ML20202B204

From kanterella
Jump to navigation Jump to search
Partially Withheld Supplemental Assistance to Insp Rept A4-83-005 Re Allegations of Improper Const Practices by Brown & Root,Inc.Related Info Encl
ML20202B204
Person / Time
Site: Comanche Peak  Luminant icon.png
Issue date: 11/30/1983
From:
NRC OFFICE OF INVESTIGATIONS (OI)
To:
Shared Package
ML18052B537 List: ... further results
References
FOIA-85-59 A4-83-005, A4-83-5, NUDOCS 8607100236
Download: ML20202B204 (21)
v • d • e


Text

AH-9

'" ' < , UNitt ts s1 At t 5 i*. L NUCLE AR REGULATORY COMMISSION

  • b OrFICL Or INvtSilC ATIONS FIE LD OF FICE AlClON tv

%+!v~/g

\.

i 611 RY AN PL AZ A DRIVE. SUITE Itm AR LINGTON.1[ X AS 7(,011 DO N OT JLSC,_0S,_, -

ASSISTANCE TO INSPECTION REPORT

" SUPPLEMENTAL" November 30, 1983

SUBJECT:

COMANCHE PEAK STEAM ELECTRIC STATION:

ALLEGED' IMPROPER CONSTRUCTION PRACTICES

~

REPORT NUMBER: [A4-83-005 g /4 ' / -

N / p,j-d

1. During the course of an unrelated investigation, informat from five forr,5.,r Brown & Roof Inc. (B&R) enplovees who wt ...vusly in an " Assistance"to Inspection Report" (AIR),

identified by report number M-63-000, cater May 20, 1983, as having knowledge of improper construction practices. These five interviewees were contacted and questioned recarding a separate investigation currently in progress; however, in addiHen these five individuals were also questioned concerning allegations tha previously raised in AIR A4-83-005. - -

2. Between November 1, 1983 and November 22, 1983, these five former B&R employees that Messerly identified as working with or in the same area as himself were interviewed. Attachments (1) through (4) are Results of Interviews with four of these individuals who stated they were not aware of any improper pro edures -y or conu ruction practices. One of these individuals stated he observed IC.

_ trim a hanger with a torch, however, quickly added he was ur. aware it nad proper authorization. Attachnent (5) is a sworn statement.wherein (nis incnidual stated he observed numerous larce hancers that were altered with a torch by a nurter of individuals (identification unknown), hcwever, i

added that he did not know whether or not proper authorizatior, had been Iu cbtained.

3. The Result of Interviews and the sworn statement, Attachment (1-) through (5-),

of these former B&R employees will be maintained at the OI rield Office, Region IV. '

4. This report is provided to the Nuclear Regulatory Commissior. Region IV r.anagement for review, evaluation, and acticn deemed a;.propriate.

1 8607100236 FOIA 860630 PDR PDR GARDE 85-59 y.

g ggggw.

y ,e DO NOT JTSC10SE

W '" A 6"y 4nd eehei ,, c. u. g , ,"'f"y dke m c n m e~1' cF % pye baring Se MZ mcke / af G_q

, r ike PR C's A+i c e %'

fe, k sa u E-

!OC4 '

l O *~' .S .

fm fc Pep fd5 niee( %l l~! 6 he c& s 5 be fW ~ rth %

m ke h e7ers i~' f~he('er S w e(y0s, a /( hac/

rod Threaded c aIs-the g c , e a % w ay Als;#*N+ r A n ~9ers A a A SW" W l7 ' *

ge7 w ere ha oy. Y"he p, es tacyed' hole ,b/"

g h S0 m P O'4 d #^'"l a,A+ un u q x _o m A r

cre w c-f Me ^^"/*F

"'" I 04 f /85 *!

re kal+ if This

~*' '

7 l l1off,5 /&

~

bE S

  • f gy (st r 764 I hvew a 4 d-4 w7.e r s I have read the foregoing statement consisting of 1 handwritten /

im;;-d p a ce s . I have made and initialed any necessary corrections and have signed my name in ink in the margin cf each page. I s' ear that the foregoing statement is true and correct. Signed on/ .26 0 t .

(date) (tine)

g .f r s .E gc,;93 d (s2 %..-. , . . 9. k. ..M...

% .uor/

Subscribed and sworn to before me this 76 -fl3 day of~ ,19d, at @c o o Ln s e s_ , , , Te,vp

'l 42

  • IfiVESTIGATOR: -)'

WITf;ESS: ,

(t:AME & TiiLEQ7EITUgihiEU)g (fM E: TYPED'OiMTlIh) /7'

n. x . ..

~,

^

y L _p

\

\, _.

C 5 s

c- * \ 6

_ _. . . . . . . '4. .

- /

.. _ . _ . _ . _ . . . . . . . _ ._ s . K. RA. . / 6 y[

_..s

}. --

4 's 0T % ._ _. .__...._._{.

~~

f

/_ ,

u

. /l h .,{ h . _. _. _ _ . '... . [. h_ _. ._. a 'a g,,

  • I' )

. .Df 6 G

.. . . _ . _ . . . _ _ . . . _ 4.__ _ _s _ .

t d.f . . t'i .- _aN . ._ .. - .

  • y. .
  • LQ. . . . _ .- _ . _. - -- .. _ __ _ C:.

_ . . . . . - . _ . . . . . _ . _ . _ . . . . n _. . . . _~ u . . _ . . '. 44 b . . _ _ - . _ _ _ _ __ _ . - .. _ .-._ _

. - . . _ . . . . . _ . . . . . _ . . _ . . . . _ _ _ . _ . . _ . . . . _ . . . _ . . _ . _ - . _ . . _ - - - - . . . - . . - - . . - - - ._- - -__e

_ __ .. .-._'. .. e .L'J__

  • / _.9 C ( _ _.._. ( u' / t.$ $

6

. . _ . . . _ . _ _ - . _ . _ _ _' r \} _ . Y~-~ % .0 .7._

. .L ' .. .. _ . . u O

~

._._-_. . . . _ . _ . .?.s. . - r; >._.

,, y -_ ... ,.t\, . -.._.c v.. . .

..* C' t  %

~ b>

.d -(.s'. .- . ___k" k5. * " . ^

I S . _ . _-C k_... __0

. . . i !. [.

v .s /

i -

.. ._ . _ . . . . - . _ . . . . .'- _ t

  • u.' - h. - -

., l . !-L(i. ,, , ..i ' c' l

. . ___-.Y . %H - ' . ' .V~' .' _. .<'.* -

  • y

.t

. W . . ,;/. % . . ..

.. . . _ . . . . _ . _ _ _ - _ _ . _ _ . . , . _ . . _m.t _ .v.n !. C '.~b._. __. . *- c ~~~; .

$..* N

. . >c. ' . ). .".>..i E . _ . - _ . .. .. 9

- b

.' I

.( . ,

s _._s

. . .. . .. . i .,

1 b

. ~ ..v . ._..._........___-........-..,l

_- s...

...._.__...T.,3 '~~.a _d'*....._._.-_..__- .,

. o e e' r

. . _ _ _ _ . . . . . . . . . . _ . _ . _ _ . . . _ _ _. _ j ' . <% - L. _ . .f_..'L v ____t r.. 2 _0 . _ .. _. _ _ . - -

.._..___..._"...._.g_

. > . .:_.  ; p

._.--__._.p...'..) y. . .. .

a. .

w.o n, . . . _ _ _ . - . . . _ _ .

. . -_. (

(

! t.

. . . .-- .. . . . . . _ . . . - . .. -. __. . . _ . . - . . . _ . . _ . _ . . . _ .. . . . .. \

v <

\ (s gs\

1 '

h=

h.m _. i. ..

. p. t.s . .l k .k~ . - . .

r..... . . . . . . . . . . . . . . _ _ _ _-..._....._......_-__-..i

- y'.

b } N &[

  1. ..,r _h.

b~J ad_ e .E.Wp _ __.. _.. .__.7_,...._ _ .

.. . .. . ._ _ . . . . . . . . . . .. = . . _ . . . . .

. _ _ L. .-; uoE .-- . t

.. _ ..__.. e

+

( .-

-I *.. .. . .aA .I* -

1*-

t V

- ~ ~ -

.y . . ___._._.__-. _ _ _ _

.-t r .. .

- * ~ _ .

-. ..- ._..,,4. . . . _ . .. -. . _ . . _ . . _ _ . . . _

... - . g.

.s - ' -

- . - - - ~~~

~~'~[;

. - _ _. . .._._.. C, _ _ .. lyf _ . ..

_ _ _ . . . _ _ _ . _ m

FOLDER NO. 17 Draft No. Date COMANCHE PEAK ALLEGATION WORK PACKAGE MECHANICAL & PIPING Category 17 - Hanger Damage Allegation Numbers: AH-9, AH-10, AH-11 Statement of Allegation: Various cutting torch applications to pipe hangers with concerns involving procedures, improper use of equipment, unapproved work performed, -

and generally poor workmanship.

i Reference Documents:

~

See source documents marked on attached pages from allegation list. Also check 4

civil / structural allegation work package (Cat. No. 6) for information related to cutting (drilling) of rebar. Allegations AH-9, AH-10, and/or AH-11 d_o not directly involve cutting of rebar. ,

Source of Allegation: y Date Received: 1983 - 1984 The above information prepared by D. M. Hunnicutt 6/4/84 Name Date Group Leader Name Date Assigned Team Members Date Assigned Date As:;1gned l

Date Assigned Date Assigned

~

FCIA-85-59 l wl m

13" ' *j 'd' a  ;

23  ;

  • 5 l.' 3

! i

I
  • 2 1*  ;

3r l

. l., j

}e t' i 3 j

! E, . II L . l4

< . I w i

r  !

,- i

=

5sl 1

3e _

,1 p, -

Jk - E -E f:f w

3 )'

I E El I' o l'l 5.ll5 ru, i$4 0 5l .

6 ':

?a u -

. t

- 5' $ a 3;  ;;

  • 5:;

-$ te

  • i O 2,5) 5: . ;:,

a I

ol St [

3 J

! 0l! 4. .

Eq

". =i y 4 I

^

5.

~ei

.e.

Wl

>t .

}

~

I r. =

Ol$l::

5f 2', 5x 9

E

~.

2 L .

3 .

'n x ;T ,

0; 3 E 3" $ l

. , i 202 :: 1

m. e e *;; th

. ir ::

g" f *'

  • 3E !!*

. . 2;, .

w < 5~2 't l 1 *:1  !* i El

,', t ie

  • 4 )O :s:

Si -

3.!

&* Og O'

  • 2.,
l. 'I t t r! i J , J22 d *_

u , . I O E,; 4 2 2 l

,{ .

> i ls  %  % 1

- -s i i

t l a

I u. aen O em g CC f I Ll9

COMANCHE PEAK OPEN XSSUE ACT10N PLAN Task: Various cutting torch applications that are concerns involving cutting of pipe hangers without procedures, and that involves poor workmanship.

