ML20091N325

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Forwards Const Implementation Overview Nonconformance Identification Rept Nir 023 Re Work Print Station 209,for Info
ML20091N325
Person / Time
Site: Midland
Issue date: 06/07/1984
From: Karr J
STONE & WEBSTER, INC.
To: James Keppler, Quamme D, Reichel N
CONSUMERS ENERGY CO. (FORMERLY CONSUMERS POWER CO.), NRC
References
NUDOCS 8406120281
Download: ML20091N325 (30)


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The following closed CIO NIR(s) is (are) forwarded for your information:

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/!N.E.Karr 9 ** "*"'9'#

DISTRIBUTION:

. Job File C.4.2 (orig + 1)

DLQuamme, CPCo o

I_NIReichel, CPCo RAWell_s, CPCo

'JGKelspleQNRCI JJHarrison, NRC BLBurgess, NRC '(site)

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JUN 7 1984 i i Initiator 8406120281 840607 PDR ADOCK 05000329

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O STONE AND WEBSTER ENGINEERING CORPORATION NONCONFORMANCE IDENTIFICATION: REPORT e

DATE OF NONCONFORMANCE:3/22-/cM.

NIR NUMBER

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IDENTIFICATION / LOCATION OF ITEMS:

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DESCRIPTION OF NONCONFORMANCE:

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i CORRECTIVE ACTION BY:

IDENTIFY ORGANIZATION TAKING CORRECTIVE ACTION CIO determined CPCo's response, provided via CPCo Letter No. CSM-0769 (Attachment 2), to be unacceptable.

CPCo's revised response to Item 086, provided via CPCo Transmittal No. CSC-7810 (Attachment 3), has been evalu-ated and found acceptable.

Based on this, CIO considers this NIR closed.

i VERIFICATION /S'AT UNSAT NEW NIR#

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NIh 023 Page 1 of 16

'dland Protest: PO tem 1943, Midland, MI 48440 e (517) 631-8050 May 4, 1984 Mr J E Karr Stone and Webster Michigan, Irc

_P 0 Box 1963 Midland, Michigan 48640 MIDLAND ENERGY CENTER PROJECT - GWO7020 STONE AND WEBSTER CONSTRUCTION IMPLEMENTATION OVERVIEW NONCONFORMANCE IDENTIFICATION REPORT NUMBER 023 DATED 03-23-84 FILE 24.2 SERIAL 27884 CSM-0769 LWW-12-84 In pursuance of Nonconformance Identification Report number 023, a response is attached to address your concerns delineated in your nonconformance identification report form.

' Should you or your staff have any questions on the content, contact Lonnie Worley at extension 7707.

(LH &

W*** %

D L Quamme Site Manager

CC DDJohnson, MEC BHPeck, MEC NIReichel, MEC-TASpellman, MEC JBKeppler, Regional Administrator, Region III.

JJHarrison, Chief, Midland Section,-Region III

-BBurgess, NRC Resident Inspector RAWells, MEC r-) 7. ^ t-1 i u _. h Ig/ m/ p >.

UAYQ1984 S & W eN ovCIO J.O. NO.14509.00

& 1

NIR 023 3:

^

Page 2 of 16 Serial ~27884 2

. Response.to:Nonconformance Identification Report number 023 bekprint. Station-209 is located with team 9.

Distribution is done by Document

. Control-and maintenance of the station is the responsibility of the team re-

=ceiving:the documents. This workprint station will be transferred to a con-trolled' document station and placed under the responsibility of Document Control for maintenance as well as distribution.

This program is in line with our

~

corrective action plan submitted in response to MCARR-DAT-1. Workprints that have not completed the conversion / verification process or been distributed as

.new workprints since lifting of the stop work orders have not been released by MPQAD for.Q-work.

The following items address each of the concerns identified:

1.

All workprints audited were old workprints that had not gone through the conversion / verification process. None of the drawings audited are being naed in work packages.

One drawing which was voided, was previously used in a work package.

The new workprint process and copies of the workprint stamp are described in FPD-1.000.

2.

Findings 5, 6, 7, 8, 9, 10, 11, 13, 15; 16.

In all drawings identified in these findings, the register reflects the new revision status which has

been processed. However, none of these drawings (or change paper) had been distributed. The sticks should reflect previously distributed information.

