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Nonconformance Rept for Feb 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
	ML19331A223
Person / Time
Site:	Midland
Issue date:	02/29/1976
From:	; CONSUMERS ENERGY CO. (FORMERLY CONSUMERS POWER CO.)
To:	;
Shared Package
ML19331A224	List: ML19331A223;
References
	NUDOCS 8006180758
	Download: ML19331A223 (66)
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$ NONCONFORMANCE - REPORYJLOG & STATUS BOOK u. ' ' ' ' ' '

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1. PROJECT NO. 7220 NCR ORIG. NONCON FORf.it.NCE STAWS DATE PREPARED BY 6-NO. DESCRIPTION /REl/ LARKS nOUTE "X f. T CLOSE D Ct CSED BY No 11-26 352 10-29 R. A. Moray B-205. Ci reni t Bro.skorn - Mandpi n ton ; anmagna- Field .i. .

-75 Identification - -75 3 101 10-29-75

.353 11-h H. D. Foster C-111. Deep impnvf nctinnn natna nn c 111 1h Field No 11-5 11-18 H.D. Foster

-75 during coniins work 1.109 1 l-h-75 -75 -75 354 11-5 C. F. Clark C-111. Dome liner olate bro);en. C-111-15 Field No 11-6

-75 1.109 , 1-5-75 -75 355 11-10 D. L. osbont C-230. Flyash below weight on one ticket, pour h ld 12-8 1-23 1-26 L. R. Albert

-75 A(614)b 1.205.: 14 -75 -73 -76 -76 356 11-14 L.R. Albert C-230. Air content. Pours A(G99)3' & A(587)b' FinlA 12-8 -76

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-75

-76 1.205 n_.14-7:; -75 _O 357 11-17 R.A. Moray F-1-193. M-92 Motnrn hn ttnT n dincnnnnntnd Pield No 12-8 2-19 R. A. Moray P

-75 4.001 l .cMf -75 -76 ,

'8 11-17 H. Boleen 4-117 Vnivn Tnecine vonniw.mnntn wi n1 -> + n d Field No 11-25 3 H. D. Fo ste r*

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-75 gggg yyj]f -75 -76 l-23 1-26 L. R. Albert "

359 11-24 E. Dutton 3-230. Air content hich, Pour #A(619ht &M 12 -76 -7(

-75 1.205 44-26-76 -75

360 11-25 R. Dennett 3-231. Curing temperature below 600 1 hrc. Fi nl a 12-8 1-26 L. R. Albert

-75 Pour #A(619)a 1.205

-76 -76 14-26-76 -75 NW i-J7-361 11-26 D.C.Thompoon 1 h?. Cnnanit npnninc. Any Til dg Rl nh Fnnl Pnnl FieM 12-12 1-30 2 D. C. Thomps on

-75 31ab 3 006 22 2- 4 76 =76 362 12-1 D.C. Thompson bh2. Conduit size reducedmfave_RI.de slab. -Eicid- 12-5

-75 3 006 12 245 -75 DW IEIL s t o-1s ' k' 363 12-1 L.R. Albert C-230. Fnil ing witnr unor tet_ w M- 12-1-75 12-16 12-18-75.dbW. R]. Albe 1.105,1.205 12 ' 75 -75 '

-75_

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Page 33

. ' , .# NONCONFORM ANCE - REPO.n,I LOG Ce STATUS BOOK n, " " 2 - * ** *) h.

p nErony oats 12 'l- 7 5 / ~2 ";

race court.

c; Q.C. E NG. SIGN

1. PROJECT NO. 7?20 STAWS NCR ORIG. NONCONFORMANCE DATE PREPARED BY DESCRIPTION / REMARKS 'nOUTE CLOSED DY NO. X.T C oSED l C-208. Concrete cylinder curir n. Pour A(61 hlb Field 1 r 76

^ "#

36h 12-h- D.L. Osborn -76 75 1.205 +a-h-75 75 Aux. Bldg. columns cut'short. Field 12 1 1-19 A . L. Boulden 36[ 12 H. Shawl C-38.

-76 75 1.201 +a-3-75 75 76 366 12 R. Dennett C.231. Curinta Temperature.AQiS0)n' & 1.10$. & Field 12 -76 ~76 75 cc(635)b' 1.205 - +2 P 7 75

.c. -/ 1-16 12 tI. Boleen 't-10h A. Damaged pipe spool upon receipt. -Fiel-a- fi 367 H ,.16-7 914-i '#g -76

.75 A5IE h.10h -

368 1 E. Dutton C-231. Curing temperature. Pour A(626.9%)n' mld. . 1-9-7( 2-9 2-9 L.R. Albert

- 76 1.205 t '/=46 : -76 -76 369 l-13 L. R. Albert c -2 30. Fly A s h ri n enn a a n nLper A s ru -

rd' eld 1-15 2-9 2-9 L.R. Albert C 618-72. 1.105,1.205 +-13 -7 6 76 -76 I-27 2-20 2-24 D.L.Osborn C-2 3 0 Slumn hirrh. Pnne A f E 99118 55gla-3'M l-19 E. Dutton -76 -76 -76

'l.205 4:50:75

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-76 1-41 ~

371 1-20 T. Lieb C-231. Field cylinder curing temperature. jfEff[6= -76 -76

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-76

-76 pour A(614)h 1.205 No ) .

2-23 R. Lus sie r 372 1-27 G. E. Depew C-50A. f >iner Plate slab nundters not match- Field 76 -76

-76 ing. 1.109 l- 28-76 2-25 2-23 L. R. Albert g-208. Concrete cylinder curing. pour EipM 373 Ig9 T. R. Lieb =

2-12 -76 -76 A (614)i 1.205 #2JJA -76 1-29 E. Dutton C-230. C on c r et e slump _tnat.f_r_epu e n cy. nour T feltl= 2-25 374 Z=M6 -76

-76 A (63 3. 2 5)a' l.205 375 2 R. A. Moray M- 1. Makeup Storage Tanks r_cenivnd =Mb B&W

-76 K. Pulito shipping damage ASM3 4.039,4.049 2-4-76

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O.C. E NG. SIGN _

i. PROJECT NO. 7220

2. 2 4 s. STATUS NCR ORIG. NONCOWORf.1ANCE ,, ,,g ,,, ,,g ,,, ,,g ,7, 33, PREPARED BY DESCRIPTION /REl/ ARKS ROUTE XMTD RETO CLOSED CLOSED BY NO. DATE 376 2-4 D.L.Osborn 7 2nn. Flyn=h Tn=t F r nquenc y , m a r e + h , " Vibid 2-19

-76 100 tons received w/o user test 1.10 5,1.20 5 = 2=4=76 -76

.577 2-5 E. Dutton C-208. Concrete test frequency exceeded. -Field: 2-19

-76 Pour A(633. 25)a' l.205 : L 4 -=71) -76 378 2-5-76 R. A. Moray C - 2 3 3 A'. F-304 3 Release #12; Nn1 =nn Sturl= nr Field No 2-5-7,6 Back-Up Plates have defective welds 1.202 2-5-76 379 Z-6 D. Martin M-1. Purification Demincr2 liter opened; ice B&W

-76 found inside ASME 4.038 2-9-76 Z-45 2-12 2-25 L. R. Albe rt 38.0 2-6 E. Dutton C-231 Cnnevnta en ring +nmperatu re, pett r r Field _g _g _g A(633.25)a' & TT(606)a 1.205 = 2=9=76

-76 Liner Plate heat number discr_enancy Field No 2-17 381 2-9 G. Depew C-50A. -76

-76 1.109 2-9-76 No 2-17 2-27 D.L.Osborn 82 2-11 D. L. Osborn .C-111. T ,ine r in n t o tni e r a nco finie ni ri ey___ Field -76

-76

-76 G50'6" to 651'6" 1.109 l-11-7(

383 2-11 s D. L. Osborn C-230. IIalf vard of hich situup conc. rete, pcur FiEId 2-19

-76 A (6 30. 75)a' l.205 = 2-12 7( -76 NT in.tA_ Pine snoels with .abipping <1 n m n g o Field 384 2-11 II. Boleen ASME 4.164,4.I'74 2.g

-76 and improper painting

-"- dihid Z-17 385 2-13 R. A. Moray WFMC-1. Weld rod heat ta catment temperature -76 ASME al-3 37f

-76 7-3029.

No 3 M i n6 14n nga re received without C /R pintna c-20-7( Fiel d 3 386 2-19 R. A. Moray )

-76 welded on. ASME 4.131 5-a.

C-111. Penetration tolernnce; T1 nit # '> F1 n e. M eld 76 387 2-26 D. L. Osborn

-76 635'6". . 1.109 :2 '2TF-76 g 1 A] oCg1 Page 35

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__Sp.ec. 7220-M-92 !

3. B T E M DESC RIP 100N 5_

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DATE 5 R/B Crane Motors

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[ CO N T fD A C T O R/t.OC A TIO N ft/A N/A e' " " /2 E- Y-Ib ish Feger Milwaukee, Wis.

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Q ROUTE TO FIELD EN' NEERING h ROUTE TO M ATERI AE. SUPERVISOR 9 9. HONCONF OR MING COND9 TOON:

Storage requirements Form F-1-193, Rev.1 requires motor space heaters to be connected to a 115 volt power supply.

__to_a_ pot!cr_ source.

Contrary to the above_,_ heaters for the five_15_) Reactor Buildino Crane Motors list.qd below are not ._-

1) 21!5 Lend _LrSck_Hotor_Cor,_2 -------- }{catet_ burned _Qut_lllu/l5

__21__2J15 Lend _TrucA_Uotor_ Cot._4 -------- llea.ter_ burned _out_11412/25 (Continued on Sheet 2)

20. y F8 ELD DISPOSITION OPar'a accoaurao^TaoN/aOuTE TO enOsECT ENG NEEn,NG Zi. r.EtD Discos.T.ON aEsui Ts.

Vandor__contatted and is shipping _ replacement parts. Upon receipt of arts, defective cc=ponents_wi11 bc_ replaced _andJut_into._scryice-lf/f/][Ef //t/Grm,Lg/2Anzpf1 M.rm _[ n,w /2- y- 7 C /d(g46%'EC A/# R/ vex 70 &T addition,_mornra_Will_bc_neggered_upon_completi n af betav- %stallation 3/E## '

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.3 oMC o e.F D RMING Co M.IT fo s Drawing E-42 Sheet 11 Rev. 3, Note 24a requires that the minimum cicar space between two adiacent conduits shall he equal to the O.D. of the larnest conduit but not less than 1 's times the size of the coarse ar,gregate. Contrary to the above; Conduits 1BC003 and InC004 @ 16' North of "Fx" Line and 10' East of 5.6 Line and Conduits 1AC003, IAC004 and 1AC005 @ 10' East of 5.6 Line and 11' South of "F" Line, Conduits 2AC'm ,

2AC010, 2AC011, 2AC012 and 2AC013 @ 20' South of "F" Line and 10' East of 6.6 Line and 13' East of 6.6 Line are c : i', c d .!<. d in the Fuel Pool Slab between "F" i.Inc and "G" Line at Clev. 616'6" with a ninimum clear space of l'; tines

.. O neto v.scos.r.on er. coo acco==r-o vioniaou, e to eno,e er ~Giace n. . ii . e.c oo o. cose r.o = a r sv61.,

Cond'-

"Use as is". Recommend that Project Engineering perform a structural ,

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_ structural integrity of the slab has not been adversely affected.

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haca_nse the struc.tur.al_i tegrity of the slab is no[

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adversely affected. See page 2 6, .' l 9 C.*. '. / M ( ~fi; f j !. !

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NONCONFORMANCE REPORT ' "*"' '

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_Concre.te_ Curing -

8. SE R 8 A L N uM et R _ Pour _I!o._A(626. 25)a' e ST A R T U P S Y S T E M No, g[ J~'NcLlf-7-7A c- .gs. _6 JTIA s PuRcN Asr oRurm No 1g no oc v er Lo essercisoM PL AN No.

e t. R E PL AC E M E N T P A R T .so

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g Rourr To r ea to tNGiNes R.NG {) Re8UT E To M A T E R4 Al %uPE RV esom

.. No c o N, o u u.MG c o,.o.T .oN:

be adequately protected to maintain concrete surface temperature of no less than 50 dehec_F".- Contrary to the nbove, for 12 hours1.388889e-4 days 0.00333 hours 1.984127e-5 weeks 4.566e-6 months on the 14 th day of care and for 6 hours6.944444e-5 days 0.00167 hours 9.920635e-6 weeks 2.283e-6 months _on the 6th day of cure, Wall Pour FP-4, A(626.25)a',

in the Aux Bldg._, had a surface temperature of 18 degrees F.

4 IIonconfonaance noted during QC Surveillance.

".q" Ilo. is 1.205 1 Ta d pplied am O FtL LD DISPoSIT eoM {]Fef LD RE COMME ND A f toNtRou TE To pro #E CT E PsG SNE E RING It. FtELo ot%Fo5titoN RESULTSt

_ Recommend " accept as is". A surface mperature of 48 F on the 4th day of cure

.will__no t_ adversely _af fect the design strength of the concrete. The cure will be 3>; tended for two additional days so that the concrete will have been water cured for a nininum of seven41 ays at a min. of 50 F.

t

.: c NG.Nr a ReNG u.srose rso Nnn db. me,. ,.(. . /- 9 76,

//

Jhe lower concre t e" curing _t empera ture_will._ tend _t;o_ reduce _phrinhagc._settingJate.__ 23 s uc ens tR SNG pesPoseTeow ResuLTs-ar.d vater demand, while increasing _d_urabili_ty_and_r. erlu_ e ired _Suting_tJme.,__Ingineer. inn _Cw F hiz<42Ep 2 oix5

_c o n e u r s_vi t h_t he _Ei e 1 d _.re co mme n d a t io n_.to_ "u s e_ a s is "._b ecau r c_lL.Th e_minimun _ co ncr et e O_dM8__

surface temperature was 48'F and freezing did not occur. 2) The deviation in_ cur.ing_ #

temperature will have an insignificant e

The cure for the subject pour

21. SS DEStGN CH ANGC REQuf Rto 28. wasR EJECT extended E o M AT E two 4 t ALfull De-LPOst U "*'*** N ** ""**

days.qg[j/meffect

_dson ' j_u .ry /, Mf 2 7. Of P

, upon requir BT......RTT-N.o. . .. ....

