ML20091L042

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Notice of Violation from Insp on 781211-13,18-20,790104-05, 09-11 & 22-25.Handwritten Notes & Jd Kane Prof Qualifications & Experience Statements Encl
ML20091L042
Person / Time
Site: Midland
Issue date: 05/01/1984
From:
NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III)
To:
Shared Package
ML17198A223 List: ... further results
References
CON-BOX-01, CON-BOX-1, FOIA-84-96 NUDOCS 8406070303
Download: ML20091L042 (23)
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Text

{{#Wiki_filter:- -~ o 6 S ( Appendix A NOTICE OF VIOLATION ~ Consusers Power Docket 5o. 50-329 4 i Company Docket No. 50-330 Based on the results of an NRC investigation conducted on Dece=ber 11-13, 18-20, 1978, and January 4-5, 9-11, 22-25, 1979, it appears, that certain of your activities were not conducted in full compliance with NRC require =ents as noted below. These items are infractions, j 1.. 10 CFR 50, Appendix B Criterion III requires, in part, that measures shall be established and executed to assure that regula-tory requirements and the design basis as specified in the license application for structures are correctly translated into specifi-cations, drawings, procedures and instructions. Also, it provides that measures shall be established for the identification and control of design interfaces and for coordinates among partici-pacing design organizations. --* CPCo Topical Report CPC-1-A policy No. 3 Section 3.4 states, in part, "the assigned lead design group or organization (i.e., the NSSS supflier, A&E, supplier or CPCo) assure that designs ar.d materials are s'uitable and that they co= ply with design criteria t and regulatory requirements." 5 /. 8406070303 840517 PDR FOIA RICE 84-96 PDR

~. d i .m' CPCo is cocsitted to aSI N45.2 (1971), Section 4.1, which states, 'in part, " measures shall be established and docu:ented to assure that the applicable specified design requirements, such as a design basis, regulatory requirements... are correctly translated isto specifi-cations, drawings, procedures, or instructiens." Contrary to the above, measures did not assure that design basis were included in drawings and specifications nor did they previde for the identification and control of design interfaces. As a result, several inconsistencies were identified in the license application ' and in other design basis documents. Specific exa=ples are set ) forth below: t a. Construction Drawing C-45 (Class I fill material areas) ./ specifies the foundation material for Class I structures to be Zone 2 material, defined as any caterial free of hu:us, organic or other deleterious. material with no restrictions or gradation while TSAR Tables 2.5-9 and 2.5-14, indicate the foundation material for support of Class I structures to be controlled compacted cohesive (clay) material. i 4 8 4 \\' / 9 e e 4 .,n.-

g f g g g y Appendix A. 1 b. The FSAR is internally inconsistent in that FSAR Figure 2.5-48 indicates settlenent of the Diesel Generator Building to be l on the order of 3" while FSAR Section 3.8.5.5 (structural acceptance criteria) indicates settlenents on shallow spread footings founded on co=pacted fill to be on the order of 1/2" or less. The Diesel Generator Building is supported by a 7 continuous shallow spread footing. I l I c. The ' design'settlenent calculations for the diesel generator and borated water storage tanks were perforned on the assunption of uniform mat foundations while these foundations were designed and constructed as spread footing foundations. ) / d. The settlement calculations for the Diesel Generator Building indicate a load intensity of,3000 PSF while the FSAR, Figure 2.5-47, shows a load intensity of 4000 PSF, as actually I constructed. t The settlement calculati'ons for the diesel generator building -. a. 3 were based on an index of compressibility of the plant fill i bet 1[eenelevations603and634of0.001. These settler, cat I I b a + l

,c. i ~'5 g ] values were shown in TSAR Figure 2.5-48. However, ?SAR, Table 2.5-l6', indicates an index of co:pressibility of the same plant fill to be 0.003. f. PSAR, Amendment 3 indicated that if filling and backfilling operations are discontinued during periods of cold weather,. all frozen soil would be re=oved or reco=pacted prior to the resumption of operations. Bechtel. specification C-210 does not specifically include instruction's for removal of frozen / thawed cc pacted nacerial upon resu=ption of votk.after winter i periods. N g. PSAR Amendment 3 indicates that cohesionless soil (sand) would be compacted to 85% relative density according to ASTM D-2049. / . However, Bechtel specification C-210, Section 13.7.2 required 1 cohesionless soil to be compacted to not less than 80% relative density. t i 4 2. 10 CFR 50, Appendix B, Criterion V requires, in part, that activities ) affecting quality shall be prescribed and accomplished in accordance + with documented instructions, procedures or drawings. s' C?Co Topical Report CPC-1-A Policy No. 5, Section 1.0 states, in . part, thatg " Instructions for controlling and performing activities ( 'N N_/ affecting quality of equipment or operation during design, construction u and operations phase of the nuclear power plant such as procura:ent. 8 O y -,m, s

