Text

Nonconformance Rept for May 1976.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
	ML19329E939
Person / Time
Site:	Midland
Issue date:	05/31/1976
From:	; CONSUMERS ENERGY CO. (FORMERLY CONSUMERS POWER CO.)
To:	;
Shared Package
ML19329E934	List: ML19329E933; ML19329E939;
References
	NUDOCS 8006180808
	Download: ML19329E939 (103)
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{{#Wiki_filter:,, ..,'..O,...,6' - NONCONFORh1 ANCE - REPON G.OG & STATUS SCOK 12. REPOF.T DATC 5' 4 C - J'M' Pact cowt..b ' M-c.c. tr:0. ::*

1. PROJECT NO.

,. 2,.:. 0 l ^,_ ,3 . tu.. STATUS c .' O. DATE PREnARED BY NONCON FOR.'.1ANCE mn e f[GCUTE ':. TD E C t. rc Ot.00CD GY DESCRIPTION / REMARKS ' 7 6 2 - '- D.L.Osborn T ?on - 1:'i m ch T r - e - 7 r -,7 ' ' ~ - Psid 2-19 5/7/73/28/7 l'. E. Ilbert ~-e -7/ h00 tons raccived w/o user tes 1.105.l ?05 a bha 7/ -76 i l 3 '77 2-5 E. Dutton C-208. Concrete test frenuencv exceeded, Edeht l 2-19 4-9-7 L 6 T; l Pour A(633. 25)a' l.205 y---Ex75 l - 7 6 D. L. Ocborn 1 37Bl 2-5-7b R. A. Moray h,- 2 3 3 ". v 304',neinnen n g w 1 y,s., hi,. n Field No 2-5-76 3-31 R. A. Mo ray l l3:.ck-Up Plates have defective weldt 1.202 2-5-76 -76 379 2-t D. Martin - 1. Pn -i fi c ati o n Dn mi n e -M,1c;_.ono n n d. i c o.B&W No 3 h-27-7'3 P. M. Pitto -72 four.d inside ASME 4.038 !2-9-76 -76 1 ? 1, .'2-A-23 I

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' ;' 0 ; ' - 6 E. Dutton C ?3? -_r w crcin c - -; n g + e rr y. -- -lu2_c, ;- gur-s__ mf.: ~ l -7: A(633.25)a' & TT(606)a 1.205 =,2 = 9 = 7 6 -D No 2-17 l3 R. G. Lus sic 331!2-9 G. Depew C-50A. Liner Plate heat number di serenanc'-l Field I f -7+ 1.109 !2-9-76 -76 -76 lD Osborn f-111. I.i n.cr ninto tn W. co 11a i' " 1 "L r___ yield No ,2-17 2-27 D. L. O.sb orn -32 2-:- . L. 650'6" to 6518 6" 1.109 k - 1 1 - 7 /, ! -76 o l lh-3 6-l

5 2-1 i

d'-230

2-19 l

l D. L. Osborn lA (63 0. 7 5)a'H.;1 f va - d of hi ch @ r py;_c.nc r e's,prj F Mpj $ 76 00 'hd 1.205 =d.12c: - l 76 M ,~ n,.m,_ m = iPe ancol F 'vi G -i,p i '" J ' a r' < l M c l-d l 4 e1_Ir!6-2-7j

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I H. B ole e n r& 10 U.. 1:. A. ' 6.- O .I .mp--~,..'. 1, 2.~~h'1-to C - s 's j "ra improper painting ASMi.: 4.154,4.17.4 00 ?c 3 3-31 . R. A. Moray 35 2-12 R. A. Moray 'rF MC-1. Wcld rod h o = t t re. trv nt r e -- n e r.,t-- -76 - ~S 7-3029. A S A. _. <W h3-=%, '-19 R, A. Moray M ' E R, ger-r o r " 4 "ncl_:.": t h n:R_Cis_pla w /F i,el d,, o, j3- - 3-26 R.I.. Moray No _76 l - e. 0 - < _' -7J ve ded on. / FME 4.131 l v u 7 f,.= 5-10 10 L. R. M ert ~ Z-'

D. L. O.sh o rn C 111 pennersin - +nt.,1 ---

,2;-.. z_ups.g. wt; 76 -7: l6 3 5 2 5". '.J 09 p 12 7.= - '7D j - '.[ -.. a3 <;..i.: r.

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. M. [~ -lg[j@le}l3 NONCONFORMANCE - REPO'RT LOG a STATUS COOK G. us i,L n, .s REPOTIT DATE * ' PAGE CCT.*al, . c. - -... _

1. PROJECT NO.

o.c. cNo. sicu -.NCR .a. t O. ;;G. PREPARED BY NONCONFORMANCE STATUS .o10. L. '.: i DESCRIPTION /REMARKo ls. n

7.DATc (c.uATE

. u Afc 10. l:CLCSc0 i nouTE ' XMTG l HETD CLCSCD CY 412'4.% T R

Lieb.

C-230. Fl va.-h _ fi n o n n s s. I =er Test -;.-iS C-- - - - - - - -2 4-29 t L I l -7/ 1.105,1.205 45N22 -76 ! = i .1 2~ ]1,.csi== 4 - 2 9 ;.O.,,., jai.:4+j T. R. Lieb !C-N mir.h ral,.- t C.m""+ Renin-h ahn jD: w !-r-i j-H.t rine calibration 1.105.1.205 MCA -7! I -m-a a-2 :. -.. . L. R..u,,,a c r t / i - a. i i

41. l4-:

R. A. Moray M-1M A. lincu ment e tion _an A r nd" n'tn A n'n Field t j -7 2ca pipe spools. ASME 4.13 53 14 - 2LE 415 4-14 H. Bole en 21-10A IT,n-e t' h + " a a -.a ~.n' ~- -7e " a d Lu. c. e d / n .u n.,-., 5, ~ actches beine anproved ASME d.102,4.112 ^ 'a_' ), To-r 51A 4-30 A. L. Boulden ASME Section TTL Field We'd. U - i t d ? Su n'n _ iField l N-Ray recuirements violated ASME 4.134 -(- 3 0 - 7 6; 417 5 -.: - 7 6 A. L. Boulden C-I I I. Unit # 1 Sumn, we!d in need of repair l Field jafter pressure test 4.128 5-4-76 i 418 ll5--s - 76 R. A. Moray . rr - g-104A. DocumanMon and Code & mmc t ln:b.,a rs ucu } lan pipe spools ASME 4.194,4.174,4.102 W75-]1 5_gc_736-3-7j jys 41o 5-4 -[ i i I H. Boleen - ? ' ~> A ^ " A' a - "n'** 6 "' " ' d " # d " * " " ! 'VIS IS l5-N-75; 1.102 r, ~ -76 4 420 5-5-7/'

11. Boleen M - l ? O. Vnive ta crinc vnrie= b n -, A n." -- n " ! Ficid

!:: 0 1, 6 8 i I l marking on MO Valves

o ASME Varies l g _ y _ ra 421 5-10 C. H. Nelson f _? 10 R a mp ' orth of Am Rid '

md n h -" .L.M 5-21-7p - 7! cautent high 1.004 _-. - p-c, 5-l? J,5 F. 422 .. ilat.er 'M M-ure-Trite "r-- m, c ".' a - Fiell e l 1.102 ~ g 3-19-75 23 5-2"-75 F.

. Pitts

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.f p g)." 'i. NONCONFORMANCE - REPOR'T LOG e STATUS SOOK

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u. RET' ORT DATE PAGE COMPL.

1. PROJECT NO.

' ' ^,, .C. ENG. MN _J 4. !5 NCR. u i.1 C. NO. ,J J. a,c PRCPAF.ED BY NONCONFORMANCE l. STATUS DESCRIPTION / REMARKS lC. p.DATE U.DATE 'L .1 'J. nt-o i c. DATE . acute xt.!To 1 rosse ctosEo cv - 'h ' i - 1 e-c.

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NONCONFORMANCE REPORT h"*2 "'3N i

2. D N A ' N G /v A tt T N O.

I' N L V. . 7. P!v 0JE CT NO.

u T J sv "

lCATL 52{Lro 2s Dt:.PosaisoN Con L uN HL M E sn.. 7220-C-203 l6 7220 CAMA-i.4/N ~W" T p> =- "-- *k

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/nr.PL A CcM CNT P A RT N$p l2.L/- % g, 'd/',hl,.(', S;.Ln ;T-7 P. 7_'" Fi .__ _ m..sh Test Frequency Batch Plant

4. 5 L s L N u M se e re

s. s r A wTup sysTtM No.

,H p e. 3 at a 9

u. 46 f 6.;*
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~ ~ ' ' ' .. CON m CrORn.oCn,0N i.. A,.u c o vu ir.sounCc U. ?. Te sting Co., Midland, MI ,'T3'.9No Subcontractor ....e,...u,.. - ~ ~ - 84 N C' i t s N G f rd ST M UCT IONE { NOuT E TO FIE LO ENGIN C E RapeG O a o u' t ' o a a' c a 'a ' 5uac a v 'so a 19 Pe O n 0 3 NS O M MIN G CO N DITION : g___ _Spenificati.on_.2220-C.-2Df,__R.en 6 Sectien_6 LZ_ststes_in_part_that, " Don.olen_shalLhe s ;_ pled and tested in accordan_c.g with ASIM _C-311. " AS T M_C -11 1 - 6B_s.t at e s in.p a_rb._".o n e_t. cat _ saropl e s'. O rep _r_e. s ent not more than 100 tonc. " Contrary to the above,_on August 28,_1975 a p_n.n sing _u s e r's te st sancele was taken at 1989 accumulative tons representing the test cycle of 1900 to 2000 accumulative tons. Th.. next user's test sample, which also passed, was taken on October 23, 1975 at 2157 accurnulative tonc reu resentine the test cycle from 2100 to 2200 accumulative tons. The user's test evele reoresentina 2000 2e g 5 sL LO DetrosaisoN ,N'rILLp ft C CO M N E N D A T IO N UtO UT E TO PR O Js;C T C NL.t N C C h t N C. 2 5. P'IC L D 0 8:.P0 $ t710 ** FIL huLT S iiele recer.rnends use as is. During the oeriod between the two passing user's tests of S.0-75 and 10-23-75, the field experienced no unusual control problens or fail-ing.ancrete strenoth tests. Attached for Project Encincerino's review are conics of t;.; passina flyash user's tests of 8-23-75 and 10-30-75. M% w iLil e _ m;1 i 22 L .o ih C C N SNG DISPO MTIO N 2. E NG IN E E se6NG OtS ADG4 TION H E $ubT$. ngi;Jering concurs with the Field Reconmandation to "use as is" hased on the foll-

cmn, The purpose of the ponsolan uscr'c test is to naintain quality end to pro-vidn :. roper control of the pozzolcn as a concrete adnixture.

It is one of several "in cocess" tests that are perferned during the course of construction to naintain cen r71 of tha structural concente.. While we concur that the frecuen y of the v ~5

O"'.."*****04" 2 4.13 f, :.j a N CH ANGC st CGulRED 2 4. R LJ C CT&D M AT C RI A L LIS/ut. TION

27. OcyCCPT e fycr,kp '

e e "C'/ 9-f* -Q. i s.'f/ s' O.c O vcs.CcATvACnCo. -d -- - .Euamag ec e me.eee n e /,,,g / o pe A w ; '. HCV.. - DCN a sv Omeat e es.see Ctwa g ,g , T C., NC V. ADD. 5F _m .__..w__ -.c-. u_, y. ... ~ u _w S Oebs 1 Whin copy . C r.C Nt or W C-G 3-4 Can.uy.% av -

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_ PCAE Ccide waJ Cspy _ OC O 4 9 .A

p _ _.._.,___ _ ___.,_NONCON FORM ANC E R EPO RT (CONT'D) ,u. c_?mo,2__ ..,, c.,,.o. _3 7 6 (E'.ock 19 continued) to 2.100 accumulative tons was ornitted. Ncnconformar.cc noted durinc routine review _tl irjash. log. "Q"lisdo5 Cicek 22 continued:. 2.l.05_and_1.201._ No holdla;;s applicd_ nozzolan user's tests did not rect - cpecification requircrcuts, the fact,that for the 2700 tens of f3yanJt.Ael_ircred to date,_28 user's tests have hean perfor provides partial prcof that the pozzolan batch is acceptable._ _ pec'_ sci _th acecAtable resul t's, -Froject En-l.ieering has determined that the properticc of the final concrete product could be significantly affected by variations in the physical cud chemical properties of the , which poccolan used, are air content and cor.prensive strength. Although variations in pos:olan prop-s crties may not have been detected by the testing frequency used, any effect of the pc: zolan on air content and strength would be dutccted by testinr, air content and stren; th samples taken at the batch plant. Both of these samples are taken at a naxieur frequency of 100 cubic yards or approximately 5 tons of pozzolan for class I structurcs Because of the foregoing, and the fact have been acceptable, Project Engineering has deterni.ed thatthat air content and compress results the pozzolan user's tests to date adequately represent the pozzolan used and that "used as is." the test results and pozzolan can be /V i - ~ ~ ~ $1_ sf)p nb- ....___.l.- .- J - t- /[' ~ ' - y/.W ; '_T L _' _ ~_ l_O.. 4.ih_4bh m._w

== s t e s s-2 ..a 7-2. .- ~ - - - - ' - - - - ~ ~ - - - ' - -- '~s. - ' " = ' ^ ~ =r--=== ~~~~ ~ WM* Cony - Orlfriator 3Q~'f Can tfCopy hel.s E n poser e Pink CCDy _ POAE Cc.idenroe Cory _ GC / 1 o ( O,/ M ?,', a a f~ ,/ (! I

L- ' r.1 is t yp J L st t.%b ' 2. L*b L L L Ly G G L L L) ALL*)'s;Il.L1 b.l I $ l--... HOBOKEN. N. J. ' 07030 ^ p TEl CPHONE: 201.702.2100 DEC 2 21975. A. r ex i Ug[ ;,s'.jl i i l-(kt e X "~ Q U A LITY' C O N TROL cliennbn@MLf/ REPORT BECHTEtg J.,0 '7220' _{ ft,4 L echtei Power Corporation vaunua Post Office Box' 2167 ~ . // NUMBER N- '~ Midland,' Michigan 48640 35692 ' = .,y D_ (Relas et this a6.7J r) Report No. 83-Sub'au Chemical / Analysis and Physical Testing of Fly. Ash taken at J 2157.54 tons Usage Supplement !!o. 1 coject: Job 7220 Midland Project-Decem.ber 15, 1975 Units 1 and 2 .. f Subcontract 7220-C-203 Physical'Results of Fly Ash Testing ' Sampling Data . v,, 7 _ Sample Identity: ~ 4'- l Michigan Ash Sales Fly Ash - Sampled at thc vs u.* g Batch Plant at 2157.54 tons usage fecm

,j RC 07*"*O F l,e,,

truck 82A and B~. .e_r9ce @L / Dates Sampled: October 23, 1975 A rrocr t.. 'C L :p y Sampled By: - (h. United States Testing Company Persor.nel El'1:CT ,13,17f () Dates Tested: October 30, 1975 thru iovember 25, 1975 necu. at the Hoboken tiew Jersey Laboratories 'act.n t cc ~ 3 noc, U,:. (' V.1;:: - . Test Data and_Results 4 4_ECEIV?t:C = 'p; Physical. Testing SppI6fdGiN~~ ^ ..F Specimen Results RequiD*ercentsht;o i

t. r.:.e DATE

. ~. - ]!.h :, Pozzolanic' Activity-'Index

c. %.

with Portland Cement at 28 Days ' f.C ASTM-C109-70T 6: I, 88.8 %-

85. ] % of Control,M i r.

.;4.'.

~:. . Qg( t. -Increase in' Drying Shrinkage 'a t 28 Days ~ {.f ASTM-C157-69T-. 0.00 % 0.0LS. IDx. r,7... ??c. '- iReactivity withCement Alkalies M. Reduction of Mortar Expansion at 14 Days ASTM-C}41-69' S1 % 4 ~ u._. i - r( ff 2;e y \\ United Jt::c: Tes:ing Corap:ny, Inc. s,: - *) - {} .,( p../.9.m %f' Cari' Jacobson ,5.u - .41F Tee $ #4 4 se t tas teeast a tt % t 4191 t r 49 -as. e daer a*,f. sr.s* p/.M/IP .* TT F st 3

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' t !.; G cat /.: Crv,tstMGles A. Atta. P40 7 f u t)E U*at t) Upsut H A ray n:I *.;u M :a l*A re c t;'E t re A O v tit Y 411 45 C T A I s* 3 T I. '. T!?2 G co a.4,*A p. f. ..<& i n 164 6; r.r til;H A t. P UllLIC.

