ML20214C521

Intervenor Exhibit I-ROREM-240,consisting of 831003 Memo Forwarding Trend Analysis Rept,Per Util Request.Rept Consists of Review of Lk Comstock Insp Correction Repts from Spet 1982 - Aug 1983

ML20214C521
Person / Time
Site:	Braidwood
Issue date:	12/04/1986
From:	Seltmann R COMSTOCK ENGINEERING, INC.
To:	Rolan F, Sommerfield T COMSTOCK ENGINEERING, INC.
References
83-10-03-02, 83-10-3-2, OL-I-ROREM-240, NUDOCS 8705200754
Download: ML20214C521 (9)

Text

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U IQ' 13 A S :42 Comstock Engineering, Inc.

Memorandum To. T. R. Sommerfield /F. Rolan ogg;e, Braidwood From: R. Saltaann

Subject:

Trend Analysis Report -

Dat'e:

October 03, 19 CONTROL NO: 83-10-03-02 The following is a Trend Analysis Report, as you requested in CECO letter BRD #9370.

The report consists of an in-depth review of L.K. Coastocks Inspection Correction Reports (ICR's) that were generated between 9/1/82 and 8/31/83. ,

During this time frame,1,405 of these reports were written. Each report has been categorized in accordance with Attschaent "A" of this report, titled "Non-Conformance Codes." Below is a listing of Non-Conformance

, Code categories and the number of reports associated with each code number.

A sununary and corresponding recommended corrective action follows the listing.

INSPECTION CORRECTION REPORTS (09/01/82 - 08/31/83)

SECTION SUB-SECTION NO. OF DEFICIENCIES 100 CONDUIT 101 Separation 3 102 Supported 7 103 Bend Radius 16 104 Identification 75 Nucttu ntcutnan comulm0N 105 Crounding 65 g,, ,, g .-v'.50 d ffoal t n. Na 2 - 10 to eion

'"**'"'"'  % <c J i s c n) - 108 Damage 2 109 Coating Threads 112 .

9,,, totNrmio 110 Hiscellaneous RICllVED 0

intenene </ RtitCito Total 282 (20%)

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Pg. 2 Trend Analysia. Report October 3,1983 1

4-INSPECTION CORRECTION REPORTS j , (09/01/82 - 08/31/63)

SECTION SUB-SECTION NO. OF DEFICIENCIES 200 CABLE FAN 201 Elevation 0 202 Bolt Torquing 3 203 Rollout / Edge Protection 0

+

204 Cleanliness 9

205 Welding 16 l

206 Identification 3 207 0 rounding 0 .

i 208 Damage 1 *

! 209 Miscellaneous 7 i

TOTAL 39 (2.8%)

i 300 SUPPORTS / HANGERS

'301 Location 0 l 302 Material / Hardware 2 303 Dimensions 3 304 Welding 567 305 Bolt forquing 5 306 Identification 0 307 Damage 2

308 Miscellaneous 9 i TOTAL 588 (41.8%)

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• 400 ANCHORS I

401 Layout 0 402 Embeddaent 0 403 Edge Distance / Spacing 2 404 Angularity 0 405 Engagement 0 406 Mardware 0 i* 407 Testing 2 408 Power Actuated Fasteners 1

)

409 Damage 0  ;

410 Miscellaneous 6 l l

! TOTAL 11 (.8%)

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! 500 WELDING j

501 Walder Qualification 0 502 Weld Rod 2 i

, 503 Stud Welding. 0 l 2 (negligible)

TOTAL l I:RCoc1y3 4

Pg. 3 Trend Analysis ' Report October 03, 1983

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INSPECTION CORRECTION REPORTS (09/01/82 - 08/31/83)

SECTION SUB-SECTION NO. OF DEFICIENCIES 600 CABLE PULLING 601 Separation 0 602 Tension 3 603 Support / Dress / Slack 15 l,i, l 604 Band Radius 0 605 Identification 2

606 Overfill 30 607 Damage 0 608 Miscellaneous 5 TOIAL 55 (3.9%)

B 700 TERMINATIONS 701 Terminated per Wiring Diagram 15 702 Separation 122 703 Bend Radius 0 7 04 Dress / Support / Slack 1 i 705 Identification 2 706 Crimping 2 707 Hardware 0 l

i 708 Crounding 14 709 Damage 0 710 Miscellaneous 79 711 Documentation TOTAL 235 (16.7%)

j 800 EQUIPMENT / JUNCTION BOXES a

801 Identification 13 802 Alignment / Location 1 803 Torquing 0 804 Cleanliness 10 805 Crounding 4

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806 Welding 78 j 807 Damage 2 i

808 Dimension (size) 1 l 809 Miscellaneous 4 1

! TOTAL 110 (7.8%)

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808 Dimen31:n (01s0) 1 809 Miccc11aneouc 4 TOTAL 110 (7.8%)

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liROO0174 901 ~ Identification' ~ ~ ~

-0 902 Storage / Handling 0 903 Installation 3 904 Testing 0 905 Torquing 0 906 Cleanliness 0 907 Documentation 0 908 Damage 0 909 Miscellaneous 0 TOTAL 3 (negligible) 1000 RECEIVINC. HANDLING, STORACE 1001 Identification 0 1002 Shipped - Short 0 i

1003 Certifications /

Documentation 0 1004 Cleanliness 0 1003 Proper Storage 5 1006 Damage 2 1007 Maintenance 11 1008 Miscellaneous 0 TOTAL 18 (1.3%)

1 1100 CONTROLLED TOOLS / CALIBRATION I l

1101 Torque Wrench 27 1102 Crimper 5 1103 Dynamometer 0 1104 Rod ovens 23 1105 Thermometer 2 I 1106 Wire Stripper 2 1107 Hiscellaneous 3 TOTAL 62 (4 . 4 *')

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Pg. 5 Trend Analysis. Report October 03, 1983

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SUMMARY

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Overall the major cause of Inspection- Correction Reports (ICR's) for the

, past year was in the category of Supports / Hangers " Configurations",

non-conformance Section 300 of this report.

