ML20042A666

QA Manual for Repairs & Alterations to ASME Code Stamped Components.

ML20042A666
Person / Time
Site:	Waterford
Issue date:	06/13/1977
From:	Rogue W CBI SERVICES, INC. (FORMERLY CHICAGO BRIDGE & IRON
To:
Shared Package
ML20042A646	List: ML20042A652 ML20042A657 ML20042A666
References
NUDOCS 8203230663
Download: ML20042A666 (17)

Text

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Chicago' Bridge & tron Company 3 s .

NUCLEAR .

QUALITY ASSURANCE MANUAL t -

FOR REPAlRS AND ALTERATIONS TO

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ASME CODE STAMPED COMPONENTS - -

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ISSUE NO. 4 This manual has been reviewed by management. They concur with and endorse this manual and the impi me ation.of the-Quality Assurance Program which it describes.

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Director, Corporate Nuclear Quality Assurance Date Authority and Responsibility provisions of the ** Nuclear Quality Assurance Manual -

< for ASME Section ill Products" are applicable to this manual.

l v- G t3 97 sus 4 Date 7 7 Senior ViG President Date

~ Senior Vice Presi%t C. Manager of Operations

• Manager of Enginerin

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3230663 820318 g ADOCK 050003sp PDR .

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,A M $( -

l m et NUCLEAR QUALITY ASSURANCE MANUAL FOR .

( , REPAIRS AND ALTERATIONS TO ASME CODE *aat e.o. 1 or 4 STAMPED COMPONENTS Issue No. 4 ev RHS oart 6-6-77

1.0 SCOPE

This manual describes the Quality Assurance Program for control

( of repairs and alterations to ASME Code (Section III) stamped components.

2.0 BASIS OF' PROGRAM The program is based on utilization cf the " Nuclear Quality

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. Assurance Manual for ASME Section III Products," current issue together with this manual. However, it may be contractually

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established to use an earlier Nuclear QA Manual if the original construction was by CBI in accordance with that Manual.. The applicable QA Manual (herein referred to as QAM) together with j

- this Manue.1 shall be issued to.a Contract QA Handbook covering i the repair or alteration work. QAM requirements shall be followed with the applicable modifications and additional requirements of paragraphs 4.0, 5.0 and 6.0 below. .,

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- 3.0 APPLICABLE CODES -

Rules governing repair and alteration after stampi.ng are contained in ASME Code,Section XI, which is mandatory for ASME Class 1, 2 and 3 pressure-retaining components and.their supports. For other' classes of work, application of .other rules must be contractually established.

) This throughmanual complies W. inter 1976. . with ASME Code Section XI,1974 Edition with Ad 4.0 GENERAL (APPLICABLE TO ALL WORK UNDER THIS MANUAL) ,

4.1 Authorized Inspection .

Authoriied Inspection for shop work shall normally be provided by CSI,

- -- - unless the customer insists on providing it. ~ Authorized Inspection for field work shall be provided by the customer, unless the customer in-( -. i sists'en CBI arranging for it. CBI's contract with the Hartford Steam Boiler Inspection and Insurance Comoany includes inspection services for repair and alteration. Prior to their agreeing to provide this -

inspection for CBI, a request must be sent to the applicable Hartford Reelonel Office. The request shall include a clear definiiiton of the work to be performed.

( - whether it will be handidd as. a riipair or alteration and whether a State jurisdiction is involved. The de-finition of work must include al+ work to be performed

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w er NUCLEAR QUALITY ASSURANCE MANUAL FOR REPAIRS AND ALTERATIONS TO ASME CODE **ct e.o. 2 or 4

• STAMPED COMPONENTS Issue No. 4 ev RHS o*TE 6-6-77 by CBI and clearly outline the scope of the Inspector's work and the documentation required.

4.2 Repair or Alteration Procedure (

A procedure shall be written covering specific requirements of the customer and govarning Code. It shall be handled

.as a repair procedure in accordance with the procedure It shall contain:

p control system of QAM. . _ . .

