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( 4 THE HOWARD P. FOLEY COMPAh7 NUMBER: NCNCO.TORMANCE RIPORT Page 1 of _ 6 {cg-[.q i, DESCRIPTION: OCP-SA - Quality Control Procedure ATTACIO'.ENTS DATE: for A1:S Welding Dl.l. The above referenced Procedure is not in accordanct Yes O No O s-s-83 with the referenced Code - At.'s Dl.l. HOLD TAG # "^ REMOVED REF. EPF/IR NUM3ER: N/A BY DATE UNIT I X UNIT II x / LOCATION Various CLASS I @ NON-CLASS I y INSPECTION CR.uuIA: DRAWING SPECIFICATION y PROCDUPI X C6DE X N TITLE AND MER: (SEE LIST OF PROCEDURES A!?D CODES ON PAGE 2) DESCR.IPTICN OF NONCONFORMANCE: (Including Cause) The referenced inspection criteria, H.P. Toley Q.A. Manual, states in part: "...special processes are performed in accordance with the require.ments of applicable design drawings, specifications, procedures, codes and standards by qualified personnel." In violation of this Q.A. Manual is the referenced Procedure (OCF-SA) because it is not in accordance with the above referenced Code (AWS Dl.1). Also, please note: (CCNTI!?UED CN PAGE 2) f& 9-/-0S w-~ __.INITIATD BY DATE Q.C. SUPERVISOR RETIr4 4 DATE H.P. 70 LEI DISPOSITION: ....m GAGO
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i s W# j DISPOSITION BY DATE QUALITI FIVIr4 DATE P.C.& E. DISPCSITION OR CONCL"P.RENCI: 1 ~ [\\ CO 67.) I f. f "O O id ,O E.l l 'V l t s CI p,.C'.4 E. Co.' *" z E$ OAIL {t DISPOSITION ACCOMPLISHED = /.5/ h EERITIED 3Y DATE Q.C. S'JPERV150R DATE
CHE HOWARD P. FOLEY COMPANY !NO. .NONCOhTORMA.NCE REPORT CONTINUATION SEEET %C7 -M CONTINUATION OF: DESCRIPTION OF NONCONFORMANCE G PAGE 2 OF F3 PROPOSED DISPOSITION O DISPOSI" ION ACCOMPLISHED O DATE 9-6-E3 INSPECTION CRITERIA: (CONTIh"JED FRO!! PAGE 1) QCP-5A - Quality control Procedure for AUS nelding Dl.1 AUS Dl.1-82 Structural 1ielding Code - Steel H.P. Foley Q.A. Manual, Section IX, Control of Special Processes 10 CFR 50 Appendix "B", Section IX, Control of Special Processes DESCRIPTION OF NONCONTORMANCE: (Includine Cause) (CO?CINUED FROM PAGE 1) 1. The Procedure (QCP-5 A), Paragraph #1 " Scope", states in part, "This Procedure outlines the ' basic require:nents to cover... gas reta2 arc welding." The Code (AWS Dl.1), Paragraph 5.1.2, requires a welding pre edure specification to be prepared for the applicable process. This has not been done. NOTE #1: The welding procedure specifications are currently for Shielded lietal Arc welding and Flux Cered Are weldi.ng (FCAW). NOIE *2: FCAU is not noted in the Procedure's Scope. 0 2. The Procedure (QCP-5A), Paragraph 3.2.1, states in part, ".... -the-*roduction-Superintendent (is) to insure Production forces under his supervision are kept informed of and are working to the latest I requirements specified in the Quality Procedure." This has not been done. Welders are frequently found' to be unaware of even the welding procedure specification that they are using. The - welders are not fermally trained in the procedure. Z T 3. The Procedure (QCP-Sa), Paragraph 6.1.2, requires that the base metalQ ~~ prepared by oxygen cutting--surf ace roughness values not to c.xceed g 1000 mil or 2000 mil, as applicable. An ANSI Surf ace Poughness Gauge is not in the H.P. Foley Tool Poom, ,,,,,i' Calibration Lab, Field or the Q.C. Department Tool Locker. p NCTE #1: This requirement is taken from the Code (AUS Dl.1) at M Paragrapa 3.2.2. Also, see Note 4 of that paragraph. NOTE #2: Discovered in the Purchasing Office was an AWS C4-1-77 C Oxy-fuel Gauge. However, these gauges are not applicable to this Z referenced Procedure or Code. 0 4. The Procedure ( GP-S A), Paragraph 7.6.1.1, references welding processes g FCAU-GMAM and SMAW. p,--. The Code (AWS Dl.1), Paragraph 5*.1.2, requires a welding procedure - - ee specification to be prepared for the applicable process. This has not been done for the GMAM p ocess. NOTE: See Item 81 of this NCR. x 5. The Procedure (QCP-5A), Paragraph 8.8, states..." caulking of welds, unless { specifically noted by constructor, is prohibited." The Code (AMS Dl.1), Paragraph 3.9, states: " Caulking of welds shall not g be permitted." (CO!CINUED ON PAGE 3) ~
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THE HOWARD P. POLEY COMPANY NO. NONCONTORMANCE REPORT - Coh"I'INUATION SEEET $ b2,.92d COhiINUATION OF: DESCRIPTION OF NONCONFORMANCE O PACE 3 OF 6 PROPOSED DISPOSITION O DISPOSITION ACCOMPLISHED C DATE \\ 9-6-83 DESCRIPTION OF NONCONFORMANCE: (Includino cause) (CONTINUED FROM PAGE 2) NOTE: The Code (AMS Dl.1), Appendix 1, "Tems and Definitions", states t " Caulking. Plastic deformation of weld and base metal surfaces by mechanical means to seal or ' obscure discontinuit'ies." 6. The Procedure (QCP-5A), Paragraph 10.3.1, references AWS Dl.1 Current Revision. The Current Revision is not in the Q.C. Library, and to the Writer's knowledge, the Current Revision is not on site. ( NOTE #1: Current !s 1983.. NOTE #2: The Procedure,(QCP-5A), Paragraph 2, references AWS D1.1-75. This year Code is not in the Q.C. Library. NOTE #3: Some site personnel have in their possession an AWS Dl.1-75 with the 1976 and 1977 Addenda. There is, to the Writer's knowledge, not one of the referenced Code (1975) on site. 7. The Procedure (QCP-5 A)', Paragraph 10.2.5, allows the straightening of distorted merbers by the use of localized heat (i.e., not to exceed f 1100 F). [ The Code (AWS Dl.1), 'Taiale 4.2 Note 3, records the maximum temperature 4 for Group "4" materials as 400 F. to 450 F., depending on the material thickness. ~ ^^ ~
es not 7 vertical, overhead, etc., welding. The referenced Procedure Paragraph per=its all position welding / NOTE M2: of autoratically controlled time welded studs. l (H.P. g# ( AUS D1.1) requires tests to be performed by the Contractor I 13. The Codefor other than flat position welding of auter.atically controlled tine l Foley) welded studs. This has not been performed. M "If the reduction in length The Procedure (QCP-5 A), Paragr aph D3.2.6 states: S - of studs as they are welded becomes less than normal (i.e., the length uf the s 14. f.#j C stud is core than 1/16" greater than specified), welding shall be stopped f Z i.nediately and not resumed mtil the cause has been corrected." i also notes the references for welding as Dl.1-82 and The Procedure (QCF-5 A) (Electrical only) at Paragraph 2, " References." The referenced Pro-g f Dl.1-75 cedure Paragraph D3.2.6 is taken from the AUS C1.1-75 Code, E The stud welding section of the Procedure should be based upon the require-p ments of D1.1-82, Section 7 and Appendix "K" per the reference secticn of the t-S Procedur e (QCP-5A). I (CO!TIINUED ON PAGE 5) e me no ee e e e-e == THE HOWARD P. TOLEY COMPANY NO. noNCONTORMMICE REPORT - CONTINUATION SHEET 6bC2, p q E CONTINUATION OT: DESCRIPTION OF NONCONTORMANCE[3 PROPOSED DISPOSITION O PACE 5 DISPOSITION ACCOMPLISHED O OT[ DA':7. 9-6-83 DESCRIPTION CT NONCONFORMANCE: (Including Cause) (CO!!"'INUED FROM PAGE 4)
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NCTE #1: AWS Dl.1-82 is basically different from the Dl.1-75 Edition for the qualification process and procedural requirements. NCTE #2: The referenced Procedure Paragraph on stud reduction has been deleted since 1978 from the Dl.1 Code and the stud length reduction is found in the Manuf acturer's Qualification Test Data for each and every diameter stud, along with its weld time cycles (in 1/60 seconds) and welding current. Also, please reference AWS C5.4, Table 4 - Typical length Reductions of Studs in Are Welding and Table 5 - Typical Weldino Conditions for Stud Welding of ' Steels and Paragraph 6 - Welding Procedure ~ (Studs). NOTE #3: AWS C5.4, Reco mended Practices for Stud Welding, is referenced in the Code, AWS Dl.1-75-83. Also, AWS C5.4 cross references itself with AWS D1.1. 15. The Procedure (QCP-5A) Weld Procedu e Specifications are not in accordance with the code AWS Dl.1.- Reference QCP-5A, WPS 1, Position of Welding - AI.I. (Vertical) g Upwards). O It is the intent of the code (AWS Dl.1) that code useis detail the position of welding (i.e. Flat, Vertical, Overhead, Horizontal) in order that the a.mps & volts parameters are conducive to p*roduce quality wlds. NOTE: This is typical throughout the weld procedure specifications.
