ML20080E698
| ML20080E698 | |
| Person / Time | |
|---|---|
| Site: | LaSalle, 05000000 |
| Issue date: | 08/18/1980 |
| From: | COMMONWEALTH EDISON CO. |
| To: | |
| Shared Package | |
| ML20080E624 | List: |
| References | |
| FOIA-83-378 80-402, NUDOCS 8402100042 | |
| Download: ML20080E698 (153) | |
Text
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, Surveillance Date_ _ - _Aucust - - - - - -18. - - 1.930 File No /
J-2590.22 , LASAI.LE Q.A. SURVEII.I.AkCC RElORT l'O. P.0 -402 Contractor / Organization Observed: , The Zach Co.npany Category: (9)
. .--.:. . . ~ .-- --- . . . .:
Audit Trentl Analysis * '
,SUcDfARY: :
.On May 19 1930, a trend analysis uns
- , Assurance,on Cc:rnonwealth Edison audit (mrfor rad by site Quali"./
the period of January 12, 19*!9 and May s 17, of Z.:ch 1930Company betueen (Scu Surveillance Report #80-231 Memo To File). During this tiac framo:a total of 12 audits resulted in 32 findinas sutd 13 observations. As. a result of possible that review, the.following areas were identified as
,trands. ._
- 1) Zack's failuro to adequately docunient and/or perform' QC inspections.
- 2) Zack's failure to adequately document and control nonconformances.and design changes. -
- 3) Zack's failure to adequatrly address 5.nd perform all required audit's/ subcontractor'surveillances.
- 4) Zack's failure to adequately qualify and certify both ;
auditors or inspection personnel. At Man.c.ger, a new sirethatQ.C. time,Manager Zack Company and four 4)(had newjust inspectors hired a for new Q A.- LaSalle, who wera in the process of revising an c:: tensive number of work procedures. It was honed that these procedural revisions would eliminate misunders'tandings
' were'to be performed.and help clarify to'what extent required inspections Since these that time, Zach ashaswellhad.ap.. proximately two months to -implement procedures, as 15, 1980, Cons.onu,en1th Edison, train the nowinspectors. On August covering Zack's Design Control finished and QC Inspections. two' extensive audits The results of these audits were less than satisfactory and resulted in a.
"stop 6, 1980work" ordei- being issued by Station Construction on- August Discussion: ^
In order to group the deficiencies so a meaningful review could be made, nine categories were established which had the follouing number of deficiencies in each: 7 .
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. , a S
- e e 8402100042 831128
,39 PDR FOIA PERRYB3-378 PDR -
G*?"'*~~_~[ _ _ ~f '--_ WQ; ~~ *'" " _
'%'_* '2_'* 7 ~~ " _ ' Y *'~~" '**~:' * *"O " '~
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. NO. AREA OF Com:E!!N
- FI!!DT!:ri.9 OU.">lDtVATIOMS 1 Desi;,n Ctmtrol 5 ---
2. Procuremmit/ccceivinc 3 1 3 Do.cuc.ent Control 4 2 4 Welding 4 ..: 2 5.
.. Inspections
./. ;
8 . { 6..... Honconformanecu , 6 2
. 7. Audit:: 6
-1 '
0
-8 ,
Tcrsonnel Qualifications
-5 -: 1
- 9. Calibration *
- 1
. 1 Total: ~7Il~~ "'I'l~
. _3 ... a Ucicw is a detailed list of daficiencies found during both the orir,inal trend analysis and the subsequent two special audits performed on 7ach Company. -
.Au.dit tiumher. Re.s__u_lt.s_ . .
4 1 80-49 (Design) (1) Findine #1: . Zack Company failed to received Report Date: 8/15/30 prlor approval for desi$n alterations. (1) Findi.n..~a #
. . Zack Ccan.any. failed to document
~ reva.cw or2:ll a drawing changes as required.
(3) Findiur: #3: Zack Comoan.v, x failed to maintain an auequate and procedures. dec.tment control system for drauing: m 1 43 - - (8) Findinn 51: ' Zach auditor and Q.C. Insoector (QC Inspections) qua).2.ricacions ucre found deficient....' '
~ Report.Date: 8/.15/80. c.,..- :
F,indinn 52':
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(6) A) Ncnconforming-items were
~ " found not beine adequately segregated.to
' ' prevent use. E7 Nonconforming items were not being identified on Zack!s final Inspection Reports. -C) .Zack's Monconformance system
. failed to adequately contrcl the number of
. nonconformances uritten and dispositioned.
(9) Finding _53: Zach failed to maintain suitable tool histro calibration cards. (5) E_indine; ah:y~ Final Inspections.being performed by Zach Q.C. v.cre being inad'equately completed for the follouing:
/- A llangers ,
.' ,- B Duct"
- C Equipment Installations
- D Storage (2) Finding $5: A) 26chrod failed to sufficientl{
~
nocui3cnv. encir wold receiving.- B) ' Z ?.c m failed to follo.: their dail requirements for uc.1d rod. y C) i::suance Zack failed to adequately control welding materials in the field. - N . . - s . e ..;- ..p... ev* w :s,- .~....m:~..*. _- 2=*P'au L Am*M* *?"*.= ' Y " "' * - ~ *' *
- V. ' : '"" "
55# --
. 4 w y q) -~u-4 l
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,3 s .
- Audit Number
~
~ .Re: nits !
'(4) Findin~ 66: A) Zach failed to document ucider
% 1-SO-48 (con'd)- "
IiEiiEi"FiciInloa. b) xach failed to! suf ficiently_ ' review wclder qualificationn. . I (5) Obnarvai. ion 01: xach failed to make provisions
/ 'for suoconcructor'n work to bq " final" incpected (3)
~
-Ob s erva ti._o._n, . .3._2_: %cch failed to adequately nainta
. . an luupectron status pro;; ram.
- (G) Observation #3: Zach failed to regularly review
. of the QA pro?, ram.
(5) . tncstatusanuadequacy(3}CEcosurveillances Obnnrvation M4: Three
. rewnn opeu pending Zach a corrective action.
d'1-SO-19 (5) Findine 01: The Zach Company has not adequately
? Report Date: - --. .
Tiup.Lemquced the provisions necessary for assurin
,f (6)^
~c leanlindsc'of inutdlled duct work... .
l 4-10 -80 Findinc #2: Zach failed to implement a system
/ - -
~
to remove all hold tags from equipment prior to
/ . installation. .
. . (5) Findinz #3: Zach has failed to imn.icment..proc.ed . .
~ necessary to assure acceptable inctallation or quipment.
. (2) Zack and#4:
Findinz CECO The' furnished site pr )6cedure for receiving h ek IIirnished material is inadequate. 4 1- 8 0 - - - - - (7 ) Findine 01: Zachs- CorPorata Management failed Corp.iOco ul ce reva.cw tuo Q. A. program at least annually. . Rep. ort Date: (8) Findin.t 6,2..:. Zack failed to meet in=pec , ,t 4-7-30 certiricaczon ,evels necessary to perr.orm tor inspects.cn. - (8) Findinz 93: Zack. lacked cvidence thct the audit: qualif~iliE? ion program had been impicmented. (7) . Findinr: #4: Zach has fniled to implement a system or p.Lanncd nnd periodic audits.
~(3) Findine #5_:~ Zack did not submit their revised organa.zational chart to CECO Corporate Q.A. for review.. -
(7) Findine #6_: Zach Audits contained insufficient ~
. ovidencWto support' determinations made on the audited items. - -
V'f. i 1-80-67 '
- 43) Findinn #1: -Zack fai. led to maintain the. latest Report Date: EG10inE Procedure in the field.
2-13-80 (1) Findint; v2,: During the installation of seismic. liangers, tack failed to follow approved - instructions, procedur'es,.or drmiings. ~
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, Audit Ntt:iber Ih r:ultn 1-80-1D --
(3) Report Date: Fi line ?1: . %::ch QP.P lacked tim detailed 2-o-80 mncuou;2.ror mc'etior; the requir::m;.ntu oP AMSI
' N45. 2.G . - I (0) .Ohn..t.n:.ve.,.t.;.rn....#1.:
Zai.h han fa curce.i:?. cat?.on nor a Icycl I;..iled to.. meet
. :.cce,rn::.ng to ANSI Guidelines.
1-79*97
'(5)
Report Date: Findina #1:' %$ch hne5 failed to establich n cumpleisTTomprehensive final f.nnpr.ction 12-12-79 procedure. .. --- -
. . (5) Ob.,m vn:: inn #1: .k ccup.t.ute in;cm.ine .t.ach incp :ctionc.
ue.Inupcetx.on :orms ucre not fn2..t.c
.. . . .-- to inclhac provisienn to identify uliich procedures u2rc uned to nccomplikh the vorh. ;-
~ ./
1-79 Ho Findinga/lio Observat ions a
"'4 1 79-70 -
(0) F.indiu : #1: Z Report Date: scanicus on t.ach has failed to perform training nc Q.A Ibnual and has not 20/o,/79 documented results of c::aminationc.
-(5) Observation.. 01:of'%nck varrunab uocumentation -
evaluation orle he toa.. provide rigging equzp: cent. sting ant 4; 1-7 9 - -- '-
-(2) Findiun 01: Zach has failed to properly Retort Data:
10'15-79
- uccument Etcir roccipt inspection of equipment reccdv'od from CF.Co. ' ' '
. (5) Fi
--.n dinr:n 02..: Zach ucra.clencies and t.has failed to. document area inspcetions.ncir resoluta.ons 2:or storage ~
(a,,) . _Obsnrvation 01: ~ Th. e 7.ach Ccmpany....d .. . . . . . . - accument enac cpec: al storage requa.oes tot .rements are.being complied with. '- - (5) Observation #2: .Zach has failed to establish and handling equipnent. acceptance cra.tcrAs for inspe 4 1 - 7 9 - 5 0 ---
----(3) Findinn._.01_:
Recort Date: not contro t.c Proceduren. anc centcince used in. .te.sti.na= were 8/6/79 - Design drawings did not centain revisionm2.csing pages. numbers for testingmaking imponsible. verification of curren't drawing (8) Fi
--.n.diu..m #. 2 : Z
' ma:ntain quala.ach .
ha.sRecords
.ficata.on failed to or e.stablish personnel. and'
.(7) Finding Audits were not performed on the 3). IfGC~5y.d03:E'em according to Zach Q.A.
~
~ Observation #1: Revised drawings ucre transmittec to ' se sicGd were in use uithout being reviewed and accepted. '
*(5) Observation #2: Zach has failed to correctly Tdentity.caen ucidars~uorh.
- 1 .
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m -W-p- , . Audi.t Miuahnr
.Re::alun 50- - -
(9) Obnorvation 3:1: Failure to catablish :nd vA.3-79,d.) (Con retracain a tool hl:: troy card on calluratlon frequency. '
- (4)
.Ob..ser_va..t_io_n,-_'_C../::
.- .. -- Test rep arts o.f welddd qunlli1catic,su warc not has..ng Mcva. cued.
.. / (4) Ob::n- vntio,.n .#5.:-- Pailure to r:cintain welding waterlaJ.1cau.mee log.
vF1-79-40 - (1) Findlna ?l: Zach failed to generate centrol w p
..c,,c... . . .. c wencitran draua..ngs.
ror field channes frein the instcllation c_1_7o ~ (5) Fludiner 02: 7,nch failed to properly insucct 2.nsta11ec work Ghich resulte.d in .p.cceptance of deficiant uork.7 .. (4) Findina 03: Zach'. failed t.o I.riint! in.f i procecEre"iri Itcbordance uith M15 Ucl-ding}ualified
'Code.
d,f ' 1 -7 9-27---- -{5) Fi6 dine #1: The field Q.C. inspector failed to Reuort Date: 'conci checklist. inspections of material when 5-10-79 removed frorn storaga. (6) Findinq 02: Zack failed to cont:616.on conformin;
~
matcllal until co,.rective action was cc:npleted.
, (4) Findine 03: Welders.4talification results were not reviewed properly.
(G) Findine -M: Zack failed to receive appre/al for repaiE uork ucrfonacd en CECO furnished couipment.
. (5) Ob.s 2.uch diccontinued the usf. of the
-Q.cervntion---
- b. i.:
- . weenly suspection report.
vy 1 G9-2 ---
-(2) Findine #1,: Zack Cc:npany failed to t$c5.ntain a Reuort Date copy . .
ycrzuo.c une open nurchase ord.er on site.~ forlcation 2-20-79 2.nspection. (G) Findinz 92: 2ach failed to centrdl nonconforming maten'ai until corrective action uns connleted (6) Findine 63: Zach's Field Sunerintendent' failed to siin tne " corrective acti'on cernplete" on completed NCR's. .-
'(7) Findinz 04: Zack's Q.C.14: nager failed to nerfort an internal audit on sections 10 -15 of Zacht s Q.A. Manual in 1978. .-
(*/-) Findinz 05: Zack failed to assure timely close-- out of~ site audits. - (6) Observation #1_: Copics of NCR's sent off site fo:
- tne project managers signature have not boon kept -
~ on file.-
.(2) Observation #2: Shipping-Receivihr- documents were micsing trom ship:nent package".