A. Scope of work on the component .

B. Operations necessary to accomplish the work C. For Section XI work, any special electrode storage and baking requirements (5.2) F

'D. Any specia'l documentation requirements

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4 E. Clarification of QAM requirements, as necessary. .

. 4.3 Acceptance of QA Program -

), - Prior to starting work, the' Project Manager'shall obtain the customer's and AI's acceptance cf the QA -

Program (comprising this manual, QAM, any addenda

• and/or supplements and the Repair or Alteration Procedure). - - -

4.4 Delete all ref erences in QAM to ASME Surveys and Certi-

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.ficates of Authorization. .

5.0 WORK GOVERNED BY ASME CODE SECTION XI , ,

5.1 Welders and welding procedures shal.1 be qualified to NB-4300 (ASME Section III) and any special requirements 4 of IWB-4400.

5.2 Special requirements for baking and storing. covered electrodes are given in IWB-4420. When these are applicable and exceed those of QAM, they shall be .

specified in the Repair or Alteration Procedure. ,

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- REPAIRS AND ALTERATIONS TO ASME CODE pass wo. 3 on 4 STAMPED COMPONENTS Issue No. 4 ev RHS oan 6-6-7'7

5. 3. Control of other special Section XI requirements exceeding QAM shall also be specif.ied in the Repair N

or Alteration Procedure.

,- 5.4 This kork shall be documented on a report form agreeable to the owner. -

6.0 WORK NOT GOVERNED BY ASME CODE SECTION XI In addition to any other contract requirements (3.0), this work shall be documented on " Manufacturer's Report of Welded Repairs or Alterations " form GE 304 (see page 4). If there -

is no welding involved, the form may be marked-up to so

, indicate. This form shall be subject to controls specified for N-1 Data Reports in QAM, including the required CNQA release prior to signing. , , , ,, .

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NAllONAL 00AAD tNsPtcIiON cChi , ;N AlPA#6 AND A1,Ttf%isONs 10 DOsLiM AND P6ESsuRL VissitS OY bhDewG lt-202 Al!I EllATION 4 H-301.2 ACCEPTANCE OF REPAIRS AND Al.TERATIONS Subject to jurisdictional requirements and prosided th3: repairs l A change in any item described on the original Manufacturer's r alterati ns shall be acceptable to the Authorized Inspection f IN:a Report which affects the pressure containing capability of the e Agency responsible for the boiler or pressure sessel, insrection and l Briter or pressure sessel. An inesease in the maximum allowable ,

. documentation of repairs and alterations may be made by e.n i working pressure or temperature of a boibr or pressure vessel shall be considered to be an alteration. '

a. A jurisdictional A'uthorized Inspection Agency.

b. The Inspection Agency of record of the organization making the R-300 GENERAL REQUIREMENTS FOR repair or aheraiion.

REPAIRS.AND ALTERATIONS cUrhe Aufborized hnpection Agency which insures the boiler or

, pressure ve%el. -

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'I he requirements ofIhe following paragraphs apply io all repair 3 and alterations to hoilers and pressure vesselsc * # " #' 'P# " # 8#"#I* E' # * ***"I performed by his employer, except as provided m. Paragraph

. R-301.3 It-301 INSl'ECTION . f

- R-301.2.1 Aucplance luspection: It shall be the responsibility of

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the organization making the repair or alteration to coordinate R-301.1 AUTIIORIZATION

. the acceptance _ inspection of the repair or alteration.

'-~t R-301.1.1 Repairs: No repair to a boiler or pressure .nsc! shall ! ?e inniated without the authoritation of the Inspcetor who shal.' .

satisfy himself that the welding procedures and wehlers are ,

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qualified and that the repair methods are acceptabic. Subject to the administrative procedures of the jurisdiction, the In- ,

An inspector employed by an Owner-User inspection Agency S spector may give prior approval for limited repairs provided he ,

may perform acweptance inspections of repairs to pressure vessels has assured himself that the repair organization has acceptable , when such repairs have been performed by his employer provided procedures covering the repairs. Examples of such sepairs are the employer's organization and inspection procedures have described in Supplement IC. In every case, howeves, the In- ' specific approval of the jurisdiction or in the absence of a jurisdic-spector shall be advised of each repair under such piior agree- tion, by the National floard when requested by the Owner-User, ment. Such acceptance inspection procedures shall be subject to the con-currence of the Authorized Inspection Agency responsible for the H-301.1.2 Alterations: A Jeration to a boiler or pressme venel .

pressure vessel. c shall be initiated > s # 'he authorization of the linpector .

who shall satisft Wf %t the welding procedures am! H-301.4 DU~lll3 0F Tile INSPECIOR welders are qualA .

