ML19339B979
| ML19339B979 | |
| Person / Time | |
|---|---|
| Site: | Midland |
| Issue date: | 10/31/1980 |
| From: | Jackie Cook CONSUMERS ENERGY CO. (FORMERLY CONSUMERS POWER CO.) |
| To: | James Keppler NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| References | |
| 10051, 10CFR-050.55E, 10CFR-50.55E, NUDOCS 8011100620 | |
| Download: ML19339B979 (239) | |
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i?O3 t'0V 10 fl1 9 44 f eneral of fices. 1945 West Parnali Road. Jackson, Michigan 49201 *(5171 788 0640
...v October 31, 1980 : ! M i3?i SERV!CES iANCH Mr J G Keppler, Regional Director Office of Inspection & Enfcreement US Nuclear Regulatory Cctrission Regien III 799 Roosevelt Road i Glen Ellyn, IL 60137 MIDLA';D PROJECT DOCFET UD 50-329, 50-330 CO:!TAIH:E;T INTER::AL STRUCTURES COATI;3 DEFICIE::CY FILE: 0.L.9.37 UFI: 73*10*01, 00210(S) SERIAL: 10051
References:
CFCo letters to J G Keppler; Midland Nuclear Plant; Unit no 1, Docket No 5C-329; Unit :To 2, Docket No 50-330; Containment Internal Structures Coating Deficiency; J 'j
- 1) Serial Eove-309-79; dated Decenber 13, 1979
- 2) Serial Hovem26-80; dated February 7, 1980
- 3) Serial Hove-75-80; dated April 15, 1960 h) Serial 9125; dated June 11, 1980
- 5) Serial 8523; dated September 9, 1980 This letter, as were the referenced letters, is an interin repcrt en the containment internal structures coating deficiency. The attachment to this report provides the status of the investigation and corrective acticns being taken.
Another report, either interim or fint1, will be provided by March 1, 1981. d dw 60. x WRB/lr #
Attachment:
MCAF-35, Containment Internal Structures Coating, Interin Report 5, dated October 2L, 1980 l i CC: Director of Office of Inspecticn & Enforcement Att Mr Victor Stello, US::RC (15) l hV Director, Office of :anarement ! Information & Froi ram Contrcl, US:;EC (1) RCeck, MRC Resident Inarect.or - Midland Site (1) l8'011100 k(d _ __ _ __
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- 2 Scrial 10051 i
e j CC: CEechhoefer, AS;3 Fanel ! GALinenberger, ASL3 Panel FPCowan, ASLB Panel AS&L Appeal Panel , E Cherry, Esq l IGinclair l j CRStephens, USNRC l WDPaton, Esq, US:!RC l l FJKelly, Esq, Atterney General l j SHFreeman, Esq, Asst Attorney Gen l GTTaylor, Esq, Asst Attorney Gen > WHMarshall 4 l GJMerritt, THK&J e l l l
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0 0i4702 Attachment 1. MCAR 35 (Issued 11/13/79) CONTAINMENT INTERNAL STRUCTURES COATING INTERIM REPORT 5 October 24, 1980 CONSUMERS POWER COMPANY MIDLAND UNITS 1 AND 2 BECHTEL JOB 72r0 I O
(r) s_s MCAR 35 INTERIM REPORT 5 014702 COuTENTS Introduction Page 1 Description of Deficiency Page 1 Investigation Page 2 Conclusions from the Investigations to Determine Root Cause Page 9 Corrective Action Page 10 ATTACHMENTS A Specification 7220-A-15(Q) B Letter Outlining Method of Application C " Approved" Nu-Klad 117 Data Sheet D Subsequent Nu-Klad 117 Data Sheet E Wall Elevations Sketches Showing Daily Coating Application, Variables, and Adhesion Test Results F Adhesion Test Procedure p)., ( G Qualification of Adhesion Test H Adhesion Test Results I Coating Material Analysis J Results of KTA Application and Adhesion Test Analysis with MR Contaning Procedure K Lab Reports on Contamination Analysis L Solvent Testing, Report 1 M Solvent Testing, Report 2 N Solvent Testing, Report 3 0 Solvent Testing, Report 4 P Manta /Ameron Report Q Corrective Action Schedule, PPS-005
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, Bechtel Associates ProfessionalCorporation i i 777 East Eisenhower Parkway
/ nn Arbor, Michigan 0i4702 us.uwess P O Box 1000. Ann Atbor. Micn gan 48106
SUBJECT:
MCAR 35 (issued 11/13/79) Containment Internal Structures Coating INTERIM REPORT 5 DATE: October 24, 1980 PROJECT: Consumers Power Company Midland Plant Units 1 and 2 Bet htel Job 7220 Introduction This interim report updates progress and summarizes investigations, evaluation of data, and planned corrective action concerning the failure of decontaminable Coating System 9, as applied to concrete in Containments 1 and 2. I . ' Description of Deficiency Coating System 9 is a decontaminable coating system applied to approximately 50,000 square feet of the concrete walls in each containment. As applied, System 9 consists of two filler /aurfacer coats of Ameron's Nu"Klad 117 and two finish coats of Ameron's Amercoat 90. Nu"Klad 117 is an epoxy coating to fill and seal the concrete surface. Amercoat 90 is a modified ph nolic epoxy coating which provides a decontaminable finish coat. Insestigations have shown that the delamination is occurring between the two coats of Nu-Klad 117. The delamination problem identified in this report does not involve the peeling or flaking of the coating from the containment walls. The problem can more accurately be defined as one of questionable adhesion. In most instances, this delamination can only be detected by adhesion testing and actually forcing the coating off the wall. Because the full impact of this questionable adhesion cannot be predicted at this time, an undesirable safety implication, i.e., blockage of the sump, cannot be ruled out. Adhesion has been found deficient in approximately 18% of the areas in Containment 2 where System 9 was applied. Containment 1 has also been l tested for adhesion and while the results have not been fully evaulated the percent of poor adhesion appears to be much lower. l (
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014702 MCAR 35 Interim Report 5 Page 2 Investigation A. Technical Design Document Review The technical design documents were reviewed for adequacy or direction, deficiencies and conflicts, and for idencification of information to be used to develop criteria by which System 9 coating work could be evaluated.
- 1. Technical Specification 7220-A-15(Q) (See Attachment A)
The specification was prepared as a contract document for application of decontaminable coatings to concrete for use by an approved coating subcontractor. This specification, along with the subcontractor's quality assurance documents including approved manufacturer's data sheets, pre sides
/~N procedures for the application of the decontaminable coating applied to concrete, including System 9.
a) A complete review of the specification for System 9 requirements did not identify any deficiency which sh3uld result in misapplication of the coating or subsequent coating failure. b) The specification, when reviewed against the subcontractors' application records, yielded the following discrepancy. The specification calls for Nu-Klad 117 to be applied j both as a filler and a surfacer. The filler is used to patch small voids ur holes in the surface; the surfacer is a full coat application to seal the entire concrete surface. [See Sections 5.1 and 8.1.1.c of Specification 7220-A-15(Q), Attachment A.] Application records indicate that two full coats of Nu-Klad-117 were applied. This is confirmed in a 4 letter from the-applicator (see Attachment B).
- 2. Design Basis Accident (DBA) Testing of System 9 System 9 has undergone DBA testing using the hydrazine spray solution used at the Midland plant. The surface preparation and coating applications were completed in
(-)' accordance with Specification 7220-A-15(Q) and the nanufacturer's Nu-Klad 117 data sheet, dated 3-78, calling for one full , coat application of Nu-Klad 117. Two coats of Amercoat 90 were applied over the surfacer. System 9, as tested, passed-the DBA test.. i 1 n , * - v
Bechtel Associates Professional Corporation. IfCAR 35 014702 Interim Report 5 Page 3 System 9, as applied in each containment (two full coats of surfacer and two coats of Amercoat 90), has not been tested. DBA tests will be repeated on core samples taken from Containment 2. This will be dealt with later under the heading of corrective action.
- 3. Manufacturer's Product Data Sheets Manufacturer's product data sheets are printed by the manufacturer to provide information about the product and to give instructions for application.
The data sheet approved for use by the subcontractor's quality assurance program, made no mention of a two full coat application of Nu-Klad 117. (See Attachment C for approved data sheet.) Subsequently, the manufacturer rg issued a Nu-Klad 117 data sheet dated 11-78, which addressed
'N,) a two-coat application. (See Attachment D for this data sheet.) This data sheet was submitted in April 1980 by the subcontractor for review and approval. Although approsal has not been granted, this data sheet is being used for information in the System 9 investigation.
There were several other revisions to the data sheet, dated 11-78. However, these revisions were primarily in
; the area of expanded information and instruction and they did not conflict with the original approved data sheet.
- 4. Subcontractor's-Quality Assurance Program The subcontractor's quality assurance program for application of this system referred to the approved manufacturer's
, data sheets and Specification 7220-A-15(Q) for appitcation of' Syn t em 9 In addl irois, the qualI y nunurance program states that where a con 111ct exists between the specification and the data sheets, the specification shall govern. The subcontractor's quality assurance program appeared adequate and, if properly executed, should havc included the submittal of the revised data sheet allowing two full coats for approval. O
Be htel Associates ProfessionalCorporation O . Oi4702 MCAR 35 Interim Report 5 Page 4
- 5. Application Records The subcontractor's daily application records were reviewed 4
and the information obtained was developed into sketches of wall elevations. The sketches isolated the individual application variables, i.e., various ranges of surface temperature, time between coats of Nu-Klad 117, batches used, and application of more than two coats of Nu-Klad 117 and where used for correlation with results of adhesion testing. These drawings sere completed for walls in Containment 2 where System 9 was applied. In some areas, it was difficult to accurately identify the specific application boundaries, however, most area have been plotted. For reference, see examples of this work in Attachment E. Also included for reference are the results
- of the adhesion testing on System 9 in Containment 2. The
] 3 () following discrepancies which conflicted with design application documents and or later manufacturer's data sheets were identified. ' a) - Two coats of Nu-Klad 117 were applied in almost all cases. b) Several areas were identified where the time between coats of Nu-Klad 117 exceeded 7 days. This is contrary to the manufacturer's data sheet dated 11-78 (see Attachment D). c) A few areas indicate more than two coats of Nu-Klad 117. I d) A few isolated areas indicate a full coat of Nu-Klad 117 over Amercoat 90. B. Adhesion Testing and Correlation with Application Data i
- 1. Adhesion Testing Adhesion testing was conducted to identify the extent of the delamination and adhesion problem with the System 9 coating.
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4 }- 9 Bechtel Associates Professional Corporatio'n i MCAR 35 014702 Interim Report 5 Page 5 j i The adhesion test was performed . by making two parallel cuts with a knife into the coating and attempting to ' delaminate the coating between the cuts. When delamination was detected, the particular coating area was interpreted as a " fail." When no delamination was detected, the 4 coating area was interpreted as a " pass." .(See Attachment F fc- the adhesion test procedure.) The knife cut test was qualified by comparing results to
- like results obtained by the elcometer adhesion test method. The knife adhesion test showed a high degree of reliability when compared to the elcometer method. Generally, the knife test caused delamination when the elcometer test l
yielded results of less than 225 psi tensile strength in the coating. The knife test did not cause delamination where the elcometer test yielded results greater than j 350 psi. Tensile strengths in this range approximate the i () range of concrete failure and were considered reasonable for this test. (See Attachmsnt G for this data.) . , System 9 was tested using che knife test performed under
! 100% quality control inapec* 1on. Baced on this test, the i results indicated adhesion was inadequate in 17.7% of the cases in Containment 2. The results also indicated failure j
occurred uin a random pattern throughout Containment 2. [ Attachment H contains all the test results on Form JLM-i 1050. Examples of the same information as shown on the i drawings is also -included for reference only. Containment 1 + has also been tested and evaluation of the results is in , progress t
- 2. Correlation with Plotted Application Documentation ;
The knife test results were plotted on wall elevations and compared with plotted data and variables identified from the application records. Although there was some correlation between the failed tests and the time between coats of Nu-Klad 117, there was no identified variable which could be
. clearly tied to areas which failed the knife adhesion test (see Attachment E).
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l , Bechtel Associates Professional Corporation 014702 ' MCAR 35 l Interim' Report 5 i Page 6 i l C. Product and Application' Variables Investigations were made into product and application variables i which could impact the adequacy of the subject coating system. The following variables were identified and investigated to determine what effect they might have.
- 1. Packaging Variables
] Nu-Klad 117 is a three-component coating consisting of
- filler material, resin, and a hardener. These ccuranents
) must be mixed in consistent ratios to provide a coating
; which will function as designed. First, several batches 4
were checked for consistency in packaging by weighing the I components and establishing deviations in packaging. The results demonstrated pacEaging within acceptable limits. Secondly, several batches were checked for chemical O consistency by use of thermographic analysis, energy dispersive x-rays, fluorescence, infrared spectroscopy, l aad gel permeation. Results indicated that the three
; batches were essentially identical and there was no reason to believe the material was faulty. (See Attachment I for test results.)
d 2. Mixing and Pot Life Proper mixing is critical to the correct preparation of
, Nu-Klad 117 for application. Based on experience in
! testing the product, pot life and product workability can vary wbtn mixed in accordance with the manufacturer's
-instructions. Insufficient or excessive mixing, and the method of handling the mixed product have definite impacts on pot life and its ability to be applied. The concern
] over pot life is that questionable adhesion occurred on
-the test panels when the coating was applied near or at
- the end of pot life. (See summary report and test procedure in Attachment J.) Considering that the coating can be
. - applied until the pot life is expired, this may be a I significant factor in this coating problem.
.W hile testing and working with Nu-Klad 117, it was found relatively difficult to mix and apply a - full batch of- Nu-(} Klad 117 within the stated pot life. This observation, s
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3 Bechtel Associates Professional Corporation MCAR 35 Interim Report 5 014702 Page 7- { l coupled with the fact that some of the Nu-Klad 117 does '
- not appear to be fully. cured (as evidenced by sof t surfacer in some areas demonstrating delamination) indicates t a possibility that the coating mix may have been modified to increase workability.
The coating mix could have been modified by reducing the
' required amount of converter component when mixing or by 2 adding solvents. Reducing the ' convertor results in extending l the pot life and the curing time. If the convertor is l
reduced enough, it will result in a coating which will not 4 completely cure.
- 3. Application Method There is no indication at this time that variation in the I application method (trowling) would result in delanination.
However, the application of two complete coats does contribute I to the problem.
- 4. Surface Contamination 4
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The application of Nu-Klad 117 over a contaminated or i improperly prepared surface was investigated as a possible
- cause of delamination. " Failed" coating chips were examined, but no unusual physical agent was found (see Attachment K
- for test - reports).
