ML20202J440
| ML20202J440 | |
| Person / Time | |
|---|---|
| Site: | Comanche Peak  |
| Issue date: | 06/27/1986 |
| From: | Hansel J, Patterson A EVALUATION RESEARCH CORP. |
| To: | |
| Shared Package | |
| ML20202J051 | List:
|
| References | |
| QI-046, QI-46, NUDOCS 8607170081 | |
| Download: ML20202J440 (20) | |
Text
{{#Wiki_filter:4 Page 1 of 11 I EVALUATION RESEARCH CORPORATION C0G0 D CO?Y CONTROL NO._DF-ool COMANCHE PEAK RESPONSE TEAM QUALITY INSTRUCTION FOR ISSUE-SPECIFIC ACTION PLAN VII.c INSTRUCTION NO: QI-046 REVISION NO: 2 ISSUE DATE: 06/27/86 DOCUMENTATION REVIEW OF STRUCTURAL STEEL O Prepared by: Date: dP 8 8h U Approved by: I' W I ' M*~ Date: I 6 Issue Coordinator Approved by: Date: h M[ [ On-Sit'e QGepresentative / / , Approved by: Date: I# 7 dl= t Q QA/Q view Team Lesder / ' wu88nn8@ A
o QI-046 Rav. 2 f ~s 1.0 PURPOSE ( This instruction describes the methods and the accept / reject criteria to be used for the document review of Structural Steel by the QA/QC Review Team. 2.0 APPLICABILITY This instruction applies to the Document Review of safety significant attributes of safety related hardware within the Structural Steel population at Comanche Peak Units 1, 2 and areas common to both units.
3.0 REFERENCES
3.1 Memorandum QA/QC-RT-1023, delineating documentation used in development of this instruction including specific sources for attributes and exclusions. 3.2 QI-045, " Reinspection Instruction for Structural Steel". 3.3 CPP-009, " Performance of Reinspection and Document Review". 4.0 GENERAL 4.1 Responsibilities 4.1.1 QA/QC Discipline Engineers The QA/QC Discipline Engineers prepare the l documentation review procedure delineating review ( requirements and attributes. 4.1.2 QA/QC Inspectors QA/QC Inspectors perform documentation review / verification in accordance with reference 3.3 and this inspection procedure and record results and deviations. 4.2 Policy Activities performed under this procedure shall conform to the policies contained in the latest Comanche Peak Response Team Program Plan and Issue-Specific Action Plan VII.c. l lO 2
01-046 Rev. 2 5.0 INSTRUCTIONS (Note 1, 2 & 3) b\-' Using the information in Reference 3.3 and below, perform documentation reviews of the sample items in this population and document the results on the document review checklist (Attachment 6 .1 )'. Attachment 6.2 lists the typical quality control reports and documents required to perform the documentation review. , Using the documents listed in Attachment 6.2 and any other available information, perform the following review: The inspector shall review the item description (Attachment 6.3) to determine which attributes are applicable. Where no inspection verification exists for applicable attributes, DR's will be initiated. A. Construction Operation Traveler Package A.1 Inspection Package Verify, by review, that a QA/QC inspection package exists for the item being reviewed. If no inspection package can be located indicate that the remaining attributes described herein cannot be verified (N/A) s and terminate the documentation review. kJ A.2 Drawings Verify, by review, that the design drawing (s) listed on the Documentation Package Inventory Card (DPIC) of the QA/QC Construction Operation Traveler, or listed on the Construction Operation Traveler, or referenced on the Inspection Report reviewed to satisfy the requirements of this instruction, are the same drawings used for the reinspection program (QI-045). A copy of the drawings from the reinspection package is included in the documentation review package. Additional drawings not used for the reinspection program may be listed on the DPIC, the Construction Operation Traveler, or Inspection Report, this is not cause for rejection. A.3 Inspector Certification Verify, by review, that the below listed documents, when reviewed to satisfy the requirements of this instruction, are either signed, or initialed by a certified inspector. A.3.1 Inspection Report (IR). A.3.2 Weld Inspection Documentation Card (WIDC). ( 3
01-046 Rev. 2 5.0 INSTRUCTIONS (Cont'd) . A.3 Inspector Certification (Cont'd) A.3.3 Material Requisition (MR). A.3.4 Structural Assembly Verification Card (SAVC). A.3.5 Construction Operation Traveler l A.3.6 Other Documents Reviewed to meet the requirements of this instruction; list the ' title on the checklist. The accept / reject criteria for inspector certification is: The Inspector must be certified in the area i or discipline for the type of inspection performed, certification to the applicable inspection procedure shall indicate area / discipline (see Attachment 6.7 for Procedure Tabulation). The Inspector's date of certification was (,)
/~' prior to inspections perforred and inspections were performed prior to certification expiration date.
