ML20202A980
| ML20202A980 | |
| Person / Time | |
|---|---|
| Site: | Comanche Peak  |
| Issue date: | 10/05/1984 |
| From: | Frankum D, Wright B BROWN & ROOT, INC. (SUBS. OF HALLIBURTON CO.) |
| To: | |
| Shared Package | |
| ML18052B537 | List:
|
| References | |
| FOIA-85-59 CP-CPM-9.10, NUDOCS 8607100166 | |
| Download: ML20202A980 (38) | |
Text
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3ROWN & KCOT, INC. PROCEDURE EFFECTIVE CPSES NUMBER REVISION DATE PAGE l
CP-CPM 9.10 12 09/19/84 1 og 19 TITLE: ORIGINATOR .
IM
. Date REVIEWED ST: '_ u / 9 ' / * '/
FABRICATION OF . ,3 s' B&R QA Date 3 e ASME-RELATED ) ,
COMPONENI SUPPORTS M. 1., /- d //'Ed. IGINEER
- /' /[Y Da te PR7 WELp7.NG APPROVED BY: b,r Ms M 7-/f- M CONTTRUCTION PROJECT MGR Data ,
o.1 TABIE OF CONTENTS f
1.0 INTRODUCTION
2.0 GENERAL 2.1 MATERIAL 2.1.1 Material Control 2.1.2 Material Identification pn ,,
2.1.3 Protective Coating Traceabilith I(f 2.1.4 Fabrication of Parts (
- 3.0 1
. PR OCEDURE ~
3.1 HANGER PACKAGES 3.2 WELDING 3.2.1 Welding Procedures and Qualifications 3.2.2 Welder's Identification 3.2.3 Cleaning of Weld Preps and Base Metal 3.2.4 Preheat /Interoass Temperature 3.2.5 Weld Joint Des 12n and Fit-up 3.2.6 Skewed Welds 3.2.7 Tack Welds 3.2.8 Inspection After Tacking 3.2.9 Interpass cleaning 3.2.i0 Wo t k=ans hip 3.2.11 Removal of Temporarv and Permanent Welds Made to Structural Shapes 3.3 GENERAL FABRICATION AND INSTALLATION REQUIREMENTS 3.3.1 Tolerances 3.3.2 '1hreaded Items 3.3.3 tocking Devices _
3.3.4 Bolt Holes .
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3.3.5 Base P late s 3.3.6 Shear Lugs 3.3.7 Wall and Ceiling Base Plate Bearing kfI 6 860630 GARDE 85-59 PDR zf6 - 9/. . _
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JOB 35-1195 ,
CCMANCHE PEAK STExi ELECTRIC STATION Construction Procedure Y CHANGE NOTICE NUM3ER DOCUME.I 1 Notice applicable to Construction Procedure No. 35-L195- CP-CPM 9.10 Rev. 12 .
This change wil'.* be incoeperated in the next revision of the procedure.
Change the procedure as follows:
Please replace / add the following pages with the attached:
Page 5 of 19 Sa of 19 Reviewed 3y:
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7[Proiect 'Jelding Engineer Date
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Origina to r ,/ Da te 9- Brown & Root Qualit-/ Assurance Cate l Approved by: [MM d ./ a. -o /XY, '*
TUGC0 Quality Assurance Date, i
h 6 A -. p /0 -4/- Pr 10/05/84 Effective Data i
I Construction Project Manager Date .
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BROWN & R00r, INC. PROCEDURE EFFECTIVE NUMBER REVISION DATE PAGE CPSES JOB 35-1195 CP-CPM 9.10 12 09/19/84 2 o f 19 3.3.8 Hanger Adjustment 3.3.9 Cocter Pin Installation 3.3.10 Seismic Limiters /Swav Struts 3.3.11 Soring Cans 3.3.12 Material Salvaging 3.3.13 Shims 3.3.14 Hanger Removal 4.0 FORMING 4.1 COLD FORMING 4.2 Har FORMING 5.0 CONSIDERATIONS FOR PRESSURE TESTIMG
1.0 INTRODUCTION
This procedure provides the criteria for the fabrication and install-ation of ASME III, Subsection NF, Classes 1, 2, and 3 component sup- ,
ports. Mome nt restraints are not within the scope of this procedure.
2.0 CENERAL 2.1 MATERIAL 2.1.1 Material Control - .
Materials used in the fabrication of NF supports shall be materials acceptable for ASME use and do not necessarily include all materials acceptable for "Q" applications. Evidence of material acceptability, including shim material, will be provided through the use of a Material Identification Log (Attachment 1). The log shall be completed by the craft based on the information provided in the Hanger Package. 5 'r ~ eb 1 ' then be cresented +n OC fo r -2ta- tal um,.<<< ,.4,, 2-a =<-,,ture.
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NOIE: Heat numbers shall be recorded for Class 1 and for impact tested sup~ port materials.
Welding material shall he controlled in accordance with CPM 6.9B.
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BROWN & RC0r, INC. PROCEDURE EFFECTIVE NUMBER REVISION DATE PAGE CPSES JOB 35-1195 CP-CPM 9.10 12 09/19/84 3 of 19 2.1.2 Material Identification Prior to cutting, the heat' or identification (MIC, code, etc.) number shall be transferred by mechanical marking, and this marking shall remain distinguishable throughout the fabrication process. When mechanical markings on the parts are not po ssible , such as on all-thread rods, the markings may be applied to bands or labels which are applied to the parts. The transfer of the markings shall be verified by QC prior to division. This verification is documented on the MIL. Additionally, the support assembly shall be mechanically identified with the hanger mark number which shall remain distinguish-able throughout the installation.
Prior to division of a bundle of bulk material, each piece of material
- shall be identified with a heat ntanber. A heat code and purchase order number .may be used instead of a heat numbe r . Prior to division of the bundle, QC shall be notified so that the markings may be veri-fied and documented in accordance with the applicable QA procedures.
NOTE: Materials used for some welded attachments will require impact testing. The need for impact tested materials will be speci-fied on the engineering drawing. Where possible, the vendor supplied attachment materials should be used. Ot herwise ,
impact tested materials shall be requested when specified on the drawings.
When design reflects a total change of hanger number but does not physically alter the support, the Package Flow Group will issue a modification MWDC whose "only holdpoint will be Operation 41, "Suppo rt Number Identification". This will allow cra ft to change the number on the hanger with QC Inspector verification, per the design change.
