ML20203A093
| ML20203A093 | |
| Person / Time | |
|---|---|
| Site: | Comanche Peak  |
| Issue date: | 03/06/1986 |
| From: | Bajada E, Greer J, Patterson A EVALUATION RESEARCH CORP. |
| To: | |
| Shared Package | |
| ML20202J051 | List:
|
| References | |
| QI-028, QI-28, NUDOCS 8607170176 | |
| Download: ML20203A093 (19) | |
Text
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EVALUATION RESEARCH "IROL gglEO Copy e
COMANCHE PEAK RESPONSE TEAM QUALITY INSTRUCTION FOR SPECIFIC ACTION PLAN VII.c INSTRUCTION NO: QI-028 REVISION NO:
1 ISSUE DATE: 03/06/86 DOCUMENTATION REVIEW OF LARGE BORE PIPE SUPPORTS - RIGID Prepared by:
k Date:
3,/4./94, Approved by:
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Date:
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Issue Coordinator 6 [fg Approved by:
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On-Site QA Represe ative Approved by:
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QAGCReviewTeamQeader
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B607170176 860711 PDR ADOCK 05000445
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1.0 PURI'OSE
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This instruction describes the methods and requirements to be used for the document review of large bore pipe supports - rigid by the QA/QC Review Team.
2.0 APPLICABILITY The instruction applies the requirements of Action Plan VII.c to safety related large bore pipe supports - rigid for piping 2 1/2 inches nominal diameter and larger which have been QC inspected and accepted.
3.0 REFERENCES
3.1 Memorandum QA/QC-RT-522 delineating documentation used in development of procedure including specific sources for attributes and exclusions.
3.2 QI-027, " Reinspection of Large Bore Pipe Supports - Rigid".
3.3 CPP-009, " Performance of Reinspection and Document Review".
4.0 GENERAL Documentation reviews are performed and documented in accordance with established project procedures and instructions. This procedure establishes the attributes and accept / reject criteria for documentation reviews of large bore pipe supports - rigid.
Reference 3.3 addresses the method to perform documentation reviews, document and process the results.
5.0 INSTRUCTIONS (NOTE 1, 3)
Using the information in Reference 3.1 and below, perform documentation reviews of the sample items in this population and document the results on the checklist (Attachment 6.1).
5.1 Support Package (1.0)
Verify, by review, a hanger / support package exists in the permanent plant records vault.
Support packages for Unit 1 and Common with system designations AF through and including CC are stored in TUCCO permanent plant record vault. All other packages will be found in Brown & Root permanent plant record or interim records vault.
(O) 2
l QI-028 I
'a Rav. 1 5.0 INSTRUCTIONS (Cont'd) 5.2 Drawing Revisions (2.0)
Verify, by review, latest revision of DWG/ CMC used for 4
i reinspection program (QI-027) is identical to DWG/ CMC used in latest inspection. A copy of DWG/ CMC from reinspection package is included in the documentation review package.
5.3 Support Package Review (3.0) j Record on inspection checklist if the support package has been
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reviewed and accepted by Quality Control Engineering for compliance to the Vendor Certified Drawing (VCD) by ensuring that the QES (Quality Engineering Signoff) Representative has j
signed and dated the Hanger Index Report (HIR) or j
Documentation Checklist as applicable. The HIR or Documentation Checklist-is located in the WP.
t 5.4 Inspector Certifications (4.0)
Verify, by review, the certification of QA/QC Inspector (s) who i
initialed / dated the items in 5.1.
The accept / reject criteria for inspector certification is:
1 a.
The Inspector must be certified in the area, discipline or procedure for the type of inspection performed, and i
b.
The Inspector's certification must be current at the l
time of inspection.
- .5 gives guidelines for the various inspector types and levels along with the type of work each inspector type and level can perform.
Inspector certification files retrieved from the Permanent Plant Records Vault (PPRV) or B&R training office shall be used for this verification.
t If this attribute is rejected, determine if the person that signed as a QC Inspector was ever certified to any instruction. If the inspector was certified, record the time period of certification, otherwise state that the person was i
never certified.
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l QI-028 Rsv. 1 5.0 INSTRUCTIONS (Cont'd)
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G 5.5 Heat Numbers (5.0)
Verify, by review, inspector has recorded, signed and dated (each entry) all applicable heat numbers, ID codes and/or serial numbers for all listed bill of material components on one or more of the following:
a.
The design drawings b.
Material Identification Log (MIL) c.
