DESIGN & CONSTRUCTION OF

PUTATAN WATER TREATMENT PLANT 2

TABLE OF CONTENTS
1 GENERAL ..................................................................................... 3

1.1 POLICY ..........................................................................................3

1.2 OBJECTIVE.....................................................................................3
1.3 INTERFACE WITH QUALITY MANUAL ..................................................3
1.4 INSPECTION ..................................................................................4
1.5 QUALITY PROCEDURE......................................................................4
1.5.1 INSPECTION NOTIFICATION .............................................................4
1.5.2 VALIDATION OF THE NOTICE ...........................................................4
2 ORGANIZATIONAL CHART ........................................................... 4

3 DEFINITION OF DUTIES .............................................................. 5

3.1 QUALITY CONTROL PERSONNEL, DUTY AND ORGANIZATION ...............5

3.2 PROJECT MANAGER .........................................................................5
3.3 CONSTRUCTION MANAGER ..............................................................5
3.4 QA/QC MANAGER ............................................................................7
3.5 QA/QC ENGINEER ...........................................................................7
3.6 Q/C ACTIVITIES .............................................................................8
3.7 ORGANIZATION ..............................................................................9
4 DOCUMENT CONTROL ................................................................ 10

4.1 GENERAL ..................................................................................... 10

4.2 DRAWING CONTROL PROGRAM ...................................................... 10
4.3 PREPARATION OF AS-BUILT DRAWING ............................................ 10
4.4 REQUEST FOR DESIGN CHANGE ..................................................... 10
4.5 ESTIMATION OF SCOPE CHANGE .................................................... 11
5 DESIGN CONTROL AND DEVELOPMENT ..................................... 11

6 PROCESS CONTROL ................................................................... 11

6.1 METHOD STATEMENT .................................................................... 11

6.2 ACCOMPLISHMENT REPORTS.......................................................... 12
6.3 INSPECTION AND TESTING PLAN (ITP) ............................................ 12
6.4 MONITORING AND MEASURING EQUIPMENT .................................... 13
6.5 TEST LABORATORIES .................................................................... 14
7 INSPECTION & TESTING HOLD ................................................. 14

7.1 REFERENCES ................................................................................ 14

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7.2 RESPONSIBILITIES ....................................................................... 14

7.3 MINIMUM TEST AND/OR INSPECTION REQUIREMENTS CIVIL
WORKS ....................................................................................... 15
7.4 MINIMUM TEST AND/OR INSPECTION REQUIREMENTS ELECTRO-
MECHANICAL WORKS .................................................................... 18
8 MATERIAL CONTROL STORAGE ................................................. 24

8.1 GENERAL ..................................................................................... 24

8.2 RECEIVING .................................................................................. 24
8.3 WAREHOUSING ............................................................................ 25
8.4 STOCK CONTROL .......................................................................... 26
8.5 ISSUING OF MATERIALS ................................................................ 26
8.6 DOCUMENTATION ......................................................................... 26
9 QUALITY RECORDS ................................................................... 26

9.1 LOT COMPLIANCE (INSPECTION AND TEST PLAN) RECORDS .............. 27

9.2 REQUEST FOR INFORMATION, VARIATION, SITE INSTRUCTIONS AND
NON-CONFORMANCE RECORDS ...................................................... 27
9.3 DRAWINGS, SPECIFICATIONS AND SCHEDULES ............................... 27
9.4 CONSTRUCTION MANAGER'S OFFICE .............................................. 28
9.5 QUALITY CONTROL OFFICE ............................................................ 28
10 CONFORMANCE & NON-CONFORMANCE .................................... 29

10.1 CONFORMANCE REPORTS .............................................................. 29

10.2 NON CONFORMANCES ................................................................... 29
10.3 CORRECTIVE ACTION .................................................................... 30
10.4 PREVENTIVE ACTION..................................................................... 30
11 RISK MANAGEMENT .................................................................. 30

11.1 IDENTIFIED QUALITY CONTROL RISKS ............................................ 31

12 AUDIT FUNCTION...................................................................... 31

12.1 PURPOSE ..................................................................................... 31

12.2 SCOPE ......................................................................................... 31
12.3 RESPONSIBILITY .......................................................................... 32
12.4 AUDIT ......................................................................................... 32
13 INSPECTION CHECKLIST & LABORATORY FORMS ..................... 34
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1 GENERAL

1.1 Policy

It is the policy of the Consortium that its project when completed, shall comply with the
contract specifications, standards, drawings applicable local regulation and acceptable
construction practices.

In the application of this policy, a continuous quality programs will be provided to assure
that applicable codes, specifications and standards are complied upon.

Inspection and quality control program will produce appropriate records and all
operations will be subject to internal audits.

The inspection and quality control program can be supplemented to satisfy contractual
regulations or to encompass new materials and techniques but may not under normal
circumstances be de-emphasized or unilaterally waived.

1.2 Objective

To provide products and services for the realization of a successful project that meets the
contract and project requirements to the satisfaction of the client.

To meet all quality requirements and technical performance criteria for the project.

To meet all commercial criteria by efficient utilization of technological, human and

material resources.

1.3 Interface with Quality Manual

This Plan is subject to modification and adaptation to the meet the specific project scope
requirements and contract specifications. As a secondary document to the Project Quality
Manual, this Plan describes all the significant activities for this project (for general
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planning purpose) and what we intend to do for quality assurance for each of these
activities.

