ML20203A390

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Rev 1 to Quality Instruction QI-020, Documentation Review of Small Bore Pipe Supports
ML20203A390
Person / Time
Site: Comanche Peak  Luminant icon.png
Issue date: 03/03/1986
From: Hansel J, Patterson A, Ross G
EVALUATION RESEARCH CORP.
To:
Shared Package
ML20202J051 List: ... further results
References
QI-020, QI-20, NUDOCS 8607170227
Download: ML20203A390 (18)
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EVALUATION RESEARCH CORPORATION CON"R0_ _ED COPY CONTROL NO D/WEl COMANCHE PEAK RESPONSE TEAM QUALITY INSTRUCTION FOR ISSUE-SPECIFIC ACTION PLAN VII.c INSTRUCTION NO: QI-020 REVISION NO: 1 ISSUE DATE: 3/3/86

) DOCUMENTATION REVIEW OF SMALL BORE PIPE SUPPORTS l

l Prepared by: 9_ _ & affumw Date: '11 6 eau r.n.y 6 (o i L Approved by: If MI ' a b'- Date: Chf[Ib Issue Coordinator Approved by: h, Date: A "j8- Id On-Site QA Representative l Approved by: Date: 33 f4 Q C Review Team Leader //

8607170227 860711 PDR ADOCK 05000445 A PDR ,

QI-020

  • Rev. I rs

( 1.0 PURPOSE This procedure describes the methods and requirements to be used for the document review of small bore pipe supports by the QA/QC Review Team.

2.0 APPLICABILITY The procedure applies the requirements of Action Plan VII.c to safety related small bore pipe supports for piping 2 inches nominal diameter and smaller which have been QC inspected and accepted.

3.0 REFERENCES

3.1 Memorandum QA/QC-RT-474 dated September 5, 1985 delineating documentation used in development of procedure including specific sources for attributes and exclusions.

3.2 QI-019, " Reinspection of Small Bore Pipe Supports".

3.3 CPP-009, "~erformance of Reinspection and Document Review".

,] 4.0 CENERAL U

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 small bore pipe supports. Reference 3.3 addresses the method to perform documentation reviews, document and process the results.

4 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 I 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 U

2

QI-020 Rsv. 1

') 5.0 INSTRUCTIONS (Cont'd)

[G 5.2 Drawing Revisions (2.0)

Verify, by review, latest revision of DWG/ CMC used for reinspection program (QI-019) 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)

Record on inspection checklist if the support package has been 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 signed and dated the Hanger Index Report (HIR) or Documentation Checklist as applicable. The HIR or Documentation Checklist is located in the WP.

5.4 Inspector Certifications (4.0) i Verify, by reviev the certification of QA/QC Inspector (s) who initialed / dated :he items in 5.1. The accept / reject criteria for inspector certification is:

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a. The Inspector must be certified in the area, discipline (g) or procedure for the type of inspection performed, and
b. the inspector's certification must be current at the time of inspection.

Attachment 6.5 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.

If this attribute is rejected, determine if the person that signed as a QC Inspector was ever certified to any l instruction. If the inspector was certified, record the time l period of certification, otherwise state that the person was never certified. ,

5.5 Heat Numbers (5.0)

Verify, by review, inspector has recorded, signed and dated (each entry) all applicable heat and/or serial numbers for all listed bill of material components on one or more of the r

-~

following:

l , a. The design drawings 3

QI-020

  • Rev. 1 5.0 INSTRUCTIONS (Cont'd) v 5.5 Heat Numbers (Cont'd)
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 Record (MRS) or Installation Checklists, that the materials shown are traceable back to Receiving Inspection Reports (RIR). Verify that the RIR contains suitable -

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; Vendor supplied components (struts, snubbers, f(

a.

associated materials, etc.) shall be provided with suitable documentation either within the support package or attached to the RIR.

b. Bulk items may not be identified by specific heat numbers. They may be traced to RIR's (usually multiple) through cross referencing the item designation (i.e. , RFT-12) on the Brown & Root computer to obtain receiving inspection report number (s).

I 5.6 Welding Documentation Review (6.0)

A. Weld Procedure Application (6A)

For additional welds identified in the reinspection

( program the discipline engineer shall provide supplemental instruction for documentation review.

1. Identify the following items from the hanger / support package:
a. Both base metals being joined are listed on the MFS (for piping) and/or MIL (for plate material) l 4

QI-020

. Rev. 1 5.0 INSTRUCTIONS (Cont'd) 5.6 Welding Documentation Review (Cont'd)

b. Weld filler metal used to make the joint. This information is specified on weld data card or Weld

, 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)
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

(N 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 I supports l

only).

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2. Verify, by review, the welder's symbol is on the WFML or veld data card (s) (as applicable).

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.

l Check " Welder Qualification Matrix" to verify that the l welder has the proper tests for the Welding Procedure s- } used.

