ML20090L894

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Rev 1 to Design Document Requirements Procedure. Related Info Encl
ML20090L894
Person / Time
Site: Midland
Issue date: 11/30/1973
From:
BECHTEL GROUP, INC.
To:
Shared Package
ML17198A223 List: ... further results
References
CON-BOX-04, CON-BOX-4, FOIA-84-96 PROC-731130, NUDOCS 8405260101
Download: ML20090L894 (44)
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Text

{{#Wiki_filter:. -.. _ - E g w v ; mger x s ) e ~ u .~ a j CONSUPERS POWER Co}!PANY a. 4i 1 . HIDLAND PLANT UNITS 1 & 2 3 d DECHTEL JOB 7220 r DESIGN DOCU!!ENT REQUIRDE!;TS PROCEDURE e a s F-ei t l. ti 1231.9g L A /\\ 7\\ ,J.'s_ 11/30/13 Issued for Use gg M 11/27/73 Issued for Trial Use and Comment )f)/yj gj g( 3,,,nl,y, m' n o - neecornrrne 3y 1 8405260101 840517 '~ PDR FOIA RICE 84-96 PDR

r - cv. A DESIGN DOCUMENT REQUIREMENTS .f 1.0 PURPOSE

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  • 1.1 The purpose of this procedure is to define the system to*be used f or assuring inclusion of all design and quality requirements in design documents and to provide documentation of th,is activity.

2.0 SCOPE 'l [y o 2.1 This procedure is applicable toya'll design work and significant revision issued after December /15, 1973, on the Consumer Power Company's Midland Plant Units 1 & 2. This design documentation procedure applies to all drawings or blocks of drawings and specifications. _ f N ,y,,, / C, M [ /' t ~ 3.0 PROCEDURE C;,, C, { } So.s.k. 9 ~ f *g @ ar_..a p %$ %y E 3.1 The engineer responsible for the origination of a design document 4 shall fill out the attached design requirement check list as he ? f'. i !' - develops the design document. The purpose is to assure all 44g applicable design and quality criteria contained in each applicable Q L ',)j document have been incorporated into the subject design and to SM verify that no omission or conflict exists. The engineer shall M 8 g,n h, c, $gi." g tj')1. initial the applicable blocks provided. , gi t' J it 3.2 If there is conflict between any of the documents containing N.' ', h, design or quality criteria, the originator shall so indicate on ( the check list and initiate any action required to resolve ~ conflict and route the check list with the subject design document to the checker. Criteria contained in the SAR or other licensing documents will prevail. Upon approval of the project engineer, design and quality criteria diff ering from the SAR may be employed, provided such diff erences are documented by a SAR change notice. Fabrication or construction of items differing in d.esign or quality from the SAR shall not commence until the.SAR change notice is approved by Consumers Power Company. i 3.3 The checker shall verify the design and originator's ccuments and then forward the check list and the subject design to the g group leader for review prior to submission to the., group super-visor. l 3 *. 4 The group supervisor will be responsible for assuring that all of the design requirements have been met and will approve that check list by noting his approval prior to issuance of that design document f or client review and/or construction. SB1231g1 G

U '.fd l.L' ". ?. etwL.Anu FR"l'.CT "Q" LISTED Docurent D NON"Q" LIST D ~ Titit. DESIGN REQUIRI'!ENTS vel:IFICA1 TON CMECKLIST Document Ns. 13 N3.17210 l-i Date 'ilDi WPPLICA3 LEI 'l k M. I SECT!ONS DESCR'PIIO:1 0F REQUIRDIENTS itSCISCERS CllCCKER'S! ACT. REQ'D DATE AC' I 1, r- !!N!TDLS 1 ISITIALS 4 aYZS/SO C017LEL 4h

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\\ Cc. itzen: List (PSAR/FSAR and jf l l-l Lieent. ins;) i '! i i 1 t rnvireneental Report i 1 I ,l 3 DRL Eafety Evaluation m

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' Public 1;carints T, j );. I 5 Correspondence (Letters to/fres j Bechtcl Telephene Memos, j! T'..?:'S and Interoffice Hemos) l \\6 Bech:el General Standards 'y. ? I Bechtel Discipline Standards i i i. J 3echtel Topical Reports } j t 8 9 1 MED'S. Enr*S, and EDI'S Ij 10' Censumars rever Cenpany Scandards 4 ( 11 . Midland Ptejoet Procedures Manual 8 ' 12 I Midland Internal Procedures Manual i iW i j I I i

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t' SB123102 h, i, h i h IDATE QUALITY E!:018EER'S APPROVAL l a l CROUP SUPERVISOR'S APPROVAL l l iAll of the abov,e applicable requiremo.nts have been checked and any actic n requirst i 1;o.acsure docueuntation ecmpliance. resa tr 1 f i DATE 1.1127/73 Rev. 0 i===ini mi

Unitod Statoo Tooting Company,, Inc. " - - - ~, mateines on sa. ins:.etion .-. e.3. O M a: O tt on 1:L.: ". i c os Di.10!c n

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>;50* 8tN. Ngw sgrtSEY 07030 l2011792 2400 (2123 9 3 0485 ~" traid.ag programs MM hD w,,bL M# -erd.:t._, C !?#I % ms pw m / y s A o._ %..,, Am.m a. i u,.., .p March 13, 1978 6 ~.n BECHTEL POWER CORPORATION Post Office Box 2167 Midland, Michigan 48640 ,,.e~. i 454 & 0c200-ATTN: Mr. J. F. Neugen 7 .b b Whut. ~ Job 7220 Midland Project Subcontract 7220-C-208 C-208-8-286 .s USTCO C-208-141 Gentlemen: File covering the captioned Project, including your letter of February 1,1978 addressed to Mr. David Edley of this Company and your telex dated December 30, 1977, have been referred to this office. From our extensive review of the files and investigation it is clear that the work in question wasunderthedirectionandcontrolofBechtelPowerCorporation(Bechtel) rather than United States Testing Company Inc. It is also clear that the identification of test locations, selection of sites,*and elevations for the work in question were made by Bechtel and not by the United States Testing Company. It is also apparent from the contractual documents that acceptance or rejection of the tasks performed thereunder was neither to be made by the United s .I States Testing Company nor was it the responsibility of this Company to do so. I Based on the facts disclosed in our review and investigation we must deny t ( that United States Testing Company is liable for the costs of $134,600 referred j to jh ' our letter of February 1,1978. ,.mf.. %...., y,>,.: /V Very truly yours, . f - (.' l # Y.h%$1[$b.x,Q UNITED ST T TESTING

tr ANY, INC.

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MolSTURE CONTENT (C) SB123074 d. p* . e

UU INFOMASTER )' BECHTEL ltIDL ,,'t .c.x. '3 003468C364 0937EST

4..... ",g.:/ 3 2071. MIDLAND, MI 12/30/77 3.'

