ML20081A963

Forwards Minutes of Feb 1984 Monthly third-party Assessment Meeting Re Underpinning & Remedial Soils Work

ML20081A963
Person / Time
Site:	Midland
Issue date:	02/21/1984
From:	Lucks A STONE & WEBSTER, INC.
To:	Harrison J NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III)
Shared Package
ML20081A941	List: ML20081A963 ML20081A974 ML20081A981 ML20081A993 ML20081A995 ML20081B003 ML20081B006 ML20081B009
References
NUDOCS 8403060407
Download: ML20081A963 (21)

Text

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STONE & WEBSTER MICHIGAN, I Cr. ,,,_ /;E-. -I' '

P.O. box 2325. BOSTON. M AssAcHusETTs 02107f -  ;, I WA~ I

'l .i_~ f fi ENF t IFllesAG February 21, 1984 Mr. J.J. Harrison J.0. No. 14509 Nuclear Regulatory Comission 799 Roosevelt Road Glen Ellyn, Illinois 60137 DOCKET NO. 50-329/330 -

MONTHLY THIRD PARTY ASSESSMENT MEETING MIDLAND NUCLEAR C0 GENERATION PLANT The protocol governing communications for the Remedial Soils and Construction Completion Programs at the Midland Plant, specifies a monthly meeting to discuss third party assessment activities and assigns preparation of the minutes of those meetings to Stone & Webster.

Enclosed are minutes of the meeting held on February 9, 1984.

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A.P. Amoruso A.S. Lucks Project Manager Project Manager Underpinning and Remedial Soils CIO Enciosures cc: JWCook, CPCo DLQuame, CPCo JAMooney, CPCo RAWells, CPCo fin e .' $$:g 1

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• MINUTES OF THE MEETING OF FEBRUARY, 1984

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STATUS OF INDEPENDENT ASSESSMENT OF UNDERPINNING AND RDiEDIAL SOILS WORK PURPOSE The purpose of the public meeting was to report the status of the Stone &

Webster Assessment Team activities and observations regarding underpinning and remedial soils work.

SUMMARY

I Mr. Lucks opened the meeting by identifying the major parts of the Assessment Team presentation:

e- A summary by Mr. P. Majeski of the Assessment Team activities

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detailed in Weekly Reports 68 through 71, e A report presented by Mr. J. Springer on the results of an assessment of the crack evaluations conducted on the el 685 slab in the Auxiliary Building, e A report by Mr. W. Kilker on the Assessment Team's response to an action item from the December public meeting concerning the criterion for rejacking of the E/W 8 grillages.

j Mr. Majeski began his presentation by describing the construction

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activities that are presently underway at the auxiliary building and the  ;

Servico Water Pump Structure.

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. 2 Mr. Majeski then described the Assessment Team activities in overviewing the Phase III activities associated with the change document Stop Work l

Order. Based upon the satisfactory results of the overview, the Stop Work Order was lifted on January 19, 1984. This overview along with one conducted by MPQAD resulted in two independent reports issued by Stone &

Webster and Consumers Power Co. stating that the complexity of the document control system contributed to recurring clerical errors. As a result of these reports, changes are being made to the document control system to address these observations. These changes include computerization of the document control registers and reviews of controlled document files.

i The Assessment Team performed an overview cf the methods for controlling I~ documents at the five soils-related Document Control Stations. The overview was conducted to assure that the proper documents rpached the appropriate station. were posted properly, and that transmittal I

acknowledgements were used effectively. The Assessment Team concluded that the current document control methods are adequate to assure that the controlled documents are properly maintained. The Assessment Team also

! evaluated three document control stations including MPQAD to determine if f

the backlog of revised documents issued from Central Document Control had been properly posted. All documents surveyed by the Assessment Team had i

been properly posted. The Assessment Team will continue to monitor the document control process.

