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- a. 'un 492o1 - (5t 717s*0453 7.c if September 7, 1982 Harold R Denton, Director Office of Nuclear Reactor Regulation Division of Licensing US Nuclear Regula' tory Commission Washington, DC 20555 MIDLAND NUCLEAR C0 GENERATION PLANT MIDLAND DOCKET NOS 50-329, 50-330 RESPONSE TO OPEN ITEMS OF DRAFT SER FILE 0485.16 SERIAL 19158 DRAFT This letter summarizes Consumers Power Company's discussions with the NRC management regarding our mutual desire to implement a successful quality program for the Midland soils remedial work.
The 1980/1981 SALP Report, presented to Consumers in late April of this year, indicated that activities in the soils area should receive more inspection effort on the part of both the NRC and CP Co. Follow-up discussions with the NRR staff and Region III Inspectors led to the conclusion that the Quality Program and its definition was adequate; however, there was concern that certain aspects were not being or might not be satisfactorily implemented.
- This was corroborated by the fact that the majority of the NRCs recent inspection findings at the Midland Site were in the soils area.
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f-Consumers Power has performed an in-depth review of all aspects of the implementation plans for the Midland Soils work activities.
This review included the areas of design and const'ruction requirements and plans, organization and personnel, project controls and management involvement. The results of this review and the proposed steps for the successful implementation of the Quality Program were discussed with the NRC management in a meeting held in Chicago on September 2, 1982.
In addition, because of nderpinning activities scheduled to begin shortly, Cohsumers proposes to retain a qualified third party for an assessment Of.the "itif
-ph ne of the implementation of these work activities.
The highlights of the September 2 discussions are presented in the following paragraphs.
The design for the required remedial activities is in an advanced state; design details and adequacy have been reviewed by numerous organizations. A.y special ACRS Subcommittee reviewed the soils activities and cenc'uded Uiot.
items A comment Y,g_ favorably on the thoroughness and t er no op conservatism of the review and remedial approaches.
Numerous submittals to I
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the NRC have been p sented t c h
sign intent. The RC aff subsequently comp M ed etailed review of all design aspphts, has acfied the one u n tha o open 1 sues emai cess qf_)ssuing an i
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Following-up on design activities, Bechtel has assigned to the site a esign team comprised of experienced structural and geotechnical engineers L
under the Resident Engineer. This team will monitor and review the field
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implementation, resolve on a timely basis routine construction questions requiring engineering response and immediately administer contingency plans iMy if any problem should arise during the underpinning work.
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- 1 Following, coupled with an effective design process, the next step in quality performance of the soils remedial war,k involves a system to assure that all design
~ requirements and commitments are properly reflected in the final product. To this end, all soils activit'es covered by the ASLB Order of April 30, 1982 are "Q-listed" and are covered under soils-specific QA plans. These require thatJ appropriate procedures are in place to accomplish the work in a. quality manner s,uccessfully and that detailed inspection plans and over-inspection plans have been developed and are utilized. Additionally, the Work Authorization Procedure T 7
and Work Permit System insure the NRC and CP Co have specifically approved and released the work.
To assure that all commitments made to the NRC are properly accounted for in design documents, Consumers reviews written records of commitments and incorporates them in design detail. The Project is also undertaking a review of past correspondence to create a computer listing of all commitments not already placed in construction documents. This computer list will be periodically reviewed to insure that commitments are incorporated in design or construction documents in a timely fashion.
Another aspect of the Company's quality implementation program calls for an i
efficient, integrated quality organization staffed by qualified, experienced personnel. The present project organization provides single-point accountability, dedicated personnel, minimum interfaces - particularly at the working level, and a quality organization integrating quality assurance and quality control. This organization is staffed by personnel with the experence oc0982-2607a102
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-2 necessary to successfully accomplish the work.
(The qualifications of key personnel were discussed in more detail in our recent meeting.)
To enhance the performance of key project organizations, the Company will maintain day-to-day control' over scheduling, both through the. construction approval process and by frequent meetings with the involved contractors and subcontractors.
Each week, underpinning subcontractors will present proposed construction work to the Company.
In addition, to reduce schedule pressures on involvedsubcontrffors,allsubcontractswereenteredintoonatime-material basis. This should improve subcontractor attention to detail in performance of specific construction activities.
Another important element of the proposed soils implementation plan involves employee training. The training program, which includes all organization and personnel, covers both general training in quality and specific training relative to the construction procedures. More specifically, all personnel associated with Remedial Soils work have attended a special Quality Assurance Indoctrination Session. This includes Bechtel Remedial Soils Group, Bechtel QC, MPQAD, Mergentime and Spencer, White and Prentis (SW&P) personnel down to the craft foreman level. This training constts of one three-hour session covering Federal Nuclear Regulations, the NRC, Quality Programs in general, and the Remedial Soils Quality Plan in detail.
In addition to the forementioned training, both Mergentime and SW&P Procedures for Quality Related Training require specific training prior to initiating any quality related construction activity. The extent of this training, and identification of individuals to receive it, are spelled out in oc0982-2607a102
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g each separate procedures governing quality related activities.. Training l
requirements are listed in the prerequisites section of each procedure, and are QC and QA Hold Points, which must be signed by a QC and QA representative prior to the beginning of r,elevant activities.
Beyond training, an additional measure to improve performance involves the creation of a new Quality. Improvement Program (QIP) for the soils project. To launch their effort, an indoctrination program will be presented to all individuals, stressing the absolutes of Quality and the concept of "Doing it
.right the first time."fMeasures specific to soils will be develop [for )
those critical areas which are indicative of a " quality product".
racking these activities will provide an indication of the effectiveness of the program. The QIP will provide mechanisms for individual " feedback" and will enhance existing QIP programs.
In addition to embracing well-defined design and implementation requirements, a qualified organization and strict performance standards, the soils remedial work will include a high level of senior management involvement.
Towards this end, project senior management will conduct weekly in-depth reviews on site of all aspects of the work including quality and implementation of commitments. ' The Company's CEO is briefed on a regular basis and schedules bi-monthly briefings on all aspects of the project including soils.
During the bi-monthly briefings the CEO tours the Midland site, oc0982-2607a102 i
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Complementing the enhanced CP Co management role, HRC Region Management overview of the construction process will be assured by monthly meeting, ajreed upon by the Region, to overview the results of the quality program and the progress of the soils p,roject. These meetings will cover any or all aspects of the project of general or special interest to the NRC management.
A final element of the Company's of quality implementation effort is the establishing of an independent appraisal program.
This program is independent of the design and construction effort and will assess implementation during 7
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i the initial three months of the underpinning of the auxiliary building or longer if circumstance warrant. This independent appraisal program implementation will be in place prior to starting Phase 3, which is defined as N
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starting with the removal of soil for the grillage beams at Piers East and West #8 (Piers E/W8 are installed as Phase 2).
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The independent appraisal will be conducted by a team of nuclear plant construction and quality assurance experts. This team will be supplemented by the addition of an underpinning consultant who will review the design documents, construction plans and construction itself to assure not only that the design intent is being implemented but also that the construction is consistent with industry standards. The assesment will further assure l
l that the QC program is being implemented satisfactorily and that the construction itself is being implemented in accordance with the construction l
documents. Contract negotiations are in process with Stone and Webster to assume the lead role in this appraisal. They will be assisted by Parsons, Brinkerhoff, Quade and Douglas, Inc who will provide technical expertise, oc0982-2607a102
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.f Based on the discussion outlined above, CP Co believes that the soils program has been thoroughly and critically evaluated, and that all prerequisites for successful implementation have been or are being accomplished. The Company's program, with the initial o,verview from the independent implementation assessment, and the continuing overview by the NRC staff and management should provide proper' assurance that the remedial soils activities will. be successfully completed.
JWC/ JAM /c1 CC Atomic Safety and Licensing Appeal Board C8echhoefer, ASLB, w/o IV1 Cherry, Esq, w/o FPCowan, ASLB, w/o RJCook, Midland Resident Inspector, w/o SGadler, w/o JHarbour, ASLB, w/o GHarstead, Harstead Engineering, w/a DSHood, NRC, w/a (2)
DFJudd, B&W, w/o JDKane, NRC, w/a FJKelley, Ewq, w/o R8 Landsman, NRC Region III, w/a WHMarshall, w/o JPMatra, Naval Surface Weapons Center, w/a W0tto, Army Corps of Engineers, w/o WDPaton, Esq, w/o SJPoulos, Geotechnical Engineers, w/a FRinaldi, NRC, w/a HSingh, Army Corps of Engineers, w/a BStamiris, w/o oc0982-2607a102 l
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- ft CONSUMERS POWER COMPANY
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Midland Units 1 and 2
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Docket No 50-329, 50-330 Letter Ser'ial Dated
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At the request of the Commission and pursuant to the Atomic Energy Act of 1954, and the Energy Reorganiz'ation Act of 1974, as amended and the Commission's Rules and Regulations thereunder, Consumers Power Company submits CONSUMERS POWER COMPANY By J W Cook, Vice President Projects, Engineering and Construction Sworn and subscribed before me this day of Notary Public Jackson County, Michigan My Commission Expires t
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, g.f CONSUMERS POWER COMPANY
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Letter Serial Dated
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At the request of the Commission and pursuant to the Atomic Energy Act of
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1954, and the Energy Reorganization Act of 1974, as amended and the
,'1 Commission's Rules and Regulations thereunder, Consumers Power Company submits I
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f CONSUMERS POWER COMPANY By
/s/ J W Cook J W Cook, Vice President Projects, Engineering and Construction Sworn and subscribed before me this day of
/s/ Barbara P Townsend Notary Public Jackson County, Michigan My Commission Expires s
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SAFETY & LICENSING DEPARTMENT
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TELECON RECORD - DATE Oct 5, 1982 Paiticipants Company
,, Codes to: UFI:
_JWCook
,; l T J Sullivan CP Co MIMiller, IL&B D Hood NRC PSteptoe, IL&B i
JEBrunner DBMiller BWMargug1:
RAWells RWHuston JAMooney ARMollenkc Route to: DMB ud z ik /LSCib_s on /B LHa rs h e /DASo mme rs iIe*:
0505.18/00.0
SUBJECT:
Independent Review Program -
Caseload Forecast Panel Visit DISCUSSION:
I colled Darl Hood to discuss the scheduling of meetings on the subject topics.
I informed hi's that our Independent Review Program Plan submittal would be to NRC by Oct S.
He said that he had discussed the need for a meeting within the Staff but would await our submittal to echedule a meeting. I emphasized the importance of an early meeting to allow us timely initiation of the program, particularly industry's cocunitment to complete INPO-type evalua-titna this year.
In response to D Hood's earlier proposal of a Caseload Forecast Panel visit on Nov 16 - 19, 1982 I pointed out a number of reasons why CP Co feels this is inappropriate:
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(c) CP Co needs to receive and xeview the forthcoming soils.SSER.
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3a (b) %e soils work is contro11 2nowever:CP aa'. mot been 2eleased -to initiate the work
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~ Ban'ce isthYP,1:o and NRC.1 *ff e
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t would be.'baneficist to e.
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(d) The current '.mituation sia ~eocame load Torecas't Panel assessment and requires more preparati'ori~aiIithEpasieYMh3iRCend CP Co and the key people who need to do tds work are currently' fully eceupie8IEying.to remove -remaining constraints to
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initiate the soils remedial ectivities.
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AscnalternativeIindicatedthatCPdointend[*kmotifytheASLBthismonththatthe7/83 l.
fual load date will not be met due to our inability-to initiate the soils work and that the pracise date is indeterminate pending issuance of the SSER, NRC release of the soils work, l
and CP Co's detailed review of production rates, construction sequences, etc, based on the i
abtve.
CP Co would be prepared to support a Caseload Forecast Panel visit approximately thrce months following initiation of soils remedial measures (auxiliary building) and a more d3 finite target fuel load date could be provided to the ASLB at that time.
l H:cd felt the Board might want a more definitive schedule but agreed that the proposed approac}
c:=s reasonable and that he should discuss it within the Staff.
He indicated the soils SSER should issue this week.