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Where Ccpy - Orig.netor GC-G3-2 CanaevCopy - Field Engineer

, Pink Copy - PGAE Go.denrod Copy - OC

O .I #

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NONCONFORMANCE REPORT

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on m~o, . a T .. ; a e v. ,. . o ,e c T .. - lT W ,~o.,JoL

, )/[ 369 T - "Y o Sp_e n._ 72 20- C- 2 3 0

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Fly Ash uo.ra Batch Plant

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19.ASME h YES tr.SouaCE Champion Inc. , Midland, Michigan Q ,.o , Subcontractor """'"'"""" ""

.. o u T .~ o . s, uc T .o- s, p ao u f e i o , .. to c ~..~ . . . a O anu'a va ~a* =a.u sueca .5aa 9 9. P.oMCoNF oaM.NG Cof.o.T.oN e S e ction_L_4._1_of_Sp ecifi ca ti on_1220 G - 230, _.Re v. a agqy C-618-72. ASTM C-613-72 in table 2 requires that the fineness 5 stat _es that_pozzolans shall conigrm to value be not less than 6500 CM /CM .

Contrary _to_the_above,__ fineness of_ fly 2nh sampled _on_12/_15/_71sva a reparted na 5662,_5543,_and_S.ZR3_CM 2 /CM3 .

_Nonconfa rinance_notcd._11uring_ routine _us ers_tes ting _of_mhte.ria1a.__f'Lliat_numhex_a_1. 105 an_d_1. 205.

- - m o.5 ounoa m O "<f \ r ) Oric'o acco===aoaT.o .iaouT= vo eaoeser e c ace . a ai. r. o o sro .T.o ..usT.,

es* h f2sL. /~8-%

I 23 E P.G.N E E a.P.G D.5Po S.. .o M 3 3. E,.G .P.E E a.NG o.5Pos.T.oM aE SULT.:

_Roncrele_cnntaining_ pozzolan with minimum fineness of' 5561 CM2_/_CM3 will have less

_t.gtal_flneness i (ccmen_t_p_lus. pozzolan)_than.. concrete containinn pozzolan with 2 minimum fineness of 6500 CH2/CM3, and consequently, will tend to gain early strength slower. A review of the concrete cy_l.inder breaks for concrete placed in December 1975 shows that early strength cylinder breaks have fallen within acceptable limits. The slump values show (Con t . )

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< 3 h r10NCONFORMANCE REPORT (CONT'D) . e . o r _S_o ,_3_N ... c. o._369 In add _i_ tion _to_the_noncon_fo_rm_ing condition noted in Block 19 of !!.C.R. Ilo. 369 these follcwing_n_onc_onformancti subsequently _fol_lojied on the same sample: _

1) Uniformity Reguirements for specific surface requires a 15% maxiraum variation from the average established by the ten precedingj tuples as required in A.S.T.li. C-518-72 Table 2. Contrary to the above_,Je_ specific _purface variation wa_s - 19.5%

2] The_Qua n tity_o f_Ai r En t ra i ning_.Sdm Lx tu r_e_requ i res a 20% ma x imum_ya r i a ti on_to_p rod uce '

an air content of 18.0 volume percent of mortar as established by tSe ten p_r_ecedinq tests as_per A.S.T.M. C-618-72 Table 2. Contrary to the above, Air Entraining Ad-mixture _ Quantity varied from the average - 62.4% and - 64.8% respectively. In .

addi_tio_n, a retest samole_obtained 1-9-76 vielded results of - 37.5% and - 43_._8% variation froa_the average- [d42_&xM__

'llock 22 EUCINEERING DISPOSITION CONT'D NM that shrinjage will not be adversely affected. _The overall effect f the pozzolan _not eceting the_rinimum_ fin cn cs s _r cquir em en t_and__unif o rmity_r equir em ents _f or._ sp ecific_ surf a c e_ulll_ b c_ ins ignif.icant.

e The_ cf f ect_o f_the_ po::ala n_no t.J:1ceting_the_unif ornity_requircments_f or_ quantity _of_ air-entraining admix tu r e_(AEA)_.is _ tha t_nir_co nt ent_tes t_r esulta_will._b cL er ra tic._f or_ concre tc . mad e _with_a_ con s tan t d o sa g e_o f_ AEA ,.__Te st_J_e su l t_s._ind.ic ale _that._al.l.__c om r_c t_e_co nt a in ing_t he subj e c t_po z z o lan_me t_sp c_qi f i c a t, ign r.c_ qui _r_emen3_s for_ air content. Based _on the above a _ Project Engineering recommends that the concrete be"used-as-is."

t oo wa White Copy - O. aator cc. :';.c;" : ; :"'~~ '

Coadeared Copy - OC e ,

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N NONCONFORMANCE REPORT

.......c. .. ,,

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( '*' "* "3h D co cu... <.

_ Spec. C-230 s e s s u os sc e s., so,.

i5 7220 s aveu Locareon

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.. c o A...c r o , toc. .on N/A C-231-2-6 8' . . . a s _cRev._0 O was souace p'.'."..*.~~,_'*.",,,~..~"*

C'tamnion Inc., Midland, Michigan .,r= Do Subcontractor

, -ou r ,~. . s , uc t .o ,

n aove r so r.r to = ~ . .. .. . o .. .u . . . . . . . .. . t s u e. . . .so .

. . . c o u , o . . ,.o o. non ,

Spec. 7220-C-2 30 Rev. 5 Tabic 9.1 stntes in part that the rejection limit for slump of D-1 concreta mix is 5". Contrary to the above, a slump of Sk" was measured at the end of the pumpline on D-1 con-

__ crete mix represented _by Ticket No. 07209 placed in the Aux.- Bldg. - Wall No. 29 pour No. A(599)L' on January 16, 1976. Nonconformance noted during routine testing of concrete. "Q" List No. 1.205. ONE lloid Tag applied.

Ticket No. 07209 rep.re_sents 8 cubic yards.

" O "t 'a o's'o"o" ppe'o acco"~raoav'oasaou,s ,o eno,ec v a....arrai~a a. . r. to o.s os.r.o .c.u61s,

_Use_as_in _ Cylinder set #732F cast on 1/16/76, from ticket #07209 Averaged 3180

_ psi 0 7 days, or_63.6'I of fe'. Based on current strength data cylinder set A Fu ,_tt Q

732F will exceed 5000 psi 0 90 days. s . 2 7-x g

_Eiuld_r_ccorniend s "use as is." /

g

,2 E Nf.IN E E M ONG Of s,o St,8aN 3,. g gg es.g g pD 8NG oSS oSO,9o R ESULTS:

_Re riew of the attached table of data for ticket No. 07209 indicates that the 5-1/4 inch slump value at the end of the pumpline may be erroneous. Slump and air con- -

' tent valtres are consht. ant _1y lower at the end of pumpline than at the t' ruck discharte.

Based on the foregoing, and since 90 day cylinder strength estimates for the D-1 mix (5000 psi) exceed 5800 poi, Engineering concurs with the Field recommendat'on to "use as is." (Continued on next page) . .- /

3.. OS ot teGM CH.NGC R EQUIRE o g 2.. RE JE C,E n M A, E RI A L Dl5,oSBTBoM O"*'***'*****"'** ... 'A c A E O ,es. ae avracw o., .. .... ... .....

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. [R AWGNO RN , Mf' aw ..s..i s . . . ..ec..a ..,e S,t c. R E V. . D o.

t es s e-s whineCopy - Origensto, ecs a-a Caaery Copy - F id Engine.,

4 '

Pink Copy - POAE

. Goldenced Copy - OC

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,7 NONCOff r oqMANCE REPORT *

w-f , . o . . o.oi. . , = o. . ,,a v: ,~ Fa o ,TcTu o. '

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cc A. . e m 7220-C-208

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_y/A u set c .o rt . .. '7.. Ti et.c a u c , s e . ..c .. vPU91~_Mi Q J")* y g g^>3 y E*) .7/g C-231-4-736 Rev. O N/A

.. con. .c o , toc.v.on

....s. o ,es ..sounce

. / " * ""< ~[7 " "

"nited.St,ates 8to u Y e G B r. T N oC T Ies SOMir Hm Co_.- llidland.,.111th. _ "=

0 No _ _ _Sub con tra Rovi r To F GE Lo E NG INc't a * *c- O o s' a. ' o = a 's a'a'c sure tor _

a viso a 5 9. 9.C,Nco f.F o#M6NG C oNot t foN :

Specification 7220-C-208 Rev. 5 paggr.iph 7.3.2 states in part that, " Concrete cylinders shall be maintained at a temperature of 60 degrees F to 80 degrees F rrior to strippin[;". Contrary to the above, the field concrete cylinder sets (708F, 711F, 714F, 719F, 721F 724F and 726F) made representing above location on January _9_,1976 were initially cured _between 60 degrees F and 82 degrees F. "Q" List No. 1.205.

Nonconformance noted during QC review of report of concrete cylinders. No llold Tags applied. -

- O "r 'o o'5"o s'"o" p<'c' *'aco~<'.oa v'oaiaour z vo rao,ccr r < ie.c c a c an. riri o o.scoser.oe. csut,s,

.Eicid_reconnends_use_as_is,__During the initial curing per_ipd of the first 24 hours2.777778e-4 days 0.00667 hours 3.968254e-5 weeks 9.132e-6 months ,_

.!i_ deviation of 2 E._for a maximum of 24 hours2.777778e-4 days 0.00667 hours 3.968254e-5 weeks 9.132e-6 months is an insignificant period to effect '

the long range strenr,th developnent of the field cylinder cast 1/9/76 from place-

-nt_A(614)ll._._.Ihe_averanc_Z_11ay_ strengths _o_f_ t; lie _ field cylinders is_.3790 psi -

27 .ves, set averaned 3525 psi and the hinhest averaged 4000 r si. J.,IbIA- t-27-%

E NG6.eE E MtNG oesrose ttoN Th9 )~ 4 %\P-

kNW%4 *44-1u curing temperature of 82*F_ maximum _,_in_11cusof the 80*F_ma_xiihum allowable. will_g,_ g reg.p.E E n eNG oesPoseT eo8. RE sutT se tend to lower the test cylinder strengths an insignificant amount. Based on the 28 _

day _ cylinder str_engths,_the 90 day cylinder strengths are estimated to average M 00 psi.

Beccuse the estimated average exceeds the minimum average requirement of 5,000 psi for the class D-2 mix, Project Engineering one,urs with F'icld Recommendation to "use as is." Q,L { A FR, _ </,, 9 lg g 9,, l h{,,s.wfAss. T/n/)b as es ocs Gn cuanGe nrou.Veco ,,* - ' '

re. aserciso marrasat oesesursor. Ua"*-~'**-~" q ac acer rance muawsna n e v.

y as. sec ayeacwao.

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White Copy - Criemetoe

Canary Copy ec s s-a

- F eld Erigineer P6ah Copy - POAE Goldeneod Copy - OC

i 2

s ' ^*- - _ - . . _ _ _ . ___ _

NONCONFORMANCE REPORT ' "or^ ' _' 1' 372 o . ~. 'w' .~ ~7 f e . . o . R" U.TE' 'o. 7 77,oW o ~ ~ r ,,,,,,,,,,,,,,co co,,E,c, FSK-C-234 !0 7220 > <~y c 8.

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_Jirm.ruBl dg. Area (For _ Cont. #1s.} 1(,14, l/-T/-Ifj( :

_ / d....1 h" .T,iner Plate _ Assembly

.. w .. e u u .. . ..sv. sys,s no. c ,t. c r o. . .. . e , . c W. .....o.......g..

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3-f 7 ~/q C-111-65 N/A 7 72 1co.0..C-50 . A

.cro..coc.v.*" Memphis," as-= 0 was o souac= ',7 ". ,,',*,,' *,,", , ,'..* y "

uthern CI ~o ,_,,, ,,,Ven,d o r__ _

our.~. ..Boile s, .uc er .on

& Tank Works., gg _Inouvator.ctoa ci -Tenn_._ _ c.cc

_ _ _ .,n

.~a -

... s, _o not,cvo -.va...osucaav.so.

93 PaoNCo M Fo M.MG Co o.v.."4:

A_ dis cre pancy_exis ts _b etween_ mill _s lah . nun.b e r_do cu:: lenta tion _and_the_vendo rs_.trans f e rre d_s t amp _

elab number. Documentation lleat Number is 518A0703 with Slab Number A79070. The plate is vendor transferred ntamped 518A0703 with last digit in slab number in question A79077. Discrepancy detected during QC field inspection r2 view. One_lloid Tag attached. Item "Q" No. 1.109.

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_._ficid_uill_ contact lincr_p. late _vendar_nel ask for verif_ication of correct niab ' _e_ lac c1' %p ,3 ges; '7 #:c'70 number. After receipt of verification, identificption will be corrected. Work j[ g ggg q,5;o,.,p.pp m nay proeeed. (T;_f_ C h w [ a, J 3 '7 /, pgjt_ss,m_fcue.d a w w

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MEMORANDUM i

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4 SOUTHERN BC.'LER S TANK WORKf INC. l l

MANUFACTURERS OF CAPUOH STCCL, AiUNINUM & SfAINLCSS STCCL 4

,c s l TAN KS, PRESSU R E V CS SCLS AN D F ADRf CATORS OF PLATC STCCL I 3.Iv. <..., ..,.,2,...... , o - . .,,,cc,

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FE'ri 12 iB..: .

BECHTEL I 0WER CORP. February 10, 1976 \

JOS 7230 g; 4

,w eson -4Cr) .

b B;chtel' Power Corporation P.O. Box 2167 Midland, Michigan 48640 Attention: Mr. J.F. Neugen t Gentlemen- t l

In response to your letter of February 3, 1976, we have checked our files on ,l shell liner plate material 1 S6-1.

Our investigation indicates that the correct slab number is A-79070._,_

This letter will serve as your authority to re-stencil this particular shell i liner panel accordingly. ,

Sincerely, 1037220

cunna'f4y $I SOUn{ERN BOILER & TANK kORKS, INC.

f C tlG.1 % , ' / '

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?! EMS.9 % p APT dig:t Robert L. Strong ,

CI .._,._, Chief Engineer RLS.:dh

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3. D g a Wr#NG/P A 4 F No, or _.)1 X 2_ 373 a NE W. P. PaoJf f ? No. 93 MEroRTEDev 8 D 21. of%rOSITeoM CoreLUMWcMCE Spec. 7220-C-208

3. 61 E M Of SC RIPf tom l'5 7220

$ a.#CplOATEDSv m R % .h b ATE') V~ll "-r- mm "z r-- a u--

S OT E M loc A f foN 94 I DATE - -

_.foncrete_ Cylinders

e. t e n sa t Numee se Aux._ Bldg._ Phen

o. sT ant ue s e sf a M No.

