ML19320A473
| ML19320A473 | |
| Person / Time | |
|---|---|
| Site: | Midland |
| Issue date: | 05/31/1975 |
| From: | CONSUMERS ENERGY CO. (FORMERLY CONSUMERS POWER CO.) |
| To: | |
| Shared Package | |
| ML19320A471 | List: |
| References | |
| NUDOCS 8006180732 | |
| Download: ML19320A473 (56) | |
Text
{{#Wiki_filter:Y b [gf1 NONCONFORMANCE - REPORT LOG & STATUS BOOK 12. ,_ ,.y
")t9 REPORT DATE N#M D' PAGE COMPL.
- 1. PROJECT NO _ 7220 ,
8A NCR O RIG. PREPARED BY NONCONFORMANCE 6- " NO. DATE DESCRIPTION / REMARKS Route 'xu^To '0E CLOSED CLOSED DY 268 1-17 2-13 J.C.Aldrid 9e :-38. Bean connectors damaqed, shipment ;ield 1-30 -75
-75 -14 1.201 t-17-7 1 -75 4-10 269 1.-20 A.L.Boulden :-111. Liner PD.ce X-Rav of reoair not ideld 1-29 4-10 A. L. Boulden 75~
-75 available 1.109 1-20-2 5 -75 -75 2-13 270 i-21 J.C.Aldridge '
- -38. Damaned beans. nine each. shin- Me&d 2 -75
-75 nent C-15 1.201 : Ti 75 271 L C.F. Clark C-111. Weldinq procedures P3-F(A-CO,,) field 1-22 4-10 5-7-7 i A.L.Boulden
-75 1.109 t 76 75 272 L tC.F. Clark C-111. Leak noted at Knuckle Plate, Field ilo .-22 1-29 2.Lussier
-75 lamination 1.109 .-21-75 -75= -75 ([
273 .-21 R.A. Moray !:ulk fiaterial. h" F, 5/R" Round bars. Field fio 1-24 5-29 R.A. Moray p
-75 7220-F-11452 .-22-70 -75 -75 M.S 274 1-22 J.C.Aldridge C-33. fla t e ri a l shimed without relhase PiWd' flo 1 1 R.A. Moray o
-75 1.201 .-22-75 75 -75 oo 275 1-27 R.A.Noray M-201. M-104A ITT-Grinnell markinn of S=idal 2 f528-
-75 J-Rayed Joints nor per M-201 ASME 4.192 J -f4 -H 75 o c,d 1-28 J.P.Betts -39. Rebars cut of do not match Dwq <=ie=l:d 1-29 2 2-10 L.R. Albert
-75 C-324 Rev 10. 1.10 3 =1 -f4 --76=-75 -75 -75 Ho 2 4 R. A. Moray 277 1-29 R.A. Moray 1-104A innrnnnr r, w 10 rnrn -)t a S g
-75== ASME,4.104 1-30-1 5 75 278 1-29 R.A. Moray NO 2 4-18 R. A. Moray 1-10AA. Imoroner G-3210. X-Ravs innrnn '1. S
-75 t -75 ar, Code Da ta .'!ane Pl a te. ASME,4.124 1-30-J 5 75 cuy n t z-6 y i - Q ' p;.ej.i 279;. 1-30 C.F. Clark C-111. Liner Plate radius out of tol- Ei el= d 1-31 2-7-78 l-75 erance after concretina 1.109 4-41-74 -75 2 ,
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/ IJ ..NCONFORMANCE - REPORT LOG & STATUS BOOK u.
REPORT DATE 3*?"U 40## T'I'7T PAGE COMPL.
- t. PROJECT NO- 7220 . . ENG. StGN
/ 3. 4 5-JR O R W.
DATE PREPARED BY STATUS [0. DESCRIPTION / REMARKS 6. 7. D ATE 8.DATE 9. DATE 10. ROUTE XMTD [292 -75 2-25 R. A. Moray C-38. RETO CLOSED CLOSED BY studs Documentiation not Rcd for weldin o M.S . No 2-28 3-17 1.101/1.201 2 75 -75 R.A.iloray 293 2-25 R. A. Moray -75 C-39.
-75 Rebar does not conform to anrvd f=id=1 3-3-75 4 4-11 R. A. Mo ray drawings 1.103 ?='_w m 75 -75 294 2-26 L.R. Albert
-75 C-231. Curing tems below Snec on 6th E:ield 3-3.-75 5-16 day of cure, CC(593.5(e 5-19 L.R. Albert 1.105q _=25 95 -75 -75 95 3 A. Boos
-75 Crequired
-?31. Aux. Blda Slab nlaced without rebars Fr6Ya 3-3-7E 3-24 4 1.203 8-8-7E -75 L. R. Albert k 9'6 3-4 A. Boos -75
-75 C-231. ti n y noin wall miuinn nnn har Field flo 3-4-75 5-15 D.C.Thomnson 297 3-5 1.203 3-4-75 -75 R. A. 11oray M-104A.
-75 Two spools with same number f=iel=d 3=13= 4-10 4.Si1E 4.134 g -qq_gg 75 -75
!SS 3-10 A. Boos
-75 0 -231. .S u x Bldo walls e n h . r-lonnthe fiv.16 3 3-24 3-24 L.R. Albert vary from requirements _
&99
~ 1.203 5 -ti-76 75 75 3-13 R. A.floray C-18. rin c o nn n t a t i n n
-75 nn ^ <: T M 6-PR Holts / Nuts u .s. No 4=1=75 4-7 R. A. Moray 1.101/1.201 D-16-70 -75 3-26
~
C R. L. Bowren r-1n
-75 namanna Rean unon receipt intreci Fielt 4-10 tion.
01 4-2 1.201 -l-26-7s -75 R. A. Iloray C-38. Damaged Beams.Shinment C-21
-75 Gield 4-10 02 1.201 i.-8-75 '
4 R. A .tio ray
-75
-75 C-33. Damaned Beam. Shinment C-23 Fi: eld t -
4-10 4-21
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-75 03 9-7 R. A. Moray fi- 104A- snnni r,h
,l-75 5-a nproved. shnntAstnn trnnineering ,
103 oma oc %_ 4.134 i n _ n-LL ' ~ - - - - "}\ h _. 01 C Y CCf^ ' 3
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NONCONFORMANCE - REPORT LOG & STATUS BOOK 12. i REPORT o#* PAGE CofNP. o.C. ENG. St G A
- 1. PROJECT NO. 7??n .
1 4 5 ER ORIG. NONCONFORMANCE STATUS PREPARED BY
- h. DATE DESCRIPTION / REMARKS houTE "xP.iTO N CLOSED b 14 4-7 R. A. Moray flo 4-11 5 '12 l -75 1- 10 4 A . S0001 ma rlii nq differs from reader sheet markings ASME 4.114 M.S.
4-8-75 -75 -75 R. A.\g h5 4 R. L. Bowren TIPGh.StoraneonSteanGenerator Field l
-75 ?E-51A. AS!1E 4.021 1-9-75 \
5- L.R. Albert 06 l 4 -75 h.R. Albert :-231 Concrato tomnnraturn- A(6no)a' 1.205 ggy d-9-76 -75 4 5-10
~ \
b7 4 R. A. Moray !1-204. Fittinos.F-10577. AF0-328. Markin g M.S II 4"10
- l -75 and Documentation. AS'1E 4 7E -75 b8 4-17 R. A. Moray H-104^- R o a rf a r chaar hae i n e n r r a c t-- s n n n H M.S. * ^' ""
l -75 numbers. ASME4.114 4-21-7 5 7 -7 i 39 4-23 L. R. Albort C -230. Batch P1 ant nualification nast pi:ehd 5 l -75 due. 1.105,1.205 h F 75 10 4-28 R . A. Moray -39. Damaned Beam. Shinment C-?d ide3d 5-1-7!i 5-16 -75 l -75 1.201 4 -gg-pi; 11 4-30 R . A. Moray F-18. Roams shinnnd. nnt nn Chinninn M.S. Il 5 5-12 R. A. Moray
-75
~
3-1-75 75 -75 List 1.201 2 4-30 R . A. Moray C.=.3n namanna annms shinnnnt C ?G lii:ohd 5 5-27 l -75 1.201 1-L-35 -75 -75 13 5-2-75 J.il. Miller I:- 3 8. Beam material tensile strenoth aie%d 5-?- 5-27 5-29 L.R. Albert over ASTM A-36 limit 1.201 ii-R-75 75 = -75 -75 14 5-29 R . A.flo ray C-38. Beams, Shinment C-27 without F ield 5 -75 weight or orientation marking 1.201 B-30-70 L 5.- -S-29 R .A. Moray C-38. E. maced Beams, Shionent C-?6 F ield
-75 -
1.201 fi-30-7! - c ioa om4 cc . Page 29 11 E- CC- " 2 i I
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NONCONFORMANCE REPORT
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, . 4 TEM LOC ATION A A CD SV 5 Liner P1 ate Containment #1 & #2 ,'ldl.3jdgf;.a //-/O.7 7 ,
l DATE/-2/ 76
- 6. V.E R G A L N U M D E R _ _.
- 9. 57 ARTuP 5YSTEM NO. t . l PL ACEMENT PA NO. *** 'Cf * 4 **- #
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_rb e s. Flouting $NSTRUCTiONSe nc-bo_ ___Cus.tnatinn nouTE TO FRELO ENGtNEER NG O aouTc To aarcata'suecaVisor' t 9. NONCON FOHMING CONDITaONs Certain Areas of the Containment liners have been welded with a combination of two velding procedures, (i.e.) the bare or seal pass is made with procedure Pl-AC-LH and the balance of weld deposit bring made with procedurc:5 Pl-F(A
.% ) 1,2,3 , This is contrary to Spec. 7220-C-111, para 7.2.2.
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Kric'o accouacNoarioNiaourc vo Pao'ccr cNGiNcca0NG . riELo oiscos Tion nesukTs. _Use an is. A].1hougl.Lthe use of a combination of weldin:t procedures is contrary to _the._ spec.if.icat. ion dher e in na_ detrimental cff_e_ct to weld _guality or structitral intenrity. Che specification intent was to minimize numbers of procedures used so as_ to better control and monitor velder performance and to enable more precise applications of proper frequency of NDE. (see Sheet 2) 2 2. E NG N E L H s NG Ui5PO 58 FIO N 2 3. CNG SN CE H 6NG DiSPOSiTlON etESULT O Project Engineering concurs _with_ Field Reco_mmendation_to use aq..is. The subject Mec// <> <r dd-#d -
, velds are acceptable because of the following: ASME Section IX requirements are gu o M b- .A/ a/<#/
that a single welding procedure specification .(WPS) be prepared for each type of 'd ' -gAf e /?>.o -/-E/<Q i]weldment. Contrary to this requirement,._ combinations of two WPSs were used in i making the subject weldments. pOz<-! g /n/~~ S Y n ~ 4 M f_ M
- 24. 83 DEssGN CH ANC E l'IEQuiH ED b HO The weldine processes which are ranremonenr1 hv 2.. REJCCTED M ATER4AL Di$PostTsoN O**
cha a ' w ' *L ' a d'S'/ 67#e 87"b/ '/ 7)~ W '5, hY ES. 5EE ATT ACHEDs .,,..n 27 gc j opt AWING R EV. DCN
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NONCONFORMANCE REPORT (CONT'D) i. uc e 2 or # - ,,,,,ucauo,__271 (Block 20 cnneinued) Further. ASrE Section IX paragraph QW 201 specifically allows combinations of procedures and processes in the
<:nnn un1d joint.
Thedo prnnedurn1 enmhinntionn vill hn entnrod in nnnehor prne nd nra enmhining rhn Rhinidnd We,1 Arc (SMA) and Flux Core Arc Welding (FCAW) processes. Since no essential variables of either process or procedure have changed. the issuance of a new procedure is simplified and does not require testing or re-aualifications. Thus. the new._Helding Procedurn Sp.ccification vill only referenttprevinnsly run Procedurn1 Qunlificatinn Ropnvre (P The_lhQCS & Pro.iect_ Engineering _ groups have_.already_hegun rhn _procedizral_ modification process nnd un nnsurn nur __ nituation is not adverse to weld quality. [O Y YY +cd / 22 'k' [L db w ,, 'c h ut cd m X Ma l- D 3 S 4_h atyn 4 _QC s b E E &k _
$lbrS. l- D ~7-C Block 22 cont.:
ccObinatinns of WPSs used can_ in accordance with ASME Secti_on IX, be_ combine [1 in_to_ sing 1c WPSs.___ Therefore,
. the veldments have met the technical requirements of ASME Section IX, but the proper documentation was not available. To correct the nonconformance, new WPSs permitting the subject welding have been- prepared by MF&QCS, and are being issued. In order to clarify the requirements for WPSs, Specification C4111 will be -
revised to delete Section 7.2.2, and ASME Section IX shall govern. T~~ ~ ( M 2-ek. lim 3 -/9-? s
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s gy R. C. Sorunerfeld (RCS-015-030) o ,. 176QCS - Ann Arbor E. E. Felton u R. W. Straiton o, MF6QCS SFHO J. Hink omic January 22, 1975 .
