ML20003C759

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IE Insp Repts 50-329/81-01 & 50-330/81-01 on 810107-09. Noncompliance Noted:Inadequate Procedures,Document Control & QA Records & Deviation from Commitment to Provide Geotechnical Engineer
ML20003C759
Person / Time
Site: Midland
Issue date: 01/28/1981
From: Fiorelli G, Gallagher E, Knop R, Landsman R, Sutphin R
NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III)
To:
Shared Package
ML20003C751 List:
References
50-329-81-01, 50-329-81-1, 50-330-81-01, 50-330-81-1, NUDOCS 8103180215
Download: ML20003C759 (13)


See also: IR 05000329/1981001

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U. S. NUCLEAR REGULATORY COMMISSION

OFFICE OF INSPECTION AND EhTORCEMENT

REGION III

Report No. 50-329/81-01; 50-330/81-01

Docket No. 50-329; 50-330

License No. CPPR-81; CPPR-82

Licensee:

Consumers Power Company

1945 Parnall Road

Jackson, MI 49201

Facility Name: Midland Nuclear Power Plant, Units 1 and 2

Inspection At: Midland Site

Inspection Conducted: January 7-9, 1981

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Inspectors:

E. J. Gallagher

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R. B. Landsman

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R. N. Sutphin, Jr.

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Reviewed By:

R. C. Knop, Chief,

Projection Section

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Approved By:

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Reactor Construction and

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Engineering Support Branch

Inspection Summary

Inspection on January 7-9, 1981 (Report No. 50-329/81-01; 50-330/81-01)

Areas Inspected: Consumers Power Company response and implementation of

corrective actions regarding the 10 CFR 50.54(f) request of question 1 of NRC

letter dated March 21, 1979 and question 23, request for e;dditional information

dated September 11, 1979; procedures, quality records and observation of work

related soils work activity; quality assurance organization status, construction

schedule; and status of personnel air locks. The inspection involved a total of

60 inspector-hours on site by three NRC inspectors.

810818o [

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Results: Three items of noncompliance and one devistion were identified in the

above inspected areas - Severity Level IV, Inadequate Procedures; Severity Level

IV - Inadequate document control; Severity VI - Inadeqt. ate Quality Assurance

Records; Deviation from commitment to provide Geotechnical Engineer.

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DETAILS

Persons Contacted

Consumers Power Company

D. Miller, Site Manager.

  • W. Bird, Quality Assurance Manager
  • T. Cooke, Project Superintendent
  • R. Davis, Quality Engineer
  • R. Wheeler, Staff Engineer
  • D. Horn, Civil Group Supervisor
  • H. Leonard, Section Head, Quality Engineering
  • D.'Turnbull, Site Quality Assurance Superintendent

D. Keating, Section Head IE and TV

Bechtel Power Company

  • J. Russel, Assistant Project Field Quality Control Engineer
  • E. Smith, Project Field Quality Cor. trol Engineer
  • P. Corcoran, Resident Assistant Project Engineer
  • P. Goguen, Lead Civil Field Engineer
  • J. Betts, Assistant Field Project Engineer
  • H. Deitrich, Project Quality Assurance Engineer
  • L. Snyder, Resident Quality Engineer

U. S. Testing Company

J. Speltz, Lab. Manager

The inspectors also contacted other licensee and contractor personnel during the

course of the inspection.

  • Denotes those in attendance at the exit meeting on January 9, 1981.

Licensee Action on Previously Identified Items

(Closed) CPCo Action Item: S100D, NRC Inspector E. W. K. Lee's concern regarding

" unreadable documents" in one of the document packages for a shop weld, as ex-

pressed.by the inspector during his October 9-10,.1979 inspection, and item "D"

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of J. L. Corley October 12,~1979, Midland Memo No. 344FQA79. CPCo determined that

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documents of concern applied to spos t piece 2CCA-61-S611-2-6 wherein parts of two

radiograph reports were not legible due to copy machine problems. Legible copies

were secured for this file.