.- w alteration methods use accept-able, and that sahlations Nye been made available.11 he R-301.4.1 Repairs: tiefore acceptance of a repair, the inspector  !

considers it necessary, oc saall make an inspection of the ob- ,

shall satisf y himself that the welding was done in accordance ject before panting such authoritation, with R-302, witness any pressure test he may require (See I, hmpics of aticianons are shu.n in supplen en I D.

S Sec Appenda ti los O*ncr-User inspection Aseneies.

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36 .

37 i ._ . _ . . __ . . . . . - - .

e NAllONAL 00ARD MPich0N COOf m RIPAths AhD AtIIRAliONs IO DQtLf Rs AND PRLssur4 Vtssits OY sitDiNG R-308), and anure that the other functions he deems neces- organization and shall be available to the Inspector prior .to the sary to assure compliance with the requirements of this Code start of welding.

have been performed.

R-303 TilERMAI IIEAT TREATMENT R 301..l.2 Alterations: llefore signing for acceptance of m alter-ation, the Inspector shall make the required inspections, satisfy himself that the welding was done in accordance with Preheating may be employed during welding to assist in comple-R-302, witness the pressure test applied (See R-308), and I tion of the welded joint. The need for and the temperature of assure that the required nonestructive examinations have been preheat are dependent on a number of factors, such as chemical performed satisfactorily and that the other functions he deems analysis, degree of restraint of the parts being joined, elesated necessary to assure compliance with the requirements of this g temperature, mechanical properties, and material thicknesses. The Code have been performed. i welding procedure specification for the material being welded shall specify the minimum prehesting requirements.

R-302 WEl. DING For recommended preheating temperatures, see Supplement 2.._

R-302.1 WEI. DING PROCEDURE SPECllICATIONS H-303.2 POSTWEl.1 IIEAT T REATMENT R-303.2.1 General: The detailed postweld heat treatment require-The organization making repairs or alterations under these rules ments and exemptions shall be in accordance with the ap-shall list the parameters applicable to welding that he performs in plicable section of the ASME Code except as described below. ,

his welding procedure specification (WPS) document. Each such organi/ation shall qualify its WPS by the welding of test coupons R-303.2.2 Alternative Methods: Under certain conditions, post-and the testing of specimens and recording the welding data and weld heat treatment as outlined above may be inadvisable or test results in its procedure qualification record (PQR) document. impractical. In such instances, any other method of postweld Welding procedure specifications shall be in accordance with the heat treatment or special welding method acceptable to the In-requirements of Section IX of the ASME Code. Spector may be used. Examples of special welding methods for

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Pl and P3 materials aifdiscribed'iri Supplemerit 3. Where deemed necessary, competent technical advice should be ob-R-302.2 WEI. DING PERFORM ANCE QUAI.lFICATION tained from the manufacturer of the object or from another Welders or welding operator > shall qualify for each welding pro- qualified source. When such procedures are used, the Inspec-cess that he uses in the repair or alteration of a boiler or pressure tor shall assure himself that the requirements of this Code are sewel. Sucit qualification shall be in accordance with the re- l met.

quirements of Section IX of the ASME Code and a qualified weld- l ing procedure specification of the organization making the repair  ! R-304 NONDESTRUCTIVE EXAMINATION or alteration. l The nondestructive examination requirements, including tecimi-4"#'#*'#"' # #'"E# "" ""#E'""## # ** " * * " """

R-302.3 WEl. DING QUAI.lFICATION RITORDS ance with the applicable sections of the ASME Code. Weld repairs The orFanitation making the repair or alteration shall maintain a and alterations should be subjected to the same nondestructive ex-record of the results obtained in welding procedure and welding amination requirements as the original welds. Where this is not performance qualifications. These records shall he certified by the possible or piactical, alacrnate NDE methods may be used.