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Conclusions:
1 Due to the lar;;c uu:aber of dericicacies fumid duriut; this tisne frame
- and the possibility of thn::e t, rendu reoccurrin;;, the P..e.ch Company is rcquested to respond to thin wrveillance concerninte, these fcur nroan of trendn by Septe:nLer 5, l'.C O . 7.:.:c h 5 c ranpodse chould
'speci.Cically state all corrective n:atisurcu enken to date on the.se crean to prevent the -likelihnod of futura probic:nn rocccurring.
' This respouce nhottld be addrexed to T. E. Qualrs, Q.A. Supervicor, h Salle County Station. --
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------.........---.-......-......'.../.!----'-..-.
J' Reported' Yb .-- : bMe -- -- .9.7.- /L N, N-- Date: !? -/ 9., Approved by:< 4 :M3 . h lvM [h,__ Date: 9/r-gd3 . 4
- FU Action Verified: Date:
V A. Eng./ Insp.
. FU Action Approved: , Date:
Q.A. S,upervisor
* / . .
~
,c c : W. J. Shewski/C. F. Marcus
- L. J. Eurhe .
Contractor- .
, T. E. Quahu/Q. A. File l
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- x. .u. **M-A,., plan,dpu. ,l .
- Bechtel. Power Corporation
- Post O! Lee Box 2167 Midland. Michigen 48840
. November 5,1980 ; -
i
\-
The Zack Company ! 4600 West 12th Place ' Chicago (Cicero), IL 60550 - Attention.: C. L. Eichstaedt, Jr. - Job 7220 liidland Project *
. Subcontract 7220-14-151 .
,f 1:aterial Shipments 14-151-D-947
Dear lir. Eichstaedt:
llate.-ial shipments from Chicago to tiie-Zack site. continue to arrive with . nonconforming conditions. This practice is consuming substantial time and ef fort at the site for all parties concerned; .Zack, Consumers, and Bechtel . We hereby request that shipments with ndnconformances be discontinued and be held in Chicago until nonconformances 'are clsared.
.' Further, we direct the Zack site to return any nonconforming material to Chicago by the same truck in which the delivery was made. The truck must be held until the receipt inspection is completed and nonconformances, both hardware and software, are found to be nonexistant with the exception of limited shipping damage. ,- ,
~
Very truly yours, -
~
' ~
~ ~ '
. E. Davis site llanager -
l
. . l LED /JUL/DFP/ ear 1,
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l . . cc: R. B. McCarley , R. L. Akers -
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. --vvisumtomanuramw>w . :n i. /. .. ;* i ;.,
ess
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_s N' . CUSTOM ME1 AL FABRICATION Pobruary 6, 1981. I .
' Seas, Inc.
.7535 W. Roosevelt Pd.
.Forrest Park, Ill. 603.11
Subject:
ASTM S.tandard for Carbon and Alloy Steel Nuts Gentlemen: In reviewing our purchases with your company since January 1970 we have specified the hex nuts to bc ASTri-A307, ASTit-A325, ASTM-A354 and/or ASTn-A400. In turn your certificate of compliances and/or material test reports stato that the nuts were manufact-ured to the above standards. In researching this further, the above is not fully accurate. The above mentioned stafidards are
~ for externally threaded fasteners, bolts, studs, etc. The above mentioned standards all refer.to " sui (able nuts are covered in Specification A563". '
+ We r'e quire a letter from your company stating that the " nuts" ' furnished to us by your company since January 1970 conform to Standard Specification ASTM-A563-72 or 78a. Your most expeditious handling would be greatly appreciated. Yours very truly, ' T11E ZACK COMPANY
- 6M .t '
carl L. Eichstaedt, Jr.
- Vice President-Nuclear Const.
CLE/nw cc: C.Z.DeZutcl
- R.Hagen File . '
~
+
[$L-
+ FOUNCED TO OC'.VZ THE 1:NICUE MET /.L FASRCATiCN NC~CS C;"!?C'J3T?.1 +
. Dr.DICATED TO CLEAN:NG AND CUG TC .ill:NG TriE A.N 07 7eis. WCHLD +
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CO. CUSTOM METAL FABRICATION N'
/
+g February 6, 1981 ,
- i. =
"Thiele
- 1644 N. Mannheim kl.
- ,Melrose Park, Ill. 60165 8
Subject:
' ASTM Standard for Carbon and Alloy Steel Huts Gentlemen: ,
. In reviewing our purchases with your company since January 1978 we have specified the hex nuts to be ASTri-A307, ASTit-A325, ASTM-A354 and/or AST!!-A490. In turn your certificate of c'ompliances and/or material test reports state that the nuts were manufact-
~
ured to the above standards. In rescarching this further, the above is not fully accurate. The above mentioned standards are for externally threaded fasteners, bolts, studs, eter The above
. mentioned standards aill refer to "sultable nut's are covered in ,
, Specification A563". . .
We require a letter from your company stating that the " nuts" i furnished to us by your company since January 1978 cc:sform to Standard Specification ASTM-A563-72 or 78a. Your most expeditious' handling would be greatly appreciated. . Yours very truly, THE ZACK COMPANY
~
bCarl L. Eichstaedt, Jr.
. .w.
~
Vice President-Nuclear Const. , l CLE/nw
*cc: C.Z.Dezutel l- *
. sammalaessur . .
** R.Hagen l File ,
=b
/U .
b3b rour4DED TO SOLVC THE Ut41QUE METAL. FABRICATION NF.EDS OF INDUGTP.Y +
- DED:CATED 70 CLEATJ;tJC ,*.N.7 CllSTOM:Zit4G THE / IR OF T:C **, . 41 l_
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4401 WL51 L*l(N
- I LIN T f41 CHIC.AN disbuu . 313/7.h. . e 40
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9 ' it h e ( A 0 % !L e o . s s / CUSTOM METAL. FADRICATION
~ -- ,
h February 6, 1981 r , .
. . Delta Screw Co.
2036 N. CampbcIl A've. Chicago, Ill. 60647 ,
Subject:
ASTM Standard for C,srbon and Alloy Steel Nuts Gentlemen:
~
5 In reviewing our purchases with your company since January 1978 we have specified the hex nuts to bc ASTM-A307, ASTri-A325, ASTH-A354 and/or ASTM-A490. In turn your certificato of compliances . and/or material test reports state that the nuts were manufact- - ured to the above standards. In researching this further, the
~, above is not fully accurate. The above mentioned syndards are
,for externally threaded fasteners, bolts,' studs, etc. The above mentioned standards all refer to " suitable nuts arc covered in Specification A563". -
We require a let.ter from your company stating that the " nuts" furnished to us by your company since January 1978 conform to
.
- Standard Specification ASTM-A563-72 or 78a. .
s Your most expeditious handling would be greatly appreciated. Yours very truly, , THE ZACK COMPANY , 1 - - C Carl L. Eichstaedt, Jr. Vice President-Nuclea'r Const.
"CLE/nw
*cc: C.Z.DcZutel, R.Hagen -
File A3& '
- FOUNDED TO SOLVE THE UNICUE METAL FABRICATION NCECS OC INDUSTRY .
- DEC:CATED TO CLEAN:NG AND CUSTO .*:2:::G TI:E AJi CF T, tE *.*.*O".:.0 +
~
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l 1' - ( 18b) CUSTOM METAL FABRICATION February 6, 1981 .
. l
- Key Crest, Inc. ,
. 428 Greenwood Ave. '
Barrington, Ill". 60010
Subject:
ASTM Standard for Carbon and Alloy Steel IJuts. Centlemen: , i ' In reviewing our purchases with your company since January 1978 we have specified the hex nuts to be ASTM-A307, ASTri-A325, ASTM-A354 and/or ASTH-A490. In turn your certificato of compliances and/or material test reports state that the nuts were manufact-ured to the above standards. In researching this further, the above is not fully accurate. The above meintioned stapdards are for externally threaded fasteners, bolts, studs, etc. The above
~~
mentioned standards all refer to " suitable nuts are covered in Specification A563". -
~
We require a letter from your company stating that the " nuts" furnished to us: by your company since January 1970 conform to Standard Specification ASTM-A563-72 or 78a. , ,
, Your most expeditious handling would be greatly appreciated.
Yours very truly,
.THE ZACK COMPANY
. CY Carl L. Eichstaedt, Jr.
M' Vice President-Nuclear'Const.
. C1r/nw . .
cc C.Z.DeZutel
- w=-1'R.Hagen File -
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- FOUNDED TO SO!.VE THE UNIQUE METAL FAERICATION iJEEDS OF INDUSTRY* =
- DEDICATED TO CLEANING At4D OUSTOMCING THE Al; OF THE WO;*1.D .
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a.U'N u s. - wm - - 44ot wE' STERN
- FLINT MICHIGAN .d503,e 3i3/730 2040
., 42]c the -
8 Q* @ X l e o. . CUSTOM METAL FABRICATION i Aprit. 16, 1981 TO: Zack Company Pessonnel
~
RE: Paichase Ordero/Sub-Contucto for .. l ; Nuclear Power Stelion Projects . I l
- r
- ALL PauJiase Orders and/or Sub-contracts issued for material, equip-ment, services, etc., for our Nuclear Power Station profecia mi44
- have the fallowing statement included as part of the order.
" Provisions of lack Company tekter, dated Decemb'er 19,1978, in re-gards to FedeAai regulation 10 CFR, Part 21, are included as an in-tegral part of this Purchase Order /Sub-Contract". . .
vP - t sept 3 CL DE 1UTEL, EXECUTIVE VICE-PRESIDENT G / e e o *
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h% = FOUNDED TO SOLVE THE UNiOUE METAL FABR! CATION NEEDS OF INOUSTRE+
= DEDICATED TO CLEANING AND CUSTOMlZING THE AIR OF THE WORLD
- _
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- FLINT MICHIGAN -dM6
- 313h786McUs>
J g D.. w . the EQ@I co. < s
. CUSTOM METAL FABRICATION 4 .
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I April 16, 1981 TO: THE ZACK COMPANYS SUPPLIERS / VENDORS / MANUF MATERIAL USED FOR NUCLEAR POWER STATION PROJECTS t FEDERAL REGULATION 10 CFR, PART 21 - . DESCRIBED IN THIS PURCHASE ORDE /* FEDERAL REGULATION 10 CFR 21 IS'NOT APPLICABLE TO IN PROCESS - ONLY TO COMPLETED WORK WH ED BY THE PURC1 LASER. ON THE ASSUMPT CON THAT THE SUPPLIER / VENDOR A POTENTIAL DEFECT SUBSEQUENT TO ACCEPTANCE OF .
- 1. - SUPPLIER / VENDOR SHALL DAYS NOTIFY AFTER THE NOTI- ZACK COMPAN IN WRITING WITHIN THIRTY -(30)
FICATION OF AWARD WHO SHALL HAVE THE RESPONS , BILITY s WITHIN HIS ORGANIZATION FOR IMPLEMEliTIN THE REQUIREMENTS OF 10 CFR 21. - 2. SUPPLIER / VENDOR SilALL, PRIOR TO THE START OF WORK, DEVELOP PROCEDURES FOR IMPLEMENTATION OF SUCH PROCEDURES SHALL EN-THESE REQUIREMENTS.
- SURE THAT THE RESPONSIBLE INDIVIDUAL DESIGNAT ABOVE RECEIVES INFORMATION
-ED PURSUANT TO "1" OF POSSIBLE DEVIATIONS WITHIN THE MEANING OF . .,
10 CFR 21 AND PROMPTLY REFERS THAT INFORMAT TO THE ZACK. COMPANY IF, IN HIS OPINION, SUBSE-
- QUENT EVALUATION MAY RESULT .
- 3. REFERRALS TO THE ZACK COMPANY WILL BE EVAL JOINTLY BY THE ZACK COMPANY AND THE SGPPLIE
'- VENDOR. THEY WILL BE REPORTED TO THE NUCLEAR REGULATORY COMMISSION (NRC) BY THE ZACK CO l
IF THEY ARE DETERMINED TOSUCN WITHIN THE MEANING OF;10 CFR 21. BEREPORTS REPORTABLE DEF M BE MADE WITHIN THE TI. IS PRE-
~
/ TO THE NRC SHAL SCRIBED BY 10'CFR 21, AND THE ZACK COMPANY SHALL , PROVIDE THE SUPPLIER / VENDOR WITH WRITTEN
- FOUS'OED TO SOLVE THE UNIQUE METAL FADR CATION NEECS CF INDUSTRY
- DEC: CATED TO C EANIN!.i AND CUSTCMILl4G THE A;R C# THE nCRLD .
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f . .g . THAT SUCH REPORTS HAVE'BEEN MADE.
- 4. SUPPLIER / VENDOR MAY REPORT INDEPENDENTLY TO THE I NCR IF IT HAS REASON 'f0 BELIEVE THAT THE ZACK -
~
. COMPANY MAY NOT FILE AN APPROPRIATE REPORT IN
- TIME TO COMPLY WITH THE REQUIREMENTS OF 1S CFR ,
l 21 OR IF SUPPLIER / VENDOR DISAGREES WITH 'RHE ZACK *
~l COMPANY EVALUATION THAT NO REPORTABLE DEFECT EX-i .
ISTS. , i
. . 5. IF SUPPLIER / VENDOR DECIDES TO FILE AN INDEPENDENT REPORT, PRIOR NOTICE (VERBAL OR WRITTEN) SHALL BE
- GIVEN TO THE ZACK COMPANY, AND A COPY O.F THE RE-PORT SHALL BE TRANSMITTED TO THE ZACK COMPANY.
