ML20090L935
| ML20090L935 | |
| Person / Time | |
|---|---|
| Site: | Midland |
| Issue date: | 03/30/1979 |
| From: | Liou C, Papudakis C BECHTEL GROUP, INC. |
| To: | |
| Shared Package | |
| ML17198A223 | List:
|
| References | |
| CON-BOX-04, CON-BOX-4, FOIA-84-96 NUDOCS 8405260117 | |
| Download: ML20090L935 (55) | |
Text
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i FINAL REPORT MIDLAND POWER PLANT
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COOLING. POND OPERATION STUDY j
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CONSUERS POWER ColPANY
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PREPARED BY 1
DR. C. P. LIOU, BIGINEERING SPECIALIST lg DR. C. N. PAPADAKIS, ASST. GIEF ENGINEER i i 1
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HYDPAULICS AND HYDROLOGY GROUP i
t GE0 TECHNICAL SERVICES - ANN ARBOR d
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BECHTEL ASSOCIATES PROFESS 10NAL' CORPORATION 8
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TA31.E OF CDltTElrIS
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IETRODUCTION l
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j 2.1 Midland Plant a d Its Coeling Feed 3
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- 1 2.2 The Tittabewessee River 4
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2.3 Appliamble water Quality standarde 3
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2.4 Seepe and Paspose of the Study 7
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3 PETSICAL AND OPERATIONAL AS8tilft!ONS
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3.1 Physical Ase g tiene 8
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- 3. 2 Operational Assumptione 9
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4 DATA f
i i 4.1 River Flows 12 4
4.2 Natural River Temperatures 12 l
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4.3 Natural River TD6 Cemeentratione 13
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4.4 Masimum A11sweble Blowdown Flowestes 15
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4 4.3 Slowdown Tamratures and lates of Pond 18 2
Evaporative water Lees
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HET300 0F IINCLATION 21 I
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18:12,78 AND DISCUS 8tCW 4.1 Base Case 23 jr 4.2 Sessitivity Analysee 27 L
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o TABLE OF F%DRES h
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1 Muend nest Coolias Feed ad the Adjesent fittebesseees River i
2 Coeling Pond Meheep and 31sedeum Systen 3
Daily Flew Freguesey Cerve of Tittebeweseee tiver et Edlend Dyper Liette of Maheep Fisweetae l
3 Deny Natural River ad Bisodeum Teeperatures for Water i
Tear 1974 l
4 Deily Naturu River TDs Cosentrattene for Water Tease 1874 and 1877 i
L 7
Seeis Mestmen Aueweble 51swdown nevretoe 8
Schemet.ie of the Trenaient Coe11a8 Pond Mothematiaal Model.
9 h atmun A11ewable Blowdows Flevretos Used in the Study i
10 Simulated Meathly Aversee Food TD6 Cemeentratica u
Standated Meethly Avere8e Pond Water surface R1evettees 12 Ristory of Monthly Diseherse of the fittebeweseen River et M u nd, Mehteen U
Den y Ch ages la Fond 700 Caseentrattaa ad Water Surface i
Elevettes 14 Ddly Chages la River now, and la Flowrotee of Maheep and Biswdown 15 Den y Food TD8 Conentraties Frequency Cerve - Saee Case i
4 16 Dany Maheup nevrete Frequeney C4ere = lese Caos 17 Ddly 31swdeva nevrete Freguesey Curve = Sese Case j
18' Deu y Pond Water Surfees Elevetten Frequency Curve = lese Case t
19 Monthly Pond TD6 Cemeentratten Frequenty Curve = Case 1 20 Meathly Pond TD4 Ceneantration Frequesey Curve = Case 2 11 hathly Pond TD6 Cemeestration Frequeney Cdeve = Case 3 511175164
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741a of Figures (continued)
A Fin re Title 22 Monthly Fond TDS Concentration Frequency Curve - Case 4 23 Monthly Fond Water Surfaca Elevation Frequency Curve - Case 5 24 Transient Discharge of Tittabawassee River at Midland, Michigan
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4 T41es Title 1
Qiaracteristics of Natural River Temperature 2
Mocchly Flowrates and Fond TDS Concentrations for i
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SIDefAIT 3
The Midland Plant cooling pond operation was simulated using a model i
i which incorporated a makaup-blowdown system to control the concentration of total dissolved solids and the watse surface elevation of the cooling pond. Raasonable asseptions regarding the timing and quantity of makeup withdrawal from the Tittabawassee River and blowdown discharge into the river were used. A physical andel study was conducted at Alden Research Laboratory to determina permissible blowdown flowrates so that the appli-cable Water Quality Stadards of the Michigan Water Resources Commission would be satisfied by both the discharges from Dow Chemical Company and from the cooling pond of the *dland Power Plant.
Ta ecoling pond operation was s'=n1=ced on a daily basis for 82 years.
The following onclusions can be unde:
i It is feasible to control the concentration of total dissolved a.
solids and the depth of the cooling pond within design limits through the makeup-blowdown system.
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i b.
The blowdown discharges into the Tittabawassee River can comply with
'i the Water Quality Standards of the Michigan Water Resources Commission.-
-l On a long term basis, cooling pond blowdown and the resulting thermal c.
p plumes in the Tittabawassee River any occur only 30% of the time.
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- d.,In this study, the Dow Chemical Company's discharge had priority over the Midland Plant blowdown discharge. As a result, the total 1
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The operation of the makeup-blowdown system is limited by its ability e.
to blowdown due to thermal plume considerations. There is sufficinnt veter for pond makeup in the Tittabawessee River, and there is no j
significant effect on the river flowrates because of ankaup withdrawel.
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2.
INTRODUCTI0tt 7
2.1 Midland Plant and Its Cooling' Pond i
h Midled Power Plant is near the Tittabawassee River at the southern limit of the city of Midland, Michigan. It utilizes two Babcock and Wilcaz pressurized wetar reactors to generate approximately 1300 MBe of electricity and 4 =4114an pounds per hour of staan. A cooling pond is used to transfer the wasta heat removed by the condenser cooling water system to the atmosphere. h==w4==
heat rejection rata from the condensers to the cooling pond is 9.05 x 10' Etu/hr corresponding to the Unit 1 back and limited and Unit 2 valves wide open operation condition.
i h heat rejected to the pond is dissipated by evaporation, back f*%
radiation and conduction processes into the atmosphere. To adequately dissipate the wasta heat and to provide sufficient storage of water o-for plant cooling during droughts, the pond is designed with a surface area of 880 acres at the design pond water surface elevation of 62 ft. and a surface area of 860 acres at the =4=4==
pond water surface elevation of 618 ft.
h pond volumes are about 12,600 acre-ft. and 4,800 acre.-f t. for the==w4==
and =f =4== water surface elevations respectively. h average full pond depth is 14.3 ft.
The pond has a baffle dika which prevents direct exchange of water between the hot and the cold side of the pond, and promotes the effective use of the entire pond surface area. h Tittabawassee River and the cooling pond configuration ara shown in Figure 1.
5B178168 3
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Due to evaporative loss of the pond water during the heat dissipat'.on 3
process, total dissolved solids (TDS) accumulate in the pond and thus their concentration must be controlled. A cooling Pond makeup-blowdown systaa is utilised for this purpose. A portion of the pond.
water from the cold and of'the pond is discharged by gravity into the Tittabawassee River, and fresh river water is pumped into the pond to makeup for water losses due to evaporation and blowdown. Consequently, i
the pond water depth and TDS concentration can be regulated to a certain degree by the makeup-blowdown system. A sketch of the system is shown in Figure 2.
Three makeup pumps with a combined rated capacity of approximately 210 cfs are used to supply makeup water to the cooling pond. Blowdown is discharged by gravity to the river via three 2.5 ft. diameter pipes. The design blowdown flow range is between 5 cfs l
e and 220 cfs. Details of the physical makeup-blowdown system are described in Referenca 1.
The mechanical equipment of the Plant's circulating water system is designed for a nominal average TDS concentration of 1206 ppa and a nominal =M==
of 1832 ppa (Reference 2). The askeup-blowdown system should be operated in such a way that the pond average TDS concentration meets the requirement of the anchanical equipment.
