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6 o IJNITED STATES f, [,,g NUCLEAR REGUI.ATORY COMMISSION
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/.c REGION 111 [i e/ o -- 5 [ 799 ROOSEVELT ROAD [ %ff / d %..** d GLEN ELLYN, ILLINOIS 60137 + October 5, 1979 HEMORANDUM FOR: R. C. Knop R. Cook D. W. Hayes T. Vandel D. H. Danielson F. Jablonski K. Naidu E. Lee G. Maxwell G. Gallagher W. Hansen K. Ward P. Barrett FROM: ,G. Fiorelli, Chief, Reactor Construction and Engineering Support Branch
SUBJECT:
MIDLAND CONSTRUCTION STATUS REPORT AS OF OCTOBER 1, 1979 The attached draft report was developed based on discussion with you, as weLL as, your written feedback to D. Knop's memo dated August 28, 1979. Let me know by October 16, 1979 if you feel the items are not properly characterized or additional items should be included. Please review the document with the thought that you wiLL be asked to concur in the final version. The document is not intended to identify such matters which we know must stiLL be closed out such as unresolved items, 50.55(eY, etc. Instead we are trying to characterize those significant matters we perceive warrants additional management attention, and if not provided could impact on the issuance of an operating License. Note, in particular, the concluding paragraph - If any of you feel l this has not been characterized property, I wiLL expect you to inform me. i f_;fMf04l$'6 G. Fioretti, Chief Reactor Construction and Engineering Support Branch
Attachment:
As stated cc: J. G. Keppler gp[5] e4o7jg RICE 84-96 PDR
C. hkkU s' .r 6 MIDLAND
SUMMARY
REPORT UPDATET Facility Data Docket Numbers 329 and 50-330 Construction Permits - CPPR-81 and CPPR-82 I ' Permits Issued - December 14, 1972 1 Type Reactor - PWR; Unit 1, 492 MWe*; Unit 2, 818 MWe NSSS Supplier - Babcox & Wilcox ~ Design / Constructor - Bechtel Power Corporation 4/G2, Fuel Load Dates - Unit 1, 3M 41T Unit 2 .6/8f // 8 / ( Status cf Construction - Unit 1, 54% Unit 2,61% Ingineering 82%
- Approximately one-half th'e steam production for Unit 1 is dedicated, by contract, to be supplied to Dow Chemical Corporation, through appropriate isolation heat exchangers.
c.p k414ey --4... 1,. m. g. ~ +a "rh teanr stitTree upon demand. /' /M-O' Nif n/[,q/ _s s Chronological isting of Major Events .b July 1970 Start of Construction under exe ion I 9/29-30 & Site inspection, four items of noncompliance identified, 10/1/70 extensive review during CP hearings 1971 - 1972 Plant in mothballs pending CP 12/14/72 CP issued 9/73 Inspection at Bechtel Ann Arbor offices, five items of noncompliance identified 11/73 Inspection at site, four items of noncompliance identified i. (cadwald problem) precipitated the Show Cause Order j 12/29/73 Licensee answers Show Cause Order conmiits to improvements on QA program and QA/QC staff 12/3/73 Show Cause Order issued suspending cadwalding operation l 12/6-7/73 Special inspection conducted by RIII & EQ personnel ~ 12/17/73 Show Cause order modified to allow cadwelding based on inspection findings of 12/6-7/73 /
...a. .y ' jf x 12/5/7 CP, reported that rebar spacing out of ' specification 50 locations in Unit 2 containment g 3/5 &'10/75 CP reported that 63 #6 rebar were either missing or misplaced in Auxiliary Building 3/12/75 RIII held management meeting with CP O 4 e .I e
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? 8/21/75 CP reported that 42 sets of #6 tie bars were missing in Auxiliary Building 4 3/22/76 CP reported that 32 #8 rebar were omitted in Auxiliary Building. A stop-work' order was issued by CP 3/26/76 RIII inspector requested CP to inform RIII when stop-vork order to be lifted and to investigate the cause and the extent of the problem. Additional rebar problems identified during site inspection ~ 3/31/76 CP lifted the stop-work order 4/19 thru RIII performed in-depth QA inspection at Midland 5/14/76 5/14/76 RIII management discussed inspection findings with site personnel 5/20/76 RIII management meeting with CP President, Vice President, and others. 6/7 & 8/76 RIII follow up meeting with CP management and discussed the CP 21 correction commitments 6/1-7/1/76.. Overall rebar omission reviewed by R. E. Shewmaker 7/28/76 CP stops concrete placement work when further rebar placement errors found by their overview program. PN-III-76-52 issued by RIII 8/2/76 RIII recoimaands HQ notice of violation be issued g/9 - 9/9/76 Tive week full-time RIII inspection conducted '8/13/76 Notice issued 10/29/76 CP responded to EQ Notice of Violations 12/10/76 CP revised Midland QA program accepted by NRR 2/28/77 Unit 2 bulge of containment liner discovered 4/19/77 TendonsheathomissionsokUnitIreported 4/29/77 IAL issued relative to tendon sheath placement errors 5/5/77 Management meeting at CP Corporate Office relative to IAL regarding tendon sheath problem e
_ ~ - -.c.m ~ ,p. i.* + 5/24-27/77 Special inspection by RIII, RI and HQ personnel to determine adequacy of QA program implementation at Midland site I 6/75 - 7/77 Series of meetings and letters between CP and NRR on applicability of Regulatory Gufdes to Midland. Commi.tments by CP to the guides was responsive 7/24/78 Construction resident inspection assigned 8221778 Measurements by Bechtel indicate excessive settlement of Diesel Generator Building. Officially reporced to Alt l JIIt'on September 7,1978 gfg 3.y. E c. - 12/78 - 1/79 Special investigation / inspection conducted at Midland sites Bechtel Ann Arbcr Engineering cffices and at CP corporate t offices relative to Midland plant fill and Diesel Generator building settlement problem 2/7R9 - Corporate meeting between RIII and CPC to discuss project status and future inspection activities. CPC informed construction performance on track with exception of-diesel filling. 5/8-11n9 ..Mid-eA inspection conducted. 5/5R9 Congressman Albesta and aids visited Midland site to discuss TMI effect on Midland. 3/21n9 10 CFR 50.54 request for information regarding plant fitt sent to CPC by NRR. 2/23/79. Meeting held in RIII with Consumers Power to discuss diesel generator building and plant area fitt problems. 3/5/79. Meeting held with CPC to discuss diesel gen'erator building and plant area fill problems. [ -- - ws M 4 'i M e e
-=_ =:: ..x a = _... =... .r c.y y Significant Mpjor Events <r Past Problems 1. - Cadweld Splicing Problem and Show Cause Order A routine inspection, conducted on November 6-8, 1973', as a result of intervenor information, identified eleven examples of four noncompliance items relative to rebar Cadwelding operations. These items were summarized as: (1) untrained Cadweld inspectors; (2) rejectable Oldwelds accepted by QC inspectors; (3) records inadequate to establish cadwelds met requirements; and (4) inadequate procedureis. onNovember9,1973whichinturnstoppedrebarinstallation0}) As a result. the licensee stopped work on cadweld operations t ne licensee agreed not to resume work until the NRC reviewed and accepted their corrective action. However, Show Cause Order was issued on December 3,1973, suspending Cadwelding operations. On December 6-7, 1973 RIII and HQ personnel I conducted a special inspection and determined that construction activity could be resumed in a manner consistant with quality criteria. The show cause order was modified on December 17, 1973, allowing resumption of Cadwelding oper.7tions based on the inspection results. I The licensee answered the Show Cause Order on December 29, 1973, committing to revise and improve the QA manuals and procedures and make QA/QC personnel changes. Prehearing conferences were held on March 28 and May 30, 1974, and the hearing began on July 16, 1974. On September 25, 1974, the Hear.ag Board found that the licensee was implementing its QA program in compliance with regulations and that construction should not be stopped. 2. Rebar Omission / Placements Errors Leading to IAL l Initial identification and report of rebar nonconformances occurred during an NRC inspection conducted on December 11-13, 1974. The licensee informed the inspector that an audit, had identified rebar spacing problems at elevations 642' - 7" to 652' - 9" of tinit 2 containment. This item was subsaquently reported per 10 CFR 50.55(e) and was identified as a item of noncompliance in report Nos. 50-329/74-11 and 50-330/74-11.- Additional rebar deviations and omissions were identified in March and August 1975 and in April, May and June 1976. Inspection , report Nos. 50-329/76-04 and 50-330/76-04 identified five noncompliance items regarding reinforcement steel deficiencies. 5
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O r Licensee response date'd June 18, 1976, listed 21 separate items (commitments) for corrective action. A June 24.1976 letter provided a plan of action schedule for implementing the f 21 items. The licensee committed not to resume concrete placement work until the items addressed in licensee's June 24 letter were resolved or implemented. This commitment was ' documented in a RIII leeter to the licensee dated June 25, 1976. Although not stamped-as an IAL, in-house menos referred to it as such. Rebar installation and concrete placement activities were resumed in early July 1976, following completion of the-items and verification by RIII. Additional action taken is as follows: E a. By the NRC (1) Assignment of an inspector full-time on site for five weeks to observe civil work in progress (2) IE management meetings with the licensee at their corporate offices (3) Inspection and evaluation by Headquarter personnel b.' By the Licensee ~ (1) June 18, 1976 letter committing.to 21 items of L corrective action (2) Establishment of an overview inspection program to provide 100% reinspection of embedments by the licensee following acceptance by the contractor t QC persont.el i l-c. By the Contractor l (1) Personnel changes and retraining of personnel (2) Prepared technical evaluation for acceptability of each identified construction deficiency (3) Improvement in their QA/QC program coverage of civil work (this was imposed by the licensee) 3. Tendon Sheath Placement Errors and Resulting Immediate Action Letter (IAL) l ' On April 19, 1977, the licensee reported, as a Part 50, Section 50.55(e) item, the inadvertent omission of two hoop tendon sheaths from a Unit 1 containment concrete placement at I
1 k' 4;d @yd h. yg, k L; h-e ~/ ' '. ~ ~. t g elevation 703' - 7". The tendon sheathe we're, for i.he most j ? part, located at an elevation in the next higher concrete f placement' lift, except that they wereliverged to the loweh s d'* placement lift to pass under a steam like penetration. ,~ FailurTt to rely on'-the ~ , proper source docuinents by construction 7and inspection [ personnel, contributed to the omission.1 q ',K} .t An IAL was issued to the licensee on April 29,1977. which spelled out six licensee commitments for correction which, included: (1) repairs and cause corrective action; (2) expansion of the licensee's QC over view program; (3) revisions to procedures and training of construction and inspection personnel.j .j ~ 7 A special QA program inspection was condhted in early May 1977.- ~ The inspection team was made up of personnel from RI, RIII, and ./ 3g HQ. Although five items of noncompliance sere identified, it I I,p -. - was the concensRus of the inspectors that the licensee's m 7- ) program was an acceptable program and-thG Hidland-- /\\, T l' t ^4, /-['..M,. ce-et~tieneaeH d Mes-wer.w* comparable-to kst nther~ I ~ 9 construcH
