ML20094P742

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Handwritten Summary of 840104 Public Meeting W/Util,S&W Bechtel Re Monthly Activities,Crack Rept,Crack Mapping & Open Items.Supporting Documentation & Attendance List Encl
ML20094P742
Person / Time
Site: Midland
Issue date: 01/13/1984
From:
CONSUMERS ENERGY CO. (FORMERLY CONSUMERS POWER CO.)
To:
CONSUMERS ENERGY CO. (FORMERLY CONSUMERS POWER CO.)
Shared Package
ML19258A087 List: ... further results
References
CON-BX19-048, CON-BX19-48, FOIA-84-96 NUDOCS 8408170365
Download: ML20094P742 (74)


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Wednesday, P.M.,. January, 4, 1983.

r I.

Dis'cussion of CPCo jacking program for maintenance of building elevation

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Review.of design basis for Auxiliary Building underpinning (Gould) 20 Mir is 20 Mit 3.

Review Af. pertinent data (Darby)

C.

A11owab1'e ' horizontal torsion betwasn the control tower and Main 20 Mit Auxiliary Building (Swanberg) -

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P.M., January 5, 1983

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II.... Discussion of bther NRC issines -

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A., Acceptability of building checket'o AC1-349 (Swanberg).4.

15 Mi B.

El. 659 fix - ACI 318 vs.. ACI 349 (Swanberg) 15 Mi Removal of building stresses during permanent underpinning (Svanberg) 15 Mi C.

D.

Analysis of Auxiliary Building with differential settlement values 30 Mi of'.25" vs.17" (Swanberg)

E Mechanical interf ace between control tower and main Auxiliary Building 15 Mi III.

Methods of crack measurement (Darby/Sozen) 20 M:

'IV.

Discussion of higher alert / action level for downward movement of SWPS 30 M:

(Swanberg/McElwey)

V.-

SWPS plate load test (Davie/Ogelby [Eanson} }

30 M Friday, A.M., January 6, 1983

'vI.

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OBJECTIVE NO INTO L E R A B L E STRESSES OR STRAINS i

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STRATEGY 25 REDUCE P O TE N TI A L LY HIGH LEVELS OF

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. S T A T E. C O M P A C T N E S S EPA T I P S. H A V E S E'T T L E D, DIFF E R E NTI A LLY WITH RESPECT T O. C O N T R O L TOWER.

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CONTROL TOWER HAS SETTLED DIFFEREN-T I A L L Y; WITH RESPECT TO MAIN A UXIL L AR Y i

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SPECIFIED LOAD

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THE REACTION OF THE E XIS TIN G STRUCTURE TO BE DEVELOPED AT THE U N D E R PININ G SUPPORT P O l li T S BASED ON TRIB U T A R Y LOADS FROM jii E XIS TING STRUCTURE AT THE C O !.t P L E T I O N OF THE INSTALLATION i-OF ALL THE T E !.tP O R A R Y SUPPORT i

( E t4 D OF PHASE 3) viz:

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RESERVE C AP ACITY LOAD

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THE REACTION OF THE E XIS TIN G STRUCTURE TO EE DEVELOPED AT U N D E R P l fs N i ti G SUPPORT POINTS IN EXCESS OF THE SPECIFIED LOAD R E C UlR E D FOR CALCULATED T R A N SIE NT T RIB UT A RY LOADS FROM THE E X I S T i ti G STRUCTURE R E S P O tJ D i f4 G TO UNEXPECTED

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HIG H STRESSES R E S U L TIN G FROM Ut* EXPECTED STRUCTURE A tJ D / O R '

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A C C E L E R, A T I O N OF PIER AGING PROCESS AND PROOF TESTING OF PIER FOR SPECIFIED LOADS OR REVERSE C A P A CIT Y LOADS fkEET 2 Of 9 I/4/e3

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THE J A C KIN G FORCE REQUIRED TO FREE THE WEDGES BETWEEN THE JACKSTAND AND.THE BEARING PLATE LOCK-OFF LOAD I

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J ACKINC. Eli'MYNtY CRILLACE 8 EM".'

II JACK LOCATIONS CRILLACE X-TURB. BLDC SLAB j

Y-SOU111 EPA l

Z--NORIll EPA ACT.

DATE InTE I.D.

ACTIVITY INITI ATED LOCKED-OFF CAUSE X

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E-R, Initial 3 acting of E-8 grillage 9-20-83 9-24-83 107.5 10 7.5 12 5 12 5 l

E-R Maintain bldg.

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elevation 9-25-83 9-27-83 EPA: 14 mils /24 126 130.6 130.6 115 130.6 130.6 1 15 130.6 130.6 l

hrs. @ T.8.

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S* rain qages elevation 10 8 3 10- 14 -8 3 not within 120s 1 16. 7 12 3.2 12 4.7 1 15 12 3.2 124.7 115 123.2 124.7 of lock-off l

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12 8. 7 127.3 132.6 110 12 5 125 110 125 12 5 E-R Ma ntain bldg.

5 elevation 11-7-83 11-9-83 10 mils /4R hrs.

13 1.3 133.5 146.4 1 10 12 5 12 5 110 125 12 5 E-R Maintain bldg.

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elevation 11-14-81 11-14-83 not wit hin 220%

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7 elevation 11-23-83 11-25-83 10 mils /4R hrs.

126.0 14 1.7 146.4 110 12 5 12 5 1 10 12 5 12 5 E-R Maintain bldg.

g elevation 11-27-83 11-29-83 16 mils /451 hrs.

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9 elevation 12 8 1 12 8 3 11 mils /48 hrs.

14 1.9 152. 1 16 2. 2 1 15 15 2. 1 16 0.0 115 135 13 5 E-R Maintain bldg.

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elevation 12 8 3 12-15-8 3 11 mils /48 hrs.

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  • INSTRUlH21TATION
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DECEMBE R 30,1983

.to (Baseline of August 23, 1982)

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/-Y SV h+taub menfW CRACK MAPPING We are presently monitoring approximately 1000 cracks in the Auxiliary Building south of Col. Line C.

