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Consunmers Povver Company M6dle,ws Project: P.O. Bom 1963, Mkiland, M6ch6een 48640. Aree Code $17 631-095 t August 25, 1982 Mr. W. D. Shafer, Chief Midland Project Section US Nuclear Regulatory Commission Region III 799 Roosevelt Road Glen Ellyn, IL 60137 MIDLAND PROJECT GWO 7020 -
REMEDIAL SOILS WORK AUTHORIZATION File:
0485.16 UFI:
12*32 Serial: CSC-6266 42*05*22*04 On August 23, 1982, representatives of Region III (Dr. Ross Landsman and Mr.
Ron Gardner) and Consumers Power Company (Mr. R. M. Wheeler and others) met at the Midland Plant site for the purpose of providing additional information prior to securing NRC approval for portions of Phase II underpinning work as requested in my August 18, 1982, letter to you (Serial CSM-0564). Specifically, the topics on the attached agenda were discussed at the meeting.
In order to commence construction work on piers 11 and 12, (Items 155054015, 155053015, 155052027, 165052015, 165053010, 165054010, 165052027, 165053015, 165054015, 155052010, 155053010, 155054010 f rom the attachment to my August 18, 1982 letter) the following agreements / understandings were developed:
- 1) Piers Wil and W12, will be probed in advance of the excavation to verify that the ground water level in granular soils is being main-tained at 12ast 2 feet below excavation.
It is understood that some perched water will be encountered at the interface with clay soils and handled in accordance with our procedures.
- 2) NRC Region III and CPCo will review NRR written approvals and attempt to locate a reference in which the NRR has concurred with the concept that the ground water level being maintained at least 2' below the excavation only applies to granular materials.
- 3) The void in the pier steel lagging will be filled with e*.hafoam.
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gap adequate for bolt installation will be lef t in the ethafoam.
- 4) A limit for the maximum water pressure to be utilized in jetting I
temporary well points for localized dewatering will be established
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and implemented.
5)
A limit for the maximum water pressure to be utilized for advancing pipes and the maximum grouting pressures for soil stabilization operations will be established and impleraa*ad i
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NRC agreed that materials for soils stabilization may be procurred 6)-
Receipt, storage, and handling of materials will be covered L
non-Q.
by the QA program.
I Probe holes at the bottom of pier bells will be filled with grout
~ 7) until confirmation from NRR staf f can be obtained for use of rebar l-
_ for filling.
During the construction of piers 11 & 12 and until FIVP support steel
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8) modifications are complete, the FIVP will be monitored to either 50 or If the agreed 100 mils (to be determined later) vertical movement.
upon limit is exceeded work will be stopped, an evaluation will be com-menced and NRC Region III adviaed. Prior to continuation of the physical excavation, NRC Region III approval must be obtained.
Jacking for the turbine building piers will not occur until the delta 9) 4 valves are added to drawing C-1493.
Delta valves will be available for the control tower, EPA and buttress 10) access shaf t prior to pier jacking.
- 11) The WJE procedure OP-41 will be revised as follows:
l Redefine the word shut down to include the words 'which describe the A.
alarming functions.
Delete the reference to allowable valves, since C-1493 no longer uses B.
l this nomeclature.
Review the.002" troubleshooting criteria and determine if it is C.
large enough.
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Clean up all previous comments, l
Work will not commen'ce on piers 11 & 12 until NRR approves the QA plan.
12)
It was noted that only resolution of items 8,11 and 12 above must be completed I
before authorization to proceed with work on piers 11 & 12.
The other items will be resolved, before the specific work activity it af fects is started.
Based upon our above described plan to resolve your concerns, we ask for author-izat' ion to proceed-with construction of piers 11 & 12.
(Item numbers delineated above)
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D. B. Miller Site Manager DBM/RMW/ vip
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Attachment cc JAMooney, P14115A AJBoos, Bechtel Ann Arbor JRSchaub, P13305 JFFisher, Bechtel Midland JKMeisenheimer, Midland LEDavis, Bechtel Midland
AGENDA NRC MEETING ON PIER 11 & 12 PREREQUISITES _
I.
WATER ELEVATIONS FOR PIERS 11 & 12 II.
FOAM IN IAGGING III.
PROCEDURE FOR IDCALIZED DEWATERING.
(HANDOUT: SECTION OF MCP-35.00)
IV.
SOIL STABILIZATION - (HAND-OUT:
MCP-2.8.00)
V.
STATUS OF INSTRUMENTATION VI.
PROCEDURE AND MANNING FOR INSTRUMENTATION A.
SCANNING REQUIREMENTS B.
WJE MANNING C.
COPY OF RSG 2.00 VII.. STATUS OF OP-41 VIII. CRACK MAPPING STATUS FIVP & EPA 8/25/82 P
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- " "%[0, UNITED STATES NUCLEAR REGULATORY COMMisslON REGION lli 5
- E 799 ROOSEVELT ROAD GLEN ELLYN, ILLINOIS 60137 JUN 10 H383 r
NOTICE OF SIGNIFICANT LICENSEE MEETING June 17, 1983 Name of Licensee:
Consumers Power Company MEETING POSTPONED -
Name of Facilities:
Midland Nuclear Plant, Units 1 and 2 TO BE RESCHEDULED IN JULY Docket Nos.:
50-329; 50-330 Date and Time of Meeting: Friday, June 24, 1983, at i:co p.m. (EDT)
Location of Meeting-:
Quality Inn Midland, Michigan Purpose of Meeting:
Management Meeting to review the Systematic Assessment of Licensee Performance (SALP)
RIII Attendees:
James G. Keppler, Regional Administrator R. F. Warnick, Director, Office of Special Cases Others as appropriate NRR Attendees:
D. Hood, Project Manager, Midland Nuclear Plant Licensee Attendees:
J. W. Cook, Vice President Others as designated by the licensee NOTE: Attendance by NRC personnel at the. meeting should be made known by June 20, 1983, via telephone call to J. J. Harrison, Region III, FTS 384-2635 Distribution:
R. C. DeYoung, Director, IE E. L. Jordan Director, Division of Emergency Preparedness and Engineering Response, IE J. M. Taylor, Director, Division of Quality Assurance, Safeguards, and Inspection Programs, IE J. A. Axelrad Acting Director, Enforcement Staff D. G. Eisenhut, Director, Division of Licensing, NRR E. G. Adensm, Chief, Licensing Branch No. 4 R. L. Tedesco, Assistant Director for Licensing, NRR l
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Cars mers Fe.er Cor:any 1.icer.n e I. + rtency C u rif f e ation:
Mid'.and N clear Fcker Station Notificatien of an 1rttual Etent Units 1 & 2 A:ere Midland, MI 48640 Site Area. Emergency
.A Docket Nos: 50-329; 50-330 General Emergency x'x h:,t Applicable Si:,4ct:
STOP-WORK ORDERS ISSUED BECAUSE OF DOCUMENT CONT 50L PROBLEMS Corsamers Power Company on October 24, 1983, notified Region III (Chicago) that it was issuing nine stop work.crders involving extensive safet -related activities at the *-
i Midland site. The orders were issued as the result of a cuality assurance audit of the design document control system.
The stop work orders included procurement activities, testing, nuclear steam supply system installation, piping and pipe support fabrication, renec'ial soils work, heating, ventilating and air _ conditioning system installation, Sechtel quality control hanger reinspections, Bechtel quality control activities, anc Sechtel post-turnover activities.
Bechtet is the architect-erygineer and princioal site centractor. The licensee estimates 500 to 600 workers wiLL be laid off as a result of the stoo work-orders.
The licensee's audit determined that field design changes were not being identified on at apolicable construction drawings, that the effects of minor design changes on design criteria were not being recalculated, and that the quality assurance organization was not reviewing design changes for non-safety-related work which might affect safety-relat'ed systems.
The licensee's corrective action will involve the review of 30,000 field design change documents. Each document involves an average of 1.7 construction drawings. The licensee has not determined how long the document review will take.
There has been local news media interest in the stop work orders. The licensee has not is a news announcement.
Region III is responding to inquiries.
The State of Michigan will be' notified.
Region III was informed of the audit findings o-October 22, 1983. This information is current as of 11 a.m. (CDT), October 24, 1983.
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J. Harrison R. Gardner CONTACT:
FTS 388-5635 FTS 388-5524 DISTRIBUTION:
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MNBB Phillips E/W Willste Choirman Palladino EDO NRR IE NMSS Cram. Cilinsky PA OIA RES Comm. Roberta MPA AEOD Comm. Asselstine ELD Air Rights MAIL:
Comm. Bernthal SP' INPO ADM:DNB SECT NSAC DOT: Trans Only ACRS CA' Applicable Resident Site PDR-Regions I 11
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REGION 111, 0FFICE OF INSPECTION AND ENFORCEMENT DAILY REPORT DATE: 4/12/83
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DIVISION:
OSC IIty/ licensee Notification item or Event Regional Action
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Midlend I and 2 Telecon from SRI - 4/11/83 Consumers Power Company announced the lay-Information only
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off of 60 Zack (heating, ventilation and air conditioning contractor) employees due.
. to lack of work. The lack of work is the
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result of not having RIII approval to resume welding,(Zack currently resolving welding problems) and not having material onsite.
Midicnd I and 2 Telecon from SRI - 4/11/83 Consumers Power Company reported that Information only
$2500 worth of company tool's were confiscated from the resident of a Midland
-l site employee. The licensee stated that g warrant had been issued for his arrest.
