ML19329E921

Nonconformance Rept for Jan 1976.Rept Consists of Bechtel Nonconformance Repts,Nonconformance Rept Log & Status Book, QA Discrepancy Repts,Quality Audit Findings & Mgt Corrective Action Repts Written or Closed During Month

ML19329E921
Person / Time
Site:	Midland
Issue date:	01/31/1976
From:	CONSUMERS ENERGY CO. (FORMERLY CONSUMERS POWER CO.)
To:
Shared Package
ML19329E918	List: ML19329E917 ML19329E921
References
NUDOCS 8006180777
Download: ML19329E921 (30)

Text

m -

NONCON FORMANCE. REPC 4 LOG & STATUS BOOK u

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nEPoHT D ATE

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PAGE CoMPL.

.. ENo. sten

1. PROJECT NO 7220 STATUS

~

NCR ORIG.

NONCON FORf.1AN CE PREPARED BY C

l NO.

DATE DESCRIPTION / REM /.RKS hc:; e 7 NTE N

c00 SED x

CLOSED BY 352 10-29 R. A. Moray R-2n$. cirnuit Brnnienrn, unmnpinton; anmngna, Ficid

^

_7

-75 Identificatinn 3 101 10-39-75 l

353 11-4 H. D. Foster

_C-111. Denp impnvenntinnn nntna nn n 111 11:

Field No 11-5 11-18 H.D. Foster

-75 during coating work 1.109 1 1-h-75

-75

-75 354 11-5 C. F. Clark 0-111. Dome liner plate broken. c-111-15 Field No 11-6 i

-75 1.109 1 1-5-75

-75 e

m 355 11-10 D. L. osborn C-230. Flyash below weight on one ticket, pour Fiold 12--8 1-23 1-26 L. R. Albert 9

-75 a(614)b 1.205 "- 0-75

-75

-76

-76 m

• ^

356 11-14 L.R. Albert C-230. Air content. Pours AIG9911' & A(487)b' T'l ald-12-8

-76

~

-75~

Q

'1.205 44--+h-7!G -75

~

357 11-17 R.A. Moray N P-1-193. M-92 Mntnrn hnntarn dinnnnnontna Pield No 12-8

-75 vy 4.001 ; 4175

-75 358 11-17 H. Boleen 4-117. vn1vn 'Paccing requiro n. nt" viole ted Field No 11-25

-75 ASME

/if/ /$

-75 1-23 1-26 L. R. Albert 359 11-2h E. Dutton

%230. Air content hi% Pour 81(fi14)n hld 12 -76

-7f

-75 1.205

-u-26-75

-75

-3 360 11-25 R. Bennett 1-231. Curin.- temnerature below 600 3 hrs.

Pi ol a 12-8 1-26 L. R. Albert

-76

-75 Pour #A(619)a 1.205 1

4 25 75

-75

-76

.m 1-27 361 11-26 D.C. Thompson 2-} 32. cnnanit npnning. Any B1dg Slnh Puni Pnni F* eld 12-12 1-30'f

-75

_ lab 3 006 22 2 -75 76 362 12-1 D.C. Thompson 3-h2. Conduit size reduced. Aux Blde slab.

-Eicid-12-5

-75 3 006 t2-2-75

-75 363 12-1 L.R. Albert c-230 Pailinc vntne unnv test.

Wlt 12-1-75 12-16 12_18-75.g. 2 7 puow; ei ns L

t<'

R. Albert

-75_

1.105,1.205 m

• 75

-75

.o.103 09/74 OC

11. #A QC C31 p

'. A b

F. -

N NONCON FORMANCE - REP OG & STATUS BOOK 12 N'

I*

• I<

dl REPORT DATE PAGE COMPL.

l

(

1. PROJECT NO.

7')20

~

STAWS NCR ORIG.

NONCONFORMANCE PREPARED BY l NO.

DATE DESCRIPTION / REMARKS 6' ROUTE X T CLOSED CLOSED BY 1 #

3 614 12 D.L. Osborn C-208. Concrete cylinder curiIg. Pour A(61 hlb FieM 12 76

~

4 75 1.205

+3-k45 75

-76 365 12 u. Shawl C-38.

Aux. Bldg. columns cut short.

FieM 12 1 1-19 A. L. Boulden 75 1.201 43-845 75 76

-76 l

1-23 1-26 L* R* Albert [

166 12 R. Bennett 0.2'41. Curing Temperature. A(j90)n' & 1.105. &

FieM 12,74

-76 3

l 75 cc'635)b' 1.205 12 " 70 75

.<:: 1 367 12 H. Boleen b10hA. Da2naged pipe spool u 3on receipt.

-FieM- -lw i s - ( G1 16

-76 75 A5iE 4 10h

- G.16-79 //s 368 1 E. Dutton C-2'11. Curine temperature. Poor A(626.25)n' m ld-- 1-9-76 76 1.205 T-t-46 =

369 l-13 L. R. Albert C-230. Fly A sh finene n n nnt-pa'- ^ RT M

- Rield 1-15

-76 C-618-72.

1.105,1.205 7 6

-76 370 1-19 E. Dutton C 230. Slumn hirrh. Pnur A(5 99)1' M54d=

-76 1.205 4:20:76

-76

^

~~

L-Li 371 1-20 T. Lieb C-231. Field evlinder curint temp e ratu re, jfffff6-

-76

-76 pour A(614)h 1.205 L72 1-27 G. E. Depew C-50A. Liner Plate slab numbers not match-Field

-76 ing.

1.109 l-28-76

,73 IQ9 T. R. Lieb C-208. Concrete cylinder curing. pour Field A(614)1 1.205 1-2-76 1-29 E. Dutton C-230.

L74 Concrete slump test frequencv. pour Field

-76 A (6 3 3. 2 5)a' 1.205 2-2-76 D-103 09/74 OC

,g

11. PAf* 3 GC-G31

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1. ^"'

NONCONFORMANCtf REPORPs L _._ _.. ___ /'

._ _ __. I or 1

3b.

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II.

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3

35. 06brosaraoM C%NCUN8 tele -

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,!p 7f ' ~- -

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3. 0 " ^ --

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s EG V.

F. P4 oJ JC r N *.J.

Spec. C-230 I 5 7220 Mc D = v

~ ~ ' da 6

~-

pour # A[ G )_

a

. irem DesC.r 1.oM

.. ircu oCar. "

b 7d - Sb[Indd

/O[3 Concrete A..un_J31dgmSlab_.Egur S-4 gtaCrucNr eaar H j acV.

g-i

...a ac Muu.cn sr anrue srsrc= No.

N/A N/A N/A I

-m

.. eunCNass onDen No.

... oC r a tp.Nse CrioN reaN No.

i. =c es.a Cr u s Nr se n saiNo.

]

/. 26 7[.,

__N /JL C-708--1=l? ?

N/A

.. CoNr n aCr o nia.oCarioH

.. ue O vr5

*ouacs 0 Lao rwhrolu;

__Chamnion ln.c.._ Midland._Mtchinon O nourc to marca. ractor_

. ' = =

g=our c ro,.ctD No.N er n.N.

usuran m on

... nou r.No NsrauCr oNs, 9 9. NONCoNFoRM8NG CoND$ r foNs Section 9.2.1 of Spec. C-230 Rev,. 5 requires that all concrete materials be menured in ac. card-shall be witlL p + 3 percent of i

ance with ASTM C-94-72 states in part that powdered.idmixtures weinhina accuracy I

the design weight.

Contrary to the above Batch Tickist No. 06594 representing concrete placed in Pour No. A(614 on 10/30/75 shows the f1vash content to be 3 lbs. be:.ow the minimum allowable weight of 310 lbs.

Nonconformance noted during QC review of Batch Tickets.

"Q" No. is 7 DOLUM 1.206.

One tag applied.

' ' - ;e.,

30.

O FIELD De PostreoM F4 ELD RECoMMENDArgoN/RourE ro PReBJECr ENGINEERING 2 9. F8ELo Dt.PostreoM #c EsuLrst

-Recommend acceptance on the basis that a reduction of 3 lbs. of flyash below the minimum should not significantly affect the required strength of the concrete.

For project engineerinn's evaluation the average of 5 sets of 28 day cylinder breaks was 4420 psi. the lowest avercne _of one set of two cylind er breaks was 4045 psi.

Re-quired fc' is 4000 psi, h jdan.osd

/2 cP-7[f)/

2 3. cNo.NacN.NG o.srosir.oM na suurs,

..N o.N e s N No D.5,o s.r.oM For pour A(614)b a C-1 mir.'containing 3 lb less than the required amount of flyash for a 4 c.y. batch will have an insignificant impact upon affected properties.

1 Based on the 28 day cylinder breaks as shown -above, Engineering concurs with NJhM/[M HU&a/Jn Unh

,i f :..Aj M ) [

l Field recommendation to "use'as is."

U 2.. R EJECTED mat EHI AL'd.sPo.IreoM Q.. w.=,eOwreba.

gy y' }g]g7 j

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gg g a4. es OEstGN CH ANGc HEQueNED o

o.a...

O ves. sac avv4CNro,

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SPEC.

REV-ADD.

