Site Quality Manual

SITE QUALITY MANUAL

EFFECTIVE DATE: REVISION NO.

DESCRIPTION

APPROVALS (Signature)

Site Quality Manager

0

Issued for Construction

Construction Engineering Manger Site Manager Client Approval

DATE

PRACTICES

SITE QUALITY MANUAL

This manual is the property of FLUOR and is loaned to

_________________________________________ It shall be returned to the Construction Technology Group on request.

The contents of this manual are confidential, and shall not be reproduced, destroyed, loaned nor given away without specific written permission.

Project Name: Contract No.: Project Location:

000 509 0000 20 Sep 04 Page 1 of 2

TABLE OF CONTENTS / DATE REVISION PAGE

Administrative Procedure No. 000 509 0000 000 509 0010 000 509 0020 000 509 0040 000 509 0050 000 509 0090 000 509 0110 000 509 0130 000 509 0140 000 509 0150 000 509 0160 000 509 0170 000 509 0180 000 509 0200 000 509 0210 000 509 0220 000 509 0230 000 509 0240 000 509 0250 000 509 5100 Inspection and Test Procedure No. 000 509 7000 000 509 7010 000 509 7020 000 509 7030 000 509 7040 000 509 7050 000 509 7060 000 509 7070 000 509 7080 000 509 7090 000 509 7100 000 509 7200 000 509 7300 000 509 7310 000 509 7320

Title Table of Contents / Date Revision Page Foreword Manual Preparation and Maintenance Organization and Responsibilities Document Control Process Control Inspection, Measuring and Test Equipment Control of Nonconformances Corrective Action Preventive Action Quality Records Quality Audits Personnel Training and Qualification Site Subcontractor Qualification Contractor Quality Requirements Surveillance of Construction Activities Field Receiving Inspection Turnover Material & Equipment Storage & Maintenance Activity Plan for Construction

Title Inspection and Testing Soils Bituminous Concrete Paving Pilling - Steel H - Piles Piling – Pre-Cast Concrete Piles Piling - Timber Piles Piling - Closed End Concrete Filled Pipe Piles Piling - Concrete Filled Thin Shell Pipe Piles Drilled Caissons Augered Cast-In-Place Piles Concrete and Grout Structural Steel Buildings Heating Ventilating and Air Conditioning Roofing Inspection

Fluor Corporation Company Confidential

Revision Date 20 Sep 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 20 Sep 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04

Revision Date 18 Feb04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04

Site Quality Manual


Inspection and Test Procedure No. 000 509 7400 000 509 7410 000 509 7420 000 509 7430 ITP 509 7440 ITP 509 7460 ITP 509 7470 000 509 7500 000 509 7510 000 509 7520 000 509 7550 000 509 7560 000 509 7570 000 509 7600 000 509 7610 000 509 7620 000 509 7640 000 509 7700 000 509 7710 000 509 7800 000 509 7810 000 509 7820 000 509 7830 000 509 7910 000 509 7920 000 509 7930 000 509 7950 000 509 F0000

000 509 0000 20 Sep 04 Page 2 of 2

Title Equipment Field Fabricated Tanks Cooling Tower Refractory Concrete Gas Turbine/Generator Steam Turbine/Generator Field Erected Stack Underground Piping Aboveground Piping Pressure Testing Hygienic Tubing Chemical Cleaning of Pipe Steam Tracing for Pipe and Equipment Electrical Inspection Electrical Testing Electrical Equipment Electrical Heat Tracing Control Systems Instrumentation Control System Calibration Coatings and Linings Insulation Fireproofing Inspection Cathodic Protection Welding Inspection Nondestructive Examination Positive Material Identification Hardness Testing Quality Control Forms

Revision Date 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 20 Sep 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 20 Sep 04

The Fluor Site Quality Program for this Project is described and documented in this Site Quality Manual.


Site Quality Manual


000 509 0010 18 Feb 04 Page 1 of 2

FOREWORD The objective of the site quality program for this project is to ensure that construction is performed in accordance with the drawings, specifications, applicable local, state and federal standards and Codes. A further objective is to provide documented evidence that confirms that the primary objective has been met. The site quality control program as delineated in this manual, is tailored to meet the quality surveillance, inspection, testing, and documentation requirements for construction/installation performed by subcontractors and Fluor self-perform construction. The site quality program is based upon the principals stated in the Operating System Requirements (OSR) and any applicable Operating System Implementation Plan (OSIP). It is designed to cover quality aspects related to construction, construction management and maintenance activities. The Site Quality Manager will coordinate the construction quality surveillance, inspection, testing, and documentation activities. He will monitor construction and quality activities to the extent necessary to provide construction management with adequate confidence that appropriate measures are being taken to control and achieve quality. The quality activity will emphasize preventing nonconformance to drawings and specifications but detecting and correcting it if it occurs. When Fluor performs construction activities using our own labor force, the quality control responsibility remains with Fluor. The Fluor construction supervision and construction engineering staffs are primarily responsible for the attainment of the quality requirements established by the drawings, specifications and contract. The supervisory, construction engineering and quality staffs will perform quality control inspection, testing, surveillance and documentation activities as outlined in this manual. The primary responsibility for performing quality workmanship rests with those actually performing the work under the supervision of the Fluor construction staff. When an element of construction is subcontracted, the quality control responsibilities governing the subcontractor's work are usually delegated to the subcontractor. The overall responsibility for verifying quality in construction remains with Fluor. This is done by surveillance and audits when the responsibility for quality activities has been delegated to the subcontractor. The subcontractors are to provide the measures required to achieve the contract quality requirements. The subcontractor's quality control responsibility is established by procedure 000 509 0210 and is stated in their contract. This site specific Quality Manual is the governing document for the Fluor quality system and will be maintained current to achieve project quality objectives. This Manual is not applicable to ASME Boiler and Pressure Vessel Code work. The Fluor "Quality Control System Manual for Boiler and Pressure Vessel Code Work" will be applied to ASME and National Board Inspection Code Work certified by Fluor.


Site Quality Manual


000 509 0010 18 Feb 04 Page 2 of 2

The Site Procedures Manual (SPM), used in conjunction with the Site Quality Manual, contain or identify approved procedures used to identify, document and verify the appropriate reviews and approvals of changes to design documents that are requested by field organizations and provide requirements for document control. The Fluor Construction Technology staff will conduct independent audits of project compliance to this manual. The audits are conducted to provide the Project Manager, Site Manager, and Client with a project independent evaluation of the site quality program status and adequacy. The initial audit will be conducted at approximately 10% mechanical completion and additional audits on a periodic basis throughout construction.


Site Quality Manual


000 509 0020 18 Feb 04 Page 1 of 2

MANUAL PREPARATION AND MAINTENANCE

SCOPE This procedure provides guidance for converting the 509 series of Corporate Site Quality procedures from Knowledge OnLine to a Site Quality Manual for a specific project. It is applicable to Construction, Construction Management, Maintenance, or projects with any of these combinations. GENERAL The initial draft of the project specific Site Quality Manual is initiated by Construction Technology's Corporate Quality Manager. It is to be based on reference procedures of the 509 series of Site Quality procedures from the Construction Knowledge Community that are listed in the Table of Contents section 000 509 0000. These reference procedures have been prepared to meet the requirements of International Standard ISO-9000. The bracket symbols ([::---::]) seen throughout these procedures identify changes or additions that are to be made in converting them to project specific procedures. Other changes are to be made as needed to be compatible with the project requirements and scope. The set of procedures in the 509 series represents the accumulated knowledge and experience gained from many construction projects. Use of these reference procedures as baseline documents will result in improved consistency between projects and entities, thus fulfilling the goal of consistency in execution. Proposed changes to these reference procedures should be communicated to Construction Technology's Corporate Quality Manager. Upon assignment of the Site Quality Manager, he/she begins development of the draft Site Quality Manual (SQM) to assure conformance to the site-specific requirements. The completed and approved project specific SQM should be in place for usage as soon after contract award as possible. As a minimum, parts of the manual should be developed for control of construction activities before the activities are performed. These activities usually begin with qualifying and issuing RFQ's to bidders for work to be subcontracted (see 000 509 0200 and 0210). If these activities begin prior to assignment of the Site Quality Manager, Construction Technology's Corporate of Quality Manager will function as the Site Quality Manager until the assignment is made Development of Site Specific Quality Manual Each section/procedure identified by 000 509 0000 is reviewed for consistency and applicability with project scope. Changes or additions will be required of the following sections as noted: -

Inspection and Test Procedures (7000 - 7999); Select the procedures that are applicable to the contracted work scope. Select the applicable forms from the procedures if all are not needed. Review the "Responsibilities" Section and modify, if needed, to suit the project organization. Also delete either the "Self-Perform" or "Subcontracted" Section, if not applicable.


Site Quality Manual


-

000 509 0020 18 Feb 04 Page 2 of 2

Table of Contents / Date Revision Page (0000); Under "Procedure Number" and "Title" change to include only those procedures used in the project manual. Under "Revision Date." enter the date, month and year for all initially approved procedures. Enter appropriate dates for each project revision it undergoes after initial project approval. Revision dates for all pages of all procedures in the project specific manual should match the dates in this Table of Contents. Revisions to the Site Quality Manual shall not waiver or negate OSR requirements or mandatory construction codes.

Revision of Site Specific Manual The Site Quality Manager controls the site issue and revision of the Site Specific Quality Manual. The manual is to be revised by procedure. A vertical line in the margin shall identify the revised portions. The revision status shall be shown on the Title page of the manual. The Table of Contents shall show the revision date of each revised procedure and shall be reissued for each revision. The Corporate Quality Control Manager in each of the respective offices shall review and approve the “Issued for Construction” Site Quality Manual prior to the approval signatures being obtained. Each subsequent revision to the Site Quality Manual shall also be approved by the Corporate Quality Control Manager. The Site Quality Manager, Construction Engineering Manager, and Site Manager should approve each revision by signing the Approval Page. The Client should also be given the opportunity for approval of the Site Quality Manual.


Site Quality Manual


000 509 0040 18 Feb 04 Page 1 of 2

ORGANIZATION AND RESPONSIBILITIES This section describes the site quality organization for performing activities described by this manual. It also provides a general description of responsibilities. Specific responsibilities are described in the individual procedures of this manual. The Site Manager is responsible for the execution of the project construction activities which includes construction quality. The delegation of authority to the Site Quality Manager for the direction and coordination of quality activities is made with the objective of maintaining the effectiveness of this quality program. The Site Manager shall provide adequate resources and assign sufficient trained personnel to manage the work and effectively carry out these verification activities, including internal quality audits. The personnel assigned to these verification activities shall be independent of those having direct responsibility for the work being performed. ORGANIZATION The project organization for site quality personnel are shown on the Site Organizational Chart maintained by the Site Manager. RESPONSIBILITIES [::The responsibilities shown are for Fluor personnel. Subcontractors should modify these descriptions to describe their personnel shown on the above organization chart.::] Quality related activities are conducted by Site Quality and other groups. The activities and persons conducting them will be under the functional control of the Site Quality Manager for the execution of the activity. Attachment 1- Quality Responsibility Matrix summarizes the activities and the persons responsible for execution. Primary responsibility for execution and verification of quality-related activities will be established on the Inspection/Test Plan or procedures.

Site Quality Manager The Site Quality Manager has the responsibility, authority, and organizational freedom to audit, inspect and witness construction activities and to verify compliance to contract quality requirements. This responsibility includes actions such as assist the construction staff in prevention of quality problems, identification of quality-related problems should they occur, initiation or recommendation of solutions and verification of corrective action. In addition, he/she is responsible for coordination of quality-related activities within the Construction staff and with the site Client quality representatives. He/she maintains the construction quality control procedures and provides technical assistance and training to construction supervision. He/she will have an active role in assisting with the prevention of quality problems. The Site Quality Manager reports directly to the Site Manager with a technical supervision channel to Construction Technology's Corporate Quality Manager.


Site Quality Manual


000 509 0040 18 Feb 04 Page 2 of 2

The Construction staff includes a Construction Engineering organization to ensure prompt engineering interpretations and decisions, review of drawings, certificates and other data to be submitted to the Client, and to actively participate in the surveillance of field construction, and to verify compliance to design/engineer requirements. Construction Engineering will provide assistance to the Site Quality Manager as necessary to assist in achieving quality objectives. NOTE:

Construction Engineers report to the Site Quality Manager when they are executing inspection/surveillance activities.

Subcontractors The subcontractor quality organization will be in accordance with the contract requirements and described in their approved equivalent Site Quality Manual. ATTACHMENTS Attachments 1 -

Quality Responsibility Matrix


Site Quality Manual


000 509 0040 18Feb04 Attachment 1 . . . 1 of 14

QUALITY RESPONSIBILITY MATRIX Section 1 - CIVIL 1.1 Construction Surveying ACTIVITY Review the construction surveying methods used by the Contractor. Check established reference points . Check control points established for construction layout on a periodic basis. Check the construction layout of the contractor's work. Review and file completed survey notes prepared by the contractor. Perform periodic surveillance on survey activities and documentation.

Construction X X

X

Construction

Qualifiy Pile Supplier Review and approve concrete mix design and mix trials Technically monitor the indicator pile testing program Check final pile locations. Monitor in-process pile driving. Monitor and test pile concreting activities.

PM=Procurement Manager MM=Material Manager X= Primary Responsibility S= Secondary Responsibility (1) Must obtain Engineering Approval

RESPONSIBILITY QA/QC

Client

X X S

X

X X

TEST LAB TEST LAB TEST LAB TEST LAB TEST LAB

1.3 Contracted Piling ACTIVITY

Client

X X X

1.2 Soils ACTIVITY Monitor in-process soils work, including cut and fill elevations, spoil and fill material, compaction methods and equipment. Perform formal audit of Soils Testing Laboratory Monitor Contractor's work to verify conformance to requirements. Monitor Soil Testing Laboratory activities for soils testing frequency, test identification and completeness. Verify the documentation of deficiencies and test failure and follow up to assure corrective action is taken and documented. Audit the soils documentation to verify correctness, completeness of coverage, retrievability as filed and inspection results. Perform and document soils testing Inspect excavations for unstable and unsuitable soils Verify the insitu soils are suitable to support foundation loads Verify backfill material is satisfactory Verify placement of the fill complies with contract specifications


X S S S S S

RESPONSIBILITY QA/QC X (1)

Construction X X X X

S S X

Client



1.4 Asphalt ACTIVITY

Construction

Review asphalt mix designs Monitor in-process asphalt construction including preparation of subgrade or previous course, asphaltic materials, spreading equipment, compaction equipment, materials and testing. Perform formal audit using Asphalt Test Laboratory Evaluation Record Monitor Contractor's quality control activities to verify conformance to requirements for asphalt testing frequency, test identification and traceability and the documentation of inspection and testing Review the documentation of the asphalt inspection and testing activities for accuracy and completeness. Verify the documentation of deficiencies and test failures and follow up to assure corrective action is taken and documented. Audit the asphalt documentation to verify correctness, completeness of coverage, review ability as filed and inspection results. Conduct asphalt testing and asphalt materials testing

X

1.5 Structural Concrete ACTIVITY Review and approve mix designs Perform formal audit of Concrete Testing Laboratory. Audit batch plant facilities. Inspect formwork, reinforcing steel and impediments prior to concrete placement. Monitor in process concreting activities. Monitor Contractor's quality control activities to verify conformance to requirements for concrete testing frequency, test identification and traceability, and the documentation of inspection and testing. Monitor post-concreting activities such as concrete curing, stripping,


Client

(1)

X

S X

X X X

TEST LAB

X S

RESPONSIBILITY Construction QA/QC X (1) S X X X X

Client

S S

X

visual examination for line, form and surface defects and checks for anchor bolt locations. Verify that 28-day strength tests are acceptable. Conduct concrete testing at the point of placement

X TEST LAB

S S

RESPONSIBILITY 1.6 Grouting of Machinery and Structural Steel Base Plates Construction ACTIVITY QA/QC Review and approve mix design. Check materials prior to start of work to verify that the materials have not deteriorated or that shelf life has not X (1) S been exceeded. Monitor in-process grouting. The inspections shall include base X S preparation,materials, forming, placing, curing and hammer void test. X Witness grout testing by Contractor. Monitor the Contractor's quality control activities to verify conformance to X l t d dd t ti i t


Client



Section 2 - STRUCTURAL STEEL

Construction


X

S

X X X

S

X

S

2.1 Structural Steel ACTIVITY Monitor in process steel erection to verify fabrication is correct and erection is in accordance with drawings. Document fabrication errors on a NCR. Witness bolting procedure including calibration of torque wrenches and load indicating washers. Maintain documentation Inspect the erected steel structure. Ensure that erected steel structures have coatings installed i.a.w. drawings Monitor the Contractor's quality activities to verify conformance to requirements for bolt tensioning procedures. Schedule final acceptance inspection activities between Contractor and Field Engineering or construction. Audit the structural steel documentation to verify correctness of data.

Client

X X

S X

Section 3 - BUILDINGS 3.1 Buildings ACTIVITY Review all Contractor proposed building materials prior to use. Verify that the building location level and position are correct prior to construction. Inspect the entire builiding upon completion and document deficiencies. Document building acceptance Monitor the in process construction to verify that the work is i.a.w. drawings. Schedule final acceptance activities Monitor the Contractor's quality control activities to verify test frequency, identification and traceability Audit building documentation


Construction X (1)


X X X

S

X X

S S X X

Client



Section 4 - EQUIPMENT 4.1 Equipment ACTIVITY Inspect installed equipment for acceptance upon completion, including attachments to the equipment, e.g. foundations, sheds, buildings, auxiliaries, etc. which comprise the entire assembled unit. Initiate action to acquire vendor representative as required. Coordinate with engineering for participation of mechanical discipline engineers, if required. Monitor the in-process installation of each equipment unit. Coordinate with vendor representative who technically supervises equipment installation. Verify vendor representative's checklists and acceptance records are signed and attached to appropriate construction documents. Verify the equipment requirements are being satisfied by the Contractor.

Construction

PM X

S

X X

S

X

S X X

4.2 Field Fabricated Tanks


Client

X PM

Monitor equipment preservation i.a.w. Section 11. Monitor the Contractor's quality control activities to verify conformance to inspection, testing and documentation requirements.

ACTIVITY Monitor the foundation construction including soils, asphalt and concrete work. Check elevation dimensions of tank shells. Check the erected dimensions of tank shells. Inspect fabricated tank structure upon completion. Check the settlement and rebound of the foundation during and after hydrotest. Verify welder performance qualifications. Verify welding procedure testing has been accomplished and procedures are acceptable. Monitor in-process welding Witness in-process examination as performed by the NDE contractor, including reviewing radiographs, witnessing PT, MT, vacuum box and leak testing Verify that equipment and components associated with tankage have been correctly installed, adjusted, tested, confirmed for proper function and inspected. Inspect the tested tank prior to closing, including final clean-up. Verify that the Contractor has affixed a nameplate listing the required data. Verify that the Contractor has submitted the required certification. Monitor the Contractor's quality control activities to verify conformance i ti t ti dd t ti i t


Construction


X X X X

S

X S

S X

X

X S

S S

X

X X

S S

X X

S S X

Client


000 509 0040 18Feb04 Attachment 1 . . . 5 of 14 Section 5 - PIPING

5.1 Underground Piping ACTIVITY Monitor in-process excavation and backfill. Inspect installed underground pipelines for acceptance. Color code the lines, indicated as punched and accepted, on a copy of the underground piping plan. Verify that the Testing Lab is performing the required soils testing of backfill. Monitor in-process coating and wrapping, including surface preparation, coating and wrapping methods and materials and arrangement for intermediate storage and stockpiling of coasted pipes. Inspect in-process pipe fabrication and installation I.a.w. drawings. Perform a final inspection of the line, when the underground piping is complete, but prior to the coating and wrapping of joints and fittings. Verify the Contractor has completed coating and wrapping of joints and fittings on tested line. Witness holiday testing of the coating and wrapping. Contractor shall document tests. Verify that required NDE is complete on the lines to be inspected. Witness the pressure test. Inspect the tested system to ensure that all items have been properly completed (restoration). Monitor the Contractor's quality control activities to verify conformance to testing and documentation requirements.

RESPONSIBILITY Construction X X


Client

X X

S

X X

S S

X

S

X

S

X S

S X X

X

S X

5.2 Site Shop Fabrication ACTIVITY Segregate and store pipe fittings, upon receipt, according to size and material. Identify storage location with commodity code number. Pipe will be marked full length with commodity code number. Maintain documentation Issue piping materials to Contractors Inspect special flange faces for correct finish and face protection. Monitor in-process pipe fabrication activities. Verify latest edition of piping drawings is being used. Random check on base material ID on pipe, fittings and spools. Spools shall be clearly identified in two locations. Monitor storage of completed spools at pipe shop including preservations. Monitor pipe identification, documentation and timely performance of NDE.

QA/QC S S

Construction


MM MM MM MM X X X

S S S

X

S

X

S X

Client



RESPONSIBILITY 5.3 Aboveground Piping Erection Construction ACTIVITY QA/QC Pipe will be marked full length with commodity code number. Alloy pipe and fittings shall be additionally color coded. Alloy storage areas shall be MM clearly identified. Maintain piping spool identity markings of piping spools fabricated off site. MM Verify MTR's are received and that heat numbers correspond. Maintain MM documentation MM S Verify PMI requirements are satisfied prior to placement in stock. MM Verify correct pipe is issued to Contractor. Monitor in-process erection I.a.w. drawings. Classify and record spool fit X S problems. X S Ensure face flange protection is maintained. X S Monitor proper bolt tensioning. X S Monitor correct gasket installed. Monitor erection to ensure that pipe installations are not subjected to X S undesirable stress. X S Check pipe drawings to assure latest revision in the field. S X Assist Contractor to maintain current piping test status. X Monitor Contractor's activities to established quality control practices. Monitor in process pipe erection and transfer of heat numbers. Verify that NDE is performed in a timely manner. Monitor pipe and welding X traceability including PWHT, PMI and Hardness Testing.

RESPONSIBILITY 5.4 Piping Inspection - Punching Construction ACTIVITY QA/QC X Flag deficiencies when not visually obvious. X Enter punch lists into data base. Check work, noted as complete, on punch lists to assure items were X corrected. Initiate action with Contractor on punching results. Add additional discrepancies to punch list. Initial and date punch list for each item X corrected. X Monitor the Contractor's punching activities. Verify that punching deficiencies are identified, documented and follow up X to verify corrective action is taken. Verify that measures are taken to assure NDE, PWHT, PMI and X traceability is completed prior to pressure testing.


Client

Client



RESPONSIBILITY 5.5 Pressure Testing of Piping Construction ACTIVITY QA/QC X S Monitor pressure testing performed by Contractor. Review drawings and specifications to verify pressure test package limits, equipment to be included or excluded, valves opened or closed and test X S blind locations. Verify that the maximum allowable test pressure of the weakest X S component within the system is not exceeded. S X Verify (through NEWS) that all NDE is complete prior to testing. Verify that shop spool/cut sheets are included in test packages and all S X NDE, PWHT and welder info is recorded. Review Contractor's pressure test package, including marked up isometric drawings indicating test blind locations, valve position X S (open/closed) and other information relating to test. X Monitor preparation of test system against test package. X Monitor restoration of the tested system. S X Monitor Contractor's pressure testing and documentation activities. S X Review test package for completion Inspect the system prior to testing notifying Contractor of deficiencies. Mark Pressure Test Record, "Ready to Test". Notify client when X S acceptable for test. Give permission to proceed with test. Inspect system under pressure. Verify test pressure and duration of test. S X Procure test acceptance signatures from Contractor and QIB. When equipment is included in the test, verify that pressure test does not X S exceed nameplate.

5.6 Piping Internal Cleaning ACTIVITY Review and approve the cleaning and preservation procedures and the limits agree with drawings. Establish hold points for witnessing tests. Monitor preparatory and in-process cleaning activities for compliance with procedures and specs. Coordinate the monitoring of Contractor inspection and testing activities. Verify the Contractor is preparing documentation as inspections and tests are being performed. Verify that internal cleaning has been accomplished. Monitor the Contractor's quality control activities.


Construction


X X X

S

X

S

X X

S X

Client

Client


000 509 0040 18Feb04 Attachment 1 . . . 8 of 14 Section 6 - ELECTRICAL

6.1 Underground Electrical ACTIVITY Monitor in-process installation of the grounding system including, grounding rod installation, backfilling. Color coding of drawings to track progress. Witness resistance to earth tests. Monitor in-process duct bank and electrical manhole installations. Witness initial testing of shielded cable, ie, insulation resistance test of power cable on reels, continuity test of reeled instrument cable. Inspect cable trench prior to installation of cable. Monitor in-process installation of underground cable. Inspect in-process cable pulling. Inspect in-process cable splicing. Witness random testing of installed underground cable, I.e. insulation resistance test (megger) cables and DC hypot medium and high voltage cables prior to termination. Inspect installation of cables upon completion of each layer to ensure spacing, labeling, etc. is correct. Inspect sand backfill per lift for quality of materials, depth and compaction. Verify the Contractor final as-built drawings are in conformance. Verify that the Contractor is preparing documentation concurrent with construction as inspection and testing are performed. Monitor the Contractors' quality control activities.

Construction


X X X

S S

X X

S

X X

S S

X

S

X

S

X X

S S

X

S X

6.2 Aboveground Electrical Construction ACTIVITY Monitor in-process installation of electrical conduit and cable tray, X including welding of supports. Witness initial testing of shielded cable, ie, insulation resistance test of power cable on reels, continuity test of reeled instrument cable and X resistance and continuity on electrical heat tracing cables. X Monitor in-process cable pulling and installation. Witness random testing of installed cable, ie, insulation resistance test on


S

power and instrumentation cables, continuity and insulation resistance testing on heat tracing and hypot of medium and high voltage cables. Verify client is being notified in advance of tests that require witness. Verify terminal to terminal checks to ensure continuity and correctness of installation. Verify conduit seals have been poured. Inspect installation upon completion. V if th t th C t t i i d t ti t ith


X X

S S

X X X

S S S

Client

Client



6.3 Electrical Equipment ACTIVITY Monitor in-process installation of equipment. Monitor equipment preservation activities Witness testing of installed equipment. Coordinate with vendor representative who will technically supervise installation. Ensure documentation is complete. Verify QIB is being notified in advance of tests requiring witnessing. Inspect electrical installation when complete. Verify that the Contractor is preparing documentation concurrent with construction as inspection and testing are performed. Monitor the Contractor's quality control activities.

Construction X X X

RESPONSIBILITY QA/QC S S S

X X X

S S S

X

S X

Client

Section 7-CONTROL SYSTEMS 7.1 Control Systems Site Shop Operations ACTIVITY Notify construction upon receipt of each instrument shipment for inspection. For nonconforming items, issue a Damage Report or NCR. Issue instruments to Contractor. Inspect each instrument shipment. Deficiencies shall be reported to the Material Manager. Inspect instrument materials i.a.w.sec.10 & project procedures Document the receiving inspection.

7.2 Control Systems Field Operations ACTIVITY Monitor the Contractor's in-process instrument installation including racks, panels, consoles, locations,mounting,process pipe connections, Instrument air tubing,pneumatic signal tubing,heat tracing and instrument wiring Witness pressure testing of the instrument piping and tubing documentation. Witness calibration of test guages. Monitor continuity tests of instrument cables.Verify that cable terminations are correct. Witness checks of control system loops. Establish notification system for IMT. Witness all loop checks Assure all instrument installation inspections and meggar tests are complete Inspect instrument installations upon completion. M it th C t t ' lit t l ti iti



Client

Construction


Client

X

S

X X

S S

X

S

X X

S S

X X S

S S X

Construction MM MM MM X X X



Section 8 - COATINGS, LININGS, INSULATION AND CATHODIC PROTECTION 8.1 Coatings Construction X X X X X X S S

ACTIVITY Ensure that the paint system is i.a.w. specifications. Monitor performance of materials preservation activities. Monitor surface preparation.Verify inspection documentation. Monitor in-process coatings applications. Check dry film thickness of applied coatings. Inspect the workmanship of completed finishes. Monitor the Contractor's quality control activities. Verify the Contractor has prepared the QC documentation. Audit coating documentation.

8.2 Insulation Construction X X X X S

ACTIVITY Monitor performance of material preservation activities. Monitor in-process installation of the insulation materials. Verify the Contractor has prepared the quality control documentation Inspect the completed work. Document acceptance.

test certificates correspond with filed batch number records. Monitor storage facilities. Ensure refractory applicators are experienced and qualified. Monitor to ensure materials are properly mixed. M it f ti t ti t d d i f


t


Client

Client

S S S X

Construction X X

RESPONSIBILITY QA/QC S S

X X

S S

X X X X S

S S S S X X

X X X X

S

8.3 Linings ACTIVITY Monitor performance of material preservation activities. Monitor surface preparation. Verify Contractor is performing temperature and humidity checks for tank linings. Monitor in-process lining application. Test applied linings to verify proper surface profile, thickness, and lining continuity. Monitor Contractor's tank lining holiday inspections. Observe tank lining curing activities. Inspect the workmanship of the completed lining. Monitor the Contractor's quality control activities. Audit coating documentation. Verify that lining materials comply with specs. Ensure that manufacture

RESPONSIBILITY QA/QC S S S S S S X X X

S S

Client



8.4 Cathodic Protection - Underground Structures. ACTIVITY Submit data to Engineering for determination of anode spacing Establish a procedure to assure work is not started prior to acceptance of previous work. Monitor the survey after each cathodic protection system is energized. Verify materials being installed. Monitor installation activities. Monitor deep well preparation activities including data logs. Monitor anode backfill operation. Witness hammer testing of thermite welds Witness electrical test used to determine current flow when the anode is backfilled with coke breeze. Monitor testing and commissioning activities. Inspect the completed work. Audit cathodic protection documentation.

8.5 Cathodic Protection - Tanks and Vessels ACTIVITY Verify materials are within specification and are properly protected from damage. Verify the vessel cathodic protection materials were installed. Monitor installation activities Verify personnel use of protective clothing (when reg's) Inspect the completed workmanship. Monitor testing and commissioning activities. Audit cathodic protection documentation.

Construction X (1) X X X X X X X X X X

Construction X X X X X X


Client

S S

S S S S X


Client

S S S X

Section 9 - WELDING RESPONSIBILITY Construction ACTIVITY QA/QC X (1) S Verify the WPS's have been approved by the Welding Engineer. X Monitor qualification tests of Contractor's welders. X S Ensure that welder ID badges have been issued and displayed. X S Check Contractors control of welder symbols. X S Check Contractor's control of welding consumables. Monitor in-process welding including consumables, joint preparation,fit-up X S preheat, interpass heat, WPS variables and final visual X S Verify Contractor is documenting welds on the Daily Welding Report. X S Verify completed welds are being documented on piping drawings. X S Monitor in-process post weld heart treatment. X Audit welding documentation. X S Verify transfer of piping material heat numbers. 9.1 Pipe Welding


Client

Project Name: Contract No.: Project Location: 9.2 Structural and Reinforcing Steel Welding ACTIVITY Verify the WPS's have been approved by the Welding Engineer. Monitor qualification tests of welders. Monitor in-process welding including consumables, joint preparation and final visual inspection. Audit welding documentation.


Construction

X

RESPONSIBILITY QA/QC X (1) X S X

RESPONSIBILITY 9.3 Piping Nondistinctive Examination (NDE) Construction ACTIVITY QA/QC X Pre-qualify NDE Contractor Verify that the NDE Contractor has established procedures that comply X with project specifications. S X Daily entry of weld data to NEWS program. X Establish and maintain NDE documentation files. X Review Contractor NDE personnel certifications. X Verify approval of NDE Contractor and procedures. Verify NDE Contractor's procedure to provide visual status of welds X requiring NDE. S X Select welds for examination DE CONTRACTO S Perform Nondestructive examinations X Review radiographic film, Contractor's interpretation and reports. X Verify code compliance for rejected welds. X Maintain a tickler file of rejected welds. Verify, through audit, welding and NDE records are traceable to the weld. X X Verify through NEWS that NDE is completed prior to pressure testing. X Audit the NDE lab Monitor the NDE Contractor's production to verify that welds are X examined within 48 hours of notification. X Verify all field welds are numbered and identified on drawings. Ensure that weld number and welder's symbols are low stress stamped X S or otherwise marked on pipe. S X Ensure that an accurate Daily Welding Report is maintained.


Client

Client



9.4 Pipe hardness Testing ACTIVITY Monitor the Contractor to verify weld identity system and compliance to specification. Establish confidence that tests are being preformed i.a.w. test equipment instructions. Verify the Contractor's compliance with hardness testing and documentation. Verify Contractor's procedure for visual identification of rejected welds. Maintain a PWHT tickler file for rejected welds. Verify hardness testing is complete prior to pressure testing. Witness tests required by the specifications as performed by Contractor.

Construction


Client

X X X X X X X

Schedule final acceptance inspection activities between the Contractor and the Field Engineer. Monitor the Contractor's quality control activities to verify conformance to requirements for test frequency, identification and traceability.

X X

Section 10 - Field Receiving 10.1 Field Receiving (IMT) ACTIVITY Control receiving operations including ID of item to purchase order, verification of quantity and size examination for shipping protection and damage, maintenance of inspection documentation. Issuance of periodic receiving reports to Construction Superintendents when technical assistance is required. Inspect received material/equipment, providing technical assistance, when requested.

Construction


MM MM S

X

RESPONSIBILITY 10.2 Field Receiving -Contractor Construction ACTIVITY QA/QC MM Receive all contractor purchased equipment and materials Review material test reports against received materials and maintain on MM S file MM Issue equipment and materials to the Contractor Inspect received material/equipment, providing technical assistance when X S requested Assure that the contractor performs the equipment and material protection as required by manufacturers instruction or specification X S requirements


Client

Client



10.3 Positive Material Identification (PMI) ACTIVITY Notify QA of receipt of material requiring PMI. Maintain PMI test results with receiving documentation. Verify receipt of PMI reports from suppliers and fabricators, Verify Contractor has established a system to maintain material ID through receiving, storage, issue, fabrication and election. Implement procedures for PMI. Monitor contractor's maintenance of piping material identification. Perform PMI as required by specification. Verify ID marking are accomplished per specification. Verify controls have been established to prevent the in advertent use of materials failing examination. Verify the filing, maintenance and retention of documentation. Assure that PMI equipment is calibrated.

Construction MM MM MM

X X S


Client

X X S X S X X X

Section 11 - EQUIPMENT AND MATERIAL PROTECTION 11.1 Equipment and Material Protection ACTIVITY Monitor equipment and material preservation in storage and document. 11.2 Equipment and Material Protection (Contractor) ACTIVITY Monitor Contractors in-process equipment and material protection/preservation activities. Check Contractors in-process equipment and material Audit the Contractor Material and equipment protection activities.

Construction MM

RESPONSIBILITY QA/QC S

Client

RESPONSIBILITY Construction QA/QC X X

S S X

Section 12 - Masterpiece Program 12.1 Masterpiece Program ACTIVITY Develop Masterpiece List Ensure Contractor is using correct materials, drawings and specifications Advise contractor when a Masterpiece is required Inspect Masterpiece prior to QA notification Request client's presence during inspection Document acceptance of the Masterpiece Notify client of accepted Masterpiece Maintain the Masterpiece log Maintain Masterpiece model as reference standard Monitor the Contractor's quality control activities to verify conformance to dwgs and specifications


Construction X X X X S S S X

RESPONSIBILITY QA/QC S S S S X X X X S X

Client


000 509 0050 18 Feb 04 Page 1 of 6

DOCUMENT CONTROL SCOPE This procedure describes the Document Control system to be used by site construction personnel. GENERAL Engineering Documents -

Design Engineering documents such as specifications and drawings that are issued to Construction are controlled and issued on site in accordance with this procedure. Construction Engineering maintains an up-to-date register of drawings and specifications. This procedure is designed to ensure that the latest drawings issued to construction, including shop drawings, specifications and instructions, as well as authorized changes thereto, are delivered to the proper locations and personnel responsible for performance of the work.

-

This procedure also provides for the prompt removal of obsolete documents from all points of issue or use.

-

The Construction Engineering staff reviews engineering documents for adequacy and completeness to perform the work and coordinates site needs for clarification with the designer. Subcontractors obtain clarification through the Fluor Construction Engineering Manager. Construction Engineering maintains drawings and specification control records, processes all design document changes, ensures proper authority for the changes, and prompt removal of obsolete documents from the field.

-

The Construction Engineering Manager is responsible for control of shop drawing submittals and certifications to include assuring that submittals are received and/or distributed.

-

The Construction Engineering Manager will maintain as-built marked-up drawings. These drawings will be maintained in a current condition. The as-built data will be submitted to Design Engineering in accordance with this procedure. Subcontractors will submit as-built information through the Fluor Construction Engineering Manager.

Request For Information -

When field conditions dictate changes to the design specifications and/or drawings, a Request For Information (RFI), Form 000 509 F0051, will be submitted for approval to ensure proper control and documentation. RFIs will be initiated by the Construction Engineering Manager who will maintain a RFI Log, Form 000 509 F0052. RFIs will be forwarded to the Design Engineer for approval and/or action. Subcontractor submittals will be sent to the Fluor Contracts Manager for submittal to the Fluor Construction Engineering Manager for evaluation and processing.


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000 509 0050 18 Feb 04 Page 2 of 6

-

The Construction Engineer shall describe the condition or design change requested in terms that can be easily understood by those who review it, including appropriate references, specific drawings and specifications to illustrate the recommended change.

-

To minimize delay in construction, authority for deviation from specifications and drawings may be acquired by direct communication with the Design Engineer and the Client pending processing of the RFI. A copy of the Record of Telephone Conversation will accompany the RFI transmitted to the Design Engineer and the Client. Approval of the Client’s construction site representative should be acquired, if possible.

-

The Design Engineer and the Client portion of the RFI indicate approval or disapproval of the field recommended change or recommends alternatives. The signed original will be returned to the Site Manager for disposition or authority to proceed.

-

The Construction Engineering Manager shall maintain a file that contains a full history of the action and data supporting the approval of each Request For Information.

Subcontractor Documents -

The subcontractors are responsible for procedures necessary to assure that all documents provided for construction are maintained to the most up-to-date revisions. Documents include procedures, letters, telexes, purchase requisitions, purchase orders, design drawings, specifications, reference drawings, vendor drawings, field sketches, test reports, etc. Documents affecting individual subcontractor's work are forwarded to the subcontractor by the Contracts Manager.

-

Subcontractor prepared field sketches and "as-built" drawings originating at the construction site shall be documented and controlled in accordance with the Request For Information (RFI) requirements described in this procedure.

Submittals - Field Contracts -

Submittals are reviewed under the direction of the Construction Engineering Manager. Subcontractor technical submittals are forwarded to Construction Engineering Manager. A submittals list shall be maintained reflecting the specification reference, description, date received, and the status of acceptance through Construction Engineering approval. The Project Quality Manager shall review submittals related to quality control requirements.

Material/Equipment Documents -

Documents related to materials, materials receiving and issue are controlled in accordance to procurement procedures.


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000 509 0050 18 Feb 04 Page 3 of 6

Quality Control Documents -

Documents and data identified as quality records are processed, retained and protected as described in 000 509 0160 "Quality Records". Primary responsibility for ensuring adequate control of quality related documents rests with the Site Quality Manager.

Procedure - Procedures issued by site personnel are controlled as described by this procedure. Vendor Documents - Vendor document supplied by Fluor Engineering Document Control to the Fluor Site Document Control for filing and distribution will be in accordance with the Project File Index and the Distribution Matrix System. PROCEDURE - The Construction Engineering Manager shall establish a standard distribution for design documents drawings and specifications with the Client. - Document Control shall provide document inventory control and receipt, and distribution accountability. This is accomplished making distribution in accordance with the Distribution Matrix System. Distribution is by individual document holder. These documents will be stamped in red with the Site Document Control stamp indicating date received. The Site Document Control stamp will be used to identify drawings, ISO, Instrumentation Specification Data Sheets, specifications, etc. Distribution of manuals will be by name and numbered copy. - A document transmittal record will be utilized for the distribution and issue of all controlled documents. The document recipient must sign the transmittal record and return it to Document Control within 10 days of issue. - Document recipients shall be responsible for control of documents upon receipt. Document Control will periodically (minimum quarterly) audit document recipients to ensure proper documents are available for use and that superseded documents have been removed from the field. Should a superseded document be required to be retained for inspection or historical data, the document will be identified as "VOID" or "SUPERSEDED" to prevent inadvertent use of the document for fabrication/installation activities.


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000 509 0050 18 Feb 04 Page 4 of 6

RECEIPT AND DISTRIBUTION OF DOCUMENTS Construction Engineering Manager - Establish document control log system for receipt of documents and provided standard distribution as indicated on the Distribution Matrix System. Document Control - Drawings (design, vendor and field sketch), specifications - Review receipt transmittal and enter date received in the Electronic Tracking System. - Review distribution list and reproduce copies as required. - Prepare distribution transmittals and distribute documents accordingly. Document Control - Manuals - Based on input from Site Manager, determine distribution for each type manual. Maintain a "Master" manual in Document Control and reproduce copies as required. - Assign individuals numbered manuals, prepare distribution transmittals and distribute accordingly. Document Recipient - Sign transmittal acknowledging receipt of documents and return signed transmittal Document Control within 10 days. - Replace superseded documents as required with the new documents. Destroy or return the superseded documents (except for inspection or historical record) to Document Control. The document recipient is responsible for maintaining documents current. Document Control - Destroy returned superseded documents. REPRODUCTION AND ISSUE OF REQUESTED DOCUMENTS Requester - Fill out document request form and present to Document Control.


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000 509 0050 18 Feb 04 Page 5 of 6

Document Control - Reproduce documents requested and obtain receipt acknowledgement from requester upon issue. DOCUMENT AUDITS Construction Engineering Manager - Determine document audit plan and schedule audits. A minimum of 5% of documents issued to the document holder will be randomly selected for the audit sample. The number of document holders to be audited will be determined by the Construction Engineering Manager. Document Control - Using a printout or list of documents and current revisions, compare documents and revisions held by document holders and note any discrepancies. Notify the Construction Engineering Manager of major discrepancies. Construction Engineering Manager -

For major discrepancies identified by Document Control audits of documents, investigate and provide recommended resolution.

Revision Control of the Site Quality Manual -


-

Revision dates for all pages of all procedures in the manual should match the dates in the Table of Contents.

-

The Site Quality Manager, Construction Engineering Manager, Site Manager and the Client (optional) will approve each revision by signing the "Approval Page".

-

Forward the approved revision and affected documents to Document Control for maintenance and distribution to all manual holders.


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000 509 0050 18 Feb 04 Page 6 of 6

REFERENCES Quality Control Forms: 000 509 F00501 – Request For Information 000 509 F00502 - Request For Information Log ATTACHMENTS Attachment 1 – Request For Information (RFI) Form Instructions


Site Quality Manual


000 509 0050 18 Feb 04 Attachment 1 . . . Page 1 of 2

Request for Information (RFI) Form Instructions Project Name:

The Project Name (i.e. Butanol)

Project #:

The Project Number (i.e. 00662255)

Date:

The date the Request is originated.

RFI #:

Unique number given to each individual RFI Form.

WBS:

Work Breakdown Structure unique to the Project, if applicable

Work Package No.:

Construction Work Package number, if applicable.

Turnover/Startup System No.:

Turnover/Startup system number, if applicable.

Discipline:

Primary discipline affected by the Request (Civil, Structural, Piping etc.)

Request To:

Enter Name of Individual submitted to (John Doe)

Company/Location

Enter Name of Company and its location of the requested organization (Fluor-Greenville)

Phone Number/Email

Enter phone number of the individual submitted to and/or email address

Subject

Enter the subject of the request

Specifications/Documents:

List all issued drawings, documents, and specifications impacted by the request.

Questions/Description/Conflict: Detail the missing information, discrepancies, questions or conflicts that must be resolved prior to construction activities continuing in the affected areas. Attach additional sheets, drawings, or sketches, if further explanation is required. Recommended Solution:

Indicate the action that the requestor believes is required to provide an acceptable solution to resolve the discrepancies and conflicts indicated on the request. Additional sheets, sketches, digital photos or drawings may be attached to provide a clear explanation of the intended resolution.

Originatated By:

The person originating the request and provided recommended action.

Title:

List the current position of the originator on the project.

Date:

The date the request is submitted for approval.

Originator’s Company Name

List Company name of the originator

Approval For Originator By

List name of Fluor person approving the request for submission to the Engineer of Record (Generally, the Fluor Site Engineering Manager will receive the request and approve it’s submission to the Design Engineer.)

Title:

List the current position of the approver.

Date:

The date the request is approved for submission



Date Reply Required:

Enter the date in which the resolution of the request must be made in order not to delay the activities in question

Response

The respondent’s resolution (generally the Design Engineer, Project Engineering Manager, CM, or Fluor’s Construction Engineering Manager) to the question, information, discrepancy, or conflict.

Respondent:

The signature of the person making the response. (Lead Construction Discipline Engineer, Construction Engineering Manager or Design Lead Discipline Engineer, etc.)

Title:

List the current position of the Approver on the project.

Date:

The date the request is approved for transmittal to the Design Engineer.

Approval for Respondent:

The signature of the person reviewing and approving the request prior to implementation. (This action might require Client approval. If the response changes the design (AFC Drawings or Specifications) the Engineer of Record must approve the resolution.)

Title:

List the current position of the Approver on the project.

Date:

The date the request is approved for implementation by the Client or Project Engineering Manager or designee.

Adequate Closure?

Indicate using the checkbox if the RFI response is acceptable for closure of the RFI. Generally, the Construction Engineering Manage must respond to this question.

Cost Impact?

Indicate using the checkbox if the RFI response has a cost impact that will require an estimate or a request for contractor pricing. If the answer is yes, indicate the requirement for a SI to be issued to the Contractor.

Schedule Impact?

Indicate using the checkbox if the RFI response has a schedule impact that will require an adjustment in the contract schedule or a request for contractor pricing. If the answer is yes, indicate the requirement for a SI to be issued to the Contractor

Closed RFI and Date Verified:

Inter the name and date the RFI was closed and verified.

Distribution:

List all parties requiring a copy of the completed request once the response has been received.


000 509 0090 18 Feb 04 Page 1 of 2

PROCESS CONTROL

SCOPE This procedure identifies construction work processes that require process control. GENERAL For most site production activities, the drawings and specifications provide adequate work instruction. These may be supplemented with additional instructions to control work sequencing, recording of installation data, material selection, etc. However, certain construction work processes require special instructions to establish the controls necessary to achieve acceptable quality, of the completed work, for the following reasons: •

Quality results of the completed work cannot be fully verified by subsequent inspection and/or testing.

•

Quality deficiencies may only become apparent after the item has entered service or operation.

Special Processes "Special processes" are highly dependent on the control of process parameters or the skill of the operator or both and are characterized by the need for one or more of the following control measures. • • • •

Written Method Statement or Procedure Procedure Qualification Operator Qualification In-Process Inspection

Special processes encountered on sites include, but may not be limited to: • • • •

Welding and Post Weld Heat Treatment Welder Qualification Nondestructive Examination (including radiography, magnetic particle, liquid penetrant, ultrasonic, and positive material identification – VT, RT, MT, PT, UT, and PMI) Other processes needing procedural control. These are: [:.Insert list site specific special processes as identified here.:] Must be developed for site application.

Special processes identified must be accomplished and documented under controlled conditions by appropriately qualified personnel using approved procedures and equipment in accordance with the governing specifications and the associated referenced codes and standards.


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000 509 0090 18 Feb 04 Page 2 of 2

PROCEDURE Site Quality Manager The Site Quality Manager shall coordinate with the Construction Engineering Manager, to research the project contract work scope and specifications in order to identify the special processes that will be utilized. If the processes are to be contracted, ensure that the required control mechanisms, i.e. procedures, qualifications, etc. are specified in the RFP and implemented before the start of work. Process control measures and responsibilities shall be identified on the applicable procedures or ITPs.


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000 509 0110 18 Feb 04 Page 1 of 4

INSPECTION, MEASURING AND TESTING EQUIPMENT

SCOPE This procedure describes the methods to be used for the control, calibration, maintenance and recall of inspection, measuring and test equipment (IMTE) used to demonstrate conformance of construction work activities to the specified requirements. It is not applicable to calibration of permanent plant devices. GENERAL Inspection, measuring and test equipment (IMTE), including test software, shall be selected, calibrated and controlled in a manner which is consistent with the required inspection, testing and examination requirements. Environmental conditions shall be suitable for the calibrations, inspections, measurements and tests being carried out. All IMTE shall be uniquely identified. This unique identification may consist of a manufacturer's unique serial number along with model number and/or the assignment and application of a unique Inventory Control Number (ICN). The handling, preservation, and storage of inspection, measuring and test equipment shall be such that the accuracy and fitness for use is maintained. All calibrations shall be performed using certified equipment having a known valid relationship to nationally recognized standards; where no such standards exist, the basis used for calibration shall be documented. "Conformance check" means the operations required to ensure that an item of measuring equipment is in a state of compliance with requirements for its intended use. Non-adjustable measuring and test equipment is not considered as calibrated equipment. Equipment of this nature (e.g. cube and proctor molds, measuring tapes, rulers, chains) is subject to a "conformance check" to dimensional, volumetric or other requirements and does not require any further verification unless apparent damage or other factors require reverification. It is the responsibility of the end-user to comply with the requirements of this section. IMTE shall be selected utilizing Attachment I "Criteria for the Selection of Inspection, Measuring and Testing Equipment" and Attachment II shall be used for guidance in procurement of calibration equipment and/or services. All IMTE calibration requirements shall be identified, on Attachment – 3 IM & TE Calibration Requirements List. This attachment is used to list the various types of IMTE in use and their


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000 509 0110 18 Feb 04 Page 2 of 4

associated calibration frequencies, calibration procedures and tolerances. Calibration procedures, frequencies, and tolerances may be obtained in conjunction with obtaining the services of an outside calibration vendor or from manufacturers. A procedure number shall be assigned. If the manufacturer has an assigned number, this should be used. Calibration procedures are quality records and shall be maintained in site files. Procedures such as published standards, practices (e.g., ASTM) or written calibration instructions from the manufacturer may be used. In the absence of either a published standards practice or an adequate manufacturer's procedure, a written procedure for the calibration method shall be written and approved for use. In addition to the above, calibration procedures should include at least the following basic information: •

Identity of the item to be calibrated using the procedure.

•

Calibration comparison standards and calibration support equipment to be used.

•

Provisions to obtain and record "as-found" accuracy measurement prior to any adjustments.

•

Sequence of operations.

•

Checks, tests and measurements instructions.

•

Calibration acceptance tolerances.

•

Calibration adjustment instructions.

•

Safety considerations.

•

Special instructions (when applicable).

•

Documentation and labeling instructions related to the specific item to be calibrated.

Perform and record (Form 000 509 F01104) the calibration in accordance with the above established calibration procedures and/or contract the services of an outside calibration services vendor. Upon completion of initial calibration, enter the equipment in the Calibration Assignment Log (Form 000 509 F01101) and record other data required by this log.


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000 509 0110 18 Feb 04 Page 3 of 4

History of Use The end user shall maintain a history of use for IMTE to enable an assessment of the validity of previous calibrations, inspections, measurements and test results when calibration as-found data reveals out-of-tolerance data points. The history shall be documented using IMTE Sign In/Out-History of Use Log (Form 000 509 F01102) and keep current to record each usage of the IMTE. If out of tolerance conditions are found, a Nonconformance Report shall be prepared in accordance with 000 509 0130. If out-of-tolerance conditions are found during recalibrations an evaluation shall be conducted to determine if inspection, measurement, test or calibration results obtained with the out-of-tolerance instrument are still valid. Evaluations shall be documented, and where required, repetitions of readings shall be compared to original results. It is the responsibility of the end user to use calibrated equipment within the environmental operating range(s) or restrictions/limitations specified by the instrument manufacturer. NOTE: Temperature or other compensating calculations shall be applied to any inspection, measurement, test or calibration results when such compensations are specified by the instrument manufacturer and/or when they can affect the basis of the results obtained. Upon satisfactory completion of calibrations, and after the recalibration due date has been determined (calculated), the end user shall make entries on the "Calibrations Tickler File" (Form 000 509 F01103) to aid in the tracking and recall of items for scheduled recalibration. DOCUMENTATION Electronic recording of the information that is required by the documentation in this procedure is permissible. All documents (except labels) generated in accordance with this procedure should be maintained in appropriate protected files throughout the construction phase of the project, and for the period of time there after specified (if any) or turned over to the Client if required.


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000 509 0110 18 Feb 04 Page 4 of 4

FORMS Quality Support Forms: 000 509 F01101 000 509 F01102 000 509 F01103 000 509 F01104

-

Calibration Assignment Log and Record IMTE Sign In/Out-History of Use Log Calibration Tickler File Calibration Data Sheet

ATTACHMENTS Attachment 1 -

Criteria for the Selection of Inspection, Measuring and Test Equipment (IMTE)

Attachment 2 -

Criteria for Procuring Calibration Services

Attachment 3 -

IM & TE Calibration Requirements List


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000 509 0110 18 Feb 04 Attachment 1. . . Page 1 of 1

CRITERIA FOR THE SELECTION OF INSPECTION, MEASURING AND TESTING EQUIPMENT (IMTE)

1.

IMTE includes inspection, measurement and/or testing equipment used to determine final acceptance.

2.

IMTE shall have a manufacturer's stated accuracy (and precision, where applicable) that exceeds the construction installation inspection, measurement and/or testing tolerance(s).

3.

IMTE shall have the durability, stability and appropriate measurement ranges consistent with the intended use(s).

4.

Calibration standards that will be required for the initial and subsequent recalibrations shall be identified when selecting IMTE. Such calibration standards shall be requisitioned or the services of a calibration facility with the calibration standards shall be contracted. NOTE: Obtaining calibration standards or services can usually require more time to procure than the time required to select and procure the needed IMTE.

5.

Purchase requisitions for IMTE, calibration standards, and calibration facility services should clearly state the requirements for accuracy, precision (where applicable), range, durability and/or stability, environmental, handling, other applicable technical requirements.



CRITERIA FOR PROCURING CALIBRATION SERVICES The following are recommended guidelines for preparing a purchase order for obtaining the services of a calibration supplier to calibrate Inspection, Measuring and Test Equipment (IM&TE). 1. The following information should be provided to the supplier: a) b) c) d)

description and unique identification of each piece of IM&TE; assigned calibration interval; calibration accuracy required; any relevant environmental requirements of use or calibration.

2. The calibration supplier must provide the following information as part of their calibration records: a) source of calibration equipment used and current certificate(s) of traceability to a recognized national standard; b) identification of the calibration procedure(s) used (if the procedure is produced by the calibration supplier, a copy must be furnished, if a recognizable standard i.e. ASTM, ANSI/ASME, is used no copy is needed). 3. The calibration records supplied by the calibration supplier for each item of IM&TE calibrated must include: a) item identification number; b) date of calibration; c) the records of the "before", "as received" or "as found" condition including actual values and the "as calibrated" or "as left" values; d) identification of the calibration procedure used; e) limits of permissible error; f) calibration standard used (including serial numbers and certificates) and traceability; g) details of any maintenance, servicing, adjustment, repairs or modifications carried out; h) identification of person performing the calibration; i) identification of person responsible for the correctness of the information provided. 4. The calibration supplier shall seal, using a unique, tamper-resistant system, all adjustment access points after calibration, where practical. The system used shall provide visual evidence of tampering. 5. The calibration supplier shall immediately notify the purchaser of any IM&TE discovered to be out of calibration by more than the stated accuracy tolerance or any piece of IM&TE that shows indication of tampering. The purchaser shall determine if the calibration process should continue. 6. The calibration supplier shall package and ship each piece of IM&TE in such a manner to preclude damage and to preserve the calibrated condition.



IM & TE CALIBRATION REQUIREMENTS LIST END USER Surveyor Surveyor Surveyor Surveyor Surveyor Mechanical Mechanical Electrical Electrical Electrical Millwrights Millwrights Millwrights Welding

DESCRIPTION Chain Level Transit Tape Distamat Pressure Gauges Torque Wrenches Meggars Simpson Mulit-Meter Digital Mulit-Meter Calipers Dial Indicators Micrometers Rod Oven Thermostat

FREQUENCY Initial Conformance 6 Months 6 Months Initial Conformance 6 Months Monthly Monthly 6 Months 6 Months 6 Months 3 Months 3 Months 3 Months 3 Months

PROCEDURE Visual*

Visual*

TOLERANCES ±1/8” (2) Per Procedure Per Procedure ±1/8” (2) Per Procedure ±5% (2) ±5% (2) ±3% (2) ±3% (2) ±3% (2) ±.02MM (2) ±.02MM (2) ±.02MM (2) ±5°F (2)

Notes: 1)

ALL WORN AND/OR DEFECTIVE MEASURING EQUIPMENT IS REMOVED FROM THE SYSTEM AND DISPOSED OF. RECORDS INDICATING REMOVAL/DISPOSAL DATE ARE MAINTAINED.

2)

THESE TOLERANCES ARE LISTED FOR SITUATIONS WHERE NO OTHER RECOMMENDED TOLERANCES ARE PROVIDED.


