ML20076N133
| ML20076N133 | |
| Person / Time | |
|---|---|
| Site: | Midland |
| Issue date: | 07/15/1983 |
| From: | Mooney J CONSUMERS ENERGY CO. (FORMERLY CONSUMERS POWER CO.) |
| To: | Harrison J NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| Shared Package | |
| ML20076N137 | List: |
| References | |
| CSC-6792, NUDOCS 8307210208 | |
| Download: ML20076N133 (20) | |
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J A Mosney Executtue Atanagn Atidiand Project offsce General offices: 1945 West Parnall Road, Jackson, MI 49201 e (517) 788-0774 PRINCIPAL STAFF July 15, 1983 yg3
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799 Roosevelt Road Glen Ellyn, IL 60137 MIDLAND ENERGY CENTER GWO 7020 RESPONSE TO NRC REGION III QUESTIONS OF JULY 14, 1983 MEETING File: 0485.16. UFI: 142*05*22*04 Serial:
CSC-6792 12*32 On July 14, 1983, the Region III Staff raised certain questions relating to drilling of the soil in the area of the Service Qater Pump Structure, technical problems encountered in the drilling of Wells #502 and #503, the procedure for drilling in "Q" concrete, and certain cocments in the Stone and Webster " Independent Assessment Report No. 41".
The Staff requested that the Company respond in writing to these questions. The Staff also asked that the Company provide justification for continuing soils work in light of the above questions.
Although the Company recognizes the significance of the Staff's concern, we believe that the clarifications and proposed corrective actions provided in this response will satisfactorily resolve these concerns. The following explains the nature of the problems, answers the Staff's questions as we understand them, and provides a more detaile: justification for continuing soils work.
ITEMS RELATING TO SERVICE WATER PUMP STRUCTURE NRC Region III Staff requested information relating to the drilling of Well #521 and Piezometer #LS-7 in the vicinity of the Service Water Purp Structure.
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W Pag'a 2 Well #521 is a dewatering well near the Service Water Pump Structure. An excavation permit was properly obtained and executed in accordance with all applicable procedures before well drilling began.
The location of the well was surveyed, verified and marked, as were underground utilities in the vicinity of Well #521. The drill r'ig was set up on a stake marking an underground utility rather than the stake designating Well #521.
- Spencer, White and Frentis and Bechtel Field Engineers verified this as the proper location. Quality Control verified that the drilling rig was positioned within allowable tolerances relative to this stake. When drilling proceeded, an obstruction was encountered at approximately elevation 619.5 feet.
Drilling was stopped and gravel was found in the drill bit.
It has been determined that the obstruction is most likely bedding material for a non-Q prestressed concrete pipe connecting the service water system to the cooling
- tower.
It is not known whether the pipe itself was hit. An investigation is planned to inspect the pipe for damage.
In the case of piezometer #LS-7,' drilling also occurred at a wrong location, as a result of misinterpreting a Field Change Request (FCR).
Again, the excavation permit system procedures were followed.
Prior to drilling, the field organization submitted an FCR to Project Engineering, asking for a change in the location of this piezometer, along with other wells, to avoid interferences with underground utilities and soldier piles.
Project Engineering approved certain relocations, revised some proposed relocations, and added additional relocation. _When the. FCR.came. back from Project _
' Engineering approved, the Field Engineers and QC inspector failed to notice the revised location for piezemeter #LS-7 made by Project Engineering. As a result, the piezoneter was drilled in an incorrect location.
As previously indicated, the excavation permit pEocedures were followed in the above two incidents.
We believe that the incidents resulted from work processes which, although basically adequate, were not specific enough to avoid error.
Corrective actions are as follows:
A. We are establishing a new procedure for identifying location markers.
Markers for utilities or obstructions will be a different color from those marking drilling location. All responsible personnel will be trained in this procedure before further drilling is implemented.
B. We are requiring Bechtel Field Engineers to verify and sign for drill rig locations before drilling commences. These individuals will be responsible, on a single point basis, for making sure drilling occurs at the correct location.
C. Bechtel Field Engineers will be required to be present during field operations.
D. Spencer, White and Prentis (SW&P) has been directed to provide additional personnel to assure full coverage 'of field operations.
E. The PQCI's will be expanded adding clarity to the related inspection activities.
This will require the QCE to: compare coordinates on the location marker to design documents.
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.J Page 3 F. Bechtel and SW&P Field Engineers and QCE's will be trained to the new requirements established above.
The Staff also questioned why an MPQAD stop work order was not issued on Saturday, July 9, 1983 when drilling at an incorrect location for Well #521 was first discovered.
