ML20202J499

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Rev 2 to Quality Instruction QI-047, Reinsp of Small Bore Pipe Welds/Matl
ML20202J499
Person / Time
Site: Comanche Peak  
Issue date: 03/18/1986
From: Bajada E, Hansel J, Patterson A
EVALUATION RESEARCH CORP.
To:
Shared Package
ML20202J051 List: ... further results
References
QI-047-01, QI-47-1, NUDOCS 8607170093
Download: ML20202J499 (17)
v • d • e


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CONTROL NO DF*l EVALUATION RESEARCH CORPORATION COMANCHE PEAK RESPONSE TEAM QUALITY INSTRUCTION FOR ISSUE-SPECIFIC ACTION PLAN ISAP VII.c INSTRUCTION NO.: QI-047 REVISION NO.:

2 ISSUE DATE: 03/18/86 O

REINSPECTION OF SMALL BORE PIPE WELDS / MATERIAL Prepared by:

/w Date:

J//4/86 f

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Date:

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l Approved by: k/jdM// h

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IssueCoorpator '

1

.3[/f[8/,

Approved by:

. [.

(h/Mr Date:

On-Site QA Represent ive Approved by:

b Date: 3[ Ed QA/

eview Team Leader 8607170093 860711 PDR ADOCK 05000445 A

PDR

e QI-047 Rev. 2

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1.0 PURPOSE (V

This instruction provides detailed instructions and accept / reject criteria for performing reinspections of the Small Bore Pipe Welds / Material (SBWM) subset of the Pipe Welds / Material (PIWM) population, and is a subset instruction of the instruction for the Pipe Welds / Material (PIWM) population, Reference 3.4.

2.0 APPLICABILITY inis instruction shall be implemented for all safety related, construction complete, and QC accepted small bore pipe and mechanical equipment pressure boundary welds / material reinspections. The SBWM subset of the PIWM population is described in the Population Description for Pipe Welds / Material, Reference 3.3.

3.0 REFERENCES

3.1 Description Memorandum for Reinspection of Small Bore Piping and Instrument Tubing / Piping Welds / Material, QA/QC-RT-413, dated October 2, 1985, J. Schauf to A. Patterson.

3.2 CPP-009, " Performance of Reinspections and Documentation f-ss (v)

Review."

3.3 Population Description for Pipe Welds / Material.

3.4 Reinspection of Pipe Welds / Material, QI-050.

3.5 Description Memorandum for Reinspection of Small Bore Pipe Welds / Material, QA/QC-RT-1375, dated March 4, 1986, from J. Schauf to A. Patterson.

4.0 GENERAL Reinspections are performed and documented in accordance with established CPRT procedures pnd instructions. This instruction establishes the attributes and accept / reject criteria for reinspectiops of Small Bore Pipe Welds / Material. Reference 3.2 provides the instructions for performing, documenting and processing the results of the reinspections.

4.1 Responsibilities QA/QC Inspectors perform reinspections in accordance with established project procedures and instructions. Reference

(N 3.2 addresses the method used to perform reinspections and to

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document and process the results.

2

4 QI-047 Rev. 2 (Oj 4.0 GENERAL (Cont'd) 4.2 Policy Activities performed under this instruction shall conform to l

the policies contained in the latest Comanche Peak Response Team Program Plan and Issue-Specific Action Plan (s).

5.0 INSTRUCTION General Requirements Prior to the start of reinspection, assure that welds are clean of foreign material which would impede an adequate visual inspection. Paint will not be removed from pressure boundary welds.

Verification of reinspection attributes shall be recorded on the Comanche Peak Responce Team Checklist, Attachment 6.1.

Record deviation locations and dimensions, and any additional reinspection remarks, on the Supplemental Remarks Form,.7.

All required data for documentation review shall be recorded on the Data Recording Form, Attachment 6.6.

/T When it is necessary to measure weld dimensions or surface

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defects during the course of the reinspection, unless specified tolerances are provided, such dimensions should be determined as accurately as is practically achievable using standard inspection tools.