Ref. No.: AH-9, AH-10, AH-11 Characterization: Various applications of using cutting torches on pipe hangers.

May involve procedures, improper instructions, and generally poor workmanship.

Initial Assessment of Significance: Region IV has not documented any dispositions of these allegations. There appears to be sufficient specificity to warrant followup.

Source: Mechanical & Piping Category 17 - Hanger Damage.

Approach to Resolution:

~

1. Review procedures, codes / standards, design requirements, NRC requirements, and licensee commitments for adequacy at time work was performed; were -

codes / standards, FSAR, contractor requirements, and other commitments met?

2. Discuss adequacy of procedures with personnel involved with design and installation and cutting. Discuss adequacy of other design / installation and cutting procedures. Examine installation and cutting, as appropriate, ,

that are associated with any inadequate procedures identified during -

interviews. ~

3. Review sample of similar-type design / installation and cutting (removal) procedures for adequacy.
4. Refer any examples of wrongdoing or significant deficiencies to TRT manager.
5. Evaluate allegations for generic / safety implications.
6. Report on results of review / evaluation of allegations.

Related Open Issues

1. Using system codes, pull open items, previous inspection findings, etc.,

from the tracking system open item list. (Region IV identify and add to this work package.)

2. Review activities necessary to close or partially close related items, either based on inspection conducted above or reasonable additional inspection while the inspector is familiar with the areas.
3. While performing physic:1 inspections above, examine surrounding systems, components, and structures for related apparent defects or indicators of faulty workmanship.
4. If workmen are still in the area of a physical inspection, interview them for related knowledge of other potential deficiencies.
5. Complete portion of IE Module on pipe supports if it relates to effort made on allegations.

FOLA 85-59 C.C lt to

' s/ , .

Status:

Review Lead:

Support:

Estimated Resources:

Estimated Completion:

CLOSURE:

Reviewed by: _

J' ~ ,, o

. -g.

e.

~

l MECHANICAL & PIPING ALLEGATION REVIEW CATEGORIES Category Est. Mandays Allegation Package Assigned Schedule No. Subject to Complete Nos. Prepared to Open Close Remarks

15. Defective hangers AH-3, AH-4, AH-6, AH-13 a 16. Hanger design AH-5, AH-8 problems
17. Hanger damage AH-9, AH-10, AH-11,
18. Hanger construction AH-7, AH-12
19. Hilti bolts AB-4, AB-5, AB-6, AB-8
20. Concrete anchor bolt AB-9, AB-10, AB-11
21. Nuts- torquing AB-7 I

. u a

^~

1 ,,

j ,

l 's t,

BROWN & ROOT, INC. PROCEDURE EFFECTIVE

., CPSES NUMBER REVISION DATE PAGE JAN 111984 CP-CPM 9.10 11 1 o f l'7 __

TITLE: ORIGINATOR U

Y dz /Jf->&-rRT Date FABRICATION OF ASME-RELATED REVIEWEDBY:h. - v b ~O B&h QA Date COMPONENT SUPPORTS 2 Y 'GINEER J.2 P3 Date PROJECT WELDING

.g 3 APPROVED BY: .

A _[/ o /-/d-ff CONSTRUCTION PROJECT MGR Date 0.1 TABLE OF CONTENTS

1.0 INTRODUCTION

2.0 GENERAL 2.1 MATERIAL 2.1.1 2.1.2 Material Control Material Identification hh Lgg 2.1.3 Protectiv'e Coating Traceability

  • 3.0 PROCEDURE .

3.1 HANGER PACKAGES 3.2 WELDING

'f 3.2.1 Welding Procedures and Qualifications 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 Skewed Welds 3.2.6 Tack Welds 3.2.7 Inspection After Tacking 3.2.8 Interpass Cleaning 3.2.9 Workmanship 3.3 GENERAL FABRICATION AND INSTALLATION REQUIREMENTS 3.3.1 Tolerances 3.3.2 Threaded Items 3.3.3 Locking Devices s>3.3.4 Bolt Holes 3.3.5 Base Plates 3.3.6 Shear Lugs 3.3.7 Wall and Ceiling Base Plate Bearing 3.3.8 Hanger Adjustment 3.3.9 Cotter Pin Installation l 3.3.10 Seismic Limiters / Sway Struts j 3.3.11 Material Salvaging '

3.3.12 Shims 3.3.13 Hanger Removal PLll&OD-59 u W - x-i -

, t f- a

. .%, ..., ,. .. __ c spose _ -w= + *

  • eww-* *a-* en4 s. a- r e- ----,,e we
  • w ~ - - e - - +- ~ - = * - * + - + - - - * + - - -

BROWN & ROOT, INC. PROCEDURE EFFECTIVE o  !

NUMBER REVISION DATE PAGE CPSES l

l CP-CPM 9.10 11 01/11/84 1 of 17 TITLE: ORIGINATOR

  • con nrinin=T einn2+,,co chaot* j Date J FABRICATION OF REVIEWED BY: *see oriainal sionature sheet
  • ASME-RELATED B&R QA Date COMPONENT SUPPORTS
  • see orininal sionature sheet
  • PROJECT WELDING ENGINEER Da te APPROVED BY:
  • con nrininal e i nn 2 +,,ro choo+*

CONSTRUCTION PROJECT MGR Date 0.1 TABLE OF CONTENTS

~

1.0 INTRODUCTION

2.0 GENERAL 2.1 MATERIAL I

2.1.1 Material Control 2.1.2 Material Identification ,.

2.1.3 Protective Coating Traceability I

2.1.4 Fabrication of Parts 3.0 PROCEDURE 3.1 HANGER PACKAGES 3.2 WELDING 3.2.1 Welding Procedures and Qualifications 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 Skewed Welds 3.2.6 Tack Welds 3.2.7 Inspection After Tacking 3.2.8 Interpass Cleaning 3.2.9 Workmanship 3.3 GENERAL FABRICATION AND INSTALLATION REQUIREMENTS 3.3.1 Tolerances 3.3.2 Threaded Items 3.3.3 Locking Devices 3.3.4 Bolt Holes 3.3.5 Base Plates 3.3.6 Shear Lugs 3.3.7 Wall and ceiling Base ? lata Bearing 3.3.8 Hanger Adjustment 3.3.9 Cotter Pin Installation 3.3.10 Seismic Limiters / Sway Struts ~'

3.3.11 Material Salvaging 3.3.12 Shims 3.3.13 Hanger Removal CP-CD" 0.10 Pev.11 DCf' 81 m -m Sheet 2 of?S

~ ^ ' ^ ^ ~

JOB 35-1195 COMANCRE PEAK STEAM ELECTRIC STATION Construction Procedure DOCUMENT CHANGE NOTICE NUMBER 6 Notice applicable to Construction Procedure No. 35-1195- CP-CPM 9.10 Rev. 11 This change will* be incorporated in the next revision of the procedure.

Change the procedure as follows:

Please replace pages 7 of 17 and ,

8 of 17 i i

Reviewed by:

A-f$-ff f4Brown & Root Quality Assurance Y $/

TWiginator Date Date Approved by:

ff // - .38-f[

Profect Welding Engineer Date 6

AJ Constructfon Project Managde Date

~

M Y-f / -

05/07/84 Effective Date m m W  %

. . -.. - . _ . . . . . . . , , . _ . . . . , , . . _ _ . _ _ . ,_ T __ , , , _ . . . . , _ , , _ , _ _

I

.l JOB 35-1195 1

COMANCHE PEAK STEAM ELECIRIC STATION Construction Procedure DOCUMENT CHANGE NOTICE NUMBER 5 CP-CPM 9.10 Rev. 11 Notice applicable to Construction Procedure No. 35-1195 This change will be incorporated in the next revision of the procedure. -

Change the procedure as follows:

Please replace the following pages with the attached:

Attachment 2: page 1 of 2 and page 2 of 2 -

4 4

Reviewed by:

fb h $$ l < Y /7 $Y

~0riginator Date Brown & Root Quali'ty Assurance Date Approved by: // ~

A/

Project Weld 1r3 2ngineer

.ll-)//-f[

Date

</ [ JI / 4/?3/84 str'uction Project Manager Date - Effective Date

,a .

J08 35-1195 -

l COMANCHE PEAK STEAM ELECTRIC STATION Construction Procedure DOCUMENT CHANGE NOTICE NUMBER 4 Notice applicable to Construction Procedure No. 35-1195- CP-CPM 9.10 Rev. I1 This change will be incorporated in the next revision of the procedure.

Change the procedure as follows:

Please replace the following page with the attached: -

Pages 11 of 17 and 12 of 17 _

Reviewed by:

/-f*W altt 4' Brown & Root Quality Assurance Y&3 Y Orfginator Date Date

<t/cf VW8s /~f//

Approved by: Date TUGC0Qualit/ surance l lUEB W-23-fl

[_Mg g 41<2 E- # 4)23/84 Construction Project Manager Date Effective Date w -w -==-e.e- - - * . m -, =*w -m

- m-o m- e.-e q +- - ,

e--e s w o s.m == -~ww --e a

~

JOB 35-1195 COMANCRE PEAK STEAM ELECTRIC STATION Construction Procedure DOCUMENT CHANGE NOTICE NUMBER 3 Notice applicable to Construction Procedure No. 35-1195 CP-CPM 9.10 Rev. 11 .

~

This change will be incorporated in the next revision of the procedure.

Change the procedure as follows:

Replace pages 5 of 17  :

8 of 17 _

11 of 17 13 of 17 14 of 17 15 of 17 16 of 17 17 of 17 Reviewed by:

3 YY 6riginator

?d J~l$' Date N $ +

Brown & Root Qual

~

1t'y Assurance Date Approved by: // # A/ 3 W-##

Project Weldin'g ' Engineer Date

,( J a a # March 14. 1984 Construction Project Manager Date eliidY-(( - Effective Date

._.-,--,.y..__. -. . _ . . . . ........_.m..___..

w _ . . _ _ _ _ . . . . . , _ _ . ._. _ . , . . . , .

1 JOB 35-1195 .

COMANCHE PEAX STEAM ELECTRIC STATION Construction Procedure 2

DOCUMENT CHANGE NOTICE NUMBER Notice applicable to Construction Procedure No. 35-1195- CP-CPM 9.10 Rev. 11 .

This change will be incorporated in the next revision of the procedure.

Change the procedure as follows:

Please replace the following with the attached:

page 16 of 17 page 17 of 17. .

1 Reviewed by:

W,& f-fff/ , a2-/3-8L/

Grfginator Date d', Brown & Root Quality Assurance. Date Approved by:

12)$ b Lu 2-192V Date Project Welding Engineer

. As /H Z-/P 02/15/84 Construction Project Manager Date . Effective Date

. , , . . . . . . _ . . . .m. - , . . . . . . . ~ - , - - - , . . - .-,.,----...r - , . - -

JOB 35-1195 .