The incident relating to hole #521 resulted from a mistake by the Field Engineers in identifying the field markings for the drilling location.
The excavation permit system and cther applicable procedures were followed.
Past work has been successfully carr$ed out using the same procedures which were in place for thic Well. After the incident was discovered, Bechtel Constructi.on tock immediate corrective action by stopping drilling and resurveying the locatien markers in the vicinity. Although we recognized the seriousness of this incident, particularly in light of the past drilling problems at Midland, MPQAD did not feel that the incident alone warranted a stop work order.
The second incident, relating to Piezometer #LS-7 was discovered on Monday, July 11, 1983.
The actual drilling began on Saturday, July 9, 1983.
Shortly after discovering that the drilling was at the wrong location, a verbal directive stopping all SWPS related drilling was issued. A written direction follcwed that afternoon.
The two different location errors, although caused by different circumstances, indicate that issues existed which must be resolved prior to continuing drilling by Spencer, White and Frentis.
The stop work order would have been issued by MPQAD on this basis alone, regardless of whether the NRC discussions had occurred on July 11, 1983. The corrective action described above vill be in place before affected drilling work resumes.-
TECHNICAL PROBLEMS ENCOUNTERED IN THE DRILLING OF WELLS #502 and #503 During the process of drilling devatering Well #502, problems were encountered with materials caving into the hole.
Because of our inability to keep the hole open, we decided to abandon this well.
Dewatering Well #503 was started approximately the same time that problems with Well #502 were experienced. Devatering Well #503 has not experienced problems similar to those noted for Well #502. Nevertheless, because the two wells are only five feet apart, we suspended drilling on Well #503, and conducted a technical evaluation of alternatives for completing wells in that An acceptable approach towards completing Well #503 in accordance with.
area.
existing procedures has been determined.
To avoid caving of holes in this area, future holes will be drilled using one of the following methods:
(1) Use of a "Becker" hammer drill, which allows the hole to be cased and drilled at the same time, or (2)
Use of smaller diameter wells similar to those used in the interior of the SWPS. We believe eithe.r of these methods will solve the prcblem relative to the dewatering wells on the east side of the SWPS.
Paga 4 PROCEDURES FOR DRILLING IN Q-CONCRETE The NRC was-presented with information during the July 14, 1983 meeting pertaining to a stop work order concerning drilling in Q-concrete.
PQCI C-1.60, Rev. 6, Concrete Drilling and Cutting of Reinforcing Steel, was considered inadequate to cover inspection of concrete drilling for work performed by FSO Direct Hire Work Forces. A recent FCR (C-5880 to Specification C-231) allows i
holes to be drilled in "Q" concrete and does not require QC inspection when a ground fault detector and carbide bit-are used.
The present PQCI revision does not require QC verification of these attributes; it only requires sampling inspection to be performed for drilling in "Q" listed concrete and block walls.
A stop work order for concrete drilling by FSO Direct Hire Work Forces was required until the PQCI could be revised and implemented.
The PQCI's applicable to Mergentime and SW&P work requires 100 percent QC inspection and are not affected by this FCR.
The PQCI is being revised to require verification of the drilling method utilized in "Q" concrete and block walls.
This PQCI will be revised prior to resuming work.
Further, a QAR is being issued by MPQAD to evaluate the impact of the PQCI's use.for drilled holes in the balance of the plant and whether corrective
~ action is required for previous work performed.
Concrete drilling inspection plans for HVAC and B&W.will also be evaluated for adequacy as a close-out to this QAR.
STAFF CONCERNS WITH STONE AND WEBSTER COMMENTS IN REPORT NO. 41 The Region III Staff expressed concerns over a number of items noted by Stone and Webster in the " Independent Assessment of Underpinning Report No. 41."
The company's response to those concerns is as follows:
A.
Page 3 - Ouality Control, Documentation and Records Concern: Timely resolution of outstanding NCR's continues to be a nagging problem.
Response: A discussion was held with the Region III Staff relative to the number of NCR's issued and time required for resolution (Attachment 1).
A program is in place to identify adverse trends and take corrective action.
Significant improvements have been realized as evidenced by the attached charts and considerable e=phasis is being placed in these areas by all Soils Remedial Organizations to improve the results.
Personnel have been assigned the responsibility in each action organiza-tion to coordinate responses and make sure that follow-up commitments are made within their respective organizations.
Action is also taken during the Weekly Project Soils Management Meetings, as required, to assure continuing improvement in addressing quality items and closure of NCR's.
