ML19329E927
| ML19329E927 | |
| Person / Time | |
|---|---|
| Site: | Midland |
| Issue date: | 04/30/1976 |
| From: | CONSUMERS ENERGY CO. (FORMERLY CONSUMERS POWER CO.) |
| To: | |
| Shared Package | |
| ML19329E924 | List: |
| References | |
| NUDOCS 8006180785 | |
| Download: ML19329E927 (123) | |
Text
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NONCONFORMANCE - REPORT LOG & STATUS BOOl' 3 2' 1 - N"'
-2'
$56n/dhrt NO'6'":r..'
3 PAGE CoMPL.
0.ca m 2220
- 1. PROJECT NO.
e.
3.
a.
t, STATUS P'CR ORIG.
NONCONFORMANCE ic.
PREPARED BY s.
7.
Are c.onTe 9.oatc NO.
DATE DESCRIPTION /RI' MAR;'.S ROUTE Xf.1TO DETD CLOf.EO CLOMOUY 244 12 R.A. foray lulk Items. Bolts not oroperlv narked field Ho 2-16 1 R.A. Moray
/4 Varies L2-4-7d
-74
-75 S15 12-6-7 1R. Revereza
- -231. Aux Bldq #8 fibbars broken, Halls Field rio
. 2-9 3-25 A.L.Boulden 1/ s rz9 1.20'l
'2 9-7J
-74
-75 14 y5 h I 1
1 246 L2 l1. llo p fe n s pi rqe r C-lin_ linor pinto enrraco d e f n c.ts,
Field 40
-74 56-15-U-2 S S5-13-U-2 1.109
.2-9-7s
-74 76 A. L. Albert 2 L.R. Albert 247 L2-10 J.C.Fitzoer11d C-231. lin i t fl Base Slab, crack in Conc Field llo P.-13
-75
-74
~
Az 300-42o 1.105
.2 ?4
-74 i
240
!2-11 R. Revereza 0-231. Aux Bldo blockout f o r S_trJtclu r a l Field flo 1 2-11 1-14 L. Shively
-74 Seams oiami t ted 1.205
. 2.- 1 1 - /4
-74
-75 IN 249 L2-11 L. Jo. " son P.-211. Exco'ssive Structural nackfill Field flo 2-12 12-12 L. Johnsch
-74
.ift olaced 1.002
.2 /4
-74
-74 o
g 250
.2-13 J. A' r'o e C-2. Damaoed Semi-Rinid Sheathino Field II0 1 M
-74 1.107
.2-13-74
-75 o
251 2-13 E. J. M m ihg C-33. Damaged Structural Steel Finid 1 1-24 8-14 R.A. Moray o
-71 1.201 1-18-04 75
-75 252
.2-13 U. Etheridqe
(- 1_1_1. U r_nn o weldinn arocedure tend Field 12-17 12-30 12-31 A.L.Boulden
-7<1 1.10q in-F,-Fr -74
-74
-74 253
"'-17 E.J.!!anning F -3". 0ananed Structural Steel. shintent.
Field 1 1-24 8-14 R.A. Moray
'-74 C-10 1.2n1 1-i7 E4
-7f -75
=75 254 2-13 A. Boos C-231. Aux Bldo llall. Rebar coverane Fieid 12-19 12-20 12-20 L.R. Albert
-71 1.?O3 1-49-? 4
-7/
-74
-74 19 h-26-76 W. M. halt e 53
.2-13 U.C.0'I:cil r-111. Gounes on edne o f Dor.ie Liner
- Field, "O
Plate RD-9-13 1.109 1-19-F4 t
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NONCONFORMANCE - REPORT LOG & STATUS BOOK 12, ' ' ' #
g"1 lggJ
. il.
n'Eroar r ATE i-
-82 "8- 's f.
PAGE CoMPL.
n.c. o no. m 7220
- 1. PROJECT NO.
STATUS 2.
3.
Lt.
j s.
NCR ORIG.
NONCONFORMANCE-g, g
g, gy.
g, PREPARED'BY N O.
DATE DESCRIPTION / REMARKS nouTE XMTD RETD CLoMD CLO EDDY n
10-6 340 9-29 R. A. Moray ll-104 A.
Rain Splashed dirt on receipt Field 10-27 H.D. Foster
-75
-75 of LS 9030 & LS 9031 ASi1E 4.104 9-30-15
_7g i J&:5Ji 341 10-2 A.L.Boulden C - 1_lL__D i s c oat _im.u i t y in liner Plato fi ci-d=
10-6 10-28 11-11 A.L.Boulden 40=.e=s5 -75
_75
_75
-75 Unit #1 130 1.109
=
N 10-29 h 342 10-0 fl. D. Fos te r a__20A Calluni d snlatinr..on 2ccn 72 1 1 Field
-75 76 P. M. Pitts
-75 Reactor Cavity D' rain Line ASME 4.343 3 0-0-7f 34 3 10-9 L.R. Albert C-230. Concrete Mixing Water Ph higher M6Ld.
/"' W 5 N
10-29 L. R. Albert
-75 than a11 owed.
1.105,1.205 -W 9-74 10g8
_7g
'I' >
11-1$
R. A. Moray 344 10-g4 R.
A. 11oray f _92 _ Mat.o.r-Da ta-Shoct s not r o c o,. vioa F-i-ci-d No 11- -
_7g 7.
for RB Cranc Motors 4.001 10-14-75 5
11-12 3h5 10-20 L.R. Albert
%211. Structural Backfill matcrini rn11c<1 2iM 12-9 12-9 L.R. Albert
-5
-75 Eradations.
1.002
.M-24 s
-75
-75 3h6 10-20 L. R. Albert C-210. Flvas1Leontent_hich. pour cC(f_70)n'
-F-leM-10-29 12-9 12-9 L.R. Albert 75 1.105
^a-29--75
-75
-75
-75 l].y.11,l/ HIIb 4.N W M 7 347 10-20 L. R. Albert C-230. Slv_rm t6' high at end of-pumpline,_pnnr
-F-ieM-10-29 11_26 11-26 L.R. Albert
-75 A(613 25)a 1.205 1 0-20-7$
-75
_7g
_7g 3h6 10-20 H. D. Foster 0-111. Li.nor Plate riccp_ imperfections. 52.e?.- U.1_Pield No 10-2h-10-30 H. D. Foster
-75
/s1_11j-U-1 1.109 (0-20-75
-75
-75 349 10-20 H. D. Foster
%111. Linex_Flate inminationn pinton S2-12 1T1
?iold No 10-27 10-30 H. D. Foster
-75
/51-15-U-1 1.109 0-20-75
_75
-75 NO 11-11 350 10-27 R. A. Moray I4-1. D_nissq_pyan_reclehf_ph1 2013-50-1 B&W
_g
-75 Reactor Coolant Pipo.
ASME h.018 10-27-7$
1-2j R.A.Horay 351 10-29 R. A. Moray B-1-R-Certific1 tion fnr itil ti Pnntearn nnt H.S.
No 11 -72
%75 receivod with shipment N/A 10-29-7$
75 0
AA6.~oiY fc
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Page 32
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NONCONFORMANCE. FiEPORY LOG & STATUS BOOK 12.
/'
nEPORT DATE
. C +M pt:9 PAGE Cof.;Pt
- 1. PROJECT NO.
7220 3.
1 G.
STATUS NOR O R IG.
NONCOWORMANCE PREPARED BY g,
7,g,,c g,g4, p g,og,g g o, NO.
DATE DESCRIPTION / REMARKS nOUTE X P.1TD RETD CLOSED Ct.03ED CY No 11-26 352 10-29 R. A. Isoray C=205 circuit Brnnienrn, N epi n +nn ; a,s ger -_ Ficla
.t
_73
-75 Identiricatinn 3 10.
10-29.75 353 11-h H. D. Foster C-111. Dee.p_.imperfontinnn nn+na nn e 111 11:
Field No 11-5 11-18 H.D. Foster
-75 during coating work 1.109 1 i-h-75
-75
-75 35h 11-5 C. F. Clark 0-111. Domo_ liner Dlat.c_.hroken._C-111-15 FiCld No 11-6 h -75 1.109 y 1-5-75
-75 76
- w. M parace 355 11-10 D. L. ocbort C-2.30. Flynsh below weircht on_one ticket, pour F,in,14 12-8 1-23 1-26 L. R. Albert
-75 AT614)b 1.205 a i a74
-75
-76
-76 356 11-1h L.R. Albert
,C-230. Air content. Pouro A(G99)i' & A(587)b' F,i. cad.
12-8
-76
-76
-75 1.205 n-o -s -75 r
357 11-17 R.A. Moray F-1-193 11-92 Moi nrn hontnrn di nnnnnnntna 71 eld No 12-8 2-19 R. A. Moray
-75 4 001 1 4') 1 s'
-75
-76 358 11-17 H. Boleen
.4-117. Yalvn Tngd ng mqni men +, viol,ted Field,
No 11-25 3 H. D. Foster
-75 ASME
- f / fi
-75
-76 1-23 1-26 L. R. Albert 359 11-2h E. Dutton 1-23Q. Air content high. Pour #1(($19)n F-it-1-d 12 -7g
,7g
-75 1.205 14-26--7-5
-75 1-26 L. R. Albert 360 11-25 R. Dennett
%231. Curi_nte temperaturo below 600 1 hrs.
Pi rl d 12-8
-76
-75
'our#A(619)a 1.205 14-26-76
-75
_76
..3 ',. r 361 11-26 D.C. Thompson
- 1-h2.__Condui t npacing, Aur El dc R1 nh Pual Unni F-ield 12-12 1-30j 2 D. C. Thompson
-75 alab 3 006 wh75
-75
-76
=76 3-12 362 12-1 D.C.ThoPJPGon h-hdi__C.CDduit CiZe reduced. ART 31dE_8_lDb.
--2ichi* -
12-5
~
-76
-75 3 006 12-245
-75 363 12-1 L.H. Albert H=231Atlivatnv unnv innt-Whl-12-1-7j; 12-16 12 18 -75
- 'R( Albert Os v tw e n r.
'u
-75 1.105,1.205 -+9 ' 75
-75 i
F 33
1
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- "f s...
NONCONFORMANCE - REPORT LOG & STATUS BOOK 3 2. ' '
- 2*
gJJ' nEPORT DATE PAGE CoM1'L.
- 1. PROJECT NO.-7220 STATUS R
ORIG.
NONCONFORMANCE PREPARED BY
'~
NO.
DATE DESCRIPTION / REMARKS
'nouie
~.$Io NN cbh fo xr ctosso ny 1-&s-36h 12-h-D.L. Osborn C-208. Concrete cylinder curing. Pour A(61Mb Field 12 76 L'
- ^ #
75 1.205
+G-h-7g 73
-76 4
365 12 II. Shawl 0-38.
Aux. Blds. columns cut nhort.
Field 12 1 1-19 A. L. Boulden 75 1.201
+a-3-75 75 76
-76 1-23 1-26 L. R Albert i
366 1 2 R. Dennett L2'31. Ow:iDe Tnperature, A(5%0.)n ' & 1.105, A Field 12 -76
-76 75 cc(635)b' 1.205 - +2-++-75 75 367 12 II. Boleen LI-10h A.
Damnged pipe spool upon roccipt.
-Fic14 IE14 7If
-76 75 A5IE h.104
- 4E,M--7% * 'Mi 363 1 E. Dutton 2-?.31,_fnrJinc_imn0Iainm, Pour A(626J$)n' 71314.-
1_g-7(
2-9 2-9 L.R. Albert 76 1.205 T-q:-76 =
-76
-76 369 1-13 L. R. Albert
.C-2 30. Fly A'sh finnnes s nnt pnr AS Eield 1-15 2-9 2-9 L.R. Albert
-76 C-618-72.
1.105,1.205 a:13 26
-76
-76
-76 l
1-27 2-20 2-24 D.L.Osborn i
370 1-19 I'.
Dutton C 230 Si unp hinh. Pnur A(599)18 r9id r]:
t
-76 1.205
- 1: 20:76
-7 4
,g 1-4/
371 1-20 T. Lieb C-231. Field cylinder curinrr temperature. _ f fyppf =
-76 6
-6
~7
.-76 pour A(614)h 1.205 572 1-27 G. E. Depew C 90A. Liner Plate slab numbers not match-Field No 3 2-23 R. Lussier
-76 ing.
1.109 I-28-76 76
-76 2-25 2-23 L. R. Albe rt
_Q9 T. R. Lieb
?-208. Concrete cylinder curing. pour JAdri 2-12 573 1
-76
-76 i
A(614)i 1.205
- f3Jh
-76
=
1-29 E. Dutton C-230.
374 Concrete slump test frequency. pour T feld=
2-25 h-9-76 h-13-76
-76 A (6 3 3. 2 5)a '
1.205 Z=.2=.S 6
-76 D. L. Osbem 75 2 R. A. Moray M - 1.
Makeup Storage Tanim_reccirnr1 wMk B&W 76 K. Pul: -'
shipping damage ASME 4.03 y, 4.04 9 2-4-76
~
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.o-t os o
r,....,..
,p '
o f)y"lh NONCONFORMANCE - REPOIl s LOG & STATUS BOOK n*
s REPORT DATE W J'-
~7' PAGE CCMPL.
- 1. PROJECT NO.
7220
.c. m.s e f-... -. - b.
4 5
NO.
DATE PREPARED BY NONCONEORMANCE STATUS DESCRIPTION / REMARKS G
^
ROUTE XP. T OSED C:.05ED BY 376 2-4 D.L.Osborn
- 2nR. vty,.h Ta =t Fren,uenc_yrmorc than FiLtd 2-19
-76 100 tons received w/o user test 1.105,1.205 = 2,1 ='74
-76 377 2-5 E. Dutton C-208. Concrete test frequency exceeded, Field:
2-19 h-9-70 k-134 5 I
-76 Pour A(633. 25)a' 1.205
- br5 =7:6
-76 I). L. Osborn 378 2-5-7o R. A. Moray C-233A. F 3043 Release #32 Nol nnn Atorin i
Field No 2-5-76 3-31 R. A. Moray nr Back-Up Plates have defective welds 1.202 2-5-76
-76 379 2-6 D. Martin t
M-1. Purification Deminnraliz.cr npenc11, ico B&W No 3 h-27-75 P. M. Pitts
-76 found inside ASME 4.038 2-9-76
-76 330 2-6 E. Dutton C-2 31 nnnn en+ n en vi 2-12 2-25 4-45
-76 g_tempcutuce --ponrm Fictd-L. R. Albert r
-76
-76 A(633. 25)a' & TT(606)a 1.205 2=9=76
-76
=
381 2-9 G. Depew C-50A.
Liner Plate heat number discrepancy Field No 2-17 3 R. G. Lus sie r
-76 1.109 2-9-76
-76
-76 382 2-11 D. L. Osborn
.Czll L. Line r Pi n t o e ni n rn n n n rin;t # 1 Ein" Fictd No 2-17 2-27 D.L.Osborn 76 65086" to 65186" 1.109 3-11-7(
-76
-76 383 2-11
's D. L. Osborn G_-2 30. Half yard of hich slunip-.cnncI_ct.c. pnu r FidIU 2-19 h -76 A (630. 7 5)a' l.205 =G;12276 -76 76 h-2g-w 384 2-11 H. Bolcen V 104A.
Pi c_apools with shipping 51;unagn Fichl 4 i2
-76 i
and in'1 proper painting ASME 4.164,4.1 ]1,~2-.
_ 76 335 2-13 R. A. Moray WFMC-1. Weld rod heat treatment temneratu ld 3-29 3-3I E' A. M rey 76 Y-3029.
= '-cl:3x7f
-76
-76 386 2-19 R. A. Moray M inri. r-inngnre rncoiverl withaut C /R pintna Fiel d
~
3-26 R.A. Moray
-76 welde'd on.
ASME 4.131
':-20-76 76
-76 3-s-367 2-26 D. L. Osborn
,_G -. I 1 1. Pennir;1irm_ tale rn n c n - I' nit #2 Fi n v-
- IEicld 76
-76 635'6".
AU-805 C3/7 l.109
=22 2TF-36 11.
OC-G31 Page 35
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NONCONFORMANCE o REPOliT LOG & STATUS BOOK n
s
~
p REPORT DATE '
%N PAGE COMPL.
a.c. Eric.sion 7220
- 1. PROJECT NO.
...... = 3. - -
2.
v.
STATUS NCR ORIG.
NONCONFORMANCE PREPARED BY NO.
DATE DESCRIPTION / REMARKS h0UTE XPTD T
b1 SED CLCCED BY 388 2-26 G. Depew CJM. Liner Plate heat number discrepancy Field No 3-4 3-31 R. G. Lus sie r g
-76
-76 S8-1 -U 1 1.109 2-26-76 No 3-26-'6 389 2-26 H. Bolcen M CILDM S e r vi c e Rt rn r t ur n c vli n ri n v <1., m., r4
~ '
-76 ed @ off-loading N/A 390 2-27 H. Bolcen M - l0_4 A. Pine snools with paintinn and weld, F reld-4 -76 cnd prep discrepancies ASME hi7k EN l
4 YicLd No 3-12 391 3-2 P. M. Pitts N4-104 A.
Code Data Form and other document s
-76 for one spool ASME 4.164 3-3-76 3-16 7
392 3-8 T. LIEB
.C-7 3 0.
Ninety.-.dzty c nn e r etc atennghtc-
---(Q1,-
3-22 L.R. Albert M
-76
-76 A(599)m', A(612.5)d' l.205 3-8-76 1%
4-6 R. G. Lus sie r C-304. Embed C 6 not loc ated per DCN ' 2 Field J
393 3 P. Neiswander 1.201 3-8-76
-76 C-287.
-76
3 [76 C.-230.
Flyash content, ticket 075072. Pour Itield-
]- 4 4-28 L. R. Albe rt 394 3-15 E.
Dutton
-76 A'630. 7 5)b' l.205 4-1-5-70
-76
-76 396 3-22 R.A.Horay M-10hA, Pim nrools with looco end clocurec Field llo 3 AsMa 15 161,15 17'4 3 76 76 5
-76 3-25 396 3-22 W. Faulkner A-231-Rahn m nmi+ led; Auv B1dc
'A' 1 inn wl1: Qi"hb 3-23
,7b I4 1.203 h22_-74
-76 g
-76 pour.
397 3-22-"610. Dutton C-231. Curinn: temperture. Pour C(62h)n '
FicLi 14-2-76
-6 Os rn 1.20$
a-2, 26_
76
[
2-25 398 ll1-23 R. Revereza
,G-.7 31. R eha r oniitind, Aux 131dg ' T8 0'K'
. m ld-3 7
-76 l
-76 line walls 1.203 1-23-70 76 399 3-23 L. R. Albert
.C-2 31.__J1tryla c ement _ F_IP signed-off fo r non r Field No 3-24
-76 8 1.203 3-24-76
-76
-76 A(630. 75)c', rescoped down to A(624)a
~
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^5E Page 36
A.I-
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NONCONFORMANCE - REPOITT LOG & STATUS BOOK u.
'JI REPORT DATE %#- D Y" ~2.!
PAGE COMPL.
.C. E N G. SIGN
- 1. PROJECT NO.
7220 4
5~
STAWS
'NCR 3' ORIG.
NONCONFORMANCE PREPARED BY 8*
NO.
DATE DESCRIPTION / REMARKS ROUTE X T CLOSED CLOSED BY 3-33 400 3-31 H. Boleen C-233A. Fabrications with imnroner welding Field No 4 A. L. Boulden
-76
-76 1.201 3-31-7(,
76 h01 h-1-76 H. Boleen M 117-T.inting ne valvnn with vnnt; nntna nn Field Ho h h receipt inspection ASIE Varies 4-1-76 76 76 P. M. Pitts 4 R. G. Lus sie r 402 4-2-76 R..]Lus sie r F 'tR structn,>1 Ta n n m 2 3 3 Bo. c r a ck 6D n n ni e Field no h ~
clip.
1.201 4-2-76 76 h03 14 7 6 T. Lieb C-230. Quality Verification Documents "I"SJIC 5-11-76 Submitted without G321D.
Varles lW6.
No 4 4-16 D.L.Osborn 404 4 J. P. Betts 1-52.
Cadweld sleeve nonents to hnva been Field 76
-76
-76 c ut off.
1.104 4-6-76 405 14 - 8 R. Hendricks 4-92. Weldiner inck of fhnion. civanr c 1-Field
-76 Jnit #1
~
~
h.001 h-12-7fi t
4e14 =
5-7-76 106 l-13-76 L. P. Wehner C ~10h. Column at 4 31 A Pr mininnatna nt
=
4 617-0.
1.201 h-t3-%
107-t-19-76 H. Boleon M-106. TTnneme Fnb nhnetn npprovna inval h Field h.112 h-19-7C 1-21-76 W. Pardee C 40A Dome Toiner Pinto TTnnt Humber T)inernpnne IField No 5-6-76 140 8 4
1.109'-
L-21 -7(i 4-22-70 No 4-29 4-30 P. Dica rlo 109 h-21-71i R. Bennett C-110 Deen courm in T,innv P1ntn ennt. #,
4 1.109 ci id
-76
-76
'410 4-23 N. Shewl C-233. Anchor lelts without ASTM A-325 nuts 2CG r41 5-3-76
-76 1.202 16 Field
- "" '7 A Tenrnnn,. pinn mnnin coverince.34-26-7 6 1-%-
141 1
m 4
P. Pitta jggIE 114.018 & h.028
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Page 37
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During QC inspection of requalification of plate, in preparation for prime coat,1 gouge was found. The depth was measured with a thorpe pit gauge and was found to be'.187(3/16") deep. The remainder of the plate was coated with carbo zine 11 as per the Spec _ification__
C-110 Rev. 6.
