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SITE QUALITY

MANUAL
EFFECTIVE DATE:
REVISION
NO.
DESCRIPTION
APPROVALS
(Signature)
DATE
Site Quality Manager
Construction Engineering Manger
Site Manager
0 Issued for Construction
Client Approval
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: 000 509 0000
Contract No.: 20 Sep 04
Project Location: Page 1 of 2


Fluor Corporation Company Confidential Site Quality Manual

TABLE OF CONTENTS / DATE REVISION PAGE


Administrative
Procedure No.
Title
Revision
Date

000 509 0000 Table of Contents / Date Revision Page 20 Sep 04
000 509 0010 Foreword 18 Feb 04
000 509 0020 Manual Preparation and Maintenance 18 Feb 04
000 509 0040 Organization and Responsibilities 18 Feb 04
000 509 0050 Document Control 18 Feb 04
000 509 0090 Process Control 18 Feb 04
000 509 0110 Inspection, Measuring and Test Equipment 18 Feb 04
000 509 0130 Control of Nonconformances 18 Feb 04
000 509 0140 Corrective Action 18 Feb 04
000 509 0150 Preventive Action 18 Feb 04
000 509 0160 Quality Records 18 Feb 04
000 509 0170 Quality Audits 18 Feb 04
000 509 0180 Personnel Training and Qualification 18 Feb 04
000 509 0200 Site Subcontractor Qualification 18 Feb 04
000 509 0210 Contractor Quality Requirements 20 Sep 04
000 509 0220 Surveillance of Construction Activities 18 Feb 04
000 509 0230 Field Receiving Inspection 18 Feb 04
000 509 0240 Turnover 18 Feb 04
000 509 0250 Material & Equipment Storage & Maintenance 18 Feb 04
000 509 5100 Activity Plan for Construction 18 Feb 04


Inspection and
Test Procedure
No.
Title
Revision
Date
000 509 7000 Inspection and Testing 18 Feb04
000 509 7010 Soils 18 Feb 04
000 509 7020 Bituminous Concrete Paving 18 Feb 04
000 509 7030 Pilling - Steel H - Piles 18 Feb 04
000 509 7040 Piling Pre-Cast Concrete Piles 18 Feb 04
000 509 7050 Piling - Timber Piles 18 Feb 04
000 509 7060 Piling - Closed End Concrete Filled Pipe Piles 18 Feb 04
000 509 7070 Piling - Concrete Filled Thin Shell Pipe Piles 18 Feb 04
000 509 7080 Drilled Caissons 18 Feb 04
000 509 7090 Augered Cast-In-Place Piles 18 Feb 04
000 509 7100 Concrete and Grout 18 Feb 04
000 509 7200 Structural Steel 18 Feb 04
000 509 7300 Buildings 18 Feb 04
000 509 7310 Heating Ventilating and Air Conditioning 18 Feb 04
000 509 7320 Roofing Inspection 18 Feb 04
Project Name: 000 509 0000
Contract No.: 20 Sep 04
Project Location: Page 2 of 2


Fluor Corporation Company Confidential Site Quality Manual
Inspection and
Test Procedure
No.
Title
Revision
Date
000 509 7400 Equipment 18 Feb 04
000 509 7410 Field Fabricated Tanks 18 Feb 04
000 509 7420 Cooling Tower 18 Feb 04
000 509 7430 Refractory Concrete 18 Feb 04
ITP 509 7440 Gas Turbine/Generator 18 Feb 04
ITP 509 7460 Steam Turbine/Generator 18 Feb 04
ITP 509 7470 Field Erected Stack 18 Feb 04
000 509 7500 Underground Piping 18 Feb 04
000 509 7510 Aboveground Piping 18 Feb 04
000 509 7520 Pressure Testing 18 Feb 04
000 509 7550 Hygienic Tubing 18 Feb 04
000 509 7560 Chemical Cleaning of Pipe 18 Feb 04
000 509 7570 Steam Tracing for Pipe and Equipment 18 Feb 04
000 509 7600 Electrical Inspection 18 Feb 04
000 509 7610 Electrical Testing 18 Feb 04
000 509 7620 Electrical Equipment 18 Feb 04
000 509 7640 Electrical Heat Tracing 18 Feb 04
000 509 7700 Control Systems Instrumentation 18 Feb 04
000 509 7710 Control System Calibration 18 Feb 04
000 509 7800 Coatings and Linings 18 Feb 04
000 509 7810 Insulation 18 Feb 04
000 509 7820 Fireproofing Inspection 18 Feb 04
000 509 7830 Cathodic Protection 20 Sep 04
000 509 7910 Welding Inspection 18 Feb 04
000 509 7920 Nondestructive Examination 18 Feb 04
000 509 7930 Positive Material Identification 18 Feb 04
000 509 7950 Hardness Testing 18 Feb 04
000 509 F0000 Quality Control Forms 20 Sep 04



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

Project Name: 000 509 0010
Contract No.: 18 Feb 04
Project Location: Page 1 of 2
Fluor Corporation Company Confidential Site Quality Manual
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.
Project Name: 000 509 0010
Contract No.: 18 Feb 04
Project Location: Page 2 of 2
Fluor Corporation Company Confidential Site Quality Manual
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.
Project Name: 000 509 0020
Contract No.: 18 Feb 04
Project Location: Page 1 of 2
Fluor Corporation Company Confidential Site Quality Manual
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.
Project Name: 000 509 0020
Contract No.: 18 Feb 04
Project Location: Page 2 of 2
Fluor Corporation Company Confidential Site Quality Manual
- 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.
Project Name: 000 509 0040
Contract No.: 18 Feb 04
Project Location: Page 1 of 2
Fluor Corporation Company Confidential Site Quality Manual
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.
Project Name: 000 509 0040
Contract No.: 18 Feb 04
Project Location: Page 2 of 2
Fluor Corporation Company Confidential Site Quality Manual
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
Project Name:
Contract No.:
Project Location:
000 509 0040
18Feb04
Attachment 1 . . . 1 of 14
Section 1 - CIVIL
1.1 Construction Surveying
ACTIVITY Construction QA/QC Client
Review the construction surveying methods used by the Contractor. X
Check established reference points . X
Check control points established for construction layout on a periodic
basis. X
Check the construction layout of the contractor's work. X
Review and file completed survey notes prepared by the contractor. X
Perform periodic surveillance on survey activities and documentation. X
1.2 Soils
ACTIVITY Construction QA/QC Client
Monitor in-process soils work, including cut and fill elevations, spoil and
fill material, compaction methods and equipment. X
Perform formal audit of Soils Testing Laboratory X
Monitor Contractor's work to verify conformance to requirements. X S
Monitor Soil Testing Laboratory activities for soils testing frequency, test
identification and completeness. X
Verify the documentation of deficiencies and test failure and follow up to
assure corrective action is taken and documented. X
Audit the soils documentation to verify correctness, completeness of
coverage, retrievability as filed and inspection results. X
Perform and document soils testing TEST LAB S
Inspect excavations for unstable and unsuitable soils TEST LAB S
Verify the insitu soils are suitable to support foundation loads TEST LAB S
Verify backfill material is satisfactory TEST LAB S
Verify placement of the fill complies with contract specifications TEST LAB S
1.3 Contracted Piling
ACTIVITY Construction QA/QC Client
Qualifiy Pile Supplier X
Review and approve concrete mix design and mix trials X (1)
Technically monitor the indicator pile testing program X
Check final pile locations. X S
Monitor in-process pile driving. X S
Monitor and test pile concreting activities. X