TLX 12-649i3 U.S. TE. STING HSXN ATTN: DAVE EDLEY .al

SUBJECT:

' JOB 7220 MIDLAND PROJECT

) :'

SUBCONTRACT 7220-C-208 i 2-FAIW'IE OF ADMINISTRATION !. ~ 'L &(.9: h... - hh. BNILDING GRADE. BEAM ;'AT. O.4.:L'INE.,;[, g,. N. :d;'[df[A.C.*h.-... C-20 8-B-283 @::'?..:.\\;; W a % :'*. 'ex..:..a um M c.- a ~ b... 4. :e..,.. :...a....: r..%..L. m.. e. =

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. i.......%. h..,,.::, c .m...w.... k..e 'P:.:: : u.., , v.. :*n:.n y.. ,. - ::.:...:-. - w. .. w _ N .ON AUGUST.23,...L97.7 VE*.NOTED A' FAILURE '0F.-THE SOIL.'.. 37. g.-S. pr.m i .i..... i.> v .t..q g. ...... SUPPORTING.THE... -05l . SUBJECT ' GRADE BEAMOfiTHIS GRADU BEAM VASYL' ACED *0N FILIf@0RlEMICKMNM S !_.j3l U.S. ' TESTING PROVIDEDtSOIL' COMPACTION. TESTING DURING THF"INSTALLAI.'N+5 $l .TI ON. PERI OD. '/. DOUR

  • ENG kNEER.ING. ' ANALYSIS.? INDI CATES' THAT.T. HE.R

. HAVE. BEEN AN ; ERROR ON.THE PART"0F. U.S.J. TESTING COMPANY ,~I-f E. ? ,' SELECTION' OF..THE1 PROCTOR.:FOR THIS. WORK.CVE ARE h' 9' . 3$: THE CIRCUMSTANCES ' (INCLUDING ' SUBSEQUENT.' TESTS THAT.H

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4 ? . PERFORMED). ANDc VILL ADVISE :.YOU IN THE NEAR' FUTURE AS TO.. M.., ' ANY'LI ABILITY '.VE FEEk U.S.T TESTING COMPANY MAYhHAVE. PER.: ARTICLE. '..::*T.r'-d:.,',.~:.2 AND. CONDIT.! *'NS".. ' e 14,." INDEMNITY" OF EXHIBIT "A", "G ENERAL. TERM S'....... 9._.e"%...# r.r TECHNI CAL SUBC ONTRACT -7220-C-208.* a.5,,:5,- m s.,, &.:itt.... a.v ? e m.. w.n.... rv. q. . s.m

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0. c.#. w.p .:..n..w . a 5::,:.. - .y..n.g.7. .. v. QUESTIONS ON.THIS MATTER SHOULD 'BE REFERRED.TO MR. 'J. 'CMCHURCH,M. M m. F'MQFW.^4* NW J" l FIELD CONTRACTS AD C.' E-t' '. ? .:.'i"".gT.:sf.9WW: ,, y, nguaz,,.:.E.:.MINISTORJ:K3.r,%. i t Mgp:dQpm.g:fg f v;. ~.y. g: e q. g. ... ;.,~,- e:, ..y,. :g,.gn.yjggs.... gy -, .~ . u.w".,.;...p..,, c. %g .B CHTrL MIDL., c .. : :....... \\ , g.,. '.,.f.. i. 2.(. {,,@.Q......... 3:2.:.a. ;.:.,..sw..a 'g. JFN/J,CC/AJ3/EM, j c

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,m, a e edam-a Intsr-office Memorandum BEnc-2045 Date January 13, 1978 To J. F. Newgen Subject Midland Plant Units 1 & 2 From R. L. Castleberry Job 7220 Of Engineering Nonconformance Report NCR-1004 At Ann Arbor Copies toFile: 0274, C-0465 i G. L. Richardson i i S. S. Afifi F. E. Meyer W. Barclay We have reviewed NCR 1004 along with the other test reports 4 i furnished by field QC. At this time we are not able to make I an evaluation based on the available information. Therefore, it is requested that standard penetration test borings in j. accordance with ASTM D1586-67 be obtained at the following locations. Visual classification of soils should be done at 5-foot intervals unless directed otherwise by the soils engineer. I. In the Vicinity of the Diesel Generator Building The following locations are approximate. ~

1) S-5040; E-250
2) S-5040; E-300 These borings shall,be extended to an elevation of 610 feet.

i, II. [ntheVicinityoftheServiceWaterPumpStructure x

1) S-5000; E-750 1

,5

2) S-4980; E-780 These horings shall extend to an elevation of 580 feet.

h Please note that the disposition of NCR 1004 will be delayed until we receive the results of the penetration tests mentioned j '. above. Please inform us of the boring schedule so that we can arrange to have a soils engineer present during the tests. u y.cWPfQ-g6;/bdis R. L.'Castleberry j s l [ bkp 0/1 SB123095 t c I 4 .D_ -l----------

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1* ^% e -.-----s e l. MASTE R OC INSTRUCTION T8TLE e QUALITY CONTROL INSTRUCTION i EARTI! WORK SUBCONTRACT SURVEILLANCE g' ' JOB NO. 7220

3. M AG1F R OC INST MUCT ION NO.

R[V.

3. PROJECT OC INSTRUC11oN NO.
4. LOG NO.

None 7220/SC-1.10 REVISION l l i INSPECTION CRI([RI A r,. c. i. e. u ;. 30. n. 32. u. is. TYPE IO[NTif 8C AlloN No R [ V. TITE.E l REV DAT[ DESCRIPTION OY CosK'o APP"D Spec. C-210

  • 4 Plant Foundation Excavation and,

Cooling Pond Dikes Spec. C-208

  • 10 Haterial Tenting Services l

/

  • NOTE:.Rev. No,'n sh ivn f ra Block 7 only identify the l

applicabic re risions of inspection criteria documents 'l used to prepa re Re v. O of this QCI. Subsequent revisions to

he irispection criteria documents that require revis ton to this QCI shall be noted appropriately in Illock 11, i.e., "PQCI revised to incorporate c ianges as required by Rev.

." In addition curr ent revisions of specific engineering an< 2 2-13 '/6 Add " Moisture Content Control, [M vendor drawin ;s, sketches, specification, procedures Log" to Activity / Task 2.2, ~ j and instructi >ns shall be entered on the applicable Block 7 Inspection Re :ord. 1 / Incorporated Client Connents SB123142 '..A

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=EV 7220 JOB NO. 7220/SC-1.10 2 3. 4. eM SPE CTIO N psSP - SUPPLeseEstT Altv c ACTIVITY OrSCRIPT80N CENERAL INSTRUCTIONS Purpose The purpose of this PQCI is to provide instructions to QCE's for surveillance inspection of on-site construction activities performed by the Earthwork Subcontractor. Scope This PQCI covers surveillance inspection of the plant area and beam backfill as described in the subcontractor for placement, moisture control, compaction and quality documentation. The individual subcontract surveillance inspection record (s) (SSIR's) may be scoped for each application at a specific work area or other definable parameter. The SSIR is to be initiated at least weekly, but may be initiated more frequently at the discretion of the QCE. Special Instructions 1. The instructions contained herein are based upon the general policy that the subcontractor retains full responsibility for the quality of his work and that of his subcontractors and that the Ilechtel Field Quality Control Engineers (QCE) are responsible for performing surveillance inspection of the on-site construction activities performed by the subcontractor. Surveillance inspection consists of a review, observation, and/or inspection of the subcontractor'a: certification of personnel; installation, inspection, examination and test control; use of calibrated measuring and test equipment; material control; control of nonconforming items; documentation of inspection activities and special process controls to determine that the subcontractor's activities are in accordance with his QC program and the requirements of the contract documents. It does not mean that all subcontractor activities, items or documentation will be continuously observed for the purpose of determining compliance. SB123143 l e Paar 2 or 9 oco.-s

