ML20078J718
| ML20078J718 | |
| Person / Time | |
|---|---|
| Site: | Midland |
| Issue date: | 07/28/1983 |
| From: | Lucks A STONE & WEBSTER, INC. |
| To: | Cook R NRC |
| Shared Package | |
| ML20078J662 | List: |
| References | |
| MPF-44, NUDOCS 8310170616 | |
| Download: ML20078J718 (16) | |
Text
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.o STONE & WEBSTER MICHIGAN, INC.
P.O. Box 2325. Boston. M AssAcHusETTs 02107 United States Nuclear Regulatory Commission July 28, 1983 Jiidland Site Resident Inspection Office Route 7 J. O. No. 14358 Midland, MI. 48640 Ref. MPF 44"
' Attention Mr. R. Cook RE: DOCKET No. 50-329/330 MIDLAND PLANTS - UNITS 1 & 2 INDEPENDENT ASSESSMENT OF UNDERPINNING REPORT NO. 44 A copy of the Independent Assessment of Underpinning, Weekly Report No. 44 for the period of July 17, 1983 through July 23, 1983 is enclosed with this letter.
Included as attachments, are the minutes cf the daily meeting held during the week between members of the Assessment Team and Site Engineering, Construction, and Quality Assurance personnel.
If you have any questions with respect to this report, please contact me at 617-589-2067.
Very truly yours, Y
- ' h Q7Qky A. Stanley Lucks Project Manager Enclosures ASL/pd O
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'J. O. No. 14358 Midland Plant Units 1 & 2
'Indep'endent Assessment of Underpinning Weekly Report No. 44
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July 17, 1983 through July 23, 1983 O
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Personnel on Site Stone & Webster Michigan, Inc.
P.
Barry 7/19 - 7/23 W.
Kilker 7/21 - 7/23 B.
Holsinger 7/20 - 7/23 A.
Lucks 7/19 - 7/20 Parsons, Brinckert.off Michigan, Inc.
J.
Ratner 7/19 - 7/22 Meetings Attended Date Represented Purpose 7/19 - 7/23 Stone & Webster Daily Meetings Bechtel Consumers Power Parsons 7/20 - 7/21 Stone & Webster Discussion of NPS Material Bechtel Receipt Inspection Status Consumers Power NPS 7/21 Stone & Webster Consumers Power ( MPQLD )
Weekly MPQAD Meeting Activities Construction:
Pier E8:
The upper and lower leveling plate installations were completed.
However, some void areas were noted in the lower plate grout requiring a re-work of the installation.
East Side Zone Excavation:
The zone excavation was completed and the area prepared for mud-mat placement.
Installation of the reactor drop-pits and th_i tieback deadman trenches were in progress.
Pi r E10:
The pier remained on active jacking throughout the we k.
Pier W8:
The upper.and lower leveling plates were installed andsgrouted.
Grout re-work was required similar to that experienced on pier ET..
J. O. No. 14358 Midlcnd Plant Unita 1 & 2 Independent Assessment of Underpinning hestSideExcavation:
The zone excavation was completed and a mud-mat installed over most of the area.
Installation of the reactor drop-pit and the tieback and deadman trenches was in progress.
Grillage beam,, leveling plate Hilti-bolt holes were drilled into the EPA mat.
Pi[rW10:
The pier remained on active jacking throughout the wedk.
SWP.S :
The settlement monitoring instrumentation system was activated on July 20i[ Sheeted pit probing continued throughout most of the week.
All other SWPS activities were curtailed by the Stop Work Order or nonconformance restrictions. An inspection of the buried concrete pipe encountered during the drilling of a well at the wrong location revealed the pipe was damaged by penetratior. of the drill bit.
BWST:
Sandblasting of the foundation surface and concrete for= work placement continued. Shear connector installation began but formwork anchor bolt activity was curtailed by the Stop Work Order.
Quality Control Documentation and Records:
1.)
Reviewed the adequacy of Project Procedures developed to comply with 10CFR50 Appendix B Criteron Vill.
2.)
Reviewed the nature of descrepiencies identified on material received from N.P.S.
3.)
Reviewed recent Quality Assurance NCR's for possible trends in the areas of inspector certification and the need for PQCI's.