Structural Assembly Verification Card (SAVC) d.
Component Modification Cards (CMC) e.
Manufacturers Record (MRs) f.
Installation Reports (irs)
Verify, by review of Vendor Drawings, Design Drawings, Component Modification Cards, Material Identification Logs (MIL), Structural Assembly Verification Cards (SAVC),
Manufacturers Records (MRS) or Installation Checklists, that the materials shown are traceable back to Receiving Inspection
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Reports (RIR). Verify that the RIR contains suitable
\\m-documentation (CMTR, C of C, etc.) providing certification for material used in the construction of the component support.
The following exceptions to the above apply:
a.
Vendor d.pplied components (struts, associated materiale, etc.) shall be provided with suitable documentation either within the support package or attached to the RIR.
i b.
Bulk items may not be identified by specific heat numbers. They may be traced to RIRs (usually multiple) through cross referencing the item designation (i.e.,
RFT-12) on the Brown & Root computer to obtain i
receiving inspection report number (s).
5.6 Welding Documentation Review (6.0)
A.
Weld Procedure Application (6A) l For additional welds identified in the reinspection program the discipline engineer shall provide i
supplemental instruction for documentation review.
- The Inspector's initials and date are acceptable provided the identity of the Inspector is unquestionable.
4 i
QI-028 Rsv. 1 5.0 INSTRUCTIONS (Cont'd) t 5.6 Welding Documentation Review (6.0) (Cont'd) 1.
Identify the following items from the hanger / support package:
a.
Both base metals being joined are listed on the MRS (for piping) and/or MIL (for plate material) b.
Weld filler metal used to make the joint. This information is specified on weld data card or Weld 3
Filler Material Log (WFML) c.
Weld procedure number (specified on weld data card or WFML) d.
Thickness of material being joined (shown on weld data card, DWG or MIL) i e.
Post Weld Heat Treatment (PWHT)
(when performed) (specified on Hanger Installation Report (HIR))
2.
Obtain Brown & Root Welding Procedure; Item 5.6A (Ic) above and verify, by review, the following:
a.
The base material, the base material thickness, the weld filler metal and the PWHT specified in the data package for the weld are within the ranges specified on the welding procedure.
B.
Weld Material Traceability (6B) 1.
Verify, by review, the weld number on the WFML is the same as specified on the weld data card and DWG/ CMC. (for Class 1 supports only).
2.
Verify, by review, the welder's symbol is on the WFML or weld data card (s) (as j
l applicable).
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5
QI-028 Rav. 1 5.0 INSTRUCTIONS (Cont'd) k' 5.6 Welding Documentation Review (6.0) (Cont'd)
C.
Welder Qualifications (6C)
Obtain unique welder's symbol from visual reinspection checklist or WFML. Check " Welder Performance Qualification Record Listing Standard Tests" effective at time of welding (use fit-up inspection date) to obtain tests welder is qualified for.
Check " Welder Qualification Matrix" to verify that the welder has the proper tests for the Welding Procedure used.
Check weld deposit thickness for grooves and compliance with Notes #4, #7, #17, and #22 on " Welder Qualification Matrix".
t Note:
The Inspector shall review all notes associated with each matrix in the course of Documentation Review.
The aforementioned notes listed above must be reviewed as a minimum.
D.
Weld Procedure Qualification (6D)
Verify, by review, the letter of approval from Gibbs and Hill or TUSI is filed with the welding procedure in Brown & Root's weld procedure manual.
E.
Impact Tests (6E)
Impact tests are required for:
1.
Piping categories 1303-2 (Main Steam) and 2003-2 (Feedwater) which are greater than 5/8" thick and more than 6" nominal pipe I
size.
(see Attachment 6.2)
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testing.
2.
Attachments to pipes that require impact 3.
Ferrous material (Plate) 5/8" thick and more.
a.
Verify, by review, the welding procedure used has been impact property tested.
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5.0 INSTRUCTIONS (Cont'd)
.V 5.6 Welding Documentation Review (60) (Cont'd) b.
Verify, by review, the base material was impact property tested by examining the Certified Material Test Report (CMTR). The CMTR may be obtained from the Received Inspection Report (RIR) referenced on the "ASME Material Heat Log".
c.
Verify, by review, the weld filler metal was impact property tested by-examining the CMTR.
d.
Verify, by review, the weld procedure supports the correct P-number'and group number.
(see.2) e.
Verify, by review, the filler metal classification is the same as specified on the weld procedure qualification as was used in production.
