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; The Notice of Violation for tiie itse of noncompliance swii,ed in paragraph i 7 of the enclosed inspection report' was forwarded to you by our letter dated August 30, 1978; therefom th'is letter does not mquim further ' , | ; The Notice of Violation for tiie itse of noncompliance swii,ed in paragraph i 7 of the enclosed inspection report' was forwarded to you by our {{letter dated|date=August 30, 1978|text=letter dated August 30, 1978}}; therefom th'is letter does not mquim further ' , | ||
regarding this matter. , , | regarding this matter. , , | ||
.ma* RIVbd .3 /\ .3 / .nik | .ma* RIVbd .3 /\ .3 / .nik | ||
Revision as of 06:23, 8 December 2021
| ML20199A592 | |
| Person / Time | |
|---|---|
| Site: | Comanche Peak, 05000000 |
| Issue date: | 07/21/1980 |
| From: | BROWN & ROOT, INC. (SUBS. OF HALLIBURTON CO.) |
| To: | |
| Shared Package | |
| ML17192A346 | List:
|
| References | |
| FOIA-85-313, FOIA-85-59, FOIA-86-A-20 CP-CPM-6.9C, NUDOCS 8606120514 | |
| Download: ML20199A592 (77) | |
Text
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- 1 ARMS i INnCYCn I
BROWN & ROOT, INC. PROCEDURE ftIffE CPSES NUMBER REVISION DATE PAGE i JOB 35-1195 j CP-CPM 6.9C 1 7/21/80 1 Of 7 l , A:N*l . . . . .- .s TITLE: #% ORIGINATOR: ' 7 WJM*- E-8 "V b/1/ 7 fd P Dk) - REVIEWEDBY:k CATION APPROVED 8 /<d af 7. -f DATE
, CONSTRUCTION PROJECT MANAGER 0.1 TABLE OF CONTENTS .
1.0 INTRODUCTION
~
2.0 GENERAL a ,M f \s l 2.1 APPROVAL AUTH I{ .~
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i(( l 2.2 RESPONSIBILITY 3.0 MATERIAL IDENTIFICATION PROCEDURE l 3.1 RECEIVING INSPECTION 3.2 COLOR CODING AND TAGGING MATERIAL w y,_ 3.3 BULK P1PE AND FITTINGS g.,, 3.4 COMPONENT SUPPORTS , - 3. a .1 Component Support Materials ! 3.4.2 Engineered / Packaged Pipe Hangers
. 3.5 VALVES .
l 3.6 PARTS AND APPURTENANCES 3.6.1 Bolts and Nuts 3.6.2 Gaskets 3.6.3 Miscellaneous Items 3.7 EOUIPMENT VENDOR SUPPLIED MATERIAL 3.8 MATERIAL REOUISITIONS 3.9 WAIVERS l
. 3.10 RETURN TO WAREHOUSE 0.11 TABLES i
j 6.9 C-1 NON "0" INTERCHANGEABLE MATERIAL 6" 0 and SMALLER 6.9 C-2 "0" INTERCHANGEABLE FATERIAL 6" O and SMALLER ) I 0.111 FIGURES 6.9 C-1 MATERIAL REOUISITION l 6.9 C-2 MATEPIAL RETURN' TO WAREHOUSE FOPM 8 8606120514 860604 PDR CARDE86-A-20 FOIA PDR Z
I JOB 35-1195 COMANCHE PEAK STEAM ELECTRIC STATION Construction Procedure : DOCUMENT CHANGE NOTICE NUMBER 2 Notice applicable to Construction Procedure No. 35-1195 CP-CPM 6.9C Rev. 1 . This change will be incorporated in the next revision of the procedure. Change the procedure as follows: I Replace page 3 of 7 and 4 of 7 l l l 1 i Reviewed by: 3-ffz%d so '~ S'~ Getsinator Date #~ Brown & Root Quali Assurance Date . O ' Approved by: TUGC0 Quality'M!furance Date M ./T/7 # f e ,.8 - / / b l/ March 16, 1984 Construction Project Manager Date' Effective Date J~&
--- LM' - - + . , , n.r wseoen~ m v _ , , _
1 JOB 35-1195 Comanche Peak Steam Electric Station Sheet 1 of 2 Constructitn Procadure 1 DOCUMENT CHANGE NOTICE NUMBER This notice applies to Construction Procedure No. 35-1195-CPM 6.9C Revision 1 . This change will be incorporated in the next revision of the procedure. Change the procedure as follows: > Replace the following page with the attached: I Page 2 of 7 4 i l I Reason for change: Change in requirements This change approved by: Reviewed by: ' l [ bu.> 7-2D3! ifuad[ si e / g /g, Originator Date p3rown & Root Quality Assuranc( Oate Reviewed by: S l s t
' hM; / "
Construction Project Manager Y .(~ i l Date 8126/81 Effective Date I h
[ i SROWN & ROOT, TNC. TSSUE { CPSES NUMBER REVISION DATE PAGE ! l ! JCS 35-1195 j ; ! 3 CP-CPM 6.9C 1 7/21/80 l 2 of 7 i l '
1.0 INTRODUCTION
This appendix to procedure CPM-6.9 contains the requi mments for the control and identification of caponents and material through unique ma rtings, color coding, etc. j 2.0 GENERAL - ! 2.1 APPROVAL AUTHORITY The origination, review and approval of this document shall be as required by CPM 6.1. 2.2 RESPONSIBILITY j The Chief Warehouseman is responsible for assuring confonnance with the requirements of this appendix. I 3.0 MATERIAL IDENTICICATION PROCEDURE 1 [ 3.1 RECEIVING INSPECTION ' Piping materials, conponent supports and weld materials s' hall be
- receipt inspected in accordance with CPM-8.1 and QAP-8.1. l i
3.2 COLOR CODING AND TAGGING MATERIAL Bulk materials shall be color coded by warehouse personnel (see FSM-00101) prior to release for construction. For "0" materials. the color cadina will be aoolied after OC has canoleted the receiot inspec-tion and accepted the material. The applicable QC Receiving Inspector conpieces oud ivom rus cne " Authorization to Color Code" fonn, as shown in procedure CPM-8.1, to the chief warehouseman pennitting the l col or coding. For Non-Q materials, the material control group shall i verify the material coding. i l Stainless steel materials shall be color coded using " Nissen" ink i ma rke rs. Carton steel materials shall be color coded using " Nissen" ink markers or other paint that will adhere to the carton steel surface and main-tain its color when ex,)osed to sJn, wind, rain, and frost. [ Ink and paint used for color coding shall be applied to exterior , surfaces only.
._.3
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- . . . CPM 6.9C_ Rev. I DCN #1 8/26/81 Sheet 2 of 2
I l PROCEDURE EFFECTIVE
- l. BROWN & ROOT, INC. NUMBER REVISION DATE PAGE l CPSES l J08 35-1195 CP-CPM 6.9C 1 07/21/80 3 of 7 i
e 3.3 BULK PIPE AND FITTINGS Pipe and fittings that are exceptions to the C&H standard categories in MS-43B and 44B shall be marked with the applicable ISO drawing number rather than being color coded. y Uncoated pipe shall have a continuous setipe applied starting 3 inches , from one pipe end and continuing the pipe length to 3 inches from the opposite end. Fittings shall have a continuous stripe applied on the outside for at least 180* around the fitting's middle. f Coated pipe shall have the color code stripe (s) applied at least 270'
' around each bare end approximately 3 inches back from the pipe end.
Material supplied as ASME Class 2 shall have the color code stripe (s) cross-hatched. If the color code requires two different colors, only
! one of the colors is required for the cross-hatch.
- The color code shall be maintained until the pipe and/or fitting is fabricated into, or becomes a pipe spool.
Should traceability of an identified pipe piece ce fitting, purchased and color coded as "Q" material, become questionable and cannot be positively reestablished and documented, the applied color code shall { be removed and the material moved to "Non-Q" storage. The applicable 3 traceability methods for "Non-Q" material shall be used as described ] in FSM-00101. Color. code markings may require removal from the material surfaces before any heat treatment, assembly which render the markings inac-c'essible, or when the markings will interfere with acceptance inspec-tions. Only when required, the markings are removed af ter the mater-
. . ial is fabricated into pipe spools.
6 For those pipe categories that specify 304 or 316 stainless steel I grade, the pipe, fittings, and/or flanges of the 316 grade shall have the number "316" written conspicuously on the outside of the items by f the warehouse personnel using a " Marsh" black ink, T-31, "AEC" marker
)
or a " Nissen" ink marker. I Material of one piping specification category may be substituted i for another in accordance with Tables 6.9 C-I and II. Class 2 j material within the same "Q" piping specification category may be substituted for class 3 material or as noted on Tables 6.9 C-1 1 1 1, CP-CPM 6.9C Rev.1 DCN#2 - 3/16/84 Sheet 2 of 3 i
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. - BROWN & ROOT, INC. PROCEDURE ;. CPSE5 MJMBER REVISION EFFECTIVE \
k . DATE JOB 35-1195
; PAGE b -
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CP-CPM 6.9C l l 1 and II. 07/21/80 4 of 7 Any substitution Tables 6.9 engineering and C-I and 11 reviewed by QC must bof material not sh e approved in writing by sit e Bulk piping material may b , ("Q" material only) . e upgraded accordance to reflect the with B&R QC proc d 3.4 upgraded condition.e ures, color an,d code thei.e. class 2,class in 3 to COMPONENT SUPPORTS must be changed 3.4.1 Component Support Material s Before i traceabilitycutting non-standard hanger ! 3.4.2 ing on the re,mainderthe of the component. heat number shall becomponents [th transferred by steel die number! Engineered / Packagedangers Pipe H -stamp- 0 k Engineered hangers, bulky to beally be prepackaged, assembledthose e designed and J:( s tagged with the hangercompletelyart assembled, by vendors each will norm- ? is to beWhere thep, and tagged. hanger is too Control Group, all tag which are engineewarehousing or either stamped assembled. personnel or s 3.5 red hangersstamp, as directed by the Mat B&R VALVES received without appropriate and/or id their erials entification.unassembled parts {5,iy be tagged with its genericAfter QCI receipt inspect numbe<r. manufacturer.These valvesnumber or its n, each permanent plant proces valve fk im s valve shall without the generic or However,should in t number (he event have this number attached , s.
~
$b e valve i"Q Engineer will instruct waspecial the appropriate valves, thevedactual sy s em valve of control, safety / relief
!*
- M-tor valve number.rehousing personnel to number) the Site Mechanical $.M Q
Non process valves, such attach a tag noting f*d g 7%i. Materials Control Group af tetc., shall be tagged by w accepted. e ~ order er theousing personnel as directed bection valves, i number and pipeThe information valves are receipt on the tag y the ~, .)$ l ;- Q.' category in which the valve is shall c ase include ;- the B' s to be used. !' I, . =
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! . BROWN & ROOT, INC. ISSUE CPSES NUMBER REVISION DATE PAGE
] i 7 JOB 35-1195 CP-CPM 6.9C 1 5 of 7 7/21/80 3.6 PARTS AND APPURTENANCES 3.6.1 Bolts and Nuts 1 Bolts and nuts to be used on flanges in process pipe systems shall be color coded in accordance with FSM-00101. The color shall be applied i to one end of each stud and to at least two hex faces of each nut for
- ' "0" studs. Identification markings on 0 studs and nuts shall be legible and distinct. "Non-0" studs and nuts can be individually color coded as stated, or they may be stored in an appropriately color
- coded box or bin.
} 3.6.2 Gaskets ; i - Flexitallic gaskets shall be clearly color coded on their outside metal face or edge in accordance with FSM-00101. Color coding material should not be on the asbestos face of the gaskets. 3.6.3 Miscellaneous Items l Miscellaneous bulk piping items, when required, will be color coded as
- a means of detemining their acceptabi'ity, quality rating, use, etc.
' The Materials Control Group shall adv1<.e the chief warehouseman of the color code requirements. The color code shall be maintained until the item is either installed,
- attached to, or made into an item which has a unique identifying number such as a spool number, equipner.t number, etc.
- 3.7 E0VIPMENT VENDOR-SUPPLIED MATERIAL Vendors will supply pipe spools, fittings, pipe, studs, nuts, gaskets, etc., loose for B&P to assemble as recuired to complete equipment
. , packages or systems. Bulk material will be color coded by the ware-house personnel, as required, in accordance with FSM-00101. Materials ! Control Group will notify the chief warehouseman in writing of any coding requirements for other vendor-supplied materials. ! When vendor-supplied materials are color coded, the associated pur-
- chase order number should be written on the pipe spools., pipe, and fittings, when practical.