000 509 0130 18 Feb 04 Page 1 of 4

CONTROL OF NONCONFORMANCES

SCOPE This procedure describes the methods and responsibilities for controlling nonconforming items to prevent their inadvertent use or installation when other control methods, inspection reports, surveillance reports (000 509 0220), etc. are considered inadequate. This procedure provides for the identification, documentation, evaluation, disposition, notification, segregation (prevention of inadvertent use/installation), and reinspection of these nonconforming items (excluding ASME Code items). GENERAL Types of NCRs Nonconformances are classified as: Use as Is- Permission to use an item that does not conform to specified requirements. Rework- Action taken on a nonconforming item to make it conform to specified requirements. Repair-Action taken on a nonconforming item to make it acceptable for use. Items Requiring an NCR Nonconformance Reports are issued when there are: •

• •

Deficiencies in materials, finished work or work processes that result in a condition that does not conform to the specifications and for which there are no existing procedures or standard trade practices which describe methods of correction and therefore require engineering disposition. Deficiencies of a serious or repetitive nonconforming nature as determined by the Site Quality Manager Construction damage has occurred to existing or turned over plant property.

Nonconformances shall be documented using Form 000 509 F01301


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000 509 0130 18 Feb 04 Page 2 of 4

Responsibility for Identifying Nonconformances -

Fluor will issue Nonconformance Reports on self-perform work, when applicable.

-

The Construction Subcontractors have the first responsibility for the identification, control, and disposition of nonconforming items within their Scope of Work. Fluor will issue a Nonconformance Report when the Construction Subcontractor has not issued one. It is not necessary to have more than one Nonconformance Report active on the identical nonconforming condition.

-

Inspection personnel usually initiate Nonconformance Reports; however, anyone may initiate an NCR.

Control of Nonconforming Items -

The Construction Manager will take measures to provide holding areas or other methods for segregating nonconforming items to prevent unauthorized use, mixing with conforming items or incorporating into future construction. Where physical segregation is not practical, tagging, marking, or other positive means of identification is acceptable. The Site Quality Manager may elect to use "HOLD" tags/stickers (Form 000 509 F01303) for additional assurance.

PROCEDURE Documentation of Nonconformance -

For materials and equipment identified as nonconforming (per the descriptions in the "General" section of this procedure), generate a Nonconformance Report (Form 000 509 F01301) to document the nonconforming item(s). The report is to be processed as follows: Initiator •

Enter the date the nonconformance is documented.

•

Enter either Fluor, the name of the Subcontractor or Vendor to identify organization responsible for the nonconforming work.

•

Use the entries in the header of the form to provide unique traceability and identification to the nonconforming item.


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000 509 0130 18 Feb 04 Page 3 of 4

•

Enter a complete description of the nonconforming condition.

•

The initiator may propose a disposition, but it is not required.

•

Enter the root cause of the nonconforming condition. The initiator provides the NCR completed as noted above to the Site Quality Manager.

Site Quality Manager NOTE: Evaluate the report to determine that the described condition is a valid nonconformance. It is not necessary to have more than one Nonconformance Report active on the identical nonconforming condition. If a Construction Subcontractor has issued the NCR, it should not be duplicated by Fluor. •

Assign a unique number to the report and enter the number on the report and on the "Nonconformance Report Log" (Form 000 509 F01302).

•

If a hold tag is needed, enter the hold tag number and have the hold tag installed on the item. The hold tag number should be the same as the NCR number. If a hold tag is not to be used, enter NA. The Site Quality Manager provides the NCR completed as noted above to the Construction Engineering Manager. Also send a copy to the Fluor Shop Inspection Coordinator for nonconformances attributed to a vendor.

Construction Engineering Manager •

Evaluate the proposed disposition, modify if necessary, or enter the disposition.

•

If the nonconforming condition will not be corrected in full conformance with the applicable specification, the Project Design Engineer shall accept the disposition. In this case, check "yes" and obtain the Project Design Engineer approval. Any documentation provided by the Design Engineer that supports the disposition should be attached to the NCR original. For subcontractor NCR's, this approval is obtained through the Fluor Construction Engineering Manager.


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000 509 0130 18 Feb 04 Page 4 of 4

If the disposition corrects the nonconformance to full compliance with the applicable specification, check "no". •

After completing the disposition instructions and obtaining the required approvals, sign and date. Send the original NCR to the Site Quality Manager and copy to the Site Manager.

Site Manager Upon receipt of the approved NCR disposition, perform the applicable construction actions specified in the NCR disposition. (Request removal of QC hold tag prior to performing work, if one has been applied.) Site Quality Manager (or Inspector) NOTE: The Site Quality Manager of Fluor Subcontractors or subtier subcontractor initiating NCR's that require Project Design Engineer approval should send a copy of the approved NCR to the Fluor Site Quality Manager (prior to performing the actions specified in the NCR disposition, if possible). •

Upon verification of satisfactory completion of the disposition, sign and date.

•

Obtain other required approvals as required.

DOCUMENTATION The Site Quality Manager shall retain all NCR’s and the NCR log in the Quality Files. FORMS Quality Forms: 000 509 F01301 - Nonconformance Report 000 509 F01302 - Nonconformance Report Log 000 509 F01303 - Hold Tag/Sticker Attachment Attachment 1 Attachment 2

- Instruction for completion of Non-Conformance Report - Nonconformance Routing Chart


Site Quality Manual



INSTRUCTIONS FOR COMPLETION OF THE NON-CONFORMANCE REPORT ( NCR ) *

1

Description of Non-conformance: The initiator shall describe the requirements that were not met and a detailed description of the Non-conformance.

*

2

Root Cause: The underlying reason(s) for the occurrence of the reported nonconformity will be evaluated and the cause code(s) including and explanation will be stated. Cause Code C01 C02 C03 C04 C05 C06 C07 C08 C09 C10 C11 C99

Description Client Driven Communication Driven Equipment or Material External Phenomenon Location Driven Management Driven Procedure (except procedure not followed) Procedure/Work Process not followed People Driven Systems Driven Work Environment Other

NOTE: If codes 7 or 8 are used, list the procedure(s) identified as the root cause. *

3

Disposition Use-as-is Re-work Repair

Requires design Engineer and Client approval. Restore to original Specification, does not require Design Engineer or Client approved. Does not meet original specification, correct (repair) for “fit-for-use” Condition.

Provide instructions for implementation or justification of the selected disposition. IMPLEMENTATION Once implementation is satisfactorily implemented, sign the “Disposition Completed” block. *

4

Action verified and Non-Conformance Closed The Fluor inspector shall indicate the method used for verification of corrective action. Sign the signature block indicating acceptance of corrective action.

*

5

The Fluor Site Quality Manager shall review the NCR for completeness and acceptance of the corrective action.



NONCONFORMANCE ROUTING CHART

Nonconformance Discovered

Site Quality Manager Review/Confirms/ Signs

NCR Initiated

Lead Field Engineer Recommended Disposition/ Signature

Site Quality Manager Assigns Number

Site Quality Manager for Routing

Corrective Action: Corrective Action Approved

1) Remove/Replace Rework to Full Design Intent

Corrective Action

NOTE 1

2) Repair

Applicable Design Authority Review Disposition Approve or Disapprove NOTE 2

3) Use As Is

Reject

Execution of Corrective Action

Quality Manager Verifies

Accepts

Distribution: Quality Manager Distributes Closed NCR Note 1:

If corrective action is 2 or 3, distribution to be same as that shown when NCR closed. If corrective action is 1, exclude area EPCM from distribution until NCR is closed.

Note 2:

For NCR’s on Activities within Regulating Authority Scope, they need to Review/Accept

Quality Manager Closes NCR


000 509 0140 18 Feb 04 Page 1 of 3

CORRECTIVE ACTION SCOPE This procedure establishes the method of obtaining and documenting corrective actions for significant conditions which are adverse to quality, such as failure to properly implement procedures, programmatic failure due to inadequate procedures or failure to correct repetitive problems. The corrective action process involves:

Reviewing nonconformities Determining their cause Evaluating the action necessary to ensure that nonconformities do not recur Determining and implementing the action needed Recording the results of actions taken Reviewing corrective action taken

GENERAL Definitions Nonconformity – The non-fulfillment of specified requirements. Also referred to as a nonconformance. Correction – The correction (fixing) of a nonconforming item to make it acceptable. When correcting an item, consideration should be given to whether other work is also affected. Corrective Action – The action taken to eliminate the cause(s) of nonconformities. Corrective Action should be appropriate to the magnitude of the problem and commensurate with the risks encountered. Root Cause – Underlying reason(s) for occurrence of a nonconformity. A root cause is determined by through analysis, (e.g. asking the question “why?” until the underlying reason has been revealed). Responsible Person – The individual responsible for the group of system where a nonconformity is identified. They would be responsible for ensuring its timely correction. Significant Condition – operating system and/or procedural deficiencies evaluated by management (as to the magnitude of the problem and commensurate to the risks encountered) and judged to warrant a Corrective Action Report (CAR). The need for a Corrective Action Report is usually identified by the Site Quality Manager or inspection personnel; however, any one may identify the need for a CAR.


Site Quality Manual


000 509 0140 18 Feb 04 Page 2 of 3

PROCEDURE A nonconformity may be identified through activities such as internal audit, surveillance, management review, or external audit finding. A nonconformity is evaluated (based on severity) to determine the appropriate level of corrective action needed to prevent recurrence. Consideration is given to the impact of the nonconformity on project cost, schedule or quality issues. Not all nonconformities require root cause analysis and/or corrective action. It is acceptable for management to determine that only correction is necessary. Root cause analysis and corrective action are applied where the reward is greater than the effort. Corrective action is documented on the CAR (Corrective Action Report) form: 000 509 F01401 Coordination of CARs is the responsibility of the Site Quality Manager. The Site Quality Manager reviews identified nonconformities to determine if a CAR is appropriate. If so, Sections 1 and 2 of the CAR form are completed and the CAR is recorded on a status log (000 509 F01402). Equivalent forms and logs are permitted providing the essential elements of the example form and log are addressed. The CAR is transmitted to the Responsible Person for further action. The Responsible Person completes Section 3 and 4 of the CAR form (refer to Attachment 01 – Corrective Action Response Instructions) and returns it to the Site Quality Manager. Should it become necessary to void or cancel a CAR during the initiation cycle (upon discovery that no nonconformity actually exists, or a CAR covering this condition already exists), and explanation will be written on the original report. The report will be signed and dated by the responsible person and copies provided to appropriate distribution including the person who identified the deficiency/condition. The Site Quality Manager is responsible for ensuring that the nonconfromity has been corrected and that the corrective action taken to eliminate the cause of nonconformity is effective. The Site Quality Manger will also ensure completion of Section 5 of the CAR form and update the Status Log. A completed copy of the CAR form will be retained. In cases where an activity (that is the subject of CAR) occurs infrequently, or where root cause analysis is determined to be not necessary, the CAR may be closed following correction of the nonconformity without verifying effectiveness of the corrective action.


Site Quality Manual


000 509 0140 18 Feb 04 Page 3 of 3

DOCUMENTATION The Corrective Action Report and associated attachments shall be retained in the Quality Control Files by the Site Quality Manager. The status of open CAR’s will be reviewed with Site Management on a periodic basis to ensure timely close out of the CAR’s. REFERENCES Quality Control Forms: 000 509 F01401 000 509 F01402

-

Corrective Action Report Corrective Action Report Log

ATTACHMENT Attachment 1 -


Corrective Action Response Instructions

Site Quality Manual



CORRECTIVE ACTION Response Instructions Corrective Action Report (CAR) The Responsible Person is required to respond to each CAR within a target of 30 days after the issue of the CAR. Responses may be provided on the CAR form, or by other written means. Responses are required to address the following points: CAR Section 3 – Correction of Nonconformity Provide a detailed explanation of the action that will be taken to resolve the specific problem identified on the CAR. State when the action has been or will be completed. Identify other work affected and if additional actions or controls are needed. CAR Section 4 – Corrective Action Section In addition to correcting the nonconformity, the Responsible Person needs to assess it’s severity/impact to see if further analysis is warranted (i.e. determine the root cause and develop a plan to prevent recurrence). When evaluating the severity of the nonconformity consideration should be given to its impact on project cost, schedule or quality issues (e.g. resulting in excessive rework). This decision is indicated by marking yes or no in section 4 or the CAR. Root Cause: The underlying reason(s) for the occurrence of the reported nonconformity will be evaluated and the cause code(s) including an explanation will be stated. Cause Code C01 C02 C03 C04 C05 C06 C07 C08 C09 C10 C11 C99

Description Client Driven Communication Driven Equipment or Material External Phenomenon Location Driven Management Driven Procedure (except procedure not followed) Procedure/Work Process Not Followed People Driven Systems Driven Work Environment Other



Plan To Prevent Recurrence: Provide details of corrective actions that have been taken or will be taken to prevent recurrence of the condition (root cause) that led to the reported Nonconformity. State when the corrective actions to prevent recurrence have been or will be completed. Upon completion, sign and date. If issued electronically, name and date may be typed. Response Coordination and Processing Upon completion of sections 3 & 4 of the above reports, route to the Site Quality Manager. The Site Quality Manager, upon receipt of all responses, provides for followup and close-out where applicable. Closed out CAR’s (Section 5 Completed) are to be copied to the Construction Technology Quality Manager.


000 509 0150 18 Feb 04 Page 1 of 3

PREVENTIVE ACTION SCOPE This procedure provides guidance on methods to identify conditions (or circumstances) which have the potential to cause nonconformities

GENERAL Definitions Preventive Action: The action taken to eliminate the cause of potential nonconformities. Preventive action will be appropriate to the magnitude of the potential nonconformity and commensurate with the potential risks that may be encountered. Nonconformities: The non-fulfillment of specified requirements. Preventive action involves the detection and elimination or modification of work performance conditions (or circumstances) which have a potential to cause nonconformities. Each employee should continually evaluate his/her work process to identify potential nonconformities. PROCEDURE Project Personnel Review appropriate sources of information that may be used to identify potential nonconformities such as:

Surveillance Reports Internal Quality Audits Client Feedback Lessons Learned Analysis and improvement of work process and operations Value Awareness Suggestion Monthly Project Reviews Employee Suggestions Registrar Feedback

The Site Quality Manager is aware of the various sources of potential nonconformities listed above and, as appropriate, will determine if an identified item should be considered for preventive action. Consideration should be based on the item’s potential impact on project cost, schedule or quality. NOTE: Note all potential nonconformities require preventive action.


Site Quality Manual


000 509 0150 18 Feb 04 Page 2 of 3

Potential nonconformities that could adversely affect the Project will have the following steps performed:

Determine cause of the potential nonconformity and record it on the log. Refer to cause codes listed below. Determine what action is required to prevent occurrence of nonconformity (i.e. issue surveillance or audit observations, revision of a work process or procedure) and add the appropriate Elimination Code number to the log (See Attachment 1). Confirm that action was taken to prevent the potential nonconformity from occurring and record this information in the preventive action log.

Preventive Actions that eliminate potential nonconformities will be submitted for management review. A log is to be maintained that records a description of the potential nonconformity, the contributing cause (see Cause Code table below), the action determine necessary to eliminate the cause (see Elimination Code table below). NOTE: Any log is permitted provided it contains the same basic information as Attachment 1. CAUSE CODES Code C01 C02 C03 C04 C05 C06 C07 C08 C09 C10 C11 C99

Code E01 E02 E03 E04 E05 E99 Fluor Corporation Company Confidential

Description Client Driven Communication Driven Equipment or Material External Phenomenon Location Driven Management Driven Procedure (except procedure not followed) Procedure/Work Process Not Followed People Driven Systems Driven Work Environment Other ELIMINATION CODES Description Revision/modification of work process/document Issuance of QA/QC report to affected personnel Issuance of document/procedure Training/orientation of affected personnel Verbally advising affected personnel Other Site Quality Manual


000 509 0150 18 Feb 04 Page 3 of 3

FORMS Quality Control Forms: 000 509 F02201 -

Surveillance Report

000 509 F01501 -

Preventive Action log

000 509 F01701 000 509 F01702 -

Audit Finding Audit Summary

ATTACHMENT Attachment 1 -


Preventive Action Log

Site Quality Manual



PREVENTIVE ACTION LOG Project Name: PA No.

Cause Code C01 C02 C03 C04 C05 C06

Project Number: Issue Date

Source

Description Client Driven Communication Driven Equipment or Material External Phenomenon Location Driven Management Driven

Description

Cause Code C07 C08 C09 C10 C11 C99

Cause Code

Elimination Code

Description Procedure (except procedure not followed) Procedure/Work Process not followed People Driven Systems Driven Work Environment Other

Confirmation of Action

Elimination Code E01 E02 E03 E04 E05 E99

Verified by

Date Closed

Description Revision/modification of work process/document Issuance of QA/QC report to affected personnel Issuance of document/procedure Training/orientation of affected personnel Verbally advising affected personnel Other


000 509 0160 18 Feb 04 Page 1 of 3

QUALITY RECORDS

SCOPE This procedure describes maintenance of Quality Records generated for and/or by construction. GENERAL Quality Records are documented evidence that construction conformed to requirements of the Design Specifications. Quality Records include: • • • • •

Test and inspection reports Radiographs Material and equipment certificates required by specification Equipment maintenance/preservation records As-built drawings

Designated construction staff are responsible for the preparation of Quality Records and are usually responsible for maintenance and retrievability of the records. Records that are identified as “Confidential” in any confidentiality agreement shall be controlled in accordance with specific procedures established by that agreement. PROCEDURE •

Site Quality Manager -

In coordination with the Construction Engineering Manager and any other group manager who receives or generates quality records, identify the quality records that will be retained during construction and identify the record custodian by job title. Record this information on Form 000 509 F01601 (Quality Records Control).

-

Reference the Project File Index and Record Retention Schedule Practice 000 037 1182. In coordination with the client and other record custodians, define the Quality Records that are to be submitted to the client upon completion of work and identify this on the Quality Records Control form. The Fluor Site Quality Manager in coordination with the Site Manager will identify all Quality Records (or copies of records) that will be retained in the Records Retention Center. Identify this on the Quality Records Control form.


Site Quality Manual


NOTE:

000 509 0160 18 Feb 04 Page 2 of 3

Reference Attachment 1 for a sample of Site Specific Quality Records Control form. [:: Attachment 1 should be made site specific ::] Maintain the Quality Records Control form current and, if possible, before records are received on site or generated.

•

Custodian -

Establish and maintain a filing system for inspection, testing, and other Quality Control records. The system shall ensure that records are readily retrievable and protected. The system shall allow the records required for turnover to be easily separated by turnover packages. The system is to be identified on the Quality Records Control Form. Prior to filing the record the custodian shall review the documents to verify the following: -

Documents are appropriate Documents are complete Entries are correct Documents are legible Documents signed/initialed by authorized person Review vendor generated documents to verify the records are complete and legible.

The custodian shall resolve any discrepancies noted during the document review with the originator or originator's supervisor. Resolve any discrepancies with vendor documents through the Fluor purchasing department. Corrections to records are accomplished by authorized personnel (i.e. record originator or originator's supervisor) by striking a single line through the erroneous entry, entering the correct information and initialing and dating the change. Turnover Maintain the records until they are requested by project turnover and/or assigned to the Records Retention Center. NOTE: Subcontractors will retain their records until they are requested by Fluor.


Site Quality Manual


000 509 0160 18 Feb 04 Page 3 of 3

The Site Quality Manager will generate a checklist and verify that all required quality records have been completed and those designated for turnover are included in the Turnover Package. All supporting documentation relating to mechanical completion/system turnover will be retained by Fluor until system acceptance by Client. After system acceptance by Client, this documentation will be transferred to Client under separate correspondence.

FORMS Quality Control Form: 000 509 F01601 - Quality Records Control ATTACHMENT Attachment 1 - Sample of Site Specific Quality Records Control Form Note: List all forms and designate if they are to be turned over.


Site Quality Manual



SAMPLE

QUALITY RECORDS CONTROL

000 509 F00501 000 509 F00502 000 509 F01101 000 509 F01102 000 509 F01103 000 509 F01104 000 509 F01105 000 509 F01301 000 509 F01302 000 509 F01303 000 509 F01401 000 509 F01402 000 509 F01403 000 509 F01601 000 509 F01701 000 509 F01702 000 509 F01801 000 509 F02001 000 509 F02004 000 509 F02006

Request For Information Request For Information Log Calibration Assignment Log I.M.T.E. Sign In/Out History of Use Log Calibration Tickler File Calibration Data Sheet Calibration Data Sheet Nonconformance Report Nonconformance Report Log Hold Tag/Sticker Corrective Action Report Corrective Action Report Log Trend Analysis Investigation Form Quality Records Control Audit Finding Audit Summary Project Specific Quality Training Site Subcontractor Qualification Concrete Batch Plant Evaluation Record

CEM CEM CEM SQM CEM CEM CEM SQM SQM -SQM SQM SQM SQM SQM SQM SQM SQM SQM

Y N N N N Y Y Y Y N Y Y Y N N N N N Y

Records Retention Center Y = Yes N = No Y Y Y Y N Y Y Y Y N Y Y Y N N N N N Y

NDE Subcontractor Evaluation Record

SQM

Y

Y

R2

000 509 F02201 000 509 F02301

Surveillance Report Receiving Inspection Checklist Permanent Plant Material Equipment Inspection List Transfer of Care, Custody and Control System Walkdown Notice Mechanical Completion Civil Checklist Mechanical Completion Electrical/Instrumentation Checklist Mechanical Completion/Mechanical Checklist Mechanical Completion/Quality Management Checklist Master Punch List Interium Turnover Notice Mechanical Completion Certificate Storage Inspection Checklist Equipment Protection Preservation and Inspection Record

SQM SQM

N Y

N Y

R2 R2

SQM

Y

Y

R1

CEM DE DE

Y Y N

Y Y N

R1 R1 R1

DE

N

Y

R1

DE

N

Y

R1

CEM

N

Y

R2

DE CEM CEM SQM

Y Y Y Y

Y Y Y Y

R2 R2 R1 R2

CEM

Y

Y

R2

Record Identification Form #

000 509 F02302 000 509 F02401 000 509 F02402 000 509 F02403 000 509 F02404 000 509 F02405 000 509 F02406 000 509 F02407 000 509 F02408 000 509 F02409 000 509 F02501 000 509 F02502

Title

Custodian

System Turnover Package

Job Title or Sub Name

Y = Yes N = No

Records Retention Center Retention (Years) 20 20 3 3 0 3 3

File Locator Code R5 R5 R2 R2 R2 R2 R2 R2 R2 -R2 R2 R2 R2 R2 R2 R2 R2 R2


SAMPLE


Title

000 509 F70101 000 509 F70102 000 509 F70104 000 509 F70801 000 509 F70901 000 509 F71001 000 509 F71002 000 509 F71003 000 509 F71004 000 509 F71005 000 509 F71006

Soil Inspection Checklist Field Compaction Test Record Nuclear Moisture Density Report Caisson Inspection Record Auger Cast Pile Record Pre-Concrete Inspection Checklist Concrete Inspection Record Concrete Pour Card Cementitious Grout Inspection Record Cementitious Grout Testing Record Epoxy Resin Grout Inspection Record Concrete Compression Strength Test Record Concrete Placement Log Grout Placement Log Grouting Checklist Structural Steel Inspection Torque Wrench Calibration Log Exchanger Closure Form Heat Exchangers & Reboilers Installation Record Centrifugal Compressor Inspection Record Inspection Record Static Equipment Inspection Record Tray Installation Inspection Record Air Cooled Heat Exchanger Air Cooler Run In Test Report Receiprocating Compressor Inspection Record Inspection Record Fan Installation Inspection Record Fun Installation Record Agitators/Mixers Inspection Record Equipment/Piping Flange Alignment Package Unit Inspection Record Installation Record Filters/Strainers Inspection Record Centrifugal Compressor Inspection Record Rotating Equipment Alignment Check Sheet Field Installed Refractory Record

000 509 F71007 000 509 F71008 000 509 F71009 000 509 F71010 000 509 F72002 000 509 F72003 000 509 F74001 000 509 F74002 000 509 F74003 000 509 F74004 000 509 F74005 000 509 F74006 000 509 F74007 000 509 F74008 000 509 F74009 000 509 F74010 000 509 F74013 000 509 F74014 000 509 F74016 000 509 F74018 000 509 F74019 000 509 F74020 000 509 F74021 000 509 F74023 000 509 F74024


Inspection Record For Draw Off Tray Leak

Custodian



Y = Yes N = No

SQM SQM SQM SQM DE SQM SQM DE SQM DE SQM

N Y Y Y Y N Y Y Y Y Y

Records Retention Center Y = Yes N = No Y Y Y Y Y Y Y Y Y Y Y

Records Retention Center Retention (Years)

DE

Y

Y

R4

DE DE SQM SQM SQM DE

Y N Y Y Y Y

Y N Y Y Y Y

R2 R3 R6 R6 R2 R3

DE

Y

Y

R3

DE DE DE

Y Y Y

Y Y Y

R3 R3 R3

DE

Y

Y

R3

DE

Y

Y

R3

DE

Y

Y

R3

DE DE DE

Y Y Y

Y Y Y

R3 R3 R3

DE

Y

Y

R3

DE DE DE DE DE DE DE

Y Y Y Y Y Y Y

Y Y Y Y Y Y Y

R3 R3 R3 R3 R3 R3 R3

File Locator Code R6 R2 R2 R6 R2 R4 R4 R4 R4 R2 R4



SAMPLE

Custodian



Y = Yes N = No

Records Retention Center Y = Yes N = No

000 509 F74025 000 509 F74026

Test Report Inspection Record For Air Coolers Final Closing Authorization Record

DE DE

Y Y

Y Y

R3 R3

000 509 F74027

Baseplate Installation Checklist

DE

Y

Y

R3

000 509 F74028

Grouting Checklist

DE

Y

Y

R3

000 509 F74030

Baseplate Leveling Record

DE

Y

Y

R3

000 509 F74031

Reverse Dial Alignment Record

DE

Y

Y

R3

000 509 F74032

Piping Alignment Data Sheet

DE

Y

Y

R3

000 509 F74033

Compressor Chock Installation Checklist

DE

Y

Y

R3

000 509 F74034

Chock Block Elevation and Leveling Data Sheet

DE

Y

Y

R3

000 509 F74035

Inspection Checklist Steam Terbine

DE

Y

Y

R3

000 509 F74036

Baseplate Leveling Record / Three Train

DE

Y

Y

R3

000 509 F74037

Tandem Mechanical Seal Bubble-Air Test Record C-361 Compressor Dry Seal Panel and Compressor Base Piping Cleaning Record C-362 Compressor Dry Seal Panel and Compressor Base Piping Cleaning Record

DE

Y

Y

R3

DE

Y

Y

R3

DE

Y

Y

R3

000 509 F74201

Inspection Record Cooling Tower

DE

Y

Y

R3

000 509 F74202

Fan, Gearbox, Driveshaft and Motor Inspection Record (Mechanical Assembly)

DE

Y

Y

R3

000 509 F75001

Underground Pipe Inspection Record

SCM

Y

Y

R1

DE

Y

Y

R1

SQM SCM

Y Y

Y Y

R1 R1

SQM

N

Y

R1

SQM DE SQM SQM DE

N Y Y Y Y

Y Y Y Y Y

R2 R1 R3 R1 R2

DE

Y

Y

R2

SQM SQM

Y Y

Y Y

R1 R1


000 509 F74038 000 509 F74039

000 509 F75002 000 509 F75003 000 509 F75101 000 509 F75102 000 509 F75103 000 509 F75201 000 509 F75601 000 509 F76001 000 509 F76002 000 509 F76003 000 509 F76004 000 509 F76005

Title

Insulation Resistance (Insulated FlangesUnderground Piping) Test Record Holiday (Spark) Test Record Aboveground Pipe Inspection Record Visual Inspection of Flanges, Gaskets and Bolting Weld Map Record Pressure Test Report Pipe Cleaning and Certification Checklist Conduit and Cable Tray Checklist Electrical Manhole Inspection Checklist Medium & High Voltage Underground Cable Splice Inspection Record Grounding/Earthing Resistance Readings Cable Pulling Inspection Checklist


File Locator Code


SAMPLE

Record Identification Form # 000 509 F76006 000 509 F76007 000 509 F76008 000 509 F76009 000 509 F76010 000 509 F76011 000 509 F76016 000 509 F76020 000 509 F76022 000 509 F76023 000 509 F76026 000 509 F76027 000 509 F76029 000 509 F76030 000 509 F76201 000 509 F76202 000 509 F76203 000 509 F76204 000 509 F76205 000 509 F76206 000 509 F76207 000 509 F76208 000 509 F76211 000 509 F76212 000 509 F76213 000 509 F76214 000 509 F76215 000 509 F76216 000 509 F76217 000 509 F76218 000 509 F76219 000 509 F76401 000 509 F76402


Title Insulation Resistance (Power, Control Wire and Cable) Test Record Insulation Resistance (Instrument Wire and Cable) Test Record DC High Potential Test (Medium Voltage Cable) Test Record Inspection of Power Transformer Inspection Record for Fan/Speed Reducer/Motor Checklist Inspection Record Electrical Motors Inspection Record Emergency Generators Inspection Record Ground Electrode Resistance Test Inspection Record Switch Houses Inspection Record Bus Bar Assemblies LV Switchgear Inspection of Switching Units – HV Switchgear Inspection of Static Supply Unit (UPS) Underground Conduit (Duct Bank) Inspection Electrical Completion Checklist Motor Control Centers Checklist High Voltage Motors and Starters Control and Relay Panels Checklist Cable Termination Checklist Grounding Continuity Checklist Electrical Equipment Checklist Grounding Rod Inspection Lighting, Receptacle, Instrument Distribution Panels Checklist Control Scheme Checklist Power Panel Checklist Switchgear Checklist Low Voltage Feeders Checklist Inspection of High Voltage Cable Electrical Equipment Inspection Record Motors Checklist Electrical Motor Run-In Test Record Local Control Panel Checklist Heat Trace Test Log Electrical Heat Tracing Inspection

Custodian



Y = Yes N = No



SQM

Y

Y

R1

SQM

Y

Y

R1

DE

Y

Y

R1

DE

Y

Y

R1

DE

Y

Y

R1

DE DE

Y Y

Y Y

R1 R1

DE

Y

Y

R1

DE

Y

Y

R3

DE

Y

Y

R3

DE

Y

Y

R3

DE

Y

Y

R3

DE

Y

Y

R3

DE DE DE DE DE DE DE DE

Y Y Y Y Y Y Y Y

Y Y Y Y Y Y Y Y

R3 R3 R3 R3 R3 R3 R3 R3

DE

Y

Y

R3

DE DE DE DE DE DE DE DE DE DE DE

Y Y Y Y Y Y Y Y Y Y Y

Y Y Y Y Y Y Y Y Y Y Y

R3 R3 R3 R3 R1 R3 R3 R3 R3 R3 R3

File Locator Code


SAMPLE

Record Identification Form # 000 509 F77001 000 509 F77002 000 509 F77003 000 509 F77004 000 509 F77005 000 509 F77006 000 509 F77007 000 509 F77008 000 509 F77009 000 509 F77010 000 509 F77011 000 509 F77012 000 509 F77013 000 509 F78001 000 509 F78002 000 509 F78101 000 509 F78102 000 509 F78201 000 509 F78202 000 509 F79001 000 509 F79002 000 509 F79003 000 509 F79202 000 509 F79301


Title Checklist Instrumentation Inspection Checklist Final Loop Check Impulse Line Pressure Test Sheet Instrument Grounding System Checklist Installation Check Sheet (Local Instr) Inspection Record Orifice Plates Instrument Calibration Sheet Safety Valve Tracking Sheet Relief Valve Inspection and Final Acceptance RIE Inspection Checklist DCS Inspection Checklist ESD System Inspection Checklist Machinery Monitoring System Checklist Coating Inspection Record Lining Inspection Record Equipment Thermal Insulation Inspection Pipe Thermal Insulation Inspection Release for Application/Inspection of Fireproofing Fireproofing Inspection Pre-Construction Checklist Daily Welding Report Post Weld Heat Treatment Log Bonding Record Nondestructive Examination Request / Record Positive Material Identification

Custodian



Y = Yes N = No



DE DE DE DE DE DE DE SQM

N Y Y Y Y Y Y Y

Y Y Y Y Y Y Y Y

R1 R1 R1 R1 R3 R3 R3 R3

SQM

Y

Y

R3

DE DE

Y Y

Y Y

R3 R3

DE

Y

Y

R3

DE SQM SQM SQM DE

Y Y Y Y Y

Y Y Y Y Y

R3 R3 R3 R3 R3

DE

Y

Y

R3

DE

Y

Y

R3

NDEC NDEC SQM

Y N Y

Y N Y

R2 R2

NDEC

Y

Y

SQM

Y

Y

File Locator Code

R2 R2 (Note 1)

R2


SAMPLE


GENERAL NOTES: Note #1 If the NDE Reports contain data on more than one line, copies of the report shall be placed in each line file to which it applies. Note #2 If radiographs are turned over to the Client, maintain the transmittal letter. Note #3 A copy of the radiographic rejectable defects statistics are to be sent to the applicable Construction Technology Regional Welding Engineer as they are generated. Note #4 Reference the Project File Index for Fluor file numbers and retention periods. FILE LOCATOR CODES: R1 R3 R5 R7

= = = =

System No. Equipment No. By FCR No. Line and Sheet

R2 = Form No. (by date of completion or alphabetical) R4 = Pour No. R6 = Drawing No.

ACRONYMS: CEM CA NDEC

= Construction Engineering Manager SQM = Contracts Administrator DE = NDE Coordinator RRC

= Site Quality Control Manager = Discipline Engineer = Record Retention Center


000 509 0170 18 Feb 04 Page 1 of 4

QUALITY AUDITS

SCOPE This procedure describes the responsibilities and activities for quality audits of subcontractors and quality audits of Fluor quality-impacting activities. Audits are performed to determine the effectiveness of the Fluor Site Quality Manual implementation and subcontractor’s quality manuals. GENERAL Audits described by this procedure are directed at Fluor self-perform and subcontractor quality impacting activities that are not under the direct control of the Site Quality Manager. The Site Quality Manager is responsible for performing these audits. He may self-perform or designate others to perform or assist him. The procedure section below is based on the audit being performed by an auditor designated by the Site Quality Manager. An audit is a planned and documented activity performed to determine, by evaluation of objective evidence, compliance with the established Site Quality Manual. PROCEDURE •


Establish a schedule for conducting Quality Audits. Refer to Attachments I for schedule examples. Other formats may be used. The schedule should show the audit dates for all subcontractors or internal activities to be assessed. Performance on previous audits should influence reaudit schedule.

-

Develop an audit plan by reviewing the Quality Program (contractor's and/or Fluor’s) and identifying the items to be verified. This may be done by marking up an uncontrolled copy of the procedures, development of a checklist or other methods. This audit does not need to include activities that are subjected to surveillance (reference 000 509 0220). Previous audit results should be considered.

-

Review and concur with the plan, checklist, marked up procedures or other acceptable method of identifying items to be verified.


Site Quality Manual


•

000 509 0170 18 Feb 04 Page 2 of 4

Auditor -

Execute the audit in accordance with established the checklist.

-

When a deficiency is found, investigate to the extent necessary to determine if the deficiency is isolated. If it is isolated and corrected during the audit, complete steps (1, 2, & 3) of Form 000 509 F01701 (Audit Finding). Indicate that the deficiency was corrected during the Audit (in Step 4) then sign and date (Step 8) indicating close-out. If it is not isolated or cannot be corrected during the audit, complete at least through Step 4 as follows: (The step numbers correspond to the space numbers designated on the form.) 1)

Enter the name of the Contractor or the Fluor activity being audited as listed on the Audit Schedule, Attachment 1 or 2.

2)

Enter the unique audit finding number shown on the schedule.

3)

Enter the date of the audit.

4)

Enter the reference, procedure number, specification number, drawing, etc. and the requirement that was not complied with.

5)

Describe the deficiency that was noted during the audit.

-

During and upon completion of the audit, notify the supervisor of the audited area of all deficiencies found. If a subcontractor is being assessed, verbally inform the subcontractor's representative of all deficiencies found.

-

Prepare an audit summary report using (Form 000 509 F01702) as an example, summarizing the audit results, and attach all "Audit Findings" (Form 000 509 F01701) and issue the report to the Site Quality Manager for processing. Root Cause Analysis

Identify significant findings and conduct and document a root cause analysis of each. The root cause analysis method that may be used that includes the following steps: 1. Identify the problem 2. Determine the significance of the problem 3. Identify the causes (conditions or actions) immediately preceding and surrounding the problem. 4. Identify the reasons why the causes in the preceding step existed, working


Site Quality Manual


000 509 0170 18 Feb 04 Page 3 of 4

back to the root cause (the fundamental reason which, if corrected, will prevent recurrence of these and similar occurrences throughout the facility). The primary objective is to determine the direct, contributing and root causes so that effective corrective actions can be taken that will prevent recurrence. •


Review and, upon concurrence, sign the audit summary report (From 000 509 F01702), attach all "Audit Findings", and address to the Site Manager. Review results of the audit. A copy should be sent to Construction Technology's Quality Manager. Additional distribution should be as requested by the Site Manager.

-

Maintain files of all audits. These files should include: · · ·

•

•

Copies of Audit Finding Reports closed upon completion of disposition and verification and acceptance by an auditor.

Site Quality Manager / Auditee -

Assign responsibility for disposition of deficiency and record in Step (5), if it is different from the proposed disposition, Step (4).

-

Sign and date in Step (6) upon documenting or concurring with the disposition (action taken to correct the deficiency).

Auditor -

•

Audit Summary with attached Audit Finding Reports and checklist/marked up procedure. Copies of objective evidence obtained during the Audit.

Sign and date in step (7) upon acceptance of the disposition.

Site Quality Manager / Lead Auditor -

Sign and date in step (8), upon completion and satisfactory verification of action taken to correct the deficiency.

-

Generate a status report of all Audit Findings that have not been completed and accepted by the Site Quality Manager and address it to the Site Manager.

DOCUMENTATION ·

Audit summary with attached Audit Findings


Site Quality Manual


·

Copy of closed audit findings

-

Root Cause Analysis

000 509 0170 18 Feb 04 Page 4 of 4

FORMS Quality Control Forms: 000 509 F01701 - Audit Finding 000 509 F01702 - Audit Summary ATTACHMENTS Attachment 1 - Audit Schedule (Fluor) Attachment 2 -Audit Schedule (Subcontractor(s))


Site Quality Manual



AUDIT SCHEDULE (Fluor Activities) Jan.

Feb.

Mar.

April

May

June

July

Aug.

Fluor Activities (1)

(3)

(2)

INSTRUCTIONS FOR AUDIT SCHEDULE (SUBCONTRACTOR ) 1. Enter the name of all site subcontractors. 2. Draw a bar between the dates the subcontractor is expected to be on site. 3. Draw a box at the date an audit is anticipated and write the scheduled audit date in the box.

Sept.

Oct.

Nov.

Dec.



AUDIT SCHEDULE (Subcontractors) Subcontractors

(1)

Jan. |

(3)

Feb. |

March |

April |

May |

(2)

INSTRUCTIONS FOR AUDIT SCHEDULE (SUBCONTRACTOR)

June |

July |

Aug. |

Sept. |

Oct. |

Nov. |

Dec. |


1. Enter the name of all site subcontractors. 2. Draw a bar between the dates the subcontractor is expected to be on site. 3. Draw a box at the date an audit is anticipated and write the scheduled audit date in the box.



000 509 0180 18 Feb 04 Page 1 of 3

PERSONNEL TRAINING AND QUALIFICATION

SCOPE This procedure identifies training in the field quality system requirements for personnel performing construction activities affecting quality. It covers the methods used for the analysis of supplemental training needs. The procedure also makes provisions for subsequent qualifications and certification (when required). GENERAL Training and orientation are important due to the need for clear definition, communication and understanding of work requirements that are essential to all construction work processes. This training is in addition to the routine orientation of quality requirements provided through daily contact and periodic meetings such as construction planning/review meetings. PROCEDURE Project Training Plans: •

Site Quality Manager Notes:

Coordinate training targeted at site management personnel for orientation to this site quality program. This target group should include the Site Manager, the Construction Manager, the Construction Engineering Manager, Site Discipline Engineers, Area Managers, Superintendents and others as determined by the Site Manager. The Site Manager may elect to invite Client representatives, especially those having a direct interface with the site quality program. Training for the site management group should provide an overview of Inspection and Testing Procedures for all disciplines and in depth training in all other sections of this Site Quality Manual.

-

Coordinate training by discipline, targeted at craft personnel for orientation to this site quality program.


Site Quality Manual


Notes:

000 509 0180 18 Feb 04 Page 2 of 3

The target group should include the craftsmen, Foremen, General Foremen, and Superintendents. Training for the group should provide in depth training in the Inspection and Testing procedures. It should provide an overview of the other sections of this Site Quality Manual. -

Determine the training needed for site personnel requiring certifications. Note: Construction Technology provides training and certification of NDE personnel and inspection personnel needing certification to ASME B31.1 and ASME B31.3.

•

Site Quality Manager/Technical Supervisor -

Coordinate training, when needed, for special processes identified in Procedure 000 509 0090. Note:

•

The target group should include the individuals responsible for performing the special processes and their foremen.

Site Quality Manager/Construction Engineering Manager -

Coordinate training when training needs are identified by procedure 000 509 0140 "Corrective Action”, and 000 509 0150 “Preventive Action".

PROJECT TRAINING SCHEDULES: •


Coordinate site training schedule

-

Ensure Site Manager’s approval of training schedule. Reschedule training session, as needed, as additional personnel are assigned to the project.

-

Provide for instructor, facilities and equipment support.

Note: Instructors will usually be the Site Quality Manager, the Construction Engineering Manager and/or discipline engineers. Training needed for certification will usually be provided by Construction Technology.


Site Quality Manual


•

000 509 0180 18 Feb 04 Page 3 of 3

Instructor -

Document the personnel receiving training on Form 000 509 F01801, or other suitable method.

FORM

Quality Control Form: 000 509 F01801 - Project Specific Quality Training


Site Quality Manual


000 509 0200 18 Feb 04 Page 1 of 2

SITE SUBCONTRACTOR QUALIFICATION

SCOPE This procedure describes the initial qualification of site subcontractors. This procedure does not apply to subcontractors that have been previously approved by Fluor or the Owner. GENERAL When qualifications of site subcontractors include an evaluation of the Quality capabilities of the subcontractor, the evaluation shall be done in accordance with this procedure. PROCEDURE •

Qualification of Subcontractors

•

Contracts Administrator -

Upon selection of a proposed subcontractor, the Contracts Administrator shall notify the Site Quality Manager and request a subcontractor qualification be performed. When construction has designated someone to technically supervise the proposed subcontractor, he shall also be notified. NOTE: The Contracts Administrator shall contact the subcontractor relative to the obtaining of documents, arranging of communication or establishment of meetings and/or visits.

•


Upon notification (including receipt of subcontractor quality programs), review the qualifications of the proposed subcontractor based upon the quality requirements to be included in the Fluor subcontract. This review may include meetings and/or visits with the subcontractor candidate. The Site Quality Manager may use the "Site Subcontractor Qualification" guidelines (Form 000 509 F02001); however, this guide does not necessarily represent the quality requirements to the subcontractor and therefore should be used only as an aid to the evaluation. The Technical Supervisor should use the applicable "Evaluation Record" (Forms 000 509 F02002-F02006).

-

Upon completion of the subcontractor qualification review, notify the Contracts Administrator of the results of the review and perform the actions stated below (as appropriate):


Site Quality Manual


•

000 509 0200 18 Feb 04 Page 2 of 2

•

If the subcontractor is not qualified, write a memo to the Contracts Administrator fully explaining the exact deficiencies that are required to be corrected along with the specific recommendations.

•

If the subcontractor is qualified, complete the "Site Subcontractor Qualification" form and evaluation record and forward to the Contracts Administrator.

•

If the subcontractor is "conditionally" qualified, complete and forward the "Site Subcontractor Qualification" form as above, however include the specific limitations and/or actions that will be required.


Process contractor qualification documents in accordance with the Document Control Section in the SPM and procedure 000 509 0160 (Quality Records).

FORMS Quality Control Forms: 000 509 F02001 - Site Subcontractor Qualification 000 509 F02002 - Soil Testing Laboratory Evaluation Record 000 509 F02003 - Asphalt Testing Laboratory Evaluation Record 000 509 F02004 - Concrete Batch Plant Evaluation Record 000 509 F02005 - Concrete Testing Laboratory Evaluation Record 000 509 F02006 - NDE Subcontractor Evaluation Record


Site Quality Manual


000 509 0210 20 Sep 04 Page 1 of 9

CONTRACTOR QUALITY REQUIREMENTS

PURPOSE This practice is for use in establishing Contractor responsibility for Quality Control. SCOPE This practice establishes the requirements for Site Contractors. APPLICATION This practice should be applied in preparation of the RFP (Request for Proposal) when documented test results and/or in-process inspection results of Contractor's Work are required, as determined by the Site Manager or representative. DEFINITIONS RFP: Request for Proposal - the inquiry document used to obtain price and schedule information on a competitive basis for the services required in Company's performance on projects. Quality Plan for Contractor's Work: A plan that identifies the activities and responsibilities for delivering, measuring, and documenting compliance to the quality requirements of the contracted work. Site Quality Manager: The project assigned individual responsible for on-site quality during the construction phase. If the person is not assigned at the time of contracting activities, Construction Technology’s Corporate Quality Manager will assume the Site Quality Manager’s responsibilities. Quality Program for Contractor's Work: Established quality implementing procedure for inspection/testing of the work, including forms for documenting same. GENERAL Contractor is responsible for providing services and performing work in accordance with the design and quality requirements as required by their contract. Company’s approach to construction management contracting normally requires each Contractor to staff and perform the inspection activities, with Company performing surveillance over the Contractor activities.


Site Quality Manual


000 509 0210 20 Sep 04 Page 2 of 9

Based on the capability of Contractor, information obtained during pre-qualifications of Bidders, and project management preference, Company may elect to either provide the QC procedures to the Contractor or require the Contractor to provide the procedures. Company also may elect to perform the inspection. This practice makes provisions for each of the above options by use of Attachments 01 through 05. The Attachments, when included in the RFP, provide the Bidder with a description of the quality system that will be required. The Attachments plus the Bidder’s response, when agreed to by Company, become the Quality Plan for Contractors Work and will become part of the successful Bidder’s contract. The following sections of this Practice describe the minimum requirements of Contractor's Quality Control System for this Scope of Work. The inspections, tests and related actions specified in this section and elsewhere in the Contract are not intended to limit Contractor's own quality assurance/control procedures that facilitate overall compliance with requirements of the Contract. Contractor may use its own QA/QC procedures provided such procedures have been reviewed and accepted by Company prior to start of Work. The Contractor’s procedures must address, as a minimum, the information contained in the applicable attachments to this practice that were included in the Contract. Quality Control Program Basic objectives of Contractor's Quality Control (QC) System shall be as follows: • To ensure that all work adheres strictly to all requirements of the Contract and governing agencies where the work is being performed. •

To maintain QC procedures to ensure that tasks performed will comply with the Contract.

•

To prevent deficiencies through pre-construction quality control coordination.

•

To detect and correct deficiencies in a timely manner.

•

To provide an auditable record of all tests, inspections, procedures, non-compliance and corrections, and any other pertinent data as required.

•

Verify compliance with Contractor’s QC procedures, including those QC procedures of subcontractors and suppliers.

•

To provide a basis of measuring Contractor’s performance for input to Company Contractor Resource Database.


Site Quality Manual


000 509 0210 20 Sep 04 Page 3 of 9

The Contractor may select either an outside "agency" or in-house personnel to administer Contractor’s QC System. In either case, the Contractor’s on-site Quality Control staff shall only be responsible for Quality Control. The QC Supervisor (or person designated as the QC Representative) shall report directly to Contractor's Site Manager. The Contractor’s QC staff shall not be involved in the management and/or control of the construction process. Contractor’s QC staff members shall interface with Company, Consultants, as required. Testing Criteria Contractor shall perform all testing and inspection of all Work (including materials) both on and off site as required by the Contract. Criteria for acceptance are specified in the Contract. QC Agencies - Selection and Qualification Contractor shall, if applicable, obtain the services of a Soils and Concrete Testing Laboratory and an accredited Nondestructive Examination Subcontractor to perform the tests and examinations required by the Contract. Inspectors employed by Contractor's Inspection and Testing Agency shall be specially qualified to perform required inspection services for the particular classification of work to be inspected and shall be certified as required by the Contract or governing agencies where the work is being performed. Responsibilities of the Contractor’s QC Supervisor (Representative) Responsibilities and duties of the Contractor’s QC Supervisor are: •

To communicate these minimum QC requirements to any suppliers and/or subcontractors.

•

To have the authority to stop Work for cause, reject Work, order Work removed, initiate remedial Work, propose solutions, and reject material not in compliance with the Contract.

•

Be present on-site during working hours and assigned "full time" to this Contract. Contractor shall designate alternate individual(s) to assume responsibilities in the temporary absence of the QC Supervisor.

•

Be completely familiar with the Contract Scope of Work, Drawings and Specifications.


Site Quality Manual


000 509 0210 20 Sep 04 Page 4 of 9

•

Establish and implement QC Programs for Contractor and with its various subcontractors, and monitor their conformance.

•

Inspect existing conditions prior to the start of new Work segments.

•

Conduct a pre-construction Quality Control meeting with Contractor’s responsible field and office representatives prior to the start of each major item of work required by the Contract.

•

Perform in-process and follow-up inspections on each of the work segments to ensure compliance with the Contract. Upon request, accompany Company on such inspections.

•

Coordinate required test, inspections, and demonstrations with Company or any other authority having jurisdiction. Assure work is accessible for test or inspection.

•

Inspect Contractor purchased materials and equipment arriving at the Site to ensure conformance to the requirements of the Contract. Prepare and submit documentation as required by the Contract.

•

Inspect material “free-issued” to Contractor by Company to ensure conformance to the requirements of the Contract. Contractor must provide immediate notification to Company when materials are found to be damaged or nonconforming.

•

Identify, report and reject defective Work not in conformance with the Contract. Monitor the repair or reconstruction of rejected Work and document corrective action, including all remedial action taken to prevent the re-occurrence of the defective Work.

•

If necessary, retain specialists or subcontractors for inspection of Work in areas where additional technical knowledge is required (mechanical, electrical, electronics, controls, communications, welding, structural, etc.). Submit qualifications of subcontractors and specialists to Company for approval.

•

Schedule and accompany Company on any Site visits when requested.

•

Work closely with Company to ensure optimum Quality Control. Attend meetings as required by Company.


Site Quality Manual


000 509 0210 20 Sep 04 Page 5 of 9

Submittals Contractor shall submit reports detailing the results of each test and describing each inspection. Submit separate reports for each test and inspection procedure immediately upon completion of each procedure and test. General QC Requirements Inspection and test reports, as a minimum, shall include: •

Date issued

•

Date of inspection or test

•

Project title and number

•

Testing agency name and address

•

Name and signature of the inspector/tester

•

Identification of the product and applicable specification section

•

Type inspection or test

•

The results as related to requirements.

Inspection, Measuring and Test Equipment The Contractor shall provide and maintain all measuring and testing devices. Laboratory devices shall be calibrated as required by Contract. The standards against which the measurement equipment is periodically calibrated shall have their accuracy verified directly by, or through a precise comparison with standards traceable to the National Institute of Standards and Technology or to a recognized national or international standard. EXECUTION Contractor's inspection shall be adequate to cover all operations, including both on-site and off-site and will be keyed to the proposed sequence of the Work and shall include as a minimum at least four (4) phases of inspection for all definable items or segments of the Work, as follows: •

Preparatory Inspection: To be performed prior to beginning any Work on any definable segment of the Work and shall include: − A review of Contract requirements − Verification that all materials and/or equipment have been tested, submitted, and accepted


Site Quality Manual


000 509 0210 20 Sep 04 Page 6 of 9

− − −

Verification that provisions have been made to provide required control testing Examination of the Work area to ascertain that all preliminary Work has been completed A physical examination of materials and equipment to assure that they conform to accepted shop drawings or submittal data and that all necessary material and/or equipment are available.

As a part of this preparatory Work, Contractor's organization will review and verify that all documents, including but not limited to, shop drawings, submittal data, method of Quality Control, product data sheets, test reports, affidavits, certification and manufacturer's instructions have been submitted and accepted by Company as required herein. Each submittal to Company shall bear the date and the signature of the Contractor's Quality Control Manager (or authorized designee) indicating that a review of the submittal and certify it to be in compliance with the Contract Drawings and Specifications or showing the required changes. •

Initial Inspection: To be performed as soon as a representative segment of the particular item of Work has been accomplished and to include: examination of the quality of workmanship and a review of control testing for compliance with Contract requirements; exclusion of defective or damaged materials, omissions; and dimensional requirements.

•

Follow-up Inspection: To be performed daily or more frequently as determined to be necessary to ensure continuing compliance with the Contract requirements, including control testing, until completion.

•

Final Inspection: To be conducted when the Work is substantially complete. Contractor shall inspect the Work for quality, workmanship and completeness prior to notification that the item or segment of the Work has been completed.

Specific tests and inspection procedures (including documentation) for each material or item of Work are specified in the Contract. Contractor’s Testing Laboratory shall perform tests according to method(s) of testing specified in the Contract. Where the Specifications or applicable Codes stipulate that a material shall conform to the American Society for Testing Materials (A.S.T.M.) specifications or other recognized standards, Contractor shall deliver an affidavit or certificate in triplicate, signed by the manufacturer or supplier that the material furnished conforms to specifications or standards


Site Quality Manual


000 509 0210 20 Sep 04 Page 7 of 9

mentioned. When tests are required, the results of such tests shall be delivered at no additional cost. Contractor shall ensure that all work that does not comply with the requirements and references specified in the Contract scope of work is identified and correctly dispositioned. All Work installed or fabricated by the Contractor shall be inspected (i.e., punched) and resolved prior to notifying Company the Work is ready for final acceptance inspection. Contractor shall record all punch list items (i.e., deficiencies) on a punch list record. Material or equipment that is supplied by Company or Owner, and is found by Contractor to have deficiencies, is to be immediately identified to Company for corrective action. Contractor shall not render any Work as inaccesible until all inspections and test have been completed and accepted by all involved parties, including Company and the Owner. Any Work that is rendered inaccesable prior to inspection and test by all involved parties may be made accessible for inspection and test at the Contractors expense. Contractor shall package and prepare all inspection and testing documentation for turnover at the completion of construction. Contractor shall develop turnover packages, by system as determined or mutually agreed by Company. Each system file will contain all field inspection and testing records for the components of the system. Unless otherwise specified, Contractor shall submit the original and as a minimum two (2) clean, legible copies of all turnover packages to Company at Mechanical completion or as determined necessary by Company. NOTE:

Some construction management projects may elect to collect the quality records daily when mulitply Contractors are involved or when the scope of work of the Contractor only involves one discipline of a mulit-disciplined scope of work for completion. Additional controls for Contractor quality are detailed in Quality Support Practices 000 509 0220: Surveillance of Construction Activities and 000 509 0170: Quality Audits.

PROCEDURE •


Initate development of the Quality Plan for Contractors Work by informing the Site Quality Manager of the project contracting plan and of the scope of work for each Contract and requesting input for the RFP from the Site Quality Manager. NOTE:


Prior to site mobilzation, Construction Technology’s Corporate Quality Manager shall act as the Site Quality Manager.

Site Quality Manual


•

000 509 0210 20 Sep 04 Page 8 of 9


The Site Quality Manager will prepare and complete the applicable Attachments (01 through 04 and/or 05). The Attachments will be modified to address the specific contract scope and responsibility assignments for Quality. The completed documents will be provided to the Contracts Administrator for inclusion in the RFP.

-

Attachments 01 through 04 are needed only if the Contractor will be performing and documenting inspections/tests or working to process control procedures listed on Attachment 03 that is provided. Affix to this attachment all QC procedures to be provided by Company. Review the testing and inspection procedures to be included in the RFP and modify to meet the Bidders work scope. NOTE: The section of Attachment 03, Quality Procedure Description, will be needed only if the Contractor will be required to prepare Quality procedures or process control procedures. The section should be modified to provide a description of only the procedures the Contractor will be required to prepare. The Site Quality Manager will consult with the Technical Supervisor (see 000 509 0090) in determining the process control procedures to be listed in Attachment 03.

-

•


•

Description of Inspection and/or Tests by Company (refer to Attachment 05) – Needed only if inspection/test for all or any part of the Contractor’s work will be performed or provided by Company.

Include in the RFP the quality requirements provided by the Site Quality Manager. Upon receipt of the Contractor’s Quality Submittal or any exceptions to quality requirements of the RFP, provide a copy to the Site Quality Manager.


Provide comments by memo on the Bidder’s Quality Submittal (their response to Attachment 04) to the Contracts Administrator with specific recommendations including explanation of deficiencies that are required to be corrected. In evaluating the Bidder’s submittal requested by Attachment 04, the Site Quality Manager should consider the following guidelines for the Contractor’s site quality organization:


Site Quality Manual


•

000 509 0210 20 Sep 04 Page 9 of 9

Contractor may select either an outside “Agency” or in-house personnel to administer the program. In either case, their Quality Manager should report directly to their Site Manager.

Contractor’s Quality organization chart shall include sufficient QC personnel staffing levels as may be necessary to accomplish complete and adequate inspection of work. Contractor’s inspection shall be adequate to cover all operations, including both on-site and off-site, and will be keyed to the proposed sequence of the Work.