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- Originator Cenery Copy

- Field Engineer j

Pink Copy

- POAE Goldenrod Copy - OC

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356

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NONCONFORMANCE REPOR n

__1 Spgc. 7220-C-230

!5 07220 m (bM

!'////y'n IJ ** # '-G -

-,-1

~JJ.

I Ol V.

T.PhOJECTNO.

3 2. N E POR T E D EV DATE 2s. D airusIT a ".N CO NCu,.H L re

"'"f; ""'~ lK

,""*" W L..r..

- /. 2 34):,

I DdTE y

{

A a.rD AT E D

2. gT EM DEsCRarf SON

.S. 0T E M LOC A TeO Concrete Pour No. A(

J A(587)b' Q )tj Mev cf, l///cy/g u./

N.

i ' E V.

~7h ^'

g,. n E rt.C Eu EN T,..

,. u.. u.

.. sE =.a c Nuu.E n

...raaTue sysTE u N O.

.til,unC,.asEO.oEnNO.

NLA N/A

[.

7d A

f. 2 2 -74

... O C r.E oD.N s,E C T.ON et. N NO.

....E rt.CE M E N T sE n,. u MG.

N/A C-231-3-665 Rev. O N/A

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[j 4 Es

.,.sOunCE

.. CON r a a C7OnicOCa T.ON ME G__, O subsontractor

.C.hamnimIncE _His11and 111chinan

E-t. ROUTING SNsTRUCTIONs; HOUT E TO FIELD ENGIN EE RING O aouTE To aATEa A' s u rE a v iso a 8 9. HONCONFO R M4NG CONOeTIO N :Spec. 7220-C-230 Rev. 5 Section 9.1.5 requires that amount of entrained air in the concrete shall be not less than three percent and not more thaa six percent of the total volume at the point of placement.

Contrary tc, the above Batch Ticket No's. 06651, 06655 and 06656 had a measured air content of 2.0%, 2.7% and 2.; [

.refinectlyely at_ the nd of the numpline in Aux. Bldg.__ Wall Placements A(599)J' and A(587)b' placed on 11/12/75.

"n" u n,- Mo. 1 ?ns.

Monconformance noted_during routLne_QC_ Testing _of_. concrete-Z hI' Y :

-8 r M u r n e

2 8. FlELE' 90sPO.BTeON RESULT 54 20.

O FIE LD DisPosBTION QFaELD RECOMMENDATsON/ ROUTE TO PR 3 AECT ENGSNEENtNG Field recommends acceptance on the basis that these r.re interior walls, below grade,

_and will_not be sublect to a freezing - thawing cycle.

Results of 7 day cylinder breaks were 4245, 4365, and 3390 psi.

Required 90 day strength is 5000 psi.

w&rg)

/z -J ~7)f

72. E NG.N E E..NG Dis,Os.v ON 2 3. E NG.,c_ ;.

.NG o.s,0s.T.ON n E so uT.,

Project Engineering concurs with the Field recommendation that low air content is i

acceptable for the subject pour because:

1) These are interior walls not subject to freeze-thaw cycles, and 1

2)

. Low air content will not' reduce strength._ Engineering concurs /}) 9,[

with Field recommendation to "use as is "Qf6,Q)-f), f u, ((// d,fg4M^.' f///e 24.15 DESIGN CH ANGE HFOutHED NO

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- Orig nator Es C G 8 2 Canary Copy

- Field Engineer Pink Copy

- POAE Goldenrod Copy - OC e

-a.

NONCONFORMANCE REPORT 1_ "' "'y ^

71 D r.'& WING /P ALT NO.

3 GM V.

T. PR OJECT N i),

t2 64 E PO LT IV CA

25. DISPOSITION ChNCURRCHC1

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I

!5 01220

__ O/wr$

f/74

[ *~" ',,'

N ""

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Spec.__1220-c-210 3 DATE Concrete Pour #A(619)a Aux. Bldg.

~ L gQ*-[ [(/ !//-2f6 _ M brbu

/.1.3 //d S. S TEM LOC AT8ON a.n4TEDSV

.. 3. eTEM DEsCR 8PTION

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D.Te

[

ed. SE RI AL NUMBER

9. ST ARTuP SYSTE M NO.

A #dPL ACE MEN T PAR T

' R E V.

• ..asesdeE o.mo ee

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m g g...i g pg l

1. f t,- 7(,

UlA I

.N/A d/A f.- 6 -7/.

2

_,'.. R E Pi. A C E M E N T sE R. A L N O.

e. PuRCN AsE ORoER NO.

... O C r.E Lo.N s,E C T.O N,L A N O.

~ "" '

• a '- a -* *- # -

N/A

~'=

N/A C-231-3-652.

Rev. O n.

oRCE

...AsM; a os mCONTRAmOR,OCAT.oM ITEM UI NO Subcontra.ctor

.Chaminion_Inc.. MidlanL_llithiann 0 8. ROUT SNG SNsT RUCT BONO f.OUTE TO F8 ELD ENGINEERING

] RO* ATE TO M AT ental suPERwasOR Snec. C-230 B_ev. 5 Ssction 9.1.5 states in_part. "That the amount of entrained air in the 8 9. NONCONFORMING CONOGTIOMs concrete shall not be less than three percent and not mare than six percent of the total volume at point of place-5 ment".

Contrary to the above Batch Ticket No. 06686 ha-1 a measured air content of 6.2% at the end of the pump-line in Aux. Bldg. Slab Pour A(619)a on 11/20/75.

Six compressive strength cylinder's made (Set #673), ("Q" No.

is 1.205.

Nonconformance noted during routing QC Testiag of concrete.

' Pun t n cm n nnl i ed.

an. r ELo oisPOs TION aEsuLTsi O Pii'a onskosiviON GriE'o aECOMMENoaTiON/Rouv E TO rescas CT ENoiHEER No so-Field recommends acceptance on the basis that an increase of 0.2% over the upper limit will not significantly affect the strength and di.rability of the concrete.

_The_Iesults_of_two 7 day cylinder breaks were 3850 and 3880 psi.

This is an average of 77% of the required 90 day strength of 5000 psi.

We

/L-8 70F

=>.ENo.

EER.No

..,0s T,0N REsuLTs, a n. E gN E E a.M. o.sros.T.O N Iliph air content tends to reduce strength while increasing durability of the concret(

28 day cylinder breaks rec.eived on 1-7-76 give an average strength of 5605 psi.

i

. Engineering concurs with Field recommendation to "use as is" because the subject con; crete with an air conter c of 6.2% meets: speci$1catidn strength requirements.

c.' /. WDI-s. 1G l1[. Ab g.gs-w $ N & J)-ls, W $ /O- ]l a, N, : J E7)"5 k-a/

/,/zc,,/74

36. R EJECTro M ATE RI AL DisPostT40N O as waa's*=**6*a=

as as oEssoN CHff6GE REQuaHED

• A"*

a.....

o u s.5 -.TTAC.Eo, OR AwsNG REV DCN SPEC E V.

ADO.

GC4 3-2 White Copy

- Originator seess a Canary Copy

- Field Engineer Pink Copy

- PoAE Goldenrod Copy - OC

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G NONCONFORMANCE REPOT

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2. ha.~. W4NG/P ART H A e ' M V.

7. PAoJE r.T No.

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'PCMTCo av

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25. os5PosaisoM CoNCU fA E

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3. Ne-

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n7770 i

S 7770-C-7 31 M oEscaerTioN

e. sT EM ooc ATtoM s.

j oATE y

(,(4 Y/267f Concrete Slab Pour # A(619)a l'

N/A N/A N/A l R E V.* * ** 8 C ' F 'M* * *

• =6*=

- A"d I /~/I[~ M, s.

. e,a

4. 5E NI A L HUMBE R

9. ST ART UP SYST EM No.

$PL ACEMEr4T PAR o.

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n. euncN AsE onoE n No.

s e. oc r.Eto.NsPEcTioN co AN No.

'"... = E et A c c M E N T s E N. A t No.

/ ~2.2. - 7d N/A C-231-4-653 N/A

.. co N T n A cTo nfooc A f ion si.AsME O vr5

'r5ovact

.....,w,,, m,..

@ No Can.strurJ.ipn 11 / 3

""M t o. Rout ONG ONSTRUCTioNSs 440UT E To F#E Lo ENGiNEEMtNG Q route To M ATENG AL SUPENvison Spec. 7220-C-2 31-Rev. 8 Sectior. 13.2.4 states in part that, during the curin_g period, the 9 9. NONCONFORMING CoNolTeoNs concrete members shall be adequately protected to maintain concrete temperature of no less than ~50 degrees.

Contrary to the above. concrete surface temperature fell below 50 decrees for approx. 3 hours3.472222e-5 days <br />8.333333e-4 hours <br />4.960317e-6 weeks <br />1.1415e-6 months <br /> for placemcht i

c - c.2 -,--

<mgo a rz

- o_dru.e e De ove's W

~4 5 ko'2-A(619)a.

"O" List No. is 1.205.

o

.h')

~hoS /ff'o)U M 0bN

_ norz r }% i on 6n Y/s-s f f.A L2 /[l2 A

y /*L$.)G ai. riEto oiscos. Tion aEsutTs>

ae.