In addition Bechtel QC reviewed 20 other M-104-A data

. packages and found 9 out of 298 pages in similar condition. Legible copies were

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made of all' discrepant pages and filed, as recorded'in L. A. Dreisbach Memo

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LAD 168S of August 8,1980, ,to J. L. Corley. This item of NRC concern is closed.

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(Closed) 329/79-12-01; 330/79-12-01 " Work Prints in use were not current :evision",

CPCo Action Item S500. CPCo advised inspector that incorrect issue (Rev. 11) of

print was removed and correct issue (Rev. 12) provided to the work area at the

time of the original inspection.

Current issue of the drawing is Revision 14,

issued September 14, 1979, title of the drawing in Question is " Decay Heat Removal,

Core Flooding System Unit 2 Hangers, Location and Identification". Three audits

have been performed since the original inspection. One was reported in May 1979,

one reported September 9, 1980, and another reported on Tovember 24, 1980, the

results of which indicate a significant improvement in the revision control of

work prints.

Based on this corrective action and commitments by CPCo to maintain

a continuing program of audits in this area of activity, the referenced item of

noncompliance is closed.

(Closed) Unresolved Item 329/80-11-03; 330/80-12-03, " Snubber Missing Required

Spacer". Two snubbers were found to have one missing spacer washer each, however,

they had not gone through the regular inspection and acceptance by Quality Control

at the time 24 pipe supports in various stages of inspection and installation were

observed by the NRC inspector. As a result of the express concern of the NRC

inspector training was planned and conducted on June 10, 1980, construction corrected

the condition of the two snubbers, and documented the inspection on a QC-G1-1 form,

and activity 3.1.c in the P-2.10 PQCI has been added to verify future configurations

and orientations are correct, per M. A. Dietrich Memo No. LAD 1754 of November 12,

1980. Based on this documented corrective action, this unresolved item is con-

sidered closed.

(Closed) CPCo Action Item: S479, NRC inspector R. N. Sutphins concern regarding

lack of update of EDPIS per comments in NRC reports No. 50-329/80-30; 50-330/80-31,

Page 11. The inspector checked the two items in the Bechtel Power Corporation

Engineering Department procedures manual and found them to be in proper order.

This concern is closed. However, additional technical review of the Engineering

Department procedures manual will be conducted at subsequent inspections.

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Section I

Prepared by

R. N. Sutphin

Reviewed by

R. C. Knop, Chief

Projects Section 1

1.

Functional or Program Areas Inspected

a.

CPCo Quality Assurance Organization

The inspector reviewed the organization chart of the combined CPCo -

Bechtel Quality Assurance Organization, issue date January 1, 1981.

Mr. M. A. Dietrich is (Acting) PQAE replacing Mr. L. A. Dreisbach who

has been reassigned.

Mr. D. M. Turnbull had reported to the site in

the position of Site Project QA Superintendent. The combined Midland

project Quality Assurance organization now has 40 persons assigned

compared to 36 as of mid October 1980. The supervisor of the adminis-

tration Group reporting to the site project Quality Assurance Superin-

tendent will be announced in January 1981. Additional information was

requested on the person who has been selected to fill an open position

as Civil Quality Control Engineer in the Bechtel Quality Control Organi-

zation.

b.

Construction Schedule

The inspector checked the status of construction and construction

schedules for the overall project, and received a copy of the January 8,

1981 CPCo report memo to NRC on the current yellow book schedule.

c.

Onsite Design Activity

The inspector checked the status of the ongoing onsite design activity

and continued his review of the engineering department procedures manual.

The inspector toured the site to observe the status of the work.

No items of noncompliance or deviations were identified.

2.

Other Inspection Areas

a.

50.55(e) Personnel Air Locks

The inspector checked on the status of the activity to resolve the

remaining open questions on the personnel air locks. The manufacturer

is working on the completion of the as-built record, revised drawings,

and updated stress report. Bechtel will review these item when they

are completed. The manufacturer will advise if any further repair or

rework is recommend. This item will remain open and additional review

will be conducted at subsequent inspections.

