ML20199A661

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Rev 3 to Procedure QI-QAP-11.1-31, Installation Insp of Mechanical Joints
ML20199A661
Person / Time
Site: Comanche Peak, 05000000
Issue date: 01/25/1982
From:
BROWN & ROOT, INC. (SUBS. OF HALLIBURTON CO.)
To:
Shared Package
ML17192A346 List:
References
FOIA-85-313, FOIA-85-59, FOIA-86-A-20 QI-QAP-11.1-31, NUDOCS 8606120572
Download: ML20199A661 (9)


Text

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, BROWN & ROOT, INC. ISSUE CPSES NUMBER REVISION DATE PAGE J08 35-1144 i i F g\ddy QI-QAP-11.1-3] 3 1 of 9 ',

ORIGINATOR 8</Me, - /AFM

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site QA Manager DATE f'APPROVEDBY:

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1.0 REFERENCES

1-A QI-QAP-11.1-26, "ASME Pipe Fabrication and Installation

- Inspection" ,

1-B QI-QAP-11.1-37, " Instruction for QA/QC Review, Approval and Utilization of Construction Operation Travelers.", _.

1-C CP-QAP-16.1, " Control of Nonconforming Items" 2.0 ~ ~ GENERAL 2.1 PURPOSE AND SCOPE This instruction delineates the requirements to be used when performing installation inspection of mechanical joints.

2.2 RESPONSIBILITY The Site Quality Assurance Manager is responsible for review, approval and implementation of this instruction.

2.3 B0UNDARIES The boundaries of a component to which piping is attached shall be at the limit of reinforcement. This boundary shall not be closer to the main shell of a vessel, pump, or valve than:

a. the first bolted flange face; the bolts shall be considered part of the piping;
b. the first threaded joint in screwed connections.

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BROWN & ROOT, INC.

ISSUE-b. N f f NUMBER ' REVISION DATE " O- h;L ,,;

CPSES * "C J08 35-1195 QI-QAP-11.1-31 3 2 of. 9 i

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I M Q L 'J n u V-rn i p![l'tl0.@hWa alsuality to be joined Control Inspector are identified (QCI) as described in shall Referenceverify that pipe 1-a. Additionally, the QCI shall record the Material Requisition number the pipe spool is released on for threaded connections only.

3.2 THREADED CONNECTIONS

, 3.2.1 Pipe Wall Thickness The QCI shall verify the pipe wall schedule is as specified on the applicable drawing by review of pipe markings and the Material Requisition Sheet.

3.2.2 Thread Compound -

The QCI shall verify that only Neolube No. 2 is used as a thread compound and is applied as follows-

.a.

Neolube onto is limited the unthreaded portion to threads of the pipe; and shall not pr

b. Neolube is applied in an even, uninterrupted coat and allowed to dry prior to thread engagement.

3.2.3 Threads The QCI shall verify the following:

l

a. all threaded ends are reamed and free of burrs;
b. threaded ends are not damaged and free of obstruction.

3.2.4 Pipe Thread Engagement l

The QCI shall verify the minimum thread engagement of threaded connections as shown in Attachment 1, column L

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BROWN & ROOT, INC. . NUMBER ,

ISSUE.[ 'sh. ..~  : 5I . -

4 REVISION DATE - '-? PAGE ' ~

CPSES T s'08 35-1195 QI-QAP-11.1-31 3 3o 9  !

1 MCd 3.2.5 _ Th raade<l Connections Requiring Seal Welding j

i'* .

Q:I shall verify: _

N0!iWPJ =_  : tinimum of 2 inches on each side of the weld joint shall be degreased prior to welding. Mechanical preparation shall result in a clean surface 1/2 inch to 1 inch on each side of the joint;

b. no thread compound used.

3.2.5.2 After Welding -

The QCI shall visually inspect seal welds on threaded connections (to include 1/2 inch on each side of the weld) in accordance with the following acceptance criteria:

a. exposed threads are completely covered with weld metal;

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b. weld edges are free from overlap forming a re-entrant angle less than 90*;

! 'c. undercut shall not exceed 1/32 inch or cause a reduction in base metal below minimum wall;

d. no cracks;
e. no incomplete fusion; l
f. no slag; 9 no porosity;
h. no arc strikes; and
1. no weld spatter.