To date we have completed three full crcck mappings. The baseline was completed 9/14/82. The next mapping was performed after the undermining of the EPA's and was completed 8/2/83. The third mapping was performed after the initial jacking of the Electrical Penetration Areas and was completed on 10/22/83. On 11/28/83, the Resident Structural Engineering group requested WJE to remeasure specific cracks after we had experienced the elevated lift-off loads on the East side. The cracks were chosen because they were the cracks which were reported to have changed in the previous mappings. A fourth full mapping requested by Resident Engineering is in progress. To date the East EPA was completed from 12/20/83 through 12/28/83. The remaining sections are scheduled for completion by 2/17/84.

Initial Jacking Evaluation of the mappings performed immediately af ter initial jacking had shown that 23 cracks had changes in width and 21 new cracks were reported.

The width changes which had occurred were 0.005 inches or less except for two cases.

In both cases the reported changes were in floor slabs. After a field review, it was determined that the changes were attributable to fluctuations in measurements.

The observed changes in crack patterns and widths, were in general, consistent with previous patterns that indicate volume change movements. The width

~

changes are within the estimated tolerance limits of 0.005 inches. All crack widths were below the alert limits.

Page 1 i

CRILLACE 8 REJACKING Af ter we had experienced _ elevated lif t off loads when rejacking the grillages, we requested WJE to check the width of cracks'which had been reported to have changed during initial jacking.

Evaluation of this data indicated that all measured crack width changes were within the estimated tolerance of 0.005 inches.

CONCLUSION EAST EPA MAPPING COMPLETED 12/28/83 There are approximately 400 cracks which are monitored in the East EPA.

The most recent crack mapping (completed 12/28/83) has shown that 18 of these cracks changed in width, 27 cracks increased in length and 11 new cracks were found, when compared to previous mapping.

All of the 18 cracks which changed in width, increased or decreased by 0.005 inches or less. These small changes can be attributable to variations in The length increases were approximately l'-0" or less except for measurement.

two cracks which increased by approximately 2'-0" and 3'-0".

Only 3 of the 27 cracks which increased in length also increased in width.

Only two of the newly identified cracks were at the alert level of.010 inches. After further checking, it was determinec that these cracks were present prior to this mapping. These cracks were identified on a previous report by Construction Technology Labs.

Page 2

t The observed' crack changes which occurred were within the measurement.

tolerance.. The crack changes do not-indicate any structural distress in the slabs and walls of the East EPA due to jacking at East 8 Grillage.

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.Yn ATTACHMENT E Page 3 of 3

SUMMARY

OF CRACK CHANGES FOR INITIAL JACKING AT E/W E GRILLAGE DESCRIPTION NEW INCREASED DECREASED Total number of cracks.

21 10 13 Number of cracks greater than 0.005" change.

0 1

1 As shown above, relatively few cracks were observed to have changed in width during the introduction of the initial jacking loads for the Grillages. Of the reported twenty-one (21) new cracks after initial jacking, eight (8) were determined to have existed before start of underpinning based on subsequent inspection.

SUMMARY

OF SELECTED CRACK CHANGES FOR REJACKING AT E/W 8 GRILLAGE INCREASED DECREASED Total number of crack changes.

6 7

Number of cracks greater than 0.005" change.

1 0

I 31 1

l

SUMMARY

OF CRACK CHANCES FOR EAST EPA NEW INCREJLSED DECREASED ELONCATED Total No. of Cracks 11 9

9 28 No. of Cracks with Width Changes 5 Mils 2*

O O

O

% of Crack Width Changes 7 5 Mils 18%

0 0

0 No. of Cracks which Elongated &

Increased in Width N/A N/A N/A 3

% of Cracks which Elongated and Increased in Width N/A N/A N/A 11%

  • Two new cracks were identified as alect level cracks on the N.F. of wall @ Col. Line K between Col. Lines 8.6 & 9.1 (area 191). These two cracks were identified on a CTL Report prior to baselining of cracks for the Auxiliary Builting.

The twc cracks are therefore not new cracks but existing cracks which were not identified during crack baselining.

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Current State of Crack Mapping as of December 28, 1983 Wiss, Janney, Elstner (WJE) personnel have been monitoring crack locations, patterns and widths since August of 1982. To date they have completed three mappings and they are presently performing the forth.

WJE procedures presently require the mapping to be performed by an originating technician with a second technician performing a check of the mapping in the field. The whole process is overviewed by a Lead Engineer.

The building is broken into smaller units and assigned area numbers by WJE. Mappings of the areas are documented on standard forms. Mappings from several areas are combined to form a submittal which is given to Resident Engineering. The submittal is reviewed by Resident Engineering and then released through Document Control.

As of December 28, 1983, WJE had documented 990 cracks in the EPA and Control Tower Areas. The range of crack widths varied from approximately 3 mils up to 25 mils.

The maximum crack width was.025 inches. WJE had identified 3 cracks of this width which were located in floor slabs.

~

Page 2 Table I shows the breakdown of the measurements for the Control Tower and EPA areas.

Mean Crack Width.0042 inches Standard Deviation.0034 inches It is our estimation that the accuracy at measurement is approximately.005 inches.

Listed in Attachment A are required crack mappings. There are twenty-one events which require crack mapping. Also listed is the option of Resident Engineering to request a mapping at any time. This would be based on our evaluation of a building movement indicated by instrumentation data. The requested mappings may be of a localized area or may be for the entire area based on our expected behavior of the structure.

Method of Monitoring and Evaluation As an example of a portion monitoring and evaluation process, the following data from the grillage at W/8 is presented.

Before we started jacking, a discussion was held between B. Dhar, Vish Verma of Ann Arbor and John Darby.

In that discussion they gave Resident Engineering deflection values that could be expected during the jacking.

In i

l addition, they outline the criteria we should use in evaluating the structure 46 response to the jacking loads. This information is given in REM-S-1115 (Attachment B).

l L

V Page 3 These criteria were then included on the forms that the residents use for monitoring during the jacking operation. Copies of the actual records for the grillage W/8 jacking are given in Attachment C.

This shows that we monitor the jacked structure, adjacent structures, and the grillage / pier system at least twice during each load increment. This information was evaluated when received and we did not proceed with jacking until we were satisfied with the behavior the building is exhibiting.