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a emossCv oC sasinuCreon no. =sv 7220 JOB NO. 7220/SC-1.10 i 2 s. ^C' .o ACrivery ossCnievion e n se< Cvo o m ease suces. a m e n v a n, CRITERI A ACT. C oot MECORD CENERAL INSTRUCTIONS Special Instructions (continued) 2. Af ter the subcontractor has moved on-site, and prior to the start of on-site work, the Project Field Quality Control Engineer shall contact the Subcontract Administrator or Project Superintendent to arrange a pre-construction meeting with the subcontractor's field construction quality control personnel and construction si;.wrvision for the purpose of discussing the requirements for sub2ontractor's performance as delineated in the Summaary Report of Preconstruction Meeting. (See Exhibit 1 of SF/ PSP C-9.1). At this meeting witness and hold points will be estab-lished mutually between the Subcontractor's QC personnel and Bechtel Quality Control. Bechtel QC will also review the subcontractor's inspection procedures for compatibility with this QCI. 3. The QCE shall use the IR to describe those inspection activities he has performed during the scoped period. When the-QCE has observed a certain piece of equipment, work operation, procedure or special process being performed he shall identify those items, procedures and processes on the I R. Items and location shall he described in Section 6, and procedures and reference criteria shall be listed in Section 7. The QCE shall describe what activities he observed or performed in Section 9. The QCE shall also note exceptions, unusual occurrences or noteworthy items in Section 10 Additional remarks for any of the IR sections shall be made on a continuation sheet. 4. When preparing Block. Number 7 on the IR the QCE shall enter the documents necessary to perform the designated inspections. These documents shall include: (1) the primary specification (s) revision number (s) all specification change notices and applicable Field Change Requests (2) Project Engineering approved drawings, all DCN's and applicable Field Change Requests. The primary specificarlons are those identified in Block thunber 6 of this QCI cover sheet. 5. All documents used as inspection criteria for quality verification shall be " controlled" documents. SB123144 um

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2. eno;scT oc susinuction e.o ats JOB PdO.__. 7220 7220/SC-1.10 2

ACT ~ h A s, ACTIVITY DESCRIPTION INSPE cTION INsP SUPPLE ME N T A RY wo, CMiiinsA ACT coot RECORD i 6. Where Project Engineering approved documents exist within the scope of work to be performed, the Project Engineering approved document shall be i used. l l 7. If during the review of the inspection criteria documents or at any time later during the performance of these inspections, the QCE determines the inspection criteria dociaments are not adequate to perform the required inspections (i.e., incomplete or omitted details, lack of l cross-referencing between drawings, documents require clarity) he shall notify the Lead Discipline QCE. The Lead Discipline QCE shall discuss the problem with the PFQCE who will take _the necessary action for resolution. The Inspection and sign off shall not be completed until the QCE is satisfied that the document problem, if any has been satisfactorily resolved. l l 8. The inspection codes in Coltaan 6 of the QCI for in-process and final l inspection activities are supplemented by one of three different symbols to further define tie type of inspection required: 1. (V) visual inspection, 2. (M) measurements, and 3. (VM) visual inspection and measurement. (V) is to inspect by visual examination, (M) is to inspect by physical measurement of dimensions or count of required quantity. (V M) is to visually examine to detect the apparent worst condition, take a measurement to verify acceptance and visually compare the other items based on this measuressent. SB123145 l J 9 2.1913.

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=Ev JOB NO-7220 7220/SC-1.10 2 8- ,' $UPPL e ed E N T A ft Y ON SPE C TIO N MSP ACTIVITV DESCRlPTION o. 9. The QOF, shall surveillance inspect subcontract quality verification documentation that has been generated during the scoped period. IIe shall review this documentation for availability, traceability, legigility completeness, acceptance and that it is prepared and controlled in accord-ance with the Subcontractor's QC program. Upon completion of the subcontractor's worl activities or portions thereof, the QCE shall review the Subcontract quality verification documentation turned over to Bechtel QC for availability, traceability, legibility, completeness and acceptance. Additionally the QCE shall review the completed SSIR's for any open exceptions and shall verify that any subcontract release documents have been prepared and signed. 10. Exceptions noted during the scoped period shall be reported in accordance with SF/ PSP (;-9.1. Quality Control shall monitor these outstanding exceptions for satisfactory resolution prior to completion of turnover of subcontractor activities for that portion of work scoped on the IR. l l SR123146

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7220 JOB NO. 2 7220/SC-1.10 3 ACT 5. 6. T. ACTIVITY DESCRIPTION INSPECTION INIP $UPPLE ME N TA RY g' CRITE RI A ACT CODE RECORD 1.0 PREREQUISITES The following activitics shall he accomplished prior to or during the actual performance of any of the in-proces s surveillance inspection activities: 1.1 Review of the latest applicable drawings, specifications, procedures and subcontract doctanents, listed under Column 6 " Inspection Criteria" on the PQC1 for familiarity and to assure: a. The inspection and reference criteria documents, including the applicable None R codes and standards are the correct revision and are available for reference when performing the surveillance inspection activities required by this PQC1. b. Field engineering and subcontract documents have the correct approval None R status. c. Preconstruction Meeting witness and hold poiats and any other outstanding None R iterns needing resolution prior to implementation, have been incorporated into the PQCI. 1.2 Review for open "Noted Exceptions on previous SSIR's which affect the scoped None R work. 1.3 Review the " Inspection Criteria" on the QCI under Block 5 and the" Drawings / Nor.e R Specifications / Procedures" on the SSIR under Block 7 to assure the criteria is understood.

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JOB NO. 7220 7220/SC-1.10 2 3* ACT 4 s. 6. 7. ACTIVITY DEf,C3fPTION P[CT ON SUPPLE MENT A RY NO. 2.0 PROGRESSIVE SURVEILIANCE INSEECTION The following progressive inspection activities shall be performed by the inspection method shown in Column 6 and identified on the SSIR to verify that the in-process work is performed in accordance with the applicable inspection and reference criteria shown on the PQCI and SSIR. 2.1 Placement of Backfill Material Prior to and during the placement of backfill material verify that: a. Foundations have been approved by Bechtel Field Engineering prior to C-210 12.5 IIP backfill. 13.5 b. Bechtel Field Engineering has approved the placing of backfill materials 12.5 IIP during freezing conditions (320F and falling). 13.5 c. Backfill material is spread in horizontal uncompacted lif ts not to 12.5 SI(V) exceed the specified thickness for the zone.being placed. 13.5 d. Backfill zones being placed are raised simultaneously with the top 12.5 SI (V) surface of the embankment to form an approximately horizontal plane 13.5 extending transversely to the final slopes and longitudinally to the abutments. e. Backfill placement shall be raaintained at all times in such a condition 12.5 SI (V) that the surfaces will readily drain. Ruts in the surface of any layer 13.5 shall be satisfactorily filled before compacting, f. Placed backfill' material that becomes sof t or yielding due to subsequent 12.5 SI (V) moisture intrusion shall be removed and replaced by suitable material. 13.5 2.2 Holsture Control For backfill requiring moisture control verify that the moisture is within 12.6 SI (V) Moisure Conten-the limits required by the Engineering specifications for compaction. 13.6 Control Log SB123148 J

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6. 7. NO. ACTIV8TY DESCRIPTION INSPECTeoN 8"S' S UPPLEMEN T A RY CRITE RI A Aci code REcomo 2.3 Compaction Verify the compaction of backfill material for the specified zones for the following: a. All roller passes for the specified zones shall be made in a systematic C-210 12.8 SI (V) manner and overlap the adjacent pass to assure the entire area is compacted uniformly, b. Backfill material when compacted shall form a homogeneous mass, with any 12.5 SI (V) voids between stones completely filled with compacted material, c. Compaction equipment shall conform to the specified requirements for the 12.7 SI (V) zoned material being placed and compacted. If equipment other than that 12.8 specified is used, it shall be demonstrated that the substitute equipment can meet or exceed the degrees of compaction achieved by the equipment .specified, as determined by Bechtel Field Engineering, d. Backfill material for the specified zones has been compacted to the 13.7 SI (V) required density as determined by the Bechtel Modified Proctor Method. 2.4 Testing The location of the tests will be as directed by the Subcontractor's QC representative. a. Verify that the field density moisture content tests have been performed 13.7 SI (y) in accordance with engineering requirements. 13.6 12.6.1 12.4 C-208 9.1 2.5 During in-process surveillance activities, verify the following: a. Subcontractor QC personnel are qualified. C-210 16.1 SI (V) b. Subcontractor QC personnel are properly preparing their QC documentation 16.5 SI (V) c. Siebcontractor is properly identifying and recording nonconforming 16.7 SI (V) conditions. SB123143 se

