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Module 12307
Objectives
%rere!uisites
&uccessful completion of the follo'ing (as) Module*s+ is re!uired before beginning study of this (as) Module, Instrumentation -evel 3. (as) Module 1231$. Craft-Related Trigonometry.
1O2/&0 M3%
(his course map sho's all of the Wheels of Learning tas) modules in the third level of the Instrumentation curricula. (he suggested training order begins at the bottom and proceeds up. &)ill levels increase as a trainee advances on the course map. (he training order may be adjusted by the local (raining %rogram &ponsor.
-040- 3 1OM%-0(0
/eceive. Inspect. 5andle. and &tore Instrumentation and 1omponent 6 Module 12307
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Section Topic . Page 1.0.0 Introduction :::::::::::::::::::::::::::: # 2.0.0 Inspection of a 1arton or 1ontainer for %hysical amage ::::. # 3.0.0 &pecial 5andling Instructions for 1artons or 1ontainers :::::. $ ".0.0 &afety /e!uirements for -ifting ::::::::::::::::::. $ #.0.0 Inspection of the /eceived Item for amage :::::::::::. ; $.0.0 Inspection of /eceived Instrumentation to Instrument ata &heet &pecifications :::::::::::::::::::::::::::: 10 7.0.0 1onsiderations for &torage of Instruments or 1omponents :::: 11 7.1.0 -evel 3 :::::::::::::::::::::::::::::::. 11 7.2.0 -evel 7 :::::::::::::::::::::::::::::::.. 12 7.3.0 -evel 1 :::::::::::::::::::::::::::::::. 13 7.".0 -evel :::::::::::::::::::::::::::::::. 13
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/eceive. Inspect. 5andle. and &tore Instrumentation and 1omponent 6 Module 12307
%ac)aging is divided into t'o broad categories. (hese categories are as follo's,
Open 7oAed
Open pac)ing consists of tie<do'ns bet'een the item and s)ids. pallets. or the beds of truc)s. railcars. or barges. 7races. pads. plugs. and other protective devices are used as necessary to secure the item. 3reas on open pac)aging that should be inspected for physical damage include, loose tie<do'ns. missing pads and plugs. bent ties and braces. and evidence of shifting bet'een the item and its supports.
7oA pac)aging. including cartons. should be inspected for physical damage. 3reas on boA pac)aging that should be inspected for physical damage include, crushed or torn areas. splintered or bro)en crating. and split or crac)ed containers. 0nvironmental damage can occur 'ith either open or boAed pac)aging. %ac)aging should be inspected for signs of rust. oil stains. 'ater mar)s. salt film. and other stains or film. 3lso pac)aging should be inspected for evidence of fire such as charred 'ood. paint. or paper. Figure 1 sho's an eAample of a chec)list that can be used to inspect pac)aging for physical damage.
transition temperatures. or any other conditions that 'arrant special instructions. (he handling instructions should provide the 'eights. sling locations. balance points. methods of attachment. maAimum hoist line speed. and any other pertinent features to be considered as necessary for safe handling. 5oisting e!uipment used for handling components is certified by the manufacturer. (he certification indicates the various parameters for the maAimum load to be handled by the e!uipment.