.J g Appendix A s. ~. . manufacturing, construction, installation, inspection, testing ... are docu=ented in instruction, procedures, sepcifications ... these docu=ents provide qualitative and quantitive acceptance criteria for determining important activities have been satisfactorily accomplished. ~ 0?Co is conmitted to ANSI N45.2 (1971), Section 6 which states, in " activities af fecting quality shall' be prescribed by documented

part, instructions,. procedures, or drawings, of a type appropriate to the 4

circumstances and shall be accomplished in accordance with these instructions, procedures or drawings." (w)o 1 ' Contrary to the above, instructions provided to field --e a. /' construction for substituting lean concrete for Zone 2 material did not addrms the differing foundation properties which would result in differential settle ent of'the Diesel Generator Building.- I e i b. Also, contrary to the above, certain activites were not accom-plished according to instruction and procedures, in that: l (1) The compaction criteria used for fill material was 20,000 I f t-lbs (Bechtel modified proctor test) rather than a

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  • compactive energy of 56,000 ft-lbs as specified in 3echtel gu Specification C-210, Section 13.7.

1 (2) Soils activites were not accomplished under the continuous supervision of a qualified soils engineer who would perform in-place density tests in the compacted fill to verify that all =atarials are placed and ec=pacted in i \\ accordance with specification criteria. This is required - by Bechtel Specification C-501 as well as ?SAR, A=end-a ment 3 (Dames and Moore Report, page 16). - 3." 10 CFR 50, Appendix B, Criterion X requires, in Part, that a pro' gram t for inspection of activites affecting quality shall be establi,shed and i executed to verify conformance with the documented instruction, proce- '/ dures and drawings for accomplishing the activit'y. i 1 1 CPCo Topical Report CPC-1-A Policy No.10, Section 3.1, states, in j part, that " work activities are accomplished according to approved l procedures or instructions which include inspection hold points 4 I i beyond which work does not proceed until the inspection is complete i i - or written consent for bypassing the inspection has been received t i from the, organization authorized to perform the inspections." 2 4 1 0 e () 4 s .3 -,.---w-

t t 1 1 s Appendix A, CPCo is coc=itted to ANSI K45.2 (1971), which states, in part, '!A program for inspection of activities affecting quality shall be established and executed by or for the organi:ation perfocuing the activity to verify confor=ance to the documented instructions, procedures, and drawings for acco=plishing the activity." Contrary to the above, Quality Control Instruction C-1.02 the program for inspection of ccepsdeed backfill issued on October 18, 1976, did not ~ provide for inspection hold points to verify that soil work was satisfactorily acco:plished according to docunenced instructions. 1 ( 4.- 10 CFR 50, Appendix B, Criterion XVI requires, in part, that measures shall be established to assure that conditions adverse to quality' such as failures, deficiencies, defective material and nonconfornances are promptly identified and corrected. In case of significant I-conditions adverse to quality, measures shall assure that corrective action is taken to preclude repetition. CPCo Topical Report CpC-1-A Policy No. 16, Section 1.0 states,_in part, " corrective action is that action taken to correct and preclude f recurrence of significant conditions adverse to the quality of.itens ~ or operations. Corrective action includes an evaluation of the \\ _,/

,' g 's N5 / conditions that led to a nonconfor=ance, that disposition of the nonconfor=ance and co=pletions of the actions necessary to prevent or reduce the possibility of recurrence." Contrary to the above, measures did not assure that soils conditions of adverse quality were promptly corrected to preclude repetition. For example: a. As of January 25, 1979, moisture control. in fill =aterial had not been established nor adequate direction given to i=plement this specification require =ent. The finding that the field was not performing moisture control tasts as / required by specification C-210 was identified in Quality ( / Action Request SD-40, dated July 22, 1977. ,s/' b. Corrective action regarding nonconfor=ance reports related to plant fill was insufficient or inadequate to preclude repeti-tion as evidenced by repeated deviations from specification requirements. For example, nonconfor=ance reports N,o. CPCo i QF-29, QF-52, QF-68, QF-147, QF-174, 'QF-172 and QF-199 ~ ~~~ contain numerous examples of repeated nonconfornances in the same, areas of plant fill construction. S e / T V ?

