ML20091F404
| ML20091F404 | |
| Person / Time | |
|---|---|
| Site: | Midland |
| Issue date: | 06/16/1983 |
| From: | James Keppler NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| To: | |
| Shared Package | |
| ML17198A223 | List:
|
| References | |
| CON-BOX-06, CON-BOX-6, FOIA-84-96 NUDOCS 8406020144 | |
| Download: ML20091F404 (4) | |
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REGIONAL ADMINISTRATOR j
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l Good morning Mr. Chairman and members of the Subcommittee. My name is James Keppler and I am Regional Administrator of the Nuclear Regulatory Commission's Region III (Chicago) office. I am. appearing before this Subcommittee today, in response to your May 6, 1983 request, to present testimony on behalf of the NRC staff concerning the NRC's procedures for handling construction quality issues at the Midland Nuclear Power Plant, l
specifically problems in the remedial soils and the Quality Assurance (QA) program areas.
The NRC has recognized that there have been significant problems at Midland. You will recall, Mr. Chairman, that at this Subcommittee's Hearing of November 19, 1981, on the subject of quality assurance, Chairman Palladino identified Midland as one of several facilities where there have been serious QA problems with broad repercussions. We want te sssure you, however, that before the NRC will issue Operating Licenses for Midland, we will be satisfied that the plant has been properly constructed and can be operated safely.
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i Since the inception of this project in 1970, there has been a series of
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QA problems. The most significant of these have been:
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inadequacies in splicing of concrete reinforcing steel in 1973, 2.
inadequate control of concrete rebar installation in safety-related structures in 1976, i
3.
omission of containment tendcas in 1977 and a bulge in containment
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liner in that same year,-
4.
failure to properly compact soil under safety-related structures, identified in 1978, 5.
deficiencies in the heating, ventilating and air conditioning system and deficiencies in reactor anchor studs identified in 1979, and
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problems in pipe suspension systems and electric cable routing, identified in 1981.
Additionally, a comprehensive NRC inspection of systems and components within the Diesel Generator Building conducted in 1982 ide=tified many construction problems which resulted from a b'eakdown in the implementa-r tion of the QA program.
Contrary to the Zimmer case where the NRC staff did not recognize the full significance of the QA problems as they unfolded, the NRC E:aff has been aware that there have been QA problems at Midland and has z= tempted to deal with them as they were identified.
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In 1981, I provided testimony to the Atomic Safety and Licensing Board (ASLB), presiding over the hearing on the remedial soils issues at the Midland' Plant. I testified on the more significant QA problems that had been experienced in connection with the Midland project and the corrective actions taken by Consumers Power Company and its contractors. I stated that, while many significant QA deficiencies had been identified, it was the NRC Staff's conclusion that the problems experienced were not indi-cative of a breakdown in the implementation of the overall QA program.
I also noted that while deficiencies had occurred which should have been identified earlier, Consumers Power Company's QA program had been generally effective in the ultimate identification and subsequent correction of these deficiencies. Furthermore, I discussed the results of Region III's special QA inspection, of May 18-11, 1981, which I had initiated to deter-mine whether modifications made to the QA program in August 1980 were effective. The results reflected favorably on the Midland Plant Quality Assurance Department, formed in August 1980 to improve QA performance.
The thrust of my testimony was that I had confidence in Consumers Power Company's QA program, both for the remedial soils work and for the remainder of construction.
In April 1982, I was made aware that additional significant QA problems were being encountered. This concerned me in view of my 1981 testimony to the ASLB. As a result I notified the ASLB that this previous' testimony would have to be modified, directed staff evaluations to assess the cause and correction of these problems, and created 'i special Section within the Region III office solely to handle the Midland facility. After reviewing the facility status and history, meetings were held with Consumers Power Company to dir:uss the NRC's concerns and to inform them that additional measures were required to assure the quality of the plant. In addition, the Midland Se: tion recommended and then conducted the comprehensive inspection of +ystems and components within the Diesel Generator Building.
As a result of the problems found in the Diesel Generator Building by the NRC staff and similar findings by Consumers Power Company in other areas, a number of a : ions have been or are being taken. These include:
1.
all safer, related work was stopped on December 2, 1982 by Consumers Power Cc=many except the following:
(1) nuclear steam supply system installe: don work, performed by Babcock & Wilcox; (2) heating, venti-lating, -=d air conditioning installation work performed by Zack Company; (3) post system turnover work; (4) hanger and cable rein-spectio:
(S) des. n engineering; (6) system layup activites and (7) rest..al soils work.
2.
a civil 3enalty of $120,000 was proposed in February 1983 for two violatio=a related to the findings from the inspection of the systems a=d components within the Diesel Generator Building, t
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a Construction Completion Program (CCP) is being developed by Consumers Power Company and is being reviewed by the NRC staff.
This CCP will require an evaluatu q of the quality of construc-tion completed to date and will p. ovide a team approach to complete future work. Furthermore, a separate review of the design and constructica of portions of three safety related systems will be performed by an independent third party (TERA Corporation).
2 Although these actions are encouraging and should lead to an acceptable QA program and assurance of plant quality, the NRC is requiring an additional third party overview of the TCP until the NRC determines that Consumers Power Company's QA program is effective on a sustained basis.
From a technical standpoint, the remedial soils work required to correct the settlement of safety related structures at Midland is complex and unique in the nuclear industry. Because of this complexity, Consumers Power Company developed a comprehensive remedial soils program. The design and construction methods for the necessary remedial work to support properly the affected safety-related structures have been reviewed and evaluated by the NRC Staff, as set forth in the Safety Evaluation Report related to the operation of Midland Plant, Units 1 4
and 2 NUREG-0793, Supplement No. 2.
During the course of remedial soils work, problems have been identified by both Consumers Power Company auf NRC inspectors. As a result of these problems, the ASLB issued an order in April 1982 requiring Consumers Power Company to obtain prior NRC staff authorization for remedial soils measures. In August 1982, Censumers Power Company and the NRC staff agreed to a Work Authorizatic: Procedure, under which the NRC staff would review and authorize re:edial soils activities before they are conducted. Remedial soils we-k at the site is presently reviewed and authorized under this procede a.
To provide assurance that the remedial soils activities are being conducted in accordance with established QA requirements, the NRC staff also requested Consumer: Power Company to r'etain an independent third pa-ty to overview the remedial soils work activities. Stone and Webster was selected for this role by Consumers Power Company and was subsequently approved by the TRC.
They have been onsite performing the independent overview since Se:tember 20, 1982.
Mr. Chairman, I have attempt-to summarize the significant issues with
.I respect to remedial soils pre less and problems in the QA area at Mildand.
I will be happy to respend tt questions concerning the Midland project.
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James W Cook f
Vice President - Projects, Engineering and Construc* ion
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Generet offices: 1948 West Pernall Road Jockeen. M4 492o1 * (517) 758 0453 i
March 29, 1983 Y
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Mr J G Keppler, Regional Administrator US Nuclear Regulatory Connaission Region III 799 Roosevelt Road Lj)
Glen Ellyn, IL 60137 MIDLAND ENERGY CENTER PROJECT DOCKET NOS 50-329 AND 50-330 RESPONSE TO SUPPORT REINSPECTION FILE 0.4.2 SERIAL 20746
Reference:
A.
R F Warnick letter to J W Cook,
Subject:
Support Reinspection dated August 30, 1982.
B.
J W Cook letter to J G Keppler,
Subject:
Support Reinspection dated November 15, 1982.
Reference A requested our schedule for the reinspection of the supports at the Midland site. Reference B identified our planned actions in this area and indicated that we expected to commence support reinspection by January 1, 1983.
Our recent effort in planning and developing the_ Construction Completion Program (CCP) has resulted in a revision to the planned actions and schedule.
j Considering the current status of construction activities, we no longer believe the approach outlined in Reference B to be consistent with timely completion of the project.
We now intend to reinspect all installed supports irregardless of the time of 4
their installation or turnover. We expect the new support reinspection procedure, training and certification of inspection personnel, QA program revisions, and other support activities to be in place so that we can commence support reinspections during the week of April 11, 1983. It is estimated that the support reinspection program will extend into 1984.
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CC RWarnick, NRC Region III WShafer, NRC Region III RGardner, h7C Region III RJCook, NRC Resident Inspector, Midland Site BBurgess, NRC Region III c
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'AUG 4 abi M5HORAMDUM FOR: Ession III Files FRON:
- 1. F. Warnick, Director, Office of Special Cases j
SUBJECT MEETING WITH CONSUMERS POWER COMPANY REGARDING CURRENT MIDLAND PROBL1!MS A meeting was held between Mr. James Sook of Ccasumers Power Company (CPCo) Mr. Gerald Charnoff, legal coursal for CPCo, and the NRC (Messrs. Esppler, Warnick, and Barrison of RIII and Messrs. Eisenhut and i
Novak of MER) at the NRC Glen Ellyn office on July 28, 1983. The purpose of the meeting (which was requested by CPCo) was to discuss current management problems at Mid1==A MRC's perception of management performance, and Consumers interface with the MRC. The discussion focused on the MRC perceptions of the problems and top Midland management's attitude and performance.
" Original'signe _d by.R. F. Warnick"
- 1. F. Warnick, Director Office of Special Cases cca
- 1. C. DeYoung D. G. 1E4===h=t i
T. M. Novak J. Lieberasa J. C. Stone l
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'AUG 4 1983t M5HORANDUMYOR: Region III Files j
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- 1. F. Warnick, Director, Office of Special Cases
SUBJECT:
MRETING WITH CONSUMRRS POWER COMPANY ascannING CURRENT MIDLAND PROBLENS A meeting was held between Mr. James Sook of Consumers Power Company j
(CPCo) Mr. Gerald Charnoff, legal counsel for CPCo. and the ERC (Messrs. Rappler, Warnick, and Harrison of RIII and Messrs. Eissahut and i
i Novak of MER) at the ERC Glen Ellyn office on July 28, 1983. The purpose of the meeting (which was requested by CPCo) was to discuss current management probleme at Mid1m=A MRC's perception of management performance, and Consumers interface with the NRC. The discussion focused on the NRC perceptions of the problems and top Midland management's attitude and performance.
" Original ~signe_d_by.R. F. Warnick" R. F. Warnick, Director Office of Special Cases ces R. C. DeYoung D. G. ui=aah=t T. M. Novak J. Lieberman J. C. Stone DMB/ Document Control Desk (RIDS) 1 g50%I0 " fg 4-
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ga me' UNITED STATES MUO*.C.*.T. 7.00U: ".T07.'.' 00*.**.*.::: C::
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799 ROOSEVELT RoAo cLEN ELLYN, ILUNolS 50137
,g AUG 3 1 1983' Docket No. 50-329 Docket No. 50-330 t
HEMORANDUM FOR:
U. Potapovs, Chief, Vendor Programa Branch, Region IV FROM:
R. F. Warnick, Director, Office of Special Casas
SUBJECT:
REQUEST FOR POLLOWUP ON POTENTIALLY GENERIC PROBLEM-REGARDING TRANSAMERICA DELAVAL DIESEL GENERATOR EXHAUST SILENCERS Enclosed is a memorandum from R. Cook of my staff identifying a problem with the Midland Diesel Generator Exhaust Silencers not being designed and fabricated as being safety-related/ seismic Category I qualified.
Mr. Cook's memorandum also points out that Transamerica Delaval had stated to Consumers Power Company (CPCo) that although they had provided safety-related equipment to other nuclear sites, they did not consider the silencers to be performing an active safety-related function. Also included as part of this enclosure is a note from D. Hood, NRR, to E. Jordan, IE, containing pages of the ASLB Hearing session of July 29, 1983, which documented this same subject and a letter from Isham, Lincoln,
& Beale (attorneys for CPCo) to the ASLB, further clarifying the silencer "Q-ness."
Region III requests the Vendor Program Branch to evaluate the generic 4
c.spects of this problem including applicability to other diesel generator vendors and the applicability of 10 CFR 21 reporting requirements for Transamerica Delaval.
Should you have additional questions concerning this matter please contact J. Harrison (384-2635) of my staff.
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R. F. Warnick, Director Office of Special Cases 4
Enclosures As stated i
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DNB/ Document Control Desk (RIDS)
R. Cook, RIII R. Spessard, RIII C. Norelius, RIII Director, DPRP, RI i
Director, DPRP, RII
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Director, DRRPEP, RIV, RV f
R. Heishman IE
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s UNITED STATES NUCLEAR REGULATORY COMMISSION 3
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790 ROo8EVELT ROAO
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OLEN ELLYN, ILLINOIS 80137 1
August 10, 1983 i
MEMORANDUM FOR:
J. J. Harrison, Chief, Office of Special Cases, Section 2 FROM:
R. J. Cook,' Senior Resident Inspector, Midland Site
SUBJECT:
MIDLAND DIESEL GENERATOR EXHAUST SILENCERS Consumers Power Company supplied additional information responding to an item of noncompliance identified in NRC Inspection Report 50-329/82-22; 50-330/82-22 (Item 82-22-08) by letter to Mr. J. G. Keppler, Regional Administrator dated l
July 12, 1983. In this response (ltr dtd July 12, 1983) Consumers Power Company
_ stated that, "TDI (Transamerica Delaval, Inc.) has stated that they had not pre-
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viously provided safety-related exhaust silencers to others, and did not consider the silencers to perform an active safety-related function." This sentence was discussed on July 29, 1983 at the ASLB Hearings. I responded to Board question-ing by stating that perhaps Transamerica Delaval, Inc. should have made a 10 CFR 50 Part 21 notification when it was established that non-safety-related silencers were supplied.