COMANCHE PEAK STEAM ELECTRIC STATION Construction Procedure DOCUMENT CHANGE NOTICE NUMBER 3 Notice applicable to Construction Procedure No. 35-1195- CP. CPM o.10 Rev. 11 .

This change will be incorporated in the next revision of the procedure.

~

Change the procedure as follows:

Please reolace the followinn panesit Dane 1 of 17 cane 3 of 17 cane a o# 17 .

nane 5 of 17 Reviewed by:

l~3 l ~ff 2l/ f8 Y Date Brown & Root Quality Assurance Dats Griginat U Approved by:

&F AAw shko PRn.1FCT WELDING ENGINEER druf cW'/ft/

~

O&te 2/1/84 Effective Date sgctionProjectManager MS _ _ _ . , . _ _ . . . .

- - , -e

i

. 1 EFFECTIVE BROW & ROOT, INC. INSTRUCTION CATE PAGc ,

) CPSES NUMBER REVISION J08 35-1195 CP-CPM 9.10 11 1 I384 2 of 17 ..

4.0 FORMING 4.1 COLD FORMING 4.2 HOT FORMING 5.0 CONSIDERATIONS FOR PRESSURE TESTING

1.0 INTRODUCTION

This procedure provides the criteria for the fabrication and install-ation of ASME III, Subsection NF, Classes 1, 2, and 3 component sup- ~

ports. Moment restraints are not within the scope of this procedure.

2.0 GENERAL 2.1 MATERIAL 2.1.1 Material Control Materials used in the fabrication of NF supports shall be materials acceptable for ASME use and do not necessarily include all materials acceptable for "Q" applications. Evidence of material acceptability, including shim material, will be provided through the use of a Material Identification Log (Attachment 1) . 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 signa-ture.

NOTE: Heat numbers shall be recorded for Class 1 and for impact tested support materials.

Welding material shall be controlled in accordance with CPM 6.9B.

2.1.2 Material Identification Prior to cutting, the heat or identification (MIC, code, etc.) number shall be transferred by mechanical marking, and this marking shall remain distinguishable throughout the fabrication process. When mechanical markings on the parts are not possible, such as on all-thread rods, the markings may be applied to bands or labels which are applied to the parts. The transfer of the markings shall be verified by QC prior to division. This verification is documented on the MIL. Additionally, the support assembly shall be mechanically identified with the hanger mark number which shall remain distinguish-able throughout the installation.

w

_e==*, re

  • em + - ,e - e+**- =*eemc e,.ep e w e e ** se **- .m* =0 - W e**** Peep erNQ.t* *** *
  • eem+, -~ew..== ==
w. q-

. - . . . - . . . . - . . .......- l PROCEDURE EFFECTIVE BROWN & ROOT, INC. NUMBER REVISION DATE PAGE

-s CPSES I

JOB 35-1195 CP-CPM 9.10 11 01/11/p4 3 of 17 Prior to division of a bundle of bulk material, each piece of material shall be identified with a heat number. A heat code and purchase order number may be used instead of a heat number. Prior to division of the bundle, QC shall be notified so that the markings may be veri-fled and documented in accordance with 'the applicable QA procedures.

NOTE: Materials used for some welded attachments will require impact testing. The need for impact tested materials will be speci-fled on the engineering drawing. Where possible, the vendor supplied attachment materials should be used. Otherwise, _

impact tested materials shall be requested when specified on the drawings. _

When design reflects a total change of hanger number but does not physically alter the support, Welding Engineering will issue a modifi-cation MWDC whose only holdpoint will be Operation #1, " Support Number , '

Identifica tion". This will allow craft to change the number on the hanger with QC Inspector verification, per the design change. ..

2.1.3 Protective Coating Traceability

/ All shop coated steel that requires protective coating and is cited for installation in the Reactor Building shall be stamped with a unique coating code number.

Unique code numbers shall be assigned and applied in accordance with CCP-30 and CCP-30A.

Upon division of materials, unique coating code numbers shall be transferred along with other unique material identification numbers.

The transfer of unique coating code numbers shall be witnessed by QC.

The transfer of coating code numbers is necessary only to steel that is cited for installation in the Reactor Building.

Additionally, upon division of material, any Q-coated steel that remains in stock shall maintain its coating code number. If coating code number transfer is necessary to accomplish this, it shall be witnessed by QC.

2.1.4 Fabrication of Parts Parts for a support, e.g. base plates, structural members, etc.,

may be fabricated without a drawing or Hanger Package provided they are described on the MIL and verified by QC as required by 2.1.1. However, when the parts are being assembled into a support, the Hanger Package shall be intact unless the MIL must be removed to fabricate another part. -

rp epm 4 in Rev 11 DCN #1 Sheet 3 of 5

.-..7 .. . ._.. . . . _ _ _ . _ . . . _ . . . _ , - . . . _ .

- ~

j PROCEDURE EFFECTIVE DATE PAGE l BROWN & ROOT, INC. NUMBER REVISION CPSES q _, ,

--J08 35-1195 CP-CPM 9.10 11 n3 f 3 3 fog 4 of 17 3.0 PROCEDURE 3.1 HANGER PACKAGES 3.1.1 Fabrication / installation of component supports will be in accordance with the Hanger Package for supports. The package will consist of the BRH drawing (or a " typical" for 2" and under hangers), the Material Identification Log (MIL), the Weld Data Card (WDC), and the Weld Filler Material Log (WFML), where welding is required, for each hanger.. Design Changes, such as CMC's af fecting the hangers may be _

issued directly to the Hanger Package for inclusion and the CMC number recorded on the WDC. The Hanger Package shall then be returned to ~

Welding Engineering for review of the CMC to determine if the Weld Data Card requires modification or revision. In those cases where a modification of the Weld Data Card is required, Welding Engineering will determine the extent of the work necessary to complete the ,

hanger in accordance with the new design and a description of the necessary activities will be entered on the back of the Multiple Weld Data Card in the space provided for this purpose.

3.1.2 Weld numbers shall be assigned by Welding Engineering in the packages

'"}/ for the following weld categories:

1. Welds to pressure retaining members.
2. Full penetration welds except flare bevel on structural tubing.
3. Rangers with multiple processes or multi-filler materials. .
4. Welds requiring NDE, other than visual.
5. All Class I support welds.

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

3.1.4 Upon completion of the hanger, the craft shall return the Hanger Package to Welding Engineering for final review. After final re-view, the Hanger Package will be returned to the craft for final inspection by QC and subsequent transmittal by QES of the Hanger Package to the Permanent Plant Records Vault.

3.1.5 If modification or redesign of a hanger, which is inspected and filed in the Permanent Plant Records Vault, is necessary. the craft may cut any welds required by authority on an " Inspected Item Removal Notice" in accordance with CPM 6.10. No re-welding may be done without issuance of the modified or redesigned Hanger Package.

3.1.6 If Welding Engineering receives drawing revisions or design changes to Hanger Packages which have already been accepted by QC, those drawings or design changes will be transmitted to the Quality Engineering Systems group.

CP-CPM 9.10 Rev 11 DCN #1 . Sheet 4 of 5

-~

~ ' - " -

~

, , . . _5 _. - .i' ' =~ ~ ~ ' ?if.=. ir - ~ ' ~ .~~_- '. n ' - . :.- . i.- - ._-

i

, PROCEDURE EFFECTIVE BROWN & ROOT, INC. MJMBER REVISION DATE PAGE CPSES i JOB 35-1195 CP-CPM 9.10 11 01/11/84 5 of 17

- - - -3. 2 WELDING ,

, 3.2.1 Welding Procedures and Qualifications All welding shall be performed in accordance with welding procedures 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. Acceptable --

agents for cleaning include either Varsol 1, Stoddard Solvent, or any other approved solvent.

Mechanical preparation shall result in a clean surface for a minimum :

of inch on each side of the joint. ,

Deoraluminate compound, used to coat weld preps, need not be removed before welding.

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

The preheat specified on the WPS shall be established before any welding or tacking.

Preheating may be performed using suitable gas burners and measured 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 Fit-up Joint type and configuration shall be as specified on the applicable BRH. For clarity, types of typical weld symbols are shown in Attach-ment 11.

The fit-up gap for buttwelded joints shall not exceed 1/8" beyond the diameter of the electrode used at the root of the joint.

CP-CPM 9.10 Rev. 11 DCN #3 -_ 3/14/84 Sheet 2 of 9

  • b

, g = 4 ma M 4 .W." $

. .-.. , ... .. ...., . c.., .-.--,-..y-e--, - ...- , ree.-. . +- -

BROWN & ROOT ,INC. INSTRUCTION EFFECTIVE ,

NUMBER REVISION DATE PAGE CPSIS  :

J08 35-1195 CP-CPM 9.10 11 N 111984 6 of 17 The maximum of fset of the finished weld shall not be greater than the amount listed in the following table. The final weld surface and adjacent base matal shall blend uniformly.

Maximum Allowable Of f set 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 gap for "T" fillet welds and lap joints shaF be as -

small as practical; however, they should not exceed 1/1o".

Joints where the gap exceeds 1/16" shall be evaluated by the PWE on a case by case basis.

Weld size of structural tubing as shown in Attachment 2 shall be .

in accordance with the weld sizes specified on the drawing. Where ~

weld sizes are not specified, the minimum weld size shall fill the groove so that the weld is at least flush with the outer surface of the member.

For the special cases where a fillet weld is specified on the design drawing to join two structural tubes of unequal size and the large tube has an excessive corner radius, the weld will be a combination flare bevel and a fillet weld.

3.2.5 Skewed Welds Weld sizes for skewed members shall be in accordance with Attachments 9 and 10.

3.2.6 Tack Welds All tack welds shall be made in accordance with an approved welding procedure by a qualified welder and deposited with an electrode or wire that is the same composition as the electrode used for the root-pass.

Tack welds incorporated into the weld shall be prepared by the welder and shall meet the following requirements:

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

M_=.--,-

  • - we==e s yeymo- p ey .pe, r - . pwr p._ ** .= 3e e ggM -w e $- *
  • . . - * - * . e y o-e, . e
  • eemmem * . * - - 9 -e e w pag - ,

BROWN & ROOT, INC. PROCEDURE EFFECTIVE REVISION DATE PAGE CPSES NUKBER JOB 35-1195 .

CP-CPM 9.10 11 01/11/84 7 of 17 3.2.7 inspection After Tacking 3.2.7.1 Pull Penetration Groove Welds and Welds to Pressure Retaining Boundaries All full penetration groove joints and all welds to pressure retaining boundaries shall be inspected by QC af ter fit-up and tacking prior to welding and shall be documented on the Weld Data Card.

3.2.8 Interpass cleaning Interpass cleaning shall consist of the following:

1. All slag and oxide shall be removed by either chipping, wire brush-ing, or grinding before making the next successive veld bead.
2. All surface defects, undercutting, and overlapping shall be re-moved 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. _

3.2.9 Workmanship The surface of finished weld shall be free of slag, oxide and overlaps. Undercuts shall be limited as noted for the following items:

1. Structural tube - 1/32", provided it does not go below 10% of the wall thickness.
2. Structural shapes - 1/32" for all sizes.
3. Plate - 1/32", provided it does not go below 7% of the thickness.
4. Pipe - 1/32", provided it does not go below 12h% of the wall thickness.

