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General Offless: 212 West Michigan Avenue..ieckson. MI 40201.(517) 788-0650 Ae==e ame
.OE h Nhase E Wasser
' ' ' ' ' " * ~ ' "
January 15, 1982 Ameest J Svese te.umed & Get e
,s see.* Amenerye Fren.m X Sarkun.s.r Charles Bechhoefer, Esq.
p J,8 g U. S. Nuclear Regulatory L, o.m d Commission
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Atomic Safety & Licensing CSS /A O',*g Board Panel
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Washington, D.C.
20555 on uN Jerry Harbour h,'/g vg 1dJi U,'.E**"*
U. S. Nuclear Regulatory h,3 U""" E Commission g
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Atomic Safety & Licensing
- goy, Board Pane 1 a v u*v.
Washington, D. C.
20555 ODam Anemeys Dr. Frederick P. Cowan 615:' N. Verde Trail Apt. B-125 Boca Raton, FL 33433 RE: Midland OM-OL Proceedings Ralph S. Decker Docket Nos. 50-329, 50-330 Route No. 4 Box 190D Cambridge, MD 21613 i
Centlemen:
l Attached are copies of reports of audits recently conducted by the Midland Project Quality Assurance Department. As per your request, I will continue to forward copies of all MPQAD audit reports as they are issued.
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James E. Brunner
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v I.
SCOPE AND OBJEt TIVE '
The scope and c bjectrie of this audit was to verify B&W Construction Company's NSSS System Installation. This was performed by verifying implementation of B&W Construc-tion. Company's Quality Control Procedures and Field Construction Precedures.
II.
AUDIT TEAM hP' 'C:In ' w! N,'I8 G R Anderson - Audit Team Leader
[ M
> 9l H L Allen - Techuical Specialist
- 7.,
R D Davis - Aucitor w
J R Decker - At ditor--in-Training gfl07 LC92 A R Gort - Aud:. tor "Q.;'pn k0.](([
A L Pucci - Observer s
Gii f,'f/,ll,* g g III.
PERSONNEL CONT..CTED DURING AUDIT Attended Attended Name Company Title Entrance Mtg Exit Meeting M A Dietrich BPCo PQAE X
T W Davis Jr B6WCC Asst Q C Supervisor X
X W G Hall B&WCC Project E22gineer X
X l
W J Lee B&WCC Project Manager X
X Conty.ct Coordinator X
X W G Linn-BWCC S M Love BPC.o Sr Contract Coordinator X
S Smith.
BPCo Contract, Coordinator X
S L Taulbee B&VCC Quality Control Supervisor X
X IV.
AUDIT
SUMMARY
A) A pre-audi ~ antrance meeting was yeld on 12/14/81 with personnel in attendance as noted in P ragraph III. The audit term was introduced and the audit scope, plan,
' schedule a: d proposed audit exit meeting were discussed.
B) Audit Chee:. lists were developed from the following B&WCC Procedures.
1 94?P-101 9-SS-100 FCP-103-B FCP-298
'9-QPP-102 9-GEM-100 FCP-104-B FCP-338 9-QPP-lli 19-EP-100 FCP-285-B FCP-366 l
9-QPP-126 FCP-54 FCP-286-B FCP-397 9-CP-100 FCP-948 FCP-287-B FCP-405 9-CP-101 FCP-102-B FCP-297-B yr-v-i w-w
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C) The audit resulted in nine (9) findings which are attached to this report.
Seven (7) findings were issued open and two (2) were issued closed.
D) The following observations were made as a result of this audit:
1.
A review of FCP-102B, for the Unit Two snu'bbers 2-F1 (right) and 1-Fi (left), was pertormed. The auditor questioned a hand written entry on the FCP which referenced 1-F1, which is the twin snubber from Unit one.
B&W answered the question by showing the auditor a copy of NCR 1792, which documented damage that had occurred to the Unit Two snubber and the justification for replacing it with the snubber from Unit One.
It was recommended that NCR 1792 be referenced in FCP-1023 as documented evidence of the change out.
2.
On the requalification record for the 3/4" shoe for pipe bending, under wall thickness reduction, entry.215" was changed to.017", this was done without signing and dating. This entry should be verified, signed and dated.
1 3.
B&W Quality Control Procedure 9-QPP-102, Section 2.4 requires the Torque Device Serial Number be recorded. Contrary to this, FCP-423, Rev 0 for Unit Two, Sequence 650 does not have the Torque Device' Serial Number re-corded.
4.
Sign-off for Sequence'060 and 080 C for FCPs 366 and 338 is not consistent.
FCP-338 reflects measuring equipment calibration due date, FCP-366 does not.
Calibration due date is not a requirement per QPP-102.
5.
