ML20086P359
| ML20086P359 | |
| Person / Time | |
|---|---|
| Site: | Midland |
| Issue date: | 02/14/1984 |
| From: | Karr J STONE & WEBSTER, INC. |
| To: | Quamme D CONSUMERS ENERGY CO. (FORMERLY CONSUMERS POWER CO.) |
| References | |
| SWQC-84-038, SWQC-84-38, NUDOCS 8402270123 | |
| Download: ML20086P359 (14) | |
Text
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MRINCIPALSTAff?
STONE AND WEBSTER MICHIGAN. INC.
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DEAR SIRS:
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l YOUR ATTENTION IS DIRECTED TO THE FOLLOWING:
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ta*== aovi== us IM PORTANT =MouLo aNv R$vl=IoM To ooCUMENT= om oma-speos arTumNEo MERfwtTM e~voLvE a etCE INCREa=E. THE su evsm MuST ofi v =TosvE,.a, r est =
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The following closed CIO NIR(s) is (are) forwarded for your information:
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/J. E. Karr
/ CIO Program Manager cc:sJGKeppler, US NRC JJHarrison, US NRC RJCook, US NRC RAWells, CPCo CIO Site File O
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Page 1 of 2 STONE AND WEBSTER ENGINEERING CORPORATION QC1 15.01 NONCONFORMANCE IDENTIFICATION: REPORT A.ttachman 4.1 (y
DATE OF NONCONFORMANCE:
January 2, 1984 NIR NUMBER 012 IDENTIFICATION /LOCATIDN OF ITEMS:
Civil Review Phase III FCR/FCN Midland CIO Office Drawings Stations 8-10-13 DESCRIPTION OF HONCONFORMANCE:
Station 8: FSK Drawings in station 8 do not agrea with Bechtels Master Composite Regist( E the revision column and the sheet column appears to be a problem.
This is a generic problem with the CI0's sampled FSX's.
Station 10:
- 1) The following Design Drawings and Specifications have inconsistent quantity distribution.
The Bechtel FDDL quantity does not agree with the actual i count in the field station. Specification # C-195, C-197, C-198, C-200.
Design Drawings # C-1492, C-1493-1, C-97, C-8 and C-2031. 2) All vendor controlled drawings have one copy in their station that is voided. This practice can not be verified per procedure.
- 3) Spencer-White and Prentice had the following Design Drawings missing from station 10, one copy (sepia) of C-8 and one copy (sepia) of C 07. Two sepia were issued for each drawing per Bechtels FDDL. 4) Design Drawing C-2031-19 revision 1 did not have FCR 6974 attached to the drawing.
(continued on Page 2) j p/ b go d R. Scallan PROGRAM MGR DATE January 3,1984 DATE J 3hV CORRECTIVE ACTION BY:
MPQAD IDENTIFY ORGANIZATION TAKING CORRECTIVE ACTION l
l Based on the corrective action taken on QAR No. RS-00106-(Attachment 1),
CIO considers this NIR 012 satisfactorily closed.
i I VERIFICATION ($ T) UN1Af NEW NIR#
CONCURRENCE INITIATOR 9 d c d b aopo m PROGRAM MGR g / L,.
DATE d
\\N Sk DATE DATE
,0 N
REMARKS-
Page 2 of 2 NIR 012 O
(5) -- pulled-back, the Composite Register did not. 6) Mergentime FSK CA 1062 Revision 6 - FCR C-6053 was on the blue-line (attached) but was not on the Sepia.
- 7) FSK 1060 shows in the Register as "FSK 1060 sheet 7", however it should indicate "FSK 1060 Revision 7 with only one sheet." 8) FSK 1062 shows in the Register as "FSK 1062 sheet 6 revision 4," however it should indicate "FSK 1062 revision 6 with only one sheet." 9) Specification C-305 located in station 10 Mergentime was missing the symbol @ to indicate that there is a retired docu-ment against this specification.
Station 13: Specification C-306 had referenced FCR C-4854 but it was not attached to the Specification. 2) Control Drawing C0482 sheet 1 outstanding attachment stamp.could not be read. Also a d) symbol was located on the drawing while the Composit Register had it voided.
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s% i,n NIOUuin PNEWECT RS-00106 QUALITY ASSumNcE oEPARTENT QU ALITY AG Ilun nE ^.,U EST 7.
oATE I e Rty 1/5/84 yy OUI N 8 9*
PAGE 1 0F / ll
- o attached page 2 of 2 for description of requirements 10 ASE RELATED casaciated with this QAR.