I While contaminants have not been determined to be a major l concern, this matter is not completely concluded and contamination testing is continuing. 1
- 5. Time Between Coats The coating manufacturer's data sheet, dated 11-78 stated
! that the time between coats of Nu-Klad 117 should not exceed 7 days at 73F. . However, subcontractor's records indicated several areas j where the 7 day requirement was exceeded. This area was ! investigated by a controlled testing prodram. The testing
- j. program clearly indicated that loss of adhesion between coats is possible when the manufacturer's recommendations for maximum time between coats is exceeded. KTA-Tator l
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Bechtel Associates Professional Corporation MCAR 35 Interim Report 5 Page 8 014702 Associates has completed extensive testing of this variable. (See Attachment J for the testing procedure and a summary report.)
- 6. Temperature Fluctuations The main effect of temperature on the coating is the influence it has on the curing process. Lower temperatures i tend to lengthen the curing time of the coating. Higher 4 temperatures shorten the curing time. If the allowable I time between coats is based on curing of Nu-Klad 117, higher temperatures could reduce the time between coats,
. conversely lower temperatures could extend the time between coats within limits. Another consideration is that when a surface temperature is at or near the dev point, it is possible for water to condense on a surface. While this appears to increase the exothermal reaction of the applied coating and might increase the cure time, it does not seem to advarsely affect application and is not deemed to have a major impact,on adhesion.
- 7. Coating Thickness The thickness of the two coats of Nu-Klad 117 as well as the complete coating system varies from surface to surface.
; While delamination is more readily detectable on greater coating thickness, it is thought that this is not a definite cause of the lack of adhesion. (See summary comments in j Attachment J.)
- 8. Addition of Solvent While the specification and the manufacturer's data sheet do not allow for the addition of solvent in Nu-Klad 117, a distinct solvent odor can be detected immediately after delaminating the coating. This could be attributed to the addition of solvent to Amercoat 90, because solvents were '
added to Amercoat 90 for thinning. However, a solvent , odor can also be detected even .when only Nu-Klad 117 has been applied. , .) 1 1 I I l i
Bechtel Associates Professional Corporation MCAR 35 014702 Interim Report 5 Page 9 To date, evidence (other than smell) of solvents in the coating material has not been substantiated. However, additional testing is being conducted to determine if, in fact, unauthorized solvents were added and are present in the applied coating. ' While efforts to detect solvents in the coating continue, studies have been performed to determine the effect of applying solvents to Nu-Klad 117 coating mix. Attacknents L, M, N, and 0 contain reports on these studies. These
. investigations have demonstrated reduced adhesion may neur when solvents are added to Nu-Klad 117.
D. Subcontractor / Coating Manufacturer's Report The subcontractor, J.L. Manta, and the coating manufacturer, Ameron, have also been involved in investigating this coating problem and have provided a report on this matter which is included in Attachment P. O E. Other Coatings Applied to Concrete in Containment Specification 7220-A-15(Q), Section 5, atte.:ied in Attachment A, identifies-the material used in coating afstems applied to concrete. Systems 6, 7, and 8 are identified along with System 9. Based on investigations of System 9, there is no reason to believe there is a similar problem with other coating systems. The filler and surfacer material are different from System 9 and the surfacer is only applied in r,ne full coat, hence delamination between two full coats of surfacer could not occur. Adhesion between the surfacer, concrete, or finish coats has not teen identified as a problem with System 9 or with System 6, 7, or 8. Conclusions from the Investigations to Determine Root Cause
! A. Adhesion testing and other investigations have not identified any significant problems with the surfacer adhering to nhe concrete or with the finish coats adhering to themselves or the surfacer.
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Bechtel Associates Professional Corporation Q, 014702 MCAR 35 I Interim Report 5 Page 10 I 'B.- Delamination is detected only when two full coats of Nu-Klad 117 . are applied. The delamination occurs at the interface of the i two surfacer coats. During investigations, the following conditions were observed.
- 1. Eighteen percent of the adhesion tests performed in Containment 2 failed to show acceptable adhesion. Questionable adhesion has also been detected in Containment 1, and the determination of extent is in progress.
- 2. Delamination, based on adhesion tests, occurs in a random
- pattern and has not been clearly tied to any specif c cause or variable.
- 3. Further investigation has indicated delamination cannot be predicted in any specific case at this time. However, there is sufficient data available to indicate the following variables may have-a significant impact on adhesion:
_( } a) Excessive cure time between coats of Nu-Klad 117 b) Mixing procedures, temperature, humidity, and solvents have an impact on curing time, thereby possibly affecting allowable time between coats j c) Application or Nu-Klad 117 near the end or after the i effective pot life. d) Pot life and apparent pot life is affected by mixing and the addition of solvents. e) Excessive coating thickness, while not identified as a causative factor, does appear to be an element in failure. 4 1 i C. Any ongoing investigations and their results will be included j in future reports. , Corrective Action While a deficiency in Coating System 9 has been confirmed, investigations i have shown that the majority of. Coating System 9 as applied, appears to be adhering adequately. The proposed corrective action is to () identify and to remove the defective coating.and to repair defective areas in .accordance with the following program. a 4
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Bechtel Associates Professional Corporation 7 u MCAR 35 Interim Report 5 014702 Page 11
- 1. Identify acceptable and unacceptable System 9 coatings. This will be done by a new adhesion testing program to identify each area containing coatings with questionable adhesion. The validity of the adhesion test program will be varified by Design Basis Accident (DBA) tests of coating samples before actual acceptance of any System 9 coatings. Areas which cannot be confirmed to have accep-table coating will have the coating removed or protected in such a way that failed coating would not reach the sump. Specific proce-dures are being developed for coating removal or protection for inclusion in the specification.
- 2. Coatings which pass the adhesion test criteria will be sampled and tested to ensure that remaining coatings will pass the Midland Plant Design Accident Criteria. Core samples from Containment 2 will be used in the test. The results of this testing will provide the criteria for the acceptability or unacceptability of the coatings in the containments.
( ') 3. An evaluation ci possible coating repair methods is being conducted and specific procedures for application are being developed. Repair coatings will then be applied to sample areas in the con-tainment where System 9 has been removed, partially removed (down to the point of delamination), and where the coating is acceptably intact (such as where " passed' adhesion tests were performed) to provide areas for sampling and testing. The samples will be tested for conformance to DBA criteria. Upon receipt of these results, the coating repair method and procedures will be evaluated and the repair procedure will be developed for inclusion in the specification. 4 Specifications, quality programs, and manufacturer's data sheets for application will be thoroughly reviewed and revised as required to prevent a recurrence of the problem identified in this report. This review and update will be completed before any System 9 concrete coating repair work begins in Containment Units 1 or 2.
- 5. Af ter completion of Items 1, 2, 3, and 4, actual coating repair will proceed.
- 6. In addition to the above ongoing actions, it should be noted that all concrete coating work in both containments except for testing, had ceased prior to initiation of MCAR 35.
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Bechtel Associates Professional Corporation MCAR 35 Interim Report 5
$lk[Q2 Page 12
- 7. Attachment Q is a project production schedule PPS-005 for the corrective action described above. Additional information will be submitted in reports on these subjects at work progresses.
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- 8. The next Interim report is scheduled for February 15, 1981, and will provide a status report on corrective actions and the results cf ongoing investigations available at that time.
Submitted b Approved by:N,#A 445ct,Atts'e rvs Concurrence by: , /2/ A i y JSC/TJM/ht i i
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ATrAc4 Sedr~d T"A G E IB o;r do Specification 7220-A-15(Q) /b Rev. 8 /'~~N \~-) TECHNICAL SPECIFICATION FOR SUBCONTRACT FOR EPOXY OR PHENOLIC DECONTAMINATIVE SURFACER CONTENTS Page 1.0 WORK INCLUDED 1 2.0 RELATED WORK NOT INCLUDED 1 3.0 QUALITY ASSURANCE 1 4.0 SUBMITTALS 2 5.0 MATERIALS 2 6.0 MATERIAL HANDLING AND STORAGE 4 s 7.0 ACCEPTANCE OF SURFACES BY SUBCONTRACTOR 4
\- 8.0 SURFACE PREPARATION 4 9.0 APPLICATION 7 10.0 INSPECTION AND TESTS 8 11.0 MEASUREMENT FOR PAYMENT 9 12.0 PROTECTION OF EQUIPMENT AND ADJACENT SURFACES 9 APPENDIXE3 A. Engineering and Quality Verification Document Requirements, Form G-321-D, Page 1,2 of 4, Rev.g g with Supp. A. Page 3,4 of 4, Rev.8 B. Specification 7220-G-23, Rev. 5, General Requirements for Supplier's Quality Assurance Programs C. Quality Assurance Program Elements Data Sheet 1, Rev. O D. Specification 7220-G-1, Rev. 6, General Project A Requirements (Purchase Orders) tQ V
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. ATTAc44nNewT A Specification 7220-A-15tus s Rev. 8 \
TAGE 4 or do () TECHNICAL SPECIFICATION FOR SUBCONTRACT FOR EPOXY OR PHENOLIC DECONTAMINATIVE SURFACER 3
- 1. C WORK INCLUDED 1.1 The work includes bot is not limited to the following:
- a. Preparing concrete and concrete masonry unit surfaces to receive surfacers.
- b. Furnishing all material equipment and i tools required to do the job
- c. Application of surfacer
- d. Repairing surfacer
- e. Protection of a'djacent areas and equipment with fire resistant materials
- f. Topcoating over surfacer 9 Quality assurance program and documentation for'"O" listed work 2.0 RELATED WORK NOT INCLUDED i
2.1 The followirg related items of work are not i included:
- a. Filling surface cracks and cavities that are 3/4 inch and greater in their least dimension
- b. Calking and sealants 3.0 OUALITY ASSURANCE Applicition of decontaminative surfacer within containment areas, shall conform to the quality assurance requirements of Appendix B, Specification 7220-G-23, and ANSI 101.4.
O i-4 1
FAcdAGNT A < Specification 7220-A-15(O) ' '
.e v . 8
( +%6 G b o F 4) t N 4.0 SUBMITTALS 4.1 Subcontractor shall submit the following to Contractor in accordance with Form G-321-D:
- a. Procedures of surface preparation, material handlina and storage, mixing, application, and the inspection thereof
- b. Inspection forms covering procedures verifi-cation, recorded data and the frequency of recording
- c. Materials listed covering materials to be used at the jobsite
- d. I'.qu ipme n t list covering proposed ap911 cation equipment, inspection tools, gages, meters, etc. to be used during application, inspection and for calibration.
- e. Documentation verifying Applicator's and inspector's qualifications in conformance to the applicable requirements of ANSI 101.4.
-'s f. Procedure of mapping and initial testing of
) Coating System 9 for delamination.
- g. Procedure for touchup and repair of Coating System 9.
5.0 MATERIALS 5.1 a. Materials are specified hereinafter by manu-facturer's name and product number in order to establish the standard of quality required,
- b. Systems used inside the containment building shall qualify with the applicable DBA require-ments of ANSI N101.2, ANSI N512.
- c. Systems used outside the containment building shall qualify with the applicable decontamination requirements of ANSI N101.2, ANSI 512.
l i l I 2 l l
Specification 7220-A-15(O) ATrecuer A Rev. 8 PA6E G op/ , MANUFACTURER: The materials are by Ameron Corrosion Control Division, Brea, California. The areas where they occur are indicated in the finish schedule. See Exhibit E. SYSTEM USE PRODUCT NAME No. 6 Filler 109 Nu-Klad or Nu-Klad 110AAB Green (N)-voids or cavities Primer Nu-Klad 108(N) i No. 7 Filler & Primer (same as System No. 6) Surfacer Nu-Klad 110AAB Green (B) 1/8" thick min. application (see Section 9.0) No. 8 Filler & Primer (same as System No. 6) Surfacer Nu-Klad 110AAB Green (B) 1/16" thick aver, application Top Coat Amercoat 90(N) (5 mil thickness) () (optional) (Indicated in finish schedule) No. 9 Filler Nu-Klad ll7(N) Thin Coat Application Surfacer Nu-Klad ll7(N) Top Coat Amercote 90(N) (10 mil thickness) 2 Coat Application Surfacer 111 Nu-Klad (formerly 1862) or Repair Nu-Klad 110AAB Green (N) - for floors Cleaner 116 Nu-Klad Alternate products of at least equal quality and suitability or the intended purpose, manufactured by other companies shall be submitted to the ' Contractor for acceptance. Product equality must be substantiated with the technical information necessary to permit an accurate comparison. This submittal shall be included with Bidder's proposal. 5.2 Acid solution shall be 10 percent of commercial grade (not fertilizer grade) phosphoric acid , water. O 1 3
ArvAca g ar 4 Specification 7220-A-15(O) Rev. 8 PAGE / op da pl
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5.3 Water shall be potable. Rinse water for washing operations shall contain no more than 200 ppm chlorides. 5.4 Neutralizing solution shall be tso percent ammonium hydroxide in water. 5.5 Cleaning solvents shall be as recommended by decontaminative surfacer material manufacturer, and shall contain no more than 200 ppm chlorides. i 6.0 MATERIAL HANDLING AND STORAGE 6.1 Materials shall be delivered in their original undamaged, unopened containers clearly marked showing manufacturer's name, brand, date of manufacture and shall be stored in dry areas for protection from weather, stain and damage until application, and shall le kept in a temperature controlled area in accordance with manufacturer's requirements. Materials older than manufacturer's recommended shelf life shall not be used and shall be removed from the area.
/'N. \s ,/ 7.0 ACCEPTANCE OF SURFACES BY SUBCONTRACTOR 7.1 Before applying materials, Subcontractor shall ascertain that the surfaces to be prepared for surfacer are suitable for surface preparation by the method specified. He shall notify Contractor in writing ir. advance of the surface conditions that adversely affect the quality of surface prepa-ration. Performance cf work by Subcontractor shall indicate his acceptance of the surfaces.
8.0 SURFACE PREPARATION 8.1 Surfaces to receive surfacer material shall be pretreated as follows: 8.1.1 General
- a. Fins, protrusions, loose particles, laitance, and other non-adhering surface deposits shall be removed from floors and walls, by power grinding and air blasting with high pressure compressed air free of oil and water.
v 4
Specification 7220-A-15(0) *A Rev . 8 /d ( f'a m d>CY M
~.) b. All surfaces shall be precleaned by steam cleaning or by scrubbing with solvent or detergent to remove oil, grease and other soluble contaminants.
- c. Voids such as rock pockets, form tie holes, cavities of 3/4 inch wide or less shall be patched with filler as specified in 5.1 flush with adjacent surface.
- d. Washing solutions, contaminants, and debris shall not be allowed to enter the plant drainage syster.;, unless previously authorized by the Contractor.