RESPONSIBILITY
RESPONSIBILITY
RESPONSIBILITY
QUALITY RESPONSIBILITY MATRIX
PM=Procurement Manager
MM=Material Manager
X= Primary Responsibility
S= Secondary Responsibility
(1) Must obtain Engineering Approval
Project Name:
Contract No.:
Project Location:
000 509 0040
18Feb04
Attachment 1 . . . 2 of 14
1.4 Asphalt
ACTIVITY Construction QA/QC Client
Review asphalt mix designs X (1)
Monitor in-process asphalt construction including preparation of subgrade
or previous course, asphaltic materials, spreading equipment,
compaction equipment, materials and testing. X S
Perform formal audit using Asphalt Test Laboratory Evaluation Record X
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 X
Review the documentation of the asphalt inspection and testing activities
for accuracy and completeness. X
Verify the documentation of deficiencies and test failures and follow up to
assure corrective action is taken and documented. X
Audit the asphalt documentation to verify correctness, completeness of
coverage, review ability as filed and inspection results. X
Conduct asphalt testing and asphalt materials testing TEST LAB S
1.5 Structural Concrete
ACTIVITY Construction QA/QC Client
Review and approve mix designs X (1) S
Perform formal audit of Concrete Testing Laboratory. X
Audit batch plant facilities. X
Inspect formwork, reinforcing steel and impediments prior to concrete
placement. X S
Monitor in process concreting activities. X S
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. X
Monitor post-concreting activities such as concrete curing, stripping,
visual examination for line, form and surface defects and checks for
anchor bolt locations. Verify that 28-day strength tests are acceptable. X S
Conduct concrete testing at the point of placement TEST LAB S
1.6 Grouting of Machinery and Structural Steel Base Plates
ACTIVITY Construction QA/QC Client
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
been exceeded. X (1) S
Monitor in-process grouting. The inspections shall include base
preparation,materials, forming, placing, curing and hammer void test. X S
Witness grout testing by Contractor. X
Monitor the Contractor's quality control activities to verify conformance to
l t d d d t ti i t X
RESPONSIBILITY
RESPONSIBILITY
RESPONSIBILITY
PM=Procurement Manager
MM=Material Manager
X= Primary Responsibility
S= Secondary Responsibility
(1) Must obtain Engineering Approval
Project Name:
Contract No.:
Project Location:
000 509 0040
18Feb04
Attachment 1 . . . 3 of 14
Section 2 - STRUCTURAL STEEL
2.1 Structural Steel
ACTIVITY Construction QA/QC Client
Monitor in process steel erection to verify fabrication is correct and
erection is in accordance with drawings. Document fabrication errors on
a NCR. X S
Witness bolting procedure including calibration of torque wrenches and
load indicating washers. X S
Maintain documentation X
Inspect the erected steel structure. X
Ensure that erected steel structures have coatings installed i.a.w.
drawings X S
Monitor the Contractor's quality activities to verify conformance to
requirements for bolt tensioning procedures. X
Schedule final acceptance inspection activities between Contractor and
Field Engineering or construction. X S
Audit the structural steel documentation to verify correctness of data. X
Section 3 - BUILDINGS
3.1 Buildings
ACTIVITY Construction QA/QC Client
Review all Contractor proposed building materials prior to use. X (1)
Verify that the building location level and position are correct prior to
construction. X
Inspect the entire builiding upon completion and document deficiencies.
X S
Document building acceptance X
Monitor the in process construction to verify that the work is i.a.w.
drawings. X S
Schedule final acceptance activities X S
Monitor the Contractor's quality control activities to verify test frequency,
identification and traceability X
Audit building documentation X
RESPONSIBILITY
RESPONSIBILITY
PM=Procurement Manager
MM=Material Manager
X= Primary Responsibility
S= Secondary Responsibility
(1) Must obtain Engineering Approval
Project Name:
Contract No.:
Project Location:
000 509 0040
18Feb04
Attachment 1 . . . 4 of 14
Section 4 - EQUIPMENT
4.1 Equipment
ACTIVITY Construction QA/QC Client
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. X
Initiate action to acquire vendor representative as required. PM
Coordinate with engineering for participation of mechanical discipline
engineers, if required. PM
Monitor the in-process installation of each equipment unit. X S
Coordinate with vendor representative who technically supervises
equipment installation. X
Verify vendor representative's checklists and acceptance records are
signed and attached to appropriate construction documents. X S
Verify the equipment requirements are being satisfied by the Contractor.
X S
Monitor equipment preservation i.a.w. Section 11. X
Monitor the Contractor's quality control activities to verify conformance to
inspection, testing and documentation requirements. X
4.2 Field Fabricated Tanks
ACTIVITY Construction QA/QC Client
Monitor the foundation construction including soils, asphalt and concrete
work. X S
Check elevation dimensions of tank shells. X
Check the erected dimensions of tank shells. X S
Inspect fabricated tank structure upon completion. X S
Check the settlement and rebound of the foundation during and after
hydrotest. X S
Verify welder performance qualifications. S X
Verify welding procedure testing has been accomplished and procedures
are acceptable. X
Monitor in-process welding X S
Witness in-process examination as performed by the NDE contractor,
including reviewing radiographs, witnessing PT, MT, vacuum box and
leak testing X
Verify that equipment and components associated with tankage have
been correctly installed, adjusted, tested, confirmed for proper function
and inspected. X S
Inspect the tested tank prior to closing, including final clean-up. X S
Verify that the Contractor has affixed a nameplate listing the required
data. X S
Verify that the Contractor has submitted the required certification. X S
Monitor the Contractor's quality control activities to verify conformance
i ti t ti d d t ti i t X
RESPONSIBILITY
RESPONSIBILITY
PM=Procurement Manager
MM=Material Manager
X= Primary Responsibility
S= Secondary Responsibility
(1) Must obtain Engineering Approval
Project Name:
Contract No.:
Project Location:
000 509 0040
18Feb04
Attachment 1 . . . 5 of 14
Section 5 - PIPING
5.1 Underground Piping
ACTIVITY Construction QA/QC Client
Monitor in-process excavation and backfill. X S
Inspect installed underground pipelines for acceptance. X S
Color code the lines, indicated as punched and accepted, on a copy of
the underground piping plan. X
Verify that the Testing Lab is performing the required soils testing of
backfill. X S
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. X S
Inspect in-process pipe fabrication and installation I.a.w. drawings. X S
Perform a final inspection of the line, when the underground piping is
complete, but prior to the coating and wrapping of joints and fittings. X S
Verify the Contractor has completed coating and wrapping of joints and
fittings on tested line. X S
Witness holiday testing of the coating and wrapping. Contractor shall
document tests. X S
Verify that required NDE is complete on the lines to be inspected. X
Witness the pressure test. S X
Inspect the tested system to ensure that all items have been properly
completed (restoration). X S
Monitor the Contractor's quality control activities to verify conformance to
testing and documentation requirements.
X
5.2 Site Shop Fabrication
ACTIVITY Construction QA/QC Client
Segregate and store pipe fittings, upon receipt, according to size and
material. Identify storage location with commodity code number. MM
Pipe will be marked full length with commodity code number. MM
Maintain documentation MM
Issue piping materials to Contractors MM
Inspect special flange faces for correct finish and face protection. X S
Monitor in-process pipe fabrication activities. X S
Verify latest edition of piping drawings is being used. X S
Random check on base material ID on pipe, fittings and spools. Spools
shall be clearly identified in two locations. X S
Monitor storage of completed spools at pipe shop including
preservations. X S
Monitor pipe identification, documentation and timely performance of
NDE. X
RESPONSIBILITY
RESPONSIBILITY
PM=Procurement Manager
MM=Material Manager
X= Primary Responsibility
S= Secondary Responsibility
(1) Must obtain Engineering Approval
Project Name:
Contract No.:
Project Location:
000 509 0040
18Feb04
Attachment 1 . . . 6 of 14
5.3 Aboveground Piping Erection
ACTIVITY Construction QA/QC Client
Pipe will be marked full length with commodity code number. Alloy pipe
and fittings shall be additionally color coded. Alloy storage areas shall be
clearly identified. MM
Maintain piping spool identity markings of piping spools fabricated off site.
MM
Verify MTR's are received and that heat numbers correspond. Maintain
documentation MM
Verify PMI requirements are satisfied prior to placement in stock. MM S
Verify correct pipe is issued to Contractor. MM
Monitor in-process erection I.a.w. drawings. Classify and record spool fit
problems. X S
Ensure face flange protection is maintained. X S
Monitor proper bolt tensioning. X S
Monitor correct gasket installed. X S
Monitor erection to ensure that pipe installations are not subjected to
undesirable stress. X S
Check pipe drawings to assure latest revision in the field. X S
Assist Contractor to maintain current piping test status. S X
Monitor Contractor's activities to established quality control practices. X
Monitor in process pipe erection and transfer of heat numbers. Verify
that NDE is performed in a timely manner. Monitor pipe and welding
traceability including PWHT, PMI and Hardness Testing. X
5.4 Piping Inspection - Punching
ACTIVITY Construction QA/QC Client
Flag deficiencies when not visually obvious. X
Enter punch lists into data base. X
Check work, noted as complete, on punch lists to assure items were
corrected. X
Initiate action with Contractor on punching results. Add additional
discrepancies to punch list. Initial and date punch list for each item
corrected. X
Monitor the Contractor's punching activities. X
Verify that punching deficiencies are identified, documented and follow up
to verify corrective action is taken. X
Verify that measures are taken to assure NDE, PWHT, PMI and
traceability is completed prior to pressure testing. X
RESPONSIBILITY
RESPONSIBILITY
PM=Procurement Manager
MM=Material Manager
X= Primary Responsibility
S= Secondary Responsibility
(1) Must obtain Engineering Approval
Project Name:
Contract No.:
Project Location:
000 509 0040
18Feb04
Attachment 1 . . . 7 of 14
5.5 Pressure Testing of Piping
ACTIVITY Construction QA/QC Client
Monitor pressure testing performed by Contractor. X S
Review drawings and specifications to verify pressure test package limits,
equipment to be included or excluded, valves opened or closed and test
blind locations. X S
Verify that the maximum allowable test pressure of the weakest
component within the system is not exceeded. X S
Verify (through NEWS) that all NDE is complete prior to testing. S X
Verify that shop spool/cut sheets are included in test packages and all
NDE, PWHT and welder info is recorded. S X
Review Contractor's pressure test package, including marked up
isometric drawings indicating test blind locations, valve position
(open/closed) and other information relating to test. X S
Monitor preparation of test system against test package. X
Monitor restoration of the tested system. X
Monitor Contractor's pressure testing and documentation activities. S X
Review test package for completion S X
Inspect the system prior to testing notifying Contractor of deficiencies.
Mark Pressure Test Record, "Ready to Test". Notify client when
acceptable for test. Give permission to proceed with test. X S
Inspect system under pressure. Verify test pressure and duration of test.
Procure test acceptance signatures from Contractor and QIB. S X
When equipment is included in the test, verify that pressure test does not
exceed nameplate. X S
5.6 Piping Internal Cleaning
ACTIVITY Construction QA/QC Client
Review and approve the cleaning and preservation procedures and the
limits agree with drawings. X
Establish hold points for witnessing tests. X
Monitor preparatory and in-process cleaning activities for compliance with
procedures and specs. X S
Coordinate the monitoring of Contractor inspection and testing activities.
X S
Verify the Contractor is preparing documentation as inspections and tests
are being performed. X S
Verify that internal cleaning has been accomplished. X
Monitor the Contractor's quality control activities. X
RESPONSIBILITY
RESPONSIBILITY
PM=Procurement Manager
MM=Material Manager
X= Primary Responsibility
S= Secondary Responsibility
(1) Must obtain Engineering Approval
Project Name:
Contract No.:
Project Location:
000 509 0040
18Feb04
Attachment 1 . . . 8 of 14
Section 6 - ELECTRICAL
6.1 Underground Electrical
ACTIVITY Construction QA/QC Client
Monitor in-process installation of the grounding system including,
grounding rod installation, backfilling. Color coding of drawings to track
progress. X S
Witness resistance to earth tests. X S
Monitor in-process duct bank and electrical manhole installations. X
Witness initial testing of shielded cable, ie, insulation resistance test of
power cable on reels, continuity test of reeled instrument cable. X S
Inspect cable trench prior to installation of cable. X
Monitor in-process installation of underground cable. Inspect in-process
cable pulling. X S
Inspect in-process cable splicing. X S
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. X S
Inspect installation of cables upon completion of each layer to ensure
spacing, labeling, etc. is correct. X S
Inspect sand backfill per lift for quality of materials, depth and
compaction. X S
Verify the Contractor final as-built drawings are in conformance. X S
Verify that the Contractor is preparing documentation concurrent with
construction as inspection and testing are performed. X S
Monitor the Contractors' quality control activities. X
6.2 Aboveground Electrical
ACTIVITY Construction QA/QC Client
Monitor in-process installation of electrical conduit and cable tray,
including welding of supports. X
Witness initial testing of shielded cable, ie, insulation resistance test of
power cable on reels, continuity test of reeled instrument cable and
resistance and continuity on electrical heat tracing cables. X S
Monitor in-process cable pulling and installation. X
Witness random testing of installed cable, ie, insulation resistance test on
power and instrumentation cables, continuity and insulation resistance
testing on heat tracing and hypot of medium and high voltage cables. X S
Verify client is being notified in advance of tests that require witness. X S
Verify terminal to terminal checks to ensure continuity and correctness of
installation. X S
Verify conduit seals have been poured. X S
Inspect installation upon completion. X S
V if th t th C t t i i d t ti t ith
RESPONSIBILITY
RESPONSIBILITY
PM=Procurement Manager
MM=Material Manager
X= Primary Responsibility
S= Secondary Responsibility
(1) Must obtain Engineering Approval
Project Name:
Contract No.:
Project Location:
000 509 0040
18Feb04
Attachment 1 . . . 9 of 14
6.3 Electrical Equipment
ACTIVITY Construction QA/QC Client
Monitor in-process installation of equipment. X S
Monitor equipment preservation activities X S
Witness testing of installed equipment. X S
Coordinate with vendor representative who will technically supervise
installation. Ensure documentation is complete. X S
Verify QIB is being notified in advance of tests requiring witnessing. X S
Inspect electrical installation when complete. X S
Verify that the Contractor is preparing documentation concurrent with
construction as inspection and testing are performed. X S
Monitor the Contractor's quality control activities. X
Section 7-CONTROL SYSTEMS
7.1 Control Systems Site Shop Operations
ACTIVITY Construction QA/QC Client
Notify construction upon receipt of each instrument shipment for
inspection. MM
For nonconforming items, issue a Damage Report or NCR. MM
Issue instruments to Contractor. MM
Inspect each instrument shipment. Deficiencies shall be reported to the
Material Manager. X
Inspect instrument materials i.a.w.sec.10 & project procedures X
Document the receiving inspection. X
7.2 Control Systems Field Operations
ACTIVITY Construction QA/QC Client
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 X S
Witness pressure testing of the instrument piping and tubing
documentation. X S
Witness calibration of test guages. X S
Monitor continuity tests of instrument cables.Verify that cable
terminations are correct. X S
Witness checks of control system loops. Establish notification system for
IMT. X S
Witness all loop checks X S
Assure all instrument installation inspections and meggar tests are
complete X S
Inspect instrument installations upon completion. X S
M it th C t t ' lit t l ti iti S X
RESPONSIBILITY
RESPONSIBILITY
RESPONSIBILITY
PM=Procurement Manager
MM=Material Manager
X= Primary Responsibility
S= Secondary Responsibility
(1) Must obtain Engineering Approval
Project Name:
Contract No.:
Project Location:
000 509 0040
18Feb04
Attachment 1 . . . 10 of 14
Section 8 - COATINGS, LININGS, INSULATION AND CATHODIC
PROTECTION
8.1 Coatings
ACTIVITY Construction QA/QC Client
Ensure that the paint system is i.a.w. specifications. X S
Monitor performance of materials preservation activities. X S
Monitor surface preparation.Verify inspection documentation. X S
Monitor in-process coatings applications. X S
Check dry film thickness of applied coatings. X S
Inspect the workmanship of completed finishes. X S
Monitor the Contractor's quality control activities. S X
Verify the Contractor has prepared the QC documentation. S X
Audit coating documentation. X
8.2 Insulation
ACTIVITY Construction QA/QC Client
Monitor performance of material preservation activities. X
Monitor in-process installation of the insulation materials. X S
Verify the Contractor has prepared the quality control documentation X S
Inspect the completed work. X S
Document acceptance. S X
8.3 Linings
ACTIVITY Construction QA/QC Client
Monitor performance of material preservation activities. X S
Monitor surface preparation. X S
Verify Contractor is performing temperature and humidity checks for tank
linings. X S
Monitor in-process lining application. X S
Test applied linings to verify proper surface profile, thickness, and lining
continuity. X S
Monitor Contractor's tank lining holiday inspections. X S
Observe tank lining curing activities. X S
Inspect the workmanship of the completed lining. X S
Monitor the Contractor's quality control activities. S X
Audit coating documentation. X
Verify that lining materials comply with specs. Ensure that manufacture
test certificates correspond with filed batch number records. X S
Monitor storage facilities. X
Ensure refractory applicators are experienced and qualified. X S
Monitor to ensure materials are properly mixed. X S
M it f ti t ti t d d i f t
RESPONSIBILITY
RESPONSIBILITY
RESPONSIBILITY
PM=Procurement Manager
MM=Material Manager
X= Primary Responsibility
S= Secondary Responsibility
(1) Must obtain Engineering Approval
Project Name:
Contract No.:
Project Location:
000 509 0040
18Feb04
Attachment 1 . . . 11 of 14
8.4 Cathodic Protection - Underground Structures.
ACTIVITY Construction QA/QC Client
Submit data to Engineering for determination of anode spacing X (1)
Establish a procedure to assure work is not started prior to acceptance of
previous work. X
Monitor the survey after each cathodic protection system is energized. X S
Verify materials being installed. X
Monitor installation activities. X S
Monitor deep well preparation activities including data logs. X
Monitor anode backfill operation. X
Witness hammer testing of thermite welds X S
Witness electrical test used to determine current flow when the anode is
backfilled with coke breeze. X S
Monitor testing and commissioning activities. X S
Inspect the completed work. X S
Audit cathodic protection documentation. X
8.5 Cathodic Protection - Tanks and Vessels
ACTIVITY Construction QA/QC Client
Verify materials are within specification and are properly protected from
damage. X
Verify the vessel cathodic protection materials were installed. X
Monitor installation activities X S
Verify personnel use of protective clothing (when reg's) X
Inspect the completed workmanship. X S
Monitor testing and commissioning activities. X S
Audit cathodic protection documentation. X
Section 9 - WELDING
9.1 Pipe Welding
ACTIVITY Construction QA/QC Client
Verify the WPS's have been approved by the Welding Engineer. X (1) S
Monitor qualification tests of Contractor's welders. X
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. X S
Monitor in-process welding including consumables, joint preparation,fit-up
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 S
Audit welding documentation. X
Verify transfer of piping material heat numbers. X S
RESPONSIBILITY
RESPONSIBILITY
RESPONSIBILITY
PM=Procurement Manager
MM=Material Manager
X= Primary Responsibility
S= Secondary Responsibility
(1) Must obtain Engineering Approval
Project Name:
Contract No.:
Project Location:
000 509 0040
18Feb04
Attachment 1 . . . 12 of 14
9.2 Structural and Reinforcing Steel Welding
ACTIVITY Construction QA/QC Client
Verify the WPS's have been approved by the Welding Engineer. X (1)
Monitor qualification tests of welders. X
Monitor in-process welding including consumables, joint preparation and
final visual inspection. X S
Audit welding documentation. X
9.3 Piping Nondistinctive Examination (NDE)
ACTIVITY Construction QA/QC Client
Pre-qualify NDE Contractor X
Verify that the NDE Contractor has established procedures that comply
with project specifications. X
Daily entry of weld data to NEWS program. S X
Establish and maintain NDE documentation files. X
Review Contractor NDE personnel certifications. X
Verify approval of NDE Contractor and procedures. X
Verify NDE Contractor's procedure to provide visual status of welds
requiring NDE. X
Select welds for examination S X
Perform Nondestructive examinations DE CONTRACTO S
Review radiographic film, Contractor's interpretation and reports. X
Verify code compliance for rejected welds. X
Maintain a tickler file of rejected welds. X
Verify, through audit, welding and NDE records are traceable to the weld.
X
Verify through NEWS that NDE is completed prior to pressure testing. X
Audit the NDE lab X
Monitor the NDE Contractor's production to verify that welds are
examined within 48 hours of notification. X
Verify all field welds are numbered and identified on drawings. X
Ensure that weld number and welder's symbols are low stress stamped
or otherwise marked on pipe. X S
Ensure that an accurate Daily Welding Report is maintained. S X
RESPONSIBILITY
RESPONSIBILITY
PM=Procurement Manager
MM=Material Manager
X= Primary Responsibility
S= Secondary Responsibility
(1) Must obtain Engineering Approval
Project Name:
Contract No.:
Project Location:
000 509 0040
18Feb04
Attachment 1 . . . 13 of 14
9.4 Pipe hardness Testing
ACTIVITY Construction QA/QC Client
Monitor the Contractor to verify weld identity system and compliance to
specification. X
Establish confidence that tests are being preformed i.a.w. test equipment
instructions. X
Verify the Contractor's compliance with hardness testing and
documentation. X
Verify Contractor's procedure for visual identification of rejected welds. X
Maintain a PWHT tickler file for rejected welds. X
Verify hardness testing is complete prior to pressure testing. X
Witness tests required by the specifications as performed by Contractor.
X
Schedule final acceptance inspection activities between the Contractor
and the Field Engineer. X
Monitor the Contractor's quality control activities to verify conformance to
requirements for test frequency, identification and traceability. X
Section 10 - Field Receiving
10.1 Field Receiving (IMT)
ACTIVITY Construction QA/QC Client
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. MM
Issuance of periodic receiving reports to Construction Superintendents
when technical assistance is required. MM
Inspect received material/equipment, providing technical assistance,
when requested. S X
10.2 Field Receiving -Contractor
ACTIVITY Construction QA/QC Client
Receive all contractor purchased equipment and materials MM
Review material test reports against received materials and maintain on
file MM S
Issue equipment and materials to the Contractor MM
Inspect received material/equipment, providing technical assistance when
requested X S
Assure that the contractor performs the equipment and material
protection as required by manufacturers instruction or specification
requirements X S
RESPONSIBILITY
RESPONSIBILITY
RESPONSIBILITY
PM=Procurement Manager
MM=Material Manager
X= Primary Responsibility
S= Secondary Responsibility
(1) Must obtain Engineering Approval
Project Name:
Contract No.:
Project Location:
000 509 0040
18Feb04
Attachment 1 . . . 14 of 14
10.3 Positive Material Identification (PMI)
ACTIVITY Construction QA/QC Client
Notify QA of receipt of material requiring PMI. MM
Maintain PMI test results with receiving documentation. MM
Verify receipt of PMI reports from suppliers and fabricators, MM
Verify Contractor has established a system to maintain material ID
through receiving, storage, issue, fabrication and election. X
Implement procedures for PMI. X
Monitor contractor's maintenance of piping material identification. X S
Perform PMI as required by specification. X
Verify ID marking are accomplished per specification. X S
Verify controls have been established to prevent the in advertent use of
materials failing examination. S X
Verify the filing, maintenance and retention of documentation. X
Assure that PMI equipment is calibrated. X
Section 11 - EQUIPMENT AND MATERIAL PROTECTION
11.1 Equipment and Material Protection
ACTIVITY Construction QA/QC Client
Monitor equipment and material preservation in storage and document. MM S
11.2 Equipment and Material Protection (Contractor)
ACTIVITY Construction QA/QC
Monitor Contractors in-process equipment and material
protection/preservation activities. X S
Check Contractors in-process equipment and material X S
Audit the Contractor Material and equipment protection activities. X
Section 12 - Masterpiece Program
12.1 Masterpiece Program
ACTIVITY Construction QA/QC Client
Develop Masterpiece List X S
Ensure Contractor is using correct materials, drawings and specifications
X S
Advise contractor when a Masterpiece is required X S
Inspect Masterpiece prior to QA notification X S
Request client's presence during inspection S X
Document acceptance of the Masterpiece S X
Notify client of accepted Masterpiece S X
Maintain the Masterpiece log X
Maintain Masterpiece model as reference standard X S
Monitor the Contractor's quality control activities to verify conformance to
dwgs and specifications X
RESPONSIBILITY
RESPONSIBILITY
RESPONSIBILITY
RESPONSIBILITY
PM=Procurement Manager
MM=Material Manager
X= Primary Responsibility
S= Secondary Responsibility
(1) Must obtain Engineering Approval
Project Name: 000 509 0050
Contract No.: 18 Feb 04
Project Location: Page 1 of 6
Fluor Corporation Company Confidential Site Quality Manual
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.
Project Name: 000 509 0050
Contract No.: 18 Feb 04
Project Location: Page 2 of 6
Fluor Corporation Company Confidential Site Quality Manual
- 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 Clients 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.
Project Name: 000 509 0050
Contract No.: 18 Feb 04
Project Location: Page 3 of 6
Fluor Corporation Company Confidential Site Quality Manual
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.
Project Name: 000 509 0050
Contract No.: 18 Feb 04
Project Location: Page 4 of 6
Fluor Corporation Company Confidential Site Quality Manual
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.
Project Name: 000 509 0050
Contract No.: 18 Feb 04
Project Location: Page 5 of 6
Fluor Corporation Company Confidential Site Quality Manual
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
- Site Quality Manager
- 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.
Project Name: 000 509 0050
Contract No.: 18 Feb 04
Project Location: Page 6 of 6
Fluor Corporation Company Confidential Site Quality Manual
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
Project Name: 000 509 0050
Contract No.: 18 Feb 04
Project Location: 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.
Originators 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 its submission to the Design Engineer.)
Title: List the current position of the approver.
Date: The date the request is approved for submission
Project Name: 000 509 0050
Contract No.: 18 Feb 04
Project Location: Attachment 1 . . . Page 2 of 2
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 respondents resolution (generally the Design Engineer, Project
Engineering Manager, CM, or Fluors 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.
Project Name: 000 509 0090
Contract No.: 18 Feb 04
Project Location: Page 1 of 2
Fluor Corporation Company Confidential Site Quality Manual
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.
Project Name: 000 509 0090
Contract No.: 18 Feb 04
Project Location: Page 2 of 2
Fluor Corporation Company Confidential Site Quality Manual
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.
Project Name: 000 509 0110
Contract No.: 18 Feb 04
Project Location: Page 1 of 4
Fluor Corporation Company Confidential Site Quality Manual
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
Project Name: 000 509 0110
Contract No.: 18 Feb 04
Project Location: Page 2 of 4
Fluor Corporation Company Confidential Site Quality Manual
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.
Project Name: 000 509 0110
Contract No.: 18 Feb 04
Project Location: Page 3 of 4
Fluor Corporation Company Confidential Site Quality Manual
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.
Project Name: 000 509 0110
Contract No.: 18 Feb 04
Project Location: Page 4 of 4
Fluor Corporation Company Confidential Site Quality Manual
FORMS
Quality Support Forms:
000 509 F01101 - Calibration Assignment Log and Record
000 509 F01102 - IMTE Sign In/Out-History of Use Log
000 509 F01103 - Calibration Tickler File
000 509 F01104 - 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
Project Name: 000 509 0110
Contract No.: 18 Feb 04
Project Location: 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.
Project Name: 000 509 0110
Contract No.: 18 Feb 04
Project Location: Attachment 2 . . . Page 1 of 1
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) description and unique identification of each piece of IM&TE;
b) assigned calibration interval;
c) calibration accuracy required;
d) 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.
Project Name: 000 509 0110
Contract No.: 18 Feb 04
Project Location: Attachment 3 . . . Page 1 of 1
IM & TE CALIBRATION REQUIREMENTS LIST
END USER DESCRIPTION FREQUENCY PROCEDURE TOLERANCES
Surveyor Chain Initial Conformance Visual* 1/8
(2)
Surveyor Level 6 Months Per Procedure
Surveyor Transit 6 Months Per Procedure
Surveyor Tape Initial Conformance Visual* 1/8
(2)
Surveyor Distamat 6 Months Per Procedure
Mechanical Pressure Gauges Monthly 5%
(2)
Mechanical Torque Wrenches Monthly 5%
(2)
Electrical Meggars 6 Months 3%
(2)
Electrical Simpson Mulit-Meter 6 Months 3%
(2)
Electrical Digital Mulit-Meter 6 Months 3%
(2)
Millwrights Calipers 3 Months .02MM
(2)
Millwrights Dial Indicators 3 Months .02MM
(2)
Millwrights Micrometers 3 Months .02MM
(2)
Welding Rod Oven Thermostat 3 Months 5F
(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.
Project Name: 000 509 0130
Contract No.: 18 Feb 04
Project Location: Page 1 of 4
Fluor Corporation Company Confidential Site Quality Manual
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
Project Name: 000 509 0130
Contract No.: 18 Feb 04
Project Location: Page 2 of 4
Fluor Corporation Company Confidential Site Quality Manual
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.
Project Name: 000 509 0130
Contract No.: 18 Feb 04
Project Location: Page 3 of 4
Fluor Corporation Company Confidential Site Quality Manual
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.
Project Name: 000 509 0130
Contract No.: 18 Feb 04
Project Location: Page 4 of 4
Fluor Corporation Company Confidential Site Quality Manual
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 NCRs 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 - Instruction for completion of Non-Conformance Report
Attachment 2 - Nonconformance Routing Chart
Project Name: 000 509 0130
Contract No.: 18 Feb 04
Project Location: Attachment 1 . . . Page 1 of 1
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 Description
C01 Client Driven
C02 Communication Driven
C03 Equipment or Material
C04 External Phenomenon
C05 Location Driven
C06 Management Driven
C07 Procedure (except procedure not followed)
C08 Procedure/Work Process not followed
C09 People Driven
C10 Systems Driven
C11 Work Environment
C99 Other
NOTE: If codes 7 or 8 are used, list the procedure(s) identified as the root cause.
* 3 Disposition
Use-as-is Requires design Engineer and Client approval.
Re-work Restore to original Specification, does not require Design Engineer or Client
approved.
Repair 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.
Project Name: 000 509 0130
Contract No.: 18 Feb 04
Project Location: Attachment 2 . . . Page 1 of 1
NONCONFORMANCE ROUTING CHART
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 NCRs on Activities within
Regulating Authority Scope,
they need to Review/Accept
Nonconformance
Discovered
NCR
Initiated
Site Quality
Manager
Review/Confirms/
Signs
Lead Field Engineer
Recommended Disposition/
Signature
Site Quality
Manager
for Routing
Site Quality
Manager
Assigns Number
Corrective
Action
Corrective
Action
Approved
Applicable
Design Authority
Review Disposition
Approve or Disapprove
NOTE 2
Quality
Manager
Verifies
Quality
Manager
Closes
NCR
Quality Manager
Distributes
Closed NCR
Execution of
Corrective Action
NOTE 1
Corrective Action:
1) Remove/Replace
Rework to
Full Design Intent
2) Repair
3) Use As Is
Distribution:
Reject
Accepts
Project Name: 000 509 0140
Contract No.: 18 Feb 04
Project Location: Page 1 of 3
Fluor Corporation Company Confidential Site Quality Manual
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.
Project Name: 000 509 0140
Contract No.: 18 Feb 04
Project Location: Page 2 of 3
Fluor Corporation Company Confidential Site Quality Manual
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.
Project Name: 000 509 0140
Contract No.: 18 Feb 04
Project Location: Page 3 of 3
Fluor Corporation Company Confidential Site Quality Manual
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 CARs will be reviewed with Site
Management on a periodic basis to ensure timely close out of the CARs.
REFERENCES
Quality Control Forms:
000 509 F01401 - Corrective Action Report
000 509 F01402 - Corrective Action Report Log
ATTACHMENT
Attachment 1 - Corrective Action Response Instructions
Project Name: 000 509 0140
Contract No.: 18 Feb 04
Project Location: Attachment 1 . . . Page 1 of 2
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 its
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 Description
C01 Client Driven
C02 Communication Driven
C03 Equipment or Material
C04 External Phenomenon
C05 Location Driven
C06 Management Driven
C07 Procedure (except procedure not followed)
C08 Procedure/Work Process Not Followed
C09 People Driven
C10 Systems Driven
C11 Work Environment
C99 Other
Project Name: 000 509 0140
Contract No.: 18 Feb 04
Project Location: Attachment 1 . . . Page 2 of 2
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 follow-
up and close-out where applicable. Closed out CARs (Section 5 Completed) are to be
copied to the Construction Technology Quality Manager.
Project Name: 000 509 0150
Contract No.: 18 Feb 04
Project Location: Page 1 of 3
Fluor Corporation Company Confidential Site Quality Manual
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 items potential
impact on project cost, schedule or quality.
NOTE: Note all potential nonconformities require preventive action.
Project Name: 000 509 0150
Contract No.: 18 Feb 04
Project Location: Page 2 of 3
Fluor Corporation Company Confidential Site Quality Manual
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 Description
C01 Client Driven
C02 Communication Driven
C03 Equipment or Material
C04 External Phenomenon
C05 Location Driven
C06 Management Driven
C07 Procedure (except procedure not followed)
C08 Procedure/Work Process Not Followed
C09 People Driven
C10 Systems Driven
C11 Work Environment
C99 Other
ELIMINATION CODES
Code Description
E01 Revision/modification of work process/document
E02 Issuance of QA/QC report to affected personnel
E03 Issuance of document/procedure
E04 Training/orientation of affected personnel
E05 Verbally advising affected personnel
E99 Other
Project Name: 000 509 0150
Contract No.: 18 Feb 04
Project Location: Page 3 of 3
Fluor Corporation Company Confidential Site Quality Manual
FORMS
Quality Control Forms:
000 509 F02201 - Surveillance Report
000 509 F01501 - Preventive Action log
000 509 F01701 - Audit Finding
000 509 F01702 - Audit Summary
ATTACHMENT
Attachment 1 - Preventive Action Log
Project Name: 000 509 0150
Contract No.: 18 Feb 04
Project Location: Attachment 1 . . . Page 1 of 1
PREVENTIVE ACTION LOG
Project Name: Project Number:
PA No.
Issue
Date
Source Description
Cause
Code
Elimination
Code
Confirmation of Action Verified by
Date
Closed
Cause Code Description Cause Code Description Elimination Code Description
C01 Client Driven C07 Procedure (except procedure not followed) E01 Revision/modification of work process/document
C02 Communication Driven C08 Procedure/Work Process not followed E02 Issuance of QA/QC report to affected personnel
C03 Equipment or Material C09 People Driven E03 Issuance of document/procedure
C04 External Phenomenon C10 Systems Driven E04 Training/orientation of affected personnel
C05 Location Driven C11 Work Environment E05 Verbally advising affected personnel
C06 Management Driven C99 Other E99 Other
Project Name: 000 509 0160
Contract No.: 18 Feb 04
Project Location: Page 1 of 3
Fluor Corporation Company Confidential Site Quality Manual
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.
Project Name: 000 509 0160
Contract No.: 18 Feb 04
Project Location: Page 2 of 3
Fluor Corporation Company Confidential Site Quality Manual
NOTE: 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.
Project Name: 000 509 0160
Contract No.: 18 Feb 04
Project Location: Page 3 of 3
Fluor Corporation Company Confidential Site Quality Manual
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.
Project Name: 000 509 0160
Contract No.: 18 Feb 04
Project Location:
SAMPLE
Attachment 1 . . . Page 1 of 6
QUALITY RECORDS CONTROL
Record Identification Custodian
System
Turnover
Package
Records
Retention
Center
Records
Retention
Center
Form # Title
Job Title or
Sub Name
Y = Yes
N = No
Y = Yes
N = No
Retention
(Years)
File
Locator
Code
000 509 F00501 Request For Information CEM Y Y 20 R5
000 509 F00502 Request For Information Log CEM N Y 20 R5
000 509 F01101 Calibration Assignment Log CEM N Y 3 R2
000 509 F01102 I.M.T.E. Sign In/Out History of Use Log SQM N Y 3 R2
000 509 F01103 Calibration Tickler File CEM N N 0 R2
000 509 F01104 Calibration Data Sheet CEM Y Y 3 R2
000 509 F01105 Calibration Data Sheet CEM Y Y 3 R2
000 509 F01301 Nonconformance Report SQM Y Y R2
000 509 F01302 Nonconformance Report Log SQM Y Y R2
000 509 F01303 Hold Tag/Sticker -- N N --
000 509 F01401 Corrective Action Report SQM Y Y R2
000 509 F01402 Corrective Action Report Log SQM Y Y R2
000 509 F01403 Trend Analysis Investigation Form SQM Y Y R2
000 509 F01601 Quality Records Control SQM N N R2
000 509 F01701 Audit Finding SQM N N R2
000 509 F01702 Audit Summary SQM N N R2
000 509 F01801 Project Specific Quality Training SQM N N R2
000 509 F02001 Site Subcontractor Qualification SQM N N R2
000 509 F02004 Concrete Batch Plant Evaluation Record SQM Y Y R2
000 509 F02006
NDE Subcontractor Evaluation Record SQM Y Y R2
000 509 F02201 Surveillance Report SQM N N R2
000 509 F02301 Receiving Inspection Checklist SQM Y Y R2
000 509 F02302
Permanent Plant Material Equipment
Inspection List
SQM Y Y R1
000 509 F02401 Transfer of Care, Custody and Control CEM Y Y R1
000 509 F02402 System Walkdown Notice DE Y Y R1
000 509 F02403 Mechanical Completion Civil Checklist DE N N R1
000 509 F02404
Mechanical Completion
Electrical/Instrumentation Checklist
DE N Y R1
000 509 F02405
Mechanical Completion/Mechanical
Checklist
DE N Y R1
000 509 F02406
Mechanical Completion/Quality
Management Checklist
CEM N Y R2
000 509 F02407 Master Punch List DE Y Y R2
000 509 F02408 Interium Turnover Notice CEM Y Y R2
000 509 F02409 Mechanical Completion Certificate CEM Y Y R1
000 509 F02501 Storage Inspection Checklist SQM Y Y R2
000 509 F02502
Equipment Protection Preservation and
Inspection Record
CEM Y Y R2
Project Name: 000 509 0160
Contract No.: 18 Feb 04
Project Location:
SAMPLE
Attachment 1 . . . Page 2 of 6
Record Identification Custodian
System
Turnover
Package
Records
Retention
Center
Records
Retention
Center
Form # Title
Job Title or
Sub Name
Y = Yes
N = No
Y = Yes
N = No
Retention
(Years)
File
Locator
Code
000 509 F70101 Soil Inspection Checklist SQM N Y R6
000 509 F70102 Field Compaction Test Record SQM Y Y R2
000 509 F70104 Nuclear Moisture Density Report SQM Y Y R2
000 509 F70801 Caisson Inspection Record SQM Y Y R6
000 509 F70901 Auger Cast Pile Record DE Y Y R2
000 509 F71001 Pre-Concrete Inspection Checklist SQM N Y R4
000 509 F71002 Concrete Inspection Record SQM Y Y R4
000 509 F71003 Concrete Pour Card DE Y Y R4
000 509 F71004 Cementitious Grout Inspection Record SQM Y Y R4
000 509 F71005 Cementitious Grout Testing Record DE Y Y R2
000 509 F71006 Epoxy Resin Grout Inspection Record SQM Y Y R4
000 509 F71007
Concrete Compression Strength Test
Record
DE Y Y R4
000 509 F71008 Concrete Placement Log DE Y Y R2
000 509 F71009 Grout Placement Log DE N N R3
000 509 F71010 Grouting Checklist SQM Y Y R6
000 509 F72002 Structural Steel Inspection SQM Y Y R6
000 509 F72003 Torque Wrench Calibration Log SQM Y Y R2
000 509 F74001 Exchanger Closure Form DE Y Y R3
000 509 F74002
Heat Exchangers & Reboilers Installation
Record
DE Y Y R3
000 509 F74003 Centrifugal Compressor Inspection Record DE Y Y R3
000 509 F74004 Inspection Record Static Equipment DE Y Y R3
000 509 F74005 Inspection Record Tray Installation DE Y Y R3
000 509 F74006
Inspection Record Air Cooled Heat
Exchanger
DE Y Y R3
000 509 F74007 Air Cooler Run In Test Report DE Y Y R3
000 509 F74008
Receiprocating Compressor Inspection
Record
DE Y Y R3
000 509 F74009 Inspection Record Fan Installation DE Y Y R3
000 509 F74010 Inspection Record Fun DE Y Y R3
000 509 F74013 Installation Record Agitators/Mixers DE Y Y R3
000 509 F74014
Inspection Record Equipment/Piping
Flange Alignment
DE Y Y R3
000 509 F74016 Package Unit Inspection Record DE Y Y R3
000 509 F74018 Installation Record Filters/Strainers DE Y Y R3
000 509 F74019 Inspection Record Centrifugal Compressor DE Y Y R3
000 509 F74020 Inspection Record Rotating Equipment DE Y Y R3
000 509 F74021 Alignment Check Sheet DE Y Y R3
000 509 F74023 Field Installed Refractory Record DE Y Y R3
000 509 F74024
Inspection Record For Draw Off Tray Leak
DE Y Y R3
Project Name: 000 509 0160
Contract No.: 18 Feb 04
Project Location:
SAMPLE
Attachment 1 . . . Page 3 of 6
Record Identification Custodian
System
Turnover
Package
Records
Retention
Center
Records
Retention
Center
Form # Title
Job Title or
Sub Name
Y = Yes
N = No
Y = Yes
N = No
Retention
(Years)
File
Locator
Code
Test Report
000 509 F74025 Inspection Record For Air Coolers DE Y Y R3
000 509 F74026 Final Closing Authorization Record DE Y Y 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
DE Y Y R3
000 509 F74038
C-361 Compressor Dry Seal Panel and
Compressor Base Piping Cleaning Record
DE Y Y R3
000 509 F74039
C-362 Compressor Dry Seal Panel and
Compressor Base Piping Cleaning Record
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
000 509 F75002
Insulation Resistance (Insulated Flanges-
Underground Piping) Test Record
DE Y Y R1
000 509 F75003 Holiday (Spark) Test Record SQM Y Y R1
000 509 F75101 Aboveground Pipe Inspection Record SCM Y Y R1
000 509 F75102
Visual Inspection of Flanges, Gaskets and
Bolting
SQM N Y R1
000 509 F75103 Weld Map Record SQM N Y R2
000 509 F75201 Pressure Test Report DE Y Y R1
000 509 F75601 Pipe Cleaning and Certification Checklist SQM Y Y R3
000 509 F76001 Conduit and Cable Tray Checklist SQM Y Y R1
000 509 F76002 Electrical Manhole Inspection Checklist DE Y Y R2
000 509 F76003
Medium & High Voltage Underground
Cable Splice Inspection Record
DE Y Y R2
000 509 F76004 Grounding/Earthing Resistance Readings SQM Y Y R1
000 509 F76005 Cable Pulling Inspection Checklist SQM Y Y R1
Project Name: 000 509 0160
Contract No.: 18 Feb 04
Project Location:
SAMPLE
Attachment 1 . . . Page 4 of 6
Record Identification Custodian
System
Turnover
Package
Records
Retention
Center
Records
Retention
Center
Form # Title
Job Title or
Sub Name
Y = Yes
N = No
Y = Yes
N = No
Retention
(Years)
File
Locator
Code
000 509 F76006
Insulation Resistance (Power, Control Wire
and Cable) Test Record
SQM Y Y R1
000 509 F76007
Insulation Resistance (Instrument Wire and
Cable) Test Record
SQM Y Y R1
000 509 F76008
DC High Potential Test (Medium Voltage
Cable) Test Record
DE Y Y R1
000 509 F76009 Inspection of Power Transformer DE Y Y R1
000 509 F76010
Inspection Record for Fan/Speed
Reducer/Motor Checklist
DE Y Y R1
000 509 F76011 Inspection Record Electrical Motors DE Y Y R1
000 509 F76016 Inspection Record Emergency Generators DE Y Y R1
000 509 F76020
Inspection Record Ground Electrode
Resistance Test
DE Y Y R1
000 509 F76022 Inspection Record Switch Houses DE Y Y R3
000 509 F76023
Inspection Record Bus Bar Assemblies LV
Switchgear
DE Y Y R3
000 509 F76026
Inspection of Switching Units HV
Switchgear
DE Y Y R3
000 509 F76027 Inspection of Static Supply Unit (UPS) DE Y Y R3
000 509 F76029
Underground Conduit (Duct Bank)
Inspection
DE Y Y R3
000 509 F76030 Electrical Completion Checklist DE Y Y R3
000 509 F76201 Motor Control Centers Checklist DE Y Y R3
000 509 F76202 High Voltage Motors and Starters DE Y Y R3
000 509 F76203 Control and Relay Panels Checklist DE Y Y R3
000 509 F76204 Cable Termination Checklist DE Y Y R3
000 509 F76205 Grounding Continuity Checklist DE Y Y R3
000 509 F76206 Electrical Equipment Checklist DE Y Y R3
000 509 F76207 Grounding Rod Inspection DE Y Y R3
000 509 F76208
Lighting, Receptacle, Instrument
Distribution Panels Checklist
DE Y Y R3
000 509 F76211 Control Scheme Checklist DE Y Y R3
000 509 F76212 Power Panel Checklist DE Y Y R3
000 509 F76213 Switchgear Checklist DE Y Y R3
000 509 F76214 Low Voltage Feeders Checklist DE Y Y R3
000 509 F76215 Inspection of High Voltage Cable DE Y Y R1
000 509 F76216 Electrical Equipment Inspection Record DE Y Y R3
000 509 F76217 Motors Checklist DE Y Y R3
000 509 F76218 Electrical Motor Run-In Test Record DE Y Y R3
000 509 F76219 Local Control Panel Checklist DE Y Y R3
000 509 F76401 Heat Trace Test Log DE Y Y R3
000 509 F76402
Electrical Heat Tracing Inspection
DE Y Y R3
Project Name: 000 509 0160
Contract No.: 18 Feb 04
Project Location:
SAMPLE
Attachment 1 . . . Page 5 of 6
Record Identification Custodian
System
Turnover
Package
Records
Retention
Center
Records
Retention
Center
Form # Title
Job Title or
Sub Name
Y = Yes
N = No
Y = Yes
N = No
Retention
(Years)
File
Locator
Code
Checklist
000 509 F77001 Instrumentation Inspection Checklist DE N Y R1
000 509 F77002 Final Loop Check DE Y Y R1
000 509 F77003 Impulse Line Pressure Test Sheet DE Y Y R1
000 509 F77004 Instrument Grounding System Checklist DE Y Y R1
000 509 F77005 Installation Check Sheet (Local Instr) DE Y Y R3
000 509 F77006 Inspection Record Orifice Plates DE Y Y R3
000 509 F77007 Instrument Calibration Sheet DE Y Y R3
000 509 F77008 Safety Valve Tracking Sheet SQM Y Y R3
000 509 F77009
Relief Valve Inspection and Final
Acceptance
SQM Y Y R3
000 509 F77010 RIE Inspection Checklist DE Y Y R3
000 509 F77011 DCS Inspection Checklist DE Y Y R3
000 509 F77012
ESD System Inspection Checklist DE Y Y R3
000 509 F77013 Machinery Monitoring System Checklist DE Y Y R3
000 509 F78001 Coating Inspection Record SQM Y Y R3
000 509 F78002 Lining Inspection Record SQM Y Y R3
000 509 F78101 Equipment Thermal Insulation Inspection SQM Y Y R3
000 509 F78102 Pipe Thermal Insulation Inspection DE Y Y R3
000 509 F78201
Release for Application/Inspection of
Fireproofing
DE Y Y R3
000 509 F78202
Fireproofing Inspection Pre-Construction
Checklist
DE Y Y R3
000 509 F79001 Daily Welding Report NDEC Y Y R2
000 509 F79002 Post Weld Heat Treatment Log NDEC N N R2
000 509 F79003 Bonding Record SQM Y Y
R2
000 509 F79202
Nondestructive Examination Request /
Record
NDEC Y Y
R2
(Note 1)
000 509 F79301 Positive Material Identification SQM Y Y R2
Project Name: 000 509 0160
Contract No.: 18 Feb 04
Project Location:
SAMPLE
Attachment 1 . . . Page 6 of 6
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 = System No. R2 = Form No. (by date of completion or alphabetical)
R3 = Equipment No. R4 = Pour No.
R5 = By FCR No. R6 = Drawing No.
R7 = Line and Sheet
ACRONYMS:
CEM = Construction Engineering Manager SQM = Site Quality Control Manager
CA = Contracts Administrator DE = Discipline Engineer
NDEC = NDE Coordinator RRC = Record Retention Center
Project Name: 000 509 0170
Contract No.: 18 Feb 04
Project Location: Page 1 of 4
Fluor Corporation Company Confidential Site Quality Manual
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 subcontractors 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
Site Quality Manager
- 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
Fluors) 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.
Project Name: 000 509 0170
Contract No.: 18 Feb 04
Project Location: Page 2 of 4
Fluor Corporation Company Confidential Site Quality Manual
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
Project Name: 000 509 0170
Contract No.: 18 Feb 04
Project Location: Page 3 of 4
Fluor Corporation Company Confidential Site Quality Manual
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.
Site Quality Manager
- 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:
Audit Summary with attached Audit Finding Reports and checklist/marked
up procedure.
Copies of objective evidence obtained during the Audit.
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
- 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
Project Name: 000 509 0170
Contract No.: 18 Feb 04
Project Location: Page 4 of 4
Fluor Corporation Company Confidential Site Quality Manual
Copy of closed audit findings
- Root Cause Analysis
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))
Project Name: 000 509 0170
Contract No.: 18 Feb 04
Project Location: Attachment 1 . . . Page 1 of 1
AUDIT SCHEDULE (Fluor Activities)
Jan. Feb. Mar. April May June July Aug. Sept. Oct. Nov. Dec.
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.
Project Name: 000 509 0170
Contract No.: 18 Feb 04
Project Location: Attachment 2 . . . Page 1 of 2
AUDIT SCHEDULE (Subcontractors)
Subcontractors Jan.
|
Feb.
|
March
|
April
|
May
|
June
|
July
|
Aug.
|
Sept.
|
Oct.
|
Nov.
|
Dec.
|
(1) (3) (2)











INSTRUCTIONS FOR AUDIT SCHEDULE (SUBCONTRACTOR)
Project Name: 000 509 0170
Contract No.: 18 Feb 04
Project Location: Attachment 2 . . . Page 2 of 2
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.
Project Name: 000 509 0180
Contract No.: 18 Feb 04
Project Location: Page 1 of 3
Fluor Corporation Company Confidential Site Quality Manual
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
- Coordinate training targeted at site management personnel for orientation to this
site quality program.
Notes: 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.
Project Name: 000 509 0180
Contract No.: 18 Feb 04
Project Location: Page 2 of 3
Fluor Corporation Company Confidential Site Quality Manual
Notes: 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:
Site Quality Manager
- Coordinate site training schedule
- Ensure Site Managers 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.
Project Name: 000 509 0180
Contract No.: 18 Feb 04
Project Location: Page 3 of 3
Fluor Corporation Company Confidential Site Quality Manual
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
Project Name: 000 509 0200
Contract No.: 18 Feb 04
Project Location: Page 1 of 2
Fluor Corporation Company Confidential Site Quality Manual
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.
Site Quality Manager/Technical Supervisor
- 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):
Project Name: 000 509 0200
Contract No.: 18 Feb 04
Project Location: Page 2 of 2
Fluor Corporation Company Confidential Site Quality Manual
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.
Site Quality Manager/Technical Supervisor
- 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
Project Name: 000 509 0210
Contract No.: 20 Sep 04
Project Location: Page 1 of 9


Fluor Corporation Company Confidential Site Quality Manual
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
Technologys Corporate Quality Manager will assume the Site Quality Managers 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. Companys approach to
construction management contracting normally requires each Contractor to staff and perform the
inspection activities, with Company performing surveillance over the Contractor activities.
Project Name: 000 509 0210
Contract No.: 20 Sep 04
Project Location: Page 2 of 9


Fluor Corporation Company Confidential Site Quality Manual
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 Bidders response, when agreed
to by Company, become the Quality Plan for Contractors Work and will become part of the
successful Bidders 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 Contractors 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 Contractors QC procedures, including those
QC procedures of subcontractors and suppliers.

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

Project Name: 000 509 0210
Contract No.: 20 Sep 04
Project Location: Page 3 of 9


Fluor Corporation Company Confidential Site Quality Manual
The Contractor may select either an outside "agency" or in-house
personnel to administer Contractors QC System. In either case, the
Contractors 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
Contractors QC staff shall not be involved in the management and/or
control of the construction process. Contractors 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 Sub-
contractor 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 Contractors QC Supervisor (Representative)
Responsibilities and duties of the Contractors 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.
Project Name: 000 509 0210
Contract No.: 20 Sep 04
Project Location: Page 4 of 9


Fluor Corporation Company Confidential Site Quality Manual

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 Contractors
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.


Project Name: 000 509 0210
Contract No.: 20 Sep 04
Project Location: Page 5 of 9


Fluor Corporation Company Confidential Site Quality Manual

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
Project Name: 000 509 0210
Contract No.: 20 Sep 04
Project Location: Page 6 of 9


Fluor Corporation Company Confidential Site Quality Manual
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.
Contractors 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
Project Name: 000 509 0210
Contract No.: 20 Sep 04
Project Location: Page 7 of 9


Fluor Corporation Company Confidential Site Quality Manual
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
Contracts Administrator
- 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 Technologys Corporate
Quality Manager shall act as the Site Quality Manager.
Project Name: 000 509 0210
Contract No.: 20 Sep 04
Project Location: Page 8 of 9


Fluor Corporation Company Confidential Site Quality Manual


Site Quality Manager
- 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 Contractors work will be
performed or provided by Company.
Contracts Administrator
- Include in the RFP the quality requirements provided by the Site Quality
Manager. Upon receipt of the Contractors Quality Submittal or any exceptions to
quality requirements of the RFP, provide a copy to the Site Quality Manager.
Site Quality Manager
- Provide comments by memo on the Bidders 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 Bidders submittal requested by Attachment 04, the Site Quality
Manager should consider the following guidelines for the Contractors site quality
organization:
Project Name: 000 509 0210
Contract No.: 20 Sep 04
Project Location: Page 9 of 9


Fluor Corporation Company Confidential Site Quality Manual
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.
Contractors Quality organization chart shall include sufficient QC personnel
staffing levels as may be necessary to accomplish complete and adequate
inspection of work. Contractors 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.

