Text

Rev 1 to Quality Instruction QI-040, Documentation Review of HVAC Ducts & Plenums
	ML20202J608
Person / Time
Site:	Comanche Peak
Issue date:	02/20/1986
From:	Bajada E, Hansel J, Patterson A; EVALUATION RESEARCH CORP.
To:	;
Shared Package
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References
	QI-040, QI-40, NUDOCS 8607170113
	Download: ML20202J608 (21)
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T Peg 2 1 of 10 O EVALUATION RESEARCH CORPORATION CONTROL D C03Y CONTROL HO_ OFei -

COMANCHE PEAK RESPONSE TEAM QUALITY INSTRUCTION FOR SPECIFIC ACTION PLAN VII.c INSTRUCTION NO: QI-040 REVISION NO: 1 ISSUE DATE: 02/20/86

. O DOCUMENTATION REVIEW OF HVAC DUCTS L'D PLENUMS i

Prepared by: 9 Date: IneS. \t 19 7(o QA/QC Discipline Enkineer Approved by: 2/6 M / [s b . Date: t[/N((

Issue Coordinator Approved by: d./ bas' erd,, Date: d!/ 9 /.P/,

On-SiteQARepresenptive Approved by: Date: k' f 'd QA/ teview Team Leader O

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B607170113 860711 PDR ADOCK 05000445 PDR

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l. QI-040 Rsv. 1 1.0 PURPOSE This instruction provides instructions and accept / reject criteria l for the documentation review of sample items of HVAC Ducts and Plenums.

2.0 APPLICABILITY This instruction is applicable to the documentation review of the l visual reinspected samples selected from the population HVAC Ducts and Plenuas, reference 3.3, at Comanche Peak Unit I and conunon, and Unit 2. The population is described in the Population Description for HVAC Ducts and Plenums.

3.0 REFERENCES

3.1 Description Memorandum for Documentation Review of HVAC Ducts and Plenues, QA/QC-RT-859, dated November 7, 1985 J. Schauf to A. Patterson.

3.2 CPP-009, " Performance of Reinspection and Documentation Reviews."

3.3 QI-039, " Reinspection of HVAC Ducts and Plenums." ,

4.0 GENERAL 4.1 Responsibilities QA/QC inspectors perform documentation reviews in accordance with established CPRT project procedures and instructions.

This instruction establishes the attributes and accept / reject criteria for the documentation review of HVAC ducts and plenums. Reference 3.2 addresses the method used to perform documentation reviews, and to document and process'the results.

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 VII.c.

5.0 INSTRUCTION l

This section provides instructions for performing a documentation review on HVAC duct and plenum components. Verif'. cation of the attributes to be reviewed will be recorded on the Comanche Peak Response Team Checklists, Attachments 6.1, 6.2, 6.3, and 6.4.

Note that alphanumerics before each attribute corresponds to the checklist attribute number.

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QI-040

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Rzv. 1 g-~ 5.0 INSTRUCTION (Cont'd)

V) The Bahnson Service Company, BSC, prepared and executed all documentation regarding this review. All documentation is located at BSC's onsite QC records facility. Unit I and common documentation is also available at the site Permanent Plant Records Vault (PPRV) .

1. Pressure Test 1

5 Verify that a pressure test was performed on she subsystem which the sample is a part of and that the te,t was witnessed by a QC representative. This is accomplisheu by verifying that form DLT-CPI-1 of the Duct Leak Testing Procedure has been i initialed or signed on the line assigned to "QC Witness".

, 2. Material Gage Verify that the gage of the material is in accordance with the requirements of either the Material Requisition Form, Duct Design Change Request (DDCR), Inspection Report or equivalent.

This is accomplished by verifying that a QC inspector has -

accepted the sample and has initialed and dated the applicable form identified above. In some cases the material gage may not be given on the same sheet as the inspector's initials. In this case, obtain the form which was used for the fabrication '

of the sample. Note that versions of procedure QCI-CPSES-002,

! O- Duct Fabrication Inspection Procedure, issued prior to May 22, 1978, did not include inspection of material gage. The inspector shall reject this attribute for QC initialing prior i to this date, note the date in the remarks column and make reference to a generic deviation report. Also note that verification of the material gage in accordance with BSC

- Ductwork Fabrication Procedure, DFP-TUSI-001, was accomplished

, under QI-039, Reinspection of HVAC Ducts and Plenums.

3. Turning Vane Installation l

f Verify that the turning vane has been installed and inspected.

l This is accomplished by verifying that a QC inspector has initialed'or signed and dated the Material Requisition form or

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equivalent.