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x Dpg REGION III, OFFICE OF INSPECTION AND ENFORCEMENT
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DATE:
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DIVISION:
OSC Notification item or Event Regional Action cilfty/ Licensee i
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PRELIMINARY NOTIFICATION OF E$ENh OR UNUSUAL OCCURRENCE--PNO-III 61 D to:
'anty is_ sogz
' This preliminary notification constitutes EAR".Y notice of, events of POSSIBLE safety or publia interest significance. The informatica is as fait.ially r'eceived without veri-
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ficction or evaluation, and is basically al'.,that is known bp the staff on this date.
Tcsility:
Consumers Power Company Lit 7 '- Emergency Cir.ssification:
Midland Nuclear Plant 6,
Notification _of Unusual Event Docket Nos: 50-329, 50-330 s
Alert d
~t Midland, MI 48640 Site Area Emergency General Emergency f
Not Applicable
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Subject:
DOW CHEMICAL TERMINATES STEAM CONTRACT WITH MIDLAND NUCLEAR.*LANT
'N ConsumerP Power Company notified Region III on July 14, 1983, that Dow Chemical Company wss terminating its contract with the utility to supply process, steam to Dow's Midland fccility from the Midland Nuclear Power Station, now under construction. A portion of th2 Unit 1 capacity was to be dedicated to the Dow steam supply system.
On July 14 Dow announced it was filing suit seeking a court judgment that all. Dow's obligations under the contract were cancelled "because of tonsumers Power's misrepresenta-tions and non-disclosures...and Consumers Power's inability to complete the Midland Nuclear Plant within any reasonable time and at a reasonable cost."
A portion of Unit 1 capacity was to be dedicated to;providing process steam to Dow.
Much of the safety related construction at Midland has been halted since December 1982
,1 es a result of construction and quality assurance problems. The licensee has prepared a Construction Completion Program for resumption of work, and that program is currently 7, being reviewed by the NRC staff.
Tha effects of the Dow cancellation on the Midland project are not known at this time.
N The licensee has issued a news announcement. Region III has responded to inquirier frcm the news media.
Th2 State of Michigan will be notified of this information.
R2gion III was notified.of this matter by the licensee at 4:30 p.m.
(CDT), July 14, 1983.
Additional informatioq was obtained on July 15. This information is cur.ent as of 11 a.m.
(CDT), July 15, 1983.'
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Contest:
J. Harrison R. Warnick FTS 384-2635 FTS 384-2575 3
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DAILY KEPORT CIII DATE 10/20/C2 FECILITV/ LICENSEE NOTIFICATION ITEM OR EVENT REGIONAL ACTION CFFICE OF THE REGIONAL ADMINISTRATOR SENEOfL MR. JAMES 0.
NEPPLER AND HEM 8ERS OF HIS STAFF INFORMATION.
WILL MEET WITH MANAGEMENT REPRESENTAT1WES OF HECHTEL power CORPORATION IN AN'd AR80Re MICHISAN CONCERNIN8 OUALITY ASSURANCE.
CFFICE OF SPECIAL Casts c!DLEND TELECON FROM THE (REF. PN0=I!!-82-1219 AT !!s3e A.N. ON FOLLOWUP PER MC 2512.
LICENSEE-10/28/R2 10/28/82e CONSUMERS POWER COMPANY REPORTED A POTENTIAL 50.55tEl ISSUE REGARDING THE UN=
f AUTHORIZED SURSTITUTION OF CLASS IE CABLES.
l THIS NATTER WAS IDENTIFIED Af THE. LICENSEE WHILE PERFORMING REINSPECTIONS OF CLASS lE CABLESe AS REQUIRED 8Y THE NRC, TO RESDLVE PREVIOUS CLASS IE MISINSTALLATIONS. TO DATE, 0 :T OF APPROXIMATELY S00 CLASS lE CASLES REINSPECTEDe FOUR INSTANCES HAVE BEEN IDENTIFIED IN WHICH $!!E 1A AWG WERE INSTALLED IN LIEU OF THE REQUIRED 10 AWG SIZE CABLES. THESE CABLEE FEED TWO DECAT NEAT C00LD0wN AND RETURN ISOLATION VALVES WHICH ARE IMPORTANT TO SAFETY. CPCO IS PREPARING A PRESS RELEASE FOR 10/29/82. DURING THE WEEK OF 10/18/82 A DETROIT TELEVISION STATION HAD BROADCAST A SERIES OF REPORTS CONCERNING CONSTRUCTION DEFICIENCIES AT THE MIDLAND SITE.
ONE OF THE IDENTIFIED ALLEGATIONS INVOLVED THE i
UNAUTHORIZED SUBSTITUTION OF CA8LES. 45 A RESULY OF THE ALLEGATIONSe CPC0 QA INSPECTORT
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MODIFIED THE REINSPECTION REOUIREMENTS FOR THE CLASS IE CABLE REINSPECTIONS. THIS MODIFICATIONe l
WHICH INVOLVED DETERMINING THE PROPER CABLE TYPE l
BY READING THE CABLE JACMET INSCRIPTIONS CATHER l
THAN THE ATTACHED C&8LE TAG $e RESULTED IN THE l
IDENTIFICATION OF THE UNAUTHORIZED SUBSTITUTIONS.
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w po son PRELIMINARY NOTIFICATION OF EVENT OR UNUSUAL OCCURRENCE--PNO-III-83-j $ Dato This preliminary notification constitutes Et.RLY notice of events of POSSIBLE safety or The information is as initially received without vari-p'ublic interest significance.ficction or evaluation, and is basically all that is known by the staff Licensee Emergency Classification:
Tccility: Consumers Power Company Notification of. nusual Event U
Midland Nuclear Power Station Alert Units 1 & 2 Site Area Emergency Docket Nos: 50-329, 50-330 General Emergency Midland, MI 48640 Not Applicable vv.
RESUMPTION OF SAFETY-RELATED WELDING WORK ON-VERT 4LATING SYSTEM Subj:ct:
e' Following a review by the Senior Resident Inspector of welding procedures and observation has authorized Consumers Power Company to of weldingpin progress, Region III (Chicago) resume safety-related welding werk The work was stopped November 30, 1983, after systems at the Midland construction site.
o utility audit determined that the quality assurance program for welder qualification and welding procedure qualification was inadequate (See PNO-III-82-130).
The audit findings involved a testing laboratory which performed tests on weld sam'ples used in certifying welders and welding procedures for the Zack Company, Inc., the heating, vintilating and air conditioning contractor.
Initially, about 27 welders The stopping of work resulted in 151 welders being laid off.is expected that some 15 will be rehired, but it News media Neither the licensee nor Region III plans to issue a news announcement.
interest may occur, because of the ongoing Operating License proceeding and continuing local news media interest in Midland.
29, 1983, authorizing resumption of Region III issued a letter to the licensee on JuneThis information is current as of 12 noon, fabrication and welding of the HVAC system.
June 29,1983.
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Contact:
R. Gardner J. Harrison 384-2524 384-2635 MNBB Phillips E/V Willste DISTRIBUTION:
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EDO NRR IE NMSS Chairman Palladino OIA RES Comm. Gilinsky PA AEOD Comm. Ahearne MPA MAIL:
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NUCLEAR REGULATORY COMMISSION y
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MEMGRANDUM FOR: James G. Keppler, Regional Administrator FROM:
R. F. Warnick, Director, Office of Special Cases
SUBJECT:
MIDLAND MONTHLY STATUS REPORT Enclosed is the status report for the Midland project for the period of January 1, 1983 through January 31; 1983.
Should you have any questions regarding this report please contact W. D. Shafer 932-2656.
Ri= L0amN R. F. Warnick, Director Office of Special Cases
Enclosure:
As stated cc w/ encl:
D. G. Eisenhut, NRR J. H. Sniezek, IE
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C GLEN E LLYN, f LLJNolS 60137 f
% v February 10, 1983 MEMOFANDUM'FOR:
W. D. Shafer, Chief, Office of Special Cases, Section 2 FROM R. J. Cook, Senior Resident Inspector, Midland Site j
SUBJECT:
MONTHLY STATUS REPORT Attached is the. status report for the Midland Nuclear Construction Site covering-the period of January 1,1983, through January 31, 1983.
The status report contains the input from each member of the Midland Inspec-tion Site Team of the Office of Special cases.
M R. J. Cook Senior Resident Inspector Midland Site Resident Office ec/attachmnts R. F. Warnick R. B. Landsman R. N. Gardner B.
L. Burgess t
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FEB141933 3
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SUMMARY
OF SIGNIFICANT MIDLAND ISSUES
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1.
Heating, Ventilation and Air Conditioning (HVAC)
Members of Consumers Power Company, Bechtel Power Company, and Zack Company conducted a meeting on January 27, 1983, to finalize comments to resolve the issue of requalification of Zack Company welders and
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to justify prior welding. Final comments conccrning the requalifica-
. tion of welders will be implemented into welding procedures.
Requali-j fication of welders is expected after final approval and qualification
- of welding procedures and the completion of welder retraining.
The NRC RIII has established a hold point prior to restart of welding to review welder requalification procedures and to observe procedure and welder requalification.
2.
Electrical Installed cable reinspection continued with no additional improperly-substituted. cables found. Currently six substituted cables of approxi-mately 6,000 cables inspected have been identified. Approximately 2,600 cables remain to be reinspected. All cables were installed in Class lE electrical systems.
The licensee is evaluating the safety significance through the use of a nonconformance report.
3.