The Headquarters Daily Report for July 28,1983 (copy attached) states that a Part 21 notification had been made '3y Gilbert Associates pertaining to the diesel generators at the Perry Nuclear Power Station and the ability of the exhaust system as designed to elevate the engine back pressure. A telecommunication with the Resident Inspector Office at the Perry Plant revealed that Perry uses Transamerica Delaval, Inc. diesel generators.
The Part 21 notification by Gilbert Associates at the Perry Plant adds credence to my belief that Transamerica Delaval, Inc. should make a Part 21 notification pertaining to diesel generator exhaust and intake systems not being safety-related.
(reference CPCo NCR M01-9-3-158 and FSAR Table 3.2-1 attached) t a
R. J. Cook Senior Resident Inspector Midland Site ec/ attachments B. L. Burgess S
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HEADQUARTERS DAILY REPORT JULY 2R. 1983 01Vi&I0%Q Q RSENCY PREPAREONE5$_AND ENGlWEERIMS_RESPONSC le POTENTIAL PART 21 = ON JULY 27, 1983e IE (ROBER I BAERI RECEIVED A POTENTIAL PART 21 NOTIFICATION FRO 4 MR. w!LLIAM SAILER OF 61LUERT ASSOCIATES. THE 40TIFICATION CONCERNE0 THE EXHAUST SYSTEM FOR THE DIESEL GENERATOR (Det UNITS FOR THE PERRY NUCLEAR P0mE t STATION AND 15 BELIEVED TO BE UNIQUE TO THOSE PLANTS.
DURING DESIGN OF N001FICAT10NS TO THE DG ENHAUS I SYSiEMe GILBERT ASSOCIATES RECHECKED THEIR CALCULATIONS.
THEY CONCLUDED THAT THE EXHAUST SYSTEMe AS DESl iNED, WOULD HAVE RESULTED IN A DG BACK PRESSURE THAT l
k EACEEDED THE MANUFACTURER'S RECOMMENDATIONS.
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POTENTIAL PART 21 - 04 JULY 2To 1983, IE tRORER I BAERI RECEIVED A POTENTIAL PART 21 NOTIFICATION FROM MR. ROBERT BRADLEY OF SIEMENS-ALLIS CORPORATE O rFICES IN ATLANTA, GEORGIA. 4 O! VISION OF THE COMPANY LOCATED IN NORw000. OH10 MANUFACTURERS MOTORS.
IN 19T9 AND 1980, A TOTAL OF FOUR HOTORS FOR AURILIARY FEE 0 WATER PUMPS WERE PROVIDED FOR SAN ONOFRE UN ITS 2 AND 3.
RECENTLYe PROBLEMS DEVELOPED AND ONE MOTOR AND SEARINGS wERE RETURNED TO THE MANUFACTURER IN JULY 13, 1983.
THE 40 TORS WERE DISASSEMBLE 0 AND EAAMINED. IT wAS FOUND THAT THE LORRICATION GR30VES IN THE SLEAVE BEARINGS HAD NOT BEEN MACHINED TO THE CORRECT DEPTH. THE PROBLEM !$ BELIEVED 10 IE UNIQUE TO THE SAN ONOFRE 2/3 MOTORS wHICH HAVE BEEN REw0RRED AT THE SITE.
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1 MIDLAND 1&2-FSAR TABLE 3.2-1 (continued)
Design FSAR Quality Code /
Seismic System / Component Section Location Group Standard Category Engine driven G
D DEMA I
30 jacket water t
pump Piping and valves 15 Engine mounted
- G NA DEMA I
27 Non-engine mounted 0,G C
III-3 I
30 Diesel Generator 9.5.6 Starting System Air receivers G
C III-3 I
Compressors G
NA NA NA Air dryers G
NA NA NA l15 Piping and valves Air receiver to engine G
C III-3 I
Compressor to receiver G
D B31.1 NA 15 Engine mounted G
NA -
DEMA I
Filters G
NA NA I
Diesel Generator 9.5.7 Lubrication System Lube oil cooler G
C III-3 I
C III-3 I
tank 30 Auxiliary lube G
C III-3 I
oil pump Engine driven lube G
D DEMA I
oil p'2mp Lube oil keepwarm G
C III-3 I
l30 pump Piping and valves Engine mounted G
NA DEMA I
l15 Aux skid mounted G
C III-3 I
Diesel Generator 9.5.8 Combustion Air Intake and Exhaust System Turbocharger G
NA DEMA I
Intake air louvers G
NA NA I
(sheet 35)
Revision 34 6/81
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o MIDLAND 1&2-FSAH TABLE 3.2-1 (continued)
Design FSAR Quality Cade/
Seismic System / Component _Section Location Group Sta:idard Category Intake filters G
NA NA " "
I l15 Ducts and dampers G
NA SMA/ 'NA I
1 Intake and G
NA NA l I
exhaust silencers Chemical Waste 9.5.9 System
.rpi Motors e
E,T NA NEMA MG-1 NA Pumps B,T D
HI NA Piping and valves U,E,T D
B31.1 NA Oily Waste 9.5'.10 System Motors E,P,T NA NEMA MG-1 NA Pumps E,P,T D
HI NA Piping and valves E,0,T,U,P D/NA B31.1 NA l21 Tanks P
D API-650 NA (sheet 36)
Revision 34 1
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NOTE TO:
E. L. Jordan Director at tits (n,,
Division of Engineering and Quality Assurance FROM:
Darl Hood, Project Manager Licensing Branch No. 4 Division of Licensing t
SUBJECT:
POTENTIAL PART 21 ISSUE REGARDING INTERNAL DIESEL GENERATOR MUFFLER FAILURES A potential Part 21 issue was identified during a hearing session on the Midland Plant, July 29, 1983. The issue-is whether or not non-seismic mufflers and exhaust systems for diesel generators can fail i a manner which would restrict the exhaust flow path and thereby, adver impact starting or subsequent operation of the emergency diesel gene tors l
following a seismic event. Enclosed hearing transcript pages 19535-19537 and James W. Cook's letter of July 12, 1983, describe this concern.
The issue is not restricted to the Midland Plant. Non-seismic mufflers l
and exhaust systems provided by Transamerica Delavel, Inc. (TDI), to other nuclear plants have not been designed to safety-related requirements.
Because the design is being corrected to be Category I on the Midland Plant, no seismic analyses of exhaust blockage potential has been provided to the NRC during its Midland review.
I also do not know whether the problem applies to plants with diesel generator vendors other than TDI.
Darl Hood, Project Manager Licensing Branch No. 4 Division of Licensing
Enclosure:
As stated cc: See next page f
t sugy AUG 29 S83
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19535 5Ib1 I
JUDGE BECHHOEFER:
Yes, there has been.
The other 2
way around.
3 MS. BERNABEI:
I think it has been that Category d
1 is always Q.
I 5
JUDGE BECHHOEFER:
Everything that is Seismic 6
, Category 1 is Q.
7 MS. BERNABEI:
The assumption of this is that Q 8
can be broken down to Category 1 and non-Q.
9 MS. LAUER:
If I can ask a preliminary question.
10 BY MS. LAUER:
11 Q
Back of the whole system is Q.
Does that mean j
12 every ccmponent in the system is necessarily Q?
1 13 A
First off, I do not know if it says that the whole Id system is Q, to be honest with yon.
I cannot answer that 15 question without having an opportunity to go back and review l
16 the words in the FSAR.
The thing was, in our prosa, we 17 indicated that -- if I remember right -- that these particular o
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18 portions, pertaining to the muffler system, that that was 3
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required to be safety related, as defined by the FSAR.
Ij 20 MS. LAUER:
No further questions.
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l 21 BOARD EXAMINATION i
j BY JUDGE HARBOUR:
22 8
23 Q
Referring to Consumers Power Exhibit 51, which j'g 24 is tpe letter to Mr. Keppler from Mr. Cook --
25 A
The Jul'y letter, July 12th letter?
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19536 1b2 1-Q That's right.
Correct.
Section C-2 -- starts 2
on the second page of C-2.
The first sentence, starting with 3
TDI, which stands for TransAmerica DeLaval.
Do you see that d
sentence there?
5 A
Yes.
I see s,everal starting with TDI.
At the 6
. top you mean?
7 Q
The top of the page.
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Okay.
Yes, sir.
9 Q
Are silencers on diesel. generators always Siesmic
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10 Category 17 11 A
I feel that they should be.
I cannot say whether 12 they always are.
The reason I feel that way is because it 13 is imperative that the diesel generator be able to function Id during the earthquake events.
So if any damage could be i
4 15 sustained by either the intake or the exhaust, it would cripple i
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the engine since it would either not put out its required 1
I 17 amount of power or would not run at all, depending.
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In other words, you believe the diesel generator --
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diesel engine on the generator would not run if the muffler was i
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It would run if the muffler was disconnected.
My E
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3 concern would be that the muffler would close off the exhaust 5
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or that a portion of the piping would become choked or such i
24 that.it would reduce the flow of exhaust gases from the engine.
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The.same concern would also apply to the intake side of she l
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engine.
2 Q
Do you know whether TransAmerica DeLaval has furnished diesel generators to be used at sites in California, d
or a site?
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es, they have and I'm trying to think what site 1
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.it was.
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I want to say Rancho Seco, if I recall right.
When 7
they issue a Part 21 notice, they put the listing of the a
affected plants and if I remember right on one of those
,j listings there was a California plant listed., I think it f
30 was Rancho Seco, but I do not want Jo say for[sure without 11 checking.
i 12 Q
To you knowledge, do all sites for ' nuclear power 13 plants in California have larger safe shutdown earthquakes Id than Michigan?
15 A
Yes, to my knowledge.
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Q Do you have any comment, then, on the statement i
17 that TransAmerica DeLaval has stated that they have not Is previously provided safety related exhaust silencers to others?
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I personally feel that IransAmerica DeLaval should 3
issue a Part 21 if that is truly the. case.
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You were asked about the root cause.
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22 description it seemed to me that the fact that the drawing 8
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did not indicate that the muffler should be Seismic category 2d I were limiting to all of the other problems.
No matter what 25 anybody did, if they referred back to the basic drawing and it i
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Vice ttesidentut and Constinnetb.QitCLt.Enstnesrima y._ A J Oeaeral O ffiese: 194e W,et Pernell Reed, Jesteen, Me de201. (St 78 788 o453 July 12, 1983 Eb 399 50 330 Mr J G Keppler, Regional Administrator US Nuclear Regulatory Commission Region III 799 Roosevelt Road Clan Ellyn, IL 60137 MIDLAND ENERGY CENTER DOCKET NO 50-329 AND 50-330 - AMENDED MIDLAND PROJECT RESPONSE TO NRC, REGION III LETTER DATED MAY 23, 1983 File: 0485.16 UFI: 42*05*22*04 Serial: CSC-6781 0.4.2 70*01
REFERENCES:
(1) J W Cook letter to J G Keppler, dated June 24, 1983, Serial CSC-6764 (2) J 0 Kappler letter to J W Cook, dated May 23, 1983 This letter, including Attachment 1, and in addition to Reference 1, provides our acended response to Reference 2.
We appreciate your consideration in extending the due date for this response in order that our personnel could properly examine the vendor information available and hopefully provide a thorough and accurate response. This was discussed with your Mr. R. Cook.
b JWC/ BHP / kin ec: RFWarnick, NRC Region III JJRarrison, NRC Region III RNGerdner, NRC Region III 1
RJCook, NRC Senior Resident Inspector, Midland Site RBLandsman, NRC Region III BLBurgess, NRC Resident In'spector, Midland Site C
4 ht m 2 01933 OC0783-0004A-CN01, gj h\\
i CONSUMERS POWER COMPANY Midland Units 1 and 2 Docket No 50-329/50-330 Letter Serial CSC-6781 Dated July 12, 1983 At the request of the Commission and pursuant to the Atomic Energy Act of
'1954, and the Energy Reorganization Act of 1974, as amended and the Commission's Rules and Regulations thereunder, Consumers Power Company submits the anended response to J G Keppler letter to J W Cook dated May 23, 1983.
CONSUMERS POWER COMPANY By I
J Cook, Vice President-Pro cts, Engineering and Construction Swornandsubscribedbeforemethis/
ay of n /,, /98.
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_T -6[-[h PATRIC1A A. PUFFER Notary Public. Bay County. Mt My Commissica Empires Mar. 41M8 e
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Amended Response to J G Keppler letter to J W Cook dated May 23, 1983 The amended response to J G Keppler letter to J W Cook dated May 23, 1983 is submitted in the following format:
NOV Item B Identification Number A.
Statement of Original Violation (from J G Keppler letter to J D Selby dated February 8, 1983: Notice of Violation EA 83-3.)
B.
Request For Additional Information (from J G Keppler letter to J W Cook dated May 23, 1983.)
C.
Statement of Additional Information 1.
Admission or denial of the alleged violation 2.
The reasons for the violation, if admitted 3.
The corrective steps which have been taken and the results achieved 4.
The corrective steps which will be taken to avoid futher violations 5.
The date when full compliance will be achieved t.