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Paga 5 B. LItem 3 - Notes of 6/27/83 Meeting
~ Concern: Use of dry-pack grout for pier leveling plates in lieu of pres-sure grout.
Response: Dry-pack grout is used for temporary pier leveling plates.
As previously discussed with the staff, pressure grouting will be used for all permanent pier leveling plates.
Ci Item 4 - Notes of 6/27/83 Meeting Concern: Use of,superplasticizer concrete.
Response: As previously agreed, CPCo will submit the concrete mix design using superplasticizer and receive NRC concurrence prior to using this mix.
D.
Item 7 - Notes of 6/27/83 Meeting Concern:. Grouting of void between existing fill and West Auxiliary Building Foundation.
Response: The attached report (Attachment 2) addresses the grouting of the gap encountered between the soil and the-Auxiliary Evilding Foundation.
E.
Item 8 - Notes of 6/27/83 Meeting Concern:
Slope layback extending under the $ nit 1 EPA.
Response: The limits of the drift north of Piers E/W 8 were at the
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discretion of the Resident Geotechnical Engineer (RGE) and the design drawings recognized the RGE's responsibility to authorize changes as necessitated by field conditions.
Since the work was completed in accordance with quality requirements, a Non-Conformance Report was not issued.
F.
Item 6 - Notes of 6/28/83 Meeting Concern:
Specification requirement'for furnishing grout.
Response: Project Engineering dispositioned NCR FSO-286 relative to furnishing grout by clarifying the requirements.and Mergentime Procedure.MCP-35.000 will be revised accordingly.
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Item 2 - Notes of 6/29/83 Meeting l
Concern:
Electrical IPIN's.
'A QA reinspection of IR's with associated IPIN's in the Auxiliary-
Response
Building monitoring system.is being conducted. The status of this reinspection was discussed with R.' Landsman and R. Cardner on July 14,11983.
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Page 6 H.
Item 3 - Notes of 6/29/83 Meeting Concern: Number of attached changes to drawings.
Response: MPQAD Soils had raised a question regarding the nucher of unincorporated changes to drawings in QAR #F-326 dated 6/20/83.
This QAR is open.
As part of the closure to this QAR, consideration will be given to the fact that CPCo Volume II Quality Assurance Program Manual Procedure #6-1 sets a limit of four attachments to a drawing for design docucents prepared by CPCo.
The final closure to the open QAR will satisfactorily address the quality concern related to the nutber of unincorporated attachments to drawings.
Concern: Use of FCR's and NCR's.
Response: The project adopted a position in June, 1983 to clearly establish the requirement that NCR's are required for "after the fact"
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FCR's; ie. FCR's written to obtain approval of "as built" conditions which do not conform to design requirements. This position clearly indicates that the Field Engineer is responsible for causing an NCR to be initiated whenever it is desired to use an FCR to get approval of an "as-built" condition which is not in accordance with design requirements.
This requirenent has been incorporated in Bechtel Field Procedures FPD-2.000 as Revision 9.
(This revision is in the final distribution as of this date.)
In addition, MPQAD Procedurc F-2M, Control cf Nonconforming Items, has been revised (Revision 6-Effectivity of 8/29/83) and requires an NCR to be-written for any item that is nonconforming and "is at a poirt in the construction process 4
where it should be in compliance with the applicable design or program requirements and it is not."
These actions will program =atically require that NCR's are written for "after the fact" FCR situations.
Stone and Webster indicated that the term " field as-built condition" in this item referred to the original constructed conditions which are encountered during the underpinning work activities and not as a result of current work activities.
I.
Item 3 - Notes of 6/30/83 Meeting Concern: Acceptability of the pumped grout test program for pier leveling plates.
Response: The pumped grout test program has been completed and the results of this program are included as Attachment 3.
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Pegs 7 J.
Item 4 - Notes of 6/30/83 Meeting Concern: Over excavation under the Unit 1 EPA.
Response: Refer to Item E.
K.
. Item 2 - Notes of 7/1/83 Meeting Concern: Number of outstanding drawing changes.
Response: Refer to Item H.
L.
Item 3 - Notes of 7 /1/83 Meeting i
Concern:
Pumped grout test program.
Response: Refer to Item I.
M.
Item 4 - Notes of MPQAD 6/28/83 Meeting Concern:
Instruction memorandum on issuing QC hold tags.
Response: The memorandum in question did not provide programmatic directions for issuing QC hold tags, but addressed action by FSO and MPQAD to avoid confusion that may occur when ""
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hold tag's are placed.