1.4 Inspection

Specific procedure such as inspection and test plans will be developed and implemented
to ensure that all quality aspects of the works will be addressed.

The Consortium is expected to have and maintain a quality control program that will
ensure the work being accepted. The reports generated in accomplishing this activity must
reflect actual physical quality checks and will be transmitted to consultants. The master
file of these forms with the appropriate signatures will be retained by the consortium at
the jobsite.

1.5 Quality Procedure

1.5.1 Inspection Notification

When Consortium is satisfied that a completed segment of the work is ready for
consultants inspection, preparation of the appropriate documentation will be made
with a request for work inspection that defines and identifies the inspection desired.

Consultants engineers will check the work and if satisfied then only the inspection
request form will be signed. Consortium is required to give consultants 24 hours to
enable to carry out an inspection.

1.5.2 Validation of the Notice

Consultants will determine if the requested inspection is valid, i.e. that the work is
indeed finished and properly documented.

2 ORGANIZATIONAL CHART
Please see enclosed QA/QC Organizational Chart.
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The organizational chart will be revised and resubmitted in case of any change of key
personnel.

3 DEFINITION OF DUTIES

3.1 Quality Control Personnel, Duty and Organization

3.2 Project Manager

The Project Manager is responsible for promulgating the Quality Policy and ensures that:

Major Duties
A. The day to day preparation for issue of all new or revised procedures, work
instructions and forms.
B. Ensuring all information is available for management review meetings, and
meeting reports and minutes are distributed to relevant persons
C. Ensure that all procedures are followed by all workers, Responsible for the
successful delivery of a Project within time, cost, safety, quality and
environmental constraints
D. Provide hands-on, day-to-day Project management during the execution phase
of Projects
E. Establish Project monitoring budget (from Tender Budget), Establishment of
PMT to ensure appropriate management of design, construction, commercial,
financial, administration, safety, quality, environment and communications
F. Establish site operational (design & construction), commercial, financial,
administration, safety, quality, environmental and communication procedures
G. Ensure appropriate reporting both internally to the Management Board and
contractually to the Client
H. Identify issues and prepare proposals for resolution of issues, Tracking and
reporting progress through establishment of key performance indicators, Trend
Analysis & Risk Management

3.3 Construction Manager

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The responsibilities of the Construction Manager include:

A. Ensure the PMT are directed in a manner that delivers a high level of safety,
health, environmental and quality standards

B. Study Project specifications to determine appropriate construction methods,

producing and maintaining a Project management plan

C. Evaluate construction methods and determine cost-effectiveness of plans

D. Schedule the Project in logical steps and budget time required to meet deadlines
delivering the Project to the contract documents on time and to budget

E. Work with the Design Manager, Commercial Manager and Project Manager to
ensure coordination

F. Confer with supervisory personnel, owners, contractors, and design

professionals to discuss and resolve matters such as work procedures,
complaints, and construction problems

G. Ensure General Contract Budget implementation and monitoring prepare and

submit budget estimates and progress and cost tracking reports

H. Keep all required records as per company procedures and as required within the
contract

I. Determine labour requirements and dispatch workers to construction sites

J. Inspect and review Projects to monitor compliance with building and safety
codes, and other regulations

K. Interpret and explain plans and contract terms to administrative staff, workers,
and Clients, representing the Client

L. Prepare contracts and negotiate revisions, changes and additions to contractual

agreements with architects, consultants, Clients, suppliers and subcontractors

M. Plan, organize, and direct activities concerned with the construction and
maintenance of structures, facilities, and systems

N. Investigate damage, accidents, or delays at construction sites, to ensure that

proper procedures are being carried out
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O. Evaluate construction methods and determine cost-effectiveness of plans

3.4 QA/QC Manager

On the instruction of the project manager, he is responsible for the assurance and
control of the quality for the project and will act as liaison between consortium and
consultants pertaining to the quality control, inspection, testing and examination in
order to meet the contractual requirements, standards and specifications for the
project.

Major Duties
A. Job instruction and observance of QA/QC plan.
B. Training/testing of laborers.
C. Maintain all required reports.
D. Conduct activities relating to the quality assurance and quality control of
the work at the jobsite and laboratory.
E. Equipment maintenance.
F. Control of the construction materials.
G. Verify all completed work against drawing standard and specification.
H. Prepare QC program for consultants approval.

I. The systems necessary to manage and control Project quality records.

J. Management and control of Project quality records during the life of the
Project.

K. Timely provision of specified records and data to the Customer/ Client.

3.5 QA/QC Engineer

The QA/QC Engineers are responsible for implementing and maintaining the Quality
Management Plan, systems and procedures by:
A. Supporting a culture that focuses on a get it right first time attitude across
the entire workforce
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B. Actioning and managing subcontractors to implement and maintain quality

systems and procedures as defined in this Quality Management Plan

C. Ensuring the delivery of the output required of their functional team is on time
and to quality specification

D. Implementing consistent lot management, including engaging in verification

and approval activities as required by the Inspection and Test Plans

E. Coordinating the development, updating and controlling Inspection and Test

Plans

F. Engaging in inspections and verification activities as required by the Inspection

and Test Plans

G. Verifying conformance prior to accepting completed works

H. Raising, investigating and reporting NCRs and implementing remedial actions

I. Monitoring direct reports lot management and providing technical support as

required

J. Cooperating with the CQR and the Client rep. to ensure compliance with the
quality system, including approvals for materials and construction methods

K. Issuing Client notifications and inspections or monitoring direct reports.

3.6 Q/C Activities

The following is a brief summary of inspection and test activities required to

ensure the quality and compliance with the construction drawings, specification
and standard.

