ML20211J747

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Rev 6 to Instruction QI-QAP-2.1-5, Training & Certification of Mechanical Insp Personnel
ML20211J747
Person / Time
Site: Comanche Peak  Luminant icon.png
Issue date: 06/11/1984
From: Morris G
BROWN & ROOT, INC. (SUBS. OF HALLIBURTON CO.)
To:
Shared Package
ML20211J491 List: ... further results
References
FOIA-85-59 QI-QAP-2.1-5, NUDOCS 8606260482
Download: ML20211J747 (31)
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Issue CPSES NW8ER REVISION DATE PAGE Jos 35-1195 QI-QAP-2.1-5 6

JUN 111984 1 or 31 TITLE:

ORIGINATOR: 32. b',

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p OA"E 6[//["V AT N REVIEWED BY:

0F MECHANICAL DATE R

APPROVED BY:

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Y Site QA Manager V

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1.0 REFERENCES

1-A Anerican National Standards Institute Standard ANSI N45.2.6 -

1978,

" Qualifications of Inspection, Examination, and Testing Personnel for Nuclear Power Plants" 1-B American Society of Mechanical Engineers ASE Boiler and Pressure Vessel Code - Section III Division 1 i

LO GENERAL

'2.1 '

PURPOSE AND SCOPE This instruction specifies the personnel

training, qualification and certification requirements implemented at CPSES to meet the intent of Reference 1-A and 1-B.

The requirements of this instruction are applicable to personnel who perfonn receipt, fabrication, installation, testing, or verification inspections of Safety Class 1, 2 and 3 systems with the exception of personnel who perfor.n nondestructive m

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examination who shall be certified in accordance with QI-QAP-2.1-1.

2.2 DEFINITIONS tv o~

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2.2.1 Activities

$1 Inspections or verifications which establish the

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cceptability of a

single characteristic in item

$@g fabrication, installation or documentation.

2.2.2 Certification Documented testimony by the Site Mechanical Level III to

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the acceptability of an individual's qualifications to perfonn inspection activities.

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ISSUE CPSES NUMBER REVISION DATE PAGE k

J08 35-1195 QI-QAP-2.1-5 6

JUN 111984 2 of n i

2.2.3 Inspection

, An act of measuring, witnessing, verifying, or conducting surveillance of an activity or itan to assure it. is accomplished in accordance with or complies with the prescribed specifications and procedures.

Inspection requires the documentation of acceptability /unacceptability.

Inspections are perfonned using standard vi sual-or measurement techniques.

2.2.4 Mechanical Ecuipment Inspection (MIME)

Mechanical equipment inspection encompasses inspection of maintenance and

storage, installation and alignment, handling and rigging, and other related special processes.

2.2.5 Mechanical Fabrication Inspection (MIFI)

Fabrication inspection encompasses inspection of pipe and hanger fabrication, welding process control, post weld heat treatment, pressure testing and other related special processes.

2.2.6 Qualification The education, skill, training, or experience, or any combination thereof, which provide an individual with the l

capability of properly perfonning an inspect. ion function.

2.2.7 Quality Records Recorded infonnation which indicates the extent of confornance of products, structural configurations, or specified process to drawing and specification requirements.

This infonnation may be based on physical inspection,

process control data, or physical or chemical tests.

2.2.8 Receiving Inspection (MERI) 4 Receiving inspection enconpasses the physical inspection of i

items received on the project to assure the absence of shipping (P.O.) damage and verifying compliance with the-Purchase order requirements.

Additionally, receiving inspection assures that docunentation accompanying items received on the project is technically acceptable and provides objective evidence of item quality.

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ISSUE CPSES NUMBER REVISION DATE PAGE

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JUN 111984 3 d 31 2.2.9 Verification Inspection The campiling, verification, statusing and Quality Assurance (QA) review of field initiated piping, equipment,. pipe support and N-5 quality records to assure all design and drawing requirements are met, prior to submitting for QA and/or Authorized Nuclear Inspector (ANI) acceptance.

2.3 PLANNING The Quality Engineering Group (QEG) Supervisor and Quality Control Group (QCG)

Supervisor are responsible for anticipating inspection personnel manning requirenents based on the schedule of project activities.

Preplanning manning requiranents shall be accomplished in a manner which shall provide for the assignment of qualified and certified -

personnel to accomplish the inspections of Safety Class 1, 2 and 3 activities established by approved QA procedures or instructions.

3.0 INSTRUCTION 3.1 INSPECTION PERSONNEL CAPABILITY Personnel perfonning inspection functions at CPSES shall be certified by the Site Mechanical Level III as having the qualifications necessary to achieve one of the following levels of capability:

a.

Level I Quantity Control Inspector (QCI)

A Level I QCI shall be capable of performing the inspections that are. required to be perfonned in accordance with documented procedures and instructions, as described in Attachment 1.

The individual shall be familiar with the tools and equipment to be employed and shall have demonstrated proficiency in their use.