Additional welding is acceptable provided it does not distort the items being joined together. Fillet welds to systems which have been acceptably pressure tested shall not exceed 3/8" throat thickness.

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

l The surface of the reinforcement of butt welded joints may be flush I

with the base materials or may have uniform crowns. .The height of I the reinforcement on each face of the weld shall notgexceed the following thickness:

3.2.10 Removal of Temporary and Permanent Welds made to Structural Shapes When welds are removed from structural shapes, the areas from l

1 CP-CPM 9.10 Rev. 11 DCN #6 - ~ ~

05/07/84 Sheet 2 of 3 w

.'-n -- - -

u - . _ _ . . . . _ . . . . . . _ . _ . _ _ _ _ . . .

I EFFECTIVE BROWN & ROOT, INC PROCEDURE i REVISION DATE PAGE CPSES NUMBER l

e - l JOB 35-1195 '

11 01/11/S4 8 of 17  !

CP-CPM 9.10 )

which they were removed shall be visually examined(Areas by theoncraftsman pressure

. ~ . . . _ -.-

to ensure that no defects are visually present.

retaining members from which welds are removed shall be documented in accordance with CP-CPM 9.10, Paragraph 3.3.13.)

Maximum Nominal Reinforcement, in.

Thickness, in.

3/32 Up to 1, incl. 1/8 Over 1 to 2, incl.

5/32 Over 2 to 3, incl. -

1/4 Over 4 to 5, incl.

5/16 Over 5 Maximum reinforcement for flare V welds shall be 3/16".

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 permissible tolerances:

3.3.1.1 Fabrication Tolerances

1. Length 1 Support members (except rods) up to 12"

- + 1/8" a.

Support members (except rods) over 12"

- + 1/4" b.

2. Holes
a. Centerline location i 1/4" or as shown on design drawing 3.3.1.2 Installation Tolerances
1. Dead weight supports Iocation axially  ! 12 inch
a.  ! 5 degrecs, or as noted on drawing
b. Plumbness
2. Seismic Restraints
a. Restraints, anchors, guides, etc.

~*

1. Location; pipe diameter 231 " and larger and 2" and smaller ASME Class 1, t 2 x pipe wall thickness +2" from theo-retical position.

05/07/84 Sheet 3 of 3 CP-CFM 9.10 Rev. 11 DCN #6

BROWN & ROOT, INC. INSTRUCTION EITS:TIVE NUMBER REVISION DATE PAGE .

CPSES

^ JOB 35-1195 CP-CPM 9.10 11 JAN 111984 9 of 17

2. Incation; pipe diameter 2" and smaller. ASME Class 2 and 3,
a. Support location tolerance is + 6" on the span indi-cated on the location isometric drawing. This toler-ance is not to be projected through or around fittingu or components.
b. Iocations of certain supports, identified with an asterisk (*) next to the dimension on the ISO, have a location tolerance of +_ ". Inability to meet this requirement must be brought to the attention of _

Engineering.

NOTE: In certain cases Class 2 and 3, 2" and smaller supports require ~

the saine location tolerances as 2 " and larger and 2" and ,

saaller Class I supports (1 above). These are identified by presence of a stress problem number on the design drawing. ,

c. Attachments to center of structural steel reaction '

members.

NOTE: A reaction member is defined as a member which is part of the building structure, i.e., embeds or embedded plates and strips.

Parts of the hanger, i.e., base plates are not considered as reaction members.

NOTE: All supports may be installed i 5' from the design orientation, unless noted otherwise on the drawing. To prevent binding with-in the clamp and/or bracket, struts and snubbers shall not be installed with an off-set of more than 5*.

3. Pipe Clearances
1. Where the design shows 1/16" on both sides, the total dimen-sional tolerance shall be 1/8" + 1/16" (e.g. , 0" on one side w/1/8" + 1/16" on the other,1/I6" + 1/32" on both sides, or any combination.)
2. Where the design shows 0" on one side and 1/16" on the other side, the sum of both gaps may not exceed 1/8" or be less that 1/32".
3. For low energy lines, if the clearances in 1 and 2 cannot be i maintained due to ambient thermal expansion, a total clear-l ance of 1/8" + 1/16" on any two adjacent sides is acceptable.

I

4. Where the design shows clearances greater than \", the dimension shown is the minimum.

. . . . . . . . . , , . . - .r.. .. . _......,.,,y--,. .w--.--,., s.- .- -

i

a ..

~ . .

.' .. _ t. __

PROCEDURE EFFECTIVE REVISION DATE PAGE BROWN & ROOT, INC. NUMBER CPSES 11 1 1 I984 10 of 17 CP-CPM 9.10

4. Axial Restraints Where the design shows 1/16" clearance between shear lugs and the restraining member, the total clearance for both sides of the re-straint shall range from 0" to 3/16".
5. Reference Dimensions All dimensions shown on the design document as refert:nce dimen-sions (indicated by "REF") shall have a tolerance of 12 inches. _
6. Field Fit Tolerances

~

The tolerances discussed herein shall be maintained for support fabrication activities. However, if during the installation the support won' t fit, the members may be " field fit" provided all tolerances are maintained. ,

Dimensions on hanger detail drawings between structural j a.

items and the pipe centerline may be adjusted within the following tolerances.

Gradient - 3/16 inch per foot maximum (this applied to horizontal lines deviating from level only. De-viations from plumbness of vertical line's and hort-zontal departure from design cer.terline of horizon-tal lines will be controlled by the two-inch tolerance on location).

Slope - Minimum slope shall be as designated on the drawings.

Location - 22 inches.

b. The working point dimensions locating the structural components of the hanger shall have a tolerance of 11 inch. If designated as a reference dimension (RL1),

the tolerance shall be 2 inches.

c. Other established tolerances regarding axial locatica, alignment and base plate attachments, etc. shall be adhered to unless otherwise noted on the drawing.

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

1

- BROWN & ROOT, INC. PROCEDURE EFFECTIVE NUMBER REVISION DATE PAGE CPSES JOB 35-1195 .

CP-CPM 9.10 11 01/11/84 11 of 17 3.3.2 Threaded Items All bolts, studs, or threaded rods shall have full thread engagement 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 or more than 1:20, a beveled washer shall be used to compensate for the lack of parallelism.

For friction-type bolted connections utilized on removable supports -

with SA-193 Grade B7 bolts, the nut shall be tightened in accordance with Attachment 7 or to the following torque values:

5/8" diameter bolts - 215 FT-#'s 3/4" diameter bolts - 390 FT-#'s NOTE: Use hardened washers under bolt head and nut except where ,

bolt head or nut is welded to the boltup assembly.

NOTE: Snug tight is defined as the tightness attained by a few impacts on an impact wrench or the full effort of a man using an ordinary spud wrench.

When Richmond inserts are used, thread engagement into the insert shall be at least 2 X the bolt diameter + 1/8". Bolting used in Richmond anchors shall be tightened snug tight.

When U-bolts are specified on the design document as not having any clearances, the U-bolt shall be snug tight so that the U-bolt cannot be moved by hand. The nuts on the U-bolts shall be installed on the side of the plate as shown on the design drawing.

3.3.3 Locking Devices All threaded fasteners, except high strength bolts, shall be pro-vided with locking devices as specified on the design document.

3.3.4 Bolt Holes

[ Holes for nonfitted bolts shall be 1/16" larger than the nominal 1 diameter of the bolt for bolt sizes up to and including 1" and 1/8"

. I larger than the nominal diameter of the bolt for bolt sizes larger than 1". The holes shall be drilled, thermally cut, subpunched and reamed. Thermal cutting shall not be used unless the surfaces are machined or ground smooth. The die for all subpunched holes shall be at least 1/16" smaller than the nominal diameter of the bolt.

CP-CPM 9.10 Rev. 11 DCN #4 4/23/84 Sheet 2 of 3

i l .

i BROWN & ROOT, INC. PROCEDURE EFFECTIVE I l CPSES NUMBER REVISION DATE PAGE JOB 35-1195 ,

CP-CPM 9.10 11 01/11/84 12 of 17 3.3.5 Base Plates If hanger base plates cannot be installed as designed and fabricated, j alternate hole patterns may be attempted. Fabrication of base plates may be performed by flame cutting on carbon steel or abrasive wheel cutting of stainless steel. Stainless steel base plates may be thermally cut by are gouging. After the thermal cutting process, an 1/8" of material shall be removed from the thermally cut edges by grinding.

If the first anchor bolt hole cannot be drilled as required . relocate it in an outwardly direction (away from steel member attachment) in ~

i accordance with CEI-20. Continue moving away until a hole can be successfully drilled. When attempting alternate hole patterns, the ,

final pattern should be as symmetrical as possible.

Upon completion of an alternate hole pattern, a CMC and/or a MIL shall be initiated. A CMC shall be prepared when the tolerances ,

cannot be met.

All structural steel attachments to base plates (i.e., wide flange, 3

structural tubing, channel, etc.) must always be within the inner

confines of the bolt hole pattern unless otherwise approved by Engineering.

i !

3.3.6 Shear Lugs Shear lugs shall be fabricated and installed in accordance with the CMC affecting the design drawing and with the following guidelines:

a

1. Hole for the shear lug shall be drilled in the concrete 3r." in diameter larger than the shear lug diameter.
2. Install the base plate.
3. Set and torque all Hilti bolts.
4. Install shear lugs and weld in place as shown on the design sketch.
5. Shear lugs shall be grouted in accordance with CEI-25.

See Attachment 8 for illustration.

3.3.7 Wall and ceiling Base Plate Bearing

. Wall and ceiling base plates shall fit flush against the mating sur-faces. Where such a fit cannot be made, the below alternativos are acceptable. Floor plates are not subject the the below requirements and will be grouted in accordance with CCP-16.

CP-CPM 9.10 Rev. 11 DCN #4 - ~ 4/23/84 Sheet 3 of 3 W

. : . m ;; ; . .._ _ ... . _ x... ; . p _ ,- - .-__. n - ~ - . .:n. ._, , . ;. .._ . - ~~T ~ - - -~

- - - . - - , , , - - . - - - , - . , . . . .,---..n . - - ---

n _, - ,, , - , , . . , - - - - , , , , - - , , .c-,-,-- n . , . .

3y-., ,_,. .- ,,-- _ y _ -. .. : ---;;

PROCEDURE EFFECTIVE REVISION DATE PAGE BROWN & ROOT, INC. NUMBER CPSES J08 35-1195 CP-CPM 9.10 11 01/11/84 13 of 17 3.3.7.1 Base Plate Gaps ,

Wall and ceiling hangers utilizing base plates shall have a minimum of 80% bearing surface between the plate and concrete. The gap between the plate and concrete may exceed 1/16" for a maximum of 20% of the plate area , (see example below) . If these dimensions are exceeded, the gap shall be epoxy grouted in accordance with CEI-25. If the gap exceeds b inch at any point, the base plate shall be grouted in accordance with CCP-16, or CEI-25 with Engineering approval.

