ML20202A877

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Rev 1 to QI-QAP-11.1-28, Installation of Insps of ASME Component Supports,Class 1.2 & 3
ML20202A877
Person / Time
Site: Comanche Peak  Luminant icon.png
Issue date: 09/11/1980
From: Hawkins J, Willis G
BROWN & ROOT, INC. (SUBS. OF HALLIBURTON CO.)
To:
Shared Package
ML18052B537 List: ... further results
References
FOIA-85-59 QI-QAP-11.1-28, NUDOCS 8607100151
Download: ML20202A877 (9)
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SROWN & RCOT, INC. ISSUE

  • CPSES NLNBER REVISION DATE PAGE JCS 35-1195 SI-0AP-11.1-28 1 9-11-80 1 Of 9 s.- ,

TITLE: CRIGINATCR:N !m .vr -

q/j CATE O SME O 90 (T REVIEWED BY: V b R._:.D A_- .b- 9/

SUPPORTS, CLASS 1,2, & 3 W E' APPROVED BY:

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Q 9-//-R ta'QA Manager CATE 5p/

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f.0 TABLE OF CONTENTS I '

1.0 REFERENCES

2.0 GENERAL g 4"

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2.1 PURPOSE AND SCOPE A' i, 2.2. RESPONSIBILITY 2.3 DOCUMENTATION ~,j ""'-

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C 3.0 INSTRUCTION 3.1 MATERIALS 4.0 WELDING 4.1 WELDING INSPECTION REQUIREMENTS (GENERAL) 4.2 WELDING INSPECTION REQUIREMENT (FIT-UP) 4.3 WELPING INSPECTION (FINAL) 4.4 NONDESTRUCTIVE TESTING ,

4.5 NDE INSPECTIONS 5.0 ASSEMBLED HANGER REOUIREMENTS 5.1 FASTENERS 5.2 SWAY STRUT 3 5.3 SWAY STRU" (MODIFICATION) 5.4 SPRING HANGERS

5. 5~ SNUBBERS 5.6 LUBRITE PLATE 5.7 SHIMMING /GROUTIffG 5.8 TOLERANCES 5.0 FINAL DOCUMENTATION RECUIREMENTS

1.0 REFERENCES

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BROWN & ROOT, INC. ISSUE CPSES NUMBER REVISION DATE PAGE JOB 35-1195 OI-QAP-11.1-28 1 9-11-80 2 Of 9 2.0 GENERAL 2.1 PURPOSE AND SCOPE This instruction delineates the criteria and requirements to be used when perfoming installation inspection of ASME component supports, Class I, 2, and 3. If a conflict exists between this instruction and the support drawing, the drawing shall take pre-cedence.

2.2 RESPONSIBILITY The general' mechanical kuperintendent id responsible for fab $ica-tion and installation of component supports.

The QC superintendent shall be ' responsible for the inspection of component supports in accordance with this procedure.

2.3 DOCUMENTATION The results of component support inspections shall be documented 1

on the "Ouality Control Hanger Inspection Report" (see attachment 1). The infomation needed to complete this Report will be obtained from the construction hanger package and physical in-spection of the component support. The Inspection Report Status Log (Attachment 5) shall be maintained by OC for the purpose of tracking "QC Hanger Inspection Report." All hold points on the Inspection Report shall be satisfied as applicable. The MWDC hold points shall be satisfied only for applications delineated in paragraph 4.2.

3.0 INSTRUCTION i 3.1 MATERIALS

! 3.I.I TraceabiTity Marking Transfer-During construction' activities, I.D. markings on bulk material shall be transfered prior to the material being cut. This oper-ation shall be monitored by QC on a random surveillance basis.

The surveillance activity will be documented at a mininum of once per shift on an "IR" ard filed in the OA department. The "IR" shall note the hanger numbers of items in which marking transfer is witnessed.

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3. L2 Material Traceability Control During fabrication, evidence of material acceptability will be provided through the use of a " Material Identification Log"

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BROWN & ROOT, INC. ISSUE CPSES NUMBER REVISION DATE PAGE JOB 35-1195 OI-0AP-11.1-28 1 9-11-80 3 of 9

( Attachment #7) by the craft. The log shall then be presented to the QC inspector for material verification and signature. The log will remain as part of the construction hanger package.