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Section 11

Prepared by

E. J. Gallagher

R. B. Landsman

Reviewed by

R. C. Knop, Chief

P: 9jects Section 1

1.

Review of Onsite Soils Works Activities

As a followup to NRC Inspection Report No. 50-329/80-32; No. 50-330/80-33

the region III inspectors performed an inspection of the current onsite

soils work activities to verify whether adequate corrective actions have

been implemented as described in Consumers Power Company response to

questions 1 and 23 of 10 CFR 50.54(f) submittals. The following are the

specific findings.

'a.

Procedural Controls for Soils Work

It was determined that U. S. Testing Company (UST) have not established

written procedures for implementing the requirements of Testing

Specification C-208.

This specification references numerous ASTM

standards for performing specific tests but does not include procedural

control or instructions for the implementation of such tests.

(1) While observing a laboratory relative density test (ASTM 2049)

it was observed that the variable rheostat on the testing

apparatus was set at maximum setting. The lab te:chnician stated

that ASTM D2049 requires the setting of the machine at maximum

amplitude.

It was determined that UST did not previously determine

the rheostat setting that produced the maximum density for the

material being used onsite.

It was assumed by UST that maximum

setting produced maximum density. Relative density tests are used

to assure that the inplace field density meets the specification

requirements.

-Corpc~of Engineers Manual EM 1110-2-1906 dated November 30, 1970,

Appendix XII,_Page XII-8 states the following:

"It has'been determined that for a particular vibrating table,

mold,.and surcharge assembly, the maximum dry density of a speci-

men may be obtained at a displacement amplitude (rheostat setting)

less than the maximum amplitude of which the apparatus is capable;

i.e. dry density may' increase with increase in rheostat setting to

a setting, beyond which the dry density decreases, therefore each

laboratory-should determine for it's apparatus the rheostat setting

at which maximum density is produced and use this setting for sub-

sequent maximum density testing."

Footnote on Page XII-8 states:

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"It may be desirable to redetermine the optimum rheostat setting

at the inception of testing for each major project."

U. S. Testing had not determined this setting nor did a procedural

control exist for the determination of the rheostat setting.

(2) While observing limited field soils work being performed at the

metering pits south of the essential service water intake structure

at elevation 630' it was determined that samples used to perform

relative density tests have been taken af te r the material has been

compacted. These samples should be taken prior to compaction since

grain size and gradations can be altered during compaction. The

relative density test should be performed on as received material

used prior to cotpaction. Grain size is one of the important char-

acteristics of how soil behaves. The inspector determined from a

review of the available grain size analysis that there appears to

be a gradation change of the material comparing before and after

compaction.

A procedural control specifying where and when to taken soil samples

should have been established. UST does not have procedural instruc-

tions specifying the field technique where and when to take samples for

density tests.

(3)

It was determined from discussions with the cognizant UST personnel

that they have been performing in place density tests "at the direction

of the onsite geotechnical engineer." However, there are no pro-

cedural instructions as to what depth below the lift being compacted

the test should be performed. A review of the density test reports

indicate.that they are not correlating the density test depth to the

lift being compacted.

Based on the above, it has been determined that CPCo is in noncompliance

with 10 CFR 50, Criterion V (Procedures) in that adequate laboratory and

field test procedures have not been established for the control of soil

testing activities.

(50-325/81-01-01; 50-330/81-01-01).

CPCo response to 50.54(f) question 23, subsection 3.11, page 23-31

states that "U. S. Testing was required to demonstrate to cognizant

engineering representatives that testing procedures, equipment, and

personnel used for quality verification testing were capable of pro-

'viding accurate test results.

.This commitment has not been

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satisfied based on the above findings.

Subsequent to the inspection CPCo informed the RIII offices on

January 16, 1981, by telephone that U. S. Testing Corporation would

develop and issue implementing procedures for soil work activities.

These procedures will be reviewed during subsequent inspections.

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b.