O ric'o o'5eas:aa E]ric'o acco==sNoavioa/aouTE To e.o,ECT ENG.NEEa.No Accept as is based _on the following:

a)

Concrete did noe freeze b)

Cure was extended one full day such that coacrete was fully protected and cured for a minimum of 7 days _at a temparature not less than 50 F.

_f_

EtnO2 ob MrW &

l2-8'" 7ISP

= >. E NG N E E niNo o.s,o. Tion EsuuT s 2,. EyNE EN No of.Pos.v.oM The lower concrete curing temperature will tend to r.2 duce shrinkage, setting rate, and i. rater demand, while increasing durability and reluired curing time.

Engineering concurs with the Field recommendation to "use as is" be ause 1) The minimum concrete c

surface temperature was 35'F and freezing did not oc:ur. 2) The ctpre for the subject j

concrete was extended one full day. 4 I4 h M.8 e M c.

N d U,nyl/7 l /r 7L

/ _t/u rc

14. OS oESIGN CH ANGE H EauiHEo Je ATd ISP S a r e'o N O = ". w.a a * * * * ** ue a

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ar oc acc T

E o

o...

o VES.5EE ATT ACHEos f

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oR AWGNG REV.

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SPEC.

REV.

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seese-a Whiie Copy

- Originator Q c-G 3-2 Canary Copy

- P solo Engineer Pink Copy

- PQAE Goldenrod Copy - OC

V NONCONFORMANCE REPOR[

#jy" 9G/PA AT P.O.

L.._.

---

t

[32

.DdM W///W ----",--g~

2b. DI$PO5f T IO N CO hCU*4 N E N w s LG V.

7. WOJE C1 N G, t

' OJs T E

2. lsG A s E8' H

_s.p e c.,..R..T..N7220-C-208 i 5 7220

_i %

9_T.

C.. A T....,,,p

.T. -. C. T.O

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Slab Pour S-4; Pour #A(614)1$

,g l/, Y2) y[},[/

f_

/,. 7 Concrete Cylinders 7.E.

CE.ENT,g O.

R E..

s.

N U -. E.,

...T A R T U

.T.T E. NO.

/

• b d *7

.. PUNC H A SE OR DE R NO.

le. QC FIELD ONSPECT BON PL AN NO.

8 6. R E PL A C E M E N T SE R t A R. NO.

J

• - ~ = -

N/A C-231-3-659 Rev.

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N/A C)'iEs irsOuaCE

.. CO TR ACTOR / OC AT.ON

-E

.T E - G,0 Subcont ractor

,ygited States _ Testing Co.,__ Midland,_Mich.

14. RO UTING GN S T FluCTIONS.

Q ROUTE TO FaELD ENGSNEERING Q ROUTE TO M A T E NS A4. SUPE R V450R I.. MONCONFORMING CONOSTsON:

Specification 7220-C-208 Rev. 5 Paragraph 7.3.2 states in part that, " Concrete cylinders shall be maintained at a temperature of 60 degrees F to 80 degrees F prior to stripping".

Contrary to the above,,

the concr_.ete cylinders made representing the concrete placed in Pour No. A(614)b on October 30, 1975 were init

'ly

~

cured between 46 degrees F and 64 degrees F.

"Q" No. is 1.205.

Nonconformance noted during QC review of report of concrete cylinders.

do $p df(cicg IS.

O FIE LO OSSPO54 TION QFIELO RECOMMENDATION / ROUTE TO PR DJECT ENG6MELHING 3 8. FsELO DISPOSIT60N RESULT S Recommend _ acceptance on the basis that the strength c f the cylinders was not

_ impaired by the louer temperatures as indicated by te st results of 5 sets of 28 day cylinder _breaksi The_ overage of two individual sets ranged from 4045 psi to 5165 psi _with overall average of 4420 psi.

Required fc' is 4000 psi.

U l1rl'n

~bM n/

/2 -R-7[yf 2 2. sp<n N E E R.NG o..PO s.T O N

,3. E NG.,. E E R,NG o,,,0 s,T,0,. R E U LT.,

C'ylinder strengths given above show that the subject i:oncrete exceeds specification strength requirements.

Engineering concurs with Field recommendation to "use as is.'

D Ws. W 2 1-m:e l} _ f Ra/A i-n.u E!/ %w~~ 40M

24. BS DESIGN CH ANGE R EQUlHED g

26. R EJECTED M AT E R S AL be5PostTsON O =naava w**ta==

a r. oc A CC E PT A N c,s b

O vEs. sEE ATT ACN.D.

1. ... M...... & " -

d

.5.

6 DR AW9NG R E V.

DCN awvneaease sesesstem eats e

SPE C.

R E..

ADO.

eGda a' White Copy

- Origenatos CaneerCopy

- F sold E ngineer Pink Copy

- PQAE Goldenrod Copy - OC

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NONCONFORMANCE REPORT 9

365

2. !L,, A WI N G /P A R T NO.

s N E V.

Y, PHOJECT hO,

_C-238

!6 7220~

12. N E PO R T E D W W ~

b'DaTE 3.. tSPO54T40N CONCUR RENCE

[ 26

" "*'~

" 'j "[

y"~

,?ddN?b: {_.'b, ' / h - 7L 3.:T/u DEscRsPTiON Steel Columns

a. eTEu LOcaTeoM

.v so4TEo av i caTE

_D4.1,_DB.3._EK1.31 & EKI.11__ Auxiliary Buildine

.X4

!/A-@ F P.OJE C T g ang em e~ ?

c.fER84LNUMBER

9. $T AR TUP 5VSTEM NO.

'REV.

. H EPLACLM ENT P ART I

ests/

.s&c-6 s am I7- %s-T'.)p

~

n/A N/A I

s. Pu =CN a sE O roe R NO.

[ g. M..[g'd.-

f'/-7/o a

s o. Oc riELD iN sPEcT.ON PLAN NO.

... R E PLac E M E NT s E R.L NO.

C-38 d -Jciv-J- /

N/A

" " ' '"* * " "* ** ' 17

.. c3 NTR acTORiLOcaT ON

...asut O vEs ir souact N/A

.'T E u'_M NO Construction i

g a. ItOUTING 6N57N UCTIONSs Q ROUTE TO FIELD ENG4NEERING O ROUTE TO uaTERiaL supervisor

90. NONCONFORMING CONDtTION:

DCN 6 to drawing C-238, Rev. 6 shows a splice at the above columns atelevation 617'-0".

Columns D4.7 and D8.3 were cut at elevation 601'-0".

Columns EK5.31 and EK7.79 were cut at elevation 616'-0".

O Number 1.201.

h tags applied.

2L C FIE LD DISPOSITION QFsELO RECOMMENDATION /POUTC TO PROJECT ENGlNEERING

11. FIE LD DISPOSITION RESULTS:

(1)

Field Recommendation for columns EK5.31 and EK7.79 is "use as is" Splice will not interfere with any beam to column connections.

(2)

Field recommends that columns D4.7 and D8.3 be repaired as follows.

Re-cut and splice column D4.7 at elevation

..-......m.,

.....'c u.t s__a t _ e l e v a t i o n 601'-0 with full penetration welds 616-0.

Repair

23. E NG IN EERING DISPOSITBON R ESULT$i

- as noted below.

22. Engineering Disposition (1) Engineering concurs to,,use as Monk (% gh'/f A 3 b &,w,sa,g '

in" the column D M as!f/04 e s b loc # #j c2cl splice at elevation 616'-0 for columns EK 5.3.1 and EK 7.79.

(2) Field Recom-fg%2h Io //c McTOLv, /hld mendation to repair the columns D4.7 and D8.3, as outlined above, is acceptable,.

~

Jg hj D.C.N. to drawing C-238 will be issued incorporating above change.

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NONCONFORMANCE REPORT ^

" ' " ' ' ' ~

e

_ _ _ _'oATE

25. otsvossiaoN CoHCunetE hr 2--

N l

F'

2. o ri A W Ally No.

e DI V.

7. PROJECT No.

12 st c Poet rE o f'?

Spec. 7220-C-2 31

!8 07220 h% b2b I&// '/S

'* "j """' - g' "'

s. si cu ocscnerraoM

• Aux.'oBidgv Pour No's.

19A rco =v

/

'onre

. d~-m'

/'?-3-N i

Concrete Curing

. _ A(510)_a' & CC(635_)b '

/f, eretacEMcNr PARr N M/2-Il-7f

.N 8A8'

' '" g o ease 9/ /

1 4

4. sc esac Nuuss a

s. stanTue sysTru no b.I

' R E V.

N/A N/A N/A V

I la'rt PE t-4[- 7(.,

86 I

e s

JacNasa onorn No.

so.oc resto iNsractioN roan No.

j.s e, acroaceutNr sensat No.

/. [b *l[ ~

N/A C-231-4-693 & C-231-4-650

[

N/A

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e. con rR ACTOR / loc AT8oM i3.A5Mc Q vg &

. 7. sou R CE J.../ A irru

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Construction g ours vo r.rto cNo.Nec. No o Nours to.rcan L surcav.w.

.ou1.No.Nsv aucrioNs.

19. NoNCoNroRMING CoNo8 TION: Spec. 7220-C-231 Rev. 8 Paragraph 13.2.4 states in part, "That concrete members shall be adequately protected to maintain concrete surface temperature of no less than 50 degrees F".

