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April 21, 1983 Mr. Jay Harrison.
VS Nuclear Regulatory Commission Region III 799 Roosevelt Mand Clan Ellyn, IL 60137 HIDI.AND ENERCY Cf. HILA PROJECT - CliR1FICATION OF CPCO POSITIONS Files 1.1.5 Serials 22124' Per requestc of Mr. Ron Cardner to Roy A. Welle during an exit meeting at the Midland Site on February 18, 1983, this letter confirms Consumers Power Company's positions in the areas noted below:
TRAINING RECARDING IPINS Personnel are being trained that IPINS are no longer authorized for use on the Midland Project. In addition, training emphasizes that once an inspection is initiated, it will be completed to the point of construction completion and that all nonconforming conditions observed will be documented on a nonconfor-mance report.
Procedures presently being written for verification and statusing activities required by the Construction Completion Plan (CCP) will cover Inspection Reports (IR) that have an 9ssociated IPIN to assure that inspections are complete and that all existing conconformances are documented. Personnel will be trained in these procedures.
h0W TO HANDt.t INSPECTTON REPORTS WITH ! PINS _
,C,losed irs Daring the verification phase of the Construction Completion Plan (CCP), all closed Inspectio't Reports (irs) that had IPINS associated with them will be 1007 verified by physical reinspection wt'ere possible and by documentation verifica-tion where attributes are inaccessible. Any no.tconforming condition observed will be documented on. a nonconformance report. Correction of nonconforming con-ditions previoissly noted on the IPIN will be specifically verified. This pro-cess will assure that the itse being reinspected has received a total verification.
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All items with an open IR and a partial inspection will be completely reinspected i
l during the systems statusing phase of the CCP. This will be done as part of the l
l System Completion Teams Phase 1 responsibility. Inspections will be done using ravised PQCIs and any nonconforming conditions will be documented on nonconfor-mance reports. During the reinspection, nonconforming conditions previously identified on an IPIN will be specifically reverified and, if they still exist, will then be documented on a nonconformance report as part of the normal rein-spection process. This process will assure that nonconforming conditions will be properly documented..that rework will not cover up a nonconforming condition, and that all units receive a total inspection before the IR can be closed.
PERFORMANCE DEMONSTRATIONS BY QA/QC PERSONNEL In order to minimise the peer pressure that might be experienced by Level II/I!!
l personnel administering performance demonstrations for Project Quality Control Instructions (PQCIs) as part of the QCE recertification process, the following approach is being used Balance of Plant PQCIs Performance demonstrations for QC personnat are being given by Level !!/I!!
personnel assigned to Balance of Plant - QA.
Soils PQCIs Performance demonstrations for QC personnel are being given by Level II/III personnel who do not have an established peer relationship with the QC inspector being tested. Bechtel QC personnel are administering performance demonstrations to Contractor QC personnel and conversely, Contractor QC personnel administer performance demonstrations to Bechtel QC personnel. Personnel assigned to QA section of the Soils organisation administer performance demonstrations to either Bechtel or Contractor QC personnel.
The above should be responsive to Mr R Cardner's questions. As appropriate, the above concepts will be incorporated into formal procedures.
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Mr. J. W. Cook Vice President Consumers Power Company 1945 West Parnall Road Jackson, Michigan 49201
Dear Mr. Cook:
Subject:
NRC 1983 Schedule for. Midland Your letter of October 28, 1983, reconsnends deferring further Case Load Fore-cast Panel (CFP) meetings for Midland Plant, Units 1 and 2 pending completion of your new Unit 2 schedule shortly after the first of the year. You note that Dow's termination and delays in approval of the CCP have invalidated the plan set forth and reviewed with the CFP in April 19-21, 1983. You provide no estimate when your decision for Unit I will be available.
Based upon the information and observations as oi' April 19-21, 1983, the staff concluded that some months beyond the second quarter of 1986 was the earliest date that completion.of Unit 2 could reasonably be expected, and that Unit I was expected to be ccmpleted about 6 to 9 months.thereafter. The staff's 1983 projection assumed' approval of the Construction Completion Plan in May 1983.
The actual approval occurred on October 6,1983. Subsecuently, several stop work orders were issued by CPCo which are currently impacting all safety-related construction.
In a November =9,1983, press release, CPCo announced preliminary indications that consnercial operation of Unit 2 may be delayed until mid-1986, rather than February 1985, based upon the. study to be completed by the end of 1983.
i Accordingly, for'our planning purposes, we intend to use September 1986 as cur planning date for completing the licensing review process for Unit 2.
We will reevaluate our pr6jection in"1984:
Sincerely,
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Thomas H. Novak; Assistant Director V
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Washington, DC 20555 DearChairmanhechhoefer Cor.sumers Power Company'is planning to announce its new construction schedule for the Midland Nuclear' Plant today. The new fuel load date. for Unit 2 is October 1984. The fuel load date for Unit 1 is February 1985.. Commercial operation dates for Units 2 and 1 are set at February 1985 and August 1985, respectively.