During walk through surveillance of storage and maintenance activities for Unit One Steam Generators, it was noted that Inspection Port Covers on secondary side were not secure'd properly. Work activity had been tem-pararily suspended pending engineering evaluation of cracked Ta'c-welds on baffle plate bolts.
l l
Measure should be taken to ensure craf tsmen adhere to requirements of 95S-100, paragraph 3.b during the interim time the work activity is l
suspended.
l 6.
FCP-38 and FCP-46, " Valve Inspection Checklist", Sequence 040 is for correction of deficiencies. There is not consistency in signing off this step, such indicatora as "OK" or "/" are used. Iherefore, there is no indication of what deficiencies have been resolved.
7.
FCP-38 (M..intenance and Inspection of Motor Operated Valves), Inspection Checklise., Sequence 020 dated 2/18/81, indicates two bolts missing from the cover. Valve inspection checklist 5/19/81 notes that bolts are miss-ing, but it appears someone else noted it on the checklist in pencil without date or initials. From the dfferent methods used to fill out the valve checklist, it is difficult to determine if there is or is not a l
requirement to correct a deficiency.
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PMoJECTS, ENQ1NEERING ano ecNarnucTioN o M
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8.
While verifying as-built condition of small bore piping, numerous mis-handling marks (sharp vise jaw marks) were noted on piping assemblies ICCA-46-1 and 2CCA-53-1. While this condition apparently is not re-jectable per B&WCC QC Procedures or ASME Section III, the vise jaw marks detract'from B&W's generally fine workmanship.
MPQAD reconsnends that B&W rework jaw plates on their bench vises and pipe turning / threading machines, or use suitable pa.dding material to prevent future mishandling marks.
9.'
Unresolved item:
See' attached URI M-03-300-1-10.
Pipe section between ICCA-33-2 FW 5 and ICCA-13-2 W 6 appears to exhibit small red rust spots. Subject pipe is 1" stainless steel, possibly con-taminated by contact with carbon steel during storage and handling. B&W to evaluate validity of this item and determine root cause.
E) An exit meeting was held on Friday, December 18, 1981, with attendance as noted in Paragraph III,.
Draft audit findings and observations were presented and discussed with the attendees.
F) Responses to the audit findings shall be directeJ to BPCo Subcontracts group for transmittal to Consumers Power Quality Assurance.
l V.
EVALUATION OF EFFECTIVENESS -
Several areas within the scope of this audit were found to be in need of attention and improveuent. These areas are identified in the audit finding reports. All other areas covered in.the scope of this audit were implemented correctly.
VI.
LIST OF ATTACHMENTS A) Audit Finding Raports M-03-300-1-01 through M-03-300-1-09.
B) Unresolved Iteo M-03-300-1-10.
C) Completed checklists (File copy only).
D)', Notification of audit (File copy only).
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AUDI 21 NDly>-6 RE,301.. ouAL.lTY ASSUR C333ggg3 caso-1 Priority: 10 Trend:
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M-03-300-1-01 F B&W Quality Control Procedure 9-QPP-126, Rev 4 " Personnel Qualifica-m,,,,,,.esa, tion - Quality Control Inspectors" paragraph Section 6.1 states, B&W Construction Co "All Level I, Level II and Level III personnel shall be given a art or tas m s visus 1 examination to assure color vision and natural or corrected December 30, 1981 naar distance acuity such that the individual is capable of reading 18*4*9 tr.z swess.
J-1 letters on the standard Jaeger's test type chart for near vision."
WRBird ALAB-2 Contrary to the above, the following Quality Control personnel JEBrunner GRAnderson qualiiication records contain discrepancies:
CMCarlin Technician I - Attachment 1," Certificate of Personnel Qualification RCook Quality InspectoC states under eye examination record that correc-MADietrich tiva lenses are not required. However, they were required to pass the examination. Also, the eye examination does not state a color 08E**187 B N guglio visiot. test was given.
DBMiller Technician II - The eye examination record form does not indicate JARutgers the type of Jaeger test that was performed.
ESmith Tachnician III - the eye examination record documents that this in-DATaggart dividual failed his color examination and there is no record of DMTurnbull ra-sxamination.
RAWells JLWood assuu.r.c -unse:m.c:mn,
- 1) B&W provide re-examination to the two individuals to determine color irision or ability to determine the difference in shades and document results.
S&W update eye examination form to reflect the need for corrective lenses.
B&W re-perform eye examination to the Jaeger 1 test as required.
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canic:as ac:ma cescs.arr.
l B&W to respond to the proposed corrective action by February 1, 1982.