This gouge is located on plate assembly S6-15-U2 in a s'tiffener on the crane bracket.
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See attachment'for sketch of locations.
Couges are approximately 1" wide by 1" to 1 " into the edite of the plate.
toc.Hotn tac Appti,=O 9 No-1 109 G) recto o.scosiv.o" O<'o arcoa"caoa v'oataouv e 'o raonct mac'ar r a'ac a..
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Repair in accordance with approved standard repair procedure. Remove nonconforming p,Mf-ygdggA, d.,p.h/
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O ROUTE,0 ATER,AL.u,E m,0H 9 9, NObeCONF OR MereG CONDe f tO N Spec. M-204 Rev. 3 states in part, Para. 5.2.1, " Care shall be taken in handling and in-stallation of piping to prevent' surface damage."
Contrary to the above, molten cadweld material was splashed on and is tightly adhered to the subject pipe (see attached sketch). Nonconformance noted during surveillance inspection.
"Q" No is 4.343 Unit 2.
One hold tast at tached.
20.
@ FtELD DeSPOSIT TON QF SE LO RECOMMEND ATsON/ ROUT C TO PROJECT ENGINEE RlNG 2 9. F tE LO DISPOSIT 40N N E SuLTSt Contrary to the above, care was taken in handling and the installation of the
/,h w,f gg.y,_., ;,, j, y.,,,, d subject piping.
Ilowever, after instalHElon and Buring a separate work operation pWW &>o i.z-7~wzt2> f;. c;5 molten cadweld material contacted the pipe.
yf7gg g.,,,,,c 7,fm 7gcag.7 The following steps shall be followed to remove the defect:
- .e /,,g,u gygf;7s ys r7@yg Continued on sheet 2.
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'. A NONCONFORMANCE REPORT (CONT'D)
.ucc 7 orN i4. aca ao._342 The elimination and repair of the defect shall be in accordance with specification M-204, rev. 4 Field Fabrication 1) and Installation of' Piping and Instrumentation for Nuclear Service, paragraph 5.2.1.
- 2) Measure and record the. minimum pipe wall thickness at existingjpe end utilizing calibrated equipment.
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- 3) Measure and record the minimum pipe 0.D. adjacent to the defect.
61Ac ' BW/1.7OF heMLpLECAlwn&L McEN 12- ?&S~ "
l/Ul 5' 'fI-7I Care Remove the defect with a medium grit aluminum oxide or silicon-carbide grinding wheel, flapper or disc.
4)
The surrounding area shall shall be taken to remove only the amount of pipe side wall to eliminate the defect.
be blended uniformerly_. o eliminate sharp discontinuties t
t
/=M/Yit' asID 7~> MMoL/E DcrGc~i Y/?flYh> Yl-7d After elimination of the defect, examine the area by the liquid penetran_t_e method in accordance with Form 84 5)
(attachment.to G-27Q) for 2" and under piping, class CCB and paragraph NB-2500 of the Nuclear Power Plant Com-penenets ponents code for the applicable product form.
SefhbRzcA hhpy^7Mn4_2c&27 /V62 _DA22*D 9'-/-7d fdff;/b W-7d Af ter the defect has been remove _d or the indication reduced to an acceptable size, measure and record the 6) m pipe 0.0. at the point of grinding.
minimu hNGE _GbMD/MG5*[7 A'<tME,~) 2 E.CS* '
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<fAMLR2V/M7 Deduct the amount removed inJrinding ff from the minimum measured wall. thick _ ness _de_te_rmined__in_ Step _.2_aboye.
7)
If the remaining pipe side wall is' equal to or greater than 87.5 percent of the nominal wall thickness, the repair However, if the remaining pipe side wall is less than 87.5 percent of the nominal shall be complete and accepted.
wall thickness, the repair shall be rejected. Sh6uld rejection occur, the isometric will be revised to indicate The repair shall be complete and ac-replacement of the affected section of the pipe in accordance with M-204.
cep'ted upon installation of new pipe.
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Tite _.l inc t_p_la te_isJ toke n_ a t__the 's ho p__s e nn_o f_.d ome_ plat e R D-9-14_of_d Oma_ pla f'a assembiv C-111-115:
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&,,y i cT,,1_ Sore s t.v-r 2 t o
a with Appendix B of Specification 7720-C-1_ll.
Cover _. seams _wltit_lenk_ chase r>En _7A c er A o C.uw.noc err-;
channel.
R'epair anticipal_eOyJov_cmher_2L_1975. Work _may_ proceed d M /TIv g I cc ic ruuued.ydyd Nec 7artii
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ss NONCONFORMANCE REPORT
. _ _. _ {^ ' 'g["' 3 7 4
- 3. DR A W SNG /P A R T NO.
aREV.
T. PROJECT NO.
I 2. FI E PO R Y E D Es v,
'DATE
- 25. Os5POSET #0M CONCUN RE NCE
_SpecmC.-2_30
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7220 bMy (k d% 8\\- M 'lt f*"["'l - 'j
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- 3. B T E M DE SC RIPTf 0N
- 8. IT E M LOC A T 40N I
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T ED.V Concrete Aux. Bldg. Pour FP#5 A(633.2 3)a2)A][pQ w e d M DATEZ9'b g f d.... /.. w.[.u _ f.. b. e.
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.n M t e ROUT 0NG INST MUCTION51 ROUT E TO F 8E LD E NGSME E RING Q ROUT E TO M A T ERI A L SUPE Rve%OR gg NotetoreFORMtNG CONDaT SON:
Spec. 7220-C-230 Rev. 5 Table 9.1.3 states in part that slump measurement shall be made for every 35 cubic yards or fraction thereof of concrete produced for Class I structures.
Contrary to the above on
_ Aux. Bldg. Pour A(633.25)a' test were taken at 176 cubic yards and 216 cubic yards. An interval of 40 cubic yards was placed. Nonconformance noted during QC review of QC-12 Form.
"Q" List No. is 1.205.
Ilold Tag Applied (1).
te.
O F8E LD DISPO5titON
{F tE LD NECOMME ND A YsONfROUTC TO PHosECT ENGINEERING
- 21. F tE LD Dl%PO$4740N R E SULT S Field recommends use asis.
Review of Batch tickets 07235 thru 07240 which represen ts the 40C Y. in which the 35 C.Y. slump frequency was exceeded, shows a decreasing
_yater con _ tent and subsequently lower w/c&p ratios.
Review of the Batch tickets discloses that the concrete placed with tickets 07236 - 07239 was conforming to sneciffention.
Listed below. for Project Ennineerins,'s review, is the dato.for tickets 07235-07240:
,b.; (,, jL; _
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~ Ticket No.'
Callons/ Batch w/C&P Ratid Yardage Slump 07235 170 0.41 176 4 172" 07236 169 0:41 184 no t-t es t ed-
.D7237 158 DJ9 192 07238 161 0.39 200 07239 159 0.39 208 2 k 5 ! bsGN Ct4 A,eGE HEOueH EO
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Engineering Disposition:
Spec if ica t ion _C-23_Q_gey,__5_ requires _a_ slump _ test _for every_35_.cuh f r-yards-This_is_not_to._say a slump _ test is necessary_at every 35 cubig_ yards. For a random sampling _pr_ogram,_te_stJ_ng at a gredhtable.f requency is neither desirable,_ necessarynnor_ practical. For the 282 C.Y. of D-1 concrete (includes 2 C.Y. of grout) produced on 1-28-76, ten slump tests were taken at the truck discharge, giving an overall frequency of 28 C.Y. per slump test.
' Based on the foregoing, and the Field Recommendation, the concrete represented by these slump tests is acceptabic_per specification requirements, and to "use as is."
hAs tspbi k~ $~96 ij&g,is tl-2-76, J
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-. Spec,m722.0_C 20B_ReydTable_.h3.2 st.ates in_part that one set of comgressive strength c v 11n ders_f ar_ca c h_100_ c u,_3d a _o f._ con c re t e_ p ro d u ce d_i s req u i re d.
j:as ting _cy_li.nders sets #733 and #735 was_104 c.u._y_ds.
Contrary _to_the_above_theJnicrval_hetween This_ concrete _was_nlaced_in_ Auxiliary _ Bldg.__Eucl_ Ecol
__PJ a ce men LB_A(6_3L 251a ' _.__Non-Con f o r. pan ce_ncted_d u rin g_QC_ Review _o f._reco rds.
_.One_ Hold _ Tag _ Applied "Q" Lis t_No._1.205
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Field recommends use as is.
' Total concrete batched for placement A(633.25)a' was 280 c.y. A total of five sets of cylinders were cast, three sets at the batch plant and two sets in the field.
Of the two field sets, One (Set #737F) is a companion to batch plant Set #736.
Based on the seven day test results, all cylinder sets &lill exceed the fc' of 5000 psi 0 90 days.
Listed below are the seven day test results.
- n. < ~c us c o.~o o.. osa.o.
Specification C-208 Rev 5 requires one set of compressive strengt H**"a"*""'"**'5"5"'**"<5"'"'
cylinders "for each IDO cubic yards of concrete of each mix design." This is not to say that a' set of cylinders is necessary 3 every 100 cubic yards.
For a random sampling testing at c_ predictable' frequency is neither desirable, necessary, nor
- program, practical.
For the 280 cubic yards of D-1 concrete produced on 1-28-76, 3 test
~
evlinder sets were tak'n at the Batch Plant Discharge, giving an overall frequency e
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. V NONCONFORMANCE FlEPORT
' ' " ^ * * '
or _1 379
- 2. o n A WING /P A R T No.
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- 7. PR o JE C T No.
.7 R E Po R T DV (
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.9. NoNCo N F oR M.NG C'oNo.T eon 3 Vessel 1R51A_was_onened_t.o_pla_ce desiqcant_as_reguired by FPG L
.,._1-2_15_Rev.
i 1.
Upon internal lasnection,_ app.ro.x.i_mately_1._ gallon of water in the form of ice was noted at the lowest point of the
.... ~...,
_ vessel.__The_ vessel.Js_s_t.ored on its side _(inreference to final position), and the ice has not entered any t
.nozzels.
Ihe vessel' annears visibly clean (inside) and all the closures were intact. This nonconformance was noteel during storage. maintainance preparation.
"Q" No. is 4.038.
Unit No. 1.
One tan applied.
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_After the ice has thawed, wipe the water with clean, lintfree cloth to maintain ffg. g.fff,,- 7,,, ffp,,,.
_cican11 ness n n r1 i eplace. the._Ilc.:ieeant.
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8Why J31-7d V-N. Asgpankar See attached
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"'"79 3
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Vessel _1R51Ayaa._onened_tp_p. lace desisqant as requ.ircd by FPG-3 7,. u.R 1-215.Rev.
1.
Unon q
_intarnal ir 'pection, ppproximat;ely_1_ gallon of water in the form of ice was noted at the lowest point of the
_ve s sc.l. "Ihu_ycssel _is_s_t;ored on its side (inrefererce to final position)_, and the ice has not entered any
.D o z z e ls." "Ihe vessel appears visibly clean (inside) and all the closures were intact. This nonconformante was noted during storage maintainance preparation.
"Q" No. is 4.038.
Unit No. 1.
One tag applied.
. O ncto o.s.os.noa 0"r 'a ac co="r a oa 'maeaou' c To rao er c ' r '< c'a r r a **
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2 3. E N G.N E E R.,.G o.$roS.T.o r.
E SU L T 5 6
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NONCONFORMANCE REPORT
' ' " ^ * ' '
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1 383 ~
- m. oM A W SNG /, A R T No.
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M.De oS8, foe. CoNCu M NE NC E Spec. C-230 5
07220
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g ouv E vo, E to E No.NEca.~a O aou'c 'o "a'r a' A' 5urra v'Soa 5 9. NoNCoNF OHM.NG CoNotitON:
Specification 7220-C-230 Rev. 5 Table 9.1, " Concrete Classification Table", states in part that the rejection limit for slump of D-2 concrete mix is 415 inches.
Contrary to the above, a slump of 6 inches was measured at the truck discharge on the D-2 concrete mix represented by Ticket No. 07311 placed in the Aux. Bldg.
Wall No. P-14 Pour No. A(630.2_5)a' on February 9,1976.
15 cubic yard of the 8 cubic yard batch was placed in the
_ pour.
Field cylinders were made for the nonconforming concrete.
Nonconformance noted during routine QC inspect-ion.
"Q" Lis t No. 1.205.
One hold tag applied.
n o,.E 6o o.s.os.r.oM g r.E to.E C o u E,.o.
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Field recomends use as is. The 1/2 c.y. placed from ticket f07311 represents nyC
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, y 0.53 of the total of 96.5 c.y. for A(630,25)a'.
Field cylinder set 744F sevr pa@. gggu
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o results are 2730 psi.
Based on current field data, the 90 day results will e ed the fc' of 5000 psi.
Estimated 90 day strength is 5490 osi.. k i.a. IL..u e.,f. [ B.? h * '
p o Vl E R @,'
2 2. E NG.N E E R.NG o.5,oSIT.ON
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,d Engineering concurs with the Field Recommendation to "use as[iW, %'t3'"'7 E1*'"
5*""'5'5' based on the following:
1.
The shrinkage and durability of the total concrete sp p
glacement will be affected an insignificant amount, because the volume of 6" slump concrete actually placed was 0.5 CY in a 96.5 CY placement.
2.
The strength of the 0.5 CY of concrete will meet s.trength requirements based on the ipfoymation contained in rho Fie']dRecommendation.d
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f l. 76 G. sE R9 AL NUMBE R
.. T A R T UP sv sT E M NO. h
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ROW TING $NsT R UCT. oms,:
ROUTE TO FIE Lo E NGINE E RING O aou ra 'o =^'ra'a' Sura av'5oa 9 9. NONCONFO RMING CO Not? BON.
Embed C-6 located 4'0" West of 6.2 on B line was not raised l'3" as shown on DCN 2 to Condition noted during routine inspection by field engineer. No hold
- C-287 Rey _._2 tag applied.
Q-list #1.201.
e..
o r < Lo oiseOs.T.ON (gr.cLo n c COMMc No A T,0NinOuT c TO pao,sC T aNo.Ne a n.No si cirLo o.sros T.ON nesuLTs.O.rs..re,. wL 1.s Repair as shown on attached sket h, s icet 2-AFSK-CA-85)
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Usa' of_. additional henm sca't_along_with_the_cnbed_to_bcan connection _as_shown in_the_ attached _ sketch _is._adequatc_Jo
- transfer beam load to tpc wall. Proicct_ Engineering concurs
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7:20 ISFCK-~85- '03 '
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}_u Q fff)h/l NONCONFORMANCE REPORT or ___1 394
- 2. on.WsNo/,A M T MO.
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- 7.,R. JECT No, t
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Concrete
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9 9. NoNCo N roR MIN. C'oNoli to,$ t s ction 9.2.1 or -Spen. C-230 Rev. 6 requirca_that_all noncrete._maitrialn_hc_mcaaured in e
accordance with ASTM.C-9h-72. ASTM C-9's-72 states in part that powdered admixtures weighing accuracy shall be within + 3 ' percent of the design volght. Contrary to the above, Batch Ticket No. 07572 representing concrete
__plac_e%onr_.A(f23n.151b' on 1-1-76 chows the fly _ach content to be h lbs below the minimum allowable weicht of h3h lbs. Nonconformance noted during QC review of Batch Tickets.
"Q" No. is 1.20$
One tag applied.
re.
O, cto o.s osir.on g r, to o c co
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Ticket,07572 which represented 3 c.y. of D-1 nrout had a' total of 4 pounds less flyash then the minimum required. This will have an insignificant effect on strength, workability or the bonding ability of the grout.
,m /dC
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3 -/ 9 -/4; 04 ) R.J. N, If 5-r9 7'
. :n. EnceNacnema osseossroon For Pour A (630.75)b'. a D-1 nrout mix containine 430 lb of f1vash in lieu as. amosamanino oss osition assuLisa of the 434 lb mitrimum required for a 3.C.Y. batch will have an insignificant impact upon affected properties.
En i eerinn concurs with the field recommendation to "use a[ is."
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s NONCONFORMANCE REPORT JQg
' ' " * "9"f 3
- a. oTeaweMoeganv No.
i nz v.
- v. Peoeccr No.
e s. nerontco ev 7220-C-201 (q)-
l6 7220
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onia ns. oescositioM concunnsNce 3
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C-231-2-777 N/A u
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. ',. ' M No Construetion
- 4. A es. NoNCONFonMING COMosisoNs
,,'-4 s e. noursNo sNs t nucTions,i Qnouts To risto ENGinerneNG Q nourt To mattuaat surtsvsson T.*
The. chear vall reinforcing de_ tails chown__qn_ drawing 7220-C-28G Rev. Is_.5.kn, o.*.. hat the
- p.-
+-
L.s_t vertical bars must continue thrqugh__ths_.intaracc_ ting.__ lls, n hqth_diIn911Dns. Contrn v to the_above. "A" t
__Line_ Mall Waa_platell_Hi.thant_the_._6_fil vertical bara_ef_ shear _walin 5 6 & 711 continuint thmu@ tho "A" Linn shear wall.
The bars were omitted between Elev. 6113'0" and 631 '6".
Nonconfomance noted during QC preplacement 5
inspection _of shear._w1G_1_at G.6 lino.
"Q" list No. 1.203.
Two hold tags attached.
20.
Q FtELo otsrostfloM QF8ELo nECoMMENoaTeoN/nouTC Yo enoJECT ENG6MEEnlNG 3 9. F gELo ossrosITsoN REsvLTs Proicet Ennineerinn to evaluate.
Om/
3-U1-76 n
' 32. ENGINE En8NG otsrosIT BoM Engineering has evaluated "as built" condition as stated above and has found that the val-1s 'are structurally ad. equate. Engineering recon: mends "use aa_is."
'The_ic_sjgn_cy_alttalian substantiatine "use as is" is contaimed in Volume 1(a) ltem 2 of.the auxiliarp building calculations found.in the engineering M
files.
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i NONCONFORMANCE REPORT g
396
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Line 'dall vau place 1 without the 6 gli vortical baru d :;hdar wallu *.. 1 i.. ;en _n42;.:.!:n.
"A"
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I'ru jeet F.'unincer f un t o valo.ite.
MAR 2 51976 1
. 'T m a. [ bn i nm /
$U i t.
BECHTEL POWER CORP.
JOB 7220 ren-l r
- - ~ - - -
s
,,. ~.......,....,,,,,...,, -
t Engineering has eva'luated "as built" condition as stated above and has found that the walls are structurally adequate. Engineering. recommends "use as is."
The design evaluation substantiating "use as is" is contained in Volume 1(a) Item 2 of the auxil bu ng calculations found in the engineering files..
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NONCONFORMANCE REPORT (CONT *D)
'E ar 2 e e.
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" a* a aa Block, l') Cont:riucil.
The cecond centence or bicek l') chould read: Contrary to the above "A" Line 'dall vac placed without the 6 dd vertical bara for.chcar walla at $.6 and 71 continuind throug3 t.hc "A" Line Q:c.sr '4all.
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Bechtel Associates Professional Co
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Inter-office Memorandum L(
To -
W. F. Holub caie Aprn 2,1976 subiect Midland Plant Units 1 and 2 I' "'
R. L. Castleberry Job 7220 Safetf Analysis Review of Of Engineering Bechtel Nonconformance copies to
. Report.Nos. 396 and 398.
AD Filet 0535.2 Ann Arbor P. Martinez J. Milandin J.,Newgen
.J. Hurley.
'.9 J. ' Co'unolly
- G." Richardson?
C. Newton G. Tuveson
Reference:
IOM V. F. Holub to R. L. Castleberry sane subject dat'ed March 25, 1976.
O\\
Project Engineering requests ths.t th[ response dato on the analysis of the Safety Parameters pertaining to Nonconformance Report Nos.
396 and 398 delineated in the above referenced IOM be extended to April 16, 1976. This extencion is requested due to the extent.
of engineering required to respond in the depth indicated.
Project Engineering vill assume this request hao been granted unless informed otherwise.
W w
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$ QC 07220 4 ri
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d f. s:cffy,.,).
[ vFOCE A. PFOCE
') CIVIL 2. L. Castleberry ELECT.
PIPING MECH.
JMc3/ht
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RECEIVI?S h
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~
.0 PEN LOO 2- ~
O YES Glio APR 061976 DATE g].
QU AtlTY CONTROL V
BECHTEL OB 7220
~
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Bechtel Power Corporatio Inter-office Memorandum
." R.'L. Ca'tieberry Ta s
care
. March 25, 1976 Sub[ect '
S.afety Analysis Review of from W. F. Holbb Dechtel Nonconformance Report Nos. 396 and 398 or Quality Assurance P. Ifartinea I
Ann Arbor Office 9 P I S . J.yagdh J' Newgen
' J. Hurley
=
J.'Connolly' G.: Richardson C. Newton Quality Assurance is requesting Becht 1 I*ngineering to periorn a Safety Analysis of the conditions presented in Bechtel Nonconformance Report Nos. 396 and 398.
The ana' lysis shduld address the Safety Parameters listed in 10 CFR Part 50
/N para. 50.'5 (e).
5 IU Response.to this request should be complete by April 2, 1976.
3 o
5QC07220 y W. F. Holub t's
)PFQCE Oi WFil/rb A. PFQC9.'
I/
WFH-3-76-595 CIVIL
~
ELECT.