Contracts Administrator
- 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 - Quality Audits
000 509 0220 - Surveillance of Construction Activities


ATTACHMENTS

Attachment 01 - Quality Requirements
Attachment 02 - Construction Subcontractor Quality Requirements Checklist
Attachment 03 - QC Procedures Description
Attachment 04 - Quality Submittal Requirements
Attachment 05 - Description of Inspection and/or Testing By Company
Project Name: 000 509 0210
Contract No.: 20 Sep 04
Project Location: 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 Contractors 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 1 day
Holiday testing 4 hours
Punching of lines prior to hydrotest 2 days
Pressure testing 4 hours
Acceptance inspection of buildings 2 days
Bolt tensioning 4 hours
DC (Direct Current) High Potential (over 2,000 volt cable) 4 hours
Motor run-ins 4 hours
Tests to electrical equipment 4 hours
Loop checks 4 hours
Acceptance inspection of vessels and equipment 1 day
Other tests 2 hours
Project Name: 000 509 0210
Contract No.: 20 Sep 04
Project Location: Attachment 1 . . . Page 2 of 2


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.
Project Name: 000 509 0210
Contract No.: 20 Sep 04
Project Location: Attachment 2 . . . Page 1 of 4


CONSTRUCTION CONTRACTOR QUALITY REQUIREMENT CHECKLIST

Procedure Title
Prepared by
Contractor
Contractor Forms
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
Project Name: 000 509 0210
Contract No.: 20 Sep 04
Project Location: Attachment 2 . . . Page 2 of 4



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
000 509 0170
000 509 0220
F01701 F02201 F01702 F02202
9. Material and Equipment Handling,
Storage and Maintenance
000 509 0250 F02501 F02502
10. Inspection and Testing Procedures (List
Title and Form Numbers)
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
10.6 Piling Closed End Concrete Filled
Pipe Piles
000 509 7060 F70301 F70302 F70303
10.7 Piling Concrete Filled Thin Shell
Pipe Piles
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
10.12 Buildings 000 509 7300
F73001 F73002 F73003 F73004 F73005
F73006 F73007 F73008 F73009 F73010
F73011 F73012 F73013 F73014 F73015
F73016
Project Name: 000 509 0210
Contract No.: 20 Sep 04
Project Location: Attachment 2 . . . Page 3 of 4



Procedure Title
Prepared by
Company
(Enclosed)
Forms (Enclosed)
10.13 Heating Ventilating and Air
Conditioning
000 509 7310 F73101 F73102
10.14 Roofing Inspection 000 509 7320 F73201
10.15 Equipment 000 509 7400
F74001 F74002 F74003 F74004 F74005
F74006 F74007 F74008 F74009 F74010
F74011 F74012 F74013 F74014 F74015
F74016 F74017 F74018 F74019 F74020
F74021 F74022 F74023 F74024 F74025
F74026 F74027 F74028 F74029 F74030
F74031 F74032
10.16 Field Fabricated Tanks 000 509 7410
F74101 F74102 F74103 F74104 F74105
F74106
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
F76001 F76002 F76003 F76004 F76005
F76006 F76007 F76008 F76009 F76010
F76011 F76012 F76013
10.30 Electrical Testing 000 509 7610
F76102 F76103 F76104 F76105 F76106
F76107 F76108 F76109 F76110 F76111
F76112 F76113 F76414 F76115 F76116
F76117 F76118 F76119 F76120 F76121
F76122 F76123 F76124 F76125 F76126
F76127 F76128 F76129 F76130 F76131
Project Name: 000 509 0210
Contract No.: 20 Sep 04
Project Location: Attachment 2 . . . Page 4 of 4


F76132 F76133 F76134 F76135
Procedure Title
Prepared by
Company
(Enclosed)
Forms (Enclosed)
10.31 Electrical Equipment 000 509 7620
F76201 F76202 F76203 F76204 F76205
F76206 F76207 F76208 F76209 F76210
F76211 F76212 F76213 F76214 F76215
F76216 F76217 F76218 F76219 F76220
F76221 F76222 F76223 F76224 F76225
F76226 F76227 F76228 F76229 F76230
F76231
10.32 Control System Instrumentation 000 509 7700
F77001 F77002 F77003 F77004 F77005
F77006
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

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.
Project Name: 000 509 0210
Contract No.: 20 Sep 04
Project Location: Attachment 3 . . . Page 1 of 4


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.
Project Name: 000 509 0210
Contract No.: 20 Sep 04
Project Location: Attachment 3 . . . Page 2 of 4


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.


Project Name: 000 509 0210
Contract No.: 20 Sep 04
Project Location: Attachment 3 . . . Page 3 of 4


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 Companys 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.

Project Name: 000 509 0210
Contract No.: 20 Sep 04
Project Location: Attachment 3 . . . Page 4 of 4


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.

Project Name: 000 509 0210
Contract No.: 20 Sep 04
Project Location: Attachment 4 . . . Page 1 of 1



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.
Project Name: 000 509 0210
Contract No.: 20 Sep 04
Project Location: Attachment 5 . . . Page 1 of 1