Document Control For Soils Work

It war determined that U. S. Testing was using uncontrolled forms to

record quality control test results. A binder was observed in the U.S.

Testing lab which contained QC forms used to record test results. On

the inside cover it stated that the index does not reflect the latest

revision of each form. The cognizant lab personnel were not able to

demonstrate that the latest revision of QC test forms were being used

since there were no document control provisions established to control

these forms. An undated U.S. Testing inter-office memo was presented

to the NRC inspector as the procedure to follow when receiving revised

forms.

It states in part, " log into controlled forms index".

The

inspector requested such a form index but did not receive it.

There

was no documentation onsite as to what forms are to be used for what

test as well as what are the latest revisions of the forms.

Based on the above, it was determined that CPCo is in noncompliance

with 10 CFR 50, Appendix B, Criterion VI, (Document Control) in that

measures have not been established to control the issuance of documents

which affect quality activities. (50-329/81-01-02; 50-330/81-01-02)

Subsequent to the inspection CPCo informed the RIII office that quality

control verification forms would be. controlled by the implementing pro-

cedures. This will be verified during subsequent NRC inspections.

c.

Soils Test Records

(1) Quality assurance records for backfill work activities were reviewed

for completeness and compliance with licensee specifications, pro-

cedures, and commitments.

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~ Bechtel field instruction FIC 1.100, Appendix A, duties and respons-

ibilities of the onsite geotechnical engineer, Paragraph 18, requires

that the onsite geotechnical engineer review and initial all accept-

able UST test report forms.

ANSI N45.2.9 (Quality Assurance Records), Section 3.2.1, requires

that " quality assurance records shall be considered valid only if

stamped, initialed, signed, or otherwise authenticated and dated

by authorized personnel".

Numerous UST density test reports were rubber stamped by the

geotechnical engineer, however, none were dated.

In addition

no procedural controls were established for the use or control

of the rubber signature stamp of the geotechnical engineer.

Based on the above it was determined that CPCo is in noncompliance

with 10 CFR 50, Appendix B, Criterion XVII (Quality Assurance Records)

in that the soil test reports are not initialed or dated and there

were no established controls on the use of a rubber signature stamp.

(50-329/81-01-03; 50-330/81-01-03)

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Subsequent to the inspection CPCo informed the RIII office that

soil test reports would be initialed and dated as required. This

will be verified during subsequent inspections.

(2) Specification C-208, Section 9.1.3(d) requires the geotechnical

engineer to review and evaluate test results when densities exceed

certain values. From discussions with the previous geotechnical

engineer, it was (ftermined that the evaluation consisted only of

a check of the numerical calculations for numerical errors.

If the

calculations were correct the disposition was "use as is", this

review does not meet the requirement to evaluate test results.

Subsequent to the inspection CPCo informed the RIII office the'.

documented evaluations of the above would be performed. This

is an unresolved item pending review of the evaluation (50-329/

81-01-04; 50-330/81-01-04).

d.

Review of Nonconformance Reports

The NRC inspector requested all nonconformance reports regarding soil

work activities since March of 1979.

The following reports were made

available.

Bechtel NRC No.

Date

Description of NRC

Status

2294

6/23/79

Failing density tests

Closed

2307

6/25/79

Failing density tests

Closed

2350

7/16/79

Failing gradation test

Closed

2492

8/30/79

Qual. of compaction equip.

Closed

3041

6/25/80

Failing density tests

re-Opened

3159

10/07/80

Failing gradation test

Closed

3165

10/09/80

Lift thickness exceeded

Closed

CPCo NRC No.

Date

Description of NRC

Status

M-01-4-0-005

1/18/80

No spec. requirement for

backfil around piping

Open

M-01-2-9-060

7/19/80

Spec & purchase ~ der for

sand gradation not the

same.

Closed

M-01-9-0-038

5/15/80

Final report on qualifica-

tion of compaction equip-

ment.

Open

The above closed NCR's were determined to be adequately resolved,

those open or reopened will be reviewed during subsequent inspections.

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e.

