ML20127C116
| ML20127C116 | |
| Person / Time | |
|---|---|
| Site: | San Onofre  |
| Issue date: | 12/13/1976 |
| From: | SOUTHERN CALIFORNIA EDISON CO. |
| To: | |
| Shared Package | |
| ML20127A193 | List: |
| References | |
| FOIA-84-885 WPP-QAI-202, NUDOCS 8506220147 | |
| Download: ML20127C116 (9) | |
Text
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202 APP.
REV.
12 TITLE:
WELDING CONTROL FOR PAGE 1
9 A
ASW DI.1 WELDING 12/13/16 issuto:
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2/17/84 WORK PLAN PROCEDURES / QUALITY CONTROL INSTRUCTIONS
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(THIS REVISION INCORPORATES PCNs 7 AND 8 AND EDITORIAL CHANGES) l
1.0 INTRODUCTION
1.1 This procedure, in conjunction with Appendix I. establishes the work plan and inspection instruction for welding and NDE for Quality Classes I.' II. III & IV items.
1.2 This procedure is limited to welding performed in accordance with the require-ments of AWS D1.1-72 including modifications specified on Project Engineering docu-ments and GR-1.
2.0 ABBREVIATIONS ASME American Society of Nechanical Engineers AWS American Welding Society CDM Corporate Documentation Management CIDR Construction Inspection Data Report CS Construction Specification FE Field Engineer FGD Field Generated Drawing FIR Field Inspection Report FWE Field Welding Engineer GR General Requirements GWS General Weld Standard NCR Nonconformance Report NDE Nondestructive Examination PCN Procedure Change Notice PFE Project Field Engineer PFQAES Project Field Quality Assurance Engineering Supervisor PQCE Project Quality Control Engineer QA Quality Assurance QCE Quality Control Engineer 50R Supplemental Data Report WPP/QCI Work Plan Procedure / Quality Control Instruction WQ Welder Qualification WQCE Welding Quality Control Engineer WR Weld Report
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No.
202 Arr.
TITLE:
WELDING CONTROL FOR PAoE 2
or 9
ASW D1.1 WELDING 3.0 REFERENCED DOCUMENTS AWS D1.1-72, Structural Weldi6g Code 1972
'/CS-C16, Visual Inspection Criteria for Structural Steel and Miscellaneous Metal Welding to Meet Design Requirements GR-1, General Requirements GWS, Structural - General Welding Standard NEPQ-BPC-2, Non Destructive Examination Personnel Qualification 50123-I-1.16, SCE Consumables Manual WPP/QCI-001 - Organization and Responsib111 ties WPP/QCI-002, Establishment and Control of Field Generated Procedures WPP/QCI-002, APP. I - Procedure Change Notice WPP-003, APP IV, Control of Quality Class III & IV Records WPP/QCI-006, Field Control of Nonconforming Items WPP-015 - Field Generated Drawing WPP/QCI-020 - Field Generated Supplemental Inspection Planning WPP/QCI-200, Control of Welding Filler Material WPP/QCI-200 APP. I, Welding Filler Material Control Procedure Specification WPP/QCI-202, APP. I, Stud Welding WPP/QCI-200, APP. III, Control of Welding Filler Material for Electrical Items.
WPP/QCI-200, APP. IV, Control Welding Filler Material for Piping Items WPP/QCI-200, APP. V, Control of Welding Filler Material for Civil Items WPP/QCI-208 Welding Control for ANSI B31.1-73 Welding WQ-1, Welding Standard Performance Specification WQ-2, Welding Standard Performance Specification 4.0 GENERAL 4.1 The initiation of WR series FORMS and documentation will be in compliance with WPP/QCI-200.
4.2 The Craft Superintendent shall assure that the welder has taken the necessary precautions to assure adequate protection of personnel, items, or components in tte immediate area. The FWE and WQCE shall perforin monitoring inspections for those 4reas. This includes cables, cable trays, equipment, air. hoses, motors, pumps, salves, open lines, etc. These shall be protected from contamination, fire, breatage, Spatter from grinding, burning, welding,. arc strikes, or any condition that may jeop-ardize.the safety of personnel cr the quality of the product.
4.2.1 If an arc strike occurs on a pipe, the welder shall notify his supervision for resolution through the FWE/QCE. The WQCE or the FWE shall inspect the arc strike and r
initiate an NCR in accordance with WPP/QCI-006.
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4.2.2 Arc strikes on structural steel or miscellaneous metal with Category A and B joints shall be reported on an NCR. Arc strikes on structural steel or miscellamous metal with Category C, D, E and F joints shall be evaluated in accordance with CS-C1 and if not acceptable, an NCR shall be prepared.
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A TITLE:
WELDING CONTROL FOR PAGE 3
or 9
AWS D1.1 WELDING 4.3 Welds joints are classified into 6 catagories in accordance with CS-C16.
4.4 Only type E-6010. E-6011 and E-7018 covered electrodes, in accordance with WPP/QCI-200, APP. I (latest revision), will be used when performing shielded metal arc welding.