5

QI-020

. Rsv. I m

I i 5.0 INSTRUCTIONS (Cont'd)

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5.6 Welding Documentation Review (Cont'd)

Check weld deposit thickness for grooves and compliance with Notes #4, #7, #17, and #22 on " Welder Qualification Matrix".

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 (M tin Steam) and Oi 2003-2 (Feedwater) which are greater than 5/8" thick and more than 6" nominal pipe size. (see Attachment 6.2)
2. Attachments to pipes that require impact testing.
3. Ferrous material (Plate) 5/8" thick'and more.
i. Verify, by review, the welding procedure used has been impact property tested.
11. 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",

iii. Verify, by review, the weld filler metal was impact property tested by examining the CMTR.

iv. Verify, by review, the weld procedure supports the correct

[N N s- P-number and group number. (see

Attachment 6.2) 6

QI-020 Rsv. 1 5.0 INSTRUCTIONS (Cont'd)

(O) s/ _

5.6 Welding Documentation Review (Cont'd)

v. Verify, by review, the filler metal classification is the same as specified on the weld procedure qualification as was used in production.

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.

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(,) 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.

G. Hold Points (5G)

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.

7

QI-020 Rev. 1 s,,/

i 5.0 INSTRUCTIONS (Cont'd) 5.7 Concrete Expansion Anchor Documentation Review (Cont'd)

B. Bolt Spacing (7B)

Verify, by review, if abandoned holes were drilled and 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 Procedure (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)

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\s l 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.

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 & Liquid Penetrant only.)

(ah 8

__a

'QI-020 Rev. 1

,,3 5.0 ' INSTRUCTIONS (Cont'd) 5 5.9_= Specific Items (9.0)

Verify the following requirements are addressed on the appropriate Inspection Reports:

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 l calibrated and the M&TE number was recorded on the inspection report or installation checklist.

j 11. Verify, by review, the torque value recorded

] for eye rod jam nuts for snubbers meet the following:

j Snubber Size 1/4 1/2 1 3 10 35 100 Torque Value(FT-LBS) 40 40 40 80 100 150 220 iii. Verify, by review, the torque value recorded

}O for load stud jam nuts -for snubbers and sway struts meet the following:

Standard Pipe Clamps

{ Snubber Size 1/4 1/2 1 3 10 35 100 Torque Value(FT-LBS) 20 20 65 145 280 485 1050 NPS Super Stiff Clamps (SSC)

'SSC Size 06 08 10 14 20 24 36 l

Lock Nut Torque 15 40 80 170 520 1000 3300 (FT-LBS) 1.

j Western Pipe Clamps l

Torque values are listed on DWG/ CMC

- i t iv. Verify, by review, the torque value recorded ,

I for SA-193 Gr. 87 friction-connections (if  :

done by torque) meet the following:  ;

i j 5/8" Diameter Bolt - 215 FT. - LBS.

{

3/4" Diameter Bolt - 390 FT. - LBS.

B. Spring Can Setting (9B)

For Spring Can/ Constant supports, verify by review hot and cold loads and settings are recorded on final

{

{ drawing.

i l

l 9

QI-020 Rsv. 1

[b i 5.0 INSTRUCTIONS (Cont'd) 5.9 Specific Items (Cont'd)

C. Snubber Adapter Thread Engagement (9C)

For Snubber adapter plate threcd engagement on size 1/4 and 1/2, verify, by review, snubber has been inspected and appropriate areas on IR have been filled out and signed.

D. Snubber Stroke (9D)

Vetify, by review, snubbers have been properly stroked and set prior to installation in field. This can be accomplished by the IR in drawing package being complete.

NOTES:

1. The inspection attribute number from the checklist is shown in parenthesis next to appropriate inspection requirement.

p i, ) 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 Attachment 6.4.

6.0 ATTACHMENTS 6.1 Inspection Checklist 6.2 Material Specifications and P Group numbers i

6.3 Hilti bolt torque requirements i

6.4 Supplemental Remarks 6.5 Inspector Certification Guidelines

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AttachmTnt 6.1

i. .QI-020 L, .

Rev. 1

. Page 1 of 2 i

1 l

1 CONANGE PEAK RESPONSE TEAM 4

CHEC:: LIST 4

F0FULAIIGN DESC 7ERITICAT!CN PKG No.

, PAGE 1 OT

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SMALL BORE PIPE SUFFORTS I

QUALITY INSTRUCTION e

01-020 REY. 1 O int =ser== 0 ant i

UNIT 2 EQUIF!iENT MARK 4"AG NO. h DOC 3ENTATION RE7%ZW C CCMMON VERITICA!!ON t A ACC:PT REJECT DATIl I l j

1. Support Packase '

1

2. Drawina Revision u
3. Support Packste Review N/A N/A

' l t

t 4. Inspector Certifications j

l-

' 5. Heat Numbers l

1 i

6. Weldins A. Procedure

' Application I s. Veld Material i Traceability J

C. Walder Oualifications l

l D. Procedure Oualifications i

E. Ir. pact Tests i

1. l 11.

I 111.