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S. 1. INSPEC1 BON $NSP guppt g eggg r a gy C ACTIVITY DESCRIPTSON 3.0 FINAL QUALITY VERIFICATION ACTIVITIES Prior to closing Quality Verification for a scope / location the following activities will be accomplished: 3.1 Review the pre-established hold and witness points and any other required None R activities necessary to complete surveillance inspection assignment for each completed work item. i 3.2 Verify that the Subcontractor's Quality Verification Documentation has been None R submitted, reviewed for availability, traceability, completeness and acceptance by Construction Quality Control. 3.3 Verify that all outstanding exceptions identified for the scope / locations of None R the SSIR are resolved prior to completion or turnover of subcontractor activities. 3.4 At the completion of Tasks 3.1, 3.2 and 3.3 submit the Construction Quality None R Control Releace Form to the PFQCE for his signature, when the subcontract or portions thereof has (have) heen completed. SB123150 . P.o. 9 o, e oco..S

Bechtel Associates ProfessionalCorporatio Inter-office Memorancum RECEIVEO Distribution

  1. 7 To Subject Midland Plant Units 1 and 2 From L.D. Curtis

! O II Bechtel Job 7220 v Responses to NRC Questions on Engineering Plant Pill s comes to At Ann Arbor Office K. Bailey

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S. Blue J. Rutgers Pile 0670.2 D. Riat E. Rumbaugh p C This is to confirm that the highest priority activity by Midland Project Engineering at this time is the close-out of NRC 10CTR 50.54 (f) I questions associated with or stemming from plant fill problems. This priority is based on several reasons, including but not limited to the following: a 1. It is assential to project schedule to start public hearings on this issue as soon as possible, hopefully no later than late summer 1980. As a prerequisite, it is necessary to close out the open items quickly, completely, and accurately. 2. Many of the previous commitment dates for responses have been missed, for various reasons. It is important to Consumers Power Company to maintain credibility with NRC on their commitments; therefore, improvements in our responsiveness are needed. ?; On or about June 5,1980, Consumers Power Company will submit te NRC an L-updated master list of all commitments made and responses due to NBC p relative to the plant fill issue. This list is being prepared by Bechtal under the leadership of shing Lo. Pisase cooperate with him on a top priority basis in closing open action items as soon as possible and in [; giving him firm scheduled completion dates for inclusion in the master 7 list being prepared by Bechtal. E J ' f: [ L.E. Curtis .g ac/db Distributions i All APE's f.l All Group Supazvisors .p All Chief Engineers G } ss170sa7l Response Requested: No .o 1

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u Bechtel Power Corporation Inter-office Memorandum .To J. Milandin o.m November 3. 1978 G. L. Richardson Soils Placement Records From sutiiect i Midland Job 7220 of Quality Assurance Staff i copies to S. Heisler L. Dreisbach At Ann Arbor i W. Barclay J. Newgen P. Martinez E. Rumbaugh { R. Castleberry H. Wahl j E t'i h ,j In accordance with your request, I have reviewed Midland jobsite I records related to the placement of backfill materials in the area of the Diesel Generator Building to assure that the project require-i j ments were properly implemented during the work operations. The attached report sumarizes the infonnation reviewed. No areas of impre)er implementation or program noncompliances were noted i during tiis review. I N .Z).f b. S j G. L. Richardson i 'i GLR /le j GLR-78-10 i attachment t 5 ^": e

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1 REPORT OF REVIEW OF SOILS PLACEMENT / INSPECTION RECORDS RELATED TO 1 EMBANKMENT IN THE AREA 0F THE DIESEL GENERATOR BUILDING I. PURPOSE: To provide assurance that records for installation of plant fill and structural backfill are complete and provide evidence the work was accoglished in accordance with the program re-quirements. II. CONTROLLING DOCUMENTS: l Technical Specifications 7220-C-210 and 7220-C-211 Project Drawings - Specifically 7220-C-44 and C-45 Canonie's QA Manual (Earthwork Subcontractors) l Quality Control Inspection Plan C-210-4 Quality Control Instructions C-1.02 & SC-1.10 Note: Revisions to these documents vary through 1975 - 1977. III. METHOD OF VERIFICATION: Program requirements were determined from the controlling documents. sumarizes the pertinent requirements for placement by the subcontractor or Bechtel. Inspection and Testing. Using these requirements, quality documents were reviewed to assure that necessary inspections and tests were carried out during the time of placement { in the area of the Diesel Generator Building. Attachments list '4 the actual documents reviewed. The results of this review is stannarized in the following paragraphs. IV. SUM 4ARY OF RESULTS: 1. The approximate dates of backfill operations in the areas of t i the Diesel Generator Building was determined from a sumary of testing prepared by Quality Control (attached). This sumary list the test results for this area and also provides plots of the location of the tests. Based on this data.- the material

1 was placed during the periods of:

i October - November,1975 - limited work in area June - September,1976 - most work was building ramp south of turbine building July - December, 1977 - Majority of fill placed during 5B103375 this period. April - July,1978 - Bechtel placement

  • l A review of the subcontractor's daily report confirmed that these dates are appropriate.
  • Earthwork Subcontractor (Cononie) operations ended about 11/10/77.

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Page 2 l 2. Quality Control files were reviewed to assure that Quality Contml Inspection Plans or inspection records were prepared to cover the scope of work and were properly implemented. Forty-two (42) FIP's and QCIR's were reviewed. This review indicates that QCIR's/FIP's were prepared to cover the work as it was in progress. These plans / records were properly scoped, prepared and completed which indicates the required surveillances and inspections were properly signed off on the records checked. 3. The Earthwork Subcontractors QA Program requires their QC Engineer to produce certain records which include daily reports and lift thickness checks. All of the records for 1975, 1976 and 1977 were quickly reviewed to assure their availability. 18 of the records were reviewed for proper implementation and i completeness and found satisfactory. The lift thickness checks 4 on these records indicate lifts less then the maximum (12") allowed by the specification. It was noted that the lift thick-ness checks for the 1976 are not in the QC files. Quality Control has identified this item and has requested subcontracts administration to obtain the missing /76 (25-11-2) i s documentation. Quality Assurance conducted an audit on 9/17 which included a review of lift thickness checks. Five lift thickness check records were reviewed for 7-14-76. 8-11-76. 8-20-76. 8-27-76 and 8-31-76 and found acceptable. This verifies the lift thickness checks were being taken and recorded. i 4. Test Records for the Diesel Generator were checked by review of the tests sumarized by Quality Control. (Copiesattached) These tests results sumarized were compared with the test " Compaction Fill Density Test Reports" (QC File C-210.3) produced by U. S. Testing and found to be accurate. The test results 4, [ percent compaction and relative density) reviewed complied with the requirements of the technical specification. The fmquency. ,i of testing for the area within the limits of coordinates S 5036 1~ to S 5185 and E 150 to E 490 is in the approximate area of one field density test for each 300 cubic yard placed. This figure is lower than the required frequency of one test for each 500 i 'l cubic yards placed. The figure based on an assumed placement >[ depth of 30 feet and 157 density tests taken. I 5. Twelve (12) QC Receiving records were reviewed for structural I backfilling along with seven (7) user gradation tests and found 'j acceptable. l

6.. Quality Assurance audits were reviewed for the period of r

construction. Eleven (11) audits were conducted covering the t l areas of Test Laboratory Operations. In-process Soils Placement and implementation of the Earthwork Subcontractors QA Program. i

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Page 3 ~ V. CONCLUSIONS The records reviewed indicate the backfill materials placed by Cononie and Bechtel were placed on approved foundations, in a manner consistent with the project requirements, and compacted to the densities required by the project documents. This is evidenced by the conpleted records produced by: 1. Cononie Quality Control Engineer 2. Bechtel Quality Control 3. U. S. Testing Laboratory 4. Bechtel Quality Assurance The records included in this review also indicate the quality programs approved for use by Cononie and Bechtel were properly implemented as related to the backfill operations in the area of the Diesel Generator Building. 1 4 1 ( f. E k i 1 i SB123377 i ?