Gaps at the wall attachments greater than 1/16" shall be shimmed either around or adjacent to the Hilti bolt. Shims shall consist of steel -

plates or washers of a size that will allow proper Hilti bolt torquing without base plate deformation. .,

EXAMPLE 10" X 10" BASE PLATE A

Total plate area - 100 in. . Crosshatched area may exceed 1/16" provided this total area does not exceed 20 in.2 3.3.8 Hanger Adjustment Adjustments to constant and spring supports, and the removal of travel stops, shall not be made unless directed in writing by Startup.

3.3.9 Cotter Pin Installation Cotter pins should be fully open 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 should be the maximum size the cotter pin hole will permit, but only need be large enough to remain in place after opening.

3.3.10 Seismic Limiters / Sway Struts Sway struts and seismic limiters shall be installed and inspected to the drawing using the criteria set fourth in CP-CPM 9.15, and CP-CPM 9.17, respectively.

3/14/84 Sheet 5 of 9 CP-CPM 9.10 Rev. 11 DCN.#3 _

D -

i

- PROCEDURE EFFECTIVE BROWN & ROOT, INC. ftJMBER REVISION DATE PAGE I CPSES JOB 35-1195 CP-CPM 9.10 11 01/11/84 14 of 17 t

, 3.3.11 Meterial Salvaging

! When items cannot be used because of redesign, misfabr4ation, damage, the disposition to Nonconformance Reports, etr., the items may be scrapped, salvaged or returned to bulk stock.

The responsible foreman shall make this determination based on the NCR, CMC or the items' physical condition, as appropriate.

When Code stamped items or partial assemblies are modified, documentation for such modification shall be prepared as required by Appendix CPM 6.9G, and the modification accomplished ~

accordingly.

Material supplied by ITT or NPSI, or B&R bulk stock may be salvaged

' for use in Class 2 or 3 systems provided traceability is maintained -

' as follows:

1. ITT - the alpha / numerical code identifying the material to a ,

particular material specification and/or grade (i.e., the code *

"L7" identifies SA-320 Crade L7 material).

2. NPSI - items identified with N-prefixed or N-suffixed MIC number.
3. B&R bulk stock - B&R procured ASME-related materials shall be maintained by heat number. Such stock designated for non-Q applications may be salvaged for Code use provided heat number traceability is maintained and is acceptable for Code use.

NOTE 1: When salvaging variable springs for use on a support other than where originally designated, the responsible personnel shall ensure that the correct size spring is used. If the load setting is to be readjusted, the original load setting mark on the face plate shall be obliterated by stamping directly over it with the letter "S".

NOTE 2: Except as permitted above, hanger parts shall be used on hangers where designated and shall not be interchanged.

Material supplied in class 1 may be salvaged for used on class i systems provided the item's serial number or heat traceability identifier (i.e., MIC number, heat number, heat code, etc.) is maintained.

In accordance with CP-CPM 8.1, 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 CP-CPM 8.1. 4 1

CP-CPM 9,10 Rev. 11 DCN.#3 3/14/84 Sheet 6 of 9 l

I

. .. . _.. ._.r. . . . . . . . . . .

l

L'~ ^ ~ ~ ." .. :. ." :.= . L ~ ~'.~ T ~~~ ' = .:. r. :: L -. .

. .F ' .

PROCEDURE EFFECTIVE REVIfD A DATE PAGE BROWN & ROOT, INC, NUMBER CPSES JOB 35-11 E CP-CPM 9.10 11 01/11/84 15 of 17 NOTE 3: When hangere parts with Code plates are salvaged and used f i

on hangers other than those for which designated, the Code plates may remain on the part. Alternatively, the Code plates may be removed in accordance with CI-CPM 6.9E-1, turned over to QC, and subsequently filed in the vendor data package. In either case, the original hanger mark number shall remain on or be transferred to the part.

3.3.12 Shims Clearances between pipe support members and piping shall be main- ~

tained in accordance with the clearance requirements of paragraph 3.3.1.2. Where such clearances are excessive, shims shall be in- --

stalled to maintain the clearance. Shim thickness shall be selected by the craf tsman and shall be one of the following materials: 8m SA-36 or A-36 SA-515, Grades 55, 60 and 65, or A-515, Grades 55, 60 and 65 A-570 2 The actual material used shall be recorded on the MIL. Care shall be exercised in the selection of a WPS that satisfies the welding on the base material used.

Sizing and welding of the shims shall be in accordance with Attach-ments 3, 4, 5 and 6, or as shown on the design drawing.

NOTE: The use of shims which have a total thickness greater than 2" shall require Engineering approval.

3.3.13 Hanger Removal The removal of hangers may be necessary because of redesign, inter-ferences, etc. Such hangers shall be removed in accordance with CPM 6.10. This includes attachment welds as discussed below.

Attachments to piping, i.e., lugs, saddles, etc., shall not be removed unless specifically directed in writing by the Engineer with a design document. Where such attachment welds are removed, the Project Welding Engineer shall be notified. The Project Welding Engineer shall initiate a Weld Data Card or a Repair Process Sheet, as appropriate, requiring liquid penetrant and ultrasonic thickness inspection of the affected areas.

Attachments of any kind to the pressure retaining boundary of systems or components which have been turned over, shall not be removed unless authorized by a SWA, even if authorized by Engineering. This includes valve actuators, retaining plates, etc.

CP-CPM 9,.10. Revs 11 DCN.#3 3/14/84 Sheet 7 of 9

~.

L -

= -. . . - - . , . - . . . . . ... .

7^' . C' ' ~4.*_*. ~.~'=... '?:T ! ' . -.. ..~

. ~ ~ . : : ~ .. .~ ~ ~ "~~. K..T"~~*^1 .~ ~

! PROCEDURE EFFECTIVE . ,

BROWN & ROOT, INC. NUMBER REVISION DATE PAGE

. _ CPSES

)

i

. l

, JOB 35-1195 -

CP-CPM 9.10 11 01/11/84 16 of 17 )

3.3.14 When weld numbers are assigned on hanger welding documentation, the l weld number (s) shall be marked by the craftsman adjacent to the weld, normally within 2 inches of the weld.

4.0 FORMING l 4.1 COLD FORMING Cold forming of U-bolts using SA-36 material of 5/8" or less in thickness may be performed provided that:

a. The minimum inside radius is equal to the stock thickness.
b. Forming is performed with the material at ambient temperature but not less than 60*F. -

4.2 HOT FORMING 4.2.1 SA-36 material stock sizes 1"5 and over, may be hot formed to a min-  :

i imum outside radius equal to the stock thickness, with the material .

heated to a temperature of 1650*F - 2100*F. The material shall be heated to a temperature sufficient to complete the initial press and the majority of the plastic deformation while above 1650*F.

Additional repressing to obtain final alignment may be performed while still in the " red" heat condition (above 1000*F) or it shall be reheated prior to completing forming. Hot formed stock shall be cooled in still air.

4.2.2 Oxy-fuel heating with neutral flame may be used to heat stock up to and including 2" thickness. Caution must be exercised when using this method t.o as to prevent any melting of the outside surface.,

4.2.3 Material over 2" thick shall be heated in a suitable furnace. The stock shall be held at the bending temperature for a minimum of 10 minutes prior to bending to assure proper heating through the cross section of the stock.

4.2.4 Temperature shall be measured using temperature indicating crayons or a chart recorder where applicable.

4.2.5 The completed U-bolt for hangers greater than 2" NPS shall be iden-tified with the mark number of the hanger with which it is to be used, and with the heat number of 2" and smaller hangers. Marking shall be by die stamping.

CP-CPM 9.10 Rev. 11 DCN #3 _

3/14/84 Sheet 8 of 9 g ..em. _ w. g.

.--..n.,..,.-n;-.

- p__..,.. , , . . .. n . __,

.= - . _

.c = = .;. . . _ . . . ---=.--.---._..-.:..

_ .-.=._.---- _

u PROCEDURE EFFECTIVE BROWN & ROOT, INC. NUMBER REVISION DATE PAGE CPSES JOB 35-1195 CP-CPM 9.10 11 01/11/84 17 of 17 5.0 CONSIDERATIONS FOR PRESSURE TESTING Hangers shall not be constructed around pipe welds which have not been pressure tested in such a manner that the hanger would pre-vent inspection of the weld during pressure testing. When it is necessary to install the hanger prior to the pressure test, QA shall be notified. Such work shall not proceed until written authorization has been obtained from QA.

l l

l l

1 CP-CPM 9.10 Rev. 11 DCN #3 3/14/84 Sheet 9 of 9 e--- s

-m m e

.._ . _-..,9

~ - . - . , _ _ . , _ . . . . .

~ - ,. . .,.---........-.q_

__ _ _ _ _ ~ . _ _ .__ _ _ _ .__ _ . _ _ _ . . , _ _ _ _ _ _ , . _ . ,

g .-... .

t PROCEDURE EFFECTIVE IGJMBER REVISION DATE PAGE

~ ~ BROWN & ROOT, INC.

^

,' CPSES JOB 35-1195 M 111934 CP-CPM 9.10 11 1 of 1 ATTACINENT 1 MATERIAL IDENTIFICATION LOG 4

1 I N

' w -

g g

W -

w P:r:2 I

S  ;

,' U g

a

1. .

=.2 i

E

~

&=

31 5-

= g-m 5

  • w 1 2 g- >

a s I j $ Su f 3" 21

==

l i

I a

b l I

i ,

' l l

8 e:::

i. a i 2" 8
-u l
    • e

..- :2 &

l

- T

/E__,e p eo.ep.e w -->=pe ***==e**** s e

-, e e g e-+-e e .+- * = 9

  • e - a= ee- e e s = omemes. * * +== e -a ew peemer osp=,a *-7 l

1 i

BROWN & ROOT, INC. PROCEDURE EFFECTIVE j 1

CPSES NUMBER REVISION DATE PAGE 1

JOB 35-1195 .

CP-CPM 9.10 11 1/11/84 1 of 2 l l l

ATTACHMENT 2 i STRUCTURAL TUBING WELD JOINT DESIGNS i

hse Structural Tubes of Equal Stre (d/D=1) d,e

~

._.__- = = . -

k L .

0  :

~

} ~ ~

NOTE.

% v twa Weld size for structural tubing shall be of the same outeron vided dimension the drawing.in accordance with the dimensicns pro-theouter the groove surface. shall be filled until the weld is flush withWhere dimensto

_Two Structural Tubes of Unequal Size

%di ,

, y 6 d ,

sin " max 450 min

,' l f

" II"I")

(t a %t) 7

( ,

(\tmin) shown on dwg. ,

=*-

t r

(1htmin) s D To be used only when the ratio *" * *** "" "

{d/D$0.8 -

To be used.when the retto of

.a,84d/ D C ._ .

l l

l CP-CPM 9.10 Rev. 11 DCN #5 - - m 4/23/84 Sheet 2 of 3 M

.. . . . .....-  : .~..