- 16..The Procedure (QCP-5A) Weld, Procedure Sycifications are not in accordance with
( the code AWS D1.'l-82. The Weld Procedure Specifications are not detailed. NOTE als Instead of detailing out the groove preparatibn' dimensions, the Procedurei states, The groove preparation (i.e. Root opening "R", Roof face "F", Groove Angl e " A") Engineering variables as noted in the code and then includes the "As @. Fit up" tolerances. Note: This allows the welder to engineer his own joint configuration. 17. The Procedures (QCP-5A) Weld Procedure Specification WPS-81 and WPS-82 weld sy:rbol is for a Flare Bevel Croove Weld. The referenesd DCC 4362 (Found in Remarks block of WPS-82) paragraph "C" states in part: Dr. Moss Davis (AUS) agrees that Flared single level (SIC) considered Fillet Welds.. 9 Groove Welds (for superstrut) shall be NOTE # 1: The H. P. Foley letter to AWS dated February 21, 1978 Figure B details it as a Fillet Weld, AWS confirms it as a Fillet Weld and the Procedure details as a Croove Weld. NOTEN 2 .The material thickness is not noted on the WPS's. NOTE # 3: WPS-81 Remarks block references DCC 4361. This should be DCC 4362 l as noted above also as noted.in WPS 78, 79 and 80. 1 18. Reference the above Item 17 Notef 2 of this NCR. WPS-81 and WPS-82 :sterial thickness is not noted.The Weld Procedure Specifications The Joint Design sketch for WPS 81 and 82 can be / could have been mistaken for Tube steel to Building ste l application using E-60XX electrodes. - )(W 'S i i L I
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N 1 CO!TTINUED ON PAGE 6:... i 'i L ~ 'N:0RMATION ON Y r. 1 - - ~ =... ~ ~' , m .:n ~.. i .n_ _ y-- m, m - wm,% E UIE HOWARD P. TCLEY COMPANY ho, NONCONTORMANCE REPORT CONTINUATION SEEE; 8802-924 CONTINdATION OT: DESCRIPTION OF NONCONFORMANCE O PA CE 6 OT 6 PROPOSED DISPOSITION O DISPOSITION ACCOMPLISF.ED C DAT DESCRIPTION OF NONCONTORMANCE: (Including Cause) CCNTINUED FROM PAGE 5: 18. NCIE # 1: The incorrectly referenced DCC 4361 (b75-e l) and DCC 4362 (WPS-8) is j readily available to craf t and inspection personnel for it is a P.G.&E. [5. not DOCvMENT. NOTE # 2: The incorrect Weld symbol (for Superstrut) is correct for Tube steel. j 19. Reference Item 18 of this NCR. and 80 prior to PCN# 12. This condition is also applicable for WPS-78, 79 20. The Procedure QCP-SA, WPS-62 is not in accordance with the Code AWS Dl.1. This Joint Configuration is not prequalified per AWS D1.1-82 or any other Code If this Joint has been qualified by H. P. Foley it is not noted, also year. which is not noted are the Joint details, such as material thickness, root
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21. The Procedure QCP-5A, WPS-62 details a dashed horizontal line on the vertical item on the right side of the sketch. It is not knowm the ir. tent of this dashed horizontal line. If then this is indeed a Non-conforming condition for it is excessivethe IGS is sho detailed on the WPS. (Joint penetration) NOTE # 1: Actual Joint Detail performance tests are required per AWS Dl.1-82. -- The Joint Detail and Welding Variables (i.e. Electrode size, A. ps, Volts, Helding positions, Root opening, etc.) should be shom en the W.P.S. NOTE # 2: This.information is required to make accurate Engineering and Inspections. , NOTE # 3: The Procedure contains in it 's written form 29 ea "tuy be", 3 ea "should be"; 1 ea "if necessary",1 ea " preferably", 2 ea " reasonably", 3 ea "as practical", t ca "where practical", 1 ea "when practical", 1 ea "where possible",1 ea "as possible",1 ea "when possible",1 ea "Sa:ne general position",1 ea " reasonable s:coth and regular". e l TORVIAT!ON OU =_e. I r~' I I 1 .$.m"""~~'
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.m.--mm m m M A C.Ta ' '. M --- - ~ ~ .I I i e 3 TO: Ivan Vines '/ FRO.M: Rick Wil.4n, Quality Director REF: NCR 8802 924 Notes of discussien 9/27/63 DATE: September 29, 1983 The following is an evaluation of the referenced NCR and the response there to:
- l. - Item 1 is not a violation of Code, but is an inconsistency between the scope and content of the procedure.
Engineering vill process a PCN. Item I has not resulted in a non-conformance, axh. ' /D '/-O D ' Q ubmit this item on a separate NCR. kd$ 3. All oxygen cut surfaces are dressed by grinding and do not r exceed the 1000 uin requirement in paragraph 3.2.2 of the AVS Code. There is no need for a roughness gage. This item '~ has not resulted in'a rsn-conformance.. j7 YY 4. This item is not a code violation, it" s much Iike Item 1. Engineering vill process a PCN. There is no non-conform.ing condition. THE 5. No caulking of velds has been performed. Engineering vill 3 WARD P. FO!.EY process a PCN to revise the procedure. COMPANY 6. Q.A. has a 1975 AWS D1.1. 7. AWS temperatures are interpass and preheat for velding and donotdealwithbgndingofshapes. There are no group 4 materials on-site 8. This le net ~.. a noni conforming condition. 9. Engineering is requesting information f rom the Ovner as to the design basis. It should he noted that H. P. Foley's I responsibility is to erect in accordance with the design supplied by the Owner. EDR 1337-1432 response to Note 4 Resubmit Note 5 on a separate NCR. l l 10. This has not resulted in a non-conforming condition. j Engineering is processing a PCN to revise the wording in the l procedure. l TORMATO V 0 \\l_Y l l l { 11. Sec lten 10. '\\ 12. No Class 1 automatie stud welding has been performed on the proj ect since the 1942 Code has been in effect. Engineering is processing a PCN to remove automatic stud welding from the procedure. 13. SeeItemk2. 14. See item 12. 15. There is no violation of the code. Electrode utilized by H. P. Foley is designated by the Code as "all position" and the range of amperage and voltage is as specified by the manufaeture. 16. The WPS's in use by H. P. Foley utili:e the full range of tolerances allowed in the Code. This in and of itself is not a non-conformance. The Ovner has' approved each WPS and H. P. Foley is erecting the material as specified by the design documents. H. P. Foley is addressing your concert-s to th*e 0.mer via an EDR. 17. There is no non-conformance. Engincering is revising the WPS to eliminate conflicts in terminology, b ~ 18. See Item 17. ed -83 19. See Item 17. m g ( 20. Resubmit on separate NCR. 21. See Item 20. THE 10 WARD P. FOLEY that there is consistency in,the use of NCR's and IR's; this COMPANY Project uses the ANSI n45.2.10 definitions. Questions concerning design are processed through H. P. Foley Engineering on an Engineering Disposition Request (EDR), and questions concerning procedure should be processed through H. P. Foley Engineering op-Quality Assurance on Procedure Change Requests. W Q g6 Y KI: tt cc NCR E602-92t. l INFORMATION OQy ( e I i -2. .e f \\ THE HQW:.RC 0- ::LEN C:1.' = :.k v TRANSMI CA*. To CI.YDE NEEDilAM ATE 10 /5I? 3 i / ENGINEERING MANAGER JOB NO. WY 'i 7' l SPEC. NO. 9307. l { ut agREBY TRANSMIT - FOR YOUR APPROVAL FOR YOUR INFORMATION 9902-932 @rrRvoURReecentworooIstosITIcn i FOR CORRECTI%/ ACTICN ] R rcR YOUR SIGNATURE l i ! E I It i i\\ l l l 1
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} STATION BATTERYS FILLET WELDS WERE MADE (TTII.IZING AI ACFJIC TS DATE: MULTI-PASS WEI,D TECHNIQUr YesO :o 8 10-3-83 1 l !!CL3 TAG
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- -- DESCmIFTI(3t OF NONCUNFORMANCEt Seruet. Weld Station Battery's Fillet welds were swnde utilizing Multi-pass weld te The Cbde (AMS DI.1-82) specifies the mininum fillet weld size and requires that thi size be made in a single pass.