If we had any doubts or questions, the situation was investigated and/or discussed with Project Engineering, FSO and Mergentime personnel until we were satisfied.

In addition, to the intensive review of the data during the jacking operation Resident Engineering receives readings from the instrumentation system every four hours. This data is reviewed by Resident Engineering when received. We are staffed to support this twenty-four hours a day.

During our reviews we look for any changes occurring which appear to be out of the ordinary.

We maintain plots of selected instrumentation data. These plots are updated and reviewed daily in order to identify trends that the buildings may be exhibiting or any identifiable reaction that could be related to construction events.

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g6 Finally an evaluation is performed by Resident Engineering of the crack mappings after the mappings have Been reviewed and released. During this process we identify the changes that had occurred from the previous mapping,

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the crack location and respective change is then placed on a sketch of the building (see Attachment D).

The changes are reviewed for any e

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Page 4 distinguishable patterns. The data is tabulated and field reviews are performed if it is judged necessary to evaluate the change further. This information is then forwarded to our consultants for their review.

At times we may see a change in a single submittal that warrants discussion with our consultants. A complete report is not necessarily written by Resident Engineering. The information is forwarded to our consultant and the situation discussed.

These discussions are documented in our daily reports.

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Before the start of Phase 2 (Drawing 7220-C-1418) construction for first baseline measurements (mapping of existing cracks) in the electrical penetration areas of the auxiliary building.

b.

After soil support removal for placing pier E/W 8 grillage beams at the ends of the electrical penetration areas, b.1.

After completion of jacking at pier E/W 8 grillage beams to support the electrical penetration areas, c.

After completion of the access drift from the utility access tunnel (UAT) to piers CT1 and CT12, and removal of soil support for excavation of piers CT1 and CT12.

d.

After completion of jacking above piers CT1 and CT12.

After removal of soil support from the excavation of the d' rift north of e.

pier E/W 5.

}

f.

After completion of jacking above E/W 5 grillage beams, g.

After removal of soil support for excavation of piers CT3 and CT10.

h.

After completion of jacking for piers CT3 and CT10.

(Hold Items i through t inclusive) 1.

After removal of soil support due to excavation for piers CTS, 8, 13 and 15.

j. After excavation of drift north of piers E/W 2.

k.

After completion of jacking above piers CTS, 8, 13 and 15.

1.

After completion of jacking above pier E/W 2 grillage beams.

After removal of soil support because of excavation for piers CT6, 7, and m.

14.

n.

After completion of jacking for piers CT6, 7, and 14.

o.

After mass excavation between 5.3 to 5.9 and 7.2 to 7.8, down to El.

591'-0".

p.

After completion of excavation under the control tower and electrical penetration areas down to El 591'-0".

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I thCATION AREA CRACK

" RACK IEASURIENTS (1 MILS.001 in.)

EVALUATION W.77N Co.AllGE WIDTH CHAIIGE AFTER Igy JACKIIIC AFTE g jcKING FIIOM 70

> 5 MILS PROM 70

> 5 MILS West EPA 146 9N N

HL No Within Tslerance.

Slab # 628' &

sa West EPA 238

'3 15 5

Yes Crack f3 in area 238 is in floor slab # 659' 0" 238

  • 13N N

HL No topping with poorly defined worn 239

  • 1 15 to Iso to 5

Ido off edges which <.ould have lead to 239

  • 6 7.5 5

No 4 dispersion. All other Q

242

  • S 15 to No cracks within tolerance.

N{

West EPA 282 1

7.5 5

Iso Within Tolerance.

Slab e 674' 6' E

West EPA 151 1

to 15 No BotII cracks within tolerance.

llorth face 154 3

5 7.5 No 7.5 5

No S

of wall i zus

=in u

im 15 0 Cracks were reenamined and tra es ol'G Col. Line K 203 82N N

HL No paint within the crack indicated LINj 614'-0* to 203 83N N

HL 80 0 it had formed before underpinning 659'.0" 203 74N N

HL No operation.

204

  • 1N N

HL Ido n

M 204 82N

  • N HL Ho^

9 South face of 339 6

7.5 5

No Within To,lerance.

E j

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i East EPA 268 83 HL 5

lio Chek #2 in area 271 is in floor Slab 9659'-0*

83 HL 5

Iso 5

10 No topping with poorly defined worn

  • 22N N

HL JIo off edges which could have lead to 271

  • 2 7.5 15 Yes measurement dispersion. All other cracks within tolerance.

eacks were noted as crazing when g

East EPA 312 1

10 Crazirg N/A 10 5

Ilo

    • Pped after initial Jacking. Valves

(

Slab 9674'6'

  • 11 10 Crazirg N/A 10 7.5 llo

[gg8/81 to 11/28/81 were withir East Era 157 zu W

NL No Both cracks within tolerance.

North face of 139 IN N

HL No I

watt e Col.

g Line K 614'-0" to 659'-0" West face 66 2N N

HL 80 0 All cracks within tolerance.

Control Tower 3N N

HL No of wall e Col.

70 14 7.5 5

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-UPWARJ VOVEMENT ESTIMATE

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SUMMARY

OF ANALYSES 4EW7MBL C

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4pk JAtXAW f JK/lLAMi A g

/64 M/LS (b)

M ML /6H0KES Hed?NMT V CMfRN sgk g jak f M M' M t 7D Af 7 4/d IMD.

C RJT/ u l 1 9 M 3 6

  • NAX/MDM 4g

/24 Mll4

2. F/N/ff ElEAf8NT M 6fA46 ff

& M Cf/ f CT/t NOM M U VA f/ M /

NHf

&) So/L 6% a n MA/M JACK /M6 //nuf/MS M u /A7 6 (kra f/ff Mt.(f=S'3endf) 4dMS/DEMM 70 STARTVJMA/AW) l (b) Ho 60tl ward EPA

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3. f/ MITE ELENSNT A,./S4 M/l4 da CT/ / 07/t MnML B O VA 7 9 ( R il A 7/ Vi C' ) $ d/L M M M A/ M M (K 3"MMV) b Ns T4 STMTVJMK/M4)

(b) SM UNm tM/Usl 7an@c./ a rr //

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FACTORS :

ACTUA L OBS ERVA TICAJS CA LCULATIOhJS W/TH FAcroes n.l5 SEArins Loss

& Ns CBSE.2VED THERMAL MovEME.C ALEnr LEVEL :

/75 Mitts Acrtou

! evec :

300 MJLL5 2

2E00A LIFY i.5 VEL :

/3 OF CA.=A C/ 7 y' f700-cemlls

'L

,,,--,,_,.,,a, m

,--p

+e m

--n-.