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  • I ham.h PROFESSIONAL QUALIFICATIONS AND EXPERIENCE NAME:

Joseph D. Kane ADDRESS: 7421 Miller Fall Road Derwood, MD 20855 EDUCATION: B.S. Civil Engineering 1961 Villanova University M.S. Civil Engineering 1973 Villanova University Post-degree studies Soils and Foundation Engineering University of California 1972 University of Maryland 1978 PROFESSIONAL REGISTRATION: ) Registered Professional Engineer (1966) - Pennsylvania 12032E PROFESSIONAL SOCIETY: American Society of Civil Engineers ( EMPLOYMENT POSITI0flS: February 1980 - Present Principal Geotechnical Engineer U.S. Nuclear Regulatory Comission Geotechnical Engineer.. May 1977 - February 1980 -- _ U.S. Nuclear Regulatory Comission-October 1975 - May 1977 Soils Engineer-- U.S. Nuclear Regulatory Comission August 1973 - October-1975 Supervisory Civil. Engineer.. _ Chief, Soils Design Section U.S. Army Corps of Engineers i i Philadelphia District l January 1963 - August 1973 Civil Engineer Soils Design Section U.S. Army Corps of Engineers l Philadelphia District January 1962 - January 1963 Design Engineer McCormick - Taylor Associates Philadelphia, Pa. l l

.e i Professional Qualifications ' and Experience Joseph D. Kane f PROFESSIONAL EXPERIENCE SUPHARY: l 1975 to Present In NRC Division of Engineering, Geotechnical Engineering Section, Mr. Kane has specialized in soil mechanics and j foundation engineering. Experiences in this position have included the following: a. Evaluation of the foundation adequacy of proposed sites for nuclear facilities with respect to design and operational safety. This work has included evaluation of geotechnical, soils and rock mechanics, foundation and earthquake engineering related aspects. i The results of this review effort are summarized in a safety evaluation report for each of the proposed facilities which have included nuclear power plants, nuclear fuel reprocessing plants and uranium mill tailings waste systems. 4 b. Serving as a technical adviser for soil and foundation j [_' engineering related aspects in the development of j ( regulatory guides, acceptance and perfonnance criteria 1 that are intended to assure construction and l operational safety of nuclear facilities. c. Serving as a technical representative for the Office i of Nuclear Reactor Regulation:on,the_NRC Advisory Group concerned _with:. federal-dam-saf.ety. d. Serving as an instructor for the Office of State Programs in the training of state personnel who are responsible for construction 2nd operational- -~- i inspections of-uranium mill tailings embankment i retention systems. l 1963 to 1975 During this period Mr. Kane was employed with the U.S. l Anny Corps of Engineers, Philadelphia District and i attained the position Chief Soils Design Section. l Foundations and Materials Branch, in 1973. Professional experiences with the Corps of Engineers have included the following: a. The embankment and foundation design of four large multi-purpose earth and rockfill dams with appurtenant structures (spillways, inlet and outlet structures. control towers, flood protection facilities, etc.). ( Responsibilities ranged from the initial planning of v l

i, i ,tions. T d subsurface investigations to select the most feasible sites through all design stages which were culminated in the final preparation of construction plans and specifications. This work included planning and evaluation of laboratory testing programs, studies on slope stability, seepage control and dewatering systems, settlement, bearing capacity, liquefaction embankment safety instrumentation and slope protection. b. Served as a technical consultant to field offices et;arged with construction inspections for assuring completion of structures in compliance with design analysis and contract specifications. Participated i in the development of needed modifications during construction whenever significant changed site 3 conditions were uncovered. c c. Directed the efforts of engineers in the Soils Design Section in other fields of civil work projects that included the embankment and foundation design of l levees, waterfront pile supported structures and disposal basins for the retention of hydraulic dredge waste. Served as design and project engineer for private consulting , fim. This work included the design of large federally .r funded highways,_a. race. track and_various structures - constructed to. provide a Pennsylvania-State park marina... 1972 0 Award 1978 ~ l ) i l

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o d he I e l ~6" Ccnse,ne,s Etb6t ' 4 (\\(cr.ch u\\s.ve., .~ DEPARTMENT OF THE ARMY 'll4 otract? 2:svatet. comes oF eN48NeenS i SO X 1027 OcTactf. MICHIGAN 44239 I 8, J F O ' NCEED-T

