Please click on NCR # to view the Nonconformance Report
 
NCR # Originator RAP # Open Date Status Item Nonconforming Condition PPPL/Supplier
WBS 12 - Vacuum Vessel
3599 PPPL 3154 7/23/2004 9 - Closed NCR VVSA Prototype The welders are only qualified for flat position welding per ASME Code. Supplier
3655 PPPL 3245 5/31/2006 Closed VVSA 1 Port to vessel fillet welds were found to be undersized Supplier
3660 PPPL 3245 7/5/2006 Awaiting Corrective Action VVSA 1  Magnetic permeability greater than the 1.02 Mu max. allowed Suppler
3664 PPPL 3250 7/21/2006 Awaiting Corrective Action VVSA 1, 2, & 3 Vertical support clevises don't match up with the threads on the Clevis bosses. Supplier
3669 PPPL 3245 10/6/2006 Closed VVSA 2 Magnetic permeability greater than the 1.02 Mu max. allowed Supplier
3670 PPPL 3245 10/6/2006 Closed VVSA 2 Port 11A was found to be shorter in length than called for on the drawing. Supplier
3676 R1 PPPL 3245 10/31/2006 Closed VVSA 3 Magnetic permeability greater than the 1.02 Mu max. allowed Supplier
3677 PPPL 3245 11/2/2006 Closed VVSA 3 Ports have dimensions that are beyond the allowable tolerance on the drawing. Supplier 
3679 PPPL 3264 11/6/2006 Closed  VVSA 3 Magnetic permeability for all checked hoses exceed allowable limit. Supplier
3688 PPPL 3268 12/12/2006 Closed VVSA 1, 2, & 3 Magnetic permeability for all checked hoses exceed allowable limit. Supplier
3689 PPPL 3268 12/12/2006 Closed VVSA 1, 2, & 3 Magnetic permeability for all checked hoses exceed allowable limit. Supplier
3691 PPPL 3268 1/2/2007 Closed VVSA 1 Weld exceed allowable magnetic perm. of 1.02 mu Supplier
3703 PPPL 3268 3/14/2007 Closed VVSA 1, 2, & 3 Magnetic permeablity greater than the 1.02 Supplier
3704 PPPL 3268 3/15/2007 Closed VVSA 1, 2, & 3 Magnetic permeability greater than the 1.02 Mu max. allowed Supplier
3710 PPPL 3268 4/13/2007 Closed VVSA 1 Dimensional deviations with the placement of the heating and cooling lines Supplier 
3714 PPPL 3268 6/19/2007 Closed VVSA 1, 2, & 3 Magnetic permeability greater than the 1.02 Mu max. allowed Supplier 
3715 PPPL 3268 7/9/2007 Closed VVSA 1, 2, & 3 Heater Tapes for electrical isolation from the VV at 600 volts with headings of greater than 10 Mega Ohms. Supplier
3718 PPPL 3250 7/18/2007 Closed VVSA 1, 2, & 3 Hairpin cotter pins for the vacuum vessel verticall support assemblies are above the max. permability allowed. Supplier
3719 PPPL 3268 7/26/2007 Closed VVSA 1 Resistance readings range from .5 meg ohms to 2.5 meg ohms on VVSA 1  Supplier
3727 PPPL 3292 9/21/2007 Closed E-3 and F-5 All studs inspected were found to have a lip at the outer edge of the ends of each stud causing an  out of tolerance. Supplier
3728 PPPL 3298 9/28/2007 Awaiting Corrective Action All VVSA's Modular coil flange hex nuts reported to be out of tolerance by the vendor. Supplier
3729 PPPL 3729 10/15/2007 Closed VVSA 2, 3 Dimensional deviations with the placement of the heating and cooling lines Supplier
3730 PPPL 3250 10/22/2007 Closed VVSA 1, 2, & 3 Cryostat thermocouple feedthroughs have magnetic permeability greater than is allowed Supplier 