8.2 The surface preparation requirements for each area will be determined by the Subcontractor in accordance with the surfacer material manufacturer's recommen-dations using the following methods, except where indicated otherwise below: 8.2.1 Concrete floor other than within reactor building shall be acid etched. The surfaces shall be swept clean, then dampened with potable water applied in a quantity to saturate the surface without N puddling. The dampened surface shall be flushed with 10% solution of phosphoric acid and allowed to stand until bubbling i stops. Before spent acid dries, the floor shall be scrubbed with stiff bristles and clean water, and rinsed with potable water. Acid application shall be repeated until the surface texture of the floor approximates the roughness of medium grit sandpaper. Af ter the required texture of the floor has been attained, the surface shall be neutralized by application of a solution of 24 ammonium hydroxide. Neutralizing solution shall be allowed to stand for approximately 10 minutes, or until a test with pH Hydrion paper indicates that the surface pH is between 7 and 9.
/^T U
5
Specification 7220-A-15(O) ArtAomNTA t Rev. P /9 PEhe 9 op 40 L.J Concrete floors and walls within reactor building areas shall be cleaned as specified in 8.1.1, then the surfaces si.all be prepared per 8.2.2 and/or 8.2.3 below. 8.2,? Concrete surfaces, if sweep blasted, shall be precleaned as specified in 8.1 above, then dry sand blasted to a uniformly textured surface approximating the roughness of medium grit sandpaper. Sand blasting abrasive shall be ground silica sand (flint or garnet) graded 18 to 40 mesh, air pressure at the nozzle shall be about 35 pounds per square inch. Blasting residue shall be removed by one or a combination of the following metho6s:
- a. Vacuum cleaning
- b. Brushing
[) v
- c. Air blasting 8.2.3 Concrete surfaces, if air blasted, shall be pre-cleaned as specified in 8.1 then cleaned free of dust and loose material by means of compressed air blast at 90 to 100 pounds per square inch.
8.2.4 Concrete surfaces if steam cleaned shall be washed with steam containing a cleaning agent (approximately 0.5%, by weight) consisting of a mild caustic, a caustic buf fering agent and a detergent. Cleaning shall proceed from higher elevations to lower elevations to obtain a flushing action and to avoid leaving an excess of moisture and residue on the cleaned portion of the work. Steam cleaned surfaces shall be rinsed with potable water to remove all traces of cleaning agent and soil, and then shall be allowed to dry. Areas where water does not wet the surface thoroughly shall be reeleaned. ( L) 6
ATTaogguyA l Specification 7220-A-15(Q) Rev. 8 PPGE 10 of Ao k- In spaces where steam cleaning cannot be used, or where installed equipment will be damaged by L steam, scrubbing.and mopping ' with a hot detergent solution, followed by rinsing with clean water and solvent spot cleaning may be permitted provided that results obtained are equal to results obtained by steam cleaning. Substitution of this method
-shall receive prior approval by P.he Contractor's field engineer.
4 8.2.5 Concrete masonry unit surfaces shall be preeleaned as specified in 8.1 above, then air blasted or steam cleaned as indicated in 8.2.3 and 8.2.4 above. 8.3 Prior to application of surfacer, the
- surface shall be dry. If drying conditions t
are unsuitable for surfacer application, i the cleaned surface shall be isolated from contaminant sources, and equipment approved i by the Contractor for dehumidification or heating to dry the surfaces may be used. 9.0 APPLICATION 9.1 Materials shall be applied in accordance , with manufacturer's printed instructions on_ handling, mixing, spraying, trowelling, curing, cleaning and other necessary procedures. Surfacer shall not be applied on surfaces exposed directly to the weather, 9.2 Decontaminative surfacer shall be~ trowelled or applied in a wet thickness so to obtain the dry thickness required on the finish schedule on upright surfaces and 1/8 inch minimum on floors, equipment pads, and curbs. Wet thickness template or other approved measuring devices shall be used to verify the required thicknesses. Unless shown otherwise, for Systems 7'and 8,
~
9.3 j g internal corners between walls shall be filled to 1/4 inch radius with surfacer O 7
. _ . - , _-~ _
ATTR4meuT A Specification 7220-A-15 (Q) l /gg Rev. 8 g- TAGE (( or 4) V material; internal corners between wall and Ih floors shall be filled to 1 inch radius; external corners shall be bull-nosed to 1/16 inch radius. All radii are nominal guide jjg dimensions and may vary +20%. 9.4 Unless otherwise shown, surfacer shall be gjg trowelled and lapped 1/4 to 5/8 inch over steel surface where steel is flush with or indented 1/4 inch or less from concrete or masonry surface. Surfacer shall be trowelled and butted against steel surface where steel protrudes or indents 1/4 inch or more from concrete or masonry surface. Steel shall be clean of flash rust and any other contaminant which may affect the bond of the surface. 9.5 Surfacer shall be applied 1-1/2 to 3 inches into thh the side surfaces of expansion or working joints before calking compound or sealant is to be applied by others. 9.6 Surfaces shall be pin-hole free after application of surfacers with System Nos. 7, 8, or /~T 9. U 9.7 Application of System No. 7 to vertical surfaces A shall be applied in two coats of approximately 1/16 m inch each. The second coat shall be applied within 48 hours after approved curing times. 10.0 INSPECTION AND TESTS 10.1 Subcontractor shall verify, with an approved measuring device in the presence of the Contractor, the wet thickness of the applied coating of decontaminative surfacer as requested by the Contractor. 10.2 Subcontractor shall record daily the work performed on the approved inspection form and submit to Contractor at end of each working day. 10.3 Subcontractor shall furnish surfacing samples on approximately 3" x 7" x 2" concrete blocks, as periodically requested by the Contractor, for the purpose of testing the correctness of mix of specific batches of material. b NI 8
Specification 7220-A-15(Q) /\ Rev.8 g
- %GE t'Z oy 4) ,
}
10.4 One hundred square feet of the initial application of each system by _ the Subcontractor will be carefully inspected using the proposal samples as a guide. Upon acceptance by the Contractor this initial application of each system will become the finish work standard for that system for the rest of the subcontract work. 10.5 Deficiencies and defects shall be removed and replaced or corrected to Contractor's satisfaction at the Subcontractor's expenne, 11.0 MEASUREMENT FOR PAYMENT 11.1 The work will be meesured for payment to the nearest whole square foot. Measurement will include only those areas on which the work has been satisfactorily accomplished in accordance with the subcontract document. 12.0 Ph0TECTION OF EQUIPMENT AND ADJACENT SURFACES 12.1 Prior to surface preparation, if the rooms or areas are occupied with equipment or (j~h s piping, the Contractor shall be notified and asked to determine the type of protection that the equipment or piping requires. 12.1.1 If the Contractor determines that only normal protection is required, the Subcontractor shall tape and cover with fire-resistant material all equipment, piping and adjacent areas as necessary to protect against damage, or defacing during surface preparation and coating applications. 12.1.2 If, however, the Contractor determines that special protection is required, the Contractor shall pack, grease or use any special packing required to protect the equipment or piping before the Subcontractor provides normal protection. NOTE: The SDDR Form attached to Specification 7220-G-1, Rev. 6, shall be submitted jgg when required in lieu of the SDDR form
-w found in specification 7220-G-23, Rev 5.
v 9
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ArrA(>4 MENT A Areas where QA Prograz0 PAM or is Required 4o O \ b/
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AA Rtv 2 yn ENGINEERING AND OUALITY VERIFICATION DOCUMENT REQUIREMENTS SHtti 1 0F 4, lRtv. a fitPR000CT104 0F TMt3 FORM 13 AUTHORt2f D QUAlftY Vf RIFICAf t04 00CUMENT TRANSMITTAL-RIPRODUCE THt$ $10f ONLY
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When meerties teams a comeiese, the Yeaf enea M Dervmeave are to be deveubd to ee reeers, eseresse pena base se esseresse une me seineveen sede sereted en Cseme 7. A sepy of es comosesed Fene G-321-0 met oncemesay assh partege* of Venfaseen Derweenu es re desonessa Ame e s ey of somemand Form 0-321-0 e to be 8asiveed are ce heemse pieamas and e see, wat meerste, to me Prorut Feed Owenty Cenerei Engsamer et es setnu. Case a Case t.wie meresse emment Case s. Bechtel Associates Proffee.onel Corp. Sechtel Pommer Corp. Sochtel Poseer Corp. P. O. Som 1000 3 3500 E. Matter Road . P.O. Som 2187 Ann Art >or, Mich60 en 48106 Mediend,Methigen 48640 Midland, Michigen 40640 Attn: Protect Engineer, Joe 7220 Attn: QueHyy Control Eficineer E. 01F141T1045 09 TI Au3. (se sse Derveent Centery Dete.neas C-221-8UP A) Sweeder - The e e gaaers arm sad o evneaymous e.m se terme uner, senser.soarester, me<enester, arbeespier, et. Reproduseos = ten be %efy deelsesed by either esserspreedtree er eterposgee $ry presem Nurofam - 26mm metrofem seavenpas to she teoustumean of me preterament dessmenet when set seasted, messer shalt emma he emedwd for espreesi. Paar Aeproval Reevered - Sarate seerseel reevered ener ts mee of dessmens a se desen, fearsmee, meunenea, or other wert prerem laetief - me fwet saamm of a essement m esseresse sie es shesee avhau agreed s to by me Sever sad the meeler. Fem - es sue m.rtes emot renas the nemution of review seemeas. er the templem sem. teel rueered. Seth are to be essessed ener to episonne fund poveset Drespass aborteed a tem must be twit aire reoroevc@es mese erem erg am decomeat Asse ent to me ese tiert. essa greewg must be cerefied and see Ovver's let tee. jet anseer, pertness oreer ave 6w. I.ae. 64.emeat, as er sees numee sad me mea =terestere eres avenerts). Cui fed - ine emed Semwe sad T.no of en eueensed sad nueenece emeievee of es metser.
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F. OECMTEL ENTRY INSTRUCT 10st 8. SUeetlEA ENTAYIngTAUCT10ers E.te, ae. i.f.rm.en ase ,ed i farm.m. Rees. red 3j t Emer Desumeat Catevery 4. mew E , sie. e Esser numest of enome of eart type of Geefety verslastien cese-
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) 70 titsuiC CATA REPORT to til Eisetrasf Property Report 28.1 WechmurW Teen
/ 38 A4ALv515 AND Ot$804 REPORY 10 18 0 C00E C0uPLI ANCI M V SO AC0vsTIC C ATA ttP0 Af tu 19 0 UT - ULTR A104'C ExAust Afl04 PRO-26 2 Elecusel feen 27.0 PROTOTYPE TIST REPORT IE & VI 10.8 $AMPLC3 iEl CfDURES (H, AND VERIFICAfl04 AE' 10 1 Tystat Qai.tv Venficenea Decomeate 28 0 SLPPLit R SHIPPthG PREPAR Afl04 Pilo-PORT 3 M CEDURE (El Specification 7220-A-15 Sheet 2 of 4
l l I PiTTMHWRT A Areas where QA Pr< grampg g op-is not required 40 m i i
\ l READ INSTRUCTIONS ON OACK DEFORE flLLING IN FORM l
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- 24. GCE Chee64a The fone sad me 0.ss+ry venfs. nee Decameem CONTROL =0. FILE NO' Seement #Werensed heese hese beee acewed .nd Dew eneenensh, to me herteere stems eenfied. OCE 5.eaerne Dete Afare QCf Cliett4e Ostnbete to: Preevrement Menaerv Faid Offse M. nape. Mmaal S.perener
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( MIDLAND PLANTS . UNITS 1 & 2 P.015PtC. NUW81R CONSUMERS POWER COMPANY s 22: 0 7220-A-15 (Q) AA RIV 2 AU-
- p. ENGINEERING AND QUALITY VERIFICATION DOCUMENT REQUIREMENi$ INEtt 3 or 4 8.J fif Pfl00UCT104 Of TMAS FORM f3 AUTHORIZE 0 00AL41Y vfRifICATION 00CUuttif TRANSMITTAL-REPRODUCI TMt3 SIDE OktY
- Appendix A
I mf Ife87 RUCTIONS FOR PREPAR6NG G-321-0 MW U( . ~ R,0,< ,.e e e m.e e. a f.m to M ..d .v ..v-.n t. . e.d.e.v ..mety d. . _..d of e. tw . stofv .o_ n.- . . e.d ., she sweener a e seeer anset for Queety Venfuocoe Desweems unen autm*ttat een to me Seyw/Contrator. 8 GE NE R AL INFORu Afl04. Ewaserwie til and 0.m.tv Vartfsanee M Osromere era deaefed D, Csemeory aveter and see a e' en N. been, C. USE, A soev et the heat of the form spall be sempested ks es mesher and prended to the Sever's/Canverter's laesster ese e ==e the selsamu Quest, VerWsanaa Dernmeno for km I reme= pner to rosesse of me vastis). O. Dr$fillIUT10N. AR (no neereg (Ei Ceremeno are se to esat to me Preiss Eaemee et the ederes seem twee (Cede et When eneparties rosess e soms4sted, the VerArevise (V) Carwmeate se to ise devemas to me reessese endreams shown below 6a essereerse see the deeressen sede asesdied a Csev ea 7. A see, of me some+med Form G-321-0 smet usemesa, enn "pastase* of Venfsessa Oessmean a sia -~ _ Aase.a see, of semessed Farm G-321-0 e se to easiveed enth me nerdnere e, ment and e sov ene see,ses, to me Pro,est Fase Gee 6 ivy Ceeira Enynes, et the setsia. Ceea e. Cees 6. With havuore ehement Code s. Bechtel Assocates ProffesL4nal Corp. Sechtel Power Corp, Bechtof Power Corp. P O. Som 1000 3500 E, Mis'er Aoed P. O. Boa 2167 An#* Art >or, Michigen 48106 Midland,Moctingen 48640 Mdtend, Michison 48640 Attn: Protect Engineer, Joe 7220 Attn: Queitty Control Engineer E. OEFiNIT10N5 0F TEmus: 15e sse Dessment Casserv De8meseas G-329-$UP A) 8 ee or - The is e r wru sure end e eveenveses enn the anne seier, usider, senement, s6essouter. esbesseler, et. Recesis46e - saa se seeer, d phsesse 6, e ear murenerosecties or seeswessurs dry ermast Merafde - 35mm messefde seaterame to es roeuww*saa of me presurement desumans amen met sessted espeler shall esbest he smederd to amorest. Pner Aserees Rosened - Orsstes esement reeuwed ener to me of sesessoa e a me desga. faerseree, easessionen, or emer wert presen, iaet.m - es fnst e4**tte of a easement a userosus sie me shedvie netwas, eyest to by the 8vver sad the meeler. , Feae - the outm.tta that entiers the reemetise of remse commeas, or the someiste e4metti reevnet. Set 9 are to be essapted ener to reasonas feel povmeat Orosines notantend a faal most be felt oss roerseaseme mese from erged serwmeat. Adissent to me aos tiest, essa drosise must be serefed and een Bever's fet ece.iet nester.ewechase erest awater, has squement, tes er sede num6et and the esaufarturer's sensi mem6erts). Catifee - ths deies $gaeture end Tale of en aumerised sad tempeannie smeievee of as mooier. Is A - Wet weiset.e - som he esse for me,meem satnes, seimme sad liams 6, Prosort segmecq and for indwided onenes tv the mooier. F. SECMTEL ENTRY INSTRUCT 104$ S. SUPPLif R (NTRY *tfilWCit0NS Entry No. late metica Roeswed Eawy No. laimmuen Roomred l Emer Desume n Category Meetw. 3 Ens poems of essa twee of Quality ventsetwa Desu-(\ ! (aver leer fcaties seregreen referenza.
