment Design Using Shear Lugs Located Outside Compression Zone.No Corrective Action Required.Not Reportable Under 10CFR50.55(e) 1992-12-31
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buALITY AUSUilANCE l'ROGilAM At.tachment 1-
., f.1ANAGEf.1ENT COHOECTIVE ACTION HEPORT H we-226-79 MCAR 1 .
REPORT NO. 33 JOB NO. _2220 0 NO. 1.1n7 DATE_ July 27, 1979 i ' DESCRIPTION (including rebronces):
1 Section 3.8.1.6.3.2 of the Midland Units 1 and 2 FSAR states in part "The differential l 1ength of any tuo wires in the sc=e tendon up to 100 feet wirc length is i 1/16 inch
- and i 1/8 inch for wires longer than 100 feet. Cutting tolerances for overall tendon ,
icngth is i 1/2 inch up to 100 feet and 1 ine.h over 100 feet." These require =ents are reficcted in Inryco Post Tensioning Precedure PT 5.1 (Fabrication Tendons).
Contrary to this requirement tendons were produced with varying unknown uire icngths.
Some tendons were accepted by Inryco QC and 17 tendons were shipped to the Jobsite (Continued on page 2)
- RECOMMENDED ACTION (Optional)
Actions to be acccmplished by supplier. Availabic data to be provided to Bechtel '
Project Engineer on or before August 8, 1979. At that t.lue a schedule for caswering other questions will be provided.
- 1. Detemine the extent of the hardware probica.
a) Ecv was problem detected.
b) Detemine which tendons are acceptabic for use and provide data and rationale to substantiate. (Continued on page 2)
REFERRED TO O ENGINEERING O CONSTRUCTION OOA MANAGEMENT O CI PROCUREMENT 1
~
ISSUED BY . D'a sA1 Project OA Eng.neer Date ,
I il REPORTABLE DEFICIENCY Potentially reportable N IFIED CLIENT O NO l
O YES ^
Pro;ect Manager
/
Date -
Yg llI CAUSE CORRECTIVE ACTION TAKEN 7908290 %'7 AUTHORIZED BY oato l'
ST ANDARD O!STRiOUTION ADDIT.ONAt. D!SiruGUTION . AS APPROPRIATE
" FORMAL REPORY TO CUENT _
IANT c'[$7I'f 3 E
' INc'? [ c.5$7" (Il Section II Applics) Date cru . C A uSNac.g #4 AAo 6 occu..e ut Nf Curst (M CUALif Y MGR L A8;10A uSHAG(ft CON %f fufet a04 M ANAGi ft AAC QA paNAGIR PftOJ sus f 54tOJ COW 6. uA.NActs f fDie Cf 9ANAGI 4 CMI F CGN$f R QC (W4t[R Ct= NT n oce AA0 t NU( C7 ML f.4fCui u AN AGE N twisba PftOCunt U(NT uGA CORRECTIVE ACTION IMPLEMENTED A40 ln ueit ut Nt u An wt n eno; sencicent utN1 pCH AAO uGR C4 f NGeef f Saeed Dry $tIrl*LitR UUALtf Y MGR A AO wJt (4 CONS 1etucICat VERIFIED BY w u . . . . .. - . .n, Project OA Eng neer Da l
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4
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IWIAGl:Ml:NT CORRECTIVE ACTIO:i REPORT
Page 2
, DESCRIPTIO:1 Continued (7 verticals and 10 horizontals). Of the tendons chipped to the Site the 7 verticals ucre inserted into the contain=ent (#2).NCR 2373 was issued placing the tendons at the
, Site on hold. Shipment frca the Florida facility have been placed on hold.
REC 02 ENDED ACTION Continued c) Is the problen limited to those tendons produced at the Ulrc Mill facility in Florida or are the tendons produced at Inryce, 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 tendons determined to be bad or questionable.
- 3. Remedial action to the manufacturing process to prevent similar problems in the future.
I a) Include complete evaluation of manufacturing process.
b) Correction of any deficiencies.
c) Proof of effectiveness of corrective actions.
J
- 4. Remedial action regarding the quality pregram to prevent similar probiccs in the future.
i a) Evaluation of Quality Program.
j b) Correction of deficiencies.
c) Proof of effectiveness of corrective action.
PROJECT ENGINEERINO
- 1. To evaluate responses from vendor and issue Interim Report on August 10, 1979 to Quality Assurance.
- 2. Also, determine reportability under 10 CFR 50.55(e) and identify in the l
Interim Report.
a w w--- v- w e w' ~ ' " w -- w-+ y -g n &
' ' Attachm:nb 2 Bechtel Associates Professional Corporation
SUBJECT:
MCAR 33 (Issued 7/27/79)
Differential Wire Length of Containment Building Prestressing Tendons INTERIM REPORT 1 DATE: August 10, 1979 PROJECT: Consumers Power Company Midland Plant Units 1 and 2 Bechtel Job 7220 Introduction This report summarizes project engineering's actions and evaluation to date regarding the differential laagth 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 lengths. This is in violation of the Inryco Post Tensioning Procedure PT 5.1, Fabrication-Tendens, and the Midland Plant Units 1 and 2 FSAR Subsection 3.8.1.6.3.2. The commitnent 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 1 1 inch for tendons over 100 feet. There were 17 tendons shipped to the site that uere manufactured in Wiremil. Out of the 17 tendons, 7 are verticala and they have been installed into the sheaths. The remainder are horizontals and they have not been installed. NCR 2373 was issued placing the tendens at the site on hold.
Investinatien An investigation was initiated, with both the Wiremil and Melrose Park facilities being enamined by Ecchtel and CPCo personnel. The finding is that only the tendons produced at the Wiremil facility are of differential wire lengths (33 tendons total). The review of the manufacture /inspectica processes at Melrose Park revealed no irdications that the tendons delivered f rem the Mel rose Park f acility are not in compliance with the FSAR.
The disposition of the 33 tendons in question has not been finalized.
A meeting was held on August 9, 1979, at Melrose Park to discuss the questions presented in MCAR 33 and the draft remedial procedures to correct the deficiencies. The infornation gathered is being evaluated and 10, 1979.
will be included in the nent' report scheduled to be issued on September
= ,
e A
Bechtel Associates ProfessionalCorporation MCAR 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 doun. 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). Ilowever, 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.
- 2) Since a tendon experiences the highest stress level during the initial prestressing operation, wires that are overstressed may break. The condition would have been detected as a part of speci-fication requirencnts 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 vill be made.
Corrective Action At present, the ten horizontal tendons not installed are being shipped back to the Jircmil facility. The disposition ef the seven installed vertical tendons, as proposed by Inryco, is being revicued. Wircmil has ,
initiated corrections to the production equipment to eliminate the source of the length variation problem. A wire length verification procedure is being formulated by Inryco. If the procedure is approved by Ucchtel and CPCo, the shipment of tendons to the site will commence.
Submitted by:
[ M dl.,,-
of Approved by: Y- % - - M'~I<
J
- Concurrence hy: [, f d'_ h-n f ' ,/
ER/pd u-8/9/15 ,