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UELDING Qyu. ~ \\%
MAR 291976 11ECEIVl9 Q U A LIT CO l
BECHTEL Jop) N T R O L
~
acumn A ))) 7220 oteen G o vrs e/,
p DATE k/
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197 it Z - = n are st en==e*
or
_72ao-C-a31
' Spec.
5 "E V-8 '"O'E C T N o.
S t. RE E'AnPoRTEo1@ i3.u-x i 9 7220 oATE
- 25. o45Po$ef ooN CONCURRENCE
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- 3. ITEM oESCRIPTBoM
- 13. V ALIo Ev.
Io4TE
_.Conqre_te__Qgring Pour C(62h)a' ~
}99/8,4 J/ddM[
d,/ 6-7(,
8,
.. SERIAL NuMBE R
- 9. 5 T Aft f uP S Y S T E M No.
35.
I' R E V.
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NA N
- mes e asese emee e ease
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ouT,No.NsTRuCT.oNs.
gRouTc To reno cNo.N R.No a Rout To M ATcR. Ac.ureRvisoR 9 9. NQ,gCoNFoRMING CoNotfloNa Rpen.__7220-C--231 ' Rov. - 9 Pn rn 13 2Ah_ataten in part, "that_concre.te_nenbers_chall be
__adequa.tely nrotected-to maintain concrete surface temperature of no less than 500 F (for seven days)."
_flontrarI_to._.the__ab_o_y_e. for 7 ho_urs of the fifth day of cure for Unit #1 Tendon Gallery Pour C(62h)a' had a suvenna iemperatura nf!O P-Monconfo2manc.e_noted during_rontino _QC Surveilbtnce.
"Q" Xqe is 1.204
--Ono hnl a +.yy applici
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O rirto o s os.r.oM grino RcCoMMcNo AT,oN,Rou,e to,Ro,cCT Nc,Necn. a 3..
.u o o sros,T,o,.Re.utT.,
Field racommendn nca ne <=.
nto rnrn
~
nr c(04)n' m extended 24_ hours fnr a total cure period of 8 days above 50*F.
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shrinkage, setting' rate, and water demand, while increasing durability and
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required curing time.
Engineering concurs with the field recommendation
~
to "6se as is" because 1) The minimum concrete surface temperature was 40*F and freez_ing did not occur.
2h The cure fo qt$jC. subject concrete was extended one full day. M/d'/MS E4 i4-% NI*.40-h k-/Nb
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- 24. 85 of.StGM CH ANGE REoutREo* N N.
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ndomistalv motected to maintD,in conorote egdget igetrature of no_less than 500 P (for aeverdayo) "
f3
_ contrAIT iD thD D.bove. for 7.h2WD,L QI 1h9_f41th d&Y of c3rg,,,@.g,pnit Q,,$ggLc.n,,,,C M_e,ry Potar C(624 i
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W lowor_ een' reta curips tercerature vill eend to reduce 3
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T.CGn,II9.d SHY.itts.. Nims. Engi,,ngering concurs with the field racecmendation to "das as is" becausa 1) The minimum conerate surface ' temperature was
- / ii
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~ 40*P and freesirs did not' occur. 2h The cura fogtM. subject concreta vu. cytendert one ftill dav. IMA.NSE4-i4 D lh N-NN e
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AWS N l 72 Sec. *3 Para _3ELA_ttates in part.'"The fillet and s ussits adjacent cuts sha"[I%
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hoo n se os so W-3A D
mont.wifhant_offnet or cutting _PEtt._fhp__p_ohtt_of tangency."
Tn1gnd_Ryrrson_approred.Jir;Lwing_s F1220-C233A-(CA-2022)-IR-66-3 and 67-3 requires that deck angles be velded with
_a 1/4" fi11n+ n_t in'teruni n nr 3 par 19 innhest Spen._.0-233_(R) Eect._7c0 Para. 7.1 states in part " Pieces shall h nu t-fomed nna nhaped_.io_nizca_ and_. Hark poinfa phown on drawinES."
cnntinnna nn p,rro 9 re.
gretto oesroseTeoM gritto nEcomuENo ATioNinouTs To enostcT ENGiNEEn NG
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t Ropniv nnnconfnming_condi.tionn nn on1 Town r Statement continued on page 2.
//// S/fcyr/Esve/EI,4Es //ece-pf te Lt/ ANerDA>JCF 7e~ 17 Fit'cRx'lf' /2/~beixeD, Reference additional ntat.cment on_page L 8//' 6/.f F. -c'-344-/-/c'/NSE
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. II. ENGINE E RING osSPo stitoN b/.aa SYc e.N'-y'- YA a
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i NONCONFORMANCE REPORT (CONT'O)
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- Tnland Ityerb.on. Drawing F1220-0233A_(CA-2022)-1R-65-3 shows plate (b) nhon welde_d. to_colum1654
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_ Contrary _to_the_abovo,_tha_following_conditiona_wcrelound:
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._Lpn - 6h c Bent.acbat_ conner. tion _to_ plates _(m) g
._2_pc_- __65 P No.tches at re-entrant _ carne.ra 1 pc - 66__C No_t.phes at re-entrant' corners Improper veldint of deck angle
_1_pc_ _66 D Notchea_at_ra-entrant cornern Tmproper_. welding _of._denk nncl a E
_Lpc - 66_B Improper veldinc of deck angle 1 po - 67 A Improper veldi.ng of deck angle
...1 pc - 65 A Plate (b) was shipped loose
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"O" No._.1.901
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=
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Repair by_. welding and grinding _to_ proper _ contour. Weld proceedure._to be uned in
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4 705T8 R CtTV - M AIN OF FICE 1118 Chese Dreve. Foner Carr, CA 94404.(415) 173 4000 SAN MATIO OF FICE 145 North Sayshoes 88vd., $an Mateo.CA 94401.14151 342 4181 e
SAN LEANDRO OFFICE 250.Dav.s Street.1ase Leandro.CA 94577.(415)S69 5274 YeaDocy",es'Jn. c C AmNo o,,,.,...,.. &. CA..
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ENCLOSupE ADCEO Totan Hours Total M.iege Yes O No C Page of PEABOOY TESTING a division of X. Ray En<yneering Company assumes no responsebility for losses of any kind due to interpretation.
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FOSTE"I C8TV - Mf.IN OF FICE 1118 Chess Dem. Foster City.CA 94404. til5) $73 4000 SAN MAf tO OFF6CE 14$ Note Seymore Sled,$an Menee.CA 94401.(4156342-4183
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l s AN LE ANORO OF FICf 2SCG Da e Street. 5mi teendre. CA 945U. 6415) S69-5274 OAELAND OF FICE 950 97m stet.OAlandlCA 94600 (415l452 1100 on of x. Ray Engineenna Co'mpany G<rTBV& 3W~-l.
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555umet no responsability for losses of any kind due to interpretation.
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FOSTD ClTY-FC.IN OF FICE 1118 Cans Dr. e. Fneer Cary. CA 94404.(4156673 6000 og,
$AN MAf tO OFFICS 14S North Bayshore Saed San Maine.CA 94401 (4156 3424113 083OC'\\
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$AN LEANO8tO 07 FICE 2504 Dee.s $ trees. Sea Leandro, CA 94577,1415) 569 5274 OAKLAND OFFICE 950 97th Street.04 knead.CA 94606.(4136652 1100 a #" 'sion of X-Ray E'ngineering Company ecec-soe CERT FIED REPORT of flDiDESTRUC"lVE EXAM t A"l0f CunTO*84 8 OAlt GrtMTh. I'sw,2 G r f.
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Total Hours Total M..-
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FOmas sta e4#F43
- i. Q.3
' ?.i,4 ;' d' W-QUALITY CONTROL !NSPECTION RECORD FOR WELDING. HEAT THEATING. AND 5
- 1. PRO.'EC T NO.-
7220
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- 2. CC Fit.E NO.
UNtT NO. $/.Cp.
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- 0. INSPECTION REFERENCE DOCUMENTS:
ISOMETRIC NO.
- 4 REV.
. DRAWING NO. h2 ? #6 )
_REV.
~7 ENGINEERING SPECIFICATIONS: NO. C - % o 5 R E V. (>
NO.
V! ELD PHOCEDURES : NO.
F/-'l-/ /
97W M'#N REV./?
NO.
REV.
r!"'T ". wee &t!RE-S : NO. //M W /17#/
N m'd'#d'6,R EV.
NO.
REV.
NDEPROCEDURES
- NO. / T-- 9 4* - /
'2 R EV.
REV.C NO.
OTHERS (DESCRIPTION AND REV.):
Ni 'T~-/- f. ?-
s ?>r'. C
_REV.
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d Kr'di.* cat'4hj p s m s: wy Srnwc.P,rL// xis?
sffs a' ' Q so-?H*1'S uno Argy r) t.y;a z WELD IDENTITY AN Mlef 6M B A /*'# 68'8 b CS Wd# C r
D /1 hw,.r,.,> x.ge s
OnlGINA1._OR RED.NO. :
REP. NO.1 REP. NO. X R EP. NO. X _
REP. NO. d SA/ ASTM MATERI AL TYPE
_ #- W 4 76 jf - o 4.56 AND GR ADE (MAT. TO MAT.)
A -- 7 6
/J-M
/J-M
- 36 DIAMETER
- M
- 4
- 4 THlCNNESS WO W/I MA
- A COVERED ELECTRODE E 70/S' E 7'c/y' g7ejg BAREWIRG WA W i" CONS. INSERT RING
- M
- M W4,
pye /3' BA 7 KING RING
//#
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BLOCKG i,4 THRU 7 8.
PREPARED BY (FWE).
A 2-DATE N N d D. REVIEWED BY (OCE) #/YhMM--*
DATE F-'-7#
) O. ACl 11.
W-DESCniPTIO.*J 12.13.
14 tYEtNS A_ccEPT Aat E 1.0 PREREQUISITES C
E A
B C
D 1.1 Blocks 1, and 4 thru 7 reviewed for familiarity.
l. 2-Inspection reference docr. cents reviewed for availability R
R
'/.; ' J.6
F4.T d
familiarity, and complcceness.
@ {'[ [p' ((#'
1.3 Revicu performed for rpen MCR's which may affect welding, R 12 ;y,,
.y.3 jS&-
,j b-3.g.,, i h-s.2_yc heat treating, and NCI activitics.
U 1.4 Wold filler metal hanoling, storage, and disbursal
- dW s 9.s
- 1 4. / -/ "O l
R
[AT' jff[ jfM /fM f
requirements reviewed for familiarity.
,t.2 -n t -/. /:
< 2
)
2.0 IN-PROCESS INSPECTION
./ 4, /(.
2.1 1]alding 1;
i a.11eJder qualification records revicued and satisfactory.R 9. i..,e
,;.,. ;, z ;.,.
.h/,O'.fjjp.ht- /fS-~
l Welder's Synbol: A _ 7 3 2-.
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- b. Materialn and equipment correct and acceptable.
[
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FFCN - Edge preparation, fit-up, purge, preheat, and c.
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- f. i.,*
QUALITY CONTROL INSPECTION P.ECOP.D E2
i OR WELDING. !! EAT TREATING. AND j>fj f,.
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- 1. PROJECT 'NO.
7220 NDE INSFECTION ACTIVITlL;S
- 2. O C H L E t m.. ~
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0 4
I"?.*/ EQUIPMENT NO.
S. SYS1 Ef.:/ SERVICE T
G. INSPECTION REFERENCE DOCUMENTS:
ISOMETRIC NO.
REV.
D R A W IN G M O. __
REV.
ETIGINEERING SPECIFICATIONS: NO.
REV.
NO.
REV.
WELD PROCEDURES : NO.
H EV.
NO.
REV.
PVlHT PROCEDURES : NO.
REV.
NO.
_I
~
REV.
NDE PROCEDURES :NO.
_ REV.
NO.
R EV.
OTHERS (CESCRIPTION AND REV.):
6.I'd 0 4.'r eMec v4Ap vecx// yef; 4'U "' /#
WELD IDENTITY A I'd #fe # // //
B #' /2'J' D M C /I' '"'Y dfA D
/ R EP. NO. :r=m_._/
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REP.NO.
R E P. N O.
SA/ ASTM MATERIAL TYPE
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4M
/? 36
// 3 6
/
-3.5 DIAMETER
//4 l'
- N-N4 THICKNESS
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//4 COVERED ELECTRODE E~70/7 8 79/_9 ji 7c/g
~
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4/4 BARE WIRE BACKING R1NG s.VA sVA
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,I
, MAX / MIN. INTERPASS TEMP.
/V/ 4
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/VM / 4 d'N
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m-DLOCKS 1,4 THRU 7 8.
PREPARE'D BY (FWE)-
&#e6 "bO DATE #d///I8 D. REVIEWED BY (OCE) ###M06 DATE M'-/- 7'6 i
- 10. Ac1 11.
i No.
DESCRIPTION
- 12. Q. R WM ACOMM c
E A
B C
D 1.0 PREREQUISITES 1.1 Blocks 1, and 4 thru 7 reviewed for familiarity.
R p.o -
j &-
,s S -
1.2 Inspection reference documents reviewed for availability, R
familiarity, and completeness.
[I h'h' jf["
r -M N
s p u, 1.3 Revicu perforraed for open NCR's which may affect welding, R ji'
.M
.S M
-heat.d'Srcatins and NDE activitics.
8 - "
1.4 Wcld filler metal handling, stiorage, and disbursal R
[f}-
p.
p requirements reviewed for familiarity.
s 2-7' s i-
J. /c
_2. 0 IN-PROCF.SS INSPECTIDN 2.1 Welding
- a. Ucider qual'ification records revicued and atisfactory.R
,h h -
,527-
, t,y Welder's Symbol: A r 32
- + 7' B
Z~ 32
(
C j _ rz
& ?".73 D:
- b. Materia]n and equip::ent correct and acceptable.
S 3'
e ip' j
- c. FPGW - Edge preparation, fit-up,.pu'n preheat,lding.
S.p j.V and I
/<
back gouging acceptahic prior to release for we j,p.
,.,c
,. j..,.,.
f.,
f NONCONFORMANCE REPORT
' ' '^ ' ' ' 2
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[$pec.
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{o4TE 2.
EPo.YE
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_._7220-51.itoc a r.o Rev 6 IR/R-1.OO-8 N/A 17AQ n...
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.... ounce Anchor Darling Valve Co., Hayward, CA
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Supplier
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... N9ntomronuswa conosv on Spec._2220 & 221 Rev. 6 sec.11.0 sta. ten in part,_"The_neller_shall submit for Buyrr's acceptance the cleaning and packaging procedures _to be used...". Anchor Valve Con:pany_ approved _ pro _e_q4_ure
__Hoyld_6-1 Seq 3,.Q_P_ ara _3.f_a.taten._"After testing _and_11rying,_.the valve _ shall_he_ thorouchly_ inspected.
No
_ _c.ontaminditottnhall_be vioibla._on_either_ihe_In1ve or_th_e_f_inaLviping_clgths...".
Continued on_ Paco 2 D r. coo o.scosir.on or.c to arcou-enoar.ou,noure vo rno,scr e-o.~en..~a a..
.. r.cte o seesiv on sutvs.
Return i t em 1 f nted_on_pagr= '> en bhb VMb
=upp14Ar far cicaning d rying_and_. inspection 4n
__accordancewithsu6n1_lerorgcedure1456-1.
Procurement Supv. to notify supplier r
-/* /B84 p4*
of return of items.
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Bechtel
- SHIPPING NOTICE
't) 7220 7220-18
- gg g y SN NO April 21 33 gg7g Anchor Darling Valve Co.
- ONS6GN,ED TO
\\
24727 Clawiter Rd.
Hayward, CA 94545 sooRESS s
CLX~ '
.tOUTINO COLLECT PR EPA 10 PURCHASE CROER NO.
O S & D NO.
M ATERIAL ORIGINALLY VENDOR PURCHASED 0 N P.O. NO.
RAaL FRDCHT 7220-M-117-AC SHIP vA REASON FOR SMlPMENT; Rework and return
^
SHIPMENT AUTHORIZEO FOR BECMTEL SY; DILL OF LADING ATTACHED aEARER P. Flanagan/B. Crubich IT EM.
QUANTITY U NIT COMPLETE DESCRIPTION O
^
1 ea.
6" gate valve 900 type serial no.
3N449 DBC-GT/1MO-3872-A-R a -
3N458 DBC-GT/2MO-3972-A-R 2
1 ea.
6" 3
1 es.
6" 3N500 DEC-GT/2MO-3972-B-R 2N561 EBB-GT-1MO-3177-B-RP 4
1 ea.
6" 5
1 ea.
6" 2N528 EBB-GT-2MO-3277B-B-RP 6
1 ea.
6" 2N496 EBB-GT-1MO-3277A-A-RP h
7 1
ea.
6" 2N495 EBB-GT-2MO-3177A-A-RP 3
't ETU R N AUTHORIZATION TWX dated 4/14/76
\\UTHORIZED BP.
E. P. Storman NUMBER:
CREDIT TERMS-
- OMPANY Anchor Valve SHIPPER l
Bechtel ACCEPTED FOR SHIPMENT f
3500 E. Miller Rd.
April 21
,, 76 s
ggy
[ Mid d,.HTj 4864'O CARRIER
ER PER
' B. Grubics 7220-1884 SN NO.
- .t.. n...... c_
...r_. c. :. :: n
..:.r,
1
'PPER i
FREIGHT CHARGES ARE PREPAID ON THIS BILI. OF LADING UNLESS MARKED COLLEC he ASE. NOTE s,s tone,. - w.-
- c. t.
SH6PPtit NO.
)
STRAIGHT BILL OF LADING 72201885 GREAT LAKES ORIGINAL-NOT NEGOTIABLE CAaaita NO.
sareess om CONSIGNEE (TO) l SHIPPE R (FROM) l 4/21/76 N&E Mwt Bechtel Power Corp Anchor N r14m, % 1v,. en.
blAtti SIAtti 24727 Clawiter Rd.-
3500 E. Miller Rd.
ZIP C1!Y.SfAlt N
CITY.$ FATE Hayward, CA 94545 Midland, MI 48640 vtHICLE NO.
ROu!E l
Wei ht CHARGES s'*eyn Kind of Packaging, Description of Ar'ticles, Special Marks and Exceptions isuusa soc $menomR"I' st.c
,e 7
Skids of valves.
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COLLECT COLLECT L
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- r**'***'******"****
FREIGHT CHARGES:
7ts(.Mt Pf.f pMo Ch b b s
p"
' * * " ' * ~ " '
'.* * *'.M RECEIVED. subint to the clowf; cot ens oad toaiffs in effect on the date of the isswe of tNs B.Il of to6ng, the property dncr; bed abo...n ooporeas good orce,. e=cep:
es noted (contents and cond.t.on of contents of packagn unknown), marked, co.nsigned, and destined as ind cated oaove wNch said corrier (the word corrier being wndee-src.od theavghovt ins contrort as meening ony person or corporation in possession of the property under the contract) og'ees to carry to its usvot piece of det..ery at It is mutwolly agreed as to each corrier of all or any of, said said datination, i',on its vowte otherwise to del ww to onother coerier on the route to said destanction.preperty over oil o any po,i heeevnoer shall be sub ect to oli the bill of lading terms and cond.hong in the governing clostifaCofion on t'ie dote of shipment.
i
$h.pper hereby certifies that he is farnliot with oil the b.it of loding terrris and conditions in the goveening closuficoteon and the said terms and conditions wre bereby versed to by the sh.pper and accepted foe Nenself ond Ns assigns.
SHIPPER CARRIER NME NME GREAT 1.AKES EXPRESS 2
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AVIM C SIGNA'.
AUinO'If 0 GN Ut
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NONCONFORMANCE REPORT or 1
402
- a. o n.
.nofra n t no.
incv.
F. en oscer no.
e na pog r r o er 1/. u.ur I'4-1 'm
_c-226M) i 5 nao n.vs as. onseosesion concun=s ncs
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- 99. No C NFoRMSNG CoMOtTeoNa SiniciuraL3ea::LW33 y 1h1 Picco W rk 933B9 hnn n 1 " arnn> fn mn onnnon+4n<; angle _ welded-to the web on the South end, M $1de.
Crack _ is in the anitle bolting cli.p_,_ ng.t__in_ the_ attaching _ycid.
Crack _
_is_in the l'illet of the_ angle clip. Thia _b_cJun_.ia_inalalleLand_haa_Avo (2) benmn fw nna fntn thn uch; n11 bolt connectiona_han_bann_ fully _torqucL(ASTM-A-324 bolis)_.
"0" No. i n 1.201 Nonennen mnnco dincoverea durfnc
_QQ_ Inspection.
Ov F'
._Hol G aga_ Applied.
g r cop oiscoser.o" O"c'o acco""c'*oa v'oaraourc wo rnosccv cuo. rr
,=a re.
si. e.sto oiseosiv.oN =esutvs.t? o f.,L 4.S?c.
r 311C_Alg.f.c.clive connectinn nngin in en hn removn,1 nnd replaced no an to meet _.the pyce r ena,, c o n w..- rer,-c.eo.!
Inguirementn nrft.innily nhnun_on rho annf r n d rnuf n r.n nna =pnnf ff encinne_
papnfr En%,r,c not r vc,? i-.% rn e,, re t" Al shall be in acqord_anc_c gith G.11.S. Structurn1 Rovinfnn 3,._ paragraph 5 5; The O'# A m M /ase.9./ e. w < % u r--%. t.v o.
o Icnnirn nurifnn,1 nhnyn the_requi romen tr.-o{- Ecchtpl npociff onef an 7??n-r *In4 GL5 y nwsontv2, rte rs ne ve.cc nnee Parar,raph 11.0 fMf/& e/- 2 7 6. M ll m.,f h y4 qu e c a c'4. f,, f j,.c. 4y,- jhi a Trer. 4 f,,,
- 32. ENGtNEE MING otSP StT eoM 2 3. E,eG IN E E R ep.G oISPostfloM stESULT.a t
- 24. IS oE54CN CH ANGE REQUIRFo C N.
