ML17138A568

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Field Survey Insp of Pipe Support Shop Welds,Q-Listed Hangers, Final Rept
ML17138A568
Person / Time
Site: Susquehanna  Talen Energy icon.png
Issue date: 11/13/1978
From:
PENNSYLVANIA POWER & LIGHT CO.
To:
Shared Package
ML17138A569 List:
References
NUDOCS 7904120264
Download: ML17138A568 (57)


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~4hos20'78<0g6gp7~~ITTGRINNELLCORPORATIONFIELDSURVEYINSPECTIONOFPIPESUPPORT-SHOPWELDSFORSUSQUEHANNANUCLEARPROJECTQ-LISTEDHANGERSFINALREPORT11/13/78h%%1fA4Zte r't

~~~~tiN2G'78'Q6gp7ByL.MoreProjecEngineerDateReviewedI~P.Stanish~ProjectManagerDate~'~<~ApprovedM.GrossoManagerofOperationsDate(R.Maerson,P.E.MaaerofResearch,DelopmentaEngineeringDate TABLEOFCONTENTSIntroductionPAGE1II.MethodofSurveyIII.MethodofAnalysisIV..AnalysisofResultsV.VI.ConclusionsAppendices:A.QualityAssuranceProcedureSQ-004B.QualityAssuranceProcedureSQ-005C.QualityAssuranceProcedureSQ-006D.StressAcceptanceCriteriaforWelds

%i--~4~~'t~s~~~\ygygG'78lf396127ABSTRACTThisreportcontainstheresultsofafieldsurvey,throughAugust15,1978ofQ-Listedsupportswithshopwelds,madebyITTGrinnellsWarrenOhiofabricationfacility,conductedbyBechtelPowerCorporationandITTGrinnell'sengineeringandQualityControlDepartments.TheresultsareanalyzedtoverifytheadequacyofthesupportsontheSusquehannaProjectfabricatedbyITTGrinnellinthefulfillmentofPurchaseOrder48856-P-3-AC'ev.12,ascommittedtotheNRCbyPennsylvaniaPower&Light.Intotal,fivehundredsixty(560)Q-Listedsupportshavebeensurveyedandonehundredfiftytwo(152)arefoundtohaveportionsofshopweldsbelowthesizespecifiedonthesupportdetail.Theseweldsareanalyzedforthe"as-fabricated"stresslevelsusingthesmallestweldsectionfoundalongtheparticularweld.Theresultsof'hisanalysisshowthatallsurveyedQ-Listedsupportsmeetweldst'ressrequirementsofANSIB31.1andthestressacceptancecriteriaforwelds.

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gy2Q'78-D"6127I.INTRODUCTIONAnagreementbetweenBechtelPowerCorporation,PennsylvaniaPower&LightandITTGrinnellwasreachedtosurveyalloftheshopweldsforQ-ListedsupportsmadeatITTGrinnell'sWarrenfacility,andshippedpriorto10/18/77.ITTGrinnellagreedtocompileandanalyzeeachshopweldfoundinthesurveyedassemblieswithanon-conformanceasdefinedbyITTGrinnellQualityControlProcedureOSQ-006Rev.0,whichwasapprovedbyBechtelonFebruary7,1978,basedonthesmallestsectionofweldfound.Thebasisofthisreportintendedtojustifytheacceptabilityofthereferencedsupports,byshowingthatnoneoftheshopweldsonthesesupportswouldbeoverstressedinthe"as-fabricated"condition.Sincespecifictolerancesarenot,re-quiredbyANSIB31.1,orthedesignspecification,itisITTGrinnell'spositionthatsupportsfabricatedwithshopweldsslightlybelowthesizespecifiedonthedesigndrawingshouldbeacceptableprovidednoshopweldsareoverstressedinthe"as-fabricated"condition.

NpY2G'>8G96127II.METHODOFSURVEYPriortoITTGrinnell'sinspectionefforts,Bechtelhadperformedapreliminarysurveyofonehundredseventytwo(172)Q-Listedsupports.Ofthese,sixty-nine(69)werefoundtohaveweldsizesdifferentfromthedesigndrawings.TheresultsofthissurveyaregiveninSectionIVofthisreport.ITTGrinnellhasinspectedthreehundredeightyeight(388)Q-Listedsupports.Ofthese,eightythree(83)werefoundtohaveweldsizesdifferentfromthedesigndrawings,asdefinedbyZTTGrinnellQ.'A.ProcedureSQ-006.Alldis-crepanciesweretabulatedandforwardedtoITTGrinnell'sHangerEngineeringDepartmentforanalysis.TheresultsofITTGrinnell'ssurveythroughAugust3.5,1978areincludedinsummaryinSectionIVofthisreport.Forthe.purposeofthisreport,ahangerrequiringreworkisdefinedasasupportthathasanyshopweldthatisover-stressedduetoundercutorshallowsizeinthe"as-fabri-cated"configuration.

III.METHODOFANALYSISWeldstresscalculationswere'erformedforeachQ-Listedsupportasrequiredtoverifythatnoneoftheshopweldswereoverstressedinthe"as-fabricated"configuration.Thesecalculationswereperformedusingthesmallestsectionfound,carriedthefulllengthoftheweld.Thisrepresentsaconservativeapproach,sinceveryfewoftheshopweldsquestionedwereundersizeforthefulllength.ForcesontheweldsweredeterminedinaccordancewithITTGrinnell'sStressCriteriadatedJanuary17,1978,seeAppendixD,whichwasapprovedwithcommentsbyBechtelonMarch9,1978.Theload'perlinearinchwascalculatedandcomparedtothemaximumallowableloadperlinearinchasspecifiedintheabovelistedStressCriteria.

