Text

Nonconformance Rept for Jan 1975.Rept Consists of Bechtel Nonconformance Repts,Nonconformance Rept Log & Status Book, QA Discrepancy Repts,Quality Audit Findings & Mgt Corrective Action Repts Written or Closed During Month
	ML19329E930
Person / Time
Site:	Midland
Issue date:	01/31/1975
From:	; CONSUMERS ENERGY CO. (FORMERLY CONSUMERS POWER CO.)
To:	;
Shared Package
ML19329E929	List: ML19329E928; ML19329E930;
References
	NUDOCS 8006180790
	Download: ML19329E930 (71)
	v • d • e

,,

____,7 NONCONFORMANCE - REPORYl.OG & STATUS BOOK u.

2 3 s I

~

L REPORT DATE e I

i l

PAGE COMPT I

1. PROJECT NO 7220 SAWS bR ORIG.

NONCONFORMANCE 8-PREPARED BY DESCRIPTION / REMARKS nouTE XMT C OSED CLOSED BY l

10.,

DATE i

10 74 L. Johnson 1-231. #R Auv. B1dn Rohnre hont imnenn-Field flo 1 1-30-74 erly, El ev. SB4' 1.203 10-11-74 l l-19-7 1 L. Johnson i

10 74 H. O'lleil

-111. Shon wold bulned and broken cield 1 )-28-7 1 i

)n Liner Plate 1.109 10 74 fio (0 74 A. L. Boulden 5

10 74 P. Carpenter

-211. Missinn tost for structural 4 eld LO-29 4 l

lackfill 1-002 - E9 T4-h 10;.16-74 L. Johnson

-231. #8 Aux. Bldo Rebars bent imnron-ricld 11-11-7 1 l

3rly 1.203 LO=16='74 No LO-30-74 Johnson

)

10 74 E. Manning 1-115. Il-Stamn not nnrmannntly fivod rield 1-28 J.F.Gibson 0'

l fo sppol ?.-GCB-009-S613-3 4.134 LO-16-74 No 10-18-74-75 l

t0 74 E.11anning 1-115. tl-Stamo not normanently fixed

ield 10-23-7 1 E. Manning @

l to spool 2-GCB-002-S613-3 4.134 LO 74 flo

.0-18-?4 1R.A. Moray [

2 -

LO 74 R. A. Moray 1-115. Documentation nroblem for 400 El It. S.

10-31-7 l

on snool 2-GCB-015-S613-3 4.134 LO 74 No

.0-31-?4 h-LO 74 H. D.

Foster 11-115. Bends buckled and N-Stamn loose ield.1-1-7" l 1-28 II.D. Foster 1-GCB-016-SG13-58,2-GCB-013-S613-2. 4.1 34-10-uG-74

-75

-75 ei C

4 LO 74 R. A. Itoray M-1.

ne,w nnenmnntatian far enca4"4ad B&W No

.0-23-74

1. C. Boothe f

"or B-67-2012-50-1 4.028 LO 74 10-23-7 1 5

.0-21-f 4 L. R. Albert C-232. Failure in Ifatorston Adhnsivo

':4 eld

.0-23-74 12-13-74 L. R. Albert 40-21-U4 1 1-14-7L 1.106/1.206 l

l f

'0 4 R.A. Moray M-104A. Missino G-3210 Form fenm Von-M.S.

No 0-31-14 R. A.flo ray 4.353 LO-24-74 10 74 l

7 LO 4 11. Itaill ey y-39. #8 Rebar broke when cold bendinnJield

!!t# llA-7540 1.103 0,'4 No 0-31-14 x.

~W (h

NONCONFORMANCE - REPORT LOG & STATUS BOOK j

g

/

REPORT DATE I T*F 24-75 PAGE COMPL.

O o.c. ENo. sics

1. PROJECT NO.

NCR ORIG.

NONCONFORMANCE STATUS PREPARED BY lNO.

DATE DESCRIPTION / REMARKS s.

u"TD E$E

'do#

route SED CLOSED BY i

!256 12-19 A. B'oos

-?11. Aux 91dn Rehar innronerly cut rield 12-19 1-14 L. Shively l

-74 luring bending 1.203 L2 74 No

-74

-75

'257 12-19 R.A. Moray IFMC-1. Improperflill Test Report on sield 1 1-14 1-15 R.A. Moray

-74 E.6010 Held Rod Varies I ?-20-74

-75

-75 f-l4-l258 12-23 J. Aldridge

-38. neam 219R1C Fabricatnd frnn 30 Y iield 12-31 S

l

-74 210 natl, not 30 X 190 1.201 4 ?-24-74

=74

'259 L2-23 J. Aldridge l1-115. Spools not marked per Spec M-201_sield 1-3

-74 Jocuments not Shop Inspected ASliE4.124 L2-24-14

-79 260 L2-24 A. Boos

-231. Rehars om.itted from Aux Rdin

ife%d 12-3'

-74 lal1s 1.203 1 ?-84-74

-74 261 L2-30 R. A. Moray l t-104A. Markinq and G-3210 Forms. Pine MS No 1 -74

ize ASME 4.104 +

L2=31= 74

-75 262 l-8-75 R.C.Boothe M-1.

Ilumi di t y indicator on Steam Gen.

BMl

-i9-El-2012-55-12 ASME 4.021 L-8-75 No 263 L-9-75 R.A. Moray L1-104A. Pine markino, not released, no MS No 1 X-Ray Films ASME 4.111,4.134. + J 7f 75 264 L-9-75 J. Aldridge f1-1.

Prntnetivn cnatinn an stanm nnn Bru 2SGIB ASilE 4.021 1-13-7 i NO 265

.-10 J.C.Aldridge

( -233A. Drawinns not availahln_ ornn{IEI D/fi. S.

1 1-21 R.A. Moray

-75 FMR Humber i.101 b 10'-75 No 75

-75 266 ;-14-71 C.F. Clark c-111. Iiner P' a to damann dun tn fi rn Ctetd 1 1 1-31 L.R. Albert 1.109 i 76 75 75 75

!67 1-15-75 R. A.floray

'f Ffic-1 F 601n unirt en d c e r t i fi c a-t lon-.- Field 1-22 1 71i

=75

>.103 osn4 oc (.

11. P c G31 V

7-p-

NONCONFORMANCE - REPORT LOG & STATUS BOOK 12, f

REPORT DATE T*3'73 Q,,

PAGE COMPL.

i

1. PROJECT NO.

7?20 RC. ENG. SIGN NCR ORIG.

NONCONFORMANCE STATUS NO.

DATE PREPARED BY DESCRIPTION / REMARKS 8-

- E 'N CEOSED nouTE x

CLOSED BY l 263 1-17

.1.C.Aldridne

-33. Bean connectors damaged, shipment sield 1-30 l

-75

.-14 1.201 E-17-7 1

-75 269 L-20 A.L.Boulden

-111. Liner Plate X-Ray of renair not J4 eld 1-29

-75 iva11able 1.109 T-20-2li

-75 270 L-21 J.C.Aldrid e

- 3 8. Damaned beams, nine each. shin-G&old 2 9

-75 nent C-15 1.201 6-21-3G 75 271 L C.F. Clark C-111. !!eldino procedures PI-F( A-CO,,)

Field 1-22

-75 1.109 t-Ri-76

-75 272 4.C.F. Clark C-111. Leak noted at I:nuckle Plate.

I feld flo

.-22 1-29 2.Lussier

-75 lamination 1.109

.-21-75

-75=

-75 273

,-21 R. A.Mo ray I; ult flaterial, h" f. 5/8" Round bars.

Vield II0 1-24

-75 7220-F-11452 l-22-70

-75 274 1-22 J.C.Aldridge C-33. 11a te ria l shirned without release Pivia]

No 1 1 R.A. Moray M.S.

-75 1.201

.-22-70 75

-75 275 1-27 R.A. Moray

1-201. M-104A ITT-Grinnell markinq of Field

-75 X-Rayed joints nor per M-201 ASME 4.192 276 1-28 J.P.Betts

-39. Rebars cut of do not match Dwq

<=ie4:d 1-29

-75 C-324 Rev 10 1.103 =t -f41--76=-75 277 1-29 R.A. Moray 1 in4A-imnrnnnr n win rnrn

-(teSg

-75==

ASME,4.104 1-30-15 278 1-29 R.A. Moray 1-104 A. Improner G-321D. X-Ra_vs innenn

1. S

-75 3r, Code Data Mane Plate.

AS f1E,4.124 1-30-; 5 279 1-30 C.F. Clark C-111. Liner Plate radius out of tol-Eteld 1-31

-75 erance after concret.in '

1.109

74 -75 Ioltos com oc bsf'oFe i1. PR 26 oc G31 q

.w

~-

s

W n

O NONCONFORMANCE - REPORT LOG & STATUS BOOK 12

-4 REPORT DATE 2 -M

,,. j '

PAGE COMPL.

i. PROJECT NO 7220 a.c. ENG. SIGN NCR ORIG NONCONFORMANCE S ATUS

?FtEPARED BY NO.

DATE DESCRIPTION / REMARKS s.

- N E 6$so nouTE x

CLOSED BY 280 1-31 G.G. Butler I -173. Hydro water for 2CCB-72 not with-Rtehr 1-31

-75 in limits of letter BEBC598. ASHE,4.353 f if-M -75 l

l aa+Nn?$Y [dY5)M, dM:,1$(I hlW[#g WO?f,'

W "s @ LM.

.mryym.m.

f

$o.io3 con 4 oc

{

Pano 27 11 oc.cs.i

e I

~~

-.m-6

. ~.

NONCONFORMANCE REPORT

7 "*

' " ^ " ' ' '

y O. C H A W4 B N G /P A R T H D.

R E V.

v. PROJECT N3.

12.

' kE D

'DAT 25 OssPOSITION CONCu R NC l__ISE_MEC-2-.1 h

7220

/

// qy&

l10/16/7h i

/

=#

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--f,

o. T:M oEtCR PTiON ff6a(Csgp'~4-o

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i DATE

..TEuLOCpTON

.v hTEo or i

!/0*7X.ff'/jdd,s.

sp@

M nnnntor mag e spray viva s

GM'8 AL NUMSER

'9. STARTUP SYSTEM NO.

. s CPLACEMENT PA NO.

REV.

Pw.ssc? rest. E N*

e

.AIS L N/A

/

M/A I

NA

~

PUNCN ASE ORDER NO.

S t. QC e -

O INSPECTION PLAN NO.

'16. REPl.ACEMENT SER I Al. NO.

,q p.... u p

j I

M-115 M-20 p -3 Rev. O N/A 7/,ci"'*r**","[fy"M(

, " p,.,Q

o. Cc NTu CTO RiLOC ATIO N ii.AsME gvES iv. source L.li,_.L.Jellogg_pamp anvhilliam anort. la.

.T E M O ao Supplier l $ 8. ROUTING 8HSTRUCTIONSs

@ ROUTE TO F8 ELD ENGINEERING O aOuTE TO M ATERiAi.suPERv sOR J

' 8 9. NtNCONPORMING CONDITION:

Pipine spool piece 2-GCB-OO9-S613-3 han an M stamn nnrae plate collav that_could slip off of thn pipa and become lost. Ref:

M. W. Kellogg, Specification ES-151 paragraph 3 4 3, "Name plates must be attached in a p:riaanent fashion".

"Q" No. h.134 m ysm+4nn nn+na an,4ng nu wn4,,onan 4nnpnn+4nn.

nnn nn,a

+n,r nnni4na.

i 23.

FIELD DISPOSITION OF8 ELD RECOMMENDATION / ROUTE TO PROJECT ENGINEERING

29. FIELD D8SPOSITION RESULT 58 Rcuork: Loose "N Stamp Name Plate Collars" will be corrected by the field in the followinn EFP Aicrn Osb ftElo Sf5P- '

manner: The existinn tack weld holdinn the collar piaces together will be broken - collars ro -fit h AUh 4 !.L. 1.5 S A TIS

.f. e nll20/75

will then be fastsned securely to the pipe with a clamn - retack collar picten,tognrher FACTt /'%

assuring a tic,ht fit between co11nr & nino.

cnrn munt hn enkon to nrevent nny vela fillnr enterihl N o N N bn in contact with the nine.

h-

-b

/O ~ /R-74 G2. CNCINE[.IIONG DISPOSITION h p

"./

(

23. ENGINEERING DISPOSITION RESULT $s j

W O,f $ f.

f f%A,13_ _ n

. ft L

_mA.

$)[l-t' Y N, A ft4 M De

2N CN ANGE REQUIRE ONO

- ""3 *cT'a "^T=a'^' a'5"oSirica O""'""""'*"

2. C PTANCE i

CbC-1ker U"~

O YEs. sEE arTACNEas REV.

DCN f

[

p........y....... y ~ a...

y n;

5 ORIGINATOR V

- 9

N 3

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NONCONFORMANCE REPORT

. =,

2 203

2. DN A WIN Q/PA WT N1 g 'i[ E V.

7. PR OJ E CT N D.

cP M-6f3

!1 7220 Q

SC.RCP a TED Y

'DATE 2 5. Dt58*OSITION C$NCuid Rl;NCC

/

no/16/7h

".;.*~~

""ji'

" j ' ','

i

2. STEM E"ESCRIPTICN S lTEM LOCATION O

,Y,b(5

~

LM ' Y8/['d ']fk '/('l rr Ib ;. >

/(/-3h /M thdTED nY 3

l DATE J'~

Containment Spray Pipes Wa' AhEu'sI,

',", ) '

=-----4

/

c. SEbo t Ab. N UM DE R S. ST ARTUP SYSTEM NO.

[1.hEPt.ACEMENT PA R 3

N/A N/A

(

N/A REV.

Nb.,,,reato a'meensees PaoJa c?

sta v a N..I bN S. PU' CH ASE ORDER 740

10. QC Fidl D INSPECTION PLAN NO.

t e. HEPLACEMENT SERI AL NO.

f,y. 7g 7220-M-115AC Rev. 1 M-115-R-2 N/A y

,f y,,p Of*"gf'{,*f[7,""

s. CO N TM A CTO R/ LOC ATION

,," * 'j'.,,

13.ASME p YES IF. SOURCE M. W. Kellogg Company /Williamsport, Pa.

iT E M O NO Vendor i

7 t $. CUTING INSTRUCTIONS:

h MOUTE TO FIELD ENGINEERING O aoure T* =^vrasai suecavisoa 3D. N2NCONFORMING CONDITION:

1.