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- 2. Se H.P.F. Drawing SK-8-OWS Rev 0 is different from the PCG E Drat **.,g of the same number.. The H. P. Foley does not have PCEE concurrence.
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PROCEDURE SPEC r: CATION (WS) I.; *. '. ' P - y ,2._ 3%.g_qg l.og dCLD TAC 8 R I2*0'.* EO REF. HPF/IR NL?.3ER: 3Y, D A!T. UNITII{/ LOCATION CI. ASS I NON-C:. ASS I O UNIT I X INSPECTION CRITERIA: DRAWING SPECIFICATION PROCEDURE @ ,DOCUlGNT TITLE AND NUMBER: We1 ding AWS D1.1 QCP-5A DESCRIPTION OF NONC NFDEMANCE: (Including Cause) The Procedure QCP-5A, WPS-62 is not in accordance with the Code AWS Dl. l. This Joint Cbnfiguration is not prequalified per AWS D1.1-82 or any other Code year. If this Joint has been qualified by H. P. Foley it is not noted, also'which i ot noted are the Joint Details, such as material thickness, root opening radius etc., so it is not known est matgrial this ~ WPS is to be used on or, have been usea on. 7 % A" / / w /D 10-+B8 d/Q' cro.).k 10 5-5 S l 1.i . Am da.ATED BY ~ DATE DATE i ( (.C'. SUPER g 'R RIEW I.P. FULET DISPOSITION: s. i r,j.u ..(. .1 J: 3 - E ~ ~as*...-..s.. 3 ..- ?. DISPOSITION SY DATE QUALITT REVIEW DATE f.:.WAV s I ' ** *' j P.G.4 E. DISPOSITIM OR COBCURRENCI i f E //
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~ -ee "U*. W.. W h Wh96 -*-".m. ..hw he .u ' it'Cdillil100Utfd Olspgsdg ...,- m.. n m riAo V - w -.>. r~m:v ' .-...a.-. m.% mi-m - .t , e -- - t J-- -- . t.i.r--.gyk".,.. m.. - r 1 ./ {* / '/ 3:A 3 1.0 " A::Y ^ '; J ")5 :;:. (?S) ?ROCID"RI SPECIF:CA';0N NO. _,,..,.. . cp 34 Material Specificacion Welding Process croup 1 and II oer Table 4.1.1 Aus 01.1' Manual or Machine shteided.wecal Are ( Posicion of Weldin6 M.uual Filler Metal Speciricacion. F All (verescal-up) -Filler Mecal Classificacion srA A3.1 Flux E701s Wald Mecal Grade. N/A =- Shie1Aa=. Gas - 70.000 Psr w/A g.'. Single;.,o Jealciple Faas_ r . S s-.Wale:ori..% 1tiple Arc. hiriele Pass
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neehemend en "When base estal enest shaft he and maintained at temperature is belov or above 70'F durina weldint. 9 . ?2. or.._. r.LscI. w an gr C_ASSESta. 1:31ZE: 5 ~7hMPS- ~ 1 V01.TS . T.. ..DU M '. i ' ' ~ ~ ~ - II ? . ? r.'. d. ?5 =i- - ... ~. ~iiCr- ::. : ^ j' .m... ~.. ===Tr .- 3/32 c Begist , t/4 .~ h t00* 20-30. ...a. ~ R,.-- ~ -~~ y red' 5-- J.5/32 -- 110-150 30 ~'".J~ Z~. ~ E 'fr ~ k W 210 20-30 -:---~' . _ ~ ' - - -) ' ' M '- 9. ~ REMA.--.RKS:. - - - .s r 1- ~ . pass tridth* 4 dia.~ of elec . Y-*---.~ after each paae. no se. botas _.. . _._ MEW 4... " ;~2 _ J ' ~ vere l' - -.. 2- - ~ trad.onany..AntermediateI -@.g. - h..t._1M..q-.f.,i -~= ?.E ~ . 9 ; t f* ' . wn.w --, %._..e n.., , v. m-a*.- +. 2 %-A++. W. yc.,;P:;---tfi y giL.h &_%;', _.. 3.;. .h.---f: ..^ ' g-. ::. v~ x.,3 - :;". :.. ~. -. .T ~. a . c :. = =.:, -. -l ~
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e.- e. 3 -... w, .,,,.,,, 2 .g..;,,...,...- t l 1 .i i l 1 i INFORMATION ONL Recommended Disposition e O THE HOWARD P. FOLIY COMPANY NLHBER: ORIGlifAL x0NCONFORMANCE REPORT ? age gf I 8802-940 Rev 1 w& .A 6 , s DESCRIPTION: me-PFurm-epe, Wrt n tNr: AITACM E':TE DATE: i ( PROCEDURE SPECIPIt'ATION (hPS) IS NT of FAT.II'ICP usC No C 10-7-R3 HOLD TAC ' 'l/A RD'.0VED REF. RPF/IR NIN3ER: N/A SY DATE UNIT I X UNIT II X / LOCATION CI. ASS I X NON-CZ. ASS I INSPECTION CRITERIA: DRAWING SPECITICATION PROCEDURE x DOCLHENT TITLE AND NLHBER: Welding AWS Dl.1 QCP-5A DESCRIPTION OF NONCONFORMANCE: (Including Cause) There is a deficiency in the above referenced Weld Proced.2re Specification (WPS) which renders the quality of all items utilizing the above referenced W.P.S. as indeterminate. The 'above referenced WPS has inadequate documentation for its qualification for its use. The weld joint details such as material thicj['nbys, root opening, radius, initial idlyt,* known what m terial this W.P.S. pass electrode size, etc., are not noted. It is to be used on, or has been used on. (/, 3 , n. 7 -t/3 - A4d 'O 7-F 3 INITIATED BT ' DATE Q.C. SUPERVI3 EW DATE H.P. FOI.ET DISPOSITION: I DISPOSITION ST DATE QUALITT REVIEW DATE P.G.& E. DISPOSITION OR CONCURRENCE: l e i A x P.G.5 E. Co. DATE i = 2 DISPOSITION ACCOMPLISHD I l-(
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t.u M t; z \\3SES e SIZE ass (, 'fot;g A2 9 3/32 70-100' 20-30 l R: quired 1/8 110-150 20-30 l 5/32 150-210 20-30 m 1 EE.P.A."U*.5 - \\ .Maximan pans width.4 dia, of elec. being / \\ tced; clean ef ter each pans, no severe ' undercutting permitted on any antermedi'ite J N m pecses. '} e ( \\ e l 6 I P g -f g e . L. t O "N*--Mh N ..h a m g.h .g p: n p - P i i t-i I I i THE HOWARD D FOLEY Ct.tP.',NY i l