1. Most of the activities will be performed by our quality control group and some by
subcontractor on behalf of consortium which in case we will make sure the
subcontractors will perform their obligations in strict accordance with project
technical specifications and standards.
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2. Materials received are inspected and signed by QA/QC Manager for condition, a
confirmation with the drawings and any damaged or discrepancies will be brought
to the attention of consultants engineers.

3. Drawing interpretation and/or field problems as well as materials problems will

be dealt with by the quality control department and supervisors, and consultants
engineers will be informed.

4. Any problems which cannot be solved within consortium are brought to the
attention of consultants engineers in writing for their actions. Problems in the
field are documented and recorded in the log book of consultants engineers and
consortium.

5. Various forms will be used for testing and quality control of construction materials
will be approved by consultants engineers before use.

3.7 Organization

The quality control section will consist of a QA/QC Manager and supplementary QA/QC
Engineers who are key personnel assigned to this quality control program and are
responsible directly to the project manager for all quality control activities in the field.
The QA/QC Engineer will answer only to QA/QC Manager.

The QA/QC Manager has a team of specialist working in the specific areas of civil, piping,
electrical, structural and architectural. Field quality control reports made by each field
supervisors shall be forwarded to the quality control supervisor/engineer, QC specialists
shall check the work on basis of the reports.

If the checking shows deviations from drawings per specifications, they shall instruct the
relevant supervisors to conduct the required corrective work, and then report it to the
QA/QC Manager.
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When the remedial work has been completed, the quality control reports will be
delivered to QA/QC Manager and Engineer. These steps shall be repeated, until the
work is determined to be acceptable by the QC specialists.

4 DOCUMENT CONTROL
4.1 General
Engineering management to be executed by consulting engineers and the consortium
will assist to consultants for this project.

4.2 Drawing Control Program

The consortium engineer will control all drawings, with CAD operators who will work full
time on site.

If there will be any field changes, the project field engineer shall review the drawing
scheduling engineer shall keep all the records about field changes, voided changes,
revised drawing and he will prepare as built drawing and submit to consultants office
through project manager upon completion of project.

4.3 Preparation of As-Built Drawing

Field supervisor shall mark "red" the progress of their work on drawings and/or on
separate sheets, and submit then to scheduling engineer after verification thereof from
consultants field engineer. Based on these marked drawings and sheets drawing
engineer shall prepare a consolidated as-built drawing. The consortium shall maintain
this as built drawing up to date and submit to consulting engineers when work on the
drawing is complete.

4.4 Request for Design Change

Field supervisors and/or foreman shall prepare and submit requests for field design
change to the consortium scheduler, who will make a Request for Information. It will
be forwarded to consulting engineers for their perusal. Upon approval of the design
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change, copies will be distributed to the supervisors and/or foremen who initiated the
requests for implementation, and will be sent to the main office and site office for filing.

4.5 Estimation of Scope Change

In the event of scope change, cost engineer shall estimate the work involved with field
engineers, the results of which shall be submitted to the project manager, the scope
change work shall be processed in accordance with contract document, change of work.

5 DESIGN CONTROL AND DEVELOPMENT

Design management is an essential component of the Project Delivery. The Project

Design will be broken down into defined components and will be classified according to
each discipline

Process
Mechanical
Electrical and Instrumentation
Civil Works including Structural and Architectural Design

Regular review meetings will be held between the design and construction consultant,
client and contractors. Meetings will be minuted, areas of concern noted for actions to
rectify and to follow up. Standard document turnaround times regarding submissions
will be implemented.

Design review will be a continuous process throughout the life of the Project. Review
workshops for all involved personnel will be conducted where amendments can be
done. The Design Manager will review and comment and initiate any amendments
before approval.

6 PROCESS CONTROL

6.1 Method Statement

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Method statements are documents that fully describe the procedure of the activity,
plant, equipment and resources, safety and environmental requirements and
considerations, inspections and test requirements. The purpose of the procedure is to
ensure adequate planning of the works and that personnel carrying out the work
understand the hazard and risk associated and the controls in place to reduce exposure
to injury and/or damage incidents.

Subcontractors and other vendors will be required to provide their own management
plans and procedures but in some cases may adopt Consortiums management systems,
where they will be required to participate in preparation of the construction procedures
as part of the consultation process.

6.2 Accomplishment Reports

Accomplishment reports should be submitted to monitor the progress of the
project, safety and health reports, procurement updates, weather condition,
manpower and equipment loading and activities within the reporting period.
Daily site report shall be submitted on the following day of report period.
Weekly accomplishment report shall be submitted every Friday, reporting the
activities from Friday of previous week to Thursday of the report week.

6.3 Inspection and Testing Plan (ITP)

ITPs will be prepared for all activities based on the applicable specifications prior to work
beginning. The QA/QC Engineer will be responsible for developing the relevant
Inspection and Test Plans for upcoming works or if necessary amend the ITP to reflect
any changes prior to the activity. The QA/QC Manager shall ensure that all specifications
and technical requirements are properly incorporated. ITPs will be owned, documented
and checked by the QA/QC Manager. They may also be authorised by the Project
Manager.