2 The individual shall also be capable of detennining that i

the calibration status of inspection and measuring and I

testing equipment (M&TE) is current, that the M&TE is l.j in proper condition for use, and that the inspection procedures or instructions are approved.

I NOTE:

A Level I QCI shall work under the

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supervision of a Level II while performing 3

examinations and/or inspections.

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ISSUE CPSES NUMBER REVISION DATE PAGE k

JOB 35-1195 QI-QAP-2.1-5 6

1UN 111984 4 or n b.

Level II Quantity Control Inspector (QCI)

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A Level II QCI shall have all of the capabilities of a

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Level I QCI for the required inspections. Addi tionally.

a Level II QCI shall have demonstrated capabilities in planning inspections, in setting up' inspections including preparation and set-up of related equipment, as appropriate, in supervising or maintaining surveillance over the inspections, in supervising lower level personnel, in reporting inspection, examination, and testing results, and in e. valuating the validity and-acceptability of inspection results as detailed in.

l 3.2 QUALIFICATIONS FOR INSPECTION PERSONNEL

'3.2.1 Education and Experience Requirements t'

The following is the recommended personnel education and experience for each level. These education and experience reconmendations should also recognize that other factors may provide assurance that a rson can carrpetently.

rf Personnel to be certified by the S chanical Level III to perform inspection functions satisfy one of the following education and experie e requirements for the applicable level of capability:

a.

Level I 1)

High school graduation or GED and six ainths of related experience in equivalent inspection activities; or 2)

Completion of college work leading to an Associate l

Degree in a related discipline plus three months of related experience in equivalent inspection activities.

i b.

Level II

(

1)

One year of satisfactory performance as Level I in

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the corresponding inspection category; or

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ISSUE CPSES NUMBER REVISION DATE PAGE k

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JUN 111984 sen l

2)

High school graduation or GED plus three years of related experience in equivalent inspection activities; or 3)

Completion af college level work leading. to an Associate egree in a related discipline plus one year related experience in equivalent inspection activities; or 4)

Four-year college graduation plus six months of related experience in equivalent inspection actitities.

When one of the above education and experience requirenents, for the applicable level of capability, are not fully satisfied, the Site Mechanical Level III must specifically -

document the factors which served as the basis for qualification and certification.

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Work expcrience obtained ther loyment may be used to partially or the experience qualification requirements riate documents (e.g., previous certifications of capability in equivalent inspection activities) are presented to the Site Mechanical Level III for evaluation and acceptance.

l 3.2.2 Training l

All personnel to be certified by the Site Mechanical Level III to perfonn inspection functions shall be indectrinated in the applicable procedures and instructions through required reading assignments which are developed and documented in accordance with CP-QAP-2.1.

Additionally, documented training in the applicable inspection category shall be required for all personnel seeking certification of qualifications.

Attachments 2 through 6

present the typical training outlines for inspecton categories within the scope of this instruction.

1 The total training hours indicated on the above attachments represent the minimum training time to be obtainal by personnel.

The minimum training hours indicated on Attachments 2 through 6 can be reduced by the Site Mechanical Level III in cases where the individual has

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sufficient experience related to a particular method.

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ISSUE CPSES NUMBER REVISION DATE PAGE 08 35-1195 QI-QAP-2.1-5 6

JUN 111984 6 or si Training conducted at CPSES shall be fonnal classroom training or Site Mechanical Level III directed "On-the-Job Training" (0JT).

Formal classroom training presented on the inspection activities outlined in Attachments 2 through 6 shall be conducted and docunented in accordance wi th CP-QAP-2.1.

OJT shall be under the direction of the Site Mechanical Level III, and shall encompass those topics.

outlined in the applicable attachment. Documentation. of OJT shall be by memo fran the assigned inspector to the Site Mechanical Level III, and shall address the scope and extent of the topics covered and the total training time (hours /.

months) involved.

Training obtained through other employers or institutions may be used to partially or - fully satisfy the minimum training times established on Attachments 2 through 6,

providing appropriate documents are presented to the Site Mechanical Level

~III for evaluation and acceptance.

Documents which provide objective evidence of training in

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the applicable inspection category include course completion certificates (with total hours), previous certification (s) indicating training hours, docurants t'# previous employers listing training hours, transcript,,, r other pertinent documents proving satisfactory completion of courses by universities, colleges, Department of Defense technical schools and vocational trade schools.

All examinations shall be approved and controlled by the Site Mechanical Level III and administered by him or his designee.

Examinations shall be prepared and administered in three (3) part::, as defined below:

a.

Part 1, General Examination: (Written, Closed Book) 2 The genaral examination shall cover the applicable j

inspection principles.

t b.

Part 2, Specific Examination (Written, Open Book)

The specific examination covers the equipment, i

inspection methods and techniques that the individual may encounter in his specific assignment.