"This " historical" information is available in system 38 and can be provided to the auditors upon request. This processing cycle information was re-viewed in the audit entrance meeting.

-Document Control has verified that all drawings and change paper that were noted on the audit report are correct on the sticks according to the cur-rent distribution-status. No further action is deemed necessary.

?3 Findings 21, 22,.23, 24.

The auditors reviewed the home office revision information as opposed to the field status which is the revision'we con-struct to..~(There are large bore isometrics which are revised in the frield to add additional welding'information. See procedure FPP-1.00).

Therefore, the wrong information was' reviewed in the register.

Document Control reviewed all-drawings against the field status, noted discrepanciesfand'took corrective action.

TheseJare'old workprints and-would have been corrected during'the con-version / verification process =to new workprints.

1The, legibility of the other drawings / change papers was-reviewed again during the-' conversion / verification process to newlworkprints.

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MTEWCa Page 3 of 16 2 <ser'ial 27884 3

4.. Findings 123, 14, 25, 26.

Drawing FSK-DVI-M-604-8, was corrected during

-the conversion / verification process to new workprints.

The. legibility of the other drawings / change paper was reviewed again during the conversion / verification process to new workprints.

'5.

Findings 4, 12, 17, 19.

Change paper has been removed or added to the drawings per pullback instructions.

This would have been corrected during the conversion / verification process to new workprints.

6.

Findings 18, 20.

An FCN was not listed on the front but was attached.

This was a clerical error and was corrected.

Document Control ^1s unable to verify the information in the Audit Report on finding 20.

Additional information will be required.

7.

Other concerns noted on the Audit Report.

Training - the Construction Assistant responsible for this workprint a.

location, attended training sessions on January 6, 1984 and January 10, 1984. Instructions on posting and other requirements of FPD-1.000 and FPP-3.000 were discussed. Do.cument Control has reviewed require-ments with the Construction Assistant.

b.

Processes followed in workprint stations - These issues will be re-solved when the workprint stations are maintained by Document Control as part of the Document Control Corrective Action Plan. Until this conversion is complete, Document Control will review training needs with the' Construction Assistants and arrange for training as appro-priate.

8.

- Quality Action. Request number RA-00155' dated 03-29-84 was written in res-ponse to Nonconformance Identification Report 023 and closed on 05-03-84.

LW~

5/4/84 w

i-

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1

NIR 023

. m a e m % M.4 Si n,_

4 c 4c g

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6. QAR Number MIDLA PROJECT RA 00199 0

QUALITY ASSURANCE DEPARTMENT

7. Date issued
8. Revision Power q,pa,g3 o

Company QUALITY ACTION REQUEST 9.

Page 1

of t

1. Requirement
10. ASME Related Yes No FPG 7.300 Rev 4 FPD 3.000 Rev 11 FPD 1.000 Rev 19
2. Deficiency Stone and Webster NIR-023 identifies the following deficiencies during a CIO evaluation of work print station 209:
1) Attachments not referenced or attached
2) L'ork prints and attachments illegible
3) Drawing stamp errors have been identified
4) Attachment status on work prints does not always reflect System 38 (DM)
11. Potential 50.55(e)

Yes No 3.

Jkiainatedb

4. Discipline / Division /Section
5. Response Due Date
12. Date Reported to MPQA Mgr o//'y 'M (., hy.g/

PAP - Tech Services 4/05/84 N/A

13. ' Action item No.
15. I' tem Priority
17. S/U Code
19. Action organization
20. CAR Reviewed by 30 5721 5

PGM00 Dh Bechtel Field

14. Discipline
16. Trend Code
18. Resb Code Dxmed Cdrol
21. Date N/A ZD-5-0001 BCPCo - STF-G a - M - 84
23. Cruse
23. Proposed Currective Action SEE ATTR(LHED 6 HEE 73 dEE ATTBC#EB S HEEP
24. Responsible organization / Person
25. Proposed Completion Date D DC.