2.2 The Tittabawassee River 1
The Tittabewassee River basin is near the center of Michigan's lower peninsula. The, river flows generally southward to the village of Sanfoti. After Sanford, it asanders to the southeast and flows inen the Saginaw River at the City of Saginaw, about 20 miles downstream 5B178169 i
l from Midland. Twenty-two miles downstream from its confluence with T
the Tittabawasses, the Saginaw River empties into Saginaw Bay, an arm of Lake Euron. The Tittabavassee River drainage area above Midland encompassas 2,400 square miles.
There are three hydroelectric dams along the Tittabawassee River upstream from Midle d.
The one closest to the plant (the Sanford Dan) is located 1
at Sanford about 10 miles upstrean from Midl ed. The dam is owned and operated by Wolverina Power Company which gaaerates electricity for part of the day on weekdays. Tittabawassee River flow at Midland varies according to the Sanford Dam operation.
Dow Chemical Company's industrial complex lies north of the Midland m
Power Plant across the Tittabawassee River. Dow diverts river water for industrial use at the Dow Cam, located about 6700 ft. upstream froa,
the river intake structure of the Midland Power Plant. On the right bank of the river (looking downstream) and 2000 ft. downstream from the Dow Dam there is a gaging station maintained by the U. S. Geological Survey (USGS). Examination of the record of rating curves prepared i
by USGS indicates that the river bed is movable at the vicinity of the f
Plant. The USGS checks and updates its rating curve every five weeks.
l Daily average river flow data at the gaging station is available from March 1936 to present. The daily flow duration curve at the USGS Midland gaging station on the Tittabawassee is shown in Figure 3.
The average i
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river flow is about 1,680 cfs.
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2.3 Applicable Water Quality Standards Discharge of cooling pond blowdown into the Tittabawassee River has 5
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two physical effects: creation of a thermal plume, and addition of N
TDS to the river. To protect the water quality of the river, the following rules of the Michigan Water Resources Commission OsrRC)
(Raference 3) shall be satisfied:
Heat load to the river shall not warm the receiving water at the a.
edge of the mixing zone to temperatures greater than the following monthly maximum tamperaturest Month:
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N D
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41 40 50 63 76 84 85 85 79 68 55 43 b.
Heat load to the river shall not vara the receiving water at the -
edge of the nizing zone more than 5'F.
m The size of the =Mng zone is limited such that it does not c.
contain more than 25% of the cross-sectional area or voltme E
of flow of the river at any river transact or both.
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i d.
The contro11abla addition of TDS to the river shall not increase i
the river TDS concentration beyond 500 ppa'as a monthly average nor more than 750 ppa at any time.
Dow Chemical Company discharges its tertiary pond affluent into the i
Tittabawassee River about 300 ft. upstream from the location of the cooling pond blowdown discharge.' Both discharges are at the south bank of the river as shown in Figure 2.
Dov's affluent adds heat and r
TDS to the river. Die rules of the Michigan Water Resources Commission apply to the combined effect of both the Dow and Midland Plant discharges 8
53178171
in this study. Durfag plant operation, average river TDS concentration s
will be asasured at the Freeland Bridge located approzinately 14 miles i
downstreat from the cooling pond blowdown discharge structure.
i 2.4 Scope and Purpose of the Study The objective of the study is to demonstrate that the cooling pond depth and TDS concentration can be satisfactorily controlled by the ankaup-blowoown systen without violating the thermal and TDS limits in the Tittabawassee River. Anticipated variations in pond depth and TDS concentration are simulated, on a daily basis for 82 years, by employing a set of reasonable operational assumptions for the system. The results of this simulation provide the basis for preparing several sections of the Midland Plant Environmental Report and for the NPDES Application for Permit to Discharge Wastewater.
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3.
FETSICAL AND OPERATIONAL ASSIDfPTIONS O
i 3.1 Physical Assumptions Simulation of the daily operation and the variations in pond depth and TDS concentrationwasbased on the following physical assicaptions:
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Total dissolved solids in the cooling pond come only from the a.
j Tittahamassee River. TDS input from plant operation, circulating water acid ad hypochlorite addition and the possible discharge of condensate domineralizar regeneration vasta. La not significant and is not considered.
b.
Ccoling pond voluna gaikt by precipitation and zunoff is neglected.
This is a conservative assumption since an annual avenge precip-itation of 30 inches (Reference 4) over the pond surface of 880 acres aguals 3 cfs, or approximately 13% of annual average o
evaporation rate for the entire heated pond.
1 A constant seepage loss of 0.5 cfs is ass' ned for each day (Reference c.
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1). No credit is taken for TDS lose from the cooling pond via 1
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d.
Fond TDS are uniformly distributed throughout the pond voluna.
The affluent of Dow Chemical Company's tertiary pond is assuand s.
to have a flowrata of 67 cfs with an excess temperature of 5'T g
, and a TDS concentration of 2500 pga.
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Average daily Tittabawassee River flows from veter years 1937 to 1977 are used.
3 The pond is assinned to be full and have a TDS concentration of l
500 pga at the beginning of the siinalation.
3.2 Operational Assumptions The operation of the cooling pond, i.e., timing and quantity of makeup and blowdown flows, was governed by the folloeing assumptions:
The annual rab_=14=! period for each unit is assumed to be one a.
month. Rafueling occurs in September for Unit 1 and in April for Unit 2.
The heat load to the cooling pond is 3,370 x 106 Beu/hr 6
6 for April; 5,680 x 10 Beu/hr for September and 9,050 x 10 Ecu/hr m
for the r - 4adaT months of the year. More details on the heat g
loads can be fotund in 3mference 5.
b.
The constraints on makeup flowrates are listed in Reference 1 and are graphically presented in Figure 4 as a function of river flows.
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The *== askaup flow utilized in the pond operation sinnlation f
is 270 cfs corresponding to the makeup pumps runout conditions.
Blowd'own flowrates are not to azeeed a set of maxiana allowable c.
values derived from considerations of thermal constraints in ths Tittabawassee River.
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- Blowdown discharge shall not cause downstream river average TDS concentration to exceed 500 ppa 2sasured at the Freeland Bridge.
SD178174
f e.
The =#==
blowdown flowrata is limited to 220 efs because of 9
hydraulic characteristics of the gravity fed blowdown scheme.
h mini== blowdown flowrate is 5 efs due to difficulty in throttling for flows below 5 cfs.
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h pond vatar surface elevation ingosas the following limits on the askaup and blowdown flowrates:
i 1.
When pond level is above 627 ft., no ankaup is permittad
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and blowdown any be discharged at its -4==
allowable i
flowrate.
2.
When pond level is below 626.5 ft., no blowdown is permitted q
and askaty withdrawal may be made at its==w4==
allowable flowrata.
i 3.
When pond level is between 627 f t. and 626.75 ft., both
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makeup withdrawal and blowdown discharge may be made at t
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their==w4== allowable flowrates.
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When pond level is between 626.75 ft and 626.5 ft., makeup l
1 flowrate may be set at its maximm allowable value and the I
blowdown flowrata is limited.so that the pond level is not lowered because of blowdown discharge.
3 Dow Chemical Company's affluent discharge into the Tittabawassee I
O River is given priority over the Midland Plant cooling pond 10 t
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blowdown discharge. When the downstresa average river TDS 5
0 concentrattaa equals or exceeds 500 ppa due to Dow effluent.
cooling pond blowdown discharge is terminated.
h.
Pond blowdown discharge is terminated when daily average natural river temperatures are within 5*F of the monthly arzimum temperatures listed in Section 2.3-e.
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DATA l
O The data used in the study include' river flove, astural river tempera-tures, natural =1ver TDS concentrations, cooling pond evaporation rates, blowdown temperatures, ami anzimia allowabla blowdown flowrates.
i 1he sources of the data are discussed below.
I 4.1 River Flows The U. S. Geological Survey (USGS) malatatas a ga,ing station at Midled on the Tittabawassee River. The gaging station is located 4700 ft. upstream from the Mid1==A Plant river intaka structure. The Bullock I
Creek drains into the Tittabarassee River between the paging station
)
and the river intake' structure, but its flow is insignificant compared n
with that of the Tittabewassea River. Daily average river flows 1
published by the USGS from water years 1937 to 1977 (Raferesca 6) were used in the cooling pond operation study (A water year starts October 1 and ends September 30, i.e., water year 1976 extends from October 1 1975 to September 30, 1976).