DESCRIPTION OF INSPECTION AND / OR TESTING BY COMPANY

Company will inspect Contractors 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 1 Day
Holiday testing 4 Hours
Punching of lines prior to hydrotest 2 Days
Pressure testing 4 Hours
Acceptance inspection of buildings 2 Days
Bolt tensioning 4 Hours
DC (Direct Current) High Potential (over 2,000 volt cable) 4 Hours
Motor run-ins 4 Hours
Tests to electrical equipment 4 Hours
Loop checks 4 Hours
Acceptance inspection of vessels and equipment 1 Day
Other tests 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.
Project Name: 000 509 0220
Contract No.: 18 Feb 04
Project Location: Page 1 of 3
Fluor Corporation Company Confidential Site Quality Manual
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
Site Quality Manager
- 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.
Project Name: 000 509 0220
Contract No.: 18 Feb 04
Project Location: Page 2 of 3
Fluor Corporation Company Confidential Site Quality Manual
- 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.
Project Name: 000 509 0220
Contract No.: 18 Feb 04
Project Location: Page 3 of 3
Fluor Corporation Company Confidential Site Quality Manual
Site Quality Manager
- 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
Project Name: 000 509 0230
Contract No.: 18 Feb 04
Project Location: Page 1 of 2
Fluor Corporation Company Confidential Site Quality Manual
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
ACTIVITY RESPONSIBILITY DOCUMENTATION
FREQUENCY
OF ACTIVITY
Warehouse receipt of
material/items
Warehouse
Personnel
O, S, and D
Per shipment
received
Determine inspection and
storage level
requirements
Construction
Engineer
Attachment 1
As project
progresses
Perform quality receipt
inspection
Site Quality
Manager
000 509 F02301
As required by
project
Responsibilities - Subcontracted Work
ACTIVITY RESPONSIBILITY DOCUMENTATION
FREQUENCY
OF ACTIVITY
Warehouse receipt of
material/items
Subcontractor O, S, and D
Per shipment
received
Determine inspection and
storage level
requirements
Subcontractor 000 509 0230, Att. 1
As project
progresses
Perform quality receipt
inspection
Subcontractor 000 509 F02301
As required by
project
Surveillance
Site Quality
Manager
Form 000 509 F02201
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.
Project Name: 000 509 0230
Contract No.: 18 Feb 04
Project Location: Page 2 of 2
Fluor Corporation Company Confidential Site Quality Manual
Determine Inspection and Storage Requirements:
- 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 Attributes for Receiving Inspection
Attachment 2 Typical Permanent Plant Material and Equipment Inspection List
Project Name: 000 509 0230
Contract No.: 18 Feb 04
Project Location: Attachment 1 . . . Page 1 of 1
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 EXCHANGERS/PRESSURE VESSELS VALVES
Damage Damage Identification Tags appropriately affixed
Corrosion Cleanliness and marked
Fit of Nut & Bolt Corrosion Damage
Size Check Flange & Opening Protection Corrosion
REINFORCING STEEL Shipping Protection Flange & Opening Protections
Damage Temporary Supports Moving Parts
Corrosion Fan Blades Valve Markings
Deformations Motors Positive Material Identification,
if required
Mill Markings Gears FITTINGS, Alloy
Mill Certifications Dessicants Damage
STRUCTURAL STEEL Vendor Instructions Corrosion
Damage Name Plate Data Piece Markings
Corrosion Shaft Rotation Positive Material Identification
Welding FIRED HEATERS & BOILERS ELECTRICAL EQUIPMENT
Piece Marking Damage Damage
Connectors Corrosion Corrosion
Dimensional Checks Flange & Opening Protection Name Plate Data
FIELD FABRICATED TANKS Edges Prepared for Welding Accessories
Damage Mill Certifications Dimensional Checks
Corrosion Dimensional Checks Shipping Protection
Edges Prepared for Welding Name Plate Data Temporary Supports
Mill Certifications Welding ELECTRICAL MATERIAL
Dimensional Checks Accessories Damage
SHOP FABRICATED TANKS & VESSELS Refractory Corrosion
Damage SPECIALITY EQUIPMENT Item Markings
Corrosion Damage INSTRUMENTS
Accessories Corrosion Damage
Flange & Opening Protection Flange & Opening Protection Corrosion
Temporary Supports Edges Prepared for Welding Shipping Protection
Dessicants Dimensional Checks Item Markings
Shop Coatings Name Plate Data Accessories
Dimensional Checks Welding COATINGS
Name Plate Data Accessories Damage
MACHINERY PIPE Deterioration
Damage Cleanliness Shipping Prep Cap Markings
Corrosion Damage WELD FILLER MATERIAL
Accessories Corrosion Damage
Shipping Protection Shop Coatings Properly Identified
Temporary Supports Pipe Markings Mill Certifications
Vendor Instructions Color Coding and/or PMI if applicable
Flange & Opening Protection
Name Plate Data
Shaft Rotation
Welding
Project Name: 000 509 0230
Contract No.: 18 Feb 04
Project Location: Attachment 2 . . . Page 1 of 1
PERMANENT PLANT MATERIAL AND EQUIPMENT INSPECTION LIST
TYPICAL
I. CIVIL
Civil materials such as:
Structural steel components Protective coatings
Load indicating bolts/washers Specialty grouts
II. 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 Vessels
Valves Fittings
Nozzles Weld Rod
V. APPROVALS
Construction Engineering Manager__________________________________ Date:
Quality Manager__________________________________ Date:
Project Name: 000 509 0240
Contract No.: 18 Feb 04
Project Location: Page 1 of 5
Fluor Corporation Company Confidential Site Quality Manual
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 RESPONSIBILITY DOCUMENTATION
FREQUENCY OF
ACTIVITY
Determine scope of
system
Turnover Engineer
Scoped drawings
and Form 000 509 FXXXX
Prior to start of work
Establish alphanumeric
number and brief scope
Turnover Engineer Turnover master listing Prior to start of work
Establish mechanical
completion dates
Commissioning/Start-up,
engineering, construction
management, and The Client
Form 000 509 F02401
Three weeks before
mechanical completion
date
Issue walk-down notice
Turnover Coordinator /
CompleteIt Administrator
Form 000 509 F02402
Two weeks before
mechanical completion
date
Generate master
punchlist
Turnover Coordinator /
CompleteIt Administrator
Form 000 509 F02407
Prior to mechanical
completion date
Generate exceptions list
Turnover Coordinator /
CompleteIt Administrator
Exceptions list format -
site specific
Generate discipline
checklist
Turnover Coordinator/
CompleteIt Administrator
Form 000 509 F02403
Form 000 509 F02404
Form 000 509 F02405
Form 000 509 F02406
Prior to mechanical
completion
Generate care, custody,
and control package
Turnover Coordinator /
CompleteIt Administrator
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
System scoping drawings,
elementary or one line diagram.
Hydro test report.
Equipment list.
Instrument list.
Exceptions list.
Loop list.
Prior to turnover of
system or area
Surveillance QC Inspector Form 000 509 F02201
Per Procedure
000 509 0220
Project Name: 000 509 0240
Contract No.: 18 Feb 04
Project Location: Page 2 of 5
Fluor Corporation Company Confidential Site Quality Manual
Responsibilities - Subcontracted Work
ACTIVITY RESPONSIBILITY DOCUMENTATION
FREQUENCY OF
ACTIVITY
Determine scope of system
Turnover Engineer /
Subcontractor
Scoped drawings Prior to start of work
Establish alphanumeric
number and brief scope
Turnover Engineer /
Subcontractor
Turnover master listing Prior to start of work
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
Form 000 509 F02407
Prior to mechanical
completion date
Generate discipline
checklist
Subcontractor/
Turnover Coordinator /
CompleteIt Administrator
Form 000 509 F02403
Form 000 509 F02404
Form 000 509 F02405
Form 000 509 F02406
Prior to mechanical
completion
Generate care, custody,
and control package
Subcontractor/
Turnover Coordinator /
CompleteIt Administrator
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
System scoping drawings,
elementary or one line
diagrams
Hydrotest Report
Equipment List
Instrument List
Exceptions List
Loop List
Surveillance QC Inspector Form 000 509 F02201
Per Procedure
000 509 0220
Project Name: 000 509 0240
Contract No.: 18 Feb 04
Project Location: Page 3 of 5
Fluor Corporation Company Confidential Site Quality Manual
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.
Project Name: 000 509 0240
Contract No.: 18 Feb 04
Project Location: Page 4 of 5
Fluor Corporation Company Confidential Site Quality Manual
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) Transfer of Care, Custody, and Control Letter
b) Discipline Managers Checklist
c) System Scoping Drawings
d) Elementary or One-Line Diagrams
e) Hydrostatic Test Report
f) Equipment List
g) Instrument List
h) Exceptions List
i) 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.
Project Name: 000 509 0240
Contract No.: 18 Feb 04
Project Location: Page 5 of 5
Fluor Corporation Company Confidential Site Quality Manual
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
Project Name: 000 509 0250
Contract No.: 18 Feb 04
Project Location: Page 1 of 2
Fluor Corporation Company Confidential Site Quality Manual
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
FREQUENCY OF
ACTIVITY
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
Subcontractor/Site
Quality Manager
Form:
000 509 F02501
Monthly during the
life of the activity
Perform Preservation
Activities
Subcontractor/Site
Quality Manager
Form:
000 509 F02502
Each Item
Resolve discrepancies
as appropriate
Subcontractor/Site
Quality Manager
Form:
000 509 F02501
As required to resolve
discrepancies
Surveillance
Site Quality Manager
(*Note 1)
Form:
000 509 F02201
Per procedure
000 509 0220
*Note 1: 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).
Project Name: 000 509 0250
Contract No.: 18 Feb 04
Project Location: Page 2 of 2
Fluor Corporation Company Confidential Site Quality Manual
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)
Project Name: 000 509 0250
Contract No.: 18 Feb 04
Project Location: Attachment 1 . . . Page 1 of 4
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
Project Name: 000 509 0250
Contract No.: 18 Feb 04
Project Location: Attachment 1 . . . Page 2 of 4
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
Project Name: 000 509 0250
Contract No.: 18 Feb 04
Project Location: Attachment 1 . . . Page 3 of 4
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 well-
ventilated 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 40F and
maximum shall be 140F 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.
Project Name: 000 509 0250
Contract No.: 18 Feb 04
Project Location: Attachment 1 . . . Page 4 of 4
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.
Project Name: 000 509 5100
Contract No.: 18 Feb 04
Project Location: Page 1 of 4
Fluor Corporation Company Confidential Site Quality Manual
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
Project Name: 000 509 5100
Contract No.: 18 Feb 04
Project Location: Page 2 of 4
Fluor Corporation Company Confidential Site Quality Manual
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 Clients 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.
Project Name: 000 509 5100
Contract No.: 18 Feb 04
Project Location: Page 3 of 4
Fluor Corporation Company Confidential Site Quality Manual
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.
Project Name: 000 509 5100
Contract No.: 18 Feb 04
Project Location: Page 4 of 4
Fluor Corporation Company Confidential Site Quality Manual
DOCUMENTATION
Approved "Activity Plan - Construction" shall be maintained by the Site Manager until project
completion.
ATTACHMENTS
Appendix I - Activity Plan - Construction (Reference Guide)
Project Name: 000 509 5100
Contract No.: 18 Feb 04
Project Location: Appendix I . . . Page 1 of 5
QUALITY ACTIVITY PLAN - CONSTRUCTION
Client Name
Project Name
Project Number
PREPARATION VERIFICATION AUTHORIZATION
ACTIVITY
DESCRIPTION
WORK
INSTRUCTION
BASIS OF
CHECK
INTER
DISCIPLIN
E REVIEW
INDEPENDENT
VERIFICATION
PERFORMED
BY
CHECKED
BY
APPROVED
BY CONSTR.
APPROVED
BY
PROJECT
APPROVED
BY CLIENT
Project Const. Plan 000.506.1300 N/A N/A SM N/A N/A PM
Const. Org. 000.506.1201 N/A N/A SM N/A N/A PM
Constructability
000.506.1100
000.506.1200
000.506.1300
000.506.1400
000.506.1500
000.506.1600
N/A PM PM N/A N/A PM
Construction
Engineering
000.505.1601 N/A CEM DCE N/A SM N/A
Human Resource
Staffing
000.505.2701 N/A N/A FHRM N/A SM N/A
Construction
Turnover
000.505.3201 000 509 0240 SM CM SQM N/A PM
Project Safety
Program
Project Safety
Plan in
Compliance with
FD-APS
N/A N/A S RSM N/A PM
Industrial
Relations
Program
000.505.2801 N/A N/A SM IRRM N/A PM
Construction
Quality Control
Plan
000.505.1701
Corporate QC
Manual 000 509
xxxx
SQM DCE CEM CM N/A
Administrative
Services
000.505.2401 N/A CEM SVM N/A N/A PM
ASME Code Work
Fluor-B-PV Code
Manual
000 510 xxxx
FD-B-PV Code
Manual
000 510 xxxx
DQW CEM SQM N/A PM
Document Control
000.509.0050
000.505.1601
000.509.0050
000.509.0160
CEM SM SQM N/A PM
Personnel Training
and Qualification
000.509.0180 N/A CEM CM SQM N/A PM
Field Design
Change Control
000.505.1400 000.509.0150 CEM DCE SQM N/A PM
Construction
Process Control
000.509.0090 000.509.0090 CEM DCE SQM CM N/A
Site Preparation
Geotechnical
Investigation
000.210.02010 000.509.7010 DCE CM SQM SM N/A
Excavation and
Backfill
000.210.02222
000.210.02224
000.509.7010 DCE CM SQM CM N/A
Shotcrete
Fireproofing
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
Grout Installation
000.215.03600A
000.215.03600B
000.509.7100 DCE CM SQM CM N/A
Structural Steel
Installation
000.215.05120
000.215.05130
000.509.7200 DCE CM SQM CM N/A
Coatings and
Wrapping of Steel
Pipe
000.285.86410
000.285.86210
000.509.7800 DCE CM SQM CM N/A
Hot Insulation 000.285.86110
000.509.7810
Contract
DCE CM SQM CM N/A
Project Name: 000 509 5100
Contract No.: 18 Feb 04
Project Location: Appendix I . . . Page 2 of 5
PREPARATION VERIFICATION AUTHORIZATION
ACTIVITY
DESCRIPTION
WORK
INSTRUCTION
BASIS OF
CHECK
INTER
DISCIPLINE
REVIEW
INDEPENDENT
VERIFICATION
PERFORMED
BY
CHECKED
BY
APPROVED
BY CONSTR.
APPROVED
BY
PROJECT
APPROVED
BY CLIENT
Internal Linings 000.285.86310
000.509.7800
Contract
DCE CM SQM CM
Raceway and
Supports Installation
000.265.65051
000.265.65052
000.509.7600 DCE CM SQM CM N/A
Cable Installation
000.265.65123
000.265.65126
000.509.7600
000.509.7610
DCE CM SQM CM N/A
Equipment
Installation
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
000.509.7400
000.509.7620 DCE CM SQM CM N/A
Meggering and Hi-
Pot Testing
000.265.65053
000.509.7600
000.509.7610
000.509.7620
DCE CM SQM CM N/A
Grounding
000.265.65053
000.265.65640
000.265.16111
000.509.7600
000.509.7610
000.509.7620
DCE CM SQM CM N/A
Meggering and
Maintenance of
Electric Motors
000.265.65053
000.509.7600
000.509.7610
000.509.7620
DCE CM SQM CM N/A
Electrical Heat Trace 000.270.01851 000.509.7610 DCE CM SQM CM N/A
Receiving and
warehousing of
Instruments
000.270.70952
000.509.0230
000.509.0250
DCE WM SQM SM
Electrical Instrument
Installation
000.270.70001
000.270.70002
000.270.70003
000.270.70007
000.270.15121
000.509.7600
000.509.7610
000.509.7620
DCE CM SQM CM N/A
Construction Testing 000.265.65053 * DCE CM SQM CM N/A
Piping, Cement
Lined
000.250.31003 000.509.7510 DCE CM SQM CM
Plastic and Plastic
Lined Pipe
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
000.509.7500
000.509.7510
DCE CM SQM CM N/A
Pipe Winterization 000.250.50008
000.509.7500
000.509.7510
DCE CM SQM CM N/A
Installation of
Rotating Equipment
000.256.56001
000.256.56002
000.256.56003
000.256.56004
000.509.7400 DCE CM SQM CM N/A
Installation of Tanks,
Vessels - Heat
Exchangers, Flares
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
000.509.7610
000.509.7500
000.509.7510
DCE CM SQM CM N/A
Mechanical
Instrument
Installation
000.270.70002
000.270.70950
000.270.70951
000.509.7700
000.509.7710
DCE CM SQM CM N/A
Project Name: 000 509 5100
Contract No.: 18 Feb 04
Project Location: Appendix I . . . Page 3 of 5
PREPARATION VERIFICATION AUTHORIZATION
ACTIVITY
DESCRIPTION
WORK
INSTRUCTION
BASIS OF
CHECK
INTER
DISCIPLINE
REVIEW
INDEPENDENT
VERIFICATION
PERFORMED
BY
CHECKED
BY
APPROVED
BY CONSTR.
APPROVED
BY
PROJECT
APPROVED
BY CLIENT
Pipe Cleaning 000.250.18801 000.509.7560
*
DCE CM SQM CM N/A
Piping Heat Tracing 000.250.50300 000.509.7610 DCE CM SQM CM N/A
Firewater Systems 000.245.00323
000.509.7500
000.509.7510
DCE CM SQM CM N/A
Fireproofing 000.245.01431 000.509.7820 DCE CM SQM CM N/A
Sewer Systems 000.250.50007 000.509.0220 DCE CM SQM CM N/A
Maintaining Quality
Records
000.509.0160 000.509.0160 SQM CM SQM CM N/A
Material Equipment
Identification,
Traceability and
Inspection Test
Status
000.509.7000
000.509.0230
FD Inspection
& Test
Procedures
000 509 7xxx
SQM
WM
CM
SQM CM N/A
Nonconformance
Reporting
000.509.0130 000.509.0130 SQM SQM SQM SM N/A
Corrective Action 000.509.0140 000.509.0140 SQM CEM CM SM N/A
Site Supplier Quality
Control System,
Requirement
Qualification and
Surveillance
000.509.0210
000.509.0200
000.509.0220
000.509.0200
000.509.0210
000.509.0220
SQM CEM SQM SM N/A
Material and
Equipment Receipt
Inspection
000.509.0230 000.509.0230 SQM
WM
CEM
SQM CM N/A
Material and
Equipment Storage
Handling
Maintenance
000.509.0250 000.509.0250 SQM
WM
CEM
SQM CM N/A
Inspection
Measuring Test
Equipment
000.509.0110 000.509.0110 SQM CEM SQM CM N/A
Surveillance of
Construction
Activities
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
SUBCONTRACTOR CONTROL
Nondestructive
Testing
Subcontractors
NDE Procedures
000.509.0220
000.509.7920
MNDT SQM SUB SQM SM N/A
Fireproofing 000.245.01431
000.509.7820
Contract
CEM SUB DCE CM N/A
Drilled Piers,
Caissons
000.215.02380
000.509.7080
Contract
CEM SUB DCE CM N/A
Auger Cast Piles 000.215.02370
000.509.7080
Contract
CEM SUB DCE CM N/A
Painting & Linings
000.285.86210
000.285.86310
000.509.7800
Contract
CEM SUB DCE CM N/A
Hot Insulation 000.285.86110
000.509.7810
Contract
CEM SUB DCE CM N/A
ASME Section VIII
Vessel Work
000.258.58001
000.258.58004
000.258.58010
000.258.58040
000.258.58050
000.258.58061
000.258.58140
Contract CEM SUB SQM CM N/A
Fired Heaters
000.257.07041
000.257.18032
000.257.19033
000.257.57103
000.509.7400
Contract
CEM SUB
SQM
DCE
CM N/A
Field Fabricated
Tank Retrofit (TK
806)
API 650
Appendix H
000.509.7400
Contract
CEM SUB
SQM
DCE
CM N/A
Cool Tower
Installation
000.257.57011 000.509 CEM SUB DCE CM N/A
Piping Tie-ins 000.250.50027 Contract CEM Client SUB DCE CM N/A
Project Name: 000 509 5100
Contract No.: 18 Feb 04
Project Location: Appendix I . . . Page 4 of 5
PREPARATION VERIFICATION AUTHORIZATION
ACTIVITY
DESCRIPTION
WORK
INSTRUCTION
BASIS OF
CHECK
INTER
DISCIPLINE
REVIEW
INDEPENDENT
VERIFICATION
PERFORMED
BY
CHECKED
BY
APPROVED
BY CONSTR.
APPROVED
BY
PROJECT
APPROVED
BY CLIENT
Fire
Protection/Sprinkler
Systems
000.245.00323 Contract CEM SUB DCE CM N/A
Substation
Equipment
Modification
000.245.65301
000.265.65303
000.265.65320
Contract CEM SUB DCE CM N/A
Electrical Equipment
Testing Hi-Pot and
Acceptance Testing
000.265.65053
000.509.7600
000.509.7610
000.509.7620
Contract
CEM SUB DCE CM N/A
Electrical Heat
Tracing
000.265.50300
000.270.01851
Contract CEM SUB DCE CM N/A
Reactor Flex-R
Instrumentation
Installation
000.270.01511 Contract CEM SUB DCE CM N/A
Field Machining Contract Contract CEM SUB SQC CM N/A
Geotechnical
Investigation
000.210.02010 Contract CEM SUB DCE CM N/A
Mechanical/
Chemical Cleaning
000.250.18801
000.250.50026
000.509.7560 CEM SUB DCE/SQM CM N/A
Post-Weld Heat
Treatment (PWHT)
000.285.18041
Fluor Welding
Manual
000.509.0220
000.509.7920
CEM SQM SUB SQM CM N/A
Soil & Concrete
Testing
000.210.02222
000.210.02224
000.215.03300
000.509.7010
000.509.7100
CEM SQM SUB
DCE
SQM
CM N/A
Underground Piping 000.245.00323 000.509.7500 CEM SUB
SQM
DCE
CM N/A
Project Name: 000 509 5100
Contract No.: 18 Feb 04
Project Location: Appendix I . . . Page 5 of 5
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
_________________________________________
Signature
_________________________________________
Print Signature
FLUOR
OPERATING COMPANY REPRESENTATIVE
______________________________________
Signature
______________________________________
Print Signature
* These checklists are provided in the "Discipline QC Functions" section (000.509.7xxx).
Project Name: 000 509 7000
Contract No.: 18 Feb 04
Project Location: Page 1 of 3
Fluor Corporation Company Confidential Site Quality Manual
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.
Project Name: 000 509 7000
Contract No.: 18 Feb 04
Project Location: Page 2 of 3
Fluor Corporation Company Confidential Site Quality Manual
R - Review
H - Hold Point 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.
Project Name: 000 509 7000
Contract No.: 18 Feb 04
Project Location: Page 3 of 3
Fluor Corporation Company Confidential Site Quality Manual
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
Project Name: 000 509 7000
Contract No.: 18 Feb 04
Project Location: Attachment 1 . . . Page 1 of 1
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 Fluors
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.
Project Name: 000 509 7010
Contract No.: 18 Feb 04
Project Location: Page 1 of 2
Fluor Corporation Company Confidential Site Quality Manual
SOILS
SCOPE
This procedure applies to inspection and testing of soils work.
RESPONSIBILITIES - Self-Perform
ACTIVITY RESPONSIBILITY DOCUMENTATION
FREQUENCY OF
ACTIVITY
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
Daily during life of
activity
Surveillance QC Inspection (Note 2) 000 509 F02201
Per Procedure
000 509 0220
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
FREQUENCY OF
ACTIVITY
Perform soils work Subcontractor
Inspect in-process soils
work
Subcontractor 000 509 F70101
Daily during life of
activity
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
Daily during life of
activity
Surveillance QC Inspector Form 000 509 F02201
Per Procedure
000 509 0220
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.
Project Name: 000 509 7010
Contract No.: 18 Feb 04
Project Location: Page 2 of 2
Fluor Corporation Company Confidential Site Quality Manual
NOTE 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 - Soil Inspection Checklist
000 509 F70102 - Field Compaction Test Record
000 509 F70103 - Density of Soil in Place by the Sand-Cone Method
000 509 F70104 - Nuclear Moisture - Density Test Report
000 509 F70105 - 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.::]
Project Name: 000 509 7020
Contract No.: 18 Feb 04
Project Location: Page 1 of 5
Fluor Corporation Company Confidential Site Quality Manual
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
FREQUENCY
OF ACTIVITY
Verify Subgrade
acceptable
QC Inspector
000 509 F70201 and
000 509 F70103 or
000 509 F70104
Prior to installing
base
Accept base and
paving material
qualification
Construction Engineer _____
Prior to start of base
and paving work
Inspect in-process
base preparation and
paving activities
QC Inspector 000 509 F70201 Daily during activity
Perform test for base Testing Agency
000 509 F70201 and
000 509 F70103 or
000 509 F70104
(Note 1)
As required by project
specifications
Perform test for
paving
Testing Agency
000 509 F70202 and
000 509 F70203 or
000 509 F70204
(Note 1)
As required by project
specifications
Technically supervise
Test Agency
Construction Engineer _____ Daily during activity
Surveillance
QC Inspection
(Note 2)
Form
000 509 F02201
Per Procedure
000 509 0220
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.
Project Name: 000 509 7020
Contract No.: 18 Feb 04
Project Location: Page 2 of 5
Fluor Corporation Company Confidential Site Quality Manual
RESPONSIBILITIES - Subcontracted Work
ACTIVITY RESPONSIBILITY DOCUMENTATION
FREQUENCY
OF ACTIVITY
Install base and
paving
Subcontractor _____ _____
Verify Subgrade
acceptable
Subcontractor
Form 000 509
F70201 and
000 509 F70103 or
000 509 F70104
Prior to installing
base
Accept base and
paving material
qualifications
Subcontractor/
Construction
Engineer
_____
Prior to start of base
and paving work
Inspect in-process
base preparation and
paving activities
Subcontractor
Form
000 509 F70201
Daily during activity
Perform testing for
base
Subcontractor
Form 000 509
F70201 and 000 509
F70103 or
000 509 F70104
(Note 1)
As required by project
specifications
Perform testing for
paving
Subcontractor
Form 000 509
F70202 and 000 509
F70203 or
000 509 F70204
(Note 1)
As required by project
specifications
Technically supervise
test agency
Subcontractor _____ Daily during activity
Surveillance QC Inspector 000 509 F02201
Per Procedure
000 509 0220
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.
Project Name: 000 509 7020
Contract No.: 18 Feb 04
Project Location: Page 3 of 5
Fluor Corporation Company Confidential Site Quality Manual
c) 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
Project Name: 000 509 7020
Contract No.: 18 Feb 04
Project Location: Page 4 of 5
Fluor Corporation Company Confidential Site Quality Manual
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-D-
2922. (F70104)
c) Bulk specific gravity of Compacted Bituminous Mixtures - AASHTO-
T166. (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.
Project Name: 000 509 7020
Contract No.: 18 Feb 04
Project Location: Page 5 of 5
Fluor Corporation Company Confidential Site Quality Manual
g) Density of bituminous concrete in place by Nuclear Method - ASTM-D-
2950. ::]
- 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-1556-
ASHTO-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.::]
Project Name: 000 509 7030
Contract No.: 18 Feb 04
Project Location: Page 1 of 4
Fluor Corporation Company Confidential Site Quality Manual
STEEL H PILES
SCOPE
This procedure prescribes the installation, inspection, and testing of Steel H Piles.
RESPONSIBILITIES - Self-Perform
ACTIVITY RESPONSIBILITY DOCUMENTATION
FREQUENCY OF
ACTIVITY
Monitor pile load test
Civil Construction
Engineer
_____ As required
Inspect in-process
pile driving
Civil Construction
Engineer
000 509 F70301
000 509 F70302
000 509 F70303
Daily during life of
activity
Check final pile
locations/installation
Civil Construction
Engineer
Survey field books As required
Surveillance
QC Inspection
(Note 2)
000 509 F02201 As required
RESPONSIBILITIES - Subcontracted Work
ACTIVITY RESPONSIBILITY DOCUMENTATION
FREQUENCY OF
ACTIVITY
Perform pile load test
(See Note 1)
Subcontractor _____
As required by project
specification
Monitor pile load test
Civil Construction
Engineer
_____ As required
Inspect in-process
pile driving
(See Note 1)
Subcontractor
000 509 F70301
000 509 F70302
000 509 F70303
Daily during life of
activity
Check final pile
installation
Subcontractor/
Civil Construction
Engineer
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.
Project Name: 000 509 7030
Contract No.: 18 Feb 04
Project Location: Page 2 of 4
Fluor Corporation Company Confidential Site Quality Manual
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) 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 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.
Project Name: 000 509 7030
Contract No.: 18 Feb 04
Project Location: Page 3 of 4
Fluor Corporation Company Confidential Site Quality Manual
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.
Project Name: 000 509 7030
Contract No.: 18 Feb 04
Project Location: Page 4 of 4
Fluor Corporation Company Confidential Site Quality Manual
- 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 inches of the elevation shown on drawings.
- Provide uplift connection at locations and as described on design drawings.
- Prebored pilot holes are prohibited.
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
Project Name: 000 509 7040
Contract No.: 18 Feb 04
Project Location: Page 1 of 4
Fluor Corporation Company Confidential Site Quality Manual
PRECAST CONCRETE PILES
SCOPE
This procedure prescribes the installation, inspection and testing of precast prestressed concrete
piles.
RESPONSIBILITIES - Self-Perform
ACTIVITY RESPONSIBILITY DOCUMENTATION
FREQUENCY
OF ACTIVITY
Monitor pile load test
Civil Construction
Engineer
_____ As required
Inspect in-process
piling installation
Civil Construction
Engineer
000 509 F70301
000 509 F70302
000 509 F70303
Daily during life of
activity
Check final pile
location/installation
Senior Field Engineer Survey Field Books As required
Surveillance
QC Inspection
(Note 2)
000 509 F02201
Per Procedure
000 509 0220
RESPONSIBILITIES - Subcontracted Work
ACTIVITY RESPONSIBILITY DOCUMENTATION
FREQUENCY OF
ACTIVITY
Perform pile load test
(See Note 1)
Subcontractor _____
As required by project
specification
Monitor pile load test
Civil Construction
Engineer
_____ As required
Inspect in-process
pile driving
(See Note 1)
Subcontractor
000 509 F70301
000 509 F70302
000 509 F70303
Daily during life of
activity
Check final pile
installation
Subcontractor/
Civil Construction
Engineer
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.
Project Name: 000 509 7040
Contract No.: 18 Feb 04
Project Location: Page 2 of 4
Fluor Corporation Company Confidential Site Quality Manual
NOTE 2: Fluor QC Surveillance is required for construction activities not being
documented on other inspection forms by Fluor Quality.
PROCEDURE
Monitor Pile Load Tests:
- 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.
Project Name: 000 509 7040
Contract No.: 18 Feb 04
Project Location: Page 3 of 4
Fluor Corporation Company Confidential Site Quality Manual
- Axial Tension Load Test - Conduct test in accordance with ASTM D3689 except as
modified below.
- Apply loads by employing both calibrated hydraulic jack and load cell. Do not
leave loaded jack unattended.
- 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.
- Use cyclic loading procedure in accordance with ASTM D3689, 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 D3966 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 beam as primary
system for measuring movement. Use surveyor's transit and scale as secondary
system.
- Use cyclic loading procedure in accordance with ASTM D3966, Section 6.3.
- 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
Project Name: 000 509 7040
Contract No.: 18 Feb 04
Project Location: Page 4 of 4
Fluor Corporation Company Confidential Site Quality Manual
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.
- Operate pile driving hammer at the speed and conditions recommended by the
manufacturer.
- 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.
- Provide uplift connection at locations and as described on design drawings.
Check Final Pile Location/Installation:
- 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
Project Name: 000 509 7050
Contract No.: 18 Feb 04
Project Location: Page 1 of 4
Fluor Corporation Company Confidential Site Quality Manual
TIMBER PILES
SCOPE
This procedure prescribes the installation, inspection and testing of timber foundation piles.
RESPONSIBILITIES - Self-Perform
ACTIVITY RESPONSIBILITIES DOCUMENTATION
FREQUENCY
OF ACTIVITY
Monitor pile load
testing
Civil Construction
Engineer
_____ As required
Inspect in-process
piling installation
Civil Construction
Engineer
000 509 F70301
000 509 F70302
000 509 F70303
Daily during life of
activity
Check final pile
location/installation
Senior Field Engineer Survey Field Books As required
Surveillance
QC Inspection
(Note 2)
000 509 F02201
Per Procedure
000 509 0220
RESPONSIBILITIES - Subcontracted Work
ACTIVITY RESPONSIBILITY DOCUMENTATION
FREQUENCY OF
ACTIVITY
Perform pile load test
(See Note 1)
Subcontractor _____
As required by project
specification
Monitor pile load test
Civil Construction
Engineer
_____ As required
Inspect in-process pile
driving
(See Note 1)
Subcontractor
000 509 F70301
000 509 F70302
000 509 F70303
Daily during life of
activity
Check final pile
installation
Subcontractor/
Senior Field Engineer/
Civil Construction
Engineer
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.
Project Name: 000 509 7050
Contract No.: 18 Feb 04
Project Location: Page 2 of 4
Fluor Corporation Company Confidential Site Quality Manual
PROCEDURE
Monitor Pile Load Tests:
- 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 pile.
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 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.
- 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 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.
- Axial Tension Load Test - Conduct test in accordance with ASTM D3689 except as
modified below.
- Apply loads by employing both calibrated hydraulic jack and load cell. Do not leave
loaded jack unattended.
Project Name: 000 509 7050
Contract No.: 18 Feb 04
Project Location: Page 3 of 4
Fluor Corporation Company Confidential Site Quality Manual
- 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.
- Use cyclic loading procedure in accordance with ASTM D3689, 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 D3966 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 beam as primary
system for measuring movement. Use surveyor's transit and scale as secondary
system.
- Use cyclic loading procedure in accordance with ASTM D3966, Section 6.3.
- 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.
- 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.
Project Name: 000 509 7050
Contract No.: 18 Feb 04
Project Location: Page 4 of 4
Fluor Corporation Company Confidential Site Quality Manual
- Use leads 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 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.
FORMS
Quality Control Forms:
000 509 F70301 - Pile Driving Inspection Record
000 509 F70302 - Pile Driving Record
000 509 F70303 - Record of Pile Driving
Project Name: 000 509 7060
Contract No.: 18 Feb 04
Project Location: Page 1 of 5
Fluor Corporation Company Confidential Site Quality Manual
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
FREQUENCY
OF ACTIVITY
Monitor pile load test
Civil Construction
Engineer
_____ As required
Inspect in-process
piling installation
Civil Construction
Engineer
000 509 F70301
000 509 F70302
000 509 F70303
Daily during life of
activity
Check final pile
location/installation
Senior Field Engineer Survey Field Books As required
Surveillance
QC Inspection
(Note 2)
Form
000 509 F02201
Per Procedure
000 509 0220
RESPONSIBILITIES - Subcontracted Work
ACTIVITY RESPONSIBILITY DOCUMENTATION
FREQUENCY OF
ACTIVITY
Perform pile load test
(See Note 1)
Subcontractor _____
As required by project
specification
Monitor pile load test
Civil Construction
Engineer
_____ As required
Inspect in-process
pile driving
(See Note 1)
Subcontractor
000 509 F70301
000 509 F70302
000 509 F70303
Daily during life of
activity
Check final pile
installation
Subcontractor/
Civil Construction
Engineer
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 no being documented
on other inspection forms by Fluor Quality.
Project Name: 000 509 7060
Contract No.: 18 Feb 04
Project Location: Page 2 of 5
Fluor Corporation Company Confidential Site Quality Manual
PROCEDURE
Monitor Pile Load Tests:
- 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 (14) 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.
Project Name: 000 509 7060
Contract No.: 18 Feb 04
Project Location: Page 3 of 5
Fluor Corporation Company Confidential Site Quality Manual
- Axial Tension Load Test - Conduct test in accordance with ASTM D3689 except as
modified below.
- Apply loads by employing both calibrated hydraulic jack and load cell. Do not leave
loaded jack unattended.
- 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.
- Use cyclic loading procedure in accordance with ASTM D3689, 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 D3966 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 beam as primary
system for measuring movement. Use surveyor's transit and scale as secondary
system.
- Use cyclic loading procedure in accordance with ASTM D3966, Section 6.3.
- Take and record readings to 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 _____ 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.
Project Name: 000 509 7060
Contract No.: 18 Feb 04
Project Location: Page 4 of 5
Fluor Corporation Company Confidential Site Quality Manual
- Operate pile driving hammer at the speed and conditions recommended by the
manufacturer.
- Protect piles during driving with cushioned caps that does not absorb hammer
energy.
- Use leads 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.
- 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 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.
- Provide uplift connection at locations and as described on design drawings.
- Prebored pilot holes are prohibited.
Project Name: 000 509 7060
Contract No.: 18 Feb 04
Project Location: Page 5 of 5
Fluor Corporation Company Confidential Site Quality Manual
Check Final Pile Location/Installation:
- 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
Project Name: 000 509 7070
Contract No.: 18 Feb 04
Project Location: Page 1 of 5
Fluor Corporation Company Confidential Site Quality Manual
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
FREQUENCY
OF ACTIVITY
Monitor pile load test
Civil Construction
Engineer
_____ As required
Inspect in-process
piling installation
Civil Construction
Engineer
000 509 F70301
000 509 F70302
000 509 F70303
Daily during life of
activity
Check final pile
locations/installation
Civil Construction
Engineer
Survey Field Books As required
Surveillance
QC Inspection
(Note 2)
000 509 F02201
Per Procedure
000 509 0220
RESPONSIBILITIES - Subcontracted Work
ACTIVITY RESPONSIBILITY DOCUMENTATION
FREQUENCY OF
ACTIVITY
Perform pile load test
(See Note 1)
Subcontractor _____
As required by project
specification
Monitor pile load test
Civil Construction
Engineer
_____ As required
Inspect in-process
pile driving
(See Note 1)
Subcontractor
000 509 F70301
000 509 F70302
000 509 F70303
Daily during life of
activity
Check final pile
installation
Subcontractor/
Civil Construction
Engineer
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.
Project Name: 000 509 7070
Contract No.: 18 Feb 04
Project Location: Page 2 of 5
Fluor Corporation Company Confidential Site Quality Manual
PROCEDURE
Monitor Pile Load Tests:
- 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 (14) 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.
- Axial Tension Load Test - Conduct test in accordance with ASTM D3689 except as
modified below.
Project Name: 000 509 7070
Contract No.: 18 Feb 04
Project Location: Page 3 of 5
Fluor Corporation Company Confidential Site Quality Manual
- Apply loads by employing both calibrated hydraulic jack and load cell. Do not leave
loaded jack unattended.
- 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.
- Use cyclic loading procedure in accordance with ASTM D3689, 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 D3966 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 beam as primary
system for measuring movement. Use surveyor's transit and scale as secondary
system.
- Use cyclic loading procedure in accordance with ASTM D3966, Section 6.3.
- Take and record readings to 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 _____ 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.
Project Name: 000 509 7070
Contract No.: 18 Feb 04
Project Location: Page 4 of 5
Fluor Corporation Company Confidential Site Quality Manual
- Operate pile driving hammer at the speed and conditions recommended by the
manufacturer.
- 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 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.
- 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.
- Cut tops of piles off and level, within _____ inch of the elevation on drawings.
- Provide uplift connection at locations and as described on design drawings.
Project Name: 000 509 7070
Contract No.: 18 Feb 04
Project Location: Page 5 of 5
Fluor Corporation Company Confidential Site Quality Manual
Check Final Pile Location/Installation:
- 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
Project Name: 000 509 7080
Contract No.: 18 Feb 04
Project Location: Page 1 of 3
Fluor Corporation Company Confidential Site Quality Manual
DRILLED CAISSONS
SCOPE
This procedure prescribes the inspection and testing of Drilled Caissons.
RESPONSIBILITIES Subcontracted Work
ACTIVITY RESPONSIBILITY DOCUMENTATION
FREQUENCY OF
ACTIVITY
Excavate Caisson Subcontractor 000 509 F70801 Each Caisson
Clean Caisson Subcontractor 000 509 F70801 Each Caisson
Install Reinforcing Subcontractor 000 509 F70801 Each Caisson
Place Concrete Subcontractor
000 509 F71001
000 509 F70801
000 509 F71002
000 509 F71003
000 509 F71007
000 509 F71008
Each Caisson
Inspect Caisson
Installation
Quality Control
Inspector
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.
Project Name: 000 509 7080
Contract No.: 18 Feb 04
Project Location: Page 2 of 3
Fluor Corporation Company Confidential Site Quality Manual
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.
Project Name: 000 509 7080
Contract No.: 18 Feb 04
Project Location: Page 3 of 3
Fluor Corporation Company Confidential Site Quality Manual
FORMS
Quality Control Forms:
000 509 F70801 - Caisson Inspection Record
000 509 F71001 - Pre-Concrete Inspection Checklist
000 509 F71002 - Concrete Inspection Record
000 509 F71003 - Concrete Pour Card
000 509 F71007 - Concrete Compression Strength Test Record
000 509 F71008 - Concrete Placement Log
Project Name: 000 509 7090
Contract No.: 18 Feb 04
Project Location: Page 1 of 5
Fluor Corporation Company Confidential Site Quality Manual
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
FREQUENCY OF
ACTIVITY
Install Pile Subcontractor 000 509 F70901 Each Pile
Grouting Subcontractor 000 509 F70901 Each Pile
Install Reinforcing
Steel
Subcontractor 000 509 F70901 Each Pile
Sonic Logging
PVC
Subcontractor 000 509 F70901
Each Pile or as required
in Project Specification
Spoils Removal Subcontractor Each Pile
Inspect Pile
Installation
Quality Control
Inspector
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 piles installation
record.
General
All Subcontractor supplied materials and proprietary items shall be subject to Fluors
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.
Project Name: 000 509 7090
Contract No.: 18 Feb 04
Project Location: Page 2 of 5
Fluor Corporation Company Confidential Site Quality Manual
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
o
F Maximum Holding Time Hours
Less than 70
From 70 to 90
Greater than 90
2.5
2.0
Shall not be used
Project Name: 000 509 7090
Contract No.: 18 Feb 04
Project Location: Page 3 of 5
Fluor Corporation Company Confidential Site Quality Manual
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 - 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.
Project Name: 000 509 7090
Contract No.: 18 Feb 04
Project Location: Page 4 of 5
Fluor Corporation Company Confidential Site Quality Manual
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 days 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.
Project Name: 000 509 7090
Contract No.: 18 Feb 04
Project Location: Page 5 of 5
Fluor Corporation Company Confidential Site Quality Manual
FORMS
Quality Control Forms:
000 509 F70901 Augered Cast-In-Place Pile Record
000 509 F71005 Cementitious Grout Testing Record
Project Name: 000 509 7100
Contract No.: 18 Feb 04
Project Location: Page 1 of 4
Fluor Corporation Company Confidential Site Quality Manual
CONCRETE AND GROUT
SCOPE
This procedure applies to inspection and testing of structural concrete and grouting.
RESPONSIBILITIES - Self-Perform
ACTIVITY RESPONSIBILITY DOCUMENTATION
FREQUENCY
OF ACTIVITY
Supply
Concrete
Supplier Batch Ticket As required
Perform
Concrete
Placement
Civil Superintendent 000 509 F71003 As required
Batch Plant
Technical
Supervision
Civil Construction
Engineer
000 509 F02004
(Concrete Batch Plant
Evaluation Record) and
000 509 F71010
Initially then
random
Concrete
Inspection
Civil Construction
Engineer
000 509 F71001 & F71002 for
Structural Concrete
F71004 for Cementitious Grout
F71006 for Epoxy Resin Grout
F71007, F71008
F71010 for Batch Plant
For individual
placements as
required by
specification.
Coordination of
Placement
Civil Construction
Engineer
F71003
(Concrete Pour Card)
Each placement
Test Concrete
Test Agency
(Note 1)
F71007 (Note 1)
(plus F71005 for cementitious
grout)
Each set of
cylinders/cubes
as required by
specification.
Surveillance
QC Inspection
(Note 2)
000 509 F02201
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: Fluor QC Surveillance is required for construction activities not being documented
on other inspection forms by Fluor Quality.
Project Name: 000 509 7100
Contract No.: 18 Feb 04
Project Location: Page 2 of 4
Fluor Corporation Company Confidential Site Quality Manual
RESPONSIBILITIES - Subcontracted Work
ACTIVITY RESPONSIBILITY DOCUMENTATION
FREQUENCY OF
ACTIVITY
Supply Concrete Supplier Batch Ticket As required
Perform Concrete
Placement
Subcontractor 000 509 F71003 As required
Batch Plant Technical
Supervision
Civil Construction
Engineer
000 509 F02004
000 509 F71010
Initially then random
Concrete Inspection Subcontractor
000 509 F71001
000 509 F71002
000 509 F71004
000 509 F71006
000 509 F71007
000 509 F71008
Each placement
Coordination of
Placement
Civil Construction
Engineer/
Subcontractor
000 509 F71003 As required
Test Concrete Test Lab
Approved test agency
form in compliance
with 000 509 F71007
and 000 509 F71005.
As required by
specification
Technically Supervise
Test Lab
Site Quality
Manager
000 509 F02005 Initially then random
Surveillance
QC Inspection
(Note 2)
000 509 F02201
Per Procedure
000 509 0220
NOTE 2: Fluor QC Surveillance is required for construction activities not being documented
on other inspection forms by Fluor Quality.
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.
Project Name: 000 509 7100
Contract No.: 18 Feb 04
Project Location: Page 3 of 4
Fluor Corporation Company Confidential 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:
- 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.
Project Name: 000 509 7100
Contract No.: 18 Feb 04
Project Location: Page 4 of 4
Fluor Corporation Company Confidential Site Quality Manual
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.::]
Project Name: 000 509 7200
Contract No.: 18 Feb 04
Project Location: Page 1 of 3
Fluor Corporation Company Confidential Site Quality Manual
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 DOCUMENTATION
FREQUENCY
OF ACTIVITY
Verify acceptability of
Interface Structures
Civil Construction
Engineer
000 509 F72002 Once for each structure
Erect Structural Steel Civil Superintendent _____ _____
Inspect In-process
Structural Steel
Erection
Civil Construction
Engineer
000 509 F72002
Daily during life of
activity
Perform Final
Inspection
Civil Construction
Engineer
000 509 F72002 Once per structure
RESPONSIBILITIES - Subcontracted Work
ACTIVITY RESPONSIBILITY DOCUMENTATION
FREQUENCY
OF ACTIVITY
Verify acceptability of
Interface Structures
Civil Construction
Engineer
000 509 F72002 Once for each structure
Erect Structural Steel Subcontractor _____ _____
Inspect In-process
Structural Steel
Erection
Subcontractor 000 509 F72002
Daily during life of
activity
Perform Final
Inspection
Subcontractor /
Civil Construction
Engineer
000 509 F72002 Once per structure
Surveillance Site Quality Manager 000 509 F02201
Per Procedure
000 509 0220
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.
Project Name: 000 509 7200
Contract No.: 18 Feb 04
Project Location: Page 2 of 3
Fluor Corporation Company Confidential Site Quality Manual
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.
Project Name: 000 509 7200
Contract No.: 18 Feb 04
Project Location: Page 3 of 3
Fluor Corporation Company Confidential Site Quality Manual
- 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
Project Name: 000 509 7300
Contract No.: 18 Feb 04
Project Location: Page 1 of 3
Fluor Corporation Company Confidential Site Quality Manual
BUILDINGS
SCOPE
This procedure describes the inspection and testing activities to be performed for buildings that
are constructed by Fluor.
RESPONSIBILITIES - Self-Perform
ACTIVITY RESPONSIBILITY DOCUMENTATION
FREQUENCY OF
ACTIVITY
Verify foundations
complete
Civil Construction
Engineer
000 509 F73001
Daily during life of
activity
Review structural steel
documents
Civil Construction
Engineer
_____ Prior to steel erection
Monitor in-process
building construction
Civil Construction
Engineer
000 509 F02201
Daily during life of
activity
Inspect completed work
Civil Construction
Engineer
000 509 F73003-F73016 Each Item
Verify building complete
Civil Construction
Engineer
Procedure 000 509 7300 Once per building
Surveillance QC Inspection (Note 1) 000 509 F02201
Per Procedure 000 509
0220
NOTE 1: Surveillance is not required if the Fluor Quality representative is performing inspections.
RESPONSIBILITIES - Subcontracted Work
ACTIVITY RESPONSIBILITY DOCUMENTATION
FREQUENCY OF
ACTIVITY
Inspect in-process
foundations
Subcontractor 000 509 F73001 Daily during life of activity
Inspect in-process
building superstructure
Subcontractor 000 509 F02201 Daily during life of activity
Witness HVAC Test
Civil Construction
Engineer/
Site Quality Manager
000 509 F73101 Each test
Inspect completed
building
Subcontractor
Discipline Engineer
Site Quality Manager
000 509 F73002 Once per building
Coordinate resolution of
deficiencies
Subcontractor/
Civil Construction
Engineer/
Site Quality Manager
000 509 F73002
As required to close open
items
Surveillance QC Inspection 000 509 F02201
Per Procedure
000 509 0220
Project Name: 000 509 7300
Contract No.: 18 Feb 04
Project Location: Page 2 of 3
Fluor Corporation Company Confidential Site Quality Manual
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.
Project Name: 000 509 7300
Contract No.: 18 Feb 04
Project Location: Page 3 of 3
Fluor Corporation Company Confidential Site Quality Manual
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
Project Name: 000 509 7300
Contract No.: 18 Feb 04
Project Location: Attachment 1 . . . Page 1 of 1
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
Project Name: 000 509 7300
Contract No.: 18 Feb 04
Project Location: Attachment 2 . . . Page 1 of 1
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 40F
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
ASCERTAIN WORKMANSHIP
1. Damp proof coating free of breaks, surface air voids in monolithic concrete
2. Waterproof coating free of wrinkles and buckles
Project Name: 000 509 7300
Contract No.: 18 Feb 04
Project Location: Attachment 2 . . . Page 1 of 1
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 40F
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
ASCERTAIN WORKMANSHIP
1. Damp proof coating free of breaks, surface air voids in monolithic concrete
2. Waterproof coating free of wrinkles and buckles
Project Name: 000 509 7300
Contract No.: 18 Feb 04
Project Location: Attachment 3 . . . Page 1 of 1
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 55F
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
ASCERTAIN WORKMANSHIP
1. Each plaster coat, smooth, plumb, true, all in one plane
2. White plaster coat free from cracks, crazing, blisters, pits, checks, discoloration
Project Name: 000 509 7300
Contract No.: 18 Feb 04
Project Location: Attachment 4 . . . Page 1 of 1
BUILDINGS, METAL DOORS AND WINDOWS INSPECTION REFERENCE
VERIFY THE USE OF CORRECT MATERIALS
1. Approved material samples
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
ASCERTAIN WORKMANSHIP
1. 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
Project Name: 000 509 7300
Contract No.: 18 Feb 04
Project Location: Attachment 5 . . . Page 1 of 1
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.
Project Name: 000 509 7300
Contract No.: 18 Feb 04
Project Location: Attachment 6 . . . Page 1 of 1
BUILDINGS RESILIENT FLOOR COVERING INSPECTION REFERENCE
VERIFY CORRECT MATERIALS
1. Approved material samples
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
ASCERTAIN WORKMANSHIP
1. 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.
Project Name: 000 509 7300
Contract No.: 18 Feb 04
Project Location: Attachment 7 . . . Page 1 of 1
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
Project Name: 000 509 7300
Contract No.: 18 Feb 04
Project Location: Attachment 8 . . . Page 1 of 1
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 50F for 24 hours prior to use
5. Ambient temperature is 40F 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
ASCERTAIN WORKMANSHIP
1. 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
Project Name: 000 509 7300
Contract No.: 18 Feb 04
Project Location: Attachment 9 . . . Page 1 of 1
BUILDINGS CERAMIC TILE INSPECTION REFERENCE
VERIFY THE USE OF CORRECT MATERIALS
1. Approved material samples
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
ASCERTAIN WORKMANSHIP
1. 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
Project Name: 000 509 7310
Contract No.: 18 Feb 04
Project Location: Page 1 of 2
Fluor Corporation Company Confidential Site Quality Manual
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
FREQUENCY
OF ACTIVITY
Verify ductwork
configuration
Construction
Engineer
000 509 F73101
000 509 F73102
Upon completion of
work
Verify ductwork
integrity
Construction
Engineer
000 509 F73101
000 509 F73102
Prior to turnover of
system
Verify leak testing
performed
Construction
Engineer
000 509 F73101
000 509 F73102
Prior to turnover of
system
Verify connections to
equipment
Electrical/Mechanical
Engineer
000 509 F73101
000 509 F73102
Prior to turnover of
system
Surveillance
QC Inspector
(Note 1)
000 509 F02201
Per Procedure
000 509 0220
NOTE 1: Surveillance is not required if the Fluor l quality representative is performing
inspections.
RESPONSIBILITIES - Subcontracted Work
ACTIVITY RESPONSIBILITY DOCUMENTATION
FREQUENCY
OF ACTIVITY
Verify ductwork
configuration
Subcontractor
000 509 F73101
000 509 F73102
Upon completion of
work
Verify ductwork
integrity
Subcontractor
000 509 F73101
000 509 F73102
Prior to turnover of
system
Perform leak test Subcontractor
000 509 F73101
000 509 F73102
Prior to turnover of
system
Connect duct to
equipment
Subcontractor
000 509 F73101
000 509 F73102
Prior to turnover of
system
Surveillance QC Inspector 000 509 F0221
Per Procedure
000 509 0220
Project Name: 000 509 7310
Contract No.: 18 Feb 04
Project Location: Page 2 of 2
Fluor Corporation Company Confidential Site Quality Manual
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
Project Name: 000 509 7320
Contract No.: 18 Feb 04
Project Location: Page 1 of 1
Fluor Corporation Company Confidential Site Quality Manual
ROOFING INSPECTION
SCOPE
This procedure prescribes the roofing system inspection activities to be performed.
RESPONSIBILITIES - Subcontracted
ACTIVITY RESPONSIBILITY DOCUMENTATION
FREQUENCY OF
ACTIVITY
Install Roofing Subcontractor
Roofing Installation
General
Requirements
Civil Construction
Engineer
000 509 F73201 Daily during activity
Inspect Roofing
Installation of
Adhered Membrane
Civil Construction
Engineer
000 509 F73201 Daily during activity

