ML20195F350

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Rev 0 to Procedure CP-CPM-9.10, Fabrication & Installation of ASME-Related Component Supports
ML20195F350
Person / Time
Site: Comanche Peak  Luminant icon.png
Issue date: 09/03/1980
From:
BROWN & ROOT, INC. (SUBS. OF HALLIBURTON CO.)
To:
Shared Package
ML20195F283 List: ... further results
References
FOIA-85-59 CP-CPM-9.10, NUDOCS 8606120083
Download: ML20195F350 (18)


Text

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i BROWN & RCOT, INC.

PROCEDURE EFFECTIVE CPSES NUMBER REVISION DATE PAGE l

D 08 35-1 M CP-CPM-9.10 0

9/3/80 1 of 8 fn ORIGINATOR:

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REVIEWED BY:

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FABRICATION AND BAR

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SUPPORTS APPROVED BY:

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/ CATE 1.0 TABLE OF CONTENTS

1.0 INTRODUCTION

2.0 GENERAL 2.1 MATERIAL 2.1.1 Material Control 2.1.2 Material Identification 3.0 PROCEDURE s

I 3.1 HANGER PACKAGES D CM #/

3.2 WELDING 3.2.1 Welding Procedures and Qualifications p eg p,g.

3.2.2 Cleaning of Weld Preps and Base Metal 3.2.3 Preheat /Interpass Temperature 3.2.4 Weld Joint Design and Fit-up 3.2.5 Tack Welds 3.2.6 Inspection After Tacking

3. 2.7 Interpass Cleaning 3.2.8 Workmanship 3.3 GENERAL FABRICATION AND INSTALLATION REQUIREMENTS 3.3.1 Tolerances 3.3.2 Threaded Items 3.3.3 Bolting 3.3.3 Base Plates a;' n 3.3.4 Shimming

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3.3.5 Hanger Adjustment

.3 3.3.6 Cotter Pin Installation

\\ h S[J 3.3.7 Seismic Limiters / Sway Struts V

3.3.8 Material Salvaging

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0.11 ATTACHMENTS Base Plates Installation Guidelines h' l

Material Identification Log j

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,o JOB 35-1195 INDEXED Comanche Peak Steam Electric Station DATL Construction Procedure 2

Sheet 1 of 4 DOCUMENT CHANGE NOTICE NUMBER 0

This notice applies to Construction Procedure No. 35-1195 CPM 9.10 Revision This change will be incorporated in the next revision of the procedure.

Change the procedure as follows:

Replace Pages 7 of 8, 8 of 8 with the attached.

Add page 8a of 8 Reason for change: Added QC Inspection Criteria.

l This change approved by:

Reviewed by:

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l Originator ~

J Date rown & Root Quality Assurance Date l

7-10.90 TUGC0 Quality Assurance Date Reviewed by:

Seotember 10, 1980 A

Constru'Ction Project Manager '

Date Effective Date

ARMS n

JOB 35-1195 lNg{X{g Comanche Peak Steam Electric Station DATE Construction Procedure DOCUMENT CHANGE NOTICE NUMBER 1

This notice applies to Construction Procedure No. 35-1195-CPM 9.10 Revision 0 This change will be incorporated in the next revision of the procedure.

Change the procedure as follows:

Replace Page 5 of 8 with the attached.

1 Reason for change: Clarification.

This change approved by:

Reviewed by:

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+M iginator Date W& Root Quality Assurance Date nIn ze ne TUGC0 Quality Assurance Date Reviewed by:

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Construction Prtrject Manager Date Effective Date

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BROWN & ROOT, INC.

ISSUE CPSES NUMBER REVISION DATE PAGE r

JOB 35-1195 2 of 8 CP-CPM-9.10 0

9/3/80

1.0 INTRODUCTION

This procedure provides the criteria for the fabrication and installation of ASME III, Subsection NF, Classes 1, 2, and 3 canponent supports.

2.0 GENERAL 2.1 MATERIAL 2.1.1 Material Control Materials used in the fabrication of NF supports shall be mater-fals acceptable for ASME use and do not necessarily include all materials acceptable for "Q" applications.

Evidence of material acceptability will be provided through the use of a Material Identification Log (Attachment 2). The log shall be completed by the craft based on the information provided in the hanger package.