-,r--,

--g-o-.

MA med dit NRC MEETING ACTION ITEMS 1.

To supply the NRC with a list of critical areas (areas of high stress during underpinning) in the Auxiliary Building. This list should be based on both upward as well as downward movement of the building.

2.

Provide a list of locations where additional extensometers may be pro-vided in the Auxiliary Building. The locations should be based on the following:

a.

E-W direction of EPA Control Tower.

b.

Slab at elevation 685' in Control Tower in connection with observed cracks.

c.

At EPA / Control Tower roof level if cracking is observed:

(The roofing should be removed in areas of high stress and inspected for cracking).

3.

Provide a table showing rebar and concrete stresses, strains (for the element) and associated deflections at critical locations of the struc-ture for the various construction stages of temporary und'erpinning.

4.

Perform a survey of'the entire EPA, CT, and Main Auxiliary Building to identify areas of cracking.

10 mills or larger cracks, must be iden-tified. Areas having clusters of multiple cracks, smaller than 10 mills, should be identified. Drawings showing cracks, should be prepared.

The drawings should show the pattern of cracking and also, inaccessible areas which could not be surveyed.

Based on this survey, an evaluation of any new cracks should be made and an explanation provided regarding the cause of these cracks based on past construction history and implications for future underpinning construc-tion.

Subsequently, a meeting will be held with Region III/NRC, to discuss CPCo evaluation and any changes to the existing crackmapping program.

5.

Indicate what C-200 actions will be taken if the Control Tower has a significant movement during excavation of CT1 and CT12 piers.'

6.

Provide a report evaluating the cause of the cracks discovered in the Control Tower slabs at elevation 685'.

7.

Based on -settlement readings from the beginning of monitoring (i.e.

1977), provi.de equivalent plots of 4, and L, at 6 months intervals.

3 2

l l

i 1

ff:,n (

L: C 13 !

FCtty MN0184-0000A-CN01 l

' k' s *,

8.

How far out of symmetry can the construction proceed between the East and West side. underpinning? Wh'at are' stresses and deflections for any unsymmetrical conditions allowed? Also, has the-effect of cracking (i.e.

twisting of -EPA /CT, cc= pared to the Main Auxiliary Building) has been considered?

9.

After the above information is provided, NRC would discuss with CPCo, the following upward'A limits proposed by CPCo:

2

~

1.

Alert = 0.175 inches 2.

Action =.300 inches, The alert and action definitions are consistent with the present defini-tio'ns'in Specification C-200.

'CPCo would also submit proposed values for upward A, values in the 3

Auxiliary Building.

10.

In the interim, NRC recommended that the following upward limits be used:

Ag (Control Tower) =.50 inches 4

=.100 inches 2

There is no limitation on jacking loads, provided they are within the capacity of the structu're ( the above criteria supersedes the present interim criteria, as contained in the CPCo. letter dated being used).

O 9

l e

i MN0184'-0000A-CN01

Jd UNITED STATES OF AMERICA

)A'

~

NUCLEAR REGULATORY COMMISSION

.f' In the Matter of

)

Docket Nos. 50-329 l

50-330 CONSUMERS POWER COMPANY (Midland Plant, Units 1 and 2)

)

CONFIRMATORY ORDER I

Consumers Power Company (the licensee) is the holder of construction permits CPPR-81 and CPPR-82 issued by the Atomic Energy Comission (now the Nuclear Regulatory Commission (the Comission)), which authorize the construction of the Midland Plant, Units 1 and 2 (the facility). The facility is under construction in Midland, Michigan.

II Since the start of construction, the facility has experienced significant quality assurance (QA) problems. Although the licensee took corrective actions in each case, problems continue to be experienced in the implementation of its QA program.

e 2

On October 6, 1983, the Director of Inspection and Enforcement issued a

" Confirmatory Order for Modification of the Construction Permits" which required that the licensee adhere to the Construction Completion Program (CCP),datedAugust 26, 1983, for the duration of the construction of the facility. 48 FR 46673 (October 13,1983). As more fully described in that order, the development of such a program was necessary to verify the adequacy of prior construction and to insure the adequacy of future construction in view of the identification of widespread QA problems in late 1982, the facility's history of QA problems, and the ineffectiveness of previous corrective actions to fully resolve these problems. An important aspect of the CCP is the third party overview by Stone and Webster Engineering Corporation which is required until the Regional Administrator, Region III, finds that the overview is no longer necessary to provide reasonable assurance that the facility can be constructed in accordance with Commission requirements. One element in any decision regarding the relaxation of the overview requirement will be a finding of confidence in the ability of the licensee's management to properly construct the facility in accordance with Commission requirements without a third party overview.

Such a finding cannot now be made.

3 III i

i On December 6,1979, the Director of the Office of Inspection and Enforcement and the Director of the Office of Nuclear Reactor Regulation issued jointly an Order Modifying Construction Permits for the Midland plant. The order was based in part on a breakdown in quality assurance related to soils work at the Midland plant which had led to excessive settlement of the facility's diesel generator building. The licensee demanded a hearing on the order, and the proceeding on the order was eventually consolidated with the proceeding on Consumers Power Company's j

application for operating licenses for the Midland plant. During the course of the proceeding, the Atomic Safety and Licensing Board issued an order that authorized the Director of the Office of Nuclear Reactor Regulation to amend the Midland construction permits to incorporate certain limitations on remedial soils work at Midland.

See Consumers Power Co. (Midland Plant, Units 1 & 2), LBP-82-35,15 NRC 1060, 1072-73 (April 30, 1982).

In accordance with the Board's order, the construction permits were amended on May 26, 1982 to include the i

Board-ordered conditions.

