ML20203A087

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Rev 1 to Quality Instruction QI-054, Documentation Review of Category I Conduit Supports/R-S-COSP
ML20203A087
Person / Time
Site: Comanche Peak  
Issue date: 02/27/1986
From: Bajada E, Boichot L, Patterson A
EVALUATION RESEARCH CORP.
To:
Shared Package
ML20202J051 List: ... further results
References
QI-054-01, QI-54-1, NUDOCS 8607170174
Download: ML20203A087 (12)
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EVALUATION RESEARCH CORPORAT 0 CONTROLNO.0F*'-

COMANCHE PEAK RESPONSE TEAM QUALITY INSTRUCTION FOR ISSUE-SPECIFIC ACTION PLAN VII.c INSTRUCTION NO.:

QI-054 REVISION:

1 ISSUE DATE: 02/27/86 DOCUMENTATION REVIEW OF CATEGORY I CONDUIT SUPPORTS /R-S-COSP l

l pa //A'cw Prepared by:

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Of Date:

2-/2-86

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Approved by:

AW'd.

  1. M+

Date:

246TC Issue Coordinator Approved by:

,b 6[erdca Date: c2.3/o -J'h On-Site QA Represen tive Approved by:

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Date:

86 I

QA/QC/ Review Team Leader

/

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8607170174 860711 PDR ADOCK 05000445 A

PDR

QI-054 Rev. 1 O()

1.0 PURPOSE This instruction describes the methods and accept / reject criteria for documentation review of Category I Conduit Supports to be used by QA/QC Reinspection Personnel.

2.0 APPLICABILITY This instruction applies to safety significant attributes which could not be verified by visual reinspection within the Category I conduit supports population.

3.0 REFERENCES

3.1 Memo QA/QC-RT-674, " Description Memorandum for Documentation Review of Category I Conduit Supports."

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

i 4.0 GENERAL 4.1 Responsibilities 4.1.1 QA/QC Discipline Engineers The QA/QC Discipline Engineers prepare the documentation review instruction delineating review requirements and attributes.

4.1.2 QA/QC Inspectors QA/QC Inspectors perform documentation review / verification in accordance with reference 3.2 and this instruction and record results and deviations.

4.2 Policy Activities performed under this instruction shall conform to the policies contained in the latest Comanche Peak Response Team Program Plan and Issue-Specific Action Plan VII.c.

5.0 INSTRUCTION Using the information in Reference 3.2 and below, perform the documentation review on the items in this population and record the I

results on the checklist, Attachment 6.1.

Should additional space n) be required for remarks on the checklist, use Attachment 6.4.

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QI-054 Rev. 1 O) 5.0 INSTRUCTION (Cont'd) q Where a conduit support is attached to any other seismic support documentation review will be done by way of a supplemental instruction.

The inspector shall review the support drawing / conduit package to determine which attributes are applicable. Where no inspection verification exists for applicable attributes, DR's will be initiated.

For lighting supports, if required, a comparison of the computer print-out items list versus the list of supports in the vault conduit package may be made in order to identify the support for the documentation review.

1.

Inspector Certification l

Verify that each inspector who signed any item on an Inspection Report or Construction Traveler was certified as follows:

i a.

The certification was valid at the time of inspection,

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i.e. the date that the inspector initialed / signed must be on or after his certification date and prior to his i 49-certification expiration date.

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4 b.

The-inspector was certified to the applicable l

procedure.

If this attribute is rejected determine if the person that sigred as QC inspector was ever certified to the procedure used.

If the inspector was ever certified to the procedure

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

NOTES: If both a. and b. are rejected they may both be treated on one DR.

Inspector's name shall be recorded on the checklist when a deviation occurs.

If any initials and/or signatures are illegible, an attempt shall be made to determine the inspector's name by checking the signature cards located in the Permanent Plant Records Vault.

If 1(er.tification cannot be made the inspector shall reject this l

attribute.

l 2.

Material Traceability l

For fabricated material other than ASTM A-36 or A-500 Gr B l

obtain the heat number or unique ID number from the Material i

Identification sheet in the reinspection verification package l

(This will be included in the documentation review package.),

l if available.