O, F.
Post Weld Heat Treatment (6F)
Verify by review of the temperature charts that the time at temperature was at least that which was called for on the Welding Procedure.
Verify, by review, the PWHT temperature was within the range specified on the welding procedure.
Verify, by review, the heating and cooling rate was correct. The code requires that above 800* F the rate of heating and cooling shall not exceed 400* F/ hour divided by the maximum thickness (in inches) of the material being heat treated, but in no case more than 400* F/ hour.
If the member being treated has been subjected to multiple PWHT cycles, verify, by review, the weld procedure was qualified to at least 80% of the total time at temperature of the production weld. Refer to the " Post Weld Heat Treatment Log" to verify number of cycles weld was subjected to.
7
QI-028 Rsv. 1 5.0 INSTRUCTIONS (Cont'd) 7-~3
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5.6 Welding Documentation Review (60) (Cont'd)
G.
Hold Points (6G) l Verify, by review, the checked QC hold points for fit-up, preheat and NDE on the Weld Data Card (s) were signed and dated.
5.7 Concrete Expansion Anchor Documentation Review (Note 2) (7.0)
A.
Hilti Bolt Torque (7A)
Verify by review:
1.
The calibration due date of the equipment is subsequent to the date the installation is being performed.
2.
The recorded torque setting value meets or exceeds the minimum torque requirements, as per Attachment 6.3.
B.
Bolt Spacing (7B)
/N Verify, by review, if abandoned holes were drilled and (m-)
subsequently covered by a baseplate.
Check that inspector noted the spacing between installed Hilti's and abandoned holes.
If abandoned holes are closer than four bolt diameters, check that documentation shows that they were filled and grouted to Procedare (35-1195-CCP-12, grouted).
C.
Rework (7C)
Verify, by review, if rework of bolts occurred, the inspector noted:
1.
Correctness of thread fit requirements.
2.
Restamping of bolt to new length designation was observed.
D.
Hole Drilling (7D)
Verify, by review, the inspector noted that no rebar cutting took place during drilling of holes without appropriate DCA permitting such cutting.
If this is not noted on Hilti Inspection Report, then it is not applicable.
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QI-028 Rev. 1 5.0 INSTRUCTIONS (Cont'd) 5.7 Concrete Expansion Anchor Documentation Review (Note 2)
(7.0) (Cont'd)
E.
Setting (7E)
Verify, by review, that bolt setting was appropriately performed. Review of this item shall be accomplished by checking if proper entries are made on inspection report.
5.8 NDE Documentation (8.0)
Where NDE was performed, verify, by review, the identification recorded on the NDE report matches the identification of the support. The report is satisfactory.
Note: It is acceptable for a signature on the Multiple Weld Data Card (MWDC) for NDE to be used in lieu of an individual report provided the inspection results are satisfactory.
(Mag. particle and liquid penetrant only) 5.9 Specific Items (9.0) l
(
Verify the following requirements are addressed on the appropriate Inspection Reports:
s A.
Torque (9A)
Verify, by review, the following torque requirements are addressed on the Inspection Report or Installation Checklist as applicable:
1.
Verify the equipment used for torque was calibrated and the M&TE number was recorded on the inspection report or installation checklist.
2.
Verify, by review, the torque value recorded for load stud jam nuts for sway struts meet the following:
SSC Size 06 08 10 14 20 24 36 Lock Nut Torque 15 40 80 170 520 1000 3300 (FT-LBS)
Western Pipe Clamps Torque values are listed on DWG/ CMC O
9
QI-028 Rev. 1
(~~N 5.0 INSTRUCTIONS (Cont'd) b 5.9 Specific Items (9.0) (Cont'd) 3.
Verify, by review, the torque value recorded for SA-193 Gr. B7 friction-connections (if done by torque) meet the following:
5/8" Diameter Bolt - 215 FT. - LBS.
3/4" Diameter Bolt - 390 FT. - LBS.
NOTES:
1.
The inspection attribute number from the checklist is shown in parenthesis next to appropriate inspection requirement.
2.
Hilti bolt inspection reports may not be included in support packages especially for Unit I and Common. Where report is not included with package, a review of computer records may be necessary to locate the report.
3.
Should additional space be required for remarks on checklist, use.4.