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4 Emr trie number of essa t at of see, tw "arev er "tmel* 12 taur rene .. e seerserete. When e someten na escurred, mem4rreis of Easmeerwg Desumeatt refseense me 6emetreatal and Sever /Cenwater's eseenasten 5 f avor sporessi reeuwemeat by X maeor "Ya" or "Ne* sesven. en me solema, and easives the meeensenee easemeaeN) m sne 8 Enter the avetor of esen had of see, of Qumov Ver faseos Venfusema Ossement Putase. Desumean reevved for reisme of taa nem er measseten. 13. 14, 15 Eater safermenee a reevned. 7 Enter 0.aner Venfmanos Des === sat derrevema sees istier a 16 Ener the nemtas of === sesered tv ee Quahty verdseeen arsedyre e.e pereersen C anem Desmosas towg ammesd. Fw enn rue.mtma som ee. teae e u.a as eawy For o.seier om saev. reessed pronse e meerse see, of es semessed form and me 9 8esuei lasposter to semeiem seen toisen $ga se leas 22. meeertme Quency Venfassen Daeumeas 10 f ator Bernio Eaemeeng .ewee sent marien. Sg= en has 23. 17.18.19 Ia'er *formenee m eneewed. Il Sesate GCE to sameme chassen. Sga en 8 re 24. 20 Enter afsatification amaterte) weasehde to es east (G boung re> 12 Eame remarta es wereeness tamsd, e4 anni no., hest ae. af messe sempeemas, smens ress as. er eest easeue eespurer. u 00CuufMT CATEGORY NutsetR$ f ae asewg (E) and Ovesesy Venfanea M Dramment Reeweweeas a aatsred a Ceivma 1, and esf.and a G4214UP A Desument Ceausory Cef.neeas For deters, see seehat.ee permersental refersared a Ceivma 2. 1.0 DR AWING 5 ft) 10.2 Tewai meterei ume 28 3 RT - RADIOGRAPMIC EXANIN Aft 0N 1.1 Oveue O.meassas. seress and Foea- IIA M ATE RI AL DESCRIPTION (t) PROCEDURES 4t), AND VERIFICATION deten/Movetg deteds 12.0 atLDING PROCEDURES AND QUALIFI' REPORT 1 M 12 Ausett, Drewmer CATIONS (1), AND VERIFICAtl088 At- 21.0 MT - MAGNETIC PARTICLE EXAMINA-
- Shoe Ostad Ors =mus POR75 M TION PROCEDURE 8 (E), AND VERIFICA.
I4 w.rme 0.eere=s 13 0 s' ELD 800 CONTROL PROCEOURt3 (El, TtON REPQRTS M 15 Conwet tesis 0.eprems ANO VERIFICAftCN REPORT 3 M 22A PT - LIQUl0 PEstf7 RANT EXAMINA. t8 P & los 14A REPAIR PROCEDURES ft). AN3 MAJOR Tl0N Proct 0URES (fl. ANO VERIFICA. 2.0 PARTS LI$7 AND CC$f iti REeAIR VERIFICATION REPORT 1M TION REPORTS (V) 3A COMPLETED SECMTEL DATA sdEffs (Ei 15A CLEAN:sfG AND COATING PROCEDURE 5 23.0 100Y CURRENT EXAtlNATION PROCE-48 INSTRUCTION 5 tE) (E). ANO VERiFICAtl0N REPORT 3 M OURES (E), AND VERIFICATICN RE-41 f restion/tastais enoa 18 0 NEAT TREATWENT PROCEDURES 11), P0c3 M 42 Coerstme ANO VERIFICATION REPORTS fVI 24.0 PRES $URE TEST - MYOR0. AIR. LEAK, 4.3 Memteaease 17.0 CERTIFif 0 MATERIAL PROPERTY RE. Sul8LE CR VACUUM TEST PROCEDURE 44 See storsee and Noaeeae PollT5 M (E). ANO VERIFICAft04 #EPORTs M le SCHicutES. ENGINEF#iNG AND fat- l '. s WTA (Carefed Meenal Tsar Roeral 25 0 INSPECTION PROCEDURE (E), AND VER-RIC ATIO8rt R ECTION:E) 17J fapart Ten Date IFICATION REPORTS M 30 QU ALITY A330RANCE M ANUAL/ PRO *t. 17.3 Fernes 0ste 28.0 PERFORMANCE TEST PROCEOuRES !!), DURES (t) 17 4 W88'el Certficato ef Compliance l ANO VERIFICATION REPORTS M I T TO SEtsuit CATA REPORT tt) 17.5 flestnsal Preseety Repens 2g.1 Washeassei Tesa 1 33 ANALYs'5 AND CESIGN REPORT (t) 18 0 CCDE COMPLIANCE M 28.2 Eintrase Teen d 90 ACOUSTIC CATA REPORT (E) 10 0 SAuPLES (E) 15.0 UT - ULTRASONIC EXAmiN ATION PRO. C10VRt3 (E!, AND VERIFICATION RE-27.0 PROTOTYPE TisT REPORT (E & V1 28 4 SUPPLif R SMIPPf MG PREPA* ATION PRO-10.1 Typstai Qvality verifcation Cecomente PORT 3 M CfDURElEl Specification 7220-A-15 Sheet 4 of 4 \
AtrumePa A TkCg U cG 4.2 ( ,) DOCUMENT CATEGORY DEFINITIONS
\J ,
(E)- Enyneenne Documentt This term compnses procedures, drawings, specifications, QA plant prototype qualification test reports, and ottier omilar documeits that require Sechtel appe oval poor to fabacation, or pnar to las s' the document in the design, f abncation,instalianon, or other work procent The term is also appbad to once hsts, and irstrucconal documenn vor handling storape, moetenanca, etc, that are of informational interest only to prosset eneneenng (V)- Duahty Venication Documents. This seem compreses mavel test reports, heet treatment charts, weldmg records, NDE results, performance test reports, etc., whch demonstrate or certify conformance to the techncal or insm: tion requirements of the procurement docaments 1.0 DR AWIN GS (E) Dutline D,mensions. Servces and Foundaten/Mountmg Detads - Dreenngs providing esternal envelope, including lugs, center line. .ation and size 1.1 f or e6ectreal cable, conduit, fluid, and other sonnce connections,isometncs, and details related to foundations and mountegt 1.2 Assembly Drowngs - Detailed drawmgs ind+cating sufficient information to facditete assembly of the component parts of an equipment stem. 1.3 Shop Detail Druwngs - Drowngs which provide sufficient detail to facihtete the fabrication or v.enuf acture of the souipment item. This includes but is not limited to, spool drewmgs, hast aschanger internal detads,interr,al piping and wiring, crossisction detsik )nd orchitectural detadt 1.4 wiring Diegrams - Drawings whch show the schemste unnng and connection information for electreal i rmt 1.$ Control Logc Dailrams - Drewings whch show sta poths which input ognels must iollow to accomplish the required responses. 1.8 P & ids - Pigms and traerumentation Desroms whch show piping system detods and $e howc control elementt 2A PA RTS LfST AN D CDST (E)- Esploded view with identf eed parts and recommended spare parts for one year's operstion with umt cost. 3D COMPLETED RECHTEL DATA SHEETS (E) -Information provided by a suppher on dem sheets furnished by Sechtal which states seriet numbers, operatmg ranges, etc., of equipment est the supplier intends to dehver to setrsty the specification requirements. 4A INSTRUCTIONS (E) 4.1 Erection /Installaeon - Desded written proceduras, instructions, and drswings raiuered to rect or install matsnal or equipment. 4.2 Operstmg - Demised wtben snstruccons destnbmg how an item or system should be opersted. 43 He nwnence - Detaded wntten instructions requwed to Jeessemble, reessemble and maintain items or systems in en opwating condition. 4.4 Sete Storage end Handhne - Detaded written instructions which defme the reewirements and time period, for lubrication, rotation, butmo, liftme or other handhng requeements to prevent damage or detenoration dunng storage and handhng at jobsits. This incluoss return shippmg instructions.
5.0 SCHEDULES
ENGINEERING AND F ABRICATION/E RECTION (E)- Bar charts, critical path methods, etc., whch chronologically detail the sequence of activitieL 60 QUALITY ASSUR ANCE MANUAL /PRDCEDURES (E) - The document (s) which describe (s) the planned and mystematic meesures that are used to ensure that structures, systems, and Jmponents adt meet the requirements of the procurement documentt 7.0 SEtSMIC D ATA REPORT (E)-The analytical or mst data whch provides physical reopense information on en item, me irol, component or system in reistion to the conditions imposed sy the stated noismec cnteria. e 8.0 ANALYSIS AND DESIGN REPORT (E)- The snelytcal dem, (atras, siectrical leering, fluid dynamics, etc.), which ensures that en imm satisfies specif.ed requirementt l 9.0 ACOUSTIC DATA REPORT (F)-The noise, sound and o$er e+bretion dem required by specifcation which is in die eudible range and above the se+:mic frequency. 10.P SAMPLES (E) 10.1 A representative data package which will be submitted for the items purchased as required in the specsfication. 10.2 A representetnre example of the materialto be used. 11A MATERIAL DESCRIPTION (E)-The technical data desenbeg a meterief which a suppher gre;wass to use for a specific order. This usually apphes to architectural itemt e.S, metal sadmg decking, doort pamts, contings 12A WELDING PRDCEDURES AND OUAllFICATlDNS (E). AND VERIFICATION REPORTS (v1-The welding procedua specification and supporting welding procedure gustifcstion test records required for weldmg, hud facing, overley.brermg and soldermg. A vent.Lation report of welds performed includes the identifcation of the quehfied welder (s), and the procedure (s) used, and certification that the welaerist were qualified. 13A WELD RDD CONT 0RL PROCEDURES (E). AND VERIFICATION REPORTS M - The procedures for controllmg issuance, handimg, storese sad sacambshty Venfication report (s) for weld rod are det ned es certified materal test reports whch include the requirements defmed by the code and meterial
] speciftation imposed by the procurement documento (V )
14A REPAIR PROCEDU RES (E). AND M AJOR REPAIR VERIFICATION REPORTS (V)- The procedures for controlling material removal end replacement by weldmg, braimg, etc., subsequent thermal treatments, and final acceptance inspection.Venfication reports may include weld repair locations (maps), material test reports for fdler metal, preendpost-weld hast truetment rec 6rds, NDE records, etc. The resolution of whether a repair is maior or not rs a Sechtsi respofEihdity. Specification 722Y I- k Ne N . Supplement A. Sheet 1 of 2
A MEM k SCs EI L 6 of %) i 15.0 CLEANING AND C0ATING PROCEDURES (E), AND VERIFICATION REPORT 3 M - The procafuros for remount of det, greams or other surface 1 contanunstsen and includes apphcotion of protective coatingL Venfcanon reportr include certification of visual enammenon for ufoce properstaan, surfets , refde, metenais, etc., humafity data, temperaturs dem and co'etmg Sickness data as squired by the procurement documentt J 1LD HEAT TREATMENT PROCEDURES (E), AND VERIFICATION REPORT 3 M - The procedures for controlims temperature, oms at temperature a a functon of thschnen, fumace atm osphers, cooling rate sad memod, etc. Venfication regarts normally include fur %ce charts or smilar rs6erds which identify 3 and certify me item (s) treated, me procedure used, turnas atmoshers, Dme at temperature, coolmg rete, etc. Venhcanon det' smay be in other narrstrve or j taoutar f orm. 17.1 CERTIFIE D M ATERfAL PROPERTY REPORTS M 4 . i 17.1 MTR (Certified Metonal T2st Rooerts) - Thees reports include all chemical, physcal, mechanical and electncel property test dets reevnsd by the
; meterol specificaten and applics$s codes. This a sophceNe to cement, concret6, metals, ce68e pocket matsnals, robar, retar sphces, etc. The 6wtfed ! MT R shellinclude a setement of conformeace ttnet the motonal me:ts the wecification tsquirementt I
- 17.2 Impact Test Osta - Raulu of au Che,7v or drop weight sum including specimen confersoon, seit temperst.rs and fracture dem.
17.3 F.mte case - Report of the femte percenage for seemise snel meanses used,induding cetmos & we6 ding Riler meet as depoemd, 17.4 Meteral Carnicate of Comphence - Venficanon document which certif,es confermance to the regarements of me assicable messisi specificocon. i 1t5 Electncal Property Reports -Report of sectncel charactensecs, s4, dissectne, impedance, instance, Rome test, corone, etc.
! ILO COD E COMPLIANCE M - Ventyuis documans (och as ese Fonse U.1, N 2, State, orc.),ushish are propered by the manufacturer er inseHar and serWind i by the Authenrod Code inssector.
19.0 UT 81LTRA30NIC EXAMIN ATION PROCEDURES (E). AND VE RIFICATION REPORTS M - Method of deternen and esaminsmen russim af presence and certain charactwistics of deconenetses and enclusens an meterm6s by es use of hegn frequency 6couste energy. 20.0 RT - RA0iOGRAPHic EXAMINATION PROCEDURES (E), AND VERIFICATION REPORTS M-Method of detection sad enemination resure of presence sad certam charactaristcs of decontmanes and inclusons in metereis by s<sy or gemme<sy suposurs of photogreshic film. , 21.0 MT - MAGNETIC PARTICLE EXAMIN ATION PROCEDURES (E), AND VERIFICATION REPORTS M - Memod of doncDon and eneminsten resuis of g p surf ace (or nest surf ace) disonenwoes en mayiste motore:s by datorton of en apphed magnetc field. I 1 d (/ 22.0 PT - LIQUID PENETR ANT EXAMIN ATION PROCEDURES (E), AND VERIFICATION REPORTS M - Meeod of detschon and esamirenen results of surf ace d,scontmmties a meterals by sophcanon of a penetroung hqud in contunction with ansehle devedoping techniques. 23.0
- E00Y CURRENT EXAMINATION PROCEDURES (E), AND VERIFICATION REPORTS M -Method for detection and eneminsten results of
- disonunwees in metened by desterton of an opphed electromspists fold.