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R. W. Straiton I suene, Midland Unite 1 & 2 ~ g T. Velanzano MN j
.soo N o. 7220 Combined Process Welding Procedures for Liner Plate Uelds File: 7220-Civil Uhile transnitting the Projects request for preparation of Welding Procedures utilizing cellulosic and low hydrogen electrodes in combination with flux-cored electrodes, Mr. Straiton was inadvertently told to combine Pl-A-e-Lh (Structural) with the flux-cored procedures. This should have been '
Pl-A-c-Lh without the (Structural) designation. He au.horized Ice to inform T. Valenzano and J. Hink of his intent to utilize P1-A-c-Lh for devalopment of the combined process procedures. This is a t.odification of his lux to E. E. Felton/T. Valenzano of January 21, 1975. -( . V f,' , D1/vL j L' R. C. Soccerfeld Materials Engineering Supervisor RCS:id 9 27 g
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41 . W .- O I
/ 5* ' NONCONFORMANCE REPORT 2.O:m . NG/,aaT wo. -
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5{I( Bulk Material List
! 07220 !.usONA. Morays// /1/21/75
'd c0.T lo.TE 2s. ois,OS.T.ON CONeua nENCE
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- 6. CON TR A CTO R/ LOC A T tO N N/A
.J. T. Ryerson Detroit, Michigan
- 81. A SM E O YES 4 7. 50 u R CE /[/ " "'#" '"'"'f *"*
IS. ROUYtNG IN STRUCT60N5 TE. &O Vendor Q ROUTE TO F8ELO ENGINEERING O aou'E to =^ vca'^'suruav'soa 9 9. NONCONFORP.IING CONDeTf 0N: _1. TheCertified
- a. 4" round bar re3uires the followiner in order Materials Testa Report to include tensile properties to _ meet the conditions of the P.
and bend test results,
- b. " Statement of Conformance. "
c.
- d. Tagging needs to include size and length of pieces, number of pieces, heat number and manufacturing 1 oc. is damaged - bent. .
- 20. [ F4 ELD Ols,054TaON CFIELD RECOMM END AT60N/ROUTC TO ,ROJECT ENGIN EEN 4NG Continued on Fago 2
- 21. FIELO DIS,05eTsON HESULTS:
11aterial Supervisor to obtain missing documentation from vendor for items l-a, b, c and 2-a, b, c as listed in block 19. M , /d M $'/.~m / M fi..i/ . Items 1-d and 2-d listed .I O d d /5 N.h , s/ A u b D. t' in block 19 will have bent portions citt avi.ay and rejected. Estimated imolementation date is 3-1-75. C,,5f /Me>d 5 .2 2,p[
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- 24. 85 DC5IGN ;t# N C N EQiflRED A*.
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[J2; ' NONCONFORMANCE REPORT "*" y
.a. L c A wsNG/PAoT NO. er 2 R E v. 7. PnoJECT N o. 294 7220-C-231-Q ; 6 07220 iz.rgPpji pg j cATE as o:Seos Tion CONCuRRcNCC
- 3. lTEM EdSCRIPTION
- 3. t TEM LOC ATION L91E.35/rt .
2/26/1 "' - g , ^;,^". , - " - Cont- #2 Cover Slab Reactor Buildinc #2
- 13. V S ATED DV [
p j.I DATE 26 M- h j/ ] { 3 ,s Q -- C. ( EM B A L N U M D E R
- 3. STA RTUP SYST CM NO. . __ //Ed / g ,j g, p N/A :. FCPLACEMCNT PAR 'f . REV. Pes o s.c7 P'ec t. . asdas. ..
C. PUMCN ASE ORDER NO. N/A .- .*T8 N' /A I
- 10. QC FIELO IN SPECTIO N PLA N No. ,.
"t, ..... ._,
. .q N/A 16. REPLACEMENT SERI AL NO. ' ....
C-231-h-h82 Rev. O
' or I, [ /h . 7 C. C .NTSlACTO R/ LOC ATION N/A -
41.ASMC c=E C YCS $ 7. SO URCE "*' "',*i" ",* 'ff**"" gj ** G NO . ................ , u.
$ 8. C UT4 NG 8H STR UCT10N Ss ROUTE TO FIELD ENGINCERING iT E M Construction *
'!F 4.4 .' W O aourc To M ATEa'^'surCavisoa a. ': ,/
- 19. N 3NCB N rO R MING CON DITION a h w.. -. .
Specification 7220-C-231-Q Rev. 6 Section 13.2.h requires that concrete surfac. *
- maintained at no less than 500 F during the curing period. e teftneratures be 0 Contrary to the above recording thermometers in the cover clab oncrete indicated temperatures of h0 and h5 during the sixth day of curing.
t.urvaillance. "Q" No. is 1.105. Nonconformance noted during rontina cc One Tao annlied. a: O riCLo oiSPOSsTroN gr:ELo RECOMMENDATION /ROUTC 70 PROJECT ENG8NECRING 2 3. FIELD DISPOSITION R E SULT S: Une nn in. The inuont enneroro c omnorn es,ro reenrded unn h n% vhich ne es,rred d,,rino s- h o As h dnv of currinn. Thin enndfrinn ton n d i ncnunrnd n r R . ~1n n .m . ' nn rho 7th dnv n F citrina. The he, ters were immediately readiusted and the curinn neriod was extended to insure that all of the affected concrete (Cont. #2 cover slab - approx, from azimuth 220 continued on Sheet 2 to 3420) received
- 22. ENGIN CCRING OtSPO SsTIO N Temperatures below 50* (and above freezing) during curing of fresh concrete have no detri- 23. ENGINEERf NG OfSPOSITION RCSULTS:
ital effect on the concrete. It merely extends the curing time required to reach a spe-cified strennth. The curing period was extended to compensate for the lower temperature and, hence, Engineering concurs with Field Recommendation to use as is. /86,6 .5 -f_ yf-nA&A
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- G no 36' aMMD MMM WMDW " ~
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NONCONFORMANCE REPORT ' ' " ^ "'"'""*
- 2. fl e. A WI N G /PI.6 T N 3. 0 'i E V. 7. P2GJ CCT N O.
I2.HCPOMTEDDY
- - - - - - - . - - - cr- I E90
'DATE 7220-0-282 (0)
~
- 3. s TC MMsCNIPT40 N
!h 07220 4. Boos 22 M M 1/3/74
- 23. DISPOSITfGN CONCURRENCE
.. S. 87CM LOC ATION I DATC Reinforcing Steel Aux. B1dg.,
- 33. Ap1 T'
- c. u.. A N u-o c. . 57 A Tu,5v 5T E. NO.
jrfc w
- 6. 4 C,L A CCo CN T , A.T NO.
l3///?f Nd(_ W ,x ,$.!7.( N/A N/A j oEv. ....u...~.g.-... '4
- 8. Pur#CH ASC ORDEst NO.
8 6. OC F4 ELD sN5PECTION PL A N NO. N/A I ,o ...... ... -
- 16. N C PL A C CM E NT SC R 8 4 L NO.
N/A C-231-2-313 Rev. 2 g (, 'Y ' N/A
- e. CsNTa ACTO / LOC ATiON ii.AS-E COOC o TES u.50u CE **"**"***y ""
_N/A ,,,,,,,,,,,,,,,,,,,, ,,,, 4 8. NouTING 4NSTRuCTIONS iT c = Q NO ._ _ C_o_natweti_on MOUTE TO F#ELO ENGeNCER4NG O aours To a^Tcaia'suPsavisOa
. .. N O NCO N,0 ..N G CO N oiT O N.
The referenced drawing specifien that the horiz. reinforcing for wall 27 shall be #8 bars 12" on center. 58k'. One (1) #8 horizontal dowel has been omitted on the east face of the 7.h wall line belo This will produce a 2h" spacing in the #8 horiz. wall reinforcing for the south face of wall 27. "Q" # 1.203
~ / / .
O.! . Y - 3,/4,/75
- 23. @ FICLD De5POSITsON
{srICLO RECOMMENO ATION/NOuTC TO PHOJECT ENGINCERING
- 28. F8CLD Da5 POSITION RC5ubT5*
Drill a hole for the missing dowel in the 7.h line wall. Fill the hole with e/4 A,ua e s Ac4 <,m44 non-shrink grout (DBECO 636) and set the required dowel. The embedment length ess m,s m ec, p com,,1,,,ct[ Con o, a of the dowel shall be in accordance with Table 36 of drawing C-211 (Q) Rev h. te c -2t f ud %C.C-2 5/9, 6C- C6 ce k cf.eex % f=1 P C-231 M74
- 22. ENGINCE H 5NG OISPOSITION b.0 WwJ Shll75" [ #
W~4'?r [k.an %3 ~/S 2 3. ENG 6 NEE RING D e5PO $4T SON RESULT 5e 2:6. 4 ) DE54GN CN ANGC R EQulH ED ONO - O vEs. SEE 4YT4CNEo. .'.'"._". S 27 " ~'~ 7tffdCENZL.jem g f5 g Oid A WIN G HEV. DCN . . . . . . . . < S PC C. REV. ADO. awes.o..ase ....cy,, ,,,, s . ., v a-o
' Wh at. Copy - Ore 0inator canary Copy QG-G3 a , , - Floid Engineer Pink Copy - PQAE Coldenrod Copy - OC o . -
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- a. O.a as eN esrauT N n. j a c v.
NONCONFORMANCE REPORT
- 7. Prioaccv N9.
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i 304 joaTc as. unseos: Tion CONcuMRCNCc _Sp ec . M-201 5 07220 / . A . l!6ra, I4/2/75 "~*** " * " '""~ """
- 3. srcu ocacnsPraoM . s. eTru LOcarioN I Aph T r 8 DAT
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- e. sTanTue system No. if,. ac'rLaccucNT rant NO. =a=
. . / . .. . c r e . . = = - - n -
2CCB-25-S611-5-4 N/A N/A ~ l'"n cv.
- c. PuT.cNasc Onota NO. so. Oc recLo eNseCcTiON etaN NO. is nces.accucNT ScRI AL NO. j g g/ .],(*
_l220-H-104A ~ M-104A-R-9 N/A
- s. c 2 N T n a cTO n/ loc aTsO N si.asur Qvcs 7. so u ac e g ****('.'g',", s*jg' 4 ,"y;;,* .g TTT. . C r4 n nell/.KcIncrSvi l 1 o H C- 'T e u O_NO __ JgILdor _
s o. < nursNG sNsv nucTiONs. O"our' va ro 'ao'acca'ao Q aou'c To "a Tea'ai Suecav'So" to. Nd NcONFORMING CONDITION: Fnrm C '421-D for P.O. 7220-M-104 A requires _ygndor to stmnly radionraphic verification rcports. The radiographic verification reports (Reader Sheets) supplied for spool 2-GCB-25-S611-5-4 (MR-78-59) welds A & B read 2-GCB-25-5611-5-4 A & 2CCB-25-5611-5-4 B. The verification reports therefore do not correspond with identification markings on the spool or spool d g. Nonconformance noted during receipt inspection.
"O" No. is 4.114. Unit 2. / Hold Tagg applied. h -[ ,4,, [ ,,, 8 , [ ,7/ p.v')
y ' 22 W IC LD DisPOssTION QFICLD RcCOMMcNDATtON/RouTc TO PNOscCT cNGINccHING 2 8. FeCLO De POSIT 80H Mc subT56 f,~,Jacf_ _.bk?eb/$v 8 bn od- gmI 4nk wl Un.$A$4 k n'Y i n f b b d.
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- 23. 83 c tssGN cNar4Gc secousHcO O NO O YcS.sceATTACNcOs
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( %') . 7 $ a.,v ... ........ .. .u. S Pe c. R E V. A o o* U~ 8 8 I ~ Wh.tecopy - Origmator Qc G3 a Canary Copy - Field Engineer J . Pinit Copy - PQAE .. Goldenrod Copy - OC , _ _ _ _ _ _ _ _ _ - _ _ _ _ _ _ .Q v V j.
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- NCIONFORMANCE REPORT ^
- 3. %3 A WINC /P A R T N O. D E V. 7. Pft OJECT NO.
,2 ' ' " ~ " '
306 7220-C-230 L t. H CPOHTCO v/ DATE l 5 07220 2 5. 0 4GPO$tTsON CONCU RR E NCC
- 3. ITEM DESCRIPTION L. R. Albert 14/9/75 " ~ " " " ' ' " ' " " "
Conge_te
.. S. ATCM LOCAT40N P10 c.cment No- A(609in' 83 YED oV 3 D ^
Q "" C. E E R I A 4. N U M o E R
-f & 4"
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CMENT PART .W NATEV*15~5$$0 O W!
- 9. 57 AstTuP 5YSTEM NO.
yg yyg t . LA . emosect e .so easif e ge s pg l' R E W. est,
- s. PvRCN A5E OROER NO.
_m ... QC F0CLO SN5PE CTION PL A N NO. I A3 ff..a%2M:w.r _ f-l.
- W
- e. C;NTR ACToRILOC ATiON c - n 1 - 3 _s n') -uu 5 6. R E PL AC CM E PIT SERi%[. NO.
( .... [=/6 =% Champion - Midland st.AsME O vCs s v. source /[#"' ""pg"' "*"T ""
,'T E M t&O , ,
8 e. HOUTING 3N 57 RUCT40Ns; QuGUTE TO PIELD CNGIN EERih G Subcontractor O aov's To u^75 "a' 5vecRvisoa s o. NONCONP ORMING CONDITION t spe r. . m n-c_93n nnu s in *bn specifies that mass concrete deposited in the forms during en1A "enther cold weather concrnH when n3 ternern the ambient turn chart air tein Section-11 1 - betueen 31 nad 4s nhn11 hnun n rempe_rnevirn r-in g frnm 45 - 65 mperature is c onh nry en eba nhavn with a temnerature of 67 while ambient temperature was 42 was placed in A(609)a' . en vne nr ennevne, least dimension creater than 24' and contains 102 CU yds. Placement A(609)a' has a concrete during placement. "Q" No. 1.205. Monconformance noted durina routine OC testine of
- 20. Q F6 ELD DeSPOSIT40N / oc Jh e o res a Amxeo QFIE LD FIECOMMENDA TION /ROUTC TO PROJCCT E NGIN EER4NG
- 21. Pl[LO DBSPO54 TION RCSULT5s Field recotmnends "Use As It," based on the following rationale:
1. The temperature was only 2* over the upper limit allowed by the referenced Specification. 2. The 8 cu. yds, which failed was the first connrete to be deposited in the form . Corrective action was taken as evidenced by
- 22. E NG INL C N ING D sse*0 5t TION the test taken on the next 8 cu. yd.