Observations Construction - Completion of the mass excavation and preparation of the tieback and deadman installations were accomplished in accordance with the project requirements.
A procedural nonconformance on fabricating threaded bars delayed the complation of the tiebacks.
The installation of the Hilti-bolt drill holes in the Unit 1 EPA mat was success-ful. The hole abandonment rate, due to encountering retar, was minor.
The increased success rate can be partially attributed to the improved rebar mapping technique.
Load transfer at Piers E/W8 was delayed by lower leveling plate grout problems and QC holds on the jackstands and transfer frames.
Quality Control. Documentation and Records:
1.)
The list of project procedures applicable to 10CFR50 Appendix B, criteron Vill ( identification and control of materials, parts, and components ) compl with the code of Federal Regulation.
2.L The grillage beams and associated fabricated items received from NPS have various weld descrepances identified'by MPQAD. The descrepancies were minor undhrcuts, slag inclusiens and excessive chipping to remove slag._-- Meetings between NPS and MPQAD plus a joint inspection of all identified discrepancies were conducted and should reduce or eliminate future QC receipt ihspection problems.
3.)
This Assessment Teams' review of MPQAD Quality Control Assurance Reports illustrates the Quality organization's ability to identify in-house problems.
J.O. No. 14358 Midland Plcnt Units 1 & 2 Independent Assessment of Underpinning Two possible trends were identified.
The first by two NCRs on QC engineers that were not certified to a PQCI/IR and an NCR on United States Testing inspections performing tasks for which they were not certified.
The second possible trend was indicated by three NCR's on direct hire personnel performing work without procedures.
Nonconformance Identification Report
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NIRiNo.
Description Date 12 NRC Reviewed for Reportability (0pened) (Closed) under 10 CFR50.55 (e),part 21.
6/16/83 7/20/83 13 PQCI Attribute for Plate Bearing 7/14/83 Verification Open Items Requiring Resolution The Assessment Team and CPCo independently reviewed the Assessment Team Weekly Reports Nos. 1 42 in order to compile a list of open discussion items described in the contents of the respective weekly reports or the attached notes of daily meetings.
Approximately 110 times were identified as of July 10, 1983 ( the date the revised open item tracking system was initiated ) only 14 items had not been formally resolved by follow-up documentation. Since July 10, a number of these open items have been closed while others remain open. The following is a list of the 14 open discussion items from Weekly Report 1 42 and their present status.
Item No.
Description Closure Reference W.R.#25,pg.5' Commitment to access training Open and personnel records.
W.R.#26,pg3 Commitment to access proposed open concrete mix designs W.R.#27,DMN 3-23,#6'*
Request for a oopy of QA/QC P. Barry verified records on pier E9 bell receipt of requested concrete placement records.
W.R.#27,DMN 3-25,#1 Request for tailgate-pumpline P. Barry verified concrete slump correlation receipt of requested
- data, data.
W.R.#28,DMN 3-29,#3 Question on concrete curing and Item 44-32 strength requirements W.R.#29,DMN 4 4 #5 Commitment on filling lagging Open O
louvers with backpacking f_
material W.R?#36,DMN 5-25,#7 Commitment to visit buttress P.3[arryverifiedthat shaft to resolve neern the3 shaft visit was on $/26/83 and concern was resolved.
W.R.#36,DMN 5-26,#1 QA concern of Programmatic Open change effect on Procedure Revisions
_________________________________________.________.________j
4 J. O. No. 14358 Midland Plant Units 1 & 2 Indepe,ndent Assessment of Underpinning Item No.
Description Closure Reference W.R.#39,DMN6-16,#2 Request for sketch snowing P. Barry verified Carlson meter test set-up recqipt of requested sketch W.R$#39,DMN6-21#4 CPCo request for projected J. fisher stated the e
completion of SWPS projected completion instrumentation date at the time was July 10.
W.R. 40, pg. 3 Concerns on proposed concrete Open mix designs W.R.41,DMN 6-30,#5 Load Transfer Acceptance
. Open Criteria W.R.42,0bserv.pg.3 Commitment to evaluate open response to Grillage Installation PQCI W.R.42,DMN 7-5#1 Status of Carlson Meter On July 6, J. Gaydos Testing presented the status of the Carlsen Meter fabrication & testing.