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are an io B&W Quality Control Procedure 9-PT-100, Rev 2, " General Proced.tre 33 1-02 F for Penetrant Examination ' paragraph 4.2 states in part, B&W construction Co i
"...The drying of the test surfaces shall be accomplished by an c,.m:,,w, normal evaporation; blotting with paper towels or clean, lint-December 30. 1981 free cloth. The minimum drying time shall be five minutes."
rua amen.
gg 4 9 Contrary to the above, an NDE Tech was vitnessed on 12/15/81, m m,,
performing a Penetrant Examination in accordance with 9-PT-106, WRBird GRAnderson which references 9-PT-100.
The NDE Tech was timed by the audi-Bmnner M B-2 tor during his performance of the examination, the five minute requirement was not adhered to, the actual drying time was less 1"
than three minutes.
GSKeeley BWMarguglio DBMiller JARutgers ESmith DATaggart DMTurnbull RAWells nwed ascemoc.c a.ansc:m acna,
- 3) B&W perform a re-examination of a representative samp1'e of the penetrant examina-tions that have been performed by the subject NDE Technician.
cana::n,erna cr ecurr.
B&W to respond to the proposed Corrective action by February.1, 1982.
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I N45.2.2-1972 " Packaging, Shipping, Receiving Storage and Hand-raufosy: 44 toi j
l1ng of items for Nuclear Power Plants" Paragraph 6.2.2 "Cleanli-B&WCC nsas and Housekeeping Practica", states, " Cleanliness and good aan er im as housekeeping practices shall be enforced at all times in the storage 12/30/81 1
crets. The storage areas shall be. cleaned as required to avoid the gy*
cccumulation of trash, discarded packaging materials and other d it;.1-
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menthi soil."
JRBird GRAnderson Contrary to the above, the Fabrication shop where Class One Piping.
Fittings and Va'lves are in temporary storage prior to fabrication bok was unclean, piping, sub-assemblies stored in contact with the floor, MDietri i unidentified pipe sections in contact with floor end discarded weld ggg,,y,.
filler =aterial in the area.
ANSI N45.2.2-1972, Paragraph 6.4.2.1 states," Items in storage shall y
hava covers, caps, plugs or other closures intact. Methods used to seal opznings shall be in accordance with Section Three of this standard." JARutge a ESMith Contrary to this, the Fabrication Shop has Class One Valves and Pip-DATagga :
ing with uncapped / unsealed openings, which has allowed dirt to enter DMTurnbi!.1 inside.
RAWells JLWood ALAB M nex.noa aa muc:m acna,
- 1) Clean Fabrication Shop to comply with ANSI N45.2.2. - 1972.
- 2) B&W should inspect open piping and valves for cleanliness, reelean if icessary, and cap in accordance with ANSI N45.2.2 - 1972.
a:aas as acna es., cut.
B&W to respond to the proposed Corrective Action by February 1, 1982.
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U M0 B-quality Control Procedure, 9-BP-100, Rev 3, " Bending of 2 inch or cmallar stainless steel pipe" Paragraph 3.2.1 states, "Requalification of binding for each combination of size, schedule, and type of material,,3y,,,,,,,,,,
provicusly qualified shall be performed in intervals not exceeding one 12/30/81 yacr from the date of approval of the original qualification".
czs e rms, Contrary to the above, Requalification Records for 1981 documenting tha rsqualification of the inct and 3/4 inch shoes exceeded their WRBird GRAnderson JEBrunner qualification dates. Both of the shoes were initially qualified en CMC /KFH Octobsr 2, 1980, however, the h inch was not requalifed until MADietrich October 13, 1981 and the 3/4 inch shoe was requalified on Oct 6, 1981.
JWCook GSKeeley BWMarguglio DBMiller JARutgers ESmith DATaggart DMTurnbull RAWells JLVood ALAB (2) am.,,ccc sansem aer:a:
- 1) Not required. B&W has documented correcti"e action on a Nonconfor=ance Report.
-cauuc::e.n.
B&W to respond to the proposed Corrective Action by February 1, 1982.
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.ield Construction Procedure (Unit Two) FCP-423, Rev 0 and General rewisser aimma.
b B&WCC Electric Drawing 816E331 requires lockwashers to be installed on the n'"8'8" "
Ouida Bearing Assembly bolts.
12/30/81 Contrary to the above, the lockwashers were not installed as required * 'Q"'
in S:quence 640.
ou..,n2, WRBird G2 Anderson JEBrunner CMC /KFH JWCook MADietrich GSKeeley BWMarguglio DBMiller JARutgers ESmith DATaggart DMIurnbull RAWells JI. Wood a
av s9 foi am mara m m7 c:.ca, Nona required. Per General Electric's letter dated 12/22/81, which states the lockwashers cra not required and the General Electric Drawing 816E331 is being revised to reflect this it, ion.
l cc.ssem acw.a m,as:e Not r: quired.