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/ ENGINEERING MANAGER JOB NO. '4Y-5 7 r, SPEC. NO. 9902. 1EE HEREBY TRANSMIT - FOR YOUR APPROVAL FOR YOUR INFORMATICN IR _sso2 ai41 Orcavouaarcoastuoroorsecstros Orcacoaarcervtactron ~ b FoR YOUR SIGNARTRE I ( I.- l THANK YOU -~k rum y E_I e i I J A""; .LC:. " * *;L M.C.~.. '. E u- '....,n 02 ;; A., I J;.43 1.:.0 0,'i.".. L.; .i i
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.l a THE HC'*ARD P. M' U.Y '.v 4N I NUMBER: ORIGINAL Noncontee r : l...l_: I sm-m DESCRIPT!CS: THE PROCEDt!RE QCP-5 A, WT.DIPC G!i.CNESTS DAIE: PROJEE".'id: - SPECIPICATION (WPS)
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.!C'.O TAG l R12".OVD REF. NPF/IR NUMBER: N/A SY DATE UNIT I @ UNIT'II @ /t @. TION' R23S I C NON-CI. ASS I O INSFECTION CRITERIA: DRAWINC Q SPECIFICATION' ] FEDCrsvag X N TITI.E AND NUMBER: WEI. DING AWS D1.1 QCP-5A DESCRIPTION OF NONCONYORMANCE: (Including Cause) details a dashed horizontal line on the vertical item on the rightThe Procedure QC - sk etch. It is not known the intent of this dashed horizontal line side of the condition for it is excessiveshowing the effective throat of the weld then this If the WPS is (Joint penetration) m ng known what material this WPS is to be used on, or has been us ddetailed on the WPS It is not CONTINUED ON PAGE 2: e on. '~ w F' /O-4~b53 h ( W T' M D RT DATE /D' 5' QYC. SUFgASOR'RITIEW DATE 5.P. FULEY DISPOSITION:
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4.ip Recommended Disorr;iih^ _,.-,,_,__-,___.__m. _, _ _ _,, -,, _ _, ~ _,.. _ _ _, _ _ _ - _ _.. - - _ _ _ - - _ _ - -,.., -, _ - m THE HOWARD P, POI.EY COMPANY M- .)RIGINAL NONCONFORMA!!CE P.EPORT 00tITINUA TIO!; SPECT 8902-941 CONTINUATION OT: OtsCP. pT!3;; 07 NONr.ONF0Fr.ANCE C PA CE 2 Or 2 - PRO PUSED DI5195
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CTTI'INUCh PROM P,V;E 1 : NCTTE # 1: Actual Joint Detail performance tests are required per AWS D1.1-82. n.e Joint Detail and Welding Variables (i.e. Electrode size, Amps, Volts, Welding positions, Ro_ot opening, etc.) should be shown on the W3.S. F NOTED 2: This information is required to make accurate Engineering and Inspectinne-q3: The Procedure contains in it's written fo rm 29 ea "may be", 3 es "should bes, g 1 ea "if necessary",1 ea " preferably", 2 ea " reasonably", 3 ea "as practical",1 ea
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d 1 JOB NO. wY-576 I SPEC. NO. ??O2 ME: HI;REDY TRANSMIT - FOR YOUR APPROVAL ___ FOR YOUR INFORMATION 95102-M 7 l FOR YCUR RECCMMENDED DISPOSITION 1 FOR CORRECTIVE ACTION FOR YOUR SIGNATURE i I 1 l l l l l THANK YOU '"Te I 9L. ::;.TL ' - ~ ~ ..b.... . w a, .J e A ~ f "... .. G;;.A,.,; a;.4D A:.~' OA'IO TC t FC a.v. ::. P..., 7. s i ISS l ( I r THE HOWARD P. TOLET COMPA;;Y NUE3ER: ORIGINAL NewcDuon..Ascr at.ma-eeo2-942 i ' 4 i DESCRIPTION: AT ACIT.C TS DAir: PROCEDURE VIOLATION - QCP-5A Yes O No 8X 10-4-83 i HOLD *AG
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REF. IFF/IR IR20lER: N/A BT DATE i UNIT I @ UNIT II @ / LOCATION CLASS I NON-CLASS -I O r., [A#'.INEF.ECTIS.CRITERIAJ, DRAWING SPECIFICATION C PROCEDURE @ ..a.. . g. m.a.,.. .s u-..- g i; - Jj ~ 'DOCWINT TITLE AND NUMBER:. p.
C. PROCEDURE
FOR AWS MEI, DING D1;l c w ~' %.m..u e~\\ a ..~ . - DESCRIPTICE OF NONCONMEMANCE: (Inc.luding Cause) The Procedure (QCP-5 A), Paragraph ' 3.2.1, states in part, ...the. Production Superintendent (is) to insure Production l ihrees under his supervision are kept informed of and are working to the latest l -- requirements specified "in Quality Procedta e." This has not been done, welders are ~ frequently fotrid to be unaware of even the welding procedure specification that they are using. The welders are not formally trained in the procedure. L aja 7 .z g&y.,n.p.- - 3%= g.. g'ps ; C;:n.- . r -* - .w /o.-4 r 5 3 _. /M - / 0- s_-f 3 [- 8 ~ r( s..ea 7:a.w wm n IT - .I Darz - Q.c. ' surer R REVIEu - nATE - p. i.- s. a " --. g.t- 'E.P POLET DISPOSITI N:
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~ THE HOWARD P. FOLEY COMPANY NUMBER: ORIGINAL NONCONTORMANCE REPORT Page 1 of 1 8802-942 Rev 1 DESCRIPTION: ATIACEMENTS DATE: PROCEDURE VIOLATION - QCP-5A Paragraph 3. 2.1 Yes O No O ROLD TAG # RDt0VED RET. EPF/IR NUMBER: N/A BY DATE i Lau I @ UNIT II@/ LOCATION t'USS 10 sos-cI ASS I O INSPECTION CRITERIA: DRAWINC ] SPECITICATION C PROCEDURE @ DOCUMENT TITLE AND NUMBER:, QCP-6 Para. 4.4s 4.Si 4.5.1r 4.