- Refers to Weekly Report No. 25, page 5.
- Refers to Weekly Report No. 27, Daily Meeting Notes March - 23, Item #6.
Open items subsequent to Weekly Report No.42 are listed below; Item No.
Description Closure Reference 43-20 Discussions of E/W8 Grillage Item 44-21 Schedule 43-24 Close-out of Assessment Team Open Open Items of Weekly Report 1-42 43-29 Discussion of Modification of Open No. of Inspection Sign-offs 43-32 E/W Grillage Layout Item 44-1 43-10 NIR # 12 Response Item 44-1Q 432%Q Receipt Package Request Open 43(. 0-Grillage Installation Questions 5
open
-Item 44-70 43470 MPQAD Policy on Implementing
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10CFR50 Appendix B, Criteria k
Vill 44-7 Request for Chronology of Events Open Surrounding Reoccurrence of loose Washers on W8 N-S Bulkhead l
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5 J.*0. No. 14358 Midland Plant U, nits 1 & 2 Independent Assessment of Underpinning Item No.
Description Closure Reference 44-20 Resolution of a Question Open on Need fer Grillage Installation Procedural Change 44-2h Commitment to Review Proposed Open Concrete Mix Designs 31 Resolution of Open Items Open from Weekly Report Nos.
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Notsa of Daily Meeting Independsnt Assessmsnt of Undarpinning Midland Plant Units 1 & 2
- Consuhers Power Company Held at Midland Site Location Midland, Michigan July 18, 1983
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Notss of Daily Raport Indspindsnt Ascastmsnt of Underpinning Midland Plant Units 1 & 2
' Consumers Power Company Held at Midland Site Location Midland, Michigan July 19, 1983
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Cohaumers Power Bechtel MPQAD Stone & Webster G.' hurray J. Fisher A. Lucks R. Weiland E. Cviki P. Barry J. Gaydos*
Part time
- Parsons J. Ratner Purpose This meeting is held each day to discuss items regarding the Independent Soils Assessment at the Midland Plant, Units 1 & 2.
Discussion Item 44-1: E/W Grillage Layout.
J. Fisher stated that selected or partial fit-up of E/W8 grillage beam components will be done to ensure proper assembly prior to installation.
( CLOSES OUT ITEM 43-32 )
Item 44-2: Grout Test Program.
In response to a request from the Assessment Team. G. Murray stated that he would provide a copy of the Grout Test Program Report. ( OPEN ITEM )
Item 44-3: Load Transfer E/W8.
J. Fisher stated that all grillage beam materials from NPS are on site and in process of receipt inspection. Load transfer for E/W8 should occur in approximately one week. ( CLOSED ITEM )-
Item 44 4: FCR on Excavation Sequencing.
J. Fisher reported that an FCR was being prepared to allow excavation of a portion of zone 2 prior to the completion of all of zone 1 excavation.
This variation would permit the work on piers E/W 13 and 14 to proceed.
( CLOSED ITEM )
Item 44-5: Pier E/W8 Leveling Plates.
J. Fisher stated that when the forms for the leveling plates for piers E/W8 wede removed voids were noticed at the plate edges and both were rejected.
Af(er the leveling plates were removed additional voids were found.
In addition, some burlap used in the curing of the pier W8 concrete 3prface was found in the grout. Subsequently, all of this leveling plate grdQt at both piers was rer,ved and regrouted.
( CLOSED ITEM )
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Independant Assessment of Underpinning Midland Site Location Consumers Power Company Held at Midland Site Location Midland, Michigan July 19, 1983 i
Item 44-6: FSO Imposed Procedural Changes at SWPS in Response to.! Drilling l
Stop Work Order.
Jq Fisher stated that the following changes are being implemented for the SWPS drilling work-1.)
Full time field engineering coverage.
2.)
New survey guidelines.
i 3.)
New field check list.
I 4.)
Training in these changes.
( CLOSED ITEM )
i' Item 44-7: W8 N-S Bulkhead Loose Washer NCR's.
J. Fisher stated that FSO will attempt to provide an answer as to what occurred between installation and the first re-inspection to try to determine what caused i
i the washer to become loose. ( OPEN ITEM )
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Item 44-8: Auxiliary Building Differential Settlement.