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~ ~ ' (gl/ The licensee issued its final report on August 12, 1977. Final review on site was conducted and documentediin report No. 50-329/77-08. PE - Current Problems 2a) L t%W'r:dd 5 1. PP t Fille-Diesel Generator Building Settlement The Licensee informed the RIII office on September 8,1978, of per requirements of 10 CFR 50.55(e) that settlement of the diesel generator foundations and structures were greater than ., f expected. ,5 ft.*s q), et. FILL material in this area was placed between 1975 and'1977, gs mid-1977. /ruction starting on diesel generator building in with const Review of the results of the RIII investigstion/ gyp /~)fq,.m [ h q inspection into the plant fill / Diesel Generator Building' [r f g settlement problem indicate many events occurred between V p/ "y0 N, p ' Late 1973 and early 1978which should have alerted E.rchtet;,, f,/ and the Licensee to the pending problem.! These events.- . fg. included nonconformance reports, audit findings, field memos k 'f) g - to engineering and problems with the administration building fill which caused modification and replacement of the already 'M(jjl-poured footing and replacement of the fill material with Lean concrete. Cause of the excessive settlement include: (1) inadequate , M, /*f placement method - urttualified compaction equipment and excessive j-f // v
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P -[ Left thickness; (2) inadequate testing of the soil material; j"IN; (3) inadequate QCinspection procedures; (4) unqualifigd /*4 uali con $r'ol inspectors and field engineering; (5)Mance q& W '4
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The proposed remedial work and corrective action are as follows: (1) Diesel Generator Building apply surcharge load in and around bgilding to preconsolidate the foundation material. Continueamonitor soil response to predict Long-tera y settlement. (2) Service Water Pump Structure - Install piles to hard glacial tiLL to support that portion of the structure founded on plant fill material. (3) Tank 1%rm # SILL has be'en determined to be suitable for the support of Borated Water Storage Ta: 'ts. Tanks are to be constructed and hydro tested while monitoring soil response to confirm support of structures. i (4) Diesel Oil Tanks - No remedial measure; backfill is considered adequate. s (5) Underground Facilities - No remedial work is anticipated with regards to buried piping. (6) Auxiliary Building and F. W. Isolation Valve Pits - Installed a number of caissons to glacial' tiLL material and replace soil material with concrete material under valve pits. (7) Dewatering System - Installed site dewatering system to l provide assurance against soit Liquid action during a seismic event. The above p-ag::d remedial measureswere proposed to the NRC staff on July 18, 1979. No endorsement of the proposed actions have been issued to th~eLicenseetodate.4[8icensee is proceeding with the above plans. -
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The NRC activities, to date, include: ":p: TRIM g" ww% 4., a g ;.: .t j Trans4erM Lead)4 responsibility to NRR from/<IE by m AL d (. November 17, 1978. i ). Site meeting on December 3-4, 1978, between NRR, IE, Consumers l Power and Bechtel to discuss the plant fill problem and prorosed corrective action relative to the Diesel Generator l Building settlement. l 8 e e
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RIII. conducted an investigation / inspection relative to the plant fill and Diesel Generator Building settlement. 4r Finding are contained in Report 50-329/78-20; 330-78-20 r dated March 1979. j Y e. NRC/ Consumers Power Co/Bechtet meetings held in RIII office to discuss finding of investigation / inspection of site settlement (February 23, 1979 and March-5,1979) 1. NRC issue of 10 CFR 50.54(f) rega-ding plant fill dated March 21,1979. ) g. Several inspections of Midland site settlement have been performed. The Constructor / Designer activities includ'e: I a. Issued NCRr1482 (August 21,1978) q b. Issued Management Corrective Action Report (!! CAR) No. 24 (September 7,1978) c. Prepared a proposed corrective action eption regarding placement of sand overburden surcharge to accelerate and achieve proper compaction of diesel generator building sub soils. d. Issued 10 CFR 50.55(e) interim report number L dated ' September 29, 1978. e. Issued interim report No. 2 dated November 7,1978. f. Issued interim report No. 3 dated June 5,1979 __. g. Issued interim report No. 4 dated February 23, 1979 i h. Issued interim report No. 5 dated April 30, 1979 1. Responddto NRC 1G CFR 50.54Cf) request for information onsitE settlement dated April 24, 1979. Subsequent XMMXIMIMM 4 Revision 1 dated May 31, 1979, revision 2 dated July 9,1979 and revision 3 dated September 13,1979. i J. Meeting with NRC to discuss site settlement causes and proposed resolution and corrective action taken dated July 18, 1979. Information discussed at this meeting is documented in Letter from CPCo to NRC dated August 10, 1979. k. Issued interim report No. 6 dated August 10, 1979. L. Issued interim report No. 7 dated September 5, 1979. t e D O f-
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2. Review of Quality Documentation to Establish Acceotability of Equipment. The adequacy of engineering evaluation of quality documentation (test reports, etc.) to determine if the documentation establishes that the equipment meets specification and environmental requirements is of concern. The Licensee, on November 13, 1978, issued a construction deficiency report (10 CFR 50.55(e)) relative to this matter. An interim report dated November 28, 1978 L was received and stated Consumers Power was pursuing this matter t not only for Bechtel procured equipment but also for NSS i supplied equipment. 3. Source Inspection to Confirm Conformance to Specifications The adequacy of equipment acceptance inspection by Bechtel shop inspectors has been the subject,of several CDN's relative to this matter. Examples of this problem include: (T) Decay Heat Removal Pumps released by the shop inspector and shipped to the c - site with one pump assembled backwards, (2) electrical i penetrations inspected and released by the shop inspector for shipment to the site. Site inspections to date indicate about 25% of the vendor wire terminations were improperly crimped. Additional inspections wiLL be conducted to determine if CP has thoroughly completed an overview of the Bechtet shop inspectors function. l
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_.. _a -. D.C 4. "Q" Tesf Equipment There have been instan:es wherein safety construction equipment installation activities have not been identified on the "Q" List. This shortcoming could affect the quality of work performed due to-the absence of quality controls identified with "Q" List items. Examples of non "Q" list activities identified which should be "Q" listed include: e f. CableTrays[ Heating and Ventilation Equipment %yf,ue(,P(oL[Rapk's ig,# The Licensee wiLL be advised to review past as weLL as future f/ '<;f g 'y i i e construction activities to confirm that they were property y .g.h defhed as "Q" List work or components. s 5. Lessons Learned Items A ^ ~ ' Noletermination has yet been made9 by the region to confirm . q w G. il d/ h] l l l l t l e that CP has incorporated the necessary modifications or p' ble; l \\ l r. 3 7,], core,ctions,resultingfcmtheconstructionexyriencesof .h-R V-Davis-Sesse ofMhe operadg experien/ i i ces of TMI. w LJ 6. Management Controls Whithsubj/ ect ve, t e reaction of Consumers Power Compapy to a. ] / ins /ction finding hasbeeno[ eof djfepis c4 nowledging the._.xistence of a pro)Lem. This has in part s,)j - W in a e o i .? d'i effected the timely disposition of matters brought to the attention } [- l(d 11 - r --e,,._,, n,,--,,n,,-,,,,,-.--.,-n._,n.,,-.,,w.,--v,,-.,,,,.,,,m..,....,,-,----..,-., c w..- ,---rn.,.w~
u ~ -. -.. - -.. =. - ..~ ~ ~ ,A .m, j -l t of CP..Some examples of problems in which this reaction f/ l / \\ ] has tieen ottserved are as -fdttows: v I )Lu.fIC w m ~ b. There have been many cases wherein nonconformances ~ y g,.g hav been identified, reviewed and accepted "as is." So ['e u.ipc~ l ,9 01,, The extent of review given by the Licensee prior to ~ [. /,lN ch* resolving problems is currently in progress. In one N.! y1f case dealing with the repair of airlock doors a determination /V:r' ' was made that an incomplete engineering review was ~ given the matter. Inspection History The construction inspection program for Midland Units 1 and 2 is approximately 60% complete. This is consistent with status of construction of the two units. (Unit 1 - 54%; Unit 2 - 61%). .<hsj l ' ~
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. '..L.'..*. l A The routine inspection program has not identified an unusual number M\\ ef of enforcement items. Of the selected major events described y% above, only one is idrectly attributable to RIII inspection activity s l-g (Cadweld splicing). The others were identified by the Licensee and 3 [\\!. 'l reported through the deficiency report system (50.55(e)). The Midland date for 1976 - 1979 is tabulated as follows. I
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Year Noncon "icnce: Inep9etiens On Sitta i 1976 14 9 646 ~ 1977 5 . 12 648 1978 .M /f ' MJ7 -Petr'll8 0 i g M /e d d s 7' /t V21 -W A resident inspector was assigned to the Midland site in July 1978. i The on site inspection hours shown above does not include his inspection \\ , 'g-)- time. [/--' The licensee's QA program has repeatedly been subject to'in-depth' review .[ by IE inspectors. Included are: July 23-26 and August 8-10, 1973, inspection report Nos. 50-329/73-06 ?. ' 1. and 50-330/73-06: A detailed review was conducted relative to the ,)V', ' . impfenentation of the Consumers Power Company's QA manual and Bechtel ~ I,' Corporation's QA program for design activities at the Bechtel Ann Arbor office. The identified concerns were reported as discrepancies reistive to the Part 50, Appendix B, criteria requirenants. s: t( b M&& & 4f-/g I t 2. September 10-11, 1973, ratport Nos. 50-329/73-08 and 50-330/73-08: A detaile.d review of the Bechtel Power Corporation QA progran for ~- l Midland was performed. Noncompliances involving'three" separate Appendix B criteria with five dif.f arent examples, were identified. 3. February 6-7, 1974, reports No.. 50-329/74-03 and 50-330/74-03: A { followup inspection at the licensee's corporate office, relative to the items identified during the September 1973 inspection (above) i along with other follovup. 4.