5.2 DESCRIPTION
OF NONCONFORMANCE: (Including Cause) The Procedure 3.2.1, states in part, "...the Production Superintendent (is) to insure Production (QCP-5 A), Paragraph forces under his supervision are kept informed of and are working to the latest requirements specified 'in Qttality Procedure." "Ihis has not been done. Welders are frequently found to be tmaware of even the welding procedure specification that the are using. indoctrinated to QCP-5A.There is no doctanentation, or training records, for some welders bein y l { j \\ i,' N, d to-7-63 ruik r INITIATED BY /o-7-33 DATE Q.C( SUPER 1 1EVIEW DATE l H.P. FOLET DISPOSITICN l t' DISPOSITION BT DATE QUALITT REVIEW DATE l P.G.& E. DISPOSITION OR CONCURRENCE: INFORMATION UNLi d x iii-P.G.& E. Co. DATE l ( DISPOSITION ACCOMPLISHED VERIFIE) BY DATE O.C. S UPER'.'!SC R
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=- ( ELECTRICAL f UNIT I Q THE HOWARD P. FOLEY COMPANY UNIT ll PRODUCTION ENGINEERING DEPT. ENGINEERING DISPOSITION REQUEST To / b la, s c. o e k subject acP r A n.m_ R. K a o a le.s werd ~, Y ~ Nblem m n,r P w e. as c o n a-4Lt u n less encwrw s,o e e.,Ji r e d ven dor s wp o lo e c) n, n-f er u n i I. e. c ni,.ne41 m o f o rs e e4. u S r o a,y r ,s e e-- .+,_ b t r
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/ n i n ((. M /o /e / n signed oate Reply dE6-( n ti n n b'b > /0 G IG3_ signed Date _rZr_1_. ___ ___..M. 1 _7..._E.____ i.._ 1 d / ~ t N 1 \\ \\ \\\\
d ~ .?;1E liOWARD. _P - W PY_.COMPA.T.,, = Wi= hor? ORIGINAL N NCONFORMANCE REPORT 8833XR-23 DESCR.LMION: C-6180 CONN CH . ] *.. {j Date: Weld 7A47B to Ext.Cel.11 V' l' ,,: r,; 2-7-83 Plate MK 3005-1 Elv. 187' - ... f.i 8833XR-14 @ Mr:t "JD REF. IIPF/IR NUMBER 8833XR-14 ATE f 7 13_ UNIT IIO / toCATION rt.u. va.T)LrNa sinc. cL.187 CtAss t e nan-CtASS I UNIT I INSPECTION CRITERIA: DRAWING g SPECIFICATION O PROCEDURE Q 4 DOCUMENT TITLE AND NUMBER: 6180-F1-13-005; OCP-5A DESCRIPTION OF NONCONFORMANCE: (Including Cause) The above preheated plate welds were accepted by Quality Control (see attached HPF/WIS). Upon cooling weld 7A crack'ed its full length, and weld 7B cracked 1/2 its length. (Both 4" welds). Plate (MK A005-1) plate is warped by 1/2". in 20" of length. 4-/ m SAO f 24 _ 8-hh W LNITIATY6 BY DATE QUALITY / TANAGER DATE PROJECT' MANAGER IIATE ( DISPOSITION INCLUDING MEANS TO PREVENT RECURRENCE: Remove Plate A-005-1 and replace. Grind area of cracked welds flush and liquid penetrant test to ensure that cracks did not propagate into base metal. Hold training meeting with Production supervision on istrotion control. f- '3 3ISPOSITION BY F D TE FROJECT MANAGER DATE l Y2-$ _. - m*h9..Y - - 4. 2.#24 -f % QUALITY MANAGER DATE PAdIFIC' CAS AND ELECTRIC CO. DATE DISPOSITION ACCOMPLISHED PT Accomplished and found Acceptable on 3-3-83 Training meetings held 3-4-83. e m s (. 5 [..., '/ h.;'f ' a-C r?.- - 2 1 2 .5
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THE HOWARD P. FOLEY COMPANY w(JNG*TJ PRODUCTION ENGINEERING DEPT.
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?. -- M 1-w. NONCONFOR$'.ANCE REPORT NUMBER: I -d ' ~ ~ ~ =. Page 1 of 2 . v. gam _ 94T, . DESCRIH10N:, ATTACHMINTS DATE: -( %.Q 3.- - _ Class One Support Rework .-.-.,.-w-. Yes C No 10-5 --~~
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7;~ reference any' vork request and do not fall withi.n the 1._ (CONTINUEI) ON PAGE 2) ope of Appendix D. " ~~ -a. -am -. :. ~. -. --k:. _. -=_.~. 3: ~ y N.pV)%__ g, _y:. -. _. --/d-G-N i."m.p.M muEw_BY-. -,. CDATE '"i ~ y *.; -' ~ _...2 m Q.C. SUPERVISOR REVIEW ..Z~- -DATE ~ - = - - ~ e i _ ":..H.7.' FOLET DISPOSITION: - - ~ m+ y..- - C. n n.. ;.--- - ~~ 1.:.-.. : . ;p. ..+ -j ~S
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VERIFIED BY DATE Q.C. SUPERVISOk W~ e-m-M
-- 'IEE HCHARD P.1 - POLEY COMPAN't NO. i NONCONTORMANCE REPORT CONTINUATION SHEET ,, n., _ NTINUATION OF: DESCRIPTION OF NCNCONFOR".ANCE C PAGE 2 OF 2, PROPOSED DISPOSITICN O DISPOSITION ACCOMPLISHED C DATE i n c;_o a DESCRIPTION OF NONCONFORMANCE: (Includine Cause) (CONTIh'UED FROM PACE 1) - - This 13 in violation of QCP-3, REV. 6 " Processing and Control of Devia ions and Nonconformances." Paragraph 3.2 of QCP-3 states: "The Production -- Superintendent or Designee assigned by the Project Manager shall be.respon-41ble for notifying Quality of deviations and nonconformances and accomplishing ~~ ,all work _in.accordance vath the specifications, design drawings and procedures." .m Per ANSI N45.2.10: " Quality Assurance Terms and Definitions": .a nonconformance r2 -
- ,. is'"a deficiency in characteristic, documentation or procedure which rehders
~ ' " the quality of an item unacceptable or indeterminate. Exac:ples of nonconformance include: physical defects, test failures, incorrect or inadequate documentation, or deviation from prescribed processing, inspection or test procedures." ~ +, ,~."**{." ~^ ~', _- e p _{- ~% T,,. ~""
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g.,j THE HOWARD P. FOLEY COMPANY ~'- UNITliy" PMDUCDON ENGINEERING DEPT. ' [. ~. " ENGINEERING DISPOSITION REQUEST y. .M. Ros s ei.E.?' ' - Subject 8tructural Welding Requirements hD brmfli ~ - Problem Per scecification 48802 welding is to be cerformed in accordance. with buildine section rectiirements of' the AWS Welding Code -for Structuril Stdai. However arolicable secti'on of the AWS Code is nod. ' referanced in other iob specifications. It is our understandine that all Structumi k'el'dWr should conform ~ with the additional recuirements of section 9 - Buildines
- Is this' ms correct ?
A A !<f.7 Ggned Date /0 4) .r M.
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Q{glgl THE HOWARD P. FOLEY COMPANY NUMBER: NONCONFORMANCE REPORT Page 1 of 2 8802-871 Rev.2 DESCRIPTION: ATTACHMENTS DATE: WPS#, Weld Rod Size and Type Unverifiable Yes No @ ' ~ HOLD TAG # REMOVED REF. HPF/IR NUMBER: N/A BY _ DATE UNIT I x UNIT II x / LOCATION Documentation Files CLASS I x NON-CLASS I INSPECTION CRITERIA: DRAWING SPECIFICATION O raocrount 8 DOCUMENT TITLE AND NUMBER: QCP-5A Rev.9, Para, 13.
2.1 DESCRIPTION
OF NONCONFORMANCE: (Including Cause) There are a number of Class I Raceway Support Wclds that the Weld Rod Type Size, and WPS are unverifiable per QCP-5A, Para. 13.2.1. d-deM sk m B1 M k e c / O / 3 -l5 3 INITIADlD BY DATE Q.C. SUPERJISOR REVIEW DATE H.P. FOLEY DISPOSITION:
- 1) Welds shall be visually accepted prior to final sign-off of support.
a) Visual inspection confirms structural integrity of welds.
- 2) 6010 and 7018 are the only types issued to Electrician Welders.
- 3) Both 6010 and 7018 are acceptable for use on electrical supports.
(Continued on next page) 0 l0 Too /O -/.9~ 73 k la /3 ft) DISPOSITION BY DATE QUALITY REVIEW WATE P.G.& E. -B'E?CS!!IGN OR CONCURRENCE: 4 -A \\t/ r5/ 03 P.G.& E. Co 'DATE DISPOSITION ACCOMPLISHED ici VERIFIED BY DATE Q.C. SUPERVISOR DATE
THE HOWARD P. T'OLEY COMPANY NO. NONCONFORMANCE REPORT - CONTINUATION SHEET CONTINUATION OF: 8802-871 Rev.2i DESCRIPTION OF NONCONFORMANCg G PAGE 2 OF _2,, PROPOSED DISPOSITION O DISPOSITION ACCOMPLISHED C DATE 10-13-83 L P. FOLEY DISPOSITION: (Continued)
- 4) Accept rod size "As Is" if visual inspection is acceptable.
a) Remove and replace weld if lack of fusion is noted. .5) Accept Ht.# "As Is" - Only acceptable filler material is issued to the Rod Control Station. 6) Revise QCP-5A to require the Electrical Welder to enter Size Heat No., and Type of rod used on the applicable " Work Copy" documumentation Q C. to verify it's entry.
- 7) Record this NCR Number on affected SIWS's or WIS's.
- 8) Accept missing WPS No. "As Is" based on Item #1), above.
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Problem On cle t,'.il _ S 19 0 ( CS n-12 7 5 2 ) the recora;.icn Ic "fix" can not be done.
