ML20202J623
| ML20202J623 | |
| Person / Time | |
|---|---|
| Site: | Comanche Peak  |
| Issue date: | 01/29/1986 |
| From: | Hansel J, Patterson A, Ross G EVALUATION RESEARCH CORP. |
| To: | |
| Shared Package | |
| ML20202J051 | List:
|
| References | |
| QI-041, QI-41, NUDOCS 8607170115 | |
| Download: ML20202J623 (20) | |
Text
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EVALUATION RESEARCH CORPORATION COT 10.'.'.1) ce".,
CONTR01. NO or=_-cm COMANCHE PEAK RESPONSE TEAM QUALITY INSPECTION FOR ISSUE-SPECIFIC ACTION PLAN VII.c INSTRUCTION NO: QI-041 REVISION:
1 ISSUE DATE: 01/29/86 REINSPECTION OF FIELD FABRICATED TANKS Prepared by: % Y
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Approved by:
Date:
Incue Coordinator Approved by:
Dater
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On-Site QA Representative Approved by:
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Date:
/
Ifi QA C Review Team Leader
/
/
D607170115 060711 PDH ADOCK OD000445 h
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QI-041 REV. 1
/N Q
1.0 PURPOSE 1.1 The purpose of this instruction is to provide direction and accept / reject criteria to be applied when performing reinspection of Field Fabricated Tanks.
2.0 APPLICABILITY 2.1 This procedure applies to all Field Fabricated Tanks contained in the Field Fabricated Tank Population for Unit 1, Common and Unit 2 which are accessible for reinspection. The population is described in the Population Description for Field Fabricated Tanks.
3.0 REFERENCE 3 3.1 Description Memorandum for Reinspection of Field Fabricated Tanks (QA/QC-RT-371), dated September 11, 1985 J. Schauf to A. Patterson.
3.2 CPP-009, " Performance of Reinspection Documentation Review".
4.0 CENERAL
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4.1 Reinspections are performed and documented in accordance with established CPRT procedures and instructions. This instruction establishes the attributes and accept / reject criteria for reinspections of Field Fabricated Tanks.
Reference 3.2 provides the instructions for performing, documenting and processing the results of the reinspection.
4.2 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 Wherever the inspector takes measurements the tools utilized shall be identified on Attachment 6.6.
5.0 PROCEDURE NOTE: The number before each Attribute corresponds to the Checklist Attribute number.
1.
Name Plate Verify that thi nameplate contains the "N" and " Class 3" stamp and that the equipment number matches the number shown on the Cibbs & Hill location drawing.
O 2
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QI-041 REV. 1 AQ 5.0 PROCEDURE (Cont'd) 2.
Shell Top Angle Visually inspect to verify that the shell top angle has been installed in accordance with the nominal dimensions shown on the CBI drawings.
3.
Anchor Bolt Ring Visually inspect and verify that the anchor bolt ring is installed in accordanen with the nominal dimensions shown on the CBI drawings.
4.
Anchor Bolt Chaire Visually inspect to verify that the anchor bolt chai s are installed in accordance with the nominal dimensions st.own on the CBI drawings.
5.
Anchor Bolt Tiahtness verify that the Anchor Bolt Nut is sufficiently tightened so that it cannot be turned by hand.
6.
Out of Roundness A.
For the Flat Botton Tanks verify that the out of roundness does not exceed 1%. The out of roundness check shall be taken by measuring the inside diameter at four places taken six feet above the tank bottom.
The first measurement will be taken at the approximate N/S centerline and each subsequent measurement at 45' moving clockwise around the tank.
The difference between the maximum and minimum measurement shall not exceed 1% of the average diameter of the tank.
The QA/QC Inspector shall record all required Data and perform the necessary calculations as shown on attachment 6.5.
B.
For the Horizontal Tanks, verify that the out of roundness does not exceed 11 inches defined as follows:
The out of roundness check shall be taken by measuring the inside diameter at four places at a location 1/2 of the shell length measured from one end of the shell.
The first measurement will be taken at the horizontal centerline and each subsequent measurement at 45' moving clockwise around the tank. The difference between the maximum and minimum diameter shall not O
exceed 1 1/2 inches for horizontal tanks.
3
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QI-041 REV. 1 5.0 PROCEDURE (Cont'd) 6.
Out of Roundness (Cont'd)
The QA/QC Inspector shall record all required data and perform the necessary calculations as shown on attachment 6.5.
Note' For "B" above, Horizontal Tanks, one set of diameters meets the code requirement for checking the shell out-of-roundness. The inspector shall take additional sets of diameters if upon visua'.ly inspecting the shell, flat places or indentations are noted.
If this occurs, an additional set of diameters should be taken at the worst appearing point. The inspector must insure that a sufficient number of diameters are taken around the shell to insure accurate maximum and minimum readings.