The log shall then be presented to QC for material verification and signature.

Welding material shall be controlled in accordance with CPM-6.98.

2.1.2 Material Identification Prior to cutting, the heat or identification (MIC, code, etc.)

numbe'r shall be transferred by mechanical marking, and this mark-ing shall remain distinguishable throughout the fabrication pro-cess. Additionally, the support assembly shall be mechanically identified with the hanger mark number which shall remain dis-tinguishable throughout the installation.

NOTE:

Heat numbers must be recorded for Class I support materials.

3.0 PROCEDURE 3.1 HANGER PACKAGES 3.1.1 Fabrication / installation o.f component supports will be in accord-ance with the hanger package for supports. The package will consist of BRH drawing, Material Identification Log (MIL), Weld Data Card (WDC) and Weld Filler Material Log (WFML) for each hanger. Design Change, such as CMCs affecting the hanger, may be issued directly to the packages for inclusion and the CMC number recorded on the WDC by the originating organization.

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BROWN & ROOT, INC.

ISSUE CPSES NUMBER REVISION DATE PAGE JOB 35-1195 CP-CPM-9.10 0

9/3/80 3 of 8 3.1.2 Weld number shall be assigned by Welding Engineering in the pack-ages for the following weld categories:

1.

Welds to pressure retaining members.

2.

Full penetration welds except flare beveling on structural tubi ng.

3.

Hanger with multiple processes or multi-filler materials.

4.

Welds requiring NDE, other than visual.

5.

All Class 1 support welis.

3.1.3 Welding documentation shall be prepared in accordance with 6.9G.

3.1.4 Upon completion of the hanger and return of the hanger package to Welding Engineering, the WFML and MIL shall be submitted to QA, and the remainder of the HP (except the WDC) should be submitted to Drafting for incorporation into the as-built drawing.

3.2 WELDING 3.2.1 Welding Procedures and Qualifications All welding shall be perfomed in accordance with welding proce-dures which have been qualified to Sections IX and III as required of the ASME Boiler and Pressure Vessel Code and as specified by the Project Welding Engineer. Welders shall be qualified in accordance with the welding procedures used.

3.2.2 Cleaning of Weld Preps and Base Metal Before welding, a minimum of two inches on each side of the weld joint shall be free of moisture, dirt, grease, and oil. Accept-able agents for cleaning include either Varsol 1 or Stoddard Sol-vent.

l Mechanical preparation shall result in a clean surface for a minimum of h inch on each side of the joint.

Deoxaluminate compound, used to coat weld preps, need not be re-moved before welding.

3.2.3 Preheat /Interpass Temperature The preheating and interpass temperature to be used for welding shall be in accordance with applicable WPS.

The preheat specified on the WPS shall be established before any welding. However, except for P4 and P5 materials, preheating above 60*F is not required before tacking.

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f BROWN & ROOT, INC.

ISSUE CPSES NUMBER REVISION CATE PAGE JOB 35-1195 CP-CPM-9.10 0

9/3/80 4 of 8 Preheating may be performed using suitable gas burners and mea-sured by the use of approved temperature indicating crayons.

Temperature indicating crayons, when used for preheating and interpass temperature measurement, shall avoid direct contact with the surface to be welded.

3.2.4 Weld Joint Design and Fit-up Joint type and configuration shall be as specified on the applic-able BRH.

The fit-up gap for buttweld joints shall not exceed 1/8 inch be-yond the diameter of the electrode used at the root of the joint.

The maximum offset of the finished weld shall not be greater than the amount listed in the following table. The final weld surface and adjacent base metal shall blend uniformly.

Maximum Allowable Offset In Final Buttwelded Joints Section Thickness (inches)

Max. Allowable Offset up to 3/4 1/4 t over 3/4 3/16 The fit-up gage for "T" fillet joints shall be as small as prac-tical; however, it should not exceed 1/16 inch.

If gap is in ex-cess of 1/16 inch but not exceeding 5/32 inch, this condition will be considered acceptable provided the leg of the fillet weld is increased by the amount of separation in excess of 1/16 inch.

(The increase in fillet size applies onl ration exceeds 10% of the joint length.)y when the excess sepa-3.2.5 Tack Welds All tack welds shall be made in accordance with an approved weld-ing procedure by a qualified welder and deposited with an elec-trade or wire that is the same composition as the electrode used for the rootpass.