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JUN 111980 7 of 31 Additionally, the specific examination shall cover the applicable acceptance criteria contained in the project inspection procedures or instructions.

c.

Part 3 Practical Examination The individual being considered for certification shall demonstrate to the satisfaction of the Site Mechanical Level III or his designee, that he is familiar with and can operate the necessary instruments and can analyze the resultant infonnation to the degree required 4n the applicable procedure or instruction.

A full description of the activity or specimen, perfonned per the applicable inspection procedure or instruction, with the results of the inspection documented.

on the answer sheet, The minimum number of questions in each examination c

.s shall be as follows:

j a.

General 20 b.

Specific 15 c.

Practical -

20 l

A minima composite score of 80 percent shall be required for certification.

In addition, individual grades for the general, specific and practical ' examinations shall be 70 percent or greater.

A percentile weight factor shall be applied to the raw scores of the various examinations (i.e., general, specific and practical). These factors are as follows:

General 0.3 Specific 0.3 Practical 0.4 The camposite grade is detennined as follows:

General raw score X

percentile factor weighted grade

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Specific raw score X percentile factor weighted grade

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Practical raw score X percentile factor weighted grade

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ISSUE CPSES NUMBER REVISION DATE PAGE

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JUN 111984 8 of n Verification and Receiving Inspector certification require only a general and specific examination with a weight factor of 0.5 for each.

Re-examinations administered to the same individual for the same activity or certification shall be prepared and N

3.2.4 Eye Examination All personnel certified to perfonn inspections in accordance witi this instruction shall satisfy the eye examination requirement specified in QI-QAP-2.1-1.

3.3 CERTIFICATION OF QUALIFICATIONS All personnel perfonning inspection of Safety Class 1, 2 and 3 activities shall be certified to Level I or. Level II i

capability by the Site Mechanical Level III.

Certifications shall be documented in accordance with CP-QAP-2.1.

The QA Training (QAT) Coordinator shall maintain the certification files for all personnel currently perfonning Safety Class 1, 2 and 3 inspection functions.

Certification files for personnel who have terminated employment at CPSES for a period in excess of six ~ months, or upon completion of the project, all certification files will be transmitted to the Owner in accordance with CP-QP-18.1.

l 3.3.1 Oualifications/ Certifications Issued 1

I The following certifications shall be issued by the Site Mechanical Level III upon completion of the listed qualification requirements:

I a.

Level II Verification Inspector Personnel certified to Level II capability in this g

inspection category shall have satisfied the following qualification requirements:

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Possess the verified ed nd experience specified in paragraph and complete l

supplementary training n

e applicable category as defined in paragraph 3.2.2; 2)

Complete the required reading specified for procedure and instruction indoctrination in accordance with paragraph 3.2.2; 3)

Complete the proficiency examination requirements specifind in paragraph 3.2.3; and 4)

Complete the physical examination requirements specified in Paragraph 3.2.4.

b.

Level I Receiving, Mechanical Equipment or Mechanical Fabrication Inspector.

r Personnel certified to Level I capability in these i..

inspection, categories shall have satisfied the i.

following qualification requirments:

1)

Possess the education and experience i

specified in paragr'aph 3.2.la and complete I

supplementary training in the applicable inspection category as defined in paragraph 3.2.2; 2)

Complete the required reading spwified for procedure and instruction indoctrination in accordance with paragraph 3.2.2; 3)

Camplete the proficiency examination requirenents l

specified in paragraph 3.2.3; and 4)

Complete the physical examination requirenents specified in paragrtyh 3.2.4 c.

Level II Receiving, Mechanical Equipment, or Visual i

Wald Inspector l

Personnel certified to Level II capability in these inspection categories shall have satisfied the

I following qualification requirenents

1)

Possess the recommended and verified education and

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experience specified in paragraph 3.2.lb; l

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Complete the required reading specified for procedure and instruction indoctrination in acconiance with paragraph 3.2.2; 3) s 4)

Complete the physical examination requirements specified in paragraph 3.2.4.

d.

Personnel certified to Level II capability in this inspection category shall have satisfied e.

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Level II ASME Inspector t

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Personnel cer'tified to this level of capability shall i

have satisfied the following qualification requirements as required by CP-QAP-2.1-1, and this procedure; 1.

Posses the recommended and verified education and experience.specified;

r 2.

Complete the required reading as specified;

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3.

Complete the physical examination required;

l 4.

Complete the required profeciency examinations; 5.

Be certified to Level II capability in the following categories; MIME, MIFI, VT, PT and verification.

3.3.2 Y

All levels of inspection personnel certified in accordance with this instruction shall be recertified by the Site Mechanical Level III at least every three years, on the i

basis of one of the following:

a.

Documented evidence of continued satisfactory t.

perfonunce transmitted in a memo initiated by the individual 's immediate supervi sor and endorsed by the QC Supervisor; or O

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ISSUE CPSES NUMBER REVISION DATE PAGE k

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Completion of re-examination in acconfance with paragraph 3.2.3 of this instruction.