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
Project Name: 000 509 7400
Contract No.: 18 Feb 04
Project Location: Page 1 of 5
Fluor Corporation Company Confidential Site Quality Manual
EQUIPMENT
SCOPE
This procedure defines the inspection, testing and documentation requirements for installation
activities for equipment erection and installation.
RESPONSIBILITIES - Self-Perform
ACTIVITY RESPONSIBILITY DOCUMENTATION
FREQUENCY
OF ACTIVITY
Implement storage,
handling and maintenance
requirement
Construction Engineer/
Craft Supervision
_____
As required by the
controlling documents
Check anchor bolt
surveying
Construction Engineer Survey Field Books
Prior to setting
equipment
Check level, alignment
and plumbness
Construction Engineer Survey Field Books
Prior to setting
equipment
Install/Erect equipment
Mechanical
Superintendent
000 509 F740XX
Once for each piece
of equipment
Monitor In-process
Installation Activities
Site Quality Manager
000 509 F740XX
000 509 F02201
Daily during the life of
the activity
Witness final alignment of
rotating equipment
Millwright Superintendent 000 509 F740XX
Once during final
alignment
Coordinate vendor
activities
Construction Engineer Vendor Reports
As required by
purchase order
Review guarantee
requirements
Construction Engineer
_____
As required by
purchase order
Perform final inspection of
installed equipment
Site Quality Manager 000 509 F740XX
Once after installation
completed
Resolve any discrepancies
identified
Construction Engineer/
Site Quality Manager
000 509 F740XX
As required to resolve
discrepancies
NOTE 1: Surveillance is not required is not required if the Fluor Quality representative is performing
inspections.
Project Name: 000 509 7400
Contract No.: 18 Feb 04
Project Location: Page 2 of 5
Fluor Corporation Company Confidential Site Quality Manual
RESPONSIBILITIES - Subcontracted Work
ACTIVITY RESPONSIBILITY DOCUMENTATION
FREQUENCY
OF ACTIVITY
Implement storage,
handling and maintenance
requirement
Subcontractor _____
As required by the
controlling documents
Check anchor bolt
surveying
Subcontractor
Survey Field Books
Prior to setting
equipment
Check level, alignment and
plumbness
Subcontractor Survey Field Books
Prior to setting
equipment
Install/Erect equipment Subcontractor 000 509 F740XX
Once for each piece
of equipment
Monitor In-process
Installation Activities
Subcontractor/
Site Quality Manager
000 509 F740XX
Daily during the life of
the activity
Witness final alignment of
rotating equipment
Subcontractor/
Site Quality Manager
000 509 F740XX
Once during final
alignment
Coordinate vendor
activities
Discipline Engineer Vendor Reports
As required by
purchase order
Review guarantee
requirements
Subcontractor/
Discipline Engineer
_____
As required by
purchase order
Coordinate discipline
inspections
Subcontractor _____
As required by
specifications/
procedures
Perform final inspection of
installed equipment
Subcontractor/
Site Quality Manager
000 509 F740XX
Once after installation
completed
Resolve any discrepancies
identified
Subcontractor
Discipline Engineer
Site Quality Manager
000 509 F740XX
As required to resolve
discrepancies
Surveillance Site Quality Manager 000 509 F02201
Per Procedure
000 509 0220
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.
Project Name: 000 509 7400
Contract No.: 18 Feb 04
Project Location: Page 3 of 5
Fluor Corporation Company Confidential 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:
- 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.
Project Name: 000 509 7400
Contract No.: 18 Feb 04
Project Location: Page 4 of 5
Fluor Corporation Company Confidential 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:
- 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
Project Name: 000 509 7400
Contract No.: 18 Feb 04
Project Location: Page 5 of 5
Fluor Corporation Company Confidential Site Quality Manual
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
Project Name: 000 509 7400
Contract No.: 18 Feb 04
Project Location: Attachment 1 . . . Page 1 of 2
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 trip-
out 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.
Project Name: 000 509 7400
Contract No.: 18 Feb 04
Project Location: Attachment 1 . . . Page 2 of 2
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.
Project Name: 000 509 7410
Contract No.: 18 Feb 04
Project Location: Page 1 of 4
Fluor Corporation Company Confidential Site Quality Manual
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
FREQUENCY
OF ACTIVITY
Verify foundation
surveying
Construction Engineer Survey Field Books Prior to start of erection
Inspect foundation
construction
Site Quality Manager Per 000 509 7100 Prior to start of erection
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
Site Quality Manager Per 000 509 7910
Daily during life of
activity
Check dimensions of
tank shell
Site Quality Manager 000 509 F74103
Periodically during life of
activity
Inspect completed tank Site Quality Manager 000 509 F74102 Each tank
Witness testing Site Quality Manager Each tank
Inspect tested tank prior
to closing
Site Quality Manager 000 509 F74026 Each tank
Project Name: 000 509 7410
Contract No.: 18 Feb 04
Project Location: Page 2 of 4
Fluor Corporation Company Confidential Site Quality Manual
RESPONSIBILITIES - Subcontracted
ACTIVITY RESPONSIBILITY DOCUMENTATION
FREQUENCY
OF ACTIVITY
Verify foundation
surveying
Construction Engineer Survey Field Books Prior to start of erection
Inspect foundation
construction
Subcontractor 000 509 F0221 Prior to start of erection
Review and approve
contractor's welding
procedures
Welding Engineering
Approval from Corporate
Welding Engineering
Prior to start of welding
activities
Review and approve
contractor's NDE
procedures
Corporate NDE Level III
Approval from Corporate
Level III
Prior to start of NDE
activities
Check dimensions of
tank shell
Subcontractor
000 509 F74103
000 509 F02201
Periodically during life of
activity
Surveillance of weld and
NDE activities.
Site Quality Manager/
Subcontractor
000 509 F02201
Daily during life of
activity
Inspect completed tank
Site Quality Manager/
Subcontractor
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:
- Verify that the foundation surveying is complete.
Foundation Construction:
- 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.
Project Name: 000 509 7410
Contract No.: 18 Feb 04
Project Location: Page 3 of 4
Fluor Corporation Company Confidential Site Quality Manual
Review and Approval of NDE Procedures:
- 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.
Project Name: 000 509 7410
Contract No.: 18 Feb 04
Project Location: Page 4 of 4
Fluor Corporation Company Confidential Site Quality Manual
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
Project Name: 000 509 7420
Contract No.: 18 Feb 04
Project Location: Page 1 of 1
Fluor Corporation Company Confidential Site Quality Manual
COOLING TOWER
SCOPE
This procedure defines the inspection, testing and documentation requirements for installation
activities for Cooling Towers.
RESPONSIBILITIES - Sub-Contracted
ACTIVITY RESPONSIBILITY DOCUMENTATION
FREQUENCY
OF ACTIVITY
Check foundation
surveying
Construction Engineer/
Subcontractor
Survey Field Books
000 509 F02201
Prior to start of
installation
Inspect in-process
installation
Site Quality Manager/
Subcontractor
000 509 F02201
Daily during life
of activity
Inspect completed
construction
Site Quality Manager/
Subcontractor
000 509 F02201
Each cooling
tower
PROCEDURE
Check Foundation Surveying:
- 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 contractors letterhead, prior to the start of
work.
Inspection of In-process Installation Activities:
- 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
Project Name: 000 509 7430
Contract No.: 18 Feb 04
Project Location: 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 RESPONSIBILITY DOCUMENTATION
FREQUENCY
OF ACTIVITY
Inspect refractory materials
Civil Construction
Engineer
000 509 F02201
Prior to each
application/job
Inspect in-process
installation activities
Civil Construction
Engineer
000 509 F74301
Each unit of equipment
requiring refractory
Witness/Perform refractory
tests
Civil Construction
Engineer
000 509 F74301
Each unit of equipment
requiring refractory
PROCEDURE
Inspection of Refractory Materials:
- 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 Installation Activities:
- 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
Project Name: ITP 509 7440
Contract No.: 18 Feb 04
Project Location: Page 1 of 3
Fluor Corporation Company Confidential Site Quality Manual
Inspection and Test Plan
Activity
Equipment Installation
Description
Gas Turbine/Gear Unit/
Generator Installation Inspection
Project Name Project Location Project Number
Client Contractor Contract Number ITP Number 000 509 ITP7440
Revision 0
Issue Date
Scope of Inspection
Item Inspection/Test Stage
Requirement and
Acceptance Criteria
Responsibility
Sub Fluor Client
Inspection
Record
CompleteIT
Input
1
Verify the installation contractor has prepared a
complete field testing plan
N/A CEM R N/A N/A
2
Inspect the equipment for guarantee requirements,
when requirements are a part of the purchase order.
PO CS I I N/A
3 Verify Nameplate Data PO CS I I 509F74401
4
Recheck the anchor bolt locations and elevation,
prior to setting equipment on the foundations.
Per approved drawings
CEM I I
509F74402
5
Verify the installer has accepted the foundations in
writing
N/A CEM I R N/A
6
Check equipment orientation, openings, elevation
and location as required for interface with other
equipment, check piping connection alignment
Per approved drawings CEM R 509F74021
7 Inspect grouting operations
Project Specification,
000 509 7100
CS I H
509F71006
509F71009
509F74401
509F74402
8
Verify field installed pressure piping hydrostatically
tested prior to final connection to the Gas Turbine
Generator system.
Hydrotest Packages
completed and
reinstated
CS R 509F74402
9
Inspect and align turbine/gear/ generator unit before
and after piping connection
Project Specification CS I H
509F74401
509F74402
509F74021
Project Name: ITP 509 7440
Contract No.: 18 Feb 04
Project Location: Page 2 of 3
Fluor Corporation Company Confidential Site Quality Manual
Inspection and Test Plan
Activity
Equipment Installation
Description
Gas Turbine/Gear Unit/
Generator Installation Inspection
Project Name Project Location Project Number
Client Contractor Contract Number ITP Number 000 509 ITP7440
Revision 0
Issue Date
Scope of Inspection
Item Inspection/Test Stage
Requirement and
Acceptance Criteria
Responsibility
Sub Fluor Client
Inspection
Record
CompleteIT
Input
10 Conduct in-process installation inspection
Per applicable check
sheet, manufacturers
specification and
Project Specification
CS I I
509F74401
509F74402
11
Inspect, or perform, equipment and material
preservation activities.
000 509 0250
Project Specification
CS P I
509F02502
509F74402
12
Verify lube oil and cooling oil systems are changed
with operating oil recommended by the
manufacturer.
Manufacturers
Recommendations -
See PO
CS P W 509F74402
13 Verify gauges and instruments have been calibrated
prior to the performance tests.
T/O package
instrument calibration
records complete
CS P R 509F74402
14
Verify the completion of electrical, pre-operational
and functional test as described in the
specifications
T/O package functional
test records complete
CS P R 509F74402
15
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
Per Approved
Drawings
CS I I 509F74402
Project Name: ITP 509 7440
Contract No.: 18 Feb 04
Project Location: Page 3 of 3
Fluor Corporation Company Confidential Site Quality Manual
Inspection and Test Plan
Activity
Equipment Installation
Description
Gas Turbine/Gear Unit/
Generator Installation Inspection
Project Name Project Location Project Number
Client Contractor Contract Number ITP Number 000 509 ITP7440
Revision 0
Issue Date
Scope of Inspection
Item Inspection/Test Stage
Requirement and
Acceptance Criteria
Responsibility
Sub Fluor Client
Inspection
Record
CompleteIT
Input
16
Monitor field mechanical running test for
compliance with test requirements and recorded
measurements
Per Manufacturers
Specification and PO
requirements,
Commissioning ITP
CEM P H 509F74402
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)
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
Project Name: ITP 509 7460
Contract No.: 18 Feb 04
Project Location: Page 1 of 22
Fluor Corporation Company Confidential Site Quality Manual
Inspection and Test Plan
Activity
Equipment Installation
Description
Steam Turbine/Generator Installation
Project Name Project Location Project Number
Client Contractor Contract Number ITP Number 000 509 ITP7460
Revision 0
Issue Date
Scope of Inspection Completion
Sign-Off Item Inspection/Test Stage
Requirement and
Acceptance Criteria
Responsibility
Sub Fluor Client
Inspection/Test
Record
Fluor GE
1
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
CEM P P
2
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.
CS P R 000 509 F74601
3
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.
4
Rigging plans reviewed and approved by FLUOR rigging
engineer
5
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.
Project Name: ITP 509 7460
Contract No.: 18 Feb 04
Project Location: Page 2 of 22
Fluor Corporation Company Confidential Site Quality Manual
Inspection and Test Plan
Activity
Equipment Installation
Description
Steam Turbine/Generator Installation
Project Name Project Location Project Number
Client Contractor Contract Number ITP Number 000 509 ITP7460
Revision 0
Issue Date
Scope of Inspection Completion
Sign-Off Item Inspection/Test Stage
Requirement and
Acceptance Criteria
Responsibility
Sub Fluor Client
Inspection/Test
Record
Fluor GE
8
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
000 509 F74602
000 509 F74609
9
Fixators installed and verified to be acceptable and the
results documented and attached.
000 509 F74603
10
Sole plates installed and verified to be acceptable and
results documented and attached.
000 509 F74604
11
Mid-standard installation (between the HP/IP and LP
sections) is to be conducted using GE documents and
the GE TAs 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
(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
000 509 F74604
Project Name: ITP 509 7460
Contract No.: 18 Feb 04
Project Location: Page 3 of 22
Fluor Corporation Company Confidential Site Quality Manual
Inspection and Test Plan
Activity
Equipment Installation
Description
Steam Turbine/Generator Installation
Project Name Project Location Project Number
Client Contractor Contract Number ITP Number 000 509 ITP7460
Revision 0
Issue Date
Scope of Inspection Completion
Sign-Off Item Inspection/Test Stage
Requirement and
Acceptance Criteria
Responsibility
Sub Fluor Client
Inspection/Test
Record
Fluor GE
12
1) LP Exhaust Hood section installation to be
verified and found to be acceptable with the results
documented and attached.
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.
000 509 F74606
13
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.
000 509 F74606
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
000 509 F74606
Measure as-received dimensions and the top and
bottom surface levelness of front standard Baseplate
Assembly. Confirm findings with the GE TAs records.
Project Name: ITP 509 7460
Contract No.: 18 Feb 04
Project Location: Page 4 of 22
Fluor Corporation Company Confidential Site Quality Manual
Inspection and Test Plan
Activity
Equipment Installation
Description
Steam Turbine/Generator Installation
Project Name Project Location Project Number
Client Contractor Contract Number ITP Number 000 509 ITP7460
Revision 0
Issue Date
Scope of Inspection Completion
Sign-Off Item Inspection/Test Stage
Requirement and
Acceptance Criteria
Responsibility
Sub Fluor Client
Inspection/Test
Record
Fluor GE
Front Standard Baseplate Assembly installation to be
conducted using GE documents and the GE TAs
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
(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
000 509 F74605
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 TAs records.
Installation of HP/IP section verified and found to be
acceptable by the GE TA document the measurements
Project Name: ITP 509 7460
Contract No.: 18 Feb 04
Project Location: Page 5 of 22
Fluor Corporation Company Confidential Site Quality Manual
Inspection and Test Plan
Activity
Equipment Installation
Description
Steam Turbine/Generator Installation
Project Name Project Location Project Number
Client Contractor Contract Number ITP Number 000 509 ITP7460
Revision 0
Issue Date
Scope of Inspection Completion
Sign-Off Item Inspection/Test Stage
Requirement and
Acceptance Criteria
Responsibility
Sub Fluor Client
Inspection/Test
Record
Fluor GE
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
Project Name: ITP 509 7460
Contract No.: 18 Feb 04
Project Location: Page 6 of 22
Fluor Corporation Company Confidential Site Quality Manual
Inspection and Test Plan
Activity
Equipment Installation
Description
Steam Turbine/Generator Installation
Project Name Project Location Project Number
Client Contractor Contract Number ITP Number 000 509 ITP7460
Revision 0
Issue Date
Scope of Inspection Completion
Sign-Off Item Inspection/Test Stage
Requirement and
Acceptance Criteria
Responsibility
Sub Fluor Client
Inspection/Test
Record
Fluor GE
- 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, trim-
cut 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
Project Name: ITP 509 7460
Contract No.: 18 Feb 04
Project Location: Page 7 of 22
Fluor Corporation Company Confidential Site Quality Manual
Inspection and Test Plan
Activity
Equipment Installation
Description
Steam Turbine/Generator Installation
Project Name Project Location Project Number
Client Contractor Contract Number ITP Number 000 509 ITP7460
Revision 0
Issue Date
Scope of Inspection Completion
Sign-Off Item Inspection/Test Stage
Requirement and
Acceptance Criteria
Responsibility
Sub Fluor Client
Inspection/Test
Record
Fluor GE
Reconfirm the LP horizontal joint level checks using a
Bronson 545 precision level (P-Level) for site use.
000 509 F74606
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)
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.
000 509 F74604
Set Front Standard Air Gaps in accordance with the GE
requirements. See GE TA for values from the FEM or
specific unit documents.
H
Project Name: ITP 509 7460
Contract No.: 18 Feb 04
Project Location: Page 8 of 22
Fluor Corporation Company Confidential Site Quality Manual
Inspection and Test Plan
Activity
Equipment Installation
Description
Steam Turbine/Generator Installation
Project Name Project Location Project Number
Client Contractor Contract Number ITP Number 000 509 ITP7460
Revision 0
Issue Date
Scope of Inspection Completion
Sign-Off Item Inspection/Test Stage
Requirement and
Acceptance Criteria
Responsibility
Sub Fluor Client
Inspection/Test
Record
Fluor GE
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.
All readings are to be verified and accepted by the GE
TA, then properly documented before performing any
welds.
H 000 509 F74608
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)
H
000 509 F74607
000 509 F74608
Project Name: ITP 509 7460
Contract No.: 18 Feb 04
Project Location: Page 9 of 22
Fluor Corporation Company Confidential Site Quality Manual
Inspection and Test Plan
Activity
Equipment Installation
Description
Steam Turbine/Generator Installation
Project Name Project Location Project Number
Client Contractor Contract Number ITP Number 000 509 ITP7460
Revision 0
Issue Date
Scope of Inspection Completion
Sign-Off Item Inspection/Test Stage
Requirement and
Acceptance Criteria
Responsibility
Sub Fluor Client
Inspection/Test
Record
Fluor GE
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
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
H
000 509 F74607
000 509 F74608
Project Name: ITP 509 7460
Contract No.: 18 Feb 04
Project Location: Page 10 of 22
Fluor Corporation Company Confidential Site Quality Manual
Inspection and Test Plan
Activity
Equipment Installation
Description
Steam Turbine/Generator Installation
Project Name Project Location Project Number
Client Contractor Contract Number ITP Number 000 509 ITP7460
Revision 0
Issue Date
Scope of Inspection Completion
Sign-Off Item Inspection/Test Stage
Requirement and
Acceptance Criteria
Responsibility
Sub Fluor Client
Inspection/Test
Record
Fluor GE
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.
H
000 509 F74607
000 509 F74608
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
Project Name: ITP 509 7460
Contract No.: 18 Feb 04
Project Location: Page 11 of 22
Fluor Corporation Company Confidential Site Quality Manual
Inspection and Test Plan
Activity
Equipment Installation
Description
Steam Turbine/Generator Installation
Project Name Project Location Project Number
Client Contractor Contract Number ITP Number 000 509 ITP7460
Revision 0
Issue Date
Scope of Inspection Completion
Sign-Off Item Inspection/Test Stage
Requirement and
Acceptance Criteria
Responsibility
Sub Fluor Client
Inspection/Test
Record
Fluor GE
Conduct the HRS Post-Weld 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)
NOTE:
Proceed only if the HRS Post-Weld Load Check and
HRS Post-Weld Position Readings are acceptable to
D/FD and GE
H
000 509 F74607
000 509 F74608
Verify alignment of the GE provided Wishbone piping
arrangement to the Main Steam nozzle on the turbine
casing
Project Name: ITP 509 7460
Contract No.: 18 Feb 04
Project Location: Page 12 of 22
Fluor Corporation Company Confidential Site Quality Manual
Inspection and Test Plan
Activity
Equipment Installation
Description
Steam Turbine/Generator Installation
Project Name Project Location Project Number
Client Contractor Contract Number ITP Number 000 509 ITP7460
Revision 0
Issue Date
Scope of Inspection Completion
Sign-Off Item Inspection/Test Stage
Requirement and
Acceptance Criteria
Responsibility
Sub Fluor Client
Inspection/Test
Record
Fluor GE
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
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.
H
000 509 F74607
000 509 F74608
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
Project Name: ITP 509 7460
Contract No.: 18 Feb 04
Project Location: Page 13 of 22
Fluor Corporation Company Confidential Site Quality Manual
Inspection and Test Plan
Activity
Equipment Installation
Description
Steam Turbine/Generator Installation
Project Name Project Location Project Number
Client Contractor Contract Number ITP Number 000 509 ITP7460
Revision 0
Issue Date
Scope of Inspection Completion
Sign-Off Item Inspection/Test Stage
Requirement and
Acceptance Criteria
Responsibility
Sub Fluor Client
Inspection/Test
Record
Fluor GE
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
Conduct the HPS1 Post-Weld 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)
NOTE:
Proceed only if the HPS1 Post-Weld Load Check and
HRS Post-Weld Position Readings are acceptable to
D/FD and GE
H
000 509 F74607
000 509 F74608
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
Project Name: ITP 509 7460
Contract No.: 18 Feb 04
Project Location: Page 14 of 22
Fluor Corporation Company Confidential Site Quality Manual
Inspection and Test Plan
Activity
Equipment Installation
Description
Steam Turbine/Generator Installation
Project Name Project Location Project Number
Client Contractor Contract Number ITP Number 000 509 ITP7460
Revision 0
Issue Date
Scope of Inspection Completion
Sign-Off Item Inspection/Test Stage
Requirement and
Acceptance Criteria
Responsibility
Sub Fluor Client
Inspection/Test
Record
Fluor GE
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
Tack weld, then complete the Root Weld and Hot Pass
of the pipe to the nozzle
After welds cool conduct a second HPS2 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.
H
000 509 F74607
000 509 F74608
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.
H
000 509 F74607
000 509 F74608
Project Name: ITP 509 7460
Contract No.: 18 Feb 04
Project Location: Page 15 of 22
Fluor Corporation Company Confidential Site Quality Manual
Inspection and Test Plan
Activity
Equipment Installation
Description
Steam Turbine/Generator Installation
Project Name Project Location Project Number
Client Contractor Contract Number ITP Number 000 509 ITP7460
Revision 0
Issue Date
Scope of Inspection Completion
Sign-Off Item Inspection/Test Stage
Requirement and
Acceptance Criteria
Responsibility
Sub Fluor Client
Inspection/Test
Record
Fluor GE
Conduct another set of HPS2 Post-Weld 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)
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
H
000 509 F74607
000 509 F74608
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
H
000 509 F74607
000 509 F74608
Tack weld, then complete the Root Weld and Hot Pass
of the pipe to each nozzle
Project Name: ITP 509 7460
Contract No.: 18 Feb 04
Project Location: Page 16 of 22
Fluor Corporation Company Confidential Site Quality Manual
Inspection and Test Plan
Activity
Equipment Installation
Description
Steam Turbine/Generator Installation
Project Name Project Location Project Number
Client Contractor Contract Number ITP Number 000 509 ITP7460
Revision 0
Issue Date
Scope of Inspection Completion
Sign-Off Item Inspection/Test Stage
Requirement and
Acceptance Criteria
Responsibility
Sub Fluor Client
Inspection/Test
Record
Fluor GE
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.
H
000 509 F74607
000 509 F74608
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.
H
000 509 F74607
000 509 F74608
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.
Project Name: ITP 509 7460
Contract No.: 18 Feb 04
Project Location: Page 17 of 22
Fluor Corporation Company Confidential Site Quality Manual
Inspection and Test Plan
Activity
Equipment Installation
Description
Steam Turbine/Generator Installation
Project Name Project Location Project Number
Client Contractor Contract Number ITP Number 000 509 ITP7460
Revision 0
Issue Date
Scope of Inspection Completion
Sign-Off Item Inspection/Test Stage
Requirement and
Acceptance Criteria
Responsibility
Sub Fluor Client
Inspection/Test
Record
Fluor GE
Conduct the LPS Post-Weld 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)
NOTE:
Proceed only if the LPS Post-Weld Load Check and
LPS Post-Weld Position Readings are acceptable to
D/FD and GE
H
000 509 F74607
000 509 F74608
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
Project Name: ITP 509 7460
Contract No.: 18 Feb 04
Project Location: Page 18 of 22
Fluor Corporation Company Confidential Site Quality Manual
Inspection and Test Plan
Activity
Equipment Installation
Description
Steam Turbine/Generator Installation
Project Name Project Location Project Number
Client Contractor Contract Number ITP Number 000 509 ITP7460
Revision 0
Issue Date
Scope of Inspection Completion
Sign-Off Item Inspection/Test Stage
Requirement and
Acceptance Criteria
Responsibility
Sub Fluor Client
Inspection/Test
Record
Fluor GE
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.
H
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
H
Final Cold Alignment Checks with all piping attached
document the final readings and that they were
acceptable to the GE TA.
H
Verify installation of Turbine enclosure
Project Name: ITP 509 7460
Contract No.: 18 Feb 04
Project Location: Page 19 of 22
Fluor Corporation Company Confidential Site Quality Manual
Inspection and Test Plan
Activity
Equipment Installation
Description
Steam Turbine/Generator Installation
Project Name Project Location Project Number
Client Contractor Contract Number ITP Number 000 509 ITP7460
Revision 0
Issue Date
Scope of Inspection Completion
Sign-Off Item Inspection/Test Stage
Requirement and
Acceptance Criteria
Responsibility
Sub Fluor Client
Inspection/Test
Record
Fluor GE
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
H
Project Name: ITP 509 7460
Contract No.: 18 Feb 04
Project Location: Page 20 of 22
Fluor Corporation Company Confidential Site Quality Manual
Inspection and Test Plan
Activity
Equipment Installation
Description
Steam Turbine/Generator Installation
Project Name Project Location Project Number
Client Contractor Contract Number ITP Number 000 509 ITP7460
Revision 0
Issue Date
Scope of Inspection Completion
Sign-Off Item Inspection/Test Stage
Requirement and
Acceptance Criteria
Responsibility
Sub Fluor Client
Inspection/Test
Record
Fluor GE
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
H
000 509 F74607
000 509 F74608
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
Project Name: ITP 509 7460
Contract No.: 18 Feb 04
Project Location: Page 21 of 22
Fluor Corporation Company Confidential Site Quality Manual
Inspection and Test Plan
Activity
Equipment Installation
Description
Steam Turbine/Generator Installation
Project Name Project Location Project Number
Client Contractor Contract Number ITP Number 000 509 ITP7460
Revision 0
Issue Date
Scope of Inspection Completion
Sign-Off Item Inspection/Test Stage
Requirement and
Acceptance Criteria
Responsibility
Sub Fluor Client
Inspection/Test
Record
Fluor GE
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).
Project Name: ITP 509 7460
Contract No.: 18 Feb 04
Project Location: Page 22 of 22
Fluor Corporation Company Confidential Site Quality Manual
Inspection and Test Plan
Activity
Equipment Installation
Description
Steam Turbine/Generator Installation
Project Name Project Location Project Number
Client Contractor Contract Number ITP Number 000 509 ITP7460
Revision 0
Issue Date
Scope of Inspection Completion
Sign-Off Item Inspection/Test Stage
Requirement and
Acceptance Criteria
Responsibility
Sub Fluor Client
Inspection/Test
Record
Fluor GE
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)
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
Project Name: ITP 509 7470
Contract No.: 18 Feb 04
Project Location: Page 1 of 2
Fluor Corporation Company Confidential Site Quality Manual
Inspection and Test Plan
Activity
Equipment Installation
Description
Generator Testing
Project Name Project Location Project Number
Client Contractor Contract Number
ITP Number 000 509 ITP7470
Revision 0
Issue Date
Scope of Inspection
Item Inspection/Test Stage
Requirement and
Acceptance Criteria
Responsibility
Sub Fluor Client
Inspection
Record
CompleteIT
Input
1 Verify Nameplate Data
PO, Generator Voltage
=Line Voltage
CS I I 509F74701
2 Conduct generator cold resistance test
Project Specification CEM P H 509F74702
3
Conduct generator insulation resistance test of
stator and rotor windings
Project Specification CEM P H 509F74701
4
Perform Polarization Index Test on each phase of
generator stator windings
Project Specification CEM P H 509F74701
5
Perform DC High Potential Test (hi-pot) on the
stator and rotor windings
Project Specification,
manufacturers
requirements
CEM P H 509F74701
6
Perform Insulation Resistance Test on pedestal
bearing.
100,000 ohm or more,
Project Specification
CEM P H 509F74701
7 Inspect Collector Ring
Project Specification CS I I 509F74701
8 Check connections per 000 509 F74701
Project Specification CS I I 509F74701
9
Check space heaters, alarm and monitoring
devices, temperature monitoring devices per 000
509 F74701
Project Specification,
manufacturers
requirements
CS I W 509F74701
10 Check excitation system
Manufacturers
requirements
CS I H 509F74701
11 Check phase sequence to verify phase rotation
Project Specification,
manufacturers
requirements
CEM I H 509F74701
Project Name: ITP 509 7470
Contract No.: 18 Feb 04
Project Location: Page 2 of 2
Fluor Corporation Company Confidential Site Quality Manual
Inspection and Test Plan
Activity
Equipment Installation
Description
Generator Testing
Project Name Project Location Project Number
Client Contractor Contract Number
ITP Number 000 509 ITP7470
Revision 0
Issue Date
Scope of Inspection
Item Inspection/Test Stage
Requirement and
Acceptance Criteria
Responsibility
Sub Fluor Client
Inspection
Record
CompleteIT
Input
12 Check Synchronization
Project Specification,
manufacturers
requirements
CEM I H 509F74701
13 Inspect, or perform, equipment and material
preservation activities.
000 509 0250
Project Specification
CS P I
509F02502
509F74701
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)
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
Project Name: 000 509 7500
Contract No.: 18 Feb 04
Project Location: Page 1 of 4
Fluor Corporation Company Confidential Site Quality Manual
UNDERGROUND PIPING
SCOPE
This procedure applies to the activities associated with inspection and testing of underground piping.
RESPONSIBILITY - Self-Perform Pipe Installation
ACTIVITY RESPONSIBILITY DOCUMENTATION
FREQUENCY OF
ACTIVITY
Request Excavation Mechanical Supt. 000 509 F75001 Each excavation
Coordinate Excavation
Release
Const. Engineer/
Mechanical
000 509 F75001 Each excavation
Inspect Excavation Site Quality Manager 000 509 F75001
Daily during life of activity and
prior to laying pipe.
Welding Inspection and
Testing
Per 000 509 7910 Per 000 509 7910 Per 000 509 7910
Inspect on-site pipe
fabrication & installation
Site Quality Manager 000 509 F75001 Each installation
Cleaning of Pipe Per 000 509 7560 Per 000 509 F75601 Per 000 509 7560
Pressure Test Per 000 509 7520 Per 000 509 7520 Per 000 509 7520