~I~~*.IV;AnalsisofResultsA.Weldsizedifferentfromdesigndrawing'istedbelowarethe"as-fabricated"weldstressesforSO>2u'78'096127theshopweldsinquestiononthesurveyedassemblies,theallowableloadpertheStressCriteriaforthe"as-fabricated"size,andthe"OCratio"whichistheallowableloaddividedbytheactualcalculatedstress.AllweldsanalyzedmeetthemaximumstressrequirementsofITTGrinnell'sStressCriteria.Sketch8ShopWeld8LoadonWeldl7{/f/in.)DBB-209-H15(Q)1HBD-62-H10(Q)1DBB-209-H3(Q)1DBB-122-H5(Q)1H10(q)1a8(q)GBB-107-H14sh.l(Q)lsh.2(Q)2HBB-101-H2(Q)1GBB-118-H5(q)1H8(q)1Hlo(Q)1218-H5(Q)1DLA-102-H4(Q)1IHBB-101-H4(Q)1,GBB>>118-Hllsh.l(q)1'h.2(Q)2GBB-107-Hll(Q)1II23HBB-108-82(q)-1II2II3.HBB-220-Hl(q)1-It2DBB-209-H5(Q)1GBB-101-H13sh.l(Q)1sh.2(q)lGBB-107-H13(Q)1II2HRC-22-a6(q)1It2GBB-101<<H30(Q)1GBB-102-H15(q)1GBB-107-H17(q)1H18(Q)1GBB-101-H14(Q)1GBB-118-H7(q)1GBB-118<<H9(q)1HBB-220-H3(Q)1160158044138512211907509953041580731385891190721190PureCompressionStiffenerPlateWeld1241385411580StiffenerPlateMeld731580731580780119016119011901911904213854051385109158010371385680119085119012571463412~1380NotLoaded778198044813804001385PureCompression12601385PureCompression.StiffenerPlateWeld225138510329.71.335.21913.416.5ll3822221.57218863333.414.51.31.814.11.23.32.53.13.56.2

~~Sketch8ShopWeldt.e2d7I096127LoadonWeldActual(///in.)Allov(0/in.)HRC-22-Hl(Q)GBB-101-Hj(Q)IIGBB-218-H3(Q)GBB-218-H8(Q)GBB-218-H9(Q)GBB-218-Hlo(Q)GBB-118-H3(Q)HRC-22-Hs(q)~H4(Q)DCA-ill-Hl(Q)DLA-104-Hl(Q)DBB-113-H2(Q)..GBB-218-H6(Q)DLA-104-H3(Q)tlGBB-118-Hl(Q)GBC-101-H63(Q)HBB-220-H5(Q)IIH6(q)DLA-103-Hl(Q)MST-022-Hj(Q)H6(Q)GBC-101-H61(Q)MSL-100-H4(Q)MST-022-Hl(Q)MST-022-H3(Q)DLA-101-H2(q)DBB-122-H4(Q)DCA-ill-H2(Q)H4(q)DBB-107-H2(Q)tlGBB-218-H2(Q)IIGBB-118-H9(Q)ItGBB-107-H12(Q)ItHRC-123-Hs(q)tlIlttIIDBB-120-Hj(Q)HRC-112-H12(Q)HRC-110-H2(q)DBA-105-H2(Q)DBB-112-H4(Q)DBB-114-H18(Q)GBB-119-H13(Q)GBB-109-Hll(Q)'BB-115-H18(Q)126111111'111112111211111.111.1111121212121234511411thru4111~110551055Compression19801980NotLoadedIIIIIIII185NotLoaded1373902765555555575Compression412.177PureCompression1190~1385138513851190119011901190158015801580PureCompression213PureCompressionPureCompressionPureCompression119050~138518513857671190StiffenerPlateWeldsOnlyStiffenerPlateWeldsOnlyStiffenerPlateWeldsOnlyStiffenerPlateWeldsOnlyStiffenerPlateWeldsOnlyNotLoadedNotLoadedPureCompressionIIIt195800Compression.CompressionNotLoadedCompressionII12813855111385132138511661385870198014451980Compression27.77.51.64.110.82.710.51.22.31.41.91.96.410.13.6521.621.621.621.621.13.848.935.58

'SkeeeklWeldl.LoadoVeldActual(Plin,).Allow((flin.096127GBB-104-H41(Q)HBB-108-Hl(Q)DBB-114-H7(Q)DBB-120-Hl(Q)HBB-110-H2(Q)GBB-107<<H12(Q)GBB-107-H12(Q)DBB-121"H2(Q)DBB-115-H12(Q)DBB-121-H3(Q)DBB-109-H18(Q)IIIIEBB-102-H3(Q)GBB-101-Hll(Q)IItttlDBB-121-H24(Q)GBB-107-H12(Q)GBB-118-H9(Q)HBB-220-H3(Q)'BB-109-H15(Q)GBB-115"H8(Q)~GSB-1O4-H29{Q)DBA-105-H2(Q)HSB-109-H3{Q)IIGBB-110-H13(Q)HBB-108-H4(Q)DSB-117-H6{Q)(Q)HRC-131-H2{Q)HRC-112-Hll(Q)GBB-104-H15(Q)Hss-12O-H5(Q)HBB-,llO-H29{Q)115to121i@254to53to5111124-72567112Stiff.Pl3to23642631thru4112132112212634a5Pure531PurePure5036418228625934Pure205277536530680680364153390275ateSec225Weld584519Weld652639'll9467558974517928074226254Compression1190CompressionCompression158013851385119011901190Compression119080011901190119011901190119013851385ondaryMember1385incompression15801580incompression1190119011901190119011901190119011901190119011902.243.1421.67.64.247.6l.275.802.892.222.241.751.753.277.773.555.036.152.703.041.821.86108.181.251.5713.371.596.644.2516.085.264.68 PIN20'78jD9Allweldsanalyzedmaintainedacertainsafetymargin(OCratio)whichrangedfrom1.10to188.Thereasonforthewidevariationinsafetymarginisthatmanyoftheshopweldsquestionedweredesignedataminimalfabri-cationsizeregardlessofthemagnitudeoftheloadapp1ied.NOTES:1-Allweldsincludedinthelistinggiveninthissectionwhichhavethecomment"compression"inthestresscolumnanddo,notlistacalculatedstress~reflectweldswhichare1/16"orlessundersize.2-Allweldsincludedinthelistinggiveninthissectionwhichhavethecomment"stiffenerplateweld"areshownwithoutacalculatedstresssincetheyaiesecondarymembers.