- 6. SUPPLIER / VENDOR SHALL REQUIRE PROVISIONS SUBSTAN-TIALLY SIMILAR TO THOSE-SET FORTH IN THIS SECTION TO BE INCLUDED AT ALL' APPROPRIATE LEVELS OF PRO-CUREMENT IN CONNECTION WITH THIS PURCHASE ORDER.
IT IS THE INTENT-OF THIS CONTRACT THAT THE RJQUIREMENTS OF
. 10 CFR 21 SHALL BE MET BY THE ZACK COMPANY AND ITS SUPPLIERS-SO THAT THE STATUTORY RESPONSIBILITIES OF EACH PARTY ARE PRE-SERVED, A DETERMINATION OF DEFECTS IS MADE, AND THE REPORTING OF DEFECTS TO THE NRC IS ACCOMPLISHED EFFECTIVELY, EFFICIENT-LY, AND IN A MANNER WHICH MINIMIZES SUPLICATION, CONFUSION AND MISINFORMATION. .
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** g'gTERN e FLINT MICHIGAN 43503
- 313?733 2040 t
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the- FM@K Qca ' CUSTOM METAL FABRICATION
, MEMO i
TO: Carl L. Eichstaedt . FROM: Christine Zack De2utel I I
SUBJECT:
Memo dated 6/30/81 1 i t I agree with your evaluation of the evidence regarding the toreign steel. As I also instructed our QA Manager I and Purchasing Agent,to suspend ordering from Edgecomb, U S Steel Supply, Northwestern Steel and Wire,.and - Reliable Galvanizing pending the results of the investi-gation, I now rescind that directive conditionally. Steel procurement may proceed normally. All nuclear-related steel being galvanized by Reliable Galvanizing will be receipt inspected by Zack's Quality i Control inspection force at the Reliable facility, and reinspected there after galvanizing by our inspectors before being released for shipment to us. As heat numbers may become illegible after galvanizing, I suggest some method of marking during the initial inspec-tion that absolutely circumvents any. possibility of error. I also encourage back charging Reliable for th_ese increased costs Zack must assume. If, during the next 90 days, any discrepancies are found,, Reliable must be removed from Zack's Approved Vendors--List and the industry appraised accordingly. CZDZ - bn - cc J. DeZutel '
~
D. Ma?zshn _ . . . D. Calkins-R. Hagen 1
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- FOUNDED TO SOLVE THE UNIDUE METAL FABRICATION NEEDS OF INDUSTRY
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- DEDICATED TO CLEANING AND CUSTOM 121NG THE AIR OF THE WORLD
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DATE Juna 5, 1981 q i 6 l
. 1 .
10' ' Dave Calkins - From Christine Z. DcZutel SUDJECT , AT I!NT:CN v ~.
- iT2!!T - -
his is to inform you of a situation which has recently come to our attention. piece of foreign (Argentian) steel was discovered incorporated into an ' nstalled hanger on the Clinton Project. . he Zack Company, upon notification from the site, began an immediate inves- - igation of the problem. . , . c have ascertained, t$.ls far, thdt Northwest Steel and hire, Edgecomb Metal, r Reliable Galvanizing caused the confusion in the suspect order.' o have tested the suspect channel through Charles C. Kawn Company and have scertained that the suspect steel conforms to AUS Standards for A-36 steel. , have ceased purchasing and/or galvanizing with the aforementioned organization: ending total clarification of this situation. . EPLY - DATE , ,. s The Zack' Company's investigt. tion thus far has no't pinpointed the cause or aus'es for this problem, our i.svestigation is continuing. When all the facts re ascertained, your'inp'ut will - - - . be required for proper disposition.
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\ . . . . i gttpenmente to Q.A. Audit rinding 8/24/81*
.The rollow2ng is a list of QA/QC personnel's training / qualification recor that violated'Zack proc,cdures as noted:
- James Michalix - OC Level II -
(l') Contrary to Zack POCP-ll, Rev. 1, para. 6.2.4, lhe zack Co. vision test form (ZOF-21) datea 6/2/81, does not reflect documented evidence of a near vision' (or equiv) test for J. Michalik. . (2) Contrary to Zack POCP-11, Rev. 1, para. 6. 2. 4 , J . Micnalik was
- . overdue for his annual eye cxam. Ile was due on 5/6/01, the actual test was performed on 6/2/81. -
,,(3) Contrary to Zack POCP-11, Rev. 1, para. 6.J.l.4, J.
not given a written examination as . a Level I.. Michalix was I i [ (4) Contrary to Zack POCP-ll, Rev. 1, para. 6.3.1.1, no Level I O.C. Reading List (ZQF-22A) was on file for J. Michalik.
.( 5 ) Contrary to Zack PQCP-ll, Rev. 1, para. 6. k i, J. Michalik was qualified was performed.
as Level I on 10/14/80, a'nd'no 30 day re-evaluation Charles Richards - OC Level II _ l (1) Contrary to Zack FOCP-11 Rev. para. 6.5.1, C.
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1, Ricncrds was qualified on 4/16/u0 and no annual re-evaluation was performed. - Ken Schaefer - QA/UC g (1) X. Senaeier's qualifications of 10/22/80 does not meet the requiron of ANSI N45.2.6 for education, experience & training. COMMENTS AS NOTED DURING THE AUDIT: ,f,
* . ,s (1) Though recoros were retrievable, a11,OA/QC records should be purged and mainttined in accordance with the requirements of ANS1 N4 5.2. 9 (2) None of tne forms u't11ized in Zack PQCP-ll, & POCP-17 had the form numb'ers,' designated in the procecure,.on the forms'.
(3) For uniformity, all forms in PQCP-ll & PQCP-1) should be given tne same' form number designation. -
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, (4) To preclude a p/rocedure violation, it is recob.menaed that D. Calkin be given tne ssignee status for Zack President in evaluating and certifying OA/QC Personnel. '
(d) Aiso, to preclude a procedure violation incorpora'te Form ZQF-uS, ( Record or Lead Auditor Qualification ) into tha.nroce Men. cc: D.1. Calkins C.Z. De o utel 1 - J.C. DeZutol - C. Micharos Q.A. tiler ~
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y , .. . , 4'Thh tha, vaolatet. foJ1ouing is Cprocedures Zach list of OA/OC as noted: personnel's training /gualification record - ' James Michalili. - OC Level II
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-([) Contiary to Zack POCP-ll, R'cv. 1, para. 6.2.4, The Zack Co'
, vision test.' form (ZDF-21). dated G/2/S1, does not reficcc doemannted evidence of a near v3.sion (or cguiv) tc#t for J.
M,ichalik. . (2) Contrary to Zack POCP-ll, Rev. 1, para. dvcidue for ha.s annual cyc exa:a. IIe was due on 5/6/81, the actual 6.2.4, b. Micnalik was test was performed on 6/2/81. (3) Contrary to Zack PQCP-11, Rev. 1, para. '6. 3.1.4, J. Michalik was given a written e>:n.aination as a Level I. not
/(4)- Contrary Reading to Lisc Zack 2
(20F-22A)* POCP-ll, kas Rev.on1,file para. 6.3.1.1, no for J. Michalik. Level I Q.C. j . -
/(5) Contrary to Zack PQCP-ll, P.ev. 1, para. 6.5.1, J. Michalik was qualified was performed. -
as Level I on 10/14/80, and. no 30 day re-evaluation c h .
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U M DATE .9/24/H1 .< -3 WA - SUBJECT _OC/OA Personnel REVIEW [ / [ / d $< . + ,[ g.~,; ,- .'n j. -il , eoCP - yp3.gy33 7
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5bO ?j'01M'O BINDINGS DA7. UNSAT. OR N/A INITIALS /DATE -
~ , Verify t.0it QCI's meet -
a ciucli 2 cc.tlon requiremen :s (see a4tachment) . unsat. . 20CP-ll, nov. 1. (PQcP-ll , N
- r. 1, para. 6.2l -
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AUDIT ?OINTS-7.INDINGS DAT. *IMSAT. On N/A INITII.IS/DATE - l n.
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. 0.A. AUDIT CHECKLIST
. Pago 3 of ,5 LIER N/A y/24/01,
. DATE N/A
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SUBJECT:
OC/OA Personnel P.EVIEW -i .C ' -
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G O Is!.1, P O C P - 1 1 , PQCP-17 * ' yp g ,[ j,[ j e f_e s -, ./ ,.,,
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AUDIT POINTS y.INDINGS I gay,' UNSAT. On N/A, INI'*IALS/D.\TE (5) verify that QCI'.s are avaluated-30 cays after cert i
' (Sde attachment) ~ , unsat. ,
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K herifythatTheZackCo. 6). NONE resident loit. designee)' is *
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euponsible':.*o'r the evaluatic6 D. Calkins, QA Mgr. es!rtification of Auditors /* was named as design 2e end Auditorn. ' (PQCP-17, Rev .
' for The Zacx'Co. Pr 2s. , para 5.2)
- for evaluation and l C- '
certirication or Aupitors/
. Lead Auditors.. Tni action
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was taken to preclu e a , proce'aure violation i. J* w, ; i i . . . . , .
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- 0. A. AUDIT CitEcKLIST
Page 4 . of 'S IU N/A DATg ts/24/01 .. xi/3 SUNECT: ot /nA pornnnnni REVIEW /.... d.:7 /, /
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b_ pnep. 1, POCP APP 110VAV I! ' }.~ . ..
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j L t.UDIT POIRTS T.INDINGS i F DAT.' UNSAT. OP. H/A, IllI*'IALS/DATE \ . . s $) Verify that Lead Audito :- NONE \- s l Auditor are qualifi,ed per . dat./ Qualirications. l-l l pich PQCP-17, Rev. O, para tor the r'ollowing s2 . gebsonnel were reviewed:
- - D.s. Calkins * )
' . . - l J. 0 Connell -
, l E.. Senacrer '
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) v$r2fy training and *
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sficiency. 't.esting pdr Zack NONE~ - Satisractory
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Page ,IER N/A DhTZ 8/24/81 -
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v '. SUIDECT: nr/nn persnnnoi REVIEll [ . ~ ' "~ ~ d ( . ._(/ - ZOP. DOC'P- 11. POCP-17' . App;1oyA h j [ ' 2 / ~ . * , AUDIT PO'IS'fS BINDINc3 BAT. UNSAT. OR 11/A INI;I.TLs/DA!3 t. (9) \ . l Verify that all' Auditors / NONE Satisfactory
- x and Auditors are evaluated
\s tonunlly. (PQCP-17, Rev. O, .
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p_.alY12E ZZAkCM C h C,El3TiFICATE OF QUAL.tFIC/.TiOI? . (AliSI ?? 6.2.6-1973)
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EMPLOYER: THE 2 ACK COMPANY
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s 4000 WEST 12Til PLACE l- cH:c Aco (c:CERO). IL 63550
.., PERSON CERTIFIED: KElmF.T}I D. SCHAEFER ACTIVITY QUALIFIED TO PERFORM: Al1 actions as detailed in The Zack Company Quality Progrcm
, LEVEL OF CAPABILITYi LEVELIIQCh ,
g i EFFECTIVE PERIOD OF CERTIFICATION: March 13,1981 to March 13,1984
/ BASIS OF CERTIFICATION: Education, experience, training, and f
test results 80.8 ** TEST RESULTS: G EN ER AL/ SPECIFIC; .
- P R ACTIC AL -
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. , M. E. D' Haem On -
3/13/81
- i CERTIFIED BY / DATE , .,
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.b1 Mt11t HKKE.11 CEi%
- , EVALUATION OF PERFORMANCE .. .
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,' / i* ($UDITORS AND LEAD AUDITORS)
~- ~~
. 'NAME Kenneth 'Schaefer CLASSIFICATION Auditor 2-20-81 DATE QUALIFIED 2-27-81 *
, lDATE OF EVALUATION j' . . . ,
.' ABOVE AVERAGE AVERAGE BELOW AVERAGE
,, / KNOWLEDGE O. @
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/ ,AUDI' TING TECHNIQUES l
AUDIT PLANNING . C,
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. ORAL COMMUNICATIONS O . .
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WRITTEN COMMUNICATION
- i -
COMMENTS:
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.I Reviewed with ab'ove named individual YES NO- .
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Individuals signature /date Af , Eval'ators u signa ure/date M M , A # 7e 4/ j j s -
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,- CERTIFICATE OF QUALII'iCATIOi; ; **
./ ' ' , .. .
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a -... . COIO:UNICATIONS , . SK.IL.L: 'Date Evaluated 2/27/81 by: Mich'ac1 E. D ' lir. t.
.. AUDITOR PARTICIPATION I -
LOCATION . AUDIT DATE
- 1. Midland Nue: car Station yg3.g.g.7 -t.; . , . The Zack Co. Feb. 185 20, 1921 g .