2.1.3 Protective Coating Traceability All shop coated steel that requires protective coating and is cited for installation in the Reactor Building shall be stamped with a unique coating code number.
Unique code numbers shall be assigned and applied in accordance with' CCP-30 and CCP-30A.
Upon division of materials, unique coating code numbers shall be transferred along with other unique material identification numbers.
The transfer of unique coating code numbers shall be witnessed by QC.
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BROWN & ROCI, INC. PROCEDURE EFFECIIVE NUMBER REVISION DATE PAGE CPSES JOB 35-1195 CP-CPM 9.10 12 09/19/84 4 o f 19 The transfer of coating code numbers is necessary only to steel that is cited for installation in the Reactor Building.
Additionally, upon division of material, any Q-coated steel that remains in stock shall maintain its coating code nu=ber. If coating code number transfer is necessary to accomplish this, it shall be witnessed by QC.
2.1.4 Fabrication of Parts Parts for a support, e.g . base plate s, structural members, etc.,
may be fabricated without a drawing or Hanger Package provided they are described on the MIL and verified by QC as required by 2.1.1. However, when the parts are being assembled into a support, the Hanger Package shall be intact unless the MIL sust be removed to fabricate another part .
3.0 PROCEDURE
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3.I HANGER PACKAGES 3.1.1 Fabrication / installation of component supports will be in accordance with the Mnger Package for supports. The package will consist of the N.g (or a " typical" for 2" and under hangers), the
.' L h u f each hanger. such as GC's a ffecting the hangers may be in_ : _ _ - -4 . - .
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for inclusion and the CMC number recorded on the WDC. The Hanger Package shall then be returned to the Package Flow Group for review of the GC to determine if the Weld Data Card requires modification or revision. In those cases where a modification of the Weld Data Card is required, the Package Flow Group will determine the extent of the work necessary to complete the hanger in accordance with the new design and a description of the necessary activities will be entered on the back of the Multiple Weld Data Card in the space provided for this purpose.
I A DOA is mt required for the fo t
- owing : 1 (A) Class I supports; i (B) Supports not fabr ica t ed; (C) Supports fabricated but not inspected; l l
(D) When modification work or repair to be performed does j not require removal of existing welds or material that were installed to the previous design.
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BROWN & ROOr, INC. PROCEDURE EFFECTIVE CPSES NUMBER REVISION DATE PAGE JOB 35-1195 CP-CPM 9.10 12 09/19/84 5 o f 19 Example 1: The addition of new material such as brackets, braces, etc., that can be installed without dismantling any portion of the existing supports.
Example 2: Increasing size of existing welds, or addition of welds in locations previously not welded, when welds are accessible without disma ntling any portion of the existing support.
When modification work is required by NCR, Unsat IR, Of C, e tc . ,
the field welding technician will determine the required rework and shall write the Description of Activities to be performed on the reverse side of the MWDC in the space provided. If a DOA is not required per this instruction, the weld tech shall make a note to tha t e f fec t on the 'DOA and reference the CiC, Unsat IR, etc., initiating rework.
Example: DOA not required per BRH R-1.
In any event, the otilization and technical content of the DOA shall be as deemed necessary by the Project Welding Engineer .
or his desigtee. -
3.1.1.1 When permanent attachments are to be welded to ASME pressure retaining process piping the spool designation shall be verified by a Field Welding Technician prior to preparation of the doc tanenta t io n. The piping isometric drawing shall be used to locate the affected piping in the field and verify the spool ntsnbe r.
3.1.2 Weld numbers shall be assigned by the Package Flow Group in the packages for the following weld categories:
- 1. Welds to pressure retaining members.
- 2. Full penetration t. elds except flare bevel on structural tubing.
- 3. . Hangers with multiple processes or multi-filler materials.
- 4. Welds requiring NDE, other than visual.
- 5. All Class I support welds.
3.1.3 Welding documentation shall be prepared in accordance with CPM 6.9G.
CP-CPM 9.10 Rev. 12 DCN #1 10/05/84 Sheet 2 of 3 5
BROWN & R00I, INC. PROCEDURE EFFECIIVE CPSES NUMBER REVISION DATE PAGE JOB 35-1195 CP-CPM 9.10 12 Sa of 19 09/19/84 3.1.4 Upon completion of the hanger, the craft shall return the Hanger Package to the Package Flow Group for final review. After final review, the Hanger Package will be returned to the craft for final inspection by QC and subsequent transmittal to the Package Flow Group.
3.1.5 If modification or redesign of a hanger, which is inspected and filed in the Interim Records Vault, is necessary, the cra ft may cut any welds required by authority on an " Inspected Item Removal Notice" in accordance with CPM 6.10. No re-welding may be done without issuance of the modified or redesigned Hanger Package.
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CP-CPM 9.10 Rev. 12 DCN #1 10/05/84 Sheec.3 of 3 l
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3RCWN & ROCI, INC. PROCEDURE EFFECTIVE NUMBER REVISION DATE PAGE i CPSES l JOB 35-1195 CP-CPM 9.10 12 09/19/84 6 o f 19 3.1.6 If the Package Flow Group receives drawing revisions or design changes l to Ranger Packages which have already been accepted by QC, those drawings or design changes will be transmitted to the Quality Engineering Group.
3.2 WELDING 3.2.1 Welding Procedures and Qualifications All welding shall be performed in accordance with weldiog procedures which have been qualified to Sections IX and III as required of the ASME Boiler and Pressure Vessel Code and as specified by the Project Welding Engineer. Welders shall be qualified in accordance with the welding procedures used.
3.2.2 Weld Identification :
l When weld numbers are assigned on hanger welding documentation, the weld ' number (s) shall be marked by the cra ftsman adjacent ~
to the weld, normally within 2 inches of the weld.
3.2.3 Cleanira of Weld Preps and Base Metal Before welding, a minimum of two inches on each side of the weld joint shall be free of moisture, dirt, grease and oil. Acceptable agents for cleaning include either Varsol 1, Stoddard Solvent, or any other approved solvent .
Mechanical preparation shall result in a clean surface for a -minimum of11 inch on each side of the joint.
Deoxaluminate compound, used to coat weld preps, need not be removed before welding.
3.2.4 Preheat /Interpass Temperature The preheating and interpass temperature to be used for welding shall be in accordance with the applicable WPS.
The preheat specf fled on the WPS shall be established be fore any welding or tacking.
