ML20236N816

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Rev 2 to Quality Instruction QI-036, Documentation Review of Duct Supports
ML20236N816
Person / Time
Site: Comanche Peak  Luminant icon.png
Issue date: 04/03/1987
From: Schanf J, Zill R
EVALUATION RESEARCH CORP.
To:
Shared Package
ML20236N530 List: ... further results
References
QI-036, QI-36, NUDOCS 8708120119
Download: ML20236N816 (23)
v • d • e


Text

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Peg 2 1 of 11 O2 Sy EVALUATION RESEARCH CORPORATION I

i COMANCHE PEAK RESPONSE TEAM QUALITY INSTRUCTION FOR ISSUE-SPECIFIC ACTION PLAN VII.c {

TION NO: QI-036 REVISION NO:  ?

ISSUE DATE: 44/I)3/87 1 t

DOCUMENTATION KEVIEW OF HVAC DUCT SUPPORTS Prepared by:

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Date: 3 /7 b)

Approved by:

Zsa a Coordinator Date: 3- $ V - F 7 Approved by: Date: ' -O h ~ $

On-Site QA Repred ntative p

Approved by: [

QA/QCReviewTeampedder 1 Date: dhkh

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8708120119 870731 PDR ADDCK 0500 5

QI-036 Rev. 2 1.0 PURPOSE

'6

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This instruction describes the methods to be used and the accept / reject criteria for the document review of HVAC Duct Supports.

2.0 APPLICABILITY The instruction applies to installed and final QC accepted HVAC duct supports in Units 1, 2 and Common areas. The population is defined in the Population Description for HVAC Duct Supports.

3.0 REFERENCES

3.1 Memorandum QA/QC-RT-1012 to A. A. Patterson delineating documentation used in development of this procedure including specific sources for attributes.

3.2 QI-035, " Reinspection of HVAC Duct Supports".

3.3 CPP-009, " Performance of Reinspection and Document Reviews".

t 4.0 GENERAL

() 4.1 Responsibilities 4.1.I' QA/QC Discipline Engineers The QA/QC Discipline Engineers prepare the document review instructions and checklist delineating the document review requirements, attributes, and accept / reject criteria.

4.132 QA/QC Inspectors I QA/QC Inspectors perform and document the reviews in accord with these instructions and Reference 3.3.

4.2 Policy 4.2.1 Activities performed under this instruction shall conform to the policies contained in the latest Comanche Peak Response Team Program Plan and Issue-Specific Action Plan VII.c.

5.0 INSTRUCTIONS General Using these instructions and information in " References" (Section 3.0), as applicable, the inspector shall perform a document review 2

QI-036

. Rev. 2 l

$.0 INSTRUCTIONS (Cont'd)

' s/ General (Cont'd) of the sample items of this population and document the results on the Document Review Checklists (Attachments 6.1 and 6.2) and associated forms.

Dr, awing Requirements SA. ERC Reinspection Drawings SA.1 Duct Support Detail Drawing Record the revision number of the referenced duct support detail drawing filed in the Bahnson permanent plant file on the document review checklist.

5A.2 Duct Support Location Plan (Layout) Drawing Record the revision number of the referenced duct support location plan (layout) drawing filed in the Bahnson permanent plant file on the documer.t review checklist. p Duct Support Inspection Reports - General O

(_) The inspector shall obtain the duct support inspection report. The inspection reports for duct supports in Unit 1 and common areas will be found in the Brown & Root vault; the inspection reports for duct supports in Unit 2 will be found in the offices of the Bahnson Services Company, Quality Assurance Group. SEE NOTE NO. 1.

The inspector shall use the original of the inspection report to perform the document review; however, it is acceptable to use a copy if the original is not available. When a copy is used, the inspector shall note this in " Supplementary Remarks" in the document review package and state briefly, why a copy was used (e.g., no original in the vault, etc.).

If a duct support inspection report cannot be located, the inspector shall initiate a deviation report referencing all of the attributes which cannot be verified. Where the Brown & Root vault is missing a duct support inspection report, but that report is located in the Bahnson file, it shall be noted on the document review checklist.

If more than one inspection report is located for a given duct support and some support attributes have been inspected and signed-off on each report, the combination of reports shall be acceptable provided all applicable support attributes have been

  • inspected.