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OC0783-0004A-CN01
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OL/OM SERVICE LIST Mr Charles Bechhoefer, Esq Mr Frank J Kelley, Esq AdminiJerative Judge Attorney General of the Atomic Safety & Licensing Board Panel State of Michigan U S Nuclear Regulatory Commission Mr Stewart H Freeman, Esq Washington, DC 20555 Assistant Attorney General Environmental Protection Div 720 Law Building Lansing, MI 48913 Dr Frederick P Cowan Mr Myron M Cherry, Esq Administrative Judge Cherry & Flynn 6152 N Verde Trail 3 First National Plaza Apt B-125 Suite 3700 Boca Raton, FL 33433 Chicago, IL 60602 Mr Michael Miller, Esq Mr Wendell H Marshall Isham, Lincoln & Beale RFD 10 3 First National Plaza Midland, MI 48640 Suite 5200 Chicago, IL 60602 Mr D F Judd, Sr Project Manager Mr John Demeester The Babcock & Wilcox Company Dew Chemical Building P O Box 1260 Michigan Division Lynchburg, VA 24505 Midland, MI 48640
.i Atomic Safety & Licensing Board Panel Ms Mary Sinclair U S Nuclear Regulatory Commission 5711 Summerset Street Wcshington, DC 20555 Midland, MI 48640 Atemic Safety & Licensing Board Panel Mr Steve Cadler U S Nuclear Regulatory Commission 2120 Carter Avenue i
Washington, DC 20555 St Paul, MN 55108 Mr William D Paton, Esq Mr Lee L Bishop j
Counsel for NRC Staff Harmon & Weiss i
U S Nuclear Regulatory Commission 1725 I Street, NW #506 Washington, DC 20555 Wa-hington, DC 20006 3
Ms Barbara Stamiris Mr C R Stephens 5795 North River Read Docketing and Service Station Route 3 Office of the Secretary Freeland, MI 4
- ,8623 U S Nuclear Regulatory Washington, DC 20555 Dr Jerry Harbour Lynne Bernabei U S Nuclear Regulatory Commission Governmental Accountability Atomic Safety & Licensing Board Panel Project (CAP)
Washington, DC 20555 1901 Q Street NW Washington, DC 20009 OC0783-0004A-CN01
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i-I NOV Item B - 2.a (82-22-08)
A.
Statement of Original Violation
" Measures were not established for the selection and review for suit-j ability of application of "Q" materials associated with the diesel gener-stor exhaust muffler in that design drawings and specifications did not i
indicate the material identity of the installed muffler saddle supports and plates."
l 3.
Request For Additional Information I
1 l
"Regarding Iten B.2.a. we reiterate our position that the lack of design documentation which specified the material requirements for the diesel generator exhaust sufflers constituted an ites of noncompliance. Please provide any additional information supplied by the vendor regarding the traceability of tha a h=a-t suffles-esteedele, ;;d es.ryseysi.i.,
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corrective actions and the results achieved, corrective actions taken to avoid further noncompliance, and the date when full compliance will be achieved."
C.
Statement of Additional Information t
i 1.
The violation is admitted.
1 2.
The violation occurred because the design intent was not implemented i
in the design, fabrication and inspection of the exhaust silencerc I
the diesel generator prime supplier, Trans' america Delavel, Inc.,
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(TDI). This was not recognised or corrected by the design organiza-tion responsible for the procurement. The design intent was that the diesel generator exhaust silencers be subject to the appropriate elements of 10CFR50, Appendix B, and ANSI N45.2-1971.
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The Bechtel procurement documents for the diesel generators specify 4
the functional performance requirements of the diesel generators. It is not the intent to specify all details of design and construction.
j The expertise for the detailed design and construction of the diesel j
generator and accessories rests with TDI.
I The procurement documents (Specification 7220-N-18 Farsgraph 12.2) l specified; " Quality assurance requirements are applicable to all components and assemblies which affect the reliability and ability of i
the equipment furnished by the galler to perform its design function."
Additionally, the specification p*rovides a check of this requirement j
hy regairing the vendor to submit a list of all items which he intends to supply as "Q" for review by Bechtel. When properly $mplemented, these requirements in Specification 7220-N-18 provide adequate direc-tion to the vendor and control by Bechtel. Bechtel did not take i
action to correct the failure of TDI to fully comply with the require-l ments of Specification 7220-M-18 Paragraph 12.3 to submit a " list of l
all itene to be furnished to quality control standards."
OC0783-0004A-CN01
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TDI has stated that they had not previously provided safety-related exhaust silencers to others, and did not consider the silencers to perform an active safety-related function. Specification requirements were not understood by TDI to apply to the exhaust silencers. As a result, the exhaust silencers were not included as an item to be safety-related. TDI procured the exhaust silencers from a sub-supflier, American Air Filter (AAF), with essentially commercial l
quality standards. TDI did specify to AAF that material cert-ification, weld procedures, and weld procedure qualifications be provided. AAF did not fully comply with the purchase order require-ments of TDI. TDI did provide a seismic analysis of the exhaust silencers to verify the capability to withstand a safe shutdown earthquake.
l The procurement documents leave the' selection of materials for cons-l truction of the exhaust silencers to TDI and AAF. The asterials of construction were selected by AAF and specified in the fabrication drawing based on its experience. Common grades of steel (e.g., A-36 and A-569) are typically used.
TDI provided a certificate of conformance to the purchase requirements for the exhaust silencers and the saddle suppport modification plates as required by the procurement documents. That information is on site. If the exhaust silencers and saddle support modification plates had been identified by TDI as having a safety-related function, they i
would have been included under the TDI quality assurance program.
That program would have required actions to be taken to assure approp-rists asterial identification and control. Specific material trace-ability (i.e., certified material test reports) is not applicable i
because of the design and function of these items.
3.
The following corrective' action for the exhaust silencers has been takent We have met with TDI and visited AAF, and subsuppliers at l
their facilities, and reviewed all available purchasing and quality l
documentation. TDI will provide a Material Certificate of Compliance to confirm that the materials used were consistent with the seismic i
l analysis. TDI has been directed to provide a fabrication inspection procedure to verify that construction of the exhaust silencer satis-fios the design and seismic analysis. This inspection will be per-formed on site under the directic'n of MFQAD. If any deficiencies are 4
found during the inspection, the silencers will be reworked to conform j
i.
to the requirements.
In accordance with the partial redisposition of NCRs 4693 and 4994, auffler saddle support end and center support plate extensions are to 4
be replaced because the dimensions of the slots / holes do not conform to the design drawings. Replacement plates will have material car-i tificates of compliance.
I Project Engineering and TDI have reviewed the technical specifications i
to determine if other items have been considered to be non-safety l
related contrary to the design intent. To date, the intake air l
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filters, intake air silencers, intake air flexible connectors, and exhaust expansion joints have been identified as not being considered j
safety related by TDI, and consequently not provided as safety related. An action plan to upgrade these items to safety-related-status by verifying that the construction of these items satisfies the design and seismic analysis is underway. NCRs M-01-9-3-158 and 4955 I
have been written to document the indeterminant status of these components.
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Further investigation to ascertain if there are any additional suspect items in the package provided by TDI is in progress and is expected to be complete by August 13, 1983.
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4.
The general approach to ensure that purchased material / equipment is i
l fabricated in accordance with the specification requirements is as follows: The Project Engineering review and acceptance of vendor submitted documents required by the specification such as drawings, i
procedures, and quality assurance manual; the Procurement Supplier Quality Department's performance of audits on adequacy of vendor i
quality program implementation and source surveillance inspections at the vendor's facility as required by the purchase order; the QC l
performance of receipt inspection to verify supplier submittal of the i
required documentation on "Q" items that are received on site; the I
Supplier Quality Review of the required documentation for adequacy; and MPQAD/QA performance of a quality overview inspection on selected items on site.
i
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In view of the experNnces on this procurement, we will conduct a review of functional / performance oriented procurements which contain i
"Q" and non "Q" items to verify that safety-related items were desig.
i nated by the vendors in accordance with project design requirements.
A review program and schedule will be developed by September 10, 1983.
5.
Full compliance will be achiered when.:
~
4 a) Receipt of the exhaust silencer Material Certificate of Compliance and completion of the fabrication inspection is expected by l
l October 15, 1983. A schedula for any subsequent rework as a result of the inspection will be established at that time.
b) The exhaust silencer saddle support and center support plate extensions are replaced and NCRs 4693 and 4994 are dispositioned.
c) MCRs M-01-9-3-158 and 4955 will be resolved by October 15, 1983.
c A. schedule for any subsequent rework resulting from this resolu-tion will be established then.
d) Further investigation to ascertain if there are any additional suspect items in che pack. age provided by TDI is expected to be cceplete by August 15, 1933.
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'N' E M Hughes, Bechtel AA K E Marbaugh, QA-NO, Mailand B W Marguglio, JSC220A h D E Miller, Site Manager \\(3) nau d4WHpondence File, P24-517 J A Rutgers, Bechtel AA P Steptoe. IL & B, Chicago R A Wells, MPQAD F C Williams IL & B Washington
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~4 piesel Generator intake (combustion air) and exhaust systems includ-1 N ;;
ing silencers, turbochargers, filters, ducts, dampers and louvers to 3 gegy, MMfiler
:ff be designed in accordance with Seismic Category I requirements.
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EHFeck i,. sascourem, JAnutgers M:*.rland Contrary to the above, only the unsupported shell (not including r;;:etrich TKSubrasarian internal components) of the silencers have received a seismic l
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re-design all above components, in their entirety, in accordance
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required to be s41st;tes11y qualffied by the FSAR/Specificetion'to' evsure thst-alli,.
components supplief by this vendor cr his supplier's compl9,with *.hese' requirements.
2, MPCAD is to receive P.he above documentation for review and, concurrence.
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.o NCR # tCl-9-3-158 Page 3 of 3 Block 16 (continued ):
Specification 7220-M-18(Q), R. 8; Appendix A - Design Data for Emergency Diesel Generators...., Article 2.1 states in part ".
the Energency Diesel Generators and their auxiliaries are designated Seismic Category 1 and shall be designed...."
Bicek 18 (continued ):
2.
If the existing, installed components are deemed by the vendor as acceptable without removal, the vendor is to submit to Bechtel documentary justifica-tion for this action.
3 If the existing components do not meet Seismic Category 1 Criteria, vendor is to replace them with acceptable components.
4 MPQAD is to review a7d concur on Corrective Action Items 1 through 3 above.
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August 12, 1983
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UNITED STATES OF AMERICA PRINCIPAL STAFF NUCLEAR REGULATORY COMMISSION RA t//,
ENF D/RA SCS G
BEFORE THE ATOMIC SAFETY AND LICENSING BOARD A/RA PAOM DPRP 5LO j
DiGA RC / s,. _
In the Matter of:
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Docket Nos. 50-329 OM W SF
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50-330 OM DE CONSUMERS POWER COMPANY
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Docket Nos. 50-329 OL ML (Midland Plant, Units 1 & 2)
)
50-330 OL OL l FILEfM /
Dr. Frederick P. Cowan 6152 North Verde Trail Apt.68-125 Boca Raton, Florida 33433 Dr Jerry Harbour Charles Bechhoefer, Esq.
Atomic Safety and Licensing Atomic Safety and Licensing Board Panel Board Panel U.S. Nuclear Regulatory U.S. Nuclear Regulatory Commission Commission East-West Towers East-West Towers Room E-454 Room E-413 4350 East-West Highway 4350 East-West Highway
.i Bethesda, Maryland 20014 Sethesda, Maryland 20t,14
Dear Administrative Judges:
At the last hearing session, Judge Harbour re-quested that Consumers Power determine the date as of which the FSAR specified that the diesel' generator exhaust system should be Seismic Category I.
This letter and the accom-panying attachments are intended to respond to that inquiry.
Mr. Bruce Peck testified that Bechtel issued the 3
.specifications to Transamerica DeLavel, Inc. ("TDI") for the i
procurement of the diesel generator system in approximately May of 1977.
(Transcript at 19563).
At that time the FSAR
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had not yet been issued and the governing document was the i
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Dr. Jerry Harbour Charles Bechhoefer, Esq.
Dr. Frederick P. Cowan
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August 12, 1983
~ Page Two PSAR.
Appendix 5A of the PSAR lists the emergency gen-erators as a Class 1 system.
The PSAR further states that
)
"[w] hen a system as a whole is referred to as class 1, portions not associated with loss of function of the system are designated as Class 2."
(Attachment A includes the relevant pages of the PSAR).
The design criteria for Class 1 and class 2 systems and equipment set forth in PSAR Ap-pendix 5A do not refer specifically to Q-ness.
However, the procurement documents supplied to TDI specified that "(q)uality assurante requirements are applicable to all components and aasamblies_which affmet +ha rati=hi14ty
==d
=lility of the equipment furnished to the Seller to perform its design function."
(C.P.Co. Exhibit 51).
The FSAR was submitted to the Midland docket in November of 1977. Attachment B to this letter includes a portion of FSAR section 9.5.8, " Diesel Generator Combustion Air Intake said Exhaust System."
Revisions to the original FSAR are noted in the right hand margin of the pages with a vertical line marking the portion revised and an accom-panying number indicating the revision which incorporated the change.
The pages included herein indicate that the diesel generator exhaust system was to be designed in ac-i cordance with Seismic Category I requirements (59.5.8.3) and that codes and standards indicated in Table 3.2-1 should Le applied to the exhaust system (59.5.8.1.3).
These require-ments have been a,part of the TSAR since November of 1977.
l As Attachment C to this letter, I have provided relevant portions of FSAR section 3.2,'
" Classification of Structures, components, and Systems," including pages from l
Table 3.2-1 referred to above. Table 3.2-1 lists the diesel l
generator intake and exhaust silencers r.s Seismic Category I and provides that design requirements were to be specified
~
by the designer "with appropriate consideration of the intended service and operation conditions."
These require-
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ments have also been a part of the FSAR since November of 1977.
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In order to provide greater clarity and more de-l tail, the Project Q-list was revised in May of 1983. This i
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Dr. Jerry Harbour Charles Bechhoefer,1sq.
Dr. Frederick P. Cowan
- August 12, 1983 Page Two Revision 10 breaks down components of the diesel generator system and now lists the exhaust silencers specifically as Q items.