I modug Conipuny, in s Cl IEf47-u 3 Ucchtel Power Cor. a t ion .!!idland, Michigan <;8640 flumber 35692 Report flo. 83 Supplement ilo. - December 15197! g Physical Resu1. Fly Ash Tes ting ( i i E. r REMARKS: al the pr c sp i ~ ca t. ion n9 r qu reci by ASTM-C618-72 y. 5 0 1 0 d d s

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2. Mr. J.F. Ilewgen cc:

1. MR. T.C. Cooke 4

2.-Mr. B. Waters I e i q, f i .' : s - l lRi, s n: ' 'c:,' .y 4 l 'I. e 49 - ,%6 = (Lli"I p, L-Page 2 k

s., u n. s, L u t w.a 16:s t 111g Lvilipui t y, li ll's a,, > il. %. HOBOKEN, N. J. 07030 8M, wh .q-E TCLCPHONE: 20s.792.2400 i - h O.. m$$Iw \\lg:d't- @' W / q- - REPORT o y .uienu Bechtel Power Corporation

,c Post Office Box 2167 NUMDER i,.'

Midland,Ilichigan 48640 35692 o s. (iefse io she a ad v) Report lio. 83 Suyeca Chemical Analysis, and Physical Testing of Fly Ash taken at 2157.54 tons Usage tiove:rber 26, 1975 PROJECT: Job 7220 Midland Project Units 1 and 2 '~ Subcontract 7220-C-203 . Supling Data Sample Identity: flichigan Ash Sales Fly Ash - Sampled at the .4 'V'

Batch Plant at 2157.54 tons usage fron truck 82A and B.

Dates Sampled: October 23, 1975 San. pled By: United States Testing Conpany Personnel Dates Tested: October 30, 1975 thru I:ovember 25, 1975 at the !!choken fleu Jersey Lal; oratories. M ~ Test Data and Results y.'. t. Chemical Analysis and Physical Testing of Fly Ash in accordance with ASTM-C618-72 l< ' and the project specifications. pp A. Chemical Analysis +:

q. -

Specimen Resul ts Specification Recuirements .J Y .SiO2 + Al 02 3 + Fe20 a: 3 94.1% 70.0% Min. I/ .M 0 9 ' {. 1.8% '. ~ ~ ' , 503 0.5% 5.0% Max.' .s. s-l,' ' Mositure Content 0.1% 3.0% Max. ' - 1.oss on Ignition

3. 0.t 12.0% Max.'

Available Alkalies 0.1%' l.5% Max. ' as fia20 c w 1 os 2 United States Testing Company, Inc. b"O h)j,'[\\i C'N/h %/ t J e.a 1.a.a.m vr e o. 3..., a. s, 4., e.>. t, e.c s s.. i.s r n, t.. a u n c u e T o w

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e CUENT:. Unituu bit.te: " bechtel Power Corp ^ tion Ostint) doinpany, Inc. Midland, Michigan.8640 tiurnber 35692 Physical Tes tin 9 Report !!o. 83 B. flovember 26, 1075 S ecimen Results ( l Fineness, air Spec. Req. permeability 6669 ca.2/ctd 6500 cm2 3 . i.1 : - ASTM-C204-72 fc;a, Min. - ,4..- Amount Retained on the flo. 325 Sieve 11.1% 20% itax. ASTM-C430-71 Multiple Factof 33.3% 150.04, thx. ' Pozzolanic Activity n.5 Index

with lime at 7 Days ASTM-C595-2 1169 psi 600 psi, Min.

!!ater Requirements ASTM-C109-70T 92.6% 105.0% o f control, Max. ' Uniformity Requirements Specific Surface - 7.0' 15% Ma x. variation i a / Specific Gravity + 4.3% uantity of Air 53 Max. variation .n b, Entraining Admixture + 4.8% Ti'~~~~~~ ~E 20~. Max. variation - Soundness, Autoclave o Expansion 0.0 h @ 07220 {.1 0.5% Max.- ASTM-C151-71 p- /. (*gcg ir - y-n,ay-. 4 Specific Gravity ^ I~ Ii ASTM-C188-72 2. 4,5 j-civI1. P L LJ ~ ' ~ a.rcT* l ~~ rieu:c C'.'".. ' MEcit. DEC 011975 ..,t gous --OUA!.1YY COMTROL 1Nh h'-w. Vi tah. 2' p. . Remarks: m I. DECHT4 103 7220 _ j.- j"__ h rea __L l!!) The rerainder of the results shall be repo I L 7t'rd25~t3Ii:E dit is completed. C3 YES O!!O ~

DATE

' CC: 2. Mr. J. F. Tiengen 1 ~'Mr. T.C. Coote [fM - y 2. Mr. B. Waters //5/I I Pac 2 \\ _./ ' t'49 M hq _ SWM b \\ 8

0

y tsaut vLattua 1 Ch t t tijj L ULLl{>s**D s31100 s'[ s H C DO KI~N, N. J. 070',',0 4z.5.g,,,q . eg Tctce sone 20s.702 2400 (%<'p;,c.k, .zy%:' RCPORT y ient: Cechtel Po,ter Corpora tion Post Office Box 2167 ( Midland, Michigan 43540 NLn.m En i 3569 e t.. o 0u..) SuNui: fiepart l'o. 77 Users Samples representing 57, 501 thru 60,000 c o saq)les at 53,802 yard 3. llove:tber 12, 1976 OJECT: Job 7720 Midland Project Subcontract 7220-C-208 Sal.p_1 ig Da ta Sample Identity: Fine Agrirogate - ilubscher & Sons 3/4" and 1 1 llatch Plant 1.'ater - Jobsite Smple Ice Water - Grand Rapids Ice Ccupany Fly Ash - Mir.higan Fly Ash Sales 'to. Trailer 83 and 70 A & B Taken at 1998.64 Tons Usage Dates Sampled: August 23, 1975 Sampled By: ,p. United States Testing Personnel .4 Dates Tes ted:

- J Sep ten.ber 15, 1975 thru October 14, 1975 at the Hoboken New Jersey Laboratories I.

Chemical Analysis an.1 Physical Testing of Fly Ash in accordance with ASTH-C613-72 c, A. Che.nical Aialysis , /..;. Sjecimen Results'

.q'd: '. '

, S i O2 + Al 02 3 + Fego3 Snec Rea. 94.4%

x. ~

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... _ _ _ _. _. _. _. _ _ _ _ _. _ _. ~ _ _ _ _ - - - _ _ _ _ _ _ - _ _ _ _ _ _ _ _ _ _ _. -........... - - - -. 4 CUENI: beatel l'ouer Cor;esition Midland, Michigan 20 Number l 35690 Report ilo. 77 e i Supplement I!o 1 Ilovember 12, lh

l " *, # "

Physical Testing I } Specinen Resu1ts Spec. R m Fineness, Air Penmability 6682 cm2/aa3 Y, ASIM-C204-72' 6500 ca2 c:a3 Min. - / i i Anount Retained on the 10.7% 110. 325 Sieve 20%, Max. ' r,. ASTM-C430-71 Multiple Factor 18.22 s 150.0%, Max. ' D ~Aalanic Activity Index with Port. land A Cement at 28 days 85.35 ASTM-C109-70T 85.0'; of control, Min.- i wi th lime at 7 Days ASTM-C595-72 828 psi E00 psi, Min. i j llater Requirements 96.9" ] AS1M-C103-70T 105.0% of control, flax. ' .I ' ^l-Uniformity Requirements L i Specific Surface .a. - 6.2% 152 Max. Variation e ' i Specific Gravity + 3. C 5 % Max. Variation ' 6( Qualit', >f Air Entraining M,. ;-. Admixture ASTM-C187-71 - 5.8% 203 Max. Variation ' i W '. : Increase of dryinq { f*.Y y shrinlage at 23 days

i: f/

ASTM-C157-69T gj.. 0.004 0.03% Max. Soundness, Autoclave . i.," Expansion ., 'J ASTM-CISl-71 - 0.03% A 053 Max. Reactivity with c.f L slag y 5 Cement Alkalics f,/[I'f/l 4 Reduction of Ibrtar 55% l ". '.. expansion at 14 days i 'F 1: M ASTM-C441-60 SpeCiIiC CraVity 2.43 ASTM-ClGS-72 page i. gy, l, < , ~ j ~1 -,,-=r--ve-wwg ...--w m. .w--r-,-,y.ymme-w-% -w-r--,.-,,y. ..ww...m-,,.. .w.m-w+. --w.w --

422,> HODOKEN, N. J.- 07030 s .m ,f6 TELEFHONCr. ::01792 2400 am ii.GRsq, Qj64 (v)l y{- $'[a REPORT Clienu . Ilochtel Power Corporation Post Office 20.x 216/ Q' llidland, Michigan 48640' NUMDER 35690 o.t.. a a.o Report flo. 77 Subicen Users Samples representing 57, 501 thru 60,00 Oct. 21, 1975 samples at 53, 002 yards. r s, .oject: Job 7720 Midland Project i Subcontract 7220-C-203 ,.c .c Samplino Data e(' i. Sample Identity: . Tine Aggregate - Hubscher & Sons 3/4" and 1-1/2 Batch Plant Water - Jobsite Sample Ice Mater - Grand Rapids Ice Coupany A & B Taken atfly Ash - Michigan Fly Ash Sales No. Trailer 1938.64 Tons Usage.

g)

. Dates Samples: August 28, 1975 V. Sampled By: .t g United States Testing Ccmpany Personnel 5 QC 07220 4 Dates Tested: September 15, 1975 thru October 14, 1975 at the lioboken New Jersey 1.aboratories I. QC7. h \\P? b 1 ' F,. PrccE ij ] c_Iv1L ~-P F.trcT. ~ y pipit:0 .'! E.Cl t.. \\ +_'. iWCLDI!:C l \\ i-. C 4-.P r' "_ l!EC *ElV v: l s 7 L 4,P OCT 281975 'om tom,k 7 Q U A I. l T Y C NYROL DATg C 'lES Q::0

..y DECliTEL JO 7220 i\\h

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70. 0:' Min.

0 109 1.6% 50 0.7% S.0% Max. 3 ioisture Content-1.4 % 3.0% tiax. .oss of Ignition 1.7% 12.0% Max. Ivailable Alkalies '0.3% 1.5% Max. as Ha2 0 3. ysical -.Tes ting / f Finess, air permeability J ASTM-C204-12. ' 6682cm /cm3 2 2 3 6500 cm fem P.i n.

s. g,-.

Anount retained on the tio. 325 Sieve ASTH-C430-71 10.7% 20.0% Max. Multiple Facter 18.2% 150.0% liax. ,,",, Pozzolanic activity index J,with Portland "if Cement at 28 days ASTM-C109-70T 85.3% 85.04 of control, Min. Ua ter Pequirements. ASTM-C109-7GT 96.9% jnyg 105.0% of control,-;%rr,p- . Uniformity Requirements ' Specific Surface -6.2 15% f.ax Variation Specif ' Gravity +3.4 52 Max Variation i ~2 4 m. y:.g.,~ \\ v '- b .pl u ('l \\

,. / .. / 19 /--? > n:LfM m ~ ~ NONC :NFORMANCE REPORT N _' " * ".--.f*[, - --- -- - - s 2 - # U--- l * "'" "'Lli ,.,_.m..~.__,.___..~- 2 ..~. 4 . -,2 apec. ,

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. n eu o, c7 ~ O. P ,~ - .u---. I u .u,-c 0 C, %m. a.u,: or..i.0,. w Ncu.NLNc. m 7' :.c ~'QO 6 7220 N , u v1.e,.% R 5.d-t N -l' 'a u T%. OTIC e r'.O N @0Tib. t is 'OCaT a~ 2%" 4 L//2[~'C rY d. M" yt ' "~ ~~ PC ^ l h o Tc.'~a h '0 _ con witv ce=entscale 3atch Plant i #[/ 9 MR @41c2N ! ' u "N $

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I 2. x a 6. NE PL A C E MEN T SE NI AL NO. k,"d a'.',,'.,ff._ O,t/ [* h[ b IN/A C-230-2-ll4 Rev. O_ N/A Co m R.C T o niLoc 4 TiO N v.,c s., .'d. cou = C c V"* a " ""- " -9f .....ML C_h_e m.i_o. ns .sInc. b 'idland Fichi.cgan- -.. .'T c E) Jo;+,,r A --e._ -= - -- -a.- l q P ~m Subcontractor .............o.. 1s hmi rsNG 8NhTRUCT EON S kOJT E TO F 5E LD ENGtNCL N8NG O aou'c to M a' ca'a'su c a visaa

19. NO NCO N F ON MsNG C O N Q g T IO N.

I S.p_ecification C-230 Rev. 6 Section 9.2.3 requires the batch plant to be certified in ,_arn rdance with the standards established by the RRMCA. The SRMCA checklist requires in section 2.1.2, " Each _Acalp_shall.,he._ accurate,yithin + 0.20_ percent of scale cayacity throunhout the range of ucc." Contrary to the _2.bove,__on_4--22--16 _dutirtg_ro_utine scale checks,_the cceent scale (6000 lb. capacity) was shock loaded causing 4 _cJ3mtic results durinn the calibration. The Michigan Department of Agriculture "condc2tcd for repair" the above _1crin. Continued on Page 2 2d [ LO ussro ss T SON tC Lf} RE COMM E N D AT *ON/NO UT L TO PHO,C CT C N Gih CE H thG 21 FtLLO Da&POJ4TsON NESULTS: '~ s nr:_arnin was_ shock loaded _and_thcIcforc_dnO!ged during_ calibration on 4-22-76. Th. _ incident _N'M witncased by n.fonhnr nf tha (htn l i ty_Contro1 ' fi e l d en g i n e e ri ng_s tn f f ind Accumented-on-the-attached-fdeld-inspect-ion-report. The-scale-did-not-d evia te-f rc._the permissable tolann_eim_mt;11_nf ter it was ch_ock lon/.ed at_th = IP.00 W, hy3 1. W a C m, mM rnd .a n d tr 11hrnend nn 4- % 76 nnd fnund e n,Mhla - = cm' s

22. E N U r f.L C et s h (. CfbfOsaTION 23 C NGIN LEMINu DeSPO: s f fGN Re gyLT%

I Inc.3EEC_Ml_ dated 4-29-76 b k $f SS 0, y,A _ +. /74 Pe s%9f_/r/,~ i 24.15 D ' I IG N C H AN G C H L QU GH L U NO O vc2.:ccarr4CncQ ,a ,, = 3%.r.t4'v~-- "ft, DR A Wi> 3 RL V. DCN n rt_ se f

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~fF r s fh. TJONCONFORMANCE REPORT (CONT'D) .. re.c e_2_o rIJ[ ...=en no.__ld.3 _ 310ck_19__Centinued_- ,_m. _lhe scale was cent off site for repairs and tras returned and recalibrated on 4-26-76 and found to be withia _the_pe rni_ss ibic_to_l,qrcnces. The attached letter is a detailed description from Champion on he.7 this ccale 3 darnged during the calibration on 4-22-76. "Q" lict number is 1 203 Ito Hold Tags applied. W~lTfC: fsrk !.?,b 7 b'G ^ r nlock 20;_sas_betched_ fret 4--22--7ftthrough 4-26-76. An evaluation of previous cc,cnt veishes is not reguir i, since it_has.bcen determined _the_.ccrent._scalc.. van _dataged_during_cclibretica. El8.tgy. lfA.c'E. -i 28-7 6 1 --.4

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s. si CM DEscroPT ON E. ITEM LOC ATION

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15. NOUTING INST R U CT f 0 N 04

{ HO UT E TO FICLD EN GIN EERING [ MOUTC TO M AT ERI AL SUPERVftOP 15 ONCO N FQQP.* LNG COhOlT 4C N r S c_cifiera_t_i_qnJ220--C-lll_ Pay __9_Snetha_L2a3_ctxtechari,_"the_individ.tv reneir +W.2d 1 % A e located with i 1" of their theoretical clevation and circumferential location." Contrary to the above, the cable.round penetration theoretically _ located at Acicuth_338 is acturlly located at 137W0'. which ic 1 inch qst of the mcified tolerance range. Ucnconfor ance noted durintg-outino QC myiew. "R" Lict No. 1.109 One hold tan attached. 20 [ FICLD DISPOSITION [FIC LD M E COM M E ND ATION/RO UT C TO Pr?OJCCT ENGIN EE rtING