3

QI-036 Rev. 2 j- 5.0 INSTRUCTIONS (Cont'd) i Duct Support Inspection Reports - General (Cont'd)

A deviation report shall be written for any applicable support attribute which was not inspected.

SB Duct Support Inspector certification Verify, by review of the Bahnson " Qualification Record" in the inspector's certification file, that the inspector (s) that signed the duct support inspection report was certified to the procedures listed below, as applicable, at the time the inspection was performed. SEE NOTE #2.

Verification that Bahnson inspectors were certified to duct support inspection procedure QCI-CPSES-003 shall be performed for all Bahnson inspectors who signed off attributes on inspection reports prior to 6/16/83. Bahnson inspectors shall i have been certified to duct support procedure QCI-CPSES-014 for' attributes signed off on inspection reports on and after 6/16/83.

Verification that Bahnson inspectors were certified to t inspection procedure QCI-CPSES-003 shall be performed for all Bahnson inspectors who signed off any of the anchor bolt

(~' and/or Richmond Insert attributes on inspection reports prior

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to 4/3/81. Bahnson inspectors shall have been certified to inspection procedure QCI-CPSES-012 for anchor bolt and/or Richmond Insert attributes signed of f on inspectica reports on and after 4/3/81.

Verification that Bahnson inspectors were certified to the weld inspection procedure QCI-CPSES-Oli shall be performed for Bahnson inspectors who signed off fit-up and welding attributes on'7/22/80 or later. Verification that Bahnson inspectors were certified to the weld procedure QCI-CPSES-001 shall be performed for Ba.hnson inspectors who signed off welding attributes prior to 7/22/80. (Note: No weld inspection was perforned by the Bahnson inspector by verification of the " Hanger Fit-up" >; tribute prior to 7/22/80. Refer to Attribute SE).

Refer to Attachments 6.5 and 6.7 for examples of inspection reports.

Welding - General The inspector shall obtain a copy of the weld procedure that was applicable at the time of welding, from the Bahnson QA representative. The weld procedure number is listed on the Weld

() Material Issue (WMI) slip which is referenced on the duct support inspection report.

4

QI-036 Rev. 2

() SC. Weld Procedure Application SC.1 Base Material Verify that the base material specified in the welding procedure is the same as that of the parts being joined. (SEE NOTE #3)

SC. Weld Procedure Application (Cont'd) 5C.2 Filler Material Verify that the filler material classification specified in the welding procedure is the same as that specified on the WMI slip. (SEE NOTE #4)

SD. Welder Qualification Obtain the welder's name or initials from the Weld Material Issue slip (WMI) or Material Requisitten Form (MRF).

Verify, by review of the Welder's Log, that the welder was qualified to the appropriat'e test at the time of welding (us/

the date specified on the WMI or MRF). The appropriate test

,n has the same number as the welding procedure.

k .- If the welder's log does not specify the effective dates of the welder's qualification, the inspector shall verify that the welder's qualification had not lapsed by one of the following methods:

1) The " Material Control Weld Material Issuance Logs" There are two logs, one for current and one for non-current welders, both filed by welder's names.

Check the Material Control Weld Material Issuance Log  ;

to verify that there has been no six month or longer period of time when the welder was not issued filler material for the appropriate wald process <.

2) WMI Slips WM1 Slips shall be checked for the welder, from the date of his most recent qualification, to the date of the sample weld. Use the date and the weld material (wire or electrode) on the WMI. For the period between the welder's qualification and the completion of the sample weld, ensure that at least one WMI for the appropriate weld process is issued, not less than once every six months for that welder.

() See Note #5.

5

. i i

QI-036 )

Ray. 2-4 5.0 INSTRUCTIONS (Cont'd) )

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(,,/ SE. Weld Fit-up Inspection Verify that a weld fit-up inspection was performed:

For duct support inspection reports dated 7-22-80 or after*, verify that " Fit-up" or " Hanger Fit-up" has been signed off.  !

  • )

For duct support inspection reports dated before l 7-22-80*, verify that weld fit-up has been added to the j duct support inspection report and signed off. )

  • The inspector shall use the date entered for fit-up or hanger fit-up attributes on the duct support inspection 1 report. '

Hilti Bolts - General j

After 04-02-81, Bahnson inspections of attributes SG, SH and 5J '

were performed on a surveillance basis. These attributes will be N/A'd by the engineers for those supports which were not inspected on a surveillance basis and "no. surveillance" will be entered in ,

remarks.

f- 5.F Hilti Bolt T,orque

(

SF.1 Torque Wrench Number Verify that the torque wrench number is entered on the duct support inspection report.