1

! In this category there was a total of 588 ICR's written against configurations -

, during the period of 9/1/82 thru 8/31/83, representing 41.8% of the total population. Of these, 567 were identified as Weldina Problems. Non-Confors-ance Code 304.

Further breakdown of these ICR's revealed three (3) main categories i

resulting in the 567 reports. The following information was obtained as a

result of the breakdown

I NON-CONFORMANCE CODE 304 'NO. OF DEFICIENCIES A) Inadequate welds 467 (82.7%) ,

B) Welds painted /inaccessable 56 (9.9%)

C) No welders stamp 42 (7.42)

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RECOMMENDED CORRECTIVE ACTION

i Due to the amount of Inspection Correction Reports being issued for welding problems, as a result of inspections on supports and hangers.

it is felt a better training program must be developed. A full time training coordinator would be extremely beneficial for both craft and j quality control personnel.

i Along with the addition of a training coordinator, to our staff, it is l also recommended that an increase in our Inspection Force would help I

eliminate non-conformances through the increase of "In-Process" l inspections, rather than final inspection. At the present time thers.

j, is approminately a 40 to 1 ratio of welders to inspectors.

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' Past history reveals that one inspector cannot perform In-Process, day to day, inspections on the activities of forty (40) eraf t welders.

History also tells us that when inspections are kept current with cons-

] tructions schedule, substantial declines in Non-Conformance writing is j evident.

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EP.C0017s

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Pg. 6 l Trend Analysis Report October 03, 1983

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i RECOMMENDED CORRECTIVE ACTION - Continued t

Properly staffed Inspection forces, performing In-Process inspections, also acts as an excellent training guide. Discrepancies can be directed to the individual responsible for the item, thus resulting in the correction of the noted deficiency. This daily exposure to Quality Control acceptance criteria sids in the development of better welds and welding techniques.

Together, the two actions stated above will assist L.K. Comstock in developin's a better welding program to aid in the reduction of non-conformance reporting. ,,

If there are any further questions concerning this report, please do not hesitate to contact the undersigned.

I*

. Sincerely, I '

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10. Seltmann Q. A. Engineer RS/dar

.i cca W. A. Cardner l I. F. DeWald R. Cosaro ,

- 1. Saklak QC file T. Vogt F. Rolan l

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1 MONCONIURMANCE CD b D

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100 CONDUIT t 300 SUPPORTS /HANCERS_ QJ 101 Separation 301 Location 4 102 Supported 302 ' Mat erial/ Hardware 103 Bend Radius 303 Dimensions 304 Identification 3 04 Welding .

<'105 Crounding 305 Bolt Torquing 106 Embeda 306 Identification 107 Locatfor. 307 Damsge 106 Don' age 308 Hisec11aneous Coating Threads 109 110 Miscellaneous 400 ANCHORS 401 Layout 200 CABLE PAN 402 Embeddoent 201 Elevation 403 Edge Distance / Spacing 202 Bolt Torquing 404 Angularity 203 -Rollout / Edge Protection 405 Engagement 2 04 Clean 11nees 406 Hardware 205 Welding 407 Testing i-

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206 Identification 408 Power Actuated Fasteners 207 Crounding 409 Damage 203 Damage $10 Miscellaneous

NonconfSrmanco Cedro - Cortinued

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ef 600 CABLE PULLINC 800 EQUIPMENT / JUNCTION BOXES _ O O

u i 601 Separation 801 Identification 602 Tension 802 Alignment / Location -

603 Support / Dress / Slack 803 Torquing 604 Bend Radina 804 Cleanliness "

605 Identification 805 Crounding 606 Overfill 806 Welding 607 Damage 807 Damage 608 Miscellaneous 808 Dimension (size) 809 Miscellaneous 700 TERMINATIONS 701 Terminated per Wiring Diagram 900

• PENETRATIONS 702 Separation 901 Identification ,

, , 703 Bend Radius 902 Storage / Handling i

! 704 Dress / Support / Slack 903 Installation j 705 Identification 904 Testing 706 Crimping 905 Torquing 707 Hardware 906 Clean 11 nema 708 Crounding 907 Documentation l 709 Damage 908 Damage 710 Miscellaneous 909 Miscellaneous 711 Documentation , _ _ , , _ __ , . _ _ _ ,

4-11-C3

! 0.inconfeirmint e Codes - Continued O CO M-O lutin,,,,_RIT.EIVINC. IIANDLINC, STORACE M

tg 1001 Id en tificat ion

- 1002 Shipped - Short 1003 CettifIcations/ Documentation 1004 Cleanliness .

lutt'i Proper Storage

. 1 0:16 Damage 1007 Ma intenance 1008 Miscellaneous 1100 CONTROLLED TOOLS / CALIBRATION

' 1101 Torque Wrench 1102 Crimper 1103 Dynamometer 1104 Rod Owens .

1105 Tl'iermometer 1106 Wire Stripper 1107 Miscellaneous h 4 .

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