Clerical personnel sufficient to accomplish timely submittal of QC reports and other required documentation shall be provided.


Reconcile quality issues and exceptions prior to contract award. Obtain input as needed from the Site Quality Manager.

-

Incorporate the agreed to quality requirements into the contract.

-

After the “Notice to Proceed”, obtain the procedures listed under “Prepared by Contractor” of Attachment 02 and process control procedure of Attachment 03 that were made a part of the contract and provide these procedures to the Site Quality Manger. NOTE: These procedures are to be approved by the Site Quality Manager or the Technical Supervisor (see 000 509 0090) before the Contractor is authorized to proceed with work within the procedure scope unless specifically approved by the Site Manager.

FORMS Quality Control Practice 000 509 0170 000 509 0220 -

Quality Audits Surveillance of Construction Activities

ATTACHMENTS Attachment 01 Attachment 02 Attachment 03 Attachment 04 Attachment 05 -


Quality Requirements Construction Subcontractor Quality Requirements Checklist QC Procedures Description Quality Submittal Requirements Description of Inspection and/or Testing By Company

Site Quality Manual


000 509 0210 20 Sep 04 Attachment 1 . . . Page 1 of 2

QUALITY REQUIREMENTS Contractor is responsible for quality and for implementing the measures necessary to achieve and document compliance to specified requirements. Attachment 2, titled Construction Contractor Quality Requirement Checklist (CCQRC) identifies the Quality procedures required to be included in the Contractor’s Quality Program Manual. The inspections, tests, and related actions specified in this section and elsewhere in the Contract are not intended to limit the Contractor's own quality assurance/control procedures, which facilitate overall compliance with requirements of the Contract. Procedures "Prepared by Company" are enclosed with the CCQRC. Procedures "Prepared by Contractor" will be required to be submitted to and approved by Company prior to work, but not with the bid. Once approved, the Contractor shall obtain Company approval of changes. Changes will not be permitted if they would, as determined by Company, result in nonconformance with the Contract requirements. The section titled "Quality Procedures Description" provides a brief description to Contractor of the procedures that are to be developed by the Contractor. Contractor will initiate, schedule, and coordinate all test and inspections. Contractor is responsible for coordinating the sequence of the work so as to accommodate all required tests and inspections. When inspection or testing is performed on a sampling basis (less than 100 percent), Company reserves the right to select the items to be inspected or tested. Company reserves the right to inspect, or have inspected at source, supplies or services not manufactured or performed on the Site. Such inspection will not constitute acceptance; nor will it in any way relieve the Contractor of responsibility to furnish all required Quality Assurance/Control. The Contractor will ensure that the Company representative is given sufficient time to witness tests and re-inspect work performed by the Contractor. The following times are considered minimum notification: Concrete placements Holiday testing Punching of lines prior to hydrotest Pressure testing Acceptance inspection of buildings Bolt tensioning DC (Direct Current) High Potential (over 2,000 volt cable) Motor run-ins Tests to electrical equipment Loop checks Acceptance inspection of vessels and equipment Other tests

1 day 4 hours 2 days 4 hours 2 days 4 hours 4 hours 4 hours 4 hours 4 hours 1 day 2 hours



Company will monitor construction and quality activities of the Contractor. Company also will perform auditing of documentation to verify correctness of data, completeness of coverage, retrievability, timeliness of scheduling, and action taken on inspection and testing results. Contractor will schedule and accompany Company on any site visits when requested, work closely with Company to ensure optimum quality, and attend meetings on quality issues as required by Company. Contractor will receive approval of Contractor employed Testing and Inspection Agencies from Company prior to them performing any inspections and tests. Contractor employed Testing and Inspection agencies will provide reports simultaneously to the Contractor and Company. Contractor and sub-tier suppliers and subcontractors are subject to a qualification survey by Company prior to the start of activities required by the contract to verify implementation of the required Quality Programs. Acceptance of the Contractor's Quality Program by Company does not relieve the Contractor of the obligation to comply with requirements of the contract including the requirements herein. If the Quality Program is subsequently found to be ineffective or inadequate in providing acceptable control, Company will require necessary revisions.



CONSTRUCTION CONTRACTOR QUALITY REQUIREMENT CHECKLIST Procedure Title 1. Document Control 2. Identification and Traceability of Equipment and Material 3. Process Control 4. Inspection, Measuring and Test Equipment 5. Control of Nonconformance 6. Quality Control Records 7. Training 8. Material and Equipment Handling Storage and Maintenance 9. Subcontractor/supplier Quality Requirement, Qualification, Surveillance and Audit 10. Inspection and Testing (List Procedures Title and Form Numbers) 10.1 10.2 10.3 10.4 10.5 10.6 10.7 10.8 10.9 10.10

Prepared by Contractor

Contractor Forms


Procedure Title


Prepared by Company (Enclosed)

Forms (Enclosed)

1. Document Control

000 509 0050

2. Identification and Traceability of Equipment and Material

000 509 0080

3. Process Control

000 509 0090

4. Inspection, Measuring, and Test Equipment

000 509 0110

F01101 F01102 F01103 F01104

5. Control of Nonconformance

000 509 0130

F01301 F01302 F01303

6. Quality Control Records

000 509 0160

F01601

7. Personnel Training and Qualification

000 509 0180

8. Contractor/supplier Quality Requirements, Qualification, Surveillance and Audit 9. Material and Equipment Handling, Storage and Maintenance 10. Inspection and Testing Procedures (List Title and Form Numbers)

000 509 0170 000 509 0220

F01701 F02201 F01702 F02202

000 509 0250

F02501 F02502 F70001 F70002

10.1 Soils

000 509 7010

F70101 F70102 F70103 F70104 F70105

10.2 Bituminous Concrete paving

000 509 7020

F70201 F70202 F70203 F70204

10.3 Piling – Steel H – Pile

000 509 7030

F70301 F70302 F70303

10.4 Piling – Pre-cast Concrete Piles

000 509 7040

F70301 F70302 F70303

10.5 Piling – Timber Piles

000 509 7050

F70301 F70302 F70303

000 509 7060

F70301 F70302 F70303

000 509 7070

F70301 F70302 F70303

10.8 Drilled Caissons

000 509 7080

F70801

10.9 Auger Cast-In-Place Piles

000 509 7090

F70901

10.10 Concrete and Grout

000 509 7100

F71001 F71002 F71003 F71004 F71005 F71006 F71007 F71008 F71009 F71010

10.11 Structural Steel

000 509 7200

F72002 F72003

000 509 7300

F73001 F73002 F73003 F73004 F73005 F73006 F73007 F73008 F73009 F73010 F73011 F73012 F73013 F73014 F73015 F73016

10.6 Piling – Closed End Concrete Filled Pipe Piles 10.7 Piling – Concrete Filled Thin Shell Pipe Piles

10.12 Buildings




Forms (Enclosed)

10.13 Heating Ventilating and Air Conditioning

000 509 7310

F73101 F73102

10.14 Roofing Inspection

000 509 7320

F73201

Procedure Title

F74001 F74006 F74011 F74016 F74021 F74026

F74002 F74003 F74004 F74007 F74008 F74009 F74012 F74013 F74014 F74017 F74018 F74019 F74022 F74023 F74024 F74027 F74028 F74029 F74031 F74032 F74101 F74102 F74103 F74104 F74106

F74005 F74010 F74015 F74020 F74025 F74030

10.15 Equipment

000 509 7400

10.16 Field Fabricated Tanks

000 509 7410

10.17 Cooling Tower

000 509 7420

F74201

10.18 Refractory Concrete

000 509 7430

F74301

10.19 Gas Turbine / Generator

000 509 7440

F74401 F74402 F74405 F74406 F74407 F74408

10.20 Heat Recovery Steam Generator

000 509 7450

10.21 Steam Turbine / Generator

000 509 7460

F74601 F74602 F74603 F74604 F74605 F74606 F74607 F74608 F74609

10.22 Field Erected Stack

000 509 7470

F74701 F74702

10.23 Underground Piping

000 509 7500

F75001 F75002 F75003

10.24 Aboveground Piping

000 509 7510

F75101 F75102 F75103

10.25 Pressure Testing

000 509 7520

F75201

10.26 Hygienic Tubing

000 509 7550

F75501 F75502 F75503 F75504 F75505 F75506 F75507 F75508 F75509

10.27 Cleaning of Pipe

000 509 7560

F75601

10 28 Steam Tracing for Pipe and Equipment

000 509 7570

F75701

10.29 Electrical Inspection

000 509 7600

10.30 Electrical Testing

000 509 7610

F76001 F76002 F76003 F76006 F76007 F76008 F76011 F76012 F76102 F76103 F76104 F76107 F76108 F76109 F76112 F76113 F76414 F76117 F76118 F76119 F76122 F76123 F76124 F76127 F76128 F76129

F76004 F76009 F76013 F76105 F76110 F76115 F76120 F76125 F76130

F74105

F76005 F76010 F76106 F76111 F76116 F76121 F76126 F76131



F76132 F76133 F76134 F76135 Procedure Title


Forms (Enclosed) F76201 F76206 F76211 F76216 F76221 F76226

F76202 F76207 F76212 F76217 F76222 F76227

F76203 F76208 F76213 F76218 F76223 F76228 F76231 F77001 F77002 F77003 F77006

F76204 F76209 F76214 F76219 F76224 F76229

F76205 F76210 F76215 F76220 F76225 F76230

10.31 Electrical Equipment

000 509 7620

10.32 Control System Instrumentation

000 509 7700

10.33 Control System Calibration

000 509 7710

F77007 F77008 F77009

10.34 Coatings and Linings

000 509 7800

F78001 F78002

10.35 Insulation

000 509 7810

F78101 F78102

10.36 Fireproofing Inspections

000 509 7820

F78201 F78202

10.37 Welding Inspection

000 509 7910

F79001 F79002

10.38 Nondestructive Examination

000 509 7920

F79201 F79202 F79203 F79204

10.39 Positive Material Identification

000 509 7930

F79301 F79302 F79303 F79304

10.40 Hardness Testing

000 509 7950

F79501 F79502 F79503

F77004 F77005

Note: When procedures that are "Prepared by Company" are used by the Contractor, the position titles (Site Quality Manager, Construction Engineer, etc.) stated in the procedures apply to those responsible for the described action in the Contractor's organization unless "Company" is specifically designated in the title. The title "Client" means Company.



QC PROCEDURES DESCRIPTION

1.

Document Control Contractor will prepare procedures to control documents and data that relate to the control of contracted Work. Contractor is responsible for ensuring that documents provided by Company for construction are maintained to the most up-to-date revisions. Contractor's control procedure should ensure that all necessary information is delivered to the proper locations and personnel responsible for the performance of the work. The procedure will ensure that obsolete documents are promptly removed from all points of issue or use.

2.

Identification and Traceability of Equipment and Material Contractor has responsibility for maintenance of the identification of material and equipment used during construction. Procedures will be developed to describe the methods of maintaining traceability.

3.

Process Control Contractor will provide procedures to control work processes. These will include the following: -

Welding Procedure Specifications and Procedure Qualification Records

-

Flushing and hydro-testing procedures

-

NDE (Nondestructive Examination) Procedures

-

Welder Qualification Procedures

-

PWHT (Post Weld Heat Treatment) [:: Delete procedures not required or add to this list other process control procedures required from the Contractor if he is awarded the work. ::] NOTE: When personnel certifications are required, they will be made available upon request.

4.

Inspection, Measuring, and Test Equipment Contractor will provide and maintain all measuring and test devices used to verify compliance to specifications. Contractor will provide a procedure for controlling calibration of this equipment. The procedure will specify the intervals and standards against which test and measurement equipment are checked. The standards against which the measurement equipment is calibrated will have their accuracy traceable to the National Institute of Standards and Technology or to a recognized industrial or national standard.



Where no such standards exist, the basis used for calibration will be documented. This equipment will bear a record of the calibration and record of use logs will be maintained. Contractor's measuring and test equipment will be made available for use by Company for verification of their accuracy and condition as well as inspection and test monitoring. 5.

Control of Nonconformances Contractor is responsible for and will develop procedures for control and disposition of nonconforming conditions. Measures will be taken to preclude work containing uncorrected deficiencies being built upon or concealed until satisfactorily dispositioned. Contractor will prepare procedures for documenting and controlling nonconforming items or services. If corrective action of the Construction Subcontractor does not result in full conformance with contract requirements, the proposed final disposition will be approved by a designated Company representative. Measures will be taken to perform the following: -

Provide holding areas or methods for segregating nonconforming items to prevent unauthorized use.

-

Maintain records identifying nonconforming items, the nature of nonconformance, its dispositions, and evidence that the disposition has been satisfactorily completed.

Company also may identify and report nonconformances. In these cases, a nonconformance report will be delivered to the Contractor who will provide for appropriate closure action. 6.

Quality Control Records Contractor will prepare procedures to collect, index, file, store, maintain, and turn over to Company the quality control records listed below: -

All records required by specifications Test and inspection reports Radiographs Material and equipment certificates required by specification Equipment maintenance/preservation records As-built drawings

Contractor will package and prepare all quality records for turnover. Timing of this will be compatible with Company Document Control System. Turnover packages are to be developed by system as determined by Company. Each system file will contain field inspection and testing records for the components of the system. Unless otherwise specified, Contractor will submit the original and 1 clean, legible copy of all turnover packages to Company at the Mechanical completion.


7.


Training Contractor will prepare a procedure for identifying training needs, and will provide for the training of personnel performing activities affecting quality. The procedures will provide for documentation of training. In addition to other training needs identified by Contractor, prior to the start of each major item of work required by the Contract, a preconstruction Quality Control meeting with responsible field and office representatives will be conducted to ensure that quality requirements are understood by those performing the work.

8.

Material and Equipment Receiving, Handling, Storage, and Maintenance Contractor is responsible for the receipt and control of their purchased material and equipment, and material and equipment that is issued to the Contractor. Contractor may reject faulty or damaged equipment upon receipt, and should promptly advise the designated Company Representative for Company issued material / equipment. Upon issue, Contractor will conduct a program for preventive maintenance of equipment, including Supplier's recommendations. The equipment protection requirements are established by Specification. Contractor will keep records of all maintenance performed on this equipment. Contractor will prepare a procedure for material and equipment receiving, handling, storage, and maintenance.

9.

Other Subcontractor/Supplier, Quality Requirements, Qualification, Surveillance, and Audit Contractor's Suppliers of services, equipment, and materials will be required to meet the same quality standards required of the Contractor. The Construction Subcontractor will perform surveillance of other lower-tier subcontractor's and supplier's quality related operations consistent with the nature and scope of service or product provided. Contractor will provide a procedure for controlling quality of the subtier suppliers/subcontractors.

10.

Inspection and Testing Within two weeks of the award of the Contract, or earlier if required by the contract schedule, the Contractor shall submit to Company for approval Inspection and Test Plans (ITP) prepared either to Company’s format (Forms 000 509 F70001 and 000 509 F70002) or to Contractor's own format provided this contains equivalent data. The purpose of the ITP is for the Contractor to describe on one document the inspection and testing activities for each definable feature of work. As a minimum the plans shall address the quality control requirements of the contractual requirements, specifications, and drawings, as well as the standards and codes referred to therein. However, these requirements are not considered exclusive, Contractor being responsible for adding to these minimum requirements to the extent that Contractor considers necessary to obtain appropriate quality levels.



Definitions: Inspection- visual checks of a qualitative nature but also including dimensional measurements. Tests- measured verifications of one or more characteristics or of performance, both being carried out to ascertain whether or not the specified requirements have been met. The ITP shall include the following features: -

a list of the inspection and test points presented in sequence in the order in which they are to be performed

-

for each point, reference to a document stating the acceptance criteria for each point, the "verification document" i.e. the document to be checked or the one used to record the result of the inspection or test for each point for both Contractor and Company, where required, an indication of: "W" for "Witness Point" "R" for "Review" "H" for "Hold Point"

Once the ITP has been approved by Company the Contractor shall apply it. Any modification must have the written approval of Company.



QUALITY SUBMITTAL REQUIREMENTS Bidder will submit the following information with the bid: a)

A description of the proposed on-site organization that will perform Quality activities. Include the on-site and off-site (if any) reporting of these personnel. Describe the roles and responsibilities of these personnel. Also, provide a manloaded schedule for their project assignment. Clerical personnel sufficient to accomplish timely submittal of quality reports and other required documentation will be provided and shown on this schedule. To be acceptable, a Quality representative must be on-site during all working hours. Bidder must designate alternate individuals to assume responsibilities in the temporary absence of the Quality Supervisor or when overtime work is being performed.

b)

Identify all anticipated testing that will be contracted.

c)

Identify any QC activities, procedures, and inspection/test plans/reports proposed by Bidder in addition to those required by the Construction Contractor Quality Requirements Checklist (Attachment 02).

d)

Exceptions may be taken by the Bidder of quality requirements imposed herein by submitting a brief statement of justification for each requirement considered not applicable. Company has the sole right to accept or reject any exception recommended by the Bidder.



DESCRIPTION OF INSPECTION AND / OR TESTING BY COMPANY Company will inspect Contractor’s work for the following work activities: Company will provide testing of Contractor's work for the following activities: Contractor is responsible for quality and for implementing the measures necessary to achieve compliance to specified requirements. Contractor will ensure that the Company is given sufficient time to witness tests and re-inspect work performed by Contractor. The following items are considered minimum notification: Concrete placements Holiday testing Punching of lines prior to hydrotest Pressure testing Acceptance inspection of buildings Bolt tensioning DC (Direct Current) High Potential (over 2,000 volt cable) Motor run-ins Tests to electrical equipment Loop checks Acceptance inspection of vessels and equipment Other tests

1 Day 4 Hours 2 Days 4 Hours 2 Days 4 Hours 4 Hours 4 Hours 4 Hours 4 Hours 1 Day 2 Hours

When inspection reveals work not conforming to requirements, the Construction Subcontractor will be informed and will perform work necessary to achieve compliance. Contractor has primary responsibility for quality. The Contractor is to implement the measures necessary to build quality into the work in accordance with the contract, drawings, and specifications. Inspection of the Contractor's work by Company does not relieve the Contractor of the obligation to comply with requirements of the Contract.


000 509 0220 18 Feb 04 Page 1 of 3

SURVEILLANCE OF CONSTRUCTION ACTIVITIES

SCOPE This procedure describes the responsibilities and activities for quality surveillance of construction activities. GENERAL The Site Quality Manager is responsible for the quality program at the construction/installation site is responsible for implementing and managing a program of quality surveillance. Surveillance is the monitoring by witnessing and observation of the Quality Program implementation during construction/installation work activities. Surveillance is performed to the extent necessary to provide adequate confidence that appropriate measures are taken to control and achieve quality. The responsible Construction Engineering Manager shall be contacted for final resolution/interpretation of design specifications or drawing requirements, when a conflict develops between interpretation of requirements and that of Quality Surveillance personnel. PROCEDURE •


The Site Quality Manager will assign surveillance responsibilities to inspection personnel.

NOTE: Scope, duration, and intensity of surveillance and/or verification activities shall be determined by the Site Quality Manager through an evaluation of the scope of the activities being performed and the quality history of the workers. •

Surveillance Personnel -

Perform periodic surveillance and/or verification activities.

NOTE: Surveillance personnel should refer to the applicable inspection/test plans or procedures and use them for determining surveillance activities. When surveillance is performed on self-performed or subcontracted activities not addressed by inspection/test procedures; the work process instructions (usually drawings and specifications) should be used to guide the inspector.


Site Quality Manual


-

000 509 0220 18 Feb 04 Page 2 of 3

Indicate the results of the surveillance verification activity (Form 000 509 F02201) in the following manner: •

Record on the Surveillance Report those areas or items monitored or reviewed. If no deficiencies are found during this surveillance, so state (satisfactory), sign, and date the report and forward to the Site Quality Manager for his review. NOTE: The “Inspector” may recommend corrective action to be taken to correct the condition or deficiency.

•

•

•

•

When a deficiency is found and will need a follow-up inspection to verify conformity, identify it on the Surveillance Report in the “Observation / Deficiency” section. Notify the responsible person of the deficiency and record the corrective action being taken. Sign and forward to the Site Quality Manager for his review. The “Inspector” shall follow-up the deficiency to ensure the corrective action is completed. Corrective action should then be recorded in the corrective action space provided and the “Inspector” shall sign and date to indicate acceptance / completion and the report is considered closed. Record the Surveillance Report information on the log provided. The log will serve as a record of site surveillance reports as well as to status the reports as “Open” or “Closed”. If corrective action is not initiated to resolve the deficiency within fourteen (14) calendar days, notify the Site Quality Manager. The Site Quality Manager may initiate and process a nonconformance report if needed.

Nonconformance Reports are issued when there are: •

Deficiencies in materials, finished work or work processes that result in a condition that does not conform to the specifications and for which there are no existing procedures or standard trade practices which describe methods of correction and therefore require engineering disposition.

•

Deficiencies of a serious or repetitive nonconforming nature as determined by the Site Quality Manager

•

Construction damage has occurred to existing or turned over plant property.

Nonconformances shall be documented using Form 000 509 F01301.


Site Quality Manual


•

000 509 0220 18 Feb 04 Page 3 of 3


Review the results of the surveillance and/or verification activities recorded on the Surveillance Report and signify review and concurrence by signing and dating.

-

Advise the Site Manager of serious quality problems.

DOCUMENTATION All Surveillance Reports shall be retained in the Quality Control files. FORMS Quality Control Form: 000 509 F02201 - Surveillance Report 000 509 F02202 – Surveillance Report Log


Site Quality Manual


000 509 0230 18 Feb 04 Page 1 of 2

FIELD RECEIVING AND INSPECTION SCOPE This procedure describes the practice and methods to perform receiving inspection of permanent plant material and equipment. RESPONSIBILITIES - Self-Perform FREQUENCY OF ACTIVITY Per shipment received

ACTIVITY

RESPONSIBILITY

DOCUMENTATION

Warehouse receipt of material/items Determine inspection and storage level requirements Perform quality receipt inspection

Warehouse Personnel

O, S, and D

Construction Engineer

Attachment 1

As project progresses


000 509 F02301

As required by project

Responsibilities - Subcontracted Work ACTIVITY

RESPONSIBILITY

DOCUMENTATION

Subcontractor

O, S, and D

Subcontractor

000 509 0230, Att. 1

Subcontractor

000 509 F02301


Form 000 509 F02201

Warehouse receipt of material/items Determine inspection and storage level requirements Perform quality receipt inspection Surveillance

FREQUENCY OF ACTIVITY Per shipment received As project progresses As required by project Per Procedure 000 509 0220

PROCEDURE •

Receipt of Material/Items: -

Warehouse personnel shall perform the initial visual inspection of the materials/items for obvious shipping damage. If there has been shipping damage, initiate an O, S, and D Report in accordance with Warehouse Procedures. Forward a copy of the O, S, and D Report to the Site Quality Manager for information. The warehouse staff shall notify the Quality Manager upon receipt of items listed on the Permanent Plant Material and Equipment Inspection List or items where receipt inspection by the Quality Inspector is indicated on the ITP.


Site Quality Manual


•

Determine Inspection and Storage Requirements: -

•

000 509 0230 18 Feb 04 Page 2 of 2

Early in the project and continuing throughout the life of the project, the Construction Engineering Manager shall determine which items of permanent plant material and equipment that will require quality receiving inspection. The list shall be provided to the Site Quality Manager with a list of items to be inspected, along with any specific inspection and storage requirements. A typical list is provided as Attachment 2. Permanent Plant Material and Equipment Inspection List.

Quality Receipt Inspection: -

Prior to receipt of materials/equipment, the quality inspector shall research the purchase order, change orders, and specifications to determine the inspections and/or verifications to be performed. Prepare a Receiving Inspection Checklist, (000 509 F02301) for each item with the attributes to be inspected or verified, Reference Attachment 1 for attributes of inspection.

-

Upon receipt of material/equipment, perform receipt inspection prior to unloading of the material/equipment, if possible. If material cannot be inspected prior to unloading, material should be unloaded and segregated from other material until receiving inspection can be performed.

-

Inspect the material/equipment and associated vendor documentation for compliance with the requirements and document the results on the receiving inspection checklist (000 509 F02301).

-

If the material/equipment is found to be nonconforming, attach a Hold Tag (000 509 F01303) and initiate a Non-conformance Report (000 509 F01301).

FORMS Quality Control Forms: 000 509 F01301 - Nonconformance Report 000 509 F01303 - Hold Tag 000 509 F02301 - Receiving Inspection Checklist ATTACHMENTS Attachment 1 Attachment 2

Attributes for Receiving Inspection Typical Permanent Plant Material and Equipment Inspection List


Site Quality Manual



ATTRIBUTES FOR RECEIVING INSPECTION INSTRUCTIONS: Field Receiving Inspection Reference This inspection is to be performed after Receiving Operations performed by the Material Manager which have already confirmed identification of item per Purchase Order, identification of parts shipped separately, quantity and size of item, condition of shipping protection and damage. ANCHOR BOLTS Damage Corrosion Fit of Nut & Bolt Size Check REINFORCING STEEL Damage Corrosion Deformations

EXCHANGERS/PRESSURE VESSELS Damage Cleanliness Corrosion Flange & Opening Protection Shipping Protection Temporary Supports Fan Blades Motors

Mill Markings Mill Certifications STRUCTURAL STEEL Damage Corrosion Welding Piece Marking Connectors Dimensional Checks FIELD FABRICATED TANKS Damage Corrosion Edges Prepared for Welding Mill Certifications Dimensional Checks SHOP FABRICATED TANKS & VESSELS Damage Corrosion Accessories Flange & Opening Protection Temporary Supports Dessicants Shop Coatings Dimensional Checks Name Plate Data MACHINERY Damage Corrosion Accessories Shipping Protection Temporary Supports Vendor Instructions Flange & Opening Protection Name Plate Data Shaft Rotation Welding

Gears Dessicants Vendor Instructions Name Plate Data Shaft Rotation FIRED HEATERS & BOILERS Damage Corrosion Flange & Opening Protection Edges Prepared for Welding Mill Certifications Dimensional Checks Name Plate Data Welding Accessories Refractory SPECIALITY EQUIPMENT Damage Corrosion Flange & Opening Protection Edges Prepared for Welding Dimensional Checks Name Plate Data Welding Accessories PIPE Cleanliness Shipping Prep Damage Corrosion Shop Coatings Pipe Markings Color Coding and/or PMI if applicable

VALVES Identification Tags appropriately affixed and marked Damage Corrosion Flange & Opening Protections Moving Parts Valve Markings Positive Material Identification, if required FITTINGS, Alloy Damage Corrosion Piece Markings Positive Material Identification ELECTRICAL EQUIPMENT Damage Corrosion Name Plate Data Accessories Dimensional Checks Shipping Protection Temporary Supports ELECTRICAL MATERIAL Damage Corrosion Item Markings INSTRUMENTS Damage Corrosion Shipping Protection Item Markings Accessories COATINGS Damage Deterioration Cap Markings WELD FILLER MATERIAL Damage Properly Identified Mill Certifications



PERMANENT PLANT MATERIAL AND EQUIPMENT INSPECTION LIST

TYPICAL I.

CIVIL Civil materials such as: Structural steel components Load indicating bolts/washers

II.

Protective coatings Specialty grouts

MECHANICAL/PIPING MATERIALS All mechanical equipment that has an equipment tag number, such as: Pumps Cyclones Heat Exchangers Flares Vessels (Including Filters & Scrubbers) Boilers Trays API Tanks Piping materials such as: Alloy Pipe Specialty piping components Weld Rod

III.

ELECTRICAL All electrical equipment that has an equipment tag number, such as: Motors Motor Control Centers Switchgear Circuit Breakers Wire & Cable rated 5kV and higher (Hi-pot test prior to storage)

IV.

HYGIENIC TUBING SYSTEMS All Hygienic equipment and materials such as: Tubing Valves Nozzles

V.

Vessels Fittings Weld Rod

APPROVALS Construction Engineering Manager__________________________________ Date: Quality Manager__________________________________ Date:


000 509 0240 18 Feb 04 Page 1 of 5

TURNOVER SCOPE This procedure establishes the sequence of events leading up to the transfer of care, custody and control of completed systems or areas from Fluor to The Client. Fluor will request The Client's acceptance of buildings, systems or areas for care, custody, and control. RESPONSIBILITIES - Self-Performed ACTIVITY

DOCUMENTATION

Turnover Engineer

Scoped drawings and Form 000 509 FXXXX

Prior to start of work

Turnover Engineer

Turnover master listing


Commissioning/Start-up, engineering, construction management, and The Client

Form 000 509 F02401

Turnover Coordinator / CompleteIt Administrator

Form 000 509 F02402

Determine scope of system Establish alphanumeric number and brief scope Establish mechanical completion dates Issue walk-down notice Generate master punchlist Generate exceptions list Generate discipline checklist Generate care, custody, and control package

FREQUENCY OF ACTIVITY

RESPONSIBILITY

Turnover Coordinator / CompleteIt Administrator Turnover Coordinator / CompleteIt Administrator Turnover Coordinator/ CompleteIt Administrator Turnover Coordinator / CompleteIt Administrator

Form 000 509 F02407 Exceptions list format site specific Form 000 509 F02403 Form 000 509 F02404 Form 000 509 F02405 Form 000 509 F02406 Transfer of care custody and control letter Form 000 509 F02401 Form 000 509 F02402 Form 000 509 F02403 Form 000 509 F02404 Form 000 509 F02405 Form 000 509 F02406

Three weeks before mechanical completion date Two weeks before mechanical completion date Prior to mechanical completion date

Prior to mechanical completion Prior to turnover of system or area

System scoping drawings, elementary or one line diagram. Hydro test report. Equipment list. Instrument list. Exceptions list. Loop list. Surveillance


QC Inspector

Form 000 509 F02201

Per Procedure 000 509 0220 Site Quality Manual


000 509 0240 18 Feb 04 Page 2 of 5

Responsibilities - Subcontracted Work RESPONSIBILITY

Determine scope of system

Turnover Engineer / Subcontractor

Scoped drawings


Establish alphanumeric number and brief scope

Turnover Engineer / Subcontractor

Turnover master listing


Establish mechanical completion dates

Commissioning/Startup/ Engineering / Construction Management / and The Client

Form 000 509 F02401

Three weeks before mechanical completion date

Issue walk-down notice

Turnover Coordinator/ CompleteIt Administrator / Subcontractor

Form 000 509 F02402

Two weeks before mechanical date

Generate master punchlist

Subcontractor/ Turnover Coordinator / CompleteIt Administrator

Generate discipline checklist


Generate care, custody, and control package


Surveillance

QC Inspector


DOCUMENTATION


ACTIVITY

Form 000 509 F02407 Form 000 509 F02403 Form 000 509 F02404 Form 000 509 F02405 Form 000 509 F02406 Transfer of care, custody, and control letter Form 000 509 F02401 Form 000 509 F02402 Form 000 509 F02403 Form 000 509 F02404 Form 000 509 F02405 Form 000 509 F02406

Prior to mechanical completion date Prior to mechanical completion

System scoping drawings, elementary or one line diagrams Hydrotest Report Equipment List Instrument List Exceptions List Loop List Form 000 509 F02201

Per Procedure 000 509 0220

Site Quality Manual


000 509 0240 18 Feb 04 Page 3 of 5

PROCEDURE • Determine Scope of System: - Determine the areas and process units that make up a system scope boundary. - Once system scoping has been determined, each system will be assigned a name and an alpha-numeric number. A brief description of scope boundary will be generated. This information will be compiled into a master list and distribution made. Scoped drawing will be prepared to indicate system boundaries. Identify content of turnover package and initiate package index. • Establish Mechanical Completion dates: - Mechanical completion dates for systems will be established with input from The Client Management and Fluor Commissioning / Startup, Construction, and Engineering. These dates will be used for tracking and scheduling. • Issue Walkdown Notice: - Approximately three (3) weeks before the established mechanical completion date for a system, a walkdown notice for Fluor will be issued (Form 000 509 F02402) • Generate Discipline Checklist: - Each discipline Manager will generate a checklist to verify all work has been completed as required by drawings and specifications. The Commissioning / Startup Administrator will generate a checklist to verify that all required quality records have been completed and those designated for turnover are included in the Turnover Package. • Generate Master Punchlist: - When the Fluor walkdown has been completed, a master punchlist will be compiled (Form 000 509 F02407). CompleteIt will be used to track and status the master punchlist. - The master punchlist will identify any incomplete items of work and/or errors in design or installation. The master punchlist will be issued to construction and engineering for corrective action. - Approximately two (2) weeks before the established mechanical completion date, the turnover coordinator will notify The Client that the system is ready for their walkdown. A copy of the open items from the master punchlist will be attached to the walkdown notice.


Site Quality Manual


000 509 0240 18 Feb 04 Page 4 of 5

• Generate the Exception List: - After The Client walkdown has been completed, the CompleteIt Administrator will schedule a joint meeting between The Client and Fluor. The purpose of this meeting will be to reconcile the punch list. Any items that will impede pre-commissioning/commissioning or cannot be completed after commissioning/start-up shall be completed prior to the mechanical completion date. These items will be coded Category 1. Any remaining incomplete items will become items on the exceptions list and be included as part of the transfer of care, custody, and control package. - The items on the exceptions list will be categorized as 2, 3, 4 or 5. Category 2 items may be completed anytime with the approval of The Client. Category 3 items are generated by the client/operations. Category 4 items are added scope. Category 5 items are other issues. • Generate Care, Custody, and Control Package: - The turnover coordinator will assemble the transfer of care, custody, and control package. The package will contain, as applicable, the following documents: a) b) c) d) e) f) g) h) i)

Transfer of Care, Custody, and Control Letter Discipline Managers Checklist System Scoping Drawings Elementary or One-Line Diagrams Hydrostatic Test Report Equipment List Instrument List Exceptions List Loop List

- The Client management has ten (10) calendar days to respond to the transfer of care, custody, and control letter. At time of acceptance, The Client should tag equipment to indicate their control of that system. - The Client shall install lockout-type devices on all isolation equipment such as breakers, valves, etc. Fluor may also install lockout devices on system boundary isolation equipment. This action will be necessary to make safe any equipment or system that has not been completed and custody transferred to The Client. - All supporting documentation relating to mechanical completion/system turnover will be retained by Fluor until system acceptance by The Client. After system acceptance by The Client, this documentation will be transferred to The Client under separate correspondence.


Site Quality Manual


000 509 0240 18 Feb 04 Page 5 of 5

FORMS Quality Control Forms: 000 509 F02401 – Transfer of Care, Custody, and Control Letter 000 509 F02402 - System Walkdown Notice 000 509 F02403 - Mechanical Completion – Civil Checklist 000 509 F02404 - Mechanical Completion – Electrical/Instrumentation Checklist 000 509 F02405 - Mechanical Completion – Mechanical Checklist 000 509 F02406 - Mechanical Completion – Quality Control Checklist 000 509 F02407 - Master Punch List 000 509 F02408 – Interim Turnover Notice 000 509 F02409 – Mechanical Completion Certificate


Site Quality Manual


000 509 0250 18 Feb 04 Page 1 of 2

MATERIAL AND EQUIPMENT STORAGE AND MAINTENANCE

SCOPE This procedure defines the requirements for periodic inspection of the storage and maintenance of designated materials and equipment. RESPONSIBILITIES - Self-Perform / Subcontracted ACTIVITY

RESPONSIBILITY

DOCUMENTATION


Develop a material/equipment storage requirement list

Subcontractor/ Construction Engineer or Project Engineer

See Attachment 1 for "Sample" list

Prior to receipt of material & equipment

Generate the storage inspection checklist

Subcontractor/Site Quality Manager

Form: 000 509 F02501

Prior to receipt of material & equipment

Inspect storage & maintenance Perform Preservation Activities Resolve discrepancies as appropriate

Subcontractor/Site Quality Manager Subcontractor/Site Quality Manager Subcontractor/Site Quality Manager Site Quality Manager (*Note 1)

Form: 000 509 F02501 Form: 000 509 F02502 Form: 000 509 F02501 Form: 000 509 F02201

Monthly during the life of the activity

Surveillance *Note 1:

Each Item As required to resolve discrepancies Per procedure 000 509 0220

Surveillance is not required if the Fluor Quality Representative is performing the inspections.

PROCEDURE •

Storage Requirement List -

•

Develop a material/equipment storage requirement list (see Attachment 1 for a sample list) consisting of protective measures to prevent damage, deterioration, or contamination of material and equipment.

Storage Inspection Checklist -

Using the material/equipment storage requirement list as a guide, generate a storage inspection checklist (refer to Form 000 509 F02501 for a sample of the storage inspection checklist).


Site Quality Manual


•

•

000 509 0250 18 Feb 04 Page 2 of 2

Inspection of Storage and Maintenance -

Perform inspections of storage areas, including items stored "In-Place", on a monthly basis.

-

Document any discrepancies noted during inspections.

Discrepancy Resolution -

Resolve any noted discrepancies with the appropriate parties.

-

Perform re-inspection(s) to verify that the noted discrepancies have been corrected.

FORMS Quality Control Form: 000 509 F02501 - Storage Inspection Checklist 000 509 F02502 – Equipment Protection Preservation and Inspection Record ATTACHMENTS Attachment 1 - Material/Equipment Storage Requirement List (Sample)


Site Quality Manual



MATERIAL/EQUIPMENT STORAGE REQUIREMENT LIST The requirements for storage are divided into four levels with respect to protective measures to prevent damage, deterioration or contamination of items and materials based upon important physical characteristics, the ambient conditions during construction installation and operation of the item or material. Level A - Items classified to Level A are those that are exceptionally sensitive to environmental conditions and require special measures for protection from one or more of the following effects: temperatures outside required limits; sudden temperature changes; humidity and vapors; gravitational (g) forces; physical damage and air-borne contamination (e.g., rain, snow, dust, slat spray, fumes). The following shall be used as a guide for classifying items intended for Level A classification: a.

Special electronic equipment and instrumentation.

b.

Special materials, such as chemicals that are sensitive to environment.

c.

Computers

Level B - Items classified to Level B are those that are sensitive to environmental conditions and require measures for protection from the damaging effects of one or more of the following: temperature extremes, humidity and vapors, gravitational forces, physical damage and airborne contamination but do not require the special protection required for Level A items. The following shall be used as a guide for classifying items intended for Level B classification: a.

Instrumentation

b.

Electrical penetrations

c.

Batteries

d.

Welding electrode and wire

e.

Motor control centers, switchgear, and control panels

f.

Motors and generators

g.

Precision-machined parts

h.

Erection spares, such as gaskets, "O" rings

i.

Air-handling filters



Level C - Items classified to Level C are those that require protection from exposure to the environment, air-borne contaminants, gravitational forces, and physical damage. Protection from water vapor and condensation is not so important as that for Level B items. The following shall be used as a guide for classifying items intended for Level C classification: a.

Pumps

b.

Valves

c.

Fluid Filters

d.

Compressors

e.

Turbines

f.

Instrument cable

g.

Thermal insulation

h.

Fans and blowers

Level D - Items classified to Level D are those that are less sensitive to the environment than Level C. These items require protection against the elements, air-borne contamination, and physical damage. The following shall be used as a guide for classifying items intended for Level D classification: a.

Tanks

b.

Heat exchangers and parts

c.

Accumulators

d.

Demineralizers

e.

Evaporators

f.

Piping

g.

Electrical cable

h.

Structural items

i.

Reinforcing steel



STORAGE REQUIREMENTS Items assigned a level of storage shall be maintained at this level of storage until they are removed from storage. Items removed from storage and installed, but not operating, shall have the assigned level of storage maintained. Levels of Storage Environmental conditions for items classified as levels A, B, C, and D described in this procedure shall meet the following requirements: Level A - Items shall be stored under those conditions described for Level B items but with any additional requirements detailed by the manufacturer and/or engineering representative. Level B - Items shall be stored within a fire-resistant, tear-resistant, weathertight, and wellventilated building or equivalent enclosure. Precautions shall be taken against vandalism. This area shall be situated and constructed so that it will not be subjected to flooding; the floor shall be paved, or equal, and well-drained. Items shall be placed on pallets or shoring to permit air circulation. The area shall be provided with uniform heating and temperature control, or its equivalent, to prevent condensation and corrosion. Minimum temperature shall be 40°F and maximum shall be 140°F or less if so stipulated by the manufacturer. Level C - Items shall be stored indoors, or equivalent, with all provisions and requirements as set forth in Level B items except that heat and temperature control is not required. Level D - Items may be stored outdoors in well-drained areas marked and designated for storage, preferable gravel-covered or paved, and reasonable removed from the actual construction and traffic so that possibility of damage from construction equipment is minimized. Items shall be stored in 4-inch cribbing or equivalent to allow for air circulation and to avoid trapping water. Care of Stored Items Care of items in storage shall be exercised in accordance with the following: a.

Items in storage shall have all covers, caps, plugs, or other closures intact. When it is necessary to remove a cover for access purposes, it shall be immediately replaced and properly resealed thereafter.

b.

Temporary preservatives shall be left intact during storage. Should reapplication of preservatives be required at the site, only those previously approved shall be used.

c.

Desiccant humidity indicators shall also be monitored, and desiccants shall be changed or reprocessed when specified.

d.

Instrumentation racks shall be energized as specified by the manufacturer.

e.

Space heaters enclosed in electrical items shall be energized.



f.

Rotating electrical equipment shall be given insulation resistance tests on a scheduled basis.

g.

The shafts of rotating equipment shall be rotated on a periodic basis. The degree of turn shall be 1 1/4 turn so that the parts receive a coating of lubrication where applicable, and so that the shaft does not come to rest in a previous position.

h.

Implement special instructions issued by the vendor or manufacturer for a particular piece of equipment.


000 509 5100 18 Feb 04 Page 1 of 4

ACTIVITY PLAN FOR CONSTRUCTION SCOPE This practice establishes instructions for the preparation of a project specific Activity Plan for Construction (inclusive of Construction Management and Maintenance). REFERENCES

N/A

GENERAL • The Activity Plan is intended to: -

List the main activities to be performed in order to meet quality system requirements.

-

Identify the work instructions for performing these activities.

-

Assign responsibility for verification, and authorization of listed activities.

-

Identify deviations from established minimum requirement work instructions provided by the Construction Operating Company.

-

Provide for Operating Company acceptance of those deviations.

• The Activity Plan - Construction - Reference Guide (Appendix I), is intended to provide guidance for development of a project specific Activity Plan - Construction. The following guidance is provided by the Reference Guide: -

Activity Description - This is a listing of primary activities performed on a construction project, except those activities for which Construction is not responsible (i.e., Project Management, Project Controls, Procurement, etc.).

-

Work Instruction - This identifies the work instruction, procedure, practice, specification, or other guidance provided or referred to by Construction for performing the work activity.

-

Basis of Check - This identifies either the checklist(s) or procedure used as a guide for checking the work.

-

Inter-discipline Review - The individual(s) normally responsible for ensuring no conflicts between disciplines/departments exist.

-

Independent Verification - This block is reserved for the entry of third party verification, (i.e., Testing Laboratory, Client, etc.), when applicable.

-

Performed By - The title of the individual who is normally responsible for performing the


Site Quality Manual


000 509 5100 18 Feb 04 Page 2 of 4

work activity. -

Checked By - The title of the individual responsible for checking and documenting activity compliance to work instructions, utilizing appropriate basis of check as required. This is normally someone other than the individual performing or directing the work.

-

Approved by Construction - The title of the individual responsible for approving from a construction standpoint, that the work is accomplished and acceptable.

-

Approved by Project - Usually reserved for project manager review and approval that the work performance and verification meets project and contract requirements.

-

Approved by Client - to be used when the work performed requires the Client’s approval (usually specified by contract). NOTE:

For subcontracted work, refer to the “Subcontractor Control” Section 1 of Appendix I for typical "Go-By".

PROCEDURE AND RESPONSIBILITIES • Site Manager or Designee -

Refer to Appendix I and revise as follows to develop the project specific AP - Construction. NOTE:

The project specific "AP - Construction" may be developed by marking up the "AP - Construction - Reference Guide" (Appendix I) to indicate changes.

•

Activity Description - Delete and add primary project specific activities as required. This should include activities Fluor is responsible for even though they may be performed by a Sub-contractor. Activities for which Fluor has no responsibility should not be listed on AP.

•

Work instruction - Identify the work instruction, procedure, practice or specification for performing the Work Activity. •

If the work instruction is to be used without deviation from the Fluor Corporate Standard, the Fluor Corporate Descriptor as listed in the Reference Guide will be used.

•

If a deviation to the Corporate Standard is made by project personnel, indicate the deviation by dropping the first three zero's of the Corporate Descriptor (e.g. 509 7031).

•

If the work instruction is from a source outside Fluor (e.g., Client procedure or specifications), list the source document description.

NOTE:

Title descriptors noted in blocks of the Activity Plan - Construction may differ from those used in locations other than United States. Where this situation exists, use the Descriptors common to the location.


Site Quality Manual


000 509 5100 18 Feb 04 Page 3 of 4

•

Basis of check - Enter the checklist number or designation used as a guide for checking the work.

•

Interdisciplinary Review - Specify the person responsible for reviewing and ensuring, thru cross-discipline review, that no discipline or department conflicts exist.

•

Independent Verification - enter a designator for any third party verification authority. This can apply to a Quality Control sub-contractor, testing subcontractor, Client, etc.

•

Performed by - Enter the title of the person responsible for performing the activity.

•

Checked By - Enter the title of the person responsible for checking and documenting activity compliance to work instruction utilizing appropriate basis of check as required.

NOTE:

"Checked By" in certain locations other than the United States will be performed by others disciplines that perform the Quality Control function and shall be so indicated as applicable.

•

Approved by Construction - Enter the responsible individual (e.g., "CM" for Construction Manager) signifying that the work, has been accomplished and accepted per the listed instructions.

•

Approved by Project - Enter the responsible individual (e.g., "PM" - for Project Manager or "OM" for Operations Manager) that has project function responsibility for approving the work. Usually involves contractual, administrative, engineering, and construction activities overview and responsibility. Intended to be the highest level of project activity approval.

•

Approved by Client - Enter the Client representative (e.g., "Client PM"), when required by project contract or Project Procedures Manual that the work be approved.

• Site Manager -

Sign and print name to indicate approval.

• Operating Company Representative -

Sign and print name to indicate approval.

• Site Manager -

After approval by the Operating Company Representative, if there are changes to the Work Instruction that result in deviations or if activities are added, notify the Operating Company Representative of these changes in writing.


Site Quality Manual


000 509 5100 18 Feb 04 Page 4 of 4

DOCUMENTATION Approved "Activity Plan - Construction" shall be maintained by the Site Manager until project completion. ATTACHMENTS Appendix I - Activity Plan - Construction (Reference Guide)


Site Quality Manual


000 509 5100 18 Feb 04 Appendix I . . . Page 1 of 5

QUALITY ACTIVITY PLAN - CONSTRUCTION Client Name Project Name Project Number PREPARATION ACTIVITY DESCRIPTION

•

CHECKED BY

APPROVED BY CONSTR.

APPROVED BY PROJECT

SM SM

N/A N/A

N/A N/A

PM PM

N/A

PM

PM

N/A

N/A

PM

000.505.1601

N/A

CEM

DCE

N/A

SM

N/A

000.505.2701

N/A

N/A

FHRM

N/A

SM

N/A

000.505.3201

000 509 0240

SM

CM

SQM

N/A

PM

Project Safety Plan in Compliance with FD-APS

N/A

N/A

S

RSM

N/A

PM

000.505.2801

N/A

N/A

SM

IRRM

N/A

PM

000.505.1701

Corporate QC Manual 000 509 xxxx

SQM

DCE

CEM

CM

N/A

000.505.2401

N/A

CEM

SVM

N/A

N/A

PM

Fluor-B-PV Code Manual 000 510 xxxx 000.509.0050 000.505.1601

FD-B-PV Code Manual 000 510 xxxx 000.509.0050 000.509.0160

DQW

CEM

SQM

N/A

PM

CEM

SM

SQM

N/A

PM

000.509.0180

N/A

CEM

CM

SQM

N/A

PM

000.505.1400

000.509.0150

CEM

DCE

SQM

N/A

PM

000.509.0090

000.509.0090

CEM

DCE

SQM

CM

N/A

000.210.02010

000.509.7010

DCE

CM

SQM

SM

N/A

000.210.02222 000.210.02224

000.509.7010

DCE

CM

SQM

CM

N/A

000.215.03360

000.509.7820

DCE

CM

SQM

CM

N/A

Pile Installation

000.215.02370 000.215.02380

000.509.7080

DCE

CM

SQM

CM

N/A

Concrete Installation

000.215.03300

000.509.7100

DCE

CM

SQM

CM

N/A

000.509.7100

DCE

CM

SQM

CM

N/A

000.509.7200

DCE

CM

SQM

CM

N/A

000.285.86410 000.285.86210

000.509.7800

DCE

CM

SQM

CM

N/A

000.285.86110

000.509.7810 Contract

DCE

CM

SQM

CM

N/A

Construction Engineering Human Resource Staffing Construction Turnover

•

Project Safety Program

•

Industrial Relations Program Construction Quality Control Plan Administrative Services

•

INDEPENDENT VERIFICATION

AUTHORIZATION

PERFORMED BY

N/A N/A

•

•

INTER DISCIPLIN E REVIEW

N/A N/A

Constructability

•

VERIFICATION BASIS OF CHECK

000.506.1300 000.506.1201 000.506.1100 000.506.1200 000.506.1300 000.506.1400 000.506.1500 000.506.1600

Project Const. Plan Const. Org.

•

•

WORK INSTRUCTION

ASME Code Work Document Control Personnel Training and Qualification Field Design Change Control Construction Process Control Site Preparation Geotechnical Investigation Excavation and Backfill Shotcrete Fireproofing

Grout Installation Structural Steel Installation Coatings and Wrapping of Steel Pipe Hot Insulation

000.215.03600A 000.215.03600B 000.215.05120 000.215.05130

APPROVED BY CLIENT



PREPARATION ACTIVITY DESCRIPTION

WORK INSTRUCTION

Internal Linings

000.285.86310

Raceway and Supports Installation

000.265.65051 000.265.65052 000.265.65123 000.265.65126 000.265.65003 000.265.65301 000.265.65303 000.265.65313 000.265.65320 000.265.65382 000.265.65400 000.265.65480 000.265.65610 000.265.65630

Cable Installation

Equipment Installation

Meggering and HiPot Testing

000.265.65053

Grounding

000.265.65053 000.265.65640 000.265.16111

Meggering and Maintenance of Electric Motors Electrical Heat Trace Receiving and warehousing of Instruments Electrical Instrument Installation Construction Testing Piping, Cement Lined Plastic and Plastic Lined Pipe

VERIFICATION

000.265.65053 000.270.01851 000.270.70952 000.270.70001 000.270.70002 000.270.70003 000.270.70007 000.270.15121 000.265.65053

BASIS OF CHECK

INTER DISCIPLINE REVIEW


AUTHORIZATION

PERFORMED BY

CHECKED BY

APPROVED BY CONSTR.

APPROVED BY PROJECT

000.509.7800 Contract

DCE

CM

SQM

CM

000.509.7600

DCE

CM

SQM

CM

N/A

000.509.7600 000.509.7610

DCE

CM

SQM

CM

N/A

DCE

CM

SQM

CM

N/A

DCE

CM

SQM

CM

N/A

DCE

CM

SQM

CM

N/A

DCE

CM

SQM

CM

N/A N/A

000.509.7400 000.509.7620

000.509.7600 000.509.7610 000.509.7620 000.509.7600 000.509.7610 000.509.7620 000.509.7600 000.509.7610 000.509.7620 000.509.7610

DCE

CM

SQM

CM

000.509.0230 000.509.0250

DCE

WM

SQM

SM

000.509.7600 000.509.7610 000.509.7620

DCE

CM

SQM

CM

N/A N/A

*

DCE

CM

SQM

CM

000.250.31003

000.509.7510

DCE

CM

SQM

CM

000.250.31004

000.509.7500 111.509.7510

DCE

CM

SQM

CM

Mechanical Piping Installation

000.250.50026 000.250.50200 000.255.03161 000.250.03713 000.250.03711 000.250.03717 000.250.05360 000.250.17131

000.509.7500 000.509.7510

DCE

CM

SQM

CM

N/A

Flanged Joints, Gaskets and Bolting

000.255.03161

DCE

CM

SQM

CM

N/A

Pipe Winterization

000.250.50008

DCE

CM

SQM

CM

N/A

000.509.7400

DCE

CM

SQM

CM

N/A

000.509.7610 000.509.7500 000.509.7510

DCE

CM

SQM

CM

N/A

000.509.7700 000.509.7710

DCE

CM

SQM

CM

N/A

Installation of Rotating Equipment

Installation of Tanks, Vessels - Heat Exchangers, Flares

Mechanical Instrument Installation

000.256.56001 000.256.56002 000.256.56003 000.256.56004 000.258.58001 000.258.58004 000.258.58010 000.258.58040 000.258.58050 000.259.59073 000.258.58061 000.258.58140 000.257.07041 000.257.18032 000.257.19033 000.257.57011 000.257.57020 000.257.57035 000.257.57103 000.270.70002 000.270.70950 000.270.70951

000.509.7500 000.509.7510 000.509.7500 000.509.7510

APPROVED BY CLIENT




WORK INSTRUCTION

Pipe Cleaning

000.250.18801

Piping Heat Tracing

000.250.50300

Firewater Systems

000.245.00323

Fireproofing Sewer Systems Maintaining Quality Records Material Equipment Identification, Traceability and Inspection Test Status Nonconformance Reporting Corrective Action Site Supplier Quality Control System, Requirement Qualification and Surveillance Material and Equipment Receipt Inspection Material and Equipment Storage Handling Maintenance Inspection Measuring Test Equipment Surveillance of Construction Activities

VERIFICATION INTER DISCIPLINE REVIEW

BASIS OF CHECK


AUTHORIZATION

PERFORMED BY

CHECKED BY

APPROVED BY CONSTR.

APPROVED BY PROJECT

DCE

CM

SQM

CM

N/A

DCE

CM

SQM

CM

N/A

DCE

CM

SQM

CM

N/A

000.245.01431 000.250.50007

000.509.7560 * 000.509.7610 000.509.7500 000.509.7510 000.509.7820 000.509.0220

DCE DCE

CM CM

SQM SQM

CM CM

N/A N/A

000.509.0160

000.509.0160

SQM

CM

SQM

CM

N/A

000.509.7000 000.509.0230

FD Inspection & Test Procedures 000 509 7xxx

SQM

WM CM

SQM

CM

N/A

000.509.0130

000.509.0130

SQM

SQM

SQM

SM

N/A

000.509.0140

000.509.0140

SQM

CEM

CM

SM

N/A

000.509.0210 000.509.0200 000.509.0220

000.509.0200 000.509.0210 000.509.0220

SQM

CEM

SQM

SM

N/A

000.509.0230

000.509.0230

SQM

WM CEM

SQM

CM

N/A

000.509.0250

000.509.0250

SQM

WM CEM

SQM

CM

N/A

000.509.0110

000.509.0110

SQM

CEM

SQM

CM

N/A

000.509.0220

000.509.0220

SQM

SQM

SQM

CM

N/A

Welding Metallurgy

000.285.18034 000.285.18041 000.285.18101 000.285.19021 000.285.85001 000.285.85002 000.285.85010 000.285.85050

000.509.7910 000.509.7920 000.509.7930 000.509.7950 Fluor Welding Manual 000.512.xxxx

CEM

CM

SQM

CM

N/A

Nondestructive Testing

Subcontractor’s NDE Procedures

Fireproofing

000.245.01431

Drilled Piers, Caissons

000.215.02380

Auger Cast Piles

000.215.02370

Painting & Linings

000.285.86210 000.285.86310

Hot Insulation

000.285.86110

SUBCONTRACTOR CONTROL

ASME Section VIII Vessel Work

Fired Heaters Field Fabricated Tank Retrofit (TK – 806) Cool Tower Installation Piping Tie-ins

000.509.0220 000.509.7920 000.509.7820 Contract 000.509.7080 Contract 000.509.7080 Contract 000.509.7800 Contract 000.509.7810 Contract

SUB

SQM

SM

N/A

CEM

SUB

DCE

CM

N/A

CEM

SUB

DCE

CM

N/A

CEM

SUB

DCE

CM

N/A

CEM

SUB

DCE

CM

N/A

CEM

SUB

DCE

CM

N/A

Contract

CEM

SUB

SQM

CM

N/A

000.509.7400 Contract

CEM

SUB

SQM DCE

CM

N/A

API 650 Appendix H

000.509.7400 Contract

CEM

SUB

SQM DCE

CM

N/A

000.257.57011

000.509

CEM

SUB

DCE

CM

N/A

000.250.50027

Contract

CEM

SUB

DCE

CM

N/A

000.258.58001 000.258.58004 000.258.58010 000.258.58040 000.258.58050 000.258.58061 000.258.58140 000.257.07041 000.257.18032 000.257.19033 000.257.57103

MNDT

SQM

Client

APPROVED BY CLIENT




Fire Protection/Sprinkler Systems Substation Equipment Modification Electrical Equipment Testing Hi-Pot and Acceptance Testing Electrical Heat Tracing Reactor Flex-R Instrumentation Installation Field Machining Geotechnical Investigation Mechanical/ Chemical Cleaning Post-Weld Heat Treatment (PWHT) Soil & Concrete Testing Underground Piping

WORK INSTRUCTION

VERIFICATION BASIS OF CHECK

INTER DISCIPLINE REVIEW


AUTHORIZATION

PERFORMED BY

CHECKED BY

APPROVED BY CONSTR.

