THE WELCH COMPANY
440 Davis Court #1602
San Francisco, CA 94111-2496
415 781 5700
S U M M A R Y
DIARY: December 1, 1988 07:29 AM .......;
Worked at BPP site on various matters.
2...Analysis of Defects in Alignment of Generator Curb Ring
3...Pit Pier out of alignment
7...Date of Accepted Measurements
9...Change Order to Voith for Correcting Sletten's Defective Work
............CUBIC YARDS DURATION
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0201 - O-0394 0301 Voith Hydro, Inc.
020101 - Mr. Kenneth L. Carlson, Field Representative, =406 266 3275
0202 - O-0392 0302 Sletten Construction
020201 - Mr. David Marsh, Project Coordinator
Computer Support on Site
0604 - ..
0605 - Summary/Objective
060601 - Follow up
060603 - Noticed the propane valve is showing a reading below 20. The Vendor
060604 - suggested he be called to charge the tank when 20% is showing on the
060605 - tank.
060607 - ..
060608 - Called Petrolane
060609 - 406 266 3815
060611 - ..
060612 - Left message to have propane tank filled.
Curb Ring Tolerance
120501 - ..
120502 - Analysis of Defects in Alignment of Generator Curb Ring
120504 - Met with Voith's superintendant, Ken Carlson, and one of his lead
120505 - mechanics, Ron Rayome. Ken said he checked the curb ring prior to
120506 - forming and found that it was within specified tolerance. He recalls
120507 - there was a check sheet prepared showing dimensions that establish
120508 - this fact.
120510 - ..
120511 - As the manufacturer's onsite consultant, specified in the contract,
120512 - Ken informed the contractor (Sletten) that it should not wedge forms
120513 - against the Curb ring; Ken, further recalled this restraint is set out
120514 - in written instructions furnished to Sletten. Ken also recalls that
120515 - during a meeting on installation, David Marsh noted that Sletten would
120516 - not connect forms to the Curb ring, because this could result in
120517 - movement that would cause misalignment of very fine tolerances
120518 - specified for this work.
120520 - ..
120521 - Ken said that during forming operations he observed Sletten workmen
120522 - wedging forms against the Curb ring contrary to standard practice and
120523 - the record of express notice cited above. He informed the Contractor
120524 - and took photographs. Ken's mechanic, Ron Rayome, (who was present
120525 - during the discussion this morning) said he recently asked a Sletten
120526 - mechanic whether Sletten checked the alignment of the Curb Ring during
120527 - or after the forming operation. Ron said he was told Sletten checked
120528 - alignment when the Curb Ring was half formed and it appeared to be
120529 - okay. It was not thereafter checked by Sletten until after the
120530 - concrete pour was completed several weeks later. Sletten then delayed
120531 - disclosing the valuations for another several weeks.
120533 - ..
120534 - This record indicates that data is problematic in this case. Each
120535 - side has taken measurements, and in some cases they have become mixed
120536 - up and misplaced, concerning conditions before and after the concrete
120537 - pour, which is critical for understanding the cause of misalignment at
120538 - this time.
120540 - ..
120541 - Solutions...
120543 - ..
120544 - Ken advised that Voith may be able to avoid extensive corrective
120545 - machining of the Gate Assembly unit by applying a shim to take up
120546 - the tolerance deviations. This option is under consideration by
120547 - Voith.
120551 - ..
1207 - Discussion with David Marsh
120801 - Dave is Sletten's Office Engineer who supervised much of the
120802 - installation on the Curb Ring. He has been off the job for several
120803 - weeks, but was here today as a result of Curb Ring matters.
120805 - ..
120806 - I went down into the Powerhouse to investigate the work and met David
120807 - Marsh who was just completing some measurements on the Curb Ring.
120808 - David asked about Voith's concerns, incidating he is aware of the
120809 - problem Ken just described.
120811 - ..
120812 - I explained the general understanding that the piece is not within
120813 - tolerance.
120815 - ..
120816 - David asked to meet with Voith (Ken) to discuss the situation.
120818 - ..
120819 - We went to Voith's field office and spoke briefly to Ken.
120823 - ..
120824 - Pit Pier out of alignment
120826 - David advised Ken that he (David) found in taking measurements this
120827 - morning that the Pit Pier is somewhat out of alignment. Therefore,
120828 - David believes deviations in Curb Ring alignment are less severe than
120829 - if the Pit Pier were within alignment.
120831 - ..
120832 - Ken said he is unaware of the Pit Pier valuations David cited.
120834 - ..
120835 - I suggested that we wait to hold further discussions when Jeff
120836 - (Tudor's project engineer) is available in about half an hour.
120838 - ..
120839 - After David left, I asked Ron Rayome about the condition of the Pit
120840 - Pier.
120842 - ..
120843 - Ron said he measured the Pit Pier within the past few days and found
120844 - that it is within specified tolerance.
120848 - ..
1210 - Meeting with Jeff, Ken Carlson, and David Marsh
121101 - Jeff gave Dave a copy of Voith's measurements on the Curb Ring.