Previously certified employees tenninated and ' rehired at CPSES within six months may be recertified without additional examination, if approved by the Site Mechanical Level III.

The period of recertification shall not exceed the expiration date doctanented on their previous certification or recertification.

3.3.3 Maintenance of froficiency QC Supervisors shall notify the Site Mechanical Level III on the Quarterly Personnel Inspector Activity Report (Attachment 7) of inspectors under their supervision having inspection activity during the quarter.

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All supervisors and inspectors shall maintain proficiency through one or more of the following:

a.

Regular and active participation in the inspection process.

b.

Review / study of

codes, standanis,

procedures, instructions., and other documents related to the QA program.

c.

Participation in training programs.

3.3.4 Revoking or Suspending Certifications The Site Mechanical Level III has the authority and i

responsibility to revoke or suspend certifications issued in accordance with this instruction when sufficient reason i

exists to question the individual's performance or i

capability.

t 3.3.5 Certifications Issued Under Previous Programs

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Certifications issued under previous CPSES programs are considered valid for the scope of activities

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II-QAP-2.1-5 6

JUN 111984 12 of 31 on the certification docuentation;

hcwever, all recertifications must comply with the requirements of this instruction.

'3.3.6 Limited Certification When individuals perfom a specific activity such as.the release of material from the. warehouse, verification of the transfer of material identification narkings, etc.,

the Site Mechanical Level III will issue a limited certification for the activity being perfomed.

Training hours and examinations to perfom such activities shall be as detemined by the Site Mechanical Level III.

3.4 LEVEL III QUALIFICATION AND CERTIFICATION i

.3.4.1 Education and Experience Requirenents

'e To be qualified for Mechanical Level III certification, the

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candidata shall satisfy one of the following education and l

l experience requirements:

a.

Six years of satisfactory perfomance as a Level II Mechanical Inspector, in accordance with paragraph 3.3.1, or equivalent; b.

High school graduation plus ten years of related experience in equivalent inspection activities, or high school graduation plus eight years experience in equivalent inspection activities with at least two years as Leve,1 II Mechanical Inspector or equivalent, and with at least two years associated with nuclear facilities - or if not, at least sufficient training to i

be acquainted with the relevant quality assurance aspects of a nuclear facility; or c.

Completion 'of college level work leading to an Associate Degree and seven years of related experience in equivalent inspection activities, with at least two years of this experience associated wi th nuclear i

facilities - or if not, at least suffic' ant training i

to be acquainted with the relevant quality assurance aspects of a nuclear facility; or

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J08 35-1195 QI-QAP-2.1-5 6

JUN 111984 13 g 31 d.

Four-year college graduation plus five years of related experience in equivalent inspection activities with at least two years of this experience associated with nuclear facilities-or if not, at least sufficient training to be acquainted with the relevant quality assurance aspects of a nuclear facility.

3.4.2 Trainina To be qualified for Mechanical Level III certification, the candidate shall complete a Required Reading List.

prepared and a,pproved by the Site QA Manager (SQAM), dich includes:

a.

The B&R CPSES QA Manual; b.

Applicable portions of the ASME Boiler & Pressure Vessel Code; I

c.

Applicable regulatory requirments

.and industry i

standards; d.

Applicable CPSES design docunents; e.

All related QA procedures and instructions; and f.

All interfacing construction and procurment 1

procedures and instructions.

l l-3.4.3 Examination i

To 'be qualified for Mechanical Level III certification, the candidate shall satisfactorily complete an examination 4

approved by the SQAM which has been prepared in accordance with paragraph 3.2.3.

The examination shall encompass the inspection categories addressed in paragraph 3.3.1 and the I

training topics listed in paragraph 3.4.2.

4 The examination shall be organized and graded as follows:

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Area Min. No. of Questions Percent Grade Weight l

General 4

50 30 l

Specific 150 40 l

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Practical 2\\ weld specimens 30 A minima composite score of 90 percent shall be required,

for certification.

Additionally, individual grades for the

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JUN 11198d M of 31 general and specific examinations shall be 80 percent or greater and the individual grade for the practical examination must be 90 percent or greater.

-3.4.4 Eye Examination The individual certified as Mechanical Level III shall satisfy the eye examination requirements specified in QI-QAP-2.1-1.

3.4.5 Certification of Qualifications The SQAM shall be the certifying authority for Mechanical Level III personnel.

Documentation of certification shall be in accordance with CP-QAP-2.1.

3.4.6 Racertification

!F Mechanical Level III personnel shall be recertified at

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least every 3

years based on continued satisfactory i

performance as evaluated by the SQAM.

I Level III personnel transferred to CPSES from other B&R nuclear projects, or do are hired at CPSES within 6 months of their termination from other B&R nuclear projects, may be certified without examination, providing:

a.

