ML20211N802

Rev 11 to Instruction QI-QP-16.0-5, Reporting of Base Metal Defects. Related Info Encl

ML20211N802
Person / Time
Site:	Comanche Peak
Issue date:	08/21/1984
From:	Duncan J TEXAS UTILITIES ELECTRIC CO. (TU ELECTRIC)
To:
Shared Package
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References
FOIA-85-59 QI-QP-16.0-5, NUDOCS 8607070390
Download: ML20211N802 (62)

Text

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ISSUE I

INSTRUCTION REVISION l OATE EAOI TEXAS UT1UTIES GENEMATING CO.,

NUMBEM r

CPSES 11

.M 1 of 7 QI-QP-16.0-5 PRE?ARED BY:

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1.0 REFERENCES

1-A CP-QP-18.0, " Inspection Reports" j

I 1-B CP-QP-11.18 " Nondestructive Examination Activities" 1-C

. CP-QP-16.0, "Nonconfomances" i

1-0 QI-QP-11.21-1, " Requirements For V ual W Inspection" l

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2.0 GENERAL

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2.1 PURPOSE C07.r

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The purpose of this inst cti is to provide the criteria for reporting _ base metal. defects incurr o n, non-ASME itens.

2.2 SCOPE l

Base m tal defects reportable in accordance wi th this

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procedure are, but are not limited to, the following:

a.

Base metal damage l

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b.

Minimum wall violations c.

Arc strikes NOTE:

This instruction does not apply to weld undercut except as specified in Paragraph 3.1.3.

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CPSES

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QI-QP-16.0-5 11 kUG 211984 2 of 7 NOTE:

The welding of misdrilled holes is a result of misfabrication or design change and is not a base metal defect and may be accomplished without an RPS, with the exception of NNS seismic category II pipe supports.

QC shall be notified prior to the start of welding for the purpose of identifying the location of the weld. Hole locations shall be documented on an Unsat IR in accordance with Reference 1-A and closed when the final weld inspection is perfomed.

I' NOTE:

Final visual weld inspections shall be perfomed in accordance with Reference 1-D.

3.0 INSTRUCTION 3.1 INSPECTION The QC Inspector shall use the following criteria in identification of base metal defects.

.I 3.1.1 Criteria for Welding of Misdrilled Holes 3.1.1.1 Holes Accessible from Both Sides The hole shall be large enough to allow the welder to manipulate the weld rod in order to obtain complete penetration.

In any case, the hole shall be welded from I

both sides.

The weld applied to the first side shall be back ground to sound metal and the weld completed from the second side.

3.1.1.2 Holes Accessible from One side Only Holes accessible from one side only shall, as a minimum, be beveled to allow access to the root portion of the weld.

In addition, the diameter of the hole shall be no less than the thickness of the part plus 5/16", perferably the hole should be enlarged to the next odd 1/16th of an inch. The diameter of the hole shall be no greater than 21/4 times the thickness of the weld.

i 3.1.2 Structural Steel The QC Inspector shall verify the following on structural steel members:

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Base metal is free of are strikes.

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INSTRUCTION ISSUE N

TEXNS UTILITIES GENERATING CO.

DAM CesEs A0, n y y 3 of 7

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QI-QP-16.0-5 11 u-b.

The damaged / defect area is ground to renove the imperfection, is well faired without abrupt changes in contour and shows no visual indication of being previously repaired, c.

The depression produced by grinding will not exceed the following:

1.

Area ground is 2 inches or less in dimeter.

2.

Structural Shapes a) 1/32 inch, for material less than 3/8 inch in thickness b) 1/16 inch, for material 3/8 to 2 inches inclusive in thickness c) 1/8 inch, for material over 2 inches in thickness 7'

3.

Plate a) 7% under plate thickness for plate 3/8 inch i

and less i

b) 7% under the plate thickness over 3/8 inches, but, in no case, more than 1/8 inch See Chart below for percentage conversions:

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3.1.3 Base Metal Damage to Cable Travs l

Any base metal damag's which creates a condition that may damate. electrical. cables or would prevent proper installation 4

of e,ectrical--cattles, shall be reported on a Nonconformance Report, for Engineering resolution.

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a.

Grinding, mishandling marks, or undercuts which do not 4

penetrate the complete section thickness of the base

'7 metal creating sharp ridges and edges which could damage the electrical cables shall be reoved by filing or buffing and the repaired area shall be i'

recoated with an approved cold galvanizing compound.

L b.

Arc strikes on base material which do not penetrate the complete section thickness, creating sharp

• ridges and

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edges which could damage electrical cables, shall be reoved by filing or buffing, and the repair area shall j

be recoated with an approved cold galvanizing compound.

j-3.1.4 Mechanical Pipino

.:j The QC Inspector shall verify the following for Mechanical

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piping:

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1 a.