Remedial Soils Work Authorization Work continued on underpinning piers 12 East and 12 West. The excava-tion for the piers is down to the bell area (the base area of both piers),
and reinforcing bars are being placed in pier 12 West in preparation to
~
pour. pier concrete.
The NRC authorized four point jacking of the feedwater isolation valve pits (FIVPs) in preparation for starting excavation of pier 9.
In addi-tion, probing for electrical duct banks around the borated water storage tanks' (BWSTs) foundations was authorized and is a prerequisite for foundation rework.
4.
Consumers Power Company Construction Ccmpletion Program On January 10, 1983, Consumers Power Company submitted a letter to the NRC detailing the Construction Completion Plan (CCP) which was initially
. presented on December 2, 1982. After NRC review of the letter, an onsite meeting was held on-January 20, 1983, between NRC inspectors and site management to clarify and answer questions.
A meeting will be held on February 8,1983, at 9:00 AM for Consumers Power Company to present the CCP to the NRC in more detail. After the formal meeting between Consumers Power Company and the NRC, the public will have the opportunity to ask questions of the NRC.
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. 5.
Enforcement Conference An enforcement conference was held on January 18, 1983, i_n the NRC Region III office to discuss the results of the diesel gendrator building inspection. As a - result of the discussion, further inspec-
~ tion was performed January 19-21, 1983, to obtain additional infor-mation regarding IPINs and closecut inspections.
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SUBJECT:
MIDLAND MONTHLY STATUS REPORT Enclosed is the monthly status report for the Midland Project.
The report is for the period of December 1,1982 through December 31, 1982.
/T SI1M"cE R. F. Warnick, Acting Director Office of Special Cases
Enclosure:
As stated cc w/ encl:
D. G. Eisenhut, NRR J. H. Sniezek, IE 8
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U. S. NUCLEAR FIGULATORY COMMISSION REGION III MIDLAND MONTHLY STATUS REPORT DECEMBER 1 - DECEMBER 31, 1982 O
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SUMMARY
OF SIGNIFICANT MIDLAND ISSUES
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11.
Heating. Ventilation and Air Conditioning (HVAC)
' The. licensee, as a result of audits of HVAC work activities, determined that welder certifications and welding procedure _',
~
l' qualifications were inadequate.. All safety-related welding on HVAC'was stopped by the licensee on November 30. 1982, and 151 craft workers were-laid off. PNO-III-82-130 was issued.
l>uring this. reporting period the' licensee has' begun developing a new set of welding procedures.
1 2.
Electrical-
.r-Two (2)
The licensee continued electrical cable reinspections.
additional improperly substituted cables have been identified.
A total of six (6) substituted cables, of approximately 4000 cables reinspected, have_been identified. Approximately 5000
. cables remain to be reinspected.
3.
Remedial Soils Work Authorization On December 9, 1982, the NRC authorized the licensee ~to commence construction work on piers 12. East and:12 West under the Turbine 4
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Building. -On December 13, 1982, Consumers Power Company began i
work on the piers. During excavation for pier 12 the licensee ran into concrete fill. The chipping and removal of the' concrete has caused the work to proceed slower than the licensee had previously-expected.
4.
' Consumers Power Company Construction Completion Program On December 2, 1982, Consumers Power Company presented to.the-I-
Region III staff a plan to establish confidence in the adequacy oof safety-related work at the Midland Site. The licensee's initial Construction Completion Program.(CCP) required a substantial reduction in most of the safety-related work activities and a subsequent reduction in the workforce involving approximately 4
i-1100 people. Implementation of the CCP required removal of i-construction equipment from the work spaces and building cleanup
'in preparation for a complete QC inspection of every safety-related system in every area. PNO-III-82-131 was issued.
' Region III has prepared a draf t report of the October-November team inspection. Escalated enforcement action _is being considered.
An enforcement conference with the licensee is scheduled for January _ 18, 1983' in RIII.
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A meeting was held _on December 7,1982 with -IE, NRR, and ELD to discuss the findings of the RIII October-November team inspection and the licensee's proposed construction completion program. A meeting with the licensee to discuss the CCP is. scheduled for February 3, 1983 in Midland.. It will be open to public att_endance.
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4 DEC 2 0 m2 MD10RANDUM FOR: James G. Keppler, Regional Administrator FROM:
R. F. Warnick, Acting Director, Office of Special Cases
SUBJECT:
MIDLAND MONTHLY STATUS REFORT Enclosed are two monthly status reports for the Midland project. The first report is for the period August 1,1982 through October 31, 1982.
The second report is for the month of November. The Midland Section of the Office of Special Cases is preparing these monthly reports to enable us to keep track of the important chronological happenings at Midland and to provide a mechanism for keeping IE and NRR informed.
The first report proved to be repetitious of information contained in monthly inspection reports and too time consuming to prepare and read.
The second report is one page and contains all the salient information.
Future reports will follow the format of the November report.
RFID A R. F. Warnick, Acting Director Office of Special Cases
Enclosures:
As stated cc w/ encl:
D. G. Eisenhut, NRR J. H. Sniezak, IE i
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U. S. NUCLEAR REGULATORY COMMISSION REGION III MIDIAND MONTHLY STATUS REPORT AUGUST 1 - SEPTEMBER 30, 1982 e
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A.
SUMMARY
OF THE MONTH Midland. Inspection Site Team efforts at the Midland Construction Site during the month of October were concentrated on inspection, of.the Diesel Generator Building. The Diesel Generator Building was chosen to be repre-sentative of the adequacy of construction on site. The inspection had not been completed as of the end of the status report period and will be addres-sed in a subsequent status report.
Remedial soils work is stopped until Quality Control Personnel are recerti-fied per an upgraded qualification program discussed in Section B.I.b.
Heating, ventilation and air conditioning.(HVAC) work has been continuing under the Consumers Quality Control and Quality Assurance organization formed to control HVAC construction.
Items identified as relevant to the Part 21 of August, 1981 are reviewed, evaluated and dispositioned.
(Sec-tion B.2)
Pertaining to misinstalled electrical cables, the licensee informed the NRC that 100% reinspection of class IE cables installed or partially installed by March 15 1982, was required. Also, during this status report period, the licensee reported a potential 10 CFR 50.55(e) regarding unauthorized substitution of underrated cables. This unauthorized substitution was de-tected as a result of Consumers Power Company modifying the reinspection requirements for class IE cables in response to allegations received through a local television station.
The licensee has agreed to a 100% reinspection of all hangers installed in CY 1980 and a sample reinspection of hangers installed after January 1, 1982.
3 Ongoing inspections during October 1982 have found additional discrepancies pertaining to classification, installation and inspection of hangers in the Diesel Generator Building.
B.
SIGNIFICANT MIDLAND > ISSUES 1.
Soils During an inspection, the inspectors determined that the licensee a.
i had apparently violated the ASLB Order of April 30, 1982. The licensee excavated below the deep "Q" soils, without prior NRC approval. The licensee stated that prior approval was granted by NRR. Subsequently, RIII issued a CAL on August 12, 1982. The licensee commitments identified by the CAL included:
4 (1) Stop all remedial soils work.
(2) ' Prior to lifting this Stop Work, the licensee will obtain prior written approval of work activities.
RIII has requested the OI to conduct an investigation into the matter.
RIII and CPCo have established a Work Authorization Procedure to ensure further compliance to the ASLB Order.
b.
During the initiation of the CPCo.recertification program for all Bechtel QC inspectors integrated into the soils QA/QC organi-zation, the'RIII inspectors determined the following while obser-ving several oral exams:
(1) The examiner would excessively repeat questions allowing the examinee several attempts to answer correctly.
(2) The examiner would mark questions NA when the examinee failed to answer correctly even though the question was relevant.
(3) The technical portion of the exam lacked technical content necessary to establish the examinee's comprehension of the activity.
(4) The examiner used a controlled copy of a PQCI to make up the exam questions which was different from another controlled copy obtained from the QC records vault.
SubsequentIT, RIII issued a CAL on September 24, 1982.-
The licensee commitments identified by the CAL included:
(1)
Stop all remedial soils work except for freezewall, dewatering wells and auxiliary building instrumentation readings.
(2) Suspend all requalifications.
(3)
Decertify all QC personnel previously certified.
(4) Establish a retraining program for all QC personnel who fail recertification.
(5) Develop written exams for recertification.
The NRC has reviewed the recertification program and authorized CPCo to commence remedial soils QC requalification activities on October 28, 1982. All remedial work will remain stopped until such time as previously decertified QC personnel are requalified.
2.
HVAC (Zack)
In January,1981, the NRC levied a S38,000 Civil Penalty against Consumers Power Company for QA deficiencies in the installation of heating, ventilating, and air conditioning (HVAC) systems. These QA deficiencies were noted during an investigation which transpired from March through July,1980. As a result of this enforcement action, d
2
'the licensee removed responsibility for QA and QC functions for HVAC system work from the subcontractor (Zack Co.) and performs these func-
~;
tions using utility personnel. Removing QA/QC responsibility from the Zack Company has resulted in apparent improvement in-performance at the site.
In August, 1982, the NRC received allegations pertaining to QA/QC irreg-
~
ularities at the Zack Company, Chicago, Illinois factory. Also, a potential 10 CFR Part 21 notification was made by the Zack Company.to RIII pertaining to discrepancies between the welder of record and the welder actually performing the weld. RIV, through the Vendor Inspection Program, performed.an inspection of the Zack Company, Chicago, Illinois operation. RIV had not issued the report on this matter at the time this ; report was prepared.