At installation inspection, the OC inspector shall document the material type, grade and (heat number for class 1 only) on the "0C Hanger Inspection Report" using the information provided on the " Material Identification Log."

3.1.3 Material Dimensional Control i

i Component on support the " Bill of material Materials" of the type andand BRH description shall beCMCs.

any applicable as showq Component support material " cut lengths" shall be as shown in the detail sketch of the BRH and any applicable CMCs. The BRH/ CMC

" Bill of Materials" will not be used to verify material cut length.

3.1.4 Material Salvaging Component support parts such as structural steel, snubbers, spring cans, etc., may be used on component supports other than those for which they are designated, provided traceability is maintained. The Material Identification log in the hanger pack-age shall identify from which hanger the substituted part came from and shall be verified by the QC inspector.

4.0 WELDING 4.1 WELDING INSPECTION REOUIREMENTS (GENERAL)

Weld filler material used in the welding of component supports shall be verified using the WFML in the construction " Hanger Pac-kage."

NOTh - OC surveillance of proper complation of the " Weld Filler Material Log" shall be veriff ad by conearin7 the WPG against the WDC and WFML. This verification shall be documented by the inspector's initials and date on the WFML.

4.2 WELDING INSPECTION REOUIREMENT (FIT-UP)

Welding Engineering will enter weld numbers on the BRH for welds

.o v..,.. . t:> pressure retaining. members,. full. penetrat.icn- welds- except. . .

flare beveling on. structural tubing, hangers with nultiple pro-cesses or multi-filler materials or welds requiring NDE, other than visual and all Class I support welds. Inspection of fit-up will be required by QC for the above mentioned welds if delin-eated on a MWDC.

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4 BROWN & ROOT, INC. ISSUE CPSES NUMBER REVISION DATE PAGE JOB 35-1195 01-0AP-11.1-28 1 g-1;-80 4 of 9 NOTE: Cleanliness and fit-up hold points may be inspected sf-multaneously.

The fit-up gap for butt weld joints shall not exceed 1/8 inch be-yond the diameter of the electrode used at the root of the joint.

The fit-up gap for "T" fillet joints shall be as small as practi-cal; however, it should not exceed 1/16 inch. If gap is in excess of 1/16 inch but not exceeding 5/32 inch, this condition will be considered acceptable provided the leg of the fillet weld

' is increased by the amount of separation in excess of 1/16 inch.

(The increase in fillet size applies only when the excess separa-i I tion exceeds 10% of the joint length.) I  ; Il The fit-up gap for " lap" fillet weld joints shall not exceed 1/8 inch at any location along the length of the joint.

J 4.3 WELDING INSPECTION (FINAL) l Fillet weld sizes specified on the drawing are the minimum size required along the full length of the weld joint. Oversize fil-let welds are acceptable providing they do not exceed twice the leg size specified on the drawing. Excessive distortion where oversize fillet welds are used should be avoided.

4.4 NONDESTRUCTIVE TESTING All NDE udll be as shown on drawings.

4.5 NDE INSPECTIONS Each Inspector will be issued an "NDE Guide" (Attachment 6) which provides information on the acceptance criteria of welded supports.

5.0 ASSEMBLED HANGER REOUIREMENTS 51 FASTENERE Fasteners will be as shown on the BRH and any applicable CMCs.

Unless otherwise shown on the drawings, fasteners will be tight-ened securely. Full thread engagement of bolts and nuts is required.

NOTE: If screwed adjustment fit is questionable, inspector i

. - r.._...-.. .4 ,-stall- notify the Quality Engineering Department. l

5. 2 SWAY STRUTS If sway struts are involved with a component support, they shall be installed as follows:

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BROWN & ROOT, INC. ISSUE CPSES NLNBER REVISION DATE PAGE JOB 35-1195 QI-0AP-11.1-28 1 9-11 80 5 of 9 NOTE 1: The sway strut unit is composed of the pipe clamp as-sembly, Attachment 2, the rear bracket assembly, At-tachment 3, and the sway strut assembly, Attachment 4 NOTE 2: The pipe clamp assembly, Attachment 2, consists of the pipe clamp halves, clamp bolts, spacer and nuts, a threaded or non-threaded, high-strength pin, two flat washers and either high-strength nuts or cotter pins, depending on vendor.

