ML20202J199

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Rev 2 to Quality Instruction QI-060, Documentation Review of Mechanical Equipment Installation
ML20202J199
Person / Time
Site: Comanche Peak  Luminant icon.png
Issue date: 06/17/1986
From: Patterson A, Zill R
EVALUATION RESEARCH CORP.
To:
Shared Package
ML20202J051 List: ... further results
References
QI-060, QI-60, NUDOCS 8607170040
Download: ML20202J199 (16)
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EVALUATION RESEARCH CORPORATION COMANCHE PEAK RESPONSE TEAM QUALITY INSTRUCTION FOR ISSUE-SPECIFIC ACTION PLAN ISAP VII.c 0To -NN INSTRUCTION NO: QI-060 b[

REVISION NO: 2 ISSUE DATE: 06/17/86 DOCUMENTATION REVIEW OF MECHANICAL EQUIPMENT INSTALLATION Prepared by: /' W dx.s Date: /'s /fM Approved by: /5 M' M- Date: [" O D/ II Issue Coordinator '-

Approved by: , Date: h /[ ~ bd On-Site QA p resentative Approved by: ) b Date: 6 /6 17 6

/

Q4/QC Review Team Le Ser /

8607170040 860711 PDR ADOCK 05000455 A PDR _,

1 QI-060

. R:v. 2 l

1.0 PURPOSE  !

This precedure provides direction and accept / reject criteria for .i the documentation review of mechanical equipment installations.

2.0 APPLICABILITY This procedure applies to the documentation review of samples selected from the Mechanical Equipment Installation population in Unit 1, common, and Unit 2. The population is defined in the population description for Mechanical Equipment Installation.

3.0 REFERENCES

3.1 Memorandum QA/QC-RT-1127, Description Memorandum for Reinspection of Mechanical Equipment Installation, dated December 11, 1985, John Schauf to A. A. Patterson.

3.2 CPP-009, " Performance of Reinspections and Documentation Reviews".

3.3 QI-059, " Reinspection of Mechanical Equipment Installation".

4.0 GENERAL 4.1 Responsibility QA/QC Inspectors perform documentation reviews in accordance with established project procedures and instructions. This instruction establishes the attributes and accept / reject criteria for documentation reviews of mechanical equipment installation. Reference 3.2 addresses the method used to perform documentation reviews and to document and process the

! results.

4.2 Policy

,, Activities performed under this procedure shall conform to the l policies contained in the latest Comanche Peak Response Team l Program Plan and Issue-Specific Action Plan VII.c.

I 5.0 PROCEDURE Most mechanical equipment installation attributes will be verified by physical reinspection. Accordingly, many of the following

, documentation reviews will only be required wt en the associated attributes are inaccessible or not recreatable for a particular l

! sample. Since the required documentation review is likely to vary l from sample to sample, the QA/QC engineer will tailor the checklist i

i 1

! 2

QI-060

. R v. 2 5.0 PROCEDURE (Cont'd) iO (Attachment 6.1) in each documentation review package by marking individual attributes "N/A" if they were satisfactorily verified by reinspection. The number before each of the following attributes corresponds to the checklist number.

1. Inspector Certification (Equipment Installation)

NOTE: If this attribute is applicable, the QA/QC engineer will prepare a supplemental instruction describing those attributes that were non-recreatable during reinspection. The QA/QC inspector will locate the latest construction operation traveler (C0T),

Maintenance Action Request (MAR) or similar document (s) covering those non-recreatable attributes. If none of the above documents are available for one or more of the attributes listed on the supplemental instruction, the QA/QC inspector will attempt to loute a

" Preliminary Installation and Erection Checklist" (Attachment 6.2); this form will usually be found in the Receiving Inspection Report (RIR) package for the equipment. The QA/QC inspector will then verify, a1 described below, the certification of the QC inspector (s) who signed the applicable step (s) on the related document (s).

