ML20105C684

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Advises of Planned Concentrated Review of Nonconformance Area.Overall Nonconformance Sys Including Trending Methods & Individual Nonconformance Repts Will Be Reviewed
ML20105C684
Person / Time
Site: Midland
Issue date: 09/27/1979
From: Knop R
NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III)
To: Fiorelli G
NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III)
Shared Package
ML20105C399 List:
References
FOIA-84-96 NUDOCS 8502090493
Download: ML20105C684 (1)
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Text

{{#Wiki_filter:Nv se ner UNITED STATES [ 8,, NUCLEAR REGULATORY COMMISSION g S REGloN lli 5' f 799 ROOSEVELT ROAD O, si GLEN ELLYN, ILLINOIS 60137 %, * * * * * / September 27, 1979 6i,. 1 MEMORANDUM FOR: G. Fiorelli FROM: R. C. Knop M

SUBJECT:

MIDLAND NONCONFORMANCES AND RELATED DOCUMENTS From time to time we have reviewed the nonconformance system at Midland in piece meal form and also as a system. During the past year we have accumulated a large number of these reports and it appears that we sh'ould again at this time do a concentrated review of the nonconformance area. It is felt that this activity is significant enough to relieve our resident inspector from his program work for approximately 50% of the time for a two month period. Additionally it is requested that other personnel be made available ~ for approximately one man month of effort to assist the resident inspector in this effort. The review will exclude areas heavily reviewed such as soils and will be centered on those NCRs which appear to have true safety significance. Timeliness and generic consideration of the NCRs by the licensee will also be considered. The overall nonconformance system including trending methods will be reviewed as well as individual nonconformance reports. This memo is to inform you that during the performance of this review it is assumed that some parts of the regular inspection program will slip. (f O o R. C. Knop, Chief Projects Section 1 cc:f.G.Keppler R. J. Cook T. E. Vandel fh2 93 840517 RICE 84-96 PDR o 3

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Dec2=er 6,1979 ' h Dxkst Ms. 50,?29 g-l . f: y Gv' so-uo M@ Consars Fewr Ccsca:rf ATnh W. S'h li, huell Vic.a Fessident i 1S15 %st Parr111 Raad f h :Isen, XI 45201 Gentlemen: h; This letter transmits to you an Ordtr Modifying Constnction Fermits M. C.CPR-81 and Mo. C#FF.-82. This action is being taken as a resuh of fir-dings by ins;ectcrs it:aa Region Ill, Office cf Icspection and Enforces,ent nacs during toe period of October 1976 to slan Airy 1973, ans the can;1usions of te, j hE staff after reviewing respsnses to the 10 CF:. 50.51(f) recuest of March [ 1973, ngarding tM proposed recedial work under and aro:ind safety-nlated y strv:t>JMs and systems at the site, son of wnice is currently uncarway. Th Croer pertains to the probites associated with t?,a soil foundatio., materials at th* site. As part of the Orcer there are two H3tices of Viciation. ins first Motici e Violation is Appendix A which contair.s infom:;io.i con:orning fear infra: tic vich several exas;1es, all of which relate to tM soil fou1catien prc61ecs. The st:ond hatice cf Vis!ation, Appenjix S, contains inforEtion ccncerning ites of no.7 ocliance which e.s detersinac to be a sterial false statemat. A:tions that Constners Ppw r Cupany may take as a result of this Order are e cas:ritad in te,e Order. k e

Sincemly, Sincerely, x

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rd. i g j.i. f""x.T a UNITED STAT ' j ()ff NUCLEAR REGULATORY COMMISSD : gi !l thj4// OHica.of Public Aff 5 II m An Er.m a, 3..H:. Washington, D.C. 20 ki {P 4 <a W. s- .,. 3, 7 a _.n.c,: r w. r, v u.e c.D a n'. - -- t y),c -' m i. C:ntact: Frank Ingrat '.% iled - Dece-bar 6, 1979) .~.e.,.t. .i. n..t.,/,,. c. % 7. _7 4, .w..w.. c v. r S (s a. ie - e.t.e e.-.r C.o. ? r P.u. _t e. .s.e.