._The.11gher__ placement _t.cppAractinc _will tend to increase shrinkage, setting rate, 2 3. ENG 4NCENING DeLPO$eTION HESULT5:
_and water demand while .aducing slump, durability and strength. A 2*F temperature difference for 8 c.y. will not have an appreciable effect on any of these factors. Ennincering concurs with Field Recommendation to use as is, pg.g4 c ., _ ,, ,. - . G 6 hkA ~S -/ - 7 C
- 24. O OCSIGN CN ANGC RCQ .8HED
/
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- O YEE.SEEA77ACNEo. 0.<=..
$Q A WING REV.
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- 2. ownwinstr .wr a r. j .u v. v. enosecr no.
____- . - - _ - . . _ , [J g,. . ~ . .j. ["i 30k Spac. 7 20-M-201 2.gr,coppav joArc 25. ossrosirica concurence.cc
- 3. a rc M oc 5ciEIP. SN l5 07220 - R. ' A.4togay/2v/4 '*- 14/17/75 " - ~ ' " " ' ' " " " ' " " " ' ' "' '
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' Pipe' Spools ' ~~~ 0 DA c. f **
QC IIold Area " B 3. [A yb
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- c. sca s A a. n uu s ca s.srAarue sysvam no. 'e s'. hcF[i.Accm r rAny # ' 'n e v.
no. eae.ect **tosa===== *a s l
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<//. r. z .'. /7.f" s.ru cw Asc onocn No.
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so.oc recto susrectioN ri.An no. is. nceLAccucur scasAL no. 7220-M-104A M-104A-R-10 N/A
~
.. cuar Acro'attoc Arion .
ii.Asuc gves ir.sounce ,,
'" ?}" ~ '" * * ' '*f"I *',,(,p-
,J,,,,,Q,,,',1;<';-
_ITT_.Grinnel/.KcInc.rsvil l r> ILC . .r m O_no is. an ursuG susrauctions' O "ours To c'o ="ciac c a'"a
$@. N 2 nCoNroRMsNG CoNosTsoNs M a_our= Vendor ro = ^rca'^' Su'c av'5oa Form G-321-D for P.O. M-104A requires vendor to supply radiographic verification reports.
The radiographic verification report (Reader Sheet) supplied for 1-ilCB-20-S612-3-3 O!R-66-15) Weld C reads n, .,_l-IIC. B-20-561_2-3-3_and report supp. lied for 2-GCB-25-S611-3-4__(!!R-78-19) Ucid A reads 2-CCn-25-5611-3-4. The ', __ verification reports do not correspond with identification markinns on the spool or spool drawinn. Nonconformance noted during rece.ot inspection. "Q" No's. are 4.114 and 4.124. Unit 2 and 1. 2 lloid tags applied.
/
2o. g(reci.o o.scosarios gric.o accouutuo Arionfuourc ro enoaccr caosuccninG mi. recto ossrosarion acsui.rs.
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- 15. 8S fJ c5tGN CH ANGc R cQu!Nco 24. McJccrco M ArcRI AL otsro$lTeoN
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- Origenator QC-GT Canary Cop / - Field Ena'noer Pink Copy - PQAE Goldenrod Copy - OC y t a
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- s. aaaw,unesur u ;
NONeGME.QRt.1ANCE REPORT
o'" 1 "' "[1 I Spec. C-38 y e v.
- s. e,.oscer no.
S.a,. o > !$_M ; use
');. f n. ous-os.r.on co ncun ucnce 5 07220 if.
n, . (s. I ray "-~ " " '
- 3. arcM oesCniPrfoN .
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I o # ^ 7' _ Aux._B.blnuRD.pns c.scusai.=uuoca OC llold_ Area
.. sraurur sesrcM uo.
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72 2_0-C-38 C-25 C-38-R-47 i s. =cecaccucnr seniai. no. Q.d((',y..,== t gj ,[dfl s 9 y -[
- 4. co nv a acr o nitocar.on N/A i..suc Code O 'c5 '7 Sou"cc
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Tngalls Iron.Sorksl.hr.ona.,_fli- s'c" El ao Vendor is. nour ~G .asrauctious' 0"ourc ro rieLo cuG.nccuinG __
.B. NoNCoNFoNMENG CONDertoN.
]{. nourc ro marca 4L surcavison Form C-321-D and Shop Inspectors Release '1VX both refer to and certify material on Shioninn I,Ist C-25.
The followinn three ( 3') beams were received with shipment C-25 but were not included _._on_.t.he Shinninn List C-25. "0" No. is 1.201. N3 lloid Tags Applied. s . ./ 421B9 439B10 2L 401B21
@ Fecco ossrosersoa Or'c'o acco==caoar'oataouTc ro dao'ccr caGiaccasac ' ai ric'o oisrosiv aoa a c5u'rs' Ma ki,,1/ Jimm X SAL Midil Ks A k C-zr' </l ,= s JK: ir k e bon r. Mk/ k l.Ew 47mf_
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, ~, < % . 6,-1 a>n LiJii.ri kvl m r-) b sr k ;# k m c /
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- 22. cNGIN ec RING Desros4 Tion
. 2 3. chC EN ecRING ofsPosersON R e ,uLrs.
as. is OcslGN CH ANGc McQulHc0
]ng 28. RcJccrcD MArcHtAL DisPostraoM O a n '** - v. sw "$'< - a,. a e n /
O ves. stc arracnco. .. .. , 4_,,.. Da AWING RcV. DCN 7 7 r
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t Pc C. A c V* = AOD. f ..., intei White copy - Originator Q C-G 3 2 Canary Copy - Fload Engineer Pink Copy - POAE Goldenrod Co ay - OC
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^-', NONCCNFORMANCE REPORT .-JT' 313' 1
- 2. . R r.WI N M / A % T N 3. -- B R C V. 7. P R O J ECT P 3. 3 .' I C PO #4 T E D is Y 'DATC 25. DISPO' sTION CL:NCUGRCNCC dQPf . 7DD-r -% -
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- 6 7220 .' _
_0/M . ~ "N ~ ~ ~ ~ ~
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- 1. lT8;M V ESCRIPTION
(. BTEM LOC AT60 N f(p [/ [ .
/O Y . DAT uruetura, m nR, nnmae '- %mma%-141n #%s / ?z f ' ^ H (!N.lmd d '27/
C. L En t A L. N U M D ER
, , ,.- '.V.- 9. 57 ARTUP SYSTEM NO. # "
h CV. 3
. f I S.'H CPLACEM ENT PART NO. *%4 = = T * * = 60 s a af
' * ,s.: ,
I nsu;;/L - p;4 T y IIcar No. H4~ 453 -
*N/A N/A l ,.;,,,,,,, ,,,,-- *. PUJ CN ASE ORDE R NO. ,. . j,- - $ 0. Q FIELD 8 fi ION PLAN NO. 5 6. R CPL ACEMCNT SERI AL NO. f j [e 2,7 *~)
7220-C-38 -
-#//g/- 4' W 2.) N/A 7 u r na = = ap = =
=a'=
- 4. C > NTG ACTO R/ LOC ATION
- j'
- St.ASME Q YES 17. SO U R C C Ingalls Iron Works, Verona, PA. * '
co 00_ NO __ Ven_ dor . _ I S. < MUTING INST R UCTION Sa e
. QROUTE TO FIELD ENGINECRING O ROuTC TO M ATCRI AL SuPCRviSOR 8 9. NSNCONFORM8NG CONDSTOON:
In accordance with 7220-C-38, Rev. 6 the applicable specification for structural steel specifics ASTM-A-36. Certified mill test report for subject heat number (H43353) states tensile strength to be 81,290 psi which exceeds the allowabic specified tensile strength range which is 58,000-80,000 psi. Nonconformance noted during document review. Q-Number is 1.201. One tag applied.
- 23. O F8C4.0 DISPontTION 2 8. F RELD DISPOSITsO N H CSULTSa
%F8CE.D e r t' RECOMMdF .. 4D ATION/ROUTC TO PRO JECT ENGIN EER8NN gv W - *
~
- 22. ENGIN C E RING DISPOS 4 TION 13. ENGIN E CRlNG D4SPOStTsO N R ESU LTS s it, n nn it The mill rest report for thc_hnar_gives an elongation of 24.5%. which passes
.__.the 20% minimum _in_ ASTM A-36. Thus. the material elonnation properties have not been detrincatally affected by the 1.6% additional tensile strength, and are acceptnble."~ l -
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T'lerafArt the material is acceptable for use. g d n g~_g,g,g ~ y, c /g -.0 : mf- ,
/ I c' a- .. .
- 20. $$ DCTIG N CH ANGC REQU4R CD NO 26. REJCCTED M ATCRIAL DISPOSIT80N O a =vva.vo sweruaa 27. C ACCCPT ANC O v CS. SCC ATT ACH ED.
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SPEC. REV. ADO.
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.y y ORIGINATOR Wj
- 2. k 6 C WING /P A RT NO. 4 N E V.
NONCONFORMANCE REPORT , ,
/ r or"" i "~ "'"a9]"sg '
- 7. PR oJCCT NO. 11.REPORTEDDV' oATE Ib. DiSPO54780N CONCUR RE NCE Spec. 7220-C-38
- 3. iT E M DESCR.PTSON l6 07220 R. A. Moray -
$'/29/75 -*" ~ > " - - " " -
j""' ' " * - S. BTEM LOC ATsON - 3 3. V A 4.40 A T E D S V I DATC (4) Au:c. ID1dg. Beans Sasse Rd. Laydown Arca L. Ll A 8 A t%NuMcEN
, , t [ h% 7;
- 9. ST A N T uP S VE TE M NO. 3 8 5. R CPL A CE M E N T P A R T NO. R E V. emesa gt resseEn. ems.e ***S 5ec B1o_clL19 U/A II/A
/
1
- 3. Pu%CN 45E ONDE N NO. 8 0. OC FIELD 6N5PECTaON PL A N NO.
9 6. H E PL A C EML N T SCRI A4. NO. 7220-C-33 C-27 C-36-R-49 N/A ....
- c. Ca NT A CTon, loc ATioN -e...?-..-..-...
ii.As-c o TE. n.souMCC Ingalls Iron Works /Verona, Pa.
- 5 pj ,,, Vcador , , , , , , , , , , , , , , , , , , , ,,,,
. .. Ms uT.No .N.T a uC T.oNs. __
g =OuTE To P ELo c~ci~cca.No o ourEToMATca AL.uPc=V.soa i.. N rNCoN,ORM No CoNo 7, "' Specification 7220-C-38 I:cv. 6 paranraph 7.5 states, "The ucinht of au cer.bers 6,033 lbs. and heavier shall be clearly stenciled thereupon and together with an orientation north or esat." Contrary to tne above, beans 516Bl , 516B2 , 520B7" and 520nS" are all listed as veinhing m than 6,000 las. on shipping notice C-2 7 but they are not marked with their weight or orientation. Nonennformance not during receipt inspection. "O" No. is 1.201. hold tags applied. 23 Q FeCLD Da5POSITeoM OPic'o accoauCNo^TaoNiaourE To PaoecCT tNoiNcCaiNo 2i. riELo oisPos TioM =E suLTs.
- 22. E NG N E E N NG D 5PostTsON 2 3. ENGINE ERING Di$ POSITION R E5uLYS4 a:. O DERIGN CN ANCC REQU4 RCD ONo ' ' " " " " " " " " " U~""~~ """""""
O vEs. scE aTTaCNEo. O .e... paAWsHG REV, DCN
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- 7. .
- a. C eem wsNG/PA NT NO. M C V.
. Or T. PR OJCCT N O. _
L 2. R C PO NT C D DV 25. DB5POSI), sN CONCURRENCE lOATC Soccification 7220-C-3G ' 6 07220 R. A. Moray 15/29/75 " - " - -
" ' " " " ~ ~ " '
- 3. OT CM DLSCRtPTION . s. 81 EM LOC ATsON (2) Aux. Bldg. Ecams 8 2. V ALID ATCO OY I * ' ' " " l "" -
QC lloid & Sasse Road
- i. lDATCT-2.7 7T'
- 4. E
- 10 A L N U M O C R r .....t
- 9. ST A R TUP EV E T EM NO, 9 s R E PL A CC M E NT PA R T 8W'ef
_fMiinnd424H3E
- s. PuMCM ASE ORDE R NO.
N/A N/A / I' R E V. I
.ose s, passe s.ee.e s. e.,e t o. QC P tCLD INSPECTION PL A N NO. ...,o ,. ..... ....
9 6. REPL ACthtCNT SCRaAL MO. 72'* 0-C-33 C-26 C- 3S-R-48
@, CSNTR ACTON/ LOC ATs IN N/A --+ >u ' u- w a - = = = '=
tt.ASMC O ves tr.souacc Innalls Iron h :rks/Verona, Pa. ', c
@ ,, Vendor .................. ....
- 18. HOUTf NG #NSTHUCTat NSa G 40UTC TO FICLD ENGtNECPING O aouTc to aaTera'suecavisoa S S. N EN CO N FORMtNel, CC 4DIT TON:
beam 415111' has n bent stiffener plate. Beam 424U3"V has two (2) bent angles with cracked velds. Drimage note d during receipt inspection. "Q" No is 1.201. hold tags applied. 23 0 nc'o oes"os'7'oa Oric'o accouacaoar'oaeaouTc va eao'cCT can'acca'ac a n ric'o oiscosirica assu'rs.