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. 9 EXAMINATION. TYPE Oral PASSED X- DATE' 2/27/81 i
' EFFECTIVE PERIOD OF CERTIFICATION: 2/27/81 through 2/26/84
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AUDITOR'Q'UALIFICATION CERTIFIED EY:Jd tg_ _ 2..2.,q-Qj NAME/DATE TITLE ' Quality Assurance Manager
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. t.oATg 8/31 /81
$ THE DELdW LISTED INDIVIOU AL(St RECEIVED QUALITY ASSURANCE TRAINING IN
, ACCORDANCE WITH THE ZACK CCMPANY QUALITY ASSURANCE TRAIN'ING PROGRAM
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NAME . INITI Al., POSITION *
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A C.2. DeZutel C Z _'0 2 President 3 J.C. DeZutel Exec. Vice-President 4, D. Mal:ahn ((7 Corporate. Sect'y. 5 6 7 . 8. s. 10 I 11. DESCRIPTION OF TRAINING SESSION CONDUCTED 4
,7 Training - 10CFR / ANSI N45.2 (1 hr.)
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- a w, Q. A. T R AINING lNSTRUCTOR
,D.E. Calkins, -
l Q.A. M7r. CC: Q.A. MANAGER , FILE-SITE. CC DEP ARTt/ ENT ^ 70F-23 is : 1
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CUSTOM METAL FAORICATION
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Ci-pte-Nr 23, IM1 . . tats;*t !'ttric:t . ricM: John O'Connell -
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/ SUDJf:CT: Survey of Edgeco;rb 2etals performed 9/18/81 I , ,
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[ An evaluation of Edgeco:-b Metals Q.A. Program was , conducted on 9/18/81, the following was noted: ,. !
. 'I FINDINGS '
- 1) The lines of organizational structure,.rcsponsibilities, and inter-functional relatio'aships were not delincated in the Q.A. ' Manual. '
- 2) No. performance of a program evaluation. -
- 3) No NCR/ CAR plan to identify, analyze and take action to correct s
deviations from quality requirements.-
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- 4) No identified plan for the maintenance of Quality records. ..
- 5) No provisions to ensure that purchased material meet quality require-ments. . . . .
. 6) No evidence of calibration records for caliper.
- 7) No vendor evaluation. '
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- 8) , No check of CMTR's against received material. ,
9)- Contrary to Edgecomb's Q. A. Manual, no receivihg inspection report
- is presently being utilized. .
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- 10) No management evaluation of the Q'uality Program. O ,
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. ,cp: C.Z. DeZu el ,
J.C. DeZu el - - D.E. Calkins - q R. Hagen . . D. Ibl.i.'.hn . Q.A. Fi;es -
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- DED'C4TED TO CLEAN;NG AND CUSTO.'.!!!!NG THE AIR CF THE WORLD -
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AUDIT PLAN ' 9 9 . DATE: n /1 uni *l
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AUDITOR: J. o!connell ORGANIZATION TO BE AUDITED: Edgecorrh Metals *
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P.O. Box 7400-A AUDIT LOCATION: woe v.,3 , a. ,
. Chicago, IL .
1 . . .- , ,. j .. - - j , AUDIT PURPOSE: ro v, rf ry +1,o va7.cn+ + 1. N. . . g _c,,.s _,w 4 , 4 + 4 ,. ,,, I implementing their Quality Program. -
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AUDIT SCOPE: ' Limited to Edgeco:nb Meth1s facility. - I . - REFERENCE DOCUMENTS: Edgeco:rb Metals OA Manna'1. ANSI N45. 2 and 10crQ2_.2.n-#,ix 3.
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COMMENTS: .
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AUDITOR: n /.A , - kEAD AUDIT $R:(. )$ // .. -
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DATE: N/A __ _ ___ _ D/sTik : ' _ _ . _ .. . . . I. '. .
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4%Wo ' . . k* . T. VALUATION OF QUALITY ASSUP.ANCE PP.OO!VJt ! PLAll OF SUPPLIERS OF COMPO;3E!.*T3 OR
*
- MATERIAL FOR CCMPLIA! CE UITl! QUALITY { .
4 - !
.. SPECIFICATION.
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. (C1!ICKLIST) .
St.TPFZn:-- Edgeco.5 2ictals . -
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11AtalAL TJn.E:...iden.tif.icati.on_Is.3 ert
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GTh'I15 CO.WD.7: F.dgecomb ihtals Q. A. Program was found to be unacceptabic L. in m=ing The Zach Comp $ny 'p'r ocurement rc'quirements.
. . . The program presently .
. ,' .1 .
be}irg .tilized is in the. process of revision. Findings cro described in the N N _ f% #- (b hW4 gmgp(gfgpp pj find"n 'Eclor.r ch un t- ma u < 1 1 , . t on g ,smm32,,, ,y ,, , m,,
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, IN ~3E'EVEtiT TilERE IS A "NO" A!;StJE11 hD ANY Oy T;iE Ci!EC)11ST QU PAG:E AND PARAGIMPl! 1;Uf:SE'A OF Tl!E Q. A. PROGR.O! PLAN A!!D/OR
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'* IS TO - .,' BE y i IDEllTIFIED L- :-
- WDER Tl!I APPROPRIATE COL 1.:.'21. -
- J. 3.0 ' , pscg s hti$.I.1TY PROGRAM L'taACDENT ' ,
, YES. _NO -
PARA. NO. 3.1, POLICY
- 1. ,,
Does the plan identify r.mnatement
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co:=it=ents which vill ensure that . quality requ~ ire::ents are net, and
- only product (s) coeting quality .
- ~ , .
standards will be supplied?
=
., .,3. 2 ORG1';TZATION ' .
1.'
,1 -
Docs the plan identify t.hnt the f t quality control organizational , t structure, responsibilit.ics and - interfunctional relationships .
' are clearly established? ,
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- 2. 3ces the plan establish that ,
i >ersonnel performing t'he quality . control function vill have the , kperformthefollowing: authority and responsibility to 1 .
- ~
A.
- Establish quality' control .
requirements and responsi-bilities for both those
- performing the inspection .
fun,ction.and 'those perfor=- -
, ing the actual manufacture? _'
'B. Plan, organize, implement _
- and verify conforcance with f
. . quality control systems and ,
s,/ , procedures? , C. Evaluate acceptability of *~ _ vork using reviews, exam-
* *inations, inspecrions,
- tests and other means?
D. Withhold ac,ceptance of - worknytceetingquality 1
. standards?- , -
3.3 }
^PR0cIDURES AND IRSTRUCTIO::S -
1.,
- Does the plan establish that the . -
,cuality centrol pre;;ra:r s f 21 -
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t$1ive ' pen.:::aerts and Jnr.t.ruct- ! f ons that. d. f'ina the tc tL ds by - hich the supplier's organi:s- ,t '
- $onal onics vi)) apply gunIJty ,
- .on trol s? '
l .
) ,, . .. ..- ..g., 84
- I' "
L. < - . * * "YACE$& . i ,.
. m . - YES NO l' ARA. NO.
l t* f 3.4 _ QUALITY PT.G*.VINC
- 3
- 1.
Does the p3:m identify that the .
~ ~
supplier yJ11 provide for quality - plannins, 1.niuling: i : .
., ,A. Identifying the quality . '
provisions necessary to - ' co= ply with the purchssa . order? .
~ 3. Estchltr.hing the inspetrion * ,
( ; , pinas to be used in the '
. concrc.1. of quality? ;___ _
C. Evaluating results of the ' *
. qual.ity controls and
- caking changes where ,
/
,I -
icprove=ents are required - to c.aintain quality? t , - 3.5 PERTORinNCE E1*AI.t'ATION .', *- *
- 1. Does the plan provide for the
. '[
supplier to assess their quality throu2h the use of audits, data . . 8
. and other ceasure=ent i:: cans? - .. .
- 3.6 -CORP.ECTIVE ACTION g ~
' d. Does the plan identify a cethod f
'whereby the supplier vill identify, -
analyze and take action to correct ,, conditions that.. deviate from '
' quality
- requirer.ent's,' and to -
prevent these 'from recurrence? .
- 3. 7 . . RECORDS -
. f/ -
- 1. Does the plan identify a method / ae ./ ' .
for maintaining records of .
- inspections, tests and product '
field.performa,nce to provide .- . necessary reference data on ' l the product? . l
' . . t CO.S!ESTS SECTION 3.0 No QA/CC Dep~t. In the Organizatio' n al Chart. No vendor '
g ~- ev,al_uation. No horrective action. No evaluation of results of the quality , control in rovem nts. 4I
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- PP.0CLT:.DCt.T CONTROI' i .
- 1. " Does tha plan provide for *
- pre.:uressat practices to be .
used that vill ensure that - pi-!=hased cacerial.nects, -
.
- l,' .
'...- quality requi.rc=ents?
. 4.1 ,77.0CtDL 1 -
NT IK70DtATION CONTROL
,1. -
Doa.s the plan provide for a .
' ~
nethod whereby the supplier's .- precurement docu:nents vill *
- 3 co=tain requirements that l
.'- 'l de. fir.e what is technien31y , .
,a required and vill provide :
- ibe measures needed to -
ensure that these technical , .
': .*' requirements are met?,. . .
4.2 RECEIV~.SG II:SPT.CTION
- 1. Deas the plan provide for a .
cethod whereby purchased .*, :
. material acceptability will be :'erified upon receipt to f -
, ^
ensure the use of the correct '. , ,
. - material during subsequent ,' . '
preduct$on processing? ' .
.' 2 **
4.3 );0NCOh70 DING MATERIALS' 1. Does the plan provide for a.
- method whereby equipment or ,
- se:--ices presented to the ,
supp1 der which are found to "' '
' he conconforming to the ,
- quality requirer:ents and .'
specifications wi.ll be .- p ide=tified, reviewed and
* ' *>I '
disposed of in 'a manner '
~ ths: vill e~asure only those .
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acceptable to the ,supplicr's , aut".orized- engineers will be . used? - ., - . CO:0'.ENIE SECTION '4.0 No check of CMTR's at receipt inspection. No receiving insoection report contrary to QAM see I$ (Att. 96) .
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PAGE 4 of 6
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ES NO
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- PARA! NO.
.;.; . 5.0
, s . . .- N- PA'?UTACTURING CtmTROL - t ; .. 1., . Dnes th'a pirin pro.-ide for's *
,' method wher.:by cai:ufacturing * .
j _.' activities, which may include , . bachinin3. fabrication, essembly
, l C -7 . ~
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' .' '"and testing of equip =ent, t-ill be done undar c:ontrolled cond'itions
- i.
- to ensure tlist t.he product ncet: .
quality regisirc=ests? ' . (([
!. 5.1 ' -15SPECTION PM.Ns j-l .
,1.- Does' the plan
- pro.ide for a method whereby the , supplier will utilize f
- preplanned n:nufscturing inspection ,, , .
~.} '
' Mans to establish significant ,.
(I revic s and exsmi=ations to' deter-
' min'e that the work ccets acceptance 4 .
i .criteris at various star,es of
~. [ . -
r ranufacturing and shipping? **
,.( , ., - ...
5.2' liATERIAL IDENTIFICATION - l* 1. Does the plan provide for a method - whereby equipment, parts and caterial - - yill be identified to.ensura that - correct and acceptable iters are - l*, I ,used, and to ensu.re that thf accept-
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...; - I . ' ynce' apparent?
status of ice.ns is reddily 5.3 FAC'ILITIES CONTROLS - 1. Does the plan' establish that only
' those manufacturing facilities ,
capable of producing equip =ent that meets the design requirement will , be utilized? ^ , I .f
- 2. Does the plan establish that
/ -i r
,[~~~~ ~ . N,/[ -
methods, vill be used to control . things such as periodic sharpen- ,
- ing of cutting- tools, lubrication , - -
c'f nachine tools, overhaul of
- e. quip =en t, calibration of measuring -
and testing instrt=ents (to recog- ' nized i'ndustry standards) and other - similar actlyities? - f,
\ .
Hist 5.4 . CONTROL or SpECIAL PROCESSES * *
'1. Does the pasrl provide for contreled . .
C' methods that are =,onit cred to
- verify quk3 i:.y? :.
_ , _ , < _,_ a . _,if, g? l __ l .-l .
. .m PACI 5 of 6 .
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,a YES NO .~=
p M:A, no,, , (
- 5.5
, coNTP.0L or !?0Nco?;Fopa Inc nEEgt3t -
,. 1. Does tive plan provile for a
~,,,, method wherchy work. not con- . -
- I
- for=J.ng to' a cceh't.snce crf teria * '
vill.,be idt:ntified, withheld,
, revleued, , aIproved, corrected -
- i or othervice dir.por.ed of by
', [
the supplier's authori:ed engineers to ensure the accept-
, ,. ability of the cbapleted product
, . to der.Ign recuirc=ents? -
' 5. M ,. 2.r:oy,rdrion, pqrpjg77o;; fy:3 pge;;73g -
,. 1. 'Does the plan provide for a
- nethod whf ch identifics that '
, equipment vill be protected.
- preserved.s.nd pact ed to insure .
its ' quality is usintained during
- nanufacture, shipment and storage?
S.7 MANDLIRC - D' '
~
. . 1. Docs the plan provide for a '
4 method which identifies thac *
- the supplier vill utilize '
, handling methods and transpoi- :
)
j tation means, which ensure , , I'. that equipment and paterf al " are not da:a;,ed during trans- :
'Portation and handling?
CO:OENTS SECTION 5.0 No control of non-confor'mir.g :.aterial. No internal audits.. No manage nent evaluation of the Quality eProgram.
