ML20202J512

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Rev 1 to Quality Instruction QI-036, Documentation Review of HVAC Duct Supports
ML20202J512
Person / Time
Site: Comanche Peak  Luminant icon.png
Issue date: 03/10/1986
From: Bajada E, Hansel J, Patterson A
EVALUATION RESEARCH CORP.
To:
Shared Package
ML20202J051 List: ... further results
References
QI-036, QI-36, NUDOCS 8607170095
Download: ML20202J512 (22)
v • d • e


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( EVALUATION RESEARCH CORPORATION C0 nD __ D CO?Y CONTROL NO.D=-ccr j COMANCHE PEAK RESPONSE TEAli QUALITY INSTRUCTION FOR ISSUE-SPECIFIC ACTION PLAN VII.c i

INSTRUCTION NO: QI-036 REVISION NO: 1 ISSUE DATE: 03/10/86 DOCUMENTATION REVIEW OF HVAC DUCT SUPPORTS Jl~ X _ Date: 6 Ih hcepared by _ Uf4

M [l Approved by: N -

804- Date: 37 Issue Coordinator Approved by: . d. .,*'

> o Date: .Y/b h4 On-Site QA Repres tative Approved by: ^% 8 Date: /d 8b Q )C Review Team Leader '

0607170095 860711 PDR A

ADOCK 05000445 PDR,

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QI-036 Rsv. 1 1.0 PURPOSE V This instruction describes the methods to be used and the l accept / reject criteria for the document review of HVAC Duct Supports.

2.0 APPLICABILITY The instruction applies to installed and final QC accepted HVAC l duct supports in Units 1, 2 and Common areas. The population is defined in the Population Description for HVAC Duct Supports.

3.0 REFERENCES

3.1 Memorandum QA/QC-RT-1012 to A. A. Patterson delineating l documentation used in development of this procedure including specific sources for attributes.

3.2 QI-035, "Re, inspection of HVAC Duct Supports".

3.3 CPP-009, " Performance of Reinspection and Document Reviews".

4.0 GENERAL 4.1 Responsibilities 4.1.1 QA/QC Discipline Engineers The QA/QC Discipline Engineers prepare the document review instructions and checklist delineating the document review requirements, attributes, and accept / reject criteria.

4.1.2 QA/QC Inspectors QA/QC Inspectors perform and document the reviews in accord with these instructions and Reference 3.3.

4.2 Policy 4.2.1 Activities performed under this instruction shall conform to the policies contained in the latest Comanche Peak Response Team Program Plan and Issue-Specific Action Plan VII.e.

5.0 INSTRUCTIONS Ceneral Using these instructions and information in " References" (Section 3.0), as applicable, the inspector shall perform a document review 2

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b QI-036 i 4

Rev. 1 l i

5.0 INSTRUCTIONS (Cont'd)

General (Cont'd) i of the sample items of this population and document the results on j-the Document Review Checklists-(Attachments 6.1 and 6.2) and r l- associated forms.

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Drawing Requirements 1 l

SA. ERC Reinspection Drawinas SA.1 Duct Support Detail Drawing Record the revision number of the referenced duct 4 support detail drawing filed in the Bahnson permar.ent ,

i plant file on the document review checklist. i 5A.2 Duct Support Location Plan (Layout) Drawing Rec 9rd the revision number of the referenced duct

support location plan (layout) drawing filed in the i Bahnson permanent plant file on the document review

! checklist.

Duct Support Inspection Reports - General

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i The inspector shall obtain the duct support inspection report. The insp.ection reports for duct supports in Unit 1 and common areas t

} will be found in the Brown & Root vault; the inspection reports for i duct supports in Unit 2 will be found in the offices of the Bahnson j Services Company, Quality Assurance Group. SEE NOTE NO. 1.

1 The inspector shall use the original of the inspection report to l perform the document review; however, it is acceptable to use a '

, copy if the original is not available. When a copy is used, the l inspector shall note this in " Supplementary Remarks" in the  ;

! document review package and state briefly, why a copy was used 1

(e.g., no origins 1 in the vault, etc.).

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If a duct support inspection report cannot be located, the inspector shall initiate a deviation report referencing all of the attributes which cannot be verified. Where the Brown & Root vault is missing a duct support inspection report, but that report is ,

located in the Bahnson file, it shall be noted on the document a

review checklist.

