ML19329F045

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Nonconformance Rept for Sept 1973.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
ML19329F045
Person / Time
Site: Midland
Issue date: 09/30/1973
From:
CONSUMERS ENERGY CO. (FORMERLY CONSUMERS POWER CO.)
To:
Shared Package
ML19329F039 List:
References
NUDOCS 8006190839
Download: ML19329F045 (15)
v • d • e


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I NONCONFORMANCE-REPORT LOG & STATUS BOOK gg,g ,7 ,,g, /, ,,,

a PAGE COMPL PROJECT NO. 7220 0.c. ENG. SIGN i .

l 8$Yh PREPARED BY NONCONFORMANCE SOURCE STATUS JCR NO. cL oA [ CLOSED BY DESCRIPTION / REMARKS DISPOSIT. ROUTE XMTD REPLY RETD C-1 1 /12/7 3. Dick _Grote Wall dowels and Asqesn_. Tendon _ Gallery Slap Field __ PE g7 A

, 8-20-73 [j,[j) g[/g' 74 Unit 2. With sketches attached. PE AA I.

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C-1-1 7-12-7d Dick Grote. Wall dowels & Access Tendon' Gallery slab. Field PE 8-1]4-7 3

)~ 8-20-72 h,[/),*'//kdp Attached Sketches. AA 7-12-7 3 3-20-73 C-2 9-7-73 Y Buck Kinnev #7 Robars in Containment #1 are Undersized PE PE AA 9-12-73 Steve Grant 28ea #9 Rebara cut off @ 682'-6" to set certain _E eld ... PE 9-13-7 3 colurunsfor suppd'tipe frarDe. B9actoi Bldg. 41 PR 9-28-71 Clay Clark Liner Plate S-1-5-2-1 veld cracked after Field- PE 10-1-73 application of prime coating. PE AA [

9-28-7 3 Steve Grant Trumplates by INRYCo in violation of documentaion Field PE 10-1-73 Requirements PE AA CD O

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N O N C (., ;4 F O R M A N C E REPORT SKETCH Yes 2 3. MO DA Y YT'

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.-. - ATTACHED g -[ 7-PflOJECT NO. 7220 DATE l .

'.1 LOCATION AREA / BLDG. 5. C'.'.'G/PART No. REV. 6. ITEM NAME Q No. I*U tn4 m t 61 -

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ENGRG. O eONSTR.O OTHER ..; iExPLAiN 7 -

7220-C-39 Tal cad-B. crc .n Chienao, Illinois

10. - 11. NONCON.'ORMANCE (CISCREPA.'JCY) DESCRIPTION: ASME .YES O NO $

N r. (LIST SERfAL NUMBERS WHE3E Ap*LICABLEl 1 #7 Ecbern in Cente4- ant di n o under.aicod.

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PROJECT NO. 7220 "

22 DATE 9 12 7' gEMgpg,y pggggfgtDG. 5. DWG/PART No. REV. 6. ITEM NAME Q No. I*Ii Blde. 41 7220-C-307 h Rebar Ibvels ECTION CRITERIA DOCUMENT NUMSER & TITLi.

I EG d SPEC O OTHER O (EXPLAIN) 7220-c-307 Rev.14 Tendon callery Det*4Ts

s. SOURCE:

ENGRG. O CONSTR.T OTHER O (EXPLAIN) '

NA 10, 11. NONCONFORMANCE (DISCREPANCY) DESCRIPTION:

No.

ASME YEs O (LIST SER!AL NUMBERS WHERE APPLICABLE) NO 3 1

Twenty-eicht 49 reba- devels extending fren the tendon nallerr inner trall to the Reactor Building #1 base slab vere cut off at the concrete line (582'-6") in order to set certain colt =ns for the cunport frening system. See attached 7220-FSK-C-1h for locations. See cheets 1 & 2 of Joseph T. Ryerson & Son, Inc. drawing sv 528626 for col- identification.

12. NCR PREPAHED BY: Date
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13. FIELD DISPOSITION:

Ad%d- eMz une 2A2 CONCURRENCE:

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wm Date REWORK O RE;ECT O ROUTE TO eRO;ECT ENGRG Q NOTIFY AUTHORIZED INSP. O ROUTE TO MAT'L SUPV. O I

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16. PROVAL OF Date 17. R EINSPECTION ENGRG.