Preheating may be performed using suitable gas burners and measured by the use of approved temperature indicating crayons.
Temperature indicating crayons, when used for preheating and interpass temperature measurement, shall avoid direct contact with the surface to be welded.
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BRCWN & RCOI, INC. PRCCEDURE EFFECTIVE NUMBER REVISION DATE PAGE CPSES JOB 35-1195 CP-CPM 9.10 12 09/19/84 7 og 19 3.2.5 Weld Joint Design Fit-up Jo int type and configuration shall be as specified on the applicable BRH. For clarity, types of typical weld symbols are shown in Attach-me nt 11.
The fit-up gap for buttwelded joints shall not exceed 1/8" beyond the diameter of the electrode used at t he roo t o f t he joint .
The maximum offset of the finished weld shall not be greater than the amount listed in the following table. The final weld sur face and adjacent base matal shall blend uniformly.
Maximum Allowable Offset in Final Buttwelded Joint s Section Thickness (inches) Max. Allowable Of fset up to 3/4" 1/4 t over 3/4" 3/16"
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The fit-up gap for "T" fillet welds and lap joints shall be as small as practical; however, they should not exceed 1/16".
Joints where the gap exceeds 1/16" shall be evaluated by the PWE on a case by case basis.
Weld size of structural tubing as shown in Attachment 2 shall be in accordance with the weld sizes specified on the drawing. Where weld sizes ar e not specified, the minimum weld size shall fill the groove so that the weld is at least flush with the outer surface o f the member .
For the special cases where a fillet weld is specified on the design drawing to join two structural tubes of unequal size and the large tube has an excessive corner radius, the weld will be a combination flare bevel and a fillet weld.
3.2.6 Skewed Welds Weld sizes for skewed members shall be in accordance with Attachments 9 and 10.
3.2.7 Tack Welds .,
All tack welds shall be made. in accordance with an approved welding procedure by a qualified wel' der and deposited with an electrode or wire that is the same composition as the electrode used for the root-pass.
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BROWN & R00I, INC. PROCEDURE EFFECTIVE NUMBER REVISICN DATE PAGE CPSES JOB 35-1195 CP-CPM 9.10 12 09/19/84 8 o f 19 Tack welds incorporated into the weld shall be prepared by the welder and shall meet the following requirements:
- 1. The start and stop for the tack weld shall be ground to a fea ther edge for ease of integration into the weld.
- 2. All slag and surface defects (e.g., porosity and cracks) shall be removed from the tack.
- 3. Tacks which crack during welding shall be removed and replaced.
- 4. Tack welds should be kept to a minimtsu number and size.
3.2.8 Inspection After Tacking 3.2.8.1 Full Penetration Groove Welds and Welds to Pressure Retaining Boundaries All full penetration groove joints and all welds to pressure retaining ~
boundaries shall be inspected by QC after fit-up and tacking prior to welding and shall be documented on the tJeld Data Card.
3.2.9 Interpass cleaning Interpass cleaning shall consist of the following:
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- 1. All slag and oxide shall be removed by either chipping, wire brush-ing, or grinding be fore making the next successive weld bead.
- 2. All surface de fects, undercutting, and overlappirg shall be re-moved by grinding be fore making the next successive bead.
- 3. All crater cracks or pits shall be removed by grindits before making the next sue.essive bead. ,
3.2.10 Workmanship The surface of finished weld shall be 'ree of slag, oxide and overlaps. Undercuts shall be limited as noted for the following items:
- 1. Structural tube - 1/32", provided it does not go below 10% of the wall thickness.
- 2. Structural shapes - 1/32" for all sizes.
- 3. Plate - 1/32", provided it does not go below 7% of the thickness.
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BROWN & ROOr, INC. PROCEDURE EFFECTIVE CPSES NUMBER REVISION DATE PAGE JOB 35-1195 CP-CPM 9.10 12 09/19/84 9 of 19
- 4. Pipe - 1/32", provided it does not go below 12 2 o f the nomial vall thickness.
Additional welding is acceptable provided it does not distort the items being joined together. Fillet welds to systems which have been acceptably pressure tested shall not exceed 3/8" throat thickne ss .
Welds requiring liquid penetrant examination shall not be power wire brushed, The surface of the reinforcement of butt welded joints may be flush with the base materials or may have uniform crowns. The height of the reinforcement on each face of the weld shall not exceed the following thickness:
Nominal Maximum Thickness, in. Re in fo rc eme nt , in.
Up to 1, incl. 3/32 Over 1 to 2, incl. 1/8 over 2 to 3, incl. 5/32 Over 4 to 5, incl. 1/4 -
Over 5 5/16 Maximum reinforcement for flare V welds shall be 3/16".
3.2.11 Removal of Temporary and Permanent Welds Made to Structural Shapes When welds are removed from structural shapes, the areas from which they were removed shall be visually examined by the craftsman to ensure that no de fects are visually present.
(Areas on pressure retaining members from which welds are removed shall be documented in accordance with CPM 6.9G.)
3.3 CENERAL FABRICATION AND INSTALLATION REQUIREMENTS 3.3.1 Tolerance s 4
Fabrication and installation shall be performed in accordat.ce with the drawing detail and t'.e following permissible tolerances:
3.3.1.1 Fabrication Tolerances
- 1. Ia ngt h
- a. Support members (except rods) up to 12" -
2 1/8"
- b. Support members (except rods) over 12" -
21/4"
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i BRCWN & ROCI, INC. PROCEDURE EFFECTIVE NUMBER REVISICN DATE PACE CPSES JOB 35-1195 CP-CPM 9.10 12 09/19/84 10 o f 19
- 2. Holes
- a. Centerline location
- 1/4" or as shown on design drawing 3 . 3 .1. 2 Installation Tolerance s
- 1. Dead weight supports
- a. Iocation axially : 12 inch
- b. P lunbness t 5 degrees, or as noted on drawing
- 2. Seismic Restraints
- a. Restraints, anchors, guides, etc.
- 1. Iocation; pipe diameter 2h" and larger and 2" and smaller ASME Class 1, t 2 x pipe wall thickness +2" from theo-retical position. .
- 2. Iocation; pipe diameter 2" and smaller. ASME Class 2 and 3.
- a. Support location tolerance is + 6" on the span indicated on the location isometric drawing. This tolerance is not to be projected through or around fittings or components.