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' If more than one inspection report is located for a given duct support and some support attributes have been inspected and signed-off on each report, the combination of reports shall be '

acceptable provided all applicable support attributes have been inspected.

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3 QI-036 Rsv. 1 i 5.0 INSTRUCTIONS (Cont'd) '

O Duct Support Inspection Reports - General (Cont'd)

A deviation report shall be written for any applicable support-attribute which was not inspected.

SB -Duct Support Inspector Certification Verify,'by review of the Bahnson " Qualification Record" in the inspector's certification file, that the inspector (s) that signed the duct support inspection report was certified to the procedures listed below, as applicable, at the time the inspection was performed. SEE NOTE #2.

Verification that Bahnson inspectors were certified to duct '

support inspection procedure QCI-CPSES-003 shall be performed for all Bahnson inspectors who signed off attributes on '

inspection reports prior to 6/16/83. Bahnson inspectors shall  ;

have been certified to duct support procedure QCI-CPSES-014  :

for attributes signed off on inspection reports on and after  !

6/16/83.  ;

Verification that Bahnson inspectors were certified to inspection procedure QCI-CPSES-003 shall be performed for all  ;

Bahnson inspectors who signed off any of the anchor bolt '

and/or. Richmond Insert attributes on inspection reports prior Q to 4/3/81. Bahnson inspectors shall have been certified to inspection procedure QCI-CPSES-012 for anchor bolt and/or Richmond Insert attributes signed off on inspection reports on t and after 4/3/81. '

I Verification that Bahnson inspectors were certified to the I weld inspection procedure QCI-CPSES-011 shall be performed for Bahnson inspectors who signed off fit-up r,nd welding attributes (all dates). l Refer to Attachments 6.5 and 6.7 for examples of inspection reports.

Welding - General The inspector shall obtain a copy of the weld procedure that was applicable at the time of welding, from the Bahnson QA representative. The weld procedure number is listed on the Weld Material Issue (WHI) slip which is referenced on the duct support inspection report.  !

SC. Weld Procedure Application i

SC.1 Base Material O Verify that the base material specified in the welding procedure is the same as that of the parts being l joined. (SEE NOTE #3) 4

OI-036

, Rt.v. 1 5.0 INSTRUCTIONS (Cont'd)

SC. Weld Procedure Application (Cont'd)

SC.2 Filler Material Verify that the filler material classification specified in the welding procedure is the same as that specified on the WMI slip. (SEE NOTE #4)

SD. Welder Qualification Obtain the welder's name or initials from the Weld Material .

Issue slip (WHI) or Material Requisition Form (MRF).

Verify, by review of the Welder's Log, that the welder was qualified to the appropriate test at the time of welding (use the date specified on the WMI or MRF). The appropriate test has the same number as the welding procedure.  ;

If the welder's log does not specify the effective dates of the welder's qualification, the inspector shall verify that the welder's qualification had not lapsed by one of the following methods:

1) The " Material Control Weld Material Issuance Logs" There are two logs, one for current and one for non-current welders, both filed by welder's names.

Check the Material Control Weld Material Issuance Log to verify that there has been no six month or longer period of time when the welder was not issued filler material for the appropriate weld process.

2) WMI Slips WMI Slips shall be checked for the welder, from the date of his most recent qualification, to the date of the sample weld. Use the date and the weld material (wire or electrode) on the WMI. For the period between the welder's qualification and the completion of the sample weld, ensure that at least one WHI for the appropriate weld process is issued, not less than once every six months for that welder.

See Note #5.

SE. Weld Fit-up Inspection Verify that a weld fit-up inspection was performed:

For duct support inspection reports dated 7-22-80 or O after*, verify that " Fit-up" or " Hanger Fit-up" has been signed off.

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QI-036 R;v. 1 g 5.0 INSTRUCTIONS (Cont'd)

(V; SE. Weld Fit-up Inspection (Cont'd)

For duct support inspection reports dated before 7-22-80*, verify that weld fit-up has been added to the duct support inspection report and signed off.

  • The inspector shall use the date entered for fit-up or hanger fit-up attributes on the duct support inspection report.