0~~..acesva.097255IV;-hnnl'sisofResultsB.UndercutWelds1.Thefollowingsketcheshaveshopw'eldsincompressionwith1/16"undercutsorless,whichGrinnellhas,handledinthesamefashionasinSectionIV.(A).DBB-107-H5(Q)DCA-110-H2(Q)GBB-103-H8(Q)GBB-214-H1(Q)'BC>>101-H68(Q)GBC-101-H82(Q)HBB-113-Hll(Q)HRC-112-H2(Q).HRC-112"H7(Q)DBB-114-HtZ(Q)HBB-110-H19(Q)HRC-112-H14(Q)Weld8.113111,21~21&2113DBB-114-)17(Q)GBB-109-H13(Q)GBC-101-H39(Q)GBC-101-H71{Q)HBB-110-H13(Q)HEB-113-H22(Q)HRC-112-H4(Q)HBB-110-H17(Q)DCA-110-H5(Q)HBB-113-H3(Q)GBB-104-H7(Q)HBB-120-H8(Q)Weld'14,111,2~71thru41&31&211152.Thefollowingsketcheshaveshopweldsintensionwith1/16"'undercutsorless.Wehavethefollowingcommentsonthosesub)ectsketches.'a.DBB-121-H22-Theundercutisonthekneebracewhichisnotneeded.Thesectionmodulusofakf4xl3is5.24andthedesignrequires2.18.Therefore,the'kneebraceisnotrequired'.b.GBB-112-H11-Theundercutisonthe1f-Beamweldto'heplate.Theareaofthismember'is3.81sq.in.a.andit.hasbeenreducedby.06sq.in.Therefore,thisundercut-'doesnotneedanyrework.c.GBB-101-H18-Theundercutisonthekneebracewhichisnotrequired.Thesectionmodulusofa6WF15.5is10andthedesignrequires6.26..Therefore,.the'kneebraceisnotrequired.

B.UndercutWelds-(cont'd.)gII2G7~.06127sd.GBB-109-H8-Theundercutisonthekneebracewhichisnotrequired.Thesectionmodulusofa4M13is5.24andthedesignrequires3.86.Therefore,thekneebraceisnotrequired.e.HRC-104-H2-TheundercutisatbothendsofitemII3foralengthof1/4ofaninch.Themaximumshearforceateachendofitem83is5818.Thesurfacearearequiredtowithstand5818islessthan1/2inch.,thesurfacearearemainingwiththeundercutis.95sq.inches.Therefore,thisundercutdoesnotneedanyrework.f.Thefollowingsketcheshaveactualcrosssectionalareasorstresseslessthanrequiredbydesignfortheundercutmaterial.Noreworkisrequired:GBB-101-H8HRC-123-H3HBB-110-H26GBB-112-HllGBB-107-H3eDBB-115-H2g.Thefollowingsupport,HBB-llO-H3,couldnotbeevaluatedduetoinadequacyontheoriginaldesign3.Wehav'econsideredundercutweldsinbending.Thefollowingsketcheshavethegreatestmomentsthatwehavefoundduringoursurvey,todate.PlateSketch.ThicknessNo.,Load~ReuitedHRC-126-Hl702552031"594"PlateNewThicknessUnder-PlateDDesiDnCutThickness.625"HCB-102-Hl340.289"375".031344"Fromtheabovefinding,Grinnellconcludedtheundercutsinbendingareallacceptable.Theremainingsupportsinthiscategoryare:

~~I\~B.UndercutWelds-(cont'd.)Hov20'l8'961273.(cont'd.)HRC>>123-Hll(Q)GBB-109-H18(Q)HRC-126-Hl(Q)HCB-102-Hl(Q)GBB-101-H17(Q)GBB>>101-Hl(Q)GBB>>104-H32(Q)DBB-115-H3(Q)HRC-131-H2(Q)HBB-113-H16(Q)HBB-110-H29'(Q)members,suchasstiffenerplates,whichmaybedisregardedfromthereport.(Q)DBB-107-H7WeldNo.2(Q)GBB-104-H22WeldNo.4,5GBB110H13(Q)4.Thefollowingsketcheshaveweldswithundercutsofsecondary3.0

V.CONCLUSIONOfthefivehundredsixty(560)Q-Listedsupportssurveyed,onehundredfiftytwo(152)werefoundtohaveshopweldsthatwereshallowerthanthesizespecifiedinthedesigndetail.Theseshopweldswererecorded,subsequentlyanalyzed,andtheactualstressinthe"as-fabricated"con-ditioncomparedagainstmutuallyagreeduponallowables.Thecalculatedsafetymargins(oCratio)rangedfrom1.1to188-Throughobservation,itwasseenthatallweldswerebelowallowables;therefore,noneofthesurveyedandanalyzedsupportshaveanyshopweldswhichareoverstressed.Asaresultofthissurvey,allQ-ListedsupportweldsonassembliesfabricatedbyITTGrinnellandshippedtotheSusquehannajobsitehavebeenvisuallyinspected,calcula-tionsperformedandallweldshavebeenfoundtomeetallrequirements.ITTGrinnellconcludesfromthisinspectionthatallQ-Listedsupportsshippedpriorto-10/18/77totheSusquehannajobsitearetotallysuitableforthedesignedservice.Allasfabri-catedweldsmeettherequirementsofANSIB31.1ortheagreeduponstresscriteria.'1