3.2.6 Documentation The results of QCI verifications shall be recorded on the Constructio'n Operation Traveler (Reference 1-8), if utilized by Construction, n on Inspection Report, Attachment 3 with the following exc tions.

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-o .es a its ISSUE BROWN & ROOT, INC. ' NUMBER REVISION DATE

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JOB 35-1195 ]I-QAP-11.1-31 3 4 of 9

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Threading verification (see 3.2.1) shall be

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QCI 1 4' M. Manufacturing . Record

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umented on the Sheet -~9 o

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b. ual inspection of saal welding s 3.2.5 shalT be ._

N0'lVill!' d OM.Visfocumented on the Weld Data Card a on an Inspection  ? y, tenart, Attachment 3, for accep able conditions. e a Unacceptable conditions shall be documented on bHDER, A

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Attachment 4.  ; fg On completion of all QCI verification, the responsible QC Superintendent shall review the documented results and

[$h i 2 indicate approval by signing and dating the appropriate Sir.

document. _,

q v; 3.3 FLANGE CONNECTIONS ~ i

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3.3.1 Cleanliness C

. C IT-The QCI shall verify flange [ faces are thoroughly cleane '

remove rust, scale, dirt, paint, etc. _

3.3.2 Traceability

'The QCI shall verify Material Requisition number and color code of gasket material, heat number or lot number of nuts and bolts or studs are recorded on the "

Operation Traveler (Reference 1-B). 7Construction  %

3.3.3 Alignment C . .

The QCI shall verify flanges are aligned as follows:

a. within 3/64 inch normal and with respect to flange outside diameter; except 1
b. when pipe is to connect to a flange on equipment (i.e., valves, pumps, etc.), the face of the flange is aligned to the lesser of 25% of the gasket thickness or as described in a. above. ~

3.3.4 Sol ting .

The QCI shall verify at least one complete thread is exposed above the nut face.

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{pl(pj{Q-gerence 1-8)Q.CI verif . . _

dn  ;;gjwyrg 0RMANCES All nonconfonning con itions will be reported in accordance with Reference 1-C.

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l SROWN & ROOT, INC. ISSUE -

i CPSES NUMBER REVISION DATE PAGE J08 35-1195 .

7 of 9 i' QI-QAP-ll,1-3' 3 ,

l C ATTACHMENT 2 K yf r ,,

WANCHE FCK STDM E' ECTRIC STATION -

l-j !h pf .j (:,![ p INSPECTION REPORT [a i irns assmar.crerT tmou.ai w a. m w c.An a c prs'as sa.cr.as m.saanc:a si ._3 .

tSE1HREADES6POCL"..

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1. l Spool ts properly identtfted per QL-QAP-11.1-26 i ll l 8

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2. I Spool is released on MRy l l l l
3. l There are no obstructions inside scoc1 I l l 4 l Threads are not daraced (Flat. Surred. Chicoed) ll l .
5. Neolube procerly acolted l l l l'
6. Thresd eneacement correct =er 0!-CAP-11.1-31. Atchet 2 i ll I
7. l Excess neolube removed ll l
8. I Pecord the followino: 1 II I 1 l l l l l A. Scool
  • to Socol l l !  !

l 8. Line No. Rework 17 l ll l l

  • Indicates Threaded Socol l ll l l -"' Check Rework If Acolicaole l l l l l 1l1 i l .+ 11I I l ./A R @. I I i  !

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r ISSUE 8ROWN & ROOT, INC. "NUM8ER REVISION DATE ' PAGE CPSES JOB 35-1195 QI-QAP-11.1-31 3 8 of 9 ATTACHMEliT 3 Y,,,

f om ans emme em ines.es amm6 - e reens

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  • VISJALEXAANNATION CHEC)(LIST O " M 'l n ccmanose fBAst Joe 1st M itte ~UNfr PAGE OF l

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l Enter NA adjacent to attribute when not amplfcable. Enter Sat./Unsat or NA above results in each sectice 1 through 4 as appitcable.