The program under which the individual was certified has been reviewed and found acceptable by the SQAM; b.

The individual's certification was by examination, and the individual's training and certification records

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are available at CPSES; c.

The program ur. der dich the individual was certified implements at a minima the requirements of References 1-A and 1-B;

.l d.

The period of recertification shall not exceed three years from the date of certification or recertifications i

by examinations.

I 3.4.7 Level III Personnel Caoabilities I

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A Mechanical Level III QCI shall have all of the capabilities of the Level II QCI certified in l

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ISSUE CPSES NUMBER REVISION DATE PAGE i (x JOB 35-1195 QI-QAP-2.1-5 6

JUN 111984 is of si accordance with this instruction.

In addi tion, the individual shall also be capable of evaluating the adequacy of specific programs used to train and test technical support / inspection personnel whose qualifications /

certifications are covered by this instruction.

The Site-Mechanical Level III shall be the qualifying /

certifying authority for all-QAT. Level I and Level II personriel qualified / certified in accordance with. this instruction.

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JUN 111984 16 of n 4

ATTACN4ENT 1 ECHANICAL INSPECTION PERSONNEL ~~~ ~

TYPICAL J08 DESCRIPTIONS - LEVEL I AND LEVEL II INSPECTOR LEVEL I ECHANICAL EQUIPMENT INSPECTORS ARE AUTHORIZEp TO PERFORM THE FOLLOWINE INSPECTION FUNCTIONS:

1.

Verify toque for mechanical joint make-up; 2.

Verify torque for mechanical equipment installation, assably or disassembly and equipment placment;

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3.

Witness valve, pimp or component disassembly and reessembly; 4..

Verify dimensional installation of wedgelock-type embeds.

torque testing, etc; 5.

Witness Plant Tag changes and identification marking transfers; 6.

Conduct surveillance checks of procedural compliance on

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equipment maintenance, storage area requirenants, housekeeping practices, and general handling operations; l

7.

Report nonconfoming conditions; 8.

Verify rigging and handling cf equipment; and 9.

Verify material identification and traceability.

l I LEVEL II MECHANICAL EQUIPENT INSPECTOR The certified Level II Mechanical Equipment Inspector shall te i

capable and authorized to perfom all Level I Mechanical Equipment.

l Inspection functions in addition to perfoming:

1.

Evaluation of Level I inspection and test results; 2.

Evaluation and reporting of nonconfoming conditions; 3.

Verify final alignment / installation of equipment; and 4.

Verification of category "A"

and "B"

lifting or handling ll operations.

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JUN 111984 17 or 31 l

ATTACHMENT 1 (con't)

LEVEL I MECHANICAL FABRICATION INSPECTORS ARE MITHORIZED TO PERFORM TR'75E5lTKTHEFr.CTION FUNCTIONS:

1.

Dimensional' verification of equipment; i

2.

Dimensional verification of supports; 3.

Report nonconfoming conditions; i

4.

Witness hydrostatic / pneumatic testing 5.

Verify and witness bC. ting flange joint and screwed connections; 6.

Verify thread engagement for bolts and studs; 7.

Witness valve, pump, or component disassembly and reassembly; 8.

Verify dimensional installation of wedgelock-type abds, torque i

testing, etc.;

9.

Witness Plant TAG changes and identification marking transfers; and

10. Verify material identification, traceability, and cleanliness control (housekeeping).

LEVEL II MECHANICAL FABRICATION IFSPECTORS

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The Certified Level II Mechanical Fabrication Inspector shall be capable and authorized to perfonn all L' vel I mechanical fabrication e

inspector functions in addition to performing:

1.

Evaluation of Level I inspection and test results; 2.

Evaluation of physical damage; 3.

Evaluation and reporting of nonconfonning conditions; 4.

Verify the installation, location, orientation, alignment and identification of pipe spools, valves and supports; and 5.

"As-constructed" installation and final line walk-downs prior to hydrostatic / pneumatic testing i

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QI-QAP-2.1-5 6

JUN 111984 18 of n ATTACMENT 1 (con'c)

LEVEL I RECEIVING INSPECTORS ARE AUTHORIZED TO PERFORM THE FOLL(NING INSPECTION FUNCTIONS:

1.

Verify quantity of itms received;'~

'2.

Verify absence of shipping damage, 3.

Verify receipt of required vendor doctmentation; 4.

Report nonconfoming conditions; 5.

Verify item identf fication, marking.and arking transfer; 6.

Conduct surveillance of warehouse storage and housekeeping requirements; and 7.

Perfo m dimensional verification and verify phsical configuration.

LEVEL II RECEIVING INSPECTORS I

T'he certified Level II Receiving Inspector shall be capable and authorized to perfom all Level I Receiving Inspector functions in i

addition to-(

I 1.

Evaluation of Level I inspection results; i'

2.

Evaluation and reporting of nor. conforming conditions; and 3.