~~~~~~hog2G'78~0~d6127VI.APPENDICES MP2G'78~096127APPENDIXAQUALXTXASSURANCEPROCEDURESQ-004 rr~~~0~~rG}}.';}=-fOOaPOfO,af}OHPIPEHANGERDIVISIONPROVIDENCE,R.l./WARRE}V,OIRIOKN20:78096127QUALITYASSURANCE/QUALITYCONTROLPROCEDURENUL1BER:SQ.-.OO2-.REVISION:Pago..3.of.....6---TITLE:QUALITYASSURANCEREQUIREMENTS-FIELDINSPECTIONOFVELDSEFFECTIVITYDATE..2.Q.5/78..SUPERCEDESREV......0....PrcparedBy%23Vtl1CDate:2p.5/7~i/ApprovedBy:LQ)~/+~'Wa+Pate.X-JP=7ApprovedBy:Dale:.O.A.IO.C.Aoorcval:i:~&in.CCc:.".~......RDR:pHD,anginaringLJHangarRsDE]Mncfaclarlng8Dinar(specify}Q}}RLlt}rooDslog<Chcc}gOnes1.0OBJECTIVE:ThisprocedureshalldocumenttheQualityAssuranceRequirementsapplyingtotheFieldInspectionnd/orRe-InspectionofWeldsonPipeSupportsproducedbyITTGrinnell.2.0APPLICATION:rThisprocedureshallapplytotheFieldInspect'onofFilletWeldsonCustomerDesigned(Non-Standard)PipeSupportsmanufacturedbyITTGrinnellfortheSusquehannaSteamElectricStat'onlocat.dnearBerwic'<,Pennsylvania.AllBechtelDesignedShopi'eldstobeinspectedshallbeindicatedontheITTGrinnellplasterChecklistasprovidedbyITTGrinnellPHD-Engineering.3g0QUALITYASSURANCER"QUIRE.'rlENTS:3.1Organization-ITTGrinnellPersonnelinvolvedintheFieldInspectionofWeldsandtheirprimaryresponsibilitieswillbeasfollows:InspectionPersonnel-willberesponsiblefortheVisual~andDimensionalExaminationofWeldsandforthegenera-tionandmaintenanceofdocumentation"srequiredbythisprocedure.ThesepersonsshallreporttotheWarrenPlantQualityControlRepresentative.WarrenPlant.QualityControlRepresentative-amemberoftheWarrenPlantQualityControlDepartmentandwillberesponsible.fortheactivitiesoftheInspectionPersonne13'lillalsoprovideinterfaceattheProjectSitebetwoenPHD-Engineeringandtheinspectionprogram,andsoforth.AlsovrillberesponsibleforcarryingouttherequirementsofthisprocedureattheProjectSite.ThispersonshallreporttotheWarrenPlantQualityControl4!anager.PxojectEngineer'amemberofPHD-EngineeringandwillberesponsibleforEngineeringactivitiesrequired.bythisprocedure.WillalsoprovideinterfacebetweenEnineer--ing,thecustomer,andQualityAssuranceactivities.GllVFORMQCteaaRF!V.A ~~GRID'itHPELLCORPORAT1ONPlPEHANGERDJVISlONPRovlDENGH,R.l./MlARREN,oHto1toy2~g'7gOgg6$2QUALITYASSURANCE/QUALITYCONTROLPROCEDURENUMBER:S9-...00.1..REVIStON:....A.......Pago..2...ot....6,TITLE:QUALITYASSURANCEREQUXRE~IEilTS-FXELDINSPECTIONOFWZLDSApprovedBy:ApprovedBy:Date:gaia:O.A./O.C.Aooroval:..........DatePreparedByZ~N~~Date:2/157FpnpHp.gnginaaringHangrRapMannfanin.ingHpiltar(gnanllr)-'Qpg14'C."'0QiigI'pl...(CheckOne>D.WarrenPlantQualityControlManager-willhavetheoveralladministrativeandQualityAssuranceRequirementsspeci.gledby.tgis.ppocedu2;e..3.2Xnspection-'eneralA.XTTGrinnellshallperformtheFieldInspectionsand/orRe-inspections.AllihspectionpersonnelperformingFieldInspectionsofFilletWeldsshallbeproperlytrainedandqualifiedin-accordancewithQualityControlProcedureSQ-005,Rey.0,PersonnelQualifications.3.3WeldXnspectionA.WeldstobeinspectedshallbethoseweldswsshownonthelatestrevisionsofthesketchestowhichthePipe~Supportsweremanufactured.Thesketchesshallbepro-videdbyITTGrinnellPHD-Engineering.B.:W'eldsshallbeinspectedtotherequirementsspecifiedinQualityCont'rolProcedureSQ-006,Rev.0;'VisualandDimensionalCriteriaforWelds.AllinspectionsperformedshallbedocumentedonadailybasisontheDailyInspectionWorksheet,Attachment1.D.TheMasterChecklistshallbenotedeachdayshovringwhichhangerassemblieshavebeeninspectedandwhetherornottheweldswereinconformancetospecifi'cations..E..Weldsthathavebeeninspectedshallbeidentifiedinthefollowingmanner:1)Eachhangerassemblyinwhichalltheweldshave'eenfoundtobeinconformancetospecificationsshallbetaggedwithaGreenQualityApprovedTag,Attachment2.2)Eachhanerassemblyinwhichoneormoreweldshavebeenfoundinnon-conformancetospecificationssha.llbetaggedwithaRedRejectTa,Attachment3.Theredtagmayberemovedanddiscardedupondispositionof'thenon-conformanceandthengreentagged,.Attachment2.CWFORMCLC.100)REV.A 0 ~~~ZlGRINHc:LLCORPORATIONPIPEHANGERDIVISIONPROVIDENCE,R.l./VIARREN,OHIONQy2L!'0a6127QUALITYASSURANCE/QUALITYCONTROLPROCEDURENUMBER'syg-QQ1,REVISION:.......A........Pago.Mof.6'ITLE:PreparedBy:M~vlikDate:2157QUALITYASSURANCEREQUIRE~IEi~iTS-FIELDINSPECTIONOF3t'ELDSApprovedBy:ApprovedBy:Date:Dais:EFFECTIVITYDATE2/15/78....SUPERCEDESRsEVa...0oA{FocDate:FOR;PHD.EnginasringUHar.-srRIDa{ann{ac{crispHOilsr{gg,cliy).{1{IK1IEV..COI'tZDL.(ChECV.OnegF.Weldsfoundtobeinnon-conformancetotherequirementsofProcedureSQ-006,Rev.0;shallbedispositionedpertherequirementsspecifiedinSection3.4below.a3c4'on-ConformancesA.Non-conforming'.