3733 PPPL 3268 10/26/2007 Closed VVSA 1, 2, & 3 Five of the VV diagnostic loop cryostat feedthough conflat flanges and 3 associated feedthrough disc exhibit magnetic permability greater than allowed Suppler
3745 Vendor 3315 1/24/2008 Closed Heater Tapes for Port Extensions Heat Tapes fails to heat-up non-functional  Supplier 
3747 PPPL 1337 1/28/2008 Closed  Gantry Crane #10 QC witnessing of Lifts at PPPL Supplier
3758 PPPL 3264 5/1/2008 Closed VVSA Heating & Cooling Hoses During pressure testing after installation, eleven of the hoses were found to leak.   Supplier 
15103 Major Tool N/A 4/16/2004 Closed VVSA Prototype Radiographic inspection requirement ASME section VIII, Division 1. Supplier
15377 Major Tool N/A 4/20/2004 Closed VVSA Prototype The material thickness on panel #5 and panel #4 is out of tolerance.  Supplier
15410 Major Tool N/A 4/16/2004 Closed VVSA Prototype The profile on panel #5 exceeds the +0.187 tolerance.  Supplier
15418 Major Tool N/A 4/19/2004 Closed VVSA Prototype The 0.250 projected true position checks 0.570. Supplier
17157 Major Tool N/A 5/12/2005 Closed All VVSA's Half Nipple 401021 Magnetic permeability Supplier
17167 Major Tool N/A  5/12/05 Closed All VVSA's Flange 120-004 Magnetic permeability Supplier
17233 Major Tool N/A 5/12/2005 Closed All VVSA's Flange 120-004 Magnetic permeability Supplier
17237 Major Tool N/A 5/12/2005 Closed All VVSA's Flange 120-004 Magnetic permeability Supplier
17240 Major Tool N/A 5/12/2005 Closed  All VVSA's Flange 8.0" Magnetic permeability Supplier
17286 Major Tool N/A  5/12/2005 Closed All VVSA's Flange 8.0" Magnetic permeability Supplier
17287 Major Tool  N/A  5/12/2005 Closed  All VVSA's Flange 12.0" Magnetic permeability Supplier
17288 Major Tool N/A 5/12/2005 Closed All VVSA's Flange 4.63" Magnetic permeability Supplier
17314 Major Tool N/A  5/12/05 Closed All VVSA's Reducing Nipple 120-004 Magnetic permeability Supplier
17342 Major Tool N/A  5/12/05 Closed  All VVSA's Flange 12.0" Magnetic permeability Supplier
18097 Major Tool N/A 10/13/2005 Closed VVSA 2 Flange 122-049 Magnetic permeability Supplier
18144 Major Tool N/A 10/13/2005 Closed VVSA 1 Flange 122-104 Magnetic permeability Supplier
18154 Major Tool N/A 10/13/2005 Closed VVSA 2 Flange 122-104 Magnetic permeability Supplier
18155 Major Tool N/A 10/13/2005 Closed VVSA 2 Flange 122-104 Magnetic permeability Supplier
18175 Major Tool N/A 10/13/2005 Closed VVSA 1 Flange 122-018 Magnetic Permeability Supplier
18402 Major Tool N/A 10/25/2005 Closed VVSA 1 Profile requirement of 0.188 (+ Unilateral) checks -0.110/+ 0.258. Supplier
18459 Major Tool N/A 10/25/2005 Closed VVSA 1 Profile requirement of 0.188 (+ Unilateral)+0.2.75/-0.101 Supplier
18526 Major Tool  N/A 10/13/2005 Closed VVSA 1 Magnetic. Permeability Requirements Supplier
18542 Major Tool N/A 11/28/2005 Closed VVSA 1 Magnetic permeability to be less than 1.02 Supplier
18590 Major Tool N/A 11/28/2005 Closed VVSA 1 Flange 122-004 (Port 4) Magnetic Permeability Supplier
18609 Major Tool  N/A 11/28/2005 Closed VVSA 1 Flange 122-018 (Port 4) Magnetic Permeability Supplier