- 30. assP 7Gs C/A; FD3G88 C G A^ h 7 " '
DaTE Or CIA C:WUT::ps GE's letter to B&W N/A dated 12 /22 /81 L
em cr ea anc-:nusses sC:3Ca Gr TEAM 137305:
This audit finding report is issued closed.
Tha auditor reviewed General Electric's letter dated 12/22/81 and concurred with the Corrective Action taken.
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,aal1ty Control Procedure, 9-QPP-102, Rev 10, " Field Construction 7:winsrt aama Proc:dures" Paragraphs 2.3.2.1 and 2.3.2.2 state as follevs:
B&WCC 2.3.2.1 "Each change of sequence (out of sequence activity and/or par-gy*/8T'$
cllol activity) shall be recorded on the FCP resequencint; form (see Attcchment 6)."
yg]8 2.3.2.2 "The FCP resequencing form shall be reviewed and approved by ausuns:
tha Field Project Engineer (FPE); Field Quality Centrol Supervisor; WR31rd ALAB (2) cnd, where applicable, the Welding Supervisor. The resequencing form JEBrunner GRAnderson shall be prepared by supervisory personnel only.
CMC /KFH Contrcry to the above, while witnessing work being performed in accor-JWCook dance with Field Construction Proce hr:
'CP-423, Rev 0 it was noted MADietrich i
that the following sequences were performed out of order:
GSKeeley
- 1) Saquence 590 was performed after Sequence 610 BWMarguglio
- 2) 5:quence 740 was performed before Sequence 730.
DBMiller
- 3) Bolts on upper guide bearing were torqued to approx 20-25 f t/lbs JARutgers in Sequence 620. These bolts were not being installed until ESnith Scquence 640.
DATaggart
- " "11 Contrary to the above requirement Field Cosntruction FCP-297's rese-quincing form indicates Secuence 050 is to be comoleted prige to 5squence 090 and signed-off (inspected). However, Sequence 030 has no JLWood e,,,,fs,
,..,,1...4 W s, e,...., 090 was ec mi e *ad ed e 4-a d e # <
as.x,.aaa c~aasem ae:ns:
- 1) This type of finding has been previously identified on two prior Audits M-03-06-1, dated 2/20/81 and M-03-42-1, dated 9/9/81.
&W is requested to research and determine the proper " Corrective Action" to prevent
.ccurrence of this finding.
cauc:a: ac:ss ecm=>as:.
B&W to respond to the proposed Corrective Action by February 1, 1982.
DATE Cr Cla CDW".2TEs:
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,Leld Gonstruction Procedure FCP-297, Rev 2, Sequence Number 060, rowinct aune B&WCC rapires the transferring of Heat Number and sign-off be recorded en Attachment "B" of FCP-297.
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12/30/81 Contrary to the above, the Heat Number for Line Item 1-610-2-7 was IT.4Y not r: corded on Attachment B.
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LG. Bird GRAnderson JEBrunner CMC /KFH IdCook MADietrich GSKeeley BWMarguglio DBMiller JARutgers ESmith DATaggart DMTurnbull RAWells JLWood ALAB (2)
SK r6J.T.C C.,MACI.T ACT.*"9:
- 1) E&W to record the correct Heat Number on Attachment B.
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Bis W to respond to the proposed Corrective Action by February 1,1982.
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3 300- -9 F CP 9-WG-106, Para 3.3.1 states in part, " The welds and adjacent t shall be examinal for...are strikes."
B&WCC 6
B&W QCP 9-WP-200, Para 7.1.4, states, "All arc striksa shall be mars or issws r:mov:d by grinding."
12/30/81 r=z maessi 18.4.9 Contrary to the above, numerous are strikes exist on small bore piping installed in Unit 1, as described below:
JRBird GRAnderson 6 cre strikes on pipe adjacent to joint ICCA-33-2, W6 JEBrunner RDDavis 3 crc strikes on, pipe adjacent to joint ICCA-46-1, W7 CMC /KFH 3 arc strikes on pipe between joints 1CCA-47-1, W 12 & 13 JWCook 1 cre strike on pipe adjacent to joint 1CCA-47-1, W 16 MADietrich 6 cre strikes on tee adjacent to joint 1CCA-47-1, W8 & ICCA-37-1,W4 c3ge,1,7 1 erc strike on pipe adjacent to elbow adjacent to joint 1CCA-37-2,W6 BWMarguglio 1 arc strike on joint ICCA-37-2-4 DBMiller Numerous are strikes also exist on piping assembly 2CCA-53-1, awaiting JARutgers instellation into Unit 2, as listed below:
ESmith 4 cre strikes on tee adjacent to W17 and W18 DATaggart DMTurnbull 1 are strike 'on pipe adjacent to W16 RAWells 4 ore strikes on pipe adjacent to W24 JLWood ALAB (7) ua.msc.u. a.uu:as acwn,
- 1) R pair are strikes
- 2) B&W to determine root cause of are strikes and provide documented evidence of ac:: ions taken to preclude recurrence.