Spec. 7220-M-201 Rev. 3 paragraph 6.3.70 states aAll bends shn11 be smooth. free from nynnkn nna nurfnce_defccin without buckles and truly circular.

The allowable flattening.

as deteTmf ried by the difference _hetween the._majnv nna minor diameters shall not be greater than 5% of the nominal diameter".

Upon visual inspection nine spools 2-GCB-016h1625BF130and2-GCB-013-S613-2havebendsthatarebuckled.

N66~/.3 23.

$ FRELD DISPOSITION QFIELD RECOMMENDATION / ROUTE TO PROJECT ENGINEERING

21. FIELD DISPOSITION RESULTS:

H.C.R. Item fl.

Field recommendo route to Pro.icct Entineerinit for approval noe attached nket Illin X/(/?

I' E>r N'-- #/<n A 1 & 2 to clarify nonconforming item.

.% w / M cn / NPM /M /5,+//: <

s U.C.R. Item J2.

Icose code data name plates have been temporarily taped to the nine.

Thece

/

^

A // o, W X/M4.'cS-looco code dab name plates vill be repaired in the field in the follovJntt mnner-

@n//2c/vy-The exted inn e

toe.k veld holdinrt the colinr nieces together vill be broken-collarn vill then be fantennd (cr v gy, g j,g fg s, ---

p

22. ENGINEERING DISPOstTION

/)

it'd.1 lt12 A'- doty [y 1? f:(5 * *0/.0 '*D.b /5 ***I V'l %J//

$Nd ffl* bl(fl.yN,.

N

23. ENGINEERING DISPOSITAON RESULTS:

NCQ ITdD-l'P dJ kab dea $ii[. llnc Tryrf 2-h."> -O/($ '.)6'/M ~ 'IS (F-/EOb iN a ' u wim u' s Nia..<-i a L o d a tYa & w,eo auc,a Sa;Mk<Jun b-nnb. 'l}Ob u]a lulk -[briku da h ab:tL n Y)vic. ut,:u d nu l/~)-

x N

-k c ll $ i b. % c n, & L. ;A'M n: v/- 2

,3 i ? <.,,1 b. / (c' S

m-me as;<

% "1 - feum i N ' A w

t ANGE REQUIRED f 28. REJECTED M ATERf AL DISPOSITION /

O 's svund to sueeus" NO

27. QC ACCE,PTANCE O YES.SEE ATTACHEDs

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==,..,,
g gr.o'.

'.,g. , ~.,, .s, ut. m. !n2I ms 1 tard o, 'A' JWED' 9-34*i sur ), $RC. 'A' ~ BECHTEL r i CORPORATION . p& l r SEP 19 D S Et%{ W f giouvo nur w/r"2] LONSw1FA*3 RWER& ~ Pb-72fD-kf-ASAC. m ~ U FIPI !!![EBLT 'I / N3*7#JS PEZyPN#/#E# t/S7 ScA/-/ cotes cont: 8' ave e c _. 4....... Tat s.t.itttest t v ( iff. 91il af. CtstalPfl08 Ngh traf a W n!TIIIAL ,,,,,,,,gy,,g s stos cuas. l spac. l sevect Iterat [ess*c. att ! otsceentees ess? srnNtzss sita As5Y. E / / C"Mo SMLs p/pf ma-I'7?SJf9" % Vla $?~/ HT *-433580 l-s.s-m ij I Ii t i K - - ~. m. 4 1 .1 ' r. i i < (vw'Y -q \\ 1 esse-sins eistni,vien palet Ft ritet e i tit 81 isfat flitt ists intti e s l N - E--------- A

S K ETC H x2. PER-05

2. C7 C. B - O l(o - S (o l3 -E B

\\ - (') V _Drra rf I t- ',s C' s'-5W Y opm- /ONO}$dK /}$1.6W,11E~A/7"f A7" gg l 0 DIb% 12/M.'Shi/77&*E> 72) E~A{62 SV T CCn=CM77.r GAJ /,hl76. honGo At.O D = (o.66" 1 s.ys .y. o s = 6.b% l T' ,O s.E y .(2. O b = to.(ole 'i x. a e.a '" / 3. O D= 6.57 8 x s.p'"g \\ . p. OD=(o.ro4(o I 3.7 s. O D =(o46 l 1 c75,, \\ . (,. O D : G,500 y 2.. \\ .7 m 7 OD: G.450 DerAit [.I_N ^ 2 \\ E.72cc S. O D = (s. 3 ST V ..\\ ' O* " # W # " ( ' 55 ,p ' 10. OD=.(c.570 c,7 rr T '"

11. O b = '.. 3 7 0

.b L.7.b' ~ % i2.. C I R.o.Ew&. lD ' f ~ / UN7+ 0

V _. / NONCONFORMANCE HEPORT ' ^" "' [" g ~

2. Lac.wwn ;.. 4 i Wa v.

7. PR *aJaCT NO.

12. tecPO ATED GY lCATO

25. t2tiPCLIT8 k N CA NCUR R ENCE C-288 (q)'

!1 7220 [. [44'4WA Ill- /4-74

3. ITEM EEbef TION S. STEM LOCATIO N 33 5

ED BY I DATE Reinforefpg Steel Aux. Bida. Slab. El. 593'-0" !//////dt ekfd[ t ll-If'/d m

c. cn : A R. N U M B E R aml

9. STARTUP SYSTEM NO.

' d. R EPcACEMENT PAFPr NO. REV. Pao,s.T F8Eko E fee SN O.75 M/A N/A N/A i ~

s. PURCN ASE ORDER NO.

80. QC FIELO INSPECTION PLAN NO.

8 8. REPLACEMENT SERIAL NO. N/A N/A N/A Q //*f ' *" '* * * * "* *f' " C. Ci NYC ACTO R/LOCATf 0N

^

tt.ASME C YES 9 7. SOU R CE N/A IT E u Gil NO Construction

30. C6UTING INSTRUCTIONSs ROUTE TO FIELO ENG8HEERING O ROUTE TO u ATERiAL SUPERVISOR 9 9. N%NCSNFORMING CONDITION:

A total of four (4) No. 6 horizontal dowels (shop-bent) projecting from A-line wall for the 1 i intermediate slab at El. 593'-0" were broken when stripping the wall forms. Non-conforming condition was noted f during routine field engineer inspection. Q. - t \\ ST Qo s \\.263 l Olt I-l e t.. n TA O. A/)N /tsh 2 ). Q FIELD DISPOSITION OFIELO RECOMMEND ATION/ ROUTE TO PROJECT ENGINEERING

24. PIELD DISPOSITION RESULTS:

aurc ous Repair in accordance with standard repair procedure. Replace broken bars as follows: j&,,,, e,o.,,,.,.,. f, ,f/v'f.,

1 Drill holes, fill holes with non-shrink grout (EMBEC0 636) and set the reauired dowels.

m,.- r.o ,' -n Lap splices and dowel embedment lengths shall be in accordance with the prescribed table x /.. ..c A.., .., // dic I on Dwg. C-211, Rev. 4, Note 3. Expected completion date 11/20/74., .,.,...,,,,,,,,.,,.)

c.,,

f. feV M V ll IC- % ....,.,,.,, i / .1,.N

22. ENutNEERsN3 DISPOSITION

23. ENGINEERING DISPOSITION RESULTS:

1 l

04. 33 DEggGN CN ANGIE REQUlflEO ONO O vES. SEE avTaCNED.

S l.".5." " ~~" "..,P 7$"'N F- ,( . '2,. - W A WINS R E V-DCN _C_PC C_.._. _ _ ~._ __._R E V.__ _.. _. ____s .urnomesso assepe crog _ A D D. o.ve

_ _ _u.

( T ORIGINATOR V

?"'

w

s Route CY lE A!. sh ~s ? Y cy _ s*J >,, o p > i TC ! ~~ A ' lI r 4 i * '. l' ' J ! i a.1.* -= s <~ se or 0, / 7 # / e/ /*. (5 #/2 e; /, DAfr i. ymg e 2/C/2 273 jo, go_ oya20 Cu JicT [,; cc. /;a Z r=r2 c+ >' 12iChi/::17iA 5 C ~~- C' S J,2 g cst: S C /2. /f D 8/5G/> C&cs-E a 1. 14'E S* 7/1 r E D Y M // r sf ' C/2- /7S //,l/ T/ 79 4 o <? 7~^' 4 7-I=~i) Ou? c' M /f C CP y C,< ) C C.? y // s) o /3,5 g,a 72,g, z;,z st./ :=,p / C ///t-7-C N. ECdEL? / // 77Esv/4 S 7~C- /-C Ca;)/ 45 C Os* Y /f's9 v s EnE.o* ~ lf/]f79 .ZE [IE / S ' F A L-N, l/N $ c ' C l'. /s &!." E L'G 'l S Cl * / l sca ceecas our av < * /2 - A <- a s s 7 ca.; i /.x 7s, h / . d' [/) 0 / Y l b'* ~/ e i i ,\\j * / ,g

[ 45;&& / , r t ._...s_, _ _... _ __... _ _ 7,oavE NONCONFORMANCE REPORT ' ' " ^ ' ' ' "h"'"7*P. .. ~ cr_.2- ~~ .. e N a -.NG,ca n t o. ..E v.

1. caoac r No.

roar o. g, 1.. Uis. osn.oN co cunute.cE _Spoc. C.-233 l 2 7220 /M, ' @ /20/74 "' " s g ~ - - - ' ~ > " ' Unit [2

" ' " ' c^"

o "'/ 'oa'E

a. n Em onscnier. "

81 " ,I//*W 7/ _2_Pipo.Rostrairi _Dabeds QC. Hold _ Area Te(. ce=///48 t 1-e.tE=.aLNuu E= .. sraavue svarEm No. j =Ev. ENY caar N ...u......~. .n. / Enbeds. for_ Slab _Els._593'6" __N A /A i 3,... d[' /f.,,? 7-7f s.evacMa:E onoEN No. ...oc riaLo.NseEcrioN rL N No. ig/EcLacEuENT sEniac No. gj _1220-F_30h3/ Reg _CC-2005Re1 J12 C-233A-R-8 Rey O N/A

e. cont = a cT oniLoc a rioH ii.

=E O vs* n.souncE w,,,,,,,,,,,,,,,,,, . Inland..Ityerson/Southfield, Michigan. Qao - - _ -Vendor. "E"

83. NoWI ONG INSTR UCT son $4 HourE To FRELD ENGtNEER9NG O aourE to marEn aL surEnvison

u. NaNeoN,on-iNG coNoir.oN.

1. G-321-D not properly filled out. Block 13 According to approved vendor drawing, suppliers order number should be (210-1012) a. b. Block 17 Buyers Reg. item number should be (P.O. 7220-F-30h32_ Rec,J c M 00.5) c. Block 20 Identification traceable to unit should be (" Pipe restraint embeds for slab at El. s93'6") d. Column 8 Supplier should - Enter number of panes of "each" tvoe of Otmlity Verification _Iocumenta hairu" submitted. Continued on Sheet No. 2 2). @ FIELD DISPostTIoM QFIELD RECOMMEND AY8oN/ route To PRoJEC, ENG4NEERING 2 9. F6ELO OtSPossTBoM RESULTSs Field Procurement Supervisor to obtain necessary Documentation,Jrom Supplier.

1. Revised G-321-D

[ F / $7 _ D / o.-. . j f '. t j. '.M. ~a) Block 13 - OK Mu. s a-L_ -- b) Block 17 - OK (( [ /70 o) Block 20 - Traceability to Field Ennineerinn to obtain nonrnvril 2-d /?//V - (Block 21 continued on Page 2) 33, ENG9NEERlNG DISPoElrlos. ~~ for uneoris1 c:,,h e

4 ei,ei n,,

~ ~ ~ ~~[ / /

23. ENG4NEERING D45P35tylON RESULTE:

34. IS DESIGN CH ANGE REQUIR ED ONo

36. REJECTED M ATERI AL DISPoSITaoM Q..vv.seve sureu.. 27[9#fggW, / /,A, A p a--

D vE .EE areAcNED, 3. ORAwsNG R E V. DCN aur.o...oe se.cre. SP3C. R E V-AOD. l.048*8 White Copy - Originator O c-G 3-2 Canary Copy <- r s.ki 69 neer 1 Pink Copy - POAE ~ G Goldenrod Copy - OC ) ~ e-

_ - _ _ _ 7 -._. fW p + NONCONFORMANCE REPORT (CONTD) ..rasJ ar 2 ...ca=3.k 1 b R1nale 19 Continued-2. Weld _ rod _verifica_ tion _:toports and material test reports for veld rod havo not been submitted with document package. 3 Purchase Order and approved vendor drawing (F-7220-C-233A-IR-6-0) require material to be ASTM A-36. Q)pg"p1ntanunnaintha ananmblies are made_from_ ASTM A-588 Grade A and ASTM A-588 Grade B. t rnhe enm. It_cannot_ho_delp.ngiped which plates are made out of which material. h. 'Pha id" bar used in the two assemblies is A_STM A-588 Grade B. Monconfomnnce noteLduring receint inspection. "Q" No. is 1.1m 2 Q.C. Hold Tags applied. 38~I/d-87f,,\\g^ / v,, r < - Blook 21 Continued. unit should _be (Pipe restraint embeds for slab at El. 593'6"). Block 20 on revised G-321-D shows traceability t.s CI 1. This shows no traceability to the embeds. d) Column 8 - Indicates a Material Certificate of Compliance was not included in the documentation package. A Ulterial_Cer_tif_icat_e_ of Compliance is reauired and should be so indicated on the G-321-D. o) Column 9 - Shop Inspector needskcomplete ~ f) G-321-D is a two-page document for C-233 Q Appendix A, Page 2 should be completed and submitted. This has not hun done. s,yfngyf ,7 Bhd 21 i%%f X i k i t G - h t-eca n il.x M J ohi m a eil s0$1 [l 'O t kg M }&)YlIr IOPY hf ft*fs }culli b' eiu~chsed ~ _ % s ' Mwc_ }bb'./l 't traA A _s ' ri'* Xtens wh[eCopy - Originator 100:e 3 p hyf'/jdM6/C>. Canery Copy - Field En06neer f 7sa.l 3 C4oS6P A?' Bf C dD C*4 S746'BEM~ [','*of,*,*,'s Caoy : aC f (5 Q aec rok- '/ u/7s-Q 3 w w

.y = ..,s... s s READ INSTRUCT 1095 ON BACK BEFORE FILLING IN FORM N These retie'rements for E,.paeerie.;.as Oi hty veilication Documenes sse te be turt.tirs an acco,cance with t*, schei suppWs f.ifurs to comply with tn.s. eetvie. men s enry res t in or:r, ca.icer.ans or wahhotL g of g.,yr,ent anta c E E[,'N OU4L11Y vf Raf sCAfsom DOCUWimTS i, g y T h I. 2.

