ML20202B046

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Rev 9 to CP-QAP-12.1, Insp Criteria & Documentation Requirements Prior to Sys N-5 Classification
ML20202B046
Person / Time
Site: Comanche Peak  Luminant icon.png
Issue date: 08/19/1983
From:
BROWN & ROOT, INC. (SUBS. OF HALLIBURTON CO.)
To:
Shared Package
ML18052B537 List: ... further results
References
FOIA-85-59 CP-QAP-12.1, NUDOCS 8607100185
Download: ML20202B046 (23)
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Text

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3RCWN 1 200T, DlC. ISSUE NI.:MBER REVISION CATE PAGE C?SE3

- '~i JOS 35-1195 I of 23 CP-QAP-12.1 9 g jgjgg3 TITLE: CRIGINATOR: EMMm /' / 74w83 INSPECTION CRITERIA / ..

AND DOCUMENTATION REVIEWED SY: /4a~ m /2/2b9 .f3 REQUIREMENTS PRIOR

+ . ' cATE -

R CAT ON APPROVED BY: 6 / 7  ?

site QA Manager DATE o

1.0 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" 1-C CP-QAP-16.1, " Control of Nonconforming Items" L-0 CP-QAP-12.3, " Testing 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 Fabricat' i on and Installation Inspections" 1-G QI-QAP-11.1-39, " Mechanical Equipment Installation Inspection" 1-H CP-QAP-11.1, " Fabrication and Installation Inspection of Components, Component Supports, and Piping" 2.0 GENERAL 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 c0lA-85-5g FOR F03MCON 0T"_Y 8607100185 860630 PDR FOIA , /

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,l BROWN & ROOT, INC. ISSUE CPSES NUMBER REVISION DATE PAGE JOB 35-1195 9 2 of 23 CP-QAP-12.1 AUG 19 Igg 3 l

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d. Verification that piping hangers comply with vendor certified drawings (large bore) or design reviewed drawings (small bore).
e. Release for preparation on N-S Data Report 2.2 SCOPE The scope of this procedure appli_es to all ASME Section III piping and components being inspected for release.

i-2.3 RESPONSIBILITY The QC Group Supervisor shall be responsible for the overall implemntation of this procedure.  ;

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

The Quality Engineering (QE) Comple'. ions / Start-up Group Supervisor shall be responsible for surplying Quality Control with all the documentation required to perfom 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 perfom system / subsystem walkdown per Paragraph 2.1. shall be the current revisions of the drawings'. QCI shall document the drawing and revi sion number on the applicable QC checklist.

3.0 PROCEDURE 3.1 . 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 Fom (Attachment 7) during preoperational/

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.

l' BROWN & ROOT, INC. ISSUE CPSES NUMBER REVISION DATE PAGE j JOB 35-1195 9 3 of 23 CP-QAP-12.1 AUG 191983

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

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

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

1 subsystem shall be performed using the "QC Pre-pressure 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 tneir identification / serial number or material identification i recorded on the System Verification Form (Attachment 7).

I 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 Supervi sor 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 permanent attachments required are installed.
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 Fonn (Attachment 4)

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BROWN & ROOT, INC. ISSUE CPSES NUMBER REVISION DATE PAGE OB 35-1195 4 of 23 CP-QAP-12.1 9 AUG 191983 shall be completed and submitted to the ANI for his concurrance. Completed Penetration Seal Release Foms shall bo forwarded to Area Management.

3.4 COMPONENT SUPPORT DESIGN VERIFICATION The QC Leads shall be responsible for perfoming 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.

Inspections of component supports shall be perfomed 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. Actual weld sizes shall be documented on the vendor certified or design review drawing.

3.4.1 Unsatisfactory items shall be documented in accordance with Reference 1-C/1-H.

The physical measurement of structural welds shall 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 welds is not required unless the weld vi sually 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 Attachment 13 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, Mile pemitting expected growth or movement due to the operating environment.

Clearances indicated on a VCD/DRD are construction

, installation clearances and do not require remeasurement after clearances are verified on process control documents, unless;

a. The support configuration is modified by design change,

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l SROWN & ROOT, INC. ISSUE CPSES NUMBER REVISION DATE PAGE JOB 35-1195 CP-QAP-12.1 9 AUG 191983 5 of 23 r

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 installation.

3.4.3 Initial load or travel settings are establi shed by Engineering to provide adequate support for the piping, while permitting 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 remeasurement after settings are verified on process control documents or QA checklists, unless:

a. The support configuration is modified by design change, ,

i or directed by Engineering -  :

3.5 N-5 WALKDOWN ,

The final status walkdown to verify completion of the system /

sub-system shall be performed using the "QC N-5 Checklist" l (Attachment 3) and current BRP's, BRHL's, Vendor Certified ~

or Design Reviewed Drawings.