Contrary to the above Wall Pour #27 in the Aux. Bldg. had a surface..tenperature of 46 degrees for 5 hours5.787037e-5 days <br />0.00139 hours <br />8.267196e-6 weeks <br />1.9025e-6 months <br />.

Pour No. CC(635)b' ir, j

the Unit #2 tendon gallery access shaf t had a concret'e. surface temperature averaging 47 degrees for two days.

Nonconformance noted during QC Surveillance.

"Q" List No's. ~l.'205 and 1.105.

Two tas;s applies.

J0.

O ris'o oiscosarioN Greuo siccouurNoarsoNiaours 1o caosscr =No Neca No; ai. risto oiseosir oN atsuoisi

_.AccepI_asd s _EaclLph nement._wae niven an additional

..y.v

,s.ytwo days. cure to assure a

_that_thc_ cnncretg_nuld not be adversely af fected by :he small temperature drop.

%dAhA /2 -/4-75w?

v

22. ENGeNE cRING oISPostrioN 2 3. ENGIN EE RING ogsPossTaoM MesuLTss

.The lower concrete curin_g. temperature will tend to redt ce shrinkage, setting rate, and water demand, while increasing darability and required curing time.

Engineering

)

concurs with the Field recommendation to "use as is" because 1) The minimum concrete surface temperature was 46*F and freezing did not occur. 2) The deviatic.n in curing temperature will have an insignificant affect upon regt. ired curing time, and goo 2.as ossacN cNaNor acouincu Ze. ncaccyco m AT en sas. ossrusirioN D a 'wa a * *.="*.. a 2 7. oc c ser4Nc,

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LQC NONCONFOftMANCE REPORT 3

i

2. D M T.W IE T re d.

8 NE V.

7. PR M C T NO.

12. R E PON T3D F

!' ?! ATE

_ Spec 7120-0-231

!8 07220 E'd.t dn u b.

25. 08,Po set 80N CoreCu1Hf.NCd I ~~14

~ ~ ' "

" " ' ~

~ ' ' '

3. B T EM D ELCHIPf EON

4. 8T EM LOC ATION 0 3. V A L.ID TEDav I DATE

_CongygtpJ. gip;r Pour No. A(626.25)a'

/ThI C #fM !/-7 I

6. SE R 6A L NUMDEN D. ST AR TUP SYSTE M NO, t 5. R E PL ACEM ENT P A RT NO.

R E W.

• • • 88 " F *st e s mesme s e ee M

_H/_A _

-H/A i

5. PuRCH ASE OMDE R fdC.

e...

8 0. G C F8 ELD INSPECTSON PLAN NO.

- l 8 6. REPLACEMENT SER4 AL, NO.

N/A C-231-h-732 l N/A G. CONTR ACTDet/ LOC A TION 39.ASME C VE&

9 7. SOURCE J/A-

'T E = be.__LConstumtion O S. HuuT8NG INSTNuC TIONSs HOuTE TO FtELD CNGsNECRfMG O aourt To =^TEasa'suPEav'soa 8 9. MONCONFOH MSNG CONOGTION:

Spqpifica_ tion 721Q-C-231 Rev. 8 Fayagraph 13.2.h states in part, "The concrete members shall

_ be adequately protected to maintain concrete surface temperature of no less than 50 degrees F.

Contrary to the above, for 12 hours1.388889e-4 days <br />0.00333 hours <br />1.984127e-5 weeks <br />4.566e-6 months <br /> on the hth day of cure and for 6 hours6.944444e-5 days <br />0.00167 hours <br />9.920635e-6 weeks <br />2.283e-6 months <br /> on i;he 5th day of cure, Vall Pour FP-h, A(626.25)a', )

in the Aux. BlUn had a surface temperature of h8 do3rees F.

Nonconformance noted during QC 'Surveillence.

"Q" No. is 1.205.

1 Tag Applied 20 O P'C'u o'5Posa r'oH EPiELo NECO==ENo ATsONiaOuTE TO Pace rCT ENo NEER.NG Zi. P ELo aisPOsiTiON aEsuLTs.

_Ecraommc1Ld " accept as is".

A surface temperature of 48 F on the 4th day of cure 0

will. not adversely affect the design strength of the ccncreta.

The cure will be

~

e>: tended for tim additional days so that the concrete vill have been water cured for i miniraum of seven, days at a min. of 50 F.

Y?nes^dbm

.m /.

/- ?- 76 22.Et eINEC H tf EG D85PQ 5eT60N

21. ENGIN E EHING DISPO$sT sO N MELuLTE:

23. is oEs GN CH AracE satouina u ONO a-~~~~~~

22. u u u n o u O vEs. sLE ATTACNEo.

O.e D et a we h n R E V.

DCN avveee. ease sat a. Tee fJ E C REV.

ADD.

meva

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White [opy Originator E

Canary Copy

- Field Enginaar Pink Copy

- PGAE Goldenrod Copy - QC

_. _ _ - - = = - - - - - - - -

l __

.P=Gn.

.s.MCu

.s NONCONFORMANCE REPORT j

0, J 36, 9 NO.

44XWT ~~-j]M/3,/A.

oATE et oss Os. ION Ca e. Cue.u NCE

. x E V.

r. P,.0,E C T N O.

2. em...N G

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SRAc, 7? 20-C-230 l5 7220

, BATE 1

3. sT E M DESCN erf EON S. BTEM LOC ATaON A TED BY l/-/ 3-7b C

Fly Ash Batch Plant g.pg R E V.

fEPLACEMENT PART NO C, L E RI A L NUM S E R

9. ET Alt T UP S v5T E M NO.

N/A N/A L

N/A I

C. PURCH A 5C ONDE R NO.

3 0. QC F 4E LD ENSPECTION PL AN NO.

{ 8 6. M E PL ACEMEN T SER s AL NO.

N/A N/A l

N/A

...A.ME o vE.

j.T.sOuaCE

o. CONT a ACiOan OC AT.ON g

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Subcontractor Champion Inc., Midland, Michigan

.T E 3 4. No u T ING GN57 N uC T sO N 5.

ROUTE TO F4 ELD ENGSNEERING

() ROUT E T O M AT ERI AL SUPENVISOR Section_LA.1 of Specifination 'L?lis-C-210, Rev. 5 states that__pozzolans shall conform to lb. NG NCONFORM8NG CONOsTIOMs ASTM C-618-72 in table 2 requires that the fineness value be not less than 6500 CM'/CM.

C 618-72.

MT-M 2

3 r*nntrary_tn the above, fi n enesa nr ny nah anmpind on_12/16/76 was reported n a 6662, 9%1, and 5783 CM /CM.

._Nonconformance_no et d during routine _.nacra_ testing _of "naterials. O list numbers 1.105 and 1. 205.

WoAw GuAmwr ec--

2 9. FIELD Os5 POSIT 80N HESULT5J 2J Q FaELQ ptSPoleTION QFIELD HECOMMENO ATBON/ ROUTE TO PROJECT ENGINCEN8NG

/s f \\ jn 1 f

W l~d-Z At 2 3. E NGINEEH aNG DasPOSIT TON HESULT&s

22. ENGSNEE R ONG DeSPOSIT40N

~)

. R EJECTED M AT E76 A L D8SPOSIT SON O =*waa = w'*6**a 2 7. QC ACCEPT ANCd 2 3. es DESIGN CH ANGC NEQueH ED O NO a.e...

O v Es..EE avr ACNED.

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'NONCONFORMANCE REPORT juAvC

a..

cweh r No, iHEV.

v. Pa mec r No.

a c Po M T E u a oisP ssinN Co Sp c. C-230 l5 7220 sh M it-A.%

j

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s. arEm oEsCRsPrioN

s. artu loc AvaoM 6Argo av 8 OAT Concrete Aux. Bldn. Wall [h9W M[/g

[ !/-l L. SE N 6 A L N UMeE R

9. ST AM rup S Y5 t EM NO.

EPLACEMENT P AR R E V.

• • ese ct seese a ns, ass ee eave

_HLA N/A N/A U

i W. PURCH A SE OR DC R NO.

IS. OC P RELD GNSPECTION PLAN NO.

3 6. REPLACEMENT SER t AL NO.

_u/A

('- M1-2=6B?

Rev._0_ _ _. I N/A

c. CoNr N ACr oniLoC A reoM ss.AsuC O vEs lsr.sounCE D No

,[_

Subcon tractor

__ Champion Inc., Midland, Michigan iv e M s e, ROUr0NG ON$rRUCr00NO

{ ROUI E TO F. ELD ENG4 NEE RgNG

] NOurE TO M AT ERS AL. 5UPC H Vg50R

5) NONCONPORMSNG CONDertOMs Spec. 7220-C-2 30 Rev. 5 Table 9.1 states in part that the rejection limit for slump of IF-1

_ cone s e mix is 5".

Contrary to the above, a slump of 5'c" was measured at the end of the pumpline on D-1 con-crete mix represen~ted by Ticket flo. 07209 placed in the Aux. Bldg. - Wall No. 29 Pour No. A(599)L' on January 16, 1976.

Nonconformance noted during routine testing of concrete.