ITPs require Client approval. Every activity must have the corresponding ITP in place and
approved by the Client before commencement of any activity.

Checklists for inclusion of:

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Witness Points and Hold Points

Inspection Points
Location (survey if required)
Test requests
Traceability i.e. underlying lots and supporting lots
Criteria for acceptance
Frequency of inspection / testing
Sign-off for closure.

6.4 Monitoring and Measuring Equipment

Calibration and service records for monitoring and measuring equipment will be
maintained in a central asset register. Equipment leased or rented will be hired on the
basis that the owner maintains them in a suitable condition at all times and provides
evidence of this. The asset register must contain as a minimum, the following
information (for owned and hired equipment):

Type
Description
Serial Number
Latest calibration (including certificate)
Next calibration date
Type of monitoring/measurements to be performed
Monitoring and measuring equipment will bear a tag, sticker or other identification
indicating calibration and/or verification status. Where this is not practical, the
calibration or verification status will be traceable through the records maintained in the
Asset Register.

All monitoring and measurement equipment used on the project must be provided with
a calibration record and must be verified before use on site and re-calibrated as
established by the manufacturer conditions. Checks
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The service and calibration will be performed by either the manufacturer or by an

organisation qualified to calibrate the instruments.

6.5 Test Laboratories

All measuring and testing required by specifications or verification will be made using
3rd party organizations recognized by the Client or other governing bodies such as DENR
and DPWH.

7 INSPECTION & TESTING HOLD

7.1 References

Standards Specification for Road & Bridges DPWH 2004

AASHTO - American Association of State Highway and Transportation Officials
ISO - The International Organization for Standardization
AWWA - American Water Works Association
ASTM - American Society of Mechanical Engineers
ASME - American Society for Testing and Materials
ANSI - American National Standards Institute
PEC - Philippine Electrical Code
NEC National Electric Code
IEEE Institute of Electrical and Electronics Engineers
NEMA - National Electrical Manufacturers Association
Project Technical Specifications

7.2 Responsibilities

The requirements of this program are implemented by:

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The assigned QC personnel (civil field engineer) who shall perform periodic inspection
and/or surveillance of works and material testing coordination as defined by this
program and shall complete or monitor the specified documentation.

The material testing personnel who shall performed material testing each work as
required. This shall be under the direction of an assigned QC personnel (engineer) for
performance and documentation compatible with this program.

7.3 Minimum Test and/or Inspection Requirements Civil Works

Below is the schedule of minimum test and/or inspection requirements for each
construction materials prior, during and/or after incorporation of them to works.

7.3.1 Embankment and Sub-Grade Preparation

For every 1500 cu.m. or fraction thereof:
Quality Test:
One (1) Grading Test ASTM C136
One (1) Plasticity Test (LL, PL, PI) ASTM D4318
One (1) Laboratory Compaction Test ASTM D1557
For each 500 sq. m. of each layer of compacted fill or fraction thereof at least
one group of three in-situ density tests (ASTM D1556). The layers shall be placed
not exceeding 200 mm in loose measurement or based on the result of
compaction trials.

7.3.2 Aggregate Sub-base Course

For every 300 cu.m. or fraction thereof:
One (1) Grading Test ASTM C136
One (1) Plasticity Test (LL, PL, PI) ASTM D4318
For every 1500 cu.m. or fraction thereof:
One (1) Laboratory Compaction Test ASTM D1557
For every 2500 cu.m. or fraction thereof:
One (1) California Bearing Ratio Test ASTM D1883
For every layer of 150 mm of compacted depth/ based on the results of
compaction trials:
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At least one group of three in-situ density tests (ASTM D1556) for each
500 sq.m. or fraction thereof.

7.3.3 Concrete
Ready Mix Concrete
For Fresh Concrete
Slump Test ASTM C143

For Structural concrete,

Compressive strength test on concrete cylinder samples (ASTM C39)
One (1) set consisting of 3 concrete cylinder samples shall be taken
from each days pouring and to represent not more than 75 cu.m of
concrete or fraction thereof

For Road surface courses

Flexural Strength Test on Concrete Beam Sample (ASTM C78)
One (1) set consisting of 3 beam samples shall represent a 330 sq. m of
pavement, 230 mm depth or fraction thereof placed each day. Volume
of concrete not more than 75 cu.m.
Cement
Tests: For every 2000 bags or fraction thereof:
One (1) Quality Test
Chemical Test
Physical Test
Aggregates
Tests: For every 1500 cu.m. or fraction thereof:
For a source not yet tested, or failed in previous quality test
One (1) Quality Test:
Grading ASTM C136
Moisture Content ASTM C127
Specific Gravity ASTM C128
Absorption ASTM C127
Soundness Test ASTM C88
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Unit Weight ASTM C29

For a source previously tested and passed Quality Test:
One (1) Quality Test for
Grading ASTM C136
Moisture Content ASTM C127
Absorption ASTM C128
For every 75 cu.m. or fraction thereof
Grading Test ASTM C136

Water
Tests: One (1) Certificate from Project Engineer or one (1) Chemical Analysis, if source is
questionable