6.0 ATTACHMENTS 6.1 Inspection Checklist 6.2 Material Specifications and P Group Numbers 6.3 Hilti Bolt Torque Requirements 6.4 Supplemental Remarks 6.5 Inspector Certification Guidelines O
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Attachm2nt 6.1 QI-028 Revision 1 Page 1 of 3 O
COMANCHE PEAK RESPONSE TEAM CHECKLIST POPULATION DESC VERIFICATION PKG NO.
LARGE BORE PIPE SUPP-RIGID R-S-LBSR-PAGE 1 0F QUALITY INSTRUCTION QI-028 0aztusrictio" UNIT t EQUIPMENT MARK / TAG NO.
@DOCUMENTATIONREVIEW UNIT 2 O connow VERIFICATION ACCEPT REJECT DATE
- 1. Support Package
- 2. Drawing Revision
- 3. Support Package Review N/A N/A
- 4. Inspector Certifications O
- 5. Heat Numbers 6.
Welding A. Procedure Application B. Wald Material Traceability C. Walder Qualifications D. Procedure Qualifications i
PREPAL."D ST:
APPROVED ST:
DISCIPLINE ENGR.
DATE LEAD DISCIPLINE ENGR.
DATE LasrEvar.u BY:
APPROVED BY:
LN5FEGIOR DATE LEAD INSPECTCR DATE CPP-007.lA. Revision 0
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Attachmant 6.1 QI-028 Revision 1 Page 2 of 3 i
COMANCHE PEAK RESPONSE TEAM CHECELIST rvrva.ATION DESC VERIFICATION PEG No.
LARGE BORE PIPE SUPP-RIG 1 D R-S-LBSR.
PACE 2 0F 3 4
VERIFICATION Amum REMARTS ACCEPT REJECT DATE
- 6. Welding (Cont'd)
E. Impact Tests a.
b.
c.
d.
e.
F. Heat Treatment C. Hold Points
- 7. Concrete Expansion Anchors A. Hilti Bolt Torque 1.
i 2.
S B. Bolt Specina C. Rework D. Hole Drillina E. Settina 8.
NDE Documentation t
i CPP-007.LB Revision 0
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Attachmant 6.1 QI-028 Revision 1 Page 3 of 3 As' COMANCHE PEAK RESPONSE TEAM CHECKLIST POPULATION DESC VERIFICATION PKG NO.
LARGE BORE PIPE SUPP-RIClD R-S-LBSR-PAGE 3 0F 3 i
VERIFICATION ACCEPT REJECT DATE 9.
Specific Items A. Torque 1.
2.
3.
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I CPP-001. LB. Revision 0 r
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Attcch:2nt 6.2 QI-028 Revision 1 l
Page 1 of 2 PIPING SPECIFICATION
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CATEGORY 1303 NUCLEAR CODE CLASS 2 Pipe Size Size 24" and smaller 26" to 32" Construction Seamless Welded ASME Size SA333 Grade 6 SA155 Class 1 Grade KCF-70 Schedule 80 1.250" Min. Wall Fittings Size 2" and smaller 3" to 24" 26" to 32" Type Forged Seamless Welded Joint Socket-Weld Butt-Weld Butt-Weld ASME Spec.
SA350 Grade LF2 SA420 Grade WPL-6 SA234 WPBW(Code case SA350 Grade LF2 1571)
Rating 3000 lb.
Schedule 80 To suit pipe PIPING SPECIFICATION CATEGORY 2003 NUCLEAR CODE CLASS 2 or 3 Pipe Size 3" and smaller 4" to 8" 10" to 24" Construction Seamless Seamless Seamless ASME Spec.
SA333 Grade 6 SA333 Grade 6 SA333 Grade 6 Schedule 160 120 140 Fittings Size 2" and smaller 3" 4" to 8" 10" to 24" Type Forged Seamless Seamless Smis or W1d Joint Socket-weld Butt-weld Butt-weld Butt-weld ASME Spec.
SA350 Grade SA420 Grade SA420 Grade SA420 Grade LF2 LF2 LF2 Rating 6000lb.