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.i 4.2 Natural liver Tegeratures
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Contiaucus instantaneous measurements of natural river temperature i
are made by the Dow '2 esical Company at the Dow Dam. Daily average t
natural river temperatures from October 1,1975 to September 30, l
1978 were entracted from the original continuous record ad were pro-
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vided for this study by Dow Chemical Company. These three years of temperature records were used to establish a model for generating long tema daily astural river temperatures from available daily dry I
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l bulb tageratures recorded at the Bishop Airport of Flint, Michigan.
O a Class 1 station of the National Weather Service.
Variations in natural river temperature and in dry bulb temperature at the see location can be separated into seasonal and non-seasonal-components. Seasonal variations la daily natural river temperature cm be established by subjecting the river temperature record to a i
n Fourier analysis. Ma first few harmonics that accome for a large percent of total variaca yield daily river temperatures that vary smoothly according to seasonal trend. H e non-seasonal variation in daily river temperatures, hereia called river temperature residue, i
1s obtained by subtracting. the seasonal component from the known daily river temperature. Seasonal daily dry bulb temperature and dry p
bulb temperature residue can be obtained by the same process.
4 n a river temperature residue on any given day can be correlated to E
4 the dry bulb temperature residue for that day and two preceding days by linear mitiple regression. Bus river temperature residue can be predicted as a linear combination of dry bulb temperature residues.
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,i -j Natural river temperatures can then be generated by adding the river 1
{ j temperature residues to the seasonal daily river temperatures. 21s
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procedure was used succe,sfully to predict Illinois River water temperatures at Ravenna for 1968 and 1969 (Reference 7).
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!i Daily average natural river temperatures and dry bulb temperatures for an " average year" were established by averaging the daily temperatures for water years 1976, 1977 and 1978. De model to samerate daily river SBUS178 13 i
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temperatures frca dry bulb temperatures was established from the 9
seasonal daily river temperatures and the residues of dry bulb and river water temperatures of the " average year".
Natural river temperatures were generated from March 1, 1949 to September 30, 1978. A comparison of mean and standard deviation of the recorded and calculated natural river temperatures for water years 1976, 1977 and 1978 is shown in Table 1.
A day to day cooperison of recorded and calculated natural river tageratures for water year 1976 is shown in Figure 5.
Table 1
_ Characteristics of Natural Fiver Temperature
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O observed '7 Calculated 'F hag Mean Standard Deviation Mean Standard Deviation 1976 58.82 15.21 60.43 14.94 1977 61.90 14.67 61.27 14.46 1978 60.60 15.80 60.59 14.95 j
1 Flint dry bulb temperatures were used instead of those at Midland
' ',I because no accurate long term air temperature record at Midland was
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available, while important meteorological parameters (including dry l
'd bulb teg arature) were readily available for Flint since January 1,
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-t 1949. Furthermore, the applicability of Fline data to Midland has j
been demonstrated in Reference 8.
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Calculated river temperatures for water year 1976 were used repeatedly D
from water years 1937 to 1948 for which no air temperatures were available.
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9 4.3 Natural River DS Concentration 9
Daily natural river DS concentrations were either directly obtained, or estimated from the natural river conductivities contained in the Monthly Operating Report of Dow Chemical Company from October 1975 to September 1977. In the Operating Report, both TDS concentration and conductivity were reported for only 8 to 10 days per month.
An average ratio of TDS concentration in ppa to conductivity in micrombos
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per contimeter was computed from these pairs for each month. For the remaining days where only conductivities were reported, the TDS i
concentrations were estimated by multiplying the conductivities by the established ratio. The daily natural river DS concentrations for water years 1976 and 1977 era shown in Figure 6.
The 1976 values were used repeatedly in the study. The sensitivity of pond TDS con-A centration with respect to natural river 2 5 concentration is discussed in Chyter 6.
1 4.4 Maxisma A1'eJ:la 31owdown Tiowrates l.
A physical andel testing program has been conducted at the Alden I
Essearch Laboratory (AEL) to determine the blowdown flowrate at. a
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given excess temperature that can be discharged intt'the Tittabezassee 4
' River without violating the 25% limits for the thermal mixing zone.
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and without resulting in a aizing some acre than 1700 ft. long (Reference q
t 9).
a, A fixed bed physical model of a 2000 ft. reach of the Tittabawassee i
River downstream from the plant makeup intake was used to determine the==v4==
allowable blowdown flowrate at a given river flow and t
blowdown excess temperature. This physical andel is an approximation of the prototype which is a novable bed alluvial river with unsteady l - r flows.
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Both the Dow tertiary pond discharge and the cooling pond blowdown O
were staulatedin the physical model.. For each model test, the Dow effluentwas set at 65 efs with an excess temperature of 5'T and a TDS concentration of 3000 ppa, conservatively larger than the 2500 4
ppa used in the operation study. The negative buoyancy of the Dow plume had no effect on the mizing of blowdown discharge with river A matrix of 275 thermocouples, positioned thz @ t the water.
model, was used to determine the==w4==
allowable blowdown flowrate for a given blowdown excess temperature and river flow.
It was found that the edge of the thermal plume was not smooth and steady, but somewhat ragged and time varying due to turbulence and t
eddy shedding caused by the interaction of the river with the Dow A
discharge and the Midland Plant blowdown. Therefore, for all data provided, the edge of the thermal plume was based on the location of the 5'T excess temperature isotherm as determined by the average tempere-
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tures obtained from 25 scans of each of the thermocouples on the physical-9, model over an everaging period of 16 minutes model time (62 minutes prototype time).
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t j The andel test rnsultswere reported in terms of a set of curves that i
relate the==*4==
allowable blowdown flowrates with blowdown excess temperatures over a range of river flows as shown in Figures 26 to 3
l 30 of Reference 9.
Due to pressing time schedules, the physical model was act adequately l
p 1
verified against its prototype before starting the final test series.
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Some verification tests were conducted after the final test series was 9
completed. These verification tests indicated that the physical model was too smooth for river flows greater than about 1200 cfs. As a j
result, the average velocity of the river upstream from the blowdown discharge was higher than that of the prototype. This higher average river velocity tends to make thermal plumes narrower. Consequently, the blowdown flavrates for those tests with thatual plume sizes that essentially coincide with the 25% limits described in Section 2.3-c were reduced. The modified curves, representing the==w4==
blowdown flowrates for river flows (after makeup withdrawal) ranging from 770 cfs to 3450 efs, are shown in Figure 7.
Because of the limited capacity of the test facilities at the Alden Research Laboratory, the physical andel could not acconsodate river flows higher than approziantely 3800 cfs. Thus, indirect calculction s
of==w4==
blowdown flowrates became necessary at higher river flows.
4 A " theoretical"==w4==
blowdown at a given excess temperature em 4
i be calculated by assuming it sizes fully with a quarter of river flow that contains the discharge from Dow Chsmical Company. The assumed y
temperature profile in the river is " top-hat" shaped with an uniform excess I
temperature of'5'F over the quarter of river used. Model test results obtained at Alden Research Laboratory indicated that in order for the
}
5'T excess temperature isothera to close within the physical model, the " actual" blowdown flowrate at the same excess temperature is less th e the theoretical flowrate. The ratio of the blowdown flowrates tha't ensures the closure of the 5'F isothera over the theoretical flowrata I
, - t-17 53 08182
..,,.------.---..-..-.------n....-
n
was related to the velocity of blowdown over a range of river flows a
according to model test results.
In the daily pond simulation, blowdown excess temperature and river flow were available for computing the ratio of blowdown flowrates.
The blowdown velocity, and consequently the blowdown flowrate, could then be enla"I=ced.
This procedure vas used to compute the enziana i
allowable blowdown flowrate for days when river flow was above 4000 cis.
4.5 Blowdown Temperatures and Pond Evaporative Water Losses A transient cooling pond mathematical model was used to estimats daily average blowdown temptratures and pond evaporative water losses. This computation was carried out separately from the time history of the pond operation, i.e., pond level fluctuations were not considered in calculating blowdown temperatures and avsporation rates..
The pond was conceptualized as composed of a surface layer and a bottom layer. Horizontal temperature distribution across the pond.
\\
var approximated by spatial temperature variations in the surface i
layer. The bottom layer temperature was assumed to be uniform. Fond I
volume was assuand to be constant.
r i !
A schematic of the mathematical model that simulaces cooling pond f
4 thermal performance is shown in Figure 8.