Verify general quality of workmanship, if specified; 4

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NOTE:

Receipt of weldsents shall be performed by a ii Level II Visual or MIFI Inspector.

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JOB 35-1195 QI-QAP-2.1-5 6

JUN 111984 19 of n ATTACHMENT 1 (con't).

LEVEL II VISUAL WELD INSPECTOR The certified Level II Visual Weld Inspector shall be capable and authorized to perfona:

1.

Fit-up and tack weld inspection of welded joints; 2.

Final visual acceptance of welded joints in accordance with approved QA Procedures or Instructions.

3.

Report nonconfonning conditions; and 4.

Verify saterial identification, traceability and cleanliness control.

LEVEL II VERIFICATION INSPECTORS The certified Level II Verification Inspector shall be capable and

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authorized to perfona the following verifications:

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Engineering / Construction drawing review; 1.

2.

Pressure boundry inprocess installation documentation verification and statsing; 3.

Component support inprocess installation docunentation verification and statusing; 4.

Pre-pressure Test /N-5 docunent verification and statusing; 1

5.

Preparation of N-5 Code Data Report; 6.

Interface with ANI, Welding Engineering, Craft, Drafting and Engineering to resolve verification deficiencies; and 7.

Report nonconfonning conditions.

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JOB 35-1195 JUN 11198'4 [ 20 gr n __.

QI-QAP-2.1-5 6

ATTACHMENT.2 -

RECEIVING INSPECTOR

- TRAINING OUTLINE u

Sub.iect

1.0 INTRODUCTION

1.1 Brief History in " Quality" 1.2 "How To" - Use Procedures and Instructions 1.3 Abbrevations, Tenns, and Definitions 1.4 General Discussion on Receiving Activities 1.5 Calibration Requirements 1.6 Nonconfonnance Control 1.7 Purchase Orders and Specifications 2.0 VENDOR DOCUMENTATION I

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2.1 Surveillance Inspection Waivers 2.2 Surveillance Release Reports 2.3 Confonnance Certificates 2.4 Manufacturer's Code Data Report 2.5 Certified Material Test Reports (CMTR's) 2.6 Certificates of Compliance (C of C) 2.7 Record of Repairs 2.8 Vendor Drawings 3.0 RECEIFT INSPECTION 3.1 Shipping Damage 3.2 Physical Configuration 3.3 Dimensional Verification 3.4 Workmanship I

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ISSUE CPSES NUMBER REVISION DATE PAGE

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JOB 35-1195 Jgy111gM QI-QAP-2.1-5 6

21 of 31 ATIACHMENT 2 (con't) 4.0 IDENTIFICATION AND TAGGING 4.1 Component and Equipment Identification Requirements 4.2 Material Marking Requirements 4.3 Identification of "Small Items" 4.4 Code Data Plates 4.5 Color Coding 4.6 Traceability 5.0 STORAGE REQUIREMENTS 5.1 Storage Levels 5.2-Special Storage Environments 5.3 Storage Area Housekeeping 6.0 MATERIAL REQUISITIONS Presentation of this training program, through classroom the job training, represents a minimum

.I cialized training in receiving inspection l

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NLNBER REVISION DATE PAGE l(

JOB 35-1195 g 11h QI-QAP-2.1-5 6

3,f 31 ATTAONENT 3.

ECHANICAL EQUIPENT INSPECTOR TRAINING OUTLINE Sub.iect

1.0 INTRODUCTION

1.1 Brief History in " Quality" 1.2 "How To" - Use Procedures and Instructions 1.3 Abbrevations. Tems, and Definitions j

1.4 General Discussion on Mechanical Equipment i

1.5 Calibration Requirements 1.6 Nonconfomance Control l3 2.0 TYPES OF MECHANICAL EQUIPENT i i '

2.1 Pressure Vessels s

2.2 Pumps 2.3 Air Handling Systes 2.4 Water Handling Systems 2.5 Cranes 3.0 STORAGE AND MAINTENANCE 3.1 Storage Requirments i i 3.2 Maintenance Requirements l

3.3 Indoctrination in Applicable Construction Procedures and Instructions 4.0 INSTALLATION AND ALIGMtENT lI 4.1 Overview of Inspection Activities

'i 4.2 Installation Procedures 4.3 Alignment Procedures t

4.4 Indoctrination in Applicable Construction Procedures and Instructions i

4.5 Disassembly / Reassembly

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ISSUE CPSES NUM8ER REVISION DATE PAGE 08 5 1195 QI-QAP-2.1-5 6

JUN 111984 2s or si ATTACHMENT 3 (con't) 5.0 RIGGING AND HANDLING 5.1 Fundamentals of Rigging 5.2 Inspection of Rigging Activities 5.3 OSHA Requirements for Rigging and Handling 5.4 Preparation, Approval and Control of Operation Travelers Presentation of this training program, through classroom ion or on the job training, represents a minimun pecialized training in mechanical equipment inspe ties.