APPROVED BY PROJECT

000.245.00323

Contract

CEM

SUB

DCE

CM

N/A

000.245.65301 000.265.65303 000.265.65320

Contract

CEM

SUB

DCE

CM

N/A

000.265.65053

000.509.7600 000.509.7610 000.509.7620 Contract

CEM

SUB

DCE

CM

N/A

000.265.50300 000.270.01851

Contract

CEM

SUB

DCE

CM

N/A

000.270.01511

Contract

CEM

SUB

DCE

CM

N/A

Contract

Contract

CEM

SUB

SQC

CM

N/A

000.210.02010

Contract

CEM

SUB

DCE

CM

N/A

000.509.7560

CEM

SUB

DCE/SQM

CM

N/A

000.509.0220 000.509.7920

CEM

SQM

SUB

SQM

CM

N/A

000.509.7010 000.509.7100

CEM

SQM

SUB

DCE SQM

CM

N/A

000.509.7500

CEM

SUB

SQM DCE

CM

N/A

000.250.18801 000.250.50026 000.285.18041 Fluor Welding Manual 000.210.02222 000.210.02224 000.215.03300 000.245.00323

APPROVED BY CLIENT


PQ

AEASSIGNED PROJECT QA ENGINEER

CS

CODE SPECIALIST/GREENVILLE

CEM

CONSTRUCTION ENGINEERING MANAGER

FL

CONSTRUCTION FUNCTIONAL LEADER

CM

CONSTRUCTION MANAGER

DCE

DISCIPLINE CONSTRUCTION ENGINEER

DQW

DIRECTOR QUALITY CONTROL AND WELDING TECHNOLOGY

FHRM

FIELD HUMAN RESOURCE MANAGER

NDE

FLUOR DANIEL NDE LEVEL III

IRRM

INDUSTRIAL RELATIONS REGIONAL MANAGER

LDE

LEAD DISCIPLINE ENGINEER

MWT

MANAGER WELDING TECHNOLOGY/GREENVILLE

N/A

NOT APPLICABLE

PD

PROJECT DIRECTOR/PROJECT MANAGER

PM

PROJECT MANAGER

RSM

REGIONAL SAFETY MANAGER

SC

SELF CHECK ONLY

SUB

SUBCONTRACTOR

SVM

SERVICE MANAGER

SQM

SITE QC MANAGER

SM

SITE MANAGER

S

SITE SAFETY MANAGER

WM

WAREHOUSE MANAGER

CTM

CONTRACTS MANAGER

*


FLUOR SITE MANAGER

FLUOR OPERATING COMPANY REPRESENTATIVE

_________________________________________ Signature

______________________________________ Signature

_________________________________________ Print Signature

______________________________________ Print Signature

These checklists are provided in the "Discipline QC Functions" section (000.509.7xxx).


000 509 7000 18 Feb 04 Page 1 of 3

INSPECTION AND TESTING Definitions Inspection and tests are defined as follows: • •

"Inspection" being visual checks of a qualitative nature but also including dimensional measurements. "Tests" being measured verifications of one or more characteristics or of performance, both being carried out to ascertain whether or not the specified requirements have been met.

Inspection and Testing Procedures Inspection and test measures to be applied are presented in this section (7XXX). These procedures provide for the inspections and tests necessary to determine that the product is acceptable and for the documentation to record compliance with the established acceptance criteria. The inspection scope and frequency will be determined on a case-by-case basis with guidance provided in the "Responsibilities" section of each procedure. If specifications, vendor manuals, test procedures, codes/standards, or other such documents required by specifications to be used as acceptance criteria are not readily available to inspection personnel, the Site Quality Manager may include this information as attachments to these procedures. Attachments may also be used to list the source documents providing acceptance criteria for tests and inspections within the scope of each procedure. Inspection and Test Plans An Inspection and Test Plan (ITP) is a document used to list the quality related activities that pertain to a distinct scope of work or process. The ITP shall consist of the following features: • • • •

a list of the inspection and test points presented in sequence in the order in which they are to be performed for each activity, reference to a document stating the acceptance criteria; for each activity, the "verification document" i.e. the document to be checked or the one used to record the result of the inspection or test; for each activity for both Contractor and FLUOR, where required, an indication of the scope of inspection as follows: I - Inspect T - Test W - Witness Point


This indicates an Inspection/Text Activity on the ITP that requires a request for the presence of the Fluor Representative.

Site Quality Manual


R - Review H - Hold Point

000 509 7000 18 Feb 04 Page 2 of 3

This indicates an inspection or test which is considered vital to the quality, integrity and safe functioning of the material or services and which can only be achieved at this point. It is an Inspection/Test Activity on the ITP that requires the presence of the Fluor Representative. The Production/Erection Process cannot proceed beyond this point until it has been cleared by the Inspection Fluor Representative.

ITPs may be used to record completion of activities, indicated by sign-off (acceptance). This is normally applicable to scopes of work encompassing a relatively self-contained unit such as a steam turbine or cooling tower. When this is the case ITP form 509 F70002 shall be used. Otherwise for processes such as concrete placement or piping installation, Inspection and Test Plans shall be documented on form 509 F70001. ITPs may be used in lieu of or in conjunction with Inspection and Test Procedures. Inspection Cycles Adequate inspection will be performed to cover required construction operations. The inspection cycle normally includes preparatory, initial, follow-up and final inspection. This cycle is described below: -

Preparatory - Performed prior to beginning work to ensure the prerequisites are satisfied and requirements understood by those who perform the work. It includes a review of requirements; a check to assure that all materials and/or equipment are on hand and are approved and that all preliminary work has been completed.

-

Initial - Performed at the outset of segments of work to get the work off to a proper start in full compliance with contract requirements.

-

Follow-up - Performed daily or as frequently as necessary to assure continuing compliance with contract requirements.

-

Final - Inspections that verify the acceptance of completed items. This occurs throughout fabrication and installation. Acceptance is indicated by use of the inspection checklist referenced by procedures of this section.

The inspection status of constructed or installed items is normally determined by reference to the inspection or test reports/checklists included as referenced forms to these procedures. These forms are completed concurrently with the construction /installation activities. Deficiencies that are found during inspection, and cannot be corrected at that time, are to be documented on Surveillance Reports (000 509 F02201), so that they can be tracked to closure. In special cases that are described by 000 509 0130 where a NCR is needed, that documentation does not need to be duplicated by a Surveillance Report.


Site Quality Manual


000 509 7000 18 Feb 04 Page 3 of 3

FORMS Quality Control Form: 000 509 F70001 - Inspection and Test Plan Form 000 509 F70002 - Inspection and Test Plan/Activity Completion From ATTACHMENTS Attachment 1

- Instructions for completion of the ITP form


Site Quality Manual



Instruction for Preparing the Inspection Test Plan Field Name

Description

Activity

Identify the general activity or scope of work for the ITP

Description

Identify the specific activity that applies to the ITP

Project Name/Number

Enter project name and number

Client

Enter Client name

Contractor

Enter contractor name (if subcontracted)

Contract Number

Enter contract or subcontract number as applicable

ITP Number

Uniquely Identify the ITP, ITP 509 7XXXX

Issue Date/Revision Number Enter the current issue date and revision Item Number

Used to identify the sequence of the quality-related activity

Quality-Related Activity

Enter a description of the quality-related activity

Requirement and Acceptance Criteria

Enter the acceptance criteria or reference to the specification or other standard where the acceptance criteria may be found.

Responsibility

Enter the Fluor position primarily responsible for executing Fluor’s participation in the activity. Use the code legend on the bottom of the ITP form to represent the entities.

Scope of Inspection

Use these fields to specify the level of participation required by the various entities.

Inspection Record

If an inspection record is to be used to document the inspection results, enter the form or record number.

CompleteIt Input

If the activity is recorded in CompleteIt indicate with a “Yes”

Completion Sign-off

Indicate if Fluor and/or Client signatures are required.


000 509 7010 18 Feb 04 Page 1 of 2

SOILS SCOPE This procedure applies to inspection and testing of soils work. RESPONSIBILITIES - Self-Perform ACTIVITY

RESPONSIBILITY

DOCUMENTATION


Perform soils work

Self-Perform

Inspect in-process soils work

QC Inspector

000 509 F70101

Daily during life of activity

Test Soils Work

Test Lab contracted to Fluor

000 509 F70102 000 509 F70103 000 509 F70104(Note 1) 000 509 F70105

As Directed

Technically Supervise Test Agency

Civil Construction Engineer

Surveillance

QC Inspection (Note 2)

Daily during life of activity 000 509 F02201


NOTE 1:

Approved test agency reports on their letterhead is preferred over the use of forms for documenting soils tests, but it must contain at least the information provided by Forms 000 509 F70102, 000 509 F70103, 000 509 F70104.

NOTE 2:

Fluor QC Surveillance is required for construction activities not being documented on other Inspection forms by Fluor Quality.

RESPONSIBILITIES - Subcontracted Work ACTIVITY

RESPONSIBILITY

DOCUMENTATION


Perform soils work

Subcontractor

Inspect in-process soils work

Subcontractor

000 509 F70101


Test Soils Work

Test Lab contracted to subcontractor

000 509 F70102 000 509 F70103 000 509 F70104 (Note 1) 000 509 F70105

As directed

Technically Supervise Test Agency

Subcontractor

Surveillance

QC Inspector

NOTE 1:

Daily during life of activity Form 000 509 F02201


Approved test agency reports on their letterhead is preferred over the use of forms for documenting soils tests, but it must contain at least the information provided by Forms 000 509 F70102, 000 509 F70103, 000 509 F70104.


Site Quality Manual


NOTE 2:

000 509 7010 18 Feb 04 Page 2 of 2

Fluor QC Surveillance is required for construction activities not being documented on other Inspection forms by the Fluor Quality.

GENERAL •

•

•

Inspection -

Inspection will include the items on the Soil Inspection Checklist Inspection Reference (Form 000 509 F70101.

-

As a minimum, there will be a Soils Inspection Checklist for each location represented by the Field Compaction Test Record (Form 000 509 F70102).

-

Monitor on-site testing for compliance to approved test procedures and schedule. The soil density test shall be given unique numbers starting with number 1 and running consecutively until the last test.

Technical supervision of the test agency will include: -

Establishing that the test agency is qualified to perform the testing required.

-

Schedule soils testing with the testing laboratory as required by the specifications.

-

Review of personnel qualifications, procedures, test equipment, and job performance.

-

Keeping the Contracts Manager informed on the laboratory's performance.

-

Verify that results and test frequency conform to specification requirements and are traceable to work. Failing tests are to be backed up by acceptable tests or a NCR.

-

Maintaining soils test and/or inspection records received from the test agency. This includes retention of failed tests. Retests shall be the same test number as the failed test using suffix R1, R2, etc.

Refer to Attachment I for test and inspection acceptance criteria. FORMS Quality Control Forms: 000 509 F70101 000 509 F70102 000 509 F70103 000 509 F70104 000 509 F70105 -

Soil Inspection Checklist Field Compaction Test Record Density of Soil in Place by the Sand-Cone Method Nuclear Moisture - Density Test Report Soil Density Test Log

ATTACHMENTS Attachment 01 - Acceptance Criteria [::This appendix is optional. It may list test procedures and specifications for soils work. It may also contain the detailed criteria from these documents that will be needed by the inspector for determining acceptability.::]


Site Quality Manual


000 509 7020 18 Feb 04 Page 1 of 5

BITUMINOUS CONCRETE PAVING

SCOPE The purpose of this procedure is to establish and define the inspection and testing necessary to verify conformance to design requirements for bituminous concrete paving. RESPONSIBILITIES - Self-Perform ACTIVITY

RESPONSIBILITY

DOCUMENTATION


Verify Subgrade acceptable

QC Inspector

000 509 F70201 and 000 509 F70103 or 000 509 F70104

Prior to installing base


_____

Prior to start of base and paving work

QC Inspector

000 509 F70201

Daily during activity

Accept base and paving material qualification Inspect in-process base preparation and paving activities

000 509 F70201 and 000 509 F70103 or 000 509 F70104 (Note 1) 000 509 F70202 and 000 509 F70203 or 000 509 F70204 (Note 1)

As required by project specifications

Perform test for base

Testing Agency

Perform test for paving

Testing Agency

Technically supervise Test Agency


_____


Surveillance


Form 000 509 F02201



NOTE (1): Approved test agency reports on their letterhead is preferred for documenting tests but they must contain at least the information provided by these forms. NOTE (2): Fluor QC Surveillance is required for construction activities not being documented on other inspection forms by Fluor Quality.


Site Quality Manual


000 509 7020 18 Feb 04 Page 2 of 5


RESPONSIBILITY

DOCUMENTATION


Install base and paving

Subcontractor

_____

_____

Subcontractor

Form 000 509 F70201 and 000 509 F70103 or 000 509 F70104

Prior to installing base

Subcontractor/ Construction Engineer

_____

Prior to start of base and paving work

Subcontractor

Form 000 509 F70201


Verify Subgrade acceptable Accept base and paving material qualifications Inspect in-process base preparation and paving activities

Form 000 509 F70201 and 000 509 F70103 or 000 509 F70104 (Note 1) Form 000 509 F70202 and 000 509 F70203 or 000 509 F70204 (Note 1)

Perform testing for base

Subcontractor


Perform testing for paving

Subcontractor

Technically supervise test agency

Subcontractor

_____


Surveillance

QC Inspector

000 509 F02201



NOTE (1): Fluor approved test agency reports on their letterhead is preferred for documenting tests but they must contain at least the information provided by these forms. PROCEDURE •

Accept Base and Paving Materials Qualification: -

Prior to placing any bituminous paving, perform necessary tests to assure material compliance to project requirements. a)

Verify that material qualification test for the subgrade have been performed.

b)

Verify that material qualification test for the bituminous concrete paving have been performed and approved.


Site Quality Manual


c) •

000 509 7020 18 Feb 04 Page 3 of 5

Verify that proposed mix formulas have been tested and approved for use.

Verify Subgrade Is Acceptable: a) That soft unstable or unsuitable material is removed and replaced with suitable material. b) That the subgrade conforms to the lines, grades and cross sections shown on the drawings. c)

That the specified compaction has been obtained.

Document these inspections on the "Bituminous Concrete Paving Inspection Checklist" 000 509 F70201 on a daily basis. •

Inspect In-process Base Preparation and Paving Activities: -

Prior to and during base preparation and paving operations, perform the following verifications and inspections. Document findings on 000 509 F70201. a)

Verify that paving and compaction equipment is in good working condition and is of the type and size specified by design.

b)

Verify that layer thickness and total thickness of base and paving is as specified.

c)

Verify that smoothness of base and paving is as specified.

d)

Verify that the prime coat is spread at the specified rate on the compacted base and allowed to cure and dry.

e)

Verify that no bituminous paving is placed during periods of unsuitable weather conditions.

f)

Verify the temperature of the bituminous concrete mix at time of spreading to assure conformance to specification requirements.

g)

Verify that the mix is placed to specified thickness for the surface course.

h)

Verify that paving mix is placed to specified width, overlapping strips at edges.

i)

Verify that pavement is periodically checked for proper line and grade and conforms to specified tolerances.

j)

Verify that construction joints between old and new pavements or between successive day's work have a continuous bond between adjoining work with


Site Quality Manual


000 509 7020 18 Feb 04 Page 4 of 5

same texture, density, and smoothness as other sections of bituminous paving. k)

Verify that rolling is accomplished in accordance with requirements and continued until required density is obtained and no roller marks remain.

l)

Verify that defective areas in new pavement are removed and replaced with fresh mix material and compacted to required density and smoothness.

m) Verify that base course has been cleared of loose material and dust, and that a tack coat has been applied at the specified rate. -

•

Prior to paving over existing bituminous surfaces, perform the following inspections and document the results on 000 509 F70201. a)

Verify that the surface to receive paving is patched, broomed, and free from dust and foreign material.

b)

Verify that the tack coat is applied to contact surfaces of previously constructed bituminous paving or surfaces abutting or projecting into pavement area at the specified rate of application.

Perform Test: -

Perform applicable test at frequency required in specifications, and record results on applicable forms.

-

Appropriate testing standards are:

[::

a)

Density of soil-in-place by the Sand Cone Method - ASTM-D-1556, AASHTO-T-191. (F70103)

b)

Density of soil and soil-aggregate in place by Nuclear Method - ASTM-D2922. (F70104)

c)

Bulk specific gravity of Compacted Bituminous Mixtures - AASHTOT166. (F70202)

d)

Bulk specific gravity of Compacted Bituminous Mixtures using Paraffin Coated Specimens - ASTM-D-1188.

e)

Bulk specific gravity of Compacted Bituminous Mixtures using Saturated Surface Dry Specimens - ASTM-D-2726.

f)

Degree of pavement compaction of Bituminous Aggregate Mixtures AASHTO-T-230.


Site Quality Manual


g) -

000 509 7020 18 Feb 04 Page 5 of 5

Density of bituminous concrete in place by Nuclear Method - ASTM-D2950. ::]

Report failing or unsatisfactory test results to the paving contractor immediately for rework or corrective action.

FORMS Quality Control Forms: 000 509 F70103 - Density Of Soil In Place By The Sand Cone Method ASTM D-1556ASHTO-T-191 000 509 F70104 - Nuclear Moisture - Density Test Report 000 509 F70201 - Bituminous Concrete Paving Inspection Checklist 000 509 F70202 - Bulk Specific Gravity 000 509 F70203 - Bituminous Concrete Compaction - AASHTO-T-230 000 509 F70204 - Nuclear Density - Bituminous Concrete ATTACHMENTS Attachment 1 - Acceptance Criteria [::This appendix is optional. It may list test procedures and specifications for soils work. It may also contain the detailed criteria from these documents that will be needed by the inspector for determining acceptability.::]


Site Quality Manual


000 509 7030 18 Feb 04 Page 1 of 4

STEEL H PILES

SCOPE This procedure prescribes the installation, inspection, and testing of Steel H Piles. RESPONSIBILITIES - Self-Perform ACTIVITY

RESPONSIBILITY

DOCUMENTATION

Monitor pile load test


_____

Inspect in-process pile driving


Check final pile locations/installation

Civil Construction Engineer QC Inspection (Note 2)

Surveillance

FREQUENCY OF ACTIVITY As required

000 509 F70301 000 509 F70302 000 509 F70303


Survey field books

As required

000 509 F02201

As required


RESPONSIBILITY

DOCUMENTATION

Perform pile load test (See Note 1)

Subcontractor

_____



_____

Inspect in-process pile driving (See Note 1) Check final pile installation

Subcontractor Subcontractor/ Civil Construction Engineer

FREQUENCY OF ACTIVITY As required by project specification As required

000 509 F70301 000 509 F70302 000 509 F70303


Survey Field Books

As required

NOTE 1:

Approved testing agency reports on their letterhead is acceptable for documenting pile information, but it must contain at least the information provided by Form(s) 000 509 F70301, 000 509 F70302, and 000 509 F70303.

NOTE 2:

Fluor QC Surveillance is required for construction activities not being documented on other inspection forms by Fluor Quality.


Site Quality Manual


000 509 7030 18 Feb 04 Page 2 of 4

PROCEDURE •

Monitor Pile Load Tests: -

Conduct tests under the direct supervision of the Civil Construction Engineer or their representative. The engineer or their representative is responsible for the following: a) b) c) d) e)

-

Approve the general plan and equipment to be used for the test. Observe the driving of test and reaction piles. Observe the application of loading apparatus. Record test data. Prepare reports in accordance with ASTM D 1143, D 3689, or D 3966 as applicable.

Drive test piles in accordance with design specifications, using the same equipment to be used for production piles. Locate cribbing or reaction piles in accordance with ASTM D 1143, D 3698, or D 3966 as applicable. Install reaction and test piles at least seven (7) days prior to commencing load tests. Provide test piles from the same manufacturer as production piles.

Axial Compression -

Conduct test in accordance with ASTM D 1143. Apply loads by employing both calibrated hydraulic jacks and load cells. Do not leave loaded jacks unattended.

-

Use two (2) dial gages mounted independently on supported reference beams as primary system for measuring movement. Do not cross-connect reference beams. Use surveyor's level as a secondary measurement system.

-

Use cyclic loading procedure in accordance with ASTM D 1143, Section 5.2.

-

Take and record readings of time, load, and pile movement immediately before and after the application of each load increment or the removal of a load decrement. Take and record additional readings after each increase in load at the following intervals: 2, 4, 8, 15, 30, 45, 60, 80, 100, and 120 minutes.

-

During periods, when the load is held constant for more than 120 minutes, take and record reading at 60 minute intervals after the first 120 minutes. During unloading, take and record readings at 10 minute intervals between decrease in loads. Take final rebound readings at 1, 2, and 12 hours after all load has been removed.


Site Quality Manual


000 509 7030 18 Feb 04 Page 3 of 4

Axial Tension Load Test -

Conduct test in accordance with ASTM D 3689 except as modified below.

-

Apply loads by employing both calibrated hydraulic jack and load cell. Do not leave loaded jack unattended.

-

Use two (2) dial gages mounted on independently supported reference beams as primary system for measuring movement. Do not cross connect reference beams. Use surveyor's level as secondary system.

-

Use cyclic loading procedure in accordance with ASTM D 3689, Section 7.3.

-

Take and record reading of time, load and pile movement immediately before and after the application of each load increment or the removal of a load decrement. Take and record additional readings after each increase in load at the following intervals: 2, 4, 8, 15, 30, 45, 60, 80, 100, and 120 minutes.

-

During periods when the load is held constant for more than 120 minutes, take and record readings at 60 minute intervals after the first 120 minutes. During unloading, take and record readings at 10 minute intervals between decrease in loads. Take final rebound readings at 1, 2, and 12 hours after all load has been removed.

Lateral Load Tests

•

-

Conduct test in accordance with ASTM D 3966 except as modified below.

-

Apply loads employing both calibrated hydraulic jack and load cell. Do not leave loaded jacks unattended.

-

Use a dial gage mounted on independently supported reference beams as primary system for measuring movement. Use surveyor's transit and scale as secondary system.

-

Use cyclic loading procedure in accordance with ASTM D 3966 standard measuring procedures.

Inspect in-process pile driving: -

Drive each pile continuously and without interruption, to refusal or until the required penetration and driving resistance as determined by load test is attained. Defined refusal as ____ blows per foot. Contact the engineer if driving is interrupted or driving resistance has not been attained before the pile reaches final penetration.


Site Quality Manual


•

000 509 7030 18 Feb 04 Page 4 of 4

-

Use one specific model of pile driving hammer for driving all Steel H Piles.

-

Operate pile driving hammer at the speed and conditions recommended by the manufacturer.

-

Protect piles during driving with cushioned caps that do not absorb hammer energy.

-

Use leads to secure the piles against lateral movement during driving.

-

Drive piles in such an order as to prevent distortion or damage to existing structures and previously driven piles. Make observations to check for any uplift of previously driven piles. Redrive uplifted piles to at least the original final driving resistance and tip elevation.

-

The center of the pile at the cutoff elevation shall not deviate more than ___ inches from the location on the design drawings. Plumb pile alignment shall not deviate more than ___ inches per foot of pile length from the batter line on design drawings.

-

Splice piles as detailed on design drawings.

-

Cut tops of piles off and level within

-

Provide uplift connection at locations and as described on design drawings.

-

Prebored pilot holes are prohibited.

inches of the elevation shown on drawings.

Check Final Pile Location/Installation: -

Reject piles that do not meet all the requirements of design specifications including those that are damaged, cracked, misplaced, or driven out of alignment tolerances.

FORMS

Quality Control Forms: 000 509 F70301 - Pile Driving Inspection Record 000 509 F70302 - Pile Driving Record 000 509 F70303 - Record of Pile Driving


Site Quality Manual


000 509 7040 18 Feb 04 Page 1 of 4

PRECAST CONCRETE PILES

SCOPE This procedure prescribes the installation, inspection and testing of precast prestressed concrete piles. RESPONSIBILITIES - Self-Perform ACTIVITY

RESPONSIBILITY

DOCUMENTATION



_____

Inspect in-process piling installation


Check final pile location/installation

Senior Field Engineer

Surveillance



000 509 F70301 000 509 F70302 000 509 F70303


Survey Field Books

As required

000 509 F02201



RESPONSIBILITY

DOCUMENTATION



Subcontractor

_____

As required by project specification



_____

As required

Inspect in-process pile driving (See Note 1) Check final pile installation NOTE 1:


000 509 F70301 000 509 F70302 000 509 F70303


Survey Field Books

As required



Site Quality Manual


NOTE 2:

000 509 7040 18 Feb 04 Page 2 of 4


PROCEDURE

•


Conduct tests under the direct supervision of the Senior Field Engineer or their representative. The Engineer or their representative is responsible for the following: a)

Approve the general plan and equipment to be used for the test.

b)

Observe the driving of test and reaction piles.

c)

Observe the application of loading apparatus.

d)

Record test data

e)

Prepare reports in accordance with ASTM D1143, D3689 or D3966 as applicable.

-

Drive test piles in accordance with design specifications, using the same equipment to be used for production piles. Locate cribbing on reaction piles in accordance with ASTM D1143, D3698 or D 3966 as applicable. Install reaction and test piles at least (7) days prior to commencing load tests. Provide test piles from the same manufacturer as production piles.

-

Axial Compression - Conduct test in accordance with ASTM D1143. Apply loads by employing both calibrated hydraulic jacks and load cells. Do not leave loaded jacks unattended.

-

Use two dial gages mounted independently on supported reference beams as primary system for measuring movement. Do not cross connect reference beams. Use surveyor's level as a secondary measurement system.

-

Use cyclic loading procedure in accordance with ASTM D1143, Section 5.2.

-

Take and record readings of time, load and pile movement immediately before and after the application of each load increment or the removal of a load decrement. Take and record additional readings after each increase in load at the following intervals: 2, 4, 8, 15, 30, 45, 60, 80, 100 and 120 minutes. During periods when the load is held constant for more than 120 minutes, take and record readings at 60 minute intervals after the first 120 minutes. During unloading, take and record reading at 10 minute intervals between decrease in loads. Take final rebound readings at 1, 2 and 12 hours after all load has been removed.


Site Quality Manual


•

000 509 7040 18 Feb 04 Page 3 of 4

-

Axial Tension Load Test - Conduct test in accordance with ASTM D3689 except as modified below.

-


-

Use 2 dial gages mounted on independently supported reference beams as primary system for measuring movement. Do not cross connect reference beams. Use surveyor's level as secondary system.

-


-

Take and record reading of time, load and pile movement immediately before and after the application of each load increment or the removal of a load decrement. Take and record additional readings after each increase in load at the following intervals: 2, 4, 8, 15, 30, 45, 60, 80, 100 and 120 minutes.

-


-

Lateral Load Tests - Conduct test in accordance with ASTM D3966 except as modified below.

-


-

Use a dial gage mounted on independently supported reference beam as primary system for measuring movement. Use surveyor's transit and scale as secondary system.

-


-

Take and record readings to time, load, and pile movement in accordance with ASTM D3966 Standard Measuring Procedures.

Inspect In-process Pile Driving: -

Prebored pilot holes are prohibited unless specified on the design drawings or approved by the Engineer.

-

Do no drive piles prior to attainment of the minimum 28 day strength.

-

Drive each pile continuously and without interruption, to refusal or until the required penetration and driving resistance as determined by load test is attained. Defined


Site Quality Manual


000 509 7040 18 Feb 04 Page 4 of 4

refusal as _____ blows per foot. Contact the Engineer if driving is interrupted or driving resistance has not been attained before the pile reaches final penetration.

•

-

Use one specific model of pile driving hammer for driving all precast concrete piles.

-


-

Protect piles during driving with cushioned caps that does not absorb hammer energy.

-

Use loads to secure the piles against lateral movement during driving.

-

Drive piles in such an order as to prevent distortion or damage to existing structures and previously driven piles. Make observations to check for any uplift of previously driven piles. Redrive uplifted piles to at least the original final driving resistance and tip elevation.

-

The center of the pile at the cutoff elevation shall not deviate more than _____ inches from the location on the design drawings. Plumb pile alignment shall not deviate more than _____ inch per foot of pile length from the batter line on design drawings.

-

Drive top of piles to within _____ inch of the elevation on drawings.

-



Retest piles that do not meet all the requirements of design specifications including those that are damaged, cracked, misplaced, or driven out of alignment tolerances.

FORMS Quality Control Forms: 000 509 F70301 - Pile Driving Inspection Record 000 509 F70302 - Pile Driving Record 000 509 F70303 - Record of Pile Driving


Site Quality Manual


000 509 7050 18 Feb 04 Page 1 of 4

TIMBER PILES

SCOPE This procedure prescribes the installation, inspection and testing of timber foundation piles. RESPONSIBILITIES - Self-Perform ACTIVITY

RESPONSIBILITIES

DOCUMENTATION


Monitor pile load testing




000 509 F70301 000 509 F70302 000 509 F70303



Senior Field Engineer

Survey Field Books

As required

Surveillance


000 509 F02201


_____

As required


RESPONSIBILITY

DOCUMENTATION



Subcontractor

_____

As required by project specification



_____

As required

Inspect in-process pile driving (See Note 1)

Subcontractor

000 509 F70301 000 509 F70302 000 509 F70303


Check final pile installation

Subcontractor/ Senior Field Engineer/ Civil Construction Engineer

Survey Field Books

As required

NOTE 1:


NOTE 2:



Site Quality Manual


000 509 7050 18 Feb 04 Page 2 of 4

PROCEDURE •


Conduct tests under the direct supervision of the Senior Field Engineer or their representative. The engineer or their representative is responsible for the following: a) b) c) d) e)

Approve the general plan and equipment to be used for the test. Observe the driving of test and reaction pile. Observe the application of loading apparatus. Record test data Prepare reports in accordance with ASTM D1143, D3689 or D3966 as applicable.

-

Drive test piles in accordance with design specifications, using the same equipment to be used for production piles. Locate cribbing on reaction piles in accordance with ASTM D1143, D3698 or D3966 as applicable. Install reaction and test piles at least (7) days prior to commencing load tests. Provide test piles from the same manufacturer as production piles.

-


-

Use two dial gages mounted independently on supported reference beams as primary system for measuring movement. Do not cross-connect reference beams. Use surveyor's level as a secondary measurement system.

-

Use cyclic loading procedure in accordance with ASTM D1143, Section 5.2

-

Take and record readings of time, load and pile movement immediately before and after the application of each load increment or the removal of a load decrement. Take and record additional readings after each increase in load at the following intervals: 2, 4, 8, 15, 30, 45, 60, 80, 100 and 120 minutes. During periods, when the load is held constant for more than 120 minutes, take and record reading at 60 minute intervals after the first 120 minutes. During unloading, take and record readings at 10 minute intervals between decrease in loads. Take final rebound readings at 1, 2, and 12 hours after all load has been removed.

-


-



Site Quality Manual


•

000 509 7050 18 Feb 04 Page 3 of 4

-


-


-


-


-


-


-


-


-

Take and record readings of time, load, and pile movement in accordance with ASTM D3966 standard measuring procedures.

Inspect In-Process Pile Driving: -

Drive each pile continuously and without interruption, to refusal or until the required penetration and driving resistance as determined by load test is attained. Defined refusal as _____ tons per foot. Contact the engineer if driving is interrupted or driving resistance has not been attained before the pile reaches final penetration.

-

Use one specific model of pile driving hammer for driving all timber piles.

-


-

Protect piles during driving with cushioned caps that do not absorb hammer energy.


Site Quality Manual


000 509 7050 18 Feb 04 Page 4 of 4

-


-

Drive poles in such an order as to prevent distortion or damage to existing structures and previously driven piles. Make observations to check for any uplift of previously driven piles. Redrive uplifted piles to at least the original final driving resistance and the center of the pile at the cutoff elevation shall not deviate more than _____ inches from the location on the design drawings. Plumb pile alignment shall not deviate more than _____ inch per foot of pile length from the batter line on design drawings.

-

Splice piles as detailed on design drawings.

-

Saw tops of piles off and level, within _____ inch of the elevation on drawings. Piles must show a solid head after cutoff.

-

Provide uplift connection at locations and as described on design drawings. Size bolt holes in piles that will ensure a driving fit.

-

Prebored pilot holes are prohibited unless specified on the design drawings or authorized by the design engineer.

-

Treat cut, bored, and damaged pile surface in accordance with AWPA-M4.

•

Check Final Pile Location/Installation -

Reject piles that do not meet all the requirements of design specifications including those that are damaged, cracked, misplaced, or driven out of alignment tolerances.



Site Quality Manual


000 509 7060 18 Feb 04 Page 1 of 5

CLOSED END CONCRETE FILLED PIPE PILES

SCOPE This procedure prescribes the installation, inspection and testing of closed end, concrete filled pipe piles. RESPONSIBILITIES - Self-Perform ACTIVITY

RESPONSIBILITY

DOCUMENTATION



_____




Senior Field Engineer QC Inspection (Note 2)

Surveillance


000 509 F70301 000 509 F70302 000 509 F70303


Survey Field Books

As required

Form 000 509 F02201



RESPONSIBILITY

DOCUMENTATION


Subcontractor

_____



_____




000 509 F70301 000 509 F70302 000 509 F70303


Survey Field Books

As required

NOTE 1:


NOTE 2:

Fluor QC Surveillance is required for construction activities no being documented on other inspection forms by Fluor Quality.


Site Quality Manual


000 509 7060 18 Feb 04 Page 2 of 5

PROCEDURE •




b)


c)


d)

Record test data

e)


-


-


-


-


-



Site Quality Manual


•

000 509 7060 18 Feb 04 Page 3 of 5

-


-


-


-


-


-


-


-


-


-


-



Drive each pile continuously and without interruption, to refusal or until the required penetration and driving resistance as determined by load test is attained. Defined refusal as _____ blows per foot. Contact the Engineer if driving is interrupted or driving resistance has not been attained before the pile reaches final penetration.

-

Use one specific model of pile driving hammer for driving all steel pipe piles.


Site Quality Manual


000 509 7060 18 Feb 04 Page 4 of 5

-


-


-


-

Drive poles in such an order as to prevent distortion or damage to existing structures and previously driven piles. Make observations to check for any uplift of previously driven piles. Redrive uplifted piles to at least the original final driving resistance and tip elevation.

-


-

Splice and drive pile that has not reached the required blow count when the top has been driven to the cutoff elevation, to a depth sufficient to develop the required driving resistance. The required driving resistance shall not be determined until the pile has been driven at least an additional 12 inches.

-

For piles driven with a mandrel, "bumping out" or reverse tapping is not permitted. Should this occur, redrive the pile to at least the original resistance and penetration.

-

Redrive piles raised during the driving of adjacent piles to at least the original resistance and penetration. If concrete has been placed in the pile, redriving shall not commence until concrete has reached its 28 day designed strength, as determined by testing.

-

Place concrete in one continuous operation. Place concrete with the use of a tremie if there is more than a 5 foot drop, to prevent segregation in the mix. Compact all concrete by use of internal vibrators.

-

Place no concrete for any pile until all driving within a radius of 50 feet has been completed. Cover tops of pipe piles immediately after driving and again immediately after inspection, to prevent debris from entering the piles.

-

A concrete mix design shall be submitted and accepted prior to start of work.

-

Cut tops of piles off and level, within _____ inch of the elevation on drawings.

-


-

Prebored pilot holes are prohibited.


Site Quality Manual


•

000 509 7060 18 Feb 04 Page 5 of 5





Site Quality Manual


000 509 7070 18 Feb 04 Page 1 of 5

CONCRETE FILLED THIN SHELL PILES

SCOPE This procedure prescribes the installation, inspection and testing of concrete filled, steel shell piles. RESPONSIBILITIES - Self-Perform ACTIVITY

RESPONSIBILITY

DOCUMENTATION



_____



Check final pile locations/installation

Civil Construction Engineer QC Inspection (Note 2)

Surveillance


000 509 F70301 000 509 F70302 000 509 F70303


Survey Field Books

As required

000 509 F02201



RESPONSIBILITY

DOCUMENTATION


Subcontractor

_____



_____




000 509 F70301 000 509 F70302 000 509 F70303


Survey Field Books

As required

NOTE 1:


NOTE 2:



Site Quality Manual


000 509 7070 18 Feb 04 Page 2 of 5

PROCEDURE •




b)


c)


d)

Record test data

e)


-


-


-


-


-


-



Site Quality Manual


•

000 509 7070 18 Feb 04 Page 3 of 5

-


-


-


-


-


-


-


-


-


-



Drive each pile continuously and without interruption, to refusal or until the required penetration and driving resistance as determined by load test is attained. Defined refusal as _____ blows per foot. Contact the Engineer if driving is interrupted or driving resistance has not been attained before the pile reaches final penetration.

-

Drive shells into pre-augured holes drilled to a minimum depth of _____ feet. Diameter of the hole shall be the diameter of the shell.

-

Use one specific model of pile driving hammer for driving all precast concrete piles.


Site Quality Manual


000 509 7070 18 Feb 04 Page 4 of 5

-


-


-

Use loads to secure the piles against lateral movement during driving.

-

Drive poles in such an order as to prevent distortion or damage to existing structures and previously driven piles. Make observations to check for any uplift of previously driven piles. Redrive uplifted piles to at least the original final driving resistance and tip elevation.

-

Do not drive piles within 50 feet of previously placed concreted piles, foundations, or structures until such concrete has cured a minimum of 7 days.

-

After the shell has been driven, visually inspect the shell interior throughout its entire length, under adequate light. Provide necessary equipment for interior shell inspection. Shells shall be free from dents or distortion that alters the diameter of any section more than 25 percent, or prevent proper placement of reinforcing steel. Shells shall also be free from holes, tears, or other damage.

-

Cover tops of shells immediately after driving and again immediately after inspection of shell interior to prevent debris from centering the shell. Place no concrete in any pile until the pile has been visually inspected and found free of water, debris or other foreign matter.

-

Place concrete in a continuous operation. If there is more than a 5 foot drop, use a tremie to prevent segregation of mix. Compact all concrete by use of internal vibrators.

-

Place no concrete for any pile until all driving within a radius of 50 feet has been completed.

-


-

Cut tops of piles off and level, within _____ inch of the elevation on drawings.

-



Site Quality Manual


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000 509 7070 18 Feb 04 Page 5 of 5





Site Quality Manual


000 509 7080 18 Feb 04 Page 1 of 3

DRILLED CAISSONS

SCOPE This procedure prescribes the inspection and testing of Drilled Caissons. RESPONSIBILITIES – Subcontracted Work ACTIVITY

RESPONSIBILITY

Excavate Caisson Clean Caisson Install Reinforcing

Subcontractor Subcontractor Subcontractor

Place Concrete

Subcontractor

Inspect Caisson Installation

Quality Control Inspector

DOCUMENTATION 000 509 F70801 000 509 F70801 000 509 F70801 000 509 F71001 000 509 F70801 000 509 F71002 000 509 F71003 000 509 F71007 000 509 F71008

FREQUENCY OF ACTIVITY Each Caisson Each Caisson Each Caisson

Each Caisson

PROCEDURE •

Excavation: -

Excavate drilled caissons to the dimensions and elevations as shown on design drawings.

-

Excavation method shall leave the sides and bottoms of the hole free from loose material that would prevent contact of concrete with firm, undisturbed rock or soil.

-

Remove all excavated material from each open caisson excavation to avoid contamination of the excavation after final cleanout.

-

Clean caisson excavation before the start of concrete placement.

-

If steel casings are required, insure that diameter of excavation in relation to diameter of temporary casings create a minimum of void space outside of casing. Excavation for permanent casing shall have a diameter equal to nominal outside diameter of casing shaft.


Site Quality Manual


•

•

000 509 7080 18 Feb 04 Page 2 of 3

Reinforcing Steel: -

Insure caisson excavation is approved prior to placing reinforcing steel.

-

At the time of placement, reinforcing shall be free of mud, oil, or coating that adversely affects bond to concrete.

-

Reinforcing steel shall be securely tied to maintain proper dimension and location during concreting operations.

-

Reinforcing shall be placed before caisson concreting begins except as approved by design engineer.

Concrete: -

Un-reinforced concrete drilled caissons shall conform to requirement of design documents and ACI 318.1.

-

Dewater drilled caisson excavation prior to placing concrete.

-

Place concrete immediately after approval of completed excavation. Do not leave uncased or belled caisson excavations open overnight.

-

If free-fall concrete is used, assure specially designed free-fall concrete is directed through a hopper with an elephant trunk, or equal, so that fall of concrete is vertical, down center of shaft without hitting sides or reinforcing.

-

If temporary casings are used, casing withdrawal shall be coordinated with concrete placement. An adequate head of concrete shall be maintained to exceed outside of soil and water pressure, above the bottom of the casing at all times during casing withdrawal.

-

Check concrete level prior to, during, and after withdrawing casing to confirm separation of shaft concrete has not occurred. Withdraw casing while concrete is still fluid.

-

Do not vibrate concrete internally before casing is to be withdrawn. Vibrate top (5) feet of concrete after casing has been withdrawn or when casing is permanent.

-

Fill any void space between casing and shaft excavation with grout or concrete or other material as defined by design engineer.


Site Quality Manual


000 509 7080 18 Feb 04 Page 3 of 3

FORMS Quality Control Forms: 000 509 F70801 000 509 F71001 000 509 F71002 000 509 F71003 000 509 F71007 000 509 F71008

-

Caisson Inspection Record Pre-Concrete Inspection Checklist Concrete Inspection Record Concrete Pour Card Concrete Compression Strength Test Record Concrete Placement Log


Site Quality Manual


000 509 7090 18 Feb 04 Page 1 of 5

AUGERED CAST-IN-PLACE PILES SCOPE This procedure prescribes the inspection and testing of Augered Cast-In-Place Piles. RESPONSIBILITIES – Subcontractor Work ACTIVITY

RESPONSIBILITY

DOCUMENTATION


Install Pile

Subcontractor

000 509 F70901

Each Pile

Grouting Install Reinforcing Steel Sonic Logging PVC Spoils Removal Inspect Pile Installation

Subcontractor

000 509 F70901

Each Pile

Subcontractor

000 509 F70901

Each Pile

Subcontractor

000 509 F70901

Subcontractor Quality Control Inspector

Each Pile or as required in Project Specification Each Pile Per 000 509 0220

PROCEDURE •

Subcontractor shall use instrumentation to monitor pile installation, and shall make an electronic recording of acquired data. Data shall include grout pressure and grout volume vs. both depth and time, and angle of pile installation. A readout device shall be supplied so data may be monitored by Subcontractor and Fluor during installation of each pile. Data shall also be stored in an electronic format and both a printed and electronic copy shall be provided to Fluor for documentation of each pile’s installation record.

General •

All Subcontractor supplied materials and proprietary items shall be subject to Fluor’s approval and shall be installed in accordance with the Contract Documents.

•

All chemical admixtures which contain chloride are prohibited for use on this project.

Materials Portland Cement •

Portland cement shall conform to ASTM C 150, type of cement as specified in the Contract Documents.


Site Quality Manual


000 509 7090 18 Feb 04 Page 2 of 5

Mineral Admixture •

Mineral admixtures, if used, shall conform to ASTM C618 Class C or Class F, as specified in the Contract Documents. Fluidifier

•

Fluidifier shall conform to ASTM C937 Water

•

Water shall meet requirements of ASTM C94. Fine Aggregates

•

Fine aggregate shall conform to ASTM C33. Reinforcing Bars

•

Reinforcing bars shall conform to ASTME A615.

•

High strength reinforcing bars shall conform to requirements of ASTM A722 Grade 150.

•

Methods acceptable to Fluor shall be provided to facilitate proper centering of any steel cores or tension reinforcing installed in the piles. Grout Mixes

•

The grout shall be a mixture of Portland cement, fine aggregate, pozzolanic material (when used), Fluidifier, and water, proportioned and mixed to produce a grout capable of being pumped. The grout shall be capable of maintaining the solids in suspension. The grout shall have a minimum 28-day compressive strength of 4000 psi unless noted other wise in the Contract Documents.

•

Grout materials shall be accurately measured to meet design proportions. Grout shall be accurately measured to meet design proportions. Grout shall be mixed at the site for a minimum of 2 minutes. Maximum holding time in the mixer shall be as follows: Temperature of Grout oF

Maximum Holding Time Hours

Less than 70 From 70 to 90 Greater than 90

2.5 2.0 Shall not be used


Site Quality Manual


000 509 7090 18 Feb 04 Page 3 of 5

•

Grout shall be protected from low temperatures in accordance with ACI 306R and from high temperatures in accordance with ACI 305R.

•

Grout test cubes shall be made, cured and tested in accordance with ASTM C942. At least six 2-inch cubes shall be made for each 4 hours (or portion thereof) during which piles are placed, for each pile rig. Test each set of 6 cubes as follows: 2 cubes at 7 days, 2 cubes at 28 days and 2 cubes held in reserve.

•

Test the flow of grout each time cubes are made and any time inconsistencies are observed per ASTM C939, except that the cone shall be modified to provide a ¾ - inch opening. Flow rates shall be between 10 and 25 seconds. The flow cone shall be provided by the Subcontractor. Construction Tolerances

•

Pile centers shall be located within a tolerance of +/- 3 inches of the locations shown in the Contract Documents, unless directed otherwise by the Fluor or otherwise specified. Vertical piles shall be plumb within 2%. Adjacent Piles

•

No piles shall be placed within 5 pile diameters, center to center, of adjacent piles containing grout that has set for less then 12 hours.

Installation Procedures •

The length, drilling criteria, and installation procedures of production piles may be modified by Fluor from information obtained during the installation of the probe piles, reaction piles, test piles and the pile load test. Production piles shall be installed with the same equipment and identical procedures used for installation of probe piles and test piles, unless modified by Fluor.

•

Drill at a continuous rate appropriate for the soil conditions until the required depth or refusal is reached. If refusal is reach prior to the required depth, notify Fluor immediately.

•

Auger refusal is defined as a rate of auger penetration of less than 1 foot per minute of drilling with maximum torque and weight applied to the auger.

•

Provide a plug in the bottom of the auger during drilling to prevent entry of soil or water into the hollow stem of the auger.

•

When the auger reaches its specified depth, raise the auger 6 to 12 inches and begin grout pumping. Re-drill the auger to the previously established tip elevation before commencing auger withdrawal, after the grout pressure builds up.


Site Quality Manual


000 509 7090 18 Feb 04 Page 4 of 5

•

Continuously maintain a grout head of a least 5 feet above the injection point during raising of the auger. If the auger jumps upward during withdrawal, if there is a decreased grout pressure, or if grouting is interrupted for any reason, reinsert the auger to 5 feet below the tip of the auger when the interruption occurred or to the bottom of the pile, whichever is less and decrease the rate of withdrawal to prevent further jumping or pressure decreases. Rotate the auger slowly during withdrawal. Counter clockwise rotation shall not be allowed at any time. After grout is flowing at the ground surface from the auger flighting, the rate of grout injection and auger withdrawal shall be coordinated so that there is a constant grout flow at the surface.

•

Place at least 115% of the theoretical grout volume in each 5-foot increment of pile. If any 5-foot increment is deficient, reinstall the pile by advancing the auger 10 feel below the deficient grout interval or to the bottom of the pile, whichever is less and re-grout pile with a reduced rate of auger withdrawal.

•

No pile shall be left partially completed overnight. All piles must be completely grouted and protected at the termination of each day’s operation.

•

Reinforcing steel shall conform to the Contract Documents, shall be placed while the grout is still fluid and shall have centering fins, spacers or other devices to assure minimum grout cover as shown on the drawings or if not shown, at least 3 inches of cover. If the reinforcing steel cannot be placed to design elevation, the reinforcing steel shall be removed and the pile reinstalled. The cost for reinstalling the pile shall be borne by the subcontractor. Promptly clear the spoil that accumulates around the auger during augering and injection of the grout. Dispose of spoils as directed by Fluor.

Obstructions If obstructions causing auger refusal are encountered above the desired tip elevation, complete the pile to the refusal depth in accordance with the specifications, unless directed otherwise by Fluor. Install additional adjacent piles as required by Fluor. Cutting Off Piles shall be cut off by removing fresh grout from the top of the pile or by cutting off hardened grout down to the final cut-off point. Adding grout after the pile has reached its initial set in order to raise the pile cut-off elevation shall not be permitted. Sleeves or casings shall be placed around the pile top when the pile cut-off elevations are above the surrounding ground surface elevation.


Site Quality Manual


000 509 7090 18 Feb 04 Page 5 of 5

FORMS Quality Control Forms: 000 509 F70901 000 509 F71005


Augered Cast-In-Place Pile Record Cementitious Grout Testing Record

Site Quality Manual


000 509 7100 18 Feb 04 Page 1 of 4

CONCRETE AND GROUT SCOPE This procedure applies to inspection and testing of structural concrete and grouting. RESPONSIBILITIES - Self-Perform ACTIVITY

RESPONSIBILITY

Supply Concrete Perform Concrete Placement

Supplier Civil Superintendent

Batch Plant Technical Supervision


Concrete Inspection


Coordination of Placement


Test Concrete Surveillance

Test Agency (Note 1) QC Inspection (Note 2)

DOCUMENTATION


Batch Ticket

As required

000 509 F71003

As required

000 509 F02004 (Concrete Batch Plant Evaluation Record) and 000 509 F71010 000 509 F71001 & F71002 for Structural Concrete F71004 for Cementitious Grout F71006 for Epoxy Resin Grout F71007, F71008 F71010 for Batch Plant F71003 (Concrete Pour Card) F71007 (Note 1) (plus F71005 for cementitious grout) 000 509 F02201

Initially then random For individual placements as required by specification. Each placement Each set of cylinders/cubes as required by specification. Per Procedure 000 509 0220

NOTE 1:

Approved Test Agency Reports on their letterhead is preferred over the use of Form 000 509 F71007 and F71005 for documenting concrete tests, but it must contain at least the information provided by these forms.

NOTE 2:



Site Quality Manual


000 509 7100 18 Feb 04 Page 2 of 4

RESPONSIBILITIES - Subcontracted Work

Batch Ticket


Subcontractor

000 509 F71003

As required


000 509 F02004 000 509 F71010

Initially then random

ACTIVITY

RESPONSIBILITY

Supply Concrete Perform Concrete Placement Batch Plant Technical Supervision

Supplier

Concrete Inspection

Coordination of Placement

Subcontractor

Civil Construction Engineer/ Subcontractor

Test Concrete Technically Supervise Test Lab Surveillance NOTE 2:

Test Lab Site Quality Manager QC Inspection (Note 2)

DOCUMENTATION

000 509 F71001 000 509 F71002 000 509 F71004 000 509 F71006 000 509 F71007 000 509 F71008

Each placement

000 509 F71003

As required

Approved test agency form in compliance with 000 509 F71007 and 000 509 F71005.

As required by specification

000 509 F02005 000 509 F02201

Initially then random Per Procedure 000 509 0220


GENERAL •

Concrete Inspection: -

Inspection will include the items on the applicable checklist (Forms F71001 and F71002, F71004 or F71006) depending on the type of concrete. Form F71001 is completed before ordering concrete.

-

Inspection is performed continuously during placement.

-

Batch plant inspection is performed for individual placements in excess of 200 cubic yards and periodically. These inspections are recorded on Form 000 509 F71010.


Site Quality Manual


•

•

-

Monitoring of water addition to assure maximum allowable is not exceeded and verify that an additional minimum of 30 revolutions at mixing speed has been applied to the load.

-

Monitoring on site inspection/testing for compliance to approved test procedures and schedule.

Batch Plant Technical Supervision -

Establishing that the concrete supplier is capable of performing the contracted scope.

-

Review and acceptance of the concrete suppliers mix design and retain copy on site.

-

Schedule the concrete testing, with the Testing Agency, as required by specifications.

-

Keeping the Contracts Manager informed of the batch plants performance.

Coordination of the placement will include: -

•

000 509 7100 18 Feb 04 Page 3 of 4

Obtaining agreement among the disciplines and/or subcontractors that concrete placement is ready to be performed. This agreement is documented on Form 000 509 F71003. Concrete placement shall not commence until all "sign offs" have been made.

Technical supervision of the Test Agency will include: -

Establishing that the Testing Agency is qualified to perform the work required.

-

Schedule testing as required by specification. Schedule the Testing Agency to periodically sample the concrete materials at the batch plant and verify compliance with specification.

-

Review of personnel qualifications, procedures, test equipment and job performance.

-

Keeping the Contracts Manager informed of the Test Agency's performance.

-

Verify that results and test frequency conform to specification requirements and are traceable to work. Failing tests are to be backed up by acceptable tests or an NCR. Maintain compression test summary on the "Concrete Placement Log" Form 000 509 F7108.

-

Maintain test and/or inspection records received from the Test Agency.


Site Quality Manual


•

000 509 7100 18 Feb 04 Page 4 of 4

Refer to Attachment I for test and inspection acceptance criteria.

FORMS Quality Support Forms: 000 509 F71010 - Batch Plant Inspection 000 509 F71001 - Pre-Concrete Inspection 000 509 F71002 - Concrete Inspection Record 000 509 F71003 - Concrete Pour Card 000 509 F71004 - Cementitious Grout Inspection Record 000 509 F71005 - Cementitious Grout Testing Record 000 509 F71006 - Epoxy Resin Grout Inspection Record 000 509 F71007 - Concrete Compression Strength Test Record 000 509 F71008 - Concrete Placement Log 000 509 F71009 - Grout Placement Log ATTACHMENTS Attachment I - Acceptance Criteria [::This appendix is optional. It may list the test procedures and specifications for concrete work including grouting of structural steel and equipment base plates. It may also contain the detailed criteria from these documents that will be needed by the inspector for determining acceptability. For grout, when the specifications invoke the grout material manufacturer's instructions, and/or the supplier equipment installation instructions and specifications, the requirements from these documents will be stated in this appendix.::]


Site Quality Manual


000 509 7200 18 Feb 04 Page 1 of 3

STRUCTURAL STEEL

SCOPE This procedure describes the functions to be performed in the inspection of the erection of structural steel. RESPONSIBILITIES - Self-Perform ACTIVITY

RESPONSIBILITY

Verify acceptability of Interface Structures


Erect Structural Steel

Civil Superintendent

Inspect In-process Structural Steel Erection Perform Final Inspection

DOCUMENTATION 000 509 F72002 _____

FREQUENCY OF ACTIVITY Once for each structure _____


000 509 F72002



000 509 F72002

Once per structure


RESPONSIBILITY

DOCUMENTATION


Verify acceptability of Interface Structures


Erect Structural Steel

Subcontractor

Inspect In-process Structural Steel Erection

Subcontractor

000 509 F72002


Perform Final Inspection

Subcontractor / Civil Construction Engineer

000 509 F72002

Once per structure

Surveillance


000 509 F02201


000 509 F72002 _____

Once for each structure _____

PROCEDURE •

Verify Interface Structures: -

Prior to structural steel being erected, verify that all interface work such as foundation elevations, and size and location of anchor bolts conform to the applicable drawings. Verify that concrete has attained adequate compressive strength before loading.


Site Quality Manual


•

•

000 509 7200 18 Feb 04 Page 2 of 3

Erection of Structural Steel: -

Structural steel shall be erected in accordance with the applicable project specifications.

-

Assure structures are not loaded prior to sufficient progression of erection and completed boltup has been accepted.

-

Welding shall be performed by AWS (or other approved recognized standards) qualified welders in accordance with weld procedure specifications approved by Fluor Manager Welding Technology or his representative.

-

Modifications to steel member shall only take place upon issuance of direction from Construction Engineering.

In-Process Inspection of Structural Steel Erection: -

Inspect the in-process steel erection to verify that fabrication is correct and erection is in accordance with the drawings. Inspection shall include checking for plumbness, rectangularity, field welds, bolt tensioning and touch-up painting.

-

Visual weld examination shall be performed in accordance with 000 509 7910, Welding Inspection.

-

Document inspections on Form 000 509 F72002, Structural Steel Inspection Checklist. Highlighted steel erection drawings may be used in conjunction with checklist to provide a clear picture of sequence of events with dates of when areas, floors, and buildings have been accepted for workmanship.

-

When a calibrated impact wrench is used for erection, the calibration shall be verify by the Civil Construction Engineer or QC Inspector and documented on Form 000 509 F72003, Torque Wrench Calibration Log.

-

When bolting inspection by impact is required, it shall be performed with a separate calibrated inspection wrench.

-

When “twist-off” type tension control structural bolt/nut/washer assemblies are specified they shall conform to ASTM F1852-98 and shall be, installed in accordance with the manufacturer'’ published specifications.

-

When load indicating washers (LIW) are specified, installation inspection will be performed in accordance with the sample rate specified.

-

Inspect bolts installed by turn-of-nut method in accordance with AISC Section 6, Specification or other approved recognized standard for Structural Joints using ASTM A325 or A490 bolts.


Site Quality Manual


•

000 509 7200 18 Feb 04 Page 3 of 3

-

The number of checklist completed should be a sufficient number to clearly indicate full coverage of all portions of the work on the project as work progresses.

-

Each checklist generated should represent a well defined piece of work, i.e., building line, floor, run of pipe rack, etc.

Perform Final Inspection: -

Perform final inspection, in part, or on the total structure. Document on Form 000 509 F72002, Structural Steel Inspection.

-

Document deficiencies, for tracking purposes, on Form 000 509 F02201, Surveillance Report.