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- Oe6sinator e c-s a-a Ceneer Copy
- Field Engin e PMk Copy
- POAE Coldenrod Copy - OC
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NONCONFORMANCE REPORT
- R E..
T.P O,.CT O.
.2
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!6 7220
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Quality Verification Docume
- e. gTEM LOCA TsON nts N/A g g v AggoATgo gy 3
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N/A
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- 5. PURCN ASE ORDE R NO.
N/A
,,. E PL A C E M E,,7,.., T,.O.
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N/A
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p/A IS. QC FtELD BNSPECTSON PLAN NO.
/
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N/A
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ROUTE TO FIELD ENGIN EE RING Q 9tOUTE TO MA TER8 AL SUPE RV8SOM 8 9, PeONCON FOftMING CO*eDeTION Speciftcation 7220-C-2 30 Anpendix D states.l~
be. usect by Buye$r/ Contractor to soccific ally identify docum n pa rt, "G-321-D is a mt>lti-cu rnose form to reouirements in:1 is to be used by the Sucolier as a cover shents recuire-I of the su;> plier to shtisfy specification submitti_nn them to the Buve'r/Contrr.ctor. "
eet for Gudlity Verification Documents when Contrary to the above.
has not use I thin form as a cover sheet when submitting n nrior to March 31, l')76, Chamnion Inc.
that..11 Cunlity Verification Documents renuire i by S oclicable documents to Bechtcl.
It should be noted f) FIELD DetPOSsTtON 30.
QFlELO RECOMMEreDATION/ ROUTE TO PROJECT ENGINEERfMGoccificaticn 7220-C-2 St. FIELO DeSPOS8700N RESULTS*
- 22. ENCON E E R ING 00$PO Sf 7808e
- 3. E NQsNEE RigG D45PO58TeON RESULTS4
- 14. 85 DESIGN CH ANGC REOUlftED NO O T Es. sE E ATT ACHED.
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3 3 DR kWING/P A R T NO, s R E w.'
- 7. PROJE C T No.
D e v, /
jDA 42 EP Y
E
- 23. DagpOse T eO N CO NCUR R E NC E 77'> n-(% 4Q9 6
7220 M/3/7[ "' * *
- l * * *"g*
I
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- l "' -
Thickened Lb}eh b, ate
/ VA
/'/
dATk Y
'eqATED B74'XAld g
i l-i-I O'/ f/'/[hgw d-(3-7/.
l
- 4. SERF AL NUMoER
- 9. ST A R T UP S YS T E M NO.
n/A N/A f!1 N/A V
l REW.
. st EPL ACEME pe? P A R T NO. l I
.. PURC r. A sg OaDE. NO.
... OC r E LO.N sPECT.O Pt A N NO.
... R E PL A C E -E,.T s E R. A L N,.
(*J[/*,,'*,",,ff f
- g. Qf.,
7220-C-52AC l
M/A N/A
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.T E M O NO Construction Ro uv eN G MsT R UCT.ON,
D ?' "' ' ' a " ' ' " * " * "' ' = " ' N a O Rau's 'o Ma'EReA'suPEavetoa
- 19. NQNcONFORMINO CONDITION: A completed and accepted f18 Cadweld splice (B Series) attached to the thickened liner pl' te for the secondary shield wall appears to have been cut off prior to placing the 2'0" cover slab at Elev.
a 593'6".
Th'c cover slab uas subsequently poured without replacing the Cadueld splice.
'Ihis does not conform to drauing 7220-C-409, Rev. 6.
The Q Number for Cadwelds is 1.104.
T.iis item was notct!during routine inspection prior to the start of interior vall ' construction.
(O;r dato G Aert wp
- a Q FEELD OtSPOS478CN OFtE LD RECOMMEND Af TOP!/seOUTE TO PROJECT ENG0NEERtNG 29.
- 31. P3 ELD DISPO50YeON R ESULTSr
__Renorc_concre to in t-h n nron of rhn mf =: sing _cadueld splice nnd nda n nnu <ndunia 540Ve,44 3 <be t'N d/ a-t splice to the thickened liner plate so as to con _ form to Dn. C-409e Rev. 6.
F/pk 6-fr-d /
II C-///-#>/j Concrete may be ren_ lac _ed with adjagng concrete nIpyment.
All above uqr];_is_to
/
be done in accordance to applicabic portion of Specifications C-111 and C-231pd AMMD/Adf.
Dwn C-624 h*tiSs
$mw A - l> 'l 6
! Y Y / S?h
- 2 2. E M6 tN E E ',6840 D 85PO'58 7 SON
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- Oeleteetor O e; 4 3 -a Cone y Copy
- Fless Epeineet Pink Copy
- POAE Goldenrod Copy - OC
~
' NONCONFORMANCE REPORT' y.
'}}6f
tREV.
7.-PROJECT NO.
.IDATE
- 23. D tSPOSIT TON CO NCUR R ENCE
- 17. (IE POR T E D e v.
,e 7220- % 02-29
! '3 7220 dbr/E., /.' d' '/
'/d 24
- * * * *
- l * * ' * " l " '" l " " " " l ** *
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Polar Crane 111-51 RR Siding
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3 5. R E PL ACE ME NT P A R T.'NO.
l'.R E V.
F. ease,p. eses..e=ese ma,e cM-7 508.*,
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S. PURCH ASE ORDER NO
- 98. GC FIELD INSPECTION PLAN Peo.
S G. REPL A CE MEN T SIL M I A L NO.
.e...
3 n.,
N/A N/A G. CONT R ACTOR / LOC ATION e-gl.ASME Q vgS 3 7. SOUNCE Ilarninchferver, Milwaukee, Wisconsin
' t} O Vendor
.T E M 9 8. ROUTING INSTR UCTIONS Q ROUTE TO FtE LD ENGINEERONG Q ROUTE TO M ATERI AL SUPERVISOR t 9. MONCO N FORMING CO NDOTION S Drm.ri n e-7220-?f 07-70 Unv. 1 nhntm n 5/16" continnnnn fillne unid en in h f enP a A.A 9 th itch 12. nnd n Ft:11 n.m o rrn r inn butt uela nnitcino igen #3 to item #2.
Contrary to'above the following was noted on girder C-1 of crane 171-51: Lack of fusion between item #13 and itens f4 & F5 internittent alonc: entire lennth of weld.
Under afw rf 11 s uni,1 f r.n n rhnn s/16") betwfiedtcri l'18 nnd f roma #4 F,#5.
Evidentn of inennnleto fnetinn ne bute welds between items #2 L #3.
Q fio. 4.001 Nonconformance discovered during field inspection of crane.
l TH, )i?Dufb 28.
Q FIELD DISPO' 4 F80M I/
S QFsELD RECOMMENDATION / ROUTE TO PROJECT ENGINEERtNG it. F9 ELD DISPOSeTION R'ISULTSs e
2 2. ENGIN E E R tNG DISPO SIT IO N
- 33. ENGINEER)NG DISPOSITtON RESULTS:
- 34. 85 DESIGP-N ANCE ttEQUtRED O NO
~~
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sa,e t0096 8 White copy
- Originator o C-G a-a Canary Copy
- Field Erigineer s
Pink Copy
- PO AE ed 6
Goldenrod Copy - OC e.-
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NONCONFORMANCE REPORT' OP-1
),0(3
- 3. oR Aw,NoiPA R T NO. -
j RE v.
T PRO,ECT NO.
...RE,OR1Eo.T g,.
joATE
......PO.. T.ON CO NCU R R E NC E 7220-C-225 6
7220 L. P. Itchner 54/8/76 j""" j a" - l * " "," l "* -
...T E M oEsCR.PT ON
- 0..T E M LO C A T,0 N
.. v A L,0,
~EO.T f 7 joATE
. L..; FO-dAtJ / M/.E' d Steel colunn 5.31 L Fx Auxiliary I:uildini; 4i
- 4. SERI A L NUM aE R
t 5. REPLACEMENT PAR T NOj REV.
ee.t.c.ps.g.
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TEM S t. FROUTING ONSTRUCTIONS Q ttOUTC TO FtELD ENGfM E ERING Q ROUTE TO M ATE RIAL SUPERV450R 9 9. NONCONFORMING CONDITION: techtel_Erauine C-225 nev. 6 nl.o:in a ntructural stec1 colurn located at the intersection of 5.31 T. Fx colunn linca. An ac-huilt survcf shous this colurm ao liciug-1 1/2 inchco nouth of thin location at Elev. 617-0 The colurm banc plate is net at I: lev. 599-0 anil concrete in placed to 612'-6".
Survey notes indicate that column base plato una set in proper location.
O I.ist_iten - 1.201 1 nnla erng appun,t 20.
O FDELD DISPOStT40N QFIE LO RE COMME ND ATION/ ROUTE TO PROJECT ENGINCER4NG 21.' FIELD DISPOstTION 9tESULTSt 2 2. E NGIN E E RIN G Ot$PO5tilON
- 23. E NGIN EE rt BNG DtSPOstTSON RESULTS 24,3S DE$tGN CN ANGC FREQUIRED ONO
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scoss t White Copy
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- POAE g
CoMemod copy - OC
2,
.,. s NONCONFORMANCE REPORT *
[.C HAW 6MGyPAN N.
Or-9.
REV.
T. PR OJECT NO.
h07
^
I 2. R CPOse T E D e Y 7220-M-209
! 3 7290 N' M~
N'DATERb
"- j "" l -~ ~ ~ j "* "," l g ~
2 5. DISPOS 07 TON CONCUftRE NCE
- 3. lTE M DE SC RIPT80N
.. BT E M LOCA TtON 9 3. V A LSD AT E D e V
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' b N. eda b !/*N b 4
- a. S E R A L N uM'a t R
- o. ST ARTue Sv5 TEM NO.
See Blnek 19 U/A iS. REPLACEMENT PAR 7 go.
jREV.
.......... w........
=aa S. PURCN A SE ORDE R NO.
' U/A l'
S.m
~
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IG. BiCPLACEMENT SERIAL NO.
7220-M-1Q6AQ Rev._3 R-1.00-12 N/A
.. CON T R AC TORSOC AT EON g vES
...ASuE of. SOURCE
_E9.'_GhN ST n u CTiO N S: ell. h ren. Ohio CODE erEM O Nn mmnli nr e s. ROUTING g ROUTE 2 0 r. ELD ENG.NEER.NG O RouvE 'a Ma'Ea' A' 5uPEav'Soa lo. MONCONFORMING CONOSTtON:
Ptt chnno Order 7290-%'106An Pav. 3 P.m 9 ntnton.
Mll annnnonin'mns<U in anl u. n for Forn G--121-I) mot be nubatited for Buysr_approvsl.
'I' hose entrinc-oring documento m%d 'YN fn en1nnn y require nonrovRnr_i_or to comencenant of fttbrication." Contrnrv to the nbove, the_ Onnli ty Pnnu-nntn tinn on-
._the_ hanmrn show tint _they were fabricated to hnn<mr +ntchen that had n Pnchtn1 npprnvn1 l ovn1 t, unn+ cpp2nyna _
Correct rtnd re<ribnitt. " Onntinnnd on Pn p 9 30.
Q FIELD DISPOSeTION QFIELD RECOMMEND ATION/ ROUTE TO PROJECT ENGINEERING 3 9. F6E LO DOSPOStf EON RESULTS:
- 32. E NGIN E E RtNG DISPOStT ION
- 23. ENGINEERONG DfSPOSIT80N RESULTSe
-a,
- 24. 85 DESIGN CN ANGE PEQUlff E O NO
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DCN SPEC.
R r V.
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30000 3 White Copy
- Originator QC-G 3-2 Canary Copy
- Field Engineer Plok Copy
- POAE Caldenrod Copy - OC
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- 2. DR AWING /P A R T NO.
Or _1 Lo8 g RE V.
T. PROJECT NO.
I2.REPORTEDSY I
_EE.C_.-3hA
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DATE IS. D eSPO tt T ION CONCUR R E NCE
- 3. BT EM DESC RIPT ON
- 8. STEM LOC ATtON 8 3. V A BDATED S V 3d 4" Ibmoliner Plate Assy Unit #1 Domo Erection Jie: M1Mtx% ' ]. kATE2/-7[:
- 4. SE RI A L NUMBER
- 9. ST A R TUP SYSTE M NO.
IS. REPLACEMEN7 PAR T NO 8
- n-h-1 N/A N/A l REV.
Pe*Je t t **e 6e e ne,see s e
- Me S. PURCH ASE ORDER NO.
_1220, R ACT O RiLOC ^"*"
8 0. OC FIELD INSPECTION PLA N NO.
9 6. REPL A C FMENT SE Rf A L NO.
...,o,,,,,,,,,
..,, 50A C-111-126 N/A_
.. CON Southern Boiler & Tank
" g= E O ns
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.TE M O NO Ve_nd_or S t. ROWTlMG iMST R UCTIONSa Q ROUTE TO F4 ELD ENGtNEERING _
Q MOUTE TO M A T ERI A L SUPE RVfSOR
- 89. NONCONFORMING CONDITION:
A discrepancy -exigte between_ mill. Blab number documentation and the vendor transferred _
staan number.
~
Ibeumentation_q1nb number la ET/L8_1382 olabJg. the vendor transferred stamp is HT! 81982 olab
_5L. Diocteplutgy_ detected durinre 00 field _incoection review. O No. 1o 1.109 Hold Teca Apulied s
20.
O FtELD Ot1 POSITION QFIELD RECOMMEND ATION/ ROUTE TO PROJECT ENGtNEERING
- 28. FIELD DISPOSITION rtESULTSt o
, 22. ENGlN E E R ING O f SPOSI t aON 2 3. ENGINEERING DISPOSITION RESULTSt i
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Or 2 hog RE V.
- 7. PNOJE CT N O.
fDATE IS. D e5POSI T IO N CO NC UR R E NCE 9
REPORTE Y
__7220-C-111
'9 7220
- 3. s v E u DEsCRiPrION W
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cKNO Construction 9 0. ROUT 6MG IN57 F'UC ? TON 58 Q ROUT E TO FIE LO E NG4N EE RING O aou'E To " A r EaiaL suPEa Vison 9 9. MONCONFORMONG CONDtTION:
SPAcifi.gali_on_Q 111 Rev 9 ApAe_ndix "B" Para 2.h states in part. " pits and couges with n anvi n ti nn rrnm pinne nr dep_th_of_ cut _creater_.than_0J6_inchen.__Thesn_defenta_musi_bs_recnrded."
Para 3.h
. ntalen in_p' art,_ "These imperfe.ctiona shall be rmoygiby_CRinding_na_ye_ quired,_an_d_. replaced with_wpld_neial.
__Crntrary_to_.the_abav_c a _ deep _gougn_ 09]"_x 7/8" x 1/jh" existes in the plate.
With the plate in the crected position thn gouge _in_. located 2'Q" 'from_the_Iight_ side _Qf_the_2RalLcharg and 6'7" from ihp bojiqm QFlELD RECOMMEND ATION/ ROUT E TO PROJECT ENGINCERING Continued on Pasre 2 20.
F aELD DISPOSet SON 2 9. FIE LD DISPOSITION ft E SULT St Repair in accordance with specification C-lll, Rev. 9 Appendix B, para. 3.4.
gg 4,q/g. g g g,pq*h
'Ihis is an approve'd std. repair procedure. York may proceed.
Implementation
@flgCJ ( Qg - MM 0 b 0)p, _ l 4 - c g
-r p h
fh h k~'f-jd &
nvpcetnd by May 15. 1976.
%0aw 4-19 8
- 0 2 2. E NG IN E E R ING DISPO$17 TON 2 3. E NGIN EERING Ot5 POSITION RESULTS t
- 24. t$ DESIGN CN ANCC REQUtstED
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/21/76 l -""- - l -" " " p y
5
......,s.....io.
___16-5tcho'r Dolt Nuts.
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._ _72. bE.1041faLnc1Zo TO-N/^
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. Construction
~'*-a*a!"--
.rc u is. nourenn insrauctio s-d nourr to resto racenscaimo O nours to marsniat suernwisoa Drawin.; C-197(0) Rev 2 shows locations of (16) anchor b' lts (for t:ahe-un tan! s 17-30 and o
T-3 31 r-ae I i' ' t.'C". and re ferences drr riiMs C-14 ~ (0) and C-195(0).
Drawin.< C-149(0) EcV.2 shous t:te abovc '
- _._ anchor ho_Itn as havina nn embedded nut.
Note 4 on drauinc, C-3.95(0) Rev l'says "All nutu shall confor:. to i.S*1:f A-32 'i L. M. ".
Contrar / to_the above, the (16) anchor bolts ucre ordered, fabricated, and installed with ASTI
/i'l4 2%'/hf/f////c /;Jfyfs) Dt f.4G' s9f' /D L /{;!//x-WA? *f Ad*' 'ff/f/t'/c 9f Df/j.?t/// 2 f A-v'7 nnts, f
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- 1.. ric to oiseo s.v.o~.a c suu,e s.
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- NONCONFORki NC'E REPORT'
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- 2. DR AWING /PA RT NO.
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7.'PR OJ E C T N O.
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7220 82 REPO ED ay I
DATE
- 25. Df SPOSITION CONCUR R E NC E
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Ctor-31 l".;
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'1, 2-11CB-1 Unit 2 N/A
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O. PURCH A SE OftOER NO.
8 0. OC FIELD ONSPECTION PLA N NO. '
S S. R EPL A CEMENT SERI AL NO.
ufA n/A N/A
' - -. o -* +-***
'... CON, R ACTO R, LOC A TION
...AS=E elves
".SouaCE
..,,,,,,,,f,,,,,,,
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.T E = 0 NO Construction
~
< 9 0. ROUTING IN STR L*CTtON S:
ROUT E TO FIELD ENGINEEftlNG
. Q ROUTE TO M ATER$AL SUPERytSOR 5 9. NONCONFO ft MtNG CO NDITION:
Specification M-204, Rev. 4 Para 6.4 states in part, "During installation of piping and all openinns for pipe connections, all access openings an'd open'cuded pipes shal1~be covered with dust
_.couipment,
_ proof covers whenever work is not actually in progress." Contrary to the above spool 2-IICB-1, Unit 2,.is not -
_ covered and spool 1-llCB-1, Unit 1, has a spool cover which is only partially occured. These pipe spools have been used as access ways for air, emergency fire water, and cicctrical cervice lines.' "Q" Number is 4.013 and 4.028.
2 IIold Tar.c Applied 20.
Q PIELD DISPOSITION QFIE LD RECOMMEND ATf0N/ ROUTE TO PROJECT ENGINEERING SI. FIE LD DISPOSf 710N RESULTSs e
- 22. E NGIN E E RING DeSPOSt r fO N
- 23. ENGlNEE RING OtSPOSITtON RESULT S:
t e
- 24. sS oEStGN CH ANGE REOutRCD O NO
- "'""^"'^'"'5" 5"'
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W 2 ' ac ^cce^"c 5 b yES, SEE ATTACHEDs G se me DR AWING REV.
DCN e,te
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- Field Engineer Pink Copy
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59 NONe;O Hro ne ttNG 4.O NDtT f 0N.
__..Section.7.4..l.of_ Specification 7220_C-230,[_Rev J_s ta.tes.that po'zzolans. sha t1_conforn to_.
- j. ss r y. c, s,4. '.r. / a e'
._.ASJit_C-6,LU _72_ln_ table _2_Icituircothat._the...finen.yalue bc. not_1cas_ than_.6500_cm2 3
ST fne'!d Isf f1 as.h s.aaP. led on 4-15-76 was reEo..r._te..d...a..s_.
5654__c.n_2/.e.n. 3 1.cn. Contiary.to..the_ aboyc_,
L -.
... H. o..n_c..o_n fo.r_m_a_ nce no.t..e_d._ d. u r.i.ng t o_u ti_n._e 'u..s e_r
._tes ting..of ptate.rl'aln. _ _".Q". lin t numbern are 1.105 anil 1. 205.
No hold ta(;c applied.
" O " nu<" - "o" D n.. o urreimon noninon,s. w ruonm r Ncinn u,N,.
mi. r.u o rus. o..mn nrsu. r.n
_u..
TL_U;;. f er.D.e...ti.e.: iu.im.t 4/.l.5/.M_.tm. / /.21/ 76..a._to r.a t o f 12 37 c.y. o f concre te
_.m_ u..hatde_d. m..! o f t h H ro tal :111 c. _v.,
tan "O"
linted.
Sew n dav cvlindm tenta In-dicate i.o nLuor ml atrere.th or nt.cena.th develonneut, and no t:nunnal a r content pro-blera rare encou.tter.:i durin", thin ;inriod.
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NONCONFORMANCE REPORT
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3.
rcu osscoiPt o=
666D lb.
s.src= tocaveon
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_capacIity 'cepmnt scale Batch Pliint jf' W, dgC inh _.D w '. 7 9 7/.
i s. v teoat > v e.
- 4. st HI A L hvMnCn
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- 10. OC F 8E L o GNsPE C rioN PL A N No.
9 8.
E PL A C E MEN r s E. A L NO.
_R/A.