O TES Q NO 2.
DEFICIENCY:
S:3 attached page 2 of 2 for description of deficiencies found at stations MPQAD Sta. 8 FSO Sta. 10 and BOP Standish Sta. 13.
- 11. POTENTIALO.55(e:
YES Noh QARgG BY*
'4.
DISCIPLINE / DIVISION /SECTION h.
RESPONSE DuE DATE
- 12.. REPORTED TO NPQA 3.
MANAGER:
MPQAD - Soils QA 1/6/84 DATE N/A
- 13. ACTIOW ITEM No:
- 15. ITEM PRIORITY:
- 17. S/J CODE:
- 19. ACTION ORGANIZATION ' 20 QAR REVIEWED BY:
U-00508 01 PCMOR W
r
- 14. DISCIPLINE:
- 16. TREND CODE:
- 18. RES8 CODE:
Document Control
- 21. DATE: '
1Fgg/pg Drc. Control C-5, R-5, C-9 F OC
~~
21 CAUSE:
Z3 PROPOSEO CORRECTIVE ACTLON:
1.
Clerical error.
None - See Block #27.
2.
Issuance of FDDL for audit prior to verification that all cormtents and changer were incorporated.
3.
FDDL did nct reflect the voiding of a centrolled ccpy by FSO.
24 RESPONSIBLE ORGANIZATION / PERSON:
- 25. PROPOSED COWLETION DATE FSO/BCP Ccnstruction.
January 6,1984.
~26 DISPOSIT ON CONCURRENCE:
JE.%E
\\ Net ah QAR REVIEWER DATE PQAE (ASE ONLT)
DATE 1
- 27. DISPOSTION ACTION TAKEN:
CORRECTIVE ACTICN TAKEN:
See attached response.
I
- 28. NETHOD OF DISF3SITION VERIFICATION
- 29. QAR CLOSED BY SEPP l I of I
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PFQCE (ASME ONLY)
DATE b~
ACCEPTABLE UNACCEPTA8LE SUPERCEDING QAR
&f3 ll1/6q WhM 1/0/"' Cav.j(( g([7/6p QAR Ns. RS-00106 Midland Projcet h,t 2.
Quality As uranco D:pt.
QUALITY ACTION REQUEST Dato:
CONTINUATION SEEET Fase 2 of E t(
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,. 7.9 v The following concerns have been identified by Stone and Webster (CIO) during an audit of the following document control stations: MPQAD Station 8. FSO Station 10, and BOF Standish Station 13. These concerns are addressed by CIO on NIR number 012 dated January 2. 1984 A.
The FSK Change Notice Composite Register shows FSK CA-1060 Sheet 7 requiring FCR 6704. FSK CA-1062 Sheet 6 requiring FCR 6053 and 6704, and FSK CA-2257 Sheet 5 requiring FCN 3743 and FCR 6890 to be attached.
Contrary to this composite register FSK's CA-1060 Sheet 7. CA-1062 Sheet 6 and CA-2257 Sheet 5 do not exist.
Also FSK CA-1060 is shown in the Register as "FSK CA-1060 sheet 7" however it should indicate FSK CA-1060 Revision 7 with only one sheet and FSK CA-1062 is shown in the Register as 1,%
"FSK CA-1062 sheet 6 revision 4." however it should indicate FSK CA-1060 revision 6 with only one. sheet. (This was e generic problem with the lb FSK's sampled by CIO).
B.
The FDDL provides the following information; Stations that receive documente, number of, and description of documents distributed. Contrary to the above, the number of Design Drawings and Specifications at Station 10 did not agree with the FDDL.
1)
Specifications C-195, C-197, C-198, C-200. Design Drawings C-1492 C-1493-1, C-97, C-8 and C-2031.
- 2) All vendor controlled drawings have one copy in their station that is voided. These voided documents could not be counted in the required number of documents per the FDDL. Thmefore all vendor controlled drawings were one short of the required amount.
3)
Spencer-White and Prentice had the following Design Drawings missing from station 10. one copy (sepia) of C-8 and one copy (sepia) of C-97.
Two sepia were issued for each drawing per the FDDL.
C.
The Change Notice Composite Registers list the applicable change notice attachments to drawings and specifications. Contrary to this requirement, 1.
Station 10 had the following discrepancies:
(a) Drawing C-2031-19 revision 1 did not have FCR 6974 attached to the Design Drawing.
(b) Design Drawing C-2036 revision 5 should have had DCN-2 attached to the drawing.The drawing indicated it was pulled-back, thn Composite Register did not.