.o
~
- 34. ENGINCCNING DISPOstTtON
- 13. ENGIN CER INC. DISPOSIT4C N RCSULT&s 34,8 3 DESIGN CNANGC HCQuaHCO O NO ^ " " * " " " " " * " " " " " " ~ ~
O.e... O Tcs. ssC aTTACNco. .. .. . OR A Ws N g REV. DCN ......... ..,, Si CC. R CV. A O D. aw'se.. a e n s.ses sve. ..,, I x s a, s White Copy - Originator GC-G 3 2 Canary Copy - Floid Engineer G Pink Copy
- PQAE Goldenrod Copy - QC
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. 3 l
vrT m a m TJTSCR M[UE O2/27/15 1 PilOJECT/OEPT./ CONTRACTOR 2. POINT OF ORIGiri
@ FIEl.D 5. OAD PREPAllED BY:
_ 07220 - Hidland [] OFFICE YORK PLAN DATE 7. CHECKLIST ITER.1 R. Sevo
- 8. WHERE FOUND
- 9. DISCUSSED WITil ,
[ 02/28/75 25.3 Champion Files J. Connolly
- 10. COtJTROLLING DOCUMEflT, SECTION, PARAGRAPH, ETC. P. Schmnnl:1 Champion Quality Assurance Manual, Rev. 3
- 11. OUOTATION Section VII Document Control "The issuance and receival of instructions . . . . . are controlled by the assignment of a document control number. All such documents are"8orded on a log sheet ..... .
Maintenance of a log sheet is the responsibility of the Plant Supervisor." - Section XVIII Quality Assurance Records "All data and correspondence relative to Quality Assurance shall be filed under the proper heading and logged. These logs and files shall be available for the 8
- 12. DISCREPANCY DESCRIPTION
'0"*""*
' Contrary to the above; (a) a log sheet is not being maintained by the Plant
_ .3upervisor. (b) Correspondence relative to Quality Assurance is not logged. (c) Copy of audit logs as of 12/10/73 are not available at the jobsite for review.
- 13. RECOMMENDED CORRECTIVE ACTION
- a. Prepare and maintain log sheet as required.
- b. Log data and correspondence relative to Quality Assurance,
- c. Hake audit logs as of 12/10/73 available at the .jobsite.
- 14. SCliEDULED COMPLETION
- 15. RESPONSIBILITY FOR CORRECTIVE ACTION DATE 03/31/75 J. P. Connolly 1G. CORRECTIVE ACTION TAKEfJ l Champion has submitted for approval Rev. l 3 of their OA Manual. Thin revi inn I i
adds a Document Control Log Form to their OA Mnno,1 Conieh of ebn audit locs , are now available at the jobsite. i 1 S fp!TTED BY ESPONSIBLE AUTHORITY
- S" S'" ATE WCOMPLETED ;- Au L }RNA l
19 CORRECTIVE ACTIOfJ \'i AIFl R ' OAE
- 20. D AT E
, . W. " $/NN .5~//f 7 5~ 'AA0-86 9/17/7 8 ' # '
,- d .: , l l 1 l O Quality Assurance Dicerepancy Report - 053 l O : 1 ( l Block Ho. 11 Continued. . nudit by contractor ..... . Section XIX Audits 1
. .... A copy of the audit logs vill be kept at the jobsite for review".
l 1 I ( 1 I l 1 s l l) v . w 9
L4 b bls1bllN {55(25-2-11
.....c 3/31/75.-
1
. ,2........,.....
g ,, . ,. . . . , . . c dland 1 & 2 Job No. 07220 Construction O-.- m...... . . . . . . . . . . . .......... c. nichardson 1 10 U. S. Testine Files'
.. <. m ... ... ............. ,.............
U. S. Testing QA !!anual, Rev. 3 ' oo . . . . . 17.1 Conditons adverse to quality shall be promply identified and reported . . .. . . . These conditions shall be corrected as soon as practicable ..... . 19.1 A comprehensive system of planned and documented audits shall be carried out quarterly ..... Deficient areas shall be re-audited ' atil corrective actions have been accomplished.
.,.1..,
- 1. An audit report dated 11/7/74 identified a deficiency in the storage of records.
No corrective action to resolve this problem has ocen taken and the area has 7 not been re-audited. . k$!. The last audit was conducted on 11/7/74. That audit (No. 4).cov[redaperiod of four months rather than the specified three conths. Audit No.5 should have been accomplished early in February.
,,_...m.....
Instruct that U. S. Testing to conduct an audit within 30 days and take action to assure future audits will be accomplished quarterly. Also instruct U. S. Testing to initiate
,cudits. timely action to correct deficiencies which are identified during these g.m......-s......... ..............................
5/2/75 PFOCE g.u...u......,... An internal audit was performed by US Testing on April 11, 1975. F. . J . Zadina, the US formedTesting auditor, stated that a new audit schedule would assure that audits are per-quarterly. He also stated that deficiencies uncovered during audits would be-H osed out and verified in a timely manner. ~ f . .. ... [ 5 S-X
....9...................
.Q.Q.
y y,_,ggu s pggcg_ g g, p p p y ,, ..,, - . I
(3/ ,, llU " 11I A UUll Hi M t6 ! ... :. 05/06/75
.')
N/A S C m ,....,..n.. . . . . . . . . . . g,,,,. . . . . . . .
!! nd 1 6 2, Job No. 07220 Construction O ** * '= = C. Richardson
. .. ....6....... .......... . . . . . . . . . . . . . ( l 8 QC Files J. Connolly m ..a. .,t.............................. . . . . . . . . Fl!! G-5. Rev. 0 Pera. 3.3.3 " Purchased items which do not require release by Bechtel PID may re-quire quality verification documents . . . . . The documentation re-quirements will be designated in the P.O. and shall be itemized on the Field Receiving Inspection Plan. Documents rcccived shall be reviewed for .... compliance with the requirements of the technical specifications and procurement documents." Contrary to the above the Field Inspection Plan C-66-R for receiving materials to Spec. 7220-C-66 does not itemize the required material test reports and there is no cvidence of review of complaince by a QCE. The same condition uas also noted for FIP C-233A-R-1 which is used to receive materials purchased to Spec. 7220-C-233. Tl o package checked: NOTE: Spec. 7220-C-66 is no longer in ,
,r C-66, MRR AE0 636 use at this site. Therefore re-C-233, MRR AE0 316 vision of the FIP is not necessary.
F. .~ . . . m . . . .
- 1. For C-66 materials review all material test reports for compliance.
- 2. For C-233 review HRR AE0 316 for compliance and revise the FIP or utilize FIP B-1-R to receive non shop inspected materials f rom this P.O. as these materials also appear on the bulk items list.
- 3. Assure that this condition has not occurred elsewhere by reviewing FIP's used to recei ve o th e r no n
- .,. m ......... .... .
rM.........nm... .ec ted i tems . l 1 06/06/73 PFOCE ' 6 ,..T..... .... - (
- f- ..,m. l T.,....s,...............
.=
l
E , QuAUTY AUDIT FINDING
._.? ! 8 "- 2 -"
05/06/75 ja , 1 N/A g .......,,..u.. ........... 'g,,.,. ....... and 1 6 2, Job No. 07220 Construction C. Richardson O .- .. . _..,e- ............. ..... .... g , ...'m*"Bb~t'ie r 1 11 QC and Maintenance files D. Martin x,~u......-.......................... . . . . . . . .
#QCNM SF/ PSP #11, Rev. 0 Field Prc:. FPG-3, Rev. 2 ..x,.... .3 PSP #11, para. 2.2 "A storage and storage maintenance' package is prepared by the MSE on permanent plant equipment in accordance with the storage a'nd s torage maintenance procedure."
The s torage . . . package consis ts of Form FPG-3, F-1. . . . . . . Field Proc. FPG-3 "The HSE is responsible . . . . for indicating es tablished re-para. 3.0 quirements on associated forms." para. 5.1 "The MSE enters storage requirements on Form FPG-3, F-1".
,....u Contrary to the above no FPC-3, F-1 Form has been prepared for materials purchased to Specification 7220-C-2. This material includes trumpet assemblics and sem. rigid l^'ithing.
)
v I.
- p. . ,L . . . ...
- 1. Prepare a F-1 Form for the above item and assure present storage is adequate.
- 2. Review existing F-1 Forms to assure the above condition does not occur elsewhere.
l
. .mou .. . ......... ................................
06/20/75 Project Superintendent y m ....,.......... - l l 1
/'. . .
r ,
.._-.m... . !
g..s..............,........ ..,, =_ ----.__...___.......__.__.__........ . _ _ _ _ , _, . . _ . , , . .
' Pouta To This opy For File 16.3,6 dSKeeley Sill!owell
! )OF Issue Date Mav 9.1975 i .' Project Midinnd 1 t, ?
HWSlance UEKessler (2) N,,, , , CQ11111s TCCooke COEiG3 N12f File Title MCR's on hechtel ( JMilandin Quality Control UFItolub I:onconfornance CLRichardson Report Ho og_4g This Honconformance Report is Issued To: Prepared By' 4 ~/4 d w Date -$ -i Mr. J. P. Connolly hyproved By <_ WbhA M Dato SY1 'E Bechtel Project Field Quality Control Written Re, Requested Date 6-6-7 Engineer Corrective Action Req ted By Date 6-6-7 uho is responsibic for corrective action. Uonconformance Description and Supporting Details: (1) Specification C-203, Rev. 4 section 7.3.2 states "A slump measurement shall be made for every 35 cubic yards or fraction thereof of concrete produced for Class I structurcs." For concrete placemento CC(652.75)a' and CC(621. 0)a ' , 56 cubic yards of concrete uas placed betueen slump measurements. (2) The C12-1 form (In-Process Concrete Test Report) for CC(652.75)a' indicates c r air meter and one thermometer was used in the field for testin . o However, at least three air meters and two thermaceters were used 11. the field. One air meter and one thermometer was needed at the pump discharge. One air meter and one thermometer was needed at the truck discharge. Also, the QC inspector noted on the C12-1 form an air meter change after obtaining 7.5% and 6.5% air with the original air meter. M mits AEC Reporta' ole YesLJ!!ohaircontentare3.0%-6.0%.See Procedure 9 (For nuclear Projects Only)
/ Stop Work necessary Yes 1:o y See Procedure 16 - Stop Work'Mo
)
/
Ecco.vmended Corrective Action: (a) For item (1) above, receive an Engineering (. evaluation of the acceptability of the concrete placcd without the required slump measurement. No additional corrective action is necessary, because it has already been covered in letter C-208-56 from Bechtel to U.S. Testing, concerning concrete i.csting frequencies and test lbcations. The written reply to this item is requested uith the Engineering cvaluation. (b) For item (2) above, take cc.r r .rctive action to , preclude these occurrences. Written reply and corrective action requested for both ! Corrective Action Taken: by June 6, 1975 l l l Verification of Corrective Action Required Yes O no Method of Verification: 1
^ Monconformance Closure Confirmed By -
, D tc l
ib be completed at time of closure by Consumers Po.:cr QA Gervicca. Pa.:,e 1 or 1
uf Attachment A Route To Tnis Copy For ,s Fi10 16.3.463.6.3.6 GSKeeley SHHowell Issue Date May 22, 1.975 HUSleger '. o Project Midland 1 & 2 l jf WEKessler (2) .' (, CQHills TCCooke JMilandin CDUSUQSC F0Ylff File Title NCR's on Bechtel (, WFHolub Uonconformance Construction & Cuality Contrc GLRichardson Report no 0F-49 ThisHonconformbecRepo$isIssuedTo: Prepared Py 3.,J)$'.L% Date E-2 2. - 7:' ~ Mr. J. F. Newgen Bechtel Project Superintendent Approved WdId > DateSN2Mr Uritten y Reques+cden7By Date Mr. J. P. Connolly 6 n-7 Bechtel Project Field Quality Control
.M Corrective Action Requested By Date 6-7'4-7 Engineer uho is responsible for corrective action.
Honconformance Dc::cription and Supporting Detc.ils: Additienal emphasis on concrete tes ing frequencies and locations were expanded beyond Specifications C-208 and C-230, in letter C-208-56 dated March 19, 1975, to U.S. Testing. 7 tem 1 in this it_tter states in part "The point of record testing for concrete slump, air content, and temperature is a t the truck discharge. . .". Iten 3 in this letter states " Slump, air content, and temperature tests taken at the batch plant must always be backed-up with a record test at the truck discharge"'. Contrary to items 1 and 5, no slump or air content tests were taken at A-1 mlx. the truck dischage for concrete placement A(589)b, four cubic yards of
, 'AEC Reportab e Yes C Eo @ See Procedure 9 (ror nuclear Projects only)
(
~'
)
.Stop Work Necessary Yes no See Procedure 16 - Stop Work No ,
( Recer: rended Corrective Actier: (a) Tseceive an Engiraering evaluation of the accepta-bility of the concrete placed without the record tests being run. The written reply to this item is requested with the Engineerihg evaluation. (b) Implement the requirements emphasized in Letter C-208-56 to preclude repetition. 1 Corrective Action Taken: 1 Verification of Corrective Action P,cquired Yes no bethodofVerification: i s L donconformance Clcrourc Confirmed By r- Date 1 To be completed at time of closure by Consumers Fouer QA Services. he 5Lfut_n l
72, g j NONCONFORMANCE - REPORT LOG & STATUS BOOK j
, 12.