P-1 Carton Steel. - Visually inspect for surface defects 1

including are strikes.

Arc strikes are to be visually inspected for linear indications such as cracks or

'i unacceptable craters or undercut, which violates section thickness.

If linear indications are found, then the blemish should be removed and the ground area j

shall be visually inspected to confinn linear indications have been removed.

b.

All other steel - Fdr these materials, all arc strikes

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should be removed.

The ground area shall be visual,1y

.j inspected to assure that any blemish has been renoved, a,

4 c.

Mechanical marks, abrasions, and other defects shall not 15 exceed 1/16 ' inch in depth or encroach on specified l'

mini. mum wall.

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d.

Excavated area after repair shall not encroach on specified minimum wall.

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Q I-Q P-16.0-5 11 AUG 21 ISS4 5 of 7 t

3.1.5 Pipe Supports The QC Inspector shall verify the following on pipe supports;.

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a.

P-1 Carbon Steel - Visually inspect for surface defects including arc strikes.

Arc strikes are to be visually inspected for linear indications such as cracks or unacceptable craters or undercut,, which violates section thickness.

If linear indications are.found, then the blemish should be reoved and the ground area shall be visually inspected to confinn linear indications have been reoved.

b.

All other steel - For these materials, all are strikes should be removed.

The ground area shall be visually inspected to assure that any blemish has been removed.

3.2 REPORTING i

When it has been detennined that a base metal indication is i' (

re' evant the inspector snall report It on an Inspection Repor_t (Attachment 1) in accordance with Reference 1-A.

l The following shall be included on the IR:

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1.

Type of base metal damage (check appropriate block on l

i IR, A through H):

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A = mishandling marks i

B = mechanical abrasions C = are strikes / gouges D = porosity i;

E = cracks F = laminations G = voids H = other (specify) 2.

Member description:

material type / grade 4

i wall / plate thickness outside diameter 3.

Draw sketch showing location and orientation of defect on member.

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Additionally, the inspector shall circle the defect on the member with a site approved marker.

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-a INSTRUCTION ISSUE REVISION PAGE NUMBER DATE i

TEXAS UTILITIES GENERATING CO.

CPSES QI-QP-16.0-5 11 AUG211234 6 of 7 I

i 3.3 CLOSURE Repairs shall be docuented on an RPS.

Upon completion of repair the inspector shall reinspect the area per the Repair Process Sheet (RPS).

Nondestructive examination specified on the RPS shall be perfomed in accordance with Reference 1-B.

If the defect has been satisfadtorily re' paired, QC shall close the IR in accordance with Reference 1-A.

Any RPS(s) issued shall be referenced in the Remarks section of the IR, and the inspector shall verify the RPS has been properly comple ted.

Arc strikes identified on structural steel components may be repaired without a RPS.

If such is the case, the QC Inspector shall close the IR upon completion of satisfactory visual inspection of the repair.

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3.4 NONCONFORMANCES In the event a

defect is repaired without proper documentation an NCR shall be issued in accordance with Reference 1-C.

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i lAUG 241994 QI-QP-11.10-1 ' o 29 J

1 of 62 !

PREPARED BY:

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1.0 REFERENCES

j 1-A CP-QP-11.10

" Inspection of Electrical Raceway Suppo rt Systems" 1-B QI-Q P-11.4-22 "QC Verification of Protective Coatings unique tu numoer iransrer-1-C CP-ECP-19. " Exposed Conduit" l

1-0 Gibbs & Hill Drawings 2323-S-910 0

1-E QI-QP-11.2-1, "Instaiiation of niiti-Oriiled-In soits-1-F QI-Q P-11.21-1 "Requirenents of Vi sual Weld Ins pection" 1

1-G QI-QP-11.0-15

" Verification of Baseplates for Grouting" 1-H CP-Q P-11.2,

" Surveillance and Inspection of Concrete Anchor Bolt Installation" 1-I CP-Q P-18. 0,

" Inspection Reports" 1-J CP-QP-16.0, "Nonconfonnances" CON"R0- ED C03Y 1-K CP-QP-15.0, " Tagging Systen" CONTROL No. % M-Doq 2.0 GENERAL 2.1 PURPOSE AND SCbPE This instruction supplements Reference 1-A and provides the

_ Mechanical OC Inspector with the criteria and attributes j

that shall be used when ins pecting seismically installed i

field fabricated electrical support systems ano miscellaneous welded electrical conponents in Class 1E systens and/or j

Cateoory I buildings requiring inspection by QC personnel.

k Cable tray supports shall be excluded from this instruction.

