ML20202J604

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Rev 1 to Quality Instruction QI-048, Documentation Review of Tubing Welds/Matl
ML20202J604
Person / Time
Site: Comanche Peak  Luminant icon.png
Issue date: 05/09/1986
From: Bajada E, Hansel J, Patterson A
EVALUATION RESEARCH CORP.
To:
Shared Package
ML20202J051 List: ... further results
References
QI-048-02, QI-48-2, NUDOCS 8607170112
Download: ML20202J604 (15)
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EVALUATION RESEARCH CORPORATION C0bTR0 RED b i C pTR6 d S M i

COMANCHE PEAK RESPONSE! TEAM QUALITY INSTRUCTION FOR ISSUE-SPECIFIC ACTION PLAN VII.c PROCEDURE NO: QI-048 REVISION NO:

1 ISSUE DATE: 05/09/86 DOCUMENTATION REVIEW OF TUBING WELDS / MATERIAL O

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QI-048 Rev. 1 1.0 PURPOSE

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This instruction provides detailed instructions and guidance for performing a documentation review of Tubing Welds / Material.

2.0 APPLICABILITY This instruction is applicable to the documentation review of the visually reinspected samples selected from the Tubing Welds / Material population at Comanche Peak Unit 1 and Common, and Unit 2.

The population is described in the Population Description for Tubing Welds / Material, Reference 3.4.

3.0 REFERENCES

3.1 QA/QC-RT-1583, Description Memorandum for Documentation Review of Tubing Welds / Material, dated April 1, 1986, J. Schauf to A.

Patterson.

3.2 QI-070, " Reinspection of Tubing Welds / Material".

3.3 CPP-009, " Performance of Reinspections and Documentation; Review.

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3.4 " Population Description for Tubing Welds / Material".

3.5 QA/QC-RT-1952, Description Memorandum for Documentation Review of Tubing Welds / Material, dated May 8, 1986, J. Schauf to A.

Patterson.

4.0 GENERAL 4.1 Responsibilities 4.1.1 QA/QC Discipline Engineer The QA/QC Discipline Engineer prepares the documentation review instructions and checklist delineating the document review requirements, attributes and accept / reject criteria, i

4.1.2 QA/QC Inspectors QA/QC Inspectors perform and document the reviews in accordance with established project procedures and

. instructions. Reference 3.3 addresses the method used 4

to perform documentation reviews and to document and j

process the results.

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QI-048 Rsv. 1 4.0 GENERAL (Cont'd) 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.

4.3 Definitions None 5.0 INSTRUCTIONS Use the information contained herein to perform the documentation review of the sample items in this population and document the results on the checklist (Attachment 6.1).

Record any additional remarks, on the Supplemental Remarks Form,.2.

Documentation review data shall be recorded on the Data Recording Form, Attachment 6.3.

Obtain the applicable Weld Data Package. These packages are filed by isometric drawing number, weld number and/or spool piece number.

Weld Data Packages for Unit 1 and Common systems, which have been

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('j' turned over to TUGCO, are located in the TUGC0 permanent plant records vault. All other packages for Unit 1 may be found in the Brown & Root permanent plant records vault (PPRV).

NOTE:

Systems which have been turned over to TUGC0 are the Auxiliary Feedwater (FW), Boron Recycle (BR),

Compressed Air (CA), and the Component Cooling Water (CC) Systems.

Weld Data Packages for Unit 2 may be found in the Brown & Root Interim Record Vault (IRV).

1.

Weld Procedure Application Identify the fc11owing item: from the Weld Data Package:

The Brown & Root Weld Procedure Specification (WPS) number specified on the Weld Data Card (WDC), the Weld Filler Material Log (WFML) and/or the Repair Process Sheet (RPS).

(In certain cases, a WFML was replaced by the " Weld Filler Metal Used" section of the weld data card.)

Both base materials being joined. Materials are specified on the Manufacturing Record Sheet (MRS),

and/or WDC. The MRS is contained in the spool package l

{,, T for the base material. The spools are listed on the WDC.

l 3

i QI-048 Rsv. 1 5.0 INSTRUCTIONS (Cont'd) 1.

Weld Procedure Application (Cont'd) i Weld filler material used to make the joint which is specified on the WDC and/or WFML.

Note:

On the WFML the weld filler material used is specified in the third column (size / class)

Obtain the Brown & Root Welding Procedure Specification, identified above, and verify, by review, that both the base materials and the weld filler metal specified in the Weld Data Package are the same as that specified in the welding procedure.