YENRT DATE 2 +7A M*0. D~ PAGE CoMPL. 7220 ""
- 1. PROJECT NO=
NCR ORIG. NONCONFORMANCE STA WS PREPARED BY 6- ^ NO. DATE DESCRIPTION / REMARKS nouTE xdTD ND CLOSED CLOSED BY 268 1-17 J.C.Aldrid 0e :-38. Bean connectors damaged, shipment He%d 2-13 1-30
-75 -M 1.201 t-f7-7 1 -75
~
4-10 269 l-20 A.L.Boulden :-111. Liner Plate X-Ray of reoair not iield 1-29 75 4-10
-75 A. L. BouldeT Ivailable 1.109 L-29-Li -75 -75 270 L-21 .:-38._Damaned beams, nine each. shin- 2-13 J.C.Aldridge Meld 2 -75
-75 nent C-15 1.201 6-31-7 b 75 271 l C.F. Clark 1
- -111. !!el dino procedures P1-F( A-CO,,) iield 1-22 4-10 5-7-7 i A.L.Boulden
-75 1.109 4 76 75 272 L tC.F. Clark C-111. Ieak noted at Knuckle Plate, F ield No .-22 1-29 R.Lussier
-75 lamina ;on 1.109 .-21-70 -75= -75 273 .-21 R.A. Moray 1:ulk flaterial. h" F. 5/3" Round hars. F ield flo 1-24 5-29 R.A. Moray
-75 7220-F-11452 .-22-70 -75 -75 M.S 274 1-22 J.C.Aldridae C-33. fla t e ri a l shirned without release IWl d' Ho 1 1 R . A . kto ra y
-75 1.201 .-22-7 75 -75 275 1-27 R.A. Moray :1-201. M-104A ITT-Grinnell markinq of E-i:eJ:d 28 -
-75 2 fs J-Rayed j oin ts nor per f1-201 ASME 4.192 J -fe -i 6 75 h/6 1-28 J.P.Betts :-39. Rebars cut of do not match Dwq =i:e4 -d 1-29 2 2-10 L.R. Albert
-75 C-37.4 Rev 10. 1.103=1 -ff,--7=5=-75 -75 -75 277 1-29 R.A. Moray 1 104A Tmnrnnnr c win rnrn 313S . No 2 4-10 R. A. Morav
-75== A75 -75
.dME,4.104 l'-30-1 5 278 1-29 R.A. Moray '1-104A. Imoroner G-3210. X-Raus innenn 't. S NO 2 4-18 R. A. floray
-75 er, Code Data Mane Plate. A S -1E ,4 .12 4 75 -75
, 1-30-J 5 ews m:, ,: .: . ~ -
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-75 erance a'aer concret' 1.109 4-81-FH 75 -
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. 1. PROJECT NO 7220 a.c. Enc.s m
- 3. 4-5*
,/R ORIG .
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. DATE PREPARED BY OMORMANCE STATUS DESCRIPTION / REMARKS G. 7. DATE 8.DATE ~ 'O. DifE 10.
292 2-25 R. A. Moray ROUTE XMTD RETD CLOSED CLOSED BY
-75 C-38.
studs Documentation not Red for weldin o M.S. flo 2-28 3-17 1.101/1.201 2-2C- 75 -75 R.A.fioray 293 2-25 R. A. Moray -75
-75 C-39. Rebar does not con form to anrva f=iel=d 4 4-11 drawings R. A. M ray
~
1.103 ?= s y,3-3-75 5 -75 294 2-26 L.R. Albert
-75 C-231. Curing temp below Snec on 6th M e l=d 3-3-75 5-16 day of cure, CC(593.5le ~ 5-19 L.R. Albert 295 1.10.5 ? =25 75 -75 -75 3 A. Boos
-75 Crequired
-231. Aux. Bldo Slab nlaced without rebars Fi=g ya 3-3-75 3-74 L.
1.203 8-8-7E -75 4 R. Albert k96 3-4 A. Boos -75 C-231
-75 Aux Rdin wall mininn nna har Field No 3-4 .5-15 D.C. Thompson
?97 3-5 1.203 3-4-75 -75 R. A. Moray 11-104 A.
-75 -
Two spools with same number : 4-10 F=i:e=h! 3=13= 93 ASME 4.134 g _qg gc 75 -75 3-10 A. Boos
-75 (
-231. Aux B1dn walls rnhar 1 <> n n e k e va ry from requi remen ts Field 3 3-24 3-24 L.R. Albert
'99 3-13
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- i. 3-26 R. L. Bowren -75
-75 r.-1n namagna nnan ,,nen "acnint increu Fieh tion. 4-10 M 4-2 1.201 !!-26-7f -75 R. A. Mo ray
-75 C-38. Damaned Beams.Shinment C-21 Eield 4-10 32 4 1.201 i 75 -75
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-75 C-33. Damaned Beam, Shinment C-23 -
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3- 4- 5- STATUS
- !R ORIG. NONCONFORMANCE VO, DATE PREPARED BY ,, ,,g ,7, g,g,7, g,g ,7, 30, DESCRIPTION / REMARKS ROUTE XMTD RETO CLOSED CLOSED DY 304 4-7 R. A. Moray 1- 10 4 A . Spool ma rliinq 'd i f fers f rom M.S. flo 4-11 5-12 R. A. floray ,
-75 reader sheet markings ASME 4.114 4-8-75 -75 -75 305 4 R. L. Bowren IIPGh.Storaceon Stean Generator Field
-75 1E-51A. AS!1E 4.021 1-9-75 306 4 h.R. Albert :-231. Concrotn temnnratnrn. A(roqia' r 5-1C 5-19 L.R. Albert
-75 1.205 jigid 9-76 4 -75 -75 U0 4" 0
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-75 and Documentation. ASME < 75 f! 4~22 5 2 R. A. Moray 308 4-17 R. A. Moray M-104A- R o a rin e chant bac inenrrnet_enno_ M,$* 5 ~
-75 numbers. ASME4.114 4-21-7 5 109 4-23 L. R. Al be rt C-230. Batch Plant nualification nast W hd 5 -75 due. 1.105,1.205 ' F 75 310 4-2" R. A. Moray 3". Damaned Beam. Shinment C 9^ 7:i el d 5-1-70 --1g
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75 -75
-75 List '1.201 5-1-75 12 4-30 R. A. Moray r-3n nananna anans. shinnnnt r _ u; %)d 5 5-27
-75 1.201 G-t-35 -75 -75 313 5-2-75 J.H. Miller C-33. Beam material tensile strenoth nie4d 5 5-27 5-29 L.R. Albert over ASTM A-36 limit 1.201 6-R-76 75 = -75 -75 314 5-29 R. A.flo ray C-38. Beams, Shioment C-27 without Field
-75 ucight or orientation marking 1.201 5-30-7 5 315 5-29 R.A. Moray C-38. Damaaed Beams, Shionent ;- 2 6 Field
-75 -
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~
noa cen4 0c Page 29 A-x y 1- w
y(. p- .. - u v r - . g.s .g g NONCONFORMANCE REPORT '#^ e 2. D H 4 W I N GgA=M +He.
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REV. 7. Pf40JEC f Nh. 12. R E PO P TEDDV {DATE 25. Dese*058T40N CONCUHr4E NCE
- 3. 8 Jddl]1 TEM DESCRIPTION
!S O M20 '
44 Mid'<W I1,/21 /73
~ ~ ~ ~ ~ * ~ " " " ' " "
S. 8 TEM LOC AT5ON 4. A A ED uv I \* "" Liner Plate
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UE L A s. N UM aE R Containment #1 & #2 4 l DATEJ-Zl-75N,,'l$Us.)hgp-w _ X/-/D-74
- o. 574 RTuP 5 vsTEM NO. "PLACEMENTP O. lREV.
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- 5. PU RCH A SC ORDE N NO. , 3 0. QC f tpLO 6NSPECTION PLA N NO.
.I m ...... .... -
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_N/A_ ' TEM Ol NO 8 8. Ed uTING INSTRUCTIONS: ROUTE TO FIELD ENG4N EC *t tNG Constsc_ tion Q ROUTE TO M ATCH8AL SUPCNVISON t o. M S NCON FO RM4NG CONOsTaON t Certain Areas of the Containment liners have been welded with a combination of two weldinit procedures, (i.e. ) the base or sea 1 pass is made with procedure Pl-AC-LH and the balance of weld deposit bring made with procedures Pl-F(A-CO,3) 1,2,3 This is contrary to Spec. 7220-C-111, para 7.2.2. - n 4)D 'f-COz.[5T12x7t)(&% Q',f/.6eW
/VO //C9 7546 W G .$ A A M /RO
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- 22. O FIELD Os5 POSIT 80N FtE LD RECOMMEND A TION /ROUTC TO Pf'CJECT ENGIN E ERING BV M A u tu d V /h$
- 21. PIELO DISPOSIT8ON RESULTS:
llss_As_is. A11hounh the_ use of a combination of welding procedures is contrarv to _the_snec1Lications _there ia_no_sletrimentaletf_ cat _ts._ rem _ntality or saractural intcarity. The specification intent was to minimize numbers of procedures used so as to better control _ and monitor welder performance and to enabic more precise applications of proper frequency of NDE. (see Sheet 2)
- 22. ENGIN EE rt eMG Ds5POWIT40re 2 3. CNGIN CER 6NG 04sPostTION HESULTS:
Proj ect Engineering concurs _uith _ Field _ Reconm,,fgdat;1gn _to use _ag The i< . stihj ec_t- / bad.B O. 2$MI - welds are acceptable because of the following: .ASME Section IX requirements are ,prM t m './ / # # that a single weldnig procedure specification (UPS) be prepared for each tyne of weldment. $4'# _gL f nu IJG Contrary to this requirement,_ combination _s of two WPSs were used in making the subject weldments. The weldine processes uhtch are r Ow!v4f M d@,b.4/d J6f/W
- 24. gj DE5sGN CH A NG C REQUs*f EO C NO '
rmonend hv ehe M 6 E. Abis/ N/75 EM's~r, ~~ N VES. SEE ATT ACH EDs ......,
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Further. ASIE Section IX paragraph QW 201 specifically allows combinations of procedures and processes in the 1 l nanc_uclLjnint- Thane _procedurn1 enmhinneinnn vill be envared in n no ther_ proc nd ura enmhining cha RhS1ded *f a rn 1 Arc (SMA) and Flux Core Arc Welding (FCAU) processes. Since no essential variables of either process or procedure havn changed the issuance ef a new procedure is simplified and does not require testina or re-oualification_s. Thus. I the neu .tfelding Procedure Sp_etification vill only reference _previously - nn Procedurnl Qnni f ficnrinn Roparen (PQR'ni The MF6QCS & Project Engineering _gIDups_hav.c_.already hegun_the nrocedural mcdification procnns nnd nennen un nur situation is not adverse to weld quality. [O Y /?Y p.-d l N~ dum. b_A y Tia #4
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tJdL m c Ag7S Im-M k b S M m M _d kWhQCS bo E G E@m. T( y l- M C __, Block 22 cont.: , cachinations of WPSs used can, in accordance uith_ASME Sectionlii bc_conibined_ int _o_ single WPSc. Therefore, the weldments have r.t the technical requirements of ASME Section IX, but the proper documentation was not available. To correct the nonconforrance, new WPSs permitting the subject welding have been- prepared by MF&QCS, and are being issued. In order to clarify the requirements for WPSs, Specification C;111 wil3 be ~ revised to delete Section 7.2.2, and ASME Section IX shall govern.Ot bd 2- /2 . im
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DY R. C. Sotunerfeld (RCS-015-030) o ,. FE6QCS - Ann Arbor E. E. Felton Tc, R. W. Straiton o, FT6QCS SFilo J. Itink o,,c January 22, 1975 /
^ ,, y,u c P 3 U. Straiton I suanc, Midland Units 1 & 2 ,
4 T. Velanzano @ 7220 Joe No. Combined Process Uciding Procedures for Liner Plate Uelds File: 7220-Civil Uhile transmitting the Projects request for preparation- of Uelding Procedures
- utilizing cellulosic and low hydrogen electrodes in co=bination with flux-cored electrodes, Mr. Straiton iras inadvertently told to co bine Pl-A-c-Lh (Structural) uith the flux-cored procedures. This should have been '
P1-A-c-Lh without the (Structural) designation. lie authorized ne to inform T. Valenzano. and J. Ilink of his intent to utilize Pl-A-c-Lh for development of the combined process procedures. This is a modification of his TWX to E. E. Felton/T. Valenzano of January 21, 1975. ( r b ' R. C. Sormerfeld Unterials Engineering Supervisor RCS:id
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- f*/ Bulk 50 pc d " 'a ' a = ~ # #
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- c. sE ni.L Muu oER s. sT.RTur sysT E u NO. /, . REPLACEMENT P A NO. 3 se Et. D82021 & Y88283 respectively N/A / U/A lREV. easaectm esadef f.g y-73
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2220- CTO 52LOC.m B-1-R-F c.CONTR.I-H,,h, 2.01. _0_a m, UM
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J. T. Ryerson Detroit, Michigan ,TC o 10 ,,o Vendor
,0. RO UT4NG EN ST R UC T sO N S.
Q HOUTE TO F8 ELD CNGINLCHING ] ROUTC TO M ATERI.L SUPE RVa50R
.9. NONCO N FONMING COf 08 TION a
- 1. The 4" round bar requires the following in qr. der to meet the conditions of thn_P_._0_2220 r-lih52.
- a. Certified Materials Tests Report to include tensile properties and bend test results,
- b. " Statement of Conformance."
- c. Tagging needs to include size and length of pieces, number of pieces, heat number and r~mufacturing ell 1.
- d. 1 oc. is damaged - bent. Continued on Pam 2
- 23. { F8E LD 045POsaf EON CF4 ELD RECOMuCNDATIONgROUTC TO PROJECT ENG4NEERING 2, . PsCLO DISPOSITsON R ESULTS:
Material Supervisor to obtain missing documentation from vendor for itcas [M, /6 .d # '/.w / M-. />4./ l-a, b, c and 2-a, b, c as listed in block 19. Items 1-d and 2-d listed .dNM/Y $ N.2./.e 4/ du D l' in block 19 will have bent portions cgt ap.ay and roiected. Estimated (Jdd.'.f /d d 5 d ,-2 ,e,.[ . imolementation date is 3-1-75. '2[ //.g 6 /,4 J/2 P Az.d d .Nr / W J m - fi
- 22. EN G 4N CC H 4N G OtLFO s4 TION
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7- F,," , I -" * ,. , y f NONCONFORMANCE REPORT (CONT'D) e. er c 2 r 2 m aca e.2 # _ Block No. 19 Contlyuad.