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.w.s h. 4 ... O A w. 3 y, .=e h be r.,.- = -4.v. trC...:3 e. n. e. ?... e. .t, '_r *2..c. w A c - he Nuclear Regulctory Co:.ission's Staff has LSSued an i 3 ceder to Conct: ers Fever Company suspending re: edial vark cri sAstaniard scil and fill beneath sore safety related strue:urt h /g and syst.e-.s and related verk at the utility's P.idland UC0 lear Power Ststion at P.;diand,.tchigan. The crder, issued Dece:her, 5, 1979, unless contested, Ill beca e effective and will continus in effect until the utility receives NRC staff approva'. of plans tc correct scil Ky and fill inadesueciee under the plant's diesel generatcr L building, water storage tanks, underg cund piping.and Other ? saf ety-related structures and systen.3. h e In August and Septenter 1973, Cons =ers PWer Company-repcrted to the NF.C stati that e>:cessive settiinc cf the d:esel gener-tcr building had teen observed. The settling of la cr was attributed tc inadeque..e a:id pocriv. ~~.- "'ad

  1. 4'i r.2:erial under the building and under Other saf etv.-relsted structures and systens at the -lant.

e 'n an investips::cn C:tcher 1979 thrcugh F. arch 1979 UEO r,1 inspe tors deter.ined that des.lgn and construction soecif-ications had ne* been fcileved dur.n: platenene. of the soll e-g fl.. natoria s and : hat. hore was a ac..< cr con:rol anu. fi supervision of the fill activities by the utility and ats D 00ntrac Ors. V rd In addition, the nc stdf has dete=ined that the utiliti 3... ; : a.:_, As . e,.,.,. g. _..:..., 3.: +,.c

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n. ..y.. r_- .n 3rrectly described the typ: Of fill nk:Cridi actual'.y 43ef for sene safety-related structuron, L V Since the ' n;;ial rep 0rt Of the fill inadequatics, the ut:.11ty has ccatinued ic subri infor: aticn to the NRC cn tho t.r:blan, both as part ti the NRC ret. ort:.ng requiremients cr.d ir d response to specific rscuects frc: the NRC staff. 4 l' .3 "W g 3, f*.. s .3 h *,

Y[, . 79-215 Bu N 8 3ased en the inforration. subritted thus f ar, the SRC staid ' Q li his not been able to c;nclude that the remedial action planned 1 t.y the utility is acceptable from a' safety standpoint cr the: ~ ~ he af fec:cd portions of there is rea;cnable assurance that t the M;diand facility can be constructed and cpareced without p undue risk to the health and safety of the public. f.. The ordor, issued by Victor Stello, Diractor of the NRC's Ei Of fice of Inspection and Enforec. ent, and Harold Denton, Directcr of the NRC Of fico of Nuclear Reacter Regulation, directs that the ccnstruction percies for tae Consuners PcWar Cenpany's M dland ' nits 1 and 2 he redified to prohibit J further work en the placement, cc paction er exectation ot safety-related fill caterial under and around cartsin safety-related structures and systens until a conss.ruction per:1t The q acendrent has been applied for and granted by :ne NRC. g order becomes effec 2ve af ter the ceriod during which a haaring tay be requested han expired or an order has been issued following any hearing on the tatter. The utility or any persons who=e interest has been nff ected ety request a hearing on the ords: u; thin 20 days. S I!, a l ~ I. 6 rs 1 re ,Q i y, l e O

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--- - - - - -.-- - - - - - - - - - ~ ~ - i.. , e. m?.o .-6~ w w. _l The Licensee or any person w sose interest 15 af fectM Dy this Order may within 20 days of the date of this Order reouest a hearing vith respect to all or at:y part of this Omr. I n the e v e n t a be a r t reg i s reques ted, the f e sues to be cons ide r-d wi l l be t t (1) wnether their facts set forth in Part II of this Order are carrect; and (2) whether this Order should be sustained. Tr.is Oroer win becosre effective on t.he espiration of t.no period durira wnich a hearing may es reques ted, or in the eve *et a hearity it requested, on the cate specifisc in an Order made fol tewinft the hearino. " ' N'* FOR THE Mu: LEAR REGULATORY COMISSION / - ~ - - - ~ ......._.n......, e k Akd.% !MW e son G. Case. Ayti ng; Li rector Victor $tello,.3r.4 Director rrtee of Nuclear Reactor Of fice of t hsovct;1on Pegula t. ion And 5.nforcement Att achments: 1. Appendia A 2. A9perCtu E Cat,ed zt Bethesda, Maryland. t, s. ~ ..,.,....,.c. -,. N w w w w as.am_m. aa_ m m m.. p.a.e.w n.-a...-~, ~?v~~.mo. .,,%_~...,.s 1.w..