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. .k:.y;. l;. s su::pcind all ordering fro:a '*Edgecc:rb :1ctals" pending resolution; of c')fYe,
- 7 findings" .As offou=d thisduri.ng date?,*,.y sur rey conducte'd . * ' a on 9/18/81 by our Q.h. Departr.ent. . . . .
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.di$9:is supplier hrdbeen renoved fro:a our Acprove3 Vendors . . ..; List '
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2 . 1 SUPPLIER / DEPARTMENT , AUDITOR: Men schaefer Fdgecomb t!ctals DATE: February 10, 1982 3348 S. Pulaski Road - SURVEY O . CIL NO._Z.25-2 00 (1) Chicago,.IL AUDIT G ,: , REAUDIT O SATISFACTORY @ ' UNSATISFACTORY O CONDITIOMAL RES'ULTS: Satisfactory conditional Edgecomb has been approved with the condition that The Zeck Company will be able to purchase only Channel and Beam material. This will be effective until Edgecomb ca.n provide tracability of angic iron as a corrective action to this finding.
. Several copies of ZQS-100 have been distributed within their organi::ation.
Upon approval by Edgecon.b management their new Q. A.1:snual will be forwarded to
/ The Zack Co. Q.A. Department for reference and vendor filing.
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- Ken s':haef'e r v CCRRECTIVE ACTlON STATEMENT
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Finding el . . - There is no available record'of calibration of any measuring equipment. Finding $2 There are no surveys on file for review .,th'at' SectionVII (Survey) of their existing Q.A. P.anual states being done. " Finding $3 1:aEerial tracability is not completely adequate for angle iron products, therefore re-audit can be perfo'rmed'they will by limi'ted to supply Channel a6d Beams until such time a
, :,, verify the tracibility of angle iron.
(See aucIlt report 2/10/82 K.5) . Follow-up in thirty (30) I days to close findings for full acceptance suggested.
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O SURVEY - Cil NO. 7,QS*-100 ( 1 ) l AUDIT CHsCKLIST .
- SUPPLIERIDEPARTMENT 8 AUDIT . DATE 2/11/82
.- REPRESENT.A_ TIVES .
e i Lt.gpo ,5 t m y.s ~ BOB FATE
- AUDITORS I
*8 S. Pultr.41' Road Bob Ford :
Ken Schaefer 1 . <*cg% _ _. , John Heinlen !
.. - g h-71oo S-SATISFACTOP.Y U-UNSATISFACTORY N/A-NOT APPLICABt.E O-OPEN -
I r, - CHARACTERISTICS . FINDINGS SECT. NO. COMMENTS T l
, plier responsible for the quality ZQS-100 k and/or raaterial being supplied o They do not have'a method of cosaplete tracibilty. !
.pliance with the requirements 2.d for all materials. -
' ~
3
?.
Tha Zack Company.purcha'se ~ l i
?ller shall have a management
- l i
.Mnc to provide work and/or 3.0 -
I s 7.1 nocting established ' quality (. - - c.d c . -
. . I s,
) :
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.. -s c.611ched Responsibilities foi-
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- 3 ,
; Control 'ersonnel: p s 30 -
Guido Lir.es - 8 . - -- t Confor.T.nr c e .
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l Acceptabatity -
*on-Contbrmance -
( l ablished T.rocedures.or instruct-i : efining m:thods used to adminis- - 3.0 - s .
- tlity Con;rol. -
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AUDIT CHECKLIST - O SURVEY ', Cll NO' 7.QS-100 ( 1
) --
SUPPLIERIDEPARTMENT REPRESENTATIVES 8 AUDIT D' ATE 2/11/02 rd 9eemb :Mta'.n . i
- Dob Fate * ,
.340 S. Pula.1ki Road
- AUDITORS Dob Ford -
5.'11CA"8 ' U'
- 17-7700 . . .
' John Heinlen *
~' - -
. s S-SNiis.vACTORY - . U-UNSATISFACTORY i
. N/A-NOT APPLICABLE -
- " O-OPEN ' ..
i CHARACTERIST!CS . FINDINQS SECT. NO. COMMENTS quality plan to show methods fo'r
\
ZQS-100 N ' detectio:t of problems and pre- 8 ' - . - tivo actions to be taken, inspect-
~
30 - ethods. - . -
;ablished cor'rective action I Nres to process as needed ~
informances.. . s 3.0 , y m
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s.:
. - - ~j
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- ord filo ofcompliance all inspectiqns, test p.a verify. ano ,
':sbility of product. s 3.0 '
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- 7 1
blier provurement. forms, state
~
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hiity,requ.irements,asspecified
.0' -
s ' 7,ack Compnany purchase order. - '
. },
*, , i .- .
citNo' 0- ,.;. l'
.. O Suavei' - '
7/11/82 - ; DATE AUDIT CHECKLIST
- i
@ AUDIT - ; ;
h ' REPRESENTATIVES AUOLTORS I Bob Fate Ken Schaefer SUPPLIERIDEPARTMENT _ _
~
Bob Ford
--Edrcomb Metals . __
_ 3348 S. Pulaski Road John IIcinlen ' U, . .
~
O-OPEN ' _L . Chicaco, N/A-NOT APPLICABLE COMMENTS 247-7700 U-UNSATISFACTORY . ' S-S ATISFAC TO.RY- FINDINGS SECT. NO. ' I l I CHARACTERISTICS 1 \ - s - ZQS-100
\
P.cceipt inspection procedures to. 's i 4,o nc.blish criteria for acceptahce and , scunentation approval
. ~~
~ ;
l 2 LO. Established method to pr6 *
' g cess 4.0 alida-cenform'ng conditions as they,
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- o: .3 ovidenc . .
s
- .. . 4 I .
\
- 11. Manufa.'.turin6 c:;tsblishe.t inspection controls points through- which have 3 50 to det:rmine acceptance criteria s out -
. l iron ,
h d method by Lack er tracibility on many size,s of ang e
- 12. , There, is an . es'tablis e . i . -
I 0 5 0- ,,
*dDich all inaterial
.recordc cuo' wing traca,
- i's marked .and bi,lity .
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. AUDIT CHECKLIST O SURVEY CIL HO. ZQS-100 ( l
- _,L_
2/11/82 SUDFi.lER/ DEPARTMENT
@ AUDIT DATE .
REPRESENTATIVES ,
- decorch 1:etals
= .
nob rate - AUDITORS _.3348.S. Pulacki' Road Bob Ford Ken Schaefer - _ Chicago, IL John !!cinlen L17-7700 - -
~
S--SATISFACTORY U-UNSATISFACTORY N/A-NOT APPLICA8LE O-OPEN CHARACTERISTICS' . FINDINGS SECT. NO. .! COMMENTS
. . - ' . -w , !A"pi'ocedure for calibration of all x
licabl'e couipment and complete gqs-100 o They have been orking on establishing a worxabic and ;. sy s tem *' ' 5,g method to record calibration.
- ~ .
y -
. . . _ _ _l Procedures for6 performing f. 411t'J ?ptance on any and all spec % ' ;csses used in manufacturing s ,
50 ,
. +... -
l- :- i - f,
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A7segrer#als e mater atedwith~ areatagging for non'-confor-method and . edure to peoces/A . 8 5.0 '
. . . . . e stablish ,orocedures:for' protection ,
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sing packing and Preserving of ' i a'ia,1 frpm. damage - - 5*0 *
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- e. . .t.n i4 Apol VI:,.*.iIi f(N
- I 1.lN i MICHib AN 41350l*
- 43.J// Jie . t #40 ,
n , fp.:mx . 6; [ '* i,; thegi M u @ ff D c o .
'N ' /
/ ClJSTOM METAL FABRICATION
'W" ' ' ;
u , October 9, PJtsl 7220-M-lL1-Cis-548 Dechtel Power Coquaration P.O. Box 2167, . Midland,13I 411640 Attn: Mr. L.E. Davis Site Manager RE: Docu entation Dicerepanciou Gentlemen: Enclosed is an interim report on the results obtained to date in the review Project. of the material certificitions'for the Midland It is important to note in reviewing 'this repor,4. that the defici-encies shown for each purchase order flave only been recorded. This report does not, address the corrective action being initiated with the suppliers to obtair) corrected certifications. At the present rate of review, it is anticipated that The Zack . Ccmpany will be ready to present a final report, on or before October 26, 1981. This should allow ample time to advise the NRC that the possible 100FR50.55 (e) it's applicability. should be withdrawn or to confirm Should you have any questions or problems concerning this report, please do not hesitate to contac't me at (312) 242-3434. t very truly yours, TIIE ZACK COMPANY .
, David E. Calk _ ins,
%k Manager Quality Assurance ; -
)
DEC/br * *
. Encla '/
- cc: John Rutgers, -(DPCo) ,
Mr. Cl$rk Ash (DPCo) H. Leor'iard, MPQAD Mgr. ( C.Z. DeZutel J.C. DcZutel C.L. Eichstnedt, Jr. Q') R.B. McCarley ' Q.A. Files / Chicago
- Q.A. Files /Hidland FOUNDED TO SO*0VE SMUtEQuft'SNSM*e " x ' "
= .
5 , .O d ulairr is, 1981
- l 1
1 TO: D. C.ilkins PitOM: 11. McCrane
- SUBJ1:CT:
Interim Neport - Document at don hevii:o s eculti., Mi.flani Station only, as of October 2, 1981 SUMMI.1W : The attached cheets tabulat.e the renults of nuhject zevi :w. Approximately 70's of the listed (from Midiami uit.e) packar;un have been located and tuviewed. All packages reviewed have been attached in individu.nl bindi ri: and iiled in the fire-resist ant cabinets in accordance with the requirunentu of t he Draf t work Inutruction for " Control, Content, and Maintenanen of Q. A. l'urchace.- Order / Certified P.aterial Test Report Files". The tabulation lists "packagen". The number of certificationu in each package varies between one and twenty. For the purpose of categorization only the more major dicerepancy in each p.ackage has been tabulated. DISCUSSION: f The results of the reviewed have been categorized as followu: Clerical Errors - Lack of reference to "I.STM", revision year, or complete lack of standard designation. - Signature Missing - Lack of written signature. Signature Errors - Typed signature and handwritten signature or initials not identic. Chem / Mech Test Data - Chemical analysis and/or mechanical test data missing, or not in accordance with ASTM Standard Hequirements., U.S. Steel Letter - Indicates P.O.'s listed in U.S. Steel Co. letter to Zack Co. stating that material on P.O. 's were not processed thru U.S. Stee: V&T program. Letter date, Sept. ,21, 1981. ~
- . Missing Certifications - Self explanatory. Certain packages lack certification for all, or for only certain items.
(Majority appear to be missing Reliable Galvanizing Co. Certs.) C of C Only - Packages containing only a Certificate of' Compliance (no test data) . Midland Tech. Spec. appears to require physical / chemical test data for materials not specifically listed by trade name. (Various fasteners, nuts, bolts, washers, etc.)
- Alterations -
Apparent alteration of certification by typed'or handwritten additions. Stickers -
- Gummed labels applied to cortifications or certific$ tion cover sheets.
These typed and signed to indicate compliance with ASTM Standards. Authent1 city of the signatures is questionable. e O -
Ea .W'o ,412 TH P_ ACE
- CHICAGO (CICERO) ILt.
Y 4/ 60650
- 312/242 3434
.01 WESTERN
- FUNT MICHIGAN 40503
- 313/733-2040 '
L .- - t h e Y c 3, d @ I CO.
' cos. rom ucrad FABRICATION October 9, 1981 Co=nonwealth Edison Co.
LaSalle County Nuclear Station Rural Route #1, Box 220, 2601 N. 21st Road, Marseilles, IL 61341 ' Attn: Mr. Willia:n Donaldson .
, Site Manager RE: Docu=entation Discrepancies
. Gentlement Enclosed is an interim report on the results obtained to date in the review of the 2.aterial certifications for 'the LaSalle Project.
It is 1:nportant to note in reviewing this reportl that the defici-encies sho n for each purchase order have only been recorded. This report does not address the corrective action being initiated with the suppliers to obtain corrected certifications. At the present rate of review, it is anticipated that The Zack
,e Co=pany will be ready to present a final report, on or before g October 26, 1981. This should allow a=ple time to advise the NRC that the possible IOCFR50.55 (e) should be withdrawn or to confirm it's applicability.
- Should you have any questions or problems concerning this. report, please do not hesitate to contact sne at (312) 242-3434.~
Very truly yours, THE ZACK CO.MPANY
/
, David E. Calkins, Manager Quality Assurance -
DEC/br . Encl: cc: L.J. Burke, Site Project Supt. T. Quaka, QA J. Dearbeck (CECO) C.E. DeZutel J.C. De2utel AN C.L. Eichstaedt, Jr. C. Bau;ngardner Q.A.lchicago/LaSalle Site i
. e,v ierssracem m em o me e~ ~
4 DOC W.12TH PLACE CHCAGO (CICERO)ILL 60650
- 312/242-3434 Ydso) WESir_RN = FUNT MK"HIGAN 40506
- 313/736 2040 *
- f - *% _
theJ E!SMEco. CUSTOM METAt FABRICATI N i
' October 5, 1981
.. %- 1 l
1 To: Dave Calkin.s From: R.A. Perry Subj ect: Interim Report - Documentation Review Results-LaSalle Station only, as of October 5, 1981 Su=marv: ' The attached sheets tabulate the results of subject review. Approximately 84% 374 reviewed, 445 total (from LaSalle site) packages have been located and reviewed. All packages have been attached in individualbinders and filed in the fire resistant j cabinets in accordance with the requirements of the draf t work l instruction for " Control Content and Maintenance of QA Purchase i Order / Certified Material Test Report Files". The tabulation lists " packages". .The number of certifications
. in each package, varies between one and twenty For the purpose of categorization only the more major discrepancy in each package has been tabulated.