4 5

APPROVED SYs PREPARED BY LIAD DISC!?LINE ENG2. DAIE i

DISCIPLINE ENG2. DAT2 APPROVED 3Y; INSFEGR dY:

f LIAD LMS?ECTOR DATE amccR Ja!:

} . CP-10 7 !.\. 34 *i.' .an 0 i

9

,y,. , _ y._,-_w,,.-_,7- . _ ~ _ , . -

..,..m., .- ,._.- _ _ .. , o,..r.,. , , , , , - . ,n_, _ .,..,,,m.m_,y,,,mmm m . gm . , , , ,7m _

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

Atttchment 6.1

,. QI-020 Rev. 1 e

Page 2 of 2 i

t

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l COMANCHE PEAK RESPONSE TEAM

! CEECELIST POFULATION DESC TERIFICATION PEG No.

PAGE 2 0F 2 SMALL SORE FIFE SUFFORTS TERIFICATION A

! ACCIFT REJECT DATE i 6. Welding (Cont'd) iv.

v.

i I

e T. Heat Treatment C. Hold Points i 7. Concrete Expansion i Anchors 4

j A. Hilti Bolt Torque

, B. Bolt Spacina 1

j C. Rework j

i D. Mole Drilling 4

E. Setting l

i

8. NDE Documentation
9. Specific Items +

A. Torque i 1. .

4 r

j 11.

iii.

iv.

8. Spring Can Settine

! C. Snubber Adapter thread engagement l

D. Snubber stroke i

i

^ - - - - .

I -

C?Pd)07. LB. Revision 0 1

d f i,

4

, ,,-,.=.m,vr,= - . - .ew,-,w-..-~y- y, - - - - . , _---,,wm ,-- - ew~5 n ey.v . w, p.+, -,--,

Attschment 6.2

. QI-020 Rev. I Page 1 of 2 (g) PIPING SPECIFICATION

' '- / CATEGORY 1303 NUCLEAR CODE CLASS 2 Pipe Size Size 24" and smaller 26" to 32" Construction Seamless Welded 4 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 SA350 Grade LF2 case 1571)

Rating 3000 lb. Schedule 80 To suit pipe PIPING SPECIFICATION CATEGORY 2003

~

'N [pCLEAR CODE CLASS 2 or 3 m)

Pipe i 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" l Smis or W1d Type Forged Seamless Seamless Joint Socket-Weld Butt-Weld Butt-Weld Butt-Weld ASME Spec. SA350 Grade SA420 Grade SA420 Grade SA420 Grade LF2 LF2 LF2 Rating 6000 lb. Schedule 160 Schedule 120 Schedule 140 0

Attachesnt 6.2

  • ~ QI-020 Rev. 1 Page 2 of 2 O

Material "P" Number and Group SA333d GR 6 PI-Group 1 SA155 CLI GR KCF-70 PI-Group 2 SA350 GR LF2 P1-Group 2 SA420 GR WPL-6 PI-Group 2 SA234 GR WPD P1-Group 2 SA516 GR 55, 60 or 65 PI-Group 1 SA516 GR 70 PI-Group 2 O

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Attachmsnt 6.3 i ; QI-020 Rev. 1 Page 1 of 1 TORQUE REQUIREMENTS Minimum Embedment Minimum Bolt Diameter Kwik Bolts Super Kwik Bolts Torque (Ft/Lbs)

I 1/4 1 1/8 -- 8 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 1 1/4 5 1/2 8 1/8 400 f

I

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Attachmsnt 6.4 QI-020 Rev. I ss. .

.s Page 1 of 1

, SUPPLEMENTAL REMARKS s

VERIFICATION PACKAGE NO.

ATTRIBUTE (NO./ DESCRIPTION) REMARKS 1

' w s.

t t

t t ,s s N

g s 5

,w,--s 4

'b g

+.

4

' s e..

l l

l l

l l

I I

I I ~

Inspector Date I

, , - , - ,.r-,e.- ----,,--n--,

, ,, , ,-. -w,,-,

Attach 2 ant 6.5

. QI-020 Rev. 1

,-s Page 1 of 2 (N--) INSPECTOR CERTIFICATION GUIDELINES LEVEL I MECHANICAL EQUIPMENT INSPECTORS

1. Verify torque for 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 Frmeral handling operations;
7. Repo'+ nonconforming conditions;
8. Verity 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

(}/

s, 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 aquipment; 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. W'.tness plant tag changes and identification marking transfers; and
11. Verify material identification, traceability, and cleanliness control.

A

Atttchment 6.5

, QI-020 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 all Level 1 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 .
4. Report nonconforming conditions;

,,) 5. Verify 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 i

The certified Level II Receiving Inspector shall be capable and authorized to perform all Level I Receiving Inspector functions in addition to:

l 1.- Evaluation of Level I inspection results; l 2. Evaluation and reporting of nonconforming conditions;

3. Verify general quality of workmanship, if specified; and
4. Verify technical acceptability of vendor furnished CMTR's and/or C of C's.
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