Inspector Certification Files - Files retrieved from the Permanent Plant Records Vault (PPRV), or other available sources, shall be used for this verification. Note: If this attribute is rejected, determine if the person that signed as a QC Inspector was ever certified to the applicable instruction in Attachment 6.7. If the inspector was certified, record the time period of certification, otherwise state that the person was never certified. B. Member Attributes From the available Construction Operation Traveler (s) and/or inspection reports determine those entries which are related to the population item being reviewed. Some of the attributes described below may be listed as individual entries or they may be included with an entry for the entire inspection assembly. Should an attribute described below not be applicable to the member being reviewed, enter N/A on the Document Review O- Checklist. (Attachment 6.1) l l l 4 l
QI-046 , Rev. 2 { l 5.0 INSTRUCTIONS (Cont'd) B. Member Attributes (Cont'd) To determine which attributes / entries are applicable, refer to Item Description Sheet (Attachment 6.3 - to be completed by the package preparer and included in the Document Review Package). B.1 Welding If the item being reviewed has field weld specified on the design drawing or is site fabricated, perform the following: Obtain the Brown & Root Welding Procedure specified in the Construction Operation Traveler / Inspection Report. B. 1. 1 Weld Procedure Qualification Verify, by review, that the letter of approval from Gibbs & Hill or TUSI is filed with the welding procedure in the Brown & Root Weld Procedure Manual. B. 1. 2 Weld Procedure Application a) Base Metal Verify that the base metal being joined (as specified on the SAVC, WIDC or Design Drawings) is as specified in the welding procedure identified above. b) Filler Metal Verify that the weld filler metal used to perform the weld joint (listed on the Weld Filler Material Log (WFML)) is as specified in the welding' procedure identified above. NOTE: WFML may specify multiple material issuance without. identifying the specific joint. Therefore, the inspector shall check all material listed on the WFML. c) Material Thickness Verify that the thickness of the material being joined (as specified on the SAVC, WIDC or Design O Drawings) is within the range specified in the welding procedure identified above. 5
QI-046
, Rev. 2 5.0 INSTRUCTIONS (Cont'd)
O B.1 Welding (Cont'd) B.I.3 Welder Qualifications Compare the welder I.D. symbols recorded during the reinspection effort (Attachment 6.3 of QI-045 - included in the document review package) to the welder I.D. symbols listed on the WFML. If the symbol (s) does not appear on the WFML note the same in the remarks section of the checklist (Attachment 6.1). (The QA/QC Discipline Engineer shall review this aspect and initiate a DR if required.) Using all of the welder I.D symbols listed on WFML perform the following: a) Obtain from the " Welder Performance Qualification Record Listing Standard Tests" effective at the time of the welding (use date specified on the WFML for each "x welder) the tests for which the welder is qualified for. b) Verify, by review of the " Welder Qualification Matrix" and the data obtained above, that the welder is qualified for the proper test for the welding procedure identified in step B.1. 3.1.4 Stress Rslieving Verify, by review, that stress relief of AWS full penetration welds on material 1-1/2" ,. thickness or greater and fillet welds 1" and l greater was performed. This can be accomplished by reviewing documentation for a QC sign off or by locating any stress relief charts in vault documentation. It is not required to have both - one or the other will satisfy this requirement. B.2 Concrete Expansion Anchors (Hilti's) O Using the Construction Operation Traveler / Inspection Report, perform the following: 6
1 QT-046
, Rev. 2 5.0 INSTRUCTIONS (Cont'd)
B.2 Concrete Expansion Anchors (Hilti's) (Cont'd) B.2.1 Torque Verify, by review, that: a) Calibration The calibration due date of the calibrated wrench is recorded and is subsequent to the date the , installation was performed. Note: It is only necessary to have the MT&E number on inspection document in order to trace calibration on equipment. i b) Torque Value The recorded torque setting value meets or exceeds the minimum torque requirements of Attachment 6.4. B.2.2 Bolt Spacing (See Note 4) f Verify, by review, that if witnessed, and if 1 abandoned holes were drilled and subsequently
; covered by a baseplate, the inspector noted that the appropriate spacing was maintained between the installed Hilti and the abandoned holes, and that if located at a distance of four bolt diameters and closer, holes were filled and patched according to Procedures 35-1195-CCP-12 (grouted).