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, BROWN & ROOT, INC. NUMBER REVISION DATE .PAGE CPSES JOB 35-1195 -I QI-QAFil .1-31 3 9 of 9 Ai u n

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8ROWN & ROOT INC. ISSUE CPSES NLMBER REVISION DATE PAGE 408 35 1195 QI-QAP-11.1-31 3 JAN 2 7 1982 1 of 9 TITLE: ORIGINATOR- [d/[e /-2r-72 ME REVIEWED m J2_-

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mem[wu=C01.fflEAPPROVEDB G -

1.0 REFERENCES

1-A QI-QAP-11.1-26 "ASME Pipe Fabrication and Installation Inspection" 1.3 QI-QAP-11.1-37, " Instruction for QA/QC Review, Approval and Utilization of Construction Operation Travelers.".

1-C CP-QAP-16.1, " Control of Nonconforming Items" 2.0 GENERAL 2.1 PURPOSE AND SCOPE This instruction delineates the requirements to be used when perfoming installation inspection of mechanical joints. -

2.2 RESPONSIBILITY The Si te Quality Assurance Manager is responsible for review, approval and implementation of this instruction.

2.3 BOUNDARIES The boundaries of a component to which p- 4 a% a -

shall be at the limit of reinforcement. T4ApoipH@ry-AhaW not be closer to the main shell of a ve: 1,' .mp,yo' vjyd than: 1 h

, b. 2,1 a,

a. the first bolted flange face; t 1e 1 considered part of the piping; boltsga)y,

,,g be i b. the first threaded joint in screwed connections, e venc :MA.-65-59

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, 1 ISSUE BRCWN & ROOT INC. NUMBER P.EVISION DATE PAGE CPSES JOB 35-1195 QI-QAP-11.1-31 3 JAN 2 7 582 2 of 9 3.0 INSTRUCTION 3.1 IDENTIFICATION

~

The Quality Control Inspector (QCI) shall verify that pipe spools to be joined are identified as described in Reference 1-A. Additionally, the QCI shall record the Material Requisition number the pipe spool is released on for threaded connections only.

, 3.2 THREADED CONNECTIONS 3.2.1 Pipe Wall Thickness The QCI shall verify the pipe wall schedule is as specified on the applicable drawing by review of pipe markings and the Material Requisition Sheet.

3.2.2 Thread Compound The QCI shall verify that only Neolube No. 2 is used as a thread compound and is applied as follows:

. .a . Neolube is limited to threads and shall not protrude onto the unthreaded portion of the pipe;

b. Neolube is applied in an even, uninterrupted coat and allowed to dry prior to thread engagement.

3.2.3 Threads The QCI shall verify the following:

a. all threaded ends are reamed and free of burrs;
b. threaded ends are not d - =d =ad #aae e' t t :ction.

3.2.4 Pipe Thread Encacement

\! FORMAT!ON The QCI shall verify the pfEh,'re'5d #[keh ent of

~ threaded connections as show in Stachmen)t 1,ch y imn L .

%Y L 1. 2 s

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U ISSUE BROWN & ROOT, INC. NUMBER REVISION DATE PAGE CPSES JOB 35-1195 QI-QAP-11.1-31 3 3 of 9 I JAN 2 7 1982 3.2.5 Threaded Connections Requiring Seal Weldin_g 3.2.5.1 Prior to Welding The QCI shall verify:

~-

a. a minimum of 2 inches on each side of the weld joint shall be degreased prior to welding. Mechanical preparation shall result in a clean surface 1/2 inch to 1 inch on each side of the joint;
b. no thread compound used.

3.2.5.2 After Welding The QCI shall visually inspect seal welds on threaded connections (to include 1/2 inch on each side of the weld) in accordance with the following acceptance criteria:

a. exposed threads are completely covered with weld metal;
b. weld edges are free from overlap;

.c. undercut shall not exceed 1/32 inch or cause a reduction in base metal below minimum wall;

d. no cracks;
e. no incomplete fusion;
f. no slag;
g. no porosity;

. h. no arc strikes; and

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1. no weld spatter, /*

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3.2.6 Documentation

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- The results of QCI verificatians shalNebcorded e i the Construction Operation Traveler veterence 1-6), u usiitzed

[ by Construction, and on Inspection Report, Attachment 2 with

the following exceptions

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r ISSUE BROWN & ROOT, INC. NUMBER REVISION DATE PAGE CPSES JOB 35-1195 QI-QAP-11.1-31 3 JAN 2 7 S82 4 of 9

a. Threading QCI verification (see 3.2.1) shall be documented on the Manufacturing Record Sheet (Reference 1-A).
  • b. Results of final visual inspection (see 3.2.5) shall be

' Inspection documented on the Weld Data Card and on the Visual Checklist, Attachment 3. Unacceptable conditions shall be documented on NDER, Attachment 4.