FORMS Quality Control Forms: 000 509 F72002 - Structural Steel Inspection Checklist 000 509 F72003 - Torque Wrench Calibration Log


Site Quality Manual


000 509 7300 18 Feb 04 Page 1 of 3

BUILDINGS SCOPE This procedure describes the inspection and testing activities to be performed for buildings that are constructed by Fluor. RESPONSIBILITIES - Self-Perform ACTIVITY Verify foundations complete Review structural steel documents Monitor in-process building construction Inspect completed work Verify building complete Surveillance NOTE 1:

RESPONSIBILITY Civil Construction Engineer Civil Construction Engineer Civil Construction Engineer Civil Construction Engineer Civil Construction Engineer QC Inspection (Note 1)

DOCUMENTATION 000 509 F73001 _____

FREQUENCY OF ACTIVITY Daily during life of activity Prior to steel erection

000 509 F02201


000 509 F73003-F73016

Each Item

Procedure 000 509 7300

Once per building

000 509 F02201


Surveillance is not required if the Fluor Quality representative is performing inspections.

RESPONSIBILITIES - Subcontracted Work ACTIVITY Inspect in-process foundations Inspect in-process building superstructure Witness HVAC Test Inspect completed building Coordinate resolution of deficiencies Surveillance

RESPONSIBILITY

DOCUMENTATION


Subcontractor

000 509 F73001


Subcontractor

000 509 F02201


000 509 F73101

Each test

000 509 F73002

Once per building

000 509 F73002

As required to close open items

000 509 F02201


Civil Construction Engineer/ Site Quality Manager Subcontractor Discipline Engineer Site Quality Manager Subcontractor/ Civil Construction Engineer/ Site Quality Manager QC Inspection


Site Quality Manual


000 509 7300 18 Feb 04 Page 2 of 3

PROCEDURE Attachments 1 through 9 are provided as inspection references to aid the inspector. •

Verify Foundations are Complete:

-

Check the elevations and locations of foundations, floor slabs, inserts and interior partitions. Document these checks on Form 000 509 F73001, Building Inspection Record.

-

When tests and inspection activities are complete, document using Form 000 509 F73001, Building Inspection Record.

•

Review of Structural Steel Documents:

-

Verify structural steel certified mill test reports and certificates of compliance have been received have been reviewed.

-

If applicable, verify the subcontractors have submitted required shop drawings, diagrams, schedules, etc., and are marked as authorized to proceed.

•

Monitor In-Process Building Construction:

-

The attachments contained in this procedure are intended to be used as guidelines for implementing this procedure.

-

Using the applicable design drawings, inspect the in-process building superstructure construction activities to verify acceptability of work.

-

Inspect membrane roofing system construction for strict compliance with drawings and specifications to include materials, substrate preparation, membrane installation and splicing, perimeter nailing, flashing and roof walkways.

-

Verify completion of applicable tests, performance tests and test data records as required by specifications: electrical, plumbing system, fire protection system.

-

Monitor subcontractor's HVAC duct, duct insulation, and equipment installation for compliance with drawings and specifications.

•

Witness HVAC Tests:

-

Witness HVAC testing is performed in accordance with the requirements of Form 000 509 F73101.


Site Quality Manual


000 509 7300 18 Feb 04 Page 3 of 3

•

Verify Building Complete:

-

Verify the proper operations of the specific keying systems is demonstrated satisfactorily.

-

Inspect the building when construction is complete. Deficiencies shall be documented on Form 000 509 F02407, Master Punch List.

FORMS Quality Control Form: 000 509 F73001 - Building Inspection and Test Checklist 000 509 F73002 - Final Building Inspection Summary 000 509 F73003 - Carpentry Checklist 000 509 F73004 - Painting Checklist 000 509 F73005 - Plumbing Checklist 000 509 F73006 - Ceramic Tile Checklist 000 509 F73007 - Concrete Checklist 000 509 F73008 - Structural Steel Checklist 000 509 F73009 - Masonry (Brickwork) Checklist 000 509 F73010 - Plaster Checklist 000 509 F73011 - Doors, Windows, Hardware, Glazing Checklist 000 509 F73012 - Computer (Raised) Floors, Checklist 000 509 F73013 - Prefab Wall Element Systems Checklist 000 509 F73014 - Building Metal Siding And Roofing Checklist 000 509 F73015 - Buildings Water Proofing and Damp Proofing Checklist 000 509 F73016 - Suspended Ceiling Checklist ATTACHMENTS Attachment 1 - Buildings Masonry Inspection Reference Attachment 2 - Buildings Waterproofing and Dampproofing Inspection Reference Attachment 3 - Buildings Plaster Inspection Reference Attachment 4 - Buildings, Metal Doors and Windows Inspection Reference Attachment 5 - Buildings Drywall Construction Inspection Reference Attachment 6 - Buildings Resilient Floor Covering Inspection Reference Attachment 7 - Buildings Carpentry Inspection Reference Attachment 8 - Buildings Built-up Roofing Inspection Reference Attachment 9 - Buildings Ceramic Tile Inspection Reference


Site Quality Manual



BUILDINGS MASONRY INSPECTION REFERENCE VERIFY USE CORRECT MATERIALS 1.

Approved panels and/or material samples

2.

Materials certifications

3.

Masonry units, color, texture, grade, size, defect tolerance

4.

Masonry mortar, cement, aggregate, lime, water

5.

Mortar cube tests, if required

6.

Anchors, ties, flashing - type, size, shape and material

INSPECT MASONRY CONSTRUCTION 1.

Ambient temperature above minimum

2.

Masonry layout fits structural framing

3.

Embedded items

4.

Control joint type and location

5.

Caulked joints

6.

Openings framed, anchored, filled with mortar

7.

Weep holes

8.

Anchors, ties, joint reinforcing

9.

Flashing installation

10.

Foundation waterproofing or damp proofing

ASCERTAIN WORKMANSHIP 1.

Bond pattern, visual appearance

2.

Mortar joints, visual appearance

3.

Brick work plumb and true, all in one plane

4.

Pointing

5.

Cleaning



BUILDINGS WATERPROOFING AND DAMPPROOFING INSPECTION REFERENCE VERIFY USE CORRECT MATERIALS 1.

Bitumen roofing felt

2.

Tar or asphalt damp proofing

3.

Mastic asphalt

4.

Hot application asphalt

5.

Bituminous adhesives

6.

Bituminous roofing

7.

Polyethylene sheet

INSPECT APPLICATION OF DAMPPROOFING/WATERPROOFING 1.

Surface preparation for cleanliness, smoothness, dryness

2.

Ambient temperature above 40°F

3.

Material temperatures

4.

Prime coat

5.

Coats, laps, and thicknesses

6.

Waterproofing details at flashing or wall penetrations

7.

Waterproofing membrane type, application, reinforcing strips

8.

Waterproofing membrane protection against backfill

9.

Waterproofing reinforcing plies where required


Damp proof coating free of breaks, surface air voids in monolithic concrete

2.

Waterproof coating free of wrinkles and buckles



BUILDINGS WATERPROOFING AND DAMPPROOFING INSPECTION REFERENCE VERIFY USE CORRECT MATERIALS 1.

Bitumen roofing felt

2.

Tar or asphalt damp proofing

3.

Mastic asphalt

4.

Hot application asphalt

5.

Bituminous adhesives

6.

Bituminous roofing

7.

Polyethylene sheet

INSPECT APPLICATION OF DAMPPROOFING/WATERPROOFING 1.

Surface preparation for cleanliness, smoothness, dryness

2.

Ambient temperature above 40°F

3.

Material temperatures

4.

Prime coat

5.

Coats, laps, and thicknesses

6.

Waterproofing details at flashing or wall penetrations

7.

Waterproofing membrane type, application, reinforcing strips

8.

Waterproofing membrane protection against backfill

9.

Waterproofing reinforcing plies where required


Damp proof coating free of breaks, surface air voids in monolithic concrete

2.

Waterproof coating free of wrinkles and buckles



BUILDINGS PLASTER INSPECTION REFERENCE VERIFY USE OF CORRECT MATERIALS 1.

Approved material samples

2.

Metal stud partitions

3.

Metal lath

4.

Plaster materials

INSPECT PLASTER WALL CONSTRUCTION 1.

Stud spacing and anchorage

2.

Studs properly anchored to adjoining walls

3.

Studs galvanized or protectively coated

4.

Studs attachment at openings as detailed on drawings

5.

Lath type, lapping, joints

6.

Lath screeds and grounds have a true, level and plane surface.

7.

Lath corner beads provided for external corners

8.

Lath installed at internal corners, where required

9.

Lath properly secured to studs

10.

Plaster area ambient temperature maintained above 55°F

11.

Plaster mix proportions, set characteristics as specified

12.

Plaster base surfaces properly prepared

13.

Plaster coats checked for thickness, density, uniformity

14.

Plaster base coat moistened before applying finish coats

15.

Plaster curing adequate


Each plaster coat, smooth, plumb, true, all in one plane

2.

White plaster coat free from cracks, crazing, blisters, pits, checks, discoloration



BUILDINGS, METAL DOORS AND WINDOWS INSPECTION REFERENCE VERIFY THE USE OF CORRECT MATERIALS 1.


2.

Guarantees, for electric power operators

3.

Doors, door bucks

4.

Window sashes and liners

5.

Hardware

6.

Window glass and glazing

7.

Caulking materials

8.

Electrical components for power operated doors

9.

Guides and panel sections for telescoping doors

INSPECT INSTALLATION OF DOORS AND WINDOWS 1.

Frames anchored, plumb, square and level

2.

All clearances adequate

3.

Caulking provided where required

4.

Weather stripping installed where required

5.

Hardware properly adjusted

6.

Glazing installation adequate

7.

Lubricants provided where needed


Each unit operates smoothly and easily

2.

Doors, flush and snug with jams

3.

Window frames, flush and snug with sashes

4.

Units with tension adjustment mechanisms are in proper adjustment

5.

Painted surfaces cosmetically pleasing

6.

Clean up is satisfactory



BUILDINGS DRYWALL CONSTRUCTION INSPECTION REFERENCE VERIFY USE OF CORRECT MATERIALS 1. Gypsum board 2. Joint cement 3. Joint tape 4. Nails INSPECT INSTALLATION OF DRYWALL 1. Gypsum board is stored in a dry, ventilated, enclosed building. 2. Ambient temperature is above freezing at time of joint cement application. 3. Surfaces to receive drywall conform to line and grade. 4. Gypsum board held tight against supports with nailing starting at center and progressing toward perimeter. 5. Paper surface torn around nail head has additional nail driven two inches away. 6. Cut and fit gypsum board is not forced into place. 7. Thin coats of cement applied immediately after taping. 8. Coats of cement on joint and nail depressions have 24 hours between applications. 9. Final cement coat feathered 12" to 16" each side of joint and is sanded smooth. ASCERTAIN WORKMANSHIP 1. Installed gypsum board free from damage. 2. All cemented joints and nail depressions will present smooth and uniform appearance when wall is painted.



BUILDINGS RESILIENT FLOOR COVERING INSPECTION REFERENCE VERIFY CORRECT MATERIALS 1.


2.

Tile color, type, size, thickness

3.

Molding color, type, size

4.

Primer

5.

Adhesive or cement

INSPECT LAYING OF TILE 1.

Sub-floor preparation

2.

Felt lining or under-layment

3.

Temperature of stored material and laying area

4.

Layout pattern of cut tiles at wall line and wall openings

5.

Application of adhesives


Tiles laid point to point

2.

Tile joints tight

3.

Tile pattern as specified

4.

Tile cuts at wall base or wall opening correct

5.

Tiles cleaned and waxed after completion

6.

Tiles protected after waxing with construction paper

*Includes asphalt, vinyl-asbestos, vinyl and rubber tile and floor covering.



BUILDINGS CARPENTRY INSPECTION REFERENCE VERIFY USE OF CORRECT MATERIALS 1.

Specifies, grade, grade stamp

2.

Defect tolerance for checks, splits, shakes, pockets, decay, grain structure, knots, % heart wood or sapwood, bark, warp

3.

Moisture content checks

4.

Storage conditions

5.

Preservative treatment

INSPECT CARPENTRY CONSTRUCTION 1.

Stud spacing

2.

Double of top plates, when required

3.

Horizontal blocking

4.

Continuous blocking between joints and studs, for fastening wall materials

5.

Stud to plate nailing adequate

6.

Diagonal wind bracing, when required

7.

Solid blocking for fixtures and attachments

8.

Doubling of studs at openings

9.

Headers as detailed on drawings

10.

Soundproof partitions as required

11.

Vertical alignment of studs to form one plane for wall surface

12.

Framing fabrication line, level and fit

13.

Anchorage to concrete and masonry



BUILDINGS BUILT-UP ROOFING INSPECTION REFERENCE VERIFY THE USE OF CORRECT MATERIALS 1.

Asphalt

2.

Nails and fasteners

3.

Insulation

4.

Vapor barrier

5.

Roofing felt

6.

Flashing

7.

Aggregate

8.

Installed roof samples, if required

9.

Roof guarantees, if specified

INSPECT BUILT-UP ROOFING INSTALLATION 1.

Surface to be roofed is dry, smooth, firm and dirt free

2.

Vapor barrier installation, provides complete seal of deck

3.

If insulation required, place by specified method immediately preceding placing of roofing felt - avoid wetting

4.

Maintain roofing felts above 50°F for 24 hours prior to use

5.

Ambient temperature is 40°F and rising for hot mopping of felt

6.

Felt is laid immediately behind mopping

7.

Temperature of bitumen is as required

8.

Extra plies installed where required, such as at eaves, rakes and flashing

9.

Roofing aggregates are as specified


Roofing felt plies free of air pockets, wrinkles and buckles

2.

Roofing felt laps are uniform and even

3.

Aggregate distribution is uniform

4.

Flashing detailing acceptable



BUILDINGS CERAMIC TILE INSPECTION REFERENCE VERIFY THE USE OF CORRECT MATERIALS 1.


2.

Tile type, size and color pattern

3.

Mortar type and color

INSPECT APPLICATION OF TILE 1.

Wall tile, location and anchorage of studs or furring

2.

Wall tile lath, placement, lap and support

3.

Wall tile scratch coat and float coat applied and cured properly

4.

Wall tile soaked and free water removed prior to application

5.

Wall tile accessories are as required

6.

Wall tile firmly set

7.

Wall tile wetted before grouting

8.

Wall tile grout, placing, tooling, curing and cleaning

9.

Floor tile installed after wall tile

10.

Floor tile setting bed preparation as specified

11.

Floor tile setting bed mix satisfactory

12.

Floor tile solidly bedded

13.

Floor tile layout acceptable

14.

Floor tile waterproofing and reinforcement when required

15.

Floor tile cuts as wall base and openings acceptable


Tiles free of chips or cracks

2.

Grout joints uniformly tooled

3.

Grout tiles all in one plane

4.

Tile pattern uniform and consistent

5.

Tile cuts at baseline, corners or openings are satisfactory


000 509 7310 18 Feb 04 Page 1 of 2

HEATING, VENTILATING AND AIR CONDITIONING DUCTWORK (HVAC) SCOPE This procedure establishes the method for inspection and verification that construction work on HVAC ductwork systems and sub-systems are acceptable. RESPONSIBILITIES - Self-Perform ACTIVITY


RESPONSIBILITY

DOCUMENTATION

Verify ductwork configuration


000 509 F73101 000 509 F73102

Upon completion of work

Verify ductwork integrity


000 509 F73101 000 509 F73102

Prior to turnover of system

Verify leak testing performed


000 509 F73101 000 509 F73102


Electrical/Mechanical Engineer

000 509 F73101 000 509 F73102


QC Inspector (Note 1)

000 509 F02201


Verify connections to equipment Surveillance NOTE 1:

Surveillance is not required if the Fluor l quality representative is performing inspections.



RESPONSIBILITY

DOCUMENTATION

Verify ductwork configuration

Subcontractor

000 509 F73101 000 509 F73102

Upon completion of work

Verify ductwork integrity

Subcontractor

000 509 F73101 000 509 F73102


Perform leak test

Subcontractor

000 509 F73101 000 509 F73102


Connect duct to equipment

Subcontractor

000 509 F73101 000 509 F73102


Surveillance

QC Inspector

000 509 F0221



Site Quality Manual


000 509 7310 18 Feb 04 Page 2 of 2

PROCEDURE •

•

•

Verify Ductwork Configuration: -

Identify the specific limits of the system/sub-system to be inspected. Obtain the latest approved revision of the drawings of the system/sub-system for verification of the work to be inspected.

-

Verify that the installed configuration of the ductwork and hangers conforms to the drawings. Hangers and supports should be observed to assure the presence of all members. Ductwork should be observed to assure installation is within allowable tolerances for line and elevation. If there are any field "trim joints" that have not been previously inspected for acceptable completion and welding, they should be checked at this time.

Verify Ductwork Integrity: -

Ductwork should be checked internally by means of the access doors to assure that it is free of obstructions such as construction debris, scrap, etc. which is to include the checking of fire dampers for obstruction. When this has been determined, the door shall be closed and sealed with an acceptance tag, in a manner that will require the tag to be broken to gain access. Use of the tag seal is intended to provide protection against unauthorized access to the ducts.

-

Verify that any internal field-installed accessories, such as dampers, are in place. Inspections prior to release for testing shall verify that openings in the ductwork are closed or fitted with temporary blank-offs as required to establish the pressure boundaries for leak testing.

Verify Leak Testing Performed: -

•

Verify that leak testing has been performed and that leakage rates are within allowable limits. The integrity of duct joints shall be confirmed via leak testing. After leak testing, verify that all temporary blank-offs are removed.

Verify Connections to Equipment: -

Verify that all external field-installed accessories, such as registers, grills and diffusers are in place. Verify that any required connections to equipment are complete and in accordance with the drawings.

FORMS Quality Control Forms 000 509 F73101 - HVAC Inspection Checklist 000 509 F73102 – Buildings Air Conditioning Checklist Fluor Corporation Company Confidential

Site Quality Manual


000 509 7320 18 Feb 04 Page 1 of 1

ROOFING INSPECTION SCOPE This procedure prescribes the roofing system inspection activities to be performed. RESPONSIBILITIES - Subcontracted DOCUMENTATION



000 509 F73201



000 509 F73201


ACTIVITY

RESPONSIBILITY

Install Roofing

Subcontractor

Roofing Installation General Requirements Inspect Roofing Installation of Adhered Membrane GENERAL •

Inspect Roofing installation -

Develop plan for frequency of roofing installation inspections to be performed.

-

Document results using Quality Control Form 000 509 F73201.

-

Inform contractor daily of problems encountered to avoid rework or coverup.

-

Coordinate manufacturer representative inspections and respond to his findings.

-

Notify appropriate craft supervision when his work, overhead or adjacent to roofing contractors work, impact the quality aspect of the roofing system.

FORMS Quality Control Form: 000 509 F73201 - Roofing Daily Inspection Checklist


Site Quality Manual


000 509 7400 18 Feb 04 Page 1 of 5

EQUIPMENT SCOPE This procedure defines the inspection, testing and documentation requirements for installation activities for equipment erection and installation. RESPONSIBILITIES - Self-Perform RESPONSIBILITY

DOCUMENTATION


Construction Engineer/ Craft Supervision

_____

As required by the controlling documents


Survey Field Books


Survey Field Books

Mechanical Superintendent

000 509 F740XX


000 509 F740XX 000 509 F02201

Millwright Superintendent

000 509 F740XX


Vendor Reports

ACTIVITY Implement storage, handling and maintenance requirement Check anchor bolt surveying Check level, alignment and plumbness Install/Erect equipment Monitor In-process Installation Activities Witness final alignment of rotating equipment Coordinate vendor activities Review guarantee requirements Perform final inspection of installed equipment Resolve any discrepancies identified NOTE 1:


_____


000 509 F740XX

Construction Engineer/ Site Quality Manager

000 509 F740XX

Prior to setting equipment Prior to setting equipment Once for each piece of equipment Daily during the life of the activity Once during final alignment As required by purchase order As required by purchase order Once after installation completed As required to resolve discrepancies

Surveillance is not required is not required if the Fluor Quality representative is performing inspections.


Site Quality Manual


000 509 7400 18 Feb 04 Page 2 of 5

RESPONSIBILITIES - Subcontracted Work ACTIVITY Implement storage, handling and maintenance requirement Check anchor bolt surveying Check level, alignment and plumbness Install/Erect equipment Monitor In-process Installation Activities Witness final alignment of rotating equipment Coordinate vendor activities Review guarantee requirements Coordinate discipline inspections Perform final inspection of installed equipment Resolve any discrepancies identified Surveillance

RESPONSIBILITY

DOCUMENTATION


Subcontractor

_____

As required by the controlling documents

Subcontractor

Survey Field Books

Subcontractor

Survey Field Books

Subcontractor

000 509 F740XX

Subcontractor/ Site Quality Manager Subcontractor/ Site Quality Manager

000 509 F740XX 000 509 F740XX

Discipline Engineer

Vendor Reports

Subcontractor/ Discipline Engineer

_____

Subcontractor

_____

Subcontractor/ Site Quality Manager Subcontractor Discipline Engineer Site Quality Manager Site Quality Manager

000 509 F740XX

Prior to setting equipment Prior to setting equipment Once for each piece of equipment Daily during the life of the activity Once during final alignment As required by purchase order As required by purchase order As required by specifications/ procedures Once after installation completed

000 509 F740XX

As required to resolve discrepancies

000 509 F02201


PROCEDURE Client involvement in the witnessing of key aspects of erection, installation and checkout shall be carefully adhered to and documented by Client signature and date. Client notification of upcoming witness points will be given in writing a minimum of twenty-four (24) hours prior to the event. If required, notify the Client's Representative that final alignment is scheduled.


Site Quality Manual


•

•

Implementation of Storage, Handling and Maintenance Requirements: -

The Construction Engineering Manager shall define the storage, handling and maintenance requirements for each type of equipment for implementation by site personnel. These requirements apply from receipt until turnover whether in lay down storage or set in place.

-

Inspect/monitor prescribed equipment preservation activities. Document on Form 000 509 F02502.

-

Verify that storage, handling and maintenance requirements are defined and implemented for each piece of equipment. Monitor these activities on a periodic basis or as required by specifications.

Verification of Anchor Bolts, Level, Alignment and Plumbness: -

•

•

•

000 509 7400 18 Feb 04 Page 3 of 5

Verify/check the anchor bolt locations and elevation, prior to setting the equipment on the foundation.

Installation/Erection of Equipment: -

The Mechanical Superintendent shall install/erect the equipment in accordance with the applicable drawings and specifications.

-

Verify/check the plumb, alignment and orientation of equipment as well as the openings for elevation and location, immediately after installation.

Monitor In-process Equipment Installation Activities: -

Initiate on Equipment Installation Checklist, Form 000 509 F740XX for each piece of equipment. Document the applicable in-process inspections as they are acceptably completed.

-

Monitor/inspect the in-process installation of each equipment unit. Document inspection as it is completed on the applicable Equipment Inspection Record.

-

Inspect for grouting of equipment as required by specification and drawings.

Final Alignment of Rotating Equipment -

Witness the final alignment process and complete Form 000 509 F740XX to document this activity.


Site Quality Manual


•

•

Coordination of Vendor Activities: -

The Construction Engineering Manager shall coordinate activities involving site vendors. Vendor schedules and purpose for site visits should be shared with site personnel for planning.

-

Quality control will interface with the Vendor's Representative on matters of inspection and testing. Vendor checklists and acceptance records should be obtained for inclusion in turnover packages as project quality records.

Review Guarantee Requirements: -

•

Inspect the equipment for guarantee requirements, when requirements are a part of the purchase order.

Final Inspection of Installed Equipment: -

•

000 509 7400 18 Feb 04 Page 4 of 5

Perform final equipment inspection at the completion of installation activities.

Resolve Discrepancies: -

Resolve exceptions and correct, deficiencies, with Client in-put as required. Perform/coordinate reinspections.

FORMS Quality Control Forms: 000 509 F74001 – Equipment Installation Checklist 000 509 F74002 – Heat Exchangers & Reboilers Installation Checklist 000 509 F74003 – Electrostatic Precipitator Checklist 000 509 F74004 – Inspection Record Static Equipment 000 509 F74005 – Tray Installation Inspection Record 000 509 F74006 - Air Cooled Heat Exchanger Inspection Checklist 000 509 F74007 - Air Cooler Run In Test Report 000 509 F74008 – Reciprocating Compressor Inspection Record 000 509 F74009 – Fan Installation Inspection Checklist 000 509 F74010 – Furnaces Inspection Checklist 000 509 F74011 – Fuel Gas Steam Generator Inspection Checklist 000 509 F74012 - Steam Turbine Inspection Checklist


Site Quality Manual


000 509 7400 18 Feb 04 Page 5 of 5

000 509 F74013 – Agitators/Mixers Inspection Checklist 000 509 F74014 – Equipment/Piping Flange Alignment Inspection Record 000 509 F74015 – Installation Checklist Travelling Cranes 000 509 F74016 – Packaged Equipment Installation Checklist 000 509 F74017 – Desuperheaters/Ejectors Inspection Checklist 000 509 F74018 – Filters/Strainers Inspection Checklist 000 509 F74019 – Centrigugal Compressor Inspection Checklist 000 509 F74020 - Rotating Equipment Inspection Checklist 000 509 F74021 – Rotating Equipment Alignment Record 000 509 F74022 - Belt Driven Equipment Alignment Record 000 509 F74024 – Inspection Record for Draw Off Tray Leak Test Report 000 509 F74025 – Inspection Record for Air Coolers 000 509 F74026 – Final Closing Authorization Record 000 509 F74027 – API 686 Baseplate Installation Checklist (Prior to Grouting) 000 509 F74028 – API 686 Equipment Grouting Checklist 000 509 F74029 – API 686 Alignment Check Sheet 000 509 F74030 – Baseplate Levelling Record 000 509 F74031 – Reverse Dial Alignment Record 000 509 F74032 – Piping Alignment Data Sheet

ATTACHMENTS Attachment 1 - Equipment Inspection Reference


Site Quality Manual



EQUIPMENT INSPECTION REFERENCE

General Requirements – Name plate data correct. – Equipment protection program in place and documented. – Anchor bolts checked for location, elevation and orientation. – Jackscrews removed and anchor bolt nuts tightened. – Pressure test documented. – Baseplate grouting complete and documented. – Field coatings checked. – Correct gaskets installed. – Correct stud bolts installed. – Final inspection performed and punch list items cleared. – Final closing authorization complete. Steam Turbines – Alignment checked and documented. – Freedom of movement and direction of rotation checked. – Bearing housing flushed and relubricated. – Carbon seals checked. – Governor mechanism free, set and operable. – Overspeed mechanism checked and tripout verified. Fired Heaters – Welding to tubes is complete and accepted. – Burner, snuffing steam and soot blower piping installed and accepted. – Convection sections team coil installed.

– – – –

Ductwork installed. Stack erected. Refractory installed and documented. Vendor representative provided service, and reports are on file. Shell & Tube Heat Exchangers

– Slide plates installed and lubricated. – Nipples in re-pads of insulated exchangers. – Ladders and platforms installed. Air-cooled heat exchangers – Fan shaft centered and plumbed. – Fan blades installed, set to proper angle, and clearance checked. – Fan & driver checked for freedom of movement. – Belts installed or coupling lubricated. – Vibration switches checked. – Final alignment checked. – Belt or coupling guard in place. – Electrical driver checks complete. Compressors – – – – – – – –

Lube and seal oil system flushed. Suction piping cleaned as per spec. Alignment checked and documented. Temporary suction screen installed. Coupling lubricated and closed. Pulsation dampening system checked. Driver activities complete. Vendor representative provided service, and reports are on file.



EQUIPMENT INSPECTION REFERENCE

Pumps – – – – – –

Bearing housing flushed and lubricated. Temporary suction screen installed. Driver activities complete. Coupling lubricated and closed. Packing installed. Vendor representative provided service, and reports are on file. – Alignment checked and documented. Vessels: – – – – – – – – – –

Slideplates installed and lubricated. Ladders and platforms erected. Internal shipping braces removed. Tray installation and orientation checked. Downcomers installation checked. Demisters checked. Packing and filter medium checked. Tray leak and level test complete. Refractory checked. Catalyst installed.


000 509 7410 18 Feb 04 Page 1 of 4

FIELD FABRICATED TANKS SCOPE This procedure defines the inspection, testing and documentation requirements for installation activities for field fabricated tanks. RESPONSIBILITIES - Self-Perform ACTIVITY


RESPONSIBILITY

DOCUMENTATION

Verify foundation surveying


Survey Field Books

Prior to start of erection

Inspect foundation construction


Per 000 509 7100


Review and approve welding procedures

Welding Engineering

Approval from Corporate Welding Engineering

Prior to start of welding activities

Review and approve NDE procedures

Corporate NDE Level III

Approval from Corporate Level III

Prior to start of NDE activities

Monitor in-process welding and NDE activities


Per 000 509 7910

Check dimensions of tank shell


000 509 F74103

Periodically during life of activity

Inspect completed tank


000 509 F74102

Each tank

Witness testing


Inspect tested tank prior to closing




Each tank 000 509 F74026

Each tank

Site Quality Manual


000 509 7410 18 Feb 04 Page 2 of 4

RESPONSIBILITIES - Subcontracted ACTIVITY Verify foundation surveying Inspect foundation construction Review and approve contractor's welding procedures Review and approve contractor's NDE procedures Check dimensions of tank shell Surveillance of weld and NDE activities.


RESPONSIBILITY

DOCUMENTATION


Survey Field Books


Subcontractor

000 509 F0221


Welding Engineering

Approval from Corporate Welding Engineering

Prior to start of welding activities

Corporate NDE Level III

Approval from Corporate Level III

Prior to start of NDE activities

Subcontractor

000 509 F74103 000 509 F02201

Inspect completed tank

Site Quality Manager/ Subcontractor Site Quality Manager/ Subcontractor

000 509 F02201

Periodically during life of activity Daily during life of activity

000 509 F74102

Each tank

Witness testing

Site Quality Manager/ Subcontractor

000 509 F74104 000 509 F74105 000 509 F74106

Each tank

Inspect tested tank prior to closing

Site Quality Manager/ Subcontractor

000 509 F74026

Each tank

PROCEDURE •

Foundation Surveying: -

•

Foundation Construction: -

•

Verify that the foundation surveying is complete.

Verify the foundation construction is complete and released for the tank erection. For subcontracted work ensure the erector has accepted the foundation prior to start of tank erection activities.

Review and Approval of Welding Procedure: -

Verify the welding procedures have been reviewed and approved by the Corporate Welding Manager or his representative.


Site Quality Manual


•

Review and Approval of NDE Procedures: -

•

•

•

•

000 509 7410 18 Feb 04 Page 3 of 4

Verify the NDE Procedures have been reviewed and approved by the Corporate NDE Level III.

Dimension Checks of Tank: -

Monitor the in-process fabrication activities. Utilize From 000 509 F74102 to document the dimension checks.

-

Verify the first course shell plates have been surveyed for levelness, circularity, and plumbness prior to setting the second course. Contractor must submit the results immediately after each survey has been completed.

Completed tank Inspection: -

Verify that a final survey has been performed of the erected dimensions of the tank after all roof framing has been installed.

-

Verify the tolerances for plumbness of roof columns and stilling wells, tank nozzles and modules are within those established by the specification.

Witness Testing of Tank: -

Witness the hydrostatic test on the completed tank in accordance with the project specifications and applicable code requirements.

-

Check the settlement and rebound of the foundation during and after the hydrotest. Excessive settlement data shall be referred immediately to the Site Engineering Manager.

-

Obtain a copy of the tank test for inclusion in the permanent file.

Inspection of Tested Tank Prior to Closing: -

Inspect the tested tank prior to closing, including final cleanup. Document the approval to close the tank using From 000 509 F74026.

-

Verify that a nameplate according to code and the Manufacturer's Certification Letter and the as-built data has been provided as required by the specifications.


Site Quality Manual


000 509 7410 18 Feb 04 Page 4 of 4

FORMS Quality Control Forms: 000 509 F74101 - Tank Elevation Tolerances Record 000 509 F74102 - Inspection Record Field Erected Tank 000 509 F74103 - Tank Plate Dimensional Control Record Field Erected Tank 000 509 F74104 - Water Filling And Settlement Record Field Erected Tank 000 509 F74105 - Tank Leak Test Record 000 509 F74106 - Tank Test Certificate 000 509 F74026 - Final Closing Authorization Record 000 509 F02201 - Surveillance Report


Site Quality Manual


000 509 7420 18 Feb 04 Page 1 of 1

COOLING TOWER SCOPE This procedure defines the inspection, testing and documentation requirements for installation activities for Cooling Towers. RESPONSIBILITIES - Sub-Contracted ACTIVITY Check foundation surveying Inspect in-process installation Inspect completed construction

RESPONSIBILITY

DOCUMENTATION

Construction Engineer/ Subcontractor Site Quality Manager/ Subcontractor Site Quality Manager/ Subcontractor

Survey Field Books 000 509 F02201 000 509 F02201 000 509 F02201

FREQUENCY OF ACTIVITY Prior to start of installation Daily during life of activity Each cooling tower

PROCEDURE •

Check Foundation Surveying: -

•

Inspection of In-process Installation Activities: -

•

Check the elevation and location of the constructed basin, prior to the release of the foundation to the Contractor. The Contractor shall acknowledge acceptance of the foundation as correct, in writing on contractor’s letterhead, prior to the start of work.

Monitor the in-process construction of the cooling tower on a daily basis.

Inspection of Completed Construction on Cooling Tower: -

Inspect the erected cooling tower for acceptance in accordance with design documents when the Contractor indicates that the work is complete.

FORMS Quality Control Form: 000 509 F02201 - Surveillance Report 000 509 F74201 – Cooling Tower Inspection Checklist


Site Quality Manual


000 509 7430 18 Feb 04 Page 1 of 1

REFRACTORY CONCRETE SCOPE This procedure is limited to premixed castable refractory concrete used in heaters, or other uncomplicated applications, and defines the inspection, testing and documentation requirements for installation activities for refractory concrete. RESPONSIBILITIES REFRACTORY CONCRETE - Installed by Fluor or Sub-Contracted ACTIVITY Inspect refractory materials Inspect in-process installation activities Witness/Perform refractory tests

RESPONSIBILITY Civil Construction Engineer Civil Construction Engineer Civil Construction Engineer

DOCUMENTATION 000 509 F02201 000 509 F74301 000 509 F74301

FREQUENCY OF ACTIVITY Prior to each application/job Each unit of equipment requiring refractory Each unit of equipment requiring refractory

PROCEDURE •

Inspection of Refractory Materials: -

•

Inspect the In-process Installation Activities: -

•

Inspect the refractory materials, prior to the start of work, to assure the materials have not deteriorated or the shelf life has expired.

Inspect the in-process refractory concrete installation. This inspection includes the anchors, forming, placing, and curing. Document these inspections using Form 000 509 F74023

Witness/Perform the Refractory Tests: -

Witness/perform the refractory tests, or prepare specimens for testing, as required by the specification and/or manufacturer's recommendation. Tests required: ball-in-hand, for consistency; in-place thickness measurements on plastic concrete; and the hammer test for soundness on concrete cured for twenty-four (24) hours. Document the tests using Form 000 509 F74301.

FORMS Quality Control Forms: 000 509 F02201 Surveillance Report 000 509 F74301 Field Installed Refractory Record


ITP 509 7440

18 Feb 04 Page 1 of 3

Activity

Inspection and Test Plan Description Gas Turbine/Gear Unit/ Generator Installation Inspection Client Item 1 2 3 4 5 6

Project Name

Project Location

Contractor

Inspection/Test Stage Verify the installation contractor has prepared a complete field testing plan Inspect the equipment for guarantee requirements, when requirements are a part of the purchase order. Verify Nameplate Data Recheck the anchor bolt locations and elevation, prior to setting equipment on the foundations. Verify the installer has accepted the foundations in writing Check equipment orientation, openings, elevation and location as required for interface with other equipment, check piping connection alignment

Contract Number Requirement and Acceptance Criteria

Project Number

ITP Number 000 509 ITP7440 Issue Date Revision 0 Scope of Inspection Inspection Responsibility Record Sub Fluor Client

N/A

CEM

R

N/A

PO

CS

I

I

N/A

PO Per approved drawings

CS

I

I

CEM

I

I

509F74401 509F74402

N/A

CEM

I

R

N/A

Per approved drawings

CEM

R

509F74021

7

Inspect grouting operations

Project Specification, 000 509 7100

CS

8

Verify field installed pressure piping hydrostatically tested prior to final connection to the Gas Turbine Generator system.

Hydrotest Packages completed and reinstated

CS

9

Inspect and align turbine/gear/ generator unit before and after piping connection

Project Specification

CS



I

I

H

CompleteIT Input N/A

509F71006 509F71009 509F74401 509F74402

R

509F74402

H

509F74401 509F74402 509F74021

Site Quality Manual


ITP 509 7440


Activity

Inspection and Test Plan Description Gas Turbine/Gear Unit/ Generator Installation Inspection Client Item 10 11 12 13 14

15

Project Name Contractor

Inspection/Test Stage Conduct in-process installation inspection Inspect, or perform, equipment and material preservation activities. Verify lube oil and cooling oil systems are changed with operating oil recommended by the manufacturer. Verify gauges and instruments have been calibrated prior to the performance tests. Verify the completion of electrical, pre-operational and functional test as described in the specifications Check the auxiliary systems to include: - Lube and control oil system: - Fuel control system - Steam or water injection system - Starting system and turning gear - Inlet air system - Exciter - Control compartment and MCCs



Project Location Contract Number Requirement and Acceptance Criteria Per applicable check sheet, manufacturer’s specification and Project Specification 000 509 0250 Project Specification Manufacturer’s Recommendations See PO T/O package instrument calibration records complete

Project Number

ITP Number 000 509 ITP7440 Issue Date Revision 0 Scope of Inspection Inspection Responsibility Record Sub Fluor Client CS

I

I

509F74401 509F74402

CS

P

I

509F02502 509F74402

CS

P

W

509F74402

CS

P

R

509F74402

T/O package functional test records complete

CS

P

R

509F74402

Per Approved Drawings

CS

I

I

509F74402

CompleteIT Input

Site Quality Manual


ITP 509 7440


Activity

Inspection and Test Plan Description Gas Turbine/Gear Unit/ Generator Installation Inspection Client Item 16

Project Name Contractor

Inspection/Test Stage Monitor field mechanical running test for compliance with test requirements and recorded measurements

Project Location Contract Number Requirement and Acceptance Criteria Per Manufacturer’s Specification and PO requirements, Commissioning ITP

Inspection Legend: P = Perform I = Inspection T = Test R = Review and Approve W = Witness (Notification of authorized inspection personnel required) H = Hold (Mandatory, do not proceed without presence of authorized inspection personnel or signed waiver)


Equipment Installation Project Number

ITP Number 000 509 ITP7440 Issue Date Revision 0 Scope of Inspection Inspection Responsibility Record Sub Fluor Client CEM

P

H

CompleteIT Input

509F74402

Responsibility Legend: CS = Fluor Construction Supervision CEM = Fluor Construction Engineering Manager QI = Fluor Quality Inspector CWI = Fluor Certified Welding Inspector RI = Fluor Receiving Inspector NDE = Certified NDE Examiner

Site Quality Manual


ITP 509 7460 18 Feb 04 Page 1 of 22 Activity

Inspection and Test Plan Description Project Name Steam Turbine/Generator Installation Client Contractor

Item

1

2 3 4 5

Inspection/Test Stage 1)

Alignment meeting between the responsible site FLUOR Construction Manager, Field Engineer, QC, Millwright Superintendent and GE TA. The meeting agenda is to include as a minimum:

• • • • • •

Roles and Responsibility Procedures and Documents to be used GE to review and agree to the FLUOR procedure Approve/Agreement/Deviation process Documentation Copies/Files/Archive System

Complete a Site Daily Activities Log sheet for each separate STG Unit, each day. Distribute copies as noted and hold the original on file in the Log Sheet Binder. Photos of in-process work, testing, and progress completed and attached. Photos to be taken a minimum of weekly and at key events throughout installation. Rigging plans reviewed and approved by FLUOR rigging engineer


Project Location Contract Number


ITP Number 000 509 ITP7460 Revision 0 Scope of Inspection Responsibility Sub Fluor Client

CEM

P

P

CS

P

R

Issue Date Inspection/Test Record

Completion Sign-Off Fluor GE

000 509 F74601

Cranes and lifting devices inspected prior to service

6

Concrete test records reviewed and approved by FLUOR Engineer.

7

Welding WPSs and PQRs reviewed and approved by FLUOR Welding Technology in advance of the start of work.


Site Quality Manual


ITP 509 7460 18 Feb 04 Page 2 of 22


Item

8

9 10

Inspection/Test Stage Foundation “Buy-Off” from FLUOR Civil/Structural by FLUOR Millwrights. Confirm the Surveys have been performed, results in accordance with specifications, approved, and documentation attached for the following points: (a) Permanent Monument set in the turbine deck concrete (b) Anchor Bolt placement within tolerances (c) Grout pocket positions and cleanliness Initial Turbine Deck Elevation readings Fixators installed and verified to be acceptable and the results documented and attached. Sole plates installed and verified to be acceptable and results documented and attached.



Activity Equipment Installation Project Number




000 509 F74602 000 509 F74609

000 509 F74603 000 509 F74604

Mid-standard installation (between the HP/IP and LP sections) is to be conducted using GE documents and the GE TA’s support for tolerances and reference locations. Basic activities include: (a) Locate properly with measurements referenced to the turbine and bearing No. 2 and No. 3 centerlines as defined by GE documents

11

000 509 F74604

(b) Verify placement is within the tolerances provided by the GE TA - document this on Form D (c) Level and verify that the top surface flatness is within GE tolerances provided by the GE TA GE TA to confirm the above noted Mid-standard placement and levelness is within GE tolerances prior to grouting


Site Quality Manual


ITP 509 7460 18 Feb 04 Page 3 of 22


Item

Inspection/Test Stage 1)

12

13

LP Exhaust Hood section installation – to be verified and found to be acceptable with the results documented and attached.







000 509 F74606

NOTE: The LP section is the “Fixed” point of the entire train with the Condenser, Generator and HP/IP Turbine aligned to the LP Turbine. LP Turbine Anchor Bolt / Casing Hole minimum clearance verified with respect to expansion direction (a) LP horizontal joint level checks using a Bronson 545 precision level (P-Level) for site use. Generator Anchor Bolt / Casing Hole minimum clearance verified with respect to expansion direction Reconfirm the LP horizontal joint level checks using a Bronson 545 precision level (P-Level) for site use after Condenser aligned to the LP Exhaust Hood and Condenser Expansion joint installation – connection between the Condenser and the LP Exhaust Hood is made Measure “as-received” dimensions and the top and bottom surface levelness of front standard Baseplate Assembly. Confirm findings with the GE TA’s records.


000 509 F74606

000 509 F74606

Site Quality Manual


ITP 509 7460 18 Feb 04 Page 4 of 22


Item

Inspection/Test Stage







Front Standard Baseplate Assembly installation to be conducted using GE documents and the GE TA’s support for tolerances and reference locations. Basic activities include: (a) Locate properly with measurements referenced to the turbine and bearing No. 1 centerlines as defined by GE documents

000 509 F74605

(b) Verify placement is within the tolerances provided bythe GE TA (c) Level and verify that the top surface flatness is within GE tolerances provided by the GE TA GE TA to confirm the above noted Baseplate Assembly placement and levelness is within GE tolerances prior to grouting Set the HP/IP section on the foundation Sole Plates. Conduct the initial HP/IP section Load Checks to eliminate / correct any “Soft Foot”

000 509 F74607

Measure “as-received” position of HP/IP rotor prior to removing the Dummy Bearing Ring that is part of transportation preparation. Compare findings with the GE TA’s records. Installation of HP/IP section verified and found to be acceptable by the GE TA – document the measurements


Site Quality Manual


ITP 509 7460 18 Feb 04 Page 5 of 22


Item








Continuation of the LP section installation Lower Inner casing levels checked Set up the “Wire Line” through the LP section Install the Upper Inner Casing half on the lower half Bolt Inner Casing joint Initial Recording of the LP Inner / Outer casing alignment. See GE TA for copy of GE drawings used to describe and record LP inner casing transverse level check and LP inner casing load checks (see GE Dwg. 364 A 6019) Attached the Upper Exhaust Hood section and bolt to the lower section - Installation of upper Exhaust Hood Rupture Disks Perform a “Tops-On” Alignment check of the LP section measuring the Top, Bottom, Left and Right clearances at the T3 and T4 bearings. Record these readings. Verify: Alignment of turning gear standards to exhaust casing Installation of condenser expansion joint rubber piece Removal of upper section of the Exhaust Hood Removal of upper half of the Inner Casing


Site Quality Manual




Item

Inspection/Test Stage -







Re-verify alignment of the lower LP Inner Casing: Installation of LP lower diaphragms, perform clearance measurements with the wire line Cut the LP lower diaphragm Elevation Keys in accordance to the clearance measurements to obtain the proper Diaphragm Height

NOTE: This is a multi-step processes of measure, trim-cut the Key, reset diaphragm, measure again, trimcut again; repeating the process until the correct Height is obtained. Be careful to not cut too much initially. Verify: Installation of oil deflectors Installation of T3 and T4 bearings (blue outer contact surfaces and Gap Check with feeler gauges) Alignment of T3 and T4 bearings Installation of the LP Rotor Rotor Clearance Checks Assembly of upper LP Inner Casing Installation of upper LP Inner Casing and bolt to the lower casing half joint Final Recording of the LP Inner / Outer casing alignment. See GE TA for copy of GE drawings used to describe and record LP inner casing transverse level check and LP inner casing load checks (GE Dwg. 364 A 6019)

H

Verify Installation of upper Outer Casing


Site Quality Manual




Item






Reconfirm the LP horizontal joint level checks using a Bronson 545 precision level (P-Level) for site use. Verify: Upper Exhaust Hood section is attached and bolted to the lower section Final alignment of HP/LP rotor to the LP rotor Final alignment of Generator rotor to the LP rotor Make up IP / LP coupling (Coupling A) Installation of bearing covers and alignment of turning gear Make up LP / Generator coupling (Coupling B) For both Coupling A and B, verify proper torque of the coupling “Windage Nuts” and/or the ‘staking’ is complete per the applicable GE documents (see the Coupling drawings)



000 509 F74606

H

Check bearings with rotor (T&T) Verify: Alignment of brush holder Fit and installation of generator brushes Installation of Condenser auxiliaries Mechanical checks – lube oil skid Grout the Sole Plates for the Generator, LP Section, HP/IP Section, Mid-standard and Front standard. Measure the post-grouting levelness of each plate. Set Front Standard Air Gaps in accordance with the GE requirements. See GE TA for values from the FEM or specific unit documents.


000 509 F74604 H

Site Quality Manual




Item








Piping installation sequence, load verification and measurement documentation are all extremely important and must be performed correctly. NOTE: Prior to welding any piping to the turbine casing, the Welding Sequence is to be discussed and agreed to with the GE TA. The sequence and checks shall be in conformance with the applicable GE documents and approved by both FLUOR and GE personnel.

H

000 509 F74608

H

000 509 F74607 000 509 F74608

All readings are to be verified and accepted by the GE TA, then properly documented before performing any welds. Conduct the Baseline Position Readings of the HP/IP section, including: 1.

Gland Bore (Right, Left and Top)

2.

Tooling Bore (Right, Left and Top)

3.

N1 Packing – Turbine End (Right, Left and Top)

4.

Balance Plug Hole with respect to Top, Bottom and LP Shell (provides HP/IP Rotor position)


Site Quality Manual




Item








Verify: -

Weld the Combined Reheat Valve (CRV) to the turbine casing on both the Right and Left sides Conduct the required Post Weld Stress Relieving Set the GE provided CRV Spring Can supports in accordance with the GE recommendations (both Right and Left sides) Conduct the Baseline Load Checks of the HP/IP section in accordance with the GE guidelines. This is to be observed by the GE TA who shall give technical guidance on the proper methodology and shall review and accept the documented results.

H

000 509 F74607 000 509 F74608

H

000 509 F74607 000 509 F74608

Verify alignment of the Right and Left side Hot Reheat Pipes to the inlet of the CRV casing Prior to pipe fit-up with the corresponding turbine casing nozzle, verify the following points are complete for the piping system from the Pipe Rack to the Turbine: •

Hydrotest Water drained from all low points

•

No extraneous Bracing or Restraints holding the pipe in position

•

Pipe Hangers – location, installation and adjustment is correct Spring Cans – position and installation is correct, Gags removed and the Spring Deflection Indicator shows the unit is in the COLD position


Site Quality Manual




Item

Inspection/Test Stage Verify tack weld, then completion of the Root Weld and Hot Pass of the pipe to each nozzle After welds cool conduct the HRS Pre-Weld Load Check of the HP/IP section in accordance with the GE guidelines. This is to be observed by the GE TA who shall give technical guidance on the proper methodology and shall review and accept the documented results. Verify: Complete the welding of each Hot Reheat pipe to the casing nozzle Conduct the required Post Weld Stress Relieving Let piping and valves cool After welds cool conduct the HRS Post-Weld Load Check of the HP/IP section in accordance with the GE guidelines. This is to be observed by the GE TA who shall give technical guidance on the proper methodology and shall review and accept the documented results.







H

000 509 F74607 000 509 F74608

H

000 509 F74607 000 509 F74608


Site Quality Manual




Item








Conduct the HRS Post-Weld Position Readings of the HP/IP section, including: 1.


2.


3.


4.


H

000 509 F74607 000 509 F74608

NOTE: Proceed only if the HRS Post-Weld Load Check and HRS Post-Weld Position Readings are acceptable to D/FD and GE

Verify alignment of the GE provided “Wishbone” piping arrangement to the Main Steam nozzle on the turbine casing


Site Quality Manual




Item








Prior to pipe fit-up with the corresponding turbine casing nozzle, verify the following points are complete for the piping system from the Pipe Rack to the Turbine: •

Hydrotest Water drained from all low points

•

No extraneous Bracing or Restraints holding the pipe in position

•

Pipe Hangers – location, installation and adjustment is correct

•

Spring Cans – position and installation is correct, Gags removed and the Spring Deflection Indicator shows the unit is in the COLD position

H

000 509 F74607 000 509 F74608

H

000 509 F74607 000 509 F74608

Verify Tack weld, then completion of the Root Weld and Hot Pass of the pipe to the nozzle After welds cool conduct the HPS1 Pre-Weld Load Check of the HP/IP section in accordance with the GE guidelines. This is to be observed by the GE TA who shall give technical guidance on the proper methodology and shall review and accept the documented results. Verify: completion of the welding of the main steam pipe to the casing nozzle Conduct the required Post Weld Stress Relieving - Let piping and valves cool


Site Quality Manual




Item

Inspection/Test Stage After welds cool conduct the HPS1 Post-Weld Load Check of the HP/IP section in accordance with the GE guidelines. This is to be observed by the GE TA who shall give technical guidance on the proper methodology and shall review and accept the documented results.






H

000 509 F74607 000 509 F74608

H

000 509 F74607 000 509 F74608


Conduct the HPS1 Post-Weld Position Readings of the HP/IP section, including: 1) 2) 3) 4)

Gland Bore (Right, Left and Top) Tooling Bore (Right, Left and Top) N1 Packing – Turbine End (Right, Left and Top) Balance Plug Hole with respect to Top, Bottom and LP Shell (provides HP/IP Rotor position) NOTE: Proceed only if the HPS1 Post-Weld Load Check and HRS Post-Weld Position Readings are acceptable to D/FD and GE Verify: the installation of both HP Steam Stop/Control Valves is correct Fit-up and weld the piping to the outlet of the HP Steam Stop/Control Valves Conduct the required Post Weld Stress Relieving Let piping cool Align the FLUOR High Pressure steam piping to the GE provided “Wishbone” piping arrangement


Site Quality Manual




Item








Prior to pipe fit-up with the corresponding turbine casing nozzle, verify the following points are complete for the piping system from the Pipe Rack to the Turbine: -

Hydrotest Water drained from all low points No extraneous Bracing or Restraints holding the pipe in position Pipe Hangers – location, installation and adjustment is correct Spring Cans – position and installation is correct, Gags removed and the Spring Deflection Indicator shows the unit is in the COLD position

H

000 509 F74607 000 509 F74608

H

000 509 F74607 000 509 F74608

H

000 509 F74607 000 509 F74608

Tack weld, then complete the Root Weld and Hot Pass of the pipe to the nozzle After welds cool conduct a second HPS2 PreWeld Load Check of the HP/IP section in accordance with the GE guidelines. This is to be observed by the GE TA who shall give technical guidance on the proper methodology and shall review and accept the documented results. Verify: Completion of the welding of the main steam pipe to the “Wishbone” arrangement Conduct the required Post Weld Stress Relieving Let piping cool After welds cool conduct a second HPS2 Post-Weld Load Check of the HP/IP section in accordance with the GE guidelines. This is to be observed by the GE TA who shall give technical guidance on the proper methodology and shall review and accept the documented results. Fluor Corporation Company Confidential

Site Quality Manual




Item








Conduct another set of HPS2 Post-Weld Position Readings of the HP/IP section, including: 1)


2)


3)


4)


H

000 509 F74607 000 509 F74608

H

000 509 F74607 000 509 F74608

NOTE: Proceed only if the set of HPS2 Post-Weld Load Check and HPS2 Post-Weld Position Readings are acceptable to D/FD and GE Verify Alignment of the LP Steam line to the casing nozzles Prior to pipe fit-up with the corresponding turbine casing nozzle, verify the following points are complete for the piping system from the Pipe Rack to the Turbine: -

Hydrotest Water drained from all low points No extraneous Bracing or Restraints holding the pipe in position - Pipe Hangers – location, installation and adjustment is correct - Spring Cans – position and installation is correct, Gags removed and the Spring Deflection Indicator shows the unit is in the COLD position Tack weld, then complete the Root Weld and Hot Pass of the pipe to each nozzle

-


Site Quality Manual




Item

Inspection/Test Stage After welds cool conduct the LPS Pre-Weld Load Check of the HP/IP section in accordance with the GE guidelines. This is to be observed by the GE TA who shall give technical guidance on the proper methodology and shall review and accept the documented results. Verify: completion of the root and hot pass welding of each LP pipe to the casing nozzle Conduct the required Post Weld Stress Relieving Let piping cool After welds cool conduct the LPS Post-Weld Load Check of the HP/IP section in accordance with the GE guidelines. This is to be observed by the GE TA who shall give technical guidance on the proper methodology and shall review and accept the documented results. Verify: Completion of the welding of each LP pipe to the casing nozzle Conduct the required Post Weld Stress Relieving Let piping cool After welds cool conduct the LPS Post-Weld Load Check of the HP/IP section in accordance with the GE guidelines. This is to be observed by the GE TA who shall give technical guidance on the proper methodology and shall review and accept the documented results.







H

000 509 F74607 000 509 F74608

H

000 509 F74607 000 509 F74608


Site Quality Manual




Item








Conduct the LPS Post-Weld Position Readings of the HP/IP section, including: 1.


2.


3. 4.

N1 Packing – Turbine End (Right, Left and Top) Balance Plug Hole with respect to Top, Bottom and LP Shell (provides HP/IP Rotor position) NOTE: Proceed only if the LPS Post-Weld Load Check and LPS Post-Weld Position Readings are acceptable to D/FD and GE Install the Crossover Piping from the IP section to the LP section NOTE: Completion of the Cold Reheat Pipes to the turbine casing nozzles is deferred until after the Steam Blow process. See the Commissioning Section below. Verify: Ancillary System piping installation including Installation of generator and turbine Lube Oil piping Welding Lube Oil piping to Mid-standard Installation of Exhaust Hood Spray Water piping Installation of Hydraulic piping Installation of H2 piping Verify the completed Ancillary Piping systems are pressure tested: Hydro-test hydraulic piping Hydro-test lube oil piping Pressure-test H2 piping Hydro-test seal oil piping Fluor Corporation Company Confidential

H

000 509 F74607 000 509 F74608

Site Quality Manual




Item

Inspection/Test Stage All Welding NDE results, Reports, Weld Maps and Hydrotest Reports reviewed and approved by FLUOR Quality Assurance. Final check of Anchor Bolt Nuts – tightness, gap check, locking device (tab-over or L-bar). See the GE TA for other information and techniques. NOTE: Be sure to check all of the Anchor Bolt Nuts including those that are hidden from direct view such as under the Mid-standard. Confirm that all Grease Lines supplying grease to the Slide Plates of the Front Standard, Mid-standard, LP Exhaust Hood and Generator are properly purged with the specified grease, and that there are no leaks in the tubing. NOTE: The GEK documents provided with the unit do not provide sufficient information to complete this activity without the support of the GE TA. Take care to avoid Over-greasing or Under-greasing these points, and see the GE TA for other information and techniques Final Cold Alignment Checks with all piping attached – document the final readings and that they were acceptable to the GE TA. Verify installation of Turbine enclosure








H

H

H

Site Quality Manual




Item








Electrical Section (abbreviated) Electrical installations completed, verified to be acceptable, results documented and attached: - Connection of generator heaters - Connection of ISO phase termination box extension - Installation of CT junction box #JB-505 - Generator wiring - Installation of Bentley Nevada Vibration - TCPL electrical connections - Exhaust electrical connections - Turbine junction box installation and wiring - Front end electrical connections - DC motor starter and connections

Instrumentation Section (abbreviated) Instrumentation installed, tested and verified to be acceptable: TCPL electrical connections Exhaust electrical connections Instrument installations Front end electrical connections Install Bentley Nevada Vibration

Commissioning Section (abbreviated) Cleanliness requirements met and acceptable Main steam targets HRS steam targets LP steam targets Seal steam line blow down Hydraulic oil flush Lube oil flush Fluor Corporation Company Confidential

H

Site Quality Manual




Item

Inspection/Test Stage Verify that the tie-in of the Cold Reheat Steam Piping to the turbine casing nozzles is completed following the same standard practice as used for the other steam lines: Align the Right and Left side Cold Reheat Steam (CRS) pipes to the turbine casing nozzles Prior to pipe fit-up with the corresponding nozzle, verify the following points are complete for the piping system from the Pipe Rack to the Turbine: • Hydrotest Water drained from all low points • No extraneous Bracing or Restraints holding the pipe in position • Pipe Hangers – location, installation and adjustment is correct • Spring Cans – position and installation is correct, Gags removed and the Spring Deflection Indicator shows the unit is in the COLD position Verify Tack weld, then completion of the Root Weld and Hot Pass of the pipe to each nozzle After weld cools conduct the CRS Pre-Weld Load Check of the HP/IP section in accordance with the GE guidelines. This is to be observed by the GE TA who shall give technical guidance on the proper methodology and shall review and accept the documented results. Verify: Completion of the welding of each CRS pipe to the turbine casing nozzle the required Post Weld Stress Relieving is conducted piping is cooled






H



000 509 F74607 000 509 F74608

Site Quality Manual




Item

Inspection/Test Stage After welds cool conduct the CRS Post-Weld Load Check of the HP/IP section in accordance with the GE guidelines. This is to be observed by the GE TA who shall give technical guidance on the proper methodology and shall review and accept the documented results.