i B.2.3 Rework , Verify, by review, that if rework of bolts l occurred, that the inspector noted: a) Thread Fit Correctness of thread fit requirements. b) Restamping Restamping of bolt to new length designation was observed. O 7 l - - . . . -
QI-046
. Rev. 2 5.0 INSTRUCTIONS (Cont'd)
-{TY
%.s B.2 Concrete Expansion Anchors (Hilti's) (Cont'd)
B.2.4 Hole Drilling (See Note 4) Verify that, if witnessed, inspector noted that no rebar cutting took place during drilling of holes without appropriate DCA permitting such cutting, and that there was no spalled concrete exceeding allowable limits under the fixture plate. B.2.5 Setting (See Note 4) Verify that, if witnessed, the bolt setting was appropriately performed including further redrilling of holes if Hilti's failed to set properly first time. Redrilling requires a minimum of 4 1/2 anchor bolt diameters for Hilti Kwik Bolts or 6 1/2 anchor bolt diameters for Hilti Super Kwik Bolts greater than the previous existing embedment depth for same size bolts or an increase in bolt ' size to the next larger diameter size. (Note
- QA/QC Inspector shall ensure that bolt
(~ length is consistent with revised length requirements if redrilling occurred.) B.3 Structural Bolting B.3.1 Tightness Verify, by review of the inspection report or Construction Operation Traveler, that the l bolts were tightened in accordance with the l design drawings. Record, (if listed) in the l comments section of the checklist (Attachment 6.1), the method listed for tightening, i.e., turn of the nut, snug tight, calibrated wrench, finger tight and/or procedure number. B.3.2 Torque a) Torque Value Verify, by review, that the torque value, if listed, meets or exceeds the minimum installation torque (Attachment 6.5). 1 l 8
a OI-046
, Rev. 2 5.0 INSTRUCTIONS (Cont'd)
B.3 Structural Bolting (Cont'd) b) Calibration The calibration due date of the torque / calibrated wrench, when recorded, is subsequent to the date of the installation / inspection date. B.4 Stud Welding B.4.1 Daily Qualification Report Verify that an inspection report for daily qualification has been filed, signed and dated and that the IR number has been recorded on the Construction Traveler or the package Inspection Report. B.4.2 Stud Testing If testing of production studs was done for this member, verify, by review, that the IR has been properly signed and dated and the IR O number was recorded on the Construction Operation Traveler. If no IR is included for testing of production studs, indicate "N/A"
! on the document review checklist.
C. Material Traceability For field fabricated material obtain the heat number or unique ID number, if available, from the reinspection package Material Identification Record. (Attachment 6.2 of QI-045, included in the document review package) For heat numbers: Obtain a copy of the Receiving Inspection Report (RIR) i from the Permanent Plant Records Vault (PPRV) for Unit 1 or the Intermediate Records Vault (IRV) for Unit 2 Structural Steel Items. This gives documentation for the specific heat number. For unique ID numbers: i ! Review the Miscellaneous Structural Steel Log in the 6 vault and obtain the corresponding heat number and thence the RIR number. 1 5 O 9
a 0I-046
. Rev. 2 5.0 INSTRUCTIONS (Cont'd)
C. Material Traceability (Cont'd) Khen no traceable heat number or unique ID number is indicated on the verification package Material Identification Record, determine from the Construction Operation Traveler package the appropriate Material Requisition (MR). From this MR obtain the heat number or unique number and thence the RIR. Should the information recorded on the Material Identification Record prove to be not traceable indicate the same on the remarks section of the checklist (Attachment 6.1). (The QA/QC Discipline Engineer shall review this aspect and initiate a DR if required.) Should the above reviews not produce a traceable heat number or unique number the below listed attributes shall be rejected. NOTE: Where copies of the RIR are not available in the vault, a check of the card file in the receiving warehouse will be necessary to obtain the RIR and the heat numbers. a) Heat Number Conformity 4 Verify that the heat number obtained j above matches the heat number from the RIR. i b) Material Conformity Verify that the material utilized for the Structural Steel is as specified on the design drawing. l l l NOTES
- 1. DesignDrawingshallincludetheG$HDrawingsandassociated
.- design change changes.
- 2. Should additional space be required for remarks on checklist, use Attachment 6.6.
- 3. Field Fabrication and Site Fabrication are synonymous.
