ML20202J682

Rev 1 to Quality Instruction QI-049, Reinsp of Large Bore Pipe Welds/Matl

ML20202J682
Person / Time
Site:	Comanche Peak
Issue date:	03/18/1986
From:	Bajada E, Boulton D, Patterson A EVALUATION RESEARCH CORP.
To:
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References
QI-049-01, QI-49-1, NUDOCS 8607170127
Download: ML20202J682 (16)

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EVALUATION RESEARCH CORPORATION CONTROLLED Co?y CONTROL No.13 c.y ,

c COMANCHE PEAK RESPONSE TEAM QUALITY INSTRUCTION FOR ISSUE-SPECIFIC ACTION PLAN ISAP-VII.c INSTTUCTION NO.: QI-049 REVISION NO.: 1 _ , , ,

N ISSUE DATE: 03/18/86

)

REINSPECTION OF LARGE BORE PIPE WELDS / MATERIAL Prepared by: v Date: J//4/B/o D. .

Approved by: M l.a_L /A M # mf Date: J//y/#4 IssueCoopuntor Approved by: E . [ b6s/s Date: 3[t M3/,

On-SiteQARepresptative O A,pr.v.e b,:

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Revies Team Leader eate: &k/ /

G607170127 860711 PDR ADOCK 05000445 A PDR

e QI-049 Rev. 1 {

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1.0 PURPOSE This instruction provides detailed instructions and accept / reject criteria for performing reinspections of the Large Bore Fipe Welds / Material (LBWM) 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 This instruction shall be implemented for all safety related, construction complete, and QC accepted large bore pipe, mechanical and electrical penetration, and mechanical equipment pressure boundary welds / material reinspections. The LBWM subset of the PIWM population is described in the Population Description for Pipe Welds / Material, Reference 3.3.

3.0 REFERENCES

3.1 QA/QC-RT-501, Description Memorandum for Reinspection of Large Bore Pipe Welds / Material, dated October 7, 1985, J. Schauf to ..

A. Patterson.

m k_s 3.2 CPP-009, " Performance of Reinspections and Documentation 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 Large Bore Pipe Welds / Material, QA/QC-RT-1374, dated March 4, 1986, from J. Schauf to A. Patterson.

4.0 GENERAL Reinspections are perforredesnd documented in accordance with l established CPRT procedures and instructions. This instruction ,

establishes- the attributes and accept / reject criteria for reinspections of Large 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

-g established project procedures and instructions. Reference q) 3.2 addresses the method used to perform reinspections and to I

document and process the results.

I l

2

QI-049 Rev. 1 4.0 GENERAL (Cont'd) 4.2 Policy Activities performed under this instruction shall conform o t

the policies contained in the latest Comanche Peak esponseR l Team Program Plan and Issue-Specific Action Plan .

(s) 5.0 INSTRUCTION General Requirements Prior to the start of reinspection, assure that the welds are visual inspection. clean of foreign material which would impede an adeq boundary welds. Paint will not be removed from pressure the Comanche Peak Response Team on Checklist, A Record deviation locations and dimensions, and any. .onal additi reinspection Attachment remarks, on the Supplemental Remarks Form 6.3. ,

All required data for the documentation Attachment 6.4. review shall be recorded on the Data Recording ~ Form, l

When it is necessary to measure weld dimensions or ce surfa defects during the course of the reinspection, unless

{

l determined as accurately as is practically standard inspection tools. g achievab

)

{ Record the corresponding code of the reinspection tools l used j Form, Attachment 6.2.for each applicable attribute eon the Reinspection Attachment 6.2 provides a list of standard reinspection tools and their corresponding codes .

1. Welds 1.A Configuration Verify the type of weld configuration.

i For nominal

~' pipe sizes of 2) inches and larger , the joint connection specified on shall be a butt the isometric weld (unless otherwise drawing).

1.B

_ Size and Profile Verify butt welded flush.weld size by assuring that the joint is For veldolet and sockolet connection welds to large bore pipe, the base verify that the weld tapers smoothly into material.