CtaA&;TDs AC;;s GeseCFLK!.
B&W to respond to the proposed Corrective Action by February 1, 1982.
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PROJECTS. ENGINEERING ANO CONSTRUCTION-M
" " ' * " ^ " " " " * " " ' " '
UNRESOLVED ITEM QA76-0 Priority: 10 SUS: PGMIMM Trend: Do Not Trend AI: S-1223 OIS;RIF I0s GF LEC:.YD IM:
1.
U31 s0:
M03-300-1-10 U tipe section between ICCA-33-2 Field Weld 5 and ICCA-33-2 Field Weld 6 appears to exhibit small red rust spots, possibly due to g[gyc centamination by contact with carbon steel during storage or hand-I.
- A n or i.R:3U ATION:
ling. Subject pipe is 1" stainless steel.
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C;.. RI2CIC3:
WRBird GRAnderson JEBrunner ALAB-2 CMCarlin JWCook MADietrich GSKeeley BWMarguglio DBMiller JARutgers ESmith DATaggart DMTurnbull RAWells JLWood T.
RI4UI?.D AC;i35 B&W to evaluate validity of this item and determine root cause.
2.
A0"IO:1 ?2:llJIRD DCH:
B&WCC 9 Ar:IO:t PEUIRD ST-tAni February 1, 1982
- 13. 2ISPC53I "O U31 11.
UE; CF.;GGATOR'S S 33C'JI/*. ATE:
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AND CONSTRUCT 1oN*
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M01-218-1 3akarich WDGreenwell MBSimpson
.JBaranyi JAHorsch ESmith rna mes.
WRBird MWKirkland DATaggart D2.4.1 JABrown BWMarguglio JLWood um, m, JWCook DBMiller.
December 2-4, 1981 LHCurtis CARixford MADietrich JARutgers Midland Document Control RE?ield KRSiv sonw su a
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Midland Plant Units 1 and 2
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RECEIVED C 3 0 i3SJ I.
OBJECTIVE AND SCOPE To verify accuracy of the following " MAPPER" applications useh bbjeg::pocument Control:
Design Drawing Register e
Design Document Register - MRs/ Specs / Misc.
e Change Notice Register - Incorporated and Unincorporated DCNs, FCNs, FCRs, e
SDDRs, SCNs.
In addition,.to determine the status of adminis,trative procedures governing Docunent Control and to assess the adequacy of retrievability and access control.
. II.
- AUDIT TEAM R E Field - Audit Team Leader (MPQAD)
M W Kirkland - Auditor-In-Training (MPQAD)
III.
PERS0! EEL CONTACTED
- M N Bakarich Project Administration
- K R Simpson Project administration
- M B Simpson Project Administration
- R C Hollar Project Quality Engineering I
- K M Baum Project Quality Engineering (part time)
- P I Hsiah Staff Reliability (part time)
- Attended Entrance and Exit Meetings l
l
- Attended Exit Meeting only.
IV.
ENTRANCE MEETING An audit entrance meeting was held December 2, 1981, with those shown in II and III above in attendance. The audit plan was presented, finding procedures explained, and communications channels established.
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PROJECTS. ENGlhEERING L
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AND CONSTRUCTION =
- =
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QUALITY ASSURANCE OgPARTMENT h
I power v
,k,eM01-218-1 Casqissy 3
" - ~ ~ *
- QA24-0 n:r V.
AUDIT
SUMMARY
A.
Areas Audited 1.
A scientific sampling plan (developed with the assistance of Staff Relia-bility) was used to obtain a degree of confidence in the accuracy of the MAPPER registers listed in I above. The basis for the plan was Military Standard MIL-STD-105D, General Inspection Level II, the single sampling plan for normal inspection. Lot sizes were provided by Project Document Control. Attachment A summarizes the pertinent data.
2.
The status of administrative procedures governing the registers listed in I above was discussed, specifically EDPI 4, 46.3, ADP 2.12 and ADI 2.12.3 3.
Document retrievability was assessed during the audit and control of access to document files was discussed.
B.
Findings, Unresolved Items, Observations Within the scope of the audit', one finding, one un' resolved item and one obser-vation were identified in the areas of register verification, procedures, and engineering document completeness. See attachments for details.
C.
Evaluation Within the audit scope and with the exception of the items described in B above, Project Document Control appears to be performing in accordance with Project requirements.
VI.
EXIT MEETING An audit exit meeting was held December 4, 1981, with those shown in II and III above attending. The audit results were presented and conmitments for correc-tive action obtained.
VII.