- 4. This attribute is a surveillance activity which is documented on separate Inspection Reports. If this I.R. is not included in or referenced on the package being reviewed mark the attribute Not Applicable (N/A). If this attribute is completed record the I.R. number in the remarks column of the checklist
() (Attachment 6.1). 10
QI-046
. Rev. 2 O 6.0 ATTACHMENTS 6.1 Document Review Checklist 6.2 Document List 6.3 Item Description 6.4 Hilti Bolt Torque Requirements 6.5 Structural Bolt Torque Requirements 6.6 Supplemental Remarks 6.7 Inspector Qualification Procedures O
e J 0 O 11
~_ . i Attachment 6.?
QI-046 Rev. 2 Page 1 of 3 O COMANCHE PEAK RESPONSE TEAM 1 CHECKLIST l F0FULATION DE5C VERIFICATION FKG No. Structural Steel R-S-STEL-PAGE 1 0F 1 QUALITY lasiaUCTION QI-046 REINSFECTION C UNIT 1 EQUIrnsat MARK / TAG NO. @ D0Ct2ENTATION RDIEW * [ UNIT 2 O coiao= VERIFICATION ATTRIBUTE ECEPT N DATI REMARKS A. Construction Operation Traveler Packene N/A INFORMATIONAL HEADER A.1) Inspection Packase A.2) Drawinas j \ A.J) Inspector Certification N/A INFORMATIONAL HEADER A.3.1) Inspection Report A.3.2) Weld Inspection Documentation Card A.3.3) Material Requisition \ A.3.4) Structural Assembly Verification Card A.3.5) Construction j operation l Traveler A.3.6) Other Documents (list) FRDARED BY: APii wizu Bt DISCIPLINI ENGE. DATE LEAD DISCIPLINI ENGE. DATE taarzussu ET: - A Fivvau BT: Laarzu wm DATE r n_n IN5FECTOR DATE I CFF-007,lA. Revision 0
Attechmsnt 6.1
, QI-046 Rev. 2 s .v C0FJ3CHE PEAK RESPONSE TEAM C*dECKLIST 20P L I;0N DESC 'JERIFICA!;GN PKO SO.
Structural Steel R-S-STEL- PAGE 20F 3 VERIFICATION A W 3CII 3 ACCEPT l REJECT DATE B. Member B.! Welding N/A INFORMATIONAL HEADER B.I.1 Weld Procedure Qualification B.I.2 Weld Procedure - Application N/A INFORMATIONAL HEADER a) Base Metal b) Filler Metal c) Material Thickness
- O i i B.1.3 Walder V Qualifiestions B.I.4 Stress Relievina B.2 Concrete Expansion Anchors N/A INFORMATIONAL HEADER B.2.1 Torque N/A INFORMATIONAL HEADER a) Calibration I
b) Torque Valve B.2.2 Bolt Specina 5.2.3 Rework N/A INFORMATIONAL HEADER a) Thread Fit b) Restampina B.2.4 Hole Drillina B.2.5 Settins
.. . =es s . 6 a . Ra'11$ 10tt I, 2
Attachmsnt 6.1 l 01-046
, )
Rev. 2 j m U CCFJ3CHE PIAK RESPONSE TEAM CHECKLIST F9P'AATION DESC VERITICA!*0N PKG NO. Structural Steel R-S-STEL- PAGE 30T 3 VERIFICATICN A ACCEPT REJECT DATE RDiARKS B.3 Structural Boltina N/A INFORMATIONAL HEADER B.3.1 Tiahtness B.3.2 Torque N/A INFORMATIONAL HEADER a) Torque Value b) Calibration B.4 Stud Weldina N/A INFORMATIONAL HEADER B.4.1 Daily Qualification Report e m B.4.2 Stud Testina l ' C. Material Traceability N/A INFORMATION HEADER a) Heat Number Conformity b) Material Conformity 4.~,......,. sov.a.un G 3
i Attachm2nt 6.2 l
- 0I-046 Rev. 2 Page 1 of I DOClHENT LIST DOCLHENT SOURCE Construction Operation Traveler Permanent Plant Record Vault (PPRV)
Inspection Report (IR) Construction Operation Traveler Weld Inspection Documentation Construction Operation Traveler Card (WIDC) Weld Filler Material Log (WFML) Construction Operation Traveler Material Requisition (MR) Construction Operation Traveler , Structural Assembly Verification Construction Operation Traveler Card (SAVC)
, Nonconformance Report (NCR) Permanent Plant Record Vault (PPRV)
Miscellaneous Structural Steel Permanent Plant Record Vault Log (PPRV) 'N/
- Receiving Inspection Report (RIR) Permanent Plant Record Vault (PPRV)
Miscellaneous Steel Fabrication Permanent Plant Record Vault Checklist (PPRV) l l l O
Attachment 6.3 4 , QI-046 Rev. 2 Verification Package No. _ R-S-STEL- Page 1 of 1 ITEM DESCRIPTION MARK 4 SITE FABRICATED U YES U NO i FIELD WELDS I YES [ NO (Attribute B1) HILTI BOLTS l l YES M NO (Attribute B2) BOLTED CONNECTIONS U YES C NO (Attribute B3) STUD WELDING (Attribute B4) [ YES U NO O , CONSTRUCTION OPERATION TRAVELER 1 4 t
?