24.0 PRES $URE TEST - HYORD AIR, LEAK,8UBBLE OR VACUUM TEST PROCEDURE (E), AND VERIFICATION REPORTS M - Method for sueousteg l es servcturf ar J mechancai edeouscy or insyrty by spolicacea of differental presures, and report af she test resuitt 25.0 INSPECTION FROCEDURE (E). AND VERIFICATION REPORTS M -Organned proces followed for me purpose of determnung that specif4ed reguremena (din,ermore, propernet performance resalts, etc.) are mv Documented fadsnes resulting from en inspection are irrtuded in the venfcetion report. 26.0 PERFO RM ANCE TEST PROCEDURES (E). AND VERIFICATION REFORTS M - Tests performed to demonstrom e.ai functend despi und eperseerut parameters era met and me report of me test resutit i 2C.1 Mecherucal Tasu, ts, pump curves, valve strokms,lood, temperature rise, cahbreuon, eneronmental, etc. 26.2 Electrical Terts, a s lood, isniuw, overtood, contmmty, voltage, temperature nse, cohbrau en, sturstion, loss, etc. 27.0 PROTOTYPE TEST REPORT IE & VI-Report of a tut which is performed on a sonderd or typical exemple of equipment, metenal or stern.endis not I required for endi stem produced in or11er to subsentiate the acceptability of eques items. *his normany includes tests whch mey, or could be espected to, result m damage to the item (s) testeit
)
28.0 SUPPLIER SHIPPING PREPARATION PROCEDURE (Et - The procedure used by a supplier to propero Rnished metano6s or equipment for shipment from his foolity to the ichnete. ' Specification 7220-A-15e Rev. 6 Supp. A. Sheet 2 Of 2
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*1 oA SUPPLIER QUALITY ASSURANCE PROGRAMS
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, , ; Koecification 7220-C-23 ,, -l
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GENERAL REQUIREMENTS FOR i SUPPLIER QUALITY ASSURANCE PROGRAMS i FOR TIIE t i s i MIDLAND PLANT UNITS 1 AND 2-4 FOR l CONSUMERS POWER COMPANY ). i i SECTION CONTENTS 4 1.0 SCOPE. l 2.0 GENERAL PROGRAM REQUIREMENTS i 3.0 ADDITIONAL REQUIREMENTS
. 4.0 QUALITY SURVEILIANCE
.b-I APPENDIX I PROPOSAL APPENDIX II -SHELF ITEM AND BULK MATERIAL ONLY .
l, APPENDIX III SDDR INSTRUCTIONS ^ EXHIBIT A SAMPLE DATA SHEET 1
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AfrAcHMENT A '! , *} , Me 2% of @ i Specification 7220-G-23 , l i 1.0 SCOPE .' 1.1 This Specification provides the Quality Assurance requirements ; for the equipment, material, or services as specified in the purchase order, specifications, or material requisitions.
- 1.2 This Specification does not delete or revise (but is in addition to) those requirements defined by the procurement documents.
If a Supplier believes that an inconsistency exists between 4 this. specification and the procurement documents and referenced codes and standards, he shall immediately notify Bechtel f,r resolution.
~
j 2.0 CENERAL PROGRAM REQUIREMENTS 2.1 The term Supplier, as used herein, includes Seller, Vendor, Contractor, and Subcontractor. 2.2 The Project Quality Assurance Program is governed by AEC Regulation 10CFRSO, Appendix B, " Quality Assurance Criteria for Nuclear Power Plants". To satisfy this requirement, Bechtel's Suppliers shall maintain a Quality Assurance Program that conforms to the applicable provisions of ANSI N45.2-1971, ;
" Quality Assurance Program Requirements for Nuclear Power O
Plants", and to the other codes and standards as cited in the technical specificaH ons. 2.3 The Supplier shall estabMah and implement a Quality Assurance Program that conforma to the requirements specified on Data h Sheet 1,.and to the other applicable codes and standards as cited in the technical specification. 'Ibese Quality Assurance requirements shall apply to all aspects of the work necessary for carrying cat this contract, including design, procurement, fabrication, installation and testing (Data Sheet 1 is attached to this Specification for reference only. This complated form is ,1\ attached to the material requisition package) . 3.0 ADDITIONAL RIQUIREMENTS , 3.1 Within thirty (30) days after award of contract and prior to startf ag any activities relating to the applicable material requisition, the Supplier shall submit a controlled cony of hb Quality Assurance Program documents which defines the program that he will follow to meet this Specification. With his Quality Assurance Manual, the Supplier shall submit a facsimile of Data Sheet 1, on which he shall complete the 8
" Supplier Document & Paragraph References" column by listing 2 document identity numbers and applicable paragraphs which ---
satisfy the criteria imposed on him (as delineated in the lefthand column of the data sheet). Bechtel may approve or approve with comments, the Supplier Quality Assurance Program de cuments . Upon 'echtel's approval, activities may proceed. 1
AtrAcNMMT A snecification 7220-C-23 ~ Pasta 15 oF @ l l l If approved with comments, the Supplier may proceed, provided that he incorporates Bechtel's comments in the quality program documents (i.e. revisions, addenda, or amendments) and resubmits them for final approval within thirty (30) days. In no case will the supplier start activities without prior approval of the portions of the program applicable to the respective operation. Changes to the Bechtel approved program shall be submitted by the Supplier for approval in the same manner as original submittals. NOTE: Approval does not relieve the Supplier of the obligation to comply with the requirements of the procurement documents, including this Specification. If the program is subsequently found to be ineffective or inadequate in providing for acceptable control, Bechtel reserves the right to require necessary revisions. All proposed program modifications shall be submitted to Bechtel for review and acceptance in accordance with the requirements for initial program submittals. 3.2 The supplier, within 48 hours after detection, shall report to Bechtel each deficiency found in design and construction, which, were it to have remained uncorrected, could have affected g'~ adversely the safety of operations of the Nuclear Power Plant i' ~ at any time throughout the expected lifetime of the plant, and vhich~ represents: jp a) A significant breakdown in any portion of the quality assuran.ce program conducted in accordance with the requirements of ANSI N45.2; or b) A significant deficiency in final design as approved and released for construction such that the design does not conform co the criteria and bases stated in the specifications; or c) A significant deficiency in construction of/or significant da= age to a structure, system, or component which will require extensive evaluation, extensive redesign, or extensive repair to meet the criteria and bases stated in this Specification or to otherwise establish the a,dequacy of the structure, system, or component to perform its intended safety functions; or d) A significant deviation from perfsrmance specifications which will require extensive evaluation, extensive redesign, or extensive repair to establish the adequacy of a structure, system, or component to meet the criteria and bases stated in the specifications or to otherwise i establish the adequacy of the structure, system, or component to perform its intended safety function. 2
ATTAc14MEdT A
. bpecitication /220-0-2J /5\
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3.2.1 Any departure from the requirements of the procuring docu-l ments, which the Supplier intends to incorporate in the com-picted item or service provided must be documented on a Lupplier Deviation Disposition Request (SDDR). Deviation l requests shall'he submitted to the Bechtel Project Engineer i with a' copy to the Bechtel Shop Inspector if assigned within
; five (5) working days after detection. Specific . instructions are contained in Appendix III.
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P bT 7k_ H &EHT A Sp;cificatien 7220-G-23 l 7p~
- fA6C C6 y 4>
m s_,' 3.3 Bechtel shall be promptly advised in writing of all supplier detected nonconformances having a proposed disposition of
" Repair" or "Use as is". Whenever the disposition of a nonconformance is " Repair" or "Use as is", Bechtel approval shall be obtained prior to i=plementation. The Supplier shall also maintain a status list of all nonconformances.
NOTE: Repair - The process of restoring a nonconforming characteristic to a condition such that the capability of an item to function reliably and safely is unimpaired, even though that item still may not conform to the original requirement . Use as is - A disposition which may be imposed for a nonconformancs when it can be established that the discrepancy 9111 result in no adverse conditions and that the item under considerations will continue to meet all engineering functional requirements including performance, maintainability, fit, and safety. 3.4 Engineering and quality verification documents shall be submitted to Bechtel in accordance with the provision of Form C-321-D. Other records required by applicable codes and standards which are necessary to verify activities affecting quality, shall be f_ maintained by the Supplier in accordance with ANSI N45.2.9. t$i
' No quality related record shall be destroyed or otherwise disposed of without written permission of Bechtel (or their designee).
3.5 All quality related records, procedures, and qualifications shall be available for examination by Bechtel or Bechtel's authorized agents. 3.6 If the Supplier's function is limited to placing the ordcr
, with the actual Manufacturer, the Supplier shall be responsible for providing a controlled copy of the Manufacturer's Quality Assurance Program Manual to Bechtel within thirty (30) days after the award. The manual must meet the requirements outlined in this Specification. If the Supplier will store, repackage, or in any way handle the cocponents/ material before shipment to Bechtel, he shall submit his program in addition to the Mc ufacturer's. The Manufacturer's and Supplier's Quality Assurance Program documents must meet the requirements as outlined in this Specification that pertain to the activities he performs. In no case will the Supplier start activities without prior approval of the portions of the program applicable to the respective operation. (Standard " Shelf Items" or bulk /$1 material orders only, see Appendix II.)
3
. ArrecdMEt4T A Pace FI cf4o 4
4.0 QUALITY SURVEILLANCE 4.1 All designing, procuring, manufacturing, processing, assembling, testin?.. cx mination, and inspection operaticns performed by the Supplier and his lower-tier Suppliers are subject to surveillance by Bechtel or Bechtel's authorized agents. This surveillance shall in no way relieve the Supplier of any contractual responsibilities. NOTE: The term Surveillance, here, may include inspection, survey and/or audit. ! 4.2 The Bechtel Inspector (s), or his designated representative, shall be given free access to the Supplier's and his sub-supplier's facilities to inspect and report on the work in all phases of design, manufacturing, and testing. h 4.3 Ihe Supplier shall give the Bechtel Inspector at least five (5) < working days prior notice of all tests, and other check points in the manufacturing program specifically requested by the Inspector, after a joint review of Supplier's work plan (s) and this Specification. 4.4 If the requirements of this Specification have not been fulfilled, the Bechtel Inspector has the authority to refuse release for shipment. O l l O 1 4 l
a
, ATTAcf4WT A FMGe' E7 of 40
, spsciticataan (zzu-U-za
. t . i Appendix I a l PROPOSAL f (This sheet applies to the bid stage) With his proposal, each Bidder shall submit a summary description of the Quality Assurance Program to be implemented in the performance
- . of the work, or an uncontrolled copy of his Quality Assurance Manual
- or Procedure. This sha?.1 include information on the organization of q the Bidder, including the authority and responsibility of personnel performing'QA/QC functions. It shall also explain administrative '
] policies ar.d procedures to be used 'in carrying out the program. j The Bidder shall provide an' adequate statement of justification if his Quality Assurt ice Program does not need to contain all of the ~ elements or portions thereof called for in 2.3, above. Any modifica-j tions agreed to by Bechtel will be identified in the procurement docu-
- ments.
{ Bechtel will evaluate the description of the Quality Assurance Program i to determine its acceptability. An acceptable Quality Assurance 4 Program is a mandatory- requirement for placing an order. ._ j ' If a Bidder is currently performing to or has coupleted a Bechtel order j which invokes the requirements of this specification, he may, in lieu of submitting a copy of his manual, submit a letter listing the date j of Bechtel acceptance. the manual revision that is currently in effect or was in effect,'and a statement that it will apply for this proposed j effort. i Bechtel reserves the right to survey / audit the Bidder / Supplier to determine the adequacy of his Quality Program as ha proposed or is executing. a J l l O
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1
. ATT.W.MENTA TAGE E6 go@a Specification 7220-G-2a
, ,g
!O Appendix Il ' SHELF ITFJIS AND BULK MATERIAL ONLY t J k' hen the manufacturer's QA manual has been previously approved by Midland , Engineering the requirement for submission of the manufacturer's QA /g manual as described in paragraph 3.6 of G-23 is not applicable. Definition: Bulk Material - Standard commodities purchased for further processing by the Buyer into a finished item. Shelf Item - Standard items procured without modification. 1 i j r e I 4 4
>r 4
4 5 O k l
A-frE44AfflTA 5' AGE @oFM ~ oyesamis.6Avu st49-0-4J /5' , Page 1 of 3 #;-
*: \ '
- APPENDIX 111 SDDR INSTRUCTIONS 4
DEVIATION - any departure from the requirements of the procuring documents, which the Supplier intends to incorporate in the completed item .' , or service provided. 1.0 The Supplier shall be required to submit deviation requests to the. Bechtel Project Engineer with a copy to the Bechtel Shop Inspector within five (5) working days after detection. When this time limit l cannot be met, notification by telephone, TWX, etc. is acceptable; at that time, a revised submittal date shall be established. Any devia-
' tion is considered unacceptable until approval from Bechtel is in writing.
4 2.0 SDDRs must be supported by technically valid information that is sufficient for Project Engineering evaluation. When necessary, Supplier shall attach supporting technical documents (of reproducible quality) to the SDDR. One copy of each attachment must also be supplied to the Bechtel Shop Inspector, if assigned. O 3.0 Detailed instructions for completion of the SDDR are shown on the attached form and instruction sheet. 4.0 A copy of the SDDR, with the applicable attachments, is returned to the Supplier after completion of Bechtel Engineering actions. 5.0
- For approved SDDRs, Suppliers may be required by. Project Engineering' to change their engineering documents to reflect the "as-built" condition without extra cost to the Buyer.
A copy of the completed SDDR (including attachments) shall be included by the Supplier in the QC data package for the item (s) to which it ' 1
- applies. The~SDDR is considered complete when all entries'are made , including Bechtel the appropriate-verification signatures by the Supplier and inspector.
If no inspector, is assigned; for. the order, arrange-nents will be made'by Bechtel-Engineering for verification of
- implementation.
I O . 1 4 4 A
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Arrace e qA
., s S 6e so <1 io
*GCM Supplier Deviation Disposition Request (3
\ i
\/ NOTT. The reverse sace of riis ter m contains the FOR 6tCHM USE me Su? plt (R U$l ggg g g gg g g, ,
e,.,g., .. * ' J,e v. 044 Submin*4 tiem marked with an asterist t o e are lot hat,te' enir ses on*r I Suppher - _ Address - City & StJie . 29 Narae . . - . . . _ . . 3, Suppher's part No 4. Supplier's Part Name 5. Date Deviation Determined 6. Previous 5002 Ao & Ca[ 2 $woner's Orcer No.
- 9. Buyer's Part Name la Secnkt inspector Notified 11. 8Khtet Eng. Not.f.ed T Su)er's P.0 No. 8. Bu)er's Pari No.
