ML20091C502
| ML20091C502 | |
| Person / Time | |
|---|---|
| Site: | Midland |
| Issue date: | 05/17/1984 |
| From: | Lucks A STONE & WEBSTER, INC. |
| To: | Cook R NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| References | |
| MPF-86, NUDOCS 8405300585 | |
| Download: ML20091C502 (17) | |
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STONE & WEBSTER MICHIGAN, INC.
A P.O. Box 2325, BOSTON. M ASSACHUSETTs 02107 United States Nuclear Regulatory Commission May 17, 1984 Midland Site Resident Office Route 7, J.O. No. 14358 Midland, Michigan Ref. MPF 86 EPRit;QlPAL STAFF _
v3A IMTM Attention: Mr.
R.
Cook J/RA DE _..
A/RA W
DOCKET No. 50-339/330 ac 0C^
MIDLAND PLANT UNITS 1 & 2 3A0 SCS INDEPENDENT ASSESSMENT OF UNDERPINNING
^GA AL 4
o REPORT NO. 86 5fF FiIe hf A copy of the Independent Assessment of Underpinning Weekly Report No. 86 for the period of May 6, 1984 through May 12, 1984 is enclosed with this letter. Included as attachments are the minutes of the daily meetings held during the week between members of the Assessment Team and Site Engineering, Construction, and Quality Assurance personnel.
If you have any questions with respect to this report please contact me at (617) 589-2067.
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Stanley Lucks Project Manager Enclosures ASL/pd cc:
JJHarrison (enc), US NRC Glen Ellyn, IL l
Grace Dow Memorial Library (enc)
DQuamme (enc) CPCo Midland (site) l JMooney (enc) CPCo Jackson JMeisenheimer (enc) CPCo Midland (site) h
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4 J.O. No. 14358
. Midland Plant Units 1 & 2 Independent Assessment of Underpinning W ekly Report No. 86 e
May 6. 1984 through May 12, 1984 Personnel on Site Stone & Webster Michigan. Inc.-
P.
Majeski 5/8 - 5/12 D.
Benvie 5/7 - 5/12 D.
Zito 5/7 - 5/11 W.
Kilker 5/6 - 5/10 L.
Rouen 5/6 - 5/8 A.
Lucks 5/9 - 5/10 D.
O' Nan 5/9 - 5/10 G.
Palmer 5/9 - 5/10 Parsons Brinckerhoff Michigan. Inc.
J.
Oliveira 5/9 - 5/12 B.
Metros 5/6 - 5/8 J.
Ratner 5/10 - 5/11 Meetings Attended D_ag Represented Purpose 5/7 - 5/9 Stone & Webster Daily Assessment 5/11 Bechtel Team Meeting Consumers Power Parsons 5/7 Consumers Power Project Soils Bechtel Meeting MPQAD Stone & Webster 5/7 Bechtel Constructability Consumers Power Review Meeting MPQAD Stone & Webster 5/8 NRC CCP/ Soils Interface Consumers Power Meeting MPQAD Stone & Webster 1
5/10 NRC Monthly NRC Meeting 4
Consumers Power Stone & Webster
e.
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.J.O. No. 14358
. Midland Plant Units 1 & 2 Independent Assessment of Underpinning Date
' Represented Purpose 5/11 Consumers Power Weekly Bechtel Interorganizational MPQAD Meeting Stone & Webster 5/11 Consumers Power Document Control Bechtel Information Meeting MPQAD Stone & Webster Underpinning and Remedial Soils - Construction Pier ES:
Concrete placement for the pier bell and the shear key between the pier and the containment drop pit was completed. Installation of the pier shaft reinforcing steel and the grillage support columns in the containment drop pit is in progress.
Pier Kc8:
Excavation of the finger drift to the pier continued.
Pier E17: Placement of concrete for the middle portion of the enlarged shaft was completed.
Piers CT3/10: Pier excavations are in progress.
Pier W5:
Concrete placement for the pier bell and the shear key between the
. pier and the containment drop pit was completed. Installation of the pier shaft reinforcing steel is nearing completion. Grillage support column installation in the containment drop pit continued.
Pier W17:
No further activity was performed pending fabrication of lagging materials to support an enlarged straight shafted pier.