Among the restrictions imposed by the Board's order and the permit amend-ment was a condition that the licensee "shall obtain explicit prior approval from the NRC staff...before proceeding with the following soils-l related activities...: any placing, compacting, excavating, or drilling soil materials around safety-related structures and systems."

i i

.w 4

Construction Permit Nos. CPPR-81 & CPPR-82, 1 2.G.(1) & 2.G.(1)a; compare LBP-82-35, supra,15 NRC at 1072-73. On July 28, 1982, an NRC inspector discovered that the licensee had excavated s541 from below the deep "Q" duct bank and had initiated relocation of the fireline in "Q" soils without prior NRC authorization.

Excavation below the deep "Q" duct bank had begun on July 23rd and relocation of the fireline had begun on July 27th. Neither activity had received explicit prior approval from the NRC staff as required by the construction permits.

In fact, exca-vation of soil material below the deep "Q" duct bank was contrary to prior directives of the NRC staff which instructed the licensee that such excavation was not authorized. Thus, excavation of the deep "Q" duct bank and relocation of the fireline by the licensee constituted violations of the construction permits.

IV The history at this site demonstrates that management has not been effective in providing the attention to detail and high quality standards necessary to the proper construction of this facility.

In view of this history, including the violation identified in section III of this order, I have determined that a management appraisal is required at this time. The licensee, in a meeting on October 25, 1983 with the Director of_the Office of Inspection and Enforcement and the Regional Administrator, Region III, and in a subsequent meeting on January 4,1984 with the

5 Regional Administrator, agreed to submit a management appraisal program to the Comission.

It is appropriate to confirm the licensee's comitment by order.

V In view of the foregoing, pursuant to Sections 103,161(i),161(o)and 182 of the Atomic Energy Act of 1954, as amended, and the Comission's regulations in 10 CFR Part 2 and 10 CFR Part 50, IT IS HEREBY ORDERED THAT:

Within 30 days of the effective date of this Order, the licensee shall submit to the Region III Administrator for review and approval a plan for an independent appraisal of site and corporate management organizations and functions that would develop recommendations where necessary for improvements in management comunications, controls, and oversight. Upon approval of the plan, the plan shall be implemented and the scheduled milestone completion dates shall not be extended without good cau a and the concurrence of the Region III Administrator.

The plan shall include at least the elements itemized below:

hld 95 P, S

4 (1) An appraisal conducted by an independent management consultant h

C(0 l

i organization retained by the licensee to evaluate the licensee's p o\\

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ho o' yd uvP

-. 2

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6 l

current organizational responsibilities, management controls, communications systems and practices, both at the Midland site and between the corporate office and the site. The appraisal shall include a review of the licensee's site and corporate construction management and supervisory personnel involved in the Midland project to determine their capability and competency for managing construction activities consistent with regulatory requirements.

(2) A description of the appraisal program, the qualifications of the appraisal team, a discussion of how the appraisal is to be documented, and a schedule with appropriate milestones.

(3) The provision of recommendations for changes in the aforementioned areas that will provide assurance that the licensee will implement NRC requirements.

The licensee shall direct the approved organization to submit to the Region III Administrator a copy of the report of the appraisal and recommendations resulting from the appraisal, and any drafts thereof, at the same time they are sent to the licensee or any of its employees or contractors.

Prior notice shall be given the Administrator of any meeting between the licensee and the organization to discuss the results, recommendations, or progress nede on the appraisal.

In addition, the licensee shall consider the recommendations resulting from the appraisal i

T.

l j

~~

l 7

and provide to the Region III Administrator an analysis of each such recommendation and the action to be taken in response to the recommendation. The licensee shall also provide a schsdule for accomplishing these actions.

The Administrator of Region III may relax or terminate in writing any of the preceding conditions for good cause.

VI The licensee may request a hearing on this Order. Any request for hearing shall be submitted to the Director, Office of Inspection and Enforcement, U.S. Nuclear Regulatory Commission, Washington, D.C. 20555 within 25 days of the date of this order. A copy of the request shall also be sent to the Executive Legal Director at the same address and to the Regional Administrator, NRC Region III, 799 Roosevelt Road, Glen Ellyn, Illinois 60137.

If a hearing is to be held concerning this Order, the Commission will issue an order designating the time and place of hearing.

If a hearing is held, the issue to be considered at such hearing shall be whether this Order should be sustained.

r 8

This Order shall become effective upon the licensee's consent or upon expiration of the time within which the licensee may request a hearing or, if a hearing is requested by the licensee, on the date specified in an order issued following further proceedings on this Order.

FOR THE NUCLEAR REGULATORY COMMISSION Richard C. DeYoung, Director Office of Inspection and Enforcement Dated at Bethesda, Maryland this day of January 1984.

e 0

e

[

?

Dti; 2 9 CC3 l

l l

f Docket No. 50-329 Docket No. 50-330 Consumers Power Company ATTN:

Mr. James Mooney Executive Manager for Soils 1945 West Parnall Road Jackson, MI 49201 Gentlemen:

We have completed our review of the corrective actions which you have taken in regards to identified crack monitoring system deficiencies. Specifically, the following corrective actions were reviewed:

1.

Wiss, Janney, Elstner and Associates, Inc. (WJE) procedures were revised and reissued.

2.

Crack monitoring system specification was revised and issued.

3.

Pertinent PQCI's were rtvised and issued.

4.

NCR's (59) documenting the crack-monitoring deficiencies were closed.

5.

QAR's (11) documenting the crack-monitoring deficiencies were closed.

This letter documents the satisfactory review of these corrective actions by the NRC staff.

Sincerely, 0k]tN'$ f-G),acl kg L 3 wurk

/

J. J. Harrison, Chief

&gt Section 2, Midland cc: See attached distribution list RIII RIII RIII RIII I,an% kr R6 Ef(Okt N'FR) k dsnan/1s Gardner

!!arrison Warnick 12/29/83 S.,'!di: i:: 'l

lIllillF Consumers Power Company 2

g cc: DNB/ Document Control Desk (RIDS)

Resident Inspector, RIII The Honorable Charles Bechhoefer, ASLB The Honorable Jerry Harbour, ASLB The Honorable Frederick P. Cowan, ASLB The Honorable Ralph S. Decker, ASLB William Paton, ELD Michael Miller Ronald Callen, Michigan Public Service Commission Myron M. Cherry Barbara Stamiris Mary Sinclair Wendell Marshall Colonel Steve J. Gadler (P.E.)