The development of the transient cooling pond mathematical andal closely followed the
?
principles outlined by Ryan and Earlaman (Reference 10) and incorporates the' following assumptions:
53178183 i
-%-e-
.----..,.-,-,-..,..-,,..+.-n,.ev.,
--,w.v-
,-., + -. -. -.,
~.--,w,-.
.ww--,
,,..m.--e,
,,r-.+
--,-e,--y,.r---
y
i.
All interfacial aizing between the layers can be lumped at N
the pond entrance via a constant entrainment ratio.
i ii.
Cirant =Hng water systen discharge and flow entrained from the bottom layer are fully sized before advancing into the pond.
i 111. Flow advances through the surface layer as a plug.
iv.
At the pond outlet, the flow leaving the pond is uniform with depth.
v.
Brady's wind speed function is used. This wind function is 1
e conservative for wind speeds between 5 mph to 10 mph, and thus generates higher than mzpected pond temperatures.
vi.
All heat -h ce with the environment is through the pond j
surface and includes solar and atmospheric radiation, back j !
radiation and evaporptive and sensible heat losses.
Local elinatological data at Flint, Michigan from January 1,1949 to September 30, 1977 were used to calculate daily cooling pond blowdown 1
temperatures and evaporative water losses for the same period. The meteorological data used included: dry bulb temperature, wind speed.
relative humidity, cloud cover and solar insolation. The first four parameters were directly available from the National Oceanic and g
Atmospheric. Administration CICAA) in the form of Tape Data Family-14 1
J 19 5D178134
,,,--,-,,--...a,
. - - -,.. -., - - -, - -, -,,,, - - ~ _ - -... -... - -, - -
..n...
Daily values for solar insolation were computed from clear sky solar O
insolation values (reported in Reference 11) and daily cloud cover i
values. Physical parameters of the cooling pond, such as surface area, depths of surface and bottom layers, and entrainment ratio were obtained or estimated from information in References 5 and 12.
6 n e heat load from the plant % the pond is 3370 x 10 Beu/hr when reactor Unit 1 is operating at back and limited condition and 6
Unit 2 is shut down for' refueling 5680 x 10 Beu/hr when reactor Unit 2 is operating at valves wide open condition and reactor Unit 1 6
is shut down for refueling, and 9050 x 10 Ben /hr when Unit 1 is back and limited and Unit 2 with valves wide open. The refueling period was assumed to be April for Unit 2 and September for Unit 1.
j A constant circulating water flowrate of 1457 cfs was assumed pu%
for the entire year. The computed daily cooling pond blevdown temperatures for water year 1976 are shown in Figure 5.
The 1976 temperatures and evaporation rates were used repeatedly from 1937 to 1948 where meteorological data was not available.
i 2
1 f
l1 1
- )
]
l 20 SD178185
5.
M3 TROD OF SDfDLATION s
(
Simniation of the cooling pond operation was performed on a daily l
l basia. The simulation period was 29,950 days, starting at the last day of water year 1977 ad running backward to the first day of water year 1937, then running forward from 1937 to 1977. This doubling of the sim:1ation period provida an opportunity to check if pond TDS concentration and water depth stay within accepable limits over the 1949-1937-1949 period where river flows were frequently low.
For each day, the natural river temperature was compared with the anzi-num temperatures listed in Chapter 2 Section 3-a.
No blevelown was discharged if the natura'. river temparaturewas within 5'F of the marM= temperature for the sana nonth. Next, tha' river TDS concentration after full r
nizing of 'Dov's affluent was computed from a mass balance computation.
If the computed concentrationvers above500 ppa no blowdownwas discharged for that day. Then a permissible blowdown flowrate was calculated on
~
the basia of not to increase the average river TDs beyond 500 ppe.
A second permissible blowdown flowrata was computed from thermal plume considerations. The =f ah= among the two permissible flowrates i
was chosen as the upper limit on blowdown flowcate. A tentative blow-down flowrate was then calculated according to operational assugtions "e" and "f", (Sec. 3.2) and compared with the upper limit.
The smaller i
of the two was chosen as the calculated daily average blowdown flowrate.
If the calculated flowrate was below the minimum flowrate of 5 efs, no blowdown was discharged.
r 21 l
SD1781sg
et" A daily average makeup flowratewas computed from pond water surface 9
elevation, river flow, and water losses due to evaporation, seepage and blowdown according to operational assumptions "b" and "f"..(Sec. 3.2).
No lower limit on askeup flow was used in the simulation since small l
askaup flowrates are of the same magnitude as daily evaporation ratas of approximately 10 cfs during refueling periods.
Fond TDS concentration and water surface elevation at the and of each day were calculated from daily evaporation and seepage rates, daily flowratas, TDS concentrations of askeup and blowdova, pond volume, and TDS concentration for the previous day, according to the principle of conservation of mass.
L g
It should be noted that Figure 7 provides only =mw4=um blowdown f
i flowrates at 5 different river flowe.
L4a==e interpolation according to river flow was used to estiasta the==w4m== blowdown flowrate for river flows (after askeup withdrawal) equal to 1620 cfs, 2475 efs, -
and 3200 cfs. The new set of curves is shown in Figure 9.
For a given day, the permissible blevdown flowrate from thermal consideration was obtained from the curve of Figure 9 with the exset or next lower i
l river flow. For example, for a river flow (after askeup withdrwal) 1 of 2100 cfs a d a blowdown excess temperature of 25'F, the 4
allowable blowdownwas read from the 2000 cfs curve as 30 cis. This procedure tends to yield' smaller (and thus conservative)==w4===
blevdown flowrates, especially when the blowdown excess temperature is below 15*F and the river flow is higher than its average value.
4 g
22 5D17S187
l 6.
RESULTS AND DISCUSSION R
The cooling pond operation was simulated by employing the available c
data as described in Chaptar 4 This simulation constitutes the Base Case of the study. To evalusta the sensitivity of pond TDS concen-trations and water surface elevations the following cases were also investigated:
4 Case 1: Simulation with base case data azcapt the==r4===
blowdown flowrate is limited to 150 cfs instead of 220 efs.
Case 2: Simalation with base casa data except the =4=4===
blowdown flowrata is set at 10 cfs instead of 5 cfs.
f'%
Case 3: Simulation with base casa data except the daily ambient river TDS concentrations are increased by 202.
'I Case 4: Simulation with base case data ascept the daily blow-down temperatures are increased by 5'F.
Case 5: Simulation with base caso data except the daily evaporation rates are increased by 10%.
6.1 Base case i
Because of the large volume of the 880 acre pond, daily variations of pond TDS concentratio6 and water surface elevation are small.- Therefore, p
to, facilitate visualizati'on, monthly averages of pond TDS concentrations and water surface elevations, computed from daily values, are plotted 23 53178188
. e es.
w.- - --
,----.-,e.
m-e a-..--.---,,....-r-
,--e.w--
3,,-,___-
+
m
.w
.. ~ _.. ~ -.. - _ - - _ _
j l
4 i
in Figures 10 and 11 to demonstrate long term trends. In guaral, O
high pond TDS periods occurred during low river flow periods. The 82 years of simulation period conservatively doubled the low river i
flow period of 1937 to 1949. Because the sinalat.on period is long..
d the initial pond TDS concentration and pond veter level (physical assumption "s". Sec. 3.2) is not crucial to the results.
The peak pond TDS concentration of 2222 ppe occurred on September 6, 1942. The pond TDS concentrations and water levels for the dry period containing this peak day are shown in Figure 13. Daily average river i
discharges ad makaup ad blowdown flowrates for the same period are shown in Figure 14. The pond TDS concentration increased at a rate of approziantaly 9 ppa per day for this period when no blowdown and j
A very little makeup could be ande The pond water surface elevation i
dropped approximately one inch per day for the same period.
t i
The frequency curve for the daily pond TDS levels is shown in Figure
- 13. The w i== TDS concentration was approminately $40 ppe. The i
circulating water system and service water system hardware nominal design average and anzimum TDS concentrations of 1206 ppa and 1832 ppa
]
vere equaled or exceeded 14% and 0.2% of the time respectively.
The freq'uency curve for daily average askeup flowrates is shown in Figure 16. With the physical and operational assumptions used in the simulation, approximately 86% o'f the time river water was ptmped into the pond for askeup. From the daily river flow frequency curve of O
Figure 3, daily river flows also equaled or exceeded 390 efs 86% of 1
24 60178199
---,,,--...-4
.r_-,.
,,,m.-,
w.,.