21. F t C LD O t? OSITIO M ft ES'J L T' :

Wn_ ar_is_._S.ubient__nenctnttion_is__:m_Alc_ctricpJ _grmnuLc_onnqc_t.Jom Varinnqe in 7 s penetration location does not affect the designed intent nor impoce any associated matn12Lchannem__ Dbricatinn_nannroccesb h N Y9.u 7 ~ 3 ~ 7 (- 9 Dn, e 3 u ( 2.1 C N'.i t N C E D IN G O l5 FO S IT iG f s 2 3. ENG IN EE HING DISF OStTIO N f CSULTS: Project Engineering has reviewed the actual location of the Subject Penetration Sleeve end has found it acccptable to " Uce As Ic". Variance in penetration location does not affect the design intent nor impose any associated materift1 changes. Y Y .-J1 4-t ?- 7f, i fhi ~ ra Mi%~ 'i-' 3 7 L O NO

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^ __(lLSpp_cificaticr, 7220-5201_ Rey _. 6,_paracrnph._S,2b,7 requinas DatrJep -_.?u-l Ltc "~ ' W % :accatation for Uuclear Piping Clas ,r__b tincludei_an nrtiltble for the 15 pipe cpools chovn on Ioad Sheets 11800 L 11631 (utta hs -3.-Cen trary-to - th e -abc - (2h _ Code __Datn._nm:nplate_for_Cp20LOHIC-51rS51620: __ _c_m_e_nt.s. A 2. 3)_. _ (2)-___Cc6 P ""neulate__for_Encol_2EEC-PP E61c)-6-Lis_::arked ac ch wa on2_ls_ inco nam.nlate sns originally starned with c 5 and was stamped over with an S by the i tat'" *-*

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$.2) } \\. NONCONFORMANCE REPORT (CONT'D) n.re b or_1 N ___m._-_ ... c,i,.o. 21:ck_19__ Continued - ,,a . ~ ntn c O p..= rav, c r rceu^, S.0 ~t__Ko D3ic Io. cation Elen Co:lte_nfe'd IblatJu e Ont b n _ _.Com mtion .'.C-ASO* 10-31-75 356 Cont _fl,_16' off va A31' 3.B lo.r$ 4.2 5s _L'h-599* 10-31-75 956 Coat _51_,__.79' off va3_1 631' 12._9 10.6 23 95 U 2D_512 11-13-75 h5 Cont #2, 95' off w.ll 610' 14.2 9.8 h.h 93 1, -5.13 11-13-75 28 Cent _j2,_1.00' off vnll 615' 13.J 9.8 3.7 93 T IIrilia 11-13-73___.316 cony._fl, 76' off m il 631' 32.6 10.6 2.c 100 Xh52h 11-17-15_25!_L h.55 line. co' 17. "A"line 610' 14.h c.8 h.6 97 .Dr525 11 7G 75 ' II. "'" lin0_(2_65_line @7' 15J 9.8 S.h 03 E:-526N 11__17-75 85' L "A" line (I 8.7 line 62h' 16.h 9.8 6.6 93 1 &52_7 11-17-73 28 Cont y2, 110' off vall 619' 14.7 98 h.9 97 % '90 11-18_-J5 965 Cont fl, 115 off vall 633' 13 9 9.8 h.1 95 ?O-El 11-18-75 31' E. h.55 line, 88' II. "A" line632' 14.3 9.8 h.5 98 a,5_32 11-18-75 108' N. "A" line c 7.8 line 628' 16.6 13 7 29 95 fD-599 11-18-75 87' II. "A" line @ 8.7 14 nc. 62h' lb.5 9.8 4.7 95 2D-59h 11-18-73 68' 77. "A" ling _C 8.7 line 62h' 16.9 13 7 3.2 99 i .lC-535._M1-28-75 25_/Chnt._ '!2,_90 '_c.fr w.11 60')' ~ 11. 8 9.8 5._o 93 1 I_Q)^ 5N 11-18-75 h5 Cent E2] 95' off vall 615' 15.1 9.S 5.3 94 T-'-~~ 11 -J8-75 93 cont _y2, 65' off wall 610' 1h 9 9.8 5.1 gg ?C-939 11-14-75 h5 _Cortl 2,_07' offarall 6_ls ' 11.9 9.8 2.1 07 0 .EnMn:

'Dtin nren revorl:ed and retc.?ted: Ece tect 170. IG-514

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I: \\ ^ Ekchtel Assocc .v as:Piofessionfil Corporatibrh. Inter-ofhcc Minvntnmluw &' n ~~ j. 'To J. F. !!cugen. o.a.. flay 13,1976 e ' sutsm Mid ad Plant - -- Unit s.1 6. 2 . Jo', /220 .r,en, P., L. Castleberry Air-Quenched Stainless Steel Piping File: 0274, 0345-w/a g, Engineering Copees to A Ann Arbor 'J. Connolly tf/a =L..Sokol

T. VanVick te/a s

It' has ccme to our attention that 23 AS!1C stainless r.tcel pipe spools which have been shipped to the site kere fabricated l using methods contrary to current revised specification require-tacn t s. The spools are listed on-the attached draft I:CR's. =Should you or the PFQCC feel an NCR(s) is appropriate to document the situat. ion and assure control of the spools, ~ Engineerint; request s that the attached drafts be used. 4 ~ Uc are actively pursuing this natter with Grinnell,n1though ue do not.as yet have a schedule for resolution. Should therc be any. questions, please contact Ilike Rothuell. / }j?~%...,. ; ;((. 6. <.,D ~ ~ (q -Ra-L.- Castleberry t3 ,H,, ! 9'2 07220- G JLH/1d &-'Q'i attachment S [f,QC,"/~h l/ ~ ^ EI.is'i t, f1 Ctt ? [/)iii',3ry ii'ijN' ~ / '!' )M T p;- i E ' EI,Ii 7<dh.~sCEl yIr c;j Y*-------.

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\\ \\s / \\ Bechtel Associa as ProfessionalCorporaling p inter-cihco Uciii.';itn:ltun ( J-L/ To J. F. Ucwgen a oaie Itay 13,1976 . sutnect. 111dland Plant - Units 16.2 p,hri, P.. L. Castleberry Job 7220 Air' Quenched Stainless Stect Piping Engineering 01 File: 0274, 0543 u/a copies to fa Ann. Arbor J. Connolly w/a L. Sokol T. VanVick u/a 7 '_ _e 7yg7 -lt has come to our attention that 23 ASME stainless r. teel pipe spools which have been shipped to the site ucre fabricated using methods contrary to current revised specification require-ments. The spools are listed on the attactied draf t l'CR's. Should you or the PFQCC feel an NCR(s) is appropriate to document the situation and assure control of the spools, Engineering requests that the attached drafts be used. ~ He are actively pursuing th'is matter with Grinnell,although

U uc do not as yet have a schedule for resolution.

Should there be any questions, please contact liike Rothwell. s - f-%-.,. ;.T((N: 0.- 7R 12r'astleberry c) d I [jQC07220 S JLH/ld ,QI.I (,_/, ~ attachment 1F [ M. P NIN I ^ .[Rvgi /))l fLW'

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C>4 NOi4CONFORMANCE REPORT m um y,. ._____--.w---_ _ _. R E PO NT E D S Y... _. _ _ _ _ _.l " ' $

2. Def A WING /PAst? NO.

i RE V.

7. PROJECT NO.

"' '$[ 92 7 '2 'C-273 !3 7223 / - ' !'DATE h 2 5. D atPOilTION CO N C U N NL NC E 2 f j " "' l -" p l ~

7. S TE M O t;3 C N IPTtO N

4. IT E M LO C A TI,ON 9 3,. V,A LID A T E D DV,;S,;'.E /.-f*C./ 4. -

'O e.:<'51 N 7 0 TCin'I uarS n,dX. l t.O. LlCV. N I D.ATC o. v... L-,,O ..? h

4. $E MI A L N UM SE R

9. ST A N T UP S YS TE M NO.

"/; U/A '3 5. pe E PL A CE M E N T P A ft T NO. I' R E V. 085 8' 'e. Le. mseas s e e..a L'/A / S, PUROH A 5E O M D E R NO. I 3 0. QC F #E LD INSPECTION PLAN NO, 5 6. RE PL A C EM E N T 5F MI AL NO. ,; f f, wf, p/ts

4. CO NT R AC TON / LOC A TsON

~ Q VES

17. SOU RCE St.ASME

.:/A

,'T E b No Cons truction t s. NOUTING f N57R UCTsON S. ROUTL TO FrELD ENGsNEERING O a ou'E To = AT E a'a'su'E= vi5oa ...NoNcON,o mNoCOND,T.ON. travin;,ru...;-C-d.- c , i n,, N rai ni cr:1 na.:s > cov.., In acctiens c', E and L s3m:s certain / s tem .r; ace %s oriented doun into t'ac uall haleu tSe constructial joint at riev. C.' +. Field Con ;truction c Nctc) t in.Mll these hars with standard hooks extendino uninto the slab a' eve. CDCo PT. has identifier.' this con;'ition as acncsaformina in tMir h'CR OF-l03. The identification of tSis condition as nonconforninq uas reiterated by CDCa's riml" to Gechtel's initial rascense to nF-100. All reference corresrondence is attac'acd. Four Hold Taos a elied. "? List i:o.1.233. 20. Q FIE LD O s$ POSIT ION OF8 ELD StE COMME NDATION/MOUTC TO PHOJECT L NGINE C$f 4NG

21. FIE LD DISPOS 4T ION H ESUL15 7 2. ENG a N E L % s N O s5POS4 T SON 23 E N C.f N L E RIN G D15 POSIT IO N N L 3U LT E:

d i

24. 85 DEstGN CH A NGC REQUsRED NO

24. R CJECTED M ATEHI AL DISPOblTION O==waa w.. *..=

2, QC ACCEPT ANCc VES. SEC ATT ACHEDt n.c... DR AWING REV. DCN

C C ** '"' C '

e... ...moavig.a ...C.** _SPE C... _. _ _ - - - - - - - - -R E V* "Do ...a sio s a-t -- ~ -- w WNte Copy - Orronator Q C 4 F2 Canary Copy - F.ofd E ncan.'er Pink Copy - POAE Goldenrod Copy - CC

. c. v. s ~ l l["lQ N - \\ s Bechtel Power Corporation x p Po.i ona. 3 0.,? in r

T,t)O r.Nu.w v,cm..i w.ao llay 10, 19 76 Const:mers Power Company P. O. Box 1963 111dland, liichigan 48640

. Attention: J. L. Corley Ref: CPCo !!CR !!o. Q F-100 Dated: 5/4/76 FQCL-0 70

Dear Mr. Corley:

'lhe Ilidland Construction Quality Control prograta for cont rolli forming itens in accordance with criteria XV of 10CFR30 ng noncen-scribed in FIM Procedure G-3. Appendix n is de-This procedure defines a nonconformance as : "A deficicney in characteristic, docuacntation or renders the quality of an item unacceptable or indeterminate" procedure which is not nonconforming; in accordance with the above d fi i i'Ih 1-2-;50 planhtory note pdinting out e n t ca. It is an c> - in the subsequent slab pour rat ~aer than inthe option was exercised of installing the bars other words, rather than down.it was decided the dowels would be install dthe wall placenents below. In with the tails up This e hand by the responsibic was a conscious decision made with knowledge before-f*ield engineer and concurred with by QC engineer as permitted by paragraph 3.3(a) of FIM Procedure G-1 which the responsible ' states in part: " Field engineers. . have the following responsibilttics: Interpretation and clarification of drawinr.s and project a. ifications through lialcon with discipline dealpn engineers " spec-The Project response to nennlatory Guide c1carly indicates 1.35 and associa ted URC ques tion led 'the rebar in ques t. ion.the propriety of the nanner in which ric1d Engineerin130.5 g hand-At my request P rocj e t En5;ineering has reviewed a ttuation and a;; tees that the field made a proper in terpretat ion cf the design this drawing. Further, to prevent future controversy, Project F.nnince ring has vised Drawing C-140 to note that discretion unicss otherwise noted. standard hooks may be oriented at re-the field's O O' ./. u

Uechlul PowerGolparation /3 ). 'u /\\ Q.q'(( yi' 0 \\, _I 2L. 1 f a \\.) lir. J. I.. Corley llay 10, 1976 Pago tio. 2 In view of the above, the conditions described in QF-100 d nonconforning condition and therefore the recommended corre ti o not constitute a issuing a llCR is not applicahic. .s c ve action of ing sessions covering the itaplementation of FI!! Proc dUc will continue to scheilule .just'as we have in the past. e ure G-3 as appropriate, Sincer.ly, / fJ. P. Connolly fFQCE JPC/jrmi [h cc: T. C. Cooke ('~'j bec: J. Newgen RichardsonQ/,d S/t 5 f 7I' C. R. licrmeston P. ?!artinez R. Castleb6rry W. IIolub D. Johnson l i

\\ ,httnel{.j(, hR$ ft 't unent A Itoutc 'D) 'lh ln C.,.S For f' ",.. 1 l't!Sou t hwo rth Silliou.. t t Fi1e l p i (, Jg, CQililin GSKeele) N. !!WSlager TCCooke \\, s 1anue Date _11 / icyf n JMilnadin Project-Mid l anet i F. 2 'rypo l ui, CCM1' men P0'.Yar rite ritie t:cn ', on lL r h t e ! _ G!,R ic hu d ::on , I;onconfomance ~ Qualir-Control 7.GTuc t:e r Report I!o QF-100 'Ihis Ironconfor: ance Report is Issued To: P. Cohnolfy. [, Prepared Byjh,hMAM/Eate f 9-/G J. llechtei PFQCE Appro red By' hELb, Date M /?/. Uritten Reply Requested'By Date S/; /:t-who is resuonsible for corrective cetion. Corrective Action Requested Dy Date 6/-//76 Ilonconfor=ance Description and Supporting Details: See Attachment A. ~ 3~Cbr r' ' \\ l ; Q \\ MAY 0 4 B76 i Q t! A ll T Y CONTROL BECli"t f( B 7220 b AEC Reportable sic u m u Ye= 0 ito Q see Procedure 9 (vor truclear rrosect - onie) Stop Work liecessary Yes O 't:o G see Procedure 16 - stop uork 1: 0 Reco== ended Corrective Action: '3 See Attachment A. .l

-o u

hQC07220g GMD.--k* A. PFQCCI Corrective Action Taken: C T V T. I. J EI'C8'- JEl!.1E3 . \\ --. l' t CC!!. '.;L1,911G m0C. )'iECI'IVIN_ Verification of Corrective Action Required Yes O i o O ~'h. g a; - - 1:ethod of Verification: g O us OW DATE i 1 lonconfomance Closure Confimed By ~ A / Date To be co=pleted at hine of closure by Consu=crs Power QA S

ervices, rage 1 of 2

i / e ir. /, Q<j i V_ll %7 4 File 16.3.6 Issue Date Itay 4,.1976 /N P roj ec t. Ifidlan.1 J 1. ? ,gj j File Title I;Cll':. on Ucchtel. Qitality Control '\\ ,i Attachment A to Report t!o Q -100 lionconformance Description and Supporting Details: Criterion XV 'of 1DCFit30(11)' states: ' tteasures shall be established to control materials, parts, or components which do not conforn to requirementr. in order ' to prevent their* inadvertent use or installation. These measures shall include, as appropriate, procedures for identification do'cumentation, tion, and notification to affected organi.zations. negregation, disposi-1;onconforming items shall be revicued and accepted, rejected, repaired, or reworked.in accordance with docu-mented procedures"s Contrary to these requirements, a nonconforming condition was noted in Block 12 of Activity / Task 2.60 on Field Inspection Plan C-231-2-858 with no nonconfomance report uritten. Furthermore,-this condition was not " reviewed and. accepted in accordance with documented procedures". Recommended Corrective 6ction: ~ 1. Urite a nonconformance report to cover the nonconforming con'dition in the referenced inspection plan. -/'ip 2. Receive disposition f rom Project Engine ~cring including engineering rationale for use as is if that is the disposition received. Review all completed Fic1d Inspection Plans for exceptions which have not 3. result.cd in I;CR's and, if any are found, proceed as in items #1 and //2 above. 4. Instruct all QCE's in the requirements of Criterion XV and the necessity of following it. (- / + Page 2 of 2

NOR S_ML_J 3 s f(f -, Allismile!S i ll f t 4 (;0mpa!y Midland Project: P.o.Dow 19G1. Midland. fAschtsan 48640. Area (. orts 511 G31-0351 May 17, 1976 lir. J. P. Connolly Bechtel Power Corp. P.O. Bo:< 2167 Midland, MI.48640 MIDLAND PROJECT - MCR OF-iOO File: l'6.3.6 Serial: 52FQA76 Contrary to your letter FQCL-070 dated May 10, 1976, the condition noted in block 12 of Activity / Task 2.60 in Field Inspection Plan C-231-2-858 does represent a nonconforming condition in that the drawings were not followed. Also while the Field Engineer does have the authority to interpret or clarify drawings, he does not have the authorit,y to change them. It should be noted that Webster's New Collegiate Dictionary, copyright 1973, defines interpret as "to explain or deter-mine the meani'q of" and defines clarify as "to make clear; to free of confution; ^- to make understandable". What was done by the Field Engineer in this case itd i not meet the definition of either clarify or interpret. It should be noted, how-that with the change you reference which was made by Project Engineering

ever, to drawing C-140, he vould now be allowed to make such a decision within the f rame-work of FIM Procedure G-1.