NOTE 3: When assembled for inspection, the washers must be in-i stalled between the clamp, halves with the high-strengtn a pin. Under no circumstances shall the clamp bolts be '

interchanged with the high-strength pin.

NOTE 4: The rear bracket assembly consists of the rear bracket, two flat washers, and a high-strength pin held in posi-tion by cotter pins or split snap rings ( Attachment 3).

When inspecting this assembly, verify the washers are installed on the inside of the bracket ams, one on either side of the sway strut spherical bearing. If cotter pins are used, they should be the maximun size.

the hole will accommodate and shall be fully opened.

If split snap rings are installed, they should be examined to verify the rings are not broken, sprung or defomed.

NOTE 5: The sway strut consists of the strut body, adjustable spherical bearing ends, and one or more jamb nuts (see Attachment 4). The spherical bearing should be tightly staked in the adjustable ends and shall have a washer on either side when installed. The sway strut should have the correct adjustment as per the design drawing and the jamb nut (s) shall be tight. If engagement sight holes are present on the strut body, thread engagement shall be verified..

NOTE 6: When correctly installed, the sway strut unit will allow misalignment up to 5* fran sway strut centerline (10' included angle). The 5* of freedom is given by the spherical bearings and their relationship to tre flat washers. Nomally the thicker flat washers are installed on the clamp end, the thinner washers on the rear bracket end.

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The location of the camponent support shall be as delineated on the BRH..

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t BROWN & ROOT, INC. ISSUE CPSES NUMBER REVISION DATE PAGE JOB 35-1195 QI-0AP-11.1-28 1 9-11 80 6 of 9 5.3 SWAY STRUT (MODIFICATION) 5.3.1 Sway Strut Modification with Socket Coupling and Fillet Weld This method applies only to the following sway strut sizes:

1. ITT Grinnell, Fig. 211, size A, B, C, and 1.

l Detemine the actual "C-C" dimension required.

I I Cut excess length (;.- pipe, including S.W. coupling take-out, so

! that each pipe section is approximately the same length (See l Figure 1). I Reconnect pipe sections utilizing appropriate size and class l 3000f S.W. coupling. Utilize vee blocks or other suitable jigs

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to assure proper alignment. All ITT Grinnell Figure 211 sizes

( A, 8, C, and 1) will require a 6000# S.W.' coupling.

Welding shall be in accordance with the approved WPS. Fit-up shall be accomplished by the use of socket weld criteria (Attach-ments 9).

f Reinstall the rod ends, rear bracket and pipe clamp as applicable, in preparation for installation.

5.3.2 Modification of NPSI Sway Strut Sizes SRS. 06 Through 36 Remove by grinding one end coupling weld.

I Shorten pipe extension piece by amount necessary to achieve required "C-C" dimension.

NOTE: Remove the rod ends, rear bracket and pipe clamp where applicable.-

Reweld in accordance with approved WPS. .

5.3.3 Modification ITT Grinnell Sway Strut Size 2 or Larger Remove the rod ends, rear bracket and pipe clamp where applic-able.

Detemine the actual "C-C" dimension required.

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Cut excess length of~ pipe so that each pipe section is approx-inately the same length.