SOILS RECORDS REVIEW LIST OF ATTACHMENTS No. 1. Soil Placement Requirements - A flow chart of pertinent requirement for placing soil which was used to detemine types of docisnents to sample. No. 2. Review Record - Record of Quality Control and Subcontractor Records Reviewed. No. 3. QA Audits - Record of QA Audits reviewed and results of audits. No. 4. Structural Backfill - List of QC records reviewed for receipt of structural backfill. No. 5. Compaction Tests - Summary of Conpaction Tests prepared by QC and reviewed during this check. d SB123378 - 1 i

1 Bechtel Power Corporation Inter-office Memorandum To Distribution oat. Tiovember 2,1973 subject itidland Project Job 7220 From L. A. Dreisbach External Audit Report - IRC File: Q 1100 of Quality Assurance LAD: 514 Copies to At Midland,f1I 48540 P. Itartine:: J. newgen R. Castleberry W. Darclay J. ftilandin i S. Heisler The attached memo issued by CPCo QA presents the results of the liRC inspection at the jobsite in the period October 24 to 27,1978. I essentially agree with the attached record as written. !! ate in the first paragraph that no items were identified as non-compliances in the exit meeting however, they could becou.e non-compliances on review by the inspectors raanagement. lAhkA L. A. Dreisbach , j Project Quality Assurance Engineer LAD /re i Attachment } cEg60-a s !\\ \\W' KON / W 30W yp.: VBet i 'Y..' snyggggs k

,._____-..__r---..-- / /' . i... 3 =t 6. B. Ecchtel Quality Control Instruction C-1.02 section 2.4 testing identir tes the applicable inspection criteria and includes Specification C-210, nec-tion 13.7 and 12.4 which includes the apparent conflict as described in detail in Part A above. C. A further review of the original subsurface investigation performed by Dames and Moore and documented in report supplement dated March 15, 1969 page 16' indicates that-the recommended minimum compaction criteria for support of structures be 100% of maximum density using a compactive effort of 20,000 foot-pounds (resulting from Bechtel Modified Proctor determina-tion). Ilowever, this 100% of Bechtel Modified Proctor corresponds to 95% compaction according to the standard ASTM D1557 method D and not 95% com-paction according to Bechtel Modified Proctor method which has been utilized for the entire plant fill area to date. Furthermore, Dames and Moore Report, page 15 states that all fill and backfill material should be placed - at or near the optimum moisture content in near horizontal lifts approxi-mately 6-8" in loose thickness. Bechtel specification permits a maximum of 12 inches which affects the compactability of the material. 7. Piping, condensate lines, duct banks, and other utilities under the diesel gen-erator building may also be affected and must be evaluated. 8. Mr. Gallagher stated he was leaving not having seen design calculations and will be discussing design calculations., assumptions made, and conflicts with the FSAR with Licensing. ? O

  • 7; 9.

The inspector observed the structural concrete crack that has developed in the east eaterior wall. The crack was observed with members from Bechtel Geo-Tech and Consumers Power Company. The crack cxtended full height of the 1 wall and continued down through the spread footing as seen from the inside of the ^ouilding. The crack is expected to have been induced flexurally caus.ed j by differential settlement. Discussion with Bechtel, design staff has indicated l that this crack is under study and is currently being evaluated. ACI-318-71 1 in the comme'ntary section 10.6.4.11mits flexural crack exposed to the outside j to 0.013". Corrective action may be required if this limit is exceeded. __ j ' j 10. The following tests were observed to be performed in accordance with the applic- - J able tests stanaards by U.S. Testing: 1 1 A. Lab Test ASTM D1557-70 i)! B. Field Test ASTM D/1556-64 SB1233SS o, - l 11. Calculations should be evaluated on the increase and the rate of increase of the pond fill and the effects of the water in other areau. ~ 12.- Mr. Gallagher stated that the KRC does not view prcloading.of the structure to-bc a fix or resolution of the problem at this time. ,a 1 -13. Scismic loading calculations should ha determined for the type of material n existing in its present~ condition. .c! s ~ ~

..3,__.... ..r. -rr..m-ese = =-rww.+ - - co"-"*" *ME "EAM '( 2 3 S$123390 s P + 2. FSAR Table 2.5-14 " Summary of Foundation Supporting Sciamic Category I Strue-tures" identifies the :mpporting coil m.iterials under the diesel generator building an i.e n:.; controlled, enn;> acted cohcrive nolin. Ilowever. count ruct ims ~: r d rnwing C-3 09, 1:. v. 9 and C-117, Rev. 6 (dent ifies the material in thin aren an Zone 2 mal eria l. Zone 2 mat.erial in blent tried an ranilimi I i l l donci iln il an any mat erlai i roe of organic or of.her eloles orions mat erlaIn. In ihe IinId a varlety of malerlain have been used fur the d ienel nencratw lonn ias.lon material, Jn partir:ular, cands, ciny, nnd Jr an r:nnerete, niit y : ands anni clayey s candn. The nyparr:nc :rinflir;t 1: L hn t. Tnhir: 2. 'i-J 4 in'r:u t. i f lov. nrknin *. si I a uhere, in actuality, cohesionless sands have been utilized. A review of the rr. srd indL*:nte that nsnds ha:e heen used hetueen sin:stion SW-6C3', arcas of clavation 611'-613' and areas between 616'-26S'. This indicates the ex-tent of the variability of.the material placed under the diesel generator ~ ~' building foundation. Mr. Callagher did not feel it was good judgement to use i random material under the support of a structure. 's 3. FSAR Table 2.5-21 " Summary of Compaction. Requirements" identify random fill to require a compaction effort of a minimum of 4 passes with the specified equipment in this table. This requirement has not been an imposed requirement . " of Bechtel Specification C-210 nor an inspection requirement of Bechtel Quality Control Instruction C-1.02 for backfill. .4. FSla section 3.8.5.5 states that settlements of shallow spread footings founded ~ on compacted fill are estimated to be on the order of Is" or less. Site Survey Program has identified settlements in the diesel generator building foundation on spread footings to range froa 0.55 inches to 2.30 inches and in excess of 3.0 inches for the diesel generator pedestal. ), 5. FSAR figurs 2.5-47. indicates the foundation of the diesel generator building to be at elevation 634', according to design drawings C-1001, Rev. 5 it is i indicated for the diesel generator spread footings and pedestal foundation to be at 628'. r l 6. A. Specification C-210, section 13.7.1 requires all cohesive backfill in the 4 plant area to be compacted -to not less than 95% maximum density as deter-i mined by ASTM D1557 method D which requires ~an effective compactive effort y of 56,000 foot-pounds of energy per cubic foot of soil. However, section i; 13.4 Testing requires testing of the materials placed in the plant ares l to be performed in accordance with~ tests listed in secti~on 12.4. This '/ section, in particular section 12.4.5.1, " Cohesive Soils," requires maxi-l 7 i mum lab densities to be determined using ASTM D1557 Method D provided 'a compactive energy equal to 20,000 foot-pounds per cubmic foot is applied -(Dechtel Medified Proctor Density). To date, the Ecchtcl Modified Proctor Density for determining maxieum proctor. density 'versus optimum moisture content has been utilized. This conflict results in an unconservative ~ I 't r.ethod of determining the maximum proctor density and method of assuring ~ that the required percent tempaction ics achieved In particular, the. t E actual in-place compaction would be less using the Bechtel Modified Proc-T . tor Density as a reference than.using the standard AST)! D1557' method D. Lj This is due to the fact that the compa:tive energy' exerted using the Bechtel l-Modified Method -is less than tha. effort exerted by the standard method D - exampic: 20,000 foot-pounds versus 56,000 foot-pounds. P