Date

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Responsible Engr. Date DISPOSITION CO CURRENCE ,.

Date F. EJECT O Remee uae Ear Daa AUTH. INSP. CONWARFd9933 a i_. m em,

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$, GRANT' nur 8 /29/73 jgg, .

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" N :. C-h iF0RMANCE REPORT NONC SKETCH Yes 3 3. MO DAY'Y O,. ATTACHED DATE PROJECTNO. 7790 .

4- 98 7 4.EEM LOCATION AREA /BLOG. S. DWG/PART No. REV. 6. ITEM NAME 1 91 O No.

ntaf eent E2 Tiner S-1-5-U-1 Tiner Plate Assenbly 7.ESPECTION CRITERIA DOCUMENT NUiVggTyLggggggng ((ggy piggg OWa O SPEC @ OTsER O (EXPLAIN) 7220-C-50 Rev. 7 & Accessor7 Steel

  • ADDRESS 9. P.O. No.

ENGRG. O CONSTR.O OTxER Z (EXPLAIN) ,

Southem Boiler & Tank Vorks. Meruhis. Tinn. 7229-C-60 10, 11. NONCONFORMANCE (DISCREPANCY) DESCRIPTION:

ASME Y:s O -

~

No. (LIST SERI AL NUMBERS WHERh APPLICABLE)

NO @ l 1 s-1-y_9 1 T.5-o- V1 tta -

Excessive veld cetal was' applied when attaching the 2" cas channel over the veld joining the two h0'-0" Liner Plate to nahe one 80'-0" Plate asse=bly.

Part of the veld cracked after the assenbly was price coated. (See attached sketch.)

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12. NCR PREPARED BY: Date CONCURRENC - Date Nor ,

9- 2-8-$ 0e'ad En "[8- 2. '

13. FIELD DISPOSITION: REWORK M REJECT O route TO eRO;ECT'rNGRo D .

NOTIFY AUTHORIZED INSP. O ROUTE TO MAT *L SUPV. O

-, v< e, a vnee or an+1 en .

Recove defective veld by grinding. Visually insteet channel and ulate for further defect. Reveld in accordance with specification 7220-c-50. Test with liquid penetrant, and pressure test per C-50.

A Date

- ( )

APPROVA OF Fi O/D S C iTi a:

Date

14. FIELD DISPOSITION 6Y:

PFE - INW U L/UMM'MD YI 75 h

lb. ENGRG DISPOSITION:

.-e" / 9-28-7$_ SubNsP" " " b N' REPA!R O RE;ECT O oCN REOo: YES O oCu No.

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16. APPROVAL Op Date 17. REINSPECTION CCEPT O Re,,ons,eie enge, oa,e ENGRG.' Date L Daie 3E; ecto Responsible Lead En6r. Oate

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NONCOf'*ORMANCE REPORT  ; KETCH hsO 3. MO DAY YR

'+- 7220 ATTACHED 9 28 73

. PROJECT NO. . DATE

4. ITEM LOCATION AREA / BLDG. S. DWG/PART No. REV. S. ITEM NAME O No. 1.13

[ Cggpin=ent #2 C-2AC Tru= plate Asse=bly 7.1. TION CalTERIA DOCUMENT NUMSEA & TITLE OWG O SPEC O OTHER E (EXPLAIN) NQAM III Paragraph 3b, number 7, page 2 Of 2 ENGRG. O CONSTR.O OTHER U(EXPLAIN) Chicago, Il nols 7220-C-2AC Inland Ryerson Construction Products.

10, 11. NONCONFORMANCE IDISCREPANCY) OESCRIPTION: ASME YES O l

No. ILIST SERIAL NUMBERS WHERE AP'PLICABLE) NO @

1 Trumplate Marked E.rbers H-2, B-2, AK-2, AC-2, AM-2, AM-2, AL-2, AE-2, A2-2 DX, A23-DX, F2-2DY, U2-2DY, E2-lDX, AA, 2-lDX, G2-2DX AC2, 1DX, and A32-lDX supplied by INRYCo in violation of documentation reauirenents. Specifically, State =ent of Conformity required was titled Certificate of Co=pliance, other specifications not referenced other than throuch the ourchase order nu=ber, scecification revision number omitted. State =ent that docu=entation meets require =ents was not included, drawings not listed nor were drawing revisions.