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%vs%,8I Distribution:
Document Control PDR Docket Nos. 50-329/330 OM,'0L t[R NSIC PRC System 1)##Fr g;;p Mr. J. W. Cook C
(16)
Vice President ELJordan, IE Consumars Power Company 1945 West Parnall Road
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Jackson, Michigan 49201
Dear Mr. Cook:
Subject:
Caseload Forecast Panel Estimate of Construction Completion Schedule On April 19-21, 1983, the NRC Caseload Forecast Panel visited the Midland Plant to evaluate construction completion schedules. The meeting discussed in detail.the basis for Consumer's revised estimates of October 1984 (Unit 2) and February 1985 (Unit 1). On April 20, 1983 the Panel con-ducted an extensive tour of both units to observe construction progress.
The Panel has now completed its own evaluation of construction completion schedules for Midland Plant, Units 1 & 2.
The Panel concludes that some months beyond the second quarter of 1986 is the earliest date that completion of Unit 2 can reasonably be expected.
Unit 1 is expected to be completed about 6 to 9 months thereafter.
The critical pathway involves reinspection and rework of pipe supports, followed by execution of preoperational and acceptance testing.
The Panel believes that Consumer's estimate of 14 months to complete preoperational and acceptance testing for both units is unduly optimistic.
The record for a recent single unit to date has been about 24 months.
Using a more realistic, but slightly optimistic, duration for two units and Consumer's present status results in a completica date in the second quarter of 1986. However, the Panel also believes that Consumer's fore-cast does not realistically account for large uncertainties in the work which must precede start of critical path testing,'and that this can be expected to add some months to Consumer's schedule.
The Panel believes i
that completion of reinspections of large and small bore pipe hangers and the amount of rework resulting from this effort is a notable example of the items expected to delay start of critical path testing by some months.
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e.ac sca.i sia ii:.a:> nn:u c:a OFF1C!AL RECORD COPY vsso;i,si 3.C
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qs 2-The Panel's estimate includes no provision for delay associated with future plant financing.
Sincerely.
Thomas M. Novak, Assistant Director for Licensing Division of Licensing Office of Nuclear Reactor Regulation cc: See next page
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'o, UNITED STATES d )w,..(/[ j NUCLEAR REGULATORY COMMISSION 3%'-J'.*j WASHINGTON, D. C. 20555 G
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Docket Nos.
50-329/330
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APPLICANT:
Consumers Power Company FACILITY:
Midland Plant, Units 1 & 2
SUBJECT:
Sumary of April 19-21, 1983 Caseload Forecast Panel Meeting On April 19 and 21, 1983, members of the NRC Caseload Forecast Panel met with Consumers Power Company (CPCo) and Bechtel to review construction completion schedules which CPCo completed February 18, 1983 and announced April 12, 1983 for Midland Plant, Units 1 & 2.
On April 20,1983 the Panel toured the plant to observe construction progress.
The purpose of the meeting and tour is to provide for an assessment by the Panal of construction completion. Meeting attendees are listed by Enclosure 1. is the meeting and tour agenda. shows some of the slides used during CPCo's presentations.
CPCo's previous and revised estimates are:
7/80 Estimate 4/83 Estimate Difference (Mos.)
Unit 2 7/83' 10/84 14 Unit 1 12/83 2/85 13 Overall plant completion is estimated by CPCo to be about 83% complete; engineering is about 76% complete; design 94%; and underpinning 4%.
CPCo finds there are three separate critical paths for construction completion:
(1) a so called " aboveground" pathway, (2) auxiliary building underpinning, and (3) the licensing / hearing pathway.
Aboveground Pathway This pathway is primarily based upon rework of large and small bore pipe supports. However, installation of three HVAC systems, penetration sealing, and installation of mirror type pipe insu1Jation also presently have zero or negative schedule float.
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f A letter af Ma h 29, 1983, notes CPCo's intent to reinspect all installed safety related upports without regard to the time ofWts installation or turnover. CPCo estimated the new support reinspection procedure, training and certification of inspection personnel, QA rrogram revisions, and other support activities would be in place in time to commence reinspections the week of April 11, 1983. CPCo plans to use three inspection qui.$ during(about 50 inspectors) and complete hanger reinspections in June 1983.
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Only two inspectors had been certified as of April 15, 1983 and had started 3
hanger inspections. The hanger reinspection pathway is the critical path for the " Construction Completion Plan" (CCP)" described in CPCo's letters of January 10 and April 6,1983 (and subsequently on April 22,1983).
At least seven 50.55(e) reports are considered by CPCo to have some potential for schedule impact in that reviews and tests are not complete and can not be fully assessed at this time. These seven are:
50.55(e) Report No.
Management Corrective Subject Action Report (MCAR) No.
1.
80-04 40 High-ener5y line break analysis (HELBA) pipe whip restraints Lowalloyfuenchedand.
2.
80-09 45B tempered tfolting 3.
82-12 63 Design of steel embedments that use tension bars and shear lugs Deficienciesin$mitorque 4.
81-01 46 valve operators 5.
82-01 55 Deficiencies in electrial components associated with main steam isolation valve actuators, and non-safety related equipnent wired as IJ, i ClassliE P
6.
82-07 59 Safety related equipment cooled by non-safety related HVAC system 7.
83-02 67 Clearances between electrical control cabinets and panels
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n CPCo noted that 543 of 850 total systems (64%) have been turned over and accepted. Some systems were accepted with multiple " xceptions" (punchlist openitemssuchas-designchangesQorrectiveaction CPCo's schedule for preoperational? testing, acceptance testing, flus ng and specific j
tests for both units provides a total duration of 14 months. Fourty-five percent of the systems have been initially checked out. About' 4% of the, v/
' total o_f 683 tests have been completed as of March' 31, 1983. /The testing program for about 134 systems were noted to be constrained by the CCP.
The present schedule assunes little rework of hanger (about 850 out of 7000) will be needed for both units.
Auxiliary Building Underpinning Pathway Six of the 57 underpinning piers have.been installed since December, 13, 1983, and a pier load test (pier W-ll) was in progress. The construction sequence will utilize an existing Utility Access Tunnel (UAT) to gain early access beneath the southern corners of the Control Tower. The revised construction scheme utilizing the UAT'is reflected in.the current completion forecasts.
c/coi CPCo's schedule assumes NRC will approve loading of fuel imediately after transfer of the EPA load to the permanent wall (i.e. in advance of EPA and FIVP soil consolidation beneath the wall; pier lockoff and grouting; replacing of backfill beneath EPA and FIVP; and striuctural stiffening at critical elevation 659 feet). l'hese latter activities will be completed by late January,1985.
Licensing / Hearing Pathvay CPCo considers that completion of the present soils "0M" hearing and "0L" hearing is also critical to the new Unit 2 fuel load estimate. CPCo's estimated need dates for the hearing are:
Complete "0M" hearing session August 1,1983 Initial Decision on "0M" matters Mid October,1983 Completion of "0L" hearing session Mid May, 1984 Initial Decision on "0L" matters Early July,1984 3
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. o Staff Conclusions
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The Caseload Panel noted that the information, provided during the meeting
.and observations made during the site tour would im further reviewed before the Panel's completion estimates are reached..
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Darl Hood, Project Manager Licensing Branch No. 4 Division of Licensing
Enclosures:
As stated cc: See next page e
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ENCLOSURE 1 CASELOAD FORECAST PANEL VISIT April 19, 1983 NAME ORGANIZATION D. Hood LB4/DL/NRR R. Gardner Region III, NRC, IE B. Harshe CPCo - Safety & Licensing J. Mooney Exec. Mgr. - CPCo R. McCue~
CPCo - Technical Supt.
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D. Miller, Jr.
CPCo - SHE Manager J. DeMeest Public N. Saari CPCo - Pub. Affairs L. Shane Midland Daily News x
J. Leech CPCo - Safety & Licensing W. Bird CPCo - Mgr. Quality Assurance J. Schaub Asst. Proj. Mgr. - Midland CPCo J. Post CPCo - Purchasing Dept.
D. Fredlund BPC - Project Planning D. Perry CPCo - Design Production G. Keeley CPCo Project Manager J. Cook CPCo, Y.P. Prof. Eng. & Const.
D. Ronk CPCo, Section Head, Midland Project Mgr.
F. Buckman CPCo - Exec. Mgr.
W. Lovelace NRC/Ron D. Sedgwick Saginaw News G. Slade CPCo - SMO A. Mollenkopf Mgr. - Sch. & Cost - CPCo R. Wells Exec. Mgr. - QA
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ENCLOSURE 1 (continued)
ATTENDEES
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April 21, 1983 NAME ORGANIZATION D. Hood LB4/DL/NRR J. Harrison USNRC/RIII/OSC R. Gardner RIII/0SC/IE A. Mercado.
CPCo - Technical Dept.
B. McCue
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CPCo - Technical Dept.
D. Miller, JR CPCo - SMD D. Fredlund BPC - Project' Ping.
A. Mollenkopf CPCo - Sch. & Cost R. Wells CPCo - MPQADF F. Buckman CPCo - Project Office N. Saari CPCo - Public Affairs L. Spane Mcs.
Midland Daily News M. Clayton DOW
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D ENCLOSURE 1 (continued)
CASELOAD FORECAST VISIT U
April 2T',1983
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4 SITE SESSION k
NAME ORGANIZATION 4
D. Hood LB4/DL/NRR R. Ricc3 CPCo - Tech. Dept. - Primary Mech.
R. Orosz CPCo -Tech.
R. McCue CPCo - Tech. Dept. Supt.
D. Miller, JR.
CPCo A. Mercado CPCo Tech. Dept. - Scheduling A. Mollenkopf CPCo - Schedule & Cost W. Lovelace NRC/RM J. Harrison USNRC/RIII R. Gardener USNRC/RIII L
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j i SOILS SCHEDULE t 1982 1983 1984 JFMAMJJAS0ND J F M A M J J A S 0 il D JFMAMJJAS0ND l Diesel Generator Building - Crack Repair Prior To First Refueling ) j Borated Water Storage Tank I 1 2 l i I j thderground Piping 36" Pipe Replacement l
- 1 fbnitoring Dewatering i
i i. Service Water Pump Structure l l
l j SOILS SCHEDULE ~ l AUXILI ARY BUILDING l I 85 l 1982 1983 1984 l JFMAMJJASOND JFMAMJJASOND JFMAMJJASOND JF Access Pit Temporary Underpinning j g i L_______ l 1 Mass Excavation Pour Permanent Wall t,. c e 4 Loa'd Transfer l Soils Consolidation Lockoff a Grout l { 1 Complete Backfill l l I
MIDLAND PROJECT REPLANNING SOf LS (UNDERPINNING) LINKAGE TO FUEL LOAD l 1 i EVENT: e Start of Soils Consolidation BASIS: e Load Transferred To Permanent Wall e Demonstrate Building Has Structural Capability To Fulfill Safety Function Required For Fuel I Load 8 Low Power Physics Test l e Present Evaluation For NRC Approval i i
AUEILIAPY'EUILDINC UNDERPINNING t FACT.SFFET A. Devaterine Vertical Freeze Holes 248 Angled Freeze Holes 79 Thermal Penitor Poles 39 F,4ectors 78 Piezometers, 13 TEtal Poles Drilled 457 Linear Feet-Freeze Header 3,036 Linear Feet Dewatering Header 3,410 B. Access Shafts (East and West) } Depth Each Shaft 76' Feet Excavated Faterial - Shafts 8,889 Cubic Yards C. Temporarv Undereinning Length of Access Drifts 1,106 Forizontal Feet Excavated Material - Drif ts 1,474 Cubic Yards Number Temporarv Piers 57 Excavated Material - Piers 3,550 Cubic Yards Reinforcing Steel - Piers 295 Tons Structural Steel - Piers 803 Tons Concrete - Pfers 3,550 cubic Yards D. - Permanent Undereinning . Mass Excavation 7,957 Cubic Yards Permanent Wall: Length: 600 Feet Width: 6 Feet Height: 35 Feet Wall Concrete 4,287 Cubic Yards Wall Peinfore.ing Steel 326 Tons Slab Concrete 257 Cubic Yards Slab Reinforcing Steel 30 Tons E. Summary Total Material Excavated 21,870 Cubic Yards Total Reinforcing Steel 651 Tons Tocci Cocerete 8,095 Cubic Yards d' FS/LET2
.~ -,~ ..u . a.~. - -. m - a___..._.-...L. w..w n .p + j l j C-195 i Scope : ~ The scope of the C-195 contract is to underpin the Control Tower and Electrical l . Penetration Areas (EPA) of the Auxiliary Building and a portion of the Turbine ' Building. f The project has been broken down into four phases of work which includes the installation.of the East.and West Access Shafts, 54 underpinning piers and six ~ ~ i grillage beam support assemblies. The piers and grillage beam assemblies j will temporarily support the Control Tower, EPA and Turbine Buildings until the permanent underpfnning wall can be constructed and the building loads transferred
- to the wall.