9 eed.w - 6 g%. e g h e c 4-e [ Bechtel Power Corporation inter-offica Memorandum 4 To Distribution Dat. fiovember 2,1978 s Subject tiidland Project Job 7220 prom L. A. Dreisbach External Audit Report - !!RC File: Q 1100 of Quality Assurance LAD: 514 Copies to At Midland,111 4S640 P. liartine:: J. flewgen R. Castleberry ~ W. Barclay J. fiilandin S. Heisler + ~ The attached memo issued by CPCo QA presents the results of the fiRC inspection at the jobsite in the period October 24 to 27,1978. i I essentially agree with the attached record as written. l!ote in the first paragraph that no items were identified as non-compliances in the exit meeting however, they could become non-compliances on reviers by the inspectors management. hM AM a.k A L. A. Dreisbach { Project Quality Assurance Engineer f, LAD /re Attachment i I e f o cEiy s "s 03 SB123331 S L WI 30 W p,it # h Tact i n. /l,,,\\ l t l ** t i ? ? 9

i. ,, o a / r,m DEllorn, Midland b.'e@ /' C011SumES o.u c October 31, 1973 [IQyJg svescer MIDLAND Pit 0 JECT - NRC i;XIT INTFRVilH OF OCT0l!ER 27,1978 File:

0.4.2 Serial

280FQA78 {"fj'^l cc SAfifi, Bechtel - Ann Arbor JLCoricy, Midland C WRBird, JSC-216B GSKeeley,'P14-408B RLCastleberry, Bechtel - Ann Arbor DB:liller, Midland j TCCooke, Midland JFNewgen, Bechtel The following people were in attendance at the subject exit. interview which was conducted at the and of C. J. Callagher's inspection of October 24-27, 1978: 4 CPCo Dechtel NRC RCBauman WLBarclay' RJCook TCCooke _ABoos CJCallagher j JLCorley RLC.tseleberry Dehorn LADreisbach e 2 CSKeeley PAMa rtines' i

DBMiller, i

BHPeck _I RMWheeler 'Mr. Callagher stated that the visit was a follow-up on 50.55(e) report of the diesel generator settlement and that it was also a fact finding visit. The in-spection consisted of a review of past data, activitics in progress and planned activities for future work. Inspection was performed by review of the FSAR com-3 mitments; Specification C-210; Specification C-211; PQCI/IR C-1.02; Dames and r Moore Report of Foundation Investigation and P.reliminary Explorations for l'orrowed [1 Materials dated June 28, 1968 and supplement to this ' report dated March 15, 1969; 's preliminary data on diesel generator settlement problem including boring plan, cross sections of fill, blow count versus the elevation graphs, lab data, settle- -[ ment data, horing logs, dutch cone. logs, weather data and penetrameter readings b;, in test pits; design drawings C-45, C-109, C-ll7 and C-1001; soil tests taken. F in the diesel generator building area during construction compiled by B. T. Cheek, Bechtel QC; observation of soil testing at the test lab and in the field; and f discussions with Bechtel Geo-Tech, Fraject Engineering, Field' Engineering, Quality p Control Engineering, U.S. Testin5, Consumers Power Company, PMO and QA personnel. y g,,,,e Mr. Callagher. stated that he. would not handle the findings as noncompliances, ,g g however, they could become items of ' noncompliance when they are'revieued by his management. His findings / observations were as follows: o e 1. ~ The FSAR states that durinn oneration, settlement rendir,gs will be taken every' 9Q_ days. Because of the diesel generator settlement probica, this frequency ) N ,s_hould be re-evaluated for adegung. a [ j ss123245 .........h N, 4:' g .~ g .g =, J-

E E FSAR Table 2.5-14 " Summary of roundation supporting Sci:.mle Categury 1 Struc-2. turcs" identif f en t he cupporting son wat erials under t he diesc1 annerator .~. building as lietng controlled, cua.p icted coheu tve solis. Ilowever, construction y [*.',M, drawing C-109, Rev. 9 and,C-11T, nov. 6 identifics the material in this area _as Zone 2 material. Zone 2 material.i.s_idcut.ified_as. r.andom__ fin described In the field as any material f ree of organic or other deleterious materials. '3 4, a variety cf materials have been used for the diesel generator foundation l material, in particular, sands, ciny, and lean concrete, silty sands and clayey The apparent conflict is that Table 2.5-14 identifies cohesive soils .T sands. A revi'ew of the t where, in actuality, cohesionless sands have been utilized. t records indicate that sands have been used between elevation 594'-608', areas a 'E of clavation 611'-613' and areas between 616'-26S'. This indicates the ex-t tent of the variability of the material placed under the diesel generator E building foundation. Mr. Callagher did not feel it was good judgement to use Z random material under the support of a structure. m.. FSAhl Table 2.5-21 " Summary of Compaction Requirements" identify random fill 3. '* k to require a compaction effort of a minimum of 4 passes with the specified E This requirement has not been an imposed requirement' equipment in this table. E /?, g r of Bechtel Specification C-210 nor an inspection requirement of Bechtel Quality ' ' g ' control Instruction C-1.02 for backfill. g FSAR section 3.8.5'.5 states that settlements of shallow spread footings founded 4. E on compacted fill are estimated to be on the or; der of 1s" or less. Site Survey e j

L Program has identified settlements in the diesfl generator building foundation j

on spread footings to range from 0.55 inches to 2.30 inches and in excess of 3.0 inches for the diesel generator pedestal. 3A. FSAR figure 2.5-47 indicates the foundation of the diesel generat 5 5 to be at elevation 634', according to design drawings C-1001, Rev. 5 it is ~ g pe+g ndicated for the diesel generator spread footings and i y vt. f a to be at 628'. E Specification C-210, section 13.7.1 requires all cohesive backfill in the m.~ 6. A. f plant area to be compacted to not less than 95% maximum ' density as deter-l I mined by ASTM D1557 method D which requires an effective compactive effort of 56,000 foot-pounds of energy per cubic foot of soil. However, section a g 13.4 Testing requires testing _ of the materials placed in the plant area E 7 to be performed in accordance with tests listed in section 12.4. This g section, in particular section 12.4.5.1, " Cohesive Soils," requires maxi-t mum lab densities to be determined using ASri D1557 Method D provided .a compactive energy equal to 20,000 foot.-pounds por cubmic foot is applied f y/ f ,) (Bechtel Modified Proctor Density). To date, the Ecchtel Modified Proctor g Density for determining maximum proctor d(usity versun optimum moisture i l "p,.e e 2 content has been utilized. This conflict results in an'unconservative method of determining the maximum proctor densLty and method of assuring E that the required percent compaction la ac hieved, In partJenlar, the i actual in-place compaction would lie leus using the 11echt.cl Modified Proc-I ' tor Density as a reference than using the standard ASTil D1557 method D. This is due to the f act that the cor.pactive energy exerted using the Bechtel ? Hodified !!cchod 18 lens ~ than the ef fort exerted by the standard method D - exaieple: ~ 20,000 foot-pounds versus 56,00J foot-pounds. f SB123246 9;.nO G 3_ 9. e=g: t

s ...,44 . ~.. ~., l +v 6. B. Ucchtel Quality Contrul Tnutruction C '1.02 cection 2.4 testing identifics the applicable insiwetJon e riteria and includes !;pecification C-210, nec- [ tion 13.7 and 12.4 whidi Lacludes the apparent conflict as described in detail in Part A above. C. A further review of the original subsurface investigation performed by Z Dames and Moore and documented in report supplement dated March 15, 1969 page 16 indicates that the recort.nended minimum compaction criterin for support of structuren be 100% or maximum denr.ity using a compactive cffort y. of 20,000 foot-pounds (resulting from 1:r chec1 Modifled Proctor determina-p tion). However, this 100% of Bechtel Modified Proctor corresponds to 95% 3 / compaction according to the standard ASTM D1557 method D and not 95% com-paction according to Bechtel Modified Proctor method which has been utilized =

E for the entire plant fill area to date.