5F.2 Torque Wrench Calibration Verify that the torque wrench was calibrated at the time of inspection. ( Note: The calibration due date may appear anywhere on the duct support inspection report provided it is identified as such.) Calibration shall be checked by review of the calibration record in the Brown & Root Calibration Lab.

SF.3 Torque Value Verify that the torque setting value is listed on the duct support inspection report and that it meets or <

exceeds the minimum torque value requirements shown in Attachment 6.6.

6

QI-036 Rav. 2 T'

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s. s SG.

Abandoned Holes Covered by Duct Support Members - Spacing

_l-l Verify that the. proper spacing between abandoned holes covered by duct support members and installed Hilti bolts was maintained. For duct support inspections that were performed before 4-03-81, this is done by checking that both " Anchor Bolt Hole" and " Anchor Bolt Angle" are signed off on the duct support inspection report. For duct support inspections that were performed on or after 4-03-81, this is done by checking only that " Anchor Bolt Hole" is signed off on the duct support inspection report.

SH. Cut Rebar Verify that no reboc was cut during the drilling of holes for Hilti bolts without the approval from Gibbs & Hill. For duct support inspections that were performed before 4-03-81, this is done by checking that both " Anchor Bolt Hole" and " Anchor Bolt Angle" are signed off on the duct support inspection report. For duct support inspections that were performed on or after 4-03-81, this is done by checking only that " Anchor Bolt Hole" is signed off on the duct support inspection report.

SJ. Resetting of Hilti Bolts I

Verify that holes for Hilti bolts that slipped, loosened or pulled out during the setting of the bolt were properly ,

reworked to allow for. adequate embedment in accord with the construction procedure. For duct support inspections that were performed before 4-20-81, this attribute shall be NA'd by the inspector and the Hilti' inspection date entered in remarks. For duct support inspections that occurred on or after 4-20-81, this is done by checking that " Anchor Bolt Torque" has been signed off on the duct support inspection report.

Materials SK. Material Traceability - General Traceability of materials used for safety related duct supports is not required after receipt inspection by Bahnson installation and inspection procedures. Therefore, this attribute relates to only receipt inspection of materials used in safety related duct supports. These are structural shapes (angle, channel, plate and tube steel) sheet metal, nuts, and {

bolts. This document review will be performed once and the '

results will apply to all samples within this population.

This generic type inspection is assigned a unique verification O, package number (R-S-HVDS-200) and the inspection checklist is shown in Attachment 6.2 l

l 7

. i QI-036

, Rev. 2

p 5.0 INSTRUCTIONS (Cont'd)

U SK.1 Material Specifications ,

Verify, for each purchase order, that the material received is in accord with the following: I ASTM A36 - angles, channels and plate steel y ASTM A500 - tube steel (TS)

ASTM A307 - bolts ASTM A563 - nuts I

ASTM A325 - flat washers The inspector shall do this by reviewing the Bahnson

" Receiving Checklist for Q Material", the Bahnson receiving inspection reports and the applicable purchase orders (see Note #6).

If the material was received from Brown & Root, verify that the Brown & Root Receiving Inspection Report t l

(obtained from information included in Bahnson receiving documentation) is in accord with the material specifications listed above.

t '

This attribute is rejected wnen'a component type (e.g.,

angle, bolts, etc.) is found on a purchase order with a .  ;

material specification other than as specified above. l All rejected items shall be listed'on Attachment 6.8. >

NOTE: Only those Purchase Orders within the scope of this reinspection program will be reviewed. (i.e.,  !

only those purchase orders with receipt inspections on or before 6/05/85).

5K.2 Material Documentation Verify that a Certified Material Test Report (CMTR) or a Certificate of Compliance (C of C) is on file (for the materials listed in 5K.1) for each purchase order .

reviewed. Inspectors shall make entries on Attachment  !

6.8 for material documentation, as applicable. (see Note #6) l 8

-__________-_-_Y

QI-036 Rev. 2 3.0 INSTRUCTIONS (Cont'd)

SK.3 Inspector's Certification Verify that the inspector (s) who prepared the Material Inspection Report and the " Receiving Checklist for Q Material" (or equivalent of each) was certified to I QXI-CPSES-004 (" Receiving Inspection and Identification Procedure"). Also, verify that the inspector was certified at the time the report was prepared by referring to the form " Qualification Record" in the inspector's certification file. The date of certification expiration is also on this form.