- June 16-l7, 1975, report Nos. 50-329/75-05 and 50-330/75-05
- Special inspection conducted at the licensee's corporate office to review the i
- new corporate QA program manual.
l 5. August 9 through September 9,1976, report Nos. 50-329/76-08 and 50-330/76-08: Special five-week inspection regarding QA program implementation on site primarily for rebar installation and other l civil engineering work. j - ll.& t I 8-
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-. ~. ~.- --... -. = 4 ~ 6. May 24-27,1977, reportNos.50-3U/7/-05and50-330/77-08: Special inspection conducted at the site by RIII, IE and RI personnel to examine the QA program implementation onsite by Consumers Power Company and by Bechtel Corporation. Although give examples of noncompliance to Appendix B, Criterion V, ere identified, the consensus of the inspectors involved was that the program and its implementation for Midland was considered to be adequate. 7. May 8-11,19795 a mid-construction QA inspection covering
- '7 purchase control and inspection of received materials i,r t
i 7 If ko V design control and site auditing and surveillance activities was 1 ;hg, (~.! / 2 C i# lLyr p',3 conducted by a team of inspectors.,While Cr,.s'.Uv).LC) ~!!d.Ylt e items wiLL u.hNr1.<h.! W- ') resolution, poMeg,Vradation of the $r. \\?/,s V ffomTbisdnspection. -lhe Licensee's Quality Assurance program has under gone a V,:J*,,s_ number of revisions i to strengthen JYMXMX it's provisions, ~~~ ~ -...n 1f.,. _ _ _ _ - - _ _.. -. '.,.# M'e-. * *. m. -.._._.. a a ny.: n m._,ptementation 7--.-. ,._of.-the pn,... ;in ~e.. mad continues to be subjectWn _ edee. gr.,;,. ~ ...,.: e, The_ mid construction _pcogneview ce. Acted-on-May-8-11J"1979'"did "] s_&..c v g e not. identify-any-signtftcant problems-of.-concara. othe-6;;:t1% however715' ave identiTretHter; cf aon==QpoLianca uh445 9 'I - quTre ' '^~ j rtsjttut4ei Li-the-L4censee. A general observation of the inspection staff has been the lack of timeliness of correcting pr,oblems. Consumers Power Company expanded their QA/QC auditing and surveillance coverage to provide extensive overview inspection coverage. This e ....a .ac. .=.:.=.- . 2.. -.w. in 1975 witf. ; commitment early in their experience with rebar installation problems and was further commit'ted by the Licensee in his Letter of June 18, 1976, responding to report Nos. 50-329/76-04 ^ and 50-330/76-04. This overview inspection activity by the Licainsee has been very effective as a supplement to the constructor's ~ own program, however, currently our inspectors perceived the overview activities cover a smaLL percentage of the work in some disciplines. 4.a. .e ., }f.).This has been brought to the Licensee's attention who has responded with j / a revised overview plan. RIII inspectors are reviewing the plan as well as determining it's effectiveness through observation of construction work. A specific area brought to the attention of the Licensee was the lack of overviewintheinstrumental,installatj)onarea. The Licensee has lpi .Mt.wW. D(Te// k responded to this' matt,e and this item is uhder review by RIII inspectors. Enforcement History ~ Approximately 6 months after restart of construction ctivities I h / (11 months af ter'C issuance) an inspection)dentified four noncompliance /- v.n.q:
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1 ~.v ties./This resulted in a show c'ause'1g,,],.",.f,'. items regarding cadwelding a H g ; :/j,,%.y 9 order being issued on December, 1973. forcement action was 4 4 4 aired publicly during hearings held by the Atomic Safety Lic.ensing Board N - w %.%i4;5;, in May 1974.[The/ hearing board issued it's decision i i m; n*,.v .:v - .q ' i%7 ' .A J p h1d m X045M ,g l ,,-.,,-...,,...,..,,,,.,,._,,.m...__.,. ,,.,____,_.__,,._______-_n,.,
t ~ k ' [ s that concluded that construction could proceed with adequate assurance of quality. Identification of reinforcing bar problems began in December of 1971. witI. the licens'ee reporting improper spacing of rebar in1he Unit. 2 concainment'. -? Further reinforcinggbar spacing and/or omissi n of rebar was wall. ~* the citations of identifie'd in August 1975 ynd again in May 1976 wit ~^ .5 noncompliances in an inspection report. An IE:BQjnotice of violation idas issued regarding the c'itations in addition to Jhe licensee iss, ing i ~- a stop tiork order./The licensee issued a responselletter dated Ju e 14, 1976 connaitting to 21 items of corrective action. / A 3echtel prep red technical assessa'ent for 'each instance of rebar deficiency was sp mitted to and review by IE:BQ,who gon'cluded' that the structures involved will ~ I sjtisfy the SAR criteria and that the function of these structures will The RIII office of NRC be emintained' during ah design conditions. i performed ~a special five week ~ inspection to assess tih'e corrective action. ~ implementation without further citation.
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n The licensee ripo'rted that two hoop tendon sheaths were omit.ged in f concrete placements of Unit 2 containment wall in April 1977.) An -T M ?- Immediate' Ac'tioTIntter was issued tolthe iicensee on April 27,1977 listing six items of licensee commitments to be completed. A!special -06 ~ inspection was performed on May 24-27,\\1977 with four NRC inspectors (1-EQ,1-RI, and 2-RIII). Although five items of noncompliance were m.9.e.,, identified, it was the consensus of the' insp.ectors that the QpQC ..S 2 program 1n effect was adequate. The constrdet6rs nonconformagce report provided an alternate.nethod of installation for the tendon shett m.. - p ,g that was accepted. -(/ 4 ,7 ' 4 1 s/ m 1 9
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.e Followup of the settlement of the diesel generator building revealed .t s,. s .j significant quality coptrol deficiencies. Inspection of the ptknt j jE h ' ic~. - i Qq fitt re at'ed probteins ind)icated controls eating with p'rJoble . q.. ~p a ..,q;. ,\\ 4 C s identificationproblemcorrectionproceduresimplemen//'tatio/ "(~l4j 1 ^/ \\ k. 4_ n l1 l \\ l l / U s. t and training /were not in place and contributed s gnificantly to this.f- > 7- [LINLt.,L.,W[/ q g ffd$fy[. a l .~ ~ c plant c nif tion. f/t 7 Z n ; -- g The RIII office of' inspectioa and enforcement instituted,an. augmented [- .3., .t,.}.,', onsite inspection coverage pr'ogram during 1974, this program has '$ ~ ~ I )p g,.1continuedineffectuntilt'heinstallationoftheresidentinspecto h, August-1978. dhe noncompliance history with this program is essentially the same as e ..a, the history of other RIII facibties with a comparable status of - m8 mnstructiW.
The noncompliance history for the Midland Project is provided in the following table. .a ;.7 :d?sh , ENFORCEMENT ACTIONS . l ',.,. u.j$'.[$ 4 ,js u~......e,.: ..,.,.,.1.w..,*:.
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W,.y...- A . +- ,,. rs,;r):h Noncompliances ,u... 4.,sd '& %.. .i A?. / i d. ".c"[! Year
- Total Criteria (10 CFR 50 Appendix D)
( ) > =her of occurrences \\. ' :c 970 4 V, X, XI,XVI' 197 -1972 0I, Construction ha ted pending CP 1.' o 9,. ' II, VCS), XI ,XV, XVII t 1973 ~ 1974 3 VC2), XVI 1975 0 / V(4), /, XII, XV, XVI, XVII, XVIII X 1976 10 1977 5 VCS),'10 CFR 50.55(e) item 1978 18 III (2), VC7), VI, VII, VIII, IX(3), ' VIC2) 1979 to date 7 III, VC2 4 VII, VIII, IX, XVI j I' / Criteria j -i t. II eA Program ...( - w...,,7, ', III Design Control Instrumentation Procedures Drawing Con' trol Work
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Summary and Conclusions _ Since the start of construction Midland has experienced some significant problems resulting in enforcement acti n. I: : :1uating th-e paiems.. y .they h n =-- a sred la clumpe+ (1) in eptember1970)relitiivetoimproper - P acement, sampling and testing of concrete and failure of QA/QC to au l [plV on identified deficiencies; (2) in September 1973 relative to drawing t-control and lack of or inadequate procedures for control of design and NY procurement activities at the Bechtel Engineering offices; -(3) in November 1973 relative to inadequate training, procedures and inspection of cadweld activities; (4) in April, May and June 1976 resulting from a series of RIII inidepth QA inspections and meetings to identify underlying causes of weakness in the Midland Q4 program implementation relative to embedments..(The noncompliance items identified involved inadequate quality inspection, corrective action, procedures and documentation,allpkimarilyconcernedwithinstallationofreinforcement steel); (5) in April 1977 relative to tendon sheath omissions; and (6) in August 1978 concerning plant soil foundations and excessive settlement of the Diesel Generator Building. w a g Following each of there problem periods (e-c'"di=g-thrien aid is nill #F4nvestigatitm), the licensee has h;; n:r~# : :;2 h.. .y [ pff a T f., - taken.exsonesee action to suehnrts:3bd-correct the gblem_ and.);g.gN ot these g*, 6 grade his QA program and QA/QC. staff. The most .m-~. 31censee actions has been an overview program which has been steadly expanded to ' over #1Nt' " safety related activities. ~' c ~ W J be,-<.-iw f The evaluation both by the licensee and II of the structures and equipment affected by these problems (again except the last) has..SD M y#- g:Epfl that they fully meet design requirements.
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b, N. Q, - h) ~. l^f' '-- Imoking at the ugderlying causes of these problems two common threads ~ -{ smerge: (1) ConIEdns -Bewer historically has tended tio over rely onNN*L( Tre;1, and (2) insensitivity on the part of both Bechtel and consumers Power to recognize the significance of isolated events or failure to adequately evaluate possible generic application of these events either y of which would have led to early identifiention and avoidance of the problendar1ndinf ek-hr;.
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y settlemens. (> \\ u Notwithstanding the above, it is our conclusion that the problems experienced are not indicative of a broadbreakdown in the overall quality 4 i assurance program. Admittedly, deficiencies have occurred shich should have been identified earlier by quality control personnel, but the licensee's program has been effective in the ultimate identification and %'v subsequent correction of these deficiencies. While we cannot dismiss the possibility that problems may have gone undetected by the licensee's T overall quality assurance program, our inspection program has not identified y significant problems ' overlooked by the licensee and this inspection -)~ effort has utilized many different inspectors.