E. Cviki reported that the differential settlement N-S across the west auxiliary building is trending toward the alert level. As a result, Engineering and FSO are investigating the need for temporary support of the EPA portion of the west j
Auxiliary Building.
Temporary support would be required only until the pier i
W8 grillage is insta,lled and loaded.
( OPEN ITEM )
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Notes of Daily Mesting Independsnt Assassment of Underpinning Midland Plants Units 1 & 2
, Consumers Power Company Held at Midland Site Location Midland, Michigan 1
July 20, 1983 Present For:
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Consumers Power Bechtel MPQAD Stone & Webster R.Z Weiland E. Cviki R. Sevo P. Barry D.
Plehn J. Gaydos S. Lucks Parsons J. Ratner l
Purpose This meeting is held each day to discuss items regarding the Independent Soils Assessment at the Midland Plant, Units 1 & 2.
Discussion Item 44-9:
Pier E/W8 Leveling Plates.
R. Sevo stated that two NCR's were written on the E/W8 leveling plates.
One was issued because of the voids in the grout and the other was written against the inspection program clean-up because of the burlap found in the grout.
( CLOSED ITEM )
1 Item 44-10: Superplasticized Concrete.
R. Weiland questioned if MPQAD required any changes of the PQCI's because of I
the addition of concrete mix superplasticizer.
R. Sevo will investigate.
( OPEN ITEM )
l Item 44-11:
Carlson Meter Encasements.
E.. Cvikl-stated that the SCN for WJE to test and evaluate Carlson meter encasement was issued.
The WJE procedure should be issued shortly. ( OPEN ITEM )
Item 44-12: Grout Strength vs Time Correlations.
J. Gaydos stated that FSO has issued an FCR to change the strength requirement for the mud mat to a time requirement when grout is used.
( CLOSED IIEM )
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Notes of Daily Masting Indepsndcnt Assassmsnt of Underpinning Midland Plant Units 1 & 2 Consumers Power Company
$ eld at Midland Site Location
- m Midland, Michigan
- July 21, 1983 4
Pre _sent For:
Consumers Power Bechtel MPQAD Stone & Webster l
R.) Weiland J. Fisher R. Sevo P. Barry G. Murray E. Cviki i
J. Gaydos
, Purpose This meeting is held each day to discuss items regarding the Independent Soils Assessment at the Midland Plant, Units 1 & 2.
Discussion t
Item 44-13: Drop Pit Excavation.
J. Fisher stated that an FCR has been written to adjust for finding the existing containment mat ledge 2 in lower than anticipated. This requires lowering the j
drop pit and dead men by 2 inches.
( CLOSED ITEM )
Item 44-14: Superplasticized Concrete.
J. Gaydos stated that a review of FSO documents indicate that a Mergentime procedure requires changing to use superplasticizer concrete and the project specification requires changing to us superplasticizer concrete for areas other than the piers.
( CLOSED ITEM )
Item 44-15: SWPS Train A andB Pipe Replacement.
J. Fisher stated that CPCo had rescinded the work permit for train A and B pipe replacement because a signed out field sketch for the temporary support l
of electrical duct bank was not available.
P. Barry asked G. Murray why this type of concern was not voicedduring the work package review stage. G. Murray 1
will advise.
t OPEN ITEM )
Item 16:
Interruptior.s During Action Jacking.
R. Sevo stated that MPQAD issued a QAR concerning the interruption of active jacking for E/W10 to move the jacking apparatus.
J. Fisher stated that this jacking was in addition to the normal load transfer procedures and was done as directed by the Resident Structural Engineer.
( CLOSED ITEM )
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Item 44-17: Carlson Meter En.asement.
E. Cvikl stated that the WJE procedure for Carlson meter encasements has been issued. ( CLOSES OUT ITEM 44-11 )
Item 44-18: Auxiliary Building Differential Settlement.
J.[ Fisher stated that a decision has been made to procure materiaJs for jack pipe piles for possible use as temporary supports for the Auxilfkry Building if needed. Final details have not been developed. ( CLOSES OUT ITEM 44-8 )
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Notes of Daily M20 ting Independent Assessment of Underpinning Midland Plant Units 1 & 2 Consumers Power Company Held at Midland Site Location Midland, Michigan July 21, 1983 ftem 44-19: SWPS Revised PQCI's.