4.5 Welders will be qualified to WQ-2 and/or WQ-1.
l 4.6 Welders Qualification Records shall be filed in the Welding Engineering Files.
4.7 All Bechtel personnel performing NDE for the purpose of accepting the work (welds, base material, etc.) will be qualified to NEPQ-2. Subcontractor personnel qualification records shall be reviewed for adequacy by Bechtel prior to performing NDE.
4.8 The NDE Standard, as designated on QUALITY CLASSES III AND IV NON-ASME FIELD WELDING CHECKLIST, FORM PF-1999 (EXHIBIT WPP/QCI-208-1), herein referred to as FORM PF-1999, or the FIELD WELDING CHECKLIST, FORM WR-5 (EXHIBIT WPP/QCI-200-12), herein referred to as the WR-5, will be used to accept work.
All marking material shall in accordance with 50123-I-1.16.
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A flow chart to illustrate this procedure is supplied as Attachment 1.
5.0 PROCEDURE 5.1 Weldina 5.1.1 Welding shall be done in accordance with the Welding Procedure Specification designated on the. FILLER METAL WITHDRAWAL AUTHORIZATION FOR QC I AND II AWS WELDING, FORM PF-1699 (WR-7 REY.1) (EXHIBIT WPP/QCI-200-11) herein referred to as the WR-7, or the FILLER METAL WITHDRAWAL AUTHORIZATION, FORM WR-99 (EXHIBIT WPP/QCI-200-2) herein referred to as the WR-99 and in accordance with the AWS (Structural).
(a) WR-7s are used for withdrawal of filler material for Quality Class I and II items.
(b) WR-99s are used for withdrawal of filler material for Quality Class III and IV items and for Construction Aid Welds.
5.1.2 The welder will place his symbol adjacent to any weld he performs welding oper-ations on. He shall use a metal stamp, keele felt marker or paint stick for carbon steel. He shall use a vibra-etch marker for stainless steel.
5.2 Acceptance of Completed Weldino (Quality Class I and II) 5.2.1 A QCE qualified for visual acceptance of welds shall inspect the completed weld g the acceptance criteria listed in CS-C16 paragraph 3.0, and/or other engineering oved documents.
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TITLE:
WELDING CONTROL FOR PACE 4
or 9
AWS D1.1 WELDING 5.2.2 Subsequent to his inspection and acceptance of the completed weld, a qualifiied QCE will place his assigned symbol, or number adjacent to all acceptable welds. He shall use a metal stamp, keel, felt marker or paint stick for carbon steel.
5.2.3 Acceptance of completed welds' will be documented by a qualified QCE on the applicable discipline CIDR SDR or WR-5.
5.2.4 Incremental acceptance of completed welds to be use'd as a basis for stampini and dating the applicable discipline CIDR or SDR at a later date shall be documented as follows:
5.2.4.1 A QCE shall color mark Project Engineering prepared or approved drawings, or FGD, or prepare FIELD INSPECTOR'S REPORT'S, FORM PF-807 (EXHIBIT WPP/QCI-202 APP I-1).
5.2.4.2 This documentation shall identify the welds inspected, the QCE (inspector) and the date of inspection. This incremental acceptance documentation shall be re-tained by a qualified QCE as a basis for signing the applicable discipline CIDR or SDR.
5.2.5 The applicable Discipline FE shall be responsible for ensuring that Design l
Changes are incorporated into the work and for notifying the QCE that work is com-plete. The applicable QCE shall be responsible for ensuring that the work associata with the Design Change is inspected.
5.3 Acceptance of completed Weldina (Quality Class III and IV) will be as descriied in Section 5.2 above, except that the FWE shall perform the inspections and docunun-tation described for the QCE.
i 6.0 DOCUMENTATION 6.1 Inspection of Weldino (Quality Class I and II) 6.1.1 The WR-7, shall be used for filler material control in accordance with WPP/QCI-200.
It is also used for "in-pmcess verification" of the welders activities
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as described by items 1 through 6A on the WR-7.
6.1.2 At least once a calendar week the WQCE shall perform a documented "in-process verification" of each welder's activities by completing the following:
6.1.2.1 The WQCE shall document his "in-process verification" by stamping and datiing items 1 through 6A on the WR-7 in the spaces provided.
6.1.2.2 The WQCE shall enter the week ending date that each welder's activities were "in-process verified" on the IN-PROCESS VERIFICATION STATUS LOG, (FOR QUALITY CLES I AND II AWS WELDING), FORM PF-1735 (EXHIBIT WPP/QCI-202-1).
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202 Arr.
- REv.12 9
- d TITLE:
WELDING CONTROL FOR PAoK 5
or AWS 01.1 WELDING l
I 6.1.3 As part of his "in-process verification" activities the WQCE shall perform the following activities:
j 6.'.3.1 The WQCE shall check the welder's qualifications to assure that only quali-find welders are performing welding.