Furthermore, Dames and Moore Report, rage 15 states that all fill ~ cnd backfill material should be placed at or near the optimum moisturo content in near horizontal lif ts approxi-2 mately 6-8" in loose thickness. Bechtel specification permits a maximum of 12 inches which affects the carpac'tability of the material. +, 'd 7. Piping, condensate lines, dbet banks, and other utilities under the diesel gen- } 7: erator building may also be affcceed and must be evaluated. i 8. Mr. Gallagher' stated he was leaving not having scen design calculations and ~ ~ will be discussing design calculations, assumptions made, and conflicts with [.'f the FSAR with Licensing. a 9. The inspector observed the' structural concrete crack that has developed in the east exterior wall. The crack was observed with members from Bechtel Geo-Tech and Consumers Power Company. The crack extended full height of the wall and continued down through the spre'ad footing as seen from the inside of the building. The crack is expected to have been induced ficxurally caused a by differential. settlement. Discussion with Bechtel design staff has indicated 4 that this crack is under study and is currently being evaluated. ACI--318-71 5 in the commentary section 10.6.4 limits flexural cracic exposed to the outside 4 to 0.013". Corrective action may be required if this lidit is exceeded.. ~ $. 10. The following tests were observed 'i be perform:ed.in accordance with the applic- [ able tests standards by U.S. Testing: f h A. Lab' Test ASTM D1557 ~ ~~. . f B. Field Test ASTM D/1556-64 S [ 11. Calculat' ions should be ovaluated on the incronne;nnd the rate of increase i p/ of the pond fill and the effects of the u. rice in other areas. 1 1 i ?- g12. Mr. Callagher stated t hat tbc NRC does not view preloading of the str ucture to be a fix 'or recolution of the probicm at this time. + 13. Seismic loading calculations should bc-determined for the type of material $1 cxinting in its;present inndition. f -SB123247 . q. ;., a - L,.. a.--z,.- .a ,,2

.s

  • Bechtel Associates ProfessionalCorporation 4

'TELECOPY Inter-office Memorandum l PROJECT OA BEBC-2480 A::*1 tiP. DOR J00 7223 Date October 4, lg 7a To J.F. Newgen Data flee::rr !: OCT 4 78 From R.L. Castleber,g,.;

,3, j,.y, jcgy Subject Midland Plant Units 1 & 2 y

Job 7220 U 'U 1

  • Instructions for Obtaining Engineering Soil Samples I

At Ann Arbor h Copiesto File: 0274, C-79-PR b.$Sw' nberg;al a CAE I 2 S. Afifi 4/6 7! L. Basinski M4./ / I J. Batts

44. O

/ E A. Marshall ~ W.B. Barclay L. Dreisbach FILE.,L,,, seejp g y 3 Com Log The following instructions are to be used to assist in obtaining soil samples from the diesel generator building area and other areas of soil investigations associated with ISA 7220-C-79(Q). This program is being implemented by the Geotech soils engineering representative at the site. Standard penetration tests, test pits, auger borings, Dutch Cone tests, undisturbed sample borings, and bag samples are performed as required. The location, depth, and selection of the type borings, tests, and X samples are determined by the Geotech engineer at the jobsite with project engineering input as necessary.

~-.

2 The boring's should be maintained at all times to prevent hole cave-in. The use of casing or drilling mud is permitted. Where drilling mud is to be used, Bentonite, Attapulgite, Revert, approved equal, or any -j combination thereof should be used to advance soil borings below the s groundwater level. When rotary drilling methods are used, the fluid in the borings should be maintained at all times above the groundwater g table. ? Penetration tests and split-barrel sampling shall be taken in accordance .b with ASTM D 1586. The samples obtained should be placed in glass jars 9 and sealed with vapor-seal screw lids. Each jar should be -clearly identified using a waterproof marker or label that is firmly attached to p the jar showing the job designatioh; date, boring number, sample number '~ The and depth, length of recovery, and standard penetration resistance. samples should be protected from freezing and direct sunlight. a N? SB12325g i ~ _,,,-..m

' '/ Bechtel Associates Professional Corporation IOM to J.F. Newgen 1 .i Page 2 l i i Undisturbed, thin-walled (Shelby) tube sampling shall be taken in accordance with ASTM D 1587. The minimum outside diameter of thin-walled (Shelby) tubes should be 3 inches. When obtaining undisturbed samples, Denison, Osterberg, or Pitcher samplers may be used as directed. The minimum outside diameter of Denison, Osterberg, or Pitcher samples should be 3 inches. The undisturbed sample should not be removed from the tube, but l should be trimmed back from the ends of the tube, the space filled with hot microcrysta-line (nonshrinking) wax, and the tube capped and sealed with. hot wax and tape. The thin-walled tube 'should be clearly identified, using a water proof marker or label that is firmly attached to the tube showing the job designation, date, boring number, sample number, depth, length (in inches), and inches recovered. i i Observation walls may be installed as directed by the Geotech representative for subsurface water level monitoring. The borings for observation wells where advanced by the rotary drilling method should use a biode-gradable drilling mud such as Revert. After installation, the observation wells should be flushed and a response test should be conducted to make certain'the wells are operative. The minimum outside diameter of riser pipes should be 2 inches. i Test pits for supplemental information should be made as directed by the Geotech soils engineer at the site. Density test and block samples may be taken, as directed. ' To assist in the above soil investigation program, the following additional ASTM standards are recommended for use. AS'IM D 2488-69 Description of Soils (Visual) 3 Manual Procedure) i ASTM D 653-67 Terms and Symbols Relating to j Soil and Rock Mechanics i. ~ ASTM D 2113-70 Diamond Core' Drilling for site j Investigation ASTM D 1452 Soil Investigation and Sampling by Auger Borings-ASTM D 3441-75T Deep, Quasi-Static, cone and ,j Friction Cone Penetration Tests of Soil yf R.L. Castleberry l! SB123253 JH/ cap . 10/4/2 6 -, +. -. - -

( ) OA SEP 121978 f a H. W. Wahl P. A. Martinez o, Bechtel Proj.Mgmt. P. A. Becnel G. S. Keeley * ,, CPCo Proj.Mgmt. J. P. LeBlanc y, September 7 ,, 7 8 R. L. Castleber o,,, 7,,,, ~ DIESEL GENERATOR SETTLEMENT 7220, MIDLAND 1I ,,,,u,_ l J. F. Newgen k S. L. Blua Advised Keeley that our investigations show the diesel e-j building settlement problem to be potentially serious E. A. Rumbaugh and we feel it should be reported to the NRC under 50:55(e) requirements. Although it is not clear that any K. Wiedner safety question would exist, the analysis is likely to be j extensive and if remedial action has to be taken it could F. E. Meyer e also be extensive. The diesel generator building and foundations are on engineered fill and while indications J. Milandin are that the fill tested out satisfactorily when placed, it is apparent that some of this fill for some reason now B. R. Hubal does not meet the specified compaction requirements. Soil testing by a firm in Boston is expected to take about two P. K. Hansen weekds. Our own top soils expert Ferris will be on-site on September 12 and in Ann Arbor on September 13 and we R. Hermeston L-would be able to brief Consumers Power further after that date. L. A. Dreisbach 1 E Keeley indicated he had been following this problem and at i "V. G. Moring h this point would ask his people to prepare a press release. k He asked to meet at the Site on Thursday, September 14, at W. G. Jones 12 noon for further briefing and addressing potential solutions. Keeley concurred with Bechtel's investigative efforts to determine if the problem exists elsewhere on-f site. y 0 --- l.; P. A. Martinez (- s N '**I" gs g( k$R SB123216 L SER i .e .e u

  • s.p s h a es

= a L 2 li M =q 5 ils!B lE S a.E R 4 5 uo.m

QUALITY ASSURANCE PROGRAM ] MANA*,EMENT CORRECTIVE ACTION REPORT MCAR.1 REPORT NO. JOB NO. 7770 0 NO. 1.An DATE C/7/7R I

  • DESCRIPTION (including references):

The Bechtel " Foundation Data Survey Program" has indicated that the settlement of the Diesel Generator Building has been greater than expected. This has been documented in NCR-1482 dated (8/21/78). A preliminary evaluation of soil boring data from an investigation being conducted by Project Engineering indicated that the magnitude of the investigative tests and analysis of test results makes this item reportable under 10CFR50.55 e, 1, iii.