(c) FCR C-6053 was attached to the Mergentine FSK CA 1062 Revision 6 blue-line but was not attached to the sepia.
2.
Station 13 had the following discrepancy:
L (a) Specification C-306 had referenced FCR C-4854 but it was not attached to the specification.
D.
The Civil One Time Deviation Register lists the drawings and specifications that require a R symbol. Contrary to this requirement:
1.
Station 10 had the following discrepancy:
l (a) Specification C-305 located in station 10 Mergentine was missing O
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this specification.
2.
Station 13 had the following discrepancies:
C 482-1 outstanding attachment stamp could not be read.
(a) Drawing $symbolwaslocatedonthedrawingwhiletheComposite Also a Register had it voided.
e ME cst Q A IR. RS -oo s of, AtWe41 fT 3 tt
% e k 3 e ii-RESPONSE TO QAR #RS-00106 l
Continuation of Block #27 Corrective Action Taken ITEM A Statement The FSK Change Notice Composite Register Liows FSK CA-1060, Sheet 7 requiring FCR 6704, FSK CA-1062, Sheet 6 requiring JCR 6053 and 6704, and FSK CA-2237, Sheet 5 requiring FCN 3743 and FCR 6890 to be attached.
Contrary to this composite register FSK's CA-1060 Sheet 7. CA-1062, Sheet 6 and CA-2257, sheet 5 do not exist. Also FSK CA-1060 is shown in the Register as "FSK CA-1060, Sheet 7",
however, it should indicate FSK CA-1060, Revision 7 with only one sheet and FSK CA-1062 is shown in the Register as "7SK CA-1062, Sheet 6 Revision 4",
however, it should indicate FSK CA-1060. Revision 6, with only one sheet.
(This was a generic problem with the FSK's sampled by CIO.
Response
This item is attributable to Document Control clerk error, concerning input into the computer. These were drawing revision numbers which belonged in the next column of the register.
The normal proof reading operation. failed to pick up this error.
-( )
The entire FSK/ Civil change notice composite register has been reviewed.
Seven additional errors were found. A marked-up register has been resubmitted to computer operators for input.
ITEM B Statement The Field Document Distribution List (FDDL) provides the following information; stations that receive documents, number of and descriptien of documents distributed. Contrary to the above, the number of Design Drawings and Specifications at Station 10 did not agree with the FDDL.
1.
Specifications C-195, C-197, C-198, C-200.
Design Drawings C-1492, C-1493-1, C-97, C-8 and C-2031, 2.
All vendor controlled drawings have one copy in their station that is voided.
These voided documents could not be counted in the required number of documents per the FDDL. Therefore, all vendor controlled drawings were one short of the required amount.
3.
Spencer, White & Prentis had the following Design Drawings missing i
from station 10, one copy (sepia) of C-8 and one copy (sepia) of C-97.
Two sepia were issued for each drawing per the FDDL.
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Response
Item 1 The FDDL issued on Friday, December 30, 1983 did not agree with the actual quantity in station 10 for the documents listed. The FDDL had been reviewed by Area 10 personnel prior to the December 30, 1983 issue, and distribution change sheets had been prepared and submitted to correct the FDDL, according to established procedures. The Document Control computer input to the FDDL had not yet caught up to these change sheets. The auditors received copies of the change sheets for the documents listed, and agreed that the count at Station 10, was the salie as that indicated en the submitted change sheets. The FDDL has now been updated to include all submitted change sheets, and the FDDL and the actual quantity at Station 10 now agree.
Item 2 This statement is accurate only for those Subcontracts administered by the Field Soils Organization (FSO), not for all vendor documents. The Field Soils Organization (Area 10) received three controlled copies of all approved subcontractor documents for Subcontract Numbers C-194, C-195 and FSC-436.
In addition, the FSO received three controlled copies of all approved shop drawings for Purchase Order No. F55739 (under Specification C-233).
For historical and commercial reasons, the FSO maintains a filing systes
~O-ef the s hcontractor and vendor documents noted in the ahove varaSra h.
The intent was to track documents as submitted, and the documents as approved and returned to these vendors.
Therefore, one of the three controlled copies of the vendor documents listed was marked " Void" upon receipt from Document Control, and was placed in the appropriate file in the FSO offices.
i The reason these documents were marbed void is because FPD-1.000 prevents the FSO from maintaining controlled and uncontrolicd documents in the same files.
The FSO has now discontinued the use of controlled copies for this purpose, and have substituted uncontrolled copies.