H



000 509 F74607 000 509 F74608

Conduct the CRS Post-Weld Position Readings of the HP/IP section, including: Gland Bore (Right, Left and Top) Tooling Bore (Right, Left and Top) N1 Packing – Turbine End (Right, Left and Top) Balance Plug Hole with respect to Top, Bottom and LP Shell (provides HP/IP Rotor position) NOTE: Proceed only if the CRS Post-Weld Load Check and CRS Post-Weld Position Readings are acceptable to D/FD and GE D/FD Start-Up and GE TAs to review the GE provided Plant Integration and Operation guidelines / recommendations for proper operations including: (a) System start-up sequence (b) Warm-up all steam lines (Hot Reheat et. al.) (c) Turbine shell warm-up criteria (d) Transition to Forward Flow Monitor the movements of the steam piping systems (measure the movement of pre-established optical targets) and the Spring Can deflections (using the scale on the housing of the spring can). Fluor Corporation Company Confidential

Site Quality Manual


ITP 509 7460 18 Feb 04 Page 22 of 22


Item


Project Location


Contract Number





Required GE and FLUOR documentation and records are completed, acceptable and transmitted to site and home office FLUOR TDC for retention.

Inspection Legend: P = Perform I = Inspection T = Test R = Review and Approve W = Witness (Notification of authorized inspection personnel required) H = Hold (Mandatory, do not proceed without presence of authorized inspection personnel or signed waiver)



Site Quality Manual



Inspection and Test Plan Description Generator Testing

Project Name

Client

Contractor

Item



Requirement and Acceptance Criteria PO, Generator Voltage =Line Voltage

Project Number

ITP Number 000 509 ITP7470 Issue Date Revision 0 Scope of Inspection Inspection Responsibility Record Sub Fluor Client CS

I

I

509F74701


CEM

P

H

509F74702

Conduct generator insulation resistance test of stator and rotor windings


CEM

P

H

509F74701

Perform Polarization Index Test on each phase of generator stator windings


CEM

P

H

509F74701

CEM

P

H

509F74701

CEM

P

H

509F74701


CS

I

I

509F74701


CS

I

I

509F74701

Project Specification, manufacturer’s requirements

CS

I

W

509F74701

CS

I

H

509F74701

CEM

I

H

509F74701

1

Verify Nameplate Data

2

Conduct generator cold resistance test

3 4

6

Perform DC High Potential Test (hi-pot) on the stator and rotor windings Perform Insulation Resistance Test on pedestal bearing.

7

Inspect Collector Ring

8

Check connections per 000 509 F74701

9

Check space heaters, alarm and monitoring devices, temperature monitoring devices per 000

5


509 F74701 10

Check excitation system

11

Check phase sequence to verify phase rotation


Project Specification, manufacturer’s requirements 100,000 ohm or more, Project Specification

Manufacturer’s requirements Project Specification, manufacturer’s requirements

CompleteIT Input

Site Quality Manual



Inspection and Test Plan Description Generator Testing

Project Name

Client Item 12

Contractor Inspection/Test Stage Check Synchronization


Requirement and Acceptance Criteria Project Specification, manufacturer’s requirements

000 509 0250 Inspect, or perform, equipment and material Project Specification preservation activities. Inspection Legend: P = Perform I = Inspection T = Test R = Review and Approve W = Witness (Notification of authorized inspection personnel required) H = Hold (Mandatory, do not proceed without presence of authorized inspection personnel or signed waiver) 13



ITP Number 000 509 ITP7470 Issue Date Revision 0 Scope of Inspection Inspection Responsibility Record Sub Fluor Client CEM

I

H

509F74701

CS

P

I

509F02502 509F74701

CompleteIT Input


Site Quality Manual


000 509 7500 18 Feb 04 Page 1 of 4

UNDERGROUND PIPING SCOPE This procedure applies to the activities associated with inspection and testing of underground piping. RESPONSIBILITY - Self-Perform Pipe Installation ACTIVITY Request Excavation Coordinate Excavation Release Inspect Excavation Welding Inspection and Testing Inspect on-site pipe fabrication & installation Cleaning of Pipe Pressure Test Coordinate Backfill Request/Release Backfill Inspection Surveillance

RESPONSIBILITY

DOCUMENTATION


Mechanical Supt. Const. Engineer/ Mechanical

000 509 F75001

Each excavation

000 509 F75001

Each excavation


000 509 F75001

Daily during life of activity and prior to laying pipe.

Per 000 509 7910

Per 000 509 7910


000 509 F75001

Each installation

Per 000 509 7560 Per 000 509 7520 Construction Engr./ Mechanical Site Quality Manager Site Quality Manager

Per 000 509 F75601 Per 000 509 7520

Per 000 509 7560 Per 000 509 7520

000 509 F75001

Each backfill.

Per 000 509 7910

000 509 F75001 000 509 F02201

Each backfill During life of activity

RESPONSIBILITY - Subcontracted Pipe Installation ACTIVITY Request Excavation Coordinate Excavation Release Inspect Excavation Welding Inspection and Testing Inspect/Test On-Site Fabrication and Installation Cleaning of Pipe Pressure Test Inspect Coating, Wrapping, Cathodic Protection, Holiday Test, Insulation Resistance Backfill Request/Release Backfill Inspection Surveillance


RESPONSIBILITY

DOCUMENTATION


Subcontractor Const. Engineer/ Mechanical

000 509 F75001

Each excavation

000 509 F75001

Each excavation

Subcontractor

000 509 F75001

Daily during life of activity and prior to laying pipe.

Subcontractor

Per 000 509 7910

Per 000 509 7910

Subcontractor

000 509 F75001

During life of activity

Subcontractor Subcontractor

Per 000 509 F75601 Per 000 509 F75201

Per 000 509 7560 Per 000 509 7520

Subcontractor

000 509 F75001 000 509 F75002

Daily during life of activity.

000 509 F75001 000 509 F75001 Not Required Form 000 509 F02201

Each backfill. Each installation. Daily during life of activity. Daily during life of activity.

Subcontractor Subcontractor Mechanical Supt. Site Quality Manager

Site Quality Manual


000 509 7500 18 Feb 04 Page 2 of 4

PROCEDURE •

•

Excavation -

Excavation Release will be signed off prior to the excavation. At this time the location that has been laid out for excavation will be accepted by the Construction Engineer and the Superintendents.

-

The Form 000 509 F75001 shall represent only the piping that the excavation release is approved for (or piping within a single pressure test boundary), whichever is more restrictive. Additional forms are used as needed so that all underground piping is documented.

-

Use Attachment 1 as a guide in performing inspections for inspection attributes.

Welding Inspection and Testing -

•

•

Pipe Fabrication and Installation -

Verify that pipe fabrication and installation activities are performed in accordance with the requirements documented in the applicable drawings and specifications.

-

Use Attachment 1 (Underground Pipe Inspection Reference) as a guide in performing inspections.

-

Use Form 000 509 F75001 to document inspection results.

Cleaning of Pipe -

•

Reference Procedure 000 509 7560 for the cleaning of pipe inspection and testing requirements.

Pressure Testing of Piping Systems -

•

Reference procedure 000 509 7910 for the welding inspection and testing requirements.

Verify that required pressure testing has been performed and documented in accordance with Procedure 000 509 7520.

Insulated Flanges - Insulation Resistance Test -

Insulation resistance testing of insulated flanges, should be performed in accordance with manufacturer instructions and the specifications and this test is documented on form (000 509 F75002).


Site Quality Manual


•

•

•

000 509 7500 18 Feb 04 Page 3 of 4

Coating and Wrapping of Pipe -

Contact Quality Representative when coating and wrapping activities are to be performed so those activities can be monitored and required inspections and testing can be accomplished.

-

Verify that piping fabrication meets all applicable requirements and that all installed pipe is ready for coating and wrapping. Coating and wrapping shall proceed only after completion of all NDE, successful pressure test, cathodic protection, and testing, including insulation resistance (insulated flanges) testing, Form 000 509 F75002.

-

Monitor the coat and wrap work performance for compliance to specification. Identify, by marking on the surface of the wrapping, any areas found to be defective. Notify the pipe superintendent of any repair areas needing rework.

-

Use Form 000 509 F75001 to document verification activities.

Holiday Testing -

Holiday testing should be performed in accordance with the equipment manufacturer instructions and the specifications, which may include:

-

Testing of coated and wrapped pipe will be performed with an electric holiday detector, set at a maximum of 2400 volts D.C. for each 1/32" of coating thickness. Calibration and usage of the holiday detector instrument shall be in accordance with manufacturer's directions.

-

Rework any areas identified as defective and reschedule inspection and test of repaired areas.

-

Document holiday test results in the appropriate section of the Underground Pipe Inspection Record (000 509 F75001).

-

Notify Piping Superintendent of the sections of accepted coated and wrapped piping which are ready for backfill.

Backfill Request/Release -

Backfill Release Form 000 509 F75001, will be signed off prior to backfilling. At this time, all work will be verified as complete, including punchlist items and holiday tests before filling over piping. Before filling over welded joints the pressure test must be complete.

-

If the Backfill Release is for only a part of the piping represented by the Excavation Release, additional "Underground Pipe Inspection Records" should be prepared with the boundaries being released identified on the form. Inspection/Test acceptance and Backfill Release should be approved on the additional forms.


Site Quality Manual


000 509 7500 18 Feb 04 Page 4 of 4

FORMS Quality Control Forms: 000 509 F75001 - Underground Pipe Inspection Checklist 000 509 F75002 - Insulation Resistance (Insulated Flanges - Underground Piping) Test Record 000 509 F75003 – Holiday (Spark) Test Record 000 509 F75201 – Pressure Test Report

ATTACHMENTS Attachment I - Underground Pipe Inspection Reference


Site Quality Manual



UNDERGROUND PIPE INSPECTION REFERENCE

Pipe Fabrication and Installation •

Flow direction correct Item code number correct Bolts or studs correct Bypass installed (if required) Extensions installed

Flanged Connections -

•

•

Flange type, material, rating Flange face preparation and condition Gasket type and condition Bolting type, size, length Torque sequence and values

Pipe Supports -

Thrust blocks Sufficient supports Anchors installed

•

Slope per drawing Dimensions per drawing Compaction test before laying pipe Bedding

Coating and Wrapping -

Valves -

•

Line size correct Material correct Line slopes per drawing Branches located correctly High point vents installed Reducers located correctly Reducer type correct Gouges, nicks, surface damage

Excavation -

General -

•

•

Surface preparation Application per specification Materials per specification Repairs per specification Holiday Testing

Cathodic Protection -

Electrical connections Flange insulating kit Insulated Flanges-Insulation Resistance Test Sacrificial material buried Rectification equipment installed


000 509 7510 18 Feb 04 Page 1 of 2

ABOVEGROUND PIPING

SCOPE This procedure applies to the activities associated with inspection and testing of aboveground piping. RESPONSIBILITIES - Self-Perform Pipe Installation ACTIVITY Welding Inspection and Testing Inspect on-site pipe fabrication and installation Cleaning of Pipe Inspect Insulation Pressure Test

RESPONSIBILITY

DOCUMENTATION

Per 000 509 7910

Per 000 509 7910

Site Quality Manager Per 000 509 7560 Per 000 509 7810 Per 000 509 7520

000 509 F75101 000 509 F75102 000 509 F75103 000 509 F79001 Per 000 509 F75601 Per 000 509 F78102 Per 000 509 F75201

FREQUENCY OF ACTIVITY Per 000 509 7910 Each installation Per 000 509 7560 Per 000 509 7810 Per 000 509 7520

Responsibilities - Subcontracted Pipe Installation ACTIVITY

RESPONSIBILITY

DOCUMENTATION

Welding Inspection & Testing

Subcontractor

Inspect on-site pipe fabrication and installation

Subcontractor

Per 000 509 7910 000 509 F75101 000 509 F75102 000 509 F75103 000 509 F79001 Per 000 509 F75601 Per 000 509 F78102 Per 000 509 75201 Form 000 509 F02201

Cleaning of Pipe Inspect Insulation Pressure Test Surveillances

Subcontractor Subcontractor Subcontractor Site Quality Manager

FREQUENCY OF ACTIVITY Per 000 509 7910 Each installation Per 000 509 7560 Per 000 509 7810 Per 000 509 7520 During life of activity

PROCEDURE •

Welding Inspection and Testing -

Reference Procedure 000 509 7910 for the welding inspection and testing requirements.

-

The Fluor Quality Control System Manual, Boiler and Pressure Vessel Code Work shall be invoked for self-perform work that will require ASME or National Board Code stamping. If the work is subcontracted and will require code stamping by the subcontractor, the subcontractor's Code program shall be invoked. Prior to the start of any work that will require Code Stamping, contact the Code Specialist, 864-281-6305.


Site Quality Manual


•

•

Pipe Fabrication and Installation -

Verify that pipe fabrication and installation activities are performed in accordance with the requirements documented in the applicable drawings and specifications.

-

Use Attachment 1 (Aboveground Pipe Inspection Reference) as a guide in performing inspections.

-

Use Form(s) 000 509 F75101, F75102, F75103 and F79001 to document inspection and examination results.

Cleaning of Pipe -

•

Reference Procedure 000 509 7560 for the cleaning of pipe inspection and testing requirements.

Insulation Inspection -

•

000 509 7510 18 Feb 04 Page 2 of 2

Reference Procedure 000 509 7810 for the insulation inspection requirements.

Pressure Testing of Piping Systems -

Verify that required pressure testing has been performed and documented in accordance with Procedure 000 509 7520.

FORMS Quality Control Form: 000 509 F75101 - Aboveground Pipe Inspection Checklist 000 509 F75102 - Visual Inspection of Flanges, Gaskets and Bolting 000 509 F75103 – Weld Map Record 000 509 F75201 - Pressure Test Report 000 509 F75601 - Pipe Cleaning and Verification Checklist 000 509 F79001 - Daily Welding Report ATTACHMENTS Attachment 1 - Aboveground Pipe Inspection References


Site Quality Manual



ABOVEGROUND PIPE INSPECTION REFERENCE

GENERAL

PIPE SUPPORTS

Line size correct. Material correct. Gouges, nicks, surface damage Installation straight and plumb. Line slopes per drawing. Branches located correctly. Branches reinforced. Weepholes in reinforcing pad. High point vents installed. Low point drains installed. Reducers located correctly. Reducer type correct Cold spring or prespring per drawing. Clearance for expansion. Exposure to contaminants.

Field supports installed. Sufficient supports. Anchors installed. Guides installed. Proper shoes installed and welded. Spring hangers properly installed.

VALVES Flow direction correct. Item code number correct. Bolts or stud correct. Bypass installed (if required). Chain wheel installed. Extension installed. Stem oriented properly. Drain, flush, connections installed. FLANGED CONNECTIONS Flange material, type, and rating. Flange face preparation, condition, cleaning. Gasket type, thickness, condition, rating. Bolt type, size, length, lubrication. Torque sequence, values.

INSTRUMENTS PSV's tested (correct item number). Correct control valves installed. Meter runs properly installed (jacking screws included). Valves at meter runs installed. Pressure gage valves installed. Pressure gages properly oriented. Temperature connections properly oriented. Sample connections installed.


000 509 7520 18 Feb 04 Page 1 of 4

PRESSURE TESTING

SCOPE This procedure applies to pressure testing of installed piping systems. RESPONSIBILITIES - Self-Perform ACTIVITY Install Piping Define Test Boundaries Provide Preparation / Test Instructions Prepare the System for Testing Perform Pre-Test Inspections/Release Perform Test Verification of Satisfactory Test Results Provide Restoration Instructions Verify Completion of Restoration Surveillance of Testing and Restoration


RESPONSIBILITY

DOCUMENTATION


Self Perform

_____

_____

Pipe Const. Engr. and Mech. Supt.

000 509 F75201

Pipe Const. Engr.

000 509 F75201

Mechanical Superintendent Pipe Const. Engr. Site Quality Manager Mechanical Superintendent Pipe Const. Engr. Site Quality Manager Pipe Const. Engr.

Each Test Package Each Test Package

_____ 000 509 F75201 000 509 F75201

_____ Prior to Test Prior to Test

_____

_____

000 509 F75201

Test Completion

000 509 F75201

Test Completion

_____

_____

Pipe Const. Engr. Site Quality Manager

000 509 F75201 000 509 F75201

Each Test Each Test


000 509 F0221

Daily

Site Quality Manual


000 509 7520 18 Feb 04 Page 2 of 4

RESPONSIBILITIES - Subcontracted ACTIVITY

FREQUENCY OF ACTIVITY _____

RESPONSIBILITY

DOCUMENTATION

Install Piping

Subcontractor

_____

Define Test Boundaries Provide Preparation / Test Instructions Prepare the System for Testing

Subcontractor

000 509 F75201

Each Test Package

Pipe Const. Engr.

000 509 F75201

Each Test Package

Subcontractor

_____

Perform Pre-Test Inspections/Release

Subcontractor Site Quality Manager

000 509 F75201

Prior to Test

000 509 F75201

Prior to Test

Perform Test

Subcontractor

_____

Verification of Satisfactory Test Results Provide Restoration Instructions

Subcontractor Site Quality Manager

000 509 F75201

Pipe Const. Engr. Subcontractor Site Quality Manager

Verify Completion of Restoration

000 509 F75201

_____

_____ Test Completion Test Completion

_____

_____

000 509 F75201

Each Test

000 509 F75201

Each Test

PROCEDURE •

Define Test Boundaries and Provide Preparation/Test Instructions: Boundaries and instructions in accordance with 000 250 3707 should be prepared and provided or made available to those responsible for Preparing the System for Testing, Performing Pre-test Inspection Release, Performing Test, and Verifying Satisfactory Test Results - Information should be included in pressure test packages. These packages are, as much as possible, to be assembled so that they comprise a portion or all of a piping system. This is required to facilitate system turnover at the end of the job. Each pressure test package shall contain the following:

-

•

Marked up P&IDs indicating extent of test; location and type of blinds; and equipment or instrumentation to be included or excluded from test.

•

Piping isometrics for lines included in the test. Isometrics are to indicate location of blinds, valves open or closed, fill point, vent locations, equipment or instrumentation excluded from test and locations of required temporary supports.

Instruction items are on Form 000 509 F75201. Initiate this form and complete the instructions through "Test Conditions".


Site Quality Manual


•

-

Notes for special test situations.

-

Instructions for marking temporary test materials for verifying line restoration.

-

Special instructions and safety precautions when the test medium is a gas or vapor.

-

Instructions for preventing air entrapment.

-

Venting instructions.

-

Test gage location.

-

Identify all required "witnesses" of test.

-

Require all joints including welds to be uninsulated and exposed for examination during the pressure test.

-

Provide retest instructions after repair of leaks detected by the pressure test.

Prepare the System for Testing: -

•

•

Make preparation for testing as required by test instructions, 000 250 3707 and 000 250 50050:

Perform Pre-test Inspections/Release: -

Verify completion (by walkdown) and acceptance of any required inspection, postweld heat treatment, NDE, hardness testing, PMI, and any other required test/inspections.

-

Verify piping system has been completely checked (punched out) and preparations for testing as required by test instructions are complete.

Perform Test: -

•

000 509 7520 18 Feb 04 Page 3 of 4

Perform the test in accordance with test instructions.

Verification of Satisfactory Test Results: -

Upon the attainment of the required hydrostatic test pressure, for at least the minimum specified time, an inspection shall be made of all joints and connections. The inspection shall be made while the system is at the required test pressure.

-

Following the application of the pneumatic test pressure and reduction to the design pressure the entire line should be walked to determine if there is any audible evidence of leakage. Any leaks found at the time shall be marked and repaired after first depressuring the line.


Site Quality Manual


000 509 7520 18 Feb 04 Page 4 of 4

After this walkdown, all joints and welds shall be covered with a soap solution in order to detect any leakage. Soap shall be commercial preparation specifically for leak detection.

•

-

If leaks are found by pressure testing, mark their locations.

-

Complete the Pressure Test Report actual test conditions for Test Media/Metal temperature, Test Pressure Test Gage Number and Calibration information.

Provide Restoration Instructions: Instructions to comply with restoration requirements of 000 250 50050 should be provided or made available to those responsible for restoring the system after pressure testing and for verifying completion of restoration. Information should include:

•

-

Instructions for removal of temporary test material (blanks, blinds).

-

Positioning of operating blinds.

-

Draining instructions.

-

Installation of equipment excluded from field test (valves, orifice plates, expansion joints, short pieces of pipe, new gaskets, bolts, vessel internals, etc.).

-

Instructions for removal of temporary supports.

-

Resetting spring hangers.

-

Drying of instruments.

-

Treatment of vent and drain connections.

-

Cleaning of strainers.

-

Painting and insulation.

Verification of Line Restoration: Verify that all restoration activities have been completed and the system(s) or partial system represented by this pressure test report is complete.

FORMS Quality Control Form: 000 509 F75201 – Pressure Test Record


Site Quality Manual


000 509 7550 18 Feb 04 Page 1 of 6

HYGIENIC TUBING SCOPE This procedure describes the activities to be performed during the installation of hygienic tubing systems. RESPONSIBILITIES - Self-Perform and/or Subcontracted Work ACTIVITY Weld Mapping Welder Quality Receipt Inspection

Preweld Inspection

Weld Inspection Blind Weld Inspection Post Installation

Welding Program Documentation Package


RESPONSIBILITY

DOCUMENTATION


Site Quality Manager Site Quality Manager

000 509 F75501 QC Drawing Stick


000 509 F75507

Each welder

Site Quality Manager Welding Operator Site Quality Manager Welding Operator Site Quality Manager Welding Operator Site Quality Manager Fitter Site Quality Manager


000 509 F75502 000 509 F75503 000 509 F75504 000 509 F75505 _____

Each shipment Each weld

_____


000 509 F75508

Each weld

000 509 F75508

Each weld

000 509 F75508

Each weld

000 509 F75508

Each weld

000 509 F75509

Prior to Hydro

000 509 F75509

Prior to Hydro

000 509 F75501 000 509 F75502 000 509 F75503 000 509 F75504 000 509 F75505 000 509 F75507 000 509 F75508 000 509 F75509 Copy of this Procedure Weld Maps Purchase Orders CMTR's Weld Equip. Data Weld Schedules Argon Certs.

Daily, turnover at project completion

Site Quality Manual


000 509 7550 18 Feb 04 Page 2 of 6

PROCEDURE Note: Prior to performing any welding, contact Construction Technology’s Corporate Welding Engineering. •

•

Weld Mapping -

Obtain a controlled copy of all Hygienic tubing drawings prior to the start of work.

-

Assign weld numbers starting with "one" on each sheet. Where drawing breaks at a weld, phantom the weld number on the downstream drawing.

-

Maintain weld map drawing stick and issue copies to field as needed, using Form 000 509 F75501, Hygienic Drawing Revision Log.

Receipt Inspection -

Enter material on the Hygienic Material Receiving Log (Form 000 509 F75502).

-

Use clean cotton gloves when handling material within two inches of a weld end.

-

Verify material type by manufacture's marking - unwrap only to verify marking, unless ID inspection is to be performed at this time.

-

Certified material test reports - when required by purchase documents. This may require extensive unwrapping and rewrapping to verify heat/identification numbers. Verify compliance to purchase specification, particularly a minimum sulfur content (usually .005% min). NOTE: Aluminum content is generally specified as .01% max.

-

ID Inspection: Borescopes (or video probe), etc. shall have a covering that will not scratch the ID of the material. This is especially critical on electropolished items. Using dry nitrogen, at a pressure not to exceed 40 PSI, blow a clean felt plug or rag (wetted with denatured alcohol or other approved solvent) through straight lengths of tubing to check for cleanliness. Plug/rag should not exhibit loose particles.

-

Borescope ID of welded tubing (if welded is allowed by purchase documents) and tees to the acceptance criteria for Weld Inspection.

-

Dimensionally check welding ends of valves and vessel nozzles. Dimensional inspection of tube/fitting ends (diameter, wall thickness) not normally required unless problems are noted during fitup; therefore, fittings may be left in their shrink packs. Accurate dimensional checks must be made with calipers (.001" graduations) or micrometer (ball anvil needed for wall thickness checks).


Site Quality Manual


•

000 509 7550 18 Feb 04 Page 3 of 6

-

Repackage or recover materials after receipt inspection to maintain cleanliness.

-

Document results on applicable receiving inspection report: Hygienic Valve Receiving Inspection Report (Form 000 509 F75503) Hygienic Vessel Nozzle Receiving Inspection Report (Form 000 509 F75504), Hygienic Tube/Fitting Receiving Inspection Report (Form 000 509 F75505).

Preweld Inspection NOTE: The following attributes are checked by the welder prior to making each weld and on a daily basis by the QC Inspector. The QC Inspector only, will document the results using the Hygienic Preweld Inspection Checklist (Form 000 509 F75506) -

Welder shall be qualified to ASME Section IX and any additional requirements listed in the Project Specifications, and the acceptance criteria of the Weld Inspection section of this procedure. Welder qualification results to be documented on the Hygienic Welder Qualification Report (Form 000 509 F75507).

-

The Weld Procedure Specification is qualified to ASME Section IX and any additional requirements listed in the Project Specification. Weld schedules and samples for each tube size and wall thickness are to be submitted to the QC Inspector for approval. Corporate Welding Engineering will furnish the initial weld schedules. All welds are to be made with automatic GTAW except small fusion tacks.

-

Argon purge is required for tackwelding and orbital welding. Oxygen Analyzer to be used. Purge to have 1% or less oxygen prior to any welding. Higher purity than welding grade Argon may be required to meet final Weld Inspection criteria. A (.2) Micron filter may be required to remove spurious particles from Argon. Welders and fitters shall not use leather gloves. Clean white cotton gloves shall be used for handling tubing, fittings, valves, etc.

-

Markers, tape, and other items coming in contact with the tubing and fittings shall not contain chlorides in excess of 50 PPM or halogenated compounds in excess of 150 PPM.

-

Weld ends square, no burrs, no chamfers. End prep tools shall not use ID collets.

-

ID and OD shall be cleaned with lint-free cloth and approved solvent for a distance of 2" minimum from the ends.

-

Tubing, fitting, valves, and other product wetted items must be capped or suitably protected from foreign materials at all times except while being used in fabrication.

-

Manual fusion tacks, if used, are made without filler metal. These tacks should be surface only with a nominal diameter of 1/16". All clamps, temporary supports, and work tables shall not allow carbon or low alloy steel to come into contact with the tube or fittings.


Site Quality Manual


-

•

000 509 7550 18 Feb 04 Page 4 of 6

Prior to the start of a shift, when changing tube size, or when changing Argon cylinders, two visually acceptable sample welds (bead on tube permissible) shall be made to assure acceptable weld schedule and quality. The welder may only vary weld schedule amperage. Log the acceptable samples on the Hygienic Orbital Welding Log, proceed with work, hold samples for QC Inspector, who will inspect and complete the log. Amperage may vary ± 10%. Other variations must be approved by the QC Inspector.

Welding Inspection -

The welder shall maintain the Hygienic Orbital Weld Log (Form 000 509 F75508) and initial in the space provided when he is satisfied that the weld meets the acceptance criteria with the exception of ID inspection with a borescope or video probe.

-

Repairs shall not be made without the direction of the QC Inspector. Any repairs requiring rewelding, cutout, or pup pieces shall be new entries on the same orbital weld log sheet with the following suffixes: "W" for rewelding, "C" for cutout, "PA" and "PB" for the pup welds.

-

The weld schedule number and amperage deviation (within the ± 10% allowed) shall be entered by the welder on the Orbital Weld Log.

-

Only one rewelding is allowed and only for the following conditions, root or face concavity, lack of penetration, tungsten crater.

-

With the approval of the QC Inspector, the ID of welds may be grit finished to correct a color deficiency (does not apply to EP Systems).

-

The Orbital Weld Log is completed by the QC Inspector who will place it in the Welding Program Documentation Package.

-

Weld acceptance criteria is as follows (Internal weld surfaces shall be examined by the QC Inspector with a mirror, borescope or video probe).

-

All welds made shall have full penetration over the complete internal weld circumference.

-

Slag or other inclusions are not permitted.

-

The weld schedule shall have a suitable finish slope to taper off the welding current at the end of the weld to eliminate any pin hole or suck back at the end of the weld.

-

Inside weld ID should be smooth with a minimum internal weld bead. While weld ID matching is ideal, minute convexity (raised bead), 25% of wall thickness maximum, is preferred to concavity (recessed bead), 0.010" maximum. Internal weld bead shall not be raised or recessed to a point which would prevent water from draining completely. The preceding measurements are estimates with the QC Inspector making the final judgement if there are any questions.


Site Quality Manual


•

000 509 7550 18 Feb 04 Page 5 of 6

-

Cracks, crevices, pits, or pin holes are not permitted.

-

Evidence of porosity in the weld is not permitted.

-

Any evidence of improper alignment of the weld in excess of 10% of the wall thickness shall cause the weld to be rejected.

-

Evidence of weld discoloration caused by improper gas backup procedures is not permitted. A yellow or straw color is acceptable. Blue or black color is unacceptable, even in the heat effected zone. There must be no indication of bubbling or sugaring of the weld area. The OD of the weld should be immediately wire brushed after welding.

-

External concavity not to exceed 25% of the wall thickness provided there in no corresponding internal concavity, otherwise .010" maximum.

Blind Weld Inspection No blind welds shall be permitted except under special circumstances as permitted by the QC Inspector and in accordance with the following conditions. -

After the blind weld has been tacked, two sample coupons will also be tacked at the end of the assembly downstream (from the back purge entry) and from the intended blind weld joint.

-

Verify the Argon purge with the use of an oxygen analyzer. The argon purge shall read less than 1% oxygen.

-

After steps 1 and 2 have been verified and recorded by the QC Inspector, one sample coupon shall be welded. After the acceptance of the sample weld by the QC Inspector, the Blind Weld shall be made in the presence of the QC Inspector and recorded.

-

After the Blind Weld has been completed, the second weld coupon will be made, and based on both the weld sample coupons a visual inspection will determine acceptance status.

-

The Blind Weld samples shall be recorded on the Orbital Weld Log using suffixes "B1" and "B2".


Site Quality Manual


•

000 509 7550 18 Feb 04 Page 6 of 6

Welding Program Documentation Package The QC Inspector shall establish the file which shall contain the following sections: a) b) c) d) e) f) g) h) i)

Copies of hygienic material purchase orders Material receiving reports Certified material test reports, where required Weld equipment, instructions, data, identification Welder qualification/training records Weld schedules (including WPS and ASME Sect. IX procedure qualification records) Orbital weld log sheets Weld maps (including hygienic drawing revision log) Argon cylinder certification, if applicable

FORMS Quality Control Forms: 000 509 F75501 - Hygienic Drawing Revision Log 000 509 F75502 - Hygienic Material Receiving Log 000 509 F75503 - Hygienic Valve Receiving Inspection Report 000 509 F75504 - Hygienic Vessel Nozzle Receiving Inspection Report 000 509 F75505 - Hygienic Tube/Fitting Receiving Inspection Report 000 509 F75506 - Hygienic Preweld Inspection Checklist 000 509 F75507 - Hygienic Welder Qualification Report 000 509 F75508 - Hygienic Orbital Weld Log 000 509 F75509 - Hygienic Post Installation Checklist


Site Quality Manual


000 509 7560 18 Feb 04 Page 1 of 1

CHEMICAL CLEANING OF PIPE SCOPE The purpose of this procedure is to establish the inspection activities necessary to verify the process of cleaning the interior surface of piping is performed in accordance with approved requirements. RESPONSIBILITIES - Self-Perform/Subcontracted ACTIVITY Verify that all pressure testing & NDE are complete Commence cleaning operation Monitor chemical cleaning process

RESPONSIBILITY

DOCUMENTATION

FREQUENCY OF ACTIVITY Prior to release for cleaning

QC Inspector Construction Supt./ Subcontractor

000 509 F75601

As required by project specs

QC Inspector

000 509 F75601


GENERAL •

Inspection Pre-Requisites -

•

Verify that pressure testing and NDE are complete prior to release for cleaning.

Inspection -

Monitor chemical cleaning process verifying that it is performed in accordance with approved project specifications and document on the pipe cleaning and verification checklist (000 509 F75601).

-

Retain water test report and certificate of conformance and attach to the pipe cleaning and verification checklist (000 509 F75601).

FORMS Quality Control Form: 000 509 F75601 - Pipe Cleaning and Verification Checklist


Site Quality Manual


000 509 7570 18 Feb 04 Page 1 of 4

STEAM TRACING FOR PIPE AND EQUIPMENT SCOPE This procedure defines the inspection, testing and documentation requirements for installation activities for steam tracing of pipe and equipment. RESPONSIBILITIES-Subcontractors ACTIVITY


RESPONSIBILITY

DOCUMENTATION

Subcontractor

000 509 F75701


Inspect in-process heat tracing installation

Subcontractor/ Site Quality Manager

000 509 F75701


Pressure test steam tracers

Subcontractor/ Site Quality Manager.

000 509 F75201

Per each line or Test Package

Subcontractor



000 509 F75701

Install steam tracing

Install Insulation Clear tubing with compressed air and commodity test the tubing system

Per each line or Test Package

PROCEDURE NOTE 1:

Whenever a difference between the specification and the flow diagram (P&ID/PMCDs), the flow diagrams shall govern.

GENERAL •

Steam tracing will be achieved by use of 150# steam (unless noted otherwise on P&ID/PMCDs).

•

Heat transfer cement may be utilized when a process line requires a high heat input and common methods of heat tracing are inadequate. The need for heat transfer cement is to be determined by process engineering and indicated on the P&ID/PMCDs.

•

Steam jacketing is utilized in specific cases where steam tracing with or without heat transfer cement is inadequate. The use of steam jacket will be identified on P&ID/PMCDs.

•

Steam tracing will be called out on the P&ID/PMCDs.


Site Quality Manual


000 509 7570 18 Feb 04 Page 2 of 4

STEAM TRACING •

Using various media such as steam, hot water, glycol or hot oil, heat tracing is installed to protect the piping and equipment against temperatures that would cause congealing or freezing of the process fluids, interfere with operation, or cause damage to the equipment. −

Piping Systems Piping systems requiring tracing are defined by process engineering and are indicated on the P&ID/PMCDs showing tracer quantity and size, media, limits and special requirements. Special requirements (i.e. heat transfer cement) are to be noted on the P&ID/PMCD by process engineering.

−

Instruments Instruments require tracing are defined by instrument engineering and are indicated on the P&ID/PMCDs. Reference 000 270 01851 Heat Tracing for Instruments. Piping will provide steam supply and condensate collection manifolds are required or drain to grade, for all instruments to be steam traced. Traps that drain to grade require Client approval. All inline instruments (i.e. local pressure guages, safety valves, control valves, etc.) that require steam tracing are to be traced with piping drawings. All instrument transmitters that require steam tracing will have pre-insulated tubing for both steam supply and condensate return provided by piping up to the transmitter location. Instruments will provide the tracing from this pre-insulated tubing as required by instrument detail drawing. Special provisions may be required to limit steam temperature to not exceed 2000F at transmitter.

SYSTEM INSTALLATION •

Steam Tracer Size, Length and Material −

Required tracer size shall be determined by process engineering.

−

Minimum tracer size shall be 3/8 of an inch OD tubing; maximum size shall be ½ inch OD tubing.

−

Maximum tracer length is 200 feet.


Site Quality Manual


−

000 509 7570 18 Feb 04 Page 3 of 4

Tubing Material Bare copper tubing is to be used whenever possible inside the pipe insulation and preinsulated copper on the exposed portion outside insulation. Stainless steel tubing is to be used when tubing will be in contact with stainless steel piping and/or when process line operating temperature exceeds 5000F Requirements for special tubing materials and/or types (i.e. Thermo DLS, SLS, etc.) are to be determined by piping and process engineering jointly. Such requirements will be indicated on the P&ID/PMCDs. NOTE: See project material line class specification for further details.

•

−

Each steam tracer shall have its own trap. Disposition of condensate from traps is dependant on site requirements and shown on piping isometrics.

−

Compression type fittings shall be installed outside of the insulation OD.

−

Socket type fittings shall be installed inside of the insulation.

−

The steam tracers shall be pressure tested before the pipe or instrument insulation is applied. Under emergency conditions, the insulation may be applied but the fittings shall be left exposed until the testing is complete. Construction is to clear the tubing with compressed air and commodity test the tubing system.

Steam Tracer Pocket Depth −

Pocket depth is the distance the tracer rises in the direction of flow from a low point to a high point. The total pocket depth is the sum of all risers of the tracer.

−

Maximum tracer total pocket depth shall be equal to or less than 40 percent of tracing steam gauge pressure expressed in feet. Example:

•

Tracing steam 150 psig 150 x 0.40 = 60 feet maximum total pocket depth

Steam Tracing Details −

For piping tracing details, refer to Fluor Daniel Standard Drawings LSM 250 50040.


Site Quality Manual


•

000 509 7570 18 Feb 04 Page 4 of 4

Steam Tracer Disposition Tables −

Tables shall be provided by engineering and maintained through construction to track the disposition of each tap and tracer on steam and condensate manifolds.

FORMS Quality Control Forms: 000 509 F75701


Mechanical Heat Tracing Inspection Record

Site Quality Manual


000 509 7600 18 Feb 04 Page 1 of 2

ELECTRICAL INSPECTION SCOPE This procedure applies to inspection of electrical installations. Refer to procedure 000 509 7010 and 7100 for work involving excavation, backfill, and concrete. RESPONSIBILITIES - Self-Perform ACTIVITY

RESPONSIBILITY

DOCUMENTATION OR INSPECTION REFERENCE _____

Install electrical items

Electrical Superintendent

Inspect in-process electrical installation

Site Quality Manager/ Construction Engineer

000 509 F760XX

Check final electrical installation


000 509 F760XX

Surveillance

Site Quality Manager (Note 1)

000 509 F02201

FREQUENCY OF ACTIVITY Each electrical item Daily during life of activity Each installation at completion Daily during life of activity and at completion


RESPONSIBILITY

DOCUMENTATION _____

Install electrical items

Subcontractor

Inspect in-process electrical installation


000 509 F760XX

Check final electrical installation


000 509 F760XX

Surveillance


000 509 F02201

NOTE 1:

FREQUENCY OF ACTIVITY Each electrical item Daily during life of activity Each installation at completion Daily during life of activity and at completion



Site Quality Manual


000 509 7600 18 Feb 04 Page 2 of 2

PROCEDURE •

Inspect in-process electrical installation activities in accordance with the applicable specifications and drawings. The appropriate checklist should be initiated and completed to document inspection activities.

•

Perform final installation checks in accordance with the applicable specifications and drawings. The final inspections should be completed on the applicable checklist.

•

Perform surveillances daily during the life of electrical activities. Document results on Form 000 509 F02201.

FORMS Quality Control Forms: 000 509 F76001 000 509 F76002 000 509 F76003 000 509 F76004 000 509 F76005 000 509 F76006 000 509 F76007 000 509 F76008 000 509 F76009 000 509 F76010 000 509 F76011 000 509 F76012 000 509 F76013


Conduit and Cable Tray Checklist Electrical Manhole Inspection Checklist Medium and High Voltage Underground Cable Splice Inspection Record Medium and High Voltage Cable Termination Checklist Cable Pulling Inspection Checklist Fan/Speed Reducer/Motor Inspection Checklist Switch Houses Inspection Checklist Lighting Receptacle, Instrument Distribution Panels Inspection Checklist Electrical Motor Inspection Checklist Aboveground Conduit Inspection Checklist Lighting Panelboard Inspection Record Underground Conduit (Duct Bank) Inspection Grounding/Earthing System (Grid or Loop) Inspection Record

Site Quality Manual


000 509 7610 18 Feb 04 Page 1 of 3

ELECTRICAL TESTING SCOPE This procedure applies to testing of electrical installation. RESPONSIBILITIES - Self-Perform DOCUMENTATION


_____

Each Test Package

_____

Each Test Package


_____

Each Test Package

Verify Test Results

Site Quality Manager/ Electrical Construction Engineer

000 509 F76004 000 509 F76006 000 509 F76007 000 509 F76008

Test Completion

Provide Restoration Instructions

Electrical Construction Engineer

_____

Each Test Package


Site Quality Manager Electrical Supervisor

000 509 F76004 000 509 F76006 000 509 F76007 000 509 F76008

Each Test

ACTIVITY

RESPONSIBILITY

Define Test Boundaries Provide Preparation Test Instructions Perform Electrical Test

Electrical Construction Engineer Electrical Construction Engineer


RESPONSIBILITY

DOCUMENTATION


Define Test Boundaries Provide Preparation Test Instructions

Subcontractor

_____

Each Test Package

Subcontractor

_____

Each Test Package

Perform Electrical Test

Subcontractor

_____

Each Test Package

Verify Test Results


Applicable Form

Test Completion

Discipline Engineer

_____

Each Test Package

_____

Each Test

000 509 F0221

Each Test

Provide Restoration Instructions Verify Completion of Restoration Surveillance

NOTE 1 -

Subcontractor/ Site Quality Manager Site Quality Manager (*Note 1)



Site Quality Manual


000 509 7610 18 Feb 04 Page 2 of 3

PROCEDURE •

•

Define Test Boundaries and Provide Preparation Test Instruction: -

Boundaries and test instructions provided by construction Electrical Construction Engineer shall be reviewed by inspection personnel prior to any testing activities.

-

Notify the Fluor/Client of testing/inspections for their involvement which they have requested/required to witness.

Test Field Installed Equipment: -

•

Verification of Test Results: -

•

Utilizing the test instructions and/or drawing(s) required, verify the acceptance of the test. Document the satisfactory results using the applicable forms referenced in this procedure.

Provide Restoration Instructions: -

•

Perform test in accordance with the test instruction provided by Electrical Construction Engineering.

Instructions to comply with restoration requirement of the applicable specification and/or drawing should be provided by Electrical Construction Engineering.

Verification of System Restoration: -

Verify that all restoration activities have been completed and the system(s) or partial system represented by this test package is complete.


Site Quality Manual


000 509 7610 18 Feb 04 Page 3 of 3

FORMS Quality Control Forms: 000 509 F76101 -Grounding/Earthing Resistance Readings (Resistance-to-Earth and Loop Continuity) Test Record 000 509 F76102 - Insulation Resistance (Power, Control Wire and Cable) Test Record 000 509 F76103 - Insulation Resistance (Instrument Wire and Cable) Test Record 000 509 F76104 - DC High Potential Test (Medium Voltage Cable) Record 000 509 F76105 – Current Transformer (And Ammeter) Test Record 000 509 F76106 – LV Overcurrent and Earth/Ground-Fault Protection Relay Test 000 509 F76107 – Overcurrent/Ground Fault Protection Relay (Induction Type) Test 000 509 F76108 – Overcurrent/Ground-Fault Protection Relay (Thermal Type) Test 000 509 F76109 – Switching Units HV Switchgear Inspection and Test Record 000 509 F76110 – Ground Electrode Resistance Inspection Test Record 000 509 F76111 – Ground Fault Protection Relay Induction Inspection and Test Record 000 509 F76112 – Grounding Continuity Inspection and Test Record 000 509 F76113 – Grounding Rod Inspection and Test Record 000 509 F76114 – Bus Bar Assembies LV Switchgear Test Record 000 509 F76115 – Neutral Grounding/Earthing Resistor Test Record 000 509 F76116 – Ground Continuity (Non-electrical) Equipment/Structures Test Record 000 509 F76117 – Ground Continuity (Electrical Equipment and Ground Test Bars) Test Record 000 509 F76118 – Insulation Resistance (Equipment) Test Record 000 509 F76119 – Insulation Resistance (Transformer) Test Record 000 509 F76120 – Liquid Dielectric Strength Test Record 000 509 F76121 – DC Proof Test Record For Motors 000 509 F76122 – Feeder Breaker (480V MCC) Test Record 000 509 F76123 - Breaker/Contactor (480V MCC) Test Record 000 509 F76124 – 460V Motor Circuit (480V MCC) Test Record 000 509 F76125 – Medium Voltage Motor Circuit Test Record 000 509 F76126 – Equipment Absorption Ratio and Polarization Index Test Record (Megger) 000 509 F76127 – Insulation Resistance (Medium Voltage Power Cables) Test Record 000 509 F76128 – Bus Throat Insulation and Ductor Reports 000 509 F76129 – Circuit Breaker Contact Timing Test Report 000 509 F76130 – Vacuum Circuit Breaker Ductor Insulation Report 000 509 F76131 – Drawout Vacuum Breaker Inspection Test 000 509 F76132 – Main Bus Insulation and Ductor Report 000 509 F76133 – Electric Motor Run-In Test Record 000 509 F76134 – Drawout Air Circuit Breaker Inspection Record 000 509 F76135 – Insulation Resistance (Rotating Equipment) Test Record


Site Quality Manual


000 509 7620 18 Feb 04 Page 1 of 4

ELECTRICAL EQUIPMENT

SCOPE This procedure applies to inspection and testing of electrical equipment. RESPONSIBILITIES - Self-Perform ACTIVITY

RESPONSIBILITY

DOCUMENTATION


Install Equipment

Self Perform

_____

_____

Inspect in-process Equipment Installation


000 509 F762XX



000 509 F02201

Periodically

Electrical Supervisor

000 509 F02201

Periodically

Define Test Boundaries


_____

Each Test Package

Provide Preparation Test Instructions


_____

Each Test Package

Test Field Installed Equipment


_____

Each Test Package

Verify Test Results


000 509 F762XX

Test Completion



_____

Each Test Package



_____

Each Test

Surveillance


000 509 F02201

Each Test

Inspect/Perform Equipment Protection

NOTE 1:



Site Quality Manual


000 509 7620 18 Feb 04 Page 2 of 4


RESPONSIBILITY

DOCUMENTATION


Install Equipment

Subcontractor

_____

_____

Inspect in-process Equipment Installation


000 509 F762XX


Inspect/Perform Equipment Protection


000 509 F02201

Periodically

Define Test Boundaries


_____

Each Test Package

Provide Preparation Test Instructions


_____

Each Test Package

Test Field Installed Equipment

Subcontractor

_____

Each Test Package

Verify Test Results


000 509 F762XX

Test Completion



_____

Each Test Package


Subcontractor/ Construction Engineer Site Quality Manager

_____

Each Test

Surveillance


000 509 F02201

Each Test

NOTE 1:


PROCEDURE •

Inspect In-process Equipment Installation: -

Perform inspection of equipment installations in accordance with the applicable specifications and drawings. The appropriate check-list should be initiated and completed to document inspection and testing activities.


Site Quality Manual


•

Inspect/Perform Equipment Protection: -

•

•

-

Boundaries and test instructions provided by Construction Engineering shall be reviewed by inspection personnel prior to any testing activities.

-

Notify the Client of testing/inspections for their involvement which they have requested/required to witness.

Test Field Installed Equipment:

Utilizing the test instructions and/or drawing(s) required, verify the acceptance of the test. Document the satisfactory results using the applicable forms contained in this manual.

Provide Restoration Instructions: -

•

Perform test in accordance with the test instruction provided by Construction Engineering.

Verification of Test Results: -

•

Verify the equipment preservation and protection is adequately implemented in accordance with the requirements established by Construction Electrical Engineering. Document the verification process using 000 509 F02201.

Define Test Boundaries and Provide Preparation Test Instruction:

•

000 509 7620 18 Feb 04 Page 3 of 4

Instructions to comply with restoration requirement of the applicable specification and/or drawing should be provided by Construction Engineering.

Verification of System Restoration: -

Verify that all restoration activities have been completed and the system(s) or partial system represented by this test package is complete.

FORMS Quality Control Forms: 000 509 F02201 - Surveillance Report 000 509 F76201 - Emergency Generators Inspection Checklist 000 509 F76202 - Inspection of Switchgear Bus-Bar Continuity (Including Incoming and Sectionalizer Units) 000 509 F76203 - Inspection LV Switchgear (Including Incoming and Sectionalizer Units) 000 509 F76204 – Inspection of Outgoing – LV Switchgear 000 509 F76205 – Inspection of Static Supply Unit (UPS) 000 509 F76206 – Motor Control Centers Inspection Checklist 000 509 F76207 – Motor Control Centers (Motors and Starters) Inspection Record


Site Quality Manual


000 509 F76208 000 509 F76209 000 509 F76210 000 509 F76211 000 509 F76212 000 509 F76213 000 509 F76214 000 509 F76215 000 509 F76216 000 509 F76217 000 509 F76218 000 509 F76219 000 509 F76220 000 509 F76221 000 509 F76222 000 509 F76223 000 509 F76224 000 509 F76225 000 509 F76226 000 509 F76227 000 509 F76228 000 509 F76229 000 509 F76230 000 509 F76231

000 509 7620 18 Feb 04 Page 4 of 4

– -

High Voltage Motors and Starters Motors Checklist Control and Relay Panels Inspection Checklist Electronic Equipment Inspection Checklist Power Panel Inspection Checklist Switchgear Inspection Checklist Low Voltage Feeders Inspection Record High Voltage Cable Inspection and Test Record Electrical Equipment Inspection Record Control Scheme Inspection Checklist Power Transformer Inspection Checklist Switching Units – HV Switchgear Inspection and Test Record Switching Units – HV Switchgear Inspection Checklist Liquid – Filled Transformer Inspection Record Busway Inspection Record Switchgear Inspection Record Motor Control Center Inspection Record Battery and Battery Charger Inspection Record Liquid Immersed Medium Voltage Disconnect Switch Inspection Record Electric Motor – Electrical Activities Inspection Record Electric Motor – Mechanical Activities Inspection Record Electric Motor For Compressor Installation Checklist Compressor Vibration Checklist Vibration Probe Record


Site Quality Manual

Project Name: Contract Number: Project Location:

000 509 7640 18 Feb 04 Page 1 of 2

ELECTRICAL HEAT TRACING SCOPE This procedure defines the inspection, testing and documentation requirements for installation activities for electrical heat tracing. RESPONSIBILITIES ACTIVITY


RESPONSIBILITY

DOCUMENTATION

Receive and Test Heat Tracing Cable

Subcontractor

000 509 F76401

For each cable

Install HT Cable

Subcontractor

000 509 F76402


Inspect in-process HT cable installation

Subcontractor

000 509 F76402


Test installed HT Circuit


000 509 F76401

For each circuit

Install Insulation

Subcontractor

Per Procedure 000 509 F7810


000 509 F76401

Perform Final Testing

For each circuit

PROCEDURE

Receipt Inspection and Testing: −

Perform receipt inspection of materials and cable in accordance with the drawings and project specification 000 270 01851. Test each heat tracing circuit and record the test results on form 000 509 F76401.

In-process and Completed Heat Tracing Installation Inspections: −

Assure the heat tracing circuit is installed in accordance with requirements defined in project specification 000 270 01851. Inspect the in-process installation activities and document form 000 509 F76402.


Site Quality Manual

Project Name: Contract Number: Project Location:

000 509 7640 18 Feb 04 Page 2 of 2

Post Installation Testing of Heat Tracing:

−

The contractor shall notify the Site Quality Manager two (2) days prior to field-testing the heat tracing system. A Site Quality Representative (Fluor) will be present during the field testing of the heat tracing system before insulating may begin.

−

The contractor shall inspect and test the electrical heat tracing system in accordance with the reference specification 000 270 01851, and the manufacturers’ recommendations for each component of the system. Document the inspection and testing on form 000 509 F76401.

Final Testing of Heat Tracing:

−

The contractor shall notify the Site Quality Manager at least five (5) working days prior to the final testing and commissioning of the electrical heat tracing system. A Site Quality Representative (Client) will be present to witness the final testing and commissioning of the heat tracing system.

−

The contractor shall obtain approval for final testing of the circuit from the Client. Contractor shall complete the testing and record the required data on form 000 509 F76401.

−

The final acceptance of the heat tracing circuit is considered complete when accepted by the Client.



Electrical Heat Trace Test Log Electrical Heat Tracing Inspection Record

Site Quality Manual


000 509 7700 18 Feb 04 Page 1 of 2

CONTROL SYSTEM INSTRUMENTATION

SCOPE This procedure applies to the inspection of installations and loop check of instrumentation. RESPONSIBILITIES - Self-Perform ACTIVITY Inspect received instruments Inspect in-process instrument installation Inspect completed instrument installation Perform Pressure Testing of Tubing Verify Pressure Testing of Tubing Test Instrument Cables Verify Instrument Cable Testing Perform/ Verify Loop Check

RESPONSIBILITY

DOCUMENTATION


E & I Construction Engineer Instrument Superintendent Site Quality Manager/ E & I Construction Engineer Site Quality Manager/ E & I Construction Engineer

_____

Each Instrument

000 509 F770XX


000 509 F770XX

Each Instrument

Instrumentation Superintendent

_____

_____

Each Pressure Test Package Each Pressure Test Package Each cable


000 509 F770XX

Each cable

Instrumentation Superintendent/ Site Quality Manager

000 509 F770XX

Each loop

RESPONSIBILITY

DOCUMENTATION


Subcontractor

_____

Each Instrument

Subcontractor

000 509 F770XX



000 509 F770XX

Each Instrument

Subcontractor

_____


000 509 F770XX

Subcontractor

_____

Each cable

000 509 F770XX

Each cable

000 509 F770XX

Each loop

Site Quality Manager/ E & I Construction Engineer Electrical Superintendent

000 509 F770XX

RESPONSIBILITIES - Subcontracted Work ACTIVITY Inspect received instruments Inspect in-process instrument installation Inspect completed instrument installation Perform Pressure Testing on Tubing Verify Pressure Testing of Tubing Test Instrument Cables Verify Instrument Cable Testing Perform/ Verify Loop Check Fluor Corporation Company Confidential

Subcontractor/ Site Quality Manager Subcontractor/ E & I Construction Engineer Site Quality Manager

Each Pressure Test Package Each Pressure Test Package

Site Quality Manual


000 509 7700 18 Feb 04 Page 2 of 2

PROCEDURE •

Receipt Inspection of Instruments: -

•

In-Process and Completed Instrument Installation Inspections: -

Assure the instrument, if required by specification, is calibrated prior to installation. Inspect the in-process installations.

-

Using a Mechanical Flow Diagram and Instrument Specification Data Sheet, perform a completed inspection prior to pressure testing. Document on Form 000 509 F77001.

•

Test Equipment Tubing: -

•

Verify the instrument tubing is properly installed, is not supported from uninsulated hot or cold pipes and adequately supported. Pressure test shall be conducted in accordance with specifications and the Instrument Specification Data Sheet.

Test Instrument Cables: -

•

The E & I Construction Engineer and the Instrument Superintendent shall coordinate the receipt inspection of instruments to support the construction schedule.

Verify the instrument electrical installation inspections and megger tests are complete and acceptable.

Loop-Check Verification: -

Verify all installation inspections, pressure testing and continuity checks have been completed and documented.

-

Notify the Client Representative, if requested to do so, prior to the loop check.

-

Verify the loop check, which generally consist of operating all instruments in the loop. Document the final loop check on Form 000 509 F77002.

