Epidemiologic Studies

Rocky Flats Plant Site

Stockpile Approved Product Records (SAPRs), 1955-1993

Location:

Active:
Inactive: RF-881 Archives; LANL, Technical Area 55, NMT-5

Arrangement: Numerical by SAPR number, thereafter by part and serial number

Originating Office: Non-Nuclear Projects, Nuclear Project/WR Engineering, Product Engineering, Production Control, and Quality Certification organizations of Dow Chemical Company, Rockwell International, and EG&G; Systems Engineering Department, Babcock and Wilcox

Finding Aids: 1-39) Records Storage Receipt; 40-42) PSP Database

Disposition Authority: 1) Records schedule under revision 2) DOE (1988) 3.3 3) Records schedule under revision 4) DOE (1988) 3.3 5) Records schedule under revision 6) DOE (1988) 3.3 7) Records schedule under revision 8) DOE (1988) 3.3 9) Records schedule under revision 10) DOE (1988) 3.3 11) Records schedule under revision 12) DOE (1988) 3.3 13) Records schedule under revision 14) DOE (1988) 3.3 15) Records schedule under revision 16) DOE (1988) 3.3 17) Records schedule under revision 18) DOE (1988) 3.3 19) Records schedule under revision 20) DOE (1988) 3.3 21) Records schedule under revision

22) DOE (1988) 3.3 23) Records schedule under revision 24) DOE (1988) 3.3 25) Records schedule under revision 26) DOE (1988) 3.3 27) Records schedule under revision 28) DOE (1988) 3.3 29) Records schedule under revision 30) DOE (1988) 3.3 31) Records schedule under revision 32) DOE (1988) 3.3 33) Records schedule under revision 34) DOE (1988) 3.3 35) Records schedule under revision 36) DOE (1988) 3.3 37) Records schedule under revision 38) DOE (1988) 3.3 39) Records schedule under revision 40) Records schedule under revision 41-42) DOE (1988) 3.3

Series Description: Stockpile Approved Product Records (SAPRs), also known as War Reserve (WR) Bomb Books, are the historical records for each nuclear weapon and weapon component in the nation's weapons stockpile. The records in this series document activities in Buildings 444, 460, 707, 750, 777, and 881 and include the following weapons programs: B43, B54, B57, B61, B83, W45, W56, W62, W68, W69, W70, W76, W79, W80, W82, W84, W87, and W88. The SAPRs in this series consist of approximately 44 different types of forms which document the fabrication, assembly, testing, and inspection and certification of each component and assembly produced at Rocky Flats. The SAPRs include the following document types, listed in alphabetical order. Names that are in italics are those used on the forms themselves; names that are not italicized are those devised to best describe the contents and nature of the form:

Acceptance Tags appear to have been attached to a component or assembly that was approved for use. Each tag contains part, suffix, serial, and lot numbers; materials source; vendor/heat lot, drawing, and Department of Energy (DOE) numbers; hardness; temperature; weight; assay; percent 240 [percentage of plutonium-240 in the component]; disposition code; acceptance signature or stamp; and date of disposition.

American Car and Foundry Inspection Route Cards are inspection travelers for stainless steel components manufactured by American Car and Foundry Industries (ACF) of Albuquerque, New Mexico, for Rocky Flats. Each traveler contains information about the inspection test results for a specific component. Data on the forms include a brief description of the component, ACF part and serial numbers, project and reference drawing numbers, inspection specifications (indicating item to be inspected), remarks, and inspectors' stamps and signatures.

Assembly Borescope Inspection Reports are test results which include part types, serial and recycle numbers, weld evaluation data, interior wall inspection results, and comments.

Assembly Process Cards document the assembly of components into a unit. The cards list part names, serial and lot numbers, operation steps and sequences, M-document numbers, operation numbers and descriptions, employee numbers and dates for each operation, comments noted by the operators, job numbers, and Atomic Energy Commission (AEC) and deviation numbers.

Assembly Product Records are indices or tables of contents which list the records pertaining to a single product.

Assembly Reject/Salvage Reports concern defect identification. They include descriptions of defects, where in the operation sequences defects were detected, defect causes, correcting departments, resultant corrective actions, and salvage data.

Band Inspection Program Records include dates, times, inspectors' last names, part type and serial numbers, tolerance levels in mm [millimeters], maximum and minimum "rd.," and deviation measurements.

Building 460 HPTC [High Pressure Test Cell?] Part Data Analysis Reports are test results for components subjected to pressure changes. Data include test cell numbers, test dates and times, software and profile configuration control numbers, design agencies, employee numbers, part and serial numbers, test types, external "STD" leak rates in cc/sec [cubic centimeters per second] and numbers, leak detector sensitivity data, and part run results for sides one and two in psi or psi/sec [pounds per square inch or pounds per square inch per second].

