ML20202A946

Rev 5 to CP-QAP-12.1, Insp Criteria & Documentation Requirements Prior to Sys N-5 Certification

ML20202A946
Person / Time
Site:	Comanche Peak
Issue date:	03/18/1983
From:	BROWN & ROOT, INC. (SUBS. OF HALLIBURTON CO.)
To:
Shared Package
ML18052B537	List: IR 05000445/1979026 IR 05000445/1980015 ML20199M024 ML20199M047 ML20199M072 ML20199M087 ML20199M099 ML20202A685 ML20202A693 ML20202A708 ML20202A712 ML20202A726 ML20202A765 ML20202A776 ML20202A785 ML20202A801 ML20202A812 ML20202A832 ML20202A837 ML20202A854 ML20202A860 ML20202A873 ML20202A877 ML20202A896 ML20202A902 ML20202A927 ML20202A934 ML20202A946 ML20202A953 ML20202A967 ML20202A973 ML20202A980 ML20202A988 ML20202A997 ML20202B002 ML20202B023 ML20202B029 ML20202B042 ML20202B046 ML20202B051 ML20202B062 ML20202B070 ML20202B076 ML20202B087 ML20202B095 ML20202B105 ML20202B111 ML20202B116 ML20202B129 ML20202B133 ... further results
References
FOIA-85-59 CP-QAP-12.1, NUDOCS 8607100161
Download: ML20202A946 (17)

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3RCWt i R007~, INC.

Nw3ER REVISICN CATE PAGE CPSES  ;

JCS 35-1*35 1 of 17 CP-QAP-12.1 5 Mp.R [ , ;.1' T

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TITt,g: ORIGINATCR:

N )A i -'N M INSPECTION CRITERIA M -

// 4 AND DOCUMENTATION RE7IE:4ED' BY: [ b ' / c m- 3-6-fi REQUIREMENTS PRIOR CATE TO SYSTEM N-5 CERTIFICATION APPROVED BY: - 7MN site'QA Manat Wr EAT E' l.0 REFERENCES 1-A QI-QAP-2.1-5, " Training and Certification of Mechanical Inspection Personnel" 1-B QI-QAP-11.1-28, " Fabrication , Installation Inspection of ASME Component Supports, Class 1, 2, and 3" l-C CP-QAP-16.1, " Control of Nonconforming Items" 1-0 CP-QAP-12.3, "Tes ti ng Phase Quality Assurance Functions Prior to ASME Code Certification and Stamping" 1-E CP-QAP-12.2, " Inspection Procedure and Acceptance Criteria for ASME Pressure Testing" 1-F QI-QAP-11.1-26, "ASME Pipe Fabrication and Installation Ins pections" 2.0 GENERAL 2.1 PURPOSE The purpose of this procedure is to establish requirements for a system / subsystem walkdown ang serification by the Quality Control (QC) Group prio.r to:

a. Release for flushing and preoperational testing

b. Pressure testing

c. o #%

Release for preparation on N-5 Data.=Rep!

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d. Release for penetration sealing r") *

e. Verification that piping hangers comply with vendor certified drawings (large bore) cr design reviewed drawings (small bore).

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BROWN & ROOT, INC. ISSUE CPSES NUMBER REVISION DATE PAGE CP-QAP-12.1 5 ypp, ! ; 2 of 17 2.2 SCOPE The scope of this procedure applies. to all ASME Section III piping and components being inspected for release.

2.3 RESPONSIBILITY The QC Group Supervisor shall be responsible for the overall implementation of this procedure.

All inspection personnel perfonning inspections required by this procedure shall be trained, qualified and certified in accordance wi th Reference 1-A.

The Quality Engineering (QE) Completions / Start-up Group Supervisor shall be responsible for supplying Quality Control with all the documentation required to perform piping systen status walkdowns and component support design verifications.

3.0 PROCEDURE 3.1 PREOPERATIONAL/ TESTING WALKDOWN The walkdown status of' the piping system / subsystem snall be perfonned using the "QC Preoperational/ Flushing Checklist" -

! ( Attachment 1), and BRP drawings.

l The following infonnation shall be recorded on the System Verification Fonn (Attachment 7) during preoperational/

testing walkdown:

. .a. Manufacturers' identification / serial nu:nber of all ASME stamped items (i.e. piping subassemblies, valves, pumps and vessels), within the boundries of the BRP.

b. Material identification (i.e., Heat numbers, heat code, material specification) for material suoplied by B&R, if available.