Admixtures
Tests: One (1) Certificate from Project Engineer or Mill Certificate per shipment

7.3.4 Joint Filler (for PCCP and others)

Poured Joint Filler
Test: One (1) Inspection Test each shipment

7.3.5 Masonry Units

Non-load bearing masonry units
Test: One (1) Quality Test* for every 10,000 units or fraction thereof
(*Compressive Strength Test)

7.3.6 Reinforcing Steel Bars

For every 10,000 kg. or fraction thereof for each size
Test: One (1) Mill Certificate for Bending, Tension and Chemical Analysis
Physical Test for Bending and Tension ASTM 615

7.3.7 High Tensile Wire Strand

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For every 20,000 kg. or fraction thereof for each size

Test: One (1) Mill Certificate for Tension and Chemical Analysis
Physical Test for Tension ASTM 416

7.3.8 Metal Members/Structures

Test: Quality Test or Mill Test Certificate for each type of materials used
Inspection Report for each type and shipment of metal used ASTM A36

7.3.9 Bored Pile

1. High Strain Dynamic Method (PDA) shall be 5% of total number of piles.
2. Low Strain Dynamic Method
a. PIT - 10% of total no. of working piles.
b. Cross Hole - 5% of total no. of working piles.
3. Static Test / Osterberg Cell Test one pile test (1.0mm dia x 35m) to represent
all bored piles with the same design to be constructed on site. The test pile
will be located on the sites worst ground condition.

7.3.10 Welded Connections

Dye Penetrant Test, a non-destructive type of test (NDT) shall be conducted by an
accredited testing company to check 5% of total welded connections of structural steel
members in the building.

7.3.11 Fence
Inspection Test for Barbed wire or ASTM A 121 Class I.

7.4 Minimum Test and/or Inspection Requirements Electro-Mechanical Works

Below is the schedule of minimum test and/or inspection requirements for electro-
mechanical equipment before and/or after installation. Each test and/or inspection will
be carried out on all units of equipment concerned. Internal tests will be carried out to
ensure that any non-conformity or defect, even minor ones, can be addressed prior to
actual tests in the presence of the client.
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Electro-mechanical tests should only commence once civil and structural works for that
particular area have passed all the required tests. Proper and documented handing-over
of the area should be observed. It should be free from construction debris and materials.
In addition, all surfaces should be finished in accordance to the specifications.

7.4.1 Factory Acceptance Test (FAT)

Prior to leaving a manufacturers factory, each item of equipment (as required in

contract specifications) shall be tested in accordance with the relevant Standards,
Specifications or Code of Practice. In the absence of such, tests shall be performed in a
manner subject to the approval of the client.

The Consortium should inform the client of the production schedule and give advance
notice of the planned FAT, especially if the factory is located abroad.

7.4.2 Physical and Pre-commissioning Inspections

All delivered equipment should be checked visually (e.g. dimensions, nameplates) if it

corresponds to the approved drawings and specifications.

Inspections should be carried out on installations to ensure that all are done properly
and are ready for commissioning.

7.4.3 Functional Tests

These pre-commissioning tests shall be carried out to demonstrate that all individual
components/systems are ready for operation and comply with contract requirements
as well as the corresponding electro-mechanical component specifications.
Two types of test can be conducted during the functional tests.

a. Dry test - conducted to verify if equipment turns in correct direction by switching

on the equipment for a few seconds.
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b. Wet test - carried out by introducing fluid into the system, to check if it can run
normally (e.g without leakage, excessive noise and vibration, etc).

Functional testing shall be performed according to Work Method Statement which

should be submitted and approved before each scheduled testing.

Equipment vendor, who will provide the Work Method Statement, and the Client will be
involved in this activity.

7.4.4 Loop Tests and Instrument Checking

A test which begins at the process variable through the controller then back to the
control device to ensure that the system is working according to the design. Please refer
to Project Commissioning Plan for more details on this matter.

All field, handheld, as well as test instruments, should be provided with calibration
certificates. Before installation, it should be ensured that none has elapsed the
expiration date.

7.4.5 Fire Detection and Alarm System (FDAS)

All components of the FDAS should be tested for functionality:

Smoke Detectors by exposure to smoke canisters
Heat Detectors by applying heat
Manual Pull Station by pulling down the addressable pull station
The corresponding horn strobes should sound the alarm every time the above activities
are carried out. At the same time, the FDAS panel should indicate the area where the
alarm sounded.

7.4.6 Other Electrical Tests

7.4.6.1 Electric Motors

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Tests: Insulation and Continuity Tests according to Philippine Electrical Code

Phase Rotation Test
Alignment Check as per approved drawings
Vibration and Temperature Check as per manufacturers recommendation

7.4.6.2 Cables and Wires

Tests: Insulation and Continuity Tests according to Philippine Electrical Code

Earth Loop Impedance Test according to Philippine Electrical Code
High Voltage Test according to Philippine Electrical Code

7.4.6.3 Structured Cabling

Copper Cable and Connectors:

Tests: Each RJ-45 Jack connector shall be tested to ensure Category 5e

performance.
Each RJ-45 Jack shall be tested for Point to Point connectivity, by utilizing
hand held time domain reflectometers (TDR ), capable of generating pulses
of 100MHz, and of testing that the following parameters:
Wire mapping for correct polarity
Length for point to point connectivity under 90 meters
Near end cross talk (NEXT)
Resistance
Impedance
Capacitance
Noise
Attenuation
Optical Fiber Cable