3.8 MATERIAL REQUISITIONS All "Q" items, pemanent material / equipment, and weld filler material shall be issued on the Material Requisition Fonn (Figure 6.9-C-1).
-s -
- W i
I* BROWN & ROOT, INC. ISSUE CPSES NtNBER REVISION DATE PAGE
! - JOB 35-1195 l CP-CPM 6.9C 1 7/21/80 6 of 7 i
Building department stock materials (Non-ASME) such as nuts, bolts, Richmond screw anchors, and Hilti Kwik-bolts that do not require OC verification, can also be issued on the material requisition form
! without OC concurrence. The following procedures apply when issuing materials.
- 1. The P.O. number shall be included on material requisitions, l except when requisitioning expendable construction material and bulk items such as pipe, pipe fittings, component supports,
! piping subassemblies, floor drains, lead, etc. NOTE: " Requisition", as used herein, is a written request to draw material / equipment from the warehouse; not to be confused 4 with " purchase" documents.
- 2. For all ."0" items, the properly prepared requisition will be signed by the appropriate CFS (or their designated alternatives),
and upon release from the warehouse, the person accepting deli-very shall sign the requisition showing both name and badge number.
- 3. No item shall be renoved from the warehouse area without proper written authorization, such as a material requisition. .
4 "0" items are not issuable to Construction until released by CC.
- 5. The material requisition should have the following minimum infor-mation:
- a. Piping Materials Quantity, description, heat No.,
pipe category, specification, color code or stock no., code class, or for field use the drawing (s) mater-
.a1 is to be used for.
- b. Piping Subassemblies Subassembly number.
- c. Component Supports Support No. for pre-engineered hangers. For field designed hang-ers, the quantit description, and drawings (s) which y, shows the pipe or hanSer material spect-fications. Class 1 ASME supports shall require a heat number for each material (except catalogue items).
o_ - - ~ . . _ . _ _ . _ _ _ _-
j, BROWN & ROOT, INC. ZSSUE ' CPSES NIMBER REVISION - DATE PAGE 4 JOB 35-1195 I CP-CPM 6.9C 1 7/21/80 7 of 7
- d. Valves Quantity, size, generic No., Serial No., and Drawing (s) on which valve (s:
are shown,
- e. Equipment Equipment No., P.O. No. and des-p cription.
- f. In addition to the above infomation, the applicable heat /
' log / serial number and code class shall be marked on the material requisition fann adjacent to the appropriate item for all "0" material .
I g. Any deviation from the original intended use or location should be so noted on the MR by the craft and verified by OCI
. as being acceptable for use (0 material only). This require-ment does not apply to bulk support materials.
I i h. Identification numbers should be noted and ve-ified on the i
' . appropriate MR. l 3.9 WAIVERS i If construction requires an iten which is on " Hold", they may reouest a waiver as provided in QAP 16.1.
( 3.10 RETURN TO WAREHOUSE j Items withdrawn from the warehouse that are not needed or that have i been fabricated by B&R construction and are returned to the warehouse { for storage until installation, shall be returned and documented on, I the " Material Return to Warehouse" form (Figure 6.9-C-2). l The responsible craft superintendent or his designee shall initiate i
) the fonn and give each one a unique number. The warehouse will treat j
these similar to MRPs and enter the quantities returned on the Material Control Cards, when applicable. I J r i g L
. BROWN & ROOT, ZNC. ISSUE CPSES NUMBER REVISION DATE PAGE JOB 35-1195 CP-CPM 6.9C 1 7/21/80 1 Of I _
TABLE 6.9C-1 Jos "Q" Interchangeable Material 6'$ and 4==17 - i Subetitute Material Material l l Cateeor7 1CCG 110G 1810 hs2G 501G 302a, 15023 6013 6023 9020 1302G2002G 100G sos. sos. nos. not. soi.
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115G 2 * ** 1513 2 E*2
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! 6013 42 f2 l so2G FSl* "i!* "!?1 d!?* "i;* I So2G i;**
ac2G f:;* 1501G l zoca 2501G l ::o o 25osG ,4
- 31. ni n1 mat. rial.
l Not. n ul zatorial e=.pt ca .e. l Note #3 n1 material above 2*p. I Note Mr All material above 2'W eznept Casses. l Note #5: ni material provided with mill test report I ezoopt nanses. l Note #6: ul zatorial 3*9 and dow. l' I i l l l l ___
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( . I l e BROWN & ROOT, INC. ISSUE l CPSES NUMBER REVISION DATE PAGE l
,. JOB 35-1195 CP-CPM-6.9C 1 7/21/80 1 of 1 J
FIGURE 6.9C-1 MATERIAL REQUISITION l BROWN & ROOT, INC. m.
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. BROWN & ROOT, INC. 1SSUE i CPSES NUMBER REVISION DATE PAGE JOB 35-1195 ,
CP-CPM 6.9C 1 7/21/80 1 of 1 i i FIGURE 6.9C-2 g . hN ma==anoor,=. j , 00071
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[ ATTACHMENT 10 8
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00CUMENTATION CHECX LIST , PACKAGE MARK NO. CC-/-I'8-O?f 74 ? #8.7 NUMBER OF PAGES TYPE OF DOCUMENT
- 1. O Manufacturing Record Sheet (MRS)
- 2. O Weld Data Card (WDC) Weld No(s).
- 3. / Weld Filler Material Log (WFML)
- 4. M4 Material Identification Log (MIL)
- 5. / Non-Destructive Examination Report (NDER)
- 6. / Inspectio'n Report (IR)
- 7. O Monconformance Report (NCR)
- 8. O Vendor Documentation j
! 9. / Repair Process Sheet (RPS) Weld No(s). 747 i t 10. O Operatiori Traveler (OT)
- 11. O Drawing (Including CMC) ,
- 12. O Material Requisition (MR)
- 13. O Miscellaneous (Describe Below) i l
The contents of this package as listed above have been reviewed per the requirements of CP-QAP-18.2 and are acceptable. OC Superintendent M cate s/ ORG Representative # Date $~h s~/f z .
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' 9 Total Number of Pages in Package ANI _W//.?~ i
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f0R INf0RMATION ORY 351 F01A-oo o3 m.wis
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[ A neRa nRx ,0. H cc - t-so - o se - ow - 2 k i NUMBER OF PAGES TYPE OF 00CUMENT
- 1. A4 Manufacturing Record Sheet (MRS)
, 2. I' Weld Data Card (WDC) Wald No(s). A-
, 3. / Weld F111er Material Log (WFML)
! ,, 4. f Material Identification tog (MIL)
- 5. 4!/- Non-Destructive Examination Report (NDER)
. s. A/4 InspectionReppre(IR) T-f 7. A/M Nonconformance Report (NCR)
I
- a. 4/A vendor Documentation
- 9. A Repair Process Sheet (RPS) Wald No(s)
- 10. M Operation Traveler (OT)
IOWG , v 11. 3 Orawing (including CMC) 2, cy_gg
- 12. A Material Requisition (MR)
! g 13. / Miscellaneous (Describe Selow) ! , A ffAct/M1f M $~ This documentation has been reviewed and accepted per CP-QAP-18.2 and the vendor certified as-built drawing. QE5 Representative Y Dat. rare, 7 /otal T
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numoer of pages in package ANI f Om 1/M/e 5 - E0R INFORMATION ONI.Y F0lA-85-59 . m us . m .- .- ,-n,_--n.
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- 4 OFFICE USE MY PIPE SUPPORT DESIGN GROUP wuct. EAR SAFETY REuTED PIPE SUPPORT _ "^ '"" " ' Cp.g gg , Qy, g p
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, COMANCHE PEAK STEAM ELECTRIO STATION
} PlPE SUPPORT DESIGN GROUP l NUCLEAR SAFETY REL ATED FrPE SUPPORT ORAWWG NO. O sur l. (p.AA.033 REv. l -oF- I
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- ATTACHMENT 5
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Pess / of 1 1
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Support Drawing Number / Revision QUALITY CONTROL CP-QAP-12.1 Rev. 7 l ^ gg, g,y J COMPONENT SUPPORT CHECKLIST l QCI/DATE SAT /UNSAT $ PARA. OP.NO. INSPECTION CRITERIA I Support Configuration complies with Vendor certi- N/"h3 i 3.5 1. LO lbuS3r mT; 3 fied or Design Reviewed Drawing (VCD/DRD) , i Structural member cut lengths comply with Refer- 4/"/O N/A 2. ence dimensions i 2" p,0,bSir 1.,+ > Baseplate attachment tolerances (excluding thick-T/#N f N/A 3. cess) comply with the VCD/DRD i is" OA/L uh INb ,- I N/A 4. Working point dimensions locatin structural com- N /#8/U - ponents comply with the VCD/DRD 1" (except for g ~
- pipe location tolerances) D [3a.mSh ma 'h a) All accessible welds reinspected and are in ! /h/U f
3.5.1 5. compliance with VCD/DRD. ' 14.t) b) All skewed welds have been reinspected and are '7/a/f3 in compliance with the VCD/DRD. '
//nA A Al/AZ-3.5.3 6. Snubber (s) Serial Number W /4 d. A Att h
! a) Nuts, bolts, cotter pins,1(ck wire, etc. in- , j stalled where required. I b) Exposed threaded surfaces are free of excess- l l ive rust or foreign material. l I c) Spherical bearings are free of foreign ma I '
- ial, and spacer (s) are installed as required.
- 7. Strut (s) (if applica IV hl - .Ale) Attun$ Y'!ff3 L N/A Serial number
?
.I a) Nuts, bolts, cotter pins, lock wire, etc. in- l 1
stalled where required. l 4 I b) Exposed threaded surfaces are free of excess-ive rust or foreign material.
- c) Spherical bearings are free of foreign material l,
'd) Jam nut (s) and barrel vill not turn by hand, l ,
l using nominal applied force. i i l
- 3. 5. 3 l' 8. Spring Can(s) (if a plicable)
Setta1 number nib O Dl%.rm% 'f/st/f) i l i ; I ' p j a) Nuts, bolts, cotter pins, lock vire, etc. in-stalled where required. !' f j j ? l
- b) Exposed threadci surfaces are free of excess- l 6 ive rust or foreign material. g l j l i
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.- . ATTACHMENT 5 M db/ 63 f o/O.7 2d P:gs 1 er A
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Support Drawing Number / Revision COMPONENT SUPPORT CHECKLIST OP.NO. INSPECTION CRITERIA QCI/DATE SAT /UNSAT i PARA. 5 - N/A 95. Concreta Expansion anchors embedment/ engagement com- 7//U plies with drawing or Attachment 55. Q Q A, % 9b. Concrete inserts have proper embedment/ engagement k (2D + 1/8"). Ono *V"An AJ/#1 l 4 ATTACH 10. Installation of.U-bolts on large bore /small bore i 5g supports shall be inspected as follows: s f 1) U-bolts used in pinned connection application (i.e., struts and snubbers) are to be installed ,
' on the pipe as shown in Figure 1 for large bore T.
I supports. dDON/M v M h1 a i 2) U-bolts on rigid frames. (large bore) shall be installed as shown in Figure 2. 008%A1 - A//A. u
- 3) U-bolts on small bore supports shall be installed as shown in Figure 1 as specified on the hanger drawing. (10A >A'/rn N/s1 f
3.5.2 11. Clearances must be verified if: a) The support configuration is modified by design change. ODBYk M/11. 1 b) The support is being reinstalled following re-f moval to accomplish a design change or other construction; or .7)A M//n A/hf. c) Directed by Engineering. A A
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i N/A 12. Remarks: FOR !!fl RMAIl0ll DNLY. t i e t 1
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APPROVAL SIGNATURES SHALL SE AFFIhD IN THE-gp,K,. I.yED,I,A,TELYf,d,ELC'd THE g*gTE? *N EA , SEQUDCI. ( lill t ,. .t.sa.2 . . i. .. -
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- :.n e, 00CUMENTATION CHECK LIST uCxa E ax NO. # cc - /-so - o 3s - ow - 3 d NUMBER OF PAGES TYPE OF DOCUMENT
- 1. A/4 Manufacturing Record Sheet (MRS)
, 2. I' Weld Data Card (WDC) Weld No(s). A-l
, . 3. / Wald Filler Material Log (WFNL)
, 4. f Material Identification Log (MIL)
- 5. M4 Non-Destructive Examination Report (NDER) .