Howard Levin (TERA)

Billie P. Garde, Government i

Accountability Project Lynne Bernabei, Government Accountability Project Stone and Webster Michigan, Inc.

I 9

e R4 J A Mooney

-} p Executive Manager Midland 14cject Office

?

General Offices: 1945 Weet Pernell Road, Jackson, MI 40201 * (617) 700-0774 December 9, 1983 (G ( b Mr J J Harrison Kk Midland Project Section j [.') 3 1' U S Nuclear Regulatory Commiss, ion

/ '

/

p,,,,.

/

g/l

[Ii Region III

'//trl 799 Roosevelt Road

  1. '"~c Glen Ellyn, IL 60137

~

,-.,;j, 5 -

MIDLAND ENERGY CENTER GWO 7020 AUXILIARY BUILDING CRACK EVALUATIONS File:

0485.16 UFI: 42*05*22*04 Serial: CSC-7074

REFERENCE:

Serial CSC-7063 dated December 6, 1983 and Serial CSC-6960 dated October 24, 1983.

The attached report, " Auxiliary Building Crack Evaluations", evaluates the changes in cracks after the initial jacking of Grillage 8 and concludes that few changes had occurred and in these cases the changes were within measure-ment tolerance of.005".

This report also evaluates changes in selected cracks af ter rejacking of Crillage 8 and concludes that thete changes were also within the measurement tolerance.

Dr. Mete Sozen of University of Illinois and Dr. A. E. Fioroto of Construction Technology Laboratories have reviewed _the. contents of this report, inspected cracks which in their opinion warranted their lnspection and concurred with the conclusions of this report.

CO M

/RMW/k1w Attachment CC RJCook DSHood 4

s h

OCl283-0003A-CN01

?5ifij&)g

g BCC JWCook, P-26-336B DBMiller, Midland (3)

TABuczwinski, Midland-207 JNLeech, P-24-507 DASonumers, P-14-106 (For SER Related Issues)

DFLewis, Bechtel DJVandeWalle, P-24-614B MIMiller, IL&B, Chicago FCWilliams, IL&B, Washington, DC CALow, P-12-237A NRC Correspondence File, P-24-517 UFI, P-24-517 BJWalraven, P-24-517 Hearings File, P-24-517 Reading File, P-24-517 4

i i

l I

a

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~ 0M/0L' SERVICE LIST L

Mr Frank J Kelley, Esq Atomic Safety & Licensing

!c

' Attorney General of the Appeal Board l.

State of' Michigan U S Nuclear Regulatory Commission Phi Carole Steinberg, Esq Washington, DC 20555 Assistant Attorney General i

Environmental Protection Division Mr C R Stephens (3) 720 Law Building Chief, Docketing & Services i.

Lansing, MI 48913 U S Nuclear Regulatory Commission Office of the Secretary i

Washington, DC 20555 s

Mr Myron H Cherry, Esq Suite 3700 Ms Mary Sinclair Three First National Plaza 5711 Summerset Street Chicago, IL 60602 Midland, MI 48640 Mr Wendell H Marshall Mr William D Paton, Esq l

RFD 10 Counsel for the NRC Staff I

Midland, MI 48640 U S Nuclear Regulatory Commission Washington, DC 20555 Mr Charles Bechhoefer, Esq Atomic Safety & Licensing Atomic Safety & Licensing-Board Panel Board Panel U S Nuclear Regulatory Commission U S Nuclear Regulatory Commission Washington, DC 20555 Washington, DC 20555 Dr Frederick P Cowan Ms Barbara Stamiris 6152 N Verde Trail 5795 North River Road Apt B-125 Rt 3 Boca Raton, FL 33433 Freeland, MI 48623 Mr Fred Williams Mr Jerry Harbour Isham, Liccoln & Beale Atomic Safety & Licensing 1120 Connecticut Avenue, NW, Suite 325 Board Panel Washingto., DC 20036 U S Nuclear Regulatory Commission Washington, DC 20555 Mr James E Brunner, Esq Mr M I Miller, Esq Consumers Power Company Isham, Lincoln & Beale 212 West Michigan Avenue Three First National Plaza Jackson, MI 49201 52nd Floor Chicago, Il 60602 Mr D F Judd Mr John Demeester, Esq Babcock & Wilcox Dow Chemical Building PO Box 1260 Michigan Division Lynchburg, VA 24505 Midland, MI 48640 Mr Steve Gadler, Esq Ms Lynne Bernabei j

l 2120 Carter Avenue Government Accountabil Ay Project l

St Paul, MN 55108 1901 Q Street, NW Washington, DC 20009 i

l l

9/3/83 miO583-0429a100 l

a t

I CONSUMERS POWER COMPANY Midland Units 1 and 2 Docket No 50-329/50-330 Letter Scrial CSC-7074 Dated December 9, 1983 At the request of the Commission and pursuant to the Atomic Energy Act of 1954, and the Energy Reorganization Act of 1974, as amended and the Commission's Rules and Regulations thereunder, Consumers Power Company submits letter serial CSC-7074 dated December 9, 1983 from R. M. Wheeler to J. J.

Harrison.

Y CONSUMERS POWER COMPANY

,/

\\u g

J A Mooney Executive Manager Sworn and subscribed before me this f -

day of [Ac).

1983.

t L /L L}

Notary Public [/f PATRICIA A. FUt t Fh Notary Pu'Jc, Bey Ccucty, f/l A?y Co nm:,,;.n rg.,, ef,., 4, ; "

My Comission Expires 3 -l/-[d N

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BP1183-0000A-CN01

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~ AUXILIARY BNILDING CRACK MAPPING EVALUATIONS l

FOR GRILLAGE 8 INITIAL JACKING & REJACKING o

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__ AUXILIARY BUILDING CRACK MOVEMENT PURPOSE The purpose of this report is to evaluate the changes in cracks in critical Auxiliary Building walls and slabs between when the soil was removed beneath the

~

Ea'st and West Electrical Penetration Areas (EPA), and when initial jacking load was transferred to both East and West 8 Crillage Beams. The crackmapping in these critical walls and slabs is required per the design specifications.