Schedule 160 Schedule 120 Schedule 140 i
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QI-028 t
Revision 1 Page 2 of 2 i
i Material "P" number and group t
SA333 GR 6 Pl-Group 1 SA155 CLI Gr KCF-70 PI-Group 2 l
SA350 GR LF2 Pl-Gro'ap 2 SA420 GR WPL-6 P1-Group 2 SA234 GR WPD PI-Group 2 i
SA516 GR 55, 60 or 65 PI-Group 1 SA516 GR 70 Pl-Group 2 SA515 GR 55, 60 or 65 PI-Group 1 SA515 GR 70 P1-Group 2 i
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j Attschmant 6.3 l
QI-028 I
Revision 1 Page 1 of 1 TORQUE REQUIREMENTS 1
Minimum Embedment Minimum i
Bolt Diameter Kwik Bolts Super Kwik Bolts Torque (Ft/Lbs) 1/4 1 1/8 8
i 3/8 1 5/8 17 1/2 2 1/4 3 1/4 70 5/8 2 3/4 120 3/4 3 1/4 150 1
4 1/2 6 1/2 230 i
1 1/4 5 1/2 8 1/8 400 e
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QI-028 Revision 1 Page 1 of 1 SUPPLEMENTAL REMARKS r
A VERIFICATION PACKAGE NO.
R-S-LBSR-
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ATTRIBUTE (NO./ DESCRIPTION)
REMARKS i
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Inspector Date
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Attechm2nt 6.5 QI-028 Rev. 1 Page 1 of 2 O) t INSPECTOR CERTIFICATION GUIDELINES y
LEVEL I MECHANICAL EQUIPMENT INSPECTORS 1.
Verify torque fcr mechanical joint make-up; 2.
Verify torque for mechanical equipment installation, assembly or disassembly and equipment placement; 3.
Witness valve, pump or component disassembly and reassembly; 4.
Verify dimensional installation of wedgelock-type embeds, torque testing, etc.;
5.
Witness plant tag changes and identification marking transfers; 6.
Conduct surveillance checks of procedural compliance on equipment maintenance, storage area requirements, housekeeping practices, and general handling operations; 7.
Report nonconforming conditions; 8.
Verify rigging and handling of equipment; 9.
Verify material identification and traceability; and
- 10. Verify cleanliness control.
LEVEL II MECHANICAL EQUIPMENT INSPECTORS The certified Level II Mechanical Equipment Inspectors shall be capable and authorized to perform all Level I Mechanical Equipment Inspection functions in
()
addition to performing:
1.
Evaluation of Level I inspection and test results; 2.
Evaluation and reporting of nonconforming conditions; 3.
Verify final alignment / installation of equipment; and 4.
Verification of category "A" and "B" lifting or handling operations.
LEVEL I MECHANICAL FABRICATION INSPECTORS 1.
Dimensional verification of equipment; 2.
Dimensional verification of supports; 3.
Report nonconforming conditions; 4.
Witness hydrostatic / pneumatic testing; 5.
Verify and witness bolting flange joint and screwed connections; 6.
Verify thread engagement for bolts and studs; 7.
Verify welder compliance to procedure or instruction requirements; 8.
Witness valve, pump, or component disassembly and reassembly; 9.
Verify dimensional installation of wedgelock-type embeds, torque testing, etc.;
- 10. Witness plant tag changes and identification marking transfers; and
- 11. Verify material identification, traceability, and cleanliness control.
l Attachmsnt 6.5 QI-028 Rev. 1 Page 2 of 2 INSPECTOR CERTIFICATION GUIDELINES (Cont'd)
LEVEL II MECHANICAL FABRICATION INSPECTORS The Certified Level II Mechanical Fabrication Inspector shall be capable and authorized to perform al?. Level I Mechanical Fabrication Inspector functions in addition to performing:
1.
Evaluation of Level I inspection and test results; 2.
Evaluation of physical damage; 3.
Evaluation and reporting of nonconforming conditions; 4.
Verify the installation, location, orientation, alignment and identification of pipe spools, valves and supports; and 5.
Conducting "as-constructed" installation and final line walk-downs prior to hydrostatic / pneumatic testing.
LEVEL I RECEIVING INSPECTORS 1.
Verify quantity of items received; 2.
Verify absence of shipping damage; 3.
Verify receipt of required vendor documentation; 4.
Report nonconforming conditions; 7-s 5.
Verffy item identification, marking and marking transfer;
(^
6.
Conduct surveillance of warehouse storage and housekeeping requirements; and 7.
Perform dimensional verification and verify physical configuration.
LEVEL II RECEIVING INSPECTORS The certified level II Receiving Inspector shall be capable and authorized to perform all Level I Receiving Inspector functions in addition to:
1.
Evaluation of Level I inspection results; 2.
Evaluation and reporting of nonconforming conditions; 3.
Verify general quality of workmanship, if specified; and 4.
Verify technical acceptability of vendor furnished CMTRs and/or C of Cs.
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