38 39

1 NAh0NAL DOARD INsP[cIlON CODE tit f4PAsic ANo AtTERAliONs 10 eO4LEfD Aho Fresurt MsMts DY MLDING 11-305 MATEltlAI.S tify that the material, design and fabrication are in accordance with the applicable section of the ASNIE Code.

The materials used in making repairs or alterations shall conform ## ' #*' #'"* # #

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to the requirements of the applicable section of the ASN1E Code or fabricated by welding and which require shop inspection by an to one of the specifications in Section 11 of the ASN1E Code. ^" *"## ' "

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N1aterial shall be of known weldable quality and be compatible i .

ing an A5N1E Certificate of Authoritation and the appropriate .

with the on. .gmal material. Carbon or alloy steel having a carbon .

Code symbol stamp. A completed N1anufacturer.s Partial Data content of more than 0.35 per cent shall not be welded. Report shall be supplied by the manufacturer.11-306 DESIGN OF WEl.DED JOINTS )11-308 l'ItESSUltE TESTS llutt joints shall have complete penetration and complete fusion I for the fulllength of the weld.The surfaces of the weld may be lett .

R-30M.I REPAIRS

• • as-welded " provided they are sufficiently free from coarse rip- The Inspector may require a pressure test after the completion of ples, undercuts, grooves, overlaps, abrupt ndges and valleys to .

a repair to a boiler or pressure vessel.

avoid stress risers.

• 4 R-308.2 Al.HRAl RN

- 11-307 ItEl'LACEMENT PitESSUltE l'AltTS

• A pressure test shall be applied to the boiler or pressure vessel on l the completion of an alteration.

R-307.1 In general, replacement parts may be classified as follows: ,

R.30s.3 REQUIRENil NT

a. Replacement parts which will be subject to internal or external Pressure tests shall be carried out in accordance with I-303.24 or pressure that consist of materials which may be formed or . 1-502.14 as applicable.

anembled to the required shape by bending, forging or other ,

forming methods, but on which no shop fabrication welding is .

performed may be supplied as material. Ntaterial and part iden- ' R-400 REPAIR METHODS tification shall be supplied in the form of bills of materials and drawings with ASN1E Code compliance certified in a statement ,

Repair methods in these paragraphs shall be used in conjunction by the parts suppher. ,

with the Eeneral requirements in Paragraph R-300.

b. Replacement parts which will be subject to internal or external

,11-401 DEFECT ltEPAlltS pressure that are preassembled by welding, but on which shop inspection is not required by the ASN11i Code, shall have the welding performed in accordance with Section IX and other ap.

• R-401.1 GENER AL plicable sections of the ASNIE Code. 't he replacement part . A repair of a defect, such as a crack in a welded joint or base awembly identification shall be supplied in the form of bills of , material, shall not be made until the defect has been removed. A material and drawings. The supplier or manufacturer shall cer- a suitable nondestructive examination method shall be used to assure complete removal of the defect, if the defect penetrates the full

• see supplement tE for cumptes of scplacement pam.

thickness of the material, the repair shall be made with a completc 40 41 6

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NAnONAL 00ARD INsPrcrCH COD ( m rdPA$s AnD ALMfMICHi10 DC%iR5 AND Pfu%urg vintts OY MLOtNG

' appropriate method of NDE for the complete surface of the repair.

penetration weld such as a double butt weld or a, single hun weld ,

with or without hacking. liefore repairing a cracked area, care For suggested methods of building up wasted areas by welding, see should be taken to investigate its cause and to determine its extent. Figure 3. page 70. See Paragraph 401.4 for repairs of minor ,

Where circumstances indicate that the crack is likely to recur, con- , defects.

sideration should be given to removing the cracked area and install-  ! H-402.2 ACCESS OPENINGS ing a patch. t