I 6. MM Inspection Report (IR)
- 7. AM Nonconformance Report (NCR)
- 8. 4/M Vendor Documentation
- 9. M Repair Pmcass Sheet (RPS) Wald No(s)
- 10. A- Operation Traveler (OT)
! 8OWG i v 11. 3 Drawing (including CMC) 2. Cr-//d
- 12. A Material Requisition (MR) g 13. / Miscellaneous (Describe Below)
, N ffActinif4/f' $~ .
l This documentation has been reviewed and ac:apted per CP-QAP-18.2 and the vendor certified as-built drawing. QE5 Representative - Y 0.te 7 Aves 7 Total usoer of pages in oackage ANI P/E OArE WM/e + EOR NORMATION ONLY F0lA-85-59 . m 3, ;
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, T ;iNcHEst COMANCHE PEAK STEAM ELECTRIC STATION l( em,s.up vent w-s 36 39 -/ 5
.65
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PIPE SUPPORT ENGINEEMtNG
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35-1195 tiv . CONTROL ), _ nnn. :.h .. 5 -
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, COMANCHE PEAK STEAM ELECTRIC STATION PIPE SUPPORT DESIGN GROUP l DR AWWG NO. O car NUCLEAR SAFETY RELATED FtPE SUPPORT (p.AA.033 R E V. l -OF- I l
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/l CC-/ 5/3 -O W-ce/o-3 [d Support Drawing Number / Revision QUALIM CONTROL CP-QAP-12.1 Rev. 7 gg, p y [ COMPONENT SUPPORT CHECKLIST QCI/DATE SAT /UNSAT' PARA. OP.NO. INSPECTION CRITERIA 3.5 1. Support configuration complies with Vendor Certi- Y"h3 to A253r Imr; l fied or Design Reviewed Drawing (VCD/DRD) '
Structural member cut lengths comply with Refer- Y/ "M N/A 2. ence dimensions i 2" f.0/5auHir 3 =-M
- 3. Baseplate attachment tolerances (excluding thick-N##N 4 N/A ness) comply with the VCD/DRD i Is"
#AA, m,% lub l I y -
N/A 4. Workingpointaimensionslocatingstructuralcom- N blI3 ' ponents comply with the VCD/DRD - 1" (except for g -- Ila/3am a m M
- pipe location colerances) 4 6
a) All accessibis welds reinspected and are in ! W##!I3 5 3.5.1 5. ' k s.t> I compliance with VCD/DRD. b) All skewed welds have been reinspected and are 7////f.3 in compliance with the VCD/DRD. /lo/%w& A)/AZ-3.5.3 6. Snubber (s) Serial Number M /4 O. O A a., O
, a) Nuts, bolts, cotter pins, idc'k wire, etc. in- ,
stalled where required. l 1 8 b) Exposed threaded surfaces are free of excess-ive rust or foreign asterial. I c) Spherical bearings are free of foreign sa i tal, and npacer(s) are installed as required. N/A 7. Strut (s) (if ap Serial number /\/plicable)/ 4 .d, . O A rt w b Y '# / f 3 a) Nuts, bolts, cotter pins, lock wire, etc. in- ; j i stalled where required. '
,e l j b) Expc, sed threaded surfaces are free of excess-ive rust or foreign material. .
c) Spherical bearings are free of foreign material ! l d) Jam nut (s) and barrel will not turn by hand. l { using nominal applied force. e l 3 I plicable) l 3.5.3 ; 8. Spring Can(s) (if ' Serial number /V/B D /3 a m s h 7 /// / I ) ! 4 V i l a) Nuts, bolts, cotter pins, lock wire, etc. in-stalled where required. !' 4 1 - Ib)Exposedthresdetsurfacesarefreeofexcess. l l ive rust or foreign material. g l e l l .
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. ATTACHMENT 5 !
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- M bGI - SB us t.oio. , 2d Pcs, t at x.
Support Drawing Number / Revision QUALITY CONTROL CP-qAP-12.1 Rev. 7 COMPONENT SUPPORT CHECKLIST PARA. OP.NO. INSPECTION CRITERIA QC1/DATE SAT /UNSAT N/A 9a. Concrete Expansion anchors embedmont/ engagement com- '///U plies with drawing or Attachment 55. a O lt A 9b. Concrete inserts have proper embedmont/ engagement (2D + 1/8"). Ono /"An Al/d2_ ATTACH .
- 10. Installation of.U-bolts on large bore /small bore 53 supports shall be inspected as follows:
- 1) U-bolts used in pinned connection application (i.e., struts and snubbers) are to be installed on the pipe as shown in Figure 1 for large bore
&DOD/n _ Al h1
( supports. v a
- 2) U-bolts on rigid frames. (large bore) shall be installed as shown in Figure 2. fif18 Eh1' A/hL U
- 3) U-bolts on small bore supports shall be installed as shown in Figure 1 as specified on the hanger drawing. d0/4 A'/r, N/>i a -
3.5.2 11. Clearances must be verified if: a) The support configuration is modified by design change. ADAY"As Af/11. F b) The support is being reinstalled following re-moval to accomplish a design change or other ) construction; or .7)/ %Ar) A/ha c) Directed by Engineering. A l 1 N/A 12. Remarks: f!! !NR MAIL 0ll ONLY. i NN ** W QWW* DWW'" *- W' W '*
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h'A n n D -{.2 7 / A 7N/ AM /-/ ACC STD : I I I I L , AS.*E III- 5 l l ' l NQir.5: 1. APPLICA6LE QC/ANI HOLD POINT 5 ShALL SE INDICAiiD SY ChEC.OAaX. ? 2. ANI INSPECTION POINTS It:0!CATID SY (X).
- 3. 0 00TE SAT.ISFACTORY.!NSPECTIONS.BY AN "S": UNSATISFACTORY INS?!CTIONS SY. A "U".
i !~ ' OPERATION F OPERATION 5 ! L Cunnnet Nember Identificatinn I l Sonerical Searinos 2 Size. Confiauration. Tolerante/0wo. 8 i All Welds /0wo. & WP5 (V.T. ) = 3 Material Correct /0wo. 9i 'nstallation Comolete ! 4 Fasteners Correct & Comolete
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. I i BROWN & ROOT, INC. PROCEDURE EFFECTIVE NUMBER REVISION DATE PAGE
.- CPSES .
JOB 35-1195 # 1 E 1984 i CP-CPM 6.9D 6 j 1of58*E!<.. T TIRE: ORIGINATOR: . [4 - /'M ~
~
' OATE l 1 CP-CPM 6.9D REVIEWED BY:h. t M / t N
(APPENDIX D)' igu . ggg -;--- gg 7 i WELDING AND RELATED REVIEWED BY: n 2 h , PROCESSES DATE
#54 TUGC0 QUAL Y ASSURANCE o c.w*- i pM REVIEWED BY: . fs/[ ;
SR. PR0iECI WELD ENGINEER
/ -@ -M DATE i APPROVED BY: N W F /-'C-5 CorblMUCTION PROJECT MANAGER DATE.
FOR OFFICE AND
1.0 INTRODUCTION
ENGINEERINS USE O 2.0 CENERAL 2.1 APPROVAL AITIHORITY 2.2 RESPONSIBILITY 2.3 SPECIAL REQUIREMENIS 2.4 PREFABRICATION / INSTALLATION VERIFICATION 2.5 DOCUMENTING WELD INSPECTIONS 2.6 WELD PARAMETER GUIDE l 2.7 BALANCE OF PLANT PIPING AND STRUCTURAL STEEL INSPECTION j AND DOCUMENTATION ;
. , 2.8 CONTROL OF WELDING PROCEDURE SPECIFICATIONS AND RELATED DOCUMENTS l 3.0 WFLDING !
3.1 LIMITED ACCESS WELDS (FIELD WELDS) 3.2 CLEANING OF WELD PREPS AND BASE METAL 3.3 PREHEAT /INTERPASS TEMPERATURE 3.4 INERT CAS ' 3.3 PURGE DAMS AND CONTROL OF PURCE DAMS 3.6 CONSUMABLE INSERTS 3.7 BACKING STRIPS AND/OR RINGS 3.8 PEENING 3.9 IMPACT TESTING 3.10 WELD JOINT DESIGN AND PIT-UP l F0lA-85-59
+
/11333
T
, / -.
PROCZDURE EFFECTIVE BROWN & ROOT, INC. NUMBER REVISION DATE PAGE CPSES JO8 35-1195 UAN 121984 . CP-CPM 6.9D 6 - ' 2 of 58 3.11 TACK WEDS 3.12 INTERPASS CLEANING 3.13 WOREMANSHIP 3.14 PIPE ATTACHMENT WELDS 3.15 WELDING TECHNIQUES 3.16 WEDMENT SURFACES 3.17 FINAL NONDESTRUCTIVE EXAMINATION i 3.18 FERRITE CONTROL l
- 3.19 WELD AND BASE METAL REPAIRS --- -- 1\bh d ' WM 3.20 WELDER QUALIFICATION -- '"
3.21 POST-WED HEAT TREATMENT !. 3.22 BRAZING OF COPPER PIPE OR TUBE 3.23 SOLDERING OF COPPER PIPE OR TUBE 0.11 TABLES
, 6.9D-1 PWBT POR ASME SECTION III, PIPING SYSTES 6.9D-2 PWHT FOR ANSI B31.1, PIPING SYSTEMS 0.111 FIGURES
~
6.9D-1 WILDPARAMETERdUEDE 6.9D-2 WELD DATA SHEET 6.9D-3 REPAIR PROCESS SHEET 6.9D-4 FIED INSPECTION REPORT 6.9D-5 PURGE DAMS 6.9D-6 PURGE DAM LOG 6.9D-7 CONSUMABLE INSERT DESIGN 6.9D-8 JOINT DETAILS FOR CONSUMABLE INSERTS ' 6.9 D-9 BUTT JOINTS WITH BACKING 6.9D-10 BUTTWELD ALIGNMENT TOLERANCES 6.9D-11 SOCKET WELD FITUP - - 6.9D-12 DELTA FERRITE LOG 6.9D-13 REQUEST POR WEDER TRAINING AND/OR TESTING 6.9D-14 WELDING PERFORMANCE QUALIFICATION WORKSHEET 6.9D-15 BRAZING PERFORMANCE QUALIFICATION WORKSHEET , 6.9D-16 PWBT W NTROL PORM 6.9D-17 THERMOCOUPLE PLACEMENT POR PWHT 6.9D-18 Q PIPE WELDING FLOW CHART
- 6.9D-19 TYPICAL FITTING TO FITTING SOCKET WELDED CONNECTION j 6.9D-20 HEATING ALIGNMENT FORM 6.9D-21 JOINf ePREPARATION FOR INSERVICE INSPECTION 6.90-22 POST WELD HEAT TREATMENT CHECKLIST I
s - PROCEDURE EFFECTIVE BROWN & ROOT, INC. NUMBER REVISION DATE PAGE CPSES JOB 35-1195 . CP-CPM 6.9D 6 ' EW4 39 of 58 Require visual examination where accessible. Require UT examination, or where possible, mechanical measurement to verify wall thickness. Where VT is impossible, RT may be substituted. 3.19.4 Base Metal Repairs 3.19.4.1 Major Defects Q,50P Base metal defects that must be repaired by welding are major repairs.. , 3.19.4.2 Minor Defects. Q,50P Base metal defects removed by grinding are minor repairs; however, if grinding violates minimum wall thickness, the repair must be completed as a major repair. 3.19.4.3 Reporting and Documenting Surface Defects BOP, Q Welding Engineering shall prepara a RPS for all major repairs. Surface defects (including laps, seams, are strikes, gouges, etc.) do not require a RPS if they can be corrected without welding. These conditions may be recorded on a Base / Weld Metal Inspection Report (B/WMIR) by QC. The B/WMIR may be presented to the craf t and corrective action taken. If during the corrective action minimum wall is violated, work shall be suspended. A RPS shall be obtained before work may be resumed. Minimum wall violations within 1" of piping and preps may be identified on a B/WMIR and forwarded to Welding Engineering for preparation of a RPS. BOP, Q Surface defects (other than are strikes) no deeper than 1/16 inch need not be repaired if the defect does not encroach on the minimum wall thickness. Minor base metal repairs do not require an RPS. QCI The QC NDE Inspector will mark the repaired area, when practical, with a " Nissen Ink Marker" showing a circle around the area and the repair number after the visual . p examination is complete. Mafor base metal repairs on the inside surface of an ites shall be located and marked on the outside surface to facilitate inspection during the pressure test.