121102 - These were previously FAXed to Paul Robinson at Sletten in Great
121103 - Falls.
121105 - ..
121106 - Initially, Dave pointed out that the Curb Ring was installed
121107 - relative to the Pit Pier.
121109 - ..
121110 - Jeff disputed this, but Ken agreed with Dave that Pit Pier alignment
121111 - is an appropriate criteria for establishing the installed tolerance of
121112 - the Curb Ring. This criteria was then accepted by Jeff.
121114 - ..
121115 - Dave maintained that the Pit Pier is out of alignment based upon
121116 - measurements he took this morning, and therefore the Curb Ring
121117 - alignment is less defective than contended by Voith. Dave
121118 - acknowledged the measurements procedure he used was "very rough" but
121119 - he believes it is an adequate indication that the the Pit Pier is out
121120 - of alignment. Ken disagreed; he cited as-built measurements
121121 - previously submitted by Sletten showing the Pit Pier is installed
121122 - within specified tolerance. Upon examination of these documents
121123 - offered by Jeff during the meeting, David accepted that the Pit Pier
121124 - was originally installed within specified tolerance. He pointed out
121125 - that temperature changes may have caused the Pit Pier measurements to
121126 - change from when the record valuations were taken. He believes the
121127 - temperature at the time the Pit Pier record measurements were taken
121128 - was approximately 75 degrees, whereas it is about 32 degrees today.
121132 - ..
121133 - Equipment Fixture
121135 - Dave explained that the "Equipment Fixture," installed to facilitate
121136 - installation of the Curb Ring, covered the top portion of the Curb
121137 - Ring when final pre-forming measurements were taken and so
121138 - measurements could not be taken directly overhead where major
121139 - deviations now seem to exist. Ken pointed out that Voith's
121140 - measurements and Sletten's measurements both indicate the Curb Ring is
121141 - out of tolerance on either side of where the "Fixture" was attached to
121142 - the Curb Ring. Dave also mentioned difficulty in achieving specified
121143 - tolerance on the Curb Ring due to Equipment Fixture. There was general
121144 - agreement that the bottom bolting of Equipment Fixture to Pier barrel
121145 - had to be loosened in order to accomplish acceptable tolerance on the
121146 - Curb Ring prior to forming.
121150 - ..
121151 - Temperature
121153 - There was agreement that the Curb Ring was within acceptable tolerance
121154 - prior to commencement of formwork by Sletten and that the readings
121155 - obtained by both Sletten and Voith show different values after the
121156 - Curb Ring encasement was poured. David believes these differences are
121157 - attributable to temperature changes between the measurement dates.
121158 - Ken disagrees. He believes any impact of temperature changes would be
121159 - generally uniform such that the relationship between the Pit Pier and
121160 - the Curb Ring should be remain constant.
121163 - ..
121164 - Disagreement
121165 - Date of Accepted Measurements
121167 - Dave believes the tolerance measurements for the Curb Ring accepted by
121168 - the Engineer and Voith, were derived after the first 6' lift of forms
121169 - was in place. Ken and Jeff do not recall that forms were in place.
121170 - The significance appears to relate to the effect of the forming
121171 - operation on tolerance changes. If the measurements were taken after
121172 - forming, then there is no basis to believe that the forming operation
121173 - itself caused the tolerance deviations.
121175 - ..
121176 - Jeff brought out the Voith check sheet prepared by Sletten and
121177 - approved by Jeff and Ken showing Curb Ring tolerances. The document
121178 - has some sketches attached which Dave believes indicate the
121179 - measurements were taken after the first 6' lift of forms. The Voith
121180 - check sheet however, contains a hand written note that states the
121181 - values were obtained prior to any forming.
121186 - ..
121187 - Formwork Procedures
121189 - Dave explained that he gave instructions to Sletten's crew to avoid
121190 - connecting formwork to the Curb Ring pursuant to recommendations by
121191 - the Engineer and Voith. He recalled discussions with the Engineer
121192 - (Jeff) in which he recognized the importance of not connecting
121193 - formwork to the Curb Ring. Dave sketched a detail showing methods
121194 - used by Sletten to form the encasement pour in which wedges were
121195 - applied to move the formwork into final alignment. Dave advised this
121196 - procedure could not have caused the Curb Ring to change alignment
121197 - because the degree of force applied to the Curb Ring was minimal. He
121198 - recalled that after alignment was achieved a heavy timber was wedged
121199 - against the Powerhouse wall and nailed into the formwork whaler to
121200 - provide support and isolate the formwork from the Curb Ring. I asked
121201 - David if the wedges between the forms and the Curb Ring were removed
121202 - prior to pouring concrete. David said they were not removed because
121203 - the timber wedges nailed into the whalers were supporting the forms.
121205 - ..
121206 - After Dave left the meeting, Jeff and Ken maintained they recalled
121207 - observing that Sletten craftsmen in fact constructed forms that
121208 - used the Curb Ring to brace the encasement formwork, contrary to
121209 - David's recollection.