On completion of all QCI verification, the responsible QC Superintendent shall review the documented resul ts and indicate approval by signing and dating the appropriate document.

3.3 FLANGE CONNECTIONS 3.3.1 Cleanliness The QCI shall verify flange faces are thoroughly cleaned to remove rust, scale, dirt, paint, etc.

3.3.2 Traceability

.The QCI shall verify Material Requisition number and color code of gasket material, heat number or lot number of nuts and bolts or studs are recorded on the Construction Operation Traveler (Reference 1-B).

3.3.3 Alionment The QCI shall verify flanges are aligned as follows:

a. within 3/64 inch nonnal and with respect to flange outside diameter; except
b. when pipe is to connecu 15]hhk)it Iequipment  !

i (i.e., valves, pumps, etc. the.. face .of, thec flange is aligned to the lesser of o{tlia gask'etit,lpfckness or as described in a. abov e,g

\j4.8 3, ' ay r., .

3.3.4 Bolting ODI t./

The QCI shall verify at least oneIdmd/ta c  %! is exposed above the nut face.

r ISSUE BROWN & ROOT, INC. NUMBER

  • REVISION CATE PAGE

, ...CPSES I

JOB 35-1195 QI-QAP-11.1-3] 3 JAN 2 7 1982 ' 5 of 9 1

3.3.5 Documentation The Construction Operation Traveler shall be used to document the in this section (Reference 1-B)Q.CI verifications described 4.0 NONCONFORMANCES All nonconforming conditions will be reported in accordance with Reference 1-C.

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SRONN & RCOT, !HC. LSSUE . ~

CPSES NLMBER REVISION DATE PAGE J08 35-1155 QI-QAP-ll,1-3' 3  !

I JAN 2 7 1982 7 of 9 -

1 ATTACHMENT 2  :

COMANCHE PEAX STEAM E.ZOTRIC STATION e.er- -r INSPECTICN REPCRT [4 wars.we sraws:.as - .c:.

ir a saw uar.ca m .r: a .aieuiu twucewer ca s OF THREADEO SPCOLS si 4 .

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1. I 50001 is properly identified per Ql-QAP-il.1-26 l l1 l l l l6 1
2. I Spool is released on MRs I l l l
3. l There are no obstructions inside s:oc1 l l l
d. l Threads are not dasreged (Flat. Burred. Chicoed) l l l .
5. I Neolube procerly soolied l ll I*

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CPSES PAGE d- M id- i J08 35-1195 QI-QAP-ll.1-31 3 JAN e 7 1982 8 of 9 T , ..?, .

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ATTACHMENT 3 .i' OM mone sus sen.om em rees -  %

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j ISSUE BROWN & ROOT. I!C. NUM8ER REVISION DATE . PAGE CPSES J08 35-1195 9 of 9 QI-QAP 11.1-31 3 JAN 2 7 E ,

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j PROCEDURE / INSTRUCTION REVIEW FORM l Procedure / Instruction No:Wf)fyg)-gg@ Tit 1e f d /) ,{a X p ,j;,, offfs,Jln;,/ so,%fr Originator: [ d ,/ M ReviewingOrganizationd;g/f/m,y l Page # /M,., f' l Paragraph ' Comunent '

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Signed D!,'*." !?. nee coy,pany i a ** r u === me:F;ENT-RE' AIM WH:TE COPY, T'CT, .N F'*"( Ca."'t

I BROWN 1 RCOT, INC. ISSUE CATE l CPSES Nt24BER REVISION P. AGE j

( 1 J08 35-1195 s QI-QAP 11.1-26 7 MAN 1%YN! I of 52 ,

I l

TIT 1.!: ORIGINATOR: M C / > L1/m 3-4-M r . .' OATE ASME PIPE FABRICATION AND REVIEWED SY:

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INSTALLATION OATE INSPECTIONS APPROVED BY: 3 Ai 3 /, ,, ,1,,,