MLu ab_ / secrLaCamaMT ran p h-? 76

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'Inited_ States Tes tag _Co .JLidland.Jiich _

'n u G ao __ __ , Subcontractor wouriNc. eMsv nuC Teo s:

p pourt ro rerLo cNG.Naca No O aos '< 'o "a'r a'a' Su cav'soa so. NoNc oMronmeMG CoMoer oNr -

S r1 Specification 7220-C-208 Rev. 5 paragrap.h 7.3.2 states in part that, " Concrete cyQndes shall n

be maintained at a temperature of 60 degrees F to 80_ degrees F prior to stripping." Contrary _to the above,_the

_J ie.1d _c o n c re te._cy lin d e r_ s e t sl728 F_an d_730J9_ma de_re p re s e n :in g _ab o_ve_lo c a tion on_01/14 /_76_we re_in i tially_ cu re d between 56 degrees F to 65 degrees _F. In_ addition,_ lab concrete cylinder sets (727 and 729)_repr_es_ent_ inn same

_lo t: a tion _.we te_ i n i t ially_c u re d _b e twe e n_6.3_deg re e s_F_an d_81_;tegre c s _E .

"Q" List _No _1.203.__Ronconformance_noted___

during QC review of report of concrete cylinders. No hold tags applied.

n. O " <'a u'5'o5"'oa 6'o a< co== < a n a r'oataou'c 'o raoJace r ac 'ac r a'mo * * "< 'o o'Seo so a a

5uu S'

_E_i c_I d_ re c omme n d s _ti s e__a s _is, During the initial curing _ ped 2 ,d a deviation of 4 F under the minimum is insignificant to effect the long range strength development ,

of field culinders #728F and 730F. Sev_en day results of 72.}F and 730F are 2670 t

osi and 3205 psi respectively. nased on current date, 90 diy results will be

., +00 psi and 6000t psi. A temperature of 1 F over the maxinum vill have an 7 2. E NGIN E K FO f MG Ot%Po SO F f oM 3 3_ g NGIN E E RING Ds5PoS4 T eO N R E $ ULT S r A_ curing _ temperature of 56 F and 810F in_ lieu _of_6.00F_to_600E_allevabic wil)._af fect cylinder __s_trengths an insignificant _pmourt_.__ Bas _e_d._on 28 day .

cylinder _ strengths,_the_90_ day cylinder._ strengths are_ estimated to_ average 6190_ psi _for_ sets _72M_and_Z30F and_5610 psi for sets 727 and 729. Because the_ estimated _ averages-exceed-the-minimum _avorago_ requirement of_5000-_ psi _for__

34. SS DEstG N CM ANGE fecoulMcD N* 26. aEJECTED MATE RI AL DISf oSET8oN 27 of ACCEPf aNC 0 vEs. se e aTTaCMco.

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NONCONFORMANCE REPORT '""***

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M-1.15 MRI-M63 N/A T coia. c oattoc...o. .....- g .s - . .. sauc e

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Makeup Storage Tanks 1T58 and 2TSE were received on a truck with carbon steci chains t. rapped around the upper nozzles. Chains caused surface marks en nozzles and upper head. Stainless steel surfaces covered

_with heavy winter road film. Units 1 and 2. "Q" No's. 4.039 and 4.049.

Nonconformance noted during receipt

. inspection. 2 Hold Tags _ applied.

a._ o c.ctoo.scosn.o" Or'o au coa"ra'oav'o 'iaou'c to racerc v s an.aca. o .. ...to o.s.o s.v .o .. sui., si Pnutc to_JLIn ILSite_Represcatative Ok h 1 )--%

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Ib oagrosse ton C oNCuRNE ,.C E

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N/A .C.o .,<oC N/A L.. A - ' * ~ ' ' = ' - ~ = ~ - " -

e Co . ... ......E a E. o ,ou.CE U. S. Testing Co. , Midland, MI ,',E g-' ,o Subcont ractor

.. -ou.. G .N ,MvC ,.oNs. g .o u , E , o . .E co E ,.G ,N E E . . G'-- O aou' r 'a M a ' = a'a' Sua' a v 'sa a 9 9. P.o*, con,oR MeNG CoNot. con a Sp e cific_a tio n_122.0 - C:.2.08, _ Re n _6_S e c tio.n_6. } ,2_s t a t e s_in .p a r t .t h a t ,_"Ro z z ol a n_s h alL b e samp1m1 and tested in accordance withlS_TJvlC .3_11.. " AS_T_ht_C - 31 1 - 68_s.t at e s_in .pa r_t , _ "o n e_ et s t,s a m pl e shall repre_sent not _more than 100 tons. " Co.n.trary_to the above, on August 28,_1375 a_p a_s.s i ng_u s.c r's t_e s t

__ sample was taken at 1989 accumulative tons reprer.cnting the test cycle of 1900 to 2000 accumulative tons.

The next user's test. sample, which also passed,__was taken on October 23, 1975 at 2157 accumulative tons representing the test cycle from 2100 to 2200 accumulative tons. The user's test cycle representing 2000 E suo,s,

...,E C, E NG.,.E E..NC . r E co o.scos. .oM

... a r.,to o...os.,,o p r.E co nE Cou-E No. oN, ov . ,o Field recor. wends use as is. During the period betvicen the tvio passing user's tests of 8-28-75 and 10-23-75, the field experienced no unusual control problems or fail-ing concrete strength tests. Attached for Project Elgineering's revievi are conies '

of the passing flyash user's tests of 8-28-75 and 10-30-75. ,90. . . (L d.( 2-is m 2B E PeC $N E E M eNG otSPoSt. con RE 5ub,S e

23. E NGIN E R. M tNG oISPots.coM se es oEseGN CH ANGE MEQutREo Oo * * " ' ' ' ' ' ' " " * ' ' " ' ^ ' ' ' ' ' ' " ' '

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NONCONFORMANCE REPORT " '[.C

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r. Paosect o. Tar oa o '

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_ Spec _]220-C-208 !6 7220 h g77 . t $n!onra8/4-1

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s. ors u orscasPreoM .. ev e u Loca tion A(633 75 E' ( uoairo =

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_ Concrete

4. S E R I A L Po u**sE R Aux. Bldg. Pour FP-5

9. S T A R T UP 5 T S T E M reo.

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9 9, NOP8C O NF oMM.NG Co N ot f.oM a Spec._12.20-C--20B_ Rey._1_Iable_21,_2_ states in part that_one set of comgressive strength -

__cyl i n d e rs_f one ach_10D_c_u 2d s ._o f_ con c r cr e_p ro d u ce d_ is_re q u i r.c d . Con t_ra ry_to_th e_ab ove_th e_i n t e rval_b erve en -

casting _ cylinders sets #733 and #735 was 104 cu. vds. 7 h is c o n c i:e t_e_ wits _pl_are d_in_ Aux ili a ry_Bld g._Eucl_f oo l -

__Pjacemen t # A(.6_3 3 25) a' . Ron-Conformance_noted_during_QC_ Review _of records. "Q" Lf :t_No- 1.705 -

_One_Rold_ Tag _ Applied

... o r .c oo o..Po.. ,,o 29, .. to .. co-o . N o. . .. ,oo u r e v o o ,. c r . M. . . . . . . . . . .. to o ..Fo . . . .o N . . u t . .

Field recommends use as is. Total concrete batched fo. placement A(633.25)a' was -

280 c.y. A total of five sets of cylinders were cast, three sets at the batch plant

and two sets in the field. Of the two field sets, OneJSet #737F) is a comoanion to -

batch plant Set #736. Based on the seven day test results, all cylinder sets will -

exceed the fc' of 5000 psi 0 90 days. Listed below are the seven day test results. .

f 2. E NGIN E C R.NG ot5Poss 7 ton 2 5. E NG 686E E RING otSPoSIf eoM 8.E tuL f 5 se. is otsacN cNaNos atouaNEo O e.o **""""^''5' '"' "

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' "'* " * * **[y , p ((t h 2-5

___.In,1and_,Ryerson /,_p_qut.h f,ie,1d, Michigan

.. -our. G . rauct.oNs:

eve u

&3 .. Vendor _

q.ou r c ro . ..to u.G. e s.. G o -ours to -arca..o suecoviso.

9 9. NoNC N FoR MING CO p.D.T eor.:

Specification _7220-C-233 Rev. 6_ paragraph _J.2 states _in part " Welded joints shall be made

_in_accordance with_.Casic_for Welding _in__B_uilding_ Construction AWS D1.1-72.. ." AWS Dl.1-72 Part VI ' Stud

--Welding _ pa ra gra ph_4.30.Ls tates__in_ part, "I f vis ual_ ins pc c tion _revea'.s_any__ stud _she a r_conne e t o r._tha t_d o c s_n qt how a full _360_degrec_ veld fillet = - , such stud-shall bo-struck-with-a hnrmor nn d_. bear en nn angla nf 15 degrees

_ Lto_q_i_ts_ original _axismstuds_that _ crack _cither in _the_ weld,_the._ base motaLon__the shank._under inspection or nuhsonnene ntrnfohtonino" ehn11 h ,. von 13,na.

se. g e.< Lo o.seos. ioa " O"<'o arco ~aicaoar'oataour< 'o racerer <aG.NurniNG .resto o.s ositioN assu6vs.

Retur_0 material to supplier 3 -,

ft z f-M a f. E NGIN E E R.t.G otsPosIT ore 2 3. E NG.N E E RING o.sPostT IoM R E suLT s:

~-

na. es orssGN CH.NGC REQu1REo Oo **"'""^"'^'"'5" ' " ' "

U'"."*~"**"

o m . W.*.G R E V.

O ves sea Avv.cNro.

oCN O .< .

av.a...se. ..scue. ....

sPE C. R E v. Aoo, seess e White Copy - Originato, o c 4E s-a Cenery Copy - Field Eneiceer Penis Copy - POAE Goldenrod Copy - OC

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fJOfJCOrJFORMAfJCE REPORT 07 1 1'93.""' *

.O..N.M,,,.=vNO. i nE w. v. ,= 0,E c r O. In M c.O , o .y g ' OnvE s.oS,OS. ,0NcONcunaENcE Part No. 1R57A

. si _., E u O E Sc . . O N .

7220

.1 E - LO c r.0,.

h[4@%

~ d oo .t, E o . , !o'.v a

CIi // " - * " ' " * * ' " " * ' " * " " ' " "

I I -I I Purification Demineralizer T mk "F" Laydown Area -

1j g, l 2. f-N 3 ff./ g.E.asEN ...gO ; ,, E ..

..SE..Lo..E. . . S . . . . . S . S . E . N O. ............. -..... ....

_H a cl ._ B D _t{o.._2 84 N/A L__N./ A I ...,..,. ... ....

- S. FuMCN ASE OM DE R NO IS. OC F gE LO SMSPE CT TON PL A N NO. 9 6. RE PL AC EME.0 7 SE R S A L NO.

" * ~ " ~ * " * " * ' * ~ " * ""

N/A N/A J..coIR _:f o._M- 1.20 aacvOaitOcaveON si.AS=C

@S er.Souact BMI/Jobsite ,,E. O .. Supplier ~

7 aOursNo NStaucr ONS. %=Our E vo r eE Lo ENGiNEEneMG O aOu'< 'O % a ' = a 'a' 5uP< a v '5o a j ~$ (G 9 9. No.eCONFOstMtf.G CO.ept 7 pON:

vesscLlR57A_vaa_ opened._to_ place desiccant as required _by FP_G _3, R-1-215 Rev. 1. Unon

_intcInal_.insnecLi_om_apno_ximately_1, o gallon of water :.n the form of ice was noted at the lowest point of the

_ vessel._._The_vesseLis_ pored on its side _(.inreference to final position), and the ice _ has not entered any _

_pozzels. The vessel appears visibly cican (inside) and all the closures were intact. This nonconformance was noted during storage maintainance preparation. "Q" No. is 4.038. Unit No. 1.

One tag applied.

24. Q FIE LO OtSPOS6T SON QFeELO MECOMMENO4TBON/MOWTE TO PROJECT ENGINEERING S t . PIE LO DeSPOStYtc.e R E SULTS:

24. E NGeN E E m eNG DISPO SITtOPG 2 3. E NG 4N E E R SNG DeSPOSe r eOM st E SukT Si

_ m 24 05 DES 4GN CN At4GC REQUGHED OO T**"'""^""'"'" * ** **^***^"c'

( O."...'****~""

O vES.SEE avr ACNE D. '.. .... ... ... ....

OR AWONG R E Y. DCN e a.....ea.ee........ e...

SPEC. R E v. ADO.

99990 0 White Copy - Originato, O cia s-a Canary Copy - F acid E ntia***

Pink Copy - POAE Coldensod Copy - OC g; .

) -

bN

' ' ' ' '*~~'"'~

NONCONFORMANCE REPORT o, 1 380 TT;;m.a,,A.;, .. - - - - -; . . . . m~o~mr -- ", "T;;. . . i o.,c y n,s .,, o c o,. c u . .u .

_ Spec. 7220-C-231 !8 07220 4 u vaun vro =v M1% Qf3/_n ' o.v r

""- ""q " ~ jm'g*-f "--- -

..... - o .c .,1.o .. . 1 c u toc.1.o.* A(6 33. 25) a' bMK

.._ uCon..c.rete_C au-.r. urin g . . . . . .r, u . . v . v . - o.__Pou _lio _TII60.6)a_ c ,t . c . . , , . , . . !2 I-b'.7b

- d....b........M.... 7 -2h.

! I

.. s.*z d

. ... d4.. b il_. **/- W/R

.n,/onc A ..e o.o . . . .N/A

.oc- . < o . .. c1.o . . ~ o. __.N/A.c

...ncet . 1..... .. #

~'

-.. ~ _2.ZI. U -

_'I/A C-208-1-139_J_E:208:1-140_ se...-c O vas . e..

. ..N./A.c ou s * * ~ ' * " " , ' ' "_ * " ,

s.cour ..c ronitoc.v.o _ ,,_ , ,,,, ,, ,

'/A "*" U "o

....ou.. .. ...uc,.o .,

g .ou r r ,o r.c to a ~c. . .. . o o_..Const u n , o .r.u. .c.t.. ion o.u,...o.