-!aterialsshallbeidentifiedpertherequirementsof3.3E-2andloggedper3.3D.Thenon-conformanceshallbenotedontheDailyInspec-.tion5'orksheet.Theextentofthenon-conformancesshal'eindicatedintheapplicablesectionsoftheworksheet.C.ThedispositionofNon-conformancesshallbeasfollows:1)TheinspectorshallforwardtoITTGrinnellPTZ)-EngineeringtheoriginalcopyoftheDailyInspectionVorksheetandthesketchforeachnon-conform!:cOnecopy.oftheY'orksheetandsketchshallbere-tainedattheSiteforreference.Theworksheet,shallidentifythenon-conformingweldsandtheextentofthenon-conformanceandthesketchshallshowthe'ypeofsupport,location,etc.(NOTE:Theweldsmaynotbenumberedonthesketch.Itmay,therefore,benecessaryforthe'inspectortonumbertheweldsinordertoprovideatie-inbetweenthev;orksheetandthesketch.Inthatevent,theweldscanbenumberedinanymannertheinspectorwantssolongastheweldscanbetiedbacktoitsapplicableworksheet.2)ITTGrinnellPHD-Engineeringshalldeterminethedispositionofthenon-,conformancesthroughcalcula.-tionsandanalysisbasedonthedatacontainedintheworksheet.Theacceptanceorrejectionofnon-con-formancesshallbepertherequirementsofQualityContxolProcedureSQ-007,Rev.0,AcceptanceCriteriaforfields.3)'HD-Engineering,afterdeterminingthedispositionofthenon-conformances,shallreturnthekforksheettotheinspector.Theivorksheetsha.llhavethedisposi-tiontobetakennotedonthev'orksheet.Thesketch+hallberetainedbyPHD-Engineeringfortheirxecords~CW~FORMQC~IC03REV.h I GRfrii4=LLCORPORATtOilFIFEHAtlGERDivisioNg'II280g612PROVIDENCE,R.i.r(NARREN,OHIOQUALITYASSURANCE/QUALITYCONTROLPROCEDURErgUMBER~QOQ+RenSIOX:...,A.......Page4or.6..TITLE:QUALITYASSURANCEREQUIREMENTS-FIELDINSPECTIONOI'IELDSEFFECTIVITYDATE2(15/78SUPERCEDESREV.ApprovedBy:ApprovedBy:Date:Date:O.A./O.C.Aooroval:.....Date:....PreparedBy:M~~gDate:2~57go(t:pgp.EngineeringHangerR(DE3ManufanluringHorner(gneuur)QtgttlitiCrgntg'..((1Ioht'CkO(tet4)XnadditiontoreturningtheWorksheet,P2D-Engineer-ingshallalsoatthattime,generateaRejectedMaterialReport{RMR),Attachment4,forrejectednon-conformances(ie.,$7eldsrequiringrework).TheRMRshallbecompletelyfilledinanddispositionsnotedandtheORBAuthorizationsignedbytheProjectEngineerorhisrepresentative.'heRMRKo.'sshallbenotedontheworksheet.5)TheRMRshallbedistributedasfollows:a)PHD-Engineeringshallretaintheyellowcopy(SupervisorCharged)fortheirrecordsandfor-wardedtotheinspector,theremainingcopies,~vrhowillinturndistributethosecopies.b)Thervhitecopy(Qu"lityControl)shallbere-tainedbytheinspectoruntilthedispositionhasbeencarriedout.Theinspectorshallverifythatthe.dispositionhasbeensatsfactorilyincompleted(thereworkshallbeinaccordanceYrithBechtelApprovedProcedures),andatthattime,heshallnoteonthecopythatthereworkisO.K.andinitialanddatethecopy.Thecopyshallthe'nbeforwardedtotheWarrenPlantQuality.Control!ianager.c)Thegreencopy(Dept.Supervisor)shallbeforvrardedtotheBechtelRepresentative.Thiscopy,shallbethemeansbywhichthecustomerisnotifiedthata.non-conformanceisunacceptableandrequiresrework..d)Thegoldcopy(ProductionControl)shallbeplacedinProjectSitefiles.e).Thehard-backcopyshallbeaffixedtotheaffectedhangerassemblyandremovedanddis-cardedaftersatisfa.ctorycompletionofthedis-position.3.5=Documentation-MaintenanceandDistribution,A.TheDocumentationrequiredfortheverificationofcom-pliancetothisprocedureshallconsistofthefollowin1)Certifica.teofQualificationforInspectionPersonnel2)ProjectSketches3)DailyInspectionWorksheets4)RejectedMaterialReports5)ITTGrinnellMasterChecklistC(W'ORhfQCe1003REY,A