3

l QI-049 Rev. 1 I l

() 5.0 INSTRUCTION (Cont'd)

1. Welds (Cont'd) 1.C Butt Weld Reinforcement Verify that the thickness of the reinforcement complies with Attachment 6.5, Table A for piping and penetrations, and Table B for pumps and valves.

l NOTE: The surface of the reinforcement of all butt welded joints may be flu;h with the base material or may have uniform crowns.

1.D Radial Weld Shrinkage Verify that the amount of weld 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. ' ~--

I') For pipe wall thickness below 3/4-inches, the

\~ / radial weld shrinkage shall not exceed one-quarter of the nominal wall thickness, see Attachment 6.6.

--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 one-half of the nominal wall thickness, see Attachment 6.6.

~'

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, b

v i

4 i

a QI-049 Rev. 1 A '

k__ 5.0 INSTRUCTION (Cont'd) l

1. Welds (Cont'd) 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.

Allowable depth of urdercut defects are tabulated on Attachment 6.7, 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.

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

()

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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.I Welders ID Symbol Record welders ID symbol on Attachment 6.4 (Data Recording Form).

NOTE: Recor4 "Not Available" if the welders ID symbol is not marked.

1.J ID and Location Verify that the weld identification and location are per the drawing and applicable design documents.

NOTE: No dimensional checks are required.

F 5

QI-049 Rev. 1

,m 5.0 INSTRUCTION (Cont'd)

( )

2. Base Materials NOTE: The reinspection shall be limited to within two (2) feet on both sides of the weld being 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, l penetration, fitting, 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 6.4 (Data Recording Form).

NOTE 1: For non-insulated pipe, inspect the area on both sides of the reinspection weld up to the l nearest weld.

NOTE 2: Record "Not Available" if the material identification markings cannot be located or ,,,

identified.

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( NOTE 3: If the weld and base material are painted (coated), also record " painted" on Attachment 6.4 (Data Recording Form).

2.B Base Material Defects Verify that the base material has no surface defects which exceed a depth greater than 1/32-inch (0.031) or 12.5% of nominal wall thickness, whichever depth is less. Allowable depth of base material defects are tabulated on Attachment 6.7, Base Material and Undercut

- Allowable Defect Depth Table.

l l 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 surf.tce rust are acceptable.

()

NOTE: The materials engineer will be available in the evaluation of bare material rust acceptability.

6 l

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- _ _ = _ - - - . - . _ . . . ._. . . _ _.. - - .. .

QI-049 Rev. 1 6.0 ATTACHMENTS j l

6.1 Comanche Peak Response Team Checklist  !

6.2 Reinspection Tools Used Form 6.3 Supplemental Remarks Form 6.4 Data Recording Form i

6.5 Weld Reinforcement Tables 6.6 Nominal Pipe Wall Thickness Table 6.7 Base Material and Undercut - Allowable Defect Depth Table i

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Attachment 6.1 p QI-049

( Rev. 1 Page 1 of 2 i ~

COMANCHE PEAK RESPONSE TEAM ~'

CHECELIST POPULATION DESC VERIFICATION PKG NO.

PIPE WELDS / MATERIALS I-M-LBWM- PAGE 1 0F 1 QUALITY INSTRUCTION QI-049 [ REINSPECTION UNIT 1 EQUIPMENI MARK / TAG NO. C DOCUMENTATION REVIEW UNIT 2 CONMON VERIFICATION ACCIPT REJECT DATE

1. WELDS A. Configuration ^-

B. Size & Profile C. Butt Weld Reinforcement D. Radial Weld Shrinkage I

i l E. Undercut F. Surface of Welds l

-w G. Cracks, Lack of Fusion, Crater l Cracks PREFARED BT: APPROVED BT:

DISCIPLINE ENGR. DATE LEAD DISCIPLINE ENGR. DATE Laurr.cAu BY: APPROVED BY:

23 reb u DATE LEAD INSPECTOR DATE CRP-007.lA. RevisigLn 0

Attachment 6.1 QI-049 Rev. 1 COMANCHE PEAK RESPONSE TEAM CHECKLIST POPUI.ATION DESC VERIFICATION PKG NO.