18762 Major Tool N/A 12/2/2005 Closed VVSA 2 Flange 122-018 (Port 12) Magnetic Permeability Supplier
18787 Major Tool N/A 12/5/2005 Closed VVSA 3 1.25 +/- .01 thickness measures 1.232-1.247 Supplier
18888 Major Tool N/A 12/19/2005 Closed VVSA 1 VVSA bosses out of tolerances Supplier
 
Attachment
19060 Major Tool  N/A 1/31/2006 Closed VVSA 1 & 3 Flange 122-049 (Port 4B) Magnetic permeability Supplier
19063 Major Tool  N/A 1/31/2006 Closed VVSA 3 Cover 122-104 (Port 12) Magnetic permeability Supplier
19081 Major Tool  N/A 1/20/2006 Closed VVSA 1 Spacer flange weld configuration. Supplier
19108 Major Tool N/A 1/20/2006 Closed VVSA 1 The spacer flange chamfers Supplier
19116 Major Tool N/A 2/27/2006 Closed VVSA 1 It was required to oversize hole pattern on majority of all round blank covers .015 diameter.  Supplier
19142 Major Tool  N/A 1/31/2006 Closed VVSA 3 Flange 122-018 (Port 12) Magnetic Permeability Supplier
19149 Major Tool N/A 1/31/2006 Closed VVSA 1 Cover 122-104 (Port 12) Magnetic permeability Supplier
19161 Major Tool N/A 1/31/2006 Closed VVSA 3 Cover 122-149 (Port 4) Magnetic Permeability Supplier
19164 Major Tool  N/A 1/31/2006 Closed VVSA 3 Cover 122-149 (Port 4A) Magnetic Permeability Supplier
19176 Major Tool  N/A 1/31/2006 Closed VVSA 3 Cover 122-104 (Port 12) Magnetic permeability Supplier
19232 Major Tool  N/A 2/14/2006 Closed VVSA 1 Thermal Cycle Supplier
19289 Major Tool N/A 5/23/2006 Closed VVSA 1 Port NB has deformation to hole pattern after welding has been completed on Port 4 A/B and 12 A/B Supplier
19254 Major Tool  N/A 2/14/2006 Closed VVSA 2 Both lot 8 & 9 outer Helicoflex metal seals are too small to allow for proper fit of retaining strip Supplier
19286 Major Tool N/A 2/20/2006 Closed VVSA 1 Seal retainer screw locked into NB cover after thermal cycling & vacuum testing, screw had no lubricant nor was it silver plated Supplier
19288 Major Tool N/A 2/20/2006 Closed VVSA 1 Viton 0-rings are damaged upon removal from port flanges after vacuum testing.   Supplier
19289 Major Tool N/A 2/20/2006 Closed VVSA 1 NB bolt holes distorted  Supplier
19293 Major Tool  N/A 3/10/2006 Closed VVSA 1 The profile exceeds the tolerance.  The profile checks from -0.0604/+0.408.  Refer to attached graphical reports.  Supplier
19391 Major Tool  N/A 3/10/2006 Closed VVSA 1 Rework of end flanges. Supplier
19392 Major Tool N/A 3/10/2006 Closed VVSA 2 SE121-013 zone B5 469 +/- .005 dimension varies around part over and undersized, .240 - .432. Supplier
19393 Major Tool N/A 3/10/2006 Closed VVSA 1 & 2 The 1.25 +/-0.10 dimension is undersize after re-work to achieve flatness. Supplier
19394 Major Tool N/A 3/15/2006 Closed VVSA 1 The O.D. of flanges did not clean-up completely on either flange. Supplier
19464 Major Tool N/A 3/21/2006 Closed VVSA 1 & 2  Weld configurations on all ports Supplier
19562 Major Tool N/A 4/13/2006 Closed VVSA 2 Profile deviation on the vessel ends causes a misalignment to the vessel flange Supplier 
19612 Major Tool N/A 4/14/2006 Closed VVSA 1 Port 18 B Supplier
19667 Major Tool N/A 5/5/2006 Closed VVSA 1 Port 4 a is out of tolerance for position and height. Supplier