FORMS Quality Control Forms: 000 509 F77001 000 509 F77002 000 509 F77003 000 509 F77004 000 509 F77005 000 509 F77006

-

Instrumentation Inspection Checklist Instrument Loop Inspection Checklist Impulse Line Pressure Inspection Checklist Instrument Grounding System Checklist Installation Check Sheet (Local Instrument) Orifice Plates Inspection Checklist


Site Quality Manual


000 509 7710 18 Feb 04 Page 1 of 2

CONTROL SYSTEM CALIBRATION SCOPE This procedure applies to calibration of instruments for control systems. RESPONSIBILITIES - Self-Perform ACTIVITY

RESPONSIBILITY

DOCUMENTATION


Inspect Instrument

Calibration Technician/ Site Quality Manager

000 509 F77001

Each Instrument

Test and Calibrate Instruments

Calibration Technician/ Site Quality Manager

000 509 F77101 000 509 F77102 000 509 F77103

Each Instrument

Surveillance Test Equipment


000 509 F0221

Periodically throughout life of project


RESPONSIBILITY

DOCUMENTATION


Inspect Instrument

Subcontractor

000 509 F77001

Each Instrument

Test and Calibrate Instruments

Subcontractor

000 509 F77101 000 509 F77102 000 509 F77103

Each Instrument

Surveillance Test Equipment


000 509 F02201

Periodically throughout life of project

PROCEDURE •

Inspect Instrument: -

Inspect each instrument for apparent damage. Verify the tag number, nameplate data, material, scale, range, etc., against the information contained on the appropriate Instrument Specification Data Sheet, and enter data on Form 000 509 F77101.

-

Damaged or nonconforming instruments shall be segregated and/or tagged to prevent inadvertent use or installation until acceptable disposition is obtained.


Site Quality Manual


•

Instrument Test and Calibration: -

•

000 509 7710 18 Feb 04 Page 2 of 2

Based on the requirements in the applicable Design Specifications, applicable manufacturer's recommendations and client requirements, calibrate the instruments and document on Form 000 509 F77101.

Test Equipment Surveillance: -

Perform surveillance of calibration activities on a periodic basis throughout the life of the project. Verify the Master Equipment used for calibration has calibration stickers on the instruments that indicate date of last check and date of next check with traceability to the National Institute of Standards and Technology.

FORMS Quality Control Form: 000 509 F77001 – Instrumentation Inspection Checklist 000 509 F77101 - Instrument Calibration Sheet 000 509 F77102 - Safety Valve Tracking Sheet 000 509 F77103 - Relief Valve Inspection and Final Acceptance


Site Quality Manual


000 509 7800 18 Feb 04 Page 1 of 3

COATINGS AND LININGS SCOPE This procedure describes the inspection, testing, and documentation required to be performed for coatings. RESPONSIBILITIES - Self-Perform ACTIVITY


RESPONSIBILITY

DOCUMENTATION

Inspect surface preparation

Supervisor/Construction Engineer/Site Quality Manager

000 509 F78001


Verify color/type coatings approved

Supervisor/Construction Engineer/ Site Quality Manager

000 509 F78001

As required by applications

Inspect in-process coating/lining


000 509 F78001 000 509 F78002


Check Thickness


000 509 F78001

As required to verify thickness requirements

Inspect completed coatings


000 509 F78001

Follow-up any deficiencies identities


_____

_____ As required to close-out deficiencies



RESPONSIBILITY

DOCUMENTATION

Inspect surface preparation

Subcontractor/Construction Engineer/Site Quality Manager

000 509 F78001


Verify color/type coatings approved


000 509 F78001

As required by applications

Inspect in-process coating/lining


000 509 F78001 000 509 F78002


Check Thickness


000 509 F78001

As required to verify thickness requirements

Inspect completed coatings


000 509 F78001

Follow-up any deficiencies identities


_____


_____ As required to close-out deficiencies

Site Quality Manual


000 509 7800 18 Feb 04 Page 2 of 3

PROCEDURE •

•

•

•

•

Surface Preparation Inspections: -

Verify the surface preparation is in accordance with the applicable specification.

-

Protect adjacent areas to coating operations from sandblasting and paint overspray.

Coating Approval: -

Verify that color/type of coatings has been approved and documented.

-

Assure pot life of coating products are not exceeded prior to application.

In-process Coating/Lining Inspections: -

Coatings application shall not be performed during unacceptable weather conditions that violate the specification requirements for application.

-

Inspect the in-process coating's applications, to verify that the work meets the requirements in accordance with the specifications.

Thickness Verification/Final Inspection: -

Check dry film thickness of applied coatings in sufficient locations to verify the required thickness has been applied. Document the inspections on Form 000 509 F78001, Coatings Inspection. Perform final coating inspection after acceptable dry film thickness is achieved.

-

Test applied linings in sufficient locations to verify proper surface profile, thickness or lining continuity, using test equipment designated in the specifications. Document the inspections on Form 000 509 F78002.

-

When specifications establish application restrictions for temperature and humidity, perform checks with certified hygrometer and temperature indicator prior to starting each day's work.

Follow-up of Deficiencies: -

Inform craft supervision of any discrepancies on a daily basis. Immediate corrective action should be taken.


Site Quality Manual


000 509 7800 18 Feb 04 Page 3 of 3

FORMS Quality Support Forms: 000 509 F78001 - Coating Inspection Record 000 509 F78002 - Lining Inspection Record ATTACHMENTS Attachment 1 -


Example – Acceptance Criteria

Site Quality Manual



EXAMPLE - ACCEPTANCE CRITERIA Coatings Inspection Guidelines Minimum Weekly Inspection Areas Storage: Environmental conditions per label Containers undamaged Shelf life not exceeded Pre-Cleaning of Metal Surfaces: Dry and oil free Sufficient lighting Blast material dry and oil free Air Supply clean and dry Post-Cleaning of Metal Surfaces: Surface profile adequate No flash rusting prior to primer Environmental conditions acceptable Coating In-Process: Application equipment acceptable Pot life limits not exceeded WFT/DFT measurements acceptable Repairs made with correct materials


000 509 7810 18 Feb 04 Page 1 of 3

INSULATION SCOPE This procedure describes the inspection activities for insulation installation. RESPONSIBILITIES - Self-Perform ACTIVITY

RESPONSIBILITY

DOCUMENTATION

Coordination of Release for Insulation

Discipline Construction Engineer

Form 000 509 F78101

Install insulation

Civil Superintendent

_____

Inspect in-process installation


Form 000 509 F78101

Inspect completed installation


Form 000 509 F78101


From 000 509 F02201

Surveillance NOTE 1:

FREQUENCY OF ACTIVITY Each piece of equipment line or structure Each piece of equipment, line or structure Each piece of equipment, line or structure Each piece of equipment, line or structure Per Procedure 000 509 0220



RESPONSIBILITY

DOCUMENTATION

Coordination of Release for Insulation

Piping Construction Engineer

Form 000 509 F78101

Install insulation

Subcontractor

_____


Subcontractor

Form 000 509 F78101


Subcontractor

Form 000 509 F78101

Surveillance

QC Inspection

Form 000 509 F02201


FREQUENCY OF ACTIVITY Each piece of equipment, line or structure Each piece of equipment, line or structure Each piece of equipment, line or structure Each piece of equipment, line or structure Per Procedure 000 509 0220

Site Quality Manual


000 509 7810 18 Feb 04 Page 2 of 3

PROCEDURE •

Release for Insulation: -

•

Install Insulation: -

•

•

The construction engineer will issue the "Release for Insulation" (Form 000 509 F7811) to the insulator and QC, for sign-off prior to insulation. At this time all work will be verified as complete including; hydrostatic tests, and punch list items requiring completion, prior to insulation.

Insulation shall be installed in accordance with the applicable drawings and specifications.

In-process Inspection for Insulation Activities: -

No insulation shall begin on a vessel, equipment, or piping until released by the appropriate field supervisor.

-

Obtain a copy of the written release, (Form 000 509 F78101), for the insulation to be installed.

-

Verify the insulation materials are free from damage and shelf life has not expired.

-

Monitor the in-process installation activities to verify that insulation materials are installed in accordance with drawings, specifications, and manufacturer's recommendations.

Completed Installation Inspection: -

Inspect the competed insulation for workmanship and damage.

-

Verify the installation conforms to applicable drawings and specifications, and document on Form 000 509 F78101.



-

Equipment Thermal Insulation Inspection Checklist Piping Thermal Insulation Inspection Checklist

Site Quality Manual


000 509 7810 18 Feb 04 Page 3 of 3

INSPECTION REFERENCE INSULATION AND TRACING Verify insulation materials are free from damage Verify insulation materials shelf-life has not expired Insulation support clips installed. Clearances adequate for insulation. Electrical tracing installed. Steam tracing installed. Correct number of tracers. Tracer size correct. Tracer length correct. Trap detail correct.


Site Quality Manual


000 509 7820 18 Feb 04 Page 1 of 3

FIREPROOFING INSPECTIONS SCOPE This procedure prescribes the quality control methods used to verify conformance to design requirements during application of fireproofing. This procedure covers the following classifications of materials: a) b) c) d) e)

Shotcrete (gunite) Sprayed Fibrous Sprayed Cementitious Magnesium Oxychloride (sprayed or troweled) Intumescent or Subliming Mastic


RESPONSIBILITY

Coordinate release for Construction Engineer fireproofing

DOCUMENTATION


000 509 F78201 000 509 F78202

Daily

Install fireproofing

Subcontractor

-----

-----


Subcontractor

000 509 F78201

Each installation


Subcontractor

000 509 F78201

Each installation

Surveillance


000 509 F02201

Per procedure 000 509 0220

NOTE: Fluor QC Surveillance is required for construction activities not being documented on other inspection forms by Fluor Quality.


Site Quality Manual


000 509 7820 18 Feb 04 Page 2 of 3

PROCEDURE The following steps shall be performed as required by conditions, before preparation, and application of fireproofing. •

•

Surfaces to be Fireproofed are released as follows: -

The Construction Engineer will initiate a Release for Application of Fireproofing (Form 000 509 F78201) for surfaces to be fireproofed.

-

The Construction Engineer shall be responsible for technical oversight, mix design approval, and qualification of application equipment and crew performance.

Install Fireproofing: -

Assure that the mix design, equipment type, and crew qualifications have been approved.

-

Review the Release for Application of Fireproofing for authorization to start work.

-

Fireproofing Subcontractor shall observe recognized safety rules during the work and shall use safe practices including materials, equipment/tools, and rigging/scaffolding.

Inspections are to be performed and documented on the Fireproofing Inspection Checklist (Form 000 509 F78201). •

Inspect In-Process Installation: -

Inspect surfaces to be fireproofed for cleanliness. Oil, grease, loose rust, scale, dirt, and other foreign matter shall be removed to assure adequate bonding.

-

Inspect areas not to be fireproofed to assure that they are adequately protected.

-

Monitor application of fireproofing materials to assure the following: a)

Areas not to receive fireproofing are protected from contamination.

b)

Fireproofing materials are applied evenly, without mounds, bald spots, sags, or runs.


Site Quality Manual


•

Inspect completed installation: -

•

000 509 7820 18 Feb 04 Page 3 of 3

Inspections shall be performed in a timely manner and coordinated with construction and subcontractor schedules and activities. a)

Cured surfaces contain no cracks, blisters, or delamination.

b)

At least once for every 100 square feet assure that the dried thickness is as required for the fire-rated protection as shown on the project drawings.

-

Construction supervision shall be kept informed of the inspection/test activity status including any nonconforming materials or work.

-

Nonconformances shall be reported and dispositioned in accordance with 000 509 0130.

Surveillance of contractor activities: -

Verify that materials delivered/brought to the site meet the requirements of the Project specifications.

-

Verify that materials are stored in accordance with the manufacturers recommendations.

-

Verify that equipment to be used is in accordance with the material manufacturers recommendations.

-

Verify that any required samples of each type of fireproofing are applied to representative surfaces to establish workmanship standards (Form 000 509 F78202).

FORMS: Quality Control Forms: 000 509 F02201 - Surveillance Report 000 509 F78201 - Release for Application/Inspection of Fireproofing Checklist 000 509 F78202 - Fireproofing Inspection Preconstruction Checklist


Site Quality Manual


000 509 7830 20 Sep 04 Page 1 of 3

CATHODIC PROTECTION SCOPE This procedure outlines the inspection activities for subcontracted installation of cathodic protection. Cathodic protection is installed for tank internals, vessel internals, underground structures and piping systems. RESPONSIBILITIES - Subcontracted Work DOCUMENTATION


Verify correct materials Construction Engineer are used

-----

Prior to installation

Verify vessel cathodic protection installed by shop fabricator

Materials Manager / Site Quality Manager

------

Upon receipt of materials

Install Cathodic Protection

Subcontractor

-----

-----


Subcontractor / Site Quality Manager

000 509 F78301


Witness hammer test of Thermite welds


As required

Witness anode backfill electrical test


As required


Subcontractor / Site Quality Manager

Once after each installation completed

Monitor testing and commissioning

Field Engineering

Prior to start-up

Audit documentation


At completion of each installation

Surveillance


ACTIVITY

NOTE 1: NOTE 2:

RESPONSIBILITY

000 509 F02201

Per procedure 000 509 0220

Fluor QC Surveillance is required for construction activities not being documented on other inspection forms by Fluor Quality. Surveillance is not required if the Fluor Site Quality Manager is performing inspections.


000 509 7830 20 Sep 04 Page 2 of 3

The Construction Subcontractor is responsible for the quality of the cathodic protection installation and shall perform his own in-process installation inspection and testing procedures and document the results as defined in his contract and Quality Control Program.

PROCEDURE General Requirements The following requirements are applicable to underground structures, vessels and tanks. •

Verify materials being installed conform to the specification requirements and are properly protected from damage.

•

Monitor installation activities for compliance with specification.

•

Inspect the workmanship of the completed cathodic protection for final acceptance.

•

Monitor testing and commissioning activities for compliance with the requirements for inspection and testing established in specifications.

•

Audit cathodic protection documentation to verify completeness, retrievability, timeliness of scheduled inspections and tests, and actions on results.

Additional Requirements for Underground Structures •

Acquire Subcontractor's deep well electrical log data and strata data and submit to the Fluor Project Engineer for determination of anode spacing.

•

Establish in coordination with the Construction Subcontractor and the Fluor Construction Supervisor, a procedure to assure work is not started prior to acceptance of previous work.

•

Monitor the survey made after each cathodic protection system is energized to determine whether it satisfies the criteria for protection listed in the specifications.

•

Monitor deep well preparation activities and verify preparation of the electrical log data and log of strata data obtained during drilling.

•

Monitor anode backfill operation for compliance with specifications.

•

Witness hammer testing of all Thermite weld connections to the structure.

•

Witness electrical test used to determine when the anode is backfilled with coke breeze. Electrical test readings shall be recorded by the subcontractor and copy furnished to Fluor.


000 509 7830 20 Sep 04 Page 3 of 3

Additional Requirements for Tanks and Vessels •

Verify that vessel cathodic protection materials were installed by the shop fabricator.

•

Verify the Subcontractor personnel are wearing protective clothing if required for physical protection of the linings in tanks and vessels.

•

When Cathodic Protection is applied to Equipment, record inspection on 000 509 F78301.

REFERENCE 000 509 F02201 - Surveillance Report FORMS: Quality Control Forms: 000 509 F78301 - Cathodic Protection Inspection Report


000 509 7910 18 Feb 04 Page 1 of 6

WELDING INSPECTION

SCOPE This procedure applies to inspection of welds from joint preparation through final acceptance for welding performed to the following codes/standards: •

ASME Section I, "Power Boilers" (FD "QC System Manual for B&PV Code Work" also applies).

•

ASME Section VIII, Division 1, Pressure Vessels (FD "QC System Manual for B&PV Code Work" also applies).

•

ASME B31.1, "Power Piping"

•

USAS B31.2, "Fuel Gas Piping"

•

ASME B31.3, "Chemical Plant and Petroleum Refinery Piping"

•

ASME B31.4, "Liquid Petroleum Transportation Piping Systems"

•

ASME/ANSI B31.5, "Refrigeration Piping"

•

ASME B31.8, "Gas Transmission and Distribution Piping Systems"

•

ANSI/ASME B31.9, "Building Services Piping"

•

ASME B31.11, "Slurry Transportation Piping Systems"

•

ASME B96.1, "Welded Aluminum-Alloy Storage Tanks"

•

API 620, "Recommended Rules for Design and Construction of Large Welded Low Pressure Storage Tanks"

•

API 650, "Welded Steel Tanks for Oil Storage"

•

AWWA D100 (identical to AWS D5.2) "Welded Steel Elevated Tanks, Standpipes, and Reservoirs for Water Storage"

•

ANSI/AWS D1.1, "Structural Welding Code, Steel"

•

ANSI/AWS D1.6 “Structural Welding Code, Stainless Steel”

•

ANSI Z117.1, “Safety Requirements for Working in Tanks and other Confined Spaces”

•

Fluor Practice 000 511 0101, “Certification of Nondestructive Personnel”


Site Quality Manual


000 509 7910 18 Feb 04 Page 2 of 6

•

Fluor Welding Manual (Self perform work only)

•

Applicable Project Specifications

RESPONSIBILITIES - Self-Perform ACTIVITY Assign numbers to field pipe welds

RESPONSIBILITY Construction Engineer

Weld Checking and Inspections (ASME Code Stamped) Surveillance

Each piping isometric drawing

FREQUENCY OF ACTIVITY Each isometric requiring field welds

Certified Welding Inspector

Form 000 509 F79001 Daily Welding Report Form 000 509 F79002 Weld Heat Treatment Log Form 000 509 F79001 Daily Welding Report Form 000 509 F79002 Weld Heat Treatment Log Per Fluor "Quality Control System Manual for Boiler & Pressure Vessel Code Work" 000 510 XXXX

Welder Foreman

None

Daily

Certified Welding Inspector

Form 000 509 F02201 Form 000 509 F79002

See general section

Welder Foreman Weld Checking and Inspections (Non ASME Code)

DOCUMENTATION

Certified Welding Inspector Welder Foreman


Daily

Daily Daily Daily

Site Quality Manual


000 509 7910 18 Feb 04 Page 3 of 6

Responsibilities - Subcontracted Work ACTIVITY Assign numbers to field pipe welds

Weld Checking and Inspections (Non ASME Code)

Weld Checking and Inspections (ASME Code Stamped)

Surveillance

RESPONSIBILITY Subcontractor Subcontractor Welding Foreman Subcontractor Certified Welding Inspector Subcontractor Welder Foreman Subcontracor Certified Welding Inspector Subcontractor Welder Foreman Subcontractor Certified Welding Inspector Site QC Manager

DOCUMENTATION Each piping isometric drawing Form 000 509 F79001 Daily Welding Report Form 000 509 F79002 Weld Heat Treatment Log Form 000 509 F79001 Daily Welding Report Form 000 509 F79002 Weld Heat Treatment Log Per the subcontractor approved Quality Control System Manual for Boiler & Pressure Vessel Code Work

FREQUENCY OF ACTIVITY Each isometric requiring field welds Daily

Daily

Daily Daily

None

Daily

Form 000 509 F02201 Form 000 509 F79002

Daily

Form 000 509 F02201

Daily

PROCEDURE •

Assign Numbers to Field Pipe Welds Develop a weld map by assigning identity numbers to all pipe field welds on the isometric drawings, including site pipe shop fabrication welds, prior to the start of work. Number the welds consecutively in the direction of flow, starting with the first weld on each isometric sheet as No. 1, continuing through the last weld on that sheet. If the drawings break at a weld, and the weld appears on both drawings, assign the number on the upstream drawing. If additional welds must be added later to facilitate actual fabrication, the weld locations shall be identified with the next available consecutive number until all additional welds between design welds are identified. A log may be used to identify the weld numbers already assigned to insure that no duplication of weld numbers occur. The inside weld of a slip on flange will carry the suffix "S".


Site Quality Manual


000 509 7910 18 Feb 04 Page 4 of 6

Attachment welds, such as shoes or other supports shall be numbered with the next available number using the prefix "X". In the case of a reinforcing pad, all welds will refer to the field weld number joining the branch to header pipe. Use the prefix "PB" and "PH" for pad to branch and pad to header respectively. When straight run pipe is being double jointed on the ground, and it is not certain to which line it belongs, then use the prefix "DJ' before these field welds. Maintain a separate log of "DJ" welds and assign unique numbers starting with DJ-1. "DJ" welds are marked at 180° intervals. Weld maps shall accurately show the final location of all "DJ" welds. Note: Welder, NDE, PMI, PWHT information/results need not appear on the weld map but must be readily traceable to the weld map and placed with the weld map at system completion. Certain things need to be emphasized: Remember that it is of primary importance to assign a unique weld number to all field welding. Once this number is assigned, do not change it for any reason. Do not renumber isometrics to keep the weld numbers consecutive in the direction of flow. Use the next available number for any alterations or additional welds. If a portion of piping containing assigned welds is cut out of a system and discarded do not reuse these weld numbers but note on the isometric that these welds are void and show the new welds on the current isometric revision. Cut shop welds will be assigned field weld numbers. •

Visual Check and Acceptance (By Foreman) In-process checking and surveillance of fabrication/erection welding is considered part of the foreman's normal supervisory duties, and includes: welder qualification verification, materials verification, control of welding consumables, joint preparation, fit-up, preheat, interpass heat, weld procedure variables, weld condition between passes, and the appearance of all finished welds. Acceptance criteria is provided by the applicable attachment to this procedure. For all welds in piping systems and for all other welds requiring post weld heat treatment or NDE, the foreman will prepare a "Daily Welding Report" (000 509 F7901) for completed welds to indicate his daily production and to document his visual check and acceptance of each weld. The foreman's signature on this form indicates his acceptance. The foreman provides these reports daily to the Certified Welding Inspector. If a weld is repaired because of rejected radiography, the identity of the repaired weld will maintain the identification number previously assigned except the designation "R1" shall be added after the joint number. A suffix shall designate subsequent repairs of the same welds, such as R2 and R3, until the weld is determined to be acceptable by radiographic examination. If welds are completely cut out the suffix shall be C1, C2, etc. The foreman should identify the first two welds made by a new welder, welding on a system requiring random RT, by noting in the "Remarks" section "1st weld" or "2nd weld"


Site Quality Manual


000 509 7910 18 Feb 04 Page 5 of 6

so that these welds can be examined by radiography to confirm welding proficiency in production. •

Inspection by the Welding Inspector - (Certification Required) Except as noted below, a minimum of 5% of groove welds shall have fit-up inspection by the inspector. Each welder's work is to be represented. This percentage is to be increased, if necessary, to satisfy the inspector that acceptable workmanship is being achieved. The inspector should normally be able to achieve adequate fit-up inspections without establishing hold points, but he may request hold points for fit-up inspection of specific joints. The "visually inspected" block on the form is initialed by the inspector to indicate joints on which he performed fit-up/final inspection. The inspector's signature on the Daily Welding Report indicates his acceptance of the completed weld(s). Acceptance criteria is specified by the applicable attachment to this procedure. The inspector should also verify that the Daily Welding Report has been accurately completed and the listed weld joints have been identified with the welder's stamp. The inspector provides these reports daily to the NDE Coordinator for scheduling of NDE. If the inspector considers any of the reported welds to be unacceptable, he will inform the foreman. If it is not repaired prior to turning in the Daily Welding Report, the unacceptable welds are lined out and recorded on a Surveillance Report (000 509 F02201) for tracking to closure. Exceptions to the level of inspection described by this paragraph is provided below:

•

-

Inspection (By Certified Welding Inspector) is not required for welds in B31.3 Category D piping systems if welds in the system will not be subjected to radiography. Surveillance by procedure 000 509 0220 is adequate for these welds.

-

For ASME B31.3 Category "M", "Severe Cyclic Conditions", longitudinal butt welds and "High Pressure Piping". In addition to the above, all material shall be verified and all fit-ups shall be inspected by the Certified Welding Inspector.

Surveillance Surveillance as described by procedure 000 509 0220 is to be performed for all welding activities including postweld heat treatment using the applicable attachments to this procedure and the approved PWHT procedure. Surveillance Reports (F02201) will be prepared for all deficiencies found during surveillance or inspection. Surveillance reports will also be prepared for welds that were not subjected to the inspection described above by the Certified Welding Inspector (i.e., category D piping).


Site Quality Manual


000 509 7910 18 Feb 04 Page 6 of 6

GENERAL Completion of Post Weld Heat Treatment will be documented on "Post- weld Heat Treatment Log" (000 509 F79002). The log is to be provided to the NDE Coordinator for scheduling hardness test if required. Temporary attachments shall be properly removed and areas visually examined. Welds requiring Code Stamping shall be examined and documented in accordance with "Fluor Quality Control System Manual, Boiler and Pressure Vessel Code Work," or the applicable Subcontractors quality program for boiler and pressure vessel code work. Certification of Welding Inspectors shall be performed in accordance with Fluor Procedure 000 511 0101 "Certification of Nondestructive Examination Personnel." For welded branch connections, perform final Weld Examination of the branch connection pressure weld prior to the addition of any reinforcing pad or saddle. For welds that will be inaccessible for inspection due to the fabrication process (eg; jacketed pipe, etc.) perform a visual inspection before fabrication renders these welds inaccessible. FORMS Quality Control Forms: 000 509 F02201 - Surveillance Report 000 509 F79001 - Daily Welding Report 000 509 F79002 - Postweld Heat Treatment Log ATTACHMENTS Attachment 1 Attachment 2 Attachment 3 Attachment 4 Attachment 5 Attachment 6 Attachment 7 Attachment 8 Attachment 9 Attachment 10 Attachment 11 Attachment 12 Attachment 13 Attachment 14 Attachment 15 Attachment 16 Attachment 17

-

Frequency of Visual Examinations Weldolet and Sockolet Fittings Attachment ANSI B16.11 Forged Steel Fittings ASME Section I Acceptance Criteria ASME Section VIII, Division I Acceptance Criteria ASME B31.1 Acceptance Criteria USAS B31.2 Acceptance Criteria ASME B31.3 Acceptance Criteria ASME B31.4 - ASME B31.8 - ASME B31.11 Acceptance Criteria ASME/ANSI B31.5 Acceptance Criteria ANSI/ASME B31.9 Acceptance Criteria ASME B96.1 Acceptance Criteria API 620 Acceptance Criteria API 650 Acceptance Criteria AWWA D100 (Identical to AWS D5.2) Acceptance Criteria ANSI/AWS D1.1 / D1.6 Acceptance Criteria Numbering of Pipe Weld Joints


Site Quality Manual



FREQUENCY OF VISUAL EXAMINATIONS 1.0

ASME SECTION 1 AND VIII, DIVISION 1 1.1

2.0

Visual examination frequency shall be in accordance with the Fluor Daniel Quality Control System Manual, Boiler and Pressure Vessel Code Work.

ASME B31.1 A.

Boiler External Piping Visual examination frequency shall be in accordance with Fluor Daniel Quality Control System Manual, Boiler and Pressure Vessel Code Work.

B.

Non Boiler External Piping All completed welds shall have a visual examination.

3.0

USAS B31.2 3.1

4.0

All completed welds shall have a visual examination

ASME B31.3(1) A.

Category "D" Fluid Service Visual examination shall be performed to the extent necessary to satisfy the examiner that components, materials, workmanship and welds conform to the requirements.

B.

"Normal Service Conditions" 1.

Sufficient welds, materials and components shall be examined to satisfy the examiner that they conform to specifications and are free from defects and damage.

2.

At least 5% of completed welds shall be examined. Each welder's work shall be included.

3.

Examine 100% of completed longitudinal welds, except those in components made from a listed specification (i.e., A53B welded pipe, A234 welded fillings).

4.

Random examination of the assembly of threaded, bolted, and other joints for conformance to engineering requirements.


5.

Random examination of alignment, guides, supports, and cold spring.

6.

Examination of erected piping for defects or deviations from engineering design.

7.

When pneumatic testing is performed, all threaded, bolted, and other mechanical joints shall be examined.

C.

"Severe Cyclic Conditions" Same as #B above except all fabrication shall be examined.

D.

"Category "M" Fluid Service Same as #B above except all fabrication shall be examined.

E.

High Pressure Piping Same as #B above except all fabrication shall be examined.

NOTE(1):

5.0

6.0


In-process weld examination frequency shall be to an extent such that the examiner is satisfied requirements are being met, except where in process inspection takes the place of random radiography required by B31.3 for Normal Fluid Service or Category "M" Fluid Service. The in-process examination in lieu of random radiography must be approved by the Engineer or Owner and shall include a final visual examination.

ASME B31.4 5.1

All piping components shall be examined for damage prior to fabrication.

5.2

All weld joints shall have a fit up, root pass, and final visual examination.

5.3

All completed welds shall be cleaned and examined prior to coating operations. Irregularities that could damage the pipe coating shall be removed.

ASME/ANSI B31.5 Sufficient welds, materials, and components shall be examined to satisfy the examiner that they conform to specifications and are free from defects and damage.

7.0

ASME B31.8 Sufficient welds, materials, and components shall be examined to satisfy the examiner that they conform to specifications and are free from defects and damage.


8.0


ANSI/ASME B31.9 Sufficient welds, materials, and components shall be examined to satisfy the examiner that they conform to specifications and are free from defects and damage.

9.0


10.0


11.0

API 620 All completed welds shall have a visual examination.

12.0

API 650 All completed welds shall have a visual examination.

13.0

AWWA D100 (Identical to AWS D5.2) Sufficient welds, materials, and components shall be examined to satisfy the examiner that they conform to specifications and are free from defects and damage.

14.0

ANSI/AWS D1.1 All completed welds shall have a visual examination.

15.0

ANSI/AWS D1.6 All completed welds shall have a visual examination.









ACCEPTANCE CRITERIA ASME SECTION I 1.0

ASME SECTION I 1.1

In process examination shall meet the following: A.

All base materials shall be identified as to type and grade (i.e; A106B, SA516G70,etc.) and per the Quality Control System Manual, B & PV Code Work (i.e; heat number).

B.

Joint preparation and cleanliness shall be in accordance with the WPS.

C.

Check welder qualification, base material for conformance to the WPS.

D.

Welding filler materials shall be in accordance with the WPS.

E.

Preheating prior to cutting or welding (including tacking) shall be in accordance with the WPS.

F.

Tack welds shall be made by qualified welders.

G.

Tack welds that are to be incorporated into the final weld shall be visually examined and be free of cracks, slag, porosity, lack of fusion, cold lap, internal undercut, excessive penetration, and the ends prepared by grinding.

H.

The backside of double welded joints shall be backgouged to sound metal and visually examined prior to welding.

I.

Each weld pass shall be free of porosity, slag, cold lap, cracks and other indications that would compromise weld quality.

J.

Arc strikes shall be properly removed and areas visually examined.

K.

Welding end transitions shall provide for a maximum 30 degree angle across the weld, with respect to the base metal (diameters, or plate thickness) on each side of the weld. Additionally where two thick sections taper down to the weld joint, the minimum angle formed by the O.D. of the base materials shall be 150 degrees.

L.

Fit-up, and alignment of butt welds shall be in accordance with the WPS and the following where "t" is the nominal thickness of the thinner section at the joint (dimensions in inches).



ALIGNMENT TOLERANCE OF JOINT TO BE BUTT WELDED (Note 1) Direction of Joints in Cylindrical Shells

Section Thickness (in) Up to 1/2, incl. Over 1/2 to 3/4, incl. Over 3/4 to 1 1/2, incl. Over 1 1/2 to 2, incl. Over 2

Longitudinal 1/4t 1/8 in. 1/8 in. 1/8 in. Lesser of 1/16 t or 3/8 in.

Circumferential 1/4t 1/4t 3/16 in. 1/8t Lesser of 1/8t or 3/4 in.

Note 1: Joints in spherical vessels and within heads and joints between cylindrical shells and hemispherical heads shall meet the requirements above for longitudinal joints in cylindrical shells. M.

1.2

The depth of insertion of a pipe or tube into a socket or sleeve shall be at least 1/4". Before welding, there shall be at least 1/16" clearance between the end of the pipe or tube and of the socket; and in the case of a sleeve, there shall be at least 1/16" clearance between the butting ends of the pipe or tube. The fit between the socket or sleeve and the pipe or tube shall conform to applicable standards for socket weld fittings, and in no case shall the inside diameter of the socket or sleeve exceed the outside diameter of the pipe or tube by more than 0.080".

Final visual weld examination shall be in accordance with the following: A.

No porosity allowed.

B.

No linear indications such as cracks, lack of fusion, cold laps or incomplete penetration are allowed.

C.

No slag or weld spatter allowed (including base material).

D.

No unfilled craters allowed (with or without associated shrinkage defects).

E.

No underfilled finished weld areas (outside surface of piping and tubing welds).

F.

Root concavity is permitted if the depression does not exceed the lesser of 3/32" or 20% of the thinner of the sections being joined. The contour of the concavity shall be smooth and the resulting thickness of the weld, including any outside reinforcement, shall be at least equal to the required thickness of the thinner section.

G.

Any allowable off-set on a finished weld shall be faired at a 3:1 taper over the width of the finished section. Additional weld metal may be added beyond edge of weld.



H.

Undercut shall not exceed 1/32" or 10% of the wall thickness whichever is less, and shall not encroach upon the required section thickness.

I.

As-welded surfaces are permitted, the surface of the welds shall be sufficiently free from coarse ripples, grooves, overlaps, abrupt ridges, and valleys to allow for proper interpretations of NDE and to avoid stress raisers.

J.

Fillet weld size shall be a specified on the engineering drawing.

K.

Each weld joint shall be identified by one of the following methods: 1.

The welder may stamp his identification mark adjacent to all welded joints or he/she may stamp adjacent to a continuous weld or a series of similar joints at intervals of not greater than three (3) feet.

2.

A record of welded joints, including the identification of the welder making the joint, may be used in lieu of stamping.

L.

For seal welding of threaded joints, the exposed threads shall be entirely covered by the seal weld.

M.

Butt weld reinforcement (internal or external) on each weld face shall meet the following:

Nominal Thickness (in)

Circumferential Joints in Pipe and Tubing (in)

Up to 1/8 Over 1/8 to 3/16, incl. Over 3/16 to 1/2, incl. Over 1/2 to 1, incl. Over 1 to 2, incl. Over 2 to 3, incl. Over 3 to 4, incl. Over 4 to 5, incl. Over 5

3/32 1/8 5/32 3/16 1/4 Note 1 Note 1 Note 1 Note 1

Note 1:

Maximum Reinforcement (in) Other Welds 3/32 3/32 3/32 3/32 1/8 5/32 7/32 1/4 5/16

The greater of 1/4 in. or 1/8 times the width of the weld in inches.



ACCEPTANCE CRITERIA ASME SECTION VIII, DIVISION I 1.0

ASME Section VIII Division 1 1.1


All base materials shall be identified as to type and grade (i.e; A106B, SA516 G70, etc.) and per the Quality Control System Manual, B & PV code work (i.e.; heat number). Non-pressure parts shall be identified as to type and grade. Review drawing to determine if Charpy Vee Notch testing of base materials and/or weld materials, and production test plates, is required. CMTR’s required for plate material and all material requiring CVN testing.

B.


C.


D.

Welding filler materials shall be in accordance with the WPS. For ASME Code Stamped items, filler material shall be traceable to the weld joint by AWS Classifications as a minimum. Traceability by heat and lot number to the weld joint is required for CVN vessels and may be required by a site specific specification for other vessels.

E.


F.


G.


H.


I.


J.


K.

When pressure parts, such as nozzle reinforcing pads, extend over pressure retaining welds, such welds shall be ground flush for the portion of the weld to be covered. Root concavity on the backside of the portion that is ground flush is not permitted.


L.


Fit-up, including misalignment of butt welds, shall be in accordance with the WPS. In addition, the edges of butt welds shall be held during welding so that the following tolerances (internal and external) are not exceeded. When fitted girth joints have deviations exceeding the permitted tolerances the joint shall be re-fit until the errors are within the limits specified. For Shells, the maximum out of roundness at any cross section shall not exceed 1% of the nominal diameter. ALIGNMENT TOLERANCES Nominal Thickness (t), inch Up thru 1/2 Over 1/2 thru 3/4 Over 3/4 thru 1 1/2 Over 1 1/2 thru 2 Over 2

*

1.2

A* 1/4t 1/8 in. 1/8 in. 1/8 in. Lesser of 1/16t or 3/8 in.

Joint Categories B,C,D* 1/4t 1/4t 3/16 in. 1/8t Lesser of 1/8t or 3/8 in.

Category A joints include all longitudinal joints in shells, heads, transitions, spheres, and circumferential joints connecting hemispherical heads to shells. Category B, C and D include all other joints. M.

Any offset within the allowable tolerances shall be faired to a 3 to 1 taper over the width of the finished weld (internally and externally). Additional weld metal may be added. The resulting weld joint and tapered areas shall not be thinner than the non tapered base material. Where fillet welds are used, the lapped plates shall fit closely and be kept in contact during welding.

N.

The depth of insertion of a pipe or tube into a socketweld fitting shall be at least 1/4". Before welding, there shall be at least 1/16" clearance between the end of the pipe and the internal shoulder of the socketweld fitting.


Both sides (ID and O.D.) of butt welds and other full penetration groove welds shall be inspected. RT examination in lieu of VT of inaccessible I.D. is acceptable.

B.


C.

No linear indications such as cracks, lack of fusion, cold laps or incomplete penetration are allowed.



D.

No slag or weld spatter allowed (including base material).

E.


F.

No underfilled finished weld areas (outside surface of piping and tubing welds).

G.

Root concavity shall not reduce the weld below the base material thickness.

H.

Any allowable off-set on a finished weld shall be faired at a 3:1 taper over the width of the finished section. Additional weld metal may be added beyond edge of weld.

I.

Undercut shall not exceed 1/32 inch, or 10% of the nominal thickness of the adjoining surface, whichever is less.

J.


K.

Fillet weld size shall be a specified on the engineering drawing.

L.

Each weld joint shall be identified by one of the following methods:

M.

1.

The welder may stamp his identification mark adjacent to all welded joints or he/she may stamp adjacent to a continuous weld or a series of similar joints at intervals of not greater than three (3) feet.

2.

A record of welded joints, including the identification of the welder making the joint, may be used in lieu of stamping.



N.


Butt weld reinforcement (internal or external) shall meet the following: Maximum Reinforcement (in) Material Nominal Circumferential Other Welds Thickness, inch Joints in Pipe/Tube Less than 3/32 3/32 1/32 3/32" thru 3/16 1/8 1/16 Over 3/16 thru 1/2 5/32 3/32 Over 1/2 thru 1 3/16 3/32 Over 1 thru 2 1/4 1/8 Over 2 thru 3 1/4 5/32 Over 3 thru 4 1/4 7/32 Over 4 thru 5 1/4 1/4 Over 5 5/16 5/16



ACCEPTANCE CRITERIA ASME B31.1 1.0

ASME B31.1 1.1


All base materials shall be identified as to type and grade (i.e.; A106B, SA516 G70, etc.) and for Boiler External Piping per the Quality Control System Manual, B & PV code work (i.e.; heat number). Non-pressure parts shall be identified as to type and grade.

B.


C.


D.

Welding filler materials shall be in accordance with the WPS. For ASME Code Stamped items, filler materials shall be traceable to the weld joint by AWS classification as a minimum. Tracing by heat and lot number to the weld joint may be required by site specific specification.

E.

Preheating prior to cutting or welding (including tacking) shall be in accordance with the WPS. Note: For piping of over 3% nominal Chromium content fabricated to B31.1, visual for cracks after preheat is interrupted and restarted as permitted by the WPS.

F.

Fit-up, including misalignment of butt welds, shall be in accordance with the WPS. Internal misalignment shall not exceed 1/16 inch unless the piping design specifically states a different allowable misalignment, in which case, the misalignment over 1/16 inch shall be tapered to a 1:3 maximum slope.

G.


H.


I.


J.


K.



L.


Welding end transitions shall provide for a maximum 30 degree angle across the weld, with respect to the base metal on each side of the weld. Additionally, where two thick sections taper down to the weld joint, the minimum angle formed by the O.D. of the base materials shall be 150 degrees. Note: Longitudinal butt welded joints shall be aligned within 1/16 inch and inside surface shall not be tapered). The resulting weld joint and tapered areas shall not be thinner than the non tapered base material.

M.

1.2

The depth of insertion of a pipe or tube into a socketweld fitting shall be at least 1/4". Before welding, there shall be at least 1/16" clearance between the end of the pipe and the internal shoulder of the socketweld fitting. Gap between O.D. of pipe and socket shall not exceed .040.

A final visual weld examination shall be in accordance with the following: A.


B.

No linear indications such as cracks, lack of fusion, cold laps or lack of penetration.

C.

No slag or weld spatter (including base material).

D.


E.

No under filled (weld cap) areas.

F.

Root concavity shall not reduce the weld below the base material thickness.

G.


H.

Undercut shall not exceed 1/32 inch and shall not reduce the wall thickness below minimum wall requirements (i.e., .875 X nominal wall for schedule pipe, the minimum ordered wall thickness of minimum wall pipe, and nominal wall minimum, minus .01 inch for nominal wall ordered pipe that is made from rolled and longitudinally welded plate).

I.

Any offset of outside butt welding surfaces shall be faired to a 30 degrees maximum taper over the width of the weld (excluding reinforcement).


J.

K.


Welding end transitions shall be as follows: 1.

The wall thickness in the transition region is not less than the minimum wall thickness of the adjoining pipe.

2.

Sharp reentrant angles and abrupt changes in slop in the transition region are avoided.

3.

There is a gradual transition between the two items. The slope of the transition to the weld does not exceed 30 degrees. Weld metal may be added to meet this requirement.

Butt weld reinforcement thickness shall meet the following: MAXIMUM REINFORCEMENT (in) Thickness of Base Metal Inches Up thru 1/8 Over 1/8 thru 3/16 Over 3/16 thru 1/2 Over 1/2 thru 1 Over 1 thru 2 Over 2 Notes:

L.

>750F 1/16 1/16 1/16 3/32 1/8 5/32

350-750F 3/32 1/8 5/32 3/16 1/4 See Note 5

<350F 3/16 3/16 3/16 3/16 1/4 See Note 5

1.

For double welded butt joints, the limitation on reinforcement given above shall apply separately to both inside and outside surfaces of the joint.

2.

For single welded butt joints, the reinforcement limits given above shall apply to the outside surface of the joint only. Internal reinforcement shall not exceed 1/16 inch for the GTAW process nor 3/32 inch for the SMAW process.

3.

The thickness of weld reinforcement shall be based on the thickness of the thinner of the materials being joined.

4.

The weld reinforcement thicknesses shall be determined from the higher of the abutting surfaces involved.

5.

The greater of 1/4 inch or 1/8 times the width of the weld in inches.

Fillet weld sizes shall meet drawing requirements. Weld leg length for socket, slip-on flanges and socket fittings shall be 1.09 time the pipe wall thickness for the hub thickness, whichever is less. Weld sizes for branch connections may be found in Figure A.



N.


O.

Each weld shall be identified with the welders symbol or traceable by documentation.



FIGURE A ASME B31.1 WELDED BRANCH DETAILS

NOTES:

These sketches show minimum acceptable welds. Welds may be larger than those shown here. tc = the smaller of 1/4" or .7 x Tb

Tr = nominal thickness of reinforcement, in.

Detail (1) w = Tb + tc

tmin = the smaller of Tb or Tr

Detail (2) w = Th + tc

Tb = nominal thickness of branch wall

Detail (3) w = Tr + tc or Tb + tc

Th = nominal thickness of header wall

Detail (4) w = Th + Tr + tc Detail (5) w = Tb + tc

w = Governing thickness for determining Postweld Heat Treat.



ACCEPTANCE CRITERIA USAS B31.2 1.0

USAS B31.2, FUEL GAS PIPING 1.1


All base materials shall be identified as to type and grade (i.e; A106B, SA516 G70, etc.).

B.


C.


D.


E.


F.

Fit-up, including misalignment of butt welds, shall be in accordance with the WPS. Any misalignment of butt welds, exceeding the WPS, shall be tapered to a 30 degree maximum angle. The resulting weld joint and tapered areas shall not be thinner than the non tapered base material.

G.


H.

Tack welds that are to incorporated into the final weld shall be visually examined and be free of cracks, slag, porosity, lack of fusion, cold lap, internal undercut, excessive penetration, and the ends prepared by grinding.

I.


J.


K.


L.

For branch on pipe connections, the opening through the pipe shall align with the bore of the branch within 1/8 inch or one-half the branch wall thickness, whichever is less.

M.



1.2



No porosity.

B.

No linear indications such as cracks or cold laps or other indications that would compromise weld quality.

C.

When accessible for visual inspection, the depth of incomplete root penetration or lack of fusion at the root shall not exceed 1/32 inch or half the thickness of the weld reinforcement (located above the indication) whichever is smaller. The total length of such incomplete root penetration or lack of fusion at the root shall not exceed 1 1/2 inches in any 6 inches of weld length.

D.

Fillet weld sizes shall meet drawing requirements. Weld leg length for socket and slip on flanges and socket fittings shall be 1.4 times the pipe wall thickness or the hub thickness whichever is less but no smaller than 1/8 inch.

E.

Branch connection weld sizes are shown in Figure A.

F.

Undercut shall not exceed 1/32 inch.

G.

*Weld reinforcement shall not exceed the following: COMPONENT REINFORCEMENT Thickness (in.) 1/2" and under Over 1/2" thru 1" Over 1" *

H.

Thickness, Max (in.) 1/8" 5/32" 3/16"

For double welded joints this limitation or reinforcement shall apply to each surface of the weld separately.

No under filled (weld cap) areas.



FIGURE A USAS B31.2 WELDED BRANCH DETAILS

NOTES:














ASME B31.3, PROCESS PIPING 1.1


All base materials shall be identified as to type and grade (i.e., A106B, SA516 G70, etc.) and heat number (if CVN testing required). Review drawing to determine if Charpy Vee Notch testing of base materials and/or weld materials is required. CMTR’s are required for all material requiring CVN testing. CMTR’s may be required for other piping as designated in a site specification.

B.


C.

Check welder qualifications, base material for conformance to the WPS.

D.

Welding filler materials shall be in accordance with the WPS. Tracing by AWS Classification, heat and lot number to the weld joint is required for CVN piping and may be required by a site specific specification for other piping.

E.


F.


G.


H.


I.


J.


K.



1.2


L.


M.


N.

When accessible for visual inspection, the internal condition of the root pass shall meet Figure A, B, or C as applicable.

Final Visual Weld Examination shall be in accordance with the following: A.

Final Visual Weld Examination shall be in accordance with Figure A and B for "Nominal Service Conditions", "Severe Cyclic Conditions" and Category "D" Fluid Service. Category "M" fluid service shall be inspected to "Normal Service Conditions" of Figure A and Figure B. "High Pressure Piping shall be examined in accordance with Figure C.

B.

Fillet weld sizes shall meet drawing requirements. Weld leg length for socket and slip-on flanges shall be a minimum of 1.4 times the pipe wall thickness or the hub thickness whichever is less.

C.

For socket welding fittings, other than flanges, the minimum weld leg lengths shall be 1.25 times the pipe wall thickness or 1/8 inch, whichever is greater. Weld sizes for branch connections may be found in Figure D.

D.


E.

Perform Visual Weld Examination prior to other nondestructive examinations and post weld heat treatment. In addition, piping constructed of P3, P4, or P5 material, perform a final visual weld examination after postweld heat treatment.



FIGURE A ASME B31.3 WELD ACCEPTANCE CRITERIA


FIGURE B ASME B31.3 WELD ACCEPTANCE CRITERIA NOTES




FIGURE C ASME B31.3 WELD CRITERIA NOTES AND WELD CRITERIA FOR TABLE K341.3.2A



FIGURE D ASME B31.3 WELDED BRANCH DETAILS

NOTES: These sketches show minimum acceptable welds. Welds may be larger than those shown here. tc = the smaller of 1/4" or .7 x Tb Tr = nominal thickness of reinforcement, in.











ACCEPTANCE CRITERIA ASME B31.4 - ASME B31.8 - ASME B31.11 1.0

ASME B31.4, "LIQUID PETROLEUM TRANSPORTATION PIPING SYSTEMS" ASME B31.8, "GAS TRANSMISSION AND DISTRIBUTION PIPING SYSTEMS" ASME B31.11, "SLURRY TRANSPORTATION PIPING SYSTEMS" 1.1


All base materials shall be identified as to type and grade (i.e., A106B, SA516 G70, etc.)

B.


C.


D.


E.


F.

Fit-up, including misalignment of butt welds, shall be in accordance with the WPS. Any misalignment of butt welds, exceeding the WPS, shall be tapered to a 30 degree maximum angle. The resulting weld joint and tapered areas shall not be thinner than the non tapered base material. Details for unequal wall thickness are shown in Figure A.

G.


H.


I.


J.


K.


L.



1.2


M.


*

Shallow crater cracks located at the stopping point of weld beads, and that are 5/32 inch or less in length are acceptable.


B.

C.

D.

Porosity is unacceptable when: 1.

The size of an individual pore exceeds 1/8 inch.

2.

The size of an individual pore exceeds 25 percent of the thickness of the thinner member joined.

3.

For cluster porosity that occurs in the weld cap, if the diameter exceed 1/2 inch or, the group length in any continuous 12 inch length of weld exceeds 1/2 inch or, an individual pore within a cluster exceeds 1/16 inch.

Incomplete penetration and incomplete fusion is unacceptable when: 1.

The length of an individual indication exceeds 1 inch.

2.

The group of indications in any continuous 12 inch length of weld exceeds 1 inch.

3.

The group of indications exceed 8 percent of the weld length in any weld less than 12 inches in length.

Incomplete penetration due to high-low fit-up shall be unacceptable when: 1.

The length of an individual indication exceeds 2 inches.

2.

The group of indications in any continuous 12 inch length of weld exceeds 3 inches.

Burn through (a portion of the root bead where excessive penetration has caused the weld puddle to be blown into the pipe) is unacceptable when: 1.

The maximum dimension exceeds 1/4 inch and the internal root concavity is less than the thinnest adjacent base metal.

2.

The maximum dimension exceeds the thinner of the nominal wall thickness joined and the internal root concavity is less than the thinnest adjacent base metal.



3.

E.

F.

G.

If more than one burn-through is present, the sum of the maximum dimensions of separate burn-through exceeds 1/2 inch in any continuous 12 inch length of weld or the total weld length, whichever is less and the internal root concavity is less than the thinnest adjacent base metal. For pipe with an outside diameter less than 2 3/8 inch, if more than one burn-through is present and the internal root concavity of more than one of the burn-through exceeds that of the thinnest adjacent base metal.

Undercut adjacent to the weld cap (external) or root pass (internal) is unacceptable when: 1.

The group length of external and internal in combination in any continuous 12 inch length of weld exceeds 2 inches.

2.

The group length of external and internal in combination exceeds one sixth of the total weld length.

Maximum dimensions of undercutting 1.

Undercut depth shall not exceed 1/32 inch or 12 1/2% of the pipe wall thickness whichever is smaller.

2.

Undercut depth shall not exceed 1/64 inch or 6% to 12.5% of pipe wall thickness whichever is smaller for a maximum length of 2 inches in a continuous 12 inch weld length or 17% of the weld length, whichever is smaller.

Accumulation of Discontinuities excluding incomplete penetration due to high-low and undercutting, are unacceptable when: 1.

The group length of indications in any continuous 12 inch length of weld exceeds 2 inches.

2.

The group length of indications exceed 8 percent of the weld length.

H.

The weld cap (weld reinforcement) shall not exceed 1/16 inch.

I.

Fillet weld sizes shall meet drawing requirements. Weld leg length for socket and slip on flanges and socket fittings shall be 1.4 times the pipe wall thickness or the hub thickness whichever is less but no smaller than 1/8 inch. Branch connection details and weld sizes are shown in Figures B, C, D, E, and F.

J.


K.

Perform visual weld examination prior to other nondestructive examinations and postweld heat treatment.


FIGURE A ASME B31.4 - B31.8 - B31.11 WELD DETAILS FOR UNEQUAL WALL THICKNESS




FIGURE B ASME B31.4 - B31.8 - B31.11 BRANCH CONNECTION DETAILS WITHOUT REINFORCEMENT


FIGURE C ASME B31.4 - B31.8 - B31.11





ASME B31.5, REFRIGERATION PIPING 1.1



B.


C.


D.


E.


F.


G.


H.


I.

The backside of double welded joints shall be back-gouged to sound metal and visually examined prior to welding.

J.


K.


L.




M.


N.

When accessible for visual inspection, the internal condition of the root pass shall meet Figure A and B "Normal Service Conditions".

1.2


Final Visual Weld Examination shall be in accordance with Figure A and B for "Nominal Service Conditions".

B.

Fillet weld sizes shall meet drawing requirements. Weld leg length for socket and slip-on flanges shall be a minimum of 1.4 times the pipe wall thickness or the hub thickness whichever is less.

C.

For socket welding fittings, other than flanges, the minimum weld leg lengths shall be 1.25 times the pipe wall thickness or 1/8 inch, whichever is greater. Weld sizes for branch connections may be found in Figure C.

D.


E.

Perform Visual Weld Examination prior to other nondestructive examinations and postweld heat treatment.



FIGURE A ASME B31.5 WELD ACCEPTANCE CRITERIA


FIGURE B ASME B31.5 WELD ACCEPTANCE CRITERIA NOTES




FIGURE C ASME B31.5 WELDED BRANCH DETAILS

NOTES: These sketches show minimum acceptable welds. Welds may be larger than those shown here. tc = the smaller of 1/4" or .7 x Tb Tr = nominal thickness of reinforcement, in. tmin = the smaller of Tb or Tr Tb = nominal thickness of branch wall Th = nominal thickness of header wall

Detail (1) w = Tb + tc Detail (2) w = Th + tc Detail (3) w = Tr + tc or Tb + tc Detail (4) w = Th + Tr + tc Detail (5) w = Tb + tc w = Governing thickness for determining Postweld Heat Treat.




ASME B31.9, BUILDING SERVICES PIPING 1.1


All base materials shall be identified as to type and grade (i.e; A53B, A570, etc.).

B.


C.


D.


E.


F.


G.


H.


I.

The backside of double welded joints shall be back-gouged to sound metal and visually examined prior to welding.

J.

Each weld pass shall be free of porosity, slag, cold lag, cracks and other indications that would compromise weld quality.

K.


L.


M.



1.2


Final Visual Examination shall be in accordance with the following: A.

No porosity.

B.

No linear indications such as cracks or cold lap or other indications that would compromise weld quality.

C.

Lack of fusion. The length of un-fused areas shall not be more than 20% of the total length of the weld and no more than 1 1/2 inches in any 6 inch weld length.

D.

Fillet weld sizes shall meet drawing requirements. Weld leg length for socket and slip on flanges and socket fittings shall be 1.1 times the wall thickness or the hub thickness whichever is less, but not less than 1/8 inch.

E.

Branch connection weld sizes are shown in Figure A.

F.

Undercut shall not exceed 1/32 inch or 12 1/2% of the wall thickness whichever is less.

G.

Weld reinforcement shall not exceed 3/16 inch.

H.

When accessible for inspection, inside root penetration shall not exceed 1/8 inch.



FIGURE A ASME B31.9 WELDED BRANCH DETAILS

NOTES:














ASME B96.1, "Welded Aluminum-Alloy Storage Tanks" 1.1


All base materials shall be identified as to type and grade (i.e.; 6061, 6063, etc.).

B.


C.


D.


E.


F.

Fit-up, including misalignment of butt welds, shall be in accordance with the WPS.

G.


H.


I.


J.


K.



1.2



No porosity.

B.


C.

Undercut shall not exceed 1/32 inch.

D.

Fillet weld sizes shall meet drawing requirements.

E.

Perform visual weld examination prior to other nondestructive examinations.

F.

Weld reinforcement shall not exceed the following.

PLATE THICKNESS, INCHES

MAXIMUM HEIGHT OF REINFORCEMENT ABOVE PLATE SURFACE

3/8 inch or less Greater than 3/8 inch to 3/4 inch Greater than 3/4 inch

3/32" 1/8" 3/16"



ACCEPTANCE CRITERIA API 620 1.0

API 620, "DESIGN AND CONSTRUCTION OF LARGE WELDED LOW PRESSURE STORAGE TANKS" 1.1


All base materials shall be identified as to thickness, type, and grade (i.e., A53B, A516 GR70, etc.), and identified by the mill heat number. Prior to cutting, the heat number shall be transferred by steel stamping. On plates less than 1/4 inch thick steel stamping shall not be used. CMTR’s are required for plate material. Review drawing to determine if CVN testing is required.

B.


C.


D.

Welding filler materials shall be in accordance with the WPS. Tracing by AWS Classification, heat and let number to the weld joints is required for CVN applications.

E.


F.

Fit-up, shall be in accordance with the WPS except misalignment of butt welds shall not exceed 1/16” for <=1/4,” and 1/8 (or 25% plate thickness whichever is less) for plates over ¼”. Do not taper plate joints.

G.


H.

Tack welds in butt joints to be welded manually shall be removed before welding.

I.

Tack welds in lap and fillet welded joints need not be removed provided they are free of cracks, slag, porosity, lack of fusion, cold lap, and the ends prepared by grinding for incorporated into the next weld pass.

J.


K.


L.



2.0



Surface porosity does not exceed one cluster (one or more pores) in each 4 inches of length and the maximum diameter of each cluster or pore does not exceed 3/32 inch.

B.


C.

Undercut does not exceed: 1.

1/64 inch for longitudinal butt joints and for welds that attach nozzles, manholes, and clean out openings.

2.

1/32 inch for circumferential butt joints.

D.

No lack of fusion.

E.

No overlaps or abrupt ridges or valleys.

F.

No underfilled (weld cap) areas.

G.

Weld reinforcement (internal or external), where RT is not required, shall meet the following: PLATE THICKNESS (INCHES)

1/2 inch or less Over 1/2 inch to 1 inch Over 1 inch

MAXIMUM THICKNESS OF REINFORCEMENT (INCHES)

Vertical Joints 3/32 1/8 3/16

Horizontal Joints 1/8 3/16 1/4

H.