The FDDL has been changed to reflect this decrease in controlled copies.
i-Item 3 When Spencer, White & Prentis first mobilized on site, they had no reproduction capability, and received no sepias in their original distribution. The original distribution list identified 19 drawings, among which were Drawings C-8 and C-97.
Af ter Spencer White & Prentis obtained reproduction capability, the FDDL was changed to read one sepia and one controlled copy instead of two controlled copies, but the FSO did not retrofit the sepias for the original distribution. Most of the original 19 drawings have been revised, and sepias were part of normal 3
distribution, but C-8 and C-97 were not revised and, therefore, did not match the revised FDDL. A complete review of all drawings was performed
~
and two additional drawings with this problem were found. All have been corrected, and the count of sepias in the field agrees with the count in the FDDL.-
I Nil oth
@AR RS-oogog MmM d.
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Neh 05 M Page 3 ITEM C Statement The Change Notice Composite Registers list the applicable change notice attachments to drawings and spacifications. Contrary to this requirement, 1.
Station 10 had the following discrepancies:
(a) Drawing C-2031-19 Revision 1 did not have F.CR 6974 attached to the Design Drawing.
(b) Design Drawing C-2036 Revision 5 should have had DCN-2 attached to the drawing. The drawing indicated it was pulled-back, the Composite Register did not..
(c)
FCR C-6053 was attached to the W rgentime FSK CA 1062 Revision 6 blue-line but was not attached to the sepia.
2.
Station 13 had the following discrepancy:
(a) Specification C-306 had reference FCR C-4854 but it was not attached to the specification.
Response
Item 1 (a) and (b)
This occurred in the Spencer, White & Prentis office, and was caused by Document Control Clerk error. The clerk misread the latest Change Notice Composite Register for these two drawings. These items were corrected and a complete review of all documents maintained by Spencer, White & Prentis was performed for proper attachments. No other errors were found.
Item 1 (c)
This occurred in the Mergentime office and is also attributable to Document Control Clerk error. The FCR was attached to the blue-line and noted on the front. The FCR was also in the book of FCR's that goes with the sepias, but was not noted in the addenda b1'ck on this sepia. This item was corrected, and a comple:e review of all documents maintained by Mergentime was performed for proper attachments. No other errors were found.
Itaa 2 (a)
This occurred in the Standish Fabrication Facility, and is attributable to Document Control clerk error. This FCR should not have been attached to Specification C-306, and was correctly removed, but was not crossed off in the addenda block. This item was corrected, and a complete review of all documents maintained by Standish was performed for proper attachments. No other errors were found.
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64u Page 4 ITEM D Statement The Civil One Time Deviation Register lists the drawings and specifications that require a R symbol. Contrary to this requirement:
1.
Station 10 had the following discrepancy:
(a) Specification C-305 located in Station 10 Mergentime was missing the symbol @ to indicate that th,e.re is a retired document against this specification.
2.
Station 13 had the following discrepancies:
(a)
Drawing C-482-1 outstanding attachment stamp could not be read. Also, a @ symbol was located on the drawing while the Composite Register had it voided.
Response
Item 1 (a)
This item is attributable to Document Control Clark error.
It was corrected, and a complete review of all documents maintained by Mergentine was performed for proper retirement symbols.
No other errors were found.
Item 2 (a)
Drawing C-482-1 was difficult to read due to reproduction quality, and was replaced. Other documents maintained by Standish were reviewed for clarity and legibility, and were replaced where appropriate. A complete i
review of all documents maintained by Standish was also performed for proper retirement sys:>ols. Drawing C-482-1 has been replaced, and no other errors were found.
l l
l Additional Corrective Action Taken On Wednesday and Thursday, January 4 and 5, 1984, instruction sessions were held for all appropriate Document Control personnel concerning how to read and l
use the various registers published by Document Control, and on auditing l
methods and processes. See Attachments I and 2 for detailed descriptions of these sessions and the attendance records.
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Date: January 4, 1984 From:
Ralph Bradford
Subject:
Document Control Instruction Session
Enclosure:
(1)
Instruction Session Attendance Pecord On Wednesday, January 4, 1984, the undersigned held an instruction session for Bechtel FSO, Mergentime and Spencer, White & Prentis Dccument Control
)
personnel, including svparvisory personnel responsible for document control. The session began at 8:00 a.m. and. lasted approximately 45 minutes. Subjects covered were document control processing methods, i
procedures, and auditing methods, including appropriate logs and registers.
