ML20198L484

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Rev 2 to Instruction QI-QP-11.14-1, Insp of Site Fabrication & Installation of Structural & Miscellaneous Steel
ML20198L484
Person / Time
Site: Comanche Peak  Luminant icon.png
Issue date: 01/04/1982
From: Scott B
TEXAS UTILITIES ELECTRIC CO. (TU ELECTRIC)
To:
Shared Package
ML20197J316 List: ... further results
References
FOIA-85-59 QI-QP-11.14-1, NUDOCS 8606040291
Download: ML20198L484 (9)
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Text

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\00 ( Y 1I l ISSUE I TEXAS UT1uTIES GENERAUNG NUMBERCO. l INSTRUCTION t

REVISICN l

OATE PAGE l

l CPSES ,

I i QI-QP-11.14-1 2 JAN 4 1982 i' i of g i

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l INSPECTION OF SITE PREPARED BY: SA M .@l ( dek @ i I'-

i FABRICATION AND CATE U U N APPROVED BY:\\h Nr1 1U - Q-81 MISCELLANEOUS STEEL APPROVED BY - '

IN DATE s

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1.0 REFERENCES

I I

1-A GaH Specification SS-16B, " Structural Steel"  !

l i 1-B G&H Specification SS-17, " Miscellaneous Steel" l 1-C MCP-10. " Storage & Maintenance of Mechanical and Electrical  !

I Equipment" l l l(

l 1-0 QI-QP-11.14-4, " Control of Material Traceability for  !

2

' Site Fabricated Structural / Miscellaneous Steel"  !

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I 1-E QI-QP-11.14-3, " Inspection of Structural / Miscellaneous Steel

! Welding" j,'

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l 1-F QI-QP-11.14-2, " Inspection of Stud Wel  !

1-G ANSIBl.1-74," Unified 1-inchScrewThreads/A  !"/  !

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f 1-H CP-QP-18.0, " Inspection Reports" 1-I CP-QP-16.0,"Nonconformancesandbeficiencies" #j!

2.0 GENERAL j '

2.1 PURPOSE -

1 The purpose of this instruction is to delineate the safety .

related QC inspection activities for Site fabrication and l installation of structural and miscellaneous steel included

.' , in References 1-A and 1-B.

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'4 INSTRUCTION ISSUE PAGE REVISION ^

TEXAS UTILITIES GENERATING CO, (

QI-QP-11.14-1 2 JAN 4 M 2 of 9 2.2 SCOPE

! The scope of this Instruction shall include all structural /

I miscellaneous steel (excluding conduit and cable tray supports).

3.0 INSTRUCTION 3.1 MATERIAL STORAGE The QC Inspector shall perfonn random surveillance over storage and control of materials in the structural / misc-eilaneous steel shop area to assure proper storage and control of materials in accordance with Reference 1-C and

' as follows: _

a. Safety-related material for items requiring traceability through installation shall be segregated from other materials and shall be identified by heat number at all times. ,

j b. The QC Inspector shall verify that segregation and heat 1  !.D. is maintained as material is drawn from storage while perfonning storage surveillance.

3.2 MATERIAL ISSUANCE AND TRACEABILITY

' Upon issuance of material, the QC Inspector shall verify I that the material is correct per fabrication drawing and traceability is maintained in accordance with Reference 1-0.

l f 3.3 FABRICATION TOLERANCES

- The following fabrication tolerances are to be used unless ~

specified otherwise on the drawing:

t Steel items Embedded in Concrete:

a. General Linear Dimensions 21/8"
b. Weld Stud Spacing 23/8"
c. Weld Stud Design Pos'ition Deviation 5 degrees

. d. Anchor Bolt Dimension (after bending) th" g i

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INSTRUCTION ISSUE PAGE REVISION

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TEXAS UTILITIES GENERATING CO.

(- CME 4

QI-QP-11.14-1 2 jag 4 1982 3 of 9 1

Structural Steel:

l a. Overall, when member has both ends l finished for contact bearing 2 1/32" t

b. All other conditions j (1) For members up to 30 feet long 21/16" (2) For members longer than 30 feet 21/8" 3.4 WELDING INSPECTION i All welding (fabrication and installation) shall be inspected in accordance with Reference 1-E.