.... is 3.o m. y ) o j Ihe RIIT - _' :t inspectors, believe that continuat n of: (1) resident site coverage. (2) the licensee overview progra= inc uding Jts recent expansionintoengineeringdesign/reviewactivities,and($,)acontinuing 4 inspection program by regional inspectors will provide adequate assurance that construction will be performed in accordance with requirements arid that any significant errors and deficiencies will be identified and corrected. c ^ ^ l g=g l l i 4 s-l '/ 1 y sy to - ung Q 2 > j er ~ l lye # ll-- Y 00
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1.: SECOND CORPORATE MEETING MIDLAND 1/11/80 OPERATIONS Introductory Comments Objectives of Inspection Program Typical Inspection Areas Licensee Presentation Pre-operational Program, Staffing, Training i Construction Introductory Comments Hardware Concerns Management Control Summary and Conclusions i Closina Remarks - NRC I i Closina Remarks - CPCO i r 4 i I { I f ( o l L
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'o UNITED STATES '[ NUCLEAR REGULATORY COMMISSION g . WASHINGTON, D. C. 20005 j l %e.... FEB 12 gggg ^ \\ (/ 5 / / ran::trAT.f7f 7 7 DIR IQ !? Docket Nos.: 50-329/330 OM,0L p p/o b l A/n / kol [ der a Mr. J. W. Cook ) Vice President Consumers Power Company m me /0* ( 1M5 West Parnall Road Jackson, Michigan 49201
Dear Mr. Cook:
Subject:
Staff Concurrence for Activation of Freezewall P My letter of November 24, 1981 expressed NRC Staff concurrence for installation of freezewall hardware in preparation for the underpinning planned for the Midland Auxiliary Building and Feedwater Isolation Valve Pits. However, that -letter noted that Staff concurrence did not include activation since the effects .of operation of the freezewall involved submittal of additional information. Your letter of January 6,1982 described the measures planned for the protection of underground utilities and structures due to the effects of ground heave and resettlement, and the associated' monitoring program. Other information was provided in your letters of November 16 and November 24, 1981 and in the hearing testimony of your consultant. J. P. Gould. This information was discussed with the NRC Staff during a meeting on January 20, 1982 and during the underpinning design audit of February 3-5, 1982. Your letter of January 6,1981 proposes to eliminate the inducement of any stresses to the conduits and piping because of heaving by excavating the soil directly beneath affected utilities within the projected area of influence of the freezewall before ground freezing begins. The NRC Staff agrees that this proposed solution would eliminate the effect of ground heaving on involved utilities and is acceptable. The Staff review has also identified that it may be several months, once the thawing begins before recompression of soils is completed and long term foundation support for the piping is assured.. Because of this concern, you have comitted to demonstrate to the NRC Staff's satisfaction that recompression of the foundation soils beneath the piping has been completed before backfilling the excavation. Our concurrence is contingent upon the successful audit by the NRC Regional Office of the implementation procedures for excavation and monitoring. We are advised that Region III plans this audit in the near future and prior to activa-tion of the freezewall. ~ FEB 181882 @W J
o,, 2-Mr. J. W. Cook Staff concurrence is further discussed in the testimony of Mr. Joseph Kane regarding the effects of foundation support for seismic Category I underground piping. This testimony will be discussed during the OM, OL hearing session scheduled to begin February 16,1982. On the basis of the information provided and your commitment to monitor for an acceptable period for recompression effects, and subject to the above audit, the Staff concurs with your plans to activate the freezewall. Sincerely, ~ Robert L. Tedesco, Assistant Director for Licensing Division of Licensing cc: See next page 4 9 e e e f e e i
MIDLAW
- Mr. J. W. Cook Vice President Consumers Power Cogav 1945 West Parnall Road Jackson, Michigan 4g201 cc: Michael I. Miller. Esq.
Mr. Don van Farrowe, Chief Ronald G. Zamerin, Esq. Division of Radiological Mealth Alan 5. Farnell, Esq. Department of Public Health Isham, Lincoln & Beale P.O. Box 33035 Suite 4200 Lansing Michigan 48g0g 1 First National Plaza ~ Chicago, Illinois 60603 William J. Scanlon Esq. 2034 Pauline Boulevard James E. Brunner Esq. Ann Arbor, Michigan 48103 Consumers Power Cogany 212 West Michigan Avenue U.S. Nuclear Regulatory Comission Jackson, Michigan 49201 Resident Inspectors Office Route 7 Myron M. Cherry, Esq. Midland, Michigan 48640 1 IBM Plaza Chicago,' Illinois 60611 Ms. Barbara Stamiris 5795 N. River Ms. Mary Sinclair Freeland, Michigan 48623 5711 Summerset Drive Midland, Michigan 48640 Mr.' Paul A. Perry, Secretary Consumers Power Cogany Stewart H. Freeman 212 W. Michigan Avenue Assistant Attorney General Jackson, Michigan 49201 State of Michigan Environmental Protection Division Mr. Walt Apley 720 Law Building c/o Mr. Max Clausen Lansing, Michigan 48913 BattellePacificNorthWestLabs(PNWL) Battelle Blvd. Mr. Wendell Marshall SIGMA IV Building Route 10 Richland, Washington 99352 Midland, Michigan 48640 Mr.1. Charak, Manager Mr. Roger W. Huston NRC Assistance Project Suite 220 Argonne National Laboratory 7910 Woodmont Avenue 9700 South Cass Avenue Bethesda, Maryland 20814 Argonr,e, Illinois 60439 Mr. R. B. Borsum James G. Keppler, Regional Administrator Nuclear Power Generation Division U.S. Nuclear Regulatory Comission. Babcock 8 Wilcox Region !!! Suite 220 799 Roosevelt Road 7910 Woodmont AvenueE0814 Glen Ellyn, Illinois 60137 Bethesda, Maryland Mr. Steve Gadler 2120 Carter Avenue St. Paul, Minnesota 55108 e s 4 m
.0 e, Mr. J. W. Cook o cc: Commander, Naval Surface Weapons Center ATTN: P. C. Huang White Oak Silver Spring. Maryland 20910 Mr. L. J. Auge, Manage. Facility Design Engineering Energy Technology Engineering Center P.O. Box 144g Canoga Park, California 91304 Mr. Neil Gehring U.S. Corps of Engineers NCEED - T 7th Floor 477 Michigan Avenue Detroit, Michigan 48226 Charles techhoefer, Esq. Atomic Safety & Licensing Board U.S. Nuclear Regulatory Commission Washington, D. C. 20555 Mr. Ralph 5. Decker Atomic Safety & Licensing Board U.S. Nuclear Regulatory Commission Washington, D. C. 20555 Dr. Frederick P. Cowan Apt. 8-125 6125 N. Verde Trall loca Raton, Florida 33433 Jerr/ Harbour, Esq. Atomic Safety and Licensing Board U.S. Nuclear Regulatory Commission Washington, D. C. 20555 Geotechnical Engineers, Inc'. l ATTN Dr. Steve J. Poulos 1017 Main Street Winchester, Massachusetts 01890 6 I e
V, 6-r ue; / UNITED STATES l NUCLEAR REGULATORY COMMISSION g -l WASHINGTON, D. C. 20555 ,/ M b INE PRIN; IPA. --a DIR Docket Nos.: 50-329 and 50-330 OM, OL 3/D l ' A.L A/n L,t o DRMI APPLICANT: Consumers Power Corupany fg7 FACILITY: Midland Plant, Units 1 and 2 DEFA,0E rile [
SUBJECT:
SUFNARY UF OCTUBER 1,1981 MEETIkG ON REMEDIAL MEASURES FOR THE MIDLAND AUXILIARY BUILDING On October 1,1981 the NRC staff met in Bethesda, Maryland with Consumers Power Company, t echtel, and consultants, to discuss the design and construction aspects of tne t,nderpinning planned beneath tne Auxiliary Building at Midland Plant, Units 1 and 2. L'ecause the underpinning scheme presented was a signi-ficant cnange from tne previously proposea remedial measure, a briefing was also provided tt NRC taandgement. Enclosure 1 is a summary of the meeting and includes a compilation of the handouts and visual aids used in the course of the meeting. k.a d } M-
- ^
Darl 5. Hood, Project Manager Licensing Branch No. 4 Division of Licensing
Enclosure:
As stated cc: See next page 1 s h / l FEB 181982 o a 1 r
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s MIDLAND Mr. J. W. Cook Vice President Consumers Power Coneany 1945 West Parnall Road Jackson, Michigan 49201 cc: Michael I. Miller Esq. Mr. Don van Farrowe, Chief Ronald G. Zamarin, Esq. Division of Radiological Health Alan S. Farnell, Esq. Department of Public Health Isham, Lincoln & Beale P.O. Box 33035 Suite 4200 Lansing, Michigan 48909 1 First National Plaza Chicago. Illinois 60603 William J. Scanlon, Esq. 2034 Pauline Boulevard James E. Brunner Esq. Ann Arbor, Michigan 40103 Consumers Power Conpany 212 West Michigan Avenue U.S. Nuclear hegulatory Commission Jackson, Michigan 49201 Resident Inspectors Office Route 7 Myron M. Cherry, Esq. Midland, Michigan 48640 1 IBM Plaza Chicago, Illinois 60611 Ms. Barbara Stamiris 5795 N. River Ms. Mary Sinclair Freeland, Michigan 48623 5711 Summerset Drive Midland, Michigan 48640 Mr. Paul A. Perry, Secretary Consumers Power Company Stewart H. Freeman 212 W. Michigan Avenue Assistant Attorney General Jackson, Michigan 49201 State of Michigan Environmental Protection Division Mr. Walt Apley 720 Law Building c/o Mr. Max Clausen Lansing, Michigan 48913 Battelle Pacific North West Labs (PNWL) Battelle Blvd. Mr. Wendell Marshall SIGMA IV Building Route 10 Richland, Washington 99352 Midland, Michigan 48640 Mr. I. Charak, Manager Mr. Roger W. Huston NRC Assistance Project Suite 220 Argonne National Laboratory 7910 Woodnont Avenue 9700 South Cass Avenue Bethesda, Maryland 20814 Argonne, Illinois 60439 ' Mr. R. B. Borsum Janes G. Keppler, Regional Administrator Nuclear Power Generation Division U.S. Nuclear Regulatory Commission, Babcock & Wilcox Region III 7910 Woodmont Avenue, Suite 220 799 Roosevelt Road Bethesda, Maryland 20814 Glen Ellyn, Illinois 60137 ff
Mr. J. W. Cook cc: Commander, Naval Surface Weapons Center ATTN: P. C. Huang White Oak Silver Spring, Maryland 20910 Mr. L. J. Auge, Manager Facility Design Engineering Energy Technology Engineering Center P.O. Box 1449 Canoga Park, California 91304 Mr. Neil Gehring U.S. Corps of Engineers NCEED - T 7th Floor 477 Michigan Avenue ~ Detroit, Michigan 48226 Charles Bechhoefer, Esq. Atomic Safety & Licensing Board U.S. Nuclear Regulatory Commission Washington, D. C. 20555 Mr. Ralph S. Decker Atomic Safety & Licensing Board U.S. Nuclear Regulatory Commission Washington, D. C. 20555 Dr. Frederick P. Cowan Apt. B-125 6125 N. Verde Trail Boca Raton, Florida 33433 Jerry Harbour, Esq. Atomic Safety and Licensing Board U.S. Nuclear Regulatory Commission Washington, D. C. 20555 Geotechnical Engineers, Inc. ATTN: Dr. Steve J. Poulos - 1017 Main Street Winchester, Massachusetts 01890 i ,.y -y,--e- - -..-, - r.- -..g