Coordinate Backfill
Request/Release
Construction Engr./
Mechanical
000 509 F75001 Each backfill.
Backfill Inspection Site Quality Manager 000 509 F75001 Each backfill
Surveillance Site Quality Manager 000 509 F02201 During life of activity
RESPONSIBILITY - Subcontracted Pipe Installation
ACTIVITY RESPONSIBILITY DOCUMENTATION
FREQUENCY OF
ACTIVITY
Request Excavation Subcontractor 000 509 F75001 Each excavation
Coordinate Excavation
Release
Const. Engineer/
Mechanical
000 509 F75001 Each excavation
Inspect Excavation Subcontractor 000 509 F75001
Daily during life of activity and
prior to laying pipe.
Welding Inspection and
Testing
Subcontractor Per 000 509 7910 Per 000 509 7910
Inspect/Test On-Site
Fabrication and Installation
Subcontractor 000 509 F75001 During life of activity
Cleaning of Pipe Subcontractor Per 000 509 F75601 Per 000 509 7560
Pressure Test Subcontractor Per 000 509 F75201 Per 000 509 7520
Inspect Coating, Wrapping,
Cathodic Protection, Holiday
Test, Insulation Resistance
Subcontractor
000 509 F75001
000 509 F75002
Daily during life of activity.
Backfill Request/Release Subcontractor 000 509 F75001 Each backfill.
Backfill Inspection Subcontractor 000 509 F75001 Each installation.
Mechanical Supt. Not Required Daily during life of activity.
Surveillance
Site Quality Manager Form 000 509 F02201 Daily during life of activity.
Project Name: 000 509 7500
Contract No.: 18 Feb 04
Project Location: Page 2 of 4
Fluor Corporation Company Confidential Site Quality Manual
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
- Reference procedure 000 509 7910 for the welding inspection and testing requirements.
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
- 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).
Project Name: 000 509 7500
Contract No.: 18 Feb 04
Project Location: Page 3 of 4
Fluor Corporation Company Confidential Site Quality Manual
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.
Project Name: 000 509 7500
Contract No.: 18 Feb 04
Project Location: Page 4 of 4
Fluor Corporation Company Confidential Site Quality Manual
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
Project Name: 000 509 7500
Contract No.: 18 Feb 04
Project Location: Attachment 1 . . . Page 1 of 1
UNDERGROUND PIPE INSPECTION REFERENCE
Pipe Fabrication and Installation
General
- 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
Valves
- 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
Excavation
- Slope per drawing
- Dimensions per drawing
- Compaction test before laying
pipe
- Bedding
Coating and Wrapping
- 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
Project Name: 000 509 7510
Contract No.: 18 Feb 04
Project Location: Page 1 of 2
Fluor Corporation Company Confidential Site Quality Manual
ABOVEGROUND PIPING
SCOPE
This procedure applies to the activities associated with inspection and testing of aboveground piping.
RESPONSIBILITIES - Self-Perform Pipe Installation
ACTIVITY RESPONSIBILITY DOCUMENTATION
FREQUENCY OF
ACTIVITY
Welding Inspection and
Testing
Per 000 509 7910 Per 000 509 7910 Per 000 509 7910
Inspect on-site pipe
fabrication and installation
Site Quality Manager
000 509 F75101
000 509 F75102
000 509 F75103
000 509 F79001
Each installation
Cleaning of Pipe Per 000 509 7560 Per 000 509 F75601 Per 000 509 7560
Inspect Insulation Per 000 509 7810 Per 000 509 F78102 Per 000 509 7810
Pressure Test Per 000 509 7520 Per 000 509 F75201 Per 000 509 7520
Responsibilities - Subcontracted Pipe Installation
ACTIVITY RESPONSIBILITY DOCUMENTATION
FREQUENCY OF
ACTIVITY
Welding Inspection & Testing Subcontractor Per 000 509 7910 Per 000 509 7910
Inspect on-site pipe
fabrication and installation
Subcontractor
000 509 F75101
000 509 F75102
000 509 F75103
000 509 F79001
Each installation
Cleaning of Pipe Subcontractor Per 000 509 F75601 Per 000 509 7560
Inspect Insulation Subcontractor Per 000 509 F78102 Per 000 509 7810
Pressure Test Subcontractor Per 000 509 75201 Per 000 509 7520
Surveillances Site Quality Manager Form 000 509 F02201 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.
Project Name: 000 509 7510
Contract No.: 18 Feb 04
Project Location: Page 2 of 2
Fluor Corporation Company Confidential 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
- 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
Project Name: 000 509 7510
Contract No.: 18 Feb 04
Project Location: Attachment 1 . . . Page 1 of 1
ABOVEGROUND PIPE INSPECTION REFERENCE
GENERAL
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.
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.
PIPE SUPPORTS
Field supports installed.
Sufficient supports.
Anchors installed.
Guides installed.
Proper shoes installed and welded.
Spring hangers properly installed.
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.
Project Name: 000 509 7520
Contract No.: 18 Feb 04
Project Location: Page 1 of 4
Fluor Corporation Company Confidential Site Quality Manual
PRESSURE TESTING
SCOPE
This procedure applies to pressure testing of installed piping systems.
RESPONSIBILITIES - Self-Perform
ACTIVITY RESPONSIBILITY DOCUMENTATION
FREQUENCY OF
ACTIVITY
Install Piping Self Perform _____ _____
Define Test Boundaries
Pipe Const. Engr.
and Mech. Supt.
000 509 F75201
Each Test
Package
Provide Preparation /
Test Instructions
Pipe Const. Engr. 000 509 F75201
Each Test
Package
Prepare the System for
Testing
Mechanical
Superintendent
_____ _____
Pipe Const. Engr. 000 509 F75201 Prior to Test Perform Pre-Test
Inspections/Release Site Quality Manager 000 509 F75201 Prior to Test
Perform Test
Mechanical
Superintendent
_____ _____
Pipe Const. Engr. 000 509 F75201 Test Completion Verification of
Satisfactory Test
Results
Site Quality Manager 000 509 F75201 Test Completion
Provide Restoration
Instructions
Pipe Const. Engr. _____ _____
Pipe Const. Engr. 000 509 F75201 Each Test Verify Completion of
Restoration Site Quality Manager 000 509 F75201 Each Test
Surveillance of Testing
and Restoration
Site Quality Manager 000 509 F0221 Daily
Project Name: 000 509 7520
Contract No.: 18 Feb 04
Project Location: Page 2 of 4
Fluor Corporation Company Confidential Site Quality Manual
RESPONSIBILITIES - Subcontracted
ACTIVITY RESPONSIBILITY DOCUMENTATION
FREQUENCY OF
ACTIVITY
Install Piping Subcontractor _____ _____
Define Test Boundaries Subcontractor 000 509 F75201 Each Test Package
Provide Preparation /
Test Instructions
Pipe Const. Engr. 000 509 F75201 Each Test Package
Prepare the System for
Testing
Subcontractor _____ _____
Subcontractor 000 509 F75201 Prior to Test
Perform Pre-Test
Inspections/Release
Site Quality
Manager
000 509 F75201 Prior to Test
Perform Test Subcontractor _____ _____
Subcontractor 000 509 F75201 Test Completion Verification of
Satisfactory Test
Results
Site Quality
Manager
000 509 F75201 Test Completion
Provide Restoration
Instructions
Pipe Const. Engr. _____ _____
Subcontractor 000 509 F75201 Each Test
Verify Completion of
Restoration
Site Quality
Manager
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".
Project Name: 000 509 7520
Contract No.: 18 Feb 04
Project Location: Page 3 of 4
Fluor Corporation Company Confidential 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, post-
weld 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:
- 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.
Project Name: 000 509 7520
Contract No.: 18 Feb 04
Project Location: Page 4 of 4
Fluor Corporation Company Confidential Site Quality Manual
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
Project Name: 000 509 7550
Contract No.: 18 Feb 04
Project Location: Page 1 of 6
Fluor Corporation Company Confidential Site Quality Manual
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 RESPONSIBILITY DOCUMENTATION
FREQUENCY OF
ACTIVITY
Weld Mapping
Site Quality
Manager
000 509 F75501
QC Drawing Stick
Prior to start of work
Welder Quality
Site Quality
Manager
000 509 F75507 Each welder
Receipt Inspection
Site Quality
Manager
000 509 F75502
000 509 F75503
000 509 F75504
000 509 F75505
Each shipment
Welding Operator _____ Each weld
Preweld Inspection
Site Quality
Manager
_____ Daily during activity
Welding Operator 000 509 F75508 Each weld
Weld Inspection Site Quality
Manager
000 509 F75508 Each weld
Welding Operator 000 509 F75508 Each weld
Blind Weld Inspection Site Quality
Manager
000 509 F75508 Each weld
Fitter 000 509 F75509 Prior to Hydro
Post Installation Site Quality
Manager
000 509 F75509 Prior to Hydro
Welding Program
Documentation Package
Site Quality
Manager
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
Project Name: 000 509 7550
Contract No.: 18 Feb 04
Project Location: Page 2 of 6
Fluor Corporation Company Confidential Site Quality Manual
PROCEDURE
Note: Prior to performing any welding, contact Construction Technologys 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).
Project Name: 000 509 7550
Contract No.: 18 Feb 04
Project Location: Page 3 of 6
Fluor Corporation Company Confidential Site Quality Manual
- 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.
Project Name: 000 509 7550
Contract No.: 18 Feb 04
Project Location: Page 4 of 6
Fluor Corporation Company Confidential Site Quality Manual
- 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.
Project Name: 000 509 7550
Contract No.: 18 Feb 04
Project Location: Page 5 of 6
Fluor Corporation Company Confidential Site Quality Manual
- 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".
Project Name: 000 509 7550
Contract No.: 18 Feb 04
Project Location: Page 6 of 6
Fluor Corporation Company Confidential Site Quality Manual
Welding Program Documentation Package
The QC Inspector shall establish the file which shall contain the following sections:
a) Copies of hygienic material purchase orders
b) Material receiving reports
c) Certified material test reports, where required
d) Weld equipment, instructions, data, identification
e) Welder qualification/training records
f) Weld schedules (including WPS and ASME Sect. IX procedure qualification records)
g) Orbital weld log sheets
h) Weld maps (including hygienic drawing revision log)
i) 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
Project Name: 000 509 7560
Contract No.: 18 Feb 04
Project Location: Page 1 of 1
Fluor Corporation Company Confidential Site Quality Manual
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 RESPONSIBILITY DOCUMENTATION
FREQUENCY
OF ACTIVITY
Verify that all
pressure testing &
NDE are complete
QC Inspector
Prior to release for
cleaning
Commence cleaning
operation
Construction Supt./
Subcontractor
000 509 F75601
As required by project
specs
Monitor chemical
cleaning process
QC Inspector 000 509 F75601 Daily during activity
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
Project Name: 000 509 7570
Contract No.: 18 Feb 04
Project Location: Page 1 of 4
Fluor Corporation Company Confidential Site Quality Manual
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
FREQUENCY
OF ACTIVITY
Install steam tracing Subcontractor 000 509 F75701
Daily during life of
activity
Inspect in-process heat
tracing installation
Subcontractor/
Site Quality Manager
000 509 F75701
Daily during life of
activity
Pressure test steam tracers
Subcontractor/
Site Quality Manager.
000 509 F75201
Per each line or Test
Package
Install Insulation Subcontractor
Per Procedure
000 509 7810
Clear tubing with
compressed air and
commodity test the tubing
system
Subcontractor/
Site Quality Manager
000 509 F75701
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.
Project Name: 000 509 7570
Contract No.: 18 Feb 04
Project Location: Page 2 of 4
Fluor Corporation Company Confidential Site Quality Manual
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
200
0
F 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 inch OD
tubing.
Maximum tracer length is 200 feet.
Project Name: 000 509 7570
Contract No.: 18 Feb 04
Project Location: Page 3 of 4
Fluor Corporation Company Confidential Site Quality Manual
Tubing Material
Bare copper tubing is to be used whenever possible inside the pipe insulation and pre-
insulated 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 500
0
F
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.
Project Name: 000 509 7570
Contract No.: 18 Feb 04
Project Location: Page 4 of 4
Fluor Corporation Company Confidential Site Quality Manual
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
Project Name: 000 509 7600
Contract No.: 18 Feb 04
Project Location: Page 1 of 2
Fluor Corporation Company Confidential Site Quality Manual
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
FREQUENCY OF
ACTIVITY
Install electrical items Electrical Superintendent
_____
Each electrical item
Inspect in-process
electrical installation
Site Quality Manager/
Construction Engineer
000 509 F760XX
Daily during life of
activity
Check final electrical
installation
Site Quality Manager/
Construction Engineer
000 509 F760XX
Each installation at
completion
Surveillance
Site Quality Manager
(Note 1)
000 509 F02201
Daily during life of
activity and at
completion
RESPONSIBILITIES - Subcontracted Work
ACTIVITY RESPONSIBILITY DOCUMENTATION
FREQUENCY OF
ACTIVITY
Install electrical items Subcontractor
_____
Each electrical item
Inspect in-process
electrical installation
Subcontractor/
Site Quality Manager
000 509 F760XX
Daily during life of
activity
Check final electrical
installation
Subcontractor/
Site Quality Manager
000 509 F760XX
Each installation at
completion
Surveillance
Site Quality Manager
(Note 1)
000 509 F02201
Daily during life of
activity and at
completion
NOTE 1: Surveillance is not required if the Fluor Quality representative is performing
inspections.
Project Name: 000 509 7600
Contract No.: 18 Feb 04
Project Location: Page 2 of 2
Fluor Corporation Company Confidential Site Quality Manual
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 Conduit and Cable Tray Checklist
000 509 F76002 Electrical Manhole Inspection Checklist
000 509 F76003 Medium and High Voltage Underground Cable Splice Inspection Record
000 509 F76004 Medium and High Voltage Cable Termination Checklist
000 509 F76005 Cable Pulling Inspection Checklist
000 509 F76006 Fan/Speed Reducer/Motor Inspection Checklist
000 509 F76007 Switch Houses Inspection Checklist
000 509 F76008 Lighting Receptacle, Instrument Distribution Panels Inspection Checklist
000 509 F76009 Electrical Motor Inspection Checklist
000 509 F76010 Aboveground Conduit Inspection Checklist
000 509 F76011 Lighting Panelboard Inspection Record
000 509 F76012 Underground Conduit (Duct Bank) Inspection
000 509 F76013 Grounding/Earthing System (Grid or Loop) Inspection Record
Project Name: 000 509 7610
Contract No.: 18 Feb 04
Project Location: Page 1 of 3
Fluor Corporation Company Confidential Site Quality Manual
ELECTRICAL TESTING
SCOPE
This procedure applies to testing of electrical installation.
RESPONSIBILITIES - Self-Perform
ACTIVITY RESPONSIBILITY DOCUMENTATION
FREQUENCY
OF ACTIVITY
Define Test Boundaries
Electrical Construction
Engineer
_____ Each Test Package
Provide Preparation Test
Instructions
Electrical Construction
Engineer
_____ Each Test Package
Perform Electrical Test Electrical Superintendent _____ 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
Verify Completion of
Restoration
Site Quality Manager
Electrical Supervisor
000 509 F76004
000 509 F76006
000 509 F76007
000 509 F76008
Each Test
RESPONSIBILITIES - Subcontracted Work
ACTIVITY RESPONSIBILITY DOCUMENTATION
FREQUENCY
OF ACTIVITY
Define Test Boundaries Subcontractor _____ Each Test Package
Provide Preparation Test
Instructions
Subcontractor _____ Each Test Package
Perform Electrical Test Subcontractor _____ Each Test Package
Verify Test Results
Subcontractor/
Site Quality Manager
Applicable Form Test Completion
Provide Restoration
Instructions
Discipline Engineer _____ Each Test Package
Verify Completion of
Restoration
Subcontractor/
Site Quality Manager
_____ Each Test
Surveillance
Site Quality Manager
(*Note 1)
000 509 F0221 Each Test
NOTE 1 - Fluor QC Surveillance is required for construction activities not being documented
on other inspection forms by Fluor Quality.
Project Name: 000 509 7610
Contract No.: 18 Feb 04
Project Location: Page 2 of 3
Fluor Corporation Company Confidential Site Quality Manual
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:
- Perform test in accordance with the test instruction provided by Electrical Construction
Engineering.
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:
- 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.
Project Name: 000 509 7610
Contract No.: 18 Feb 04
Project Location: Page 3 of 3
Fluor Corporation Company Confidential Site Quality Manual
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
Project Name: 000 509 7620
Contract No.: 18 Feb 04
Project Location: Page 1 of 4
Fluor Corporation Company Confidential Site Quality Manual
ELECTRICAL EQUIPMENT
SCOPE
This procedure applies to inspection and testing of electrical equipment.
RESPONSIBILITIES - Self-Perform
ACTIVITY RESPONSIBILITY DOCUMENTATION
FREQUENCY OF
ACTIVITY
Install Equipment Self Perform _____ _____
Inspect in-process
Equipment Installation
Site Quality Manager/
Construction Engineer
000 509 F762XX
Daily during life of
activity
Site Quality Manager/
Construction Engineer
000 509 F02201 Periodically
Inspect/Perform
Equipment Protection
Electrical Supervisor 000 509 F02201 Periodically
Define Test Boundaries Construction Engineer _____ Each Test Package
Provide Preparation
Test Instructions
Construction Engineer _____ Each Test Package
Test Field Installed
Equipment
Electrical Superintendent _____ Each Test Package
Verify Test Results
Site Quality Manager/
Construction Engineer
000 509 F762XX Test Completion
Provide Restoration
Instructions
Construction Engineer _____ Each Test Package
Verify Completion
of Restoration
Site Quality Manager/
Construction Engineer
_____ Each Test
Surveillance
Site Quality Manager
(Note 1)
000 509 F02201 Each Test
NOTE 1: Fluor QC Surveillance is required for construction activities not being documented on other
inspection forms by Fluor Quality.
Project Name: 000 509 7620
Contract No.: 18 Feb 04
Project Location: Page 2 of 4
Fluor Corporation Company Confidential Site Quality Manual
RESPONSIBILITIES - Subcontracted Work
ACTIVITY RESPONSIBILITY DOCUMENTATION
FREQUENCY OF
ACTIVITY
Install Equipment Subcontractor _____ _____
Inspect in-process
Equipment Installation
Subcontractor/
Site Quality Manager
000 509 F762XX
Daily during life
of activity
Inspect/Perform Equipment
Protection
Subcontractor/
Site Quality Manager
000 509 F02201 Periodically
Define Test Boundaries Construction Engineer _____ Each Test Package
Provide Preparation
Test Instructions
Construction Engineer _____ Each Test Package
Test Field Installed
Equipment
Subcontractor _____ Each Test Package
Verify Test Results
Subcontractor/
Site Quality Manager
000 509 F762XX Test Completion
Provide Restoration
Instructions
Construction Engineer _____ Each Test Package
Verify Completion of
Restoration
Subcontractor/
Construction Engineer
Site Quality Manager
_____ Each Test
Surveillance
Site Quality Manager
(Note 1)
000 509 F02201 Each Test
NOTE 1: Fluor QC Surveillance is required for construction activities not being documented on other
inspection forms by Fluor Quality.
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.
Project Name: 000 509 7620
Contract No.: 18 Feb 04
Project Location: Page 3 of 4
Fluor Corporation Company Confidential Site Quality Manual
Inspect/Perform Equipment Protection:
- 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:
- 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:
- Perform test in accordance with the test instruction provided by Construction Engineering.
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 contained in this manual.
Provide Restoration Instructions:
- 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
Project Name: 000 509 7620
Contract No.: 18 Feb 04
Project Location: Page 4 of 4
Fluor Corporation Company Confidential Site Quality Manual
000 509 F76208 - High Voltage Motors and Starters
000 509 F76209 - Motors Checklist
000 509 F76210 - Control and Relay Panels Inspection Checklist
000 509 F76211 - Electronic Equipment Inspection Checklist
000 509 F76212 - Power Panel Inspection Checklist
000 509 F76213 - Switchgear Inspection Checklist
000 509 F76214 Low Voltage Feeders Inspection Record
000 509 F76215 - High Voltage Cable Inspection and Test Record
000 509 F76216 - Electrical Equipment Inspection Record
000 509 F76217 - Control Scheme Inspection Checklist
000 509 F76218 - Power Transformer Inspection Checklist
000 509 F76219 - Switching Units HV Switchgear Inspection and Test Record
000 509 F76220 - Switching Units HV Switchgear Inspection Checklist
000 509 F76221 - Liquid Filled Transformer Inspection Record
000 509 F76222 - Busway Inspection Record
000 509 F76223 - Switchgear Inspection Record
000 509 F76224 - Motor Control Center Inspection Record
000 509 F76225 - Battery and Battery Charger Inspection Record
000 509 F76226 - Liquid Immersed Medium Voltage Disconnect Switch Inspection Record
000 509 F76227 - Electric Motor Electrical Activities Inspection Record
000 509 F76228 - Electric Motor Mechanical Activities Inspection Record
000 509 F76229 - Electric Motor For Compressor Installation Checklist
000 509 F76230 - Compressor Vibration Checklist
000 509 F76231 - Vibration Probe Record
Project Name: 000 509 7640
Contract Number: 18 Feb 04
Project Location: Page 1 of 2
Fluor Corporation Company Confidential Site Quality Manual
ELECTRICAL HEAT TRACING
SCOPE
This procedure defines the inspection, testing and documentation requirements for installation
activities for electrical heat tracing.
RESPONSIBILITIES
ACTIVITY RESPONSIBILITY DOCUMENTATION
FREQUENCY OF
ACTIVITY
Receive and Test
Heat Tracing Cable
Subcontractor 000 509 F76401 For each cable
Install HT Cable Subcontractor 000 509 F76402
Daily during life of
activity
Inspect in-process HT
cable installation
Subcontractor 000 509 F76402
Daily during life of
activity
Test installed HT
Circuit
Subcontractor/
Site Quality Manager
000 509 F76401 For each circuit
Install Insulation Subcontractor
Per Procedure
000 509 F7810
Perform Final Testing
Subcontractor/
Site Quality Manager
000 509 F76401 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.
Project Name: 000 509 7640
Contract Number: 18 Feb 04
Project Location: Page 2 of 2
Fluor Corporation Company Confidential Site Quality Manual
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.
FORMS
Quality Control Forms:
000 509 F76401 Electrical Heat Trace Test Log
000 509 F76402 Electrical Heat Tracing Inspection Record
Project Name: 000 509 7700
Contract No.: 18 Feb 04
Project Location: Page 1 of 2
Fluor Corporation Company Confidential Site Quality Manual
CONTROL SYSTEM INSTRUMENTATION
SCOPE
This procedure applies to the inspection of installations and loop check of instrumentation.
RESPONSIBILITIES - Self-Perform
ACTIVITY RESPONSIBILITY DOCUMENTATION
FREQUENCY
OF ACTIVITY
Inspect received
instruments
E & I Construction Engineer
Instrument Superintendent
_____ Each Instrument
Inspect in-process
instrument installation
Site Quality Manager/
E & I Construction Engineer
000 509 F770XX
Daily during
life of activity
Inspect completed
instrument installation
Site Quality Manager/
E & I Construction Engineer
000 509 F770XX Each Instrument
Perform Pressure
Testing of Tubing
Instrumentation Superintendent _____
Each Pressure
Test Package
Verify Pressure
Testing of Tubing
Site Quality Manager/
E & I Construction Engineer
000 509 F770XX
Each Pressure
Test Package
Test Instrument Cables Electrical Superintendent _____ Each cable
Verify Instrument
Cable Testing
Site Quality Manager 000 509 F770XX Each cable
Perform/
Verify Loop Check
Instrumentation Superintendent/
Site Quality Manager
000 509 F770XX Each loop
RESPONSIBILITIES - Subcontracted Work
ACTIVITY RESPONSIBILITY DOCUMENTATION
FREQUENCY
OF ACTIVITY
Inspect received
instruments
Subcontractor _____ Each Instrument
Inspect in-process
instrument installation
Subcontractor 000 509 F770XX
Daily during
life of activity
Inspect completed
instrument installation
Subcontractor/
Site Quality Manager
000 509 F770XX Each Instrument
Perform Pressure
Testing on Tubing
Subcontractor _____
Each Pressure
Test Package
Verify Pressure
Testing of Tubing
Subcontractor/
Site Quality Manager
000 509 F770XX
Each Pressure
Test Package
Test Instrument Cables Subcontractor _____ Each cable
Verify Instrument
Cable Testing
Subcontractor/
Site Quality Manager
000 509 F770XX Each cable
Perform/
Verify Loop Check
Subcontractor/
E & I Construction Engineer
Site Quality Manager
000 509 F770XX Each loop
Project Name: 000 509 7700
Contract No.: 18 Feb 04
Project Location: Page 2 of 2
Fluor Corporation Company Confidential Site Quality Manual
PROCEDURE
Receipt Inspection of Instruments:
- The E & I Construction Engineer and the Instrument Superintendent shall coordinate the
receipt inspection of instruments to support the construction schedule.
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:
- 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 - Instrumentation Inspection Checklist
000 509 F77002 - Instrument Loop Inspection Checklist
000 509 F77003 - Impulse Line Pressure Inspection Checklist
000 509 F77004 - Instrument Grounding System Checklist
000 509 F77005 - Installation Check Sheet (Local Instrument)
000 509 F77006 - Orifice Plates Inspection Checklist
Project Name: 000 509 7710
Contract No.: 18 Feb 04
Project Location: Page 1 of 2
Fluor Corporation Company Confidential Site Quality Manual
CONTROL SYSTEM CALIBRATION
SCOPE
This procedure applies to calibration of instruments for control systems.
RESPONSIBILITIES - Self-Perform
ACTIVITY RESPONSIBILITY DOCUMENTATION
FREQUENCY OF
ACTIVITY
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
Site Quality Manager 000 509 F0221
Periodically throughout
life of project
RESPONSIBILITIES - Subcontracted Work
ACTIVITY RESPONSIBILITY DOCUMENTATION
FREQUENCY OF
ACTIVITY
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
Site Quality Manager 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.
Project Name: 000 509 7710
Contract No.: 18 Feb 04
Project Location: Page 2 of 2
Fluor Corporation Company Confidential Site Quality Manual
Instrument Test and Calibration:
- 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
Project Name: 000 509 7800
Contract No.: 18 Feb 04
Project Location: Page 1 of 3
Fluor Corporation Company Confidential Site Quality Manual
COATINGS AND LININGS
SCOPE
This procedure describes the inspection, testing, and documentation required to be performed for coatings.
RESPONSIBILITIES - Self-Perform
ACTIVITY RESPONSIBILITY DOCUMENTATION
FREQUENCY
OF ACTIVITY
Inspect surface
preparation
Supervisor/Construction
Engineer/Site Quality Manager
000 509 F78001 Daily during life of activity
Verify color/type coatings
approved
Supervisor/Construction
Engineer/ Site Quality Manager
000 509 F78001
As required by
applications
Inspect in-process
coating/lining
Supervisor/Construction
Engineer/Site Quality Manager
000 509 F78001
000 509 F78002
Daily during life of activity
Check Thickness
Supervisor/Construction
Engineer/Site Quality Manager
000 509 F78001
As required to verify
thickness requirements
Inspect completed
coatings
Supervisor/Construction
Engineer/Site Quality Manager
000 509 F78001 _____
Follow-up any
deficiencies identities
Supervisor/Construction
Engineer/Site Quality Manager
_____
As required to close-out
deficiencies
RESPONSIBILITIES - Subcontracted Work
ACTIVITY RESPONSIBILITY DOCUMENTATION
FREQUENCY
OF ACTIVITY
Inspect surface
preparation
Subcontractor/Construction
Engineer/Site Quality Manager
000 509 F78001 Daily during life of activity
Verify color/type coatings
approved
Subcontractor/Construction
Engineer/Site Quality Manager
000 509 F78001
As required by
applications
Inspect in-process
coating/lining
Subcontractor/Construction
Engineer/Site Quality Manager
000 509 F78001
000 509 F78002
Daily during life of activity
Check Thickness
Subcontractor/Construction
Engineer/Site Quality Manager
000 509 F78001
As required to verify
thickness requirements
Inspect completed
coatings
Subcontractor/Construction
Engineer/Site Quality Manager
000 509 F78001 _____
Follow-up any deficiencies
identities
Subcontractor/Construction
Engineer/Site Quality Manager
_____
As required to close-out
deficiencies
Project Name: 000 509 7800
Contract No.: 18 Feb 04
Project Location: Page 2 of 3
Fluor Corporation Company Confidential Site Quality Manual
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.
Project Name: 000 509 7800
Contract No.: 18 Feb 04
Project Location: Page 3 of 3
Fluor Corporation Company Confidential Site Quality Manual
FORMS
Quality Support Forms:
000 509 F78001 - Coating Inspection Record
000 509 F78002 - Lining Inspection Record
ATTACHMENTS
Attachment 1 - Example Acceptance Criteria
Project Name: 000 509 7800
Contract No.: 18 Feb 04
Project Location: Attachment 1 . . . Page 1 of 1
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
Project Name: 000 509 7810
Contract No.: 18 Feb 04
Project Location: Page 1 of 3
Fluor Corporation Company Confidential Site Quality Manual
INSULATION
SCOPE
This procedure describes the inspection activities for insulation installation.
RESPONSIBILITIES - Self-Perform
ACTIVITY RESPONSIBILITY DOCUMENTATION
FREQUENCY
OF ACTIVITY
Coordination of
Release for
Insulation
Discipline
Construction
Engineer
Form 000 509 F78101
Each piece of
equipment line or
structure
Install insulation Civil Superintendent _____
Each piece of
equipment, line or
structure
Inspect in-process
installation
Site Quality Manager Form 000 509 F78101
Each piece of
equipment, line or
structure
Inspect completed
installation
Site Quality Manager Form 000 509 F78101
Each piece of
equipment, line or
structure
Surveillance
QC Inspection
(Note 1)
From 000 509 F02201
Per Procedure
000 509 0220
NOTE 1: Surveillance is not required if the Fluor Quality representative is performing
inspections.
RESPONSIBILITIES - Subcontracted Work
ACTIVITY RESPONSIBILITY DOCUMENTATION
FREQUENCY
OF ACTIVITY
Coordination of
Release for Insulation
Piping Construction
Engineer
Form 000 509 F78101
Each piece of
equipment, line or
structure
Install insulation Subcontractor _____
Each piece of
equipment, line or
structure
Inspect in-process
installation
Subcontractor Form 000 509 F78101
Each piece of
equipment, line or
structure
Inspect completed
installation
Subcontractor Form 000 509 F78101
Each piece of
equipment, line or
structure
Surveillance QC Inspection Form 000 509 F02201
Per Procedure
000 509 0220
Project Name: 000 509 7810
Contract No.: 18 Feb 04
Project Location: Page 2 of 3
Fluor Corporation Company Confidential Site Quality Manual
PROCEDURE
Release for 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.
Install 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.
FORMS
Quality Control Forms:
000 509 F78101 - Equipment Thermal Insulation Inspection Checklist
000 509 F78102 - Piping Thermal Insulation Inspection Checklist
Project Name: 000 509 7810
Contract No.: 18 Feb 04
Project Location: Page 3 of 3
Fluor Corporation Company Confidential Site Quality Manual
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.
Project Name: 000 509 7820
Contract No.: 18 Feb 04
Project Location: Page 1 of 3
Fluor Corporation Company Confidential Site Quality Manual
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) Shotcrete (gunite)
b) Sprayed Fibrous
c) Sprayed Cementitious
d) Magnesium Oxychloride (sprayed or troweled)
e) Intumescent or Subliming Mastic
RESPONSIBILITIES - Subcontracted Work
ACTIVITY RESPONSIBILITY DOCUMENTATION
FREQUENCY OF
ACTIVITY
Coordinate release for
fireproofing
Construction Engineer
000 509 F78201
000 509 F78202
Daily
Install fireproofing Subcontractor ----- -----
Inspect in-process
installation
Subcontractor 000 509 F78201 Each installation
Inspect completed
installation
Subcontractor 000 509 F78201 Each installation
Surveillance Site Quality Manager 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.
Project Name: 000 509 7820
Contract No.: 18 Feb 04
Project Location: Page 2 of 3
Fluor Corporation Company Confidential Site Quality Manual
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.
Project Name: 000 509 7820
Contract No.: 18 Feb 04
Project Location: Page 3 of 3
Fluor Corporation Company Confidential Site Quality Manual
Inspect completed installation:
- 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
Project Name: 000 509 7830
Contract No.: 20 Sep 04
Project Location: 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
ACTIVITY RESPONSIBILITY DOCUMENTATION
FREQUENCY OF
ACTIVITY
Verify correct materials
are used
Construction Engineer ----- Prior to installation
Verify vessel cathodic
protection installed by
shop fabricator
Materials Manager /
Site Quality Manager
------
Upon receipt of
materials
Install Cathodic
Protection
Subcontractor ----- -----
Inspect in-process
installation
Subcontractor /
Site Quality Manager
000 509 F78301
Daily during life of
activity
Witness hammer test
of Thermite welds
Site Quality Manager As required
Witness anode backfill
electrical test
Site Quality Manager As required
Inspect completed
installation
Subcontractor /
Site Quality Manager