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Tack welds incorporated into the weld shall be visually exanined by the craftsman and meet the following requirements:

1.

The start and stop of the tack weld shall be ground to a feather edge for ease of integration into the weld.

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8 BROWN & ROOT, INC.

ISSUE CPSES NUMBER REVISION DATE PAGE r

JOB 35-1195 CP-CPM-9.10 0

5 of 8 9/3/80 2.

All slag and surface defects (e.g., porosity and cracks) shall be removed from the tack.

3.

Tacks which crack during welding shall be removed and replaced.

4.

Tack welds should be kept to a minimum number and size.

3.2.6 Inspection After Tacking All full penetration groove joints and all welds to pressure retaining boundries shall be inspected by OC after fit-up and tacking prior to welding.

Tack welds not requiring QC inspection shall be inspected by the craftsman.

3.2.7 Interpass Cleaning Interpass cleaning shall consist of the following:

1.

All slag and oxide shall be removed by either chipping, wire brushing, or grinding before making the next successive weld bead.

2.

All surface defects, undercutting, and overlapping shall be removed by grinding before making the next successive bead.

3.

All crater cracks or pits shall be removed by grinding before making the next successive bead.

3.2.8 Workmanship The surface of finished weld shall be free of slag, cracks, over-laps, and undercut in excess of 1/32" in depth.

Fillet weld sizes specified on the drawing are the minimum size required along the full length of the weld joint.

Oversize fillet welds are acceptable providing they do not exceed twice the leg size specified on the drawing.

Excessive distor-tion where oversize fillet welds are used should be avoided.

Welds requiring liquid penetrant examination shall not be power wire brushed.

The surface of the reinforcement of butt welded joints may be flush with the base material or may have unifom crowns. The height of reinforcement on each ' face of the weld shall not exceed the following thickness:

CPM 9.10, Rev. O, DCN# 1 9/9/80 Sheet 2 of 2

BROWN & ROOT, INC.

ISSUE CPSES NUMBER REVISION DATE PAGE n

JOB 35-1195 CP-CPM-9.10 0

9/3/80 6 of 8 Nominal Maximum Thickness in.

Reinforcement, in.

Up to 1, incl.

3/32 Over 1 to 2, incl.

1/8 Over 2 to 3, incl.

5/32 Over 3 to 4, incl.

7/32 Over 4 to 5, incl.

1/4 Over 5 5/16 3.3.

GENERAL FABRICATION AND INSTALLATION REQUIREMENTS 3.3.1 Tolerances Fabrication and installation shall be performed in accordance with the drawing detail and the following permissable tolerances:

3.3.1.1 Fabrication Tolerances 1.

Length a.

Support members (except rods) up to 12" 1/8" b.

Support members (except rods) over 12" 1/4" 2.

Holes a.

Diameter

+1/16" b.

Centerline location 1/8" 3.3.1.2 Installation Tolerances 1.

Dead weight supports a.

Location Axially 12" b.

Plumbness 2 degrees 2.

Seismic Restraints a.

Restraints, anchors, guides, etc.

Location; (2 x pipe wall thickness 2" from theoreti-cal pos.ition) b.

Attachments to center of structural steel reaction membersi Location; 2", and plumbness 2 degrees e

BROWN & ROOT, INC.

ISSUE CPSES NUMBER REVISION DATE PAGE JOB 35-1195 CP-CPM-9.10 0

9/3/80 7 of 8 c.

Pipe Clearances 1.

Where the design shows 1/16" on both sides, the total dimensional tolerance shall be 1/8" 1/16" (e.g., 0" on one side w/1/8" 1/16" on the other, 1/16" 1/32" on both sides, or any combination).

2.

Where the design shows 0" on one side and 1/16" on the other side, 0" must be maintained while 1/16" 1/32" is required on the other side.

3.

Where the design shows 0" on one side w/1/16" on the other side, if 0" cannot be maintained on the side shown, the situation will have to be investi-gated and resloved by Site Engineering.

3.3.1.3 In the use of these deviation values, when more than one direc-tion plane is involved, the resultant (canbined) value shall not exceed the above permitted deviation values.