- b. Locations of certain supports, identified with an asterisk (*) next to the dimension on the ISO, have
, a location tolerance of + h". Inability to meet this requirement must be brought to the attention o f Engineering.
N7IE: In certain cases, Class 2 and 3, 2" and smaller supports require the same location tolerances as 2h" and larger and 2" and smaller Class 1 supports (1 above). These are identified by presedce of a stress problem number on the design drawing.
- c. Attachments to center of structural steel reaction members.
NOIE: A reaction member is defined as a member which is part o f t he building structure, i.e., embeds or embedded plates and strips.
Parts of the hanger, i.e., base plates are not considered as reaction members.
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BROWN & ROOr, INC. PROCEDURE EFFECTIVE CPSES NUMBER REVISION DATE PAGE JOB 35-1195 CP-CPM 9.10 12 09/19/84 11 o f 19
- 3. Pipe Clearances
- 1. Where the design shows 1/16" on both sides, the total dimen-sional tolerance shall be 1/8" + 1/16" (e.g., 0" on one side w/1/8" + 1/16" on the other, 1/16" + 1/32" on both sides, or any combination.)
- 2. Where the design shows 0" on one side and 1/16" on the other side, the stra of both gaps inay not exceed 1/8" or be less than 1/32".
- 3. Where the design shows clearances greater than Is", the dimension shown is the minimum.
- 4. Axial Restraints Where the design shows' 1/16" clearance between shear lugs and the restraining member, the total clearance for both sides of the re-straint shall range from 0" to 3/16".
- 5. Reference Dimensions .
All dimensions shown on the design document as re ference dimen-sions (indicated by "REF") shall have a tolerance of t2 inches.
- 6. Field Fit Tolerances The tolerances discussed herein shall be maintained for support
, fabrication activities. However, if during the installation the support won' t fit, the members may be " field fit" provided all tolerances are maintained.
- a. Dimensions on hanger detail drawings between structural items and the pipe centerline may be adjusted within i che following tolerances.
Gradient - 3/16 inch per foot maximum (this applied to horizontal lines deviating from level only. De-viations from plumbness of vertical lines and hori-zontal departure from design centerline of horizon-tal lines will be controlled by the two-inch tolerance on location) .
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l BROWN & RCCI, INC. PROCEDURE EFFECTIVE NUMBER REVISION DATE PAGE CPSES JOB 35-1195 CP-CPM 9.10 12 09/19/84 12 o f 19 Slope - Minimum slope shall be as designated on the drawing s .
Location - 12 inches.
- b. The working point dimensions locating the structural components of the hanger shall have a tolerance of 21 inch. If designated as a reference dimension (REF),
the tolerance shall be 22 inches.
- c. Other established tolerances regarding axial location, alignment and base plate attachments, etc. shall be adherdd to unless otherwise noted on the drawing.
3.3.1.3 In the use of these deviation values, when more than one direction plane is icvolved, the resultant (combined) value shall not exceed the above permitted deviation values.
3.3.2 Threaded Items All bolts, studs, or threaded rods shall have full thread engagement in the cut .
Surfaces of bolted parts in contact with the bolt or nut shall have a slope of no more than 1:20 with respect to a plane normal to the bolt axis. Where the surface of a high strength bolted part has a slope of more than 1:20, a beveled washer shall be used to compensate for the lack of parallelism.
For friction-type bolted connections utilized on removable supports '
with S A-193 Grade B7 bolts, the nut shall be tightened in accordance with Attachment 7.
NOTE: Use hardened washers under bolt head and nut except where bolt head or nut is welded to the boltup assembly.
NOTE: Snug tight is defined as the tightness attained by a few impacts on an impact wrench or the full ef fort of a man using an ordinary spud wrench.
When Richmond inserts are used, thread engagement into the insert shall be at least 2 X the bolt diameter + 1/8". Botting used in Richmond anchors shall be tightened snug t'ght.
When U-bolts are specified on the design document as not having any clearances, the U-bolt shall be snug tight so t hat the U-bolt cannot ,
be moved by hand. The nuts on the U-bolts shall be installed on the j side of the plate as shown on the design drawing. I i
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BRCWN & ROOr, INC. PROCEDURE EFFECIIVE REVISICN DATE PAGE l CPSES NUMBER JOB 35-1195 CP-CPM 9.10 12 09/19/84 13 o f 19 3.3.3 locking Devices All threaded fasteners, except SA-193 and S A-325 bolting materials, and Hilti bolts, shall be provided with locking devices as specified ,
on the design document. /
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3.3.4 Bolt Holes Holes for nonfitted bolts shall be 1/16" larger than the nominal diameter of the bolt for bolt sizes up to and including 1" and 1/8" Larger than the nominal diameter of the bolt fo r bolt sizes larger than 1". The holes shall be drilled, thermally cut, subpunched and reamed. Thermal cutting shall not be used unless the surfaces are machined or ground smooth. The die for all subpurched holes shall be at least 1/16" smaller than the nominal diameter of the bolt.
3.3.5 Ba se P late s If hanger base plates cannot be installed as designed and fabricated, alternate hole patterns may be attempted. Fabrication of base plates may be performed by flame cutting on carbon steel or abrasive wheel cutting of stainless steel. Stainless steel base plates may be thermally cut by are gouging. After the thermal cutting process, an 1/8" of material shall be removed from the thermally cut edges by gr inding .
If the fir st anchor bolt hale cannot be drilled as required, relocate it in an outwardly direction (away from steel me=ber attach =ent) in accordance with CEI-20. Continue moving away until a hole can be successfully drilled. When attempting alternate hole patterns, the final pattern should be as symmetrical as possible.
Upon completion of an alternate hole pattern, a OfC and/or a MIL shall be initiated. A CiC shall be prepared when the tolerances cannot be met.
All structural steel attachments to base plates (i.e., wide fla nge ,
. tructural tubing, channel, etc.) must always be within the inner confines of the bolt hole pattern unless otherwise approved by E ng ineering .
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PROCEDURE EFFECTIVE BROWN & ROCr. INC. PAGE NUMBER REVISION DATE CPSES JOB 35-1195 CP-CPM 9.10 12 09/19/84 14 e g gg 3.3.6 Shear Lugs Shear lugs shall be fabricated and installed in accordance with the CfC affecting the design drawing and with the following guidelines:
- 1. Hole for the shear lug shall be drilled in the concrete k" in diameter larger than the shear lug diameter.