The changes in widths for selected cracks were also evaluated after rejacking.

The cracks considered for this evaluation were those which were reported to have changed in width after initial jacking of Crillage 8.

An overall plan and elevation of the Auxiliary Building are given in Attachment A.

The location of Grillage 8 is also shown on these sketches.

Attachment B shows the dates of crackmapping, initial jacking of. Grillage.8 and re-jacking of Grillage 8.

METHOD OF ANALYSIS 1.

Each critical wall a slab was divided into several areas with unique area numbers. (e.g. 18 ).

2.

All cracks which were reported to have increased or decreased in width and all reported new cracks were reviewed after initial jacking. These crack chanees are shown in Attachment C.

3.

All the cracks which changed in width and all new cracks found after initial jacking, were again meas ured af ter re-jackings of Crillage 8.

Observed changes in the width of these cracks are given in Attachment D.

4.

Crack vidth measurements at a given location have an estimated tolerance of 1.0025 inches. Therefore, readings taken at two different times for the same crack could easily differ by.005 inches.

5.

The location, vidth and direction of cracks which changeo were compared qualitatively with expected structural behavior during excavation, initial jacking and re-jackings.

6.

The evaluation of cracks after the initial jacking event and the selected cracks after rejacking is tabulated in Attachment E.

7.

Dr. Mete Soren of the University of Illinois and Dr. A. E. Fiorato of Construction Technology Laboratory inspected cracks which ig their opinion warranted field inspection. Theyalsoreviewedthyreportand concurred with the conclusions which follow.

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CONCLUSION A.

For Crillage 8-Jacking There are approximately 2,000 cracks which were monitored in the Auxiliary Building after initial Grillage 8 jacking. Evaluation of the crackmapping data has shown that only twenty-three (23) of' these cracks changed in width (approximately 1%) while only twenty-one (21) new cracks were found (approximately 1% increase). The width changes which occurred were.005 inches or less except for two cases. In both of these cases the observed cracks were in the floor topping. After physical observation, it was judged that in these two cases, width changes were attributable to measurement dispersion. See Attachment E for summary of crack changes and evaluation of these changes. No alert or action level cracks were found during mapping.

It should be noted that crackmapping is intended to be used to-identify a need for evaluation of the building. Alert and action levels for the crack widths are set forth to trigger this evaluation. The primary

^

monitoring. device is the building movement instrumentation. The strain instrumentation, is the secondary monitoring device..

The observed changes in crack patterns and widths are in general consistent with previous patterns that indicate volume change movements.

The width changes are within the estimated tolerance limits of i

measurements. All of the crack widths are well below the alert limits, therefore need for special evaluation is not warranted.

B.

For Grillage 8 Re-jackirg Width of cracks which had been observed to have changed during initial jacking, were measured after re-jacking. Evaluation of this data, I

indicates that all measured crack width changes are within the estimated i

}

tolerance of.005 inches. None of these cracks reached alert level.

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CHANGE IN CRACK MAPPINC d'![1 I Airy 9t'f LPikC g

FA97 rJr,rTRICAL PCNETP_aTTON AptA 1

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EL 684 0"

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10/4/83 and g

11/28/83 rien.racxx c at c/w a to si-re-es a

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LOCATION AREA CRACK CRACK MERSURMENTS (1 MIL =.001 in.)

EVALUATION I.D. N0 s

WIDT11 CHANGE WIDTil CilANGE AFTER I g g JACKING AFTE(M N FROM TO

> 5 MILS FROM TO

> 5 MILS West EPA 146 9N N

flL No Within Tolerance.

Slab 6 628' 6" West EPA 238

'3

'5 5

Yes Crack #3 in area 238 is in floor g

slab e 659' 0" 238

  • 13N N

HL No topping with poorly defined worn m

239

'1 15 10 No 10 5

No off edges which could have lead to 239

'6 7.5 5

No measurement dispersion. All other fil 242

'8 15 10 No cracks within tolerance.

l E

West EPA 262 1

7.5 5

No Within Tolerance.

p Slab @ 674' 6' y

Q West EPA 151 1

10 15 No Both cracks within tolerance.

o3 North face 154 3

5 7.5 No 7.5 5

No S

of wall @

20.3 "IN N

HL No Cracks were reexamined and traces ofC Col. Line K 203

'2N N

HL No paint within the crack indicated th; ty 614 '-0

to 203

'3N N

!!L No it had formed before underpinning g 659'-0" P03

'4N N

llL No operation.

204

  • 1N N

llL No 204

'2N N

Ill No X

S South face of 339 6

7.5 5

No Within Tolerance.

E wall.

g East EPA 268

  • 1 HL 5

No Crack #2 in area 271 is in floor Sla b @659 '-0"

'3 HL 5

No 5

10 No tbpping with poorly defined worn

'22N N

llL IIo off edges which could have lead to 271

  • 2 7.5 15 Yes measurement dispersion. All other cracks within tolerance.

East EP A 312 1

10 Cra zir g N/A 10 5

No Cracks were noted as crazing when Slab #67 4'6" 11 10 CrazirE N/A 10 7,5 No mapped after initial Jackir.g. Valves g p g 83 tn 11/28/83 were withir East EPA 167 2N N

HL No Both cracks within tolerance.

$E North face of 139 IN N

HL No i

wall e Col.

" E[

l Line K 614 '-0" 2, E to 659'-0" o

M Control Tower 66 2N N

llL No gll cracks within tolerance.

A West face 3N N

Ill No of wall 6 Col.

70 14 7.5 5

No i

Line 7.8 m. -

~. _ _

-.--,s e

LOCATION AREA CRACK CRACK MEASUREMENTS (1 MIL =.001 in)

EVALUATION 9.

I.D. NO.

WIDTH CHANGE WIDTH CHANGE I -

AFTER INITIAL JACKING AFTER REJACKING

-p, (MILS)

(MILS) j FROM TO 5 MILS FROM TO 5 MILS Control Tower 84 10N N

HL No HL 5

No Both cracks within tolerance.

l East face of

-+1N N

HL No en i

Wall @ Col.