Verify, by referring to the records in the individual's certification file, that the QC inspector who signed each applicable step on the COT or other work document covering each attribute specified in the supplemental instruction was certified to perform that inspection at the time the inspection took place. Attachment 6.3 provides quidelines for the inspections that may be performed by the various types and levels of mechanical inspectors.

I

If this attribute is rejected, record the applicable document j number, step number from the document, and QC inspector's name on the DR. If a Preliminary Installation and Erection I

Checklist was used, record that fact and the file number of

. the checklist on the DR. Determine if the person that signed as QC inspector was ever certified to perform the inspection.

If so, record the time period of certification; otherwise I

state that the person was never certified.

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. i QI-060

, Rsv. 2 5.0 PROCEDURE (Cont'd)

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'- ' 2. Alignment

a. Alignment Adequacy Review the latest Rotating Equipment Alignment Record (Attachment 6.4 or similar TUGC0 operations document) for the equipment to verify that the equipment was aligned within the tolerances specified or approved by the manufacturer or, if no tolerances were specified by the manufacturer, verify that both parallel (rim-to-rim) and angular (face-to-face) alignment were within .003 inch.
b. Inspector Certification Verify that the QC inspector that signed the Rotating Equipment Alignment Record was certified to perform this inspection at the time the inspection was performed.

~

If this attribute is rejected, record the name of the person that signed as QC Inspector on the DR and determine if that person was ever certified to perform rotating equipment alignment inspections. If so, O record the time period of certification; otherwise state on the DR that the person was never certified.

3. Coupling Cap Review the latest Rotating Equipment Alignment Record for the fine alignment of the equipment, and/or the associated work document to verify that the coupling gap specified or approved by the equipment manufacturer was established within the specified tolerance or, if no tolerance was specified by the manufacturer, verify that the required coupling gap was established within .020 inch.
4. Seismic Restraints Review the document covering installation of the seismic restruint(s) to verify that the cold (and/or hot, if specified) position and clearances of the installed restraint (s) were within the tolerances specified by the manufacturer.

NOTE: QA/QC Inspector shall obtain associated Torquing and Spacing Eilti's (Attachment 6.5) and Hilti Bolt Surveillance (Attachment 6.6) Inspection Reports. These reports form the basis for documentation review of attributes 5 through q 11. If any items on the Inspection Reports obtained by the 4

QI-060 l Rsv. 2

-~

5.0 PROCEDURE (Cont'd) 1

4. Seismic Restraints (Cont'd)

I QA/QC Inspector are marked "UNSAT", the Inspector should look for a later repart with all items marked " SAT". If a later report cannot be found, the QA/QC engineer should be

requested to provide additional information. Inspector shall ensure conformance with these instructions by completing checklist (Attachment 6.1) provided. The applicable Inspection Report number shall be indicated in the " Remarks" column.
5. Hilti Inspector Certification Verify that the QC Inspector listed on the Inspection Report
has been properly certified to perform Hilti inspections in accordance with QI-QP-11.2-1 at the time the inspections were performed.

If this attribute is rejected, record the inspection report i

number and the name of the QC Inspector on the DR and determine if that person was ever certified to perform Hilti

, inspections. If so, record the time period of certification; otherwise state on the DR that the person was never certified.

/~'\ 6. Hilti Bolt Torque k_,

4 Verify that:

] a. The calibration due date of the torque wrench is subsequent to the date the installation was performed.

b. The recorded torque setting value meets or exceeds the

, minimum torque requirements, as per Attachment 6.7.

/

I

7. Hilti Bolt Spacing i

Note: This attribute is a surveillance activity which is documented on separate Inspection Reports. If a

, surveillance Inspection Report cannot be found for the particular Hilti installation being reviewed mark the

( attribute Not Applicable (N/A). If this attribute is i completed record the I.R. number in the remarks column i

of the checklist (Attachment 6.1).

Verify that, if witnessed, and if the inspector noted that i abandoned holes were drilled, which are covered by the plate.

l that inspector noted that appropriate spacing was maintained j between the installed Hilti's and the abandoned holes, and l that if located at a distance of four bolt diameters and I

closer, that the inspector witnessed that the holes were filled and patched according to Procedure 35-1145-CCP-12 li (Grouted).