General hanger locations and hanger number for permanent hangers and attachments to piping shall be recorded on the B RP .

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BROWN & ROOT, INC. ISSUE l  !-

CPSES NUMBER REVISION DATE PAGE ,

l JOB 35-1195 3 of 17 CP-QAP-12.1 5 MAR i? G i

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j 3.2 PRE-PRESSURE TEST WALXDOWN l

The pre-pressure test walkdown status of the piping system /  ;

subsystem shall be perfonned using the "QC Pre-pressure i Test Checkli.st" (Attachment 2), current BRP drawing, previous BRP drawings and any CMC's that have not been incorporated into the latest drawings. .

Valves, pumps, vessels, piping subassemblies and/or Brown & .

Root supplied material that has been installed by a GiC or ,

a revision to the BRP used during that last walkdown shall identification / serial number or material 4

have their identification recorded on the System Verification Form I*

(Attachment 7).

All additional component supports shall be recorded on the BRP (reference paragraph 3.1).

3.3 N-5 WALXDOWN The , final status walkdown to verify completion of the piping

! system shall be performed using the "QC N-5 Checklist" (Attachment 3) and current BRP's , BRHL's , Vendor Certified or Design Reviewed Drawings.

The QCI shall record all component support numbers and _

general location on the respective BRP's.

3.4 RELEASE FOR PENETRATION SEALING The Area Management Penetrations Seals Supervisor shall notify QC Systems Superintendent of piping penetrations they want released for sealing.

The QC Systens Lead shall verify the penetration meets the.

following acceptance requirements:

a. All welds inside penetrations are completed , pressure tested and acceptable.

b. No base material defects.

c. Free of foreign ;naterial .

BROWN & ROOT, INC. ISSUE CPSES NUMBER REVISION DATE PAGE J08 35-1195 4 of 17 CP-QAP-12.1 5 ER 1 r -

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d. Hangers and permanent attachments required are ins talled.

e. Pipe clearance and gradient.

The QC Group will notify Area Management of penetrations acceptable for sealing. Prior to releasing a penetration for sealing, the Penetration Seal Release Form (Attachment 4) l shall be completed and submi tted to the ANI for his concurrence. Completed Penetration Seal Release Forms shall be forwarded to Area Management.

3.5 COMPONENT SUPPORT DESIGN VERIFICATION The QC Systens Leads shall be responsible for performing an inspection of all ASME component supports to verify they are in compliance with the vendor certified (Large Bore) or design reviewed (Small Bore) drawings.

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! Inspections of component supports shall be performed using the "QC Component Support Checklist" (Attachment 5).

Any welds on component supports that are not required by the vendor certified or design reviewed drawing shall be inspected in accordance with the requirements of Reference .

1-B but actual weld sizes do not have to be documented. -

3.6 SYSTEM / SUBSYSTEM DOCUMENTATION All items defined on the "QC Checklist" as unsatisfactory shall be documented on the "QC Punchlist" (Attachment 6).

Base material defects and arc strikes shall be identified and resolved per Reference 1-C, in addition to being r3 corded on the "QC Punchlist".

When the prerelease walkdown is completed, the QC leads shall t eturn walkdown documentation supplied by Quality Ea jinee-ing and a copy of the "QC Punchlis t" to the QE Completions / Start-up Group for coordinating resolution of punchlist itens (Reference 1-D).

I The QE Completions / Start-up Group shall notify the 4

{ responsible QC Systens leads when the "QC Punchlist" items

' have been corrected by returning their copy of the Punchlist

! and supporting documentation to the QC leads. The corrected

! itens will be reinspected to verify acceptability and a copy

! of the punchlist returned to the QE Completions / Start-up Group.

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! SROWN 1 ROOT, INC. I ISSUE CPSES NUMBER REVISION l OATE PAGE

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.'0B 35-1195 5 hjAR 13 'd d I 5 of 17 CP-QAP-12.1 l

Any unsatisfactory items that require an Engineering evaluation or rework will be identified on NCR's in accordance with Reference 1-C.