Once after each
installation completed
Monitor testing and
commissioning
Field Engineering Prior to start-up
Audit documentation Site Quality Manager
At completion of each
installation
Surveillance Site Quality Manager 000 509 F02201
Per procedure
000 509 0220

NOTE 1: Fluor QC Surveillance is required for construction activities not being documented
on other inspection forms by Fluor Quality.
NOTE 2: Surveillance is not required if the Fluor Site Quality Manager is performing
inspections.
Project Name: 000 509 7830
Contract No.: 20 Sep 04
Project Location: 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.
Project Name: 000 509 7830
Contract No.: 20 Sep 04
Project Location: 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
Project Name: 000 509 7910
Contract No.: 18 Feb 04
Project Location: Page 1 of 6
Fluor Corporation Company Confidential Site Quality Manual
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
Project Name: 000 509 7910
Contract No.: 18 Feb 04
Project Location: Page 2 of 6
Fluor Corporation Company Confidential Site Quality Manual
Fluor Welding Manual (Self perform work only)
Applicable Project Specifications
RESPONSIBILITIES - Self-Perform
ACTIVITY RESPONSIBILITY DOCUMENTATION
FREQUENCY OF
ACTIVITY
Assign numbers to
field pipe welds
Construction
Engineer
Each piping isometric
drawing
Each isometric
requiring field
welds
Welder Foreman
Form 000 509 F79001
Daily Welding Report
Form 000 509 F79002
Weld Heat Treatment Log
Daily
Weld Checking and
Inspections
(Non ASME Code)
Certified Welding
Inspector
Form 000 509 F79001
Daily Welding Report
Form 000 509 F79002
Weld Heat Treatment Log
Daily
Welder Foreman Daily Weld Checking and
Inspections (ASME
Code Stamped)
Certified Welding
Inspector
Per Fluor "Quality Control
System Manual for Boiler
& Pressure Vessel Code
Work" 000 510 XXXX
Daily
Welder Foreman None Daily
Surveillance
Certified Welding
Inspector
Form 000 509 F02201
Form 000 509 F79002
See general
section
Project Name: 000 509 7910
Contract No.: 18 Feb 04
Project Location: Page 3 of 6
Fluor Corporation Company Confidential Site Quality Manual
Responsibilities - Subcontracted Work
ACTIVITY RESPONSIBILITY DOCUMENTATION
FREQUENCY OF
ACTIVITY
Assign numbers to
field pipe welds
Subcontractor
Each piping isometric
drawing
Each isometric
requiring field
welds
Subcontractor
Welding Foreman
Form 000 509 F79001
Daily Welding Report
Form 000 509 F79002
Weld Heat Treatment Log
Daily
Weld Checking and
Inspections
(Non ASME Code) Subcontractor
Certified Welding
Inspector
Form 000 509 F79001
Daily Welding Report
Form 000 509 F79002
Weld Heat Treatment Log
Daily
Subcontractor
Welder Foreman
Per the subcontractor
approved Quality Control
System Manual for Boiler
& Pressure Vessel Code
Work
Daily
Weld Checking and
Inspections (ASME
Code Stamped)
Subcontracor
Certified Welding
Inspector
Daily
Subcontractor
Welder Foreman
None Daily
Subcontractor
Certified Welding
Inspector
Form 000 509 F02201
Form 000 509 F79002
Daily
Surveillance
Site QC Manager 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".
Project Name: 000 509 7910
Contract No.: 18 Feb 04
Project Location: Page 4 of 6
Fluor Corporation Company Confidential Site Quality Manual
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"
Project Name: 000 509 7910
Contract No.: 18 Feb 04
Project Location: Page 5 of 6
Fluor Corporation Company Confidential Site Quality Manual
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).
Project Name: 000 509 7910
Contract No.: 18 Feb 04
Project Location: Page 6 of 6
Fluor Corporation Company Confidential Site Quality Manual
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 - Frequency of Visual Examinations
Attachment 2 - Weldolet and Sockolet Fittings Attachment
Attachment 3 - ANSI B16.11 Forged Steel Fittings
Attachment 4 - ASME Section I Acceptance Criteria
Attachment 5 - ASME Section VIII, Division I Acceptance Criteria
Attachment 6 - ASME B31.1 Acceptance Criteria
Attachment 7 - USAS B31.2 Acceptance Criteria
Attachment 8 - ASME B31.3 Acceptance Criteria
Attachment 9 - ASME B31.4 - ASME B31.8 - ASME B31.11 Acceptance Criteria
Attachment 10 - ASME/ANSI B31.5 Acceptance Criteria
Attachment 11 - ANSI/ASME B31.9 Acceptance Criteria
Attachment 12 - ASME B96.1 Acceptance Criteria
Attachment 13 - API 620 Acceptance Criteria
Attachment 14 - API 650 Acceptance Criteria
Attachment 15 - AWWA D100 (Identical to AWS D5.2) Acceptance Criteria
Attachment 16 - ANSI/AWS D1.1 / D1.6 Acceptance Criteria
Attachment 17 - Numbering of Pipe Weld Joints
Project Name: 000 509 7910
Contract No.: 18 Feb 04
Project Location: Attachment 1 . . . Page 1 of 3
FREQUENCY OF VISUAL EXAMINATIONS
1.0 ASME SECTION 1 AND VIII, DIVISION 1
1.1 Visual examination frequency shall be in accordance with the Fluor Daniel Quality
Control System Manual, Boiler and Pressure Vessel Code Work.
2.0 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 All completed welds shall have a visual examination
4.0 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.
Project Name: 000 509 7910
Contract No.: 18 Feb 04
Project Location: Attachment 1 . . . Page 2 of 3
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): 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.
5.0 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.
6.0 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.
Project Name: 000 509 7910
Contract No.: 18 Feb 04
Project Location: Attachment 1 . . . Page 3 of 3
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 ASME B31.11
Sufficient welds, materials, and components shall be examined to satisfy the examiner that
they conform to specifications and are free from defects and damage.
10.0 ASME B96.1
Sufficient welds, materials, and components shall be examined to satisfy the examiner that
they conform to specifications and are free from defects and damage.
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.
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Contract No.: 18 Feb 04
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Contract No.: 18 Feb 04
Project Location: Attachment 4 . . . Page 1 of 3
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).
Project Name: 000 509 7910
Contract No.: 18 Feb 04
Project Location: Attachment 4 . . . Page 2 of 3
ALIGNMENT TOLERANCE OF JOINT TO BE BUTT WELDED (Note 1)
Direction of Joints in Cylindrical Shells
Section Thickness (in) Longitudinal Circumferential
Up to 1/2, incl. 1/4t 1/4t
Over 1/2 to 3/4, incl. 1/8 in. 1/4t
Over 3/4 to 1 1/2, incl. 1/8 in. 3/16 in.
Over 1 1/2 to 2, incl. 1/8 in. 1/8t
Over 2 Lesser of 1/16 t or 3/8 in. 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. 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".
1.2 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.
Project Name: 000 509 7910
Contract No.: 18 Feb 04
Project Location: Attachment 4 . . . Page 3 of 3
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)
Maximum
Reinforcement (in)
Other Welds
Up to 1/8 3/32 3/32
Over 1/8 to 3/16, incl. 1/8 3/32
Over 3/16 to 1/2, incl. 5/32 3/32
Over 1/2 to 1, incl. 3/16 3/32
Over 1 to 2, incl. 1/4 1/8
Over 2 to 3, incl. Note 1 5/32
Over 3 to 4, incl. Note 1 7/32
Over 4 to 5, incl. Note 1 1/4
Over 5 Note 1 5/16
Note 1: The greater of 1/4 in. or 1/8 times the width of the weld in inches.
Project Name: 000 509 7910
Contract No.: 18 Feb 04
Project Location: Attachment 5 . . . Page 1 of 4
ACCEPTANCE CRITERIA
ASME SECTION VIII, DIVISION I
1.0 ASME Section VIII Division 1
1.1 In process examination shall meet the following:
A. 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. CMTRs required for plate material and all material
requiring CVN testing.
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. 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. 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. 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.
Project Name: 000 509 7910
Contract No.: 18 Feb 04
Project Location: Attachment 5 . . . Page 2 of 4
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 Joint Categories
A* B,C,D*
Up thru 1/2 1/4t 1/4t
Over 1/2 thru 3/4 1/8 in. 1/4t
Over 3/4 thru 1 1/2 1/8 in. 3/16 in.
Over 1 1/2 thru 2 1/8 in. 1/8t
Over 2 Lesser of 1/16t
or 3/8 in.
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.
1.2 Final visual weld examination shall be in accordance with the following:
A. 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. No porosity allowed.
C. No linear indications such as cracks, lack of fusion, cold laps or
incomplete penetration are allowed.
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Contract No.: 18 Feb 04
Project Location: Attachment 5 . . . Page 3 of 4
D. No slag or weld spatter allowed (including base material).
E. No unfilled craters allowed (with or without associated shrinkage defects).
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. 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.
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:
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.
M. For seal welding of threaded joints, the exposed threads shall be entirely
covered by the seal weld.
Project Name: 000 509 7910
Contract No.: 18 Feb 04
Project Location: Attachment 5 . . . Page 4 of 4
N. Butt weld reinforcement (internal or external) shall meet the following:
Maximum Reinforcement (in)
Material Nominal
Thickness, inch
Circumferential
Joints in Pipe/Tube
Other Welds
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
Project Name: 000 509 7910
Contract No.: 18 Feb 04
Project Location: Attachment 6 . . . Page 1 of 5
ACCEPTANCE CRITERIA
ASME B31.1
1.0 ASME B31.1
1.1 In process examination shall meet the following:
A. 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. 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. 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. Tack welds shall be made by qualified welders.
H. 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.
I. The backside of double welded joints shall be backgouged to sound metal
and visually examined prior to welding.
J. Each weld pass shall be free of porosity, slag, cold lap, cracks and other
indications that would compromise weld quality.
K. Arc strikes shall be properly removed and areas visually examined.
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Contract No.: 18 Feb 04
Project Location: Attachment 6 . . . Page 2 of 5
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. 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.
1.2 A 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 lack of
penetration.
C. No slag or weld spatter (including base material).
D. No unfilled craters allowed (with or without associated shrinkage defects).
E. No under filled (weld cap) areas.
F. Root concavity shall not reduce the weld below the base material
thickness.
G. 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.
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).
Project Name: 000 509 7910
Contract No.: 18 Feb 04
Project Location: Attachment 6 . . . Page 3 of 5
J. 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.
K. Butt weld reinforcement thickness shall meet the following:
MAXIMUM REINFORCEMENT (in)
Thickness of Base
Metal Inches >750F 350-750F <350F
Up thru 1/8 1/16 3/32 3/16
Over 1/8 thru 3/16 1/16 1/8 3/16
Over 3/16 thru 1/2 1/16 5/32 3/16
Over 1/2 thru 1 3/32 3/16 3/16
Over 1 thru 2 1/8 1/4 1/4
Over 2 5/32 See Note 5 See Note 5
Notes: 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.
L. 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.
Project Name: 000 509 7910
Contract No.: 18 Feb 04
Project Location: Attachment 6 . . . Page 4 of 5
N. For seal welding of threaded joints, the exposed threads shall be entirely
covered by the seal weld.
O. Each weld shall be identified with the welders symbol or traceable by
documentation.
Project Name: 000 509 7910
Contract No.: 18 Feb 04
Project Location: Attachment 6 . . . Page 5 of 5
FIGURE A
ASME B31.1
WELDED BRANCH DETAILS
NOTES: These sketches show minimum acceptable welds. Welds may be larger than
those shown here.
t
c
= the smaller of 1/4" or .7 x T
b
T
r
= nominal thickness of reinforcement, in. Detail (1) w = T
b
+ t
c
t
min
= the smaller of T
b
or T
r
Detail (2) w = T
h
+ t
c
T
b
= nominal thickness of branch wall Detail (3) w = T
r
+ t
c
or T
b
+ t
c
T
h
= nominal thickness of header wall Detail (4) w = T
h
+ T
r
+ t
c
Detail (5) w = T
b
+ t
c
w = Governing thickness for determining Postweld Heat Treat.
Project Name: 000 509 7910
Contract No.: 18 Feb 04
Project Location: Attachment 7 . . . Page 1 of 3
ACCEPTANCE CRITERIA
USAS B31.2
1.0 USAS B31.2, FUEL GAS PIPING
1.1 In process examination shall meet the following:
A. All base materials shall be identified as to type and grade (i.e; A106B,
SA516 G70, etc.).
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. 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. Tack welds shall be made by qualified welders.
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. The backside of double welded joints shall be backgouged to sound metal
and visually examined prior to welding.
J. Each weld pass shall be free of porosity, slag, cold lap, cracks and other
indications that would compromise weld quality.
K. Arc strikes shall be properly removed and areas visually examined.
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. 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.
Project Name: 000 509 7910
Contract No.: 18 Feb 04
Project Location: Attachment 7 . . . Page 2 of 3
1.2 Final visual weld examination shall be in accordance with the following:
A. 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.) Thickness, Max (in.)
1/2" and under 1/8"
Over 1/2" thru 1" 5/32"
Over 1" 3/16"
* For double welded joints this limitation or reinforcement shall apply
to each surface of the weld separately.
H. No under filled (weld cap) areas.
Project Name: 000 509 7910
Contract No.: 18 Feb 04
Project Location: Attachment 7 . . . Page 3 of 3
FIGURE A
USAS B31.2
WELDED BRANCH DETAILS
NOTES: These sketches show minimum acceptable welds. Welds may be larger than
those shown here.
t
c
= the smaller of 1/4" or .7 x T
b
T
r
= nominal thickness of reinforcement, in. Detail (1) w = T
b
+ t
c
t
min
= the smaller of T
b
or T
r
Detail (2) w = T
h
+ t
c
T
b
= nominal thickness of branch wall Detail (3) w = T
r
+ t
c
or T
b
+ t
c
T
h
= nominal thickness of header wall Detail (4) w = T
h
+ T
r
+ t
c
Detail (5) w = T
b
+ t
c
w = Governing thickness for determining Postweld Heat Treat.
Project Name: 000 509 7910
Contract No.: 18 Feb 04
Project Location: Attachment 8 . . . Page 1 of 6
ACCEPTANCE CRITERIA
ASME B31.3
1.0 ASME B31.3, PROCESS PIPING
1.1 In process examination shall meet the following:
A. 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. CMTRs are required for all material requiring
CVN testing. CMTRs may be required for other piping as designated in a
site specification.
B. Joint preparation and cleanliness shall be in accordance with the WPS.
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. Preheating prior to cutting or welding (including tacking) shall be in
accordance with the WPS.
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. Tack welds shall be made by qualified welders.
H. 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.
I. The backside of double welded joints shall be backgouged to sound metal
and visually examined prior to welding.
J. Each weld pass shall be free of porosity, slag, cold lap, cracks and other
indications that would compromise weld quality.
K. Arc strikes shall be properly removed and areas visually examined.
Project Name: 000 509 7910
Contract No.: 18 Feb 04
Project Location: Attachment 8 . . . Page 2 of 6
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. 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.
N. When accessible for visual inspection, the internal condition of the root
pass shall meet Figure A, B, or C as applicable.
1.2 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. For seal welding of threaded joints, the exposed threads shall be entirely
covered by the seal weld.
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.
Project Name: 000 509 7910
Contract No.: 18 Feb 04
Project Location: Attachment 8 . . . Page 3 of 6
FIGURE A
ASME B31.3
WELD ACCEPTANCE CRITERIA
Project Name: 000 509 7910
Contract No.: 18 Feb 04
Project Location: Attachment 8 . . . Page 4 of 6
FIGURE B
ASME B31.3
WELD ACCEPTANCE CRITERIA NOTES
Project Name: 000 509 7910
Contract No.: 18 Feb 04
Project Location: Attachment 8 . . . Page 5 of 6
FIGURE C
ASME B31.3
WELD CRITERIA NOTES AND WELD CRITERIA FOR TABLE K341.3.2A
Project Name: 000 509 7910
Contract No.: 18 Feb 04
Project Location: Attachment 8 . . . Page 6 of 6
FIGURE D
ASME B31.3
WELDED BRANCH DETAILS
NOTES: These sketches show minimum acceptable welds. Welds may be larger than
those shown here.
t
c
= the smaller of 1/4" or .7 x T
b
T
r
= nominal thickness of reinforcement, in. Detail (1) w = T
b
+ t
c
t
min
= the smaller of T
b
or T
r
Detail (2) w = T
h
+ t
c
T
b
= nominal thickness of branch wall Detail (3) w = T
r
+ t
c
or T
b
+ t
c
T
h
= nominal thickness of header wall Detail (4) w = T
h
+ T
r
+ t
c
Detail (5) w = T
b
+ t
c
w = Governing thickness for determining Postweld Heat Treat.
Project Name: 000 509 7910
Contract No.: 18 Feb 04
Project Location: Attachment 9 . . . Page 1 of 6
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 In process examination shall meet the following:
A. All base materials shall be identified as to type and grade (i.e., A106B,
SA516 G70, etc.)
B. Joint preparation and cleanliness shall be in accordance with the WPS.
C. Check welder qualifications, 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. 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. Tack welds shall be made by qualified welders.
H. 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.
I. The backside of double welded joints shall be backgouged to sound metal
and visually examined prior to welding.
J. Each weld pass shall be free of porosity, slag, cold lap, cracks and other
indications that would compromise weld quality.
K. Arc strikes shall be properly removed and areas visually examined.
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.
Project Name: 000 509 7910
Contract No.: 18 Feb 04
Project Location: Attachment 9 . . . Page 2 of 6
M. 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.
* Shallow crater cracks located at the stopping point of weld beads, and that
are 5/32 inch or less in length are acceptable.
1.2 Final Visual Weld Examination shall be in accordance with the following:
A. 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.
B. 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.
C. 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.
D. 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.
Project Name: 000 509 7910
Contract No.: 18 Feb 04
Project Location: Attachment 9 . . . Page 3 of 6
3. 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.
E. 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.
F. 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.
G. 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. For seal welding of threaded joints, the exposed threads shall be entirely
covered by the seal weld.
K. Perform visual weld examination prior to other nondestructive examinations
and postweld heat treatment.
Project Name: 000 509 7910
Contract No.: 18 Feb 04
Project Location: Attachment 9 . . . Page 4 of 6
FIGURE A
ASME B31.4 - B31.8 - B31.11
WELD DETAILS FOR UNEQUAL WALL THICKNESS
Project Name: 000 509 7910
Contract No.: 18 Feb 04
Project Location: Attachment 9 . . . Page 5 of 6
FIGURE B
ASME B31.4 - B31.8 - B31.11
BRANCH CONNECTION DETAILS WITHOUT REINFORCEMENT
Project Name: 000 509 7910
Contract No.: 18 Feb 04
Project Location: Attachment 9 . . . Page 6 of 6
FIGURE C
ASME
B31.4 - B31.8 - B31.11
Project Name: 000 509 7910
Contract No.: 18 Feb 04
Project Location: Attachment 10 . . . Page 1 of 5
ACCEPTANCE CRITERIA
ASME B31.5
1.0 ASME B31.5, REFRIGERATION PIPING
1.1 In process examination shall meet the following:
A. All base materials shall be identified as to type and grade (i.e; A106B,
SA516 G70, etc.).
B. Joint preparation and cleanliness shall be in accordance with the WPS.
C. Check welder qualifications, 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. 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. Tack welds shall be made by qualified welders.
H. 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.
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 lap, cracks and other
indications that would compromise weld quality.
K. Arc strikes shall be properly removed and areas visually examined.
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.
Project Name: 000 509 7910
Contract No.: 18 Feb 04
Project Location: Attachment 10 . . . Page 2 of 5
M. 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.
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 the following:
A. 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. For seal welding of threaded joints, the exposed threads shall be entirely
covered by the seal weld.
E. Perform Visual Weld Examination prior to other nondestructive
examinations and postweld heat treatment.
Project Name: 000 509 7910
Contract No.: 18 Feb 04
Project Location: Attachment 10 . . . Page 3 of 5
FIGURE A
ASME B31.5
WELD ACCEPTANCE CRITERIA
Project Name: 000 509 7910
Contract No.: 18 Feb 04
Project Location: Attachment 10 . . . Page 4 of 5
FIGURE B
ASME B31.5
WELD ACCEPTANCE CRITERIA NOTES
Project Name: 000 509 7910
Contract No.: 18 Feb 04
Project Location: Attachment 10 . . . Page 5 of 5
FIGURE C
ASME B31.5
WELDED BRANCH DETAILS
NOTES: These sketches show minimum acceptable welds. Welds may be larger than
those shown here.
t
c
= the smaller of 1/4" or .7 x T
b
T
r
= nominal thickness of reinforcement, in. Detail (1) w = T
b
+ t
c
t
min
= the smaller of T
b
or T
r
Detail (2) w = T
h
+ t
c
T
b
= nominal thickness of branch wall Detail (3) w = T
r
+ t
c
or T
b
+ t
c
T
h
= nominal thickness of header wall Detail (4) w = T
h
+ T
r
+ t
c
Detail (5) w = T
b
+ t
c
w = Governing thickness for determining Postweld Heat Treat.
Project Name: 000 509 7910
Contract No.: 18 Feb 04
Project Location: Attachment 11 . . . Page 1 of 3
ACCEPTANCE CRITERIA
ASME B31.9
1.0 ASME B31.9, BUILDING SERVICES PIPING
1.1 In process examination shall meet the following:
A. All base materials shall be identified as to type and grade (i.e; A53B, A570,
etc.).
B. Joint preparation and cleanliness shall be in accordance with the WPS.
C. Check welder qualifications, 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. 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. Tack welds shall be made by qualified welders.
H. 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.
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. Arc strikes shall be properly removed and areas visually examined.
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. 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.
Project Name: 000 509 7910
Contract No.: 18 Feb 04
Project Location: Attachment 11 . . . Page 2 of 3
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.
Project Name: 000 509 7910
Contract No.: 18 Feb 04
Project Location: Attachment 11 . . . Page 3 of 3
FIGURE A
ASME B31.9
WELDED BRANCH DETAILS
NOTES: These sketches show minimum acceptable welds. Welds may be larger than
those shown here.
t
c
= the smaller of 1/4" or .7 x T
b
T
r
= nominal thickness of reinforcement, in. Detail (1) w = T
b
+ t
c
t
min
= the smaller of T
b
or T
r
Detail (2) w = T
h
+ t
c
T
b
= nominal thickness of branch wall Detail (3) w = T
r
+ t
c
or T
b
+ t
c
T
h
= nominal thickness of header wall Detail (4) w = T
h
+ T
r
+ t
c
Detail (5) w = T
b
+ t
c
w = Governing thickness for determining Postweld Heat Treat.
Project Name: 000 509 7910
Contract No.: 18 Feb 04
Project Location: Attachment 12 . . . Page 1 of 2
ACCEPTANCE CRITERIA
ASME B96.1
1.0 ASME B96.1, "Welded Aluminum-Alloy Storage Tanks"
1.1 In process examination shall meet the following:
A. All base materials shall be identified as to type and grade (i.e.; 6061, 6063,
etc.).
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. Fit-up, including misalignment of butt welds, shall be in accordance with the
WPS.
G. Tack welds shall be made by qualified welders.
H. 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.
I. The backside of double welded joints shall be backgouged to sound metal
and visually examined prior to welding.
J. Each weld pass shall be free of porosity, slag, cold lap, cracks and other
indications that would compromise weld quality.
K. Arc strikes shall be properly removed and areas visually examined.
Project Name: 000 509 7910
Contract No.: 18 Feb 04
Project Location: Attachment 12 . . . Page 2 of 2
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. 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 3/32"
Greater than 3/8 inch to 3/4 inch 1/8"
Greater than 3/4 inch 3/16"
Project Name: 000 509 7910
Contract No.: 18 Feb 04
Project Location: Attachment 13 . . . Page 1 of 2
ACCEPTANCE CRITERIA
API 620
1.0 API 620, "DESIGN AND CONSTRUCTION OF LARGE WELDED LOW PRESSURE
STORAGE TANKS"
1.1 In process examination shall meet the following:
A. 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. CMTRs are
required for plate material. Review drawing to determine if CVN testing is
required.
B. Joint preparation and cleanliness shall be in accordance with the WPS.
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 let number to the weld joints is required for
CVN applications.
E. Preheating prior to cutting or welding (including tacking) shall be in
accordance with the WPS.
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 . Do not taper plate joints.
G. Tack welds shall be made by qualified welders.
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. The backside of double welded joints shall be backgouged to sound metal
and visually examined prior to welding.
K. Each weld pass shall be free of porosity, slag, cold lap, cracks and other
indications that would compromise weld quality.
L. Arc strikes shall be properly removed and areas visually examined.
Project Name: 000 509 7910
Contract No.: 18 Feb 04
Project Location: Attachment 13 . . . Page 2 of 2
2.0 Final Visual Examination shall be in accordance with the following:
A. 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. No linear indications such as cracks or cold lap or other indications that
would compromise weld quality.
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:
MAXIMUM THICKNESS OF
REINFORCEMENT (INCHES)
PLATE THICKNESS
(INCHES)
Vertical Joints Horizontal Joints
1/2 inch or less 3/32 1/8
Over 1/2 inch to 1 inch 1/8 3/16
Over 1 inch 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 through 1, and 1/8 for plates over 1
thickness.
I. Weld repairs shall be feathered to a 4:1 taper.
Project Name: 000 509 7910
Contract No.: 18 Feb 04
Project Location: Attachment 14 . . . Page 1 of 3
ACCEPTANCE CRITERIA
API 650
1.0 API 650 "Welded Steel Tanks for Oil Storage"
1.1 In process examination shall meet the following:
A. 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 CMTRs are
required by drawing or purchase order. Review drawing to determine if
CVN testing is required (if so, CMTRs 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. 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 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 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. Preheating prior to cutting or welding (including tacking) shall be in
accordance with the WPS.
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. Tack welds shall be made by qualified welders.
H. Tack welds in vertical butt joints to be manually welded shall be removed
before welding.
Project Name: 000 509 7910
Contract No.: 18 Feb 04
Project Location: Attachment 14 . . . Page 2 of 3
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. The backside of double welded joints shall be backgouged to sound metal
and visually examined prior to welding.
K. Each weld pass shall be free of porosity, slag, cold lap, cracks and other
indications that would compromise weld quality.
L. Arc strikes shall be properly removed and areas visually examined.
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. Undercut does not exceed:
1. 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:
MAXIMUM THICKNESS OF
REINFORCEMENT (INCHES)
PLATE THICKNESS
(INCHES)
Vertical Joints Horizontal Joints
1/2 inch or less 3/32 1/8
Over 1/2 inch to 1 inch 1/8 3/16
Over 1 inch 3/16 1/4
Project Name: 000 509 7910
Contract No.: 18 Feb 04
Project Location: Attachment 14 . . . Page 3 of 3
H. Where RT is required, weld reinforcement shall not exceed 1/16 for plates
<= , 3/32 for plates over 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
when using a 36 sweep board (for vertical joints, the sweep board must
meet tank curvature).
Project Name: 000 509 7910
Contract No.: 18 Feb 04
Project Location: Attachment 15 . . . Page 1 of 2
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 In process examination shall meet the following:
A. All base materials shall be identified as to type and grade (i.e; A106B,
SA516 G70, etc.).
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 oxy-
fuel methods.
C. Check welder qualifications, 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. 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 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. The backside of double welded joints shall be backgouged to sound metal
and visually examined prior to welding.
J. Each weld pass shall be free of porosity, slag, cold lap, cracks and other
indications that would compromise weld quality.
K. Arc strikes shall be properly removed and areas visually examined.
Project Name: 000 509 7910
Contract No.: 18 Feb 04
Project Location: Attachment 15 . . . Page 2 of 2
1.2 Final Visual Examination shall be in accordance with the following:
A. No cracks.
B. No porosity.
C. Undercut does not exceed:
1. 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. No linear indications such as cracks or cold lap or other indications that
would compromise weld quality.
F. No underfilled (weld cap) areas.
G. Weld reinforcement, internal and external, shall not exceed the following:
Maximum Thickness of
Reinforcement (Inches)
Plate Thickness
(Inches)
Vertical Joints Horizontal Joints
inch and less 3/32 1/8
Over 1/2/ inch to 1 inch 1/8 3/16
Over 1 inch 3/16 1/4
H. Welders 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
when using a 36 sweep board (for vertical joints, the sweep board must
meet tank curvature).
Project Name: 000 509 7910
Contract No.: 18 Feb 04
Project Location: Attachment 16 . . . Page 1 of 2
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.
F. 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.
1.2 Final Visual Weld Examination shall be in accordance with the following:
A. 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.
Project Name: 000 509 7910
Contract No.: 18 Feb 04
Project Location: Attachment 16 . . . Page 2 of 2
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 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.
Project Name: 000 509 7910
Contract No.: 18 Feb 04
Project Location: Attachment 17 . . . Page 1 of 3
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
Project Name: 000 509 7910
Contract No.: 18 Feb 04
Project Location: Attachment 17 . . . Page 2 of 3
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-to-
branch 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 DJ-
1 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
Project Name: 000 509 7910
Contract No.: 18 Feb 04
Project Location: Attachment 17 . . . Page 3 of 3
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.
Project Name: 000 509 7920
Contract No.: 18 Feb 04
Project Location: Page 1 of 5
Fluor Corporation Company Confidential Site Quality Manual
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
FREQUENCY
OF ACTIVITY
Perform RT, UT, MT,
PT, PMI, HT
NDE Coordinator
Report as specified in
the approved NDE
Procedure
Per specifications
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
Per specifications
Coordinate Weld
Repairs
Welding Specialist _____ Each rejected weld
Responsibility - Subcontracted Work
ACTIVITY RESPONSIBILITY DOCUMENTATION
FREQUENCY
OF ACTIVITY
Perform RT, UT, MT,
PT, PMI, HT
Subcontractor
Report as specified in
the approved NDE
Procedure
Per specification
Technical
Supervision of NDE
Subcontractor _____ _____
Selection for NDE
and Status
Maintenance
NDE Coordinator
(Note 1)
Welds: 000 509 F79201
000 509 F79204
or NEWS program.
Other than welds:
000 509 F79204
Per specification
Coordinate Weld
Repairs
Subcontractor _____ Each rejected weld
Surveillance QC Inspector 000 509 F02201
Daily during life of
activity.
NOTE 1: This activity may be delegated to the Installation Subcontractor
Project Name: 000 509 7920
Contract No.: 18 Feb 04
Project Location: Page 2 of 5
Fluor Corporation Company Confidential Site Quality Manual
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.
Perform RT, UT, MT, PT, PMI, HT
- 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.
Project Name: 000 509 7920
Contract No.: 18 Feb 04
Project Location: Page 3 of 5
Fluor Corporation Company Confidential Site Quality Manual
- 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 (000-
509-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.
Project Name: 000 509 7920
Contract No.: 18 Feb 04
Project Location: Page 4 of 5
Fluor Corporation Company Confidential Site Quality Manual
- 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 - Welder B31.3 Random Radiography Control Log
000 509 F79202 - Nondestructive Examination Request/Record
000 509 F79203 - Radiographic Rejectable Defects Statistics
000 509 F79204 - Welding/NDE Status Log
000 509 F79205 - Ferrite Test Report
000 509 F79001 - Daily Welding Report
000 509 F79002 - Post Weld Heat Treatment Log
Fluor Nondestructive Examination Procedures:
Practice: 000 511 0101 Certification of Nondestructive Examination Personnel
Practice: 000 511 0104 Liquid Penetrant Examination of Weldments and Materials -
ASME Code (Visual Dye/Solvent Removable)
Project Name: 000 509 7920
Contract No.: 18 Feb 04
Project Location: Page 5 of 5
Fluor Corporation Company Confidential Site Quality Manual
Practice: 000 511 0106 Magnetic Particle Examination of Weldments and Materials
(Dry Particles - Continuous Method)
Practice: 000 511 0108 Radiographic Examination of Weldments
Practice: 000 511 0109 Ultrasonic Examination Methods
Practice: 000 511 0116 Positive Material Identification Testing using X-Ray Diffraction
Practice: 000 511 0117 Hardness Testing of Weldments
Project Name: 000 509 7920
Contract No.: 18 Feb 04
Project Location: Attachment 1 . . . Page 1 of 1
ASME B31.3 RANDOM RADIOGRAPHY REQUIREMENTS REFERENCE
If ACCEPTABLE, all
welds in this welder's
lot are considered to
be acceptable
Radiograph
2nd Weld
If BOTH additional
welds are acceptable,
the balance of welds
in this welder's lot are
considered to be
acceptable.
Radiograph
3rd Weld
2nd Weld
Acceptable
2nd Weld
Rejected
3rd Weld
Acceptable
2nd Weld
Rejected
3rd Weld
Rejected
Radiograph
6th Weld
Radiograph
7th Weld
3rd Weld
Rejected
If BOTH additional
welds are
ACCEPTABLE,
consider the balance
of the welds in this lot
to be acceptable.
If EITHER of these
welds are
REJECTED, all welds
by this welder in this
lot shall be 100%
Radiographed.*
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.*
Radiograph
4th Weld
Radiograph
5th Weld
Radiograph
4th Weld
Radiograph
5th Weld
Select weld from
welder's lot of
welds **
Radiograph Weld
If REJECTED,
select two
additional welds
from same lot
** Note: The first two pressure piping butt welds radiographed for each
welder are not to be included in the welder's lot.
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.
Project Name: 000 509 7930
Contract No.: 18 Feb 04
Project Location: Page 1 of 5
Fluor Corporation Company Confidential Site Quality Manual
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 DOCUMENTATION FREQUENCY
Warehouse Receiving
Warehouse
Manager/Supervisor
On-going
Receiving Inspection Site Quality Manager
_____
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
Site Quality Manager _____ _____
Resolve Accept and
Rejects
Site Quality Manager project specifications Per Rejects
RESPONSIBILITY Subcontractor Supplied Materials and Alloy Welds
ACTIVITY RESPONSIBILITY DOCUMENTATION FREQUENCY
Receiving Inspection
Subcontractor Quality
Manager
_____ On-going
Perform PMI NDE Subcontractor project specifications Per Specification
PMI of Welds
Subcontractor Quality
Manager
project specifications Per Specification
Identification Subcontractor
_____
On-going
Document Results Subcontractor
Form 000 509 F79301
Form 000 509 F79302
Form 000 509 F79304
Technically Supervise
PMI
Subcontractor Quality
Manager
_____ _____
Resolve Accept and
Rejects
Subcontractor Quality
Manager
project specifications Per Rejects
Project Name: 000 509 7930
Contract No.: 18 Feb 04
Project Location: Page 2 of 5
Fluor Corporation Company Confidential Site Quality Manual
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.
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
subcontractors 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.
Project Name: 000 509 7930
Contract No.: 18 Feb 04
Project Location: Page 3 of 5
Fluor Corporation Company Confidential Site Quality Manual
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.
- Extent of PMI shall be per the project specifications.
PMI of Alloy Piping
- 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 manufacturers containers.
- Each container must have the AWS Classification, heat and lot number clearly marked.
- Filler metal certification is required.
Project Name: 000 509 7930
Contract No.: 18 Feb 04
Project Location: Page 4 of 5
Fluor Corporation Company Confidential 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
- 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.
Project Name: 000 509 7930
Contract No.: 18 Feb 04
Project Location: Page 5 of 5
Fluor Corporation Company Confidential Site Quality Manual
- 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 - PMI Inspection Record
000 509 F79302 - Bulk Material Positive Material Identification Record
000 509 F79303 - Pipe Spool Positive Material Identification Record Point Sheet
000 509 F79304 - Weekly PMI Log
ATTACHMENTS
Attachment 1 PMI Procedure for the Field
Attachment 2 Color Code for Metal Identification
Project Specifications:
000 285 85010 General Specification for Positive Material Identification (PMI)
Project Name: 000 509 7930
Contract No.: 18 Feb 04
Project Location: Attachment 1. . . Page 1 of 3
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 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. Obtain or make the drawing.
2. Make the point sheet.
3. 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).
4. PMI the component and record results on the point sheet.
5. Color-code the component.
6. Repeat sequentially for the next component.
Project Name: 000 509 7930
Contract No.: 18 Feb 04
Project Location: Attachment 1. . . Page 2 of 3
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. PMI Company
2. PMI Technician name in print and date
3. PMI Technician signature
4. Site Quality Representative name in print and date
5. 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. Automated welding---one sample from each girth or long seam.
2. Manual welding---one sample from each girth seam < 24 in. diameter.
3. Manual welding---two samples from each girth seam equal to or > 24 in.
diameter.
4. Autogenous welded pipe and fittings---PMI verification of base metal only.
5. 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 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.
Project Name: 000 509 7930
Contract No.: 18 Feb 04
Project Location: Attachment 1. . . Page 3 of 3
6.0 Welding Wire (Bare):
6.1 Bare wire shall be purchased in unopened manufacturers 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.
Project Name: 000 509 7930
Contract No.: 18 Feb 04
Project Location: Attachment 2 . . . Page 1 of 1
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 Low-
Temperature Service (Below -
20F)
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)
Project Name: 000 509 7950
Contract No.: 18 Feb 04
Project Location: Page 1 of 2
Fluor Corporation Company Confidential Site Quality Manual
HARDNESS TESTING
SCOPE
This procedure describes the functions to be performed in the performance of hardness testing.
RESPONSIBILITIES
ACTIVITY RESPONSIBILITY DOCUMENTATION
FREQUENCY OF
ACTIVITY
Review Job Specification for
Hardness Testing
Requirements
Site Quality Manager Prior to start of work
Hardness Testing Equipment Site Quality Manager Prior to start of work
000 509 F79501 Yearly or each applic.
Personnel Training & Vision
Test
Site Quality Manager
000 509 F79502 Yearly
Preparation of Surface to be
Tested
Piping
Superintendent
Each test location
Perform Hardness Testing &
Report Results
QC Inspector/NDE
Technician
000-509-F79503
As required by code
or specification
PROCEDURE
Review Job Specification for Hardness Testing Requirements
- Obtain a copy of the Code/Job Specification requirements prior to the start of work.
Hardness Testing Equipment
- 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.
Project Name: 000 509 7950
Contract No.: 18 Feb 04
Project Location: Page 2 of 2
Fluor Corporation Company Confidential Site Quality Manual
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 - Verification of Training For Hardness Testing
000 509 F79502 - Report of Vision Test
000 509 F79503 - Hardness Testing Report