RT Sevo stated that the PQCI's on soldier pile installation, drilling, and deep probing have been revised because of the obstruction encountered during drilling at the SWPS.
Formal training including examinations are required on the PQCI's before work can proceed. ( CLOSED ITEM )
Item 44-20: Pier Tie-backs and Struts.
In response to Assessment Team questions on grillage installation documents
( refer to Notes of MPQAD Meeting Item 43-50 ) R. Sevo stated that a procedure may be required for this activity.
J. Fisher will investigate the need for this type of construction procedure.
In addition,R. Seso stated that load indicating Washers have not been approved for use by Engineering.
( OPEN ITEM )
Item 44-21: Grout Test Program.
G. Murray stated that a copy of the Grout Test Program Report had been provided to the Assessment Team.
( CLOSES OUT ITEM 44-2 )
Item 44-22: Grillage Installation Schedule.
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Fisher provided a brief discussion of grillage beam installation schedule.
( CLOSES OUT ITEM 43-20 )
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Notas of Daily Mesting Indspsndant Asasssmsnt o. snderpinning Midland Plant Units 1 & 2 Consumers Power Company Held at Nidland Site Location Midland, Michigan July 22, 1983 Present For:
Cons $mersPower Bechtel MPOAD Stone & Webs'ter R. Wieland J. Fisher R. Sevo P. Barry G. Mderay E. Cviki W. Kilker R. Wheeler J. Gaydos B. Holsinger Parsons Purpose This meeting is held each day to discuss items regarding the Independent Soils Assessment at the Midland Plant, Units 1 & 2.
Discussion Item 44-23: General Status of Field Activities.
J. Fisher reported that piers E/W10 continue on active jacking and that load transfer for piers E/W8 should occur within 4 or 5 days depending upon the release status of the transfer frame and jackstands.
The west excavations are generally complete and the deadman and drop pit excavations should be finished within a day or two.
There will be no field work by SWP on the SWPS until July 27 to allow all revised procedures and training to be completed.
SWST shear connector and sandblasting work is on-going. ( CLOSED ITEM )
Item 44-24: QC Receipt Inspections.
There was a general discussion between repressntatives of SMO, FSO & MPQAD on the lengthy QC receipt inspection time required for NPS.naterials to date.
Reportedly the average time has been on the order of 11 days per shipment.
P. Barry stated the Assessment Team was not concerned with this time as long as it did not impact the field installation. ( CLOSED ITEM )
Item 44-25: Regrouting of E/W8 Lower Leveling Plates.
As stated in Item 44-5 both plates were removed and regrouted.
Although QC pro-vided inspection during the installation, the NCRs were reissued based on suspi-cion that new voids may exist in the replacement grout.
FSO stressed the need to resolve this issue to avoid load transfer impact. ( CLOSED ITEM )
Item 44-26: Excavation of Service Waterline Train A.
In response to Item 44-15, G. Murray & R. Wheeler explained that during the Work Package review, MPQAD requested that a FSK be developed to show the temporary suppbrt required.
FSO rearonded with an FCN stating the field would provide the requjred support when required.
G. Murray said that normally FSKs have not been a required part of the Work Package submitted. ( CLOSES OUT ITEM y715 )
Item'44-27: Superplastercized Concrete Mix Designs.
g W. Kilker stated the Assessment Team has received a copy of the SCE for the proposed concrete mix designs and will comment on the completeness and adherence to the codes.
( OPEN ITEM )
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2 Notes of Daily Meatin6
- Indapsndsnt Assestmant of Underpinning Midland Plant Units 1 &2 Consu,mers Power Company Held at Midland Site Location Midland, Michigan July 22, 1983
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T5em44-28: PQCI Modifications for Supe; plasticized Concrete.
R, Sevo stated that the new concrete mix designs will not have a major impact j
ch the PQCI. ( CLOSES OUT ITEM 44-10 )
Item 44-29: EPA Temporary Support.
J. Fisher stated that Mergentime has been directed to pursue the procurement of materials for jack piles in case temporary support is required.