It was e-tablished that the Midland Site did receive fabricated HVAC i
. items from Chicago, Illinois. However, Consumers Power Company per-forms a complete receipt inspection, including visual weld inspections.
The tracking system that Consumers Power Company has established for HVAC items, allows the licensee the ability to locate any nonconforming item. Consumers Power Company also has established controls such that any of the, suspect HVAC system components would not be covered by ongoing work until it can be established whether rework will be neces-sary. Many of the HVAC system couponents are fabricated on site.
3.
Electrical During the special team inspection conducted in May,1982, the NRC identified concerns in regards to the adequacy of inspections performed by electrical Quality Control inspectors. These concerns were the result of the NRC's review of numerous Nonconformance Reports (NCR) issued by i
MPQAD personnel during reinspections of items previously inspected and accepted by Bechtel QC inspectors. The NRC required the licensee to perform reinspections of the items previously inspected by the QC inspectors associated with the MPQAD NCR's.
The licensee, in reports 4
submitted to the NRC in May and June, 1982, reported that of the 1084 electrical cables reinspected, 55 had been determined to be misrouted in one or more vias. This concern was upgraded to an item of noncom-pliance and is documented in Inspection Report No. 50-329/82-06; 50-330/82-06.
On September 2, 1982, the licensee was informed by the NRC that a 100%
~
reinspection of class 1E cables installed or partially installed before
(
March 15, 1982, was required. In addition, the licensee was required l
to develop a sample overinspection program for those cables installed
(
after March 15, 1982. The licensee, on October 15, 1982, agreed to perform these overinspections.
3 l
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t.
. 3 On October 28, 1982, Consumers Power Company reported'a' potential l
50.55(e) 1ssue regarding.the unauthorized substitution of class 1E cables.. This issue.was identified by ^ the licensee while performing the aforementioned reinspections. During the week of October 11, 1982, a Detroit television station had broadcast a series of reports
~
concerning construction deficiencies at the Midland site. One of the alleged deficiencies involved the unauthorized substitution of cables.
- As a result of the alleged' deficiency, Consumers Power Company QA inspectors modified the reinspection requirements for the class 1E
^
cable reinspections. 13iis modification, which involved determining
-the proper cable type by reading the cable jacket inscriptions rather than the attached cable tags, resulted in the identification of the unauthorized substitutions.
4.
Mechanical During the NRC-Region III team inspection conducted in May, 1981, i
a Region III inspector observed that piping suspension system i
components were not constructed and installed-in accordance with drawing and specification requirements.
In addition, the inspec' tor determined that QC inspectors had failed to identify the installation deficiencies.
(Inspection Report No. 50-329/81-12; 50-330/81-12)
In response to the inspector's finding, the licensee performed an overinspection and determined that a large percent. age of rejectable hangers were not identified during Bechtel QC inspections.
A request was made to the licensee for a 100% reinspection of all hangers installed in CY 1980, and a sample reinspection.of hangers installed after CY,1980. In a letter dated-September 30, 1982, 1
Consumers Power Company agreed to reinspect 100% of hangers' installed before January 1, 1981, and a sample inspection of hangers installed af ter January 1,1981.
~
Inspection conducted during the month of October, 1982 has found addi-tional problems related to the installation and inspection of-hangers in the Diesel Generator Building. The concern involves hangers that are built to seismic category one standards, but are considered "non-Q" by system designation. Consumers has taken exception to Reg. Guide 1.29 titled " Seismic Design Classification," which delineates requirements s
for non-Q systems which could impact safety related systems during a l'
seismic event. A letter from NRC Region III has been sent to NRR requesting resolution.
C.
CONSTRUCTION STATUS 1.
Soils Remedial soils activities performed by the licensee thus far in 1982 involve:
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a.
Termanent dewatering wells.
b.
Temporary auxiliary building dewatering wells, c.
Freezewall around auxiliary building.
d.
Auxiliary building underpinning access shafts to EL 609.
e.
Modification work of overhead temporary FIVP support structure, f.
Auxiliary buildin'g underpinning monitoring instrumentation.
.2.
HVAC (Zack)
The licensee QA group has performed an audit of the on-site Zack Company Training and Documentation functions during October, 1982.
The' audit report is not finalized, but the licensee indicated there were some " minor findings. - The Zack Company has retained a mechani-cal engineer (P.E.') as a Project Field Engineer on site and upgraded other staff positions.
The specifications for inspecting HVAC duct work has been modified 'to
' include a provision for rigorously testing with differential air-pressure those isolated portions of duct work that have either reject-able or uninspectable welds that cannot be repaired without extensive rework. If the questionable welds maintain integrity throughout the pressure testing, it is planned to make an acceptable engineer dispo-sition based on' the test.
Consumers Power Company QA is ' performing a 100% overinspection on all ongoing welder qualification in accordance with an established and approved inspection plan. The individual performing the inspection must be certified by AWS as a qualified welding inspector.
Approximately 25% of all HVAC quality items have been accepted by the 4
licensee.
3.
Electrical-As of the date of this report, a significant amount of electrical cable installations, cable terminations, raceway installations, and equipment I
installations has been completed at the Midland Site.. The bulk of present ongoing work activities continues to reflect these activities.
Overall electrical construction status is estimated to be as follows:
i
~
91%
a.
Conduit installations l
b.
Wire and cable installations 91%
c.
Cable terminations 79%
d.
Cable tray installations 100%
i e.
Equipment installations 98%
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'4.
Mechanical As of the date of this report, a significant amount of small and large bore piping has been completed at the Midland Site. The bulk of present ongoing work activities involve hanger and instrument impulse line installation. Mechanical construction status is estimated to be as
.follows:
a.'
Large pipe installations 98%
b.
Large pipe hanger installation 95%
c.
Small pipe installation 95%
d.
Small pipe hanger 81%
e.
, Mechanical equipment 99%
5 Miscellaneous a.
Formation of Office of Special Cases In July, 1982, the Regional Administrator formed the Office of Special Cases (OSC) and assigned Mr. R. F. Warnick as the Acting Director. This office has full responsibility for inspection activities at the Midland and Zimmer nuclear facilities.
Under the direction of the Acting Director, OSC, the Midland See: don was formed consisting of a section Chief, two Regional-based inspectors, a Senior Resident Inspector, a Resident Inspec-tor, and a full-time Resident Secretary.
The majority of inspection effort conducted by the Midland Section was related to the soils remedial work. This work is described in.
Sections B.l.a. and b. of this report.
b.
Stone and Webn:t_er Assessment of the Soils Remedial Work The third party independent assessment team reported to the site on September 20, 1982. Since that time, reports have been sent to the Resident Inspector office. A review of these reports reveal no significant issues have been identified. These reports and Nonconformance Identification Reports are enclosed as attach-
- ment A to this report.
D.
COMMUNICATIONS 1.
Enforcement Meetings None 6
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)
2.
Management Meetings August 11, 1982 Meeting with CPCo Managem(nt regarding soils remedial work taking place without prior staff authorization. Considered a potential viola-tion of a Board Order.
W August 26, 1982 &
Meeting between CPCo Senior Management, September 2, 1982 D. Eisenhut, and J. G. Keppler to discuss NRC's concerns with Midland and possible recommended solutions.
September 8, 1982 Meeting with CPCo management, NRR, and Region III to discuss Consumer's draft proposal for a third party independent assessment. No conclusions reached.
Licensee was advised to submit their proposal formally.
Septerber 15, 1982 Meeting between Region III and CFCo lawyers
)
to establish when NRC investigation of GAP allegations would be completed.
September 28, 1982 Meeting between the Midland Inspection Site Team and members of Stone & Webster and Con-sumers Power Company to introduce the Third Party Independent Assessment Team for the remedial soils work.
October 29, 1982 Meeting in Aan Arbor, Michigan between Region III, Region IV, and Bechtel management to discuss NRC concerns with Bechtel performance and recommended solutions.
3.
Public Meeuings August 5, 1982 Meeting in Midland, Michigan between Region III and CPCo Management to discuss disagreements regarding the Systematic Assessment of Licensee Performance (SALP) report and CPCo's May 17, 1982, response to this report.
September 29, 1982 Meeting in Midland, Michigan between Region III and CPCo Management regarding the requalifica-tion and certification of 'll Bechtel QC person-nel at Midland.
7
October 25, 1982 Meeting in Bethesda, Maryland between NRR, Region III, CPCo Management, and CPCo contract personnel to discuss third party independent assessment.
~
- 4.
Other Significant-Meetings None
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i 81 s ed Si t e K >..c i 2ent Inspection Of fice r.c ut e 7 J.C.Nc. 14 ~458. 06 Midl and, MI 4S540 F ef. MPR-1 Att ention Mr. R. Cook
Dear Sir:
FI: DOCKET NO. 50-329/330 MID'JSP FLAN! - UNITS 1 AND 2 I_N__3I_?:.*;'.E.NT..A_SS E__S.F..!'E N.T OT AL'.YT1. IARY.S_U_I.l.DI NO US ?..?.FF IN,:I NG A e py cf :hr-. rf e r=:id e nt Ar.s er sr.r..-
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If y.'u ave any eu t st i cm s vith res pect to this re p: r:, pl eas e cc.n act ne
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Ver y trit;y yours,
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A. Sta nley Luc Frej ect Manager Ind osure AF1.:ch
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.s J.0.No. It.358 Mi dIt.pd p1 ant Uni ts 1 a nd 2 Indt pendent 'Arscos'wnt Auxiliary Buildi ng Underpi nning Week 1v Renort No. I hpi e:bt r 19 through 26 1982 2
Tersonnel on Site _
Stone & Webst er Engi nee ri ng Corpora: ion (SaTC)
W. E. Kilker 9/20/SO-9/26/82 P. Barry 9/20/82-9/23/82
- L. T. Rouen 9/20/82-9/24/82 E. Fol singer 9/20/82-9/26/82 A. Scott 9/20/82-9/26/82 A. S. Lucks 9/21/82-9/23/82 Parsens, Brinker.hoff, Quade,. & Douglas (FFQD)
P. Pari sh 9/21/82-9/24/62 J. Ra:ner 9/22/82-9/24/82 A c ti vi ti e_s_
This re psrt s e:::ari zes the first week of activi:ies and obs er vati ens of the SWIC indt pendent arsess=ent t e a= (including the 17 QC ;+ r s enn el ).