Do you have an alternate methoc'?
On detail S-428 ( CSP.-12 7 3 4 3 ) the veld synbol shows we have to
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weld all the way around.
Can ue weld on three sides only?
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e p at f L % G a e n n ~a n a w is, a 4 m-tr7s an e? usz n us. a.m. z han asa 'R d -4(y As>40,'cc %puvisor I;m 7/,cw[sc.? cuid -fk (972 ear 4;e. c,f M3 z a ss.a.to.
- 3
_d e.F h 6 s ,a M3 rdemte I b ry, As such) tk <4 7_3 e d,(;9 1 is acupMic -Gr J.f.Foky c,,tids s; fe. L c.Iosi. I ash f c s kh +6k th. wcas cwus%,'I;1y .Ser sa.\\d y lies e;% klana.p ne.d ad M c wpkme.4 6 cwJ ccubc( f A % cly hoyam. L ho n ec s - U s a4e. e your comcerns, 7#43 01-9 wy u 3 NauapswM (u.s nA s de-fl14c decision wd cows g e.'.fl/ c.ed-oow #c iorc.:- a sa -[ec nd decision. M 13 yoac c o p,,s E W y; as. T y Lc & me.ks - pd u x e_ J cenAbs an nok moaapud mwd e AAress 9emps % T.,sguke, 4 c_annoh 10- Iw.}A a.ccoNde_ -[e.c de.d sit vtS ce0dA (oy MmweAY. L+ yes Gal (ha.b Hems ofconcern uwt #abssed qppso.kly7 I w t v A J p im 1s y hke.g lf iese. concec.1s of purs.
- 4. 1k Ch il sinesd7 s'
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- 1\\.i:. !
!.g ;,; ; ] ] SI'ECI t'ICATION O >.e-' O INSPECTION CRITERIA: D E/ ti l.'*' : DOCLMENT TITLE AND NLHBER: rYP-5 A Prv. 9 Para. 11.2.1 Dr.SCRIPTION OF NONCONFOR..A;.CE: ( Inr l utii ne Cau 1 5 There are a nu +* r <>f Cl ass I we= l e !' t h<s t t he: '!c l ei
- 7d Ty:e, s i r..
a n t w:c c.r. uriverif yable r e r rv p_53 n u 3, 13,7,3, i mm ? E, vv, L w,.,9 ppNITIA$BY DATE Q.C. SUPERVISOR REVIEW DATE H.P. FOLEY DISPOSITION:
- 1) Visually inspect welds in question to existino vinual accer'ance criteria.
- 2) Accept weld filler rnetal type A': Is.
a) s.r*10 and 7n o are the only tyr4s i s noeti t o I:1..;t r i c i.a n e i ie rs, b) F.,eh 010 an! 701A are a. -m til I r.- f r. r oss <>4 c l. c '. r a c, : ur r 3r '. ( DI.iO)L I T I N: COf4 TIN"F.D rJ PAGE.') l APPROVAL OF D SPOSITION 2hJL L c s.K s i./c2 .) fi&L._. 4 /n j DISPOSITION 84 DATE/ QUAL ITY R EV I E.! ') A TE P.C.& E. DISPOSITION OR Cri.*:CURPCICE: .,e I i f "* r l! l l f ~.. b c E t j m.- .. p e l ~~ * - f t 1. c l... g j - - $W ..p I x y a : ~ '. 5
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I T!!E !!OWARD P. FOLEY CO'tPANY NU-NONCONFORMA!!CE REPORT - CONTINI *. TION S!! PCT 51002-*'l * * * - NTINL'A TION OF: PESCRIPTION 0" I:0NCO::FOR:M:3CE C PVI: 0F Ph0PO:i"D DISPOSf7 ION O DTSPOSITION ACCOMPLIS 1tru O ci Te 5-1 wl H. P. F'il F " I t ! S.vS T T i nti: c :! !* t-i '.* * : t,.r " t:
- 3) Accapt rod '6izo A2 In if viroa'. in.r< ce i. > i :. v:<. s
- Tt 1..
a) ' tem vo arid replace w It' if l a<:k o f f u.i ton a r. i n '. < i. i
- 4) Accept Ht.e An_Is - Only acceptable filler material in issueel to the r?) control station.
- 5) Revise NP-SA to reesire tiw welder to ente r ni:.., beat N. and tyrm of te uvei on the aprlicable "t:ork Cocy" documentation. OC to verif y it 's ent r..
I
- 6) Record this NCD Number on affected STtS's i
!!IS's. sf o l aus-APPROOAL OF DISPOSTTION = at <
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F SQr,' Ig THE HOWARD P. FOLEY COMPANY I %nsE;: NONCONFORMANCE REPORT Page I of_2 8802-871 Rev.2 I- ), DESCRIPTION: ATTACHMENT 3 DATE: WPS#, Weld Rod Size and Type Unverifiable y 10-13-83 HOLD TAG # REMOVED REF. RPF/IR NLHBER: N/A BY DATE UNIT I x UNIT II x / LOCATION Documentation Files CLASS I x NON-CLASS I INSPECTION CRITERIA: DRAWING SPECIFICATION PROCEDURE @ DOCLHENT TITLE AND NLHBER: QCP-5A Rev.9, Para. 13.
2.1 DESCRIPTION
OF NONCONFORMANCE: (Including Cause) There are a nu=ber of Class I Raceway Support Welds that the Weld Rod Type, Size, i and WPS are unverifiable per QCP-5A, Para. 13.2.1. $J aN ,\\mM INITIA W BY /O1343 DATE t Q.0. SUPERJISOR REVIEW DATE H.P. FOLEY DISPOSITION: 1) Welds shall be visually accepted prior to final sign-off of support. a) Visual inspection confirms structural integrity of welds.
- 2) 6010 and 7018 are the only types issued to Electrician Welders.
3) Both 6010 and 7018 are acceptable for use on electrical supports. (Continued on next page) { OX Woo /O -/3-73 ] kCA fofn fu DISPOSITION BY DATE QUALITY REVIEW ' ilATE P.G.& E. -9!!?OSITION OR CONCURRENCE: e i e1 -1 \\t/ rs/03 P.G.6 E. Co 'DATE l DISPOSITION ACCOMELISHED 1 i II J $l i k " " " " " ERA 4W1R tresv s "*"p8 <e
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- HE HOWARD P. FCLEY COMPANY NO.
, de NONCONFORF.ANCE REPORT - CONTINL'ATION SHEET 8802-871 Rev.2 . j/ CONTI WATION OF: JESCR!? TION OF NONCONTORMANCE G PAGE 2 OF ' PROPOSED DISPOSITION ~ DISPOSITION ACCOMPLISHID O dan H.P. FOLEY DISPOSITION: (Continued)
- 4) Accept rod site "As Is" if visual inspection is acceptable.
a) Re=ove and replace weld if lack of fusion is noted.
- 5) Accept Hr.# "As Is" - Only acceptable filler caterial is issued to'the Rod Control Station.
- 6) Revise QCP-5A to require the Electrical Welder to enter Size, Heat No.', and Type of rod used on the applicable " Work Copy" documumentation.
Q.C. to verify it's entry.
- 7) Record this NCR Nu=ber on affected SIWS's or WIS's.
S) Accept missing WPS No. "As Is" based on Item #1), above. M 4
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- 11/ bcscos3cdA) 61* Tre.bUPS - s//ptu Tra' tuecDet &NTER.