3 To File r i .= From GSKeeley, P-14-113B I,)/ e CONSUNERS s j p-POWER Date October 27, 1981 L COMPANY Subject MIDLAND PROJECT Internal DI?"93FION WITH STAFF ON - Correspondence RE:n SAL TIXES FOR AUXILIARY BUILDING - ON OCTOBER 1, 1987l FILE 0485.16 SERIAL 14705 CC JWCook, P-26-336B w/o att DBMiller, Midland w/att WRBird, P-14-418A w/att RSevo, Midland w/o att JBrunner, M-1079 w/att TRThiruvengadam, P-14-400 3 att ABoos, Bechte.1 4 copies w/att RZamarin, IL&B w/o att DMBudzik/TJSullivan, P-24-624A w/att RHuston, copies w/att i Introduction - A. l'urpose - To explain the Jes!gn sad construction aspects of the under-pinning scheme for the,4axilizry Buziding including methods to be used to assure minimal effects on structures in place. The proposed schedule for preparatory work and starting of underpinning will also be discussed. Also make staff aware of the interfacing of the various groups in-volved in performing the work. We will have a technical report which we will pass out at end of meet-ing which will be in format requested by SRP and we will be verbally presenting today what's in the report to enable staff to ask question. (Technical Report and drawings transmitted by JWC to Denton letter dated September 30, 1981.) We will be talking about the design aspects, dewatering, underpinning methods, instrumentation and geo tech aspects of the work. After this, we will also discuss the QA to be applied on the job which will be under the CP Co and Bechtel QA programs. We will present a list of activities which will come under the QA program and a matrix of who is responsible for the various activities under desi n, procurement and E construction slides used are not in tech report but will be passed out. I l B. Parties Involved - L CP Co - Setting policy, licensing, review Bechtel - design of structures I Mueser - Rutledge - advisor on construction methods including instrumentation, review of tech spec, and geo tech advice during design l-and construction. l Mergentime - Construction ic1081-0882a102 l l =
2 i I 2. Design.and Construction Schedule-(See attachment) 44 Permanent Wells - Complete before underpinning starts January 1,1982. Can't develop wells during underpinning since have to dewater. Can be used to. support underpinning. - 3. (a) Presented and explained slides. Mentioned that prestressed tendons for temporary support of wing walls during dewatering and FW Valve Pit is being supported by beams. Will analyze structure to account for underpinning activities at critical points during construction. New structure analyzed for 50% additional seismic load. Will monitor cracks in area effected by jacking and construction. '(b) Gould discussed their experience including that in Washington area. Freeze wall practically eliminates problem of water in pits to im-prove working conditions and therefore gets rid of fines removal during work activities. -Use rotary drill for casing installation. Use brine for cooling. Ethelyne Glycol has been used. Freeze wall layout may not be exactly as shown along admin building side. 4 (c) Gould discussed construction details as provided in technical report. (d) Gould discussed instrumentation. Closing loop of relative measure-ments has temperature correction to it. On jacking, acceptance criterion are 0.01"/1 hr to reach 90 day settlement point. This is monitored on a continuous basis. Carlson stress meters show load gain or decrease, but nave at least a day to arrest movement. Monitoring - discussed what's in tech write up. (e) Jim Gould - Discussed sample pictures of borings taken by WCC and that it is very uniform fill (COE 17 & 18) and some samples. Feels it's a black and white case of knowing you're in good fill and it's a common sense decision. It's not a sensitive material to being dis-turbed. Application of load by jacking will be gasic proof test. Consolidation tests for fill ghows 30-80 kips /f t -. Feels 80 is more applicable. 6 - 7 UU kips /ft (shear strength). Feels its insen-sitive plastic material. Not as firm as at SWPS but are using low bearing-pressure. To' monitor penetrometer is only a device to help make a judgement evaluation. Will also use torvane device. Is pleased that site-is being ringgd to prevent water from going-to fill. Load of 6.8 and 8.8 kips /ft for elec pen and control tower. 5 to 8 factor of safety and 4 to 4.5 on elec pen and control tower. They estimate settlement values of 0.6" with 0.4" on jacking to 0.9" with 0.6" Jacking so 0.2" and 0.3" for penetration area and control tower. ic1081-0882a102
o 3
- Showed estimate of Aux Bldg settlement versus time. Most settlement
~in 10 days (0.5) with concrete shrinkage from 10 to 90 days of (0.1). T/G Building piers more heavily loaded and estimate 1" settlement. Landsman wanted data that was taken every 8 hours to be reviewed instead of waiting until 24 hours. Told him we'd evaluate. (f) Bob Sevo presented QA program. (See attachments) QA-will be ' obtaining a person with underpinning experience. BQAM controls procurement, design and construction. CP Co Topical controls MPQAD QA Activities. EDPI has to show' input from on-site geo tech to Eng and then to AA geo tech. Gilray - wants to make sure that administrative procedures show control of review by geo tech Bechtel engineering review of what consultants do. l.fter this. meeting with the staff, Hood asked that Keeley and Chuck Gould discuss with NRC management the high points of the previous presentation to t.Ne staff and include the schedule of when we propose the various activities would commence. This presentation was made to Hood, Adensam, Tedesco, Heller, Lehr, Kane, Singh and Schauer. f s ic1081-0882a102 l I t
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AUX BLDG REMEDIAL ACTIVITIES
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INTRODUCTION A) PURPOSE OF MEETING B) PARTIES ENVOLVED IN REMEDIAL ACTIVITIES 2. DESIGN AND CONSTRUCTION SCHEDULE 3. PRESENTATION OF TECHNICAL REPORT A) STRUCTURAL CONSIDERATIONS (POST TENSIONING AND IEMPORARY SUPPORTS) B) DEWATERING (EFFECTS TO DATE ON STRUCTURE) C) U/P METHOD D) INSTRUMENTATION E) GEO IECHNICAL DISCUSSION
- F) 00ALITY PROGRAM 4.
GENERAL DISCUSSION SEPTEMBER 29, 1981 i
r. SCHEDULE FOR AUX BUILDING UNDERPINNING & SUPPORT ACTIVITIES 10/15/81 DRILL-& DEVELOP ADDITIONAL 44 PERMANENT PLANT DEWATERING WELLS. (MEMO TO DENTON 9/16/81) 11/ 1/81 START RECHARGE TEST (2 MONTHS DURATION) 11/ 1/81 START HOLES & INSTALLATION OF FREEZE PIPING (5 WEEKS) 12/ 1/81 MOBILIZE & START INSTALLATION OF SCCESS RAMPS OR SHAFTS 12/ 7/81 START FREEZING GROUND (3 4EEKS) 1/ 1/82 START EXCAVATION '40RK, CONSTRUCT UNDERPINNING, TRANSFER LOAD, ETC. (61 NEEKS) V l SEPTEMBER 29, 1981-l l
l / 1 ) REMEDIAL SOILS WORK QUALITY PROGRAM i e CPCo QUALITY ASSURANCE PROGRAM MANUAL FOR NUCLEAR POWER PLANTS . Volume I - Policies (Topical CPC-1-A) i l . Volume 11 - Procedures for Design and Construction l e BO-TOP-1, REVISION 1 A i . Bechtel Nuclear Quality Assurance Manual 1 L E E.S WOF 9/2 981 G 186441
w 4 i MIDLAND PROJECT QUALITY ASSURANCE ORGANIZATION CPCe MIDLAND PROJECT OFFSCE ] CPCe ENWtRONMENTAL QUALITY A$$URANCE i i I SECNTEL BECHTEL I j OA RSANAGER PROKCT MANAGER l g i I l gig OA DEPARTMENT I e MIDL AND PROKCT OA MANAGER " " " " "" I A Off ANO 3 (2) I (CPCoL _ _ _ _, ADMUdlSTRATION t.m - um e en an an am en se me em em en - am m" e PQ AE (Sechte8) 1 3 h h DECHTEL 3 l PO AE (SQAMp 1 l l SITE OA SUPERINTENDENT i I t l I I I J 4 INSPECYBON, ] OA EX AM4 NATION
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i Op %pl%, s6 4h \\ FOR APPLICATION OF OA PROGRAM TO DESIGN BECHTEL PROJECT ENGINEERING (CIVIL SOILS GROUP) G + 04 & STEP 1 i 0 4 CONSULTANTS STEP 4 RGENTIME SECHTEL CONSHUCNN 1 G 8884 29 l {
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~ g. i QUALITY RELATED ACTIVITIES l e DESIGN CONTROL . Temporary Underpinning Supports and Load l Transfer I . Permanent Underpinning Supports and Load Trarisfer l e DETECTION OF MOVEMENT OF STRUCTURES AND LOAD MEASUREMENTS . Instrument Calibration i . Procedures e CONSTRUCTION PRE-DRAINAGE l . Fines Monitoring e EXCAVATION . Location, Size, Sequence, Protection of Utilities
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QUALITY RELATED ACTIVITIES l (cont'd) 1 e SUBGRADE INSPECTION e PROCUREMENT (Q list items) i . Structural Concrete and Grout j = Rebar/ Connectors i i . Miscellaneous Steel . Dowels I . Weld Rod ~ "a sa'e'='.,,,,o,
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QUALITY RELATED ACTIVITIES (cont'd> e INSTALLATION OF TEMPORARY AND PERMANENT UNDERPINNING SUPPORTS l . Forming (location, size, sequence) . Structural Concrete (production, placement) l . Rebar/ Connectors [ . Welding . Miscellaneous Steel l ~ l . Joint Preparation . Drypack
- Dowels RE E L S
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al QUALITY RELATED ACTIVITIES (cont'd) ~ 1 e LOAD TRANSFER ) . Calibration of Jacking System . Procedures I i i i e QA INDOCTRINATION i 4 HEMED L S K 9/25/81 G 186419 i
k, .3 PROJECT FUNCTIONAL MATRIX / ~ h-h -h' $$/ r POtlCV DESIGN PROCUREMENT INSTALLATION O O e e ceco enoJ uout O e e O securet enos ucus cec. pnoouctiow tucao O O O O O O O BECHi[L uGul todGnG e e e e O seenvet enos enano e e e e e e e e e e e e e e e j secnitt ouAteiv t=cno e e e e a e tesuo O O O O O ucunst enoJ otovecq e e e e e e e O e e secuvat ntsaotest otofECH utaceninse cone i .ancno O O O O O O O O e cousin S e ucunst nasmus enca 4 McMitL CoNsinuCYaoM e e O e . FsELD Esson e e .sunvsv e e .suecomunActs McMstt ouAtliv cdNinot e e e e e . nectivmeo oct e e e e e e e . civit oct NcHIEL PaoCuntestNT q e e e e S .Pson e e e . oepecessEto Iseoao e e e e S e e e e e e e e e e e e e e JAcasoes O e e e e e e . coat . oAE 9 e e e e e . sE s iv e e e .eQAE l 8 =or"*"' h ** n 4 site tsAwAGin a i e