Inspectors shall make entries on Attachment 6.2 for material documentation inspector"s certification.

NOTE-. Inspector certification shall be verified for each Bahnson purchase order verified under Attributes SK.1 & 5K.2.

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QI-036 ,

3 Rev. 2

. NOTES:

(,,/ 1. To obtain duct support inspection reports from the vault, the inspector must identify the turnover package number to vault-personnel To obtain the duct support inspection reports from Bahnson, the inspector must provide the Bahnson QA representative with the following information:

Duct support mark number The duct support location plan (layout) drawing number The turnover number These Ltems will be listed on Attachment 6.4, " Pertinent Duct Support Information". (Ref. Section 5.0, " Duct Support Inspection Reports").

2. If this attribute is rejected, the inspector shall determine if the QC. inspector (s) who signed the inspection report were ever certified to the applicable procedure (s). If never certified, this shall be so noted in the remarks column. If certified at some time, but not at the time of inspection, the inspector shall record the time period (s) of certification. Bahnson inspector's ,

certification periods shall be obtained from the " Qualification Record" form in the Bahnson inspector's certification file. After fg r 7/8/81, the certification period shall be three (3) years with the t

5 4

exception of inspectors certified after 3/11/82 and before 7/8/83.

The certification period between 3/12/82 and 7/7/83 (inclusive) shall be two (2) years.

3. Duct support materials are as follows:

plates, angle and channel members: ASTM-A36 tube steel  : ASTM-A500 sheet metal  : ASTM-A526 or A527 ,

(Ref. Section SC.1) i

4. If the filler material classification is not specified on the WMI slip, it c.an be obtained from the heat number. Bahnson QA representatives are prepared to assist inspectors in obtaining this information. (Ref. Section 5C.2)
5. The inspector shall perform a check to determine if the welder .

symbol (when recorded during the duct support reinspection) matches I the welder listed on the WMI slip. If they are different, the inspector shall evaluate the qualification of the welder to whom the symbol belongs (see Section SD). If the symbol cannot be I

traced to a welder, the inspector shall note this on the document

/'"N review checklist. (Ref. Section SD.)

10

)

l

4 QI-036 Ray. 2 NOTES: (Cont'd)

6. The following items are exempt from the requirements of attributes j

SK.1 and 5K.2 where they appear on material purchase orders-(for '

Bahnson purchase orders only):

L 1 1/2" x 1 1/2" x 3/16" I

  • L 2" x 2" x 3/16" L 2" x 2" x 1/4" L 3" x 3" x 3/8" l L 4" x 4" x 1/2" 5/16" x 1 1/4" bolts 5/16" dia. nuts sheet metal (10-18 gauge)

However, these items shall be verified for the requirements of ,

attributes SK.1 and SK.2 when the material was supplied to Bahnson by Brown & Root.

(Ref. Section 5K.1 and SK.2) g 11

1 .-__--.__-__-__-__

QI-036 Rev. 2 6.0 LIST OF ATTACHMENTS 6.1 Document Review Checklist (2 sheets) 6.2 Material Document-Review Checklist (2 sheets) l 6.3 Supplemental Remarks (1 sheet) 6.4 Pertinent Duct Support Information (1 sheet) 6.5 Duct Support Inspection-Report Forms (Samples) (1 sheet) 6.6 Hilti Bolt Torque Requirements (1 sheet) 6.7 Duct Support /Hilti Bolt Inspection Report Forms'(Samples)

(2 sheets) 6.8 Duct Support Materials ~(1 sheet)-

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. Attachm2nt 6.1 COMANCHE PEAK RESPONSE TEAM QI-036 CHECKLIST Rev. 2 (N POP'.TLATION DESC VERIFICA!!0N PKG NO.

( ,, HVAC DUCT SUPPORTS R-S-HVDS- PAGE 1 0F l

QUALITY INSTRUCTION QI-036 [ REINSPECTION [ UNIT 1 EQUI? MENT MARK / TAG NO.

[ DOCUMENTATION REVIEW [ UNIT 2

[ COMMON VERIFICATION A TE ACCEPT REJECT DATE REMARKS 5A. ERC Reinspection NA NA For Information Only Drawings '

SA.1 Duct Support Detail Drawing 5A.2 Duct Support NA NA For Information Only Location Plan (Layout) Drawing ,

. ~. 5B. Duct Support Inspector .