3.5 STUD WELDING Stud welding shall be inspected in accordance with

( Reference 1-F.

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3.6 BOLT THREADING The QC Inspector shall review the detailed infomation i drawing to detemine the applicable pitch diameter range to be welded in accordance with Reference 1-G.

The first and last bolts threaded shall be checked for pitch diameter accuracy and as a minimum, at least ten percent (10%) of the bolts threaded shall be checked using the screw thread micrometer, wire gages or outside micrometers.

If any of the bolt threads checked do not confom to the

, specified tolerances, an additional ten percent (10%) of d the bolts shall be checked. If any bolts threads of the

second ten percent (10%) do not confom to the specified I tolerances, one hundred percent (100%) of the remaining shall be scrapped.

.k' The QC Engineer / Inspector shall document the serial number and calibration due date of the M&TE used to check the l bol t threads during the bolt threading operation on

( Attachment 1.

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i .lNSTRUCTION l$ UE REVISION PAGE TEXAS UTILmES GENERATING CO.

CPSES QI-QP-11.14-1

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2 34 1982 4 of 9 3.7 BOLTED CONNECTIONS 3

The QC Inspector, when inspecting bolted connections, shall i visually inspect for the following:

i

a. Bolts are the correct length as indicated by having the i bolts flush with, or outside of, the face of the nut

.I when completely installed.

b. Turning elements are on the correct face.
c. Washers are used when required.
d. Bolt heads and nuts shall rest squarely against the metal or washer.
e. Where bolts are used on surfaces having slopes greater than 1-in-20 with a plane nonnal to the bolt axis,

- beveled washers shall be provided to give full bearing to the head or nut. 7

f. Threaded bolts shall be tightened with properly calibrated wrenches or by turn-of-nut method.

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g. When " Turn-of-nut" method is used for bolt tightening, the impact wrench or other pneumatic device does not

' require calibration. However, the device shall be of adequate capacity and sufficiently supplied with air to perfonn the required tightening of each bolt in

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i approximately ten seconds. When this method is used, i.he following steps will be followed by construction:

1. All bolts in each joint shall first be brought to ,

a " snug tight" condition (snug tight is defined as I the tightness attained by a few impacts of an impact wrench or the full effort of a man using an ordinary spud wrench).

2. All the nuts shall then be match-marked using an approved industrial marker, i.e.: Nissen; which has certified contents.
3. All the bolts in the joint shall then be tightened 1

' by the applicable amount of nut rotation specified in Attachment 2.

4.

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Tightening shall progress systematically from the i most rigid part of the joint to its freest edges.

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INSTRUCTION ISSUE NUMBER REVISION AGE TEXAS UTILITIES GENERATING CO. DATE

( CPSES y,I-QP-11.14-1 2 W4 E 5 of 9

5. There shall be no rotation during tightening of the part not turned by the wrench.
6. The end of all bolts shall be marked with the industrial marker when required nut rotation has been attained.

., h. When using the " Calibrated Wrench" method for tightening bolts, the following steps will be followed (j by construction:

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1. Impact wrench shall be calibrated prior to use each morning and afternoon for each adjusted tension setting.

T 2. Impact wrenches shall be recalibrated at any time

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significant changes are made in the equipment; f f.e., air hose length changed by more than 200 p

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( feet or a significant difference is noted in the condition of the bolts, nuts, or washers.

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+ 3. By use of Bolt-Tension Calibrator adjust impact 9

j wrench until 3 consecutive bolts are tightened to required tension; (See Attachment 3 for required tension).

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T* 4. Use new bolt and nut each time the calibrator is used, i.e., 3 bolts tightened require 3 new bolts and nuts; if a washer is to be used in the s truc tu re, then a washer shall also be used when calibrating the impact wrench.

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5. When several bolts are installed in a single joint, the impact wrench shall be returned to

" touch-up" bolts previously tightened to assure that any bolts which may have been loosened by the tightening of subsequent bolts are tightened to the prescribed amount.