3.3.2 Threaded Items All bolts, studs, or threaded rods shall have full thread engage-ment in the nut.

Surfaces of bolted parts in contact with the bolt or nut shall have a slope of no more than 1:20 with respect to a plane normal to the bolt axis. Where the surface of a high strength bolted part has a slope of more than 1:20, a beveled washer shall be used to compensate for the lack of parallelism.

3.3.3 Base Plates When field personnel determina that the original pipe hanger base plate cannot be irstalled as designed, design modification may be made in accordance with the " Base Plates Installation Guidelines" (Attachment 1).

If a modification to the design can be accomp-lished within the guidelines, a CMC shall be used to make the modification in accordance with applicable controlled Engineering documents.

If the modification cannot be made withing the guide-lines, the problem will be turned over to the responsible Mech-anical Engineer.

3.3.4 Shimming Component support wall or ceiling plates that do not fit flush against concrete mating surfaces do not require shims unless the gap exceeds 1/16 inch. Shim material may consist of shim plates or washers of a size necessary to allow proper Hilti bolt torqu-ing without base plate deformation.

BROWN & ROOT, INC.

ISSUE CPSES NUMBER REVISION DATE PAGE

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JOB 35-1195 C P-C PM-S.10 0

9/3/80 8 of 8 Component support wall and ceiling plates must have a minimum of 80% bearing surface against the concrete face. The maximum allowable gap, for the renaiaing portion of the plate, shall not exceed ~1/16 inch.

If this criteria cannot be met, the plate must be grouted with a non-shrink epoxy grout in accordance with CCP-12. Floor plates not subject to the above requirements will also be grouted in accordance with CCP-12.

The grout filling hole shall not be drilled within 1" of a con-crete anchor. The hole shall be located outside of the bolt hole pattern.

3.3.5 Hanger Adjustment After installation of the supports on a system, the supports shall be adjusted to the design location in the cold position.

All constant and spring supports shall be securely blocked cut with the factory supplied travel stops. After final adjustment, hanger travel stops shall not be removed unless directed by TUGCO.

3.3.6 Cotter Pin Installation Cotter pins should be fully opened to the extent that they cannot become dislodged from the pin or bolt they are securing, and such that they do not present a hazard to personnel. Cotter pins shall be the maximum size the cotter pin hole will permit.

3.3.7 Seismic Limiters / Sway Struts Sway struts and seismic limiters shall be installed and inspected to the drawing using the criteria set forth in the individual manufacturer's catalogs or instructions. Requirements for sesmic limiters are delineated in CPM-9.11.

3.3.8 Material Salvaging When items cannot be used because of redesign, misfabrication, damage, the disposition to Nonconformance Reports, etc., the items may be scrapped, salvaged, or returned to bulk stock. The responsible foreman shall make this determination based on the i.

NCR, CMC or the iten's physical condition, as appropriate. When l

Code stamped items or partial assemblies are modified, documenta-l tion for such modification shall be prepared as required by Appendix 6.9G, and the modification acconplished accordingly.

i NOTE:

Except as permitted above, hanger parts shall be used on hangers where designated and shall not be inter-changed.

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~ CPM 9.10, Rev. O, CN# 2 Sheet 3 of 4 t

' l BROWN & ROOT, INC.

ISSUE CPSES NUMBER REVISION DATE PAGE r

JOB 35-1195 CP-CPM-9.10 0

9/3/80 8a of 8 In accordance with ACP-3, a " Return to Warehouse" form shall be used when an item is returned to the warehouse, and a copy should be sent to the Production Control Department. Subsequent reissue of these materials shall be in accordance with ACP-3.

When an item is salvaged for use on a support other than the one for which it was designated, the original support number shall remain distinguishable on the item. The item's description and the original support mark shall be recorded in the appropriate spaces provided on the Material Identification Log.

t CPM 9.10, CN#2 Sheet 4 of 4

BROWN & ROOT, INC.

ISSUE CPSES NLNBER REVISION DATE PAGE r

JOB 35-1195 1 of 3 CP-CPM-9.10 0

9/3/80 ATTACHMENT 1 BASE PLATES INSTALLATION GUIDELINES SCOPE Construction guidelines for the installation of pipe support base plates and concrete anchor bolts which deviate from the original design.