UNITED STATES / o,, NUCLEAR REGULATORY COMMISSION c
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' O h WASHINGTON. D. C. 20555 ,) Y' -*'g E I,' i I Docket Nos.: 50-329 I-I and 50-330 OM, OL i
- .iM Ad hp APPLICANT: Consumers Power Company FACILITY:
Midland Plant, Units 1 and 2
SUBJECT:
SUMMARY
OF DECEMBER 10, 1981 MEETING ON CRACKS IN MIDLAND BUILDINGS ON PLANT FILL On December 10, 1981, the NRC staff met in Bethesda, riaryland with Consumers Power Company, Bechtel, and consultants to discuss concrete cracks in the Auxiliary building, Service Water Pump Structure and Diesel Generator building at Midland Plant, Units 1 and 2. is a summary of the meeting and includes a list. of meeting attendees. A L. \\ b r t- {l ~k i Darl S. Hooo,l'roject hanager Licensing branch No. 4 Division of Licensing
Enclosure:
As stated cc: See next page e r'EB i 11882 p
-MIDLAND 4 Mr. J. W. Cook Vice President Consumers Power Conpany 1945 West Parnall Road Jackson, Michigan 49201 cc: Michael I. Miller Esq. Mr. Don van Farrowe, Chief Ronald G. Zamarin, Esq. Division of Radiological Health Alan S. Farnell, Esq. Department of Public Health Isham, Lincoln & Beale P.O. Box 33035 Suite 4200 Lansing, Michigan 48909 1 First National Plaza Chicago, Illinois 60603 William J. Scanlon, Esq. 2034 Pauline Boulevard James E. Brunner, Esq. Ann Arbor, Michigan 48103 Consumers Power Conpany 212 West Michigan Avenue U.S. Nuclear Regulatory Conrnission Jackson, Michigan 49201 Resident Inspectors Office Route 7 Myron M. Cherry, Esq. Midland, Michigan 48640 1 IBM Plaza Chicago, Illinois 60611 Ms. Barbara Stamiris 5795 N. River Ms. Mary Sinclair Freeland, Michigan 48623 5711 Summerset Drive Midland, Michigan 48640 Mr. Paul A. Perry, Secretary Consumers Power Company Stewart H. Freeman 212 W. Michigan Avenue Assistant Attorney General Jackson, Michigan 49201 State of Michigan Environmental Protection Division Mr. Walt Apley 720 Law Building c/o Mr. Max Clausen Lansing, Michigan 48913 Battelle Pacific North West Labs (PNWL) Battelle Blvd. Mr. Wendell Marshall SIGMA IV Building Route 10 Richland, Washington 99352 Midland, Michigan 48640 Mr. I. Charak, Manager Mr. Roger W. Huston NRC Assistance Project Suite 220 Argonne National Laboratory 7910 Woodmont Avenue 9700 South Cass Avenue Bethesda, Maryland 20814 Argonne, Illinois 60439 Mr. R. B. Borsum James G. Keppler, Regional Administrator Nuclear Power Generation Division U.S. Nuclear Regulatory Commission, Babcock & Wilcox Region III 7910 Woodmont Avenue, Suite 220 799 Roosevelt Road Bethesda, Maryland 20814 Glen Ellyn, Illinois 60137 L
I' Mr. J. W. Cook '- cc: Commander, Naval Surface Weapons Center ATTN: P. C. Huang White Oak Silver Spring, Maryland 20910 Mr. L. J. Auge, Manager Facility Design Engineering Energy Technology Engineering Center P.O. Box 1449 Canoga Park, California 91304 Mr. Neil Gehring U.S. Corps of Engineers NCEED - T 7th Floor 477 Michigan Avenue Detroit, Michigan 48226 Charles Bechhoefer, Esq. Atomic Safety & Licensing Board U.S. Nuclear Regulatory Commission Washington, D. C. 20555 Mr. Ralph S. Decker Atomic Safety & Licensing Board U.S. Nuclear Regulatory Commission Washington, D. C. 20555 Dr. Frederick P. Cowan Apt. B-125 6125 N. Verde Trail Boca Raton, Florida 33433 Jerry Harbour, Esq. Atomic Safety and Licensing Board U.S. Nuclear Regulatory Commission Washington, D. C. 20555 Geotechnical Engineers, Inc. ATTN: Dr. Steve J. Poulos 1017 Main Street Winchester, Massachusetts 01890 3
ATTENDEES December 10, 1981 Organization Name Darl-S. Hood LBv4/ NRR F. Rinaldi SEB/tdRR F. Schaver SEB/NRk J. Haarstad NRc/ Consultant Pao Huang-hRC/ Consultant John P. Hatra, Jr. NRC/ Consultant Joseph D. Kane 14RC/00E/HGEti H. Kuo Nf;L T. E. Johnson Bechtel N. Swanberg bechtel Dennis Budzik Consumers Power Company Fernando Villalta Consuners Power Company W. Corley PCA (CPCo Consultant) Bechtel (Consultant) H. Sozen
Ditet-o w.a my 4, w roc To File 0465.21 g,,gs far Fo ' "'e O^~ ' ""*"" i kf^' From FVillalta, P-14-421 f7Y CONSUMERS POER COMPANY Date December 28, 1981 Subject MIDLAND PROJECT - Internal MEETING W/NRC STAFF TO DISCUSS EXISTING Correspondence CONCRETE CRACKS IN AUX BUILDING, SWPH AND DG BUILDINGS ON DECEMBER 10, 3981 - FILE 0485.21 SERIAL 15416 CC JWCook, P-26-336B (w/o) MIMiller, IL&B-Chicago RCBauman, P-14-314B (w/o)PSteptoe, IL&B-Chicago JEBrunner, M-1079 TRThiruvengadam, P-14-400 DMBudzik, P-24-517A FWilliams, IL&B-Washington DBMiller, Midland RWHuston, Washington (4) 1.0 Dr William G Corley - Presentation. Dr Corley showed slides of a water tank structure, 2 feet thick wall resting on a rock till foundation. Concrete was placed on 60 feet long pours resulting in through cracks due to volumetric changes by temperature and shrinkage. Cracks were mapped from 2 to 20 mills (0.002"-0.020") to ch-ck water leakage in the tank. 2.0 Dr Mete Sozen - Presentation. Professor Sozen showed slides of an e box experimental cyclic loading behavior of a reinforced concret. structure that was observed and reported by Umemura of the University of Tokyo. Lateral load developed flexural and shear cracks in both directions in the walls. The test results demonstrate that cracks in concrete structures with adequate amount of anchored reinforcement crossing the cracks do not affect the strength of the system. 3.0 Significance of Existing Concrete Cracks: 3.1 Auxiliary Building Dr Corley stated that the cracks observed in this building are due to volumetric changes in the concrete by temperature and shrinkage. Some flexural cracks were observed on floor slabs. The crack pattern does not indicate they are due to settlement. 3.2 Service Water Pump Building Dr Corley and Dr Sozen stated that the cracks in this building are a combination of settlement and volumetric changes in the concrete as the case in the Auxiliary Building. 3.3 Diesel Generator Building Dr Corley and Dr Sozen stated that the crack pattern can be associated with settlement due to the cracks fanning out in the wall near the top of the duct banks, before their isolation from the walls. The construction of the walls at different time pours of concrete also contributes to the cracking of the wall. ic1281-1202a102
' ' SERIAL 15416-2 4.0 NRC Concerns 4.1 Darl Hood stated the purpose of this meeting is to establish an acceptance criteria for existing cracks in the buildings. 4.2 Frank Rinaldi is concerned on how to evaluate a crack and the behavior of reversible stresses on cracks going from tension into compression. 4.3 F Schauer is concerned of a wall designed for a vertical "P" tension load. The wall was cracked for an additional "P" horizontal load. Will the wall take the vertical "P" load? 4.4 F Schaver asked what is the criteria for mapping cracks. 4.5 J D Kane would like to make sure that settlement is not a concern for cracks. 4.6 P Huang is concerned on multiple cracking for reversible loads or change of load application as mentioned in Question 4.3. 5.0 Answers to NRC Concerns Answer to 4.1 is addressed in Item 6. Answer to 4.2 - Dr Corley outlined the following nine steps to evaluate a crack: 1. Type of member (structural or nonstructural) 2. Type of loads and direction 3. Type of reinforcing 4. Type of construction and sequence of construction 5. Location of the crack 6. Length of the crack 7. Ratio width / length of the crack 8. Direction of the crack 9. Multiple crack pattern Dr Sozen addressed reversible stresses in his presentation in Item 2.0 for cyclic loading behavior. Answer to 4.3 - Dr Sozen stated that if horizontal reinforcement is adequate to cross the cracks then the wall can take the vertical load "P" in tension or compression. Answer to 4.4 - Dr Corley stated that a skilled technician from the PCA laboratory would be able to map a two or three mills crack. A 5 mills (0.005") crack is hard to read with a magnifying instrument. Answer to 4.5 - Dr Sozen and Dr Corley stated that settlement is not a concern because of the crack pattern existing on the walls. l ic1281-1202a102
\\ SERIAL 15416 3 Answer to 4.6 - Consultants Dr Sozen and Dr Corley will provide engineering information in regards to change of load application. 6.0 Future Crack Monitoring and Acceptance Criteria Consultants Dr Sozen and Dr Corley will review each structure to evaluate the present strength for the existing cracks. Dr Sozen proposed to use the following criteria: The ratio of reinforcement. times its yield strength should be larger or equal than 7 four times the square root of the strength of concrete (pfy > 4\\/f c). If this requirement is not met, a limit analysis for a subsection of the structure with its membrane forces should be done. Underpinning of the Auxiliary Building will take care of the concern of cracking caused by differential settlement. T E Johnson stated that Bechtel Power Corporation is working on the structural analysis to simulate the jacking loads due to the construction sequence during the underpinning operation. -The consultants will reevaluate the crack width limits for acceptance as proposed by Bechtel Power Corporation as follows: Evaluate any new or existing crack width larger than 10 mills a. (0.010"), b. Stop construction for crack widths larger than 30 mills (0.030"). An'"on call" evaluation and monitoring of cracks by the consultants was suggested for the future serviceability and durabilility of the buildings. Dr Sozen stated is not a need to seal cracks for water leakage when the water is not corrosive. T E Johnson stated that Bechtel will seal cracks larger than 0.013". FV/mo ic1281-1202a102 i
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o; J. o ATTENDEES December 10, 1981 Name Organization Darl S Hood LBA4/NRR F Rinaldi SEB/NRR F Schaver SEB/NRR J Haarstad NRC/ Consultant Pao Huang NRC/ Consultant John P Matra, Jr NRC/ Consultant Joseph D Kane NRC, DOE, HGEB H Kuo NRC T E Johnson Bechtel N Swanberg Bechtel Dennis Budzik Consumers Power Co Fernando Villalta Consumers Power Co * W, t, ' _/ P,' p ' c f '. 7,. jV, ).s. f }.