1.' Oty er Serial No I!). Deviation Cescription iAttach ertra sheets, photograpns, sketches, etc. as risessaryl _ _. ___. . . .}.. _
~ ~ ~ ~ ~ **
~' '
~
_ -'_ _'~. - _
'~~ ~~
~~ - --
It Suppher's Disposition Classifgat.on: C Accept As is O Repair O modi'> Buyer s accuiremeni 15 Prapose3 Dispositsen aM Technstal Justification: 16 Assxiated succher Document Change Isit _ . . . . _.
- 17. Supphers Authorsted Representahve Signature _ _.
Title. ____,_ ,__. Name . . . _ . . . . _ . . _ . _ _ . Dak: _ _ _ . . . _ _ . . . . _
'la Bechtet lagtg Action : Engrg. Follow-up: Dag Change O other O 5eeca.i. Change
^] Accepted C Rejected Rejeckd Resubmit O Discieiine or Sueohers ati c*d .
- 19 6echteicies, tion Statement including Justification (Attrh estra snee4s, sketches etc. as r.ecessary) j p\ . ._.
i
/, J _. - _ _ .. _ _ .
V _/ m
*10 8ecntei Engineering Approval Dat VerifKaten 5tgnatures Date C5-
- 21. Suppher _. .
g O '22. Sechtel insp. , . . (D . ll et la 1
ATweh A
,, j'AGTE N N h
*
- T
'D D D / y6 W - O INST R UCTIONS FOR COMPLETING SDDR FORM Thes form is used bs a suppher to; .
al ' Nuuf, leechtet e.f desistavns from estabbshed requirements and docunient the suppber's proposed despea6 tion, and b) h ecord lies htet's appros at of the estabhshed resolution. A deniaban as aets departuee ' nam the requecments of the procunns documents whach the suppber intends to incorporate in the completed item or scruce prouM "*uatsoe lesposataan een be classahed as Repast, t/se-As-la, or Modify Requarement. Repair es defened as the penceu of restonne a nonconfornung charactenshe to a condation such that the capabibly of an stem to functioe-rehably and ulel* es tenempered, esen itsough that stem stati may not eunform to the onginal sequarennent. Hepast includes alterauons to the properters of the neaterial through heat treasang. weldant. metal deposition. chemical process 4ns.etc. Thas form ts not to be use,s for caws where Dechtet has pre,suusly pensa< led authoniataon to proceed uaeng a.3 approved repaar procedure govenng a spectfee type of repair; hom eter. records must be maintaaned for each speenfic sepair. Acceptance of the Suppher Deviation Disposshon Request by Bechteldoes not teleeve the Suppher from sesponsabihty for the accuracy, adequaev,or sudabdity of the item or neruce bems provided as dehned in the proeunns docussents. NOTE: Items marked by an astefisk (*) are for Bechtel use only. Block No. Entry Information l. Suppber's name and address.1.ast loner tier Suppber' name..nd locapon (City and State)if appiseable.
- 2. Enter the Suppher's order number if one has been asesned.
- 3. Enter Suppher's Part No. as appiscable froan the drawing. catalog, eritemal spreiheation, etc. If the Deviation Request apphes to all parts and addatsonal space is needed.a hat of parts to wh6eh the regerst appises may be attached.
- 4. Enter Suppher's Part Name.
S. Enter the date and the method (Spet, review. NDE. dielectric trat.etc.) used to determine the de'viation. 6. List any s.revious SDDR's and their dates that have been e=bru itted for sinular deesations requested on this Purchase Order. 7 Enter the Bechul Purchase Order Number. 8 Fnter the Bechtel Requisshon item number and the part tag or code number asal appears tn the requesteon. If additional K space es needed.a separate sheet man be attached.
)
/ 9 Enter the Rechtel Part Narne af one has been assigneJ.
%d
- 10. Enter the date and the method (Tw X, phone, letter. etc.) used to notsfy the Rechsellaspector.
II. Enter the date and the method (TW N. phone, letter, etc.1 used to notify Bechtel Emeneering. 12. As appheable, enter quanhbes or senal nun'bers of the items to which the devastion apphes. If not senalized record lot, batch heat or other applicable sdenutvina snformation. 13. Desenbe the deviating charsetenstics and dehne the estent nf the out of specinnation cond6Laon for each identAhed piece affected. Identate the location ut the deveahng charactenstic by pnnt coordanates et speethe locesson, as appucable. Attach e stra sheets. photographs. sketc hes, etc.. as necessary.
- 14. Identale disposition classaf cation.
15. Desenbr Use proposed dispositeun and provuse techneesi susufseation for Seehtel%eentuation,if the deviation is correctable by sepair submst a detailed repair peucedure se reference the precedure prevecialy approved (Levell) by Bechtet ser har en smalar situatsons. Proside Rechtel control number. suppher enntrol number and peacedure title. 46. Idenhfy the nature of rhangen that may result on assocasted suppber documents (dramangs. specs.. procedures. Installation enstructaons. e te.l. S t. Fater and theseined date name tisped at pnnteelt. signature and taste of the mappher respresensative authonaing the daspositaon sequest
'lA f nier ari X en the appheabic buses les dehne the attoon required bv Sechtel Praseet Enganeering.
*19 Pen..de spinvenate susteheatenn far the Bechtel acteunts) endiented an 8 heck 18. erhen enantes to drawinsa.speenheahons, treuessteonn. or other Heentel doevenents are inmhed, each document should be sdenhised and the associated chante bns fly desenlee d if other disceplenes or supphees are affected. endecate who they are and the document that insbeled ribaluhun of that involtement. *'stthes" folnow-up achon (et the need for addetsanal Bechtel calculahons, addstsonal draw seas ne sketches, enspechan hs a Pensec& Fngencenna repress atahve, etc.) shused also be sdenhhed here.
*20 G% - Sesnature ni the respanneble paesphne Ornup hspervisor approving the Engsmeerang action and the approval date.
Qt
%snature of the Quahlv t sigineer who revien ed and enneurred with the disposition and the date sagned.
Pt. - Apprusal ugnature est the licehtrl Pensert Engsneer and the det:' ugned. 25- Mgnature ut the suppher*# ens #=echet ne edher n presentatsve authansed la eenf t
- hat the accepted despostion was correetly aceaseitphshrd.
'21
[ Mgnatuer of the hrs h tel Inspreher ser other reparreentatete verifysag tha- te accepted desposstaan was correctly act um pItshs d. k I G
ATT AC+4 /AEt*T A QUALITY ASSUI .NCE PROGGAM ELEMENTS g}f3 g [o { D/ 'A SHEET 1 ) 7220-C-23
. O. *~
THE FCLLOW'NG ANS M5.2 1971 QUALITY ASSURANCE i {qj'N PROGR Af." ELEMEN ., AFPL TO THIS SPECIFICATION. l TO DE COMPLETED TO DE COMPLETED BY Tl4E SUPPLIER BY 1:LCitTE L SUPPLIE 1 DOCUMSNT AND PAR AGR APH REFERENCES APP LIC AC'_E QUALITY ASSURANCE PROGRAM ORCANIZATICN DES;GN CCNTMOL PROCURE?. ENT DOCUMENT CONTROL INSTRUCTION
S. PROCEDURE
S. AND DRAWINGS DCCut.;ENT COP. TROL . CO?;TP.0L OF PURCHASED M ATL., EQUIP., & SERV:CES = puv
=
i;.,;... . .. u.7, TROL OF MATLS., PARTS.COMPONEtsTS CONTROL Or S?ECIAL PROCESSES l /~T I g () ] ::u;CT:ON TL5T CONTROL CONTROL Of f.tEASURING AND TEST EQUIPMENT HAP.DLING, STORAGE AND SHlPPING INSPECT:CN. TEST AND OPERATING STATUS NONCONFOItNGITEMS
] COis 1ECTiVE ACTION QUALITY ASSURANCE RECORDS ,
AUDITS
] OTHERS i -
l
! J j
() b NO. l DATE I REVISIONS BY Cl-!EC.<ED l Af PROVED ;
~~g l
JOB NO. __ 7220-G-23 (j Of'CUMENT NO. l F.EV._)
. . . . . . . . I
DAfd/4E47 k QUALITY ASSURANCE PROGRAM ELEMENTS PAGE sd 9 @ ( DATA SHEET 1 )
- 7. _
l ; THE FOLLOWING ANSI N45.2 1971 OUALITY ASSUR ANCE \ _, ,/ PROGR AM ELEMENTS APPLY TO THIS SPECIFICATION. TO BE COMPLETED TO BE COMPLETED BY THE SUPPLIER BY BECHTEL SUPPLIER DOCUMENT AND PARAGR APH REFERENCES APPLICABLE QUALITY ASSURANCE PROGRAM ORGANIZATION DESIGN CONTROL PROCUREMENT DOCUMENT CONTHOL INSTRUCTION
S. PROCEDURE
S V DOCUMENT CONTROL CONTROL OF PURCHASED MATL., EQUlk. & SERVICES IDENT. & CONTROL OF MATLS., PARTS,U MPONENTS CONTROL OF SPECIAL PROCESSES t'N ( V INSPECTION
-/ .
)
TEST CONTROL CONTROL OF MEASURING AND TEST EQUIPMENT HANDLING, STORAGE AND SHIPPING er INSPECTION AND OPER ATING STATUS NONCONFORMING ITEMS (
] CORRECTIVE ACTION
# QUALITY ASSURANCE RECORDS AUDITS OTHERS l
l l
, A l 0 1 -(1-% Issued for bids ufrY6+ JAK Jc- #M N ~ CHECKED APPROVED
(} NO. DATE REVISIONS BY 7220
^^
JOB NO. Epoxy or Phenolic DecontaminatiVe DOCUMENT NO. REV. Surfacer 7220-A-15(a) DATA SHEET 1 0
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, , hTTA4 /NENT A
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Pace 34 c54o _B Bechtel Associates Professional Corporation (~) E ,, \s' c f 11 EI tE "e
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I 2E C8-AE jj GENERAL PROJECT REQUIREMENTS
/ - er Eh (PURCHASE ORDERS)
E3 "i bE II Ej MIDLAND PLANT, UNITS 1 AND 2 4E pu CONSUMERS POWER COMPANY Q d% \v/ t EY S:
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- 2 ..
c6 W. If I/'/F Revised as sho m - Sheet 2 /p ,g> b p; 5\ ]/yt .- .rt Revised as shotm - Sheet 2 LAM ff'? , 5 -} [ ,( f ({1 I, j , _$. I'8-/-% Revised as shown - Sheet 2 h t II
~ 424
/3\ 1/10/7D Revised for Project Standard /,( _g gyg ij 3/16/73 Revised and reissued by Bechtel Associates
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f ei Professional Corporation d, , 3yV i! 1.i10/29/70 Updated for Project Standard _ , /v/ f 4 d /j , 7- -_0__4 ~' 5 - d 9 .nngjued for Project Standard -
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( j __A .12 - 1 'i - t'R Tecuca fnr Drnjnce c*ananva r e r- ccT h u_:_ a- Dan af visio= s o *c'a e, en = l acee ,
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/ 6 7220-G-1 i c.
hWW W W M bbtf& l i Yt T 'A I ^ SHEET
^T T SHEET TEST SHEET SHEET gfy 5HEET SHEET SHEET gEV EV g R R v E 6 l l l l 1 l 2 6 l l l l l 3 4 I I ll l l! ! !
4 I i l i 1 1 I i i s 3 s lj l l I i l l i j Exhibi L l l A-1 6 i l A-2 6 I l l I l 1 l l l l } l l I ! l I I i i I ! l
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i 6 h: Revised Exb 'iit A GD c$ 7-I
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s P3iged@egt s 4 'h + W.t"s?"r:mkd"X"6fodg'3 # _ CATE REVISIONS BY CHK*D l AFr*D N O. DATE REVISIONS BY CHK*O Ar,
- NO.
[ < FACING SHEET JOB No. 7220 4 MIDLAND PLANT UNITS 1i ' r" -
~
cCHI GENERAL FROJECT REQUIRD:ENTS 4 3I (PURCHASE ORDERS) 7220-G-1 0 Sheet 2 of s 8___________
\
l A TTEHMdT A l 7220.G-1, Rev. 4 PAGr3G @ l
* * ^
-, CENERAL PROJECT REQUIREMENTS (V 1.0 S:tc Information and Locat ion Tne plant will be built and owned by Consumers Power Company on a site located generally-vithin Section 27 of Midland Township, Michigan. The site is on the south side of the Tittabawassee River, across the river from the Dow Chem-ical Company's Midland Plant.
The plant site is accessible via Interstate Highway I-75, U.S. Highway 10 and by the Chesapeake and Ohio Railroad, with a railroad yard immediately west of Saginaw Road, on the south side of the main line. The Midland' site is on level terrain of the lower peninsula of Michigan. Final plant grade elevation will be approximately 634. The average annual precipita-tion is 30 inches which includes 33 inches of snow fall. Mean monthly temper-atures range from 25'F in-January and February to-72'F in July. The highest and lowest recorded temperatures are 106*F ar.d -30*F, respectively. 2.0 Schedule The scheduled date of commercial operation is March 1,1981 for Unit 2 and March 1, 1982 for Unit 1. fN Scheduling and execution of the work must conform with established overall plant construction schedules. To implement the above, the Seller shall produce acceptable documents, render required assistance, expedite deliveries, conduct tes ts, e tc. , for itens within his responsibility. When called for in the technical specification, the Seller shall submit a - proposed comprehensive work schedule for engineering design,- fabrication, shop testing, and shipment. The Buyer will review this schedule and the Buyer and the Seller shall agree upon a final schedule to which the Seller shall adhere. 3.0 Division of Responsibility The extent of the equipment and services to be provided by the Seller is described in the technical specifications. However, it'shall be the Seller's responsibility to ensure that the equipment and services furnished will be complete and operable and of~the' quality described. The Seller will have the right of inspection and review of work furnished by others insofar as it may affect his costs, warranties and other responsibilities. 4.0 Drawing and Data Submittals All drauf ngs submitted by the Seller must bear the following identification in fs_3-/ or near the title block: Midland Plant, Units 1 and 2 Consumers Power Company (Mame of Equipment) (Buyer's Purchase Order Number) Sheet 3 of 5 /i a
- ATTAC%%ENT 7220-C-1, Rev. 5 gg q og
.. /* .