Date CONCURRENC Date

12. n'"'"; NCR PREPAREDABY0'M$
13. FIELD DISPOSITION:

?flh5 ":m" . / .  ? 8 /6Ah3

REWORK O RE;ECT O ROUTE TO PRO;eCT MGRG #

NOTIFY AUTHORIZED INSP. O ROUTE TO MAT *L SUPV. O

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-e -r f N O 1 , 1 \ (

L_ NS M D0Y'* (1W (Y I sA /*s VPMt . . Y .

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14. FIELD DISPOSITIOP ~ Y: . Date APPROVA L, OF FIE}.0 pp*P/sfITION:

l Date

! PFE - U* Ur N YhvM l0h "?b Oh/ A* A \ lObl14 $*tl$$s " b $ 'Y

15. ENGFsG DISPOSIT40 p O mm O mum mO ma USE AS IS O SEe BetOW O NO O l

'S. APPROVAL OF Date, . t 7. REINSPECTION ACCEPT O Respons.oie Engr. o...

ENGRG. Date PFE Date Date REJECT O Responscie Leao engr.

DISPOSITION CONCURRENCE . . , , , , , , , . ,

3, 7

d' - STATUS OF QUAL'ITY ASSURANCE AUDIT FINDINGS (QAF)

QAF No. STATUS '50MMENT From Construction audit July 17-19, 1973 (Audit No.'C-1) -

001 Open Corrective' action' time extended to 10-12-73 002 Open Issued Management Corrective Action Report (MCAR-1) 003 - 011 Corrective action completed and verified 012 Voided 013.- 015 Corrective action completed and verified From Engineering audit September 5-9, 1973 (Audit No. E-2)

QA #1 Open NCR issued. Corrective

/

action due 10-19-73 QA #6 Corrective action completed and verified QA h8 Open Corrective action due 10-19-73 Notes 1. Bechtel Quality Assurance is developing a new numbering syste=

for Quality Audit Findings to distinguish Construction Engineering, and Procurement audits from'one another. The new system vill be implemented in the near future.

2. QA #2 through #5 and QA #7 through #17 are not construction related~and are, therefore, not reportable.

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'- GIF"rfY A!!DIT Fi: ";G _

~. L l SEP i 73 .

7-17-73 nrnr.,

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,,., ........... . . . . . . . . . . . .  :. .~.

Systens ~ ' ' " J. Dotson Midland .7220 ............ ..........

.a.......-

- C. Kinnoy 9 Q ulity Control

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10CFR-50 hpondix B Criteria II NOAM Section V ru=ber 6 Para. 2.5 -

CChiof field quality control engineer: pr'paros and implemento, with the e

.t assistanco of his staff and project field QCEa, a for=al cnd continuous quality centrol training progas which includes utilization of the field inapcotion canual." 1 1

.* l l

No formal indoctrination / training propas has been established or implemented at nidland. .

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D3volopandimpicnontanindoctrination/trainingprogram.

s

c. m 8/17/73-- D. R. Johnson /C. Kinney

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N ' %h I n M.O(A.$ fn cc.}$') tn 4'N 9% f 0 '. M N y N'

ks Ty % ,J.y: nyofyc.v. b.a c.w. e , l ...u..,: .. ,. a!. s ..

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- T/2 $*/13 ,474 - o

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01'"M td!DIT F33

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l July 17, 1973

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.. ,g m Mid1rmA 7220 Svnt<*m **'"*

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......... 7,;.Hl.i6 . /!7el"b j

1 6 Th ntrine Contici P~ nchovink 1

Field Innnnetion M muni G-2. r see nnh 4.1  !

...2 "The Print Coordinator /Clork shall nacure that auporoodod drcvinsa are withircxn frca uso."

.~ .

Many, drawings on the Civil Stick Filo have boon marked void end havo not boca ,

removed.