PIPE WELDS / MATERIALS I-M-LBWM. PAGEL OF L l VERIFICATION

• ACCEPT N REJECT DATE H. Weld Rust (Stainless steel only)

I. Welders ID Symbol N/A N/A Use Data Recording (not accept / reject l Form, Attachment 6.4 attribute)

J. ID and Location '

R

2. BASE MATERIALS A. Base Material N/A N/A Use Data Recording Traceability Form. Attachment 6.4 l (not accept /

reject attribute)

B. Base Material Defects l C. Base Material Rust ,

l (Stainless steel l l only)

O I CFF,007.11,. Revision 0 2

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_ =_

Attachment 6.2 REINSPECTION TOOLS USED FORM QI-049 Rev. 1 PIPE WELDS / MATERIAL Page 1 of 2 l

J VERIFICATION PACKAGE NO. I-M-LBWM- i ATTRIBUTE TOOL CODE SERIAL N0/ CALIBRATION DUE DATE

1. WELDS A. Configuration B. Size and Profile C. Butt Weld Reinforce-ment D. Radial Weld Shrinkage E. Undercut F. Surface of Welds G. Cracks, Lack of Fu-sion, Crater Cracks ,, ,

H. Weld Rust t

I. Welders ID Symbol J. ID and Location INSPECTOR DAIE REINSFECTION. TOOL 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 GAGES ST STEEL TAPE MEASURE l

FL FLASHLIGHT TG TAPER GAGE V FM FIBRE METAL FILLET GAGES UD UNDERCUT GAGE (DIAL)

GG GAL FILLET CAGES UP UNDERCUT GAGE (PIT) l HL HI-LOW GAGE UT MG ULTRASONICDIGITALGAGE l MAGNIFYING GLASS VC VERNIER CALIPER MI MICROMETERS VT VISUAL INSPECTION

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

1 l

, REINSPECTION TOOLS USED FORM Attachment 6.2 QI-049 PIPE WELDS / MATERIAL Rev. 1 l

O VERIFICATION PACKAGE NO. I-M-LBWM-J l

ATTRIBUTE TOOL CODE SERIAL N0/ CALIBRATION DUE DATE

2. BASE MATERIAL A. Base Material Traceal>111ty l

B. Base Material Defects l C. Base Material Rust l

7 O INSPECTOR DATE REINSPECTION TOOL 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 GAGES ST STEEL TAPE MEASURE FL ELASHLIGHT TG TAPER GAGE FM FIBRE METAL FILLET GAGES UD UNDERCUT GAGE (DIAL)

O GG HL MG GAL FILLET GAGES HI-LOW GAGE MAGNIFYING GLASS UP UT VC UNDERCUT GAGE (PIT)

ULTRASONICDIGITALGAGEl VERNIER CALIPER ,

MI MICROMETERS VT VISUAL INSPECTION 1

2

Attachment 6.3 QI-049 Rev. 1 Page 1 of 1 O SUPPLEMENTAL REMARKS FORM PIPE WELDS / MATERIAL VERIFICATION PACKAGE NO. I-M-LBWM-ATTRIBUTE (No./ Description) REMARKS

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O O e 1

1 l

i 1

O INSPECTOR DATE

1 Attachmsnt 6.4 QI-049 Rev. 1 p Page 1 of 1 Q DATA RECORDING FORM PIPE WELDS /MATFRIAL VERIFICATION PACKAGE NO. I-M-LBWM-l ATTRIBUTE ^

DATA 4

1. Welds I. Welders ID symbol 5

h d

2. Base Material A. Base Material Traceability (heat number, code or lot number, /

and/or additional markings).

O e INSPECTOR DATE O

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.. Attachmznt 6.5  !

QI-049 Rev. 1

-s Page 1 of 1

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WELD REINFORCEMENT TABLES TABLE A (PIPING AND PENETRATIONS)

For 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 Thickness Maximum 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:

Nominal Thickness Maximum Reinforcement Inches Inches Up to 1, incl. 3/32 Over 1 to 2, incl. 1/8 over 2 to 3, incl. 5/32 O

a NOMINAL PIPE WALL THICKNESS TABLE Attachment 6.6 QI-049 Rev. 1 Page 1 of 1-y 8 =.

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