GENERAL These guidelines apply only to pipe support base plates attached to structure with four concrete anchor bolts.

Any of the following conditions require engineering evaluation, on a case-by-case basis, prior to design deviation in excess of construction tolerances:

A.

Base plates attached with more than or less than four con-crete anchors.

B.

Base plates attached with Ih" Super Hilti anchor bolts (all lengthes.)

C..

Core drilled base plate anchors.

D.

Base plates ik" or greater in thickness.

E.

All violations of minimum Hilti spacing.

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i' DRILLING ANCHOR BOLT HOLES 1.

If the first anchor bolt hole cannot be drilled at original design location because of rebar, relocate it in an out-wardly direction (away from steel member attachment) a short distance.

Continue moving outwardly until hole can be successfully drilled.

2.

Locate remaining holes in such a way that the final bolt hole pattern is as symmetrical as possible.

BROWN & ROOT, INC.

ISSUE CPSES NUMBER REVISION DATE PAGE

- JOB 35-1195 2 of 3 C P-C PM-9.10 0

9/3/80 SUBSTITUTION OF ANCHOR BOLTS 1.

If the new anchor bolt location varies from the original location, less than or equal to 2 inches, then use anchor size as specified on bill of material.

2.

If new anchor bolt location is greater than 2 inches from original bolt location, substitute the next larger size anchor bolt with the greatest stocked length. This is pro-viding that the minimum Hilti bolt spacing criteria is met for that particular Hilti bolt size.

3.

If next size anchor bolt cannot be installed due to spacing requirements, increase bolt length to the greatest stocked length of the original bolt diameter.

In the case of 1" x 12" Hiltis, substitute with " Super" Hiltis of equal length.

NOTE:

Anchor bolt embedment length cannot exceed 80% of the thickness of the concrete slab or wall being attached to.

4.

All structural steel attachments to base plates (i.e., wide flange, structural tubing, channel, etc.) must always be s

within the inner confines of the bolt hole pattern.

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FINAL PLATE DIMENSIONS PLATE THICKNESS If the length and/or width dimensions increases from the original distance greater than 2 inches, increase the plate thickness to the next greater size.

In the case of an increase of 6" or more in either direction, increase original plate thickness by h".

OVERALL PLATE DIMENSIONS To maintain all corners square the "X" dimension must be deter-mined.

The easiest methed is to compare dimensions A&B and select the largest. Add the necessary edge IDST (E) which is 1 -

BROWN & ROOT, INC.

ISSUE CPSES NUMBER REVISION DATE PAGE JOB 35-1195 CP-CPM-9.10 0

9/3/80 3 of 3 determined by the bolt size (see chart). Therefore, the distance "X" is fran center line of the member to the edge of the plate.

X = A or B E

Repeat this process for each side of plate.

(select largest)

PROCEDURE EFFECTIVE

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11ROWN.& ROOT, INC.

NUMBER REVISION DATE PAGE CPSES r

EB 35-M CPM 9.10 0

9/3/80 ATTACHMENT 2 MATERIAL IDENTIFICATION LOG h

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ISSUE CPSES NLtiBER REVISION DATE PAGE g

JOB 35-1195 C

0 9/3/80 5 of 8 g

g { CPM-9.10 W

0 defects (e.g., porosity and cracks) 2.

All s1 i

shall be re the tack.

3.

Tacks which crack during welding shall be removed and g pf A l replaced.

4.

Tack welds should be kept to a minimum number and size, 3.2.6 Inspection After Tacking All full penetration groove joints shall be inspected by QC after fit-up and tacking prior to welding.

Tack welds not requiring QC inspection shall be inspected by the craftsman.

3.2.7 Interpass Cleaning Interpass cleaning shall consist of the following:

1.

All slag and oxide shall be removed by either chipping, wire brushing, or grinding before making the next successive weld bead.

2.

All surface defects, undercutting, and overlapping shall be removed by grinding before making the next successive bead.

3.

All crater cracks or pits shall be removed by grinding before making the next successive bead.

3.2.8 Workmanship The surface of finished weld shall be free of slag, cracks, over-laps, and undercut in excess of 1/32" in depth.

Fillet weld sizes specified on the drawing are the minimum size required along the full lerigth of the weld joint.