The undersigned presented a detailed, step-by-step review of the methous for conducting a document control audit, and how to read and use the various logs and registers published by Document Control. The purpose of the session was to ensure that all Document Control personnel, including supervisory, have a thorough knowledge of auditing practices and to ensure that all personnel are working from the same basic information.
~
All personnel were instructed to return to their respective areas and again s
perform a 100% audit of the entire Document Control stations. This audit is to be complete by close of busir. css Wednesday, January 4, 1984, and will include all specifications, design drawings, procedures and subcontractor / vendor shop drawings for the Civil discipline. All questions were answered and problems resolved, and all attendees confirmed that they understood the information covered.
,0 Ralph Bradford Senior Contracts Administrator RB/nj cc:
D. H. Lavelle J. F. Fisher R. Bradford All Attendees - See Enclosure (1)
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January 5, 1984 Reinstruction of Document Control Personnel On Thursday, January 5,1984, the undersigned reinstructed Document Control personnel to take extra caution in submitting input to mapper. They are to make sure the information is entered under the corrset column headings to minimize the number of input errors. The ma;per operators are to take caution in inputing, proof reading, and verification of entries.
Attached is the attendance sheet for the Document Control personnel who received this reinstruction.
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M/R._ Oll Arwhed i Midicnd Project d N d N QAR No. RS-00106 Quality Assurance Dept.
QUALITY ACTION REQUEST Date: 01-07-84 CONTINUATTON SHEET Page 11 of 11 Block 18.
Method of Disposition Verification (Contirued from page 1)
A.
All controlled Civil Specifications were reviewed at stations 10 (FSO including Mergentime and Spencer, White & Prentice) and 13 (BOP-Standish).
O N M. Thi r vi w g ulted in satisfactory results.
B All were reviewed at stations 8 (MPQAD-Soils), 10 (FSO including Mergentime and Spencer, White & Prentice), 24 (MPQAD-Receiving did not have any FSK's) and 64 (Subcontractors-FSK's sent to supplier, only card
(
system was reviewed).
FSK-CA-1062 had a R on th'e stick dracing at Station 13 (Standish) which should have been removed as it had been removed on the three other copies at this location. A FCR at Station 8 did not have a " CONTROLLED" stamp on it.
Because all controlled Civil FSK's wers reviewed as stated above and the problems above were corrected, no further action is required.
C.
A sample of Controlled Bechtel Civil Drawings was reviewed at stations 10 (FSO including Mergentime and Spencer, White & Prentice) and 13 (BOP-Standish).
All Controlled Bechtel Civil Drawings requiring the R symbol at station 13 (BOP-Standish) were reviewed for the R symbol. The only problem found was at Station 13 (BOP-Standish) whera drawing C-436 Revision 9 had a R symbol which was not required.
Because of this problem and the problem at Station 13 (BOP-Standish) identified in B above, the corrective action taken tc resolve the problems of R symbols on documents at Standish is unacceptable.
Refer to QAR RS-00109 for further corrective action.
O D.
A sample of Controlled Civil Vendor Drawings at stations 10 (FSO including Mergentime and Spencer, White & Prentice) and 13 (BOP-Standish). The only problems identified in this review were found at Mergentime and are as follows:
1.
Vendor Drawing C233A-F55739-80-4 had an addenda. change block on the front of I drawing and 1 sepia indicating FCR C6868 was attached.
FCR C6868 was not attached and was not required to be attached.
This problem was corrected at the time of the QAR RS-00106 corrective action verification review.
2.
Vendor Drawing C233A-F55739-58-4 did not indicate FCR C6466 in the addenda change block on the front of I drawing and 1 sepia.
FCR C6466 was attached to the drawing and was required to be attached. This problem was corrected at the time of the OAR RS-00106 corrective action verification review.
3.
Vendor Drawing C233A-F55739-70-3 and C233A-F55739-82-3 did not have an addenda change b~1ock indicating the applicable FCR on the front of I drawing and 1 sepia. However, the applicable FCR was attached to each of the drawings.
4.
Vendor Drawing C233A-F55739-78-4 did not indicate FCR C6756 in the addenda change block on 1 drawing and 1 sepia and it was not attached to the drawing.
It should be noted that item 1 and 2 above were found in the first sample selection and 3 and 4 were found in the increased sample selection.
Based q
on the problems identified at Mergentime, the corrective action taken hy Q
Mergentime to resolve the problems identified in this QAR is unacceptable.
Refer to QAR RS-00109 for further corrective action.
E.
Reviewed instruction documentation attached to this QAR.
_ _ _ _ _ _ _ - _ _ _ _ - _ _ - _ _ _ _ _