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QI-054 Rev. 1

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5.0 INSTRUCTION (Cont'd) 2.

Material Traceability (Cont'd)

For heat numbers:

Documentation for specific heat numbers are contained in the Receiving Inspection Report (RIR). The RIR can be found in the Permanent Plant Records Vault (PPRV) for Unit 1 or the Interim Records Vault (IRV) for Unit 2 Conduit Supports.

i NOTE: Where copies of the RIR are not available in the vault, a check of the card file in the receiving warehouse will be necessary to obtain the RIR and the heat numbers..

a.

Verify that the material utilized for the support matches the drawing requirements.

4 b.

Verify that the heat number from the Material Identification sheet matches the heat number from the conduit package, if available.

For unique ID numbers:

h Check the Miscellaneous Structural Steel Log in the vault and v

obtain the corresponding heat number and thence the RIR number from the vault resources.

Proceed as above.

In item b replace " heat number" with "ID number".

When no heat number or unique ID number is indicated on the visual checklist proceed as follows:

From the conduit package in the PPRV obtain the Material Requisition (MR) number. Using this number and ths MR Log in the Miscellaneous Iron and Steel Fabrication Shop to obtain the heat number and the RIR number.

Proceed as before.

NOTE:

If no MR number is listed obtain th'e inspection or installation date.

Proceed to the MR Log as above and obtain the heat number and the RIR number.

3.

Concrete Expansion Anchors (HILTI)

From the vault review the following attributes.

3.1 Torque Verify that:

a.

The calibration due date of the torque wrench is subsequent to the date the installation was performed.

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QI-054 Rev. 1

)

5.0 INSTRUCTION (Cont'd)

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3.

Concrete Expansion Anchors (HILTI) (Cont'd) r b.

The recorded torque setting value meets the minimum torque requirements of Attachment L

6.2.

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3.2 Bolt Spacing Verify, by review, that if witnessed, and if abandoned j

holes were drilled and subsequently covered by a baseplate, that the inspector noted that the appropriate spacing was maintained between the installed HILTI and the abandoned holes, and that if located at a distance of four bolt diameters and closer, holes were filled and patched according to Procedures 35-1195-CCP-12 (grouted).

3.3 Rework

Verify, by review, if rework of bolts occurred, that the inspector noted:

Correctness of thread fit requirements.

f Restamping of bolt to new length (s,-

designation was observed.

i' 4.

Welding i

4.1 Weld Procedure Application Obtain the following information from the conduit package in the vault.

I Weld filler metal used to make the joint (specified on the Weld Filler Material Log 1

l (WFML).

Weld Procedure Specification (WPS) number used (specified on the WFML).

Obtain the Brown & Root Welding Procedure Specification identified above. Verify that the base material, and weld filler metal for the weld are within the ranges c

specified on the Welding Procedure.

4.2 Welder Qualification Obtain welder symbol from the WFML and the reinspection verification package (included in the documentation review package). If the welder symbol is not the same O

on both reject this attribute.

If reinspection did not produce a welder symbol use the WFML symbol.

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QI-054 Rev. 1

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5.0 INSTRUCTION (Cont'd) 4.

Welding (Cont'd)

Check the " Welder Performance Qualification Record Listing Standard Tests" effective at time of welding (use date shown on WFML) to obtain tests welder is qualified for. Check the " Welder Qualification Matrix" to verify that the welder has the proper tests for the welding procedure used.

4.3 Weld Procedure Qualification For weld procedure other than WPS 10046 (ref. memo QA/QC-RT-674), verify that the letter of approval from Gibbs & Hill or TUSI is filed with the welding procedure in Brown & Roots weld procedure manual.

5.

Stud Welding a.

Verify that an inspection report for daily qualification has been filed, signed and dated. The IR number is normally recorded on the construction traveler.

i b.

Verify that torqueing of threaded production studs was

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done. This is documented by a properly signed and dated entry on the construction traveler or an IR.

c.

Verify final visual inspection of stud welds with a signed and dated Nelson stud size and type on the Construction Traveler or an IR.

6.

Structural Bolting Verify torqueing of bolts by a signed and dated entry on the IR or Construction Traveler and that if recorded, the torque value meets the torque requirements shown on Attachment 6.3.