- 2. The 6/8" round bar requires the following .in order to meet the conditions of the P.O. 7220-F-11_h62. ~
- a. Certified Material Test Reports to include tencile yroperties and bend test results,
- b. " Statement of Confomance."
- c. Tagging needs to include heat number and manufacturing mill.
- d. 2 pcm. nye damaged - bent.
.Honc.onformang_e_peted_ dtiring_rencipt insppe_tiqm_____ c 8 I{o.ld tags._gpplied.
OneK 2O (ennlinu ed\ ML (so) ni m s x 40' 4 4 " An . % ,s a be h be a re J c, s un- Q emd Pt> PAC + L4 T t (4 5 v\ r\0
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/- s NONCONFORMANCE REPORT ,^"*'
F- A.NGv.RTN - y ~> "'""* j ::Ev. 1.P.:OJCCr NO. er 7220-C-231-Q 294
; 6 07220 it.geOjigpf y FATE as. O.SPOSiT ON CONCuaRCuCC
- 3. 8TCM O CSCRIPTION
- 4. ITEM LOCATIO N _f._' f Mfcrt ,
e/26/75 "- "'"~ ~ '
."".'i. e.
Cont. #2 Cover Slab Reactor Building #2 83.V : I ATCO DV g w" " "1 .' 8,y,""g[_[~y
~ ,
- c. im. 8 A L N U M D E R
- 9. FT AR T UP SYSTE M t'O. _ J'M W",DATE26D,-
n/A 5 CPLACEMENT PAR 'F'. 8 REV. p o.s cr ei.so me.4=.a.
] .x g N/A i 'g save S. PUZCH ASC ORDER NO.
3 0. OC FIE LO IN SPECTAON PLAN NO, N/A i ,yigggw
~,
, , g .,, ,.T N/A 3 6. REPL ACCMENT SERIAL NO. _s .
b CC NT.J ACTOR / LOC ATION C-231-h-h82 Rev. O p =. . . . . , h ,' ve..-i [w/$o...
'st.ASME N/A '
C YES 9 7. SO U R CE '""" * *
- 7/'"" gl **"
9 8. QUTIN G $NSTR UCTION U TCM G NO ROUTE TO FeELD CNGINCCRING Constructi.on ' '
':* '7 34 .' d
- 10. N T NCO N FO R M8 NG CO NO 8TsONs O aourc to =^rcai^'surtav'Soa .-yy , ,,.; ' * ',/
maintained at no less than 50 F during the curing period. Specification jtce 7220-C-231-0 termeratures be oncrete indicated temperatures of h00 and h50 Contrary to the above_ recording ther:coceters in the cover slab surviillance. "Q" No. is 1.105 during the sixth day of curing. Honconfomance noted during routivo 00 20 One Tao annlied. Q FIELD DISPOSITION
@FsELO RCCOMMCND ATlON/ROUTC TO PROJECT ENGINCERING
__ys e n n in. 21. FlCLD OlSPOSITION RESULTS: The inucnt enneroro r ovmorn rn ro roenrava vnc o d:*y o f enrine. An r vhich necurroa anring Pho neh Thic cnnd f f-inn un n dicenvered nr R '? "4 0 n _ m nn . rhn 7th day nf enrina_ ' The _ofheatersthe affec'ted wereconcreteimmediacciv (Cont. readiusted and the curtne neriod 1 insure uns that all extco3 ed to
#2 cover clab - approx. from azimuth 220 Continued on Sheet 2 to 342 ) received
- 22. E NG4N CE RINC OISPOSs TION Tenperatures below 50* (and above freezinn) during curing of fresh concrete h nt'al effect on the concrete. ave no detri- 23. ENGINEERING 08SPossTION RESULT $s It merely extends the curing time required to reach a spe-
_ cified strength. The curing period was extended to compensate for the lower temperature end, hence, Engineering concurs with Field Recommendation to use as is
/[64 .( -f- pf-nAALdl l'
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=
=
2 IS DESIGN CHANCC REQUIRED . h NO
- O vES. SEE ATTACNED.
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3 NONCONFORMANCE REPORT _ . _ _ _ _ _ _ _ . _ . _ _ _ _ _ _ _ _ _ . . - .- . - - _ - . . - cr.] 296
- 2. Let t.WS N J /P,WT NO. 8RCV. 7. PR O J ECT H J. I 2. H LPOHTCO uv 25. O t% POSIT LON CoreCU N HLieCC 7220-c-282 (o)
- 2. 8 TCM OC5CR4PT ION
!h 07220
- 4. 87 CM LOC A T aO N A. Boos _22 84Id' '
O ATC - . - 3/1/74 ~~~ " ' ' " ~~~~ " " ~~'
. ... 13. I' E DATC Reinforeing Steel G 'e C R G A L N U M DER Aux. Bldg.
- 9. 5T ARTuP SYSTEM NO.
f5. CPL ACCMENT PART NO. lS//[f R C V. mud}2.l[.m.f >
*..ss s e ee 6. e.esa
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#. a .is N/A __H/A N/A I -
.. PU RCN AsC OR oC R NO. . .. O'C r n LO .N sPCCriON ,L A N NO. . .. R uPi. ACCM EN r sC a. Ai. NO. G ,/^g"....ff d' ,,,,,
3-4"""'76 N/A C-231-2-313 Rev. 2 N/A g a "*'- -"-* J/' aCONTRACTOR,LOCAT.ON
,...=0== . Ou u
_lT/,A - 'T C M _ Q ao_ _ Cons _truc_tiRD -. 3 0. HouTING IN STR uCTION S. ROUT C TO riC LO ENGINEERENG O aOurt 'O =^rCaia' 5uPcavisOa
..t. ONCO"" a"'"** "
"' "' The referenced drawing specifies that the horiz. reinforcing for wall 27 shall be #8 bars 12" on center. One (1) #8 horizontal dowel has been omitted on the cast face of the 7.h wall line below elevation 58h'. This will produce a 24" spacing in the #8 hori=. wall reinforcing for the south face of wall 27. "Q" # 1.203e
/ , .
O.b ins-rr2. 3/4/75 -
/ !
7 21 @ FaCLO OBSPOSITeON 2 9. F 4CLO OtSPO$af TON RC5 ULT 5a QFICLO RECOMMENDA T60N/HOUTC TO PRO JCCT ENGINE ER4NG Drill a hole for the missing dowel in the 7.4 line wall. Fill the hole with f /, 4 % f,, f _ a L L ,,,. ,, 4 4 non-shrink grout (EMBECO 636) and set the required dowel. The embedment length cis par. mee.Reor.,m,,iefc[Co,so,.d of the dowel shall be in accordance with Table 36 of drawing C-211 (Q) Rev. h. be c -2t t u nd S c.C-2 3 / 9. 6C - C6
- nk ehret 'l o PI P. C-231 - 2 .Wh 2 2. ENG8N CE RING D s5POS6 TION bb0 WmJ 'YY/7.5' !
@ n. L . ( k .< o _ 4'-3-75
- 23. ENGINCCRING D15PO$6740N RESULT 14
- 24. 33 OC$3G N CH ANCC R EQ ueH CO O NO g, g=/y K O v Cs. .CC ATTACNCO. .. .... .i ..'...... <
OR AWING ggy. OCN ase t... .a s . en. .es s ,.. ..,. S. PC C. REV. A D O. a.% s s Whke Copy
. - Originator Q C G a-2 Canary Copy - Field Engineer Pink Copy - POAE Goldenrod Copy - CC
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- 2. 2.w N uPw T NO.
NONCONFORMANCE REPORT I 3_ t. f/p 7. p+ ;OATC _ '] '--t "" 03 4 p Cv.
.j2,p. ,Tt fY T. ,Rs;ECT N 2 i g 23. OisPus. Tion CONCuNRC NCE Spec _ M-201 l 5 07220 /:r.A.,.E&ra i4/2/75
~ ~ ~ " " " ' " ~ ~ ' ' '" " '
- a. STEM OCSCH0PTsON . 8. BTEM LOC ATsON $fVA i T Qb B Y , I OAT }
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_Eine_ Spool O. L CRAAL NuMuEN OC Hold Arc.,
- 9. ST ANTUP SysTCM NO. . .
t h. NEPLACCMENT P ART NO.
- .!I
[ I R E V. posee ct Pohe eheeme te GATE 2CCB-25-S611-5-4 N/A N/A
~
S. Pu stCH A SC O R DE R NO. 10. QC FaELO SNSPCCT40N PLA N NO. t e. R E PLA C EM E NT SE R 4 A L NO. J f "7[ __2120-M-JO 4A M-104A-R-9 M/A */'".'g g *(,*] y
- 5. Ch NT R ACTOR / LOC ATaON I3.ASME YES I7.EOUNCE 4 y[fgg COOC ,,
T rT Criancil/Kcrnersvi11c - N.E. 8 0. O Ouf tNG IN bTRUCT40N 5a
. TEM O NO
- Vendar--
" Q ROUTE TO FIELO CNGSNCCHING RO UTE TO M ATERI AL SUPER VtEOR 91 NONCON FONM4NG CO NOsTsON E .
Forn C 't?1-D for P.O. 7220-M-104A rqnuires re_ndor to sunnly radionraphic verification reports. The radiographic verification reports (Reader Sht cs) supplied for spool 2-CC3-25-S611-5-4 (MR-7S-59) ucids A & B read 2-GCB-25-5611-5-4 A & 2CCB-25-5611-5-4 B. The verification reports therefore do not correspond with identification markings on the spool or spool d+g. Nonconformance noted during roccipt inspection.
"O" No. is 4.114. Unit 2. / Hold Tag; applied. U Y ,d,,/,,,, 8 [ J/'-;0/)
- 22. ICLO OsSPO5a T60N
\J '
QF8ELO RECOMMEND AYtON/ ROUTE TO PHOJCCT ENGaNCCNsNG 29. FICLQ 00 yO5sTION NC5ubT5a l /* r s*W s- } C- f (<. M 'f/ J /~P kQ A d *- 2{ -
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,.--- p. yp 2 3. ENG tNEEs4 tNG Os5POS4T 40N R E5uLTss
.h. s 29,. 83 OE34GN CN ANGC R EQueRED O NO "
YES. SEE ATT ACHCOs
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.. .... g ,,jg, s 7 r ee t. WIN G R E V. OCN d^e., . j _,$ j g,g,gg awe =ee.a a e . ..a c re. e...
SPEC. RCV. ADO. tsnea white Copy - Oreg,netor GC+32
. Canary Copy - Field Erigineer Pinir Copy - PQAE ..
Goldenrod Copy - oC
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NONbONFORMANCE REPORT
- 1. 0,.co.N u,wT z
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, '2 " b"6 p E v. ,. ,-cc T NO. ...N ,0 TcO ;e.sj g q j oATE . . O.s~ s.T.ON cO N eu a E N cc 7220-C-230 5 07220 L. R. Alb'ert 14/9/75 " - * " " ""~
, J. IT EM DESCRIPT40N .. 5. lTEM LOC ATlON . 43 A L,sQ T E O D Y I Qj "*
Concrete Placement No. A (609 ) n ' / /g / !'D ATE /-9-7IkM/ s_~~ (- /**st' - N
- 4. s E 8. a A L N u M B E R s. sT ArtYuP sV STEM NO.
- I . LACcMENT PART emoseCF***se sad ***
- N/A
- s. runcN A sE Onoc. NO.
N/A
.. 0c r.Eto .N s,EcT ON ca.AN No.
/A
. .. .c,c A cEM E N T sen Ar. NO.
l REV. N..ofp p.E... j f.jc,.7.5 ufb c-9n1-3-509 ...AsMc nfp f*""*'~~'**
.. cONTa ACTO =i60c AT ON o TEs in.souncE g,],,,,,, ,,,,,,,,&_ ",,",,
Champion - Midland .'T E M C%.O_ _ Sub_ con trac to_r
. .. n o u T.N G N sT a ucT.O N s' D nouTE TO r.cco cNG.NEta NG o nouTE TO M A rEa AL surEnv son 3 9. NONCONFOH MING CONDITION:
span. 7?on-c_93n nnsr_ 5 in rhn en1A usather canceneing-temperaturn chart. h orein- 11 1 specifies that mass concrete deposited in the forms during cold weather when the ambient air temperature is between 31 nna as e.h n 1 1 h!.nin n enmnnr,r.,rn rango f rn 65 con ernr-f en ehn 'hnsrn 9 r" vh nf en crata with a temperature of 67 while ambient temperature was 42 was placed in A(609)a' . Placement A(609)a' has a least dimension streater than 2!s' and contains 102 CU yds. Nonconformance noted durino routine OC testinn of concrete during placement. "Q" No. 1.205. / oc //o t o 7 a c: ,q n f y , f, m.. O r'c'o o'5"os'o a Grac'o accoMMcao^Taousaouve ro ***oeccT rac'acca'ao ai res'a o'Seasarioa ac5u'25-Field recommends "Use As Is" based on the following rationale:
- 1. The temperature was only 2* over the upper limit allowed by the referenced Specification.
- 2. The 8 cu. yds. which failed was the first concrete to be deposited in the form.
~
Corrective action was taken as evidenced by the test taken on *-he next 8 cu. yd.
- 32. cNGIN EcRING Dispos. TION 2 3. ENGIN EER.NG O.SPo s.T.O N R LsukTs r The higher _ placement _lfrpAGture vill tend to increase shrinkage, setting rate, and water demand while reducing slump, durability and strength. A 2*F temperature difference for 8 c.y. Will not have an appreciable effect on any of these factors.