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R-401.2 UNSTAYED HOll.EH FUHNACE CHACKS ,

or they may be repaired as described m l'igure 4, page 71. In Cracks at the knuckle or at the turn of the flange of the furnace boiless the area to be so repaired shall not be closer than 2 in. (50.8 opening require immediate replacement of the affected area or mm) from any knuckle-l specific approval of repairs by the jurisdiction. (See Figure 1, page . H-402.3 Fl.ANGES M.) "*#' "#"E# "##* *"Y #'#""# I 0roug y an u ! up with It-441.3 HivtT OH STAyliOI;r llOI.E CHACKS '

, weld metal. They should be machm.ed m. place if possible to a Cracks radiating from rivet or staybolt holes may be repaired if thickness not h:ss than that of the original flange or that required 9

the plate is not seriously damaged. If the plate is seriously dam- i by calculations in accordance with the provisions of the applicable aged, it shall be replaced. For suggested methods of repair, see . section of the ASNIE Code. Wasted flangc' rnay also be re-

' machined in place without building up with wekt metal prosided .

Figure 2, page 69. ' the metal remosed in the process does not seduce the thickness of H-401.4 MINOH DEFECTS e the flange to a measurement below that calculated abose. Flanges

! which leak because of warpage or distortion and which cannot be Niinor cracks, isolated pits, and small plate imperfections should remachined shall be replaced with new ilanges which have at least be examined to determine the extens of the detect and whether ,

' the dimensions conforming to the applicable section of the ASNIE welding is required. See Chapter 11 for tolerance criteria. When welding is required, these defects shall be prepared for welding by Code.

semoving to sound metal. Liquid penetrant or magnetic particle ex- , H-402.4 'l UllES

.umnanon may be used before or after welding. Wasted areas on tubes may be repaired by welding provided that

. It-401.5 DEFECTIVE IlOll LING l in the judgement of the luspector the strength of the tube has not been impaired.

Deftetive botting material shall not be repaired but shall be ,

replaced with suitab!c material which meets the specifications of

' R-403 SEAL WELDING the applicable section of the ASNtE Code. l H-403.1 SEAL. WEl. DING OF TULLES Tubes may be seal welded provided the ends of the tubes hase R-402 WASTED AREAS l sufficient wall thickness to prevent burn through and the require-

' ments of the abpropriate sections of the ASNIE Code are satisfied.

H-402.1 SIIEl.LS,1) HUMS, llEADERS (See Figure 5, page 72.)

Wasted areas in stayed and unstayed shells, d ums and headers ,

H 403.2 SEAL, WEl. DING OF HIVETED JOIN'IS may be built up by weldmg provided that m the judgement of the ,

inspector the strength of the structure will not be impaired. Where Edges of butt straps, plate laps and noules, or of connections at-

' tached by riveting may be restored to original dimensions by weld-estensive weld build up is employed, the Inspector may require an 43 42

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' H-1101.2 ASNIE CODE SnillOI. STASIP

. h. When the organi/ation responsible for the sepair does not hold a valid Certificate of Authoritation to use the National lloard . An organization in possession of a valid ASME Certificate of "R" stamp, the "R" syinbol and Repair symbol stamp number Authorization may perform repairs to boilers and pressure vessels shall not appear on the naineplate or stampmg. ,

provided such repairs are within the scope of the organization's

c. When the same repair organization carries out ruore than one Quality Control System.

repair to the same boiler or pressure vessel it shall not be necessary to add a new nameplate or stamping provided the date H-1101.3 JilHISDICTION Al AUTilOHlZATION of each repair is stamped in the appropriate location; such date Repairs to boilm ud pm als my W M'mW h a to correspond with the date on the Form H-1 " Report of I aganization working within a governmental jurisdiction provided Welded Hepair* dat prisdiction b ism Morizadon I'm h ghim m perform such repairs.

j R-1000 REPAIRS OF A ROUTINE NATURE i R-1102 ALTERATIONS '

i Subject to the administrative procedures of the jurisdiction and the approval of the Inspector, nameplates and stamping may not be lixcept as provided in R-801(a), alterations to boilers and I

required for repairs of a routine nature. Supplement IC provides pressure vessels shall be performed by an organization in posses- ,

general guide to the types of repairs which may be designated 6.s sio of a valid ASME Certificate of Authorization provided the .

routine. In all cases, the type and extent of repairs necessary shall alterations are within the scope of such authorization.  !

be considered prior to waiving the requirement. ,

i.

d f

R-1100 AUTHORIZATION OF ,

ORGANIZATIONS MAKING REPAIRS OR  !