l General:'. Mergentime, the prime contractor for the Auxiliary Building, will accomplish this work by excavating drifts (tunnels) from both the East and West Access Shafts. The drifts will only advance as far~as the next scheduled pier location. At this point, the pier will be excavated, lagged, rebar installed, instrumentation [ and embedded items installed and concreted. p j Once the concrete has achieved the specified strength, the pier will be jacked i against the building and the load transferred to the pier. The drift will then i procede to the next pier and the same process followed. This method will continue from both sides until all the piers and grillage systems have been .f installed and the load temporarily transferred. 1 I Once the Control Tower, EPA and Turbine Building have been supported temporarily, Mergentime will begin mass excavating the area in stages to the final elevation of 571'z. During the mass excavation, the Contractor will install a strut system to brace the piers as the excavation procedes, since excavation is on only one t j side of most piers. Mass excavation of the Access Shafts will coincide with the mass excavation under the building. After mass excavation is complete, the Contractor will construct a six foot wide, i 35 feet high wall.approximately 600 L.P. long, (4,287 cubic yards of concrete). This will serve as the new foundation for the building once the load has been transferred from the piers to the wall. l When the load has been transferred to the permanent wall, the " ballroom" will be l backfilled on the way out, as well as the Access Shafts. l l Pertinent Datat Pier concrete 3550 C.Y. Wall Concrete 4287 C.Y. Miscellaneous i Concrete 600 C.Y. I Rebar (Total) 1,274,784 lbs. Material Removed 21,870 C.Y. I 4 i h &llL. <uh. + ~
~ w SERVICE WATER PtHP STRUCTt4Z UNDEPPINNING Phase.I Agreed Quantities as of 11/19/82 FACT SHEET A. Dewaterins Ejectors (Inside) 33 Piesometers (Inside) 3 Ejectors (Outside) 47 4 - Fiesometers (Outside) J P j-Total Holes 92 i-Linear Feet 8" Dewatering Header 1,375 t i Linear Feet 10" Dewatering Header 345 l l B. Access Shaft i 1. Soldier Files 2L each i 2. Sheeted Pits for S.F. 3377 34. Fc. l, 3. Excavation Sheeted Fits for S.P. 109 CYS. -l r 4. Concrete for S.F. 16.5 CYS, i' 5. Lean Flyash Concrete for S.F., 65.3 CYs. t j 6. Lagging 2700 Sq. Ft. ] 7. Excavation 981 CYS. I 8. Structural Steel (Struts, vales, bracing) 95 Ton i e i C. Approach Fits. Underpinnina Piers. & Tunnel i } 1. Excavation 680 CYS. 2. Pier Reinforcing 32 Ton ] i 3. Lagging 10.585 Sq. Ft. j 4 Concrete 670 CTS. [ 5. Backfill and Tunnel Concrete 46 CTS. l l 6. Anchor Bolts & Plates. Etc. 47 Ea. i 7. Hydrau11e Jacks (Estimated) 50 Es. [ i PS/LET2 'l ..i
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.-w. . - - -..... - ~ -.. -. Summary of Underpinning o't Service Water Pump Structure The scope of the work involves two Phases, I and II. Phase I entails work related to the actual underpinning of the Service Water Pump Structure. Phase II involves excavation and rebodding of piping. Phase I work begins with the location of utilities within'the work area, both for excavation and installation of dewatering wells. After all utilities are located, approximately 47 dowatering wells will be installed outside of the building. Concurrently with this operation, 33 dowatering wells will be placed in <the Service Water Pump Structure and the Circulating Water Intake Structure. Afso,'a total, of 12 piezometers are to be installed. , l. The installation of soldier piles will be the next activity. This will' consist of 27 total soldier piles being installed; 20 will be placed in drilled holes, and the remaining seven will be placed in sheeted pits. Once the soldier piles have been installed, the Access Shaft excavation can begin. Lagging and bracing 4111 be installed as the shaft is dug. An estimated 785 'oubio. yards of emoavated anterial vill be removed from ground elevation down to elevstion 614. ' ' ' From the Access Shaft, aseves pits will be dug to. enable the pier excavations d e proceed. A total,of 20 piars are to be installed in a predetermined maquence. After aits 1, 1A, 2 and 2A are installed, a tunnel will begin Wing excavated undet* the Servios Water Pump Structure, next to the Circulating Afster Intake Structure. This tunnel will be approximately 6' x 6' x 30' in length upon completion. The above will entail, for all piers, 680 cubio yards of excavation, 670 cubio yards of pier concrete, and 102,425 pounds of robar. The tu inel will have 50 outio yards of unavation. Orice a pier is ilistalled, jacking will ta'ke place to transfer the load to the ' pier. After,the;1oad is transferred, the pier will be wedged to maintain the applied load. Large anchor bolts, connecting the pier to the Service Water Pump Structure,:will be tightened to maintain contact between the building and the pier. This process will be repeated for each individual pier. After all piers have been loaded, the access tunnel will be backfilled with a lean concrete mix. Additional work for the Phase II operation will include probing for utilities, installation.of dowatering wells, installation of soldier piles, excavation, lagging and bracing. This work is being done to uncover certain utilities which must be rebodded. The actual embedmont will be performed by Bechtel forces. Quantities for this work have not been calculated by the Field. I 8 sees ( e /J
AUXILIARY BUILDING SCOPE ITEM QUANTITY BUDGET RATE 1,106 ft 3 If/cs Horizontal Drift: Pier Excavating 3,550 cy 3 vf/cs Pier Reinforcing Steel 295 T 500 lb/cs i Pier Concrete 3,550 cy 7 cy/cs Mass Excavation 7,957 cy 10 cy/cs Permanent Wall Concrete 4,287 cy 29 cy/cs I 4 i l P 4 e s O
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j 'Mh,59~' ~, = 1. ? 'b- .f f fl)f.y li ., l,, j ( ' / t TEST PROGRAM STATUS AND REVISION 12 - TEST SCHEDULE 3 PREPARED BY: TECHNICAL DEPARTMENT MIDLAND' ENERGY CENTER-CONSUMERS POWtR COMPANY April 12, 1983 i e ^? dn e r fm i/ D fL TI W
o. a, - y ( e' b \\ -+ i i l h t 1 i ,I ({'3 TABLE OF CONTENTS 1 I. INTRODUCTION 1 [] II. TEST PROGRAM SCHEDULE STATUS (AS OF 3-31-83) j'
- 1. System Turnovers Ii, 2.
Testing Activities Summary i f;
- a. Electrical d
- b. Instrumentation and Control
- c. Nuclear Steam Supply Systems
- d. Auxiliary Systems
- e. Feedwater/ Condensate N
- f. Turbine /HVAC j_
- g. Process Steam
- h. Programmatic Testing 1[
3. Procedure Development .u,
- a. Status - Procedure Development and Approval g
- b. Status - Tests Completed III.'
PROJECT TEST SCHEDULE - REVISION 12 ' A. Rev 12 Test Schedule Philosophy a;;
- 1. 95% of Unit 1 testing will be performed prior to Unit 2 Fuel Load Ti.
- 2. Inherent time frames are built into the merged schedule to absorb Punchlist Open Items following major Milestone Testing.
2
- 3. No two Unit 1 & 2 Milestone events are required to be performed
) simultanecusly (except ILRT and HFT). 'I
- 4. Separation of Fuel Loads.
J'
- 5. LLRT/ILRT/ SIT are performed nearly piggy-back during the same time frames.
- 6. Integrated ESFAS Test would be a common Test Phase.
11
- 7. Rev 11 disadvantages have become less significant in Rev 12
- 8. Initial Turbine Roll - Milestone added to allow early testing prior to HFT.
_j B. Rev 12 Test Program Plans
- 1. Planned Activities Leading to the Next Target Milestones
- 2. Auxiliary System Flushes into Reactor Vessel
- 3. Refueling Canal Hydro and Wet Fuel Handling Test t'
- 4. Reactor Coolant System Cold Hydro
- 5. Feedwater System Flush-7* -
- 6. Condenser Vacuum I
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- 7. Initial Turbine Roll e(.
- 8. Hot Functional Testing m=
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- 9. Integrated Leak Rate Test
- 10. Integrated Safeguards Features Actuation System Test
- 11. Fuel Load C.
Manpower for Rev 12-List of Figures and Tables Figure 1 - Actual System Turnovers and Rev 12. Demand Turnover curve Table 1 - Procedure Development and Approval Status Report Figure 2 - Procedure Development - Curve of Actual vs Goal 4 'j Table 2 - List of Tests Completed f Figure 3 - Curve of Testing Completions - Actual and Rev 12 Projections Figure 4 - Plan for two unit startup, Rev 12 Table 3 - Rev 12 Listing of Test Procedures and Time Frames for Completion. i j Figure 5 - Manpower curves [?) 6 1 1 r s } In if
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INTRODUCTION d j This report contains; d l. The status of the Test Program Schedule as of March 31, 1983, and 2. Revision 12 of the Test Schedule based upon the Two-Unit startup +i concept. ij - (') The basic premise in the development of this schedule is to estab-lish a safe, organized, and logical approach to meeting the Project Objectives in a timely manner without sacrificing quality, i k ,i t f) 1 k .4 w $s ( .s.r e.-a .n ae - w* -e-w- - - - - ~ m *- .,,.y.,
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TEST PROGRAM S,CHEDULE STATUS 4 The status of the Test Program Schedule as of March 31, 1983 is present- .t. ed in this section in terms of System Turnovers, what we have accom-I plished so far in the Test Program, and where we are relative to Test i r, Sj Program Milestones leading to initial fuel load. t t .g-l .i Ii 4 S (7g/ 1 f-
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I L 'h ~ u. a 2 1 1.- ) E gv l. System Turnovers - Summary Total scoped Systems (approximate) - 850 543 Total System Turnovers Accepted 307 Remaining System Turnovers % complete = 543 = 64% 850 Figure 1 shows a graph of actual number of systems accepted thru March 31, 1983. It also shows the remaining system turnovers based upon Revision 12 Turnover demand dates. The numbers in parenthesis o show ACTUAL % complete. 2. TESTING ACTIVITIES
SUMMARY
The status of the Test Program Network as of 3-31-83 is presented below. It should be noted that " checkout complete" as reported in N this Section may not be necessarily 100% complete due to remaining punchlist open items such as design changes, corrective actions, and turnover exceptions requiring checkout and/or retest,
- a. ELECTRICAL SYSTEMS 321 of 371 Electrical Systems have been turned over to CPCo.
j (87 %). l. ~ 83_ % have been initially checked out and energized.- No ua L' ..m
m t- 'f' e e F 3 . i. Preoperational tests or Acceptance Tests have started. Significant activities completed and/or in progress include: 1 1 BOTH UNITS' MAIN POWER XFMRS and STATION POWER XFMRS have been j turned over and checked out. The Common Startup Power XFMRS are energized and in operation. Final " Pre-energize" testing will be ^ performed in 1983. Backfeed from 345 KV System is dependent on Turnover of Main Generator Protection and Microwave Systems. - all 6.9 KV BUSSES, 4.16 KV Busses, have been energized; maj or portions of 480 VAC Load Control Centers, 460 VAC Motor Control Centers, 250 VDC Motor Control Centers, 125 VDC Control Power Panels, 120 VAC Instrument Power Panels, and 480 VAC Distribution Panels have also been energized and are in operation. QA overinspection of class lE cable routing is 91% complete. eL - Electrical Reactor Building penetration repairs and replacement resulting from rodent damage and faulty Bunker-RAYMO modules is 95% complete.