4. Weld Procedure Application (Ducts and Flexible Connections) l Obtain "take-off" sheet filed by duct joint number, or i equivalent, found on the Material Requisition Form, or equivalent. Using the welder's initials and the date of welding specified on the "take-off" sheet obtain the Welder Material Issue (WMI) slip which is filed by date. ,

Note: the "take-off" sheet only specifies the welder's

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initials whereas the WMI may have the welder's name or

! initials.

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QI-040 Rsv. 1 5.0 INSTRUCTION (Cont'd)

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4. Weld Procedure Application (Cont'd)

From the WMI slip identify the welding procedure number and

, filler material classification. (If classification is not specified on the WMI use the heat number to obtain classification).

Obtain BSC welding procedure identified above. (Use revision effective at the time of welding).

Note that versions of procedure QCI-CPSES-002, Duct Fabrication Inspection Procedure, issued prior to May 22, 1978, did not include documentation of companion angle welding. The inspector shall reject this attribute for QC initialing prior to this date, note the date in the remarks column and make reference to a generic deviation report.

4.a Base Material Verify that the base material specified on the welding procedure covers the material used in production. The production material is as follows:

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Ducts and plenums: ASTM A526 or ASTM A527 Structural steel: ASTM A36 4.b Filler Metal Classification l Verify that the filler metal classification specified on the welding procedure is the same as that specified on the WMI slip or as obtained from the purchase order (for this documentation review, E70S-2, E70S-3, and j

E70S-6 shall be considered the same filler metal I classification).

( Weld Procedure Application (Plenums) 5.

Obtain Inspection Report (IR) for the plenum filed by plenum drawing number.

From the WMI slip which is referenced on the IR, identify the welding procedure number and weld filler material classifiestion used to make the joint (if classification is not specified on the WMI slip, use the heat number specified en the WMI to obtain the purchase order which specifies the classification).

Obtain BSC's welding procedure identified above (use revision l

j O effective at the time of welding).

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QI-040 Rsv. 1 5.0 INSTRUCTION (Cont'd)

5. Weld Procedure Application (Cont'd) 5.a Welding Procedure i Verify that the welding procedure referenced on the WMI is the same as that specified by the plenum drawing.

l 5.b Base Material Verify that the base material specified on the welding procedure covers the material used in production. The production material is as follows:

Ducts and plenums: ASTM A526 or ASTM A527 ,

Structural steel: ASTM A36 5.c Filler Metal Classification Verify that the filler metal classification specified -

l on the welding procedure is the same as that specified on the WMI slip or as obtained from the purchase order (for this documentation review, E70S-2, E70S-3, and E70S-6 shall be considered the same filler metal

classification).

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6. Welder Qualification Verify that the welder was qualified to the appropriate test at the time of welding. The appropriate test has the same number as the welding procedure (for this documentation review, qualification to BSC-12 procedure shall also qualify the welder j to BSC-11 procedure).

Obtain the welder's name or initials from the WMI slip,

Material Requisition Form or equivalent. Check the welder's i

log to verify that the welder was qualified to the appropriate test at the time of welding (use date specified on WMI slip) .

If the welder's log does not specify the effective dates of the 7

l welder's qualification to the required test, the inspector has two alternative methods for verifying that the welder's qualification had not lapsed.

1. The Material Control Weld Material Issuance Logs l

There are two logs, one for current and one for non-current welders, both filed by welders' names. Check the Material Issuance Log to verify that there has been no six month or longer period of time when a welder was not issued filler metal for the appropriate weld l

process. If there is no six month or greater lapse then the welder is considered qualified to that process l

at the time of welding.

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QI-040 Rev. I 5.0 INSTRUCTION (Cont'd) 1 6. Welder Qualification (Cont'd)

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2. WMI Slips

WMI slips shall be checked for the welder from the date of his or her most'recent applicable qualification prior to making the weld, up to the completion date of the sample's weld. Check the date and the weld

. material (wire or electrode) on the WMI. For the interim between the welder's qualification and the

completion of the sample's welding, ensure at least one WMI for the appropriate weld process is issued not less than once every six months for the welder.

If a WMI slip is issued not less than once every six months, then the welder is considered to have been qualified at the time of welding for that process.