The next major Assessment Team activity was reviewing the status of the upgrading actions being taken by U.S. Testing. Two of last month's five i BDI-14358-26

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open action items are now closed. The closed items are. Item No., 16 from the original MPQAD audit; and providing Level III capability at the site.

Three open action items remain:

e To improve efficiency, the majority of Laboratory Technicians are

'to be cross-trained to 20 procedures by June 1984. This is nov 75 percent complete, e Two Laboratory Chiefs were to be cross-trained to all procedures by April 1984. This goal has been changed to exclude cross-training to certain procedures such as for testing that .

will be done offsite or for tests which probably will not be k required in the future. The new goal is to have the chiefs certified to 44 of 61 work instructions. This cross-training is 60 percent complete.

e Work instructions for testing activities are to be prepared and incorporated into U.S. Testing procedures by April of 1984.

There are ten procedures affected by this item. Two of the revised procedures, which include several work instructions, are scheduled to be completed by the end of February.

The Asses sment Team concurs with the revised goals and believes that U.S.

Testing is making satisfactory progress.

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4 The Assessment Team observed the performance of the grout test program for the Service Water Pump Structure. This program was implemented to provide data to the control grouting operations. The Team concluded that the l

j program and 'results provide the necessary information to perform grouting i

1 according to the design requirements.

Differential movement of the west EPA reached 92 mils during extremely cold weather. To stabilize the differential movement below the alert level of 100 mils Consumers Power chose to maintain the load at the W8 grillage on active jacks. Due to this action and after increases in temperature, the

- differential movement decreased to 46 mils, well below the alert level.

The Assessment Team concurs with this action, k

Mr. Majeski then summarized the status of the Nonconformance Identification Reports (NIRs) that were active during the past month:

e NIR 20 concerns the calibration of concrete admixture dispensers 4

and was discussed last month. It is expected to be closed out a

during the third week of February, i

e NIR 21 concerns the weld tech sheets of the subcontractor's welding procedures. In certain cases the essential variables were not clearly defined on the velding procedure qualification test records. This is a documentation problem. There were no nonconformances associated with the procedures or the welds l

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. 5 themselves. This NIR is expected to be cleared during the third ,

I veek of February.

With referenh.e to the status of the Work Activity Packages (WAPs), the one  !

l remaining question from the Assessment Team's review of WAP 71 concerning Service Water Purp Structure anchor bolt holeF was answered, and the WAP review was closed out.

Mr. Majeski concluded his presentation by stating that there are currently thirteen Open Items from the daily meetings that require action prior to closure.

Mr. J. Springer presented the following report on crack map' ping.

In late January, the Assessment Team assessed the crack evaluation program currently in progress for the concrete slab at el 685. The Assessment Team was assisted by two members of Stone & Webster's Structural Division from Boston. One of these engineers is the Structural Division Chief who also is a member of the Management Review Team.

After becoming familiar with all of the appropriate design documents for the slab in question, the Team reviewed the associated crack monitoring dats, and the crack evaluation reports. This was followed by an inspection of the cracks themselves and an examination of a recent core sample taken' from the slab at el 685. The Assessment Team then met with the Contractor's BD1-14358-26

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Engineering Staff to discuss the crack mapping program and resolve any questions.

The Assessment Team relied heavily on engineering experience and judgement in assessing these activities because a detailed review of the building design is not within the Team's scope of work. The following conclusions were reached: f e Evaluations performed by the Contractor on the cracks have been thorough and the Assessment Team concurs with the findings.

e The cracks in the slab at el 685 are related to shrinkage and I negative moments.

l e It appears that the contribution to cracking by building settlement, if any, is minor.

In summary, these cracks are not unusual for this type of concrete structure.

In response to the action item from the December Public Meeting W. Kilker presented the Assessment Team's position on whether there should be a settlement criteria during rejacking on the E/W 8 Grillages initiated by a  ;

change in strain of greater than 20 percent in the support columns. Review .