(A) The front page of each instruc tion manual shall contain a brief recapitulation V of the equip-ent soccified. This recapitulation shall include the titic, equipment number, and purchase order number assigned by Bechtel to this equip-ment. Also, the Seller's designation of size, type, model number, e tc. , should be entered for each item on the purchase order. With regard to the text of the manual, it shall have non-applicable paragraphs and illustrations crossed out. A complete manual shall also include principal drawings, data sheets, and char-acteristic curves for the equipment purchased. Material and equipment = hall be-f urnished in the maximum sub-assembly sizes consistent with delivery restriction. Shop f abrication shall be to maximum extent to minimir.e field erection or instal-lation. 5.0 Shipment The Seller shall prepare all articles for shipment in such a manner as to pro-tect flanges, nozzles, machined surfaces, and other finished parts from any damage to which they might be subject both in transit and handling. The Seller shall be responsibic for, and shall repair or replace at his own expense, any and all damaged equipment where damage was due to improper preparation for shipment. , All Q-listed caterial, components, or items shall be packaged, shipped, received, ~ d stored, and handled per the requirements delineated in the procurement documents. Each piece of equipment shall be identified with a securely-fastened metal tag, bearing the purchase order number and the appropriate equipment number as spec-ified. Packing slips showing all equipment and/or material shipped shall accompany all shipments. l ,f 4 V f, . 0 Supplier Deviations. (For Q- Listed purchases follow instructions in specificatic3" 7228-G-23 for RDDR submitta { ' 6.1 Any departure from the requirements of t e procuring documents, E previously approved by Bechtel or Bechtel approved Supplier drawings [ or specifications which the Supplier intends to incorporate in the co=pleted item or service provided must be documented on a Supplier
, Deviation Disposition Request (SDDR) . Deviation requests shall be submitted to the Bechtel Project Engineer with a copy to the Bechtel J Supplier quality representative if assigned within five (5) working h~' .-
days after detection. When this time limit cannot be met, notification by telephone. IWX, etc is acceptable; at that time, a revised submittal date shall be established. Any deviation is considered unacceptable c until approval from Bechtel in writing is obtained. fil 6.2 SDDRs must be supported by technically valid information that is sufficient for Project Engineering evaluation. When necessary, Supplier shall attach supporting technical documents (of reproducible quality) to the SDDR. One copy of each attachment must also be supplied to the Bechtel Supplier quality representative, if assigned. 1 ) i 6.3 Detailed instructions for completion of the SDDR are shown on the j attached form and instruction sheet. (Exhibit A) It is required that , 1 all portions of the SDDR applicable to the Supplier be completed { prior to submittal to Bechtel including Block No. 10. If the entries are not completed, the SDDR will be returned to the Supplier for , inclusion of the pertinent information. 3 hU 6.4 A copy of th- .DDR, with the applicable attachments, isreturnedandhU. shall be malauined by the Supplier after completion of Bechtel Engineering actions. 6.5 For approved SDDRs, Suppliers may be required by Project Engineering to change their engineering documents to reflect the "as-built" condition without extra cost to the Buyer. Shnet 4 ors
S-AfrAGH AW k 7220-G-1, Rev. 5 gg y, o A. l
/
6.6 A copy of the completed SDDR (including attachments) shall be included by the Supplier in the data package for the item (s) to which it applies. The SDDR is considered complete when all entries are made including the appropriate verification signatures by the Supplier and bechtel Supplier quality representative. If no representative is assigned for the order, arrangements will be k made by Bechtel Engineering for verification of implementation.
/3 NN '
n is.-} Sheet 5 of 5
ATTMMMarA ru3s se op 4 ExhiDit A 7220-C-1, Rev 6 % fcf y,., Supplier Deviation Disposition Request raae . or 2 y [v') - NOTE: The reverse side of this form contains ther FOR EECHt1L USE FOR SUPPUf R USE instructions for its pfeparat!on and use. eBetw w u
- 0aw Nw Suppher $DDR No. Date Submitted tems marmed with an asterin tot are lor Bechtet entries oniv.
Supplier shati ccmpete all blocu ltnrough ls asth c!ack ink or type *riter. Use t.A for f.et Apphcaaie.
- 1. Suppber Address City & State Zo Name; .
4 Sucpf.er's PariName 5. Date Deviahon Determined 6. Previous 50DR M & Oter
- 2. Suponer's oroer No. 3. Suppher's PariNo.
ICL Bechti ins;=ctor Notified 11. Bechtei[ng. Not.fisc 7, Bechtel P 0. No 8, Becnte Part No 9. Bechtet Part Name 11 Cry or Serial No 11 Dev:stron Cescript:en i Anacn ertra snects, pnotographs, stetcnes, etc as naessary; 14 Supher's Disposition Classification: Use As is O aepair s O moe:tr ecnteiaccu rement
- 15. Preosed Discosition and Technical JustificJtion iAttach entra sheets she'ches etc. as ficcessaryl
( (./
- 16. Associated Supober Document Change tst:
- 17. Cost Effects:
11 Suechers Authorized Representative
Title:
$sinature: Oak: Name. o }9. Sechtel [ngrg. Action : (ngrg foll>-u O o 9 chan9e []otner O * ] 5pecteq. Chan9e Dnposition D rsoesition D otner 5s. ochers A'tected O Accesea O aciecree
- 20 Bechter Disposition Stavrrent including Justifica' ion (Attach extra eeets, sketches, cE as necessaryl
/
i t V Cate Cate Verincaten Signatures
*21. Bechief Acceo'ance G5 22. Supatier _. .
g *23 BKhtet supplier roe Quality Representative . . . . . - E U D '" Y ' dAccocc7s .
A_
~' ~
ATTPt.WfStT A 1%CQ q g Exhibit A 7220-C-1, Rev. 6
- Page 2 of 2 1 lNSTRUCTIONS FOR COMPLETING SDDR FORM
( V (Use Illack ink or Typewriter) 1 his form as used by a supplier to: ' 4 Notify Bechtel of desistions from approved technical requirements and document the suppher's proposed disposition,and with their technicaljustification b) Record Bechtcl's dnpontion of the SUDR.' A dcviation n any departure from the techmcal acquirements of the procutirip documents which the suppher proposes toincorporate m
- the completed item or senice prosided. Devution dnpusation can bc classified as Repair, Use-As-Is, c,r Modify kcquirement.
Rcrast n defmed as ths prckess of resturing a nonconforming characterntic to a condition such that the capability of an Item to fu stion sclubly and salcly is Wmpaired, even though that stem still may not conform to the origmal requnement. kcpair includes alterations to the propertics of the niatcrial thrriugh heat.treatmg, sciding, metal deposition, chemical procewing, etc. Thn form is not to be used for cases shcre bechtel has previous!) provided authorization to proceed using an acsepted repair procedure covering a speciGc 13 pc of repair; however. records must be maintained for cach spccific repair, i Bechters engineering action .ad Sposition statement does no: febeve the Supplier from responsibility for the accuracy, sJequacy,or suit-abihty of the item or scruce being provided as defined in the precuring documents, not does it constitute waiver of the right to renegotiate the terms of the procuring documents. " NOTE: Items marked by an asterisk (*) are for Bechtel use only. I Block No. Entry Information
- 1. Suppuer's name and address. I,ist lower-tier Suppher's name and location (City and State) If applicable.
- 2. Er>ter the Suppher's order number if one has been assigned.
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- 3. Enter Supplier's Part No. as applicable from the drawing, catatos, internal speelhcation, etc. If the Deviation Request
. apphes to all parts and additional space is needed, a hat of parts to whsch the request apphes may be attached.
- 4. Enter Suppber's Part Name.
- 5. Enter the date and the method ISpec. review. NDE, dielectric test,etcJ used to disclose the deviation.
- g. Lnt any pressous SDDR's and their dates that have been submitteJ for deviations requested on this Purchase Order.
- 7. Enter the Bechtel Purchase Order Number. l
%d 8. Enter the Bechsel Requisition item. part, tag or code Jiumber as it appears in the requisition. If additional space is needed, a separate sheet may be attacheJ.
- 9. Enter the Bechtel Part Name if one has been assigned, t 0.- Later the date and the eneihod ITWX, letter,etcJ useJ to notify the Bechtcl Suppl er Quaht) Rcpresentaesse.
< tI. Enter the date and the method (T% X, letter,eic] uwd to noufy Bechtel Engmeering. ,
- 12. As appticable, enter quantatics or serial numbers of the items to which the deviation apphes. If not seriahred. record lot, j batch, heat or other apphcabte edentilsing mformahon.
1 13, Describe the deviating charactenstics and defme the estent of the out-of. specification conditic for each identified piece effected. Idenufy the tocation of the devtating characteristic by print coordinates or spec.fac location, as apphcable. ALtach estra sheets, photographs, sketches, etc., as necessary.
- 14. Identify dirposition elaasification.
e 15. Desente the propowd doposition and provide technical Justification for Bechters evaluation. If the deviation is correctable by repair, submit a detailed repatr procedure or seference the procedure previously accepted (Level Ilby Bechtel for use m similar situations. Provide Bechtel control number, suppber control number and procedure title. 1 i 16. Identify Lt.c nature of changes that may result on associated suppber documents tdrawings. specs., procedures.insta!!a' ion instructions, etc.).
- 17. I nief the cost impast of the subject deviation.
I R. Inter the name it> ped or printed), ugnature and title of the supplier reprewntatise authorizing the disposition request and date signcJ.
*19. I nter an X in the applicable boses.
'20. Proiide appropriate justif teation for the Beshtet actmnto indicated in !!!ock 19. When changes to drawings. specit:Jati ms requintions, or other lle.htcl documents are imobed, each document should be identified and the amiated slunge bneth desti5ed. If ether supphers are attected,indicaie w ho the) are and the document that initiated resolution of slut msobemtnt.
Other" tolhim-up a. tion tes, the need for additional lieshiel calculations, additional drawings or skets-hes. inspection by a
- Project I rigancermy rs presentatnc, etc.) should aho be identilied here..
*21 GS .- Signature of the responsible Drwirlme Group Supersisor accerting the I nrmeering astion and the date signed.
f em. PL - Signature of tN Heshtel Project I ngineer .ir:J the date signed.
< 22. Sivnature of the uprheriinspector or other representatise authorpeJ to sertt) that the awerteJ diesition was sortestl) accomphshed.
'21 Siyniture of the licshtel Suppher Quaht) P vreuntathe or other reprewntatise serif >ing that the acceptcJ dnposition a o correstly assomplished.
NOli ? A sop) of the completed SI1DR form stull be mstudeJ bs the suppher in the UCJ.ita padace for was h item to Sh 0 it appiin
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DB n( _l a m n JS NTA J. L. Manta. Inc. 7757 South Chicago Avenue Cnica;;o. litiros 6o619 Phone (312) 731-5300 TE LE3 MANICQ CGQ 29$o April 15, 1980 A Letter # M-450-178 BECHTEL POWER CORP Bechtel Power Corporation JOB 7220 P. O. Box 2167 Midland, Michigan 48640 PEMO W //-/6 - Attention: Mr. L. E. Davis Re: Job 7220 Midland Project Containment 2 System 9 Delarination Bechtel Letter A-15-B-308 Gentlemen: Eaclosed please find a copy of the sequential listing v'[ . of steps for the application of System No. 9 as done by J. L. Manta, Inc. ki se, plc;;c f-1.n d_- e nc.le c e d : e s p ;, ;f th ; ; c ; 4,rg%,t-e 3-or " c = ~_ b o r iL 1474 ne r o e. n o c r o s If I can be of further assistance to you, please feel free to contact me. Thank you. Yours very truly, J. L. MANTA, INC. u . .. .l k. 1,4._ T- ,
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94L 2cy & JL fo/(NTA SURFACE PREPARATION FOR SYSTEM #9
- 1. Scrape off loose fins 6 protrusions
- 2. Wet down wall with clean water
- 3. Spray on a solution of warm water & T.S.P.
- 4. Scrub surface using a stiff bristle broom
- 5. Rinse wall again with clean water
- 6. Air blast with 90 - 100 P.S.I.
- 7. Allow to dry APPLICATION OF NU-KLAD 117 SURFACE TEMPERATURE 500 - 80
- 1. Tape off embeds
- 2. Mix Nu-Klad 117 per J.L.M. 450-A-1, Paragraph 6.4.2
- 3. Material applied with American Olean Groutmaster Trowel 4.
Move material over surface left to right and finally in an upward direction removing excess material
- 5. Allow to cure 24 hours @ 73 or longer A. Per manufacturer's data sheet; surfaces to receive 6.
protective coatings may require a second application. Second coat applied same as Item 4 above
- 7. Allow to cure
' 'N APPLICATION OF AMERC0AT 90 SURFACE TEMPERATURE 50 - 800
(
- i. 1. Mix Amerocat 90 per JLM 450-A-1 6.1.2 thinning with no more than 1 pint #6 thinner / gal.
- 2. Applied with Graco Airless at 8 - 10 mils wet film thickness.
Each spray overlaps previous pass by 50%. Large areas cross hatched.
- 3. Allow to cure 8 Hrs. @ 50 5 Hrs. @ 60 3 Hrs. G 700
- 4. Second coat required to attain topcoat of 10 mils dry film thickness, applied same as Item 4 above.
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'El Packagirry (unitized) . . . . . . . 5.5 lbs. unit net w.ighte: -- . ~. -
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a .- . .. - Envircrrnental Cerriitions - Optirmm ter.peratutes for handlfrsfEixi uss'ef'1,u-KUd 117 EE~c'Etv.een 65 ani 80*F. F.gdving, application,_cr_ set;tihcr bele(65'E" cr alcve 80T certain precauths aret requirei. . ,. e m -. :;;..,.m .
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_ . . . . . . .__.s. . OG N e Precaraticn - W:rter cured cercrete. Reicve all firI,, sharp surface projecticns, k.f .i,ed edges arri ridges. Rancve by cc er grindi:x3 cr rub heick (r-M nw dum stene), - c T ist concrete surface using high pre-e (100 psi) cogrmM air.. High pressure
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i Md hardener to resin ecupenent. Mix until. uniform. D:pty:appp%tely 1/2 of filler . gnent into 1 gallon centainer, add mixed resin / hardener. t nix. tirrcughly Md re-
- aining filler cc:penent and mix tieroughly until naterial.-is.:=Mnimly:blerxled ,to a scrhable censisterry. : :- u-
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- Title 29 and applic=bla state arxi incal regulations regarding;requirmwnta.for use of.
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with local applic= - hie regulations. In - case of fire, bIarsiets ha ifhw dry ch==fc=1_, - l, .2 .
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$80 APR 2 81980
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BECHTEL POWER RP.