Tests: White light tests to confirm end to end connectivity on delivery to site, after
installation and prior to field termination
After field termination, point to point connectivity shall be tested on each
cable
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7.4.6.4 Earthing system

Test: Ground Resistance Test according to Philippine Electrical Code

Earth Loop Impedance Test according to Philippine Electrical Code

7.4.6.5 Lighting and Small Power

The following should be verified for the lighting fixtures:

Indoor Lighting - LED type with power ratings following specifications in the
approved drawings
Perimeter Lightning High pressure sodium lamps mounted on steel structures
Outdoor Lighting Metal halide floodlight mounted on wall/structure

Socket Outlets:
All outlets located outside the plant should be verified to be IP56 rated and with
the following specifications:
o Single phase, 230V, with 2 flat pin + E
All breakers should be verified to be of the RCD type.

7.4.6.6 Generator Set

Test: Load Bank Test based on manufacturers recommendation

Source Emission Test in accordance with the Clean Air Act
Noise Level Test to comply with OSHA Standard 29 CFR 1910.95

7.4.6.7 Transformer

Tests: Ratio tests at the rated voltage connection and all tap connection.
Polarity and phase relation tests on the rated voltage connection.
Applied potential tests.
Induced potential tests.
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Non-load and excitation current at rated voltage on the rated voltage

connection
Resistance measurements of all windings on the rated voltage connections
Impedance and load loss at rated current

7.4.6.8 MCC and Switch Gear

Tests: Phase sequence and voltage levels

Sequential operational test of all control circuits including interlocks.
Insulation Test (Phase to phase, Phase to neutral and Phase to earth)

7.4.7 Plant Commissioning

This is a process to guarantee that all systems and its components of an industrial plant
are designed, constructed and installed properly as entailed in the contract
requirements.

QA/QC Engineers will run the whole process line with water loaded then adjust
parameters accordingly by aiming at the optimum performance of the system. Water
quality will be measured regularly and results will be utilized to direct parameter
adjustments.

Detailed information on this is discussed in the Project Commissioning Plan.

7.5 Sign-off and Agreement with Employer

After the completion of a particular testing activity which is deemed satisfactory by the
Employer, QC engineers should secure signed-off commissioning checklists and test
reports from them.

In case of any non-conformance, the comments should be recorded. These items should
be complied with accordingly before obtaining the signed-off documents.
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7.6 Environmental Compliance

Compliance with the standards set by DENR and other regulatory bodies (e.g. LLDA) will
be strictly implemented by the Consortium during the course of the project. In addition,
all necessary environmental permits (e.g. PTO, discharge, et al.) will be secured before
operating the plant.

7.7 Health and Safety

The Consortium, including all subcontractors and suppliers, shall comply with the
requirements to operate under the project environmental management and safety
system.

Please refer to the approved HAZOP and HAZCON for further details on the related
general safety provisions.

8 MATERIAL CONTROL STORAGE

8.1 General
The responsibility at the construction site for all material handling and operation lies
with the material controller reporting to project manager, who with his staff
controls records, receiving, warehousing and issuing of materials. Consortium will
assign well experienced competent personnel to ensure the implementation of
these procedures and the system to this project.

8.2 Receiving

When materials are received at the jobsite in a manner described in the schedule of
contract, a physical count must be made to verify that the quantity shown in the
packing list is correct conform to shipment record. After the material has been
checked, tagging the material by item according to its nature is done and the
materials receiving report (MRR) is prepared and issued daily with a brief
description of all materials received.
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Whenever discrepancies is found, and over, short and damage (o.s. & d) report must
be prepared to the project manager.

8.3 Warehousing

Materials are turned over to the warehouse section with a copy of the MRR, after
the material has been routed to its proper storage location. MRR is channeled to
stock control.

All materials have designated areas by commodities, which are clearly defined and
identified with appropriate location signs. Materials required special care, to be
protected from direct ray of the sunlight and to be prevented from heat and
humidity and fragile materials are stored indoor. Also such inflammable materials
such as paint, adhesives, petroleum products and dry liquid chemical items are
stored indoor in the separately installed storage facilities.

All storage areas are safe, secure, and tidy secure areas, with access limited to
authorized personnel.

Hazardous (flammable, corrosive or poisonous) materials will be clearly labeled

indicating name of substance, danger symbol, etc. Including safety advice sheet.

Separate areas for drums of chemical will be established with the appropriate flash
point warning signs displayed. No smoking signs and appropriate fire
extinguishers will be on site in consultation with safety officer.

Where the material has a shelf life, the storekeeper will ensure that an adequate
and effective rotation of stock occurs by recording dates which will be reviewed
prior to issuance.

All the equipment, materials, tools, etc. in custody will be safeguarded and ensured
that they are treated with due care.
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Supplied goods and materials which are not acceptable and cannot be repaired,
shall be returned to the supplier/sub-contractor, together with clear instructions
regarding reasons for rejection and re-supply instructions. Please see attached
proposed warehouse locations.

8.4 Stock Control

The control system with 20 by 12 cm. bin cards is used on a one card for one item
basis. The card label shows tag or code number size and a brief description. The
back of the card is used to show material take off quantity, requisition number,
quantity ordered, etc. The front of the card shows the quantity received (with MRR)
number, date & location), quantity issued (with date and warehouse requisition
number) and balance on hand.