6.1.3.2 The WQCE shall check the WR-7 to assure that the Welding Procedure Specifi-cation, filler material and thickness limitations of the welder's qualifications are compatible with the base material being welded.
6.1.3.3 The WQCE shall check and assure that GWS (Structural) is being complied with.
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6.1.3.3.1 Fit-up of all full penetration butt welds shall be inspected and accepted prior to welding the joint. The WQCE shall place his assigtied symbol next to the joint, indicating fit-up acceptance, using keel, paint stick or felt pen for carbon steel. In addition, the WQCE shall stamp and date the WR-7 in the space provided on the original copy by rubber stamp. For full penetration butt welds that require radi-ography, the WR-5 will be used for documentation along with the WR-6 Form for filler metal withdrawal.
.3.3.2 Fit-up of partial penetration welds does not need to be inspected prior to ding for standard vendor items purchased with completed weld bevel preparations.
-up of other partial penetration welds shall be checked on a surveillance basis by the WQCE.
6.1.3.4 The WQCE shall assure that the welders are placing their assigned symbol l
adjacent to the weld as required by 5.1.2.
l 6.1.3.5 The WQCE shall notify his supervisor and the welder's supervisor imediately I
if there is a variation from the requirements or if the welder's work is substandard.
l 6.1.4 At least once a calendar week, the FWE shall perform an "In-Process Verifi-cation " of each welder's activities and document these activities on a FIELD INSPEC-TOR'S REPORT, FORM PF-807 (EXHIBIT WPP/QCI-202 APP. I-1) herein referred to as a FIR.
As part of his "In-Process Verification" activities the FWE shall perform the fol-lowing activities:
i 6.1.4.1 The FWE shall check welder's qualifications to assure that only qualified I
welder's are performing welding.
6.1.4.2 The FWE shall check the WR-7 to assure that the Welding Procedure Specifi-I cation, filler material and thickness limitations of the welder's qualifications are compatible with the base material being welded.
6.1.4.3 The FWE shall check and assure that the GWS (Structural) is being complied I
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AWS D1.1 WELDING 6.1.4.4 The FWE shall assure that the welders are placing their assigned symbol adja-I cent to the weld as required by 5.1.2.
6.1.4.5 The FWE will notify his supervisor and the welder's supervisor insnediately if I there is a variation from the requirements or if the welder's work is substandard.
6.1.5 NCR's for structural items dispositioned ' REWORK" or ' REPAIR' and requiring I
welding must be processed as follows:
6.1. 5.1 Upon request from the Craft Superintendent, the FWE will issue a WR-7 for
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i filler material withdrawal. The WR-7 will be completed as described in WPP/QCI-200 APP. III (electrical items), WPP/QCI-200 APP. IV (pipe supports), or WPP/QCI-200 APf.
V (civil items), and will reference the applicable drawings for the item being welded on.
6.1.5.2 After completion of repair welding, the craft superintendent will notify tSe B WQCE to visually inspect the completed weld repair. Additionally, the WQCE will re-quest NDE if required. The WQCE will transmit the WR-7 to QA. After final inspection of the repair, acceptance shall be documented on the NCR and the NCR, along with any applicable NDE reports, will be transmitted to QA by the applicable QCE.
6.2 Inspection Of Weldino (Quality Class III and IV) 6.2.1 The WR-99, shall be used for filler material control in accordance with WPP/QCI-200.
6.2.2 At least once a week the FWE shall perform an undocumented "In-process Verifi-cation" of each welder's activities which he shall document on an FIR.
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6.2.2.1 The FIR will be transmitted to the LFWE for review and filing.
I 6.2.3 As part of his "In-Process Verification" activities, the FWE shall perform the following activities:
6.2.3.1 The FWE shall check welder's qualifications to assure that only qualified l
welders are performing welding.
6.2.3.2 The FWE shall check the WR-99 to assure that the Welding Procedure Specif1-cation, filler material and thickness limitations of the welder's qualifications are compatible with the base material being welded.
l 6.2.3.3 The FWE shall assure compliance with the GWS (Structural).
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6.2.3.3.1 Fit-up of all full penetration welds shall be inspected and accepted prior to welding the joint. The FWE shall place his assigned symbol next to the joint, indicating fit-up acceptance, using keel, paint stick or felt pen for carbon steel.
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9 or AWS D1.1 WELDING 6.2.3.4 The FWE shall assure that welders are placing their assigned symbol adjacent to the weld as required by 5.1.2.
6.2.3.5 The FWE will notify his supervisor and the welder's supervisor insnediately if there is a variation from the requirements or if the welder's work is substandard.
6.3 Final Documentation 0.3.1 The WR-5s and WR-7s CIDRs and SDRs for Quality Class I and II shall be for-warded by the QCE to QA for review. After QA review, the documents will be forwarded by QA to CDM.
6.3.2 The WR-99 shall be forwarded to the LFWE. The LFWE may at this time discard the fonn at his discretion.
6.3.3 Quality Class III and IV documentation shall b'e filed in the Welding Engi-neering Files Jntil complete.
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