Note: 1 The Welding Procedure Specification identifies the base materials by P Nos. Use the following table to cross-reference the P No. with the corresponding material designation.

Note: 2 Materials for tubing and fittings are sometimes identified by their ASTM designation. These may be, for example, A213 Type 304, A479-76 Type 304, etc.The

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number -76 signifies the year (1976) and it is not part of the material designation.

ASME IX Designation Material Designation P No.

SA 213 Grade type 304 8

A 213 Grade type 304 SA 213 Grade type 316 l

SA 403 WP 316 l

A 479 Grade type 304 i

l 43 SB 166 2.

Base Material Traceability This attribute is applicable to both base materials of each welded joint. The inspector shall record on the Data Recording Form, Attachment 6.3, his findings for each base material.

Incore Detector Tubing / Couplings / Nozzles When the base material traceability (heat / lot number) was O

recorded at reinspection on the Data Recording Form (QI-070,.4), the inspector shall verify by review, the following:

4

QI-048 R2v. 1

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5.0 INSTRUCTIONS (Cont'd) 2.

Base Material Traceability (Cont'd)

That the recorded information for the base material is the same heat / lot number as that listed on the MRS, when available, and/or the WDC.

( See NOTE 1.)

l That the recorded information is traceable back to a material manufacturers Certified Material Test Report (CMTR) and/or the Certificate of Compliance (C of C)

(as defined by ASME III). These documents are available in the Receiving Inspection Report (RIR).

(See NOTE 2).

That the base materials size (see Note 3), material specification, grade, and ASME Code Class, certified in the CMTR and/or the C of C is the same as that required by the isometric drawing and/or the MRS, when available.

When no information was recorded at reinspection on the Data Recording Form (QI-070, Attachment 6.4), the inspector shall verify by review, the following:

That the base material heat / lot number listed on the I gs)

MRS, when available, is traceable to a CMTR and/or C of I

(

i C.

These documents are available in the RIR (See Notes l

1 and 2).

That the base materials size (See Note 3), material specification, grade and ASME Code Class listed on the isometric drawing, the MRS bill of materials, when available, and the CMTR and/or the C of C are the same. l Tubing and Fittings other than Incore Detector Tubing and Fitting l

l When the base material traceability (color coding and/or heat /let number) was recorded at reinspection on the Data Recording Form (QI-070, Attachment 6.4), the inspector shall verify by review, the following:

That the recorded information for the base materials has the same color coding, and/or heat / lot number as that listed on the MRS, when available, and/or the WDC. l (See NOTE 4).

For Tubing only, that the recorded information is traceable back to a CMTR and/or C of C.

These documents are available in the Receiving Inspection l

Report (RIR).

(See NOTE 5).

In the case where multiple heat numbers are given for a single color code l

(e.g., 3/8", green), the inspector shall verify traceability using both heat numbers, i

5

QI-048 Rsv. 1 l

5.0 INSTRUCTIONS (Cont'd)

O 1

2.

Base Material Traceability (Cont'd)

For fittings, that the recorded information and the material heat / lot number listed on the MRS, when available, and/or WDC is identified as "316" and "Caj on"/"Swagelok" or "316" and "C".

Fittings are not identified by specific heat numbers. A CMTR and/or C of C is not required to be verified for fittings / couplings.

That the base materials size (see NOTE 6), material specification, grade, and ASME Code Class listed on the isometric drawings, the MRS bill of materials (when l

available), and CMTR/C of C (for tubing only) are the same.

For tube fittings, verify that the same diameter fitting is specified on the MRS (when available) and isometrics drawing. In addition, verify that the bill i

of materials for the applicable piece (s) (i.e., size, etc) on the MRS, when available, has been signed / initialed and dated by the QC inspector.

When no information was recorded at reinspection on the Data Recording Form (QI-070, Attachment 6.4), the inspector shall verify by review, the following:

l For tubing only, that the base material heat / lot number listed on the MRS is traceable to a CMTR and/or C of C l

(see Note 4).

In the case where multiple heat numbers are given for a single color code (e.g., 3/8", green) the inspector shall verify traceability using both heat numbers.

For fittings only, that the base material heat / lot number listed on the MRS, when available, is identified j as "316" and " Cajon"/"Swagelok" or "316" and "C".

I That the base material size, (see Note 6), material specification, grade and ASME Code Class listed on the isometric drawing, the MRS bill of materials, when

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available, and CMTR/C of C (for tubing only) are the same.