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CML ATTAGED IS A PART 21 REPORT FROM IE f%Il UNIT - ROOM 359EAl W PART 21 IIETTIFICATION l0. 90 -/75 -01 C0fPAt# t#E% of MIE OF LETfER 4[rr/ P o D00ETto. DATE DISTRIBUTED Y//7/to 0RIGltML REPORT [ SUPPLBBfTARY,[ DISTRIBJTION:

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am ae g PEACTOR(R) F.:717sj i REL CYCE & SAFEGUARDS (S) MN;Ti-l i-/ lWTERIALS(M) NRR/IDRMP3hkVdA*4f -O/FFMSI - AD/SG-IE v% _ HRR/DR4 DIRECT 5f"/' lies / fos AD/RDI AD/RDI ( 2 ) PEGIUiS REGIONS AD/RCI lE FIES l!RR/IDR,DIPECTOR REGIO PJR IMSS/SG SS-881 IE FIES (2) LPDR PDR CBriP/L FILES CENTPAL FIES-SS-395 LPDR CBfiRAL FILES (OFUD CSTT AL FIES(CHRD.'O TEPA (01 PDR IE FIES (2) LPDR CBITPAL FIES 016 TEPA L0EBAPA l4G 5715 CBiTRAL FILES (CH! CENTPALFILES-S! LCE3#PA liG 5715 ACTION: LDEBAPA liG 571 PRELIMillARY EVu'd.ATION OF TIE ATTAGED REPORT INDICATES LEAD RESPONSIBILITY FOU.Gt-UP AS S O ( BELN: JE,( IE 2 ~ Mfd 2 DIlB'E SG FFMSI .t ,.y , ~.. Erv, 2/26/80 L%ID

amencan warming anc ventilating inc April 8, 1980 90 -19 7 ~0* U.S. Nuclear Regulatory Commission Washington, D.C. 20555 Att.n: Director, Office of Inspection and Enforcement t l From: American Warming & Ventilating, Inc. 1310 Indian Wood Circle Maumee, Ohio 43537

Subject:

10 CFR 21 Notification Dated February 6,1890 Centlemen: As a follow up to my notification letter of February 6, q 1980, AW has been notified by ITT General Controls that the I,n y Data that was to be supplied by April 1,1980 will not be in the 4 [ mail to AW until the week of April 14 thru 18,1980. Upon receipt y y AW will evaluate the subject Data for completeness, convert the actuator force values to torque and then compare the torque to the required damper torque values. It is estimated that this effort will take AW several weeks to complete. Please be advised that AWV has been at work gathering and compiling the damper data required to make the above comparison since the original February 6, 1980 notification date and every possible effort will be made to clear up this matter as quickly as possible. Note: The attached listing of AWV's affected customet%"have also been notified of this developement. Very truly yours, t N Donald E. Sloan Quality Assurance Manager cc: W.B.B., R.L.B., R.L.A., J.M.T., R.J.M., D. S. L'., S. F. G P o DOA 379 1310 INos AN WOoo ComCLE MAUMtE ohs 0 43S37 14193 99 Mot t ) APR.16 Fm ^"c' ~'-a a .th20c5t9me

d Titl2 Attcchment to Tchruary 6, 1980 Letter to th2 N.R.C. cencerning ITT A1190 series cr Nil 90 ceries Actuators supplied by ITT Ceneral Controls. The following is a listing of American Warm'ing & Ventilating. Inc. Customers and Projects af fected and notified: 1. Duke Power Company; Bahnson. Services McGuire Nuclear Station AW Job No. 80290 2. Cincinnati Cas & Electric Company f