- 2. Install the base plate.
- 3. Set and torque all Hilti bolts.
- 4. Install shear lugs and weld in place as shown on the design sketch.
- 5. Shear lugs shall be grouted in accordance with CEI-25.
See Attachment 8 for illustration.
3.3.7 Wall and Ceiling Base Plate Bearing Wall and ceiling base plates shall fit flush against the mating
- sur-face s. Where such a fit cannot be made, the below alternatives are acceptable . Floor plates are not subject the the below requirements and will be grouted in accordance with CCP-16.
3.3. 7.1 Base Plate Caps Wall and ceiling hangers utilizing baseplates shall have a minimum o f 80% bearing sur face between the plate and concrete. The gap between the plate and concrete for a maximum of 20% o f the place may exceed 1/16 inch, but at no point shall the gap exceed h inch.
If these conditions cannot be met, the gap shall be grouted with cement or epoxy grout in accordance with site procedures. If cement grout is used on painted walls, permanent dans shall be installed to ensure that the cured grout doe sn' t slip out. The dams shall consist of angle iron held in place with k inch Hilti bolts. Due to the negligible loads on these Hilti bolts, the separation criteria betwe'en these bolts and the pipa. support.
Hitti bolts may be waived. Caps at the wall attachment greater than 1/16 inch may be shimmed by placing steel shims either around or adjacent to the wall attachment. Grout holes shall not be greater than k inch in diameter and shall be drilled outside bolt hole pattern and a minimun o f 1 inch shall be maintained from the concrete anchors. It is not required to weld up the grout hole.
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BROWN & ROCI, INC. PROCEDURE EFFECIIVE NUMBER REVISION DATE PAGE CPSES JOB 35-1195 CP-CPM 9.10 12 09/19/84 15 o f 19 Gaps at the wall attachments greater than 1/16" shall be shimmed either around or adjacent to the Hitti bolt. Shims shall consist of steel plates or washers of a size that will allow proper Hilti bolt torquing without base plate de formation.
EXAMP LE 10" X 10" BASE PLATE
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Total plate area - 100 in.2 Crosshatched area may exceed 1/16" provided this total area does not exceed '20 in.2 3.3.8 Eaqur Adj ustment Adjustments to constant and spring supports, and the removal of travel stops, shall not be made unless directed in writing by Startup.
3.3.9 Cotter Pin Installation Cotter pins should be fully open to the extent that they cannot become dislodged from the pin or bolt they are securing and such that they do not present a hazard to personnel. Cotter pins should be the maximum size the cotter pin hole will permit, but only need be large enough to remain in place after opening.
3.3.10 Seismic Limiters / Sway Strut s Sway struts and seismic limiters shall be installed and inspected to the drawing using the criteria set fourth in CP-CPM 9.15, and CP-CPM 9.17, respectively.
3.3.11 Spring Cans Spring cans shall be installed within a tolerance of 21* of the angle provided by design.
3.3.12 Material Salvaging When items cannot be used because of redesign, misfabrication, damage, the disposition to Nonconformance Reports, etc., t he
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BROWN & R00I, INC. PROCEDURE EFFECIIVE NUMBER REVISICN DATE PAGE CPSES JOB 35-1195 CP-CPM 9.10 12 09/19/84 16 o f 19 items may be scrapped, salvaged or returned to bulk stock.
The responsible foreman shall make this determination based on the NCR, C3C or the items' physical condition, as appropriate.
When Code stamped items or partial assemblies are modified, documentation for such modification shall be prepared as required by Appendix CPM 6.9C, and the modification accomplished accordingly. Banger mark numbers should not be removed or obliterated when the part is used on a hanger other than the one for which it was designated.
Material supplied by ITT or NPSI, or B&R bulk stock may be salvaged for use in Class 2 or 3 systems provided traceability is maintained as follows:
- 1. Trr - the alpha / numerical code identifying the material to a particular material specification and/or grade (i.e., the code "L7" identifies SA-320 Grade L7 material) .
- 2. NPSI - items identified with N-pre fixed or N-suffixed MIC number. .
- 3. B&R bulk stock - B&R procured ASME-related materials shall be maintained by heat number. Such stock designated for non-Q applications may be salvaged for Code use provided heat numbe r traceability is maintained and is acceptable fo r Code use .
NOTE 1: When salvaging variable springs for use on a support other than where originally designated, the responsible personnel shall ensure that the correct size spring is used. If the load setting is to be readjusted, the original load setting mark on the face plate shall be obliterated by stamping directly over it with t he le tter "S".
NOTE 2: Except as permitted above, hanger parts shall be used on hangers where designated and shall not be interchanged.
Material supplied in class 1 may be salvaged for used on class 1 systems provided the item's serial number or heat traceability identifier (i.e., MIC number, heat number, heat code, etc.) is ma inta ined.
In accordance with CP-CPM 8.1, a " Return to Warehouse" form shall be used when an item is returned to the warehouse, and a copy should be sent to the Production Control De partment. Sub seque nt reissue of these materials shall be in accordance with CP-CPM 8.1.
NOTE 3 : When hanger parts with Code plates are salvaged and used on hangers other than those for which designated, the Code plates may remain on the part. Alternatively, the Code am pse y *-.ew n aus - 4
BROWN & ROCI, INC. PRCCEDURE EFFECTIVE NUMBER REVISICN DATE PACE CPSES t
JCB 35-1195 CP-CPM 9.10 12 09/19/84 17 of 19 plates may be removed in accordance with CI-CPM 6.9E-1, turned over to QC, and subsequently filed in the vendor data package. In either case, the original hanger mark number shall remain on or be transferred to the part.
3.3.13 Shims
. Clearances between pipe support members and piping shall be main-tained in accordance with the clearance requirements of paragraph 3.3.1.2. Wt.ere such clearances are excessive, shims shall' be in-stalled to maintain the clearance. Shim thickness shall be selected by the craftsman and shall be one of the following materials:
' S A-36 on A-36 SA-515, Crades 55, 60 and 65, or A-515, Grades 55, 60 and 65 A-570 The actual material used shall be recorded on the MIL. Care shall
~
be exercised in the selection of a WPS that satis fies the welding on the base material used.
Sizing and welding of the shims shall be in accordance with Attach-ments 3, 4, 5 and 6, or as shown on the design drawing.
NOIE: The use of shims which have a total thickness greater than 2" shall require Engineering approval.