While we are not saying that the h <>k bars in question could not have been turned, u@l re saying that the manner in which you proceeded with respect to them did @ 07M0v1TT ate criterion xv of 10CFR50, Appendix B. "" crefore, our position on correc-ti$ action remains unchanged. i 1FQCl; l' I'/g' e n w ffici 11y stated your position on this NCR and we have, by this e }h. ITQCih gg h j, 0,. rej ec ted i t. We feel it is now time to get on with the corrective action ct tl 'itied in our NCR. It appears that you still have sufficient time to implement p.i r.CL c1 1 recommended corrective action. Ilowever, if you do not, please let us know IPI P l tit;

[ggg, Ei %at we may grant you a time extension if warranted.

ill51'C !"LO,C. \\m.'nl'tCC F.I.g 7 Ipy/ / '4 1,p97. Corley 'hYESQ110il.ty Assurar Superintendent DATES 2'C/d "*'\\/ CC" TCCooke " ' ~ ' kI e% GSteeley e llWSlager f,hW l 71976 ITSouthworth GLRichardson Q U A 1.1 T J ; M 7270 C 0 H T 1: o g, 7.GTucker DEClH. stanAsure_.)?.

2/ /03 ['. ,..c ( #

QUAL.lTY # "URANCE DISCREPANCY REPORTI,'

4. ISSUE DATE 5.-l1-76

1. PROJECT / DEPT./ CONTRACTOR

2. POINT OF ORIGIN V

@ FIELD

5. GAD PREPARED BY:

Miainra unita 1

7. ?

O OFFICE G. Ili ch a rd.~ o n

3. WORK PLAN DATE

7. CHECKLISTITEM C. WHE:1E FOUND 18

9. Ol"> CUSSED WITH v

'- (p' il / A M/A n. c Dar nrA (t'ro 'd

10. CONTROLLING DOCUMENT. SECTION, PARAGRAPH, ETC.

? Snac. 722n-M-201 Pav. 5 (P.O. 7??O-M-10da ACl

i. ~1

11. QUOTATION ev-.

1. naranraph 6.2.2a, "All naterials shall be marked with the information renuired bv t,.. the anolicable manufacturina specification, and the fluclea~r Power Plant Corconents gj,. 'kh.' Code, paragrach IlB-2150. 1

p

12. DISCREPANCY DESCRIPTION Contrary to the above Dechtel flCR's 263, 278, 418 identify code data name plates

'.w. ' v.a incorrectly marked with a "5" instead of an "S" and Bechtel flCR's 304 and 308 .N.i identify verification reports witfi a 5 instead of an S. n:. >.. W. p: ,.', y fiOTE: f' 93. All of these flCR's except tio. 418 were identified to C. Buhl in W. Holubs - li.i.,h > letter dated 4/15/76. . ' t[/ yj

13. RECOMMENDED CORRECTIVE ACTION En 1.

Identifv this.recurrino nroblen to ITT Grinnell and assure affective enernction t.rg.. 'q[i. action hv their nenani7ation.

9..

4. M;-

2. Based on this findinc and the probleats identified by U. Holehs Tottar tn c_ an51 t '.g. '

14. SCHEOULED COMPLETION

15. RESPONSIBILITY FOR CORRECTIVE ACTION

. J. DATE -6 /4 76 (Continued page 2) Dottaror

N

16. CORRECTIVE ACTION TAKEN l.w

?.c;. - i

17. DATE COMPLETED

.18. SUBMi1TED BY RESPONSIBLE AUTHORITY %Y.

19. CORRECTIVE ACTION VERIFIED BY OAE

,. r,

20. DALE-

'l,Ij,@ '. AAO-86 9/17/74 O e v s },,...,.,.. - - - -

' g"J/' ^ # N ~~ 3, OAD ID5flT.tJO. p J. n 103 . ' g *, , ' Q U A l.lT Y. JURANCE DISCREPANCY REPORT \\*.

4. ISSUE DATE

1. P110 JECT / DEPT /CCNTRACTOR S 13-76

2. POINT OF ORIGiti

[ II.;'" f41diand' Uilits 1 & 2 @ FIELO

5. GAD PREPARED BY:

O OFFICE e o.' WORK PLAN DATE

7. CHECKLISTI TEM U. WHERE FOUND r H & rdson y'l.e,.

0. DISCUSSED WITH

.,l,j;.?; ' fl/A fl/A Q.C. Records (flCR's)

10. CONTROLLING DOCUI.1ENT SECTION, PARAGRAPH, ETC.

S p'e C. 7220-t4-201 Rev. 5 (P.O. 7220-fi-104A-AC) 'i.,. f i .]

11. OUOTATION

..M 3 j

: Tt.

J',

;)

12. DISCREPANCY DESCRIPTION Y

!w< 3.:, - 3

. v. -

.:rMl W N,w::- Kf ::i. .u.- .il i ' t .i. : ? ,:Q. !; q t; @,e,il'

13. RECOf.*f.1ENOED COARECTIVE ACTION p, t.L). -

dated 4/15/70 y - provides necessary trainino for the resnonsihin Rechtal ehnn y4..(.v-T ~ r..r gy ' /.}.:. to preclude or reduce the nrobsility of racm rnnea 3. ~ their coordination with othar sitos whan similm nrnhinForward this 1,t y ' h'. *

or p,9 4 -

14. SCHEDULED COMPLETION

<m., hn 8 DATE

15. RESPONSIBILITY FOR CORRECTIVE ACTION n.c.~<,-

4 E,' *,[ 1G. CORRECTIVE ACTION TAKiiN " ).. 4.*;. - )

17. DATE CdMPLETED

10. SUBMITTED UY HESPONSIBLE AU THORITY w,,

19. CORRECTIVE ACTION VERIFIED BY OAE

,,0

20. DATE

-e T;';ilr . AAO-06 9/17/74 w. -.m.

y,........w. ~ 1 i QUAL.lTY A.. JRANCE DISCREPANCY REPORT 101 i

4. ISSUE DATE 7s 5-10-76

(.-)

1. PROJdCT/ DEPT./ CONTRACTOR

2. POINT OF ORIGitJ O FIELD

5. GAD PREPARED BY:

~ .: \\ I. Midland 1 & 2 @ OFFICE G. A. 'n'aldrop G. WORK PLAN DATE

7. CHECKL'3T ITEM C. WHliRE FOUND D. DISCUSSED WITH g.o.4..

j,$'! U/A N/A Docu :ent Control T. J. Behres

10. CONTROLLING DOCUMENT.SECilON, PARAGRAPH, ETC.

FPG-8, Rev. 1 and FPG-1, Rev. 4 i 11.- QUOTATION 1. FPG-8, Page 4, first paragraph: "The originator or author of inter-V v,-ninar envrn-nnaanaa w t etsta 4 tha "subiect" that the letter is cuality telated." d. 9. FM 8. Pve h. sechnd nqrem-anh: " Letters renerated between Bechtel nersonnel vithin the project which are not quality related do not require registration in the iflp corraswondence loc. Such letters shall nass uncontrolled within the system." 5.' K1 .;'? 3 FPG-8, Page 8, Step 16: " Typing Pool, Insure that reference to original . l; corresnondence is contained in letter." 4. FPG-1, Pa6e 1, paragraph 1: "This procedure establishes the cethods and controls-for drnfting... field procedures.

)

12. DISCREPANCY DESCRIPTION 1.

This is not actual practice on the jobsite. (Examples: j[m y'm'-p 7 s L 7_5_7( unn? %S re h 15 % n.,a nnne 1103 ne h-po-76. ) J \\ , V't i'.y' y*- 4 2. This is not actual practice on the jobsite. All correspondence is controlled. ,y .;.[4 This responsibility should be included in step 15 as it is the respansibility of 3 tha "n t4 cn nmirnce'.'. etr., tW '. 7 4. FPG-8 "Y.. ofFPC-8.h Rev. 1, does not conform to the requirements of FPG-1. (See Index page .c hh, 5'

13. t!ECOMMENDED CORRECTIVE ACTION ft:4 Reviev Pield Procedure FPG-8.

Bring the procedure requirenents and actual practice r, 9....'.. . '. '. ~. into arreer.ent. '.k,b. Revise FPG-8 to conform to pro;1ect requirenents for instruction for .' G ' construction usage, r,Q:I+

14. SCHEDULED COMPLETION

15. RESPONSIBILITY FOR CORREC;lVE ACTION DATE 07/09/76 Pro.iect Superintendent

.}*,,2

16. CORRECTIVE ACTION TAKEN E

t'r r g ( )

17. DATE COMPLETED

10. SUBMITTED BY RESPONSIBLE AUTHOnlTY

%./

19. CORRECTIVE ACTION VERIFIED BY OAE

20. DATE

'j ~ ',j'h AAO-86. 9/17/74 ) i I

3. OAD ID Ell T. f.O.

,. y 7 104 .T ,00ALITY ASSL..ANCE DISCREPANCY REPORT

4. ISSUE DATE O

5-13-76 V

1. PROJECT / DEPT./ CON TRACTOR

2. POINT OF ORIGit!

5. OAO PREPARED BY:

O FIELD I ' Mfdla.nd 1. A 2-FICE c,A,y31gcop/p]

3. WORK PLAN DATE

- 7. CHECKLIST ITEM U.WHEREFOUND

9. DISCUSSED '.*itTH M/A N/A Document Control A. Boos

10. CONTROLLING DOCUMEfJT.SECTION, PARAGRAPH, ETC.

SF/P3P #h Rev. 1, Paragraphs 3.1 5 and h.1

11. QUOTATION gr/ psp #h Pnree rnnh' ~4.1.5-

"DmM" cr controls, inmted neriodically fmm desivn vill ha che. eked neninct the field inc to insure all drautn. s have bnen received bv'the ff. eld." SF/ PSP ilk Paragraph h.1:' "The DCN vill b'e. treated as drnving transrtittal covered by Section '4.1 and ~4.2 of this trocedure." k

12. OlSCREPANCY DESCRIPTION p

enn+vnvy in +hn nbnvn rivn ui n e r'nn em1 vor.1c+nre na n hof re. nvi n..nci en vanu4v a. t\\ ~

13. RECOMMENDED CORRECTIVE ACTION Implement the regttirec:ents of SF/ PSP gh.

14. SCHEDULED COMPLETION

15. RESPONSIBILITY FOR CORRECTIVE ACTION DATE 6-lh-76

.T. F. ITave cn

16. CORRECTIVE ACTION TAKEN b.

4 -q\\.

17. DATE COMPLETED; 18. StfBMITTED BY RESPONSIBLE AUTHORITY 1D. CORRECTIVE ACllON VEntflED BY OAE; 20. DATE
AAO-86 9/17/74 l

105 QUALITY AF RANCE DISCREPANCY REPORT

4. Issua DATE 5-21-To

( )

1. FROJECT/ DEI'T./ CONTRACTOR

2. PCINT OF ORIGitJ Dj FIELD

5. OAD PREPARED BW s

Miainnd 1 & 2 O OFFICE G. A. Waldrop 'Ly G. W'ORK PLAN DATE

7. CHECKLIST ITEt.1

8. WHERE FOUt D D. DISCUSSED VilTH A. Eoos N/A N/A Auxiliary Building J. P. Connolly

10. CONTROLLING DOCUt4ENT, SECTION, PAR AGRAPH, ETC.

Field Instruction F1W-1, Rev. O "Ecchtel Welder Guidelines"

11. QUGTATION PTV-1 Pane h. Iten 8.

"DO NOT veld or burn unless all exeosed mterini is adequatelv urotected. Particular attention shall be urovided in the area 4 helov vour veld." I PTw1 D,ga 8. Tea, c. "g protect facility couinnent 'from enarks or slart by coverine ' I n-'vn-nvine it hat'nva nutting n-valM ner. " i r i.

12. DISCREPANCY DESCRIPTION Contrary to the foregoing, velding operations for pipe (3.

(_) hanger installation vere observed in-process in the Auxiliary Building above Decay wo w - ,,,m 1 ntevnhnener 1r-60A vith no trotective cover used to protect the n nnutp"ent h on smrks and slag. i !~

13. RECO.*4t4EtJDED CORRECTIVE ACTION See Attached Sheet -

14. SCHEDULED cot 4PLETION

15. RESPONSIBILITY FOR CORRECTIVE ACTION DATE June 4.1976 1 & 3: PFOCE 2: Project Sunerintendent 1G. CORRECTIVE ACTION TAKEN I

Ok)

17. DATE COTAPLETED

18. SUBralTTED BY RESPONSIBLE AUTHORITY 1D. COdRECTIVE ACTIOrl VERIFIED DY OAE

20. DATE

{ AAD-85 9/17/74 I

^ - es -3 .j QAD#105 .G. A'. Waldrop Block 813 1 QC - Inspect -1E-60A to deternine if dat:nge or contanination has. Ecurred. Docunent this inspection and initiate remedial action as required. 2. hoject Superintendent -. Reinstruct Field Personnel and Wciders 'in the requirements of the procedure.

3.. $ - Detemine why procedure vas not enforced by QC. Take appropriate training action to encure Q.C Engineers are faniliar with the required protective practicos.

J o / t.) -C

106 ~ OUALITY A' JRANCE DISCREPANCY REPORT

4. ISSus DATE lhy 21, 1976

1. PROJEC1] DEPT./CONTR ACTOR

2. POINT OF ORIGir2 Q FIELD

5. OAD PREPARED BY:

Midland 1 & 2 Job 7220 0 OrriCE

s. T. stojkov

6. WORK PLAN DATE

7. CHECKLIST ITEf.1

8. WHERE FOUND

9. DISCUSSED WITH 5/15/76 - 5/28/76 N/A Amciliary Building J. Miller

10. CONTROLLING DOCUMENT, SECTION, PARAGR APH, ETC.

FPG-16, R5v. O, Paragraphs 5 3 and 8.0

11. QUOTATION Pnrn 7mpk c;. *J cnyn in m -t?

"'Phe pe #cmance of the nnintenenea

nny 4v - a e n (o n M4*antad en tha F-In fod is the res;7ensibility of the M&S."

I' i Pn-n 7,7h A_n en y,- i n p n *t. "Te p da#4atorev occurs. the f."G shall ch%in technical a 4 'v~.+ 4 -n nna,mprn7vinto nnr'antiva tina l imit e f rom the t a ':'. " ? I

12. DISCREPANCY DESCRIPTION r

UCR 425 deceribes the nonconforming condition of the nitrogen purge pressures on Decay 3 on i k, ) Heat Renoval Heat Exchangers 1E-60A, lE-60B, 2E-60A and 2E-60b being out of specified rangeonnineoutoftenconsecutivedaysfrom5/10/76to5/20/76. A subsequent check on 5/21/76 showed the purge prescures still out of the specified range (belov 2 psig). .i.