C-230-2-ll4 Rev. O N/A
" - = " " * * - - * * - " - " '
~""'
.. co m u n ac r o ntocc a r eon w
i s. 4.u c vcs ser.sounce
_ Champ _i__on Inc.,, }Ildlan_d, Micliigan
' 'l oT Subcontractor
_ _.v r u
... nour.~c. ~sy n uc t.ou s.
gnourc vo..cto c~ain een.~c o naure.vo
.re...osuP nv, son
... uoncour o u-,~o co no.1,ou,
Spec _ification C-230 Rev. 6 Section 9.2.3 requires the batch plant to be certified in
_.a_qc_ordance with the standards established by_the NRMCA. The NRIICA che::klist requires in section 2.1.2, " Each Acnle shall be accurate within + 0.20 percent of scale capacity throughout the range of use " Contrary to the
__ abo.ve,_on_4:22-16,__ducing xoptine_s.cale__che_cky.,_the cement scale (6000 'Ib. capacity) was shock loaded causing
_e_rja.t_i_c res_ul_ts during the calibration. The Michigan Department of Agriculture "condemmed for repair" the above
_ scale.
.gci.o nacomutuoav ouinourc vo Pno,ccr cucincen,uo Oy. coo u.5Posn.au Continued on Page 2 so.
.\\,
... P.a to u.sPos.r.ou n e sus., s, 0
._The scale.sas _ shock.. loaded _and therefore_ damaged _.during calibration on' 4-22-76.
Th<
__ incident.Sas._uitnessed__by a_membnr nf the_ Quality __ Control._fleid _ engineering,_staf f
._nnd._ documented _on-the-attached-f-ield-inspection-report.-The-scale did-not-deviate-
__f_ rom __the perminna_b_le_tol_crances_urit f 1 af ter it van shock J oaded._a_t__the_1100db_._leyf L, o
The neni n tenn vnnnirnd nnd roen14hrnrod
/i-7 6 -7 6.Ind (nund ncceptahi n -
Mn ennercia nn ss. n nu. nr.tnena ausPoso san 2 5. ENGINF E ff fMG ossroStTION EsuLYS.
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- Originator QC Gn 2 Canary Copy
- Field Engtneer Pink Copy
- PG AE Coldenrod Copy - OC 3
J
_HE ch_19_ Con tin uc(L-
_NONCONFORMANCE REPORT (CONT'D) y s
. Lea:E 2 orf
.'..~csno_ h13 -
The scale was. sent off sge for repai'rs and was returned. and recalibrate'd on'4-16-76 and fou d t
_the..pp_rmissible tolerances.
n, o be within damaged during the calibration on 4-22-76.The attached letter is a detailed description from Cham' pion on how t "Q" list number in 1 205 No Hold Tags applied.
f~T.~7G'7]i <~
t
'/l:-I d-
_ Block _2D.: _was.J>atched_fron _4 76_thrpygb 4-26-76.,_An evaluation of previous cement wei ht
~
f, s is not resp ied,.
-since it has._bcen_ determined _the cement.. scale was. damaged durip' g calibration: -
)_ ')dt. v. LB. 'd-28: 7L Sb.wm/
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2 FIELD INSPECTION REPORT
- 3. RECORD CONT
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CONTROL NO.
us FILE NO. Ncf-fl
- 1. PROJECT NO. --
j
- 7. D ATE I
b b
PAGE _
OF_
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di G M c5 S. LOCATION O N ' 5 ' T t_
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- 6. TYPE OF INSPECTION-.
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- 7. STAND ARD /-COOC-*tHGCE DUHE-4RAWsNG4,SPECLFJCATiO4 M N\\ C A
- 8. l.*4SPECTION EOUlPVENT.USED _.__k.Th M D %D
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- 9. RESULTS OE INSPECTION:
. SATISFACTORY !)
UNSATISFACTORY 3
- 10. ACTION TAKEN IF UNSATISFACTORY _h_dOO b 1
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- 11. ENGIN EE R S
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NONCONFOR'MANCE REPORT '
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_SPCce i Ev
. PROJEC T NO.
- 7220-5-201
! '6 7220~
~
i t. rrE POR T o Sy f
/84[
,2 4 /
M' o AT Ed8YI
- -*"SPosiTiON CONCuReiE NC E 2 s. o
. - s. :TEu oEsCRiPTiON l " " l "'" j '"" ",' " l "* - -- -
y
- e. TEu LOCATION f(r vaLeo3Tio ev */
' [2) 42" Pipe Spools' Locked Area ^fl
(
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- 4. SERI A L NUMSC R j @ h h-$(}-1-1
- 9. ST A R TUP S YST E M NO.
II. REPLACEME NT PAR f NO. 'REV. Paese cr eesse sse.e-e s, s. eats 5T [._2CBH_26-S635-1-1 H/A
- 9. PURCN A 5E ORDER NO.
5 -' "- N/A - i 10 QC FtELD IN%PECTION PLAN NOs IS. R E PLACEMENT SE RI AL NO. 1 7220-II-104A. QCIR# R-le00-55 . s. CONT 80 ACT O M/ LOC AT 80N j N/A 4 gf.ASME h VES, S T. 5OU RCE, ITT Crinnell, Kernersville,' NC ', *TE " O No Supplier /- is. RouTsNG INSTRUCTION $s ROUTE M MLD ENG4NEERING
- 19. NONCO NFOR MING CONDITION t
, Q ho TE W MATERI AL SUPERVISOR Tuo pipe spools 1CBB-76-S635-1-1 and 2CBB-76-S635-1-1, vere fabricated by National Anneallog Box Company, Washington, PA for ITT Crinnell. Bechtel Shop Insp'ection was not perforned for-these spools. The _ following, nonconformances were noted during receipt inspection. - Units A S.s2. "Q" list nur6er is 4.1353 2 Iloid Tags Applied Continued on Page 2 20. Q &8 ELD OfSPottTeON QFIELO RECOMMEND ATION/ROUTC TO PROJECT ENotNEERING 2 9. FIELO DISPOSITION RESUL*St s \\ 3..% pm/
- 22. ENG4N EE R4NG OfSPO SITION 2 3. ENGINE E RING OtSPOSITeON RESULTSs t
as. sS oEsscN CMancE REOut"' O NO "^'*"'^5" O 7E3. Er ATTACNEoe O."e... " '
- c ^ c c ' ^ " c "
DR AWING R E V. OCN SPEC. R E v. A p p.
- w*a.an s e eases ce..
s oo s s-White copy - Originator oc-Ga 2 g Canary Copy - Field Enginest Pink Copy - PGAE . Goldenrod Copy - OC o
.. '.,.[fs ~ f :.};.. _. v 3,. ~ ] . Y.l,' D <~ {,. L- , NONCONFORMANCE REPORT (CONT *D) ' w 'c.'s. em 2 a r_ 5,,, g,,,,, L. 434 /. :, .s Hio.ck 19 continued- - i ~ 15 ' SpdcIficallon 7220-M-201. Rev. '6. Para.' 7.2,2_ state' s in part " Nuclear' Class 2 pl i ~ . P ~. f.. p nc shall be ex:rmined In accordance with applicable portions of the Nuclear Power Plant Components Code Article NC 50 includesi which a n. ' All accessible surfaces of completed fillet b. V-socket and attdchment welds" and the heat - affected zones of the base metal adjacent to the weld, shall be examined by r$agnetic particle or liquid penetrant nacthods. '! - Th,, received form G-321-D indicates MT examirj.;1ons were performed,' ho~ wever, the reports of th have not been received. collar for pipe spools I-CBB-76-S635-1-1 and 2-OBB-76-S635-2-1.MT examination report i Form G-321-D for P.O. 7220-M-104A reoutres vendor to submit weld rod verification report 2) ~~ Specification 7220-M-201,'Rev. 6 Para. 9.1 states in part "The seller shall establish and s. system for the control of quality during fabrication and shipping which will assure that all materi l maintain a including purchased and subcontracted items conform to these Specification a s, This system shall be organized in such a manner that it will be possible to relate every component of the finished sp its fabrication history. " ool to Weld rod reports submitted can not be related to rod used in the welding 'of 3/8" plate to the O.D. a the welding of the 3/3" otate to the I.D. of pipe spools 1-CBB-76-S635-1-1 and 2 CBB 76 5635 1 1 These 3/S" plates are part of the non-code cover assemblies. 3) Specification 7220-M-201 Rev. 6, Para. 6.6.7 states in part '.'Each section of fabricated pibe assembly or separate fitting shall be clearly marked with durable paint or ink with appro'priate line , eine designation data to indicate its place in the final Installed assembly. This marking shall be repeated at oppose' te sides and ends of each spool to facilitate reading. " Contrary to the above, pipe spools 1-CBB-76-S635-1-1 and 2-CBB-76-S635-1-1 have not be n e n,a rke d. White Copy - Originator Canary Copy - Field Engine.r Pink Copy - POAE Goldenrod Copy - OC g m -..
Ky'r(:s.,. jig!::$.g.j.[j[h,:-Y[. Oy%i[{I ONCON bRM NCE RE' PORT (CONT'D)' !; ,,. o..,,, .,. y,.,., [i.e ar-3. ' 6.aedo-4I4
- W.i 'B'thek I'9 centinuid.
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- )
4} spectrication 7220-M 2&l Rev: '6;' pa rd. :'6.6Jh r.taten in pn et "rnr ca rb. ,7 c,,$._:.__ piping,_ bagged allica-gel'demmicanLnhall_he_ff emly_ attached in tha interInc alda nf t'h on_ n to n1 Nn 61a m e n t-i > = 1 a n A ~> a end: protect,re '" - '., (. hf ' b *. '*i .[. __ Contrary to the nhnve-dessiennt wan nnt veenived with npooln 1 c n n 7 /,- S63 'i 1 1 i n d '> c B B' S 6 352 i 85 ) The Code' Data Report of pipe _npnol 1-CBB-76-S635-1-1(Aianufacturern serin 1 Nn. - GR4 7)' nhnwe = poni is ASME IILClass 2. Code Data R eport and rubbing _of nameplate)-The Cod.c_J1ala Nameplate for thl:tspoo ~ (i) ARMP cnde Section TII, Artfele subassemhlics_ahall be marked vzit}La nauplate. "N A M17 etatos_in-part "Dn_rts, appurtenanco Thc_cadc_namcpinto fnr npanin 1 -CRR _ES619 1 1 and 2-CBB-76-S635-1-1 a re attached to_ the non-code wc14 protectinn enver ' this is oermissible under the code. it I i ind ete rmIn n t a n h, m a,- r 80090 2 White Copy - Orleinetor Cenery copy - Field Er'elneer ~ Pink Copy - POAE Goldenrod copy - OC
1 uti\\15 2.i AAUl At!! UllEllS IJATA IIEPOlil'liOli hUCLEAlt PAlil' AM) AP a. A2 regiiire d by the l' revisions of the ASIE Coda !!nic..
- 1. (a).stanufactured by __ NA T I O N A L AN NE A t. I N o Co'5' ' Colt p AE Y.~ WA S H f N G T o N,
~ _PA (N,me sad aJJews s of ; tan !acevree tal 'ast) l (b).\\tanufactured fot _1 TT G e NNELt_INousTR1AL PfPfNO INC.._ K E a H E ' s v i t t. E. W. C. n Otame er.d adJeems of Laufact aree of compteted notteer component)
- 2. Identification-Manufacturer's Serial No. of Parcbb 7 Natt Bd. No.
~ (n) Construeced AccordiIsd to 'Dra[ving No.NG3251 -4RE v.I ,2 D ing prepared by NATt. ANNEALING 80X CC (b) Description of Part Inspected _ P i P i N c Sua A s s ENa t y MARK 2-IC88-76 * (c) Applicable AS\\fECode:Seerion!!!, Edition _ ID71_, Addendadue S73 _, Case N'o. Class 2 50"O. D. x 2 "TK. Cf % t. A a J S A '515 Ga. 70 ) WE
- 3. Remarks:_
(ti*et description of servase for which cosponent was designed) ~' (N A 3 C o S/N 583'A sS.TnEss REttEvED. P PE AND M. T. -l Ns P EC TEo. ONE ~END O< PfPE MACHINE BEVELED. Non-CODE VELD PROTECTION COVER INSTAtt BEvELEo cNo. ITT GRINNEtt P.O. KER-1258-M SU P P.hi.* N58C AS We cer:if forms to th y thatthe scarements enade in this report see c'orrece and this vesset pa rules of construction of the ASalE Code Section !!!. (The appIIcab!e Design Specification and Stress Report are tot the cesponsibili l Manufacturer is responsible for fuertishing a separate Design Specification and St ty of the part Atanufacture in the cornponene Design Specification and Stres s Report.) res:. Report if the appurtenance is no included Date _ 19 ._, SignedNA T t. A N N E A L f N G 80X C Osy__ / e (3 ctanur*'") 37 , \\ J Certificate of Authorization Expices 0.c @-r 1% CeD.CYPHr..,F PROJEcr enc.i __ certificare of Authorization ..N-?Oh CEltTIFICNDON OF DEMGN FUit APPUliTENANCE (when applicable) Design information on file at Stress analysis report on file at 1 Design specifications certified by , ?, .4.h '_ Prof.Eng. Scare eg. No. Scress analysis report certified by- .6 e.-. .e- _ Prof.-Eng. Scare _ R eg. No.
- ~. <
CERTIFICATE OF SHOP INSPECTION 3 1, the unders"gned, holding a valid commission issued by the Na:ional Board of Boiler
- 7 of H A R T F O R D, _CR.?M.C.C T f C U Tand/or the State or Province of MLN.S.
3 T M RO f _t E rr I N S.o _ Q N Stanufacturer's Partia! Data Reporr ort - have inspected the part o'! a pressdre. vessel described in this and bklief, the Stanufacturer has constructed thisgart in accordance with the AS4E C d192[, a ing the parc described in this Manufacturer's Parrlst Data ReportBy signing p e Sveri n (11. 9 anty, expressed or, implied, concern.' shall be liable in an with this inspection. y martner,for any per>onal injttry or property damage or a loss of an Date _ '19 - f"N v r te pect S w nature Commission s
- S pplemental sheets in fo1 of lists, s,tectches or drawing N.stional Hoerd, 3 ste, P,rovince and No.
data report is incluete? on each sheet /end G) each sheet is nuncereds may be u.,d peav! Jest (!) aire is 8%" u I 1", G a9J numbee of sheets is recorded in tren 3, "Remacks". ems 3 2 on tMs ^ ':S
- U 9
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- w. p b U ' V.s
" ~ 1... - 0 ^ r . 1 '"^**'g 4}S . 2. D8t A WING /PA RT NO. - e R E V. T.'PHOJECT NO. ,f... he hh.
- 12. R E PO R T E D. Y AM'Nk 1-3' W
< ' :$- I !' 4.'r < -. /ON) /M '* :.!' DATE
- 25. DISPOSST40N CONCURRE NCE
'/ - 1 '.I 3. ITEM DESCRIPTION S. IT E M LOCA T f 0 N,.,$.,4 3 y " - * - l " l - * '* ** l - ' * * * ,4 f. h$pe 0 frts LgD ATED e{v ' " - I .. c.. f_ . f.4 - O TE ' l'L]'$!r QQ fC$$ ff 6'!' gOWh Nff t ... S E R, A N U M. E., .N .u. S. ST A TUP S.S TE M NO. ,.,, E P,. A C E,. E, T P A '~i.p. Bee' Block 19 > - WN.' S N/A M a n,r @... $: M5 N/A s T,,0 MO d ' E.. S. PU RCN A SE OR DE R NO. ~
- 18. OC F RELO lHSPECT TOM PLAN NO.
- t.. R EPLA CEME NT SE RI AL NO.~
7220-M-lo6AC ' net. 3' ' ~ 4'. E-1.00-37 i It N/A- .. CONT R A CTOR, LOC AT ON -->"'1'--==--- ...ASME 33 vES. ITI' Grinnell, Warren, Chlo ,,. SOURCE '~- ' O NO ' ~ Supplier ,. 88. ROUTING INSTRUCTIONSs .T E M e, Q ROUTE TO PIELD ENGlNEERING Q ROUTE TO M ATERI AL SUPERVISOR
- 99. NONCONPORMING CONO8TSONs Purchase (Arder 7220-M-106AC Rev. ~4 Para 2 states: "All> documents c:arked' in colum C'321-D en.st be nubmitted for Duyer approval. Those engineering " documents marked YES in coltian 5 require
_rtporoval prior tq_commenecment 'of fabrication." Contrary to the abohe. the Otality Documentation for the hangers
- 1. _ chov that they were fabricated to hanger sketches that_ had a Bechtcl_npumval level Is "Not mT
. _and ' restibnitt. " '~ 't "cantinnaa nn n. nm o s 29. O PIELD DISPOSITION CP8 ELD RECOMMEND ATION/ ROUTE TO PROJECT ENG8HEERING 'h.. 2 9. PIELO DeSPOSITBON RESULTS
- 22. ENGINEERING DISPOStT f0N 2 3. ENGdNEE,f tNG DISPOSITeON RESULTS:
f t,~ a
- 24. sS DcSicN CH ANCE REQUtRED ONO
- * " ' ' ' ' ' ' " " ^ " " ' ^ ' " ' ' " ' " ' "
O vES. SEE ATTACNED. O."e... "'**^*c^"c" DR AWBMG R E y.' DCN SPEC. M E V. ADO. .w t...e s...se e...v.. 39994 0 White Copy - Origlaiator QC-st a Certary Copy - F3.Id Erigtneer Pink Copy ' - POAE Goldenrod Copy - OC s
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- %. z. n R A wsNo/PA R T NO.
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7: PROJECT NO. I s a. REPORTEO m? Wf2'.$'MD80 ,4EIIfh[ - lDATE rs OsSPOEtTsON CONCURRENCE FSK-11-21 1 U/lL f)7220 M.55 ' A #/JR6 " * *" ' "'" ' l ""' j "" ". " l " * ~
- 3. 97EM DESCRIPT80N N
1*
- 8. ITEM LOCATaON s
.s .4/-.-- 9 3. V ALID ATE D e f I . Coolpat_I2rnin Field Weld ~ Unit 42 sun'm" S h o _,.'. D A 1 d Y @ L ~ DATE
- 4. SE RI A L N UMBE R W. ST A R TUP S TETEM a'eO.
e ' NM J,
- 5 \\#
g S. NEPLACEMEN T PART NO 3 NM
- :v'E*EI 5 '. ' '-
'7 WA' 's-R E V. P..seCfF884 8.ee.es. . ate t'- ... s ~ S. PURCN ASE ORDER NO. 9 0. GC PIELD INSPECT,00M PLA N NO." t o. REPLACEMENT SERIAL NO. _ /A
- y f' ?
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- .ASuE
~N CooE tT E M OO Construction o.:..... ..u... Is. ROUTfNG INSTRUCTtONS4 hMOUTE TO PIELD ENGtNEERtNG Q ROUTE TO MATER 8AL SUPERVISOR t 8. NONCOMPORMING CONDtTtONt QA Audit findin.g 087 113-11,1-1) renorts a radiograph taken of* 4".ncn drnin 1<no rv sp1, Field Veld #2, located in Containment 72 does not have the 1 tad letter "F" properly lncea nn the f*t1m recoc: mended corrective action is to reradiograph the field veld.
- nna This veld is now embedded and is not accessible _
, j. _ for rcradiography. Note by' level III Examiner on Audit Report: '%e radiograph is accintable in n11 nther ende ' requirements including the velde " ' "Q" No. i s I 1316 fio hola tnsrd_npp1iedi s_, t E 20. O POELD DISPOSITION QPlELD RECOMMENDATION / ROUTE TO PROJECT ENGlNEERING II. P8 ELD DISPOSITION AESULTSt
- 32. E NGf N EE R pNG DISPOstTION 3 3. ENGINEERareG DeSPOSITION RESULTSs
- 24. IS DESPGN CN ANGE REQUIRED O NO
"~""""*""*""" U~""~~ " ~ " " " " " " O YES.SEE ATTACNED. Dee.a. ...e.... DR A WlNG REV. OCN SPEC. R E V-A D O. aus..mes s. eseses se.. ..,e sosee s White Copy
- - Field Engineer
- Originator QCs S-3 Canary Copy ' - PQAE Pink Copy Goldenrod Copy - OC. s n c e g
.;G ., Q[m'C.. '-~,o,. . ~ - ' s ) u,
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- 11. CUOTATION Para. 3.2.3.1.2:
" Distribution (cf d c sings) shall be individually 'dateminad by t' e Project 7iald "a;;inaer. - D avines cry be '.ncludad on the dravir.r dis c--Yhstina 14 e N'- t his instructicas". Para. 3.2.3.2.3:. "Distributica c f those drawings (revie.ved dir-ectly fron supp'.lar) shall be in accordanca uith 3.2.3.1". Para. 5.1.b .. any suparseded drawings r.ust be earhed " Void end destroyed, or if requir2d bv tiie Innd I t Engineers, dr: wings will be narkad " Void" cnd an appropriate reascn for retentica .g addad... '. I
- 12. DISCRE?ANCY DESCR:? TION 1.
Distribution sho:-. the 'drcvine control eerds dees net - atch the,2-v t-~ .14,- \\ d bution list fer 7220-C-24 (QC Stick Adfed) p-.,.0-C .v.+ n i n n 7220-C-106 p o.0-C-19 ). n u n u 7220-C-147 l .a. Cen t %*,2 I i'. SECO?.1..iENDED CCRRECTIVE ACTIO.'. 1. Ering drawing distribution list, drs71ng ccatrol cards and drauin r dist -ib. ti~. i ( i:to agreement. 2. P.enove void drmiinrs fron field. I
- 14. SCHECULED CCT.i?!.ETION
- 15. RES?CN5i3!Lt TY FOR CORRECT VE ACTION i
DATE 5/1/76 Project senarinten nnt } 15. CORRECT;VE ACTION TA;'EM t b 7 V 1' 1 .s D,. - - c..r...n. 3 1,..c.a a... TT.. r.