Hilti Bolts - General l

After 04-02-81, Bahnson inspections of attributes SG.I. SG.2, 5H and 5J were performed on a surveillance basis. These attributes will be N/A'd by the engineers for those supports which were not inspected on a surveillance basis and "no surveillance" will be entered in remarks.

5.F Hitti Bolt Torque SF.1 Torque Wrench Number Verify that the torque wrench number is entered on the duct support inspection report.

5F.2 Torque Wrench Calibration Verify that the torque wrench was calibrated at the time of inspection. ( Note: The calibration due date may appear anywhere on the duct support inspection report provided it is identified as such.) Calibration shall be checked by review of the calibration record in the Brown & Root Calibration Lab.

5F.3 Torque Value Verify that the torque setting value is listed on the duct support inspection report and that it meets or exceeds the minimum torque value requirements shown in Attachment 6.6.

SG. Abandoned Holes Covered by Duct Support Members SG.1 Spacing Verify that the proper spacing between abandoned holes covered by duct support members and installed Hilti bolts was maintained. For duct support inspections that were performed before 4-03-81, this is done by checking that both " Anchor Bolt Hole" and " Anchor Bolt 6

QI-036

, -Rav. 1 5.0 INSTRUCTIONS (Cont'd)

SG. Abandoned Holes Covered by Duct Support Members (Cont'd)

Angle" are signed off on the duct support inspection report. For duct support inspections that were performed on or after 4-03-81, this is done by checking '

only that " Anchor Bolt Hole" is' signed off on the duct

support inspection report.

SG.2 Patching Verify that abandoned holes, covered by duct support j members, spaced less than or equal to four bolt i diameters from installed Hilti bolts have been properly

' filled and patched. For duct support inspections that were performed before 4-03-81, this is done by checking 1 that both " Anchor Bolt Hole" and " Anchor Bolt Angle" 1

are signed off on the duct support inspection report.

For duct support inspections that were performed on or after 4-03-81, the inspector shall look for an additional line item entered on the inspection report, t

that clearly shows that this inspection was performed.

5H. Cut Rebar

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I Verify that no rebar was cut during the drilling of holes for l Hilti bolts without the approval from Gibbs & Hill. For duct j support inspections that were performed before 4-03-81, this

is done by checking that both " Anchor Bolt Hole" and " Anchor '

j Bolt Angle" are signed off on the duct support inspection i report. For duct support inspections that were performed on j or after 4-03-81, this is done by checking only that " Anchor 3

Bolt Hole" is signed off on the duct support inspection report. .I l

SJ. Resetting of Hilti Bolts j Verify that holes for Hilti bolts that slipped, loosened or j pulled out during the setting of the bolt were properly i reworked to allow for adequate embedment in accord with the

construction procedure. For duct support inspections that <

I were performed before 4-20-81, this attribute shall be NA'd by '

the inspector and the Hilti inspection date entered in remarks. For duct support inspections that occurred on or 4 after 4-20-81, this is done by checking that " Anchor Bolt l Torque" has been signed off on the duct support inspection

! report.

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QI-036 Rev. 1

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5.0 INSTRUCTIONS (Cont'd)

' Materials SK. Material Traceability - General l

Traceability of materials used for safety related duct supports is not required after receipt inspection. Therefore, this attribute relates to only bulk receipt inspection of materials used in safety related duct supports. These are structural shapes (angle, channel, plate and tube steel) and nuts, bolts and washers. This document review will be performed once and the results will apply to all samples within this population.

This generic type inspection is assigned a unique verification package number (R-S-HVDS-200) with the inspection checklist shown in Attachment 6.2.

SK.1 Material Specifications Verify, for each purchase order, that the material received is in accord with the following:

ASTM A36 - angles, channels and plate steel ASTM A500 - tube steel (TS)

ASTM A307 - bolts ASTM A563 - nuts ASTM A325 - flat washers The inspector shall do this by reviewing the Bahnson

" Receiving Checklist for Q Material" for the applicable purchase order. (SEE NOTE #6) This attribute is rejected when a component type (e.g. , angle, bolts, etc.) is found on a purchase order with a material specification other than as specified above. All rejected items shall be listed on Attachment 6.8.