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Wm. H. Zimmer Pwr. Sta. - Unit I-AW Job No. 90083 ,,, f ' ' 3. Powers Regulator; Stone & Webster Engr. Corp. Shoreham Nuclear 'AW Job No. 90084 4.- Bahnson Services ,y McGuire Nuclear Station AW Job No. 90096 [ 5. Powers Regulator En. H. Zimmer Nuclear Power Station AW Job No. 90120 6. Powers Regulator LaSalle County Station AW Job No. 90121 7. Bechtel Corp. (San Francisco) Susquehanna Steam'Elec. Sta. Units 1 & 2' ' AW Job No. 90125 8.

  • Tennessee Valley Authority I

Bellefonte Nuclear Plants Units 1 & 2 AW Job No. 90162 ~9. Tennessee Valley Authority Bellefonte Nuclear Plants Units 1 & 2 AW Job No. 90163 10. Ebasco Services Waterford Unit f3 AW Job No. 90181 l .3 j 11. Bechtel Corp. (San Francisco) Limerick Generating Station AW Jon No. '90186 l f e' a I..

..a uu s y 12. Eb::sco Services St. Lucie #2 AW Job No. 90193 13. Stone 6 k'cbster Eng. Corp. ; Duquesne Light Besver Valley Power Station - Unit No. 2 ~ AW Job No. 90216 4. Bechtel Corp. (Ann Arbor) Hidinnd Plant AW Job No. 90235 15.- Ecchtel Corp. Hidland. Plant AW Job No. 90236 SIGNED: / h ~ TITLE: MM Mmo DAT': 2 /4,/80 ~ E ~ Revised 3/19/80 to Include: 16. Buffalo. Forge Co. St. Lucie AW Job No. 90263 -b SIGNED: m TITLE: O M. Mme ~ f DATE: 3 S./JIo ~

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GLEN ELLYN. lLLINolS G0137 April 30, 1960 ~.{. .,3 MEMORANDUM FOR: G. Fiorelli, Chief, Reactor Construction j and Engineering Support Branch \\ , 4C THRU D. W. Hayes, Chief, Engineering Support Section 1 ' FROM: E. J. Gallagher, Reactor Inspector CONSUMERSPOWERCOMPANYMIDLANDUNITS1AbD2

SUBJECT:

ANSWER TO NOTICE OF HEARING --~~'# Refs (1) NRC Order Modifying Construction Permits i dated December 6, 1979 (2) Consumers Power Company Answer to Notice of Hearirg As per your request, the following are comments to Consumers Power i Company (CPCO) submittal entitled " Answer to Notice of Hearing" regarding the Midland Unit 1 and 2 construction projects 1 ^ 1. CPCO response (pages 2-3) denies the statements made in the NRC order (pages 1-2) which states,.... This investigation revealed a breakdown in quality assurance related to soil construction l activities under and around safety-related structures and systems in that (1) certain design and construction specifications related to foundation-type material properties and compaction requirements j were not followed; (2) there was a lack of clear direction and support between the contractor's engineering office and construc-i tion site as well as within the contractor's engineering office; (3) there was a lack of <:ontrol and supervision of plant fill placement activities which contributed to inadequate compaction of foundation material; (4) corrective action regarding nonconformances related to plant fill was insufficient or inadequate as evidenced by repeated deviations from specification requirements; and (5)'the TSAR contains inconsistent, incorrect, and unsupported statements with respect to foundation type, soil properties, and settlement values". l Comments l A " breakdown in quality assurance" did substantially occur in the soil l construction activities and the list of five items above were contributing factors to the failure of the licensee to control the backfill and its l placement and compaction at the Midland site. o,dLb5 r vvr u