A system or portion of a system shall not be considered completed until Quality Assurance has verified through the above mentioned QC walkdown and QE Systems documentation review that all permanent piping, valves, pumps and hangers are complete and intact and have been installed in accordance wi th current design documentation (i.e., BRP drawings, BRHL's , BRH's , GHH's , CNC 's , etc. ) . Also the pressure test shall have been completed and accepted by the ANI and the Owner in accordance with Reference 1-E.

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BROWN & ROOT, INC. ISSUE CPSES NUMBER REVISION DATE PAGE JOB 35-1195 5 f,M R l ' ' 6 of 17 CP-QAP-12.1 i

ATTACHMENT 1 OC PREOPERATIONAL/ FLUSHING CHECKLIST Prerelease flo.

QC Checklist BRP & Rev. Unsat Items 1

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SROWN & ROOT, INC. I ISSUE !

CPSES NUMBER ,REVISIONf DATE j PAGE l 7 of 17 CP-QAP-12.1 5 fMAR'"

I ATTACHMENT 1 (Continued)

QC PRERELEASE CHECKLIST h ITEMS INSPECTION CRITERIA QCI/0 ATE SAT /UNSAT

1. The temperature and pressure indicated .

1 on the Code Data Plate for valves and .

equipment is in compliance with the I piping design requirements indicated on BRP drawings.

2. Valve location and orientation is in aCCordance with the design documents.

3. ASME Code Name Plates are attached to "N" stamped pumps and vessels.

4. Items show no visible sign of datnage.

5. For liquid service, stops are removed i

from support spring cans. l

! 6. For steam, gas or air service the stops are installed in support spring cans.

j CCNMENTS:

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SROWN & ROOT, !NC. ISSUE CPSES NUMBER REVISION DATE PAGE JCB 35-1195 CP-QAP-12.1 5 bQ-

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i ATTACHMENT 2 OC PRE-PRESSURE TEST CHECKLIST Pressure Test System QC Checklist BRP & Rev. CMC Unsat Item l

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BROWN & ROOT INC. ISSUE CPSES NUMBER REVISION DATE PAGE JOB 35-1195 9 of 17 CP-QAP-12.1 5 [1,;p 1 ]

ATTACHMENT 2 (Continued)

ITEMS INSPECTION CRITERIA QCI/DATE SAT /UNSAT

1. All items within the test boundary are complete and readily accessible.

2. Gradient (Unit 1 and common buildings only):

3/16" per foo.t maximum (this applies to horizontal' lines deviating from level only) . Deviations from plumbness of vertical lines and horizontal departure from design will be controlled by the two-inch tolerance on location.

3. Gradient (Unit 2 building): 1/16" per foot maximum (vertical and horizontal).

4. The size of all pipe socket welds shall be checked to the requirements of Reference 1-F.

5. All items in the pressure test boundary -

are free from arc strikes and base metal defects, when identified, they shall be handled in accordance with Reference 1-C. ,

NOTE: Piping shall be installed within the following tolerances of items 6 thru 9.

6. Slope - Minimum slope shall be as designated on the drawings.

7. Clearance - A minimum of two inches of clearance shall be maintained, including pipe insulation with respect to other piping when one or both lines have an cperating temperature of 200*F or greater. l t All other lines may be installed with a '

minimum of one-inch clearance, with j respect to other piping.

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BROWN & ROOT, I1C.  ! ISSUE i CPSES NUMBER REVISION l DATE PAGE JOB 35-1195 5 'Mg . . ', 10 of 17 CP-QAP-12.1 ATTACHMENT 2 (Continued)

ITEMS INSPECTION CRITERIA OCI/DATE SA7/UNSAT

8. For clearance of pipe (with an operating temperature of 200*F or greater) from

hangers, walls, ceiling, hand rails , etc. ,

other than pipe to pipe, a minimum of one inch shall be maintained, including pipe insula tion. All other lines may be installed with a clearance only for insulation; however, on a case by case basis it might be necessary to notch insulation to establish clearance i

which will require engineering

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approval.

9. When installed in blockouts, sleeves shall be installed so that, for lines with operating temperatures at or above 200*F, their centerlines are within 1/4 inch of piping centerlines. For lines with operating temperatures of -

I less than 200*F, the sleeve inside diameter must be no less than 1/2 inch from pipe outside diameter.