Discussion The results of the review have been categorized as follows: Clerical Errors - Lack of reference.to " ASTM" revision year, ' or complete lackof standard designation. " Sicnature missing -lack of a written' signature. <
- a. .
Signature Errors - Typed signature and handwritten " signature or initials are not identical. Chem / Mech Test. Data - Chemical analysis and/or mechanical test data missing and/or not in accordance with ASTM standard requirements. - ,
~
U.S. Steel Letter - Indicates P.O. 's listed in U.S. Steel Co. letter to Zack Co'mpany stating that material on P.O. 's were not processed thru U.S. Steel V & T program. Letter dated ' 9/21/81. Missing Certifications - Self explanatory. Certain p'ackages
- lack certification for all, or for only certain items. (Major-ity appear to be missing Reliaboe Galvanizing Co. certs) .
C of C only - Packages containing a certificate of compliance h;o test cata) f. J - A43 . 1 1
- -~ ... w en, ve rwe i t'vouE f.tEW. F.GRIC.tTICy NEEDS C.P:NousTaY* __ y _
pcyc 2 f..
~
October F 1981 . ,t L . Alterations - Apparent alteration of certification b'y typed' or handwritten additions. i
~
Stickers - Gu==ed labels applied to certifications or r erti-Yication cover sheets. These typed and signed to indicate c6mpliance with ASTM standards authent i city of the signatures is questionable.
~
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- e 0
8 9 h 9 GS e @ e e 1 G .
. )
9 og 28 l
r' 97
- Surveillance Date: October 9, 1981 ~ File No.,J-2590.26
/
LASALLE Q.A. SURVEILLANCE REPORT NO. 81-661 Contractor /OrganizationObgrved:. Zack Company 00130 All - l 4 C ategory: (1,2,3,5)
~ '
. Item Observed: -
- On October 9,1981, a surveillance was performed at Zack's Corporate s
-Office to evaluate the step (e)taken to date concerning Zack's notificat of a possible 10CFR 50.55 relating to documentation discrepancies. Upon arrival, Mr. D. E. Calkins, Zack's ManaEer of Quality Assurance presented an interim' report dated October 9,
, 1981 (See Attached), on Zack's review so far. This surveillance is based on a review of Zack's activities in progress and the above report dated 10-9-81 ,
Zack is currently re-reviewing all purchase orders and associated documentation. This documentation is being reviewed in detail, specifically for missing certs, missing signatures, any alterations, preper physicals and. chemicals and compliance,,with purchase order and specification requirements. A log is being maintained on each purchase order, showing results of this review and any corrective action required. For certs that are missing, found deficient or appaa t'o have been altered, Zack is notifying the Supplier and requesting ne certifications. hopefully assdre a.These response.conversations are followed up by letters, to To date, numerous revised certs have bee
, received, but many more are required. .
The personnel Zack has acquired to perform this indepth review were found to be adequately qualified and properly trained. The group leader was found to be a Consumer Power employee with 15 years of do'cumentation experience. Three Quan-tech personnel were also hired to assist the Group Leader. Finally, two additional Zack personnel were brought in t'o be trained and to eventually take over the documentation review once this initial evaluation is complete. ~ During were thisbeing found initialused. re-review, all necessary standards and specificatic Some questions did' exist concerning LaSalle's Specification due~to vagueness in actual. documentation requirements. These questions will be addressed in Zack's Final Report scheduled for completion on October 26, 1981., . The follouing'information w's a checked during this surveillance to assure the quality of Zack's review. All comments and questions raised by Zack were being entered in their Master Log as required. Some of the comments found by Zack may not be concerns for LaSalle Start-Up of Unit 01 based on my understanding of Specification J-2590, requirements. The follouinc; Cortifica tion : we'.c sevir .ed: e
}$
g i g .- -' '
. .- \
r- .
)7f., g, . o
(. ' A) Certs containing clerical errgrs -and missing signatures:
,* 4 s- ,
P.O. 0624 - Inland Stecl'Co. (Coils) P.O. required certifications. howevdr, certs fai. led to identify which year of ASTM - A527 was used. [ ' ..
.._.P.O. #831 - U.S. Secel. Supply (HR Bars) P.O. required certifications, but th'c Northt.'estern .5 teel Cert failet to identify " ASTM" A-36. The C, of G..from U.S. Stec)
.. Supply did however show heat ? and AS'1M-A36.
~. -
, . P.O. #947. , National Metal Fabricators (Angle rings) P.O. requirec
. .;i . . . _. ; Certs. Some of the heats received did not state it; ?
~
. J. ' " ASTM" only A36-77.
.- Other heats failed to identify
.. cither ASTM or A36 desi .
.' Edge-c'ombmetals(Plate)gnation.P.O. requiicd certs. .The
~
P.O.' #1094
- a -
.- actual CMTR was missing a legible signature. ..The covc j: - -
f._ sheet .was' . hot.:cver signed and acceptable'. -
' ~
' ^ ~
B)
~
-9,"! i . Missing Certifications .
..e ,
P.O. #508 - P.O. was written for 4-325 bolts. . Cortifications werc' h./ .1 4...?, ' . 2. . required, however, only a Cert of Compliance wgs kJs,. .
. received t/nich failed to reference " ASTM".
$~f .P.O. #572 - No certs were available, coul[,not be located. a . . 1; . . P.O. #586 - P.C.'waf for duct sealant and required a Product' e , Spec. sheet which was received. Zack is now requestil '. / J- ' - f "Ecrts.for the, shipment. LaSalle spec is not clear on ' if certs are required. P.O. #565 - Bro'ck Tool Co. '(Phillips Redhead. Wedge anchor) letter
~
;. . certification only, no actual CMTR's received. . '
'P.O. required'certs. - . . . . _ . .n..
'P.O. ?4105 K.cy Crest Inc. (Nuts & Bolts) P.O. required certs, however, only C of Compliance received..
'. C) Altered reports .
. /. . .
P.O. #914 - P.O. .requir'ed certs, howev6r, the CMTR's received
. contained.an ASTM da,te which had a different type setting. . .
P.O. #947 - Pr.0. required certs. O'ne CMTR was of poor quality.I As a result, thc' heat # was highlighted by someone.
~
. fh -
It should be noted that there was another acceptable heat # shown on the CMTR. - D), Chemicalandphysicalr.esultsnotperspecification ' -
",' P.0.'#826-halumetSteel(HRAng'e)P.O.requiredASTM-A36 l (
steel, which was received. Although; LaSalle's - Spec. for this tyne of necel -a; f r-1.^.c.TM A575 Cn.(2 M-1020 P.O. 6630 - Reliable Galvanizing (HR Angle) P.O. requir.2d /.3G whic l .
~
was roccived, however, LaSclle required ASTM A575 Grad: i M-1020 - t
, , , , , _ __a_-
- _ TW . *** ***- '#**
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. o. 681 641 .
8
. .~- .
l. D) Con' ti: - P.O. #1094 - Edge- comb Metals (Plate St'ec1) P.O. reciuired i, ASTM- A36, however, l.aSalle Spec.. regt.lired ASTM-A:- , e . Grade A.- ..
. P.O. #1102 - Edge. comb Metals (Plate) Same as P.O. #1094.
,.s .... ; .
l:: . , . . - '
. Based on these results,'Zack's review appears sufficient to -
3 .j. , identify any inconsistencies within Zack's procurement documentati.. i;5f .:' . _Various Spec devict' ions' have been identified which should 'have bc - { .2.. :- accepted by Commonwealth Edison Engineering prior t.o usc. 'These 2.j F , i. ~ , will still necd to 'be resolved. . Sarghnt & T. undy will al-so bc ;- ~
. contacted to clarify actual record requirements for certain materie fD . Pending 7.ack's . submittal of their Final -Report .on ~10-26-81,
.{ ;C;., ; ' ' disposition from Project Engineering and Zack's success in obtainir.
y,y ' re?ised certs, no additional problems.can'bc foreseen. Site QA wil i,4: .7;2 review the records to substantiate acceptable disposition of ident.t
.:. . . . . - .. concerns. at ... a later date..
.i.?.$. . . ~ Corrective' Action Taken: .
~.. W- . ' .
p- \
. .~
. Njg -
j Follow Up Action: .
;,,. ../,,.--
.. . . njg..- . \ -
---.--_-...----.:......:..____-_____.z.__ . -
f.,'* ,.
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5 . , .,RcPorted by:' ;_m.f I/ h
-~~
Date: /o,/fe;-
, Appr5ved by: ' ' k GL S w.u M
" ~
,- ' . .. N ; 3 ..'-( Date: /o[/j.
. a :. . : :;. 1. i.
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[ ;. ' . , ' . . y 97, :
.7.',,"
.., :FU. Action Verified: NAM c M Date: ' ' ' ~ ~
QA Eng. nsp. p, y. ,
.. ,, 3 . : ,
-.'.h . ~. .
FU Action Approved: N A h__N Da e: /0 /c; - ' i,: :.'.e. . .
., s.
. ' . - .,! ' . . :e .
. QA Supervisor
~7
[ . cc: . . J. Shewski/G. F.14arctis - L. J. Burke /h'. H. Donaldson
? J.'
T. E. Quaka/Q. A. File . . . ,
~
Contractor -
. . s /. . .. .
( 1 *
- .:. r- - -- ,~,.e. ; .. , , ~,- .. - .--,.. .
. -r. - . . . --. m - n--
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. . .,- i 4SOO W.12TH PLACE
- CHICAGO (CJCERO)ILI. GO650 + 312/242 3434 4401 WESTERN
- FUNT MICHIGAN 48506
- 313/736 2040 Ms c
rv \. - iRC' /'!nokMiCO.
.s - -
/ -
CUSTOM METAL FABRICATION
' / '
, October 23, 1981 -
'IOi ALL ZTG CIEP14% CIX23ZT2.T PNEL
'~~
i MCM: M.L. Skates, L.Q.A.E. ~ j .- SGGIET: On1ity Mmnmce Ibement.htrol ALL Omlity Assurance.DocuTentaticn to and frtrn fSt; pliers" of naterials, shall be transnitted to.the D:xastent Cbntml Clerk for inLW prior to issuance. .
'Ibe fol3coing &xrments shall include but rot be limited to; Purchase Recuisiticas .
. O r g xderc e C of C etc. -
i ~
~ ~ - ~ ' - ~ ' ~ '
- THE ZACK CIEPANI'
% .L.sb d m M.L. Skates, L.Q.A.E. .
Wity AssL'.arce Depart:ent/ Chicago ( \ b Cf f.
- FOUNDED TO Sot.vr 'nw travv ir unas en nou a mau we-m ~ ..~. .
-a ~ -
. ;;g*s77'xes%
G5 - (- o* . . - October 30, 1981 ' LCS 2752 l TOi J. J. Ihley, I'2 nager of Projects
- 3. 3. Stephenson, Project I*anager ,
L. O. De1 George, Nuclear Licensing Ad-inistrator V. J. Shevski, .'hnager of @;alitf- Assurance
, T. E. Qua*:a, Site Qt.ality Assurance Superintendent FROM: L. J. Bitrke -
u M CT: Interin Report on Reportable Deficiency LCS 531-08; Zack Co=pany Documentation Deficiencies r An evaluatien report dated October 23, 1981 has been submitted by the 1 Zack Co=pany. Included in the report are descripticas of the deficiencies, - found during the quality review, corrective a tion r.nd planned action to pro-Tent rocccurrence. Initial indications are that a reportable deficiency does not exist. Co==enucalth Edisen Corpany is still reviewing the following:
- a. Corrective action planned by Zack Co pan; '
- b. Required engineering resolution for r.aterial with indetortinate or unacceptable caterial properties. Infor:atien available indi-
. cates that the. properties vill te able .to be obtained or determined to be acceptable. .
'fne final report is e:coected to be co=olete,by 'Dece=ber 1,1981. If.
' further infor=ation is required, please contact us 4- ediately.
W I* Sof?I L. g41rke -
, Proaect Construction Super'intendent DS/st t cc: 3. R. Shelton T. E. Watts ,
- 3. J. I'c!.ndrev
!, R. E. Folyo?.k P. F. I*::. ning {} . V. R. Bc.aldcen -- [ t
~
A46 . . e
S 632V\MEUL4WJ e [fl[Rh(MgD'Je$AN J 4B5oD
- 313/73D 2o4o m .- - . . .
y - -
< u thed(3A@@$ '-, . .
co. CUSTOM METAL FABRICATION
, k~ . ... .
' -~
November 4, 1981 t,
.C To: All Cognirant Personndl
- From: C. L. Eichstaedt, Jr.
Re: Purchase Requisitions and Purchase, Orders for Nuclear Projects and Commercial Operations. Effective today, November 4,.1981 the following shall be adhered: ,
, 1. All purchase orders'for Chicago' Commercial operations (specific to a job, not stock) shall be issued by purchasing dept. Five (5) digit numbers shall be used beginning with C-17428. All P pO.'s shall be accountable. .