19697 Major Tool N/A 4/25/2006 Closed VVSA 2 The profile of the flange of half A checks -0.194/+0.190 under low limit and 0.002 over high limit. Supplier
19704 Major Tool N/A 4/25/2006 Closed VVSA 3 Profile of the vessel skin exceeds the tolerance. Supplier
 
Attachment
19754 Major Tool N/A 5/4/2006 Closed VVSA 1 VVSA bosses out of tolerances Supplier 
 
Attachment
19766 Major Tool N/A 5/4/2006 Closed VVSA 1 Port 8 a & b is out of positional tolerance Supplier
19767 Major Tool N/A 5/4/2006 Closed VVSA 1 Port 15 a & b is out of positional tolerance Supplier
19768 Major Tool N/A 5/4/2006 Closed VVSA 1 Port 11 a & b is out positional tolerance  Supplier
19769 Major Tool N/A 5/4/2006 Closed VVSA 1 Port 10 a& b is out positional tolerance Supplier
19770 Major Tool N/A 5/4/2006 Closed VVSA 1 Port 9 a & b is out of positional tolerance  Supplier
19771 Major Tool N/A 5/4/2006 Closed VVSA 1 Port 7 a & b is out positional tolerance  Supplier
19772 Major Tool N/A 5/4/2006 Closed VVSA 1 Port 6 a&b is out of positional tolerance Supplier
19773 Major Tool N/A 5/4/2006 Closed VVSA 1 Port 5 a & b is out of positional tolerance  Supplier
19774 Major Tool N/A 5/4/2006 Closed VVSA 1 Port 2 a & b is out positional tolerance Supplier
19776 Major Tool  N/A 5/4/2006 Closed VVSA 1 Profile of the vessel wall checks -0.404 /+ 0.543 Supplier
19832 Major Tool N/A 5/12/2006 Closed VVSA 2  Testing operation the high vacuum gauge display wouldn't illuminate.  Supplier
19868 Major Tool N/A 6/8/2006 Closed VVSA 2 Port NB has deformation to hole pattern after welding.  Supplier
19869 Major Tool N/A 8/15/2006 Closed VVSA 3 Port NB has deformation to hole pattern after welding has been completed on Port 4 A/B and 12 A/B Supplier
19990 Major Tool N/A 6/8/2006 Closed VVSA 3 Vessel wall on half B is mismatched to the inside of the flange. Supplier
20069 Major Tool N/A 7/27/2006 Closed VVSA 2 Port lengths and dome misalignment Supplier
20120 Major Tool N/A 7/27/2006 Closed VVSA 2 Port NB flange thickness & 2 dwg. SE-120013 dimensions (0.469 & 0.637) Supplier
20175 Major Tool N/A 7/27/2006 Closed VVSA 2 Various dimensional OOT shown in final Veri-surf data Supplier
20282 Major Tool N/A 8/15/2006 Closed VVSA 3 Zone G4 0.637 +/- .005 dim checks .587 to .910, zone B5 0.468 +/.005 dim checks .400 to .490,  and zone G4: 0.75 +/- 0.010" half a flange checks 0.620 - 0.650 (half B is within tolerance) Supplier
20353 Major Tool N/A 8/25/2006 Closed VVSA 3 The profile of the spacer is out of tolerance,  the profile checks from -0.144/+0.266.  The area that is out of tolerance is about a 12" long area on the top flange side profile.  Refer to attached graphical report. Supplier
20354 Major Tool N/A 8/25/2006 Closed VVSA 3 The flatness of the VV flange Seal on half B checks 0.088 (0.038 out of tolerance) Supplier
20384 Major Tool N/A 8/28/2006 Closed VVSA 3 VVSA-3 final profile deviations Supplier
21404 Major Tool  N/A 3/26/2007 Closed VVSA 1 Port Cover Plate 12 Supplier
               
               
 
 
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