Ennineering concurs with Field Recommendation to use as is, pg. f 4 _, , , c
/ M fdd4 'S - / - 7 C
/
- 14. as DESIGN CH %NGC R Cou.a ED gg 16. REJECTED M ATERIAL DisPOstTION O"'.'.*.*"'*'""**
- a. 2 F. QC.tACC EPTANCE/
ch-lr e_ O YEs. sEC ATTAcNEo. ._.... . c,, ;4 ?/ms
.g..... f am, DR AWING Rev. DCN aven...a ......s,.. ..,.
seEc. R C v. A D O. 38888
, Whita Copy - Originator Q C-G 3 2
, Canary Copy - Fiord Engin#er Pink CopT - POAE g Goidenrod Copy. - OC f . . r
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.. , , .? NONCONFORMANCE REPORT 8
[L7 ( pg ']^* 2., x Aw.Noiru f NO. j nev. , , OJc cT NO. i ' *' "30 ' ~ "d Spec. 7220-M-201 '5 07220 2. pro 70 of 7;,,es joArt 2.os Os.riONcONCunatNet
- 2. eT CM ossCairTaON ., s. TzM LOC ATiON R.'A Miogay 14/17/75 " - ~ ~ ~ "'"' ~""" ""'
",3.'
istv ' 3oA C Pipe Spools ~~' QC Hold /rea
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- t. sCH 4 AL NUMeaER -
S. ST ARTvP S YsT EM nO. 't h'. E CPL A CEM EN T PA R T NO. #
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- 8 8 8 T * *e 6. e .s e.e e . eats Scc._ Black 14 I' 'M E V.
- c. runcN AsC Osioca NO. --
M/> H/A 1 s so.Oc rasto aNseccTsON rLAN No. 722.0-M-104A is. nCrLACsMcNr sCas AL NO. g
....ucd*....>g ,gyf.... [f" M-104A-R-10 N/A
. 4. C : NTR ACTOM/ LOC AT40N II.ASMC OTEE 17. SOU R CE -
""*"*'"*?'*"{"" #
CooC a****"'**""" " N ,f . ITT_ Crin.NsTaucT.ONs.nel/.Kerne.rsvi11
- 2. c Q uT.N c O aou'c m "c'or> c~o'acca'ao eT cf V
,,. NONcON,0a M.No rONOe riON.
O " Maou'c 'cndar - o a arca'a' 5urc av'wa Form G-321-D for P.O. M-104A requires vendor to supply radiographic verification reports. The radiographic verification report (Reader Sheet) supplied for 1-HCB-20-S612-3-3 OfR-66-15) Weld C reads HCB-20 ,5612-3-3 and report supplied for 2-CCB-25-S611-3-4 O!R-78-19) Weld A reads 2-CCB-25-5611-3-4. The _ verification reports do not correspond with identification markinns on the spool or spool drawinn. Nonconformance _ noted during receipt inspection. "Q" No's, are 4.114 and 4.124. Unit 2 and 1. "2 Hold tags applied.
/
p 2 ). [FtCLO DesrOSITeON OFICLD MECOMMENDATaON/aOUTE TO PROJCCT EP*G4NCCRsNG
- 2 8. F#CLO Da5 POSIT 80N RCSULT54 h* * ? N >A f .' / ff*A */* d / *t7 M .? - / -
l_ f % /*
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- 22. ENGeN ECMING OssPOttTtON
/ M A.-
4 2 3. ENGINEERaNG DISPO&aTaore RESULT 56 210 DCstG N CN ANG C REQuiMED NO 26. H CJECTED M A TERIAL DISPOSITION Q .a tw.. M sw. 6.e . 27.O A dC O T es. sec ATT AcNco, o . ... Jrti,[CAMfC s/Ae , f7s- ?r~ u n AwaNa nev. ocN g:43, , n, 7
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. ;JEC. R E V. ADO. ~e....n......e... ..,e
. u.... - -- Whste Copy Canary Copy , --OriGanator QC-G3 2 Feeld Eng near Pinia Copy - PGAE Colcenrod Copy - CC l .
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f NONCO.NEQflMANCE REPORT ,,
- a. ONz.ws N 2/PA w T N .; '~
^ 1
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' 25. 045PJSITION Ca NCuN#eCNCC Spec. C-38 5 07220
- 3. 8 7tM OCSCRsPT80N . S. STEM LOC ATION M. s..
foray / 14/29/75 5 g- ^
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'7 V 'L}O ATL D D V , OATC
__AuL._Mdg . Beams __ 0C Hold Area -8%4
- c. sEnsAL NuMaEN s.sT ARTue sysTEu MO.
h k-3d-7T is- I <l- 7 t NO.
/ /REPLAcCMENT P *=..=ce-a*== p a ==*4 lREv.
_Sec nlock_L9
- 5. PU N C e* A S E O N D E N N O.
N/> " M/A I 3 e.OC PICLO sNSPECTION PLAN NO. . - .- 7220-C-38 8 6. R EPL AC EM E N T SE R G AS. NO.
?}[ fy# g
- g 3 '/ * ]
C-25 C-38-R-47 N/A **** O. CO N TR A CTO R/ LOC AT ION 33.ASMC O vc= " sou"cs ' 7'"' ' *"* " ~ ~g'f' av ==.e.s e e..es e v.e Tngnlle Iron _ Hark <:/Verona. Ja- - c " NI "o .. Vendor
. ave is. MOuTiNG eNsTRuCTsONs.
O ao u'c 'o "a ("S aa cc a'a c g aau'c 'a "^'ca'^' 5u"cav'5 a 8 9. NONCO NPOM MING CONOef TON Form G-321-D and Shop Inspectors Release TWX both refer to and certify material on Shinnine I.Ist C-25. The followinn three (3) beams were received with shipment C-25 but were not included on the Shinnine List C-25. "O" No. is 1.201. 42189 9 Hold Tans Applied. 439B10 20. 401B21
@ PaCLO Ot5 POSIT 80N QPIELO MECOMMEND ATION/ ROUTE TO PROJECT ENGSMEER$84G ll PtELO DISPO3tisON N CSULTS:
AfaL/ 5,mac+ E A L p l u u ,/ K r & C1c' kLX2.a &Tnl
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- 22. E NG4NE CNING OsSPOStTION
- 33. ENG 4NEER4NG OISPOOaTaON RE6uLTE:
as as DCssGN CN ANGE Ns.Ov."c
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- o ' 5 'o 5 ' o " O-*****"--** ar OC (C/Pr a '/ M$rq TES. SEE ATTACHEOs ,,,,,,,
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/f&* '- fYhf CR A WlNG R C V. OCN f rE C. R C v. A DO.
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sasse s ( wn.te Copy - Originator e C-G a a Canary copy - Fleks Engineer Pink Copy - PCAE CotJenrod Copy - CC o m - g
~
- ": ' NONCONFORMANCE REPORT
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- 2. .i H r. WIN G /Pl.H T N'% . I R C V. 7. PR$J ECT NO. t IEPORTsD SY 'DATE 25. DISP 2SITION CNNCUH RENCC
._S rme . 77?O-c-1R -
**6' 7220 > JMA ~N ~~ ~
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- 3. ITasM DCSCniPTION ,, ,.
. E. 8TCM LO CATIO N g ((p@
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[ .Y D D Y D A T 8' "k'
<tructurn1 R ea al 1tanm (s)
C. L L R I A L N U M l3 E H . , , , ,a A"* W
- nui4 Mng])ffjfn S. ST AHTUP SYSTCM NO.
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l'5. 'H EPt 'A CC M E N T PA R T N O. 7( ' _f [
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___Hea.t.No. H43353 N/A N/A i , ,. ,y .,,,,,,,,, c o.,<
- 8. PUCCH ASE ORDCR No. , ;,* ' FIELO I K4glON PLAN NO. 16. H cpl. A CEM ENT SE R I A L NO.
h [.7,7 - g*jc' m'a ac cap ==
- f 7220-C-38 10.Qp/f/'
// / liW 75 N/A =a'a
- 4. CL NTR ACTO R/ LOC AT40N .
f*, I4.ASME I 7. SOUR CE C YES -- Ingalls Iron Works, Verona, PA. ,'y c 'o _ ____ 00_N O _ ___ __ Vendor _ _ _ . _. 8 0. ROUTING $NSTR UCTIO N S; '
. QRO UTE TO FIC E.D ENGIN EE RING O noTc To M^Tcas^' SuPcavasoa
- 19. NONCON FORMING CONDITIONa In accordance with 7220-C-38, Rev. 6 the applicabic specification for structural steel specifics ASTM-A-36. Certified mill test report for subject heat number (1143353) states tensile strength to be 81,290 psi whf.h exceeds the allowable specified tensile strength range which is 58,000-80,000 psi. Nonconformance noted during document review. Q-Number is 1.201.
One tag applied.
- 20. O FIELD DISPOS 8 TION D ATION/ ROUTE TO PROJECT ENGINCERING 21. FtCLD DISPO SITsO N R CSULTS:
hFtELD m e RECOMMbr r~ .- __ _/ W -- YS~
- 22. E NGIN CC RING 08SPO SITION 2 3. EN GIN C ERING DISPOSITIO N R ESul.TSa ITe n nn fc_ The mill t es t- report for the heat gly _es_an elongation of 24.5%. which passes
. 1the 207' mininum in ASTM A-36. Thus. the material clonnation properties have not been detricentally affected by the 1.6% additional tensile strength, and are acceptable.~,,! . ,..
-> . i Therrfore, the material is acceptable for use. g M g f) f f ,
gj, g/g g -O : .. wj- l v s - [ f f*; e
- 20. 83 D ESIG N CH AN G E R EQU4 R CD NO * " ^
[g
. O vES. SEC ' ATTACHED . gung ._, MwM7' / ,;,, j DR AW8NG REV. DCN *
avvmoniato ees,eactom ones SPEC. - R E V. ADD.
* .s t . . -
_ Q./ w
s NONCONFORMANCE REPORT "'"
, e <
' "^ OF
l 314 G. DHis W4NG/P A N T NO. R E V. 7. PH OJECT NO. 31. N E PO H T C D D Y' 1,. DISPG5tT SO N CONCUR NCNCC Spec. 7220-C-38 lDATE l6 07220 n. A. Moray '
5/29/75 - - - - ~~" - " - '" " ~
- 3. .T C M O ELC R IPT 80 N e. STEM LOC ATION
$ 3. V ALBO ATCD DV I DATC (4) Aux.iBldg. ncams Sasse Rd. Laydown Arca '
- e. uul AL NuMoER e sT ARvuP svsTcM NO.
...RcPLACEMCNrP,NTNO.
- ./ h% 7>i R E V. ...... ......~..-..- -
See illo_ch 19 11/A N/A ' f 1 ......,. ...... S. Pul4 CH A LC C H DE R NO. 5 0. QC FsC LD IN5PECTION PL A N NO. .... 9 6. Sf E PL A C LM E NT LC H 4 A L NO. 7220-C-33 C-27 C-36-R-49 N/A ......--c.-...- ....
' O. CU NTR ACTOR / LOC AT60N 91.ASME O vES s' sovacc Ingalls Iron Works /Verona, Pa.
,j , c y ,, Vcador _ _ _ _ _ ..m t 8. N3f UTING 4N ETN uCTeON $4 ROUTE TO FIELD CNGINCEN8 4G O aourc To M A T E ai^'su' c e'viso a 9,. Nf NCON FOR MaNG CONDIT60N a Specification 7220-C-30 nev. 6 paragraph 7.5 states, "The ucinht of all c:cc.bers 6,033 lbs.
and heavier shall be clearly stenciled thercupon and together with an orientation north or east." Contrary to F # the above, bearas 51GBl , 516B2 , S20B7" and 520nS" are all listed as weighing, more than 6,000 lbr.. on shipping notice C-27 but they are not marked with their ucight or orientation. Nonconfornance noted during receipt inspection. "O" No. is 1.201. hold tars applied. 29. O r'c'o oisros'rio" OFIELD RECOMMENDATsON/NOUTC TO PrtOJECT ENGareCERING 21. FICLr 345 POSITION RE 5 ULT 5a 2 2. E NGIN EE RING Ds5POS8T 00N 2 3. ENGIN ECRING D85PostTION R ESU;.T5:
- 23. Bs DEStGN CH ANGC HEQUlHED ONO *""" " " ""'" """ ~ " " ~ ~ """""""
O yEs. sEC ATTACH CD. a.c... OR AW6NG REV. DCN ....
.wwwo.aa.oon.*.evo, e.,e SP E C.
REV. ADO. ses,s e _ _____ __ m'. ' WNto Copy - Originator C G 3-1 Canary Copy - Field En01neer Golcfenrod Copy - QC l u - f v v _
s
- NONCONFORMANCE REPORT ,-
- 2. D U. wing /PA R T N O.
. .- /. y 0, 1 ' ' ' ."y, r;' " " * '
REV. F. PROJECT NO. I 2. N CPOHTED OY 25. DISPossT40N COreCU et fiLNCE lOATL Soncification 7220-C-33 ' 6 07220 PJ. A. Moray - 15/29/75 - " " - - """ ~ " " " '""" '"
- 3. 87CM DESCRIPTION . S. STEld LOCP 40N 3 3. V ALsO ATED a v I (2) Aux. Bldg. Enama OC ll,1d 6 Sasse Road -
f .... l DATED 2;/ 7 f
. t /,
C. i E H 8 A L N U M B E R S. ST ARTUP S YSTEM NO. 15. R EPL A CE M ENT P AR T NOl
~
418 HIE nad 4241;3 E Paesac,resto smesmese on.e I' R E V.
!!/A M/A '
I E. PURCH A SE ORDE ft NO. t o. QC F8 ELD sr.5PCCTION PLA N NO. 5 6. R EPLA CCM ENT SERI AL NO. 7220-C-33 C-26 C-3S-R-48 li/A >=a=6===<+~==- '-
- 6. CEN TR A CTO N/ LOC ATION ll.ASME C YES - 9 7. 50U R C C Innalls Iron Works /Verona, Pa. c
,'c 6 ,, Vendor .................. ....
