ML20202B023

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Rev 8 to CP-QAP-12.1, Insp Criteria & Documentation Requirements Prior to Sys N-5 Certification
ML20202B023
Person / Time
Site: Comanche Peak  
Issue date: 08/03/1983
From:
BROWN & ROOT, INC. (SUBS. OF HALLIBURTON CO.)
To:
Shared Package
ML18052B537 List: ... further results
References
FOIA-85-59 CP-QAP-12.1, NUDOCS 8607100180
Download: ML20202B023 (23)
v • d • e


Text

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SRGisN 1 RCOT, INC.

ISSUE CPSEI NUMBER REVISION CATE PAGE JCB 35-1195 1 of 23 CP-QAP-12.1 8

,AUG 0 31983, 9//zd63 TIT 1.E:

ORIGINATCR: M Y.

OATE/

INSPECTION CRITERIA

/*

REQUIREMENTS PRIOR T'/_ ~I3 AND DOCUMENTATION REVIEWED BY: 'A

/

APPROVED SY:

/1 87 RI CAT ON ute QA Mnager 0ATc j

1.0 REFEREfCES 1-A QI-QAP-2.1-5,." Training and Certification of Mechanical Inspection Personnel" 1-B QI-QAP-11.1-28, " Fabrication, Ins tallation Inspection of ASME Component Supports, Class 1, 2, and 3" 1-C CP-QAP-16.1, " Control of Nonconfoming Items" 1-0 CP-QAP-12.3, "Tes ting 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" 1-G QI-QAP-11.1-39, " Mechanical Equipment Ins tallation Inspection" 1-H CP-QAP-11.1,

" Inspection Criteria and Documentation Requirenents Prior to System N-5 Certification"

.1 2.0 GENERAL

{[

d 2.1 PURPOSE The purpose of this procedure is to establish requirements for a system / subsystem walkdown and verification by the Quality Control (QC) Group prior to:

a.

Release for flushing and preoperational testing b.

Pressure testing c.

Release for penetration sealing ng72 m o eso620 M WTWM M MW GARDE 85-59 PDR 88'3l/

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I' SROWN & ROOT, INC.

ISSUE CPSES NUMBER REVISION DATE PAGE i

JOB 35-1195 l

CP-QAP-12.1 8

AUG 0 31983 2 of 23 l

d.

Verification that piping hangers comply with vendor i

certified drawings (large bore) or design reviewed l

t drawings (small bore),

i e.

Release for preparation on N-S Data Report 2.2 SCOPE y.

Th'e scope of this procedure applies to all ASME Section III I:

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 with Reference 1-A.

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

Design drawing's (i.e. BRP 's, BRHL's, GHH's, VCD's, ORD, etc.)

used to perform sys tem /subsys tem wal kdown per Paragraptr 2.L shall be the current revisions of the drawings'.

QCI shall document the drawing and revision number on the applicable QC checklist.

3.0 PROCEDURE 3.L PRE 0PERATIONAL/ TESTING WALKDOWN The walkdown status of the piping system / subsystem shall be performed using the "QC Preoperational/ Flushing Checklist" (Attachment 1), and BRP drawings.

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

i testing walkdown:

a.

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

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l BROWN & ROOT, INC.

ISSUE CPSES NUMBER REVISION DATE PAGE JOB 35-1195 CP-QAP-12.1 8

UG 0 31983 3 of 23 b.

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

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

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3.2 PRE-PRESSURE TEST WALKDOWN The pre-pressure test walkdown status of the piping system /

subsystem shall be performed using the "QC Pre-pres sure Test Checklist" (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 CMC or a revision to the BRP used during that last walkdown shall have their identification / serial number or material identification recorded on the System Verification Fonn (Attachment 7).

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

3.3 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 Systems 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 material.

d.

Hangers and pennanent attachments required are installed.

e.

Pipe clearance and gradient.

acceptabTe Tor sealing. y Area Management of penetrationsPrior to releasing a pene The OC Groun will notif for sealing, the Penetration Seal Release Form (Attachment 4)

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BROWN & ROOT, INC.

ISSUE CPSES NUMBER REVISION DATE PAGE JOB 35-1195 CP-QAP-12.1 8

AUG 0 31983 4 of 23 shall be completed and submitted to the ANI for his concurrence. Cmpleted Penetration Seal Release Foms shall be fonwarded to Area Management.

3.4 COMPONENT SUPPORT DESIGN VERIFICATION The.QC Leads shall be responsible for perfonning an inspection of all ASME component supports to verify they a.*

in compliance with the vendor certified (Large Bore) or design reviewed (Small Bore) drawings.