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f INSTRUCTION ISSUE REVISION PAGE NUMBER DATE TEXAS UTILITIES GENERATING CO.

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'O QI-QP-11'.10-1 29 AUG 241984 2 of 62

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l NOTE:

Electrical "S t-up s" less than 24 inches in 3'

length and unsuffarted " Flex" conduit or conduits requiring no sopports do not fall wi thin the scope of this instruction and will not be ins pected.

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3.0 INSTRUCTION

.i 3.1 MATERIAL TRACEABILITY AND TRANSFER OF PROTECTIVE C0ATING gf5 UNIQUE IDENTIFICATION NUMBER g

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. 3.1.1 Material Traceability Conduit and electrical quipment supports and components f

associated witn enese apports do not require materiaJ identification or a MM for matertais contoming to ASTM A236 -

.i or Engineering approved equivalent per QI-QP-ll.14-4.

N 3.1.2 Transfer of Protective Coa.ino Unique Identification Number 3

For all coated bulk steel intended for use in the Reactor 1

Building (as designated by the presence of a "QP" unique i

l 1 identification nunber) the QC Inspector shall verify and j ', '

document the transfer of the "QP" number prior to cuttino in-j accoronace witn Meterence 1-S.

FIELD FABRICATION AND INSTALLATION 3.2 Construction Travelers (Attachment 3, 4, and 11) shall be completed for each support on the conduit raceway system,

',j as required per Reference 1-C.

3.3 SUPPORT MARKING OF CONDUIT SUPPORTS 4

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3.3.1 Sequential f.'umbering System i i Each support inspected on a raceway systen shall be given a

'd.1 number by Construction as outlined in Reference 1-C.

Supports shall be stamped (stenciled) with the support

.1 number, with the exception of unistrut hangers.

Unistrut l;

hangers shall be marked with a nissen marker or by other i*

permanent suitable methods that will not damage the support.

j'j In cases where not enough roon is available to stencil unique nunber, the unique nunber (EX. CA-SA type hangers) shall be I$

marked with a Nissen marker or other suitable methods on the i

l conduit strap which will not damage the conduit strap.

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TUGC0 INSTRUCTION

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QI-QP-11.14-4 Rev. 14 Page 1 of 5 SEP 211934 CONTROL OF MATERIAL TRACEABILITY FOR SITE FABRICATED STRUCTRUAL/ MISCELLANEOUS STEEL PREPARED BY:

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1.0 REFERENCES

1-A QI-QP-11.14-1 " Inspection of Site Fabrication and Installation of Structural and Miscellaneous Steel" 1-8

- QI-QP-11.4-22 "QC Sune111ance of Protective Coating Unique Identification Number Transfer" 1-C CPM-6.3, " Preparation, Approval and Control of Operation Travelers" 1-0 CP-QP-18.0, " Inspection Reports" 1-E CP-QP-16.0, "Nonconfonnances"

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2.0 GENERAL

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2.1 PURPOSE MD SCOPE The pumose of this instruction is to describe material trace-ability requirements ror seismic structural / miscellaneous steel fabrication per Reference 1-A.

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TUGC0 INSTRUCTION QI-QP-11.14-4 Rev. 14

- CPSES -

Page 2 of 5 SEP 211984 3.0 INSTRUCTION 3.1 ISSUANCE AND CONTROL OF MATERIALS 0gMg The shop forman will notify the QC Inspector when it is necessary i

to withdraw safety related materials from the storage area.

In g this case, a Material Requisition (MR) will be prepared by the i

craft. The M shall provide the quantity, description, heat / nark

&p, j

nunber, and a description of the intended use of the

[$ g material (e.g., generalshims,etc.).

This MR shall be presented to QC y(/

for material traceability verification. OC verification shall be documented by the Inspector's signature and date on the MR.

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,,t equipment supports, and attachments associated NOTE:

Conduit suppo rts, cable try suppo rts, electrical with N. g

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these supports do not reautre material ide mificationgd or an M for materials conformina to AS7 A-36 or g A5'IM A-500 Grade B specification.

The M shall be presented to QC at the time ' f inspection to o

ernedite material traceaDili ty verirication..

3.2 SUBDIVISION OF MATERIALS

.The OC inspector shall verify that if it is necessary to sub-divide material, that traceability is transferred prior to, cutting N OC verification shall docunented on the MR.

Operational Traveler, or IR as applici le.

NOTE:

In the event that the steel is coated and has a Protective Coatings Unique Identification Number stamped on it (a QP nunber indicating use in Reactor.

l Building), the QC inspector shall also verify transfer of this nunber in acconiance with Reference 1-8.

l 3.3 UNIQUE NUMBERING The QC Inspector shall maintain a material traceability 100 for safety related miscellaneous and str">:tural steel items fabricated in the shop rriuiring unique nunbers s shown below.