13. HECOMMENDED CORRECTIVE ACTION See Attached Sheet

14. SCHEDULED COMPLETION

15. RESPONSIDILITY FOR CORRECTIVE ACTION DATE 6/11/7A Prciact Stmarintandent

16. CORRECTIVE ACTION T AKEN

? f% 3 )

17. D AT E CO.*.1PL F.T E D

10. SUSMITTED BY RESFONSIGLE AUTilORITY v,

i

19. CORRECTIVE ACTION VERIFIED BY OAE

20. DATE AAO-86 9/17/74 1

4 j

.-wa 4 '4s- -e.. j l QAD#106 i l'ay 21,1976 ' * - B.-T. Stojkov j. Block //13 k_ s . l. Determine the cause of the continued failure to' comply with i j ~ the Decay l Heat Rea: oval Heat Exhangers t:aintenance requirements as stated (on the F-10 form). t i l

2. ; Develop a plan of action to prevent the recurrence of the failure l

to co= ply with maintenance requirements for equipment not in the j; - storage program.- r l= } "i e 4 ~ .4 g ) 2 ~ l i ; i i s T 4. 1 3 +"a ++. em m. + =#w .rme-y- ,,,- sr v - -wr4 .,-O-'.

m-e Wg-g -a es "" oew, w - *

-w ,--,m,, -,-%-m -e, ,m

I-080 QUALITY ASSU' TNCE D!SCREPAt*CY REPORT l o- ~

4. Issus DATE

/ .s 2Lzu:1:

1. PROJECT /OEPT./ CON TRACTOR

2. PoltiT OF ORIGitj Q) FIELD

5. Om P.1EPARED BW Midland 1 L 2 - 07220 0 OFFICE C. Richardson

, G. YiORK PLAN DATE

7. CH ECKLIST ITEt.1

8. V/HEfiE FOUND

9. DISCUSSED VilTH 2/14-27/76

/A QC Records Arca J.

Connolly

10. CONTROLLING DOCUMEtJT, SECTION, PARAGRAPH, ETC.

FI!! C-6 Rev. 6; SF/ PSP #3 Rev. 4

11. QUOTATION C-6 Para. 2.5: "The Project Field Quality Control Engineer is responsible for prepar-ation and implementation of Field Inspection Plans."

SF/ PSP r!3 Para. 5.1; "The in-process quality control surveillance and quality veri-fication inspections and tests required to be perforced by QCE's shall be predeter rained and identified on the Master Inspection Plans.

12. DISCREPANCY DESCRIPTION t nn erwy en rhn nhn re Master Insneetten Plan 7220-C-2-1, " Post Tensionine Sheathine.

insts11ntions" was not used for insnection of the cheathine installation for y Containment No. 1 Elev. 6 32 ' 5" to 642 ' 7". This sheathing was enbedded in concrete-on 2/12/76 (P.cf: Placement C(642.58)a').

13. TIECOW.1 ENDED CORREC TiVE ACTIO.*J Based on the above and CPCo MCR No. OF-76 which identifien a sinuinr nroblen the following corrective action is reconmended:

Issue a Field Inspection Plan to cover the b b in cuestion and detert..ir.e 1. its

14. SCHEDULED COMPLEllON

15. RESPONSIBILITY FOR CORRECTIVE ACTION DATE 3/26/76 PFOCF.

10. CORRECTIVE ACTICN TAKEtJ See netached sheet.

{ )17. l>AT32 COMPti.TED 13.' SUBMITTED BY RIsrot.SISLE AUTHOR:TY u. > - i.. ..n _. <. c /- p;c m '. CORFiECTiVE ACTION VERIFif ' F 10 GAE " w '/ k J$a k ~ J~ Ao/? &

20. D A E n.

AA0-86 9/17/71 g~

o-cectite; rower Lorporatiori ? e ~ Block 1:o. '13 Continued. (j /f D A 8 8 h 1 acceptability. 2. ~ Determine the extent of this problem by review of use of Field Inspection Plans for the remainder of completed work on the Containments and in other This review should include cach discipline and can be on a sample areas. basis. Additional review may be necessary based on the results of the first sample. 3. Develope a system of issuance of FIP's that vill preclude (or reduce the l probability of) recurrence." ) l 5 e e + 4 G e I / ___m_.__ _.. -. _ _ _ _ _. _ _.'

..,.' w .. ~ Bechtel PowerCorporation ) Interoffice Memorandum 7' G.~L. Richardson Da April 6, 1976 saw Rer.ponse to QADR #80 F' '" J. P. Connolly QCFM-1021' of Quality Control Copes to At Midland, Michigan Job No. 07220 1. FIP C-2-1-14 was issued to doctutent the previously accomplished acceptable inspections at the subject locations. 2. A training class was conducted on April 2, 1976 on the importance of requesting and releasing FIP's for all "Q" listed work. ~ 3. An indepth review of previously accomplished "Q" listed work showed no work other than the two case sit 6d as being accomplished without a released FIP. 4. .All Quality Control Engineers have been instructed in Field In-spection Procedure G-6 and PSP SF/16 and given a list of all cur-rent MIP's defining there scope. b f gdbh J. P. Connolly PFQCE JPC/IIDF/jt:w 1 e M f b f W / v $024 (tM2) ---.-.u., .~_

h t o?, i Bechtel PowerCorporation ry (V 4 Interoffice Memorandum G. L. Richardson May 6, 1976 8A'C' Response to QADR #080 From J. P. Connolly QCFM-2001 of Quality Control Midland, Michigan y Job No. 07220 E. D.-Newman In response to our conversation this como supersedes Memo No. QCFM-1021 dated April 6,1976. 1. FIP C-2-1-14 was issued to document the previously acconplished acceptable inspections at the subject locations. 2. A training class was conducted on April 2,1976 on the importance of requesting and releasing Ficid Inspection Plans for all "Q" ,] listed work. 3. A review of previous 1 ad "0" listed work showed no work other than thebgsm: pgigM28Ye*Ing accomplished with-eg=5s2.t out a released Field Inspection Plan. 4. All Quality Control Engineers have been instructed in Field -Inspection Procedure G-6 and given a list of all current MIP's defining their scope, future additional training sessions iu accordance with the FIM G-6 and PSP G-6.1. UdC J. P. ConnolJy PFQCE JPC/jn:9 ,q film G'71976 (j CECHTEl. POWER CORP. 300 7220 pig s y 0094 (10-7 4 ~.. .m

e i OUALITY AS.,'%NCE DISCREPANCY REPORT OS3

c. Issus DATE

? 0t/25/76

1. PROJECT /DjiPT./CONTFIACTOR

2. POIN T OP ORIGlia S FIELD

. CAD.oR E MRED M !!1dland 1 and 2 O OFFICE

6. WORK PLAN DATE 3, 7, ge,jggy

7. CilECKLIST ITEM D. WHERE FOUND D. DISCUSSED WITH 03/13-26/76 N/A GC Hold Area

?.. !laray t: 9,,1 i e n

10. CONTROLL!tJG DOCUMEtJT, SECTION, PARAGRAPH, ETC.

Field Inspection Procedure G-3 Paragraphs 4.1.4 and 6.0

11. QUOTATION Pnta. 4.1.4:

Client nurMin ~d r,en a.,1 nn a en~%,-, n.M i n .,sn. noch al control at the jobsite shall be inspected in accordance with proiect resocasib ilitics cotablished by the Client and requirenents established by the supplier. A procedure to inplement these requirements shall be tiritten by the PFQCE and approved by the Chief Field Quality Control Engineer". Para. 6.0: " Segregated storage areas shall be established for separating noncon-forning. itens f rom conforning items."

12. DISCREPATJCY DESCRIPTIOtJ Client furnished valvas and pipe (purchased for Palisades Project) have been on the site for approximately 2 years, but have not yet been inspected in accordance trith Client requirements nor has an inspection procedure been tiritten.

Also, although not established as nonconforming, the material is being held in QC Hol.d areas tiith nonconforming material.

13. RECOMMENDED CORRECTIVE ACrlON 1.

Prepare and implement a procedure to cover inspection of Client furnish ed naterial. 2. Perforn insoection of Client furnished natarini noir on hand in QC Hold areas. 3. Disposition inspected naterial in accordance trich FIP G-3.

14. SCHEDULED COMPLETION

15. RESPONSIBILITY FOR CORRECTIVE ACTION DATE 05/14/76 PFOCE

16. CORRECTIVE ACTION TAKEt2 See Attached Sheet.

/ s t { }7 DATE COMPLETED

18. SUDMITTED 13Y RESPQNS!3LE AUTHORITY t /. ? / - /(.

'yi! /.,. 9 f, - L !.. j /,-c', (E 11 CODItECTIVE ACTION VERIFIED BY CAQwk-T% L c!s hu

20. DA*E AAO-06 9/17/74 d

+, _.

~,; B ;.tel PowerCorporation e O(/ t Block No.'16 Continued. QADR No. 083 SF/ PSP #3 Rev. 4', Job 7220 "1.0 SCOPE 'Ihe requirements for construction quality contained in the Field Inspection Manual and Quality Control Notices Manual shall be applied to 4 all "Q" listed materials and equipment. Application of these requirecents to other permanent or temporary plant materials and equipment shall be as directed by Bechtel Construction Management and Consumers Power Company." Client furnished valves and pipe (purchased for Palisades Project) were stored and controlled in the QC F.old Area until it could be decided whether this material was "Q" list or not. It has been decided that the pipe is non "Q". Field Engineering is taking inventory of this material and should be removed from the QC Hold Area in the near future. It has also been decided to return the valves to the Palisades Project. nem - .op. us F/2 r/,c, 9f!R 4 s v e y m,a,, # we, e-.s, --,-m+

~ , 4.,, ! ' j.hy OUAll fY ASSURANCE DISCREP.ANCY REPORT 4.1.;! oATE E ~ 5/5/76'

1. PROJECT / DEPT./CONTR ACTOil

2. POINT O.: ORIGl:1

5. GAD PaWARED FIELD tit'dland_.1_li _2 O OFFICE C. A. Waldro' e

G. WOHK PLAN DATE

7. CHECxLtST ITEM C. WiERE FOUNO D. DISCUS::ED '/!!T I

j ,1@ N]_A _ OC Files

11. D. Foster

10. CONTROLLit:G DOCUMENT. SECTION, PAR AGil A?H, ETC.

FIff Procedure C' 3 3 *.

11. OUOTATION FIP C-3 Para. 3.2, " Disposition, the action required to correct or resolve a 1

nonconformanCc". FIP C-3 App. B, Block 19, "... concise and complete description. t..t it n umb s FIP C-3, App. B, Block 22, " Repair: Enter the repa5.r'information/ instruction whit when accomplished, will make the-item acceptable." ns 3 ] .N,,

12. DISCREPANCY DESCRIPilOf1 During a QC hold point inspection of the coatings applied to liner.lplate C-lll-64 7

a rejectable defect in the liner plate metal was found NCR #409 was issued..% e' 1, '_j plate was not identified in Block 19 a.s required by C-3. The disposition address,t \\ the repair of the defect, but had no provision for replacemed't of the coating whic +' J; had to b'e recoved to accomplish the repair to the plate. Plate repairs'were signe

.~

] of f in Block 21 by-QC with the coating not restored. 'y

13. RECOMMENDED CORRECTIVE ACTION
7 1.

Revise NCR'to identify plate. 4 2. Issue additional NCR to cover renoved coating. 3. Review ali nonconformances issued against liner plate coatings' for similar-inc + i:

14. SCHEDULED COtAPLETIOiJ

15. RESPONSIBILITY FOR CORilECTIVE ACTidN dispositior p

DATE 5/28/76 PFQCE a9 1G. CORRECTIVE ACTION TAKEN l. fiCR NO3 has been revised to identify the plate. ?a ] it. 2- & 3. A record ' copy Dwo. FSK C-319 Rev. 6 has been added' to' the scope of ' liner plate' coating, FIP's identif)ing damaqed ' coating.

17. DATE COMPLETED

18. SI)GMITTED fly RESPOff31GLE AU THOillTY N - 2G - />..

' I i.. / ? ;' 2 f%. ' i ! I '.h t -th. j ~ = T

19. COf tRECTIVE ACTION VERIFIED DY OAE)'

20. D AT E.

/f:N/hp/ { {*, f ':' m i AAO-86 ')/17/ 74 .\\ %)

,.g.

,. :.1m.

p..- -1 ! "Y

C

'\\ }i H 090 (? i-2-2 ) c .c..... 9 = M.;,r..w.. ....,,J.R '7/74 7 ( gT. -]........., 3,,,,, Midiind 16 2 Construction []...... G. PJ.chardson ~ c.... o ,..., 1,,,.m o 25 ~)-.'> 1 12 US Testing I': cords B. Waters m,.m.........,,....,.,......,..c. US Testing QA Manual, Rev. 3, 03/31/74 ..,u... .2 Para. 5.1; " Procurement documents for naterials and equipment used to test safety related materials shall be reviewed "and 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 adequate quality materials and equipment is specified." e ~ }..... Contrary,to the above there are no records of review of the procurement documents for purchase of concrete cylinder capping compound _.. 'and concrete cylinder molds. NOTE: Both itens were tested for compliance to applicable ASTM Standards upon receipt. r 07$4k.. 6. e. Instruct US Testing to perform the required reviews on all future procurements and to document these reviews.

1.... m....,.......

'..rJ:..-.~in,...... e v.,..s.... 05/14/76

e. 3.. m........=,n.. :.~

- PFQCE US Testing has been formally instructed to review all future procurements documents End to document these reviews. This instruction was transmitted in letter form on April 22, 1976. g 4,.& w-

4.,

TWO .9 .s ,F 'y*.$ . mm.=u -. [,, *- t (7" ff O ~ s" W Y e- /f ___.t..$ .S/ ?]G__ V-

g1. * ^ .2...w r Njp: j- 'I QUAUTY AUDIT HN0iMG j....,5.1 " 3-t ' -" ,/ Lj l 3-25-76 ~ s-l '..=m.=.. ;rv..n..-

m.......

gg... Midland ' Spec ial Process Contrcg.,,... K. D. Un t.

w. o s......

11 .QC Vault-A. Boulden ... m............................... RT-XG-2 Para. 4.1d ' I;Q-A'l-ASME. III Div. 1 -Ex 10 ~ If the ucid reinforcement and/or backing strip is not.recoved, a shin of radiographically aim,ilar. material to the ucid metal shal]. be placed under the penetramcter. The shim thickne shall be selected so that the total thickness being radiographed under the penetrameter shal equal to the total weld thickness, including the baching strip if used and not removed. Ueld' 21 (C2), FSK-MPC-2-1, 4"0D, 0.237" Thickness, S/S, RT 11-18-74 M here is no shim under the penetrameter. t 1 l * \\vI,, l l 1 l l \\ 4.vr...... gr a-l l P.cradiograph uith a shim under the penetrame.ter. NOTE: The film ' ' density does meet Code requirenents uithout' the shim, also all other Code requirements, including acceptable veld. All NDE personnel performing I .and interpreting at this time,are no longer on job site. .m.. w. rd.r.=r ~~ %,rv.....,.. c... u..,,......,

=.W%a.--

Reradiographed to RT-XC-2 Rev. I requirements. Results reviewed and found to be - Ecceptable by ASNT Level II. Film and documentation subject to A.I. review and .f ~;cceptance. ,/ 6- . t;rt.;;.1.ni. w==:====9 ;T-Tif,2;;r.VJg.... "./.w b i" s'-3-76 .w ty /Rt4 e r- - % pT S gJ.<,.- q-- I=r y O m.- s L.

. /p ' *) 6.2 fl0N.uMUD!i Fm0li!0 n ......?.' 7 " 3- " t - ) 3-25-76 v:...... _ f i \\ / l -~- p' Special Procesu Con t rup.,,...r== g::::.--=..--- w a................... j K. D. a rd Midland 'l.......... 11- . QC Vatilt

A. liouldea

.,: 7. ca,...............,.............

RT-XC-2. Para. 3.3 Note: BQNt-ASME III, Div. 1 Ex 10__. Filn side pencerameters, when used, shall be' identified by a ' cad letter "F" u._least as hig'h. 1 at as the identification numbers placed adjacent to the penetranater. J F ~* Weld #2, FSK-M-21, 4.5"0D, 0.120" Thickness,S/S,RT 3-7-74. The lead letter "F" is on the penetrametec. !-m\\, ' '\\j i

",l*?!. n.......:.-

derudiograph with "F" adjacent to the pcactrameter. Note: The radiograph is acceptabic in all other Code requiremcuts including the vald. All MDE. personnel performing and interpreting at this time'are no longer on job site. w.i..... o50 if.""=.-- " - '7. T.".'*0 m............, -5/1/76 PFL!CE ..... m....~.,.... L'21d joint is inaccessable to reradiograph. IiCR No'. 416 issued. ,.m ( \\. i / v iiiih c g.T.. " % grnr.CC'.cn.;rtir.f.. - -^- ^ ^ - ....c.c [ f 3 ~2(.;. - ,. g.;c.,( (,l" fG(.& a...u.......,-V;T%d";"7;.. - "~" **"- - ". " - -"* = --- - l 1 tSj 'II a m. .= a.