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 c.r design reviewed drawing shall be inspected in accordance with the requirements of Reference 1-B.

Actual weld sizes shall be documented on the vendor certified or design review drawing.

3.4.1 Unsatisfactory items shall be documented in accc,rdance with Reference 1-C/1-H.

The physical measurement of structural welds shalI be conducted in accordance with the following guidelines :

a.

On supports, where welds have been mapped on Attachment 13 of Reference 1-B,, remeasurement of the werds is not required unless the weld visually indicates contour modification, or the weld size is changed by a starred

(*) revision to the VCD/DRD; b.

On supports where welds have not been mapped on 3 of Reference 1-B, remeasurement of accessible welds shall be performed due to weld contour modification.

3.4.2 Pipe to support clearances are established by Engineering to provide adequate support for the piping, while permitting expected growth or movement due to the operating environment.

Clearances indicated on a

VCD/DRD are cons truction installation clearances and do not require remeasurement af ter clearances are verified on process control documents, unless; a.

The support. configuration is modified by design change, 9.-.-

SROWN & ROOT, INC.

ISSUE CPSES NUMBER REVISION DATE PAGE J08 35-1195 CP-QAP-12.1 8

AUG 0 31983 s of 23 b.

The support is being reinstalled following removal to accomplish a design change or other constuction, or c.

Directed by Engineering.

d.

Visual examination indicates the sum of the clearances have not changed after verification at time of ins talla tion.

i 3.4.3 Initial load or travel settings are es tablished by Engineering to provide adequate support for the piping, while pennitting expected growth or movement due to the operating environment. Load or travel settings indicated on a VCD/DRD are construction installation clearances and do not require

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remeasurement after settings are verified on process control documents or QA checklists, unless:

a.

The support configuration is modified by design change, or directed by Engineering.

3.5 N-5 WALXDOWN The final status walkdown to verify completion of the system /

sub-systen shall be perfomed using the "QC N-S Checklist" (Attachment 3) and current BRP's, BRHL's, Vendor Certified or Design Reviewed Drawings.

3.6 SYSTB4/ SUBSYSTEM DOCUMENTATION All items defined on the "QC Checklist" as unsatisfactory shall be documented on the "QC Deficiency List" (Attachment

6) and entered ort the Master Data System Description (Attachment 8). QE Completions / Start-up Group /QE Task Force shall verify that all items on the QC Deficiencies List are inputted and shall monitor until system turnover / start-up.

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

When the prerelease walkdown is completed, the QC leads shall return walkdown documentation supplied by Quality Engineering and a copy of the "QC Deficiency List" to the QE Completions / Start-up Group for coordinating resolution of deficient items (Reference 1-D).

The QE Comdtbie QC Systemsletions/ Start-up Group /QE Task Force shall notify the respo leads when the "QC Deficiency i

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BROWN & ROOT, INC.

ISSUE CPSES NUMBER REVISION DATE PAGE JOB 35-1195 e f 23 CP-QAP-12.1 8

AUG 0 31983 I

List" items have been corrected by returning their copy of the deficiency list and supporting documentation to the QC leads.

The corrected items will be reinspected to verify acceptability and a copy of the deficiency list returned to the QE Completions / Start-up Group.

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 pennanent 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, CMC 's, etc. ).

Also the pressure. test shall have been completed and accepted by the ANI and the Owner in accordance with Reference 1-E.

1 4.0 REPORTING DEFICIENCIES /NONCONFORMANCES Deficiencies /Non-Conformances shall be reported and documented in accordance with References 1-C/1-H.

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Slest & ROOT, INC.

CPSEE NUMBER REVISION CATE PAGE a 35-use CP-QAP-u.L a

AUG 0 31983 7 or 23 ATTAQMENT 1 Page 1 of 2 OC PREOPSIATT(MAUPJ5HING CHECXLIST l-Ii Prerelease No.

QC Qtecklist j

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C?SES NUMBER REVISION DATE PAGE i

i oua 75:rIsr-cr-c a -12.2.

8 AUG 0 31983 8 or 23 ATTACB eff 1 (Contianad)

QC PREDPERATENIAL/FLD5EIEG t menmr Pate 2 of 2 0r.30.l IEEPECITW G1TEEIA f QCI/ MTE SAT /UNSAT FAAA.

3.1 1.

ne toeparamure and prammune w t - a as the Code Dess Flame far valves and ag=4m is la cumpli-i amme etah the papias desian require.mmes indicaced es W Drestage.

2.