ALTERATIONS  ;

11-1101 IWl'AlltS .

Repairs to boilers and pressure vessels shall be made by a repair erranization having one of the following types of authoritation: ,

H-Il01.1 NATIONAL. IlOARD AUTIIORIZATION ,

kepairs to boilers and pressure vessels may be performed by an '

organization in ponession of a valid Certificate of Authoritation for use of the **lt" Code symbol stamp, issued by the National {

11oa r d. '

'lufoisnation regardmg authorisation to use the "R" symtn 1 stamp may be ob-t.a.s.cJ from tlic National lloard or ihnter and l*rewure Vcuct linpectors. Colum- ,

. , tun. Otuo. (See Appendia D.R) ,

5I 50 ,

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D. EXAMPLES OF ALTERATIONS: 1 I

Alterations are defined in R-202. Examples are listed below: ,

!. To increase the maximum allowable working pressure or '

temperature of a boiler or pressure vessel regardless of whether or not a physical change was made to the boiler or  ; gyppfggggf y pressure vessel.

2. The addition of new nozzles or openings in a boiler or  ! Preheat.ing pressure vessel except those classified as repairs. .

3. A change in the dimensions or contour of a pressure Some minimum temperatures for preheating are given below as a vessel. l general guide. It is cautioned that the preheating temperatures

4. In a boiler, an increase in any heating surface. ' listed do not necessarily ensure satisfactory completion of the

5. The addition of a pressurized jacket to a pressure vessel. welded jomt. Requirements for m, dividual materials withm the P. Number listing may have preheating requirements more or less

6. Replacement of a pressure retaining part in a pressure restrictive than this general guide. (Ref. R-303.1) met or boiler with a material of different nominal , j strength or nominal composition from that used in the original design. MINIMUM TEMPERATURES FOR PREllEATING t (Thicknesses referred to are nominal at the weld for the parts to q E. EXAMPl.ES OF REPLACEMENT ,

- be joined.)

PRFSSURE PARTS:

! 1. P-No.1 Groups 1,2 and 3 l Replacement pressure parts are discussed in Para. R-307.1. Ex- '

amples of the different classifications discussed in the refer- ' a.175F (80C) for material which has both a specified max-enced paragraphs are as follows: imum carbon content in excess of 0.30 percent and a thick-

' ness at the joint in excess of I in. (25 mm).

1. Ref. para. R-307.l(a) seamless or welded tubes or pipe supplied separately or in bundles; forged nozzles; heads or t b. 50F (10C) for all other materials in this P-No.

tube sheets forged or machined from a single piece of 2. P No. 3 Groups 1,2 and 3 material; subassemblics of tubes or pipe attached together  !

' a.175F (80C) for material which has either a specified mini-mechanically. mum tensile strength in exceu of M,M W W Wa) m a

2. Ref. para. R-307.l(b) boiler furnace panel wall or floor l thickness at the joint in excess of 5/8 m. (16 mm).

assemblies; prefabricated openings in boiler furnace walls such as burner openings, air ports, inspection openings or b. 50F (IOC) for all other materials in this P-No.

e soot blower openings, j 3. P-No. 4 Groups I and 2

3. Ref. para. R-307.l(c) a bciler or pressure vessel replace- a. 250F (120C) for material which has e.it her a specified m.im-ment part falls within this classification if a ""*'#" *"Eth y excen oM,M psi W Wa) or a

• Nianufacturer's Partial Data Report would normally be . tMnen at the jm.nt m excen d U2 in. W nug l ,

required under the provisions of the applicable section of

b. 50F (IOC) for all other materials in this P-No.

the ASN1E Code, j f ,

t ,

l 57 56

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