10. All bolts installed in flanged connections .

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11. Bolting material shall be verified by heat numoer ci color code. Occument

' i heat number / color code on Attachment 7.

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. NOTE: Any valves and equipnent installed with CMC's ce revisions to the BRP used during tne last walkdown must have items 12 thru 16 complied with.

12. The tunperature and pressure indicated i on the Code Data Plate for valves and ,

} equipment is in compliance with the i piping design reouirements indicated j on BRP drawings, f

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i SROWN & ROOT, INC. ISSUE CPSES NUMBER REVISION DATE PAGE JOB 35-1195 5 lkyo, i g gg3 11 of 17 l CP-QAP-12.1

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ATTACHMENT 2 (Continued) j ITEMS INSPECTION CRITERIA QCI/DATE SAT /UNSAT

13. Valve location and orientation is in accordance with the design documents.

. 14. For in-line concentrated loads or equipment tie-ins, a support (pennanent i or temporary) should be located as l-close as possible.

15. For liquid service, stops are removed from support spring cans.

16. For steam, gas or air service the stops are installed in support spring cans.

17. Identify all hangers and permanent attachments on BRP.

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3ROWN & ROOT, INC. ISSUE CPSES NUMBER REVISION DATE PAGE JOB 35-1195 5 MAR 1 ' '993 12 of 17 CP-QAP-12.1 ATTACHMENT 3 OC N-5 CHECKLIST System Checklist Checklis t BRP Unsat BRHL Unsat

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l Checklist Checklis t BRH/GHH Unsat Vendor Unsat

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BROWN & ROOT, INC. ISSUE CPSES NUMBER REVISION DATE PAGE JOB 35-1195 CP-QAP-12.1 5 MAR I C 13 f 17 I

ATTACHMENT 3 (Continued)

ITEMS INSPECTION CRITERIA QCI/DATE SAT /UNSAT

1. Piping system / subsystem and component supports show no visible sign of damage. l i

2. All punchlist items have been corrected.

j 3. All permanent component supports

are installed per final design

drawings.

4. Piping configuration complies

! wi th BRP 's .

5. All Equipment indicated on BRP is installed.

COMMENTS: ,

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' I I l SROWN & ROOT, INC. ISSUE .

PAGE 1 I CPSES  ! NUMBER REVISION l OATE i I JOB 35-119S  !CP-QAP-12.1 5 MAR 1 13dj 14 of 17

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ATTACHMENT 4 RELEASE FOR HIGH DENSITY PENETRATION SEALS PENETRATION SEAL RELEASE FORM Report #

Date Room # BLDG. #

Bisco Dwg.

Released for sealing by:

QC ANI Exceptions - Holds l l

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BROWN & ROOT, INC. ISSUE CPSES NUMBER REVISION DATE PAGE JOB 35-1195 5 M,GR13',-- 15 of 17 CP-QAP-12.1 ATTACHMENT 5 QUALITY CONTROL COMPONENT SUPPORT CHECKLIST HANGER NUMBER ITEMS INSPECTION CRITERIA QCI/0 ATE SAT /UNSAT

1. Support configuration complies with vendor (Large Bore) or Design

• certified Reviewed drawing Drawing (Small Bore).

2. Al1 parts are ins talled (1.e. , bolts, nuts ,

"U" clamps, etc.)

3. All accessable welds reinspected and are in compliance with Vendor Certified or Design Reviewed Drawings.'

4. All s kewed welds have been. reinspected and are in compliance with the Vendor Certified or Design Reviewed Drawings.

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5. Support completed.  ! -

6. Comments:

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1 BROWN & ROOT, INC.

CPSES NUMBER RE'/ISION O pAGE JC8 35-1195 5 fi,3R [ 9. ' '

16 of 17 CP-QAP-12.1 ATTACHMENT 6 i4-N12.1 TElrr ec. PN2 w 0.C. m2cust ISO /Pfr.t m l

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3ROWN & ROOT, INC. ISSUE l CPSES NUMBER REVISION DATE PAGE JOB 35-1195 CP-QAP-12.1 5 hiARi.3^] 17 of 17 I

,l ATTACHMENT 7 SYSTEM VERIFICATION FORM DRAWING REV.

AT PC.# WELO# HT.# S/N#

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