Telve laenssas and oe4 - =1== is is ammmedamse visit the emmtes deemmmacs.

1 3.

ASE Cmde same Places are area-h-d to "1I". camped pumps aos vammela.

4.

Items ehme ao visible sier of damage.

5.

Poe lagmid ammvice.. cope are rammeusL fram suppere

.pring cams.

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Issue CPSE1 MWEER RE/ISION CATE PAGE aca 35-1195 cp-qAP-12.1 a

AUG 0 31983 9 oe 23 ATTAOSEftf 2 OC ME-ME55URE TEST CHECXLIST pag.

1 _of 3

Presure Test Systes Qc checxlist SRP & Rev.

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SRC1n & RCCT, INC.

ISSUE CPSES MJMBER REVISION CATE PAGE Jos 3s-uss cr-qa -t2.1 a

AUG 0 31983 to or 23 ATT300 eft 2 (Continued)

Page 2 of 3 OC PRE-MtISSURE TEST CHECILIST

' PARA.

OF.NO.

DIEFECTION GITERIA QCI/DATE SAT /tRISAT 3.2 1.

All icans vitais the case w =*y are complace and readily assassible.

2.

Gradtees: 3/16* per feet ammimmen (this applies to hertsencal 11ame dariacias from level only. Devi-asseme from p4mmdumans of varetaal times and best-l

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samaal departure from denies will be camere11ed by the too.ineer talaremme on Lesacian.)

l The stam of all pipe sentmc unido shall be i

3.

chenhed re the rugmiremmace of amferumse 1-F.

4 All itema in the pressure case W are free free ese scribes and base metal defects: when idencified, they shall be hand 1=d la accordance

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witat Enferemco 1-C.

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l 3: Pipiss shall be installed within the followiss colaremsen of itans.6 thru.9--

5.

h -Isissamm siepe ana11 be as designated oo

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the drusines.

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6.

CLeasnese - A mistamma of cue insbes (2") of cisne-emas shall be==d===4==d f=,1=dtag pipe t - 1=r1=

with respost to ocamer piptas chan one or both 11ame haue as operating campermeare of 2008 or grancer.

ALL other llame use he <== =21=d eith a esasame at one.inser (1") clanummme, witte respeec to other pipias.

7.

For clearamme of $1pe (with as operacias tempere-ters of 200* F or grancer) fram hmmsers. valle, ceilias, band rails, etc., other them pipe to pipe, a etniammm of one tack shall be==i=*=f==d tacluding i

ptpe f===1=r1 =. All other lines any be insamt tad with a clearamme omir for inenlacios: however, on a case by case beets, is miske be necasesry to notch tamalacios to escattiah clearances unich will re-caire==T*===-tas approval.

9.

Whms f==rattad La bla* w =, sleeves shall be in-scallad so chec, for 11ame with operacias tempera-I

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tures at or above 200* F, their camcor11aes are with is 1/4 tactr of pipias concerlines. For lines with operacias temperatures of tems chma 200*, the siesee

, inside dt===rer mese be no tese tram 1/2 inch frome l pipe onceide dianacer.

'I 9.

All bolsa ineralled in flanged connections.

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SRC)M & ROOT, INC.

gS3ug GSE3 NUMBER REVISION DATE PAGE

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70s M;1195 u e 23 CP-QAP-C.1 8

AUG 0 31983 i

ATIACMMDff 1 (C mcinued)

QC PRE-PRES 5URE TEST m Ist Fase 3 of 3 QCI/DATE

$AT/UNSAT FAAA.

OF.110.

IEEPECTICIf CRIIERIA 10.

matrim, sacarial shall be verified by haec amber er eelse code. Desummat hans ensber/ color code as Am m

e y, l

@ Auf selves aos T P i====ff=d with d

l M's or rarisisms to the W umme during the lame =th umse home icane 11 thre 16 W i=d wie.

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11.

The temperacare and preneure indienced am the Cada 3oce Place for valves and vi

- is in compli-anse with the piping desism requiremmacs indir=*=d as SEF drumstage.

11.

Talve locacias and ori==raria= is in accordance with the destas doenuments.

l 13.

For ta=11am e==

-rwad loads or wf p===c tie-

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ins, e suppers (perummame or temporary) sham 14 be imanced as eleme as pomethia.

1&.~ For 11sym14 service, scope are remmend fram suppers spring came.

12.

Per scam see or-air seem the scope are ta ae=1 M to support spetas came.

16.