Where RT is required, weld reinforcement shall not exceed 1/16” for plates <=1/2”, 3/32” for plates over ½” through 1”, and 1/8” for plates over 1” thickness.

I.

Weld repairs shall be feathered to a 4:1 taper.



ACCEPTANCE CRITERIA API 650 1.0

API 650 "Welded Steel Tanks for Oil Storage" 1.1


All base materials shall be identified as to type and grade (i.e; A106B, SA516 G70, etc.) and identified by the mill heat number if CMTR’s are required by drawing or purchase order. Review drawing to determine if CVN testing is required (if so, CMTR’s are required).

B.

Joint preparation and cleanliness shall be in accordance with the WPS. Edges of Plates to be welded shall not be manually gas cut. Vertical joints shall be staggered a minimum of five times the plate thickness.

C.


D.

Welding filler materials shall be in accordance with the WPS. Tracing by AWS Classification heat and lot number to the weld joint is required for CVN applications. Low Hydrogen electrodes are required for SMAW when welding: 1.

Attachment of the first shell course to the bottom or annular plates.

2.

For shell courses over ½” thick made from material Groups I – III.

3.

For all welds, including temporary and permanent attachments, in shell courses made of material from Groups IV – VI.

E.


F.

Fit-up shall be in accordance with the WPS except misalignment of vertical butt-welds for plates over 5/8” shall not exceed the lesser of 1/8” or 10% of the plate thickness, and shall not exceed 1/16” for plates 5/8” or less. For horizontal butt joints, the upper plate shall not project over the lower plate by more than the lesser of 1/8” or 20% of the plate thickness for plates 5/16” and over. For plates under 5/16”, the projection shall not exceed 1/16”. Do not taper plate joints.

G.


H.

Tack welds in vertical butt joints to be manually welded shall be removed before welding.


1.2


I.

Tack welds in horizontal butt joints, lap and fillet welded joints need not be removed. Provided they are free of cracks, slag, porosity, lack of fusion, cold lap and the ends prepared by grinding for incorporation into the next weld pass.

J.


K.


L.



No porosity.

B.


C.


1/64 inch for vertical butt joints and for welds that attach nozzles, manholes, clean out openings and permanent attachment.

2.

1/32 inch for horizontal butt joints.

D.

Surface porosity does not exceed one cluster (one or more pores) in any 4 inches of length and the diameter of each cluster or pore does not exceed 3/32 inch.

E.

No lack of fusion.

F.

No under-filled (weld cap) areas.

G.

Weld reinforcement (internal or external) shall meet the following: PLATE THICKNESS (INCHES)

1/2 inch or less Over 1/2 inch to 1 inch Over 1 inch

MAXIMUM THICKNESS OF REINFORCEMENT (INCHES)

Vertical Joints 3/32 1/8 3/16

Horizontal Joints 1/8 3/16 1/4



H.

Where RT is required, weld reinforcement shall not exceed 1/16” for plates <= ½”, 3/32” for plates over ½” through 1”, and 1/8” for plates over 1” thickness.

I.

Areas where temporary attachments have been removed shall be ground smooth and visually inspected.

J.

Peaking at vertical joints and banding at horizontal joints shall not exceed ½” when using a 36” sweep board (for vertical joints, the sweep board must meet tank curvature).



ACCEPTANCE CRITERIA AWWA D100 1.0

AWWA D100 (identical to AWS D5.2) "Welded Steel Elevated Tanks, Standpipes, and Reservoirs for Water Storage" 1.1



B.

Joint preparation and cleanliness shall be in accordance with the WPS. Straight edges of plates to be welded shall not be manually cut with oxyfuel methods.

C.


D.


E.


F.

Fit-up shall be accordance with WPS except misalignment of vertical (and other primary stress joints) butt-welds for plates over 5/8” shall not exceed the lesser of ¼” or 10% of the plate thickness, and shall not exceed 1/16” for plates 5/8” or less. For horizontal (and other secondary stress joints) butt joints for plates over 5/8” shall not exceed the lesser of 3/8” or 20% of the plate thickness. And shall not exceed 1/8” for plates 5/8” and less. Do not taper plates.

G.

Tack welds shall be made by qualified welders and visually inspected.

H.

The separation between lap joints shall not be greater than 1/16 inch. Where separation occurs, the weld size shall be increased by the amount of separation.

I.


J.


K.



1.2



No cracks.

B.

No porosity.

C.


1/64 inch for vertical joints (lap or butt weld).

2.

1/32 inch for horizontal joints (lap or butt weld).

D.

No lack of fusion.

E.


F.

No underfilled (weld cap) areas.

G.

Weld reinforcement, internal and external, shall not exceed the following:

Plate Thickness (Inches) ½ inch and less Over 1/2/ inch to 1 inch Over 1 inch

Maximum Thickness of Reinforcement (Inches) Vertical Joints Horizontal Joints 3/32” 1/8” 1/8” 3/16” 3/16” 1/4”

H.

Welder’s identification shall be stamp (low stress stamps) adjacent to the weld at intervals not to exceed 3 feet or the constructor may supply a record of welders employed on each joint.

I.

Peaking at vertical joints and banding at horizontal joints shall not exceed ½” when using a 36” sweep board (for vertical joints, the sweep board must meet tank curvature).



ACCEPTANCE CRITERIA ANSI/AWS D1.1 / D1.6

1.0

ANSI/AWS D1.1, STRUCTURAL WELDING CODE-STEEL (STATICALLY LOADED) ANSI/AWS D1.6, STRUCTURAL WELDING CODE-STAINLESS STEEL (STATICALLY LOADED) 1.1

In process weld examination shall meet the following: A.

Joint preparation shall be in accordance with the WPS. Full and complete information regarding location, type, size, and extent of all welds shall be clearly shown on the drawings. The drawings shall clearly distinguish between shop and field welds.

B.

Fit-up, cleanliness and alignment of butt welds shall be in accordance with the WPS. Backing bar gap shall not exceed 1/6 inch.

C.

Fillet weld fit-up gap shall meet the WPS unless otherwise specified on the drawing. If the gap is greater than 1/16 inch, the leg of the fillet weld shall be increased by the amount of the root opening.

D.

Check welder qualification, filler material for conformance with the WPS.

E.

For butt welding parts of unequal thickness, the joint preparation shall provide for a transition at a taper not-to-exceed 1:2 1/2. Chamfering of the parts shall be a specified on the drawing, otherwise the taper shall be accomplished across the weld joint. Parts to be butt welded shall not exceed a mismatch of 10% of the thinner of the two members being joined, but in no case more than 1/8". In correcting misalignment, the parts shall be drawn in to a slope not greater than 1/2 inch in 12 inches. In addition, where the thicknesses of the two members being joined differ, the weld and/or base materials are to be tapered to a smooth transition with slop not-to-exceed 1 inch 2 1/2 inches.

F.

1.2


No porosity.

B.

No linear indications such as cracks, lack of fusion, cold laps.

C.

No slag or weld spatter (including base material).

D.

No craters except for ends of intermittent fillet welds outside their effective length.



E.

No under filled areas.

F.

Undercut: AWS D1.1 – For material less than 1” thick, undercut shall not exceed 1/32” except a maximum of 1/16’ is permitted for an accumulated length of 2” in any 12”. For material equal to or greater than 1’, undercut shall not exceed 1/16” for any length of weld. AWS D1.6 – For material less than 3/16”, undercut shall not exceed .010”. For material equal to 3/16” and less than 1”, undercut shall not exceed 1/32”. 1/16” undercut is permitted for an accumulated length of 2” in any 12” for material greater than ½’ thick.

G.

Butt weld reinforcement shall not exceed 1/8 inch.

H.

Convexity of a fillet weld shall not exceed .07 times the actual width, plus .06 inch.

I.

Any offset of outside surfaces shall be faired to a 1:2 1/2 taper over the width of the weld.

J.

In any single continuous fillet weld the actual size may be less than the specified size by not more than 1/16 inch provided that the undersize portion does not exceed 10 percent of the weld length. On web-to-flange welds on girders, no under-run is permitted at the ends for a length equal to twice the width of the flange. NOTE: Visual examination for A514 and A517 steels shall be performed not less than 48 hours after completion of the weld.



NUMBERING OF PIPE WELD JOINTS All pressure retaining welds and attachment welds to pressure piping shall be given a unique number which will serve to identify all data concerning the weld. 1.0

Field Welds - All pressure retaining piping welds and attachment welds shall be numbered. Upon receipt of the isometric drawings or layout piping plans, the Site Quality Manager shall (if possible) pre-number all field welds. If this pre-numbering proves impractical, the Welding Inspector shall assign weld numbers as the welds are made. A Log may be used to identify the weld numbers already assigned to ensure that no duplication of weld numbers occurs. Certain things need to be emphasized: Remember that it is of primary importance to assign a unique weld number to all field welding. Once this number is assigned, do not change it for any reason. Do not renumber isometrics to keep the weld numbers consecutive in the direction of flow. Use the next available number for any alterations or additional welds. If a portion of piping containing assigned welds is cut out of a system and discarded do not reuse these weld numbers but note on the isometric that these welds are void and show the new welds on the current isometric revision. Cut shop welds will be assigned field weld numbers. If the shop weld and mark piece can be identified, not this in the remarks portion of the Daily Welding Report. 1.1

SOCKET WELDS, HALF COUPLINGS, WELDOLETS (UNDER 2") All socket welds shall be numbered by isometric drawing. Each sheet shall start with weld 1 and be numbered with the flow. In the event that additional welds are added, use the next numbers not previously used on each sheet for the new welds. In this manner all socket welds will have a single digit or two digit weld number.

Half couplings and weldolets (under 2") shall also have a single digit or two digit weld number assigned by isometric drawing. In other works, the numbering of a series of half coupling on a header will be welds 1, 2, 3 etc. on the main header line number which shows these welds. The socket welds on lines running from these half couplings will be numbered as described above, for each line number. 1.2

BUTT WELDS, BRANCH CONNECTIONS (2" AND OVER), WELDOLETS (2" AND OVER) ETC. All butt welds, mitre welds, branch connections (2" and over), weldolets (2" and over) and slip-on flanges shall have a three digit weld number running consecutively throughout all lines contained in the modification. Each modification shall begin with weld 001 and numbered with the flow to the end of the line. Additional lines should continue with the next number and progress until all such welds are numbered. A log attached to the field welding isometric package should



readily identify the last weld number used. If additional welds are needed, the next unused numbers will be assigned and logged. On modifications where it is not practical to pre-number the welds, the next consecutive number, as determined by the log, shall be used as the welding progresses. 1.3

ATTACHMENT WELDS Attachment welds shall be numbered using the nearest (upstream) piping weld as a part of the weld number with the suffix "X1". In other words, a shoe welded between welds 021 and 022 will be numbered 021X1. Additional attachment welds in this area will be numbered 021X2 and 021X3, etc. In the common case of a reinforcing pad, all welds will refer to the field weld number joining the pipe-tobranch pipe. The pad-to-branch pipe weld will be "X1". In other words, the stub-in weld will be a three digit weld number, say 007, with the pad-to-branch pipe weld 007X1 and the pad-to-main pipe weld 007X2.

1.4

DOUBLE-JOINTED PIPE When straight run pipe is being double jointed on the ground, and it is not certain which line it belongs t, then use the prefix "DJ" before these field welds. Maintain a separate log of "DJ" welds that is unique to the "DJ" number using Exhibit 9-7R, Welding/NDE Status Log (Double Joints). In other words, there will only be on DJ1 on the entire job. Ensure each "DJ" weld is marked twice at 120 intervals. Weld maps shall accurately show the final location of all "DJ" welds. Each isometric drawing shall have Exhibit 9-6R, Welding/NDE Status Log, attached over the Bill of Material section. This log must be maintained on a daily basis as it will serve as a complete summary of all NDE/PWHT performed on that portion of the line. This information is essential when the time comes to provide NDE clearance for test packages.

2.0

Pipe Shop Welding - All welds on piping fabricated in the Site Pipe Shop shall be given a unique number by the Pipe Shop Supervisor prior to fabrication. All mark pieces shown on an isometric drawing shall be assigned consecutive numbers beginning with the lowest numbered mark piece and numbered with the flow until all shop welds on all mark pieces on the isometric have been identified. Any additional welds on any mark piece shall be given the next unassigned number on the isometric. In other words the first weld on the first mark piece will be "SW1" and continuing throughout all mark pieces on the isometric drawing. Thus the unit number, line number sheet number, mark piece number and weld number will constitute a unique weld identification as required. 2.1

Double Jointed Welds - All random length piping being welded by the Site Pipe Shop into double (or triple) lengths for ease in field erection shall be given a unique number. If the line number and line class are unknown at the time of fabrication these welds shall be given consecutive four digit weld numbers prefixed by "DJ". A



log shall be maintained by the Pipe Shop Supervisor of the "DJ" weld numbers used to prevent duplication of weld numbers. All "DJ" weld numbers shall be hard stamped or etched across the weld in two locations 120 degrees apart, 60 either side of the welders stamp. These "DJ" welds shall be radiographed 100 % and stockpiled for eventual use. These welds will be tracked as "Unassigned Welds" and transferred when the actual modification, line number and class are known. All random length piping being double (or triple) jointed in the Site Pipe Shop where the modification number, line number and line class are known at the time of fabrication shall be given consecutive three digit shop weld numbers beginning with SW100 and numbered consecutively within that particular modification. These welds will be subject to the normal shop weld NDE requirements and welder control based on the line class requirements. These weld numbers shall be hard stamped or etched as described above with the exception of "DJ" prefix which will be "SW" in this case. All random length piping double (or triple) jointed in the field for installation on a particular modification where the line number and line class are known shall be given consecutive field weld numbers within the modification. These numbers shall be hard stamped or etched by the Piping Supervisor for eventual location in the piping system. These welds shall be subject to the normal NDE and welder control for the line class at the time of production. 2.1.1

Piping Drawings All field welds on pressure piping (both pressure retaining and attachment welds) shall be accurately located on the isometric drawing (or plot plan). Since other records will show the welder and the date or production (Daily Welding Report, Line Welding and NDE Record) this information is not necessary to include on the drawing. Double joint ("DS") random length pipe welds shall be accurately shown on the isometric, rack, or plot plan drawings in relation to the field tie-in welds.


000 509 7920 18 Feb 04 Page 1 of 5

NONDESTRUCTIVE EXAMINATION SCOPE This procedure describes the activities and controls for performing nondestructive examination of weldments when specified by project requirements. Methods within the scope of this procedure include radiographic testing (RT), ultrasonic testing (UT), magnetic particle test (MT), liquid penetrant test (PT), positive material identification test (PMI) and hardness test (HT). RESPONSIBILITY - Self-Perform ACTIVITY

RESPONSIBILITY

DOCUMENTATION Report as specified in the approved NDE Procedure


Perform RT, UT, MT, PT, PMI, HT

NDE Coordinator

Technical Supervision of NDE

NDE Coordinator

_____

Selection for NDE and Status Maintenance

NDE Coordinator

Welds: 000 509 F79201 000 509 F79204 or NEWS program. Other than welds: 000 509 F79204

Coordinate Weld Repairs

Welding Specialist

_____

Each rejected weld

DOCUMENTATION


Per specifications _____

Per specifications

Responsibility - Subcontracted Work ACTIVITY

RESPONSIBILITY


Subcontractor

Technical Supervision of NDE

Subcontractor

Selection for NDE and Status Maintenance

NDE Coordinator (Note 1)

Coordinate Weld Repairs

Subcontractor

Surveillance NOTE 1:

Report as specified in the approved NDE Procedure _____ Welds: 000 509 F79201 000 509 F79204 or NEWS program. Other than welds: 000 509 F79204 _____

Per specification _____

Per specification

Each rejected weld

Daily during life of activity. This activity may be delegated to the Installation Subcontractor QC Inspector


000 509 F02201

Site Quality Manual


000 509 7920 18 Feb 04 Page 2 of 5

GENERAL •

Fluor personnel performing RT, UT, MT, PT, and PMI are to be qualified and certified to the requirements of NDE Practice 000 511 0101 "Certification of Nondestructive Examination Personnel". Personnel performing hardness tests must be trained in the use of the equipment and procedure but do not require certification.

•

Fluor self-performed NDE will be performed in accordance with the referenced NDE procedures.

•


•

-

Volumetric Nondestructive Tests should be completed and results reported within 24 hours after the welds are reported as complete. For special circumstances, such as the start of the welding program, or when the NDE Contractor does not have a jobsite laboratory, welds requiring radiography may be accumulated, but in these cases there should not be a backlog of more than ten (10) welds.

-

Other NDE methods should be completed as soon after the NDE request as practical.

Technical Supervision of NDE includes: -

•

The activities listed under Technical Supervision of procedure 000 509 0090 and activities listed under the NDE Coordinator responsibilities of 000 509 0040.

Weld Selection and Status Maintenance includes: -

Obtain a weld map (developed by 000 509 7910) and post the status of NDE for line classes requiring 100% NDE by a specific method or for individual welds requiring NDE by specification. Also post the status of welds that have been postweld heat treated. Alternately, Form 000 509 F79204 may also be kept for each isometric sheet. Either of these documents is to provide for accountability that all welds on the line were examined and accepted.

-

Using the "Daily Welding Report" and the Post Weld Heat Treatment Log (000 509 F79001 and F79002), select the welds for NDE as they are completed.

-

Examine the selected welds for surface contour that may interfere with the NDE method.

-

Notify the NDE Contractor or the inspector if self-performed, of the required NDE, by submission of a copy of the Nondestructive Examination Request/Record (000 509 F79202). Maintain the original to verify completion of NDE.


Site Quality Manual


•

000 509 7920 18 Feb 04 Page 3 of 5

-

Maintain a tickler file of rejected welds. The Site NDE Coordinator's copy of the NDE Report shall remain in the tickler file until the repair for that weld is noted as accepted on a subsequent report. At that time, the reports of the original and repaired weld and the radiographic film for both welds, shall all be placed together in the file. The acceptance date shall be logged on the isometric sheet or line sketch.

-

The data on F79202, Nondestructive Examination Request /Record, the NDE Reports (annotated with Fluor Site NDE Coordinator review) and the Radiographic film shall be traceable to the weld location shown on the spool drawing or pipeline sketch.

Selection of Welds under a random radiographic program includes: -

Select welds for random radiography to satisfy ASME B31 requirements from individual welder histories established on the "Welder B31.3 Random Radiography Control Log "Form 000 509 F79201. Welds to be radiographed for random radiography must be selected from sample lots established from the data on Form 000 509 F79201. For simplicity, it is suggested that sample lots be established as 20 welds for 5% radiography.

-

Select the first two welds made by a welder on a system requiring random radiography to confirm the welder's proficiency in production. These two production welds shall not be counted as part of the random radiography sample lot. This should be waived if other welds made by the welder were radiographed.

-

Identify the welds to be radiographed.

-

Notify the Foreman of the welds selected for radiography.

-

Log the radiographic examination results for random radiography on Form 000 509 F79201 "Welder B31.3 Random Radiography Control Log". Post the completed welds reported by the foreman, the date reported, and the results of radiography on the Weld Map. Notify the Foreman and Welding Specialist of the results.

-

For random radiography, when a weld is rejected, select two previous similar welds by the same welder, from a specified sample lot, for additional radiography, in compliance with ANSI B31.1. The selection shall be made from the welder's history on Form 000 509 F79201 "Welder B-31.3 Random Radiography Control Log. The welds are to be selected from the sample lot used to select the initial weld.

-

Selection of welds and maintenance of status can be performed using the computer program NEWS. In this case, the forms for manual weld tracking (000509-F79201 and F79204) do not need to be maintained. It is recommended that the NEWS program be used for projects with 200 or more joints to be radiographed.


Site Quality Manual


000 509 7920 18 Feb 04 Page 4 of 5

-

Issue periodic weld reject rate reports for welds examined by radiography using Form 000 509 F79203, "Radiographic Rejectable Defects Statistics". When statistical data indicates high or increasing reject rates, the Site Manager, the Welding Specialist, and the Quality Manager shall be informed. A copy of the weld reject rate reports should be sent to the Construction Technology Welding Engineer.

-

This section also applies if UT is substituted for RT.

NOTE: Informative RT shall not be performed on welds that have been capped out. •

Coordination of Weld Repairs includes: -

For those welds which have been rejected, determine the exact location, extent, and nature of the defect.

-

Consult with the welder and foreman on defect cause and prevention and repair technique.

-

When the weld has been repaired, have the weld reported on the "Daily Welding Report" to schedule radiography of the repair. Identify the repaired weld with the identification number previously assigned, except the subscript R1 shall be added after the designation. Subscripts shall designate subsequent repairs of the same welds, such as R2 and R3, until the weld is determined to be acceptable by examination.

ATTACHMENTS Attachment 1 – ASME B31.3 Random Radiography Requirements Reference FORMS Quality Control Forms: 000 509 F79201 000 509 F79202 000 509 F79203 000 509 F79204 000 509 F79205 000 509 F79001 000 509 F79002

-

Welder B31.3 Random Radiography Control Log Nondestructive Examination Request/Record Radiographic Rejectable Defects Statistics Welding/NDE Status Log Ferrite Test Report Daily Welding Report Post Weld Heat Treatment Log

Fluor Nondestructive Examination Procedures: Practice: 000 511 0101 Practice: 000 511 0104 Fluor Corporation Company Confidential

Certification of Nondestructive Examination Personnel Liquid Penetrant Examination of Weldments and Materials ASME Code (Visual Dye/Solvent Removable) Site Quality Manual


Practice: 000 511 0106 Practice: Practice: Practice: Practice:

000 511 0108 000 511 0109 000 511 0116 000 511 0117


000 509 7920 18 Feb 04 Page 5 of 5

Magnetic Particle Examination of Weldments and Materials (Dry Particles - Continuous Method) Radiographic Examination of Weldments Ultrasonic Examination Methods Positive Material Identification Testing using X-Ray Diffraction Hardness Testing of Weldments

Site Quality Manual



ASME B31.3 RANDOM RADIOGRAPHY REQUIREMENTS REFERENCE

If ACCEPTABLE, all welds in this welder's lot are considered to be acceptable Select weld from welder's lot of welds **

** Note: The first two pressure piping butt welds radiographed for each welder are not to be included in the welder's lot. Radiograph 4th Weld 2nd Weld Acceptable

Radiograph 5th Weld

3rd Weld Rejected

If EITHER of these welds are REJECTED, all welds by this welder in this lot shall be 100% Radiographed.*

Radiograph Weld Radiograph 2nd Weld

2nd Weld Rejected

Radiograph 3rd Weld

3rd Weld Acceptable

Radiograph 4th Weld Radiograph 5th Weld

If REJECTED, select two additional welds from same lot

If BOTH additional welds are acceptable, the balance of welds in this welder's lot are considered to be acceptable.

If BOTH additional welds are ACCEPTABLE, consider the balance of the welds in this lot to be acceptable.

2nd Weld Rejected

Radiograph 6th Weld

3rd Weld Rejected

Radiograph 7th Weld

If ALL FOUR of these welds are ACCEPTABLE, consider the balance of the welds in this lot to be acceptable.

If ANY of these four welds are REJECTED, all of the welds by this welder in this lot shall be 100% Radiographed.*

ALL REJECTED WELDS MUST BE REPAIRED OR REPLACED AS NECESSARY TO MEET APPLICABLE QUALITY *NOTE: WELDER MAY BE REQUIRED TO DEMONSTRATE HIS ABILITY TO PRODUCE WELDS QUALITY STANDARDS.


000 509 7930 18 Feb 04 Page 1 of 5

POSITIVE MATERIAL IDENTIFICATION EXAMINATION SCOPE This procedure describes the activities and controls for performing Positive Material Identification (PMI) examination of specified alloy and other special materials in accordance with the requirements of project specifications. RESPONSIBILITY – Materials Supplied by Fluor to Subcontractors ACTIVITY

RESPONSIBILITY Warehouse Manager/Supervisor

DOCUMENTATION

Receiving Inspection


_____

On-going

Perform PMI

Fluor NDE Coordinator/ Subcontractor

project specifications

Per Specification

Identification

Subcontractor

_____

On-going

Document Results

Fluor NDE Coordinator/ Subcontractor

Form 000 509 F79301 Form 000 509 F79302 Form 000 509 F79304

Each test

Technically Supervise PMI


_____

_____

Resolve Accept and Rejects



Per Rejects

Warehouse Receiving

FREQUENCY On-going

RESPONSIBILITY – Subcontractor Supplied Materials and Alloy Welds ACTIVITY

RESPONSIBILITY Subcontractor Quality Manager

DOCUMENTATION

FREQUENCY

_____

On-going

Perform PMI

NDE Subcontractor


Per Specification

PMI of Welds

Subcontractor Quality Manager


Per Specification

Identification

Subcontractor

_____

On-going

Document Results

Subcontractor

Form 000 509 F79301 Form 000 509 F79302 Form 000 509 F79304

Technically Supervise PMI


_____

_____

Resolve Accept and Rejects



Per Rejects

Receiving Inspection


Site Quality Manual


000 509 7930 18 Feb 04 Page 2 of 5

GENERAL •

Warehouse Receiving Inspection -

The Warehouse Supervisor shall be responsible for receiving inspection to confirm that all incoming alloy and special materials are received with the required positive material identification (PMI) performed, with PMI identification coding in place, and, when specified, with PMI documentation confirming identity verification conformance. (Note: material test reports do not satisfy the requirement for PMI documentation.)

-

Nonconforming items (alloy or special materials for which the required PMI has not been performed, items without the required PMI identification coding in place, and/or items without PMI documentation) shall be placed in a “Quarantine” area or tagged “Hold” until such time as the nonconformance is resolved. The Material Manager shall be responsible for obtaining disposition for incoming items found to be nonconforming. ¾ The Site Quality Manager shall be notified of any alloy or special materials identified at initial Warehouse Receiving as nonconforming. NOTE: Do Not release nonconforming or indeterminate materials, components, or equipment for use in the facilities being constructed.

•

-

Provide notification to the NDE Coordinator when alloy or special materials are received at the construction site.

-

Request PMI analysis for alloy and special materials received at warehouse by notification to the NDE Coordinator.

-

Provide an area in the warehouse for receiving inspection.

-

Palletize piping components or other small items for Receiving Inspection and place in a “Hold” area.

-

Identify the location of alloy pipe, plate, or large fabrication and equipment items that have been received and require Receiving Inspection confirmation of prior PMI.

Subcontractor Receiving Inspection Each Subcontractor is responsible to ensure that all items supplied to him by Fluor or the subcontractor’s own vendors/suppliers meets the requirements of the project specifications. Nonconforming items (alloys for which the required PMI has not been performed, items without the required PMI identification coding in place, and/or items without PMI documentation) shall be placed in a “Quarantine” area until such time as the nonconformance is resolved. The Subcontractor Quality Manager shall be responsible for obtaining disposition for incoming items found to be nonconforming.


Site Quality Manual


•

000 509 7930 18 Feb 04 Page 3 of 5

Perform Positive Material Identification -

PMI will be performed by trained personnel whose ability to successfully operate the PMI test equipment has been documented by test.

-

Non-destructive methods used for PMI testing shall be capable of identifying the material quantitatively. Acceptable test equipment for non-destructive PMI testing is listed below: Portable x-ray fluorescence analyzers. Use is limited to the following instruments or their equivalents unless Fluor Engineer gives prior approval. The Engineer may designate another instrument as equivalent based on demonstrated and documented performance testing. TN Technologies Alloy Analyzer 9266, 9277 (The metallurgist XR) or Metallurgist Pro. Metorex – X-MET 880, X-MET 960 or X-MET 2000. Portable optical emission analyzers. Use is limited to the following instruments or their equivalent unless Fluor Engineer gives prior approval. Care shall be taken not to damage critical surfaces (e.g., bearings) when using optical emission analyzers. SpectroPORT Model TP-07 or TFO-02, Specto Test F. Metroex ARC-MET 900 or ARC-MET 930.

•

PMI of Alloy Piping -

•

Extent of PMI shall be per the project specifications.

All field installed alloy piping will be 100% PMI verified in the “as installed” position. Each spool and the weld will be verified and results documented on the fabrication spool drawing/isometric, listed on the PMI point sheet and marked with the appropriate verification color by the PMI Technician as each point is analyzed. See Attachment 1 for complete instruction.

PMI of Welding Wire (Bare) -

Bare wire shall be purchased in unopened manufacturer’s containers.

-

Each container must have the AWS Classification, heat and lot number clearly marked.

-

Filler metal certification is required.


Site Quality Manual


•

•

-

The greatest of 5% or 5 pieces of welding wire shall be PMI checked from each container.

-

Coated electrodes do not require PMI checks prior to use. Deposited filler metal (SMAW) must be PMI checked in the “as welded” condition.

Identification -

Each item (pipe spool, plate, weld, fitting, valve, etc.) that has been verified shall be marked using project specifications (See Attachment 2).

-

Items which cannot accommodate this identification shall be individually tagged with the above.

-

Paints/Markers used for applying color code for PMIV are controlled by the Site Quality Manager.

-

Each fabricated spool must have verification marks applied to each component and weld by the PMI Technician.

-

Pipe and fittings should be painted with a stripe that is parallel with the axis of the pipe.

-

Welds should be marked along their circumference perpendicular to the axis of the pipe so that the verification markings will be visible when the pipe spool is installed.

-

Small connections and short branches should be painted through their entire length.

Document Results -

•

•

000 509 7930 18 Feb 04 Page 4 of 5

Document PMI test results on the appropriate Positive Material Identification (PMI) Inspection Reports Form 000 590 F79301, F79302 or F79303.

Technically Supervise PMI will include: -

Ensuring that only properly trained personnel conduct PMI testing in accordance with a procedure which has been reviewed and approved by the Fluor NDE Level III.

-

The Site Quality Manager shall have overall responsibilities for the implementation of this PMI Program.

Verification of PMI -

A Fluor Quality Representative must witness initial calibration/standardization of the PMI equipment at the start of each work period and observe PMI testing randomly during the work period to assure compliance with this procedure. A Fluor Quality Representative must witness a minimum of 5% of all PMI testing randomly during the work period.


Site Quality Manual


-

•

000 509 7930 18 Feb 04 Page 5 of 5

These observations must be noted on the PMI isometrics by initialing and dating the drawing and listing test points that are witnessed by the Fluor Quality Representative. A Weekly PMI log, Form 000 509 F79304 will be maintained by the Fluor Quality Representative to verify the percentage of PMI testing observed.

Resolved Accept and Rejects -

If the PMI test results fall outside of the acceptable ranges, the item will be rejected.

-

All rejected materials shall be isolated in a "Quarantine" area, tagged "REJECTED", and a Nonconformance Report initiated.

-

When an item from a representative sample is rejected: a) 100% of the remaining components from which the sample was taken shall be examined. b) 100% of the components from the next two lots shall be examined. c) If no further components are rejected in a) or b), above, the extent of examination shall return to that specified in project specifications. Rejected items shall be returned to the original source of supply at no cost to the Fluor.

REFERENCES Quality Control Forms: 000 509 F79301 000 509 F79302 000 509 F79303 000 509 F79304

-

PMI Inspection Record Bulk Material Positive Material Identification Record Pipe Spool Positive Material Identification Record “Point” Sheet Weekly PMI Log

ATTACHMENTS Attachment 1 Attachment 2

PMI Procedure for the Field Color Code for Metal Identification

Project Specifications: 000 285 85010 – General Specification for Positive Material Identification (PMI)


Site Quality Manual



PMI Procedure for the Field 1.0

Piping:

(a)

PMI Verification is dependent on the ability of Inspection to see the verification marking on each component and to compare visual verification with the listing of each component on a point sheet and spool drawing or field/shop isometric.

(b)

These “point sheets” must be signed by the PMI technician who performed the tests and a Fluor Quality Representative.

(c)

The verification marking should be a color that is not associated with other activities, (i.e. material color code, dismantling, blinding, etc.).

(d)

Attachment 2 has designated colors to be used as verification markings on the most widely used alloys. These colors shall be listed in the PMI plan as per this attachment. In cases where an alloy is to be used that is not listed in Attachment 2, the alloy should be assigned a pre-determined color and included in the PMI plan as such.

(e)

All PMI locations must have PMI verification color markings and the PMI Technician must apply the markings at the time of actual PMI testing. Each component should be marked with a ½” dot of the appropriate color marking.

(f)

The markers used for PMIV are controlled by the Site Quality Manager and shall not be issued for any other application. The Site Quality Manager representative will issue them to the PMI technician at the fabrication facility or job site.

1.1

All fabricated alloy spools shall be PMI checked at the time of receipt.

1.2

PMI shall be performed at the, job-site or designated lay-down area by a qualified PMI Technician under the direct supervision of an the Site Quality Manager.

1.3

Each check must be sequentially recorded, as each point is analyzed, not after the fact. The procedure for PMI should be as follows: 1. 2. 3.

4. 5. 6.

Obtain or make the drawing. Make the point sheet. Compare the drawing to point sheet while performing PMI to verify all components are listed. (If the PMI technician finds a point not listed on the point sheet, he should PMI the point and list it on the bottom of the point sheet as a sub-listing of the previous point. Example: a weld between points 5 and 6 would be numbered 5a). PMI the component and record results on the point sheet. Color-code the component. Repeat sequentially for the next component.



2.0

Drawings:

2.1

Shop spool drawings of field isometric drawings must indicate all components.

2.2

The spool drawings, isometrics and point sheets must be signed off as follows: 1. 2. 3. 4. 5.

PMI Company PMI Technician name in print and date PMI Technician signature Site Quality Representative name in print and date Site Quality Mechanical Representative signature

2.3

Any alteration of shop spools must be noted on as-built shop spool drawings or isometrics and this information must be recorded on the primary point sheet.

2.4

Completed spool drawings, isometrics and point sheets must be attached to Inspection isometrics.

3.0

Number of PMI points for Piping Welds:

3.1

Welds requiring PMI shall be inspected according to the following: 1. 2. 3. 4. 5.

Automated welding---one sample from each girth or long seam. Manual welding---one sample from each girth seam < 24 in. diameter. Manual welding---two samples from each girth seam equal to or > 24 in. diameter. Autogenous welded pipe and fittings---PMI verification of base metal only. Semi-automatic welding in the 1 G (rotated) position---one sample from each girth seam.

4.0

Ring Joint Gaskets:

4.1

Ring joint gaskets (alloy) must be PMI tested and marked prior to installation.

4.2

The PMI Technician should place a single ¼” diameter paint mark on each ring adjacent to the alloy designation of the ring gasket.

4.3

All ring joint gaskets must be checked out of the designated holding facility by the piping job supervisor or foreman.

4.4

PMI Verification will be dependent upon the placement of the ring gasket in the flange so that the Inspector can see the paint marking and the alloy designator for the ring.

5.0

Valves:

5.1

All alloy valves will be PMI tested in two (2) locations (Valve body and Bonnet).

5.2

The PMI Technician will mark each location with the designated verification color.



6.0

Welding Wire (Bare):

6.1

Bare wire shall be purchased in unopened manufacturer’s containers.

6.2

Each container must have the AWS Classification, heat and lot number clearly marked.

6.3

Filler metal certification is required.

6.4

The greatest of 5% or 5 pieces of welding wire shall be PMI checked from each container.

6.5

Coated electrodes do not require PMI checks prior to use. Deposited filler metal (SMAW) must be PMI checked in the as welded condition.

7.0

Non-Conformances:

7.1

If there is a component in a PMI system that does not meet the necessary chemistry, that component must be flagged with a color of flagging tape that does not conflict with other colors designated for NDE or PWHT. The PMI Technician must inform the Site Quality Manager immediately of any non-conformances and these must be corrected by the fabricator/erector as a matter of priority.

8.0

Verification/Audit of PMI Procedure The Site Quality Representative must witness initial calibration/standardization of the PMI equipment at the start of each work period and observe PMI testing randomly during the work period to assure compliance with this procedure. These observations must be noted on the PMI point sheets by initialing the test points that are witnessed by the Site Quality Representative. The Site Quality Representative during the PMI operation must witness a minimum of 5% of all PMI testing. A weekly log will be maintained by the Site Quality Representative to verify the percentage of PMI testing observed.



COLOR CODE FOR METAL IDENTIFICATION

SINGLE STRIPE MAGNETIC METALS

COLOR

DOUBLE OR BROKEN STRIPE NONMAGNETIC METALS

Plain Carbon Steel

None

Aluminum - All Grades

Carbon Steel for LowTemperature Service (Below 20°F)

Yellow

Type 304 (18 Cr - 8 Ni)

Carbon-Moly Steel

White

Type 316 (16 Cr - 10 Ni- 3 Mo)

AISI 4140 Steel

Red

Alloy 20 (20 Cr - 29 Ni)

1-1/4 Cr - 1/2 Mo steel, B-16 Studs

Gray

Red Brass (85 Cu - 15 Zn)

2-1/4 Cr - 1/2 Mo steel

Orange

Incoloy 800 (20 Cr -32 Ni) R.A. 330 (19 Cr -35 Ni - 1-1/4 Si)

5 Cr - 1/2 Mo steel

Green

Type 304-L, Low-Carbon (16 Cr - 10 Ni - 3 Mo)

9 Cr - 1 Mo

Purple

Type 316-L Low Carbon (16 Cr - 10 Ni - 3 Mo)

12 Cr - 2 Mo Steel, Type 410S, 405

Black

Hastelloy "B: (65 Ni - 30 Mo)

17 Cr Steel, Type 430

Pink

Inconel 600 (72 Ni - 15 Cr)

3-1/2 Ni Steel

Blue

Monel (67 Ni - 30 Cu)

Ductile, Nodular Iron

Brown

Hastelloy "C" (60 Ni - 15 Cr - 17 Mo)


000 509 7950 18 Feb 04 Page 1 of 2

HARDNESS TESTING SCOPE This procedure describes the functions to be performed in the performance of hardness testing. RESPONSIBILITIES ACTIVITY

RESPONSIBILITY

DOCUMENTATION


Review Job Specification for Hardness Testing Requirements



Hardness Testing Equipment



Personnel Training & Vision Test


Preparation of Surface to be Tested

Piping Superintendent

Perform Hardness Testing & Report Results

QC Inspector/NDE Technician

000 509 F79501

Yearly or each applic.

000 509 F79502

Yearly Each test location

000-509-F79503

As required by code or specification

PROCEDURE •

Review Job Specification for Hardness Testing Requirements -

•

Hardness Testing Equipment -

•

Obtain a copy of the Code/Job Specification requirements prior to the start of work.

Obtain the hardness testing equipment required or contract with a supplier of hardness testing services.

Personnel Training & Vision Test Assure that the personnel performing the hardness testing have been trained in the use of the equipment or have used the equipment within one (1) year and have a current vision test (Jaeger 2 at 12 inches minimum within one (1) year).

•

Preparation of the Surface to be Tested -

Assure that the surface to be tested is buffed/filed to a relatively flat smooth texture to avoid erroneous measurements which may result from a coarse surface. Care must also be taken to assure that any grinding or other mechanical working does not generate sufficient heat to affect the material hardness.


Site Quality Manual


•

000 509 7950 18 Feb 04 Page 2 of 2

Perform Hardness Testing & Report Results -

Perform the hardness testing in accordance with the equipment manufacturer's written procedure as required by the code or job specification. For hardness testing in the weld heat affected zone (HAZ), the test instrument indenter shall not be greater than three (3) millimeters across the tip.

-

Report hardness testing results. For local hardness testing on welded joints, three tests shall be conducted at each location required by code or job specification. Each reading shall be reported and the average for the three shall be computed and reported on Form 000 509 F79503.

FORMS Quality Control Forms: 000 509 F79501 000 509 F79502 000 509 F79503 -


Verification of Training For Hardness Testing Report of Vision Test Hardness Testing Report

Site Quality Manual


000 509 F0000 20 Sep 04 Page 1 of 8

FORMS INDEX Form Number 000 509 F00501 000 509 F00502

Form Title

Revision Date 18 Feb 04 18 Feb 04

Request For Information Request For Information Log

000 509 F01101 000 509 F01102 000 509 F01103 000 509 F01104

Calibration Assignment Log and Record I.M.T.E. Sign In/Out History of Use Log Calibrations Tickler File Calibration Data Sheet

18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04

000 509 F01301 000 509 F01302 000 509 F01303

Nonconformance Report Nonconformance Report Log Hold Tag/Sticker

18 Feb 04 18 Feb 04 18 Feb 04

000 509 F01401 000 509 F01402

Corrective Action Report Corrective Action Status Log

18 Feb 04 18 Feb 04

000 509 F01501

Preventive Action Log

18 Feb 04

000 509 F01601

Quality Records Control

18 Feb 04

000 509 F01701 000 509 F01702

Audit Finding Audit Summary

18 Feb 04 18 Feb 04

000 509 F01801

Project Specific Quality Training

18 Feb 04

000 509 F02001 000 509 F02002 000 509 F02003 000 509 F02004 000 509 F02005 000 509 F02006

Site Subcontractor Qualification Soil Testing Laboratory Evaluation Record Asphalt Testing Laboratory Evaluation Record Concrete Batch Plant Evaluation Record Concrete Testing Laboratory Evaluation Record NDE Subcontractor Evaluation Record

18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04

000 509 F02201 000 509 F02202

Surveillance Report Surveillance Report Log

18 Feb 04 18 Feb 04

000 509 F02301

Receiving Inspection Checklist

18 Feb 04

000 509 F02401 000 509 F02402 000 509 F02403 000 509 F02404 000 509 F02405 000 509 F02406

Transfer of Care, Custody and Control (Turnover Notice) System Walkdown Notice Mechanical Completion Civil Checklist Mechanical Completion Electrical/Instrumentation Checklist Mechanical Completion/Mechanical Checklist Mechanical Completion/Quality Control Checklist



000 509 F0000 20 Sep 04 Page 2 of 8

Form Number 000 509 F02407 000 509 F02408 000 509 F02409

Form Title Master Punch List Record Interim Turnover Notice Mechanical Completion Certificate

000 509 F02501 000 509 F02502

Storage Inspection Checklist Equipment Protection Preservation and Inspection Record

18 Feb 04 18 Feb 04

000 509 F70001 000 509 F70002

Inspection and Test Plan Inspection and Test Plan

18 Feb 04 18 Feb 04

000 509 F70101 000 509 F70102

18 Feb 04 18 Feb 04

000 509 F70104 000 509 F70105

Soil Inspection Checklist Field Compaction Test Record Density of Soil Place by the Sand-Cone Method ASTM D1566 AASHTO-T-191 Nuclear Moisture-Density Test Report Soil Density Test Log

000 509 F70201 000 509 F70202 000 509 F70203 000 509 F70204

Bituminous Concrete Paving Inspection Checklist Bulk Specific Gravity Bituminous Concrete Compaction Nuclear Density Test Report – Bituminous Concrete

18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04

000 509 F70301 000 509 F70302 000 509 F70303

Pile Driving Inspection Record Pile Driving Record Record of Pile Driving

18 Feb 04 18 Feb 04 18 Feb 04

000 509 F70801

Caisson Inspection Record

18 Feb 04

000 509 F70901

Augered Cast-In-Place Pile Record

18 Feb 04

000 509 F71001 000 509 F71002 000 509 F71003 000 509 F71004 000 509 F71005 000 509 F71006 000 509 F71007 000 509 F71008 000 509 F71009 000 509 F71010

Pre-Concrete Inspection Checklist Concrete Inspection Record Concrete Pour Card Cementitious Grout Inspection Record Cementitious Grout Testing Record Epoxy Resin Grout Inspection Record Concrete Compression Strength Test Record Concrete Placement Log Grout Placement Log Concrete Batch Plant Inspection Record

18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04

000 509 F72002 000 509 F72003

Structural Steel Inspection Torque Wrench Calibration Log

18 Feb 04 18 Feb 04

000 509 F70103

Revision Date 18 Feb 04 18 Feb 04 18 Feb 04

18 Feb 04 18 Feb 04 18 Feb 04


000 509 F0000 20 Sep 04 Page 3 of 8

Form Number 000 509 F73001 000 509 F73002 000 509 F73003 000 509 F73004 000 509 F73005 000 509 F73006 000 509 F73007 000 509 F73008 000 509 F73009 000 509 F73010 000 509 F73011 000 509 F73012 000 509 F73013 000 509 F73014 000 509 F73015 000 509 F73016

Form Title Building Inspection and Test Checklist Final Building Inspection Summary Carpentry Checklist Painting Checklist Plumbing Checklist Ceramic Tile Checklist Concrete Checklist Structural Steel Checklist Masonry (Brickwork) Checklist Plaster Checklist Doors, Windows, Hardware, Glazing Checklist Computer (Raised) Floors Checklist Prefab Wall Element Systems Checklist Building Metal Siding And Roofing Checklist Buildings Water Proofing And Damp Proofing Checklist Suspended Ceiling Checklist

Revision Date 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04

000 509 F73101 000 509 F73102

HVAC Inspection Record Buildings Air Conditioning Checklist

18 Feb 04 18 Feb 04

000 509 F73201

Roofing Inspection Checklist

18 Feb 04

000 509 F74001 000 509 F74002 000 509 F74003 000 509 F74004 000 509 F74005 000 509 F74006 000 509 F74007 000 509 F74008 000 509 F74009 000 509 F74010 000 509 F74011 000 509 F74012 000 509 F74013 000 509 F74014 000 509 F74015 000 509 F74016 000 509 F74017 000 509 F74018 000 509 F74019 000 509 F74020

Equipment Installation Checklist Heat Exchangers & Reboilers Installation Record Electrostatic Precipitator Checklist Inspection Record Static Equipment Tray Installation Inspection Record Air Cooled Heat Exchanger Inspection Checklist Air Cooler Run In Test Report Reciprocating Compressor Inspection Record Fan Installation Inspection Checklist Furnaces Inspection Record Fuel Gas Steam Generator Inspection Checklist Steam Turbine Inspection Checklist Agitators/Mixers Inspection Checklist Equipment/Piping Strain and Alignment Inspection Form Installation Checklist Travelling Cranes Package Equipment Installation Checklist Desuperheaters/Ejectors Inspection Checklist Filters/Strainers Installation Record Centrifugal Compressor Inspection Record Rotating Equipment Inspection Record

18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04


000 509 F0000 20 Sep 04 Page 4 of 8

Form Number 000 509 F74021 000 509 F74022 000 509 F74024 000 509 F74025 000 509 F74026 000 509 F74027 000 509 F74028 000 509 F74029 000 509 F74030 000 509 F74031 000 509 F74032

Form Title Rotating Equipment Alignment Record Belt Driven Equipment Alignment Record Inspection Record For Draw Off Tray Leak Test Report Inspection Record For Air Coolers Final Closing Authorization Record API 686 Baseplate Installation Checklist (Prior to Grouting) API 686 Equipment Grouting Checklist API 686 Alignment Check Sheet Baseplate Leveling Record Reverse Dial Alignment Record Piping Alignment Data Sheet

Revision Date 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04

000 509 F74101 000 509 F74102 000 509 F74103 000 509 F74104 000 509 F74105 000 509 F74106

Tank Elevation Tolerances Record Inspection Record Field Erected Tank Tank Plate Dimensional Control Record Field Erected Tank Water Filling And Settlement Record Field Erected Tank Tank Leak Test Record Tank Test Certificate


000 509 F74201

Inspection Record Cooling Tower

18 Feb 04

000 509 F74301

Field Installed Refactory Record

18 Feb 04

000 509 F74401 000 509 F74402 000 509 F74405 000 509 F74406 000 509 F74407 000 509F74408

Gas Turbine/Generator Gear Inspection Checklist Gas Turbine Inspection Record Shop-Fabricated Field-Erected Stack Inspection Record Heat Recovery Steam Generator Inspection Record Breeching And Duct Work Inspection Record Equipment Protection Activities Record – Gas Turbines


000 509 F74601 000 509 F74602 000 509 F74603 000 509 F74604 000 509 F74605 000 509 F74606 000 509 F74607 000 509 F74608 000 509 F74609

Site Daily Activities Log Stg Foundation Settlement Record Stg Fixators Stg Sole Plates Stg Front Standard Base Plate Assembly Exhaust Hood Horizontal Joint Levelness Stg Shell/Casing Load Test Stg Piping Attachment Stg Foundation Top of Concrete Elevations

18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04

000 509 F74701 000 509 F74702

Generator Test Checklist Generator Cold Resistance Test Record

18 Feb 04 18 Feb 04


Form Number 000 509 F75001

000 509 F0000 20 Sep 04 Page 5 of 8

000 509 F75003

Form Title Underground Pipe Inspection Record Insulation Resistance (Insulated Flanges-Underground Piping) Test Record Holiday (Spark) Test Record

000 509 F75101 000 509 F75102 000 509 F75103

Aboveground Pipe Inspection Record Visual Inspection of Flanges, Gaskets and Bolting Weld Map Record

18 Feb 04 18 Feb 04 18 Feb 04

000 509 F75201

Pressure Test Report

18 Feb 04

000 509 F75501 000 509 F75502 000 509 F75503 000 509 F75504 000 509 F75505 000 509 F75506 000 509 F75507 000 509 F75508 000 509 F75509

Hygienic Drawing Revision Log Hygienic Material Receiving Log Hygienic Valve Receiving Inspection Report Hygienic Vessel Nozzle Receiving Inspection Report Hygienic Tube/Fitting Receiving Inspection Report Hygienic Pre-weld Inspection Checklist Hygienic Welder Qualification Report Hygienic Orbital Weld Log Hygienic Post Installation Checklist

18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04

000 509 F75601

Pipe Cleaning and Verification Checklist

18 Feb 04

000 509 F75701

Mechanical Heat Tracing Inspection Record

18 Feb 04

000 509 F76001 000 509 F76002

Conduit And Cable Tray Checklist Electrical Manhole Inspection Checklist Medium & High Voltage Underground Cable Splice Inspection Record Medium and High Voltage Cable Termination Checklist Cable Pulling Inspection Checklist Fan/Speed Reducer/Motor Inspection Checklist Switch House Inspection Checklist Lighting Receptacle, Instrument Distribution Panels Inspection Checklist Electrical Motor Inspection Checklist Aboveground Conduit Inspection Checklist Lighting Panelboard Inspection Record Underground Conduit (Duct Bank) Inspection Grounding/Earthing System (Grid or Loop) Inspection Record

18 Feb 04 18 Feb 04

000 509 F75002

000 509 F76003 000 509 F76004 000 509 F76005 000 509 F76006 000 509 F76007 000 509 F76008 000 509 F76009 000 509 F76010 000 509 F76011 000 509 F76012 000 509 F76013 000 509 F76101

Grounding/Earthing Resistance Reading (Resistance-to-Earth and Loop Continuity) Test Record


18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04


Form Number

000 509 F0000 20 Sep 04 Page 6 of 8

000 509 F76128 000 509 F76129 000 509 F76130 000 509 F76131 000 509 F76132 000 509 F76133 000 509 F76134 000 509 F76135

Form Title Insulation Resistance (Power, Control Wire And Cable) Test Record Insulation Resistance (Instrument Wire And Cable) Test Record DC High Potential Test (Medium Voltage Cable) Record Current Transformer (And Ammeter) Test Record LV Over-current And Earth/Ground-Fault Protection Relay Test Over-current/Ground Fault Protection Relay (Induction Type) Test Over-current/Ground Fault Protection Relay (Thermal Type) Test Switching Units HV Switchgear Inspection And Test Record Ground Electrode Resistance Inspection Test Record Ground Fault Protection Relay Induction Inspection and Test Record Grounding Continuity Inspection and Test Record Grounding Rod Inspection and Test Record Bus Bar Assemblies LV Switchgear Test Record Neutral Grounding/Earthing Resistor Test Record Ground Continuity (Non Electrical) Equipment/Structures Test Record Ground Continuity (Electrical Equipment and Ground Test Bars) Test Record Insulation Resistance (Equipment) Test Record Insulation Resistance (Transformer) Test Record Liquid Dielectric Strength Test Record DC Proof Test Record for Motors Feeder Breaker (480V MCC) Test Record Breaker/Contractor (480V MCC) Test Record 460V Motor Circuit (480V MCC) Test Record Medium Voltage Motor Circuit Test Record Equipment Absorption Ration and Polarization Index Test Record (Megger) Insulation Resistance (Medium Voltage Power Cables) Test Record Bus Throat Insulation and Ductor Reports Circuit Breaker Contract Timing Test Report Vacuum Circuit Breaker Ductor Insulation Report Drawout Vacuum Breaker Inspection Test Main Bus Insulation and Ductor Report Electric Motor Run-In Test Record Drawout Air Circuit Breaker Inspection Record Insulation Resistance (Rotating Equipment) Test Record

000 509 F76201

Emergency Generators Inspection Checklist

000 509 F76102 000 509 F76103 000 509 F76104 000 509 F76105 000 509 F76106 000 509 F76107 000 509 F76108 000 509 F76109 000 509 F76110 000 509 F76111 000 509 F76112 000 509 F76113 000 509 F76114 000 509 F76115 000 509 F76116 000 509 F76117 000 509 F76118 000 509 F76119 000 509 F76120 000 509 F76121 000 509 F76122 000 509 F76123 000 509 F76124 000 509 F76125 000 509 F76126 000 509 F76127

Revision Date 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04


Form Number

000 509 F0000 20 Sep 04 Page 7 of 8

000 509 F76227 000 509 F76228 000 509 F76229 000 509 F76230 000 509 F76231

Form Title Inspection of Switchgear Bus-Bar Continuity (Including Incoming and Sectionalizer Units) Inspection LV Switchgear (Including Incoming and Sectionalizer Units) Inspection of Outgoing – LV Switchgear Inspection of Static Supply Unit (UPS) Motor Control Centers Inspection Checklist Motor Control Centers (Motors and Starters) Inspection Record High Voltage Motors and Starters Motors Checklist Control and Relay Panels Inspection Checklist Electronic Equipment Inspection Checklist Power Panel Inspection Checklist Switchgear Inspection Checklist Low Voltage Feeders Inspection Record High Voltage Cable Inspection and Test Record Electrical Equipment Inspection Record Control Scheme Inspection Checklist Power Transformer Inspection Checklist Switching Units – HV Switchgear Inspection and Test Record Switching Units – HV Switchgear Inspection Checklist Liquid – Filled Transformer Inspection Record Busway Inspection Record Switchgear Inspection Record Motor Control Center Inspection Record Battery and Battery Charger Inspection Record Liquid Immersed Medium Voltage Disconnect Switch Inspection Record Electric Motor – Electrical Activities Inspection Record Electric Motor – Mechanical Activities Inspection Record Electric Motor for Compressor Installation Checklist Compressor Vibration Checklist Vibration Probe Record

000 509 F76401 000 509 F76402

Heat Trace Test Log Electrical Heat Trace Inspection Record

18 Feb 04 18 Feb 04

000 509 F77001 000 509 F77002 000 509 F77003 000 509 F77004 000 509 F77005 000 509 F77006

Instrumentation Inspection Checklist Instrument Loop Check Sheet Impulse Line Pressure Test Sheet Instrument Grounding System Check Sheet Installation Check Sheet (Local Instruments) Orifice Plate Specification Check Report


000 509 F76202 000 509 F76203 000 509 F76204 000 509 F76205 000 509 F76206 000 509 F76207 000 509 F76208 000 509 F76209 000 509 F76210 000 509 F76211 000 509 F76212 000 509 F76213 000 509 F76214 000 509 F76215 000 509 F76216 000 509 F76217 000 509 F76218 000 509 F76219 000 509 F76220 000 509 F76221 000 509 F76222 000 509 F76223 000 509 F76224 000 509 F76225 000 509 F76226

Revision Date 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04


000 509 F0000 20 Sep 04 Page 8 of 8

Form Number 000 509 F77101 000 509 F77102 000 509 F77103

Form Title Instrument Loop Check Sheet Safety Valve Tracking Sheet Relief Valve Inspection and Final Acceptance


000 509 F78001 000 509 F78002

Coating Inspection Record Lining Inspection Record

18 Feb 04 18 Feb 04

000 509 F78101 000 509 F78102

Equipment Thermal Insulation Inspection Piping Thermal Insulation Record

18 Feb 04 18 Feb 04

000 509 F78201 000 509 F78202

Release For Application/Inspection Of Fireproofing Checklist Fireproofing Inspection Preconstruction Checklist

18 Feb 04 18 Feb 04

000 509 F78301

Cathodic Protection Inspection Report

20 Sep 04

000 509 F79001 000 509 F79002

Daily Welding Report Post Weld Heat Treatment Log

18 Feb 04 18 Feb 04

000 509 F79201 000 509 F79202 000 509 F79203 000 509 F79204 000 509 F79205

Welder B31.3 Random Radiography Control Log Nondestructive Examination Request/Record Radiographic Rejectable Defects Statistics Welding/NDE Status Log Ferrite Test Report

18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04

000 509 F79301 000 509 F79302 000 509 F79303 000 509 F79304

PMI Inspection Record Bulk Material Positive Material Identification Record Pipe Spool Positive Material Identification Record “Point” Sheet Weekly PMI Log

18 Feb 04 18 Feb 04 18 Feb 04 18 Feb 04

000 509 F79501 000 509 F79502 000 509 F79503

Verification Of Training For Hardness Testing Report Of Vision Test Hardness Testing Report

18 Feb 04 18 Feb 04 18 Feb 04

Site Quality Manual

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