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ISSUE CPSES NUMBER REVISION DATE PAGE

!k JOB 35-1195 QI-QAP-2.1-5 6

24 of 31 ATTA0 MENT 4 ECHANICAL FABRICATION INSPECTOR

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TRAINING OUTLINE Sub.iect

1.0 INTRODUCTION

1.1 Brief History in " Quality" 1.2 "How To" - Use Procedures, Specifications and Manuals 1.3 Abbreviations. Tems, and Definitions 1.4 General Discussion on Fabrication Activities 1.5 Calibration Requirements 1.6 Nonconfomance Control

!l 2.0 DRAWINGS

I i

2.1 Drawing Preparation and Use 2.2 Numbering Requirements i

2.3 Drawing Utilization 3.0 WELD FILLER MATERIAL (WFM) CONTROL l'

3.1 Procurement Responsibilities 3.2 Handling of WFM 3.3 Storage of WFM 3.4 Issuance of WFM 3.5 Identification of Inconsistencies 3.6 Disposition of Returned WFM i

3.7 Disposition of Nonconforming WFM 4.0 IDENTIFICATION OF COMPONENTS AND MATERIALS 4.1 Responsiblity 4.2 Material Identification Procedure A.

Receiving Inspection i

B.

Color Coding and Tagging Material 1

C.

Bulk Pipe and Fittings

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D.

Traceability l

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REVISION DATE PAGE NUMBdR CPSES 6

25 of 31 k

JOB 35-1195 QI-QAP-2.1-5 ATTACHMENT 4 (continued)

Component Support Materials 4.3 4.4 Valves 4.5 Miscellaneous Items A.

Bolts and Nuts B.

Gaskets C.

Bulk Piping Itens WELDING AND RELATED PROCESSES _

5.0 Code Applicabifity Weld Procedure Specifications (WPS) 5.1 Prefabrication / Installation Verification 5.2 5.3 Documenting Weld Inspections s

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5.4 Material / Parts Verification 5.5 Weld Parameter Guide 5.6 Docuneritation Requirenents I

5.7 Design Location Welding Process and Related Requirements 5.8 Cleaning of Wald Preps and Base Metal

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5.9 5.10 Preheat /Interpass Temperature 5.11 5.12 Inert Gas Purge Gas 5.13 Consumable Inserts / Backing Strips 5.14 Wald Joint Design and Fit-up 5.15 Weld and Base Metal Repairs 5.16

5. 17 Welder Qualification Post Wald Heat Treatment 5.18 PIPE VERIFICATI0K AND INSTALLATION _

6.0 e

Procedure Control of Piping Materials in the Pipe Fab Shop 6.1 6.2 Machining /Counterboring 6.3 Pipe Bending 6.4 Requirements for Pipe Joints 6.5 A.

Screwed Joints B.

Flanged Joints C.

Expansion Joints i

l 6.6 Valve Installation 6.7 Buried Piping 6.8 Fabrication Tolerances e

6.9 Torttuing

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QI-QAP-2.1-5 6

26 of 31 ATTA0 MENT 4 (continued) 6.10 Pipe Design Location 6.11 Material Salvage 6.12 Component Supports 6.13 Valve Disassembly / Reassembly 6.14 Marking - Methods / Techniques / Requirements 6.15 Pipe Installation Requirmentsr A.

Pipe Hangers 7.0 FABRICATION AND INSTALLATION OF COMPONENT SUPPORTS

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j 7.1 Procedure for Fabrication and Installation i

7.2 Component Support Documentation Package (Hanger Package - IP) i Control A.

Class 1, 2 and 3 IP's B.

Review of the HP h

7.3 General Requirments i

A.

Structural Itas i

B.

Damaged / Lost Material / Replacement C.

Shirming/ Grouting D.

Marking / Identification 7.4 Seismic Limiters / Sway Struts 7.5 Dimensional Tolerances 7.6 Preparation, Approval and Control of Operation Travelers 8.0.

DOCUENTATION FOR WELDING. FABRICATION AND i

INSTALLATION ACTIVITIES ResponsibilitiesfRequirements 8.1 A.

Tracking 8.

Storage C.

QA Surveillance D.

ANI Review E.

Inspection Plan /Docuentation i

F.

Modification Requirements (i.e., Vendor Supplied Caponent Modification Record - [VSCMR])

-,j G.

Field Welds (Piping) l 8.2 Preparation and Process Cycle A.

Weld Data Card (WDC)

B.

Multiple Weld Data Card (MWDC)

C.

Manufacturing Record Sheet (MRS)

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D.

Weld Filler Material Log (WFM.)

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ISSUE CPSES NUMBER REVISION DATE PAGE Ik JOB 35-1195 QI-QAP-2.1-5 6

27 of 31 ATTACHMENT 4 (continued) 8.3 Pre-established Repair Sequence A.

Repair Process Sheet (RPS)

B.