- b. Instrumentation and Control (I&C) Systems 36 of 69 I&C Systems have been turned over to CPCo (52 %).
.,a. ...,e-m > = m
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.. m. n 4 + 37% of I&C Systems have been checked out. No Pre-operations / Acceptance Tests have started. Six apecific procedures have been completed. 4 Significant Activities completed and/or in progress include: Plant computer installation, checkout, energization, and vendor acceptance test are complete. Computer points input verification is in progress and will continue throughout the Preoperational Test Program. Unit Control Room Annunciator Cabinets (both Units), Evaporator Building Annunciator Logic cabinets, and Radwaste annunciator logic cabinet, bave been energized and icgic verification completed. The HVAC Annunciator logic cabinet has been energized. Non-Nuclear Instrumentation (NNI Cabinets and Modules both units) The electrical checkout and initial energization of NNI cabinets are complete. Incore Monitor Remote Analog Peripherals (both units) - partial j i I&C checkout is complete. The Incore Guide Tube Clearance checks have been completed.
. ~,. g 5 j ,h ^ CRD Stator Preinstallation check was completed on both Units. ' ICS cabinets and Modules (both units) - The electrical checkout is complete, the pre-turnover calibration of modules is complete; initial energization of ICS cabinets is in progress including the Evaporator System Development Demand (ESDD) Cabinets. i Instrument Racks - (Note: Each instrument rack represents one system) - Electrical checkout and energization, of the following instrument racks are complete: o Balance of Plant Instr. Rack 1C-49, 2C-49 u 1C-53, 2C-53 i 1C-166, 2C-166 0C-180 2c ',46 OC-343 Radwaste Instrument Rack OC-167 Evaporator Instrument Rack OC-168 OC-281 4 Analog Isolation Cabinets 1C46, 2C46 - Electrical and I&C check-out are complete. -y__-.__ 7-,
g.:
- ~
3 ,e j 6 t 1 a t e~., Digital Isolation Cabinets IC47, 2C47 - Electrical and I&C checkout are complete. 4 - Process Steam Transfer Instrument Rack, including power supply and peripheral - electrical checkout, I&C checkout of power i supply, and energization of Instrument Racks OC391 and OC386 are complete. Boron Recovery and Liquid Waste Programmetic Controller System including remote I/O Cabinets - Prepower checks, and electrical checkout of I/O cabinets are complete, ladder checks are essentially complete except for design changes requiring retest. ~% - Radwaste Gas System P'rogrammatic Controller System including remote I/O cabinets - prepower checks, Part 1 - Power ON prelimi-nary checks, and Part 2 Ladder checks are complete. C. Nuclear Steam Supply Systems (NSSS) 14 of 56 systems have been turned over to CPCo (or 25_ %.) l l~ No Preop or Acceptance Tests have been started. One specific l procedure (Unit 2 Decay Heat Removal Initial Pump Run) has been completed. Significant Activities completed or in progress include: 'l ,._,_______._m___.___ 7 _ _ g- - I
b. "[ * ' 3: j. .,a ;.., ma.c 2 U; 7 Ie. 1 L Turbine Bypass Valves - Unit 1 Electrical and.I&C checkout complete; Unit 2 electrical checkout complete. Unit 1 Reactor Vessel Internals Modification is in progress s J Unit 2 Reactor Vessel Internals Modification complete; the HFT Flow screen is installed / attached to the PLENUM; the CRD dummy i guide assemblies being installed in the PLENUM. Unit 2 Reactor Coolant Pump Motors - partial electrical checkout complete; all 4 RCPM's have been bumped for proper rotation and 3~ anti-rotation devices have been installed. Preparations are ,(j) underway for initial motor runs. Unit 2 Decay Heat Removal System (portions in the Auxiliary s Building) - Electrical and I&C checkout are essentially complete; Initial Pump Runs-Recire Mode, complete; Gravity flush to suction of DH Pumps and Velocity flesh of lines from pump discharge to BWST recirc lines ccmplete. d - Unit 2 Makeup System (High Pressure Injection Pumps) - Gravity flush to MU pump suction complete; two of the 3 HPI pump motors have been run and preparations are underway to run the third HPI pump motor. s i' j .i ' u., .--n.. .= ~.=
-. - -, a [ ~ a c. . i r )- 8 l l ~ Unit 1 & 2 Boronometer - Electrical checkout complete. l - Unit 2 - Boric Acid Addition - The mix tank has been cleaned; electrical and I&C checkout in progress - Unit 1 & 2 Hydrazine and Lithium hydroxide - Electrical I&C, and mechanical checkouts complete. Nitrogen blow to hydrazine drums complete. Unit 2 flush to suction of LIOH and Hydrazine Pumps complete. - - Unit 2 RB Spray suction piping - partial flush complete. t.' Unit 2 Borated Water Storage Tank Outlet-Piping - Flush to suction of DH pumps complete. The BWST Circulation pump initial run complete.
- d. AUXILIARY SYSTEMS 26 of 84 Auxiliary systems have been turned over to CPCo (31_ %).
Preformance of two flush procedures (Unit 1 & 2 FH Bridge Air System Flush) and one Specific Procedure (Receipt of Dummy Fuel Assemblies and Control Rods) have been completed. l r. Significant Activities completed and/or in progress include: a f .,e .,*..,m. a, .-m e.m m_. a.u .re-. ,,..... - - ~ ..-...,v.u
=> F -- - : J-f~ .e-s 9 Service Water Sluice Gates - I&C checkout complete; electrical checkout in progress. component cooling water - Portions of the system (B-Loop) i required to provide cooling water to the RCP motors have been checked out and flushed; this includes piping to the CCW and Decay Heat Coolers and DH Pump Seal Coolers. Reactor Building Vent Header - Electrical checkout of valves complete. - Radwaste pump seal water / headers - electrical checkout complete. t - Filter Handling - Electrical checkout complete. Primary Mixed Bed demineralizer - Electrical checkout complete. New Fuel Elevator - electrical checkout complete. Spent Fuel Pool Handling Bridge - electrical checkout complete - Unit 1 Reactor Building Fuel Handling (FH) - electrical and I&C l checkout complete, portions associated with Dry Indexing Preoperational-Test (Milestone lA) complete 1 -m -vm ,_-n,,_. e. _.w-* -+---*M- --e%-++-- ww-7-*---+ -++-e
-- x :. M '" = ~ _( l, 10 ^ Unit 2 Reactor Building Fuel Handling - Electrical and I&C checkout complete, portions associated with Dry Indexing Preoper-ational Test (MILESTONE 2A) complete 3 Unit 1 FH Transfer Mechanism - I&C checkout complete; Fuel Transfer Hydraulic System Flush in progress Unit 2 FH Transfer. Mechanism - Electrical and I&C checkout l complete FH Transfer Hydraulic System Flush in progress. Service Water System - electrical c/o Main Header valves in progress, I&C, checkout of common Header to the Turbine Building G. Service Water complete; electrical checkout Unit 1 & 2 Turbine Building Service water complete; electrical checkout Unit 2 Turbine Building service water complete. Initial Pump and/or motor runs completed to date include: Primary Water Storage Transfer and Vacuum Pumps (Motor only), service water Travelling screens, four of the five service water pump motors, four of the five service water strainers, and one of the j CCW pumps. e. Feedwater/ Condensate Systems 55 of 100 systems have been turned over to CPCo (55%). l c.
L ~
- -w
11 1 -m Performance of one Specific Procedure (Aux Boiler Initial Operation and Boilout) and 6 Flush Procedures, described below, have been completed. i Significant Activities completed and/or in progress include: 4 Unit 2 Condensate supply and Low Pressure Feedwater Heating - Electrical, I&C, and mechanical checkouts complete; condensate pumps initial run complete. - Unit 1 & 2 Hotwell makeup and Rejection - Electrical and I&C checkout complete except for Unit 2 I&C checkout which is in progress. f Unit 1 & 2 Main Condenser - I&C checkout complete. - Unit 1 & 2 Condenser Hotwell sampling - Electrical checkout complete. Common Feedwater crossconnect - electrical C/0 complete. Unit 2 Condensate Demineralizers and Associated Systems - Electrical and I&C C/0 in progress. Makeup Demineralizers - all checkouts complete, system is 1 J functional. ,_...w~~ =*mw~*-
- ' f *
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g'- M*u c.. { 12 4. i Demineralized Water Storage and Transfer - all checkout essentially complete; system is functional and providing primary source of Flush Water; Flushes associated with the storage and 3 transfer header branch lines to all hose stations, and Unit 1 & 2 Reactor Building piping, complete. ? Makeup Demineralizer Chemical Storage and Transfer - all system checkout and flushes complete; system is functional. Condensate storage (common system) - partial electrical and I&C checkout complete, flush to Unit 1 &2 Auxiliary Feedwater Pump recire lines complete. i N 4 Unit 1 Condensate Storage - Tank has been cleaned; I&C C/0 complete. Unit 2 Condensate Storage - all system C/0 complete except for electrical C/0; tank has been cleaned; flush from tank to Hotwell complete (Milestone 2E). l Condensate Transfer - For the common system, all electrical and I&C C/0 complete; condensate jockey and transfer pumps have been run; flush of the system is complete. l '- Unit I system electrical and I&C C/0 complete. I 1. i it l L.
_ ze.ja ; ( ..a,.,
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n 13 7. Ammonium Hydroxide Storage and Transfer - The common unit electrical and I&C C/0 complete; chemical addition pumps have been coupled. The Unit 1 & 2 systems electrical and I&C C/0
- complete, c "b' j
k - Hydrazine Addition System - Unit 1 & 2 Electrical and I&C C/0 complete. Hogging / Exhaust Piping Vacuum Relief - Unit 1 & 2 I&C C/0 complete. Circulating Water Supply - Unit 1 & 2 initial motor run of 4 C) circulating water pump motors complete. Water Box Scavenging - Unit 1 & 2 Electrical and I&C C/0 complete. Acid Storage, Supply, Distribution - Electrical checkout complete; pumps have been coupled. Auxiliary Boiler - all system C/0 complete; both boilers have been fired and Auxiliary System flushes completed; boiler tuning and load test is in progress. Auxiliary Boiler Steam Distribution - all systn. C/0 complete steam blow of main headers complete. 4 t i T we...e . r, m r. * - <e.ym.. w, - - e.
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- e 14
\\ \\ .i-l i gm I ~' Air Compressors / Instrument Air Dryer - all system C/0 complete; compressors are functional; presently clearing punch 11st open items; air blows main header complete. Service Air Distribution - all system C/0 of the Unit 1, 2 and 5: j common headers complete; air blows to subheaders and branch lines M'l in progress. Instrument Air Distribution - All system C/0 complete; Instrument j air is available to Evap Bldg, Miscellaneous Buildings, Dow pump 3-house Turbine Building (both units), and portions of the d j Auxiliary Building.
- 1 4
g, ii. Fire Water Supply / Distribution - System C/0 comp 1'ete; Diesel Fire ' and electric pump initial runs is complete. System is supplying site fire water protection. 4 -i Transformer Deluge - I&C C/0 complete. Carbon Dioxide Fire Protection - I&C and Electrical C/0 in 3 progress on those portions that are turned over. Building Deluge Protection - Electrical and I&C C/0 for portions of the system turned over is complete. t -r s i 5 74 ww-.-+w .-7 e-.s -ey,. ...p. ....y,,-.e..,.-. w-- 9
g-- w s. ,,s e, g m. 15 ! ~ q r - Hose Station Protection - Checkout of Hose Stations complete (to Warehouse 2. Turbine Building, Reactor Building, and l Miscellaneous Buildings. I Nitrogen System - System C/0 complete; N blow / purge of systen 2 ? ' complete; the distribution system is undergoing redesign work and therefore flushing will have to be done over. Natural Gas Evap Bldg Lab - System C/0 complete; flush of system complete. Vacuum Fume Hood (Evap Bldg Lab) - Elect C/0 and piping flush complete. r. Acid and Caustic Waste - Unit 2 sumps have been cleaned; I&C and electrical C/0 complete; initial pump run of Neutralizing sump pump complete. f. Turbine /HVAC Systems 76, of 150 systems have been turned over to CPCo (50%). Performance of one Acceptance Test (D G Electric Heat Test) and 6 Flush Procedures as described below have been completed. -l Significant activities completed or in progess include: 5 y
~~ m e x,..,__. - f-l 16 {'.