"Q" Lis t No.' 1.205. ONE Hold Tag applied.

Ticket No. 07209 represents 8 cubic yards.

a ).

O P'E'o ui5Posar'oN QP E'o aECouuENo AiioNi>= oui s to PMoeE:r ENGiNCER.NG a. r.ELo oisPos.r.oM REsuLrs

_11so n n _.is : Cylinder set #732F cast on 1/16/76, from ti:ket #07209 Averaged 3180 psi 0 7 days, or 63.6% of fc'.

Based on current stren,th data cylinder set

1. 732F will exceed 5800 psi 0 90 days.

M. F mtL 7-%

M L __, t. u. 4

_Eield recommends "use as is."

7 a t. ENGINE E MtNG DISPO5ev EON 13, E NG 4N EERING OtSPO51rsON N E $ ULT $s a. es oEssGN CN ANGC REouiNE ONo U"'."..'"~~~

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37 W. '4 R A WB; TNg e sM V.

7. PH OJIC T NO.

HEPURTED&V

-h' O A TE8/%

2 5. D 45Po t e T ION CO NC U X M !NC' Spec, Tl20-C-208

!5 7220

%D

3. 87EM OE SCRIPT ION

0. 0T EM LOC ATION 8 3. V T

S$ V E DATE

- ConCrct 1.indar<-

A i nv. Rld. Slnh 4 Pntir A(6. l)h 4

/~20 i

3 C. b s N t A L N U M 9.5TARTUP57 TE M NO.

3 5. H C A EMENT PART N paces sy Peass emesme se e.te N/A ng

/A l NEV.

2' C. Fu rtCD9 A SE O RDE R MO 9 o. OC PSE D.D 4N$PECT10 N PL A N NO.

3 5. REPLAC EM ENT SE RI AL NO.

_nLA C-2 31-4-736 Rev. O _ __I N/A

c. CON TR ACTORiLOC Af SON s i. AsuE O vas lii.souaCE ~

M_N.O _ I Subconnster

_.1!nited S ta tes_.Tes t.ing_fo e_Midlan d e_Hf.ch -

'na 6 4. Rou f f reg INSTNUCT60N$;

HOUTE TO FIELD kNG4NEERING Q NOU TE TO M A T E NI AL SUPCH V 850R t ). HONCON F O R M 8NG CO NDs T TON.Specification 7220-C-208 Rev. 5 pa ragraph 7.3.2 states in part that, " Concrete cylinders shall be maintained at a temperature of 60 degrees F to 80 d g,rees F prior to stripping".

Contrary to the above, the field concrete cylinder sets (708F, 711F, 714F, 719F, 721F, 724F and 726F) made representing above location on January 9,1976 were initially cured between 60 degree s F and 82 degrees F.

"Q" List No. 1.205.

Noncon formance noted during QC review of report of concrete cylinders.

No Hold Tags applied.

2 ).

O PIELO DISPosaTSON FIC LD RECOMMEND ATION/HOUTE TO PitOJE C T ENG4NEER 8NG 2 9. PtE LD DeSPOSITeoas R E5uLTS4 Eic1d._reconmencla_usc as is.

Durinn the initial curinn acriod of the first 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br />, a deviation of 2 F for a maximum of 24 hours2.777778e-4 days <br />0.00667 hours <br />3.968254e-5 weeks <br />9.132e-6 months <br /> is an insiinificant period to effect the long range strength development of the field cylindar cast 1/9/76 from place-wn t_A(614)1L The_averane 7 day _atrengths of tite field cylinders is 3790 psi -

lowest set averaned 3525 psi and the hinhest averaged 4300 psi.

klS-+ll3-217L

• N 4

• L.

• I LP 2 3. ENG tNEE R ONG D45POSeT SON RESU675:

8 3. E N GIN E E H 8NG O B5PO5 ei SON a

2f4 IS DESIGN CH AP4GC HEOutN E O O NO

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t u.s e s whate Copy

- O#ig.nator QCGaa Cenary Copy

- Field Engineer Penk Copy

- PO AE GoWenrod Copy - OC

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=

1' NONCONFORMANCE REPORT

' ' "{

f " '

Or 1<2

c. DR A wsNG,P A R T NO.

i R E V.

T. PROJE CWis.

~

I i

ErORTEDmy DATE zS. DiSPoseT eoM CONCURRENCE FSP-C-2 3',

!0 722')

v e Il?>/-u-- ! 951/4

" ' " ' " j '"" " "

3 S TE M DESC RtPT90N

4. ST EM LOC ATION

• 3. V A LID A T E D S v #

'DATE

' I,ia. r Plate Assanly Ji: B1th. Area (For Cont.

l) Nf M Lt l

l 0 37 A C. S E R I A L N UM BE R

9. ST A N TUP SY ST E M NO.

S. R E PL A CE M E N T PA R Y NO.

REV.

• • .s. c v e s. 6e s ee.e.e s.

-.c..L-li-1

_n/A S. PURCH ASE ORDER NO.

"/A I

g o. OC FIE LD GNSPEC TfON PL an N NO.

4. RE PL A CE ME N T SE R3 AL NO.

7 721-C-5dA C-111-63

':/A

• =

4 CONT R ACTOR / LOC ATION

},8gg,3{g.St.ASME Q VES T. SOURCE Southeirn hoiler & Tan!: 'lorha, In c. -To m.

O NO Vendor

.T E M NOUTING GNSTRUCT80NSt Q ROUTE TO F8 ELD ENGeNEhRING Q al'uTc 'o M a'<a'a' supe avisoa

~

9 9. NONCO N F O R MING CONDIT ION:

A t'istrenaacv exin ts bettmen _ntil sini _nunhsr_<Lo_cuncutntion und the venc! ora trans ferred st.tn r

si ab nurber.

i.bcuncatation sicat Number is 51GAa703 uith S Lab :iu::ibc c A79070.

The nlate is vendor transferred staaped.21GA0733 vith laat. di;;it in clab nua'ior in question A79377.

Discrepancy detected durian OC field int,pection review.

One !!ald Tag attached.

Item "0" No. 1.109.

19 Q F 0 ELD DISPOSOT 60H QF6 ELD RECOMMENDATION / ROUTE TO PROJECT EP G4NEERING

15. FIELD DISPOSlTlON RESULTS:

22. EPeGtHE E RING DISPOSIT BON

23. ENG tNEERtNG DeSPOSITsON RESULT $r i

e 3 3. :S DESiGM CN AraGE REOuenED ONO

• • "' " ^ ' ' " ' ^ ' " '"' "

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.wveso.eae e e.ees ce..

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$ PE C.

REV.

' ADD.

' ^ ' ' ' '

White Copy

- Originator QC-Ga-a Canary Copy

- Field Engineer Pink Copy

- PQAE Gosdenrod Copy - OC 1

/

1 3

s:

NONCONFORMANCE REPORT

-. - - v. ~

' " ^ ~ ~ ' '

WEPA R T N O.

o r _ __ 1 373

, R E V.

v. PROaC T NO.

Ti. N E PO R T EH, Spec.-7220-C-208 l5 7220

.oATE 2.. o sPOS,T.O N CON gc R,.E NCE t N.,.- l\\-Wh..

,\\

3. STEM DESCRtPT80N m-l ~ ~ '-

m"

e. IT EM LOC AT ION l'our A 614 1 5V A LIDATED BY I

t!

___Cucretc_._ Cylinders Auxddg.__EIPJDE E it lab __ 'd*/t / W r M - W.. r# -N 1 DATE e

/

C. L E R $ A L N UM BE R

9. S T A R T UP S YS TE M NO.

- tI/A S I' R EPL ACE M E N T P A R T NO.

3 R E V.

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I W PURCH ASE ORDER NO.

9 0. QC P sELD GN SPEC TION PL A N NO.

44. REPLACEMENT SENsAL NO.

_2UA C-2al-4-739

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c. Cs N T,,4 C T O, LOC AT ON

...;SM; o TES n.=URCE

__Upf,tn.N G.N S T R UC T.O N S..d States Togtian_Qo,.._, flidland _llich NEER.NG O NO

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iTE M

.s. ROUT g ROurE TO riELD ENG O RO.T E T O M AT ERe Ai. SUPE RviSOR

.t.NONCONPORM.NG CONo.Y.ON. Specification 7220-C-208 Rev. 5 paragr1ph 7.3.2 states in part that

" Concrete cylindes shall bn maintained at a temperature of 60 degrees F to 80 degre 2s F prior to stripping."

Contrary to the above, the

_ field concrete cylinder sets (728F and 73')F) made represen:ing above location on 01/1/i/76 were initielly cured between 56 degreca F to 65 degrees F.

In addition, lab concrete cylinder sets (727 and 729) representing sar.e

_ location were initially cured between 63 denrecs F and 81__.!cgrees F.

"O" List No. 1.205.

Monconformance noted during QC review of report of concrete cylinders. No hold tags applied.

LO C PRELD DISPOSlTION QPIELD RECOMMENDATION / ROUTE TO PROJECT ENC eNEERING al. PIELD 08SPOSSTION R ESULT St s

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27. KNGINEENING Da%POSeiSON

23. ENGINEE RgNG OISPOSIT40N RESULTSs a

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27.ce C,,,rANCE O TES. SEE 47Y ACMEo, Crt AWING REV.