Identify all h== gars and perummac sce=,w= no SEP.

gy, r,p.i p e

,a -4=g is in aa='r**** with E*f 1"G (Qt-Gar =11.139 Parasemphe 3.6.3 and 3.6.3.D i

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snow a noor In tssut CPSEE NtseER REVISICM CATE PAGE i

a as-uss CP-4AP-u.1 s

AUG 0 31983 12 or 23 ATTACN8Eff 3 Fage 1 _of 2

OC b6 CHECK 1.IST Sys to-Check!fs Gneck!fst BRP thsat BRML Unsat Items 1

I*Jun Ror Rev 1

QME11151 Checklist 3RN/GE theat Vander Umsat Items Orewing Itu m Rev i

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ISSUE

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  • MBER REVISION wu t mur.

i JOB 35-1195 ij CP-QAP-12.1 AUG 0 31983 13 e 23 8

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ATTm:sserr 3 (cancimmes)

Peon 2 at 2 o.e.

s -e PaEA.

CF.ms.

M (TTTamTA QCZ/R&TE

$AT/I] NEAT

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3.3 1.

Piedag syeematemheyotem aus a w supposta shee en vtasada maan of damasa.

2.

ALL pommmmmme emmpammme supports are '==1t=d per egnet w damedmas.

3.

Pipses cmediW-complias with SEP's.

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ALI.r e p===* indssment os ERP ias'====1 tad.

g 5.

Egmismee ammhertes emmplies wick Enf.1-C

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(QE-4ar-Lt.1-39. Paragenphe 3.4.3 4 3.4.3.1) 6.

Jam mus(s) on sekhurs mas scrues are cisme set vs.LL mac cura y head. wing want appiime fases.

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7.

sues, belts, aseter pass, lack wir= and my 6 amammessal items are '==e=11=d h repaires (sambhmes, scruss, sprses came, empso-

, sama ammmme,tH elan,aes.)

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- --- W 1: 155 PIFING HAL SEIN W ATTrt. ANT DAMAGE TO PIFIIRC ST5 tdt M'hvE-~~~ '*~

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SEIN IDENTIFIED DUEIEE CT.IadCNESS IN5FECTON PRIDE TO Ut3UIATION.

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AUG 0 31983 14 oe 23 l.

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ATT30900 7 4 Ratsse Fan stan cosm parraArten sats.

PENTRATICE SDL RELD5E FORR Report A

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SL3E. #

Sisca Omg.

7 Released for samling. hy; 5

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SROWI & ROOT, INC.

ISSUE C.oSES NUMBER REVISION DATE PAGE JOB 35-1195 AUG 0 31983 15 oe 23 w -12.1 s

ArfACHMENT 5 ATTAosserf S Pese of

$49eert JrWWieg Wr/teTleLee QUALITT CDNTROL CP-CAP-12.1 Rev.

CIztroperT SUPPot? CEECEL137 PaAA.

CP.NO.

CBSPECT!0er CRITIRIA QCI/DATE SAT /U:ESAT 3.3 1.

Suseert Candtenresise compitas with Temeer certt-ftet er Ometon Aertssme Ovastag (TCD/Dec) 8/A 1.

$trustural ammer cas langsmo camply with Refee-ease dimmmatene 2 2*

5/A

).

Sameplage toleramaan (estludtag thi h al comp 17 with the TCD/ DES ! %".

  1. 4 1/4 6

hking potat diammetano Lasating stTusretal com=

pometa campi? wtsa the VC3/DRO.1" (emseet for pipe lesactee talarantee) 3.3.1 5.

a) All assenethis welda reisepeated and are ta complianse vita TC3/DRD.

b) All ehmuss walds hose been reameposted and are La esmoLianas esta the TCD/ DAD.

3.3.3 6.

h--f e) serial summer al sets. belte. settee ptse. Lasa wtre, ecs. ta=

stallas where regetred.

t) Ensamme threment unrfases are free of emesse.

Lee emot er terator masertal.

a) Somertaal beurtmas are free of foreign sneer-141 ame sommartel are tascalled ao reentres.

3/A f.

Stmats) (if applicaele)

Serial nummer a) has. telsa, carter pias. Leet wire, etc. ta=

stalled wnere reestree.

g) r-tarenda6 surf aseo are free of esseme-Lve rust er foreign umserial.

c) Spherical beertage arer f ree of forelin essertal di Jam nat(s) and berres will est turn to hand.

estas nominal asplies fertow 3.3.3 8.

$pring Cam (e) (if applicaele)

SertaL nummer a) has, belts. cetter stae. Each wire, etc. ta=

stalled waere reemires.

b) Esseese enreases eerf acee are free of emesse-Lee ruas er foreign escorial.