Certification Tickets were used during the inspection process to insure that components met proper quality levels. Each ticket provides part type; serial and lot numbers; DOE part number; designations for "Accept, Scrap, Salvage, Rework, or Deviation"; deviation number; final disposition code; location where component was shipped; date; reference number; certified part/"SA" type number; and overall certification signatures and acceptance stamps.

Cutting Sheets document efforts to cut raw materials into smaller, usable sections. The sheets contain start and finishing dates; customer, part, order, purchase order, charge, die, job, bar, heat, and cutter numbers; lot sizes; materials; "B numbers"; lengths; weights; counts; cutter names; approximate yields; quantities; and remnants.

Engineering Process Data Entry Forms were used to record part numbers and revision codes; part names; "process by"; ECOs [Engineering Change Orders] in effect; department codes; sequence numbers; descriptions of operations; total numbers; work centers; and set-up, run, and queue times.

Final Part Certification Cards were used to document the components that met required specifications. Each includes part types; serial, casting/batch, "I&A" drawing and revision, radiofilm, materials specification certification drawing sheet and revision, and overall disposition code numbers; final disposition dates; "matching" notes; material stream identifications; and verification and supervisory signatures.

Flowtester Test Data Reports include software, employee, and serial numbers; part types; dates and times of tests; starting system vacuums; rates of rise; temperatures during tests; differential pressure rates; volumes for test configuration; and calculated flow and mole rates.

Forge Welder No. 2 Data Acquisition Reports are computer-generated reports which provide part types and serial numbers, fixture numbers, dates, times, employee numbers, primary and secondary "RMS" weld current readings in amps [amperes], average weld forces in pounds, average weld pressures in psig [pounds per square inch gage], relative weld placements in inches, average total forces in pounds, average total pressures in psig, relative total displacements in inches, and indications of acceptability for the components undergoing weld testing.

Gas Mass Spectrometry-Backfill Gas Analysis Reports include MSL [Mass Spectrometry Laboratory?] numbers, analysis dates, analyst names and employee numbers, unit serial numbers, total unit pressures measured in Torr, components, percentages by volume, partial pressures, and authorizing MSL signatures.

"GTA" Data Acquisition Weld Summary Reports contain dates; times; part serial numbers; weld types; operation and man numbers; and mean weld data, which include high and low weld currents, "ARC" voltages, part rotation line feeds, argon and helium flows, and graphs of test results.

Inspection Data Sheets were used to record results of the visual inspection and disposition of a component. Each form contains part type; casting batch and WR lot numbers; materials specification certification drawing number; material type and "p.o." numbers; job, part serial, "I&A" drawing and revision, and AEC part numbers; overall dispositions; accept or reject dates; and manufacturing disposition codes.

Job Status Reports were used to track vendor orders. They consist of job, charge, order, part, and operation numbers; customer and engineer names; quantities ordered and shipped; shipment dates; department names; hours worked; dollar amounts of orders; and remarks.

Laboratory Sample Results are computer-generated summary reports which list pertinent test results from laboratories involved in component testing. Each report indicates identification number; entry date; casting and DJO [Development Job Order] numbers; account charged; building number; "class."; and results from the Atomic Absorption Spectrometry, Plutonium Chemistry, Emission Spectrometry, Isotopic Mass Spectrometry, and Radiochemistry laboratories. All results are given in ppm [parts per million], with the exception of results from the Isotopic Mass Spectrometry Laboratory, which are given in percentages.

Manufacturing Process Evaluation Request [MPER] Reports were used to request that a process be evaluated for the possibility of enhancing efficiency. The forms provide MPER and quality control lot numbers; originators; dates; sections; descriptions of the problem/improvement objectives; quantities; part and component types; "WR Process," Route Card, revision, "Departs WR Process" step, and "Resumes WR Process," step numbers; special processing and inspection/test instructions; certification information; comments; and approval signatures.

Measuring Record/Zeiss Comet Reports are computer-generated reports apparently created during component testing. They provide tape, serial, drawing and supplemental drawing, and operator numbers; dates; and results under the headings "ADR/REC," "Operat.," "U-Tol," L-Tol," [upper and lower tolerance?] and "Dev."

Non-Destructive Testing Radiographic Reports give a general description of a component's or an assembly's condition and overall quality based on the results of radiographic testing.

Norland Data Reports are computer-generated reports that apparently document the results of component welding. Data on the reports include date and time; man and part serial numbers; weld being performed; primary and secondary current; "XFMR" Ration readings for Pre-heat, Weld, and Post-heat; and primary and secondary DC [Direct Current] Offset readings. All readings are given in volts.

Overall Certification Cards provide MC [major component], serial, and DOE part numbers; Accept, Scrap, Salvage, Rework, and Deviates designations; component lists with serial, lot, and deviation numbers; shipping container numbers; and inspector signatures, presumably for parts manufactured by vendors.

Pit Count Sheets were used to document that pits contained the proper amount of plutonium-240 (Pu 240). They contain assembly, source, and part numbers; "Q value"; counts; weights; and total weights of Pu in pits. Weights are given in grams.