/eceiving Inspection /eport 9o. DDDDDDDDDDDDDDDDDDDDDDDDDDD &ystem 9o.?9ame DDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDD 1omponent ? %art 9o. DDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDD &erial 9o.?Model 9o. DDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDD %.O. 9o. DDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDD 4endor DDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDD &pecification 9o. DDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDD CRITERIA 1rushed areas (orn areas &plintered crating 7ro)en crating &plit container 1rac)ed container -oose tie<do'ns Missing pads Missing plugs 7ent (ies 7ent braces 0vidence of shifting /ust Oil &tains Eater mar)s &alt film Other stains of film 1harred 'ood 1harred paint 1harred paper ACC DDDDDD DDDDDD DDDDDD DDDDDD DDDDDD DDDDDD DDDDDD DDDDDD DDDDDD DDDDDD DDDDDD DDDDDD DDDDDD DDDDDD DDDDDD DDDDDD DDDDDD DDDDDD DDDDDD RE% DDDDDD DDDDDD DDDDDD DDDDDD DDDDDD DDDDDD DDDDDD DDDDDD DDDDDD DDDDDD DDDDDD DDDDDD DDDDDD DDDDDD DDDDDD DDDDDD DDDDDD DDDDDD DDDDDD N&A DDDDDD DDDDDD DDDDDD DDDDDD DDDDDD DDDDDD DDDDDD DDDDDD DDDDDD DDDDDD DDDDDD DDDDDD DDDDDD DDDDDD DDDDDD DDDDDD DDDDDD DDDDDD DDDDDD COMMENTS DDDDDDDDDDDDDDDDDD DDDDDDDDDDDDDDDDDD DDDDDDDDDDDDDDDDDD DDDDDDDDDDDDDDDDDD DDDDDDDDDDDDDDDDDD DDDDDDDDDDDDDDDDDD DDDDDDDDDDDDDDDDDD DDDDDDDDDDDDDDDDDD DDDDDDDDDDDDDDDDDD DDDDDDDDDDDDDDDDDD DDDDDDDDDDDDDDDDDD DDDDDDDDDDDDDDDDDD DDDDDDDDDDDDDDDDDD DDDDDDDDDDDDDDDDDD DDDDDDDDDDDDDDDDDD DDDDDDDDDDDDDDDDDD DDDDDDDDDDDDDDDDDD DDDDDDDDDDDDDDDDDD DDDDDDDDDDDDDDDDDD
/eleased for &torage ? Installation F *1ircle+ =es 9o /emar)s DDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDD DDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDD DDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDD C1 Inspector DDDDDDDDDDDDDD
Signat re
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/eceive. Inspect. 5andle. and &tore Instrumentation and 1omponent 6 Module 12307
8igure 1. %hysical
WARNING! 5oisting e!uipment must not be loaded beyond its rated load.
as certified by the manufacturer. eAcept for test purposes. 8or special lifts. hoisting e!uipment may be re<rated. upon approval of the manufacturer. /e<rated e!uipment must be given a dynamic load test over the full range of lift using a test 'eight at least e!ual to 110G of the lift 'eight. 3 dynamic test includes raising. lo'ering. and traversing the load in contrast to a static test 'here the test 'eight may be increased incrementally 'ith no movement.
/igging is not frayed. 'orn. or other'ise deteriorated. 5oisting e!uipment ratings are e!ual to or greater than the load. 0!uipment and rigging is clean and free of contaminants that are
detrimental to the item being handled. /igging items such as hoo)s. shac)les. and turn buc)les have not yielded. distorted. or deformed. -oad measuring devices such as strain gauges or pressure gauges are used 'hen specified. /apid or jer)ing movement is avoided. -ifting lugs or other appropriate loading surfaces on the item are used. 3mple space eAists for the movement or transporting.
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3 vital part of the inspection process is the visual inspection of the received items. 4isual eAamination of all items is performed to ensure that no obvious damage has been done to the received item. Ehere possible. the visual eAamination is performed prior to off<loading of items in order to avoid accepting custody of items if they are damaged. 3 thorough inspection of the item is performed noting on the inspection form any signs of damage. 8igure 2 sho's a typical receiving inspection report. 7ro)en glass is a sure sign of damage on e!uipment such as pressure gauges. flo' meters. and instruments 'ith glass face covers. NOTE$ 3ll bro)en glass and lenses should be noted on the inspection form.
3lthough it often appears that this )ind of damage is minor and can be easily corrected 'hen the item is installed. this is not necessarily true. 7ro)en glass splinters can accidentally get into the mechanism of gauges and instruments causing them to malfunction.
If oil or fluids has spilled out of an item. the lea)age needs to be noted on the inspection form. Many times a piece of e!uipment can be damaged. or the potential for damage can eAist if fluid or lubricating oil has lea)ed into electrical contacts. s'itches. motors. diaphragms. and other electrical components.