Record on Attachment 6.5, Reinspection Tools Used Form, the corresponding code of the reinspection tools used for inspecting each attribute, as applicable. Attachment 6.5 provides a list of standard reinspection tools and their corresponding codes.

1. Welds 1.A Configuration

~

~' Verify the type of weld configuration. For nominal pipe sizes of 2 inches and smaller the joint connection shall be a socket veld unless otherwise specified on the isometric drawing or associated design documents.

1.B Size and Profile Verify the weld size.

(

NOTE:1 Fillet and socket weld sizes must meet or exceed the minimum specified in Attachment 6.2, Table C of Attachment 6.3, and.4 (as applicable).

3

i QI-047 Rev. 2 A(,)

5.0 INSTRUCTION (Cont'd)

1. Welds (Cont'd)

NOTE:2 For butt welds, the size is verified by i

assuring that the joint is welded flush.

For weldolet and sockolet connection butt welds, verify that the weld tapers smoothly into the base metal.

NOTE:3 Unequal leg size convex fillet welds are acceptable, provided the smaller leg meets or exceeds the minimum specified size.

1 NOTE:4 For concave fillet welds the actual throat size must be equal to or greater than the theoretical throat size.

NOTE:5 Seal welds on threaded joints must have a minimum fillet weld size of 1/8", and exposed threads must be covered by the weld metal or removed entirely.

NOTE:6 For situations encountered other than those

above, consult engineering for supplemental b

instructions.

v 1.C Butt Weld Reinforcement Verify that the thickness of the reinforcement complies with Attachment 6.3 Table B for pumps and valves, and Table A for piping.

NOTE:

The surface of the reinforcement of all butt welded joints may be flush with the base j

material or may have uniform crowns.

1.D Radial Weld Shrinkage i

Verify that the amount of shrinkage does not exceed the following:

~

ASME Class I welds For pipe wall thickness of 3/4-inches and greater, the radial weld shrinkage shall not exceed 3/16-inches.

For pipe wall thicknesses below 3/4-inches, the radial weld shrinkage shall not exceed

/%

one-quarter of the wall thickness, see k,).4.

s 4

s QI-047 Rev. 2

(_-

5.0 INSTRUCTION (Cont'd)

1. Welds (Cont'd)

ASME Class 2 and 3 For pipe wall thickness of 3/8-inches and greater, the radial weld shrinkage shall not exceed 3/16-inches.

For pipe wall thicknesses below 3/8-inches, the radial weld shrinkage shall not exceed 1/2 (one-half) of the nominal wall thickness, see Attachment 6.4.

NOTE:

The amount of shrinkage shall be measured by the distance from the lowest point of shrinkage (at the toe of the weld) and the top of the base metal.

1.E Undercut Verify that the weld has no undercuts which exceed a depth greater than 1/32-inch (0.031) or 12.5% of the' " -

nominal wall thickness, whichever depth is less.

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)

Allowable depth of undercut defects are tabulated on

\\.8, Base Material and Undercut - Allowable Defect Depth Table.

1.F Surface of Welds Verify that the surface of welds are sufficiently free of overlap, abrupt ridges and ripples so that proper interpretation of radiographic and other required nondestructive examinations could have been performed.

l 1.G Cracks, Lack of Fusion, Crater Cracks Verify that the welds have no visible cracks, lack of fusion or crater cracks.

1.H ~' Weld Rust (Stainless Steel Only)

Verify that the weld has no rust colored corrosion product build-up which may be linear or localized.

Thin films of surface rust are acceptable.

NOTE:

The materials engineer will be available in the evaluation of weld rust acceptability.

1 1

5

. _ ~. _. -

=-

..=.

QI-047 Rev. 2 5.0 INSTRUCTION (Cont'd)

1. WELDS (Cont'd) 1.1 Welders ID Symbol Record welders ID symbol on Attachment 6.6 (Data Recording Form).

NOTE:

Record "Not Available" if the welders ID symbol is not marked.

l.J ID and Location Verify that the weld identification and location are j

per the drawing and applicable design documents.