39 MoNC o M FO.eq.NG Co Molf .oN:

Spec._12 2_Q-C _2.31_ Rey,__B_foragrapit.13..!. 4_s tates in part, "Th a t_concre te_mcabers_.sb n 1 1

_he_adequaroly pratacred en mintain. concrete-surf ace-tempe rature-of-nor-less-than 50_ degrees _F__for_.seven_ days "

_ Contrary _to_the-_above,_the_ following_two_nonconformances ware _found For fi hours _on_the_fif th_ day _of_ cure.

_ wall p ou r_FP-1 A( 633 25 ) a '_h ad_a_s u r f ace _ temp era ture_ of_45 _de grees _F. On_the_ third _d ay_o f_ cure ,_l e nn b a ck f i l l

_p ou r TT (606 ) a_na_ tha_S o u thwe s t_ co rn e r.__(5 . 3_ at_KC l i ne)_ tem ) erature_.o f__40_ degree s F_ Ilonconformanen noted during Oc nurvnil lnn en. "O" tin _ f .: 1_705 7 IInid Tns s Applind 3 C) r c to oi.cosi,.on (3rica.o nccowur no.v eoninou r c to rooercv c, o.Na r n.no a s. r.sto os.cosit.on assutv M . s. sts Field recommends use as is. On placement ' *(d33.25)a' . thi cure was extended two (2) days and for Tr(606)a the cure was \ extended one (1) day. On each of the extended cure days, the temperature was above 50 F. .ba.q us. M.Mi Z //-76 32 E N G.N E L . ING D# Po.e, .o M 3 3. E NG ..e t E . .*.G o...o..T .oM E su tT .s wi1Ltend_to_ reduc t_ shrinkage The_

rate and lower _concretacurinkikemScratur$_ngdurabilityandrequiredcurl._settine water demand, w e ncreas ng time. ,

Engineeringconcurswiththefieldrecommendationto"us[ asis"because

1) The mininum concr_ete._ curing. terperatures_p6to_4'NE_for_ pour FP-5A(633.25)a*, b,-

40CF for pour TT(606)a and freezing _di_d_not oc. cur. 21_Ihe__ cure _was_extendedrwaM '.

.II:L days for pour FP-5A(633.25)a' and one day for pour TTM00n at ternernrnrn= nhnC00r U'/ >'M'A 2-l## -

n. . oc..cu c .nuc arou aro ,. o v.......,,.c...

so. acescur o a avra**' os.co. nso a

{',';-" " """" 2 gg y

-o r .. o-f ,E C. R E w. . o o.

WNee Copy o c-G s-2 S ee 9 9-.

Cenary Copy _- Onsinator F s.ld Engin r r6nts Copy - POAE

Goldenrod Copy - OC .

NONCONI-ORMANCE REPORT m=m ..... ...... m .. m=. . o . . -

o.

,,"" a1 ...o_ca o,-

o.

"' " ' 3"8"1

_. . c.

ISK-C-234 !0 7220 a< w v b /:c w^

a 3on s I.~# - "-"] " '" ' ' " ' "" =j g

s. .v e u o t sc a.et.o .. e .t r u tocar.on . v 4a.ioa rro ov ,

.tI".s.- I,. .fne 'dE L ' ~ 7(~ d a n _M. . .a.p ,I. . . . b..#D.. .....K...~.~.MM

)

_ vr .P.latO-ASser.bly . oa

.I131d.Q~.s A.rc_a o . (For_ Cont._f1 p ...t e u o .

1 ruA -

Nza i .

.s-. ,us- 3-u.c o-.. . ...

c ., a ... oc r . t o . .. c r.o e. no.

.. a a rta c a-a ~ r se..ai. =o Q. iQ..__.g.. ,[ ,

t -/./ /'h C-lllhs 67 N/A [f-*---'a-*~""

Memp is ,

.7

. 720-C-50A, comsmacrontoc a r .oM av~c 0 vis Savaca *"*

coor Southern Boiler & Tankwork,s_, Inc. Tenn. ,, . . C'2 ,. Vendor

. . . .o u v . . s , . uc e .o-s . y,n.our n , o . .= to a no.-r u - .~o o noursio-ava... .u ca..so.

... NoNCoMr on M. . CoNo.f.ON:

Two discrepancies exist between mill heat number documentation and the vendors transferred stamp heat number. De documentation mill heat numbers is 518A0703 with Slab Number A79080 and the other plate

_ pill heat _ number _i.s_518A0703 with Slab Number A7 90 6 1. The_ plate _is vendor transferred stamped 518A08040 and Slab No. A79080; also the other plate hear number is stamped 518A08040 and Slab No. A79061. He question is with the mill heat numbers- the slab numbers are in accord. Discrepancies detected _during QC Field Ine>ection Review.

One hold tan attached. Item "Q" No. 1.109. _

a . . r .r i.o o.s.os.. .on . nut v . ,

n.. a r.,to o...os.r.o. O,.a to .eco--c-oa v.on,.ou r a to coa ,a cv r oa. . .. .

_ Ficid_will r nn ta c t.- liner._ p la te_vcndor_and _ask_f o r._ve ri fic a t ion _o L_norre_g t_13 ea t

_Dyntmt ._._ Af ter_r_cceipt of verification. identification will be corrected, Work may proceed. fh[ @[A r I_3 - / y

. . o. ...... o...o....o a . e ao. a -.~o o.seos. .o = -noi.n,

a. .. on:..o enanoe neou.as o O ~o ' ' " ' ' ' ' ' ' " ^ " " ' ' ' ' ' ' ' " ' * "

U"..".*""**~"

o ..

O vs .. e avvac so. .. .... ... ... . . . .

""^'""* "*"- "*" . ........ . .. ....

- E C. .g y, noo.

" awii 6....-. w . C.J - c. .. ...o, Cana,y Copy - F eeld E ng. nee.

P M Copy - POAE

Goldenrod Copy - OC

1 d

~

NONCONFORMANCE REPORT

*" '"*""*~

n.o ...uc.,.=1 no. . e v. 1. n o,c c , uo. f. 7',T""' ,,"o,Joso

!9 i

o.

S E.,pecification c u oe sca.,rion Ceneral Liner Plate C-111

. na 7220 toca,.on

v. .1rb 2

d.54

k. '

couco....c.

"" ' - * ' ' * * * ' " " =

IUO I I Reactor Bldg. No. 1 M .p((,b _

&.t. nz,L.crLe m r e.u r no.c'N v//74

o. t e n..o mu-or n

s. st an rue svsv ru no. #

_ gf n a y.

.,Ihc.seo......

o Wo eb. o . s cc v.o. et. .. ..Y,o.c e- u, se...o 1

N

y Q $ 'pi"; h C' Q 2-/'. ) 4 gA N/A o.

a co . . .c o.itoc. v.o= N/A -

....... o ... ..souace * * ** *- = = - - g JLA ,,,,,_,,,,,,,_,,

. nourino . st auc tions, new G uo onstruction ,,,,

gaout e to r ecto cwG.=c e n.no O ao'"5 to aa v r a'.i sura av'soa

.. o co-r o -.~o co~on. "'

Spec. 7220-C-lll Rev. 9 Section 8.1.2_ states in apart that deviations in the liner glate when checked with an 8 foot long template curved to the require 1 radius cced 1". Contrary to the above, measurements made on .2 cross one of more welded seams'shall not ex-Nield seam at 300 degrees Azimuth from Elev. 650'6" to

_Elcym651' 6" in_ Con t ._fl_in dic a.ted_a _devia tion _o f.l__1/ 8' ._ _Ron cortfo mance_no ted_d ur ing_ rout ine__QC_in spc c t i on l_iner_ plate tolerances. "Q" List No. 1.109. _ .

C4/p //gy 7 E-rr r3,n to onco.n.*~

M MfEES @#d' M /7#

Orasi o acco aurao.r. oar oure to r o,cc, r.n . ca.... ...,,,too,,,,,,,,,,,,,,,o,,,,

loply_ external _ press _ur.c._t_o__ ou.t-of-toler_ance area of liner plate to move plate to J, fc/ ff j jo yd an acceptable _Iolcr_artsc, Rertairs vill be nade in accordar.cc with appendix B of fc/ /,,g,fc e

__ SEECS-2220_C-111-Rey. 9. O, #

f.gf. h & / / g ., e

.- 5' _g 2,-/3-7p _in/ f//[c /oo f,N[ M

~

//wo--

'P - / 7- 7[o /1 .#

p ,,, . ./ /

2 8. E NGIN E E M.MG o.SPos.T eor. yo, 7c 2 3. ENG INE E M 8NG oss,oS.T oM RE 5pti ss 21 3 of s.GN CH.NGE REQul Eo >r .. ?

C No 28. R EJECTE M AT E R..L Du,3su.oM ' " '"*V'" 2 .

O vss. sea 41r.cneo. .. .. .

om . w. . T E V. oCN . , . . . . .

- * *e ss e o e .ee c .e. ,,,,

. we.

wh .e Cod - Origina.or ec7.5 Canar y Copy - Fee.d Engineer P4pitCopy - POAE Goldenrod Copy - OC

t,,s'e

~

, I

~ ..

\- '

D C-t NONCONFORt1ANCE REPORT '" " ' " ' " " .

383

,. pn a ereme.,Pa n t no. e m w.

- + . . or 1 I.

p. rseos;c t no.

sa con t e y ,_ ___ , oaf 7 m -

_ Spec. C-2 30 l5 07220 ' as. oeseosev ec u comcumat e.cz 1

l

_C

o. ,c...... . . . . .. . o c . . .o .

g

, , . . .h.op . .

s

..f j~m- j-"- l-"""l""

.. .o. n..c.re t e_

e u-... P

.. ..o.u.rv._N _

.o

. E....6.30J5h '

. . . . . .n ' O c , M . l, . . , . ! 2 N/A N/A , .

O PuMCo. A SC oMot n No. 4 0. oC F DE Lo SMSPE C,00pe PL A P. 9.e t N/A 1 ,,,, ,,,,,,,,,, ,,,,

g G. R E PLA CE ME M F SE 8 84 8. 9.o.

a..cous . ..c ro.itoc a r o c-2 n 130 _ -

.....M,- ulA ~ ~ ~ ' ' * * ' ' " ~ ~ " *-

.,- O vas 'rsovace Champion Inc., Midland, Michinan- .r- D Mo Subcontractor M7u i ,~ o . . .uc .o~ s.

g our.ro . oo. a.-aca. 5 O aov'< 'o M a '< ='ai su'< a v'so a 99 f.oNCon F o RMar.G C oNo t t so*e r Specificztion 7220-C-230 Rev. 5 Table 9.1,_" Concrete Classification Table", states in part that the rejection limit for slump of D-2 concrete nix is 4's _ inches. Contrary to the above, a slump of 6 inches was measured at the truck discharge on the D-2 cor. crete mix represented by Ticket No. 07311 placed in the Aux. Bld:

Wall No. P-14 Pour No. A(6 30.25)a' on February 9,1976. Is cubic yard of the 8 cubic yard batch was placed in the

_ pour.

Field cylinders were made for the noncor. forming concrete. Nonconformance noted during routine QC inspect-ion. "Q" List No. 1.205. One hold tag applied.

... O ,. co c...os.r.o gg r.c oo ., c o. . . . , o u v e 13 ,,,o,, c , ,, c. . . . . .

,, , ,, 6 o o , . . . . . . . , . u t y . ,

Field reconmnds use as is. The 1/2 c.y. placed from ticket 507311 re.nresen ts 0.53 of the total of 96.5 c.y. for A(630.25)a'. Field cylir. der set 744F seven day results are 2730 psi. Based on current field dati, the 90 day results will exceed the fc' of 5000 psi. Estiaated 90 day strength i; 5490 osi. 3 ,

q w . I L O :.,ecn.

f ., . c. .... . o.. .....

33 E NG eo.E E M eMG otSpose f soM 8tE SuLT S-

a. es oesec.n ewance secoueaco Oo "'""^""'***"'" * * * * * ' ' ' ' " ' '

O vas.see avvac ro. .......

U".".'.*"~""

O. .

oM AWeMa ... ...

.e g v. oCN ....

sag e .w. ...e.o ...g,e.

n r v. Apo. e.,,

seese a __s. .

wn.recepy - Oreg aato, ._ec 4 3-a Canary Copy - F .eed E agmeer Peak Copy PGAE Gokseated copy - CC

. 2 N* f TJONCOfJFORMAfJCE REPORT ' ' " * '

","~

,. .._. , ...._. . . ..=. .....,m_.._... _

or m ~4L

, , . . . . . . ... .. ..,.e,..~<o,<...~m 7229-:f-231 '6 7220 //.. i ,% - t . - a r/: 4 " - - - '

. . r e M or sc -....o u . ..s= Loc rean -

. , . . . to . r o . , a o.,r . l"'"'I""~""""" I I jh1

_51.t.c. .p_F.aM

.. b .r.i.ca tr.d pipc_S p o ols_

___0. C. _. .E.o.l.L. . .u.c.a d'N' M/ *

.L . .. . .

.....L o M. . .. . .. ... ...... ... ... ....

See Bloch !!o. 19 II/A !!/A I ... ... .... ....

9 PURC a st Onnre O 8 9, oC r sE Lo sN1PE C F eOM PL.N NO. 9 4. stE PL A C r M E P.T SE m e.L MO.

7229- ::-l yi A-AC P.ev. 2 ?!-194 A-R-19 Rev. O !!/A - - . " * * * - - * ~ ~ " - -"

e co.e s a.cron/ Loc.'som es..sut hyr s sp.sOu=CE IT Grinnell/i:ernoraville, S.C. ,',,".l 0 ~e Supplier t e MOUf 8NG SNST RUC T 99M S-

{. ROUl r f o r aE LO E NG IN E E se..eG Q ROUTE T O M.T E e.L 5UPE RVe%OR 99 MOMC ON F ORM.*aG CO De f eOM FI:t C-3 Pcv. O Para. 3.3.4/a/3 - ftates in part: "Preli:tinary Innpection: "Ih t t inspection shall be to ascertaia f reedon_ fro.i the follouinr.: 3)_ _ Environnental da tage water or oil rarks. da:.2.coaditions.

dirty areas. or salt flin (indicating expose to sea vnter or vinter road salt che:uicals). 4). T1' doua failure -

Shif ted. broken, loose or twisted chipping ties. and vorn material tmder ties, indicating inproper blocking and tie dova during ship::nnt."