. _ - . . _ _ , . ., ._ . , . - _ . - _ . . _ _,m ,m . . - . , . . __.___m-,--...,_.-m _m _ , , , _ . , , - _ _ _ , _ . _ _ . . _ _ . _ _ _ - -
. i -
PROCEDURE EFFECTIVE BROWN & ROOT, INC. NUM8ER REVISION DATE PAGE CPSES CP-CPM 6.9D 6 II 1984 40 of 58 QCI After performing base metal repairs the repaired area shall be inspected as required by Appendix 6.9G and as supplemented by the PWE. QCI Westinghouse will evaluate and provide resolution on any enjor or minor repairs on Westinghouse supplied items (this shall include all are strike repairs. Modification of any Westinghouse-supplied items must have Westinghouse approval prior to the modification. All are strikea shall be removed from base metal surfaces. I NOTE: Defect repair cavities shall be sufficiently wide to permit complete fusion and allow free manipula-tion of the electrodes during repair welding. 3.19.5 Documentation and Evaluation of Minimua Wall Violations 3.19.5.1 Minimus Wall violations at Weld End Preps
- 1. QC shall place a hold tag on the item ani note the rejectableNDE report number on the hold tag.
- 2. Submit the NDE report to Welding Engineering.
- 3. If the minimum well violation at weld end preps can be repaired in accordance with the requirements of Speci-fications MS-100 or MS-43B or MS-445, then Welding Engineering will issue a RPS (for completed or par-tially completed welds) or additional operations on the WDC (for joints where welding is not initiated).
- 4. If the minimum well violations at weld end props cannot be repaired in accordance with the requirements of Specifications MS-100 or.MS-438 or MS-448, then Welding Engineering shall submit the RPS to Mechanical Enginee'-
ing for evaluation and resolution.
- 5. The hold tag will be removed by QC prior to start of work only af ter the RPS has been issued or the NCR dispositioned "use as is" by engineering.
3.19.5.2 NCR's for Minimus Wall Violations
- 1. Welding Engineering shall review the condition stated on the NCR and compare the stated wall thickness against the specified minimum wall for the piping system in accor-dance with the following criteria.
l _- m_ v -
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SROWN 1 RCOT INC. ISSUs O CPS s Ntmasa RevtSION oArt PAaz J08 35-1195 . QI-QAP-11.1-21 16 'RN 11 W i of 73 itTLE: ORIGINATOR: M 4 -#8/ DATE
- IC ON AND E GED BY* M- A- [. hv k INSTALLATION
- C#
l INSPECTIONS APPROVED BY: , d & , site ( A Manager V QATE d l
1.0 REFERENCES
1-A ASME Boiler & Pressu re Vessel Code, Section 111, 1974 Edition with Addenda through Summer,1974 1-B 2323-MS-100 1-C Brown & Root Quality Assurance Manual ' 2.0 GENERAL OR WORgG0K 00 2.1 PlRPOSE AND SCOPE This instruction delineates the requirenents and criteria to be used when perfo nning fabrication or installation inspection of ASME Code piping to assure compliance with the above applicable references. This instruction is i applicable to the fabrication and installation of Safety Class 1, 2 and 3 piping and applicable camponents. When - implemented for other than Safety Class 1, 2 and 3 piping,
, third party inspection (i.e., MI) is not required.
2.2 RESDONSIBILITY l The Quality Control Group Supervisor shall be responsible for implementation of this instruction. 2.3 PERSONNEL QUALIFICATIONS All QC Inspectors (QCI) pe rfonning inspections in accordance with this instruction shall be trained, qualified and certified in acconiance wi th the requi renents of QI-QAP-2.1-5.
' l L 8- 2.4 R00 TINE OBSERVATIONS q Inspection personnel performing inspection T =
q . observe general workmanship conditions in all areas of p an l
- cons truction. Observa t hall include such itens as
- r
r / . g [8ROWN & ROOT, ING. 4 CPSES
./
J08 35-1195 NUMBER i REVISION ISSUE DATE I-QAP-11.1-26 16 PAGE 3.10 y y y gg 33 of 73 3.10.1 WEl.D AND BASE METAL REPAIRS In Process Weld Repairs In process repairs prior All majorto final Code required E. NDshall be defined as t scovered shall be
' Process Sheet evaluated (RPS by theore PWE final whoweld defects d (Atta N
sequence at his disc)retion. chment 26,may generate inspection a Repair 1 OTE: typical) operational i
,' Through wall repairs l 2 1
3.10.2 Weld Metal Repairsless metal remains shall req i u re a RPS. 3.10.2.1 Major Repairs l f. M The ~ [. code following required NDE shall bedefects during discovered .
- a. All cracks and classified as "or after fin +
Major Repairs"al: i the final inspec/or linear defects b-
- b. ic'
~repair,Cracks, that are and repairedtion of during a weld joint. .Uide G
- c. Minor repair then reappear after the @p@j
,.i that reduces 1/8" or less the thicknessexcavating that result in a r ff ,j
- d. of the weld to approximatelyepair cavity N .%jD Any defect which i 1:$I
- e. hydrostatic testing.s identified during fi b) W' 3 All defects which penetra nal PWiT or p, g4 3.10.2.2 as grind-throughs or burn te the root of iS;w"t')
throughs. the weld, such PWE Resolution of epa Major irs R 'y i,(!} The >
; *s resolution '
contain as a minimum,
- a. w ng:
the follo ishall be by the PWE using ,.l An explanation and shall excava te the of the method gouging). defect (mechanicalto means or be used and to locate thennal
- ss fa; '
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,l! JOB 35-1195 QI-QAP-11.1-26 16 i 35 of 73 To limited be minimize to sensitization two repairs. of SS material, each defect shall If the defect has not been eliminated in two attenpts the procedure shall be submitted (1
by the Project approval Welding defining Engineer (PWE) to the Owner for me thods for further repair and sensitization control. When a weld is completely removed for any reason, the weld prep configuration may be restored and the weld replaced in accordance with an approved WPS. If any weld defects are evident in the replacement weld, a procedure shall be submitted by the PWE to the Owner for repair and sensitization control torenoved completely remove such defects. In no case shall and replaced more than twice without a weld be 4-specific Owner approval. NOTE: \ When stainless steel items which have been welded , previously the nextaresequential reused, the new weld number shall be ' s the highest alphanumeric weld number.nunber of the iten wi th ' 3.10.3 Base Metal Reoatrs I Base metal repairs shall be defined, evaluated, resolved, and documented in accordance with CP-QAP-16.1. I g I 3.11 POST-WELD HEAT TREATMENT 4 h, Post-weld heat treatment, when required, shall be perfonned 6 to the qualified WPS and to the specified heat treatment procedure approved by the PIE. ' N W 3 QC inspection and 3 surveillance of PWHT shall be in accordance with the procedura referenced on the process (: sheet and Checklist documented (Attachment on the 27, typical) Post Weld provided Heat Treatment by the PWE. N
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The time-tenperature chart shall < to assure that PWHT is perfonned be verified by the QCI l l].p applicable WPS. in accordance with the 4, , , , 3.12 } ' ,a PIPE BENDER OUALIFICATION Bender shoes carbon steel nay be used for bo th stainless steel and interchangeably without > O decontamination. intermittent '
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Note: Major rewrite, no change barn. BROWN & RCOT, INC. ISSUE NU48ER REVISION DATE PAGE
$ CPSES 408 35-C95 1 of 37 21 CP-QAP-16.1 ,g y g h;h. TITLE: CRIGINATOR: M .
4 /AM sA.. CONTROL OF REVIEWED BY:
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CATE N% NONCONFORNING APPROVED BY: ' dN 6 ' 9/
. Site QA Manager OATE
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1.0 REFERENCES
2.0 GENERAL FOR N ~0R V A"LON 0'\"' Y 2.1 PURPOSE M0 SCOPE
! The purpose of this procedure is to establish a methaJ by
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< O resolved, and closed . The requirenants contained herein 1, 2, i are applicable to Safe ty Class
' and 3 fluid piping sys tens, their supports, and in-line equipment. When implemented for other than Safety Class 1, 2, and 3 itens, third party inspection (i.e., ANI) is not required.
NOTE: It is the responsibili ty of site enployees to ider tify nonconfoming conditions in accordance with this procedure. d 2.2 DEFINITIONS l 2.2.1 Nonconfonnance 4 A deficiency in characteristic, documentatiun, or procedure wnich ren(trs the quali ty of an iten unacceptable or indetenninate. 2.2.2 Nonconfomance Report (NCR)_ A Nonconforrance Report is the document that is used to identi fy, disposition and veri fy adequacy of the executed disposition of properly identified and documented nonconfomances. O R RO
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'SR00 & ROOT, INC. ISSUE REVISI0il DATE PAGE
, , CPSES NUMBER JOB 35-1195 9 of 37
. CP-QAP-16.1 21 JUN 11199
! I 3.2 INSPECTION REPORTS 3.2.1 Base / Weld Metal Inspection Reports Nonconfonning cHitions may be identified on a Base / Weld Metal Inspection nort (B/WMIR, Attachment 7) as delineated in the following paragraphs.
NOTE: a. Prior to writing a B/WMIR the QCI should refer to Attachment 8 of this procedure for clartf tcation of noted condition. I
- b. Base metal defect and are strikes discovered on "N" Symbol stamped conponent shall be documented on a NCR.
3.2.1.1 Minimum Wall Violation Minimum wall violations within 5" of piping end preps can
$ be identified on a B/ WHIR and forwarded to Welding Engineering for action.
The repair shall be perfonned in acconiance with a standard repair / rework procedure. All other minimum wall violations shall be documented on a NCR. 3.2.1.2 Defects Discovered After System / Subsystem Pressure Testing Arc strikes and base / weld metal defects discovered af ter accepted systen testing shall be documented on a NCR. NOTE: Weld repair to a pressure retaining item af ter an acceptable pressure test does not require the retest of the repaired area provided:
- a. The defect was not detected by RT.
- b. The depth of repair cavity prior to welding did not exceed 3/8" or 10% of the actual thickness, whichever is less.
3.2.1.3 Distribution Once the B/ WHIR has been initiated, the serialized B/ WHIR f number, item description and condition shall be entered on the QC 8/WMIR Log (Attachment 9). The B/WMIR shall then be forwarded to the applicable craf t personnel for action and subsequent QC inspection.
F ht3WN & R007. INC. ISSUE CPSES NUMBER REVISION DATE PAGE f'q JOB 35-1195 CP-QAP-16.1 21~ JUN 111984 10 of 37 I ; I, l 3.2.1.4 Close Out When the B/WMIR is satisfactorily completed, the QC 8/WMIR Log shall be updated to reflect the status and the B/ WHIR ! will be stamped with a QA Record Stamp (Attachment 10). The S/ WHIR shall then be forwarded to the QE for review for technical adequacy, clarity, legibili ty and trending from the list of trend categories (Attachment 11). When , entering the applicable trend categories on the B/WMIR, the QE will initial and date the entry. After QE review, the B/ WHIR shall be processed in accordance with CP-QAP-18.1. .,
.g 3.2.2 Reportino Deficiencies 3.2.2.1 General The purpose of the Inspection Report (IR, Attachment 12) is i to establish a method of documenting field QC activities not recorded on other Process Control or QA documents.
O NorE: IR's shaii not be used to document any deficiency dich is: I
- a. Related to an "N" Symbol stamped canponent; ,
- b. Any deficiency identified after final QA acceptance of a hanger package or required i Code pressure testing; or
- c. Cannot be reworked in accordance with 1 existing approved project procedures.
3.2.2.2 Preparation /Use The IR shall empletely and accurately describe the iten or i activity observed. Questions regarding inspection i characteristics should be directed to the QCE/QC Supervisor. 3.2.2.3 Numbering
) Satisfactory inspections reported on an IR do not require a log number. The QCI shall enter sufficielt applicable ' identification on the IR to maintain traceaoility to the
- item being inspected and N/A the IR log number space.