- of the data taken during five rejackings of the grillages indicated that pier settlement has been insignificant during these rejackings. The BD1-14358-26

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purpose of rejacking that is initiated by the change in strain level in the support columns is to readjust the distribution of the loads on the grillage to agree with the design intent. The Assessment Team concluded that the existing rejacking criteria is adequate and a settlement criteria is not needed for this type of rejacking. The NRC closed this Action Item.

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i This concluded the Assessment Team presentation.

Mr. Mooney of Consumers Power Co. presented a status report on the crack mapping program, an Action Item from the January Public Meeting.

The presentation began with a brief history of the crack mapping program.

4 k He explained the role of Wiss Janney as a subcontractor to survey and identify cracks, and the role of Construction Testing Laboratories (CTL) as i

2 a subcontractor to evaluate the significance and impact of the cracks identified.. The ~information assembled by these subcontractors first I

d provided baseIine data for establishing critical mapping areas and now provides the main program inputs. Review of the program implementation by Consumers Power Co. and the Assessment Team resulted in changes to the program in the areas of procedures, timing, and supervision. Tlese changes also included defining the minimum size of crack that must be mapped.

l Mr. Mooney then sunmarised the cracks that had been added to the program since January 1, 1984.

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The presentation next addressed the cracks found in the slab at- el 685.

The details of actions taken to evaluate the cracks were the same as those identified by J. Springer of the Assessment Team. A Bechtel review and a final evalus' tion by CTL resulted in the following conclusions.

1. Possible causes for the cracks were identified as volume changes, tensile stress due to bending, or differentisi settlement.

- 2. The cracks are not due to the underpinning activities and i

underpinning activities should continue.

3. The load bearing capacity of the slab has not been effected.

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4 A survey and evaluation of the Auxiliary Building is currently being conducted and any significant cracks that are identified will be added to the crack mapping program. A sample of the results of the survey has been given to the NRC for review. Also the instrumentation system is being 1

supplemented by the installation of Whittemore gauges and rosettes.

Consumers Power Co. concluded that the crack monitoring - and evaluation program and the instrumentation system that includes deep seated benchmarks and extensometers, is very adequate for evaluating the condition of the buildings and identifying any changes that may be related to underpinning operations.

( This concluded the Consumers Power Co. presentation.

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l The NRC stated that they would review the crack data provided by Consumers Power Co. and confer with other members of the NRC staff to determine an NRC position on this subject. This item will remain open pending this l I

review.

QUESTIONS AND ANSk'ERS The NRC asked several questions concerning items included in Weekly Reports 68 through 71

1. The Assessement Team observation on page 2 of Weekly Report 69 concerns an update on the status of transferring the lessons I learned during the underpinning activities for the Auxilia Bpilding to the Service Water Pump Structure. What is the status of this item? Consumers Power Co. indicated that all of the original 36 items had been dispositioned. The Assessment team stated that they had alraady reviewed 34 of the items and the the remaining items would close out the review of two observation.

2. The NRC asked Consumers Power Co. to clarify the criteria for identifying cracks that had to be mapped. Consumers Power Co.

stated that, with the exception of slabs, any crack 5 mils or greater will be mapped. In slabs, cracka 5 mils or greater and :

at least 24 inches long will be mapped unless the slab width is less than 24 inches. In this case, the criteria on crack length l

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is 1/3 the width of the slab. For the engineering evaluation of l significant cracks, a 10 mil criteria is being used.

3. Concerning item 69-4 in Weekly Report 69, the NRC asked Consumers Power Co. to identify the new interim criteria for differential upward movement. The new interim criteria are 100 mils on delta These 2 and 50 mils on delta 1 relative to the control tower.

are the criteria that have been agreed upon with the NRC.

4. Page 2 of Weekly report 71 concerns NIR 21 on filling out the velding procedure qualification test record. The NRC asked why this nonconformance did not affect the velding procedures or the

( velds. Stone & Webster stated that in some cases one or two blocks on the qualification test records were not filled out correctly. The information in this block did not effect the procedures or the velds because the qualifications had been done properly.