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A1 2 - X "f W &'W 21,, u ff '} UNITED STATES 'g y p, NUCLEAR REGULATORY COMMISSIO,N - gyngy p ;, g r, t j WASHINGTON, D. C. 20555 -~ %.yt../ res. a82 hd: Docket Nos: 50-329/330 OM, OL
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V egz p V 'nt { APPLICANT: Consumers Power Company l;~ w ~ pf FACILITY: Hidland Plant, Units 1 and 2 SUBJ ECT: SulhxRY OF JANUARY 26, 1982 TELLPHONE DISLUSSluk REGARDING SURCHnRGE RLSULTS Fuk THL Bn5T FOUhuaTlukh On January 26, 1982, Hessrs. J. Kane and U. Hood of the NRC staff received a telephone call from Lonsumers Power Loupany and Bechtel, to discuss the settlement measurements obtained since the valve pits for the Borated Water Storage Tank were filled witn water on uctober 26, 1961. Participants in the call are listed by Enclosure 1. as a basis for this discussion, Enclosures.2 and 3 were delivered just prior to the call by Lonsumers' Bethesda Licensing Repre'sentative. These enclosures plot the settlement for one point on edch of the two valve pits since the time of initial filling. Lonsuuer's discussion of the enclosures included the following points: 1. The criteria for maximum settlement is 0.5". Although the curve for marker U-41 on January 12, 1962 reads 0.5", Consumers does not consicer this to be an accurate reading, as demonstrated by the January 18, 1962 reading which shows about 0.4". 2. Other measured points also show the dip which occurred on January 12, 1962. Consumers speculates that survey inaccuracies may be at fault for the January 12, 1982 readin9s. 3. Consumers feels the current dato demonstrate that the fill beneath the uwbT founaations is now in secondary consolidation. The secondary consolidation rate for the tanks has been estimated to be 1/2" per decade. Mr. (one replieo that the settlement dato for markers D-29 drio D-41 do not clearly indicate that the fcundation soils beneath tne valve pit are in seconocry consolidation. if the questionable redoings of January 12, 1982 are enluded, and overage suooth settlement curve through the plotted points coulu te drawn since hoveuber 24.19u1 (tne date for placing the third and final surcharge loaa increment) which woulo indicate the founaation soils are still in priuory consolidation. Hr. Kane requested that the settlement ddta tur tne other marAers be provided for review. \\ 'I
- h. A Dorl d. nood, Project Handger Licensing uranch No. 4 Division of Licensing
Enclosures:
as st;.cea cc: See next page FEB 101982 4x, (. M.- X v
.D ^ MIDLAND Mr. J. W.' Cook Vice President Consumers Power Conpany 1945 West Parnall Road Jackson, Michigan 49201 cc: Michael. I. Miller, Esq. Mr. Don van Farrowe, Chief Ronald G. Zamarin, Esq. Division of Radiological Health Alan S. Farnell, Esq. Department of Public Health Isham, Lincoln & Beale P.O. Box 33035 Suite 4200 Lansing, Michigan 48909 1 First National Plaza Chicago, Illinois 60603 William J. Scanlon. Esq. 2034 Pauline Boulevard Janes E. Brunner, Esq. Ann Arbor, Michigan 48103 Consumers Power Conpany .212 West Michigan Avenue U.S. Nuclear Regulatory Commission Jackson, Michigan 49201 Resident Inspectors Office Route 7 Myron M. Cherry, Esq. Midland, Michigan 48640 1 IBM Plaza Chicago, Illinois 60611 Ms. Barbara Stamiris 5795 N. River Ms. Mary Sinclair Freeland, Michigan 48623 5711 Summerset Drive Midland, Michigan 48640 Mr. Paul A. Perry, Secretary Consumers Power Company Stewart H. Freeman 212 W. Michigan Avenue Assistant Attorney General Jackson, Michigan 49201 State of Michigan Environmental Protection Division Mr. Walt Apley 720 Law Building. c/o Mr. Max Clausen Lansing, Michigan 48913 Battelle Pacific North West Labs (PNWL) Battelle Blvd. Mr. Wendell Marshall SIGMA IV Building Route 10 Richland, Washington 99352 Midland, Michigan 48640 Mr. I. Charak, MLnager_ Mr. Roger W. Huston NRC Assistance Fcoject Suite 220 Argonne National Laboratory 7910 Woodnent Avenue 9700 South Cass Avenue Bethesda, Maryland 20814 Argonne. Illinois 60439 Mr. R. B. Borsum Janes G. Keppler, Regional Administrator Nuclear Power Generation Division U.S. Nuclear Regulatory Commission, Babcock & Wilcox Region III 7910 Woodmont Avenue, Suite 220 799 Roosevelt Road Bethesda, Maryland 20814 Glen Ellyn, Illinois 60137 ~ _. _ _ _ _
c. Mr. J. W. Cook cc: Commander, Naval Surface Weapons Center ATTN: P. C. Huang White Oak Silver Spring, Maryland 20910 Mr. L. J. Auge, Manager Facility Design Engineering Energy Technology Engineering Center P.O. Box 1449 Canoga Park, California 91304 Mr. Neil Gehring U.S. Corps of Engineers NCEED - T 7th Floor 477 Michigan Avenue Detroit, Michigan 48226 Charles Bechhoefer, Esq. Atomic Safety & Licensing Board U.S. Nuclear Regulatory Commission Washington, D. C. 20555 Mr. Ralph S. Decker Atomic Safety & Licensing Board U.S. Nuclear Regulatory Commission Washington, D. C. 20555 Dr. Frederick P. Cowan Apt. B-125 6125 N. Verde Trail Boca Raton, Florida 33433 Jerry Harbour, Esq. Atomic Safety and Licensing Board U.S. Nuclear Regulatory Commission Washington, D. C. 20555 Geotechnical Engineers, Inc. ATTN: Dr. Steve J. Poulos 1017 Main Street Winchester, Massachusetts 01890
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Geoa v. ~5. t w ;eso, sit ~ ~ ^ Bechtel Power Corporation o %3 Ann Arbor Power Division 1 TELECOPIER MESSAGE i to SE COMPLETED BY ORIGINATOR DO NOT WRtTE IN TMi$ SP/dE i MNO TOO-Ka0E nterrygo j 0, s. ta u c/o R, h*o " " ^
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'82 Ja 25 Pit 't zy soi-(,5a-Sc34 TELEC ~.d;4TIONS ononwation coos: csanx to: 1 '746-- 9 f 9 % '~)MC>-lO ) mm: Gb,,ommm vas h [/ TELECOMMUNICATIONS CENTER USE ciiLY To:
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? AA's*J il Attn: 3
- 6 Date:
ddr' Time: No. of Pages: 80 'l Verified with: Note: /si L // ,/, yv\\ l&, ( / l n ~ l'1 l / ll/ g _ _.... ~... --- -....- ~- -. g.... % 76,-{ lg.." ; A** j i N' i I Y '- ' ' N' 7 e t l%/ ', n!. f,. ~ l OPERA 1orrstNtrtAts_ _. _.' !I i ~ ~ ~~~~' .wr. ;,.a
I ~ cA MG/>ce v a eg[o, /(fg i $ 2' M. na a'r UNITED STATES 4 k f.___ ", a '..,o NUCLEAR REGULATORY COMMISSION { WASHINGTON. D. C. 20555 Y.U _,' - -- 'lD gg,b122 J-cri _ t ortTIk Docket Nos.: 50-329 ptP&Od NC and 50-330 OM, OL APPLICANT: Consuners Power Company FACILITY: Midland Plant, Units 1 and 2
SUBJECT:
SUHinRY OF OCTOBER 7,1981 MELTli46 Oh DIESEL GENERATOR BUILDING On October 7,1981, the NRC staff met in Bethesda, Maryland with Consumers Power Company, Bechtel, and consultants, to discuss soil consolidation test data and analyses for the Diesel Generator Building for Midland Plant, Units 1 and 2. Meeting attendees are listed by Enclosure 1. is a sunnary of the meeting wi:h a compilation of the handouts anc visual aids used in the cuurse of tne meeting. k4 d l l..< 'J ... ) Darl S. Hood, Project Manager Licensing brancn No. 4 Division of Licensing Enclusures: As stated cc: St! next page l FEB 22 tagg T1anf431(
,3 MIDLAND Mr. J. W. Cook Vice President Consumers Power Company 1945 West Parnall Road l Jackson, Michigan 49201 cc: Michael 1. Miller, Esq. Mr. Don van Farrowe, Chief Ronald G. 2amarin, Esq. Division of Radiological Health Alan S. Farnell, Esq. Department of Public Health Isham, Lincoln & Beale P.O. Box 33035 Suite 4200 Lansing, Michigan 48909 1 First National Plaza
- Chicago, Illinois 60603 William J. Scanlon, Esq.