- 2. For Nuclear projects and shop stock - ALL purchase orders shall be iss.ned by purchasing dept./ Quality Assurance dept. at' CORPORATE headquarters.-
! A. Site requested
.- 1. Site to transmit purchase requisition for office supplies, tools, etc. (not part of project) to Chicago.
. 2. Site to transmit fabric'ation ticket (Traveler) to Chicago for requisition of project incor-porated material.
. 3. All requisitions / travelers transmitted to corporate project management.
, , 4. Corporate project management to issue pur-- l
, , , chase requisition to purcihasing dept./QA dept. -
l I
. 5. Purchasing dept./QA dept. to generate and
- issue order to supplier / vendor.
. N'OTE: If " Time-is-of-the-essence"," site to tele-
- / phone and/or Owip. requisition to corporate .
project management. Corporate project management thru purchasing dept'./QA dept. will verbally issue purchase nup.ber*to. site. Site shall then issue verbal purchase order
~
. number -c n :plior/vendcr. Sire ic sti:1 responsibla for trans?,itting written requisi-g /; /
Continued
- FOUNCED TC SOLVE THE Ut;*C;;E !.a1 TAL FAC;? C/ TIO* l'irEre s: C N--U MY *
- DEC;CATED TO CLEA: sir G ,.:.0 CL'O C.::.;;;:NO TI;E A:7. (,,;; o;c v.py;LO *
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- l ' tion to corporate project management.
Confirming written purchase order shall. -
~
not be issued without written requisition / f traveler within 72 hours. , B. Plant Generatec (specific project and stoc'k)
~1. All Requisitions shall be. transmitted thru
~
corporate projec't' management.
- 2. Corporate project' management shall generate
- requisition and transmit to purchasing dept./ -
QX dept.
- 3. Purchasing dept./QA dept. shall generate and3
' issue 'psrchase order -to supplier / vendor.
~ 1 , ' ~; ~ ~
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C. All purchase orders for nuclear projects shall
,j be four (4) digit numbers commencing with C-1422.'
The above directive shall be'in effect until pernanent changes / procedures are developed and implemented. f.
- x. GC M #
/ --' k 4 Carl L. Eichstaedt, JM David Calkins Donald R. Mal'hhn
- I c *'.: : : := . . '
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Sites to return all unused purchase orders and P.O. logs to corporate headquarters. ___
~
~~ ~
Note: Distribution of purchase orders is as f.ollows:_ A. Two (2) c,opies (white and goldenrod) to supplier / ' vendor. . B. One (1) copy (yellow) to corporate QA dept. file'. C. One (17 copy (green) to corporate accounting dept. file.
! D. One (1) copy (Xerox) to purchase requisition initiator..
E. One (1) copy (Xerox) to corporate engineering dept. file.' F. Onekl) copy (Xerox) to corporate purchasing dept, file.
; i l
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4'JOO W.121H PLACE e CHICAGO (CICERO)l..L G0650 e 312/242-3434 , 4 4401 WESTERN
- FLINT MICHIGAN 48506 e 313/733-2040
,T, . . . . l Si iheMe@DU co.
- s. CUSTOM METAL FABRICATION
. n,_p// c MEETING SCHEDULED FOR:
FRIDAY, NOV. 13, 1981
'l
[ 10:00 A,M. -CONFERENCE ROOM-You are requested to attend the above scheduled meeting to be held in the " Conference Room" at 10:00 a.m. 11/13/81
. f
SUBJECT:
Bechtel Audit of Novemb,er 18,'19, 20th 1981 at the Chicago facilities. . I . jfh David E. Calkins, Manager Quality Assurance
, .s ' -
ATTENDEES: C.Z. DeZutel N. Rosa ,
' B. Prim
- G. Kollaritsch
, J. Engh ; -
R. Greune j T. Howard D. Henigan H. McGrane - R. Basiaga - M. Skates ( i MF .
+ FOUf 'DED TO SOLVE THE U'V.VE f.*ET AL FAER O&.T+0N IJEED5 On WJJSTRi'.
- DEDICATED TO CLEANING AND CUSTOM 121NG THE AIR OF THE WORLD + - L'7 -
. NO . 11, 1981*
's , UNTIL FilRTHER NOTICE THE FOLLOWING RECORD REVIEW PROCEDURE WILL BE; '
- 1. NO FILE OR FILE MATERIAL WILL LEAVE THE DOC MENT ROOM.
~ '
2.' FILES ARE TO BE REVIEWED IN THE DOCUME T. TABLE PROVIDED. 3. IF EXTENSIVE REVIEW OF FILE MATERIAL IS NEEDED, COPY / COPIES OF PERTINENT DATA WILL BE MADE BY DOCUMENTATION PERSONNEL.
- 4. FILE MATERIAL IS AVAILABLE .TO ZACK OR ZACK RELATED PERSONNEL INVOLVED IN RELATED RESEARCH.
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- 7. .
J November 12, 1981
)LLt. 3.W. Cook
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Vice-Presidentt, PESC-Midland SLtc
. Consumers Powen Company 1945 Parnatt Road, P 356- B Jackson, Michigan 49201
Dear k. Cook,
The Zack Company would like .to exptess our sincere gratitude
.to Conswners Powcr Company for tJte loan of your employee, bVt. Howard McGrane, for .the . total docwnent codroi audit of .
our Corparation. . His ptofcssionalism, exper.tise and dcneanor are a credLt to his employer and himself. . Concurrently, we deeply appteciate the opportw1Lly afforded
.to us, to valida.te the good reputation and name we sincerely have fought .to maidain and vindicate.
Sincerely, ~ c w Chris. tine 2. - a% et, mR - President ' - C2D/br cc: k. H. Leonard -
@ L L.y H @tane; -
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.a.s ArI
- FOUNDED TO SOLVE THE UNIQUE METAL FABRICATION NEEDS 0 INDUSTRY.
- DEDICATED TO CL EANING AND CUSTOM!2iNG THE MR OF THE WC9LD.
i w, ' L AUDIT REPORT
\
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ren Seliae t er-SUPPLIERIDEPARTMENT _ _ _ _ . _ . . . - . . . . AUDITOR.
. UY.AS, it4C.
. . . . _ . . . DAT E- l'el o terL_ J 'i . I 'nu 7535 H. ROOSEVEur n!>. .
SURVEY O 2C/L NO. M's-100 (1) l ron!:3T I AltK, Ir. AUDIT 15d
- - _ . . _ .. REAUDIT C SATISFACTORY C UNSATISFACTORY @
RESULTS: UtisATIsrAc-@ny Through the audit perfoamed .it the Sc.ia, Inc. office, it has been determined that this organization will not. bu .ible to meet. the minimum entablished quality requirements as establiched by Tlie Y.ek Coinpany. From the information received they cannot verify aniy proiluet f u r n i:,hed. f I
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von ecaefer > n n ipp AUDITOR CORRECTIVE ACTION STATEMENT Resurvey to determine further auditing should be made within the year.
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Correet;on ;
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Jpecific:tions _._ 'Your files ' d Details -
'.,- Your films & Distribution '
- __._ Final Approval Relees, for Produ: tion
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- SARGENT & LUNDY
- CNG E N CCRS
' , S S C AST M ON ROE $*R EET CHIC AGO. BLLINCIS 40403 TELEPMONE 312 269 2000 s . .,- .
February 15, 1982 - l Project Nos. 4266-00 j 4267-00 C5mmonwealth Edison Company - LaSalle County Station . 1
~ ' - -
Nonconformance Report (NCR) . No. 566* EVAC Material Documentation" -
~
Punchlist Item 6.36 .
.- ~ . * ...- ;. , . .*
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Mr. T. E. Watts - Proiect Engineer ' -
- .- , ~
P. O. Box 767
. 2 ,
Chicago, Illinois 60690 . .E. . , . b g ,'. . . '.. .. . . .
References:
- 1. Sargent & Lundy (S&L) , (E. P. Ricohermoso) letter to Commonwealth Edison Company (CECO) , (T. E. Watts) dated November 24, 1981, regarding NCR Nos. 566, "
557 and 558.
- 2. S&L (E. P. Ricohermoso) letter to CECO (T. E. Watts)',
dated November 25, 1981, regarding~NCR No. 558. .
Dear Mr. Watts:
We have reviewed tlie subject nonconformance concerning the inability of the HVAC Contractor to obtain the complete certified Mill Test Report for the material used in the HVAC System. The following actions were performed to resolve the~nonconformance: .
- 1. Requested additional information such as the specific application of the material in the HVAC System. ,
Per Mr. J. Dierbeck of CECO - LaSalle County Station on February 3, 1982, the materials listed in the.NCR attachments were used as SHIM for the Primary Containment' Cooling Coil
. Cabinets (lVPfi3AA/B and 2VP03AA/B) supports.
_%kP4
- 2. Evaluated the chemical analysis report 4by#Eontractor for the material. Based on the application of the materials in'the i I
HVAC System, the absence of physical test report 3.s acceptable. The subject nonconformance is accompanied by letter of certification , from the contractor which certifies that the material is produced r to ASTM A36-77a specification. With this supporting document and the l actual application of the material in tho'HVAC System, we accept j the material as is, withou t reports.
/\55 -
1 G - .: . . .. . .~.
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' SARGENT & LUNDY J ENGlNCCR9 CMf C AGO February 5, 1982 Mr. T. E. Watts Pago 2 Co==onwealth Edison Company ,
~
Should you have any further questions regarding the above, . . .. please call me. ! Yours very truly, ,
.- 'E. P. RICOHERMOSO :
, E. P. Ricohermoso . ,
HVAC Project Engineer
... ' .-~
EPR:le In duplicate
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"J:i V. Reklaitis (1/l) .,
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.COI VIESTERN
- FLINT !.'.lCHIGAN A b C. ~r\ dpel co, .
t h' a ' h'~ c 7 _ CUSTOM METAL FABRICATION v .- . 1 Td'E ZACK COMPANY
- LM OF CERTIFICATION .
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Ref: P.O. #C-683 ite=s 102, 103 and 104 This letter is to certify that the above referenced material. items
- were supplied by Edgecomb Metals from ASTM A-36-77a materials. ..
fication from Edgecomb are attached. The letter and material c r ) However, Edgecomb Netals is unable to trace heat numbers back to their 1978 records and is therefore, unable to provide the physical test re-- sults. . n ._ r n . David E.'CaDtins ' f Manager, Quality Assurance _ ~ . . , . , . .
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- FOUNDED TO SOLVE THE UN#0UE METAL AIR OF THE FABRICATION WORT.D . NEED
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hljl,N LN U jjid c.auvr, ,% k,.! mM.U w ~ c b s: lN. LL{ OZ S~ october 22, 198.1 ,, c:. . The..zack Co. . .
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Chicago,.Il. 60650 ..y....
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'Mr. David E.:Calkins. .
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23,.- 'T; 1 ' . " " [ Y '["3n reference to your letter of' September
, . -lg .
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195i".I have contacted Northwestern Stee1 & Wire Co. I'..' about tbe problem of certified mill test reports not
....- directly . ref erencing '.'. ASTM'.' . . .
_ Nor'thwestern Steel & Wire Co.. has sent me that a- ,,
-'.- letter, which'I have attached for your records, :
"'.'.. ' states all. A.-36 . material purchased by Edgcomb, Metals , ,
"-r ,
Co. is'produ.ced ..
.to ASTM-A:36-77a. .,
I hope i.h'is will solve the problem stated in
~ .
ye'ur letter and want you to know that if you have any
- further questions, please do riot. hesitate to call. . .
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-- Sincerely, . .
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John P. Heinlen . . Manager Hot Rolled Products t . '
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g EoGCoMB METALS COMPANY
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- C.'1\ ort Gehtern Steel anc
- Sterling, Illinois G1081 v
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' Gentlerten:
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, .. fact that all 'A'-36 malierial purc ase d h
.' .by' Ed om 1 tals o m gh sternSteel5l{iTeisproducedto ,, 3 .' . .(,'. 7.~ . .- Y" ASTM- A36- 77a. .
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n the process of worh.ng t us 5^ " :
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e sorry for any i$...onVience..t'his may have causeg. . , . Ue. ar
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.. > Yours Truly Northwestern Steel G lb..re -
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Merb C1eseng'er '.. .
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Chief Inspector .
. . Quality Control .
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f;c R. DEnv .,~.f.,** (APPS7 DIX B) TELEPHONE IG40RANDUM 4 o #f Record of Telenhone Resolution of Nonconfor=ances { .O 7 S k'O -2 # NCR No. 6/a5
- 1. Nonconformance Reported'By:
~
- 2. Date Reported: _ b/3//P/ -
- 3. NersonsContacted: '
Title _ Date Person-f%4. 6% -
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T. E. svJcd:ko - u
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- 4. J1esolution: ,
# A TE e 14 L- b# I5-
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. & ' 6/nla Date:
SignatureY O Paperwork.Tollow-up: 5.