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,,.,,1('. ~,,.a. -v a.r -s. e t 4 .,,.*g es - '2.. Actual distribut. ion does 'not =.2:c'a drawing con.. trol card for: l .. m .e.1 > a ... u .y '4 m C-38-4' . (Distrib.ution2=ade to QC ' Stick)4. * ..'~c", .e 2.~ . g ',': ..z. n - - ',< %g v C-3S-32 ..g m.:7. - w.f.;fc *' - .e,, s . r'.. ~ s,/, am <:.3 -. :,qc.. e r. - se ,2., -oo-o w -... ~ ' r. .. c. ~ '
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C-3S-1'59 'c- -f. C-33-144 -(Distribution.'.'=ade tci AEx. : h2) M 1 ~. v.. ~ ~....,... .. =.;.. ?..... W.3..Obso.leta drevings not =arkad.:" void".in field::. ', A. ~. -.:n (m) 79...c - - . C-3S-144 (Aux. #2 c:E Ironworkars-Stic'k Rev. 9) l ' L:..- ' I.\\,;.3. ( %.) ' ' A T'*.' ,s (.a.
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- n. Palner Field Procedurc F10-t6, tiev. L' dated 3/20/ 75 para. 4.1
" Basic orientation and indoctrination of cach individual shall consist of a QC indoctrination unit, a basic application and use of the :QA!!, a F.It! unit and a QC"Rt unit". paca. 4.2 "A taonthly training session shall be scheduled by Lead Field Engineces....". para. 4.2.3 "Individuni training records shall be main tained....". [
- .. i...
There are no records of training sessions for the ' disci lines being held during the month of June, 1975. Re.u 'pI The engineer responsible for the training programnindicated that the basic orientation and "* t e r' E 'ic m
- u c'-~~
' >O indoctrination program h "- y N1 M a rc. "N o Y i+ UC.I L ABL k~ ):~oK PR ES EdvT4 710W /} T Th u T~lM E. Z/A v/@s f m.3 1. Schedule and hold training sessions for July and the future in accordance with FIC-16. 2. ' Develope and implement a basic orientation / indoctrination prograra. j 1.- " Sept. 2, 1975 Project Superintendent n See attached Memo (0-974, dated 08/28/75. ss file 0$lf clhek If/2.lil, se - et .n f I t/ 9 A e l - a s ....e6.... ...mee,r...,...e. } fI //fA *O -- $$ o' (/W ~ g f u..................... 7b \\
1 c) Bechte1 PowerCorporation 5C/ Interoffice Memorandum To G. L. Richardson D'i' August 28, 1975 svejea Job 7220 Itidland Project prom J. F. !!cwgen QAF #060 0-974 - Quality Related Construction o, liidland, !!ichigan The following addresses items no. 1 and 2 of QAF #060: 1) Training sessions have been held, however, such training has been on a reduced frequency and not in strict accord with the formalized pro-cedure FIG-16. The continuous and formalized indoctrimation and-training program (FIG-16) that was implemented in 1974 is not currently necessary due to the 1975 projdct slowdown and the fact that a high level of experience exists in the personnel that have remained on the proj ect. Under current circumstances, discussions between the lead-engineer and field engineers have been substituted for formalized sessions. Since all parties are actively engaged in field engineering , f] work, this approach provides sufficient instruction, yet allows complete .(f utilization of personnel. Letters from discipline leads will reflect this ' training except in the electrical and welding disciplines where there is only a lead engineer in each discipline. ~ 2) Development of the required basic orientation indoctrination ~ program requires some basic trainirg aids. IIowaver, the experience level of current employees overrides basic units of training covering introduction to igual' ty control. Such training would be redundant. The scope of i training procedure FIG-16 will be amended to specify that basic training will be given to new employees and personnel not having had previous experience involving quality control requirements similar to those used at Midland. Presentation material is being assembled and formalized for presentation to inexperienced employees upon arrival. Training records will reflect this basic crientation/ indoctrination program. (_Tj f.tgeu T]@ hwy]bf = $e'- nk) 3 A U G ') W l 5 l ~ SECH19. POWER coop, b\\ JOS 7220 q v-snj d y e 9%G$ ;94 44D 4 g-., -, -,-~ m - - -
C' V Bechtel PowerCorporation Interoffice Memorandum to G. L. Richardson om March 12, 1976 sue ~ Job 7220 Midland Project QAF 060 File 0464 . F. Newgen Construction Indoctrination of Construction Midland, Michigan ce.s e D. L. Palmer A, D. P. Tanner
Reference:
Letter - Richardson to Newgen dated 12/31/75 (I-3901) l' In response to QAF 060, be advised that our Training Coordinator has developed: A) Individual training records containing a description of the session attended; amount of time involved; instructor's name; and date of session (see attachment 1). B) A log for' each training session which assigns a unique identification number (see attachment 2)., C) An accumulative file which gives detailed information about the training session. including specifics of subject matter (see attachment 3). In progress is the assemblage of a three-part orientation program consisting of units on-the Bechtel organization and quality construc-tion programs, the NQAM, the~QCNM and FIM. These are.in rough draft at present as is the form on which attendance' at these sessions is to be recorded (see attachments 4, 5, 6, 7). Training has,'in fact, been initiated on the FIM. ~ -It is anticipated that the program will be compl'eted for presentation "on March 15, 1976. ? JFN/DT/jrh p' Attachments - W j,. MAR 121976 d BECHTEl. POWER ~ CORP' /MB 7220 i //t) ne y DI _,-.----.--t- -~-
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' m W 9 e'fi-TTT. 91.. !!n-1 Ptene.vnnh 4,3 7220 't-204 (M Rev. ' O, Para craph 5.1.6 'Bechtel t?ciding Standard t!D-1, Paragraph 4.3 siites: ~ "Tne !! elder Identification Symbols... such as P for Pipefitter,. Specification 7220-11-204,- paragraph 5.1.6 states: "All velds t/ill be identified with the velder's identifying symbol". 7,..... e b]' Symbol Pti-22, vice P-22. Pipe Spo61'GCB-003-S613-6 has Field tield Ft1 13 marked /' s s Remove the incorrect fielder Symbol and mark the jo' int with the proper IIelder Symbol. . g.... y............ g.mv., a,.../ 76 04/23 J. F. !!eugen Pipo spool C-CD-003-SS13-6 R!-13 was marked Pt!-22 and this has been renoved and is nov P-22. G. A. Italdrop, who was auditor and diserapancy ori;inator, uitnessed the marking and uas satisfied uith the change. }- a A m ) --- a *...=...- /, ........,...............w. l (t a f. s _ ~ ) ,,.,. xy 3,-... f.,.. p 'Ts.t:.. - - Was s j, y ,e-/9-71 4 f 5
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- A. Boulden RT-XG-2 Parn. 3.3 Note:
EQMi-ASME III, Div. 1 Ex 10 .s Film side penetrar.eters, when used, shall be* identified by a lead letter "F" at'1 cast as high es the identification numbers placed adjacent to the penetrameter. e J.... Vald #2, FSK-M-21, 4.5"0D, 0.120" Thickness,S/S,RT 3-7-74. Tha lead letter "F" is on the penetrameter. lC'( 8 w.............. ,/&adiographwith"F"adjacenttothepenetrameter. Nota: The radiograph is acceptable in all other Code requirements including the weld. All HDE personnel performing and interpreting at this time are no longer on job site. .....,m.................... 5/1/76 PFQCE ... -,.,y.... \\ \\- \\ J L.....i.6.. ............... m x. m..... .u ! W O. C.... 7.~........... e m m
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~ 11 .QC Vault A. Boulden u... RT-XG-2 Para. 4.1d ' BQ-AM-ASME III, Div. 1 Ex 10 If the veld reinforcement anci/or b'acking strip is not removed, a. shim of radiographically ~ sim,ilar material to the weld metal shall be placed under the penetrameter. The shim thickness shall be selected so that the total thickness being radiographed under the penetrameter shall
- equal to the total weld thickness, including the backing strip if used and not removed.
i j tiald-21 (C2), FSK-MPC-2-1, 4"0D, 0.237" Thickness, S/S, RT 11-18-74 There is no shim under'the penetrameter. e ? i7 Reradiograph with a shim under the penetrameter. NOTE: The film density does meet' Code requirements without the shim, also all other Code requirements, including acceptable weld. All NDE personnel performing j and interpreting at this time are no longer on job site. g. 5/1/76 PFOCE i )I._,..............................l.........'.. - O
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== ...,..........,..u.. g,,,,. Midland 1 4 2 Construction O.,... . c. Richardson .....p,. g.r:b 23-2-P-1 12 US Testing Records B. Waters u,,,.................................. U3 Tasting QA Manual, Rev. 3, 08/31/74 m.,.... 98 Para. 5.1; " Procurement docu:nants for materials and equipmant used to test safety related materials shall be reviewed 'hnd approved' by the V.P. of Engineering Inspection or the Laboratory Chief. They shall assure that the procurement documents contain requirements necessary to assure that adequata quality materials and equipment is specified." Contrary to the above there are no recards of review of the procurement documents for purchase of concrete cylinder capping compound 'and concrete cylinder molds, e x., NOTE: Both items were tested for compliance to applicable ASTM Standards upon receipt. e ....4,........ 18 Instruct US Testing to perform the required reviews on all future procurements and to document these reviews. .c.. ...,m 05/14/76 PFQCE .m'J.fA.........a....g.a. 93 b g ,A, A u,, es e '4. 4 c b.es.,1............4. .....e.. Otor..,.................... g ee
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.diand 1 & 2 Job NO. 7220 Construction [...... C. L. Richardsen .4.... 18-2-P-1 8 .QC Files ' T*' Lieb g Unter9 m..m.......-..,.................... 'S pec. 7220-C-208, Rev. 6, 01/14/76 Spec. 7220-C-230, Rev. 6, 02/12/76 u C-20S Para. 6.5: "Non-shrink grout testa shall be proportioned and mixed in accordance with tha manufacturers instructions in a bench type mixer. Nine cylinders (round 2" X 4" molds) shall be cast." " Prior to u$e, a test batch shall be made and submitted to the contractor C-230 Para. 10.2: for testing. g,.... ~ Contrary to the above the tests for expansion and compressive strength of non-shrink grout f ~ re accomplished utilizing 2" X 2" grout cubes rather than the squired 2" X 4" cylinders. 'MalityControlreviewedandacceptedthet i 1 est report (No. S-212) on 09/19/75. NOTE: The tests results (No.S212) indicate acceptable non-shrink grout. ,7............ 1. Run the required tests utilizing the specified procedures. 2. Include this subject in a QC Training Session and emplasiz'e the importance of utilizing all specified requirceents when reviewing and accepting subcontractor test reports.
- g. ~.............
05/30/76 PFQCE 8 g<...m....................... on
v.r-n., QQr b<= QUAUTY AUDITiINDit!G k?.?2.8-2-3) j 4/8-13/75 g,... ,,m........,, m.. p. G. L. Richardson land 1 & 2 Job No. 7220 Construction s ...q,;..m ...s...... 18-2-?-l 2 US Testing Records Bt Waters <..m................................ Spac. 7220-C-208, Rev. 6, 01/14/76 Spec. 7220-C-230, Rev. 6, 02/12/76 y..... "The Batch Plant Inspector shall check that, cement delivered to the site C-208 Para. 6.1.1: does not exceed a temp. of 150 degrees F., and shall also review for co=pleteneiis the mill t:st' reports received with each load as' delivered to the batch plant." C-230 Para. 12.2.1: (Cement) : " Subcontractor shall furnish mill test reports for each load of-ccm:nt / C-230 Appendix D (C-321'-D) : This form indicates that the nill test reports should be submitted to "Bechtel Power Corp.".. },...., 2. US Testing's Eatch Plant inspector does not review the nill test reports for cement for completeness. 2. The intent of the term " review for completeness" is not clear. O The submittal requirements of Spec. 7220-C-230 (Subcontract for Gn-Sita Batch Plant) in-( ) dicates transmittal of the test reports to Bechtel and does not provide for review by '~' US Testing. NOTE: All of the cement mill' test reports received to date.have been reviewed by Qualitiy l Control for compliance to the specified requirements. p.............. Re coseende d 1. Direct US Testing to review the subject test reports for completeness. 2. Project Engineering should provide clarification o'f the term " review for completeness".i.e. review for compliance to specification or review for availability and proper form com-pletion. Project Engineering should review Specification 7220C-208 and Specification 7220-C-230 for
- 3.,
Thi l .the subject area and revise these specifications as necessary to provide consistance. response should be coordinated with the resolution of Bechtel NCR Ho. 403. w................ 5/14/76 " l: _PFQCE; 2 & 3: Proj ect Engineer s ,,,~m..... kn_,............,....... a" 4
fy QUAUTY AUDIT FiMDING ~ p..' '.f.3?'< " ~ April 14 1975
- 9... ::.
a.- } u/A p. 4,,.......,.u..... g,,,,, ...,.4 'dland 1 & 2 Job Uo. 7220 Construction O... B. T. stoikov c...s...... 25-3-P-2 9.3 Ghampion, Inc. Office Files K. Ito..ttan ...as................................ Chropion, Inc. QMI, Rev. 11, Article XIII a,l,..... ) Champion-QMI, Articic XIII states inpart: " Champion, Inc. Quality Control Procedure provide fer the calibration of measuring equipment used in production of concrete. This includes . scales, meters, admix dispensars. 9 Tha scalas and meters'are calibrated. . with traceability to the standards of the National 1 Bursau of Standards." g....~ 7~m. calibration records for ad:.1x dispenser No. ( ) to calibrate to the National. Bureau of Standards.1 do not provide traceability of the standard NOTE: Admix dispensers are calibrated by US Testing on site. p 1.,,..... * ~ Re coc:: ended. 1. Establish traceability of calibration standard used to calibrate admix dispensers to the National Bureau of Standards. J Remind' cognizant Champion, Inc. personnel of the requirement for, documented traceability 2. of calibration standards. J........,..........,,,,..... m.. ,.w.............. May 14. 1976 PFQCE 7,. me............. I <.~ m....... ................. m...... .n
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...u.....,..,- J-1-?-1 2.3 Subcontrr.cott's Offica Files C. If. 'fillia s .....u.,...n........................... Peabody QA Program Raquirements, Rev. 3, Parazraph 1.5.1 - -..a... Paragraph 1.5.1 states in part: "Tae purpose of the Quality A s 's urance [ndoctrination Progra:n is to familiarize the new or transferrac" employee with the Quality Assurance Progra:2 require-nant strassing the importance and meaning of Quality Assurance / Quality Control as it applies to tha employee's position". f Naithar of th.e subcontractor's personnel currently at the site tave received Quality Assurance indoctination. ( ) %./ s..... ra..... '
- a 143CoIJaanced es
~ Provide Quality Assurance indoctrination for all currently acting site personnel. Retain records of this indoctination on the site. Based on the number of discrepancies uncovered, indoctrination should emphasi=e program implementat' ion., ....w ...i......... .....,.....,,.....o......... Jo.sxi. 23, 19 75 PFQCI: 9. l m.T~ ........v........6......., \\ o g................,........ 3.. methe4
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...-s.....- ....< <.a m........, 25-1-P-1 Items 4.0, 7.1 Su5cantractor's In;oaction Procedures G. M. 171 !!ia-s L,.,..s-..........................,.. Peabody 0A Progrars Reauiracents, Rev. 3. Parageschs 5.1.2.1 & 9.1.1 Paragraph 5.1.2.1 statas: "A Quality Control Procedure including forms, chec ses, in-spedtion shaets, reports or other means of docuneatdion shall 'oe provided for each of the tect and inspection proceduras to assura naintenanca of the required quality level for the operation perfor:2d". Paragraph 9.1.1 status: "The procedure (NDS) shall specify: 1 1. A Quality Control Procedure.
- v....
s Tha following.NDE Procedures did not include or specify an applicable QC Procedurer-IPRT-140-23-03, Rev. A, Rev. B IPl!T-240-23-03, Rev. 0,.Rev. A w/ IPPT-300-23-03, Rev. O, Rev. A .............** Re ep==e ade d . Determine all job inspection and test procedures which do not include the required QC Procedure and pro' vide a QC Procedure, or delete the requirement from the QA'Progra:2. ...,m.....,..... June 18, 1976 PFQCE e....n 1 I .m........ O, -"= a Oh .N-- - - - 6 4M. .p.4.-
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=....=_.._.a-.... =. _ - __ __ _g. -__ _ m _ m,. g,,,. _._: - "..... - Midinnd 1 & 2 J6 No. 7220 i Construction O...e = U. T. Sc>ihsv .....,s e.. 4.,,,,,, .,...,. ~.. . 2...... 25-1-?-1 Ite: 13.3 Subcontractor's Of fice Files .o....u..........=,....,........,.. C. ?!. L'illia::s Peabot/ OA Program Requitecents. Rav. 3, Paragraph 15. 2.1.3 L, i Para,raph 16.2.1.3 states in part: be 6aintained for each project or facility.""A Log of Nonconformance Reports and thhir statu o No Log of Non,conformances is being maintained. ,. m ( i e >wy e ~ eu. s.reva..r.. 1UACOr.CanG5G ~ es Prepare and maintain a Log of Ilonconfor=ances. i uhare necessary information is available. Include previously ' issued nonconformances i l _u... u ...,ur.. II le May,_2 8. 1976 PFOCE .... w............... 0& s,...,,.. ......p..s.....,. O 3,....<............... e o, s
-rM." -;4 .M. ..u?d4, q: i.dp i.}T'l a tip21. i :.!w73 i m.'2i-1-2) .-su.'T c'vbn1 . 22 ~.... rx2 rw
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- 3. T. Stoiko't 25-1-P t Ite.s 14.1 & 14.2 Subcontractor's Office Piles C. M. Wil11ama s,...,.........,,,,,y....,...........
S Peabod/ OA Progran Recuirenants. Rev. 3. Para :raoh 17.1 ..,.n... ..Paragraph 17.1 states in part: "The QA Plan 'shall require at a ninimum the following (record a. Operating Logs b. Results of Reviews c. Inspection Results d. Test Results c. Audits f. Material Inalysis g. Work Performance Monitoring Result h. Qualification of Personnel, Procedures and Equipment Continued. \\ Records are not being collected or naintained for. the following itess: operating logs, results of revieus,. inspection results and material analysis. ND2 reports do not include i ^~wner's name. Personnel qualification records do not include' owner's name, client's name 11 4 ,!r project identification. !.*'""""* ^'"*~ Re co r=ende d 1. Review the listing.of required records and determine those applicable and necessary. To-those categories selected, prepare files as required including currently available documents
- 2., Review records and bring their identification into cobpliance with prograc requirements.
~~..-............. o 1 & 2: June 18, 1976 PFQCE
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r Block No.10 Continued. QAF Uo. 097 t.' The identification systen to be used shall be completely described in the It shall includa - the following: project or facility QA Plan. a. Ovnar's Nace b. Client's Name Project Identification c. Traceability to Iten or Activity d. / \\ ~ N.,) E 8., O
I h.!k!.k kNb! J !:!b!iY.I .S$. [ r .y'~ } 04/12/75 "4 y 3._ s_.._... s,,,....,....,.. m. C. j.,,,._ _. _ ___,.. ___ a
- " din.d 1 & 2 JoS '70.
7220 Construction O ~ *" n.,- s ~..,.. ~ .-,e..,... ......o.,. 23-1-P-1 Iten 15.0 Subcontractor's Office Files
- c. ?f u41 s t,.,-
..........r....,..............,2. Paabody QA Progras Raquircreats, Rev. 3. Parseraoh 13. 5. 3 Paragraph 18.5.3 states in part: "A urj tten report pill be prepared.... The report shall ha distributed to tha Client (or designated representative), the. president of Paabody Test'.nt;, the chi 2f executive office of the organizational unit audited and tha ~ c.cna er'of the project or facility audited. ~ ~ ' J 1 .., +... The audit repo'rt of the internal audit perfomed on October 29, 1976 was not compl'eted (not signed by Peabody Director of Quality Assurance) or distributed. 7-_ss e( ) xs
- 1. Coc:plete and distribute the report of the internal audit performed on October 29, 1975'.
- 2. Reinstruct internal auditors on required audit reporting procedures..
1 & 2: May 28, 1976 PFOCE I.. .....,v... l ., "...,57......., a E,...................... f;,. c.. .. - l W ' "P m '- Q L c g.g
QUAUTY AllDIT RNDING 65 (10-3-1) / (v) ....../ 3 /75 11 ...1..,..........,.m.. g.,.,, Midland - 7220 Construction 0-- C. Richardson ..J.*Connolly/J. Mill 1&2 OC Records 7................................... FIP C-7 Rev.' 4 Pera. 4.2: "After review and acceptance the records are entered the appropriate section of ti records log. The control number and file number are entered on the record and placed in the selected file". App. A. " Start the first entry in each book with number one and consecutively number sub-Bleck 4: sequent entries. This number is part of the control number entered on the records l y.... 1. The following records do not have the control number entered on them, M-1, control 135 (AE0 1028); C36A.3, control #7, #17, #1; Project Audit reports (All); Measure / Test equip-ment records (All); NDE Test records (All). The following records were noted to have control numbers different than the numbers entered in the log. This condition was apparently the r' sult of prep'aring new logs. durint e the month of October, 1974. Spec. C-39, control 3.20 (MRR AEO-81); C-39 Control 15,10, 41; Filler metal certs E-6010. Control 8 (MRR QC-34). g.~.........** Recomme nded.