Unique numbers may be applied to it..ns in lieu of heat numbers when due to configuration, a unique nunber is more feasible.

NOTE: Catalog type items such as nuts, bolts, and washers that require only a Certificate of Compliance shall not be encompassed within the scope of this instruction.

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TijGC0 INSTRUCTION

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QI-QP-11.14-4 Rev. 14 i

Page 3 of 5 SEP 211984 The QC Inspector shall assign a consecutive unique I.D. control nisaber beginning with "1001" to each unique iten or group of itens being fabricated for field installation.

Upon assignment of a unique I.D. control ntsaber, the QC Inspector shall enter it on the Miscellaneous / Structural Steel Traceability Log Attachment 1, along with the following information:

.a.

Assenbly Quantities - The total ntsnber of unique assenblies or itens being issued or fabricated, b.

Draving No. - The B&R miscellaneous or structural steel fabrication drawing nLaber.

c.

Sheet - The B&R miscellaneous or structural steel fabrication drawing sheet number.

d.

Revision The B&R miscellaneous or structural s teel fabrication drawing revision number.

e.

Date - The date that fabrication of the iten(s) is conpleted.

f.

Assembly - le unique asse,bly title /ntaber of the iten being issued or fabricated as shown in the Bill of Materials on the drawing.

g.

Sub-Assembl Itas - The size, type and grade of material used for "Q' items to make the assenbly.

h.

Itan Quantity - The total nisnber of each iten used to make the required number of assenblies.

1.

Heat Number - The heat or lot ntmber of each "Q" iten used to make the assenbly.

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P.O. Number - The purchase order ntsnber on which the material was procured.

3.3.1 Change of Seque e_

The following ct ditions or variables shall warrant the assignment of a new unique 5.D. control number:

J a.

A change of P.O., heat or lot ntsnber 1

b.

A change of material, size, type or grade l

c.

A change of assenbly ntsnber or assenbly dimensions d.

A change of fabrication date e.

A change of drawing ntsnber-

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TEXAS UTILITIES GENERATING CD.

TUGC0 INSTRJCTION

- CPSES -

QI-QP-11.14-4 Rev. 14 Page 4 of 5 SEP 211984 3.3.2 Field Fabricated Itans I

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QC field inspection / verification shall be docunented and processed,in accordance with References 1-C or 1-D as applicable.

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f gc QC shall verify Heat Numbem applicable to material type being u

used and enter it in the comments section of the IR, or as k directed by Operational Traveler.

3.4 DOCUENTATION The saintenance of operation travelers shall be in accordance with Reference 1-C.

The QC Inspector shall forward Miscellaneous / Structural Steel Traceabili+y Log (MTL) sheets to the Penenetn Platn Records Vault (PP. V.

Inspection Reports, as applicable, shall be R

processed per Reference 1-0.

3.5 DISCREPANCIES Discrepancies found during inspection shall be docunented on the IR and/or a NCR per Reference 1-D and 1-E respectively, as directed by the QA/QC Supervisor.

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- CPSES -

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I .. o ..a .. COMANCHE PEAK OPEN ISSUE ACTION PLAN Task - Determine if fabrication work done in the iron fab shop is done in compliance with procedures. Ref. No. AQ-138 Initial Assessment of Significance - Incorrect or untraceable material may have been fabricated and installed in the plant therefore rendering systems operation indeterminate. Source - QA/QC Category 5B. Approach to Resolution l-1 1. Review A-59 statement, the TRT technical review with alleger, and the alleger furnished notebooks. it i-2. Review fabrication / installation and inspection procedures applicable. 3. .rform an audit of work in-process in the fab shop to determine the availability of documentation required by procedures. i l 4. Review procedures for receipt storage and issue of material. l _.. g

_ _ _ -_y .. 5. Audit material requisition files in fab shop to determine if work is performed to memos and sketches instead of travelers hanger package or e drawing as required by procedures. 6. Interview shop foremen QC inspectors and craft personnel to determine their familiarity with and implementation of procedures. 7. Observe fabrication work in-process and verify adherence to procedures, inspection requirements and traceability documentation. 8. Walkdown material storage (laydown) areas to verify identification and segregation of materials. 4 9. Consult with B&R quality engineers to determine the adequacy of procedures.

10. Refer any examples of wrongdoing or significant deficiencies to the TRT manager.

11. Evaluate allegations for generic / safety allegations and potential i violations. 1 i

12. Report on results of review / evaluation of allegations.

Related Open Issues - None. Em -A}}