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A. fidR Date Signed: Remarks:- ,- Date Rec'd: . - B. Revised Dwg./ Spec./Proced. ' Released
.: Checked By:
. .Date Due: Date Rec'd:
N . ; I
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(....C. Date R? leased NCR to Field (Site or Vendor) - Released By-gf( -
s k- . SARGENT & LUNDY UI d*" CNGIN C CR O o S S E AST MON AOC $TN E t t I ' CHIC ASO. ILLINOIS 90003
. ' TCLEPHONC 312 269 2000 ,
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-} :
rebruary 2, 1982
'"s Project Nos. 426 -00
' - 4 4267-00
t Commonwealth Edison Company
.~
- LaSalle C.ounty Station - Units 1 and 2 Non-conformance Report (NCR) , , .
~
No. 566f 9
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.'Mr.'J. Dicrbeck
~ '
- Co:nomicalth Edison Company *
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.LaSalle County Station R. R. fl, Eox 240 '
61341
' s . ., , .
- , Marseilles, Illinois .
e.
Reference:
Sargent tr Lundy's (E. P. Ricohermoso) letter to - Commonwealth Edison Company, (CECO), (T. E. Watts), ' dated November 15, 1981.
Dear Mr. Dicrbock:
In order that the subject NCR can be evaluated by Sart,ent & Lundy, will you please let us know where the materials were used or have d
.The Zack Company fusther justify where the materials were use , ,
in the UVAC System. , . . . Yours very truly, .. 3 /., ', . 2, '.e I. .. ..
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. E. P. RICOMERMOSO .
, . j..,4 -
,y.
' E. P. Ricohermoso i
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HVAC Project Engineer ;
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. EPR: 1e s y, yg.,5 PEA HN. J. D/Ese8&c/c c/' afco - 4 SC 6 0,J f
.In c,uplicate Copies: THE MA TE}C/A L 5 SNowd e.J 7wse Mcx wee J. L. Clark U. SED 04 TMS Suppoxys [swN$} cp sypg3AAjg D. 3. Skoza -
C. Eichstaedt AMD 2VA:73A A /6 . rNe2.<' d.psts nME d.sM .
.J. D. Engh ,<6FEAENL:E 4hm . Mo. M - / 9 7/ -
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24 February 19K2
~
\*
- INTEROFFICE MEMO .
To: Zac.k Company Document Contro.1 Departmen't' - Chicago QA/.0C - Chicago - Re: 'Writtt.a Reports, . Effective this date, any and all written reports to
- Zack Company clients, customers or' sui > plier,s must bc ,
reviewed and approved by Corporate Seni.or Management prior to dispatch. . .
~
MW . 'L '~2., t e
~
JosephC.beZutel O .
,. Executive Vice President -
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'WE5 TERN
- FLINT MICHIGA SOS
- 313/736 2040 O
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- 0 the \ M^$.h/ CO. ,.
CUSTOM METAL FABRICATION -
~
March 1, ,1982 Commonwealth Edison Company
#1 Box 240 R.R.
Marseilles, IL 62341
- Attn: Mr. J. Dierbeck Re: NCR's Related to Reportable Defect Evaluation Report Mr. Dierbeck, Attached are 99 NCR's that have been generated to close out items that.are currently included on the reportable defect evaluation list. Items covered by these NCR's are items purchased soley for the LaSalle Project and items 'purchas-ed for stock and used at LaSalle.
Of the 99 reports, 30 have been closed internally by The Zack Company. Closure of these reports was accomplished through project management review and the surfac-ing of documents and information made available by project manageme'nt. On these grounds we determined that it was within the authority of the The Zack Company to close these reports. Xerox copies of the closed reports are included for infor-mation. Any comments or additional information you may have concerning the affect-ed items would, of course, be welcome. The 69 open NCR's are submitted for an accept as is disposition in all cases. These are items for which, at this point in time, it seems unlikely that necessary
. documentation to correct deficiencies can be obtained. Also in this group are items that cre correctly docume-ted but are not included in the LaSalle Tech. Spee.
Closure of the above referenced NCR's will reduce the number of open items on the list to 35. These items are of a cle,rical nature and we are reasonably certain that necessary documentation can be obtained to correct the deficiencies. NCR's were not written on these remaining items based on this belief. Although a time frame for completion of all items on the list.cannot be establish-ed, closure of the enclosed NCR's and continuing effort on the remaining items will certainly bring this matter to a close in a timely manner. Very truly yours, The Zack Company
'b*% e . .y , y' Rt.y.Tond J. Basia O*A* '.nsincer
,g,g~ g g ] g',]-
Zack Senior Mda ament d FCUNCED TO SOLVE T'HE UNIQUE METAL FABRICATION NEEDS OF lNDUSTRY
- A5'7 CE&cwo To c't=o ao cuS rc=No T"E 'un c7 T"E woai o -
m fI
. ;, March 1, 1982 CECO. Mr. J. Dicrbe-1:
Page 2 j , ? PJB/dm - 4 cc: C. DcZutel J. DeZutel . M. Skates
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- 313/732 2040 the :.7JA@% co. ~
CUSTOM METAL FABRICATION April 12[.1982
"~,
' ~
E5gineering Draluation - , i, tGB~5crda.e-ah _ Affected P.O.'s - C-1089, C-9355 and C-475 ._ " NCR Violation . No CKrR's for 100 ft. 6" x 4 x 1/2" ST, 2000 lbs. ' 2" x 2" x 1/4" angle iron, 2000 lbs. 3) x 31 x 1"
~
angle iro'n , 100 ft. of 4" x 4" x 1/4" angle iron and 100 pcs.1/2" x 18" x 18" plate. , Discussion 1, C-475: ..
~
This order was to Jones and Laughlin Steel Company for . 100 pes. of 1/2" plate (A36) 18" x 18". In researching our corporate records there is_no evidence that Zack Co=pany ever received the items. There is no receipt
- inspection; no " quality control" yellow sheet; no delivery receipt; and no invoice from Jones and Laughlin. .
- However, had any of this mater:'.a1 ever reached the site, the timing is such that none wguld have been used with-out verification of certifications. It should also be noted that ASTM A-36 is a very low grade carbon steel and any co=mercial carbon steel would provide similar character-istics. . . 2. C-9355:
This order was for 2000 lbs.- ( 600 f t.) of 2" x 2" x 1/4" galvanized angle iron, 2000 lbs. ( 320 ft.) of 31"x 31"x 1" galvanized angle iron, 100 ft. of 4" x 4" x 1/4" galvanized angle iron. Material was received by Zack Company on May 25, 1976. Researching the fabricarion tickets for the
.LaSalle project show that the 2" x 2" x 1/4" angle iron was
. .used in the Service Bui3 ding for hangers. Lakes Steels
' standard practice is to furnish either ASTM-A36, ASME SA36 and/or M1020 Merchant Quality steel when' angle iren is ordered,in all cases we believe this meets the intent of the design. The 3) x 3] x 1/4", and 4" x 4" x 1/4" angle ircn ,
were used in Service Building and Turbine Building for hangers. Zack Corpany did not start fabrication of seismic hangers until mid-1977, approximately one year af ter the material was received. Therefore it is reasonable to assume that none of the above material was used on seismic hangers.
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- FOUNDED TO SOLVE THE UNIQUE METAL FABRICATION NEEDS OF INDUSTRY
- p
- DEDICATED TO CLEANING AND CUSTOMII:NG THE AIR OF THE WORLD
- y .
O c. t . Enginaaring Eviluntion NCR No. L-287
< April 12, 1982 Page 2 ,
- 3. C-1089:
mis order was for six various sizes of Structu.ral Tubing. The order was to Chicago Tube and Iron (3-6-80) which possesses an N -stamp (N-1397), see attachment 1) . Zack Ccuipany has a certificate of conformance from Chicago Tube and Iron stating the structural tubing "was manufactured to meet: _
- .. . ASTER-A-500 1978 Gr. B" (See attachment 2). We do not a
have the actual .CMTR from manufacturer for the particular size 6" x 4" x 1/2" as called for in the ASTM standard. We do have the CMTR's for the other five. items. C.T. and I have been in contact with Audrey DePaul, 523-1441 in regards - to the a::issing CMTR. , e
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, THESE TEST REFONTS APPfY TO YOUR
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thep24@T co. ' CUSTOM METAL FABRICATION J April 12, 1982
- i Engineering Evaluation -
' i' ,
IICE: Ic2S4 _ Affected P.O.'s- C-642 (1-12-78) C-696 (5022078) C-9411 (4-5-76) NCR Violation: 40 Tons - 22 ga. and 20 Tens - 18 ga. galanized coil c.aterial has no ASTM designation on certs. Discusstion: 1- C-9411 (20 Tons - 22 ga. ) ; As of 4/6/82 corrected CMTR from U.S. Steel has been received and reviewed acceptable by Zack Corpany Q.A. depar w nt. , ,,- ,.
- 2. C-696 (20 Tons - 22 ga.); Ee received 5 coils weighing
~
a total of 43,640 lbs. 3 coils were from heat number 06R037 (407, 408 and 409) .-The chemical analysis as. listed on the test report falls within the che=ical analysis of ASTM-A527-71. The physical analysis of 40000 psi yelld and 52700 psi tensile is in the same
- range as ASTM-A527-71 steel, when'it.is physically
~
~
tested. The ASTM A-527-71 does not have a physical testing requirement. The other 2 coils (405 and 406) were from heat nu=ber 06TS13. The chemical analysis as listed on the test re.crt falls within the che=ical
. analysic of ASTM-A527-71. The physical analysis of
.39,470 psi yeild and 52,630 psi tensile is in the same 'rance as ASTM-A527-71 steel, when it is physically tested. The U.S. Steel CMTR and invoice states "Galv '
'~
. Steel Carbon IJQ G90 Chem Treat No Oil." (See attachment 1) IEQ is abbreviation for "lockforming quality." ASTM A-527-71 is standard for "lockforming quality steel sheet, zine coated galvanized." The
- G90 is the designation for the coating as specified in AS':21-A526-76,.77, 79 and/or 80A The purchase order just previous C-695 issued the same date to U.S. Steel for 20 gage does state "A527-71, ISQ, G90 Chem Treat" on U.S. Steel invoice (see attachment 2) . Two coils of P.O. C-695 came from the same heat as thiee coils of C-696. .
AR l = FOUNDED TO SOLVE THE UNICUE METAL FABR: CATION NEEDS OF INDUSTRY
- l
*. DEDfCATED TO CLEANING AND CUSTOM! ZING THE AIR OF THE WORLD
- l l
h
- h *
, April 12, 1982 ,
Engineering Evaluation NCR-L-284 .
~
Page 2 . 4
- 3. C-642 (20 Tons - 18 gage) r We received four coils (338, 339, 340 and 341) weighing a total of 42190 lbs. '~he shipping notice
- and invoice from Bethlehem Steel Company states "B5THCC7 COILS, LOCK FORM QCAL, G90 Type Q, Spec: AS-~21-A527-71." The CFlIR states "B 7 ECON COILS, LCCK FOP.M QUAL, G90 (See attachment 3, 4 and 5) ." The chemical analysis as shown on the test rem falls within the chemical analysis of ASTM-A527-71. (See attach =ent #5). The , physical tests as listed on PTL reports (attachment 6, 7 and 8) are in the same range as AST. M-A526-71 material, when it is physically tested.
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- I 9730650001 23 05/15/78 C-696 rsLL uu tC'al tuL es0. U3 OnDe n oso.
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. COIL NO HEAT-NO COILS LIN.FT. ACT-LB THEO-LB . - 198586 06T513 1 1525 9650 9&-31 -
198586 06T513 1 1725 '10950 10555
-G16C28 06R037 1 1037 6700 6345 -
G16428 06R037 1 1279 8240 7326 . 016428 06R037 1 1272 8100 7283 CENTS /LB
~ - 41640 . 25.5250 10679.6
- - 5 6838 43640 41840 ZINC PRICE ADJUSTMENT CENTS /LB 41840 .1400 58.5
- TOTAL 10738.2 PLUS TR ANSPORTATION CH ARGE 43640 2.0000 872.8 TL 40M PER 100LB LESS COMP ALLOW PER 100 LB 43640 1.7000 741.5 TOTAL DELIVERED VALUE 10869.
LESS COLLECT TRANS CHARGE 43640 2.0000 872.8
. TL 40M PER 100LB h HD C' - MN P. S
.025
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.0360 MINX 60 CGIL. ' ,'
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.. . ID 20 -
PRICE.HUMBER .B 23-0 515 .
.'.. CGIL NO HEAT-NO COILS LIN.FT. ACT-LB THEO-LB -
095630 01R001 ~ 1 847 6450 6 Z2 0 -
'005630 01R001 1 -
1332 9900 9561 .' 005630 01R001 1 1354 10400 9242 - 023654 06R037 . I 1381 10900 10141 023654 06R037 1 1535 11750 11051 ' CENTS /LB
.~ 5 6389 49400- 46915 46915 25.4250 11928.1- . ZINC. PRICE ADJUSTMENT '
CENTS /LB 46915 .2700 103.2~
~
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TOTAL . 12331.3 ,
.~. _
- PLUS TRANSPORTATION CH ARGE _
958.3 ' TL GON PER 100LB 49400 -1.9400 LESS COMP ALLOWANCE PER 100 LB 49400 1.6000 790.4
. TOTAL' DELIVERED VALUE . ,
12199. LESS COLLECT TRANS' CHARGE - 958.3 TL 40M PER.100LB 49400 1.9400 LT NO' C MN P- S
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