I g, When comple ted , the IR shall become part of the i ten's
- documentation package.
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PROCEDURE EFFECTIVE
/ NUMBER REVISION DATE DAGE g- BRCWN & ROOTe INC.
CPSES i e JOB 35-1195 JUN 111984 24 of 37 2 't CP-QAP-16.1 ATTAC1 DENT 7 SERIAL NUMSER
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- BASE / WELD METAL INSPECit0N REPORT .aas *_
UNff PAGE CP , JOB NO 35-119g PAOJECT: COMANCHE PEAK CLASS: 1 2 3 OTHERj *2 SYSTEM: [ OR AWING: ITEM NUMSER: LOCATION: MTL THICKNESS: MTL. TYPE: 1 Skaten & Commene _ MIN. WALL GOUGE _ ARC STRIKE BASE METAL O ACCEPTANCE STD ears Rev. Accese O Ameet C : __ _ u; v.T.: oars P.T.: Rev. Accost 2 Reect C Insoector Cienner Seica a p.c . .t seien a Atrechment a Devecoor 8. ten # eart U.T.: Rev. Accoot C Remet C inesector Cel. Dwe Oete: M4TilRC # m-nan macain g - ::: e .-ee
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; , i IT f PROCEDURE EFFECTIVE REVISION DATE PAGE BROWN & ROOT, INC. NUMBER CPSES ,
JOB 35-1195 g yy g 25 of 37 i CP-QAP-16.1 21 i ATTACILENT 8 , t 1.0 BASE METAL DAMAGE AND ARC STRIKE REPAIR ON THE BASE METAL i 1.1 REPAIR OF ARC STRIKES MD BASE METAL DAMAGE ON ASME CODE CLASS 1 (NB) PIPING
- a. Arc strikes on ASME code class 1 items shall be rmoved Q.
by grinding or buffing. The ground area shall be blended unifonnly into the surrounding area and shall be examined by PT or MT. Pipe wall thickness shall be , N checked after grindi ng or blending to assure that minimum wall thickness requirements have not been $ violated, per Table 1.
. b. Mechanical erks, abrasions or other surface defects including cable marks, tool marks or pits, deeper than' 1/16 inch, shall be renoved by grinding and blending.
followed by PT or MT to assure removal of the defect. t g Also, surface defect no deeper than 1/16 inch if of I abrubt nature and becomes a stress riser, shall be removed by grinding and blending followed by PT or MT f; to assure removal of the defect. The defect area shall be minimum all thickness examined to assure that the requirements, per Table 1 have not been violated. NOTE: Surface defects no deeper than 1/16 inch need i not be removed if the defect is unifonnly j blended into the surrounding area and does not encroach on minimum wall. 1.2 REPAIR OF ARC STRIKES M0 BASE METAL DAMAGE ON ASME CODE CLASS 2 (NC) AND CLASS 3 (NO) PIPING
- a. Arc strikes on P-1 Carbon Steel shall be visually inspected for linear indications such as cracks or unacceptable undercuts or crater. (Surface my require preparation by filing or application of abrasive paper to provide a surface suitable for visual inspection.)
If linear indications are found, they should be lightly l ground and blended then visually inspected and followed { by a minimtsn wall thickness examination to assure that , the requirements per Table 1 for class 2 and 3 piping ! f have not been violated. Arc strikes on all. steel, other than P-1, shall be removed by grinding and
/ visually inspected to assure that it has been removed.
O After grinding and blending, wall thickness shall be checked to assure the minimum wall. t __ .u. ._ . _ . . . - . 9
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CPSES ISSUE ! NUMBER REVISION ' DATE PAGE J08 35-1195 t l CP-QAP-16.1 21 l g I1 lbb4 26 of 37 i L ATTACHMENT 8 (Continued) ! E
- b. llechanical marks, abrasions or other surface defects including 1/16 inch,cable marks, tool marks, or pits, deeper than shall be removed by f-followed by a visual inspection. grinding and blending Also, surface defect O no deeper than 1/16 inch if of abrubt nature and becomes a stress ri ser, shall be reoved by and ,
blending followed by a visual inspection. grinding F The defect area shall then be minimum wall thickness examined to assure that the requirements per Table 1 for class 2 , and 3 piping have not been violated. l NOTE: ,! Surface defects no deeper than 1/16 inch need ' not be blended reoved if the defect is unifonnly into the surrounding area and does not encroach on minimum wall. . 1.3 - 1.3.1 REPAIR OF ARC STRIKES AND BASE METAL DAMAGE ON N NF Class 1 Hancers ,
- a. ,
Arc strike on Class 1 itms shall be reoved by 0 grinding and ground area shall be examined by VT. The grinding and detennination of possible weld repair ' shall be in accordance with Table 2. ,
- b. l, Mechanical marks, abrasions , cable marks, tool marks or pits shall be removed by grinding if it violates V-section by VT. minimum wall and ground area shall be examined Determination of possible weld repair shall be in accordance with Table 2. l 1.3.2 ;
NF Class 2 and 3 Hancers l a. Arc strike on P-1 carton steel shall be vi sually inspected for linear indications such as cracks or l l unacceptable undercuts ~or crater. (Surface may require l i preparation by filing or application of abrasive paper I i < to provide a surface suitable for visual inspection.)If linear in ' Detenninationreoved by grinding and area shall be visually examined. of possible weld repair shall be in : accordance with Table 2. l Arc strikG on all other steel ' (i.e., vi other sually than P-1) shall be removed by grinding. and examined. - Detennination of possible weld l '. repair shall be in accordance with Table 2. l ,- t s M I
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The information preceding was given to CASE in the form of an affidavit However, I did not want them to turn it in in the hearings on December 18, 1982. or to turn it over to the NRC or the utility. I gave the information to sone newspaper reporters, and an article ran in the FORT WORTH STAR-TELEGRAM onAf te January 7,1983. A copy of that article is attached. l I was shot at and have been on the run One CASE a few times by phone from different states. ever since night when and I camehave home.been in tou -l l 1 found my cat; its head had been cut off smooth and its body was mi Since the article appeared ,in thethre.e different vehicles (one truck 14ve and two ca l same problem -- the nuts were just about to fall off the tie-rod ends. I
-b:cn scared to go back and sign up every six weeks for my unemployment because l'm scared someone may shoot me.
I know about at Some of the reasons I'm scared is because of the thin ere I've'sorked t ' Com nche Peak and another r.uclear lant As I mentioned fore, there, are j
'wald seams around the Reactor Core and new spent fuel pools which we Were told were not supposed to lose 1/2 ounce of contaminated liquid per year per seam.
Thtse seams were approximately 100 feet long;when weInstead tested these seams,some of repairing some l of them were losing approximately 65 lbs. a minute cf these seams, the gauge was blocked off and pressure was put on the gauge only.
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When the inspector passed the weld. seam, he thought the whole 100 feet was under Also, some of the stainless liner walls broke pressure, not just a few inches. losse from embedded plates that are in concrete walls which sone of these plates w:;re improperly welded. By these walls breaking loose they sprang out several
- inches from concrete wall; therefore, when refueling Of course, the the reactors, weight of thethe stainless water w.ill I st:el liners were flooded with water. After The refueling process is 'over . '
i I push the liner walls back to the concrete.and water is drained out of t could result in welds cracking or walls splitting. tiens to Brown & Root's Vice President, he told me he was rd that concerned about the gauges being blocked off but he was concerned about the walls breaking loose. If I had told him of improper welding on these walls, I wonder if he l ! I feel these pr,oblems should be repaired. w:uld have been concerned at all? For instance, quality control is supposed to verify the torquing of[ R torquing. l , The hanger is on a 20 foot piping sup' port that should be torqued atQuality 130 lbs.control is on the floor; the torque y cailing with a scaffold built to them. wrench is sent down to get QC to verify the number and setting of the torque * ' g wrench and carried back up and placed on,the nut before torquing. QC hears Wh'at h a torque ' wrench click twice on each nut and buys off (approves) .th,e hanger. 5 f QC di'd not know was that the construction personnel'had The second torque a second wrench wastorque set wrench l and also had a nut welded on the scaffold. Therefore, the > * }~ ct a low torque' poundage such.as 3 lbs. and they clicked it twice . l . For instance,
" There were also violations such as pipe supports around the pipe.
3/16" clearance is s'upposed to be maintained on each. side.Fdr andinstance, on top and a the pip
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l l is' supposed to be resting gently on the bottom of the support.a construc 2" pipe: crewmen so when QC comes to inspect the support, the weight will push the pipe
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to the bottom. In so'me cas'es, the pipe was. binding so tight they would use
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! j pipe, they take a grinder and grind between the pipe and tube steel, which in % sone cases results in a reduction of wall thickness of pipe. I believe this could result in a rupture of the pipe. Construction has also tried to straighten g a pipe support by using a sledge hamer; this is done. quite of ten. An employee told me that while hitting on the hanger he also hit the pipe and caved in the side of the 2" pipe 1/2 inch or more. He reported it to his supervisor who said . not to tell anyone and covered it up with I.D. tags. . Another incident is improper personnel designing and engineering pipe supports . For instance, one helper told me while he was employed at the. plant he designed many pipe supports for engineers. One day he wondered if.they p-were using his engineering and if they were then checking his work, so he deci.ded that he would design a hanger improperly and send it to engineering. The engineer passed it on to construction which built the hanger and it is presently installed
- . improperly. The helper said that he did not want to go to any NRC hearing but.
he would love to have a showing and he could show m'a'ny things if he was allowed . to take investigators and actually show them the supports in the plant. Other I , helpers have also been involved in making major decisions for which they are not j qualified. ~ Another violation is a sensor in a dam was run over and broken by a bulldozer. - I understand that these sensors are placed in the dam in a vertical position in
, order to tell whether the dam moves or not. This senser was not removed or re-i paired. It was held up and dirt packed around it while being embedded in the dam.
[ The construction company, Brown & Root, lost a $3 million contract at ! Crystal River Power Company in Florida, by a dam breaking, I was told by one
- of the Vice Pmsidents of Brown & Root. What concerns me is that if this dam .
- ' breaks, they will lose more than a $3 million contract; it will endanger many li ves . .
There is also a violation that concerns me regarding the use of rejected
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concrete material .in the early stages of the plant when the reactor core was poured. A friend of mine told Brown & Root's Vice President's investigating i crew that he was a front end loader operator at the concate plant and one day a QC inspector told him that the concrete should be thrown away because it l was hard and dried. 'The inspector walked away and my friend started throwing ): it away and a supervisor told him to put it back in and use it and they did. My friend a' Iso told the investigating crew of some type of sampling machi,ne that tells whether there are good, samples or bad samples in .the concrete. It - had a, wire run to it while QC watched 'the machine to verify the use of good samples., Parsonnel would pull the wire to make it read. good when it was.not. My friend also told of other people that know of these violations and as far as I know. Bro,tn & Root did not. contact aily of these people, but talked with one of their
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supervisor.s and his brother that worked at the batch plant; they, of course, told / i them that they knew nothing of this incident and since the superintendent is deceased, they did not see any further investigation of this incident. I.am sure that the NRC is aware of this statement, because it was in the FORT WORTH STAR TELEGRAM
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article (attached). Undoubtedly, they are not concerned about the s.ituation.
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I have not been contacted and neither has my friend. '
.. Document Nau:
- AQ-77, 79 & 138 II f t Requestor's ID:
JEAN / { f/ f Author's Name: pf 3/15 Document Comments: Commoed from NRCDSI 3/25/85 O l i \.