The tea =,
shi ch at the present time cohsists of seven engineers repres enting Geotech-nical, Structural, Construction, and Quality Assurance di s ci pli nes, arrived the si te between Sep: caber 20 and Sept or.ber 22.
at The assessment team has established s e parat e on-site office space and has contract ed f or clerical assistance.
Introductions of all team members were made to on-site personnel repres enting Becht el Engineering and Construction; Cons umer s Power Co= pany Qu ality
. Assurance and Quality Control; Viss, Janney & Els:ner (WJ6E)
Ins t r ument ati on Monitoring;.and Mergentime Construction. Tours and bri efings of the various areas and ac ti si ti es. re l at ed to the gnderpi nning vere gi ven throughout the week at :he recuest of :he asserscent : e at,
i n cl ud ed in these tours and bri efi ngs were t he i n pl a:e access shaf ts and FIVF superstructure
- supports, the des p-s e a t ed ben c h:ar ks and r el a ti ve en ion me as ur caent 5:ations, the
- ext ens ome
- er and st r ai r. rage ins t r um en: ari on ins: all ati ons, the crack mapp-ing, the VJ6E instr u entation moni t ering and. at a re cor din g st ati on, the laggi ng and rei nf orcing har f abri cati on, sheps, and the :.a: e ri al t es ti ng l aborat ory.
Also, the ass essmen: trac peri odically obr erved the work on the mock up pier (located near th e Out age - Buil ding ) and the j a: king s:and mock up (l oc at ed adj a:ent to the lag;ing f abri ca:i on shep).
All latging and shoring vere in place on the en:k up prior to the teac's arrival on site, but observa: ions i
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( _ Daily ocetiEgs were held starting September-21 \\between personne7 re presenting ie the asfessment team, Bechtel Engi neering and Cons t.rt.c t i on, and Cons tr:re rs
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i f X h me:b[trs of(the ' team have read the, Fur:c:ary of Soil s-K el at.-d I ssues F eport and 6a are reviewing applicable speci fications, drawings, cc.ne truction, and Quality
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dent Constners Pc er Cccpany, and Ee cht el (p[ys onnel have complied @ith team re qu es t s for ac.:ess to exi' sting installations, briefinFs, doctsnents, and records.
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9 STONE 6 WEBSTER ENGINEERING CORPORATION 245 SUMMER STREET. Boston. massachusetts Amonces ALL CORRESPONDENCE TO P.O. BOX 2385. SoSTON. M ASS. 0810F W.U TELEX 94 C001
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United States Nuclear Regulatory Commission October 12, 1982 Midland Site Resident Inspection Office Route 7 J.O.No. 14358 Midland, MI 48640 Ref. MPR-2 Attention Mr. R. Cook RE: DOCKET NO. 50-329/330 MIDLAND PLANT - UNITS 1 AND 2 INDEPENDENT ASSESSMENT OF AUXILIARY BUILDING UNDERPINNING-REPORT NO. 2 A copy of the Independent Assessment of the Auxiliary Building Underpinning Weekly Report No. 2 for the period September 27 through October 3,1982, is enclosed with this letter.
If you have any questions with respect to this report, please contact me at (617) 589-2067.
4 A. Stanley Lucks Project Manager Enclosure ASL: pus r
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September 27 through October 3, 1982 Personnellon Site Stone & WebJter' Engineering Corporation (SWEC) i
-W. E. Kilher.,
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P. Barry 9/27/82-10/1/82 L. T. Rouen 9/27/82-10/1/82 B. Holsinger 9/27/82-10/1/82 A. Scott.
9/27/82-10/1/B2 A. S. Lucks 9/27/82-9/29/82' Parsodb, Brink'eroff, Quade, & Douglas (PBQD)
P. Paiish 9/27/82-10/1/82 J. Ratner 9/29/82-10/1/82 i
Activities 4
,n The assessment team continued their review of 'it.e reports, specifications, drawings and procedures in order to gain familiarity wit;h the initial phases of the pending underpinning work. The review concentrated on issued excavation, lagging, ground stabilization and concrete placement procedures. Discussions to resolve any questions concerning these' procedures were held with Bechtel and Consumers Power site personnel. The plant QA program and Quality Control procedures on concrete and reinforcement were reviewed by QA t' am members.
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The Assessment team and representatives of Con'sumers' Power Company met with NRC representatives. The role of the assessment team and the interaction with the various cice groups, 4.nd the methods of reporting the team findings were discussed in this meeting.
c Two of the team members attended a public meeting of the NRC and Consumers Power Company.
The discussion focused oni the establishment of the Midland Plant QA program under Consumers Power Company administration and control and the certification of QC inspectors under the Consumers Power Company program.
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Meetings Attended Date Represented Purpose 9/28/82 Stone & Webster Introduction of USNRC Consumers Power Co.
and Assessment Team.
Discus-U.S.. Nuclear Regulatory sion of Assessment Team's Cosmissior, role.
9/29/82 Stone & Webster Public Meeting - Discussion Bechtel of QA Administration and USNRC QC Certification.
Public i
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9/30/82 Stone & Webster Presentation of Underpinning Consumers Power Co.
model.
Bechtel 10/1/82 Stone & Webster Weekly Soils Review Meeting Consumers Power Co.
I Bechtel Mergentime 9/27/82 Stone & Webster Daily Meeting.
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through Consumers Power Co.
10/1/82 Bechtel Observations The Assessment Team has continued to receive cooperation of on-site personnel.
Team members observations, questions or ' suggestions have been given prompt and complete attention by the appropriate site personnel.
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United States Nuclear Regulatory Commiseion October 13, 1982 Midland Site Resident Inspection Office Route 7 J.O.No. 14358 Midland, MI 48640 Ref. MPR-3 Attention Mr. R. Cook RE: DOCKET No. 50-329/330 MIDLAND PLANT - UNITS 1 AND 2 INDEPENDENT ASSESSMENT OF AUXILIARY BUILDING UNDERPINNING-REPORT NO. 3 A copy of the Independent Assessment of the Auxiliary Building Underpinning Weekly Report No. 3 for the period October 3 through October 9, 1982, is enclosed with this letter.
If you have any questions with respect to this report, please contact me at (617) 589-2067.
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A. Stanley Lucks I
Project Manager Enclosure ASL:mmm F0 t
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,. A. 1 J.O.No. 14358 s.j Midland Plant Units 1 and 2 Independent Assessment Auxiliary Building Underpinning Weekly Report No. 3 Octobe-3 through October 9, 1982 Personnel on Site Stone & Webster Engineering Corporation (SWEC)
W. E. Kilker 10/5/82-10/8/82 P. Barry.
10/4/82-10/8/82 L. T. Rouen 10/4/82-10/8/82 B. Holsinger.
10/5/82-10/8/82 A. Scott 10/4/82-10/8/82 Parsons, Brinkerhoff, Quade, & -Douglas (PBQD)
P. Parish 10/4/82-10/8/82 J. Ratner 10/4/82-10/8/82 Activities The start of the underpinning work has been delayed pending the recertification of the Soils Remedial Quality Control Inspectors.
In the interim, the Assess-ment team members have completed the review of severdi of the construction specifications and procedures associated with the initial phases of the under-pinning work. Team member questions or observations have been presented to site personnel for resolution.
Several of the team members toured the off-site concrete batch plant and received a briefing on the plant lay-out and production procedures. A general interest tour of the Auxiliary Building and Reactor Containment Structure was given to all of the team members by site engineers.
Observations were made of the un'derpinning contractor performing routine back-packing mainter:ance with sand and excelsior on the access shafts' lagging.
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Meetings Attended Date Represented Purpose 10/8/82 Stone & Webster Weekly Soils Review Meeting Consumers Power Co.
Bechtel Mergentime 10/4/82
. Stone & Webster Daily Meeting through Consumers Power Co.
10/8/82 Bechtel Observacions Familiarization with the specifications, drawings, and construction procedures associated with the initial phase of construction is generally complete.
Observations and questions from the team members on the construction documents have been discussed with site personnel.
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245 SUMMER STREET. BOSTON. M AS S ACHUSETTS ADDRESS ALL CORRESPONDENCE TO P.O. BOX 232S. SOSTON. M A S S. 02107 W U. TELEX $ 4 -0001 es ons C m.TavCTION "l:.""
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Midland Site Resident Inspection Office Route 7 J.O.No. 14358 Midland, MI 48640 Ref. MPR-4 Attention Mr. R. Cook RE: DOCKET No. 50-329/330 MIDLAND PLANT - UNITS 1 AND 2 INDEPENDENT ASSESSMENT OF AUXILIARY BUILDING UNDERPINNING REPORT NO. 4 A copy of the Independent Assessment of the Auxiliary Building Under-pinning Weekly Report No. 4 for the period October 10 through October 16, 1982, is onclosed with this letter.