- - - ---_%_,_.-,mr.,,-,m-y.--_n-,.-.3.e,,
I the time. The river flow of 390 cfs represents an assumed cutoff point he' low eich no makeup is withdrawn from the river (see Figure 4).
Therefore, water was pumped into the pond whenever the river now was above 390 cis. Bowever, the full anotmit of as 11able water for askeup was not gaaerally utilised. This can he seen by notias that the avail-2 able ankaup flowrate is 210 cfa when river flow eaceeds 1000 afs i
(Figure 4). Free Figure 3, daily river flows esseeded 1000 ofs 422 of 1
1 I
the time.
CorresFonding to this 42% frequency, the makamp fisurate was only 34 cia as shown in Figure 16, considerably smaller than the available 210 efs.
I i
The frequency cutve for daily average blowdown flowrates is showa in s
{
Figure 17. Only.ibout 27% of the time the Midland Flast used the 1
o Tittabewassee River as the receiving water body for its pond blowdown 4
i I
l discharge.
Typically little blowdown occurred in sumer useths.
j I
Figure 18 shows the frequency of pond water surface elevations. The 4
+
pond was full appreziastely 70% of the cias. A margia of aste thea i
_j 2 ft. existed between the lowest staalated pond level and the snaimum
{
operating level of 614 ft.
, s 4,
4
~
1 Monthly average river c'ischarges, evaporation plus seepage, makeup, blowdown, and pond TDs consentrations for the " average year" defined i
t i
from the 82 years of sinnslation are shown in Table 2.
1 4
w e
, x s
50DS130 4
25 7
Table 2 q
Monthly riowraces & Pond TDS Concentrations for Averste Year Pond TDS River Flow Evaporation Makeup Flow Blowdows Concentration H! Lag (cfs) 4 Seesame (cfs)
(efs)
Flow (cfs)
(son)
Jan 1316 20.8 30.3 9.6 863 Feb 1630 21.8 34.8 12.7 856 Mar 3835 23.7 46.9 41.2 438 Apr 3612 30.2 70.6 35.7 850,,,,,
May 2126 30.2 70.4 35.7 450 Jun 1296 38.3 60.4 15.4 892 Jul 735 39.2 35.7 4.9 919 Aug 551 34.3 28.0 2.3 922 Sep 692 25.9 32.0 4.2 912 l
Oct 802 29.6 33.0 2.6 909 Nov 1153 27.2 36.3 4.2 891 Dec 1260 21.3 29.6 4.0 872 i
j i
Also of interest is the severity of various constraints impeeed om the pond operation. Based on the data and assumptions described la O
Chapters '3 and 4, the cooling pond operation study indicated the followinst 50% of the time blowdova was withbald becease Dow 1
i effluent uses the whole TDS capasity of the river: 8.3% of the time blowdova could not be disaharged because natural river temperatures were withia 5'T of the asethly W-temperatures set by WitC: 13%
of the time the calculated blowdown flowrotes were below the preset I
mialaus blowdown fievrate of 3 efs and no biswdown took place: 1.6%
of the time the pond water level was below 624.5 ft. and me blowdown was discharged. Eisk blowdown TDS concentrations caused suspenstem of the blowdown discherst r *,./ 0.04% of the tias. When blewdown teek I
place.
24% of the time its flowrate was limited by thermal plume considerations la the Tittabawassee River and 31 of the time was A
limited by the blowdown systen espasity of 220 efs.
L te.
5317S131 9
=
O 6.1 Sensitivity Analyses 9
Mt The effect of the capacity.of the blowdown system os pond TDS concentration was investigated by reducing the capacity from 220 efs to 130 cis. This condities any correspond to the situatise where one -
of the three blowdown pipes is out of service durfag high river flow periods. The monthly average pond TD8 concestrations thus computed
.i are negared in Pipre 19 with these of the base case. It ces be seted l
that the TDS esasentrattaa tacreased by approsiastely 80 pra on the awarese.
i The seminal desian average pond TDs legal (1204 pra) was exceeded 20%
of the tian La this case, en increase of 72 from that of the base case.
The moniaal deeias manima poed TDS leval was easeded 0.4% of the time.
gg3,Ja The effect of the alaimum blowdeva flowrate os pond TDS A
concentrations was studied by increasing its minima value from 3 cfs to 10 ofa. The comparises of the resulting monthly pond TDS values with those of the base case is shown in Figure 20. It is seem that the pond TDS concentrationwes not sensitive to the 3 afs increase.,
I i
From Figure 17, the blevdeva flowrotewas between 3 afs and 10 efs for only approximately 3.7% of the time. This infrequent occurrence of blowdown flowrates la the rense seasidered esplataa uhy the poed TDs concentratian was met sensitive to the bloudeva flowrote lower 1
limit.
i Case 3:
Ta the operstica study the daily natural river TDS concentrattees i
used were only available for water years 1976 and 1977. Although the
~
annual averase TDs seacastrations for these two years were eenparable,,
A the daily values pletted t' a Figure 6 were frequently quite different.
50178132 27
- s,.
..\\'
i-9 s
~
s e
i t
s.
<s.
x "nas;the use of dbr UF4 venies,of water year 1976 repostadif over s
S m -
the 82 years simulacion, although it representee the best ue111mstion 4
of availAls data, stykt t.ot be conservative for seas periods. Case 3 4 empisyed~ daily rl.ver DS 4.oncentrae:r.ons fr. creased by 20T from their
.s 1976 valmis. ThA resulting pond DS cacentrations shown in Figure x
21, were jewttoic higher'than those of the base case but etill 3
\\
within acceptable inval.
""w percent of exceedanze for the nominal
\\,
\\
s design average; and==='=== potsd TDE esscentrations were found equal x.
to 31% and 5.3% of the eine respectively.
s y
,.,e.-
[
8-
\\
Case 4:SThe blowdown excess temperature was calculated from the temperature of the blowdown and the natural river water. Those two quantities were in turn estimated from asteoeelogical data. The y
e ovorall accuracy of blepdown temperaturesle[aputed this way vos estimated to be, approrfmately 5*F.
As'shown in Figure 22', the effect Td a.5*F increase in bibdows gesperacEs 'on the cooling pond TD5 concens i
ration was an increase of 100 ppa. However, during, prolonged low riveg flow periods w'hein i%e TDS concentration of the cooling a
- 4 pond viss hM, an increase of 5'7,in blowdown temperature could 4
caus 'the ec'$ lids pond TD$slavel to increase by appresinately 300_ ppa.
The nomihal Josigala'verase and marfd TJS concentratiosus were
% T Y
excended 241 att 1,4% o$ the tim 4,1*espectively.
4
^l g-
-- s
\\
,x I
-s s
-.s O j.
y *g g,,3 c
N Case St -EMaccuracy in umuputieg dai1Paverage evaporation rates v
was estimated to be about luL Thu
- n. e-.s the effect of possible higher g
+ -
- evapotation.raias oui pond water surface elevations 'was investigated by increasingsthe-daily evaporation values used in the base case by i
N.
3 g
10%..' resulta^are shown in. Figure 23 where it can be observed that-s
-. x.
~
'N '
n
.50178193' 1
w 233 -
l q>
.,i
- ~
i 4
5
't.
~
.N e p*
a
t 60% of the time the pond water level was not affected by the increase T
in evaporation rate. However, additional makeup water was withdrawn frca the river to compensate for the increased pond evaporative votar loss.
Lower pond water levels occurred in case 5 only when makeup water was not available due to low river flows. However, sufficient margin still existed between the low pond level computed with the i
increased evaporation rates and th's miniana pond operating level of 618 fc.
In ~mmary, the results of the base case together with the limitad sensitivity analyses demonstrate that it is feasible to control Pond TDS concentration and pond depth within acceptable limits. The applicable Michigan Water Quality Standards are satisfied since they vers incorporated into the assumptions of this study.
as 9
e 4
I i
i l
I i
9 O
A
~
sat 78134 29 e9 - m
-w,2
-,.m,w e,..
,.-s-v.,-
-,mw.,--,,.y
--.e.--s.-e-n 4,---a--,v-w-w-w-
e w+<.----
ww,.
.--.w-wa
--w%-w.--,e-..w-..-#+
-*w---
1 7.