SK.2 Material Documentation Verify that a Certified Material Test Report (CMTR) or a Certificate of Compliance (C of C) is on file (for the materials listed in SK.1) for each purchase order reviewed. Inspectors shall make entries on Attachment 6.8 for material documentation, as applicable. (SEE NOTE #6)

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QI-036 Rsv. 1 NOTES:

L' 1. To obtain duct support inspection reports from the vault, the inspector must identify the turnover package number to vault personnel. To obtain the duct support inspection reports from Bahnson, the inspector must provide the Bahnson QA representative with the following information:

Duct support mark number The duct support location plan (layout) drawing number The turnover number These itens will be listed on Attachment 6.4, " Pertinent Duct Support Information". (Ref. Section 5.0, " Duct Support Inspection Reports").

2. If this attribute is rejected, the inspector shall determine if the QC inspector (s) who signed the inspection report were ever certified to the applicable procedure (s). If never certified, this shall be so noted in the remarks column. If certified at some time, but not at the time of inspection, the inspector shall record
the time period (s) of certification. Bahnson inspector's certification periods shall be obtained from the " Qualification Record" form in the Bahnson inspector's certification file. After

, 7/8/81, the certification period shall be three (3) years with the

, exception of inspectors certified after 3/11/82 and before 7/8/83.

The certificat: ion period between 3/12/82 and 7/7/83 (inclusive) shall be two (2) years.

3. Duct support materials are as follows: l plates, angle and channel members: ASTM-A36 tube steel  : ASTM-A500 t

sheet metal  : ASTM-A526 or A527 (Ref. Section SC.1)

4. If the filler material classification is not specified on the WI

, slip, it can be obtained from the heat number. Bahnson QA i

representatives are prepared to assist inspectors in obtaining this information. (Ref. Section SC.2)

5. The inspector shall perform a check to determine if the welder symbol (when recorded during the duct support reinspection) matches the welder listed on the WI slip. If they are different, the inspector shall evaluate the qualification of the welder to whom the symbol belongs (see Section SD). If the symbol connot be traced to a welder, the inspector shall note this on the document O

review checklist. (Ref. Section 5D.)

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i QI-036 Rav. 1 NOTES: (Cont'd) ,

6. The following items are exempt from the requirements of attributes l SK.1 and SK.2 where they appear on material purchase orders: ,

L 1 1/2" x 1 1/2" x 3/16" L 2" x 2" x 3/16" r L 2" x 2" x 1/4" l t

L 3" x 3" x 3/8" ,

5/16" x 1 1/4" bolts 5/16" dia nuts f sheet metal (Ref. Section 5K.1 and 5K.2)  ;

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' QI-036 Rav. I

! 6.0 LIST OF ATTACHMENTS i

6.1 Document Review Checklist (2 sheets)

', .6.2 Material Document Review Checklist (2 sheets) 6.3 Supplemental Remarks (1 sheet) i l '6.4 Pertinent Duct Support Information (1 sheet) i j 6.5 Duct Support Inspection Report Forms (Samples) (1 sheet) l 6.6 Hilti Bolt Torque Requirements (1 sheet) 6.7 Duct Support /Hilti Bolt Inspection Report Forms (Samples) l (2 sheets) f

)t 6.8 Duct Support Materials (1 sheet) i I

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  • Attachmint 6.1 COMANCHE PEAK RESPONSE TEAM 01-036 CHECKLIST Rev. 1

() POPULATION DESC HVAC DUCT SUPPORTS VERIFICATION PKG NO.

R-S-HVDS. PAGE 1 0F 2 QUALITY INSTRUCTION QI-036 () REINSPECTION ((] UNIT 1 EQUIPMENT MARK / TAG NO. @ DOCUMENTATION REVIEW UNIT 2

((] COMMON VERIFICATION

^ "

ACCEPT REJECT DATE 5A. ERC Reinspection NA NA For Information Only Drawings 5A.1 Duct Support Detail Drawing SA.2 Duct Support NA NA For Information Only Location Plan (Layout) Drawing

. SB. Dutt Support Inspector N- - Certifications SC. Weld Procedure Application SC.1 Base Material SC.2 Filler Material SD. Welder Qualification SE. Weld Fit-up Inspection PREPARED BY: APPROVED BY:

DISCIPLINE ENGR. DATE LEAD DISCIPLINE ENGR. DATE O INSPEGIED BY: APPROVED BY:

IN5FECTOR DATE LEAD INSPECTOR DATE CPP-007.lA. Rev.iaton 0 .