THt3 ON 716% Wo/K COPY becc.jp EAri~.+T(ch ? a.. Sano G.c. xFer 7 pee parn To Tre IQwr8? 4 Stoe n. Q.c. Renova (en co& ypts gpuergrao "wo4x cery "poca-MENTSice A\\ To sopfsa.T gs F.ArtiEs (tF St<'b.) oa RwZ/2.* 'EreA1 'f) REF&lls 7b 3ZW$s puT~ 702 PccuMENT.S fp VadeD y A P c 8 IA) Z A s. Y TF : blo 37tctFcc "itcc2rr-45-ts "Srg7CM&wt(s (AlcLvDeo (A) L pc3Poswie A FcA WELP teob TYPE, AS /3 pcDE fdA 96p 3(2E(4) W-
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- ~ ENGINEERING DISPOSITION REQUEST fy]To
. f.'; .'M. Ro s s e 'LE ' ' - Subim Structural Welding Requirements V- ~ p - Probiern Per scecification #8802 welding is to be performed in accordance, srith building section reqtiirements of' the AWS Welding Code for '9tEucturil S te'e i. However anolicable'secti'oh of the AWS Code is not - referanced in other iob specifications. It is our understanding that all Structura-1 i'5fd 6g should conform with the additional recuirements of section 8 - Buildings : Is this corr'ect ? A A h Signed Date /0 7 u.> ~ ~. e o s_. Rep y vMim 06 SAW % M C oft A E B 70 % G-RE005RE M T V i ev rqE SECTt c N Q.6 L A Tim #e, _ Tb. (M.s s YUES E D. N E. ' M d nJA .a (_coE SF C Tso4*b. W E. C oce. RE QodEv A% Co Q, M30t,r $ co e. 53 cft' ~ AeeLY 00 L4.% %Pe.c.wta LLY R.re VGft E.cc E.th. A Signed Uesuts hmeut / zeew. - Date O 7890 / 'l C7cfw.. h-Y 9 l CREct' ruas ouT~ f wvc
s Origimi THE HOWARD P. FOLEY COMPANY NUMBER: 3 NONCONFORMANCE REPORT Page 1 of 2 8802-871 Rev.2 DESCRIPTION: ATTACHMENTS DATE: WPSf, Weld Rod Size and Type Unverifiable 10-13-83 7 i HOLD TAG # I REMOVED REF. HPF/IR NUMBER: N/A BY
- DATE, UNIT I x
UNIT II x / LOCATION Documentation Files CLASS I x NON-CLASS I O INSPECTION CRITERIA: DRAWING ] SPECIFICATION O raocznunt 8 DOCUMENT TITLE AND NUMBER: QCP-5A Rev.9 Para. 13.2.1 DESCRIPTION OF NONCONFORMANCE: (Including Cause) There are a number of Class I Raceway Support Welds that the Weld Rod Type. Size, and WPS are unverifiable ; er QCP-5A, Para. 13.2.1. i dt J _ OM sk m B1 ~ / O / 3 4.1 e INITIiuiuBY1*as;,W.,, DATE Q.C. SUPERfISOR REVIEW DATE Hu- .qM re-.. H.P. FOLEY DISPOSITION:
- WT5x: 's#
W' elds shall be visually accepted prior to final sign-off of support. 1)
- 0) Visual inspection confirars structural integrity of welds.
- 2) 6010 and 7018 are the only t/ pes issued to Electrician Welders.
- 3) Both 6010 and 7018 are acceptable for use on electrical supports.
l (Continued on next page) I-(. lL). W e s f e!H fu /O =/3~ Y A DISPOSITION BY DATE QUALITY REVIEW ' WATE P.C.& E. ^'S"^"TIGi; OR CONCURRDICE:. i E ~ e. ..g.g P.G.6 E. Co 'DATE ~ DISPOSITION ACCOMPLISHED
- c MC VERIFIED BY DATE Q.C. SUPERVISOR DAI l
o-Ofj
- 'n'"j m
THE HOWARD P. FOLEY COMPANY NO. NONCONTORMA!!CE REPORT CONTINUATION SHEET 8802-871 Rev.2 CONTINUATION OF: DESCRIPTION OF NONCONFORMANCE UU pA GE 2 OF 2 PROPOSED DISPOSITION O ~ DISPOSITION ACCOMPLISHED C DATE 10-13-83 _ _..H.P. FOLEY DISPOSITION: (Continued)
- 4) Accept rod size "As Ic" if visual inspection is acceptable.
a) Remove and replace weld if lack of fusion is noted.
- 5) Accept Ht.# "As Is" -'Only acceptable filler material is issued to the Rod Control Station.
- 6) Revise QCP-5A to require the Electrical Welder to enter Size. Heat No., and Type oF fod usid on7hE'4ppIRable'+vork Topy~~docdinumentation.
~Q.C. to veri ~y It's entry.
- 7) Record this NCR Number on affected SIWS's or WIS's.
- 8) Accept missing WPS No. "As Is" based on Item vi), above.
5P Q P,? g g, y e s a n s art: n v S v.,a.w : m'L l l l \\ I i ~= i l i
fj lgl THE HOWARD P. FOLEY COMPANY g NUMBER: NONCONFORMANCE REPORT Page 1 of 2 8802-871 Rev.2 DESCRIPTION: ATTACHMENTS DATE: j WPS#, Weld Rod Size and Type Unverifiable 10-13-83 7 MOLD TAG # t 4EMOVED I REF. HPF/IR NUMBER: N/A BY
- DATE, UNITII@/LOCATIONDocumentationFiles UNIT I x CLASS I x NON-CLASS I O I INSPECTION CRITERIA:
DRAWING SPECIFICATION PROCEDURE @ DOCUMENT TITLE AND NUMBER: QCP-5A Rev.9, Para. 13.
2.1 DESCRIPTION
OF NONCONFORMANCE: (Including Cause) There are a number of Class I Raceway Support Welds that the Weld Rod Type, Size, and WPS are unverifiable per QCP-5A, Para. 13.2.1. d-. - d c_ N W'f cM s k rvm M /0 /.3 h 3 INITIA%:2D BY DATE Q.C. SUPERJISOR REVIEW DATE H.P. FOLEY DISPOSITION:
- 1) Welds shall be visually accepted prior to final sign-off of support.
c) Visual inspection confires
- structural integrity of welds.
- 2) 6010 and 7018 are the only types issued to Electrician Welders.
- 3) Both 6010 and 7018 are acceptable for use on electrical supports.
(Continued on next page) ( W.Ter /O -/.3~ Y.S k /0 /3 ft) DISPOSITION BY DATE QUALITY REVIEW WATE P.G.& E. M S?OS' TIC 5 OR CONCURRENCE:. E e T -k(
- I m/ t 5/g3 P.G.6 E. Co
'DATE DISPOSITION ACCOMPLISHED I N6 h VERIFIED BY DATE Q.C. SUPERVISOR DATE .y- _. - _ _,, _ _ _. _ _ 7,__ ---,-y m,
THE HOWARD P. FOLEY COMPANY No. NONCONFORMANCE REPORT - CONTINUATION SHEET 8802-871 Rev.2 CONTINUATION OF:. DESCRIPTION OF NONCONFORMANCE Q PACE 2 OF 1 PROPOSED DISPOSITION O DISPOSITION ACCOMPLISHED C DATE 10-13-83 H.P. FOLEY DISPOSITION: (Continued)
- 4) Accept rod size "As Is" if visual inspection is acceptable.
a) Remove and replace weld if lack of fusion is noted.
- 5) Accept Ht.# "As Is" - Only acceptable filler material is issued to the Rod Control Station.
- 6) Revise QCP-5A to require the Electrical Welder to enter Size, Heat No., and Type of rod used oh the appitcable ~ work Copy" documu'mTnTdtibn.
Q.C-~ to7erify 'it 's-entry.
- 7) Record this NCR Number on affected SIWS's or WIS's.
- 8) Accept missing WPS No. "As Is" based on Item-#1), above.
s h e i "w a=
011pnd THE HOWARD P. FOLEY COMPANY NUMBER: NONCONFORMANCE REPORT Page 1 of 2 8802-871 Rev.2 DESCRIPTION: ATTACHMENTS DATE: WPS#, Weld Rod Size and Type Unverifiable 10-13-83 HOLD TAG # REMOVED REF. HPF/IR NUMBER: N/A BY DATE UNIT I @ UNIT II @ / LOCATION Documentation Files CLASS I @ NON-CLASS I INSPECTION CRITERIA: DRAWING ] SPECIFICATION PROCEDURE x DOCUMENT TITLE AND NUMBER: QCP-5A Rev.9, Para. 13.
2.1 DESCRIPTION
OF NONCONFORMANCE: (Including Cause) There are a number of Class I Raceway Support Welds that the Weld Rod Type. Size, and WPS are unverifiable per QCP-5A, Para. 13.2.1.