- (
T . ( 7., Unit.1 & 2 Turbines - System C/0 complete; Turbine has been placed on turning gear. d 3 I . Unit 1 & 2 Turbine Generator Bearing Lube Oil Supply - System C/0 complete; 011 flush complete; system functional. y d j Generator H and CO - Unit 1 & 2 I&C C/0 complete; 2 2 preparations under way to perform Generator Air Drop Test. P Unit 1 & 2 Hydrogen Seal Oil - System C/0 complete except for I&C 4' J C/O. Oil flush complete. [ - Turbine Lube Oil Storage, Transfer, and Purification (Unit 1, 2, and Common) - All system C/0 complete; oil flush complete; system functional. Cooling Pond Makeup Screens / Screen Wash - System C/0 complete: system is functional. i Cooling Pond Makeup, traveling screens, sluice gates, trash J; racks - Cooling Pond has been filled with water, checkout of I screen wash pumps, screens, makeup pumps, sluice gate, valves complete. Cooling Pond blowdown system checkout is in progress. Hot Water Supply / Chemical Treatmant - Electrical C/0 complete; ~' initial motor run of hot water pumps complete. l, g ar - --,,--., y y; ,.e
T- _ x., x g -4 s 4 i 17 y): ^ r; '- r Plant Hot Water Heat Systems - Unit 1 & 2 Turbine Building electrical C/0 and initial motor runc complete; electrical C/0 j Auxiliary Bldg Hot Water heat complete; Unit 2 electrical, I&C j l C/0 and initial motor runs complete; office, Service Building j g electrical, I&C C/0 complete including initial motor runs; Intake, Hypochlorination, Service Water Building electric heat-system C/0 complete; Unit 1 & 2 Diesel Generator Building electric heat - system C/0 complete - The Diesel Generator Building Electric Heat Acceptance Test is complete. Reactor Buidling Hot Water Heat.(Unit 1, common) electrical C/0 complete; Process Evaporator Hot Water Heat electrical C/0 []i including initial motor runs complete; Auxiliary Building Safeguard Room Electric Heat - electrical and I&C C/0 complete (common Unit; Unit 1 - electrical C/0 in progress); Guard House electric Heat - I&C and electrical C/0 complete. 4 i Turbine Building Chilled Water - Unit 1 & 2 I&C C/0 complete; chilled water pump motors were run and coupled; the system flushes are in progress. Office / Service Building Chilled Water - Electrical and I&C C/0 complete; startup of chillars and pumps complete; proof flush is complete. l t 's d s ~-# . l, h n. __._. _
~ 18 i i n - Office / Service Building HVAC - System C/0 complete, air balancing and setting of dampers complete. ? Chlorination Building HVAC, Cooling Pond MU Building HVAC, } j Cooling Pond Intake Building HVAC, Guard House HVAC, and Pond
- i
)7 Blowdown Building HVAC - System C/0 is complete. - Evaporator Building HVAC, Circulating Water Intake Building HVAC, Oily Waste Treatment Building KVAC, and Dow Condensate Return Pump House KVAC - electrical C/0 in progress. Refuel Pool Air Supply (Unit 1) - electrical c/o in progress. %: ) Domestic Water Storage. Transfer, and Heating - System c/o complete and system is functional. Hydrogen Supply - Electrical and I&C C/0 complete; purging H 2 system with nitrogen complete (common system); Unit 1 & 2 H 2 system is functional up to the Main Generator and to the RCS MU Tank. Oily Waste System - Common Unit electrical and I&C c/o complete. Unit 1 electrical and ISC c/o complete and flush is complete; Unit 2 electrical and I&C c/o complete. l =- n.
_c_ y c. ..a v- .o. i, 19 V ~ '(- 1 9 y? Turbine Bolt He,ater Panels - Both Unit I heater panels have been 1 turned over; one of the panels have been checked out. Four of h r the Unit 2 Hester panels have been turned over; of these 1 heater panel has been checked out. A
- g. Process Steam i
12 of 15 Process Steam Systems have been turned over to CPCo (80%). Performance o'f one Flush Procedure (Demineralized Water Supply) has been completed, i 'I 4 j) Significant Activities completed and/or in progress include: f'a ~ Steam to HP Evaporatdr - I&C C/O complete, electrical C/0 in / / progress. ? b ~~
- )
condensate Return / Unit 2 Condenser, HP steam to Dow Isolation ,1 ij Valves-I&CC/dcomplete l
- f i
,.c LP Steam to Dow Isolacion Valve.- I&C C/0 in progress. ] 1 i PucessSteamBlowdowntI,Dow Electrical and ISC C/0 complete; motorrunhasbeenperformedanhcouplingofpumptomotors ~ ~' complete. 7,- e a f .-t' 9 rl' [ + ~
W k%2: - o =.a__ s. - ~ ~' U ..-~ ~ 20 l ~ ' " condensate return from.Dow - Electrical, mechanical and I&C C/0 complete (for CPCo equipment only). i ). CondensateChemicaladdition-electricalc/ocomplete;[HP i chemical Feed flush, sodium sulfite chemical feed flush and 1 associated pump runs complete. i condensate Supply / Vacuum Deserator - system c/o complete; Dow Domineralized Water Tank (2.5 million gal) is filled with water - for flushes; initial domin pump run 'and flush complete, evap is dearator feed pump initial run complete. L l Feedwater Supply - Electrical, Mechanical, and I&C C/0 is near o completion; initial motor run of HP Feed Pump motor is complete. Iron removal (Condensate Return) - Mechanical and I&C c/o complete. 2 .I bl Iron Removal armp - system c/o and iron removal sump pump run complete. t HP Boilers - Initial checkout, start up, and testing complete, ~ all 3 boilers have been fired up. Process steam plant sampic - I&C c/o complete, s. e i m. o. t .,...i.. p. A=. ,..a 2 + m-g Ai e s.%e. ---.n,. ,--.m,-4.ry...-- .g, 7 .e .e-
n -. .z.,. 21 - h. Programmatic Testing 3 of 5 systems were accepted by CPCo (60%) 3 ) Significant activities completed and/or,in progress include: - The Unit 1 & 2 Reactor Building Tendon Test Facility has been turned over as well as the Unit 2 RB Structural Integrity Test Facility. i 3. Procedure Development
- a. The status of Procedure Development and Approval required for the Test Program is summarized below and detailed breakdown of each Procedure type and Discipline is shown on Table 1.
STATUS - PERCENT OF TOTAL Procedure Type Drafts In Review & Not Approval Total Written Cycle Approved Preoperational Test Procedure 268 23% 56% 21% Acceptance Test Procedures 128 29% 38% 33% i l. ~- l.
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. ar - ??~ 22 1 ~ }I Flush Procedures 168 2% 20% 69% ' Specific Procedures 119 13% 21% 66% Generic Procedures 46 4 22% 74% 729 16% 33% 45% (Total) (Not) (in) (Approved) ~ (Written) (Review) Our goal is to have all Procedures approved by March 1984. Figure 2 shows a curve of Procedure Development - Actual.vs Scheduled. Based upon Rev 12 Test Schedule, we project that procedures required to support Testing Activities will be developed and approved at least 2 months before the scheduled test start date,
- b. The status of Test Program Procedure Performance completions is summarized below and shown in detail in TABLE 2 and Figure 3.
PROCEDURES COMPLETED Preoperational Tests completed - None Preoperational Tests started /not complete - 2 Acceptance Tests completed - 1 Acceptance Tests started (not complete) 0 Fluches completed - 16 .---w-- m- _p.-g. -..---e=__ wa.,
- n
_=- c 23 p Flushes started (not complete) - 17 Specific Tests completed - 9 Specific Test started (not complete) - 23 Generic Tests / Checkout - Checkout procedures are performed for all components, subsystems, controls, and similar items to ensure that they function properly and are installed correctly prior to the start of system Preoperational or Acceptance Testing. Due to ~ the natur$ of checkout (i.e. required for electrical, mechanical, 5 and I&C), the status of checkout is presented below only as an approximate. The " completion" status is assumed that the checkout activity in itself is complete but there may be punchlist items that are stil'1 open and require checkout testing. In addition, the following guidelines were assumed in reporting checkout complete: Electrical - system is checked out and energized Mechanical System - electrical, I&C and mechanical C/0 are complete I&C - electrical and I&C C/0 are complete ../ ..w_- w,
f., _ u : =m- - ~,..-g o y. L ', a.; - i i + Generic Checkout J DISCIPLINE' Percent-Complete r I Electrics 1 83 I&C 37 i' - Turbine /HVAC 24 Feedwater/ Condensate 25 v. NSSS 4 ' Auxiliary System 8 Process Steam 15 Total 45% I In siimmary, 45% of the Systems (850) in the Plant have been initially + ( ': checked out, and 4% of required Tests (Preop, Acceptance, Flush, and Specific) have been performed. I t ,y.-.<*.4 ,,w, m
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. a a. x - III. Project Test Schedule - Rev 12 A. Rev 12 Test Schedule Philosophy The Rev 12 Test Schedule Philosophy is basically the same as Rev 11 relative to the dual Unit startup concept and is summarized in this section. Figure 4 shows Rev 12 Test sequence through commercial-operation for both Units. 1. The majority (95%) of Unit 1 preoperational testing will be performed prior to Unit 2 Fuel Load. This will relieve Unit 1 preoperational testing of restraints and delays due to Unit 2 license operating restrictions (technical specifications and surveillance testing). This will increase U Unit 2 availability for power production owing to fewer interferences from Unit 1 preoperational te' sting. 2. Inherent timeframes are built into the merged schedule to absorb corrective design and/or main *:enance following major periods of integrated initial plant ope'ation and preoperacional testing. Historically, nuclear plant test programs have suffered lengthy delays immediately following the Cold Hydro Test Phase and the Hot Functional Test Phase due to equipment or other operational failures. These failures have in the past slowed and in many cases stopped critical path progression onto the next succeeding scheduled event (s) until repairs and/or design problems were i resolved. These timeframes are shown on Figure 2 as " Resolve Punchlist Items-- ". ~s e v +- c.- e-p y-t ,-w. ---w -.- w r,% ~ r ,w,ky--,.,. ,--1.r.- ,--.w
3 2.;: _s ~ 4 i 3. No two Unit 1 and Unit 2 milestone events are required to be . performed simultaneously. It is impractical to focus site activities on more than one (1) major Unit 1 and Unit 2 milestone activity at the same time. The Midland Site is currently being staffed to permit simultaneous component testing with each Unit but not for simultaneous integrated milestone testing. To do so would require two of every resource j including the Testing Group, Operations Group, Bechtel, B&W, and CPCo Management support. However, one major change in this philosophy is that,.on Rev 12 the ILRT on one Unit is now scheduled to be performed simultaneously with HFT on the other unit. Since Testing manpower requiired to perform ILRT is different from HFT, and since there is no system nor technical relationship between ILRT on one unit and HFT on the other unit, we believe that these two events can occur in parallel. 4. Separation of" Fuel Loads ~ f Unit 1 and Unit 2 Fuel Loads are separated in time to support the Dow requirements with regard to process steam availability. 5. LLRT/ILRT/ SIT are performed nearly piggy-back during the same timeframes. Containment leak rate and structrual integrity testing would benefit by capitalizing on the commonality of equipment, personnel, and vendor support required to perform these tests. 6. The integrated ESFAS Test would be a common test phase. The safeguards system for the Midland Project is essentially a common system in that each plant is designed to respond to the others safeguards action. As such, this particular milestone test for each plant will include the other plant to the extent that neither could provide sustained power during conduct of the test. Thus, ESFAS testing will be performed for each plant at approximately the same timeframe tc avoid duplicatien of effort. and int.crrupe. ion of power production S a the "on-line" pinnt. ~
-r-y ~< ~e nw r w. = i e ."/ 7. Several. disadvantages with the Rev 11 schedule at the time it was developed have become less significant in terms of the Rev 12 schedule. These are: L f a. The potential problem of Spent Fuel Pool area work I' interferring with fuel receipt would be less significant. ti n 4 Receipt and storage of new fuel on site imposes a number of i restrictions on the fuel storage facilities (spent fuel pool area). Typically, this means all activities are limited to either fuel handling itself or to routine maintenance of fuel handling related equipment. Usually, the license for receipt 6 and storage of "special nuclear materials" (fuel) specifically prohibits construction activity or any other dirt generating or heavy maintenance work which could potentially affect clean 1iness or structural integrity of the new fuel. Based upon Rev 12, only 7 systems remain to be turned-over to support fuel receipt. The potential problem of receiving and storing Unit 2 fuel conflicting with construction of Unit 1 (construction access to the inside of the containment) is now much less significant due to large amount of construction work i completed. There is no longer the problem associated with Tendon tensioning on the Unit 1 R3 interferring with fuel receipt because the Tendon tensioning is complete. b. Construction has a better chance of achieving the turnover demand dates since there are only 307 of 850 turnovers remaining. In addition, the CCP concept is predicated on quality work which would result in a more complete system at the time of turnover, i.e. less construction deficiencies. e c. The feedsater and condensate system will not have to be laid up for a long time between chemical cleaning and the start of HFT. i d. We have more time to reduce backlog punchlist open itemc. ..j t -w-s -.4 +.w-e*e*wa---- -e=======-e= - < = = = - - =+==eM w-- p
_ 7;;uw - m pn "'-v ~+ ~'> s-n> 29 7. $1 8. Initial Turbine Roll.s-Three temporary high pressure boilers were installed in 1982 and fully tested to primarily allow early l-testing of the Process Steam Systems which will result in ~ ~ [ ' considerable schedule gains during power escalation testing of t-j Unit 1. The Temporary High Pressure Boilers will also be capable of supplying steam to support Secondary Plant Testing including-Initial Turbine Roll. Early Testing of the Secondary Steam Side of the plant and the Main Turbine will result in overall test schedule gains in the secondary side of the Plant. A Turbine Roll Milestone (TR) has been added to the Test Sequence which is required to be accomplished approximately 1 to 2 months prior to j HFT. The Pre HFT Schedule Gains is expected from being able to 1 perform early testing of relief valves, initial steam leak. tests, e steam blows and flushes of Secondary Side Systems,. B. REV 12 TEST PROGRAM PLAN This section describes the Test Program Plan Revision 12, both in narrative form discussing the Testing highlights and Tabular / Chart i forms showing details of the Test Program. Figure 4 shows the Rev 12 Test Program Schedule Sequence showing the major milestones leading to initial fuel load and commercial otera-tion. Figure 5 shows the full-blown Test Schedule in Tabular form 6 listing the projected start dates for Preoperational, Acceptance. and Specific tests as well as system flushes.