- r4 Site QA Manager CATE

1.0 REFERENCES

1-A ASME Boiler & Pressure Vessel Code,Section III, 1974 Edition with Addenda through Summer,1974 1-B CP-QAP-2.1-5, " Training and Certification of Inspection Personnel" 1-C CP-QAP-8.1,"QCReceivingInspectjon" 1-0 CP-QAP-16.1, " Control of Nonconforming Items" 1-E QI-QAP-11.1-31, " Installation Inspection of Mechanical Joints" 1-F i e of Welder Performance 1-G CP-QAP-16.1-2, dah "I Violations, and Arc Stri se M ir fe s, Minimum Wall 1-H CP-QAP-18.2, "QA Review of ASME Sectio o,c en ation" 2.0 GENERAL

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This instruction delineates th '..Sregyttggen an'd crit ria to be used when perfonning biFMation ,g vinstalla ion inspection of ASME Code piping ( ference '

2.2 RESPONSIBILITY The Quali ty Control Manager shall be responsible for implementation of this instruction.

W --

H O A b b.. -o ,_ S rh3M

. l. SROWN & ROOT, INC.

ISSUE

'.- CPSES NUMBER REVISION DATE PAGE QI-QAP-11.1-26 7 MAR 121982 3 of gg l

l 2.6 ROUTINE OBSERVATIONS l

Inspection personnel perfonning inspections shall routinely 4

observe general workmanship conditions in all areas of plant i cons truction. Observations shall include such items as: -

a. Handling / Rigging
b. Housekeeping / Storage Maintenance
c. Contamination of Stainless Steel (Material Segregation) j d. Physical Damage Observations which are adverse to quality and existing site procedures shall be documented using Field Deficiency Reports (FDR's). The FDR's shall be forwarded to Quality Engineering for evaluation.

2.7 INSPECTION OF MECHANICAL JOINTS y

Inspection of flanged joints, threaded joints, etc.,

shall be accomplished in accordance with Reference 1-E.

l 3.0 I)ENTIFICATION. MARKING. CLEANING. FIT-UP AND FINAL VISUAL

{ I15PECTION REQUIREMENTS i

! 3.1 MATERIAL IDENTIFICATION AND MARKING REQUIREMENTS

! Material identification shall be maintained on all items during fabrication and installation activities. The __.

, material identification shall be such that traceability i is maintained between the item and its as 1

documentation. . , r) ,

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l 3.1.1 Maintenance of Material Identification \dultiii 'buttiM'0oerattirh ,

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! When cutting is perfonned in order to m dify% v,enddrsV)pl i piping spool, a B&R fabricated piping 1 or, ginoces bulk pipe for fabrication purposes, the

rify the following is transferred legibly, and \in accord m v paragraph 3.1.4,toeachcutpiecepriortocuttin'g)
\,34\'ith N
a. Vendor supplied piping spool - the\.. spoo- 'l number and drawing number.

b.. Process bulk pipe - the heat number, ASTM /ASME type i and grade, schedule / wall thickness, spool number, drawing number, and piece number.

1 l

L

BRoliN & ACOT, INC. ISSUE l CPSES NLNBER REVISION CATE FAGE J08 35-1195 QI-QAP 11.1-26 8 APR 151982 1 of 53 TITLE: ORIGINATCR: .cl C b.) M d-44 -92 UATE IC ON AND REVIEWED BY: v cu i 4 N- fl INSTALLATION DATE INSPECTIONS f APPROVED BY: M Y Y 'd ) -

t. e QA Manager DATE
1. 0~ REFERENCES 1-A ASME Boiler & Pressure Vessel Code,Section III, 1974 Edition with Addenda through Sumer,1974 1-B CP-QAP-2.1-5, " Training and Certification of Inspection Personnel"

, 1-C CP-QAP-8.1, "QC Receiving Inspection" 1-D CP-QAP-16.1, " Control of Nonconfonning Items" 1-E QI-QAP-11.1-31, " Installation Inspection of Mechanical Joints" 1-F CP-QAP-10.3, "QC Surveillance of Welder Performance Qualification" 1-G CP-QAP-16.1-2, " Documenting Base Metal Repairs , Minimum Wall Violations, and Arc Strike Repairs" 1-H CP-QAP-18.2, "QA Reyiew of ASME Section III Documentation" 2.0 GENE I [r0, 2.1 PURP0 g This instruction delineates O!U r u t criterM to be used when perfonning fabrica L intt'ailkitAn

  • inspection of ASME Code piping (Referen e.kh '.OPu"', , , , . , ,,

2.2 RESPONSIBILITY 8 'A I- Ti.

u

'g The Quality Control Manager shall b p le for implementation of this instruction.