Pier Kc5:
Excavation of the pier is in progress.
Access Shaft Level C Wales:
Installation of the Level C W les was completed.
a SWPS: Installation of the upper level wales continued on the north and west sides. Excavation and lagging installation was completed to El. 623 ' along the east side of the excavation.
BWSTs: Reinforcing steel, fontwork installation, and concrete placement continued.
Cathodic Protection: Trench excavation work continued.
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J.O. No. 14358 FRdland Plant Units 1 & 2 Independent Assessment of Underpinning Assessment Team Observations - Construction Water seepage was effectively controlled in the E5 pier bell prior to placement of concrete for the working mat.
The Contractor installed a perimeter trench around the bell periphery to intercept seepage along the side of the bell.
Intermittent lateral trenches were excavated to divert any possible seepage away from the founding area of the bell. Subgrade soil which had been softened prior to excavation of the drainage trenches was removed in accordance with the procedures.
The effectiveness of seepage control for the foundation of the E5 pier bell was judged to be satisfactory.
Concrete placement was observed at the E17 pier and the E/W5 bells. Key items noted included placement technique consolidation and curing of concrete. Place-ment methodology and consolidation were judged to be satisfactory.
The concrete was wet cured in accordance with the procedures.
The Assessment Team attended a constructability review for the FIVP load transfer.
The purpose of the review was to discuss design requirements and finalize the logic and construction sequence associated with the FIVP load transfer. Items reviewed included intent and clarity of drawings, sequence of loading, procedure preparation requirements, proper sequencing of construction operations, interfacing between engineering, construction and quality organizations and allowances for contingencies. The Assessment Team believes that the constructability review was very thorough. The various organizations involved with the review were knowledge-able of the design and engineering requirements for the FIVP load transfer.
Pertinent engineering and construct' ion input was provided by all the organizations involved in the review. Additionally, the review was scheduled in a timely manner ensuring enough lead time for incorporation of applicable comments into the design drawings, and preparation of the required procedures and inspection plans prior to the scheduled construction dates.
The Assessment Team observed cadwelding of rebar and repair of 1.0 in. exploration holes at the BWST Unit 1 valve pit. The cadweld, packing and clamps were properly installed. The assembly was then preheated in accordance with the procedures.
The crucible was installed and the filler metal was fired.
The hardware was removed after initial solidification and the slag removed from the completed cadweld.
The resulting quality of the completed cadweld was indicative of the satisfactory workmanship observed during the cadwelding process. Drypack was used to repair the 1.0 in. exploratory holes.
The holes were presoaked in accordance with procedures.
Drypack was mixed in small quantities appropriate for the size of this operation, ensuring that freshly mixed material was used at all placement locations. The dry-pack was rammed into the holes with a tamping rod and hammer, resulting in a well compacted and sound repair.
The Assessment Team inspected the condition of the backpacking completed to date for the SWPS east access shaft.
In several locations the backpacking had fallen out from behind the lagging. This condition is attributable to the type of back-packing material and level of effort being implemented to install the backpacking.
The situation is aggravated by vibration caused during flyash concrete removal around the soldier piles.
The Assessment Team has previously expressed concern with this backpacking material and method of installation.
The Assessment Team does not believe that the problems experienced to date have affected the overall stability of the excavation.
- However, the continuing problems associated with maintaining the backpacking in place indicates more diligence is required by the
J.O. No. 14358 Midland Plant Units 1 & 2 Independent Assessment of Underpinning Contractor to correct this situation before the excavation is significantly extended below the present levels. The Assessment Team has had further discussions with the Contractor concerning this situation. One modification being implemented involves the use of clay at the bottom of every second or third lagging board to prevent the sand backpacking from falling out. The Contractor is implementing the use of clay to upgrade the backpacking placed to date. It is planned to continue this backpacking method at least until
-excavation of the access shaft proceeds below the sand fill and into the clay fill. Once the excavation is in clay, it is anticipated the excavation can be maintained closer to design lines, thereby ensuring more contact between the lagging and in-situ soil. As an additional preventive measure,where necessary, the Contractor also plans to place excelsior in the spaces between the lagging.