V-J - fp

26. Disposition Concurrence 73 G\\;

M/5/e 4 iM N 4/50/F4 QAR Reviewer Date

.PQAE (ASME Onivl Date

87. Disposition Action Taken 6GE RTTK} LED 6HEET5 f,hb%

t

28. Method of D soosition Verification 29 OAR Closed by Ssg Arm C H ED rcR C LOCa (2E Ju.s77t= tcM700.

Q gg MPQAD G

/

bte O

a rrw s/ sire PFOCE {AShlE only)

(

/ Date Acceptable Unacceptable Superceding QAR-

_c NIR 023 c.

Page 5 of 16 Response to NIR 023, dated March 23,1984, QAR PA-00153, dated March 28, 1984

Subject:

Workprint Station 209

'Workprint station 209 is located with team 9.

Distribution is done by Document Control and maintenance of the station is the responsibility of the team receiving the documents.

This workprint station will be transferred to a controlled document station in 4-6 weeks and placed under the responsibility i

of document control for maintenance as well as distribution. This program is

~inline with our corrective action plan submitted in response to MCARR-DAT-1.

Workprints that have not completed the conversion / verification process or beem distributed as new work prints since the lifting of the stop work orders have not been released by MPQAD for Q-work.

Note For ease of reading, the findings have been grouped by subject.

The letter identification noted on the NIR has been retained for cross-referencing.

1.

Old Workprints versus New Workprints All workpriats audited. were old workprints that had not gone through the i

conversion / verification process. None of the drawings audited are being used in work packages. One drawing which was voided, was previously used in a work package.

These workprints will need to complete the i

conversion / verification process if they are to be used in the field in work' packages. The new workprint process and copies of the workprint i

stamp are described in FPD-3.000.

2.

Discrepancies Between Resisters and Information on Sticks (Findinas 5, 6, 7, 8, 9, 10, 11 _13, 15. 16) 1 i

In all drawings identified in these findings, the register reflects the new revision status which has been processed. However, none of these drawings (or change paper) had been distributed. The sticks should l

reflect previously distributed information.

This " historical" information is available in System 38 and can be provided to the auditors upon request. This processing cycle information was reviewed in the

{

audit entrance meeting.

Document Control has verified that all drawings and change paper that were noted on the audit report are correct on the sticks according to I

current distribution status. No further action is deemed necessary.

3. --

Misinterpretation of Register Revision Information (Findinas 21, 22, 23, 24) l-L The auditors reviewed the home office revision information as opposed to L

the field' status which'is the revision we construct to.

(These are large

. bore isometrics which are revised in the' field to add additional welding information.- See. procedure FPP-1.000). Therefore the wrong information was reviewed in the register.

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-.Pggi 2 Page 6 of 16 Document Control reviewed all drawings against the field status, noted discrepancies and took corrective. action as follows:

Finding (22)-

FCR was removed.

1 ICS stamp was placed on front of drawing.

Finding (23)-

Status stamp was placed on front of drawing.

Finding (24)-

ICS stamp will be noted on front of drawing.

These are old workprints and would have been corrected during the conversion / verification process to new workprints.

'4.

Lenibility (Findi=as 23, 14, 25, 26)

Drawing FSK-DVI-M-604-8, was illegible. It win be corrected during the conversion / verification process to new workprints.

FSK-DVI-M-6048 will be checked at an other stations for legibility by April 6,1984.

The legibility of the other drawings / change paper is believed to be acceptable. It will be reviewed again during the conversion / verification process to new workprints.

5.

Channe Paper Not Removed or Added to Drawinas (Findinas 4. 12. 17, 19) i Change paper had not been removed from or added to the drawings per pull back instruction.

This would have been corrected during the conversion / verification process to new workprints.

.I

~

6.

Other Miscellaneous (Findinas 18, 20)

An FCN was not listed on the front but was attached.

This is a clerical error and will be corrected.

Document Control is unable to verify the information in the audit report on finding 20. Additional information will be required.

7.

Other Concerns Noted on the Audit Report a)

Trainina l[

The construction assistant responsible for this workprint location l

attended training sessions on January 6, 1984 and January 10, 1984.

Instructions on posting and other requirements of FPD-1.000 and FPP-3.000

[

were discussed.

(Attendance sheets attached). Document Control will l

again review requirements with the construction assistant.

b)

Processes followed In Workprint Stations These issues will be resolved when the workprint stations are maintained

-by Document Control as part of the Document Control Corrective Action i

Plan._ Until this' conversion is complete, document control will review training needs with the construction' assistants and arrange for training l

as appropriate.