5. Item 71-9 of Weekly Report 71 discusses the cumbersome nature of the-attachments to the U.S. Testing QA Manual. The NRC asked how many attachments accompany the manual and their approximate volume. Stone & Wabster indicated that t!.ere were 14 attachments t

' and they were approximately 1/2 the volume of the total QA manual. Consumers Power Co. stated that these attachments' I

resulted fros the recent upgrading conducted by U.S. Testing and I ( .The requirements for incorporating j

is a unique situation.

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. 11 changes to the manual had been changed from every 6 months to every 3 months. The NRC stated that the requirements for incorporting changes should not depend solely on frequency, but should also consider the site of the change. Consumers Power Co.

agreed and indicated they would follow up on this concept.

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6. With reference to Item 71-10, the NRC asked Consumers Power Co.

if the alert levels for delta 1 and 2 were being raised.

Consumers Power Co. indicated that they were not. This item dealt with the hypothetical question of what could be done if all other actions did not result in decreasing the differential settlement. Consumers' Power Co. did not intend to take any

( action with respect to changing alert levels without informing 1

the NRC.

Required Action ,

No actions are required for the Assessment Team from this meeting'.

4 The following item remains open for Consumers Power Co.:

1. The NRC and Consumers Power Co. will confer on the crack mapping survey data presentsd during February.

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- MINUTES OF THE MEETING ON FEBRUARY 9, 1984 i

STATUS OF CONSTRUCTION IMPLEMENTATION OVERVIEW (CIO) PROGRAM Purpose To discuss Third Party Overview activities of Stone & Webster (S&W) and f problems encountered regarding the Construction Completion Program (CCP) during January 1984.

_ Summary Mr. A.P. Amoruso, Project Manager for the CIO Program, presented a summary of Program activities for January 1984. The following topics were covered:

• Assessment Activities Opportunities to assess the Construction Completion Program (CCP) continued to be limited during January because of stop-work orders that had been issued to control the situation while resolving concerns about FCR/FCN figid change documents. Although documents relating to several disciplines

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were released during the month, statusing and verification work was conducted in a deliberate manner to ensure that the startup of the CCP went smoothly.

Activities that were assessed included the FCR/FCN Resolution Program, i

document control corrective actions, Phase I statusing and verification, i training presentations, and training records. Summaries of these activities follow:

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- FCR/FCN Resolution Program. Architectural, civil, electrical, and instrumentation / control documents were cleared through the three phases i

cf the Resolution Program and released for Phase I work. Mechanical documents were in the process of being checked through the resolution phase of the Program at the end of January. The documents have since . .

been cleared and released for Phase I work, t

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. Minutes 6f Mesting l PAGE 2

- Document Control Corrective Actions. A corrective action program for problems identified during the resolution of FCR/FCNs was implemented

! by Consumers Power Company. Short-term items were checked and. determined to be in accordance with the objectives of this program.

! - Phase I Statusing and Verification. Statusing and verification of coatings or, conc' rete and structural steel were checked. The statusing was ac-complished in accordance with CCP procedures, and verifications were conducted in accordance with applicable quality control instructions (PQCIs).

, People involved in the activities had been trained in accordance with the

! CCP training program, and documents being used were in agreement with applicable registers.

- - Training Presentations. Six training presentations were evaluated.

l These presentations followed lesson plans and met training objectives.

- Training Records. Some 2100 training records, representing some 290

( people, were checked for administrative discrepancies that had been identified previously. Results of these checks were satisfactory.

In two of the three areas outside the CCP but within the scope of the CIO; i namely, the Nuclear Steam Supply System (NSSS) and the Heating Yentilation, and Air Conditioning System (HVAC), assessment opportunities were limited by '

the small amount of work taking place. In the third area, the Spatial System

. Interaction Program (SSIP), the analyses of five interactions were witnessed.