CONCLUSIONS 1
The following conclusions can te drawn from the results'of the simulation of the cooling pond operation:
It is feasible to control the pond TDS concentration through use a.
of the==hant-blowdown systas. Based on the assiseptions and the available data set forth in Chapters 3 and 4, the resulting pond i
TDS concentrations are acceptr.ble for the circulating water and service water system hardware. Cooling pond water surface elevations also rammin above the mini== pond level of 618 ft.
for the period of simulation.
I 1
d b.
The blowdown discharges into tha Tittabawassaa River can be made in compliance with the Water Quality Standards of Michigan Water Resources Commission.
In this study, the Dow Chemical Company's affluent discharge had c.
priority over the Midland plant cooling pond blowdown. As a result, i
the total dissolved solids in Dov's affluent severely limited the occurrence of cooling pond blowdown discharge.
i I
d.
On a long torn basis, cooling pond blowdown and the resulting thermal plumes will exist in the Tittabawassee River for about 27% of the time. For the remaining time, there will be no blowdown J
discharge.
r i
Based on the assumptions and the available data used, the operation e.
30 5B17S195 t
t-f
&T v
g-as
-T--e ere,c-,
9--
.,---g wg
,g y
y
-,y91,_-g
,,-..wgq,_ye.-.
yr.yy.-,,.g-y
-gp-~
g-
,_s,,y---
- m l
of the makeup-blowdown systen is limited by its ability to blowdown 9
due to thermal plume considerations. h re is adequate amount of water for pond nakaup from the Tittabawassee River, and there la no significant effect on river flows because of plant makeup withdrawal.
h simulation of the cooling pond is performed on an average daily basis while river flows are known to vary considerably within one day. h trasiant river discharge is caused by water releases from the upstrema Sanford Dam. An example of such variation is shown in Figure 24. h river flow changee observed on April 22, 1977 are typical for weekdays.
h river flow approaches a steady state on Saturday and Sunday since no flow is released form the dam. Due to the wide range of river flow g
varirtion within a short time period, a control system to regulate the blowdown discharge in phase with the varydag river flow is desirable.
9 i
i e
e l
9 9
e 50178136 4
5 31 P
I
-l
... _. _ -,.. _. _, -.. -.,.. _. - _. _ _..,... ~,.
~
I REFERENCES 9
1.
Environmental Report, Operating License Stage. Midland Flant Units 1 & 2, Volume 2, Section 3.4 Consumers Power Company, November 1978.
2.
Circulating Water System Description, 7220-SD-M-46. Revision 0.
3.
Michigan Water Resources Cosmission General Rules, Part 4 -
Water Quality Standards. Approsed September 21, 1973 Effective December 12, 1973.
4.
Climate of Michigan by Stations, Michigan Department of Agriculture and Michigan Weather Service, Second Edition. December 1971.
l 5.
Cooling Pond Thermal Performance Summary Report, Midland Flant Units 1 & 2, Prepared for consumers Power Company, Rechtel Incorporated, San Francisco, August 1973.
6.
Water Resources Data for Michigan, Water Years 1937 through 1977, 41 Volumes.
U. S. Geological Survey Water-Data Report.
7.
"Use of Air-Water Relationships for Predicting Water Temperature" by V. Kothandarman and R. L. Evans. Report of Investigation 69, Illinois State Water Survey, Urbana 1972.
A 8.
Final' Safety Analysis Report, Midland Flat Unita 1 & 2. Section 2.3.3.9.2, March 1978.
9.
" Investigation of a Thermal Plume in a.bilow River - Hydrothermal Nodel Studies of Cooling Pond 31owdow:. tischarge, !!idland :helaar Power Station", Alden Research Laboratory, Worcester Polytechnic Institute, Iolden, Massachusetta April 1979.
i 10.
"An Analytical ad Experimental Study of Transient Cooling Food i
Tehavior" by L J. Ryan and D. R. F. Earleasa, R. M. Farsons LabgratoryReportNo.161, January 1973.
Li
- 11. Hamon, L W., Weiss, L. L., and Wilson, W. T., " Insolation as
)!
as Emperical Function of Daily Sunshine Duration", Monthly Weather t
Review, Volume 82, No. 6, 1954.
I i
- 12. Model Study - Midland Cooling Pond by Alder. Research Imboratories, 1
.t January 1970.
I
- c p
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QL-C32f Onfe ccJiTr.ucnoN co /P.O. Box 5% /u S. 31 & M-43 / SOUTH HAVEN.MtCHIGAN 40090 / tG1C) 6371171
@ h ih W
s-Mr. John Church "d
Subeentracts Department
,,gg, 77,7 7 Bechtel Power Corporation g pogg3 @ Pf.
P.O. Box 2167 Midland. Michigan k86h0 job 72204 2M
Subject:
Consumers Power Company Midland Station Units 1 & 2 Ecchtel Power Corporation Subcontract FT220-C-210 Plant Foundation Excavation and Cooling Pond Dikes canonie Construction Co. Quality Assuranc'e Program dated August 1976 Addendum dated h/5/TT, Rev. 3
Reference:
Contract Change Notice kk-F, Ser f C-210-B-190, dated h/21/TT letter dated 6/29/76, T. F. Newgen to Canonie Construction Co.
Letter dated 9/lk/76, J. P. Newgen to J. McKane Des: Sir:
In response to the referenced letters above, Canonie Construction Co.
submits for your review, cc:n ent, and acceptance the attached addendum to
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i the subject Canonie Construction Co. Quality Assurance Program. This ad-dendum shall be applicable for all work covered by the above referenced subcontract for the scope of work defined in the referenced specification.
a Vork requiring the implementation of the quality Assurance W.
is defined in Exhibit D, Technical Specification for Plant Foundation Excavation 4
and Coeling Pond Dikes, of the subject subcontract specification. The Quality related activities so defined are as follows:
A.
Place =ent of plant area backfill and berm backfill. Backfill is defined.by section 13.2 of the referenced subcontract.
l 3.
Moisture control of the plant area and berm material to verify confor=sace to the provisions of section 12.6 of the referenced k
subcontrSct.
a i
C.
Compaction requirements for backf111 in the plant area and the berm to be in co=pliance with Bechtel requirements stated in section 13.7 and 12.8 of the referenced subcontract.
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JUN 231977 d
BECHTEL POWZi? CORP.
JOB 7220 Earth.m ne 2 / Pinog and Caisson Found.it*ons
/ Power PlanPCdkutsuedoMd i
An E.7uot opportunity Entalcyer
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Mr. John Church
^
Pcge 2 Msy 3. 1977 Purther, to assure the successful execution of the above referenced subcontract in ce=pliance with all owner /architeet/ engineer-constructor requirenents, the attached addendum shall be in effect until such time as it is revised or terminated in order to affect the successful inplementation and comuletion of all work.
W. R. Moore Quality Assurance Yntrineer, Canonie Construction Co.
l J. K. McKane Vice President, Earthmoving Division; Mana6er of 0.uality Assurance, Canonie Construction Co.
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Enclosures (1/1) ce:
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t "W M Ytto-M. LT/J/2 Yk L EkT*L e,} #2'h ? ? c-fjl * // l %n REVISION l K1_ M p l Canonle cCN5TRUCTION CO, 7220- C 7\\O ~b L. f ']f.26-(.52/O ~ /. Date: 4/5/77' Page 1 of 13 Rev 3 Addendun to: Canonie Construction Co. quality Assurance Manual ~ Dated, August, 1976 i Contract: Bechtel Subcontract No. 7220-C-210 ' Location: Midland Station Units 1&2 -Midland, Michigan Owner: Consuners Power Conpany Title Supplenental Requirenents for the Canonie Construction Co Quality Control Program for Q Listed Areas MAY 161977 ) l @ u,..., l 3gw. ],3Omee a ' C **~'*.;~::.T C ".:. % ~ . e O ~ ~. s-. -.. I e Q a.-. ..a.-, w e u,m,;... ?.,.. e j
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~. -i i ~ t Canonle s Page 2 of 13 Item I, changes: Add to para. 2 section 1.0,
Introduction:
The Quality Assurance manual shall be supplemented by Quality Control procedures written to clarity and further implement the Quality Assurance program of Canonie Construction Co. Prior to site implementation, these procedures shall be approved by the Kanager of Quality Assurance, Canonie Construction Co. and the Contractor or appropriate owner's representative. All Quality I!! Control procedures shall be controlled in the same manner as the l Quality Assurance program and revisions and addenda shall be re-viewed and approved in the same manner as originals. These pro-cedures shall indicate the scope of activities covered therein, the personnel designated by said procedures with responsibilities by job title, and shall provide sufficient instructions to clearly indicate what activities are necessary to demonstrate compliance with the accepted Quality Assurance program. Delete para. 3, section 2.4 as written and insert: The Quality Control Engineer shall have the authority to stop the continuation of work that is deficient in characteristic, ) docunentatien, or procedure which renders the quality of an item unacceptable or indeterminant. This shall include, but not be linited to physical defects, test failures, incorrect or inadequate docunentation, or deviation from prescribed processing, inspection or testing procedures. Delete sentence 1, para. 4, section 3 1 as written, and insert s i Activities which may be routinely performed by Canonie Con-struction Co. as part of inspection services on a project, such l as concrete testing, structural earthwork control or testing of reinforcenent steel, shall be conducted to recognic6d standards j or referenced specifications. i ~j Delete sentence 4, para. 2 section 3 2 3 as written and insert: Hevision receipts shall be signed and da'.ed by the assignee, or e i designated representative, and r,eturned to the Manager of Quality
- j Assurance within 15 days of receipt.