3.3.14 Hanger Removal The removal of hangers may be necessary because of redesign, inter-ferences, etc. Such hangers shall be removed in accordance with CPM 6.10. This includes attachment welds as discussed below.
Attachments to piping, i.e. , lugs, saddles, etc., shall not be removed unless specifically directed in writing by the Engineer with a design document. Where such attachment welds are removed, the Project Welding Engineer shall be notified. The Project Welding Engineer shall initiate a Weld Data Card or a Repair Process Sheet, as appropriate, requiring liquid penetrant and ultrasonic thickness inspection of the a f fected areas.
Attachments of any kind to the pressure retaining boundary of systems or components which have been turned over, shall not be removed unless authorized by a SWA, even if authorized by Engineering. This includes valve actuators, retaining plates, etc.
- - - - - - -. . . ~ . . .. , , _ . . .
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BROWN & RCar, INC. PRCCEDURE EFFECIIVE NUMBER REVISION DATE PAGE CPSES JOB 35-1195 CP-CPM 9.10 12 09/19/84 18 o f 19 4.0 FORMING 4.1 COLD FORMING Cold forming of U-bolts using SA-36 material of 5/8" or less in thickness may be performed provided that:
- a. The minimum inside radius is equal to the stock thickness,
- b. Forming is performed with the material at ambient temperature but not less than 60*F.
4.2 HOI FORMING 4.2.1 SA-36 material stock sizes 1 5" and over, may be hot formed to a min-imun outside radius equal to the stock thickness, with the material
. heated to a temperature of 1650*F - 2100*F. The material shall be heated to a temperature suf ficient to complete the initial press and the majority of the plastic de formation while above 1650*F. ~
Additional repressirg to obtain final aliganent may be performed while still in the " red" heat condition (above 1000*F) or it shall be reheated prior to completing fo rming. Hot formed stock shall be cooled in still air.
4.2.2 0xy-fuel heating with neutral flame may be used to heat stock up to and including 2" thickness. Caution must be exercised when using this method so as to prevent any melting of the outside surface.
4.2.3 Material over 2" thick shall be heated in a suitable furnace. The stock shall be held at the bending temperature for a minimum of 10 minutes prior to bending to assure proper heatirg through the cross section of the stock.
4.2.4 Temperature shall be measured using temperature indicating crayons or a chart recorder where applicable.
4.2.5 The completed U-bolt for hangers greater than 2" NPS shal,l be ide n-tified with the mark number of the hanger with which it is to be used, and with the heat number of 2" and smaller hangers. Marking shall be by die stamping.
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BROWN & ROCI, INC. PROCEDURE EFFECTIVE NUMBER REVISICN DATE PAGE CPSES JCB 35-1195 CP-CPM 9.10 12 09/19/84 19 of 19 5.0 CONSIDERATIONS FOR ?RESSURE TESTING Haagers shall not be constructed around pipe welds which have not been pressure tested in such a manner that the hanger would pre-vent inspection of the weld during pressure testing. When it is necessary to install the hanger prior to the pressure test, QA shall be notified. Such work shall not proceed until written authorization has been obtained from QA. ,
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BROWN & ROOT, INC. PROCEDURE EFFECTIVE CPSES NUMBER REVISION DATE PAGE JOB 35-1195 CP-CPM 9.10 12 09/19/84 1 of 1 ATTACHMENT I MATERIAL IDENTIFICATION LOG t .
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i 4 3ROWN & ROOT, INC. PROCEDURE EHECTIVE CPSES NUMBER REVISICN DATE PAGE JOB 35-1195 CP-CPM 9.10 12 09/19/84 1 of 2 ATTACHMENT 2 STRUCTURAL TUBING WELD JOINT DESIGNS Two $tnictural Tunes of Igual Size (4/0=1) d.i .
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, _ _.- -- -\ *~ 'V" ~ ~ (g; n.rA Wela size for strac*. ural tubing shall te of the sa me vided on tae Pawing. outer dimensica is acccedance with the dimensicns aro-the the outergroovesurface. small be filled until the weld fs flusa withWhere dimensions
_Two Structural Tubes of Unequal Size
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(14 : min)
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use only . hen the estig t
- Thickness of tainner material
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To be used wnen the estig of l _ _ . 8 4d / Q (1 i
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BROWN & ROOT, INC. PROCEDURE sectCTIVE i CPSES NUMBER REVISION DATE PAGE 1 ,
JOB 35-1195 CP-CPM 9.10 12 09/19/84 2 of 2 ATTACHMEMI 2 (Cont'd)
Structural Tubing Weld Joint Design Full Penetration Circular Tubing (Stanchion) Weld Joir.:
8-r Aree for , d Deted A or 8
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0 '/ ~M 0 Aree for Detail 8 Aree for
% ,n.,ne,, Detad C or 0
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- 1. The acodicabie joint detail (A. 8. C. or 01 for a partcular oart of the connection is determmed by the local dahedras angie. +, meica changes continuassly in progressing around the branch anomber, as follows:
Decad Acodicande range of local dibedral ang6e A 180* to 135' 8 150* to 50*
C 75* to 30* l Sarnode joint required for O 40* to 15* I groove ang#es under 30*
- 2. The angte and dirnemonal ranges given in Detail A. 8. C or 0 include moeimurn asioinense to e,ances.
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, += 180* 135* += 150* 50* += 75* 30* +=40*.15*
End preoerstuwi(wl As needed to meu 90* 90* obtain d men 45* 10* or to-45* for +> 105*
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Notes: 1. Area D requires throat c':ic': ness of 2T. .
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BROWN & ROOT, INC. PROCEDURE EFFECTIVE CPSES NUMBER REVISION DATE PAGE JOB 35-1195 CP-CPM 9.10 12 09/19/84 1 of 1 ATTACHMENr 3 SHLM
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TUBE STEEL i(
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" LESS THAN l l
- MIN. WILD I.ENGTR 1/16 1/16 1/2 1/8 1/8 1/2 1
3/16 -3/16 1 l
1/4 *:s A $ 1/2 -
1/4 ** -
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d 1/2< A S 3/4 5 /16 ** 1 1/2 3/4< A S2 3/8 ** 1 1/2 ~
- The weld new not be larger than 3/16. The weld length shTil be as shcwn.
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BROWN & ROOT, INC. PROCEDURE EFFEcuv t:.