1 1. When Richmond inserts are used, thread engagement into

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the insert shall be at least 2 X the bolt diameter +

1/8". Therefore, the required length of the bolts used = [(2 x bolt diameter) + 1/8 inch] + (grout 3

(; thickness + thickness of structural member attached

+thicknessofwasher(asapplicable)].

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INSTRUCTION ISSUE

" REVISION PAGE TEXAS UTILITIES GENERATING CO.

CPSES

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QI-QP-11.14-1 2 JAN 4 1982 6 of 9 3.8 ,

HOLES All holes in structural steel shall be punched or drilled.

No holes shall be made or enlarged by burning without approval by designer.

3.9 STRAIGHTENING OF DEFORMED MEMBERS 4 Members which are distorted from welding may be straightened by mechanical means or be application of localized heat. In the event that heat is used, QC 'shall veri fy that the j temperature does not exceed 1100* F for quenched and tempered steels. Temperature determination shall be made using temperature indicating crayons.

3.10 FINAL INSPECTION The QC Inspector shall perform a final inspection of each fabricated item as follows: g y a. Verify final dimensions .

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b. Verify traceability maintained

! c. Verify identification markings are legible 3.11 DOCUMENTATION An inspection report, Attachment 1. shall be prepared in accordance with Reference 1-H to document required inspections. The final documentation package (IR, NDE  :

reports, Stud Welding Qualification Record, as applicable) '

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shall be forwarded to the Permanent Plant Records Vault for retention, i 3.12 NONCONFORMANCES Nonconforming items which cannot be reworked per normal

! construction practices shall be reported in accordance with

! Reference 1-I.

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INSTRUCTION ISSUE CAR N TEXAS UTILITIES GENERATING CO.

_ CPSES I' OI-QP-11.14-1 2 JAN 4 1962 7 of 9 l l

ATTACHf'ENT 1 -

CCasaa: CME 8tM STEAas (1.ET111C S TA?!CN ,

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2. + verify weleer Qualf fication 8 9 4  ; i Welder Statiol: 1 I i , I

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3.  !- Vf sual fnseeetten of Al' Aweesatic Stud Wetes
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a.  ! rf nal visual Insoection of Wetes 1 I I i 1 6 .

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INSTRUCTION I 8U PAGE REVISION

" r TEXAS UTILITIES GENERATING CO. '

f CPSES QI-QP-11.14-1 2 l J AN 4 E 8 of 9 i l I l l

- ATTACHMENT 2 i

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MJT ROTATION FROM SNUG TIGHT CONDITION 4

Disposition of Outer Faces of Bolted Parts

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Both faces normal to bolt axis, or one face Both faces sloped not more -

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nomal to axis and other face sloped not more than 1:20 from normal to bolt than 1:20 (bevel washer not used) axis (bevel washers not used)

Bolt lengthb not exceeding Bolt length b exceeding For all length of bolts 8 diameters or 8 diameters or 8 inches 8 inches t (

3/4 turn

, 1/2 turn 2/3 turn .

a. Nut rotation is rotation relative to bolt regardless of the elenent (nut or bolt) being turned. Tolerance on rotation: 30o over or under.

For coarse thread heavy hex structural bolts of all sizes and length and heavy hex semi-finished nuts.

b. Bolt length is measured from underside of head to extreme end of point.

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    • l; TEXAS UTILITIES GENERATING CO.

- INSTRUCTION

" REVISION ISSUE

^

PAGE l

CPSES QI-QP-11.14-1 2 JAN a 1982 9 of 9 i

ATTACHMENT 3 MINIMUM FASTENER TENSION A325 A490 Bolt Size Required 107% Required 107%

1/2 12,000 12,840 15,000 16,050 5/8 19,000 20,330 24,000 25,680

( 3/4 28,000 29,960 35,000 37,450 7/8 39,000 41.730 49,000 52,430 1 51 ,000 54,570 64,000 8.480-1 1/8 56,000 59,920 80,000 85,600 1 1/4 71,000 75,970 102,000 109,140 .

1 3/8 85,000 90,950 121,000 129,470 l 1

158,360 I 1 1/2 103,000 110,210 148,000 4 A l l

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