Delete ssntence 4, para. 3, secti:n 3 2.3 as written and insert: A new approval sheet, signed by the President, Canonie Con-struction Co. and the Fanager of Quality Assurance, shall be issued to indicate the. current revision nunber and date of the nanual issue in effect. This shall indicate Canonie Construction .} Co. acceptance of the policies and procedures defined therein. Celete sentence 2, para. 1, section 3.4.2 as written and insert: A file of all Quality Assurance / Control records shall be main-tained to conply with all owner / constructor contractually specified require =ents. These records shall be maintained as required by e .~.-.-
e,q_.u,+s a.a M ENw eS.*Sm40-+ a'**4"D' 'O FI'F'8""*d9 I ~ ~ ~ w 7l canonis' 58173778 Page 3 of 13 l this manual and applicable code and regulatory requirements. II relets sentence 2, para. 1, section 4.4 as written and insert: l For all the various activities included in the scope of work i-! for the referenced specification, ,a Item II. Suntle': tents : 1.0 Orsanization The Canonie Construction Co. Quality Control Organizational interface with the Bechtel. Power Corp. is shown in figure 1. i 1.1 The Project Manarer performs overall site supervision to ensure that construction schedules are maintained and that the work is performed in compliance with drawings and specifications. He cocrdinates work with the site i Quality Control Engineer to assure compliance to the accepted quality program. 1.2 The oc Enrineer has responsibilities and duties as follows: } l 1.2.1 He will document the classification of the borrow o by the Testing Imboratory to the Project Manager 4 j-i for use by the Field Foreman. l 1.2.2 Based on borrow selections he prepares daily . f reports verifying by station, by zone, the fill 4 ; placement, the moisture control, and the com-paction conformance necessary to meet specs. l 1.2 3 In this function, he is completely mobile and , i will by available for comment from the General 11 Contractor's inspection force. He will be in i communication with the Project Manager to correct any deviations in the fill requirements as established by the project specifications. - t i 1.2.4 The Quality Control Engineer has the authority to assure total compliance to the Quality Assur-. ance/ Quality Centrol program by all Canonie Con-struction Co. personnel. 13 The Field Sumerintendent shall initiate compliance'with the borrow / cut programs as outlined by the QC Engineef through the Project Manager. He shall be responsible for reporting field production requirements to the Project ./ Manager. 1.4 "hs Project Enrineer shall work closely with the pro- .ect manager and QC Engineer to establish survey and ~ _
i k SB178773 canonia ) Page 4 of 13 control methods required to assure proper defin'ition ~ of zone fills and lift controls. 2.0 Quality Control Prorram 2.1 The Quality control Team or member shall 1xt responsible for quality control and documentation for all Q Listed areas as designated by contractor's and/or owner's specifications. The inspection unit shall assure that the project specifications are strictly enforced. Quali-I fled and experienced personnel shall comprise the inspec-tion force. 2.2 The Qvality Contro: Engineer and/or his reDresentative shall be responsib:.e to the Canonie Construction Co. project QC manager and shall be independent of pro-duction, construction, scheduling and procurement. 23 The UC Ehrineer shall develop, in the course of his duties and ac required, adequate forms, charts and logs to compile and assimilate required QC information and documentation of Q listed work. 2.4 All CC 3ecords and Documentation shall be stored in a fire resistant filing cabinet. The records shall identify the inspector or data recorder, the activity monitored, date of inspection or test, test results, acceptability and any corrective action required or , I taken. This information shall be supplemented as j required. t 1 2.4.1 The on Site Records shall be filed in an orderly l ; fashion and shall be readily identifiable and' retrievable. Upon completion of construction work, records shall be turned over to the owner's operations group or his designated representative. 1 i 25 The Oc Innineer shall assure that the proper zoned materials are delivered to the proper location and the 4 l proper compaction control is performed as required by the specifications. 2.6 The CC Enrineer shall schedule his work so that all operations, reports, documentation and related itema shall be availabic to the contractor and/cr owner and to facilitate the establishment of a functional inter. face between the appointed testing laboratory, general contractor and field superintendents. ss 27 The CC Reeresentative shall become faniliar with the testing laboratory personnel testing methods and indi-vidual soil classification characteristics. e
,e N'- m, CanOnle- - SB178780 I Page 5 of 13 2.8, The QC Engineer % level of authority shall be equal to the hiEhest ranking production unit ie. rupervisor or superintendent. The QC Engineer does,not direct' work forces, except through supervisory personnel, and -.[ then only in quality related areas to insure compliance with job specifications, procedures, and drawings. s 6.0 Cocument Control 6.1 Inder Card File System 6.1.1 Individual Card for Each WG shall be maintained listing 8 WG Title and Number ' Revision Number Revision Date t'- Date Received ]) Number Received Classi'fication: Preliminary or Approved Distribution: Stick Number or Name of Person drawing is issued to j 6.2 A Drawine Summary List shall be maintained listing = l Stick Number Drawing Number l Title i i Revision and Date S tatus : Preliminary 1 or Approved 4 63 Drawine Awareness New or revised drawing will to routed to assure all l personnel concerned are aware of change. A list of t docunent assignees shall be maintained to assure proper
- 8 distribution.
i 6.4 Separate storage of Superseded Drawings and Specifica-tions to Maintain Adequate Control shall be provided. All superseded documents shall be voided. 65 Document control shall not be confused with documenta-tion control. It is not intended 't at document control J shall be specifically a function or the quality control I Engineer. An authorized agent of the QC Department may 1
m CanQMle - Page 6 of 13 SB178?s:L , perform the document control function. Documentation shall be a function of the QC Engineer and shall sh.ow all pertinent information as required by contractofk specifications. 8.0 Identification and Control of Materials Parts and' Components t i 8.1 Ibe QC Retresentative, working with the general con-tr.setor's representative, shall inform subcontractor's field supervision force of soil classifications in borrow areas as designated by the-testing laboratory. 15 0 Non-Conformine Materials. Parts or Comeonents 13 1 Comcaction Eouiement 15 1.1 The utilization of dissimilar compaction equip-ment outlined in exhibit D of 7220-C-210 shall be as follows: ) 15 1.2 The owner's testing laboratory shall be re-quested to perform tests on controlled test-fills within the embankment as required to determine pass requirenants for each individual type conpactor. 15 2 Backfill Materials In the event that non-conforming materials are dis-covered in borrow areas by the testing laboratory, the contractor shall be notified for disposition. Non-conforming material shall be renoved ar.d/or dis-posed of as required by contractor. 16.0 Corrective Action 'dhen corrective action is required the following cutline of activities shall be followed: 16.1 Identification of source of non-conformance. 16.2 Evaluation of causes, conditions, present requirements and potential solutions. 16 3 Inplementation of corrective action. 4 16.4 Co'ntractor and/or testing laboratory analysis of s problen is required if caused by external, uncontrol-lable sources, ie. excessive precipitation causing moisture content of cohosive soils to exceed accept-l ance criteria and preclude conformance to compaction requirements.
5 7 cay,,ge 5B178782 Page 7 of 13
- 16. 5 when internal corrective action is required, it shall be documented for review and concurrence by the QA
- Fanager.