Production Orders provide serial or lot, part, drawing, DOE, control, deviation, heat/lot, procedure, operation, and account numbers; work centers; part descriptions; employee numbers; dates; quantities; and "data or pendant" numbers.

Proof and Leak Test Data Reports contain part serial, test cell, and bell jar numbers; employee numbers; dates; times; design agencies; system software configurations; part profile software configuration numbers; leak detector calibration and part run data; disposition (i.e., accepted or rejected); tester names; and comments.

Purchase Orders document the purchase and shipment of weapon components from vendors. The orders include purchase document numbers; supplier addresses; "F.U. Code"; seller and code numbers; delivery dates; requisition, job, building, Rockwell International code, and item numbers; material and specifications descriptions; quantities; and unit and total prices.

Quality Control Disposition Cards describe defects and deviations in components which were found during manufacture and inspection. Each card consists of a date; part name and number; shop order number; originating department; operation number; machine group; production operator clock number and shift; inspection station; quantities received, inspected, and accepted; description and assigned cause of the defect; and corrective and deviation actions taken.

Radiography Tags may have been attached to components or assemblies to indicate that they had undergone radiographic testing. The only recognizable data on the tags are dates.

Receipt Inspection Reports include request numbers; by whom the requests were made; dates; items; names; contract identification codes; suppliers; part serial numbers; general appearances; proper identifications; dispositions; forging lot, drawing and revision, material control, and procedure and revision numbers; and remarks.

Release for Production Reports contain die and part numbers, revision codes, charge and job numbers, customer names, part and lot data, and notes on changes to drawings and shop cards.

Shipment Memoranda accompany units entering and leaving the site. They provide shipper and receiver names and addresses; material classifications; shipment dates; Rocky Flats, DJO, and container numbers; sizes; weights; types; descriptions; and radiation information.

Shop Travelers are forms which accompanied components or assemblies during manufacturing to document that they were produced according to design specifications and program requirements. Each traveler includes order, part, lot, and serial numbers; quantity produced; part description; control and deviation numbers; heat/lot code; "work acct. ctr."; operation numbers and descriptions; procedure instructions; drawing numbers; materials and specification document and M-document numbers; revision numbers; employee numbers; dates operations were completed; EO [Engineering Order] number; and part classification code. Recent versions may also include bar codes which were used to track a unit's status via a computer database.

Site Return Cards accompanied pits and weapon components which were returned to Rocky Flats for disassembly and reuse in other weapons.

Special Order Certification Data Reports accompanied special-order components to insure that they met unique specifications. The reports include DJO, "PO," part type, and serial numbers; design agency drawing and Rocky Flats drawing numbers; dimensional inspection data; tolerance data; weights; employee numbers; dates; material specification, certification, and analysis numbers; Product Engineering acceptance indicators; and radiographic report numbers.

Specification Exception Releases (SXR) gave authorization for the use of components which failed to meet specification requirements. Each release provides an SXR number, drawing number and suffix, use limitations, quantity, part name, drawing requirements and variation from the drawing, marking requirements, corrective action, agency, date, references, and remarks.

Supplied Material Certification Reports were used to document that materials and components supplied by vendors met Rocky Flats specifications. Each report consists of a certification number; item name; drawing, forging lot, material control, and serial numbers; quantity; comments; and certifying signatures.

Travel Card-Final Operations accompanied an assembly during final processing. Each card lists the final operations to be completed, dates performed, employee initials, and M-document numbers.

Universal Travel Card for Preassembly Processing Operations seem to be travelers which accompanied components during preassembly. They include part and serial numbers, lists of operations, employee numbers and dates for completed operations, M-document numbers, and remarks.

Volume Test from the Volumetric Determination System Reports provide the results of volume tests conducted on weapon components. These computer-generated reports include drawing, serial, employee, data software, and system software numbers; dates; start and end times; adaptor volumes; calculated volumes and ranges; pressure readings; and internal and external leak readings.

Weld Wire Certification Reports contain certification stamps; sizes; lot, height, and stock numbers; net weights; purchase order numbers; quality assurance authorizing signatures; and dates.

For related records, see Volume IV. American Car and Foundry (ACF) Inspection and Certification Records, 1961-1968; Assembly/Disassembly Site Return Records, 1964-1983, 1986-1988; Assembly Process Cards, 1965-1984, 1986, 1989; Component Inspection and Certification Records, ca. 1954, 1959-1989; Deviation Request and Approval Records, 1958-1968, 1971-1973, 1978-1982, 1984; Nuclear Materials Shipment Memoranda, 1974, 1981-1985, 1988-1991; Production Orders (POs), 1966, 1970-1973, 1977-1979, ca. 1981-1985; Shop Travelers, 1960, 1967, 1989-1992; and Vendor Purchase Orders (POs), 1961-1988.

Data Elements: 8, 16, 88-89, 120