SUBJECT:

NRC Midland Project, Request for Additional Borings and Existing Soil Data - Revision No. 1 U.S. Nuclear Regulatory Commission Dr. Robert E. Jackson Division of Systems Safety '4 ail Stop P-314 Washington, D.C. 20555

Dear Dr. Jackson:

Inclosure 1 to our letter of 27 March 1980 has been revised and attached hereto. The two caps provided indicating boring locations renain unchanged. FOR THE DISTRICT ENGINEER d, L, u l a .. ~. -. L Inci p g3. ng; As stated g g,3,q,4 Divist.c h/ i i u$ 4, ,f ~: g.6 Y

ih(kkyttiQoevt kR(% C,cE,4t030*'t ( 1% Mh N bkb uCb %' Ud 4h {Umant@~$W($tf/ut3

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's 1NCLOSURE 1 1. It is requested that the applicant furnish the boring logs listed below indicating when and how these were taken, the ty+ptof sampling, and sampggsg pg.M-M h W-h 1 + iP srorise, to G w M A < 5 / (utacej,n Tvyt 2 taken: R. ) l Pull down holas PD-1 thzu PD_27* D1_ holes) _b. LOW-1 thru LOW-13 &.W-1_thru W-4 (18 Holesh 5iev. b Nat F.3L.%t. A inA, 74-1 thru T4-5 & P1-1 thru PZ-48 (53 holes) OW-1 thru OW-3 &'hidl ibru'lL t9 holes)~~ E'Q I4sTE __. __. _ _ _ ) TEW-1 thru TEW-7 & Q-1 thru Q-12 09 holes) = Includes SA, 20A, 208, 20C, 15A, 158,15C, & 27A.

2. Locations, boring logs and test data from any other drill holes taken in 1979 and 1980 are also requested.

f cde. 2.4.1 -R- - -- ,s. 5 %-- - - ~ T q,,,,s: g %n. 3 3. Dutch cena penetrometer data from holet P-1 thru P-13 must also be %.Do O provided. U.',a aev404 e xf7 5%. ?'c 4 ~~ h - - "~~ gg Information is requested on all piezorseters that, were installed to.:sonitor gg '.. The information should include the number and ""$problemsrelatedtoplantfill. location, the time of installation, the type of filter around the piezometer, o the installed depth, and the type of piezometer. %4 M yulch,, ht/,1% ofv whrovde; - Asr., {w '1 m = pne.,eiu bles / required. ' N '"'" /'8'ggs for each installation with dates and times are (.., 3. All piezometer,readi n a,,, <a cat. repestd d b). : m ca: m s 6. The data and information requasted in paragraphs 1 thru 5 above is needed ** to verify the applicant's computations and conclusions and to make any needed computations for the dewatering analysis, the seismic analysis and the settlement analysis. 7. A need exists for additional borings, since random exploratory borings throughout the plant site h,*va revealed pockets of soft clay subject to settlement and or consolidation and loose sands subject to liquefaction. A need also exists to check the results of the proposed remedial fueasures of surcharge loading at the Diesel Generator Building and the dewatering plan. s. In the ense of the Diesel Generator Building, check borings 1:ust be made in the vicinity of borings which identified low "N* values in the clay and sand fill. The proposed borings shall be carried into the 31acial till 2ndallsamples,includingthoseinthebacialtill,testedasindicated l wlow. teC A %)c..,3a.seco,4,,A..r%gsis %,,,,, et,,, &,, r,, y Tm-St.W ov-} ,,s5g ,,, 7. re,,w 7 *ce m m e g to,og, q k., I

5 8 deb 4 7Y1 . w \\ ,/ \\ ,/ '[Theboringlocationsareasindicatedontheattachedmap. All soil for the ' full depths of the borings shall be classified according to the Unified Soil Unitweightandmoisturecontentof's.11hUplpoilshallbe Any tests necessary to classify the I Classification Systaa. e Ps'h'o'uld also be ! accomplished. determined. The samples obtained from any cohesive strata shall be tested. . The tests for cohesive asterial shall be a consolidationginggndyig Q g 3g E8 ig y, " triaxial shear tests (R&S) and a consolidation test with -,.a - e m u.a. .a , _ g, _,. ;. n,. ;, ; u ,.,,, _ _ n, the sands shall be tested in direct shear for a loose and dense condition and the relative density of the sand in situ determined. Mn.ovd