For tube fittings, verify that the same diameter fitting is specified on the MRS (when available) and isometrics drawing.

In addition, verify that the bill of materials for the applicable piece (s) (i.e., size, etc) on the MRS, when available, has been signed / initialed and dated by the QC inspector.

6

QI-048 Rsv. 1 5.0 INSTRUCTIONS (Cont'd) 2.

Base Material Traceability (Cont'd)

NOTE 1:

For Incore Detector Tubing identified by line identification numbers, e.g., TBX-11-G-5, the corresponding heat numbers may be obtained by reviewing the Westinghouse Quality Assurance Inspection Instructions and Data Sheets which are located in the TUGC0 Vault. Reference Westinghouse documents QRf34629/P.O.263681 for Unit I and QR 43316/P.O. 263682 for Unit 2.

NOTE 2:

For Incore Detector Tubing identified by heat / lot numb.er on the MRS, when available, the RIR may be retrieved from the TUGC0 vault by using the following Westinghouse document numbers:

Unit 1 - QRf35376 P.O. #249801 Unit 2 - QRf33731 P.O. #249802 The RIR for the Incore Detector couplings may be retrieved from the PPRV by using the heat number.

7s The RIR for the Incore Detector nozzles may be r

retrieved from the TUGC0 Vault by using the following Westinghouse document numbers:

Unit 1 - QR# 29193; P.O. #172236 and Westinghouse Material Ident. Vessel Dwg.

11773-161-001 i

Unit 2 - QR# 38939; P.O. #172246 and Westinghouse Material Ident. Vessel Dwg.

10773-161-001 NOTE 3:

Verify that the tubing is 3/4" nominal special tubing (.99" OD) with wall thickness.240" and couplings are 3/4" nominal with wall thickness of

.378" or certified to the dimensions of Westinghouse drawing #501B510.

Nozzles size is not required to be verified since they are furnished as part of the reactor vessel.

NOTE 4:

For color coded tubing, use drawing TNE-11-0075 (Instrument Tubing Color Code / Heat No. Reference Table, Attachment 6.4) to cross reference the

/~~'s recorded color with the heat number for the

\\s /

corresponding tube size.

l l

7

QI-048 Rav. 1 5.0 INSTRUCTIONS (Cont'd) 2.

Base Material Traceability (Cont'd)

NOTE 5:

For tubing the RIR may be retrieved from the Permanent Plant Records Vault (PPRV) by using the heat / lot number listed on the MRS and/or the WDC.

NOTE 6:

Verify that the same tubing diameter is specified on the MRS and the isometric drawing and that the CMTR/C of C specifies the same tube diameter and wall thickness as that on drawing TNE-Il-0075 for the corresponding heat / lot number.

I 3.

Weld Material Traceability P

Verify that the Serial No., Weld No., and the Drawing No., on the WFML and the RPS (when applicable) are the same as that on the WDC.

When the welder's symbol is recorded at reinspection on the Data Recording Form (QI-070, Attachment 6.4),

verify that it matches the welder's symbol on the WFML or WDC.

Verify that the filler material classification on the (V)

WFML (when available) is the same as that shown on the 1

WDC.

Verify that the weld filler material classification (s) and heat / lot number (s) indicated on the WFML or the Filler Material Used section of the WDC are traceable back to a CMTR and/or C of C.

These documents may be obtained from the RIR in the PPRV by using the corresponding heat / lot number (s).

4.

Weld Procedure Qualification Verify, by review, that the letter of approval from Gibbs and Hill or TUSI for the applicable B&R qualified welding l

l procedure is on file. Normally, this letter is filed with the procedures.

5.

Welder Qualifications Obtain the unique welder's symbol from the WFML. Check the

" Welder Performance Qualification Record Standard Tests" effective at the time of the welding (use the issuance date of the weld filler material on the WFML) to obtain the tests the welder is qualified for.

For situations where the WFML has been replaced by a " Weld Filler Metal Used" section on the WDC, it may be necessary to determine the date the weld filler metal was issued by obtaining the Weld Material Requisition s.,

(WMR) from the TUGC0 vault using the WMR number on the WDC.

8

QI-048 Rsv. 1 i

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5.0 INSTRUCTIONS (Cont'd)

%J 5.

Walder Qualifications (Cont'd)

Verify by reviewing the " Welder Qualification Matrix", that the welder was qualified by the proper test (s) required by the Welding Procedure used.