N. Law --

NIR 023 STONE AND WEBSTER ENGINEER!NG CORPORATION Page 7 of 16 NONCONFORIGNCE IDENTIFICATION: REPORT 1

i DATE OF NONCONFORMANCE: 3/.22-[M NIR NUMBER od3 IDENTIFICATION / LOCATION OF ITEMS:

fha /WN7?OAl 20V DESCRIPTION OF NONCONFORMANCE:

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Page 12 of 16 DISTRIBUTION FOR QAR # RA-00155 ACTIONEE:

BTFoote, Bechtel-Midland INFORMATION:

JABauer, Midland WRBird, P-14-418A JEBrunner, M-1079-RECameron, Midland JWCook, P-26-3368 p

GREagle, AAO-TASK Dehorn,-Midland LRJessmore, Midland JFKnight, P-14-416 ODLanham, Midland BWMarguglio/DJones, JSC-220A ERMouser, Midland GEParker, Midland RCSember, Midland CMrhompson (ALAB - 2)

I'

!.a

NIR 023 Page 13 of 16 To LWWorley

" "el*Y Consumem one May 2, 1984 POWOI company sueJccr MIDLAND ENERGY CENTER PROJECT -

QAR RA-00155

,,,,,,y FILE 17.0 SERIAL 27881 coaacsrosocuce Lhw 10-84 CC During an overview of Document Control Station (209 team 9) items 1 through 7 were found to be corrected.

Action implemented as a result of QAR RA-00155:

1) Attachments not referenced or attached
2) Work prints and attachments illegible 3)

Drawing stamp errors have been identified 4)

Attachment status on work prints does not always reflect system 38.

Action of Document Control Assurance Group:

1) Document Control Assurance Group performed 100% overview of Station 209 of discrepancies identified in the (QAR RA-00155).

The discrepancies noted have been correct:4.

No other discrep-ancies were found.

Recommend closure of QAR number RA-00155.

i L

urrcwa STONE AND WEBSTER ENGINEERING CORPORATION Page 14 of 16 NONCONFORI%NCE IDENTIFICATION: REPORT DATE OF NONCONFORI%NCE:3/22-/M NIR NUMBER OJ5 IDENTIFICATION / LOCATION OF ITEMS:

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DESCRIPTION OF NONCONFORIGNCE:

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NIR 023 Page 1 of 9 O

1 CONSUMERS POWER COMPANY MIDLAND ENERGY CENTER Transmittal No:

CSC-7810 Date: May 29, 1984 To:

Stone & Webster P O Box 1963 Midland, MI 48640 Attached Ist Partial Response To 1

Complete Response To For Your Information Other

==

Description:==

Tracked Action Item 086.

i RECElVED cc:

JCKeppler, NRC Region III w/a JJHarrison, NRC Region III w/a RJCook, NRC Site w/a g g g tg g RAWells, MPQAD w/a E*hf Mz w/a S & Wocw C10 DDJohnson, MEC w/a J.0. M0.14509.00 LWorley, MPQAD w/a

{

Dehorn, MEC w/a

Page 2 of 9 ITEM / HOLD POINT NOTIFICATION FORM Sheet 1 of j ITEM NMER HOLD POINT N@BER

\\

gyggg g ygggygg 086 i

CONSTRUCTION IMPLEMENTATION O TRACKED ACTION ITEM l

OVERVIEW O TRACKED INFORMATION ITEM N/PIANP ##clE44 MANTJ.0. NO. /+509 0 TRACKED RECOMMENDATION ITEM O UNTRACKED ITEM 1 REFERENCE (S)

QAR RA-00155/QAR RA-00157 0 HOLD POINT NOTIFICATION CONDITION DETAILS Due to the conflicting responses received from Bechtel and that of MPQAD (See Reference below) concerning NIR 022/NIR 023, we request one reply clarifying our initial findings.

l. Current replies orovide inaccurate and confifeting information.

Reference:

1. Stone & Webster NIR No. 022
2. Stone & Webster NIR No. 023 CPCo Letter #CSM-0768 CPCo Letter iCSM-0769 OAR RA-00157 QAR RA-00155 l

l 4

h s woos spa b NO s)

ATTACHMENTS DATE RESPONSE REO'D.