(Attachment D provides the relevant portions of the cmtrent Q-List).
At the time when the diesel generators were ordered, Revision 7 to the Q-list did not provide this level of detail.
(See Attach:nent E).
The appropriate use of the categorizations Seismic Category I and Q-listed is further clarified in Consumers Powers' responsa to DGB Notice of Violation Item B-2e which states that strtictures, systems, or components identified r.s Seismic Category I are considered Q and project QA program requirements are to be applied to them. A review was per-formed to confirm that where the Seismic Category I'desig-nation was applied to structures, systems, or components QA program requirements had been applied.
(See Attachment 1 to B. Pack testimony following Tr. 18921 at p. A2-24).
Very truly yours, Rebecca J. Lauer One of the Attorneys for l
CONSUMERS POWER COMPANY l
I RJL:bc Encs.
cc:
Midland Service List (w/enes) l e
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ATTACHMENT "A"
APPElIDIX SA rISIG*l PASIS FOR STRU""IVFIS, SYSTE'G A*:D E;UIPII:T -
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.CENERAL De design bases for structures for normal operating conditions are governed by the appli able building design codes. The design bases for specific systems and equipn.ent are stated in the appropriate PSAR Section. The basic design cri erics for the envi-u: less-of-coolant accident and ceic=ic condi-tions is that there be no loss of function if that function is related to public safety.
CIASSES OF STRTTUP.ES, SYSTE".5 A!!D EQUIPIGFT CLASS 1 Class 1 structures, systems and equipment are those vhese failure could cause release of radioactivity which would exceed 10 CFR 20 limits at the site bound-ary or these essential for insediate and long-ter= operation following a less-of-ecolant accMant or those necessary for safe shutdown. When a syste= as a whole is referred to as Class 1, portions not associated with loss of function of the system are designated as Class 2. '
The following are typical Class 1 structures:
Reactor buildings.
Portions of the auxiliary building housing the engineered safeguards systems, centrol room and radioacttve materials.
Enclosures for the service water pumps, auxiliary fe,ed-water pu:ps 4
3 and diesel generators.
1 Diesel fuel storage facilities.
Supports for Class 1 system components.
Typical Class 1 equipment and systems follow:
Reactor vessel and internals including control rods and control rod drives.
Other reactor coolant system components (steam generators, pressur-
~
iter, pumps, etc) and piping, including vent and drain piping inside the reactor building.
Reactor building penetrations up to and including the first isola-
)
tion valve outside the reactor building.
1 Main steam and main feed-water piping up to the first stop valves outside the reactor building.
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5A-1 Amend:ent No. 6 12/26/69 j
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new and spent fuel stcruce ract.s and fai nar.dling equipent., in-clading the crane above the fuel pool (unloaded conditien).
Motor-driven and steam-driven auxiliary feed-water systems.
~
Emergency generators including fuel supply.,
Reactor building crane (unloaded condition).
Control boards, switchgear, load centers, batteries, transformers, and cable runs serving Class 1 equipment.
Service water systems (critical portions).
Cc=penent cooling (critical portions).
Reactor building spray system.
Reactor building air recirculatica and coeling system.
Icv-pressure injection and decay heat removal system.
Makeup and purification system (critical portions).
Core flooding tanks and piping.
Borsted water storage tank.
CIASS 2 Class structures, systems and equipment are those whose failure veuld not result in the release of radioactivity which would exceed 10 CyR 20 li=1ts at
!thesiteboundaryandwouldnotpreventsafeshutdown.
The failure of Class 2 structures, systems and equi;xnent may interrupt power generation.
DESIGN EASES CIASS 1 STRUC'NRES DESIGN Normal Operation - Per loads to be encountered during normal plant operation (excluding earthquake loads), Class 1 structures are designed in accordance with design methods of accepted standards and codes insofar as they are i
applicable.
(Paragr7;h Deleted) i fhe final design of Class 1 concrete structures (except the reactor building)
~
under normal operating conditions satisfies the most severe of the following load combination equations. (Design equations for the reactor building are giver in Section 5, Reactor autiding and structurss.)
I 1
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5A-2 Anend:ent no. 6 12/25/69 w
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p = 0.65 f or tention, shear, bond, and nn:t ra.;e in reinf:,rcel 4
concrete.
d = 0 75 for spirally reinforced eenerete co=pression members.
- = 0 70 for tied compression members.
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$ = 0 90 for fabricated structural steel.
( = 0 90 for ;einforcing steel (not prestressed) in direct tension.
- = 0.85 for lap splices of reinforcing steel.
- = 0 90 for velded or mechanical splices of reinforcing steel.
)
( = 0 95 for prestressed tendons in direct tension.
l The reactor building, engineered safeguards, steam and feed-water syste:
components are protected by barriers frem all credible missiles which might i
be generated from the reactor coolant system. Iccal yielding or erosion of barriers is per=issible due to jet or missile i= pact, provided there is no general failure.
The final design of the missile barrier an'd equipment supiert stzJetures inside the reactor building is reviewed to assure that they can withstand a;plicable pressure loads, jet forces, pipe reactions and earthquake loads without loss of function. The deflections or deformations of structures and supp rts are checked to assure that the functions of the reactor building and engineered safeguards equip =ent are not impaired.
CLASS 1 SYSTE!S AND EqUIPEUT DESIGN C: ponents and systems classified as Class 1 are designed in accordance with the following criteria:
a.
Pri=ary steady state stresses when ec=bined with the seismic stress resulting from the " Design Earthquake" are maintained within the allowable working stress limits accepted as good practice as set forth in the appropriate design standards, i
eg, ASME Boiler and Pressure Yessel Code, UASAS 331 7 Code for Pressure Piping.
b.
Primary steady state stress when combined with the seismic stresses resulting from the " Maximum Earthquake" are limited so that the function of the component or system is not so in-paired as to prevent a safe and orderly shutdown of the plant.
l CLASS 2 STMJC'IURES DESION i
l Class 2 structures are designed in accordance with design methods of accepted
{
codes and standards insofar as they are appliesble. Seismic design is in A
),
l, 5A-5 Amendment No. 5 11/3/69 1.
- l. '
accernance with he Uniform Bunding Code with Go apptwpride -wd.L.s A.u..
a n ovance and shear coefficient,s.
CIASS 2 EYEC*S A!:D ERUIPEITT DESIGN Class 2 systens and equipment are designed in accordance with design rethods
'of accepted codes and standards. Wind loads and seismic loads, where appli-cable, confor= to the requiremente of the Uniform Building Code.
VDID AIID EARTHOUAE ICADS FOR CIISS 1 STRUCTURES MDD TOR:E Class 1 structures (excepttheenclosureoverthefuelstcragefacilities) are designed to resist the effects of a tornado.
The reactor building is analyzed for tornado learling (not coincident with accident or earthquake) on the following basis:
Differential bursting pressure between the inside and outside of a.
the reactor building is assu=ed to be three pounds per square inch positive pressure.
b.
Imteral force is assumed as the, force caused by a tornado funnel having a maximum peripheral tangential velocity of 300 =ph and a forward progression of 60 mph. These ecmponents are conservatively applied as a 300 mph vind over the entire surface of the structure for each reactor building and are additive for a 360 mph vind over the entire surface of other Class 1 structures. The applicable por-tions of vind design methods described in DCE Paper 3269 are used, particularly for shape factors. The provisions for gust factors and variation of vind velocity with height are not applied.
Tornado driven missiles equivalent to an airborne k inch by 12 c.
inch by 12 foot plank traveling end-on at fC mph, or a 4000 pound automobile flying through the air at 50 mph and at not more than 25 feet above the ground, are assu=ed.
SEISMIC MRCES (E AND E')
AEC Publication TID 7024, "Ituelear React)rs and Earthquakes," is used as the basic design guide for seismic, analysis.
The " Design Earthquake" used for this plant is a ground acceleration of 0.06 g horizontauy and 0.04 3 verticany, acting simultaneously. The
" Maximum Earthquake" is a ground acceleration 0.12 g herinentauy and 0.08 g vertica n y, acting simultaneously.
Seismic loads on structures, systems and equipment are determined by realis-tie evaluation of dynamic properties and the accelerations obtained from the attached acceleration spectrum curves. (Figures 5-A-1 and 5-A-2 in this Appendix)
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MIDLAND 142-FSAR
" TACHMENT "B" 9.5.7.4 Tests and Inspections Testing of the diesel generator system as discussed gener, ally in Subsection 8.3.1.1.3.
Abstracts of the diesel generator. system The diesel generator 15tbrica' tion are provided in Chapter 14.
system is operationally tested during the startup and periodic check-out of the diesel generator.
Lube oil pressure and temperature are monitored to ensure operability of the engine driven pump and the recirculation lines.
Operation of the electric pump and heater are evidence of their operability.
Inspection and testing of the system can be performed without disturbing normal plant operations.
The oil is checked periodically to determine that it is within the engine The duplex filters and strainers manufacturer's specifications.
are valved for full flow through one side only and may be removed and inspected for the buildup of impurities following engine operation.
Periodic testing of the diesel generator is discussed in Chapter 16.
9.5.7.0 Instrumentation Applications Instrumentation provided for the diesel generator lubrication system includes pressure and temperature switches, indicators, and automatic protecticn' devices.
The temperature and pressure switches support the automatic control modes of lubrication Diesel generator controls and indication are provided operation.
at the local diesel generator control panels and in the control room.
These controls, instruments, and annunciators are discussed in Subsection 8.3.1.1.3.
In addition, a dipstick is provided on the engine oil sump.- Low lube oil level is the primary means provided for lube oil leakage detection.
A 10 secondary means of detection is provided by the diesel tanerator room sumps which are equiped with high level alarms as shown on Figure 9.5-30.
No lube oil sump high level alarm is provided.
9.5.8 DIESEL CENERATCR CCMBUSTION AIR INTAKE AND EXHAUST SYSTEM This subsection discusses the mechanical features of the diesel The standby generator combustion air intake and exhaust system.
power supply (i.e., the diesel generator system) is discussed in detail in Subsection 8.3.1.1.3.
The diesel generator building ventilation system is discussed in Subsection 9.4.7.
i 9.5.8.1 Design Bases criteria for the selection of design bases are stated in Subsection 1.1.2.2.
Protection of the dies 62 generator combustion air intake and exhaust system from wind and tornado effects is discussed in Section 3.3.
Flood design is discussed in Section 3.4.
Missile s,
Revision 10 9.5-29 6/78 l
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MIDLAND 1&2-FSAR protection is discussed in Section 3.5.
Protection against dynamic effects associated with postulated rupture of piping is discussed in Section 3.6.
Environmental design is discussed in
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Section 3.11.
1 9.5.8.1.1 Safety Design Bases SAFETY DESIGN BASIS ONE - The diesel generator combustion air
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intake nnd exhaust systems are capable of supplying adequate combustion gir and disposing of resultant exhaust products to permit continuous operation of each diesel generator under a load of 110% of rated load.
SAFETY DESIGN BASIS TWO - The diesel generator combustion air intake and exhaust systems are designed to remain-functional during and after a design basis earthquake.
SAFETY DESIGN BASIS THREE - The diesel generator combustion air intake and exhaust systems are designed so that a single failure of any component, assuming a loss of offsite power, cannot result in loss of both diesel generators.
SAFETY DESIGN BASIS FOUR b The diesel generator combustion sir intake and exhaust systems are capable of being tested even during operation of the diesel generators in accordance with 10 CFR 50 General Design criterion 10.
9.5.8.1.2 Power Generation Design Bases The diesel generator combustion air intake and exhaust system has no power generation design bases.
9.5.8.1.3 Codes and Standards codes and standards applicable to the diesel generator c=mbustion air intake and exhaust system are listed in Table 3.2-1.
9.5.8.2
System Description
9.5.8.2.1 General Description Each diesel generator is provided with an air intake and exhaust system.
The system is shown in Figure 1.2-27..
Major components of the system include intake filters, intake and exhaust silencers, and two turbochargers with aftercoolers for each diesel generator unit.
A more detailed description of components 10 is included in Table 9.5-7.
Performance data for the aftercooler heat exchangers are provided in Table 9.5-10.
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MIDLAND 1&2-FSAR 9.5.8.3 Safsty Evaluation Safety evaluations are numbered to correspond to the safety design bases.
SAFETY EVALUATION ONE - The conbustion air intake provides enough
.&ir to the turbochargers to ensure rated diesel output un' der the most adverse conditions.
. SAFETY EVALUATION TWO - The diesel intake and exhaust system is designed in accordance with Seismic Category I requirements as specified in Section 3.2.
Systems, equipment, or structures whose failure could result in loss of a required function of the diesel generator intake and exhaust system are checked to determine that they will not fail when subjected to seismic loadings.
SAFETY EVALUATION THREE - The diesel generator air intake is sized to provide adequate combustion air as described in safety evaluation one above.
A single failure of the air intake or exhaust may be assessed as a failure of the diesel generator with which the failure is associated.
In such a circumstance, safe shutdown is attained and maintained by,the appropriate redundant diesel generator installation.
SAFETY EVALUATION FOUR - All active components are capable of being tested during power generation to ensure proper functioning of the system as discussed in Subsection 9.5.8.4 below.
9.5.8.4 Tests and Inspection Testing of the diesel generator system is discussed generally in Subsection 8.3.1.1.3.
Abstracts of the diesel generator system are provided in Chapter 14.
Visual inspections, pressure and leak testing, and operational checks of the combustion air intake and exhaust system are performed as the system is installed.
The diesel generator combustion air intake and exhaust system is operationally checked during the periodic testing of the diesei generator system.