H 3ccept H /eject
Material eficiency /eport DDDDDDDDDDDDDDDDDDDDDDDD N&A COMMENTS DDDDDD DDDDDDDDDDDDDDDDDD DDDDDD DDDDDDDDDDDDDDDDDD DDDDDD DDDDDDDDDDDDDDDDDD DDDDDD DDDDDDDDDDDDDDDDDD DDDDDD DDDDDDDDDDDDDDDDDD DDDDDD DDDDDDDDDDDDDDDDDD DDDDDD DDDDDDDDDDDDDDDDDD DDDDDD DDDDDDDDDDDDDDDDDD DDDDDD DDDDDDDDDDDDDDDDDD DDDDDD DDDDDDDDDDDDDDDDDD DDDDDD DDDDDDDDDDDDDDDDDD DDDDDD DDDDDDDDDDDDDDDDDD DDDDDD DDDDDDDDDDDDDDDDDD DDDDDD DDDDDDDDDDDDDDDDDD DDDDDD DDDDDDDDDDDDDDDDDD
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CRITERIA %hysical %roperties imensions Eeld %rep Eor)manship -ubricants?Oil 0lectrical insulation &pecial I and Mar)ings Manufacturing ocuments %rotective 1overs?&eals 1oatings?%reservatives Inert >as 7lan)et essicant %hysical amage 1leanliness
/eleased for &torage ? Installation F *1ircle+ =es 9o /emar)s DDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDD DDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDD DDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDD
/eceive. Inspect. 5andle. and &tore Instrumentation and 1omponent 6 Module 12307
C1 Inspector DDDDDDDDDDDDDD
Signat re
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It should be noted that this type of visual inspection is usually performed on the eAterior of the received item. (he inspector is not eApected to loo) inside a control console to see if any damage eAists inside. 3lso. it is not eApected that the inspector 'ill disassemble and inspect any items sealed and bolted together. (he inspection is to closely eAamine the out'ard appearance of the items or material and document the results of the inspection. &ealed items are typically unsealed to permit a visual inspection and then resealed. Many items re!uire protective covers since they might be going into storage for an eAtendedd period of time. Items that re!uire cap plugs 'ill normally arrive 'ith them in place. 7ut. in some cases the plugs may be damaged or dislocated as a result of handling or due to using the 'rong siBe caps. &mall openings such as fittings on instruments might be sealed 'ith plastic or 'ith a seal made from durable tape. 5o'ever. scre'<in or scre'<on plugs are desirable for these types of items. &ome items may arrive in a pressuriBed container 'hich should be mar)ed 'ith a statement that the container is sealed and charged 'ith an inert gas. In such cases. the inspection is performed visually through the sealing material if transparent. or delayed until installation if opa!ue. 3 pressure indicator 'ill indicate the internal pressure of the item. Ehen inspecting the item this pressure should be recorded on the inspection form.
WARNING!
o not open these containers unless directed to do so because the gas could be displaced by. or become miAed 'ith moist air that can cause condensation inside the container.
esiccant material absorbs moisture from the air. (he material may be crystals enclosed in a small pac)et or in a plastic vial as sho'n in Figure 3. If items have desiccant materials enclosed. save the material to put bac) after completion of the inspection.
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8igure 3.
esiccant Material
0ach received item should also have supplier documents. (his 'ill normally include information on the instrumentation such as installation information. 'iring information. and?or a technical manual. 3ny deficiencies found 'hen verifying the instrument received to the instrument data sheet should be noted on the receiving inspection form.
/eceive. Inspect. 5andle. and &tore Instrumentation and 1omponent 6 Module 12307
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level of protection necessary is dependent on the nature of the specific items but 'ill fall into one of four levels of storage. -evels 3 through . 3ll storage areas are arranged and controlled in such a manner as to minimiBe handling of items and the ris) of accidental damage from vehicular traffic. cranes. and hoists. 3ll items in storage are arranged such that rac)s. cribbing. or crates support the 'eight of the item 'ithout distortion of the item. 3lso. identification is maintained on all items in storage. Items are positioned in storage such that identification can be verified 'ith minimal handling. -arge items are typically stored in their shipping crates on floor s)ids. 2ncrated large items are typically stored on floor s)ids 'hether the item is being stored inside or outside. &maller items are typically stored on shelves or rac)s inside. 1leanliness and house)eeping measures are used to minimiBe the possibility of damaging or contaminating items in storage. %eriodic cleaning of storage areas is done to avoid the accumulation of trash. discarded pac)aging materials. and other solids. 8ood anddrin)s are prohibited in storage areas. /odent control should be provided as necessary.