- d. -l QM i
e W' d i k rv% B1 e /0/3 53 INITIikiu BY DATE Q.C. GUPERTISOR REVIEW DATE H.P. FOLEY DISPOSITION:
- 1) Welds shall be visually accepted prior to final _ sign-off of support.
.' ) Visual inspection confirtrs structural integrity of welds.
- 2) 6010 and 7018 are the only types issued to Electrician Welders.
- 3) Both 6010 and 7018 are acceptable for use on electrical supports.
(Continued on next page) 0 LO. T e oc /O-/.5~75 k Ia f/3 ft) DISPOSITION BY DATE QUALITY REVIEW WATE P.G.& E. -MS?CSITIGN OR CONCURRENCE:, oc T k( l ital i3 / q 3 P.G.6 E. Co 'DATE DISPOSITION ACCOMPLISHED VERIFIED BY /47 DATE Q.C. SUPERVISOR DATE
Original THE HOWARD P. FOLEY COMPANY No. NONCONFORMA!;CE REPORT - CONTINUATION SHEET CONTINUATION OF: 8802-871 Rev.2i '\\ . DESCRIPTION OF NONCONFORMANCE UD PA GE 2 PROPOSED DISPOSITION O OF1l DISPOSITION ACCOMPLISHED C DATE 10-13-83 H.P. FOLEY DISPOSITION: (Continued)
- 4) Accept rod size "As Is" if visual inspection is acceptable, a) Remove and replace weld if lack of fusion is noted.
- 5) Accept Ht.# "As Is" - Only acceptable filler material is issued to the Rod Control Station.
- 6) Revise QCP-5A to require the Electrical Welder to enter Size, Heat No., and Type of roo used on th rdpp11dable "worY Co W ocumumentations-Q.C.~to~ verify it's"'
entry.
- 7) Record this NCR Number on affected SIWS's or WIS's,
- 8) Accept missing WPS No. "As Is" based on Item #1), above.
w D I e i i f N 1 = I
r e THE HOWARD P. FOLEY COMPAMY NUMBER: NONCONFORMANCE REPORT Page 1 o f _1 8802-861 DESCRIPTION: A TTACICd.ENTS DATE: WELDLRS AND WELD PROCEDURES QUALIFIED TO PRO:In AWS CODE YesONoa 6-13-83 HOLD TAG # N/A RD10VED REF. HPF/IR NUMBER: N/A BY DATE UNIT I Q UNIT II { / LOCATION CLASS I Q NON-CLASS I ] INSPECT 10*? CRITERIA: DRAWING ] SPECIFICATION g PROCEDURE @ Spec. 8802 6.1 DOCUMENT TITLE AND NUMBER: QCP-5A AWS Dl.1-82 Par. 1.
2.2 DESCRIPTION
OF NONCONTORMANCE: (Including Cause) Specification 8802, Paragraph 6.1 states, H.P.F. for Arc & Gas Welding in Building Construction, publ'..hed by AWS".is required to comply H.P.F. QCP-5A Revision 9 requires welder qualifications and production welding to be in compliance with AWS Dl.1-82. D1.1-82, Paragraph 1.2.2 specifies a minimum base metal thickness of 1/8" and states that AWS Dl.3 should apply to base metals less than 1/8" Contrary to this requirement, H.P.F. 's Welder and Procedure Qualification and Production Welding in the Electrical support work has been performed in accordance with AWS Dl.1 instead of Dl.3. 7 / l 8-/L/--85 i d-//-83 f INITIATED BY DATE Q.C. SUPERVISOR REVI DATE DISPOSITION: Revisa ()CP-5 and QCP-5A to call out D.1.1 - 75 for electrical welding spec 8802 per attached letter from PG&E , as (June 14, 1983). Previous work was accrznplished as per the attached procedures. Accept as is. Procedure qualifications was performed and is acceptable. b Y/W/2 GISP051 TION B1 DATE QUALITY REVIEW ' DA'IE t i P.G.& E. CO. g D/(TE DISPOSITION ACCONPLISHED v DL& 5 N C.UISE D R E ". N C E .S~ f QLP Gd T2Gt%dv Rif h,v " 8 W G s t e cas wc,2 t A c syTr* 4 /% IS 5 A' A*V' W ? ) c \\ [ .5 i /ERIFIEDBY DATE r. ' Q. C. ...SU.PERVISOE CATE s F03AF0FATi9N#2 Gose tI1el Nr 4
r G h- '~ %\\ ~ %-%8 D %h ] g Task: Allegation or Concern No. 98 [r F ^2 /'[ '\\ -r c ATS No.: RV-83-A-0085 BN No. Characterization A vendor in the nuclear industry (Brand Industrial Services Company, (BISCO) is improp3rly installing penetration seals. They may be involved at Diablo Canyon. Implied Significance to Plant Design, Construction, or Operations ~ Improperly in.talled penetration seals may fail during accident conditions, resulting in a failure to contain or limit liquid or gaseous effluents to a room or section in the Auxiliary Building. Assessment of Safety Significance This allegation was received in Region V on December 2, 1983 and subsequently investigated and resolved in SSER No. 21 (dated December, 1983). The staff concluded in SSER No. 21 that BISCO had never performed any work either as a contractor or as a subcontractor at Diablo Canyon. Subsequent to the writing of SSER No. 21, BISCO contracted with PGE to work on 179 safety-related l pressure seals at the Diablo Canyon site. BISCO completed their contracted work on February 1, 1984 and is no longer onsite. 1 l l4
I. To resolve the allegation that BISCO improperly installed penetration seals, the staff examined the BISCO Quality Assurance Manual (BQAM), the BISCO quality control procedures, records of employee qualification and certification, records of completed work, and examined a number oY the BISCO installed penetration seals. The staff's examination of the BISCO Quality Assurance Program indicated that the program complied with the requirements of 20 CFR 50, Appendix B and ANSI N45.2, and that quality control personnel were certified and qualified in accordance with the program requirements. Examination of ten BISCO installed penetration seals in the Unit 1 Auxiliary Building did not reveal any discrepancy from the licensee and/or the BISCO requirements. The staff's inquiry into the extent of the licensee's QA/QC surveillance of BISCO's in process work revealed that no formal audit or surveillance had been perfo rmed. The licensee's explanation was that BISCO's work scope was so limited, i.e. for a short period of time, that a formal audit was not scheduled. However, the licensee is in the process of performing a quality control inspection of 5% of BISCO's work to verify proper installation of the pressure seals. l t Staff Position l The staff concludes that this allegation does not represent a safety concern l at Diablo Canyon. This conclusion is based on the staff's review of the BISCO's quality assurance program, quality control procedures implemented I t i
I . 3 . during BISCO's work at Diablo Canyon, and the field examination of the BISCO installed penetration seals. ~ Action Required The licensee's audit recults of BISCO's work will be reviewed during the regularly scheduled NRC Inspection program. I e l 4 i \\ , - ~, - - - - - - - - - - - - -- --- --- ' - - - - - ~ ' ' " ' ~ - ~ ~ ~-
y w .i , IL Problem Statement h Allegation f(s):. N o. 96 ATS No.(s): REBbA4II 5 2 BN(s): N /A 1 This document lists (or directly references) each allegation or concern brought to the attention of NRC personnel. The purpose of this statement sheet is to assure that all points raised by the alleger are covered. If the problem statement is not clear as to who, what, where, when, or why regarding the issue, the commentary section will amplify the statement. The commentary section will also be used if there is apparent confli'cting information or if there is no or very little original information available which describes the concern (s). (This can occur if, for example, a line concern was received in an interview). Problem Statements (use extra sheets as necessary) Allegation # Verbatum Statement or Reference i A5+<3 ( Brd A.98 A. sj u a.< in t% nu4Aeu L elustna_1 s < v.c. a, Cm , Btsco) is mpropaq ind iW$ p w.er > % sd, I m bc. snvo\\ve A wsN CMo km. O Commentary wm .a. Date This Statement was Completed "b/s/BQ hM. gm '_ Tsahnife41 Reviewer Sign ue ISO/ .}}