These analyses were determined to have been performed in accordance with gov-erning procedures.

• CIO Items, Nonconformances, and Hold Points Nine CIO items were identified during January. These items follow:

- Need to review the plan for resuming diesel generator work to ensure

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. PAGE 3 that rel'ated documents have been processed through the FCR/FCN Resolution Program. .

- Request for CCP training procedures for Consumers Power Company people.

- Need to verify adequacy of corrective actions for document control problems.

- Request for Independent Design and Construction Verification (IDCV)

Reports.

- - Request for controls that will be used with checklists which do not contain all attributes of governing procedures.

- Request for documents relating to the development of the NRC Commitment Tracking Program.

- Recommendations to improve control of Status Assessment Prints (SAP) and Work Prints (WP).

I - Need to resolve the inconsistency between specifications C305 and C306 regarding spacing between anchor bolts of different diameters.

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- Need to review practices at the Consumers Power Company document distribution center for decontrolling change documents and receiving uncontrolled documents and to proceduralize those practices if appropriate.

Four items were closed during January. Two of the items had been opened in January and two in previous months. Reque,ts for training procedures and IDCV reports were closed when the material was provided. A question about the future 1

use of FCNs for safety related systems was closed when information was provided that FCNs would continue to be used for those systems. The item addressing plans to use checklists that do not contain all attributes of govering procedures was l l closed so that a new item could be issued when a reply to the first item did not ,

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Minutes of Meeting

- PAGE 4 Six nonconformances identified by the CIO Program were open at the end of January. These nonconformances follow:

? - Administrative discrepancies noted in training records for CCP supporting groups.

- Inadequate training levels prescribed in the Construction Team Training Matrix.

- Inconsistencies in marking drawings with the retirement symbol.

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. - Discrepancies noted in civil documents.

- Discrepancies noted in electrical FCNs.

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- Transmittals for safety related vendor documents not being sent required to the Midland Project Quality Assurance Department (MPQAD) and the Project Supplier Quality Representative.

One nonconfonnance was verified corrected and closed during Janutry. That nonconformance involved administrative discrepancies tre the training records

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of CCP team members.

4 Five Hold Points established by the CIO were open at the end of January. These Hold Points follow:

- Development of a vendor equipment verification program before the start of Phase II of the CCP.

5 - Evaluation of the management review of the results of Phase I activities before the start of Phase II of the CCP.

- Upgrading the level of training in five elements of the Construction System Team Training Matrix before people involved are used in the statusing part of the CCP.

- Verification of Phase I and II evaluations of the FCR/FCN review before stop-work orders are lifted.

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Minutes of Meeting PAGE 5

!- Three additional Hold Points were established and released during January.

These Hold Points controlled the use of civil and architectura1 documents ,

, until the adequacy of corrective actions for document control problems was verified.

• Highlights of January

- FCR/FCN Resolution Program i Details of the Resolution Program were discussed at the Janu=ry meeting.

Since that meeting, a corrective action program for document control problems has been initiated, and the two nonconformances that addressed discrepar.cies concerning architectural and civil documents have been closed. Architectural, civil, electrical, and instrumentation / control documents have been cleared through the three' phases of the Resolution Program and have been released for work. Since January, mechanical i

documents have also been cleared and released. With the exception of followup checks, the FCR/FCN Resolution Program has been completed.

- Document Control Corrective Actions i Document control problems that were discussed at the January meeting were caused by clerical errors and an unfamiliarity of some people with the procedural details of a complex document control system. Both short and long term corrective actions have been implemented by Con-i sumers Power Company to improve the situation. Short term items include:

- Increased supervision.

- Reduced number of distribution points and distributed documents.

- Increased verification of registers.

. - Improved communications between field document control center and

i. users.

( - Specialized training.

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,' PAGE 6 Long term items include:

- Establishing the minimum number of distribution points needed on the site.