3..

4 1. E. 7.

s. 1 3.

tt II. 11. e...a se..ne .a m.as u e, ra.

o. nny o.an. f.e.,) i, ci.

t r;.:4 a.m is i C.s.t.,y Ps. M el C.mm R.e.e'.d

'.."e P

3 Am 8 h. %da,s4 8(e R CCE n.mg., 3d, a. g,,. Cod. ' Out Chat I. last ll F a.1 Y.s 4. 8.im I ] s ,.4 .w. 1+.>1+3 x Shop Detail Drm-ings i 1.3E 6.0 = ='.'a, 1 Transparency +3 arints n,wau. 2 6 Quality Assurance Manual 6.OE 11.1 uad" x n.,w w. 2 2 Welding Procedures and 12.OE ' 7.2 u .u. [/ x Qualifications n, w Ws,. Alm n.,,w .w. 2 2 x g, of Weld Rod Control ~ 13.OE u.a.n. I Procedures a .ew.w. u.a.n. a..w.cs 2 2-i x Repair Procedures .i 14.0F 7.0 v.avia n,w.isi. 1 a M One extra copy to Engineering 14.0v 7.0

u. u.

at. Ann' Arbor for sign-off l n, s.ai. 2 2 Cleanine and Coatine l< 15.OE 10.0 we ea= Pro c erb.ve s g/. Cleaning and Coating _J} .v.s. -1 a 10.0 b.15.Ov Nr NA - v.,.um ars was. 1 a ~ Verification Reports Certificate Material Test N k. 17.1v 5.0 .... o NA ppm re / a.,,w.m. 1 .a - 7 Ma'terial Certificate % 17.4v 5.0 v. u. A)ff NA nf &,,14nne, 2 2 __ x $ 25.0E 8.1 Inspection Procedures N' i 1 a k% Insoection Procedure 1 25.0v 8.1 I NA y,,_tg;e,,,n,,,,,,,. e y

115e,4er's ced.r ne.

54.Suppu.r's Pat Ise. IL m's 1= IL Ouesury f/C-/0/8 A0 /kp h$fx$h S g..y,. g

u. a.,. m,y - C i g =.m.

..c. M% -ro$r ic-fr9 " '--"Yjn Abd "'t:,cc., ,a, ...-+u AWZ,a &cMbBdh ymLJr hubA 9B" ~ - % @;g - GU%:- a),g gr si,r.= TW D""*** D.. W t we est. sed b rs.a nat.lut.,y 4.mp.s gg/, _ __"' .i i,.. .,+..... m f f w -# ,,c,.,,,,,, IIIat dw *I'1

c..

Th. C l.ty V.af.c.i.e D.s.m.ga s.t.nin.d s. Eapa.e,ias

,=
. i m s.

.d i .w....%...... . w cp 5.a.t 24 ,C,,,6 u,n. Thel m.as ri. QJ.h?y Vet 14.ii.e D.c., wats eefseer.d C y, b.,s.e.. teve e.c e4.at eta, ee'.s..esNp 3. t. h.,f re CONTA 0 L it0. 1 LE ls o. 41. ..nie& CCE s p.n, 21CAE A. 4 C'5 - &c.tv..nz Th. C..f87 Vs. Int; Osc.rwes f.rnishd eith this n. h

n..

4. cat - s e t.,e e D.r. no oC: Cs=u. :...>.i. m p..,,,1,.a. u. r r, e er. u.. u.w.i su,m., ,(. PURCHASE OF MISCEI.UJ;EOUS >STAL ne wo. !7220 CO: SL"ERS P3MER COM?ANY 3 MIDLAND PUJ;T UNITS 1 & 2 C-3EIQ}.n, i con.o MIDLAND, MICHIGAN Appendix A ENGINEERING AND CUALITY YERiflCATION DOCUMENT REQUIREMENTS o u. t 2 Cr S d l. h

g e READ INSTRUCTIONS ON BACK BEFORE FitLING IN FORIA q These esgoisements los Eqmees.ep end Oretery Vee.t.cre.ei Daevriests ese es be lett.ttcd in occudents weth thischedde set f2eth befew. s.,p.e. isa, .em,i, a thos se. ere.ii.,, si = d,e ce.sen...e meld.: pe,~ e.s c mpi.ence i.uuahed.- ,q e 00 U 1 5 OUALITY VtRIFICATION DOCUttihT1 St, j 1. 2, 3. 4. 5. 6. J. Eg. 9. t O. II.. 12. Ad Dessene.t Specificaisee Kind

Osaatrr, Frise 3naterv Distri-l5. ppt,q inspection Easianeria Feeld glemeigs Cateeeey Paragesph of Copies flessued A 8 7 "I heavved bution Conferer Reisaw Resiew OCE leembes Referease I

fee Code Chack Chech Inst aA fena! Yes. No Reteese la Repeeducible Essefdm R,,,edeciue 1 1 I e 16.OE 5.10 nere'da 6 Re,od.cm. g 7 3 16.OV 5.10

= 52=

R,pred.c.we 1 i x 21.OE 5.10 ita'e'da (Frior to Inspection) Reprodwesble 5 21.OV 5.10- "<da a Repteducsble M.csside Repredsc.hte ta.crofJse Repredes.ble Esset.im Reptedverble Ecesfde Reproduc.ble Ecref'Je, Reproducible '~ fA.cretdm Reproduc.%1e ht.crafde ) i l 13. sappiers Order No. Id. Suppl ers Part Jia.

15. Suppti FartN me

% 1/&/d/z' @/ de h hr/rds,16. Quantay E

17. Seyer's Reg. trees No.

18. anyee's Line!Egmp, Tag se Code No.

T9 Burers Part Name f. .I $$$?!!r Jf-0489'-llF2 k bb.55 Ar smlds &Sh sys'A"_

21. Sup)t.ers ne cerbry that tne listed work and eeguired documents

\\ Ceafema.:e snest the requieements of the psocering documents. ~ SuppGre s..te-.* 1,s.,.re f.t.e 0,e

22. Basms.ea week wm selened kned en satesfactory templetica ut enred esisticas YES. setsd nadar 12. Remuks @CNE Raye ff y

,, fy. y ,eci.e. and.eeisw ei,-..r.e.ut.ee -ps.; net..e / -- Daie

23. Eog.neenas The Castie, Venfiestien Documean subm.tted to tasiacening #

g,,,,,, . with this form have been see ewed for confennance se the Suwt .specifwd seevirements and are acceptable. Enginere 20 DCE Cterk-la This form and the Owfir, verifkat.ea Documents 5tstement referessed berren Esee been recebed and their CONTROL NO. Fitt P40. setatieasbp to the haedaare steras ee,.fied. OCE-5 ssstese Cate After DCE Chechen 0.stsibute to-Prosv ement n'anacee. Tield Off.ce t/.r.a;er, tforeist Supereher c N PURCHASE OF MISCELT).NEOUS IETAL dO3 sD. 7220 CONS,UMERS PO'4ER COXP.414Y ,j ,g c.m o . MIDLAND PLANT UNITS 1 te 2 C-213 )",,,,,,, Appen xA a AA REV2 ' ENGINEERING AND QUALITY VERIFICATION DOCUtA!NT REQUIREMENTS g.34 AIV l sHtti 3 CF. 3 RI7RODuct:04 07 THis FOR'A is AUTbOR22fD QUAti!Y Vif.;FICAT:0:i CCClxitif TRA?.S*:ITTAL-RITACCUC,1 THis $i::1 m _

j.c#r;W.u g1 FIELD CHANGE REQUEST PAGE - 1 OF 1 T

'b-PROJECT NO. 7220 Q Ns. 1 107 DATE 10 23

4. REF(,0jlG. OR SPEC.

REV.

5. TITLE C-391 Rev. 0 & SK-C-429 Rev. A Pipe Restraint Er.: beds

,.{ }EssGN Oa G s: ENGRG ,. 0,:1 .a.. .:s .~..zw..gt p p b n p.m 'I I .5 s J il 10 d NOV 191974 .EECiRE! PC/E2 CO?2. joy 37050 py 11 UW_ / 10.nEVIEWED BYr*7 / ^' f D (

d *-.

I~2 ~ M- ~~ CIVIL

11. APPROVAL OF/ICLD DISP" ITION

~ , l Y.6'< / f'" Z -/

f f ELECT.

n #/ t-f )' ECH. b ?$ Y * >-/.' $ U*NS K. ' * *, / l ,,/ $~'uG LotNG .s fs.". Q 9 p,y L. ', ^' ~ Preic:: F n:'c d o r *.r / c..t e Oj_M-j;.gir._s s,1 , f. /.

12. PROJECT ENG*n*G APPAOVAL: YES h NO O PRO;.E x a.: <. >. -

ou,. ~ .i- [*. jf'

N REMARKS:

_ _l .. f ElllTT. - PRINT COOltulNATOR C/Y'bMD - F li L O t tua rt U,..""2'

~ y Bechtel Associates Professional Corporalit. i intCort Inter-office Memorandum BEEC - 653 To E. E,Felton Date December 17, 1974 subi-et Midir.nd Plant Units 1 & 2 From R. L. Castleberry Job No. 7220 Purchase of Xiscellancous Metal os Engineering $11er FCR Log, C-233 PR, 0274 E.e g ,n,

r-> i n b 5 h 5. J 7 C j!

Copies to Ann Arbor R. Stafford At S. Velker [I}, C. Yen DEC19]SN

Reference:

FCR C-219 approved 11-1-74 BECHTEi. PCWEn co,y JGB 72.20 PEfL In response to verbal request from R. Grote on 12-17-74, Proj ect Engineering approves the use of ASTM A-588 Grade A or Grade B material for the embedments specified in the referenced FCR. .J R. L. Castleberry RPJjef ( O e G -.-.r e'&" " " ~

~ * " '

WW/ / -?' llts/!s' NONCONFORMANCE REPORT ' * /

3. M. A WIN r/PAwT NO.

Or _-4 _

2. 3 P2 eREV.

7. PROJECT NO.

t 3. REPORTED SV 'DATE .:S. DISPOS 87f0N CONCURRENCE 7220-0-111 !5 7220 Mgt'7/M 1/99h1,~ j "" " "

3. aTEM DESe:serPTsON

s. stem LOCAT Ose sh EO Sv s oAgg Liner Plate Containment #2 M/ / %

k//dM// Jd[, [ m/ /-//.'/#

c. sER8AL NUMBER

3. ST ARTUP STSTEM NO.

IST RIF(ACEMENT PART NO. SIIE V.'

=h P.

s I na u/a SS. Gb FIELD INSPECYBON PLAN NO. nA i

s. PU CH A SE ORDER NO.

.t., ,....v,. _g t4.REPL CEMENT SEMBAL NO. n/A n/A n/A F * ** * * " * * * ** *""U f. ,,f gg(E.%f, / 4 j'. [, 9.CxNTRACTON,OCAT,0N __J/A__ -. ...A= a TES ....OURCE G aa constructinn ' ' = = 3 8. KOUTING ONSTRUCTIONS4 ROUTE TO FsELD ENG6NCERING C ROUTE TO M ATERB AL SUPERVISOR .. NO,.COM PO R M.NG COND.T.ON. Subsequent to a fire in Containment #2 on Nov. 21,197h, slight bulges in the liner plate were noted at two locations. (See attached sketch). Height of these bulges measured from an 8 foot template curved to the theoretical radius of the liner plate was a maximum of 3/8 inches. These deviations are within the tolerances specified in Para. 8.1.2 of Specification 7220-0-111 Rev. 5, but exceed the requirements of Para. 8.1 3 of specification 7220-C-111 Rev. 5 "Q" No. in 1.109 .' y :,i r2 ec a pr, f: f, L*J. Q FRELO OgSPOStYsON QPIELD RECOMMENDATSON/ ROUTE TO PROJECT ENGINEERaNG

29. FeELD D$$ POSITION RESULTS:

Use As Is-The following information is offered in support of this recommendation. 1. Attached FSK-CC2-22 illustrates the approximate location of the fire. It should be emphasized that the most intense heat of the flame did not impinge directly against the liner plate but did rise parallel to the liner plate altoving7ho7sse Tntensa fi m to rise up and out the interior or the structur e [h rs A f-f* n r*h ts tI Ch rits t ) e.

22. CNGINE[4'RgNG DisPoseTION Fnt'incering. concurs _to "usc-as-is". the UnCL. plate and other materials exposed to the effects of the fire.