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- 1. Allegation Group: QA/QC, Category SB
- 2. Allegation Number: .AQ-77, AQ-79 and AQ-138. -
- 3. Characterization: It is alleged that the onsite structural fabrication .
and hanger shop (iron fab shop) made component parts, such as eyebolts
, fasreplacementsjforpartsthatwerelostafterreceipt inspection (AQ-77); that safety-related parts were made in the iron' fab shop in response to telephone requests, without any fabrication instruc-tions or the required quality control inspections (AQ-79); and that (1) craft personnel .in the iron fab shop were asked by their supervisors to perform work without any knowledge the paperwork, (2) the paperwork was illegal because it was post-dated, (3 onsafety-related material was mixed with safety-related material, (4) s rvisor directed personnel not to mark indeterminate material as scrap (5) during consolidation of the electrical and iron fab shops, safety-related materials were mixed from 4
both areas, (6) electrical fab personnel used undocumented material, (7) ASME QC personnel in the fron fab shop did not' check Brown & Root (B&R) fabricated threads, (8) undocumented weld repairs were made on base 1 metals, (9) threaded rod was cut in the iron fab shop without a QC check to verify the heat numbers before cutting, (10) arc gouging (cutting) on stainless steel was done too close to the cut line to minimize grinding time (11) beam clips may have been cracked during the fabrication process, and (12) a device (stainless steel hook and chain) was fabricated without 2 regard to procedure (AQ-138). I
. I
- 4. Assessment of Safety Significance:
7 i AQ The TRT review of this allegation found that the processes i utilized for B&R shop fabrication and QC inspection of component parts were addressed by site construction procedures CP-CPM-9.10, Fabrication of ASME-Related Components and Component Supports,'and the QC inspection was controlled by procedure QI-QAP-11.1-28, Fabrication Installation Inspection of Safety Class Component Supports. The TRT interviewed fabrication shop personnel and observed fabrication work in process. When vendor-supplied item replacements and modifications were fabricated onsite, specific instructions were provided by engineering on a construction operation , traveler and vendor cencurrence was obtained, either by signoff by the site vendor representative or by correspondence. Component support modification was controlled by procedure CP-CPM-9.13, Modification of - Vendor-Supplied Catalog Items. TRT examined the following quality controlled work packages from the iron fabrication shop and found that the work was performed and inspected in compliance with the applicable proce. dure.
< Sway Strut / Eye Rod H-CS-2-SB-083-002-2 Hanger CS-2-327-406-S56R Rear Bracket VD-2-013-437-536R Sway Strut CS-2-SB-079-005-2 Hanger MS-2-RB-040-004-2 Vortex Breaker Cage MW84-6811-8902 c
l This list of work packages included both safety-related and
> nonsafety-related assemblies. Since both safety and nonsafety-related
! work was conducted concurrently 'at the iron fab shop, close examination of the operation travelers and the hanger packages was required to distinguish between them. The TRT also reviewed the processes utilized in cutting, grinding, fitting, and assembling components onsite. This review revealed that current shop practices are in compliance with the
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I The TRT discussed the B&R fabri foremen in the irononfabricati cation shop. of I-Bolts with the supervi shop fabricated the I-Bolts as re l personnel stated Those sor and that th that were missing or lost aftp acements for vendor supplied e it for rigging and hoisting er vend receipt on site. ems of the quality controlled packageor components. The I-Bolts were used same rigorous Further, TRT interviews with fistandards
; that is, they were not subjec aso the permanent strut components.
the I-bolts were load eld tested installation personnel indicat d 1 appurtenances of safety and related co prior to use toe ass inspected that . L hoisting and rigging activitie ure that - a
- s. mponents were not overstressed d i uring undocumented installation. fabrication of I-Bolt The TRTesdid of not find an h s used for permanent plant -
k. AQ is the fron fabrication shop withTo assess the allega k L required QC inspections; out theany TRT fabrication i instructionsa ifeet or the craft personnel, fabrication work in process reviewed the applinterviewed n shop the shop sup d
. cable proce' ures, and observed work was controlled by procedure CP CPIt wasshop
- found that this gsh Component Supports and CP-CPM 9 13 r cation Items. . M-9.10, Fabrication of ASME-Rel -
j ated QI-QAp-11.1-28, Fabrication and InstallThe og f, Component Supports. o this activity, were required by , t ' Section 2.1.4 stated: The TRT noted that procedure Cppdu - CPa M-9.10, Rev. 11, $MS Parts for a support, e g be fabricated without . . base a plates, drawin structural members, Q@fyf gr; etc described as on the required by 2.1.1. MIL (Material g dentification or HangerLog I package provided they y are [, into a support, theHowever, Hanger Pack when the parts are) beinand verified : . irg by must be removed toage fabricate anoth shall be intact er part. g assembled unless the MIL i M i b 3 M@
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. l The TRT found that the parts referred to in the allegation were additional parts needed or replacements for parts which (for some 1 1 unspecified reason) were not usable at the time when the support was in i the process of being installed. The fabrication shop requirement consisted of selection of the correct material and cutting the material to the requested dimension. Although the shop fabrication may have been accomplished without documented instructions and the shop QC inspection i may not have been performed, the acceptability for use and the material traceability was documented.by QC inspection at installation on the hanger inspection report per QI-QAP-11.1-28, Attach. 2. The TRT assessment of allegation AQ-138 in this SSER also addresses the lack of , )
required documentation (instructions) at the time that work is performed in the iron fabrication shop. Although the allegation specified no particular parts, the TRT reviewed work packages for a hanger (MS-2-RB-040-004-2), sway strut (CS-2-SB-079-005-2), and vortex breaker cage (MX84-6811-8902). The TRT identified the processes used in cutting material for hangers as mechanical sawing, grinding, and thermal cutting. The TRT found that traceability documentation was properly transferred to each piece cut and that QC inspector verification was recorded on the appropriate document. The TRT found that current shop practices were in compliance with the I procedures reviewed. The TRT interviewed representatives from Texas Utilities Electric Company (TUEC) concerning the allegation, but could identify no specific examples of work performed as the result of telephoned instructions. TUEC personnel acknowledged that the iron fabrication shop may have received telephone request to fabricate a part, but only in accordance with a previously issued drawing to which the shop had access. When such a request was made, the shop work order was subsequently sent. TUEC personnel also s'ated that if a hanger installation required a replacement part, the material traceability was maintained by use of the MIL in i w.s - - m ue n- - -
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* -g-accordance with procedure. The TRT reviewed the MILS on the shop work packages and determined that their statements were correct.
" To assess the allegation that iron fab shop personnel were AQ-138 i asked to perform work without any knowledge of the paperwork (e.g.
/
drawings, travelers, and hanger packages) the TRT performed an unannounced I audit of inprocess fabrication activity in the iron fab shop. The TRT assessed the availability of traveler packages and the included documentation to determine if the information provided was in accordance with procedures and if craft personnel had the required information (documentation) to perform the assigned task. . The TRT audited eight traveler packages at the location where the fab shop activity was inprocess. The travelers audited covered fabrication of ASME Code class supports, nonsafety supports, miscellaneous steel, electrical supports, and modification of vendor-supplied items (e.g., snubber-spring hanger). The TRT reviewed procedures for fabrication / installation, inspection, material traceability, and receipt and storage, all of which are applicable to activities performed in the 1ron fab shop. The TRT found that the audited hanger packages and operation travelers contained the documentation (e.g. dr'awings and MILS) required by the applicable procedure and were current for the status of the work inprocess. The TRT noted that procedure CP-CPM-9.10, Section 2.1.4, allows the shop fabrication of parts for a support without a drawing or hanger package j provided the parts are described on the MIL and verified by QC. i The TRT did not find any examples of shop fabrication of safety related material inprocess without the availability of the required documentation Y f (hanger package og drawing) at the location where the work was performed. I During discussions with the iron shop foremen and the assigned QC inspectors, the TRT found that the shop foremen, assigned to shop 9 i
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l . . fabrication of non-nuclear safety seismic category II pipe supports (procedure CP-CPM-9.9), miscellaneous steel (procedure CCP-21), and electrical supports kP-19kprocedure)could not identify and were not familiar with the shop fabrication procedures which controlled the work performed under their supervisory responsibilities. Although the TRT did j not find any examples of unacceptable quality workmanship, the TRT found f that the foremen's lack of knowledge of these procedures indicates need for procedure indoctrination and additional training for the foremen. The TRT reviewed the documentation furnished by the alleger which identi-fied material requisitions (MRs) as specific examples for the allegation , that, iron fab shop personnel were asked to perform work without any knowledge of the paper work (e.g. controlled drawing, hanger package, or traveller). The TRT interviewed the shop general foreman and the MR . coordinator, reviewed the appifcable procedures and the shop MR file. The TRT found telephone requests, memos, and sketches attached to the MRs. In further discussion with the foreman and coordinator, the TRT found that the shop fabrication work was performed per the MR instead of: (1) the , hanger package as required by procedure CP-CPM-9.9, Section 3.1, which states, " fabrication shall be accomplished in accordance with the hanger I package"; and (2) controlled drawings per proc'edure CCP-21, Section 3.1.3, which states, "all work shall be accomplished in accordance with controlled , drawings." Procedure ECP-19, Exposed Conduit / Junction Box and Hanger ,. Fabrication and Installation, does not contain a requirement for the availability of the hanger package or traveller at the location where fabrication is performed; however, the TRT also found that parts were fabricated per the MR without the availability of the hanger package or f traveller in the iron fab shop. The TRT found that the QC inspection and $ material traceability were recorded on the MR. The TRT found that MRs issued in the iron fab shop were not properly prepared in accordance with procedure CP-CPM-8.1, Receipt Storage and ] } l Issue of Items, Section 3.4. The MRs did not contain the information required by the block titles, e.g., material type was entered in the code i
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, l 1 ; class column, the code class was not identified, and the vague information l entered for intended use was taken from the requestor's memo or sketch rather than specific information given on the applicable drawing, hanger i package, or traveler. Considering these conditions the TRT agrees with f the allegation that the iron fab shop personnel performed their work
} without the required paperwork (documentation required by procedures). i e alleger did not' identify any specific items for the allega' tion that l [' the paperwork was illegal because it was postdated. This allegation is l addressed in the previous paragraph as it relates to work performed
- without knowledge of the paperwork. In the TRT interview with the
- l
- alleger, the alleger had refused to do work per a note paper sketch, and I a day later, a traveler was written to document the fabrication process,
~
thus the allegation. The TRT found that although sketches were used, the material issue, fabrication activity, material traceability, and QC inspection were documented on an accompanying MR. The MR traveled with j the fabricated items to the installation location, where subsequent QC $ inspections documented the acceptability of the item in the hanger ( package or on the operation traveler. l 1 To assess the allegation that nonsafety material was mixed with safety
- V material in the iron fab shop, the TRT, accompanied by a representative
! from the B&R material control group, examined the bulk material and vendor-supplied supports storage areas to lear.n the standard ansite h procedures and methods for segregating safety and nonsafety materials. The materials were identifiable and segregated as required. Based on the g. j g..", satisfactory compliance with methods and procedures in those areasj ihe f // TRT, accompanied by fab shop personnel, also examined the iron fab shop
/ N material storage (laydown) areas, where the TRT found designated areas for N.'. the storage of safety related bulk materials. A saapling of the material fp revealed heat number markings, as required. The TRT found a pile of what s ..
as obviously scrap material, and although it was separated, it was not 7 b;[ identified as scrap, nor was the area identified as a scrap / salvage area.,
/
.4 8" The TRT also found that there were unidentified bulk materials mingled (
t . 8-with safety and nonsafety material in the laydown yard adjacent to the former electrical hanger shop. This condition was in noncompliance with j procedure CP-CPM-8.1, Sections 3.3 and 3.5 which require: , 1 3.3 Within each of the storage areas (type A through E as delineated ! { in Appendix 1) safety-related items should be physically l
- separated from non-safety-related items, and identified. Where
{ , segregation is not practical, due to size, configuration, or specific storage requirements, etc., positive identification . shall be maintained which clearly identifies the material. ! 3.5 Items which have been withdrawn from the warehouse and are not needed shall be transmitted to the warehouse by the " Material , Return to Warehouse" form (Attachment 3). i f } In further assessment of this allegation, the TRT noted that procedure ! QI-QP-11.14-1, Inspection of Site Fabrication and Installation of
- Struc.tural/ Miscellaneous Steel, Section 3.1, requires that "The QC /
inspector shall perform random surveillance over storage and control of D l (] materials in the Structural / Miscellaneous Steel shop area to assure proper
, storage and control of materials in accordance with Reference 1-C and as j p follows: safety-related material for items requiring traceability through l installation shall be segregated from other materials and shall be identi-i fled by heat number at all times." The TRT found no evidence that the required _ random surveillances were, performed, a condition in noncompliance with the procedure quoted.