Oversize fillet welds are acceptable providing they do not exceed twice the leg size specified on the drawing.

Excessive distor-tion where oversize fillet welds are used should be avoided.

Welds requiring liquid renetrant examination shall not be power wire brushed.

The surface of the reinforcement of butt welded joints may be flush with the base material or may have unifom crowns. The height of reinforcement on each face of the weld shall not exceed the following thickness:

BROWN & ROOT, INC.

ISSUE CPSES NUMBER REVISION DATE PAGE C

JOB 35-1195 CP-CPM-9.10 0

7 of 8 9/3/80 3.

f these deviation values, when more than one direc-involved, the resultant (combined) value shall not ove pemitted deviation values.

3.3.2 s

All bolts, studs, or threaded rods shall have full thread engage-O ment in the nut.

Surfaces of bolted parts in contact with the bolt or nut shall have a slope of no more than 1:20 with respect to a plane nomal to the bolt axis. Where the surface of a high strength bolted part has a slope of more than 1:20, a beveled washer shall be p(db used to compensate for the lack of parallelism.

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3.3.3 Base Plates When field personnel detemine that the original pipe hanger base plate cannot be installed as designed, design modification may be made in accordance with the " Base Plates Installation Guidelires" (Attachment 1).

If a modification to the design can be accorp-lished within the guidelines, a CMC shall be used to make the modification in accordance with applicable controlled Engineering documents.

If the modification cannot be made withing the guide-lines, the problem will be turned over to the responsible Mech-anical Engineer.

3.3.4 Shimming Component support wall or ceiling plates that do not fit flush against concrete nating surfaces do not require shims unless the gap exceeds 1/16 inch. Shim material may consist of shim plates or washers of a size necessary to allow proper Hilti bolt tsrqu-ing without base plate defomation.

Component support wall and ceiling plates must have a minimum of 80% bearing surface against the concrete face. The maximun allowable gap, for the renaining portion of the plat'e, shall not exceed 1/16 inch.

If this criteria cannot be met, the plate nust be grouted with a non-shrink epoxy grout in accordance with CCP-12.

Floor plates not subject to the above requirements will also be grouted in accordance with CCp-12.

The grout filling hole shall not be drilled within 1" of a con-crete anchor. The hole shall be located outside of the bolt hole iblA 85 5E 6

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BROWN & ROOT, INC.

ISSUE CPSES NUMBER REVISION DATE PAGE b

JOB 35-1195 8 of 8 CP-CPM-9.10 0

9/3/80

'3.3.5 Hanger Adjustment s

After installation of the supports on a system, the supports shall be adjusted to the design location in the cold position.

All constant and spring supports shall be securely blocked out with the factory supplied travel stops. After final adjustment, hanger travel stops shall not be renoved unless directed by TUGCO.

3.3.6 Cotter Pin Installation Cotter pins should be fully opened to the e

not become dislodged fran the pin or bolt the re l

uch that they dc not prese.r:t a hazard to personnel.

t shall be the maximum size the cotter pin hole will pemit.

3.3.7 Seismic Limiters / Sway Struts Sway struts and seismic limiters shall be installed and inspected to the drawing.using the criteria set forth in the individual manufacturer's catalogs or instructions. Requirements for sesmic limiters are delineated in CPM-9.11.

3.3.8 Material Salvaging When items cannot be used because.of redesign, misfabrication, damage, the disposition to Nonconfomance Reports, etc., the items may be scrapped, salvaged, or returned to bulk stock.

The responsible forenin shall make this detemination based on the NCR, CMC or the item's physical condition, as appropriate. When Code stamped items or partial assemblies are modified, documenta-tion for such modification shall be prepared as required by-Appendix 6.9G, and the modification acccmplished accordingly.

NOTE:

Except as pemitted above, hanger parts shall be used on h.ingers where designated and shall not be inter-changed.

In accordance with ACP-3, a " Return to Warehouse" fom shal'1 be used when an item is returned to the warehouse, and a copy should be sent to the Producticn Control' Department. Subsequent reissue of these materials shall be in accordance with ACP-3.

When an item is salvaged for use on a support other than the one for which it was designated, the original support number shall remain distinguishable on the iten. The iten's description and the original support mark shall be recorded in the appropriate spaces provided on the Material Identification Log.

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