(n-) Certifications l

SC. Weld Procedure Application SC.1 Base Material SC.2 Filler Material SD. Welder Qualification SE. Weld Fit-up Inspection PREPARED BY: APPROVED BY:

DISCIPL!NE'ENCR. DATE LEAD DISCIPLINE ENGR. DATE

,r'N ih5PECTED SY: APPROVED BY:

5, s

N5PECTOR 2 ATE LEAD INSPECTCR DATE 2 P- E . . .\ . 2 e"; .5
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COMA _NCHE PEAK RESPONSE TEAM QI-036 i CHECKLIST Rev. 2

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'- ) POPULATION DESC HVAC DUCT SUPPORTS VERIFICATION PKG NO.

R-S-HVDS- 2 PAGE _20F )

VERIFICATION

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ACCEPT REJECT DATE i

i SF. Hilti Bolt Torque I

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5F.1 Torque Wrench l i

Number 5F.2 Torque Wrench Calibration 5F.3 Torque Value SG. Abandoned Holes Covered by Duct Support Members

- Spacing e'

5H. Cut Rebar

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SJ. Resetting of Hilti Bolts

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Page 1 of 2 Attachttent 6.2 COMANCHE PEAK RESPONSE TE.AM CHECKI.!ST QI-036 1 ,, Rev. 2 l [s l POPULATION DESC VERIFICATION PKG NO.

HVAC DUCT SUPPORTS R-S-HVDS-200 PAGE 1 0F j QUALITY INSTRUCTION QI-036 REINSPECTION

[XUNIT1 EQUIPMENT MARK / TAG NO.

DUCT SUPPORT MATERIAL

[xDOCUMENTATIONREV!EW [XUNI'2 TRACEABILITY

[X COW.ON VERIFICATION ATTRIBUTE ACCs.PT REJEC . DATE REMAPIS Purchase Order No.:

SK.1 Material '

Specification 5K.2 CMTR or C of C SK.3 Inspector's Certification '

,-~ Purchase Order No.:

SK.1 Material Specification 5K.2 CMTR or C of C 5K.3 Inspector's Certification Purchase Order No.:

SK.1 Material Specification SK.2 CMTR or C of C SK.3 Inspector's Certification PREPARED BY:

APPROVED BY:

DISCIPLINE ENCR. DATE LEAD DISCIPLINE ENGh. DATE INSFECTED BY:

APPROVED BY:

.N5FEGOR 3 ATE LEAD INSPECTOR DATE 2P-407.;A. Rev,,s an .

Page 2 of 2 1

1 v.n a66ucumuu6 l COMASCHE PEAK RESPONSE TEAM QI-036 CHECKLIST Rev. 2 g

POPULATION DESC VERIFICATION PKG S0.

's HVAC DUCT SUPPORTS R-S-HVDS-200 pggg __2 0F 2 VERIFICATION A

ACCEPT REJECT DATE REMARKS Purchase Order No.:

SK.1 Material Specification I

5K.2 CMTR or C of C

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1 SK.3 Inspector's Certification

......................o........o................4..................................

Purchase Order No.:

1 SK.1 Material Specification

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SK.2 CMTR or C of C

( SK.3 Inspector's Certification

..........u.................o.................................

Purchase Order No.:

SK.1 Material Specification

= -----------------.----------------------------- =----= -

SK.2 CMTR or C of C 5K.3 Inspector's Certification

....................... ........o.................. .................................

Purchase Order No.:

SK.1 Material Specification SK.2 CMTR or C of C SK.3 Inspector's Certification

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Attechm2nt 6.3 QI-036 Rev. 2 7 g SUPPLEMENTAL REMARKS

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v DOCUMENT REVIEW PACKAGE NO. R-S-HVDS-DUCT SUPPORT DETAIL DRAWING NO.

Attribute No./ Description Additional Remarks e

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Attachm.nnt 6.4 QI-036 R2v. 2 Verification Pkg. No. R-S-HVDS- Ref. Note Ill Page 1 of I

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PERTINENT DUCT SUPPORT INFORMATION

1. Drawing No.
2. Location Plan (layout) Drawing No.
3. Mark No.
4. Turn /Over Package No. ,

V QA/QC Discipline Engineer Date

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