J

~ .

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a..........

Renova superseded drawings frca uno as requirod in Sootion G-2 of the Fiold .

Inspection Manual. .

m.............. ................................

__ 8/17/13 M. Pr.lton

.x....... ...... -

Supsrseded drawings have been removed from use. .

U A..m. .. ......... - . . . . . --

Md 79

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Q6allTY AUDIT Fli!Dl?S .....

Sept. 5, 1973

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' Midland 7220 Engineering System Ga '= = J. Dotson 5 I 8 Civil Discipline -

C. Kinnev

... .u... a ............................. . . . . .

Material Receivine Report No.~3435 & 3036 PO 7220-C-2

.u,.

'D:curentation was reviewed and found satisfactory" h

I .s A review by the auditor of the documentation supplied shows the following discrepancies:

F'N Certificate of compliance supplied was signed by the supervisor of Quality Assurance

' Q for Inland Ryerson not by the. appropriate individual in the manufacturer's crganization.

(2) Materials report of tests and analysis from Bethlehem Steel was signed by the Inland Ryerson QA Supervisor not by the appropriate individual from Bethlehem.

(3) No traceability provided for anchorage assemblies. * *)

(4) G-321-D form required by 7220-C-33 not provided as part of documentation.

p. ..u ..

Issue NCR for incorrect documentation (1) '

. l

- . i (2) Institute immediately indoctrination / training cicsses for recognization of documentation deficiencies, r

.._,.w .... ......... . . . . . . . . . . . , , , . . . . . . . . . . . . . . . . . i 9-11-73 E. Felton -

A,%'4,l'7 3 E. ,8. ... . .

D .

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  • ' . 96
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lMi. md 7220 -

Engineering Systens L5..- .. J. Dotson

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5 6 Field . J. Southard en ral Require =ents for Supplier Ouality Assurance Programs 7220-G-20 (Attachment to C-39)

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% Qunlity Assurance ' Program re'quirements for the elements listed above are described in American National Standards Institute (ANSI)45.2 - 1971" .

  • LNSI 45.2 Paragraph 9 requires "where identification marking is employed, the narking shall bs'cicar, unambiguous and indelible . . ." .

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Reinforcing steel was shipped to the field with paper tags and non indelible carkings.  ?

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(".) Appraise Inland Ryerson of their failure to =cet ANSI - 45.2 requirements and require ic=ediata imple=entation of new tagging syste, .. .

and . ..

(2) Indoctrinate / train shop and field inspections in ANSI 45.2 requirements and (3) Retag material in field.

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ko.64so .t.,io o... a . . .o. . .. a ss , v o. . e a . s '. .w . . . ..o e. .

l 9/24/73 " E. Rye /J. Southard/E. Felton is to do corrective action (2) only w .m .u....... ,

2.) Qualit Control. Engineer's and. Field. Engineers had' received Indoctrination Straining. and will continue..to receive Inde:.:trination- on Material Receiving Field I.nsp'ection. -A continuous Training Program has bee.n established at

.'b. site sinc.e August 1973. .

)Allmaterial.sinfieldhavebeenrejag,ed.. ~ -

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. . ... - . ~ . . . . .. ,...-- . ;~ . .

...s. .M.2rw,

ue .su,av ......

ne/>s " 3%. . . , .. ... -

'8 LAUTY AUDIT Fli!Diis . . . . . .

- 9/7/73

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O. ' " - " -

Mid1rnd Encineerinn g .,,.. . J. Dotson .

....u. .....u..... .......... .............

2 1 4 Field Engineerine T- vntansnnn

....m u.. u ...-.......................... ........

10-CFR-50 Appendix B Criteria III "Th2 Design Control Measures shall provide for verifying or checking the adequacy cf Dc2ign. . . ." -

.h i.

Prccedures for control of field engineering design review of vendor drawings havs not been developed or implemented for field controlled / purchased materials c ent or services. .

t

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i .

f .

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. .t p............

,l

  • t Develop / Implement Design keview procedures for Vendor Design Review. ,

. .? /

s m._ ..... ......... ........T_.....................

'*9/28/73 " E. Felton ,

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