See additional Engineering comments on page 3 of this UCR. ,Yy*/z(' t, r /.I. '/ ly s*

25. 83 DCStGN CH ANGE I4EOU1HED NO O vEs. SEY AYTACHEo, f

y[f .. ar...... ~ w - ,;,c,, gps 3A wgNO R E V. DCN "c [c- -_____?_______'***:__. Whit. Copy - Os10inator Q C-G s-a Canary Copy - Fa ed En0ln t Plek Copy - POAC Goldenrod Copy - OC e V (

f 'T ' </fr.,- NONCONFORMANCE REPORT (CONT'D) 2 o,,t, t ,.,2,,,,2 3 &

e. re.ce Bicek 20 (Continued) 2.

ne blankets _ partially burned in theit._ausgended_ position and than fall ta tha 591' 6" elevation-f-loor. There,_they_c_.a tinued to burn wh_ile_.r_esting_oq_.the_bsttom_ layer _of_ reinforcing _ steel _for tha 'i93' 6" elevation cover slab (the top layer had not been instaned). Inspection _of_ thia _rehar_waa_ conducted-by cleaning with a hand wire brush followed by visual examination for_pi_t_t_ing, surface coriq#19n. ' cracking, distortion or other irregularities that would indicate damage to the reinforcing steel. Rere were no indications whatever that the reinforcing steel had been subj_ected to damage. Additionalh. tie wires on the reinforcing steel showed no damage. The most notable affect observed was due to soot and residue which must be removed. 3. 'ihe 3" x_2" v 1/4"_ stiffener _ angles _wera_ located nn the-.inside_ face _of_th e_.line r_pla te._by_ measu rin g -f rom seam welds. Hammer soundings subsequently taken indicated solid anchorage at the stiffener locations. The bulges identified in. Block 19 are located between the stiffener angles. 4. Investigation of the affect to the Carbo-Zinc #11_ prime coat included solvent cleaning and wire _._b_r_us_hinn for soot removal followed by a visual examination with a "5X Keane-Tator Surface Profile Comparator." The Carbo-Zinc #11 showed no apparent degradation due to heat. The most notable affect from the fire was smoke and melted plastic residue. 5. The 3/4" dia. leak chase piping did not receive enough heat to cause any distortion. In most cases, the duct tape covering the pipe ends had not completely burned off. 6. Wooden plugs that had be'en' inserted into liner plate penetrations received scorching damage and soot contamination but did not burn. These,_ observations support Field Engineering's position that although sufficient heat occurred to cause these bulges from localized thermal expansion of. the liner place, there was not heat of sufficient magnitude to affect Mt.1 e chemical and physical pro crties/ characteristics' of the liner pintg,,,,, MerN 1 - ~~ and adjacent concrete. j / i/'.(f c.n.,vcopy - ri.us enoin, / /, s t,'.Q.' l Pink Copy - POAE ,g /- d' Gold.nsod Copy - OC Q O, q-

y. NONCONFORMANCE REPORT (CONTD)

s. u w 3 o,3 I8 23y

,m fl ek 22 (e ntinu^d): T l rng4 nom.4ng'. concurrence to "use-as-is" is based on the following evaluations / comments: A 4-1/2" x 4-1/2" liner plate sample was removed from one of the larger bulges in accordance with Project _ j l'. Engineerinn's directions and forwarded to the Bechtel laboratory. Test results indicate the hardness of the t ~ plate to be normal, metallographic checks revealed no decarburization, and we conclude that the plate suffered no deleterious effects. Project Engineering has also checked the additional stresses & strains resulting from the bulnes and conclude they do not exceed allowables. I 2. In the area from where the liner nlate section was removed, the concrete surface was visually examined, and also tested with a Swiss hammer. The concrete surfaces visually exhibited no damage, and the Swiss hammer test { results exceeded the design strength. It is concluded that the concrete behind the liner plate did not suffer significant structural damage. 3. Inasmuch as the concrete coverinn the embedded rebar was not damaged. We conclude that the embedded rebar itself also suffered no damage. t I Non embedded rebar (i.e."rebar in slab between 591'-6" to 593'-6") was also exposed to the fire. 4 Three rebar l' I samples were tested to ascertain if the mechanical properties of the rebar remain satisfactory. One sample had l i I a vield strennth of 59.8 ksi. which is 0.3% below the minimum vield; inasmuch as the test machine accuracy is i 1%, we have accepted this test result as satisfactory. All other test results met or exceeded the ASTM A-615 l l reaufrements. Therefore, we conclude that the non embedded rebar did not suffer significant structural damage. ( 5. It was determined that no bulge extended over a stiffner angle. Also, our calculations conclude that stresses / ' { strains, if any, on the stiffener from the adjacent bulge do not exceed allowables. ) 6. The Field has advised that the leak chase system in the area of the fire has been retested. In one area a small I i l _ pinhole was noted and satisfactorily repaired. i 7. Dnmane to the liner nlate coatings has been reviewed under NCR 239. i t 8. In nutsprv. ve_ tonclude the fire did not adversely affect the liner plate, concrete, exposed and/or embedded rebar, stiffener angles, and leak chase materials. We recommend to "use-as-is" the containment building wall. 6W gem D'O 6

O ORIGINATOR C.

) \\ 3 - a 2 -a w e 3 n. QC s e r D a O 4 TA m Jn e. G s I RO )D T' N O C ( TRO PER E C .g NA M i R S O C O F N F O M / C D N S O f N y y y n s

t a

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" " * ' " ~ I NONCONFORMANCE REPORT Or 1 272

s. m. A N Miin LT NO.

i m v. T.,R a c7 N 2. ..,E77 joATE . P. g .. o.,0s T.ON concur ENcE _ Spec. 7220-0-111 !6 07220 Clar 11/21/73 """".'"'"y'*"*"'""'- "f 7

3. ITJM DESCR8PT80N

8. STEM LOC AT80N I

$7ED.T DATE Liner Plate Containment #1 /Lt !/ 2 ( 75. j(',[/r2 [Irwad -/-f..M7 m.A N...ER ...T A T....... N O. ,....ENT. ART

R E..

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e.,UxcM A.514 N/A

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e. czMTR AcTORis.Oc AT ON ii. g=,; O vEs ir*OuaCE y

.R/A__.. 10 NO Conatntetion .. = S G. SEQUTONG INSTR UCTIONS: ROUTE TO FIELD ENGIN EEMING O aOuT= 'O =arraia'suraavisOa ... NONcO N r ON=.NG cOND 7.ON. While testing knuckle plate leak chase, a leak was found in the liner plate just off the U weld at El. 693'0" Az. 2hO. Thring tha rapnir proce nva it van nnted that tha pleta vag lami"=ted-Q No. 19 1.109. a Ona QC Hold tag applied. 29. @ FIELO DI5FJ5eTION QF8 ELD RECOMMEND AT80N/ ROUTE TO PROJECT ENGINEERING 2 8. FIELD CISPostT40N RESULTS4 Repair - Remove the nonconforming area and replace with sound metal. All new h .., _ A .we d.,.rg seams to be covered with leak chase. All work to be done in accordance with mif/. n 6,.,_./ u Nf/.S _ approved standard repair procedure (Specs. 7220-C-111 App. "B") Vork may proceed. sm u A Jn implenentation expected prior to 1/30/75. CL,fr @And

o,bA, /t. 24-h'

, - z,.,.--- y

22. ENGIN EEft4NG DISPO5af SON

33. ENGINEERONG DISPOSITeON RESULTSe C "*.**ve.weeue" $ OC ACCE AN a a nc. GN cet ANGC itEOUaHED 28 NEJECTED MATERI AL DISPosaTION O

a u.. ,u 1so.- tt,.1 - 19.*W D vEs..EE aTT4cMED. r. D2 A WING R E v. DCN .ee ree..es.. e.se.sv.. R E v. A O D. 1.C,C. C.n.ty Copy - F6 eld Engin t Pink Copy - PQAE Goldenrod Copy - OC ~

[" ETahT NO. jT.'I T.7EUniiG.- ~ ~ ~ ~ ~ ~ ~ ~ - ll{PON ~ ~ ~j paf

n. u.sro.IIloM cONcuMI.8 NCx than1Awawas utruiu f

~j-s g j-.y T imA f r{; I, ifalk Mat; rial Lic.t l 07220 A. Moray 1/21/75 dd_b3 p" ~ ~"" " ' / / - ---= e '=a'= ~~'=a"/ l 50 pc *a ' aca'"a

3..T:M emSCilPT.oa

._-$A ./._1 7 100 c?".round._barA_5/8"._round.bar_._oc. Ho1LAren 'M3<' d Flf 7I eeeeee ee e ee e n e am st a t e HubpEft S. ST A R TUP SYSTEM NO. g. REPLACCMENT PA NO. REV. C. SE ta s A _Ht. D82021 & Y88283_respeoti vely. N/A _ _, _ [ _N/A // i ,,,,, -M,, ;,;;- - / 6 PUI4Cid ASE OstDCIf NO. f t. GC PIELO INSPECTBON PLAN NO. t 4. REPLACEMENT $EleIAL NO. .j f p r"------- .322o-r-nh52_ n-1-a-25 nev.. o_ n/A 99.ASME O VES 1T. SOURCE

6. CONTIB A CTOR/ LOC ATION lb _NO Vendor _ _,_,,,_ _ _ _

J. T. Ryerson Detroit, Michigan . EM

19. OIOUT tHG INST R UCT90N S:

Q nOUTE TO FIELD ENGINEERING O Ro u'= 'a = ^v e a'a' SurcV'So*

19. MOMCONFORMlNG CONDITIONS 1.

The 4" round bar requires the following_in order to meet the condili_qns of the_Ee_De__7220-F-llh52-Certified _ Mater _ials Tests _R p. ort to include tensile properties and bend test results. 9 a. b. " Statement of Conformance." Tagging needs to include size and length of pieces, number of pieces, heat number and manufacturing mill. ce d. 1 pc. is damaged - bent. Continued on Page 2 St. FIELD OISPOSITION RESULTSs St. Q FIELO DISPOSITION QF82LD RECOMMEND ATIONfROUTE TO PROJECT ENGINEERING Material Supervisor to obtain missing documentation from vendor for items 1-a, b, c and 2-a, b, c as listed in block 19. Items 1-d and 2-d listed in block 19 will have bent portions cut aw.ay and rejected. Estimated implementation date is 3-1-75. ~/r' //.n 6 p 6.W / F

33. ENGINEERtNG DISPOSITION RESULTS

33. ENGlNEERING DISPOSITION

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' ' ' ^ " ' ~ NONCONFIRMANCE REPORT 2 774 - A or yp' oaTE 1,gny j/ 18/22/74 . A.... G rea = T wo. j nE v. as. oiscos T.on concunaEacE T. enoeEcT wo. .Epec._I-38 6 07220 / . Aldridge if j y So ATEo SV 'DATE

3. eT EM oESCRIPTioN S. GTE M loc ATeoM

[ ( 7h.VbA l/-22'75- [ . f,[_ ) z / s w /. 2 /-7( 12 pcs. Plate h" X 3/8" x 9" .varehouse qC Hold Area sf f}vr_.e ,'ap,= Era.acEuENT rang 7 l n Ev. .~......= 6. 's==p = c.u:asat numeEn e sTanTur svsTEu no. _ Plate No. 2Cl;A N/A / / N/A L/ I Q {- g,.... f/[A ,.f,.n, f.y f.J$,

c. cone

..E o.oE= =o. ... oc r E Lo.= sPE cT.o =,L.= no. ....Er .cE-E=T.En.... ..../jt.c E j **"*"****[" .7,220.Cg8, Loc. Tion c R-15 Rev. n M Ac o-T c -E o vE. ou c y,,,,,,,,,,,,,,,,,, Ingalls Iron Works, Verona, Pa. 10.. Vend _o_r .Y E. ....ou T.u o.u s T a uc T." *' O ao u' < 'a r 'c a o c"* '"*

a '"*

M aou 'o "^'*"'^5 5u'< a v'$oa . noncoNeou-.=G cono Tio=12 plates mark no. 2ChA received with material on shipment C-lh are in nonconformance for the following. 1. TWX # 6576 releases material on shipping list C-lh. Contrary to this, the above plates are not on shipping _liat C-lh. 2. The form C-321-D received is acceptance of material on shipping list C-lh. Contrary to this the above plates are not on shipping list C-lh. Continued on Page No. 2 20. FaELD otSPoSOYDoM QFIELD RECoMMENo ATIoN/ route To PROJECT ENGINEERING

39. reELo DSSPoSITeoM RCSubTE.

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22. ENGINEE RING DISPoSITeoM

33. ENGSMEERING DtSPoSITIO,N RESukYst at.tS DESIGM CN ANGC HEQul.4ED ONo

/g f' O YEs..EE 477acNEo. 4/.; 7 7

* ^ * ' " "

SPEC. R E v. ^ Uo-see.e White Copy - Orielnator o c-Gs

Canary Copy

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b. ' ' k. ,.,i. UI ~ f . d@:I'.i ' M '." j' ' 4 NONCONFORMANCE REPORT (CONT'D)

i. ras-A-rl'

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,y NONCONFORMANCE REPORT er 1 27G A l'N G (/{}()(K f43 V.

7. PMGJCCT N9.

I CP9 ) 2p bY r DATC

25. DISPostT80fd CCNCUf 48BENCC 7220-C-324 l10 7220

(. 6d64 11/28/75 ~e -' ~ " " +

3. IT L'M ECSCRIPTION

3. ITEM LOC ATION V

ATCDDY I DATC Rehar - fil Bundles Containment Wall - Unit #2 qQyg !/-bfT

4. 5 Clfl Al. N UM D E R

9. STAllTUP SYSTEM NO.

a E IC Pl. A C C M E N T 'At T NO. R E V. ruosser reassa me.eas.sien sa v es N/A N/A j N/A I G. PU;iCH ASE ORDER NO. le. OC FIELO INSPECYlON PLAN NO. I S. R CPLACEMENT SERI Al. NO. 7220-C-39AC C-231-2 N/A C. C'.;N TR A CTO R/LO C ATIO N st.ASMC Q VE3 3 7. SO U R C E CODE

- '**'3"'***'*"

N/A [g NO Construction IT E M 8 8. SC3UTING INSTRUCTION S: QROUTE TO FIELD ENGINEERING C NOUTE TO M ATERI AL SUPCRVISOR S 9. N!NCONFORMING CONDITIONE 8-2 #11 hundled hauch bars were cut off to unke room for the penetrations unidad to,_the liner pinge at El. 596'-0 in Reactor Building #2. The attached Drawing FSK-C-296 shows the #11 bars that were cut off. These bars __d3 n7t conform to Section A of Dr. awing C-324, Rev.10. The Q number for rebar is 1.103. The item was noted during liner p1r ta installation., vornra v.,v4,,u. 2 88. O r'<'o o85 Position RFIELD RECOMMENDATION / ROUTE TO PROJECT ENGINEERING II. FIELD DISPOSITION FICSULTS: USE AS IS. Field engineerinn eniculated that since #18 9 12 nrn vnnnirod; i t-uald tako-- 346 #18 bars or 468 #11 bundles to meet the design requirements. We have installed 476 #11 bundics and as such,we cut the tails of 8 bundles necensnrv, to install the liner n1nta_ Thsrefore the design requirements are still met d b /I H Ref. BEBC-442 Attached

22. ENGINEERING DISPOSITION

23. ENGINEERING DISPOSITION RESULTS:

34.IS DESIGN CHANGE REQUtRED ONO

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21. x uCmAuE D ec a-O vEs..zEATTACtEo.