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7. Inspectors' Certification Note: If one of the following attributes is rejected, determine if the person that signed as a QC Inspector was ever certified to perform the inspection. If the inspector was certified, record the time period of

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certification, otherwise state that the person was never certified.

i 7.a Welding

! Verify that the inspector who signed or initialed the welding inspection report for plenums or the Material Requisition Form or equivalent Form for ducts, was ,

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certified to QCI-CPSES-002, Duct Fabrication Inspection i Procedure and QCI-CPSES-011, Visual' Inspection of Welds. Note that QCI-CPSES-002, revision 3 does not

reference galvanizing. For the period of time revision 3 is in effect, see QCI-CPSES-011 for galvanizing inspection requirements. Also verify that the i inspector was certified to make the inspection at the l time the inspection was perforned by referring to the l form " Qualification Record" in the inspector's I certification file. The date of certification

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expiration is also on this form.

7.b Pressure Test Verify that the inspector who signed or initialed as witness to the Duct Leak Testing Procedure was l

certified to DFP-TUSI-006, Duct Leak Testing Procedure.

Also verify that the inspector was certified to witness the test at the time the test was performed by referring to the form " Qualification Record" in the j

inspector's certification file. The date of certification expiration is also on this form.

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QI-040

'Rav. 1 5.0 INSTRUCTION (Cont'd)

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7. Inspectors' Certification (Cont'd) 7.c Material Gage Verify that the inspector who initialed the Material Requisition Form, or equivalent, was certified to QCI-CPSES-002, Duct Fabrication Inspection Procedure. :

i Also verify that the inspector was certified to inspect the fabrication of the sample at the time the

inspection was performed by referring to the form

" Qualification Record" in the inspector's certification

file. The date of certification expiration is also on this form.

7.d Turning Vane Installation Verify that the inspector who initialed the Material

Requisition Form, or equivalent, for fabrication of the

! elbow was certified to QCI-CPSES-002, Duct Fabrication i Inspection Procedure. Also verify that the inspector -

i was certified to make the inspection at the time the 3

inspection was performed by referring to the form i " Qualification Record" in the inspector's certification .

l file. The date of certification expiration is also on

this form. ,

8. Material Traceability

I This section relates only to bulk receipt inspection of sheet metal ductwork, reinforcing and connecting angles and nuts and bolts. The documentation review is performed once and the i results apply to all samples within this population. These generic type inspections are assigned verification package numbers R-M-DUPL-150 for sheet metal, R-M-DUPL-151 for structural angles, and R-M-DUPL-152 for nuts and bolts.

Inspection checklists for these items are Attachments 6.2, 6.3 and 6.4 of this procedure respectively.

Sheet Metal Ductwork (see checklist Attachment 6.2)

1. Material Verify for each purchase order that the material received is in accordance with ASTM A526 or A 527. l This is accomplished by obtaining the BSC form, ;

Receiving Checklist for Q Material, for the particular purchase order and verifying the material received from the information found on that form. If sufficient information is not contained on this form, refer to the purchase order or an Inspection Report. I O This applies only to 10 through 18 gage material.

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QI-040 Rev. 1 5.0 INSTRUCTION (Cont'd) b 8. Material Traceability (Cont'd)

2. Certified Material Test Reports (CMTR) or Certification of Compliance (COC).

Verify for each purchase order that either a Certified Material Test Report or a Certificate of Compliance is on file.

3. Verify that the inspector who signed the Material Inspection Report, or equivalent, was certified to QCI-CPSES-004, Receiving Inspection and Identification.

Also verify that the inspector was certified at the time the report was prepared by referring to the form

" Qualification Record" in the inspector's certification file. The date of certification expiration is also on r this form.

t Structural Angles (see checklist Attachment 6.3)

1. Material

! ' Verify for each purchase order that the material received is in accordance with ASTM A36. This is

accomplished by obtaining the BSC form, Receiving

'O Checklist for Q Material, for the particular purchase order and verifying the material received from the

j. information found on that form. If aufficient

information is not contained on this form, refer to the I purchase order or an Inspection Report. This applies i only to 1-1/2" x 1-1/2" x 3/16", 2" x 2" x 3/16", 2" x ,

2" x 1/4", 3"x 3"x 3/8", and 4"x 4"x 1/2" angles. l

2. Certified Material Test Reports or Certificates of l Compliance.

Verify for each purchase order that either a Cestified l Material Test Report or a Certificate of Compliance is on file.

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l 3. Verify that the inspector who signed the Material Inspection Report, or equivalent, was certified to QCI-CPSES-004, Receiving Inspection and Identification.

i Also verify that the inspector was certified at the

{ time the report was prepared by referring to the form l " Qualification Record" in the inspector's certification i file. The date of certification expiration is also on l

this form.