D QUAUTY AUDli FiliDRIG . 5'.f

3-' ' -"

3-25-76

x;;....;mi.u.z - -

j...: =, - g.W ~.....= Midland apecial Process Contro) K. D. Ilard .... = 11 a QC Vault A. Bouldon _1 f-XG,j,.....,.... p..........., c,4.1c)l),4.4.ld),3.3b),. 3 Note: ' 1;Qldt-ASME III Div. 1 Ex.10 ,m.,. , para. ..m.... .2 Penetrameters shall be placed on the source side ~of the section being ct.amined and should be pla,ced so that'the place of the penetraceter is normal to the radiation beam. If the ucld reinforcement and/or backing strip is not removed, a shim of radiographically similar material to the weld metal shall be placed under'the penetrameter. Panetrameters shall comply uith the applicable Code, and Table I of the procedure. The l=d letter "F",is placed adjacent to tho' penetrameter. ... s !!cid 6., FSK-M-21, 12.75 OD, 0.375" Thickness,C/S-S/S,RT 3-7-74 1. 11rong penetrameter, should be a 110, not a 012. 2. The penetraneter'is not on a shim. '.i There is a 1 cad "F" on penetrameter.not adjacent too. The penetrameter is out of.the area of interest, not normal t'o the beam. I s ? 1...... c... R: radiography using a #10 penetrameter, placing the penetrameter gn a shim in the center of the radiograph. Note: The veld is acceptable and the penetrameter is cicar, but the penetrameter la outside the area of interest on the uc1d. All NDE personnel. performing and interpreting at this time are.no. longer on the jobsite. M..."":,a...-.m.=;; ~ ^ . a.;;;....,... - m M.e,.., ^. ^ ^"" 5/1/76 'PFOCE e...m............

1. Reradiographe.1 per RT-XG-2 Rev. 1 requirements. Results reviewed and found to be ac-ceptable by ASNT Level II,.

60 .V db-in 4 See Attached Sheet. ~ ~, m.n.:m. y n -7YT.. ~ ~ ~ ' w = =.=v.r wa 4.....r.n. f.w--FO.L f,'.m..u.3 - 76 5 t S = mr b d__ a

'Br htelPowerCorporation ( 'NI s.- Block 15 Continued. QAF 086 (13-1.11-1) 2. 100% audit review has been completed of all (20) remaining ASIE Section III. Radiographs audit review sheets are attached. Two additional radiographs were found to have discrepancies (FSK-M-47 W-1 and FSK-M-47 W-7) that required a rcradiograph' to co= ply with RT-XG-2. These are no longer classified as ASIE Section III welds, but have been reradiographed with the following results: W f' T* FSK-M-47 W Acceptable. p a. p b. FSK-M-47 W Could not obtain acceptability using original radiography technique. New technique was developed requiring a finer grain, slower speed film. This resulted in obtaining an acceptable quality radiographs that re-veals two rejectable areas in the field weld. NCR No. 417 was issued. 6 NOTE: These welds have been re-classified from Section III to C-Ill specification on Rev. 2 of FSK-M-47. [ t 3. On 4/20/76, a training session was presented by M&QS Level III ASNT representative V with all Bechtel jobsite Level II radiographic film interpreters and NDE Subcontractor Project Manager in attendance. The training session covered all jobsite NDE procedures and applicable code requirements, yg7A,fdC Tft h D / h V, 'N

Q-

.=. .,. ~

69' OW (I 'l-1.1-1 ) 4 IT, q v 03/15/76 f-( I - w_Is/A ~(/

,, =

,-g,,.,. ,,..u.. 11dland 1 and 2 Job 7220 Construction 0 --. -

n. T. stathov it/A 13-1.1-P-1 Item L Socrification 7220-C-27(0)

Rev. 1

n. Parker (t4ms)

..... u... .....u................... nQrt - AS>ts III. Div. 1, Parn ranh 5223 - - ~ Parar,raph 5223 states in part: " Specific Dechtcl KDE Procedures are selected for use. by Project ragineering uith the revision and concurrence of I!FLQCS. NDE Procedures are listed on Forn 34. fQ 3

s.. p

' w+n / p. The follouing discrepancies betueen Forn 34, the Log of Procedures and the UDE Procedures contained in Specification 7220-C-27(Q) were found. Jt i - fC.- D. M T

3-1. '

[.,'J.. Procedures P'T-XG-9 and 14T-SR-1,2 are show t on the Mechanical Forn 84 (Shents 5 GS) \\d but are not listed in the los of procedures. 9g 2. Procedures PY--XG-1 and.UT-PE-1,2 shmin on the Civil Form S4 are not marked fer- ~ Form 84 - Civil in the Ld3 of Procedures. e 3. The Log of Procedures does not shou a revision nu:$ber for Procedure LT-VB-1,2 or the applicable revision for Procedura ANS Dl.1. {. / j,,. ' ' ') J.3 g g.............. Revicu Specification 7220-G-27(Q) for consistency between Forn 84, the Log of Procedures and the velding, NDE and general specifications. Incorporate any correcticas necessary in Specification 7220-C-27(Q) by SCH or the pending Revision 2. .........w........ ,......u,........ 05/14/76 Proicct Eno.inear S. See Attachoent / 7g l ) Lj e .ea.sJ,...........".._.,e..,.- -w_ --en= _m.m-een w... a 4 .... f .8 4 $ $ 8..=

b....

\\ s ) .e' e.* _ 0 'sT.7M.U"OW.O.'. 5"2." ~ ~'" T4"'

* * " " " " " ' ~ ~

- - - ~ ~ ~~ ~'.,'.Z 1 L .\\. '3A h/#--%-- m-------- --~.- e .m.m. _.-=- -= - p.

J. m ~ ATTACHMENT TO QAF 084 (13-1.1-1) In response to the findings listed in block 11, the following revisions have been incorporated in Specification G-27 Rev. 2: 1. Procedures Sheet 6, RT-XG-9, was revised to read RT-XG-2 ad sheet 8 MT-SR-1,2, was revised to read MT-P-1,2.M Procedures RT-XC-1 b. 1 and UT-PE-1 2. Rev. O were marked as applicable to Civil Form 64 in the Log of Procedures. 3. Procedure LT-VB-1,2 was designated as Rev. O and has been marked as such in the Log of Procedures.9C 4. AWS D1.1 is n'ot a procedure, but a code. The revision is not designated because the applicable revision will be allowed to float.with the latest revision of the code. This is annotated on Civil Form 84*.gt! E e S 8 ,,e O s e e k 4 f s e e B e / p.. v I m ,----,m . - -,,. -, -_ 779 7 -

P -~ M QdAl.'I AljDIT Fl?lDl?iG J'--3) .a.._. ~ A..u.r.il 27 ~43. lo76 ,-~; u-i %/ -]llA 7..,,........,,..u.. g,,,,, _h..a..l_apd 1 & 2 0...... B. T. Stojkov 14-1-P-2 12 Quality Control Storage Records D. Martin, H. Boleer .m....m............................. FFG-3, Rev. h, Paragraphs 5 2 ?4 7.0; SF/PS? G-5 1, Rev,' 1 Paragraph h.2 PG-3, 5 2 says in part: "The performance of the storage requirements. :. is the r;;ponsibility o'r the MSS. The mintenance requirements are perfomed by the MSS or his representative..." FPG-3, 7.~o says in part: "Upon task completion, the issued F-2 Fom,... s' hall be forwarded to the p'QCE for vault storage." SF/FSPG-5.1,4.2saysinpart: "(The responsible Quality Control Engineer shall) verify that... required mintenance activities are performed in accordance with the storage .and storage maintenance requirements..." y,. F-1-203, Rev. 1 for "B" series Cadweld Sleeves requires storage maintenance activity af, 90 day intervals. Dates on successive forms F-2-1277 and F-2-2211 vere 10/8/73 and. 3/1/76 rerpectively. :It was confirmed with the Assistant ~ Material Supervisor for material Control f J no unreported storage maintenance activity had occurred in the approximately 150 day ' (,srval. Form F-2-2211 was reviewed and signed by the responsible Quality Control Engineer. (*:L r.JJ..... 1. Reinstruct the Material Storage Supervisor and his representatives on the neccessity for timely completion-of the required storage maintenance activities. 2. Reinstruct the responsible Quality Control Engineers t'o check F-2 Fom for timely completion of required storage xaintenance activities. g. w.......,4 g............,J................ .,1_f.g O June h M 7_6 _1 - Pr_o.ieet Sunerintenientu? - PZQCE p..., u........ 1 \\ i v i m;w.... a...... frir.............. ~ ! { E T i....T.. T r....'-.T.. ' - ~ ~ T.T. s enee..- e,, N-

^ QUAuTY AUDIT RNDDIG !.29,8-s-4) 4./.76./76 - 6/1 3/76 aa. ft/A LP. ....,.........,.,u..

g.,..

Midland 1 1, 2 Job 7220 O...... B. T.'stojkov '18-5-P-3 '6 ' Quality Control Records A. Albert ......m................................ 'Spac. 7220-C-231Q, Rev. 9 Paragraph 10.13.4 .,. ~,.., Paragraph 10.13.4 states in part: "For all T-series Exothermic Splices,....., separate test cycles shall be established for mechanical splices in horizontal, vertical and diagonal bars and for each bar size as follows: If production and sister splices are tested, the sample frequency shall be: One production splice of the first 10 production splices." = ' Of the first 10 production splices for vertical #11 bar in both Containment #2 and the xiliary Building one sister splice was tested not one production splice. 'I p,.~. w;,....... Provide justification for accepting sister splices in lieu of production splices for the tuo ('2) instances cited. Include a review of cadweld test requirements in the next Civil Discipline Training Session. 7,................. Jyne,l PFOCE

.~.....l.

1976 N p.r..c.... ,,..w....................... i, g.c. a.................... h wh

.p+ -- -h. AWht A - Route ib This Copy For Fila

16. 't. 4

^ y ensuut.nwor tta suuowell- [ ' Issue Date ' March 1, 8.976 p / IWSinger-GSI"celey s t. Projeeb Midinnd 1 & 2 b-CQllills TCCooke JMilandin CON.M emf File Titic t;Gtcs on deen:ci 'JFHolub Construction. t' GLRichardson Honconformance PESchmanski Subiect File Report Ho OF-79 'ihis'nonconformance Report is Issued ib: Prepared ByS:wJ1df odo%v Date 3-l-76 L F. Newgen Approvedoj [~M.-, Date.5M72 ' ly Requaspj[By Date Bechtel Project Superintendent Written 3-31-7 Corrective Action Requested By Date 3-31-7 who ic responsible for corrective action. Uonconformance Description and Supporting Details: The Champion QA Manual issued March 12, 1974 states in section III that "A regular review of the status of adequacy of the quality assurance program shall be made by Champion, Inc., management, and properly documented. This chall be done at yearly intervals". Contrary to this requirement, there is no proper documentation on these reviews for 1974 or 1975. 1 AEC Reportable '.Yes No @ See Procedure 9 (For Nuclear Projects 0nly) .O j* Stop Work recessary Yes no x See Procedure 16 - Stop Work No 4 No. hold; tags applied. Recc:: mended Corrective Action: (1) Champion management shall revicu the adequacy of their quality assurance program ~ for.1974~and 1975 and send the results of that review. (2) Corrective action should be taken by Chaapion if any deficiencies are found. (3) Champion shall implement this procedure to preclude repetition. 1Corrective Action Taken: (1). Cha= pion management has documented previous reviews of their q'uality assurance program. (2) Champion has revised tiheir manual accordingly to the review results. (3) Champion will provide yearly management audits as specified in the current revision 'of their QA Manual (Issue Date February 23, 1976). Verification of_ Corrective Action Required Yes X No 0 1 ~ Method ~of Verification: (1) - (2)' Review of letter.BCCC-1722 dated May 6,1976 and letter from Cha= pion to Bechtel dated April 29, 1976. (3) Review of letter BCCC-1659 dated April 1,1976. I p Honconfor=ance Closure Confirmed By ,%93. f. h Q Date

s. t Z.

76 I L To be completed at time of_ closure by ' Consumers Power QA Services. i Page 1.of 1 t.

1-g ( ,) Attc + ent A Route To' This Cony For T File 16.3.6 (]M e.%southworth SdHowaii Issue Date March 12, 1976 \\_,/ 3WSlager GSKeeley j Project m a t,,,d 1 r. ') i, CQ11111s TCCooke i JUilandin CC;;S!!m!.O F0W2r File Titic NCR's on Bechtel WFHolub Quality Control U"#

^""

GLRichardson e 8tTE~icct File Report No OF-83 Tnis Nonconfor.~.a.nce Report is Issued 'ib: Prepared Eybe.d C.b.v Date 3-f 2 ~~75 J. P. Connolly ^22 Y* 7 Bechtel Project Field Quality Control Written Reph Reques By Date 4-12-7C Engineer Corrective Action Rec;uested By Date 4-12-76 who is rernonsible for corrective cetion. Nonconfcmce Description and Supporting Details: Specification C-208, Rev. 6 section 7.3.2 second paragraph states in part that " Cylinders shall be made, cured and tested i accordance with Asni C-31, and C-39". ASni C 31-69 section 7.3, states in pprt " Remove test specimens made for checking the adequacy of the laboratory cinture proportions for strength, or as the basis for acceptance, from the colds at the end of 20 + 4 hr. and stored in a moist condition at 73.4 f 3 F (23 1.7 C) until the moment of test. As applied to the treatment' of demolded specimens, moist curing means that the test speci-mens shall have free water maintained on the entire surface area 'at all times. This condition is met by immersion in saturated line water and may be met by storage in a moist roen or cabinet 'neeting the requirements of ASn! Specification C 511". -(Contd on Attachsen ( ) AEC Reportable Yes No @ See' Procedure 9 (For Nuclear Projects Only) v Stop Work Hecessary Yes O no x see Procedure 16 - sto? work ro ~ Recc::nended Corrective Action: (1) Receive a Project Engineering evaluation on the acceptability of these si:c concret cylinder results and how these results represent the concrete placed. (2) Take corrective actiori to preclude repetition. The written reply to this is requested with the Project Engineering evaluation. 1Corrective Action Taken: (1) Project Engineering's evaluation, dated April 26, 1976, concludes by stating "the strength properties of the concrete will be insignificantly affected, and the cylinders and cylinder test results may be used as is". (2) To preclude repetition of this deficiency, a training meeting was held by United States Testing on March 10, 1976. The topic was " keeping cylinders moist at all times". ~ Verification of Corrective Acbien Recuired Yes @ No Method of Verification: (1) Reviewed Project Engineering's evaluation, Interoffice Memorandun dated April 26, t 1976, from R. L. Castleberry. (2) Reviewed letter FQCL-066 dated April 28, 1976. Reviewed documentation, dated . March 10,_1976, of training meeting' held by United States Testing. 1 (, Nonconfo::ance Closure Confirmed By b d C. i l Date 5:. 4- ~/6 1To be co=pleted ct time of closure by Concusers Power QA Services. Pa-se 1 of 2

=... F1 e - T 6.3.6 Issue te Macch 12, 1976 1 Project. Midland 1.5 2 File Titic NCR's on.Bechtel O , 4g Quality Control i 4 Attachment to NCR No QF-83 j. ' Nonconformance Description and Supporting Details: (Contd) , ASTM C 511-68 section 3.1 states in part that "The atmosphere in 'a moist cabinet ~ or roo:a shall have a temperature of 23 t 1.70C and a relative hu:sidity of not less i than 90 percent. The moisture in the atmosphere shall be saturated to the degree e needed to ensure that the exposed surfaces of all specimens in storage will both' t look moist and feel moist at all times". Contrary to these requirements, six con ' crate cylinders being cured by immersion in water were found partially exposed to the air in the curing tank for approximately 4-6 hours. The six concrete i cylinders were lying horizontal, approxi=ately one inch of the cylinders was not 4 ersed in the saturated lime water and approxf=ately one third of the ex-4 l posed surface, of the cy14miers did not look moist. f 1 i ] i' ~ t. 4 k l i' 4 } Page 2 of.2 j

Attach =2nt A y' f% Route To 7his Cc, For / x File 16.3.6 abouthworth danowell ( Issue Date April 15 1976 CQIlills CSKeeley . p) u.' Project M u t e.,a 1_

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( HUSlager TCCooke V JMilandin CC3219r3F033r File Title NCR's on Becht'el UFHolub thmliev conevn1 CLRichardson ,ypy, Report Ho 0F-91 This Ironconfor=ance Report is Issued To: Prepared By (([hWate #-/5-7/. AP2# Y8d E Mr. J. P. Connolly Project Field Quality Control Engineer Written P,e h Requeste Date 4-29-7 Corrective Action'Re sted By Date 4-29-7 who is responsible for corrective action. Nonconformance Description and Supporting Details: 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 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. 2 Contrary to the above, liner plate assembly C-111-72 vs.s accepted and coated without the repair of sharp edged shallow gouges. AEC Reportable,Yes No @ See Procedure 9 (For nuclear Projects Only) ("32 t Stop Uork Hecessary Yea no See Procedure 16 - Stop Work Ho Noholdtagsapplied.f Recer=: ended Corrective Action:

1) Inspect liner plate 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: See Attachment. 1 Verification of Corrective Action Requlred Yes @ No C Method of Verification: See Attachment. bronconformanco Closure Confir=ed By .f Date 5 - 2 7. 7t; / 1To be co:pleted at tbe of closure by Consu=ers Power QA Services, Page 1 of 2

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<j File 16.3.6 Issun to April 15, 1976 Project Midland 1 & 2 File Title NCR's on Bechtel

(} Quality Control \\~ / Attachment to Report No QF-91 Recommended Corrective Action: (Contd)

3) Instruct cognizant inspection personnel of requirements established for re-qualification of liner plate and associated inspeccion criteria. This instruc~

tion is to be documented. 1Corrective Action Taken:

1) Liner plate assembly C-lll-72 vas reinspected and sharp edged shallow gouges identified on Bagwell Coatings NCR BC104146-RR-2. The Bagwell NCR requires repair of the gouges and coating in accord with Bagwell procedures.