3.6 SYSTEM / SUBSYSTEM DOCUMENTATION All items defined on the "QC Checklist" as unsatisfactory

! shall be documented on the "QC Deficiency List" (Attachment

6) and entered on 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 systen 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 Quali ty l Engineering and a copy of the "QC Deficiency List" to the QE Completions / Start-up Group for coordinating resolution

of deficient items (Reference 1-0).

i The QE Completions / Start-up Group /QE Task Force shall notify the responsible QC Systems leads when the "QC Deficiency

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BROWN & ROOT, INC. ISSUE -

CPSES NUMBER REVISION DATE PAGE ,

OB 35-1195 s of 23 CP-QAP-12.1 9 AUG 191983 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 permanent piping, valves, pumps and hangers are complete and intact and have been installed in accordance with 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.

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

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SiOM & ROOT, INC. ISSUE .

NimBER REVISION DATE PAGE CPSES JOB 35-1195 CP-QAP-12.1 9 AUG 191983 7 or 23 ATTAOMENT l Page 1 of 2 OC PREOPGATIONAUFl.USHING CHECXLIST Prerelease No.

QC Checklist SRP & Rev. Umat Itans l

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SR0lel & ROOT, INC. '1SSUE CPSES NUMBER REVISION DATE PAGE

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CP-QAP-12.1 9 AUG 191983 8 oe 23 4TTACIBEElfT L (Concinued) ..

QC PREOFERATI0ttAL/FLUSRIl0G ("mffTT TST P.aSe 2 of 2 PARA. OP.30. INSPECTION MITERIA 73/DATE SAT /UNSAT j

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3.1 1. The temperature and pressure indicated as the Code Deca Plate for valves and W. t ia in compli- l

_ - - , ance with the piping design requiremmnets indicated j on ERP Drostags. >

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2. Talve locacias and oriastation is in accordance with the design decommes. _

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3. AEIE Code Name Places are attached to "5 stamped l p g and va===1=. l I
4. Itame shoe no visible sign of damage.

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3. bor iftsid service, scope are femmved from support . i spring cans. .  !

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6. For steam, gae or air service, the stops are in- l s'allad in support spring cans. -
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ATTACM4ENT 2 CC PRE-PRESSURE TEST CHECXLIST 7 3.,; , , og 3

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Pressure Tes- Sys'E QC Qeca:s I 3RP i Rev. CMC Unsa: Itz::

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SROWN & ROOT, INC. ISSUE CPSES NUMBER REVISION CATE PAGE JOB 35-1195 to a 23 CP-QAP-12.1 9 AUG 191983 . . _ . _ _ _ _ -

ATTAQ9ENT 2 (Continued) Page 2 of 3 QC PRE-PRESSURE TEST CHECII,IST PARA. OF.NO. DIEFECTION CRITERIA QCI/DATE SAT /QISAT

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

2. Credient: 3/16" per foot maaimma (this applies to  !

horizontal lines deviacing from level only. Devi- ""

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ations from pt=h==== of vertical lines and hoot- .

sental departure from design will be controlled  !

-- - by the two-iach tolerance ce location.) _.

3. The size of all pipe nochec welds shall be I

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rh=*had to the requir====e= of Reference' 1-F. -

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. . . ... 6. All it m s the preneure test boemdary are free _ , _ , _ - . . . _ . - . -

from are strikes and base metal defects when .

identified, they shal.1 be ti==dled La accordance ,

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. . . . . . . .._ NOTT Pipias shall be installed within the , _ , ._

following tolerances of iteme.6 thru,9.

5. Stooe - IMai- slope shall be as designated on - -- - --"~ I t

the drarings. }

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6. Cigarence - A statenes of two inches (2") of clear-ance small be maisemia-d. ineld ing pipe imaalatica ..

- - - - - - with respect to other piping when one or both lines -

have en operacing comparature of 2008 or greater.

All other lines any be installed with a sialmen of , , , , _ . , _ _ _

one-inch (L") cimerence., witts respeec to othee pipias.

7. For clearance of pipe (with an operating tempera-ture of 200* F or greater) froi hengers, walls, , , , , _ _ _ , _,

ceilias, head rails, etc.. other then pipe to pipe,

, a. aimisema of one inch shall be esistained. Incle' ins

. - - pipe f a-1arion. All other lines any be installed --- -

with a etmar - only for insulatica; hoeuver, on a.

case by case besia, it sishc be necessary to notch ~ ~ ~ ~ '

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insulation to establish clearances which will re-quire sosineering approval.

8. When inse=11=d in blockouts, sleeves shall be in-stalled se that. for lines with operating tempera- I

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tures ac or above 200* F. their center 11aea are with" in 1/4 inch of piping casterlines. For lines with

. operating cueyeratures of less then 200*. the sleeve . . ..... . .

l Inside diameter enee be no less than 1/2 inch from

pipe outside diameter. _ . . . .

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9. All bolts installed in flanged connections.