Coatinued on Pane "o. 2 se. O * * * 'a o'5*o *"'o a O'er'o as =o== = aoa vso'.saou's 'o ao>sc v r aa'a= = a saa a ' * *r 'o o'**o *

no = a = $u * *

'e as s NGsNu t emo paseoses eon a s. s usens E R.hG D.SPOS4 T eO 8*E SULTS.

se. es ots.on en.nGe ge ouenso Oo "*o"^""'^'"*5"'*" cc"^"c' O , a .. . . . . , v . c w. .. U"..."..*'"""*"

o

.. . e .s ..v. oc=

SPr C. R E V. Aon-Se e W'ut. Copy - O.see.o. eC e s-a Cen yCopy - rtaid Enes.ee.

Pina Copy - POAE Goiden.ed Copy - OC e eO eP '

- es,.ee --e me._.+-- _ . . . - - .

F N **F#*D'**T be. . .....-=n NONCONFORM.1NCE REPORT (CONT *D)

. . Pac z__ 2 x r._2- is ac= =o 6L.

~ ~ ~ ' ' - ~ ~ ~ - - - - - *

- / rdock_tio. 19 Continued, 7223-:t-201_)_Q)_Eev. 6 Para. 6.6.1 Su5. Sec. b - States __in_part : " A_ne t al_ cap _sh all_b e_ p.la ce d_arcr_Lacl ._o pna f n -

and scaled to theJ_ipe with at least 3 passes of sealing tepc." Para. 6.6.3 - S_tates in_p. art: "CaIb.on__3 tcol flan;,cs shall be scaled with ectal or non-retallic dish boltert to the flange." Parad.5,_6 - S_ta cca_in._part<-_

"All exter.tal surfaces of carbon accci pipinn assemblies except nachined surfaces,__shalLb_a_nivna_nne__shon_. coat of priner af ter the ends have been sealed.

Grinnell Spec. PS-1236-4 III/5 - States in pa t: "The__ surface _shall__.be_nrit_binatmLto_near_vhitc_r.ctc1, prolun t- ;

a nurface free of all oil, p.rcase, dirt, visible mill scale, rusty corrosion _ products, ontdes, paint or nay_f_orci ;t natter." .

Contrary to the above the follcuing was found:

FI;tc-5[0 it-201/2 t-!-23tL2 !-!-201/2 Crhnell._ Spec.e TIb"1 G 5/0 FIM C-5fc 3.3.4/a/3 3.3.4/a/4 3_J,_4/p /4 6.6 1/n 6.6.Jfa 6.ft. 6 PS-1235 ? /T T T / 5 1?orn Itat. Loose _U::. Nog !!ot Blasted Contemination Loose Tic Toosn Do.ms Under Ties Cann Covers Painted X

X 2-t!BC-131-5617-9-2 X X X

X X X X ,_,

2-IlliC-133-5617-6-1 X X X X 2-ilSC-133-S617-6-2 X X X X X 2-:lisC-123-S617-6-4 X X ,

X X X X 2-linc-133-SG17-3-3 X X X X X 0-115C-3')-5617-7-2 X X

X X X 0-itLC-5')-0617-7-3 X X X X 2-113C-131-5517-7-3 X X -

X X X X 2-ilGC-131-3517-7-4 X X X X 1-it a C-131-S G16-9-1 X -

X X X X X 1-113C-131-5516-7-2 X X X X 1-litC-12 3-Sa16-6-6 X X X X X X 1-ilnc-135-5616-6-4 "o"_ ro. 4.164, 4,.174 13 QC iloid Tnr.[asplied.

floted during rece *ving inspectica, Unit fl, 2 & Cocmon. - o,va.w, w w Cooy

......: Ceneev Copy - F ield E e*senee, Peak Copy - POAE Goldeared Copy - OC s.

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9. Punf M A SE O R DE R No.

IRA L N/A I ........ ... ....

.0 OC f .E LO .NSPEC T.o PL A N O. . . . R E PL A C E M E Y S E R. A L h.

7220-F-3029 WFMC-1-R-34 N/A '"""""-~'"-"*

T Coe T.Evo-aoC ..o ....s E gg ,E. ,,.sou CE yja 1, Ipy,,0,ggen ay_

/L.ous. CL ty, Michigan .v C = 0 ~o Construetion

.. our. 2. s...uCr gg.o u r E v o r .uo E .. u ..ao O a o u " ' o = ^ " = '* ' 5u'E a v '5o a

. 9. M O CO,.F O M M .N G C O O. . .O N 4 WFMC-1 Rev. 1 including _Amendmelt 1 for Job No. 7220 paragr_aph 2.2 3) requires tensile and impact tests for carbon steel and alloy filler materials to be performed in both the "as welded" and " post heat

.tzc a te d"._condi tion. The__ temperature for post weld heat treatment for P-1 materials is 1150 degrees F + 10 degrees _ F.

fe r_ti_ fica _t. ions _for 16_,700__1b of_3/3.2" E7018 weld rod eith Lot No. L529NIAC and Heat No. 412T5581,17.500 lb of 1/8" E7018 weld rod with Lot No. K519M1AD and IIcat No. 07L541, and 7,600 lb of 5/32" E7018 weld rod with Lot No. L510M1AE and Heat No. 01L559 all show that the post veld heat treatment temperature was 1125 degrees F. Continued on Sht. 2

- O*'E'ao'5"os'noa J1"E 'o a E Co==E aoa oai~ou' E v o a 'o >E C r E ~o'a < C a'* o a'. " u n o'5eo5o= =E5uS Field recomends "use as is". ASME Sec. III Table Nil-4622 1-1 1971 edition allous a minimum post veld heat treatment of 11000 Int-4623.3 states: "During holding period, there shall not be a greater difference than 1000F betueen the highest and lowest temperature." 1125 F meets both table UB-4622.1-1 and para. NC-4623.3.

l ...E c.~EE.. . o.s os.1.n a. E,.c.~EE . . o...as.. .E,uL,s

a. .s DE S.GN CH ANGC REQU.NED hO 26. E JECT ED M A, E R. A L D.5POSlT.ON 3F QC ACCE PT ANCE O*".W..**"""S*"

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NONCONFORMANCE REPOR J ' ' " ' ' ' ' ' ' " "

FisiiR.'7.i7,aai

. .ior -- - ;i. v. T. Fi.oiEr

, 38/ .

oave , s o . .Z. . .. c o c u . . . c .

2-613-4-31 t,2-613-3-3

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_12-2itCB-6-Il 7, .. . . . . . . r . . . o. ; .. . f..v... .. ... .. t. .>.w.g. _____ .

s coac ase o.os.l N/A

~o & 12-2flCB-5-II? ... oc r .a t o . s,c c r.o = eta = _.

N/A I

.11-106

o. ... .r ruace-c 1 se a.at .

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s g ,o.d.. jj g-b X ft-106 A-R-4 N/A

s. co m u n a c r o nfooc a r.om s o*. *a sus $ss v r. sovac t f " ~~'"'g* **'/(/g " *

l; ;-

ITT Crinnell/ Taylor, Michigan

.. nou rino .asu nuciim.s.

., r O. Vendor b noui s vo r.ato r o.=ren.no T =ouv e vo ua v a a.ai. surs aw.se a '

.. nowco r o==.no co-o.r.on.

Hanger Sketches 2-613-4-21 Rev. I and 613-3-3 Rev. 1 show that the_S/S Ilanger Stanchions

_12-2_IICB-5-II-3 and 12-2ItCP.-6-!!3]as shown on; age 3 of._sketche_s)_are to be velded to C/_S__ plates in th" _ shop as

__sinown on page_1 of the sketch). 'Ihe above stanchions were received as shown on page 3 of the~ sketches without the

__C/S_p la te s . Nonconformance noted during' receipt insppction. Unit #2, "Q" List No. 4.131. Reactor Bldg. Spray System. Noted Ifanger Sketches attached. 2 irola Tans attachea.

n.. O r .: to o.scos.r.o" O'.r'o aeco===aoav.oa/aourc va eae ><ce cas.arra.as ai . it'o o.s osmoa assuem -

Return to ITT-GRIfiUEI4._W_arren. Ohio Plaq_t for complet _iqn_of shop uork required in accordanc. with ITT-GRINNELL sketches 2-613 21 Rev. 1. and 2-613-3-3 Rev. 1.

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spec. . ........ ..... ....

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whi.e Copy - Oekiae.oe oc-o n-a Cenery Copy - Piefd Easia***

Pink Copy - PGAE Goldeared Copy - OC

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NONCONFORMANCE REPORT

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l'"""'

I

. On 1 3 If "'" g I

2. D T AWI N GjP A 917 *.O. I Ft CV. 7. Prt OJ C CT N O. 3 2. 34 f.I*O R T C O D Y / DATO 2 3. u t: POLIT IOf4 CO f4 Cu pa n t rer.r.

ecc. 7220-0-111 i9 7220 d,XM,A l7/df6 -- --- --- - - - -

J. 8T Cr D L 3 Cst er*T IO ra s. ITC F4 LOC ATIO N (3 3. Y M's $DhT CD DY ~. Id Cablo Ground Penetration

4. $r.Fil A t,. N Ur t DCR Cont. #2 Elev. 635 5 at 338

9. ST ARTUP Sv5TCM NO.

10666%

' I S. ICPLA CEM EN T PART/N'O.

& N ATb20 7b Pa est(f P egge t agght ge D4TE

/

l l' R E V.

_ .1. /A U/A I ,m.,,,; = ,,,

3. Pu ractl ASC OR DCst NO. ID.CC PICLO INSPECTION PLAN NO. ' .N/A I6 TIEPLA CCM CF47 SE RI AL NO.

ne

4. CO N TR ACTO ft/ LOC ATION n/A U/A ""**'****"" ''

ll.ASMC O vs5 5 7. sO U R CC N/A .T C M 00 Nc. Cenntntetion __

5 5. 710 U T 8 *4 G $ N 3T f t UC TIO fe $s { ROUTC TO FICLO CMGINCCRING O nourc To =^Tc'i'ai 5urcavisoa l '. JN CO N FOl3 Miff G CONDITIO t4:

Specification 7220--C-111 Rev. 9 Scr_tjen 8.Ii3_:Ltatns_in_parL_."fhe_individunl V net,,tien : A 11 he-located with la of their theorotical cicvation and ciretnferential location." Contrary to tho above, the cabic ground 0

,__penetre. tion thooretically located at Aaimuth 3380 in actus11y located at 317 608 which is 1 inch out of the_rps.cified tolerence rango. Ncnconfomanco noted during routine 0.0 review. "Q" List No. 1.109. One hold tan attached.

19. O "'c'o o'5rus' Tron G FIELD RCCOMM END AT8CN.'RO UT C TO PRO 8CCT CNGIN CCRING 21. FIELD D 6= POSITION 8t ESULTSs lla, an_la. fad ing_t_ t geni:tt_rJ_tinn_is an cinc.trien1 nround connrection. Variance in pcuctraticn location docs not affcct the designed intent nor itspose any associated r2Msrial.citnunca . Fabriqdian_nav Dr._o_c.ced. h> N Ol 7 ' 3 - 7 /.

\ER.L.,bv , is e -s . 7e

21. CNGIFILCHING DISPOSITION C/' 2 3. ENGIN CCRING Di$ POSITION R E SULTSt 2 8.15 DC3lf,N Cll ANC C $4 CQ UIH CO O rio * * " * " " "" " "u n e o--=-- n a mmua .

O.cano O T Cs. SCC ATT ACNCO. , , . . . , , , . . . , . . . . .

DFr Awstan R E V. DCN ewrecomeans see.cactoe oaer v e. f. R C V. A O O.

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NONCONTORMANCE REPORT "3 5{1" " '

m __

-. oCl s .2. DaawsNo, PAR T HO. .

I R E v.

7. PRO sEC Y NO.

_mp 12 PO ER vc D a y _

. T _Du_4 _E 2s. Dispos TION COr CunnENCE -

. - FE $0

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- 3. ITE M DESC RIPTION

. -[2. 20

3. BTEM LOC A7 SON

/ i T. A T Eb B Y I DAT , y y"c

. : _}LLinor. Plato _Anacably

. 'sE H I A L N UM B E R JLc11ds_Arca-(tor _cout._EL)_ L. $^ @fdb{./ J

9. ST A R TUP S YST EM NO. d* */4 dEPLACEMENT PART tr. REV. *sease c t F es to e sswes.e

'. __S-3--1-U--1 1/A V IT/A I C. PURCD ASE ORDER NO. ,, . ..... .

10. OC FIELD INSPgCTION PLAN NO. , 3 6. R EPLACEM ENT SERI AL NO., 3 **

_ m o_c-soA C. CON T R A CTO R/ LOC ATION c_111-.63 ' ~

n/A y- - - - -- --

a St.ASME CODE Q vEi 3 7. SOURC E I

_.fr>uthergJoilerATank,yp$o - liemphis,_Tenn,_

_ IT E M Dm_ Yendor

' 9 9. ROUTING INST RUCTIONS: -

{ ROUTE TO FIELD ENGINEERING O aOUTE TO M ATERI AL SUPERVISOR

<4 UNCO NFO RMING CONDITION:

Ono_diacropency_crioto_bolveen_ pill _ hcat_punber_.docunentationA_thq_3rendors._trancforred_Dtarap kn,4 nu,hnT.

'th n ancu::nnhtinn mf H heat mnbeT- f nJ1 tI A 1745_(with_ slab _ number _JL131235) . 'Pha_twnnf' erred atamp.hea+

__nu: bor_la_510A1715_(vith_elab__nunber_A_131235).1 The_quep1.j on_ i o_vttit_thoJoat_ numb _e r;_.thq_olab_nushor_is_irLaccordance-

, _ m ncrepency_detectea anvang_QQ_ field innpection_ review. LHoldlag_ attached. Item q no._1.109 4

23. @ FIELD dsSPOSITlON ,

OFIELD RECOMMENDATION / ROUTE TO PROJECT ENGINEERING . 2 5. FIELO DISPOSITION R ESULTS:

~ Field Engineer 153 will contact vendor and verify correct heat number. Documentation will then 'be i

r e'c ted . Work may proceed.

'(yf:s (@y s-3-7p ,

I s 3 ,. ; -

22. ENGtNEERING DISPOSBTION .s' )- 2,. ENGIN EERING OfSPOStTION R E SU LTS:

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21. IJ DESIGN CH ANGE REQUIRED CNO .