Qualifications of Onsite Geotechnical Engineer

CPCo response to 50.54(f) question 23, subsection 3.7, page 23-20, states

. that, "one full time and one part time onsite geotechnical soils engineer

have been assigned." The inspector requested the qualifications of the

onsite geotechnical engineer. A resume was presented to the inspector

as representing the assigned individual to implement the commitment in

order to preclude-future soils problems. This engineer is to provide

-the technical direction and monitoring of the entire earthwork process.

The resume that was presented was of an " Engineering Technician" with

no previous formal education in engineering or geotechnical engineering.

-The engineering technician had nominally 15 years of field and laboratory

testing of soils.

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This information was discussed with representatives of the NRC geotech-

nical branch.

It was determined that CPCo committed to provide techn-

ical direction from a geotechnical engineer capable of being recognized

and licensed by a. state board of registration of professional engineering

or equivalent.

In view of- the fact that adequate' technical direction had not been pro-

vided per the commitment by CPCo ir. the 50.54(f) response it has been

determined that CPCO is in deviation from a NRC commitment as described

in Appendix B of the transmittal letter of this report.

(50-329/81-01-05;

. 50-330/81-01-05).

- Subsequent,to the inspection, CPCo informed the RIII office that a

geotechnical engineer would be'onsite beginning January:19,.1981 and

that job descriptions and qualifications for the geotechnical engineer

-for the speciality remedial: work to follow would be developed. This

. action willibe verified during subsequent inspection.

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Borated Water Storage Tank Reanalysis

During the inspection, the. licensee informed the inspector that the prelimin-

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ary structural reanalysis of the-borated water storage tank ring foundation

~ yielded results that indicated-the foundation to be overstressed. The in--

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spector inquired to .the. quality assurance group if this. condition had been-

considered for reportability. After this inquiry, the Manager of Quality

Assurance produced the CPCo form entitled, " Safety' concern and reportability

3 evaluation" for.the BWST. ring foundation.

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This ' document indicates that a finitefelement analysis results in forces

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and moments in excess ~of FSAR'allowables. .The reportability evaluation-

' indicated the event was "not reportable" with further evaluation necessary.

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The planned ~ actions included retaining a consultant to_ review the results

obtained'by the analysis and/or perform'an independent check and excavate

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.and Linspect: the foundation for' aigns of overstressing1(i.e. , cracking).

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On January 23, 1981, CEPo informed the RIII office the excavation around the

Unit 1 tank was complete and that cracks were observed in the areas of over-

stress. CPCo identified this item as a 50.55(e), significant construction

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deficiency. This item is under review by the NRC staff.

The inspector informed the Region III office and NRR project manager on

January 9, 1981. The licensee's evaluations of the matter are included as

Attachment No. 1 of this report.

Unresolved Items

Unresolved items are matters about which more information is required in order to

ascertain whether they are acceptable items or items of noncompliance or deviations.

Unresolved items disclosed during this inspection are discussed in Section II,

Paragraph 1.c.(2).

Exit Meeting

The inspectors met with licensee and contractor representatives at the conclusion

of the inspection on January 9,1981 and summarized the inspection scope and

findings. The licensee acknowledged the inspection findings. Subsequent to the

exit meeting the inspectors and RIII management. telephoned on January 14, 1981

the Quality Assurance Manager in order to verify what corrective action would

be taken based on the inspection findings. On January 16, 1981, CPCo informed

the RIII office of the actions to be taken which are contained in the report

Section II, Paragraph la, Ib, Ic, and le.

Attachment:

Attachment No. 1

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Attachment No 1

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SAFETY CONCERN AND

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OUAtlTY ASSURANCE CtPARTMEN

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REPORTABILITY EVALUATION

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HOW WAS CONCERI; IDEiiTIFIED WHEN, WERE?

TO ~ MANAG ER-MPQ A

Asaresultofthe50.54(f3commitmentstodoa

1. FROM:

R L Rixford

structural reanalysis of Category I Structures (See Items

14-7 and 48-2), the BWST ring foundation was reanalyzed

, OEMNIQ WD - 30{

and values were obtained which were inconsistent with

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previous values, and inconsistent with FSAR requirements.