  • RECOMMENDED ACTION (Optionell 1.

Determine the amount of settlement of the Diesel Generator Building (DGB) and increase the frequency of foundation survey measurements to find if the settlement is or will be excessive. 2. Determine the cause of the settlement. 3. If the settlement is or will be excessive, determine what actions are required to correct the condition and preclude recurrence. REFERRED TO I ENGINEERING CONSTRUCTION QA MANAGEMENT ISSUED BY T.. Dre4=hach o/7/7R Deu Protect QA Enyneer r 11 REPORTABLE DISCREPANCY ATIFIED CLIENT-9/7/7F NO @YES zI-Y'// / Pro Wst Mene.or ) fete ///,h til CAUSE V i i CORRECTIVE ACTION TAKEN I l SB123217 AUTHORIZED BY l one l oismemiom J.B. Violette i e,esect Mane,w FORMAL REPORT TO CLIENT l g,a','~,,';*a uge - S. I. Heisler llt seetion n Aponies o,,, l e,...a u L.A. Dreisbach *L'TYi /,1*#1"',',. J. Amaral (Gaithersburg) CORRECTIVE ACTION IMPLEMENTED

    • 7,',I,*.c7*'"I".*.*e*u, J.E. Bashore (Norwalk)

E,^.8,* * **'"' VERIFIED BY ' Describe en space provW end ettsch reference docuen,nt. Project GA Engineer oote I maf:.?nma, e dD

~ .,1,. -.. ;- n.,.; c.:w. w .n e-mm.,. m- -., ~ <. ~ ~ ~. -. ~.. w+ A e s pa g 4 elg, I l s 1 i G. L. Richardson 9/13/70 owr FIAtt CMART FOR FIACEBENT OF PIANT AREA SACEFILL/ STRUCTURAL BACEFIIJ. ~ ~ ~ SOURCE FIACE8 Elf? COMPACTION TESTS ,. ~ t Plant Area Backfill (C-210) ~ p Material Excavated from Material moved to placement Material compacted by approved borrow or required area and spread for compaction - rollers or by hand held equip-Escavation 12* Max. loose 1. ft - moisture ment to required compaction. l Spec C-210 Table 12-1 content ad beted to i 24 of optimum if necessary if - Ir Test Frequency heting performed 0 9001sture content teste Moisture content teste (C-2.10, 3 i sorrow to determine taken as required C-1210(12.6.1) para 13.5) Field donetty teste Moisture content = 1/500 yde moisture content and Lift thicknese checks taken (C-210, Para 13.7) lSjare f.2ea elve Soile (ASTM D-1557) y Field density - 1/500 yde 3 gradation by subcontractor

  • Col Spec C-210 (12.4.1)

(Subcontractor ch Manual)

  • C netoo lese Soile Compaction (Lahman)

( reass F./ No established frequency ( TM-D-2043) (allmeterialog ( = 1/10,000 yde g Crain Slse For structural 5.F. (C-211) i (Fleid 88.C. & doneity) 3 l l' / q/

  • Large area 1/500 yds jk
  • Confined area 1/10 - 1/100 yde Structural sackfill (C-211) FE Approved Foundet on Compaction requirementes

'Coh$elve So11a = 95% of maximum density C-210 QC serve 111ance (13.7.1), C-211 (5.5.2)

  • Cohenelonless soile = 004

- Material received on ette relative density gg Deceipt inspected and C-210 (13.7.2) C-211 (5.5.1) tested for gradation then released to constructiese Oc as sillance CC surveillance QC moview Poselble Fallers Mode / System

  • Compaction met uniform
  • Reference curves to develop
  • Lifts too thick material density lab man not seaterial taken from
  • Compactie.. not Ef fective representative of material 4

unapproved borrow tw* E.waip/ Overlap /Possee) use (not from borrow /not l from actual compacted materieff , Mees f**e met /. i e

  • Fleid test not representative of material leolated g',,'),,,, / f w. ~. h, /<>...., #

f^**

  • hetergeneous vol m

. #.r f

  • ssaterial not tested at all or 7,,, -

(< j,,. k, too low a frequency ' Test technician error i.

  • Testitchniques epectiled SB123221 I

h.

~ f id S. E. Afifi P. A. Martinez Bechtel PM A. Boos ,y o, G. S. Keeley CPCo PM R. L. Castlebe m y, o, September 26, ,, 78 L. A. Dreisbach o,,, 7, RECORDS ON REMOVAL OF NATURAL SANDS 7220, MIDLAND 1 & svener

,, y, D. R. Johnson J. F.,Newgen The call was made to update Keeley on our search for records relating to removal of the natural sands. This q ;J. Milandin

~ search had been started as a result of the April 1978 FSAR question 362.2 which asked for a discussion of the W. G. Moring i methods employed in mapping and removing the sands under Class 1 structures and beneath non-Class 1 structures if their failure could endanger the adjacent Class 1 structures. We have records to show that the sand was removed under the main plant power block and under ths service water pump structure. From the present boring program it appears that there areno natural sands under the diesel building. We have not so far been able to find records on the tank farm north of the power block or the service water piping or the Class 1 electrical duct runs. We are still reviewing Field Engineering records and expect to be complete with s this in about two weeks. Keeley indicated that Consumers Power intends to discuss I; this record search with the NRC today. We think that is 7 a good idea to brief them although we do not see it as a C major problem yet, since we have so far not encountered any soft natural sands under the Class 1 structures or i components. The FSAR question will be ansiered when the present boring program results have been evaluated. A-f PAM/pp P. A. Martinez RECE!VED- ) Jons~MILANDIN 5B123235

File

AAo.522

yow m e. ym %s/? % '~ J)&ffr Au?c.ZKVOZ19/176W...Or... - .... _ _ D/r]EL G ENER4 TOR Su/LD/NG ..r i..s x3.. E l ~7 G~ -~., i d 3 a.. u 74 m. uAJJ o. ,,uJ mf A A. ..,y-.Ms. l+ad s-Q... fo M~--y ' 3+C Z co AM 4._.6 / K % >LJA -._'~.-u2eu...3 m a-t.4 ~x=_1 ~ da A l J L Ja _..... . x M. Z s a d. -, % --g.- l. h. 4 ~ J -.~..M M K n.> J..-.L.~-. W - m m.d2 . a.. sr..x se A.... e Q. f % n D 2 1 3@ 'Tr-yL !~ 72,,9 L

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L t) TL ' i. ^ . M._a,sw../ w_n 4 L.AJ J s.M '~ in { 4A o 1.h M. L J u, 't.1.)_-f;b A.-. % ~m \\ m&.. --) h At 5gg.,, s). Z? 7% a 2 - .cpwjn %. u - c. uo_gA -. J y i. s M ' & ' vs ) m.s a sw

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~ l Q +J -.s L x. J A &. L..L / Sl m A / l_u /)&a,.j ' z4 1 LJ/m-4. 1 e __ cL JL.~ ~ -, a , f-A W)$ 3 _SB123222

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