Thank you for your attention.
Very truly yours E Brunner I
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3 STONE 6 WEBSTER ENGINEERING CORPORATION 245 SUMMER STREET. B o STO N. M A SS ACHU SETTS ADDRESS ALL CORRESPONDENCE TO P.O. SON 2323. SOSTON. M A S S. 02107 l
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United States Nuclear Regulatory Commission February 23, 1983 Midland Site Resident Inspection Office Route 7 J.O.
No.
14358 Midland, MI 48640 Ref. MPF 22 Attention Mr. R. Cook RE: DOCKET No. 50-329/330 MIDLAND PLANT - UNITS 1 and 2 INDEPENDENT ASSESSMENT OF AUXILIARY BUILDING UNDERPINNING REPORT NO. 22 A copy of the Independent Assessment of the Auxiliary Building Under-pinning Weekly Report No. 22 for the period February 13, 1983 through February 19, 1983, is enclosed with this letter. Included as attachments are the minutes of the daily meetings held during the week between members of the Assessment Team and Site Engineering, Construction and Quality Assur-ance personnel.
If you have any questions with respect to this report, please contact me at (617) 589-2067.
PRINCIPAL STAFF Very truly yours, L RA
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J.O. NO.
14358 Midland Plant Units 1 and 2 l
Independent Assessment Auxiliary Building Underpinning Weekly Report No. 22 i
j February 13, 1983 through February 19, 1983 Personnel on Site Stone & Webster Engineering Corporation (SWEC)
B. Holsinger 2/17 - 2/19 W. Kilker 2/17 - 2/19 L. Rouen 2/14 - 2/16 P. Barry 2/14 - 2/16 A. Scott 2/14 - 2/19 Parsons, Brinckerhoff, Quade and Douglas (PBQD)
J. Ratner 2/14 - 2/17 Meetings Attended Date Represented Purpose 2/14 Stone & Webster Daily Meetings through Bechtel 2/18 Consumers Power Parsons (2/15 - 1/17)
Activities Construction - At the W12 pier location, the upper and lower leveling plates were bolted to the turbine building mat and the top of the pier, respectively.
The nominal 2 inch spaces between the leveling plates and the structural concrete j
surfaces were than filled with dry-pack grout.
l The telltale instrumentation was installed in pier E12, the formwork between El 600 and 605 was completed and the concrete'was placed in a continuous pour from the bottom of the bell, El 565, to top of the pier, E1 605. The upper leveling plate was installed. The proorload jacking of Unit 2~ FIVP was perforned.
l Quality Control, Documentation and Records i
j 1.
Reviewed the Quality Control Instruction on proof-jacking the FIVPs.
2.
Reviewed the QC Inspection Report completed for the Unit 2 FIVP proof-jacking.
3 Observec the Unit 2 FIVP prooficad jacking and the in-progress QC inspection of the jacking.
4.
Reviewed performance history of concrete mix utilized for piers W12 and E12.
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14358
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Midland Plant
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Units 1 and 2 Independent Assessment Auxiliary Building Underpinning 2
I Quality Control, Documentation and Records - (continued) 5.
Witnessed QC inspection of dry-pack placement for upper plate at pier W12.
l 6.
Observed the placement of the concrete at pier E12.
7.
Witnessed the QC inspection and testing of concrete during the pier E12 concrete placement.
Observations Construction - The placement of the dry-packgrout between the leveling plates and the structural concrete at pier W12 was properly done. However, the initial t
handling of the grout material was found wantir.g in that the bags of grout were openned and spread-out well before required for placement. As the activity pro-ceeded the Contractor modified the handling so that the grout bags remained sealed until just prior to mixing and placement.
Observations of the bell area of pier E12 prior to concrete placement revealed minor unraveling of the exposed soil. This occurrence was due to air exposure for a period of at least 11 days. Altnough no significant problems occurred on this bell, the Assessment Team feels that based on normal good industry practice, for future piers the time between bell excavation and concreting should be appreciably reduced.
The concrete-mix and placement procedure for pier E12 were in accordance with the project documents. The Contractor selected the same concrete mir design used for pier W12 since the mix design using plasticizer had not yet been app-roved.
The proorload jacking of Unit No. 2 FIVP was well planned and executed. The entire organization responded efficiently in resolving a jack recalibration non-conformance.
I Ouality Control, Documentation and Records - The Quality Control procedures and reports reviewed by the Assessment Team were properly prepared and executed.
The QC inspectors performing the inspections had a good understanding of the activity being inspected as well as their own role. With respect to the FIVP I
proorload jacking in particular, the Quality Assurance organization produced a good quality inspection plan from the field procedure outlined on a project I
drawing. In addition, the QA organization recognized ahead of time the need for training the construct 1on personnel on the jacking procedure and established training as a prerequisite for the jacking.
With respect toa minor problem noted in Weekly Report No. 20, the Team verified that a change has been made. The PQCI and corresponding Inspection Report l
l now provide a means for documentin6.the results of concrete consolidation.
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- J.O. No.