L i It was alleged that a supervisor directed craft personnel not to mark l indeterminate (non-traceable) material as scrap. The TRT did not find any 3 procedural requirement for identification marking or color coding of M scrap. The TRT reviewed record documentation and found that the material identified by the alleger as )(I1 determinate was in fact traceable by heat number. O 5 __m
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_ t It was alleged that during consolidation of the electrical and the iron fab shops, safety related ("Q") materials from both areas were mixed. In g7 its assessment, the TRT observed that the storage area (laydown yard) was b a common area for the storage of material for the fabrication of both electrical and component supports. The TRT found that B&R procedure ECP-19, Section 1.1., states in part: " Structural steel members are to be those obtained from the electrical fab shop or [from] designated "Q" storage areas." The TRT noted that according to the procedure, there was no conflict in regard to the location where "Q" materials were stored or obtained. . I To assess the allegation concerning the use of undocumented material in g the electrical fabrication shop, the TRT reviewed electrical support , traveler packages and observed the shop fabrication work inprocess. The TRT also considered the assessment of this allegation during the verifi-h cation of documentation for the assessment of other allegations reported in this SSER (e.g. material traceability and work performed without knowledge of the paperwork). The TRT found compliance with traceability requirements for heat number, unique number, and. coating code number. The TRT also found that the QC inspection process for verification and documentation assures the use of and documentation for traceable material. Although the alleger did not identify a specific instance of undocumented material use, the TRT found that the procedures as implemented would prevent the use of undocumented materials. It was alleged that the~ASME QC inspector in the iron fab shop did not 3 check threads on any job unless it was a prescribed operation on a s traveler that required QC inspection. To assess this allegation, the TRT I
- reviewed fabrication procedure CP-CPM-9.10 and the QC inspection procedure QI-QAP-11.1.-28 and found that neither document requires the QC inspection of threads fabricated in the fron fab shop. The TRT found that operation travelers were neither required nor used for the fabrication and inspection
- - - - , - - - - - , - , - , - - - - ,- - ~ - v-,, r--,,
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10 _ of threaded rod used in ASME-related safety class components supports. In S its review of the fabrication procedure, the TRT found that the procedure did not provide a general reference to design drawings nor the identifica-3 i tion of the design specification or specify a national standard that would i enable the acceptable fabrication of threads in conformance with design f specification, to assure quality (e.g., size, pitch, length, and class of ) i fit). ! The TRT interviewed a B&R quality engineer assigned to ASME related
- construction activities who explained that B&R relied on an acceptable
) inspection during installation as the means to assure the quality and ) , l acceptability of the B&R fabricated threads as defined in QI-QAP-11.1-28. ( f The TRT also reviewed a typical hanger inspection report and verified that / the thread inspection requirement was defined. The TRT found that the - threads fabricated in the iron fab shop were inspected in compliance with 7 j the requirements of the applicable procedures at installation. i It was alleged that undocumented weld repairs were made on base metal
~
) ,
- I (plate) which was damaged by flame cutting during the fabrication process. -
l To assess the allegation, the TRT reviewed TUEC procedure QI-QP-16.0-5, Reporting of Base Metal Defects, and B&R proce' dure CP-CPM.6.90, Welding f
- and Related Processes, that controlled the alleged activity. The TRT
{ interviewed the shop general foreman, foremen, QC inspectors, and welders, all of whom stated that it was standard shop practice to discard a damaged , l piece and cut a new piece as a replacement. The personne1x alsog demon-strated a knowledge of the procedural requirements for reporting base
- metal defects. During discussions, welders demonstrated an awareness of the procedural constraints on repair welding and the requirements for
- authorization of, and documentation for, repairs made by a welding process.
i The TRT could not find any occurrences of the alleged practice during its audit and shop walkdowns. The TRT found that procedures were implemented and that the alleged repairs, if they occurred, were not standard or common shop practice. l n . . . w , rg .
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t . . e t It was alleged that QC inspection verification of heat number was not done before threaded rod was cut into pieces. In its assessment of this allegation, the TRT found that B&R procedure CP-CPM-9.10, Section 2.1.2, required that the transfer of traceability marking be verified by g QC prior to cutting, except where marking was not possible such as on rods threaded the complete length of the piece. Standard practice in the iron fab shop was to obtain a length of bulk rod, record the heat number on the MIL or other required documentation, thread the rod, cut the
~
required number of pieces, and mark the heat number on the ends of the cut pieces. The marked' cut pieces, and any remaining length of the threaded bulk rod, were then QC inspected. By comparing the number marked on the cut pieces to the number recorded on the MIL and on the remaining bulk rod, the QC inspector verified the accuracy of the number transferred. . The TRT witnessed the threading of rod for drawing Item 15 of hanger SI-2-031-430-S32A and found that the' activity was done in compliance with procedures CP-CPM-9.10 and QI-QP-11.1-28, which were applicablet'o the fabrication and inspection of ASME related component supports. The TRT found that traceability was maintained. , e
\ I It was alleged that are gouging (cutting) on stainless steel was done as close as possible to the cut line to minimize grinding. B&R procedure
# CP-CPM-9.10, Section 3.3.5, states that, " Stainless steel base plates may
.) be thermally cut by arc gouging. After the thermal cutting process, 1/8 inch of material shall be removed from the thermally cut edges by grinding." ,
To assess the allegation, the TRT interviewed the fron fab shop foreman and QC inspector who were responsible for the iron shop fabrication and inspection of ASME-related component supports. The foreman stated that it was standard shop practice to layout stainless steel materials to an oversize cut dimension of 1/8 inch minimum when the prescribad method of cutting was by are gouging. The foreman also stated that it was standard shop practice for him to check layout dimensions prior to the cutting of materials by the craft persennel. Although not able to check 100 percent of the layouts, he stated with confidence that he does check more than 90 percent. The assigned QC inspector stated that the cut edges were checked MwL 1 ~~ '- ~. a : iW MW=______._ -
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visually for acceptability concurrently with dimensional inspection prior to release from the shop. The foreman then stated that he performed a check of the traveler package and a visual check of the condition of the fabricated item to assure its acceptability before it was released for field installation. No are gouging was inprocess during the TRT's assess-ment. Arc gouging and removal of the heat affected zone adjacent to the cut is standard industry practice. The TRT could find no examples that this practice was violated. The alleger requested that the TRT look specifically at two jobs: (1) ~ beam clips that may have been cracked, and (2) a triple hook on a 30-foot long stainless steel chain which was hot formed and documented after it was built. . In its assessment of the beam clips, the TRT found that the allegation referred to beam clips, bent to prescribed angles, for welded installation
\ in the patch panel platform in the reactor building (RB), Unit 1. The clips,were identified in the bill of material included in DCA 17551, kk Revision 6, to drawing 232J-SI-0525 as piece 20, SA36 plate (structural steel) 3/8 x 3 1/2 x 8 inches.
The TRT was unable to verify the alleged condition of the clips because they were welded in place with the outside radius on the side hidden from view. To assess the potential for the alleged condition, the TRT requested that the iron fab shop form a 90' bend on a like piece of the same heat
.:s < 3er material from which the original clips were fabricated. The sample piece was cut as a longitudinal section (with the grain) and cold formed to a 90' angle. The outer radius was then wire brushed. Visual inspection (without magnification) by the TRT detected minute surface indications which the TRT assessed as not a relevant indication (defect). The sample was then checked by the craftsman who cut and formed it, and inspected by the QC inspector responsible in that area of the shop where the original clips were produced. Both agreed that the sample piece was acceptable.
The piece was then subjected to a nondestructive examination by liquid dye l
._ . ._ _ _ ._. - w._
13 - ) penetrant (PT), visible color contrast method, and found to have no indica-tions. The TRT found that this method of forming clips was done in accordance with acceptable practice as detailed in the American Institute for Steel Construction (AISC) handbook. In its assessment of the 30-foot chain, the TRT reviewed the FSAR and interviewed TUEC project engineers to determine the identification and k application of the device described by the alleger. The device could not be identified by the TRT. The TRT interviewed the iron fab shop general foreman and learned that although the stainless steel chain was an odd or unusual item, he could not remember its fabrication. The TRT also inter- ~
- viewed representatives from the material control groupy the millwright department,and a TUEC instrumentation engineer but could not find an ,
example of the alleged device.
- 5. Conclusion and Staff Positions: The TRT concludes:
AQ-77 Onsite fabrication practices for the fabrication of replacement parts such
/ askboltswereproperlycontrolledbyconstructioninspectionprocedures and instructions. The TRT review did not identify instances where the iron fab shop manufactured safety-related replacements without the appropriate procedures or without QC inspection and was unable to sub-stantiate the allegation. Therefore, the TRT finds that this allegation has neither safety significance nor generic implications.
A0-79 Based on a review of applicable documents, shop inspections, and interviews with TUEC personnel, the TRT concludes'that the allegation that the iron fabrication shop made parts in response to telephoned instructions rather than to written instructions cannot be traced to a specific event and, therefore, cannot be substantiated. (Also see AQ-138.) Some nonsafety-related parts may have been fabricated based on telephoned instructions;
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i . i however, safety-related parts were fabricated in compliance with appli-cable procedures. Current iron fab shop practices also provide adeauate assurance that material traceability was maintained in compliance with the applicable procedures. Accordingly, this allegation has neither safety significance nor generic implications. In a meeting with the alleger on December 10, 1984, the TRT presented its findings and conclusions for AQ-77 and AQ-79. A brief discussion ensued. AQ-138 . The TRT assessed the allegations by a review of procedures and documenta-tion, an audit of fab work inprocess, witnessing the fabrication and PT - examination of a comparison sample, witnessing the fabrication of threaded rods, and by a walkdown verification of material laydown storage areas. The assessment also included interviews with B&R shop foremen and craft personnel, QC inspectors, quality engineers, material control personnel, and a.TUEC instrumentation engineer. The TRT substantiated the allegation (1) that iron fabrication shop personnel were asked to perform work without knowledge of the paperwork. The TRT's assessments did not substantiate the allegations that: (3) safety and nonsafety materials were mixed, (4) identification marking on scrap material, (5) electrical shop safety related material was mixed with iron fab shop material (7) ASME QC did not check threads in the fron fab shop, (9) ASME QC did not verify heat number on threaded rod before cutting,.and(11)beamclipswerecrackedinthefabricationprocess.Nhe TRT's assessment was unable to substantiate the allegations that: ] (2) paperwork was illegal because it was post dated, (6) the electrical i shop used undocumented material, (8) undocumented weld repairs were made on base metal, (10) arc gouging on stainless steel was too close to the l cut line to minimize grinding time, and (12) a stainless steel hook and l chain was fabricated without a procedure. w n. -
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l . 7t[$ OM - l Tt.e TRT found procedural noncompliances, however,.th ocumentation t examined by the TRT in the iron fab shop indi~cated that the required QC inspections were performed and material traceability was maintained and documented. The TRT therefore concludes that the allegations have neither l safety significance nor generic implications. I I In a meeting with the elleger on November 14, 1984, the TRT presented its assessment of AQ-138'and its conclusion. The alleger had no major dis-agreements with the TRT's assessments and conclusion. No new concerns or allegations were identified. .
/
- 6. Actions Required: See item 8 of enclosure 1 with 0.G. Eisenhut letter to M.D. Spence dated January 8, 1985. ~
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- 8. At d ments: None.
! 9. Reference Documents:
- 1. CP-QAP-11.1, " Fabrication and Installation Inspection of Components, j
Component Supports and Piping." l
- 2. CP-CPM-9.10, Rev.11, " Fabrication of ASME Related Components Supports."
- 3. CP-CPM-9.9, Rev 8, "NNS-Seismic Category II Support."
- 4. CP-CPM-9.13, Rev.10, " Modification of Vendor-Supplied Catalog i
Items." i l
- 5. TUGC0 letter TXX-4180 dated May 25, 1984.
- 6. AQ-138: TRT interview with alleger A-59, September 13, 1984.
l 7. FSAR Figure 9.5-52, sheets 1 and 2.
- 8. B&R ECP-19, " Exposed Conduit / Junction Box and Hanger Fabrication j and Installation."
- 9. B&R CCP-21, " Fabrication of Miscellaneous Steel."
- 10. B&R CI-CPM-8.1, " Color Coding of Piping Materials."
l
. . . - . . . __ _ . . . _ . _ - _ _ _ _ - . _ _ _ . . _ _ _ . ~ . _ . . . . _ _ . _ . _ _ -
1 1 , I + ' 11. B&R CP-CPM-6.9C, " Material Identification." 1
- 12. B&R CP-QAP-14.1, " Inspection of Storage and Maintenance of l
Permanent Plant Equipment."