K o

Fu!M~ous co M3P .

1 BROWN & ROOT, INC. ISSUE CPSES NUMBER REVISION DATE PAGE QI.QAP-11.1-26 8 APR 1519D' 3 ,, 33 2.6 ROUTINE OBSERVATIONS i

Inspection personnel performing inspections shall routinely observe general workmanship conditions in all areas of plant construction. Observations shall include such . items as: -

a. Handling / Rigging
b. Housekeeping / Storage Maintenance
c. Contamination of Stainless Steel (Material Segregation)
d. Physical Damage Observations which are adverse to quality and existing site procedures shall be documented using Field Deficiency Reports (FDR's). The FDR's shall be forwarded to Quality

?

Engineering for evaluation, i

2.7 INSPECTION OF MECHANICAL JOINTS l

Inspection of flanged joints, threaded joints, etc.,

shall be accomplished in accordance with Reference 1-E.

3.0 ')ENTIFICATION. MARKING. CLEANING. FIT-UP AND FINAL VISUAL

15PECTION REQUIREMENT 5 3.1 MATERIAL IDENTIFICATION AND MARKING REQUIREMENTS Material identification shall be maintained on all items during fabrication and installation activities. The material identification shall be such that traceability is maintained between the iten and its associated documentation.

3.1.1 Maintenance of Material Identification durino Cuttino Operations When cutting is performed in order to modify a vendor-su oli" piping spool, a B&R fabricated piping spool, c ces tj \

f' Oh l bulk pipe for fabrication following is transferred legibly, and in ac orun purposes, the .

QCI shall V paragraph 3.1.4, to each cut piece prior to cut i 'g }y.e.<g }. e 7

a. Vendor supplied piping spool - the spool drawing number.

(Mb O

b. Process bulk pipe - the heat number, AS /ASME t d and grade, schedule / wall thickness, spo r, drawing number, and piece number.

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I SROWN & R00To 19C. l S!UE  !

CPSES i P;GE NUMBER REVIS;0tll DATE I J05 35-1135 QI-QAP-11.1-26 8 5El 10 # 53 l

l 3.3.4 Cold Springino .

i i i The QC Inspector shall verify at fit-up, prior to welding, i that cold springing does not exist, and document resul ts on the Visual Examination Checklist. '

l l 3.4 PREHEAT /INTERPASS TEMPERATURE Thbpreheating and interpass temperatures to be used for welding shall be in accordance with the applicable WPS.

Where the temperature of the surface of material to be welded falls below 60'F and a higher preheat is not required by the. WPS, the weld area shall be preheated to a hand war 1n condition.

The preheat specified on the WPS shall be established before any welding. However, except for P4 and P5 materials, preheating above 60*F is not required before tacking.

l Preheat and interpass temperatures shall be measured by the l i use of approved temperature indicating crayons, attached I

thermocouples, pyrometers or any other method approved by j the Owner. Temperature indicating crayons shall be of the  !

special lead-free, sulphur-free and halogen free type such i*

as Tempilstick.

The area to be preheated on any weld joint shall be 3 times the wall thickness on each side of the maximum weld width.

The area shall be uniformly preheated to' the required temperature before the start of production welding.

Temperature indicating crayons, when used for preheat and interpass temperature measurement shall be applied to avoid direct contact with the surface to be welded.

The interpass and preheat temperature shall be measured on the surface of the base material, on the side whi

.nt. edge,'ir.

welding and along theis performed, next weld pass.

joint 1 inch fromwithin 1 inch the starting po of the we@ % Qqithe

,, .., - q".:$[ t y-3j, v. ; / y Preheat and Interpass (if necessary) verified by the OCI in accordance with tempprature a're n ,

documented on the Preheat and Interpass tempet 4,Ye blocAtyveLavTd i t i .. j on the applicable WDC. '

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$A01dN & A007, INC.  !!3UE CPSES NUM8ER REVISION CATE PAsg i

JOS 35-1195 QI-QAP-ll.1-26l 8 44 of 53 fAPR 151982$ ,

ATTACHMENT 16 g BrowriO9mounc.

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