OCN J #c**semese avveeeeese,eneescre.

SPEC.

REV.

ADD.

ame e White copy

- Origenator e C<.3 a Canary Copy

- Field Engineer Pink Copy

- POAE Condenrod Copp - OC e

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NONCONFORMANCE REPORT 1

174

2. DN A WING /P A R 7 NO.

,, = - - - - -

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.R E Y.

7. PROJE C 7 NO.

I 2. M E PO RTED Dv lDATE 2 5. O s5PO51Y IO N CC6HC U R R E NC E

_ Spec. C-230 l5 7220

3. IT E M DE SC R IPTION S. 8 TEM LOC ATaON Ii

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Concrete Aux. liidg. Pour FPBS A(633.2 >)a L.1,iA,. p p A $'h" /'h ATE'Y 7t D

4. SE Re A L N UMRE R

9. S T A R TUP S v5 TEM NO.

9 5. REPL A C E M E N T P A RT NO. *

'REV.

...se ct e as te e..e.e s.

DA's S. PURCH ASE O R DE R NO.

99. QC F8ELO GNSPECTtON PLAN NO.

N/A l

- N/A N/A 9 4. R E PL A CEM E N T SE R 0 A L NO.

N/A C-2 31-3-749

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- - - ~ ~ " - - - -

CODE. (j vEs is. SOURCE

.. CON T R A CT ORiLOC AT ON

...AsME US Testin / !!dl_and. ichican O NO, _

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iT E M t o. ROU FING INSI ST UC TIONS:

QROUTE TO FIELO ENGtNEERONG O aou's to M Avra' A' $uPravisoa 9 9. NONCONFORMING CONDIT goNr Spec. 7220-C-230 nev. 5 Table 9.1. 3 staten in part that sitmp measureuent shall be mada for overy 35 cu'ile yards or fraction thereof of concrete produced for clann I structures.

Contrary to the above on Aux. 111d g. Pour A(633.25)a' test vere taken at 175 cubic yards and 216 cubic yards.

An interval of 4f1 cubic yart was placed. Nonconformance noted during QC review of QC-12 Form.

"Q" List No. is 1.205.

Hold Tag Applied (1).

29.

O P'<'o pasPosar'oa Or'c'o arco ="cao Avioataou'r to Paoe'.cr racia==aiao s ' ric'o o'5Posiveoa a ssu'vs.

22. ENG5N EERONG DSSPO5sf EON 2 3. E NCONE E R$NG Os5 POSITION R ESULTS:

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24. s oEseGN CH ANGT REOUGHED O NO

26. R EJECTED M ATENIAL DISPOS 8TaON 2 7. OC ACCEPTANCE O ee O v Es. EE ATT ACNEc.

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DR A WONG REV.

DCN

.u s.o.ea s e eme s.e e,o.

e.,,

SPEC.

REV.

ADD.

seese s WNie Copy

- Originator Q C <. 3-a Canary Copy

- Field E n2in**r Pink Copy

- POAE Goldenrod Copy - QC J

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(lUAUT! AUET F!ND!NG L.?2 515-1-u i.1/19/76

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Iland 1 & 2/ Job 7220 Construction B. Stojkov

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M/A 15-1-P-3', I tems NCR Log, Transmittal File J.' Miller, D. Palmet l

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C. Newton, D. Long - i FIP G-3, Rev. 6, S/17/74, para. 4.6.2 Para. 4.6.2 Raads in part:- "The PFE's authority to make 51sposition 'of.nonconformances-chall be subject' to... the following:

c.

Use approved repair procedure:

Requires notification of the'PE prior to or -

. concurrent with implecentation.

d.

' Reject: Requires notification of the PE prior 'to or concurrent with implementation for items pugchased to an engineering specification".

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The PE's files were checked for the presence o'f copies of five (5) dispositioned NCR's (255, 297, 327, 342 and 354) and'fiiTe (5) closed NCR's (307, 317, 348,. 349 and 353).which had d.thar "use approved repair procedure".or'"p$8 ject" dispositions.' - No evfdance that project in wring had been notified was available at the site or Project office. for'six (6) NCR','s.

/2 354, 307, 348, 349-and 353).

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' Datermine which NCR's having "use approved repair procedure" or " Reject" dispositions 1.*

have not been transmitted to the PE and transmit immediately.

^

2.

'The PFE, in coordination with the PFQCE, establish a cathod to assure ~ timely trans -

taittal of subject NCR's to PE.;.

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1/30/76, 2:

2/23/76 Proiect Suoerintendent

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i/A 12-1-P-2 Item 1 FMR-1 PO Files R. Mathews, R. Grote

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7220-C-233(Q) Rev. 5 9/22/75 Append. A 7220-C-23 Rev. 3, 4/15/74 Append. 1

~

O C-233(Q) Appendix A, states in part, "The seller / subcontractor shall establish and maintain and effective QA Program which will caet the applicable requirements of G-23...".

G-23, Appenix 1, states in part, "With the proposal, each bidder shall submit a su:=aary d scription of his QA Program.

, or an uncontrolled copy of his QA Manual or procedure.

If a bidder is currently performing' to or has cocpleted a Bechtel order which invokes the. re-quirecants of this specification, he nay, in lieu of submitting a copy of his manual, submit a latter listing the date of BechtMcSWEnual revision that is currently in effect or was in affect, and a statement that it will apply for this effort."

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...g Purchase Orders 7220-F-12726(Q) and 7220-F-12974(Q) resulting from FMR's CA-3038 and CC-2131, respectively, were a.earded to Inland-Ryerson.

Specification 7220-C-233(Q) Rev. 5 is the controlling specification on both orders.

Subsequently, 7220-G-23 is also applicable.

Inland RE~on is currently performing work controlled by Specification 7220-C-233(Q), and has sub-

) and had approved for use a Quality Assurance Manual.

However, on neither of the sul i 4rder: h:: I:1:n?. P.Jcr ca sul.sitte' le s. Lu siaLing thac the work to ce pertorned on a

the orders will be controlled by their currently approved program as specified in 7220-G-23, Apprndix.1.,

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Obtain from Inland-Ryerson stattent of the applicablity of their currently approved QA Program to the subject orders as specified in 7220-G-23, Appendix 1.

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2.

Reinstruct Field' Buyers to obtain satisfaction of QA requirements prior to award of Purchase Orders as specified.

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1; 01/30/76:

2: 02/27/7[

Project Superintendent

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i FPC-9 Rev. 3, 9/5/75 Para. 3.10.1 l

"FP-9 " Reparation of Field Ifaterial Requisitions" Pera. 3.10.1 states in part, "Q-Listed caterials shall be identified in the initial des-cription by the statement "Q-Listed Material".

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o Two (2) of the seven (7) na's for "Q-Listed" material checked (CA-3040 and AM-1006) did no dentify the' nateri'ai as "Q-Lis ted".

(NOTE:

The FMR's were processed as "Q-Lis ted" al even though not identified as such and the resulting Purchase Orders were correct.

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Assure that. all RfR's for "Q-Listed" material have been identified as "Q", prccessed and purchased as "Q-Listed".

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2.. Reinstruct Field Engineers as to the requirements for writing and processing FMR's for "Q-Listed" material.

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3 1 & 2:

02/27/76 Project Superintendent

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Attach =ent A 4 Reissued January 19, 1976 Route To

'Ihis Cony For I$

File 16.3.6 7h, v MSouthworth Sill!cwell Issue Date May 9. 1975*

i J

131Slager GSKeeley

\\uj Project Midland i & 2 CQIlills TCCooke UW EICEEN File Title NCR's on nachtel JM11andin UFilolub I*onconformance GLRichardson Report Ho 0F-43 Stib l oc t File This I*onconfor=ance Report is Issued To:

Prepared ByNn,,,d8 MmDate 5-9-75 Mr. J. P. Connolly Approved By

[/, /d.1 Date N

[

Bechtel Project Field Quality Control Written Reip y Request [By Date 6-6-75 Engineer Corrective Action Requested By Date 6-6-75 who is resuonsible for corrective action.

Nonconformance Description and Supporting Details: (1) Specification C-208, Rev. 4 section 7.3.2 states "A slump measurement shall be made for every 35 cubic yards or fraction thereof of concrete produced for Class I structures." For concrete placements CC(652.75)a' and CC(621.0)a', 56 cubic yards of concrete us placad between slump (2) The C12-1 form (In-Process Concrete Test Report) for CC(652.75)a' measurements.

indicates one air meter and one thermometer was.used in the field for testing.

However, at least three air meters and two thermometers' vere used in the. field.

One air meter and one themometer was needed at the pump discharge.

One air meter and one themometer was needed at the truck discharge.

Also, the QC inspector noted on the C12-1 form an air meter change af ter obtaining 7.5% and 6.5% nir with the

,m original air meter.

Limits on air content are 3.0%-6.0%.

I

)

AEC Reportable

.Yes ('~] Ho R See Procedure 9 (For nuclear Proiects Only)

Stop Work Necessary Yes No @ See leocedure 16 - Stop Work Ko Recommended Corrective Action:

(a) For item (1) above, receive an Engineering evaluation of the acceptability of the concrete placed without the required slump No additional corrective action is necessary, because it has already measurement.

been covered in letter C-208-56 from Bechtel to U.S Testing, concerning concrete testing frequencies and test locations.