Periodic testing of the diesel generator is discussed in Chapter 16.
i 9.5.8.5 Instrumentation Application Diesel generator controls and indication are provided at the local diesel generator control panels and in the control room.
l The local diesel generator control panels are mounted on the 27 diesel generator building foundation, which is structurally isolated from the diesel generator pedestals.
The controls, Instruments, and annunicators, associated with the diesel generators are discussed in Subsectic.: 8.3.1.1.3.
Revision 27 3/80 9.5-31 L
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- 4 UIDL?.iiD 162-FELR ATTACHMENT "C" 6
3.2 CLASSITICATIO!" OF STRUCTURES, COMFCNENTS, AND SYCTEMS This section provides a guide to the classification method of structures, components, and systems.
i Subsection 3.2.1 applies to the balance of plant; that is, all
[
structures, components, and systems except those provided by the NSSS supplier.
Subsection 3.2.2 applies to all components and systems provided j
by the NSSS supplier.
Subsection 3.2.3 lists effective dates of major codes for components including balance of plant and NSSS supplied items.
3.2.1 CLASSIFICATION OF BALANCE OF PIANT STRUCTURES,
' COMPONENTS, AND SYSTEMS 3.2.1.1 Seismic Classification General Design Criterion 2 of Appendix A to 10 CFR 50, General Design criteria for Nuclear Power Plants, and Appendix A to 10 CFR 100, Seismic and Geologic Siting Criteria for Nuclear lower Plants, require that nuclear pcwer plant structures, systems, and components important to safety be designed to withstand the effects of earthquakes.
3.2.1.1.1 Definitions Seismic Category I structures, ccmponents, and systems are defined in accordance with NRC Regulatory Guide 1.29 as those necessary to assure:
I a.
The integrity of the reactor coolant pressure boundary b.
The capability to shut down the reactor and maintain it in a safe shutdown condition j
c.
The capability to prevent or mitigate the consequences of accidents that could result in potential offsite 4
exposures comparable to the guideline exposures of l
Seismic Category I structures, components, and systems are designed to withstand the appropriate seismic loads as discussed in Section 3.7 and other applicable loads without loss of t
function.
Seismic Category I structures are sufficiently isolated or protected from other structures to ensure that their f
integrity is maintained at all times.
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Components (and their supporting structures) which are not I
f Seismic Category I and whose collapse could result in loss of
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3.2-1 I
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MIDLAND 162-FSAR required function of seismic category I structures, equipment, or systems are reviewed to confirm their integrity against collapse when subjected to seismic loading resulting from the safe shutdown earthquake.
3.'2.1.1.2 classifications Table 3.2-1 provides a listing of structures, components, and systems and identifies those which are seismic category I.
Where only portions of systems are identified as seismic category I on this table, the boundaries of the seismic category I portions of the system are shown on the piping and instrument diagrams in appropriate sections of this report.
compliance of the above seismic classifications with NBC Begulatory Guide 1.29 is discussed in Appendix 3A.
3.2.1.2 system cuality Group classification
~
This subsection provides the system quality group classification for each fluid or gas system pressure-containing component.
components are classified according to safety-related importance i
as dictated by service and functional requirements and by the consequences of failure.
The design, fabrication, inspection, and testing requirements fixed for each classification provide the required degree of conservatism in assuring pressure i
integrity.
3.2.1.2.1 Quality Group classifications Equipment quality group classifications are indicated in Table 3.2-1.
system quality group classifications and interfaces i
between classifications in systems with components of different classifications are indicated on the system piping and instrumentation diagrams which are found in the pertinent sections of this safety analysis report.
The boundaries are designated by a three letter sequence, for example, "HSD." The last letter (A, B, c or D) stands for applicable code which i
corresponds to a quality group in the table, as described in Regulatory Guide 1.26.
Regulatory Guide 1.26 does not apply if the last letter is F, G, B, or J.
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Last Letter of Three Letter corresponding Group Quality Group A
A 3
3
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C C
D D
F NA G
NA H
NA J
NA Compliance of quality group classification with NBC Regulatory Guide 1.26 is discussed in Appendix 3A.
'3.2.1.2.2 Code Requirements The code requirements applicable to each quality group classification are identified in Table 3.2-2.
Design code requirements corres' pond to those indicated in Section 50.55a of 10 CFR 50 and NRC Regulatory Guide 1.26, Table 1,.except for quality group D pumps.
The design standard of these pumps is discussed in the footnote of Table 3.2-2.
Codes and applicable addenda for all piping and equipment in the plant are listed in Tables 3.2-3 and 3.2-4.
3.2.2 CLASSIFICATION OF STRUCTURES, COMPONENTS, AND SYSTEMS PROVIDED BY THE NSSS SUPPLIER A system boundary includes those portions of the system required to accomplish the specified safety function and connected piping up to and including the first valve (including a safety or relief valve) that is either normally closed cr capable of automatic closure when the saf ety function is required.
This section identifies the acw classification method for structures, components, and systems.
It is intended that 1) the seismic classification of structures, systems, and components, and 2) the system quality group classification for pressure-containing components of fluid systems utilize the guidelines set forth in Regulatory Guides 1.29 and 1.26 l
respectively.
3.2.2.1 Seismic Classification General Design Criterion 2 of Appendix A to 10 CFR 50, General Design Criteria for Nuclear Power Plants, and Appendix A to 10 CFR 100, Seismic and Geologic Siting Criteria for Nuclear Power Plants, require that nuclear power plant structures, 9
Revision 1 1
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MIDLAND 1&2-FSAR TABLE 3.2-1 DESIGN CRITERIA
SUMMARY
8" Design FSAR Quality Code /
Seismic System / Component Section Location Group Standard Catecory SEISMIC CATEGORY I STRUCTURES Concrete 3.8.1 containment Containment C
NA AC I-318
I l43 building AWS D1.1 Crane supports C
-NA.
.ACI-318t" I
AISC AWS D1.1 Liner plate C
NA ACI-318:25 I
AISC AWS D1.1 Penetration sleeve C
NA ACIe3187 I
Personnel lock, C
NA ACI-31823 I
AISC 30 emergency airlock, ASME equipment hatch Containment 3.8.3 Internal Structures NSSS supports C
NA ACI-3182>
I AISC AWS D1.1 Other internal C
NA ACI-318:2i I
AISC structures AWS D1.1 Auxiliary 3.8.4 A
NA ACI-318t2' I
AISC Bu11 dine AWS D1.1 Diesel Generator 3.8.4 G
NA ACI-318:25 g
AISC Buildino AWS D1.1 (sheet 1)
Revision 43 4/82 s,
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as MIDLAND 1&2-F5 Alt TABLE 3.2-1 (continued)
Design.
FSAR Quality Code / -
Seismic
-System / component Section Location Group Standard Category
- Engine driven G
D DEMA I
30 jacket water pump Piping and valves 15 Engine mounted
- G NA DEMA I
27 Non-engine mounted O,G C
III-3 1
30 Diesel Cenerator 9.5.6 starting System Air receivers C
C III-3 I
- Compressora G
NA NA NA Air dryers G
NA NA NA l15 Piping and valves Air receiver to engine G
C III-3 I
compressor to receiver G
D B31.1 NA 15 Engine mounted G
NA DEMA I
Filters G
NA NA I
Diesel Generator 9.5.7 Lubrication System Lube oil cooler G
C III-3 I
C III-3 I
tank 30 Auxiliary lube G
C III-3 I
oil pump Engine driven lube G
D DEMA I
oil pump Lube oil keepwarm C
C III-3 I
l30 Pump Piping and valves Engine mounted G
NA DEMA I
l15 Aux skid mounted G
C III-3 I
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Diesel Generator 9.5.8 i
combustion Air i
intake and Exhaust System t
NA DEMA I
Intake air louvers G
NA NA I
(sheet 35)
Revision 34 l
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TABLE 3.2-1 (coratinued)
Design T
FSAR Quality Code /
Seismic System / Component Sectig Location Group Standard Category Intake filters G
NA NA I
l15 Ducts and dampers G
NA SMACNA I
Intake and G
NA NA I
exhaust silencers Chemical Waste 9.5.9 system Motors E,T NA NEMA MG-1 NA Pumps E,T D
HI NA Piping and valves U,E.T D
B31.1 NA i
e
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Oily waste 9.5.10 system i
i Motors E.P,T NA NEMA MG-1 NA Pumps E P,T D
HI NA l
Piping and valves E,0,T,U,P D/NA B31.1 NA l21 4
Tanks P
D API-650 NA I
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4 1l 1
1 1
(sheet 36)
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i MIDLAND 1&2-FSAR TABLE 3.2-1 (continued)
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NOTES:
A. ' Equipment hangers and supports are designed to the same quality classification as tha associated equipment when the equipment is required for safety.
B. Bangers and supports of Seismic Category I systems in seismic Category I buildings meet the seismic Category I requirements.
C. The trays and supports for safety-related cables meet Seismic Category I requirements.
Conduit and wireways a,s well as the support materials for all raceways for safety-related cables O
are designed to maintain their integrity during a safe shutdown earthquake.
D. This equipment is seismically qualified as required to ensure that, during normal and safe shutdown earthquake conditions, fuel damage will not occur that would release radioactivity in excess of allowable limits.
in Below are listed the definitions of abtreviations used in this table for each table heading.
FSAR Section Number:
Section where system, component, or structure is discussed.
NA:
The FSAR does not discuss this system, component, or structure.
Location A:
Auxiliary building C:
Containment l
E:
Evaporator and auxiliary boiler building G:
Diesel generator building i
i B:
Guard house t
l M:
Main chlorination facility 0:
outdoors onsite (sheet 44) l t
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MIDLAND 1&2-FSAR e
TABLE 3.2-1 (continued)
F:
011 waste treatment facility R:
Solid radwaste building S:
Office and service building T:
Turbine building U:
Underground onsite W:
Service water pump structure X:
Circulating water intake structure
~~
T:
naneup water-pump structure Quality Group A, B, C, D:
Quality group cla'ssification as defined in Regulatory Guide 1.26.
NA Quality group classification as defined in Regulatory Guide 1.26 does not apply.
Desion Code / Standard I: ASME Boiler and Pressure Vessel Code,Section I III:
ASME Boiler and Pressure Vessel Code,Section III III-1, 2, 3:
ASME Boiler and Pressure Vessel Code,Section III, Class 1,.2, 3
III-A ASME Boiler and Pressure Vessel Code,Section III, 39 Class A (1968)
IV:
ASME Boiler and Pressure Vessel Code,Section IV VIII:
ASME Boiler and Pressure Vessel Code,Section VIII ABMA:
American Boiler Manufacturers Association
~
ACI-318-63:
American Concrete Institute, " Building Code Requirements for Buildings" (for calculations initiated prior to February 1, 1973)
ACI-318-71: American Concrete Institute, " Building Code Requirements for Building" (for calculations initiated on or after February 1, 1973)
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MIDLAND 1&2-FSAR TABLE 3.2-1 (continued) i IEEE-344:
Institute of Electrical and Electronic Engineers)
Recommended Practices for Seismic Qualification of Class lE Equipment for Nuclear Power Generating Stations IEEE-382:
Institute of Electrical and Electronic Engineers, Standard for Type Test of Class IE Electric Cables. Field Splices and Connections for Nuclear Power Generating Stations IEEE-387:
Institute of Electrical and Electronic Engineers, Trial-Use Criteria for Diesel-Generator Sets Applied.as Standby Power Supplies for Nuclear Power Generating Stations IEEE-450:
Institute of Electrical and Electronic Engineers; Recommended Practice for Maintenance, Testing, and Replacement of Large Lead Storage Batteries for Generating Stations and Substations IPCEA-5-19-81:
Insulated Power Cable Engineers Association:
Rubber Insulated Wire an'd-Cable for the Transmission and Distribution of Electrical Energy MSAR-71-45: Entrained Moisture Separator for Fine Particle Water-Air-Stream Service, Their forformance Development and 30 Status NA:
Design requirements specified by designer with appropriate consideration of the intended service and operation conditions NEC:
National Electrical Code NEMA ICS-1 to 110:
National Electrical Manufacturers' Association, Industrial Controls and Systems NEMA MC-1:
National Electrical Manufacturers' Association, Motors and Generators 1
NEMA SM-22:
National Electrical Manufacturers' Association, Single Stage Steam Turbine for Mechanical Drive Service 1
NFPA:
National Fire Protection Association 1
SIP:
Standard Industrial Practice j
SM CNA:
Sheet Metal and Air Conditioning Contractors National Association, Inc.
l (sheet 48)
Revision 44 6/82 s,.
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MIDIRfD 1&2-FSAR TABLE 3.2-1 (continued)
TEMA-C: Tubular Exchanger Manufacturers Association Class C TEMA-R: Tubular Exchanger Manufacturers Association Class R USC: Uniform Building Code UL:
Underwriters' Laboratories Seismic Category I:
Construction in accordance with seismic requirements of Regulatory Guide 1.29 and Appendix A to 10 CFR 100 NA:
Not Seismic Category I
- See referenced FSAR section for additional codes and standards applicable to these structures.
~
- These components alid associated supporting structures must be designed to retain structural integrity during and after a seismic Category I event but do not have to retain operability for protection of public safety. The design basis requirement is prevention of structural collapse and damage to equipment and structures required for protection of the public safety.
- For other applicable codes and standards see Section 7 1 and referenced FSAR sections.
'58 Air handling unit fans and unit cooler fans are not rated in accordance with AMCA.
The entire unit is rated in accordance with ARI.
l 4
- Refer to Subsection 10.'2.1.3 for further discussion of l
turbine-generat'or codes and standards.