14358
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Midland Plant Units 1 and 2 Independent Assessment Auxiliary Building Underpinning
'3 Non-Conformance Identification Reports
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Status of previous issues:
(NIR numbers on longer listed have been closed-cut.)
NIR No.
Description Date (Opened)
(Closed) 5 Concrete Mix 2/10/33)
Qualification w
D V Aq Project' Engineer Project. Manager I
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M INDEPENDENT ASSESSMENT TEAM MEETING WITH BECHTEL l.
Date: February 14, 1983 i
Attendees:
Bechtel Stone / Webster MPQAD CPCo J. Fisher L. Rouen R. Sevo E. Cviki P. Barry J. Gaydos 1.
J. Fisher said trial mixes of all new concrete mixes will be run. Not-ification will be given to all interested parties when begun.
I 2.
Cenerete placement for C12 is scheduled for Wednesday. Unit 2 FIVP jack-ing is scheduled for Tuesday.
3 R. Sevo asked about load trasfer mock-up.
J. Fisher will check on this.
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1 INDEPENDENT ASSESSMENT TEAM MEETING WITH BECHTEL Date: February 15, 1983 f
Attendees:
Bechtel Stone / Webster MPQAD CPCo I
J. Fisher L. Rouen R. Sevo G. Murray I
E. Cviki J..Gaydos Parsons J. Ratner 1.
In response to an earlier Team question, J. Fisher said bentonite was notused to prevent slaking because Mergentime felt it would not adhere to the clay surface.
2.
J. Fisher advised that if a pier was poured using both a mix with plasti-cizer and without, cylinders would be made for each mix.
3 J. Ratner expressed concern about the bell in pier E12 being exposed to air,for such along period of time.
J. Fisher said that he and M. Lewis had discussed this before and will if necessary take measures to pro-tect the face of the excavation.
4.
E. Cviki stated that a new crack in the FIVP had been mapped. Tnis crack would be inspected by CTL Company.Cechtel Ann Arbor will evaluate.
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INDEPENDENT ASSESSMENT TEAM MEETING WITH BECHTEL Date: February 16, 1983 Attendees:
Bechtel Stone / Webster MPQAD CPCo E. Cviki A. Scott R. Sevo G. Murray J. Fisher P. Barry L. Rouen Parsons J. Ratner 1.
J. Fisher will advise when trial mixes will be run for the concrete rix a
C-Sc with & without plasticizer.
2.
The schedule for FIVP jacking has been delayed, due to the fact that the jack calibration records must be checked for those jacks used to install anchor bolts.
3 L. Rouen asked for clarification on which steps in MCP 16.000 on splicing of Fox-Howlett couplers must be performed by the qualified splicer whose identification mark goes on the bar.
4 J. Fisher advised that there would be a " dress renearsal" for the load transfer prior to actual pier loading. Will advise the time.
5.
L. Rouen stated the FIVP proof jacking and pier W12 concrete placersnt were performed adequately in the vieds of the Assessment Team members present.
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INDEPENDENT ASSESSMENT TEAM MEETING WITH BECHTEL Date: February 17, 1983 l
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Attendees:
Bechtel Stone / Webster MPOAD CPCo l
D. Lavelle A. Scott J. Shah G. Murray i
E. Cvikl J. Gaydos Parsons J. Ratner 1.
D. Lavelle reviewed the list of requirements needed prior to jacking the FIVP Unit 2 east side. At present the start of jacking will be 7:00 AM on February 18, provided all requirements are met this date.
2.
A " dress rehearsal" for pier W12 load transfer will be held in Mergentime's Mechanical Shop at 10:00 AM and 5:30 PM on February 18, and at pier W12 on Monday February 21, with the actual load transfer to be performed on February 22.
3.
D. Lavelle presented a new organization chart to show how Bechtel plans to organize their forces to expedite the disposition and closing of NCR's
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and to effect better planning and scheduling of materials for.the con-struction forces.
4.
Mr. Cviki stated that CTL had been on the job to investigate the new crack that appeared in the west FIVP and that he was awaiting a written report.
5.
J. Ratner asked if there were plans to reduce the time fcr leaving tha bell open.
J. Fisher stated that scheduled time for the bell to be open j
was to be 12 to 13 days and thought this was good and not detrimental.
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6.
A. Scott requested information concerning the resolution of the question j
originally raised on January 27, concerning " hold tag" on Reshore Channel i
and which was dropped on February 10 from the meeting notes. " Hold tag" is still in-place.
J. Fisher indicated he would raise this concern in the weekly management meeting.
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INDEPENDENT ASSESSMENT TEAM MEETING WITH BECHTEL Cate: February 18, 1983 Attendees:
Bechtel Stone / Webster MPQAD CPCo E. Cvikl A. Scott G. Murray J. G.aydos W. Kilker J. Fisher 1.
J. Fisher advised that jack stand fabrication will begin today at the Poseyville fab. shop.
2.
J. Fisher said FIVP, Unit 2 proof-jacking will be either on February 18 or February 19. Will advise.
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