CLOSING ITEMS l
Written responses are required as follows:
AFR M01-218-1-01F by January 4, 1982 l
URI M01-218-1-01U by February 1, 1982 l
Please address responses to:
l G R Eagle i
Supervisor, DQAE MPQAD-TASK Ann Arbor b
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PROJECTS, ENGINEEIING Ano consinuction-R PO.R--
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Casga87 mem wo H01-218-1 QA2 W t o _ L e-1 VIII.
ATTACHMENIS A.
Summary of Register Sampling B.
AFR No. M01-218-1-01F C.
URI No. M01-218-1-01U D
Observation E.
Audit Plan (file copy only)
F.
Audit Notification Letter (file copy only)
G.
Audit Worksheets, including Sampling Plan, Random. No. Tables, Sample Lists and Results (file copy only) r e
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M01-218-1 ATTACHMENT A i
LOT SAMPLE SAMPLE ACCEPT REJECT I
i LOT LOT **
SIZE SIZE SIZE LEVEL LEVEL ACCEPTED REJECTED STATUS CODE A
6521 200 L
7 8
197 3
ACCEPT B
1101 80 J
3 4
78 2
ACCEPT C
2245 125 K
5 6
122 3
ACCEPT D
1045 80 J
3 4
78 2
CCEPT E
80 13 E
O 1
4 9
REJECT ***
F 160 32 G
1 2
31 1
ACCEPT G
2783 125 K
5 6
125 0
ACCEPT AQL - Acceptable Quality Level - the maximum percent defective which can be considered satisfactory as an average. In this case, equals 1.5 errors per 100 documents entered.
- A Drawings j
B MRs/ Specs / Misc.
C FCNs D
FCRs E
SDDRs F
SCNs G
DCNs
- See AFR M01-218-1-01F 6
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art a 3D M01-218-1-01F ratd/DErr AWLCIL.
In comparing the Midland Design Document Registers to the docu-Midland Doc. Control ments themselves (or to microform reproductions), Lot E (SDDRs) gagfr on-was rejected and requires corrective action as described below.
'if2"'4"i Lots A, B, C, D, F & G require no corrective action beyond cor-
- w:uns:.
rection of the identified errors.
(Given to Document Control MNBakarich DBMiller during audit.)
JJBaranyi CARixfort WRBird JARutgero JABrown KRSimpson JWCook ESmith LHCurtis DATaggaru MADietrich JLWood REField MBSinpson WDGreenwell JAHorsch MWKirkland BWMarguglio uuam, unsc:m acuce, for Lot E,.SDDRs, perform a complete review of the register and correct all discrep-cncies. Instruct all involved DCC Personnel how to identify affected design documents.
CMaa:*:4& e.:'1CE LLs9%W.e As above.
By January 4, 1982 un er e/s cose:zrt:si cac. msar r:
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Projeet Administration M N Bakarich urs er efa.,,...
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Ldland Project Document Control is not following ADP 2.12, Rev 0, 2.
PRc3/ IPT AUDr!ID Midland Project Admin.
sr EDPI 4.46.3.
It is understood the latter is no longer pertinent since CEBUS has been eliminated, and that variances from ADP 2 12 12Y~81 3-have been directed by Project Management and are described in a draft ADI, #2.12.3.
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MNBakarich DBM111er JJBaranyi CARixford WRBird JARutgers JABrown KRSi:ipson JWCook MBSimpson I.HCurtis ESaith MADietrich DATaggart REField JLWood WDGreenwell JAHorsch MWKirkland BWMarguglio 7.
M4UIAD ACTIC* e J
Approve and issue the draft ADI or some other procedure directing Midland Document Control w rk.
Project Administration 2/1/82 8.
ACTIO3 FIWIPID TBCH:
9 AC"I:n RIWIRID BT-:ATZ
- 10. RISPC331 To UBIs
- 11. URI CAIGILATOR'S SIG5ATURZ/ rE:
- 12. SUFIRVISCA'S SIC:iATURZ/DATE:
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URI C.050RE BASID m :
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M01-218-1
-r OBSERVATIONS 1)
In several instances, the audit team observed that document register entries were incomple'te (i.e., lacking sheet and revision numbers).
In checking the documents themselves (DCNs, FCRs, etc.), it was found that Project Engineering had not provided the information on the docu-ments. Engineers should take care to identify the document f, type, sheet i and revision to which the change or deviation applies in order to obtain an accurate and conplate register.
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'otrich RAWells 18.4.3.4 18.4.3.6 GSIOoley JLWood un y m, BWMerguglio CMC /KFH 11/17/81 - 12/2/81 DBMiller JWCroy JARutgers TRCharette Esmith RCHirzel Bechtel Construction /QC s::.::r mon =,w :n.n/ms, o n/ usa m e r un q
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t-I.