8.5 Issuing of Materials

Issuing of material is realized by material issue slip verified and signed by material
superintendent at the written request of the field engineer based on the work
schedule.

Warehouse supervisor confirms job numbers, phase number, and checks off the
material issued against material issue slip to let warehouse keeping clerk release.
Material issue slip is returned to stock control supervisor with a daily material issue
report for appropriate record.

8.6 Documentation
Copies of forms listed below basically used in the material control program:
A. Material Receiving Report
B. Daily Material Issue Slip
C. Over/Short And Damage Report
D. Stock Control Card
E. Material Forecast

9 QUALITY RECORDS
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All information formats generated internally, sent externally or received will be

documented. This documentation may be in paper format, electronic format, records of
telephone or personal meetings or observation notes. Control of this documentation
will be extended to all periods of the Project and functions (e.g. environmental, quality,
safety and health).

The Client will have access to obtain primary records and information at any time
through request according to agreed communication protocols. At completion of the
Project, the Consortium may provide the client with any primary records required,
either soft or hard copies.

Primary records include all records required to evidence conformance of work to the
Clients Representative and required by the Client to enable monitoring and quality
auditing. The work under the contract shall be completed in accordance with the
provisions of the Contract, works shall be inspected and tested in accordance with the
requirements in the contract, inspection and test results shall be analysed to
demonstrate compliance with the contract and conformance reports shall be issued
according to the requirements.

9.1 Lot compliance (Inspection and Test Plan) records

The Project will maintain a lot register and the status will be progressively updated as
work on the lot moves forward.

9.2 Request for information, variation, site instructions and non-conformance

records

Separate registers will be maintained pertaining to Request for Information (RFI)

variations, client site instructions and Non-conformance Records (NCR). The registers
will be updated regularly for status changes.

9.3 Drawings, specifications and schedules

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The document controller will ensure that the most recent drawings, specifications and
schedules are in use and registered as Issued for Construction or For Reference as
appropriate.

On receipt of drawings, specifications or schedules, the document controller will:

a) Record the date of receipt

b) Verify if each document received is as stated on the document transmittal
c) File the document transmittal
d) Input information into the corresponding register

The document controller will maintain a master file of current drawings, specifications,
schedules, RFIs and NCRs and distribute copies to other key personnel. The document
controller will be responsible for setting up and maintaining document registers and
continuing operation.
As drawings, specifications and schedules are revised or reissued document control will
check that the documents have the necessary approvals, register the changed
documents and distribute them as to the relevant personnel and subcontractors /
suppliers. The document controller will remove and stamp Superseded on superseded
documents from the master file and will maintain at least one copy of superseded
documentation for record and reference purposes. Holders of drawings, specifications
and schedules are responsible for either destroying or identifying and removing from
use any superseded documents in their control

9.4 Construction Manager's Office

Each construction manager shall maintain a file for all audit report and correspondence
showing corrective actions taken in response to audit findings and recommendation.

9.5 Quality Control Office

The quality control office shall maintain a file of all audit reports and correspondence
showing test results, findings and action taken in response to audit findings and
recommendation.
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10 CONFORMANCE & NON-CONFORMANCE

10.1 Conformance reports

A conformance report shall be prepared for each lot and shall be accompanied by the
following:

Inspection and Test records

Analysis of the results to demonstrate compliance with the relevant standard
As-built drawings, whenever applicable

10.2 Non conformances

10.2.1 Non conformity identification and communication

The Consortium aims to rectify deficiencies as soon as possible, to ensure a solution is

found to minimize recurring deficiencies, improve processes and product quality. Non-
conformity will not be taken negatively, but will be considered as a process of
improvement and will be produced, promoted and received in this tone. NCRs will be
raised and issued in an even-handed manner; including all contractors, suppliers,
consultants and the project team.

All non-conformities identified will be registered in a designated register. A non-

conformity report (NCR) will be issued for every non-conformance to the applicable
specifications, design standards, special requirements, drawings or procedures for any
conditions whereby the product or service does not meet contract requirements. The
NCR shall be raised within 24 hours of detection whenever possible, and created and
maintained within the document management system. The QA/QC Manager will be
responsible for ensuring that all relevant parties are notified of the creation of any non-
conformity reports. He will also be responsible for ensuring all relevant personnel are
consulted regarding close-out instructions. These parties may include the Client,
Regulatory Authorities and Legislative Authorities as deemed necessary.
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To ensure that all quality issues are reported, resolved and not repeated, the following
hierarchy of controls will be used:

a) Elimination of situation causing non-conformance

b) Physical constraints to remove chance of fault occurring during activity
c) Procedural action to control the occurrence of fault.

Summaries or specifics of NCRs will be reviewed and analysed as part of the

management meetings, reported and included in management reviews.

10.3 Corrective Action

Corrective action will be adopted to eliminate the recurrence of non-conformities. This

process will be adopted in the case of recurring non-conformities, where action is
required to eliminate the root causes and shall include analysis of the trend of non-
conformities, root cause determination, approval, implementation and monitoring of
the corrective action.