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QI-060

., R v. 2 5.0 PROCEDURE (Cont'd)

N.J

8. Hilti Rework Varify that, if rework of the bolts occurred, inspector noted:

a) correctness of thread fit requirements and b) restamping of bolt to new length designation was observed. If no rework has occurred, the inspector shall "N/A" the attribute and state "NO REWORK" in the " Remarks" column.

9. Hilti Hole Drilling Note: This attribute is a surveillance activity which is documented on separate Inspection Reports. If a surveillance Inspection Report cannot be found for the particular Hilti installation being reviewed mark the attribute Not Applicable (N/A). If this attribute is completed record the I.R. number in the remarks co}umn of the checklist (Attachment 6.1).

Verify that, if witnessed, inspector noted that no rebar cutting took place during drilling of holes withott appropriate DCA permitting such cutting, and that there was no unacceptably spalled concrete under the baseplate of the installed equipment.

10. Hilti Setting Note: This attribute is a surveillance activity which is documented on separate Insp2ction Reports. If a surveillance Inspection Report cannot be found for the particular Hilti installation being reviewed mark the attribute Not Applicable (N/A). If this attribute is completed record the I.R. number in the remarks column of the checklist (Attachment 6.1).

Verify that, if witnessed, the inspector noted that the bolt setting was appropriately performed including further redrilling of holes if Hilti's failed to set 1,roperly the first time. Redrilling requires a minimum of 4 1/2 anchor bolt diameters for Hilti T.wik Bolts or 6 1/2 anchor bolt diameters for Hilti Super l'.wik Bolts greater than the previous existing embedment depth for same size bolts or an increase in bolt size to the next larger diameter size. (Note - QA/QC Inspector shall ensure that bolt length is consistent with revised length requirements if redrilling occurred.)

O 6

s QI-060 Rev. 2 6.0 ATTACHMENTS

\ 6.1 Conanche Peak Response Team Documentation Review Checklist -

Mechanical Equipment Installation 6.2 Preliminary Installation and Erection Checklist 6.3 Inspector Certification Guidelines 6.4 Rotating Equipment Alignment Record.

6.5 Hilti Torquing and Spacing Inspection Report 6.6 Hilti Bolt Surveillance Inspection Report 6.7 Hilti Bolt Torque Requirements

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Attachment 6.1 COMANCHE PEAK RESPONSE TEAM QI-060 CHECKLIST Rev. 2 (h> POPULATION DESC Mechanical Equipment Installation VERIFICATION PKG NO.

R-M-MEIN- PAGE l 0F 2 QUALITY INSTRUCTION QI-060 REINSPECTION UNIT 1 EQUIPMENT MARK / TAG NO. DOCUMENTATION REVIEW UNIT 2 C COMMON VERIFICATION ACCEPT REMARKS REJECT DATE

1. Inspector Certification (Equipment Installation)
2. Alignment a) Alignment Adequacy b) Inspector

[ Certificaeion

3. Coupling Gap
4. Seismic Restraints
5. Hilti Inspector Certification
6. Hilti Bolt Torque a) Calibration b) Setting Value l
7. Hilti Bolt Spacing i

PREPARED BY: APPROVED BY:

DISCIPLINE ENGR. DATE LEAD DISCIPLINE ENGR. DATE INSPEG1 w BY: APPROVED BY:

LNSPECTOR DATE LEAD INSPECTOR DATE CPP-007.LA. Revision 0

  • AtticTtasnt 6.1 COMANCHE PEAK RESPONSE TEAM QI-060 CHECKLIST Rev. 2 POPL1ATION DESC VERIFICATION PKG NO.