! FILE NO: 15.1

The results of the analysis were obtained 1-4-81 and dis- !DATERECEIVED:

cussed la a 1-5-81 CPCo/Bechtel meeting. The Project

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Manager attended this meeting and subsequently briefed

D YES @fic

the Manager of Quality Assurance.

WHENT

N/A

BY WHOM?

N/A

3. IS NRC AWARE CF THIS?

YES M UO

WHENT

N/A

(CONTINUE ON NEXT PAGE)

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BY WHOM?

N/A

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BRIEF DESCRIPTION OF C0"CERN - SYSTEM, CCMPONENT, ACTIVITY, POSSIBLE SAFETY IMPACT -

(ATTACH SUPPCRTING DOCUMENTS).

The BWST ring foundation was analyzed for several loading combinations including the. dead

load plus live load which was determined to be the most severe. The analysis was first

performed using the methods of BC-TOP-4A, Rev. 3 (this method uses springs for soil /

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structure interaction during a seismic event), but gave displacement values inconsistent

with anticipated and measured values. The analysis was then done using a finite element

technique which gave consistent displacement values but forces and moments in excess of

FSAR allowables. The values obtained fron the reanalyses which have been done indicate

an overstressing and, hence, a potential for failure of the foundation of the Category 1

BWST.

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(CONTI!IUE CU NEXT FAGE)

6.

IWEDIATE REPORTABILITY EVAIDATION:

7

ORGANIZATION REFONSIBI.E FOP FURTHER

a. O REPCRTABLE

- GO TO 13

EVALUATION:

b.

POTENTIE LY REPORIABLE - GO TO 13

Bechtel Engineering - Civil

e.O NOT REPOICABLE, FURTHER EVALUATION

8.

FINAL REPORTABILITY EVALUATION

d. O nor REF0FTABLE

(IP 6 e. CHECK 3D):

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R3POPTABLE

b, U NCT REFORTABLE

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QA APPRO'lAL OF EVALUATION

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OF BLOCVS 1 TO 7:

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MANACER - MPQA

DATE

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10.

JUSTIFICATION OF EVALUATION - ( ATTACH SUPPORTING DOCUMENTS)

The first reanalysis gave displacement values which vere inconsistent with measured

settlement and anticipated values. This cast doubt upon the spring values used in the

analysis. The subsequint finite element analysis gase displacement values which were con =

sistent with the.other values available for comparison, but gave forces.and moments which

exceeded the FSAR allo tables by an amount suf ficient to warrant an additional check on

these values also.

Two acticas planned to check these values are:

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Retain a consuleant to review the results obtained by analyses donc, and/or

do an independent check.

2

Excavate and inspect the founda*. ion for signs of overstressing (i.e., cracking).

It was considered prenature to judge this a reportabic condition prior to confirmation of

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the values obtained'by the finite element analysis.

(CONTINUE 0:: NEXT PAGE)

11.

EVALUATO E

NATUhE/DAT":

12. FINAL QA AlPROVAL - I'AI!AGER MFQA/DisTE:

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13. EC Nor'?ICA110N: 110'!?

DATE:

TIME:

INDIVICUAL NJTIFIFD:

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dAFETY CONCERN AND

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REPORTABILITY. EVALUATION """"[j'joi"f""

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CONTINUED

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CONTINUED

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lb. MINIMUM DISTRIBUTION:

15

ADDITIONAL DISTRIBUTION:

VICE PRESIDENT - PELC

11PQAD - DQAE Supervisor

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VICE PRESIDENT - MIDLAND PROJECT

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DIRECTOR - E:iVIRONMEllTAL SERVICES & QA

MIDLMIP SITE IWIAGER

SITE QA SUPERINTENDE!!T

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MANAGER - SAFETY & LICENSING

'MIDLA'.ID FILE NO 15.1

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