NOTE:

No dimensional checks are required.

2.

Base Materials _

NOTE:

The reinspection shall be limited to within two (2) feet on both sides of the weld being j

reinspected or to the nearest weld, whichever,,,

distance is less, unless stated otherwise.

2.A.

Base Material Traceability Record the material heat number (pipe, valve, fittings, l

etc.), code or lot number, and/or any additional markings, (i.e., there may be a marking symbol or code which identifies the material), on Attachment 6.6 (Data l

Recording Form).

NOTE 1:

For non-insulated pipe, inspect the area on j

both sides of the reinspection weld up to the nearest weld.

NOTE 2:

Record "Not Available" if the material l

identification markings cannot be located or identified.

I

- - NOTE 3:

If the weld and base material are painted (coated), also record " painted" on Attachment i

6.6 (Data Recording Form).

)

2.B.

Base Material Defects i

Verify that the base material has no surface defects which exceed a depth greater than 1/32-inch (0.031) or

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12.5% of nominal wall thickness, whichever depth is less. Allowable depth of base material defects are tabulated on Attachment 6.8, Base Material and Undercut - Allowable Defect Depth Table.

6

e QI-047 Rev. 2 O(,)

5.0 INSTRUCTION (Cont'd)

2. Base Materials (Cont'd)

Surface defects consist of the following possible types: are strikes, grinding marks, pit marks, gouges and scratches, indentations, identification markings, etc.

2.C.

Base Material Rust (Stainless Steel only)

Verify that the base material has no rust colored corrosion product build-up which may be linear or localized. Thin films of surface rust are acceptable.

NOTE:

-The materials engineer will be available in the evaluation of base material rust acceptability.

6.0 ATTACHMENTS 6.1 Comanche Peak Response Team Checklist 6.2 Fillet and Socket Weld Dimensions

,s

\\- /

6.3 Weld Reinforcement Tables, and Concave Fillet Weld Minimum Theoretical Throat Size Table 6.4 Minimum Fillet Weld Sizes, and Pipe Sizes and Wall Thicknesses Tables 6.5 Reinspection Tools Used Form 6.6 Data Recording Form 6.7 Supplemental Remarks Form 6.8 Base Material and Undercut - Allowable Defect Depth Table O

7

i

..1 QI-047 Rev. 2 p

Page 1 of 2

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COMANCHE PEAK RESPONSE TEAM CHECKLIST POPULATION DESC VERITICATION PKG NO.

PIPE WELDS / MATERIALS I-M-SBWM-PAGE I 0F QUALITY INSTRUCTION (if-047 x REINSPECTION C UNIT 1 EQUIPMENT MARK / TAG NO.

C DOCUMENTATION REVIEW C UNIT 2 O co" Mon VERITICATION ACCEPT RZJECT DATE 1.

WELDS A. Configuration l

B.

Size & Profile C.

Butt Weld l

Reinforcement D.

Radial Weld l

Shrinkage

(

E.

Undercut F.

Surfaca of Walds l

G.

Cracks, Lack of l

Fusion, Czater Cracks 4

PRZIARED BT:

APPROVED BT:

i DISCIPLINE ENGR.

DATE LEAD DISCIPLINE ENGR.

DATE Laurzwar.u RT:

APPROVED BI:

k LN5 F EGOR DATE Lf.AD INSPECTOR DATE CPP-007.lA, Revision 0

=

Attachmsnt 6.1 QI-047 Rev. 2 O

I COM10 C*:E ?E.*Jt RE 7CN02 T7.X; CHECILIST POPULATION DESC VERIFICATION PKG NO.

PIPE WELDS / MATERIALS I-M-SBWM-FACE L OF L VERIFICATION RE'AtKS

[

ACCEPT REJECT DATE H.

Weld Rust l

(Stainless steel only)

I.

Welders ID Symbol N/A N/A Use Data Recording l

(not accept / reject Form, Attachment 6.6 attribute)

~ " - -

J.

ID snd Location O

2.

BASE MATERIALS A.