cc'e~~RIHi4"LLCO990;"rlollPIPEHAFIGERDlglISIOtfPROVIDEa'ICE,R.l./'aVARFIE.'I,OHIO'gg2Q'8Q361~QUAlITYASSURANCE/QUAL)TYCONTROLPROCFOURENUMBER:.SQ.-..QO:3.......REVISION:Page..5....of..6..TITLE:QUALITYASSURANCEREQUIREMENTS-FIELDINSPECTIONOFFIELDSApproved'y:Rale:PreparedBy:.ReMVlit$..0atc:2l57.ApprovedBy:Oatc:EFFECTIVITYDATE...........g......SUPERCEDFSREV.....O..-.-O.A,Io.c.Acorcvat:...........0toFQR:LJpH9gnglearingHan,.rR'9UManuiacrurlngHolher(apecgyy%1vlixizCoflyI'01,tChePkOat>B.Thema'intenanceoftheabovelisteddocumentationshallbeasfollows:')CertificateofQualification-ThisdocumentshallbekeptonfilewiththeVr'arrenPlantQualityControlManagerandbeav"ilableforreview.AcopyoftnedocumentshallalsobekeptonfilebytheYlarrenPlantQualityControlrepresentativeattheProjectSiteandbeavailableforreview.2)ProjectSketchesshallbemaintainedasfollows:b)Sketchesinvolvingweldsinconformancewithspecificationsmaybediscardedaftertheinspec-tionofthosewelds.Sketchesinvolvingweldsthatareinnon-confor-mancetospecificationsshallbekeptonfilevrithPHD-Engineeringandbeavailableforrevew.3)DailyInspection57orksheetsshallbemaintainedasfollows:a)OnecopyofallworksheetsshallbekeptonfileattheProjectSite.b)Acopyoftheworksheetsinvolvingnon-con-formancesshallbekeptonfilebyPHD-Engineer-1ngeP~c)TheoriginalcopiesofallworksheetsshallbekeptonfilebytheWarrenPlantQualityControlManager.r4)RejectedMaterialReportsshallbekeptonfilebythosegroupsreceivingcopiesasoutlinedin3.4C.15)ITTGrinnellMasterChecklist-onecopyshallberetainedbytheinspectiongroupattheProjectSiteandonecopymaintainedbyPHD-Engineering.C.Distributionoftheabovedocumentsduringtheimple-mentationofthisprocedureshallbeinaccordancewiththespecificsectionsofthisprocedurewhichaddrossthosedocuments.Anyotherdistributionofthedocumentsshallbeatthediscretionofthe1'farrenPlantQualityControlManager.O'LV~FORMQCI000REV.A MIz~~!!!PlFLLCO.POR".TtOHPIPEHANGERDIVISIOIIPROVIDENCE,R.I.IV/ARREN,OHIOgy2J'78.'z~6127hROCEDURENUMBER:.K..Og')......REVISION:.......A.........,,egePago...6.......oI.....6..........PreparedBy:.RDGV~DaIe:2157I.ApprovedBy:Date:..QUALITYASSURAzICE/QUALITYCOASTROLPTITLE:QUALITYASSURANCEREQUIREilENTS-PXELDINSPECTIONOFWELDSApprovedBy:Dale:EFFECTlViTYDATE~E~~ESSUPERCEDESREV.O.A./O.C.Aooroval:.............DateFQR:pHD.EngineeringHangerRzg2]ManuranturingIX2orner(znenlfr)-QrzDliggl-.CDDDDou--..(CheekOnegD.UponcompletionoftheFieldInspectionofWelds,theProspectSiteshallforwardalltheirrecordstotheWarrenPlantQualityControlhlanager.ITTGrinnellshallatthattime,inaccordancewithcontractreouirements,notifythecustomerthattheinspectionprogramhasbeencompletedandobtainfromthecustomer,directionsastowhattheywantdonewiththerecords,ie;destroy,store',orsehdtocustomer.CWFORMacIOOiREV.A ~ls'toe~~I~.ITi'lott!(CIA14Wtt'It~0!lIO1%112It!f1'fFZICktMORY"lttX'1'IO.~~llhtGERNRKttOomaHO.SPECIFIEDWCU)SIZlSIZCICllt.DQ'Cl'nt.SIZE1Clll.lfttt)1J!SI%1'.S17Z(ant.SI7$.'~fitl.AClUALFILETWEU)SlZCIHt)ICATEACIUAI.Sl'ZC(S)IFUHM!SIZEAND,'lllClf)tG)ltOF'tllCSI74'(S).OVCR-SlZEMt:U)0)ttt'OtHN!CC'FONL'tQIGINllsslSossmss~os'AKE!TAS-IS81)lO!!K(ltEJ!Lt'ISfVSFFKtt!YANDlATEOFFt!RDISPGSITIOtlteerrWt(F)V.Ittattt-.C.rruZ-1'81P.ll.D.1l4lttCtmtXiUSC,Ifs~gl,si4~~sI~Ifss~INSPKTOR~~~~~0I~~~~4I~~ 'gyp'///QA)fghoY.2i78'56.3.27~rI~~~~)'ii're4'w~M,!4PkeJJla.iiOI'4Cb'NalLj15'547i;;:.::":,'-:;:,::.";,-'lrispeo!or.-'":":;.Date.;""'"':":.'~0 1I/pPfA//4~~~~<m-ooq:-4--'-'='--'--'--:---'Ž':~~4~ytpM~fC' ggfjfcc/rl!FPffSQ-oo4'N2G<<.0~6127.v*RcoausINcssrnNMsCIIICArrorII.LINOIS!QQQQ'QQQ'Q'QQQQTTGri'nnellCorporationi'peHangerDivision.Iarran,OhioC4481RrGIGrfCGlfiititQIrG$3~4I.RClporr+No.02363FigureNoJDescripticnDvrgISketchNo.IntendedforRev.OrderNo.SourceLogNo.lnspectorDateLotSiteSampieSiterTosatNo."'Reject-1NSPECTOR'SREPORTiten3'I-MR8D1SPOSIT1ON~rAcceptasisiSeeconments)Revork,a.c.ENG..RepairScrapOtf!er{SpecifyinCommentsbfock)comments:\~>AMCw&c1028QUAUTYCONTROL~>>>>N~~W>> APPENDIXBQUALITYASSURANCEPROCEDURESQ-005 ~$Gfvffdr'f"-LLCORPQRATior'f'IPEHANGERDl'llSIONPROYIDENci,R.l.l"lARREN,OHlttto]2G'78.0u6127QUALITYASSURANCE/QUALITYCONTROLPROCEDURENUMBER:.5$.-..00.5REvIsIDN:...,,....0....Pago.~ot....