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MyN b. Where piling or caissons are propose to underpin t Phervice ater Building and Auxiliary Building - feed water valve pits which are located on fill, the load bearing capacity of the bearing strata must be determined. The capability to resist lateral shearing stresses that could be induced in low "N" value soil subjected to seismic action must also be determined. The same tests required for soil samples obtained from the new borings at the Diesel Generator Building shall also be made on soil samples from new borings for chaise buildings. c. The questionable site area fill may have a counterpart in the cooling pond embankment which was constructed contemporaneously with the site fill. It is requested that exploratory continuous drive borings be taken at a number of points along the north and east embankments, omitting the slurry trench cutoff areas which are positively sealed. The approximate boring locations are as indicated on the attached map of the cooling pond. Upon completion of drive boring a second undistrubed boring shall be made adjacent oc the disturbed boring to sample cohesive soils. The tests on the soil samples obtained from the borings in tp,egbankments shall include the following g tests, consolidated + drained;tri xial shear tests, (cohesive samples) Atterberg limits and all soils classified t cording to the Unified Soil Classification System. The drive borings sk . be continously sampled using a standard split spoon sampler. The hole shall be held open using a hollow geen g4 auger or casing. Particular attention T Tbe paid to ground water -- C,lon 9,,,ggA \\ conditions during and af ter completion of drilling. In the case of Hole 5, y y M "' "2*h[h the boring should be drilled to the depth of the cooling pond bottom while the ,,,d m remaining borings need penetrate only 5 feet into underlying residual soils a*' unless sof t ground indicates a need for f reher hole penetra ion. % =.5 bed q 54ea q,e gae,.M,sd f kg (* Summary of Requested Drilling O U1 4'41' f O 9. s. Diesel Generator Building 6 holes around the perimeter of the 5 gtk g building. SampisA af_a11Jerata Jrma s m aA su_rface._1nt3 A glacial till y/ , (HolesJ-1MMaclude downhole,'"crosshole Sask surface geophysical tests t p5 (tig,; l y s >g (~y > destan check nencioned on ps. ta q viz-e of Interim sta. .u,.7.t.a a Qtc. ' jop ihe'5 SfWsEIblish insitu compression and shear moduli for floor response spectra 3 gir- ~ ge 8 ON *f.*M d'.('Jm N, p %.,7. h d. pp U>* z. ( ...+M M y, w.m % b f,U

) h M T hit h ' 1, 1 b. Auxiliary Building j-aka two borings around the proposed support piling or caisson for emedial-froutin]gf loose sands and soft clays adjacent to pile atBorings need to penetratepp glaciaI gr4und against lateral caisson to se eggdggg till. (see attached map for loading. boring locations - Holes 4 & 5.) c. Service Water Building - A boring (Hole 16) shall be made as indicated on the attached map to and into the glacial till. All samples obtained shall be classified according to the Unified Soil Classification System also consolidation, drained and undrained triaxial compression tests made on cohesive soil samples and direct shears for a loose and dense condition shall be made on all granular soil samples, as spe,cified in paragraph 7B. "Ilwn)rCJL. h d W d. Plant Area Borings - 11 feasible some borings should be taken under kb the Radwaste and Turbine Buildings cli"Tetermine if unwatered pockets exist or d h " persist. Suggested boring locations would be as indicated on the attached Further investigation could be needed afEar the results of these borings G/E b I cp# map. are obtained. No borings presently exist in these areas. The borings should g g y /fu g ' gp be cased or hollow stem auger borings with drive samples every 2-1/2 feet 7M j 1-

cf chrough the fill.

f a E n W o h 4 5 l: a r.o a..u. uo. k 80 r'_ --- 1. '.M._ ', 2, 2, . D.- M t >q. 's e. The site visit of 27 or 28 February 1980 turned up two differential settlement points on the retaining wall adjacent to the Service Water Pump Structure. Two borings, Holes 14 and 15 as indicated on the attached map shall be taken gg* vestigate this problem. Tests required are, consolidation tests, triaxialgcompression tests, Atterberg limits and gradation tests made oncohesivesoils,anddirectshearforlooseand,dgnseconditionsand gradation tests made on granular soils. St*ha#,(t-ckte

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I f. In all new borings made, the water table shall be determined. vtpesentrIut h (06, 9 'mC h[A Jh4 Ort eye >*th

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