2) The Lead QC Engineer reviewed the QC Engineer's inspections of liner plate requalification. As part of this review liner plate nssemblies C-lll-57, C-111-60, C-111-635, C-111-67, C-111-71 and C-lll-72 were reinspected by Bechtel QC to verify that a proper QC requalification inspection was made. The plates were found to be satisfactory..

3) All second lift Un

One plates will be reinspected under Master Inspection Plan C-lll-4, "Ereet an of Reactor Building Liner Plate.

\\~ -] I

4) A one hour additional training lastruction for cognizant personnel uas con-ducted on liner plate surface requalification.

e 1Method of Verification:

1) Bagwell Coatings Nonconformance Report BC1 04146-RR-2 was reviewed. The NCR does not address specific sharp edged shallow gouges but any sharp edged shallow gouges on C-lll-72.

The NCR requires repair of the gouges and re-coating in accordance with Bagwell procedures. f2) Liner plate assemblies C-lll-57, C-111-60, C-lll-63, C-111-67, C-111-71 and C-111'-72 were inspected for sharp edged shallow gouges. The plates appeared satisfactory with the exception of gouges identified on Bagwell NCR's. Field Inspection Plan C-110-67 was reviewed and found satisfactory.

3) Verified that Master Inspection Plan C-111-4 contaita the inspection point for the inspection committed to under the corrective action taken.

4) Documentation of the training session (letter QCFM-1065, dated April 27, 1976) was reviewed. Cognizant personnel were reinstructed on liner plate requalifica-tion inspection requirements.

L[ ~) Q,/ Page 2 of 2

( ( ~ 3 Attach:n:nt A t. ) Routo To This Copy For f s. File 16.3.6 FM6outhworth SHilowell i., ('.; j , Issue Date M,v 4. 197 6 [m') CQ: tills GSKeeley \\ / Project ?.u.n na 1 r, 9 5 / TCCooke \\. W3188" r z Ccumers Fowtr ylle ziele nea 3,o, %cnent WFHolub Nonconfomance [1 Report No OF-46 ardson 'Ihis Nonconfomance Report is I cued To: Prepared By C// 716/4/E Date dM7t-J. P. Connolly ^E2"#'d I I ' U" ~ ~ Bechtel PFQCE WrittenRep'hRequeste[/Date 5/07/7e Corrective Action Requested By Date 5/17/7: who is responsible for corrective action. Nonconfomance Description and Supporting Details: Field Inspection Plans C-231-2-827 and C-231-2-858 have notes in Block 12 of Activity / Task 2.60 which, in essence, are exceptions to the QCE's acceptance. However, Block 5.10 is signed off indicating that there are no exceptions open. Also, the exceptions on these plans. indicate a total of twenty bars left out (fourteen in the first and six in the latter) when actually fifty-two bars were left out (tuenty-six in each case). The second of these was after the additional corrective action was started in response to FSW-7. AEC Reportable Yes O no Q see Procedure 9 (For nuclear Pro 3ecta on1 ) 7 Stop Work Necessary Yes No See Proceduro 16 - Stop Work No Consumers Power Company will continue inspect 1.)ns of all rebar placement. Recc== ended Corrective Action: 1..- Reinstruct QCE's in completion of Field Inspection Plans. 2. Correct the referenced plans. 3. Since the additional corrective action after FSW-7 still did not result in all missing bars being accounted for, develop additional corrective action in this area. 1Corrective Action Taken: See Attachment. Verification of Corrective Action Required Yes No C b'ethod of Verification: See Attachment. bionconfomance Clocure Confimed By[ /[o R }) l Date g // > t. 1 To be co.~.pleted at _ time of closure by Consumera Power QA Services. Page 1 of 2 1

/ .? j/ , Film i 16.3.6 rr n ,f-Issua Date May 3, 1976' Project ' Midland.1 6-2 - gA. l File Title MCR's on Bechtel U Quality Control Attachment to Report No QF ICorrective Action Taken:

1. - AresponseletterfromJ.P.'ConnollystatedthattheLeadQuah.ityControl Engineers were instructed in the nethod of changing completed inspection plans and later were instructed on Section 3.5 of PSP G-7.1 which was issued for portion of the corrective action of QF-95.

2. ~ Bechtel NCR-427 was issued and an Engineering disposition stated that, "The Field installation satisfies the design requirements and was acceptable". In addition, a DCN No 9 to Drawing C-140 w4s recently issued allowing for rebar hooks.to be turned in'any direction to facilitate construction and-all Field Inspection Plans were reviewed, evaluated and review results documented by a letter from L. R. Albert to the QC file which indicated that the Lead QCE reviewed'and evaluated the entries made in Block No 9 not pertaining to NCR's -which was related to this NCR. 3. There was no additional corrective action after Field Stop Work-7 required since Bechtel's letter of response' stated 'in part that, "The problem then was not-that Bechtel QC was unaware of requirements for these bars but rather that the omitted bars were improperly documented. The reference to the bars in question should have been changed 'to the scope of the inspection plan rather than an exception to activity 2.60. The decision not to include the bars in the subject placements was a change to the scope of tha placement rather than - an exception or nonconformance to the placement". 1Method of Verification: 1. The response' letter from Bechtel QC was reviewed and accepted. .2. Bechtel NCR-427 and the Engineering disposition was reviewed and found acceptable. Also, DCN 9 to Drawing C-140 was reviewed for content. 3. The response letter from Bechtel QC was reviewed for content. i Page 2 of 2

' ~ r 'i Attachment A ~ ~ Reute ib nic Comy For File 16.3.6 y FMSouthworth Silltowell ( CQllills CSKeeley (s,'. Issue Date Bfav 4, 1976 Proiect tffdland 1 & 2 \\/ HWSlager TCCooke UNK8i3 EOM File Title NCR's on Bechtel JMilandin WFHolub onnlity cnntrol Nonconfomance gehardson Report no nF-97 Sic Ucnconfomance Report is Iccued ib: Prepared By M#d h Date S '/-74 Approved BkIYJYa Date #///ht. - J. P. Connolly Bechtel Project Field Quality Control Written Rhly Request [By Date 6-01-7f Engineer Corrective Action Requested By Date 6-15-7f who is responsible for corrective action. Honconfomance Description and Supporting Details: See Attachment A. AEC Reportable Yes no y See Procedure 9 (For Nuclear Projects Only) () Stop Work Necessary Yes O No see Procedure 16 - Stay wora no No hold tags applied. Recen:= ended Corrective Action: See Attachment A. 1Corrective Action Taken: Verification of Corrective Action Required Yes No C biethodofVerification: bionconfomance Closure confir=ed By f j Date V 1To be completed at time of closure by Consumers Power QA Services. Page 1 of 2

~. ~~ 16.3.6 File Issuacode May 4, 1976 Project Midland 1 & 2 j'"3 File Title NCR's on Bechtel ) Quality Control Attachment A to Report No QF-97 Nonconformance. Description and Supporting Details: 4 " Nondestructive Examination Standard Procedure Specification RT-XG'2, Rev. O, Radiographic (Nucicar)," requires under section 3.5 a) that, "Each radiographic film shall be identified through the use of lead numbers and letters to show the 3 j following as a part of the radiographic image:

1) Date of radiograph.

2).Bechtel identification.

3)' Bechtel job number.

4). Component identification.

5) Seam or weld identification. 6). R for repair - R2, R3, etc. if more than one repair". Contrary to the above, the following liner plate radiographs were accepted without the R for repair appearing on the radiographic image:

1) Radiograph C-lll-135, 14'-4" North on seam A, R1.

This film was subsequently reshot and the reshot was acceptable. Records still indicate the original (N film was acceptable.

2) Radiograph C-111-136, 34'-6" North on seam A, Rl.

Peabody Testing records, Bechtel QC records, and the film show that the shot is a tracer. The fibn envelope shows that the shot is a repair and a review of the film shows that the weld has been repaired. This film has not been reshot. ' Recommended Corrective Action:

l) Revise the affected records, bjr appropriate procedures, to show that the originally accepted films are rejectable.

. :2) Review all acceptable film shot during March and April,1976 to verify that: a) All films that represent a weld that was repaired contain the required R. and b) That all associated records for each film agree with regard to weld identi-fication. Associated records are considered to be the Peabody Testing reader sheets, Bechtel QC reader sheets, and the film envelone. ' 3) With regard to item 2) under the nonconformance description either: I a) Reshoot the film with_ the required R. or b) ' Justify the film as being accep, table without the required R. / }

4). Instruct cogni= ant: personnel in the current requirements of-film identification.

~ \\- / ^ . Document to whom the. instruction was given and who gave the instruction. Page 2 of 2 ~.

Attach:nent A g, Route To This Cony For File 16.3.4 fw FMSouthworth SHHowell Issue Date Mav 4, 1976 ( ) CQHills CSKeeley \\'> Project tf td t u 4 1 t. ? %. / HIJSlager TCCooke JMilandin CD 3M80 E03.4 File Title NCR % on Ilochtel UFHolub Nonconfomance gehardson Report No 07-98 This Nonconfomance Report is Issued To: Prepared ByM[M Date J~-4-74 J. F. Newgen Approved By@fhMb Date f/1/~/[4 Bechtel Project Superintendent Written Re h Requesy k By Date '5-18-7 Corrective Action Requested, By Date 6-01-7 who is responsible for corrective action. Nonconfomance Description and Supporting Details: The Bagwell QA manual section III C, page 10 requires for the coating material, that "...each container that is shipped to the job site will be stenciled with the manu-facturer's batch number and the Purchase Order Number..." Contrary to the above, not all cont,ainers of the coating material had the purchase order number on them.. No @ See Procedure 9 (For Nucle::.r Projects Only) AEC Reportable Yes Stop Work Necessary Yes O no B See Procedure 16 - Stop Work No i No hold tags applied. Recer:nended Corrective Action:

1) Notify the coating material supplier of this requirement and require compliance.-

2) Verify that the lack of the purchase order number on the containers of coating material does not affect the traceability of the material.

If the traceability is affected, the applied coatings are to be justified and any existing containers of coating currently on site must be appropriately dispositioned. 1Corrective Action Taken: Verification of Corrective Action Required Yes O No bethodofVerification: bonconfomance Closure Confined By ( Date .d' Ilb be completed at time of closure by Consu=ers Power QA Services. Page 1 of 1

~ //p, Attach::nnt A Route To This Cory For [,. File 16.3.4 m FMSouthworth S!!Howell I' Incue Date grav 4 1976 ( i CQllills GSKeeley (. s Project Midlan 1 1 r 2 r HUSlager T e g,y h g IIFHolub Honconformance GLRichardson Site Report No 0F-99 This Uonconfor=ance Report is Issued To: Prepared Dy.d M M M Date 5 4 -70 J. F. Newgen Approved By Md.di/Date M#dd ' Bechtel Project Superintendent Written RepIr Requested By Dato 5-18-7 Corrective Action Requested By Date 6-01-7 vho in resnonsibic for corrective action. I Uonconformance Description and Supporting Details: d Bagvell procedure 3232 BCP01B " Application Procedure Phenoline 305 Finish" requires in section III D that for airless application, a Graco 30:1 Bulldog pump and Graco Colden Gun with a.015 tip be used. Contrary to the above, Baguell has,used a Speed Flo pump and 11 gun for the application of the intermediate co'at of Phenoline 305. Ye=0noQSeeProceeure9(FornuclearProsectsonly) AEC Reportable b Stop Ucrk Hecessary Yes No x See Procedure 16 - Stop Work No No hold tags applied. Recc== ended Corrective Action:

1) Assure that the use of' the different equipment has not affected tho quality of the coating.

2) Comply with the procedure or revise the procedure to allou the use of alternate equipment.

ICo rective Action 'Daken: See Attachment. 1 1Verification of Corrective Action Required Yes X Ho kiethod of Verification: The manufacturer's (Carboline) latest written reco=:endation for Phenoline 305 application was reviewed and it was verified that the equipment used met the manufacturer's recommendation. r^' Honconformance Closure Confirmed By Tm ' (,.)g Date.c s.s -74 / lTo be completed at tine of closure by Consumers Power QA Servi.ces. PaGe 1 of 2

4 -[ "" ~ ~ ~ File 16.3.4 9* k.4 ~ Issuete May 4, 1976 9 7 Projec6 Midland 1 & 2 .. [j File Title NCR's on Bechtel t 2 fm Construction Attachment.to Report No QF-99 -1 l Corrective Action Taken: - Specification C-110 "Recoating Work of the Containment Building Liner Plat.e" governs,, over the Baguell QA Manual per a statement in the QA Manual. The specification requires that the " Application shall be in accordance with the manufacturer's latest writt(< recommendations governing..., airless or air spray equipment;..." The equipment used was in accord with the manufacturer's recommendation and thus the' l ' liner plate was coated in accordance uith the specification a d meets the required n quality. As it is stated that the specification governs, a revision of the procedure is not considered caudatory. i a 4 i ~ 4 i l' [ t l 1 I ~ i 9 4 i / o Page 2 of.2 4 ,F _,m 9 g,_, _,,,,_,,_,,p__,,y,Y,,,,.p,,__,_,,,,_,,,,,,,,_,,y,,,_

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/ ~ Attr.ch= Int A' \\ h@w' Route To This Cony For File 16.1.6 FMSouthworth SHHowell q Issue Date m,r 4. lo76 (fh CQHills CSKeeley s,/ Project Midinnd 1 & 2 HWSlager TCCooke w JMilandia C0f!3K.U3 FG?l!T File Title NCR'c on Bechtel WFHolub Quality Control GLRichardson Nonconformance 7.Glucker Report No 0F-100 This Nonconfor=ance Report is Issued To: Prepared ByjSN dMdate [9,M J. P. Connolly Appr ved 4 [ N d, fDate Mhb." Bechtel PFQCE Written Reply Requeste,ddy Date 5/r/5t-Corrective Action Req 5 tested By Date 4/4/76 uho is restonsible for corrective action. Nonconfomance Description and Supporting Details: See Attachment A. No @ See Procedure 9 (For Nuclear Projects Only) AEC Reportable Yes Stop Work Necessary Yes O no see Procedure 16 - stop Wora No Reco=sended Corrective Action: See Attachment A. 1 1Corrective Action Taken: 1Verification of Corrective Action Required Yes No b.iethodofVerification: bionconformance Closure Confimed By _ i Date .\\) ITo be cc=pleted at time of closure by Consumers Power QA Services. Page 1 of 2'