If you have any questions with respect to this report, please contact me at (617) 589-2067.
k A. Stanley L ks Project Manager Enclos ure ASL:ck I
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.r' Midicnd Plcnt Units 1 and 2 Independent Assessment Auxiliary Building Underpirming Weekly Report No. 4 October 10 through October 16, 1982 Personnel on Site Stone & Webster Engineering Corporatice (SWEC)
W. E. Kilker 10/12/82-10/15/82 P. Barry 10/12/82-10/15/82 L. T. Rouen 10/11/82-10/15-82 B. Holsinger 10/11/82-10/15/82 A. Scott 10/11/82-10/15/82 Parsons, Brinckerhoff, Quade, & Douglas (PBQD)
J. Ratner 10/11/82-10/15/72 Activities The Assessment Team completed the review of all construction specifications I
and procedures associated with the initial phases of the underpinning.
Familiarization with the drawings and Quality Assurance / Quality Control procedures continued.
Discussions with site personnel were h eld to resolve questions and observations on the various construction documents.
Team members read the portions of the NRC's Supplanental Safety Evaluation Report No. 2 applicable to the Auxiliary Building Underpinning.
The team members attended the site Soils Training ' Classes on quality plans, soils work permits and coordination forms.
~
Meetings Attended Repres ented Pur pos e 10/11/82 Stone & Webster Daily Meetings through Constaners Power 10/15/82 Be chtel 10/14/82 Stone & Webster Soils Renedial and Constsners Power Training Program 10/15/82 Bechtel Cours es 1
Mer gentine 10/15/82 Stone & Webster Weekly Soils Constaners Power Review Meeting Becht el Mergentime Observations - None YhkYu 5 Proj ect Engineer Proj ect Manager BX214358-2
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Unitr., 1.cnd 2 Ind: pendent Assessment
, Auxiliary Building Underpinning STONE A!C WEESTEC ENGINEE:.ING CORPORATION rDrCON:0:wA'.CE 10ENTIFICAT10N REPORT 10/2*/82 1
DATE 07 NONC0hFOR".ANCE:
NIR a n er 1DENTIFICATION/LOCAT10h 0F ITEMS: Proceduze for Mechanical Snlicine of Reinforcement (MCP 16.000; Rev. 3.1 DESCRIPT10N OF h3NCON:0R*ANCE:
Technical Soecification for Underninnine.
of Auxiliary Buildine and Feed-<a ter Isola tion Va l ve Pits (navn 11.5.3-e) reouires subcontractor's procedure for w chaniemi Splicing of Reinforcement to nrovide a me.thod of mechanienlly locking the position splices.
The Mergentime Procedure does not nrovide for mechanienlly locking spJ ic e s.
Ihll!ATOR:
DATE:
PROJECT MA'.15EMENT CONCURRENCE:
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(IDEhiTTT BMETIITTDN tar,1NG ccF.RECTIVE AclTDh; I
lhlTIA10R CONCURRENCE:
PROJECT PANAGEMENT CONCURRENCE:
DATE:
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'rcje : Fro:e::are 5-2.C At:atnment 1 Fage 1 of 1 STONE AN WEESTER ENG;hEERING CORDOR* TION NDNCONTO:v.4CE IDENTIFICAT!3N REPORT DATE OF N?h~3hT03.v.*NCE: October 28, 1982 N:R Num er p
IDENTIFICATION / LOCATION OF ITEw.5: Technical Steeification for Unde-rtnnine n+
Auxiliary Euilding and Feedvater Isolation Valve Pits. sne maseef aba cdno Series Drawings, located at MP4AD and QC.
DESCRIPTION OF h0N~0h:0RvANCE: The MP4.AD and QC centre 11ed ee;ies nf %.hev-Specificatien and Drawinr are missins the following chaqe decurents:
QC's -
- 1) Specificatica - Specification Chance Netice (SCN)
No. 12002, 12003. and 12004 QC and
- 2) Drawing C1h24 2 - Drawing Change Notice (DCN) No. 7 KPRAD Field Change Reauest (FCR) - No. CL7k'i and Chl85.
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PROJECT M:.h'~EMENT CONC'JRRENC :
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IhlilATCP CONCL'RRENCE:
?F? JECT MiNaGEMENT CCN~'JF.RENCE:
DATE:
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3 STONE 6 WEBSTER ENGINEERING CORPORATION 245 SUMMER STREET. BOSTON. MASSACHUSETTS ADDRESS ALL CORRESPONDENCE TO P O. BCE 2323. BOSTON. M ASS. 02907 W U TELEX 54-0001 w
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United States Nuclear Regulatory Commission October 27, 1982 Midland Site Resident Inspection Office Route 7 J.O.No. 14358 Midland, MI 48640 Ref. MPR-5 Attention Mr. R. Cook RE: DOCKET No. 50-329/330 MIDLAND PLANT - UNITS 1 AND 2 INDEPENTENT ASSESSMENT OF AUXILIARY BUILDING UNDERPINNING REPORT NO. 5 A copy of the Independent Assessment of the Auxiliary Building Under-pinning Weekly Report No. 5 for the period October 17 through October 23 1982, is enclosed with this letter.
If you have any questions with respect to this report, please contact me at (617) 589-2067.
A. Stanley Lucks Project Manager Enclosure ASL:nb M*""'"
1
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-,.ndent Assessment axiliary Building Underpinning W' ekly Report No. 5 e
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October 17 through Octot:r 23, 1982 Personnel on Site 3,one & Webster Ehgineering Corporation (SWEC)
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W.E. Kilker 10/18 - 10/20 P. Barry 10/18 - 10/22 L.T. Rouen 10/18 - 10/22 B. Holsinger 10/20 - 10/22 A. Scott 10/20 - 10/22 Activities-The focus of the Assessment Team effort was the disposition of numerous questions that had been raised over the past 3 weeks with respect to the pending underpinning construction specifications, drawings and procedures. To this end, the team members had meetings and discussions with site engineering and ccnstruction personnel and resolved the majority of the items. Pending items will be resolved within the next two weeks.
Team Phmbers attended a critique meeting on the placement of rein-forcing and concrete in the mock-up pier. The team was also represented at discussions of recently recorded settlement date.
Meetings Attended Date Represented Purcose 10/18 Stone & Webster Daily Meeting through Consumers Power 10/22 Bechtel 10/19 Stone & Webster Settlement Consumers Power Monitoring Bechtel Records Mergentime-10/19 Stone & Webster Critique of Consumers Power Mock-Up Pier-Bechtel Reinforcing Steel Mergentime and Concrete Placement 10/20 Stone & Webster Discussion of Bechtel Excavation and Mergentime Lagging Procedure 10/20 Stone & Webster Training Sessions on Bechtel Excavation and Lagging, Mergentime Jacking, and Soil Stabilization 2
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. pendent Assessment Naxiliary Building Underpinning Meetings Attended Date Represented Purpose 10/22 Stone & Webster Resolution of Bechtel Observations and Questions on Con-struction Specifications and Procedures
~
Observations The Assessment Team has completed the review of the reports and construction documents applicable to the initial phase of the underpinning work. Most questions have been resolved by discussion with site personnel.
The ceam will, commencing October 25, scale down it's presence on the site until actual start of construction.
Nonconformance Identification Reports NIR No.1 - Issued 10/21/82 - The Mergentime Procedure for ; splicing reinforcing bars did not address a specification requirement.
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MIDLAND MONTHLY STATUS REPORT Midland Site' Inspection Team efforts at the Midland Construction-Site during the month of November were concentrated on the completion of the Diesel Generator Building inspection. The inspection was completed on November 25 and the inspection report is currently being written.
Significant inspection findings are being evaluated by the Region III staff.
Remedial soils work continues based on a work agreemen,t between the NRC and Consumers Power Company. Auxiliary building underpinning remains halted pending resolution of the independent third party assessment effort.
The licensee continued the reinspection of 100% of Class'1E cables
' installed or partially installed. No further underrated or undersized cables have been found as of the end of the status report period.
A 10D% reinspection of all hangers installed in CY 1980 and a sample reinspection of hangers installed after January 1, 1982 is continuing by the licensee.
All safety related welding on the heating, ventilating and_ air condition-ing (HVAC) was stopped November 30, 1982 after the licensee det. ermined that the Quality Assurance Program for welder certification and procedure qualification was inadequate. Zack Company, the HVAC contractor, discontinued all welding on safety related HVAC systems, laying off 151 craft workers.
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UNITED STAT ES
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NUCLEAR REGULATORY COMMISSION 17 ll.j',' -_ f L'
-hk 7es noosEvELT Road q.v
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GL EN ELLYN, ILLINOIS 63137 e
August 13, 1982
.3 MEMORANDUM FOR: All Midland Section Personnel i
FROM:
W.
D. Shafer, Chief, Midland, Section SU3 JECT:
REMEDIAL SOILS ACTIVITIES Effective inmediately, we.will authorize remedial soil work activities, including work affecting remedial soils activities as defined in.the "C"'
boundaq -in licensee drawing C-45, in accordance with the NR /CPCo Work Auth:rization Procedure, effective August 12, 1981.
All work in this area is "C" and nust be ~ accomplished -in accordance with a staf f approved QA plan.
Dr. R:ss Landsman has the lead responsibility for recensending authorization of this werk. Each of us are responsible for keeping Dr. Land: an informed abo t autnerizations for non-civil werk activities.