Q Mechanical Equipment R-M-MEIN- PAGE 2 0F 2 Installation - --

VERIFICATION

^ REMARKS ACCEPT REJECT DATE

8. Hilti Rework a) Thread Fit b) Restamping
9. Hilti Hole Drilling
10. Hilti Setting O

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1 CPP-007.IB. Revision 0 l

Attachmant 6.2 QI-060 Rev. 2 Page 1 of 1

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Attachmsnt 6.3 QI-060 Rev. 2 Page 1 of 2 INSPECTOR CERTIFICATION GUIDELINES MECHANICAL INSPECTION PERSONNEL

  • LEVEL I MECHANICAL EQUIPMENT INSPECTOR Level I Mechanical Equipment Inspectors are authorized to perform the following inspection functions:
1. Verify torque for mechanical joint make-up.
2. Verify torque for mechanical equipment installation, assembly or disassembly and equipment placement.
3. Witness valve disassembly and reassembly.
4. Verify dimensional installation of wedgelock-type embeds -

torque testing, etc.

5. Witness Plant Tag changes.
6. Conduct surveillance checks of procedural compliance on equipment maintenance, storage area requirements, housekeeping practices, and general handling operations.
7. Report nonconforming conditions.
8. Verify rigging and handling of equipment.
9. Verify material identification and traceability.
10. Verify cleanliness control.
  • LEVEL II MECHANICAL EQUIPMENT INSPECTOR The certified Level 11 Mechanical Inspector is authorized to O perform all Level I Mechanical Inspection Activities in addition to:
1. Evaluation of Level I inspection and test results.
2. Evaluation and reporting of deficiencies and/or nonconformances.
3. Verify fine alignment / installation of equipment.
4. Verification for field procurement activities.
5. Evaluation and verification for field design changes.
6. Witnessing and verification of hydrostatic and pneumatic testing.
7. Conducting "as-built" line verifications.
8. Vendor document review.
9. Evaluation and acceptance of proposed repair / rework documents.
10. Verification of category "A" and "B" lifting or handling operations.
11. Verify installation and torquing of drilled-in "Hilti" bolts.

O

AttachmInt 6.3 QI-060 Rev. 2 I

( ,j INSPECTOR CERTIFICATION GUIDELINES MECHANICAL INSPECTION PERSONNEL (Cont'd)

  • LEVEL I FABRICATOR INSPECTOR The Certified Level 1 Mechanical / Fabricator Inspector is authorized to perform the following inspection functions:
1. Dimensional verification of equipment.
2. Dimensional verification of supports.
3. Report deficiencies and nonconforming conditions.
4. Witness hydrostatic / pneumatic testing (H/PT).
5. Verify and witness bolting flange joint and screwed connections.
6. Verify thread engagement for bolts and studs.
7. Verify welder operation to procedure requirements.
  • LEVEL II FABRICATOR INSPECTOR The Certified Level II Fabricator Inspector shall be capable and authorized to perform all Level I activities listed above in addition to:
1. Evaluation of physical damage.
2. Evaluation of Level I inspection and test results (counter-signature of Level I verification is neither required

\ nor implied).

3. Evaluation and reporting of nonconformance or deficiencies.
4. Verify hydrostatic / pneumatic test.
5. Verify the installation, location, orientation, alignment and identification of pipe spools, valves and supports.
  • For non-ASME related structures and components, Inspector need only be

( certified per QI-QP-2.1 procedure's and instructions.

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Attachment 6.4 QI-060 Rev. 2 0 Page 1 of 1 EDTATINE EQU!PpWff AL!Geeff MCORD rtNE EDECK NOT CHECK Oag.g Re.,fr.W sy Date M_et,,pff.

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HII.TI BOLT SUR'.'!ILLMICI v -

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. Attach =snt 6.7 QI-060 Rev. 2 Page 1 of 1

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HILTI BOLT TORQUE REQUIREMENTS Minimum Embedment Minimum Bolt Diameter Kwik-Bolts Super Kwik-Bolts Torque (Ft/Lbs) 1/4 1 1/8 --

8 3/8 1 5/8 --

17 1/2 2 1/4 3 1/4 70 5/8 2 3/4 --

120 3/4 3 1/4 150 1 4 1/2 6 1/2 230 1 1/4 5 1/2 8 1/8 400 rN O

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