AUDIT SCOPE AND OBJECTIVES f
The audit scope included receiving, fabrication, and erection of miscellaneous and structural steel, as well as review of quality documentation associated with the Project Quality Control Instructions for receiving, fabrication, and erection of mi.scellaneous and structural steel. The audit was conducted to verify ccm-pliance to Specifications 7220-C-304(Q) and 7220-C-233(Q) and applicable codes, standards, and PQCI/ irs.
II.
IDENTIFICATION OF AUDITORS J W Croy - Audit, Team Leader T R Charette - Auditor R C Hirzel - Auditor C E Harbour - Auditor-in-training 111. PERSONS CONTACTED DURING AUDIT Attended Attended Name Company Title Entrance Mtg Exit Mtg S Kirker Bechtel QC X
B MacGlasham Bechtel QC Receiving X
E Dutton Bechtel QC X
X P Goguen Bechtel Lead Civil Field Engr.
X X
J Stubbs Bechtel Action Item Coordinator X
T Gelnett Bechtel QCE D Vandoorne Bechtel QCE IV.
AUDIT
SUMMARY
A.
Entrance Meeting The " Miscellaneous and Structural Steal" audit entrance meeting was held November 17, 1981. The purpose of the entrance meeting was to present the scope and objectives of the audit, and to introduce the audit team to the audited organizations.
See Paragraph III for the entrance meeting roster.
B.
Areas Audited Proper erection and configuration of five (5) Reactor Pressure Vessel Upper Lateral. Supports and one fan support were verified. Checklist #2 was used for this ~ portion of the audit.
MCJECTS. INGihEERING 1
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@ QA24-0 ANo COMsTRUCTION =
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f Fabrication and QC inspection of 46 pieces of miscellaneous steel was observed.
Checklist #3.was used for this portion of the audit.
A review of 15 completed Quality Control Inspection Records for correct-ness and completeness was performed. Checklist #4 was used for this portion of the audit.
Inspection of incoming steel to purchase order requirements had been planned but no miscellaneous steel was received during the period of this audit (Checklist #1).
C.
Audit Findings The audit resulted in no findings being identified.
D.
Observations Two (2) observations were made and closed before issuance of the report.
- 1) Signoff~in Block 14 was missing for-Act. 2.3 of QCIR C-2.20-923.
2)
In Block 4 of QCIR C-2.10-259, the total number of pages was not noted.
E.
Exit Meeting A post audit exit meeting was held on December 2, 1981 with those in atten-dance as noted in Paragraphs II and III.
The audit observations were dis-cussed with the audited parties.
V.
EVALUATION OF EFFECTIVENESS With the exception of the o5servations, QA Program element effectiveness and implementation, within the scope of this audit, is considered adequate.
VI.
LIST OF ATTACHMENTS 1.
Completed checklists (File copy only - 18.4.3.4)
/
2
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^
3 COnsumart /,
d' Pn:Jacts, two:nznisa AND c xstnucTioN=
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v cuAury assunAuct osnnrueur Date of Issuance:
1-8-82 m 1, 2 umm AML? 'ME e
I sh HPleonard ALAB-2 M01-601-1 BWMarguglio ir.2 uma.
DBMiller RECEIVED
.18,4,7 JWCoo JARutgers LEDavis ESmith JAN 111982 a s, m gy, MADietrich DATaggar t 12/16/s1 - 12/18/81 CSKteley RAWells E CO. I4gol Bechtel II:.M A&;:!; my "2 *"fM3s AMROVZ3 37/t.A-r. /
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I.
SCOPE AND OBJECTIVE The objective of the audit was to verify Bechtel Power Corp. compliance to applicable program requirements for the handling and distribution of controlled documents required by the Zack Co. for HVAC construction activities, as defined in the audit scope.
The audit scope included those activities covered in the following procedures and instruction:
A)
FPD-1.000, Rev. 9, " Design Document and Corresponding Control."
B)
FPD-2.000, Rev. 4, " Field Change Request / Field Change Notice' Procedures."
C) FID-2.100, Rev. 1, " Outstanding FCR/FCN Retirement."
IDENTIFICATION OF AUDITURS The audit was performed by the following personnel:
DKMartin - Audit Team Leader (MPOAD)
SKCox - Auditor (MPOAD)
AAKunz - Auditor-in-Training (MPQAD)
EWCoold - Auditor-in-Training (MPQAD)
III.
PERSONS CONTACTED DURING THE AUDIT The following personnel were contacted during the audit:
Audit Audit Name Organization Title Entrance
- Audit, Exit RWSoderholm Bechtel Project Supt. Services X
X RCAsh Bechtel Field Contract Admin.
X X
X BSThind Bechtel Lead Contract Coord X
X LVRice Bech tel Senior Contract Coord. Zack X X
HEEntrekin Bechtel Lead Contract Admin.
X X
JClimartin Bechtel Project Field Engineer X
JDDavis Bechtel Offices Services Sup.