2034 Pauline Boulevard Janes E. Brunner, Esq. Ann Arbor, Michigan 48103 Consumers Power Cogany 212 West Michigan Avenue U.S. Nuclear Pegulatory Commission Jackson, Michigan 49201 Resident Inspectors Office Rcute 7 Myron M. Cherry, Esq. Midland, Michigan 48640 1 IBM Plaza Chicago, Illinois 60611 Ms. Barbara Stamiris 5795 N. River Ms. Mary Sinclair Freeland, Michigan 48623 5711 Summerset Drive Midland, Michigan 48640 Mr. Paul A. Perry, Secretary Consumers Power Cogany Stewart H. Freeman 212 W. Michigan Avenue Assistant Attorney General Jackson, Michigan 49201 State of Michigan Environmental Protection Division Mr. Walt Apley 720 Law Building c/o Mr. Max Clausen Lansing, Michigan 48913 Battelle Pacific North West Labs (PNWL) Battelle Blvd. Mr. Wendell Marshall SIGMA IV Building Route 10 Richland, Washington 99352 Midland, Michigan 48640 Mr. I. Charak Manager Mr. Roger W. Huston NRC Assistance Project Suite 220 Argonne National Laboratory 7910 Woodmont Avenue 9700 South Cass Avenue Bethesda, Maryland 20814 Argonne, Illinois 60439 Mr. R. B. Borsum Janes G. Keppler, Regional Administrator Nuclear Power Generation Division U.S. Nuclear Regulatory Commission, Babcock & Wilcox Region III 7910 Woodmont Avenue, Suite 220 799 Roosevelt Road Bethesda, Maryland 20814 Glen Ellyn, Illinois 60137 m,.--,.
v. i I Mr. J. W. Cook 2-cc: Commander, Naval Surface Weapons Center ATTN: P. C. Huang White Oak Silver Spring, Maryland 20910 Mr. L. J. Auge, Manager Facility Design Engineering Energy Technology Engineering Center P.O. Box 1449 Canoga Park, California 91304 Mr. Neil Gehring U.S. Corps of Engineers NCEED - T 7th Floor 477 Michigan Avenue Detroit, Michigan 48226 Charles Bechhoefer, Esq. Atomic Safety & Licensing Board U.S. Nuclear Regulatory Commission Washington, D. C. 20555 Mr. Ralph S. Decker Atomic Safety & Licensing Board U.S. Nuclear Regulatory Commission Washington, D. C. 20555 Dr. Frederick P. Cowan Apt. B 125 6125 N. Verde Trail Boca Raton, Florida 33433 Jerer Harbour, Esq. Atomic Safety and Licensing Board U.S. Nuclear Regulatory Commission Washington, D. C. 20555 Geotechnical Engineers, Inc. ATTN: Dr. Steve J. Poulos 1017 Main Street Winchester, Massachusetts 01890 ,,,,-~--g ,--,--,,n-- ,.-w., e,,,s, ,,,,,n n,--.-yw a
a. ^. ENCLUSURE I aTTENDLES N#li ORGANIZATIDN G. 5. Keeley Consumers Powers Company J. Brunner-CPCo D. Lewis bechtel N. Ramanujam CPCo S. Afifi Bechtel A. Farnell Ishem, Lincoln & Deale R. Zamarin Isham, Lincoln & Deale D. Budzik CPCo - F. Rinaldi NRC/SEo F. Cherney NRL/DE/MEu H. brammer NRC/DE/MEB M. Hartzman kRL/DE/rtEB ~J. Kdne NnC/DE/nLEu H. Singn Anny Corps of Engineers A. Hodgdon Attorney, NRC M. Blume Attorne/, NRC D. Hood NkC/DL W. Paton Attorhey, NRL L. Heller-kkC/HGLB t 4 O
ENCLOSURE 2 l To File 0485.16 (w/a) .. [l e l Froe _GSKeeley, P-14-113B.f.,. CONSUMERS ~Date-October 26, 1981 POWER COMPANY Subject MIDLAND PROJECT Internal DISCUSSION WITH STAFF AND LAWYERS Correspondence ON D/G(SOILS AND STRUCTURAL) ON 10/7/81 FILE 0485.16 SERIAL 14585 CC JWCook, P-26-336B (w/o) NRamanujam, P-14-100 (w/a) SAfifi, Bechtel (w/a) ABoos, Bechtel (w/o). DMBudzik/TJSullivan, P-24-624A (w/o) TRThiruvengadam, P-14-400 (w/o) JBrunner, M-1079 (w/a) RZamarin, IL&B (w/o) RHuston, Bethesda (w/a) Discussed D/G samples. Discussed DGB consolidation test data. Ram indicated that CP Co and consultants had reviewed existing literature and did not find any problems with the max load of 64 Tsf. ASTM and corps of Engineers Manual clearly indicates that the loading can be higher so that one can be in the virgin portion of the consolidation curve. Woodward-Clyde Consultants and Dr Peck independently decided that they should go to 64 Tsf to define the virgin part of the curve. Based on the above fact CP Co feels that the maximum load of 64 Tsf in more applicable to define preconsolidation Pressure', Pc' for this kind of material that has been compacted and surcharged.2 X'"* ~
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review of data that 8 hours was adequate, but 16 Tons /ft would be more adequate for preconsolidation. Sherif - load for testing has to be large enough for compacted, surcharged soil. Kane - says we're out of range of virgin curve _beenuse void ratios are too low. Agrees that lab data shows the soil to be very dense. Staff discussed with COE Ohio River and they have 2 never run tests up to 64 T/ft But H Singh said that he has seen tests up to 128 Tsf and higher. 2 Using new 16 T/ft plots, staff picked out borings and levels where they suggestedthatsettlementshouldbecalculaged. Will have to compute new ': by same person who computed Ce from 64 T/ft curve. If this calculation snows that its only slightly more than settlement shown by actual dewatering settlement readings, would they accept readings as being proper? They want range of settlement and not force us to use this calculated settlement for structural analysis. i Structural (Navy) needs what it is for soil springs (for settlement) and can compute stresses and then add to it what is estimated to occur. Have to model soil under footing and this has to be based on results of estimated settlement from preconsolidation tests. Kane - would agree to force the calculated settlement numbers by a percentage (50%)for jacking up measured numbers which . ire based on stiffness of structures. Use dewatering values to adjust calculated values from consolidation tests. After CP Co Caucus - Met with Staff and Legal. 1. Use structural analysis model using soil springs. (Staff needs dynamic and static soil springs used and basis for them.) ic1081-0794a112 1.
2 ~n t 2. Geo-Tech input modified as discussed previous to handle consolidation test ' data. We_want to talk to J W Cook on this before making a commitment. Zam - on not providing staff testimony on October 30, 1981 is it strictly -soils. Patton - have problem on crack analysis. Rinaldi - D/G structure is not a typical structure. Feels its a research type problem. NRC is still reviewing crack analysis info given them last week and addendum ~given them yesterday. Can't assume text book type. design analysis. Also, have-to resolve monitoring scheme for cracks for-lifetime of plant. Also..have to factor in new analysis for Geo Tech input. All they're ready to do is.give status report to board. 3-LMB - Crack report is our report and all we're. talking about today is modifying spring constants and reruning model. Presented Model in April. Rinaldi - Still have to decide whether crack analysis justifies structural adequacy. DMB - our letter says no more crack analysis. Appendix J (white' paper was presented to staff in April). Rinaldi - Can't make decision until after discussing with management. DMB - We used NUREG, which handles simply the cracks and we have run . sophisticated computer program. Effects of cracks based on NUREG have been during OL. . Margin review program for SSRS will be factored into structural calculations. 4 Patton - D/G building has to be analyzed for new SSRS. Kane - structural has 4 been affected by surcharge and board could ask for adequacy of surcharge and effect it had on D/G building at new SSRS. l ~ DMB - everything we've said is how other dockets have been done. l Zam - We don't have figures yet on SSRS and board will have to make decision based on fact that margin check won't come until OL. If we decide to do L. additional cale on consolidation tests and if we complete it by October 16, P 1981, then staff has agreed this should handle Geo Tech, j Agreed to provide staff input and results of analysis dene todate. They want l new springs used. Will try to get this by October 16, 1981 and if they have this, they may be able to be ready for hearing on November 16, 1981. 2 ic1081-0794a112 -e--- ,#._w.v--..,,,~ ,.-..w--e -.y,-+ ,,-,-3.,,,,-,.._,,ev.,re,w . g en..w-%,,---,.,,-,,.,,m.w---e,,ew-.,_w,., ,e.- p.-
3 Kane - thinks we will have settlement resolved by hearing date, but may not agree on crack analysis and use of SSRS. Attachments: Replots of load vs estimated preconsolidations pressure at 16 and 64 Tons /ft with actual densities at sample location. ic1081-0794a112
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I Y^'LV, -N J A o O 77 % TU a pxx==r dCr= x== i SEP 2 4 882 $. D ""[4 g 3ecket No. 50-329 nocket No. 56-330 Consumers Power CompanyMr. James W. Cook ATggs Vice Framident Midland Project 1945 West Fernall Road 49101 Jackson. MI 24, 1982, between discussion en septemberffice and Mr. D. Mil f Centleman: This letter confirms the telephoneMaests. Warnick and in the remedial soils QC requalification your staff regarding the problemsGardner and Landsman. program identified by Masers. at ear understaniing of the actions The purpose of this letter is to docums you have takaa er plan to take. tand that you have taitiate d or d As a result of our discussion,we un ers tions: plan to initiate the following ac ed with the asception All work on remedial soils has been stopph as asistaining the fr of those conciamens activities suc (1) 1 soils QC requalification wall and well yesping. i usly certified have been All amanisations reisted.to._ -id=have stepped (2) decertified. h d and conducted for all A retrainias program will be establis e failures. QC persommel who failed and for futureed for all QC requalific (3) l A writtan cem=imation will be deve oparea,of remedial soils,
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O. M5NFICIAL RECORD COPY DMt
,, e h... 2 r. i CONFIRMATORY ACTION LETTER $l*p p 4 g Consumers Power Company 29, 1982, h our staff on September I ill establish to accelerate the requalification We also understand that you will meet wit l favolved in the balance of plant to describe what measures you wand certification of the QC pers quality progren. t in accordance with the above, If our understandinS of your actions is no l please contact this office 4===diate y. Sincerely. James G. Esppler Regional Admi.nistrator DMS/ Document Control Desk (RIDS) Besident Inspector, IIIIThe Honorable Charles Bechhoefer, ASL ec: The Bonorable Jerry Barbour ASLB The Monorable Frederick P. Cowan, ASLB The Bonorable Ralph S. Decker, ASLB Michael Miller Bona 1J Callen, Michigan Public Service Commission Myron M. Cherry Barbara Stamiris Mary Sinclair Wendell MarshallColonel Steve J. Gadler (P.E.) William Faton, ELD 1 . K.e...l e......... i ~ ovaceI[ h1.1.. .....g ..... v..i.s............ 7 d )...........,..................... ....d. f..n... c.......... W swa"'"*)' j5M ,.....h..V..d.....,...,.7.,............,..... OFFICIAL RECORD COPY
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