CPSES NUMBER REVISION DATE PAGE JOB 35-1195 CP-CPM 9.10 12 09/19/84 1 og 1 ATTACHMENT 4 SHIM SIZE Total Length of Shim .
Macer 5ize 1/8 "
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llmwsummwss a. , s msssus .um m sms, su..smss mm- ms ll Soth Sides 3
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, - Length of Shim No. 2 5 + 1/8 J., , i.engen or anim No, i ,j Minimum il Ii msu s es -s, - seu. su .w ssmu m,,u su.-sms .we N///// ///////////fo //o/ ///// //// //////// //// /// /
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- 1. he minimum shim width is equal to the minimum weld length, required oy attachment 3, plus one inch.
- 3. For 2" and s;::ailer diameter pice, the minimum snim width shall r.at ce l ess : nan :: inch unless ctherwise noted on the drawing a-.
. - - - - . .: .: -- ~: -
BROWN & ROOT, INC. PROCEDURE EFFECTIVE CPSES NUMBER REVISION DATE PAGE JOB 35-1195 CP-CPM 9.10 12 09/19/84 1 of 1 ATTACEMENT 5 SHIM SIZE AND WELD FOR STRUCTURAL MEMBERS 510 0t!3 CT
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- IF $201 31CCt31233 ; MAN Re:CE WICCESS SEN: $=*3 TiESS CT fil!M M:C3 1/15. (!! IM TCR 1/8" $MIM. $=L/8 & 1/15* SHIM sal /16) ev w .pa-u I
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- 1. The minimum shim width is equal to the minimum welc leng-h, recuir-by A::actment 2, ;:lus one inch.
- 2. -er larg e :are 01:<, :he :f nimum shim nit:h is 2't.
- 3. Fcr 2" inc smaller diameter pica, the einfeum shim ..id:.. snali cc: te l es s tran , ircn un! sss c .herwise rctec :a. :he tr!wteg.
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BROWN & ROOT, INC. PROCEDURE ETIECTIVE CPSES NL?fBER REVISION DATE PAGE JOB 35-1195 CP-CPM 9.10 12 09/19/84 1 of 1 ATTACHMENT 6 WELD SIZE AND LENGTHS FOR COMBINED SHIMS NOTE: 111EN COMBINING SHIMS, TdE TdICKER OF TdE Ta'0 SHIMS SECUI.D BE ATTACHED TO THE TUBE STEEL UNLESS OTdERWISE AFPROVED BY ENGINEERINO GREATER THAN 2" REQUIRES ENGINEERING APPROVAL L @ J l7 O E r e 3 m i
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- = FIIJ.ET SIZE REQUIRED PLUS 1/8 INCH.
Fillet size is equal to the thickness of shim No. 2./The maximum size required is 3/16. Length of' the fillet is equal to 5 times the shim thickness. The maximum length required is 15/8". For small bore, the weld length is equal to the shim width.
BROWN & RCOT, INC. PROCEDURE EFFECTIVE CPSES NUMBER REVISION DATE PAGE JOB 35-1195 CP-CPM 9.10 12 09/19/84 1 of 1 ATTACHMENT 7 TURN OF NUT TIGHTENING METHOD
- BOLT LENGTH (L) TURN PAST SNUG TIGHT 0
L & 4 Diameters 120 1 30
+ 01A.<L s 8 Diameters 180 + 300 0
L > 8 Diameters 240 1 45
BROWN & ROOT, INC. PROCEDURE Em e r.c u v e.
CPSES NUMBER REVISION DATE PAGE JOB 35-1195 12 09/19/84 1 of 1 CP-CPM 9.10 ATTACEMENT 8 SHEAR LUGS Aess sarrme., her w. si::
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or tw Snat 44G it nef'stMeest .
$49lA LUG = (AnnitTM buvok nW&tht,
$4 % A& TIT /d Of AFC$Y A09(llMXNS.
DECGNSES /ACftJEt IX, maTF le ce+urs na Aurzw<.tou air n cetu.m /S ocsss.
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I BROWN & ROOT, INC. PROCEDURE EFFECTIVE CPSES NLWBER REVISION DATE PAGE JOB 35-1195 CP-CPM 9.10 12 09/19/84 1 of 1 ATTACHMENT 9 WELD DETAIL FOR TUBE STEEL SKEWED AT LESS THAN 45*
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/ */ r l 'id NOTES:
- 1. Size of weld is determined by the thickness of the material and the slope.
- 2. When the engineer requires a weld other than shown above, a weld detail shall be shown on the drawing.
- 3. Grinding is required in all cases.
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BROWN & ROOT, INC. PROCEDURE EFFECTIVE CPSES NUMBER REVISION DATE PAGE JOB 35-1195 CP-CPM 9.10 12 09/19/84 I o f' 1 ATTACHMENI 10 WELD DETAIL FOR TUBE STEEL SKEWED AT LESS THAN A 60*
t.G3s TAnd co*
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N N
N N
N N N N
[. Ns S
NOTE:
- 1. When engineer requires a groove weld other than the above, a weld detail shall be provided on the drawing.
- 2. Weld is a partial penetration groove weld.
- 3. S (weld size) shall be as specified on the drawing.
NOTE (Other s'ewed k weld details are provided in in Attachments 14, 15, 16.)
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_ BROWN & ROOT, INC. PROCEDURE EFFECTIVE CPSES NUMBER REVISION DATE PAGE JOB 35-1195 CP-CPM 9.10 12 09/19/84 1 of 1 4
ATTACHMENT 11 PIPE SUPPORT BOX FRAME WELD SYMBOL i
The following weld symbols as they appear on the drawing.
YO.
we 1,'ef n"2 ,,
- -7d afs y,v MM shall be interpreted as shown below.
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BROWN & ROOT, INC. PROCEDURE EFFEcuvs CPSES NUMBER REVISION DATE PAGE JOB 35-1195 CP-CPM 9.10 12 09/19/84 1 of t ATTACHMENT 12 PARTIAL PENETRATION WELDS WITH UNEQUAL LEGS
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3ROWN & ROOT, INC. PROCEDURE EFFECTIVE CPSES NUMBER REVISION DATE PAGE JOB 35-1195 CP-CPM 9.10 12 09/19/84 t af t ATTACHMENI 13 5
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Due to manufacturing tolerances the actual thickness may be less than the nominal thickness.
This is acceptable and the weld need not be any greater than the actual thickness if the difference ( A) between the actual thickness and the nominal thickness does not exceed the following.