7-. r ' File 16.3.6 Issua. ;e May'4, 1976 .,r Project Midland 1 & 2 File Title NCR's on Bechtel (,_) Quality Control L/ - n cAttachment A to Report No QF-100 Nonconformance Description and-Supporting Details: Criterion XV of 10CFR50(B) states: " Measures shall be established to control materials, parts, or components which do not conform to requirements in order to prevent their inadvertent use or installation..These measures shall include, as appropriate, procedures for identification documentation, segregation, disposi-tion, and notification to affected organizations.. Nonconforming items shall be reviewed and accepted, rejected, repaired, or reworked in accordance with docu-mented procedures". . Contrary to th'ese requirements, a nonconforming condition was noted in Block 12 of Activity / Task 2.60 on Field Inspection Plan C-231-2-858 with no nonconformance report written. _ Furthermore, this condition was not " reviewed and accepted in l accordance with documented procedures". Recccmended Corrective Action: 1. Write a nonconformance report to cover the nonconforning condition in the referenced inspection plan. [\\ 2. Receive disposition from Project Engineering including engineering rationale N-- for use as is if that is the disposition received. 4 e 3. Review all completed Field Inspection Plans for exceptions which have not resulted in NCR's and, if any are found, proceed as in items #1 and #2 above. 4. Instruct all QCE's in the requirements of Criterion XV and the necessity of following it. i s i -- Y ~\\ ) w/ 1 I Page 2 of 2

~ Attach:nent A / [1 Route To' This Cony For File 16.3.6 h FMSouthworth SliHowell / Issue Date ynv r,. 1976 k) CQHills GSKeeley -/ Project Midland I & 2 8 HWSlager TCCooke CCWmST: F0Wif File Title NCR's on Bechtal JMilandin UFHolub Nonconfomance GLRichardson Report No QF-101 noinknnnn This Nonconfomance Report is Issued To: Prepared By Date { M( J. P. Connolly Appr ved y + Date Bechtel PFQCE Written Reply Requested By Date 6/4/7 Corrective Action Requested By Date 7/2/7 who is resnonsible for corrective action. Uonconfomance Description and Supporting Details: See Attachment A. 4 AEC Reportable Yes No @ See Procedure 9 (For Nuclear Projects Only) ( Y s./ Stop Work Necescary Yes Uk X See Procedure 16 - Stop Work No Rece== ended Corrective Action: 1. Revise Bechtel Quality Control procedural commitments to address the cited requirements of ANSI N45.2.6. or 2. Prepare alternatives to implementation of ANSI N45.2.6 which will be acceptable to the USNRC, Division of Reactor Licensing, QA Branch for inclusion in the 1 Midland PSAR and amend the commitment in G-8 section 1.0. Corrective Action Taken: 1Verification of Corrective Action Required Yes O no Method of Verification: bionconfomance Closure Confi=ed By S ) Date 1To be co=pleted at t'i=e of closure by Consumers Power QA Services. Page 1 of 3

t ,/. ~ 7 File 16.3.6 / Issue Dace May 6, 1976 [,;. j Project Midland 1 & 2 } File Title NCR's on Bechtel /% - Quality Control // /, Attachment A to Report No QF-101 Nonconformance Description and Supporting Details: (Contd) b. "A Level II person shall have experience and training in the perfor5ance - of required inspections and tests and in the organization and evaluation of the results of the inspections and tests. He shall be capable of supervising or maintaining surveillance over the inspections and tests performed by others." "A Level III person shall have broad experience and formal training c. in the performance of inspections and tests and shall be educated through formal courses of study in the principles and techniques of the inspections and tests that are to be performed.....He shall be capable of organizing and reporting results and of certifying the validity of results." ~ B. Contrary to the G-8 Section 1.0 commitment, section 4.3 b of G-8 requires for a' Level II person " Completion of college level work leading to an Associates - Degree in a related discipline, plus two years of experience in the quality control aspects of quality assurance, including inspection or testing of equiva- [) ' ' lent construction or installation activitics". ANSI U45.2.6 does not address 3_ / requirements relative to an " Associates Degree" and, therefore, section 4.3 b should require four years at experience (the requirement for a high school graduate). i t. xJ l Page 3 of 3

(- (O Attac!= lent A v Routa To-This C w f For File 16.3.6 JMSouthworth SHHoweli Issue Date May 17. 1976 p(# CQHills CSKeeley g a,. Project Midinmi 1&2 r HUSlager-TCCooke JMilandin C0f,3 tim 3r1FOMr File Title NCR's on Bechtel WFHolub Nonconformance ' CLRichardson Report no 0F-102 vm This Honconformance Report is Iss' led To: Prepared By I [ M Date S-/7-% Mr J. P. Connolly Approved W S Ih b Date h / f h Bechtel Project Field ' Quality Control Writter/ ly Reque/eIBy Date 6-1-7f Engineer Corrective Action Requested By Date 6-1-7f who is resnonsible for corrective action. Honconformance Description and Supporting Details: Bechtel Field Inspection Plan (FIP)~ C-110-b-64, "Recoating Work of the Retetor Building Liner Plate," contains an. inspectd : point under Act/ Task No. 3.00 which reluires that the liner. plate be inspected for det ' pits and gouges prior to coating. The inspection on liner plate assembly C-111-64 failed to identify a deep gouge. The gouge was subsequently identified by Bechtel during the hold point for liner plate requalification and documented on Bechtel NCR 409..NCR 409 states that the gouge was prime coated indicatin'g that the gouge did not occur during handling subsequent to the prime coating. The gouge has been repaired in accordance with the disposition on NCR 409 and the coating repair has been addressed through corrective action on Bechte] Quality Assurance Discrepancy report 099 and there is no further hardware repair requi AEC Reportable Yes O no G See Procedure 9 (For Nuclear Projects Only) Stop Work Recessary Yes O ni see Procedure 16 - stov work ro No hold tags applied. Rec-mied Corrective Action:

1) Instruct personnel in proper requirenents for surface inspection of.the reacto'r building liner plate.

I Corrective Action Taken:- Cognizant personnel received instruction on liner. plate surface inspection. Verification of Corrective Action Required Yes @ Ho NethedofVerificationi Reviewed documentation of the instruction that was given (letter QCFM-1055). _ The instruction was given prior to the issuance of this NCR in response to NCR QF-91. All liner plate will be reinspected for surface defects under the C-lll-4 inspection plan. Uonconforcance Closure Confirmed By. M Dat6 s.-so.74 V 1lb be co=pleted at time of closure by Consurars Power QA Services. Page 1 of 1 t :_

9 Attachm3nt A Route To 211s Cony For File 16. 't. 6 s m. FMSouthworth SHHowell Issue Date .[V M.,7. > c, _ io76 l CQHills CSKeeley (.i Project Midinnd 1 6 2 HWSlager TCCooke JMilandin EC ESMI File Title nep's em %< b e< 1 LTHolub Nonconfoz=ance GLRichardson Report No _OF-103 no Ta n ~,, This Nonconformance Report in Issued To: Prepared ByffkM'dDate d'-pf-> J. P. Connolly Approved By'7 N d 2. Date d 4 Bechtel Project Field Quality Control liritten Refly Requestedfh/ Date g _9 c;_7 Engineer v Corrective Action Requested By Date 6-25-7 who is responsible for corrective action. Nonconformance Description and Supporting Details: 10CFR50 Appendix B, Criterion VI,_ Document Control states in part, " Measures shall be established to control the issuance of documents". Contrary to the above, Master Inspection Plan C-231-2, Rev.11 was used to prepare Field Inspection Plan C-231-2-667, Rev. O in which the inspection activities were signed off on 1-9-76. However, C-231-2, Rev. 12 was implementable on 12-30-75 to be used preparing Field Inspection Plans C-231-2-667, but was not used for final inspection. AEC Reportable Yes O No O see Procedure 9 (For Nuclear Prodeets Onir) /m Stop Uork Necessary Yes No See Procedure 16 - Stop Work No e Reco= tended Corrective Action: l. Review the Field Inspection Plan Log for date completed. Review all plans that were revised within 30 days of the completed date for the plan to assure that the latest revision was implemented. 2. ~ Provide a procedure to control revisions of open Field Inspection Plans to reflect the latest MIP revision. 3 1 Train QC personnel on new procedure. Corrective Action Taken: Verification of Corrective Action Required Yes NoO b'ebhod of Verification: bonconformanceClosureConfirmedB' f 1: Date i._) 1To be~ co:::pleted at ti$:te of closure by Consumers Power QA Services. Page 1 of 1

~~ '/ (g IG)'* Attach =snt A Route To This Copy For f' File 16.3.6 FMSouthworth SHHowell i. Incue Date itav 25. 1976 ,,.s _ ) CQHi.11s CSKeeley (i. Project Midland 1&2 (O !!WSlager TCCooke UEMI File Title NCR's on Bechtel JMilandin 0""" E " UFHolub Nonconfor=ance Report Uo OF-104 n This Nonconformance Report is Issued To: Prepared By d)[ M b /$ # bate 5:J 9-X Approved ByMIdN s Date $N.Mc J. P. Connolly Bechtel Project Field Quality Control Written Repky Request.edby Date 6-15-7t' S ""*# Corrective Action Requested By Date 6-30-7f 1/no is responsible for corrective action.' Honconformance Description and Supporting Details: Project Special Provisions notice SF/ PSP #16, Rev. O, section 3.1 states in part, "The Lead Field Quality Control Engineers (LFQCE) shall submit written requests to the Fielt Inspection Planning Coordinator for the preparation of the required Field Inspection Plans". Contrary to the above,. only one of four Field Inspection Plan Request forms asked for was presented. The one presented did not show documented evidence of submittal by LFQCE. No @ See Procedure 9 (For Unclear Projects Only) AEC Reportable Yes r ., l Stop Work necessary Yes No See Procedure 16 - Stop Work No ( Reco:= tended Corrective Action: 1. Revise procedure to conform to field practice. 2. Provide a system for con. trol of written request forms or specifically state these forms are not to be rett.ined. If the written requests are not retained, the FQCE who submitted the request should have the persorfs name and date of request appear in Block No. 5 of QC-C6-1A form. 3. 1 Train QC personnel on revised procedure. Corrective Action Taken: Verification of Corrective Action Required Yes no kethod of Verification: 1Jonconfor::tance Closure Confirmed By / O' Date l .\\ v \\ j To be completed at time of closure by Consumers Power OA Services. I Page 1 of 1 r -'Y-

~ /' Fila 16.3.6 Issue L a May 6, 1976 j Proj ect Midland 1 & 2 f File Title NCR's on Bechtel ff. l Quality Control J Attachment A to Report No QF-101 Nonconformance Description and Supporting Details: ^ The Field Inspection Manual Procedure #G-8 Section 1.0 states "This procedure pro-vides a formal program...to meet the requirements of ANSI Standard N45.2.6 and AEC Regulatory Guide 1.58". A. Contrary to this, Bechtel Quality Control personnel were not able to provide-satisfactory evidence of procedural co=mitments to the following requirements of ANSI N45.2.6 - 1973: 1. Section 1.3 states "It is the responsibility of each organization partici-pating in the project to assure that only those personnel within their respective organizations who meet the requirements of this standard are permitted to perform inspection, examination, and testing activities that result in or as'sure the attainment of quality". Section 2.2 states "Each person who verifies conformance of work activities to quality requirements shall be certified by his employer as being qualified to perform his assigned work". p - ) NOTE: While commitments relative to the implementation of the preceding r requirements were found relative to Quality Control Instructions (QCNM G-6.1) similar commitments were not found relative to Inspec-tion Plans.

2. - Section 3.1.2(1) requires a Level II candidate who is a graduate of a four year accredited engineering or science college or university to have "two years experience in quality assurance..."

NOTE: FIM G-8 sectic,n 4.3 a) only commits to one year of experience. ~ 3. Section 3.1.3 (1) and (2) requires that for a Level III man who does not have at least two years of experience associated with nuclear facilities, "the individual shall have training sufficient to acquaint him thoroughly with the safety aspects of a nuclear facility". NOTE: FDI G-8 section 7.2 does commit to training all QC personnel relative to a) the Construction Department QC program b) the use of the NQAM and FIM c) the use of QC Notices; however, this training is not considered to be sufficient to implement the cited ANSI requirement. 4. Section 3.2.2 a requires: "A Level I person shall have experience or training in the performance a. of the inspections and tests that he is required to perform. He shall '] be familiar with inspection and measurement equipment." ) Page 2 of 3 .j

~ Attach =ent A Route To This Copy For /~~ File 16.3.6 FMSouthworth S!!Howell f Issue Date rey 2 r;. 1976 CQilills GSKeeley (_a Project u pp...,a i r. f HUSlager TCCooke JMilandin C MUMST3 M. f File Title NCR's on Bechtel H UFl!olub "^ Ilonconformance GLRichardson DRJohnson Report no OF-105 This Honconformance Report is Issued To: Prepared EypM8 3 Date 5 -J:79-2 Approved By W$,$., Date Wribi J. P. Connolly / Bechtel Project Field Quality Control 17ritten Re-617 Request,ed By Date A-??-74 Engineer Corrective Action Ref uested By Date 6-22-76 l who is resuonsible for corrective action. Ironcenfor=ance Description and Supporting Details: FIM C-6, Block No. 6 states, "The Lead Discipline Quality Control Engineer shall review the plan for content, adherence to this procedure and completeness and shall signify approval by entering his signature and the date before the plan is utilized for inspec-tion by the Quality Control Engineer". Contrary to the above,.two inspection plans C-231-4-632, Rev. O and C-231-3-631, Rev. O vere found with documentation missing in Block No. 6. (No approval signature and date. no @ See Procedsre 9 (For nuclear Projects Only) AEC Reportable Yes ^ ) Stop Work Mecessary Yes no @ See Precedure 16 - Stop Work Ito Recor= ended Corrective Action: l. Review all inspection plans from September of 1975*to present for entry information in required blocks. 2. Document this review and evaluate. 3. Based on results, state in written reply the corrective action taken to preclude repetition. 1Corrective Acti6n Taken: Verification cf Corrective Action Required Yes no O b:ethod of Verification: bronconfor..anceClosureCanfirmedBy Date ( l 1To be completed at time of closure by Consumers Power QA Services. Page 1 of 1

Time of increase in construction activities.

Attach =:nt A l This Cony For Routo To /' File 16.3.6 FMSouthworth Srlilowell { Issue Date M n. 2 5, 19 7 6 ) w. CQ!Illis GSKeelcy \\s Project m a t.,,, A 1 e. 7 ( I 'HWSlager TCCooke N -- JMilandin U;MUZH3 ET.Hf File Title Nca's on Heentel UFilolub Qualitv Control CLRichardson Report no 0F-106 n o w,.,,,,,, This Nonconformance Report is Issued To: Prepared By c5I' f/ -[,.ddate,p.pMc J. P. Connolly Approved ByOMMdb, Date [M M76 Bechtel Project Field Quality Control WrittenRe[lyRequested4yDate 6-25-7( Engineer Corrective Action Requested By Date 6-25-7f who is recoonsible for corrective action. Honconfomance Description and Supporting Details: Quality Control Inspection Plan MIP No. C-231-3, Rev. 10, Act/ Task No. 4.00 states, "Supolementary Records - The following supplementary records shall be reviewed to verify that the required quality documentation has been satisfactorily completed:" and includes truck trip tickets in Act/ Task 4.20. Contrary to the above, batch ticket 07160 in pour package A(614)h did not show the revolutions of the truck mixer where required and was not documented with an NCR by Bechtel Qualit'y Control. No @ See Procedure 9 (For nuclear Projects Only) AEC Reportable Yes / Stop Work Necessary Yes No See Procedure 16 - Stop Work No Reco=: ended Corrective Action: 1. Deternine cause of problem and document with uritten reply to Consumers Power Quality Assurance Department. 2. Have Project Engineering make an evaluation to determine acceptability of concrete placed associated with batch ticket. 3. Train QC personnel on proper documentation of deficiencies. 1Corrective Action Taken: 1Verification of Corrective Action Required Yes No Method of Verification: bonconformanceClosureConfirmedBy A Date l ) LJ yTo be cocplete:1 at time of closure by Consumers Power QA Services. Page 1 of 1 m lh _ _ _ _}}

ML19329E939

Text

Dear Mr. Corley:

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