X X
JCard Bechtel Document Control Coord.
X ASaenz Bechtel Design Section Lead X
CBowen Bechtel Construction Assistant X
JShe ehan Zack Document Control Sup.
X CJohnson CPCo Const. Field Engineer X
SEBandla HPQAD Observer X
PM0JECTS. ENC: NEE 08tG
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AND CONSTRUCTION =
ouat:TY AssunANCE CEPARTMENT C0mpagy 4A24-0
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Audit Audit Name Organization Title Entrance Audit Exit DKMartin MPQAD Audit Team Leader X
X X
SKCox MPQAD Auditor X
X X
AAKunz MPQAD Auditor-in-Training X
X X
EWGoold MPQAD Auditor-in-Training X
X X
IV.
AUDIT SU)2fARY A) 'Ihe audit entrance meeting was held on 12/16/81 with personnel in attendance as noted in paragraph III. The audit scope, plan, tentative schedule, and audit finding procedure were discussed.
B) Checklists for this audit were developed from the Bechtel instruction and procedures noted in paragraph I.
Specific sections audited are as noted in the completed checklists. Data was collected by proceeding through the checklists for each procedure audited. All checklists employed during the course of this audit are attached to the file copy of this report.
C) The audit resulted in one (1) finding, M01-601-1-01, requirements of FPD-1.000 not adhered to, which was issued closed.
')
One (1) observation was made as a result of this audit:
D Only the PFOCE of Bechtel is furnished with copies of retired FCN's and FCR's per section 4.15 of FID-2.100, Rev. 1.
It isrecommended that all organizations with construction or inspection activities governed by criteria on Bechtel design drawings be included under section 4.15 of FID-2.100 for thoss design documents affected by FID-2.100.
It is noted that this observation and recommendation has been considered by
. Bechtel. A revision to include organizations with construction or inspection activities governed by criteria on Bechtel design drawings under section 4.15 of FID-2.100 is presently in the review cycle.
E) The audit exit meeting was held December 18, 1981 with those in attendance as noted in paragraph ZII. At that time, one (1) draf t audit finding and one (1) observation were. presented and discussed. Commitment dates for responses were agreed upon.
V.
EVALUATION OF EFFECTIVENESS Use of the procedures listed in paragraph I was satisfactory.
VI.
LIST OF ATTACHMENTS
- 1) Audit Finding Report M01-601-1-01
- 2) Audit Plan (file copy only)
- 3) Completed checklists (file copy only)
/
J TREND: 01d-G3, New-C5
@ I" PROJECTS. ENGINEEll86G AND CoNSTRUCTtoN a oUALITY ASSURANCE DEPARTletNT I:",,
AUDI. FINDING Rt.30U i
a u* canica rosa u amman f n amus c=nm una ursacei ain am.
M01-601-1-01 FPD-1.000, Rev. 9, section 3.2.3 - vendor drawings and data,
,wnsrr aana. Midland 162 paragraph 3.2.3.1, subparagraph 3 requires Project Engineering.'
Bechtel SC/DCC
)
cpproved drawings and data received shall be routed as outlined an or amm.: on-in section 3.2.1, subparagraph 3.
12-18-81 rum maams.
3.2.1 subparagraph 3 states, "The New Drawing Sign-Off Sheet, etmov,'s.l 7 18 4 Exhibit G, will be routed to the responsible Engineers for RCAsh review, along with an uncontrolled print of the drawing. Upon WRBird return to Document Control, New Drawing Sign-Off Sheet will JEBrunner become part of the file."
JWCook MADietrich Contrary to the above, there is no objective evidence available CSKeeley to verify that the requirement is being implemented as specified HPLeonard in FPD-1.000, Rev. 9, section 3.2.1, subparagraph 3.
BWMarguglio DBMiller JARutgers ESmith DATaggart RAWells ALAB-2 mmo ors cc=ctm crm:
Implement the requirements as specified in FPD-1.000, Rev. 9, section 3.2.1, subparagraph 3.
GLAAAc'D6 ACT&Cs Q,8.GD&Jr,.
Evaluate reconnended corrective action for applicability and acceptability. Response date of December 29, 1981, for cocunitment on corrective action determination and completion. Bechtel Letter BCCC-6155, dated December.30,1981, concurs with the recommended corrective action with implementation effective December 28, 1981.
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December 28, 1981 Document Control JDavis sESCO GF FD1FIGTICs:
- 1) Review of Bechtel Letter BCCC-6155, dated Decenwer 30, 1981.
- 2) Verified that vendor drawings and data received af ter December 28, 1981, are in review routing cycle. Material verified were uncontrolled prints and nes drawing sign-off sheets for Vendor Drawings F7220-A67-4 and F7220-C90-4-1.
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