DISCUSSION OF JUSTIFICATION FOR CONTINUING SOILS WORK Because of the concerns previously discussed in this letter, the Region III Staff has asked whether the soils work at Midland should be allowed to continue. We recognize and acknowledge the Region's concerns, which we share, with aspects of the performance of soils remedial work thus far. We are mindful of the need for continuing close attention, and extensive management involvement, to correct deficiencies and avoid errors, As previously described, steps are being taken to correct the deficiencies of concern to the Staff, as expressed in meetings this week.
-(ks the question of whether these concerns warrant an overall stoppage of soils remedial work at Midland, we believe the answer is no.
In our opinion, the concerns, while valid, do not run deep enough or are not widespread enough to call into question the overall integrity of the work, or the soundness of as-built hardware.
In our epinion the most serious of the various items cited by the NRC are the drilling incidents. We -acknowledge that there have been drilling problems at the Midland Site in the past;. however, the two drilling incidents discussed above occurred after a period of successful implementation of involved procedures.
The drilling rig mislocations that occurred appear to be caused primarily by too narrow a view of the inspection requirements and lack of specific verification of proper drill rig locations by both field engineers and QC personnel..The entire corrective actions listed previously will, we believe, prevent recurrence of this.and possible related problems.
In addition, the drilling has been stopped until the corrective actions noted' herein are implemented.
M iPage 8 Anoth'er item referenced by the NRC.is an MPQAD stop work order.related to drilling in "Q"; concrete. Corrective actions, including the issuance of a
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revised PQCI, are being taken..This represents a case where our Quality Organization identified a problem and stopped work until corrective action has been taken.-
Additionally, the NRC had concerns about comments in Stone and Webster's Report.No. 41.
None of these -items resulted in a Stone and Webster nonconformance.- By contrast, when deemed appropriate, Stone and Webster has issued nonconformances in carrying out their responsibilities as an independent
. assessor. We take seriously the need to consider all Stone and Webster comments, and where appropriate, initiate corrective action in our work activities.
Without understating the significance of Stone and Webster's comments, we do not believe any of them question the basic adequacy of the work in the soils area.
In summary, while we have not achieved perfection, the quality of our final product is meeting design requirements and commitments. Our Quality Organization and Field Engineers are finding and correcting problems. The substantial upgrading of our quality effort in 1982 has achieved noticeable and acceptable results.
The Stone and Webster 90-day assessment of the underpinning work has not identified
.any major probitms.
Indeed, Stone and Webster determined that the initial under-pinning work, which-constitutes the significcnt activities presently being
]
accomplished, was being performed with a high degree of quality cnd since this l
report was issued, Stone and, Webster has not advised us of any situation which would change this assessment.
Based on all of these factors and in consideration of the overall quality' of the work, we believe the soils work at Midland should continue.
Continuing basic attention to detail by the Soils Organization with overview and involvement by~ Stone and Webster and NRC Region III will insure
.immediate identification and resolution of concerns and provide adequate assurance that the soils activities are successfully completed.
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EXPLANATION OF GRAPHS 1 AND 2 The weekly periods begin with Week 1, January 1 through January 15, 1983, and end with Week 27, July 10 through July 16,1983.
Graph 1 :
The. cumulative number of NCR's is plotted for each weak. The broken / slashed line represents all FSO NCR's written. The dotted line represents FSO NCR's written and corrected for those NCR's inherited from the Balance of Plant. These " inherited" NCR's predate the FSO organization and represent long term Non "Q" soil replacement. The solid line represents the number of NCR's closed.
Graph 2: The average time to close an NCR for a given.
week is plotted for each week. We number shown beside each point is the number of NCR's used that week to determine the average.
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MC? 15.C00 Rev. 3 ATTACHP.I!;T C To MC? 15.000 w
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GROC7 PLACIF :;T PLA.N 3
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Prepared 3y:
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.(RS TE) l Approved By:
Y.(f06)
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Location:
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O C // M J T F Plate Orientation: -
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Type of Grout:
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Method of Greut Placement:.
I 1 Gravity i
Pressure - Hand Pump p Pressure - Mechanically Driven Pump; f
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i
. (For pressure grout placement with !
Maxi =um Grout Pressure:
7g a mechanically driven pump only.) i g
Sketch:
'(Indicate plate orientation, location of forms, location of vent holes and/or vent pipes, grouting secuence to avoid air _p.ptrap=ent, location of grout pipes, edge treatment fer nd remarks or special notes.)
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Page 12 of 12!
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