The written reply to this item is requested i

with the Engineering evaluation.

(b) For item (2) above, take corrective action to preclude these occurrences.

Written reply and corrective action requested for both Corrective Action Taken; by June 6, 1975.

(a) A Bechtel Engineering evaluation of the concrete cylinders was performed on the concrete placed without the required slump measurements and the concrete was determined acceptable.

(b) The missing information in (2) above, was found and placed in the placement package for CC(652.75)a'.

Also, -e-training acccics was given on May 16, 1975 for U.S. Testing personnel to preclude repetition.

Sf.H.Hff 76 Verification of Corrective Action Required Yes @ No O Method of Verification:

(a) Reviewed letter BEEC-807 dated June 6, 1975 from R. L. Castleberry to J. P.

Connolly, that stated Engineering's evaluation.

(b) Reviewed placement package for CC(652.75)a' to confirm the corrective action taken.

Also reviewed the docu-mentation of the training cc:M ers 9fi.9.

I-N- 76 l

konconfor=cnceClosureConfirmedBy

%.O

b. HO'Tsyv' Date 5 '-t

~75 1To be cocplet'ed at ti:,c of closure by Consumers Pouer 'M Services,

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[*'

J Attach =ent A M-Reissued January 19, 1976 Route To

'Ihis Copy For 7, '

File 16.3.6

'Q,)g FMSouthworth Sillicwell

]

Iscue Date Aucust 7. Jo75**

EUSlager GSKceley (2)

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./

Project m d t,na i 4 7 C

CQllills TCCooke

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C N N FG W File Title NCR's on Bechtel Oura 1' Jnilandin WFHolub Konconfor=ance GLRichardson Ecport Eo OF-52 c h eet 2 21 n This Honconfoirr_nce Report is Issued To:

Prepared ByNc:JM$lb%Date R-7 '75 Mr. J. P. Connolly

^EE#

7 Bechtel Proj ect Field Quality Contrcl WrittenneplyRequeste[ByDate o-s-7 Engineer Corrective Action Requested By Date 9-5-7 who is resnensible for corrective action.

Nonconfermance Description and Supporting Details: (1)

Specification C-210 Rev. 4 Section 13.6 for plant area backfill and berm backfill states " Moisture control of the plant area and berm materials shall conform to section 12.6".

Under section 12.6, 12.6.1 states in part that "the water content during compaction shall not be more than two percentage points below optimum coisture content and shall not be more than two percentage points above optimum coisture content".

Contrary to this requirement, test no. MD202 for plant area fill located 14' east of 8.7 linc and 36' north of A line at elevation 594.5 had a ' moisture content 2.9 below optimum moisture content.

Approximately 7 f eet of material has been placed over this failing material.

(Contd)

AEC Reportable Yes no [ See Procedure 9 (For Nuclear Projects Only)

(j stnp un* Wecess wf von ] Un @ h a penna @re 14 - Ste; Merk He

/

Recommended Corrective Action:

(1) Receive a Proj ect Engineering evaluation on the acceptability of the material in question or remove the material.

(2)

U.S. Testing should have. training sessions to take corrective action to preclude repetition.

(3)

Quality Control should have training sessions to take corrective action to preclude repetition. The written replies to these items is requested' with the Project Engineering evaluation.

1Corrective Action Taken:

(1) Project Engineering has evaluated and accepted the in place material with low moisture content based on a satisfactory compaction test result (2)

United States Testing and Bechtel Quality Control have each had training sessions re-emphasiaing the acceptance criteria for soil tests.

Verification of Corrective Action Required Yes X Ho 1Method of' Verification:

Rcviewed Iechtel ECR #324 covering item (1) of this KCR (QF-52 and the Project Engineering disposition. Also reviewed letter FQCL-049 dated 8-13-75*

that states U.S. Testing and Bechtel Quality Control have each had training sessions to re-emphasiac the acceptance criteria for soil tests.

I

>1Ronconfor.ance Closure Confirmed By k--J,id.9Lyw.

Date H-ps 15 1

To be completed at time of closure by Consumers Power QA Services.

Pace 1 of 2 k

00 e r"~-

• Corrmend, prov!cudTi.-,enet P_7_7s e e -'

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• • Reissued January 19, 197f Filo

,.)

16.3.6

/

Issuo Date August 7,1975**

Proj ect Midland 1 & 2 Filo Title NCR's on Ecchtel Quality Control Nonconformance Report No QF-52 (Contd)

Nonconformance Description and Supporting Details:

(Contd)

~

(2)

QC-Cl as passlug by U.S. Testing in the remarks column.This fail (3)

On the back of the QC-Cl form. in the FIM, it states the entry inforcation For Block no. 3 the entry information ' states "to be signed and dated by the Q Engineer signifying the form has been reviewed for completeness and correctne Contrary to this requirement, fill density test r. aport the acceptance of MD202 which had actua 4

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Attechm:nt A

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Route 'ib This Cony For File 16.3.4 & 36.3.6 (q,Iy' fj Issue Date October 13.19h P:ISou thworth SliHowell litislager GSKeeley Fr j t Midland 1 & 2 j

CQllills TCCooke g,j g

.EHolub Construction and Cualitv Control Eonconfor=cnce GLRfchardson Eerort No OF-67 sum ee t File 1his Ncnconfor=ance Ecport is Issued '1b:

Prepared Byhf/ 6>.dk/.,~ Dcte M-!3-75 J. P. Connolly Approved By kM8N+ Date Nd?Am-Bechtel Project Field Quality Control WrittenRepYyRequeste8ByDate 11 Engineer V

J. F. Newgen Corrective Action Requested By Date 13 $,992h1MPMbbEMIT6$fcYve cetion.

Ecnconfermance De::cription and Supporting Details: PSAR section 5.1.3.3.la states in part that "In a 'dition to the tests required of the cement manufacturers, the followir user tests are p. formed:... ASTN C-115 Fincncss of Portland Cement".

Spcc. C-208 Rev.

section 6.1.1 states in part that (1)

" Prior to cc:=lencing of any concrete work cemer.

from the source selected by the concrete supplier shall be given an initial Acceptance Test consisting of a complete chemical and physical analysis by the Subcontractor in accordance with Paragraph 7 of ASTM C150 with the fineness to be determined by AST11 C115."

(2)

"In addition, for each subsequent grind the subcontractor shall perform an Acceptance Test consisting of a complete chemical and physical analysis..."

(Cc 'd

)

AEC ReyviI,abic 1*ca U Uu h See Proceduru 9 (For Nuclear Erojects ung)

Stop Ucrk Necessary Yes No @ See Procedure 16 - Stop Work No Recc:= tended Corrective Action:

(1) Review the initial Acceptance Test, Acceptance Tests and User Tests for similar deficiencies (2) Receive a Project Engineering evaluation on the acceptability of the cement tested by the alternative method (3) Notify U.S. Testing of this nonconformance and take corrective ac. tion to preclude these occurrences (4)

Instruct QC personnel on the propcr test method for determining the fineness of Portland Cement.

The written reply to these items is yrequested with the Project Engineering evaluation.

Corrective Action Taken:

(1) The results of all fineness tests performed in accordanc with ASTM C204 were reported to Project Engineering.

(2) Project Engineering evaluate the test results and determined that the cement is acceptabic.

(3) Both U.S. Tcsting and Bechtel Quality Control personnel have been notified of the correct test require-trents.

(4) PSAR Change Notice No. 0101 has been reviewed and cpproved by CPCo Enginec inn.

The change will require cement to be tested for fineness in accordance with AST!! C150. This in turn will permit the use of the f the test methods, ASTM C115 3 Verification of Corrective Action Eequired Yes No or ASTM C204.

1Nethod of Verification:

Reviewed letter FQCL-058 dated January 19, 1976.

Reviewed letter BEBC-921 dated January 16, 1976 in the Ecchtel QC file for NCR QF-67.

Tclecon with R. C. Bauman on January 20, 1976 confirmed CPCo revleu and approtal of PSAR Cinng Notice No. 0101.

INonconfo'rmance Clocure Confirmed By mdk b.b%d Date % w w - 3 0 p 1G v

u ITo be completed at ^ c of closure by Consuncrc Fowc

'A Services.

c/

)

File:

)

16.3.4 & 16.3.6 Issua Date: October 13, 1975 Project:

Midland 1 & 2-File

Title:

NCR's on Bechtel

~ s

• 7 i

Construction and Quality Control

~s Nonconformance Report No QF-67 (Contd)

Nonconforcance Description and Supporting Details:

(Contd)

(3)

"Also, Tor every 5000 cubic yards of concrete produced...a User's Test con-sisting of a complete chemical and physical analysis" is =ade.