Nominal Thickness Allowable Difference
< 3/8 1/32 A3/8 1/16 If the difference (6) is greater than soecified above, notify enginaar.ing for approval of a reduced weld size.
The toes of most rolled shapes are rounded. In that case the edge is tutit uo to ensure full throat of weld as shown above.
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BROWN & R00r, INC. PROCEDURE EFFECTIVE CPSES NUMBER REVISION DATE PAGE JOB 35-1195 CP-CPM 9.10 12 09/19/84 1 of 1 ATTACHMENT 14 1 1
For skewed welds where the angle is greater than or equal to 30' but less than !
45*, the weld shall be considered a partial penetration groove weld in lieu of a fillet weld. For a given weld size (s), the "d" dimension shall be measured and shall at a minimum, meet the requirements of the table shown below.
sN
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'4 ELD SIZE REQUIRED (S) "d" min.
3/8 1 5/16 7/16 6 3/8 j 1/2 1 3/8 ;
, 9/L6 1 7/16 .
' 5/8 1 1/2 11/16 I 9/16
. 3/4 4 9/16 ,
Note: If a fillet weld symbol was used, the fillet size is (S) .
1 4
BROWN & ROOT, INC. PROCEDURE EFFE CTIVE CPSES NUMBER REVISION DATE PAGE JOB 35-1195 CP-CPM 9.10 12 09/19/84 1 of 1 ATTACEMENT 15 i
f For skewed welds where the angle is greater than or equal to 45 . but less than 60*, the weld shall be considered a groove weld in lieu of a fillet weld.
The "d" dimension shall be measured and shall, at a minimum, meet the require-ments of the table shown below.
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- JELD SIZE (S) 1 3/161 1/4 t 5/16 1 3/S I 7/16 1/2 .
590 1.1607I.2143 !.2679 i.3214 1.3750 4236 ,
58* l.1509 !.2120 1.2650 1.3180 1.3710 1.4240 570 1.1572 1.2096 1.2620 1.3145 1.3669 l.4193 550 1.1536 1.2047 f.2559 i.3071 .3583 .4145 530 1.14971.1996 1.2495 .2995 .3494 .3993 500 1.1436 1.1915 1.2393 .2872 1.3351 .3830 48 1.1393I.1857 1.2322 .2786 f.3251 .3716 l 45 1 .132! i .1767 I .2209 1 .2652 1 .3093 .3535 l
Example: The drawing calls for a weld size (s) of 3/8(0.375); 0=50*. l The measured "d" dimension must be at least 0.2872. l Not e : Skewed weld joints with an acute angle less than 60* have been detailed utilizing either a fillet or a partial penetration weld symbol, either symbol is acceptable.
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BROWN & R00r, INC. PROCEDURE EFFECTIVE CPSES NUMBER REVISION DATE PAGE JOB 35-1195 CP-CPM 9.10 12 09/19/84 1 of 1 ATTACHMENT 16 For skewed welds where the angle is greater than 135', will be a normal fillet weld with size determined by the thickness of the material and the slope. If a weld size is provided on the applicable drawing, the drawing weld size will govern (see sketch #1 below.)
4or4 rrp wen M
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W SWF i <_ H
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roa m u A::c:.:s wea: so" < i < 135*
908 > $ > 60*
The "S" dimensions shown in sketch #2 and 3 below agree with the weld size shown on the applicable drawing are minimum sizes, e e .
90<#$135 i
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i h 90 >$k 6$
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PROCEDURE ISSUE (i) TEXAS UTILITIES GENERATING CO NUMBER REVISION DATE PAGE CPSES CP-QP-2.0 1 10-9-79 1 of 2 PREPARED BY: h /0/8/79
^
IMPLEMENTATION OF THE CPSES QA PROGRAM APPROVED BY: ,4 At 4A /o!9/7f DATE '
1.0 REFERENCES
X l-A
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TUGCO/TUSI CPSES QA Plan 1-B Brown & Root Quality Assurance Manual 1-C TUCCO Quality Procedure Manual 1-D Brown & Root Quality Assurance Procedures Manual 1-E Brown & Root Non Destructive Examination Procedure Manual v
2.0 GENERAL This document describes procedures that have been prepared for implementation of the CPSES Quality Assurance Program as defined in Reference 1-A.
3.0 PROCEDURE 3.1 B&R CONSTRUCTION PROCEDURES Construction procedures implement applicable Quality Assurance criteria defined in References 1-A and 1-B and establish construction methods and techniques to assure compliance with engineering requirements. Basic procedures also outline QA or QC interfaces and construction operations necessary to assure satisfactory completion of the CPSES project in accordance with code and regulatory requirements. These procedures are prepared by construction personnel and are reviewed by appro-priate QA/QC personnel for compliance to project requirements prior to issue.
F01A-85-59 na in g, Form No. 2
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PROCEDURE ISSUE REVISION PAGE e
NUMBER DATE
- TEXAS UTILITIES GENERATING CO.
CPSES CP-QP-2.0 1 10-9-79 2 of 2
'i
? 3.2 TUGC0 AND B&R QUALITY PROCEDURES Reference 1-C contains procedures describing QA/QC functions that are the direct responsibility of TUCCO. Reference 1-D
, contains procedures implementing QA/QC functions that have been delegated to Brown & Root. Exceptions to this procedure development concept include areas such as receipt inspection and NDE functions which are described within References 1-D and 1-E. These procedures are prepared by QA/QC personnel and reviewed internally for compliance to project requirements prior to issue.
3.3 TUSI TECHNICAL PROCEDURES ,
These procedures implement basic requirements in the area of Design Change Control, Engineering review of nonconforming conditions and other areas that have been delegated to TUSI.
These procedures are prepared by personnel assigned to TUSI's staff and are reviewed internally for compliance to project requirements prior to issue. QA Staff personnel participate in the procedure preparation phase as necessary to assure compliance with applicable Quality Assurance Criterion.
I 3.4 SUBCONTRACTED EFFORTS Project purchase orders / subcontracts define applicable QA/QC criteria for efforts subcontracted by TUSI or Brown & Root.
First level control of these activities is normally accomplished by the selected subcontractor with QA Staff personnel involved in Audit or Surveillance functions. At the option of the TUGC0 Site QA Supervisor, first level control of subcontracted efforts at the CPSES Site, may also be accomplished by the Site QA/QC Staff.
Form No 3