I i lO Preparar-QA/QC Discipline Engineer Date 1 1 1
. . _ . - . ~ , _ _ . _ _ _ . _ . . _ . . _ _ _ _ _ _ _ . _ _ _ _ _ . . . . _ ,_ . _ _. _ .__._______. _ _. _ _ _ _ . _ _ _ _ _ _ _ . . _ _ _ . ~
Attachmsnt 6.4 i
. 0I-046 Rev. 2 Page 1 of 1 4
O HILTI BOLT TORQUE REQUIREMENTS Minimum Embedmont Minimum Bolt Diameter Kwik-Bolts Super Kwik-Bolts Torque (Ft./Lbs) 1/4 1 1/8 -- 8 3/8 1 5/8 -- 17 1/2 2 1/4 3 1/4 70 i 5/8 2 3/4 -- 120 3/4 3 1/4 -- 150 1 4 1/2 6 1/2 230 1 1/4 5 1/2 8 1/8 400
- O .
I i l l l , { O
.. --. _. - . - ~ . . . = , . .. ._ . . - _ . .- -. . - - -. . _. _.
% l Attachment 6.5
, 0I-046 Rev. 2 Page 1 of 1 f
) INSTALLATION TORQUE VALUES ASTM A325 ASTM A490 Bolt Size Torque Torque (Inches) (Ft. Lbs.) (Ft. Lbs.)
1/2 93 5/8 228 3/4 387 500 l 7/8 518 650 1 725 1320 l . 1 1/4 - 2620 1 1/2 - 4565 1 i l i l I l ? I l O 1
i Attachment 6.6
, 0I-046 Rev. 2 b
SUPPLEMENTAL REMARKS VERIFICATION PACKAGE NO. R-S-STEL-ATTRIBUTE (NO./ DESCRIPTION) REMARKS O i O Inspector Date I
+. - .- .
4 e i
~. Attachmsnt 6.7
_, QI-046 s' Rev. 2 Page 1 of 1 p, INSPECTOR QUALIFICATIO!i PROCEDURES
-()
Hilti Inspections: , Prior to 12/13/79: TUGC0 Instruction QI-QP-11.2-3 " Torquing and Spacing of Concrete Anchor Bolts" ' or TUCCO Instruction QI-QP-11.2-4 " Inspection o "Hilti" Super Kwik Bolts" After 12/13/79* but before 12/16/83: TUGC0 Instruction QI-QP-11.2-3 or TUGC0 Instruction QI-QP-11.2-4 or TUGC0 Instruction QI-QP-11.2-1 " Installation of ";{ilti" Drilled-in Bolts" After 12/16/83*: TUGC0 Instruction QI-QP-11.2-1 Structural Bolting: TUGC0 Instruction QI-QP-11.14-1 " Inspection of Site Fat rication and Installation of Structural and Miscellaneous Steel" O Welding (Weld Inspection Documentation Card): Prior to 1/20/84: TUGC0 Instruction QI-QP-11.4-3 " Inspection of Structural / Miscellaneous Steel Welding" After 1/20/84*: TUGC0 Instruction QI-QP-11.21-1 " Requirements for Visual Weld Inspection" Material Requisition: TUGC0 Instruction QI-QP-11.14-4 " Control and Traceability for Site Fabricated Structural / Miscellaneous Steel" or TUGC0 Procedure CP-QP-8.0 " Receiving Inspection" Structural Assembly Verification Card (SAVC): TUGC0 Instruction QI-QP-11.14-1 " Inspection of Site Fabrication and Installation of Structural and Miscellaneous Steel" O
- Inclusive l
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