- Refer to Table 3.2-6
- see Response to Regulatory Guide 1.143 in Appendix 3A.
I33
- The engine-mounted fuel and cooling water lines are composed I
of either ASTM A 53 or A 106, Grade A seamless steel pipe.
- 7 For pipe sections to be bent or formed. ASTM A 106 Grade B is used, with the compatible 106 Grade A pipe.
(sheet 49)
Revision 44 6/82
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10 Sheet i REV.
DATE REASON FOR CHANGE APPROVAL SIGNATURES
- OtSCIPt.lNE TITLE b
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h General Revision for the Y Y d Ss*4 a.' Architecture 3
Purpose of Updating Informa onA 85" M O UTiv11 Struct/ Soils 3
/4h}" Control Svstems i
h.Mp. [e-M Elaetrical
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No.
DATE REVWONS SY CMarD AFD NO.
DATE Revisl0ms lSY l CHCD AM FACING SHEET JOB No. 7??o f gg MIDLAND FIANT UNITS 1 & 2 R e v.
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PROJECT Q-LIST i
Ii8S53 CONSUMERS POWER CDMPANY MIDLAND PLANT UNITS 1 AND 2 e Project Q-List is the master control document which 4dentifies the structures, systems, components, and services that are important to safety and necessary to ensure 1) the
-integrity of the reactor coolan: pressure boundary, 2) capability to shut down the reactor and maintain it in a safe shutdown condition, or 3) capability to prevent or nitigate the consequences of accidents which could result in potential offsite exposure in arcess of the guideline exposures of 10 CFR 100.
Q-listed portions of structures, systems, and components are designated as seismic Category 1 or Electrical Class 12.
l2$1 Acelication:
e 1.
Each item supplied by the Babcock & Wilcox Company is identified in the purchaser solumn by 'B&W.*
Quality Assurance for the design, fasrication, shipment, and shop testing of such items is the responsibility of B&W and shall be in accordance with the latest revision of NPGD QA Manual 19AN.1 with erception for the CPCo contract.
2.
Items purchased by the Bechtal Power Corporation are jgg identified by 'BPC.*
Quality Assurance for the design, procurement and installation of these ite=s is the responsibility of Bechtel and shall be in accordance with the Bechtel NQAM.
3.
Items supplied by Consumers Power Company are identified in the purchaser column by "C?co.*
Quality Assurance for the design, procurement, and installation of these items is the responsibility of CPCo and shall be in accordance with the CPCo QA Manual.
4.
All Q-listed items are subject to the requirements of the Consumers Power Company Quality Assurance Pro i
for design, procurement, shipping, construction, gram i
preoperational testing, fuel loading, operation and 1
maintenance.
Notes Referenced in the 0-List:
1.
All Q-valves, dampers, strainers, restricting orifices, i
lines, and pressure boundary'D, HVAC duct layout drawing 2hi instruments will be l
~
identified on the system PEI j
system, isometric drawings and piping class summary sheets, and the applicable material requisition or j
specification.
4 e
j 0020u sheet 1, Rsv. 10 l
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+ es e e o e em 9 e e et 9 empene e e e
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Preieet 0-List.4,.4 <qntinued)
,iw, All Q electrical instruments, devices, and components l.02I3 can be identified through the use of logics, loops, b
1 schemes, and applicable material requisition or specification.
2.
Portions required for control room emergency ventilation.
- 3..See penetration schedule Drawings M-301 and M-302.
4.
Material requisition number is not available at this time.
5.
See penetration schedule Drawing C-334.
6.
B&W supplied equipment is identified by a Bechtel/CPCo d
file number.
This number is not the MR number for that item.
7.
Only the NDE that applies to field welding of Q-listed structures and systems as reqyired by applicable specifications is Q-listed.
8.'
seismic category 1 applies only to those components necessary to insure structural integrity cf the system d
during a seismic event.
No electrical portions are seismic category 1.
}
9.
Identified and purchased wi'.h driven equipment.
.{
- 10. This item is included on the Q-List to provide additional controls to ensure a 90% data recovery between March 1, 1975 and February 28, 1977 as required by Regulatory Guide 1.23.
Operation of the neceorology program after February 28, 1977, is for information only and is not Q-listed.
Meteorological tower instrumentation and its operation does not meet the i
Q-List definition of a safety-related system.
- 11. Piping, valves, hangers, and supports for 2 inch and smaller piping are field routed.
Refer to FSK-M drawings.
- 12. For control valves and solenoid valves which are part of these systems, see the control systems portion of Q-List.
- 13. This item covers Q-listed plans applicable to remedial g
soils activities. The Q-List for this work is included in MPQP-2, Quality Plan for Remedial soils Activities j
- and soils-Related Work in Q Areas. This quality plan is applicable for all aspects of the reme',ial soils i
activities and, as such, the activiti6. *nd materials associated with this work are deemed 0-1$'ted.
Q-listing provided in MPQP-2 covers activities, items, and structures beyond the requirements provided in the
't 0020u Sheet 2, Rev.10 Ei i t
m MMMMi Mi-r N,
4-Ii8953 Pro $Tct Q-List (Continued)
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bh5NR.. This extension to provide quality assurance
",1 tem.;wt11 provide additiona1 assurance e3at po activity program coverage over and above strictly: safety-related Ii62 a-I will Adversery affect safety-related structuresp T
- 14. See Instrument Installation Summary J-705(Q)i for guide \\
to details of indiv3duat instrument installations.
See' 4
\\/h individual installation details for specific,use of e
instrument' valves, valve manifolds, instrunent \\ tubing s
and fittings, flexible metal hose, and sinstrument and 4
tubing supports. '
L
?.5. This item is CPCo purchaser responsibility and is 1
identified by a Bechtel file number.
This number i gnot the MR number"for that item.
N
- 16. This specification is Q listed for receipt, inspection, and placement only. Design is not Q listed (based on ASLB Order of April 30, 1982).
?
Suceerting Documents 1.,
Mechanical equiement List - An alphanumeric liscing of equipment by equipment number with additional information such as MR number, equipment rating, location, vencor, P&ID number, and cost code.
Prepared an'd. updated by the mechanical group.
Assigned Drawing 7220-M-485(Q).
M-425 is not definitive in designating Q or non-Q.
DrawingControlLog-_hnumericallistingofall 2bh 2.
drawings subdivided by' discipline groups.
Contains the title, Q-Aesignation,' trevision number, and revision date.
Prepared and updated by the project administrator on a monthly basis.
3.
Material. Requisition and. eecifiestion Centrol Log - A numerical 11stingxof specifications and =atar:21 requisitions subdivided by discipline groups.
Contsins such supp!amentary information as revision dates and purpose, date purchase order issued, and the supplier.
Prepared and updated by the Project Administrator on a monthly basis.
4.
Piping Class Summary Sheets.~ Specify the desi'n and key g
operating conditions for each piping system andi subsystem shown on the Piping and Instrument Diagram, s
~ and Piping Design Specifications.
A numerical listing of piping by line number subdivided by piping class.
Contains such information as seismic class, design rating, service conditions, insulation class, and critical hanger designation.
Prepared and updated by the mechanical group. Assigned Drawing 7220-M-480(Q).
s
~ L 0020u
^
Sheet 3, Rev. 10
lioS3J Project Q-List (Continued) 5.
Instrument Index - An alphanumeric' listing of
~
Ii6275 1a*trua'at= *ad '*1 bY in=tru=*nt numb *r with additional information such as MR number, location, and related trawings'.
Prepared and updated by the Control Systems Group.
Assigned Drawing 7220-J-700.
Instrument Q categories of Qg (hown in the Q colhan of the functional) and Q3 (pressure boundary only) are s instrument index.
(The instrur.ent index is not a
'Q*
~
document because it is referenced for information only.)
6.
7220-G-33(Q) - Provides for the purchase of Q-listed bulk materials / shelf items and special service orders, j
excluding ASME Section III materials in accordance with the quality assurance requirements of Specification 7220-G-33(Q).
Items procured under G-33 are not listed herein.
7.
Loeic and Looe Diaorams - Logic diagrams represent the functional logic of the equipment and clarify the intended use (Q and non-Q) of individual system components.
Loop diagrams represent the wiring of the system components (generally for analog systems) and indicate Q or non-Q usage of components.
8.
Instrument Installation summary (J-705(O)1 - Provides Q status for all Bechtel-installed instrumentation.
Provides reference to applicable location drawing installation detail and instrument supports.
4 1
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s 0020u Sheet 4, Rev. 10 5
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PROJECT g-LIST M
r-J MIDLAND UNITS 1 AND 2
-.- g Joe N0. 7220 t
MECNANICAL PAGE 18 Identity satel at Waterial povlo g
- weber Ites/ Description purchaser Wu r
Dreutne pequisttlen le 4.402 Piping SPC (1)
M-640(G)
N-IS4A40) lonly Containment Penetration)
(III h-2151GI m-3esl01 (Spec N-204f95)
(Spec M-21410ll g
'88 4.493 valves stC (Il a-640(c1 N-12SC(QI W
(only containment Penetration) till n-129Al01 ut N-284105 ta)
IS 4.404 Beactor Sleg penctration SPC (3)
N-381(Ole M-11180)
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Plued Needs M-39210) 7 4.49 PLANT WA?tR STOR ACE AND IBA5'FER SYSTiM m-449(g) 13 4.491 Supporte and Nangers BPC (Il N-649(01 u-le6(Gl 10hdy Contalement Penetration) till (Spec M-326(Oli ISpec M-34310ll (Spec M-36680le 3-211(Oli la 4.4W2 Piping SPC (3)
M-649101 M-194A(0)
(Only contalament Penetration) liti M-21580)
M-3GS(0)
M-20410)
M-214801 le 4.493 Valves (12)
SPC (Il M-649(9)
N-244(O),
lonly containment Penetratical (183 M-125CIG),
n-129 Anal 0),
s N-37*al03 1
le 4.494 Beactor alds Penetration DPC (3)
M-30ll0le N-11180)
Plued heads 1
M-38280) i le 4.52 DIESEL ENGINE, CENERATOR, AND i
_ACCESSOnIES j
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le 4.525
- elesel Engine, Generator, and arc Isil w/A n-legg)
Engine nounted Ausillarlee 2Cll le 4.522 blesel Engine, Cenerator, and SPC ICl2 n,'A n-Isl0B Engine Mounted Aust!!arles 2Cl2 it 4.523 supports & I! angers SPC lli N-6 52(f})
n-le610),N-18101 issiec H-326EGil ISg*ec M-34 310ll (Sg.ec ft-366 801, n-21780ll U
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P30 JECT O-LIST NIsLANs UNITS 1 ANs 2 Cn JOs No. 722e McCNAMICAL PACS 19 N
-s Identity talelpeent Noterial U1 seelslom Number _
ltes/seactlption Purchaser
_ Numt.er lproulag gequialtlea 10 4.524 toergency slesel oli transfer Pompe seC tr78A,e N-45210)
N-19808 t
and Motors 2r7en s e
m le 4.525 Flplag arc (1)
.:-652101 N-184Al0),N-18f0)
N-452808 N-2158ul (JS 1
Bill M-345105 u
N-18 ispec N-28480ll IV.P.)
(spec M-214(Oll 10 4.524 toergency sleset.oll say stC IT774,8 N-45280)
N-64101 Teats 2T71A,e i?
10 4.527 feetgency slesel 011 Storage Tanke sPC 2770&,a N-45210)
N-64101 2T70A,a le 4.52s Valves arc (1)
N-652401 N-127A,s,sCic),
till N-tel01,N-379sl01 4
le 4.529 Jacket water Coolere arc le25A,a N-419801 N-Is(01 2 25A,'d le 4.5210 Valves, strainere, elitere and arc N-45280) as-127sl01 Miscellaneous Componente N-1810)
N-336801 1
le 4.5211 Aemittery Fuel oli sooeter Pumpe BFC IP-137A,a N-18-26 N-ISI0l 2r-137A,e (V.P.)
le 4.5212 Alt neceivers stC IT-934 s,Ces N-452l01 N-18403 27-934,s,Ces le 4.5213 Jacket Mater standpipe sPC 17-944,8 N-452(0)
N-te(Ol 27-94A,3 le 4.5214 Embe oil swap Tank BPC IT-6IAes N-18-23 N-18(0)27-61A,e (V.F.I a
le 4.5215 Ausillary Imbe oil Pumpe stC 3r-137A,3 N-10-23 N-It{gl 2F-137A,e (V.P.I
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le 4.5216 1.ube oil Coolere BPC lt-SIAes N.ls 23 N-19801 2t-SIA,a (V.P.I 4
le 4.5217 Control penete and Instrumentation sPC IClitell2 N-18 IV.P.)
N-18(0)
P 2Clllell2 BC238,232 2C231,232 le 4.5210 Intake Air Filter sPC IF-ISA,s,C,s N-IS (V.F.I N-18tOI 2r-19A,s,C,D O
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PROJECT 0-List i
NIDLAND WWl?S 1 Alle 2 JOS 810. 7228 NECMANICAL PAGE 28 Edentity Equi et Natorial nestelen Number Ites/seeerIption Purchaser Wu r
Drawine pequieltlen 4
8 le 4.523g Intake Air silencer stC IN-Itea,e,C,e M-18 tv.P.) N-10fel 2N-10GA,3 C D
!j le 4.5220 tahaust silencer stC In-1814,5 N-IS (V.P.)