~~.......TITLE:PERSONNELQUALIFICATIONSEFFECTIVITYDATE,...1/31/78SUPERCEDESREV.....Z/A,.PreparedByR..PavlAIData:.1/31/.I.ApprovodBye~~J<~'~Dale:7-.lApprovedgy:~~~Onle:O.A.IO.C.Aoorova.:;h.X"~.'ftc:ff~<'ORPHO.gngineerlngHangerRrOManuranrurtng8Orner(gpenlfy)fiUR3,gtfrCOlltlOlCheckOne)1.0OBJECTIVE:'I,,Thisprocedureshalldocumentihetrainingandqualification'equirementsforInspectionPersonnelconductingFieldInspectionsofWelds.2.0APPLICATION:~~ThisprocedureshallapplytoallInspectionPersonnelperformingFieldInspectionsofFilletWeldsonPipeSupportsmanufacturedbyITTGrinnellfortheSusquehannaSteamElectricStation.3.0TRAININGANDOUALIPICATIONREQUIRE~MIENTS:3.1AllInspectionPersonnelshallhavea.VisualExaminationtoassurenaturalor.correctedneardistanceacuitysuchthattheyarecapableofreadingstandardJ-1LettersonStandardJagerTesttypechartsfornearvision.Theexam'nationmustbetakenatleastonceannuallytomaintainqualificationforFieldInspectionofkields.'a3.2AllInspectionPersonnelshallattendatrainingsessionofatleast21/2hours(orcombinationthereof).ThetrainingsessionshallbeconductedbytheBarrenPlantQualityControlDepartment.Thecoursecontentsshallconsistofthefollowing:A.QualityAssuranceRequirements(ProcedureSQ-004,Rev.0).B..InspectionCriteria(ProcedureSQ-006,Rev.0)'C..Inspectionmethods,Techniques..D..Use,HandlingofInspectionGagtsandTools3.3Uponcompletionofthetrainingsession,eachcandidateshallbetestedasfollows:'rA.'lrittentestcoveringtopicslistedabove.B.PracticalTesttodemonstrateproficiencyininspection.Thetestshallconsistofhavingeachcandida.tevisuallyanddimensionallyinspectingselectedweldeditemsandevaluatingthepersonsuseofgagesandtechniques.Alsogeneralquestionsshallbeaskedreardingtheproceduretobefollowedfornon-conformingweldsandthelike.CW~FORMCC~I003REV.A X2GRtt".'fgJ:-LLCOP.PORATfONIJPIPEHANGERDIVISION~~II6g2'7ROVIDENCE,R.i./WARREN,OHIO~2QUALITYASSURANCE/QUALITYCONTROLPROCEDURENUrvtt'ttt:g3.gg,-...au.u...REvistoN:........0.....Pago~or.....3'TITLE:PreparedByB.>a3r~Dato3./r.33.PERSONiIELtntUALlFTCATIONS'eApprovedBy:.ApprovedBy:Date:Date:EFFECTIVITYDATE1J.3.1/.78.SUPERCEDESREV.~<../AO.A./O.c.Aooroval:..'...........Dale:FOR:pHD.gngirreerlng.Hangerg'DHfaanufnluringHDiner(gpanifl)0DR1g1'7CODgroltehec'kOne>3,4TobequalifiedtoFieldXnspect.7,'elds,inadditiontotherequirementsspecifiedin3.1,3.2,and3.3above,eachpersonmustachieveapassinggradeonthetestsspecified..in3.3above.Apassinggradeiscombinedaverageof805forbothtests,ivithascoreofnotlessthan70".oforany'.individualtest.3e5ACertificateofQualificationshallbemadeoutforeachpersonwhosuccessfullyc:ee:s'therequirementsofthisprocedure.(AttachmentI)CVr~FORMCCe1003RFV.*~eue~ehhe~~~"~ 'HI3Y2G'78O.i>6jpy'7'IG,"inl;Cl/l"0:Para;i.C.;621Oanahvenve,N.E..Warren,Ohio-~A"Sf,,Telephone(216]399-7566CERTIFICATEOFQUALIFICATIONThisis,metthetestingSQ-005,qualifytocertifythat*'asaPplicablerequirementsforformaltrainingan'dinaccordanceivithQualityControlProcedureRev.0,PersonnelQualificationsinordertofor:FIELDINSPECTIONOFFILLET3'FIELDSAPPROVEDBY:TITLE:DATE:APPROVEDBY:QChfGR.:DATE:TESTSCORES:written:PRACTICAL:AVERAGE:&ecutive0IIicesIProvidence,RhodeIsland.~~r~or~~ APPENDIXCQUALITYASSURANCEPROCEDURESQ-006 GRINNELLCORPORATIONPIPEHANGEROIVIEIOHE((tnu"IEg6jIO7ROVIDENCE,R.f./WARREN,OHfbQUALITYASSURANCE/QUALITYCONTROLPROCEDURENuMBER:,Stat-.006REVtstoN:..0Page1ofVISUAL'ANDDIMENSIONALCRITERIAFORWELDSEFFECTIVITYDATE.Pl.i/78SUPERCEDESREV.NJ.APreparedBy:MMKVlikDate:2/+2~Z~ApprovedByj~l~~gDalelApprovedBy:~.DateO.A.IO.C.AoorovaC;/.'A~FDGte:..~Z7.~FOR:p.H.O.EngineeringHang.rREOManuianiuring(C(Oiher(Sunnily)tChect(Ones1.0OBJECTIVE:2.0ThisprocedureshalldocumenttheVisualandDimensionalCriteria'applyingtoFieldInspectionof%'elds.APPLICATION:3.0ThisprocedureshallapplytoFieldVisualandDimensionalInspec-tion,ofFilletYieldsonPipeSupportsmanufacturedbyITTGrinnellforSusquehanna.SteamElectricStation.TYPESOFEXAMINATIONS:3e1VisualExamination:VisualExaminationshallconsistofinspectingwelds.usingunaidedeyesight,exceptfortheuseofarticiciallightingandmirrorsforhardtogetweldsandw'ldslocatedinareaswithinsufficientlighting.'