INITIATOR /DATE INITIATION APPR VE /DATE VPA den 00%

sfttIn 8

We

  • 5-24-84 RESPONSE (SEE NOTE)

Attachments 1 and A provide a complete response to NIR-022.

Attachments 2 and B provide a complete re'ponse to NIR-023.

1 i

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@ YES wo's8

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O NO ATTACHMENTS 1, A, 26B q

n l

EST. CORRECTIVE ACTION RESPON E TITLE DATE

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$f RESPONSE ACCEPTED DATE RESPONSE VERIFIED / CLOSED UATE i

note - con inacaso actionitsus omtv, eartain etsanty on asesan=cs Atracqusers rosit _ _ _ _

Page 3 of 9 Pag.s 1 of 2 The following response is to clarify the response to your initial findings in NIR No. 22 as' requested in Tracked Action Item 086.

Note: For ease of reading, the findings have been numbered per attachment A i

and have been grouped by subjcet.

Workprint station 219 is located with team 19.

Distriktion was done by Document Control and maintenance of the station'was the responsibility of the team receiving the documents at the time of the audit. His workprint station has been transferred to a controlled satellite station (main library) and placed under the responsibility of h= ant control for maintenance as well as distriktion. All workprints audited were new workprints (either distributed after the stop work order or reviewed in the conversion / verification process).

21s program is in line with our corrective action plan submitted in response to MCARR-DAT-1.

1.

Missing Documents (findings 1 and 11)

Documents were found to be missing at the workprint station. Rese have been corrected.

i 2.

In-Process Work Activities (findings 2, 9,17)

In all cases, distribution (distrik tion may include new documents or pillwks) had been made from document control and the distribution j

date (distribution date of pillwks are not given on the register but were obtained from a pullback call up from the computer).was noted on 4

I l

the register. In some cases, the attachments in question were pillwks which had not been received by the station. Therefore, even.though.the register iruitcated an update, the station logs and h_==nts had not i

been updated.' he changes'had not been posted by the personnel at the workprint station. Therefore, the amendment stamp on the front of the drawing and the logs were not updated accordingly.

No' unreasonable l

time delays were found. A procedure to clarify posting requirements j

(FPD-1.000) was issued'on March 23,~1984. Rese findings would all be in compliance with.tk new procedural requirements of FPD-1.000 which

. requires posting be completed within three working days of the distri-f tution date. - Construction assistants were reminded that changes must be i

completed in three working days per new procedural requirements (FPD-1.000).

~

I Discrepancies listed have been corrected.

3.

Update of Work Station logs and/or Amendment Stamps on front of drawing-j~

to reflect conversion / revision (findings 3, 4, 5, 6, 7, 8, 9, 10, 14, 16, 18)

Norkprint station logs and/or amendment stamps on front of drawings were i

not updated to reflect workgrints that had been converted / verified.

Per-sonnel were reminded of the need to update logs.

Workprint maintenance

. requirements were reviewed with team personnel responsible for maintaining workprints.

4 L

This workprint station has been transferred to a controlled satellite document station (main library). Workprint station logs / cards have been standardized.'. Discreparx:ies listed have been corrected.

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NIR 023 Page 4 of 9 1

Page 2 of 2 4.

Conversion / Verification Errors (findina 12, 13)

Change paper had not been removed, therefore, the workprint station log and amendment stamp on the front of these drawings had not been revised.

'Ihe change paper has been removed from these drawings and the amendment stamp on the front of the drawings and the workprint station log have been corrected.

5.

Leaibility (findings 19, 20)

Drawings were replaced. Workprint personnel were remitided of the need to check drawing legibility.

6.

Miscellaneous (findings 3, 10, 15)

Finding 3 - FRL-1 was incorporated in drawing M-652-1-H130 Revision 1 and is presently not listed on the front of the drawing as indicated on the Audit Report.

Finding 10 - Drawing M-18-176 is revision 1 per the register and the sepia.

Finding 15 - Drawing M-18-370; there are 1064 pages including alpha and numeric pages. 'Ihis total page count is used for microfilming.