,--...y.....,..

-..g.-. , .

I .

~ ~ ~

BROWN & ROOT, INC. PROCEDURE EFFECTIVE NUMBER REVISION DATE PAGE CPSES l

JOB 35-1195_ .

CP-CPM 9.10 11 1/11/84 2 of 2 e .

ATTACHMENT 2 (Cont'd)

Structural Tubing Weld Joint Design Full Penetration Circular Tubing (Stanchion) Weld Joint Branch member ,

ku kr , b -

Detael A or 8 /

~

/ )

0 '/ M 0 Aree for Detail 8 Area for Detail C or D min member Noems:

1. The applicatde joint detael ( A, 8. C. or D) for a particular part of the connection is deeermined by the local dihedral angle. +, which changes continuoJuly in progressmg around the branch member, as follows:

Detail Applicable range of local dihedral angle A 180* to 135*

8 150* to 50' C 75* to 30* l Sample joint required for D 40* to 15* I groove angles under 30*

2. The angie and dienanmenei ranges given in Detail A. 8. C or D include moeimum =8" toi.,_.s.

- n q

--- c.

! 'C@5. Xserj@.AT xx

, 1 e,* M~.i t*

i g .

(

L h7- br l

+= 75*.30*

+=40* 15*

+= 18&.135* += 150*-50* ,

End preparation (wl . As needed eo mee gC* 90* obtain 8 men 45* gr or 10*

45 lor $> 105* .

Notes: 1. Area D requires throat thickness of 2T.

CP-CPM 9.10 Rev. 11 DCN #5 4/23/84 Sheet 3 of 3 z _ m

_ . . . m.. . _ _ . . . . . . . . . . . _ . . . _ , _ _ , _ ,

l a .-c-,. -

..:.. .:x' y ;; y - ~

, .. a :. . .u * .:.-}j., &q'y:h?l{:g :. a :.q,yyqt;.y_,y_j. .q4y;q, l

t PROCEDURE EFFECTIVE REVISION DATE PAGE i BROWN & ROOT, INC. NUMBER 3 CPSES J08 35-1195 DAN 11198'- 1 of 1 CP-CPM 9.10 11 i

l- ATTACFMENT 3 1

1 5

' sHIx ! ,

A

~~ l -

S Y i n

r r 1 ,

3 4 * '

TUBE STEEL s I(

_+_

- " LESS THAN

} -

(" LESS THAN OR EQUAL TO - _ _ _ _ _ _

i .. . . - . .

! "S" WELD SIZE

  • MIN. WELD LENGTH l

"A" SHIM THICKNESS 1/16

~

1/16 1/2 1/8 1/8 1/2 3/16 1 3/16 5 1/4 $ A $ 1/2 1/4 ** 1 1/4 1/2< A$ 3/4 5 /16 ** 1 1/2 3/4< A $ 2 3/8 ** 1 1/2 ..

  • For small bore, the weld is equal to the width of the shim.
    • The weld need not be larger than 3/16. The weld length shTl1 be as shown.

'l i

i J a 1 j

._..___.3 3_

. - - - - - - . , . - - - - - , , - - - - - . , . - .m- - - . - , - - - - - ,.-...-.,------,.r- y-- ,- - , . , - - - , - - - - ---.-.,y-e- ,-- ,

PROCEDURE EFFECTIVE 1 BROWN & ROOT, INC. NUMBER REVISION DATE i PAGE  !

CPSES l lJAN 117994 JOB 35-1195 l t ,

11 l

l 1 Of 1 '

CP-CPM 9.10 l ATTACHMENT 4 SHIM SIZE Total Length of Shim

~

Member Size 1/8"

~ -*

M in.

wwswwwm swmwwwwassymsmssewwwww w th 3

Shim

-- e. -e -

Length of Shia No. 2 .

S + V8, - -

Length at snia No.1 - ,

Minimum l l kWNMVWh\s sWWss%WWWWNW%s%\W\\M%mWW WW\\%%M

~

////////X///////////O'///////////'///// '///////*r o/////////////s W G

m-SHIM WIDTH

-[

$ mmwswsw .ms msw,wm Shim Plate h / Tube Steel. _ E i

/ .

1. The minimum shim width is equal t'o the minimum weld length, required by Attachment 3, plus one inch.
2. For large bore pipe, the minimum shim width is 2b".
3. For 2" and smaller diameter pipe, the minimum shim width shall not be less than h inch unless otherwise noted on the drawing.

PROCEDURE EFFECTIVE BROWN & ROOT, INC. NUMBER REVISION DATE PAGE CPSES IO34 1 of 1 JOB 35-1195 CP-CPM 9.10 11 ATTACHMENT 5 SHIM SIZE AND WELD FOR STRUCTURAL MEMBERS (s+1/8=)nIr - _IuICENESS OF SuIn N

. VfWe%Y/dWMAW474MW49;@r;l ,

Nf

^

] *

, r

/

S=$IZE OF WELD T

2 L .

( h j

- IF SHDI 0F EQUAL OR CREATER IRICENESS THAN FIJufGE (T) THEN: $=T MIW S 1/16.

- IF SHDt IHICENESS t.ESS THAN FTANCE THICKNESS THEN $=INICENESS CF SHIM MIWS 1/16. (EICEPT TCR 1/8* SHIN. $=1/8 4 1/16" SHIM s=1/16) turn utnTu 1

i twew;: nyw+w;i WI",E FLA;tCZ

1. The minimum shim width is equal to the minimum weld length, required by Attachment 2, plus one inch,
2. For large bore pipe, the minimum shim width is 24,
3. For 2" and smaller diameter pipe, the minimum shim width shall not be less than h inch unless otherwise noted on the drawing.

~

-- . -., ._ _ . ._c., ,..

O '. v;*v

~

-.-t _ v: ' uf. d .

~ -

_ + 1:L _ . _ _.

i ---... . - . . . .

i j -

PROCEDURE EFFECTIVE J

BROWN & ROOT, INC, NUMBER REVISION DATE PAGE

" CPSES JAN 111934 JOB 35-1195

} CP-CPM 9.10 11 1 of 1

?

i ATTACHMENT 6 j WELD SIZE & LENGTHS FOR COMBINED SHIMS I

I"' NOTE: WHEN COMBINING SHIMS, THE THICKER OF THE TWO SHIMS SHOULD BE i ATTACHED TO THE TUBE STEEL UNLESS OTHERWISE APPROVED BY ENGINEERING

_ l GREATER THAN 2" REQUIRES ENGINEERING APPROVAL

. I l @ I l7 @

(r ,

u c '

  • = FILLET SIZE REQUIRED PLUS 1/8 INCH.

Fillet size is equal to the thickness of shim No. 2./The maximum size required is 3/16. Length of the fillet is equal to 5 times the shim thickness. The maximum length required is 15/8". For small bore, the weld length is equal to the shim width.

e h

,4.*4*".',

. . s

' b A

  • At
  • M=~
  • -E***** ' * * * ' ~ ' '

PROCEDURE EFFECTIVE BROWN & ROOT, INC. NUMBER REVISION DATE PAGE CPSES JOB 35-1195 JAN 111984 CP-CPM 9.10 11 1 of 1 ATTACHMENT 7 TURN OF NUT TIGHTENING METHOD BOLT LENGTH (L) TURN PAST SNUG TIGHT -

0 0 L & 4 Diameters 120 1 30 0 0

+ DIA.<L s 8 Diameters 180 1 30 0

L > 8 Diameters 240 1 45 M

y-Z

'* ** * * * * * * ** r** -- **+ =a ,,+e- ... . m .w w n, -w , , .--

  • .
  • 4 a

PROCEDURE EFFECTIVE REVISION DATE PAGE BROWN & ROOT, INC. NUMBER CPSES ~

. l JAN 111984 JOB 35-1195 CP-CPM 9.10 11 ,

1 of 1 ATTACHMENT 8 SHEAR LUGS

'.. swuo seas s s.trua r,;:,*aasarcwo inur a sit) aasuisa:a sy ut.o u :ir:

((

- Aaraaneso as a.tu A.asesa w b .stataw 6sa~ad.

l'aI s 1  !

G:::. os i! -

i, 6

t ,

lg1  !

ll .

ll p " o u:1^sR42 11 w w nLUCri w .1

/ss M r-a 219.e912 cas,- JAe TH4

~

Il Ef34tl246 e 2

'l I'

Il s*g r ii

/ j.T.d s'

714 onL64seu !.o;L: .a. Aav$ 21(/*)

. 22:edICL154 :.! f=4 4*1M LJ.s 4.tuurd.

LatM 46:et Ait A64.4/ N4?AL;2: Si 9 fyk atC pr ? t M.J. ?atels)<a .

i e"d 4 %d =CLe ?= 0 a. I'*4 fad. 4ufs

/ red 4.d4Ad e is A;;" /E4:241e inlai 44flr * /*GiAM4?it fat,J*d neu!Mh*M4M.

tt n at.z.'.at a x2sr ers.:a..ws.

  • iss..aAza s >anau u.r i;.us.~1a .

':ulusert P:s earttR 424+ Sul 72 ses.Aa pwiss.

SHEAR LUG , BASE P!. ATE

/

i wv i

+; .

.p..y CONCRETE af .,.1,,.', d + e

.e .

TYP SECTION M% _

-. w . *1* 'M

. . . - . -* w ..e = + m w*

. .m ..

.,.,4..

PROCEDURE EFFECTIVE I' BROWN & ROOT, INC. NUMBER  ; REVISION DATE PAGE la CPSES ' '

CP-CPM 9.10 f 11 I2 564 1 of 1 ATTACFNENT 9 WELD DETAIL FOR TUBE STEEL SKEWED AT LESS THAN 450 A

q1 TATER THAN 19 9* -

/ Menu.

V \8se'O /  :

/

/ *

/

y LSSS m / / '

49,

, / / -

'~~

/ v ,

%2' NOTES:

1. Site of weld is determined by the thickness of the material and tre slope.
2. '4 hen the engireer requires a weld other than shown aeove, a weld estat1 sna11 te sacwn on ene drawing.
3. Grinding is required in all cases.

9 i

a .

J

. . . ....-.... . _ . . _ . . . - . _ . . . . . - - - - - - - ~ . . . --.-- - -

j

- . ~ _ . ._- . _ . . - .

PROCEDURE EFFECTIVE BROWN & ROOT, INC. NUMBER REVISION DATE PAGE

,...3 CPSES~

JOB 35-1195 CP-CPM 9.10 11 JAN 119og4 1 of 1 l ATTACHMENT 10 WELD DETAIL FOR TUBE STEEL SKEWED AT LESS THAN A 60 L4ss wm4 so*

ri o n s w w 3 0 * ,

N N -

N N. i

\ \ .

\ # N.