The Assessment Team will continue to monitor backpacking at the SWPS to ensure the stability of the in-situ soil support is maintained.
Assessment Team Observations QA/QC The Assessment Team attended a quality awareness session held during a Subcontract-or's toolbox meeting. At this meeting, the requirements for belling and excavation of piers were discussed.
During the discussion, the importance of predetermined hold points and quality criterion was reviewed.
This session was judged to be adequate in providing the craftsmen with an awareness of quality requirements associated with the belling and excavation of piers.
MPQAD calibration of vibrators and US Testing inspection and testing of concrete placed for the E17 pier was overviewed by the Assessment Team. Vibrators were inserted into fresh concrete and the required minimum frequency of vibration was verified. Preparation of concrete cylinders and air, slump and temperature testing conformed with ASTM procedures.
The Assessment Team attended a training session conducted by the SWPS underpinning subcontractor to familiarize their field engineers with quality requirements for jacking equipment. The discussion reviewed quality procurement requirements.
Ianufacturers' equipment documentation, and calibration data needed prior to installation of the jacks.
The content of the training session was judged to be thorough, detailing all the necessary documentation requirements to be met prior to jack installation.
Work Activity Packages No work activity packages were overviewed or active during the past week.
Nonconformance Identification Reports NIR No.
Description Status (0pened)(Closed).
25 Compressive Strength 3/30/84 5/9/84 Testing of Concrete Cylinders
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J.O. No 14358 Midland Plant Units-1 & 2 Independent Assessment of Underpinning Open Items OPEN ITEM - An item for which an action is required. The item will remain
--open until the required action has been taken. Tracking is required.
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CLOSED ITEM - An item usually brought forward by the Assessment Team that is discussed and adequately responded to.
No tracking is required.
INFORMATION ITEM - An item brought forward to provide general background inforvation regarding work, such as work status or an upcoming design change.
No tracking is required.
OPINION ITEM - An opinion or suggestion given by the Assessment Team expressing an alternate construction or quality assurance technique. The ocinion or suggestion is given as a possible alternate that may facilitate an operation.
CLOSES ITEM -XX-XX - This notation identifies an action that closes a previously identified open item. Tracking of the open item stops.
The following listing of all Open items from the Daily Meeting Notes with Bechtel and the text of the Weekly Reports. Carry-over items from past weeks which have been Closed this week are also listed.
Item No.
Description Closure 64-10 Trend Analysis Open 71-17 Computerized Civil Open Drawing Register 74-21 US Testing Corrective Open Action 79-26 Upper Leveling Plates Open 79-28 SWPS Backpacking Open
. Material 79-34 SWPS Backpacking Open Placement 81-24 BOP Construction Open Verification of Soils Work 82-9 Trend Analysis Open 84-20 Design Drawing Requirements 86-6 for BWST Ring Beam Addition
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- n J.O. No. 14358 Midland Plant Units 1 & 2 Independent Assessitent of Underpinning
-Itern No.
Description Closure 85-5 SWPS North Wall Concrete 86-18 85-29 Auxiliary Building Access Open Shaft Grout Shirts 86-4' Auxiliary Building Open Crackrtapping 86-16 Vibration of BWST Open Concrete (bl/bb%
WCA$Yw$//Shhi Project Engineer Project Manager
J Note] of Daily Meeting Independent Assessment of Underpinning Midland Plant, Units 1 & 2 Consumers Power Company Held at Midland Site Midland, Michigan May 7, 1984 Present For:
Consumers Power Bechtel MPQAD Stone & Webster G. Murray J. Fisher J. McMaster L. Rouen J. Kelleher R. Sevo W. Kilker E. Cviki D. Benvie Parsons Brinckerhoff B. Metros PURPOSE This meeting is held each day to discuss items regarding the Independent Soils Assessment at the Midland Plant, Units 1 & 2.
DISCUSSION Status Items Item 86-1 Auxiliary Building Underpinning Activities Excavatior. of the pier CT 3/10 drop pits continued.
Bell excavation and bracing installation is in progress for piers E/W5.
Excavation of the finger drifts has begun for piers Kc 5/8.
Installation of the Level G Wales is nearing completion for both access shafts.