If the causes of non-confoming conditions. are external and outside the specified jurisdiction i of the subcontractor, recommended corrective action shall be requested of the contractor and/or his agent, i and shall be concurred with by Canonie site quality control. 16.6 Documentation as required by owner shall be maintained in accordance with document control procedures. 17.0 Cuality Control Records shall be compiled and submitted to Bechtel for their review and retention. Copies shall be maintained by Canonie Construction Co. and shall include related data such as qualifications of personnel, procedures, and equipment. Consistent with applicable regulatory require-ments, the owner / contractor shall establish requirements con-cerning record retention and turn-over, such as record detail and type, and systems effected. Canonie Construction Co. ] Quality Assurance shall be' notified in ieriting of any and all changes in documentation requirements. 17 1 The following forms shall be used to document the . implementation of quality program on site. 17 1.1 Lift Thickness Control - Pi mre 2 By determining elevation before and after place-1 ment operations from grade stakes, the QC Engin-ear shall determine the lift thickness achieved. He will prepare a report from information listing the following data: l Observation Zone Work Location Size of Area Elevation (s): Before + After Lift Thickness Date These random lift thickness checks shall be performed on an average of two areas daily de-pending on the working area conditions and the materials clasaltication. .s 17 1.2 Ceeraction - Fin re 1 Cn a daily basis the QC Engineer shall prapara ~ e +- ,.-4
wa 14 6. ww wsom.=== hc===Q canonte ~ ~~"""~ 5B178783 - Page 8 of 13 a report for each sone and work area listing the following information: date, shift, weather, features, foreman,' station, offset, elevation obtained, results of roller - speed checks, eouipment numbers, type, and frequency checks t including vibration rate checks and time taken, and load counts. 17.1.3 Borrow Accentance - Fisure k The QC Engineer will obtain classification of asterial 2 from the Bechtal representative and/or the testing laboratory. ~ 17.1.k Deficiency - Corrective Action - Piaure 5 When notified by the Bechtel representative that a defi-i 'ciency exists the QC Engineer shall note the date, time, i feature, location, shift, foreman, elevation, and type of deficiency, ie. failing test. He shall notify the I troject manaser or his representative and corrective actions shall be implemented. After corrective action innlementation, a new test shall be performed and the results noted. Where necessary, further corrective .), action shall be instituted. 17.2 Quality Assurance / Control Records l M the aforementioned reports shall be compiled and submitted to Bechtel for their review and retention. Copies shall be maintained on file by Canonie Construction Co. 18.0 Audits A syst'em of planned, periodic, and documented internal a2dits has been i established to verify compliance with all aspects of the accepted quality assurance program. j .I 18.1 Audits shall be performed in accordance with written check lists by personnel qualified and trained in the performance of audits and familiar with the scope of work being performad. e 18.2 Audit personnel shall be selected to preclude the possibility of personnel participating in audit activities in areas where they have direct responsibility. 16.3 Audit results are documented and reviewed by management personnel having responsibility for the areas being audited. 1 d 18.) Corrective action is isolamented to correct deficiencies revealed by audit activities, and to correct system inadequacies determined to be the cause for significant conditions adverse to quality. 18.5. Audit results and corrective actions are reviewed by upper manage- . ment to determine the effectiveness of the audit program in correcting conditions adverse to cuality and to verify the i implementation of corrective action. -.,,-,-y ,,,,w,w,,~,, w,--, +,,-,,m-,v-,,,,.-._m_-_,7,.,,-a-,--w.-.-.m,--,,,, ,-,v,#,m.,..-r- ,,-,-,,. -,. - -,. -, - - ~.,, -. - -. -.,, - -
l s l W 's Canonle I Page 8-A of 13 18.6 Where necessary to establish objective evidence of imple-mentation, corrective action shall be verified by the perfor-mance of re-audits of those areas previously determined to be non-confominst. t 1 1 4 i 58178784 1 O , i .*. e 9 e t j l i 1 p 4 l i p l e l l J l \\ r a v e. v-,4w ~,--m, w--
'I O M1stland Stat.1on lini ts l A2 __.S S Pinnt Founda tion Erenvntion & Cooling Pond D1kes COMOMIO. President Consumers. Power Bechtel Power Canonie Const, Co. Cescpany Corp. I Group Vice President Quality Assurance Division Leader Engineer 11gr. of Quality Assurance Construction M r. 6 m Bechtel Power o$ I Project Ihnnager f ---- - I -------------~------i f----" Corp. I I i w l Equip. Supt. Project Engineer Field Supt,__.. Office ligra... Quality Control. ] Test lab l o Engineer U 4 e Direct flesponsibility ~,
Conusunication ae
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t M Mc:=' Figure 2 3 Rev. 1, 7/26/73
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canonle m J Page 10 of 13 - MIDLAND !.'UCLEAR UNITS 1&2 P.M. CANONIE CONSTRUC" ION Co. G.S. P.S. LIFT '"HICKNESS C'riECK t 03SERVATION NUE3ER: DATE: I ZONE: LENGTH: STATION: TO STATION: WIITfE 0FFSET: i ELEVATION: EFORE AFTER LIFT THICKNESS BEFORE AFTER LIFT TEICKNESS EFORE AFTER LIFT TEICKNESS } 3EFORE AFTER LIFT THICKNESS._ AVERAGE LIFT THICKNESS i RZi*GS/ SKETCH: i 1 - t 1 . 3 e I BY: CARONIE CONSTRUCTIO?d CO. 4 QC REPRESENTATIVE a sur7s7ss k l 4 i
kc===$, Figure 3 Rev.1, 7/26/73 Canonle G Pase 11 of '13 ~ MIDLAND NUCLEAR UNITS 182 P.M. CANONIE C0!!STRUCTION Co. G.S. F.S. FILL PLACEMENT QA-QC DAILY REPORT FIA'URE : DATE: ( ) D*.EEGENCY COOLING POND BE2M SHIFT: ( ) PLANT AEEA FILLS WEATHER: ( ) R/R EM3AN N ;T FORE!!AN: ( ) LAYEC'4N ARIA ELEIATION: ( ) C0 CLING POND DIKE STATION: To STA: OFFSET: ZONE: MOISTURE TESTS: ( )1 ( )4 ( ) 1-A ( ) 4-A ( )2 .( ) ()3 ()Je LOAD CCUNT COMPACTION EQUIP!E:r": EQUIP.No. TIPE FREQUENCY TIME SPEED 4. i 3 EEI'A?l'S /SEETCH s t 50178787 .s BY: CA;;0i?IE CC:;STRUCTION CC. I
i ^3 Pigure 4 _2 Car",lcr115 - " Rev. 2, h/12/74 ] m Page 12 if 13 MIDLAND NUCLEAR UNITS 1&2 P.H. CANONIE CONSTRUCTION CO. G.S. P.S. 30RECW PIT ACCEPTANCE AREA: ( ) CCOLIUG POED DATE: ! i ( ) "IKE FCU1:DATION GRID LCCATIOS: MATIS.IAL: ( ) II2E27IOUS ZONE 1 ( ) IIDERVIOUS ZONE l-A APPROXIMATE ELE 7: 1 ( ) EANDCM l i SEE!CE: s I t t, I i l {
- The above area has been found to contain a suitable amount of t
n:sterial conforming to the requirements of the spacification and, ,I therefore, has been classified a borrow area. 1 I It is understood that the borrow pit shall remain so designated until there occurs a marked change in the characteristic of the excavated
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5D178788 REIIA?.KS : i ) RY: 3Y: EICETIL PC'4ER CORF. CAN0 HIE CON 3TRUCTION CO. ~. _.
w -4 l i f l Figure 5 Rev. 1, 7/26/73 g@", O s C a n Qnle Page 13 of 13 FIDLAND NUCLEAR UNITS 1&2 P.M. CANONIE CONSTRUCTION Co. G.S. P.S. DE*ICIENCY CORRECTIVE ACTION REPORT DATE: TIME: S'HIFT : FEATURE: FOREMAN: LOCATICE: ELEVATION: DEFICIENCI: CORRICTIVE ACTION:. ): o SUGG".:.STED PEVIKIATIVE FEASUEIS: 1 i CCE?C-CTI75 ACTIC:: QUALITY ASSURANCE: TESTIEG: OTE?.: 5:0ZTCE (IF EZQ'D): b0178783 3Y8 BY: 3ECE!IL 70'JER CCM. CAN0;;IE CUNST3'JCTICH CO. --+w ,~--,,- -, +e -}}