26. R EJECTED M AT ER B AL ;"O SITIO N O = = 'u a a * * **- ** 2 7. OC ACCEPT ANCE O*caa-O vES. scc ^TTACNEDi .. .. . **"'**-***

DR A WING REV. MN Autosomess o e. eses cwo. on,g EPE C. R E V. ADD. * *

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NONCONFORMANCE REPORT w- Or 1 389

2. 0 9e A vw 1NM4P A R T NO. 3 6)2 V. 7, PR O JE C T NO. 3 2. R E PQH T ED u DATE 25. 085POS BTION CONCU R R E NC E

_2pm_M-).

3. IT E M DESCRIPTION 7220 S. IT EM LOC AT SO N h1h *.chts T KL1D A TED R Y

&Zi/7&

I DATE

"""* "c' "'"' " " ' ' " *n EA T"II f'ad tTLIC tilrQ_Cyl IM A A P C. iM M I A L N UM BE R "E" IanVdQWM

9. ST ARTUP SYSTEM NO.

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/t dR EPL ACEMENT PA RT NO.

~

p. . s. e , e . s. . .e s=e . . ..v.

ELUo. 329 C. PURCN Ast ORDER NO.

N/A t o. QC F sELD INSPECTION PLA N NO.

M/A l' REV. ...,..,........ ....

9 4. R EPLACEM ENT SERI AL NO.

gg gji .......... ........... ....

C. C N T R ACTO R/ LOC ATION 88.ASME coo, []YEl. 9 7. 50U R CE J8%MI Cm & chhnrm JA COUTING 8MST RUCTIONS:

IT E M p NO_ Donsir.gction

@ ROUTE TO FIELD ENGINEERING O aOuT E TD M ATERI Ai. suPERvis " X &'a u 6 M'd 40NCONFORM4NG CONDITIONI B&W Spec. USS 19M 3 FS-TTT-lO Parl III Sec. 212.~4 Staten._"Yeri fv that._ applicable coltings are intact." Contrary to the above. surfac_q_ damage oqcurrei_ducing off_ loading._Joted during receip_t_inSpcC_ tion,

/ Ko1Llaca_ App 1Les 21 O r'E'o o'5ros"'on OFf ELD RECOMM EN D ATION/ ROUTE TO PROJ ECT ENGINEE RONG 21. FsELD Di$ POSIT 80N RESULTS:

22. f4NGSNEE RING DISPOSITSON 2 3. ENG IN E E RING OfSPOSITtON R E SULT S:

s 2 0. 85 DESIG N CH ANGE R EQUIRED **""""""""S*"" "~""~~" ' ' " " " " "

O NO O .e...

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CR AWeNG REV. DCN

..vse..es. . so se. ew.. ..yg (P2C. REV. ADD. gN r '

J ORIGINATOR ~ * *

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NONCONFOT.MANCE REPORT (CONT'D)

_ _ -2 o r _ _ _ _ _

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_31oc-g u o tv ,+4n, .cl.

h that_ct mac.rd voll thicmeos vill uca Tyra 2 374 bwel cita

_. Spec.._7220-I'ch73_1?cL_}L5ho_charAJIt w o 0 of 9 n x.in

_prora.raticn. L'nd__pr3 pars _tions do not he.vo the required 1/16' lend.

~

"The m:rft.co chcIl be r;rit blasted to noiryhito notcl, producintf Crinnoll Srco. PS-1235-h III 15 - Statos in p: rt: d cto, oxidea, paint or ray foreigt i

__n curface freo of all oil, groace, dirt, vloibic mill ecale, nioty corroc on pro u 1_qter." Contmry to the above tho following conittiones vom found:

Grinnell S ec. IlliT]/h II201/6 EEi_C-6/0 M-201/6 Pg. 6 of 9 6.6._6

'- 33.h/c/h 6.6 3/n PS-1236-h/III/$

liot Illanted Wold Ihd Pc. int on (Coatinreal Vo_m Matl Loono Fls:

Pren. Ihd Prop.

Under Tien Cover X X 1-2BC-131-E616 ',-3 X X

X 1-iGC-1"41-r616-7-h I X

X 1--TI30-lh1--3616-8-3 X X X

.Y X

__1-110 l '>? .0516- 8 1 X '

X X

",1-h sC--12'.:-5616-6-1 X _

X

-13C-12h-S616-6-2

X _

X X

l-I'.20-126-2516-6-1 X X 2-'_EC-136-S$17 6-1 X X 2 @ C-123-3517-6-1A X X

2- *lDC-12h-S617-6-1 X X X X

2-E3C-11;1-0617-3-5 X X X X

0-FIh50-nil 7-7-11 X 40 Hold Tags Applica. "0." no k.16h, h.174 liotea atu-ing recolpt inopection, Unit 1, 2. rad c.c=non. ____I.7.

Q C-G 3k

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15-1-l U /t.. NCR Log, Trcasmittal File J. Mille , D. Pai

. . . . . . . . . . . . . . . . . . . . . . . . . . . ' . . . . . . . , . .3. Itcas C. ,n,ewton , D. Ler

.- FI, G_.1, Rev. 6, 5/17/74, para. 4.6.2 .

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" Para. 4.6.2. Reads in part: "Tne PfE's authority to nake Eisposition of .nonconforr.ances.

shull be subject' to . . . the following: -

c. . Use approved repair procedure: Requi.es notification of the PE prior to or - .

., concurrent,uith implacentation.

, d. Reject: Requires notification of the PE prior 'to or concurrent uith t '

': ;implecentation for ite::'.s purchased to en engineering specification".

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Tod PE s files were checked for the presence of copies of five ~ (5) .. . .dispositioned MCR's

?

-(255, 297, 327, 342 and 354) and fife (5) closed nCR's (307, 317, 348,J 349 and 353) .which h

[lther "use approved repair procedure" or'" project" dispositions.' Mo evnhnee that proiect

' (,hduuring had been notified uas avaiiaole at the site or Project office, for'six (6) NCR'fs

7. (255, 354, 307, 348, 349 and 353). -

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Datermine which UCR*s having "use approved repair procedure" or " Reject" dispositions have not been transmitted to the PE and transait ic=ediately.

22

' Toe ?FE, in coordination with the PFQCE, establish a nethod to ascure' timely tirans--

uittal of subject NCR's to PE.; ;..,,....- . ,. . , " ' , . . - - J a . . . .

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1: 1/30/76, . ....

2: 2/21/76 proicet Suoerintendent .

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QUALITY AUDIT FINDING

, . 15. CORRECTIVE ACTICN TAKEN ,

1. e A compl'te review of the NCR log has established a listing of

" Standard Repair" NCR's and " Reject" NCR's written on the Midland Project as of January 22, 1976. Copies of these NCR's have been transmitted to Project Engineering for notification and review.

2. Copics of " Standard Repair" and " Reject" NCR's will be transmitted to Project Engineering by the Quality Control Documentation Supervisor. Transmittal will be accomplished concurrently with normal site distribution to ensure timely notification of Project Engineering.

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C. Richardson E...d i.n.n.d i nn e! 2 722 0 1 6 Field Office A. Roos. R'. Grote v......u.................................. .

N/A Snec 7220-r-231. Fev. 8. 9/19/75 t.......

Section 7.1; " Construction joints shall be in accordance with section 6.4, ACI 318, except as may be shown on the drawings."

Drawing 7220-C-200(Q), Rev. 5, 7/29/74, Auxilary Building Foundation Plan, General note 8;

" Construction joint interface roughness c?litude shall be=!c",

except as noted or specified otherwise."

The intent and application of General note 8 c,a Drawing 7220-C-200 (Q), Rev. 5 has not been determined by Field Engineering.

In\

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1. Obtain intent and application clarification of the note from Project Engineering.

2. Based on the clarification take any corrective action as may be necessary to assure compliance to the drawing. If previous construction joints are non-conforming issue a NCR in coordination with the PFQCE.

2/20/76 " Project Superintendent .

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3. GAD iO EN r. Flo.

-s OUALITY ASSURA Pane 1

. 076 E DISCREPANCY REPORT ~

l

4. ISSUE DATE '

O 1. PROJECT / DEPT./ CONTRACTOR

2. POINT OF ORIGlh 2/5/76 Midland 1 & 2 - 7220 Q FIELD 5. GAD PR2P/. RED BY:

6. WORK PLAN DATE 0 OFFICE

7. CHECKLISTITEM 8. WHERE FOUNO G. L. Richard:so n i 2/4/76 -

D. DISCUSSED '.71TH E. Baber

10. CONTROLLiflG DOCUMENT, SECTION, PARAGRAPH, ETC. Document D. P.M ree r Control C Field Procedure FPG-10 Rev. 2, 3/14/75

11. OUOTATION

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12. DISCREPANCY DESCRIPTION i O .

t 1

3. RECOMMENDED CORRECTIVE ACTION

.14. SCHEDULED COMPLE"' 't DATEl) 2/13/76, _ , , 15. RESPONSIBILITY FOR CORRECTIVE ACTION

16. CORRECTIVE'AtTTO//1'XKEN Proicct Sunerintendent v

. DATE COMPLETED

.T 18. SUBMITTED BY RESPONSIBLE AUTHORITY

10. CORRECTIVE ACTION VERIFIED BY-OAE

20. DATE AAO-86 ')/17/ 74

l

, (;~~~Pege 2

/ Block 11 FPG-10, Rev. 2, I 4 3

\

2.0 PURPOSE This procedure provides written instructions and establishes the necessine records for positive control of Field Work Prints. The procedure ensnres

.that the most current field work prints and DCN's are maintained in che -

1 field and superseded work prints are removed and destroyed pro =ptly as they are superseded.

5.0 REVISED DRAWINGS & DCN'S

Action Required Responsible Individual Document Control 1. Revised drawings and DCN's received by

- Document Control for registration.

2. Composes, " Documents Received on Sire" (Fig. 2) list and co= pares revisica list to entries in the Work Print Control Sheet Log for superseded Work Prints or > N's.

3. Notification of a revision is sent to the field engineer via " Document Received On Site" list (Fig. 2) . Drawings in his possession and/or area of responsibility requiring revision vill be highlii;hted.

Field Engineer 4. Notifies responsible craf ts=an to who=

{ Work Print has been issued to destroy

. outdated Work Print. Field engineers are responsible to ensure return and/or i

destruction of Work Prints issued s:= der

'their authority. NOTE: Where crafts I

L have continued need for a superseded

- print for information, the Work Print

- . - , , , - , - , - , - - . - . - , . , .n.-y - , , , , , . , , , . . _ . , . . _ ,

I .

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f shall be marked void", signed and dated by assigned responsible user. The

(

Control Sheet Log shall be noted in the

" Remarks" column as " VOIDED, Retained in Field."

6.0 , A quarterly check shall be made by Document Control to ensure superseded Work Prints are not improperly lef t in the field. (Document Control shall select Work Print entries from the control log and check the assigned person.for possession of the assigned Work Print. Randum samples may be utilized. Increased sample frequency shall be used as. discrepancies increase.) Document Control shall notify the field engineer of discre-l

,pancies by memo. A written record of the quarterly checks and discrepancies i

shall be maintained by Document Control indicating time of check, results, and follow-up corrective actions taken.

O Block 12 Twenty-one prints available in the field were selected for review with the following results:

1. The following superceded prints were found available for use-and were not marked void.

C-247 Rev. 3 issued to N. Shawl. Rev. 4 Rec'd. on-site 1/20/76.

H-863 Sht. 2 Rev. 1 issued to G. Butler. Rev. 2 Rec'd. on-site 1/19/76.

C-204 Rev. 2 issued to J. Lockstein. Rev. 3 Rec'd. on-site 12/22/75.

2. Drawing's C-247 Rev. 4 and M-863, Sht. 2 Rev. 2 did not appear on the

" Documents Received on Site" list resulting in the filed engineers not being notified that drawings in their possession - had been superceded.

i 3. The work print log indicates that two copics of Drawing C-247 Rev. 3 I

were issued to R. Revereza on 1/22/76. C-247 Rev. 4 was received on site ;

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(T on 1/20/76.

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4 The following work prints did not have outstanding DCI's attached.

C-205, Rev. 2, issued to R. Revereza on 12/18/75 - DCN 5 C-205, Rev. 2, issued to A. Boos on 12/10/75 - DCN 5 l

C-205, Rev. 2, issued to J. Lockstein on 12/17/75 - DCI 5 M-204, Rev. 7, issued to C. Butler on 12/11/75 - DCT 16 5.

- There are no records that Document Control has performed the quarterly 1 i

audits as required.- Discussion with E. Baber indicated the last audit l c,onsisted of removing superceded prints from the field but no record 1 I

of the results was prepared. l 1

Block 13 1

1. Removed the identified superceded prints from the field and attached the appropriate DCN's to the identified prints.

2. Perform a quarterly audit in accordance with FPC-10. This audit should be complete enough to assure only current prints are in use with all, :

appropriate changes (DCN's & FCR's) at'tached. Main'tain a written record of this audit and notify field engineers of discrepancies found by IOM.

3. Reinstruct the document control personnel responsible for the dif-ficiencies on the requirements of Field Procedure FPG-10, Rev. 2. A written record of these instructions is laquired.

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p OUALITY ASSUR4**gE DISCREPANCY REPORT '

Page 1

4. ISSus DATE

1. PROJECT / DEPT./ CONTRACTOR

2. POlt T OF ORIGirl 2/5/76 O FIELD 5. GAD PREPARED BW Document Control

6. WORK PLAtJ DATE :@ OFFICE C. Waldrop

7. CHECXLIST ITEM D. WHERE FOUND $ 9. DISCUSSED WITH 2/2/76 - 2/13/75 9.2 E. Baber Docutr.ent Control

10. CONTROLLING DOCUMENT, SECTION, PARAGRAPH, ETC.

D. Palmer SF/ PSP #4 Rev.1, ParaRraph 3.

11. QUOTATION See attached sheet.

D 12. DISCREPANCY DESCRIPTION

(]

N) See attached sheet.

1 t

13. RECOMMENDED CORRECTIVE ACTION See attached sheet.

14. SCHEDULED COMPLETION DATE 15. RESPONSIBILITY FOR CORRECTIVE ACTION 3/5/76_

16. CORRECTIVE ACTION TAKEN

Prniect Sitnerintendent

) '

17. DATE COMPLETED

18. SUBMITTED BY RESPONSISLE AUTHORITY

10. CORRECTIVE ACTION VERIFIED BY OAE

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

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Block 11 *

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, 1. Paragraph 3.1.3, "If any of the, following deficiencies exist, the PFE will initial the transmittal . . .

and, 3.1.3.1 "A DCI received out of sequence".

2. Paragraph 3.2.2.3, "The New Drawing Sign-Off Sheet will be routed to the designated responsible engineers and superintendents. . .".

