ML20203A039
| ML20203A039 | |
| Person / Time | |
|---|---|
| Site: | Comanche Peak  |
| Issue date: | 04/24/1986 |
| From: | Bajada E EVALUATION RESEARCH CORP. |
| To: | |
| Shared Package | |
| ML20202J051 | List:
|
| References | |
| QI-007, QI-7, NUDOCS 8607170166 | |
| Download: ML20203A039 (10) | |
Text
'
I 3
l Page 1 of 5 i
N v
EVALUATION RESEARCH CORPORATION CONTRO?_ ED COPY CONTROL I.'0.3F -co/
COMANCHE PEAK RESPONSE TEAM QUALITY INSPECTION FOR ISSUE-SPECIFIC ACTION PLAN V.d s
INSTRUCTION NO.: QI-007 REVISION:
4 EFFECTIVE DATE: 04/24/86 O
REINSPECTION OF PLUG WELDS i
Prepared By:
Date: f/r2/M Q
/
b+
ate:
-/IM Approved By:
es
'~
ction Plan Issue Coordinator
+@
M 2 3!8 A Approved By:
b.
/, i 6/r;d6-Date:
On-Site QA Represent ive 44!Ff, Approved By:
TC Date:
QA/QQi Review Team Leader 0607170166 860711 2
PDR ADOCK 00000445 A
i i
)
l QI-007 Rev. 4 AQ 1.0 PURPOSE The purpose of this procedure is to provide detailed instructions for the location and inspection of weld repaired misdrilled holes (Plug Welds) in cable tray supports, pipe supports, and base plates.
2.0 APPLICABILITY This procedure shall apply only to those supports or base plates which are selected for reinspection in accordance with the random sampling plan as outlined in the Issue Specific Action Plan V.d for the Flug Welding Issue.
This procedure is not applicable to vendor supplied components which have predrilled hole i
3.0 REFERENCES
3.1 TRT Action Plan Number V.d, Rev. 2.
4.0 GENERAL 4.1 Responsibility 4.1.1 Responsibility for the implementation of this procedure is as follows:
Reinspection - ERC Paint Removal / Acid Etch - Brown & Root Construction Engineering Evaluation & Analysis - TUGC0 Engineering Random Sample Selection - TUGC0 Issue Coordinator Overview - TERA (third party) 4.1.2 Evaluation Research Corporation (ERC) is responsible for the implementation of this instruction. ERC personnel shall perform the reinspections in accordance with this Quality Instruction and shall be trained and shall I
satisfactorily demonstrate their proficiency in accordance with Attachment 6.2 of this Q.I.
All training shall be documented per ERC procedure CPP-003 (Indoctrination, Training, and Certification of Personnel).
Inspectors shall receive training in the requirements and shall satisfactorily demonstrate their proficiency in accordance with Attachment 6.2 of this procedure.
Personnel performing inspections to this procedure shall be certified Level II Inspectors and meet the education and experience requirements in accordance with ANSI N45.2.6, l
1978 and Reg. Guide 1.58.
The lead inspector shall be a certified Level II Welding inspector.
2
QI-007 Rev. 4 C\\
()
4.1.3 A list of the random samples and drawings for supports and base plates to be inspected in accordance with this instruction shall be provided to ERC by the TUGC0 Issue Coordinator. ERC will notify TUGC0 of any support or base plate that is determined to be not accessible and request an alternate support be selected.
4.1.4 The criteria for evaluation of accessibility of supports within the sample shall be as follows:
accessible supports shall have a minimum of 75% of their surfaces clear for examination.
Insulation, except bonded insulation, shall be removed to provide access for examination.
supports that are covered by bonded insulation shall be considered inaccessible.
supports emersed in fluids or otherwise concealed due to uncontrollable circumstances shall be considered inaccessible.
Supports that are evaluated to be inaccessible shall be O
deleted from the Sample and replaced by an alternate support.
Records shall be maintained to document the accessibility evaluation.
5.0 PROCEDURE 5.1 Utilizing a calibrated Dry Film Thickness Gage, a measurement of paint thickness shall be performed on each hanger and/or base plate selected for inspection. The technique and acceptance criteria for paint thickness measurement shall be in accordance with Attachment 6.3 of this procedure.