(

l Line 7.8 5

i

n 3

. s<

Control Tower 128 5

5 to no crack #12 in area 129 is-in rioor o

I Sla b e614 '-O'"

12 10 5

No 5

10 No topping with poorly. defined worn 14 7.5 5

No 5

7.5 No off edges which could have Ipad to E-129 9

7.5 5

No 5

7.5 No measurement dispersion.

An other U

12 10 5

No 5

15 Yes cracks within tolerance.

C~

Control tower 221A 8

5 7.5 No 7.5 5

No Within Tolerance.

Slab 6646'-0" E"

5

)

Control tower 248 5

12.5 10 No 10 5

No Within Tolerance.

S' Slab e659'-0"

.5 s

n

e Aux. Bldg.

219 1N N

HL No i

Sla b 6646'-0" 2N N

flL No All cracks within tolerance.

S 220 IN N

5 Ne 5

HL No

  • n 2N N

llL No 3N N

HL No 5

!j O

p Aux. Bldg.

260 4N N

HL No Both cracks within tolerance.

Slab e659'-0" 261 3

10 5

No I

Aux. Bldg.

30 3

N 5

No Within Tblerance.

Wall @ Col.

Line 7.4 &

i 7.8

~

d i:

Aux. Bldg.

25

'l 75 10 No Both cracks within tolerance.

7N 3

Wall @ Col.

24

'2 10 12.5 No 9E I;

Line 5.3 &

n>0 l;

5.6 ob "S

y

"' m 1

O Inspected by Dr. A. E Fiorato (CTL) and Dr. Mete Sozer: (Univ. of I ll)

I

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A CLO;? P0wer

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. COIISumBIS a * =. ev

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Executwe Afanager Mdland Ivoject Office General Offices: 1945 West ParnaH Road, Jackson, Mt 49201 = (5173 788-o774 V RA e,,

DPRP D/RA DE December 6, 1983 h/RA.

DRMSP vRC

%/

ORMA.

, 43 DAO SCSv m

IGA ML 3

Mr J J Harrison W

r;ge 3

Midland Project Section U S Nuclear Regulatory Commission Region III 799 Roosevelt Road Glen Ellyn, IL 60137 MIDLAND ENERGY CENTER GWO 7020 CONCURRENCE FOR ADDITIONAL JACKING LOADS FOR THE EAST /8 GRILLAGE File:

0485.16 UFI: 42*05*22*04 Serial:

CSC-7063 12*32 In the above referenced letter, it was clarified that 160% of the specified load is planned to be jacked, in 5% incremencs (over the locked off load) into grillage 8 (EPA jacks) prior to completing the excavation for grillage 5.

The letter also stated that the load in grillage (EPA Jacks) will be reduced to the specified load (800 tons) as the load at grillage at 2 is applied.

At the time of the lettet, the jacking load in grillage 8 (EPA jacks) had been locked off at 125% of specified load.

(Percentages expressed hereafter are percentages of specified load.)

In a September 20, 1983 telecon, Dr. R.

Landsman informed CPCo not to institute additional reserve capacity load above 125% without NRC concurrence.

On November 15, 1983, CPCo indicated in a conference call with the NRC (Dr.

Landsman, J. Kane and others) that it would be necessary to increase the jacking loads for east 8 grillage to maintain the building elevation.

East and West 8 grillage jacking and building elevation history was discussed.

It was mentioned that with the NRC restriction on jacking additional reserve capacity load, frequ.ent rejacking of the grillages may be necessary to comply with the design specification.

It was explained that in one instance of rejacking of east 8 grillage, the lif t-off loads experienced were 131.3% for the X jacks, 133.5% for the Y jacks and 145.4% for the Z jacks.

(The X jacks support the Turbine Building, and the Y and Z jacks support the EPA.)

In a November 28, 1983 conference call with the NRC (Dr. Landsman-)nd J. Kane), CPCo again requested permission to increase the jacking lock off

.los.d.s for the east 8 grillage.

Mr. Could of Mergentime explained that the previously agreed limitation on lock off loads (X=110%, Y=125%, Z-125%) is hindering our ability to maintain the Auxiliary Building elevation.

Specifically, the east 8 grillage had been recently rejacked twice over the Thanksgiving Holiday with the overall effect of losing building elevativa.

l oC1283-0000A-CN01 g.cja,; :, :n r DEC 121983 V

2

.). R Mr. Gould indicated that the current adjusted jack loads for the east 8 grillage were X=ll5%, Y=141.7% and Z=149%.

lock frequent rejacking on the east side may be due to_ smal 48 hour5.555556e-4 days <br />0.0133 hours <br />7.936508e-5 weeks <br />1.8264e-5 months <br />' period, as structure reaching a downward movement of 0.010 inch in aCPCo recommended the off loads.

specified in the construction procedure.

h t8 h

actions:

Maintain current jack loads (X=115%, Y=141.7%, Z=lA9%) for t e eas in 48 hours5.555556e-4 days <br />0.0133 hours <br />7.936508e-5 weeks <br />1.8264e-5 months <br /> is grillage / pier until_the acceptance criteria of 10 m.ls 1.

satisfied.

reduce the E8 grillage / pier loads to After the acceptance criteria is met,X=ll5%, Y=135%, Z-135% and 2.

nded Mr. Kane and Dr. Landsman indicated they concurred with actions.

mended action.

h issue in It was also indicated by Mr. Kane that he would like to resolve t e total through the following steps:

CPCo will complete its' evaluation of crack mapping and.other data to Upon determine the effects of jacking loads on the Auxiliary Building.

1.

the cone-completion of this evaluation, CPCo will provide in wr lding to the NRC by December 9, 1983.

1983 A meeting is tentatively scheduled for the week o l

ly 2.

loads.

resolve the outstanding issues relative to increasing jacking l

Discussions will include data and other information required to reso ve the matter of jacking loads.

d for the Although permission has been received to increase lo h increased fficient to jacking loads presently authorized may not necessarily be suIf the jacking l ficient due to unanticipated conditions, we may be requestin maintain the building elevation.

4 for high'er jacking loads.8 including pier and' foundation capacity ha We thank you for your which provides for any unanticipated conditions.)

cooperation on this matter.

'/h47Ccatu 0

)

f JAM /RMW/klw t-OC1283-0000A-CN01

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