N-10(0) 2N-IteA,e
- 10 4.5221 Espanelen JeInte BPC IEJ-52014,5, N-IS (V.P.I N-18103 m
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BEJ-5202A,b, gg s/
CD 2EJ-5202A,8, Con 6
4.53 gtActos cultplNo NV & AC sysTEN URIT I 7
4.531
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subcoatract le 4.532 Decirculating Air Coollag SPC (1)
N-453(0)
N-151801 Unit Doctuork and supporte N-515 fincluding lastallationi sh llel le 4.533 Nydrogen secombiners SPC IVE54A,a N-453(Ol N-169101 10 4.534 Deacter Bellding socirc. Alt BPC IVN56A,5 N-453(0)
N-163(0)
Coollag patte C,e 18 4.535 seactor sellding peelte. Air SPC IVV53A,8 N-45340)
N-16310)
Coollag unit Pane CD le 4.536 seacter Building Purge Penetra-SPC (1)
N-453101 N-16810)
Lion teolation Valves (includes N-513 N-127809 N3 Vent and Air Room Isolation sh 180)
M-129(0)
Valveel N-11480),
M-Sis, sh 180) 18 4.537
- Reactor sallding Penetration stC (3)
N-3 ell 01 N-Illl01 Plued Neads le J.530 Reactor Cavity vent & Access Pipe DPC (Il N-45310)
N-104A10) and supporta N-517(gl, M-518, Si,1803 8836u P
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FROJECT Q-LIST I
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FOR THE g1 CONSUMERS F0WER COMPANY
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MIDLAND FIANT UNITS 1 AND 2 I
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'I DISCIPLINE TITLE REV.
DATE REASON FOR CHANGE APPROVAL $1GNATUREC a{
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General Revision for the purposa E
"fl of updating information and sto' rage W Civil gi V/70 on ATS gg a'y ontrol Systems
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PROJECT g-LIST MIDI. Alm lAllTS 1 AMD 2 PACE 16 MECilAMICAL Joe MO. 1219 s
Egult.
DWo.
M.R.
Iso.
80 0.
pgv.
IDEMflTY PtmCMAsta geo.
aso.
, leo.
ITDE/DESCRIPflege SAPC (3)
M-30l(g).M-302(g)
M-111(Q) seactor 91dg Penetration 7
4.484 Flued Meads M-449(g) 7 4.49 PlAMT tfAftR STORACE AND
?!uussrER Sv5 TEM SAPC/BPC (1)
M-649(g)
M-104(g)
(spec M-324(01) 7 4.491 Supports and llengers (spec M-343(g))
j SAPC/SPC
{T)
M-649(g)
M-104A(9)
- M-215(g) 7 4.492 Piping M-305(g)
M-204(g)
M-214(9)
SAPC/BPC (1)
M-649{9)
M-204(g)
M-129A&s(g) 7 4.493 valves SAPC (3)
M-301(Q).M.302(g)
M-111(g) 7 4.494 Seactor 314g Penetration Flued Meads M-452(g)
.8 4.S2 sqEsopecT DIESEL. CEMERATOR AMD Assoc ATEn systems J
SAPC 3G11 N/A M-Is(g) 7 4.S21 Diesel Generator 2011 SAPC 1C12 M/A M-te(g) 7 4.522 Diesel Generator 2G12 SAPC/
(1)
M-652(g)
M-196(g)
(spec M-326(gl)
T 4.523 Supports & Mangers sPC (Spec M-343(g)l BAPC IP78A.B N/A M-19(g) 7 4.524 Emergency Flesel Oil Transfer Pumps 2P18A.B ased esotors BAPC/BPC (1)
M-652(g)
M-lo4A(9) t 7
4.525 Piping M-215(g)
M-305(g)
(spec M-204(gli trpec M-214(Qil 8APC 17774,8 M/A M-64(g) 7 4.526 Emergency Diesel oil supply ZTTIA. h 7.anks e
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PnGJCCT Q-E.8ST s.
Mint.AINI UNITS 1 AND 7 PACE 17 MEMIANICAL JOS 300. 7229 EQUIP.
IMG.
M.R.
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IDElfflTT PtNICMASER No.
88 0.
80 0.
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80 0.
37EM/DESCRIPfl0N 7
'4.527 Energency Islesel oil Storage Tanker BAPC 1778A.s N/A M-64(Q) 2T78A.B a
BAPC/
(1)
M-652(g)
M-127B(9)
'7 4.52s valves BAPC IE25A.B II/A M-IS(g) 3 4.52, Disel Cenerator Cooler 2E254.8 (Spec M-204(g))
,j M-453(g) 6 4.53 REAC1cm SultalleG HW & AC SYSTEM Usett 1 I
7 4.531
---DELETED---
subcontract O
4.532 Reactor Building Ductwork and BAPC/SPC (1)
M-453(9)
M-15ttg)
Supporte SAPC IVE54A,8 M-453(g)
M-16g(g) 7 4.533 Ilydrogen Recombiseers 7
4.534 seector nullding mecirc. Air BAPC IVM56A.B M-453(g)
M-163(g)
C,0 Cooling unite 7
4.535 Reactor Building pectre. Air SAPC 1VV5?A.B M-453(g)
M-163(g) 1 C,o Cooling unit,rans 7
4.536 heector autiding Purge Penetra-BAPC (1)
M-453(g)
M-16e(9) tion isolation valves (includes M Vent and Air moon Isolation
. VIntves }
7 4.537 peector Building Penetration BAPC
. (3)
M-301(g)
M-111(9) rimed Meads 7
4.530 peector Cavity vent & Access Pipe BAPC (1)
M-453(g) pe-ledaggi and supports BAPC (1)
M-453(g)
M-104A(g) 7 4.539 M Vent Systen Piping & Supports M-215(Q)
WIthin peactor pueldeng (Spec M-204(0))
(spec M-214(Q))
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4
'.' o UNITED STATES OF AMERICA 1
NUCLEAR REGULATORY COMMISSION BEFORE THE ATOMIC SAFETY AND LICENSING BOARD In the Matter of:
)
Docket Nos. 50-329 OM
)
50-330 OM CONSUMERS POWER COMPANY
)
Docket Nos. 50-329 OL (Midland Plant, Units
.1 s 2)
)
50-330 OL CERTIFICATE OF SERVICE I, Rebecca J. Lauer, hereby certify that copies of the letter to the Administrative Judges,' dated August 12, 1983, in the above-captioned proceeding have been served upon all persons shown in the attached service list by deposit in the United States mail, first-class postage prepaid, this 12th day of August, 1982.
~
Rebecca JT Lauer Isham, Lincoln & Beale Three First National Plaza suite 5200 Chicago, Illinois 60602 (312) 558-7500 i
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SERVICE LIST Frank J. Kelley, Esq.
Steve Gadler Attorney General of the 2120 Carter Avenue State of Michigan St. Paul, Minnesota.55108 Carole Steinberg, Esq.
Assistant Attorney General Environmental Protection Div.
Atomic Safety & Licensing 720 Law Building Appeal Board Lansing, Michigan 48913 U.S. Nuclear Regulatory Comm.
Washington, DC 20555 Cherry & Flynn Suite 3700 Mr. Scott W. Stucky
~
Three First National Plaza Chief, Docketing & Services Chicago, Illinois 60602 U.S. Nuclear Regulatory Come..
Office of the Secretary Washington, DC 20555 Mr. Wendell H. Marshall 4625 S. Saginaw Road Midland, Michigan 48640 Ms. Mar' Sinclair 5711 Sumerset Street Midland, Michigan 48640 Charles Bechoefer, Esq.
Atomic Safety & Licensing Board Panel William D. Paton, Esq.
U.S. Nuclear Regulatory Comm.
Counsel for the NRC Staff Washington, DC 20555 U.S. Nuclear Regulatory Comm.
Washington, DC 20555 Dr. Frederick P. Cowan 6152 N. Verde Trail Atomic Safety & Licensing Apt. B-125 Board Panel Boca Raton, Florida 33433 U.S. Nuclear Regulatory Comm.
Washington, DC 20555 James E. Brunner, Esq.
Consumers Power Company Jerry Barbour 212 West Michigan Avenue Atomic Safety & Licensing Jackson, Michigan 49201 Board Panel U.S. Nuclear Regulatory Comm.
Washington, DC 20555 Mr. D. F. Judd Babcock & Wilcox P.0. Box 1260 Ms. Lynne Bernabei Lynchburg, Virginia 24505 Mr. Thomas Devine Mr. Louis Clark Government Accountability Barbara Stamiris Project of the Institute 5795 North River Road for Policy Studies Route 3 1901 Q Street, N.W.
Freeland, Michigan 48623 Washington, DC 20009 L
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NUCLEAR REGULATORY COMM!SSION fjj/[
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AUG i 91983 MEMORANDi[M FOR:
Uldis Potapovs, Chief, Vendor Program Branch, Division of j
Vendor and Technical Programs, RIV FROM:
Richard C. Lewis, Direc, tor, Division of Project and Resident Programs
SUBJECT:
CONSTRUCTION DEFICIENCY REPORT - CONFIRMATION OF TELECON (AITS NO. F02700381 )
Enclosed is a 10/CFR 50.55(e)/10 CliR 21 report received from Carolina Power anr _3 icht Co This appears to be a generic problem. Would you please follow up on the generic aspects of the problem with the AE/ Vendor? Should you have additional questions, we will be glad to discuss them with you.
PRINCIPAL STAFF
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Richard C. Lewis VRA
?Ao L}W SLO
Enclosure:
cera ac 10/CFR 50.55(e)/10 CFR 21 Report MASP ut' cc w/ encl:
HL R. W. Starostecki, DPRP, RI OL FILEL/tf7 i
l J. A. Olshinski, E0P, RII C. E. Norelius, DPRP, RIII i
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J. E. Gagliardo, DRRP&EP m2 J. Crews, DRRPEI, RV R. F. Heishman, RCPB, IE C. J. Heitemes, Jr., AE00 CONTACT:
P. R. Bemis (242-5649 )
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NOTIFICAT10tl 0
liEH OR EVElli REG 10fiAL ACTION
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3' I Licensee, 8/18.'
Potential 50.55e - Diesel Generator, Receipt -
Followup per HC 25i2 DNS: 50-4($
f Inspection Deficiencies: During receipt
,RIV notified 50-401 inspection of Units 1 and 2 Diesel Generator rotor, stator and AC boxes (IASA & IBSB)j ined 1
dimensional, electr,ipal a,nd, specification ww 14../.~/~/
deficiencies, The deficiencies are under i.
evaluat' ion by the licensee. Delaval is supplier.
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8:'ilonal Administratur (Original) j APPHOVED BY:
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R. C. Butcher for P. Bemis
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Section Chief % /
,,' 5Il liranch Chief " M s
tir. Lewis
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WASHINGTON. D. C. 20555
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MEMORANDUM FOR:
R. W. Starostecki, Director, DP&RP, RI J
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- ot igite jg;L R.A. Lewis, Director, DP&RP, RII W. E. Norelius Director, DP&RP, RIII./g ;
J. E. Gagliardo, Director, DRRP&EP, RI#
J. L. Crews, Director, DRRP&EI, RV FROM:
Robert L. Baer, Chief Engineering and Generic Communications Branch Division of Emergency Preparedness and Engineering Response, IE
SUBJECT:
~ -" ~ RESOLUTION TO TRANSAMERIGA DELAVAL DIESEL GENERATOR TURBOCHARGER THRUST BEARING LUBRUATION PROBLEM The enclosed subject report is forwarded for your information. The problem pertains to Transamerica Delaval diesel generators at nuclear sites in all regions. The lube oil system has been or should be modified by the appropriate licensees or construction permit holders as recommended by the vendor and descrjbed in the enclosed report. While some of the nuclear sites are presently in the process of working on this modification, other nuclear sites may not f
i, require their diesel generator for many years because of construction delays.
For these sites, you may want to include this matter in the outstanding items list.
If you have any further questions pertair.ing to the subject, please call Wolfgang Laudan of my staff on FTS 492-9759.-
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N-" W q &olms*n i
ert L.
er, Chie Entjineering and Generic Communications Branch
[1 vision of Emergency Preparsjness and Engineering Response, IE
Enclosure:
Closecut Report cc:
see page 2 CONTACT:
W. Laudan, IE i
49-29759
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Multiple Addressees.HJL 12 ES3 cc:
R. C. DeYoung, IE J. H. Sniezek. IE
~ J. M. Taylor. IE R. L. Baer, IE W. Laudan. IE R. H. Vollmer, NRR D. G. Eisenhut, NRR R. J. Mattson, NRR C. Michelson, AEOD J. C. Higgins, SRI A. R. Wagner, SRI P. K. Vandoorn, SRI i
J. F. Schapker, SRI J. D. Wilcox, SRI B. L. Burgess, RI M. L. Gildner, RI D. L. Kelley, SRI A. E. Chaffee, RI A. D. Toth, SRI 4
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RESOLUTION TO TRANSAMERICA DELAVAL DIESEL GENERATOR TURBOCHARGER THRUST BEARING LUBRICATION PROBLEM SUMMt.RY The design of the lubricating oil system permits the oil flow to the turbocharger bearing only when the diesel is running. When the diesel is in the standby mode, the turbocharger bearing lube oil system is bypassed in order to prevent a possible fire hazard by having pressurized oil leaking around the bearing seals onto hot impe11ers. Therefore, during startup a sufficient amobnt of oil would not be available to adequately lubricate the -
turbocharger bearing. Since diesels are started once a month and run for a short length of time, premature bearing wear was experienced because of insufficient lubrication /
At San Onofre, the wear rate for this condition after 100 hours0.00116 days <br />0.0278 hours <br />1.653439e-4 weeks <br />3.805e-5 months <br /> of operation was equivalent to 15,000 to 20,000 hours0 days <br />0 hours <br />0 weeks <br />0 months <br /> of continuous operation.