Block 12

1. DCI 5 to Drawing 7220-C-213 Q was received with no evidence of issuance of DCI 4. Transmittal sheet 18133 which transmitted DCI 5 was not initialled by the Project Field Engineer.

2. Routing of DCI's is not to the engineers and superintendents specified

, in Instruction FIG-1, Rev. O of January 30, 1974', and no more-recent

, dintriburfan instractions ucre n::.ilihin.

Block 13 t

1. Obtain PFE's initials on Transmittal Sheet 18133. Instruct document control perosnnel in the provisions of SF/ PSP #4.

2. Issue written instructions designating responsible engineers and superintendents who will review and Sign-Off DCI's. Instruct document control personnel to distribute DC1's in accordance with SF/ PSP #4 to the designated responsible engineers and superintendents for review

~

- and Sign-Off. . .

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. - - - , , - - - , , , - - - , , - , , . , , . , - - - , - - , , , , - , - ,---~.n,-r-e-,. , + , . , , - - - --,--w,- , - - - - - , - - - -

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. . . . - . . . . ~. . . . - .

q QUAL.lTY ASSURMLCE D'SCREPANCY REPORT 078

-'3 Issus DATE

1. PROJEc f/ DEPT./ CONTRACTOR 02/25/76

2. POINT OF ORIGl?1

@ FIELD 5. GAD PREPARED isY:

Midland 1 & 2 - 07220 0 OrP:Ce

6. YlORK PLAN DATE 7. CllECKLISTITEM G. Utidron

8. Y!HERE FOUND

9. DISCUSSED Y!!TH 2/14/27/76 N/A Calibration T,ab. R. Tao.

10. CONTROLLING DOCUMENT.SECTION, PARAGRAPH, ETC. 'I FPC-4 Procedure for the Control of Inspection Measuring and Test Ecuipeent.

11. QUOTATION

, Paragraph 2.5.b.1 states:

"A list ,)f 111 & T Equipment shall be made each Friday for recall of affected ~

I instruments the following deek." i "2.6 File Maintenance" !

l

~

"2.6.3 Calibration and Recall shall be maintained per Section 2.1.0 and 2. 5. 0 of this procedure."

D 12. DISCREPANCY DESCRIPTION -

b v The Calibration Laboratory Engineer could not produce obiective evidence th u such

, a list is made. .

13. RECOMMENDED CORRECTIVE ACTION Take action to assure that actual calibraton laboratory practice arid the provisions or Procedure FPG-4 are in agreement.'

14. SCHEDULED COMPLETION 15. RES?ONSIBILITY FOR CORRECTIVE ACTION DATE 3/26/76 .T . v. Mau~an

~

16. CORRECTIVE ACTION TAKEN .

b.

17. DATE COMPLETED

\-_/ 18. SU8MITTED SY RESPONSIBLE AUTHORITY j 1

19. CORRECTIVE ACTION VERIFIED EY CAE

20. DATE AAO-86 9/17/74

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_- . 7 . -, o . u c . . . . . . v.

n QUAUTY ASSUHf7E DISCREPANCY REPORT

~

0 73

4. ISS'us cATE n 1. PROJECr/OEPT./ CON

rRACTOR 9/M /76

2. POINT OF ORIGl.'J O FIELD 5. GAD PREPARED BY:

MidT &*d 1 .and 9 - 07?90 -

0 OFFICE

6. WORK PLAN DATE 7. CHECKLIST ITEM 8. WHERE FOUND rm Ufwe

, 9. DISCUSSED YilTH II/A II/A Records' Area D. Palmer

10. CONTROLLING DOCU.'.1ENT, SECTION, PARAGRAPH, ETC.

Field Procedure FPG-1 Rev. 4 Para. 4.0

11. OUOTATION Para. 4.1

. "When the need for a field procedure or instruction has b'een established, the originating individual shall notify the PFE . . . . Ilhen approval is grant d the originator shall draf t and issue the document to the following persons for review and approval (as a ninimum) Quality Assurance Engineer."

o D 12. DISCREPANCY DESCRIPTION . -

.m . * '

d contrarf te the cheve tha foliowius,- procedures and instructions have been issued for I

, use without being issued for review by. Quality Assurance. (Note: not all procedures require QA sign-of E, but QA nust make this deter tination) . FPM-1 Rev. 1 - 2/10/76, FIG-19 Rev. 0 - 2/20/76, FPG-15 Rev. 0 - 10/27/75, FIS-2 Rev. 0 - 2/11/76, FIG-13 Rev. 0 - 2/13/76, FIMl- Rev. 0 - 11/17/75, FIW-3 Rev. 0 10/17/75. .

13. RECOMMENDED CORRECTIVE ACTION

1. Issue these procedure to OA for determination of the necessity to review.

2. Develope a system that will assure all future procedures or revisions to these procedures vill be issued for QA review prior to issuing for used.

14. SCHEDULED COMPLETION 15. RESPONSISILITY FOR CORRECTIVE ACTION DATE 3/26/76 J. F. Neunen -

16. CORRECTIVE ACTION TAKEN

(')

b

17. DATE COMPLETED IC. SUOMITTED BY RESPONSIBLE AUTHORITY .-

i

19. CORRECTIVE ACilON VERIFIED BY OAE

20. D AT E

. AAO-86 9/17/74 1 _ -. _ .__.-- l ------- -- -- -' ~

~ 080 3 OUALITY ASSURAf i D!SCREPANCY REPORT 4. ISSUE DATE i l

2 /v iv

( 1. PROJECTiOEPT./ CONTRACTOR 2. POINT OF ORIGIN

@ FIELD 5. CAD 7RNARED BY: _

Midland 1 & 2 - 07220 0 OFFICE G. Richardson !

G. WORK PLAN DATE 7. CHECKLIST lTE.*.1 8. WHERE FOUND 9. OlSCUSSED '.* NTH 4

~

2/14-27/76 N/A QC Records Area J. Connolly

10. CONTROLLING DOCU?.1ENT, SECTION, PARAGRAPH, ETC. . ;

j FIM G-6 Rev. 6; SF/ PSP #3 Rev. 4 i

11. OUOTATION i

. C-6 Para. 2.51 "The Project Field Quality Control Engineer is responsible for prepar- i

_ation and implementation of Field Inspection Plans." .

SF/ PSP #3 Para. 5.1; "The in-process quality control surveillance and quality veri- l fication inspections and tests required to be performed by QCE's shall be predeter .

rained and identified on the Master Inspection Plans . . .".

D 12. DISCREPANCY DESCRIPTION '

cnnern-v en rhn nhove M c:ter Insocetion Pian 7220-C-2-1, " Post Tensioning Sheathing

\ tw n t t,tions" was not itsect tor inspection et the shenthine installation for j

. Con tainment No. 1 Elev. 6 32' 5" to 642 ' 7.". This sheathing was embedded in concrete

, on 2/12/76 (Ref: Placement C(642.58)a').

13. RECO?.if.1 ENDED CORRECTIVE ACTION Based on the above and CPCo NCR No. OF-76 which identifies a sina'ar nroblen the following corrective action is recommended:

1. Issue a Field Inspection Plan to cover the e! in question and determine its

14. SCHEDULED CO?.;PLETION 15. RESPONSIBILITY FOR CORRECTIVE ACTION -

DATE 3/26/76 " ""

PFQCE .

1G. CORRECTIVE ACTION TAKEN l

O

~

V 17. D ATE CO?.?Pt.ETED 18. SUBt.11TTEO BY RESPONSIELE AUT!!ORITY l

,, 19. CORFsECTiVE ACilON VERIFiEO BY OAE 20. DATg l

l AAO-86 9/17/7i

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Bechtel PoWef~ Corporation

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Block No. 13 continued. (j/?DA 030 acceptability.

2. Determine the extent of this prebica by review of use of Field Inspectica Plans for the remainder of completed work on the Containments and in other areas. This review should include each discipline and can be on a sample basis. Additional review may be necessary based on the results of the first sample.

3. Develope a system of issuance of FIP's that will preclude (or reduce the probability of) recurrence.

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Route 'fo '1his Cony Fe'".- File ~ 16 'l 1 FMSouthworth SHHowell } Issu< ate n m.c w. 1n, 1 m y /. Projeeb Midinnd 1 6 9 HWSlager GSKeeley E p CQHills TCCooke Commf; pmr File Title NCR's on Rechtal JMilandin Engineerina 11FHolub nonconformance CLUichardson Report I!o QF-71

, 3dbiect File -

This Nonconfomcc Report is Issued To: Prepar'ed By9.v9) F1wDate (? - 64 Mr. R. I,. Casaleberry Midland Project Engineer Approved By MI M Date / g/,.od Bechtel Power Corporation Written Np/ly Requested ,By Date 12-24 Ann Arbor, MI 48106 Corrective Action Requested By Date 1-12 uho is resnonsibls for corrective action.

$ Nonconfor=ance Description and Supporting Details: PSAR section 5.1.1.3.1 for the Rea Building states in part that "All cor: crete work is in accordance with ACI 318-63, Bu'il Code Requirements for Reinforced Concrete and ACI-301, Specifications for Structural Concrete for Buildings". ACI-301-72 section 12.3.1 states in part "When the mean dail outdoor ~ temperature is less than 40 F, the temperature of the concrete shall be main-tained between 50 and 70 F for the requ. ired curing period..." Contrary to this requir ment, Specification C-231 Revision 8 section 13.1 refers to ACI 306 for. cold weather concreting, and section 13.2.4' states .in part "During the curing' period the concrete members shall be adequately protected to maintain concrete surface temperatare of no less than 50 0 F," but neither ACI 306 nor Specification C-231 Revision 8 require an

upper temperature lim ~

AEC Reportable Yes No @ See Procedure 9 (For Nuclear Projects Only)

This will be determined after Bechtel Project Engineering has established.the correcti Stop Work necessary Yes No X See Procedure 16 - Stop Work No Qgntobe v

Recc= ended Corrective Action: Implement section 5.1.1.3.1 of the PSAR'for the 'Reacto Building or write a PSAR change to describe the temperature requirements used in the curing of concrete during cold weather. .

4 1

Corrective Action Taken: PSAR Change Notice No. 0102 was approved. This PSAR Change Notice deletes ' reference to ACI 301 Section 12.3.1 for curing requirements during cold weather concreting, and . adds reference to ACI 306-66 as the applicable standard to be used. '

I -

Verification of Corrective Action Required Yes v Ho bethodofVerification: Reviewed PSAR Change Notice No. 0102, letter BLC-2258 (written reply to this NCR), letter BLC-2264 and letter Serial: 2132 (cover letter returning the CPCo approved PSAR Change Notice No. 0102 to Bechtc1).

IsonconformanceClosureConfibedBy -M7 b. W n Date '?. 76 U 1 To be completed at time of closure by Consumers Power QA Services.

Page 1 of 1 1,,

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Attachunt A Route To This'Comr ~'r -

[, '

File ' 16.3.6 FMSouthworth SHliowell ,

Issu. Date February J. 19/O CQHills CSKeeley .

a . Project Midland 1 6 2 HWSlager TCCooke (O,I JMilandin UFHolub EM File Title NCR's on Bechtel 9" liU" c "t#'I r

Nonconformance g ehardson Report No np_71 This Honconfor=ance Report is Issued To: Prepared By[/bM Date 2-S-76 Mr. J. P. Connolly Approved EMIM[I b Date d&7/ ~

f Project Field Quality Control Engineer. Written-ReplyReques,te8ByDate 2 ./

Corrective Action Requested By Date 3 .

who is restonsible for corrective action.

Nonconfomance Description and Supporting Details: SP ecification C-111 (Q), Rev. 9,

" Technical Specification for The Erection of the Reactor Building Liner Plate," statt under Tolerances (Section 8.1.1) "The radial location of any point on the liner plats shall not vary from the design radius by more than + 2-1/2" provided that at any givi elevation the maximum diameter minus the minimum diameter does not exceed 5".

Measurements shall be made from the center line of the reactor building. The above requirements shall be satisfied by taking radial measurements every 20 degrees start:

at the 5 degree azimuth. Measurements shall be made at the center and top of each 1:

Contrary to the above, measurements that were taken, were not taken starting at the !

degree azimuth and thus there are no measurements on the required azimuths.

AEC Reportable Yes No @ See Procedure 9 (For Nuclear Projects Only)

Stop Work Necessary Yes No See Procedure 16 - Stop Work No Recer= ended Corrective Action: . .

1) Take measurements on required azimuths for the lower lift of Unit 2 liner plate.

or

2) Justify the measurements that were taken

3) Comply with Specification C-111 for futui e measurements Corrective Action Taken: -

1) Radial measurements on Unit 2 liner plate were taken every 20 degrees starting at the 5 degree azimuth at the center and the top of the lower lift and the liner plate was found to be within radial tolerances. Remeasurement was done on 2-10-;

2) Future measurement locations will conform to the requirements of Technical Specification C-111.

Verification of Corrective Action Required Yes @ No C b4ethodofVerification:

1) Reviewed records of Unit 2 remeasurement and verified that the results show that the liner plate is within radial tolerances.

2) Reviewed records of Unit 1 measurement to verify that Bechtel is complying with j Specification C-111 for subsequent measurements. Records show that the measure-( ments were taken on the required azimuths and that the liner plate is within i radial tolerances. i Nonconfor=ance Closure ',onfirmed By Ah #

(O) Date 2-/7-76 c/

t l

'~' I To be co=oleted at t e of closure by Consu=ers Power QA Services.

Page 1 of 1

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Attachment A Route To This Copy For /' File 16.3.6 h FMSouthworth S!IHowell Issue Da e bruary 3

[5 I

CQllills INSlager GSKeeley (Q , Pro.iect Midland 1 & 2 M

TCCooke CCMUmtf3 POW 2r File Title NCR's on Bechtel I o b ""

! .Nonconformance "#

G Richardson Report no OF-74 This Nonconfor- mce Report is Issued To: Prepared By b.ad+<" Date 2-3-74 Mr. J. P. Connolly Approved- ByC--7N[d' Date 2dM/-

Project Field Quality Control Engineer. WrittenRepIVRequested'ByDate f

2-17_7 Corrective Action Requested By Date 3-16-7 uho is resnonsible for corrective action.