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SR0ldM & ROOT, INC. ISSUE CPSES .1 UMBER REVISION CATE PAGE

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Joa 3!i 1195 CP-QAP-12.1 9 AUG 19 $83 ueu AITACitMENT 2 (Continued)

OC PRE-PRESSLTE TEST CHECKLIST Page 3 of 3 QCI/DATE SAT /UNSAT PARA. OP.10. DESPECTI0tt CRITERIA

10. Belting material shall be verified by heat nimmber or color code. Docummat hast nisaber/celor code on Attactummac 7.

NOTE: Amy valves and - 4 installed with OIC's or rev4mia== to the 3RF used during the last =th most have items 12 thru le e==pI1ad with.

11. The temperature and pressure indicated oe the code Data Place for valves and equipumac ir. Un compli-ance with the piping design requirements indicated om BRP drawings.
12. Valve location and oriancation is in accordance with the design docummacs.
13. For in-line concancreted loads or equipment tie-ins, a support (pecumment or camporary) should be located as close as possible.
14. - For liquid service. scope are removed frump support ,

syrias came.

13. For stamm. gas or air service, the scope are in-ar=1 fad is support spring. cans. l c attactments on l
16. Identify all hangers and p .

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17. Equipment au:.horing is in compliance with Ref.1-C j (q1-qAF-11.1-39. Paragraphs 3.4.3 and 3.4.3.1)  ;

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SR0idN & ROOT, INC. ISSUE CPSES NUMBER REVISION DATE PAGE

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CP-QAP-12.1 9 AUG 191983 u or n ATTACWENT 2 (Continued)

QC PRE-PRESSLTE TEST CHECKLIST Page 3 of 3 QCI/DATE SAT /UNSAT

! PARA. OP.No. DISFECTION CRITERIA

10. Solting material shall be verified by heat msmber or color code. Dec e ant heat number / color code on Attachment 7. ,

c NIFTE: Amy velves and equipment installed with OIC's or revisions to the BEF used during the last =1h anst have itamm 12 thru 16 complied with.

11. The temperature and pressure indicated on the Code Data Place for velves and equipment in in compli-ance with the pipias design requirements indicated on SRP drawings.
12. Valve location and orientation is in accordance with the design docummata.
13. For in-line concentrated loads or equipment tie-tas, a support (perummmat or temporary) should be located as close as possible. __
14. - For liquid service, scope are removed from support -

spring came.

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13. For steen, gas or air service, the scope are in- l scattad in support spring cana. j
16. Identify all hangers and permament attachments on SAF. '

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17. Equipment
  • ring is in compliance with Ref.1-C {

(QI-QAF-11.1-39. Paragrcphs 3.4.3 and 3.4.3.1)  ;

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310 m & 100T,.INC. Issue i CP5ES MlJMBER REVISION QATE PAGE l l

JOB 35-1195 CP-QAP-12.1 9 AUG 191983 12 or 23 i

I ATTAQMOIT 3 Page 1 of 2

! OC b6 CHECXLIST i

i System checkItst checkItst SRP Unsat BRHL Unsat

& Itas & Itas Rev Rev i l

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Checklist Checktist I SRH/GHH Unsat Vendor Unsat

! & Ita s Orewing Items Rev i

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SR0im & ROOT, INC. ISSUE u'3c NUMBER REVISION uaiE muc J08 35-1195 i

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CP-QAP-12.1 9 AUG 19 G83 u e 23 1

ATTAOSENT 3 (Continued) Page 2 of 2 0.C. M-5 tirerTT TW FAEA. OF.NO. DIEFECTION CRITERIA QCI/DATE SAT /U11 SAT 3.3 1. Piping systan/subsyntam and c e t supports show me visible sian of damage. _

2. All perumment P C supports are installed

- -- - per final design drastags.

3. Piping configuration complies with 3RF's. _

4 All Equipment indicated on BEF is installed.

5. Equi m e anchorias complias with taf. 1-C .

(QI-QAF-L1.1-39. Paragraphe 3.4.3 6 3.4.3.1) , ._ __ -.

6. Jan aut(s) on sembbers and struts are tishe

. - . - . ... and will noe turn by hand, using nominal "'- ~' ~

applied force.

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7. Nats, bolts, cotter pins, lock wire and any removable - k fral itses are installed where

- required (esmbbers, struts, spring cans, expen- '- ~ ~ ~ ~

sine ==ehar. U-beits, etc.)

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. 's7TE 1: WHEN FIPDC RAS SEIN 35UtaTED, ANT DAMAGE TO PIPDC ST5TDI tJOUCD' RAVE""~ ~~ ~' *-~ ~~~~~

SEEN IDENTIFIED DURDG CLEANI.IltESS INSFECTION PRIOR TO DSUtaTION.

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IS31JE CPTES *mBER REVISION CATE PAGE .

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J08 35-1195 CP-QAP-12.1 9 14 of 23 i

I,UG 191983 I

ATTAom e T 4 .

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RELEASE FOR HIGH 00tSITY POETRATION SEAL 1 . .... . _ . . -

POIETRATION.SD L RELEASE FORR l

Report 7

- Date- Roaus t BLDE. #

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Released for sea 11rul by:

QC l Amr Exceptiars - Holds I

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