(INFORMATION ITEM)
Item 86-2 SWPS Backpacking Material J. Fisher reported that the use of cement with sand for backpacking the soldier pile wall will be discontinued. Use of the sand and cement mix produced a backpacking which was too stiff and prevented the contractors ability to sub-sequently check for voids in areas other than the spaces between lagging. Clay will be used instead of cement with the sand as a means to rtaintain the back-packing in place.
(Item 79-28 remains OPEN)
(INFORMATION ITEM)
Item 86-3 BOP Construction Verification of Soils Work J. Fisher reported that a meeting with the Assessment Team is scheduled today to discuss interfacing between FSO and the Balance of Plant (BOP) with respect to instances when BOP verification of underpinning activities will be required.
(Item 81-21 rettains OPEN)
(INFORMATION ITEM)
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y Notes gr Daily Meeting Independent Assessitent of Underpinning Midland Plant, Units 1 & 2 Consumers Power Cortpany Held at Midland Site Midland, Michigan May 7, 1984 i
New Iterns Item 86-4 Auxiliary Building Crackmapping W. Kilker requested a copy of the MPQAD review of the required auxiliary buildine crackrtapping associated with jacking of piers CT 1/12.
J. McMaster will rescond.
(OPEN ITEM)
Item 86-5 FIVP Crackrtapping E. Cviki reported that FIVP crackrtapping perforrted in April.using the new grid system did not result in issuance of any NCRs. Previously, cracks in the FIVP were referenced to building colurta lines, resulting in differing interpretations as to the correct location of the cracks.
(INFORMATION ITEM)
Response Iterns Itert 86-6 Design Drawing Requirertents for BWST Ring Beart Cracks E. Cvikl provided the Assessrtent Team with a copy of the FCR addressing elevation inconsistencies in the top -elevation of the valve pit, existing ring beart,and ring beam addition at the BWSTs. 'Ihe FCR specifies that the' top.of the ring beam
-addition will be sloped as required to rtatch the existing top elevation of the valve pit, while reaintaining a rtinittun 2 in. of concrete cover over the reinforcing steel. The Assessrtent Team concludes that possible interface problerts between the valve pit and ring beam addition due to elevation inconsistencies have been adequately addressed.
(CLOSES ITEM 84-20)
1 Notes of Daily Meeting Independent Assessment of Underpinning Midland Plant, Units 1 & 2 Consumers Power Company Held at Midland Site Midland, Michigan May 8, 1984 Present For:
Consumers Power Bechtel MPQAD Stone & Webster G. Murray J. Fisher J. McMaster L. Rouen J. Kelleher R. Sevo W. Kilker E. Cvikl D. Benvie Parsons Brinckerhoff B. Metros PURPOSE This meeting is held each day to discuss items regarding the Independent Soils Assessment at the Midland Plant, Units 1 & 2.
DISCUSSION Status Items Item 86 Auxiliary Building Underpinning Activities Excavation of the CT 10 pier shaft has begun.
Rebar installation is in progress for pier E17.
Bell excavation and placement of the grout mudmat was completed for pier W5.
(INFORMATION ITEM)
Item 86-8 Auxiliary Building Crackmapping E. Cviki reported the submittal of the auxiliary building crackmapping results performed after jacking of the CT 1/12 piers is scheduled for 5/11/84.
J. McMaster stated the MPQAD should complete their review of the crackmapping results approximately 2 weeks after submittal.
(Item 86-4 remains OPEN)
(INFORMATION ITEM)
New Items Item 86 BWST Ring Beam Addition J. Fisher reported that concrete will be placed today for the west segment of the Unit 2 ring beam addition.
(INFORMATION ITEM)
Item 86 Rejacking of the W8 Grillage E. Cviki reported that the W8 grillage will be reiacked today. The W8. grillage is being rejacked in response to a change of 20% in the grillage posts strain gage readings and an increase in the rate of building settlement
a Notes of Daily Meeting Ind:p;nd:nt As::ssment of Und rpinning Mid1:nd Plent, Unita 1 & 2 Consumers Power Company
' Held at Midland Site Midland, Michigan May 8, 1984 (7 mils /48 hrs) in the vicinity of the W8 grillage. (INFORMATION ITEM)
Item 86 Welderete W. Kilker asked if the contractor planned to restur.e the use of Weldcrete since the NCR addressing concerns with the vendors QA program had been resolved.