8 i G. Fiore111 2-April-30, 1960 2. CPCO response (Appendix, page 2) denies the findings with respect to the Borated Water Storage Tanks and states that,... The ~-). assumptions used for the borated tank settibment calculations are .,j appropriate for the type of design utilized". Comments A uniform rigid mat foundation will not behave in the same manner as a flexible circular ring wall foundation. The inspection finding indicated the lack of design control interface and verification between the geo-technical group who performed settlement calculations under the assump-tion of a uniform rigid mat foundation while the civil / structural group performed a design and analysis of the BWST using a ficxfble ring wall foundation. 3.' ' CPCO response (Appendix, page 3) states, in part, that the.. " Licensee denies that instructions. provided to field construction for sdostituting lean concrete for Zone 2 material were contrary to 10 CFR 50, Appendix B, Criterion V". Cc= ment: Loan concrete material was permitted to be used indiscriminately by the Bechtel letter dated December 27, 1974 which states, " lean concrete back-fill is considered acceptable for replacement of Zone 1 and 2". This instruction was given without proper consideration and coordination, and its effect on other design basis, i.e. settlement effects. The instruc-tion which was b;plemented was therefore inadequate and contrary to criterion V. 4. CPCO response (Appendix, page 4) states, in part,..."Licencee denies that Quality Control Instruction C-1.02 is contrary to 10 CFR 50, . Appendix B, Criterion X, CPCO Tbpical Report CPC 1-A, Policy No. 10, Section 3.1 or ANSI N45.2 (1971)". Co==ent QCI 1.02 (quality control instruction for soil placement) did not provide a comprehensive and adequate program of inspection of activities affecting the quality of safety-related structures. The QCI permitted a random surveillance of an activity which required 100% inspection in order to verify soils material was placed and compacted to design requirements. o 9 b

_s ~, G.'Fiorelli April 30, 1960 s 5. CPCO response (Appendix, page 4) states, in part, that the... " Licensee denies the general allegation that " measures did not assure that soils conditions of adverse quality were promptly '0 corrected to preclude repetition". Licensee denies that its (*J f actions and measures were contrary to ]O CFR 50, Appendix B, Criterion XVI". Comment: Adequate measures were not taken by the licensee to preclude repetitive nonconforming condition adverse to quality by virtue of recurring deviations of moisture control and the erroneous selection of laboratory standard used in attempting to achieve the required compaction. 6. CPCO response (Appendix, page 8) states, in part, that the.." Licensee admits that " materials other than controlled compacted cohesive fill were used to support the Diesel Generator Building". Licensee alleges that only controlled and compacted fill was used to support the Diesel Generator Building". Cc==ent: Material other than cohesive fill was used to support the Diesel Generator Building. The material was random fill, which was of any classification and consistency. However, controlled and compacted fill was not used. The compaction of material was not controlled by either its consistency or by the method of compaction. The equipment used in attempting to co: pact the fill was not qualified to a particular method of compaction, i.e., lift thickness, material type, and equipment used, and therefore not placed under controlled conditions. It was later determined that the method used could not be qualified to achieve the. required density of the fill. CPCO's response to the NRC order admits to a number of technical details of Appendix A of the order. The items admitted to are consistent with previous NRC findings. If there are any questions regarding the above, please let me know. "rs;.I,) j E. d. Gallaghak cc J. G. Keppler D. W. Hayes R. C. Knop T. Vandel -> R. Cook

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3 EPL-1 3 1 Paragraph 4.2 Procedure 10. Se:tico 5 of the Ee:html Midlasd ~~' "' Fuelear Quality Assurs.n=e Kasus1 requires that the cliect he ..L_tl' r.otified tac:4diately when a supplier actifies Rechtel of a ""' *# 'r f . / r. 10CTI.21 report. (Conte on Fase 2) U" .I ,,-8-80 8 c no n.e apparant root causes are: 1. A failure of Bechtel Field persocnol to recognita or understand } the NQAM requirement and, t. A failure of Bechtal sad NFSI to properly comunicate, under- /b stand and co 17 with the rsportability requirements of the Z,"n*J.", assxNR&MG:.5 lachtel is requested to ' 1ADreisbach i 1. Datent.ine vby CFCo was not actified f= =diately of the 10Cn.11 report.