Base Material N/A N/A Use Data Recording l

Form, Attachment 6.6 Traceability (not accept /

l reject attribute) l B.

Base Material Defecta l

C.

Base Material Rust (Stainless steel only)

Av E?*hl'.'I.

' d *? ". J '. * ?.

)

..2 QI-047 Rev. 2 q

Page 1 of 1 FILLET AND SOCKET WELD DIMENSIONS SURFACE OF

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VERTICAL MEM8ERS CONCAVE g

CONVEX FILLET WELD FILLET SIZE OF WELD SURFACE OF

  • E'O

/

HORIZONTAL MEMBERS

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w THEORETICAL THROATW e--hZE OF EQUAL LEG FILLET WELD WELO NOTE: THE " SIZE OF AN EQUAL LEG FILLET WELD IS THE LENGTH OF THE LARGEST INSCRIBED RIGHT ISOSCELES TRIANGLE.~ THEORETICAL THROAT =0.7 s SIZE.

SURFACE CF VERTICAL MEMBERS

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CONVEX FILLET WELD FILLET Size OP SURFACE OF P

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HORIZONTAL MEM8ERS

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' 'G, WELO m

THEORETICAL THROAT UNEQUAL LEG FILLET WELD NOTE: FOR UNEQUAL LEG FILLET WELOS, THE SIZE OF THE WELD l$ THE LEG LENGTie OF THE,,

LARGEST MIGHT TRIANGLE WHICH CAN BE INSCRISED WITHIN THE FILLET WELD CROSS SECTIOR slZE OF FILLET WELDS g

-o

  • - X MIN.

{X MIN.(I i

sn murt>

f

-* *- 1/16 in. APPROX.

BEFORE WELDING SOCKET WELDING FLANGE t, = NOMINAL PIPE WALL THICKNESS X MIN. = 1.4 t, OR THICKNESS OF THE HUS.WH4CHEVER IS SMALLER QUT NOT LESS THAN 1.'8 in.

WELDtMG DETAIL 1 FOR SOCKET-WELDING FLANGES l

Is eW NCMINAL MPE l

WALL THICKNESS cx

r h

eX 1/16.n. APPROXIMATELY l

BEFORE WELDING

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l 0 V

c, MIN. = 1.09 t, BUT NOT LESS THAN 1/8 in.

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FILLET AND SOCKET WELD DIMENSIONS

-.~__.-

Attachmsnt 6.3 QI-047 Rev. 2

()

WELD REINFORCEMENT TABLES TABLE A (PIPING)

For double welded butt joints and single welded butt joints the reinforcement shown shall apply to the outside surface. The reinforcement shall be measured from the higher of the abutting surfaces involved.

Nominal Maximum Thickness Reinforcement Inches Inches Up to 1/8, incl.

3/32 Over 1/8 to 3/16, incl.

1/8 Over 3/16 to 1/2, incl.

5/32 Over 1/2 to 1, incl.

3/16 Over 1 to 2 incl.

1/4 TABLE B (PUMPS AND VALVES)

The height of reinforcement on each face of the weld shall not exceed

(

the thickness in the following table:

Section Thickness Maximum Allowable Inches Reinforcement Up to 1, incl.

3/32 Over 1 to 2, incl.

1/8 TABLE C CONCAVE FILITT WELD MINIMUM THEORETICAL THROAT SIZE i

Fillet Size (s)

Minimum Theoretical Throat 1/8" 0.088" (*3/32) 3/16" 0.133" (*5/32) 1/4" 0.177" (*3/16) 5/16" 0.221" (*1/4) 3/8" 0.265" (*9/32) 7/16" 0.309" (*5/16) 1/2" 0.354" (*3/8) 5/8" 0.442" (*15/32)

O 3/4" 0.530" (*17/32) 7/8" 0.617" (*S/8) 1" 0.707" (*23/32)

  • denotes conversion

..4 i

l MINIMUM FILLET WELD SIZES FOR ASME lil/

QI-047 Rn. 2 l

SOCMET WELDED PIPE FLANf4ES Page 1 M 1 DECIMAL 1 A.%

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..5 QI-047 Rev. 2

()s Page 1 of 2

(_,

REINSPECTION TOOLS USED FORM PIPE WELDS / MATERIAL VERIFICATION PACKAGE NO.