J. Kelleher responded that it is planned to use Weldcrete for applications related to temporary underpinning activities. Engineering is presently evaluating the use of Welderete for the permanent under-pinning.
(CLOSED ITEM)
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Notes of Daily Meeting Independent Assessment of Underpinning Midland Plant, Units 1 & 2 Consumers Power Company Held at Midland Site Midland, Michigan May 9, 1984 Present For:
I Consumers Power Bechtel MPQAD Stone & Webster G. Murray P. Goguen J. McMaster W. Kilker J. Schaub J. Fisher R. Scvo D. Benvie J. Kelleher D. Zito E. Cviki P. Majeski B. Brandes N. Swanberg Parsons Brinckerhoff J. Oliveira PURPOSE This meeting is held each day to discuss items regarding the Indecendent Soils Assessment at the Midland Plant, Units 1 & 2.
DISCUSSION Status Items Item 86-12 Auxiliary Building Underpinning Activities Shaft excavation for pier CT 10 has proceeded to the concrete mudmat at el. 583 No perched groundwater has been encountered to date.
Excavation of the CT 3 pier shaft has started.
Bell excavation was completed for the E5 pier.
Concrete placement for the shear key between the containment drop cit and the W5 pier was completed.
Excavation of the Kc5 pier shaft has begun.
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-(INFORMATION ITEM)
Item 86-13 U.S. Testing Corrective Action J. Kelleher provided a status on the U.S. Testing upgrading process.
All l
Quality Control Procedures (QCPs) with attached work instructions have been submitted and approved.
Issuance of the QCPS is in progress. Qualification i
of U.S. Testing Technicians to Level I for 20 or more certifications is continuine.
Five technicians remain to be cross trained to at least 20 certifications.
(INFORMATION ITEM)
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i Notes of Daily Meeting Independent Assessment of Underpinning Midland Plant, Units 1 & 2 Consumers Power Company Held at Midland Site Midland, Michigan May 9, 1984 New Items Item 86-14 MPQAD Receipt Inspection of the E/W5 Crillages P. Majeski asked if MPQAD receipt inspection of the E/WS grillages was completed and if so were any NCRs issued.
J. Kelleher stated that MPQAD receipt inspection had been completed. Procedural nonconformances were noted during the inspection, resulting in issuance of an NCR. No hardware deficiencies were found during the receipt inspection.
(CLOSED ITEM)
Item 86-15 Lessons Learned J. Schaub asked if there were lessons learned from the Level C wale installations that can be applied to the remaining wale installations in the access shafts.
J. Fisher responded that changes will be made to design documents to incorporate lessons learned from the Level C wale installation.
(CLOSED ITEM)
Item 86-16 Vibration of BWST Concrete D. Zito noted that an NCR had been issued due to insufficient vibration of the concrete placed yesterday for the BW9T Unit 2 ring beam addition. It was noted that heavy rebar congestion prevented the contractor from adequately vibrating the concrete. Mr. Zito asked what provisions will be taken to address this problem for the remaining BWST concrete placements where there is a high concentration of rebar.
P. Goguen stated that modifications being evaluated to address this problem in the future include :
A.
Bundling of rebar to allow passage of vibrators into these heavily congested areas.
B.
Using form vibrators to provide additional consolidation of the concrete.
C.
Placing starter grout in areas where rebar congestion is extensive to ensure full penetration of concreto.
The Assessment Team will overview upcoming concrete placements at the BWST.
Impicmentation of the proposed modifications will be evaluated for effectiveness.
(OPEN ITEM)
Response Items Item 86-17 NIR 25 - Compressive Strength Testing of Concrete cylinders The Assessment Team has reviewed the QAR response to NIR 25 detailing deficiencies associated with the use of the maximum load indicator dial on the U.S. Testing concreto compression machine. The QAR states that the use af the needle is not required by ASTM procedures. Although the concrete compression machine at the U.S. Testing Laboratory is equipped with the needle, the tech-7 cians do not use it because it affects the reading of the crimary load measuring 1
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Notes of Daily Meeting Independent Assessment of Underpinning Midland Plant, Units 1 & 2 Consumers Power Company Held at Midland Site Midland Michigan May 9. 1984 arm.