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2. Raview the violatica of the NQAM require: ant with all Bechtel RC24uman JAF.utgers persojel who were avsta of the 10Cn.21 report. L'2. Bird t-j (conta en Pare _2) M ock E. -._ --,-, w ooke in :merr w man c me, J1Corley as LE0urtis d M I 1.ZDavis SGowell q 3*='Marguglia..* i JNftandia ' t. N I DEMiller m-no czur res ame ums. q .P. n a : w cures==r m acne emeurus. '( 1 r u rra e earns emmaa avi anus. u- =,.i=== a e. 2 pa m aum.nuw -- rvi - .s ,1 1 y g., 'T,1 l;, h A l I.. m....=.u. a.,, m..m m... I i. L

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.M iic m QUU.1TT F R. LIM Ctx.Eu IIDI: i}, s ctd from Page 1) - % 'i l 'V 1 l 7# _a t.) ' _.j l Do July 30, 1920 CFCo was 1.nformed by the UrnC that NFS Industries. Inc (IFSI) tk. f E had issued a 10CI121 report en the Midl.and Project pipe whip restraint broken j belt reckles. 1squiry revs. clad that on Jese 13, if *G Suht 1 had L.es s.o:ified 1..g.Q, of bPSI's intent to file a report, on June 16,1583 NF11 did maka a submittal I to the h7C and that EPs! had forwarded a cepy of their report to Bechtel by a y -; y

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I cever letter dated June 20, 1950. This transsittal to 5 chtel was addressed i g to the se:htel Site Manager with copies to the Project Field Eegineer,' tbs f--.s]-

laad Field Civil Engineer, and Field Procursac.c Supervisor. CFCo was first n

prev 14ed a copy of the 100F1J1 report on July 31,1980. - Attachment No 1 to 's fe ' this tcAFJt is a chrocology of ernsts related to the outject of reporcability g ff j as ascertained to this date. h yh I evisten 4 of techtel Purchase Order 7220-F-3107Q was isaned to NFSI on February _ t ' :" 2 '.. _. % =_j L22,1978 and states, "This purchase crder is subject to reguistion 10CI121 as ' = 1 rer attached ' Exhibit A' v* ich by this reference is in:orporated into this FC". ... -. J " Attachment No 2 to this M*.n1 is the 'Fshibit A'. currently used by Field Fre- ~ Qw' fcurement. To date Field Procurement has been unable to produce the actual ,. i u;. ' 'Fshibit A' wT16w,as sent ta EFFI. ~ L'- '-C MCM j J1though Revistos 4 to Order 7220-7-3107Q was acknowledged by NF5I on March 27 A D {*(did not centain 10CF121 reporting requires.ents. 4978, on May 13,1980 MFS! told CPCo and Rechtal that theit order from Bechtal s '. ',, U;N. " The submittala to Rechtel 6de by NFs! on June 20, 1980 are not in accordance with the requiremants of j i ! c.,. i_ l'EzhibitA'. Specifically, the report was sent to the wTong Bechtel personnel. In addition, it appears that the deviation in question requires evaluatico by .k D b g U behtel in order to detemine if the deviation from specification requirements 9 4 ble case, but there is saParagraph (4) of 'Ezhibit A' identifies the procedure for l 1a indeed a defect. i evidence that Bechtel participated in the determina-Co. g u, 7 4._. O#., $6)TJTI2) PROCESS COFJICTIVE ACTIGl: k,d'~~1' \\ i;,., $d free Fage 1) f. l M W,9 I J ' 4 Involved with 10Cf121 or 10CF130.55(e) reporting.For= ally re-emphasize the NQA r!. U I ! h, ', *'. { l l ,etermine why the Field Procurement files do not contain a couplete record if the purchase order revisica sent to NFSI. /' f ! valuate the adequacy of the field purchase, rder wording for 10CTR21 report- .bility requirements and make changes as necessary. Specifically, address b*i '. larity needed tor g i . C..Y; j p{.'S i. Insure the vendor recognites his obligation under the law. J-5 l J I .n.sure both Bechtel and supplier personnel understand the specific 7',.9S d

.9'. 4 contractual requireaants for reportability.

l >, M.# 71, Insure the participation of both the supplier and 3echtet when l "",f'd to cake the deternisatioe. of a defect tr. at:ordance with %*p j' g n'.%,..,, '^ W f 2 an- --m m,p a ~ .e 4 -}}

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