Should anyone question whether -the actual ingle.5.enting work meets the licen-see's com-ittment to NRR, please' notify re i..,ediately so that we may expedite an acceptable resolution.
Anyone identifying unauthorized work in progress will notify me immediately.
Unauthorized work will be considered a direct violation of tne board order.
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Jfn LO W. D. Shafe.
Chief, Midland Section c:: '
R. F. Wamick R. C. Cook
- 5. L. Surgess R. N. Gardne r R. E. Landsman-I i
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NRC AND CPCO WORK AUTHORIZATION PROCEDURE Effective Date August 12, 1982 APPROYED (00 Ld.,t/
Q Midland Project Office
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APPROVED A
Chief, Mrd1Ynd Ss'fion~ OSC t
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i NRC AND CPCO WORK AUTHORIZATION PROCEDURE SCOPE i
To review all construction work covered by the ASLB Order of April 30, 1982.
PURPOSE To provide a mechanism for NRC Region 3 review and authorization of activities to be implemented at the Midland site as described in the ASLB Order.
To designate appropriate NRC and CPC0 responsible individuals.
REFERENCES
- 1) ASLB Memorandum and Order dated April 30, 1982.
- 2) ASLB Memorandum and Order dated May 7,1982.
- 3) Letter to J W Cook from D G Eisenhut dated May 25, 1982, " Completion of Soils Remedial Activities Review".
PROCEDURE 1.0 CPCo Project Management Organization will provide, at the beginning of the month a detailed list of all work activities to be implemented.
This list will cover the construction activities anticipated to be in progress for the next 60-day period.
2.0 Upon receipt of the list the NRC will review the list and designate those activities as critical or non critical and advise CPCo Construction in writing of this designation.
2.1 For those activities designated non critical, CPCo is authorized to proceed with the work. This work shall be accomplished in accordance with the staff approved Quality Assurance Plan.
2.2 For those activities designated critical, the NRC will advise CPCo Construction of the required details essential for further staff review to determine the specifics of the work.
CPCo is not authorized to proceed with work prior to receiving written authorization from the NRC.
Page 2' 2.2.1 CPCo Construction will provide the work details as requested by the Region.
2.2.2 Af ter review by the Region, CPCo will be provided with specific written authorization to conduct the identified work activities.
2.3 Should these ' authorized activi, ties not start within 90 days, these activities will be resubmitted for authorization.
3.0 Changes may be required for authorized critical and non critical activities.
These changes shall be processed as follows:
' 3.1 Changes that alter the description of a previously submitted activity, in 1.0 above, shall be submitted to the Region for review. The review and authorization process will be as in 2.0 above.
3.2 Changes which do not alter the description of a previously submitted I
activity, in 1.0 above, are not required to be submitted to the NRC but,ishall be accomplished in accordance with the staff approved Quality Assurance Plan.
4.0 Work activities not previously identified on the work list, in 1 0 above shall-be identified and authorized as in 1.0 and 2.0 above. Approval of f
these work activities may be given verbally by the NRC responsible indivi-dual to the NRC Senior or Resident Inspector, who will then issue written authorization.
5.0 Emergency work activities may be performed to mitigate conditions which could affect personnel safety or could result in damage to facilities and equipment.
These activities shall require inmediate notification of the Senior Resident Inspector.
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6.0 Responsible individuals
. 6.1 The 'NRC representative shall be the Chief, Midland Section Office of
~ Special Cases or his designee.
6..
The CPCo designated representative shall be the Site Manager or his designee.
7.0 Changes to this procedure shall be approved the the Chief, Midland Section Office of Special. Cases and the Site Manager.
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...e WORK ACTIVITY LIST FOR SEVEN DAYS FROM LIFTING OF STOP WORK ORDER Aux Bldg 1.
Operate all instruments in seven day " baseline" 2.
Test all instrumentation systems per C-1493 3.
Adjust set and finalize covers on all instruments 4.
Verify post tension systems on control tower 5.
Maintain instrument system
-Freeze Wall.
6.
Continue monitoring utility protection pits (4) 7.
Install clay to below duct bank (pit 4) (details attached) 8.
Add additional wells '(up to 5) on west perimeter. (outside C-45) 9.
Continue operation of systems and wells FIVP 10.
Install and grout bolts and plates 11.
Life off test on bolts (and hardness tests) 12.
Tension bolts Crack Mapping 13.
Clean FIVP to crack map
-14.
Crack map F1VP's 15.
Crack map EPA's 16.
Crack map remainder Aux Bldg Underpinning 17.
Drif t to piers 12 E/W 18.
Dig piers 12 E/W 19.
Install piers 20.
Drift to piers 9 E/W 21.
Implement C-200 if needed 22.
Install bumpers, handrails, stairs, etc in access shaft SWPS 23.
Complete fireline relocation 24.
Install 6 deep seated benchmarks 25.
Install ejector wells 26.
Install soldier piles 27.
Excavate 36" service water pipe (train A)
BWST 28.
Construct new ring beams Other 29.
Finish 72" line repair 30.
Approval of Quality Assurance Plans JRSchaub 8-12-82
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Uni:ed S:at es Nu: lear R egulatory C r eit si x
% n.-r.5e r 29, 1982 5'idland Sit e Resident Ins pection Of fi:e Rtu:e 7 3.C.Nc. 1-358.0E M id' and. MI
!.8 6!.0 -
N f. ':FE-1 At:ention Mr. R. Cook Lear Sir:
RE : DOCKET No. 50-329/330 MIDIAND PLANT - UNITS 1 AND 2 INDEPENDENT ASSESS!ENT OF AUXII.IARY BUILDING CNDE RFINNING A copy of the Independent Ass ess.ent of th e &_ ri '. i t y Euil din g Und e r pi n ning
'n'ee kl y R e po rt No. I f or the period Sep:enber 19 :hrough 26. 1982, is enclosed with this l e tt er.
If you have any questions with res pec: te this re rr:, please contact me
~
at ( 61 7) 589-2067.
i Very truly yours,
I
. A)*w 1
i A. S t a nle y Luc r.s Proj ect Manager En cl os ure ASL:ch d /N: h l ^
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BX214 358. 06 OCT 5 082
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J.O.No. la358 '
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IMid'Od Plant
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'M Uni ts 11 snd 21
,' Ui SInde psndent-Assessment :
$uxiliary BuildinF Und erpi ~nni ng Week 1v Reoort No. l' e
c p yrber 19 through 26. 1982 Personnel on'5i:e Stone,& Webster Engineering Corporation (SWEC)
W. E. Kilker 9/20 /82-9 /26/82 L P. Barry 9/20/80-9/23/82 L.~ T. ' Roben
' L 9/20/82-9 /24/82 E. Helsinger 9/20/82-9/26/82D i
iL -Scott'
'9/20/82-9/26/82 R
A. S. Eucks 9/21/82-9/23/82.
Parsons, Brinker.hoff, Quade, - & Douglas '(PBCO )
P. Parish 9/21/82-9/24/62 l
J. Ratner 9/22/82-9/24/82 A: tivi ti es L
Thi s re po r: s u== ari ze s the first week of a: tivi:ies and obs erva:i sts of the
[
SWEC : inde pendent _ ars es ocen: team (including the PEQ2 p-rs onn el l.
Tn e t e am,
which at the present. time cohsists of seven engineers repres en:ing Ceotech-l nical,- Structural, Construction', and Quality Assurance dis ciplines, arrived at"the site between September 20 and Sep:enber 22.
'The assessment team has. established separate on-site office s pace and has contract ed f or ' clerical 1 assistance.
Introdue: ions of all team members were made to on-site personnel repres enting Becht el Engineering and Construction; ' Cons umers' Power Comptny. Qu ality.
Ass urance 'and Quality Control;. Wiss, Janney & Elstner (WJ&E) ' Instrumentation
- Monitoring; and Mergentime Construction.
Tours and briefings of the various areas and ac tivi ti es rel at ed to the week :st the reauestf of. the ~
underpinning were given throughout- 'the as s es sm en t t e am.
In:1uded in these tours and i
briefings were the in place access shaf ts and TIVP supers:ru::ure supports, l
the - dee p-seated ben:h: arks and relative ention measurement st ations,. the extensometer and strain gage instrument a: ion inst allations, the crack mapp-
' ing, - the J WJ&E instrucen:ation monitoring and da:a re ecr ding 'st ation, ':he i
lagging' and. 'reinf orcing ba: fabrication shops, and the ma t e ri al t es ting L
l aboratory.
l-Also,.thh ass essment' team pe riodi cally cbs erved the acrk on the mock-up pier (located 'near :he Outage Buil ding ) and :he j a: king s:and mock-up (locat ed adj acent. to the lagFint f abrica: ion sher).
A:' Iagging and' shoring were in place on the mock-up prior to the team's arrival cr. si:e. but observa tions 4
l
'EX214358.05
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- 2 a de of t he -rei r'or m -nt inst al
- a-i <e and the p: -:+, snt 'of cc ur at e i t.'
~
- * ;_.-r half of the pier. Th rce. e.be rs of the ass er s.en t t + xt en:ered the pi er -~ f s: fi rs t i is nd observd ions of the-ins t all ati on.
The Quality Control
- attivities und & r estatier. prepared prior to release f or concrete plac e ent
-ere des cribed and /:,r. pr ovi !ed as re quest ed by the team embe r_s.
Daily meetings were held starting September _21 between personnel representing the : assessment t e. s =, 3echtel Engineering ' and Cons t ructi on, and Consmers Pever Co=pany Engineering ' and Quality Assurance.