~ _ _ - _ _ _

i Attachment A l

DI5.CRFPRNGE~5 @ STR7'/ON 2 / 9 IN 5 TR.

' DOCUMEWT REV REN DOCUfENTS IN DSTED ON RTTCH.7D OTHER

$* NUMBER Dw&

TfE& IN QUE5TIDN REG FRONT BRCH cot 1MENTS LDG

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Page 6 of 9 Page 1 of 2 Se following response is to clarify the response to your initial findings in NIR No. 23 as requested in Tracked Action Item 086.

i Note: For ease of reading, the findings have been numbered per attachment B l

and have been grouped by subject.

Work:rint station 209 fi,alocated with team 9.

Distribution was done by Docu-t Control and maintenance of the station was the responsibility of the team receiving the documents at the time of the audit. This workprint station has been transferred to a satellite controlled document station (main library) and placed under the responsibility of Document Control for maintenance as well as distribution. mis program is in line with our corrective action plan submitted in response to MCARR-DAT-1.

Workprints that had not completed the conversion / verification process or been distributed as new workprints since the lifting of the stop work orders had not been released by MPQAD for Q-work.

1.

Old Workorints versus New Workprints "Old" workprints were eliminated by April 14, 1984 in the field. Se Document Control Assurance Group has not found any "old" workprints since April 14, 1984 and will continue to monitor. Senew workprint process

.and copies of the workprint stamp are described in FPD-3.000.

. 2.

Discrepancies between Registers and Information on Sticks (findings 5, 6, 7, 8, 9, 10, 11, 13, 15, 16 )-

In all drawings identified in these findings, the register reflects the new revision status which has been processed. However, none of these drawings (or change paper) had been distributed. Se ' sticks should reflect previously distributed information. This " historical" information is available in System 38 and can be provided to the auditors upon request.

mis processing cycle information was reviewed in the atriit entrance meeting.

Document Control has verified that all drawings and change paper that were notedonthe audit report are correct on the sticks according to current distribution status. No further action is deemed necessary.

3. ' Misinterpretation of Register Revision Information and Miscellaneous

}

Discrepancies (findings 21, 22, 23, 24) me auditors reviewed the home office revision information as opposed to e

the field status which'is the revision constructed to.

(These are large

. bore: isometrics which are revised in the field to add additional welding information.

(See procedure FPP-1.000). Serefore the wrong information was reviewed in the register.

Document control reviewed the drawings against the field status, noted j

discrepancies and took corrective action as follows:

Finding (22) - KR was removed

. - ICS stamp was placed on front of_ drawing 4

Finding -(23) - Status stamp was placed on front of drawing Finding (24) --ICS stamp was placed on front of drawing

=

o Page 7 of 9 Page 2 of 2 4.

Legibility (findings 2, 3, 5, 6, 7, 8, 9, 11, 12, 13, 14, 19, 23, 25, 26)

W e Document Control Assurance Group reviewed these drawings at station 209 on May 23, 1984. It was found that four (4) of these drawings have been deleted from distribution for station 209. Nine (9) of these drawings have been superseded by later revisions and one (1) of these drawings was voided.

In all cases, the review for legibility of the existing drawings found the drawings adequate for use by construction.

5.

Change Paper not removed or added to Drawings (findings 4, 12, 17, 19)

Change paper had not been removed from or added to the drawings per pull back instruction. Discrepancies have been corrected.

6.

Other Miscellaneous (findings 18, 20)

An FCN was not listed on the front but was attached.

' Ibis is a clerical error and has been corrected.

Document Control is unable to verify the information in the audit report on finding 20. Additional information will be required.

7.

Other Concerns noted on the Audit Report a) Training he construction assistant responsible for this workprint location attended training sessions on January 6, 1984 and January 10, 1984.

Instructions on posting and other requirements of FPD-1.000 and FPD-3.000 were discussed.

Document Control has also reviewed the requirements with the construction assistant since these training sessions.

b) Processes followed in Workprint Stations These issues will be resolved when the workprint stations are maintained by Document Control as part of the Document Control Corrective Action Plan.

Until this conversion is complete, Document Control will review training needs with the construction assistants and arrange for training as appro-priate.

u.

L6TED DN RTTGil.J{[y:.QTilEK Aihr<"4g,mq%.90

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