5.2 Those supports which have unacceptable paint thickness per attachment i
6.3 shall have the paint stripped prior to inspecting for repaired holes, except in the base of tube steel where the inside surface is not painted and is accessible for visual examination.
5.3 It shall only be necessary to remove paint from those areas of the support identified as unacceptable per attachment 6.3.
5.4 Where the paint thickness exceeds the maximum as described in 5.2 above the inspector shall Unsat the paint thickness attribute on the Inspection Report for that support and indicate the high spot (s) on the support drawing attached to the report and forward the report to the designated TUGC0 Issue Coordinator for paint removal in acccrdance with construction procedures. Additionally, the inspector shall O
circle the hi h spot (s) on the support and mark it with a "P".
E i
3
QI-007 Rsv. 4
(~~T 5.5 If_ paint thickness is within acceptable limits or has been removed, s,)
inspection of the support and/or base plate shall,be accomplished by examining all accessible surfaces by holding a light at an oblique angle to the surface in order to locate any repaired misdrilled holes.
5.6 The inspector shall circle the suspected repaired hole on the support and mark it with a "W", record each suspected repaired hole only on the drawing then forward the copy of the drawing to the TUGC0 Issue Coordinator.
5.6.1 Upon receipt of the drawing from the inspector for a support, the TUGC0 Issue Coordinator shall have the paint removed from the suspected repaired holes recorded on the drawing. An acid etch shall then be performed to conclusively determine the existence of repaired misdrilled holes. Acid etch shall be performed in accordance with B&R WEI-9.
5.6.2 Upon completion of the acid etch the TUGC0 Issue Coordinator shall direct the lead inspector to examine the suspected areas and record the number and location of the weld repaired holes on the Inspection Report.
5.7 Weld Inspection Once existence of a weld repaired misdrilled hole is confirmed, a visual inspection of the weld shall be performed O-in accordance with the final visual inspection criteria listed in 5.8 for cable tray and Non-ASME pipe supports.
Inspection of repaired misdrilled holes in ASME supports shall be in accordance with the criteria listed in 5.9.
5.8 Weld Surface Cable Tray And Non-ASME Pipe Supports 5.8.1 The inspection criteria for cable tray and non-ASME pipe supports is in accordance with the requirements of AWS Dl.1-75.
5.8.2 All welds shall be free from cracks.
5.8.3 Thorough fusion shall exist between weld metal and base metal.
- 5.8.4 Undercut shall not exceed 1/32".
5.8.5 The sum of diameters of porosity shall not exceed 3/8" in any linear inch of weld.
5.9 Weld Surface ASME Pipe Supports.
5.9.1 The inspection criteria for ASME pipe supports is in accordance with ASME III, Subsection NF-1974 Edition, Winter 1974 Addenda.
5.9.2 Welds shall be free of cracks.
4
=--
QI-007 Rev. 4 5.9.3 Thorough fusion shall exist between weld metal and base metal.
5.9.4 Undercut shall not exceed 1/32".
5.9.5 Indications with major dimensions 1/16" or less shall be con-sidered non relevant.
5.10 Inspection results shall be recorded on the Inspection Report (Attachment 6.1) which was previously used to document the location of the plug welds.
5.11 Completed Inspection Reports shall be forward to the TUGCO Issue Coordinator who shall obtain a copy of the documentation package for those supports containing repaired holes and forward the package and inspection reports to Third Party Issue Coordinator for review.
Inspection Reports for supports which did not contain plug welds will also be forwarded to the Third Party Issue Coordinator. Copies of the i
documentation package for these supports need not be forwarded.
6.0 ATTACHMENTS 4
6.1 Inspection Report, QI-007.1 6.2 Inspector Training N
6.3 Paint Measurement i
i 1
!O i
5
?.~.
INSPECTION REPORT
'2nd INSPECTION
+
s SUPPORT NUMBER CABLE TRAY ~ PIPE ['
LOCATION INSPECTOR ELCOMETER SERIAL NUMBER CALIBRATION DUE DATE
^
PAINT THICKNESS ACCEPTABLE [ UNACCEPTABLE [
~
PAINT REMOVAL NA _
ACCEPTABLE _ UNACCEPTABLE _
PERCENT SUPPORT INSPECTED i
SUSPECTED REPAIRED HOLES YES -
NO -
3
-.m y.