- 1.. Enter appropriate control numbers on the identified records. Determine extent of the problem and correct other records as necessary.
2. Correct the identified records. Review the remaining records affected by the log revisior 'and make corrections as necessary. 1 7,... 3/1/76 PFQCE j 1. Control numbers are now entered on the identified records and the remaining files were checked and corrected as required. , [7. The identified records have been c'orrected to assure the control numbers and the logs () are consistent. All o,ther records and logs were reviewed for similar inconsistencies " and corrections made where necessary. 6 p.............,M.......,.. m..m.... ra-t...% ?RwE y
w-
- 4. e.....r w,
p g WAli,i AUDIT RNDMG- ~ ~ ?6?,.C --) f'; 11/25/75 g ...,..........,..m.. gg,,.,. Midland 1-& 2 Construction O.... G. nichardson 7..... 1&2 QC Records p.. m................................. FIP G-7 Rev. 4 Pers.~4.1: "A records log QC C-7--I will be established to provide accoutability and filing location of completed records". Pera. 4.2: "Af ter review and acceptance the records are entered in the appropriate section of the records log". 7,... Similar records that flow into the vault periodically are not being logged on the QC G-7-1 Form. Only one entry has been made for each type of record in the log. Subsequent records era then placed in the folder with no further entries on the log. mples are: Tement Certification Records. 2,. Measure / Test Equipment Calibration Records 3. Storage and Maintenance Records. 4. NDE Test Results.
- 5. Uelder/NDE Qualification Records.
6. NDE' Material Certs. 7. Bechtel Audit Reports. JeCommended c Datermine all the areas where the described method of control is currently utilized and przpare proper logs for thes'e records. Assure that all future records of this type will ba properly logged and identified. g................ 3/1/76 PFOCE .,g.................. SF/ PSP C-7.1'Rev. O was issued to allow tables of contents or logs traceable to filed records. All files were reveiwed for the problem identified in Block 11 and corrected. Now tablea of contents'or logs provide accountability for records placed into, files over [ ? period of time. J ' ~ ~ 5 " 4'- :C -76: _................ %...J,rce d y,s......? R2 G L. +w e. e,... ....s...s., d 3!7d /lu /2<
0.UAl.lTY AUBlT FINDING- .......? 17 NOV. 1975 e' /]g WG-2 V ,,..*.. X ......... REENWELL W. G QA MANAGEMENT =............. MA0 LAND' PROJECT G. RICHARDSON DOCUMENT CONTROL CENTER .w.....
- FG 1.1 - ( 4 )
'1 p QADP C-ll, REV. 0 l i and' Scope - This procedure establishes the requirements for deve op ng it,equirements manuals, and ' maintaining an up-to-date list of the quality program 1.0 instructions in effect for each project. l to quality General _'- The term " documents" in this procedure applies on y.
- NQAM, related manuals, procedures and instructions required by the 2.0 and approved by Quality Assurance.
i d in ite Quality Assurance has not'apprcved 44 Field Procedures l ste 10-20-7 5 (issued by PQAE) as Project Quality Program Document List dtd. f~idenced by:FPG-7, Rev. 1 selected as'one of audit sample of three proce u) was not approved by Quality Assurance.Holub dated 9-4-75 documenting ' Memo - G.L. Richardson to W. to review only nine of fif ty-one Field Proceilures with only seven '(b) accomplished. Verbal confirmation by site personnel. (c) -m i i t required y....................... Resolve conflict between'Pr'oject Quality Program D d r s. ...........s................ 19 Dec. 1975 PQAE F. -................. b 7 W W TuE 0]E r h e r, g.q ]p5 h%%r Ug kl 1 %.- % h s y y f % b h sdcW v k j i-g T[_{#~"%]",Q_d( .... / / ... h. V,. ?)) M n :r' i 73 -- i y -......,..W..........- / -y ..,,.,, _,, -(~ "' :.',.. - c.~.m: ym.;. y_. g.3 r m .m ~.
.v.n ~ - - GUAL: TY A'JCL*.' A.3:CC I'RUGHA?.1 .'.1 AT! AG E.'.iEN T CC!ill ! C TI'.*:: ACliott i'EPO!!T t.1 til i \\J tili'e:tT.; a r O:40. DAiC .,2 4 r 7:c - s: 2.r.i 31.-l.- n:. See Attached w
- RECO?.t.'.iENDED ACTION (Optional)
See Attached Quality ]QA f.1ANAGEf.1ENT ,7 ]EFERRED TO ENGINEERING x CONSTRUCT!CN x Control ' V . Original Signed By. ISSUED BY - .W. F. Ho!ub 4/1/76 Date Project GA Enyneer 11 REPORTABLE DISCREPANCY NOTIFIED CLIENT @ NO YES Date i woiem,.4.w,
- e...
ill CAUSE CORRECTIVE ACTION TAKEN AUTHORIZED BY oate ,~ / .*rH60uTIO, \\ w.'.....o s..., FORT.1AL REPORT T'O CLIEtJT r...... u... e.e.n.., .t........ 3.,e. 2., ,6,cc Transr2Ittal flf 5ectson if Apphed 0.t a ""1.,'",' 'l,' ((,'.l',,C * ".",, *',*. CORRECTlVE ACTlO?! It.1PLEtAEflTED c.e..e w.. as cc r.n 2.,... ,.,e,...,,,.......,,,, c.., t.. c..a........ . V E R IFIEO.6 Y. ..........,..,....,e....,..,...,.,,.... r,cin e o A ra ;n,.,e
, o.. i f Bechte! Power CorporaMer. ,e %s I Problem. Description On March 22, 1976 Consuc' ers Pot.er Co:pany ' issued a Stop Work Order (FSU-7) to the Ecchtel Project Superintendent for the following reason; A Bechtel genersted nonconformance report No. 396 tras issued concerning rebar c:itted from the auxiliary building "A" line wall. Soon afterward it was discovered that placcnent A(630-75)C' had been stopped also due to rebar fcund tissing. Because of the instance noted in NCR 396 Quality control reviewed co=pleted concrete placecents on existing walls and detercined another instance of missing rebar. Quality Control was in the process of draf ting another non-conformance report (398) 7.8 line at J & K, 'when Consumers issued their Stop Work Order. Additionally the following items are su==arided; The field engineer involved with the' concrete place =ent that resulted a. in UCR's 398 and 399. stated that altheush he used' the relevant design dracings, he in fact relied cost heavily on the fabrication drawing for check-out of the reinforcing steel. r"'s b. The Quality Control engineers have stated that they signed off in errer () on the inspection pisus for placements which resulted in these UCR's. 6 In the case pf NCR 3c6,' the inspection plan prepared by Quality Control c. Engineering did not list all of the drawings involving the reber called for in the placement (Drawing C-278, which is one of the drawings detailing the tissing bar, was not referenced on Inspection Plan Ko. C-321-2-729, P.ev. 0). d. There has been substantial inpact, due to the 1975 Project slowdown on staffing, training, and fasiliarication of personnel with special design details. Since reactivation in 1975, Quality Control has increased frca 6 to 26 engineers, Field Engineering fren 21 to 103, and supervision from 5 to 23. Because of the resulting discontinuity in staffing, the never personnel lack the Icarning from past probic=s that cight have prevented this occurrence. F.eco= mended Corrective Action. 'Although considerable action in the form of Ecchtel Hs/agecent involvement has already taken place for the purpose of lif ting the CPCo Stop Work Order, it is felt that additional action is needed and should be addressed. The reco== ended action described below corresponds to the items mentioned in a thru d. Iten a) In addition to the increased cephasis en design drauings as being the primary document to use in placement and acceptance,the use of a stamp on cach of the rebar detail drawings is recot=cnded. The clacp should read " For Installati_on and Fabrication Use Only. See Design Drawings for latest Changes". p_ G'1
'fl8^ # Bechtel Power Corporauco ~ ,e ....4 g(~ ~ Item b) The Quality Control organination should consider a check off system to be used when reviewing drawings for cocpleted work acce' tance p f purposes. A method of crossing a line through the ite=s verified on the drawing (dimensions, notes, etc.) for the purpose of assuring that all items vere indeed verified prior to sign off on the Inspection Plan. Item c) Field Engineering in their review for clarity of design' drawings ~ should flag additional reference drauings that may have been missed en the design drawing. This flagging technique should input back to Project Engineer-ing for the purpose of changing the design drawing. The flagging technique cheuld also alert the work operations when and if it is found that references are ineceplete. Item d) Field Engineering and quality Control should re. view their current training programs with the following items in mind; Are Quality Control Engineers and Field Engineers cycled through their respective training progrecs frequently enough? Do the respective training programs emphasize pass problems to both new and currt 't ecployees? ,() Is their adequate technical description presented in the respective training prograns? Does a means exist to incorporate problems and solutions found on~ other Eachtel jobs into the projects respective training progrcm. The results of your review of the re'co=nended correc,tive actions a thru d need to be addressed and docu=ented in the response to this Management Corrective Action. Your response should be completed by April 15, 1976 noting What actions have been taken and/or planned to correct the noted discrepancies. 4 a 'P.cferences Attachments: + NCP. 396 and 398 BLC'2441 ' Martinez to Slager ELC 2449-Martinez to Slager. O (::); ~ 6 9 e
- l
h Attachment A g? 16.3.4 Route To This Coor For File t, Quills SHuowell Issue Date February 20, 1976 O HWSlager CSKeeley Project Midland j FMSouthworth TCCooke File Title NCR's on Rechtel CCnsumers Powef JMilandin 2 ~ UFHolub' C"" ~ Nonconfomance GLRichardson Report No 0F-77 4 This Nonconfomance Report is Issued To: Prepared By #8MM Date :2./:2.ahd A"' [ J. F. Newgen, Bechtel Project Superintendent Written Reques By Date 3/05/ Corrective Action R sted By Date' 3/19/ who is resnonsible for corrective action. Nonconfomance Description and Suyp ting Details: On 2/19/76 at approximately 12:15 y. J we were notified, that the manway in core flood tank 2T-63A* was open to the atmosphere. The tank was checked at 12:30 p.m.'and found to be open with nobody working around the opening-The MSS was contacted and said the manway had been covered at approximately 11:00 but that the wind must have blown the temporary plastic cover off. The dessicar. was being changed and the permanent cover had been taken to the combination shop to modify the~dessicant basket. t The storage requirement form F-1-ll2 says " Closures opened for internal access ~ at any time for any. reason shall be immediately replaced and resealed af ter completion of the reason for removal.. are mu t be taken to prevent contamination with foreign materia: AEC Reportable Yes No See Procedure 9 (For Nuclear Projects Only) (Contd on Attachmen Stop Work Necessary Yes No X See P ocedure 16 - Stop Work No ~ Recommended Corrective Action: i Provide assurance that the t' nk was not contaminated by foreign materials during I 1. a 1 the time it was open and '4nattended.- 2. Instruct personnel in the importance of observ'ing the requirements in the notes and cautions on the F-1 forms, and also that these are requirements, not guidelin 3. Evaluate this situation to see if the method of covering the opening and securing the cover was adequate to withstand normal weather conditions'and preclude the en 3Corrective Action Taken: of foreign material 1. Before the tank was closed the interior was inspected by the MSS and the QCE responsible for material storage, and found to be free of foreign material. 2. Personnel hav.,been instructed to consider the ieather conditions and take pre-cautions to meet the maintenance requirements. The " Notes & Cautions" are con-1 sidered an integral part of th'e instruction ice s age requirements. Verification of Corrective Action Required Yes Y No (Contd on Attachment) biethod of Verification:
- l.. The storage records for the core flood tank 2T-63A were reviewed and found to document the inspection of the core flood tank interior which was found to be free of foreign material.
2. Discussion with the MSS confirmed that he had been instructed in methods to be used to temporarily cover any openijn s during maintenance operations. Nonconfor=ance Closure Confir=ed By /b hjMu 1 Date 4-// /M 1To be completed at time of closure by Consumers Power QA Services. Page 1 of 2 1. ._.-,,,,.m m, -,,. - - _. ..,,_,_.,,........,.___..,_,.,_,f_....
tr m h.4 U Filo Issue Date February 20, 1976 Proj ect Midland File Title NCR's on Bechtel Construction Attachment to NCR Report No QF-77 (Contd) Nonconformance Description and Supporting Details: (Contd) while closure is removed". It further states, "Any operations which may affect interior cleanliness of tanks (e.g., opening closures for replacing dessicant, etc.), must be performed with sufficient precautions to prevent entrance of foreign materials into tank interiors". The manway may have been open for as long as 135 hours because the temporary gover was blown off. The fact that the cover had blown off would indicate that sufficient precautions were not taken. korrectiveActionTaken: (Contd) 3. The measures taken to temporarily cover the open manway.were evaluated by Bechtel field engineering and found to be inadequate. New methods have been devised to prevent a similar occurance. / s ) ' LJ 9 e - l 7m ( i v Page 2 of 2
) )- Attach =ent A Route To This Cony For s File 16.3.4 FMSouthworth SHHowell Issue Date March 1. 1976 HUSlager GSKeeley Project MidiaM 1 & 2 a CQHills TCCooke JMilandin CCT.WmEG PCEf File Title NCR's on Bechtel UFHolub GLRichardson PESchmanski Nonconformance Subiect File Report No OF-80 This Nonconfomance Report is Issued To: Prepared By,Tr J 8. b c Date 3-I ~hI> J. F. Newgen Approved 4 Date M M. Bechtel Project Superintendent Written t.: ply Reques'ted By Date 3-31-76 / Corrective Action Requested By Date 3-31-76 who is resnonsible for corrective action. Nonconfomance Description and Supporting Details: The Champion QA Manuals issued March 12, 1974 and June 5,1975 both state in section X that "We feel that the manu-facture of aggregates for concrete is considered a special process. We therefore, are extremely careful in selecting a supplier for our aggregates and frequent visits are made to the plants". Contrary to this requirement, the last visit to the coarse aggregate manufacturer (Dru=ond Isla' nd) was on July 26, 1974.. No @ See Procedure 9 (For Nuclear Projects Only) ,/ AEC Reportable Yes T \\ / Stop Work Necessary Yes O no 6 see r=oceau=e 16 - stoP wora no Recc= ended Corrective Action: (1) Cha= pion shall make an evaluation of this requirement to determine whether the visits to the coarse aggregate manufacturer are relevant to the quality of their Concrete or not. (2) If Champion's evaluation detemines the visits necessary, then they shall implement this requirement. 1(3) If Champions evaluation detemines the visits unnecessary, then they shall Corrective Action Taken: revise this requiremen:: to so indicate. Cha= pion has evaluated this requirement and has determined the visits to the coarse aggregate manufacturer (Dru=mond Island) are unnecessary, but visits to supplier - (Wirt Stone of Bay City) are necessary. Champion has revised their manual (issue date February 23, 1976) to incorporate their evaluation. Verification of Corrective Action Required Yes x No O Method of Verification: The need for visits to the coarse aggregate manufacturer was discussed in the Post-Audit Conference on February 17, 1976. The letter BCCC-1650 was reviewed. Champion QA Manual (issue date February 23, 1976) was reviewed. ('S bionconfor ance Closure Confirmed By h w M O. h w (_/ Date 4 76 1 To be co=pleted at time of closure by Consumers Power QA Ser. ices. Page 1 of 1
=.- Attachme'nt A Rocta To This Cony For File 1 A. 4.4 FMSouthworth SHHowell H Issue Date March 23, 19i6 ../ Project w, y a, e. 9 HUSlager CSKeeley a CQHills TCCooke C33mec Power File Title NCR's on Bechtel JMilandin "8* * * " WFHolub Nonconfor=ance Michardson Report No OF-87 l This Nonconformance Report is Issued To: Prepared By [ [ [ ^ N Date J-27-74 Approved By 9 f d 4d_. I Date M. M W Mr. J. F. Newgen ly Reque[ed By Date 4-06-7 Bechtel Project Superintendent Written R Corrective Action Requested By Date 4-20-7 who is resnonsible for corrective action. Nonconformance Description and Supporting Details: Identification and Control of Materials, Parts Criterion VIII of 10CFR50, Appendix B, and Components," requires that traceability be maintained fo'r materials, parts, and components by appropriate means. Letter BCCC 471 dated July 16, 1974 (copy attached) i concerning reusable liner plate scrap, contains a commitment to stamp heat and slab numbers in pieces cut out of liner plate. The stamping provided the traceability required. Also, the letter commity to maintaining all future usable scrap in an orderly manner. l Contrary to the above commitment, liner plate scrap located at the northeast corner of, i the jig building and west of the unit two dome erection jig was observed to have scra pieces that did not have heat and slab numbers s:cmped and that were not. on cribbing. i AEC Reportable Yes No @ See Procedure 9 (For Nuclear Projects Only) No hold tags applied.Q1'O No O See Procedure 16 .StoP wora No Stop Work Necessary Yes i r Recommended Corrective Action: If
- 1) Irovide required traceability on items that lack the heat and stamp number -
traceability cannot be determined, dispose of the material as non-usable scrap. The traceability is to, be provided by stamping the heat and slab number as committed to in the above referenced letter. l
- 2) Clarify " orderly manner" as described in the above referenced letter and then 1
store the scrap in that manner. (Contd on Attachment)- Corrective Action Taken:
- 1) Bechtel has implemented the requirements of. letter BCCC 471. Pieces of liner plate cutouts which are considered usable will be identified with the heat and slab numbers of th,e original plate. Pieces not marked are considered scrap.and disposed of as nonusable scrap.
(Coned on Attachment) Verification of Corrective Action Required Yes @ No O ' Method of Verification:
- 1) Visual observation of the areas referenced under the nonconformance description shows that the subject scrap has been disposed of.
The scrap stored at Sasse Road laydown was observed to be properly stored. Observation shows ~' 9t all plateJsstoredproperlyorhasbeendisposedof.' (Contd on.- schmeat) Nonconformance Closure Confirmed By M .Date f-27-2,f e i yTb be co=pleted at' time of closure by Consumers Power QA Services. Page 1 of 2 l A
Fila 16.3.4 Is:ua D3te March 23, 1976 Projcet Midland 1 & 2 File Title NCR's on Bechtel Construction Attachment to Report lio QF-87 Recommended Corrective Action: (Contd)
- 3) ' Notify cognirant personnel of the requirements for liner plate scrap and document the notification.
1Corrective Action.Taken: (Contd)
- 2) The term " orderly manner" shall indicate that the subject material shall be stacked and cribbed to prevent' contact with ground surface, and stacking shall be consistent with normal industry practices to prevent da= age, injury, and provide access for retrievability.
- 3) The liner plate superintendent shall be provided a copy of this finding with reco= mended actions. This notification shall serve to instruct the-responsible person of the corrective actions ascessary for this finding and the commitment of the previous referenced letter.