Attrchm;nt 6.1 COMANCHE PEAK RESPONSE TEAM QI-036 CHECKLIST Rev. 1 I ) POPULATION DESC VERIFICATION PKG NO.

~~#

HVAC DUCT SUPPORTS R-S-HVDS- PAGE 2 0F 2 VERIFICATION ACCEPT REJECT DATE REMARKS SF. Hilti Bolt Torque SF.1 Torque Wrench Number 5F.2 Torque Wrench Calibration SF.3 Torque Value SG. Abandoned Holes Covered by Duct Support Members SG.1 Bolt Spacing SG.2 Patching

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(,/ SH. Cut Rebar SJ. Resetting of Hilti Bolts I

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d CPP-007.lB. Revision 0

Attachmsnt 6.2 COMANCHE PEAK RESPONSE TEAM QI-036 CHECILIST Rev. 1 POPULATION DESC VERIFICATION PKG NO.

RVAC DUCT SUPPORTS R-S-HVDS-200 PAGE L OF 2 QUALITY INSTRUCTION QI-036 () REINSPECTION [}] UNIT 1 EQUIPMENT MARK / TAG NO. @ DOCUMENTATION REVIEW UNIT 2 DUCT SUPPORT MATERIAL TRACEABILITY ] COMMON VERIFICATION ACCEPT REJECT DATE REMARKS Furchase Order No.:

SK.1 Material Specification SK.2 CMrR or C of C

.. ..........-....--........------- --=====-- =====================================

f Purchase Order No.:

SK.1 Material Specification SK.2 CMTR or C of C

.---......--.... ..............--------------o-----.- --==========================

Purchase Order No.:

5K.1 Material Specification SK.2 CMTR or C of C

............=..............o-.---.... .......--o======o==============================

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! PREPARED BY: APPROVED BY:

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DISCIPLINE ENGR. DATE LEAD DISCIPLINE ENGR. DATE INSPELItu BY: APPROVED SY:

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( LNSFECTOR DATE LEAD INSPL ', TOR DATE C??-007.!A. Revision 0 i

  • AttachmInt 6.2 COMANCHE PEAK RESPONSE TEAM QI-036 CHECKLIST Rev. 1

) POPULATION DESC VERIFICATION PKG NO.

HVAC DUCT SUPPORTS R-S-HVDS-200 PAGE 2_ 0F 2 VERIFICATION ATTRIBUTE REMARKS ACCEPT REJECT DATE Purchase Order No.:

5K.1 Material Specification SK.2 CMTR or C of C

.......................... ......... ..................o .............................

Purchase Order No.:

SK.1 Material Specification w

SK.2 CMTR or C of C

.........................o........o........ .........o...............................

Purchase Order No.:

SK.1 Material Specification SK.2 CMTR or C of C

.........................o........o.................o...............................

Purchase Order No.:

SK.1 Material Specification ----

SK.2 CMTR or C of C --_- .

.........................o........ ..................o........................

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CPP-007.1B, Revision 0

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-l Attachsant 6.3 QI-036 .

Rev. 1 '

Page 1 of 1 SUPPLEMENTAL REMARKS ,

DOCUMENT REVIEW PACKAGE NO. R-S-HVDS-DUCT SUPPORT DETAIL DRAWING NO.

Attribute No./ Description Additional Remarks i

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l INSPECTOR DATE

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Attachesnt 6.4

. QI-036 Rev. 1 Ref. Note #1 Verification Pkg. No. R-S-HVDS- Page 1 of 1 PERTINENT DUCT SUPPORT INFORMATION

1. Drawing No.
2. Location Plan (layout) Drawing No.
3. Mark No. ,

! 4. Turn /Over Package No.

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i QA/QC Discipline Engineer Date

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l QI-036 Rev. 1  ;

Ref. Sec. 5F.2  !

HILTI BOLT TORQUE REQUIREMENTS Minimum Embedment 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 5/8 2 3/4 --

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& SK.2 O Page 1 of 1 DUCT SUPPORT MATERIALS VERIFICATION PACKAGE NO. R-S-HVDS-200 Documentation Purchase Material Hardware CofC CMTR None Remarks Order No. Specification Description O

i O

Inspector Date

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