7.1.0 -040- 3
Items 'ill be categoriBed for level 3 storage if they are eAceptionally sensitive to environmental conditions and 'ould re!uire special protective measures for the follo'ing,
9arro' temperature limits &udden temperature changes 5umidity and vapors 3irborne contamination such as rain. sno'. dust. dirt. salt spray. and fumes. >ravitational forces due to acceleration or deceleration. Items that re!uire one or more of the above considerations 'ill be assigned storage space in a facility that provides humidity and temperature control. as 'ell as proper ventilation 'ith filters to remove dust and vapors. (hese spaces or facilities should al'ays be closed. and no foreign material should be allo'ed in. (his building should have a paved floor and should be 'ell sealed to )eep out foreign material. Items stored should be on pallets or shoring to provide for air circulation. It should not be subject to flooding and should be fireretardant. 0Aample of -evel 3 items include the follo'ing,
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7.2.0 -040- 7
Items 'ould be categoriBed as -evel 7 if they conditions described for -evel 3 but do not re!uire re!uired by -evel 3. 8or eAample. -evel 7 items narro' temperature or humidity controls as -evel 3 are sensitive to the the special protection 'ould not re!uire as items.
-evel 7 storage 'ill probably be in a fire<resistant. 'eather<tight. 'ell ventilated building or enclosure made of durable material. (his might be a sealed. plastic<covered 'ood frame structure or a conventional 'arehouse building. (he storage area should not be subjected to flooding. In addition. the floor should be paved. or covered 'ith 'ood plan)ing. ply'ood. or some similar material. Items stored here 'ould be placed on pallets. shelves. bins. or cribbing supports to provide for air circulation. (he area 'ill usually have temperature control. and possibly humidity control. (he maAimum allo'able temperature 'ill probably be about ;# degrees. 0Aamples of -evel 7 items include the follo'ing,
%lant batteries &ome instrumentation e!uipment Eelding electrodes 0lectrical penetrations Motor control centers &'itchgear Motor generators (urbine generators &ome precision e!uipment
7.3.0 -040- 1
Items 'ould be categoriBed as -evel 1 if they re!uire protection from the environment. airborne contaminants. acceleration?deceleration forces. and physical damage but are not particularly susceptible to deterioration from 'ater vapor. condensation. and large temperature variations. 0Aamples of -evel 1 items include the follo'ing,
%umps 4alves Instrumentation cable 0lectrical cable 8ans 1ement %aint &ealants
/eceive. Inspect. 5andle. and &tore Instrumentation and 1omponent 6 Module 12307
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(an)s 5eat eAchangers &tructural steel %ipe /einforcing steel Items not affected adversely by 'eather
Figure 4 is a summary of the storage level listing the re!uirements and the items associated normally stored in each area.
Le' e( 3
Storage Consi"erations < 1ontrolled temperature < 1ontrolled humidity < 4entilation filters to remove contaminants. fumes. and vapors < %rotection from vibration and shoc) < %rotection from physical damage < (emperature limits < 1ontrolled humidity < %rotection from vibration and shoc) < %rotection from physical damage < %rotection from airborne contamination
T)pica( Ite!s < &pecial electronic e!uipment < &ensitive instrumentation e!uipment < 5aBardous chemical < /adioactive material < Instrumentation e!uipment < 0lectrical penetrations < Eelding electrodes and 'ire < 1ontrol rod drive < electrical s'itchgear and panels < Motors and genertors
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< %recision machine parts < %rotection from < %rotection from contamination < %rotection from shoc) < %rotection from the environment airborne vibration and physical damage < < < < < < < < < < < < < %umps 4alves /eactor internals Instrument cable /efueling e!uipment 1ement (an)s 5eat eAchangers 3ccumulators /eactor vessels %iping &tructural items /einforcing steel
< %rotection from airborne contamination < %rotection from physical damage
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(his module has covered the basics of receipt inspection and handling and storage re!uirements for instrumentation. (he performance of inspections of received items for carton or container damage 'ere covered as 'ell as the performance of inspectors of received items for physical damage and conformity to specifications. 5andling and storage re!uirements 'ere covered. to include the levels of storage.
/eceive. Inspect. 5andle. and &tore Instrumentation and 1omponent 6 Module 12307
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/eferences
8or more advanced study of topics covered in this (as) Module. the follo'ing 'or)s are suggested, 39&I &tandards 10 18/ #0
2.
3. ".
1$
c. d. #. $.
/emove and thro' a'ay any desiccant materials. Inspect the out'ard appearance of the item.
(he specifications of the received instrument are compared to the DDDDDDDDDDDDDDDDDDDD. Most instrumentation should be stored in 'hat level of storageF a. -evel 3. b. -evel 7. c. -evel 1. d. -evel .
2.
3.
/eceive. Inspect. 5andle. and &tore Instrumentation and 1omponent 6 Module 12307
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