In this case, four diameters would be the minimum acceptable.
7.
Longitudinal Weld Seas Of fsets f-Verify that all longitudinal weld seams are offset, 6 inches minimum from weld seams in adjacent course for flat bottom tanks, for horizontal tanks this shall be 5 5/8 inches.
8.
Bottos Plate Seam Offset Verify that a (3) plate lap joint is not closer than 12 inches from another (3) plate lap joint or from the tank shell.
9.
Nozzle Size and Type A.
Verify that the nozzle sizes are as shown on the CBI drawings.
B.
Verify that the nozzle type (welding end, flanged end, coupling, etc.) are as shos t on the CBI drawings.
10.
Nozzle Location Verify that the nozzles are located as shown on the CBI drawings for vertical placement only. The vertical tolerance is i 1 inch.
Note:
The nozzles to be checked will be marked on O
the CBI General Plan drawings included in the verification package.
4
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QI-041 REV. 1 5.0 PROCEDURE (Cont'd) 11.
Nozzle Insert Reinforcement Plate Verify that the correct nozzle insert plate (s) has been installed by measuring the nominal dimension shown on the CBI drawings.
12.
Nozzle and Manhole Reinforcing Pads Verify that the correct reinforcing pads have been installed bf measuring the nominal thickness and dimensions shown on the CBI drawings.
13.
Seismic Restraints A.
Verify that the seismic restraint is installed.
B.
Record on Attachment 6.7 the elevation of the seismic bracket. QA/QC Inspector shall note the location of this elevation i.e. top of bracket web.
Note:
This elevation will be used to verify this elevation in the documentation review.
(j C.
Verify that no weld exists attaching the tank seismic bracket to the wall embedded seismic restraint.
14.
Internal Pipe A.
Verify that the internal piping arrangement is the same as that shown on the CBI Drawings.
B.
Verify that the dimension between the bottom of the tank and the end of the pipe is as shown nn the CBI drawings. Read tape to nearest 1/8 inch.
15.
Welds Notes:
j.
Prior to the start of inspection assure that welds are clean of any foreign material which would impede an adequate visual inspection.
Coatings need not be removed unless an inspector feels that due to excessive and/or uneven coating application he is unable to provide an adequate inspection of the weld.
Then he shall contact the level III inspector and with his concurrence oniv then may the O
coating be remove.
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QI-041 REV. 1 7
5.0 PROCEDURE (Cont'd) 15.
Welds (Cont'd) jj. All necessary weld dimensions, to be measured during the course of an inspection, should be determined as accurately as is practically achievable using standard weld inspection tools. See attachment 6.6.
jjj. For each Tank, CBI's General Plan drawings j
showing the welds to be inspected will be included in the reinspection package.
A.
Confisuration Size and Profile Verify that the weld configuration (fillet field welds only) and location are the same as shown on the CB&I drawings.
Verify that the weld size and length meets or exceeds the minimum specified on the CBI drawings.
For bevel welds wi'.h back side inaccessible the size is verified by assuring that the joint is welded flush.
For Fillet Welds size and profile refer to.2 and Table A of Attachment 6.3.
Note Unequal leg size convex fillet welds are acceptable, provided the smaller les meets or exceeds the minimum specified size. For concave fillet welds with unequal legs the theoretical throat must be determined by the QA/QC Inspector.
B.
Butt Weld Reinforcement The surface of the reinforcement of all butt welded joints may be flush with base material or may have uniform crowns.
Verify that the thickness of the reinforcement complies with, Table A of Attachment 6.4.
C.
- Undercut, Verify that undercut does not exceed 1/32-inches.
O 6
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QI-041 REY. 1 5.0 PROCEDURE (Cont'd) 15.
Welds (Cont'd)
D.
Surfaces of Welds Verify that the surfaces 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.
E.
Offset of Butt Welds Verify that for butt welds the maximum offset of the finished weld is not greater than that specified in Table B of Attachment 6.3.
F.
Fairing of Offsets Verify that any offset within the allowable tolerances of Table B, Attachment 6.3 have been faired to at least a 3 to 1 taper over the width of the finished weld.
G.
Cracks Lack of Fusion and Crater Cracks Verify that the welds have no visible cracks, lack of fusion or crater cracks. Notes Refer to Section 15 Note J.
H.
Indications Verify that the welds have no indications which exceed the acceptt.nce standards of Table B,.4.
Refer to Section 15 Note j.
16.
Base Material A.
Material Identification When the base material identification (i.e.,
material specification, grade, heat number or heat code, marking symbol or code) is marked either side of the sample weld joint, record it on.8.
B.