10.4 Preventive Action

Preventive actions are adopted to avoid the root causes appearing. This process will be
used to eliminate potential non-conformities before their occurrence, by analysing
potential non-conforming situations during planning of activities and applying the
hierarchy of control to those situations that are deemed of high risk.

11 RISK MANAGEMENT

The Consortium undertakes risk identification and mitigation through a structured

process coordinated by the Project Manager. For quality activities related to
construction there are specification nominated approvals to control the outputs of the
process and material controls to control the quality of the product. The Consortium will
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use internally nominated approvals for those activities it deems of higher risk, and these
will be identified through the as well as non-conformance rectification actions.

11.1 Identified quality control risks

Risks to the quality control of the Project include non-compliance and inadequacies of:
Change in law, standards and regulations applicable to the project
Guarantees of the treatment
Approval Procedures
Inflation and currency exchange fluctuation

The risk register will initially define and manage common foreseeable risks and also
assist in determining which project activities involve levels of risk requiring formal
documented controls. The Consortium will hold an initial risk workshop to transfer the
tender stage risk assessment and identify and assess the project scope of works and the
subsequent project specific activities and appropriate control measures in accordance
with relevant client/company/project standards, regulations, standards and Codes of
Practice.

For Quality specific risks the preparation of management documents including

construction procedures, method statements, inspection and test plans will identify the
key risks and aspects of the project. These will be verified internally through objective
evidence and observation/inspection of site activities using trained personnel.

12 AUDIT FUNCTION

12.1 Purpose
The periodic review of actions and of inspection results that all works is being performed
in accordance with contractual requirements and that deviations are being corrected or
accepted.

12.2 Scope
The audit program described in this section applies to all quality related work performed
by consortium or subcontractors during construction of the project.
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12.3 Responsibility
The construction manager has overall responsibility for the implementation of an
effective quality control program. Planning and implementing the audit program shall
be done under the direction of the QA/QC Manager.

12.4 Audit
12.4.1 Audit Team

Audit shall be performed by team of auditors who are familiar with, but not directly
responsible for, the work of activities being audited. The audit team shall be headed
by the QA/QC Managers supervision and shall include such other personnel as he may
appoint to secure the coverage desired in the audit.

12.4.2 Audit Schedules

The type of frequency of audits shall be recommended by the QA/QC Engineer and
approved by the Project Manager. The audit schedule shall then be prepared and
issued by the QA/QC Engineer, audit shall be done. Initial audit schedule shall be
conducted six months after the project start, succeeding audit shall be once a year.
The activities which shall be audited shall be as follows, but not limited to:
A. Overall Quality Control Program
B. Document Control
C. Field Procurement Control
D. Materials And Equipment Control
E. Test Control

12.4.3 Unscheduled Audits

Unscheduled audits and spot checks may also be conducted at the discretion of the
QA/QC Manager when the following condition exists.
A. Areas of work and activities are newly started.
B. Receipt of verbal or written reports of deviations of deficiencies.
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C. Previous audit of an area indicates need for follow-up.

D. Period of time established in an earlier for implementing corrective action
has elapsed.

12.4.4 Audit Planning

A written plan shall be prepared prior to conduct of the audit. Each audit team member
shall review all documents which prescribe the work or activity to be audited, and shall
prepare a checklist of items to be audited. The audit team leader shall review and
approve the audit plans and checklists prepared by each audit team member prior to
conducting the audit.

12.4.5 Notice of Audit

The construction manager of the job to be audited shall be notified at least three
working days in advance of audit. At that time he shall be advised of the proposed audit
agenda. The audit team leader shall coordinate with the chief field engineer to assure
that the audit conduct will not unduly affect construction activities.

12.4.6 Audit Conduct

The audit shall proceed, seeing the prepared plans and checklists as a guide. However,
the audit team leader may deviate from the plan when progress in the audit reveals the
need in order to properly cover the scope of audit. A record of the activity audited,
names and responsibilities of persons contacted, and the audit findings shall be
documented in the audit report checklists used shall become part of the audit record
file, and shall indicate items that were checked and found acceptable as well as those
found to require corrective actions.

12.4.7 Audit Review Meeting

The audit team leader shall schedule a post audit meetings with construction manager
to discuss audit findings and recommend corrective actions.
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12.4.8 Audit Report

The audit findings and recommendations shall be documented in an audit report issued
to the construction manager of the job audited. An information copy of each audit shall
be transmitted to the project manager responsible for the site audited.

12.4.9 Audit Close Out

The chief field engineer on the job audited shall assure the required corrective actions
are completed within the specified time. When action on the findings is complete, he
shall report such action to the QA/QC Manager.

The QA/QC Materials Manager, the Project Manager and the manager of engineering,
shall review the action reported for each finding and, if action is considered satisfactory,
issue a close out report.

13 INSPECTION CHECKLIST & LABORATORY FORMS

13.1 See attached sample for the following forms:

Inspection Request Forms

Request for Inspection of Work (RIW)
Request for Rebars Inspection (RRI)
Request for Formworks Closure (RFC)
Concrete Pouring Request (CPR)

Laboratory Forms
(Third Party Laboratory Testing Center format)

Document Submittal Forms

Request for Information Form
Request for Materials Approval Form
Request for Sub-Contractors Approval Form
Shop Drawing Submittal Form
Technical Submittal Form
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Transmittal Form

Reporting Forms
Daily Site Report (Weather Chart)
Weekly Report