,y..+,+. - = ~ - - b i 30 I c. The narrative presented b'elow pertain to Unit 2; however, due to similarities between the two units, it is applicable also to Unit 1.
- 1. Planned Activities Leading to the Next Target Milestones (B-Auxi-ij liary System Flushes and G-Feedwater System Flushes) i The major thrust during this period is to complete system check-outs and flushes for the 543 systems now in the hands of CPCo (as of 3-31-83).
In addition, approximstely 60 System Turnovers and subsequent checkout and flushing activities are projected to occur during this time frame. 6 i c In the electrical area, turnover of the remaining electrical w power systems and subsequent energization are scheduled to provide permanent power to run the mechanical systems. Backfeed from the 345 KV lines through the Station Transformers will be a major event to ensure that sufficient power is available to support major test events and their power load requirements, and allow testing of the electrical systems. In the I&C area, the major effort will be devoted to completing I&C checkout of instrument racks, cabinets, modules, and annunciators that have been turned over to CPCo. The majority of the remaining I&C system turnovers are scheduled during this time frame to allow as much checkout as posaible in aupport of Mcchan- ) ical systems checkout and startup. Veriffection of input /r>utput s V 4 4 y. v. m- -_-e c.7 w=-- 6 -4.s_ -..-aw - +-ey w y, ai.-_
p y.- - _.g,.1 a. g. %l 31 g-r signals to the plant
- computer, annunciators, indicators, and controls will be an on-going process.
In the primary systems area, seven (7) systems remain to be 4 turned over to support Milestone B-Auxiliary System Flushes into (~ the Reactor Vessel. The major objective during this period is to 3 t checkout and flush the individual auxiliary systems which support the Reactor Coolant System (RCS). These include the DH Removal, High Pressure Injection, RCP seal injection, RC makeup, Core Flood, RCS letdown, and portions of the Reactor Coolant System Cold leg piping. In the secondary side of the planc, the major testing activities involve checkout and flushing of the entire condensate system and the Deaerators. Seven (7) Systems remain to be turned over to allow the next target Milestone (G). to start, which is the Main Feedwater Flush. In the Evaporator Building, major activities in 1983 will include complete checkout and flush of Secondary and Tertiary Systems; complete flusning after remaining five (5) systems are turned over to CPCo; complete Tunnel modifications, and initial piping heatup using the HP Boilers. ij lN
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- 2. Milestone B-Auxiliary System Flushes into Reactor Vessel e
This Milestone involves. flushing of the low and high 'r pressure injection, and Core Flooding lines into the Reactor Vessel. Other activities scheduled to be performed / completed during this period include: Reactor Vessel internals modification and final clean up - Reactor Vessel internals pre-HFT baseline inspection Reactor Cooling Pump Motor initial runs, seal installation, ~ alignment and coupling to pumps, - After flushes to the RV, setting the Core Support Assembly and filling the RV up to the flange level. Conducting the Reactor internals Vent Valve Test, and surveillance specimen holder tube test.
- 3. Milestone C - Refueling Canal Hydro and Wet Fuel Handling Test The Milestone will verify the integrity of the Refueling Canal and the seal plate, and the FH equipment and fuel index test with refueling canal water at its full level / simulating refuc).4r:;
operations). .--e-we.e-.~.... -.me- + .-e - - = - -. - +-m+,.*--e-e- -e--- =- -
~- .s, --, _ 1. s 33 l 'e i 1: s Following CANAL Hydro', several key events take place in prepara-J k tion for RCS COLD Hydro. Some of the activities include the j following: ) Set Planum in Reactor Vessel Vc 4 Install RV Head and Tension Studs i l-Couple Control Rod Drive Mechanism lead screws and install 4j closures. i Fill and Vent Reactor Coolant System Draw Pressurizer Bubble, and Run Reactor Coolant Fumps.
- 4. Milestone D - RCS COLD HYDRO During this test, the RCS is pressurized to 125% of design pressure to verify system integrity. During the Hydro phase, miscellaneous tests will be conducted such as:
RCP Flow Tests MU/HPI/LPI/CF System Tests Secondary Side, Steam Generator Hydro Test x- ~w.e - e n. r -s .~,,.,-p e.-_ --- m n., -
n _,_-. -. c v, 34 0 [ l~ .l Following Unit 2 RCS d.epressurization, test and manpower emphasis will be shif ted to Unit 1. At this point, resolution of punchlist open items will be vigorously pursued and remaining RCS r t i insulation will be installed in preparation for Unit 2 HFT.
- 5. Milestone G - Feedwater System Flush 9
Following the Condensate System flushes and Turnover of the i Feedwater System, the Deaerator will be filled and the Feedwater 1 f Booster Pumps will be used to flush the feedwater system includ-l ing piping through the condensate demineralizers. Other activ-s ] ities during this time period include: b ~ - Turnovers, checkout, and f1tish of remaining systems required for drawing vacuum in Condenser and initial Turbine roll. I
- 6. Milestone H - Condenser Vacuum I
Drawing a vacuum in the condenser involves the checkout and { operation of the air ejectors, vacuum pumps, and the Circulating Water System. Any air inlaakage to the condenser will be iden- ?; tified and required at this time prior to HFT. The permanent Auxiliary Boilers or temporary HP Boilers will be operated to provide steam to the gland seal otcam system and blanketing steam ,f, on the Moisture Separator rehcater, tube side. The HP Heater a y__
_,.y.- p;,. c 35 L d li (_ ' Vents, drains and leve'l control sytem will be in operation. The Turbine will be placed on turning gear with support systems such I' r as Seal and Lube oil, and cooling water, in operation, k i 1 4
- 7. Milestone TR - Initial Turbine Roll 0i Due to the availability of the HP Boilers, the Main Turbine fj initial roll can be accomplished independent of the Reactor it i
Coolant System and Steam Generators. To support initial Turbine J q roll the Condensate and portions of the Feedwater System have to be in operation and the Condenser in a vacuum. In addition, the a 't following systems have to be functional: s ,1 i - Main Turbine Steam Supply and drains. - Moisture Separator Reheater supply and drains
- o d
l' - Stator Cooling ? 1 .1 - Turbine EHC System 'i - Main Turbine Supervisory Instrumentation - Main Generator Protection '._) - Mictovave System
- 1 i
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- 8. Milestone J - Hot Functional Testing i
During HFT, operation ' of-the NSSS and secondary systems is integrated for the first time: The test will-be conducted at ambient conditions, heatup, hot shutdown conditions (2,155 psig and 532F), and cooldown. A significant number of Preoperational and Acceptance Tests will be conducted during this time.
- 9. Milestone K - Integrated Leak Rate Test i
a The ILRT involves pressurizing the Containment above the Design Bases Accident Pressure and conducting a leak integrity _ check to r ensure that the building and penetrations are air tight and capable of isolating the structure in the unlikely event of an accident involving release of radioactivity. Prior to this test, the Local Leak Rate Test of all containment penetrations will be conducted. Based upon the two-Unit startup concept, the ILRT for Unit 1 will precede Unit 2 ILRT.
- 10. Milestone L - Integrated Safeguards Features Activation System Test s
Upon completion of HFT and ILRT, the next major milestone is the SFAS Test. The prerequisites for this test involve: l'l. tw - Reactor Vessel Head Removal s ['fi L.' iJ .e-,, e-,-,t -w-,
{ s., j .,- 7.:.. 2. -.. e g_ i 37 - RV internals removal - Turnover, checkout, and testing of all system / components that receive a signal from the SFAS cabinets. During the SFAS test, operation of all emergency core cooling systems is checked. An emergency condition will be simulated which will cause the plant's automatic safeguard systems to start in response to the signal. The Diesel Generators, HPI and LPI pumps, and containment spray pumps will be actuated. Required <g flow conditions will be verified as well as the order in which systems respond and the length of time elapsed before the re- 'sponse is initiated.