Uonconformance Description and Supporting Details:

state., in part, that: 10CFR50, Appendix B, Criterion X

" Examinations, measurements, or tests of material or products processed shall be performed for each work operation where necessary to assure qua The inspection plan for liner' plate tolerances of the first lift, Unit 2 shell was signed off on December 31, 1974, indicating that all tolerances were met. Subsequent work operations resulted (i.e., form in movement of the adjustment liner plate.,for containment building- exterior concrete) ,

There is no documentation that subsequent tolerance checks taken were not place them out of tolerance. reviewed to verify that adjustments to the plates did AEC Reportable O Yes O no

,() see Proceaure 9 (For nuclear Prosects on = )

Stop terk Hecc : ry Y:: C Ul, { 5ee Proceaure 16 - Stop Work No Neommended Corrective Action:

1) Document the review conducted of subsequent .

Unit 2 liner plate. tolerance checks for first lift of

2) Change the scope of the field inspection plan so that it is signed off after completion of subsequent work operations that could affect tolerances.

1

3) If present scope of the field inspection plan is to be retained, add a review Corrective Action Taken: point to Master Inspection Plan C-lll-4 to assure that anytolerance

' subsequent (Contd on Attachment A) i Verification of Corrective Action Required Yes O no b'ethod of Verification:

bronconformance Closure Confirmed By .

A. Date

]

I To be co=pleted at time of clocure by Consumers Power QA Services.

Page 1 of 2

--, ~ - . - . -

File 16.3.6

Issus Date Febru, -r 3, 1976 Project Midlai. 1 & 2 File Title NCR's on Bechtel Quali*.y Control Attachment A to NCR No QF-74 Recommended .,orrective Action:

3) checks are reviewed for out of telerance measurements. The Master' Inspection Plan is to be submitted for CPCo QA approval in accordance with procedures.

4) Obtain clarification of Specification C-lli (Sec. 8.0) to indicate when tolerance checks are to be made.

5) Review Quality Control involvement in liner plate tolerance checks to assure timely inspections and completeness of documentation.

s G

S v -

* " ~ * * * ' ' '

g ,,

_. Attachnint A Route To his Couy ror /

' File 16.3.6 FMSouthworth SHHowell '

) Issue Date Feb m rv 1 to76 CQHills CSKeeley , Project Midland 1 & 2 O# HWSlager TCCooke C

B2 F M tf JMilandin File Title NCR's on Bechtel r WFHolub lionconformance " ^ " " "U# I

, CLRichardson Report 1l0 OF-75 ynn This lionconfomance Report is Issued To: Prepared By ,// M 4,v 0'sf Date 2 -J _

Mr. J. P. Connolly Approved,,~ By Y W R $ ! Date :b/M.

Project Field Quality Control Engineer' WrittenRehi,yRequested[ByDate 2-24 '

/

Ccrrective Action Requested By Date 3-16

who is resnonsible for corrective action.

Ironconfomance Description and Supporting Details: 10CFR50, Appendix B, Criterion XVII, states, in part, that: " Sufficient records shall be ciaintained to furnish evidence of activities affecting quality. The records shall include at.least the following:

Operating logs and the results of reviews, inspection, tests... monitoring of work performance... Inspection and test, records shall as a minimum, identify the inspector or data recorder, the type of observation, the results, the acceptability, and the action taken in connection with any deficiencies noted." .

Contrary to the above, sufficient records were not maintained to provide back-up data for the " blanket" sign-off on Unit 2, first lif t liner plate shell tolerances.

AEC Reportable Yes (Contd on Attachmer.

lio @ See Procedure 9 (For liuclear Projects Only) r"%

Stop Work I!ecessary Yes O lio ] See Procedure 16 - Stop Work IM .

Reco= mended Corzective Action: .

1) Remeasure and document remeasurement.

or

2) Demonstrate that liner plate tolerances were met.

3) To prevent recurrence, provide adequate back-up data where a " blanket" sign-off is used, or scope inspection plans so that each inspection is signed for as it is I #

CorrE N N b tion Taken:

l Verification of Corrective Action Required Yes lio Method of Verification:

bionconfomance Closure Confirmed By '

Date l'Ib be completed at time of closure by Consumers Power QA Services.

PaBe 1 of 2 w, -

'~'

File 16.3.6 a

Issue Date Febr ~~ ty 3, 1976

.' Project Midland 1 & 2 File Title NCR's on Bechtel Quality Control Attachment A to NCR No QF-75

Nonconformance Description and Supporting Details: (Contd) r Specifically, the back-up data was incomplete with regard to template checks of-the shell and penetrations, elevation and location checks of penetrations, and vertical tolerance checks with a straight edge.

l i

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l 1

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. i l

! l 4 l l l 1

l I

l i ,

\\

Sheet 2 of 2

-~ _ - - - . . - - . . -

Attachm:nt A Route 'Ib This Cow For p3 File 16.3.6 maoutnworta snuoWen Md Iscue Date Februarv 9, 1976 HWSlager GSKeeley (,, Project O

Midinna 1 & 2 CQitills TCCooke C03Sumh3 F0Wgr JHilandin File Title NCR's on Bechtel UFHolub g Oua H tv Control GLRichardson Sub he t File l Report no M-76 This Ironconforr.ance Report is Issued To: Prepared BMw2)f.%% Date 2- 3 -7(:,

J. P. Connolly #* "*"

[ ' ~

Bechtel Project Field Quality UrittenR'eplyRequestedByDate 2-27-76 Control Engineer Corrective Action R'e uested By Date 2-27-7'6 who is recuonsible for corrective cetion.

Honconfor=ance Description and Supporting Details: Field Inspection Procedure G-6 Revision 6, section 2.5 in Bechtel's Field Inspection Manual states in part that "The Project Field Quality Control Engineer is responsible for preparation and implementation of Field Inspection Plans". Contrary to this requirement, a Field Inspection Plan has been prepared and implemented for only one of more than twenty User Tests of Concrete Materials. However, initials and signature,s of Quality

! Control Engineers do appear on the User Tests indicating a form of review.

AEC Reportable Yes O no E See Procedure 9 (For Nuclear Projects Only) fS / This will be determined af ter Bechtel Quality Control responds to this NCR.

't Sfop Work Necascary Yes O Un { See Procedure 16 - Stop Um k Na Reco:: tended Correct'ive Action: (1) Prepare and impl'ement the. Field Inspection Plan '

for User Tests of Concrete Materials (2) Describe to what extent the User Tests have been reviewed befnre the Quality Control Engineer's sign-off was placed on the User Tests.

1 Corrective Action Taken: '

(1) Future Concrete Material Users Tests will be documented in accordance with Field Inspection Procedure G-6 Rev. 6 Para. 2.5.

(2) J. P. Connolly, the Project Field Quality Control Engineer.,has stated in letter .[-

FQCL-062 dated 2-27-76 that "All Concrete Material Users Tests were satisfactorily-reviewed in accordance uith Bechtel Specifications 7220-C-208 and 7220-C-230 prior t to the Quality Control Engineer signing the Users Test Reports.

Verification of Corrective Action Required Yes @ No O kethodofVerification:

(1) Bechtel QC has initiated Field Inspection Plan No. C-208-2-2, Log No. 2208 on 2-25-76 for Users Test No. 28. The plan no. and J.og no. were verified on March 1,1976 in the Civil Field Inspection Plans log.

(2) 21 User Tests were reviewed to compare the results obtained with the specifications.

obcobf'bWeWNr[hiG$cGtc;This 0 g y, revicu q7 is documented

.~ .

in my daily lo)c for l' i- Date 9 76 V

l'Ib be co:pleted at time of closure by Concur.ers Power QA Servicca.

Page 1 of 1

Attachment A Route To This Cony For -

Cyiilla.s swfoweli File 16.3.4

Issue Date February 20. 1976 j'] IMSlager CSKeuley V FMSouthworth TCCooke ga /

Project Midland JM11andin C0HSum2T3 FD'#8f WFHolub File Title _NcR 's o , I;or h eet Honconformance * " * " "

gGLRichardson IFfle Report No _ OF-77 This Nonconfor=ance Report is Issued To:

Prepared By (((.<2Ob Date ;1/20/74 J. F. Newgen, Bechtel Project Superintendent Approved ByddMd Date NMA WrittenP[hRequeste By Date 3/05/7 Corrective Action R sted By Date 3/19/7 who is reswnsible for corrective action.

Nonconformance Description and Supporting Details: On 2/19/76 at approximately 12:15 p.

we were notified that the manway in core flood tank 2T-63A was open to the atmosphere.

The tank was checked at 12:30 p.m. and found to be open with nobody working around the opening.

11:00 but The MSS was contacted and said the manway had been covered at approximately that the wind must have blown the temporary plastic cover off. The dessicant modify the changed was being dessicantand the permanent cover had been taken to the combination shop to basket. "

The storage requirement form F-1-112 says " Closures opened for internal access at any time forfor reason any reason Care removal. shall must be immediately replaced and resealed after completion of the AEC Reportable Yes No x be taken to prevent contamination with foreign materials "N See Procedure 9 (For Nuclear Projects Only) (Contd on 1

x Atenebmaa*T uJ Stnp Herk Mecess::y '?ca C Ib C See Proceaure 16 - Stop Work No ~~

Recommended Corrective Action: '

l. Provide assurance that the time it was open and unattended.the tank was not contaminated by foreign materials 2.

Instruct personnel in the importance of observing the requirements in the notes

3. and cautions on the F-1 forms, and also that these are requirements, not guidelines.

1 Evaluate this situation to see if the method of covering the opening and securing the cover Corrective wasTaken:

Action adequate to withstand nornal weather conditions and preclude the entry of foreign material.

Verification of Corrective Action Required Yes C No blethod of Verification:

I bionconformanceClosureConfirmedBy Date v

1 To be co=pleted at time of closure by Consumers Power QA Services. ,

Pa6e 1 of 2 l

__ J

$ +9 0 Vb & fj f4,t N$#e Y tb

/g,%,g'c/#s

%y + g y- 4 #+i !

\ IMAGE EVALUATION NNNN I TEST TARGET (MT-3) l l

1.0 lgm gu uEMll]2.2 E EM 1.1 ['"UM 1 .8 1.25 1.4 1.6 4 6" %

4k ff' '4;;fS 4.,

W

l dh h

%W+YG,<> ///h<#

\ IMAGE EVALUATlON NNN TEST TARGET (MT-3) 1.0 552 RM 1

W "12 \\\1=u u 1 l,l f,* bb l.8

'l.25 1.4 1.6

6"

I 4%% +4 L#,w,

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- . g dy File ; .4

.. g Issue Date Febru " 20, 1976 Proj ect Midlana File Title NCR's on Bechtel Construction

/' - Attachment to NCR Report No QF-77 (Contd)

Nonconformance Description and Supporting Details: (Contd) while closure is removed". It further states, "Any operations which may affect interior cleanliness of tanks (e.g., opening closures for replacing dessicant, etc.)

must be performed with sufficient precautions to prevent entrance of foreign materials into tank interiors".

The manway may have been open for as long as 1 hours1.157407e-5 days 2.777778e-4 hours 1.653439e-6 weeks 3.805e-7 months because the temporary cover was blown off. The fact that the cover had blown off would indicate that sufficient precautions were not taken.

N 1

2

(

.s I -

\

Page 2 of 2

. --- r,.- ,.y .

._,y. . , . . + ,,, _ .,. . , _ _ . . _ .,__.-.,,_..m,_n, ,,._y,, . , , ,,_ m_,

._- --~

Attachnent A

~

,' Routa To This ' Cow ~ ~_ -

Fils ^' _

16.3.4 D!Southworth SilHowell ( g- Issue Date Febrtiarv 23. 1976 CQHills GSKeeley i

/ Project Midl.,nd 1 & ?

HNSlager TCCooke d JMilandin CCASUmm F0Wer File Title NCR's on Bechtel WFHolub Const m m n

-Nonconformance GLRichardson Report No OF-78 File This Nonconfomance Report is Issued To: Prepared By[/YM Date 2-23-71 Mr. J. F. Newgen Appr ved By #[ .

Date //2 4 /7/.-

Project Superintendent n

WrittenReplyRequepdByDate j 3-08-7 Corrective Action Requested By Date 3-22-;

who is responsible for corrective action.

Nonconfomance Description and Supporting Details: WFMC-1, Rev. 1, Welding Filler Material Control Procedure Specification," governs weld rod control for li:'er plate work per section 7.4 of Specification C-lli, " Technical Specification for the Erection of the Reactor Building Liner Plate". Section 6.0 of WFMC-1, " Disbursement and Control During Fabrication," requires that:

1) Where physically possible, low hydrogen type electrodes shall be used directly from the rod warmer. (Sec 6.4 7)) '

2) For combination welding procedures that require more than one classification of-electrode, separate, individually identified containers shall be used for holding each classification of electrode. (Sec. 6.7)

(Contd on Attachment)

AEC Reportable Yes no @ See Procedure 9 (For Nuclear Projects Only)

, Stop Work Neces.3ary Yes No See Procedure 16 - Stop Work No Reco= ended Corrective Action: -

1) Reinstruct all welders on site in proper weld' rod control and document the reinstruction.

2) Analyze this discrepancy as a generic problem with weld rod control and also describe in your response how weld rod control is maintained with Non-Q sub-contractors doing both permanent and temporary work as well as Q work subcon-tractors.

1 Corrective Action Taken:

1 Verification of Corrective Action Required Yes [ No bethodofVerification:

blonconfor=anceClosureConfir=edBy Date -

^ i

^' '

1 To be completed at time of closure by Consumers Power QA Services.

Page 1 of 2

-" ," 7

n =- ^- -- ~

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j -

Fils 16.3 ^3

, Impus Date Febn. ry 23,'1976 Proj ect Midland 1 & 2 File Title NCR's on Bechtel Construction l- . Attachment to Report No QF-78 (Contd) l Honconformance Description and Supporting Details: (Contd)

3) Individual velders shall keep their work areas clear of unauthorized and discarded welding filler materials. Damaged and discarded electrodes shall be placed in vaste bins or stub buckets and periodically removed from the work area or roturned-to the rod room at the end of the shif t or upon completion of the work operation, whichever occurs first. (Sec. 6.8) l Contrary to the above requirements, a welder on liner plate assembly C-lll-69 was I

observed welding with a stub, taken from a stub bucket, of low hydrogen rod (E7018).

It was physically possible for him to use electrodes directly from a warmer as there were other warmers on the liner plate surface. The stub bucket contained two types of electrode (E6010 and E7018) and the welder was using discarded elec-trodes to perform the welding.

The welding being performed was " pick-up" work on leak chase fillet weld. The NCR documents a lack of weld rod control in an area where Q-listed welding was in progress.

l .

l l

l V .

Page 2 of 2

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