051 AWIN B REV. DCN .vynonease suer.crom CPE C. R E V. ADD. i T,. s G, ORIGilWOR .\\,.\\, N v-

o \\ k t Bechtel Associates Profesa, . inter-office Memorandum stec - 442 Ta E. E. Felton DM August b, 1974 se,.9c t!Ldland Plant Uniu 1 & 2 Frwa Jdb IIo. 7220 'R. L. Cas tleberry. Rec tor Building #2 Reinforcing or Engineering S teel File: C-0294, C-2122, 0274 Ann Arbor cm p. J. Hink

Reference:

(1) IOM E. Yelton to P. Martinez, dated June 21, 1974, BCBE @, 8 M. We have reviewed the as built condition described in Reference 1 con-cerning cutting the tail of 8-2011 inclined bundled bars which interfere with penetrations at elevation 596'-0" in Reactor Building #2. We request that you issue an NCR for the above mentioned subject since it was a deviation from the design drawing. Our review has indicated that the as built condition is structurally adequate, and we will approve the NCR to "use-as-is" when it is received in our office. ,x,- Q f hf hf f M -~ h R. L. Castleberry * ._s TRT/kb AUG 121974 BECHTEL POY!ER CORP. ~ J O 8 7 210 PEfr_ ,f.., . 4 g ; 7,-.7.,. .,y. .-= e -,-4.. q,..>,.,- M.. 7....p -. 5......,. : Q_,. ,,. s. 4 : 4,..3l, g-. g - g.,. v.n, q-g q...

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8. 4TEne LOCATsON s.

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e. g,AsuE - Qv E s. sr.sOuaCE 4..CITT Grinnell/rernery.4 ~.. ."e 111e,, ~..-.f N.O.i, p~ c: 4, aO Vendor ' ..s :., i,.. ..,....."~ - '*~W ,E. h e s. smuTaNG ONSTR uCT80NSs,.*.,.,., g l Q RO UT F TO FIE LO ENG 8M E E R 8NG, OUTE TO M ATER8AL suP3MVISOR *, ,,s,. p."*"c*""?""'a* 50",T,' "' The (2)(G23214)'s submitted for pipo imHeated on loading'eheets'LS6121 'and LS6123 have not y' l hb' sin properly fill'edWin detail'WSMai.iMUN# ' Y . MP $d%,4. M ' r M1. ' G-321-D with tra'os'abiliti'if'LS6121.":Nd"M F " 4 N Y'1 " W (h., hr.,..' a',: / Blocks '11khM'20 ofiaN# C iot fillEdfeut.l M M M M M' T :'J8' !% 2r i dM b. * 'P0/Spe'oNhinnb'e'r%1'o'oli onSEEe"2 sliould 'bo 7220-H-10hA. not 7220-M-NA.9 D ' I I r f 't' g'. '.r, .v- . : 2., wt'; ;is ,.o - 4,. g Continued on Pago 2 k e . 3 0, ,Q re5LO OsSPOS$TeON. { lq J '

QP8ELO ftECOMMEMO4 TION /ftOuTE TO PROJECT ENGtNEERING g

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9. 8Y ARTuP 5YSTEM NO.

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a NONCONFORMANCE REPORT **'l j 279 _ % CCD. i R E v.

v. PROJECT NO.

a. p aw evere=NS-w (IKW.'aY ll/30/75 s 3. RLPOsgTLI,'hd.. -

DATC as.Discoser:ON CONCuNnE NCi: 7220-0-111 ]6 7220 ~ > " i

3. 8 TEM DESCRIPTION

8. BTEM LOC AY40N l'3.

LtD A E V I DAT _Lincr_ Plate. Containment #1 - - w(/..<.~ -_!/ ehi C.57R8ALNUMBER

3. ST A RTUP SVETEM NO.

g(. s CPLACEMENT PART SeO. / REV. .e.a. cr e e.te. m.ser..a e.t. .u/> N1A ulA e

5. 6 URCN A S E OR D E fB NO.

8 S.GC FIELD INSPECTION PLAN NO. 9 4. EltiPLACEMENT SCRI AL NO. N/A H/A c-231-2-h31 N/A E:

8. CJiNTR ACTO R/ LOC ATIO N t9.ASME Q YE5 9 7. SOURCE MA n,E M pNO Cgns,t m tion _,,,,,

18. ROUTING INSTH UCTiONS:

QROUTE TO FIELO ENGINEER 8MG O ROUTE TO M ATCHI AL SUPERVISOR 9 9. NONCONS OftM8NG COND4740Ne Ihring a routine inspection _ of liner plate tolcrances prior to _the conc _ rete po.u. r. two cmall areas are noted to be in excess of allowable tolerances of 7220-0-111 Rev. 6 Para. 8.1.2. When using the 8'0" template, the liner plate'extenda 1/h" beyond allowable limita. The areas are at 1800 E1 593'6" 0 and 200 El. 593'6" "Q" No. is 1.109 / qc go,.o Ts c Appups 30. Q FIELD DISPOSITION [FSELD RECOMMEND AT80N/ ROUTE TO PitOJECT ENG8MEERING St. PIELD OtSPOS8780N RESULTsa Use as is - The areas noted are approximately h" X 6" in size. Probable cause was weld heat concentration in this area. Attempts to straighten the areas may cause more harm to the plate than good. Vork may continue. o.,, 0 $ b/!!$ 0drTV YA k T r s c ~ f r

13. ENGBNEERING DISPC$tTION

23. ENGINEERING OtSPO50740N REEWLT56 24.45 QEStGN CN ANGC REQUIRED ONO o....."~~

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? NONCONFORMANCE REPORT

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C. E.. N o..E ......m,P.... E. N o. _n/A_ NM NM I i C. PureCN ASE o feoE R M., t e. QC F RELo $NSPECYeoM PLAN No. t e. RCPLACEMENT SE RS AL A 5 no/A M-201-2-5 Rev. O N/A N 4 - - - - - * = = ~ - = = Nsa.CroniLoCarioM (,,,,,,,,,,_,,,, / .....uE o vEs i,.sou CE Site .v E u O Mo Construction 8 8. 480UTBNG ONSTRUC FloNS: { Rou1E To f*sELo ENGINCEHtNG O aou rs To "a'=a'a' supe aw'soa

53. NoNCoNFoftMsNG C.NDITeoMt LetterJEBC_#598 s.tates_ quality 2equirca._ror_the_wat.er tq_de use_a_to_bydrost;atic__icat_.Mtut._

2" 2CCB-72.. A hydrostatic test of this line was performed on 1/3/75 using water supplied __by CPCo. Upon review of the_ lab analysis report, indicaMng analysis was performed on 1/21/7{, it was determined that the water did not comply with the quality requirements as detailed in letter #EEBC #598. 'I 45 %.563 One Hold tag _ app].ied. 3 ). O r'c'o o'sPoson Erie'o acCo==<anavsoaraouvE io caosECr tasiaEEaiao si. r E'o oisPosarsoM aEsu'ss. Use_as is. If reguired by Engineering, the installed line could be flue _he.d after a demineralized water supply is established at the.iobsite, d/rd,X. 6. '/3eMW / -3 / - 7.5 8 2 3. ENG0NEER $NG DISPossTaoM

23. ENG 6NEERtNG otSPo$3780N RE5ukTse as. es UCS8f3N CH ANGC REQUtteCo ONo U".a."."" ~ ~

a O vE...EE neve CNEo. ER AWING R E V. oCN C PE C. REv A O u. sensI White Copy - Originatos G C4' 3 3 Cana yCopy - Feoid Engineer Pinta Copy - POAE 'O ] Goldenrod Copy - OC i n hN A

Bechtel Associato Professional Corp "[ Int:r-offica M morandum ~BEBC: 598 u m

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) E. E. Felton om, November 6,1974 a Midland Plant Units 1 & 2 R. L. Castleberry Job No. 7220 f h f f f 'f Testing of 2" Reactor Cavity Drain Engineering og File: 0274, M-5004 copies to Ann Arbor NOV U 1974 9 ^8

s. Blue G. Eshleman BECHTEL POWER CORP.

JOB 7220 PEP-This is a complete response to BCBG-427. ~ Reactor cavity drain lines 2" - 1CCB-72 and 2" -2CCB-72 are to be hydro-tested at 1500 psig per ASME Section III NC 6000. The design pressure is 1000 psig, the design temperature is 3000F. The water to be used shall be demineralized water with the following quality: Tempertture 450F min Conductivity 2.5 umho/cm max pH Rangs @ 770F 6.5 - 7.5 Fluoride Ion (F) 1.0 ppm max - v '. Chloride Ion (Cl) 1.0 ppm max Suspendr:d solids ,0.1 ppm max Water purity measurement must be made in accordance with ASTM standards. I l h!-(,

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. l'i January 30, 1975.N/ [...*. 4..;. e.f e s x .. h i 'd..,d;.cg.% ...po ,.. o. . :.s..., g w. M@t*0Q M.4 2" Reactor Cavity Drain Hydto e p?M. Job 7220 Midland Project .,u,,,,y> ',3;W'y ' E. E. Falton ..i

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E%.T.M,.,. 2 0;%'jhpf. ductivity and suspended solids do not conform to tbasa specifie

'P i.f "Nf*r.*T;y { $TSt'y': i -/. ' 3lq* ii$,h,5] ... 7 g BEBC 598 ,g, 43.pg,; ',f,, 3 }.. g g4,,,;;;.y 4 ssy,yy,, rg.;.i.. :, g/ k,;g Please advisa via IWI by February'3,1975 your concurren 9 a q,C M. consnants. '. C.g,p !g;j t-.g ,"<. p veggg'. i- <rc C t4+bf 7. )N r (Qitf}g This line (2" - 2 CCB-72),is scheduled to be' embed ./:R e g Ps A.*.W floor slab on February 7,'1975. e .., 9 Alf?non-confornance report to fonow.g%b,Q&$g@ ' W Q. %@n.W g s Wk g g., .;f,g. 4 h IO4 H&%j$S.M.';$.41/ :.. Wv&#,&@V, %u.W.1;.$0MGINAL SIGN $tE "$ .mn 4v N;p&.::wpe..%m;;. :.w.M' c. t

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4F 0.UAUTV AUDIT FIP3ijlP3G ll s; 9, 11/21/74 RS-1 .(042) a.j .a-x . rut,AND JOB 7220 MANAGEMENT R. SOMIERFELD 13 7 c. DOCUMENT STORAGE VAULT A. BOULDEN m._.u........................... t!EPQ-VT, REV. 1, PARA. 2.0 p... 2.1 "Each condidate.... shall be examined for near distance visual ability on an annual basis". 2.2 The candidate shall read J-l' letters on a standard Jaegers Tes t... " g_ l. Vision test records of NDE personnel are not properly completed as follows: Bechtel Personnel 3 G.A. Durbee: Vision test record not dated. S.E. Tucker: Jaeger 1 test results improperly recorded with 20/20 'F. indication. (Rexamined 11/20/74) s X-Ray Engineering Personnel M.A. Cross: Jaeger 1 test results improperly recorded with 20/20 indication. G.A. Green: 'Jaeger 1 test results improperly recorded with 20/20 indication. l ,,1..>.................. R3 test for Jaeger 1 results or correct form if backup data is available. 1 1 r l m.o......... f 11/2 3/~'.'. PFQCE

7..

l All test records noted have been corrected where backup data was not available, retests were performed and properly documented. 3(m l v; .8 p. Ll' /0 ~7 5~ A k...... b/ 'Pi%LE .j g

s.. m"~* 1/17/75 . l.: c " - c l N/A n = ;.:......,..... g3...,. 7..... ud 07220 Construction O. -. sevo p*.......... / 5 1-?-0 ! 1 b.l.$) QC Document Control J. P. Connolly' ,.=..u:........(................ FIM G 3 Rev. 3 (A) para. h.h.3 (B) App. B (C) App. C A. Each tag shall contain the NCR number plus a unique subnumber' identifying the tag and the total number of tags for that NCR. B. In'structions for preparing the nonconformance report. Block No. Entry Information 8 Enter location of the nonconforming item. C. Instructions for preparing the hold for QC Clearance Tag.. Block No. Entry Information 2 Signature,..... of the QC Engineer. i A. Two hold tags for NCR 207 did not have unique subnumbers and the total number of tags were not indicated. B. Item location for NCR 207 and NCR 230 not as indicated. NCR Indicated' Location ~ Actual Location 207 Fab Shop QC Hold Area 230 Poseyville Siding Adj. to East jig b1dg. R's 207 and 230: hold tags showed persons other than QC Engineers as responsible r ngineers. NCR's 200 and 253: hola tags showed persons no longer employea as res-ponsible engineers. s _.. _,. ~.....

1. R; view open NCR's and hold tags to assure current status of locationu, responsible tngineers, etc. are provided.

2. Provide for periodic review of open NCR's and hold tags to update for necessary changes.

m. ~........ 1 /31 /76 PFQCE m.......; .2

1. All NCR's and' Hold tags' reviewed and updated.

y

2. In the future, NCR's will be updated to indicate applicate storage area as non-conforming material is moved from' one storage area to another.

4 - /-2 7-W 'PFGC6

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7 QUAUTY AUDIT FiliDlNG .... h8 8 ....... /17/75 1 /( n/A 00 '== a.......,.... Sevo Midland 07270 construction . = = .... g. y.3,, 16-1-P-0 Field Engineering T. Valenzano ......u............................... FIM G-3 Rev. 6 para h.10.1. m...,.. Tha PMCE shall route a copy of the completed NCR to the organization responsible for control of the' activity which apparently caused the nonconformance. Each'such or-ganization will evaluate the feed back information provided by the NCR and initiate whatever correctiva action may be warranted to prevent recurrence. Contrary to the above, no evidence was available n's to evaluation made of feedback information as described above on completed NCR's 248, 256, 223, 164, 208, and 222 which were routed to E. E. Felton. ( 1 ~ I

1.

Provide objective evidence to satisfy compliance with this requirement.

l ~ i I ........ E... l 2/28/75 E. E. Felton 'I o s d Q.- ga 8,........................ a u

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~ ?- I i...... 1/2L/ M I n/k T, 2?iM S....,..,.. - i.>g,,, -....., 7"'-- ,.......nr f, u) Midiud 07220 conctruction O =- a = G. L. Richardse 3.,..ATbVit, J. Hillers 1_ QC Files H. Hoofensnirger o._..,es................................ Spec. 7220-C-208 Rev. 3 . 6...... ~para.6.2 Aggregate acceptability tests " Aggregate camples subctitted'by the concrete supplier from his proposed source shall be tested by the subcontractor". "The following tests shall be performed" " Petrographic Examination - - - C-295" (AsTn Designation) ' Tha results of " Petrographic Examination" for the 3/1" and 1 " concrete aggregate 5 prenntly being used were not available for review in the QC files and could not b2 located during this audit. Quality Control hab indicated that the tests have been

-un.

) ( y( ( Obtain results of these tests if available or submit new camples for enmietion and ebtain these results. -l

l 2,..