121211 - ..
121212 - Jeff said Tudor has photographs which show the bracing.
Curb Ring Tolerance Dispute
Voith Claim, Recommendations
to Tudor and DNRC
140601 - ..
140602 - Change Order to Voith for Correcting Sletten's Defective Work
140604 - Jeff advised that Tudor intends to issue a change order to Voith as a
140605 - result of measurements furnished by Ken Carlson and his comments that
140606 - the condition of the Curb Ring is defective and requires immediate
140607 - corrections.
140609 - ..
140610 - Discussed this with Jeff and Norman.
140612 - ..
140613 - Suggested that Tudor consider that, prior to issuing a change order
140614 - taking money from Sletten and paying it to Voith, the Engineer should
140615 - direct Voith to make a formal submittal of its findings and concerns
140616 - with respect to the as-built condition of the Curb Ring. Tudor should
140617 - not rely on verbal representations from Ken Carlson, as the basis for
140618 - a determination that potentially involves a finding of defective work
140619 - by Sletten, with consequent substantial loss of payment to Sletten,
140620 - since this could wind up causing a claim against the State and the
140621 - Engineer for bad performance of a legal duty.
140623 - ..
140624 - Voith should be directed to proceed with the work and can submit
140625 - written notice of any difficulty it may have installing the generator
140626 - and appertances due to as-built conditions of the curb ring installed
140627 - by Sletten that deviate from specified requirements. If Voith incurs
140628 - extra time and expense, and can submit credible evidence that a
140629 - material defect exists, then the Engineer can approve extra payment,
140630 - following notice to Sletten and receipt of any response to Voith's
140631 - evidence. If conflicting evidence is presented, then the Engineer
140632 - would have to resolve it through independent sources.
140634 - ..
140635 - A contrary position may indicate favoritism in the treatment of
140636 - contractors, which would act against the interests of Tudor and DNRC.
140638 - ..
140639 - We discussed the record showing no extrinsic evidence that the
140640 - as-built condition of the Curb Ring is different from that which Voith
140641 - typically encounters on other jobs. Voith claims it will be more
140642 - difficult than if the dimensions were closer to those it specified,
140643 - but that does not, in and of itself, establish a right to perform
140644 - solely under specified dimensions. It may turn out that specified
140645 - tolerances are so difficult to meet that they are rarely or never
140646 - actually accomplished in the field. In that case, Sletten could not
140647 - be held accountable unless the deviation is outside industry
140648 - standards. Therefore, Voith's recovery should be similarly bound.
140650 - ..
140651 - Voith may well be able to show that the deviations are material. But
140652 - until they do, they should proceed with the work in the manner
140653 - prescribed by the Contract.
140655 - ..
140656 - This recommendation is supported Voith's prior record on as-built
140657 - dimensions that deviated from specified tolerances for the Draft Tube
140658 - Liner (DTL). In that case, as being proposed here, on 880823, the
140659 - Engineer relied on representations by Voith's field staff, led by Ken
140660 - Carlson, and verbal assurances from Voith management. ref SDS 1 OP5I
140661 - However, when Voith was asked to confirm these representations in
140662 - writing, their letter on 880915 failed to do so, ref SDS 2 EM7I, and
140663 - this has exposed the State and the Engineer to a claim by Sletten to
140664 - recover extra expense caused by unsubstantiated requirements imposed
140665 - on the contractor.
Curb Ring Tolerance
Concrete Pour review
relative to measurement
1607 - Assignment
160801 - ..
160802 - Following the meeting with Sletten and Voith, Jeff requested that I
160803 - review the concrete pour batch tickets to determine the dates of Curb
160804 - Ring encasement.
160806 - ..
160807 - He wants pour date, quantity and duration of each pour. Jeff believes
160808 - the duration of each pour is in the batch ticket file.
160812 - ..
1610 - Review of file 1189 0951 0711 01 10
1612 - Concrete Test Reports - Batch Tickets
1614 - Bid Item #23 "Concrete Encasement for Steel Fabrications."
161501 - CONCRETE TICKET BID ITEM REPORT (Cumulative)
161503 - ..
161504 - Dated: 881031 475 CY
161507 - ..
161508 - CONCRETE TICKET BID ITEM REPORT (Daily)
161510 - QUANTITY
161511 - DATE CUBIC YARDS DURATION
161512 - CUBIC YARDS DURATION
161513 - ----------- --------
161514 - 881028 16 Not shown
161515 - 881031 13 Not shown
161516 - 881103 18 Not shown
161517 - 881104 8 Not shown
161518 - 881105 13 Not shown ("Topped off Curb Ring.")
161519 - ------
161520 - 68 Total
Coordination Harp Contract
Sletten move trailer from
Transmission Line Guys
170601 - ..
170602 - Norm requested a report on this account. He said Sletten is refusing
170603 - to comply with prior agreements to move its trailer.
170605 - ..
170606 - Prepared this for information purposes. Did not make formal submittal.
Distribution. . . . See "CONTACTS"