N

'] . '\ ,-

_t NOTE:

i

1. When engineer requires a groove weld other than the above, a weld detail shall be provided on the drawing.
2. Weld is a partial penetration groove weld.
3. S (weld size) shall be as specified on the drawing.

S

e. m ---A

. . . . . - . - . ~ . . . . . . . .-. . ..

.._m.._ - - ._ , _ , , . _ _ _ , _ _ _ . . , , - . , - , - - - , , _ , . - - . . , , _ _ .

,_ .,1 ,

, EFFECTIVE .:

PROCEDURE BROWN & ROOT, INC. NUMBER , REVISION i DATE l PAGE

,})

CPSES JOB 35-1195 i ' JAN y CP-CPM 9.10 11 l N4 1 of 1 f

ATTACl44ENT 11 PIPE SUPPORT BOX FRAME WELD SYMBOL The follouring veld symbols as they appear on the drawing

' ?5(*. **t?.

Nr i

[ t t rean >l l 9

  • anu y, / m

% ia" " ' 'i'/J sra m *.c sof shall be interpreted as shown below.

'4 *:e l$,'

~:..

.y -

y

& 3/ ,V

-\ /- )

y[

l

- - .

  • e, ., ,.. , 7 . . , , ,

e ~w

  • ew m meme . gp 4,s.e _

-- ..,-p --- _ - , . ,

-,/ .

PROCEDURE EFFECTIVE BROWN & ROOT, INC. NUMBER REVISION DATE PAGE

] CPSES JOB 35-1195 .

' JAN b84 1 of 1 CP-CPM 9.10l 11 ATTACHMENT 12 PARTIAL PENETRATION WELDS WITH UNEQUAL LEGS t b d _

e N <  :

iSx5 7 W '

w/

I 4 e

2

t

..me.--.... .;- ,.,+,....e,7

w. -. ,. . ., e. . , . - . .

. .s. -

'O

~ ~ ~

PROCEDURE EFFECTIVE NUMBER REVISION DATE PAGE BROWN & ROOT, INC.

q _. _ _ CPSES

g. ~~' .. -

JOB 35-1195 Jg y y CP-CPM 9.10 11 1 of 1 ATTAC)NENT 13 S'

i U . . . _ _ . . . _

~~ '

Ai t. ._

~.J q . . d. A/OWIA/AC '

g@sW. _. .

7 8 x1 . . .

c y ~ ' ~ - - ~ ~ ~ ~ -

-t 2 p t y 1-- N - .. .

l.

i Due to manufacturing tolerances the actual thickness may be less .than the g nominal thickness.

~? This is acceptable and the weld need not be any greater than the actual thickness if the difference ( A) between the actual thickness and the nominal thickness does not exceed the following.

Nominal Thickness Allowable Difference i

< 3/8 1/32 A3/8 1/16 If the difference (A) is greater than specified above, notify enginaar.ing for approval of a reduced weld size.

The toes of most rolled shapes are rounded. In that case the edge is built up to ensure full throat of weld as shown above.

h

~~

]b=#

[*,g ,

. UNITED TT ATE S

[N .

NUCLEAR REGULATORY COMMISSION '

oFFict OF INvtSticAlloNS FIELD office, REGloN IV /

, f e#

N.';,,/ = "==.vahe ASSISTANCE TO INSPECTION REPORT F

SUBJECT:

COMANCHE PEAK ALLEGED IMPROPER CONSTRUCTION PRACTICES REPORT NUMBER: A4-83-005 ,

1. On February 3,1983, ~provided an affidavit to the Citizens Association for Sound Energy (CASE)~, an intervenor that included three alle-Brown & Root personnel at

)

gationsregardingimproperconstructionpract4 / alleged the following:

the Comanche Peak Steam Electric Station. #i.

a. That Brown & Root employees drilled undocumented unauthorized holes through -

rebar, and such cutting of rebar was done at the direction of supervisors.

~

b. That the main steam line pipe in Unit I was moved using the polar crane, thereby placing the pipe under unsafe tension.

I That a Brown & Root employee used a cutting torch on hanger material in  : l

c. l violation of procedure.
2. On meetingApril 6,1983, was arrange 0 wit Gj)h p fort@y c ntacted the following day, by theontacted reporting b.nv reporting investigator on pril 7, 1983, and requested the'mheting ce changed to April 8, 1983.

/ 3. On A ril 8,1983, NRC 01F0 Director R.K. HERR and the reporting investigator met T N at a restaurant in Fort Worth, Texas.bh g was accompanied by Ms. Juanita ELLIS, a CASE representative, and Ms. ELLfr husband.

Ms. ELLIS wished to record the meeting; however, 01F0:RIV was not previously informed of her intended presence nor of desire to record the interview.

OlF0 did not have a recorder, and in accor ance with 01's policy, the meeting was rescheduled. On April 10, 1983, arrangements were made to use a room at the U. S. Attorney's office, Fort Worth, Texas, and 'for a court reporter to transcribe the interview of (TM D

4. On April 14, 1983,,. -

u as interviewed at the U.S. Attorney's office with Ms. ELLIS present testimony was taken under oath, Attachment (1),

and % ELLIS_made ner dwn personal recording of the interview, l_n his testi-mony expanded in detail on his original allegations. m 9Bnamed BrownTRoot e ployees responsible for thf alleged improprieties and those who could substantiate his allegations. W;"&~~ % also identified numerous employees by titig, and agreed to lafer provide the corresponding names when he was able to refresh his memory with his personal records located at his residence. T h also provided the NRC with a copy of a log. ( p p explained that he maintained this log to document the cutting of recar at Conanche Peak. (Note: Cg;J did not allege that all the entries in the log documented unauthori:cd cuts through rebar, but rather that some of the entries in the log may have been for holes drilled through rebar that may not have had_the appropriate accompanying authorizations.) During this interview, ILJ made a fourth allegation regarding instances of 1

^*

1 c.c l[l

A4-83-005 Page Three r10. Eight Brown & Root employees alleged to have knowledge concerning the improper use of cutting torches on hanger material were interviewed. Two witnesses stated they remembered an instance during the redesign of a hanger in which a piece of tube steel was discovered to have had the bolt holes enlarged using a torch, which was a procedural violation. The testimony of the two witnesses indicated that this hanger was scrapped because of the procedural violation, and was replaced with new material. The other six had no knowledge of improper

use of cutting torches or hangers.

L_-

11. Two Brown & Root employees were interviewed concerning their alleged knowledge of lugs improperly welded onto stainless steel pipe without purging the pipe.

Both executed signed, sworn statements, and indicated that they did not know of_

any instances where welding was done on stainless steel pipe which required purging by procedure unless a " purge deletion" was received from the engineers. ,

12. All of the employees mentioned by n his affidavit who were still employed or available for interview enied the allegations made by No evidence was uncovered during these inquiries which indicated deception on ,

the part of the witnesses. The witnesses ranged from pipe fitter helpers to /

Brown & Root superintendents. A Piping Design Services Inc. engineer and the Dravo Constructors Inc. project manager also provided testimony which contra-dicted the allegations.

13. The signed, sworn statements are maintained in 01F0:RIV. No further inquiries are anticipated unless staff inspections identify additional pertinent information that would tend to substantiate the allegations or discredit the interviewees.

Attachments:

(1) Testimony of - dated 4-14-83 (2) List of Interviewees (3) List of terminated employees identified in Attachment (1)

REPORTED BY: 7!/ '

H. Brooks Griffin, $ vestigator 01 Field Office, Region IV APPROVED BY: .[ [ p Richard 'K. He'rr, ~Directdr

~

01 Field Office, Region IV cc: W. Ward, 01:DF0 - w/ attachments J. Collins, RIV - w/ attachments E. Johnson, RIV - w/o attachments

o e

.. , l

)

, braft T 11/3/84 M: AH ' 1 (P4 SSER

1. Allegation Grcup: Mechanical and Piping Category 32

(

Unauthorized Fabrication Techniques on Hangers, _

Unqualified Perscnnci ,

1. Allegation Number: AH-4, AH-9, AH-10, AH-ll, Ah-lE, AF-20, AH-21 ,
3. Characterization: It is alleged that various instances of unauthorizec fabrication occurred contrary to establish procedures, such as cutting hangers with a torch, installation of structural steel without approved orawings, and hitting hangers with a sledge haxer. It is also alleged that an uncuelified individual was in charge of cor.structier of some hangers. i
a. Assessnent of Safety Significar.ce: The implied safety significance of ru f these allegations is that the fabrication of sene pipe supports g have beer completed contrary tc approved precedures. This nay cr nay not have safety significance based upon the severity of the deficiency. Since nest of these aliegations are closely related to fabricatier, practices, the f,RC Technical Review Tean (TRT) reviewed the hanger ard support fabrication and inspection procedures. Each allegatior wili be addresscd separately.

qw R 1 A l s, ;r= ,s=

p f IM, f ' ~ '^ i 4

l

4 0 2

AH-4 This allegation states that a w(ider was instructed to welo a leg L on a hanger which was not authtrized by the drawing. The TRT reviewed the procedures pertaining to hanger drawings. Brown & Rcot (B&R) procedure CP-cpl'-9.10 paragraph 2.1.4 requires that the hanger packagt ,

(HP) be intact when parts are being assembled inte a support. This ,

paragraph also states that part! for a support, i.e. structural membcrs, may be fabricated without a drawing er HP provided they are described on ,

i the Material Identification Log (H L) and verified by Q.C. The incident a t

i described by the alleger ccula have occurred within procedure, however i more information was required.

On August 28, 1984, the TRT initiated a telephone conversation with the I

alleger. The TRT asked if the e.eger could ider.tify specifically which i

hanger was involved or in what building, elevation, or area the hanger l

was located. The alleger cculd not provide any further ir.fornatior about the incident than already existed. The alleger indicated that no further details concerning the welding of the hanger coulc be provided.

Additional questions concerning the date, the Q.C. inspector involved, and whether any NCR was initiated yielded similar results. The TRT also attenpted to contact the alleger's supervisor at the tine of the incident, but he no ler.ger works at the site and his whereabouts was

! unknown, i

I

i 1

i.

I l Thc TR1 ir.tcrviewed Pipt- Support Er.gineerirg (tst) anc brev.n A Root Of t c deternint- if w(lding of a henger without a drawir.g was perritte6. both PSE & QC seid that only a Component Modificaticr. Card (CFC) cculd be used to rake a change to a hanger drawing other than a revirion to the

! drawing. The CMC is a connonly usc$ vehicle to allow a nodification tc a drawing ar.d its controlled use is covered in varicus procedures. ,

Acccrdir.g to PSE, QC, and pipt hanger fabricatier, no other r.cthed war

! used to ir. stall har.gers. The cperation described by thc aileger would have tc tavc been ar.rctated or a keld Data Card and the heat r.unber of the piece would have to be recorded on the MIL and docurented by 0.C. ..

! Mithout tbc identification of the hanger ir question, oc further i

j investigatien is possible.