,__.~..,...... p /M, /74 pypcp 2 - a........... 2 Subject test report has been receiven and is en file. S J L,' 8' '? "'pg2cg .,._.................g. e

QUAUTY ASSURANCE DISCREPANCY REPORT 3 oao ioENT.no. (OA DAILY LOG SUPPLEMENT) JOB NO. 7220 029 4 ISSbE DATE r 9/12/7!i' 1 PROJECT /DEPTJ3ELLEH 2 PolNT oF ORIGIN @ FIELD 5 oAD PREPAREo BY Midland - 7220 O OFFICE R. E. Savo 6 DAILY log DATE 7 CHECKLISTITEM 8 WMERE FoUND 9 olSCUSSEo WITH I. Quality Control J. Aldridge 9/11/74 N/A II. Storage Areas D.*lbrtin 10 CONTROLLING ooCUMENT.SECTioN, PARAGRAPH,ETC J. Tice G. Dexter c) FIP G-$, Rev. O b) FPG-3, Rev. 2 c) FPP-15 G. Lithen 11 oUoTATsoN c. h.1 Quality Control Engineers shallJinspect the storage areas...to verify conpliance with progran criteria. h.2.1 The QCE nhall perfozm periodic inspections...to assure that designated storage areas are being properly maintained. Following are eranples of itens to be included inithe inspection: a, b, c, d, c. b. 8.3 3 _ Storage Areas 1 Itens should retain purchase order identification for retrievability and inventory control, as applicable.... 8.3 3 1 Access to storage areas shall be limited to personnel.... h. c. ( 3). ...a conprehensive storage plan shall be worked out. c. 1 This storna knv co,-rnnpnnan tn p'avinunly n nkod loentionn 12 otsCREPANCY DESCRIPTION storage plan. on th* comrehar nij g I QC storage inspection reports reviewed do not provide evidence of in'spection results for all storaga areas since storage areas are not designated. Also reports do not address evaluation of storage areas as to acceptability based upon criteria given in FIP G-5, Para. h.2.11.e. control of access to storage areas has not been identified. II Contrary toathe above, materials storage. engineer could not provide evidence of the following: Designated storage areas, and conprehensive plan were not available. a b Inventory control nor F.O. identification *.for retrievability were available. Limitations on access to storage areas were not available. c 13 REcoMMENDEo CORRECTIVE ACTION I Provide docunentation during inspections to assure acceptability per listed criterd a for each storage area. iia Designate storage areas and provide storage plan., iib Provide assurance of limited access. Y. 4 vv- %..u - ---.,__.---c u a s c, - +, _ c-, _ u, -..-t e, 4 +, a 4..a -,. -a,a ~FSCH'EoUilo}Co. (7fT16 y N 1 ATF ib'AESToN'SINOWFoR CoRRYCIIVE' df8dE" ~ ~",""'~~# -~ ~ ' ' " ' ' ' ~ T & TT C_ I J. Connolly II E. E. Pelten 16 CORRECTIVE ACTloN TAKEN 1. Storage areas have been designated in a memo (and in several updates) to J. P. Conno (PFQCE).. lly Sketchts showing locations of the-laydown areas are posted in the Materials l }upervisorsoffice. (qee A ached Sheet) 'Ib MNI b b1 ( 19 ConifECTIVE ACTION VERI'FIEo BY oAE [ / / or E v riduRE 7.38

i. 4, 046 p QUALITY ASSURANCE DISCREPANCY REPORT

4. ISSUE DATE 12/10/74 1.. PROJECT / DEPT./CONTR ACTOR

2. POINT OF ORIGIN 6 FIELD

5. GAD PREPARED BY:

gQ Midland - 7220 0 OFFICE R. E. Sevo S. WORK PLAN DATE

7. CHECKLISTITEM

8. WHERE FOUND

9. DipCUggig 12/10/74 N/A U.S. Testing /Q.C. Records K. Rademacner

10. CONTROLLING DOCUMENT, SECTION, PARAGRAPH. ETC.

Spec. 7220-C-208, Rev. 3, Paragraph 7.3.1 e

11. QUOTATION

...each test will not represent more than 250 tons of aggregate size delivered.... If an aggregate sample fails to meet these requirements two additional tests will be performed.... If either of-the two additional tests fail, the contractor will either reject the material or evaluate it to assers its acceptability. O 1

12. DISCREPANCY DESCRIPTION Contrary to the above, incoming aggregate records for the period of June through O

September 1974 were reviewed with these results; of the 20 days reviewed, 93 tests C(/ were taken of wnich 61 failed. Evidence is not available as to additional tests take.- for each failure, also evidence of rejection or evaluation for acceptability is not available. Frequency of tests not. assured due to improper log entries. It-should be noted that belt samples during this period indicated material to be acceptable, which is the final point of acceptance.

13. RECOMMENDED CORRECTIVE ACTION 1.

Direct the testing lab in proper maintenance of testing frequency log. 2. Assess acceptability of aggregate during this period. 3. Provide method of assuring compliance with this requirement.

14. SCHEDULED COMPLETION

15. RESPONSIBILITY FOR CORRECTIVE A'i6h DATE 12/20/74 1., 3.

J. P. Connolly J., S. E. E. Felton a- _w

16. CORRECTIVE ACTION TAKEN

..a. ,n . Response to QADR #046 was accomplished by attachel letter, 7220-C-231-4 from

f Terry Valenzano to Jim Connolly.

/

17. DhTE COMPLETED

18. SUBMITTED BbYESPONSIBLE AUTHORITY)26 l

-- 7/ C . ') 6 l Tr a ~

19. CORRECTIVE ACTION VER L BY OAE 26.OATE um Ih i s Wh/ll YU AAO-86 9/17/74 g~

~ &W L

OUALITY ASSbANCE D!SCREPANCY REPORT

c. ISSUE ATE 1/10/74

1. PROJECT / DEPT./CONTR ACTOR

2. POINT OF ORIC1N

@ FIELD

5. OAD PREPARED BY:

Midland 1 & 2 O OFFICE [ G. @lORK PLAN DATE 7.CHECKLirTITEM

8. WHERE FOUND g

9. DISCUSSED WITH s

N/A N/A QA/QC files R. Mul m' e

10. CONTROLLING DOCUMENT,SECTION, PARAGRAPH, ETC.

NQAM II #5

11. OUOTATION 2.0 "The design process includes the preparation, review, approval and dis-tribution of design documents. Chnnges to design output documents shall be controlled to assure that an interfacing orgnnizations are notified.....

changes are trnnnmitted to using organizations". d

12. DISCREPANCY DESCRIPTION Rev. 6 of the Q-list has been issued. At the time of issunnce the document con-(

troller deleted several holders of tha Q-list from the distribation list.

How,

~U ever, these holders of Rev. 5 were not notified nor were the superceded copies of the Q-list destroyed or voided. Rrnmples: G. Richnedtion, L. Albert, I). Thompson.

13. RECOMMENDED CORRECTIVE ACTION Notify holder of the Q-list that are no longer on distribution and destroy or void the superceded Q--lists.

14. SCHEDULED COMPLETION

15. RESPONSIBILITY FOR CORRECTIVE ACTION DATE 2/10/75 E. E. Felton

16. CORRECTIVE ACTION TAKEN

.g J7. DATE COMPLETED18. SUBMITTED BY RESPONSIBLE AUTHORITY (

19. CORRECTIVE ACTION VERIFIED BY OAE 20.DATE AAO-86 9/17/74 p

9 ^~~

dv Route To Thio @opy 17or l File If@ E.6 ~ ~ %~ Istue Data August 21, 1974 ( C.Q. Hills W.E. Kranlcr (2' Project mawa 1 & '> .,.C.S. Kc21cy S.H. H:w:11 H.W. Slager W.F. Holub hm F05r:t File Title NCR's on Bechtel File construction p ] (last) p Nonconfomance No QF-18 This Nonconfomance Report is Issued to: Prepared By [MMr-j Date Mr. E. E. Felton DM Bechtel Power Corporation P. O. Bdx 2167 Written R ly Requi By Dat:9, Midland, Mi. 48640 9-18-74 etion Required By Date who is responsible for correction action. NoI}confomance Description and Supporting. Details: ~ WFMC-1, Rev.'O entitled " Welding Filler Material Control Procedure Specification" item 4.3.4 states in part, " Electrodes shich are removed from ,a rod room storage oven shall be placed in heated portab1'e rod warmers,, for issuance to welders. In violation of item 4.3.4 it was observed that about 10# of E7018 elec-trode was removed from the red room storage oven and placed in a cold-portable rod. warmer and ssued to a welder. ..~ AEC Reportable Yes O no see Proceaure 9 ' nerortins of Deficiencies to AEC Notified on By Method l Reco=nended Corrective Action (If Appropriate): I 1. Comply with WFMC-1, Rev. O, item 4.3.4. ( 2. Providd training of cognizant personnel 1 Corrective Action To Be Taken: l See Attachment A. ) I I l Underlying Cause of Nonconfomance: See. Attachment A. (corrective Action Implemented and Nonconformance Closed) Confir=ed By b Date /-/o-75' ) ) .1 b De Provided 'by Addressee. ~ 3/15/74 Pe6e 1 d

s Attcchm:nt A to NCR QF-18 '[ Augurt 21, 1974 y-sY,5 7 )1 Corrective Action To Be Taken: Initial response by Bechtel indicated that the requirement for heated portable rod warmers would be deleted by field change request #174. The justifica-

[

tion given for deletion of the requirement is that even the most critical rod can be exposed to ambient conditions for h hour and most low hydrogen rod can be exposed for four hours to ambient conditions. The field change request was denied as WFMC-1, Rev. O was E _ng revised. Revision 1 of WFMC-1, however, did not change the requirement for i.eated rod warmers. WFMC-1, Rev.. I will become effective with issuance of the BQAn. As the requirement will still be in effect in Rev.1 of WFMC-1, a decision was made by Consumers Power QA to verify that the requirement was being met and then close the NCR. It was verified on 1-10-75 that portable rod warmers are preheated prior to placing rod in the warmer for issuance to the welder. The rod room has electrical . outlets provided specifically for the preheating of portable rod warmers. Underlying Cause of Nonconformance: Difference of interpretation of WFMC requirements. f% \\/ 8 e _a e m

m.e m , Jun i. mpy For F113 16.3.6 , S. Keelsy S. E, How;11 Icsu2 Data Ancust 26;'1974 , Q. Hilly W.* E. Keaclcr' C ) Project Midlr.nd 1 & 2 A . W. Singer' M'..y. Holuh.. ,gg-File Title NCR's on Bechtel [ile _ Quality Control 2 r9w) Nonconformance No QF 25 m This Nonconformance Report is Issued to: Mr.,,..fi P *, Connolly Prepared B M % Q) f. h Date 8-M-Y .s , gg_j,,, page gzj/,Lg l y,,$,ygg y B2chte1[.Pfoject Field Quality Contr'ollEngineer Written Reply Reqhd By Date 9-4-74 ~. Action Required,By Date 9-26-74 \\ uho is responsible for correction action. Nonconformance Description and Supporting Details: Specification C--230 Rev. 3, Srctiqn 11.'2 states -to obtain the following placing. temperatures:-. b) For mass concrete, ecctions two and.eue-h'alf. foot or more in thicknes's and 'up' t'o six. foot thickness, not to ~ l excred 7.5.F for any.one batch and also not to exce'ed 70 F. for the'avera~ge' temperature. of cll batch'es used ~during 'the placement. ~ 'For concrete ' our No. A'.(584)C. only 20 b' arches-p '.y of 77 batche.s' were ' checked for temperature. ~; _ ;.. . b'... .' i... '. - - . ^., -AEC Reportable..'Yes O ' no G. see Procedure 9 - aerortins of reticiencies to Arc AEC Notified on-By _ Method ,'ho. mended Corrective Action (If ppropriate): ~ ~. f -%) I '1). 'Present. sufficient; data? to as~ sure;the.57 batches not checke.d for temperature were... .'sithin the' specification'ab'ove (2)';:Rmjnd.'your.QC inspectors ofl.this' specification.- I 3. z..... . ~u 3_ Corrective Action To Be Taken: - ~ lf Prdcent sufficient ~ data to assure th'e 57 bat.ches not clie'cked for temperatur'e were within tih:2.pp'eliticit' ion:above. ' -, ~- Y- .M .'.,,:.~...

- -: l.... :

.f ..l, l..- ~ .- }

... :;}G.~ y %

b

c O.

p:

.j.-

,.c.,,.. s-t , q...- s ~ .= .-. o. . derKytng Cause of Ronconformatice: ' '. " -".q' :3..Gi'.;i'.; v Tha underlying cause' of. the rienconformance was' a, di.fference -f,n' iriterpietation. of Technical . Spreificationc.C-230i. Rev. 4. by, Q.C;. r. ~ e.:. u: .-. -; ~ < - . f, _. . y ). ~..z .l-l s ~ (Corrective Action Implemented and Nonconformance Closed) Confirmed By mv@) $.b Sufficient data was presented to as,sure the 57 batches not- 'ced for, temperature were within the specification above. Date hwAM; P % s'pectors' vere reminded of.this specification. Also Specification C-2.30, Rc.v. 5 .-avices the temperature checking frequency. e ~. l - 'b Be'Provided by Addressee. l3 ... x..\\-: -.:.. -.. ~.. c -

r..ru w su 'An A5 UCDY FOtrT File -10. .1 ~ Iasue Date %.ms., 9g lova CSKuley SHHowell l d Project . Midland 1 & 2 ~

CQHillo WEK=clar (2).