- 11. Milestone M thru 0 - Fuel Lead and Post Fuel Load Activities This phase of the Test Program is called the Startup phase and i
will not be described in this report. For planning purposes, Figure 2 shows the Major Milestone Target dates beyond Fuel Load, and shows a duration of approximately 4.5 months from Fuel Load to Commercial Operation (UNIT 2) and approximately 6 months for Unit 1. ) - - -.. - ~. _ -., .uw, c.- mm-w w o.n ee. - m-u w_ -
.g p....,. -.. 38 ,P% C. Manpower Requirements - Revision 12 Figure 5 shows manpower resource curves for Test Engineers, operators, electrical checkout (ECO) personnel, I&C Technicians, Maintenance Mechanics, Maintenance electricians, and Chemistry and Health Physics Technicians required to support Revision 12 of the Test Schedule. The Midland Plant has been staffed to support the Dual Unit Startup Plan. The resource availability for each of the above resources has been superimposed en the appropriate curves. It is also worth noting that a separate organization, Construction General Service Organization (CGS 0), will perform the majority of work associated with Post Turnover Punchlist items. The present load of CGSO personnel is: Non-Manual - 55 Manual (Crafts) 100 Breakdown of Manual: I Pipefitters and Welders 55 Electricians 35 l l Laborers 10 l t' e. _n y9+ ow. -w.-- +e,
' ~ ' ' a.. _a.- a.- =.. ?c - t I 39 1-c~, In terms of shift work', the estimated durations in the Test Schedule were assumed as follows: 1. The majority of Post Turned-over activities were assigned a 5-day work week, 8 hrs / day. 2. Mainline Activities and Milestones (such as RCS initial fill and vent, RCS Hydro, HFT, etc.) AND key systems (such as Auxiliary Systems required to support RCS Hydro) were assigned a 7 day work week, 24 hrs / day. 3. The majority of System Flushes and initial fill and vent operations requiring Operations support were assigned a 7 day work week, 24 hours / day. l l
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- j SPECIFIC TESTS 2!ti OSP-ANN.02 OC173 Annunciator Cab Energization Approval Cycle 05P-ANN.03 OC155 Annunciator Cab Energization Approval Cycle OS?-AXB.01 Aux Boiler Initial Operation And Boilout Approval Cycle t';
b ISF-CRD.03 Control Rod Drive Tech Stator Pre-Inst Approval Check Cycle 2SP-CRL.03 Control Rod Drive Tech Stator Pre-Inst Approval Check Cycle .D 2SP-DHR.01 Decay lleat Removal Initial Pump Run Approval Cycle b 9 t. ' [] TABLE 2 - TEST PROCEDURE PERFORMANCE COMPLETIONS vi RESULTS , REVIEW PROCEDURE NO TEST STATUS OSP-Fils.06 Receipt of Dununy Fuel Assemblies and Approved Control Rods ISP-NNI.01 Non-Nuclear Instrumentation (NNI) Approval l Initial Energization Cycle i OSP-PIN.05 BOP Rack Power Supply Checkout Approved f: i i. .) = = i ji c i r a e e. 4 E 4, a /f. q ai ~ e r L. , u.s - TT. -
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= -==- ~ r-3 ' URN.ED.0VER SYSTEMS- (543) REMAINING TURNOVERS (307) T 3'6% ~ 64% AUX 7% AUX 3% ELECT 6% ELECT 38% FEED /COND 5% FEED /COND 7%- . I&C - 4% 'ISC 4% NSSS 5% 'NSSS 2% TURB/HVAC 8% TURB/HVAC 8% PROC STM 2%. PROC STM 1% / l TOTAL SYSTEMS ='850 TURNED OVER 5.93 REMAINING = 307 % COMPLETE = 64 8YSTEM TURNOVERS BY DISCIPl INF - (3--81-83) ____.-__-.-__.__-.,,_4 IY. w- -+m - -, -, - -,,,,.. ~,
+ a.= I i NIT 2 yyggo UNIT 2 pygg 12% 39g UNIT 1 yyggo S.5,p, 11% FUEL RECEIPT PROCESS STEAM 5% UNIT 1 HFT 19% UNIT 2 HFT 34%. 79 [ REMAINING SYSTEMS = 307 i REMAINING SYSTEMS BY MILESTONES - (3-31-83) u L 3 1' l* l, n ,____._,,,___,;;;2.,_,_,
- L _ _ _.. - - ,. 7 4 ?, REVISION 12 ***
=
SYSTEMS ACCEPTED = 544 0F 850 TOTAL I noter TURNOVER = = ! 452 b4so a h ! 40
- 4co FORECAST DEMAND j
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e TEST STATUS a I f-(REFER TO HAND 0UT MATERIAL) j EASE ELECTRICAL 2 IaC 3 NSSS 6 AUXILIARY 8 FEEDWATER/ CONDENSATE 10 TURBINE /HVAC 15 PROCESS STEAM 19 PROGRAMMATIC 21 f' l r i i
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t ##. r_ .2, . ~_. u -. z b 1 GENERIC (%) 6% i e i i SPECIFIC (119) i PRE-OP ('268) ^ 37% FLUSH (168)' 23% ACCEPTANCE (128) 18% 1. TEST PROCEDURES - PROCEDURE TYPES (729) (5) [1 t -~n. ~- + e- ~ =-o N
s e i 4 Y t e 7 / / DRAFTS NOT ] / SUBMITTED (119) 1 / 16% j / 1 / l! / / APPROVED TEST / PROCEDURES (328) I
- i 45%
REVIEW & APPROVAL / CYCLE.(ISS) '27% \\ / \\. / ,. ?..... I, \\ ? \\ / ~:' / TWG REVIEW / CYCLE (87) N / 12% \\ j M TEST PROCEDURE - STATUS 3-31-83 (729) I t e ,....einr.is ..si..y i...q we, e
f 2 +.__ . ~ / ,, ~ [ ~ / \\ / APPROVED-TEST DRAFTS NOT PROCEDURES (57) SUBMITT5D (61) 7 21% 23% / A N TWG REVIEW CYCLE (78) REVIEW & APPROVAL CYCLE (72). 27%- I PREOPERATIONAL TEST PROCEDURES (268) r
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..z [ .y .s. 1: 1 ( DRAFTS NOT SUBMITTED (4) / f 2% / / i i / 7 REVIEW & APPROVAL 3 / CYCLE (48) 29% \\ . \\ APPROVED TEST PROCEDURES (116)- \\ \\ \\ 69% \\ y \\ / 6 FLUSlilNG PROCEDURES (168) /% M ND f f i . ~.....
[pf ' a a...- . +.. . =m - ~ " r. i f 1 7 / l f DRAFTS NOT' SUBMITTED (15y f h / 13% l h / l / REVIEW & APPROVAL CYCLE (18) I 15% APPROVED TEST PROCEDURES-(79) TWG REVIEW \\ \\ CYCLE (7) i g- \\ 66% N \\ 6x \\ \\x j ~ ~~ M
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_e. 8 STARTED /NOT COMPLETED COMPLETE PRE-OPERATIONAL TESTS ',1. '. 0 2 '., s ACCEPTANCE TESTS e^^* 1 0 t SYSTEM FLUSHES 16 17 SPECIFIC TESTS 9 23 TOTAL 26 42 TOTAL TESTS REQUIRED (EXCLUDING GENERIC TESTS) 683 % TEST COMPLETE = 4 j l L TESTS CO'MPLETED - (3-31-83) L l l 1
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//j{/f TASK.*;0 : 4 DATE: ASE INTERFRE ;~:.EEE lT TAC =: 141433 PROBLEM: Midland /Clinton - Deficiencies in HVAC LEAD OFFICE: /[/I&E /[/NP.R /1/ REGION / [/ JOINT NOTIFICATION:
REFERENCES:
Itemo to DEisenhut fm RSpessard dated 08/04/83 subject: " Request to Review the Structural Design Adequacy of the Midland and Clinton HVAC Systems." Telecon between D. Danielson and R. Wessman on 8/15/83 regarding above memo. ACTION PLAN:
- 4. 4tt/MTe 5 NRR:
Technical Assistance Ais requested to resolve problems identified in safety related HVAC systems at Midland and Clinton. These problems relate to potentially altered materie.ls specification records. Identified issues concern:
- 1. Evaluate HVAC dthign basis and its implementation by A-E at flidland and Clinton (Midland A-E*is,8echtel; Clinton A-E is Sargent & Lundy) s
- 2. Evaluate Age @c.) ~of analhses' Leing accomplished by A-E with respect to:
- a. adenuac)"of'usterials,
+ .accgatability f substitute materials ' b": 3., Evaluate at.tquacy of progra;ra; for control of design changes and field modifications "in luding onsite anc home o{ ice controls. (Region III to assist in QA aspects) c _4r Prov'de technical suppor,t to Region 'dIlit Midland Licensing Board hearing, i f.' requi red. s t l CONTINUED ON BACK - - - - i s i NRks @ignatt Lead Project Manager to assi n TMS and coordinate correspondence, S m?etings, snJ recorts (ORBn / LB# 4, O. Hood).PM to prepare memo Jo Region III(for DL signature transmitting re'tylts of NRR findings. / ///M. 7 ,,.t OFFICE th0RD1MORS: R.Vo11ber (X 27207) & Holaha .(X27415) !i ? cvah - t,,__. ( X 27425) APPROVED: t h E\\\\i, %s. s. i - (x ) 3g). q (X ) L. Spessard s (Region _y L) { '\\ F. Miraglia (X27492) f. g'. AE0" I'. ' Tnompson, NRR_. R. Purple, NRR ~ t r cc: V. Ste110, ROGR J. Heltemd Regional Adms. D. Danielson,, l'- fli T.' Speis. NRR R. Wessman, NRR J. Taylor IAE \\\\ l D. Eisenhut NRR iead Project Manager E. Jordan, IAE E3*n k q to11mer, NRR .. Adensam, LBP4 (I,;Lainas.NRR 'R. Baer. I&E D. A, A. Schwencer, LB#2 G. Lanik. I&E H.DentonI.ER
- 1. t havak, MR D. TErao, MEB E. Case.
RR //.' Micaglia, NRR D. Sellers, MTEB J.Jniezek, I&E {DeYoung.IAE R. % tt'on, NRR G."Ho13han, NRR H. Abelson, LB#2 s
~ l ACT 0', PLAN: NRRi ~ Requested to assist Region III in determining if these issues impact plant safety, including review of documentation, particioation 'in licensee meetings 'and preparatih'n of a technical evaluation for Region III. (ME 'MTEB) t O 'w h t e s, I i ( e
y $8/ IASKND.: -p8 TASK INTERFACE AGREEMENT DATE: AUGUSI 2 I' SU TAC d: 141433 PROBLEM: 141dland/Clinton.- Deficiencies in HVAC LEAD OFFICE: /[/I&E /[/NRR /1/ REGION / I/ JOINT NOTIFICATION:
REFERENCES:
llemo to DEisenhut fm RSpessard dated 08/04/83 subject: " Request to Review the Structural Design Adequacy of the Midland and Clinton HVAC Systems." Telecon between D. Danielson and R. Wessman on 8/15/83 regarding above memo. ACTION PLAN: % Mt3/MTea flRR: Technical Assistance Ais requested to resolve problems identified in safety related HVAC systems at Midland and Clinton. These problems relate to notentially altered materials specification records. Identified issues concern: (JTkthe men d) *fe. "
- 1. Evaluate HVAC design basis and its implementation by A-E at Midland and Clinton (Midland A-E'Is Bechtel; Clinton A-E is Sargent & Lundy)
- 2. Evaluate adequacy of analyses being accomplished by A-E with resoect to:
- a. adequacy of materials,
- b. acceptability of substitute materials
- 3. Evaluate technical aspects of control of design changes and field modifications including onsite and home office centrols. (Region III'to assist in QA aspects)
- 4. Provide technical support to Region III at Midland Licensinn Board hearing, if required.