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SROWN & ROOT, INC.

ISSUE C?SES NUMBER RE'/ISION CATE PAGE JOB 3S-1195 AUG 0 31983 16 or 23 CP-QAP-12.1 8

ATIAcaterr 5 (cont'd.)

aracmar s Page of 5eseert 3reastes. w r#Bevtates ocaun crw-tz.1 a.

c:Neenist sw,conmx.

m cuen.rst ocunaft uric m r naa. or.m.

tunerton cuma euse eum 4r er ut=am.= ss."em s- = co -

cam.,=. s.o.-a. am.m.re a sia

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Cameroes tamarts hase proper _

/aetasemmet (ZD + 1/8").

AT!Acu 10.

taeraI1metsa of U-eelts se large bere/ sus 11 tore 5A seoverts small be Laepested as fellowes L) 0-tetts used ta ptssed caementise appbtee (i.e.

sersts and someters) are to be tascalled our the pipe se samme La ficare L for *.arie bare sueeerte.

2) U-eelte se rigid fremme, (larse bere) small be tassa11ad as sas== ta rimsre 1.

31 U-teiss en omall bero sue,orte san 11 be tassa11ad as semes ta risere i er as e,estites se the homeme drwtas.

6) Clamramsso se spesifiat se TCDiOW 3.3.1 11.

claeronese auss be vertfias Lf:

an The summere cafignsmeisse Le umsif Lee W doetga 44 b) T! e seppert is betas retascalles follawt.t 14 esval to accomplism a destes chaasa er othe constresstses c) Stresset be tagtseertas.

4) Tisaal F==1=~i-Ladicarne the suo of the clearensee home est 'av after verificatise at time et lastal t aatm.

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SR0tst & ROOT INC.

ISSUE PAGE CPSES M ER REVISION CATE

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8 AUG 0 31983 u or u ArfACEMENT SA e

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ISSUE C?SE3 NUMBER REVISION DATE PAGE l-

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= 25-uss-8 LUG 0 31983 18 oe 23

[

cr-g a -12.1 ATTACHMENT SB l'

TABLE 5 BOLI DIAMETER MINIMCM EMBEDHENT Kwik-Bolts Super Kwik-Bolts 1/4 1-1/8 3/8 1-5/8 1/2 2-1/4 3-1/4 i-l' 5/8 2-3/4 3/4 3-U4

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1 4-1/2 6-1/ 2 1-U4 5-U2 8-US NOTE: "Embedment Length" is the length of the bolt i

extending below the surface of the structural concrete prior to setting (tightening).

During tightening the nut, the change in bolt projection. shall not exceed one nut height

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unless otherwise approved by the engineer.

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SRoim & ROOT, INC.

ISSUE'

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CPSES NUMBER REVISION CATE p; uG 0 31983 7g3 g3 19 or 23 c?-qu-12.1 a

A19'Arwar SC LENGTH IDENTIFICATION SYSTEM STAMP ON UiNGTH OF ANCHOR (INCHES)

ANCHOR FitCM UP TC BUT NOT INCLUDING A

1-1/2 2

i a

2 24/2 C

M/2 3

D 3

34/2 E

34/2 4

F 4

44/2 G

44/2 5

i+

5 ST/2 1

'51/2 6

J M/2 K

M/2 7

L 7

74/2 M

7-T/2 8

N 8

84/2 0

84/2 9

P 9

94/2 Q

94/2 10 R

10 IT S

IT 12 T

12 13 U.

13 14 V

T4 15 W

15 16 X

16 17 Y

17 18 Z

18 19

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SRCm & R00T,INC.

t$syg C35ES NUMBER REVISION CATE PAGE Jca as-tiss Cr-qAP-u.1 8

AUG 0 31983 20 or 23 9

ATTACHMENT SD

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ace SIZE NUMsER 11/8 = 01AISTER i

3g3) 3 MAI. RfC. t GAD /t_15.

WM SIZE 300 SIZ1 STA18348D 65 M.

1508F.

I.88.

FIS N

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T888AD LIMME 03 3/8 1-1/2 610 540 0.J76 f

06 U2 2.U1 LD0 1010 0.668 05 5/8 2 U1 1810 1610 1.04 06 3/4 3

2710 2420 1.50 f

07 7/8 3-U2 3770 3360 2.04 08 1

4 4960 4420 2.67 09 1-US 4-U1 6230 5560 3.38 10 1-U4 5

8000 7140 4.17 12 1-U2 6

11630 10370 6.01 14 1-3/4 7

13690 14000 8.18

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