INSPECTOR'S SIGNATURE /DATE...
~.
~
~
ACID ETCH ACCEPTABLE _. UNACCEPTABLE [
~
REPAIRED HOLES IDENTIFIED YES _
NO [
NUMBER REPAIRED HOLES IDENTIFIED LOCATIONS * (INCLUDE ITEM f) i 4
I
- NOTE:
If no item number is on drawing the inspector shall assign a number and initial and date.
-e WELD INSPECTION ACCEPTABLE - UNACCEPTABLE DESCRIBE INDICATIONS i
i i
LEAD INSPECTOR'S SIGNATURE /DATE 6
l QI-007.1 6/85 ry-.--p.m,------y-,.
,,,,,,r.,.-
---,-,mww----,-,--...--,-=+-r e.
*---------=-s---w-
~----r--"-
.1 QI-007 Rev. 4 Page 1 of I D
V Attachmsnt 6.2 QI-007 Rev 4 Page 1 of 2 INSPECTOR TRAINING 1.0 PURPOSE The purpose of this Attachment is to provide an outline of the orientation to be given inspectors that will perform the exami-nations and inspections as described in Action Plan TRT V.d.
2.0 BACKGROUND
INSPECTION Potential inspectors shall be provided the background of the welding repair issue and the purpose and methodology of locating misdrilled hole repairs. Action Plan TRT V.d will be reviewed at this time.
3.0 PAINTED SAMPLES / DRY FILM GAGE 6
Inspectors will be given the opportunity to observe samples of structural members which have welded holes and have received several coats of paint. A demonstration as to the correct use of a Dry Film Thickness Gage for paint thickness measurement will be given.
\\
4.0 FIELD TOUR t
Potential Inspectors shall be given a tour of the plant area where they may observe cable tray supports with known misdrilled hole repairs, some of which are in a painted condition and some which have had the paint removed from the repair area and an acid etch performed.
l l
5.0 DEMONSTRATION OF ABILITY Prior to being accepted to perform examinations and inspections in accordance with TR.T V.d, potential inspectors must demonstrate their ability to locate velded holes under simulated field con-dicions. This will be accomplished by providing mock-ups of cable tray and pipe supports in fixed positions which have re-paired holes and have been painted. To successfully l
demonstrate ability the inspector must identify at least 75%
l of the repaired holes in the mock-up supports end record the location en the drawing for the support.
O
__ ~
Attachmant 6.2 QI-007 Rev 4 Page 2 of 2 6.0 RECORDS OF TRAINING 6.1 The ERC Training and Certification Administrator shall prepare and maintain records.
6.2 Training records applying to QI-007 shall be included in the final documentation package for the inspection program.
l i
i l
l 2
/
1 Attechmant 6.3 QI-007 Rev 4 Page 1 of I
[]
PAINT MEASUREMENT
\\- /
1.0 ?URPOSE The purpose of this Attachment is to outline the methods to be utilized by inspection personnel to measure paint thickness on supports and base plates selected for inspection in accordance with this procedure.
2.0 GENERAL 2.1 The inspector shall perform a Dry Film Thickness measurement (DFT) of the coating utilizing a calibrated 0-25 E1cometer Inspector DFT Gage Model III/IE, or equivalent.
Since the magnetic gage is sensitive to geometric discontinuities in the steel, measurements less than 1 inch from an edge or a hole should be avoided where possible.
2.2 A spot measurement shall consist of a series of three measurements in the same general area. The probe should be moved a short distance for each gage reading. Discard any unusually high or low gage reading that cannot be repeated consistently. Take an average of the three gage readings as one spot measurement.
()
2.3 A spot measurement shall be taken on each accessible surface of structural members, to be inspected for plug welds.
3.0 ACCEPTANCE CRITERIA 3.1 Any paint thickness in excess of 15 mils shall be identified as unacceptable on the IR and drawing.
3.2 If the average DFT measurement on a single support is in excess of 13 mils, those high spots above 13 mils shall be identified as unacceptable on the IR and drawing.
3.3 In the event that.any spot is found to be unacceptable per 3.1 l
and or 3.2, three additional spots shall be taken at j
approximately 6" and radially spaced 120' from the failed
[
spot, to determine the extent of the unacceptable area.
Dimensions and locations of unacceptable areas shall be documented on the drawing.
i l.
--.