R. Sevo pointed out the need to consider all respects of this support scheme including materials procurement, scheduling and plann!ng.
J. Fisher suggested that Engineering, SMO and FSO convene to discuss this proposal.
( CLOSED ITEM )
Item 44-30:
Pf9cedural Requirements for Direct Hire Activities.
P. Barry questioned if the recent NCR written on the absence of a Bechtel procedure on bolt fabrication was indicative of a requirement for additional procedures by the direct-hire group.
.R. Wheeler responded that the NCR recommendation was inappropriate and would be so note'd in the response.
( CLOSED ITEM )
l Item 44-31: Resolution of Open Items from Assessment Team Weekly Reports 1-42.
W. Kilker submitted copies of two Open Items frc;m. previous reports that require FSO, SMO or MPQAD assiotance in closing out.
These items are Nos. 5 and 1 from the Daily Meeting Notes of April 4 and May 26, respectively.
Resolution will follow as soon as possible.
( OPEN ITEM )
Item 44-32:
Concrete Strength Requirements.
There was a discussion of cure periods and strength requirements for concrete.
J. Fisher stated that the cure time requirements of the specification are always adhered to for a given installation. However, the unit can be put into service once the strength is obtained.
( CLOSES OUT ITEM # 3 of March 29 Daily Meeting Notes )
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Notcs of MPQAD Wsckly Met.ng Indspgndtnt Aacassmsnt of Undsrpinning Midland Plant Units 1 &2 Heid at ' Midland Site Lccation Midland, Michigan July 21, 1983 Present For Stoni& Webster MPQAD i}
B. Rolsinger J. Meisenheimer M. DeWitt
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D. Horn Purcose This meeting is held each week to obtain information from MPQAD regarding the Soils Underpinning work at the Midland Plants Units 1 & 2.
Discussion Item 44-10: Status of NIR # 12.
S & W stated that NIR # 12 has been closed based upon the revised response received 7-20-83. ( CLOSES OUT ITEM 43-10 )
Item 44-20: Grillage Beam Receipt Inspection Package.
Receipt inspection is continuing and no packages have been completed.
The Assessment Team restated its' request for two of the packages when complete. (OPEN ITEM Item 44-30: Status of Questions on Grillage Beam PQCI.
MPQAD is continaing to work on the response and will provide the status next week.
( OPEN ITEM )
Item 44 40: Criteria V111.
MPQAD provided a list of eleven documents that describe the policy and imple-menting procedures for 10CFR50 Appendix B, Criteria V111. ( CLOSES OUT ITEM 43-7Q )
Item 44-50: Status of Stop Work Orders For SWPS and BWST.
MPQAD has reviewed the process corrective action for the Stop Work Order re-garding the drilling operations for the SWPS.
As a result of this review, a QAR was written requiring a satisfactory response from FSO as a conditior. for lifting the Stop Work Order.
It was also described by MPOAD that revisions to the'SWPS drilling proceoures ( not related to the Stop Work Order ) will require retraining and certification.
This process may also cause a delay in lifting the Stop Work Order.
With respect to the Stop Work Order on the inadequate inspection of Hilti bold; installation, MPQAD is reviewing the need to revise the PQCI.
Lifting of thic Work Order depends on the necessary PQCI actions.
The forecast com-plef.lon date has not yet been determined.
( CLOSED ITEM )
Ited"44-60: Work Procedures.
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MPQAD presented two QA NCR's which may impact work activities.
On's dealt with threading of rebar to be installed in the tieback deadmen on the Auxiliary Building E/W8 piers.
These bars were fabricated by the contractor without a procedure &
proper documentation of the activity.
The second NCR dealt with certain 1"O
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Notta of MPQAD Meating-I IndspandantAsnostmant Underpinning Midland Plant Units 1 & 2
. Held at Midland Site Location Midland, Michigan July 21, 1983 shear connector bolts for the BWST being fabricated without a procedure.
( CLOSED ITEM )
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U. S. Testing.
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MPQAD stated that two NCR0 will be issued against U.S. Testing.
One NCR will deEl with performing tasks without certification such as sampling of material steckpiles.
The second NCR treats not providing timely notification so that certain tests could be witnessed by Quality Control. ( CLOSED ITEM )
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