Contrary to the requirements above, the fineness for User Tests 20 (Report 66),

21 (Report 67) and 23 (Report 74).and Acceptance Tests for Silo 20 (Report 41),

Silo 18 (Report 58), Silo 12 (Report 62), Silo 20 (Report 69) and Silo 17 (Report 76) was determined by ASTM C204, Test for Fineness of Portland Ce=ent by Air Per eability Apparatus instead of by ASIM C115, Test for Fineness of Portland Cement by the Turbidimeter.

l

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9 4

l I

i 1

s_._-

Page 2 of 2

f' f

Attach ~nt A Route To Tais Copy For Filo y 16.3.6 & 16.3.4 FMSouthworth ' Sitifowell r/6 Issue Date December LG. 1975 INSlager CSKeeley "y /

Project Midland 1 & 2 E

E f

11 din File Title NCR's on Eechtel WFHolub Konconfomance Ouality Control & Bechtel Construc GLRichardson Subject File Report No _OF-69 This Nonconfomance Report i: Issued To:

Prepared By/6/,L/uM/pa.

Date a//4 -

Bechtel j

t Field Quality Control Appr ved E d d d I.

Dateded-No' Engineer J. F. Newgen Written'RIply Reque;Ied'By Date 1-9-76 Bechtel Project Superintendent n h@esM W Dah M4 uho ic responsible for corrective action.

Uonconforacnce Description and Supporting Details:

Bechtel's storage requirement for decay heat removal pump motors file nos. F-1-37, 38, 39 Rev. 2, Section 5 2 all sta in part, " rotate shaf t 10-25 complete revolutions plus one quarter turn at intervals not to exceed 90 days, record final keyway position".

the shaf t rotation of the three decay heat removal pump c:otors exceeded thContrary requirement.

Elapsed time of 99 days between rotation existed.

e 90 day performed on August Last rotation was 27, 1975 and next rotation performed was on December 4, 1975.

AEC Reportable Yes No @ See Procedure 9 (For nuclear Projects Only)

Stcp W0rh Ucccs34.y

~ica U hoe tiee Procedure 16 - Stop Work No Reco::=lended Corrective Action:1) Evaluate and determine motor acceptability '

2) Take corrective action to preclude recurrences.

Corrective Action Taken:

See Attachment A.

1 Verification of Corrective Action Required Yes x no O Met' hod of Verification:

Visually verified that motor acceptability was docum a.

b.

e CE.

ment F-2 forms stating that"cmooth rotation indicates bearing coated withrequire-Bechtel QCE and MSE.

oil'jby Verified by reviewing requirement for c c.

h!onconformance Closure Confirmed By38p /%jt,o age off motors in Instruction Man

{

.w/$g/

GEH-3160J.

Date

)~s9-pr To be completed at' time of closure by Consumers Power QA Services.

Page 1 of 1

[)

[)

16.3.6 & 16.3.4 File

/

Issue Date December 10, 1975 Project Midland 1 & 2 File Title NCR's on Bechte. Quality Control & Bechtel Con-

. (g.

\\,)

struction

. Attachment A Nonconfotaiance Report No QF-69 Corrective Action Taken:

1.

a.

Received a ' response from Bechtel Project Superintendent stating that motors had been inspected and determined to be acceptable.

b.

Received response from PFQCE stating that the motors were hound acceptable and the statement was documented on storage requirement forms F-2.

~

-2.

a.

Bechtel Project reinstructed the concerned personnel in regards to prepara-tion and performance of maintenance instructions.

In addition, the periodic inspection times have been' adjusted to weeks rather than to days to preclude

. inspection times falling during weekends causing inadvertent tine extensions.

Meggering equipment is under consideration for purpose to prevent equipment shortages at critical inspection periods.

b.

Bechtel QC has instructed the assigned QCE to document any delayed maintenance activities on the F-2 form for equipment concerned.

OO

.)

l s

-s Page 2 of*2 L-_.--.,.

)

,[

Attacimnt A Route To This Cory For Q

File 16.3.6 & 16.3.4 F.MSouthworth SHilowell h

Issue Date December 12. 1975

'Hk'Sleger CSKecicy

' 'hr Pr ject Midinnd 1 &7 l

l CQIlills TCCooke COM!mb FCY:Ci File htlc iiCR's on idechtel Qual JMilandin C ntr 1 & Bechtel conetroreirn tFHolub Nonconformance hu

'[ ij" Report no QF-60a This %onconformance Report is Issued 'ib:

Prcpsred DypM /bdMDate

/.7- /.7-J. P. Connolly Approved 37 9g8{My Date /Ch/X+

Eechtel Project Field Quality Engineer Written Rep &lyRequestc[iByDate 1-9-7

/

J. F. Newgen W

Correct.d.ve Action Requested By Date 1-9 Bechtel Project Superintendent who is resuonsible for corrective action.

Nonconfomance Description and Suppcrting Details:

,echtel storage requirement for-decay heat removal pump motors file nos. F-1-37, 33, 39, Rev. 2 Section 5.3 all stated in part, " test insulation resistance uith a meggerand record readings at intervals not to exceed 30 days".

Contrary to this requirement, the motor meggering of the three decay heat removal pump motors exceeded the 30 day requirement.

Elapsed time of 38 days between meggering existed. The last meggering was performed on August 27, 1975 and the next meggering performed was on December 4,1975.

AEC Reportable Yes O no Q see Procedure 9 (For Nuclear Pro 3ects on17) i Stop Work Recessar/- Yes C Ho @ See Procedure 16 - Step Work Ko V-Reco= mended Corrective Action:

1.

Evaluate and detemin't motor acceptability.

2.

Take corrective actica to preclude recurrences.

1Corrective Action Taken-See Attachment A.

1Verification of Corrective Action Required Yes X No b4ethodofVerification:

Reviewed correspondence from Bechtel Project Superintendent and Bechtel PFQCE.

a.

b.

Visually verified that motor acceptability was noted on the F-2 form.

Meggering of motors on 12-4-75 determined motors insulation acceptable.

c.

d.

Reviewed GE Instruction Manual - GEH-3160J, page 2 " storage requirement".

b;onconfor.s ce Closure Confirmed By M fM '7!

Date / - : 7c ~; g, 1To be completed at ti:ae of closure by Const=crs Fo eer QA Services.

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~;~

Fils 16.3.6 & 16.3.4

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I :ue Date December 12, 1975

' Project Midlcnd 1 & 2 File Title NCR's on Bechtel Quality Control & Bechtel Con-

,b struction v

Attachment A Nonconforcance Report No QF-69a Corrective Action Taken:

1.

a.

Bechtcl-Project inspected and dercrmined the motors to be acceptable.

b.

Bechtel QCE and the Bechtel MSE evaluated and agreed that there was no 1 mage to the motors as a result of the delay in the maintencnce activity nnd the motor acceptability was documented on the storage requirement form F-2.

2.

a.

Bechtel Project reinstructed the concerned personnel regarding the prepara-tion and performance of maintenance instructions.

b.

Bechtel QC has instructed the assigned QCE to document any delayed maintenance activities on the F-2 form for equipment concerned.

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Page 2 of 2

f Attac'=nt A c

Rout 7 To 9.is Cot 7 For

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Filo

/16.3.4 & 16.3.6 i

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Issue Date Dece=cer Lu, 19/5 HUSlager SHHowell CQilills CSKeeley Project Midland tiuclear Plan:

a N

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I?!Southworth TCCooke

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h WFHolub CESUdfl3 ESW3f File Title I!CR's on Bechtel

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CLRichardson Conconformance JMilandin Report Uo op-70 This Conconformance Report is Issued To:

Prepared By W[ 6] h Y b v Date I W Ml W J. F. Neugen, Bechtel Corp.

Project Superintendent Auproved By Nb/ Date / 2-4.-ds p

J. P. Connolly, Bechtel Corp., Project Written R lyReque:gedByDate 12/24/

Field Quality Control Engineer Corrective Action Requested By Date 1/12/

v'io is resnonsible for corrective action.

Uonconformance Description and Supporting Details:

Storage requirement forms F-1-207 and F-1-208 for the Upper and Lower Reactor Vessel Internals require that any nitrogen addition be logged weekly.

For the period from 11/21/75 to 12/5/75 the storage records do not show any addition of nitrogen.

The F-2 form that was issued 11/14/75 indicate the flow meter was removed because it did not allow enough nitrogen to be added.

AEC Reportable Yes O no O see Proceeure 9 (For nuclear rrosects only)

Stop Unrk Necessatm va= O No { See Precetc.rc 16 Ctcp ',Tork Mc, Recc = ended Corrective Action:

1.

Rework internals storage cannisters to reduce nitrogen leakage to a level that the flow meter will indicate, or install a flow meter with a higher range.

2.

Reinstruct personnel in the preparation and performance of. maintenance instruc-tions, so that the final records reflect the written instructions.

lCorrective Action Taken:

1.

A QC training session was held concerning the storage and maintenance program and the proper documentation of delayed or missed tasks.

2.

Field engineering personnel were reinstructed regarding the preparation and performance of maintenance instructions so that final records will reflect the written instructions.

3 1

Storage requirement forms F-1-207 and F-1-20 evised deleting the requirener wer Verification of Corrective Action Required Yes Ho to log the addition of 1

^Eethod of Verification:

nitrogen.

1.

The records of the QC training session were reviewed.

2.

The revised F-1-207 and F-1-203 forms were reviewed.

9 Honconformance Closure Confi:ned By iN[MMM-Date //I'!/7C I

To be completed at time of closure by Censumers Po rer QA Services.

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