\\," - HWSlager (last: WFHolub' N.,.1::;4M PTMF File Title NCR's on Bechtel GLRichardson' Construc tion g File Nonconfor=ance No 0F-33 This Honconforniance Report la Issued to: i Prepe. red BygMMW Dace //_.2 E. E. Felton 7 Bechtel Power Corporation Written R ly RequirdBy Datta/,l_11 Action Required By Date 12/2@ vito is responsible for correction action. Uonconfomance Description end Supporting Details:- FPG-3, " Procedure for Storage and Storage Maintenance of Q-Listed Equipment and Material" states that for Level D items storage shall be on cribbing or equivalent to allow for air circulatio,n and to avoid trapping water. (Section. 8.3.2 (4) ). ~ Contrary to the above statement, reusable liner plate scrap located at the northeast corner of the liner plate jig building is buried under earthwork, spoil. Additionally, floor liner plate stored in s. hat area is in contact with water and the ground as are other pieces of reusable scrap that are not buried under the spoil. , Reference attached letter BCCC 471 for previous commitments made with "M 6 Ne*cSrki # P gt,e rTd See Procedure 9 - Reporting of Deficiencies'to AEC aS9 e AEC Notified on By_ Method Recocmended Corrective Action (If Appropriate): i m,/ Clean-up affected area so that storage, requirements of FPG-3 are inet. (- and commitments of letter BCCC 471 are effected and maintained. Corrective Act on To Be Taken: 1. Affected material will be stored properly. 2. Supervisory personnel have been instructed to maintain proper storage of this material in this storage area and to provide closer surveillmuce to assure compliance. 1Underlying Cause of Nonconfor=mnce: The status of the material and the applicable storage requirements of FPG-3 were misunderstood. l (Corrective Action Implemented and Nonconfor--7ce Closed) Confined By Date P/7-73* m \\l ~ ~ T5 De 'Privided by' AE.dr' ssee. " e ~ ~ l. 3/15/74

c -. 16 4. N. Issue Date ' Decenb4r~1L 1974

SKeelek '

SHHowe'll \\- / Project Midland 1 & 2 mily". WEKnorltr.(2)

QHi.llo WFH21ub.-

g g g., g pile Title NCR's on Bechtel Oualiti CL chardson Control ' ile Nonc:mformance. No QF-37 'This Ronconfomance Report,is Issued tor x ' Prepared Byh.~0,( f@wDate 1: ~ 1.II M MP. #r. P$ Conno1Ty b* (.. ' Reviewed'B[, k Date M5/' 75 BrchteI. Project. Field Quality Contiql,.' 1gi. '.er Erit. ten Re/'ly. Req By Date 12-20-74 l ? p s.;. a,. Action Required. By Date 1-10-72 who is responsible foi correction action. Nonconfor~'"ce Description and Supporting Details: Speci.fication C-e208 Rev. 3 ~. ..M -secti,o.n 7./3,2. states..',' Cylinders shall be made,. cured,. and teste'd.in adedrdance with ASTM C-( Mnd C-39.E ASTM.C-31'see tion' 7.2; atated, for; i,nitial.qurinFJ,. store. all

test specimens, under.

,.,cnnditions, tilat maintaiti.',the, temperature. ir::mediat,ely adjacent to t,he ;specimeris "a the rapge

.60 to 60 tF.

From..'a r'eview ~of U.S. -Te.stingPs concrete,.cy1'inders log: *(1).35 sets.of cylinda '. had.initiat 'c.tring temperatures 'out: of.ths 60 to B0 F, range". Ihe range. of th'ese were 'from- . 349 to 99. "(2): 22 seti o' 'chintiers. had. nd initial curing. temp' era.tures', listed.., ASTM,C-31 f %setion -7 3 s'tates " Remove. test " specimens.made for Jchecking the adequacy of the' laboratory. ".I' mixture pr'opot "tions 'fo[.s'ttenith, c'r pa. thh basis -Tod.acqeptaitie_, 'from%he mo.lds at the' en! of' 20 + 4, h and st'ored 18 a moist'. condition' ht' 73.4' + 3. F -(23 + 1.7C)'sutil the ' moment of.N 'tagt."- Fros a r,evieP6f U.S. Testing's. concrete' cylinders log':7. (3) 21 sets. of c'yfinders wp ~ ~ ~ ~ no (Continued' on 'page 2 of 2). - AEC Reportable, Yes O. E. see Procedure 9 - Resortins. or Deficiencies to AEC. ..AEC Notified on, By Method P h.. tended Corrective Action (If Appropriate): '(1) Evafua'te the cyliiider.acce~ptability l the cylinder'b.reak.results '.accep ret' ion" to preclude. these occurrences.t, ability for the'above cylixiders. '(2)' Talde-corrective" ~.. / 6. w.,. .~ .a. .~ . ~...;. . s. 3 Corrective Action ToBe Taken:.f(1} Evaluate theIcylinder aced,ptabili.ty' and. the cy.in,dSr. ,.Meak..rb..su1,Uq fo,r t.he.~c.ylinders ab@e.'.e(27.'Take 'c.o.rra.Et!iv. e action. to preclu.de lh .1 i a a.c,curren.ces.......... .. -.3:... e.. 3 n* .. ; :.....,....,...s. ...u..... s.. .. n.... 4 .p-C ....., ~. .3 .. n ';.i.

e..

c. ~.. ":haderbing Cause o'f x=neanfor= nice: ; ina..deqhf, tei. eviQ . u:.. . n :. y.1: .. lqr.yli.tiys i:. ? .. t a- . y ~..W

~.

~;. .. ~. ..p j r-g.,,, . x.7.. r.

s..... -.

..<s. 1 ,,...j..,. ;...,;,. .:r , ser ...s s .a. Corre'etive Action. Implemented and henconformance Closed) Confimed By nvJ)f.b An evaluation;of,all.the cylinders has,been,made and all Date Gl, M nder treak result,s have been accepted. u u b' yta att'e..*U.S.. Testing is reviewing and.up-dat163'thefconcrete cylinder *.lo^g and. vill-keep it' (3) Quality.C.ontrol lias initiat,cd a. personnel change ln the position of laboratory supervisY ' 'b Be Provided by Addressee..' ~ ~ "Page1ok ' w' a

~ ~- y (Continued from p g2 1 cf 2, NCR QF-37) Page 2 of 2 not stripped within the 20 t 4 hrs. The range was 15 hrs. 36 minutes to 46 hrs. 10 minutes. (4) 13 sets of cylinders had no elapsed time between caoting and 7~ \\ stripping. From a review of U.S. Testing's Curing Tanks Temperature Log for November, 1974: (5) 33 temperatures were below the 70.4 minimum. e O e%, e a G .i (. ~ v O 6 o S e

. -'" fN I. -,,m- -- - j gg - GSKeeley SHHowell \\ ICsue Datn _ December

11.1974

.. \\... Project Midltnd 1 & 2 CQHillo - WEKe2Olar..(2)., HWSlagcr \\" WFHolub - g g g p g.y File Title NCR's,on Bechtel Qualit GLRichardson Control Wile Ronconfo;.uance. No QF-38 This Nonconformance, Report,is Issued to: Prepared ByNOA C.'9Few,Date f.F Il-7 Mr!* J P[Connolly-h,. ~,, *. Rekrieved'By '.~ Md.M Date /.idd B:chtel *Pfej ect Ei' eld. Quali,ty: Contrbl Engineer. Writ. ten Rep 3y.Re=uir//ed By Date _12-20-7 '... ~ Action. Required By Date t-10-7 l w'no is responsible fsi correction ection. Nonconfoi.~.ance Description and Supporting Details:. Specification C 6208 Rev. 3.section ctates."The Batch Plant.' Inspector shall obtain. samples and conddet the'fbliowing tests. durin k his' shif t! 'Repohts o'f' these tests','sha' 1*.'be 'aub;nitted: to the Con' trac, tor'. 7.3.1 states Two 1 .aand samples,(st two sspafQE times).and:ene. coarse agdegate sample from each nominal si.ze grbup, foi gra'dati6n dh'all be taked..If.an 'aggre' gate, pampi.e fails 'to 'me,et. gradati.on require ' dents; two 6,dditional. samples:shall be.taken. R.eviewing,thd Batch' Plant Inspdctor Daily - e . JNports.1n th'e.QC Tile for ' san'd.(r)/The second t2st was.not,found for, 4-4-74 7.(2),No, ..grcdation' tedt's;were fpun,d(,for 16-l'6 :74; pour number' CC(59,3.5)a . (3)-N'o /gradatiBn testa' 7 s -%r'o f-ound. tor.~ 1Q. N,.pou'rcn, umber-Y(6.32)d. ' (t) T.he.';secgna te' t;. was,not foupd ~for 11-i8-2 s r..- i- -AEC Reportdble. Yes O No B. see Procedure 9 - Reportins of Deficiencies to Arc '.. ., AEC Notified on. By Method )co rnended Corrective Action (If 5pp'ropriate): (1) Locdts the missidg'. tests dnd. place {d in, the file.".,(2).If the missing,, tests ~were not made,' evaltiate [

oncrete-placedf th t ' day,;. (3). Ta.ke corr.ective ac'tlon to preclude. fdrther occurrences.

9 -3 . '.. c. e ? . ~ - .e., ~~

-.,- l: .... :. : n :. : * ' f ;. ~.' '

~ ^ ~1 ~' .' Corrective Action To Be Taken: .'c(1) Locate theI issidg tes'ts a'nd place 'th'em'in theffile'. m .that, da.the' missing testE were not 'made,'-Ma16 ate the acce'ptability of t(he' co.Ecrete p (2T If y ". (3)** ....Takd corr'dctive actio.n Edf. rec 10.de f.urEh',er;uccurrencys - p 8..;.. ... -...;....,..: y..:... s.

m.. -.. -

.e

.., v. r. 4 ~... .? .. s- .,;a. .~ .... ~ ~.... ~... ~. .v : ~. .s. ..,s ,.., ; ~. ~: p....;....

s....-

.,. ~. z..,. <;... . rg, _.,., erlying Cause of.W=nconforma: ice:l I. cadehiati teFi.e@o'fi,'r,e:cir.as.by',gijality,' . ~, .;.,.... s... !. ..r 2 ',

f. ~,. : ;...... ;.,.,.

..:.... '- o... :> .. e..:,. r 'i...-..(. ~. ~. ..J

,i ; g. :~ ~,1 1 ;._.,.. ' " Q ':. ;.y...

_ ',. ; a :., .: -......v - .. ^. ~. %rr ~. .a. .~ -e ~ Corre'etive'Actiond=plementdd and Nonconfor=ence Closed) Confirmed BybM8.h The. second. test for 4-24-74 was,not found, but adequate dataDate b w s (7. W -- l he U.S$ Testing 1-og' indicates this. test was run.and,it had ^ v ( 4 ( uate results. The seco~nd. test.for:11-18-.74 was not found, but :had been.previously mihntified,on NCR-227 and an evaluatio'n of 1;he acceptability. of' the ' concrete will be made. Thd other mi'ssing tests have bee,ri locat'ed and".pladed. in the. QC files

i

'~ - (2) An in depth -Quality Cohtrol, audit, of.all U;S. ", Testing documentq'tiort and activity is now nd;rway. Quality Contjicol has initiated a personnel change in the position of laboratory st lie Provided by Addressee. Page 1 o. L n. ..s

() Issue Date December *12, 1974 i .SEHow'211.~

5 Project _

Midlend 1 & 2 EWSidger WIKmicr- (2). CQHillo WFH lbb: W ig g = F e glT File Title NCR's on Bechtel Oualit? CLRicharfson, Control File L# Nonconfr.u muck No _OF-39 e U1h Q Nonconformance Report is Issued to: Prepared BybAilf.%s.Datel A-D. ~1 MrII.Ph.connoN1y Reviewed'ByMM's Date /ke/h B;chtel Project Field Quality Control Engine 6r Urtt. ten Re2.L7.Bequi3[ed $f Date ~ l 12-20-74 I,",[ Action Required By Date 1-110-75N 'who is responsible foi correction action. ~ ~ Nanconfor~"'ce Description and Supporting Details: Frou a review of the Batch. Plant Inppe.c. tors' Daily. Report 1.in the QC file for.3/4." and ih" aggrega' e:.. (1) Tor 3-1-74, 3/4'A, t cggregate'.h'as th,st CCl-77, this sh6uld'be,C -77, (2).-For. 3 ~1-7h 1 '!. iggregate has no, log. .. number, etest 'CC-80.is '.wr'dhg /. it.should be. C-:0.0 (3;) :For 4.-l.9-74,1, " aggregate has retest. C^119, 'this 'should bv CC.-l'19'. (4); Fo'r.7.-5-74.shows }iourGo. K(592.25)a ',, this should be'. - ~.,h(582. 25@p. (5) For. 8-22-74;,1M" aggregat'e has,ifirst bin 't' st. missing..' (6) For.;10-18-731 e 1 e ,;y'different~. ~(7) Log numbers were missing ond 10-J.9-73','.1 ".has the igam' . n reports' for.10-22.73,,10-75.-73, 8-28-74.&

J.l

'10 3,.74...'.

?.:. ' ' '.. '. *. ',

' \\ *. ~. '.. - '.~... ' \\ ... ~. - e . AEC Rehortable. Yes O ' wo G. see Procedure 9 - ae a.ing or neficiencies to AzC.." e r .,.AEC Notified on, By Method o=mmded Corrective Action (If Appropriate): '(1) Corr'ec't the reports.,(2.) Review entire aggrega,te. daily repdrts for correctness and wika corrections if necessary... ( )' Q' ~ . Take..co. itectiv.e 'a.c,ti.on to..preclu'd'e..these ocebrrences. t / ..i ..t, .s. .-.c-L { s .-:- )..~ J-orrective Action To Be Taken: '.....(l). Correct th'.Eepor'ts. - 2) ~ c

d. $ily,.r. E.por.,ts, f'o,r..co. rrh.e.tnes.s and'.niake. ".c.o. rre' ctions. if. 'de'cessar(y. {t e

(3) Take forrective actiot ~ ' .to prdelude.t!e.1 se o.cc.ur.rences... .. Y. ' .....' c .- e...- .,.....,::....r ......c..- .,.1 2 .s, ..., ;.... ~, ..... ~..... * < s derlying Cause of.Woncon2br=ezice:l_.,.. r. M e Inadeqvata+evi'y: df 7ecbras"by.'Quhlitg. Control. '_.. 1 s .. ~ q. ~. l, ;. *; .s, c... . 5,. n : ~.... - \\ c: .?....* v

x. :

... s ...........n .- a . q. ' (Corre'etive'Actiondsplemented and Nonconfor=a.nce Closecl) Confirmed By 'df.kv (1) The;subj'ect reports have been corrected. l - Date h 8 [ f

(-'\\*{'hecbmp,letefile,ofaggregatedailyrepofts,iscurrently

,A j undergoisg a joint r,ev'iew by -Quality.C.on' trol and U.S. Testing

personnel.

i~ ;i3) An in.d.epth Quality Control auditi of all U.S. Te. sting, documenta'ti'on and activity is now underwiy., Quali$y Control Jias initiated,a personnel change'in the positio'n of laboratod ~ cupe. rvisbr. ~ ~ To Be Provided by Nidressee. .. he - - ~ HymAML