I thod of Verification: (Contd) ge
- 2) A discussion was held with the liner plate superintendent. The liner plate 7-'3 superintendent stated that he was provided a copy of the finding with recem-(' ')
mended action and a copy of the response and that he was familiar with the requirements of letter BCCC 471. It was also indicated that all liner plate. scrap is now stored properly or has been disposed of. The material in the, areas referenced under the nonconformance description was disposed of, and thus it was not necessary to have traceability determined. s 7-i kJ Page 2 of 2
colisus.es Powra Colary Bechtel Power Corporation D E bIE3 h }7 Nm.;*' Poa C:l;ca cox 2107 JUL 131974 h riop e r.:;cnia,n.csco LJ d 1 e .MID'.XNo PLAN 7 p30 LECT July 16,1974 MIDLAND, MICHIGAN f. /- ' inc tGy, }. Consumers Power Company { g.,,,[,. g, P.O. Box 1963 14idland, Ilichigan 48540' k- /6. Attention: J. L. Corley. Daar Mr. Corley: Job 7220 Midland Project ' Liner Plate Scrap BCCC 47,1 ~ This is in resp 6nse to your letter of July 11,1974, (File 16.0,' Serial 75 FQAE 74) pertaining to the storage of usable and non-usable liner plate scrap material. As normal cut outs in the: liner plate are made, the heat p,. and slab numbers of the original plate are transferred to the piece cut out ,(~J' by means of metal stamps. is then laid.aside for possible future use.The cut out, or so called usable scrap m He agree thit the pile of usable scrap m'aterial at the hortheast corner of the Jig Building needs correction. to restack that material en cribbing and to maintain all future usableW scrap in an orderly mann'er.- scrap as pieces in this category are disposed of.-There is no segregation re s Very truly yours,. f m. ,E. E. Felton EEF/CFC/ja e ,evn-__ l' ~ Nj e
'[.r " h h Atta + -nt A Routa To This Copy For Fila 16.3.4 .,[ F:tSouthworth SHHowell Issue Date April 6, 1916 p (~' HWSlager CSKeeley Project Midland 1 & 2 ' \\"/ CQHills TCCooke ? CIltichardson C3f:30mtr3 Faw!r File Title NCR'y on Bechtel JMilandin Cmemdm Nonconfor=ance lub Report No or_go y, This Nonconforr.ance Report is Issued To: Prepared By fg/e/MitS Date 4/e/74 Approved By M [ d Date Yd4 /r 6 J. F. Neugen Bechtal Project Superintendent Written Re7h Reques By Date 4/20/76 Corrective Action Requested By Date 5/04/76 who is rerponsible for corrective action. Nonconfor=ance Description and Supporting Details: At the present time a tag with the following information is attached to the upper internals shipping container. "D0 NOT REMOVE THIS TAG, Refer to FPG-3, F-1-207, F-2-1872 Dated 1/8/76 and letter from Babcock and Wilcox to Bechtel dated 3/19/76..." There is not a provision in FPC-3 for tagging material until a problem is corrected. The only existing procedure for tagging an item to identify a problem that needs correcting is FIM G-3 for nonconforming items. AEC Reportable Yes No @ See Procedure 9 (For Nuclear Projects Only) [ Stop Work Necessary Yes No @ See Procedure 16 - Stop Work No" ' \\s_ / One Hold Tag applied. Rece=nended Corrective Action: 1. Issue a nonconformance report to document the problem that exists in the upper internals shipping container. 2. Hold a training session to inform the 4ppre;rface personnel how to handle situa-tions that do not conform to specified requirements. 1Corrective Action Taken: J 1 4 Verification of Corrective Action Required Yes No O b!sthodofVerification: bronconfor=anceClosureConfi:=edBy /- Date k 1 To be co:pleted at time. of closure by Consumers Power QA Services. Page 1 of 1 w~-----=wewwmv mw nm- .mv-=
a. At+= M _t A Route m Dis Cony For File 16.3.6 FMSouthworth buifowell ? Issue D3.te Aoril 7, 1976 O HWSlager GSKeeley j Project w ay,,a 1 r, 9 a CQHills TCCooke JMilandin-DMO Pen File Title NCR's on Bechtel WFHolub' Ouality Control "U" GLRichardson Subiect File Rep d No 0F-90 This Nonconfomance Report is Issued To: Prepa: ped ByMC.#b Date 4 -'7 76 ) J. P. Connolly ^*'" Bechtel Project Field Quality Written 17 Reques):ed, By Date 5-7-76 l Control Engineer Corrective Action IIequested By Date 5-7-76 who is resoonsible for corrective action. j Nonconfor=ance Description and Sunws.ing Details: Specification C-208 Revision 6 I section 5.3 states in part that ','The Subcontractor shall keep a current list of ') his equipment and the dates each were calibrated. He shall also affix a sticker to his' equipment bearing'all calibration,information".- Contrary to this require. ment, U.S. Testing does not have calibration stickers on slump cones 'or tamping
- rods, i
p AEC Reportable,Yes No @ See Procedure 9 (For Nuclear Projects Only)- ~ Stop Work Necessary Yes No X See Procedure 16 - Stop Work No i Rec = "ded Corrective Action: (1) Project Engineering should deternine whether the calibration stickers are practical on slu=p cones or tamping rods. (2) If the stickers are determined practical, implement this requirement. (3) If the stickers are determined unpractical, change the specification to allow for a more practical method of identifying slump cone and tamping rod calibration information. Corrective Action Taken: f g 3 ~ Verification of' Cccedive Action Required Yes No thod of Verification: Nonconformance Closure Confimed By _ Date \\ y To be co=nleted at time of closure by Consumers Power QA Services. Page 3. of 1 -et w-w v-T -+er - e ew-e-m ee m-w-ws-u--w-+-is-w=-u----w'-m*- Y e --=-We*w+ue+-g--.-eme m
Attac1 ne'nt A i i Route To This Cocy For [ -s File 16.3.6 rM5outaworta snriowell Issue Date April 15, 1976 CQHills GSKeeley / Project M m.,,,a i r, ? HWSlager TCCooke JMilandin C0fts9m8f3 POW 8f File Title NCR's on Bechtel WFHolub-GLRichardson Nonconformance File Report No QF-91 This Nonconformance Report is Issued ib: Prepared Bf ((bMJate #-/S-74 Mr. J. P. Connolly Approved 8((dbate MMM-Project Field Quality Control Engineer - Written [ h ' Request Date 4-29-76 Corrective Action Re sted By Date 4-29-76 who is resnonsible for corrective action. Nonconfomance Descriptio'n and Supporting Detam: Master Inspection Plan C-110-(a-d) "Recoating Work. of the Containment Building Liner Plate," (Rev. O through Field Change 6) contains an inspection point for surface preparation (Act/ Task No. 3.00) and a hold point for requalification of the liner l plate (Act/ Task No. 8.00). Both points require an inspection for shallow pits and gouges and require the repair of sharp edged shallow gouges. Contrary to the above, liner plate assembly C-lll-72 was accepted and coated without j the repair of sharp edged shallow gouges. No @ See Procedure 9 (For Nuclear Projects Only) AEC Reportable Yes Stop Work Necessary Ye No @ See Procedure 16 - Stop Work No No hold tags applied. Recommended Corrective etion:- i i
- 1) Inspect liner platu assembly C-111-72, identify gouges and repair, or document for repair, the gouges and the coating.
- 2) Assure that other 2nd lift Unit 1 plates coated during this mobilization were inspected to the proper inspection criteria and that they do not contain sharp edged shallow gouges.
1Corrective Action Taken: kerificationofCorrectiveActionRequired Yes No O b!ethod of Verification: 1Nonconformance Closure Confirmed By Date .J lid be compl'eted at tibe of closure by Consumers Power QA Service,. Page 1 of 2 l
File 16.3.6 Issue Date April 15, 1976 Project Midland 1 & 2 i File Title NCR's on Bechtel 4 Quality control Attachment to Report No QF-91 4 Recommended Corrective Action: (Contd) I
- 3) Instruct cognizant inspection personnel of requirements established for re-qualification of liner plate and associatsd inspection criteria. This instruc-tion is to 'be documented.
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[ Attachsdnt A / Route To This Cocy For File 16.3 FMSouthworth SHHowell f il Issue Date e,o 19 1976 i CQHills CSKeeley .e Project Midland 1 & 2 INSlager TCCooke C FD W File Title NCR's on Bechtel PAMartinez JMilandin Nonconformance Y rdson Report No 0F-92 r This Nonconfomance Report is Issued To: Prepared ByM[# d=v Date f -7/-7/. D. S. Parker Approved ByYIdM Date $ /3/N6 f M&QS Uritten Reply Reques / Date May 7, 1976 ^"" ^# Corrective Action Requested By Date
- who is resnonsible for corrective action.
Nonconfomance Description and Supporting Details: " Nondestructive Examination Standard Performance Specification NEPQ-RT (Level II)," Revision.1, covers personnel qualification for radiograph interpretation. The procedure requires under section 1.3 that " Certification shall be by a Bechtel NDE Level III Examiner". It further requires under section 6.1 a. that "... copies of the certifica-tion records of the Level III Examiner who certified the Level II personnel shall accompany the above records," (i.e., be filed on site). The documentation of certifi-cation is done with the NDE I, II form. (Contd on ' Attachment) No ( See Procedure 9 (For Nuclear Projects Only) AEC Reportable Yes Stop Work Necessary Ye.1 No See Procedure 16 - Stop Work No i No hold tags applied. Afb Reco== ended Corrective Action: ~
- 1) Revise NDE I, II form to show that the Level III examiner's signature indicates that the Level II is certified.
If this corrective action is taken, all personnel certification records on site that contain NDE I, II, Rev. 5 forms are to be updated using the new revision. 1Corrective Action Taken: 1Verification of Corrective Action Required Yes No b!ethod of Verification: b[onconformanceClosureConfir=edBy Date J 1 To.be compl'eted at time of closure by Cons'raers Power QA Services.
- To be established after written reply is repeived.
Page L of 2
= -- File 16.3 Issue Date April 19, 1976 Project Midland 1 & 2 File Title NCR's on Bechtel J Attachment to Report No QF-92 Nonconformance Description and Supporting Details: (Contd) Contrary to the above, where revision 5 of NDE I, II was used, the level III examiner only " recommends" certification. A supplemental M&QS letter, not referenced in any procedure, shows that certification is by the Manager of M&QS. There are no Level III certification records on file for_the Manager of M&QS. Recommended Corrective Action: (Contd) or,2) Revise the procedure to reference the supplemental letter as documentation of certification for Level II personnel. If this correctiv.s action is taken, Level III certification records for the Manager of M&QS are to be provided for filing on site. i l 1 l i i , - e )- w' Page 2 of 2 l r i
r_. _ m -m-k, ___[$M_hb_k _ '.._ ~ Attachs mt A y \\ -a-*- C-File 6.3.4616.3.6 Ecute b 2, (O FMSouthworth 3 HMSlage: CSKe ley ( Pr ject W inna 1 & 7 .CQHills C::nsumers Power File Title NCR's on Bechtel in. Construction &Oualityl ..-. lub -eno Ilonconfor=ance Control C1. Richardson Report No QF-93 i _ om, -,. n i,, bis Nonconfor=ance Report is Issued To: Prepared By kd8.h Date 4. -2. 3 -7.4 I J. P. Connolly Approved /' Date 2..I76 Bechtel project Field, Quality y j ' Control Engineer Written-Reply Requested By Date 5-24-7fl y J. F. Newgen Corrective Action Requested By Date' 5-24-7f Bechtel Project Supdrintendent who is re nonsible for corrective action. Nonconfo:=ance Description and Stppw.;. lng Details: ' The G-321-D form is a muli:1-purpose form to be used by Buyer / Contractor to specifically~ identify documents required of the i Supplier to satisfy specification requirements, and is to be used by the Supplier as a i cover sheet for Quality Verification Documents when submitting them to' the Buyer / Contractor. The G-321-D form provides for. a review by Engineering of the test and material data submitted, for conformance to the requirements of the procuring documents. The G-321-4 form also provides for a QCE Check-In Statement that verifies the completed G-321-D form and attached data have been received. (Contd on Attachhent', AEC Reportable ,Yes No @.See Procedure 9 (For Nuclear Projects Only) No hold tags applied. ~ See Proc 9n-e 16 - Stop Work No Stop Work Necessary Yes No X Recc=nended Corrective Action: (1) Engineering should review all of the Certifie'd Material Test Reports, Material. Certificates of Co=pliance and Performance Verif,1catio: Reports for certification of the Batch Plant, scales and meters for confor=ance to the requirements of.the procuri'ng documents and are complete and acceptable. (2). Quality Control should review the above for verification of traceability. 1Corrective ' Action '5aken: Verification of' Corrective Action Required.Yes No Method of Verification: ['T Nonconfo:=ance Closure Confirmed By (j Date 1To be ec=pleted at time of clocure by Concusers Power QA Services. Pcge 1 of 2 n.,
Y i (' ~ ~ File 16.3.4 & 16.3.6 Issue Date April 23, 1976 O Project ' Midland 1 & 2 V Fild Title NCR's on Bechtel Construction & Quality t Control. -Attachme'nt to Report No QF-93 i Nonconformance Description and Supporting Details: (Contd) lr " The' Material Requisition.No. 7220-C-250 Rev. 2 for Operating On-Site Batch Plant. l and Furnishing Concrete requires documents per an attached Form G--321-D. j $ The Form G-321-D requires in part that an MTR (Certified: Material' Test Report) for each' load'of 'ement delivered; a Material Certificate of Compliance for porzolans,
- i c
~ ! L unter reducing and air entraining agents for'every delivery; and Performance Veri, j ;- fication Reports for certification of the Batch Plant, scales and Meters approxi-- mately every 25,000 cubic yards of concrete produced or every six months, whichever occurs first shall be accompanied
- by a G-321-D completed by the Supplier.
'Contrarytotheserequirements,Chamhionhasnot'usedtheG-321-6formasacove'r ~ sheet for Certified Material Test Reports, Material Certificates of Compliance or ~ 4' Perfor=ance Verification Reports for certification of the Batch Plant, f. scales or meters.~ Consequently, there is no documentation of a. review and acceptance by Engineering or a QCE Check-In Statement. j ~ ] ",' Recoamended Corrective Action: (Contd) p (3)' Other Subcontracts should be reviewed for similar problems with the G-321-D - foro. (4) Project Engineering should evaluate the requirements on this G-32h.-D forn and ' - other G-321-D forms, if. simil ar problems' are found. The evaluation (s) should determine whether the r'equirements are to b'e implemented per the G-321-D or some other. method. (5) Implement Project Engineering's decision (s) from (4) above. a ~. O ~ \\/ Page 2 of 2
Attach:sint A Route Tb This Cory For File 16.3.4 FMSouthworth SHHowell Issue Date April 30, 1976 CQHills GSKeeley \\a Project Midland 1 & 2 HWSlager TCCooke EC 3 EDWW File Title NCR's on Bechtel JMilandin WFHolub Nonconfomance ' GLRichardson Report No 0F-9t+ [I This Nonconfomance Report is Issued To: Prepared By((M Date A-Jo-7A J. F. Newgen ApPmved By M[ Date YMM Bechtel Project Superintendent Written Reply Requ .ed By Date '5-10-76 Corrective Action Requested By Date 5-28-76 who is resnonsible for corrective action. Nonconfomance Description and Supporting Details: 'Nt T.&. See Attachment A. .w'a ~ ~ *
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,;.Qi; AEC Reportable.Yes O no G see Procedure 9 (For nuclear Projects onier) " G:, 1 -N / Stop Work Necessary Yes No C See Procedure 16 - Stop Work No . }:, 4 i i l' No hold tags applied. Recc= mended Corrective Action: %;[M, .,'-l. See Attachment A. -idl .g. g 3:. n. 9:0 A - v e r. cQ. a
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1Corrective Action Taken: .f?:3 /M < fg . $.:.1% S e.
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> -nkp@ f t ~ u:,x - Verification of Corrective Action Required Yes No ' Q.j b!ethod of Verification: [.d$ 1* 'i onconformance Closure Confi=ed By Date LJ Tb be co=pleted at tibe of closure by Consumers Power QA Services. I Page 1. of 3 c z.,
File 16.3.4 Issua Date April 30, 1976 Project Midland 1 & 2 ~N File Title NCR's on'Bechtel [J Construction Attachment A to Report No QF-94 Nonconformance Description and Supporting Details: Bechtel field procedure FIW-2, Rev. O, " Welding and Weld Filler Metal Control -- ~ Subcontractors," contains the requirements for weld filler material control by-subcontractors on site. The condenser erection subcontractor (Non-Q work) was observed to be in violation of the requirements of FIW-2 in the following specific instances:
- 1) 'FIW-2, section 2.2 requires for low hydrogen rod, that "... rod warmers shall be used by each welder".
Contrary to the above, welders were observed using low hydrogen rod from shipping containers and back pockets. 2) FIW-2, secti.on 4.1 requires that, " weld filler material must be issued in such a manner that there is complete control by the subcontractor". Section 4.4 states that, "It will be the responsibility of the subcontractor to main-tain rod stub control and insure good housekeeping by their personnel". [) Contrary to the above, low hydrogen electrodes and rod stubs were observed \\- ' to be laying loose in the work area. It was also observed that where shipping containers were used to hold rod, that container was being used as a stub i ~ l bucket. 3) FIW-2, section 4.2, requires that, "All rod shall be color coded on the holder end with a color agreed upon by the subcontractor and the contractor". Contrary to the above, none of the rod observed in the work area had the required color coding. 4) FIW-2, section 4.5, requires that, "All low hydrogen electrodes must be issued in rod warmers to maintain the proper moisture level in the covering or flux". Contrary to the above, a full, open shipping container of low hydrogen rod 2 was observed in the work area. 5) FIW-2, section 4.5, requires that, " Warmers must be plugged in at all times". Contrary to the above, numerous instances of unplugged rod warmers in the work -area were observed. 6) FIW-2, section 4.5, requires that, "Any rod that has been exposed to 'the atmos-phere four (4) hours or more must be-disposed of or rebaked". Contrary to the above, it was observed that loose electrodes (see 2) above) i were exposed for 24 hours and were not disposed of or rebaked. d Fage 2 of 3 ~.-
File 16.3.4 Issun Date April 30, 1976 Project Midland 1 & 2 File Title NCR's on Bechtel (~')s Construction ( Attachment A to Report No QF-94 Nonconformance Description and Supporting Details: (Contd) 7) FIW-2, section 4.6, requires that, "Any damaged rods or low hydrogen rods that have been dropped on damp surfaces-must be disposed of". ~ Contrary to the above, a watersoaked cardboard box of low hydrogen rod was observed to be sitting in a water puddle for 24 hours without being disposed of. This instance also violates sections 4.1 and 4.5 (see items 2) and 6) above). Additionally, a shipping container, one-third full of water, was observed to contain low hydrogen electrode and stubs. 8) FIW-2, section 4.7, requires that, "No rod is pernitted to be carried in the back pocket or in a pouch". Contrary to the above, two veld rs were observed carrying low hydrogen elec-trodes in their back pockets in the work area. Reconnended Corrective Action: 'g
- 1) Enforce requirements of FIW-2.
,, d Demonstrate how the notification of the subcontractor of the requirements for 2) weld rod control has been effective in view of these findings. '3). Instruct cognizant personnel of the requirements of FIW-2 and document to whom the instruction was given and who gave the instruction.
- 4) Demonstrate the effectiveness o'f the " periodic" checks done as required by section 1.3 of FIW-2.
Also, clarify the meaning of " periodic" to indicate how i often these checks are performed and how they are documented. F N \\ d Page 3 of 3 3f.-p
i j l Attachment A i 1 f[ } Issue Date April 30, 1976 Route. To 'D11s Ccny For w File 16.3.6 ![' RISouthworth ' SHHowell '~ CQHills GSKeeley v. s ; Project Midland 1 & 2 hWSlager-TCCooke PAMartinez CCMWi!8f3 POW File Title NcR'a nn nacheal Nonconformance GLRichardson ZGTucker Report No 0F-95 'Ihis Nonconformance Report is Issued To: Prepared By Date J. P. Connolly Approved By MM, Date 4/s /74 y Written Reply Requespd By Date 5'/W/74-Bechtel PFQCE Corrective Action Requested By Date 4N74 ] who is resnonsible for corrective action. Honconfomance Description and Supporting Details: A copy of Field Inspection Plan C-231-2-827 obtained on or about 3/27/76 has only a signature and date of 3/2/76 at the bottom of Block 12 for Activity 2.60.
- However, a copy of the same plan obtained 4/29/76 has a lengthy exception added with no date, signature, nor initials. Obviously, an inspection record has been changed. This is unacceptable to Consumers Power Company without a controlling mechanism.
No @ See Procedure 9 (For Nuclear Projects Only) AEC Reportable' Yes Stop Work Necessary Yes O no G see Proceaure 16 - stoP Work no Recczmended Corrective Action: l. Develop a mechanism for changing and controlling the changes to completed inspection plans. or 2. Decide that such changes will not be made. 3. Train all QC personnel in the alternative chosen. Corrective Action Taken: Verification of Corrective Action Required Yes C No j i 7"ethod of Verification: Tonconformance Closure Confirmed By Date O 1To be-co=pleted at ti5e of closure by Consu=ers Pcwer 'lA Services. Page 1 of 1
P NONCONFORMANCE REPORT ' ' ' ^ * * ' E 2&b or i
- 2. CM AWING /PART NO.
I R C V.
- 7. PROJECT NO.
92 REPORT D Sv DATE
- 25. DISPOSITION CONCUR RENCE 7220-C-202 i4 7220 O
O- & 74 Q
- 3. ITEM DESCRIPTION
- s. ITEM LOCATION
.VA TEDBy I DATE Reinforcinn Steel Auxiliary Bldn. Walls 27 & 20 l/3 ' b"7Q 4*/ ] [ keu) '/#. #1.d
- 4. MRI AL NUM DER
- 9. 5TARTUP SYSTEM NO.
t If Pt.ACEM ENT PA O. R E V. P= Watt asse amesdae
- eat, N/A N/A N/A I
e.
- 5. PURCN A5E ORDER NO.
- 80. QC P Zt.O INSPECTION PLA N NO.
3 4. REPLACEMENT SEVBAL NO; /2 *//. H/A N/A N/A
- * ' ' '* * * " "* 'f "
- 6. CENTR ACTOR / LOCATION,
33. ME O vEs ir.sOuaCE N/A .T E M G NO Constru5 tion 3 0. ROUTING BNSTR UCTION'Is ROUTE TO FIELD ENGINEERING Q Ft"UTE TO M ATERIAL $UPERVISOR In strainlitening the field' shop-bent horizontal' dowels (#8) proicctinn from 7.4 line wall *. cl. 574'-0 to 584'-0. 5 bars for wall #27 and 4 bars for wall #29 were broken by field forces. Non-conforminn condition was noted durinn routine field ennineer inspection. 0-List - 1.203 2 - 0C /-l0/ /) 7~/90 $ kAf4/d8 23. QFIELD DISPOSITION OFIELD RECOMMENDATION / ROUTE TO PROJECT ENGINEERING
- 21. FIELD OBSPOSITION RESULT 5s Repair'in accordance with approved standard' repair procedure as follows:
1)' Chip concrete jfjad 'Mgf 4, .tround broken bars to allow' for splicing clearance 2) Weld reinforcing steel splices in gjgj j;7h ggg,., y accordance with BPC. Welding Proce' dure F1-A-Lh (rebar) upon approval of FCR C-231.by. jgg jj ~. Project Engineering.
- 3) Repair' chipped areas in accordance with Specification 7220-C-231, Rev. 5, y p f, g g g,:-
Expect'ed implementation date: Decemb'er 19, 1974 ki KEV f/MAA 12 - 4 7<- W N$$$$((4fA
- 22. ENGINEEniNG DesPOssTiON g 23.ENGeNEERsNG DisPoseTsON RCsuCTs/
26 is DEStGN CNANGE REQUIRED O NO '""C*"'*""* @ [7 " ~~ 8' g _ p* " y f c g y g g,s 9-OyE.:CE4TvACNED. .f f,,,, NRAWING. R EV. DCN aurnomesso anseuc,oss on,, t PEC. REV. ' ADO. ^ O 8 43 0 s-s Q C-G 3-ORIGINATOR y ~ ,}}