I-M-SBWM-ATTRIBUTE TOOL CODE SERIAL N0/ CALIBRATION DUE DATE

1. WELDS A. Configuration B. Size and Profile C. Butt Weld Reinforcement D. Radial Weld Shrinkage E. Undercut F. Surface of Welds

'~

G. Cracks, lack of Fusion Crater Cracks

,- s I\\-)

H. Weld Rust I. Welders ID Symbol J. ID and Location INSPECTOR DATE REINSPECTION TOOLS AND CODES CODE TOOL CODE TOOL AF ANGLE FINDER MM MIRROR BL BUBBLE LEVEL MN MAGNET BS BOROSCOPE PB PLUM BOB BW 1/32", 1/16", 3/32", 1/8" WIRE PR PROTRACTOR CG CONTOUR GAGE SC SLIDE CALIPER DF DRY FILM THICKNESS GAGE SR 6" RULE FG FEELER CAGES ST STEEL TAPE MEASURE Q

FL FLASHLIGHT TG TAPER CAGE

\\_,/

FM FIBRE METAL FILLET CAGES UD UNDERCUT CAGE (DIAL)

GG GAL FILLET GAGES UP UNDERCUT GAGE (PIT)

HL HI-LOW CAGE UT ULTRASONIC DIGITAL GAGE MG MAGNIFYING GLASS VC VERNIER CALIPER MI MICROMETERS VT VISUAL INSPECTION

m-

..5 QI-047 Rev. 2

/h Page 2 of 2

(,,)

REINSPECTION TOOLS USED FORM PIPE WELDS / MATERIAL VERIFICATION PACKAGE NO.

I-M-SBWM-ATTRIBUTE TOOL CODE SERIAL N0/ CALIBRATION DUE DATE

2. BASE MATERIAL A. Base Material Traceability B. Base Material Defects C. Base Material Rust i

I INSPECTOR DATE O

REINSPECTION TOOLS AND CODES CODE TOOL CODE TOOL AF ANGLE FINDER MM MIRROR BS BOROSCOPE MN MAGNET BL BUBBLE LEVEL PB PLUM BOB BW 1/32", 1/16", 3/32", 1/8" WIRE PR PROTRACTOR CG CONTOUR CAGE SC SLIDE CALIPER DF DRY FILM THICKNESS GAGE SR 6" RULE FG FEELER GAGES ST STEEL TAPE MEASURE FL FLASHLIGHT TG TAPER CAGE FM FIBRE METAL FILLET GAGES UD UNDERCUT GAGE (DIAL)

GG GAL FILLET GAGES UP UNDERCUT GAGE (PIT)

HL HI-LOW GAGE UT ULTRASONIC DIGITAL GAGE MG MAGNIFYING ptASS VC VERNIER CALIPER MI MICROMETERS VT VISUAL INSPECTION U

.-.-.,,-.-,....-,,--,-.-.m,.,

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

.,n-,.,,

Attachmsnt 6.6 QI-047 Rev. 2 l

DATA RECORDING FORM 1

PIPE WELDS / MATERIAL i

VERIFICATION PACKAGE NO.

I-M-SBWM-l ATTRIBUTE DATA i

I 1.

Welds I

I.

Welders ID symbol l

2.

Base Material 1

A.

Base Material Traceability.

(Heat number, code or lot number and or additional markings) i i

i e

4 4

INSPECTOR DATE

)

i i

a i

...7 QI-047 Rev. 2 O

Page 1 of 1 SUPPLEMENTAL REMARKS FORM PIPE WELDS / MATERIAL VERIFICATION PACKAGE NO.

I-M-SBWM-ATTRIBUTE (No./Dpseription)

REMARKS

  • M, O

O e INSPECTOR DATE

,.8 QI-047 Rev. 2 i

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