Material Defects Record and map the location and depth of base material defects.When the base material has any defect (i.e., are strikes, grinding marks, pit marks, gouges, indentations, etc.) either side of l
the sample weld joint, inspect only the surface area within two (2) feet on either side of the weld joint being reinspected or the nearest weld joint whichever distance is less.
7
QI-041 REV. 1 5.0 PROCEDURE (Cont'd) 16.
Base Material (Cont'd)
Note:
The depth at which a defect becomes recordable will be defined in the Verification package Supplemental Inspection Procedures.
17.
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.
s Note:
The materials engineer will be avail:tble in the evaluation of weld rust acceptability.
18.
Material Rust (Stainless Steel Only)
Verify that the base material has no rust colored corrosion product build-up which may be linear or localised. Thin films of surface rust are acceptable.
Note:
The materials engineer will be available in the evaluation of base material rust Oi acceptability.
19.
Groutina Verify that the grout is installed.
6.0 ATTACHMENTS 6.1 Checklist 6.2 Fillet Weld Dimensions 6.3 Table A - Fillet Weld Site Table B - Maximus Allowable Offset In Final Welded Joints 6.4 Table A - Thickness of Wald Reinforcement for Vessels Table B - Indications 6.5 Tank Out of Roundness Record Sheet 6.6 Inspection Tool and Codes 6.7 Record of Seismic Bracket Elevations 6.8 Data Recording Form 8
T Attr.shment 6.1
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QI-041 COMANCHE FEAK RESPONSE TEAM Rev. 1 CEECELIST Page 1 of 3 Os ForutATION DE5C VERITICATION PKG NO.
Field Fabricated Tanks I-M-FFTA-PAGE 1 0F 3 QUALITY Di5imusuCN REINSPECTION C UNIT 1 QI-041 EQUIPMENT MARK / TAG NO.
DOCUMINTATION REVIEW UNIT 2 Colet0N VERIFICATION ACCEPT REJECT DATE 1.
Name Plate 2.
Shell Top Angle 3.
Anchor Bolt Ring 4.
Anchor Bolt Chaire 5.
Anchor Bolt Tightness 6.
Out of Roundness 7.
Longitudinal Wald Seen offsets 8.
Botton Plate Wald Sena Offset 9.
Nossie Sise and Type A. Sise B. Type
- 10. Nossle Location
- 11. Nossle Insert Reinforcement Plate
- 12. Nossle and Manhole Reinforcing Pads PRETARED BT APPROVED ST:
DISCIPLINE ENCR.
DATE LEAD OtSCIPLINE ENCR.
DATE LN3FELsw BY:
APPROVED SY LN3FELsuR DATE LEAD INSPECTOR DATE C?P-007.1A. Revision 0 5
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Att:chsenc 6.1 QI-041 COMANCHE PEAK RESPONSE TEAM Rey, t CHECELIST
(
FOPULATION DESC VERIFICATION PKG NO.
Field Fabricated Tanks I-M-FFTA-PACE _20F 3
VERIFICATION ACCEPT REJECT DATE
- 13. Seismic Restraint A. Installation B. Elevation C. Weld 14.
Internal Pipe A. Arrangement B. Dimensions
- 15. Welds A. Configuration Size and Profile O
B. Butt Wald Reinforcement C. Undercut D. Surfaces of Welds E. Offset of Butt Welds T. Fairing of Offsets C. Cracks Lack of Tusion and Crate?
Cracks H. Indications
- 16. Base Materials A. Material Identification B. Material Defects 4
CPP-007. L3. Advis ton 0
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Attr,shment 6.1
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COMANCHE PEAK RESPONSE TEAM CHECKLIST n
POPULATION DESC VERIFICATION PKG NO.
Field Fabricated Tanks I-M-FFTA-PACE _30F 3
VERIFICATION ACCEFT REJECT DATE
- 17. Wald Rust
- 18. Material Rust
- 19. Grout O
O 4
G??-001.43..tavision 0
Attachmsnt 6.2 QI-041 Rev. 1 Page 1 of 1
.i FILLET WELD DIMENSIONS e.
Snarfame of Vertises Menes' Sudess of vertmae Memeer Ceaues Piteet need Sies W p;g ye,eg M
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Attrchm:nt 6.3 QI-041 Rev. I Page 1 of 1 p
V TABLE A FILLET WELD SIZE 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) 3/4" 0.530" (*17/32) 7/8" 0.619" (*S/8) 1" 0.707" (*23/32)
- Denotes Conversion.
(NOTE:
If'the profile is concave, verify the minimum theoretical throat per the table below is attained.)
O TABLE B MAXIMUM ALLOWABLE OFFSET IN FINAL WELDED JOINTS Section Thickness (t)*
Direction of Joints in inches Longitudinal Circumferential Up to 1/2, Incl.
1/4e 1/4e Over 1/2 to 3/4 Incl.