Note: Be certain to read all applicable notes on the matrix.

6.

Hold Points Verify, by review, the following:

That when purging is required by the isometric drawing (FSI), it is included as a hold point on the WDC.

That the checked QC hold points on the Weld Data Card (WDC) were signed / initialed and dated by the QC Inspector as satisfactory (SAT).

In the case, where a hold point in the WDC is identified as unsatisfactory (UNSAT), verify that a Repair Process Sheet (RPS) is in the package and that the checked QC hold points were signed / initialed and dated by the QC Inspector as satisfactory.

7.

Inspector Certification Verify, by review, that the QA/QC Inspector (s) who initialed / signed and' dated the inspection results on the Feld Data Card, the RPS (when applicable), the NDE report (s), and the MRS (when available) were certified at the time the inspection was performed. To accomplish this, check the Monthly Mechanical and NDE Certification Report effective at I

the time of the inspection or the inspectors certification records as follows:

The Inspector's area or category of certification is QC Level II as a minimum, for Visual Welding Inspection (VT) or the appropriate htE as applicable.

Inspector's date of certification was prior to the date of the inspections performed, and inspections were performed prior to certification expiration date.

l NOTE:

If this attribute is rejected, determine if the person that signed as a QC Inspector was l

ever certified in the appropriate area or category.

If the inspector was certified, l

record the time period of certification, otherwise state that the person was never certified.

I 9

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QI-048 Rav. 1 6.0 ATTACHMENTS 6.1 Comanche Peak Response Team Checklist 6.2 Supplemental Remarks Form 6.3 Data Recording Form 6.4 Instrument Tubing Color Code / Heat No. Reference Table O

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t Attachmtnt 6.1 COMANCHE PEAK RESPONSE TEAM QI-048 CHECKLIST Rev. 1 POPULATION DESC VERIFICATION PKG NO.

Tubing Welds / Material R-M-TUWM-PAGE 1 0F 1 QUALITY INSTRUCTION QI-048

] REINSPECTION UNIT 1 EQUIPMENT MARK / TAG NO.

]DOCUMENTATIONREVIEW UNIT 2 O couxon VERIFICATION

^

ACCEPT REJECT DATE

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1. Weld Procedure Application i
2. Base Material Traceability
3. Weld Material Traceability
4. Weld Procedure Qualification
5. Welder Qualifications
6. Hold Points l
7. Inspector Certification PREPARED BY:

APPROVED BY:

O DISCIPLINE ENGR.

DATE LEAD DISCIPLINE ENGR.

DATE INSPEc1m BY:

APPROVED BY:

INSFECTOR DATE LEAD INSPECTOR DATE CP-007. LA, Revision 0 l

l

Attachmant 6.2 QI-048 j

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

R-M-TUWM-ATTRIBUTE (No./ Description)

REMARKS 1

}

I INSPECTOR DATE

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

'.3 QI-048 Rev. 1 Page 1 of 2 N/

DATA RECORDING FORM TUBING WELD / MATERIAL Verification Package No.

R-M-TUWM-Equipment Mark / Tag No.

i ATTRIBUTE DATA

1. Weld Procedure Application
  • B&R Weld Procedure Specification No./Rev./

Interim Change Notice

  • Base Materials from MRS and/or WDC l
  • Weld Filler Material from WDC and/or WFML
2. Base Material Piece 1 Piece 2 Traceability
  • Identification / Color Code or Heat / Lot Number
  • Recorded Per QI-070
  • WC l
  • Receiving Inspection l

Report (RIR) No, i

  • RIR (Vault / Location)

I

  • Base material size, j

spec., grade, ASME a

Code Class.

  • Isometric
  • MS
  • CMTR/C of C

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Attachmsnt 6.3 QI-048 Rev. 1

'l DATA RECORDING FORM TUBING WELD / MATERIAL (Cont'd) 4 Verification Package No.

R-M-TUWM-Equipment Mark / Tag No.

ATTRIBUTE DATA 3.

Weld Material Traceability

  • Heat / Lot Number from WFML l

or WDC r

WFML WDC O

  • Welders Symbol Recorded:

)

Per QI-070 WFML/WDC

  • Filler Metal from:

RIR (Vault / Location)

WFML WDC

5. Welder Qualifications
  • Tests welder is qualified for 6.

Hold Points

Identify type of Weld Repair (i.e.,

cosmetic, etc.)

Inspector Date 2

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