7.

Drawing Revision Verify, by review, that the latest revision of the generic / design drawing used for the reinspection program (QI-053) is the same used in the latest B&R or TUGC0 inspection.

(A copy of the drawing from reinspection is included in the documentation review package).

8.

Junction Box Configuration If the notes on the drawing for the junction box support f-~g indicates that support capacity verification is not required i.

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then proceed as follows:

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QI-054 Rev. 1

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5.0 INSTRUCTION (Cont'd) 4 8.

Junction Box Configuration (Cont'd)

Obtain the number of conduit actually entering and exiting the junction box. This information is available either on the capacity / span sketch in the reinspection package or in the remarks column of the reinspection attribute checklist.

Where more than one conduit enters and exits a junction box, obtain the electrical conduit layout drawing number from the junction box package in the vault.

If no CMC's, DCA's or NCR's exist indicating otherwise, verify that the actual number of entering / exiting conduit is the same as on the layout drawing.

6.0 ATTACHME:ITS 6.1 Documentation Review Checklist 1

l 6.2 Hilti Bolt Torque Requirements 6.3 Torque Schedule 6.4 Supplemental Remarks t

O

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..1 COMANCHE PEAK RESPONSE TEAM QI-054 CHECKLIST Rev. 1 n()

x-POPULATION DESC VERIFICATION PKG NO.

ategory I Conduit Supports R-S-COSP PAGE 1 0F 2

QUALITY INSTRUCTION QI-054

(}REINSPCCTION UNIT 1 EQUIPMENT MARK / TAG NO.

DOCUMENTATION REVIEW UNIT 2

((] COMMON VERIFICATION REMARKS ACCEPT REJECT DATE

1. Inspector Certification
a. Date
b. Procedure
2. Material Traceability
3. Concrets Expansion Anchors s.

m 3.1 Torque

a. Calibr. due date
b. Torque setting 3.2 Bolt Spacing

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3.3 Rework

4. Welding 4.1 Weld Procedure Application 4.2 Welder Qualificetion 4.3 Weld Procedure Qualification PREPARED BY:

APPROVED BY:

DISCIPLINE ENGR.

DATE LEAD DISCIPLINE ENGR.

DATE INSPECTED BY:

APPROVED BY:

INSPECTOR DATE LEAD INSPECTOR DATE CPP-007.IA. Raviaica 0

..1 COMANCHE PEAK RESPONSE TEAM QI-054 CHECKLIST Rev. 1

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POPULATION DESC VERIFICATION PKG NO.

Category I Conduit Supporta R-S-COSP PAGE jL OF _jL, VERIFICATION

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REMARKS ACCEPT REJECT DATE i

5. Stud Welding
a. Daily Qualification
b. Production Studs i
c. Final Visual
6. Structural Bolting
7. Drawing Revision f
8. Junction Box Config.

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_._ PP-007.1B, kevistuu._o_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _, _ _ _ _. _ _ _ _ _ _ _ _ _. _.

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Attachm2nt 6.2 QI-054 Rev. 1 Page 1 of 1 O

HILTI BOLT TORQUE REQUIREMENTS Minimum Embedment Minimum Bolt Diameter Kwik-BoIts Super Kwik-Bolts Torque (Ft./Lbs) 8 1/4 1 1/8 17 3/8 1 5/8 1/2 2 1/4 3 1/4 70 120*

5/8 2 3/4 150 3/4 3 1/4 1

4 1/2 6 1/2 230 1 1/4 5 1/2 8 1/8 400

  • Where 5/8" diameter bolts are used in conjunction with Unistrut members for conduit supports in such a way that the bearing surface under the nut, used with a flat washer, bears against the open side of the Unistrut, the minimum installation torque shall be 80 ft.-lbs.

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F2558 36" 84 IINISTRUT (A-307) BOLTS BOLT SIZE TORQUE (INCllES)

(FT. LBS.)

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i Attach:ssnt 6.4 QI-054 i

4 Rev. 1 5

Page 1 of 1

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SUPPLEMENTAL REMARKS i

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VERIFICATION PACKAGE NO.

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ATTRIBUTE (NO./ DESCRIPTION REMARKS I

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