3 6. W4WT 4NG GN STRUCT SON 5a - Q ROUTE TO FIELD ENGINEEftlNG O aouTc To adarcasA' 5u cav'soa 3 9. NONCONFOrtM6NG CO NORTIONs Beam 41831' has a bent stiffener plate. Ecan 424U3 L' has tuo (2) bent an;;1cs with cracked welds. Damage noted during receipt inspection. "Q" No. is 1.201. hold tags applied.
)
2'. O F4 ELD DISPO58780N Orac'o accoaMcao ATson/aourc To PaoacCT caGiaccaiNG Zi. ricLO O 5 Posit.ON Rc5uLTS, L
- 22. ENGIN EE MINC D45 POSIT 80N
- 23. ENG 4N EE RING DISPO58 TION R ESULT 54
- 23. IS DCSIG N CH ANGC RCQU4H C 0-"''***'"-
O NO "* a c'ccT co "^'c a '^' o'5"o s'T'on
- 27. OC ACCcPT ANCr O vES.5EEATvACNEO, U*"
ec emesmese 03 f, W l N G N E V.. DCN , , , , a.vmonsas o esses s**- ea,a SPEC. REV. ADO. IM 48 I White Copy - Originator Q C-G 3 2 Canary Copy - F6 cad Engineer
~
9 9 ,/ Pink Copy Goldenrod Copy - QC
- PQAE s 1
- o . IF vj W NCE FlSCREPANCY REPORT 4, ISSUE DATE
- 1. PROJECT / DEPT./ CONTRACTOR 02/27/75
- 2. POINT OF ORIGiri
@ FIELD 5. GAD PREPARED UY:
l_ 07220 - Midland O OrFiCE YORK PLAN DATE 7. CHECKLIST ITEM
- n. sevo
- 8. VlHERE FOUND
- 9. DISCUSSED Y!ITH
-I 02/28/75 '
25.3 J. Connolly ( Channion Files P. Sch mnski
- 10. .CONTROLLING DOCUMENT. SECTION, PAR AGR APH, ETC.
Champion Quality Assu ance Manual, Rev. 3
- 11. OUOTATION Section VII I)ocument Control "The issu;2nce and receival of instructions . . . .. are controlled by the assignment of a document control number. All such documents are"8orded on a log sheet . . . . . .
Maintenance of a log sheet is the responsibility of the Plant Supervisor." Section XVIII Quality Assurance Records "All data and correspondence relative to Quality Assurance shall be filed under the proper heading and logged. These logs and files shall be available for the :
- 12. DISCREPANCY DESCRIPTION
'M**"'
i Centrary to the above; (a) a log sheet is not being maintained by the Plant
- Supervisor. (b) Correspondence relative to Quality Assurance is not logged.
( (c) Copy of audit logs as of 12/10/73 are riot available at the jobsite for review.
- 13. RECOMMENDED CORRECTIVE ACTION
- a. Prepare and maintain log sheet as required.
- b. Log data and correspondence relative to Quality Assurance.
c. Make audit logs as of 12/10/73 available at the jobsite.
- 14. SCHEDULED COMPLETION
- 15. RESPONSIBILITY FOR CORRECTIVE ACTION DATE 03/31/75 J. P. Connolly -
1G. CORRECTIVE ACTION TAKEN - Champion has submitted for approval Rev. 3 of their OA Manual. Thin vnvicinn adds a Document Control Lon Form to their OA Mnnn,1 Coniek nf thn audit lots , ____ are now available at the jobsite. ATE COMPLETED 1gs PJplTTED BY ESPONSIBLE AUTHORITY
- *S~ W Y: DW htMY Y~
- 19. CORRECTIVE / CTION hlFI Rp" O AE 20. DAT E w o, . !"Ak m $10k*f
(~AAO-86 9/17/ 74V # S~/h&h}~
, w? . '- ,
O,QualityAssuranceDiscrepancyReport-053 G' ( Block ITo. 11 Continued. audit by contractor ..... . Section XIX Audits
" .... A copy of the audit logs will be kept at the jobsite for review".
d O s 1 s e
'y/
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ttdAUT AN DIT FINDING ...?55 j2 5-2-n 3/31/75. 1
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g.... ....... Midland 1 & 2 Job No. 07220 Construction 0.- = = c. Richardson j . . . . . . . . . . . 1 10 U. S. Testing Files'
..mu.................................. ..-.....
U. S. Testing QA llanual, Rev. 3' - o u,. a.<.. 17.1 Conditons adverse to quality shall be promply identified and reported ...... . These conditions shall be corrected as soon as practicable ..... . 19.1 A comprehensive sys' tem of planned and documented audits shall be carried out quarterly ..... . Deficient areas shall be re-audited until corrective actions have been accomplished.
- 1. An audit report dated 11/7/74 identified a deficiency in the storage of records.
No corrective action to resolve this problem has been taken and the area has
/
-m
\
not been re-audited. .
\' !
'2.
The last audit was conducted on 11/7/74. That audit (No. 4). covered a period of four months rather than the specified three months. Audit lio.5 should have k been accomplished early in February.
....a.,.a..,...
I'nstruct U. S. Testing to conduct an audit within 30 days and take action to assure that future audits will be accomplished quarterly. Also instruct U. S. Testing to initiate timely action to correct deficiencies which are identified during these
,cudits.
;,.. ..u .... .... .... ,
SL2/75 PFOCE 7 . - ..,..... .. . l An internal audit was performed by US Testing on April 11, 1975. E.J. Zadina, the US Testing auditor, stated that a new audit schedule would assure that audits are per-formed quarterly. He also stated that deficiencies uncovered during audits would be-fNosed out and verified in a timely manner. I
/
l - b N~W <Ah f4 , PfdfCS z . . w . .. . . . . . . . . . .. . . .g 4 . . g p ,,. g w a , ____, J . . . . ,, f, c_
Y Y0$ 0$h0$$N . . . . . , . . 05/06/75 N/A e,r s......,..... , , . . . . . . . . ,
- g. .. ,. . . . . , . .
Hi._,nd 1 6 2, Job No. 07220 Construction 0 c= G. Richardson ( 1 8 QC Files J. Connolly
- c. .. m .....co .......................... . . . . . . . .
FIM G-5, Rev. O u_..,. Para. 3.3.3 " Purchased items which do not- require release by Bechtel PID may re-quire quality verification documents . . . . . The documentation re-quirements will be designated in the P.O. and shall be itemized on the Field Receiving Inspection Plan. Documents receivad shall be reviewed for .... compliance with the requirements of the technical specifications and procurement documents." Contrary to the above the Field Inspection Plan C-66-R for receiving materials to Spec. 7220-C-66 does not itemize the required material tes . reports and there is no evidence of review of complaince by a QCC. The same condt ton was also noted for FI " -233A-R-1 which is used to receive materials purchased to Spec. 7220-C-233. ( ! ThU Lwo package checked: NOTE: Spec. 7220-C-66 is no lony,cr in ( C-66, HRR AE0 636 use at this site. Therefore re-C-233, MRR AE0 316 vision of the FIP is not necessary. l %...~......
- 1. For C-66 materials revicu all material tes t reports for compliance.
- 2. For C-233 review HRR AE0 316 for compliance and revise the FIP or utilize FIP B-1-R to receive non shop inspected materials f rom this P.O. as these materials also appear on the bulk items list.
l
- 3. Assure that this condition has not occurred elsewhere by reviewing FIP's used to receive other non phon i ns ne c t ed__i.tems .
- ... m ...m......... ................................
06/06/75 PFoCE s-en =. y . - .m . . . . . . . . . . . , . . . . . . . . . . . . . . . . . . , Q.....a..........,...
7p .
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. QudlTY AUDIT FDDMG . . . . 58324-2-2) 05/06/75 N/A
. ........,..u.. . . . . . , . . . .
j ,,. ,. ....... M land 1 & 2, Job No. 07220 Construction O. . - G. Richardson
..s. ...co..,....
,--........ ...cm. 7gt.1er
. 1 11 QC and Maintenance files D. Martin
.... . u.... ...... ....c,. ................ . . . . . . . .
#QCtlM SF/ PSP #11, Rev. O Field Proc. FPG-3 Rev. 2 e........
PSP #11, para. 2.2 "A storage and storage maintenance package is prepared by the MSE on permanent plant equipment in accordance with the storage and s torage maintenance procedure." The s torage . . . package consis ts o f Form FPG-3, F-1. . . . . . . Field Proc. FPG-3 "The MSE is responsible .... for indicating established re-para. 3.0 quirements on associated forms." para. 5.1 "The MSE enters storage requirements on Form FPG-3, F-1". Contrary to the above no FPG-3, F-1 Form has been prepared for materials purchased tm Specification 7220-C-2. This material includes trumpet assemblics and sem. rigid ( ; thing. g...............- l
- 1. Prepare a F-1 Form for the above item and assure present sto ne is adequate. l
- 2. Review existing F-1 Forms to assure the above condition does not occur elsewhere.
l l l u ...m .. . .... .... .....,.............c......... 06/20/75 Project Superintendent om.u ...... ......
~
i9 rs (..
.m ... , . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
g~.-..,................. ,,,,
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*~$RouteTo Ynis'uopy For -
-
- File 16'.3.6
" " N'" 9' 197S
-GSKeoley Sill!owell Sat
/ ccw M and 1 & 7 HNSlance WEKessler (2)
CQ11111s TCCooke CCHS b FE Ef File Title 1:CR's on liechtql JMilandin Quality Control' WFilolub Eonconformance
. CLRichardson Report Ifo OF-l.8 Tnis Honconformance Report is Issued To: Prepared ByI S 4 2 C'OS , Date N P Mr. J. P. Connolly Approved By -GNNd* L Date .@h/'I Bechtel Project Field Quality Control , WrittenRepl'yNequested Date 6-6~
= Engineer -
Corrective Action Re ted By Date 6-6-J vho is responsible for corrective action. Nonconformance Description and Supporting Details: (1) Specification C-208, Rev. 4. section~ 7.3.2 states "A slump measurement shall be made for every 35 cubic yards or fraction thereof of concrete produced for Class I structures." For concrete placement: CC(652.75)a' and CC(621.0)a', 56 cubic yards of concrete was placed between slump measurements. (2) The C12-1.13rm (In-Process Concrete Test Report) for. CC(652.75)a' indicates.-one air meter and one thermometer was used in the field for testing. However, at least three air meters and two thermometers were used in the field. One air meter and ~ one thermometer was needed at the pump discharge. One air meter and one thermometer was needed at :the truck discharge. Also, the QC inspector noted on the C12-1 form an air meter change af ter obtaining 7.5% and 6.5% air with the
. original air meter. Maits AEC Reportable Yes U no kn air content are 3.0%-6.0%.See Procedure 9 (For Nuclear Projects O Stop Uork Necessary Yes no See Procedure 16 - Stop Work'No J .
RecoTaended Corrective Action: (a) For item (1) above, receive an Engineering (. - evaluation of the acceptability of the concrete placed without the required slump measurement. No additional corrective action is necessary, because it has already been covered-in letter C-203-56 from Bechtel to U.S. Testing, concerning concrete testing frequencies and test locations. The ufitten reply to this item is requested wit'h-the Engineering evaluation. (b) For' item (2) above, take corrective action to preclude these occurrences. Written reply and corrective action requested for both Corrective Action Taken: by June 6, 1975. 1 Verification of Corrective Action Required Yes ,no ' I I?cthod of Verification: . l 1 l I Konconformance Closure Confirmed By
'L. Date h 7 To be completed at-time of closure by Consumers Po'or QA Gervices.
Pace 1 of 1 ,
. -1
, m____ ,
Attachment A Route To This Copy For File 16.3.4 & 1.6.3.6 CSKeeley 511Howell
; ) .
Issue Date May 22, 1975 g/ m!Slager Project Midland 1 & 2 _ WEr.cssler (2) %@ / CQHills TCCooke C0nsumSS Fcyler JMilandin File Title NCR's on Bechtel
- Construction 6 Ouality Contr WFHolub Nonconformance GLRichardson Report Ho OF-49 ousauuu . tiu This Honconformance Report is Issued To: Prepared Bf' 3,M) 6'f%e m Date ~s .2 2 J:
Mr. J. F. Newgen Bechtel Project Superintendent Approved [By. dd, Date f/4 / r Mr. J. P. Connolly Written Reph Reques,te,de/By Date 6-7 %7
.y Bechtel Project Field Quality Control Engineer Corrective Action Requested By Date 6-7't-7 who is responsible for corrective action.
Nonconformance Description and Supporting Details: Additional emphasis on concrete tes ing frequencies and locations vere expanded beyond Specifications C-208 and C-230, in letter C-208-56 dated March 19, 1975, to U.S. Testing. Item 1 in this letter states in part "The point of recotd testing f or concrete slump, air content, and temperature is at the truck discharge. . .". Item 5 in this letter states " Slump, air content, and temperature tests taken at the batch plant must always be backed-up with a record test at the truck discharge". Contrary to items 1 and 5, no slump or air content tests were taken at the truck discharge for concrete placement A(589)b, four cubic yards of A-1 mix. AEC Reportable Yes Fo @ See Procedure 9 (For nuclear Projects Only) ( ( Stop Work Necessary Yes Ho See Procedure 16 - Stop Work Ko , h Recos:: ended Corrective Action: (a} Receive an Engineering evaluation of the accepta-bility of the concrete placed without the record tests being run. The written reply to this item is requested with. the Engineerihg evaluation. (b) Implement the requirements emphasized in Letter C-208-56 to preclude repetition. 1 Corrective Action Taken: 1 Verification of Corrective Action Required Yes no Method of Verification: Ldonconformance Closure Confirmed By Date t' (- I To be completed at time of closure by Consumers Power QA Services. Pa.3e 1 of 1
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