AH-9, AF-ll 4

These allegations state that the alleger saw his supervisor and cther ir.dividuals use a cutting torch on various hangers. However, he is not sure whether CMC's were used to authcrize these cuts. :n his sworn

statement dated liovember 22, 1983, the alleger identified three hangers specifically by hanger number on which he nad kncv.iedge of torch cutting i

(AH-9). The TRT attempted te review the HP's fcr these hangers, however, .

t

! the exact henger numbers as identified by the alleger were incorrect.

The TRT interviewed the allegcr on September 11, 19Et. After sorx i questions concerning the incorrect hanger numbers in his tkverber 22, 1983 swcro statement, the alleger changed the hanger r.unbers to the best i

i

t 4

4 i of his recollection. he it.dicated ti tt hc wes ra t cc .cerred about the use cf torches te cut steel, but about th( fit-up ci tt.e nating pitees. He confirred that all torch cut piecer ucrc eith(r greurd sncoth or machincd per procedurc. The alleger said that these corcerrs had becn addressed previcusly by the resident NRC inspector at CPSES erc that he, the

! allegcr. was givcr. a copy of the fit.al inspcctier rcpert. Upon further ,

i review, the lhT discoverec that the tnret hanger runbcrs revised by the alleger (US-1-004-007-C72K, MS-1-002-005-C72K rec UC-1-004-0C9-C72K) were indeed addressed it; RIV IR 80-445/E4-05. Tr.cse concerrs have been ,

reviewed by the TRT in AP-lS, AP-20, arc AF-22 (see category 731). f The TP.T discussed the use of cutting torches er rar.gers with PSE, B&RQC 1

and pipe hancer fabrication personnel. One of tre allegations, AH-il, statec that cutting tcrches were regularly used to enicrge holes in structural tubing to accennodate anchcr bolts that weren't exactly perpendicular. All individuals interviewed saic that even tough thermal cutting was allowed by paragraph 3.3.4 of CP-CPM-9.10, this would have been a very inefficient methcd tc use. Cutting cf holes with a torch would have required grinding te smooth cut the rcugh ocges and allow for proper seating of the nut. Acccrding te har.ger fabrication persennel, drillirg was used by the crafts for enlargirg h:ics sirce it required very little clean up work on the helt. This was verified by OC and the alleger. Also, this paragraph specifies a particular tolerance on hole pes-frapresicuu D ry size that wculd only account for a very snall arcunt on :: pendicul;rity cf the mating anchor bcit. Any amount of tolerar.ce beyond that listed in the procedure would require engineering dispcsition.

.r .

During the irittrview, t bt illeger verified that this was the only hanger (unidentificc, e> cept that it was ir Ur.it 2) he had ever seen with a torch cut bolt belt. H( also vcrified that his crew had torn it down arid rebuilt it.

AH-10 AF-18 ,

i These allegatier.s are very closely related to AH-9 & AH-ll, in that they nake rtference tc the sare ircident of cutting bolt beles with a tcrch. .

In allegation AF-10, the supervisor of the alleger in AH-9 reiterates the /

sane ccncerr, abcut enlarging bolt hcles with a torch. No specific information concerning the allegation was given. However, the alleger dio stipulate that eight B&R employees had knowledge of the incidents.

The TRT reviewe f;RC assistant to Inspection Report A4-83-005 which addressec the statements of the eight B&R empicyees. Two individuals <

remembered ar. instance cf enlarging bolt holes with a cutting torch in a piece of tube steel, however, the hangers were scrapped and replaced with new material. The TRT reviewed a sworn statement by the alleger in AH-9 concerning this incident. He stated that he had knowledge of tube steel that had to be cut to alicw proper fit-up with the anchor bolts, however, all hangers had Cf1Cs autherizing the work. He alsc expressed knowledge cf the abcVE Centioned ircident, sir.ce it was his crew that rebuilt the hanger. The statenent gives no further inferration that would identify the harger. The remaining six enplcyees interviewed by 01 had no knowledge

e of irfrcper use of cutting torches on hangtrs.

The 1RT reviewed Region IV (RIV) Inspection Report (:R) 50-445/E?-27 which acdressed this allegation. The RIV inspecter discussed tht use of cutting torches cr hangers with B&R welding and fabrication engireers and was toic that this operation is not prohibited. The TRT v(rifiec this ,

thougn siniiar irterviews with hanger fabrication and QC perscrnel and reviev.ir.g paragraph 3.3.4 of CP-CPM-9.10. The R:V inspectcr alsc was telc that heles are normally enlarged, if required, by drilling cffset holes, and cutting torches were permitted cn other types of structural y nembers. The TRT again confirmed this in similar interviews. The RIV inspectcr examinec approxinately 60 hangers in the certainment building between elevations 860' and 905' that certained tubular sections connected with archcr bolts. Although the inspector was limited in visual

, accessibility te the belt hole, the RIV inspector did not find any hole that was enlarged by a cutting torch. The TRT, as part of allegation AC-3, inspected 150 anchors connecting tubular steel between the same elesations, and found ne violation of the installation procedure. The inspection was conducted for the purpose of reviewing the allegation of non-perpendicular anchor bolts, however, the conditicn of enlarged holes by torch cutting was not observed by the TRT.

The IRT contacted the allegcr to identify the specific hangers and-the indivicual who was considered to be incompetent. The alleger was ur.able i to identify specifically any hangers; however, he did identify the persen t

1 l

7-alleerd to be incompetent. Sinct the inchidual wat no ic nger on the jcbsite and was unavailable for a follcrup interview, the allegetion 1"E .

concernineincompetentemploye[cannotbepursuedwithoutmorespecific g

information.

AH-20, AH-21 i These allegations concern the use of sledge harr9ers and grinders te strcighten pipe hangers and establish the correct clearance around the pipe as described on the design drawing. One cf the allegations contcnds .. !

that due to binding and/or nisalignment of the pipe, wood timbers were used to jack the pipe dcwn to the bottom of the hanger frane in order to naintain the design clearances. Another instance describes crewman sitting on the pipe to force the pipe tc the botton cf the frame during a OC inspection. The TRT interviewed the alleger on August 24, 1984 and was told that he did not have first hand knowledge cf these allegations.

he said that a former employee whose name he refused to reveal, related these allegations to him. The TRT asked the alleger to contact the individual to deterr.iine if he was willing tc talk to the TP.T concernir.g

! more detailed information on these allegations. The alleger said that since he had no details or the allegatiens, he wculc contact this individual, and either the alleger or the individual wculd contact the TRT. Neither ir.dividual has contacted the TRT, and further attenpts by the TRT to contact the alleger have been unsuccessful. j

1

. [, .

The TRT discussed the ccostructior. ard inspection of pipt hengers witt.

S&k hanger fabr4 cation engineers and C.C. persenr.(i. Hanger Fabricatici said "Slecge Hanrers" would not be allowcd, hcwever, t 4-pound rubbcr

) riallet used with a piece cf wood to soften the blow cculd have been usec tc align the structurai members durirg welding. The use of such tools was not ccvered by a specific procedure. This practice was confirmcc tg 0 0.C. Inspector as a practice that cculd have cccurred. Withcut additicrtl detaiicd information, no furthcr investigation was possible.

5. Ccnclusion and staff positions: The TRT reviewed all allegations ,.

pertaining to irproper hanger fabrication practices. Since many of the allegations are similar in centent or related, the cccclusions are grcuped as shown.

AH-4 Ah-20, AH-21 All of these allegations are either vague or generic ir. content. The TRT interviewed both allegers and was ur.able to accumulate more detailed informatien needed to properly assess the allegations. Ever, though the alleger for allegaticr.s AH-20 & AH-21 agreed tc ccntact the TF.T with mere clarifying informatier, the TRT nace an unsuccessful attempt to reach the alleger. The IRT reviewed constructicr. and inspection prccedures relating te the allegatiens and found evidcr.cc of proper practices. Tre

1 9

TRT interviewed LER constructicn and inspection pera r.nel end f rund thet these indiviauals concurred that th( constructicn practicct in genertl conformed kith procedures. All B&R individuels ir.terviewrc indicated that an NCR should have been initiatre f er the typc of inpreper pr6ctices described in the allegations. These allegations can neither be substantiated or refuted, thereferc there is r. tither safet) significance .

cr general applications. _,

AH-9, AH-10, AH-11, AH-18 These allegations are either relatec or identical in content. The TRT interviewed the alleger for AH-9 and AH-11 and discovered that AH-9 duplicates the review down for AP-18, AP-20 and AP-2: ir Category r31.

The TRT also learned that AH-ll pertained to a sirgle hanger er Unit 2 and had been replaced. The alleger knew of no other instar.ces to support w ess this allegation. AllegatiCns AH- and AH-ll c2r 'C'I be" he Subit!' tilted

-nGn refuted and have no safety significance or generic implications.

The TRT could find no specific details fcr AH-10 sir.ce it was very vague The TRT reviewed RIV IR 83-27 and agrees with the inspecters assessment.

The TRT, as part cf allegatier AC-31, irspected 150 anchors of the type described by the alleger and found ne evidence of torch cutting. The TRT contacted the allcger of Ah-18 and identified the fcretar believed to be incoopetent; however, he is ne longer at the jobsite. Allegatiens AH-10

& AF-18 can neither be substantiated or refuted. All the allegaticns have neither safety significance or generic implicaticos.

. f_

j .- .

,. (

L l 6. Act ic r . Facuired: f;c t( .

'~

, /

i i

' Attachments: f;one.

8.

l i

9. Reference dccunents:

i

1) Swcrn Statement cf taker er Septenber 15, 1953. ,
2) Intervie< bety.een r c' C.: on Septenber 15, 19E3. f
3) Assistance to Ir.spectier. Ecpert A4-53-CC5 dated t; vember 30, 1983 4

frcm GI f

4) Sworn Statement of taken on ';cvember 22, 1983.

l

5) Assist?nce to Inspecticn Repert ~4-63-005 dated itay 20, 1923 from t

f 01.

6) Assistar.ce to inspection Repert A4-83-005 m dated itay 20, 1983 from 01.
7) Swcrn Staterer.t cf dated June 18, 1983 pages 35, 36, and 49. -.

E) Affidavit cf 2tec i;cvember 26, 19E3. l i

I <

9) Affidavit of efore the ASt.E, dated February 3, 1963 j

> s l pages 6 & 7.

10) Affidavit cf datcc March 31, IEE4 pages 3&4

]

i a l

11) brewn & Rect procedures CF-fPM-9.1G, CP-CPM-E.96, QI-0AP-11.1-28.
12) TUGC0 Frecedures CP-EF-2.1, CF-EF-lC.3, CP-CF-4.6, CP-EP-16.1.

i 13) Regien IV 1rspecticr. Report 50-445/03-27

10. Thi- statererit r,t(pared by:

Name Late P.eviewed by:

Group Leader Date Apprcved by:

Project Director Date 1

1 1

i

.

Retrieved from "https://kanterella.com/w/index.php?title=ML20202B204&oldid=2996303"