- 13. B&R CP-QAP-8.1, " Receiving Inspection."
f 14. B&R QI-QAP-11.1-28, " Fabrication and Installation Inspection of Safety Class Component Supports." ~ l 15. B&R CP-CPM-6.90, Welding and Related Processes, i 16. B&R MCP-10, " Storage and Storage Maintenance of Mechanical and-Electrical Equipment."
- 17. B&R CP-CPM-8.1, " Receipt Storage and Issue of Items."
~
l 18. TUEC QI-QP-11.10-1, " Inspection of Seismic Electrical Support and i Restraint Systems."
- 19. TUEC QI-QP-11.16-1, " Installation Inspections of NNS Seismic ,
i Category II Supports for Class V Piping."
- 20. TUEC QI-QP-11.14-1, " Inspection of Site Fabrication and l
j Installation of Structural and Miscellaneous Steel." l 21. TUEC QI-QP-16.0-5, " Reporting of Base Metal Detectors." i 22. ,TUEC QI-QP-11.4-4, " Control of Material Traceability for Site ? Fabricated Structural / Miscellaneous Steel." l
- 23. Design Change Authorization 17551.
]
- 24. Hanger Packages,'CP-82-086-8903, CP-82-008-8903, and l CP-84-224-02-8902.
- 25. AQ-77 and AQ-79: Alleger A-3 statement and interview.
- 26. TRT meeting with A-59 November 14, 1984.
)
- 27. TRT meeting with A-3 December 10, 1984, pp. 115-138.
l 10. This statement prepared by: J. Malonson, Date f Technical' Reviewer I i ! M. Bull , Tech cal iewer {
1
.t t .
i f, A m Mc rton,
\_
te Tec ical Re J i wer Reviewed by: H. Livermore, Date Group Leader
. Approved by:
O V. Noonan, Date Project Director 4 t _T I T l 5
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Cdgog 10 3 A 910 5 l b' , g, 4 l September 1g.1978 - In Reply Refer To: ? RIV , Docket No. 50-445/Rpt. 78-1F * . t 50-446/Rpt. 78-13 * , ,
- ~
~
j Texas utilities Generating Casperty
- ATTN: Mr. R. J. Gary. Executive I President and Generaf* Manager ~ .
2001 Bryan Tower
- Dallas. Texas 75201 ~
Gentlemen: ,. 1 . 4
~
This refers to the inspection *. activities perfomed by our Resident Inspec- ! tor. Mr. R. E. Taylor. during the period August 1-31. 1978, of activities authorized by NRC Constructiori Permit Mos. CPPR-126 and 127 for the Comanche Peak facility. Units b.1 and 2, and to the discussion of our l findings with Mr. R. G. Tolsori and other members of your staff at the. j conclusion of the inspection.~ ,. 3 Areas examined during the insliection and our findings am discussed in the 1 enclosed inspection report. Within these amas, the inspection consisted of selective examination of piecedures and representative records, inter-views with personnel, and obse[rvations by the inspector., - 1 j- During the inspection. it was'found that certain activities unde.' your 4 license appear to be in noncompliance with Appendix B to 10 C7R 50 of the NRC Regulations. " Quality Assurance Criteria for Nuclear Power Plants." , i The Notice of Violation for tiis item of noncompliance i+(^wd in paragraph '_
; 11 of the enclosed inspection report is sent to you pursuant to the pro- l visions of Section 2.201 of tiie NRC's " Rules of Practice." Part 2. Title 10 -
Code of Federal Regulations. 'Section 2.201 mquires you to submit to this office. within 30 days of youf mceipt of this notice, a written statement , or explanation in reply including: (1)correctivestepswhichhavebeen l taken by you, and the results' achieved; (2) corvective steps which will be t j taken to avoid further noncoup,71ance; and (3) the date when full cog 11ance
, will be achieved.
I
; The Notice of Violation for tiie itse of noncompliance swii,ed in paragraph i 7 of the enclosed inspection report' was forwarded to you by our letter dated August 30, 1978; therefom th'is letter does not mquim further ' ,
regarding this matter. , ,
.ma* RIVbd .3 /\ .3 / .nik
- . . . * ._RGlayloT/nl .WACr oss # d _._WCSeSe._.WEYe$er'
.m
- 9L?]116 9h1118 __ 91170 8 .9/R/78 EE0lA-85M M7'
~ ~ ~~~~ ~
t -
s . .. Failure to Follow (Closed) Infraction (50-445/78-11; 50-446/78-11):The licensee stated, in his lette 1bO
, Piping of July Installation 28, 1978, Procedures.that compliance with procedure 35-1195-PCI-001 was essentially attained by July 25, 1978, Theand is being maintained IE inspector, through a asseries verified through periodic audits.
of tours of the various plant areas where pipe erection was in progress, observed that all pipe ends were capped, taped and tagged as required - The licensee has revised the procedure to delete the -
~
by the procedure. requirement to use only red tape and now allows tne use of . The IE inspector also verified that the periodic ~ audits of the process , are being accomplished as committed. This item is considered closed. l
- 3. General Construction Area Tours - !
The IE inspector toured one or more plant areas several times weekly during the reporting period to observe the progress of safety related installation work and the general construction practices involved including housekeeping. Two tours were conducted during a portion of . the licensee's second shift to observe the type of work involved and I The second shift appears to be about one third the level of effort. of the day shift and to largely involve civil type construction. No j safety related welding effort was detected on either second shift tour. - During the course of the tours, the IE inspector Included with-paid partic protected during the transporting and erection processes.in the c service water pipe spools, and several stainless steel pipe spools. Also observed was the handling and transport'of component cooling system-pumps and electric drive motors. No items of noncompliance or deviations were identified.
- ~
- 4. Electrical and Mechanicak Safety Related Equipment Warehousing f
l The IE inspector extensively inspected the three primary storage ware-houses, the adjacent outdoor temporary shelters and open laydown areas i on August 2g,1978, with the following results:
- a. All stainless and carbon steel pipe spool pieces stored in the open-to-the-weather laydown areas were on wood dunnage with ends i
and branch nozzles sealed adequately to prevent the ingress of water or debris. All spools were marked with appropriate coding The acceptance status of the to allow complete identification. spools was clearly identified with " Released for Construction" or "QC Hold" tags secure y a l ffixed to each spool observed in the areas. 4
, s
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_ : =t ym . . m - mL .ae, m em _~ mwn 's-- e ' - a n . - o,. ~ . T
A-l ,- [ 7 CcA .[er h o) ># to.['i 4
- 27 pgg _
i
- . t J-k- In Reply Refer To: .7 ,. ' -
t r 4 RIV . l' i Docket No. 50-445/Rpt. 79-04
- 1.
50-446/Rpt. 79-04 , 1-
't Texas Utilities Generating Company '
ATTN: Mr. R. J. Gary, Executive Vice
~
- President and General Manager , 2001 Bryan Tower . ' a Dallas, Texas 75201
'j j ,
t 8 i Gentlemen. *
-. , . . ,)
This refers t'o the ins ticIn conducted by Mr. L. D. Gilbert and other F j members of our staff d ring the period February 5-8,1979 of activi- . i 1 ties authorized by NRC Construction Pemit Nos. CPPR-126 and .127 for~ y the Comanche Peak facility, Units No.1 and 2, and to the discussion of - [; our findings with Mr. R. G. Tolson and other members of your staff at.- , ~
.j the conclusion of the inspection.
- j -
f Areas examined during the inspection and our findings are discusse'd in
- the enclosed inspection report. Within these areas the inspection con- ,
j sisted of selective examination of ' procedures and representative rc,6 ds, ! interviews with personnel, and observations by the inspectors -
.. r .
.i.
During the inspection.' it was found that certain activities under your license appear to be in noncompliance with Appendix B to 10 CFR 50 of '. ' the HRC Regulations " Quality Assurance Criteria for-Hut:1 ear Power Plants." The item of noncompliance and references to the pertinent- i } requirements' am identified in the enclosed Notice of Violation. , j . ! j This notice is'sent to you pursuant to the provisions of Section 2.201 H . of the NRC's " Rules of Practice," Part 2. Title 10. Code of Federal i 1 [' Regulations. Section 2.201 requires ~ you to submit to this office, with- - in 30 days of your receipt of,this notice, a written statement or expla-i 3 1 nation in. reply including: (1) corrective steps which have been taken by !
- you, and the results' achieved; (2) corrective steps 6thich will be .taken. '- '
to avoid further noncompliance; and 13) the date when full compliance ' will t,e achieved. 3 1
. cru m1-- --
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.. LQGi.lher.t....4AGInylot.....j iolACrossman....
9 .....2/,7,f79
....REHall.......... ...WCSeidle.......
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. ....287..G S........L.. 291.?...... ... .
. * - ~ - - ...... ..... .
~
_ L _ fhyz _
/
l, ~1 9 0 4 .- .
- c. Review of Records
~
The IE inspector reviewed the following records: (1) RIR 08318 - Main Control Boards , (2) MRR CP-3563 - Main Control Boards . (3) RIR 5722 - Component Cooling Motor cpl-CCAPCC-O1M - (4) MRR 2772 - Component Cooling Motor cpl-CCAPCC-01M l (5) NCR E1132 - Component Cooling Motor CP1-CCAPCC-O1M . (6) CalibrationRecordsofrMTE558(Megger) ' (7) Maintenance Records for RHR Pump Motor #1, Containment i Spray Pump Motor #4 and Safety Injection Pump Motor il j
. No items of noncompliance or deviations were identified.
- 5. Eouipment Storage and Maintenance Two Positive Displacement Charging' Pumps and four Component Cooling
( Water Pumps were inspected for proper in-place storage. Brown & Root ~ i Construction Procedure No. 35-1195-MCP-10 Revision 2. " Storage and Storage Maintenance of Mechanical and Electrical Equipment," requires supplemental storage and maintenance requirements for individual com-ponents. Storage and Maintenance Requirement No. 35-1195-MEI-19-473 applies to Positive Displacement Charging Pump TCX-CSAPPD-01. This document requires that unpainted carbon steel surfaces be maintained During the inspection with preservative for the duration of storage. - of the Charging Pump TCX-CSAPPD-01, corrosion was observed on the underside of the pump housing. The oxidation that was present appeared superficial and did not appear to have caused permanent damage to the surface; no preservative was evident. The maintenance records for the Control Room Ventilation Fan CPX-VAFNAV-37 were also reviewed. Storage and Maintenance Requirement No. 35-1195-MEI-10-783, Rev. O requires that the shaft be rotated sufficiently to lubricate bearings every thirty days. The maintenance record indicates that the shaft on this fan was rotated (on September 12, 1978, and November 13,1978) only two times for the five month period starting September 12, 1978, through February 7, 1979. This corresponds to a i quarterly instead of monthly shaft rotation. The manufacturer's instruction book, B&R Doc # CP-092.2-001, requires shaft rotation every ninety days during long term storage; therefore, the likelihood of equipment damage for failure to perform this maintenance is minimal.
.- --em.sess e e m ' _e <e etmas%s.w are. o. . er #e- o , --.. ..u <
The lack of preservative on the Positive D1spiaceme... ppear toControl be Ro
- i TCX-OSAPPD-01 Ventilation Fan as required and by failure todocumented maintenance rotate the sh procedures pro-
- in noncompliance with the requirements related to the i of activities affecting quality in accordanc l . ' 6. Structural Concrete.
- a. Concrete Placement. bserved in complished Portions of the following concrete placements irements: were order to ascertain whether activities w cubic yards for the 105-7873-001 & 002; 390 73.
Placement No. (1) Unit i Safeguards Building slab at elevation 006, 007 8 003-4860-001, 002, 003, 004, 005, Building (2) Placement No. cubic yards for the Fuel Handling 008, 009; 130 core walls from ele.vation .860 to 898. l conform to l L Work and inspection activities observed b & Hill SPeCiffs- appea the* implementing instructions contained in Gib 2323-55-9, slump and air cation No. Guality Instruction No. QI-QP-ll.0-3, R l / content were also observed for the placement . Building. ved during this l No items of noncompliance or. deviations were portion of the inspection. _
- b. Concrete Records 101-8805-001 dome) were bc The following concrete records fo reviewed:
bc
- ' fo (1) Concrete Pour Card AD, Inspection Report I
(2) IE l Sti (3) Concrete Placement Plan i ELI NRF Concrete Placement Sumary r (4) MIP
~
MBCPOEM318(9
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