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7 QI-040 Rsv. I r-A 5.0 INSTRUCTION (Cont'd) l

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8. Material Traceability (Cont'd)

Nuts and Bolts (see checklist Attachment 6.4)

1. Material Verify for each purchase order that the nuts are in accordance with ASTM A563 and that the bolts are in accordance with ASTM A307. This is accomplished by obtaining the BSC form, Receiving Checklist for Q Material, for the particular purchase order and verifying the material received from the information found on that form. If sufficient information is not contained on this form, refer to the purchase order or an Inspection Report. This applies only to 5/16" nuts and 5/16" x 1-1/4" long bolts.

2. Certified Material Test Reports or Certificates of Compliance Verify for each purchase order that either a Certified Material Test Report or a Certificate of Compliance is on file.

3. Verify that the inspector who signed the Material N- Inspection Report, or equivalent, was certified to QCI-CPSES-004, Receiving Inspection and Identification.

Also verify that the inspector was certified at the time the report was prepared by referring to the form

" Qualification Record" in the inspector's certification file. The date of certification expiration is also on this form.

9. Welding Verify that welding has been inspected. This is accomplished by verifying that a QC inspector has initialed or signed and dated the Material Requisition Form or equivalent.

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10. Touch-Up Galvanizing Verify that galvanizing removed during the welding process and the weld have been touch-up painted. This is accomplished by verifying that a QC inspector has initialed or signed and dated j the Material Requisition Form or equivalent.

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QI-040 Rsv. 1 6.0 ATTACHMENTS 6.1 Comanche Peak Response Team Documentation Review Checklist 6.2 Comanche Peak Response Team Documentation Review Checklisc for Sheet Metal Material Traceability 6.3 Comanche Peak Response Team Documentation Review Checklist for Structural Angles Material Traceability 6.4 Comanche Peak Response Team Documentation Review Checklist for Nuts and Bolts Material Traceability l

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Attachmint 6.1

COMANCHE PEAK RESPONSE TEAM QI-040 CHECKLIST Rev. 1

() POPULATION DESC HVAC Ducts and Plenums VERIFICATILN PKG NO.

R-M-DUPL- PAGE 1 0F 2 QUALITY INSTRUCTION QI-040 () REINSPECTION ([] UNIT 1 EQUIPMENT MARK / TAG NO. DOCUMENTATION REVIEW UNIT 2 BSC Dwg. 2323-M BSC Subsystem

[)) COMMON VERIFICATION REMARKS ACCEPT REJECT DATE

1. Pressure Test

2. Material Gage

3. Turning Vane Installation .

4. Weld Procedure Application (Ducts and Flexible Connections)

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a. Base Material

b. Filler Metal Classification

5. Weld Procedure Application (Plenums)

a. Welding Procedure

b. Base Material

c. Filler Metal Classification l'

, PREPARED BY: APPROVED BY:

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

LNSPECTOR DATE LEAD INSPECTOR DATE CPP-007.1A. Revision 0

Attschment 6.1 COMANCHE PEAK RESPONSE TEAM QI-040 CHECKLIST Rev. 1

() POPULATION DESC HV.4C Ducts and Plenues VERIFICATION PKG NO.

R-M-DUPL- PAGE 2_ 0F 2 VERIFICATION REMARKS ACCEPT REJECT DATE

6. Welder Qualification

7. Inspector's Certification

a. Welding

b. Pressure Test

c. Material Gage

d. Turning Vane Installation

8. Material Traceability *

9. Welding

10. Touch-up Galvanizing 1

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Note: Material Traceabi1 Lty for s neet mets 1, structural angles and nuts and bolts i O are found in R-M-DUPL-150 (see che :klist At checklist Attachment 6.3) , and R-N-DUPL-15: (see checklist Attachment 6.4) tachment h.2), R-M-DUPL-151 (see

- respectively.

CPP-n07.1B, Revision 0

Attschment 6.2 COMANCHE PEAK RESPONSE TEAM 91_040 CHECKLIST Rev. 1 POPULATION DESC VERIFICATION PKG NO.

HVAC Ducts and Plenums R-M-DUPL-150 PAGE 1 0F 3 QUALITY INSTRUCTION C REINSPECTION UNIT 1 i QI-040 EQUIPMENT MARK / TAG NO. { DOCUMENTATION REVIEW UNIT 2 Sheet Metal Material Traceability COMMON VERIFICATION ACCEPT REMARKS REJECT DATE Purchase Order ,

Number:

1. Material

ML20202J608

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3.0 REFERENCES

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