- Centralizing functional control of document distribution points.

- Establishing a single register for document status.

- Improving accuracy and u n fulness of the field document dis-tribution list.

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- Improving document control procedures.

Short term actions have been assessed. The steps taken should improve document control on the site. Gains made by these actions, however, can be diluted as construction activity increases. Therefore, checks i on progress being made in the document control area will continue and results reported at monthly meetings. The schedule for accomplishing long tern actions is expected to be promulgated in the middle of February.

- CCP Status Assessment and Physical Verification Checks were conducted to verify that statusing and verification parts of the CCP were ready to start. For statusing, the or-

! ganization, procedures, training of CCP Teams, and preliminary l

walkdowns were checked. For verification, the training of MPQAD inspectors was reviewed and checklists for CIO inspectors were ,

prepered. Results of these checks and appropriate corrective actions have been discussed during previous monthly meetings.

Status assessment and physical verification of Module 340, the containment area of Unit 2, began in late December in the -

architectural area and in January for the civil, electrical, I and instrumentation / control disciplines. CIO monitored status assessment activities related to those disciplines and checked the adequacy of verifications of completed work by MPQAD through sample

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Minut3s of Meeting '

- PAGE 7 inspections. Activities to date have been minimal with no significant findings. Activities are expected to increase in the latter,part of February and March, expecially now that the mechanical discipline has been released.

Miscellaneous Ite.t

- CIO Staff The CIO staff remained at 29 but is expected to increase by a few people during February in preparation for increased CCP activity.

Action Item from Last Meeting

• Consumers Power Company (CPCo) had one action item, which was to discuss the condition of a cable that was in contact with nails in a board which was lying in a cable tray. Mr. R.A. Wells, CPCo, stated that when the cable was inspected, the board with the nails has been removed and only a minor scratch was seen on the cable

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jacket. Based on this inspection, the nonconformance report was closed. After further discussions with the CIO, another non-conformance was issued. This nonconformance recommends to engineering that the condition cf the cable be verified and approprate repairs or' replacement be made.

Questions and Answers

• Mr. B.L. Burgess, NRC, asked what changes would be made to the document control.. system from CIO recommendations.

Mr. Amoruso stated that recomendations had been made regarding status assessment prints (SAPS) and work prints (WPs). Those recommendations included documenting the training program for people involved, tenducting practice runs before starting up, and documenting the steps ~ involved in verifying registers.

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Minutes of Meeting PAGE 8

• Mr. R.N. Gardner, NRC, asked what electrical areas of Phase I of the

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CCP had started.

Mr. D.L. Quame, CPCo, stated that preliminary work had begun on raceways in Module 340.

• Mr. Burgess asked about the transfer of responsibilities from the CIO to

. the Remedial Soils Team for documents at soils stations.

Mr. J.E. Karr, CIO, stated that the areas that were passed to the Remedial Soils Team for continued monitoring included operations at field stations after the document distribution process was reactivated, retraining of people involved, and distribution of documents to vendors.

Mr. Burgess asked if the CIO would continue to track exceptions to the FCR/FCN Resolution Program.

Mr. Karr stated that the CIO would track exceptions.

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• Mr. Gardner, NRC, asked about the nature of coments about the FCR/FCN Resolution Program that were made by Mr. Doherty S&W, during a visit.

The coments had been categorized as unsubstantial in a CIO weekly report.

Mr. Karr stated that the coments included changing the title on an organizational chart, correcting an organizational title in a procedure, and clarifying a statement on the responsibilities of project engineers.

• Mr. J.J. Harrison, NRC, asked if the Public had any questions. The following items were discussed:

- Sending new crack mapping information to the Atomic Safety and Licensing Board.

- Initial findings of the Quality Verification Program.

Basis for CIO staffing.

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- Electric cable reinspection program.

l . - Improvements to crack monitoring program.

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Action Items None l

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