It should be noted that the concrete compression machine has been calibrated with and trithout the maximum load indicator dial. Additionally, chock associated with concrete failure during testing can effect the maxirrum load indicator reading.
Therefore, the US Testing Technicians only read the load measuring arm. The Assessment Team contacted various QA organizations involved with the nuclear industry and found that although the maximum load indicator is used during testing, the primary load measuring ann value is used to document maximum load. The Assessment Team concludes therefore that the procedure being implemented is adequate. NIR 25 is CLOSED.
(INFORMATION ITEM)
Item 86 SWPS North Wall Concrete Surface.
J.
Fisher responded to the Assessment Team question concerning repair of honeycombing and form tie holes for the SWPS north wall. All areas of the north wall where surface imperfections such as honeycombing or fort tie holes exist will be repaired in accordance with design requirements. The repair work trill be completed prior to placement of concrete for the missile shield protection on the SWPS north wall.
(CLOSES ITEM 85-5)
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Notes of Daily Meeting Independent Assessrtent of Underpinning Midland Plant, Units 1 & 2 Consu:ters Power Cottpany Held at Midland Site Midland, Michigan May 10, 1984 No rtecting was held on this date.
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i Notes of Daily Meeting Independent Assessment of Underpinning Midland Plant, Units 1 & 2 Consumers Power Company Held at Midland Sito Midland, Michigan May 11, 1984 Present For:
Consumers Power Bechtel MPQAD Stone & Webster G. Harray J. Fisher J. McMaster D. Benvie R. Wheeler J. Kelleher D. ' Zito E. Cviki P. Majeski Parsons Brinckerhoff j
J. Oliveira J. Ratner PURPOSE f
This meeting is held each day to discuss items regarding the Independent j
Soils Assessment at the Midland Plant, Units 1 & 2.
DISCUSSION Status Items Item 86 19 Auxiliary Building Underpinning Activities Concrete placement was completed for the W5 pier bell.
The first lift of concrete was placed for the middle portion of the E17 pier shaft.
Level C wale installation has been completed in the east access chaft.
(INFORMATION ITEM) l Item 86 20 SWPS Under;, inning Activities J. Fisher reported that an FCR allowing the use of wood lagging in areas where i
the lagging span is Icos than 8 ft.was issued. Tubular steel lagging will still be used where the lagging span exceeds 8 ft.
(INFORMATION ITEM)
New Items Item 86-21 BWST Crack Review E. Cviki reported that Resident Engineering has reinspected the existing BWST ring beams to determine if additional cracking had occurred in areas where concrete placement is scheduled in the near term, subcequent to repair of the j
original cracks. No additional cracks were found.
(INFORMATION ITEM) t l
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1 Notes of Daily Meeting Independent Assessroent of Underpinning Midland Plant, Units 1 & 2 Consurters Power Cortpany Held at Midland Site Midland, Michigan May 11, 1984 Item 86-22 Independent Assessrtent 270 Day Report P. Majeski stated that the 270 Day Report surntarizing the Assessrtent Team observations of the underpinning work perfonted since the 90 Ihy Report had been recently issued. He noted that the Assessttent Team will address follow-up of the conclusions and recoratendations contained in the report in the near fbture.
(INFORMATION ITEM)
Itert 86 NCR Trending by FSO P. Majeski requested an update on NCR Trending being perforrted by FSO.
J. Fisher stated that FSO has recently revised their in-house trending rtethod to include tracking of NCR trends for very specific w6rk activities. FSO trending tracks the nurtber of nonconforrtances for a given level of work effort.
The level of work effort is expressed as a quantity (e.g., nurtber of expansion anchors, cubic yards of concrete, etc.) which has been selected to best repre-sent the work effort for,a specific activity.
(INFORMATION ITEM)
Itert 86 Weekly Report #85 The text of Weekly Report #85 was reviewed.
It was deterrtined that all open iterts had been previously identified.
(INFORMATION ITEM)
Response Iterts No respense iterts were addressed.
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