,. JOB 7220 '
Per _ _ BE:;HTEL ASSOC.PA0f ESSiCNALCORP. p SUPPLtER DOCLs/ENT STAuP F t O woma uv enwes,. P 01STRIBUTlON z a m uw, Detto. suoun ru.At onwim. ' t0FT 1 Q pfvtrt AhnPtsufwsf. WOMs W Av ritNitD $wtJECT TO i l cast'
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Put,.e cmtms l I G.oson NU-KLAD 117 m ^ s 'o*" " '62' CORROSION RESISTANT PRODUCTS (rormerly 1871N)
~~EC N ICAL JA~~A S - E ET 11/78 i Supersedes R3/78
- Excellent filler for formed concrete or concrete block
- Fills / seals most voids and air pockets in a single application
- Easy to mix; easy to apply Nu-Klad 117 is used to fill holes and voids in formed concrete or concrete block to provide a smooth surface for the application of f.mercoat protective coatings. Nu-Klad 117 fills voids in formed concrete st:rfaces up to 3/4 inch ;
across as measured in their largest dimension. A single application will fill l or seal most air bubbles and holes. PHYSICAL DATA _ ,es., , Col o r . . . . . . . . . . . . . . . Off-whi te ( ! ' Components ............ 3
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Description . . . . . . . . . . . . . Epoxy resin, hardener, filler Cure ............... Chemical reaction between components Surface . . . . . . . . . . . . . . Formed concrete, concrete block, Nu-Klad 108 Primer / Sealer Application . . . . . . . . . . . . Squeegee Recomended thickness . . . . . . . Not applicable Calculated coverage / unit ..... 715 mil sq.ft. (Based upon application over a smooth and flat surface; does not include material for filling of air bubbles or holes.) Working time (ASTM C 308) . . . . . 45 to 60 minutes at 73 F Ready for epoxy coating . . . . . . 24 nours at 73*F , Cleaner . . . . . . . . . . . . . . Amercoat 12 ! Packaging . . . . . . . . . . . . . 5.5 lb. Unit: resin in 1/2 gallon can; hardener in pint can; filler in gallon can Shipping weight . . . . . . . . . . 7.0 lbs. Freight classification. . . . . . . Acid proof building cement Shel f l i fe. . . . . . . . . . . . . 1 year from shipment date when stored indoors in unopened, tightly sealed containers at 40-100 F TYPICAL PROPERTIES Density (modified ASTM D 71). . . . 92.5 lbs./cu.ft. ( Bond strength to 3,000 psi concrete G)' (ASTM C 321) ........ 300 psi (concrete failure) Compressive strength (ASTM C 579) . 6900 psi after 7 days at 73 F _ 7 7-> b - A 7 'I 8.
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,y . APPLICATION INSTRUCTIONS SURFACE PREPARATION. In nuclear facilities, Nu-Klad 117 is applied over formed concrete that is either (1) water cured, or (2) cured using Hu-Klad 108 Primer / Sealer as a curing membrane * (See Nu-Klad 108 Primer / Sealer Product Data Sheet and Appli-cation Instructions). Concrete must cure a mini 6um of 14, days and until 80 percent of its physical properties have been attained before application of Nu-Klad 117. Formed surfaces (verticals and overheads) must be adequately vibrated to minimize air bubbles and holes. Select a form facing material which will produce a smooth, hard uniform texture on the concrete. Do not use form release agents, such as form oils, that will deposit a residue on the con-crete surface. ' Use only film forming release agents that will not impart residues onto the surface. Repair all defects. All fins and projections must be completely removed. Air blast formed surfaces using high pressure (100 psi) compressed air to open air bubbles or holes crusted over with a thin laitance layer. High pressure air line must be equipped with operating oil and moisture separators. Nu-Klad 108 Primer / Sealer is not normally required on concrete block walls 7- in nuclear facilities. Concrete block walls must be laid plumb and square with flush joints. DO NOT RAKE JOINTS. , Formed concrete and block surfaces must be clean and dry. Vacuum surfaces to remove dust or dirt. Remove contaminants such as grease or oil using a solution of trisodium phosphate, approximately 6 ounces / gallon (50 grams / liter) followed by a clean water rinse. Repeat as necessary to completely remove all contamination. If Nu-Klad 108 Primer / Sealer has aged beyond.one year, roughen by abrasive blasting using 60-80 mesh silica or equal. Remove al.1 loose material. ENVIRONMENTAL CONDITIONS If Optimum material and surface temperatures are between 65 and 80*F. components are below or above this range, store in an area within 65 and 80 F until they have reached the proper- temperature Below 65*F workability is reduced and application is more difficult. Above 80*F working time de-creases. Nu-Klad 117 can be applied to surfaces that are as low as 50 F; although curing will be retarded, typical properties of the cured Hu-Klad will not be affected. Application under direct sunlight and rising surface temperatures can result rN in bubbling of the filler compound due to release of air or moisture from Q the concrete. Shade concrete that has been exposed to direct sunlight for 24 hours prior to application of Nu-Klad 117, and keep shaded until after initial set has taken place. Where surface temperatures are rising, it may be necessary to postpone application.
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ATva mt47 o { j%GC4orO ( ; g_I ). I fG Mix only full units. Make no additions or deletions. Any deviations will inhibit curinE ano alter final physical properties. Do not mix more material than can be used within the working time: 45 to 60 minutes at 73*F. itaterial which has begun to set is unsatisfactory and must be discarded. A power mixer is recomended, such as a 1/4" Jiffy Mud and Resin Mixer (avail-able from Goldblatt Tools, Kansas City, Kansas) thucked into a suitable power drill. Before combining, thoroughly stir resin component to disperse pigment. Add hardener to resin component. Mix until uniform. Empty approximately half of filler component into a 1-gallon container, and add mixed resin and hardener. Mix thoroughly. Add remaining filler component and mix thoroughly until uniformly blended to a workable consistency. To check material for working consistency, scoop out a quantity of filler compound on the end of a spatula or putty knife. Holding the blade in a vertical position, allow excess material to flow off the end of the blade. Approximately 1/2 inch of material should remain on the blade. If this does not occur, continue mixing until this can be attained. Nu-rslad 117 is ready for use imediately after mixing; no induction time is required. APPLICATIJN ("; Applj Nu-Klad 177 Epoxy Fillec Compound to the concrete surface using a V short nap rohair roller or trowel. Spread and work material across the surface using an epoxy floor trowel with flexible rubber face such as American Olean KR Groutmaster, rubber bladed squeegee, or steel trowel. Continue working the compound across the surface, apply pressure to fill or seal most voids and achieve a smooth finish. Leave only a slight film above the surface plane. The filler compound should appear somethat trans-parent allowing the concrete surface to remain visible. A single application will normally provide a suitable surface for application of a coating over concrete block. - For complete filling and sealing of formed concrete surfaces to receive protective coatings, a second application nv/ be reqJired. Allow overnight curing at 73 F, or until first application .s firm. Do not exceed seven days at 73 F before the second application. When making second application, use only reasonable pressure to build the film thickness -to approximately 5 to 10 mils above the surface plane, and at the same time' remove ridges left during spreading of the filler compound by the application tool. Repair all holidays with Nu-Klad 117 before applying coating. CLEAN-Up Immediately after use, clean all' mixing equipment and application tools with . Amercoat 12 Cleaner. f" ,. READY FOR TOPC0ATING , ws Allow 24 hours cure at 73 F before applying recommended epoxy topcoats. I Nu-Klad 117 which has cured outdoors beyond 10 days at 73 F or 21 days at 50 F must be roughened by abrasive blasting before applying epoxy topcoats. If Nu-Klad 117 has cured beyond 6 months indoors, special treatrent may be re-quired before topcoating; consult your Ameron representative.
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[cw cb c . 4 ,5METY ltJCMTIO1 PAGg 6 cp 6 ! /~ to.Klad 117 Filler k Caution! May cause irritation. Contains silica , Avoid breathing dust. Repeated inhalation over an extended period of time could cause injury to the lungs. Consult U.S. Department of Labor Code of Federal Regulations Title 29 and applicable state and local regulations regarding requirernents for use of dust respirator. In case of spillage, vacuu:s or wet down and then sweep. h ortant: Fead precauticas shown for Resin and Harderer conponents. hu Klad 117 Resin Cautto..! May cause irritation. , , Contains liquid epoxy resin.. Avoid contact with skin and eyes. Keep container tightly closed and upright to prevent leakage , when not in use. In case of spillage, absorb and dispose of in accordance with local applicable re%ations. In case of fire, blanket flames with dry chemical. carbon dioxide, or foam. ! First Ald: In case of skin contact, wash thoroughly with soap and water; for eyes, flush in-cediately with plenty of water for 15 minutes and get medical attention. fr.;iortant: Read precautions shown for Filler and Bardener components.
, Nu-Klad 117 Hardener ., ,
Danger: Liquid may cause severe eye and skin burns. Skin contact may cause serious delayed dernatitis. Vapor hamful. Contains polyamines p)_ g v Do not get in eyes, on skin or on clothing. Use protective clothing, gloves, and face ,rotection to prevent contact. Protect exposed areas of skin with a barrier cream. Prolonged or repeated skin contact r.ay cause sensitization and rash. If sensitization occurs, avoid further exposure - to this pro het. Wash thoroughly af ter handling. Remove contaminated clothing and launder before reuse. Avoid breathing of vapor. Use only with adequate ventilation. Keep closures tightly closed and vpright to prevent leakage when not in use. In case of spillage, absorb
, and dispose of in accordance with local applicable regulations.. In case of fire, blanket flames-3 with dry cher41 cal, carbon dioxide, or foam. Toxic fumes of oxides of nitrogen nay be formed on burning.
I First Ald: If affected by inhalation of vapor, remove to fresh air. In case of contact, in- , mediately flush skin with plenty of soap and water; for eyes, flush with plenty of water for
,i at least 15 minutes and set medical attention. . .
I important: Read precautions shown for Resin and Filler cbponents.
- Af ter components are nized,
'the amiTe~ vapor hazards are sharply reduced. After mixing, and during application, avoid contact with skin and eyes. Department of Labor Material Saf,ety Data Sheets available on reqgest.
IF YOU 00 t;0T COMPLETELY UNDERSTAfl0 THESE INSTRUCTIONS OR ARE UNABLE TO COMPLY WITH THDi, CONTACT , YOUR SUPERVl50R BEFORE USING THIS PRODUCT.
< t; otic'e: This product is for industrial use only.
Uarranty - Ameron warrants that this produe:t conforms to the specific description in Ameron trade literature as to character and quality of raw materials, workmanship, and adaptability for recom-mended use. Within one year from date of purchase, Ameron shall supply replacement material for this product or any portion thereof, or at its option equivalent material, F.O.B. Aneron manufac-turing facility, if it fails to meet the foregoing warranty, provided that installation and appli- ; cation of the product have been properly accomplished and that keron has been promptly notified i of the defect. The preceding constitutes the sole remedy of the Buyer and the sole liability of Ameron for < product defect. i No other express or implied warranties, whether of nerchantability or of fitness for any particular 3 purpose or use, shall apply. Ameron shall not be responsible for consequential damages. Ameron's Standard Terms and Conditions of Sale apply to purchase of this product. This product data sheet and the recorrendations for usage it contains were based on test data be-lieved to be reliable, and are intended for use by personnel having skill and know-how, at their own discretion and risk, in accordance with current industry practice and nornal operating condi-tions. Variation in environ ent, changes in cperating procedures', or entrapolation of data ray 4 cause unsatisfactory results. Since we have no control over the conditions of service, we ex-pressly disclaici responsibility for the results obtained or for any consequential or incidental rffects of any kind. . . .* .
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_ JLM-450-A5 F%CE/4 y t J. L. MANTA, INC. TEST PROCEDURE CONTA110iENT 2 MIDLAND NUCLEAR STATION
1.0 SCOPE
This procedure shall provide inspection Cf mting System No. 9.as applied to concrete walls in Containment No. 2. This test procedure shall provide a basis for pass / fail determination of coating adhesion using a prescribed area of approximately 100 square feet. 2.0 MAPPING & TEST AREAS 2.1 Drawing SNA 205 through SKA 216 shall be provided by Bechtel Engineering. , 2.2 Each drawing will show wall elevations with a grid pattern for identification of specific test areas and for recording results.- 2.3 Each grid test area shall be identified by drawing number and symbol located in the bottom righthand corner of each' grid area. 2.4 A minimum of one (1) test shall be performed in each grid-area. , 2.5 No two (2) tests from dif ferent grid areas shall be performed within 6'-0" of each other unless directed by Bechtel. 2.6 Additional tests may be performed within each test area in order to verify conclusively that the area can be classified , as pass or fail. 2.7 Testing shall begin at elevation 593'6" and progree to higher . elevations. 2.8 Testing may be 'nodified by Bechtel Project Engineering as to extent and progression. 3.0 TEST MEIBOD I i 3.1 be p rmed by J. L. Manta, Inc. QA/QC Inspector All l rgg- 1 :@ASTMD 2197 Method B, Paragraph 9.0. f - gpwp_Qq requirements and - apparatus described are not applicable.
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~ ) 3.2 A disposable blade cutting knife shall be used. This shall be U a Stanicy Medel 09 knife or as approved by Bechtel Engineering.
Each breakaway section of the knife blade shall be renoved before a maximum of eleven _ (11) cuts. 3.3 Three (3) inch minimu -garallel cuts shall be made in the coating. g, The' cuts shall be 1/ 6 1/16 inch as measured with a ruler and the coating between tfie cuts shall be examined for delamination.
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3.4 If delamination is not apparent, a knife shall be used to pry the coating loose at a cut edge. 3.5 Failure shall be noted only if a clean separation occurs , resulting in a paint chip. 3.6 Test areas where clean separation does not occur shall.be interpreted as pass. 3.7 Test areas shall be identified with orange tape. 3.8 The failed paint chip shall be placed in an envelope identified with grid test area as documented on the appropriate Bechtel print. This sample shall be retainell and submitted as directed by Bechtel Project Engineering, p 4.0 DOCUMENTATION OF TESTS l 4.1 All test results shall be recorded by the QA/QC Inspector on the drawing in the corresponding test grid area. !
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4.*2 The QA/QC Inspector shall measure the distance between cuts to verify compliance or use a straight edge jig to define the width of the cut. 4.3 The QA/QC Inspector shall record distance between cuts on the Inspection Record JLM-1,050 (see attached fonn). - 4.4 The QA/QC Inspector shall document on Form JLM-1050 the date of the test, the grid area, the verification of the distance between cuts, results (pass / fail), and name and position of person (s) monitoring the test.' 5.0 QA/QC INSPECTOR QUAL FICATION 5.1 The QA/QC Inspecte shall be qualified by eight(8) , hours 61 instruction. .four (4) hours of instruction on sne written procedur: and four (4) hours of instruction on the performing of the specific test procedure. n V
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(]y 5.2 The instruction noc11 be documented on Form J1.M-1000 and signed by the instructor and reviewed and accepted by Bechtel Project Engineering. 5.3 The instructor's name and qualifications and program of in-struction shall be presented to Bechtel for approval. 6.0 REPAIR OF TESTED AREA s 6.1 Test areas shall not be repaired until tests are evalbated - and accepted. 6.2 J. L. Manta Inc. repair procedures shall be submitted to Bechtel Engineering for approval. - i v 4 l t /'T kh - Ees. 1 fS~S O ~) hj = {,-Q,, 2-11-80 Page 3 of 3 2
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