Required Approvals 8.4 Doctmentation Activities During Fabrication / Installation 8.a NDE Examination Documentation Requirements 9.0 CLEANLINESS CONTROL 9.1 Inspections 9.2 Requirments for Cleaning and Packaging of Piping i

Subassemblies 9.3 Cleaning Operation A.

Interior B.

Exterior C.

Stainless Spools i.

D.

Carbon Steel Spools

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E.

Packaging 9.4 Requirments for Installation Activities 9.5 Materials and Methods A.

Solvents B.

Mechanical C.

Drying 10.0 PRESStRE TESTING 10.1 Punose/ Methods 10.2 Specific Requirements 10.3 Test Hedia 10.4 Pre-Test Inspections 10.5 Doctmentation 10.6 Valves 10.7 Pressure Gauges 10.8 System Inspection Requirements

.l 10.9 Leakage 11.0 ULTRASONIC DIGITAL THICKNESS TESTING i

11.1 Purpose / Methods i

11.2 Application

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Presentation of this training program, through classroon on-the-job training, represents a minimum of specialized training in mechanical

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ation inspection activities.

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ISSUE CPSES NUMBER REVISION

.DATE.

PAGE f(

JOB 35-1135 QI-QAP-2.1-5 6

28 of 31 ATTACIMENT 5 i

VISUAL WELD INSPECTION TRAINING OUTLINE Sub.iect l

1.0' INTRODUCTION 1.1 Brief History of Nondestructive Examination and Visual Examination i

1.2 Purpose of Visual Examination l

1.3 Qualification for Certification 20 WELDING

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2.2 Types of Weld Joints (Skewed Joints, T, joints, etc.)

i 2.3 Visual Equipment and Aids t

2.4 Lighting and Requirenants 3.0 WELDING DEFECTS 3.1 Arc Strikes 3

3.2 Buttweld in Backing Ring 3.3 Backing Ring Root Undercut 3.4 Burn Through i

3.5 Crater Cracks 3.6 Crater Pits 3.7 Melt Through 3.8 Lack of Fusion 3.9 Lack of Penet:ation 3.10 Porosity 3.11 Loss of Punje Indication 3.12 Fuse Through 3.13 Stress Risers

'i 3.14 Incomplete Insert Melting l]

3.15 Surface Concavity (Suck-back) l i

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ISSUE CPSES NUMBER REVISION DATE PAGE JOB 35-1195 l(

QI-QAP-2.1-5 6

JUN 111984 29 of 31 ATTACHMENT 5 (con't) 3.16 Overlap 3.17 Reinforcement (Build-up) 3.18 Fused Root Surface Convexity (Reinforcement) 3.19 Slag Inclusion 3.20 Tungsten Inclusion 3.21 Undercut 3.22 Weld Spatter 4.0 MANUFACTURE AND PROCESSING OF IRON AND STEEL DEFECTS 4.1 Lamination 4.2 Inclusions 4.3.

Seams l

4.4 Shrink Crack or Hot Tears 4.5 Laps 4.6 Heat Treat Cracks 4.7 Grinding Cracks 4.8 Pickling of Plate Cracks t

4.9 Fatigue Cracks 1,

4.10 Pipe and Attachments

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4.11 Porosity and Blow Holes t

l 4.12 Cold Spring 5.0 VISUAL EXAMINATION EVALUATION 5.1 Related Acceptance C:iteria 5.1.1 Marking and Tagging 5.1.2 Cleanliness - Other NDE Nethods Requirements 5.2 NDE Procedures and Standards 5.3 Docunentation and Reports I

I Presentation of this training program, through classroom n or on the job training, represents a minimum of specialized training in visual weld ivities.

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NUMBER REVISION DATE PAGE 1

CPSES i

JOB 35-1195 QI-QAP-2.1-5 6

JUN 11 N 30 of 31 ATTACHMENT 6 VERIFICATION INSPECTION TRAINING OUTLINE Subject

1.0 INTRODUCTION

1.1 Brief History in " Quality"

1. 2 "How To" - Use Procedures and Instructions 1.3 Abbrevations, Terms, and Definitions 1.4 General Discussion on Piping, Equipment and Supports 1.5 Nonconformances Control i

2.0 MATERIAL VERIFICATION 3.0 VERIFICATION OF ASME FABRICATION AND INSTALLATION j

ACCEPTABILITY

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4.0 VERIFICATION OF COMPONENT SUPPORT INSTALLATION ACCEPTABILITY 5.0 VERIFICATION OF COMPLETED COMPONENT ACCEPTABILITY IN PREPARATION FOR CODE PRESSURE TESTING 6.0 N-5 PREPARATION 7.0 STAMPING Presentation 'of this training program, through classroom instruction and on the job training, represents a minimum of ten (10) hours of specialized training in this activity.

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CesEs J08 35-1195 ggg QI-QAP-2.1-5 6

31 of 31 ATTACHMENT 7 If tv!

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