To assure proper lubrication during startup, a design modification in form of a 4
lubrication oil drip system causing the lubricating oil to drip on the bearings through an orifice at a given rate was proposed, installed, and tested. At sites where this design modification was implemented, its operation was found to be satisfactory. Only at San Onofre the modified lube l
oil system did not perfom as intended because the pre-lube pumps have an inadequate head capability at the required flow and, therefore, does not provide sufficient lube oil flow to the thrust bearings. Rather than replacing the pre-lube pumps at San Onofre, the licensee decided to adopt the vendors proposed option, to revise the operating procedures. Prior to a noma]il pump for 30-60 seconds and confirm lube oil pressure to thestart (mo lube o 3
turbochargers prior to starting.
In the event of an emergency start, the bearings will function until oil pressure is developed.
i
, BACKGROUND i
On December 16, 1980, Transamerica Delaval reported to the NRC under 10 CFR f
Part 21 a potential defect in their DSR and DSRV standby diesel generators.
The potential problem with lubrication of the thrust bearing of the
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turbochargers could result in engine non-availability.
.l Transamerica Delaval reported the following nuclear sites as being affected:
Shoreham Perry upon n '
Grand Gulf Beiie onte
]dland Catawba WPPSS No. 1
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San Onofre Connanche Peak 1 & 2 Phipps Bend The turbochargers are manufactured by the ELLIOTT Company of Jeanette, Pennsylvania. They are installed on the engines by Transamerica Delaval and lubricated in accordance with the ELLIOTT Co. reconnendations.
In order to eliminate the lubricating oil system problem as described @ the 1
I sunnary, Transamerica Delaval modified the lubrication system to assure l
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adequate lubrication to the thrust bearings during startup. Transamerica Delaval will furnish al'i necessary information, parts, and technical services on request to their customers. Detailed instructions for performing inspections of the turbocharger thrust bearings and for performing the lube-oil modification were sent to the above licensees.
The first modification was installed and field tested at the San Onofre nuclear plant.
It failed to operate due to a lack of lube oil supply to the drip system. The San Onofre prelube pump (Johnston No. H-1730-A,104 spm at 26 ft head) had inadequate head capability at the required flow. All other Transamerica Delaval diesel generators have turbochargers with lubricating oil pumps from IMO P/N 74033-101, with 125 gpm at 25 psi. Site operational testing of drip systems at sites with IMO pumps was found to be functional and satisfactory.
To aid San Onofre in their operations, options to the drip system were reviewed. San Onofre decided not to replace the Johnston purp with an..IMO pump for a drip system, but rather pre-prime.the turbo thrust bearings manually as described in the sunnary.
Most of the nuclear sites affected are presently not in commercial operation.
While some of the nuclear plants are presently in the process of installing the drip lube system, others may not require this modification for many For these sites, the regional and/or resident inspectors may want to years.
include this matter on their outstanding item list.
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s.,,...,i.s and Const,we, ion oeneral officas: 1945 West Pernell Road. Jockem, MI 492o1 + (517) 78&o453 December 30, 1982 82-16 #1 Mr J G Keppler, Regional Administrator US Nuclear Regulatory Commission Region III 799 Roosevelt Road Glen Ellyn, IL 60137 MIDLAND NUCLEAR C0 GENERATION PLANT -
DOCKET NOS 50-329 AND 50-330 POTENTIAL 50.55(e) REPORT CONCERNING PROCURED ELECTRICAL EQUIPMENT FILE 0.4.9.72 SERIAL 19130 On December 3, 1982, W R Bird reported a potential 50.55(e) condition concerning delivered, safety-related electrical equipment not meeting project I
requirements to R Gardner of your Staff. The attachment provides a description of the problem and the overall corrective actions to resolve this issue. This letter is the first interim report on this subject.
The condition remains as a potential reportable condition in that it is indeterminate whether the specific nonconforming conditions found would have prevented the equipment / components from properly functioning during all design basis events. The types of electrical equipment in question are those panels i
and cabinets having extensive vendor wiring and which provide instrument, control, and power functions. Actions being initiated to support the overall corrective actions include:
1 1.
Establishing a comprehensive review of the subject equipment purchases to support determining root causes as to how equipment was manufactured with deficiencies and delivered to the Midland site without detection of the deficiencies.
2.
Development of a matrix of past corrective actions implemented to provide improvements in this area versus the timing of manufacture and delivery of j
nonconforming equipment.
3.
Development of specific inspection planning to be utilized at the supplier facilities for source or receipt inspection of future orders.
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4.
Review the status of the overinspections performed on delivered subject equipment to assure that no items were missed.
i oc1282-1489a131 Q7bWh5 l.
JAN 5 1983
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5.
Dispositioning and necessary rework or replacement of items identified.
Either another interim or final report will be submitted on or before February 28, 1983.
WRB/MJS/ja
Attachment:
Management Corrective Action Report MCAR-1, Report No 66, Rev 2, dated 12/30/82 CC: Document Control Desk, NRC Washington, DC R J Cook, NRC Resident Inspector Midland Nuclear Plant CBechhoefer, ASLB Panel RSDecker, ASLB Panel FPCowan, ASLB Panel JHarbour, ASLB Panel g
AS&L Appeal Panel MMCherry, Esg MSinclair BStamiris CRStephens, USNRC WDPaton, Esq, USNRC FJKelley, Esq, Attorney General SHFreeman, Esq, Asst Attorney General WHMarshall "IMerritt, Esq, TNK&J Great Lakes QA Managers i
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6 AIf A5014 c/u PGM000 Pricrity 02 QUAUTY ASSURANCE PROGRAM MANAGEMENT CORRECTIVE ACTION REPORT MCAR1 REPORT NO.: 66-Revision 2 JOB NO.:
7220 Q NO.:
DATE:
12/30/82 I DESCRIPTION * (Including References):
Unacceptable workmanship conditions, such as insufficient solder, broken wire strands, damaged wire insulation, leads pulling from lugs, loose identification tags and markers, use of improper wire lugs, and improper crimping have been identified on electrical control panels and cabinets supplied by various suppliers. Approximately 30 discrepancy reports (continued on page 2)
RECOMMENDED ACTION * (Optional):
The following recommended corrective actions are for vendor supplied electrical panels and cabinets.
A.
Safety Evaluation of Identified Conditions l.
Based on cases of workmanship identified as not in compliance with MPQAD overinspection (plan 01-E-7B) predict the potentiel effects on 1
comoonent performance. (continued on page 2)
MEFERRED TO:
2 Engineering O Construction XX QA Management XX onmHev
$ Procurement (Supplier Quality)
XI MPQAD NOTE: This condition was reported to the ISSUED BY:
I N
NRC by CPCo as potentially aportable
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on 12/3/82.
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11 REPORTABLE DEFICIENCY:
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til CAUSE:
CORRECTIVE ACTION TAKEN:
AUTHORIZED BY:
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Description (continued)
(e.g., nonconformance reports and quality action requests) have been written in the last two years on electrical equipment for similar conditions discovered during MPQAD overinspections using Consumers Power Company Project inspection Plan 01-E-75.
Recent examples of these conditions have also been noted on items supplied by Terry Corp. (auxiliary feedwater pump turbine control panel), Vitro Laboratories (ESIS cabinet internal circuit board) and Transamerica Delaval (diesel engine control panel).
The above is evidence of a weakness in the electrical panel and cabinet suppliers for Midland to fully meet specified requirements in the areas identified. The source and receipt inspection activities have not been structured to be completely effective in identifying the vendor's discrepancies.
Recommended Actions 2.
Evaluate the effects on plant safety due to the predicted effects from item A.1 above.
B.
Evaluation of Requirements and Vendor Prograss 1.
Review the material requisitions for definition of workmanship f
requirements or criteria using the discrepancy reports 1
(nonconformance reports and quality action requests) from MPQAD overinspection plan 01-E-75.
This will be input to item B.2.
2.
Evaluate the vendors' programs (i.e., workmanship standards, inspection planning, etc.).
Modify the programs as appropriate.
3.
Evaluate the vendors' implementation of their program (i.e., methods used and results obtained) in the area of workmanship. Initiate corrective action as appropriate.
C.
Evaluation of Bechtel Programs 4
1.
Evaluate the source and receipt inspection programs with regard to vendor workmanship and modify the programs as appropriate.
2.
Determine process corrective actions necessary for Bechtel to improve control of vendors' performance in the area of workmanship.
D.
Interia Report 1.
Provide interim report by February 15, 1983 to meet client commitment date of February 28, 1983.
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. PRINCIPAL STAFF POWct RA o'a^
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+3 Company A/RA sk DPRP SLO ORMA RC M*ead Proiest: Po ses tes3. uwend, M 4 esso. tat 7)sas-seso 0:iMSF August 18, 1983
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Mr Stanley Baranow Store & Webster Construction Co Midland Nuclear Cogeneration Plant PO Box 1963 Midland, MI 48640 MIDLAND ENERGY CENTER - SERIAL: 23517 FILE: 24.2
References:
1.
MLCurland letter to RAWells, dated August 8, 1983, Serial 25172
~
2.
RAWells. letter to_ JWCook, dated August 8,1983, Serial 23677 3
RAWells letter to DBMiller, dated August 9, 1983, subject: Midland Energy Center Project -(MateriaJ. Araw..bitIty aeview CCP Zone y Please find attached copies of the three memos referenced above which deal with
@erialtraceabilityp
'Should you have any questions, please feel free to contact me or Brien Palmer.
89/
HPLeonard, General CA Superintendent Plant Assurance Division Midland Project Quality Assurance Department HPL/BMP/ckb cc: JHarrison, USNBC c
DBMiller, Midland BMPalmer, Midland DATaggart, Midland RAWells, Midland
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To RAWells WM r.
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DATE August 8, 1983 Power susscc7 MIDLAND INERCY CENTER PROJECT -
PROCRAMMATIC REVIEW OF MATERIAL jl TRACIABILITY BT MPQAD to..c,,
ogmeg FILE 24.0 SER TAT-25172 tC i
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l MPQAD has completed a review of the procedures and systems in use at the Midland Plant, for identification and control of material and components in response to a Zone 6 action item of the Construction Completion Program. An evaluation was made of the adequacy ~of iihese procedures and systema to fulfill 1
j and adhere to regulatory, code and standard requirements regarding material identification and control. The revity consisted ofs, a search of require-ment documents, procedures, specifications and instructior.s s personnel contacts and observations of stockroons, storage areas and field-installations. Inves-tigations concentrated on.pspe hangers and supports, structural materials.
piping, and weld fillet.Jsag_erial.
Based on this review, my staff and I have concluded that the systems in use for material ider.tification and cor. trol do provide for compliance.with ASME Code requirements of identification through fabrication, and for 10CFR50 Appendix 3 requirements of preventing the use of incorrect material. Although j.
the requirements are met, the degree of compliance is considered minimal. The report prepared by my staff does recommend some actions which it is believed 4
will provide a more positive control for future activities and will lessen l
project vulnerability to subsequent difficulty in responding to questions of material acceptabili,ty. However, it is my judgement that the present i
program and the verification of material identification imposed by appropriate i
PQCIs complies with the commitments for this project. 74 is my conclusion i
that although certain improvements will be recosmended. as noted above, there I
should be no constraint ~or holds placed on the inspect /on. process at this time.
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Faoi RAWells, Midland bONSUEOII car August 8, 1983 power
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I Company Sussect MIDLAND ENERGY CENTER PROJECT -
CCP PROGRAMMATIC REVIEWS
$cN.c.,cc j
MATERIAL TRACEABILITY
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FILE 24.0 SERIAL 23677
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CC WRBird, P-14-4181 DBMiller, Midland l
MLCarland, Midland BMPalmer, Midland HPLeonard, Midland As part of our Construction Comple. tion Program, MPQAD was assigned the i
responsibility to conduct certain programmatic reviews as a prerequisite to initiation of Phase 2 of the CCP. The purpose of this y==a is to address the review conducted on material identification and control. This study has been completed under the direction of M L Curland, Principal Quality Advisor for I
MPQAD. The fundamaatal conclusion of the study is that the systems in use i
for material identification and control do provide ic.r compliance with ASME
^
Code requirements of identification through fabrication, and for 10CFR50 Appendix B requirements of preventing the use of incorrect material.
9 l
The detailed findings', conclusions and reIcommendations contained in Ehe,MPQAD report will be presented to the CCP Management Review group and selected staff 4
l in the very near future. It,is the position of MPQAD that our material identi-i fication and control systema are acceptable, although certain recommendations j
nay be made for future improvements. Additionally, since material identifica-tion and control verification is required where necessary through appropriate PQCIs, it is concluded that the program for material identification and, control i
requirements and verification is acceptable for inspection purposes. Although some improvements will be recommended to the overall program, these are not considered a constraint to our inspection process., The ongoing larger rain-i spection effort'and reinspections under the QVP will meet programmatic material identification and control requirements.
1 i
This position is based upon a collective review of the final draft report by
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my staff and upon the recommendation' of M L.Curland, attached.
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To DEM111er
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rno RAWell Consumers Darc August 3
Power company Sussect MIDLAND ENERGT CENTER PROJECT -
MATERIAL TRACEABILITT REVIEW surca 46
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The attaghed menos indigate that NPQAD has completed its revies of.msteriil,
- l traceability as required by Zone 6 of the CCP; As, indicated in the stti?hed, the programs presently in place are acceptable, although,some recommenditions for improvements for future use will be made.. The. details of the study And conclusions will be. pre.ented to the CCP management group for inforestion in the near future.
I consider this CCP assignment cioned.
31, CONSUMRS MWR mm ECEIVEy AUG 10 563 HP LEONARD 9
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