.03.2Dimensional.Examination:DimensionalExaminationshallcon-sistofcomparingweldswithsketch.requirementsusingweldfilletgages,scales,andsteeltapesnotrequiringcalibra-tion.LEVELSOFEXAMINATION:5.0-BothVisualandDimensionalinspectionsshallbemadeforthetotallengthofallweldsrequiringinspection.VISUALACCEPTANCECRITERIAOFOLDS:5.1Thefollowingindicationsshallbeconsideredtobeinnon-conformance:ta)Cracks-external'surfaces..b)UndercutonsurfacewhichisgreaterasdeterminedbycomparisonwithITT.Comparator.than1/32inchdeepGxinnell'Cg.3,ibratedc);Lackoffusiononsurface.d),Incompletepenetration(Appliesonlyisreadilyaccessible).wheninsidesurface5.2HeldProfilesshallbeasillustratedinFigurel.GWuFORMCC~teeaREV.IA ~~eOPED"!NFILCORPORATIONPIPEHANGERDIVISIONPRovlDENGE.R.l.rvllIIIREN,CHIDIIOEZIP'7E0J61QUALITYASSURAIICE/QUALITYCONTROLPROCEDURENUte10EA;O'Q.000ljfEVISION:.......0......Pago..2...oI...g.TITLE:.'ISUALANDDIMENSIONALCRITERIAFOR7(ELDSEFFECTIVITYDATE....2..1.7SSUPERCEDFSREV....N..AeeApprovedBy:ApprovedBy:-Date:.DaIc:O.A./O.c.Aoroval:..........Date:preparedBy:R,Pa.vllkDaIc:.../.1/78FDRP.H.D,EnglneerlngHangerREDManulacturingIZZIDiner(EPecllr)~laRlgE.gCDot1:0(CheckOggel6.0DIMENSIONALACCEPTAiCECRITERIAOFFIELDS:6.13'fieldsshallbeinspectedforsizeasillustratedinFigure1.(NOTE:Foranglesgreaterthan120oorlessthn60o,thesizeoftheweldshallbedeterminedbymeasuringto~thelinesoffusionasillustratedinFigure1.6.2Allweldsinwhichanypartofthelengthweldisbelowthesizeindicatedonthesketch,shallbeconsideredinnon-conformancetothesketchrequirements.7.0iION-CO'~xOR.'L<ÃCZS:Non-conformancesshallbedocumentatedanddispositionedpertherequirementsspecified'nProcedureSQ-004,QualityAssuranceRequirements.8.0SURFACECONDITIONS:fieldswillbeinspectedintheascoatedcondition,freefromsurfaceconditionsthatwillinterferewithobtainingmeaningulresults.,IrI~I-~GW~FORh1QC~IN)II'.A~~a~4~e~ ~~t~'>>~~:-"~PIG~cK2.Angle90o~30oAngle0'>20~~.Angle~60oe~XSize4rSizeSizeDesiable="-et)leld.'defiles~~SizeCI~$~I1'4+s~>Acceptablebidet~nelP.r74S~QIProfilesS>SISizeISi"eISizeISizeIsize'Size'Size~.ISizeizeI'SizeS'"eIXnsufficientThx'oat'ize-IRecessiveConvew~gSizeExcessiveUndez;CutISize.'ve"lapISizeXnsufficietttLeg~<<O~I<<~~~~~~~~..Defec":veFilletRelP.P=ofiles~~ f~~~I'I~~gAPPENDIXDSTRESSACCEPTANCECRITERIAFORNELDS

  • TcJl'c-I~~N072G'78QQ6jpyMI-~~PI("',~)IXItS$Q~SUSQ".-:.'.i:J.U:iZvg'1~'>gg31'7eFI"'w'.CIGv'.','.'.'"3'ILlano::aolcload/inchforonesidefilletweld3/1r'-~c-1/R.=-G:::,,",".-..5/16=~.3/6=2,":;.-,":..pURT'r'SIOlHAP"-'~"'"Sllew0~/'i~l8'PC<lL8C.R/<ncaSC/i!'()o~/trlBECHTELCOMMENTa)4~)~c)hfeasureeffectivelengthofthcfilletweld.measuret¹sizeoffilletweldwithtneappropriategage.Seenoh4.~c~gQl4(PLLccfl<c,(eP1+g+bzu~de~iKdwr1~d)4I'~W+~e~V4VaJ~~V\vVIVIV~~,A~l.kipLyLoa.dplhC,Q0u+Ql~QOllo~a4LcCa(c<~+cRl.oa.di-e)Comparecalcu'tdallowaoleloadV'VkVVO~GVvv.SS~J~C<a~at,84CC-"~VC.4?~i.~hQe~uPw6"lodwiththedesign+g+f)~o~'Ifthcallo:Klecalculatedloadisgreatertha!ithodesi'oad,weldisapproved.Iitisless'hanthedesi~load,weldisdisapproved.PUFZCOVZ!iHSSXOI(HUGGERSfSHEN.GRNGG8S...a).Ifl.oldisonl~'/16"under"ized,thewoldi:.'approved.Ifthoundersi"ei"greaterthnI/16'..:repeat.tep"Cthrou!".,hFabove.'I'IForsuT,.;orth'ithbendin"load"onthl;.old,theallo!'=-l1~load".":.icudbc<<aculatedaccordin.,to'ttoclvT't1(SccL:"="..~1cI:f)PMP~PgTTaB=gBaFL.SP<FoRFiute<A<C:6Pv'AIuC.E~Thesupportt~vohouldboa.':perSFHOfig.1::-26-PPPLdC.t.d.'5lh*4vt~CledbCNlt<1$!PG~4PQCSP-OP/3Z8ha(.tbcdeduce.4edpron+kCSl)4Wle<iu.eeLea'el)andd)about',deS!CI~CP4bltC.R~<~C!~a.4eSMkcVmd<~!gw.41L<etCO>dt's!~gm~P6-~SICclt.LQ.I~POS.Si6La.-fCa.C.4t<~!4HiSQOed>WAG~SbCLL;-,'-Qchl~><FQ6CoR9!S>ec~->otJ.

'I ~"'t<'"'tel"":I~~1.~+---.i~~'~~"iv.ll91c1'-'-'-'"~~>>e-,~wt(i'l...c.A/j/(<ig~1-.y~"2if)ala.ol),-'(~"."st\'h.$o1c..'c1z."P.r.>>"(:="~As~~I~~a~'sCJ((aaal4s~J.).a-)a='ijo14wl2b8inch.":o<1/4~rGe,".i.e'>:lf~=1L"W:iPC~~-"5C~g/62x7i'27Zv;,Tova.11L>>Pay272=172+<.="P~i.,1Jeluisa-,.~rove'uketQcIP~t$In~0CrV~~~ Janlta~1I0Agl~grta~tmoma'~MMJ081S4s3.I,3e.::loadedasho:;nbelo~;~elCisare~.'=as'edanQareha~a1/4">geldallar"""'ho'nnl"elddiag,."~Z-ppSlP=70004'i=140000in7;Q<dioIield18:4are1/16Undersized.PromTable4{SeeAttachient2)f=YiSlibut,fforthcro.".sec'.iona'"oveisnotconstant.Uec"nst'lrelatethemo.-.,entcapac'tyofthei;elhitotheapplic"benzoin~m"."..entandifthemomentcapacity'fthc'i;alag)-";:"~isgreaterthantheappliedmo.'ent,thentheveldisacce;.-';:.'le.Therefoe,'ro"tabl<<4E:g{SeeAttachment3).f.(Sn)=V>~~'.'-f1/0=I.f'/n..I3/16=~3";;in//gg{fl/~)).(S~'~l/4)+(f'>~/1Q)(S>;P/16)=I8~o~nAg~

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