C0f!TIl!UED ON BACK - - - - NRR: Designate Lead Project Manag pr4:, sign TACS a -. rdinate correspondence, a meetings, and reports (ORSrr( / LB, a _ n un PM to prepare memo.to Region III for DL signature transmitting results of NRR findings. OFFICE C0ORDINATORS: R. Vollmer ' G. Holahan ) (X27415) (X 27207) T.Noh hJ (X 27425) APPROVED: _ (X ) 1&E) ( } L Sp'lis 7 do~ vi (Region III ) Mu% F. Miraaliaypffgf l I (X27492 ) 9%s cc: V. Stello, ROGR J. Heltemes AE00 H. Thompson, NRR R. Purple, NRR Regional Adms. D. Danielson,, R-III. Speis, NRR R.'Wessman, NRR T J. Taylor, I&E D. Eisenhut, NRR Lead Project Manager E. Jordan, I&E "k R. Vollmer, NRR E. Adensam, LBr4 R. Baer I&E D Gas G. Lainas, NRR A. Schwencer, LB#2 G. Lanik, I&E II. Denton, NRR T. Novak, NRR D. TErao, MEB J. Sniezek, I&E E. Case, NRR F. Miraglia, NRR D. Sellers,'MTEB R. DeYoung, I&E R. Mattson, NRR G. Holahan, NRR H. Abelson, LB#2
t t ACTIOff PLAtt: e t4RR: - Requested to assi* t Region III'in determining if these ; issues impact -plant safety, including review of documentation, particioationL in licensee meetings,\\and preparatibn of a technical evaluation for ' Region III. (MEB,MTEB) ~ vtslee u Q <Et. A<s i -* ( i e f i l~ i. r F e r 9 1
[p reau UNITED ST ATES c ,a a 'n NUCLEAR REGULATORY COMMISSION E' 3.. / E REGION ll1 3g r#, A '[ 799 ROOSEVELT ROAD e G L E N,E L LYN, lLLINOl5 60137 %, *" b' ,c ..,+ AUG 4 1983 MEMORANDUM FOR: D. G. Eisenhut, Director Division of Licensing FROM: R. L. Spessard, Director Division of Engineering - Region III
SUBJECT:
REQUEST TO REVIEW THE STRUCTURAL DESIGN ADEQUACY OF THE MIDLAND AND CLINTON hTAC SYSTEMS As discussed between Mr. D. H. Danielson of my staf f and Mr. R. J. Bosnak of the NRR staff, we request that NRR perform a review of the HVAC design methodology for the Midland and Clinton facilities. These revi s should be of the same type and magnitude as your recent effort (TIA 82- ) relative to the LaSalle HVAC system. As you know, TERA Corporation is conducting an Independent Design and Construction Verification Program (IDCVP)at the Midland Plant. One of these systems is the control room HVAC system and you ray wish to factor this into your review. We intend to use the results of your review to complement our onsite inspection efforts at both facilities. The combination of our respective efforts will address (1) the adequacy of the HVAC systems as they are constructed and (2) allegations of former Zack employees as they relate to Midland and Clinton. We are projecting that our inspection efforts at Midland will conclude on November 1, 1983, and cn January 1, 1984 at Clinton. If your schedule allows, we believe it would be to NRC's benefit to have your effort completed by those dates also. Our contact for coordination of Region III's actions concerning this matter is Mr. Danielson (FTS 384-2610). Please contact us if we can provide you further information regarding this request. f kC 42-4-ac, R. L. Spessa , Director l Division of Engineering cc: G. M. Holahan, NRR R. J. Bosnak, NRR R. H. Wessman, NRR E. L. Jordan, IE J. M. Taylor, IE Directors, Div. Engr, RI, RII, RIV and RV > > n Al tb DM V ' i
P ~ LIMIKARY SOTIFICATION Oy EVEST OR UNUSUAL OCCUUINCE--FNO-III-83-70 Date: 8/5/83 s-prelininpry notification constitutes EARLY notice of events of POSSIBLE safety or Lic interest algnificance. The inforrr.atien is as initially received without veri-ation er evaluation, and is basically all that is known by the staff on this date. ility: Cemsonwealth Edison Company Licensee Emergency Classification: Brdidwood Station - Units 1 & 2 Notification of Unusual Event Braidwood, IL Alert Docket Nov. 50-456; 50-457 Site Area Emergency General Emergency X Not Applicable jcct: HVAC k'ORK REDUCED BECAUSE OF NRC INSPECTION FINDINGS b a result of the preliminary findings of an ongoing Region TTI (Chicago) inspection,
- crk han heen reduced on safety-related heating, ventilating, and air conditioning (H7AC) ~
installation at the Braidwood site. Pullman Power Products, the HVAC contractor, has imid off 46 cs:ployees (primarily craf ts personnc]) as a result of the work being-aduced. Reinspection and program review work by Pullman is continuing. Ih2 NRC inspection, which began August 1, 1983, has identified concerns regarding contractor. implementing procedures for documentation of welding procedures used and s::1d caterial-t raceability. Concerns were also identified regarding CECO audit secp3 and content and carrective actions. The inspection is continuing. Neither Region III nor the licenscc inteuds to issue a news ' announcement at this time. The State of T111nois will be notified. Begion III identified these HVAC prob 1 cms during, an inspection on August 3 and 4, 1983. This information is current as of 12:00 p.m., August 5,1983. .~ e D = NTA 4 d* h Y-4 D. R. unter D. h'. Hayes J. F. Streuter R. C. Knop R. pessard k84-2555 384-2543 384-2541 384-2547 384-2552 IBUTION: St. MNBB Phillips E/W Willste iraan Pciladino EDO NRR IE NMSS OIA RES . Gilinsky PA MPA AEOD r. . Roberts . ELD Air Rights MAIL: . Ascalstine SP INFO ADM:DMB NSAC DOT: Trans Only Applicable Resident Site + b rem ons I n Il IV y Licensee (Cosiysrate Office), n
d' t, UNITED STATES /'*y. NUCLE AR REGULATORY COMMISSION E REGION lit 2-k ,8 799 ROOSEVELT ROAD "g * ( e j GL E N,E L LYN, ILLINOIS 60137 a...+ AUG 4 SS3 MEMORANDUM FOR: D. G. Eisenhut, Director Division of Licensing FROM: R. L. Spessard, Director Division of Engineering - Region III
SUBJECT:
REQUEST TO REVIEW THE STRUCTURAL DESIGN ADEQUACY OF THE MIDLAND AND CLINTON HVAC SYSTEMS JY As discussed betwee Mr. D. H. Danielson of my staff and Mr. R. J. Bosnak of the NRR staff, we request that NRR perform a review of the UVAC design methodology for the Midland and Clinton facilities. These revi s should be of the same type and magnitude as your recent ef f ort (TIA 82- ) relative to the LaSalle HVAC system. As you know, TERA Corporation is conducting an Independent Design and Construction Verification Program (IDCVP)at the Midland Plant. One of these systems is the control room HVAC system and you may wish to f actor this into your review. We intend to use the results of your review to complement our onsite inspection efforts at both facilities. The combination of our respective efforts will address (1) the adequacy of the HVAC systems as they are constructed and (2) allegations of fermer Zack employeer as they relate to Midland and Clinton. We are projecting that our inspection efforts at Midland will conclude on Novetber 1, 1983, and on January 1, 1984 at Clinton. If your schedule allows, we believe it would be to NRC's benefit to have your effort completed by those dates also. Our contact for coordination of Region III's actions concerning this matter is Mr. Danielson (FTS 384-2610). Please contact us if we can provide you further information regarding this request. [ R. L. Spessa a, Director Division of Engit. ering cc: G. M. Holahan, NRR R. J. Bosnak, NRR R..H. Wessman, NRR E. L. Jordan, IE J. M. Taylor, IE Directors, Div. Engr, RI, RII, \\lO RIV and RV 1 k b fd - t
i LIM S?TI)10ATION OF EVENT OR UN"SUtd O'CUPJLENCE--PNO-III 70 Date: 8/5/83 a prolininary notificatier. constitutes EAP.LY notice of events of POSSIBLE safety or lic inscrest significence. The information is as initially received without veri-asien er evaluation, and is basically all that is known by the staff on this date. ility: Cc==c:r-ealth f.dison Company Licensee Emergency Classification: Braidwood Station - Units 1 6 2 Notification of Unusual Event Alert Sraidwood, 11. Docket Nos. 50-456; 50-457 Site Area Emergency General Emergency x Not Applicable >jact: EVAC WORK REDUCED DECAUSE OF NRC INSFECITON FINDINGS As c result of the preliminary findings of an ongoing Region TTI (Chicago) inspection, 3::rk h.u been reduced on safety-related hearing, ventilating, and air conditioning (HVAC)/
- , ~
installation at the Brnidwood site. Pullman Power Products, the HVAC contractor, has inid off 46 cmployees (pricarily craf ts personnel) as a result of the work being' rcduced. Reinspection and program review work by Pullman is continuing. G Th2 NRC inspection, which hcgan August 1,1983, has identified concerns regarding contractor implementing procedures for documentation of welding procedures used and veld caterial traceability. Concerns were also identified regarding CECO audit [ acopa and content and. corrective actions. The inspection is continuing.
- [,
.3 a-Neith'e'r Ker, ion III nor the licensce intends to issue a news ' announcement at this t!ime. I' The State of T111nois will be notified. } F.ep,t en III identified these HVAC prob 1ces during, an inspection on August 3 and 4,1983. i This information is current as of 12:00 p.m., August 5, 198.3. r i .~ Z TO .4 E ~ [ B
- h lCONTA d*
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- f. Streeter R. C. Knop R. b.- pessard 384-2555 384-2543 384-2541 384-2547 384-2552 I
$TRIBUTION: E/W Willste 'St. MNBB Phillips bircan Pc11adino EDO NRR IE NMSS c=. Gilinsky PA OIA RES MPA ~ AEOD
==. Rtbe rt s . ELD Air Rights MAIL: O d'% Q [- =n. Assolstine SP INFO ADM:DMB V CY NSAC DOT: Trans Only 25 Applicable Resident Site D R nions I o II IV y Licensee (Co g orate Office) n
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- 4 Axl RE QUESTE R $ tNtTI ALS
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- l 2
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- t *'
v, af L 7 gs;J g g g - g i /. 9 e - @ ~ A:%. (t'l T L 1 -l t[i @ { i.f $4 W t i I 4 I i l I i I t 1 i i l I i l i 1 1 1 I i 'l 1 1 I i l I I I I t I l i l I i i l l t 1 I I I I I I l l 1 ! I I I f f I I I f I f NRc e ORM 397
l 8L MCO [4 'o UNITED STATES e' /' g NUCLEAR REGULATORY COMMISSION 3 k,'f.. (7 ' E o W AsW NGTON, D. C. 20555 % % f.. l FEB 13 1984 Docket Nos. 50-329/330 MEMORANDUM FOR: Thomas M. Novak, Assistant Director for Licensing Division of Licensing FROM: William V. Johnston, Assistant Director Materials, Chemical & Environmental Technology Division of Engineering
SUBJECT:
TASK INTERFACE AGREEMENT 83-78, REGION III REQUEST FOR DESIGN ADEQUACY OF THE MIDLAND HVAC SYSTEMS (TAC #52311) In a previous memorandum on this subject dated January 24, 1984, mention was made of materials discrepancies, which had been identified that were not expected to cause operating problems with the HVAC system. Specifi-cally, this referred to bolts from Midland which had been hardness tested. Of the nine (9) ASTM A307 bolts selected by Region III for testing by Franklin Research Center, four (4) exceeded the maximum hardness for ASTM A307 Grade A. Another bolt exceeded the hardness maximum for Grade B but not the hardness maximum for Grade A. However, ASTM A307 states (in 1.2) "If no grade is specified in the inquiry, contract or orders, Grade A bolts shall be furnished." As no grade was stated in the information provided, it is assumed that all bolts were Grade A so only four (4) of the nine (9) tested exceeded specification requirements. The maximum hardness found on these four bolts was Rockwell C 29. In a telecon between W. Hazelton of MTEB and D. Danielson of Region III, it was agreed that MTEB would determine the preload necessary to merit concern for potential stress corrosion failure and Region III would perform a breakaway torque test on a selected sample of installed bolts of the same type exhibiting the nigh hardness. l Calculations have been performed that demonstrate that the subject bolts, although in excess of the specification requirements, would probably not be in a stress corrosion regime at Rockwell C values much below Rockwell l C 35. Because the highest hardness found in the Midland sample bolts was Rockwell C 29, we conclude that torque testing of the installed bolts is not necessary. l} <Y WilliamV.Johnston(AssistantDirector Materials, Chemical & Environmental .,/ 4 /lN h,/h 3 Technology 1-Division of Engineering 4 'f e w. ee age 2
Contact:
C. D. Sellers y '3' 3 n,vyj _ X-28049 v i
l EE.h I J 1903 Thomas M. Novak cc: R. Vollmer D. Eisenhut E. Sullivan R. Bosnak J. P. Knight L. Rubenstein
- 0. Parr E. Adensam M. Mill y
'bTHood( ~D. Terao W. Le Fave B. D. Liaw S. Pawlicki D. Danielson, Region J'I F. Hawkins, Region III W. Key, Region III W. Hazelton R. Klecker C. Y. Cheng C. D. Sellers DISTRIBUTION: Iris - Docket Files MTEB Reading Files MTEB Midland Files 1 DE:MTEB(D2 DE:MTEB h D Ei DE W. C T C. D. Sellers: jar W. Hazelton O [ B. D. iaw W. V. Johnston 2/9/84 2/ f /84 2/ g /84 2/ 13 /84}}