""h es e mee tin F5 Provided a
~
fo m at for ' the as s es, rent :tse to request i nf orn ati on and clarification as well as to dis e ass ebservaticns.
Mebe rs of the team have - read the Su= mary of Soils-F el ated Issues R eport and are reviewing applicable specifications, drawings, etnstruction, and Quality Con trol pro cedure s, instru=ent moni toring proc +dures, and pl ant Quality Assurance doctraents.
An assesscent. team Proj ect Manual has been prepared that i: cl udes the Proj ect Organiza tion Qu alit y -Assurance Plan and re por ting and doctreent ation procedures.
Me e tin gs Date K e ores ent ed Purpos e 9/20/82 Stone & Webster Int roducti on to Cons tr ers F ower Cc.
Site rers onne '.
3etht el
':e r ge ntim e 9/21/S2 Stone 6, Webster Daily Meeting through ~
Parsons 9/25/82 Constners Fewer Co.
Bechtel Observations The ass esscent team received,f ull cooperation of on-site pe rsonnel. Ind e pe n-dent office space and telephone cocaunication have been provided. Constners Power C ompa ny and Be cht el pe rs onnel have complied with team re ques t s for to existing installations, briefings, doctments, and records.
access
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Project Engineer Prej ect Mana ger EX214358. 06 m
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SIONE & WEUSIER MICillGAN, INC, MIDLAND NUCLEAR COGENERATION PLANT CIO O8SERVATIONS Originating CPCo Response
. Status Close-Out "UU Observations Document /Date Document /Date Open/ Closed Document /Date
[ber 001 MRC Meeting 5/18/83 Letter-minutes Letter Closed Report No. 4 SUBIllLE AND OBJECTIVES OF CCP of meeting of 7/1/83 7/12/83 Prov! F details:.
5/18/83
\\
(a) to improve project information status (b) to improve implementation of the QA program 002 MRC Meeting 5/18/83 Letter-minutes Letter Closed Report No. 4' Status of Bil0 PILOT lEAM of meeting of 7/1/83 7/12/83 (a) are procedures for statusing approved 5/18/83 (b) provide results of preliminary lianger walkdowns 003 MRC Meeting 5/18/83 Letter-minutes Letter Closed Report No. 4 liANGER TEAM ENGINEERS of meeting of 7/1/83 7/12/83 1
(a) how are NCR's' processed and evaluated 5/18/83
~
004 -
MRC Meeting 5/18/83 Letter-minutes Letter
-- Closed Report No. 4 IIANGER TEAM QUALITY REPRESENIATIVE of meeting of 7/1/83 7/12/83 (a) clarification on Q-Non Q interface 5/18/83
~
005 MRC Meeting 5/18/83 Letter-minutes Letter Closed Report No. 4 PROCEDURES / INSPECTIONS of meeting of 7/1/83 7/12/Q3 (a) provide objective evidence that 5/18/83 listing of procedures, specifications and drawings are complete l
PAGE 1 of ;
L
-e
.SIONE & WEGOTER MICillGAN. INC.
MIDLAND NUCLEAR COGENERATION PLANT CIO OBSERVATIONS Obs:rvation Originat.ing CPCo Response
$tatus Close-Out Number Observations Document /Date Document /Date Open/ Closed Document /Date 1
006 MRC Meeting 5/5/83 l Report No. 1 Letter Closed Report.No. 5 Program (Training) requires revision to 6/3/83 7/1/83 7/18/83 address how " Trainers" are trained 007 Method of communication / notification with Report No.1 Letter Closed Report No. 4 MPQAD when PQCI's are found to be ambiguous 6/3/83 7/1/83 7/12/83 or do not meet code requirements i
008 MRC Meeting 6/1/83 Report No. 2 Letters Closed Report No. 9 Adequacy of drawings (A8) - large bore
$/14/83 7/1/83 8/15/83 l
pl)e hangers 8/9/83 l
Ilo)d Point Released 8/15/83 009 MRC Meeting 6/1/83 Report No. 2 Letters Closed Report No. 9 Additional verification of equipment 6/14/83 7/1/83 8/15/83 received and installed 8/9/83 (E-2) 010 MRC Meeting 6/1/83 Report No. 2 Letters Closed Report No. 9 Material traceability of installed 6/14/83 7/1/83 8/15/83 1
hangers (E3) 8/9/83 lloid Point Released 8/15/83 i
e i
011 MRC Meeting 6/1/83 Report No. 2 Open pending 5/14/83 receipt of (a) discussion of nonconforming items Nutech Pro-with Project Engineering gram (b)-has a program beert developed and responsibilities established of personnel assigned to process s
nonconformances?
NOTE:
lloid Point Released 8/15/83 v
t
.SIONE & WEBSTER MICilIGAN. INC.
MIDLAND NUCLEAR COGENERATION PLANT CIO OBSERVATIONS Obs:rvation Originating CPCo Response
. Status Close-Out i Number Observations Document /Date Document /Date Open/ Closed Document /Date 012 MRC Meeting 6/1/83 Report No. 2 Letter Closed Report No. 9 Identification of QVP related connitments 6/14/83 7/1/83 8/15/83 013 MRC Meeting 6/1/83 Report No. 2 Response given Closed Report No. 2 Would a critical path Level !! network 6/14/83 at meeting 6/14/83 be issued?
'014 HRC Meeting 6/1/83 Report No. 2 Letter Closed Report No. 5 Are job descriptions and responsibilities 6/14/83 7/1/83 of CPCo personnel engaged to implement the QVP available?
015 Inspection attributes do not lend them-Report No. 2 PQCl P*1.60 Closed Report No. 8 selves to the title of the PQCI "In-6/14/83 Rev 7 8/9/83 8/8/83 i
Process"______.
4 l
016 Clarification of paragraph 1 under "Special Report No. 2 PQCI P-1.60 Closed Report No. 8' i
instructions," PQCI P-1.63 6/14/83 Rev 7 8/9/83 8/8/83 i
017 System Interaction Walkdown Program not Report No'. 2' Response by Closed Report No. 2 reviewed by Region 111 HRC nor the NRR 6/14/83 D. Miller dur-6/14/83 Ing meeting 6/14/83 018 MRC Meeting 6/17/83 Letter Letter Closed Report No. 6 i
Matrix of CPCo conunitments to the NRC 6/17/83 7/1/83 7/25/83 should be complete DACC
- )
nF c
SiONE & WEDSIER MICillGAN. INC.
MIDLAND NUCLEAR COGENEllAI'10N PLANT CIO O8SERVATIONS Observation Originating CPCo Response
. Status Close-Out
%,7 Observations Document /Date Document /Date Open/ Closed Document /Date 019 MRC Meeting 6/17/83 Letter Letter Closed Report No. 6 The 14 required to resolve Management 6/17/83 7/1/83
'7/18/83 Review Team %servations should be reviewed and approved l
020 MRC Meeting 6/23/83 Letter tetter Closed Report No. 12
]
Audit responses 'should not be readdressed 6/28/83 8/9/83 9/6/83
~
021 MRC Meeting 6/23/83 Letter Letter Closed Report No. 12 Observations by Review Team should be 6/30/83 8/9/63 9/6/83 sulinitted in advance of meetings 022 MRC Meeting 6/23/83 Letter Letter Closed Report No. 12 Restraints require expeditious resolutions 6/30/83 8/9/83 9/6/83 023 -
Concerns regarding methods of evaluating Report No. 3 Letter Closed Report No. 5 s
construction training courses 6/28/83 7/1/83 7/18/83
=
024 MRC to convene' to confinn or modify Report No. 5 Letter-J. Cook Closed Report No. 9 reconmendations of R. A. Wells memo of 7/18/83 to J. Rutgers 8/15/83 6/7/83 Serial 22848 7/13/83
~.-
PAGE 4 of 4
STONE & WEDSTER MIClllGAN, INC, 49 MIDLAND NUCLEAR C0 GENERATION,l'LANT
,d as.
f A+
I<-
CIO OBSERVATIONS
~
P 2 )
i Cservation Originating CPCo Response' l. Status
'[
Close-Out '.,f L ^k _
Number Observations Document /Date Document /Date. *Open/ Closed Document /Date %Ef a
, i' ky2 sg
,025 Ten course rosters unsatisfactory due to Report No. 7 Telecon on Closed
- 5. deport No. 11 transcription errors and improperly 8/1/B3 8/25/83 that
~ f;
, h 8/29/83 3
s filled out.
corrections Reverified /
have been made Daily Inspec ;
tion e
M' Report 8/25/83 k
026 14 discrepancies-Construction Training Report No. 8 Telecon 8/22/83 Closed Report No. 9
)
matrix vs. Computer Printout P/8/83 Reverified-8/15/83 one deficiency Daily Inspec-NIR 001 issued lon
~
Reports 8/22/83 r
027 NIR 001 dispositioned and issued as closed Report No. 9 N/A Closed CIO Closeout '
~
i by CIO 8/15/83
?
8/15/83
./
c 028 '
13 discrepancies-Construction Training Report No. 9 Memo from Close[1 Report No. 10 matrix vs. Computer Printout 8/15/83 Training Daily Inspec-Coordinator tion Report 8/18/83 8/18/83 4'
F i
/
029 Duplication of welding criteria in various
. Report No. 9 Telecon with Closed Report No. 11 PQC1's
'B/}5/83,
R. Davis MPQAD 8/29/83 8/26/83 030 Need to review Vendor Equipment Report No. 5 Open Verification Program-MPQAD/SMO 7/18/03 PAGE 5 of 5
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