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BROWN & ROOT, INC. ISSUE CPSES NUMBER REVISION DATE PAGE JOB 3S-1195 OI-0AP-11.1-28 1 9-1F80 7 of 9 Butt weld the two ends together utilizing vee blocks or other suitable jigs to assure proper alignment. The weld shall be a full penetration butt weld with backing and made in accordance with an approved project butt welding procedure. Example: (WPS 11032) t 5.3.4 Sway Strut Alignment & Fabrication Tolerance i

Pipe centerline misalignment at joint shall not exceed

  • for sway struts utilizing socket welded couplings or butt weld joints

' (not socket welded end couplings as in 5.3.2 abovet ll This measurement fshould be made utilizing a jig as shown below: i Sc.-ibe .5. art

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l If the measurement as taken from the top of the jig to the sway l

strut varies within the dimensional tolerance given at "A" above i with readings taken at 90* intervals arour.d the strut, then the

! alignmerit may be considered to be acceptable. This measurement j should be taken from both ends of the coupling.

5.3.5 Inspection and Documentation of NF Components All work and inspections shall be documented as follows:

j A. All hold points shall be satisfied on the back side of a

MWDC.

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8. Af ter- the above- has beert carpleted .and verified,. denote on the "QC Hanger Inspection Report," coments section: Sway Strut Modification Acceptable, Inital and Date.

A record of modification must be included in the documentation package for the modified cmponent.

5. 4 SPRING HANGERS n .. . c. , .; . . . " ~

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'Wherr sprfng' hangers are part of the bpport,' provisions sha1T be made to verify stop installation. This verification shall be documented in the cmments section of the OC Hanger Inspection Report by denoting " Spring Can Stops Installed," inital and date.

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BROWN & ROOT, INC. ISSUE

  • CPSES NUMBER REVISION DATE PAGE JOB 35-1195 ,

01-0AP-11.1-28 1 9-11-80 8 of 9 '

i 5.5 SNUBBERS Temporary flat bar cut to the appropriate " pin-to-pin" length requirement may be used when snubbers or struts are not available .

t-for immediate installation. When supports are completed with the exception of items such as struts or snubbers, all other inspec-tions may be perfomed and the applicable items signed as accept-able. Any such exceptions shall be noted on the "CC Hanger Inspection Report" placing an asterisk next to the inspection t which cannot be canpleted. An explanation of the uncompleted inspections shall be entered in the comments section as per the l following example: , l l l l  : i EXAMPLE: Snubber (or strut) not installed.

5.6 LUBRITE PLATE Check the support for correct hardware. Supports containing lubrite plate assemblies should come with a lubrite plate (2 for type "G" & "H" assemblies) a keeper (2 for type "G" & "H" assem-blies for 14" thru 30" pipe) (the keeper is generally small slice of tubing), the pipe attachment (generally a channel, tee or wide flange assembly) and usually a pipe clamp.

The pipe attachment will have a smooth surface left unpainted where it mates with the lubrite plate. This surface should be coated with Liquid Lubricant AE-6 to protect it from rusting.

Check the coating for good coverage. If the mating surface is not covered or the coating is damaged, apply additional Liquid Lubricant AE-6.

NOTE 1: The lubrite plate should not be in place when welding the keeper.

NOTE 2: Care should be taken to assure the surface where the lubrite plate will rest is- level or follows the slope of the pipe and is aligned properly.

5.7 SHIMMING / GROUTING Component support wall and ceiling plates must have a minimum of 80% bearing surface against the concrete face. The maximum allowable gap, for the remaining portion of the plate, shall not exceed 1/16 inch. If this criteria cannot be met, the plate must 2- - - - t- . be grouted.aetth- a. non-shrinis epoxy grout. - .

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BROWN & ROOT, INC. ISSUE CPSES NUMBER REVISION DATE PAGE l' JOB 35-1195 QI-QAP-11.1-28 1 9-11-80 9 of 9 4

5.8 TOLERANCES For tolerances not given in the text of this Instruction, refer .-

to those listed in Attachment #8.  !'

Small bore hanger installation / tolerances shall be in accordance with this procedure and small bore general notes. -

6.0 FINAL DOCUMENTATION REOUIREMENTS When inspections are completed and a hanger is found acceptable, the QC Hanger Inspection Report shall be filled out, attached to

[e I the hanger package and both given to the QC superviscr or his ,

designee for routing to the QA Vault. A transmittal shall be signed by the QC Inspector and given to the craft for their pro-cessing.

NCR number (s) shall be denoted on the OC Hanger Inspection Report.

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