__ A a

p= T sue Dat2 D2cember*1 GSi, -oe21ef SHHow;11 i Project Midlend 1 & 2 i RKS1?ger WIKmicr- (2). ~ CQHillo WFH;1bb: . Cii# Ecg R43 * - File Title NCR's on Bechtel Ouali@ .CLRichar son Control File Nanconfb2mance. No _OF-39 'Inis Ronconformance Report is 1ssued to: Prepared ByhDjlf.h. Date l A-D.-9 hfI. I.,F..Conno'k.1y Reviewed'ByMM'i Date 4de/h

3:chtel.11f oject F' eld Qdality Con. trol Eng'neer i

Written Reply.Requi:ged By Date 12-20-7) ..{, Action Required By Date 1410-75y '1(no is responsible foi correction action. f Nanconfor ce Description and Supporting Details: Frou a review of the Batch. Plant 1 -In;pe,c. tors' Daily Report'..in the QC. file for.3/4." and 1 " aggregate:.. (1) "For 3-1-74, 3/4'A .cggregate' h'as test CC:77, this.sh6uld'bd,C-77, (2).<For 3 ~1--7h 1 '! a'ggregate has no leg. . number,.-tiesti CC-80.is Swr'dtig,2.it should be.C38.0 (,3;) for.4--19-74,1,3r/' aggregate has retes,t (4)* For.7.-5-74.shows pourGo. A'(592.25)a',.this should be '. - {, '.C-119, this should be CC3-119. ~ )(5'82. 25.)a'j- (5) For.'8-22--74$- lb" aggregat~e has [first bin ' test missing ',. (6) - For 10-18--73'- e ~ .glind 10-J.9-73','.1h".6as th' iga' 'e. log nkmber f6r retests'CC-31, but' ts.e tes't result;s are e m ..diff erent. ~(7), Log. numbers. vete missing.on reports

for.10.-22-73,.10-25-.73, 8-28-74.&

.j l*. y ."10. 3 74....," .- " * ' ' ~...- '.... ~.. e... ... -..i. c n. .AEC Repo$ table. Yes O wo B. see Procedure 9 - mesortins of reficiencies to AzC..' t ~ ..AEC Notified oni By Method cc= mended Corrective Action (If ppropriate): (1) Correc't the reports.. (2) Review ent-ire aggrega,te. daily repcrts for. correctness and make ) Take,correctitre 'ac. tion to,, preclu'de,these ocebrrences.,.corfections if necessa g ,0 8 . 3, . ~. ~ -

g....

3 ".....(1), Correct th'e depdr'ts. - }2) Iteview the 'en' tire agg' . Ctrrective Action To Be Taken: 3$11y.r. i.ipor.,ts. f'o,r. co. rr'e.c.tnes.s and'.miake. ".c.o.'rrectio.ns. if.. Ne'chssary. (3) Take Eorrdetive ac'i'os r t .to. prdc3,ude. the.s.e o.ccur.renc.es... m .,...,T. .. F, - . g....'. :. :-. :: ~. ..;....,u..- ... :.. c ..... :.m. .. -..c..:..

r...

c.. % 2,,,;.,1,y.c,,,, g, y,,,.,,y;=g,, q,g,gg,,;g g.,;,g. y

j,j: .....q,,yg-...g,,,;.,1,.

.a. .. t.. .....~. ... m : c... ~.... -.... ...a a. . q q.., -;r .. ). ... n. ............h.

.. s. ~... -

.r.r. . (Co:rective Action Teplemented and Nonconfor=ence CloseEL) Confirmed ByAlf. M (1) The;subfect reports have been corrected. Date b 8 ~N~

{'he comp,lete fil-e, of a'ggregate da,ily reports,is, currently u.idergoing a joint r.ev'iew by Quality C.odtrol and U.S. Testing ' personnel.

3 (~ 3 ) An in,d.epth Quality Control audit' of. all U.S. Te. sting, documenta'ti'on dud activity is now und erwa'y.. Quality Control Jias. initiated.a personnel change 'in the positio'n of laborat.'oid supe.rvisbr... ~ ~ To De Provided by Abess'ee., .s ( Pase 1 ofj a %.ws

poutaTo Thia Copy For ~ File 16.3.4 Issuo Date Drcember 19, 1974 ! F CQHills WEKessler (2) Pro #ct Midland 1 & 2 GSK2q1cy SHHowell HWSlager ~WFHolub C3.", BW3 PPJ!f File Title NCR's on Bechtel GLRichardson Construction . ~ File Nonconformance No ng_an This Nonconformance Report is Iss'ued to: Prepared By[dbW Date/2 d Mr. E. E. Felton Bechtel Power Corporation Reviewed' Date P.O. Box 2167 h RequirkBy Date 1-D Written Midland, MI 48640 1 Action Required By.Date; l-l@1 who is responsible for correction action. i

=:

Nonconfoznance Description and Supporting Details: Criterion VIII 6t IOCFR50 Appendix.B. " Identification and Control of. Materials, Parts, and Coinponents, requires that traceability be maintained for materials, parts, and. cosponents by appropriate means. Letter ~BCCC 471 dated' July 16,1974 (copy attached) concerning ' reusable liner plate scrap, contains a commitment to stamp heat and slab numbers is ~ pieces cut out of 11ner plate. The stamping provided the traceability. required. Contrary to.the above' commitment, it was observed'that several pieces of'! reusable liner plate scrap' located at the northeast corner of. the jig building did I not have heat and slab numbers transferred to them from the parent liner plate - material. c AEC Reportable Yes No @ See Procedure 9 - Reporting of De'ficiencies to AEC AEC Notified on By Method Recommended Corrective Actiori (If Appropriate): 1. Provide required, trac.,eability on all pieces' of reusable liner plate ( 2. If the unstamped material is 'nonusable scrap, provide for segregated scrap. ( storage as requested in letter 75FQAE74 dated July 11, 1974 from J. L. Corley to E. E. Felton or dispose of the material as has been, stated in letter BCCC 471. Corrective Action To Be Taken: Letter BCCC 835 dated 12-27-74, stated that all material in the subjec,t ser,ap area would be discarded. Subsequent to that letter-and prior to verification by CPCo. QA.on 1-16-75 a decision was made to store one 3 4 section of reusable liner plate scrap in the area. That piece is stored properly . and has the heat and slab numbers stamped. All other scrap was discarded. As the one remaining sect' ion of liner plate scrap is stored and marked properly, his NCR can be closed. derlying Cause of Nonconformance: The riaterial in the scrap area was not going to be used for 'further repairs and thus scrap was not stamped. Underlying cause provid.ed by Consumers Power QA. (Corrective Action Implemented and Nonconfor=ance Closed) Confirmed By Date ps745 -) g y To De Provided by Addressee. ~ 3[15[7% -1. Pane 1 of

Rfuta To Thia Copys Jr ze Midland 16.2 GSK cley SHHowall Ichua Date May 30, 1974 CQHilla WEKons1cr (2) Projrch Midland Units 1 & 2 HWSlager WFHolub .O ,JLCorley NMow3 pmygr File Title NCN s on Consumers ( '() hildland File 16.2 Project Organization Tickler File N"""onraswinee Na 65 p Thir..innconrarwinco lleport.18 lasued to: Prepared Dyj/w/N0 ate 6jdi/h T. C. Cocke Beviewed By hkJ /Date Y5-/ / Project Superintendent WrittenHeplyRequireMyDate 6/17j Consumers Power Company Action Required By Date 7/1/74 who ir, responsible for correction action. Nonconformance Description and Supporting Details: 2.1.2.1 of the MPPM requires that the Field Operations Supervisor maintain a log of letters identifying qua'.ity problems originating from the Project. Such a log is not presently being maintained. 4,f/p, .v. c /Q s ,=w l ' cw.DQ i !gg4+- ,,-y l 3 le - I l ur w l AEC lleportable Yes O No x See Procedure 9 - neportins of Deficiencies to AzC AEC Notirled on By Method RecommendedCorrectiveAction(IfAppropriate): ( That the Project implement this requirement as defined in their ,( Procedures Manual. ~ ~~ 1 Corrective Action To Be Taken: CONSUMERS POWER COMPANY Same as reco=sended. q. Dq .n t lj W h w a na w .t_ _.h SEP121974 y 1underlying cause or Nonconformance: FIELD QUALITY ASSURANCE Failure to implement (oversight). + (Corrective Action Implemented and Nonconformance Closed) ConfinnedjDy Date cyj,p yz,_ Implementation of this NCR has been verified in the Field by /] 'J. L. Corley.. /C To De ~ Provided by Addressee. 3/15/74 -1 Pcge 1 of

^ Ro'uta To This Cop 'For Midland 16.2 e o i Issua Date May 30, 1974 CSKrcley SHHow211 CQHilla EKacsler (2) Project Midland Ucits 1 & 2 ~ h( k "8'# of1 C::::Eletra P.irst File Title NCR's on Consumers e Project Organization ./Midland File 16. 2"""""" Tickler File // _ /. f f Th lt: Noneontbrunneo Hepart is issued to: Prepared D y,,f/ M j Date h h T. C. Cooke Reviewed By [ [ b dit/ Date 8/.b/ Project Superintendent <v< Consumers Power Company Written Heply RequirMy Date 6/17f7 Action Required By Date 7/1/7h who it: responsible for correction action. Nonconformance Description and Supporting Details: .,3 2 3 cf the MPPF MfAE8 keg 0W{lhc%%PM,1 requires that the system for the control of field 4 des Jip g% 1e mo h3 verify adherence to established procedures. These gge@s Comp n revi lare t e n t ed. Doccmentation for such reviews were not available. _b SEP121974 _9 FIELD QuaOTY ASSURANCE MIDLAND, MICHIGAN AEC Reportable Yes No x See Procedure 9 - Reporting of Deficiencies to AEC AEC Notified on By Method Recommended Co'riective Actior$ (If Appropriate): ~

(

That the Project review the MPPM and update it to reflect the duties as '( they are presently being performed and provide adequate documentation to verify - these activities. Corrective Action T'o Be Tak'en: Project implementing this requirement per their manual. Documentation will be provided on future reviews. u-ff 5l y 3E..i. 4 s. Underlying Cause of Nonconformance: [ g" !O( f! ,{f I Failure to specify time intervals and assign responsibility'. (Corrective Action Implemented and Nonconformance Closed) Confirined y Date C c/7D Based upon the corrective ahtion to be taken by the project and' the-l O Quarterly Management Meeting on the Midland Quality Effort held on August 23, 1974, A/ this NCR is considered closed. During the QA Management Meeting it was a6 reed that (' Project Field Engineering surveillance activities were not related to the QA Program. ality Assurance is responsible for the surveillance: and documentation of this activ o De Provided by Addresse'e. 1 3/15/74 -1 s .Pame 1 of

Houta To This Copy /or r Eg)ddlcnd 16.2 Issus Data Iday 30, w/4 GSK;cl y SHHowall Project Midland Units 1 & 2 CQHills WEKessler(2) Slager WFHolub ts;:g;;m pysyt File Title NCR's on Consumers J J6:orley Project Organir.ation v Midland File 16. 2Nonennrnrmnner Nn 67 A Tickler File 1/ n , i Thin itanconf*annnnen liepart. Is Issued to: Prepared Ity /bf3fb/ Dnte Ch'M / Reviewed By ((bh/ Date8d-/ T. C. Cooke Project Superintendent Consumers Power Company g . y Date 6/lh/' Action Required By Date 7/1/74 l ' who in responsible for correction action. Nonconfomance Description and Supporting Details: 3.2.4 of the MPPM requires that the Bechtel system for the field control i of construction drawings will be reviewed by Consumers Power Company Field Engi-neers at periodic intervals to verify that drawings in use have been properly i approved. These reviews aregUMERS POWER COMPANY umented. Documentation for such reviews were not available. ~ SEP121974 3 J AEC Reportnb1 - Yes Npg gAgl Y ASSUiMtfGB eedure 9 - Reporting of Deficiencies to AEC AEC Notirled on RecommendedCorrectiveActionYIfApp,ropr$akeN LANu MIC I A x That the Project review the MPPM and update it to reflect the duties as they are presently being perfor=ed and provide adequate documentation to verify these x activities. Corrective Action to Be Taken:- Project implementing this requirement per their manual. Documentation will be completed on future reviews. t T s -- a -j Underlying Cahse of Nonconformance: [ A,5 L Failure to spccify time intervals and assign responsibilityl,,] ~ '(Corrective Action implemented and Nonconformance Closed) Confirme By Date 67 fi W Based upon the corrective action to be taken by the project and'the g ) Quarterly Management Meeting on the Midland Quality Effort held on August 23,197 t, 1 /V this NCR is considered closed. During the QA Management Meeting it was agreed that (- Project Field Engineerins surveillance activities were not related to the QA Program. ality Assurance is responsible for tue curveillance' and documentation of this activd o lie Provided by Addressee. ~ 3/15/74 -1 revn_SLna__.J

. j 4fid1nd 16.2 uto To This Cop ror GSKealty SHHow211 Iccua Date May 30, 1974 CQHilla WEK2calcr (2) Projset Mid1rnd Units 1 & 2 HWSlager WFHolub 7 L[ ]) gJCCorley CCER:T3 FCWK File Title NCR's on Constmers y Midland File 16.2 Project organir '. ion s Tickler File Nonconroswinec No 68 'I ' Tliin :tinconrotwinen Itepart. Is Jesued to: Prepared it hv,4 Md/Date @(/7 Reviewed By /8/rII$./Date d/~k/ Pro et u rintendent Consumers Power Company Written Reply Require y Date 6/b Action Required By Date 7/1/74 ~ ho in responsible for correction action. w Nonconformance Description and Supporting Details: The forward of the MPPM requires overall ind'octrination and training of Project personnel. Although formal courses taken by field personnel are .being documented, there was no docume % gyp @i@l20tiiW)Yrovide verification of other training programs conducted Po et Q SEP121974 J IEL QUALITY ASSURANCE AEC lleportable Yes No X See tp6kGA:lle of Deficiencies to AEC roc g @Metho@d t AEC Notified on By Recommended Corrective Action (If Appropriate)- ( sJ ' _. yM: ..a Document all training as having been completed and verified. ,is e.. l ~ u .., R _ ~ iJ.2."' 1.. _ !- J.. Corrective Action To Be Taken: [ __ " " MPPM revised to provide trnining and indoctrination documentation. 1Underlying Cnuse or Nonconformance: Interpretation of what training requires documentation by Project. (Corrective Act. ion Implemented and Nonconfomance Closed) fira d D 4 Implementation of this NCa has been verified by J. L. Corley. LJ s ko lie Provided by Addressee. ~ 3/15/74 -1 FFage 1 mr .}}

ML19329E930

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