Project Name: 000 509 F0000
Contract No.: 20 Sep 04
Project Location: Page 1 of 8


FORMS INDEX
Form Number Form Title Revision Date
000 509 F00501 Request For Information 18 Feb 04
000 509 F00502 Request For Information Log 18 Feb 04

000 509 F01101 Calibration Assignment Log and Record 18 Feb 04
000 509 F01102 I.M.T.E. Sign In/Out History of Use Log 18 Feb 04
000 509 F01103 Calibrations Tickler File 18 Feb 04
000 509 F01104 Calibration Data Sheet 18 Feb 04

000 509 F01301 Nonconformance Report 18 Feb 04
000 509 F01302 Nonconformance Report Log 18 Feb 04
000 509 F01303 Hold Tag/Sticker 18 Feb 04

000 509 F01401 Corrective Action Report 18 Feb 04
000 509 F01402 Corrective Action Status Log 18 Feb 04

000 509 F01501 Preventive Action Log 18 Feb 04

000 509 F01601 Quality Records Control 18 Feb 04

000 509 F01701 Audit Finding 18 Feb 04
000 509 F01702 Audit Summary 18 Feb 04

000 509 F01801 Project Specific Quality Training 18 Feb 04

000 509 F02001 Site Subcontractor Qualification 18 Feb 04
000 509 F02002 Soil Testing Laboratory Evaluation Record 18 Feb 04
000 509 F02003 Asphalt Testing Laboratory Evaluation Record 18 Feb 04
000 509 F02004 Concrete Batch Plant Evaluation Record 18 Feb 04
000 509 F02005 Concrete Testing Laboratory Evaluation Record 18 Feb 04
000 509 F02006 NDE Subcontractor Evaluation Record 18 Feb 04

000 509 F02201 Surveillance Report 18 Feb 04
000 509 F02202 Surveillance Report Log 18 Feb 04

000 509 F02301 Receiving Inspection Checklist 18 Feb 04

000 509 F02401 Transfer of Care, Custody and Control (Turnover Notice) 18 Feb 04
000 509 F02402 System Walkdown Notice 18 Feb 04
000 509 F02403 Mechanical Completion Civil Checklist 18 Feb 04
000 509 F02404 Mechanical Completion Electrical/Instrumentation Checklist 18 Feb 04
000 509 F02405 Mechanical Completion/Mechanical Checklist 18 Feb 04
000 509 F02406 Mechanical Completion/Quality Control Checklist 18 Feb 04
Project Name: 000 509 F0000
Contract No.: 20 Sep 04
Project Location: Page 2 of 8


Form Number Form Title Revision Date
000 509 F02407 Master Punch List Record 18 Feb 04
000 509 F02408 Interim Turnover Notice 18 Feb 04
000 509 F02409 Mechanical Completion Certificate 18 Feb 04

000 509 F02501 Storage Inspection Checklist 18 Feb 04
000 509 F02502 Equipment Protection Preservation and Inspection Record 18 Feb 04

000 509 F70001 Inspection and Test Plan 18 Feb 04
000 509 F70002 Inspection and Test Plan 18 Feb 04

000 509 F70101 Soil Inspection Checklist 18 Feb 04
000 509 F70102 Field Compaction Test Record 18 Feb 04
000 509 F70103
Density of Soil Place by the Sand-Cone Method ASTM D-
1566 AASHTO-T-191
18 Feb 04
000 509 F70104 Nuclear Moisture-Density Test Report 18 Feb 04
000 509 F70105 Soil Density Test Log 18 Feb 04

000 509 F70201 Bituminous Concrete Paving Inspection Checklist 18 Feb 04
000 509 F70202 Bulk Specific Gravity 18 Feb 04
000 509 F70203 Bituminous Concrete Compaction 18 Feb 04
000 509 F70204 Nuclear Density Test Report Bituminous Concrete 18 Feb 04

000 509 F70301 Pile Driving Inspection Record 18 Feb 04
000 509 F70302 Pile Driving Record 18 Feb 04
000 509 F70303 Record of Pile Driving 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 Pre-Concrete Inspection Checklist 18 Feb 04
000 509 F71002 Concrete Inspection Record 18 Feb 04
000 509 F71003 Concrete Pour Card 18 Feb 04
000 509 F71004 Cementitious Grout Inspection Record 18 Feb 04
000 509 F71005 Cementitious Grout Testing Record 18 Feb 04
000 509 F71006 Epoxy Resin Grout Inspection Record 18 Feb 04
000 509 F71007 Concrete Compression Strength Test Record 18 Feb 04
000 509 F71008 Concrete Placement Log 18 Feb 04
000 509 F71009 Grout Placement Log 18 Feb 04
000 509 F71010 Concrete Batch Plant Inspection Record 18 Feb 04

000 509 F72002 Structural Steel Inspection 18 Feb 04
000 509 F72003 Torque Wrench Calibration Log 18 Feb 04
Project Name: 000 509 F0000
Contract No.: 20 Sep 04
Project Location: Page 3 of 8



Form Number Form Title Revision Date
000 509 F73001 Building Inspection and Test Checklist 18 Feb 04
000 509 F73002 Final Building Inspection Summary 18 Feb 04
000 509 F73003 Carpentry Checklist 18 Feb 04
000 509 F73004 Painting Checklist 18 Feb 04
000 509 F73005 Plumbing Checklist 18 Feb 04
000 509 F73006 Ceramic Tile Checklist 18 Feb 04
000 509 F73007 Concrete Checklist 18 Feb 04
000 509 F73008 Structural Steel Checklist 18 Feb 04
000 509 F73009 Masonry (Brickwork) Checklist 18 Feb 04
000 509 F73010 Plaster Checklist 18 Feb 04
000 509 F73011 Doors, Windows, Hardware, Glazing Checklist 18 Feb 04
000 509 F73012 Computer (Raised) Floors Checklist 18 Feb 04
000 509 F73013 Prefab Wall Element Systems Checklist 18 Feb 04
000 509 F73014 Building Metal Siding And Roofing Checklist 18 Feb 04
000 509 F73015 Buildings Water Proofing And Damp Proofing Checklist 18 Feb 04
000 509 F73016 Suspended Ceiling Checklist 18 Feb 04

000 509 F73101 HVAC Inspection Record 18 Feb 04
000 509 F73102 Buildings Air Conditioning Checklist 18 Feb 04

000 509 F73201 Roofing Inspection Checklist 18 Feb 04

000 509 F74001 Equipment Installation Checklist 18 Feb 04
000 509 F74002 Heat Exchangers & Reboilers Installation Record 18 Feb 04
000 509 F74003 Electrostatic Precipitator Checklist 18 Feb 04
000 509 F74004 Inspection Record Static Equipment 18 Feb 04
000 509 F74005 Tray Installation Inspection Record 18 Feb 04
000 509 F74006 Air Cooled Heat Exchanger Inspection Checklist 18 Feb 04
000 509 F74007 Air Cooler Run In Test Report 18 Feb 04
000 509 F74008 Reciprocating Compressor Inspection Record 18 Feb 04
000 509 F74009 Fan Installation Inspection Checklist 18 Feb 04
000 509 F74010 Furnaces Inspection Record 18 Feb 04
000 509 F74011 Fuel Gas Steam Generator Inspection Checklist 18 Feb 04
000 509 F74012 Steam Turbine Inspection Checklist 18 Feb 04
000 509 F74013 Agitators/Mixers Inspection Checklist 18 Feb 04
000 509 F74014 Equipment/Piping Strain and Alignment Inspection Form 18 Feb 04
000 509 F74015 Installation Checklist Travelling Cranes 18 Feb 04
000 509 F74016 Package Equipment Installation Checklist 18 Feb 04
000 509 F74017 Desuperheaters/Ejectors Inspection Checklist 18 Feb 04
000 509 F74018 Filters/Strainers Installation Record 18 Feb 04
000 509 F74019 Centrifugal Compressor Inspection Record 18 Feb 04
000 509 F74020 Rotating Equipment Inspection Record 18 Feb 04
Project Name: 000 509 F0000
Contract No.: 20 Sep 04
Project Location: Page 4 of 8


Form Number Form Title Revision Date
000 509 F74021 Rotating Equipment Alignment Record 18 Feb 04
000 509 F74022 Belt Driven Equipment Alignment Record 18 Feb 04
000 509 F74024 Inspection Record For Draw Off Tray Leak Test Report 18 Feb 04
000 509 F74025 Inspection Record For Air Coolers 18 Feb 04
000 509 F74026 Final Closing Authorization Record 18 Feb 04
000 509 F74027 API 686 Baseplate Installation Checklist (Prior to Grouting) 18 Feb 04
000 509 F74028 API 686 Equipment Grouting Checklist 18 Feb 04
000 509 F74029 API 686 Alignment Check Sheet 18 Feb 04
000 509 F74030 Baseplate Leveling Record 18 Feb 04
000 509 F74031 Reverse Dial Alignment Record 18 Feb 04
000 509 F74032 Piping Alignment Data Sheet 18 Feb 04

000 509 F74101 Tank Elevation Tolerances Record 18 Feb 04
000 509 F74102 Inspection Record Field Erected Tank 18 Feb 04
000 509 F74103 Tank Plate Dimensional Control Record Field Erected Tank 18 Feb 04
000 509 F74104 Water Filling And Settlement Record Field Erected Tank 18 Feb 04
000 509 F74105 Tank Leak Test Record 18 Feb 04
000 509 F74106 Tank Test Certificate 18 Feb 04

000 509 F74201 Inspection Record Cooling Tower 18 Feb 04

000 509 F74301 Field Installed Refactory Record 18 Feb 04

000 509 F74401 Gas Turbine/Generator Gear Inspection Checklist 18 Feb 04
000 509 F74402 Gas Turbine Inspection Record 18 Feb 04
000 509 F74405 Shop-Fabricated Field-Erected Stack Inspection Record 18 Feb 04
000 509 F74406 Heat Recovery Steam Generator Inspection Record 18 Feb 04
000 509 F74407 Breeching And Duct Work Inspection Record 18 Feb 04
000 509F74408 Equipment Protection Activities Record Gas Turbines 18 Feb 04

000 509 F74601 Site Daily Activities Log 18 Feb 04
000 509 F74602 Stg Foundation Settlement Record 18 Feb 04
000 509 F74603 Stg Fixators 18 Feb 04
000 509 F74604 Stg Sole Plates 18 Feb 04
000 509 F74605 Stg Front Standard Base Plate Assembly 18 Feb 04
000 509 F74606 Exhaust Hood Horizontal Joint Levelness 18 Feb 04
000 509 F74607 Stg Shell/Casing Load Test 18 Feb 04
000 509 F74608 Stg Piping Attachment 18 Feb 04
000 509 F74609 Stg Foundation Top of Concrete Elevations 18 Feb 04

000 509 F74701 Generator Test Checklist 18 Feb 04
000 509 F74702 Generator Cold Resistance Test Record 18 Feb 04

Project Name: 000 509 F0000
Contract No.: 20 Sep 04
Project Location: Page 5 of 8


Form Number Form Title Revision Date
000 509 F75001 Underground Pipe Inspection Record 18 Feb 04
000 509 F75002
Insulation Resistance (Insulated Flanges-Underground Piping)
Test Record
18 Feb 04
000 509 F75003 Holiday (Spark) Test Record 18 Feb 04

000 509 F75101 Aboveground Pipe Inspection Record 18 Feb 04
000 509 F75102 Visual Inspection of Flanges, Gaskets and Bolting 18 Feb 04
000 509 F75103 Weld Map Record 18 Feb 04

000 509 F75201 Pressure Test Report 18 Feb 04

000 509 F75501 Hygienic Drawing Revision Log 18 Feb 04
000 509 F75502 Hygienic Material Receiving Log 18 Feb 04
000 509 F75503 Hygienic Valve Receiving Inspection Report 18 Feb 04
000 509 F75504 Hygienic Vessel Nozzle Receiving Inspection Report 18 Feb 04
000 509 F75505 Hygienic Tube/Fitting Receiving Inspection Report 18 Feb 04
000 509 F75506 Hygienic Pre-weld Inspection Checklist 18 Feb 04
000 509 F75507 Hygienic Welder Qualification Report 18 Feb 04
000 509 F75508 Hygienic Orbital Weld Log 18 Feb 04
000 509 F75509 Hygienic Post Installation Checklist 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 Conduit And Cable Tray Checklist 18 Feb 04
000 509 F76002 Electrical Manhole Inspection Checklist 18 Feb 04
000 509 F76003
Medium & High Voltage Underground Cable Splice Inspection
Record
18 Feb 04
000 509 F76004 Medium and High Voltage Cable Termination Checklist 18 Feb 04
000 509 F76005 Cable Pulling Inspection Checklist 18 Feb 04
000 509 F76006 Fan/Speed Reducer/Motor Inspection Checklist 18 Feb 04
000 509 F76007 Switch House Inspection Checklist 18 Feb 04
000 509 F76008
Lighting Receptacle, Instrument Distribution Panels Inspection
Checklist
18 Feb 04
000 509 F76009 Electrical Motor Inspection Checklist 18 Feb 04
000 509 F76010 Aboveground Conduit Inspection Checklist 18 Feb 04
000 509 F76011 Lighting Panelboard Inspection Record 18 Feb 04
000 509 F76012 Underground Conduit (Duct Bank) Inspection 18 Feb 04
000 509 F76013 Grounding/Earthing System (Grid or Loop) Inspection Record 18 Feb 04

000 509 F76101
Grounding/Earthing Resistance Reading (Resistance-to-Earth
and Loop Continuity) Test Record
18 Feb 04

Project Name: 000 509 F0000
Contract No.: 20 Sep 04
Project Location: Page 6 of 8


Form Number Form Title Revision Date
000 509 F76102
Insulation Resistance (Power, Control Wire And Cable) Test
Record
18 Feb 04
000 509 F76103
Insulation Resistance (Instrument Wire And Cable) Test
Record
18 Feb 04
000 509 F76104 DC High Potential Test (Medium Voltage Cable) Record 18 Feb 04
000 509 F76105 Current Transformer (And Ammeter) Test Record 18 Feb 04
000 509 F76106 LV Over-current And Earth/Ground-Fault Protection Relay Test 18 Feb 04
000 509 F76107
Over-current/Ground Fault Protection Relay (Induction Type)
Test
18 Feb 04
000 509 F76108
Over-current/Ground Fault Protection Relay (Thermal Type)
Test
18 Feb 04
000 509 F76109 Switching Units HV Switchgear Inspection And Test Record 18 Feb 04
000 509 F76110 Ground Electrode Resistance Inspection Test Record 18 Feb 04
000 509 F76111
Ground Fault Protection Relay Induction Inspection and Test
Record
18 Feb 04
000 509 F76112 Grounding Continuity Inspection and Test Record 18 Feb 04
000 509 F76113 Grounding Rod Inspection and Test Record 18 Feb 04
000 509 F76114 Bus Bar Assemblies LV Switchgear Test Record 18 Feb 04
000 509 F76115 Neutral Grounding/Earthing Resistor Test Record 18 Feb 04
000 509 F76116
Ground Continuity (Non Electrical) Equipment/Structures Test
Record
18 Feb 04
000 509 F76117
Ground Continuity (Electrical Equipment and Ground Test
Bars) Test Record
18 Feb 04
000 509 F76118 Insulation Resistance (Equipment) Test Record 18 Feb 04
000 509 F76119 Insulation Resistance (Transformer) Test Record 18 Feb 04
000 509 F76120 Liquid Dielectric Strength Test Record 18 Feb 04
000 509 F76121 DC Proof Test Record for Motors 18 Feb 04
000 509 F76122 Feeder Breaker (480V MCC) Test Record 18 Feb 04
000 509 F76123 Breaker/Contractor (480V MCC) Test Record 18 Feb 04
000 509 F76124 460V Motor Circuit (480V MCC) Test Record 18 Feb 04
000 509 F76125 Medium Voltage Motor Circuit Test Record 18 Feb 04
000 509 F76126
Equipment Absorption Ration and Polarization Index Test
Record (Megger)
18 Feb 04
000 509 F76127
Insulation Resistance (Medium Voltage Power Cables) Test
Record
18 Feb 04
000 509 F76128 Bus Throat Insulation and Ductor Reports 18 Feb 04
000 509 F76129 Circuit Breaker Contract Timing Test Report 18 Feb 04
000 509 F76130 Vacuum Circuit Breaker Ductor Insulation Report 18 Feb 04
000 509 F76131 Drawout Vacuum Breaker Inspection Test 18 Feb 04
000 509 F76132 Main Bus Insulation and Ductor Report 18 Feb 04
000 509 F76133 Electric Motor Run-In Test Record 18 Feb 04
000 509 F76134 Drawout Air Circuit Breaker Inspection Record 18 Feb 04
000 509 F76135 Insulation Resistance (Rotating Equipment) Test Record 18 Feb 04

000 509 F76201 Emergency Generators Inspection Checklist 18 Feb 04
Project Name: 000 509 F0000
Contract No.: 20 Sep 04
Project Location: Page 7 of 8


Form Number Form Title Revision Date
000 509 F76202
Inspection of Switchgear Bus-Bar Continuity (Including
Incoming and Sectionalizer Units)
18 Feb 04
000 509 F76203
Inspection LV Switchgear (Including Incoming and
Sectionalizer Units)
18 Feb 04
000 509 F76204 Inspection of Outgoing LV Switchgear 18 Feb 04
000 509 F76205 Inspection of Static Supply Unit (UPS) 18 Feb 04
000 509 F76206 Motor Control Centers Inspection Checklist 18 Feb 04
000 509 F76207
Motor Control Centers (Motors and Starters) Inspection
Record
18 Feb 04
000 509 F76208 High Voltage Motors and Starters 18 Feb 04
000 509 F76209 Motors Checklist 18 Feb 04
000 509 F76210 Control and Relay Panels Inspection Checklist 18 Feb 04
000 509 F76211 Electronic Equipment Inspection Checklist 18 Feb 04
000 509 F76212 Power Panel Inspection Checklist 18 Feb 04
000 509 F76213 Switchgear Inspection Checklist 18 Feb 04
000 509 F76214 Low Voltage Feeders Inspection Record 18 Feb 04
000 509 F76215 High Voltage Cable Inspection and Test Record 18 Feb 04
000 509 F76216 Electrical Equipment Inspection Record 18 Feb 04
000 509 F76217 Control Scheme Inspection Checklist 18 Feb 04
000 509 F76218 Power Transformer Inspection Checklist 18 Feb 04
000 509 F76219 Switching Units HV Switchgear Inspection and Test Record 18 Feb 04
000 509 F76220 Switching Units HV Switchgear Inspection Checklist 18 Feb 04
000 509 F76221 Liquid Filled Transformer Inspection Record 18 Feb 04
000 509 F76222 Busway Inspection Record 18 Feb 04
000 509 F76223 Switchgear Inspection Record 18 Feb 04
000 509 F76224 Motor Control Center Inspection Record 18 Feb 04
000 509 F76225 Battery and Battery Charger Inspection Record 18 Feb 04
000 509 F76226
Liquid Immersed Medium Voltage Disconnect Switch
Inspection Record
18 Feb 04
000 509 F76227 Electric Motor Electrical Activities Inspection Record 18 Feb 04
000 509 F76228 Electric Motor Mechanical Activities Inspection Record 18 Feb 04
000 509 F76229 Electric Motor for Compressor Installation Checklist 18 Feb 04
000 509 F76230 Compressor Vibration Checklist 18 Feb 04
000 509 F76231 Vibration Probe Record 18 Feb 04

000 509 F76401 Heat Trace Test Log 18 Feb 04
000 509 F76402 Electrical Heat Trace Inspection Record 18 Feb 04

000 509 F77001 Instrumentation Inspection Checklist 18 Feb 04
000 509 F77002 Instrument Loop Check Sheet 18 Feb 04
000 509 F77003 Impulse Line Pressure Test Sheet 18 Feb 04
000 509 F77004 Instrument Grounding System Check Sheet 18 Feb 04
000 509 F77005 Installation Check Sheet (Local Instruments) 18 Feb 04
000 509 F77006 Orifice Plate Specification Check Report 18 Feb 04
Project Name: 000 509 F0000
Contract No.: 20 Sep 04
Project Location: Page 8 of 8


Form Number Form Title Revision Date
000 509 F77101 Instrument Loop Check Sheet 18 Feb 04
000 509 F77102 Safety Valve Tracking Sheet 18 Feb 04
000 509 F77103 Relief Valve Inspection and Final Acceptance 18 Feb 04

000 509 F78001 Coating Inspection Record 18 Feb 04
000 509 F78002 Lining Inspection Record 18 Feb 04

000 509 F78101 Equipment Thermal Insulation Inspection 18 Feb 04
000 509 F78102 Piping Thermal Insulation Record 18 Feb 04

000 509 F78201 Release For Application/Inspection Of Fireproofing Checklist 18 Feb 04
000 509 F78202 Fireproofing Inspection Preconstruction Checklist 18 Feb 04

000 509 F78301 Cathodic Protection Inspection Report 20 Sep 04

000 509 F79001 Daily Welding Report 18 Feb 04
000 509 F79002 Post Weld Heat Treatment Log 18 Feb 04

000 509 F79201 Welder B31.3 Random Radiography Control Log 18 Feb 04
000 509 F79202 Nondestructive Examination Request/Record 18 Feb 04
000 509 F79203 Radiographic Rejectable Defects Statistics 18 Feb 04
000 509 F79204 Welding/NDE Status Log 18 Feb 04
000 509 F79205 Ferrite Test Report 18 Feb 04

000 509 F79301 PMI Inspection Record 18 Feb 04
000 509 F79302 Bulk Material Positive Material Identification Record 18 Feb 04
000 509 F79303 Pipe Spool Positive Material Identification Record Point Sheet 18 Feb 04
000 509 F79304 Weekly PMI Log 18 Feb 04

000 509 F79501 Verification Of Training For Hardness Testing 18 Feb 04
000 509 F79502 Report Of Vision Test 18 Feb 04
000 509 F79503 Hardness Testing Report 18 Feb 04

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