1/8 in.
1/4t Over 3/4 to 1-1/2, Incl.
1/8 in.
3/16 in.
- t = nominal thickness of the thinner section at the joint.
(NOTE: Joints in 'sads and joints between cylindrical shells and hemispherical heads shall meet the requirements in TABLE B for longitudinal joints.)
Attcchment 6.4 QI-041 Rev. 1 Page 1 of.1 TABLE A (THICKNESS OF WELD REINFORCEMENT FOR VESSELS)
The height of reinforcement on each fa a of the weld shall not exceed the thickness in the following table:
Nominal Thickness Maximus Reinforcement Inches Inches Up to 1, Incl.
3/32 Over 1 to 2, Incl.
1/8 TABLE B (Indications) 1.
The following relevant indications are unacceptable:
f Rounded indications with dimensions greater than 3/16 in.;
a.
b.
Tour or more rounded indications in a line separated by 1/16 in. or less edge to edge; Ten or more rounded indications in any 6 sq. in. of surface c.
with the major dimension of thic area not to exceed 6 in, with the area taken in the most unfavorable location relative to the indications being evaluated.
2.
Indications with major dimensions greater than 1/16 in. shall be considered relevant.
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TANK OUT OF ROUNDNESS Attcchsent 6.5 RECORD SHEET QI-041 Rev. 1 C*
Page 1 of 1 4
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5 C' 170*
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Tank Names i
i Tank Number:
Dia #1 =
Sun Total Dia #2 =
Average Diameter =
4 Dia #3 =
Dia #4 -
Average Diameter =
Sun Total =
l Max Allowable Difference = (0.01) X
=
1%
Average Diameter (Max Measured Dia) - (Min Measured Dia) =
O DATE INSPECTOR
Attechm2nt 6.6 QI-041 Rev. 1 Page 1 of 3 INSPECTION TOOL AND CODES CODE TOOL AF Angle Finder BL Bubble Level BS Boroscope BW 1/32", 1/16" 3/32", 1/8" Wire CG Contour Gauge DF Dry Film Thickness Gage FG Feeler Gages FL Flashlight FM Fibre Metal Fillet Gages GG GAL Fillet Gages EL Hi-Low Gage MG Magnifying Glass MI Micrometers MM Mirror MN Magnet PE Plum Bob PR Protractor SC Slide Caliper SR 6" Rule ST Steel Tape Measure O
TG Taper Gage TW Torque. Wrench UD Undercut Gage (Dial)
UP Undercut Gage (Pit)
VC Vernier Caliper VT Visual Inspection O
attechnent 6.6 QI-041 Rev. 1 Page 2 of 3 O
I-M-FFTA-INSPECTION TOOLS USED Page 1 of 2 ATTRIBUTE TOOL CODE SERIAL NO./ CALIBRATION DATE
- 1. Name Plate
- 2. Shell Top Angle
- 3. Anchor Bolt Ring
- 4. Anchor Bolt Chairs
- 5. Anchor Bolt Tightness
- 6. Out of Roundness A. Flat Bottom Tank B. Horizontal Tank s
- 7. Longitudinal Weld Seam Offset
- 8. Botton Plate Seam Offsac
- 9. Nozzle Size and Type A. Size B. Type
- 10. Nozzle Location
- 11. Nozzle Insert Reinforcement Place
- 12. Nozzle and Manhole Rein. Pads
- 13. Seismic Restraints A. Installation B. Elevation C. Weld
..6 QI-041 Rev. 1 O
Page 3 of 3 I-M-FFTA-INSPECTION TOOLS USED
' age 1 of 3 ATTRIBUTE TOOL CODE SERIAL NO./ CALIBRATION DATE
- 14. Internal Pipe A. Arrangement B. Dimensions
- 15. Welds A. Configuration, Size and Profile B. Butt Weld Reinforcement C. Undercut D. Surface of Welds E. Offset of Batt Welds F. Fairing of Offsets G. Cracks, Lack of Fusion and Crater Cracks H. Indications
- 16. Base Materials l
A. Material Identification B. Material Defects
- 17. Weld Rust
- 18. Material Rust
- 19. Grout O
l
,.7 QI-041 Rev. 1 Page 1 of 1 RECORD OF SEISMIC BRACKET ELEVATIONS i
)
Bracket Tag No Location of Measurement Elevation
{
1 l
1O O
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,.8 QI-041 Rev. I p
Page 1 of 1 (j
DATA RECORDING FORM FIELD FABRICATED TANKS ATTRIBUTE DATA TANK NO.
BASE MATERIAL IDENTIFICATION Material specification, grade, heat code, marking symbol or code, and/
or additional markings BASE MATERIAL DEFECTS O
ee,th Size Type l
t
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